Volkswagen Golf 1984 Jetta 1984 Workshop Manual – PDF DOWNLOAD

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Volkswagen Golf 1984 Jetta 1984 Workshop Manual – PDF DOWNLOAD

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Volkswagen Golf 1984 Jetta 1984 Workshop Manual – PDF DOWNLOAD 

Language : English
Pages : 17986
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Volkswagen Golf 1984 Jetta 1984 Workshop Manual – PDF DOWNLOAD 

00051705820 4 speed manual gearbox 020 1
Title 1
Manual Repair Groups 2
00-1 Gearbox identification 4
00-3 – Code letters, allocation, ratios, capacities 5
00-7 – 4 Speed manual gearbox 020 7
00-15 – Transmission changes: 4 speed manual gearbox 1A 11
00-16 – Transmission layout 11
30-1 Repairing clutch controls 13
30-1 – Release shaft, release lever, return spring, clutch lever and release bearing 13
30-6 – Repairing clutch 15
34-1 Controls, Housing 20
34-1 – Repairing shift linkage 20
34-5 – Repairing shift linkage 22
34-8 – Adjusting shift linkage 23
34-10 – Repairing shift linkage 24
34-15 – Adjusting gear shift linkage 27
34-20 – Modifications to the shift linkage 29
34-20 – Boot with cap 29
34-22 – One-piece shift rod bearing 30
34-23 – Relay lever with larger rubber ball 31
34-23 – Type of grease 31
34-24 – Removing and installing bonded rubber bushes for gearbox carrier 31
34-29 – Removing and installing gearbox 34
34-36 – Dismantling and assembling gearbox 37
34-40 – Removing and installing Housing 39
34-57 – Service installation of the 5 speed manual gearbox 48
34-59 – Selector shaft cover modified 49
34-60 – Selector shaft lever serf-locking nut 49
34-61 Dismantling and assembling gearbox 50
34-61 – Removing and installing drive shaft, output shaft and differential 50
34-64 – Removing and installing drive shaft 51
34-72 – Dismantling and assembling Gearbox 55
34-77 – Modifications to gearbox housing 58
34-78 – Repairing bearing housing 58
34-86 – TDC sensor adapter in clutch housing 62
34-87 – “Floating” shift fork rod 63
34-88 – Location and bearings of gearshift shaft in gearbox modified 63
34-94 – Gearbox breather relocation 66
34-96 – Additionally securing magnet in clutch housing with sealing compound 67
35-1 Dismantling and assembling input shaft 68
35-20 – Adjusting input shaft 77
35-25 – Dismantling and assembling output shaft 80
35-45 – Adjusting output shaft 90
35-50 – Securing the output shaft needle roller bearing 92
35-51 – Repair instructions: 93
39-1 Repairing differential 94
39-1 – Removing and installing drive flange oil seal 94
39-3 – Dismantling and assembling differential 95
39-15 – Adjusting differential 101
39-19 – Differential bevel gear shaft secured with extended rivets 103
39-20 – Adjustment list 103
00051705920 5 speed manual gearbox 020 104
RLF SA Golf, Scirocco 5 speed manual Gearbox 020 104
List of Workshop Manual Repair Groups 105
00-1 Gearbox identification 108
00-3 – Speedometter drive pinions 109
00-4 – Code letters, gearbox allocation, ratios, oil capacities (up to 07 82) 109
00-6 – Code letters, gearbox allocation, ratios, oil capacities (up to 07 82) 110
00-8 – Code letters, gearbox allocation, ratios, oil capacities (up to 07 82) 111
00-10 – Code letters, gearbox allocation, ratios, oil capacities (from 8 82) (up to 07 83) 112
00-12 – Code letters, gearbox allocation, ratios, oil capacities (from 8 82 up to 07 83) 113
00-14 – Code letters, gearbox allocation, ratios, oil capacities (from 8 82 up to 7 83) 114
00-16 – Code letters, gearbox allocation, ratios, oil capacities (from 8 83) 115
00-18 – Code letters, gearbox allocation, ratios, oil capacities (from 8 83) 116
00-20 – Code letters, gearbox allocation, ratios, oil capacities (from 8 83) 117
00-22 – Code letters, gearbox allocation, ratios, oil capacities (from 8 83) 118
00-26 – Transmission layout 120
30-1 Clutch 122
30-1 – Repairs to the clutch mechanism 122
30-4 – Clutch cable chafing against brake fluid reservoir 123
30-6 – Repairs to clutch (190/200 mm dia ) 124
34-1 Controls, Housing 129
34-1 – Operation of shift mechanism 129
34-4 – Repair shift linkage 130
34-8 – Adjusting gearshift linkage 132
34-10 – Adjusting selector shaft retaining screw 133
34-11 – Adjusting retaining screw for 5th gear 134
34-12 – Selector shaft lever self-locking nut 134
34-13 – Removing and installing bonded rubber bushes for gearbox carrier 135
34-15 – Removing and installing gearbox 136
34-19 – General view 138
34-21 – Dismantling and assembling gearbox 139
34-26 – Dismantling and assembling gearbox 141
34-29 – Dismantling and assembling gearbox 143
34-51 – Dismantling and assembling gearbox 154
34-58 – Dismantling and assembling gearbox 157
34-62 – Dismantling and assembling gearbox 159
34-66 – Vehicles with gearchange and consumption indicator 161
34-67 – Additional bearing for output shaft 162
34-69 – Gearbox breather relocation 163
34-70 – TDC sensor adapter in clutch housing 163
34-71 – Spring for the reverse gear relay lever 164
34-72 – Modified locating and mounting of the selector shaft in the gearbox 164
34-76 – Additionally securing magnet in clutch housing with sealing compound 166
34-77 – Selector shaft cover modified 167
35-1 Gears, Shafts 168
35-1 – Dismantling and assembling input shaft 168
35-15 – Dismantling and assembling output shaft 175
35-25 – Adjusting output shaft 180
35-30 – Synchronizer hub for 5th gear with retaining ring for locking keys 182
35-33 – Dismantling and assembling output shaft (pinion shaft) 184
39-1 Final drive, Differential 185
39-1 – Removing and installing drive flange oil seal 185
39-3 – Dismantling and assembling differential 186
39-12 – Adjustment table 190
39-13 – Adjusting differential 191
39-16 – Play free location of drive flange shafts 192
39-17 – Differential with cones: dismantling and assembling 193
39-23 – Differential bevel gear shaft secured with extended rivets 196
00051706220 General body repairs 197
RLF SA Citi Golf Body repair work 197
List of Workshop Manual Repair Groups 198
55-1 Bonnet, flaps 200
55-1 – Adjusting engine bonnet lock cable – Golf, Jetta 200
55-2 – Renewing tailgate – Golf 200
55-3 – Boot lock / exploded view – Jetta 201
55-4 – Installing gas – filled spring – Golf 201
57-1 Front door / exploded view – Golf, Jetta 203
57-11 – Front door / exploded view – Scirocco 208
58-1 Rear door / exploded view – Golf, Jetta 209
58-8 – Stiff window winder operation 212
60-1 Sliding roof / exploded view – Golf, Jetta 214
60-7 – Adjustment operations on the sliding roof – Golf, Jetta 217
60-9 – Cleaning water drain hoses – Jetta 218
60-10 – Tilting roof/exploded view – Scirocco 218
60-12 – Removing tilting roof panel – Scirocco 219
60-13 – Installing tilting roof panel and manual drive – Scirocco 220
60-14 – Adjustment operations on the tilting roof – Scirocco 220
60-17 – Cleaning water drain hoses – Scirocco 222
63-1 Renewing bumper covering – Golf, Jetta 223
63-3 – Renewing rear bumper side part – Scirocco 224
63-4 – Painting of Citi Golf polypropylene bumpers 224
64-1 Service installation of vent wing – Golf 226
66-1 Service installation of left-hand outer rear-view mirror (with linkage) – Golf 227
66-3 – Service installation of left-hand outer rear-view mirror (with linkage) 228
66-7 – Sticking on trim strips – Scirocco 230
66-8 – Removing radiator grille – Jetta 230
70-1 Removing and installing instrument panel – Jetta 231
70-5 – Removing and installing knee bar – Jetta 233
70-6 – Removing and installing front door trim panel – Jetta 233
70-9 – Removing and installing rear door trim panel – Jetta 235
70-11 – Removing and installing instrument panel – Scirocco 236
74-1 Renewing rear seat – Golf 237
00051707320 K Jetronic ignition system EV GX GZ RG 238
Title 238
Manual Repair Groups 239
Technical Bulletin No 1 313
Contents 240
00051707420 KE Jetronic ignition system GX HT RD 317
Title 317
Manual Repair Groups 318
Technical Bulletin No 1 392
Contents 319
00051707720 Diesel injection and glow plug system JP JR ME RA SB 1V 393
Title 393
Manual Repair Groups 394
Contents 395
00053148720 Wheels and Tyres Guide Standard 432
44 – Wheels, tyres, vehicle geometry 440
1 General notes on wheels and tyres (passenger cars) 440
2 Legislative and technical conditions for converting wheel and tyre combinations 442
2 1 Legislative conditions for converting wheel and tyre combinations 442
2 2 Technical conditions for converting wheel and tyre combinations 442
2 3 Additional wheel housing extensions (flaps) 443
2 4 „Series 80“ tyres 443
3 Documents and codes/designations 444
3 1 New vehicle registration documents since 01 10 2005 444
3 2 COC document (EEC Certificate of Conformity) 445
3 3 EU general type approval number, sales type and sales or trade designation 445
4 Useful information regarding tyres 447
4 1 Identification markings on the tyre sidewall 447
4 2 Explanation of tyre markings 448
4 3 Speed ratings for tyres 449
4 4 Undulations 450
4 5 Tyre storage 451
4 6 Tyre ageing 451
4 7 Tyre sizes for vehicles with four-wheel drive 453
4 8 Winter tyres 453
4 9 Winter tyres with speed symbol „V“ 454
4 10 Extra Load (XL) V winter tyres 455
4 11 Maximum speeds for V and Extra Load (XL) winter tyres 455
4 12 Reinforced and Extra Load (XL) tyres 456
4 13 Snow chains 456
5 Tyre wear/ mileage for passenger car tyres 458
5 1 General 458
5 2 Requirements to be met by tyres 458
5 3 Wear behaviour of high-speed tyres 459
5 4 Factors influencing the service life of a tyre 459
5 5 Driving style 459
5 6 Tyre maintenance 460
5 7 Evenly worn tyres 461
5 8 Measuring tread depth 462
5 9 One-sided wear 462
5 10 Outer shoulder wear 465
5 11 Wear in middle of tyre 465
5 12 Diagonal washout 467
6 Tyre noise 468
6 1 General notes on tyre noise 468
6 2 Saw-tooth wear 468
6 3 Flat spots (from locking wheels) 469
7 Vehicle pulls to one side 471
7 1 General 471
7 2 Conicity 471
7 3 Remedies when vehicle pulls to one side 472
7 4 Strategic rotation of wheels for non-directional tyres 473
7 5 Strategic rotation of wheels having unidirectional tyres 474
8 Tyre damage 476
8 1 General information 476
8 2 Construction of a radial belted tyre 477
8 3 Impact damage 477
8 4 Cuts 479
8 5 Damage caused by foreign bodies 479
8 6 Loss of air from tyre 479
8 7 Tyre pressure 479
8 8 Tyre damage due to insufficient tyre pressure 480
8 9 Rising tyre temperature caused by insufficient inflation pressure 481
8 10 Tyre damage due to fitting error (fitting damage) 482
9 Tyres with run-flat properties 484
9 1 General 484
9 2 Design and identification 485
9 3 Retrofitting/requirements when using run-flat tyres 485
9 4 Repairs 486
10 Rolling resistance optimised tyres 487
11 Facts about disc-type wheels (passenger cars) 488
11 1 Design of disc-type wheel 488
11 2 Data on wheel rims 488
11 3 Wheel rims – pitch circle diameter 489
11 4 Split rim composite wheels 489
11 5 Alloy wheels with exchangeable trim elements 489
11 6 Alloy wheels with exchangeable trim elements (Zaragoza) 490
11 6 1 Tools 490
11 6 2 Materials 491
11 6 3 Installing trim element 491
11 6 4 Removing trim element 493
11 7 Care and maintenance of alloy wheel rims 494
11 8 Restoring alloy wheels 494
11 9 The valve 496
12 Notes on use of temporary spare wheels 497
13 Fox from model year 2006 498
13 1 Fox, type 5Z model year 2006 to model year 2012 498
13 2 Wheel allocation for Fox, type 5Z model year 2006 to model year 2012 499
13 2 1 5 J x 14 500
13 2 2 6 J x 14 500
13 2 3 6 J x 15 502
14 up! from model year 2012 505
14 1 Advance information about up! Model year 2012 505
15 Polo from model year 2010 506
15 1 Polo, type 6R model year 2010 to model year 2012 506
15 2 Wheel allocation for Polo, type 6R model year 2010 to model year 2012 508
15 2 1 5 J x 14 508
15 2 2 6 J x 15 offset 38 509
15 2 3 6 J x 15 offset 40 509
15 2 4 7 J x 16 510
15 2 5 7 J x 17 511
16 Polo BlueMotion from model year 2010 512
16 1 Polo BlueMotion, type 6R model year 2010 to model year 2012 512
16 2 Wheel allocation for Polo BlueMotion, type 6R model year 2010 to model year 2012 513
16 2 1 51/2 J x 15 513
16 2 2 6 J x 15 offset 38 514
16 2 3 6 J x 15 offset 40 514
17 CrossPolo from model year 2011 516
17 1 CrossPolo, type 6R model year 2011 to model year 2012 516
17 2 Wheel allocation CrossPolo, type 6R model year 2011 to model year 2012 518
17 2 1 5 J x 14 518
17 2 2 6 J x 15 offset 38 519
17 2 3 6 J x 15 offset 40 519
17 2 4 7 J x 16 520
17 2 5 7 J x 17 521
17 2 6 71/2 J x 17 522
18 Polo GTI from model year 2011 523
18 1 Polo GTI, type 6R model year 2011 to model year 2012 523
18 2 Wheel allocation Polo GTI, type 6R model year 2011 to model year 2012 524
18 2 1 6 J x 15 offset 38 524
18 2 2 6 J x 15 offset 40 524
18 2 3 7 J x 16 525
18 2 4 7 J x 17 526
19 Golf from model year 2009 527
