Volkswagen Beetle NBLNBC 2012 Repair Manual – PDF DOWNLOAD

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Volkswagen Beetle NBLNBC 2012 Repair Manual – PDF DOWNLOAD

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Volkswagen Beetle NBLNBC 2012 Repair Manual – PDF DOWNLOAD 

Language : English
Pages : 13574
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Volkswagen Beetle NBLNBC 2012 Repair Manual – PDF DOWNLOAD 

00053148720 Wheels and Tyres Guide Standard 1
44 – Wheels, tyres, vehicle geometry 9
1 General notes on wheels and tyres (passenger cars) 9
2 Legislative and technical conditions for converting wheel and tyre combinations 11
2 1 Legislative conditions for converting wheel and tyre combinations 11
2 2 Technical conditions for converting wheel and tyre combinations 11
2 3 Additional wheel housing extensions (flaps) 12
2 4 „Series 80“ tyres 12
3 Documents and codes/designations 13
3 1 New vehicle registration documents since 01 10 2005 13
3 2 COC document (EEC Certificate of Conformity) 14
3 3 EU general type approval number, sales type and sales or trade designation 14
4 Useful information regarding tyres 16
4 1 Identification markings on the tyre sidewall 16
4 2 Explanation of tyre markings 17
4 3 Speed ratings for tyres 18
4 4 Undulations 19
4 5 Tyre storage 20
4 6 Tyre ageing 20
4 7 Tyre sizes for vehicles with four-wheel drive 22
4 8 Winter tyres 22
4 9 Winter tyres with speed symbol „V“ 23
4 10 Extra Load (XL) V winter tyres 24
4 11 Maximum speeds for V and Extra Load (XL) winter tyres 24
4 12 Reinforced and Extra Load (XL) tyres 25
4 13 Snow chains 25
5 Tyre wear/ mileage for passenger car tyres 27
5 1 General 27
5 2 Requirements to be met by tyres 27
5 3 Wear behaviour of high-speed tyres 28
5 4 Factors influencing the service life of a tyre 28
5 5 Driving style 28
5 6 Tyre maintenance 29
5 7 Evenly worn tyres 30
5 8 Measuring tread depth 31
5 9 One-sided wear 31
5 10 Outer shoulder wear 34
5 11 Wear in middle of tyre 34
5 12 Diagonal washout 36
6 Tyre noise 37
6 1 General notes on tyre noise 37
6 2 Saw-tooth wear 37
6 3 Flat spots (from locking wheels) 38
7 Vehicle pulls to one side 40
7 1 General 40
7 2 Conicity 40
7 3 Remedies when vehicle pulls to one side 41
7 4 Strategic rotation of wheels for non-directional tyres 42
7 5 Strategic rotation of wheels having unidirectional tyres 43
8 Tyre damage 45
8 1 General information 45
8 2 Construction of a radial belted tyre 46
8 3 Impact damage 46
8 4 Cuts 48
8 5 Damage caused by foreign bodies 48
8 6 Loss of air from tyre 48
8 7 Tyre pressure 48
8 8 Tyre damage due to insufficient tyre pressure 49
8 9 Rising tyre temperature caused by insufficient inflation pressure 50
8 10 Tyre damage due to fitting error (fitting damage) 51
9 Tyres with run-flat properties 53
9 1 General 53
9 2 Design and identification 54
9 3 Retrofitting/requirements when using run-flat tyres 54
9 4 Repairs 55
10 Rolling resistance optimised tyres 56
11 Facts about disc-type wheels (passenger cars) 57
11 1 Design of disc-type wheel 57
11 2 Data on wheel rims 57
11 3 Wheel rims – pitch circle diameter 58
11 4 Split rim composite wheels 58
11 5 Alloy wheels with exchangeable trim elements 58
11 6 Alloy wheels with exchangeable trim elements (Zaragoza) 59
11 6 1 Tools 59
11 6 2 Materials 60
11 6 3 Installing trim element 60
11 6 4 Removing trim element 62
11 7 Care and maintenance of alloy wheel rims 63
11 8 Restoring alloy wheels 63
11 9 The valve 65
12 Notes on use of temporary spare wheels 66
13 Fox from model year 2006 67
13 1 Fox, type 5Z model year 2006 to model year 2012 67
13 2 Wheel allocation for Fox, type 5Z model year 2006 to model year 2012 68
13 2 1 5 J x 14 69
13 2 2 6 J x 14 69
13 2 3 6 J x 15 71
14 up! from model year 2012 74
14 1 Advance information about up! Model year 2012 74
15 Polo from model year 2010 75
15 1 Polo, type 6R model year 2010 to model year 2012 75
15 2 Wheel allocation for Polo, type 6R model year 2010 to model year 2012 77
15 2 1 5 J x 14 77
15 2 2 6 J x 15 offset 38 78
15 2 3 6 J x 15 offset 40 78
15 2 4 7 J x 16 79
15 2 5 7 J x 17 80
16 Polo BlueMotion from model year 2010 81
16 1 Polo BlueMotion, type 6R model year 2010 to model year 2012 81
16 2 Wheel allocation for Polo BlueMotion, type 6R model year 2010 to model year 2012 82
16 2 1 51/2 J x 15 82
16 2 2 6 J x 15 offset 38 83
16 2 3 6 J x 15 offset 40 83
17 CrossPolo from model year 2011 85
17 1 CrossPolo, type 6R model year 2011 to model year 2012 85
17 2 Wheel allocation CrossPolo, type 6R model year 2011 to model year 2012 87
17 2 1 5 J x 14 87
17 2 2 6 J x 15 offset 38 88
17 2 3 6 J x 15 offset 40 88
17 2 4 7 J x 16 89
17 2 5 7 J x 17 90
17 2 6 71/2 J x 17 91
18 Polo GTI from model year 2011 92
18 1 Polo GTI, type 6R model year 2011 to model year 2012 92
18 2 Wheel allocation Polo GTI, type 6R model year 2011 to model year 2012 93
18 2 1 6 J x 15 offset 38 93
18 2 2 6 J x 15 offset 40 93
18 2 3 7 J x 16 94
18 2 4 7 J x 17 95
19 Golf from model year 2009 96
19 1 Golf, Golf 4Motion, sales type 5K model year 2009 to model year 2012 96
19 2 Wheel allocation for Golf, Golf 4Motion, sales type 5K model year 2009 to model year 2012 100
19 2 1 6 J x 15 100
19 2 2 61/2 J x 15 101
19 2 3 6 J x 16 102
19 2 4 61/2 J x 16 103
19 2 5 6 J x 17 108
19 2 6 7 J x 17 109
19 2 7 71/2 J x 17 112
19 2 8 71/2 J x 18 114
20 Golf BlueMotion from model year 2009 118
20 1 Golf BlueMotion, sales type 5K model year 2009 to model year 2012 118
20 2 Wheel allocation for Golf BlueMotion, sales type 5K model year 2009 to model year 2012 120
20 2 1 6 J x 15 120
20 2 2 61/2 J x 15 121
20 2 3 61/2 J x 16 122
21 Golf GTD from model year 2010 128
21 1 Golf GTD, sales type 5K, model year 2010 to model year 2012 128
21 2 Wheel allocation for Golf GTD, type 5K model year 2010 to model year 2012 130
21 2 1 6 J x 16 130
21 2 2 61/2 J x 16 130
21 2 3 6 J x 17 135
21 2 4 7 J x 17 136
21 2 5 71/2 J x 17 139
21 2 6 71/2 J x 18 141
22 Golf GTI from model year 2010 145
22 1 Golf GTI, sales type 5K, model year 2010 to model year 2012 145
22 2 Wheel allocation for Golf GTI, type 5K model year 2010 to model year 2012 147
22 2 1 6 J x 16 147
22 2 2 61/2 J x 16 148
22 2 3 6 J x 17 153
22 2 4 7 J x 17 153
22 2 5 71/2 J x 17 157
22 2 6 71/2 J x 18 158
22 2 7 71/2 J x 19 161
23 Golf R from model year 2010 163
23 1 Golf R, sales type 5K model year 2010 163
23 2 Golf R, sales type 5K model year 2011 to model year 2012 164
23 3 Wheel allocation for Golf R, type 5K model year 2010 to model year 2012 165
23 3 1 6 J x 17 166
23 3 2 7 J x 17 166
23 3 3 71/2 J x 17 166
23 3 4 71/2 J x 18 168
23 3 5 8 J x 19 171
24 CrossGolf from model year 2011 173
24 1 CrossGolf, sales type 521 model year 2011 to model year 2012 173
24 2 Wheel allocation CrossGolf, sales type 521 model year 2011 to model year 2012 176
24 2 1 6 J x 15 176
24 2 2 61/2 J x 15 177
24 2 3 6 J x 16 178
24 2 4 61/2 J x 16 179
24 2 5 6 J x 17 184
24 2 6 7 J x 17 offset 47 185
24 2 7 7 J x 17 offset 54 185
24 2 8 71/2 J x 17 189
25 Golf Cabriolet from model year 2012 190
25 1 Golf Cabriolet, sales type 517 from model year 2012 190
25 2 Wheel allocation Golf Cabriolet, sales type 517 from model year 2012 192
25 2 1 6 J x 15 192
25 2 2 61/2 J x 15 193
25 2 3 6 J x 16 194
25 2 4 61/2 J x 16 195
25 2 5 6 J x 17 200
25 2 6 7 J x 17 201
25 2 7 71/2 J x 17 204
25 2 8 71/2 J x 18 206
26 Golf Plus from model year 2009 210
26 1 Golf Plus, sales type 521 model year 2009 to model year 2011 210
26 2 Golf Plus, sales type 521 model year 2012 215
26 3 Wheel allocation for Golf Plus, sales type 521 model year 2009 to model year 2012 219
26 3 1 6 J x 15 219
26 3 2 61/2 J x 15 220
26 3 3 6 J x 16 221
26 3 4 61/2 J x 16 221
26 3 5 6 J x 17 226
26 3 6 7 J x 17 227
26 3 7 71/2 J x 17 230
26 3 8 71/2 J x 18 232
27 Golf Plus BlueMotion from model year 2010 236
27 1 Golf Plus BlueMotion, sales type 521, model year 2010 to model year 2012 236
27 2 Wheel allocation for Golf Plus BlueMotion, sales type 521, model year 2010 to model year 2012 238
27 2 1 6 J x 15 238
27 2 2 61/2 J x 15 239
27 2 3 6 J x 16 240
27 2 4 61/2 J x 16 241
28 Golf Variant from model year 2010 247
28 1 Golf Variant, Golf Variant 4Motion, sales type AJ5 model year 2010 to model year 2012 247
28 2 Wheel allocation for Golf Variant, Golf Variant 4Motion, sales type AJ5 model year 2010 to model year 2012 253
28 2 1 6 J x 15 253
28 2 2 61/2 J x 15 254
28 2 3 6 J x 16 255
28 2 4 61/2 J x 16 256
28 2 5 6 J x 17 261
28 2 6 7 J x 17 262
28 2 7 71/2 J x 17 265
28 2 8 71/2 J x 18 267
29 Golf Variant BlueMotion from model year 2010 271
29 1 Golf Variant BlueMotion, sales type AJ5, model year 2010 to model year 2012 271
29 2 Wheel allocation for Golf Variant BlueMotion, sales type AJ5, model year 2010 to model year 2012 272
29 2 1 6 J x 15 272
29 2 2 61/2 J x 15 273
29 2 3 6 J x 16 274
29 2 4 61/2 J x 16 275
30 Jetta from model year 2011 281
30 1 Jetta, sales type 162 model year 2011 to model year 2012 281
30 2 Wheel allocation Jetta, sales type 162 model year 2011 284
30 2 1 6 J x 15 284
30 2 2 61/2 J x 15 285
30 2 3 6 J x 16 286
30 2 4 61/2 J x 16 287
30 2 5 7 J x 17 292
30 2 6 71/2 J x 17 296
30 2 7 71/2 J x 18 297
31 Jetta from model year 2011 (NAR) 301
31 1 Jetta, sales type 162 from model year 2011 (NAR) 301
31 2 Wheel allocation for Jetta, sales type 162 from model year 2011 (NAR) 303
31 2 1 6 J x 15 303
31 2 2 61/2 J x 15 303
31 2 3 6 J x 16 305
31 2 4 61/2 J x 16 305
31 2 5 7 J x 17 310
31 2 6 71/2 J x 17 314
31 2 7 71/2 J x 18 315
32 Beetle from model year 2012 319
32 1 Beetle, sales type 5C1, from model year 2012 319
32 2 Beetle, sales type 5C1, from model year 2012 320
32 2 1 61/2 J x 16 321
32 2 2 7 J x 17 321
32 2 3 8 J x 18 323
32 2 4 8 J x 19 324
33 Scirocco from model year 2009 325
33 1 Scirocco, sales type 137, model year 2009 to model year 2011 325
33 2 Scirocco, sales type 137 model year 2012 328
33 3 Wheel allocation for Scirocco, sales type 137 model year 2009 to model year 2012 330
33 3 1 61/2 J x 16 330
33 3 2 61/2 J x 17 330
33 3 3 7 J x 17 331
33 3 4 8 J x 17 331
33 3 5 8 J x 18 333
33 3 6 8 J x 19 334
34 Scirocco R from model year 2010 336
34 1 Scirocco R, sales type 137, model year 2010 to model year 2011 336
34 2 Scirocco R, sales type 137 model year 2012 337
34 3 Wheel allocation for Scirocco R, sales type 137, model year 2010 to model year 2012 338
34 3 1 61/2 J x 17 339
34 3 2 7 J x 17 339
34 3 3 8 J x 17 339
34 3 4 8 J x 18 341
34 3 5 8 J x 19 343
35 Touran from model year 2003 344
35 1 Touran, type 1T model year 2003 to model year 2006 344
35 2 Touran, type 1T model year 2007 to model year 2010 347
35 3 Touran, type 1T and type 1t model year 2011 to model year 2012 352
35 4 Wheel allocation Touran, type 1T and type 1t model year 2003 to model year 2012 357
35 4 1 6 J x 15 357
35 4 2 61/2 J x 15 358
35 4 3 6 J x 16 359
35 4 4 61/2 J x 16 359
35 4 5 6 J x 17 365
35 4 6 7 J x 17 365
35 4 7 71/2 J x 18 366
36 CrossTouran from model year 2008 367
36 1 CrossTouran, type 1T model year 2008 to model year 2009 367
36 2 CrossTouran, type 1T and type 1t model year 2010 to model year 2012 370
36 3 Wheel allocation CrossTouran, type 1T and type 1t model year 2008 to model year 2012 374
36 3 1 6 J x 15 374
36 3 2 6 J x 16 375
36 3 3 61/2 J x 17 375
36 3 4 8 J x 17 376
37 Touran BlueMotion from model year 2009 377
37 1 Touran BlueMotion, type 1T and type 1t model year 2009 to model year 2012 377
37 2 Wheel allocation Touran BlueMotion, type 1T and type 1t model year 2009 to model year 2012 379
37 2 1 6 J x 15 379
37 2 2 61/2 J x 15 380
37 2 3 6 J x 16 381
37 2 4 61/2 J x 16 381
38 Tiguan from model year 2008 387
38 1 Tiguan, type 5N model year 2008 to model year 2011 387
38 2 Tiguan, type 5N, model year 2012 388
38 3 Wheel allocation for Tiguan, type 5N model year 2008 to model year 2012 390
38 3 1 6 1/2 J x 16 390
38 3 2 61/2 J x 17 392
38 3 3 7 J x 17 392
38 3 4 7 J x 18 393
38 3 5 9 J x 19 394
39 Eos from model year 2006 395
39 1 Eos, type 1F from model year 2006 395
39 2 Eos, type 1F model year 2007 to model year 2012 396
39 3 Wheel allocation for Eos, type 1F model year 2006 to model year 2012 399
39 3 1 61/2 J x 16 399
39 3 2 7 J x 16 400
39 3 3 6 J x 17 402
39 3 4 71/2 J x 17 403
39 3 5 8 J x 18 406
40 Passat saloon from model year 2011 409
40 1 Passat saloon, sales type 362 model year 2011 to model year 2012 409
40 2 Wheel allocation Passat saloon, sales type 362 model year 2011 to model year 2012 414
40 2 1 61/2 J x 16 415
40 2 2 7 J x 16 415
40 2 3 6 J x 17 416
40 2 4 61/2 J x 17 417
40 2 5 71/2 J x 17 417
40 2 6 8 J x 18 418
41 Passat Variant from model year 2011 420
41 1 Passat estate, sales type 365 model year 2011 to model year 2012 420
41 2 Wheel allocation Passat estate, sales type 365 model year 2011 to model year 2012 425
41 2 1 61/2 J x 16 425
41 2 2 7 J x 16 426
41 2 3 6 J x 17 427
41 2 4 61/2 J x 17 427
41 2 5 71/2 J x 17 428
41 2 6 8 J x 18 429
42 Passat CC from model year 2009, CC from model year 2010 431
42 1 Passat CC, sales type 357 model year 2009 431
42 2 Passat CC, CC, sales type 357 model year 2010 to model year 2012 433
42 3 Wheel allocation Passat CC, CC, sales type 357 model year 2009 to model year 2012 434
42 3 1 61/2 J x 17 434
42 3 2 8 J x 17 435
42 3 3 8 J x 18 436
42 3 4 8 J x 19 438
43 Phaeton from model year 2003 439
43 1 Phaeton, type 3D, model year 2003 to model year 2009 – short and long wheelbase 439
43 2 Phaeton, type 3D and type 3d, model year 2010 to model year 2012 – short and long wheelbase 442
43 3 Wheel allocation for Phaeton, type 3D and type 3d, model year 2003 to model year 2012 – short and long wheelbase 444
43 3 1 71/2 J x 16 444
43 3 2 71/2 J x 17 444
43 3 3 71/2 J x 18 446
43 3 4 81/2 J x 18 446
43 3 5 81/2 J x 19 offset 38 448
43 3 6 81/2 J x 19 offset 45 449
43 3 7 9 J x 19 offset 35 449
43 3 8 9 J x 19 offset 40 450
43 3 9 9 J x 20 450
44 Sharan from model year 2011 452
44 1 Sharan, Sharan 4Motion, type 7N model year 2011 to model year 2012 452
44 2 Wheel allocation Sharan, Sharan 4Motion, type 7N model year 2011 to model year 2012 454
44 2 1 6 1/2 J x 16 454
44 2 2 7 J x 17 455
44 2 3 71/2 J x 18 455
45 Touareg from model year 2010 457
45 1 Touareg, type 7P and type 7p, model year 2010 to model year 2012 457
45 2 Wheel allocation for Touareg, type 7P and type 7p, model year 2010 to model year 2012 459
45 2 1 71/2 J x 17 459
45 2 2 8 J x 18 460
45 2 3 81/2 J x 19 461
45 2 4 9 J x 20 461
45 2 5 91/2 J x 21 462
46 Touareg hybrid from model year 2011 464
46 1 Touareg hybrid, type 7PH and type 7pH, model year 2011 to model year 2012 464
46 2 Wheel allocation Touareg hybrid, type 7PH and type 7pH, model year 2011 to model year 2012 465
46 2 1 8 J x 18 465
46 2 2 81/2 J x 19 466
47 Breakdown set for VW Vehicles 468
48 Temporary spare tyres and wheels for VW vehicles 469
49 Recommended summer tyres 470
49 1 Summer tyres for Fox from model year 2006 470
49 2 Summer tyres for Polo from model year 2010 470
49 3 Summer tyres for Polo BlueMotion from model year 2010 471
49 4 Summer tyres for CrossPolo from model year 2011 472
49 5 Summer tyres for Polo GTI from model year 2011 472
49 6 Summer tyres for Golf from model year 2009 473
49 7 Summer tyres for Golf BlueMotion from model year 2009 474
49 8 Summer tyres for Golf GTD from model year 2009 475
49 9 Summer tyres for Golf GTI from model year 2009 475
49 10 Summer tyres for Golf R from model year 2010 476
49 11 Summer tyres for CrossGolf from model year 2011 477
49 12 Summer tyres Golf Cabriolet from model year 2012 478
49 13 Summer tyres for Golf Plus from model year 2009 479
49 14 Summer tyres for Golf Plus BlueMotion from model year 2010 480
49 15 Summer tyres for Golf Variant from model year 2010 481
49 16 Summer tyres for Golf Variant BlueMotion from model year 2010 482
49 17 Summer tyres for Jetta from model year 2011 483
49 18 Summer tyres for Beetle from model year 2012 485
49 19 Summer tyres for Scirocco from model year 2009 485
49 20 Summer tyres for Scirocco R from model year 2010 485
49 21 Summer tyres for Touran from model year 2003 486
49 22 Summer tyres for Touran BlueMotion from model year 2009 486
49 23 Summer tyres for CrossTouran from model year 2008 487
49 24 Summer tyres for Tiguan from model year 2008 487
49 25 Summer tyres for Eos from model year 2006 488
49 26 Summer tyres for Passat saloon from model year 2011 488
49 27 Summer tyres for Passat Variant from model year 2011 489
49 28 Summer tyres Passat CC from model year 2009, CC from model year 2010 490
49 29 Summer tyres for Sharan from model year 2011 490
49 30 Summer tyres for Phaeton from model year 2003 490
49 31 Summer tyres for Touareg from model year 2010 491
49 32 Summer tyres for Touareg hybrid from model year 2011 491
50 Recommended all-season tyres 492
50 1 All-season tyres for Polo from model year 2010 492
50 2 All-season tyres for Polo BlueMotion from model year 2010 492
50 3 All-season tyres for CrossPolo from model year 2011 492
50 4 All-season tyres for Polo GTI from model year 2011 493
50 5 All-season tyres for Golf from model year 2009 493
50 6 All-season tyres for CrossGolf from model year 2011 493
50 7 All-weather tyres Golf Cabriolet from model year 2012 494
50 8 All-season tyres for Golf Plus from model year 2009 494
50 9 All-season tyres for Golf Variant from model year 2010 495
50 10 All-season tyres for Jetta from model year 2011 495
50 11 All-season tyres for Jetta from model year 2011 (NAR) 495
50 12 All-season tyres for Touran from model year 2003 496
50 13 All-season tyres for Beetle from model year 2012 496
50 14 All-season tyres for Tiguan from model year 2008 496
50 15 All-season tyres for Eos from model year 2006 496
50 16 All-season tyres for Passat saloon from model year 2011 497
50 17 All-season tyres for Passat Variant from model year 2011 497
50 18 All-season tyres Passat CC from model year 2009, CC from model year 2010 497
50 19 All-season tyres for Sharan from model year 2011 498
50 20 All-season tyres for Phaeton from model year 2003 498
50 21 All-season tyres for Touareg from model year 2010 498
50 22 All-season tyres Touareg hybrid from model year 2010 498
51 Recommended winter tyres 500
51 1 Winter tyres for Fox from model year 2006 500
51 2 Winter tyres for Polo from model year 2010 500
51 3 Winter tyres for Polo BlueMotion from model year 2010 501
51 4 Winter tyres for CrossPolo from model year 2011 501
51 5 Winter tyres for Polo GTI from model year 2011 501
51 6 Winter tyres for Golf from model year 2009 501
51 7 Winter tyres for Golf BlueMotion from model year 2009 502
51 8 Winter tyres for Golf GTD from model year 2009 502
51 9 Winter tyres for Golf GTI from model year 2009 502
51 10 Winter tyres for Golf R from model year 2010 502
51 11 Winter tyres for CrossGolf from model year 20011 503
51 12 Winter tyres Golf Cabriolet from model year 2012 503
51 13 Winter tyres for Golf Plus from model year 2009 503
51 14 Winter tyres for Golf Plus BlueMotion from model year 2010 504
51 15 Winter tyres for Golf Variant from model year 2010 504
51 16 Winter tyres for Golf Variant BlueMotion from model year 2010 504
51 17 Winter tyres for Jetta from model year 2011 505
51 18 Winter tyres for Beetle from model year 2012 505
51 19 Winter tyres for Scirocco from model year 2009 505
51 20 Winter tyres for Scirocco R from model year 2010 505
51 21 Winter tyres for Touran from model year 2003 506
51 22 Winter tyres for Touran BlueMotion from model year 2009 506
51 23 Winter tyres for CrossTouran from model year 2008 506
51 24 Winter tyres for Tiguan from model year 2008 507
51 25 Winter tyres for Eos from model year 2006 507
51 26 Winter tyres for Passat saloon from model year 2011 507
51 27 Winter tyres for Passat Variant from model year 2011 507
51 28 Winter tyres Passat CC from model year 2009, CC from model year 2010 508
51 29 Winter tyres for Sharan from model year 2011 508
51 30 Winter tyres for Phaeton from model year 2003 508
51 31 Winter tyres for Touareg from model year 2010 508
51 32 Winter tyres Touareg hybrid from model year 2010 509
D3E801F2B16 Electrical system General information 510
27 – Starter, current supply, CCS 514
1 Battery 514
1 1 Fundamentals for batteries 514
1 2 Battery load test 514
1 2 1 Battery with »standard« colour indicator 515
1 2 2 Battery with »enhanced« colour indicator 515
1 2 3 Absorbent glass mat battery 516
1 2 4 Lithium ion battery 516
1 3 Warning notices and safety regulations 516
1 3 1 Dangers when handling vehicle batteries 516
1 3 2 Safety markings on battery 517
1 3 3 Working on airbag system 518
1 4 Battery load test 518
2 Checking battery 520
2 1 Checking the various types of batteries 520
2 1 1 Checking a battery with colour indicator 520
2 1 2 Absorbent glass mat battery 520
2 2 Inspection 521
2 3 Information about battery replacement and battery gas venting 522
2 4 Checking colour indicator in battery cover 523
2 4 1 Checking colour indicator, “3-colour” 523
2 4 2 Checking colour indicator, “2-colour” 524
2 5 Battery tester with printer -VAS 6161- 525
2 5 1 Description of battery tester with printer -VAS 6161- 526
2 5 2 Perform battery test with battery tester with printer -VAS 6161- 526
2 5 3 Genuine Volkswagen battery test 528
2 5 4 “Non”-VW battery test 528
2 5 5 Carrying out stock maintenance 529
2 5 6 Comments concerning test print out 529
2 5 7 Assessing test results 530
2 6 Midtronics -MCR340V- battery tester only for USA/Canada vehicles 530
2 6 1 General description 531
2 6 2 Performing battery test with Midtronics -MCR340V- battery tester 532
2 6 3 Assessing test results 533
2 6 4 Dealing with problems with Midtronics -MCR340V- battery tester 533
2 7 Current draw test 534
3 Charging the battery 536
3 1 Battery charger -VAS 5095 A- 536
3 1 1 Description of battery charger -VAS 5095 A- 537
3 1 2 Charging battery with battery charger -VAS 5095 A- 538
3 1 3 Charging totally discharged battery with battery charger -VAS 5095 A- 539
3 1 4 Charging battery in support mode with battery charger -VAS 5095A- 540
3 1 5 Charging battery in trickle charge mode with battery charger -VAS 5095 A- 542
3 2 Battery charger -VAS 5900- 543
3 2 1 Description of battery charger -VAS 5900- 543
3 2 2 Charging battery with battery charger -VAS 5900- 544
3 2 3 Charging battery in service mode with battery charger -VAS 5900- 547
3 2 4 Charging totally discharged batteries with battery charger -VAS 5900- 550
3 2 5 Charging battery in support mode with battery charger -VAS 5900- 552
3 2 6 Charging battery in trickle charge mode with battery charger -VAS 5900- 554
3 3 Battery charger -VAS 5900 A- 555
3 3 1 General description – battery charger -VAS 5900 A- 555
3 3 2 Charging battery with battery charger -VAS 5900 A- 557
3 3 3 Charging totally discharged battery with battery charger -VAS 5900 A- 558
3 3 4 Charging battery in support mode with battery charger -VAS 5900 A- 561
3 3 5 Mains supply mode with battery charger -VAS 5900 A- 563
3 4 Battery charger -VAS 5903- 564
3 4 1 Description of battery charger -VAS 5903- 565
3 4 2 Charging battery with battery charger -VAS 5903- 565
3 4 3 Charging battery in refresh charge mode with battery charger -VAS 5903- 568
3 4 4 Charging totally discharged battery with battery charger -VAS 5903- 571
3 4 5 Charging battery in support mode with battery charger -VAS 5903- 573
3 4 6 Charging battery in trickle charge mode with battery charger -VAS 5903- 575
3 5 Battery charger -VAS 5906- 576
3 5 1 General description 576
3 5 2 Charging battery with battery charger -VAS 5906- 577
3 6 Battery charger -VAS 5908- 579
3 6 1 General description – battery charger -VAS 5908- 579
3 6 2 Auto mode on battery charger -VAS 5908- 581
3 6 3 Charging battery with battery charger -VAS 5908- 582
3 6 4 Charging battery in support mode with battery charger -VAS 5908- 584
3 6 5 VAS I-CHECK current draw test with battery charger -VAS 5908- 586
3 7 Midtronics -INC 940- battery charger only for USA/Canada 588
3 7 1 General description of Midtronics -INC 940- battery tester 588
3 7 2 Charging battery 589
3 7 3 Dealing with problems with Midtronics -INC 940- battery tester 591
3 8 Solar charger module -VAS 6102B- 592
3 8 1 Charging battery in trickle charge mode with solar panel -VAS 6102B- 592
3 9 Totally discharged batteries 593
4 Cruise control system (CCS) 595
4 1 Activating and deactivating cruise control system (CCS) 595
90 – Gauges, instruments 596
92 – Windscreen wash/wipe system 597
1 Washer fluid line hose couplings 597
1 1 Windscreen and rear window washer system 597
1 2 Headlight washer system 598
2 Hose repair 599
2 1 General description 599
2 2 Repairing smooth pipe 599
2 3 Repairing corrugated pipe 599
3 Distinguishing features of jointless wiper blades 602
94 – Lights, bulbs, switches – exterior 603
1 Operation and safety notes for gas discharge lamps 603
96 – Lights, bulbs, switches – interior 606
1 12 V socket 606
1 1 Removing and installing 12 V socket 606
1 2 Removing and installing socket illumination bulb -L42- 606
2 Cigarette lighter -U1- 607
2 1 General description 607
2 2 Assembly overview 608
2 3 Removing and installing cigarette lighter socket 609
2 4 Removing and installing cigarette lighter illumination bulb -L28- 612
97 – Wiring 614
1 Vehicle diagnosis, testing and information systems 614
1 1 Connecting vehicle diagnostic tester 614
1 2 Connecting vehicle diagnostic tester Golf Model Year 1998 – 2003 616
2 Repairs to wiring harnesses and connectors 617
2 1 General notes concerning repairs to vehicle electrical system 617
2 2 Wiring harness repair set 619
2 2 1 Wiring harness repair set -VAS 1978- 619
2 2 2 Upgrade kit -VAS 1978/50- 619
2 2 3 Wiring harness repair set -VAS 1978A- 620
2 2 4 Release tool set -VAS 1978/35- 620
2 3 Tool descriptions 621
2 3 1 Special pliers with insert 621
2 3 2 Release tools for contacts 622
2 3 3 Assembly tools for single wire seals 622
2 3 4 Wire stripper -VAS 1978/3- 622
2 3 5 Hot air blower 220 V/50 Hz -VAS 1978/14- 624
2 3 6 Crimping pliers -VAS 1978/1A- 624
2 4 Repairing wiring harnesses 626
2 4 1 Repairs to airbag and belt tensioner wiring 626
2 4 2 Repairing CAN bus wiring 628
2 4 3 Repair of Flexray wires with sheath 629
2 4 4 Repair of Flexray wires without sheath 630
2 4 5 Renewal of aerial wiring 631
2 4 6 Repairing 0 13 mm2/0 35 mm2/0 5 mm2 wire 633
2 4 7 Repair of 10 mm2 or 16 mm2 wire with single butt connector 638
2 4 8 Repair of 2 5 mm2, 4 mm2 or 6 mm2 aluminium wire with single butt connector 645
2 4 9 Wiring open circuit with one repair position 651
2 4 10 Wiring open circuit with two repair positions 654
2 5 Repairing fibre optic cables 656
2 5 1 Preparing fibre optic cable 657
2 5 2 Detaching fibre optic cable from cable harness connector 664
2 6 Repair of aerial wires 665
2 6 1 Repair set, aerial cable VAS 6720 665
2 7 Repairs to contact housings and connectors 677
2 7 1 Notes on repairs to contact housings and connectors 677
2 7 2 Repairs to contacts in contact housings 677
2 7 3 Fitting single wire seals 679
2 7 4 Repairs to contact housings using cut-and-clamp method 682
2 8 Releasing and dismantling contact housings 683
2 8 1 Notes on releasing and dismantling contact housings 683
2 8 2 Secondary locking element 683
2 8 3 Primary locking element 684
2 8 4 Round connector systems 685
2 8 5 Flat connector systems 686
2 8 6 Special connector systems 688
3 Contact surface cleaning set -VAS 6410- 691
3 1 Using contact surface cleaning set -VAS 6410- 691
3 1 1 Repairing ring terminals 691
3 1 2 Repairing threaded connections 693
3 1 3 Cleaning battery clamp and battery terminal 695
3 1 4 Anti-corrosion treatment 697
4 Renewing lambda probe 699
4 1 Renewing LSF Lambda probe (4-pin) 699
4 2 Renewing LSU Lambda probe (6-pin) 700
4 3 Types of protective tube on universal lambda probes 701
5 Exhaust gas temperature sensor 703
D3E803A5E78 5 speed manual gearbox 0A4 704
00 – Technical data 708
1 Safety information 708
1 1 Safety measures when working on vehicles with a start/stop system 708
1 2 Safety precautions when using testers and measuring instruments during a road test 708
2 Identification 709
2 1 Gearbox identification 709
3 Repair notes 710
3 1 General repair instructions 710
4 Technical data 714
4 1 Capacities 714
4 2 Allocation gearbox – engine 714
4 3 Calculation of gear ratios 715
5 Overview – power transmission 717
5 1 Overview – power transmission – front-wheel drive 717
6 Electrical components 719
6 1 Overview of fitting locations – electrical components 719
6 1 1 Overview of fitting locations – electrical components, manual gearbox 719
6 1 2 Overview of fitting locations – electrical components, clutch mechanism 720
30 – Clutch 721
1 Clutch operation 721
1 1 Assembly overview – pedal cluster 721
1 2 Assembly overview – clutch hydraulics 724
1 2 1 Assembly overview – clutch hydraulics, left-hand drive 724
1 2 2 Assembly overview – clutch hydraulics, right-hand drive 726
1 3 Assembly overview – clutch release mechanism 727
1 4 Removing and installing clutch pedal 728
1 5 Removing and installing over-centre spring 730
1 6 Removing and installing mounting bracket 732
1 7 Removing and installing clutch master cylinder 739
1 8 Removing and installing clutch slave cylinder 741
1 9 Bleeding clutch mechanism 745
1 10 Checking clutch master cylinder and clutch slave cylinder 746
1 11 Removing and installing clutch position sender -G476- 746
1 12 Repairing clutch release mechanism 750
2 Clutch 751
2 1 Determining make of clutch 751
2 2 Assembly overview – clutch 752
2 2 1 Assembly overview – clutch in conjunction with Sachs dual-mass flywheel 752
2 2 2 Assembly overview – clutch in conjunction with LuK dual-mass flywheel 754
2 2 3 Assembly overview – clutch with simple flywheel 756
2 3 Removing and installing clutch 757
2 3 1 Removing and installing clutch in conjunction with Sachs dual-mass flywheel 757
2 3 2 Removing and installing clutch in conjunction with LuK dual-mass flywheel 760
2 3 3 Removing and installing clutch in connection with simple flywheel 764
34 – Controls, housing 768
1 Selector mechanism 768
1 1 Installation position – selector mechanism 768
1 2 Assembly overview – gear knob and cover 770
1 3 Assembly overview – Gear lever and selector housing 771
1 4 Assembly overview – Selector cables 773
1 5 Removing and installing gear knob 777
1 6 Removing and installing selector mechanism 779
1 7 Adjusting selector mechanism 785
1 8 Checking selector mechanism 789
1 9 Removing and installing gear selector cable and gate selector cable 789
1 10 Renewing selector shaft seal 790
1 11 Dismantling and assembling selector mechanism 791
2 Removing and installing gearbox 798
2 1 Specified torques for gearbox 798
2 2 Removing gearbox 799
2 2 1 Removing gearbox, vehicles with 1 8 l – 125 kW petrol engine 799
2 2 2 Removing gearbox, vehicles with 2 5 l – 125 kW petrol engine 812
2 2 3 Removing gearbox – vehicles with 1 6 l – 77 kW diesel engine 824
2 2 4 Removing gearbox – vehicles with 2 0 l – 81 kW diesel engine 836
2 3 Installing gearbox 849
3 Assembly mountings 856
3 1 Assembly overview – assembly mountings 856
4 Transporting gearbox 858
5 Dismantling and assembling gearbox 859
5 1 Schematic overview – gearbox 859
5 2 Assembly overview – cover for gearbox housing and 5th gear 861
5 3 Assembly overview – gearbox housing and selector mechanism 862
5 4 Assembly overview – selector unit 863
5 5 Assembly overview – input shaft, output shafts, differential, selector rods 864
5 6 Assembly overview – selector forks 865
5 7 Repairing selector unit 866
5 8 Repairing selector forks 867
5 9 Dismantling and assembling gearbox 871
5 10 Removing cover for gearbox housing and 5th gear 885
5 11 Installing cover for gearbox housing and 5th gear 891
6 Gearbox housing, clutch housing 895
6 1 Assembly overview – gearbox housing 895
6 2 Assembly overview – clutch housing 897
6 3 Repairing gearbox housing 898
6 3 1 Removing and installing input shaft bearings in gearbox housing 898
6 3 2 Removing and installing output shaft bearings in gearbox housing 900
6 3 3 Removing and installing differential bearings in gearbox housing 903
6 4 Repairing clutch housing 905
6 4 1 Removing and installing input shaft bearings in clutch housing 905
6 4 2 Removing and installing output shaft bearings in clutch housing 906
6 4 3 Removing and installing differential bearings in clutch housing 908
7 Securing to engine and gearbox support 911
8 Gear oil 912
8 1 Checking gear oil level 912
8 2 Draining and filling gear oil 912
35 – Gears, shafts 915
1 Input shaft 915
1 1 Assembly overview – input shaft 915
1 2 Dismantling and assembling input shaft 918
1 3 Adjusting input shaft 924
2 Output shaft 929
2 1 Assembly overview – output shaft 929
2 2 Dismantling and assembling output shaft 932
2 3 Adjusting output shaft 942
3 Reverse shaft 949
3 1 Assembly overview – reverse shaft 949
3 1 1 Assembly overview – reverse shaft with synchromeshed gear for reverse gear 949
3 1 2 Assembly overview – reverse shaft with locking collar for reverse gear 950
3 2 Dismantling and assembling reverse shaft 951
39 – Final drive – differential 954
1 Oil seals 954
1 1 Overview of fitting locations – seals 954
1 2 Renewing left seal 955
1 3 Renewing right oil seal 957
1 3 1 Renewing right oil seal, gearbox installed 957
1 3 2 Renewing right oil seal, gearbox removed 960
1 4 Renewing input shaft seal 962
2 Differential 965
2 1 Assembly overview – differential 965
2 2 Dismantling and assembling differential 967
2 3 Adjusting differential 973
3 Adjustment overview 977
D3E803A5EB6 6 speed manual gearbox 0AJ 978
00 – Technical data 982
1 Safety information 982
1 1 Safety measures when working on vehicles with a start/stop system 982
1 2 Safety precautions when using testers and measuring instruments during a road test 982
2 Identification 983
2 1 Gearbox identification 983
3 Repair notes 984
3 1 General repair instructions 984
4 Technical data 989
4 1 Capacities 989
4 2 Allocation gearbox – engine 989
4 3 Calculation of gear ratios 990
5 Overview – power transmission 991
5 1 Overview – power transmission – front-wheel drive 991
6 Electrical components 993
6 1 Overview of fitting locations – electrical components 993
6 1 1 Overview of fitting locations – electrical components, manual gearbox 993
6 1 2 Overview of fitting locations – electrical components, clutch mechanism 994
30 – Clutch 995
1 Clutch mechanism 995
1 1 Assembly overview – pedal cluster 995
1 2 Assembly overview – clutch hydraulics 997
1 2 1 Assembly overview – clutch hydraulics, left-hand drive 997
1 2 2 Assembly overview – clutch hydraulics, right-hand drive 999
1 3 Assembly overview – clutch release mechanism 1001
1 4 Removing and installing clutch pedal 1002
1 5 Removing and installing over-centre spring 1005
1 6 Removing and installing mounting bracket 1008
1 7 Removing and installing clutch master cylinder 1017
1 8 Removing and installing clutch slave cylinder 1020
1 9 Bleeding clutch mechanism 1024
1 10 Checking clutch master cylinder and clutch slave cylinder 1025
1 11 Removing and installing clutch position sender -G476- 1025
1 12 Repairing clutch release mechanism 1029
2 Clutch 1031
2 1 Assembly overview – clutch 1031
2 2 Removing and installing clutch 1031
34 – Controls, housing 1038
1 Selector mechanism 1038
1 1 Installation position – selector mechanism 1038
1 2 Assembly overview – gear knob and cover 1039
1 3 Assembly overview – Gear lever and selector housing 1040
1 4 Assembly overview – selector cables 1042
1 5 Removing and installing gear knob 1044
1 6 Removing and installing selector mechanism 1047
1 7 Adjusting selector mechanism 1056
1 8 Checking selector mechanism 1060
1 9 Removing and installing gear selector cable and gate selector cable 1061
1 10 Repairing selector mechanism 1063
1 11 Renewing selector shaft seal 1064
1 12 Dismantling and assembling selector mechanism 1066
2 Removing and installing gearbox 1074
2 1 Specified torques for gearbox 1074
2 1 1 Specified torques for gearbox with engine lifting eyes »at front« of engine 1074
2 1 2 Specified torques for gearbox with engine lifting eyes »at rear« of engine 1075
2 2 Removing gearbox 1076
2 3 Installing gearbox 1090
3 Assembly mounting 1101
3 1 Assembly overview – assembly mountings 1101
4 Transporting gearbox 1105
5 Dismantling and assembling gearbox 1107
5 1 Schematic overview – gearbox 1107
5 2 Assembly overview – cover for gearbox housing and 5th/6th gear 1107
5 3 Assembly overview – selector unit 1109
5 4 Assembly overview – input shaft, output shafts, differential, selector rods 1111
5 5 Assembly overview – selector forks 1113
5 6 Repairing selector forks 1114
5 7 Dismantling and assembling gearbox 1119
6 Gearbox housing, clutch housing 1144
6 1 Assembly overview – clutch housing 1144
6 2 Assembly overview – gearbox housing and clutch housing 1144
6 3 Assembly overview – gearbox housing cover 1146
6 4 Repairing gearbox housing 1148
6 5 Repairing gearbox housing cover 1149
7 Securing to engine and gearbox support 1153
8 Gear oil 1155
8 1 Checking gear oil level 1155
35 – Gears, shafts 1157
1 Input shaft 1157
1 1 Assembly overview – input shaft 1157
1 2 Dismantling and assembling input shaft 1160
1 3 Renewing input shaft seal 1171
2 Output shaft 1173
2 1 Assembly overview – output shaft 1173
2 2 Dismantling and assembling output shaft 1176
39 – Final drive – differential 1184
1 Oil seals 1184
1 1 Overview of fitting locations – seals 1184
1 2 Renewing left seal 1184
1 3 Renewing right seal 1187
2 Differential 1192
2 1 Assembly overview – differential 1192
2 2 Dismantling and assembling differential 1194
2 3 Adjusting differential 1201
D3E803A5EDA 6 speed manual gearbox 02Q 1205
00 – Technical data 1209
1 Safety information 1209
1 1 Safety measures when working on vehicles with a start/stop system 1209
1 2 Safety precautions when using testers and measuring instruments during a road test 1209
2 Identification 1210
2 1 Gearbox identification 1210
3 Repair notes 1211
3 1 General repair instructions 1211
3 2 Contact corrosion 1214
4 Technical data 1215
4 1 Capacities 1215
4 2 Allocation gearbox – engine 1215
4 3 Calculation of gear ratios 1216
5 Overview – power transmission 1217
5 1 Overview – power transmission – front-wheel drive 1217
30 – Clutch 1219
1 Clutch operation 1219
1 1 Assembly overview – pedal cluster 1219
1 2 Assembly overview – clutch hydraulics 1222
1 2 1 Assembly overview – clutch hydraulics, left-hand drive 1222
1 2 2 Assembly overview – clutch hydraulics, right-hand drive 1224
1 3 Assembly overview – clutch release mechanism 1226
1 4 Removing and installing clutch pedal 1226
1 5 Removing and installing over-centre spring 1232
1 6 Removing and installing mounting bracket 1237
1 7 Removing and installing clutch master cylinder 1244
1 8 Removing and installing clutch slave cylinder together with release bearing 1246
1 9 Removing and installing lines for clutch mechanism 1247
1 10 Removing and installing bleeder 1250
1 11 Bleeding clutch mechanism 1251
1 12 Checking clutch master cylinder and clutch slave cylinder 1252
1 13 Removing and installing clutch position sender -G476- 1252
1 14 Repairing clutch release mechanism 1255
2 Clutch 1257
2 1 Determining make of clutch 1257
2 2 Assembly overview – clutch 1258
2 2 1 Assembly overview – clutch in conjunction with Sachs dual-mass flywheel 1258
2 2 2 Assembly overview – clutch in conjunction with LuK dual-mass flywheel 1260
2 2 3 Assembly overview – clutch with simple flywheel 1261
2 3 Removing and installing clutch 1262
2 3 1 Removing and installing clutch in conjunction with Sachs dual-mass flywheel 1262
2 3 2 Removing and installing clutch in conjunction with LuK dual-mass flywheel 1266
2 3 3 Removing and installing clutch in connection with simple flywheel 1271
34 – Controls, housing 1275
1 Selector mechanism 1275
1 1 Installation position – selector mechanism 1275
1 2 Assembly overview – gear knob and cover 1277
1 3 Assembly overview – Gear lever and selector housing 1278
1 4 Assembly overview – Selector cables 1280
1 5 Removing and installing gear knob 1283
1 6 Removing and installing selector mechanism 1286
1 7 Adjusting selector mechanism 1290
1 8 Checking selector mechanism 1294
1 9 Removing and installing gear selector cable and gate selector cable 1294
1 10 Renewing selector shaft seal 1296
1 11 Dismantling and assembling selector mechanism 1299
2 Removing and installing gearbox 1305
2 1 Specified torques for gearbox 1305
2 2 Removing gearbox 1305
2 2 1 Removing gearbox, vehicles with petrol engine 1305
2 2 2 Removing gearbox, vehicles with diesel engine 1317
2 3 Installing gearbox 1329
3 Assembly mountings 1337
3 1 Assembly overview – assembly mountings 1337
4 Transporting gearbox 1340
5 Dismantling and assembling gearbox 1341
5 1 Schematic overview – gearbox 1341
5 2 Assembly overview – gearbox housing and selector mechanism 1342
5 3 Assembly overview – selector unit 1344
5 4 Assembly overview – input shaft, output shafts, differential, selector rods 1345
5 5 Assembly overview – selector forks 1347
5 6 Dismantling and assembling gearbox 1347
6 Gearbox housing, clutch housing 1362
6 1 Assembly overview – gearbox housing 1362
6 2 Assembly overview – clutch housing 1364
6 3 Repairing gearbox housing 1365
6 4 Repairing clutch housing 1372
7 Securing to engine and gearbox support 1376
8 Gear oil 1377
8 1 Checking gear oil level 1377
35 – Gears, shafts 1379
1 Input shaft 1379
1 1 Assembly overview – input shaft 1379
1 2 Dismantling and assembling input shaft 1380
1 3 Renewing input shaft seal 1384
2 Output shaft 1386
2 1 Assembly overview – output shaft 1386
2 1 1 Assembly overview – output shaft for 1st to 4th gears 1386
2 1 2 Assembly overview – output shaft for 5th, 6th and reverse gear 1390
2 2 Dismantling and assembling output shaft 1393
2 2 1 Dismantling and assembling output shaft for 1st to 4th gears 1393
2 2 2 Dismantling and assembling output shaft for 5th, 6th and reverse gears 1405
2 3 Adjusting output shaft 1415
2 3 1 Adjusting output shaft for 1st to 4th gears 1415
2 3 2 Adjusting output shaft for 5th, 6th and reverse gears 1420
39 – Final drive – differential 1426
1 Oil seals 1426
1 1 Overview of fitting locations – seals 1426
1 2 Renewing left seal 1427
1 3 Renewing right oil seal 1430
2 Differential 1433
2 1 Assembly overview – differential 1433
2 2 Dismantling and assembling differential 1435
2 3 Adjusting differential 1440
3 Adjustment overview 1444
D3E803A7FFA Heating air conditioner 1445
00 – Technical data 1451
1 Safety information 1451
1 1 Safety precautions when working on air conditioning systems 1451
1 2 Safety measures when working on vehicles with a start/stop system 1451
1 3 Safety precautions when using test and measuring instruments during a road test 1452
1 4 Safety precautions when working on the cooling system 1452
1 5 Safety precautions when handling refrigerants 1452
1 6 Safety precautions for working on vehicles with auxiliary/supplementary heater 1453
2 Identification 1455
2 1 Identification of heater and air conditioning unit 1455
2 1 1 Identification of heater and air conditioning unit made by Valeo 1455
2 1 2 Identification of Denso heater and air conditioning unit 1455
3 General information 1457
3 1 Type plates 1457
3 2 Notes concerning odours in air conditioned vehicles 1457
3 3 Notes for vehicles with start-stop system 1458
3 4 Notes on dust and pollen filter 1459
4 Repair notes 1460
4 1 Rules for cleanliness 1460
4 2 Nuts and bolts 1460
4 3 Pipe/wire routing and attachment 1461
4 4 Fitting radiators and condensers 1461
4 5 Checking heater output 1461
4 6 Checking cooling output 1464
4 7 Working on refrigerant circuit 1466
4 8 Paint work on vehicles with air conditioning system 1466
4 9 Refrigerant circuit seals 1467
5 Technical data 1468
5 1 Refrigerant capacity 1468
5 2 Refrigerant oil capacities 1468
5 3 Oil distribution 1468
80 – Heating 1470
1 Overview of fitting locations – heating 1470
1 1 Overview of fitting locations – components not located in passenger compartment 1470
1 2 Overview of fitting locations – components located in front section of passenger compartment 1471
2 Heater 1474
2 1 Assembly overview – heater unit 1474
2 2 Removing and installing flexible shafts 1476
2 2 1 Removing and installing flexible shaft for air distribution 1476
2 2 2 Checking flexible shaft for air distribution 1477
2 2 3 Removing and installing Bowden cable for temperature flap 1477
3 Control motors 1480
3 1 Removing and installing fresh air and air recirculation flap control motor -V154- 1480
4 Air duct 1481
5 Operating and display unit 1482
5 1 Overview of operating and display unit 1482
5 2 Removing and installing operating and display unit 1484
5 2 1 Removing and installing front part of operating and display unit 1484
5 2 2 Removing and installing rear part of operating and display unit 1486
6 Other controlling and regulating components 1488
87 – Air conditioning system 1489
1 Overview of fitting locations – air conditioning system 1489
1 1 Overview of fitting locations – components not located in passenger compartment 1489
1 2 Overview of fitting locations – components located in front section of passenger compartment 1491
1 2 1 Overview of fitting locations – components inside front passenger compartment, air conditioning system with electric/manual controls 1491
1 2 2 Overview of fitting locations – components inside of front passenger compartment, Climatronic 1494
2 Refrigerant circuit 1498
2 1 System overview – refrigerant circuit 1498
2 2 Assembly overview – condenser 1500
2 3 Removing and installing high-pressure sender -G65- 1502
2 4 Removing and installing expansion valve 1503
2 5 Removing and installing condenser 1507
2 6 Removing and installing desiccant bag or cartridge 1510
2 7 Removing and installing evacuating and charging valves on low and high-pressure side 1512
2 8 Removing and installing refrigerant line from air conditioner compressor to evaporator 1514
2 9 Removing and installing refrigerant line from condenser to air conditioner compressor 1518
2 10 Removing and installing refrigerant line from air conditioner compressor to evaporator 1521
3 Air conditioner compressor 1524
3 1 Assembly overview – drive unit of air conditioner compressor 1524
3 2 Assembly overview – pulley 1526
3 2 1 Assembly overview – pulley, Denso air conditioner compressor 1526
3 2 2 Assembly overview – belt pulley, Sanden air conditioner compressor 1526
3 3 Removing air conditioning compressor from and installing on bracket 1528
3 4 Removing and installing air conditioner compressor 1529
3 5 Checking high-pressure safety valve on air conditioner compressor 1533
3 6 Removing and installing pulley 1534
3 6 1 Removing and installing Denso belt pulley 1534
3 6 2 Removing and installing Sanden belt pulley 1537
4 Control motors 1538
4 1 Overview of fitting locations – control motors at front 1538
4 2 Removing and installing centre flap control motor -V70- 1540
4 3 Removing and installing defroster flap control motor -V107- 1541
4 4 Removing and installing air recirculation flap control motor -V113- 1543
4 5 Removing and installing left temperature flap control motor -V158- 1547
4 6 Removing and installing right temperature flap control motor -V159- 1549
4 7 Removing and installing fresh air/air recirculation, air flow flap control motor -V425- 1551
4 8 Removing and installing fresh air/air recirculation, air flow flap actuator 1553
5 Front heater and air conditioning unit 1555
5 1 Assembly overview – add-on parts of heater and air conditioning unit and of air intake box 1555
5 2 Assembly overview – heater and air conditioning unit 1560
5 2 1 Assembly overview – heater and air conditioning unit, air conditioning system with electric/manual controls 1560
5 2 2 Assembly overview – heater and air conditioning unit, Climatronic 1562
5 3 Assembly overview – evaporator housing 1564
5 4 Removing and installing evaporator 1565
5 5 Checking auxiliary air heater element -Z35- 1567
5 6 Removing and installing auxiliary air heater element -Z35- 1570
5 7 Removing and installing heater and air conditioning unit 1572
5 8 Dismantling and assembling heater and air conditioning unit 1578
5 9 Removing and installing air distribution housing 1580
5 10 Removing and installing dust and pollen filter 1582
5 11 Removing and installing fresh air blower -V2- 1583
5 12 Removing and installing fresh air blower control unit -J126- 1584
5 13 Removing and installing heat exchanger 1585
5 13 1 Removing and installing heat exchanger, left-hand drive vehicles 1585
5 13 2 Removing and installing heat exchanger (RHD) 1591
5 14 Removing and installing coolant pipes on heat exchanger 1597
5 15 Removing and installing evaporator temperature sensor -G308- 1599
5 16 Removing and installing condensation drain 1599
5 17 Checking condensation drain 1600
5 18 Removing and installing fresh air blower series resistor with overheating fuse -N24- 1601
5 19 Removing and installing glove box cooling 1601
6 Air duct 1603
6 1 Assembly overview – air duct and air distribution in passenger compartment 1603
6 2 Air intake and air outlet openings 1606
6 2 1 Removing and installing centre vent 1606
6 3 Removing and installing driver side footwell vents 1607
6 4 Removing and installing front passenger side footwell vents 1608
6 5 Removing and installing rear footwell vent 1609
6 6 Installing plug in air duct to centre vent 1610
6 7 Removing and installing air ducts 1611
6 7 1 Removing and installing air duct/connecting piece for side vent 1611
6 7 2 Removing and installing air duct for centre vent 1612
6 8 Removing and installing forced ventilation for passenger compartment 1613
6 9 Checking forced ventilation for passenger compartment 1614
6 10 Removing and installing fresh air intake 1614
6 11 Removing and installing air duct for defroster vent 1616
6 12 Removing and installing air duct for centre dash panel vent 1616
7 Operating and display unit 1618
7 1 Overview of fitting locations – operating and display unit 1618
7 1 1 Overview of fitting locations – operating and display unit, air conditioning system with electric/manual controls 1618
7 1 2 Overview of fitting locations – operating and display unit, Climatronic 1620
7 2 Removing and installing operating and display unit 1622
7 2 1 Removing and installing operating and display unit, air conditioning system with electric/manual controls 1622
7 2 2 Removing and installing operating and display unit, Climatronic 1622
8 Other controlling and regulating components 1625
8 1 Removing and installing sunlight penetration photosensor -G107- 1625
8 2 Working principles of air quality sensor -G238- 1626
8 3 Removing and installing air quality sensor -G238- 1627
8 4 Removing and installing ambient temperature sensor -G17- 1628
8 5 Removing and installing left vent temperature sender -G150- 1629
8 6 Removing and installing left footwell vent temperature sender -G261- 1629
8 7 Removing and installing right footwell vent temperature sender -G262- 1630
D3E803BF17F Communication 1631
00 – Technical data 1635
1 Repair instructions 1635
1 1 General repair instructions 1635
1 2 Notes on repair of CAN bus wiring 1635
91 – Communication 1636
1 Sound system 1636
1 1 Components of sound system 1636
1 1 1 Sound system, 4 loudspeakers, 8RE 1636
1 1 2 Sound system, 6 loudspeakers, 8RL 1637
1 1 3 Sound system, 8 loudspeakers, 8RM 1638
1 1 4 Sound system, 9 loudspeakers, 8RU 1639
1 2 Overview of fitting locations – sound system 1640
1 3 Renewing rotary knobs of display unit for front information display and operating unit control unit -J685- 1641
1 4 Removing and installing digital sound package control unit/amplifier 1642
1 4 1 Removing and installing amplifier -R12- 1642
1 5 Removing and installing rear treble loudspeakers -R14-/-R16- 1643
1 6 Removing and installing front treble loudspeakers -R20-/-R22- 1644
1 7 Removing and installing rear bass loudspeakers -R15-/-R17- 1645
1 8 Removing and installing front bass loudspeakers -R21-/-R23- 1647
1 9 Removing and installing subwoofer -R211- 1648
1 10 Pin assignments 1649
1 10 1 Connector pin assignment, amplifier -R12-, Volkswagen sound system 1649
1 10 2 Connector pin assignment, amplifier -R12-, Fender Sound, Branded Sound 1650
2 Aerial systems 1653
2 1 Components of aerial systems 1653
2 1 1 Overview – aerial systems, Coupé 1653
2 1 2 Overview – aerial systems, Cabriolet 1653
2 2 Overview of fitting locations – aerial systems 1654
2 2 1 Overview of fitting locations – aerial systems, Coupé 1654
2 2 2 Overview of fitting locations – aerial systems, Cabriolet 1655
2 3 Removing and installing frequency modulation (FM) frequency filter R178/R179 1657
2 3 1 Removing and installing frequency modulation (FM) frequency filter in negative wire -R178-, Coupé 1657
2 3 2 Removing and installing frequency modulation (FM) frequency filter in positive wire -R179-, Coupé 1657
2 4 Removing and installing aerial module 1658
2 4 1 Removing and installing right aerial module -R109-, Coupé 1658
2 4 2 Removing and installing left aerial module -R108-, Coupé 1659
2 4 3 Removing and installing right aerial module -R109-, Cabriolet 1659
2 4 4 Removing and installing left aerial module -R108-, Cabriolet 1660
2 4 5 Removing and installing satellite aerial -R170-, Cabriolet 1661
2 4 6 Removing and installing satellite aerial -R170- (in spoiler), Cabriolet 1662
2 5 Removing and installing GPS aerial 1662
2 5 1 Removing and installing GPS aerial -R50-, Cabriolet 1662
2 6 Removing and installing traffic data aerial 1663
2 7 Removing and installing roof aerial 1664
2 7 1 Removing and installing roof aerial -R216- 1664
2 8 Removing and installing aerials for vehicle location system 1665
3 Radio 1666
3 1 Components of radio system 1666
3 1 1 Overview – radio, RCD 310, 8AE, 8AP 1666
3 1 2 Overview – radio, Premium 8, 8AX 1668
3 1 3 Overview – radio, RCD 510, 8AI, 8DD 1671
3 1 4 Components of RCD 030+ radio 1675
3 1 5 Components of RCD 300+ radio 1675
3 1 6 Components of RCD 510+ radio 1677
3 1 7 Components of Composition Colour radio 1680
3 1 8 Components of Composition Media radio 1682
3 2 Overview of fitting locations – radio 1684
3 2 1 Overview of fitting locations – radio, RCD 310 1684
3 2 2 Overview of fitting locations – radio, Premium 8 1685
3 2 3 Overview of fitting locations – radio, RCD 510 1686
3 2 4 Overview of fitting locations – radio, RCD 030+ 1687
3 2 5 Overview of fitting locations – radio, RCD 300+ 1688
3 2 6 Overview of fitting locations – radio, RCD 510+ 1689
3 2 7 Overview of fitting locations – radio, Composition Colour, Composition Media 1690
3 3 Assembly overview – radio 1692
3 3 1 Assembly overview – radio, any versions except for Composition Colour and Composition Media 1692
3 3 2 Assembly overview – radio, only Composition Colour and Composition Media 1692
3 4 Removing and installing radio 1693
3 4 1 Removing and installing radio, any versions except for Composition Colour and Composition Media 1693
3 4 2 Removing and installing radio, only Composition Colour and Composition Media 1696
3 5 Pin assignments 1698
3 5 1 Pin assignments, RCD 310 1698
3 5 2 Pin assignments, Premium 8 1701
3 5 3 Pin assignments, RCD 510 1704
3 5 4 Pin assignments, RCD 030+ 1708
3 5 5 Pin assignments, RCD 300+ 1710
3 5 6 Pin assignments, RCD 510+ 1713
3 5 7 Connector pin assignment, Composition Colour 1717
3 5 8 Connector pin assignment, Composition Media 1720
4 Telephone system 1725
4 1 Components of telephone system 1725
4 1 1 Overview – telephone system, UTP High with Bluetooth, 9ZA 1725
4 1 2 Overview – telephone system, UTP Premium with Bluetooth and audio streaming, 9ZU 1726
4 1 3 Overview – telephone system, universal preparation for mobile telephone in radio navigation system 315, 9ZI, 9ZT 1727
4 1 4 Components of telephone, UMI 1728
4 1 5 Components of telephone, Bluetooth hands-free system 1729
4 1 6 Components of telephone, Bluetooth car phone online 1730
4 2 Overview of fitting locations – telephone system 1731
4 2 1 Overview of fitting locations – telephone system 1731
4 2 2 Overview of fitting locations – telephone system, UMI 1731
4 2 3 Overview of fitting locations – telephone system, Bluetooth hands-free system, Bluetooth car phone online 1732
4 3 Removing and installing telephone microphone -R38- 1733
4 3 1 Removing and installing telephone microphone -R38-, Coupé 1733
4 3 2 Removing and installing telephone microphone -R38-, Cabriolet 1733