19 1 Golf, Golf 4Motion, sales type 5K model year 2009 to model year 2012 527
19 2 Wheel allocation for Golf, Golf 4Motion, sales type 5K model year 2009 to model year 2012 531
19 2 1 6 J x 15 531
19 2 2 61/2 J x 15 532
19 2 3 6 J x 16 533
19 2 4 61/2 J x 16 534
19 2 5 6 J x 17 539
19 2 6 7 J x 17 540
19 2 7 71/2 J x 17 543
19 2 8 71/2 J x 18 545
20 Golf BlueMotion from model year 2009 549
20 1 Golf BlueMotion, sales type 5K model year 2009 to model year 2012 549
20 2 Wheel allocation for Golf BlueMotion, sales type 5K model year 2009 to model year 2012 551
20 2 1 6 J x 15 551
20 2 2 61/2 J x 15 552
20 2 3 61/2 J x 16 553
21 Golf GTD from model year 2010 559
21 1 Golf GTD, sales type 5K, model year 2010 to model year 2012 559
21 2 Wheel allocation for Golf GTD, type 5K model year 2010 to model year 2012 561
21 2 1 6 J x 16 561
21 2 2 61/2 J x 16 561
21 2 3 6 J x 17 566
21 2 4 7 J x 17 567
21 2 5 71/2 J x 17 570
21 2 6 71/2 J x 18 572
22 Golf GTI from model year 2010 576
22 1 Golf GTI, sales type 5K, model year 2010 to model year 2012 576
22 2 Wheel allocation for Golf GTI, type 5K model year 2010 to model year 2012 578
22 2 1 6 J x 16 578
22 2 2 61/2 J x 16 579
22 2 3 6 J x 17 584
22 2 4 7 J x 17 584
22 2 5 71/2 J x 17 588
22 2 6 71/2 J x 18 589
22 2 7 71/2 J x 19 592
23 Golf R from model year 2010 594
23 1 Golf R, sales type 5K model year 2010 594
23 2 Golf R, sales type 5K model year 2011 to model year 2012 595
23 3 Wheel allocation for Golf R, type 5K model year 2010 to model year 2012 596
23 3 1 6 J x 17 597
23 3 2 7 J x 17 597
23 3 3 71/2 J x 17 597
23 3 4 71/2 J x 18 599
23 3 5 8 J x 19 602
24 CrossGolf from model year 2011 604
24 1 CrossGolf, sales type 521 model year 2011 to model year 2012 604
24 2 Wheel allocation CrossGolf, sales type 521 model year 2011 to model year 2012 607
24 2 1 6 J x 15 607
24 2 2 61/2 J x 15 608
24 2 3 6 J x 16 609
24 2 4 61/2 J x 16 610
24 2 5 6 J x 17 615
24 2 6 7 J x 17 offset 47 616
24 2 7 7 J x 17 offset 54 616
24 2 8 71/2 J x 17 620
25 Golf Cabriolet from model year 2012 621
25 1 Golf Cabriolet, sales type 517 from model year 2012 621
25 2 Wheel allocation Golf Cabriolet, sales type 517 from model year 2012 623
25 2 1 6 J x 15 623
25 2 2 61/2 J x 15 624
25 2 3 6 J x 16 625
25 2 4 61/2 J x 16 626
25 2 5 6 J x 17 631
25 2 6 7 J x 17 632
25 2 7 71/2 J x 17 635
25 2 8 71/2 J x 18 637
26 Golf Plus from model year 2009 641
26 1 Golf Plus, sales type 521 model year 2009 to model year 2011 641
26 2 Golf Plus, sales type 521 model year 2012 646
26 3 Wheel allocation for Golf Plus, sales type 521 model year 2009 to model year 2012 650
26 3 1 6 J x 15 650
26 3 2 61/2 J x 15 651
26 3 3 6 J x 16 652
26 3 4 61/2 J x 16 652
26 3 5 6 J x 17 657
26 3 6 7 J x 17 658
26 3 7 71/2 J x 17 661
26 3 8 71/2 J x 18 663
27 Golf Plus BlueMotion from model year 2010 667
27 1 Golf Plus BlueMotion, sales type 521, model year 2010 to model year 2012 667
27 2 Wheel allocation for Golf Plus BlueMotion, sales type 521, model year 2010 to model year 2012 669
27 2 1 6 J x 15 669
27 2 2 61/2 J x 15 670
27 2 3 6 J x 16 671
27 2 4 61/2 J x 16 672
28 Golf Variant from model year 2010 678
28 1 Golf Variant, Golf Variant 4Motion, sales type AJ5 model year 2010 to model year 2012 678
28 2 Wheel allocation for Golf Variant, Golf Variant 4Motion, sales type AJ5 model year 2010 to model year 2012 684
28 2 1 6 J x 15 684
28 2 2 61/2 J x 15 685
28 2 3 6 J x 16 686
28 2 4 61/2 J x 16 687
28 2 5 6 J x 17 692
28 2 6 7 J x 17 693
28 2 7 71/2 J x 17 696
28 2 8 71/2 J x 18 698
29 Golf Variant BlueMotion from model year 2010 702
29 1 Golf Variant BlueMotion, sales type AJ5, model year 2010 to model year 2012 702
29 2 Wheel allocation for Golf Variant BlueMotion, sales type AJ5, model year 2010 to model year 2012 703
29 2 1 6 J x 15 703
29 2 2 61/2 J x 15 704
29 2 3 6 J x 16 705
29 2 4 61/2 J x 16 706
30 Jetta from model year 2011 712
30 1 Jetta, sales type 162 model year 2011 to model year 2012 712
30 2 Wheel allocation Jetta, sales type 162 model year 2011 715
30 2 1 6 J x 15 715
30 2 2 61/2 J x 15 716
30 2 3 6 J x 16 717
30 2 4 61/2 J x 16 718
30 2 5 7 J x 17 723
30 2 6 71/2 J x 17 727
30 2 7 71/2 J x 18 728
31 Jetta from model year 2011 (NAR) 732
31 1 Jetta, sales type 162 from model year 2011 (NAR) 732
31 2 Wheel allocation for Jetta, sales type 162 from model year 2011 (NAR) 734
31 2 1 6 J x 15 734
31 2 2 61/2 J x 15 734
31 2 3 6 J x 16 736
31 2 4 61/2 J x 16 736
31 2 5 7 J x 17 741
31 2 6 71/2 J x 17 745
31 2 7 71/2 J x 18 746
32 Beetle from model year 2012 750
32 1 Beetle, sales type 5C1, from model year 2012 750
32 2 Beetle, sales type 5C1, from model year 2012 751
32 2 1 61/2 J x 16 752
32 2 2 7 J x 17 752
32 2 3 8 J x 18 754
32 2 4 8 J x 19 755
33 Scirocco from model year 2009 756
33 1 Scirocco, sales type 137, model year 2009 to model year 2011 756
33 2 Scirocco, sales type 137 model year 2012 759
33 3 Wheel allocation for Scirocco, sales type 137 model year 2009 to model year 2012 761
33 3 1 61/2 J x 16 761
33 3 2 61/2 J x 17 761
33 3 3 7 J x 17 762
33 3 4 8 J x 17 762
33 3 5 8 J x 18 764
33 3 6 8 J x 19 765
34 Scirocco R from model year 2010 767
34 1 Scirocco R, sales type 137, model year 2010 to model year 2011 767
34 2 Scirocco R, sales type 137 model year 2012 768
34 3 Wheel allocation for Scirocco R, sales type 137, model year 2010 to model year 2012 769
34 3 1 61/2 J x 17 770
34 3 2 7 J x 17 770
34 3 3 8 J x 17 770
34 3 4 8 J x 18 772
34 3 5 8 J x 19 774
35 Touran from model year 2003 775
35 1 Touran, type 1T model year 2003 to model year 2006 775
35 2 Touran, type 1T model year 2007 to model year 2010 778
35 3 Touran, type 1T and type 1t model year 2011 to model year 2012 783
35 4 Wheel allocation Touran, type 1T and type 1t model year 2003 to model year 2012 788
35 4 1 6 J x 15 788
35 4 2 61/2 J x 15 789
35 4 3 6 J x 16 790
35 4 4 61/2 J x 16 790
35 4 5 6 J x 17 796
35 4 6 7 J x 17 796
35 4 7 71/2 J x 18 797
36 CrossTouran from model year 2008 798
36 1 CrossTouran, type 1T model year 2008 to model year 2009 798
36 2 CrossTouran, type 1T and type 1t model year 2010 to model year 2012 801
36 3 Wheel allocation CrossTouran, type 1T and type 1t model year 2008 to model year 2012 805
36 3 1 6 J x 15 805
36 3 2 6 J x 16 806
36 3 3 61/2 J x 17 806
36 3 4 8 J x 17 807
37 Touran BlueMotion from model year 2009 808
37 1 Touran BlueMotion, type 1T and type 1t model year 2009 to model year 2012 808
37 2 Wheel allocation Touran BlueMotion, type 1T and type 1t model year 2009 to model year 2012 810
37 2 1 6 J x 15 810
37 2 2 61/2 J x 15 811
37 2 3 6 J x 16 812
37 2 4 61/2 J x 16 812
38 Tiguan from model year 2008 818
38 1 Tiguan, type 5N model year 2008 to model year 2011 818
38 2 Tiguan, type 5N, model year 2012 819
38 3 Wheel allocation for Tiguan, type 5N model year 2008 to model year 2012 821
38 3 1 6 1/2 J x 16 821
38 3 2 61/2 J x 17 823
38 3 3 7 J x 17 823
38 3 4 7 J x 18 824
38 3 5 9 J x 19 825
39 Eos from model year 2006 826
39 1 Eos, type 1F from model year 2006 826
39 2 Eos, type 1F model year 2007 to model year 2012 827
39 3 Wheel allocation for Eos, type 1F model year 2006 to model year 2012 830
39 3 1 61/2 J x 16 830
39 3 2 7 J x 16 831
39 3 3 6 J x 17 833
39 3 4 71/2 J x 17 834
39 3 5 8 J x 18 837
40 Passat saloon from model year 2011 840
40 1 Passat saloon, sales type 362 model year 2011 to model year 2012 840
40 2 Wheel allocation Passat saloon, sales type 362 model year 2011 to model year 2012 845
40 2 1 61/2 J x 16 846
40 2 2 7 J x 16 846
40 2 3 6 J x 17 847
40 2 4 61/2 J x 17 848
40 2 5 71/2 J x 17 848
40 2 6 8 J x 18 849
41 Passat Variant from model year 2011 851
41 1 Passat estate, sales type 365 model year 2011 to model year 2012 851
41 2 Wheel allocation Passat estate, sales type 365 model year 2011 to model year 2012 856
41 2 1 61/2 J x 16 856
41 2 2 7 J x 16 857
41 2 3 6 J x 17 858
41 2 4 61/2 J x 17 858
41 2 5 71/2 J x 17 859
41 2 6 8 J x 18 860
42 Passat CC from model year 2009, CC from model year 2010 862
42 1 Passat CC, sales type 357 model year 2009 862
42 2 Passat CC, CC, sales type 357 model year 2010 to model year 2012 864
42 3 Wheel allocation Passat CC, CC, sales type 357 model year 2009 to model year 2012 865
42 3 1 61/2 J x 17 865
42 3 2 8 J x 17 866
42 3 3 8 J x 18 867
42 3 4 8 J x 19 869
43 Phaeton from model year 2003 870
43 1 Phaeton, type 3D, model year 2003 to model year 2009 – short and long wheelbase 870
43 2 Phaeton, type 3D and type 3d, model year 2010 to model year 2012 – short and long wheelbase 873
43 3 Wheel allocation for Phaeton, type 3D and type 3d, model year 2003 to model year 2012 – short and long wheelbase 875
43 3 1 71/2 J x 16 875
43 3 2 71/2 J x 17 875
43 3 3 71/2 J x 18 877
43 3 4 81/2 J x 18 877
43 3 5 81/2 J x 19 offset 38 879
43 3 6 81/2 J x 19 offset 45 880
43 3 7 9 J x 19 offset 35 880
43 3 8 9 J x 19 offset 40 881
43 3 9 9 J x 20 881
44 Sharan from model year 2011 883
44 1 Sharan, Sharan 4Motion, type 7N model year 2011 to model year 2012 883
44 2 Wheel allocation Sharan, Sharan 4Motion, type 7N model year 2011 to model year 2012 885
44 2 1 6 1/2 J x 16 885
44 2 2 7 J x 17 886
44 2 3 71/2 J x 18 886
45 Touareg from model year 2010 888
45 1 Touareg, type 7P and type 7p, model year 2010 to model year 2012 888
45 2 Wheel allocation for Touareg, type 7P and type 7p, model year 2010 to model year 2012 890
45 2 1 71/2 J x 17 890
45 2 2 8 J x 18 891
45 2 3 81/2 J x 19 892
45 2 4 9 J x 20 892
45 2 5 91/2 J x 21 893
46 Touareg hybrid from model year 2011 895
46 1 Touareg hybrid, type 7PH and type 7pH, model year 2011 to model year 2012 895
46 2 Wheel allocation Touareg hybrid, type 7PH and type 7pH, model year 2011 to model year 2012 896
46 2 1 8 J x 18 896
46 2 2 81/2 J x 19 897
47 Breakdown set for VW Vehicles 899
48 Temporary spare tyres and wheels for VW vehicles 900
49 Recommended summer tyres 901
49 1 Summer tyres for Fox from model year 2006 901
49 2 Summer tyres for Polo from model year 2010 901
49 3 Summer tyres for Polo BlueMotion from model year 2010 902
49 4 Summer tyres for CrossPolo from model year 2011 903
49 5 Summer tyres for Polo GTI from model year 2011 903
49 6 Summer tyres for Golf from model year 2009 904
49 7 Summer tyres for Golf BlueMotion from model year 2009 905
49 8 Summer tyres for Golf GTD from model year 2009 906
49 9 Summer tyres for Golf GTI from model year 2009 906
49 10 Summer tyres for Golf R from model year 2010 907
49 11 Summer tyres for CrossGolf from model year 2011 908
49 12 Summer tyres Golf Cabriolet from model year 2012 909
49 13 Summer tyres for Golf Plus from model year 2009 910
49 14 Summer tyres for Golf Plus BlueMotion from model year 2010 911
49 15 Summer tyres for Golf Variant from model year 2010 912
49 16 Summer tyres for Golf Variant BlueMotion from model year 2010 913
49 17 Summer tyres for Jetta from model year 2011 914
49 18 Summer tyres for Beetle from model year 2012 916
49 19 Summer tyres for Scirocco from model year 2009 916
49 20 Summer tyres for Scirocco R from model year 2010 916
49 21 Summer tyres for Touran from model year 2003 917
49 22 Summer tyres for Touran BlueMotion from model year 2009 917
49 23 Summer tyres for CrossTouran from model year 2008 918
49 24 Summer tyres for Tiguan from model year 2008 918
49 25 Summer tyres for Eos from model year 2006 919
49 26 Summer tyres for Passat saloon from model year 2011 919
49 27 Summer tyres for Passat Variant from model year 2011 920
49 28 Summer tyres Passat CC from model year 2009, CC from model year 2010 921
49 29 Summer tyres for Sharan from model year 2011 921
49 30 Summer tyres for Phaeton from model year 2003 921
49 31 Summer tyres for Touareg from model year 2010 922
49 32 Summer tyres for Touareg hybrid from model year 2011 922
50 Recommended all-season tyres 923
50 1 All-season tyres for Polo from model year 2010 923
50 2 All-season tyres for Polo BlueMotion from model year 2010 923
50 3 All-season tyres for CrossPolo from model year 2011 923
50 4 All-season tyres for Polo GTI from model year 2011 924
50 5 All-season tyres for Golf from model year 2009 924
50 6 All-season tyres for CrossGolf from model year 2011 924
50 7 All-weather tyres Golf Cabriolet from model year 2012 925
50 8 All-season tyres for Golf Plus from model year 2009 925
50 9 All-season tyres for Golf Variant from model year 2010 926
50 10 All-season tyres for Jetta from model year 2011 926
50 11 All-season tyres for Jetta from model year 2011 (NAR) 926
50 12 All-season tyres for Touran from model year 2003 927
50 13 All-season tyres for Beetle from model year 2012 927
50 14 All-season tyres for Tiguan from model year 2008 927
50 15 All-season tyres for Eos from model year 2006 927
50 16 All-season tyres for Passat saloon from model year 2011 928
50 17 All-season tyres for Passat Variant from model year 2011 928
50 18 All-season tyres Passat CC from model year 2009, CC from model year 2010 928
50 19 All-season tyres for Sharan from model year 2011 929
50 20 All-season tyres for Phaeton from model year 2003 929
50 21 All-season tyres for Touareg from model year 2010 929
50 22 All-season tyres Touareg hybrid from model year 2010 929
51 Recommended winter tyres 931
51 1 Winter tyres for Fox from model year 2006 931
51 2 Winter tyres for Polo from model year 2010 931
51 3 Winter tyres for Polo BlueMotion from model year 2010 932
51 4 Winter tyres for CrossPolo from model year 2011 932
51 5 Winter tyres for Polo GTI from model year 2011 932
51 6 Winter tyres for Golf from model year 2009 932
51 7 Winter tyres for Golf BlueMotion from model year 2009 933
51 8 Winter tyres for Golf GTD from model year 2009 933
51 9 Winter tyres for Golf GTI from model year 2009 933
51 10 Winter tyres for Golf R from model year 2010 933
51 11 Winter tyres for CrossGolf from model year 20011 934
51 12 Winter tyres Golf Cabriolet from model year 2012 934
51 13 Winter tyres for Golf Plus from model year 2009 934
51 14 Winter tyres for Golf Plus BlueMotion from model year 2010 935
51 15 Winter tyres for Golf Variant from model year 2010 935
51 16 Winter tyres for Golf Variant BlueMotion from model year 2010 935
51 17 Winter tyres for Jetta from model year 2011 936
51 18 Winter tyres for Beetle from model year 2012 936
51 19 Winter tyres for Scirocco from model year 2009 936
51 20 Winter tyres for Scirocco R from model year 2010 936
51 21 Winter tyres for Touran from model year 2003 937
51 22 Winter tyres for Touran BlueMotion from model year 2009 937
51 23 Winter tyres for CrossTouran from model year 2008 937
51 24 Winter tyres for Tiguan from model year 2008 938
51 25 Winter tyres for Eos from model year 2006 938
51 26 Winter tyres for Passat saloon from model year 2011 938
51 27 Winter tyres for Passat Variant from model year 2011 938
51 28 Winter tyres Passat CC from model year 2009, CC from model year 2010 939
51 29 Winter tyres for Sharan from model year 2011 939
51 30 Winter tyres for Phaeton from model year 2003 939
51 31 Winter tyres for Touareg from model year 2010 939
51 32 Winter tyres Touareg hybrid from model year 2010 940
00053323020 Golf Jetta 1984 941
Title 941
Manual Repair Groups 942
Contents 943
00053779220 Running gear 1038
Title 1038
Manual Repair Groups 1039
Technical Bulletin No 1 1174
Technical Bulletin No 2 1188
Technical Bulletin No 3 1194
Technical Bulletin No 4 1195
Technical Bulletin No 5 1198
Technical Bulletin No 6 1199
Contents 1040
00053780320 General body repairs Golf Convertible 1979 (1) 1201
Title 1201
Manual Repair Groups 1202
Technical Bulletin No 1 1259
Technical Bulletin No 2 1262
Technical Bulletin No 3 1264
Technical Bulletin No 4 1273
Technical Bulletin No 5 1283
Contents 1203
00053780320 General body repairs Golf Convertible 1979 1300
Title 1300
Manual Repair Groups 1301
Technical Bulletin No 1 1358
Technical Bulletin No 2 1361
Technical Bulletin No 3 1363
Technical Bulletin No 4 1372
Technical Bulletin No 5 1382
Contents 1302
00053781120 Heating Air conditioner 1399
Title 1399
Manual Repair Groups 1400
Technical Bulletin No 1 1458
Technical Bulletin No 2 1460
Technical Bulletin No 3 1461
Technical Bulletin No 4 1465
Technical Bulletin No 5 1473
Contents 1401
00053782220 Electrical system 1475
Title 1475
Manual Repair Groups 1476
Technical Bulletin No 1 1651
Contents 1477
00053786120 General body repairs 1652
Title 1652
Manual Repair Groups 1653
Technical Bulletin No 1 1701
Technical Bulletin No 2 1706
Technical Bulletin No 3 1707
Technical Bulletin No 4 1709
Technical Bulletin No 5 1715
Technical Bulletin No 6 1717
Technical Bulletin No 7 1722
Technical Bulletin No 8 1723
Technical Bulletin No 9 1725
Contents 1654
00053788220 Electrical system Scircoco 1981 1727
Title 1727
Manual Repair Groups 1728
Technical Bulletin No 1 1861
Contents 1729
D3E801B268E 4 cylinder diesel engine (2 0 l engine common rail) 1862
00 – Technical data 1868
1 Technical data 1868
1 1 Engine number 1868
1 2 Engine data 1868
10 – Removing and installing engine 1870
1 Removing and installing engine 1870
1 1 Removing engine 1870
1 2 Separating gearbox from engine and assembling 1883
1 2 1 Disconnecting 1884
1 2 2 Installing 1885
1 3 Securing engine on engine and gearbox support -VAS 6095- 1886
1 4 Notes on installing 1887
2 Assembly mounting, except Jetta 2011 ▶ 1891
2 1 Assembly overview – assembly mountings 1891
2 2 Checking adjustment of engine assembly mountings 1894
2 3 Adjusting assembly mountings 1894
3 Assembly mounting, Jetta 2011 ▶ 1900
3 1 Assembly overview – assembly mountings 1900
3 2 Removing and installing engine mounting 1902
3 3 Removing and installing gearbox mounting 1907
3 4 Removing and installing pendulum support 1909
3 5 Supporting engine in installation position 1910
3 6 Adjusting assembly mountings 1915
3 7 Checking adjustment of assembly mountings 1916
13 – Crankshaft group 1918
1 Dismantling and assembling engine 1918
1 1 Assembly overview – poly V-belt drive 1918
1 2 Removing and installing poly-V belt 1919
1 2 1 Removing 1920
1 2 2 Installing 1920
1 3 Removing and installing poly V-belt tensioner 1921
1 4 Removing and installing bracket for ancillaries 1923
1 5 Assembly overview – toothed belt drive 1924
1 6 Removing and installing engine bracket 1927
1 7 Assembly overview – cylinder block 1930
2 Removing and installing sealing flange and flywheel 1933
2 1 Renewing crankshaft sealing flange – flywheel end 1934
2 1 1 Pressing out sealing flange with sender wheel 1935
2 1 2 Pressing in sealing flange with sender wheel 1937
2 2 Renewing crankshaft oil seal – pulley end 1945
2 2 1 Removing 1946
2 2 2 Installing 1947
2 3 Removing and installing sealing flange – pulley end 1948
2 3 1 Removing 1949
2 3 2 Installing 1950
2 4 Removing and installing engine speed sender -G28- 1952
2 4 1 Removing 1953
2 4 2 Installing 1953
3 Pistons and conrods 1955
3 1 Assembly overview – pistons and conrods 1955
3 2 Removing and installing pistons 1959
3 3 Separating new conrods 1961
3 4 Bearing shells – installation position 1961
3 5 Piston and cylinder dimensions 1962
3 6 Checking piston projection at TDC 1962
3 6 1 Cylinder head gasket identification 1963
4 Crankshaft 1965
4 1 Assembly overview – crankshaft 1965
4 2 Crankshaft dimensions 1966
4 3 Pulling needle bearing out of and driving into crankshaft 1967
15 – Cylinder head, valve gear 1970
1 Cylinder head 1970
1 1 Assembly overview – cylinder head cover 1970
1 2 Removing and installing Hall sender -G40- 1972
1 3 Removing and installing engine cover 1975
1 3 1 Removing 1975
1 3 2 Installing 1975
1 4 Removing and installing cylinder head cover 1976
1 4 1 Removing 1977
1 4 2 Installing 1980
1 5 Assembly overview – cylinder head 1982
1 6 Removing, installing and tensioning toothed belt 1985
1 6 1 Removing 1986
1 6 2 Installing and tensioning 1988
1 7 Removing and installing cylinder head 1994
1 7 1 Removing and installing cylinder head (engine codes CBEA, CJAA) 1994
1 7 2 Removing and installing cylinder head (engine codes CBDA, CBDB, CEGA) 2008
1 8 Removing and installing vacuum pump 2019
1 8 1 Removing 2019
1 8 2 Installing 2020
1 9 Checking compression 2021
2 Valve gear 2023
2 1 Assembly overview – valve gear 2023
2 2 Removing and installing camshafts 2025
2 2 1 Removing 2027
2 2 2 Installing 2029
2 3 Removing and installing camshaft oil seal 2034
2 3 1 Removing 2034
2 3 2 Installing 2035
2 4 Renewing valve stem seals (with cylinder head installed) 2036
2 4 1 Removing 2037
2 4 2 Installing 2039
2 5 Checking valve guides 2040
17 – Lubrication 2042
1 Engine oil: 2042
1 1 Oil capacities 2042
1 1 1 Engine code CBEA 2042
1 1 2 Engine codes CBDA, CBDB, CEGA, CJAA 2042
1 2 Checking engine oil level 2042
2 Parts of lubrication system (engine codes CBEA) 2044
2 1 Assembly overview – oil pump, sump, balance shaft module 2044
2 2 Removing and installing oil sump 2047
2 2 1 Removing 2048
2 2 2 Installing 2049
2 3 Removing and installing oil pump 2051
2 3 1 Removing 2051
2 3 2 Installing 2052
2 4 Removing and installing balance shaft module 2052
2 4 1 Removing balancer shaft module 2053
2 4 2 Installing a new balancer shaft module 2054
2 4 3 Installing a previously used balancer shaft module again 2058
2 5 Pulling spur gear off crankshaft and shrink-fitting new spur gear 2060
2 5 1 Pulling spur gear off crankshaft 2061
2 5 2 Shrink-fitting new spur gear 2062
3 Parts of lubrication system (engine codes CBDA, CBDB, CEGA, CJAA) 2065
3 1 Assembly overview – oil pump, sump 2065
3 2 Removing and installing oil sump 2067
3 3 Removing and installing oil pump 2072
4 Oil filter bracket, oil cooler, oil pressure and oil supply line 2073
4 1 Assembly overview – oil filter bracket and oil cooler 2073
4 2 Removing and installing oil filter bracket together with oil cooler 2075
4 3 Removing and installing oil supply line to turbocharger 2078
4 3 1 Removing 2079
4 3 2 Installing 2080
4 4 Checking oil pressure and oil pressure switch -F1- 2081
4 4 1 Checking oil pressure switch -F1- 2082
4 4 2 Checking oil pressure 2083
19 – Cooling 2085
1 Parts of cooling system 2085
1 1 Assembly overview – parts of cooling system, body side 2086
1 2 Parts of cooling system – engine side 2088
1 2 1 Assembly overview – parts of cooling system, intake side with no engine preheater (engine codes CBEA, CJAA) 2088
1 2 2 Assembly overview – parts of cooling system, intake side with engine preheater (engine codes CBEA, CJAA) 2089
1 2 3 Assembly overview – parts of cooling system, gearbox side (engine codes CBEA, CJAA) 2091
1 2 4 Assembly overview – parts of cooling system, engine side (engine codes CBDA, CBDB, CEGA) 2092
1 3 Coolant hose connection diagram 2094
1 3 1 Coolant hose schematic diagram, no engine preheater (engine codes CBEA, CJAA) 2094
1 3 2 Coolant hose schematic diagram, with engine preheater (engine codes CBEA, CJAA) 2094
1 3 3 Coolant hose schematic diagram (engine codes CBDA, CBDB, CEGA) 2095
1 3 4 Connection diagram for coolant hoses (vehicles with 4/2-way valve) – all vehicles apart from Jetta from MY 2011 2096
1 3 5 Connection diagram for coolant hoses (vehicles with 4/2-way valve) – only for Jetta from MY 2011 2097
1 4 Removing and installing cowling together with radiator fan -V7- and radiator fan on right of radiator -V35- 2098
1 5 Removing and installing radiator 2100
1 5 1 Removing 2101
1 5 2 Installing 2101
1 6 Removing and installing coolant pump 2101
1 6 1 Removing 2102
1 6 2 Installing 2102
1 7 Removing and installing thermostat 2103
1 7 1 Removing 2103
1 7 2 Installing 2104
1 8 Removing and installing 4/2-way valve with thermostat 2104
1 9 Draining and adding coolant 2107
1 9 1 Draining 2108
1 9 2 Filling 2109
1 10 Checking cooling system for leaks 2112
1 10 1 Check pressure relief valve in cap 2113
1 11 Checking oil cooler for leaks 2114
1 12 Engine preheater (engine codes CBEA, CJAA) 2117
1 12 1 Assembly overview – engine preheater 2117
1 12 2 Removing and installing engine preheater 2118
20 – Fuel supply system 2120
1 Safety regulations for working on fuel supply 2120
2 Rules for cleanliness 2121
3 Procedure in event of misfuelling 2122
3 1 Step 1 (Engine was started with incorrect fuel) 2122
3 2 Step 2 (Engine was not started with incorrect fuel) 2123
3 3 Step 3 (There are filings in fuel delivery unit and fuel tank) 2125
3 4 Step 4 (There are no filings in fuel delivery unit and fuel tank) 2125
3 5 Step 5 (There are filings in high-pressure pump) 2126
3 6 Step 6 (There are no filings in high-pressure pump) 2126
4 Parts of fuel supply system 2128
4 1 Assembly overview – fuel tank, all vehicles apart from Jetta from MY 2011 2129
4 2 Assembly overview – fuel tank, only Jetta from MY 2011 2131
4 3 Emptying fuel tank 2133
4 3 1 Emptying fuel tank if it is more than 3/4 full 2135
4 3 2 Emptying fuel tank if it is less than 3/4 full 2136
4 4 Removing and installing fuel tank 2137
4 4 1 Removing fuel tank 2138
4 4 2 Installing fuel tank 2141
4 5 Removing and installing fuel delivery unit 2142
4 5 1 Removing 2143
4 5 2 Installing 2145
4 6 Removing and installing fuel gauge sender -G- 2146
4 6 1 Removing 2146
4 6 2 Installing 2147
5 Separating plug-in connectors 2148
6 Repairing fuel supply 2154
6 1 Assembly overview – fuel filter 2154
6 2 Removing and installing fuel filter 2155
6 2 1 Removing 2156
6 2 2 Installing 2157
6 3 Checking fuel system pressurisation pump -G6- 2157
6 3 1 Checking fuel delivery rate 2158
6 3 2 Checking voltage supply 2160
6 3 3 Checking current consumption 2161
6 4 Checking supplementary fuel pump -V393- (inline electronic fuel pump) 2163