4 4 Removing and installing telephone bracket -R126- 1734
4 4 1 Removing and installing iPhone holder 1734
4 5 Removing and installing telephone transmitter and receiver unit 1735
4 6 Removing and installing mobile telephone operating electronics control unit -J412-, UMI 1736
4 7 Removing and installing operating unit for preparation for mobile phone 1737
4 7 1 Removing and installing operating unit for preparation for mobile telephone, Coupé 1737
4 7 2 Removing and installing operating unit for preparation for mobile telephone, Cabriolet 1738
4 8 Pin assignments 1738
4 8 1 Connector pin assignment telephone transmitter and receiver unit -R36- 1738
4 8 2 Connector pin assignment of mobile telephone operating electronics control unit -J412-, UMI 1739
4 8 3 Connector pin assignment, Bluetooth hands-free system, Bluetooth car phone online 1741
5 Navigation system 1742
5 1 Components of navigation system 1742
5 1 1 Components of RNS 315 navigation system 1742
5 1 2 Overview – navigation system, RNS 315+, 7UC 1744
5 1 3 Overview – navigation system, RNS 510, 7T2 1747
5 1 4 Overview – navigation system, RNS 510, Japan 1749
5 1 5 Overview – navigation system, RNS 510+, 7T6 1751
5 1 6 Components of navigation system, Discover Media 1754
5 2 Overview of fitting locations – navigation system 1754
5 2 1 Overview of fitting locations – navigation system, RNS 315 1754
5 2 2 Overview of fitting locations – navigation system, RNS 315+ 1755
5 2 3 Overview of fitting locations – navigation system, RNS 510 1756
5 2 4 Overview of fitting locations – navigation system, RNS 510, Japan 1757
5 2 5 Overview of fitting locations – navigation system, RNS 510+ 1759
5 2 6 Overview of fitting locations – navigation system, Discover Media 1759
5 3 Pin assignments 1760
5 3 1 Pin assignments, RNS 315 1760
5 3 2 Pin assignments, RNS 315+ 1764
5 3 3 Pin assignments, RNS 510 1767
5 3 4 Pin assignment, RNS 510, Japan 1771
5 3 5 Pin assignments, RNS 510+ 1775
5 3 6 Connector pin assignment, Discover Media 1779
5 4 Removing and installing control unit for navigation system 1779
5 4 1 Removing and installing control unit with display for radio and navigation -J503- 1779
5 4 2 Removing and installing control unit for navigation system, Discover Media 1782
5 5 Removing and installing chip card reader control unit 1782
5 6 Removing and installing control unit for vehicle location system 1782
6 TV system 1784
6 1 Overview – TV system 1784
6 1 1 Overview – TV system, Japan, QV2 1784
6 2 Overview of fitting locations – TV system 1785
6 2 1 Overview of fitting locations – TV system, Japan 1785
6 3 Pin assignments 1786
6 3 1 Connector pin assignment of TV tuner -R78- 1786
6 4 Removing and installing TV tuner 1787
6 5 Removing and installing TV card reader 1788
7 Reversing camera system 1790
7 1 Components of reversing camera system 1790
7 2 Overview of fitting locations – reversing camera system 1790
8 Multifunction steering wheel 1792
8 1 Components of multifunction steering wheel 1792
8 2 Assembly overview – multifunction steering wheel 1793
8 2 1 Assembly overview – multifunction steering wheel, up to model year 2013 1793
8 2 2 Assembly overview – multifunction steering wheel, as of model year 2014 1793
8 3 Removing and installing steering wheel multifunction buttons -E441-/-E440- 1794
8 3 1 Removing and installing multifunction buttons in steering wheel -E441-/-E440-, up to model year 2013 1794
8 3 2 Removing and installing multifunction buttons in steering wheel -E441-/-E440-, as of model year 2014 1796
8 4 Removing and installing Tiptronic switch in steering wheel -E439-/-E438- 1799
8 4 1 Removing and installing Tiptronic switch in steering wheel -E439-/-E438-, up to model year 2013 1799
8 4 2 Removing and installing Tiptronic switch in steering wheel -E439-/-E438-, as of model year 2014 1800
9 Connection for external multimedia devices 1801
9 1 Components of connection for external multimedia units 1801
9 1 1 Overview – connection for external multimedia devices, AUX-IN socket 1801
9 1 2 Overview – connection for external audio sources, USB socket, UF6 1803
9 1 3 Overview – connection for external multimedia devices, multimedia system control unit -J650-, UF9 1803
9 1 4 Components of connection for external multimedia devices, multimedia system control unit -J650-, UMI 1805
9 1 5 Components of connection for external multimedia devices, USB connection holder -R193- 1806
9 1 6 Components of connection for external multimedia devices, connection for external audio sources -R199- 1806
9 2 Connectors, connection for external multimedia devices 1807
9 2 1 Connectors, connection for external multimedia devices, AUX-IN socket 1807
9 2 2 Connectors, connection for external multimedia devices, USB socket 1808
9 2 3 Connectors, connection for external multimedia devices, multimedia system control unit -J650- 1808
9 2 4 Connectors, connection for external multimedia devices, multimedia system control unit -J650-, UMI 1809
9 2 5 Connectors, connection for external multimedia devices, USB connection holder -R193- 1811
9 2 6 Connectors, connection for external multimedia devices, connection for external audio sources -R199- 1811
9 3 Removing and installing connection for external multimedia devices 1813
9 3 1 Removing and installing connection for external multimedia devices, AUX-In socket 1813
9 3 2 Removing and installing connection for external multimedia devices, USB socket 1814
9 3 3 Removing and installing connection for external multimedia devices, multimedia system control unit -J650-, vehicles up to model year 2012 and RHD vehicles 1814
9 3 4 Removing and installing connection for external multimedia devices, multimedia system control unit -J650-, vehicles as of model year 2013 1815
9 3 5 Removing and installing connection for external multimedia devices, multimedia system control unit -J650-, UMI 1816
9 3 6 Removing and installing connection for external multimedia devices, USB connection retainer -R193- 1816
9 3 7 Removing and installing connection for external multimedia devices, connection for external audio sources -R199- 1817
10 Car-Net 1818
10 1 Overview – Mobile Online Services, EL2 1818
10 2 Overview of fitting locations – Car-Net services 1819
10 3 Connectors of emergency call module control unit and communication unit -J949- 1820
10 4 Removing and installing emergency call module control unit and communication unit -J949- 1821
10 5 Removing and installing suppression filter -C10- 1822
D3E803C9F6A General body repairs exterior 1824
50 – Body – front 1832
1 Lock carrier 1832
1 1 Assembly overview – lock carrier 1832
1 1 1 Assembly overview – lock carrier, saloon 1832
1 1 2 Assembly overview – lock carrier, Cabriolet 1833
1 2 Removing and installing lock carrier 1833
1 3 Moving to and back from service position 1838
2 Wings 1842
2 1 Assembly overview – wing 1842
2 2 Removing and installing wing 1846
2 3 Removing and installing wing bracket 1850
3 Plenum chamber bulkhead 1852
3 1 Assembly overview – bulkhead 1852
3 2 Assembly overview – plenum chamber cover 1853
3 3 Removing and installing plenum chamber cover 1854
53 – Body – rear 1859
1 Rear wing 1859
1 1 Assembly overview – rear wing 1859
1 2 Removing and installing rear wing 1859
1 3 Removing and installing anti-abrasion film 1862
55 – Bonnet, rear lid 1865
1 Bonnet 1865
1 1 Assembly overview – bonnet 1865
1 2 Assembly overview – Bowden cable 1866
1 3 Removing and installing bonnet 1868
1 4 Adjusting bonnet 1871
1 5 Removing and installing bonnet lock 1873
1 6 Removing and installing bonnet lock operating lever 1874
1 7 Removing and installing striker pin 1876
1 8 Removing and installing hinges 1877
1 9 Removing and installing insulation 1879
1 10 Removing and installing bonnet seals 1881
1 11 Separating and connecting Bowden cable coupling 1882
1 12 Removing and installing bonnet stay 1884
2 Rear lid 1887
2 1 Assembly overview – rear lid 1887
2 1 1 Assembly overview – rear lid, Saloon 1887
2 1 2 Assembly overview – rear lid, Cabriolet 1890
2 2 Removing and installing rear lid 1894
2 2 1 Removing and installing rear lid, Saloon 1894
2 2 2 Removing and installing rear lid, Cabriolet 1896
2 3 Adjusting rear lid 1899
2 3 1 Adjusting rear lid, Saloon 1899
2 3 2 Adjusting rear lid, Cabriolet 1906
2 4 Removing and installing bonnet lock 1912
2 4 1 Removing and installing rear lid lock, Saloon 1912
2 4 2 Removing and installing lid lock, Cabriolet 1913
2 5 Removing and installing operating mechanism 1915
2 6 Removing and installing striker pin 1917
2 7 Removing and installing hinges 1917
2 8 Removing and installing rear lid seal 1920
2 8 1 Removing and installing rear lid seal, Saloon 1920
2 8 2 Removing and installing rear lid seal, Cabriolet 1922
2 9 Removing and installing gas strut 1924
2 10 Releasing gas from gas strut 1926
3 Tank flap unit 1928
3 1 Assembly overview – tank flap unit 1928
3 2 Removing and installing tank flap unit 1928
3 3 Removing and installing actuator 1931
57 – Front doors, door components, central locking 1933
1 Door 1933
1 1 Assembly overview – door 1933
1 2 Removing and installing door 1935
1 3 Adjusting door 1937
1 4 Adjusting striker pin 1940
1 5 Removing and installing door arrester 1941
1 6 Removing and installing inner door seal 1943
1 6 1 Removing and installing inner door seal, saloon 1943
1 6 2 Removing and installing inner door seal, cabriolet 1946
1 7 Removing and installing outer door seal 1948
2 Door components 1951
2 1 Assembly overview – door components 1951
2 2 Assembly overview – door handle and door lock 1953
2 3 Removing and installing window regulator motor 1955
2 4 Removing and installing window regulator 1958
2 5 Removing and installing inner door cover 1960
2 6 Removing and installing striker pin 1962
2 7 Removing and installing cap on door handle 1964
2 8 Removing and installing lock cylinder 1968
2 9 Removing and installing door handle 1970
2 10 Removing and installing mounting bracket 1972
2 11 Removing and installing door lock 1974
2 12 Removing and installing window slot outer seal 1976
2 13 Removing and installing outer padding 1977
3 Central locking 1980
3 1 Overview of fitting locations – central locking system 1980
3 1 1 Overview of fitting locations – central locking, Saloon 1980
3 1 2 Overview of fitting locations – central locking, Cabriolet 1982
3 2 Assembly overview – ignition key 1984
3 3 Removing and installing ignition key battery 1985
3 4 Adapting ignition keys to remote control 1986
58 – Rear doors, door components 1988
1 Door components 1988
1 1 Removing and installing window regulator 1988
1 2 Removing and installing window regulator motor 1994
60 – Sunroof 1998
1 Sliding/tilting sunroof 1998
1 1 Assembly overview – panorama sliding/tilting glass roof 1998
1 2 Assembly overview – sunroof roller blind 2000
1 3 Function description 2002
1 4 Adapting sliding sunroof adjustment control unit -J245- 2002
1 5 Closing sunroof by hand 2003
1 6 Removing and installing glass panel 2004
1 7 Adjusting glass panel 2008
1 8 Removing and installing slotted guide 2010
1 9 Removing and installing sliding sunroof frame 2013
1 10 Removing and installing wind deflector 2023
1 11 Removing and installing sliding sunroof adjustment control unit -J245- 2025
1 12 Removing and installing sunroof sun blind cover 2028
1 13 Removing and installing transverse reinforcement 2029
1 14 Removing and installing sunroof roller blind 2030
1 15 Removing and installing interior seal 2034
1 16 Removing and installing trim 2037
1 17 Removing and installing tension bow 2045
2 Water drain hoses 2049
2 1 Assembly overview – water drain hoses 2049
2 2 Cleaning water drain hoses 2049
61 – Convertible roof, hardtop, canopy 2052
1 Convertible top 2052
1 1 Assembly overview – convertible top 2052
1 2 Assembly overview – convertible top frame 2054
1 3 Assembly overview – stop buffer 2056
1 4 Assembly overview – convertible top latch 2056
1 5 Assembly overview – control unit, microswitch for convertible top actuation 2057
1 6 Assembly overview – windscreen frame seal 2059
1 7 Removing and installing front trim 2059
1 8 Removing and installing side trim panels 2062
1 9 Removing and installing convertible top 2065
1 10 ‏Removing and installing convertible roof headliner 2078
1 11 Removing and installing convertible top cover 2089
1 12 Repairing water trap channel 2108
1 13 Removing and installing rear window control link 2109
1 14 Removing and installing tensioning cord for convertible top 2111
1 15 Repairing tensioning cords 2111
1 16 Removing and installing tensioning strap 2112
1 17 Removing and installing bolted retaining strips 2115
1 18 Removing and installing riveted retaining strip 2117
1 19 Removing and installing convertible top motor 2119
1 20 Removing and installing toothed segment 2122
1 21 Removing and installing convertible top latch 2123
1 22 Removing and installing convertible top latch motor 2124
1 23 Removing and installing convertible top lock 2126
1 24 Removing and installing striker pin 2128
1 25 Removing and installing windscreen frame seal 2130
1 26 Removing and installing convertible top seals 2134
1 27 Removing and installing water drip tray 2134
1 28 Checking water drainage from convertible top 2136
1 29 Removing and installing retaining plate 2137
63 – Bumpers 2139
1 Bumper, front 2139
1 1 Assembly overview – bumper cover 2139
1 2 Assembly overview – attachments 2140
1 2 1 Assembly overview – attachments 2140
1 2 2 Assembly overview – add-on parts, Dune 2141
1 3 Assembly overview – guides and brackets 2142
1 4 Assembly overview – bumper carrier 2143
1 5 Removing and installing bumper cover 2145
1 6 Removing and installing attachments 2148
1 7 Repairing bumper cover 2149
1 8 Installing holder for parking aid sender 2149
1 9 Installing brackets for park assist steering 2154
2 Bumper, rear 2159
2 1 Assembly overview – bumper cover 2159
2 2 Assembly overview – attachments 2160
2 2 1 Assembly overview – attachments 2160
2 2 2 Assembly overview – add-on parts, Dune 2161
2 3 Assembly overview – guides and brackets 2162
2 4 Assembly overview – bumper carrier 2163
2 5 Removing and installing bumper cover 2164
2 6 Repairing bumper cover 2167
2 7 Installing holder for parking aid sender 2167
2 8 Installing brackets for park assist steering 2172
64 – Glazing 2177
1 Repair notes 2177
1 1 Minimum drying times for bonded windows 2177
1 2 Window repair 2177
1 3 Installation instructions for bonded windows 2178
1 4 Removing broken window 2179
1 5 Preparing old undamaged windows for installing 2180
1 6 Preparing new windows for installing 2180
1 7 Preparing body flange for installing 2181
1 8 Cleaning off excess adhesive 2182
2 Windscreen 2183
2 1 Assembly overview – windscreen 2183
2 1 1 Assembly overview – windscreen, Saloon 2183
2 1 2 Assembly overview – windscreen, Cabriolet 2183
2 2 Removing and installing windscreen 2184
3 Rear windscreen 2190
3 1 Assembly overview – rear window 2190
3 2 Removing and installing rear window 2190
4 Side windows 2195
4 1 Assembly overview – rear side windows 2195
4 1 1 Assembly overview – rear side window, saloon 2195
4 1 2 Assembly overview – rear side window, cabriolet 2195
4 2 Removing and installing rear side window 2196
4 2 1 Removing and installing rear side window, saloon 2196
4 2 2 Removing and installing rear side window, cabriolet 2199
4 3 Adjusting rear door window 2203
5 Door windows 2209
5 1 Assembly overview – front door window 2209
5 2 Removing and installing front door window 2209
5 3 Adjusting front door window 2213
5 3 1 Adjusting front door window, Saloon 2213
5 3 2 Adjusting front door window, Cabriolet 2219
66 – Exterior equipment 2226
1 Radiator grille and front trim 2226
1 1 Removing and installing front trim 2226
2 Spoiler 2229
2 1 Assembly overview – spoiler 2229
2 1 1 Assembly overview – spoiler, Saloon 2229
2 1 2 Assembly overview – spoiler, Cabriolet 2229
2 2 Removing and installing spoiler 2230
2 2 1 Removing and installing spoiler, Saloon 2230
2 2 2 Removing and installing spoiler, Cabriolet 2237
3 Mouldings, trims, extensions 2244
3 1 Assembly overview – side member trim, Dune 2244
3 2 Assembly overview – trim strip and covers 2245
3 2 1 Assembly overview – decorative strip on door and side panel 2245
3 2 2 Assembly overview – decorative strip around shoulder of convertible top 2245
3 3 Removing and installing trim strip 2246
3 3 1 Removing and installing trim strip, door and side panel 2246
3 3 2 Removing and installing trim strip, shoulder of convertible top 2250
3 4 Removing and installing step moulding 2253
3 5 Removing and installing retaining strip for side member extension, Dune 2256
3 6 Removing and installing side member trim, Dune 2259
3 7 Removing and installing wheel arch covers 2263
3 7 1 Removing and installing front wheel arch trim 2263
3 7 2 Removing and installing rear wheel arch trim 2266
4 Noise insulation 2271
4 1 Assembly overview – noise insulation 2271
4 1 1 Assembly overview – noise insulation, Saloon with petrol engine 2271
4 1 2 Assembly overview – noise insulation, Saloon with diesel engine 2272
4 1 3 Assembly overview – skid plate, saloon 2272
4 1 4 Assembly overview – noise insulation, Cabriolet 2273
4 2 Removing and installing noise insulation 2274
4 2 1 Removing and installing noise insulation, petrol engine 2274
4 2 2 Removing and installing noise insulation, diesel engine 2275
4 2 3 Removing and installing skid plate 2276
5 Underbody cladding 2278
5 1 Assembly overview – underbody cladding 2278
5 1 1 Assembly overview – underbody cover, Saloon 2278
5 1 2 Assembly overview – underbody cover, Cabriolet 2279
5 2 Removing and installing tunnel cross-piece 2279
6 Exterior mirror 2281
6 1 Assembly overview – exterior mirror 2281
6 1 1 Assembly overview, exterior mirror without turn signal repeater 2281
6 1 2 Assembly overview, exterior mirror with turn signal repeater 2282
6 2 Removing and installing exterior mirror 2283
6 3 Removing and installing mirror glass 2286
6 4 Removing and installing mirror adjustment unit 2288
6 5 Removing and installing mirror frame 2291
6 5 1 Removing and installing mirror trim, exterior mirror without turn signal repeater 2291
6 5 2 Removing and installing mirror trim, exterior mirror with turn signal repeater 2292
6 6 Removing and installing mirror cover 2294
6 6 1 Removing and installing mirror cover, exterior mirror without turn signal repeater 2294
6 6 2 Removing and installing mirror cover, exterior mirror with turn signal repeater 2295
6 7 Removing and installing assembly bracket 2297
7 Wheel housing liner 2299
7 1 Assembly overview – front wheel housing liner 2299
7 2 Assembly overview – rear wheel housing liner 2300
7 3 Removing and installing front wheel housing liner 2301
7 4 Removing and installing rear wheel housing liner 2304
8 Lettering, emblems and decorative films 2306
8 1 Instructions for affixing the lettering 2306
8 2 Dimensions – lettering and emblems on rear lid 2307
8 3 Dimensions – lettering and emblems on wing 2308
8 3 1 “Fender” lettering 2308
8 3 2 “50s”, “60s” lettering 2308
8 3 3 “70s” lettering 2309
8 3 4 “R-Line” lettering 2310
8 3 5 “iBeetle” lettering 2311
8 3 6 “KARMANN” emblem 2312
8 4 Removing and installing front badge 2313
8 5 Instructions for affixing decorative films and protective films 2314
8 6 Protective film on rear wing 2316
8 7 Decorative film, door and side panel 2317
8 8 Decorative films, Beetle »Herbie« 2318
8 8 1 Assembly overview – decorative films, Beetle »Herbie« 2318
8 8 2 Affixing decorative film to bonnet 2319
8 8 3 Affixing decorative film to roof 2322
8 8 4 Affixing decorative film on top of rear lid 2324
8 8 5 Affixing decorative film on bottom of rear lid 2326
8 8 6 Affixing decorative film to door 2328
9 Special add-on parts 2331
9 1 Overview of fitting locations – special add-on parts, Dune 2331
D3E803C9F6B General body repairs interior 2332
00 – Technical data 2338
1 Safety information 2338
1 1 Safety measures when working with pyrotechnic components 2339
1 2 Safety instructions for airbag 2340
1 3 Deactivating the airbag 2340
1 4 Roll-over bar 2341
1 5 Storage, transportation and disposal of airbag, belt tensioner and battery isolator units (pyrotechnic components) 2342
1 6 Additional safety instructions for repair work on seat occupied recognition for front passenger airbag deactivation – country-specific 2342
1 7 Measures for seat occupied recognition for front passenger airbag deactivation following an accident – country-specific 2343
1 8 Checking airbag securing parts after an accident 2343
1 9 Accident without airbag triggering 2344
1 10 Check belt webbing 2344
1 11 Checking inertia reel (locking mechanism) 2345
1 12 Visually checking belt buckle 2346
1 13 Check operation of belt buckle 2346
1 14 Checking belt relays, and buckle tongues 2347
1 15 Checking securing parts and anchorage points after an accident 2347
1 16 Safety instructions for belt tensioners 2348
68 – Interior equipment 2349
1 Compartments/covers 2349
1 1 Removing and installing dash panel cover on driver side 2349
1 1 1 Removing and installing dash panel centre cover on driver side 2349
1 1 2 Removing and installing left dash panel cover on driver side 2350
1 2 Removing and installing dash panel cover on front passenger side 2352
1 2 1 Removing and installing dash panel cover on front passenger side, cover with reinforcement 2352
1 2 2 Removing and installing dash panel cover on front passenger side, cover with storage compartment 2354
1 3 Removing and installing upper steering column trim 2355
1 4 Removing and installing lower steering column trim 2355
1 5 Removing and installing glove compartment opener 2356
1 5 1 Removing and installing glove compartment opener, upper glove compartment 2356
1 5 2 Removing and installing glove compartment opener, lower glove compartment 2357
1 6 Removing and installing glove compartment 2359
1 6 1 Removing and installing glove compartment, upper glove compartment 2359
1 6 2 Removing and installing glove compartment, lower glove compartment 2360
1 7 Removing and installing headliner storage compartment 2361
1 8 Removing and installing handbrake lever boot 2363
2 Equipment 2366
2 1 Assembly overview – windbreak 2366
2 2 Removing and installing sun visor 2366
2 3 Removing and installing sun visor centre mount 2368
2 4 Removing and installing roof grab handle 2369
2 5 Removing and installing bracket for roof grab handle 2371
3 Centre console 2373
3 1 Assembly overview – securing bracket for centre console 2373
3 2 Removing and installing centre console 2373
3 3 Removing and installing centre console securing bracket 2378
3 3 1 Removing and installing securing brackets for centre console, front securing bracket 2378
3 3 2 Removing and installing securing brackets for centre console, rear securing bracket 2379
4 Front centre armrest 2381
4 1 Assembly overview – front centre armrest 2381
4 2 Removing and installing front centre armrest 2382
5 Interior mirror 2383
5 1 Assembly overview – interior mirror 2383
5 2 Assembly overview – interior mirror 2383
5 2 1 Assembly overview – interior mirror, Basic 2383
5 2 2 Assembly overview – interior mirror, rain sensor 2385
5 3 Removing and installing interior mirror 2386
5 3 1 Removing and installing interior mirror, Basic 2386
5 3 2 Removing and installing interior mirror, rain sensor 2386
5 4 Removing and installing retaining plate for interior mirror 2389
5 4 1 Removing and installing retaining plate for interior mirror, base 2389
5 4 2 Removing and installing retaining plate for interior mirror, rain sensor 2391
69 – Passenger protection 2393
1 Seat belts 2393
1 1 Assembly overview – front three-point seat belt 2393
1 1 1 Assembly overview – front three-point seat belt, Saloon 2393
1 1 2 Assembly overview – front three-point seat belt, Cabriolet 2395
1 2 Assembly overview – rear outer three-point seat belt 2396
1 2 1 Assembly overview – rear outer three-point seat belt, Saloon 2396
1 2 2 Assembly overview – rear outer three-point seat belt, Cabriolet 2397
1 3 Removing and installing front 3-point seat belt 2397
1 3 1 Removing and installing front three-point seat belt, Saloon 2397
1 3 2 Removing and installing front three-point seat belt, Cabriolet 2401
1 4 Removing and installing rear three-point seat belt 2405
1 4 1 Removing and installing rear three-point seat belt, Saloon 2405
1 4 2 Removing and installing rear three-point seat belt, Cabriolet 2406
1 5 Removing and installing front belt guide 2408
1 6 Removing and installing front belt buckle 2409
1 7 Removing and installing rear belt buckle 2412
2 Child seat anchors 2415
2 1 Assembly overview – rear child seat anchors 2415
2 2 Testing after accident 2415
2 3 Removing and installing rear child seat anchors 2416
2 3 1 Removing and installing rear child seat anchors, ISOFIX 2416
2 3 2 Removing and installing rear child seat anchors, top tether 2416
3 Airbag system 2418
3 1 Overview of fitting locations – airbag system 2418
4 Airbag control unit 2419
4 1 Removing and installing airbag control unit -J234- 2419
5 Driver’s airbag 2421
5 1 Removing and installing airbag unit with igniter 2421
5 2 Removing and installing return spring with slip ring (coil connector) 2424
6 Front passenger side airbag 2426
6 1 Removing and installing front passenger side airbag unit with igniter 2426
6 2 Removing and installing key-operated switch to deactivate front passenger airbag 2432
7 Side airbags 2433
7 1 Removing and installing front side airbag with igniter 2433
8 Airbag crash sensors 2437
8 1 Removing and installing front airbag crash sensor, driver side -G283- 2437
8 2 Removing and installing front airbag crash sensor, front passenger side -G284- 2438
8 3 Removing and installing front side airbag crash sensor -G179-/-G180- 2439
9 Seat belt verification 2442
9 1 Removing and installing Seat occupied sensor, front passenger side -G128- 2442
10 Seat occupied recognition 2444
10 1 Assembly overview – seat occupied recognition 2444
10 1 1 Assembly overview – seat occupied recognition, Basic 2444
10 1 2 Assembly overview – seat occupied recognition, Sport 2447
10 2 Removing and installing seat occupied recognition 2450
10 2 1 Removing and installing seat occupied recognition; Removing pressure sensor for seat occupied recognition -G452-, Basic 2450
10 2 2 Removing and installing seat occupied recognition; Installing pressure sensor for seat occupied recognition -G452-, Basic 2454
10 2 3 Removing and installing seat occupied recognition; Installing pressure sensor for seat occupied recognition -G452-, Sport 2458
10 2 4 Removing and installing seat occupied recognition, seat occupied recognition control unit 2464
10 2 5 Removing and installing seat occupied recognition, bracket for seat occupied recognition control unit 2465
11 Roll-over bar 2467
11 1 Assembly overview – roll-over bar 2467
11 2 Removing and installing roll-over bar 2468
70 – Trim, insulation 2473
1 Front door trims 2473
1 1 Removing and installing front door trim 2473
1 2 Removing and installing mirror cover trim 2477
2 Dash panel 2480
2 1 Removing and installing dash panel end cover 2480
2 2 Removing and installing trim panel for dash panel 2482
2 3 Removing and installing iPhone storage compartment 2483
2 4 Removing and installing radio/navigation system blanking plate 2489
2 5 Removing and installing retaining frame for dash panel insert 2490
2 6 Removing and installing dash panel 2492
2 7 Aligning dash panel in vehicle 2500
2 8 Removing and installing dash panel vents 2503
2 9 Removing and installing side defroster vent 2504
3 Dash panel central tube 2506
3 1 Assembly overview – dash panel central tube 2506
3 2 Assembly overview – impact absorber and glove compartment bracket 2507
3 3 Removing and installing dash panel central tube 2508
3 4 Removing and installing mounting bracket 2512
3 4 1 Removing and installing mounting bracket on driver side 2512
3 4 2 Removing and installing mounting bracket on front passenger side 2512
3 5 Removing and installing impact absorber 2513
3 5 1 Removing and installing impact absorber on driver side 2513
3 5 2 Removing and installing middle impact absorber 2514
3 5 3 Removing and installing impact absorber on front passenger side 2514
4 Interior trims 2515
4 1 Assembly overview – side trim panel 2515
4 1 1 Assembly overview – side trim panel, Saloon 2515
4 1 2 Assembly overview – side trim panel, Cabriolet 2517
4 2 Assembly overview – rear panel trims 2518
4 3 Removing and installing sill panel moulding 2518
4 4 Removing and installing A-pillar trim 2520
4 4 1 Removing and installing A-pillar trim, upper A-pillar trim, Saloon 2520
4 4 2 Removing and installing A-pillar trim, upper A-pillar trim, Cabriolet 2521
4 4 3 Removing and installing A-pillar trim, lower A-pillar trim on driver side 2522
4 4 4 Removing and installing A-pillar trim, lower A-pillar trim on front passenger side 2524
4 5 Removing and installing A-pillar trim deformation element 2525
4 6 Removing and installing B-pillar trim 2526
4 6 1 Detaching and attaching B-pillar trim 2526
4 6 2 Removing and installing upper B-pillar trim 2528
4 7 Removing and installing C-pillar trim 2530
4 8 Removing and installing side trim panel 2532
4 8 1 Removing and installing side trim panel, Saloon 2532
4 8 2 Removing and installing side trim panel, Cabriolet 2535
4 9 Removing and installing rear shelf 2540
4 10 Removing and installing rear panel trims 2541
4 10 1 Removing and installing rear panel trims, middle rear panel trim 2541
4 10 2 Removing and installing rear panel trims, upper rear panel trim 2541
4 10 3 Removing and installing rear panel trims, trim for rear belt inertia reel 2543
5 Luggage compartment trims 2545
5 1 Removing and installing luggage compartment floor 2545
5 2 Removing and installing lock carrier trim 2546
5 3 Removing and installing luggage compartment side trim 2548
5 3 1 Removing and installing luggage compartment side trim, Saloon 2548
5 3 2 Removing and installing luggage compartment side trim, Cabriolet 2549
5 4 Removing and installing rear shelf support 2551
5 5 Removing and installing upper rear lid trim 2552
5 6 Removing and installing lower rear lid trim 2554
5 7 Removing and installing rear lid trim 2555
5 8 Removing and installing rear lid lock 2557
6 Roof trims 2559
6 1 Assembly overview – roof frame trim 2559
6 2 Detaching and fastening moulded headliner 2559
6 3 Removing and installing moulded headlining 2562
6 4 Installing roof reinforcement to body 2566
6 5 Removing and installing roof frame trim 2568
6 5 1 Removing and installing roof frame trim, removing and installing upper roof frame trim 2568
6 5 2 Removing and installing roof frame trim, removing and installing lower roof frame trim 2569
7 Convertible roof box 2571
7 1 Assembly overview – convertible top compartment 2571
7 2 Removing and installing bracket for convertible top tensioning strap 2571
72 – Seat frames 2573
1 Front seats 2574
1 1 Removing and installing front seat 2574
1 2 Removing and installing handle for seat height adjustment 2579
1 3 Removing and installing seat height adjustment 2580
1 4 Removing and installing seat trim on tunnel side 2582
1 5 Removing and installing seat trim on sill side 2583
1 6 Removing and installing bracket for seat trim 2584
1 7 Removing and installing lumbar support adjustment 2585
1 8 Removing and installing backrest adjustment 2586
1 9 Removing and installing front backrest 2587
1 10 Removing and installing head restraint 2589
1 11 Removing and installing head restraint guide 2589
1 12 Removing and installing trim for backrest release mechanism 2591
1 13 Removing and installing backrest release mechanism 2592
1 14 Removing and installing backrest release holder 2593
1 15 Removing and installing Bowden cable for backrest release 2595
1 16 Adjusting Bowden cable for backrest release mechanism 2597
1 17 Removing and installing interconnecting Bowden cable 2599
1 18 Removing and installing easy-entry Bowden cable A 2600
1 19 Adjusting Bowden cable A for entry assistance 2602
1 20 Removing and installing easy-entry Bowden cable B 2604
1 21 Removing and installing slider 2606
1 22 Removing and installing torsion rod 2607
1 23 Removing and installing torsion rod bush 2610
1 24 Removing and installing heated front seats control unit -J774- 2611
2 Rear seats 2613
2 1 Assembly overview – rear seat backrest 2613
2 2 Removing and installing bench seat / individual seats 2614
2 3 Removing and installing head restraint guide 2615
2 4 Removing and installing rear seat backrest 2617
2 4 1 Removing and installing rear seat backrest, Saloon 2617
2 4 2 Removing and installing rear seat backrest, Cabriolet 2620
2 5 Removing and installing locking mechanism for rear seat backrest 2623
2 5 1 Removing and installing locking mechanism for rear seat backrest, saloon 2623
2 5 2 Removing and installing locking mechanism for rear seat backrest, cabriolet 2625
2 6 Removing and installing Bowden cable for locking mechanism for rear seat backrest 2626
2 7 Removing and installing frame for rear seat backrest 2627
2 7 1 Removing and installing frame for rear seat backrest, saloon 2627
2 7 2 Removing and installing frame for rear seat backrest, cabriolet 2629
2 8 Removing pressure stud for backrest release 2630
74 – Seat – padding, covers 2632
1 Front seat covers and padding 2632
1 1 Removing and installing cover and padding for seat pan 2632
1 2 Removing and installing backrest cover and backrest padding 2638
2 Rear seat covers and padding 2644
2 1 Removing and installing covers and padding 2644
2 1 1 Removing and installing bench seat cover and padding 2644
2 1 2 Removing and installing rear seat backrest cover and padding, Saloon 2645
2 1 3 Removing and installing rear seat backrest cover and padding, Cabriolet 2647
2 2 Separating cover and padding 2649
D3E803D8F67 Electrical system 2651
00 – Technical data 2659
1 Safety information 2659
1 1 Safety measures when working on vehicles with a start/stop system 2659
1 2 Safety precautions when using testers and measuring instruments during a road test 2659
1 3 Operation and safety notes for gas discharge lamps 2660
2 Repair instructions 2662
2 1 Contact corrosion 2662
2 2 Routing and attachment of lines 2662
3 Battery 2663
3 1 Battery – general notes 2663
3 2 Types of battery 2663
27 – Starter, current supply, CCS 2664
1 Battery 2664
1 1 Assembly overview – battery 2664
1 2 Removing and installing battery 2666
1 2 1 Removing and installing battery, petrol engine 2666
1 2 2 Removing and installing battery, diesel engine 2667
1 3 Adapting battery monitor control unit -J367- 2669
1 4 Disconnecting and connecting battery 2669
1 5 Removing and installing battery tray 2672
1 6 Checking battery 2672
1 7 Charging battery 2673
1 8 Removing and installing earth wire with battery monitor control unit -J367- 2673
1 9 Adapting battery monitor control unit -J367- 2674
2 Alternator 2676
2 1 Assembly overview – alternator 2676
2 1 1 Assembly overview – alternator without sliding bushes 2676
2 1 2 Assembly overview – alternator with sliding bushes 2676
2 2 Removing and installing alternator 2678
2 2 1 Removing and installing alternator -C-, vehicles with 1 2 l TSI engine 2678
2 2 2 Removing and installing alternator -C-, vehicles with 1 4 l TSI engine 2680
2 2 3 Removing and installing alternator -C-, vehicles with 1 8 l/2 0 l TSI engine 2684
2 2 4 Removing and installing alternator -C-, vehicles with 2 5 l petrol engine 2688
2 2 5 Removing and installing alternator -C-, vehicles with diesel engine 2690
2 3 Checking alternator 2693
2 4 Checking poly V-belt 2693
2 5 Removing and installing poly V-belt pulley 2694
2 5 1 Removing and installing poly V-belt pulley, without freewheel 2694
2 5 2 Removing and installing Bosch poly V-belt pulley with freewheel 2695
2 5 3 Removing and installing Valeo poly V-belt pulley with freewheel 2697
2 5 4 Removing and installing poly V-belt pulley, decoupler pulley with freewheel 2700
2 6 Removing and installing voltage regulator 2704
2 6 1 Removing and installing Bosch voltage regulator -C1- 2704
2 6 2 Removing and installing Valeo voltage regulator -C1- 2705
3 Starter motor 2708
3 1 Assembly overview – starter 2708
3 1 1 Assembly overview – starter, vehicles with manual gearbox 2708
3 1 2 Assembly overview – starter, vehicles with automatic gearbox 2708
3 1 3 Assembly overview – starter, vehicles with dual clutch gearbox (DQ200-7F) 2709
3 1 4 Assembly overview – starter, vehicles with dual clutch gearbox (DQ250-6F) 2710
3 2 Removing and installing starter 2711
3 2 1 Removing and installing starter, vehicle with manual gearbox 2711
3 2 2 Removing and installing starter, vehicles with automatic gearbox 2714
3 2 3 Removing and installing starter, vehicles with double clutch gearbox (DQ200-7F) 2717
3 2 4 Removing and installing starter, vehicles with double clutch gearbox (DQ250-6F) 2719
3 3 Checking starter 2721
4 Cruise control system (CCS) 2722
5 Start/stop system 2723
5 1 General description – start/stop system 2723
5 2 Removing and installing voltage stabiliser 2724
90 – Gauges, instruments 2726
1 Dash panel insert 2726
1 1 Assembly overview – dash panel insert 2726
1 2 Assembly overview – additional instruments 2726
1 3 Removing and installing dash panel insert -KX2- 2727
1 4 Removing and installing additional instruments 2729
1 5 Warning lamp symbols on dash panel insert 2730
1 5 1 Warning lamp symbols on dash panel insert for Rest of World 2730
1 5 2 Warning lamp symbols on dash panel insert for USA 2731
1 6 Multi-pin connector pin assignment on dash panel insert 2732
1 7 Removing and installing ambient temperature sensor 2733
2 Horn 2734
2 1 Assembly overview – horn 2734
2 2 Removing and installing treble horn -H2- and bass horn -H7- 2734
92 – Windscreen wash/wipe system 2736
1 Windscreen wiper system 2736
1 1 Assembly overview – windscreen wiper system 2736
1 2 Moving wipers to service position 2737
1 3 Removing and installing wiper arms 2737
1 4 Adjusting wiper arms 2739
1 5 Renewing windscreen wiper rubber 2740
1 6 Removing and installing wiper motor -V- 2741
1 7 Renewing wiper motor 2742
1 8 Removing and installing rain and light sensor 2743
1 9 Repairing rain and light sensor -G397- 2746
2 Windscreen washer system 2748
2 1 Assembly overview – windscreen washer system 2748
2 2 Removing and installing washer fluid reservoir 2749
2 3 Removing and installing windscreen washer fluid level sender 2751
2 4 Removing and installing windscreen washer pump 2751
2 5 Removing and installing spray jets 2752
2 6 Adjusting spray jets 2753
3 Washer fluid lines 2754
3 1 Repairing washer fluid lines 2754
94 – Lights, bulbs, switches – exterior 2755
1 Headlights 2755
1 1 Assembly overview – headlight 2755
1 1 1 Assembly overview – halogen headlight 2755
1 1 2 Assembly overview – headlight, xenon headlight 2756
1 2 Removing and installing headlight 2758
1 3 Removing and installing carrier plate for headlights 2759
1 4 Adjusting headlights 2761
1 5 Adjusting headlight installation position 2761
1 6 Converting headlights from driving on right to driving on left 2763
1 7 Converting headlights from driving on left to driving on right 2763
1 8 Removing and installing headlight range control motor -V48-/-V49- 2763
1 8 1 Removing and installing headlight range control motor for halogen headlight 2763
1 8 2 Removing and installing headlight range control motor, xenon headlight 2765
1 9 Removing and installing dipped-beam headlight bulb 2766
1 10 Removing and installing gas discharge bulb -L13-/-L14- 2768
1 11 Removing and installing side light bulb -M1-/-M3- 2770
1 12 Removing and installing daytime running light bulb -L174-/-L175- 2771
1 13 Removing and installing gas discharge bulb control unit -J343-/-J344- 2773
2 Fog lights 2774
2 1 Assembly overview – fog lights 2774
2 1 1 Assembly overview – fog lights, except for “Dune” 2774
2 1 2 Assembly overview – fog lights, only “Dune” 2774
2 2 Removing and installing fog light 2775
2 2 1 Removing and installing fog light, except for “Dune” 2775
2 2 2 Removing and installing fog light, only “Dune” 2777
2 3 Removing and installing fog light bulb -L22-/-L23- 2778
2 3 1 Removing and installing fog light bulb -L22-/-L23-, except for “Dune” 2778
2 3 2 Removing and installing fog light bulb -L22-/-L23-, only “Dune” 2779
2 4 Adjusting fog lights 2779
3 Side marker light 2780
3 1 Removing and installing front side marker light 2780
3 2 Removing and installing side marking light bulb 2780
4 Lights in exterior mirror 2782
4 1 Assembly overview – lights in exterior mirror 2782
4 2 Removing and installing turn signal repeater bulb -L131-/-L132- 2782
4 3 Removing and installing entry light in exterior mirror 2783
5 Front turn signals 2785
5 1 Assembly overview – front turn signals 2785
5 1 1 Assembly overview – front turn signals, except for “Dune” 2785
5 1 2 Assembly overview – front turn signals, only “Dune” 2785
5 2 Removing and installing front turn signal 2786
5 2 1 Removing and installing front turn signal, except for “Dune” 2786
5 2 2 Removing and installing front turn signal, only “Dune” 2788
5 3 Removing and installing front turn signal bulb 2789
6 Tail lights 2791
6 1 Assembly overview – tail light cluster in body 2791
6 1 1 Assembly overview – tail lights in vehicle body, with bulbs 2791
6 1 2 Assembly overview – tail light clusters in vehicle body, with LEDs 2792
6 2 Removing and installing bulb carrier 2793
6 3 Removing and installing tail light cluster 2794
6 4 Removing and installing rear fog light 2794
6 5 Removing and installing rear fog light bulb -L46-/-L47- 2796
6 6 Removing and installing brake and tail light bulb -M21-/-M22- 2796
6 6 1 Removing and installing brake and tail light bulb -M21-/-M22-, tail light cluster with bulbs 2796
6 6 2 Removing and installing brake and tail light bulb -M21-/-M22-, tail light cluster with LEDs 2796
6 7 Removing and installing reversing light bulb 2797
6 7 1 Removing and installing reversing light bulb, tail light cluster with bulbs 2797
6 7 2 Removing and installing reversing light bulb, tail light cluster with LEDs 2797
6 8 Removing and installing turn signal bulb 2798
6 8 1 Removing and installing turn signal bulb, tail light cluster with bulbs 2798
6 8 2 Removing and installing turn signal bulb, tail light cluster with LEDs 2799
7 High-level brake light 2800
7 1 Removing and installing high-level brake light 2800
8 Number plate light 2803
8 1 Removing and installing number plate light -X4-/-X5- 2803
8 2 Removing and installing bulb for number plate light -X4-/-X5- 2803
9 Entry and start authorisation system 2805
9 1 Overview of fitting locations – entry and start authorisation system 2805
9 2 Removing and installing entry and start authorisation control unit -J518- 2808
9 2 1 Removing and installing (left-hand drive models) entry and start authorisation control unit -J518- 2808
9 2 2 Removing and installing entry and start authorisation control unit -J518-, right-hand drive 2809
9 2 3 Coding entry and start authorisation control unit -J518- 2810
9 3 Removing and installing door exterior handle contact sensor -G415-/-G416- 2811
9 4 Removing and installing interior aerial 1 for entry and start authorisation -R138- 2811
9 5 Removing and installing interior aerial 2 for entry and start authorisation -R139- 2812
9 6 Removing and installing driver side aerial for entry and start system -R134- 2812
9 7 Removing and installing front passenger side aerial for entry and start system -R135- 2813
9 8 Removing and installing luggage compartment aerial for entry and start system -R137- 2813
9 9 Removing and installing rear bumper aerial for entry and start system -R136- 2814
9 10 Checking entry and start system aerials and sensors 2815
10 Steering column switch module 2816
10 1 Assembly overview – steering column switch module 2816
10 1 1 Assembly overview – steering column switch module, Valeo 2816
10 1 2 Assembly overview – steering column switch module, Kostal 2817
10 1 3 Assembly overview – steering column switch module, KESSY 2818
10 2 Removing and installing steering column electronics control unit -J527- 2820
10 2 1 Removing and installing steering column electronics control unit -J527-, Valeo 2820
10 2 2 Removing and installing steering column electronics control unit -J527-, Kostal 2821
10 3 Coding steering column electronics control unit -J527- 2822
10 4 Removing and installing steering column combination switch 2823
10 4 1 Removing and installing steering column combination switch -E595-, Valeo 2823
10 4 2 Removing and installing steering column combination switch -E595-, Kostal 2826
10 5 Removing and installing base for steering column combination switch 2829
10 5 1 Removing and installing base for steering column combination switch, Valeo 2829
10 5 2 Removing and installing base for steering column combination switch, Valeo with KESSY 2832
10 5 3 Removing and installing base for steering column combination switch, Kostal 2835
10 5 4 Removing and installing base for steering column combination switch, Kostal with KESSY 2838
10 6 Removing and installing ignition/starter switch 2841
10 7 Checking ignition/starter switch 2842
10 8 Removing and installing lock cylinder 2843
10 9 Removing and installing steering lock housing 2845
10 10 Removing and installing ignition key withdrawal lock solenoid -N376- 2846
11 Parking aid 2847
11 1 Assembly overview – parking aid 2847
11 2 Removing and installing parking aid control unit -J446- 2849
11 3 Adapting parking aid control unit -J446- functions 2849
11 4 Removing and installing front parking aid warning buzzer -H22- 2850
11 5 Removing and installing rear parking aid warning buzzer -H15- 2851
11 5 1 Removing and installing rear parking aid warning buzzer -H15-, Coupé 2851
11 5 2 Removing and installing rear parking aid warning buzzer -H15-, Cabriolet 2851
11 6 Adapting volume and frequency of front parking aid warning buzzer 2852
11 7 Adapting volume and frequency of rear parking aid warning buzzer 2853
11 8 Removing and installing front parking aid senders 2853
11 9 Removing and installing rear parking aid senders 2856
11 10 Bonding sender bracket in bumper cover or in radiator grille 2858
11 11 Repairing sender bracket in bumper cover 2860
11 12 Renewing parking aid senders 2860
11 13 Testing parking aid senders 2861
12 Automatic headlight range control 2862
12 1 Assembly overview – automatic headlight range control 2862
12 2 Removing and installing headlight range control unit 2863
12 2 1 Removing and installing headlight range control unit, Coupé 2863
12 2 2 Removing and installing headlight range control unit, Cabriolet 2864
12 3 Making basic headlight setting 2864
13 Blind Spot Monitor 2866
13 1 Assembly overview – Blind Spot Monitor 2866
13 2 Removing and installing warning lamp for Blind Spot Monitor -K303-/-K304- 2866
13 3 Removing and installing Blind Spot Monitor control unit -J1086-/-J1087- 2867
13 4 Calibrating Blind Spot Monitor 2868
13 4 1 Measurement location 2868
13 4 2 Preparatory measures for calibration 2869
13 4 3 Performing calibration 2874
96 – Lights, bulbs, switches – interior 2876
1 Lights 2876
1 1 Overview of fitting locations – lights in luggage compartment 2876
1 2 Overview of fitting locations – lights in roof trim 2877
1 3 Removing and installing footwell light -W9-/-W10- 2877
1 4 Removing and installing front footwell illumination bulb -L151-/-L152- 2878
1 5 Removing and installing Central locking SAFELOCK function warning lamp -K133- 2879
1 6 Removing and installing luggage compartment light -W3- 2880
1 7 Removing and installing illuminated vanity mirror -W20-/-W14- 2882
1 8 Renewing front interior light bulb -W1-/-W13-/-W19- 2884
2 Controls 2886
2 1 Overview of fitting locations – controls in dash panel 2886
2 2 Overview of fitting locations – controls in front doors 2887
2 3 Overview of fitting locations – controls in centre console 2888
2 4 Overview of fitting locations – controls in roof trim 2889
2 5 Removing and installing rotary light switch -EX1- 2890
2 6 Removing and installing regulator for switch and instrument illumination -E20- 2892
2 7 Removing and installing headlight range control regulator -E102- 2892
2 8 Removing and installing Start/Stop operation button -E693- 2893
2 9 Removing and installing parking aid button -E266- 2894
2 10 Removing and installing front passenger side airbag deactivated warning lamp -K145- 2895
2 11 Removing and installing hazard warning lights button -E229- 2896
2 12 Removing and installing mirror adjuster switch -E43-/-E168- 2897
2 13 Removing and installing operating unit for window regulator in driver door -E512- 2899
2 14 Removing and installing window regulator switch in front passenger door -E107- 2900
2 15 Removing and installing driver side interior locking button for central locking system -E308- 2902
2 16 Removing and installing front passenger side interior locking button for central locking system -E309- 2902
2 17 Removing and installing rear lid remote release button -E233- 2903
2 18 Removing and installing tyre pressure monitor display button -E492- 2904
2 19 Removing and installing door contact switch -F2-/-F3- 2905
2 20 Removing and installing starter button -E378- 2906
2 21 Removing and installing button 1 for tilting roof -E582- 2906
2 22 Removing and installing front interior light/reading light 2907
2 22 1 Removing and installing front interior light -W1-, Coupé, without sliding sunroof 2907
2 22 2 Removing and installing front interior light -W1-, Coupé, with sliding sunroof 2908
2 22 3 Removing and installing front interior light -W1-, Cabriolet 2910
2 23 Removing and installing garage door operating unit -E284- 2911
2 24 Removing and installing interior monitoring deactivation switch -E267- 2912
3 Anti-theft alarm 2914
3 1 Assembly overview – interior monitor 2914
3 2 Removing and installing alarm horn -H12- 2916
3 3 Activating and deactivating anti-theft alarm 2917
3 4 Removing and installing interior monitoring sensor -G273- 2917
4 Immobiliser 2919
4 1 Removing and installing immobiliser control unit 2919
4 1 1 Overview – immobiliser, generation IV 2919
4 1 2 Overview – immobiliser, generation V 2920
4 1 3 Removing and installing immobiliser control unit -J362- 2920
4 1 4 Adapting immobiliser control unit -J362- 2920
4 1 5 New identity on renewing all components 2920
4 1 6 Online system test 2921
4 2 Removing and installing immobiliser reader coil 2921
4 3 Ignition key 2921
4 3 1 Removing and installing battery of ignition key with remote control 2921
4 3 2 Ignition key – variable code transponder 2921
4 3 3 Loss of an ignition key 2921
4 3 4 Adapting ignition key to immobilizer 2922
4 3 5 Checking ignition key with remote control 2922
97 – Wiring 2923
1 Relay carriers, fuse holders, electronics boxes 2923
1 1 Overview of fitting locations – relay carriers, fuse holders, E-boxes 2923
1 2 Removing and installing electronics box (E-box) 2924
1 3 Removing and installing relay and fuse holder in electronics box 2925
1 4 Removing and installing relay and fuse holder behind dash panel on driver side 2927
1 4 1 Removing and installing fuse holder behind dash panel on driver side 2927
1 4 2 Removing and installing onboard supply control unit -J519- 2928
2 Select Control units 2930
2 1 Overview of fitting locations – control units 2930
2 2 Removing and installing onboard supply control unit -J519- 2931
2 3 Adapting onboard supply control unit -J519- functions 2933
2 4 Removing and installing converter box -J935- 2933
2 5 Removing and installing garage door operation control unit 2934
2 6 Removing and installing data bus diagnostic interface -J533- 2934
2 6 1 Description of data bus diagnostic interface -J533- 2934
2 6 2 Removing and installing (left-hand drive models) data bus diagnostic interface -J533- 2935
2 6 3 Removing and installing data bus diagnostic interface -J533-, right-hand drive 2936
2 7 Adapting data bus diagnostic interface functions -J533- functions 2937
2 8 Driver door control unit -J386- 2937
2 9 Front passenger door control unit -J387- 2938
3 Connectors 2939
3 1 Repairing electrical wiring harnesses and plug-in connections 2939
4 Repairing aerial wires 2940
5 Vehicle diagnosis, testing and information systems 2941
D3E803D2627 4 cylinder injection engine (2 0 l engine chain drive) 2942
00 – Technical data 2948
1 Identification 2948
1 1 Engine number/engine data 2948
2 General information 2950
2 1 Numbering of cylinders 2950
3 Safety information 2951
3 1 Safety regulations for working on fuel supply 2951
3 2 Safety precautions when using testers and measuring instruments during a road test 2953
3 3 Safety precautions when working on cooling system 2953
3 4 Safety precautions when working on ignition system 2954
3 5 Releasing high pressure in fuel system 2954
3 5 1 Releasing high pressure in fuel system, engine codes CBFA, CCTA 2954
3 5 2 Releasing high pressure in fuel system, engine code CCZA 2956
4 Repair instructions 2958
4 1 Rules for cleanliness 2958
4 2 Foreign objects in engine 2958
4 3 Contact corrosion 2958
4 4 Routing and attachment of lines 2959
4 5 Fitting radiator and condensers 2959
10 – Removing and installing engine 2960
1 Removing and installing engine 2960
1 1 Removing engine 2960
1 2 Separating engine and gearbox 2971
1 3 Securing engine on engine and gearbox support 2972
1 4 Installing engine 2974
2 Assembly mountings 2977
2 1 Assembly overview – assembly mountings 2977
2 2 Removing and installing engine mounting 2979
2 3 Supporting engine in installation position 2985
2 4 Adjusting assembly mountings 2991
2 5 Checking adjustment of assembly mountings 2993
3 Engine cover panel 2994
3 1 Removing and installing engine cover 2994
13 – Crankshaft group 2995
1 Cylinder block (pulley end) 2995
1 1 Assembly overview – poly V-belt drive 2995
1 2 Removing and installing poly-V belt 2998
1 3 Removing and installing tensioner for poly V-belt 3000
1 4 Removing and installing vibration damper 3006
1 5 Removing and installing bracket for ancillaries 3013
1 6 Renewing crankshaft oil seal – belt pulley end 3016
2 Cylinder block, gearbox end 3019
2 1 Assembly overview – cylinder block, gearbox end 3019
2 2 Removing and installing flywheel 3021
2 3 Removing and installing drive plate 3023
2 4 Removing and installing sealing flange on gearbox side 3026
2 4 1 Removing and installing sealing flange on gearbox side, version A sealing lip faces outwards 3026
2 4 2 Removing and installing sealing flange on gearbox side, version B sealing lip faces engine 3029
3 Crankshaft 3034
3 1 Assembly overview – crankshaft 3034
3 2 Renewing needle bearing in crankshaft 3036
3 3 Crankshaft dimensions 3038
3 4 Measuring axial clearance of crankshaft 3039
3 5 Measuring radial clearance of crankshaft 3040
3 6 Allocation of main bearing shells 3040
3 7 Removing and installing sender wheel 3042
4 Balancer shaft 3044
4 1 Removing and installing balance shaft 3044
4 1 1 Removing and installing balance shaft, inlet camshaft 3044
4 1 2 Removing and installing balance shaft, exhaust camshaft 3048
5 Pistons and conrods 3052
5 1 Assembly overview – pistons and conrods 3052
5 2 Checking pistons and cylinder bores 3054
5 3 Separating new conrod 3056
15 – Cylinder head, valve gear 3058
1 Cylinder head 3058
1 1 Assembly overview – cylinder head 3058
1 2 Removing and installing cylinder head 3062
1 3 Removing and installing vacuum pump 3083
1 4 Checking compression 3085
2 Cover for timing chain 3087
2 1 Assembly overview – cover for timing chain 3087
2 2 Removing and installing timing chain cover 3089
2 2 1 Removing and installing timing chain cover, upper cover 3089
2 2 2 Removing and installing timing chain cover, lower cover 3091
3 Chain drive 3101
3 1 Assembly overview – camshaft timing chains 3101
3 2 Assembly overview – drive chain for balance shaft 3103
3 3 Removing and installing camshaft timing chain 3106
3 4 Removing and installing drive chain for balance shaft 3117
3 5 Checking valve timing 3121
3 5 1 Setting engine to TDC using dial gauge -VAS 6079- 3122
4 Valve gear 3124
4 1 Assembly overview – valve gear 3124
4 2 Measuring axial play of camshaft 3126
4 3 Removing and installing camshaft 3127
4 4 Removing and installing valve stem oil seals 3137
4 5 Removing and installing camshaft control valve 1 -N205- 3143
5 Inlet and exhaust valves 3145
5 1 Checking valve guides 3145
5 2 Valve dimensions 3146
17 – Lubrication 3147
1 Sump, oil pump 3147
1 1 Assembly overview – sump/oil pump 3147
1 2 Removing and installing lower part of sump 3150
1 3 Removing and installing upper part of sump 3153
1 4 Removing and installing oil pump 3160
1 5 Engine oil: 3162
2 Engine oil cooler 3164
2 1 Removing and installing engine oil cooler 3164
2 1 1 Removing and installing engine oil cooler, engine code CBFA and CCTA 3164
2 1 2 Removing and installing engine oil cooler, engine code CCZA 3165
3 Crankcase ventilation 3168
3 1 Removing and installing oil separator 3168
4 Oil filter, oil pressure switch 3170
4 1 Checking oil pressure and oil pressure switch 3170
4 1 1 Checking oil pressure and oil pressure switch (engine codes CBFA, CCTA) 3170
4 1 2 Checking oil pressure and oil pressure switch (engine code CCZA) 3172
4 2 Assembly overview – oil filter housing, oil pressure switch 3176
4 2 1 Assembly overview – oil filter housing, oil pressure switch, engine codes CBFA and CCTA 3176
4 2 2 Assembly overview – oil filter housing, oil pressure switch, engine code CCZA 3177
4 3 Removing and installing oil pressure switch -F22- 3179
4 4 Removing and installing oil pressure switch for reduced oil pressure -F378- 3180
4 5 Removing and installing oil pressure regulating valve -N428- 3181
19 – Cooling 3182
1 Cooling system/coolant 3182
1 1 Connection diagram – coolant hoses 3182
1 1 1 Connection diagram – coolant hoses, vehicles with manual gearbox 3182
1 1 2 Coolant hose schematic diagram, vehicles with dual clutch gearbox 3183
1 2 Checking cooling system for leaks 3184
1 3 Draining and adding coolant 3187
2 Coolant pump, regulation of cooling system 3193
2 1 Assembly overview – coolant pump, thermostat 3193
2 2 Assembly overview – electric coolant pump 3196
2 2 1 Removing and installing continued coolant circulation pump -V51- 3196
2 3 Removing and installing coolant pump with thermostat housing 3197
2 4 Detaching coolant pump from thermostat housing/attaching coolant pump to thermostat housing 3200
2 5 Removing and installing thermostat 3203
2 6 Removing and installing toothed belt for coolant pump 3207
2 7 Renewing seal for coolant pump drive 3210
2 8 Removing and installing electric coolant pump 3212
2 8 1 Removing and installing continued coolant circulation pump -V51- 3212
2 9 Removing and installing coolant temperature sender 3213
3 Coolant pipes 3217
3 1 Assembly overview – coolant pipes 3217
3 2 Removing and installing coolant pipes 3218
3 2 1 Removing and installing coolant pipes, front coolant pipes 3218
3 2 2 Removing and installing coolant pipe, small coolant pipe 3221
4 Radiator, radiator fan 3225
4 1 Assembly overview – radiator/radiator fan 3225
4 2 Removing and installing radiator 3226
4 3 Removing and installing radiator cowl 3228
4 4 Removing and installing radiator fan 3230
21 – Turbocharging/supercharging 3231
1 Turbocharger 3231
1 1 Assembly overview – turbocharger 3231
1 1 1 Part I 3232
1 1 2 Part II 3234
1 1 3 Part III 3235
1 1 4 Part IV 3237
1 2 Removing and installing turbocharger 3238
1 3 Checking vacuum unit for turbocharger 3246
1 4 Renewing vacuum unit for turbocharger 3248
2 Charge air system 3249
2 1 Schematic overview – charge air system 3249
2 2 Assembly overview – charge air system 3250
2 3 Checking charge air system for leaks 3251
2 4 Assembly overview – charge-air hose connections 3253
24 – Mixture preparation – injection 3255
1 Injection system 3255
1 1 Overview of fitting locations – injection system 3255
2 Injectors 3262
2 1 Assembly overview – fuel rail with injectors 3262
2 2 Removing and installing injectors 3264
2 3 Renewing seals on injectors 3268
2 4 Cleaning injectors 3271
3 High-pressure pump 3273
3 1 Assembly overview – high-pressure pump 3273
3 2 Removing and installing high-pressure pump 3275
4 Senders and sensors 3278
4 1 Assembly overview – actuator for structure-borne sound and control unit for structure-borne sound 3278
4 1 1 Assembly overview – actuator for structure-borne sound -R214- and control unit for structure-borne sound -J869-, left-hand drive vehicles 3278
4 1 2 Assembly overview – actuator for structure-borne sound -R214- and control unit for structure-borne sound -J869-, right-hand drive vehicles 3279
4 2 Removing and installing air mass meter 3280
4 2 1 Removing and installing air mass meter -G70- 3280
4 3 Removing and installing fuel pressure sender -G247- 3282
4 4 Checking fuel pressure sender -G247- 3284
5 Intake manifold 3288
5 1 Assembly overview – intake manifold 3288
5 2 Removing and installing intake manifold with fuel rail 3291
5 2 1 Disconnecting fuel rail from intake manifold 3298
5 3 Removing and installing throttle valve module 3299
5 4 Cleaning throttle valve module 3301
5 5 Checking intake manifold change-over 3302
6 Air filter 3305
6 1 Assembly overview – air filter housing 3305
6 2 Removing and installing air filter housing 3307
7 Engine control unit 3309
7 1 Removing and installing engine control unit -J623- 3309
26 – Exhaust system 3312
1 Exhaust pipes and silencers 3312
1 1 Assembly overview – silencers 3312
1 1 1 Assembly overview – silencer, engine code CBFA 3312
1 1 2 Assembly overview – silencer, engine codes CCTA and CCZA 3314
1 2 Removing and installing front exhaust pipe 3318
1 3 Separating exhaust pipes from silencers 3321
1 4 Aligning exhaust system free of stress 3323
1 5 Checking exhaust system for leaks 3325
2 Secondary air system 3327
2 1 Assembly overview – secondary air system 3327
2 2 Removing and installing secondary air pump motor -V101- 3327
2 3 Removing and installing secondary air inlet valve -N112- 3328
3 Exhaust manifold 3331
28 – Ignition system 3332
1 Ignition system 3332
1 1 Assembly overview – ignition system 3332
1 2 Removing and installing ignition coils with output stage 3334
1 3 Removing and installing knock sensor 3336
1 3 1 Removing and installing knock sensor 1 -G61- 3336
1 4 Removing and installing engine speed sender -G28- 3337
1 5 Test data, spark plugs 3338
D3E803D3542 Fuel supply system petrol engines 3339
00 – Technical data 3343
1 Safety information 3343
1 1 Safety regulations for working on fuel supply 3343
1 2 Safety precautions when using testers and measuring instruments during a road test 3343
1 3 Safety measures when working on vehicles with a start/stop system 3344
2 Identification 3345
2 1 Engine number/engine data 3345
3 General information 3347
3 1 Rules for cleanliness when working on auxiliary/supplementary heater and fuel system 3347
4 Repair instructions 3348
4 1 Routing and attachment of lines 3348
4 2 General repair instructions 3348
20 – Fuel supply system 3349
1 Fuel 3349
1 1 Assembly overview – fuel tank 3349
1 2 Emptying fuel tank 3350
1 2 1 Emptying fuel tank when fuel pump is intact 3350
1 2 2 Emptying fuel tank if it is more than 3/4 full 3354
1 2 3 Emptying fuel tank if it is less than 3/4 full 3356
1 3 Removing and installing fuel tank 3360
1 3 1 Removing and installing fuel tank – vehicles with semi-independent suspension 3360
1 3 2 Removing and installing fuel tank – vehicles with multi-link suspension 3365
2 Fuel delivery unit, fuel gauge sender 3371
2 1 Assembly overview – fuel delivery unit/fuel gauge sender 3371
2 2 Removing and installing fuel delivery unit, fuel gauge sender 3372
2 3 Removing and installing fuel gauge sender -G- 3376
3 Wiring 3378
3 1 Removing and installing fuel lines 3378
4 Plug-in connectors 3382
4 1 Separating plug-in connectors 3382
5 Fuel filter 3386
5 1 Assembly overview – fuel filter 3386
5 2 Removing and installing fuel filter 3386
6 Activated charcoal filter system 3389
6 1 Connection diagram – activated charcoal filter 3389
6 1 1 Connection diagram – activated charcoal filter, Vehicles with activated charcoal filter in rear right wheel housing 3389
6 2 Assembly overview – activated charcoal filter system 3390
6 2 1 Assembly overview – activated charcoal filter, Vehicles with activated charcoal filter in rear right wheel housing 3390
6 2 2 Assembly overview – Activated charcoal filter system, activated charcoal filter fitted in engine compartment 3391
6 3 Removing and installing fuel system diagnosis pump 3392
6 4 Removing and installing activated charcoal filter 3393
6 4 1 Removing and installing activated charcoal filter, activated charcoal filter fitted in engine compartment 3393
6 4 2 Removing and installing activated charcoal filter, activated charcoal filter fitted in wheel housing at rear right 3393
6 5 Checking fuel tank breather 3394
6 6 Checking fuel system for leaks 3397
7 Accelerator pedal 3402
7 1 Assembly overview – accelerator module 3402
7 2 Removing and installing accelerator module with accelerator position sender -G79-/-G185- 3402
8 Fuel pump 3405
8 1 Checking fuel system pressurisation pump -G6- 3405
8 1 1 Checking operation and power supply of fuel pump, vehicles with fuel pump control unit – J538- 3405
8 1 2 Checking operation and power supply of fuel pump, vehicles without fuel pump control unit – J538- 3409
8 1 3 Checking fuel pressure 3413
8 1 4 Checking holding pressure 3418
8 1 5 Checking fuel delivery rate, vehicles with fuel pump control unit – J538- 3423
8 1 6 Checking fuel delivery rate, vehicles without fuel pump control unit – J538- 3431
8 1 7 Checking current consumption 3439
D3E803D6781 Brake system 3442
00 – Technical data 3446
1 Notes on safety 3446
1 1 Safety precautions during a road test using test and measuring equipment 3446
1 2 Safety precautions when working on vehicles with start/stop system 3447
2 Identification 3448
2 1 Allocation of PR number – brakes 3448
2 1 1 PR number 3448
2 1 2 Front brakes 3448
2 1 3 Rear brakes, twist-beam rear axle 3448
2 1 4 Rear brakes, multi-link rear axle 3449
3 Technical data 3450
3 1 Technical data for brakes 3450
3 1 1 Brake master cylinder and brake servo 3450
4 Brake test 3453
4 1 General information 3453
4 2 Checking vehicles with front-wheel drive 3453
45 – Anti-lock brake system 3454
1 General information 3454
1 1 Repair instructions for repair work on ABS 3454
1 2 Vehicle diagnosis, testing and information system 3456
2 Fitting location overview 3458
2 1 Fitting location overview – ABS 3458
2 1 1 Fittings locations overview – ABS Mark 70 3458
2 2 Fitting location overview – ABS/ESP 3460
2 2 1 ABS Mark 60 EC (ABS/EDL/TCS/ESP) – vehicles without electromechanical power steering, North America 3460
2 2 2 ABS Mark 60 EC (ABS/EDL/TCS/ESP) – vehicles with electromechanical power steering, North America 3462
2 2 3 ABS Mark 60 EC (ABS/EDL/TCS/ESP) – vehicles with electromechanical power steering 3464
3 Control unit and hydraulic unit 3466
3 1 Assembly overview – control unit and hydraulic unit 3466
3 1 1 Assembly overview – control unit and hydraulic unit, LHD, ABS mark 70 3466
3 1 2 Assembly overview – control unit and hydraulic unit, RHD, ABS mark 70 3469
3 1 3 Assembly overview – control unit and hydraulic unit, LHD, ABS mark 60 EC 3471
3 1 4 Assembly overview – control unit and hydraulic unit, RHD, ABS mark 60 EC 3474
3 2 Removing and installing ABS control unit -J104- and ABS hydraulic unit -N55- 3477
3 2 1 Removing and installing ABS control unit -J104- and ABS hydraulic unit -N55-, LHD vehicles with petrol engine 3477
3 2 2 Removing and installing ABS control unit -J104- and ABS hydraulic unit -N55-, LHD vehicles with 5-cyl petrol engine and ABS Mark 70 (ABS/TCS) 3485
3 2 3 Removing and installing ABS control unit -J104- and ABS hydraulic unit -N55-, LHD vehicles with 4-cyl petrol engine and ABS Mark 70 (ABS/TCS) 3492
3 2 4 Removing and installing ABS control unit -J104- and ABS hydraulic unit -N55-, LHD vehicles with 4-cyl diesel engine and ABS Mark 70 (ABS/TCS) 3501
3 2 5 Removing and installing ABS control unit -J104- and ABS hydraulic unit -N55-, RHD vehicles with ABS Mark 70 (ABS/TCS) 3512
3 2 6 Removing and installing ABS control unit -J104- and ABS hydraulic unit -N55-, LHD vehicles with diesel engine 3519
3 2 7 Removing and installing ABS control unit -J104- and ABS hydraulic unit -N55-, LHD vehicles with 5-cyl petrol engine and ABS Mark 60 EC (ABS/EDL/TCS/ESP) 3526
3 2 8 Removing and installing ABS control unit -J104- and ABS hydraulic unit -N55-, LHD vehicles with 4-cyl petrol engine and ABS Mark 60 EC (ABS/EDL/TCS/ESP) 3534
3 2 9 Removing and installing ABS control unit -J104- and ABS hydraulic unit -N55-, LHD vehicles with 4-cyl diesel engine and ABS Mark 60 EC (ABS/EDL/TCS/ESP) 3543
3 2 10 Removing and installing ABS control unit -J104- and ABS hydraulic unit -N55-, hybrid vehicles and ABS Mark 60 EC (ABS/EDL/TCS/ESP) 3554
3 2 11 Removing and installing ABS control unit -J104- and ABS hydraulic unit -N55-, vehicles with 4-cyl diesel engine with emission control module 3562
3 3 Separating control unit from hydraulic unit 3577
3 3 1 Separating ABS control unit -J104- from ABS hydraulic unit -N55-, ABS Mark 70 3577
3 3 2 Separating ABS control unit -J104- from ABS hydraulic unit -N55-, ABS Mark 60 EC 3578
3 4 Fitting control unit to hydraulic unit 3580
3 4 1 Installing ABS control unit -J104- to ABS hydraulic unit -N55-, ABS Mark 70 (ABS/TCS) 3580
3 4 2 Installing ABS control unit -J104- to ABS hydraulic unit -N55-, ABS Mark 60 EC (ABS/EDL/TCS/ESP) 3581
3 5 Connecting brake lines to hydraulic unit 3584
3 5 1 Connecting brake lines to ABS hydraulic unit -N55-, LHD vehicles with ABS Mark 70 (ABS/TCS) 3584
3 5 2 Connecting brake lines to ABS hydraulic unit -N55-, RHD vehicles with ABS Mark 70 (ABS/TCS) 3585
3 5 3 Connecting brake lines to ABS hydraulic unit -N55-, LHD vehicles with ABS Mark 60 EC (ABS/EDL/TCS/ESP) 3586
3 5 4 Connecting brake lines to ABS hydraulic unit -N55-, RHD vehicles with ABS Mark 60 EC (ABS/EDL/TCS/ESP) 3587
4 Sensors 3589
4 1 Assembly overview – sensors and actuators 3589
4 1 1 Steering angle sender -G85- on steering column 3589
4 2 Assembly overview – speed sensor on front axle 3591
4 2 1 Assembly overview – speed sensors -G45-/-G47- on front axle 3591
4 3 Assembly overview – speed sensor on rear axle 3592
4 3 1 Assembly overview – speed sensors -G44-/-G46- on rear axle, twist-beam rear axle with drum brakes 3592
4 3 2 Assembly overview – speed sensors -G44-/-G46- on rear axle, twist-beam rear axle with disc brakes 3593
4 3 3 Assembly overview – speed sensor -G44-/-G46- on rear axle, multi-link rear axle 3594
4 4 Removing and installing speed sensors on front axle -G45-/-G47- 3595
4 5 Removing and installing speed sensors on rear axle -G44-/-G46- 3596
4 5 1 Removing and installing speed sensors -G44-/-G46- twist-beam rear axle with drum brakes 3596
4 5 2 Removing and installing speed sensors -G44-/-G46- twist-beam rear axle with disc brakes 3596
4 5 3 Removing and installing speed sensors -G44-/-G46-, multi-link rear axle 3597
46 – Brakes – mechanism 3599
1 Front brakes 3599
1 1 Assembly overview – front brakes 3599
1 1 1 Assembly overview – brake caliper FS III without brake pad wear indicator 3599
1 1 2 Assembly overview – brake caliper FS III with brake pad wear indicator 3601
1 1 3 Assembly overview – brake caliper FN 3 without brake pad wear indicator 3603
1 1 4 Assembly overview – brake caliper FN 3 with brake pad wear indicator 3605
1 2 Removing and installing brake pads or linings 3606
1 2 1 Removing and installing brake pads, brake caliper FS III 3606
1 2 2 Removing and installing brake pads, brake caliper FN 3 3609
1 3 Removing and installing brake caliper 3612
1 3 1 Removing and installing brake caliper, FS III brake caliper 3612
1 3 2 Removing and installing brake caliper, FS III brake caliper 3616
1 4 Removing and installing brake carrier 3619
1 4 1 Removing and installing brake carrier, brake caliper FN 3 3619
1 5 Removing and installing brake disc 3621
1 5 1 Removing and installing brake disc, brake caliper FS III 3621
1 5 2 Removing and installing brake disc, brake caliper FN 3 3623
1 6 Removing and installing brake splash plate 3625
1 6 1 Removing and installing cover plate, brake caliper FS III 3625
1 6 2 Removing and installing splash plate, brake caliper FN 3 3627
2 Rear brakes 3630
2 1 Assembly overview – rear brakes 3630
2 1 1 Assembly overview of drum brake, twist-beam axle 3630
2 1 2 Assembly overview – drum brake 3632
2 1 4 Assembly overview – torsion beam rear suspension, rear brakes, Bosch ZOH BIR 38 3634
2 1 5 Assembly overview – torsion beam rear suspension, rear brakes, CI 38 3636
2 1 6 Assembly overview – multi-link rear suspension, rear brakes, Bosch ZOH BIR 38 3639
2 1 7 Assembly overview – multi-link rear suspension, rear brakes, CI 38 3642
2 2 Removing and installing brake pads or linings 3644
2 2 1 Removing and installing brake pads; Rear brakes, Bosch ZOH BIR 38 3644
2 2 2 Removing and installing brake pads; Rear brakes, CI 38 3646
2 3 Removing and installing brake caliper 3650
2 3 1 Removing and installing brake caliper; Rear brakes, Bosch ZOH BIR 38 3650
2 3 2 Removing and installing brake caliper; Rear brakes, CI 38 3653
2 3 3 Removing and installing wheel brake cylinder 3657
2 4 Removing and installing brake carrier 3659
2 4 1 Removing and installing backplate for drum brakes 3659
2 4 2 Removing and installing brake carrier for disc brakes 3661
2 5 Removing and installing brake disc 3663
2 5 1 Removing and installing brake disc 3663
2 5 2 Removing and installing brake drum 3665
2 6 Removing and installing brake shoes 3667
2 7 Retracting drum brakes 3669
2 8 Removing and installing brake splash plate 3670
2 8 1 Removing and installing splash plate for brakes, twist-beam rear axle 3670
2 8 2 Removing and installing splash plate for brakes, multi-link rear axle 3671
3 Handbrake 3674
3 1 Assembly overview – parking brake 3674
3 2 Removing and installing handbrake lever 3675
3 2 1 Removing and installing handbrake lever 3675
3 3 Adjusting parking brake 3678
3 3 1 Adjusting handbrake, drum brakes 3678
3 3 2 Adjusting handbrake, disc brakes 3680
3 4 Removing and installing rear brake cable 3683
3 4 1 Removing and installing brake cable, drum brakes 3683
3 4 2 Removing and installing brake cable, disc brakes on twist-beam rear axle 3687
3 4 3 Removing and installing brake cable for disc brakes on multi-link rear axle 3691
4 Brake pedal 3695
4 1 Assembly overview – brake pedal 3695
4 1 1 Assembly overview – brake pedal, left-hand drive 3695
4 1 2 Assembly overview – brake pedal, right-hand drive 3697
4 2 Separating brake pedal from brake servo 3697
4 3 Connecting brake pedal to brake servo 3699
4 4 Removing and installing mounting bracket 3699
4 4 1 Removing and installing mounting bracket, left-hand drive 3699
4 4 2 Removing and installing mounting bracket, right-hand drive 3701
4 5 Removing and installing brake pedal 3704
4 5 1 Removing and installing brake pedal, LHD 3704
4 5 2 Removing and installing brake pedal, RHD 3705
47 – Brakes – hydraulics 3707
1 Front brake caliper 3707
1 1 Assembly overview – front brake caliper 3707
1 1 1 Assembly overview – FS III 3707
1 1 2 Assembly overview – FN 3 3708
1 2 Removing and installing brake caliper piston 3708
1 2 1 Removing and installing brake caliper FS III 3708
1 2 2 Removing and installing brake calliper piston FN 3 3711
2 Rear brake caliper 3714
2 1 Assembly overview – rear brake caliper 3714
2 1 1 Assembly overview – rear brake caliper, rear brakes, Bosch ZOH BIR 38 3714
2 1 2 Assembly overview – rear brake caliper, rear brakes, CI 38 3715
2 2 Removing and installing brake caliper piston 3716
2 2 1 Removing and installing brake caliper piston; Rear brakes, Bosch ZOH BIR 38 3716
2 2 2 Removing and installing brake caliper piston; Rear brakes, CI 38 3718
2 2 3 Pre-bleeding brake caliper 3720
3 Brake servo and brake master cylinder 3721
3 1 Assembly overview – brake servo/brake master cylinder 3721
3 1 1 Assembly overview – brake servo/brake master cylinder (left-hand drive vehicle) 3721
3 1 2 Assembly overview – brake servo/brake master cylinder (right-hand drive vehicle) 3724
3 2 Removing and installing brake servo 3726
3 2 1 Removing and installing brake servo, LHD vehicles with 5-cyl petrol engine 3726
3 2 2 Removing and installing brake servo, LHD vehicles with 4-cyl petrol engine 3735
3 2 3 Removing and installing brake servo, LHD vehicles with 4-cyl diesel engine 3741
3 2 4 Removing and installing brake servo, RHD vehicles with 4-cyl diesel engine 3749
3 3 Removing and installing brake master cylinder 3760
3 3 1 Removing and installing brake master cylinder, LHD vehicles with 5-cyl petrol engine 3760
3 3 2 Removing and installing brake master cylinder, LHD vehicles with 4-cyl petrol engine 3766
3 3 3 Removing and installing brake master cylinder, LHD vehicles with 4-cyl diesel engine 3771
3 3 4 Removing and installing brake master cylinder, RHD vehicles with 4-cyl petrol engine 3777
3 4 Removing and installing brake fluid reservoir 3784
3 4 1 Removing and installing brake fluid reservoir, LHD vehicles 3784
3 4 2 Removing and installing brake fluid reservoir, RHD vehicles 3788
3 5 Removing and installing brake light switch 3790
3 5 1 Removing and installing brake light switch -F-, LHD vehicles with 5-cyl petrol engine 3790
3 5 2 Removing and installing brake light switch -F-, LHD vehicles with 4-cyl petrol engine 3791
3 5 3 Removing and installing brake light switch -F-, LHD vehicles with 4-cyl diesel engine 3792
3 5 4 Removing and installing brake light switch -F-, right-hand drive 3794
4 Vacuum system 3795
4 1 Assembly overview – electric vacuum pump 3795
4 2 Assembly overview – vacuum pump 3796
4 2 1 Brake servo vacuum pump, vehicles with 5-cyl petrol engine 3796
4 2 2 Brake servo vacuum pump, vehicles with 4-cyl petrol engine 3796
4 2 3 Brake servo vacuum pump, vehicles with 4-cyl diesel engine 3796
4 3 Checking vacuum system 3797
4 3 1 Instructions 3797
4 3 2 Connecting vacuum gauge for brake servo -VAS 6721- 3798
4 3 3 Checking vacuum generation 3799
4 3 4 Checking for leaks 3799
4 3 5 Vacuum generation with manual vacuum pump -VAS 6213- 3801
4 4 Checking non-return valve 3801
4 5 Removing and installing vacuum sender -G608- 3802
5 Brake lines 3803
5 1 Repairing brake lines 3803
5 1 1 Tools for brake line repair 3803
5 1 2 Assembly overview – flanging tool 3805
5 1 3 Work instructions 3805
6 Hydraulic system 3808
6 1 General notes on brake fluid 3808
6 1 1 General information 3808
6 1 2 Changing brake fluid 3810
6 2 Pre-bleeding hydraulic system 3810
6 3 Bleeding hydraulic system following standard procedure 3812
6 4 Subsequent bleeding of hydraulic system 3816
6 5 Testing for leaks 3817
6 5 1 Pressurised leak test 3817
6 5 2 Checking wheel brake cylinder for leaks 3817
D3E803D6783 Running gear axles steering 3819
00 – Technical data 3825
1 Evaluating accident vehicles 3825
1 1 Check list for evaluating running gear on accident vehicles 3825
2 General information 3827
2 1 Tyre types 3827
3 Repair instructions 3828
3 1 Steering rack 3828
3 2 Gaskets and seals 3828
3 3 Nuts and bolts 3829
3 4 Electrical components 3829
3 5 Raising suspension to unladen position (vehicles with coil springs) 3829
3 5 1 Raising wheel bearing assembly to unladen position (vehicles with coil springs), front axle 3829
3 5 2 Raising wheel bearing assembly to unladen position (vehicles with coil springs), rear axle 3831
40 – Front suspension 3834
1 Front axle 3834
1 1 Overview of fitting locations – front axle 3834
2 Subframe 3836
2 1 Assembly overview – subframe 3836
2 2 Assembly overview – subframe strut 3839
2 3 Removing and installing subframe strut 3839
2 4 Fixing position of subframe 3840
2 5 Lowering subframe 3844
2 6 Removing and installing subframe without steering rack 3847
2 7 Removing and installing subframe with steering rack 3852
2 7 1 Removing and installing subframe with steering rack, hydraulic steering 3852
2 7 2 Removing and installing subframe with steering rack, electromechanical steering 3859
2 8 Repairing subframe 3865
2 9 Removing and installing anti-roll bar 3873
2 10 Repairing thread in longitudinal member 3877
3 Suspension strut, upper suspension link 3878
3 1 Assembly overview – suspension strut, upper suspension link 3878
3 2 Removing and installing suspension strut 3879
3 3 Repairing suspension strut 3884
4 Lower suspension link, swivel joint 3887
4 1 Assembly overview – lower suspension link, swivel joint 3887
4 2 Removing and installing lower suspension link 3889
4 2 1 Removing and installing lower suspension link, Basic 3889
4 2 2 Removing and installing lower suspension link, left side of vehicles with automatic or dual clutch gearbox 3890
4 3 Checking swivel joint 3895
4 4 Removing and installing swivel joint 3896
4 5 Renewing bonded rubber bush for lower suspension link 3899
4 5 1 Renewing bonded rubber bush for lower suspension link, front bonded rubber bush 3899
4 5 2 Renewing bonded rubber bush for lower suspension link, rear bonded rubber bush 3902
5 Wheel bearing 3904
5 1 Assembly overview – wheel bearing 3904
5 2 Removing and installing wheel bearing housing 3905
5 3 Removing and installing wheel bearing unit 3910
6 Drive shaft 3914
6 1 Overview – drive shaft 3914
6 2 Assembly overview – drive shaft 3915
6 2 1 Assembly overview – drive shaft, constant velocity joint VL100 3915
6 2 2 Assembly overview – drive shaft, constant velocity joint VL107 3917
6 2 3 Assembly overview – drive shaft, triple roller joint AAR2600i 3919
6 2 4 Assembly overview – drive shaft, triple roller joint AAR3300i 3920
6 3 Removing and installing drive shaft 3921
6 3 1 Removing and installing drive shaft, constant velocity joints VL100 and VL107 3921
6 3 2 Removing and installing drive shaft, triple roller joint AAR2600i 3924
6 3 3 Removing and installing drive shaft, triple roller joint AAR3300i 3928
6 4 Loosening and tightening threaded connections of drive shaft 3931
6 5 Removing and installing drive shaft heat shield 3933
6 6 Dismantling and assembling drive shaft 3933
6 6 1 Dismantling and assembling drive shaft, constant velocity joint VL100 3933
6 6 2 Dismantling and assembling drive shaft, constant velocity joint VL107 3938
6 6 3 Dismantling and assembling drive shaft, triple roller joint AAR2600i 3942
6 6 4 Dismantling and assembling drive shaft, triple roller joint AAR3300i 3947
6 7 Checking outer constant velocity joint 3952
6 8 Checking inner constant velocity joint 3953
42 – Rear suspension 3956
1 Rear axle 3956
1 1 Overview – rear axle 3956
1 1 1 Overview – rear axle, torsion beam axle 3956
1 1 2 Overview – rear axle, multi-link suspension 3959
1 2 Lowering rear axle 3961
1 3 Removing and installing rear axle 3963
1 3 1 Removing and installing rear axle, retaining bracket for torsion beam axle 3963
1 3 2 Removing and installing rear axle, multi-link suspension 3967
2 Axle beam 3972
2 1 Assembly overview – axle beam 3972
2 2 Assembly overview – plate for axle beam 3974
2 3 Removing and installing axle assembly 3975
2 4 Removing and installing plate for axle beam 3980
2 4 1 Removing plate for axle beam 3980
2 4 2 Installing plate for axle beam 3981
2 5 Renewing bonded rubber bush for axle beam 3986
2 6 Removing and installing cross piece 3991
2 7 Renewing bonded rubber bush for cross strut 3994
3 Subframe 3997
3 1 Assembly overview – subframe 3997
3 2 Assembly overview – radius rod 3999
3 3 Fixing position of subframe 3999
3 4 Removing and installing radius rods 4001
4 Anti-roll bar 4003
4 1 Assembly overview – anti-roll bar 4003
4 2 Removing and installing anti-roll bar 4003
5 Suspension link, track rod 4006
5 1 Removing and installing upper transverse link 4006
5 2 Removing and installing lower transverse link 4007
5 3 Removing and installing track rod 4009
6 Suspension strut, shock absorber, spring 4012
6 1 Assembly overview – suspension strut, shock absorber, spring 4012
6 1 1 Assembly overview – suspension strut, shock absorber, spring, torsion beam axle 4012
6 1 2 Assembly overview – suspension strut, shock absorber, spring, multi-link suspension 4014
6 2 Removing and installing shock absorbers 4014
6 2 1 Removing and installing shock absorbers, torsion beam axle 4014
6 2 2 Removing and installing shock absorbers, multi-link suspension 4016
6 3 Repairing shock absorber 4017
6 4 Removing and installing spring 4019
6 4 1 Removing and installing spring, torsion beam axle 4019
6 4 2 Removing and installing spring, multi-link suspension 4021
7 Wheel bearing assembly, trailing arm 4024
7 1 Assembly overview – wheel bearing 4024
7 1 1 Assembly overview – wheel bearing assembly, drum brakes, torsion beam axle 4024
7 1 2 Assembly overview – wheel bearing assembly, disc brakes, torsion beam axle 4026
7 1 3 Assembly overview – wheel bearing assembly, multi-link suspension 4027
7 2 Removing and installing wheel bearing housing 4028
7 3 Removing and installing wheel bearing unit 4031
7 3 1 Removing and installing wheel bearing unit, drum brakes, torsion beam axle 4031
7 3 2 Removing and installing wheel bearing unit, disc brakes, torsion beam axle 4034
7 3 3 Removing and installing wheel bearing unit, multi-link suspension 4037
7 4 Removing and installing wheel bearing pre-seal 4040
7 5 Renewing bonded rubber bush for wheel bearing housing 4042
7 6 Removing and installing trailing arm with mounting bracket 4045
7 7 Repairing trailing arm 4049
43 – Self-levelling suspension 4053
1 Vehicle level sender 4053
1 1 Assembly overview – rear vehicle level senders 4053
1 1 1 Assembly overview – rear vehicle level senders, torsion beam axle 4053
1 1 2 Assembly overview – rear vehicle level senders, multi-link suspension 4054
1 2 Removing and installing rear vehicle level senders -G76-/-G77- 4054
1 2 1 Removing and installing rear vehicle level senders -G76-/-G77-, torsion beam axle 4054
1 2 2 Removing and installing rear vehicle level senders -G76-/-G77-, multi-link suspension 4056
44 – Wheels, tyres, vehicle geometry 4057
1 Wheels, tyres 4057
1 1 Specified torques for wheel bolts 4057
1 2 Pressing tyre off wheel rim 4057
1 3 Removing tyre from wheel 4058
1 4 Fitting tyre 4058
1 5 Wheel change 4059
1 5 1 Wheel change, protecting wheel centring seat against corrosion 4059
1 5 2 Wheel change, installation requirements 4059
1 5 3 Wheel change, installation instructions for wheel change 4060
1 5 4 Wheel change, wheel installation 4062
1 6 Tyre sealant disposal 4062
1 7 Models with breakdown set 4062
2 Tyre Pressure Monitoring System 4063
2 1 System description – Tyre Pressure Monitoring System 4063
3 Wheel alignment 4065
3 1 Notes for wheel alignment 4065
3 2 Conditions for testing 4066
3 3 Test preparations 4066
3 4 Checking trailing arm of axle beam (torsion beam rear axle) using VAS 241 001 4068
3 5 Checking trailing arm of axle beam (torsion beam rear axle) using VAS 801 4070
3 6 Specifications for wheel alignment 4073
3 6 1 Specified values for wheel alignment, torsion beam axle 4073
3 6 2 Specified values for wheel alignment, multi-link suspension 4074
3 7 Wheel alignment procedure 4075
3 8 Necessity of wheel alignment 4076
3 8 1 Necessity of wheel alignment, torsion beam axle 4076
3 8 2 Necessity of wheel alignment, multi-link suspension 4077
3 9 Transverse vehicle inclination – zero position 4079
3 10 Adjusting camber at front wheels 4079
3 11 Adjusting camber on rear axle 4081
3 11 1 Adjusting camber at rear axle, torsion beam axle 4081
3 11 2 Adjusting camber at rear axle, multi-link suspension 4081
3 12 Adjusting toe at rear axle 4082
3 12 1 Adjusting rear axle toe, torsion beam axle 4082
3 12 2 Adjusting toe on rear axle, multi-link suspension 4082
3 13 Adjusting front axle toe 4083
3 14 Vehicle data sticker 4084
3 15 Steering angle sender -G85- basic setting 4084
4 Vibration due to wheels/tyres – causes and rectification 4085
4 1 Causes of rough running 4085
4 2 Conducting a road test before balancing wheels 4085
4 3 Balancing wheel 4086
4 3 1 Balancing wheel, conditions 4086
4 3 2 Balancing wheel, balancing wheel on stationary wheel balancer 4086
4 3 3 Balancing wheel, balancing wheel with finish balancer 4089
4 4 Vibration control system 4090
4 5 Checking radial and lateral runout of wheels and tyres 4090
4 5 1 Checking radial and lateral runout of wheels and tyres, tolerances 4090
4 5 2 Checking radial and lateral runout on wheels and tyres with tyre gauge 4091
4 6 Checking radial and lateral run-out on wheel rim 4091
4 7 Matching wheels and tyres 4092
4 8 Determining flat spots on tyres 4093
48 – Steering 4095
1 Steering wheel 4095
1 1 Assembly overview – steering wheel 4095
1 2 Removing and installing steering wheel 4095
2 Steering column 4098
2 1 Assembly overview – steering column 4098
2 1 1 Assembly overview – steering column, left-hand drive 4098
2 1 2 Assembly overview – steering column, right-hand drive 4100
2 2 Checking steering column for damage 4100
2 3 Handling and transporting steering column 4101
2 4 Removing and installing steering column 4102
2 4 1 Removing and installing steering column, left-hand drive vehicle 4102
2 4 2 Removing and installing steering column, right-hand drive vehicle 4109
2 5 Removing and installing control unit for electronic steering column lock -J764- 4118
2 5 1 Removing and installing control unit for electronic steering column lock -J764- 4118
2 5 2 Removing and installing control unit for electronic steering column lock -J764-, renewing control unit for electronic steering column lock -J764- 4118
3 Steering rack 4120
3 1 Assembly overview – steering rack 4120
3 1 1 Assembly overview – steering rack, hydraulic steering rack 4120
3 1 2 Assembly overview – steering rack, electromechanical steering rack, left-hand drive vehicle 4121
3 1 3 Assembly overview – steering rack, electromechanical steering rack, right-hand drive vehicle 4123
3 2 Removing and installing steering rack 4125
3 2 1 Removing and installing steering rack, hydraulic steering 4125
3 2 2 Removing and installing steering rack, electromechanical steering rack, LHD vehicles 4131
3 2 3 Removing and installing steering rack, electromechanical steering rack, RHD vehicles 4140
3 3 Removing and installing boot 4145
3 4 Removing and installing track rod 4148
3 5 Removing and installing track rod ball joint 4151
3 6 Repairing steering rack 4152
3 6 1 Repairing steering rack, hydraulic steering 4152
3 6 2 Repairing steering rack, electromechanical steering 4154
4 Hydraulic power steering 4155
4 1 Assembly overview – hydraulic lines, reservoir 4155
4 1 1 Assembly overview – hydraulic lines, storage tank; hydraulic lines, 5-cylinder petrol engine 4155
4 1 2 Assembly overview – hydraulic lines, storage tank; storage tank, 5-cylinder petrol engine 4157
4 2 Assembly overview – vane pump 4157
4 3 Checking hydraulic fluid level of power steering 4158
4 4 Bleeding steering system after repairs 4159
4 5 Check steering for leaks 4159
4 6 Checking delivery pressure of vane pump 4160
4 7 Removing and installing vane pump 4163
5 Sensors 4166
5 1 Removing and installing steering angle sender -G85- 4166
5 1 1 Removing and installing steering angle sender -G85-, vehicles with hydraulic steering rack 4166
5 1 2 Removing and installing steering angle sender -G85-, vehicles with electromechanical steering rack 4168
D3E803EAFBB Body Repairs 4169
00 – Technical data 4175
1 Basic instructions 4175
2 Vehicle identification data 4176
2 1 Vehicle identification number 4176
2 2 Vehicle data sticker 4177
3 Safety instructions 4178
4 Basic notes 4179
5 Safety instructions 4180
6 Moulded foam elements 4181
7 Galvanized body parts, high/higher-strength and hot-formed body panels 4183
7 1 Body 4183
7 2 Overview 4185
8 Laser welding 4188
9 Body panel gaps/shut lines 4189
9 1 Body – front 4189
9 2 Body – centre 4190
9 3 Body – rear 4193
10 Body dimensions 4194
10 1 Body – front 4194
10 2 Body – centre 4196
10 3 Body – rear 4201
10 4 Floor group – front 4202
10 5 Floor group – centre 4203
10 6 Floor group – rear 4204
11 Contour correct surfaces 4205
12 Tools 4206
13 Alignment bracket set 4207
13 1 Overview 4207
13 2 Procedure for body structural damage on vehicles from Volkswagen 4207
14 Portal gauge 4208
50 – Body – front 4209
1 Renewing left console 4209
1 1 Tools 4209
1 2 Removing 4210
1 3 Installing 4212
1 3 1 Preparing new part 4212
1 3 2 Welding in 4213
2 Renewing right-hand bracket 4214
2 1 Tools 4214
2 2 Removing 4215
2 3 Installing 4216
2 3 1 Welding in 4216
3 Renewing subframe 4218
3 1 Tools 4218
3 2 Removing 4219
3 3 Installing 4220
3 3 1 Preparing new part 4220
3 3 2 Welding in 4221
4 Renewing front bumper bracket 4222
4 1 Tools 4222
4 2 Removing 4223
4 3 Installing 4224
4 3 1 Welding in 4224
5 Replacing upper wheel housing longitudinal member 4225
5 1 Tools 4226
5 2 Removing 4226
5 3 Installing 4228
5 3 1 Preparing new part 4229
5 3 2 Welding in 4229
6 Renewing front wheel housing 4232
6 1 Tools 4233
6 2 Removing 4233
6 3 Installing 4234
6 3 1 Preparing new parts 4234
6 3 2 Welding in 4235
7 Repairing threads for securing subframe 4238
7 1 Contents of thread repair kit 4240
7 2 Repairing threads 4240
7 2 1 Drilling thread 4240
7 2 2 Cutting thread 4241
7 2 3 Inserting thread insert 4242
8 Renewing front left longitudinal member 4244
8 1 Tools 4245
8 2 Removing 4245
8 3 Installing 4248
8 3 1 Preparing new part 4248
8 3 2 Welding in 4249
9 Renewing front left longitudinal member – part section 4253
9 1 Tools 4254
9 2 Removing 4254
9 3 Installing 4256
9 3 1 Preparing new part 4256
9 3 2 Welding in 4257
9 3 3 Shortening longitudinal member with cover plate 4261
10 Renewing front right longitudinal member 4265
10 1 Tools 4266
10 2 Removing 4266
10 3 Installing 4269
10 3 1 Preparing new part 4269
10 3 2 Welding in 4270
11 Renewing front right longitudinal member – part section 4274
11 1 Tools 4275
11 2 Removing 4275
11 3 Installing 4277
11 3 1 Preparing new part 4277
11 3 2 Welding in 4278
51 – Body – centre 4282
1 Renewing roof 4282
1 1 Tools 4283
1 2 Removing 4285
1 3 Installing 4287
1 3 1 Preparing new part 4287
1 3 2 Setting the depth dimension 4289
1 3 3 Bonding in 4290
1 3 4 Welding in 4296
2 Renewing roof side member 4298
2 1 Tools 4299
2 2 Removing 4300
2 3 Installing 4301
2 3 1 Preparing new part 4302
2 3 2 Welding in 4305
3 Renewing front roof cross member – vehicles with no panorama glass sliding/tilting sunroof 4308
3 1 Tools 4309
3 2 Removing 4309
3 3 Installing 4310
3 3 1 Welding in 4310
4 Renewing front roof cross member – vehicles with panorama glass sliding/tilting sunroof 4312
4 1 Tools 4313
4 2 Removing 4313
4 3 Installing 4314
4 3 1 Welding in 4315
5 Renewing rear roof cross member – vehicles with no panorama glass sliding/tilting sunroof 4318
5 1 Tools 4319
5 2 Removing 4319
5 3 Installing 4321
5 3 1 Welding in 4322
6 Renewing rear roof cross member – vehicles with panorama glass sliding/tilting sunroof 4326
6 1 Tools 4327
6 2 Removing 4327
6 3 Installing 4329
6 3 1 Welding in 4330
7 Renewing A-pillar 4333
7 1 Tools 4334
7 2 Removing 4334
7 3 Installing 4336
7 3 1 Preparing new part 4337
7 3 2 Moulded foam elements 4339
7 3 3 Welding in 4340
8 Renewing A-pillar reinforcement – part section 4343
8 1 Tools 4344
8 2 Removing 4344
8 3 Installing 4346
8 3 1 Preparing new part 4346
8 3 2 Moulded foam elements 4347
8 3 3 Welding in 4348
9 Renewing B-pillar reinforcement 4352
9 1 Tools 4353
9 2 Removing 4354
9 3 Installing 4355
9 3 1 Preparing new part 4355
9 3 2 Moulded foam elements 4356
9 3 3 Welding in 4357
10 Renewing inner B-pillar 4360
10 1 Tools 4361
10 2 Removing 4361
10 3 Installing 4363
10 3 1 Preparing new part 4363
10 3 2 Welding in 4365
11 Renewing inner B-pillar – part section 4368
11 1 Tools 4369
11 2 Removing 4369
11 3 Installing 4371
11 3 1 Preparing new part 4371
11 3 2 Welding in 4373
12 Renewing side member 4376
12 1 Tools 4377
12 2 Removing 4377
12 3 Installing 4378
12 3 1 Preparing new part 4379
12 3 2 Welding in 4381
13 Renewing side member reinforcement 4384
13 1 Tools 4385
13 2 Removing 4385
13 3 Installing 4386
13 3 1 Preparing new part 4386
13 3 2 Welding in 4387
14 Renewing seat middle cross member 4391
14 1 Tools 4391
14 2 Removing 4392
14 3 Installing 4393
14 3 1 Preparing new part 4393
14 3 2 Welding in 4394
15 Renewing outer mounting for seat cross member 4396
15 1 Tools 4397
15 2 Removing 4398
15 3 Installing 4399
15 3 1 Preparing new part 4399
15 3 2 Welding in 4400
16 Renewing inner mounting for seat cross member 4402
16 1 Tools 4402
16 2 Removing 4403
16 3 Installing 4404
16 3 1 Preparing new part 4404
16 3 2 Welding in 4405
53 – Body – rear 4407
1 Renewing cross panel 4407
1 1 Tools 4408
1 2 Removing 4408
1 3 Installing 4409
1 3 1 Preparing new part 4409
1 3 2 Welding in 4411
2 Renewing tail light mounting 4414
2 1 Tools 4415
2 2 Removing 4415
2 3 Installing 4416
2 3 1 Preparing new part 4416
2 3 2 Welding in 4418
3 Renewing connecting part for tail light 4420
3 1 Tools 4421
3 2 Removing 4421
3 3 Installing 4422
3 3 1 Welding in 4422
4 Renewing lock carrier 4425
4 1 Tools 4426
4 2 Removing 4426
4 3 Installing 4427
4 3 1 Preparing new part 4427
4 3 2 Welding in 4428
5 Renewing inner lower part of left C-pillar 4430
5 1 Tools 4431
5 2 Removing 4431
5 3 Installing 4432
5 3 1 Preparing new part 4432
5 3 2 Welding in 4433
6 Renewing sealing channel 4435
6 1 Tools 4436
6 2 Removing 4436
6 3 Installing 4437
6 3 1 Preparing new part 4437
6 3 2 Welding in 4439
7 Renewing luggage compartment floor 4441
7 1 Tools 4442
7 2 Removing 4442
7 3 Installing 4443
7 3 1 Preparing new part 4443
7 3 2 Moulded foam elements 4445
7 3 3 Welding in 4445
8 Renewing luggage compartment floor – part section 4447
8 1 Tools 4448
8 2 Removing 4448
8 3 Installing 4449
8 3 1 Preparing new part 4449
8 3 2 Welding in 4450
9 Renewing C-pillar reinforcement 4452
9 1 Tools 4453
9 2 Removing 4453
9 3 Installing 4454
9 3 1 Preparing new part 4454
9 3 2 Welding in 4456
10 Renewing rear longitudinal member – part section 4458
10 1 Tools 4459
10 2 Removing 4459
10 3 Installing 4460
10 3 1 Preparing new part 4460
10 3 2 Welding in 4461
11 Renewing side panel – part section 4463
11 1 Tools 4464
11 2 Removing 4465
11 3 Installing 4467
11 3 1 Preparing new part 4468
11 3 2 Marking area where no welding work may be carried out 4471
11 3 3 Moulded foam elements 4471
11 3 4 Welding in 4472
D3E803FFF74 4 cylinder injection engine (1 2 l direct injection engine EA111 turbocharger) 4476
00 – Technical data 4482
1 Identification 4482
1 1 Engine number/engine data 4482
2 General information 4484
2 1 Numbering of cylinders 4484
3 Safety information 4485
3 1 Safety precautions when working on fuel system 4485
3 2 Safety precautions when using testers and measuring instruments during a road test 4485
3 3 Safety precautions when working on the cooling system 4486
3 4 Safety precautions when working on ignition system 4487
3 5 Releasing high pressure in fuel system 4488
4 Repair instructions 4489
4 1 Rules for cleanliness 4489
4 2 Foreign objects in engine 4489
10 – Removing and installing engine 4490
1 Removing and installing engine 4490
1 1 Removing engine 4490
1 2 Separating engine and gearbox 4501
1 2 1 Vehicles with manual gearbox 4501
1 2 2 Vehicles with dual clutch gearbox 4502
1 3 Securing engine on engine and gearbox support 4503
1 4 Installing engine 4505
2 Assembly mountings 4508
2 1 Assembly overview – assembly mountings 4508
2 2 Removing and installing engine mounting 4510
2 3 Supporting engine in installation position 4518
2 4 Adjusting assembly mountings 4526
2 5 Checking adjustment of assembly mountings 4528
13 – Crankshaft group 4529
1 Cylinder block (pulley end) 4529
1 1 Assembly overview – cylinder block (pulley end) 4529
1 2 Assembly overview – poly V-belt drive 4533
1 2 1 Assembly overview – poly V-belt drive, without air conditioner compressor 4533
1 2 2 Assembly overview – poly V-belt drive, air conditioner compressor 4535
1 3 Removing and installing poly-V belt 4538
1 4 Removing and installing tensioner for poly V-belt 4541
1 4 1 Removing and installing tensioner for poly V-belt, with air conditioner 4541
1 4 2 Removing and installing tensioner for poly V-belt, without air conditioner 4542
1 5 Removing and installing vibration damper 4544
1 6 Removing and installing bracket for ancillaries 4548
1 6 1 Removing and installing upper ancillary bracket 4548
1 6 2 Removing and installing lower ancillary bracket 4551
1 7 Renewing crankshaft oil seal – belt pulley end 4551
2 Cylinder block, gearbox end 4555
2 1 Assembly overview – cylinder block, gearbox end 4555
2 2 Removing and installing sealing flange on gearbox side 4557
3 Crankshaft 4568
3 1 Crankshaft dimensions 4568
3 2 Renewing needle bearing in crankshaft 4568
4 Pistons and conrods 4570
4 1 Assembly overview – pistons and conrods 4570
4 2 Checking pistons and cylinder bores 4572
4 2 1 Checking piston 4572
4 2 2 Checking cylinder bores 4573
4 3 Separating new conrod 4574
15 – Cylinder head, valve gear 4576
1 Cylinder head 4576
1 1 Assembly overview – cylinder head 4576
1 2 Removing and installing cylinder head 4579
1 3 Removing and installing cylinder head cover 4590
1 4 Checking compression 4603
2 Cover for timing chain 4605
2 1 Removing and installing valve timing housing (timing case) 4605
2 1 1 Removing and installing upper valve timing housing 4605
2 1 2 Removing and installing lower valve timing housing 4608
3 Chain drive 4613
3 1 Removing and installing camshaft timing chain 4613
3 2 Removing and installing timing chain and chain drive for oil pump 4621
3 3 Checking valve timing 4622
3 4 Adjusting valve timing 4625
4 Valve gear 4635
4 1 Assembly overview – valve gear 4635
4 2 Measuring axial play of camshaft 4641
4 3 Removing and installing camshaft 4642
4 4 Removing and installing valve stem seals 4644
17 – Lubrication 4647
1 Sump, oil pump 4647
1 1 Assembly overview – sump/oil pump 4647
1 2 Engine oil: 4650
1 3 Removing and installing sump 4651
1 4 Removing and installing oil pump 4654
2 Engine oil cooler 4656
2 1 Removing and installing engine oil cooler 4656
3 Oil filter, oil pressure switch 4657
3 1 Checking oil pressure and oil pressure switch 4657
19 – Cooling 4659
1 Cooling system/coolant 4659
1 1 Connection diagram – coolant hoses 4659
1 2 Checking cooling system for leaks 4659
1 3 Draining and adding coolant 4662
2 Coolant pump, regulation of cooling system 4669
2 1 Assembly overview – thermostat 4669
2 2 Removing and installing coolant pump 4669
2 3 Removing and installing coolant pump pulley 4671
2 4 Removing and installing electric coolant pump 4673
2 4 1 Removing and installing coolant circulation pump -V50- 4673
3 Radiator, radiator fan 4676
3 1 Assembly overview – radiator/radiator fan 4676
3 2 Removing and installing radiator 4678
3 3 Removing and installing radiator cowl 4680
3 4 Removing and installing radiator fan 4682
21 – Turbocharging/supercharging 4683
1 Turbocharger 4683
1 1 Assembly overview – turbocharger 4683
1 1 1 Assembly overview – turbocharger 4683
1 1 2 Assembly overview – turbocharger with attachments 4685
1 2 Removing and installing turbocharger 4687
1 3 Removing and installing charge pressure positioner -V465- 4692
2 Charge air system 4695
2 1 Assembly overview – charge air system 4695
2 2 Removing and installing charge air cooler 4697
24 – Mixture preparation – injection 4700
1 Injection system 4700
2 Injectors 4701
2 1 Removing and installing injectors 4701
2 2 Renewing seals on injectors 4704
2 3 Cleaning injectors 4708
3 Air filter 4710
3 1 Assembly overview – air filter housing 4710
3 2 Removing and installing air filter housing 4711
4 Intake manifold 4713
4 1 Assembly overview – intake manifold 4713
4 1 1 Assembly overview – intake manifold 4713
4 1 2 Assembly overview – intake manifold, vehicles with manual gearbox 4715
4 1 3 Assembly overview – intake manifold, vehicles with dual clutch gearbox 4717
4 2 Removing and installing intake manifold 4719
4 3 Removing and installing throttle valve module -J338- 4722
4 4 Cleaning throttle valve module 4724
5 Senders and sensors 4726
5 1 Checking fuel pressure sender -G247- 4726
6 Engine control unit 4730
6 1 Removing and installing engine control unit -J623- 4730
7 High-pressure pump 4733
7 1 Assembly overview – high-pressure pump 4733
7 2 Removing and installing high-pressure pump 4734
26 – Exhaust system 4738
1 Exhaust pipes and silencers 4738
1 1 Assembly overview – silencers 4738
1 2 Separating exhaust pipes from silencers 4738
1 3 Installation position of clamp 4740
2 Emission control 4743
2 1 Assembly overview – emission control 4743
28 – Ignition system 4746
1 Ignition system 4746
1 1 Assembly overview – ignition system 4746
1 2 Removing and installing engine speed sender -G28- 4748
1 3 Test data, spark plugs 4748
D3E804D3C4E 4 cylinder diesel engine (2 0 l engine common rail generation II) 4749
00 – Technical data 4755
1 Identification 4755
1 1 Engine number/engine data 4755
2 General information 4757
2 1 Numbering of cylinders 4757
3 Safety information 4758
3 1 Safety precautions when working on fuel system 4758
3 2 Safety measures when working on vehicles with a start/stop system 4759
3 3 Safety precautions when using testers and measuring instruments during a road test 4759
3 4 Safety precautions when working on the cooling system 4760
4 Repair instructions 4761
4 1 Rules for cleanliness 4761
4 1 1 Rules for cleanliness when working on auxiliary heater and fuel system 4761
4 1 2 When working on turbocharger 4761
4 2 Foreign objects in engine 4761
4 3 Checking vacuum system 4762
10 – Removing and installing engine 4763
1 Removing and installing engine 4763
1 1 Removing engine 4763
1 2 Separating engine and gearbox 4777
1 2 1 Separating engine and gearbox, manual gearbox 4777
1 2 2 Separating engine and gearbox, dual-clutch gearbox 4779
1 3 Securing engine on engine and gearbox support 4782
1 4 Installing engine 4784
2 Assembly mountings 4788
2 1 Assembly overview – assembly mountings 4788
2 2 Removing and installing engine mounting 4790
2 3 Supporting engine in installation position 4799
2 4 Adjusting assembly mountings 4808
2 5 Checking adjustment of assembly mountings 4810
3 Engine cover panel 4812
3 1 Removing and installing engine cover 4812
13 – Crankshaft group 4814
1 Cylinder block (pulley end) 4814
1 1 Assembly overview – poly V-belt drive 4814
1 1 1 Assembly overview – poly V-belt drive with tensioning element and air conditioner compressor 4814
1 1 2 Assembly overview – poly V-belt drive with tensioning roller and air conditioner compressor 4815
1 1 3 Assembly overview – poly V-belt drive without air conditioner compressor 4817
1 2 Removing and installing poly-V belt 4818
1 2 1 Removing and installing poly V-belt, with tensioning element and air conditioner compressor 4818
1 2 2 Removing and installing poly V-belt, with tensioning roller and air conditioner compressor 4820
1 2 3 Removing and installing poly V-belt, without air conditioner compressor 4822
1 3 Removing and installing tensioner for poly V-belt 4823
1 4 Removing and installing vibration damper 4825
1 5 Removing and installing bracket for ancillaries 4826
1 6 Removing and installing engine bracket 4828
1 7 Assembly overview – sealing flange, belt pulley end 4831
1 8 Renewing crankshaft oil seal – belt pulley end 4833
1 9 Removing and installing sealing flange on pulley end 4835
2 Cylinder block, gearbox end 4840
2 1 Assembly overview – cylinder block, gearbox end 4840
2 2 Removing and installing flywheel 4841
2 3 Removing and installing sealing flange on gearbox side 4843
3 Crankshaft 4857
3 1 Assembly overview – crankshaft 4857
3 2 Crankshaft dimensions 4858
3 3 Renewing needle bearing in crankshaft 4858
3 4 Measuring axial clearance of crankshaft 4860
3 5 Measuring radial clearance of crankshaft 4861
4 Pistons and conrods 4862
4 1 Assembly overview – pistons and conrods 4862
4 2 Measuring piston projection at TDC 4864
4 3 Checking pistons and cylinder bores 4866
4 3 1 Checking piston 4866
4 3 2 Cylinder bore 4868
4 3 3 Piston and cylinder dimensions 4869
4 4 Separating new conrod 4869
4 4 1 Bearing shells – installation position 4870
4 5 Checking radial clearance of conrods 4870
15 – Cylinder head, valve gear 4871
1 Cylinder head 4871
1 1 Assembly overview – cylinder head 4871
1 2 Assembly overview – cylinder head cover 4875
1 3 Removing and installing cylinder head 4877
1 4 Removing and installing cylinder head cover 4893
1 4 1 Renewing seals for injectors 4895
1 5 Removing and installing vacuum pump 4896
1 6 Checking compression 4898
2 Toothed belt drive 4901
2 1 Assembly overview – toothed belt 4901
2 2 Removing and installing toothed belt 4903
2 2 1 Differences between versions of tensioning roller 4903
2 2 2 Removing and installing toothed belt, tensioning roller of type A 4904
2 2 3 Removing and installing toothed belt, tensioning roller of type B 4915
3 Valve gear 4927
3 1 Assembly overview – valve gear 4927
3 2 Measuring axial play of camshaft 4929
3 3 Measuring radial play of camshaft 4930
3 4 Removing and installing camshaft oil seal 4931
3 4 1 Removing and installing camshaft oil seal, vehicles with »former« seal 4931
3 4 2 Removing and installing camshaft oil seal, vehicles with »new« seal 4935
3 5 Removing and installing camshaft 4939
3 6 Checking hydraulic compensation elements 4948
3 7 Removing and installing valve stem seal 4949
3 7 1 Renewing valve stem seal with cylinder head installed 4949
3 7 2 Renewing valve stem seal with cylinder head removed 4953
4 Inlet and exhaust valves 4958
4 1 Reworking valve seats 4958
4 2 Checking valve guides 4958
4 3 Checking valves 4959
4 4 Valve dimensions 4959
17 – Lubrication 4960
1 Sump, oil pump 4960
1 1 Assembly overview – sump/oil pump 4960
1 1 1 Assembly overview – sump/oil pump, without balance shaft module 4960
1 1 2 Assembly overview – sump/oil pump, with balance shaft module 4963
1 2 Removing and installing oil sump 4966
1 3 Removing and installing oil pump 4971
1 3 1 Removing and installing oil pump, without balance shaft module 4971
1 3 2 Removing and installing oil pump, with balancer shaft module 4972
1 4 Removing and installing oil level and oil temperature sender -G 266- 4973
2 Engine oil cooler 4975
2 1 Assembly overview – engine oil cooler 4975
2 2 Removing and installing engine oil cooler 4975
3 Oil filter, oil pressure switch 4979
3 1 Assembly overview – oil filter housing, oil pressure switch 4979
3 2 Removing and installing oil pressure switch -F1- 4980
3 3 Checking oil pressure 4981
3 4 Checking oil pressure and oil pressure switch 4982
3 5 Removing and installing oil filter housing 4983
4 Oil circuit 4989
4 1 Assembly overview – oil circuit 4989
4 2 Removing and installing oil return line for turbocharger 4989
5 Balancer shaft module 4995
5 1 Removing and installing balance shaft module 4995
5 1 1 Removing balancer shaft module 4995
5 1 2 Installing a previously used balancer shaft module again 4997
5 1 3 Installing a new balancer shaft module 5000
19 – Cooling 5005
1 Cooling system/coolant 5005
1 1 Coolant hose connection diagram 5005
1 2 Checking cooling system for leaks 5007
1 3 Draining and adding coolant 5008
1 3 1 Draining 5008
1 3 2 Filling 5011
2 Coolant pump, regulation of cooling system 5015
2 1 Assembly overview – coolant pump, thermostat 5015
2 2 Coolant circulation pump 2 -V178- 5015
2 2 1 Assembly overview – coolant circulation pump 2 -V178- 5015
2 2 2 Removing and installing coolant circulation pump 2 -V178- 5016
2 3 Removing and installing coolant pump 5019
2 4 Removing and installing 4/2-way valve with thermostat 5021
2 5 Removing and installing coolant temperature sender 5027
2 5 1 Removing and installing coolant temperature sender -G62- 5027
2 5 2 Removing and installing radiator outlet coolant temperature sender -G83- 5029
3 Coolant pipes 5032
3 1 Assembly overview – coolant pipes 5032
3 2 Removing and installing coolant pipes 5034
3 2 1 Removing and installing left coolant pipe 5034
3 2 2 Removing and installing front coolant pipe 5037
3 2 3 Removing and installing upper front coolant pipe 5043
3 2 4 Removing and installing right coolant pipe 5044
4 Radiator, radiator fan 5047
4 1 Assembly overview – radiator, radiator fan 5047
4 2 Removing and installing radiator 5047
4 3 Removing and installing radiator cowl with radiator fan 5050
4 4 Removing and installing radiator fan 5051
21 – Turbocharging/supercharging 5052
1 Turbocharger 5052
1 1 Assembly overview – turbocharger 5052
1 2 Removing and installing turbocharger 5054
1 3 Renewing vacuum unit for turbocharger 5061
2 Charge air system 5068
2 1 Assembly overview – charge air system 5068
2 2 Assembly overview – charge-air hose connections 5070