6 5 Removing and installing supplementary fuel pump -V393- (inline electronic fuel pump) 2166
6 5 1 Removing 2166
6 5 2 Installing 2168
7 Electronic power control (EPC) 2169
7 1 Function of EPC system 2169
7 2 Assembly overview – accelerator module 2169
7 3 Removing and installing accelerator pedal module 2170
7 3 1 Removing 2171
7 3 2 Installing 2171
21 – Turbocharging/supercharging 2173
1 Safety precautions when working on charge air system and turbocharger 2173
2 Rules for cleanliness 2174
3 Turbocharger 2175
3 1 Assembly overview – turbocharger with exhaust manifold and attachments 2175
3 1 1 Engine codes CBEA, CJAA 2175
3 1 2 Engine codes CBDA, CBDB, CEGA 2179
3 2 Removing and installing turbocharger with exhaust manifold (engine codes CBEA, CJAA) 2181
3 3 Removing and installing turbocharger with exhaust manifold (engine codes CBDA, CBDB, CEGA) 2184
3 4 Changing vacuum unit with position sender for charge pressure positioner -G581- 2187
3 5 Removing and installing exhaust gas temperature sender -G235- 2195
4 Charge air system 2199
4 1 Assembly overview – parts of charge air cooling 2200
4 2 Dismantling and assembling plug-in connector between charge air cooler and connecting hose 2202
4 2 1 Dismantling 2202
4 2 2 Assembly 2203
4 3 Checking charge air system for leaks 2204
4 4 Vacuum hose schematic diagram (engine codes CBEA, CJAA) 2207
4 5 Vacuum hose schematic diagram, (engine codes CBDA, CBDB, CEGA) 2208
4 6 Checking vacuum system 2209
4 6 1 Checking fuel supply line and non-return valve 2210
4 6 2 Checking control line to turbocharger 2212
4 6 3 Checking control line to vacuum unit for exhaust gas recirculation cooler changeover function (engine codes CBDA, CBDB, CEGA) 2212
23 – Mixture preparation – injection 2214
1 Observe safety precautions when working on diesel direct injection fuel system 2214
2 Rules for cleanliness 2216
3 Diesel direct injection system 2217
3 1 System layout 2218
3 1 1 System layout (engine codes CBEA, CJAA) 2218
3 1 2 System layout (engine codes CBDA, CBDB, CEGA) 2220
3 2 Assembly overview – fuel system 2221
3 3 Removing and installing injector (piezo injector) 2224
3 3 1 Removing 2226
3 3 2 Installing 2227
3 3 3 Installing high-pressure lines 2229
3 4 Checking fuel pressure regulating valve -N276- 2231
3 5 Removing and installing fuel pressure regulating valve -N276- 2232
3 5 1 Removing 2233
3 5 2 Installing 2234
3 6 Removing and installing fuel pressure sender -G247- 2234
3 6 1 Removing 2235
3 6 2 Installing 2236
3 7 Removing and installing fuel system high-pressure pump 2236
3 7 1 Removing 2238
3 7 2 Installing 2240
3 8 Filling/bleeding fuel system 2241
3 9 Checking for leaks in the fuel system 2242
3 10 Checking pressure retention valve in fuel return line 2242
3 11 Assembly overview – intake manifold with attachments 2244
3 12 Removing and installing intake manifold 2245
3 13 Assembly overview – air filter 2249
3 13 1 Assembly overview – air filter (engine codes CBEA, CJAA) 2249
3 13 2 Assembly overview – air filter (engine codes CBDA, CBDB, CEGA) 2251
3 14 Removing and installing air filter housing 2252
3 15 Removing and installing air filter element 2253
3 15 1 Removing 2254
3 15 2 Installing 2254
3 16 Checking changeover flap for intake air preheating 2255
3 17 Removing and installing changeover flap for intake air preheating 2257
3 18 Removing and installing air mass meter -G70- 2259
3 18 1 Removing 2260
3 18 2 Installing 2260
4 Engine control unit (engine codes CBEA, CJAA) 2261
4 1 Removing and installing engine control unit -J623- with no anti-theft device, all vehicles apart from Jetta from MY 2011 2261
4 1 1 Removing 2261
4 1 2 Installing 2262
4 2 Removing and installing engine control unit -J623- with anti-theft device, all vehicles apart from Jetta from MY 2011 2263
4 2 1 Removing 2264
4 2 2 Installing 2266
4 3 Removing and installing engine control unit -J623-, only Jetta from MY 2011 2267
4 3 1 Removing 2267
4 3 2 Installing 2268
5 Engine control unit (engine codes CBDA, CBDB, CEGA) 2270
5 1 Removing and installing engine control unit -J623- with no theft protection 2270
5 2 Removing and installing engine control unit -J623- with theft protection 2272
26 – Exhaust system 2276
1 Exhaust system (engine codes CBEA, CJAA) 2276
1 1 Assembly overview – particulate filter with NOx storage catalytic converter 2276
1 1 1 Assembly overview – particulate filter with NOx storage catalytic converter, one-piece (only CBEA) 2276
1 1 2 Assembly overview – particulate filter with NOx storage catalytic converter, two-piece (CJAA, CBEA) 2279
1 2 Note installation position of securing clamps and exhaust gas temperature sender 2282
1 3 Removing and installing particulate filter with NOx storage catalytic converter 2284
1 3 1 Removing 2286
1 3 2 Installing 2292
1 4 Removing and installing NOx storage catalytic converter 2296
1 5 Assembly overview – exhaust flap control unit -J883- with SCR catalytic converter 2297
1 6 Routing cables/lines of components for exhaust system 2299
1 7 Assembly overview – silencers 2301
1 7 1 Vehicles with code CBEA 2301
1 7 2 Vehicles with code CJAA 2303
1 8 Separating and joining exhaust system 2305
1 8 1 Disconnecting 2305
1 8 2 Connecting 2306
1 9 Aligning exhaust system free of stress 2307
1 10 Checking exhaust system for leaks 2309
1 11 Installation position of clamp 2309
2 Exhaust system (engine codes CBDA, CBDB, CEGA) 2312
2 1 Assembly overview – front exhaust pipe with particulate filter 2312
2 2 Removing and installing particulate filter 2315
2 2 1 Removing 2316
2 2 2 Installing 2320
2 3 Assembly overview – silencers 2321
2 4 Cutting exhaust pipe 2321
2 5 Aligning exhaust system free of stress 2322
3 Exhaust gas recirculation 2324
3 1 Assembly overview – exhaust gas recirculation 2324
3 1 1 Assembly overview – exhaust gas recirculation, engine codes CBDA, CBDB, CEGA 2324
3 1 2 Assembly overview – exhaust gas recirculation, engine codes CBEA, CJAA 2326
3 2 Removing and installing exhaust gas recirculation filter 2328
3 3 Removing and installing exhaust gas recirculation cooler, engine codes CBDA, CBDB, CEGA 2330
3 4 Removing and installing exhaust gas recirculation cooler, engine codes CBEA, CJAA 2335
3 5 Checking exhaust gas recirculation cooler for leaks 2337
3 6 Removing and installing temperature sensor for exhaust gas recirculation 2342
3 7 Cleaning exhaust gas recirculation system 2347
3 7 1 Initiating exhaust gas recirculation system cleaning procedure 2347
3 7 2 Cleaning exhaust gas recirculation valve -N18- and connecting pipe 2353
28 – Glow plug system 2355
1 Glow plugs 2355
1 1 Removing and installing glow plug 2355
1 1 1 Removing 2356
1 1 2 Installing 2359
1 2 Removing and installing connectors for glow pin plugs 2359
1 2 1 Removing: 2360
1 2 2 Installing: 2361
D3E801CBF24 5 speed manual gearbox 0AF 2362
00 – Technical data 2366
1 Gearbox identification 2366
1 1 Location on gearbox 2366
1 2 Identification code, assembly allocation and capacities 2367
2 Overview – power transmission 2369
3 Calculating overall gear ratio “i” 2371
4 General repair notes 2372
4 1 Components 2372
4 1 1 Gearbox 2372
4 1 2 O-rings, seals, gaskets and sealants 2372
4 1 5 Bearings 2374
4 1 7 Synchro-rings 2374
4 1 8 Gears, synchro-hubs, sleeves for needle bearings 2374
4 1 9 Synchromeshed gears 2375
4 1 10 Clutch 2375
30 – Clutch 2376
1 Fault finding, power transmission 2376
2 Repairing clutch mechanism 2377
2 1 Overview 2377
2 2 Assembly overview – pedal cluster 2378
2 3 Removing and installing over-centre spring 2379
2 3 1 Removing 2380
2 3 2 Installing 2382
2 3 3 Specified torques 2384
2 4 Removing and installing clutch pedal 2384
2 4 1 Removing 2385
2 4 2 Installing 2388
2 4 3 Specified torques 2390
2 5 Removing and installing mounting bracket 2390
2 5 1 Removing 2391
2 5 2 Installing 2394
2 5 3 Specified torques 2396
2 6 Removing and installing clutch master cylinder 2396
2 6 1 Removing 2396
2 6 2 Installing 2397
2 7 Removing and installing clutch position sender -G476- 2398
2 7 1 Removing 2398
2 7 2 Installing 2400
2 8 Assembly overview – hydraulics (LHD) 2400
2 9 Assembly overview – hydraulics (RHD) 2403
2 10 Removing and installing clutch slave cylinder 2404
2 10 1 Removing 2404
2 10 2 Installing 2405
3 Bleeding clutch mechanism 2407
4 Repairing clutch release mechanism 2409
4 1 Assembly overview – clutch release mechanism 2409
4 2 Removing and installing clutch release lever, release bearing and guide sleeve 2410
5 Repairing clutch 2411
34 – Controls, housing 2415
1 Repairing selector mechanism 2415
1 1 Installation position of selector mechanism 2415
1 2 Overview of selector mechanism 2416
1 3 Assembly overview – gear lever knob and cover 2417
1 4 Removing and installing gaiter with gear knob and noise insulation 2417
1 5 Assembly overview – selector lever and selector housing (up to 10 06) 2419
1 6 Assembly overview – selector lever and selector housing (from 11 06) 2421
1 6 1 Dismantling and assembling selector mechanism 2423
1 7 Assembly overview – Selector cables 2428
1 8 Removing and installing selector mechanism 2432
1 8 1 Removing 2432
1 9 Removing and installing gear selector cable and gate selector cable 2436
1 9 1 Removing 2436
1 9 2 Installing 2437
1 10 Adjusting selector mechanism 2438
1 10 1 Functional check 2440
1 11 Plastic relay lever 2440
2 Removing and installing gearbox, Jetta 2005 ►, Golf Variant 2007 ► and Golf Variant 2010 ► 2444
2 1 Removing gearbox 2445
2 2 Installing gearbox 2450
2 2 1 Specified torques 2457
3 Removing and installing gearbox, Jetta 2011 ► 2458
3 1 Removing gearbox, Jetta 2011 with 1 6 l engine and 2 0 l engine 2458
3 2 Installing gearbox, Jetta 2011 with 1 6 l engine and 2 0 l engine 2467
3 2 1 Specified torques 2473
4 Transporting gearbox 2475
5 Checking gear oil 2477
6 Dismantling and assembling gearbox 2479
6 1 Overview – gearbox 2479
6 2 Assembly overview 2480
6 3 Assembly overview – removing and installing cover for gearbox housing and 5th gear 2481
6 4 Assembly overview – removing and installing clutch housing 2482
6 5 Assembly overview – removing and installing input shaft, output shaft, differential, selector mechanism and selector forks 2483
6 6 Dismantling and assembling procedure 2484
6 6 1 Dismantling gearbox 2486
6 6 2 Assembling gearbox 2490
7 Repairing gearbox housing and clutch housing 2495
8 Repairing selector unit 2500
9 Dismantling and assembling selector forks 2503
35 – Gears, shafts 2508
1 Input shaft 2508
1 1 Dismantling and assembling input shaft 2508
2 Output shaft 2519
2 1 Dismantling and assembling output shaft 2519
39 – Final drive – rear differential 2527
1 Renewing flange shaft oil seals with gearbox installed 2527
1 1 Renewing oil seal for left flange shaft 2527
1 1 1 Removing 2527
1 1 2 Installing 2528
1 2 Renewing seal for right flange shaft 2529
1 2 1 Removing 2529
1 2 2 Installing 2530
2 Differential 2531
2 1 Dismantling and assembling differential 2531
2 2 Adjusting differential 2538
2 2 1 Determining shim S2 2541
D3E801F2B16 Electrical system General information 2543
27 – Starter, current supply, CCS 2547
1 Battery 2547
1 1 Fundamentals for batteries 2547
1 2 Battery load test 2547
1 2 1 Battery with »standard« colour indicator 2548
1 2 2 Battery with »enhanced« colour indicator 2548
1 2 3 Absorbent glass mat battery 2549
1 2 4 Lithium ion battery 2549
1 3 Warning notices and safety regulations 2549
1 3 1 Dangers when handling vehicle batteries 2549
1 3 2 Safety markings on battery 2550
1 3 3 Working on airbag system 2551
1 4 Battery load test 2551
2 Checking battery 2553
2 1 Checking the various types of batteries 2553
2 1 1 Checking a battery with colour indicator 2553
2 1 2 Absorbent glass mat battery 2553
2 2 Inspection 2554
2 3 Information about battery replacement and battery gas venting 2555
2 4 Checking colour indicator in battery cover 2556
2 4 1 Checking colour indicator, “3-colour” 2556
2 4 2 Checking colour indicator, “2-colour” 2557
2 5 Battery tester with printer -VAS 6161- 2558
2 5 1 Description of battery tester with printer -VAS 6161- 2559
2 5 2 Perform battery test with battery tester with printer -VAS 6161- 2559
2 5 3 Genuine Volkswagen battery test 2561
2 5 4 “Non”-VW battery test 2561
2 5 5 Carrying out stock maintenance 2562
2 5 6 Comments concerning test print out 2562
2 5 7 Assessing test results 2563
2 6 Midtronics -MCR340V- battery tester only for USA/Canada vehicles 2563
2 6 1 General description 2564
2 6 2 Performing battery test with Midtronics -MCR340V- battery tester 2565
2 6 3 Assessing test results 2566
2 6 4 Dealing with problems with Midtronics -MCR340V- battery tester 2566
2 7 Current draw test 2567
3 Charging the battery 2569
3 1 Battery charger -VAS 5095 A- 2569
3 1 1 Description of battery charger -VAS 5095 A- 2570