2 2 1 Fitting charge air system hose connections, plug-in connector 5070
2 2 2 Fitting charge air system hose connections, ribbed union and hose clamp 5071
2 3 Removing and installing charge air cooler 5072
2 4 Removing and installing charge air pressure sender -G31-/intake air temperature sender -G42- 5074
2 5 Checking charge air system for leaks 5075
23 – Mixture preparation – injection 5079
1 Injection system 5079
1 1 Schematic overview – fuel system 5079
1 2 Filling/bleeding fuel system 5081
1 3 Checking fuel system for leaks 5082
2 Vacuum system 5083
2 1 Connection diagram – vacuum system 5083
2 2 Checking vacuum system 5084
2 2 1 Checking supply line, vacuum reservoir and non-return valve 5084
2 2 2 Checking control line to turbocharger 5085
3 Injectors/high-pressure accumulator (rail) 5087
3 1 Assembly overview – injectors 5087
3 2 Adapting correction values for injectors 5090
3 3 Testing jammed-open injectors 5091
3 4 Removing and installing injectors 5093
3 5 Removing and installing fuel rail 5097
3 6 Removing and installing high-pressure lines 5101
4 High-pressure pump 5106
4 1 Assembly overview – high-pressure pump 5106
4 2 Removing and installing high-pressure pump 5108
5 Senders and sensors 5114
5 1 Checking fuel pressure regulating valve 5114
5 2 Removing and installing fuel pressure regulating valve 5115
5 3 Removing and installing fuel pressure sender 5117
5 4 Removing and installing air mass meter 5120
5 5 Removing and installing differential pressure sensor 5121
6 Intake manifold 5123
6 1 Assembly overview – intake manifold 5123
6 2 Removing and installing intake manifold 5124
6 3 Removing and installing throttle valve module 5129
7 Lambda probe 5131
7 1 Removing and installing Lambda probe -G39- with Lambda probe heater -Z19- 5131
8 Air filter 5133
8 1 Assembly overview – air filter housing 5133
8 2 Removing and installing air filter housing 5135
8 3 Checking changeover flap for intake air preheating 5137
8 4 Removing and installing changeover flap for intake air preheating 5138
9 Engine control unit 5141
9 1 Removing and installing engine control unit 5141
9 2 Removing and installing engine control unit with protective housing 5142
26 – Exhaust system 5145
1 Exhaust pipes and silencers 5145
1 1 Assembly overview – silencers 5145
1 1 1 Assembly overview – silencers 5145
1 2 Separating exhaust pipes from silencers 5146
1 3 Aligning exhaust system free of stress 5148
1 4 Installation position of clamp 5149
2 Emission control 5151
2 1 Assembly overview – emission control 5151
2 2 Removing and installing particulate filter 5154
3 Exhaust gas temperature regulation 5163
3 1 Removing and installing parts of exhaust gas temperature regulation 5163
3 1 1 Removing and installing exhaust gas temperature sender -G235- 5163
3 1 2 Removing and installing exhaust gas temperature sender -G495- 5165
3 1 3 Removing and installing exhaust gas temperature sender -G648- 5167
4 Exhaust gas recirculation 5170
4 1 Assembly overview – exhaust gas recirculation 5170
4 2 Removing and installing exhaust gas recirculation cooler 5171
4 3 Checking changeover for exhaust gas recirculation cooler 5174
4 4 Checking exhaust gas recirculation cooler for leaks 5175
4 5 Cleaning exhaust gas recirculation system 5180
4 5 1 Initiating cleaning of exhaust gas recirculation system 5180
4 5 2 Cleaning connecting pipes and pipe union 5186
28 – Glow plug system 5188
1 Glow plug system 5188
1 1 Removing and installing glow plug 5188
1 2 Removing and installing automatic glow period control unit -J179- 5190
1 3 Removing and installing Hall sender -G40- 5192
1 4 Removing and installing engine speed sender -G28- 5193
D3E804F81DA Body Repairs 5196
00 – Technical data 5202
1 Basic instructions 5202
2 Vehicle identification data 5203
2 1 Vehicle identification number 5203
2 2 Vehicle data sticker 5204
3 Safety information 5205
4 Basic instructions 5206
5 Moulded foam inserts 5207
6 Galvanized body parts, high/higher-strength and hot-formed body panels 5209
6 1 Installing 5209
6 2 Overview 5211
7 Laser welding 5214
8 Body panel gaps/shut lines 5215
8 1 Body – front 5215
8 2 Body – centre 5217
8 3 Body – rear 5219
9 Body dimensions 5220
9 1 Body – front 5220
9 2 Body – centre 5222
9 3 Body – rear 5227
9 4 Floor panel – front 5228
9 5 Floor panel – centre 5229
9 6 Floor panel – rear 5230
10 Contour correct surfaces 5231
11 Tools 5232
12 Alignment bracket set 5233
12 1 Overview 5233
12 2 Procedure for body structural damage on vehicles from Volkswagen 5233
13 Portal gauge 5234
50 – Body – front 5235
1 Renewing right console 5235
1 1 Tools 5235
1 2 Removing 5235
1 3 Installing 5237
1 3 1 Welding in 5237
2 Renewing left console 5239
2 1 Tools 5239
2 2 Removing 5239
2 3 Installing 5242
2 3 1 Preparing replacement part 5242
2 3 2 Welding in 5243
3 Renewing subframe 5244
3 1 Tools 5244
3 2 Removing 5244
3 3 Installing 5246
3 3 1 Preparing replacement part 5246
3 3 2 Welding in 5247
4 Renewing bumper bracket 5248
4 1 Tools 5248
4 2 Removing 5248
4 3 Installing 5249
4 3 1 Welding in 5250
5 Replacing upper wheel housing longitudinal member 5251
5 1 Tools 5252
5 2 Removing 5252
5 3 Installing 5254
5 3 1 Preparing replacement part 5255
5 3 2 Welding in 5255
6 Renewing front wheel housing 5258
6 1 Tools 5259
6 2 Removing 5259
6 3 Installing 5260
6 3 1 Preparing new parts 5260
6 3 2 Welding in 5261
7 Repairing threads for securing subframe 5264
7 1 Contents of thread repair kit 5266
7 2 Repairing threads 5266
7 2 1 Drilling thread 5266
7 2 2 Cutting thread 5267
7 2 3 Inserting thread insert 5268
8 Renewing front left longitudinal member 5270
8 1 Tools 5271
8 2 Removing 5271
8 3 Installing 5274
8 3 1 Preparing replacement part 5274
8 3 2 Welding in 5275
9 Renewing front left longitudinal member – part section 5279
9 1 Tools 5280
9 2 Removing 5280
9 3 Installing 5282
9 3 1 Preparing replacement part 5282
9 3 2 Welding in 5283
9 3 3 Shortening longitudinal member with cover plate 5287
10 Renewing front right longitudinal member 5291
10 1 Tools 5292
10 2 Removing 5292
10 3 Installing 5295
10 3 1 Preparing replacement part 5295
10 3 2 Welding in 5296
11 Renewing front right longitudinal member – part section 5300
11 1 Tools 5301
11 2 Removing 5301
11 3 Installing 5303
11 3 1 Preparing replacement part 5303
11 3 2 Welding in 5304
51 – Body – centre 5308
1 Renewing front upper roof cross member 5308
1 1 Tools 5309
1 2 Removing 5309
1 3 Installing 5310
1 3 1 Welding in 5310
2 Renewing front cross member for roof 5313
2 1 Tools 5314
2 2 Removing 5314
2 3 Installing 5316
2 3 1 Welding in 5316
3 Renewing windscreen frame 5319
3 1 Tools 5320
3 2 Removing 5320
3 3 Installing 5321
3 3 1 Preparing replacement part 5321
3 3 2 Welding in 5322
4 Renewing A-pillar 5325
4 1 Tools 5326
4 2 Removing 5326
4 3 Installing 5328
4 3 1 Preparing replacement part 5329
4 3 2 Moulded foam inserts 5331
4 3 3 Welding in 5332
5 Renewing A-pillar reinforcement 5335
5 1 Tools 5336
5 2 Removing 5336
5 3 Installing 5338
5 3 1 Preparing replacement part 5338
5 3 2 Moulded foam inserts 5339
5 3 3 Welding in 5339
6 Renewing A-pillar reinforcement – part section 5344
6 1 Tools 5345
6 2 Removing 5345
6 3 Installing 5347
6 3 1 Preparing replacement part 5347
6 3 2 Moulded foam inserts 5348
6 3 3 Welding in 5349
7 Renewing upper A-pillar reinforcement 5353
7 1 Tools 5354
7 2 Removing 5354
7 3 Installing 5355
7 3 1 Preparing replacement part 5355
7 3 2 Welding in 5356
8 Renewing B-pillar reinforcement 5360
8 1 Tools 5361
8 2 Removing 5361
8 3 Installing 5363
8 3 1 Preparing replacement part 5363
8 3 2 Moulded foam inserts 5364
8 3 3 Welding in 5364
9 Renewing inner B-pillar 5369
9 1 Tools 5370
9 2 Removing 5370
9 3 Installing 5372
9 3 1 Preparing replacement part 5372
9 3 2 Welding in 5373
10 Renewing side member 5376
10 1 Tools 5377
10 2 Removing 5377
10 3 Installing 5378
10 3 1 Preparing replacement part 5379
10 3 2 Welding in 5381
11 Renewing side member reinforcement 5384
11 1 Tools 5385
11 2 Removing 5385
11 3 Installing 5386
11 3 1 Preparing replacement part 5386
11 3 2 Welding in 5387
12 Renewing side member reinforcement – part section 5391
12 1 Tools 5392
12 2 Removing 5392
12 3 Installing 5394
12 3 1 Preparing replacement part 5394
12 3 2 Welding in 5396
13 Renewing slot reinforcement 5399
13 1 Tools 5400
13 2 Removing 5400
13 3 Installing 5401
13 3 1 Preparing replacement part 5402
13 3 2 Moulded foam inserts 5402
13 3 3 Welding in 5403
14 Renewing crash tube 5405
14 1 Tools 5406
14 2 Removing 5406
14 3 Installing 5407
14 3 1 Preparing replacement part 5407
14 3 2 Welding in 5408
15 Renewing floor panel 5410
15 1 Tools 5411
15 2 Removing 5411
15 3 Installing 5412
15 3 1 Preparing replacement part 5412
15 3 2 Welding in 5413
16 Renewing crash reinforcement 5416
16 1 Tools 5417
16 2 Removing 5417
16 3 Installing 5418
16 3 1 Preparing replacement part 5418
16 3 2 Welding in 5419
17 Renewing seat middle cross member 5421
17 1 Tools 5421
17 2 Removing 5421
17 3 Installing 5423
17 3 1 Preparing replacement part 5423
17 3 2 Welding in 5424
18 Renewing outer mounting for seat cross member 5426
18 1 Tools 5427
18 2 Removing 5428
18 3 Installing 5429
18 3 1 Preparing replacement part 5429
18 3 2 Welding in 5430
19 Renewing inner mounting for seat cross member 5432
19 1 Tools 5432
19 2 Removing 5432
19 3 Installing 5434
19 3 1 Preparing replacement part 5434
19 3 2 Welding in 5435
53 – Body – rear 5437
1 Renewing cross panel 5437
1 1 Tools 5438
1 2 Removing 5438
1 3 Installing 5439
1 3 1 Preparing replacement part 5439
1 3 2 Welding in 5441
2 Renewing lock carrier 5444
2 1 Tools 5445
2 2 Removing 5445
2 3 Installing 5446
2 3 1 Welding in 5446
3 Renewing sealing channel 5448
3 1 Tools 5449
3 2 Removing 5449
3 3 Installing 5450
3 3 1 Preparing replacement part 5451
3 3 2 Welding in 5453
4 Renewing luggage compartment floor 5455
4 1 Tools 5456
4 2 Removing 5457
4 3 Installing 5458
4 3 1 Preparing replacement part 5459
4 3 2 Moulded foam inserts 5460
4 3 3 Welding in 5460
5 Renewing sealing channel reinforcement – part section 5463
5 1 Tools 5464
5 2 Removing 5464
5 3 Installing 5465
5 3 1 Preparing replacement part 5465
5 3 2 Welding in 5466
6 Renewing rear longitudinal member – part section 5468
6 1 Tools 5469
6 2 Removing 5469
6 3 Installing 5470
6 3 1 Preparing replacement part 5470
6 3 2 Welding in 5471
7 Renewing side panel 5473
7 1 Tools 5474
7 2 Removing 5474
7 3 Installing 5477
7 3 1 Preparing replacement part 5478
7 3 2 Moulded foam inserts 5479
7 3 3 Welding in 5480
D3E8020F8EE 4 cylinder diesel engine (1 6 l engine common rail) 5484
00 – Technical data 5490
1 Marking 5490
1 1 Engine number/engine data 5490
2 General information 5492
2 1 Numbering of cylinders 5492
3 Safety information 5493
3 1 Safety precautions when working on fuel system 5493
3 2 Safety measures when working on vehicles with a start/stop system 5494
3 3 Safety precautions when using testers and measuring instruments during a road test 5494
3 4 Safety precautions when working on the cooling system 5495
4 Repair instructions 5496
4 1 Rules for cleanliness 5496
4 1 1 Rules for cleanliness when working on auxiliary/supplementary heater and fuel system 5496
4 1 2 When working on turbocharger 5496
4 2 Foreign objects in engine 5497
4 3 Checking vacuum system 5497
10 – Removing and installing engine 5498
1 Removing and installing motor 5498
1 1 Removing motor 5498
1 2 Separating engine and gearbox 5510
1 2 1 Separating engine and gearbox, manual gearbox 5510
1 2 2 Separating engine and gearbox, dual-clutch gearbox 5512
1 3 Securing engine on engine and gearbox support 5515
1 4 Installing engine 5517
1 4 1 Notes on installing 5517
2 Assembly mountings 5521
2 1 Assembly overview – assembly mountings 5521
2 2 Removing and installing engine mounting 5523
2 3 Removing and installing gearbox mounting 5531
2 4 Removing and installing pendulum support 5532
2 5 Supporting engine in installation position 5533
2 6 Adjusting assembly mountings 5540
2 7 Checking adjustment of assembly mountings (engine and gearbox mountings) 5542
3 Engine cover panel 5544
3 1 Removing and installing engine cover 5544
13 – Crankshaft group 5545
1 Cylinder block (pulley end) 5545
1 1 Assembly overview – poly V-belt drive 5545
1 1 1 Assembly overview – poly V-belt drive with tensioning element and air conditioner compressor 5545
1 1 2 Assembly overview – poly V-belt drive with tensioning roller and air conditioner compressor 5546
1 1 3 Assembly overview – poly V-belt drive without air conditioner compressor 5549
1 2 Assembly overview – sealing flange, belt pulley end 5549
1 3 Removing and installing poly-V belt 5551
1 3 1 Removing and installing poly V-belt, with tensioning element and air conditioner compressor 5551
1 3 2 Removing and installing poly V-belt, with tensioning roller and air conditioner compressor 5553
1 3 3 Removing and installing poly V-belt, without air conditioner compressor 5555
1 4 Removing and installing tensioner for poly V-belt 5555
1 5 Removing and installing vibration damper 5557
1 6 Removing and installing bracket for ancillaries 5558
1 7 Removing and installing engine bracket 5560
1 8 Renewing crankshaft oil seal – belt pulley end 5563
1 9 Removing and installing sealing flange on pulley end 5566
2 Cylinder block, gearbox end 5571
2 1 Assembly overview – cylinder block, gearbox end 5571
2 2 Removing and installing flywheel 5572
2 3 Removing and installing sealing flange on gearbox side 5574
2 3 1 Pressing out sealing flange with sender wheel 5574
2 3 2 Pressing in sealing flange with sender wheel 5577
3 Crankshaft 5588
3 1 Assembly overview – crankshaft 5588
3 2 Crankshaft dimensions 5589
3 3 Renewing needle bearing in crankshaft 5589
3 4 Measuring axial clearance of crankshaft 5591
3 5 Measuring radial clearance of crankshaft 5592
4 Pistons and conrods 5594
4 1 Assembly overview – pistons and conrods 5594
4 2 Measuring piston projection at TDC 5596
4 3 Checking pistons and cylinder bores 5598
4 3 1 Checking piston 5598
4 3 2 Cylinder bore 5600
4 3 3 Piston and cylinder dimensions 5601
4 4 Separating new conrod 5601
4 5 Checking radial clearance of conrods 5602
15 – Cylinder head, valve gear 5603
1 Cylinder head 5603
1 1 Assembly overview – cylinder head 5603
1 2 Assembly overview – cylinder head cover 5607
1 3 Removing and installing cylinder head 5609
1 4 Removing and installing cylinder head cover 5624
1 5 Removing and installing injector seals 5627
1 6 Removing and installing vacuum pump 5628
1 7 Checking compression 5630
2 Toothed belt drive 5633
2 1 Assembly overview – toothed belt 5633
2 2 Removing and installing toothed belt 5636
2 2 1 Differences between versions of tensioning roller 5636
2 2 2 Removing and installing toothed belt, type A 5637
2 2 3 Removing and installing toothed belt, type B 5648
3 Valve gear 5660
3 1 Assembly overview – valve gear 5660
3 2 Measuring axial play of camshaft 5662
3 3 Measuring radial play of camshaft 5663
3 4 Removing and installing camshaft oil seal 5664
3 4 1 Removing and installing camshaft oil seal, vehicles with »former« seal 5664
3 4 2 Removing and installing camshaft oil seal, vehicles with »new« seal 5668
3 5 Removing and installing camshaft 5672
3 6 Checking hydraulic compensation elements 5681
3 7 Removing and installing valve stem seals 5682
3 7 1 Removing and installing valve stem seals with cylinder head installed 5682
3 7 2 Removing and installing valve stem seals with cylinder head removed 5686
4 Inlet and exhaust valves 5691
4 1 Reworking valve seats 5691
4 2 Checking valve guides 5691
4 3 Checking valves 5692
4 4 Valve dimensions 5692
17 – Lubrication 5693
1 Sump, oil pump 5693
1 1 Assembly overview – sump/oil pump 5693
1 1 1 Assembly overview – sump/oil pump, without balance shaft module 5693
1 1 2 Assembly overview – sump/oil pump, with balance shaft module 5696
1 2 Engine oil: 5699
1 2 1 Oil capacities 5699
1 2 2 Checking engine oil level 5700
1 3 Removing and installing oil sump 5700
1 4 Removing and installing oil pump 5704
1 4 1 Removing and installing oil pump, without balance shaft module 5704
1 4 2 Removing and installing oil pump, with balancer shaft module 5705
1 5 Removing and installing oil level and oil temperature sender -G266- 5707
2 Engine oil cooler 5709
2 1 Assembly overview – engine oil cooler 5709
2 2 Removing and installing engine oil cooler 5709
3 Oil filter, oil pressure switch 5713
3 1 Assembly overview – oil filter housing, oil pressure switch 5713
3 2 Removing and installing oil pressure switch -F1- 5714
3 3 Checking oil pressure 5715
3 4 Checking oil pressure and oil pressure switch 5716
3 5 Removing and installing oil filter housing 5717
4 Oil circuit 5722
4 1 Assembly overview – oil circuit 5722
4 2 Removing and installing oil return line for turbocharger 5722
5 Balancer shaft module 5728
5 1 Removing and installing balance shaft module 5728
5 1 1 Removing balancer shaft module 5728
5 1 2 Installing a previously used balancer shaft module again 5730
5 1 3 Installing a new balancer shaft module 5733
19 – Cooling 5738
1 Cooling system/coolant 5738
1 1 Connection diagram – coolant hoses 5738
1 2 Checking cooling system for leaks 5740
1 3 Draining and adding coolant 5741
1 3 1 Draining 5741
1 3 2 Filling 5744
2 Coolant pump, regulation of cooling system 5750
2 1 Assembly overview – coolant pump, thermostat 5750
2 2 Assembly overview – electric coolant pump 5750
2 3 Removing and installing electric coolant pump 5751
2 3 1 Removing and installing coolant circulation pump -V50- 5751
2 4 Removing and installing coolant pump 5754
2 5 Removing and installing 4/2-way valve with thermostat 5756
2 6 Removing and installing coolant temperature sender -G62- 5762
2 7 Removing and installing radiator outlet coolant temperature sender -G83- 5764
3 Coolant pipes 5767
3 1 Assembly overview – coolant pipes 5767
3 2 Removing and installing coolant pipes 5769
3 2 1 Removing and installing front coolant pipe 5769
3 2 2 Removing and installing left coolant pipe 5774
3 2 3 Removing and installing upper front coolant pipe 5777
3 2 4 Removing and installing right coolant pipe 5778
4 Radiator, radiator fan 5782
4 1 Assembly overview – radiator/radiator fan 5782
4 2 Removing and installing radiator 5783
4 3 Removing and installing radiator cowl with radiator fan 5784
4 4 Removing and installing radiator fan 5786
21 – Turbocharging/supercharging 5787
1 Turbocharger 5787
1 1 Assembly overview – turbocharger 5787
1 2 Removing and installing turbocharger 5789
1 3 Renewing vacuum unit for turbocharger 5796
2 Charge air system 5804
2 1 Assembly overview – charge air system 5804
2 2 Assembly overview – charge-air hose connections 5806
2 2 1 Fitting charge air system hose connections, plug-in connector 5806
2 2 2 Fitting charge air system hose connections, ribbed union and hose clamp 5807
2 3 Removing and installing charge air cooler 5808
2 4 Removing and installing charge pressure sender -G31- 5810
2 5 Checking charge air system for leaks 5811
23 – Mixture preparation – injection 5815
1 Injection system 5815
1 1 Schematic overview – fuel system 5815
1 2 Filling/bleeding fuel system 5817
1 3 Checking fuel system for leaks 5818
2 Vacuum system 5819
2 1 Assembly overview – vacuum system 5819
2 2 Checking vacuum system 5820
2 2 1 Checking supply line, vacuum reservoir and non-return valve 5820
2 2 2 Checking control line to turbocharger 5822
3 Injectors/high-pressure accumulator (rail) 5824
3 1 Assembly overview – injectors 5824
3 2 Assembly overview – fuel system 5825
3 3 Adapting correction values for injectors 5828
3 4 Testing jammed-open injectors 5829
3 5 Removing and installing injectors 5830
3 6 Removing and installing high-pressure lines 5834
3 7 Removing and installing fuel rail 5838
4 Air filter 5843
4 1 Assembly overview – air filter housing 5843
4 2 Removing and installing air filter housing 5845
5 Intake manifold 5848
5 1 Assembly overview – intake manifold 5848
5 2 Removing and installing intake manifold 5850
5 3 Removing and installing throttle valve module -J338- 5854
6 Senders and sensors 5856
6 1 Checking fuel pressure regulating valve -N276- 5856
6 2 Removing and installing fuel pressure regulating valve -N276- 5857
6 3 Removing and installing fuel pressure sender -G247- 5859
6 4 Removing and installing air mass meter -G70- 5862
6 5 Removing and installing pressure differential sender -G505- 5863
7 Engine (motor) control unit 5867
7 1 Removing and installing engine control unit -J623- 5867
7 2 Removing and installing engine (motor) control unit -J623- with protective housing 5868
8 High-pressure pump 5871
8 1 Assembly overview – high-pressure pump 5871
8 2 Removing and installing high-pressure pump 5873
9 Lambda probe 5880
9 1 Removing and installing Lambda probe 5880
9 1 1 Removing and installing Lambda probe, removing and installing Lambda probe -G39- 5880
26 – Exhaust system 5882
1 Exhaust pipes and silencers 5882
1 1 Assembly overview – silencers 5882
1 1 1 Assembly overview – silencers, Saloon 5882
1 1 2 Assembly overview – silencers, Cabriolet 5883
1 2 Removing and installing rear silencer 5884
1 2 1 Removing and installing rear silencer, Saloon 5884
1 2 2 Removing and installing rear silencer, Cabriolet 5885
1 3 Aligning exhaust system free of stress 5886
1 4 Installation position of clamp 5887
2 Emission control 5889
2 1 Assembly overview – emission control 5889
2 2 Removing and installing particulate filter 5892
3 Exhaust gas temperature regulation 5901
3 1 Removing and installing parts of exhaust gas temperature regulation 5901
3 1 1 Removing and installing exhaust gas temperature sender -G235- 5901
3 1 2 Removing and installing exhaust gas temperature sender -G495- 5903
3 1 3 Removing and installing exhaust gas temperature sender -G648- 5905
4 Exhaust gas recirculation 5908
4 1 Assembly overview – exhaust gas recirculation 5908
4 2 Removing and installing exhaust gas recirculation cooler 5910
4 3 Checking changeover for exhaust gas recirculation cooler 5913
4 4 Checking exhaust gas recirculation cooler for leaks 5914
4 5 Cleaning exhaust gas recirculation system 5919
4 5 1 Initiating cleaning of exhaust gas recirculation system 5919
4 5 2 Cleaning connecting pipes and pipe union 5925
28 – Glow plug system 5927
1 Glow plug system 5927
1 1 Removing and installing glow plug 5927
1 2 Removing and installing automatic glow period control unit -J179- 5929
1 3 Removing and installing Hall sender -G40- 5931
1 4 Removing and installing engine speed sender -G28- 5932
D3E8039C55A 7 speed dual clutch gearbox 0AM 5935
00 – Technical data 5939
1 Safety information 5939
1 1 Safety measures when working on vehicles with start/stop system 5939
1 2 Safety precautions when using testing and measuring instruments during a road test 5939
1 3 Safety precautions when working on the mechatronic unit 5939
1 4 Safety precautions when tow-starting or towing 5941
1 5 General safety provisions 5941
2 Identification 5942
2 1 Gearbox identification 5942
3 Repair notes 5943
3 1 Rules for cleanliness 5943
3 2 General information 5943
3 3 General repair instructions 5946
4 Technical data 5948
4 1 Capacities 5948
4 2 Allocation gearbox – engine 5949
5 Overview – power transmission 5950
5 1 Overview – power transmission – front-wheel drive 5950
30 – Clutch 5951
1 Clutch mechanism 5951
1 1 Assembly overview – clutch engagement 5951
1 1 1 Assembly overview – clutch engagement, gearboxes made up to 05 2011 5951
1 1 2 Assembly overview – clutch engagement, gearboxes made as of 06 2011 5952
1 2 Removing and installing clutch engagement 5953
1 2 1 Removing and installing clutch engagement, gearboxes made up to 05 2011 5953
1 2 2 Removing and installing clutch engagement, gearboxes made from 06 2011 onwards 5956
1 3 Adjusting clutch engagement 5959
1 3 1 Adjusting clutch engagement, gearboxes up to 05 2011 5959
1 3 2 Adjusting clutch engagement, gearboxes as of 06 2011 5970
2 Clutch 5982
2 1 Assembly overview – dual clutch 5982
2 1 1 Assembly overview – dual clutch, gearboxes made up to 05 2011 5982
2 1 2 Assembly overview – dual clutch, gearboxes made as of 06 2011 5983
2 2 Installing dual clutch 5984
2 3 Removing dual clutch 5989
2 4 Renewing input shaft seal 5994
2 5 Renewing oil seal for inner input shaft 5995
34 – Controls, housing 5998
1 Mechatronic unit 5998
1 1 Overview – mechatronic unit 5998
1 2 Removing and installing mechatronic unit 5999
1 3 Moving mechatronic unit for dual clutch gearbox -J743- into »removal position« by hand 6012
1 4 Renewing bellows with clutch actuator 6016
2 Selector mechanism 6021
2 1 Assembly overview – selector mechanism 6021
2 2 Emergency release from position P 6022
2 3 Removing and installing selector mechanism 6023
2 4 Checking selector mechanism 6028
2 5 Checking and adjusting selector lever cable 6029
2 6 Removing and installing selector lever handle 6031
2 7 Moving push-button in the handle to installation position 6033
2 8 Renewing selector shaft seal 6035
3 Removing and installing gearbox 6036
3 1 Specified torques for gearbox 6036
3 1 1 Gearbox to TFSI engine (EA 111) 6036
3 1 2 Gearbox to TFSI engine (EA 211) 6037
3 1 3 Gearbox to diesel engines 6037
3 2 Removing gearbox 6039
3 2 1 Removing gearbox, vehicles with 1 2 l petrol engine, EA 111 6039
3 2 2 Removing gearbox, vehicles with 1 4 l petrol engine, EA 111 6050
3 2 3 Removing gearbox – vehicles with 1 2 l and 1 4 l TFSI engine (EA211) 6061
3 2 4 Removing gearbox, vehicles with diesel engine 6068
3 3 Installing gearbox 6079
4 Assembly mounting 6084
4 1 Assembly overview – assembly mountings 6084
5 Transporting gearbox 6085
6 Dismantling and assembling gearbox 6087
6 1 Schematic overview – gearbox 6087
6 2 Dismantling and assembling gearbox 6088
6 2 1 Dismantling gearbox 6088
6 2 2 Assembling gearbox 6097
7 Gearbox housing, clutch housing 6110
7 1 Assembly overview – gearbox housing 6110
7 2 Assembly overview – clutch housing 6111
7 3 Repairing gearbox housing 6112
7 4 Repairing clutch housing 6117
8 Securing to engine and gearbox support 6122
9 Gear oil 6124
9 1 Draining and filling gear oil 6124
9 2 Draining and filling hydraulic fluid for mechatronic unit 6128
35 – Gears, shafts 6131
1 Input shaft 6131
1 1 Dismantling and assembling input shaft 6131
1 1 1 Dismantling and assembling outer input shaft 6131
1 1 2 Dismantling and assembling inner input shaft 6134
2 Output shaft 6138
2 1 Assembly overview – output shaft 6138
2 1 1 Assembly overview – output shaft 1 6138
2 1 2 Assembly overview – output shaft 2 6140
2 1 3 Assembly overview – output shaft 3 6141
2 2 Dismantling and assembling output shaft 1 6142
2 2 1 Dismantling output shaft 1 partially 6142
2 2 2 Dismantling output shaft 1 completely 6143
2 2 3 Assembling output shaft 1 6147
2 2 4 Dismantling and assembling locking collars and synchro-hubs of output shaft 1 6154
2 3 Dismantling and assembling output shaft 2 6154
2 3 1 Dismantling output shaft 2 6154
2 3 2 Assembling output shaft 2 6158
2 3 3 Dismantling and assembling locking collars and synchro-hubs of output shaft 2 6164
2 4 Dismantling and assembling output shaft 3 6164
2 4 1 Dismantling output shaft 3 6164
2 4 2 Assembling output shaft 3 6167
2 4 3 Dismantling and assembling locking collar and synchro-hub of output shaft 3 6170
2 5 Adjusting output shaft 6170
2 5 1 Notes on gearbox adjustment 6170
2 5 2 Calculating shims for clutch housing 6171
2 5 3 Calculating shims for gearbox housing 6184
3 Parking lock 6205
3 1 Removing and installing cover for parking lock 6205
3 2 Removing and installing parking lock 6207
39 – Final drive – differential 6208
1 Oil seals 6208
1 1 Overview of fitting locations – seals 6208
1 2 Renewing left seal 6208
1 3 Renewing right oil seal 6210
2 Differential 6212
2 1 Removing and installing left flange shaft 6212
2 2 Removing and installing right flange shaft 6214
3 Gearbox control system 6217
3 1 Overview of fitting locations – gearbox control 6217
D3E8039F22F 6 speed dual clutch gearbox 02E 6219
00 – Technical data 6223
1 Safety information 6223
1 1 Safety measures when working on vehicles with a start/stop system 6223
1 2 Safety precautions when using testers and measuring instruments during a road test 6223
1 3 Safety precautions when tow-starting or towing 6223
1 4 General safety provisions 6224
2 Identification 6225
2 1 Gearbox identification 6225
3 Repair notes 6227
3 1 Rules for cleanliness 6227
3 2 General information 6227
3 3 General repair instructions 6228
3 4 Safety functions of gearbox control unit 6230
4 Technical data 6232
4 1 Capacities 6232
4 2 Allocation gearbox – engine 6232
5 Electrical components 6233
5 1 Overview of fitting locations – electrical components 6233
30 – Clutch 6234
1 Clutch 6234
1 1 Assembly overview – dual clutch 6234
1 2 Removing and installing clutch end cover 6236
1 3 Installing dual clutch 6241
1 4 Removing dual clutch 6247
34 – Controls, housing 6249
1 Mechatronic unit 6249
1 1 Removing and installing mechatronic unit 6249
1 2 Removing and installing gearbox input speed sender -G182- and oil temperature sender in multi-plate clutch -G509- 6258
2 Selector mechanism 6260
2 1 Assembly overview – selector mechanism 6260
2 2 Emergency release from position P 6261
2 3 Removing and installing selector mechanism 6262
2 4 Checking selector mechanism 6265
2 5 Checking and adjusting selector lever cable 6266
2 6 Removing and installing selector lever handle 6268
2 7 Moving push button in the handle to installation position 6270
2 8 Renewing oil seal for selector shaft 6271
3 Removing and installing gearbox 6274
3 1 Specified torques for gearbox 6274
3 2 Removing gearbox 6274
3 2 1 Removing gearbox, vehicles with diesel engine 6274
3 2 2 Removing gearbox, vehicles with petrol engine 6285
3 3 Installing gearbox 6296
4 Assembly mounting 6301
4 1 Assembly overview – assembly mountings 6301
5 Transporting gearbox 6303
6 Dismantling and assembling gearbox 6304
6 1 Assembly overview – gearbox 6304
7 Installing to engine and gearbox support 6309
8 Gear oil circuit 6311
8 1 Removing and installing gear oil cooler 6311
8 2 Removing and installing gear oil pump 6313
8 3 Removing and installing gear oil filter 6316
9 Gear oil 6319
9 1 Checking gear oil level 6319
9 2 Draining and filling gear oil 6322
35 – Gears, shafts 6326
1 Dismantling and assembling gears and shafts 6326
39 – Final drive – differential 6327
1 Oil seals 6327
1 1 Overview of fitting locations – seals 6327
1 2 Renewing left oil seal 6328
1 3 Renewing right oil seal 6330
D3E8046D49A Wheels and Tyres Guide – General Information 6334
44 – Wheels, tyres, vehicle geometry 6342
1 Instructions on using the guide 6342
1 1 Overview 6342
1 1 1 Wheels and Tyres Guide – General Information 6342
1 1 2 Wheels and Tyres Guide – Vehicle-specific section 6342
1 2 General information 6342
1 3 Notes 6343
1 4 Determining correct wheel and tyre combinations, according to NEDC with tyre package 6344
1 4 1 Determining the required tyre package via PR number 6344
1 4 2 Determining the required tyre package via version key in the vehicle registration certificate part 1 6344
1 5 Determining correct wheel and tyre combinations according to WLTP 6345
1 5 1 Vehicle registration certificate part 1 6345
1 5 2 COC document, item 0 10 6347
1 6 NEDC, WLTP and RDE 6347
1 6 1 What are NEDC, WLTP and RDE? 6347
1 6 2 What are the differences between WLTP and RDE? 6347
1 6 3 Since when are WLTP and RDE valid? 6347
1 7 Definition of tyre package 6347
1 8 Explanations regarding world regions 6348
2 Legislative and technical conditions 6350
2 1 Legislative conditions 6350
2 1 1 Permissible wheel and tyre combinations in Germany 6350
2 1 2 Vehicles with Tyre Pressure Monitoring System 6350
2 2 Technical conditions 6351
2 3 Load-carrying capacity depending on vehicle speed, winter tyres 6351
2 4 Vehicle registration documents since 01 10 2005 6353
2 5 COC document (EEC Certificate of Conformity) 6354
2 6 EU general type approval number, sales type and sales or trade designation 6354
3 Wheel change 6357
3 1 Fitting instructions 6357
3 2 Protecting wheel centring seat against corrosion 6360
3 3 Fitting wheels 6360
3 4 Position of anti-theft wheel bolts for steel wheels 6361
4 Fitting tyre 6363
4 1 Pressing tyre off wheel rim 6363
4 2 Removing tyre sealant 6364
4 3 Removing tyre from wheel 6364
4 3 1 Removing tyres, wheels without and with tyre pressure monitoring 6364
4 3 2 Removing tyres, run-flat tyres, ultra-high-performance tyres 6366
4 4 Ensuring proper assembly temperature for tyres 6368
4 5 Fitting tyre 6369
4 5 1 Mounting tyre, wheels without and with tyre pressure monitoring 6369
4 5 2 Mounting tyre, run-flat tyres, ultra-high performance tyres 6371
4 6 Matching wheel rims and tyres 6373
4 7 Checking radial and lateral runout of wheels and tyres 6374
4 7 1 Checking radial and lateral runout of wheels and tyres, tolerances 6374
4 7 2 Checking radial and lateral runout on wheels and tyres with tyre gauge 6375
4 8 Matching wheels and tyres 6376
4 9 Balancing wheel 6377
4 9 1 Conditions 6377
4 9 2 Balancing wheel on stationary wheel balancer 6377
4 9 3 Balancing wheel with finish balancer 6380
4 9 4 Checking radial and lateral run-out on wheel rim 6381
4 10 Tyre sealant disposal 6382
5 Tyre Pressure Monitoring System 6383
5 1 System description – Tyre Pressure Monitoring System 6383
5 1 1 System description – Tyre Pressure Monitoring System with indirect measurement (Tyre Pressure Loss Indicator) 6383
5 1 2 System description – Tyre Pressure Monitoring System with direct measurement (with tyre pressure sensor) 6385
5 1 3 Button behaviour – Tyre Pressure Monitoring System with direct measurement (with tyre pressure sensor) 6385
5 1 4 System description – Tyre Pressure Monitoring System, Tyre Pressure Monitoring System (TPMS) with autolocation 6386
5 2 Overview of fitting locations – Tyre Pressure Monitoring System 6387
5 2 1 Overview of fitting locations – Tyre Pressure Monitoring System (TPMS) with autolocation 6387
5 2 2 Overview of fitting locations – Tyre Pressure Monitoring System, Trigger 6388
5 2 3 Overview of fitting locations – Tyre Pressure Monitoring System, Autolocation 6390
5 3 Assembly overview – tyre pressure sensor 6391
5 3 1 Assembly overview – tyre pressure sensor, tyre pressure sensor with valve 6391
5 3 2 Assembly overview – tyre pressure sensor, tyre pressure sensor without valve, version 1 6393
5 3 3 Assembly overview – tyre pressure sensor, tyre pressure sensor without valve, version 2 6395
5 4 Removing and installing tyre pressure sensor -G222-/-G223-/-G224-/-G225- 6396
5 4 1 Removing and installing tyre pressure sensor, tyre pressure sensor with valve 6396
5 4 2 Removing and installing tyre pressure sensor, tyre pressure sensor without valve, version 1 (customer service version) 6397
5 4 3 Removing and installing tyre pressure sensor, tyre pressure sensor without valve, version 1 (production version) 6399
5 4 4 Removing and installing tyre pressure sensor -G222-/-G223-/-G224-/-G225-, version 2 6402
5 5 Removing and installing Tyre Pressure Monitoring System control unit -J502- 6404
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 6405
5 5 2 Removing and installing tyre Tyre Pressure Monitoring System control unit, Passat 2011, Passat Estate 2011 6407
5 5 3 Removing and installing Tyre Pressure Monitoring System control unit, CC 2010, CC 2012, Passat CC 2009 6407
5 5 4 Removing and installing Tyre Pressure Monitoring System control unit, Phaeton 2003 6407
5 5 5 Removing and installing Tyre Pressure Monitoring System control unit -J502-, Touran 2016 6407
5 5 6 Removing and installing Tyre Pressure Monitoring System control unit -J502-, Tiguan 2008 6408
5 5 7 Removing and installing Tyre Pressure Monitoring System control unit -J502-, Tiguan 2016, Tiguan 2017 (BW2), Tiguan 2021 6409
5 5 8 Removing and installing Tyre Pressure Monitoring System control unit, up to model year 2014, Touareg 2010 6410
5 5 9 Removing and installing Tyre Pressure Monitoring System control unit, as of model year 2015, Touareg 2015 6411
5 5 10 Removing and installing Tyre Pressure Monitoring System control unit, Touareg 2018 6412
5 5 11 Removing and installing bracket for Tyre Pressure Monitoring System control unit, Touareg 2015 6413
5 6 Removing and installing tyre pressure monitor sender unit in wheel housing 6413
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 6413
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 6414
5 6 3 Removing and installing sender unit for Tyre Pressure Monitoring System in wheel housing, Phaeton 2003 6415
6 Wheel bolts 6416
6 1 Wheel bolts, versions 6416
6 2 Wheel bolts, anti-theft wheel bolt 6418
6 3 Wheel bolts, adapter sets for anti-theft wheel bolts 6418
7 Information on tyres 6421
7 1 Identification markings on the tyre sidewall 6421
7 2 Tyre dimension 6423
7 3 Load rating code/load index (LI) 6423
7 4 Speed rating code 6424
7 5 EU tyre label 6424
7 5 1 EU tyre label, summary 6424
7 5 2 EU tyre label, objectives 6425
7 5 3 EU tyre label, categories 6426
7 6 Structure of a radial belted tyre 6430
7 6 1 Cross section of a radial belted tyre 6430
7 6 2 Run-flat tyres, structure and identification of a SST tyre 6431
7 6 3 Run-flat tyres, seal inside technology 6433
7 7 Run-flat tyre, SST (Self Supporting Tyre) 6436
7 7 1 Run-flat tyres – general information 6436
7 7 2 Run-flat tyres, retrofitting/requirements when using run-flat tyres 6437
7 7 3 Run-flat tyres, repair work 6437
7 8 Tyre storage 6437
7 9 Reinforced and Extra Load (XL) tyres 6438
7 10 M+S tyres 6439
7 11 Winter tyres with speed symbol V 6441
7 12 All-season tyres 6442
7 13 Optimised rolling resistance tyres 6443
7 14 Tyre ageing 6443
7 15 Tyres with flange protection 6445
7 16 Tyre sizes for vehicles with all-wheel drive 6445
7 17 Increase in temperature due to insufficient tyre pressure 6445
8 Tyre sealant 6447
8 1 Models with breakdown set 6447
8 2 Storage life 6447
8 3 Disposal 6447
9 Information about wheels (rims) 6448
9 1 Structure of wheel (rim) 6448
9 2 Identification 6449
9 3 Composite wheels 6450
9 4 Care and maintenance of alloy wheel rims 6450
9 5 Restoring alloy wheels 6450
9 6 Removing and installing hub cover for alloy wheels with open threaded connection 6451
9 7 Renewing trim elements 6452
9 7 1 Renewing trim elements, bonded trim elements 6452
9 7 2 Renewing trim elements, bolted trim elements 6456
9 8 Removing and installing valve 6457
9 8 1 Removing and installing valve, description of the valve 6457
9 8 2 Removing and installing valve, rubber valve 6458
9 8 3 Removing and installing valve, metal valve 6459
10 Handling problems 6461
10 1 Rolling noise 6461
10 1 1 General notes on tyre noise 6461
10 1 2 Flat spots (from locking wheels) 6462
10 2 Vehicle pulls to one side 6463
10 2 1 General information 6463
10 2 2 Conicity 6463
10 2 3 Remedies when vehicle pulls to one side 6465
10 2 4 Strategic rotation of wheels for non-directional tyres 6466
10 2 5 Strategic rotation of wheels having unidirectional tyres 6467
10 3 Vibration 6468
10 3 1 Vibration, causes for vibration 6468
10 3 2 Vibration, conducting a road test before balancing wheels 6468
10 3 3 Vibration, vibration control system 6468
10 4 Eliminating flat spots caused by storage or handling 6469
11 Evaluating tyres 6471
11 1 Flat spots caused by storage or handling 6471
11 2 Undulations 6471
11 3 Saw-tooth wear 6472
11 4 Flat spots caused by hard braking 6472
11 5 Swellings in the tyre sidewall 6472
11 6 Cuts 6474
11 7 Damage caused by foreign bodies 6474
11 8 Stripped profile 6475
11 9 Tyre damage due to insufficient tyre pressure 6475
11 10 Checking tyres 6476
11 11 Damage caused when fitting 6477
12 Tyre wear 6479
12 1 Factors influencing the service life of tyres 6479
12 2 Saw-tooth wear 6480
12 3 Wear behaviour of high-speed tyres 6481
12 4 Measuring tread depth 6481
12 5 One-sided wear 6482
12 6 Outer shoulder wear 6484
12 7 Diagonal washout 6485
12 8 Wear in middle of tyre 6486
12 9 Permissible deviation in tread depth 6486
13 Overview of components 6487
13 1 Assembly overview – wheel 6487
14 Snow chains 6490
14 1 Assembly and use of snow chains 6490
15 Regular and temporary spare wheels, recommended temporary spare tyres 6491
15 1 Spare wheel with yellow sticker 6491
15 2 Temporary spare wheels and recommended temporary spare tyres 6492
15 2 1 Atlas 2017 6492
15 2 2 Golf 2013, e-Golf 2014 6492
15 2 3 Golf 2017, e-Golf 2017 6492
15 2 4 Golf SV 2015 6492
15 2 5 Golf Variant 2014 6493
15 2 6 Golf Variant 2017 6493
15 2 7 Golf 2018 (AU2/BX6) 6493
15 2 8 Jetta 2018 6493
15 2 9 Taos 2021 6494
D3E8046F985 Fuel supply system Diesel engines 6495
00 – Technical data 6499
1 Safety information 6499
1 1 Safety regulations for working on fuel supply 6499
1 2 Safety precautions when using testers and measuring instruments during a road test 6499
1 3 Safety measures when working on vehicles with a start/stop system 6500
1 4 Safety precautions when working on the SCR system 6500
2 Identification 6502
2 1 Engine number/engine data 6502
3 General information 6503
3 1 Rules for cleanliness when working on auxiliary heater and fuel system 6503
4 Repair notes 6504
4 1 Routing and attachment of lines 6504
4 2 General repair instructions 6504
20 – Fuel supply system 6505
1 Procedure should vehicle be misfueled 6505
2 Fuel tank 6512
2 1 Assembly overview – fuel tank 6512
2 1 1 Assembly overview – fuel tank, saloon 6512
2 1 2 Assembly overview – fuel tank, Cabriolet 6514
2 2 Removing and installing fuel tank 6515
2 2 1 Removing and installing fuel tank, saloon 6515
2 2 2 Removing and installing fuel tank, Cabriolet 6520
2 3 Emptying fuel tank 6526
2 3 1 Emptying fuel tank when fuel pump is intact 6526
2 3 2 Emptying fuel tank if it is more than 3/4 full 6527
2 3 3 Emptying fuel tank if it is less than 3/4 full 6529
2 4 Removing and installing misfuelling prevention device 6531
2 5 Deactivating misfuelling prevention device 6534
3 Fuel delivery unit, fuel gauge sender 6535
3 1 Assembly overview – fuel delivery unit and fuel gauge sender 6535
3 2 Removing and installing fuel delivery unit, fuel gauge sender 6536
3 3 Removing and installing fuel gauge sender -G- 6540
4 Lines 6542
4 1 Removing and installing fuel lines 6542
5 Plug-in connectors 6547
5 1 Separating plug-in connectors 6547
6 fuel filter 6551
6 1 Assembly overview – fuel filter 6551
6 1 1 Assembly overview – fuel filter, engine codes CAYC, CFFB, CJAA 6551
6 1 2 Assembly overview – upper part of fuel filter, engine codes CAYC, CFFB, CJAA 6552
6 1 3 Assembly overview – fuel filter, engine codes CVCA, CUUA, CUUB, DEBA, DELA, DGMA 6553
6 1 4 Assembly overview – fuel filter, vehicles with water separator sender -G63- 6554
6 2 Removing and installing fuel filter 6556
6 2 1 Removing and installing upper part of fuel filter, engine codes CAYC, CFFB, CJAA 6556
6 2 2 Removing and installing fuel filter, engine codes CAYC, CFFB, CJAA 6558
6 2 3 Removing and installing fuel filter, engine codes CVCA, CUUA, CUUB, DEBA, DELA, DGMA 6562
6 3 Fuel hoses in the engine compartment 6565
6 3 1 Fuel hoses in engine compartment, engine codes CVCA, CUUA, CUUB, DEBA, DELA, DGMA 6565
6 4 Drain water from fuel filter 6566
7 Accelerator pedal 6567
7 1 Assembly overview – accelerator module 6567
7 2 Removing and installing accelerator module with accelerator position sender -G79-/-G185- 6567
8 Fuel pump 6571
8 1 Checking fuel system pressurisation pump -G6- 6571
8 1 1 Checking voltage supply of fuel system pressurisation pump -G6- 6571
8 1 2 Checking fuel pressure of fuel system pressurisation pump -G6-, engine codes CAYC, CFFB, CJAA 6573
8 1 3 Checking fuel delivery rate of fuel pump -G6-, engine codes CAYC, CFFB, CJAA 6580
8 1 4 Checking supplementary fuel pump -V393- (inline electronic fuel pump), engine codes CFFB, CJAA 6588
8 1 5 Checking fuel pressure, engine codes CVCA, CUUA, CUUB, DEBA, DELA, DGMA 6589
8 1 6 Checking fuel delivery rate, engine codes CVCA, CUUA, CUUB, DEBA, DELA, DGMA 6595
8 1 7 Checking current consumption of fuel system pressurisation pump -G6- 6602
8 1 8 Checking supplementary fuel pump -V393- or fuel pump 2 -V277- (Inline EFP), engine codes CFFB, CJAA 6604
8 2 Removing and installing fuel pump 6607
8 2 1 Removing and installing supplementary fuel pump -V393- or fuel pump 2 -V277- (Inline EFP), engine codes CFFB, CJAA 6607
9 Senders and sensors 6611
9 1 Removing and installing water separator sender -G63- 6611
D3E80443C86 4 cylinder injection engine (1 4 l direct injection EA 111 engine turbocharger and supercharger) 6613
00 – Technical data 6619
1 Identification 6619
1 1 Engine number/engine data 6619
2 General notes 6621
2 1 Numbering of cylinders 6621
3 Safety information 6622
3 1 Safety regulations for working on fuel supply 6622
3 2 Safety precautions when using testers and measuring instruments during a road test 6623
3 3 Safety precautions when working on the cooling system 6624
3 4 Safety precautions when working on ignition system 6625
3 5 Releasing high pressure in fuel system 6625
4 Repair notes 6627
4 1 Rules for cleanliness 6627
4 2 Foreign objects in engine 6627
4 3 Contact corrosion 6627
4 4 Pipe/wire routing and attachment 6627
4 5 Fitting radiator and condensers 6628
10 – Removing and installing engine 6629
1 Removing and installing engine 6629
1 1 Removing engine 6629
1 2 Separating engine and gearbox 6640
1 2 1 Separating engine and gearbox, vehicles with manual gearbox 6640
1 2 2 Separating engine and gearbox, vehicles with dual clutch gearbox 6641
1 3 Securing engine on engine and gearbox support 6642
1 4 Installing engine 6643
2 Assembly mountings 6646
2 1 Assembly overview – assembly mountings 6646
2 2 Removing and installing motor mounting 6648
2 3 Supporting engine in installation position 6653
2 4 Adjusting assembly mountings 6659
2 5 Checking adjustment of assembly mountings (engine and gearbox mountings) 6661
3 Motor cover 6662
3 1 Removing and installing engine cover 6662
13 – Crankshaft group 6663
1 Cylinder block (pulley end) 6663
1 1 Assembly overview – cylinder block (pulley end) 6663
1 2 Assembly overview – poly V-belt drive 6666
1 3 Removing and installing poly-V belt 6668
1 4 Removing and installing vibration damper 6670
1 5 Removing and installing bracket for ancillaries 6674
1 6 Renewing crankshaft oil seal – belt pulley end 6675
2 Cylinder block, gearbox end 6679
2 1 Assembly overview – cylinder block, gearbox end 6679
2 2 Removing and installing sealing flange on gearbox side 6680
3 Crankshaft 6690
3 1 Assembly overview – crankshaft 6690
3 2 Renewing needle bearing in crankshaft 6691
3 3 Crankshaft dimensions 6693
4 Pistons and conrods 6694
4 1 Assembly overview – pistons and conrods 6694
4 2 Checking pistons and cylinder bores 6695
4 3 Separating new conrod 6696
4 4 Removing and installing pistons 6697
4 5 Removing and installing oil spray jets 6698
15 – Cylinder head, valve gear 6700
1 Cylinder head 6700
1 1 Assembly overview – cylinder head 6700
1 2 Removing and installing cylinder head 6702
1 3 Removing and installing camshaft housing 6705
1 4 Checking compression 6712
2 Cover for timing chain 6715
2 1 Removing and installing timing chain cover 6715
3 Chain drive 6720
3 1 Removing and installing timing chain and chain drive for oil pump 6720
3 2 Checking timing chain 6727
3 3 Checking valve timing 6734
3 4 Adjusting valve timing 6737
4 Valve gear 6745
4 1 Assembly overview – valve gear 6745
4 2 Measuring axial play of camshaft 6747
4 3 Removing and installing valve stem seals 6748
5 Inlet and exhaust valves 6750
5 1 Reworking valve seats 6750
5 2 Checking valve guides 6751
17 – Lubrication 6752
1 Sump, oil pump 6752
1 1 Assembly overview – sump/oil pump 6752
1 2 Removing and installing oil sump 6755
1 3 Removing and installing oil pump 6757
1 4 Engine oil: 6760
2 Oil filter, oil pressure switch 6761
2 1 Checking oil pressure and oil pressure switch 6761
19 – Cooling 6763
1 Cooling system/coolant 6763
1 1 Connection diagram – coolant hoses 6763
1 2 Checking cooling system for leaks 6763
1 3 Draining and adding coolant 6765
2 Coolant pump, regulation of cooling system 6772
2 1 Assembly overview – thermostat 6772
2 2 Removing and installing coolant pump 6773
2 3 Removing and installing coolant pump pulley 6777
2 4 Removing and installing electric coolant pump 6780
2 4 1 Removing and installing coolant circulation pump -V50- 6780
3 Radiator, radiator fan 6783
3 1 Assembly overview – radiator/radiator fan 6783
3 2 Removing and installing radiator 6784
3 3 Removing and installing radiator cowl with radiator fan 6785
3 4 Removing and installing radiator fan 6786
21 – Turbocharging/supercharging 6787
1 Exhaust turbocharger 6787
1 1 Assembly overview – turbocharger 6787
1 1 1 Assembly overview – turbocharger, part I 6787
1 1 2 Assembly overview – turbocharger, part II 6789
1 2 Removing and installing turbocharger 6790
1 3 Checking vacuum unit for turbocharger 6795
1 4 Adjusting vacuum unit for turbocharger 6796
1 5 Renewing vacuum unit for turbocharger 6802
2 Charge air system 6805
2 1 Assembly overview – charge air system 6805
2 1 1 Assembly overview – charge air system, without condensate trap 6805
2 1 2 Assembly overview – charge air system, with condensate trap 6807
2 2 Removing and installing charge air cooler 6808
2 3 Assembly overview – charge-air hose connections 6810
2 4 Checking charge air system for leaks 6811
3 Compressor 6814
3 1 Assembly overview – supercharger 6814
3 2 Removing and installing supercharger 6816
3 3 Removing and installing ancillary drive unit and decoupling spring 6821
3 3 1 Replacing the compressor drive unit seal 6821
24 – Mixture preparation – injection 6825
1 Injectors 6825
1 1 Assembly overview – fuel rail with injectors 6825
1 2 Removing and installing injectors 6825
1 3 Renewing seals on injectors 6828
1 4 Cleaning injectors 6831
2 High-pressure pump 6833
2 1 Assembly overview – high-pressure pump 6833
2 2 Removing and installing high-pressure pump 6834
3 Senders and sensors 6837
3 1 Assembly overview – actuator for structure-borne sound and control unit for structure-borne sound 6837
3 1 1 Assembly overview – actuator for structure-borne sound -R214- and control unit for structure-borne sound -J869-, left-hand drive vehicles 6837
3 1 2 Assembly overview – actuator for structure-borne sound -R214- and control unit for structure-borne sound -J869-, right-hand drive vehicles 6838
3 2 Checking fuel pressure sender -G247- 6839
4 Intake manifold 6844
4 1 Assembly overview – intake manifold 6844
4 1 1 Assembly overview – intake manifold, part I 6844
4 1 2 Assembly overview – intake manifold, part II 6846
4 2 Assembly overview – lower part of intake manifold with fuel rail 6847
4 3 Removing and installing lower part of intake manifold 6848
4 4 Removing and installing throttle valve module -J338- 6848
4 5 Cleaning throttle valve module 6849
4 6 Removing and installing regulating flap control unit -J808- 6850
5 Air filter 6852
5 1 Assembly overview – air filter housing 6852
5 2 Removing and installing air filter housing 6853
6 Engine (motor) control unit 6854
6 1 Removing and installing engine (motor) control unit -J623- 6854
26 – Exhaust system 6856
1 Exhaust pipes, silencers 6856
1 1 Assembly overview – silencers 6856
1 2 Removing and installing front exhaust pipe 6857
1 3 Separating exhaust pipes, silencers 6858
1 4 Aligning exhaust system free of stress 6859
1 5 Installation position of clamp 6861
2 Exhaust gas cleaning 6862
2 1 Assembly overview – emission control 6862
2 2 Removing and installing catalytic converter 6863
28 – Ignition system 6866
1 Ignition system 6866
1 1 Assembly overview – ignition system 6866
1 2 Test data, spark plugs 6867
1 3 Removing and installing ignition coils with output stage 6867
1 4 Removing and installing engine speed sender -G28- 6869
D3E803979ED 6 speed automatic gearbox 09G 6871
00 – Technical data 6875
1 Safety information 6875
1 1 Safety precautions when using testers and measuring instruments during a road test 6875
1 2 Safety precautions when tow-starting or towing 6875
1 3 General safety provisions 6876
2 Identification 6877
2 1 Gearbox identification 6877
2 2 Identification of torque converter 6877
3 Repair notes 6878
3 1 Rules for cleanliness 6878
3 2 General information 6878
3 3 General repair instructions 6879
4 Technical data 6881
4 1 Capacities 6881
4 2 Allocation gearbox – engine 6881
32 – Torque converter 6882
1 Torque converter 6882
1 1 Assembly overview – torque converter 6882
1 2 Removing and installing torque converter 6883
1 3 Draining torque converter 6884
1 4 Checking torque converter 6885
1 5 Removing and installing torque converter oil seal 6885
37 – Controls, housing 6887
1 ATF circuit 6887
1 1 Assembly overview – ATF circuit 6887
1 1 1 Assembly overview – ATF cooler, round version 6887
1 1 2 Assembly overview – ATF cooler, rectangular version 6888
1 2 Removing and installing ATF cooler 6889
1 2 1 Removing and installing ATF cooler, round design 6889
1 2 2 Removing and installing ATF cooler, rectangular design 6891
2 ATF 6893
2 1 Check ATF level 6893
2 2 Draining and filling ATF 6896
3 Removing and installing gearbox 6899
3 1 Specified torques for gearbox 6899
3 2 Removing and installing gearbox 6899
4 Assembly mounting 6920
4 1 Assembly overview – assembly mountings 6920
5 Transporting gearbox 6921
6 Installing to engine and gearbox support 6922
7 Selector mechanism 6924
7 1 Assembly overview – selector mechanism 6924
7 2 Checking selector mechanism 6925
7 3 Emergency release from position P 6926
7 4 Removing and installing selector mechanism 6927
7 5 Removing and installing selector lever handle 6930
7 6 Moving push button in the handle to installation position 6932
7 7 Checking and adjusting selector lever cable 6934
7 8 Removing and installing multifunction switch 6936
7 9 Adjusting multifunction switch 6939
7 10 Renewing oil seal for selector shaft 6940
38 – Gears, control 6942
1 ATF system 6942
1 1 Removing and installing oil pan 6942
1 2 Removing and installing ATF strainer 6944
2 Valve body 6945
2 1 Assembly overview – valve body 6945
2 2 Wire routing, connectors, connections and retainer on valve body 6948
2 3 Removing and installing valve body 6949
2 4 Removing and installing wiring harness for solenoid valves 6955
2 5 Removing and installing sender wiring harness 6956
2 6 Removing and installing gearbox input speed sender -G182- 6957
2 7 Removing and installing gearbox output speed sender -G195- 6957
39 – Final drive – differential 6958
1 Oil seals 6958
1 1 Overview of fitting locations – seals 6958
1 2 Renewing left oil seal 6958
1 3 Renewing right oil seal 6961
2 Gearbox control system 6964
2 1 Overview of fitting locations – gearbox control 6964
D3E80460004 Wheels and Tyres Guide 6969
44 – Wheels, tyres, vehicle geometry 6973
1 General notes on using the “Wheels and Tyres Guide” 6973
1 1 General 6973
1 2 Explanations regarding world regions 6974
1 3 Definition of tyre package 6975
1 4 Procedure for determining the right tyre package 6975
1 4 1 Determining the right tyre package via PR number 6975
1 4 2 Determining the right tyre package via version key in the vehicle registration certificate part 1 6976
2 Notes on the vehicle registration certificate 6977
2 1 Vehicle registration certificate part 1 6977
2 2 Version key, D2 6977
3 Wheel and tyre combinations without tyre package 6979
3 1 Beetle – from model year 2012 (sales type 5C1) 6979
3 2 The Beetle Cabriolet – from model year 2013 (Sales type 5C7) 6989
4 Wheel and tyre combinations depending on tyre packages 7001
4 1 Type approval number (K): e1*2007/46*0539*18 7001
4 2 Type approval number (K): e1*2007/46*0539*19 7002
4 3 Type approval number (K): e1*2007/46*0539*20 7004
4 4 Changing to other wheel and tyre combinations 7005
5 Wheel allocation 7007
5 1 61/2 J x 16 offset 44 7007
5 2 7 J x 17 offset 43 7008
5 3 8 J x 18 offset 44 7010
5 4 8 J x 18 offset 48 7010
5 5 8 J x 19 offset 48 7011
5 6 8 J x 20 offset 48 7012
6 Recommended summer tyres 7013
6 1 Recommended summer tyres, Europe, South America, Mexico 7013
6 2 Recommended summer tyres, North America 7013
6 3 Recommended summer tyres, Japan, Singapore, South Korea 7014
7 Recommended all-season tyres 7015
7 1 Recommended all-season tyres, Europe 7015
7 2 Recommended all-season tyres, North America 7015
8 Recommended winter tyres, worldwide except North America and China 7016
9 Recommended temporary spare tyres and wheels 7017
D4B802AD690 6 speed manual gearbox 02S 7018
00 – Technical data 7022
1 Safety information 7022
1 1 Safety measures when working on vehicles with a start/stop system 7022
1 2 Safety precautions when using testers and measuring instruments during a road test 7022
2 Identification 7024
2 1 Gearbox identification 7024
3 Repair notes 7025
3 1 General repair instructions 7025
4 Technical data 7029
4 1 Capacities 7029
4 2 Allocation gearbox – engine 7029
4 3 Calculation of gear ratios 7030
5 Overview – power transmission 7031
5 1 Overview – power transmission – front-wheel drive 7031
30 – Clutch 7033
1 Clutch operation 7033
1 1 Assembly overview – pedal cluster 7033
1 2 Assembly overview – clutch hydraulics 7036
1 2 1 Assembly overview – clutch hydraulics, left-hand drive 7036
1 2 2 Assembly overview – clutch hydraulics, right-hand drive 7038
1 3 Assembly overview – clutch release mechanism 7040
1 4 Removing and installing clutch pedal 7041
1 5 Removing and installing over-centre spring 7046
1 6 Removing and installing mounting bracket 7051
1 7 Removing and installing clutch master cylinder 7058
1 8 Removing and installing clutch slave cylinder 7060
1 9 Bleeding clutch mechanism 7063
1 10 Checking clutch master cylinder and clutch slave cylinder 7064
1 11 Removing and installing clutch position sender -G476- 7065
1 12 Repairing clutch release mechanism 7067
2 Clutch 7069
2 1 Assembly overview – clutch 7069
2 2 Removing and installing clutch 7070
34 – Controls, housing 7073
1 Selector mechanism 7073
1 1 Installation position – selector mechanism 7073
1 2 Assembly overview – gear knob and cover 7075
1 3 Assembly overview – Gear lever and selector housing 7076
1 4 Assembly overview – Selector cables 7078
1 5 Removing and installing gear knob 7082
1 6 Removing and installing selector mechanism 7084
1 7 Adjusting selector mechanism 7090
1 8 Checking selector mechanism 7094
1 9 Removing and installing gear selector cable and gate selector cable 7094
1 10 Renewing selector shaft seal 7095
1 11 Dismantling and assembling selector mechanism 7096
2 Removing and installing gearbox 7103
2 1 Specified torques for gearbox 7103
2 2 Removing gearbox 7103
2 3 Installing gearbox 7117
3 Assembly mountings 7126
3 1 Assembly overview – assembly mountings 7126
4 Transporting gearbox 7128
5 Dismantling and assembling gearbox 7129
5 1 Schematic overview – gearbox 7129
5 2 Assembly overview – cover for gearbox housing and 5th/6th gear 7130
5 3 Assembly overview – gearbox housing and selector mechanism 7132
5 4 Assembly overview – selector unit 7133
5 5 Assembly overview – input shaft, output shafts, differential, selector rods 7134
5 6 Assembly overview – selector forks 7135
5 7 Repairing selector unit 7138
5 8 Repairing selector forks 7139
5 9 Dismantling and assembling gearbox 7143
5 9 1 Partially dismantling and assembling gearbox, removing and installing 5th and 6th gears 7143
5 9 2 Dismantling and assembling gearbox completely 7155
6 Gearbox housing, clutch housing 7175
6 1 Assembly overview – gearbox housing 7175
6 2 Assembly overview – clutch housing 7177
6 3 Assembly overview – gearbox housing cover 7178
6 4 Repairing gearbox housing 7179
6 4 1 Removing and installing input shaft bearings in gearbox housing 7179
6 4 2 Removing and installing output shaft bearings in gearbox housing 7181
6 4 3 Removing and installing differential bearings in gearbox housing 7184
6 5 Repairing clutch housing 7186
6 5 1 Removing and installing input shaft bearings in clutch housing 7186
6 5 2 Removing and installing output shaft bearings in clutch housing 7187
6 5 3 Removing and installing differential bearings in clutch housing 7189
6 6 Repairing gearbox housing cover 7191
7 Securing to engine and gearbox support 7193
8 Gear oil 7194
8 1 Checking gear oil level 7194
8 2 Draining and filling gear oil 7194
35 – Gears, shafts 7197
1 Input shaft 7197
1 1 Assembly overview – input shaft 7197
1 2 Dismantling and assembling input shaft 7200
1 3 Adjusting input shaft 7204
2 Output shaft 7210
2 1 Assembly overview – output shaft 7210
2 2 Dismantling and assembling output shaft 7213
2 3 Adjusting output shaft 7223
3 Reverse shaft 7230
3 1 Assembly overview – reverse shaft 7230
3 2 Dismantling and assembling reverse shaft 7233
39 – Final drive – differential 7236
1 Oil seals 7236
1 1 Overview of fitting locations – seals 7236
1 2 Renewing left seal 7237
1 3 Renewing right oil seal 7239
1 4 Renewing input shaft seal 7242
2 Differential 7245
2 1 Assembly overview – differential 7245
2 2 Dismantling and assembling differential 7247
2 3 Adjusting differential 7253
3 Adjustment overview 7258
D4B804B4CFF 4 cylinder injection engine (1 2 l 4V EA211 turbocharger) 7259
00 – Technical data 7265
1 Safety information 7265
1 1 Safety regulations for working on fuel supply 7265
1 2 Safety measures when working on vehicles with a start/stop system 7265
1 3 Safety precautions when using testers and measuring instruments during a road test 7266
1 4 Safety precautions when working on the cooling system 7266
1 5 Safety precautions when working on ignition system 7266
2 Identification 7267
2 1 Engine number/engine data 7267
3 Repair notes 7268
3 1 Rules for cleanliness 7268
3 2 Foreign bodies in engine 7268
3 3 Contact corrosion 7268
3 4 Routing and attachment of lines 7268
3 5 Fitting radiator and condensers 7269
10 – Removing and installing engine 7270
1 Removing and installing engine 7270
1 1 Removing engine 7270
1 2 Separating engine and gearbox 7282
1 3 Securing engine on engine and gearbox support 7284
1 4 Installing engine 7286
2 Assembly mountings 7289
2 1 Assembly overview – assembly mountings 7289
2 2 Removing and installing engine mounting 7292
2 3 Removing and installing gearbox mounting 7294
2 4 Removing and installing pendulum support 7296
2 5 Supporting engine in installation position 7296
2 6 Adjusting assembly mountings 7305
2 7 Checking adjustment of assembly mountings 7307
13 – Crankshaft group 7309
1 Cylinder block (pulley end) 7309
1 1 Assembly overview – poly V-belt drive 7309
1 1 1 Assembly overview – poly V-belt drive, vehicles without air conditioner compressor 7309
1 1 2 Assembly overview – poly V-belt drive, vehicles with air conditioner compressor 7311
1 2 Removing and installing poly-V belt 7313
1 2 1 Removing and installing poly V-belt, vehicles without air conditioner compressor 7313
1 2 2 Removing and installing poly V-belt, vehicles with air conditioner compressor 7315
1 3 Removing and installing tensioner for poly V-belt 7316
1 4 Removing and installing vibration damper 7317
1 5 Removing and installing engine support 7319
1 6 Renewing crankshaft oil seal – pulley end 7321
2 Cylinder block, gearbox end 7325
2 1 Assembly overview – cylinder block, gearbox end 7325
2 2 Removing and installing flywheel 7326
2 3 Removing and installing sealing flange on gearbox side 7327
3 Crankshaft 7338
3 1 Crankshaft dimensions 7338
3 2 Renewing needle bearing in crankshaft 7338
3 3 Measuring axial clearance of crankshaft 7341
4 Pistons and conrods 7343
4 1 Assembly overview – pistons and conrods 7343
4 2 Removing and installing pistons 7346
4 3 Checking pistons and cylinder bores 7347
4 4 Separating new conrod 7349
4 5 Checking radial clearance of conrods 7350
4 6 Removing and installing oil spray jets 7350
15 – Cylinder head, valve gear 7352
1 Cylinder head 7352
1 1 Assembly overview – cylinder head 7352
1 2 Assembly overview – camshaft housing 7354
1 3 Removing and installing cylinder head 7356
1 4 Removing and installing camshaft housing 7361
1 5 Checking compression 7365
2 Toothed belt drive 7368
2 1 Assembly overview – toothed belt cover 7368
2 2 Assembly overview – toothed belt 7368
2 3 Removing and installing toothed belt guard 7370
2 3 1 Removing and installing upper toothed belt guard 7370
2 3 2 Removing and installing lower toothed belt guard 7371
2 4 Removing and installing toothed belt 7371
2 5 Checking valve timing 7377
2 6 Adjusting valve timing 7385
2 7 Removing toothed belt from camshaft 7392
3 Valve gear 7397
3 1 Assembly overview – valve gear 7397
3 2 Measuring axial play of camshaft 7398
3 3 Removing and installing camshaft oil seal 7399
3 3 1 Removing and installing camshaft oil seal for inlet camshaft, belt pulley end 7399
3 3 2 Removing and installing camshaft oil seal for exhaust camshaft, pulley end 7401
3 3 3 Removing and installing camshaft oil seal for exhaust camshaft, gearbox end 7403
3 4 Removing and installing camshaft adjuster 7406
3 5 Removing and installing camshaft control valve 1 -N205- 7409
3 6 Removing and installing valve stem oil seals 7410
3 6 1 Removing and installing valve stem seals (cylinder head installed) 7410
3 6 2 Removing and installing valve stem seals (cylinder head removed) 7415
3 7 Removing and installing toothed belt pulley 7420
4 Inlet and exhaust valves 7423
4 1 Checking valve guides 7423
4 2 Checking valves 7424
4 3 Valve dimensions 7424
17 – Lubrication 7425
1 Sump, oil pump 7425
1 1 Assembly overview – sump/oil pump 7425
1 2 Engine oil: 7429
1 3 Removing and installing oil sump 7430
1 4 Removing and installing oil pump 7435
1 5 Removing and installing oil level and oil temperature sender -G266- 7438
2 Engine oil cooler 7439
2 1 Assembly overview – engine oil cooler 7439
2 2 Removing and installing engine oil cooler 7439
3 Crankcase ventilation 7441
3 1 Assembly overview – crankcase breather system 7441
3 2 Removing and installing oil separator 7442
4 Oil filter, oil pressure switch 7446
4 1 Assembly overview – oil filter/oil pressure switch 7446
4 2 Removing and installing oil pressure switch for reduced oil pressure -F378- 7446
4 3 Checking oil pressure and oil pressure switch 7447
4 4 Removing and installing oil filter housing 7449
19 – Cooling 7451
1 Cooling system/coolant 7451
1 1 Connection diagram – coolant hoses 7451
1 2 Checking cooling system for leaks 7453
1 3 Draining and adding coolant 7455
2 Coolant pump, regulation of cooling system 7465
2 1 Assembly overview – coolant pump, thermostat 7465
2 2 Assembly overview – electric coolant pump 7468
2 3 Assembly overview – coolant temperature sender 7469
2 4 Removing and installing electric coolant pump 7470
2 5 Removing and installing coolant pump 7472
2 6 Removing and installing thermostat 7478
2 6 1 Removing and installing thermostat for large cooling circuit 7478
2 6 2 Removing and installing thermostat for small cooling circuit 7480
2 7 Removing and installing toothed belt pulley for coolant pump 7481
2 8 Removing and installing coolant temperature sender -G62- 7483
2 9 Removing and installing radiator outlet coolant temperature sender -G83- 7484
3 Coolant pipes 7486
3 1 Assembly overview – coolant pipes 7486
3 2 Removing and installing coolant pipes 7486
4 Radiator, radiator fan 7490
4 1 Assembly overview – radiator, radiator fan 7490
4 2 Assembly overview – radiator cowl and radiator fan 7492
4 3 Removing and installing radiator 7493
4 4 Removing and installing water radiator for charge air cooling circuit 7494
4 5 Removing and installing radiator cowl 7497
4 6 Removing and installing radiator fan 7499
4 6 1 Removing and installing radiator fan -V7- 7499
4 6 2 Removing and installing radiator fan -V177- 7500
21 – Turbocharging/supercharging 7502
1 Turbocharger 7502
1 1 Assembly overview – turbocharger 7502
1 2 Removing and installing turbocharger 7504
1 3 Removing and installing charge pressure positioner -V465- 7508
2 Charge air system 7510
2 1 Assembly overview – charge air system 7510
2 2 Removing and installing charge air cooler 7513
2 3 Removing and installing charge pressure sender -GX26- 7516
2 4 Checking charge air system for leaks 7516
2 5 Removing and installing air intake pipe 7518
24 – Mixture preparation – injection 7520
1 Injection system 7520
1 1 Overview of fitting locations – injection system 7520
2 Injectors 7524
2 1 Assembly overview – fuel rail with injectors 7524
2 2 Removing and installing fuel rail 7526
2 3 Removing and installing injectors 7526
2 4 Cleaning injectors 7533
3 Air filter 7534
3 1 Assembly overview – air filter housing 7534
3 2 Removing and installing air filter housing 7535
3 3 Removing and installing resonator for intake air 7537
4 Intake manifold 7539
4 1 Assembly overview – intake manifold 7539
4 2 Removing and installing intake manifold 7541
4 3 Removing and installing throttle valve module -GX3- 7544
4 4 Cleaning throttle valve module -GX3- 7545
5 Senders and sensors 7547
5 1 Removing and installing intake manifold sender -GX9- 7547
5 2 Removing and installing fuel pressure sender -G247- 7547
5 3 Checking fuel pressure sender -G247- 7549
6 Engine/motor control unit 7552
6 1 Removing and installing engine control unit -J623- 7552
6 1 1 Removing and installing engine control unit -J623- without protective housing 7552
6 1 2 Removing and installing engine (motor) control unit -J623- with protective housing 7553
7 High-pressure pump 7556
7 1 Assembly overview – high-pressure pump 7556
7 1 1 Assembly overview – high-pressure pump, Hitachi 7556
7 1 2 Assembly overview – high-pressure pump, Continental 7557
7 1 3 Assembly overview – high-pressure pump, Bosch 7559
7 2 Removing and installing high-pressure pump 7560
7 3 Removing and installing high-pressure pipe 7562
8 Lambda probe 7565
8 1 Assembly overview – Lambda probe 7565
8 2 Removing and installing lambda probe 7566
8 2 1 Removing and installing Lambda probe 1 before catalytic converter -GX10- 7566
8 2 2 Removing and installing Lambda probe 1 after catalytic converter -GX7- 7567
26 – Exhaust system 7570
1 Exhaust pipes and silencers 7570
1 1 Assembly overview – silencers 7570
1 1 1 Assembly overview – silencers, Saloon 7570
1 1 2 Assembly overview – silencers, Cabriolet 7571
1 2 Separating exhaust pipes from silencers 7573
1 3 Removing and installing rear silencer 7575
1 4 Aligning exhaust system free of stress 7576
1 5 Checking exhaust system for leaks 7577
1 6 Installation position of clamp 7577
2 Emission control 7580
2 1 Assembly overview – emission control 7580
2 2 Removing and installing catalytic converter 7582
28 – Ignition system 7587
1 Ignition system 7587
1 1 Assembly overview – ignition system 7587
1 2 Test data, spark plugs 7589
1 3 Removing and installing ignition coils with output stage 7589
1 4 Removing and installing knock sensor 1 -G61- 7592
1 5 Removing and installing Hall sender -G40- 7592
1 6 Removing and installing engine speed sender -G28- 7593
D4B804B3226 4 cylinder injection engine (1 4 l 4V EA211 turbocharger) 7595
00 – Technical data 7601
1 Safety information 7601
1 1 Safety precautions when working on the fuel supply system 7601
1 2 Safety measures when working on vehicles with a start/stop system 7601
1 3 Safety precautions when using testers and measuring instruments during a road test 7602
1 4 Safety precautions when working on the cooling system 7602
1 5 Safety precautions when working on the ignition system 7602
2 Identification 7603
2 1 Engine number/engine data 7603
3 Repair notes 7605
3 1 Rules for cleanliness 7605
3 2 Foreign material in engine 7605
3 3 Contact corrosion 7605
3 4 Routing and attachment of lines 7605
3 5 Installing radiators and condensers 7606
10 – Removing and installing engine 7607
1 Removing and installing engine 7607
1 1 Removing engine 7607
1 2 Separating engine and gearbox 7620
1 3 Securing engine on engine and gearbox support 7622
1 4 Installing engine 7623
2 Assembly mountings 7627
2 1 Assembly overview – assembly mountings 7627
2 2 Removing and installing engine mounting 7630
2 3 Removing and installing gearbox mounting 7632
2 4 Removing and installing pendulum support 7633
2 5 Supporting engine in installation position 7634
2 6 Adjusting assembly mountings 7643
2 7 Checking adjustment of assembly mountings 7645
13 – Crankshaft group 7646
1 Cylinder block, pulley end 7646
1 1 Assembly overview – poly V-belt drive 7646
1 1 1 Assembly overview – poly V-belt drive, vehicles without air conditioner compressor 7646
1 1 2 Assembly overview – poly V-belt drive, vehicles with air conditioner compressor 7648
1 2 Assembly overview – sealing flange, pulley end 7650
1 3 Removing and installing poly-V belt 7652
1 3 1 Removing and installing poly V-belt, vehicles without air conditioner compressor 7652
1 3 2 Removing and installing poly V-belt, vehicles with air conditioner compressor 7654
1 4 Removing and installing poly V-belt tensioner 7656
1 5 Removing and installing vibration damper 7657
1 6 Removing and installing engine support 7659
1 7 Renewing crankshaft oil seal (pulley end) 7662
1 8 Removing and installing sealing flange, pulley end 7665
2 Cylinder block, gearbox end 7668
2 1 Assembly overview – cylinder block, gearbox end 7668
2 2 Removing and installing flywheel 7669
2 3 Removing and installing sealing flange on gearbox side 7670
3 Crankshaft 7681
3 1 Crankshaft dimensions 7681
3 2 Renewing needle bearing in crankshaft 7681
3 3 Measuring axial clearance of crankshaft 7684
4 Pistons and conrods 7686
4 1 Assembly overview – pistons and conrods 7686
4 2 Removing and installing pistons 7689
4 3 Checking piston and cylinder bore 7690
4 4 Separating new conrod 7692
4 5 Checking radial clearance of conrods 7693
4 6 Removing and installing oil spray jets 7693
15 – Cylinder head, valve gear 7696
1 Cylinder head 7696
1 1 Assembly overview – cylinder head 7696
1 2 Assembly overview – camshaft housing 7698
1 3 Removing and installing cylinder head 7700
1 4 Removing and installing camshaft housing 7705
1 5 Checking compression 7710
2 Toothed belt drive 7713
2 1 Assembly overview – toothed belt cover 7713
2 2 Assembly overview – toothed belt 7713
2 3 Removing and installing toothed belt guard 7715
2 3 1 Removing and installing upper toothed belt guard 7715
2 3 2 Removing and installing lower toothed belt guard 7716
2 4 Removing and installing toothed belt 7716
2 5 Checking valve timing 7723
2 6 Adjusting valve timing 7729
2 7 Removing toothed belt from camshaft 7738
3 Valve gear 7743
3 1 Assembly overview – valve gear 7743
3 2 Measuring axial play of camshaft 7744
3 3 Removing and installing camshaft oil seal 7745
3 3 1 Removing and installing camshaft oil seal for inlet camshaft, belt pulley end 7745
3 3 2 Removing and installing exhaust camshaft oil seal, pulley end 7747
3 3 3 Removing and installing exhaust camshaft oil seal, gearbox end 7749
3 4 Removing and installing camshaft adjuster 7751
3 4 1 Removing and installing camshaft adjuster for inlet camshaft 7751
3 4 2 Removing and installing camshaft adjuster for exhaust camshaft 7757
3 5 Removing and installing camshaft control valve 1 -N205- 7763
3 6 Removing and installing exhaust camshaft control valve 1 -N318- 7764
3 7 Removing and installing valve stem oil seals 7765
3 7 1 Removing and installing valve stem seals (cylinder head installed) 7765
3 7 2 Removing and installing valve stem seals (cylinder head removed) 7770
4 Inlet and exhaust valves 7776
4 1 Checking valve guides 7776
4 2 Checking valves 7777
4 3 Valve dimensions 7777
17 – Lubrication 7778
1 Sump, oil pump 7778
1 1 Assembly overview – sump/oil pump 7778
1 2 Engine oil 7782
1 3 Removing and installing lower part of sump 7782
1 4 Removing and installing upper part of sump 7787
1 5 Removing and installing oil pump 7794
1 6 Removing and installing oil level and oil temperature sender -G266- 7795
2 Engine oil cooler 7797
2 1 Assembly overview – engine oil cooler 7797
2 2 Removing and installing engine oil cooler 7797
3 Crankcase breather 7799
3 1 Assembly overview – crankcase breather system 7799
3 2 Removing and installing oil separator 7800
4 Oil filter, oil pressure switch 7804
4 1 Assembly overview – oil filter/oil pressure switches 7804
4 2 Removing and installing oil pressure switch -F1- 7805
4 3 Removing and installing oil pressure switch for reduced oil pressure -F378- 7806
4 4 Checking oil pressure 7807
4 5 Removing and installing valve for oil pressure control -N428- 7809
19 – Cooling 7810
1 Cooling system/coolant 7810
1 1 Connection diagram – coolant hoses 7810
1 2 Assembly overview – engine preheater 7811
1 3 Checking cooling system for leaks 7812
1 4 Draining and filling cooling system 7815
1 5 Removing and installing engine preheating element -Z97- 7824
2 Coolant pump, regulation of cooling system 7827
2 1 Assembly overview –coolant pump, thermostat 7827
2 2 Assembly overview – electric coolant pump 7830
2 3 Assembly overview – coolant temperature sender 7831
2 4 Removing and installing electric coolant pump 7832
2 4 1 Removing and installing charge air cooling pump -V188- 7832
2 5 Removing and installing coolant pump 7834
2 6 Removing and installing thermostat 7840
2 6 1 Removing and installing thermostat for large cooling circuit 7840
2 6 2 Removing and installing thermostat for small cooling circuit 7842
2 7 Removing and installing toothed belt pulley for coolant pump 7843
2 8 Removing and installing coolant temperature sender -G62- 7845
2 9 Removing and installing radiator outlet coolant temperature sender -G83- 7846
3 Coolant pipes 7848
3 1 Assembly overview – coolant pipes 7848
3 2 Removing and installing coolant pipes 7848
4 Radiator, radiator fan 7853
4 1 Assembly overview – radiator/radiator fan 7853
4 2 Assembly overview – radiator cowl and radiator fans 7855
4 3 Removing and installing radiator 7856
4 4 Removing and installing water radiator for charge air cooling circuit 7858
4 5 Removing and installing radiator cowl 7861
4 6 Removing and installing radiator fan -V7- 7863
4 7 Removing and installing radiator fan 2 -V177- 7864
21 – Turbocharging/supercharging 7865
1 Turbocharger 7865
1 1 Assembly overview – turbocharger 7865
1 1 1 Assembly overview – turbocharger, version 1 7865
1 1 2 Assembly overview – turbocharger, version 2 7866
1 1 3 Assembly overview – lines on turbocharger 7867
1 2 Removing and installing turbocharger 7869
1 3 Removing and installing charge pressure positioner -V465- 7875
1 3 1 Removing and installing charge pressure positioner -V465-, version 1 7875
1 3 2 Removing and installing charge pressure positioner -V465-, version 2 7877
2 Charge air system 7880
2 1 Assembly overview – charge air system 7880
2 2 Removing and installing charge air cooler 7883
2 3 Removing and installing charge pressure sender -GX26- 7886
2 4 Checking charge air system for leaks 7886
2 5 Removing and installing air intake pipe 7888
24 – Mixture preparation – injection 7890
1 Injectors 7890
1 1 Assembly overview – fuel rail with injectors 7890
1 2 Removing and installing fuel rail 7892
1 3 Removing and installing injectors 7892
1 4 Cleaning injectors 7898
2 Air filter 7900
2 1 Assembly overview – air filter housing 7900
2 2 Removing and installing air filter housing 7901
2 3 Removing and installing resonator for intake air 7902
3 Intake manifold 7904
3 1 Assembly overview – intake manifold 7904
3 2 Removing and installing intake manifold 7906
3 3 Removing and installing throttle valve module -GX3- 7910
3 4 Cleaning throttle valve module -GX3- 7911
4 Senders and sensors 7913
4 1 Removing and installing fuel pressure sender -G247- 7913
4 2 Checking fuel pressure sender -G247- 7914
4 3 Removing and installing intake manifold sender -GX9- 7916
5 Engine/motor control unit 7918
5 1 Removing and installing motor control unit -J623- 7918
5 1 1 Removing and installing engine control unit -J623- without protective housing 7918
5 1 2 Removing and installing engine control unit -J623- with protective housing 7919
6 High-pressure pump 7923
6 1 Assembly overview – high-pressure pump 7923
6 1 1 Assembly overview – high-pressure pump, Hitachi 7923
6 1 2 Assembly overview – high-pressure pump, Continental 7924
6 1 3 Assembly overview – high-pressure pump, Bosch 7926
6 2 Removing and installing high-pressure pump 7927
6 3 Removing and installing high-pressure pipe 7929
7 Lambda probe 7932
7 1 Assembly overview – lambda probe 7932
7 2 Removing and installing lambda probe 7933
7 2 1 Removing and installing Lambda probe 1 before catalytic converter -GX10- 7933
7 2 2 Removing and installing Lambda probe 1 after catalytic converter -GX7- 7934
26 – Exhaust system 7937
1 Exhaust pipes and silencers 7937
1 1 Assembly overview – silencers 7937
1 1 1 Assembly overview – silencers, Saloon 7937
1 1 2 Assembly overview – silencers, Cabriolet 7938
1 2 Separating exhaust pipes from silencers 7940
1 3 Removing and installing rear silencer 7942
1 4 Aligning exhaust system free of stress 7943
1 5 Checking exhaust system for leaks 7944
1 6 Installation position of clamp 7944
2 Emission control 7947
2 1 Assembly overview – emission control 7947
2 2 Removing and installing catalytic converter 7949
28 – Ignition system 7955
1 Ignition system 7955
1 1 Assembly overview – ignition system 7955
1 2 Test data – spark plugs 7957
1 3 Removing and installing ignition coils with output stage 7957
1 4 Removing and installing knock sensor 1 -G61- 7960
1 5 Removing and installing Hall sender 7960
1 5 1 Removing and installing Hall sender -G40- 7960
1 5 2 Removing and installing Hall sender 3 -G300- 7961
1 6 Removing and installing engine speed sender -G28- 7961
D4B805CB339 Manual for Troubleshooting and Diagnosing Noises 7964
00 – Technical data 7970
1 Introduction 7970
2 Acoustic considerations during vehicle development 7971
2 1 Vibration insulation film 7971
2 2 Insulation 7972
3 General procedure for identifying noises 7974
3 1 General procedure 7974
3 2 Identifying a noise 7974
3 2 1 Localising origin of noise 7974
3 2 2 Identifying the type of noise 7975
3 2 3 Identifying the point in time when the noise occurs 7975
3 2 4 Identifying the noise by definition or designation 7975
3 3 Aid for localising noise by means of audio recordings (frequencies) 7975
3 3 1 Preparing an audio CD with downloaded files 7976
3 3 2 List of audio tracks 7976
3 3 3 Conditions for testing 7976
3 3 4 Conditions for performing the audio test 7977
3 4 Checklist 7977
4 Volkswagen equipment for localising noises 7981
4 1 Ultrasonic tester -VAG 1842- 7981
4 1 1 Design of the ultrasonic tester -VAG 1842- 7981
4 1 2 Example of procedure for identifying noises using ultrasound 7981
4 2 Borescope -VAS 6748A- 7985
4 2 1 Design of the borescope -VAS 6748A- 7985
4 2 2 Procedure for identifying noises using the borescope 7986
5 Attachments 7987
5 1 Checklist 7987
5 2 Designations for noises 7989
D4B805CD31D Manual on Localising the Ingress of Water 7990
00 – Technical data 7996
1 Introduction 7996
2 Causes 7997
2 1 Vehicle fluids 7997
2 2 External factors 7997
2 3 Components 7997
3 Localising water ingress 8001
3 1 Preparation by customer service advisor 8001
3 2 Work performed by the mechanic 8001
3 3 Examples of components causing water ingress 8002
4 Tools for localising ingress point 8004
5 Attachments 8005
5 1 Checklist 8005
D4B807DC77D Chemicals Manual 8007
00 – Technical data 8013
1 — Change history — 8013
2 Introduction 8015
3 List of Suppliers 8016
3 1 3M do Brasil 8016
3 2 Brascola Ltda 8016
3 3 Castrol Brasil Ltda 8016
3 4 Cia Brasileira de Petróleo Ipiranga 8016
3 5 Chemours 8016
3 6 Chevron Brasil S/A 8016
3 7 Cremer S A Prod Têxteis e Cirúrgicos 8016
3 8 Dow Corning do Brasil Ltda 8016
3 9 Elf Lubrificantes do Brasil 8016
3 10 ExxonMobil 8016
3 11 Henkel do Brasil Ltda 8016
3 12 Klüber Lubrification Lubrificantes Especiais Ltda 8016
3 13 Loctite Brasil Ltda 8016
3 14 Lumobrás Imp Com Ind Ltda 8016
3 15 Motul Synthetic Lubricants 8016
3 16 Ocean Indústria Química 8016
3 17 Pentosin do Brasil Ltda 8017
3 18 Petrobras Distr S/A 8017
3 19 Shell Brasil S/A 8017
3 20 Sika S/A 8017
3 21 Solplás – Ind de Plásticos Ltda 8017
3 22 Solvay Química 8017
3 23 Three Bond do Brasil Ind e Com Ltda 8017
3 24 Total Lubrificantes Brasil Ltda 8017
3 25 Tutela Lubrificantes S/A 8017
3 26 Valvoline Lubrificantes Internacionais Ltda 8017
4 Work Instructions for Handling Chemicals 8018
4 1 Handling of Solvents 8018
4 2 Work instruction – Flammable material handling 8020
4 3 Handling used engine oil 8021
4 4 General guidelines on the storage of chemicals 8022
5 List of authorized products 8023
5 1 Polyurethane-based sealing adhesive 8023
5 2 High-resistance locking adhesive 8023
5 3 Low viscosity lock adhesive 8023
5 4 Sealing adhesive 8023
5 5 Self-adhesive PVC tape 8023
5 6 Double-sided adhesive tape 8023
5 7 Refrigerant gas – R134a 8024
5 8 Underbody coating 8024
5 9 Lubricating engine oil as per VW 502 00 and VW 505 00 standards 8024
5 10 Lubricating engine oil as per VW 507 00 standard 8024
5 11 Lubricating engine oil as per VW 508 88 and VW 509 99 standards 8025
5 12 Lubricating oil for manual gearbox and steering rack – SAE 90, MIL-L-2105B, API – GL5 8025
5 13 Lubricating oil for manual gearbox – SAE 80, MIL-L-2105, API – GL4 8025
5 14 Tire assembly paste 8025
5 15 Biodegradable degreasing product 8025
5 16 Grease remover spray 8026
6 List of fractionated products 8027
6 1 -000 096 319 D- Polishing material (chromium and aluminium) 8027
6 2 -032 198 561- Additional seal 8027
6 3 -AMV 188 001 02- Adhesive silicone 8028
6 4 -AMV 188 200 03- Sealing paste 8028
6 5 -AMV 189 300- Activating agent 8029
6 6 -AMV 189 400- Sealing compound 8029
6 7 Liquid sealant -D 000 600 A2- 8029
6 8 -D 001 210 M2- Universal adhesive 8030
6 9 -D 002 000 A2-Adhesive remover 8030
6 10 -D 004 660 M2- Adhesive set 8030
6 11 -D 007 000 A2- Spray silicone 8031
6 12 -D 009 200 02- Glass primer 8031
6 13 -D 009 401 04- Cleaning solution 8032
6 14 -D 009 500 25- Applicator 8032
6 15 Liquid sealant -D 154 000 A1- 8033
6 16 Liquid sealant -D 154 100 A1- 8033
6 17 -D 154 102 A1- Sealing compound 8033
6 18 -D 154 103 A1- Adhesive silicone 8034
6 19 -D 169 300 M1- Window adhesive 8034
6 20 -D 169 300 M2- Window adhesive 8034
6 21 -D 172 090 A2- Adhesive 8035
6 22 -D 174 003 M2- Silicone sealant 8035
6 23 -D 176 404 A3- Adhesive silicone 8036
6 24 -D 176 204 R2- Adhesive silicone 8036
6 25 -D 176 404 M2- Adhesive silicone 8036
6 26 -D 176 501 A1- Adhesive silicone 8036
6 27 -D 180 KU1 A1- 2-component adhesive for plastic 8037
6 28 -D 180 KU2 A1- 2-component adhesive for plastic 8037
6 29 -D 181 220 A1- Activating agent 8038
6 30 -D 181 655 A1- Activating agent 8038
6 31 -D 181 802 M1- Glass primer 8038
6 32 Liquid sealant -D 185 400 A2- 8039
6 33 Liquid sealant -D 185 400 A3- 8039
6 34 Liquid sealant -D 185 410 A2- 8039
6 35 -D 185 520 A2- Sealing compound 8039
6 36 -D 190 MKD A3- Assembly adhesive 8040
6 37 Liquid sealant -D 192 100 A2- 8040
6 38 -D 195 850 A1- Cleaning solution 8040
6 39 -D 316 D38 A2- Protective wax 8041
6 40 -D 322 000 A2- Wachs-spray 8041
6 41 -D 322 100 M2- Wachs-spray 8041
6 42 -D 330 KD2 A1- Cavity spray 8042
6 43 -D 366 PR1 A1- Plastic primer 8042
6 44 -D 454 300 A2- Sealing compound 8042
6 45 -D 469 101 A3- Gluing and sealing compound 8043
6 46 -D 822 150 A1- Plastic surfacer 8043
6 47 -G 000 100- Coupling teeth lubricant compound 8043
6 48 -G 000 115 A2- Spray lubricant 8044
6 49 -G 000 150- Consistent lubricating paste 8044
6 50 -G 000 405 A2- Silicone paste 8044
6 51 -G 000 450 02- Lubrication paste 8045
6 52 -G 000 650- Consistent lubricating paste 8046
6 53 -G 052 109 A2- Assembly paste 8046
6 54 -G 052 112 A3- High temperature paste 8046
6 55 -G 052 128 A1- Thrust ring sealing grease 8047
6 56 -G 052 133 A2- Lubricating paste for high temperatures 8047
6 57 -G 052 135 A1- Lubricating oil 8047
6 58 -G 052 142 A2- Polyurethane lubricating compound 8048
6 59 -G 052 150 A2- Lithium lubricating paste 8048
6 60 -G 052 168 A1- Steering box lubricant 8049
6 61 -G 052 172 A1- Special lubricant 8049
6 62 -G 052 172 M2- Special lubricant 8049
6 63 -G 052 181 A4- Lubricating paste for constant velocity joints 8050
6 64 -G 052 528 A2- Lubricating paste for constant velocity joints 8050
6 65 -G 052 565 A1- Silicone paste 8050
6 66 -G 052 723 A2- Moly paste 8051
6 67 -G 052 735 A2- Multi-purpose grease 8051
6 68 -G 052 738 A2- Lubricating paste for constant velocity joints 8051
6 69 -G 052 738 A3- Thrust ring sealing grease 8052
6 70 -G 052 745 A3- Lubricating paste for low temperature 8052
6 71 -G 052 751 A1- Molybdenum pasta 8052
6 72 -G 052 778 A2- Spray lubricant 8053
6 73 -G 052 817 A1- Contact grease 8053
6 74 -G 055 128 A1- Thrust ring sealing grease 8053
6 75 -G 060 567 A2- Special lubricant 8054
6 76 -G 060 735 A2- Multi-purpose grease 8054
6 77 -G 060 751 A2- Consistent lubricating paste 8054
6 78 -G 065 567 A2- Cleaning solution 8055
6 79 -G 070 528 R2- Lubricating paste for constant velocity joints 8055
6 80 -G 294 421 A1- Lubricating oil for assembly 8055
D4B807E3B5B Body Repairs General Body Repairs 8056
1 Safety instructions 8060
1 1 Part removal 8060
1 2 Battery and welding operation 8060
1 3 Electronic control unit 8060
1 3 1 Processing of the electronic control unit after repair dueto a traffic accident 8060
1 4 Paint, glass, soft pad and trim 8061
1 5 Fuel tank or fuel delivery pipeline 8061
1 6 Air conditioner 8061
1 6 1 Remedial measures: 8061
1 7 Airbag System 8062
1 8 Check the seat belts 8062
1 8 1 Belt body 8063
1 8 2 Automatic retractor (locking function) 8063
1 8 3 Visual inspection of the seat belt buckle 8064
1 8 4 Seat belt buckle function 8064
1 8 5 Seat belt guide member and tongue 8065
1 8 6 Fixing piece and fixing point 8065
1 9 Safety specifications for the seat belt tensioner 8065
1 10 Body repair on a vehicle equipped with the seat belt tensioners 8066
1 10 1 The following vehicles have been equipped with: 8066
1 11 Perform cutting off, correcting and/or leveling on a vehicleequipped with airbags 8067
1 12 Remove the front seats with a side airbag 8067
2 Basic instruction 8068
2 1 Diagnosis of the accident vehicle 8068
2 2 Condition of the body and/or the parts for delivery to thepainting workshop 8068
2 3 Correction 8068
2 4 Cutting 8068
2 5 Body-cut part and part section 8068
2 6 Original connection 8069
2 7 Galvanized body parts 8069
2 8 Remove the rest part 8069
2 9 New parts 8069
2 10 Parts 8069
2 11 Molded foam plastic pads 8070
3 Symbolic interpretation 8071
3 1 Symbolic interpretation for welding 8071
3 2 Symbolic interpretation for the operation method 8071
3 2 1 Grinding 8072
3 2 2 Thinning 8072
3 2 3 Punching 8072
3 2 4 Drilling 8073
3 2 5 Polishing 8073
3 2 6 Cavity corrosion protection 8073
3 2 7 Bonding 8074
3 2 8 Precise sealing 8074
4 Body repair tools 8075
4 1 Flaring tool -V A G 1317- 8075
4 2 Punching pliers -V A G 1329- 8075
4 3 Basic equipment -V A G 1366/3- 8075
4 4 Bottom protection layer spray gun -V A G 1379- 8076
4 5 Electric blower -V A G 1416- 8076
4 6 Door tensioner -V A G 1438- 8076
4 7 Body equipment component -V A G 1439- 8077
4 8 Pneumatic cutting knife -V A G 1523 A- 8077
4 9 Air chisel -V A G 1577- 8077
4 10 Edge closing iron block -V A G 1585- 8078
4 11 Welding fume ventilator -V A G 1586- 8078
4 12 Welding spot releasing device -V A G 1731- 8078
4 13 Pneumatic spray gun -V A G 1761/1- 8079
4 14 Pneumatic punching and thinning pliers -VAS 1996- 8079
4 15 Pneumatic adhesive spray gun -V A G 2005- 8079
4 16 Door hinge correction tool 8080
4 17 Hose kit 5023 for the inert gas protection welding 8080
4 18 Angle grinder -VAS 5174- 8080
4 19 Angle grinder -VAS 5175- 8081
4 20 Wire brush -VAS 5182- 8081
5 Body bonding 8082
5 1 Transporter 1991 → 8082
5 1 1 Separation process: 8082
5 1 2 Bonding process: 8082
5 2 Bonding types 8082
5 2 1 Bonding-strong 8082
5 2 2 Bonding-spot welding 8083
5 3 Repair method for replacing the parts 8083
5 3 1 Spot welding and bonding 8083
5 3 2 Plug welding and bonding (if spot welding is impossible) 8083
5 3 3 Welding fume ventilator 8084
5 3 4 Preparations 8084
5 3 5 Trimming 8084
6 Corrosion protection measures 8085
6 1 Corrosion protection 8085
7 Waste disposal instructions 8086
7 1 Waste disposal 8086
7 2 Air pressure tappet exhaust 8086
7 3 Airbag 8087
7 3 1 Waste disposal 8087
8 Contact corrosion protection 8088
8 1 Connection of aluminum alloy/magnesium alloy with steel 8088
9 Steel plate repair 8089
9 1 High-strength body plate 8089
9 2 Galvanized body parts 8089
9 2 1 Preparations 8089
9 2 2 Part cutting 8090
9 2 3 Connection process 8090
9 3 Welding on the galvanized body steel plate 8090
9 3 1 Inert gas protection plug welding SG of the galvanized steelplate 8090
9 3 2 Resistance pressure spot welding RP of the galvanized steelplate 8091
9 3 3 Welding transformer 8091
9 3 4 Welding clamp 8091
9 4 Tearing test 8091
10 Aluminum repair 8092
10 1 Painting 8092
10 2 Surface treatment 8092
10 3 Leveling 8093
10 4 Temperature control for heating 8093
11 Plastic repair method 8094
11 1 Material 8094
11 2 Repairing the pit 8095
11 3 Repairing the scratch 8096
11 4 Repair the crack 8098
11 5 Repairing the small hole (the diameter is more than 30 mm) 8099
11 6 Plastic repair (glass fibre material) 8100
11 7 Repair process 8101
11 7 1 Repairing the breakage position 8101
11 7 2 Repairing the surface damage 8103
12 Glass repair 8104
12 1 Repairing the windshield 8104
12 1 1 Premises 8104
12 1 2 Required special tools, operating equipment, testing instrumentsand auxiliary tools 8105
12 1 3 Repair description 8106
D4B808B9B1E 4 cylinder injection engine (1 8 l 2 0 l TFSI engine EA888 generation III) 8110
00 – Technical data 8118
1 Safety information 8118
1 1 Safety regulations for working on fuel supply 8118
1 2 Safety measures when working on vehicles with a start/stop system 8118
1 3 Safety precautions when using testers and measuring instruments during a road test 8119
1 4 Safety precautions when working on the cooling system 8119
1 5 Safety precautions when working on ignition system 8119
2 Identification 8120
2 1 Engine number/engine data 8120
3 Repair instructions 8122
3 1 Rules for cleanliness 8122
3 2 Foreign objects in engine 8122
3 3 Contact corrosion 8122
3 4 Routing and attachment of lines 8123
3 5 Fitting radiator and condensers 8123
3 6 Checking vacuum system 8123
10 – Removing and installing engine 8124
1 Removing and installing engine 8124
1 1 Removing engine 8124
1 2 Separating engine and gearbox 8135
1 3 Securing engine on engine and gearbox support 8137
1 4 Installing engine 8139
2 Assembly mountings 8142
2 1 Assembly overview – assembly mountings 8142
2 2 Removing and installing engine mounting 8145
2 3 Removing and installing gearbox mounting 8147
2 4 Removing and installing pendulum support 8148
2 5 Supporting engine in installation position 8149
2 6 Adjusting assembly mountings 8157
2 7 Checking adjustment of assembly mountings 8159
3 Engine cover panel 8160
3 1 Removing and installing engine cover 8160
13 – Crankshaft group 8161
1 Cylinder block (pulley end) 8161
1 1 Assembly overview – cylinder block (pulley end) 8161
1 2 Removing and installing poly-V belt 8164
1 3 Removing and installing tensioner for poly V-belt 8165
1 4 Removing and installing vibration damper 8166
1 5 Removing and installing bracket for ancillaries 8173
1 6 Removing and installing engine support 8177
2 Cylinder block, gearbox end 8179
2 1 Assembly overview – cylinder block, gearbox end 8179
2 2 Assembly overview – drive plate 8180
2 3 Removing and installing drive plate 8181
2 4 Removing and installing flywheel 8183
2 5 Removing and installing sealing flange on gearbox side 8185
3 Crankshaft 8190
3 1 Assembly overview – crankshaft 8190
3 2 Crankshaft dimensions 8193
3 3 Allocation of main bearing shells 8193
3 4 Renewing needle bearing in crankshaft 8195
3 5 Measuring axial clearance of crankshaft 8198
3 6 Measuring radial clearance of crankshaft 8199
3 7 Removing and installing sender wheel 8200
4 Balancer shaft 8202
4 1 Assembly overview – balance shaft 8202
4 2 Removing and installing balance shaft 8204
4 2 1 Removing and installing balance shaft, inlet side 8204
4 2 2 Removing and installing balance shaft, exhaust side 8207
4 3 Renewing oil seal for balance shaft (inlet side) 8209
5 Pistons and conrods 8211
5 1 Assembly overview – pistons and conrods 8211
5 2 Removing and installing pistons 8215
5 3 Checking pistons and cylinder bores 8217
5 4 Separating new conrod 8218
5 5 Checking radial clearance of conrods 8219
5 6 Removing and installing oil spray jets 8219
15 – Cylinder head, valve gear 8222
1 Cylinder head 8222
1 1 Assembly overview – cylinder head 8222
1 2 Removing and installing cylinder head 8225
1 3 Assembly overview – vacuum pump 8231
1 4 Removing and installing vacuum pump 8232
1 5 Checking compression 8234
2 Cover for timing chain 8237
2 1 Assembly overview – cover for timing chain 8237
2 2 Removing and installing camshaft control valve 1 -N205- and exhaust camshaft control valve 1 -N318- 8239
2 3 Removing and installing timing chain cover 8239
2 3 1 Removing and installing upper timing chain cover 8239
2 3 2 Removing and installing timing chain cover (bottom) 8242
2 4 Renewing seal for vibration damper 8247
3 Chain drive 8251
3 1 Assembly overview – camshaft timing chains 8251
3 2 Assembly overview – drive chain for balance shaft 8254
3 3 Removing and installing camshaft timing chain 8257
3 4 Removing and installing drive chain for balance shaft 8269
3 5 Checking valve timing 8272
3 6 Checking chain elongation 8275
4 Valve gear 8277
4 1 Assembly overview – valve gear 8277
4 2 Removing and installing camshaft 8280
4 3 Installing ball for sliding piece 8289
4 4 Removing and installing actuators for camshaft adjustment 8290
4 5 Removing and installing valve stem seals 8291
4 5 1 Removing and installing valve stem seals (cylinder head installed) 8291
4 5 2 Removing and installing valve stem seals (cylinder head removed) 8297
5 Inlet and exhaust valves 8303
5 1 Checking valve guides 8303
5 2 Checking valves 8304
5 3 Valve dimensions 8304
17 – Lubrication 8305
1 Sump, oil pump 8305
1 1 Assembly overview – sump/oil pump 8305
1 2 Engine oil: 8308
1 3 Removing and installing lower part of sump 8308
1 3 1 Removing and installing bottom section of sump, plastic sump 8308
1 3 2 Removing and installing bottom section of sump, sheet-metal sump 8310
1 4 Removing and installing upper part of sump 8314
1 5 Removing and installing oil pump 8319
1 6 Removing and installing oil level and oil temperature sender -G266- 8321
2 Engine oil cooler 8323
2 1 Assembly overview – engine oil cooler 8323
2 2 Removing and installing engine oil cooler 8323
2 3 Removing and installing mechanical switching valve 8325
3 Crankcase ventilation 8326
3 1 Assembly overview – crankcase breather system 8326
3 2 Removing and installing oil separator 8327
4 Oil filter, oil pressure switch 8330
4 1 Assembly overview – oil filter 8330
4 2 Assembly overview – oil pressure switches/oil pressure control 8330
4 3 Removing and installing piston cooling jet control valve -N522- 8332
4 4 Removing and installing oil pressure switch -F1- 8333
4 5 Removing and installing oil pressure switch for reduced oil pressure -F378- 8334
4 6 Removing and installing stage 3 oil pressure switch -F447- 8335
4 7 Checking oil pressure 8337
4 7 1 Checking engine oil pressure 8337
4 7 2 Checking oil pressure and oil spray jets 8339
4 8 Removing and installing oil pressure regulating valve -N428- 8341
19 – Cooling 8343
1 Cooling system/coolant 8343
1 1 Connection diagram – coolant hoses 8343
1 2 Checking cooling system for leaks 8344
1 3 Draining and adding coolant 8348
2 Coolant pump, regulation of cooling system 8357
2 1 Assembly overview – coolant pump, thermostat 8357
2 2 Assembly overview – electric coolant pump 8359
2 3 Assembly overview – coolant temperature sender 8360
2 4 Removing and installing auxiliary pump for heating -V488- 8361
2 5 Removing and installing coolant pump 8364
2 6 Removing and installing toothed belt for coolant pump 8365
2 7 Removing and installing thermostat housing 8368
2 8 Removing and installing coolant valve for gearbox -N488- 8372
2 9 Removing and installing actuator for engine temperature regulation -N493- 8373
2 10 Removing and installing coolant temperature sender -G62- 8376
2 11 Removing and installing radiator outlet coolant temperature sender -G83- 8377
3 Coolant pipes 8379
3 1 Assembly overview – coolant pipes 8379
3 2 Removing and installing coolant pipes 8379
3 3 Removing and installing upper coolant pipes 8381
4 Radiator, radiator fan 8383
4 1 Assembly overview – radiator/radiator fan 8383
4 2 Assembly overview – radiator cowl and radiator fan 8384
4 3 Removing and installing radiator 8385
4 4 Removing and installing radiator cowl 8386
4 5 Removing and installing radiator fan 8388
4 6 Removing and installing auxiliary radiator 8388
21 – Turbocharging/supercharging 8391
1 Turbocharger 8391
1 1 Assembly overview – turbocharger 8391
1 1 1 Assembly overview – turbocharger, Mahle charge pressure positioner -V465- 8391
1 1 2 Assembly overview – turbocharger, Cooper charge pressure positioner -V465- 8394
1 2 Removing and installing turbocharger 8397
1 3 Adjusting charge pressure positioner -V465- 8406
2 Charge air system 8409
2 1 Assembly overview – charge air system 8409
2 2 Removing and installing charge air cooler 8411
2 3 Removing and installing charge pressure sender -G31- 8412
2 4 Checking charge air system for leaks 8413
24 – Mixture preparation – injection 8416
1 Injection system 8416
1 1 Overview of fitting locations – injection system 8416
1 2 Releasing high pressure in fuel system 8425
2 Injectors 8426
2 1 Assembly overview – fuel rail with injectors 8426
2 2 Removing and installing fuel rail 8428
2 3 Removing and installing injectors 8428
2 4 Renewing seals on injectors 8433
2 5 Cleaning injectors 8435
3 Air filter 8438
3 1 Assembly overview – air filter housing 8438
3 2 Removing and installing air filter housing 8440
4 Intake manifold 8442
4 1 Assembly overview – intake manifold 8442
4 2 Removing and installing intake manifold 8444
4 3 Removing and installing throttle valve module -GX3- 8450
4 4 Cleaning throttle valve module -GX3- 8451
5 Senders and sensors 8453
5 1 Removing and installing fuel pressure sender -G247- 8453
5 2 Checking fuel pressure sender -G247- 8455
5 3 Removing and installing intake manifold sender -GX9- 8458
5 4 Removing and installing air mass meter -G70- 8459
6 Engine control unit 8461
6 1 Removing and installing engine control unit -J623- 8461
6 1 1 Removing and installing engine control unit -J623- without protective housing 8461
6 1 2 Removing and installing engine (motor) control unit -J623- with protective housing 8462
7 High-pressure pump 8465
7 1 Assembly overview – high-pressure pump 8465
7 2 Removing and installing high-pressure pump 8467
8 Lambda probe 8471
8 1 Assembly overview – Lambda probe 8471
8 2 Removing and installing Lambda probe -GX10- 8471
8 3 Removing and installing Lambda probe after catalytic converter -GX7- 8474
26 – Exhaust system 8476
1 Exhaust pipes and silencers 8476
1 1 Assembly overview – silencers 8476
1 1 1 Assembly overview – Silencers, torsion beam axle 8476
1 1 2 Assembly overview – Silencers, multi-link suspension, Saloon 8478
1 1 3 Assembly overview – Silencers, multi-link suspension, Cabriolet 8479
1 2 Removing and installing rear silencer 8481
1 2 1 Removing and installing rear silencer, torsion beam axle 8481
1 2 2 Removing and installing rear silencer, multi-link suspension 8483
1 3 Aligning exhaust system free of stress 8484
1 4 Checking exhaust system for leaks 8485
1 5 Installation position of clamp 8485
2 Emission control 8488
2 1 Assembly overview – emission control 8488
2 2 Removing and installing catalytic converter 8488
3 Secondary air system 8493
3 1 Assembly overview – secondary air system 8493
3 2 Removing and installing secondary air pump motor -V101- 8495
3 3 Removing and installing secondary air inlet valve -N112- 8495
28 – Ignition system 8497
1 Ignition system 8497
1 1 Assembly overview – ignition system 8497
1 2 Test data, spark plugs 8499
1 3 Removing and installing ignition coils with output stage 8499
1 4 Removing and installing knock sensor 1 -G61- 8501
1 5 Removing and installing Hall sender -G40- 8502
1 6 Removing and installing Hall sender 3 -G300- 8503
1 7 Removing and installing engine speed sender -G28- 8503
D4B8032F3B2 4 cylinder injection engine (1 8 l 2 0 l TFSI engine EA888 generation III) 8505
00 – Technical data 8513
1 Safety information 8513
1 1 Safety regulations for working on fuel supply 8513
1 2 Safety measures when working on vehicles with a start/stop system 8513
1 3 Safety precautions when using testers and measuring instruments during a road test 8514
1 4 Safety precautions when working on the cooling system 8514
1 5 Safety precautions when working on ignition system 8514
2 Identification 8515
2 1 Engine number/engine data 8515
3 Repair notes 8517
3 1 Rules for cleanliness 8517
3 2 Foreign objects in engine 8517
3 3 Contact corrosion 8517
3 4 Routing and attachment of lines 8518
3 5 Fitting radiator and condensers 8518
3 6 Checking vacuum system 8518
10 – Removing and installing engine 8519
1 Removing and installing engine 8519
1 1 Removing engine 8519
1 2 Separating engine and gearbox 8527
1 3 Securing engine on engine and gearbox support 8529
1 4 Installing engine 8532
2 Assembly mountings 8535
2 1 Assembly overview – assembly mountings 8535
2 2 Removing and installing motor mounting 8537
2 3 Removing and installing gearbox mounting 8538
2 4 Removing and installing pendulum support 8539
2 5 Supporting engine in installation position 8539
2 6 Adjusting assembly mountings 8547
2 7 Checking adjustment of assembly mountings (engine and gearbox mountings) 8549
3 Motor cover 8550
3 1 Removing and installing engine cover 8550
13 – Crankshaft group 8551
1 Cylinder block (pulley end) 8551
1 1 Assembly overview – cylinder block (pulley end) 8551
1 2 Removing and installing poly-V belt 8552
1 3 Removing and installing tensioner for poly V-belt 8554
1 4 Removing and installing vibration damper 8554
1 5 Removing and installing bracket for ancillaries 8560
1 6 Removing and installing engine support 8562
2 Cylinder block, gearbox end 8564
2 1 Assembly overview – cylinder block, gearbox end 8564
2 2 Assembly overview – drive plate 8565
2 3 Removing and installing drive plate 8566
2 4 Removing and installing flywheel 8567
2 5 Removing and installing sealing flange on gearbox side 8568
3 Crankshaft 8572
3 1 Assembly overview – crankshaft 8572
3 2 Crankshaft dimensions 8573
3 3 Allocation of main bearing shells 8574
3 4 Renewing needle bearing in crankshaft 8575
3 5 Measuring axial clearance of crankshaft 8578
3 6 Measuring radial clearance of crankshaft 8579
3 7 Removing and installing sender wheel 8579
4 Balancer shaft 8581
4 1 Assembly overview – balance shaft 8581
4 2 Removing and installing balance shaft 8582
4 2 1 Removing and installing balance shaft, inlet side 8582
4 2 2 Removing and installing balance shaft, exhaust side 8584
4 3 Renewing oil seal for balance shaft (inlet side) 8586
5 Pistons and conrods 8588
5 1 Assembly overview – pistons and conrods 8588
5 2 Removing and installing pistons 8589
5 3 Checking pistons and cylinder bores 8591
5 4 Separating new conrod 8592
5 5 Checking radial clearance of conrods 8593
15 – Cylinder head, valve gear 8594
1 Cylinder head 8594
1 1 Assembly overview – cylinder head 8594
1 2 Assembly overview – camshaft housing 8597
1 3 Removing and installing cylinder head 8598
1 4 Removing and installing vacuum pump 8602
1 5 Checking compression 8603
2 Cover for timing chain 8606
2 1 Assembly overview – cover for timing chain 8606
2 2 Removing and installing timing chain cover 8608
2 2 1 Removing and installing upper timing chain cover 8608
2 2 2 Removing and installing timing chain cover (bottom) 8609
2 3 Renewing seal for vibration damper 8614
3 Chain drive 8617
3 1 Assembly overview – camshaft timing chains 8617
3 2 Assembly overview – drive chain for balance shaft 8618
3 3 Removing and installing camshaft timing chain 8621
3 4 Removing and installing drive chain for balance shaft 8635
3 5 Checking chain elongation 8635
3 6 Checking valve timing 8636
4 Valve gear 8639
4 1 Assembly overview – valve gear 8639
4 2 Removing and installing camshaft 8642
4 3 Removing and installing camshaft control valve 1 -N205- 8655
4 4 Removing and installing valve stem seals 8656
4 4 1 Removing and installing valve stem seals (cylinder head installed) 8656
4 4 2 Removing and installing valve stem seals (cylinder head removed) 8660
5 Inlet and exhaust valves 8664
5 1 Checking valve guides 8664
5 2 Checking valves 8665
5 3 Valve dimensions 8665
17 – Lubrication 8666
1 Sump, oil pump 8666
1 1 Assembly overview – sump/oil pump 8666
1 2 Engine oil: 8669
1 3 Removing and installing lower part of sump 8669
1 4 Removing and installing upper part of sump 8671
1 5 Removing and installing oil pump 8674
1 6 Removing and installing oil level and oil temperature sender -G266- 8676
2 Engine oil cooler 8678
2 1 Assembly overview – engine oil cooler 8678
2 2 Removing and installing engine oil cooler 8678
2 3 Removing and installing mechanical switching valve 8680
3 Crankcase ventilation 8681
3 1 Assembly overview – crankcase breather system 8681
3 2 Removing and installing oil separator 8682
4 Oil filter, oil pressure switch 8683
4 1 Assembly overview – oil filter 8683
4 2 Assembly overview – oil pressure switches/oil pressure control 8684
4 3 Removing and installing piston cooling jet control valve -N522- 8685
4 4 Removing and installing oil pressure switch -F1- 8685
4 5 Removing and installing oil pressure switch for reduced oil pressure -F378- 8686
4 6 Removing and installing stage 3 oil pressure switch -F447- 8687
4 7 Checking oil pressure 8689
4 7 1 Checking engine oil pressure 8689
4 7 2 Checking oil pressure and oil spray jets 8691
4 8 Removing and installing oil pressure regulating valve -N428- 8692
19 – Cooling 8694
1 Cooling system/coolant 8694
1 1 Connection diagram – coolant hoses 8694
1 1 1 Coolant hose schematic diagram, cooling system without auxiliary radiator 8694
1 1 2 Coolant hose schematic diagram, cooling system with auxiliary radiator 8695
1 1 3 Vehicles with manual gearbox and engine code CULC 8696
1 1 4 Vehicles with dual clutch gearbox and engine code CULC 8697
1 2 Checking cooling system for leaks 8697
1 3 Draining and adding coolant 8699
2 Coolant pump, regulation of cooling system 8706
2 1 Assembly overview – coolant pump, thermostat 8706
2 2 Assembly overview – electric coolant pump 8708
2 3 Assembly overview – coolant temperature sender 8711
2 4 Removing and installing continued coolant circulation pump -V51- / auxiliary pump for heating -V488- 8711
2 5 Removing and installing coolant pump 8713
2 6 Removing and installing coolant shut-off valve -N82- 8714
2 7 Removing and installing coolant valve for gearbox -N488-, vehicles with dual clutch gearbox 8716
2 8 Removing and installing toothed belt for coolant pump 8718
2 9 Removing and installing thermostat housing 8720
2 10 Removing and installing coolant temperature sender -G62- 8723
2 11 Removing and installing radiator outlet coolant temperature sender -G83- 8724
3 Coolant pipes 8726
3 1 Assembly overview – coolant pipes 8726
3 2 Removing and installing coolant pipes 8726
3 3 Removing and installing upper coolant pipes 8727
4 Radiator, radiator fan 8730
4 1 Assembly overview – radiator/radiator fan 8730
4 2 Assembly overview – radiator cowl and radiator fan 8731
4 3 Removing and installing radiator 8731
4 4 Removing and installing radiator cowl 8732
4 5 Removing and installing radiator fan 8733
4 6 Removing and installing auxiliary radiator 8733
21 – Turbocharging/supercharging 8736
1 Exhaust turbocharger 8736
1 1 Assembly overview – turbocharger 8736
1 1 1 Assembly overview – turbocharger, Mahle charge pressure positioner -V465- 8736
1 1 2 Assembly overview – turbocharger, Cooper charge pressure positioner -V465- 8739
1 2 Removing and installing turbocharger 8741
2 Charge air system 8748
2 1 Assembly overview – charge air system 8748
2 2 Removing and installing charge air cooler 8749
2 3 Removing and installing charge pressure sender -G31- 8750
2 4 Checking charge air system for leaks 8750
24 – Mixture preparation – injection 8753
1 Injection system 8753
1 1 Overview of fitting locations – injection system 8753
1 2 Releasing high pressure in fuel system 8755
2 Injectors 8757
2 1 Assembly overview – fuel rail with injectors 8757
2 2 Removing and installing fuel rail 8759
2 3 Removing and installing injectors 8760
2 4 Renewing seals on injectors 8762
2 5 Cleaning injectors 8764
3 Air filter 8766
3 1 Assembly overview – air filter housing 8766
3 2 Removing and installing air filter housing 8767
4 Intake manifold 8769
4 1 Assembly overview – intake manifold 8769