3 1 2 Charging battery with battery charger -VAS 5095 A- 2571
3 1 3 Charging totally discharged battery with battery charger -VAS 5095 A- 2572
3 1 4 Charging battery in support mode with battery charger -VAS 5095A- 2573
3 1 5 Charging battery in trickle charge mode with battery charger -VAS 5095 A- 2575
3 2 Battery charger -VAS 5900- 2576
3 2 1 Description of battery charger -VAS 5900- 2576
3 2 2 Charging battery with battery charger -VAS 5900- 2577
3 2 3 Charging battery in service mode with battery charger -VAS 5900- 2580
3 2 4 Charging totally discharged batteries with battery charger -VAS 5900- 2583
3 2 5 Charging battery in support mode with battery charger -VAS 5900- 2585
3 2 6 Charging battery in trickle charge mode with battery charger -VAS 5900- 2587
3 3 Battery charger -VAS 5900 A- 2588
3 3 1 General description – battery charger -VAS 5900 A- 2588
3 3 2 Charging battery with battery charger -VAS 5900 A- 2590
3 3 3 Charging totally discharged battery with battery charger -VAS 5900 A- 2591
3 3 4 Charging battery in support mode with battery charger -VAS 5900 A- 2594
3 3 5 Mains supply mode with battery charger -VAS 5900 A- 2596
3 4 Battery charger -VAS 5903- 2597
3 4 1 Description of battery charger -VAS 5903- 2598
3 4 2 Charging battery with battery charger -VAS 5903- 2598
3 4 3 Charging battery in refresh charge mode with battery charger -VAS 5903- 2601
3 4 4 Charging totally discharged battery with battery charger -VAS 5903- 2604
3 4 5 Charging battery in support mode with battery charger -VAS 5903- 2606
3 4 6 Charging battery in trickle charge mode with battery charger -VAS 5903- 2608
3 5 Battery charger -VAS 5906- 2609
3 5 1 General description 2609
3 5 2 Charging battery with battery charger -VAS 5906- 2610
3 6 Battery charger -VAS 5908- 2612
3 6 1 General description – battery charger -VAS 5908- 2612
3 6 2 Auto mode on battery charger -VAS 5908- 2614
3 6 3 Charging battery with battery charger -VAS 5908- 2615
3 6 4 Charging battery in support mode with battery charger -VAS 5908- 2617
3 6 5 VAS I-CHECK current draw test with battery charger -VAS 5908- 2619
3 7 Midtronics -INC 940- battery charger only for USA/Canada 2621
3 7 1 General description of Midtronics -INC 940- battery tester 2621
3 7 2 Charging battery 2622
3 7 3 Dealing with problems with Midtronics -INC 940- battery tester 2624
3 8 Solar charger module -VAS 6102B- 2625
3 8 1 Charging battery in trickle charge mode with solar panel -VAS 6102B- 2625
3 9 Totally discharged batteries 2626
4 Cruise control system (CCS) 2628
4 1 Activating and deactivating cruise control system (CCS) 2628
90 – Gauges, instruments 2629
92 – Windscreen wash/wipe system 2630
1 Washer fluid line hose couplings 2630
1 1 Windscreen and rear window washer system 2630
1 2 Headlight washer system 2631
2 Hose repair 2632
2 1 General description 2632
2 2 Repairing smooth pipe 2632
2 3 Repairing corrugated pipe 2632
3 Distinguishing features of jointless wiper blades 2635
94 – Lights, bulbs, switches – exterior 2636
1 Operation and safety notes for gas discharge lamps 2636
96 – Lights, bulbs, switches – interior 2639
1 12 V socket 2639
1 1 Removing and installing 12 V socket 2639
1 2 Removing and installing socket illumination bulb -L42- 2639
2 Cigarette lighter -U1- 2640
2 1 General description 2640
2 2 Assembly overview 2641
2 3 Removing and installing cigarette lighter socket 2642
2 4 Removing and installing cigarette lighter illumination bulb -L28- 2645
97 – Wiring 2647
1 Vehicle diagnosis, testing and information systems 2647
1 1 Connecting vehicle diagnostic tester 2647
1 2 Connecting vehicle diagnostic tester Golf Model Year 1998 – 2003 2649
2 Repairs to wiring harnesses and connectors 2650
2 1 General notes concerning repairs to vehicle electrical system 2650
2 2 Wiring harness repair set 2652
2 2 1 Wiring harness repair set -VAS 1978- 2652
2 2 2 Upgrade kit -VAS 1978/50- 2652
2 2 3 Wiring harness repair set -VAS 1978A- 2653
2 2 4 Release tool set -VAS 1978/35- 2653
2 3 Tool descriptions 2654
2 3 1 Special pliers with insert 2654
2 3 2 Release tools for contacts 2655
2 3 3 Assembly tools for single wire seals 2655
2 3 4 Wire stripper -VAS 1978/3- 2655
2 3 5 Hot air blower 220 V/50 Hz -VAS 1978/14- 2657
2 3 6 Crimping pliers -VAS 1978/1A- 2657
2 4 Repairing wiring harnesses 2659
2 4 1 Repairs to airbag and belt tensioner wiring 2659
2 4 2 Repairing CAN bus wiring 2661
2 4 3 Repair of Flexray wires with sheath 2662
2 4 4 Repair of Flexray wires without sheath 2663
2 4 5 Renewal of aerial wiring 2664
2 4 6 Repairing 0 13 mm2/0 35 mm2/0 5 mm2 wire 2666
2 4 7 Repair of 10 mm2 or 16 mm2 wire with single butt connector 2671
2 4 8 Repair of 2 5 mm2, 4 mm2 or 6 mm2 aluminium wire with single butt connector 2678
2 4 9 Wiring open circuit with one repair position 2684
2 4 10 Wiring open circuit with two repair positions 2687
2 5 Repairing fibre optic cables 2689
2 5 1 Preparing fibre optic cable 2690
2 5 2 Detaching fibre optic cable from cable harness connector 2697
2 6 Repair of aerial wires 2698
2 6 1 Repair set, aerial cable VAS 6720 2698
2 7 Repairs to contact housings and connectors 2710
2 7 1 Notes on repairs to contact housings and connectors 2710
2 7 2 Repairs to contacts in contact housings 2710
2 7 3 Fitting single wire seals 2712
2 7 4 Repairs to contact housings using cut-and-clamp method 2715
2 8 Releasing and dismantling contact housings 2716
2 8 1 Notes on releasing and dismantling contact housings 2716
2 8 2 Secondary locking element 2716
2 8 3 Primary locking element 2717
2 8 4 Round connector systems 2718
2 8 5 Flat connector systems 2719
2 8 6 Special connector systems 2721
3 Contact surface cleaning set -VAS 6410- 2724
3 1 Using contact surface cleaning set -VAS 6410- 2724
3 1 1 Repairing ring terminals 2724
3 1 2 Repairing threaded connections 2726
3 1 3 Cleaning battery clamp and battery terminal 2728
3 1 4 Anti-corrosion treatment 2730
4 Renewing lambda probe 2732
4 1 Renewing LSF Lambda probe (4-pin) 2732
4 2 Renewing LSU Lambda probe (6-pin) 2733
4 3 Types of protective tube on universal lambda probes 2734
5 Exhaust gas temperature sensor 2736
D3E801F5940 4 cylinder diesel engine (1 6 l engine common rail) 2737
00 – Technical data 2743
1 Technical data 2743
1 1 Engine number 2743
1 2 Engine data 2743
10 – Removing and installing engine 2744
1 Removing and installing engine 2744
1 1 Removing and installing engine cover 2744
1 2 Removing engine 2745
1 3 Separating gearbox from engine and assembling 2753
1 3 1 Disconnecting 2754
1 3 2 Installing 2754
1 4 Securing engine on engine and gearbox support -VAS 6095- 2754
1 5 Notes on installing 2756
2 Assembly mounting, except Jetta 2011 ▶ 2759
2 1 Assembly mountings 2759
2 2 Checking adjustment of engine assembly mountings 2761
2 3 Adjusting assembly mountings 2761
3 Assembly mounting, Jetta 2011 ▶ 2765
3 1 Assembly overview – assembly mountings 2765
3 2 Removing and installing engine mounting 2766
3 3 Removing and installing gearbox mounting 2769
3 4 Removing and installing pendulum support 2771
3 5 Supporting engine in installation position 2772
3 6 Adjusting assembly mountings 2776
3 7 Checking adjustment of assembly mountings (engine and gearbox mountings) 2777
13 – Crankshaft group 2778
1 Dismantling and assembling engine 2778
1 1 Assembly overview – poly V-belt drive 2778
1 1 1 Assembly overview – poly V-belt drive without air conditioning compressor 2778
1 1 2 Assembly overview – poly V-belt drive with idler roller and air conditioner compressor 2780
1 1 3 Assembly overview – poly V-belt drive with tensioning element and air conditioner compressor 2781
1 2 Removing and installing poly V-belt without air conditioner compressor 2781
1 3 Removing and installing poly V-belt with idler roller and air conditioner compressor 2782
1 4 Removing and installing poly V-belt with tensioning element 2783
1 5 Removing and installing tensioning element for poly V-belt 2784
1 6 Removing and installing vibration damper 2786
1 7 Removing and installing bracket for ancillaries 2786
1 8 Assembly overview – toothed belt drive 2788
1 9 Removing and installing engine bracket 2790
1 10 Assembly overview – crankcase 2793
2 Removing and installing sealing flange and flywheel 2795
2 1 Assembly overview – cylinder block, gearbox end 2795
2 2 Removing and installing dual-mass flywheel 2797
2 3 Renewing crankshaft sealing flange, flywheel end 2798
2 3 1 Pressing out sealing flange with sender wheel 2799
2 3 2 Pressing in sealing flange with sender wheel 2800
2 3 3 a) Securing seal with sender wheel on assembly tool -T10134- 2801
2 3 4 b) Securing assembling tool -T10134- with sealing flange on crankshaft flange 2803
2 3 5 c) Bolting assembly tool -T10134- onto crankshaft flange 2804
2 3 6 D – Pressing sender wheel onto crankshaft flange using assembly tool -T10134- 2804
2 3 7 e) Checking sender wheel installation position on crankshaft 2804
2 3 8 f) Re-pressing sender wheel 2805
2 4 Renewing crankshaft oil seal, pulley end 2806
2 5 Removing and installing sealing flange – pulley end 2808
2 6 Removing and installing engine speed sender -G28- 2811
3 Pistons and conrods 2813
3 1 Assembly overview – pistons and conrods 2813
3 2 Separating new conrod 2816
3 3 Piston and cylinder dimensions 2816
3 4 Checking piston projection at TDC 2816
4 Crankshaft 2819
4 1 Assembly overview – crankshaft 2819
4 2 Renewing needle bearing in crankshaft, vehicles with dual clutch gearbox only 2820
4 3 Crankshaft dimensions 2821
15 – Cylinder head, valve gear 2822
1 Cylinder head 2822
1 1 Assembly overview – cylinder head cover 2822
1 2 Removing and installing Hall sender -G40- 2823
1 3 Removing and installing cylinder head cover 2825
1 4 Removing and installing injector seals 2831
1 5 Assembly overview – cylinder head 2831
1 6 Removing, installing and tensioning toothed belt 2834
1 6 1 Differences between versions of tensioning roller 2836
1 6 2 Removing toothed belt 2837
1 6 3 Installing and tensioning toothed belt 2842
1 7 Removing and installing cylinder head 2848
1 7 1 Removing 2851
1 7 2 Installing 2858
1 8 Removing and installing vacuum pump 2860
1 9 Checking compression 2860
2 Valve gear 2862
2 1 Assembly overview – valve gear 2862
2 2 Checking valve guides 2863
2 3 Renewing valve stem seals 2864
2 4 Removing and installing camshafts 2868
2 4 1 Removing 2869
2 4 2 Installing 2871
2 5 Checking hydraulic compensation elements 2875
2 6 Removing and installing camshaft oil seal 2875
17 – Lubrication 2878
1 Engine oil: 2878
1 1 Oil capacities 2878
1 2 Checking engine oil level 2878
2 Parts of lubrication system 2879
2 1 Assembly overview – oil pump, sump 2879
2 2 Removing and installing sump 2881
3 Oil filter bracket, oil pressure, engine oil cooler and oil supply line 2885
3 1 Assembly overview – oil filter bracket and engine oil cooler 2885
3 2 Checking oil pressure and oil pressure switch 2886
3 2 1 Oil pressure switch -F1- 2887
3 2 2 Checking oil pressure 2887
4 Oil supply line and turbocharger support 2889
4 1 Assembly overview – oil supply line and turbocharger support 2889
4 2 Removing and installing oil supply line and turbocharger support 2889
19 – Cooling 2895
1 Parts of cooling system 2895
1 1 Assembly overview – parts of cooling system, body side 2896
1 2 Assembly overview – parts of cooling system, engine side 2898
1 3 Connection diagram for coolant hoses – not for Jetta from MY 2011 2900
1 4 Connection diagram for coolant hoses (vehicles with 4/2-way valve) – not for Jetta from MY 2011 2901
1 5 Connection diagram for coolant hoses (vehicles with 4/2-way valve) – only for Jetta from MY 2011 2901
1 6 Assembly overview – coolant pump and thermostat 2903
1 7 Assembly overview – coolant pump and 4/2-way valve with thermostat 2904
2 Repairing cooling system 2905
2 1 Removing and installing cowling with radiator fan -V7- and radiator fan 2 -V177- 2905
2 2 Draining and adding coolant 2906
2 2 1 Draining 2908
2 2 2 Filling 2909
2 3 Removing and installing radiator 2911
2 4 Removing and installing coolant pump 2913
2 5 Removing and installing thermostat 2914
2 6 Checking thermostat 2916
2 7 Removing and installing 4/2-way valve with thermostat 2916
2 8 Checking cooling system for leaks 2922
2 8 1 Check pressure relief valve in cap 2923
2 9 Checking engine oil cooler for leaks 2924
20 – Fuel supply system 2926
1 Safety measures when working on fuel supply 2926
2 Rules for cleanliness 2927
3 Procedure should vehicle be misfueled 2928
3 1 Step 1 (Engine was started with incorrect fuel) 2928
3 2 Step 2 (Engine was not started with incorrect fuel) 2929
3 3 Step 3 (There are filings in fuel delivery unit and fuel tank) 2930
3 4 Step 4 (There are no filings in fuel delivery unit and fuel tank) 2931