4 2 Removing and installing intake manifold 8770
4 3 Removing and installing throttle valve module -J338- 8774
4 4 Cleaning throttle valve module 8775
5 Senders and sensors 8777
5 1 Assembly overview – actuator for structure-borne sound and control unit for structure-borne sound 8777
5 2 Removing and installing actuator for structure-borne sound -R214- and control unit for structure-borne sound -J869- 8777
5 2 1 Removing and installing actuator for structure-borne sound -R214- 8778
5 2 2 Removing and installing control unit for structure-borne sound -J869- 8778
5 3 Removing and installing fuel pressure sender -G247- 8778
5 4 Checking fuel pressure sender -G247- 8780
6 Engine (motor) control unit 8783
6 1 Removing and installing engine (motor) control unit -J623- 8783
6 1 1 Removing and installing engine control unit -J623- without protective housing 8783
6 1 2 Removing and installing engine (motor) control unit -J623- with protective housing 8784
7 High-pressure pump 8787
7 1 Assembly overview – high-pressure pump 8787
7 2 Removing and installing high-pressure pump 8788
8 Lambda probe 8792
8 1 Assembly overview – Lambda probe 8792
8 2 Removing and installing Lambda probe -G39- 8792
8 3 Removing and installing Lambda probe after catalytic converter -G130- 8794
26 – Exhaust system 8795
1 Exhaust pipes and silencers 8795
1 1 Assembly overview – silencers 8795
1 1 1 Assembly overview – Silencers, torsion beam axle 8795
1 1 2 Assembly overview – Silencers, multi-link suspension, Saloon 8796
1 1 3 Assembly overview – Silencers, multi-link suspension, Cabriolet 8797
1 2 Removing and installing rear silencer 8798
1 2 1 Removing and installing rear silencer, torsion beam axle 8798
1 2 2 Removing and installing rear silencer, multi-link suspension 8800
1 3 Aligning exhaust system free of stress 8801
1 4 Check exhaust system for leaks 8802
1 5 Installation position of clamp 8802
2 Exhaust gas cleaning 8804
2 1 Assembly overview – emission control 8804
2 2 Removing and installing catalytic converter 8804
3 Secondary air system 8808
3 1 Assembly overview – secondary air system 8808
3 2 Removing and installing secondary air pump motor -V101- 8809
3 3 Removing and installing secondary air inlet valve -N112- 8809
28 – Ignition system 8811
1 Ignition system 8811
1 1 Assembly overview – ignition system 8811
1 2 Test data, spark plugs 8812
1 3 Removing and installing ignition coils with output stage 8812
1 4 Removing and installing knock sensor 1 -G61- 8814
1 5 Removing and installing Hall sender 8815
1 6 Removing and installing engine speed sender -G28- 8815
D4B8036EADF Vehicle specifice paint information 8817
00 – Technical data 8821
1 Explanation of symbols 8821
1 1 Sanding 8821
1 2 Seam seals 8821
1 3 Cavity sealing 8823
2 Paint structure 8824
2 1 Structure of factory finish, cathodic dip primer 8824
2 2 Structure of factory finish, filler-primer 8825
2 3 Structure of factory finish, base coat 8829
2 4 Structure of factory finish, clear coat 8833
3 Areas exposed to stone chipping 8837
3 1 Body areas exposed to stone chipping 8837
4 Masking areas 8839
4 1 Masking areas, front body 8839
4 2 Masking areas, rear body 8844
5 Seam seals 8846
5 1 Seam seals, front body 8846
5 2 Seam seals, middle body 8851
5 3 Seam seals, rear body 8853
6 Undercoating 8860
6 1 Undercoated areas, middle body 8860
6 2 Undercoated areas, rear body 8862
7 Cavity sealing 8864
7 1 Cavity sealing, overview of body 8864
7 2 Cavity sealing, front body 8865
7 3 Cavity sealing, middle body 8866
7 4 Cavity sealing, rear body 8868
8 Contrasting shades 8870
8 1 Instructions for bonding decorative films 8870
8 2 Contrasting shades, Beetle »GSR« / »Turbo R« 8871
8 2 1 Contrasting shades, Beetle »GSR« / »Turbo R« – Assembly overview 8871
8 2 2 Applying contrasting shade on bonnet 8874
8 2 3 Bonding decorative film, wing 8880
8 2 4 Bonding decorative film, door and side panel 8880
D4B8066C4CE General body repairs exterior 8882
50 – Body – front 8890
1 Lock carrier 8890
1 1 Assembly overview – lock carrier 8890
1 1 1 Assembly overview – lock carrier, saloon 8890
1 1 2 Assembly overview – lock carrier, Cabriolet 8891
1 2 Removing and installing lock carrier 8892
1 3 Moving to and back from service position 8897
2 Wings 8900
2 1 Assembly overview – wing 8900
2 2 Removing and installing wing 8904
2 3 Removing and installing wing bracket 8908
3 Bulkhead 8910
3 1 Assembly overview – bulkhead 8910
3 2 Assembly overview – plenum chamber cover 8911
3 3 Removing and installing plenum chamber cover 8912
53 – Body – rear 8917
1 Rear wing 8917
1 1 Assembly overview – rear wing 8917
1 2 Removing and installing rear wing 8917
1 3 Removing and installing anti-abrasion film 8920
55 – Bonnet, rear lid 8923
1 Bonnet 8923
1 1 Assembly overview – bonnet 8923
1 2 Assembly overview – Bowden cable 8924
1 3 Removing and installing bonnet 8926
1 4 Adjusting bonnet 8929
1 5 Removing and installing rear lid lock 8931
1 6 Removing and installing bonnet lock operating lever 8932
1 7 Removing and installing striker pin 8934
1 8 Removing and installing hinges 8935
1 9 Removing and installing insulation 8937
1 10 Removing and installing Bowden cable 8939
1 11 Removing and installing bonnet stay 8941
1 12 Removing and installing bonnet seals 8943
2 Rear lid 8945
2 1 Assembly overview – rear lid 8945
2 1 1 Assembly overview – rear lid, Saloon 8945
2 1 2 Assembly overview – rear lid, Cabriolet 8948
2 2 Removing and installing rear lid 8952
2 2 1 Removing and installing rear lid, Saloon 8952
2 2 2 Removing and installing rear lid, Cabriolet 8954
2 3 Adjusting rear lid 8957
2 3 1 Adjusting rear lid, Saloon 8957
2 3 2 Adjusting rear lid, Cabriolet 8964
2 4 Removing and installing rear lid lock 8970
2 4 1 Removing and installing rear lid lock, Saloon 8970
2 4 2 Removing and installing lid lock, Cabriolet 8971
2 5 Removing and installing operating mechanism 8973
2 6 Removing and installing hinges 8975
2 7 Removing and installing striker pin 8976
2 8 Removing and installing rear lid seal 8978
2 8 1 Removing and installing rear lid seal, Saloon 8978
2 8 2 Removing and installing rear lid seal, Cabriolet 8980
2 9 Removing and installing gas strut 8982
2 10 Releasing gas from gas strut 8984
3 Tank flap unit 8986
3 1 Assembly overview – tank flap unit 8986
3 2 Removing and installing tank flap unit 8986
3 3 Removing and installing actuator 8989
57 – Front doors, door components, central locking 8991
1 Door 8991
1 1 Assembly overview – door 8991
1 2 Removing and installing inner door seal 8993
1 2 1 Removing and installing inner door seal, saloon 8993
1 2 2 Removing and installing inner door seal, cabriolet 8996
1 3 Removing and installing outer door seal 8998
1 4 Removing and installing door 9000
1 5 Adjusting door 9003
1 6 Adjusting striker pin 9006
1 7 Removing and installing door arrester 9007
2 Door components 9009
2 1 Assembly overview – door components 9009
2 2 Assembly overview – door handle and door lock 9011
2 3 Removing and installing window regulator motor 9013
2 4 Removing and installing window regulator 9016
2 5 Removing and installing inner door cover 9018
2 6 Removing and installing striker pin 9020
2 7 Removing and installing door handle 9021
2 8 Removing and installing mounting bracket 9024
2 9 Removing and installing door lock 9025
2 10 Removing and installing window slot outer seal 9027
2 11 Removing and installing lock cylinder 9029
2 12 Removing and installing cap on door handle 9032
2 13 Removing and installing outer padding 9036
3 Central locking 9038
3 1 Overview of fitting locations – central locking system 9038
3 1 1 Overview of fitting locations – central locking, Saloon 9038
3 1 2 Overview of fitting locations – central locking, Cabriolet 9040
3 2 Assembly overview – ignition key 9042
3 3 Removing and installing ignition key battery 9043
58 – Rear doors, door components 9045
1 Door components 9045
1 1 Removing and installing window regulator motor 9045
1 2 Removing and installing window regulator 9048
60 – Sunroof 9055
1 Sliding sunroof 9055
1 1 Assembly overview – sliding sunroof 9055
1 2 Assembly overview – sunroof roller blind 9057
1 3 Removing and installing sliding sunroof frame 9058
1 4 Removing and installing wind deflector 9068
1 5 Removing and installing glass panel 9070
1 6 Adjusting sunroof panel 9074
1 7 Removing and installing slotted guide 9076
1 8 Removing and installing sliding sunroof adjustment control unit -J245- 9079
1 9 Removing and installing sunroof sun blind cover 9082
1 10 Removing and installing transverse reinforcement 9083
1 11 Removing and installing sunroof roller blind 9084
1 12 Adapting sliding sunroof adjustment control unit -J245- 9091
1 13 Removing and installing sliding sunroof seals 9092
1 14 Manual operation 9096
1 15 Removing and installing trim 9096
2 Water drain hoses 9105
2 1 Assembly overview – water drain hoses 9105
2 2 Cleaning water drain hoses 9105
61 – Convertible roof, hardtop, canopy 9108
1 Convertible top 9108
1 1 Assembly overview – convertible top 9108
1 2 Assembly overview – convertible top frame 9110
1 3 Assembly overview – stop buffer 9112
1 4 Assembly overview – convertible top latch 9112
1 5 Removing and installing convertible top 9113
1 6 Repairing water trap channel 9126
1 7 Removing and installing rear window control link 9127
1 8 Removing and installing tensioning strap 9128
1 9 Removing and installing bolted retaining strips 9131
1 10 Removing and installing riveted retaining strip 9133
1 11 Removing and installing toothed segment 9135
1 12 Removing and installing convertible top latch 9136
1 13 Removing and installing convertible top lock 9138
1 14 Removing and installing striker pin 9140
1 15 Removing and installing water drip tray 9142
1 16 Checking water drainage from convertible top 9144
1 17 Removing and installing retaining plate 9146
2 Convertible roof cover 9148
2 1 Removing and installing convertible top cover 9148
2 2 ‏Removing and installing convertible roof headliner 9166
2 3 Removing and installing tensioning cord for convertible top 9178
2 4 Repairing tensioning cords 9178
3 Attachments 9181
3 1 Assembly overview – windscreen frame seal 9181
3 2 Removing and installing front trim 9181
3 3 Removing and installing side trim panels 9184
3 4 Removing and installing windscreen frame seal 9187
3 5 Removing and installing convertible roof seals 9191
4 Electrical and electronic components 9192
4 1 Overview of fitting locations – electrical and electronic components 9192
4 2 Removing and installing convertible top motor 9194
4 3 Removing and installing convertible top latch motor 9196
63 – Bumpers 9199
1 Bumper, front 9199
1 1 Assembly overview – bumper cover 9199
1 2 Assembly overview – add-on parts 9200
1 2 1 Assembly overview – add-on parts 9200
1 2 2 Assembly overview – add-on parts, Dune 9202
1 3 Assembly overview – guides and brackets 9203
1 4 Assembly overview – bumper carrier 9203
1 5 Removing and installing bumper cover 9205
1 6 Removing and installing add-on parts 9208
1 7 Repairing bumper cover 9209
1 8 Installing holder for parking aid sender 9209
1 9 Installing brackets for park assist steering 9214
2 Bumper, rear 9219
2 1 Assembly overview – bumper cover 9219
2 2 Assembly overview – guides and brackets 9220
2 3 Assembly overview – bumper carrier 9221
2 4 Assembly overview – add-on parts 9222
2 4 1 Assembly overview – add-on parts, all models except Dune 9222
2 4 2 Assembly overview – add-on parts, Dune 9223
2 5 Removing and installing bumper cover 9224
2 6 Repairing bumper cover 9227
2 7 Installing holder for parking aid sender 9227
2 8 Installing brackets for park assist steering 9232
64 – Glazing 9237
1 Repair notes 9237
1 1 Minimum drying times for bonded windows 9237
1 2 Window repair 9237
1 3 Installation instructions for bonded windows 9238
1 4 Preparing old undamaged windows for installing 9239
1 5 Removing broken window 9240
1 6 Preparing new windows for installing 9241
1 7 Preparing body flange for installing 9241
1 8 Cleaning off excess adhesive 9243
2 Windscreen 9244
2 1 Assembly overview – windscreen 9244
2 1 1 Assembly overview – windscreen, Saloon 9244
2 1 2 Assembly overview – windscreen, Cabriolet 9244
2 2 Removing and installing windscreen 9245
3 Rear windscreen 9250
3 1 Assembly overview – rear window 9250
3 2 Removing and installing rear window 9250
4 Side windows 9255
4 1 Assembly overview – rear side windows 9255
4 1 1 Assembly overview – rear side window, saloon 9255
4 1 2 Assembly overview – rear side window, cabriolet 9255
4 2 Removing and installing rear side window 9256
4 2 1 Removing and installing rear side window, saloon 9256
4 2 2 Removing and installing rear side window, cabriolet 9259
4 3 Adjusting rear door window 9263
5 Door windows 9269
5 1 Assembly overview – front door window 9269
5 2 Removing and installing front door window 9269
5 3 Adjusting front door window 9273
5 3 1 Adjusting front door window, Saloon 9273
5 3 2 Adjusting front door window, Cabriolet 9279
66 – Exterior equipment 9286
1 Radiator grille and front trim 9286
1 1 Removing and installing front trim 9286
2 Spoiler 9289
2 1 Assembly overview – spoiler 9289
2 1 1 Assembly overview – spoiler, Saloon 9289
2 1 2 Assembly overview – spoiler, Cabriolet 9289
2 2 Removing and installing spoiler 9290
2 2 1 Removing and installing spoiler, Saloon 9290
2 2 2 Removing and installing spoiler, Cabriolet 9296
3 Mouldings, trims, extensions 9303
3 1 Assembly overview – trim strip and covers 9303
3 1 1 Assembly overview – decorative strip on door and side panel 9303
3 1 2 Assembly overview – decorative strip around shoulder of convertible top 9304
3 2 Assembly overview – side member trim 9305
3 3 Removing and installing trim strip 9306
3 3 1 Removing and installing trim strip, door and side panel 9306
3 3 2 Removing and installing trim strip, shoulder of convertible top 9310
3 4 Removing and installing step moulding 9313
3 5 Removing and installing retaining strip for side member extension 9316
3 6 Removing and installing side member trim 9319
3 7 Removing and installing wheel arch covers 9323
3 7 1 Removing and installing front wheel arch trim 9323
3 7 2 Removing and installing rear wheel arch trim 9327
4 Noise insulation 9332
4 1 Assembly overview – noise insulation 9332
4 1 1 Assembly overview – noise insulation, Saloon with petrol engine 9332
4 1 2 Assembly overview – noise insulation, Saloon with diesel engine 9333
4 1 3 Assembly overview – skid plate, saloon 9333
4 1 4 Assembly overview – noise insulation, Cabriolet 9334
4 2 Removing and installing noise insulation 9335
4 2 1 Removing and installing noise insulation, petrol engine 9335
4 2 2 Removing and installing noise insulation, diesel engine 9336
4 2 3 Removing and installing skid plate 9337
5 Underbody cladding 9339
5 1 Assembly overview – underbody cladding 9339
5 1 1 Assembly overview – underbody cover, Saloon 9339
5 1 2 Assembly overview – underbody cover, Cabriolet 9340
5 2 Removing and installing tunnel cross-piece 9340
6 Trim film and protective film 9342
6 1 Instructions for affixing decorative films and protective films 9342
6 2 Protective film on rear wing 9343
6 3 Decorative film, door and side panel 9344
7 Exterior mirror 9346
7 1 Assembly overview – exterior mirror 9346
7 2 Removing and installing exterior mirror 9347
7 3 Removing and installing mirror glass 9350
7 4 Removing and installing mirror adjustment unit 9352
7 5 Removing and installing mirror cover 9354
7 6 Removing and installing mirror frame 9356
7 7 Removing and installing assembly bracket 9358
8 Wheel housing liner 9360
8 1 Assembly overview – front wheel housing liner 9360
8 2 Assembly overview – rear wheel housing liner 9361
8 3 Removing and installing front wheel housing liner 9362
8 4 Removing and installing rear wheel housing liner 9365
9 Lettering and emblems 9367
9 1 Instructions for affixing the lettering 9367
9 2 Dimensions – lettering and emblems on rear 9368
9 3 Dimensions – lettering and emblems on sides 9368
9 3 1 Lettering, “R-Line” 9368
9 4 Removing and installing badges at front 9369
10 Special add-on parts 9372
10 1 Overview of fitting locations – special add-on parts, Dune 9372
D4B8066C4E4 General body repairs interior 9373
00 – Technical data 9379
1 Safety notes 9379
1 1 Safety precautions when working on pyrotechnic components 9381
1 2 Safety instructions for airbag 9382
1 3 Deactivating airbags 9382
1 4 Automatic Rollover Support System 9383
1 5 Storing, transporting and disposing of airbag units, belt tensioner units and battery isolators (pyrotechnic components) 9383
1 6 Additional safety regulations for working on seat occupied sensor controlling deactivation of front passenger airbag – country-specific version 9384
1 7 Procedure for dealing with seat occupied sensor controlling deactivation of front passenger airbag following an accident – country-specific version 9385
1 8 Checking airbag securing parts after an accident 9385
1 9 Accident without airbag triggering 9386
1 10 Check belt webbing 9386
1 11 Checking inertia reel (locking mechanism) 9387
1 12 Visually checking belt buckle 9388
1 13 Check operation of belt buckle 9388
1 14 Safety information for belt tensioners 9389
1 15 Checking belt relays, and buckle tongues 9389
1 16 Checking securing parts and anchorage points after an accident 9390
68 – Interior equipment 9391
1 Compartments/covers 9391
1 1 Removing and installing dash panel cover on driver side 9391
1 1 1 Removing and installing dash panel centre cover on driver side 9391
1 1 2 Removing and installing left dash panel cover on driver side 9392
1 2 Removing and installing dash panel cover (passenger side) 9394
1 2 1 Removing and installing dash panel cover on front passenger side, cover with reinforcement 9394
1 2 2 Removing and installing dash panel cover on front passenger side, cover with storage compartment 9396
1 3 Removing and installing upper steering column trim 9397
1 4 Removing and installing lower steering column trim 9398
1 5 Removing and installing glove compartment opener 9399
1 5 1 Removing and installing glove compartment opener, upper glove compartment 9399
1 5 2 Removing and installing glove compartment opener, lower glove compartment 9400
1 6 Removing and installing glove compartment 9402
1 6 1 Removing and installing glove compartment, upper glove compartment 9402
1 6 2 Removing and installing glove compartment, lower glove compartment 9403
1 7 Removing and installing headliner storage compartment 9404
1 8 Removing and installing handbrake lever trim 9405
2 Equipment 9409
2 1 Removing and installing sun visor 9409
2 2 Removing and installing sun visor centre mount 9411
2 3 Removing and installing roof grab handle 9412
2 4 Removing and installing grab handle bracket 9414
2 5 Removing and installing windbreak 9415
3 Centre console 9416
3 1 Assembly overview – securing bracket for centre console 9416
3 2 Removing and installing centre console 9416
3 3 Removing and installing centre console securing bracket 9422
3 3 1 Removing and installing securing brackets for centre console, front securing bracket 9422
3 3 2 Removing and installing securing brackets for centre console, rear securing bracket 9423
4 Front centre armrest 9425
4 1 Assembly overview – front centre armrest 9425
4 2 Removing and installing front centre armrest 9425
5 Interior mirror 9427
5 1 Layout – interior mirror 9427
5 2 Assembly overview – interior mirror 9427
5 2 1 Assembly overview – interior mirror, Basic 9427
5 2 2 Assembly overview – interior mirror, rain sensor 9428
5 3 Removing and installing interior mirror 9429
5 3 1 Removing and installing interior mirror, Basic 9429
5 3 2 Removing and installing interior mirror, rain sensor 9430
5 4 Removing and installing retaining plate for interior mirror 9433
5 4 1 Removing and installing retaining plate for interior mirror, base 9433
5 4 2 Removing and installing retaining plate for interior mirror, rain sensor 9435
69 – Passenger protection 9438
1 Seat belts 9438
1 1 Assembly overview – front three-point seat belt 9438
1 1 1 Assembly overview – front three-point seat belt, Saloon 9438
1 1 2 Assembly overview – front three-point seat belt, Cabriolet 9439
1 2 Assembly overview – rear outer three-point seat belt 9440
1 2 1 Assembly overview – rear outer three-point seat belt, Saloon 9440
1 2 2 Assembly overview – rear outer three-point seat belt, Cabriolet 9441
1 3 Removing and installing front three-point seat belt 9442
1 3 1 Removing and installing front three-point seat belt, Saloon 9442
1 3 2 Removing and installing front three-point seat belt, Cabriolet 9447
1 4 Removing and installing rear three-point seat belt 9451
1 4 1 Removing and installing rear three-point seat belt, Saloon 9451
1 4 2 Removing and installing rear three-point seat belt, Cabriolet 9453
1 5 Removing and installing front belt guide 9455
1 6 Removing and installing front belt buckle 9456
1 7 Removing and installing rear belt buckle 9459
2 Child seat anchors 9462
2 1 Assembly overview – rear child seat anchors 9462
2 2 Checking after an accident 9462
2 3 Removing and installing rear child seat anchors 9463
2 3 1 Removing and installing rear child seat anchors, ISOFIX 9463
2 3 2 Removing and installing rear child seat anchors, top tether 9463
3 Airbag system 9465
3 1 Overview of fitting locations – airbag system 9465
4 Airbag control unit 9466
4 1 Removing and installing airbag control unit -J234- 9466
5 Front airbag 9469
5 1 Removing and installing airbag unit with igniter 9469
5 2 Removing and installing return spring with slip ring (coil connector) 9472
6 Front passenger airbag 9474
6 1 Removing and installing front passenger airbag unit with igniter 9474
6 2 Removing and installing key-operated switch to deactivate airbag on front passenger side 9480
7 Side airbags 9482
7 1 Removing and installing front side airbag with igniter 9482
8 Airbag crash sensors 9486
8 1 Removing and installing front airbag crash sensor for driver side -G283- 9486
8 2 Removing and installing front airbag crash sensor, front passenger side -G284- 9488
8 3 Removing and installing front side airbag crash sensor -G179-/-G180- 9490
9 Seat belt verification 9493
9 1 Removing and installing seat occupied sensor, front passenger side -G128- 9493
10 Seat occupied recognition system 9495
10 1 Overview of fitting locations – seat occupied recognition system 9495
10 1 1 Overview of fitting locations – seat occupied recognition, Basic 9495
10 1 2 Overview of fitting locations – seat occupied recognition, Sport 9497
10 2 Removing and installing seat occupied sensor 9500
10 2 1 Removing and installing seat occupied recognition; Removing pressure sensor for seat occupied recognition -G452-, Basic 9500
10 2 2 Removing and installing seat occupied recognition; Installing pressure sensor for seat occupied recognition -G452-, Basic 9504
10 2 3 Removing and installing seat occupied recognition; Installing pressure sensor for seat occupied recognition -G452-, Sport 9510
10 2 4 Removing and installing seat occupied recognition, seat occupied recognition control unit 9516
10 2 5 Removing and installing seat occupied recognition, bracket for seat occupied recognition control unit 9518
11 Automatic Rollover Support System 9519
11 1 Assembly overview – rollover bar 9519
11 2 Removing and installing rollover bar 9521
70 – Trim, insulation 9528
1 Front door trims 9528
1 1 Removing and installing front door trim 9528
1 2 Removing and installing mirror cover trim 9533
2 Dash panel 9535
2 1 Removing and installing dash panel end cover 9535
2 2 Removing and installing dash panel trim 9537
2 3 Removing and installing radio/navigation system mounting frame 9538
2 4 Removing and installing retaining frame for dash panel insert 9539
2 5 Removing and installing dash panel 9541
2 6 Aligning dash panel in vehicle 9549
2 7 Removing and installing outer dash panel vents 9552
2 8 Removing and installing side defroster vent 9553
3 Dash panel cross member 9555
3 1 Assembly overview – central tube for dash panel 9555
3 2 Assembly overview – impact dampers and glove compartment brackets 9556
3 3 Removing and installing dash panel cross member 9557
3 4 Removing and installing mounting bracket 9562
3 4 1 Removing and installing mounting bracket on driver side 9562
3 4 2 Removing and installing mounting bracket on front passenger side 9563
3 5 Removing and installing impact damper 9564
3 5 1 Removing and installing impact absorber on driver side 9564
3 5 2 Removing and installing middle impact absorber 9564
3 5 3 Removing and installing impact absorber on front passenger side 9565
4 Interior trims 9567
4 1 Assembly overview – side trim 9567
4 1 1 Assembly overview – side trim panel, Saloon 9567
4 1 2 Assembly overview – side trim panel, Cabriolet 9568
4 2 Assembly overview – rear panel trims 9569
4 3 Removing and installing sill panel moulding 9570
4 4 Removing and installing A-pillar trim 9572
4 4 1 Removing and installing A-pillar trim, upper A-pillar trim, Saloon 9572
4 4 2 Removing and installing A-pillar trim, upper A-pillar trim, Cabriolet 9574
4 4 3 Removing and installing A-pillar trim, lower A-pillar trim on driver side 9575
4 4 4 Removing and installing A-pillar trim, lower A-pillar trim on front passenger side 9577
4 5 Removing and installing A-pillar trim deformation element 9578
4 6 Removing and installing B-pillar trim 9579
4 6 1 Detaching and attaching B-pillar trim 9579
4 6 2 Removing and installing upper B-pillar trim 9581
4 7 Removing and installing C-pillar trim 9584
4 8 Removing and installing side trim 9585
4 8 1 Removing and installing side trim panel, Saloon 9585
4 8 2 Removing and installing side trim panel, Cabriolet 9588
4 9 Removing and installing rear shelf 9593
4 10 Removing and installing rear panel trims 9594
4 10 1 Removing and installing rear panel trims, middle rear panel trim 9594
4 10 2 Removing and installing rear panel trims, upper rear panel trim 9595
4 10 3 Removing and installing rear panel trims, trim for rear belt inertia reel 9597
4 11 Removing and installing floor covering 9599
5 Luggage compartment trims 9600
5 1 Removing and installing lower rear lid trim 9600
5 2 Removing and installing upper rear lid trim 9601
5 3 Removing and installing rear shelf 9603
5 4 Removing and installing luggage compartment side trim 9605
5 4 1 Removing and installing luggage compartment side trim, saloon 9605
5 4 2 Removing and installing luggage compartment side trim, Cabriolet 9606
5 5 Removing and installing luggage compartment floor 9608
5 6 Removing and installing lock carrier trim 9609
5 7 Removing and installing rear lid trim 9611
5 8 Removing and installing trim for rear lid lock 9613
6 Roof trims 9614
6 1 Assembly overview – roof frame trim 9614
6 2 Removing and installing moulded headliner 9614
6 3 Installing roof reinforcement to body 9618
6 4 Removing and installing roof frame trim 9621
6 4 1 Removing and installing roof frame trim, removing and installing upper roof frame trim 9621
6 4 2 Removing and installing roof frame trim, removing and installing lower roof frame trim 9622
7 Convertible roof compartment 9624
7 1 Assembly overview – convertible roof compartment 9624
7 2 Removing and installing bracket for convertible top tensioning strap 9624
72 – Seat frames 9627
1 Front seats 9627
1 1 Removing and installing front seat 9627
1 2 Removing and installing seat height adjustment handle 9633
1 3 Removing and installing seat height adjuster 9635
1 4 Removing and installing seat trim on tunnel side 9636
1 5 Removing and installing seat trim on sill side 9637
1 6 Removing and installing seat trim bracket 9638
1 7 Removing and installing lumbar support adjuster 9640
1 8 Removing and installing backrest adjuster 9641
1 9 Removing and installing front backrest 9642
1 10 Removing and installing head restraint 9644
1 11 Removing and installing head restraint guide 9645
1 12 Removing and installing trim for backrest release mechanism 9647
1 13 Removing and installing backrest release mechanism 9649
1 14 Removing and installing backrest release holder 9650
1 15 Removing and installing Bowden cable for backrest release 9652
1 16 Adjusting Bowden cable for backrest release mechanism 9655
1 17 Removing and installing interconnecting Bowden cable 9657
1 18 Removing and installing easy-entry Bowden cable A 9659
1 19 Adjusting Bowden cable A for entry assistance 9662
1 20 Removing and installing easy-entry Bowden cable B 9665
1 21 Removing and installing slider 9667
1 22 Removing and installing torsion rod 9668
1 23 Removing and installing torsion rod bush 9672
1 24 Removing and installing seat heating control unit 9674
2 Rear seats 9675
2 1 Assembly overview – rear seat backrest 9675
2 2 Removing and installing bench seat/individual seats 9675
2 3 Removing and installing head restraint guide 9677
2 4 Removing and installing rear seat backrest 9679
2 4 1 Removing and installing rear seat backrest, Saloon 9679
2 4 2 Removing and installing rear seat backrest, Cabriolet 9683
2 5 Removing and installing locking mechanism for rear seat backrest 9686
2 5 1 Removing and installing locking mechanism for rear seat backrest, saloon 9686
2 5 2 Removing and installing locking mechanism for rear seat backrest, cabriolet 9688
2 6 Removing and installing Bowden cable for locking mechanism for rear seat backrest 9690
2 7 Removing and installing frame for rear seat backrest 9691
2 7 1 Removing and installing frame for rear seat backrest, saloon 9691
2 7 2 Removing and installing frame for rear seat backrest, cabriolet 9693
2 8 Removing pressure stud for backrest release 9694
74 – Seat – padding, covers 9696
1 Front seat covers and padding 9696
1 1 Removing and installing cover and padding in area of seat pan 9696
1 2 Removing and installing backrest cover and backrest padding 9702
2 Rear seat covers and padding 9709
2 1 Removing and installing cover and padding 9709
2 1 1 Removing and installing bench seat cover and padding 9709
2 1 2 Removing and installing rear seat backrest cover and padding, Saloon 9710
2 1 3 Removing and installing rear seat backrest cover and padding, Cabriolet 9713
2 2 Separating cover and padding 9715
D4B8066C4EB Brake system 9717
00 – Technical data 9721
1 Safety information 9721
1 1 Safety measures when working on vehicles with a start/stop system 9721
1 2 Safety precautions when using testers and measuring instruments during a road test 9721
2 Identification 9722
2 1 Allocation of PR number – brakes 9722
2 1 1 PR number 9722
2 1 2 Front brakes 9722
2 1 3 Rear brakes, multi-link rear suspension 9722
3 Technical data 9723
3 1 Technical data for brakes 9723
3 1 1 Brake master cylinder and brake servo 9723
4 Brake test 9726
4 1 General information 9726
4 2 Checking vehicles with front-wheel drive 9726
45 – Anti-lock brake system 9727
1 General information 9727
1 1 Repair instructions for repair work on ABS 9727
2 Overview of fitting locations 9730
2 1 Fitting location overview – ABS 9730
2 1 1 Fittings locations overview – ABS Mark 70 9730
2 2 Overview of fitting locations – ABS/ESP 9732
2 2 1 ABS Mark 60 EC (ABS/EDL/TCS/ESP) – vehicles without electromechanical power steering, North America 9732
2 2 2 ABS Mark 60 EC (ABS/EDL/TCS/ESP) – vehicles with electromechanical power steering, North America 9734
2 2 3 ABS Mark 60 EC (ABS/EDL/TCS/ESP) – vehicles with electromechanical power steering 9736
3 Control unit and hydraulic unit 9738
3 1 Assembly overview – control unit and hydraulic unit 9738
3 1 1 Assembly overview – control unit and hydraulic unit, LHD, ABS mark 70 9738
3 1 2 Assembly overview – control unit and hydraulic unit, RHD, ABS mark 70 9741
3 1 3 Assembly overview – control unit and hydraulic unit, LHD, ABS mark 60 EC 9743
3 1 4 Assembly overview – control unit and hydraulic unit, RHD, ABS mark 60 EC 9746
3 2 Removing and installing ABS control unit -J104- and ABS hydraulic unit -N55- 9749
3 2 1 Removing and installing ABS control unit -J104- and ABS hydraulic unit -N55-, left-hand drive vehicles with petrol engines 9749
3 2 2 Removing and installing ABS control unit -J104- and ABS hydraulic unit -N55-, left-hand drive vehicles with 5-cyl petrol engine and ABS Mark 70 ABS/TCS 9757
3 2 3 Removing and installing ABS control unit -J104- and ABS hydraulic unit -N55-, left-hand drive vehicles with 4-cyl petrol engine and ABS Mark 70 ABS/TCS 9765
3 2 4 Removing and installing ABS control unit -J104- and ABS hydraulic unit -N55-, left-hand drive vehicles with 4-cyl diesel engine and ABS Mark 70 ABS/TCS 9773
3 2 5 Removing and installing ABS control unit -J104- and ABS hydraulic unit -N55-, RHD vehicles with ABS Mark 70 (ABS/TCS) 9784
3 2 6 Removing and installing ABS control unit -J104- and ABS hydraulic unit -N55-, left-hand drive vehicles with diesel engine 9791
3 2 7 Removing and installing ABS control unit -J104- and ABS hydraulic unit -N55-, left-hand drive vehicles with 5-cyl petrol engine and ABS Mark 60 EC ABS/EDL/TCS/ESP 9799
3 2 8 Removing and installing ABS control unit -J104- and ABS hydraulic unit -N55-, left-hand drive vehicles with 4-cyl petrol engine and ABS Mark 60 EC ABS/EDL/TCS/ESP 9807
3 2 9 Removing and installing ABS control unit -J104- and ABS hydraulic unit -N55-, left-hand drive vehicles with 4-cyl diesel engine and ABS Mark 60 EC ABS/EDL/TCS/ESP 9815
3 2 10 Removing and installing ABS control unit -J104- and ABS hydraulic unit -N55-, ABS Mark 60 EC (ABS/EDL/TCS/ESP) 9826
3 3 Separating control unit from hydraulic unit 9834
3 3 1 Separating ABS control unit -J104- from ABS hydraulic unit -N55-, ABS Mark 70 9834
3 3 2 Separating ABS control unit -J104- from ABS hydraulic unit -N55-, ABS Mark 60 EC 9835
3 4 Fitting control unit to hydraulic unit 9836
3 4 1 Installing ABS control unit -J104- to ABS hydraulic unit -N55-, ABS Mark 70 (ABS/TCS) 9836
3 4 2 Installing ABS control unit -J104- to ABS hydraulic unit -N55-, ABS Mark 60 EC (ABS/EDL/TCS/ESP) 9838
3 5 Connecting brake lines to hydraulic unit 9839
3 5 1 Connecting brake lines on ABS hydraulic unit -N55-, LHD vehicles with ABS Mark 70 (ABS/TCS) 9839
3 5 2 Connecting brake lines to ABS hydraulic unit -N55-, RHD vehicles with ABS Mark 70 (ABS/TCS) 9840
3 5 3 Connecting brake lines to ABS hydraulic unit -N55-, LHD vehicles with ABS Mark 60 EC (ABS/EDL/TCS/ESP) 9841
3 5 4 Connecting brake lines to ABS hydraulic unit -N55-, RHD vehicles with ABS Mark 60 EC (ABS/EDL/TCS/ESP) 9842
4 Sensors 9844
4 1 Assembly overview – sensors and actuators 9844
4 1 1 Steering angle sender -G85- on steering column 9844
4 2 Assembly overview – speed sensor on front axle 9846
4 2 1 Assembly overview – speed sensors -G45-/-G47- on front axle 9846
4 3 Assembly overview – speed sensor on rear axle 9847
4 4 Removing and installing speed sensors on front axle -G45-/-G47- 9847
4 5 Removing and installing speed sensors on rear axle -G44-/-G46- 9848
46 – Brakes – mechanism 9850
1 Front brakes 9850
1 1 Assembly overview – front brakes 9850
1 1 1 Assembly overview – brake caliper FS III without brake pad wear indicator 9850
1 1 2 Assembly overview – brake caliper FS III with brake pad wear indicator 9852
1 1 3 Assembly overview – brake caliper FN 3 without brake pad wear indicator 9854
1 1 4 Assembly overview – brake caliper FN 3 with brake pad wear indicator 9856
1 2 Removing and installing brake pads/linings 9857
1 2 1 Removing and installing brake pads, brake caliper FS III 9857
1 2 2 Removing and installing brake pads, brake caliper FN 3 9860
1 3 Removing and installing brake caliper 9864
1 3 1 Removing and installing brake caliper, FS III brake caliper 9864
1 3 2 Removing and installing brake caliper, brake caliper FN 3 9867
1 4 Removing and installing brake carrier 9870
1 5 Removing and installing brake disc 9872
1 5 1 Removing and installing brake disc, brake caliper FS III 9872
1 5 2 Removing and installing brake disc, brake caliper FN 3 9874
1 6 Removing and installing brake splash plate 9877
1 6 1 Removing and installing cover plate, brake caliper FS III 9877
1 6 2 Removing and installing splash plate, brake caliper FN 3 9878
2 Rear brakes 9881
2 1 Assembly overview – rear brakes 9881
2 2 Removing and installing brake pads/linings 9883
2 3 Removing and installing brake caliper 9886
2 4 Removing and installing brake carrier 9890
2 5 Removing and installing brake disc 9892
2 6 Removing and installing brake splash plate 9894
3 Parking brake 9897
3 1 Assembly overview – parking brake 9897
3 2 Removing and installing handbrake lever 9897
3 3 Adjusting parking brake 9901
3 4 Removing and installing rear brake cable 9903
4 Brake pedal 9907
4 1 Assembly overview – brake pedal 9907
4 1 1 Assembly overview – brake pedal, left-hand drive 9907
4 1 2 Assembly overview – brake pedal, right-hand drive 9909
4 2 Removing and installing mounting bracket 9909
4 2 1 Removing and installing mounting bracket, left-hand drive 9909
4 2 2 Removing and installing mounting bracket, RHD 9911
4 3 Separating brake pedal from brake servo 9915
4 4 Connecting brake pedal to brake servo 9916
4 5 Removing and installing brake pedal 9916
4 5 1 Removing and installing brake pedal, left-hand drive vehicles 9916
4 5 2 Removing and installing brake pedal, right-hand drive vehicles 9917
47 – Brakes – hydraulics 9919
1 Front brake caliper 9919
1 1 Assembly overview – front brake caliper 9919
1 1 1 Assembly overview – FS III 9919
1 1 2 Assembly overview – FN 3 9920
1 2 Removing and installing brake caliper piston 9921
1 2 1 Removing and installing brake caliper FS III 9921
1 2 2 Removing and installing brake caliper piston FN 3 9923
2 Rear brake caliper 9927
2 1 Assembly overview – rear brake caliper 9927
2 2 Removing and installing brake caliper piston 9928
2 3 Pre-bleeding brake caliper 9931
3 Brake servo and brake master cylinder 9932
3 1 Assembly overview – brake servo/brake master cylinder 9932
3 1 1 Assembly overview – brake servo/brake master cylinder (left-hand drive vehicle) 9932
3 1 2 Assembly overview – brake servo/brake master cylinder, RHD 9935
3 2 Removing and installing brake light switch 9937
3 2 1 Removing and installing brake light switch -F-, LHD vehicles with 5-cyl petrol engine 9937
3 2 2 Removing and installing brake light switch -F-, LHD vehicles with 4-cyl petrol engine 9938
3 2 3 Removing and installing brake light switch -F-, LHD vehicles with 4-cyl diesel engine 9939
3 2 4 Removing and installing brake light switch -F-, right-hand drive 9940
3 3 Removing and installing brake servo 9941
3 3 1 Removing and installing brake servo, LHD vehicles with 5-cyl petrol engine 9941
3 3 2 Removing and installing brake servo, LHD vehicles with 4-cyl petrol engine 9951
3 3 3 Removing and installing brake servo, LHD vehicles with 4-cyl diesel engine 9958
3 3 4 Removing and installing brake servo, RHD vehicles with 4-cyl petrol engine 9966
3 3 5 Removing and installing brake servo, RHD vehicles with 4-cyl diesel engine 9972
3 4 Removing and installing brake master cylinder 9984
3 4 1 Removing and installing brake master cylinder, LHD vehicles with 5-cyl petrol engine 9984
3 4 2 Removing and installing brake master cylinder, LHD vehicles with 4-cyl petrol engine 9989
3 4 3 Removing and installing brake master cylinder, LHD vehicles with 4-cyl diesel engine 9994
3 4 4 Removing and installing brake master cylinder, RHD vehicles with 4-cyl petrol engine 10000
3 4 5 Removing and installing brake master cylinder, RHD vehicles with 4-cyl petrol engine 10003
3 5 Removing and installing brake fluid reservoir 10011
3 5 1 Removing and installing brake fluid reservoir, left-hand drive vehicles 10011
3 5 2 Removing and installing brake fluid reservoir, right-hand drive vehicles 10015
4 Vacuum system 10018
4 1 Assembly overview – electric vacuum pump 10018
4 1 1 Assembly overview – electric vacuum pump, vehicles with 1 2 l petrol engine 10018
4 1 2 Assembly overview – electric vacuum pump, vehicles with 1 4 l petrol engine 10019
4 2 Assembly overview – vacuum pump 10020
4 2 1 Assembly overview – vacuum pump, vehicles with 1 8 l – 125 kW and 2 0 l – 155 kW petrol engine 10020
4 2 2 Assembly overview – vacuum pump, vehicles with 2 0 l diesel engine 10021
4 2 3 Assembly overview – vacuum pump, vehicles with 2 5 l petrol engine 10021
4 3 Checking non-return valve 10022
4 4 Removing and installing vacuum sender -G608- 10022
4 5 Checking vacuum system 10022
4 5 1 Instructions 10022
4 5 2 Connecting vacuum gauge for brake servo -VAS 6721- 10023
4 5 3 Checking vacuum generation 10024
4 5 4 Checking for leaks 10025
4 5 5 Vacuum generation with manual vacuum pump -VAS 6213- 10026
4 6 Removing and installing electric vacuum pump 10027
5 Brake lines 10029
5 1 Repairing brake lines 10029
5 1 1 Tools for brake line repair 10029
5 1 2 Assembly overview – flanging tool 10031
5 1 3 Work instructions 10031
6 Hydraulic system 10034
6 1 General notes on brake fluid 10034
6 1 1 General information 10034
6 1 2 Changing brake fluid 10036
6 2 Pre-bleeding hydraulic system 10036
6 3 Bleeding hydraulic system following standard procedure 10038
6 4 Subsequent bleeding of hydraulic system 10041
6 5 Testing for leaks 10042
D4B8066C47B Running gear axles steering 10043
00 – Technical data 10049
1 Safety information 10049
1 1 Safety measures when working on vehicles with a start/stop system 10049
1 2 Safety precautions when working on subframe 10049
2 Evaluating accident vehicles 10050
2 1 Check list for evaluating running gear on accident vehicles 10050
3 Repair instructions 10052
3 1 Leaks at shock absorbers 10052
3 2 Noises from shock absorbers 10052
3 3 Checking shock absorbers when removed 10053
3 4 Steering rack 10053
3 5 Gaskets and seals 10054
3 6 Nuts and bolts 10054
3 7 Electrical components 10054
3 8 Raising suspension to unladen position (vehicles with coil springs) 10055
3 8 1 Raising wheel bearing assembly to unladen position (vehicles with coil springs), front axle 10055
3 8 2 Raising wheel bearing assembly to unladen position (vehicles with coil springs), rear axle 10058
4 Disposal 10061
4 1 Releasing gas and draining front gas-filled shock absorbers 10061
4 1 1 Releasing gas and draining front gas-filled shock absorbers, conventional shock absorbers 10061
4 1 2 Releasing gas and draining front gas-filled shock absorbers, DCC shock absorbers 10062
4 2 Releasing gas and draining rear gas-filled shock absorbers 10063
4 2 1 Releasing gas and draining rear gas-filled shock absorbers, conventional shock absorbers 10063
4 2 2 Releasing gas and draining rear gas-filled shock absorbers, DCC shock absorbers 10063
40 – Front suspension 10065
1 Front axle 10065
1 1 Overview of fitting locations – front axle 10065
2 Subframe 10067
2 1 Assembly overview – subframe 10067
2 2 Assembly overview – subframe strut 10069
2 3 Removing and installing subframe without steering rack 10070
2 4 Removing and installing subframe with steering rack 10076
2 4 1 Removing and installing subframe with steering rack, hydraulic steering 10076
2 4 2 Removing and installing subframe with steering rack, electromechanical steering 10084
2 5 Repairing subframe 10092
2 6 Removing and installing subframe strut 10103
2 7 Removing and installing anti-roll bar 10104
2 8 Repairing thread in longitudinal member 10108
2 9 Fixing subframe in position 10108
2 10 Lowering subframe 10113
3 Suspension strut, upper suspension link 10119
3 1 Assembly overview – suspension strut, upper suspension link 10119
3 2 Removing and installing suspension strut 10119
3 3 Repairing suspension strut 10127
4 Lower suspension link, swivel joint 10130
4 1 Assembly overview – lower suspension link, swivel joint 10130
4 2 Removing and installing lower suspension link 10132
4 2 1 Removing and installing lower suspension link, vehicles with manual gearbox or 7-speed dual clutch gearbox 10132
4 2 2 Removing and installing lower suspension link, with 6-speed dual clutch gearbox or automatic gearbox 10134
4 3 Checking swivel joint 10140
4 4 Removing and installing swivel joint 10140
4 5 Renewing bonded rubber bush for lower suspension link 10145
4 5 1 Renewing bonded rubber bush for lower suspension link, front bonded rubber bush 10145
4 5 2 Renewing bonded rubber bush for lower suspension link, rear bonded rubber bush 10148
5 Wheel bearing 10152
5 1 Assembly overview – wheel bearing assembly 10152
5 2 Removing and installing wheel bearing housing 10153
5 3 Removing and installing wheel bearing unit 10160
6 Drive shaft 10165
6 1 Overview – drive shaft 10165
6 2 Assembly overview – drive shaft 10166
6 2 1 Assembly overview – drive shaft, constant velocity joint VL100 10166
6 2 2 Assembly overview – drive shaft, constant velocity joint VL107 10168
6 2 3 Assembly overview – drive shaft, triple roller joint AAR2600i 10170
6 2 4 Assembly overview – drive shaft, triple roller joint AAR3300i 10172
6 3 Removing and installing drive shaft 10174
6 3 1 Removing and installing drive shaft, constant velocity joints VL100 and VL107 10174
6 3 2 Removing and installing drive shaft, triple roller joint AAR2600i 10178
6 3 3 Removing and installing drive shaft, triple roller joint AAR3300i 10182
6 4 Loosening and tightening threaded connections of drive shaft 10186
6 5 Removing and installing drive shaft heat shield 10187
6 6 Dismantling and assembling drive shaft 10188
6 6 1 Dismantling and assembling drive shaft, constant velocity joint VL100 10188
6 6 2 Dismantling and assembling drive shaft, constant velocity joint VL107 10194
6 6 3 Dismantling and assembling drive shaft, triple roller joint AAR2600i 10199
6 6 4 Dismantling and assembling drive shaft, triple roller joint AAR3300i 10205
6 7 Checking outer constant velocity joint 10213
6 8 Checking inner constant velocity joint 10214
42 – Rear suspension 10217
1 Rear axle 10217
1 1 Overview – rear axle 10217
1 2 Lowering rear axle 10218
1 3 Removing and installing rear axle 10222
2 Subframe 10228
2 1 Assembly overview – subframe 10228
2 2 Assembly overview – radius rod 10230
2 3 Fixing subframe in position 10231
2 4 Removing and installing radius rods 10233
3 Anti-roll bar 10235
3 1 Assembly overview – anti-roll bar 10235
3 2 Removing and installing anti-roll bar 10235
4 Suspension link, track rod 10238
4 1 Removing and installing upper transverse link 10238
4 2 Removing and installing lower transverse link 10240
4 3 Removing and installing track rod 10242
5 Suspension strut, shock absorber, spring 10245
5 1 Assembly overview – suspension strut, shock absorber, spring 10245
5 2 Removing and installing shock absorber 10245
5 3 Repairing shock absorber 10247
5 4 Removing and installing spring 10249
6 Wheel bearing assembly, trailing arm 10253
6 1 Assembly overview – wheel bearing assembly 10253
6 2 Removing and installing wheel bearing housing 10255
6 3 Removing and installing wheel bearing unit 10259
6 4 Removing and installing wheel bearing pre-seal 10263
6 5 Renewing bonded rubber bush for wheel bearing housing 10266
6 6 Removing and installing trailing arm with mounting bracket 10269
6 7 Repairing trailing arm 10274
43 – Self-levelling suspension 10278
1 Vehicle level sender 10278
1 1 Assembly overview – rear vehicle level senders 10278
1 2 Removing and installing rear vehicle level senders -G76-/-G77- 10278
44 – Wheels, tyres, vehicle geometry 10280
1 Wheels, tyres 10280
1 1 Specified torques for wheel bolts 10280
1 2 Pressing tyre off wheel rim 10280
1 3 Removing tyre from wheel 10281
1 4 Fitting tyre 10282
1 5 Wheel change 10283
1 5 1 Wheel change, protecting wheel centring seat against corrosion 10283
1 5 2 Wheel change, installation requirements 10283
1 5 3 Wheel change, installation instructions for wheel change 10285
1 5 4 Wheel change, wheel installation 10286
1 6 Tyre sealant disposal 10287
1 7 Models with breakdown set 10287
2 Tyre Pressure Monitoring System 10289
2 1 System description – Tyre Pressure Monitoring System 10289
3 Wheel alignment 10291
3 1 Notes for wheel alignment 10291
3 2 Conditions for testing 10291
3 3 Preparations for testing 10292
3 4 Specifications for wheel alignment 10293
3 5 Wheel alignment procedure 10295
3 6 Necessity of wheel alignment 10296
3 7 Transverse vehicle inclination – zero position 10297
3 8 Adjusting camber at front wheels 10297
3 9 Adjusting camber on rear axle 10299
3 10 Adjusting toe at rear axle 10300
3 11 Adjusting front axle toe 10301
3 12 Vehicle data sticker 10302
3 13 Steering angle sender -G85- basic setting 10303
4 Vibration due to wheels/tyres – causes and rectification 10304
4 1 Causes of rough running 10304
4 2 Conducting a road test before balancing wheels 10304
4 3 Balancing wheel 10305
4 3 1 Balancing wheel, conditions 10305
4 3 2 Balancing wheel, balancing wheel on stationary wheel balancer 10305
4 3 3 Balancing wheel, balancing wheel with finish balancer 10307
4 4 Vibration control system 10308
4 5 Checking radial and lateral runout of wheels and tyres 10309
4 5 1 Checking radial and lateral runout of wheels and tyres, tolerances 10309
4 5 2 Checking radial and lateral runout on wheels and tyres with tyre gauge 10310
4 6 Checking radial and lateral run-out on wheel rim 10311
4 7 Matching wheels and tyres 10312
4 8 Determining flat spots on tyres 10313
48 – Steering 10315
1 Steering wheel 10315
1 1 Assembly overview – steering wheel 10315
1 2 Removing and installing steering wheel 10315
2 Steering column 10318
2 1 Assembly overview – steering column 10318
2 1 1 Assembly overview – steering column, left-hand drive vehicles 10318
2 1 2 Assembly overview – steering column, right-hand drive 10318
2 2 Checking steering column for damage 10319
2 3 Handling and transporting steering column 10319
2 4 Removing and installing steering column 10321
2 4 1 Removing and installing steering column, left-hand drive vehicle 10321
2 4 2 Removing and installing steering column, right-hand drive vehicle 10331
2 5 Removing and installing control unit for electronic steering column lock -J764- 10341
2 5 1 Removing and installing control unit for electronic steering column lock -J764- 10341
2 5 2 Renewing electronic steering column lock control unit -J764- 10342
3 Steering rack 10343
3 1 Assembly overview – steering rack 10343
3 1 1 Assembly overview – steering rack, hydraulic steering rack 10343
3 1 2 Assembly overview – steering rack, electromechanical steering rack, left-hand drive vehicle 10344
3 1 3 Assembly overview – steering rack, electromechanical steering rack, right-hand drive vehicle 10346
3 2 Removing and installing steering rack 10348
3 2 1 Removing and installing steering rack, hydraulic steering 10348
3 2 2 Removing and installing steering rack, electromechanical steering rack, LHD vehicles 10356
3 2 3 Removing and installing steering rack, electromechanical steering rack, RHD vehicles 10366
3 3 Removing and installing bellows 10374
3 4 Removing and installing track rod 10376
3 5 Removing and installing track rod ball joint 10381
3 6 Repairing steering rack 10383
3 6 1 Repairing steering rack, hydraulic steering 10383
3 6 2 Repairing steering rack, electromechanical steering 10383
4 Sensors 10385
4 1 Removing and installing steering angle sender -G85- 10385
4 1 1 Removing and installing steering angle sender -G85-, vehicles with hydraulic steering rack 10385
4 1 2 Removing and installing steering angle sender -G85-, vehicles with electromechanical steering rack 10387
5 Hydraulic power steering 10388
5 1 Assembly overview – hydraulic lines, reservoir 10388
5 1 1 Assembly overview – hydraulic lines, storage tank; hydraulic lines, 5-cylinder petrol engine 10388
5 1 2 Assembly overview – hydraulic lines, storage tank; storage tank, 5-cylinder petrol engine 10390
5 2 Assembly overview – vane pump 10390
5 3 Checking hydraulic fluid level of power steering 10391
5 4 Bleeding steering system after repairs 10392
5 5 Check steering for leaks 10393
5 6 Checking delivery pressure of vane pump 10393
5 7 Removing and installing vane pump 10398
D4B8066C53E Wheels and Tyres Guide 10401
44 – Wheels, tyres, vehicle geometry 10405
1 General notes on using the “Wheels and Tyres Guide” 10405
1 1 General information 10405
1 2 Explanations regarding world regions 10406
1 3 Definition of tyre package 10407
1 4 Procedure for determining the required tyre package 10407
1 4 1 Determining the required tyre package via PR number 10407
1 4 2 Determining the required tyre package via version key in the vehicle registration certificate part 1 10408
2 Notes on the vehicle registration certificate 10409
2 1 Vehicle registration certificate part 1 10409
2 2 Version key, D2 10409
3 Wheel and tyre combinations depending on tyre packages 10411
3 1 Type approval no (K): e1*2007/46*0539*21 to e1*2007/46*0539*23 10411
3 2 Changing to other wheel and tyre combinations 10413
4 Wheel allocation 10414
4 1 61/2 J x 16 offset 44 10414
4 2 7 J x 17 offset 43 10415
4 3 8 J x 18 offset 44 10418
4 4 8 J x 18 offset 48 10418
4 5 8 J x 19 offset 48 10419
4 6 8 J x 20 offset 48 10420
5 Recommended summer tyres 10422
5 1 Recommended summer tyres, Europe, South America, Mexico 10422
5 2 Recommended summer tyres, North America 10422
5 3 Recommended summer tyres, Japan, Singapore, South Korea 10423
6 Recommended all-season tyres 10424
6 1 Recommended all-season tyres, Europe 10424
6 2 Recommended all-season tyres, North America 10424
7 Recommended winter tyres, worldwide except North America and China 10425
8 Recommended temporary spare tyres and wheels 10426
D4B8066C461 Electrical system 10427
00 – Technical data 10433
1 Safety information 10433
1 1 Safety measures when working on vehicles with a start/stop system 10433
1 2 Safety precautions when using testers and measuring instruments during a road test 10433
1 3 Operation and safety notes for gas discharge lamps 10434
2 Repair instructions 10436
2 1 Contact corrosion 10436
2 2 Routing and attachment of lines 10436
3 Battery 10437
3 1 Battery – general notes 10437
3 2 Types of battery 10437
27 – Starter, current supply, CCS 10438
1 Battery 10438
1 1 Assembly overview – battery 10438
1 2 Removing and installing battery 10439
1 3 Disconnecting and connecting battery 10442
1 4 Removing and installing battery tray 10444
1 5 Checking battery 10445
1 6 Charging battery 10445
1 7 Removing and installing earth wire with battery monitor control unit -J367- 10445
1 8 Adapting battery monitor control unit -J367- 10446
2 Alternator 10447
2 1 Assembly overview – alternator 10447
2 1 1 Assembly overview – alternator without sliding bushes 10447
2 1 2 Assembly overview – alternator with sliding bushes 10447
2 2 Removing and installing alternator 10448
2 2 1 Removing and installing alternator -C-, vehicles with 1 2 l/1 4 l TSI engine 10448
2 2 2 Removing and installing alternator -C-, vehicles with 1 8 l/2 0 l TSI engine 10451
2 2 3 Removing and installing alternator -C-, vehicles with 2 5 l petrol engine 10454
2 2 4 Removing and installing alternator -C-, vehicles with diesel engine 10456
2 3 Checking alternator 10458
2 4 Removing and installing poly V-belt pulley 10458
2 4 1 Removing and installing poly V-belt pulley, without freewheel 10458
2 4 2 Removing and installing Bosch poly V-belt pulley with freewheel 10459
2 4 3 Removing and installing Valeo poly V-belt pulley with freewheel 10462
2 4 4 Removing and installing poly V-belt pulley, decoupler pulley with freewheel 10464
2 5 Removing and installing voltage regulator 10468
2 5 1 Removing and installing Bosch voltage regulator 10468
2 5 2 Removing and installing voltage regulator, Valeo 10469
3 Starter 10471
3 1 Assembly overview – starter 10471
3 1 1 Assembly overview – starter, vehicles with manual gearbox 10471
3 1 2 Assembly overview – starter, vehicles with automatic gearbox 10471
3 1 3 Assembly overview – starter, vehicles with 7-speed dual clutch gearbox 10472
3 1 4 Assembly overview – starter, vehicles with 6-speed dual clutch gearbox 10473
3 2 Removing and installing starter 10474
3 2 1 Removing and installing starter, vehicle with manual gearbox 10474
3 2 2 Removing and installing starter, vehicles with automatic gearbox 10477
3 2 3 Removing and installing starter, vehicles with 7-speed dual clutch gearbox 10480
3 2 4 Removing and installing starter, vehicles with 6-speed dual clutch gearbox 10482
3 3 Checking starter 10484
4 Cruise control system (CCS) 10485
5 Start/stop system 10486
5 1 General description – start/stop system 10486
5 2 Removing and installing voltage stabiliser 10486
90 – Gauges, instruments 10488
1 Dash panel insert 10488
1 1 Assembly overview – dash panel insert 10488
1 2 Removing and installing dash panel insert -KX2- 10488
1 3 Multi-pin connector pin assignment on dash panel insert 10490
1 4 Removing and installing ambient temperature sensor 10490
2 Horn 10492
2 1 Assembly overview – horn 10492
2 2 Removing and installing treble horn -H2- and bass horn -H7- 10492
3 Additional instruments 10494
3 1 Assembly overview – additional instruments 10494
3 2 Removing and installing additional instruments 10494
92 – Windscreen wash/wipe system 10496
1 Windscreen wiper system 10496
1 1 Assembly overview – windscreen wiper system 10496
1 2 Moving wipers to service position 10497
1 3 Removing and installing wiper blade 10497
1 4 Removing and installing wiper arms 10498
1 5 Adjusting wiper arms 10499
1 6 Removing and installing wiper motor -V- 10501
1 7 Renewing wiper motor 10502
1 8 Removing and installing rain and light sensor 10505
1 9 Repairing rain and light sensor 10507
2 Windscreen washer system 10509
2 1 Assembly overview – windscreen washer system 10509
2 2 Removing and installing washer fluid reservoir 10509
2 3 Removing and installing windscreen washer fluid level sender 10512
2 4 Removing and installing windscreen washer pump 10512
2 5 Removing and installing spray jets 10513
2 6 Adjusting spray jets 10514
3 Washer fluid lines 10515
3 1 Repairing washer fluid lines 10515
94 – Lights, bulbs, switches – exterior 10516
1 Headlights 10516
1 1 Assembly overview – headlight 10516
1 1 1 Assembly overview – halogen headlight 10516
1 1 2 Assembly overview – headlight, gas discharge headlight 10517
1 2 Removing and installing headlight 10519
1 3 Removing and installing carrier plate for headlights 10520
1 4 Adjusting headlights 10522
1 5 Adjusting headlight installation position 10522
1 6 Converting headlights from driving on right to driving on left 10523
1 7 Converting headlights from driving on left to driving on right 10524
1 8 Removing and installing headlight range control motor -V48-/-V49- 10524
1 8 1 Removing and installing headlight range control motor for halogen headlight 10524
1 8 2 Removing and installing headlight range control motor, gas discharge headlights 10525
1 9 Removing and installing headlight dipped beam bulb 10527
1 10 Removing and installing headlight main beam bulb -M30-/-M32- 10529
1 11 Removing and installing gas discharge bulb -L13-/-L14- 10529
1 12 Removing and installing side light bulb -M1-/-M3- 10531
1 12 1 Removing and installing side light bulb -M1-/-M3-, halogen headlights 10531
1 12 2 Removing and installing side light bulb -M1-/-M3-, gas discharge headlights 10532
1 13 Removing and installing daytime running light bulb -L174-/-L175- 10532
1 14 Removing and installing LED modules for daytime running light and side light -L176-/-L177- 10532
1 15 Removing and installing gas discharge bulb control unit -J343-/-J344- 10533
2 Fog lights 10535
2 1 Assembly overview – fog lights 10535
2 2 Removing and installing fog light 10535
2 3 Removing and installing fog light bulb -L22-/-L23- 10537
2 4 Adjusting fog lights 10537
3 Side marker light 10538
3 1 Removing and installing front side marker light 10538
3 2 Removing and installing side marking light bulb 10539
4 Lights in exterior mirror 10540
4 1 Assembly overview – lights in exterior mirror 10540
4 2 Removing and installing turn signal 10540
4 3 Removing and installing turn signal repeater bulb -L131-/-L132- 10541
5 Front turn signals 10542
5 1 Assembly overview – front turn signals 10542
5 2 Removing and installing front turn signal 10542
5 3 Removing and installing front turn signal bulb 10543
6 Tail lights 10545
6 1 Assembly overview – tail light cluster in body 10545
6 1 1 Assembly overview – tail lights in vehicle body, with bulbs 10545
6 1 2 Assembly overview – tail light clusters in vehicle body, with LEDs 10546
6 2 Removing and installing bulb carrier 10547
6 3 Removing and installing tail light cluster 10548
6 4 Removing and installing rear fog light 10548
6 5 Removing and installing rear fog light bulb -L46-/-L47- 10550
6 6 Removing and installing brake and tail light bulb -M21-/-M22- 10550
6 6 1 Removing and installing brake and tail light bulb -M21-/-M22-, tail light cluster with bulbs 10550
6 6 2 Removing and installing brake and tail light bulb -M21-/-M22-, tail light cluster with LEDs 10550
6 7 Removing and installing reversing light bulb 10551
6 7 1 Removing and installing reversing light bulb, tail light cluster with bulbs 10551
6 7 2 Removing and installing reversing light bulb, tail light cluster with LEDs 10551
6 8 Removing and installing turn signal bulb 10552
6 8 1 Removing and installing turn signal bulb, tail light cluster with bulbs 10552
6 8 2 Removing and installing turn signal bulb, tail light cluster with LEDs 10553
7 High-level brake light 10554
7 1 Removing and installing high-level brake light 10554
8 Number plate light 10557
8 1 Removing and installing number plate light -X4-/-X5- 10557
8 2 Removing and installing bulb for number plate light -X4-/-X5- 10557
9 Entry and start authorisation system 10559
9 1 Overview of fitting locations – entry and start authorisation system 10559
9 2 Removing and installing entry and start authorisation control unit -J518- 10561
9 2 1 Removing and installing (left-hand drive models) entry and start authorisation control unit -J518- 10561
9 2 2 Removing and installing entry and start authorisation control unit -J518-, right-hand drive 10562
9 3 Removing and installing door exterior handle contact sensor -G415-/-G416- 10563
9 4 Removing and installing interior aerial 1 for entry and start authorisation -R138- 10563
9 5 Removing and installing interior aerial 2 for entry and start authorisation -R139- 10564
9 6 Removing and installing driver side aerial for entry and start system -R134- 10564
9 7 Removing and installing front passenger side aerial for entry and start system -R135- 10564
9 8 Removing and installing luggage compartment aerial for entry and start system -R137- 10565
9 9 Removing and installing rear bumper aerial for entry and start system -R136- 10565
10 Steering column switch module 10567
10 1 Assembly overview – steering column switch module 10567
10 1 1 Assembly overview – steering column switch module, mechanical ignition lock 10567
10 1 2 Assembly overview – steering column switch module, electronic ignition lock 10568
10 2 Removing and installing lock cylinder 10569
10 3 Removing and installing ignition key withdrawal lock solenoid -N376- 10572
10 4 Removing and installing ignition/starter switch 10572
10 5 Removing and installing steering column switch module 10574
10 6 Removing and installing steering column electronics control unit -J527- 10577
10 7 Removing and installing turn signal switch -E2- 10579
10 8 Removing and installing cruise control system switch -E45- 10581
10 9 Removing and installing intermittent wiper switch -E22- 10581
10 10 Removing and installing base for steering column combination switch 10582
10 10 1 Removing and installing base for steering column combination switch, vehicle with mechanical ignition lock 10582
10 10 2 Removing and installing base for steering column combination switch, vehicles with electronic ignition lock ignition lock 10582
10 11 Removing and installing steering lock housing 10582
11 Parking aid 10585
11 1 Assembly overview – parking aid 10585
11 2 Removing and installing parking aid control unit -J446- 10586
11 3 Removing and installing front parking aid warning buzzer -H22- 10587
11 4 Removing and installing rear parking aid warning buzzer -H15- 10588
11 4 1 Removing and installing rear parking aid warning buzzer -H15-, Coupé 10588
11 4 2 Removing and installing rear parking aid warning buzzer -H15-, Cabriolet 10588
11 5 Removing and installing front parking aid senders 10589
11 6 Removing and installing rear parking aid senders 10591
11 7 Renewing parking aid senders 10594
12 Blind Spot Monitor 10595
12 1 Assembly overview – Blind Spot Monitor 10595
12 2 Removing and installing warning lamp for Blind Spot Monitor -K303-/-K304- 10595
12 3 Removing and installing Blind Spot Monitor control unit -J1086-/-J1087- 10596
12 4 Calibrating Blind Spot Monitor 10597
12 4 1 Measurement location 10597
12 4 2 Preparatory measures for calibration 10598
12 4 3 Performing calibration 10603
96 – Lights, bulbs, switches – interior 10605
1 Lights 10605
1 1 Overview of fitting locations – lights in luggage compartment 10605
1 2 Overview of fitting locations – lights in roof trim 10606
1 3 Removing and installing footwell light -W9-/-W10- 10606
1 4 Removing and installing front footwell illumination bulb -L151-/-L152- 10607
1 5 Removing and installing Central locking SAFELOCK function warning lamp -K133- 10608
1 6 Removing and installing luggage compartment light -W3- 10609
1 7 Removing and installing illuminated vanity mirror -W20-/-W14- 10611
1 8 Renewing front interior light bulb -W1-/-W13-/-W19- 10613
2 Controls 10614
2 1 Overview of fitting locations – controls in dash panel 10614
2 2 Overview of fitting locations – controls in front doors 10615
2 3 Overview of fitting locations – controls in centre console 10616
2 4 Overview of fitting locations – controls in roof trim 10617
2 5 Removing and installing rotary light switch -EX1- 10618
2 6 Removing and installing regulator for switch and instrument illumination -E20- 10619
2 7 Removing and installing headlight range control regulator -E102- 10620
2 8 Removing and installing Start/Stop operation button -E693- 10620
2 9 Removing and installing parking aid button -E266- 10621
2 10 Removing and installing front passenger side airbag warning lamp -K145- 10622
2 11 Removing and installing hazard warning lights button -E229- 10623
2 12 Removing and installing exterior mirror adjuster -EX11- 10624
2 13 Removing and installing operating unit for window regulator in driver door -E512- 10625
2 14 Removing and installing window regulator switch in front passenger door -E107- 10626
2 15 Removing and installing driver side interior locking button for central locking system -E308- 10628
2 16 Removing and installing front passenger side interior locking button for central locking system -E309- 10629
2 17 Removing and installing rear lid remote release button -E233- 10630
2 18 Removing and installing tyre pressure monitor display button -E492- 10630
2 19 Removing and installing door contact switch -F2-/-F3- 10631
2 20 Removing and installing the starter button -E378- 10631
2 21 Removing and installing button 1 for tilting roof -E582- 10632
2 22 Removing and installing front interior light/reading light 10632
2 22 1 Removing and installing front interior light/reading light, Coupé 10632
2 22 2 Removing and installing front interior light/reading light, Cabriolet 10634
2 23 Removing and installing garage door operating unit -E284- 10636
2 24 Removing and installing interior monitoring deactivation switch -E267- 10636
3 Anti-theft alarm 10638
3 1 Assembly overview – interior monitor 10638
3 2 Removing and installing alarm horn -H12- 10640
3 3 Activating and deactivating anti-theft alarm 10640
3 4 Removing and installing interior monitoring sensor -G273- 10641
4 Immobiliser 10642
4 1 Removing and installing immobiliser control unit 10642
4 2 Removing and installing immobiliser reader coil 10642
4 2 1 Removing and installing immobiliser reader coil, vehicles with mechanical ignition lock 10642
4 2 2 Removing and installing immobiliser reader coil, vehicles with electronic ignition lock 10642
97 – Wiring 10644
1 Relay carriers, fuse holders, electronics boxes 10644
1 1 Overview of fitting locations – relay carriers, fuse holders, electronics boxes 10644
1 2 Removing and installing electronics box (E-box) 10645
1 3 Removing and installing relay and fuse holder in electronics box 10647
1 4 Removing and installing relay and fuse holder behind dash panel on driver side 10649
1 4 1 Removing and installing fuse holder behind dash panel on driver side 10649
1 4 2 Removing and installing onboard supply control unit -J519- 10649
2 Select Control units 10651
2 1 Overview of fitting locations – control units 10651
2 2 Removing and installing onboard supply control unit -J519- 10652
2 3 Removing and installing converter box -J935- 10652
2 4 Removing and installing garage door operation control unit 10653
2 5 Removing and installing data bus diagnostic interface -J533- 10653
3 Connectors 10654
3 1 Repairing electrical wiring harnesses and plug-in connections 10654
4 Releasing and dismantling connector housings 10655
5 Repairing aerial wires 10656
6 Vehicle diagnosis, testing and information systems 10657
D4B8066C601 Communication 10658
00 – Technical data 10662
1 Repair instructions 10662
1 1 General repair instructions 10662
1 2 Routing and attachment of lines 10662
1 3 Notes on repair of CAN bus wiring 10662
91 – Communication 10663
1 Infotainment system 10664
1 1 Layout – infotainment system 10664
1 2 Overview of fitting locations – Infotainment system 10668
1 3 Removing and installing control unit 1 for information electronics -J794- 10669
1 4 Renewing rotary knobs of display unit for front information display and operating unit control unit -J685- 10670
2 Sound system 10672
2 1 Components of sound system 10672
2 1 1 Components of sound system, vehicles with 8 loudspeakers (8RM) 10672
2 1 2 Components of sound system, vehicles with “Fender” sound system (8RU) 10673
2 2 Overview of fitting locations – sound system 10675
2 3 Removing and installing digital sound package control unit/amplifier 10676
2 4 Removing and installing rear treble loudspeakers -R14-/-R16- 10676
2 5 Removing and installing front treble loudspeakers -R20-/-R22- 10677
2 6 Removing and installing rear bass loudspeakers -R15-/-R17- 10677
2 7 Removing and installing front bass loudspeakers -R21-/-R23- 10678
2 8 Removing and installing subwoofer -R211- 10680
3 Aerial systems 10682
3 1 Components of aerial systems 10682
3 1 1 Overview – aerial systems, Coupé 10682
3 1 2 Overview – aerial systems, Cabriolet 10682
3 2 Overview of fitting locations – aerial systems 10683
3 2 1 Overview of fitting locations – aerial systems, Coupé 10683
3 2 2 Overview of fitting locations – aerial systems, Cabriolet 10685
3 3 Removing and installing frequency modulation (FM) frequency filter R178/R179 10686
3 3 1 Removing and installing frequency modulation (FM) frequency filter in negative wire -R178-, Coupé 10686
3 3 2 Removing and installing frequency modulation (FM) frequency filter in positive wire -R179-, Coupé 10686
3 4 Removing and installing aerial module 10687
3 4 1 Removing and installing right aerial module -R109-, Coupé 10687
3 4 2 Removing and installing left aerial module -R108-, Coupé 10687
3 4 3 Removing and installing right aerial module -R109-, Cabriolet 10688
3 4 4 Removing and installing left aerial module -R108-, Cabriolet 10689
3 5 Removing and installing satellite aerial -R170- 10690
3 5 1 Removing and installing satellite aerial -R170-, Coupé 10690
3 5 2 Removing and installing satellite aerial -R170-, Cabriolet, in dash panel 10690
3 5 3 Removing and installing satellite aerial -R170- (in spoiler), Cabriolet 10691
3 6 Removing and installing GPS aerial 10691
3 6 1 Removing and installing GPS aerial, Coupé 10691
3 6 2 Removing and installing GPS aerial, Cabriolet 10692
3 7 Removing and installing telephone aerial 10692
3 7 1 Removing and installing telephone aerial, Coupé 10692
3 7 2 Removing and installing telephone aerial, Cabriolet 10692
3 8 Removing and installing traffic data aerial 10693
3 9 Removing and installing roof aerial 10693
3 10 Removing and installing aerials for vehicle location system 10695
4 Radio 10696
4 1 Components of radio system 10696
4 1 1 Components of radio, Composition Colour 10696
4 1 2 Components of radio, Composition Media 10696
4 2 Removing and installing radio 10696
5 Telephone system 10697
5 1 Components of telephone system 10697
5 2 Overview of fitting locations – telephone system 10697
5 3 Removing and installing telephone microphone -R38- 10698
5 3 1 Removing and installing telephone microphone -R38-, Coupé 10698
5 3 2 Removing and installing telephone microphone -R38-, Cabriolet 10698
6 Navigation system 10699
6 1 Components of navigation system 10699
6 2 Overview of fitting locations – navigation system 10699
6 3 Removing and installing control unit for navigation system 10700
6 4 Removing and installing chip card reader control unit 10701
6 5 Removing and installing control unit for vehicle location system 10701
7 TV system 10702
7 1 Overview – TV system 10702
7 2 Overview of fitting locations – TV system 10703
7 3 Removing and installing TV tuner 10703
7 4 Removing and installing TV card reader 10704
8 Reversing camera system 10705
8 1 Components of reversing camera system 10705
8 2 Overview of fitting locations – reversing camera system 10705
9 Multifunction steering wheel 10707
9 1 Components of multifunction steering wheel 10707
9 2 Assembly overview – multifunction steering wheel 10707
9 3 Removing and installing steering wheel multifunction buttons -E441-/-E440- 10709
9 4 Removing and installing Tiptronic switch in steering wheel -E439-/-E438- 10711
10 Connection for external multimedia devices 10713
10 1 Components of connection for external multimedia units 10713
10 2 Removing and installing connection for external multimedia devices 10713
11 Car-Net 10714
11 1 Components of Car-Net 10714
11 2 Overview of fitting locations – Car-Net services 10714
11 3 Removing and installing emergency button -E276- 10715
11 3 1 Removing and installing emergency button -E276-, Coupé 10715
11 3 2 Removing and installing emergency button -E276-, Cabriolet 10716
11 4 Removing and installing emergency call module control unit and communication unit -J949- 10716
11 5 Removing and installing suppression filter -C10- 10717
D4B8068C2D0 Vehicle specific paint information 10719
00 – Technical data 10723
1 Explanation of symbols 10723
1 1 Sanding 10723
1 2 Seam sealing 10723
1 3 Cavity sealing 10725
2 Paint structure 10726
2 1 Structure of factory finish, cathodic dip primer 10726
2 2 Structure of factory finish, filler-primer 10727
2 3 Structure of factory finish, base coat 10730
2 4 Structure of factory finish, clear coat 10733
3 Areas exposed to stone chipping 10736
3 1 Body areas exposed to stone chipping 10736
4 Masked sectors 10738
4 1 Masking areas, front body 10738
4 2 Masking areas, rear body 10743
5 Seam sealing 10745
5 1 Seam seals, front body 10745
5 2 Seam seals, middle body 10750
5 3 Seam seals, rear body 10752
6 Underseal 10758
6 1 Undercoated areas, middle body 10758
6 2 Undercoated areas, rear body 10760
7 Cavity sealing 10762
7 1 Cavity sealing, overview of body 10762
7 2 Cavity sealing, front body 10763
7 3 Cavity sealing, middle body 10764
7 4 Cavity sealing, rear body 10766
D4B80457A6B 4 cylinder common rail engine (2 0 l 4V turbocharger) 10768
00 – Technical data 10776
1 Safety information 10776
1 1 Safety measures when working on fuel supply 10776
1 2 Safety measures when working on vehicles with a start/stop system 10777
1 3 Safety precautions when using testers and measuring instruments during a road test 10777
1 4 Safety precautions when working on the cooling system 10777
1 5 Safety precautions when working on SCR system 10778
2 Identification 10779
2 1 Engine number/engine data 10779
3 Repair instructions 10781
3 1 Rules for cleanliness 10781
3 2 Adapting learnt value for SCR system 10781
3 3 Foreign objects in engine 10781
3 4 Contact corrosion 10782
3 5 Routing and attachment of lines 10782
3 6 Fitting radiator and condensers 10782
4 Technical data 10784
4 1 Coolant 10784
10 – Removing and installing engine 10786
1 Removing and installing engine 10786
1 1 Removing engine 10786
1 2 Separating engine and gearbox 10796
1 3 Securing engine on engine and gearbox support 10797
1 4 Installing engine 10799
2 Assembly mountings 10803
2 1 Assembly overview – assembly mountings 10803
2 2 Removing and installing engine mounting 10805
2 3 Removing and installing gearbox mounting 10806
2 4 Removing and installing pendulum support 10807
2 5 Supporting engine in installation position 10808
2 6 Adjusting assembly mountings 10813
2 7 Checking adjustment of assembly mountings (engine and gearbox mountings) 10814
3 Engine cover panel 10815
3 1 Removing and installing engine cover 10815
13 – Crankshaft group 10816
1 Cylinder block (pulley end) 10816
1 1 Assembly overview – cylinder block (pulley end) 10816
1 2 Assembly overview – sealing flange, belt pulley end 10818
1 3 Removing and installing poly-V belt 10818
1 4 Removing and installing tensioner for poly V-belt 10820
1 5 Removing and installing vibration damper 10820
1 6 Removing and installing bracket for ancillaries 10821
1 7 Removing and installing engine support 10822
1 8 Removing and installing sealing flange on pulley end 10823
2 Cylinder block, gearbox end 10826
2 1 Assembly overview – cylinder block, gearbox end 10826
2 2 Removing and installing flywheel 10827
2 3 Removing and installing sealing flange on gearbox side 10828
3 Crankshaft 10837
3 1 Assembly overview – crankshaft 10837
3 2 Crankshaft dimensions 10838
3 3 Renewing needle bearing in crankshaft 10838
3 4 Measuring axial clearance of crankshaft 10840
4 Pistons and conrods 10842
4 1 Assembly overview – pistons and conrods 10842
4 2 Removing and installing pistons 10844
4 3 Measuring piston projection at TDC 10845
4 4 Checking pistons and cylinder bores 10847
4 5 Separating new conrod 10849
4 6 Checking radial clearance of conrods 10849
4 7 Removing and installing oil spray jets 10849
15 – Cylinder head, valve gear 10851
1 Cylinder head 10851
1 1 Assembly overview – cylinder head 10851
1 2 Assembly overview – cylinder head cover 10853
1 3 Removing and installing cylinder head 10855
1 4 Removing and installing cylinder head cover 10865
1 5 Removing and installing injector seals 10867
1 6 Removing and installing camshaft housing 10869
1 7 Checking compression 10873
2 Toothed belt drive 10875
2 1 Assembly overview – toothed belt cover 10875
2 2 Assembly overview – toothed belt 10876
2 3 Removing and installing toothed belt guard 10877
2 3 1 Removing and installing upper toothed belt guard 10877
2 3 2 Removing and installing lower toothed belt guard 10879
2 4 Removing and installing toothed belt 10880
2 5 Removing toothed belt from camshaft 10891
3 Valve gear 10896
3 1 Assembly overview – valve gear 10896
3 2 Measuring axial play of camshaft 10899
3 3 Removing and installing camshaft oil seal 10900
3 4 Removing and installing camshaft adjuster 10901
3 5 Removing and installing camshaft control valve 1 -N205- 10904
3 6 Removing control valve from and installing on inlet camshaft control valve 1 -N205- 10905
3 7 Checking hydraulic compensation elements 10907
3 8 Removing and installing valve stem seals 10908
3 8 1 Removing and installing valve stem seals (cylinder head installed) 10908
3 8 2 Removing and installing valve stem seals (cylinder head removed) 10911
4 Inlet and exhaust valves 10915
4 1 Checking valve guides 10915
4 2 Checking valves 10916
4 3 Valve dimensions 10916
17 – Lubrication 10917
1 Sump, oil pump 10917
1 1 Assembly overview – sump/oil pump 10917
1 1 1 Assembly overview – sump/oil pump, vehicles with two-piece sump 10917
1 1 2 Assembly overview – sump/oil pump, vehicles with one-piece sump 10920
1 2 Engine oil: 10922
1 3 Removing and installing sump 10922
1 4 Removing and installing lower part of sump 10925
1 5 Removing and installing upper part of sump 10929
1 6 Removing and installing oil pump 10933
1 7 Removing and installing oil level and oil temperature sender -G266- 10934
1 7 1 Removing and installing oil level and oil temperature sender -G266-, vehicles with two-piece sump 10934
1 7 2 Removing and installing oil level and oil temperature sender -G266-, vehicles with one-piece sump 10935
2 Engine oil cooler 10936
2 1 Removing and installing engine oil cooler 10936
3 Oil filter, oil pressure switch 10937
3 1 Assembly overview – oil filter housing, oil pressure switch 10937
3 2 Removing and installing oil pressure switch -F1- 10938
3 3 Removing and installing oil pressure switch for reduced oil pressure -F378- 10939
3 4 Checking oil pressure 10940
3 5 Removing and installing oil filter housing 10940
3 6 Removing and installing oil pressure regulating valve -N428- 10942
19 – Cooling 10944
1 Cooling system/coolant 10944
1 1 Connection diagram – coolant hoses 10944
1 2 Assembly overview – engine preheater 10946
1 3 Checking cooling system for leaks 10946
1 4 Draining coolant 10948
1 5 Filling with coolant 10949
1 5 1 Filling with coolant without electric vacuum pump 10949
1 5 2 Filling coolant with electric vacuum pump -VAS 6096/2- 10953
1 6 Checking electric vacuum pump -VAS 6096/2- 10959
1 7 Flushing cooling system 10959
1 8 Flushing cooling system, quick reference guide 10980
2 Coolant pump, regulation of cooling system 10982
2 1 Assembly overview – coolant pump, thermostat 10982
2 2 Assembly overview – electric coolant pump 10984
2 2 1 Assembly overview – charge air cooling pump -V188- and auxiliary pump for heating -V488-, version 1 10984
2 2 2 Assembly overview – charge air cooling pump -V188-, version 2 10985
2 2 3 Assembly overview – charge air cooling pump -V188-, version 3 10986
2 2 4 Assembly overview – auxiliary pump for heating -V488-, version 2 10987
2 2 5 Assembly overview – auxiliary pump for heating -V488-, version 3 10988
2 3 Assembly overview – coolant temperature sender 10989
2 3 1 Assembly overview – coolant temperature sender -G62- 10989
2 3 2 Assembly overview – radiator outlet coolant temperature sender -G83- 10990
2 4 Removing and installing electric coolant pump 10990
2 4 1 Removing and installing charge air cooling pump -V188-, version 1 and 2 10990
2 4 2 Removing and installing charge air cooling pump -V188-, version 3 10992
2 4 3 Removing and installing auxiliary pump for heating -V488-, version 1 10994
2 4 4 Removing and installing auxiliary pump for heating -V488-, version 2 10996
2 4 5 Removing and installing auxiliary pump for heating -V488-, version 3 10999
2 5 Removing and installing coolant pump 11002
2 6 Removing and installing thermostat 11003
2 7 Checking thermostat 11003
2 8 Removing and installing coolant valve for cylinder head -N489- 11004
2 9 Removing and installing coolant temperature sender -G62- 11004
2 10 Removing and installing radiator outlet coolant temperature sender -G83- 11005
3 Coolant pipes 11007
3 1 Assembly overview – coolant pipes 11007
3 2 Removing and installing coolant pipes 11008
3 2 1 Removing and installing coolant pipes (top front) 11008
3 2 2 Removing and installing lower front coolant pipe 11009
3 2 3 Removing and installing coolant pipe (front left) 11010
3 2 4 Removing and installing left coolant pipes 11011
3 2 5 Removing and installing rear coolant pipe 11013
3 2 6 Removing and installing rear right coolant pipe 11015
4 Radiator, radiator fan 11019
4 1 Assembly overview – radiator/radiator fan 11019
4 2 Removing and installing radiator 11021
4 3 Removing and installing water radiator for charge air cooling circuit 11022
4 4 Removing and installing radiator cowl with radiator fan 11025
4 5 Removing and installing radiator fan 11026
21 – Turbocharging/supercharging 11027
1 Turbocharger 11027
1 1 Assembly overview – turbocharger 11027
1 2 Removing and installing turbocharger 11029
1 3 Renewing vacuum unit for turbocharger 11033
1 4 Removing and installing connection for turbocharger 11038
2 Charge air system 11040
2 1 Assembly overview – charge air system 11040
2 2 Removing and installing charge pressure sender -G31- 11042
2 3 Checking charge air system for leaks 11042
23 – Mixture preparation – injection 11045
1 Injection system 11045
1 1 Schematic overview – fuel system 11045
1 2 Overview of fitting locations – injection system 11046
1 3 Filling/bleeding fuel system 11052
1 4 Checking fuel system for leaks 11052
2 Vacuum system 11053
2 1 Connection diagram – vacuum system 11053
2 2 Checking vacuum system 11053
3 Injectors/high-pressure accumulator (rail) 11055
3 1 Assembly overview – injectors 11055
3 2 Assembly overview – fuel rail 11057
3 3 Adapting correction values for injectors 11058
3 4 Testing injectors 11058
3 5 Checking return flow rate of injectors with engine running 11058
3 6 Checking return flow rate of injectors at starter speed 11061
3 7 Testing jammed-open injectors 11062
3 8 Removing and installing injectors 11063
3 9 Removing and installing high-pressure lines 11066
3 9 1 Removing high-pressure pipe between fuel rail and high-pressure pump 11066
3 9 2 Installing high-pressure line 11066
3 10 Removing and installing fuel rail 11068
4 Air filter 11070
4 1 Assembly overview – air filter housing 11070
4 2 Removing and installing air filter housing 11071
5 Intake manifold 11074
5 1 Assembly overview – intake manifold 11074
5 2 Removing and installing intake manifold 11076
5 3 Removing and installing throttle valve module -J338- 11079
6 Senders and sensors 11082
6 1 Removing and installing fuel pressure regulating valve -N276- 11082
6 1 1 Versions of fuel pressure regulating valve -N276- 11082
6 1 2 Removing and installing fuel pressure regulating valve, version 1 11083
6 1 3 Removing and installing fuel pressure regulating valve -N276-, version 2 11086
6 2 Checking fuel pressure regulating valve -N276- 11088
6 3 Removing and installing fuel pressure sender -G247- 11089
6 4 Removing and installing air mass meter -G70- 11090
6 5 Removing and installing pressure differential sender -G505- 11092
6 6 Removing and installing exhaust gas pressure sensor 1 -G450- 11093
6 7 Removing and installing NOx sender 2 -G687- 11094
6 8 Removing and installing control unit for NOx sender -GX30- 11096
6 8 1 Removing and installing control unit for NOx sender -GX30-, version secured with clips 11096
6 8 2 Removing and installing control unit for NOx sender -GX30-, version secured with bolts 11099
6 9 Removing and installing charge air temperature sender before charge air cooler -G810-/charge air temperature sender after charge air cooler -G811- 11101
6 10 Removing and installing fuel temperature sender -G81- 11102
6 11 Removing and installing temperature and pressure sender for low-pressure fuel system -GX20- 11103
7 Engine control unit 11105
7 1 Removing and installing engine (motor) control unit -J623- 11105
7 2 Removing and installing engine (motor) control unit -J623- with protective housing 11106
8 High-pressure pump 11109
8 1 Assembly overview – high-pressure pump 11109
8 2 Removing and installing high-pressure pump 11109
9 Lambda probe 11113
9 1 Assembly overview – Lambda probe 11113
9 1 1 Assembly overview – Lambda probe; vehicles without SCR system 11113
9 1 2 Assembly overview – Lambda probe; vehicles with SCR system 11114
9 2 Removing and installing Lambda probe 11115
9 2 1 Removing and installing Lambda probe 1 before catalytic converter -GX10- 11115
9 2 2 Removing and installing Lambda probe after catalytic converter -G130- 11116
26 – Exhaust system 11118
1 Exhaust pipes and silencers 11118
1 1 Assembly overview – silencers 11118
1 2 Assembly overview – front exhaust pipe 11120
1 3 Removing and installing front exhaust pipe 11121
1 4 Separating exhaust pipes from silencers 11122
1 5 Removing and installing rear silencer 11123
1 6 Aligning exhaust system free of stress 11124
1 7 Checking exhaust system for leaks 11124
1 8 Installation position of clamp 11125
1 9 Align end exhaust pipes 11125
2 Emission control 11127
2 1 Assembly overview – emission control 11127
2 2 Removing and installing emission control module 11129
2 3 Removing and installing exhaust flap control unit -J883- 11135
3 SCR system (selective catalytic reduction) 11137
3 1 Assembly overview – tank for reducing agent 11137
3 2 Assembly overview – reducing agent delivery line 11139
3 3 Assembly overview – delivery module for reducing agent 11140
3 4 Assembly overview – injector for reducing agent 11141
3 5 Removing and installing reducing agent tank 11142
3 6 Removing and installing reducing agent supply line 11144
3 6 1 Removing and installing front part of reducing agent supply line 11144
3 6 2 Removing and installing rear part of reducing agent supply line 11145
3 7 Removing and installing reducing agent supply line 11146
3 7 1 Removing and installing front part of reducing agent supply line 11146
3 7 2 Removing and installing rear part of reducing agent supply line 11148
3 8 Disconnecting reducing agent supply line 11150
3 9 Removing and installing delivery module for reducing agent 11154
3 10 Removing and installing injector for reduction agent -N474- 11156
3 11 Removing and installing control unit for reducing-agent heater -J891- 11157
3 12 Draining reducing agent tank 11158
4 Exhaust gas temperature regulation 11161
4 1 Assembly overview – exhaust gas temperature regulation 11161
4 1 1 Assembly overview – exhaust gas temperature regulation, vehicles without SCR system 11161
4 1 2 Assembly overview – exhaust gas temperature regulation, vehicles with SCR system 11163
4 2 Removing and installing exhaust gas temperature sender 1 -G235- 11164
4 3 Removing and installing exhaust gas temperature sender 2 -G448- 11165
4 4 Removing and installing exhaust gas temperature sender 3 -G495- 11168
4 5 Removing and installing exhaust gas temperature sender 4 -G648- 11169
5 Exhaust gas recirculation 11172
5 1 Assembly overview – exhaust gas recirculation 11172
5 1 1 Assembly overview – exhaust gas recirculation 11172
5 1 2 Assembly overview – exhaust gas recirculation, vehicles for USA 11174
5 2 Assembly overview – exhaust gas recirculation valve 1 -GX5- 11176
5 3 Removing and installing exhaust gas recirculation cooler 11176
5 4 Checking exhaust gas recirculation cooler for leaks 11179
5 5 Removing and installing exhaust gas recirculation valve 1 -GX5- 11182
5 6 Removing and installing exhaust gas recirculation valve 2 -GX6- 11183
5 6 1 Removing and installing exhaust gas recirculation valve 2 -GX6- 11183
5 6 2 Removing and installing exhaust gas recirculation valve 2 -GX6-, vehicles for USA 11184
5 7 Removing and installing exhaust gas recirculation temperature sensor -G98- 11186
28 – Glow plug system 11188
1 Glow plug system 11188
1 1 Assembly overview – glow plug system 11188
1 2 Removing and installing glow plug 11190
1 3 Removing and installing automatic glow period control unit -J179- 11192
1 4 Removing and installing Hall sender -G40- 11193
1 5 Removing and installing engine speed sender -G28- 11193
D4B80609EAF Air conditioning systems with refrigerant R1234yf – General information 11195
00 – Technical data 11201
1 Safety information 11201
1 1 Safety precautions when working on air conditioning systems 11201
1 2 Safety precautions when handling refrigerants 11202
1 3 Safety measures when working on vehicles with a start/stop system 11202
1 4 Safety precautions when using air conditioner service stations 11202
1 5 Safety measures for working on vehicles with high-voltage system 11203
1 6 Safety precautions when working in the vicinity of high-voltage components 11204
1 7 Safety precautions when working on pressure vessels 11204
2 Laws and regulations 11205
2 1 Legal regulations and standards 11205
2 2 Charging refrigerant circuit with different refrigerants 11206
2 3 Occupational health and safety 11207
3 Repair notes 11208
3 1 Rules for cleanliness 11208
3 2 Refrigerant circuit seals 11208
3 3 Refrigerant and refrigerant oil 11209
3 3 1 Important repair notes for refrigerant and refrigerant oil 11209
3 3 2 Refrigerant oil 11210
3 4 Handling pressure vessels 11211
3 5 Handling refrigerants 11212
4 Identification 11214
4 1 Notice for refrigerant circuit 11214
5 Technical data 11215
5 1 Refrigerant capacity 11215
5 2 Refrigerant oil capacities 11215
5 3 Safety data sheets 11215
6 Basic technical and physical properties 11216
6 1 Basics of air conditioning technology 11216
6 1 1 Physical properties of air conditioning system 11216
6 1 2 Pressure and boiling point of refrigerant 11217
6 1 3 Vapour pressure table for refrigerant 11218
6 2 Physical properties 11220
6 2 1 Refrigerant R1234yf 11220
6 2 2 Potential risks with refrigerant R1234yf 11220
6 2 3 Physical and chemical properties of refrigerant R1234yf 11221
6 2 4 Critical point 11221
6 2 5 Environmental aspects of refrigerant R1234yf 11222
6 2 6 Trade names and designations of refrigerant R1234yf 11222
6 2 7 Colour and odour of R1234yf refrigerant 11223
6 2 8 Vapour pressure of R1234yf refrigerant 11223
6 2 9 Physical properties of R1234yf refrigerant 11223
6 2 10 How R1234yf refrigerant reacts to metals and plastics 11223
6 2 11 Critical temperature / critical pressure of R1234yf refrigerant 11224
6 2 12 Water content of R1234yf refrigerant 11224
6 2 13 Flammability / decomposition of R1234yf refrigerant 11224
6 2 14 Charge factor of refrigerant R1234yf 11224
6 2 15 Evidence of leaks in a refrigerant circuit with R1234yf refrigerant 11225
6 2 16 Analysis of refrigerant R1234yf 11225
6 2 17 Returning contaminated R1234yf refrigerant for analysis, processing or disposal 11226
6 3 Product characteristics 11227
6 4 Function and role of air conditioning system 11227
6 4 1 Principle of operation 11227
6 4 2 Comfort 11228
6 4 3 Environmental aspects 11228
6 5 Other reference material 11229
87 – Air conditioning system 11230
1 Refrigerant circuit 11230
1 1 System overview – refrigerant circuit 11230
1 1 1 System overview – refrigerant circuit with expansion valve and receiver 11230
1 1 2 System overview – refrigerant circuit with restrictor and reservoir 11232
1 1 3 System overview – refrigerant circuit with electrically driven air conditioner compressor (with and without battery cooling module) 11233
1 2 General description – components of refrigerant circuit 11236
1 2 1 Layout and function of refrigerant circuit 11236
1 2 2 Mechanical air conditioner compressor 11237
1 2 3 Electrical air conditioner compressor for hybrid vehicles 11240
1 2 4 Condenser 11243
1 2 5 evaporator 11244
1 2 6 Reservoir 11246
1 2 7 Heat exchanger for heat pump mode 11246
1 2 8 Liquid receiver 11247
1 2 9 Restrictor 11247
1 2 10 Receiver 11249
1 2 11 Expansion valve (with and without shut-off valve) 11251
1 2 12 Refrigerant shut-off valves 11253
1 2 13 Refrigerant line with internal heat exchanger 11255
1 2 14 Quick release couplings of refrigerant lines 11256
1 2 15 Seals 11257
1 2 16 Pipes and hoses in refrigerant circuit 11258
1 2 17 High-pressure safety valve 11258
1 2 18 Non-return valves 11260
1 2 19 Quick-release coupling connections in refrigerant circuit 11261
1 2 20 Connections with valve for switches in refrigerant circuit 11265
1 2 21 Pressure senders and switches in refrigerant circuit 11266
1 2 22 Refrigerant pressure and temperature sender 11267
1 2 23 Air conditioner compressor regulating valve -N280- 11270
1 2 24 Refrigerant temperature sender 11271
1 3 Possible complaints 11272
1 3 1 Prerequisites for investigating a complaint 11272
1 3 2 Possible complaints 11272
1 3 3 Odours from heater and air conditioning unit 11274
1 4 Investigating leaks 11276
1 4 1 General information about investigating leaks in the refrigerant circuit 11276
1 4 2 Searching for leaks in refrigerant circuits using an electronic leak detector 11277
1 4 3 Searching for leaks with UV leak detection system 11278
1 4 4 Detecting leaks in a vacuum test using air conditioner service station, or in a pressure test 11284
1 4 5 Detecting leaks in a pressure test (with nitrogen or compressed air) 11285
1 5 Renewing components 11287
1 5 1 General information about renewing components 11287
1 5 2 Renewing leaking or damaged components of empty refrigerant circuit (apart from air conditioner compressor and receiver) 11288
1 5 3 Renewing leaking or damaged components of charged refrigerant circuit (apart from air conditioner compressor and receiver) 11290
1 5 4 Renewing air conditioner compressor with no need to clean refrigerant circuit 11291
1 5 5 Renewing air conditioner compressor due to leaks or internal damage 11294
1 5 6 Renewing desiccant cartridge / receiver after cleaning refrigerant circuit 11295
1 5 7 Renewing receiver with no need to clean refrigerant circuit 11297
1 5 8 Renewing desiccant cartridge / desiccant bag with no need to clean refrigerant circuit 11298
1 6 Cleaning refrigerant circuit 11299
1 6 1 General information about cleaning refrigerant circuit 11299
1 6 2 Preparations for cleaning refrigerant circuit (flushing with R1234yf refrigerant) 11301
1 6 3 Refrigerant circuit cleaning procedure 11305
1 6 4 Principle circuit diagrams for cleaning (flushing circuits) – refrigerant circuit with expansion valve and receiver 11305
1 6 5 Principle circuit diagrams for cleaning (flushing circuits) – refrigerant circuit with restrictor and receiver (without high-voltage system) 11310
1 6 6 Adapters for setting up flushing circuits 11313
1 6 7 General information about blowing through with compressed air or nitrogen 11326
1 6 8 Blowing through refrigerant circuit with compressed air or nitrogen 11330
1 7 Checking pressures with pressure gauge 11331
1 7 1 Display on pressure gauges 11331
1 7 2 Pressure gauges enable the following test and measurement work 11332
2 Working with air conditioner service station 11335
2 1 Working with air conditioner service station 11336
2 2 Connecting air conditioner service station to refrigerant circuit 11338
2 3 Performing gas analysis of refrigerant 11341
2 4 Purging refrigerant circuit 11344
2 5 Evacuating refrigerant circuit 11347
2 6 Charging refrigerant circuit 11353
2 7 Bringing air conditioning system into service after charging 11356
2 8 Switching off air conditioner service station and separating from refrigerant circuit 11358
2 9 Charging refrigerant in reservoir 11360
2 10 Emptying air conditioner service station 11361
2 11 Cleaning electrical air conditioning compressor 11361
2 12 Cleaning refrigerant circuit 11364
2 13 Filling contaminated refrigerant in a recycling cylinder for analysis, processing or disposal 11367
2 13 1 Filling contaminated refrigerant into recycling cylinder using extraction unit -VAS 581 011- 11367
2 13 2 Filling contaminated refrigerant into recycling cylinder using extraction unit -VAS 581 007- 11368
2 14 Checking pressures 11372
2 14 1 General information on checking pressures in the refrigerant circuit 11372
2 14 2 Pressures and temperatures in refrigerant circuit 11374
2 14 3 Checking pressures in the refrigerant circuit with the ignition switched off 11378
2 14 4 Checking pressures with air conditioning system switched on – vehicles with mechanical air conditioning compressor 11385
2 14 5 Checking pressures with air conditioning system switched on – vehicles with electrical air conditioning compressor 11407
3 Testing equipment and tools 11460
3 1 Tools and materials available from distribution centre or importer 11460
3 2 Tools and materials available commercially 11460
D4B80796BA2 Wheels and Tyres Guide General Information 11462
44 – Wheels, tyres, vehicle geometry 11466
1 Instructions on using the guide 11466
1 1 Overview 11466
1 1 1 Wheels and Tyres Guide – General Information 11466
1 1 2 Wheels and Tyres Guide – Vehicle-specific Section 11466
1 2 General information 11466
1 3 Notes 11467
1 4 Explanations regarding world regions 11468
1 5 Definition of tyre package 11468
1 6 Procedure for determining the required tyre package 11469
1 6 1 Determining the required tyre package via PR number 11469
1 6 2 Determining the required tyre package via version key in the vehicle registration certificate part 1 11469
1 7 Vehicle registration certificate part 1 11470
2 Legislative and technical conditions 11472
2 1 Legislative conditions 11472
2 1 1 Permissible wheel and tyre combinations in Germany 11472
2 1 2 Vehicles with Tyre Pressure Monitoring System 11472
2 2 Technical conditions 11473
2 3 Load-carrying capacity depending on vehicle speed, winter tyres 11473
2 4 Vehicle registration documents since 1 10 2005 11475
2 5 COC document (EEC Certificate of Conformity) 11476
2 6 EU general type approval number, sales type and sales or trade designation 11476
3 Wheel change 11478
3 1 Fitting instructions 11478
3 2 Protecting wheel centring seat against corrosion 11481
3 3 Fitting wheels 11482
3 4 Position of anti-theft wheel bolts for steel wheels 11482
4 Fitting tyre 11483
4 1 Pressing tyre off wheel rim 11483
4 2 Removing tyre sealant 11483
4 3 Removing tyre from wheel 11484
4 3 1 Removing tyres, wheels without and with tyre pressure monitoring 11484
4 3 2 Removing tyres, run-flat tyres, ultra-high-performance tyres 11485
4 4 Ensuring proper assembly temperature for tyres 11487
4 5 Mounting tyre 11488
4 5 1 Mounting tyre, wheels without and with tyre pressure monitoring 11488
4 5 2 Mounting tyre, run-flat tyres, ultra-high performance tyres 11490
4 6 Matching wheel rims and tyres 11493
4 7 Checking radial and lateral runout of wheels and tyres 11494
4 7 1 Checking radial and lateral runout of wheels and tyres, tolerances 11494
4 7 2 Checking radial and lateral runout on wheels and tyres with tyre gauge 11494
4 8 Matching wheels and tyres 11495
4 9 Balancing wheel 11496
4 9 1 Conditions 11496
4 9 2 Balancing wheel on stationary wheel balancer 11497
4 9 3 Balancing wheel with finish balancer 11500
4 9 4 Checking radial and lateral run-out on wheel rim 11501
4 10 Tyre sealant disposal 11502
5 Tyre pressure monitoring system 11503
5 1 System description – tyre pressure monitoring system 11503
5 1 1 System description – tyre pressure monitoring system with indirect measurement (Tyre Pressure Loss Indicator) 11503
5 1 2 System description – tyre pressure monitoring system with direct measurement (Tyre Pressure Monitoring System) 11504
5 1 3 System description – tyre pressure monitoring system, tyre pressure monitoring system (TPMS) with autolocation 11505
5 2 Overview of fitting locations – tyre pressure monitor system 11505
5 2 1 Overview of fitting locations – Tyre Pressure Monitoring System (TPMS) with autolocation 11505
5 3 Assembly overview – tyre pressure sensor 11507
5 3 1 Assembly overview – tyre pressure sensor, tyre pressure sensor with valve 11507
5 3 2 Assembly overview – tyre pressure sensor, tyre pressure sensor without valve, version 1 11508
5 3 3 Assembly overview – tyre pressure sensor, tyre pressure sensor without valve, version 2 11509
5 4 Removing and installing tyre pressure sensor -G222-/-G223-/-G224-/-G225- 11510
5 4 1 Removing and installing tyre pressure sensor, tyre pressure sensor with valve 11510
5 4 2 Removing and installing tyre pressure sensor, tyre pressure sensor without valve, version 1 (customer service version) 11511
5 4 3 Removing and installing tyre pressure sensor, tyre pressure sensor without valve, version 1 (production version) 11512
5 4 4 Removing and installing tyre pressure sensor -G222-/-G223-/-G224-/-G225-, version 2 11514
5 5 Removing and installing tyre pressure monitor control unit -J502- 11517
5 5 1 Removing and installing Tyre Pressure Monitoring System control unit -J502-, Arteon 2018, Passat 2015, Passat Estate 2015 11517
5 5 2 Removing and installing tyre pressure monitoring system control unit -J502-, Touran 11518
6 Wheel bolts 11520
6 1 Wheel bolts, versions 11520
6 2 Wheel bolts, anti-theft wheel bolt 11521
6 3 Wheel bolts, adapter sets for anti-theft wheel bolts 11521
7 Information on tyres 11524
7 1 Identification markings on the tyre sidewall 11524
7 2 Tyre dimension 11526
7 3 Load rating code/load index (LI) 11526
7 4 Speed rating code 11527
7 5 EU tyre label 11527
7 5 1 EU tyre label, summary 11527
7 5 2 EU tyre label, objectives 11528
7 5 3 EU tyre label, categories 11529
7 6 Structure of a radial belted tyre 11532
7 6 1 Cross section of a radial belted tyre 11532
7 6 2 Run-flat tyres, structure and identification of a SST tyre 11533
7 6 3 Run-flat tyres, seal inside technology 11534
7 7 Run-flat tyre, SST (Self Supporting Tyre) 11536
7 7 1 Run-flat tyres – general information 11536
7 7 2 Run-flat tyres, retrofitting/requirements when using run-flat tyres 11537
7 7 3 Run-flat tyres, repair work 11538
7 8 Tyre storage 11538
7 9 Reinforced and Extra Load (XL) tyres 11538
7 10 Winter tyres 11539
7 11 Winter tyres with speed symbol V 11541
7 12 Rolling resistance optimised tyres 11542
7 13 Tyre ageing 11542
7 14 Tyres with flange protection 11544
7 15 Tyre sizes for vehicles with four-wheel drive 11544
7 16 Increase in temperature due to insufficient tyre pressure 11545
8 Tyre sealant 11546
8 1 Models with breakdown set 11546
8 2 Storage life 11546
8 3 Waste disposal 11546
9 Information on wheel rims 11547
9 1 Structure of wheel rim 11547
9 2 Identification 11548
9 3 Composite wheels 11548
9 4 Care and maintenance of alloy wheel rims 11548
9 5 Restoring alloy wheels 11549
9 6 Removing and installing hub cover for alloy wheels with open threaded connection 11549
9 7 Renewing trim elements 11550
9 7 1 Renewing trim elements, bonded trim elements 11550
9 7 2 Renewing trim elements, bolted trim elements 11554
9 8 Removing and installing valve 11556
9 8 1 Removing and installing valve, description of the valve 11556
9 8 2 Removing and installing valve, rubber valve 11556
9 8 3 Removing and installing valve, metal valve 11557
10 Handling problems 11559
10 1 Rolling noise 11559
10 1 1 General notes on tyre noise 11559
10 1 2 Flat spots (from locking wheels) 11560
10 2 Vehicle pulls to one side 11561
10 2 1 General information 11561
10 2 2 Conicity 11561
10 2 3 Remedies when vehicle pulls to one side 11562
10 2 4 Strategic rotation of wheels for non-directional tyres 11563
10 2 5 Strategic rotation of wheels having unidirectional tyres 11564
10 3 Vibration 11565
10 3 1 Vibration, causes for vibration 11565
10 3 2 Vibration, conducting a road test before balancing wheels 11565
10 3 3 Vibration, vibration control system 11566
10 4 Eliminating flat spots caused by storage or handling 11566
11 Evaluating tyres 11568
11 1 Flat spots caused by storage or handling 11568
11 2 Undulations 11568
11 3 Saw-tooth wear 11569
11 4 Flat spots caused by hard braking 11569
11 5 Swellings in the tyre sidewall 11569
11 6 Cuts 11571
11 7 Damage caused by foreign bodies 11571
11 8 Stripped profile 11571
11 9 Tyre damage due to insufficient tyre pressure 11572
11 10 Checking tyres 11572
11 11 Damage caused when fitting 11573
12 Tyre wear 11575
12 1 Factors influencing the service life of tyres 11575
12 2 Saw-tooth wear 11576
12 3 Wear behaviour of high-speed tyres 11576
12 4 Measuring tread depth 11577
12 5 One-sided wear 11577
12 6 Outer shoulder wear 11580
12 7 Diagonal washout 11581
12 8 Wear in middle of tyre 11581
12 9 Permissible deviation in tread depth 11582
13 Exploded view of components 11583
13 1 Assembly overview – wheel 11583
14 Snow chains 11585
14 1 Assembly and use of snow chains 11585
15 Regular and temporary spare wheels, recommended temporary spare tyres 11586
15 1 Spare wheel with yellow sticker 11586
15 2 Temporary spare wheels and recommended temporary spare tyres 11587
15 2 1 Arteon 2018 11587
15 2 2 Atlas 2017 11587
15 2 3 Golf 2013, e-Golf 2014 11587
15 2 4 Golf 2017, e-Golf 2017 11587
15 2 5 Golf SV 2015 11588
15 2 6 Golf Estate 2014 11588
15 2 7 Golf Estate 2017 11588
15 2 8 Passat 2015, Passat Estate 2015 11588
15 2 9 Polo 2018 11589
15 2 10 Tiguan 2016 11589
D4B802605A6 General information Paint passenger vehicles 11590
00 – Technical data 11596
1 Safety information 11596
1 1 Safety precautions when painting natural gas-powered vehicles 11596
1 2 Safety precautions when painting electric drive vehicles 11597
2 General information 11598
2 1 Paintwork structure of a factory finish 11598
2 2 Paint structure of service department finish 11601
2 2 1 Paintwork structure, base coat 11601
2 2 2 Paintwork structure, metallic effect 11604
2 3 Fundamental approach to dealing with areas sanded through to the substrate (bare metal surface) 11606
2 4 Reduced paint structure in engine compartment and inside of bonnet 11606
2 5 Instructions for work on underbody and stone chip protection 11606
2 6 Work instruction for window flange area 11608
2 7 Pre-treatment of bonded surfaces when renewing laser-welded roofs 11610
2 8 Corrosion protection measures for wing surface in contact with wheel housing liner 11614
2 9 Notes on treating corroded fold areas 11615
2 10 Corrosion protection for body components, add-on components and welded components 11617
2 11 Painting parking aid sensor 11618
2 12 ACC – Adaptive Cruise Control 11620
2 13 Instructions for painting bumper cover in area of lane change assist control unit 11620
3 Genuine products 11622
3 1 Paint products in customer service 11622
3 2 General application instructions for repair and painting systems 11623
3 2 1 Aqua Premium – application instructions for water-based products 11623
3 2 2 Setting gloss level of HS clear coats and HS top coats with matting additive 11626
3 2 3 Setting gloss level of 2-pack HS clear coats with 2-pack clear coat, matt 11636
3 2 4 Repair paintwork system for matt-finished vehicles 11638
3 2 5 Paintwork system for plastic components 11643
3 2 6 Aqua Premium system, blending system for 2-stage colours 11651
3 2 7 Aqua Premium system, blending system for 3-stage colours 11660
3 2 8 Aqua Premium system, product preparation for processing 11667
3 2 9 Aquaplus design and multi-colour painting 11674
3 2 10 Processing instructions for paint with limited hiding power 11679
3 3 Filler 11679
3 3 1 2-pack steel filler set 11679
3 3 2 2-pack fine filler 11683
3 3 3 2-pack fine filler, flexible 11687
3 3 4 2-pack spray filler 11690
3 3 5 2-pack IR premium filler 11696
3 3 6 2-pack epoxy resin filler 11701
3 4 Priming metal 11705
3 4 1 1-pack anti-corrosion wash primer 11705
3 4 2 1-pack wash primer 11710
3 4 3 2-pack wash primer 11715
3 5 Priming plastic materials 11721
3 5 1 Adhesion promoter (transparent) 11721
3 6 Surfacer 11725
3 6 1 2-pack HS Vario surfacer 11725
3 6 2 2-pack HS premium surfacer 11735
3 6 3 2-pack HS Performance surfacer 11744
3 6 4 2-pack primer surfacer for plastics 11753
3 6 5 2-pack HS wet-on-wet surfacer 11759
3 6 6 2-pack base filler, professional 11769
3 7 Top coats 11786
3 7 1 2-pack HS top coat 11786
3 7 2 Aquaplus system, uni (solid-colour) and metallic colours 11795
3 7 3 Aquaplus system (pearlescent and heliochrome) 11803
3 7 4 Aquaplus blending system 11811
3 7 5 Aqua Premium system 11817
3 7 6 Aqua Premium blending system 11830
3 7 7 Aqua Premium system (painting rims) 11837
3 8 Clear coats 11846
3 8 1 2-pack HS clear coat 11846
3 8 2 2-pack MS matt clear coat 11853
3 8 3 2-pack HS Vario clear coat 11859
3 8 4 2-pack HS optimum clear coat 11867
3 8 5 2-pack HS optimum plus clear coat 11873
3 8 6 2-pack HS brilliant clear coat 11878
3 8 7 2-pack HS brilliant plus clear coat 11883
3 8 8 2-pack HS Performance clear coat 11889
3 8 9 Blender 11895
3 9 Hardener 11900
3 9 1 2-pack HS hardener 11900
3 9 2 2-pack VHS hardeners and 2-pack VHS Performance hardeners 11904
3 9 3 Hardener for 2-pack primer surfacer 11908
3 9 4 Aqua Premium hardener 11908
3 10 Thinners 11909
3 10 1 2-pack thinner 11909
3 10 2 HS spot thinner 11912
3 10 3 Demineralised water 11914
3 11 Anti-corrosion materials 11915
3 11 1 Anti-corrosion wax 11915
3 11 2 Cavity sealant 11916
3 11 3 Anti-corrosion wax (in aerosol can) 11919
3 12 Underseal 11920
3 12 1 Permanent underseal -D 314 D36 M2-, grey 11920
3 12 2 Permanent underseal -D 314 D37 M2-, black 11923
3 12 3 Permanent underseal -D 314 D38 M2-, light 11926
3 12 4 Underseal -D 314 D39 A3-, black 11929
3 13 Stone deflector 11931
3 13 1 Stone chip guard -AKR 311 KD1 05- 11931
3 13 2 Stone chip guard -AKR 311 KD1 10- 11933
3 14 Wax-based underseal 11940
3 14 1 Wax-based underseal -D 316 D38 A2- 11940
3 14 2 Wax-based underseal -D 316 000 A1- 11942
3 14 3 Spray wax -D 322 100 M2- 11944
3 15 Sealing materials 11945
3 15 1 Polyurethane adhesive sealant (bonding compound) 11945
3 15 2 Sprayable sealant 11948
3 15 3 Adhesive sealant 11951
3 16 Cleaning agents 11953
3 16 1 Silicone remover 11953
3 16 2 Cleaner for plastics 11955
3 16 3 Cleaner for plastics, anti-static 11956
3 16 4 Industrial dirt remover 11956
3 17 SprayMax system 11958
3 17 1 1-pack anti-corrosion primer 11958
3 17 2 1-pack test paint 11962