3 5 Step 5 (There are filings in high-pressure pump) 2931
3 6 Step 6 (There are no filings in high-pressure pump) 2931
4 Parts of fuel supply system 2932
4 1 Assembly overview – fuel tank, all vehicles apart from Jetta from MY 2011 2932
4 2 Assembly overview – fuel tank, only Jetta from MY 2011 2934
4 3 Emptying fuel tank 2936
4 3 1 Emptying fuel tank when fuel pump is intact 2937
4 3 2 Emptying fuel tank if it is more than 3/4 full 2938
4 3 3 Emptying fuel tank if it is less than 3/4 full 2939
4 4 Removing and installing fuel tank 2939
4 5 Removing and installing fuel delivery unit 2942
4 6 Removing and installing fuel gauge sender 2946
5 Repairing fuel supply 2948
5 1 Assembly overview – fuel filter, all vehicles but Jetta from MY 2011 2948
5 2 Assembly overview – fuel filter, only Jetta from MY 2011 2950
5 3 Removing and installing fuel filter 2950
5 4 Removing and replacing fuel hoses in engine compartment, 6 0 bar low pressure fuel system 2953
5 5 Assembly overview – fuel filter, 6 0 bar low pressure fuel system 2954
5 6 Removing and installing fuel filter, 6 0 bar low pressure fuel system 2955
5 7 Checking fuel pump (pressurisation pump) -G6-/fuel pump 2 -V277- 2956
5 7 1 Checking delivery pressure 2956
5 7 2 Checking fuel delivery rate 2957
5 7 3 Checking voltage supply 2959
5 7 4 Checking current consumption 2960
5 8 Checking fuel pump – vehicles with 6 0 bar low pressure fuel system 2962
5 8 1 Checking delivery pressure of fuel pump 2963
5 8 2 Checking fuel system pressurisation pump delivery rate 2967
5 8 3 Checking voltage supply of fuel pump 2970
5 8 4 Checking current consumption of fuel pump 2971
6 Electronic power control (EPC) 2974
6 1 Function of EPC system 2974
6 2 Assembly overview – accelerator module 2974
6 3 Removing and installing accelerator pedal module 2975
6 3 1 Removing 2976
6 3 2 Installing 2977
21 – Turbocharging/supercharging 2978
1 Safety precautions when working on charge air system and turbocharger 2978
2 Rules for cleanliness 2979
3 Turbocharger 2980
3 1 Assembly overview – turbocharger 2980
3 2 Tightening exhaust gas temperature sender 1 -G235- 2983
3 3 Removing and installing turbocharger 2984
4 Charge air system 2992
4 1 Assembly overview – charge air system 2992
4 2 Removing and installing charge air cooler 2993
4 3 Assembly overview – charge-air hose connections 2995
4 3 2 Hose connections with plug-in connectors 2996
4 3 3 Removing and installing charge air pipe »hot« side 2997
4 4 Vacuum hose connection diagram 2998
4 5 Checking charge air system for leaks 2999
4 6 Checking vacuum system 3002
4 6 1 Checking fuel supply line and non-return valve 3002
4 6 2 Checking control line to turbocharger 3003
4 6 3 Checking control line to vacuum unit for exhaust gas recirculation cooler changeover function 3004
23 – Mixture preparation – injection 3005
1 Observe safety precautions when working on diesel direct injection fuel system 3005
2 Rules for cleanliness 3006
3 Instructions for working on fuel system 3007
4 Diesel direct injection system 3009
4 1 System layout 3010
4 2 Assembly overview – fuel system 3012
4 2 1 Versions of fuel return lines 3014
4 2 2 Versions of high pressure pumps and fuel pressure regulating valve -N 276- 3016
4 3 Assembly overview – installation position of clamp 3017
4 4 Removing and installing injectors (piezo injectors) 3018
4 4 1 Removing 3019
4 4 2 Installing 3020
4 5 Removing and installing fuel rail 3022
4 6 Removing and installing high-pressure lines 3026
4 6 1 Removing high-pressure lines between fuel rail and injectors 3027
4 6 2 Removing high-pressure line between fuel rail and high-pressure pump 3028
4 6 3 Installing high-pressure lines 3029
4 7 Checking fuel pressure regulating valve -N276- 3031
4 8 Removing and installing fuel pressure regulating valve -N 276- 3032
4 9 Removing and installing fuel pressure sender -G247- 3034
4 10 Removing and installing high-pressure pump 3036
4 11 Filling/bleeding high-pressure pump/fuel system 3042
4 12 Checking for leaks in the fuel system 3043
4 13 Check pressure retention valve in fuel return line 3044
4 14 Checking injectors (piezo injectors) with vacuum 3045
4 15 Assembly overview – intake manifold with attachments (vehicles with intake manifold flap -V157-) 3047
4 16 Assembly overview – intake manifold with attachments, vehicles without intake manifold flap 3049
4 17 Removing and installing intake manifold (vehicle with intake manifold flap -V157-) 3050
4 18 Removing and installing throttle valve module -J338- 3053
4 19 Assembly overview – air filter 3054
4 20 Removing and installing air filter housing 3056
4 21 Removing and installing air filter element 3057
4 21 1 Removing 3057
4 21 2 Installing 3058
4 22 Removing and installing air mass meter -G70- 3059
4 22 1 Removing 3060
4 22 2 Installing 3060
5 Engine control unit 3061
5 1 Removing and installing engine control unit -J623- with no anti-theft device, all vehicles apart from Jetta from MY 2011 3061
5 2 Removing and installing engine control unit -J623- with anti-theft device, all vehicles apart from Jetta from MY 2011 3063
5 3 Removing and installing engine control unit -J623-, only Jetta from MY 2011 3066
5 3 1 Removing 3066
5 3 2 Installing 3067
26 – Exhaust system 3069
1 Exhaust system 3069
1 1 Assembly overview – particulate filter, all vehicles apart from Jetta from MY 2011 3069
1 2 Assembly overview – particulate filter, only Jetta from MY 2011 3072
1 3 Tightening exhaust gas temperature sender 3 -G495- 3073
1 4 Removing and installing pressure differential sender -G 505- 3074
1 5 Assembly overview – front exhaust pipe with catalytic converter 3077
1 6 Removing and installing particulate filter 3079
1 6 1 Removing particulate filter 3080
1 6 2 Installing particulate filter 3085
1 7 Assembly overview – silencers 3087
1 8 Separating exhaust system 3087
1 9 Aligning exhaust system free of stress 3089
1 10 Installation position of clamp 3090
2 Exhaust gas recirculation 3091
2 1 Assembly overview – exhaust gas recirculation 3091
2 2 Checking changeover for exhaust gas recirculation cooler 3092
2 3 Removing and installing exhaust gas recirculation cooler 3093
2 4 Checking exhaust gas recirculation cooler for leaks 3096
2 5 Cleaning exhaust gas recirculation system 3099
2 5 1 Initiating cleaning of exhaust gas recirculation system 3099
2 5 2 Cleaning connecting pipes and pipe union 3105
28 – Glow plug system 3106
1 Glow plug system 3106
1 1 Removing and installing glow plug 3106
1 2 Checking glow plugs 3108
D3E802A6B9C Electrical system 3109
27 – Starter, current supply, CCS 3117
1 Battery 3117
1 1 Types of battery 3117
1 2 Battery – general notes 3117
1 2 1 Warning notices and safety regulations 3117
1 2 2 Battery terminal connection 3117
1 2 3 Battery recharging or jump start on vehicles with start/stop system 3117
1 3 Assembly overview – battery 3118
1 3 1 Assembly overview – battery -A- in engine compartment 3118
1 3 2 Assembly overview – battery -A- in luggage compartment, high-voltage vehicle 3119
1 4 Removing and installing battery 3120
1 4 1 Removing and installing battery -A- in engine compartment 3120
1 4 2 Removing and installing battery -A- in luggage compartment, high-voltage vehicle 3121
1 4 3 Adapting battery -A- 3122
1 5 Disconnecting and reconnecting battery 3123
1 5 1 Disconnecting battery -A- in engine compartment 3123
1 5 2 Reconnecting battery -A- in engine compartment 3124
1 5 3 Disconnecting battery -A- in luggage compartment, high-voltage vehicle 3125
1 5 4 Reconnecting battery -A- in luggage compartment, high-voltage vehicle 3126
1 6 Removing and installing battery tray 3127
1 6 1 Removing and installing battery tray in engine compartment 3127
1 6 2 Removing and installing battery tray in luggage compartment, high-voltage vehicle 3127
1 7 Checking battery 3128
1 8 Charging battery 3128
1 9 Removing and installing earth wire with battery monitor control unit -J367- 3128
1 9 1 Battery monitoring control unit -J367- 3128
1 9 2 Renewing and commissioning battery monitor control unit -J367- 3129
1 9 3 Removing and installing battery monitor control unit -J367- in engine compartment 3129
1 9 4 Removing and installing battery monitor control unit -J367- in luggage compartment, high-voltage vehicle 3130
2 Alternator 3132
2 1 Assembly overview – alternator 3132
2 1 1 Assembly overview – alternator, 1 2 l petrol engine, 77 kW 3132
2 1 2 Assembly overview – alternator, 1 4 l petrol engine, 90/110/118 kW 3133
2 1 3 Assembly overview – alternator, 1 6 l petrol engine, 77 kW 3134
2 1 4 Assembly overview – alternator, 2 0 l petrol engine, 85 kW 3135
2 1 5 Assembly overview – alternator, 2 0 l petrol engine, 147 kW 3136
2 1 6 Assembly overview – alternator, 2 5 l petrol engine, 125 kW 3137
2 1 7 Assembly overview – alternator, 1 8 l petrol engine, 125 kW 3138
2 1 8 Assembly overview – alternator, 1 6 l diesel engine, 77 kW 3139
2 1 9 Assembly overview – alternator, 2 0 l diesel engine, 81/103 kW 3140
2 2 Removing and installing alternator 3142
2 2 1 Removing and installing alternator -C-, 1 2 l, 77 kW petrol engine 3142
2 2 2 Removing and installing alternator -C-, 1 4 l, 90/110/118 kW petrol engines 3144
2 2 3 Removing and installing alternator -C-, 1 6 l, 77 kW petrol engine 3147
2 2 4 Removing and installing alternator -C-, 2 0 l, 85 kW petrol engine 3149
2 2 5 Removing and installing alternator -C-, 2 0 l, 147 kW petrol engine 3151
2 2 6 Removing and installing alternator -C-, 2 5 l, 125 kW petrol engine 3154
2 2 7 Removing and installing alternator -C-, 1 8 l, 125 kW petrol engine 3157
2 2 8 Removing and installing alternator -C-, 1 6 l, 77 kW diesel engine 3159
2 2 9 Removing and installing alternator -C-, 2 0 l, 81/103 kW diesel engines 3162
2 3 Checking alternator 3165
2 4 Checking poly V-belt 3165
2 5 Removing and installing poly V-belt pulley 3165
2 5 1 Removing and installing poly V-belt pulley, without freewheel 3165
2 5 2 Removing and installing Bosch poly V-belt pulley with freewheel 3166
2 5 3 Removing and installing Valeo poly V-belt pulley with freewheel 3168
2 6 Removing and installing voltage regulator 3171
2 6 1 Removing and installing Bosch voltage regulator -C1- 3171
2 6 2 Removing and installing Valeo voltage regulator -C1- 3171
3 Starter 3174
3 1 Assembly overview – starter 3174
3 1 1 Assembly overview – starter, automatic gearbox or dual clutch gearbox 3174
3 1 2 Assembly overview – starter, manual gearbox 3175
3 1 3 Assembly overview – starter, 1 8 l petrol engine and automatic gearbox 3176
3 2 Removing and installing starter 3177
3 2 1 Removing and installing starter, 1 6 l petrol engine, 77 kW, automatic gearbox 3177
3 2 2 Removing and installing starter, 2 0 l petrol engine, 85 kW, automatic gearbox 3180
3 2 3 Removing and installing starter, 2 5 l petrol engine, 125 kW, automatic gearbox 3182
3 2 4 Removing and installing starter, 1 8 l petrol engine, 125 kW, automatic gearbox 3185
3 2 5 Removing and installing starter, 1 2 l petrol engine, 77 kW, dual clutch gearbox 3187
3 2 6 Removing and installing starter, 1 4 l petrol engine, 90/110/118 kW, dual clutch gearbox 3190
3 2 7 Removing and installing starter, 2 0 l petrol engine, 85 kW, dual clutch gearbox 3192
3 2 8 Removing and installing starter, 2 0 l petrol engine, 147 kW, dual clutch gearbox 3194
3 2 9 Removing and installing starter, 1 6 l diesel engine, 77 kW, dual clutch gearbox 3196
3 2 10 Removing and installing starter, 2 0 l diesel engine, 81/103 kW, dual clutch gearbox 3198
3 2 11 Removing and installing starter, 1 2 l petrol engine, 77 kW, manual gearbox 3200
3 2 12 Removing and installing starter, 1 4 l petrol engine, 90/110/118 kW, manual gearbox 3202
3 2 13 Removing and installing starter, 1 6 l petrol engine, 77 kW, manual gearbox 3205
3 2 14 Removing and installing starter, 2 0 l petrol engine, 85 kW, manual gearbox 3207
3 2 15 Removing and installing starter, 2 0 l petrol engine, 147 kW, manual gearbox 3209
3 2 16 Removing and installing starter, 2 5 l petrol engine, 125 kW, manual gearbox 3211
3 2 17 Removing and installing starter, 1 6 l diesel engine, 77 kW, manual gearbox 3213
3 2 18 Removing and installing starter, 2 0 l diesel engine, 81/103 kW, manual gearbox 3216
3 3 Checking starter 3218
4 Cruise control system (CCS) 3219
5 Start/Stop system 3220
5 1 Safety precautions when working on vehicles with start/stop system 3220
5 2 General description – start/stop system 3220
5 3 Removing and installing voltage stabiliser 3222
5 3 1 Removing and installing ( left-hand drive models) voltage stabiliser -J532- 3222
5 3 2 Removing and installing (right-hand drive models) voltage stabiliser -J532- 3222
90 – Gauges, instruments 3224
1 Dash panel insert 3224
1 1 Assembly overview – dash panel insert 3224
1 1 1 Overview – dash panel insert 3224
1 1 2 Assembly overview – dash panel insert 3224
1 1 3 Warning lamp symbols in dash panel insert, High version 3225
1 1 4 Warning lamp symbols in dash panel insert, petrol engine, Low version 3227
1 1 5 Warning lamp symbols in dash panel insert, diesel engine, Low version 3228
1 2 Removing and installing dash panel insert 3229
1 2 1 Renewing dash panel insert 3229
1 2 2 Removing and installing dash panel insert 3229
1 3 Multi-pin connector pin assignment on dash panel insert 3230
1 4 Removing and installing ambient temperature sensor -G17- 3230
2 Horn 3232
2 1 Assembly overview – horn 3232
2 2 Removing and installing horn 3232
92 – Windscreen wash/wipe system 3234
1 Windscreen wiper system 3234
1 1 Assembly overview – windscreen wiper system 3234
1 2 Moving wipers to service position 3235
1 2 1 Moving wipers to service position 3235
1 2 2 Deactivating wiper motor control unit -J400- APP function 3235
1 3 Removing and installing wiper blade 3235
1 4 Removing and installing windscreen wiper arms 3236
1 5 Adjusting windscreen wiper arms 3237
1 6 Removing and installing windscreen wiper motor -V- 3239
1 6 1 Removing wiper frame with linkage and wiper motor -V- 3239
1 6 2 Removing and installing windscreen wiper motor -V- 3239
1 7 Removing and installing rain and light sensor -G397- 3241
1 7 1 Repairing rain and light sensor -G397- (made by TRW) 3243
2 Windscreen washer system 3245
2 1 Assembly overview – windscreen washer system 3245
2 2 Removing and installing washer fluid reservoir 3246
2 2 1 Removing and installing filler neck 3246
2 2 2 Removing and installing washer fluid reservoir 3247
2 3 Removing and installing windscreen washer fluid level sender -G33- 3247
2 4 Removing and installing windscreen washer pump -V5- 3248
2 5 Removing and installing washer jets 3249
2 6 Adjusting spray jets 3249
3 Headlight washer system 3250
3 1 Assembly overview – headlight washer system 3250
3 2 Removing and installing headlight washer system pump -V11- 3250
3 3 Removing and installing washer jets 3251
3 4 Adjusting spray jets 3252
3 5 Removing and installing pop-up cylinder 3252
4 Washer fluid lines 3254
4 1 Repairing washer fluid lines 3254
94 – Lights, bulbs, switches – exterior 3255
1 Headlight 3255
1 1 Operation and safety notes for gas discharge bulbs 3255
1 2 Assembly overview – headlight 3258
1 2 1 Overview – headlights, halogen bulbs, halogen headlights 3258
1 2 2 Overview – headlights, gas discharge bulbs, cornering light, Xenon headlights 3258
1 2 3 Assembly overview – headlights, halogen bulbs, halogen headlights 3259
1 2 4 Assembly overview – headlights, gas discharge bulbs, cornering light, Xenon headlights 3261
1 3 Removing and installing headlight 3262
1 4 Adjusting headlights 3263
1 4 1 Adjusting headlights, headlight with halogen bulb 3263
1 4 2 Adjusting headlights, Xenon headlights 3263
1 4 3 Performing basic settings for Xenon headlights 3264
1 5 Adjusting headlight installation position 3264
1 6 Removing and installing front turn signal bulb 3265
1 6 1 Removing and installing front turn signal bulb, headlight with halogen bulb 3265
1 6 2 Removing and installing front turn signal bulb, Xenon headlights 3266
1 7 Installing repair kit for headlight housing 3267
1 7 1 Repairing outer retaining tab 3267
1 7 2 Repairing centre retaining tab 3268
1 7 3 Repairing inner retaining tab 3269
1 7 4 Repairing lower retaining tab 3270
1 8 Changing headlights over from driving on right to driving on left 3271
1 9 Changing headlights over from driving on left to driving on right 3272
1 10 Removing and installing headlight range control actuator 3273
1 10 1 Removing and installing headlight range control actuator 3273
1 10 2 Checking headlight range control actuator 3274
1 11 Renewing headlight dipped beam bulb 3275
1 12 Renewing headlight main beam bulb 3275
1 13 Removing and installing gas discharge bulb 3276
1 14 Removing and installing bulb for daytime running light/side light 3278
1 14 1 Removing and installing bulb for daytime running light 3278
1 14 2 Removing and installing side light bulb 3279
1 15 Removing and installing daytime running light 3280
1 15 1 Removing and installing LED module for daytime running light and side light 3280
1 16 Removing and installing headlight screen adjustment solenoid 3281
1 16 1 Removing and installing headlight screen adjustment solenoid 3281
1 16 2 Testing headlight screen adjustment solenoid 3281
1 17 Removing and installing swivel module position sensor 3281
1 17 1 Removing and installing swivel module position sensor 3281
1 17 2 Checking swivel module position sensor 3281
1 18 Removing and installing static cornering light bulb 3282
1 19 Removing and installing gas discharge bulb control unit 3283
1 20 Removing and installing power output module for headlight 3284
1 20 1 Removing and installing power output module for headlight 3284
1 20 2 Checking power output module for headlight 3284
2 Fog lights 3286
2 1 Assembly overview – fog lights 3286
2 1 1 Assembly overview – fog lights, Jetta 3286
2 1 2 Assembly overview – fog lights, Jetta GLI 3287
2 2 Removing and installing fog light 3287
2 2 1 Removing and installing fog light, Jetta 3287
2 2 2 Removing and installing fog light, Jetta GLI 3288
2 3 Removing and installing fog light bulb 3289
2 3 1 Removing and installing fog light bulb, Jetta 3289
2 3 2 Removing and installing fog light bulb, Jetta GLI 3289
2 4 Adjusting fog lights 3290
3 Side marker light 3291
3 1 Removing and installing side marker light bulb 3291
4 Lights in exterior mirror 3293
4 1 Assembly overview – lights in exterior mirror 3293
4 2 Removing and installing turn signal repeater bulb 3293
4 3 Removing and installing entry light in exterior mirror 3294
5 Tail lights 3295
5 1 Assembly overview – tail lights in body 3295
5 1 1 Assembly overview – tail lights in vehicle body (bulbs) 3295
5 1 2 Assembly overview – tail lights in vehicle body (LEDs) 3297
5 2 Assembly overview – tail lights in rear lid 3298
5 2 1 Assembly overview – tail lights in rear lid (bulbs) 3298
5 2 2 Assembly overview – tail lights in rear lid (LEDs) 3298
5 3 Removing and installing bulb carrier 3299
5 3 1 Removing and installing tail light bulb carrier, tail light in body 3299
5 3 2 Removing and installing tail light bulb carrier, tail light in rear lid 3300
5 4 Removing and installing tail light in rear lid 3300
5 5 Removing and installing tail light in body 3301
5 6 Removing and installing tail light bulb 3301
5 7 Removing and installing rear fog light bulb 3302
5 8 Removing and installing bulb for brake light and tail light 3302
5 9 Removing and installing reversing light bulb 3303
5 9 1 Removing and installing reversing light bulb (conventional bulb) 3303
5 9 2 Removing and installing reversing light bulb (LED) 3303
5 10 Removing and installing turn signal bulb 3304
5 10 1 Removing and installing turn signal bulb (conventional bulb) 3304
5 10 2 Removing and installing turn signal bulb (LED) 3304
6 High-level brake light 3306
6 1 Assembly overview – high-level brake light 3306
6 2 Removing and installing high-level brake light 3306
6 3 Removing and installing high-level brake light bulb -M25- 3307
7 Number plate light 3308
7 1 Removing and installing number plate light 3308
7 1 1 Removing and installing number plate lights, bolted fitting 3308
7 1 2 Removing and installing number plate lights, clipped fitting 3308
8 Entry and start authorisation 3309
8 1 Assembly overview – entry and start authorisation system 3309
8 1 1 Overview – entry and start authorisation system 3309
8 1 2 Assembly overview – entry and start authorisation system 3310
8 2 Removing and installing entry and start authorisation control unit -J518- 3311
8 2 1 Removing and installing (left-hand drive models) entry and start authorisation control unit -J518- 3311
8 2 2 Removing and installing entry and start authorisation control unit -J518-, right-hand drive 3312
8 2 3 Coding entry and start authorisation control unit -J518- 3313
8 3 Removing and installing interior aerial for entry and start authorisation 3314
8 3 1 Removing and installing interior aerial 1 for entry and start authorisation -R138- 3314
8 3 2 Removing and installing interior aerial 2 for entry and start authorisation -R139- 3314
8 4 Removing and installing front passenger side aerial for entry and start authorisation 3315
8 4 1 Removing and installing front passenger side door exterior handle 3315
8 5 Removing and installing driver side aerial for entry and start authorisation 3315
8 5 1 Removing and installing driver side door exterior handle 3315
8 6 Removing and installing luggage compartment aerial for entry and start authorisation -R137- 3316
8 7 Removing and installing rear bumper aerial for entry and start authorisation -R136- 3316
8 8 Checking entry and start system aerials and sensors 3317
8 8 1 Checking driver side aerial for entry and start authorisation -R134- 3317
8 8 2 Checking front passenger side aerial for entry and start authorisation -R135- 3318
8 8 3 Checking rear bumper aerial for entry and start authorisation -R136- 3318
8 8 4 Checking luggage compartment aerial for entry and start authorisation -R137- 3318
8 8 5 Checking interior aerial 1 for entry and start authorisation -R138- 3319
8 8 6 Checking interior aerial 2 for entry and start authorisation -R139- 3319
8 8 7 Checking driver door exterior handle touch sensor -G415- 3319
8 8 8 Checking front passenger door exterior handle touch sensor -G416- 3320
8 9 Removing and installing entry and start authorisation switch 3320
9 Steering column switch module 3321
9 1 Assembly overview – steering column switch module 3321
9 1 1 Assembly overview – steering column switch module, Valeo 3321
9 1 2 Assembly overview – steering column switch module, Kostal 3323
9 1 3 Assembly overview – steering column switch module, KESSY 3323
9 2 Removing and installing steering column electronics control unit -J527- 3325
9 2 1 Removing and installing steering column electronics control unit -J527-, Valeo 3325
9 2 2 Removing and installing steering column electronics control unit -J527-, Kostal 3326
9 2 3 Coding steering column electronics control unit -J527- 3327
9 3 Removing and installing steering column combination switch -E595- 3328
9 3 1 Removing and installing steering column combination switch -E595-, Valeo 3328
9 3 2 Removing and installing steering column combination switch -E595-, Valeo with KESSY 3330
9 3 3 Removing and installing steering column combination switch -E595-, Kostal 3332
9 3 4 Removing and installing steering column combination switch -E595-, Kostal with KESSY 3335
9 4 Removing and installing steering column switch base 3337
9 4 1 Removing and installing steering column switch base, Valeo 3337
9 4 2 Removing and installing steering column switch base, Valeo with KESSY 3339
9 4 3 Removing and installing steering column switch base, Kostal 3341
9 4 4 Removing and installing steering column switch base, Kostal with KESSY 3343
9 5 Removing and installing electronic steering column lock control unit -J764- 3345
9 5 1 Removing and installing electronic steering column lock control unit -J764- 3345
9 5 2 Renewing electronic steering column lock control unit -J764- 3346
9 6 Removing and installing ignition/starter switch -D- 3347
9 6 1 Removing and installing ignition/starter switch -D- 3347
9 6 2 Checking ignition/starter switch -D- 3348
9 6 3 Removing and installing steering lock housing 3348
9 6 4 Removing and installing lock cylinder 3349
9 7 Removing and installing ignition key withdrawal lock solenoid -N376- 3350
10 Parking aid 3352
10 1 Assembly overview – parking aid 3352
10 1 1 General description 3352
10 1 2 Assembly overview – parking aid 3353
10 2 Removing and installing parking aid control unit -J446- 3355
10 2 1 Removing and installing parking aid control unit -J446-, left-hand drive vehicle 3355
10 2 2 Removing and installing parking aid control unit -J446-, right-hand drive vehicle 3356
10 2 3 Coding parking aid control unit -J446- 3356
10 2 4 Adapting optical presentation of parking aid control unit -J446- 3356
10 2 5 Parking aid control unit -J446-, final control diagnosis for parking aid 3357
10 3 Removing and installing front parking aid warning buzzer -H22- 3357
10 3 1 Removing and installing front parking aid warning buzzer -H22- 3357
10 3 2 Adjusting volume of front parking aid warning buzzer -H22- 3358
10 3 3 Adjusting pitch of front parking aid warning buzzer -H22- 3358
10 4 Removing and installing rear parking aid warning buzzer -H15- 3359
10 4 1 Removing and installing rear parking aid warning buzzer -H15- 3359
10 4 2 Adjusting volume of rear parking aid warning buzzer -H15- 3359