3 17 3 1-pack clear coat 11965
3 17 4 1-pack wash primer 11968
3 17 5 1-pack Fill Clean spray can -LLS MAX 099-/1-pack Fill Clean spray can -LLS MAX 100- – Aquaplus system 11973
3 17 6 1-pack fill clean spray can -LLS MAX 112-, Aqua Premium system 11980
3 17 7 2-pack surfacer 11988
3 17 8 2-pack HS Performance surfacer 11995
3 17 9 2-pack clear coat 12003
3 17 10 2-pack epoxy primer surfacer 12008
3 17 11 2-pack wash primer 12014
3 17 12 Silicone remover -LLS MAX 007- 12020
3 17 13 Slow-drying silicone remover -LLS MAX 008- 12022
3 17 14 Blender 12025
3 17 15 Adhesion promoter 12027
3 18 Additional materials 12031
3 18 1 Matting additive -ALN 775 106- 12031
3 18 2 Matting additive -LVM 769 810 A2- 12038
3 18 3 Texture additive 12041
3 18 4 Blending additive for Aquaplus 12047
3 18 5 Additive for Aqua Premium 12048
4 Workshop equipment 12049
4 1 Tools 12049
4 1 1 Spray can filling device -VAS 6425- 12049
4 1 2 Paint thickness tester -VAS 6272- 12050
4 1 3 Paint thickness tester -VAS 6197- 12051
4 1 4 Paint thickness tester -VAS 5278- 12051
4 1 5 Stone chip tester -VAS 5102A- 12052
4 1 6 Pneumatic brush grinder set -VAS 6446- 12053
4 1 7 Brush grinder set -VAS 6776- 12053
4 1 8 Suction feed spray-gun -V A G 1538- 12055
4 1 9 Infrared heater -VAS 6873- 12056
4 1 10 Stand -VAS 6873/1- 12056
4 1 11 Infrared heater -VAS 6874- 12057
4 1 12 Infrared heater -VAS 6875- 12058
4 1 13 Infrared heater -VAS 6876- 12058
4 1 14 Infrared heater -VAS 6877- 12059
4 1 15 Infrared heater -VAS 6878- 12060
4 1 16 Infrared heater -VAS 6879- 12061
4 2 Tack cloths 12061
4 2 1 Tack cloth -VAS 6177- 12061
4 2 2 Buffing cloth, white -VAS 6176- 12062
D4B8027068B Air conditioning systems with refrigerant R134a General information 12063
00 – Technical data 12069
1 Safety information 12069
1 1 Safety precautions when working on air conditioning systems 12069
1 2 Safety precautions when working on high-voltage system 12070
1 3 Safety precautions when working in the vicinity of high-voltage components 12070
1 4 Safety precautions when tow-starting or towing 12071
2 Repair instructions 12072
2 1 Rules for cleanliness when working on high-voltage system 12072
3 General information on air conditioning 12073
3 1 Other reference material 12073
3 2 Basics of air conditioning technology 12073
3 2 1 Physical principles: 12073
3 2 2 Heat always flows from a warmer to a colder substance 12074
3 2 3 Pressure and boiling point 12074
3 3 Vapour pressure table for refrigerant R134a 12075
3 4 Refrigerant R134a 12076
3 4 1 Physical data of refrigerant R134a 12076
3 4 2 Critical point 12076
3 4 3 Environmental aspects of refrigerant R134a 12077
3 5 Properties of refrigerant R134a 12077
3 5 1 Trade names and designations 12077
3 5 2 Colour 12077
3 5 3 Vapour pressure 12077
3 5 4 Physical properties of R134a 12078
3 5 5 Effects on metal 12078
3 5 6 Critical temperature and critical pressure 12078
3 5 7 Union 12078
3 5 8 Charge factor 12078
3 5 9 Detecting leaks 12078
3 6 Refrigerant oil 12079
3 6 1 Properties of refrigerant oil 12079
3 7 Comfort 12080
3 7 1 Environmental aspects 12080
3 8 How air conditioning works 12081
3 9 General work safety 12081
3 9 1 Product characteristics 12081
3 9 2 Handling refrigerants 12082
3 9 3 Wear safety goggles 12082
3 9 4 Wear protective gloves and apron 12082
3 9 5 Do not allow liquid refrigerant to come in contact with the skin 12082
3 9 6 Do not breath in refrigerant vapour 12082
3 9 7 Absolutely NO SMOKING 12082
3 9 8 Welding and soldering on refrigeration systems 12082
3 9 9 Pungent smell 12083
3 9 10 First aid 12083
3 9 11 Handling pressure vessels 12083
3 9 12 Do not heat up above 50°C 12083
3 9 13 Do not expose to uncontrolled heat 12083
3 9 14 Seal empty tanks/containers 12083
3 9 15 Safety instructions for using extraction and charging equipment 12084
3 10 Safety measures when working on vehicles with air conditioning and when working with refrigerant R134a 12084
3 11 Basics for working on refrigerant circuit 12085
3 11 1 O-ring 12086
3 11 2 Before operating the air conditioning system after recharging with refrigerant 12087
4 General information on refrigerant circuit 12088
4 1 Components of refrigerant circuit 12088
4 1 1 Distribution of the refrigerant circuit components and their influence on the high-pressure and low-pressure sides 12088
4 1 2 Air conditioning system compressor with magnetic clutch: 12088
4 1 3 Air conditioner compressor without magnetic clutch 12089
4 1 4 Air conditioner compressor without magnetic clutch, with elastic drive coupling 12090
4 1 5 Electrical air conditioner compressor for high-voltage system 12091
4 1 6 Condenser 12092
4 1 7 evaporator 12092
4 1 8 Reservoir 12093
4 1 9 Restrictor 12093
4 1 10 Receiver 12094
4 1 11 Expansion valve 12095
4 1 12 O-ring 12096
4 1 13 Pipes and hoses of refrigerant circuit 12096
4 1 14 High-pressure safety valve 12096
4 2 Design of refrigerant circuit 12099
4 2 1 Refrigerant circuit with expansion valve and evaporator 12099
4 2 2 Refrigerant circuit with restrictor and reservoir 12099
4 3 Evacuation and charging valves for quick-release couplings of air conditioner service station on refrigerant circuit 12100
4 3 1 Evacuation and charging valve with Schrader valve 12100
4 3 2 Extraction and charging valve, high-pressure side 12101
4 3 3 Extraction and charging valve, low-pressure side 12102
4 4 Switches and senders in refrigerant circuit and related connections 12102
4 4 1 High-pressure switch for air conditioning system -F23- 12102
4 4 2 High-pressure switch for magnetic clutch -F118- 12103
4 4 3 Low-pressure switch for air conditioning system -F73- 12103
4 4 4 Connections with valve for switches in refrigerant circuit 12104
4 4 5 Air conditioning system pressure switch -F129- 12104
4 4 6 High-pressure sender -G65- 12105
4 4 7 Refrigerant pressure and temperature sender -G395- 12106
4 4 8 Air conditioner compressor regulating valve -N280- 12106
4 5 Electrical components not installed in refrigerant circuit 12107
4 5 1 Control and regulating unit for air conditioning system -J127- 12107
4 5 2 Radiator fan control unit -J293- 12107
4 5 3 Radiator fan control unit -J293- 12108
4 5 4 Temperature switch for evaporator -E33- 12109
4 5 5 Evaporator output temperature sender -G263- or evaporator temperature sensor -G308- 12109
4 6 Pressures and temperatures in refrigerant circuit 12110
4 7 Refrigerant circuit with expansion valve 12110
4 8 Refrigerant circuit with restrictor and reservoir 12112
4 9 Test and measurement work that can be performed using a pressure gauge 12114
4 9 1 Pressure gauges enable the following test and measurement work 12114
4 10 Air conditioner service and recycling equipment 12115
4 10 1 Classification of extraction and charging devices in groups 12115
4 10 2 Charging devices that do not require a permit 12115
4 11 Notes to repairs on refrigerant circuit 12116
5 Laws and regulations 12117
5 1 Laws and regulations 12117
5 2 Recycling and refuse law 12122
5 2 1 Disposal of refrigerant and refrigerant machine oil 12122
5 3 Converting R12 refrigerant circuits to R134a refrigerant circuits and servicing them (retrofitting) 12123
5 4 Maintaining records on refrigerant 12123
6 Refrigerant circuit 12124
6 1 Important repair notes on air conditioning 12124
6 2 Converting refrigerant circuits from R12 refrigerant to R134a 12124
7 Working with the air conditioner service station 12125
7 1 Important instructions for working with the air conditioner service station 12125
7 2 Connecting a air conditioner service station for measuring and testing 12126
7 3 Drain the refrigerant circuit using the air conditioner service station 12127
7 4 Evacuating refrigerant circuit using air conditioner service station 12127
7 5 Filling refrigerant circuit with air conditioner service station 12129
7 6 Bringing air conditioning system into service after charging 12130
7 7 Charging the container in the air conditioning service station with refrigerant 12130
7 8 Emptying air conditioner service station 12131
8 Detecting leaks in refrigerant circuit 12132
8 1 Leak detection in refrigerant circuit using compressed air or nitrogen 12133
8 2 Searching for leaks in refrigerant circuits using leak detector -V A G 1796- 12134
8 3 Detecting leaks in refrigerant circuit using leak detecting system -VAS 6196- or leak detecting system -VAS 6201- or a later model 12135
9 Clearing refrigerant circuit of contaminants 12143
9 1 Vehicles with high-voltage system (hybrid vehicles) 12143
9 2 Blowing through refrigerant circuit with compressed air and nitrogen 12144
9 2 1 Flushing refrigerant circuit 12146
9 3 Flushing refrigerant circuit with refrigerant R134a 12146
9 3 1 Principle circuit diagrams for various purging circuits 12154
9 3 2 Purging electrical air conditioner compressor 12160
9 3 3 Adapters for setting up flushing circuits 12164
10 Clearing refrigerant circuit of contaminants, commercial vehicles 12178
10 1 Vehicles with high-voltage system 12178
10 2 Flushing refrigerant circuit with refrigerant R134a 12179
10 3 Adapters for setting up flushing circuits 12179
10 4 Procedure for setting up and flushing refrigerant circuit, Amarok 2023 ► 12183
10 5 Procedure for setting up and flushing refrigerant circuit, Amarok 2010 ► 12183
10 5 1 Connection diagram for flushing circuit 12183
10 5 2 Procedure for setting up and flushing refrigerant circuit 12184
10 6 Procedure for setting up and flushing refrigerant circuit, Caddy 2004 ► 12189
10 6 1 Connection diagram for flushing circuit 12189
10 6 2 Procedure for setting up and flushing refrigerant circuit 12190
10 7 Procedure for setting up and flushing refrigerant circuit, Crafter ►2017 12196
10 7 1 Connection diagram for flushing circuit, vehicles with one evaporator 12196
10 7 2 Connection diagram for flushing circuit, vehicles with second evaporator 12197
10 7 3 Procedure for setting up and flushing refrigerant circuit, vehicles with one evaporator 12198
10 7 4 Procedure for setting up and flushing refrigerant circuit, vehicles with second evaporator 12205
10 8 Procedure for setting up and flushing refrigerant circuit, Crafter 2017 ► or MAN TGE ►, Crafter Grand California ► 12213
10 8 1 Connection diagram for flushing circuit, vehicles with one evaporator 12214
10 8 2 Connection diagram for flushing circuit, vehicles with second evaporator 12215
10 8 3 Procedure for setting up and flushing refrigerant circuit, vehicles with one evaporator 12216
10 8 4 Procedure for setting up and flushing refrigerant circuit, vehicles with second evaporator 12221
10 9 Procedure for setting up and flushing refrigerant circuit, Transporter 2016 ►, Transporter 2020 ► 12230
10 9 1 Connection diagram for flushing circuit, vehicles with one evaporator 12230
10 9 2 Connection diagram for flushing circuit, vehicles with second evaporator 12231
10 9 3 Procedure for setting up and flushing refrigerant circuit, vehicles with one evaporator 12232
10 9 4 Procedure for setting up and flushing refrigerant circuit, vehicles with second evaporator 12237
11 Complaints 12246
11 1 Possible complaints about refrigerant circuit 12246
11 1 1 Conditions for testing: 12246
11 1 2 Possible complaints 12246
11 2 Odours from heater and air conditioning unit 12247
11 2 1 Does the odour emanate from the evaporator or heat exchanger? 12247
11 2 2 Ultrasonic air conditioner cleaning unit -VAS 6189A- 12248
11 2 3 Spraying the evaporator with the suction feed spray-gun -V A G 1538- and spray lance 12249
12 Connecting the air conditioning service station 12250
12 1 For vehicles that have connections on both low-pressure and high-pressure sides of refrigerant circuit 12250
12 1 1 Connecting a air conditioner service station for measuring and testing 12250
13 Checking pressures on vehicles 12251
13 1 Checking pressures in the refrigerant circuit (using a air conditioning service station) 12251
13 1 1 Conditions for testing 12251
13 1 2 Checking pressures 12252
13 1 3 Continuation of checking pressures 12254
13 2 Checking systems with a restrictor and collector (with internally regulated air conditioner compressor) 12255
13 2 1 Specifications: 12255
13 3 Checking systems with an expansion valve and reservoir (with internally regulated air conditioner compressor) 12259
13 3 1 Specifications: 12259
13 4 Checking systems with an expansion valve and reservoir (without regulated air conditioner compressor) 12264
13 4 1 Conditions for testing 12264
13 4 2 Check 12264
13 4 3 Specified values 12264
13 5 Checking systems with a restrictor and reservoir and air conditioner compressor regulating valve -N280- (with externally regulated air conditioner compressor) 12265
13 5 1 Specifications: 12265
13 6 Checking systems with an expansion valve, receiver and air conditioner compressor regulating valve -N280- (with externally regulated air conditioner compressor) 12270
13 6 1 Specifications: 12270
13 7 With expansion valve, receiver and electrical air conditioner compressor 12281
14 Renewing components 12282
14 1 In the event of leaking or damaged components (apart from the air conditioner compressor, receiver or reservoir) 12283
14 1 1 If the refrigerant circuit was completely empty 12283
14 1 2 If there is still refrigerant in the refrigerant circuit 12285
14 2 Renew the air conditioner compressor 12285
14 2 1 Without needing to flush refrigerant circuit of contaminants (cleaning), e g in cases of external damage after an accident 12285
14 2 2 Leaks or internal damage (e g noises or lack of power) 12287
14 3 Replace receiver or reservoir and restrictor 12287
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 12287
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 12289
15 Testing equipment and tools 12290
15 1 List of test equipment, tools and materials 12290
15 1 1 Tools and materials available from regional sales centre or importer 12290
15 1 2 Tools and materials commercially available 12291
15 1 3 Tools and materials available from regional sales centre or importer 12292
15 1 4 Tools and materials commercially available 12298
D4B8065298D Body Repairs 12301
00 – Technical data 12307
1 Basic instructions 12307
2 Vehicle identification data 12308
2 1 Vehicle identification number 12308
2 2 Vehicle data sticker 12309
3 Safety instructions 12310
4 Basic notes 12311
5 Safety instructions 12312
6 Moulded foam elements 12313
7 Galvanized body parts, high/higher-strength and hot-formed body panels 12315
7 1 Body 12315
7 2 Overview 12317
8 Laser welding 12320
9 Body panel gaps/shut lines 12321
9 1 Body – front 12321
9 2 Body – centre 12322
9 3 Body – rear 12325
10 Body dimensions 12326
10 1 Body – front 12326
10 2 Body – centre 12328
10 3 Body – rear 12333
10 4 Floor group – front 12334
10 5 Floor group – centre 12335
10 6 Floor group – rear 12336
11 Contour correct surfaces 12337
12 Tools 12338
13 Alignment bracket set 12339
13 1 Overview 12339
13 2 Procedure for body structural damage on vehicles from Volkswagen 12339
14 Portal gauge 12340
50 – Body – front 12341
1 Renewing left console 12341
1 1 Tools 12341
1 2 Removing 12341
1 3 Installing 12344
1 3 1 Preparing new part 12344
1 3 2 Welding in 12345
2 Renewing right-hand bracket 12346
2 1 Tools 12346
2 2 Removing 12346
2 3 Installing 12348
2 3 1 Welding in 12348
3 Renewing subframe 12350
3 1 Tools 12350
3 2 Removing 12350
3 3 Installing 12352
3 3 1 Preparing new part 12352
3 3 2 Welding in 12353
4 Renewing front bumper bracket 12354
4 1 Tools 12354
4 2 Removing 12354
4 3 Installing 12355
4 3 1 Welding in 12356
5 Replacing upper wheel housing longitudinal member 12357
5 1 Tools 12358
5 2 Removing 12358
5 3 Installing 12360
5 3 1 Preparing new part 12361
5 3 2 Welding in 12361
6 Renewing front wheel housing 12364
6 1 Tools 12365
6 2 Removing 12365
6 3 Installing 12366
6 3 1 Preparing new parts 12366
6 3 2 Welding in 12367
7 Repairing threads for securing subframe 12370
7 1 Contents of thread repair kit 12372
7 2 Repairing threads 12372
7 2 1 Drilling thread 12372
7 2 2 Cutting thread 12373
7 2 3 Inserting thread insert 12374
8 Renewing front left longitudinal member 12376
8 1 Tools 12377
8 2 Removing 12377
8 3 Installing 12380
8 3 1 Preparing new part 12380
8 3 2 Welding in 12381
9 Renewing front left longitudinal member – part section 12385
9 1 Tools 12386
9 2 Removing 12386
9 3 Installing 12388
9 3 1 Preparing new part 12388
9 3 2 Welding in 12389
9 3 3 Shortening longitudinal member with cover plate 12393
10 Renewing front right longitudinal member 12397
10 1 Tools 12398
10 2 Removing 12398
10 3 Installing 12401
10 3 1 Preparing new part 12401
10 3 2 Welding in 12402
11 Renewing front right longitudinal member – part section 12406
11 1 Tools 12407
11 2 Removing 12407
11 3 Installing 12409
11 3 1 Preparing new part 12409
11 3 2 Welding in 12410
51 – Body – centre 12414
1 Renewing roof 12414
1 1 Tools 12415
1 2 Removing 12416
1 3 Installing 12418
1 3 1 Preparing new part 12419
1 3 2 Setting the depth dimension 12420
1 3 3 Bonding in 12421
1 3 4 Welding in 12427
2 Renewing roof side member 12429
2 1 Tools 12430
2 2 Removing 12430
2 3 Installing 12432
2 3 1 Preparing new part 12433
2 3 2 Welding in 12436
3 Renewing front roof cross member – vehicles with no panorama glass sliding/tilting sunroof 12439
3 1 Tools 12440
3 2 Removing 12440
3 3 Installing 12441
3 3 1 Welding in 12441
4 Renewing front roof cross member – vehicles with panorama glass sliding/tilting sunroof 12443
4 1 Tools 12444
4 2 Removing 12444
4 3 Installing 12445
4 3 1 Welding in 12446
5 Renewing rear roof cross member – vehicles with no panorama glass sliding/tilting sunroof 12449
5 1 Tools 12450
5 2 Removing 12450
5 3 Installing 12452
5 3 1 Welding in 12453
6 Renewing rear roof cross member – vehicles with panorama glass sliding/tilting sunroof 12457
6 1 Tools 12458
6 2 Removing 12458
6 3 Installing 12460
6 3 1 Welding in 12461
7 Renewing A-pillar 12464
7 1 Tools 12465
7 2 Removing 12465
7 3 Installing 12467
7 3 1 Preparing new part 12468
7 3 2 Moulded foam inserts 12470
7 3 3 Welding in 12471
8 Renewing A-pillar reinforcement – part section 12474
8 1 Tools 12475
8 2 Removing 12475
8 3 Installing 12477
8 3 1 Preparing new part 12477
8 3 2 Moulded foam inserts 12478
8 3 3 Welding in 12479
9 Renewing B-pillar reinforcement 12483
9 1 Tools 12484
9 2 Removing 12484
9 3 Installing 12486
9 3 1 Preparing new part 12486
9 3 2 Moulded foam elements 12487
9 3 3 Welding in 12488
10 Renewing inner B-pillar 12491
10 1 Tools 12492
10 2 Removing 12492
10 3 Installing 12494
10 3 1 Preparing new part 12494
10 3 2 Welding in 12496
11 Renewing inner B-pillar – part section 12499
11 1 Tools 12500
11 2 Removing 12500
11 3 Installing 12502
11 3 1 Preparing new part 12502
11 3 2 Welding in 12504
12 Renewing side member 12507
12 1 Tools 12508
12 2 Removing 12508
12 3 Installing 12509
12 3 1 Preparing new part 12510
12 3 2 Welding in 12512
13 Renewing side member reinforcement 12515
13 1 Tools 12516
13 2 Removing 12516
13 3 Installing 12517
13 3 1 Preparing new part 12517
13 3 2 Welding in 12518
14 Renewing seat middle cross member 12522
14 1 Tools 12522
14 2 Removing 12522
14 3 Installing 12524
14 3 1 Preparing new part 12524
14 3 2 Welding in 12525
15 Renewing outer mounting for seat cross member 12527
15 1 Tools 12528
15 2 Removing 12529
15 3 Installing 12530
15 3 1 Preparing new part 12530
15 3 2 Welding in 12531
16 Renewing inner mounting for seat cross member 12533
16 1 Tools 12533
16 2 Removing 12533
16 3 Installing 12535
16 3 1 Preparing new part 12535
16 3 2 Welding in 12536
53 – Body – rear 12538
1 Renewing cross panel 12538
1 1 Tools 12539
1 2 Removing 12539
1 3 Installing 12540
1 3 1 Preparing new part 12540
1 3 2 Welding in 12542
2 Renewing tail light mounting 12545
2 1 Tools 12546
2 2 Removing 12546
2 3 Installing 12547
2 3 1 Preparing new part 12547
2 3 2 Welding in 12549
3 Renewing connecting part for tail light 12551
3 1 Tools 12552
3 2 Removing 12552
3 3 Installing 12553
3 3 1 Welding in 12553
4 Renewing lock carrier 12556
4 1 Tools 12557
4 2 Removing 12557
4 3 Installing 12558
4 3 1 Preparing new part 12558
4 3 2 Welding in 12559
5 Renewing inner lower part of left C-pillar 12561
5 1 Tools 12562
5 2 Removing 12562
5 3 Installing 12563
5 3 1 Preparing new part 12563
5 3 2 Welding in 12564
6 Renewing sealing channel 12566
6 1 Tools 12567
6 2 Removing 12567
6 3 Installing 12568
6 3 1 Preparing new part 12568
6 3 2 Welding in 12569
7 Renewing luggage compartment floor 12572
7 1 Tools 12573
7 2 Removing 12573
7 3 Installing 12574
7 3 1 Preparing new part 12574
7 3 2 Moulded foam inserts 12576
7 3 3 Welding in 12576
8 Renewing luggage compartment floor – part section 12578
8 1 Tools 12579
8 2 Removing 12579
8 3 Installing 12580
8 3 1 Preparing new part 12580
8 3 2 Welding in 12581
9 Renewing C-pillar reinforcement 12583
9 1 Tools 12584
9 2 Removing 12584
9 3 Installing 12585
9 3 1 Preparing new part 12585
9 3 2 Welding in 12587
10 Renewing rear longitudinal member – part section 12589
10 1 Tools 12590
10 2 Removing 12590
10 3 Installing 12591
10 3 1 Preparing new part 12591
10 3 2 Welding in 12592
11 Renewing side panel – part section 12594
11 1 Tools 12595
11 2 Removing 12595
11 3 Installing 12598
11 3 1 Preparing new part 12599
11 3 2 Marking area where no welding work may be carried out 12602
11 3 3 Moulded foam inserts 12602
11 3 4 Welding in 12602
D4B8075727A 4 cylinder common rail engine (2 0 l 4V turbocharger) 12607
00 – Technical data 12615
1 Safety information 12615
1 1 Safety regulations for working on fuel supply 12615
1 2 Safety measures when working on vehicles with a start/stop system 12616
1 3 Safety precautions when using testers and measuring instruments during a road test 12616
1 4 Safety precautions when working on the cooling system 12616
1 5 Safety precautions when working on the SCR system 12617
2 Identification 12618
2 1 Engine number/engine data 12618
3 Repair instructions 12620
3 1 Rules for cleanliness 12620
3 2 Adapting learnt value for SCR system 12620
3 3 Foreign objects in engine 12620
3 4 Contact corrosion 12621
3 5 Routing and attachment of lines 12621
3 6 Fitting radiator and condensers 12621
10 – Removing and installing engine 12622
1 Removing and installing engine 12622
1 1 Removing engine 12622
1 2 Separating engine and gearbox 12632
1 3 Securing engine on engine and gearbox support 12633
1 4 Installing engine 12635
2 Assembly mountings 12639
2 1 Assembly overview – assembly mountings 12639
2 2 Removing and installing engine mounting 12641
2 3 Removing and installing gearbox mounting 12642
2 4 Removing and installing pendulum support 12643
2 5 Supporting engine in installation position 12644
2 6 Adjusting assembly mountings 12649
2 7 Checking adjustment of assembly mountings (engine and gearbox mountings) 12650
3 Engine cover panel 12651
3 1 Removing and installing engine cover 12651
13 – Crankshaft group 12652
1 Cylinder block (pulley end) 12652
1 1 Assembly overview – cylinder block (pulley end) 12652
1 2 Assembly overview – sealing flange, belt pulley end 12654
1 3 Removing and installing poly-V belt 12654
1 4 Removing and installing tensioner for poly V-belt 12656
1 5 Removing and installing vibration damper 12656
1 6 Removing and installing bracket for ancillaries 12657
1 7 Removing and installing engine support 12658
1 8 Removing and installing sealing flange on pulley end 12659
2 Cylinder block, gearbox end 12662
2 1 Assembly overview – cylinder block, gearbox end 12662
2 2 Removing and installing flywheel 12663
2 3 Removing and installing sealing flange on gearbox side 12664
3 Crankshaft 12673
3 1 Assembly overview – crankshaft 12673
3 2 Crankshaft dimensions 12674
3 3 Renewing needle bearing in crankshaft 12674
3 4 Measuring axial clearance of crankshaft 12676
4 Pistons and conrods 12678
4 1 Assembly overview – pistons and conrods 12678
4 2 Removing and installing pistons 12680
4 3 Measuring piston projection at TDC 12681
4 4 Checking pistons and cylinder bores 12683
4 5 Separating new conrod 12685
4 6 Checking radial clearance of conrods 12685
4 7 Removing and installing oil spray jets 12685
15 – Cylinder head, valve gear 12687
1 Cylinder head 12687
1 1 Assembly overview – cylinder head 12687
1 2 Assembly overview – cylinder head cover 12689
1 3 Removing and installing cylinder head 12691
1 4 Removing and installing cylinder head cover 12701
1 5 Removing and installing injector seals 12703
1 6 Removing and installing camshaft housing 12705
1 7 Checking compression 12709
2 Toothed belt drive 12711
2 1 Assembly overview – toothed belt cover 12711
2 2 Assembly overview – toothed belt 12712
2 3 Removing and installing toothed belt guard 12713
2 3 1 Removing and installing upper toothed belt guard 12713
2 3 2 Removing and installing lower toothed belt guard 12715
2 4 Removing and installing toothed belt 12716
2 5 Removing toothed belt from camshaft 12727
3 Valve gear 12732
3 1 Assembly overview – valve gear 12732
3 2 Measuring axial play of camshaft 12735
3 3 Removing and installing camshaft oil seal 12736
3 4 Removing and installing camshaft adjuster 12737
3 5 Removing and installing camshaft control valve 1 -N205- 12740
3 6 Removing control valve from and installing on inlet camshaft control valve 1 -N205- 12741
3 7 Checking hydraulic compensation elements 12743
3 8 Removing and installing valve stem seals 12744
3 8 1 Removing and installing valve stem seals (cylinder head installed) 12744
3 8 2 Removing and installing valve stem seals (cylinder head removed) 12747
4 Inlet and exhaust valves 12751
4 1 Checking valve guides 12751
4 2 Checking valves 12752
4 3 Valve dimensions 12752
17 – Lubrication 12753
1 Sump, oil pump 12753
1 1 Assembly overview – sump/oil pump 12753
1 1 1 Assembly overview – sump/oil pump, vehicles with two-piece sump 12753
1 1 2 Assembly overview – sump/oil pump, vehicles with one-piece sump 12756
1 2 Engine oil: 12758
1 3 Removing and installing sump 12758
1 4 Removing and installing lower part of sump 12761
1 5 Removing and installing upper part of sump 12765
1 6 Removing and installing oil pump 12769
1 7 Removing and installing oil level and oil temperature sender -G266- 12770
1 7 1 Removing and installing oil level and oil temperature sender -G266-, vehicles with two-piece sump 12770
1 7 2 Removing and installing oil level and oil temperature sender -G266-, vehicles with one-piece sump 12771
2 Engine oil cooler 12772
2 1 Removing and installing engine oil cooler 12772
3 Oil filter, oil pressure switch 12773
3 1 Assembly overview – oil filter housing, oil pressure switch 12773
3 2 Removing and installing oil pressure switch -F1- 12774
3 3 Removing and installing oil pressure switch for reduced oil pressure -F378- 12775
3 4 Checking oil pressure 12776
3 5 Removing and installing oil filter housing 12776
3 6 Removing and installing oil pressure regulating valve -N428- 12778
19 – Cooling 12780
1 Cooling system/coolant 12780
1 1 Connection diagram – coolant hoses 12780
1 2 Assembly overview – engine preheater 12782
1 3 Checking cooling system for leaks 12782
1 4 Draining and adding coolant 12784
2 Coolant pump, regulation of cooling system 12790
2 1 Assembly overview – coolant pump, thermostat 12790
2 2 Assembly overview – electric coolant pump 12792
2 2 1 Assembly overview – charge air cooling pump -V188- and auxiliary pump for heating -V488-, version 1 12792
2 2 2 Assembly overview – charge air cooling pump -V188-, version 2 12793
2 2 3 Assembly overview – charge air cooling pump -V188-, version 3 12794
2 2 4 Assembly overview – auxiliary pump for heating -V488-, version 2 12795
2 2 5 Assembly overview – auxiliary pump for heating -V488-, version 3 12796
2 3 Assembly overview – coolant temperature sender 12797
2 3 1 Assembly overview – coolant temperature sender -G62- 12797
2 3 2 Assembly overview – radiator outlet coolant temperature sender -G83- 12798
2 4 Removing and installing electric coolant pump 12798
2 4 1 Removing and installing charge air cooling pump -V188-, version 1 and 2 12798
2 4 2 Removing and installing charge air cooling pump -V188-, version 3 12800
2 4 3 Removing and installing auxiliary pump for heating -V488-, version 1 12802
2 4 4 Removing and installing auxiliary pump for heating -V488-, version 2 12804
2 4 5 Removing and installing auxiliary pump for heating -V488-, version 3 12807
2 5 Removing and installing coolant pump 12810
2 6 Removing and installing thermostat 12811
2 7 Checking thermostat 12811
2 8 Removing and installing coolant valve for cylinder head -N489- 12812
2 9 Removing and installing coolant temperature sender -G62- 12812
2 10 Removing and installing radiator outlet coolant temperature sender -G83- 12813
3 Coolant pipes 12815
3 1 Assembly overview – coolant pipes 12815
3 2 Removing and installing coolant pipes 12816
3 2 1 Removing and installing coolant pipes (top front) 12816
3 2 2 Removing and installing lower front coolant pipe 12817
3 2 3 Removing and installing coolant pipe (front left) 12818
3 2 4 Removing and installing left coolant pipes 12819
3 2 5 Removing and installing rear coolant pipe 12820
3 2 6 Removing and installing rear right coolant pipe 12822
4 Radiator, radiator fan 12826
4 1 Assembly overview – radiator/radiator fan 12826
4 2 Removing and installing radiator 12828
4 3 Removing and installing water radiator for charge air cooling circuit 12829
4 4 Removing and installing radiator cowl with radiator fan 12832
4 5 Removing and installing radiator fan 12833
21 – Turbocharging/supercharging 12834
1 Exhaust turbocharger 12834
1 1 Assembly overview – turbocharger 12834
1 2 Removing and installing turbocharger 12836
1 3 Renewing vacuum unit for turbocharger 12840
1 4 Removing and installing connection for turbocharger 12845
2 Charge air system 12847
2 1 Assembly overview – charge air system 12847
2 2 Removing and installing charge pressure sender -G31- 12849
2 3 Checking charge air system for leaks 12849
23 – Mixture preparation – injection 12852
1 Injection system 12852
1 1 Schematic overview – fuel system 12852
1 2 Overview of fitting locations – injection system 12853
1 3 Filling/bleeding fuel system 12859
1 4 Checking fuel system for leaks 12859
2 Vacuum system 12860
2 1 Connection diagram – vacuum system 12860
2 2 Checking vacuum system 12860
3 Injectors/high-pressure accumulator (rail) 12862
3 1 Assembly overview – injectors 12862
3 2 Assembly overview – fuel rail 12864
3 3 Adapting correction values for injectors 12865
3 4 Testing injectors 12865
3 5 Checking return flow rate of injectors with engine running 12865
3 6 Checking return flow rate of injectors at starter speed 12868
3 7 Testing jammed-open injectors 12869
3 8 Removing and installing injectors 12870
3 9 Removing and installing high-pressure lines 12873
3 9 1 Removing high-pressure pipe between fuel rail and high-pressure pump 12873
3 9 2 Installing high-pressure line 12873
3 10 Removing and installing fuel rail 12875
4 Air filter 12877
4 1 Assembly overview – air filter housing 12877
4 2 Removing and installing air filter housing 12878
5 Intake manifold 12881
5 1 Assembly overview – intake manifold 12881
5 2 Removing and installing intake manifold 12883
5 3 Removing and installing throttle valve module -J338- 12886
6 Senders and sensors 12889
6 1 Removing and installing fuel pressure regulating valve -N276- 12889
6 1 1 Versions of fuel pressure regulating valve -N276- 12889
6 1 2 Removing and installing fuel pressure regulating valve, version 1 12890
6 1 3 Removing and installing fuel pressure regulating valve -N276-, version 2 12893
6 2 Checking fuel pressure regulating valve -N276- 12895
6 3 Removing and installing fuel pressure sender -G247- 12896
6 4 Removing and installing air mass meter -G70- 12897
6 5 Removing and installing pressure differential sender -G505- 12899
6 6 Removing and installing exhaust gas pressure sensor 1 -G450- 12900
6 7 Removing and installing NOx sender 2 -G687- 12901
6 8 Removing and installing NOx sender -G295- 12903
6 9 Removing and installing intake air temperature sender -G42-/charge air temperature sender after charge air cooler -G811- 12904
6 10 Removing and installing fuel temperature sender -G81- 12904
6 11 Removing and installing temperature and pressure sender for low-pressure fuel system -GX20- 12905
7 Engine control unit 12907
7 1 Removing and installing engine (motor) control unit -J623- 12907
7 2 Removing and installing engine (motor) control unit -J623- with protective housing 12908
8 High-pressure pump 12911
8 1 Assembly overview – high-pressure pump 12911
8 2 Removing and installing high-pressure pump 12911
9 Lambda probe 12915
9 1 Assembly overview – Lambda probe 12915
9 1 1 Assembly overview – Lambda probe; vehicles without SCR system 12915
9 1 2 Assembly overview – Lambda probe; vehicles with SCR system 12916
9 2 Removing and installing Lambda probe 12917
9 2 1 Removing and installing Lambda probe 1 before catalytic converter -GX10- 12917
26 – Exhaust system 12918
1 Exhaust pipes and silencers 12918
1 1 Assembly overview – silencers 12918
1 2 Assembly overview – front exhaust pipe 12920
1 3 Removing and installing front exhaust pipe 12921
1 4 Separating exhaust pipes from silencers 12922
1 5 Removing and installing rear silencer 12923
1 6 Aligning exhaust system free of stress 12924
1 7 Check exhaust system for leaks 12925
1 8 Align end exhaust pipes 12925
2 Exhaust gas cleaning 12926
2 1 Assembly overview – emission control 12926
2 2 Removing and installing emission control module 12928
2 3 Removing and installing exhaust flap control unit -J883- 12934
3 SCR system (selective catalytic reduction) 12935
3 1 Assembly overview – tank for reducing agent 12935
3 2 Assembly overview – reducing agent delivery line 12937
3 3 Assembly overview – delivery module for reducing agent 12938
3 4 Assembly overview – injector for reducing agent 12939
3 5 Removing and installing reducing agent tank 12940
3 6 Disconnecting reducing agent supply line 12943
3 7 Removing and installing delivery module for reducing agent 12945
3 8 Removing and installing injector for reduction agent -N474- 12947
3 9 Removing and installing control unit for reducing-agent heater -J891- 12949
3 10 Draining reducing agent tank 12950
4 Exhaust gas temperature regulation 12953
4 1 Assembly overview – exhaust gas temperature regulation 12953
4 1 1 Assembly overview – exhaust gas temperature regulation, vehicles without SCR system 12953
4 1 2 Assembly overview – exhaust gas temperature regulation, vehicles with SCR system 12955
4 2 Removing and installing exhaust gas temperature sender 1 -G235- 12956
4 3 Removing and installing exhaust gas temperature sender 2 -G448- 12957
4 4 Removing and installing exhaust gas temperature sender 3 -G495- 12960
4 5 Removing and installing exhaust gas temperature sender 4 -G648- 12962
5 Exhaust gas recirculation 12965
5 1 Assembly overview – exhaust gas recirculation 12965
5 2 Assembly overview – exhaust gas recirculation control motor -V338- 12967
5 3 Removing and installing exhaust gas recirculation cooler 12967
5 4 Checking exhaust gas recirculation cooler for leaks 12970
5 5 Removing and installing exhaust gas recirculation control motor -V338- 12972
5 6 Removing and installing exhaust gas recirculation control motor 2 -V339- 12973
5 7 Removing and installing exhaust gas recirculation temperature sensor -G98- 12975
28 – Glow plug system 12978
1 Glow plug system 12978
1 1 Assembly overview – glow plug system 12978
1 2 Removing and installing glow plug 12980
1 3 Removing and installing automatic glow period control unit -J179- 12982
1 4 Removing and installing Hall sender -G40- 12983
1 5 Removing and installing engine speed sender -G28- 12983
D4B80674265 Heating air conditioner 12985
00 – Technical data 12991
1 Safety information 12991
1 1 Safety precautions when working on air conditioning systems 12991
1 2 Safety measures when working on vehicles with a start/stop system 12991
1 3 Safety precautions when using testers and measuring instruments during a road test 12992
1 4 Safety precautions when working on the cooling system 12992
1 5 Safety precautions when handling refrigerants 12992
1 6 Safety precautions for working on vehicles with auxiliary heater 12993
2 Identification 12994
2 1 Identification of heater and air conditioning unit 12994
2 1 1 Identification of heater and air conditioning unit made by Valeo 12994
2 1 2 Identification of Denso heater and air conditioning unit 12994
3 General information 12996
3 1 Type plates 12996
3 2 Notes concerning odours in air conditioned vehicles 12996
3 3 Notes for vehicles with start-stop system 12997
3 4 Notes on dust and pollen filter 12998
4 Repair notes 13000
4 1 Rules for cleanliness 13000
4 2 Nuts and bolts 13000
4 3 Pipe/wire routing and attachment 13000
4 4 Fitting radiator and condensers 13001
4 5 Checking heater output 13001
4 6 Checking cooling output 13003
4 7 Working on refrigerant circuit 13006
4 8 Paint work on vehicles with air conditioning system 13006
4 9 Refrigerant circuit seals 13007
5 Technical data 13008
5 1 Refrigerant capacity 13008
5 2 Refrigerant oil capacities 13008
5 3 Oil distribution 13009
80 – Heating 13010
1 Overview of fitting locations – heating 13010
1 1 Overview of fitting locations – components not located in passenger compartment 13010
1 2 Overview of fitting locations – components located in front section of passenger compartment 13011
2 Heater 13013
2 1 Assembly overview – heater unit 13013
2 2 Removing and installing flexible shafts 13014
2 2 1 Removing and installing flexible shaft for air distribution 13014
2 2 2 Checking flexible shaft for air distribution 13015
2 2 3 Removing and installing Bowden cable for temperature flap 13015
3 Control motors 13018
3 1 Removing and installing fresh air and air recirculation flap control motor -V154- 13018
4 Air duct 13019
5 Operating and display unit 13020
5 1 Overview of operating and display unit 13020
5 2 Removing and installing operating and display unit 13021
5 2 1 Removing and installing front part of operating and display unit 13021
5 2 2 Removing and installing rear part of operating and display unit 13023
6 Other controlling and regulating components 13024
87 – Air conditioning system 13025
1 Overview of fitting locations – air conditioning system 13025
1 1 Overview of fitting locations – components not located in passenger compartment 13025
1 2 Overview of fitting locations – components located in front section of passenger compartment 13026
1 2 1 Overview of fitting locations – components inside front passenger compartment, air conditioning system with electric/manual controls 13026
1 2 2 Overview of fitting locations – components inside of front passenger compartment, Climatronic 13029
2 Refrigerant circuit 13032
2 1 System overview – refrigerant circuit 13032
2 2 Assembly overview – condenser 13034
2 3 Removing and installing high-pressure sender -G65- 13035
2 4 Removing and installing expansion valve 13036
2 5 Removing and installing condenser 13039
2 6 Removing and installing desiccant bag or cartridge 13042
2 7 Removing and installing evacuating and charging valves on low and high-pressure side 13045
2 8 Removing and installing refrigerant line from air conditioner compressor to evaporator 13047
2 9 Removing and installing refrigerant line from condenser to air conditioner compressor 13051
2 10 Removing and installing refrigerant line from air conditioner compressor to evaporator 13054
3 Air conditioner compressor 13058
3 1 Assembly overview – drive unit of air conditioner compressor 13058
3 2 Assembly overview – pulley 13059
3 2 1 Assembly overview – pulley, Denso air conditioner compressor 13059
3 2 2 Assembly overview – belt pulley, Sanden air conditioner compressor 13060
3 3 Removing air conditioning compressor from and installing on bracket 13061
3 4 Removing and installing air conditioner compressor 13062
3 5 Checking high-pressure safety valve on air conditioner compressor 13067
3 6 Removing and installing pulley 13068
3 6 1 Removing and installing Denso belt pulley 13068
3 6 2 Removing and installing Sanden belt pulley 13070
4 Control motors 13072
4 1 Overview of fitting locations – front control motors 13072
4 2 Removing and installing centre flap control motor -V70- 13074
4 3 Removing and installing defroster flap control motor -V107- 13075
4 4 Removing and installing air recirculation flap control motor -V113- 13076
4 5 Removing and installing left temperature flap control motor -V158- 13080
4 6 Removing and installing right temperature flap control motor -V159- 13081
4 7 Removing and installing fresh air/air recirculation, air flow flap control motor -V425- 13083
4 8 Removing and installing fresh air/air recirculation, air flow flap actuator 13084
5 Front heater and air conditioning unit 13086
5 1 Assembly overview – add-on parts of heater and air conditioning unit and of air intake box 13086
5 2 Assembly overview – heater and air conditioning unit 13089
5 2 1 Assembly overview – heater and air conditioning unit, air conditioning system with electric/manual controls 13089
5 2 2 Assembly overview – heater and air conditioning unit, Climatronic 13090
5 3 Assembly overview – evaporator housing 13092
5 4 Removing and installing evaporator 13093
5 5 Checking auxiliary air heater element – Z35- 13094
5 6 Removing and installing auxiliary air heater element -Z35- 13097
5 7 Removing and installing heater and air conditioning unit 13098
5 8 Dismantling and assembling heater and air conditioning unit 13104
5 9 Removing and installing dust and pollen filter 13106
5 10 Removing and installing fresh air blower -V2- 13107
5 11 Removing and installing fresh air blower control unit -J126- 13107
5 12 Removing and installing heat exchanger 13108
5 12 1 Removing and installing heat exchanger, left-hand drive vehicles 13108
5 12 2 Removing and installing heat exchanger (RHD) 13113
5 13 Removing and installing evaporator temperature sensor -G308- 13117
5 14 Removing and installing condensation drain 13117
5 15 Checking condensation drain 13118
5 16 Removing and installing fresh air blower series resistor with overheating fuse -N24- 13118
5 17 Removing and installing glove box cooling 13119
6 Air duct 13120
6 1 Assembly overview – air duct and air distribution in passenger compartment 13120
6 2 Air intake and air outlet openings 13123
6 2 1 Removing and installing centre vent 13123
6 3 Removing and installing driver side footwell vents 13124
6 4 Removing and installing front passenger side footwell vents 13124
6 5 Removing and installing rear footwell vent 13125
6 6 Installing plug in air duct to centre vent 13126
6 7 Removing and installing air ducts 13126
6 7 1 Removing and installing air duct/connecting piece for side vent 13126
6 7 2 Removing and installing air duct for centre vent 13127
6 8 Removing and installing forced ventilation for passenger compartment 13128
6 9 Checking forced ventilation for passenger compartment 13129
6 10 Removing and installing fresh air intake 13129
6 11 Removing and installing air duct for defroster vent 13130
6 12 Removing and installing air duct for centre dash panel vent 13131
7 Operating and display unit 13132
7 1 Overview of fitting locations – operating and display unit 13132
7 1 1 Overview of fitting locations – operating and display unit, air conditioning system with electric/manual controls 13132
7 1 2 Overview of fitting locations – operating and display unit, Climatronic 13134
7 2 Removing and installing operating and display unit 13136
7 2 1 Removing and installing operating and display unit, air conditioning system with electric/manual controls 13136
7 2 2 Removing and installing operating and display unit, Climatronic 13136
8 Other controlling and regulating components 13138
8 1 Removing and installing sunlight penetration photosensor -G107- 13138
8 2 Principle of operation of air quality sensor -G238- 13138
8 3 Removing and installing air quality sensor -G238- 13140
8 4 Removing and installing ambient temperature sensor -G17- 13141
8 5 Removing and installing left vent temperature sender -G150- 13141
8 6 Removing and installing left footwell vent temperature sender -G261- 13142
8 7 Removing and installing right footwell vent temperature sender -G262- 13142
D4D8083926E 4 cylinder diesel engine (2 0 l engine common rail) 13143
00 – Technical data 13149
1 Identification 13149
1 1 Engine number/engine data 13149
2 Safety information 13151
2 1 Safety precautions when working on fuel system 13151
2 2 Safety measures when working on vehicles with a start/stop system 13152
2 3 Safety precautions when using testers and measuring instruments during a road test 13152
2 4 Safety precautions when working on the cooling system 13153
3 Repair instructions 13154
3 1 Rules for cleanliness 13154
3 1 1 Rules for cleanliness when working on auxiliary/supplementary heater and fuel system 13154
3 1 2 When working on turbocharger 13154
3 2 Foreign objects in engine 13155
3 3 Checking vacuum system 13155
10 – Removing and installing engine 13156
1 Removing and installing engine 13156
1 1 Removing engine 13156
1 2 Separating engine and gearbox 13170
1 2 1 Separating engine and gearbox, manual gearbox 13170
1 2 2 Separating engine and gearbox, dual-clutch gearbox 13172
1 3 Securing engine on engine and gearbox support 13174
1 4 Installing engine 13176
2 Assembly mountings 13180
2 1 Assembly overview – assembly mountings 13180
2 2 Removing and installing engine mounting 13182
2 3 Supporting engine in installation position 13191
2 4 Adjusting assembly mountings 13200
2 5 Checking adjustment of assembly mountings 13201
3 Engine cover panel 13203
3 1 Removing and installing engine cover 13203
13 – Crankshaft group 13205
1 Cylinder block (pulley end) 13205
1 1 Assembly overview – poly V-belt drive 13205
1 1 1 Assembly overview – poly V-belt drive with tensioning element and air conditioner compressor 13205
1 1 2 Assembly overview – poly V-belt drive with tensioning roller and air conditioner compressor 13206
1 1 3 Assembly overview – poly V-belt drive without air conditioner compressor 13209
1 2 Removing and installing poly-V belt 13209
1 2 1 Removing and installing poly V-belt, with tensioning element and air conditioner compressor 13209
1 2 2 Removing and installing poly V-belt, with tensioning roller and air conditioner compressor 13211
1 2 3 Removing and installing poly V-belt, without air conditioner compressor 13213
1 3 Removing and installing tensioner for poly V-belt 13214
1 4 Removing and installing vibration damper 13215
1 5 Removing and installing bracket for ancillaries 13217
1 6 Removing and installing engine bracket 13219
1 7 Assembly overview – sealing flange, belt pulley end 13222
1 8 Renewing crankshaft oil seal – belt pulley end 13224
1 9 Removing and installing sealing flange on pulley end 13226
2 Cylinder block, gearbox end 13231
2 1 Assembly overview – cylinder block, gearbox end 13231
2 2 Removing and installing flywheel 13232
2 3 Removing and installing sealing flange on gearbox side 13234
3 Crankshaft 13248
3 1 Assembly overview – crankshaft 13248
3 2 Crankshaft dimensions 13249
3 3 Renewing needle bearing in crankshaft 13249
3 4 Measuring axial clearance of crankshaft 13251
3 5 Measuring radial clearance of crankshaft 13252
4 Pistons and conrods 13253
4 1 Assembly overview – pistons and conrods 13253
4 2 Measuring piston projection at TDC 13255
4 3 Checking pistons and cylinder bores 13257
4 3 1 Checking piston 13257
4 3 2 Cylinder bore 13259
4 3 3 Piston and cylinder dimensions 13260
4 4 Separating new conrod 13260
4 4 1 Bearing shells – installation position 13261
4 5 Checking radial clearance of conrods 13261
15 – Cylinder head, valve gear 13262
1 Cylinder head 13262
1 1 Assembly overview – cylinder head 13262
1 2 Assembly overview – cylinder head cover 13266
1 3 Removing and installing cylinder head 13268
1 4 Removing and installing cylinder head cover 13283
1 5 Removing and installing injector seals 13285
1 6 Removing and installing vacuum pump 13286
1 7 Checking compression 13288
2 Toothed belt drive 13291
2 1 Assembly overview – toothed belt 13291
2 2 Removing and installing toothed belt 13293
3 Valve gear 13305
3 1 Assembly overview – valve gear 13305
3 2 Measuring axial play of camshaft 13307
3 3 Measuring radial play of camshaft 13308
3 4 Removing and installing camshaft oil seal 13309
3 4 1 Removing and installing camshaft oil seal, vehicles with »former« seal 13309
3 4 2 Removing and installing camshaft oil seal, vehicles with »new« seal 13313
3 5 Removing and installing camshaft 13317
3 6 Checking hydraulic compensation elements 13326
3 7 Removing and installing valve stem seal 13327
3 7 1 Renewing valve stem seal with cylinder head installed 13327
3 7 2 Renewing valve stem seal with cylinder head removed 13331
4 Inlet and exhaust valves 13336
4 1 Reworking valve seats 13336
4 2 Checking valve guides 13336
4 3 Checking valves 13337
4 4 Valve dimensions 13337
17 – Lubrication 13338
1 Engine oil: 13338
1 1 Oil capacities 13338
1 2 Checking engine oil level 13338
2 Sump, oil pump 13340
2 1 Assembly overview – sump/oil pump 13340
2 2 Removing and installing oil sump 13343
2 3 Removing and installing oil pump 13348
2 4 Removing and installing oil level and oil temperature sender -G 266- 13349
3 Oil filter, oil pressure switch 13351
3 1 Assembly overview – oil filter housing, oil pressure switch 13351
3 2 Removing and installing oil pressure switch -F1- 13353
3 3 Checking oil pressure 13354
3 4 Checking oil pressure and oil pressure switch 13355
3 5 Removing and installing oil filter housing 13357
4 Oil circuit 13362
4 1 Assembly overview – oil circuit 13362
4 2 Removing and installing oil supply line to turbocharger 13362
4 3 Removing and installing oil return line for turbocharger 13364
19 – Cooling 13371
1 Cooling system/coolant 13371
1 1 Coolant hose connection diagram 13371
1 1 1 Coolant hose connection diagram, vehicles without 4/2-way valve 13371
1 1 2 Coolant hose connection diagram, vehicles with 4/2-way valve 13371
1 2 Overview of fitting locations – cooling system 13373
1 2 1 Overview of fitting locations – cooling system, front, without engine preheating 13373
1 2 2 Overview of fitting locations – cooling system, front, with engine preheating 13374
1 2 3 Overview of fitting locations – cooling system, gearbox side 13376
1 3 Engine preheater 13377
1 3 1 Assembly overview – engine preheater 13377
1 3 2 Removing and installing engine preheater 13377
1 4 Checking cooling system for leaks 13379
1 5 Draining and adding coolant 13381
1 5 1 Draining 13381
1 5 2 Filling 13384
2 Coolant pump, regulation of cooling system 13387
2 1 Assembly overview – coolant pump, thermostat 13387
2 2 Coolant circulation pump 2 -V178- 13387
2 2 1 Assembly overview – coolant circulation pump 2 -V178- 13387
2 2 2 Removing and installing coolant circulation pump 2 -V178- 13388
2 3 Removing and installing coolant pump 13391
2 4 Removing and installing 4/2-way valve with thermostat 13393
2 5 Removing and installing coolant temperature sender 13399
2 5 1 Removing and installing coolant temperature sender -G62- 13399
2 5 2 Removing and installing radiator outlet coolant temperature sender -G83- 13401
3 Coolant pipes 13404
3 1 Assembly overview – coolant pipes 13404
3 2 Removing and installing coolant pipes 13406
3 2 1 Removing and installing left coolant pipe 13406
3 2 2 Removing and installing upper front coolant pipe 13412
3 2 3 Removing and installing right coolant pipe 13413
4 Radiator, radiator fan 13416
4 1 Assembly overview – radiator/radiator fan 13416
4 2 Removing and installing radiator 13417
4 3 Removing and installing radiator cowl with radiator fan 13420
4 4 Removing and installing radiator fan 13421
21 – Turbocharging/supercharging 13422
1 Turbocharger 13422
1 1 Assembly overview – turbocharger 13422
1 2 Removing and installing turbocharger 13426
1 3 Renewing vacuum unit for turbocharger 13430
1 3 1 Changing vacuum unit with position sender for charge pressure positioner -G581- 13432
2 Charge air system 13440
2 1 Assembly overview – charge air system 13440
2 2 Assembly overview – charge-air hose connections 13442
2 2 1 Fitting charge air system hose connections, plug-in connector 13442
2 2 2 Fitting charge air system hose connections, ribbed union and hose clamp 13443
2 3 Removing and installing charge air cooler 13444
2 4 Removing and installing charge air pressure sender -G31-/intake air temperature sender -G42- 13447
2 5 Checking charge air system for leaks 13448
23 – Mixture preparation – injection 13453
1 Injection system 13453
1 1 Schematic overview – fuel system 13453
1 2 Filling/bleeding fuel system 13455
1 3 Checking for leaks in the fuel system 13456
2 Vacuum system 13457
2 1 Connection diagram – vacuum system 13457
2 2 Checking vacuum system 13458
2 2 1 Checking supply line, vacuum reservoir and non-return valve 13458
2 2 2 Checking control line to turbocharger 13459
3 Injectors/high-pressure accumulator (rail) 13461
3 1 Assembly overview – injectors 13461
3 2 Removing and installing injectors 13465
3 3 Installing high-pressure lines 13470
4 High-pressure pump 13473
4 1 Assembly overview – high-pressure pump 13473
4 2 Removing and installing high-pressure pump 13475
5 Senders and sensors 13480
5 1 Checking fuel pressure regulating valve -N276- 13480
5 2 Check pressure retention valve in fuel return line 13481
5 3 Removing and installing fuel pressure regulating valve -N276- 13482
5 4 Removing and installing fuel pressure sender -G247- 13484
5 5 Removing and installing air mass meter -G70- 13486
5 6 Removing and installing differential pressure sensor 13488
5 6 1 Removing and installing pressure differential sender -G505- 13488
6 Intake manifold 13490
6 1 Assembly overview – intake manifold 13490
6 2 Removing and installing intake manifold 13491
6 3 Removing and installing throttle valve module 13496
7 Lambda probe 13499
7 1 Removing and installing Lambda probe -G39- 13499
8 Air filter 13501
8 1 Assembly overview – air filter 13501
8 2 Removing and installing air filter housing 13503
8 3 Removing and installing air filter element 13504
8 4 Checking changeover flap for intake air preheating 13506
8 5 Removing and installing changeover flap for intake air preheating 13508
9 Engine control unit 13511
9 1 Removing and installing engine control unit 13511
9 2 Removing and installing engine control unit with protective housing 13512
26 – Exhaust system 13515
1 Exhaust pipes and silencers 13515
1 1 Assembly overview – silencers 13515
1 1 1 Assembly overview – silencers, Saloon 13515
1 1 2 Assembly overview – silencers, Cabriolet 13516
1 2 Separating exhaust pipes/silencers, saloon 13518
1 3 Removing and installing rear silencer, Cabriolet 13519
1 4 Aligning exhaust system free of stress 13520
1 5 Installation position of clamp 13521
2 Emission control 13523
2 1 Assembly overview – emission control 13523
2 1 1 Assembly overview – particulate filter 13523
2 1 2 Assembly overview – exhaust flap control unit -J883- with SCR catalytic converter 13528
2 1 3 Note installation position of securing clamps and exhaust gas temperature sender 13530
2 1 4 Routing cables/lines of components for exhaust system 13532
2 2 Removing and installing particulate filter with NOx storage catalytic converter 13534
3 Exhaust gas temperature regulation 13542
3 1 Removing and installing parts of exhaust gas temperature regulation 13542
3 1 1 Removing and installing exhaust gas temperature sender -G235- 13542
3 1 2 Removing and installing exhaust gas temperature sender -G495- 13544
3 1 3 Tightening exhaust gas temperature sender -G495- 13546
3 1 4 Removing and installing exhaust gas temperature sender -G648- 13547
3 1 5 Removing and installing exhaust gas recirculation temperature sensor -G98- 13548
4 Exhaust gas recirculation 13553
4 1 Assembly overview – exhaust gas recirculation 13553
4 2 Removing and installing exhaust gas recirculation filter 13555
4 3 Removing and installing exhaust gas recirculation cooler 13557
4 4 Checking changeover for exhaust gas recirculation cooler 13560
28 – Glow plug system 13562
1 Glow plug system 13562
1 1 Removing and installing glow plug 13562
1 2 Removing and installing connectors for glow pin plugs 13565
1 3 Removing and installing automatic glow period control unit -J179- 13568
1 4 Removing and installing Hall sender -G40- 13569
1 5 Removing and installing engine speed sender -G28- 13572