10 4 3 Adjusting pitch of rear parking aid warning buzzer pitch -H15- 3359
10 5 Removing and installing front parking aid senders 3360
10 5 1 Removing and installing front parking aid senders 3360
10 5 2 Bonding sender retainer in front bumper cover 3362
10 5 3 Renewing front parking aid senders 3363
10 5 4 Repairing sender retainer in front bumper cover 3364
10 5 5 Checking front parking aid sender 3364
10 6 Removing and installing rear parking aid senders 3364
10 6 1 Removing and installing rear parking aid senders 3364
10 6 2 Bonding sender retainer in rear bumper cover 3366
10 6 3 Renewing parking aid senders 3367
10 6 4 Repairing sender retainers in rear bumper cover 3368
10 6 5 Testing parking aid senders 3368
11 Main beam assist 3369
11 1 Overview – main beam assist 3369
11 2 Overview of fitting locations – main beam assist 3369
11 3 Removing and installing main beam assist control unit -J844- 3370
11 4 Renewing main beam assist control unit -J844- 3371
11 5 Coding main beam assist control unit -J844- 3371
11 6 Removing and installing light sensor -G399- 3371
12 Automatic headlight range control 3373
12 1 Assembly overview – automatic headlight range control 3373
12 2 Removing and installing cornering light and headlight range control unit -J745- 3374
12 2 1 Removing and installing cornering light and headlight range control unit -J745- 3374
12 2 2 Coding cornering light and headlight range control unit -J745- 3375
12 2 3 Renewing cornering light and headlight range control unit -J745- 3375
12 2 4 Making basic headlight setting 3375
13 Towing bracket 3376
13 1 Assembly overview – towing bracket socket 3376
13 2 Removing and installing trailer detector control unit -J345- 3376
13 3 Removing and installing trailer socket -U10- 3377
96 – Lights, bulbs, switches – interior 3379
1 Lights 3379
1 1 Overview of fitting locations – lights in dash panel 3379
1 2 Overview of fitting locations – lights in luggage compartment 3381
1 3 Overview of fitting locations – lights in roof trim 3382
1 4 Removing and installing glove compartment light -W6- 3382
1 5 Removing and installing central locking SAFELOCK function warning lamp -K133- 3384
1 6 Removing and installing luggage compartment light -W3- 3385
1 7 Removing and installing illuminated vanity mirrors 3386
1 8 Renewing bulb of front interior light -W1- 3387
1 9 Removing and installing centre reading lights 3389
1 10 Replacing bulb of rear interior light -W43- 3389
2 Controls 3392
2 1 Overview of fitting locations – controls in dash panel 3393
2 2 Overview of fitting locations – controls in front doors 3394
2 3 Fitting locations overview – controls in rear doors 3395
2 4 Fitting locations overview – controls in centre console 3396
2 5 Fitting locations overview – controls in roof trim 3397
2 6 Removing and installing light switch -E1- 3397
2 6 1 Checking light switch -E1- 3398
2 7 Removing and installing regulator for switch and instrument illumination -E20- 3399
2 7 1 Checking switch and instrument illumination regulator -E20- 3399
2 8 Removing and installing key-operated switch to deactivate front passenger side airbag -E224- 3400
2 9 Removing and installing tyre pressure monitor display button -E492- 3401
2 10 Removing and installing rear central switch for interior locking -E286- 3401
2 11 Removing and installing driver side interior locking button for central locking system -E308- 3402
2 12 Removing and installing front passenger side interior locking button for central locking system -E309- 3403
2 13 Removing and installing remote release button for fuel filler flap and rear lid -E463- 3404
2 14 Removing and installing start/stop operating mode switch -E693- 3405
2 15 Removing and installing TCS and ESP button -E256- 3406
2 16 Removing and installing parking aid button -E266- 3407
2 17 Removing and installing the starter button -E378- 3409
2 18 Removing and installing button for electric drive -E656-, high-voltage vehicle 3410
2 19 Removing and installing warning lamp for airbag deactivated on front passenger side -K145- 3411
2 20 Removing and installing hazard warning light button -E229- 3412
2 21 Removing and installing glove compartment light switch -E26- 3413
2 22 Removing and installing mirror adjustment switch -E43- 3413
2 23 Removing and installing operating unit for window regulator in driver door -E512- 3414
2 24 Removing and installing window regulator switch in front passenger door -E107- 3415
2 25 Removing and installing interior monitoring deactivation switch -E267- 3417
2 26 Removing and installing rear window regulator switch in door 3418
2 27 Removing and installing rear lid contact switch 3419
2 27 1 Removing and installing rear lid locking unit -F256- 3419
2 28 Removing and installing button 1 for tilting roof -E582- 3419
2 29 Removing and installing front interior light/reading light 3420
2 29 1 Removing and installing front interior light -W1-, vehicle with no sliding sunroof 3420
2 29 2 Removing and installing front interior light -W1-, vehicle with sliding sunroof 3421
2 30 Removing and installing rear interior light/reading light 3422
2 30 1 Removing and installing rear interior light -W43- 3422
2 31 Removing and installing garage door operating unit -E284- 3423
3 Immobiliser 3425
3 1 Overview – immobiliser 3425
3 2 Immobiliser control unit -J362- 3426
3 2 1 Removing and installing immobiliser control unit -J362- 3426
3 2 2 Adapting immobiliser control unit -J362- 3426
3 2 3 New identity on renewing all components 3426
3 2 4 Online system test 3426
3 3 Immobiliser reader coil -D2- 3427
3 4 Ignition key 3427
3 4 1 Ignition key – variable code transponder 3427
3 4 2 Loss of an ignition key 3427
3 4 3 Adapting ignition key to immobiliser 3428
3 4 4 Checking ignition key with remote control 3428
4 Anti-theft alarm system 3429
4 1 Assembly overview – interior monitor 3429
4 2 Activating and deactivating anti-theft alarm system 3430
4 3 Central locking and anti-theft alarm system aerial -R47- 3431
4 4 Removing and installing alarm horn -H12- 3431
4 5 Removing and installing interior monitoring sensor -G273- 3432
4 6 Removing and installing bonnet contact switch -F266- 3432
4 7 Adaptations of anti-theft alarm system 3432
4 7 1 Adapting alarm delay on opening driver door 3432
4 7 2 Adapting country setting for alarm horn -H12- 3433
5 Cigarette lighter, socket 3434
5 1 Removing and installing AC/DC converter with socket 3434
97 – Wiring 3437
1 Relay carriers, fuse holders, electronics boxes 3437
1 1 Fitting locations overview – relay carriers, fuse holders, electronics boxes 3437
1 2 Removing and installing electronics box (E-box) 3438
1 3 Removing and installing relay and fuse holder in electronics box 3439
1 4 Removing and installing relay and fuse holder behind dash panel on driver side 3440
1 4 1 Removing and installing fuse holder behind dash panel on driver side 3440
1 4 2 Removing and installing onboard supply control unit -J519- 3441
1 5 Removing and installing fuse holder on battery -A-, high-voltage vehicle 3442
2 Control units 3443
2 1 Fitting locations overview – control units 3443
2 2 Removing and installing onboard supply control unit -J519- 3444
2 2 1 Description of onboard supply control unit -J519- 3444
2 2 2 Removing and installing onboard supply control unit -J519-, High version 3446
2 2 3 Removing and installing onboard supply control unit -J519-, Low version 3447
2 2 4 Renewing onboard supply control unit -J519- 3447
2 2 5 Final control diagnosis of onboard supply control unit -J519- 3448
2 2 6 Coding onboard supply control unit -J519- 3449
2 2 7 Deactivating factory mode of onboard supply control unit -J519- 3449
2 2 8 Adapting remote control key 3450
2 2 9 Checking remote control unit key 3450
2 2 10 Coding rain and light sensor -G397- 3450
2 3 Removing and installing data bus diagnostic interface -J533- 3451
2 3 1 Description of data bus diagnostic interface -J533- 3451
2 3 2 Renewing data bus diagnostic interface -J533- 3451
2 3 3 Removing and installing data bus diagnostic interface -J533-, LHD, High version 3452
2 3 4 Removing and installing data bus diagnostic interface -J533-, RHD, High version 3452
2 3 5 Coding data bus diagnostic interface -J533- 3453
2 3 6 Checking bus activity of data bus diagnostic interface -J533- 3453
2 3 7 Adapting bus subscriber of data bus diagnostic interface -J533- 3454
2 4 Removing and installing garage door operation control unit -J530- 3454
3 Connectors 3455
3 1 Separating left door connector 3455
3 1 1 Separating A-pillar door connector 3455
3 1 2 Separating B-pillar door connector 3455
3 2 Separating right door connector 3456
3 2 1 Separating A-pillar door connector 3456
3 2 2 Separating B-pillar door connector 3456
3 3 Repairing electrical wiring harnesses and plug-in connections 3456
4 Vehicle diagnostic, testing and information systems 3457
D3E802AF00D 4 cylinder diesel engine (2 0 l engine common rail generation II) 3458
00 – Technical data 3466
1 Technical data 3466
1 1 Engine number 3466
1 2 Engine data 3466
10 – Removing and installing engine 3468
1 Removing and installing engine 3468
1 1 Removing and installing engine cover 3468
1 2 Removing engine 3469
1 3 Separating engine from gearbox 3478
1 4 Separating engine from dual clutch gearbox 3480
1 5 Securing engine to assembly stand 3483
1 6 Installing engine 3485
1 6 1 Notes on installing 3485
2 Assembly mounting, except Jetta 2011 ▶ 3489
2 1 Assembly overview – assembly mountings 3489
2 2 Checking adjustment of engine assembly mountings 3492
2 3 Adjusting assembly mountings 3492
3 Assembly mounting, Jetta 2011 ▶ 3498
3 1 Assembly overview – assembly mountings 3498
3 2 Removing and installing engine mounting 3500
3 3 Removing and installing gearbox mounting 3504
3 4 Removing and installing pendulum support 3507
3 5 Supporting engine in installation position 3508
3 6 Adjusting assembly mountings 3513
3 7 Checking adjustment of assembly mountings 3514
13 – Crankshaft group 3516
1 Dismantling and assembling engine 3516
1 1 Poly V-belt drive with tensioning element and air conditioner compressor 3516
1 1 1 Assembly overview – poly V-belt drive 3516
1 1 2 Removing and installing poly-V belt 3517
1 1 3 Removing and installing poly V-belt tensioner 3519
1 2 Poly V-belt drive with tensioning roller and air conditioner compressor 3520
1 2 1 Assembly overview – poly V-belt drive 3520
1 2 2 Removing and installing poly-V belt 3522
1 3 Poly V-belt drive without air conditioning compressor 3524
1 3 1 Assembly overview – poly V-belt drive 3524
1 3 2 Removing and installing poly-V belt 3525
1 4 Removing and installing bracket for ancillaries 3526
1 5 Assembly overview – toothed belt drive 3528
1 6 Removing and installing engine bracket 3530
1 7 Assembly overview – crankcase 3534
2 Removing and installing sealing flange and flywheel 3536
2 1 Assembly overview – Sealing flange, belt pulley end 3536
2 2 Renewing crankshaft oil seal, pulley end 3538
2 3 Removing and installing sealing flange – pulley end 3540
2 4 Assembly overview – Dual-mass flywheel and sealing flange 3544
2 5 Removing and installing dual-mass flywheel 3545
2 6 Renewing crankshaft sealing flange, flywheel end 3546
2 6 1 Pressing out sealing flange with sender wheel 3547
2 6 2 Pressing in sealing flange with sender wheel 3549
2 7 Removing and installing engine speed sender -G28- 3557
3 Pistons and conrods 3559
3 1 Assembly overview – pistons and conrods 3559
3 2 Piston and cylinder dimensions 3563
3 3 Separating new conrods 3563
3 4 Bearing shells – installation position 3564
3 5 Piston and cylinder dimensions 3565
3 6 Checking piston projection at TDC 3565
3 6 1 Cylinder head gasket identification 3567
3 7 Measuring radial clearance of conrods 3567
4 Crankshaft 3568
4 1 Assembly overview – crankshaft 3568
4 2 Crankshaft dimensions 3568
4 3 Pulling needle bearing out of and driving into crankshaft 3569
15 – Cylinder head, valve gear 3572
1 Cylinder head 3572
1 1 Assembly overview – cylinder head 3572
1 2 Assembly overview – cylinder head cover 3576
1 3 Assembly overview – toothed belt 3578
1 4 Removing and installing cylinder head cover 3581
1 4 1 Renewing seals for injectors 3584
1 5 Removing, installing and tensioning toothed belt 3584
1 5 1 Removing 3585
1 5 2 Installing 3588
1 6 Removing and installing cylinder head 3593
1 6 1 Removing 3596
1 6 2 Installing 3603
1 7 Removing and installing vacuum pump 3605
1 8 Compression test 3606
2 Valve gear 3608
2 1 Assembly overview – valve gear 3608
2 2 Removing and installing camshafts 3610
2 2 1 Removing 3612
2 2 2 Installing 3614
2 3 Measuring axial clearance of camshaft 3619
2 4 Measuring radial clearance of camshafts 3620
2 5 Removing and installing camshaft oil seal 3621
2 5 1 Vehicles with »old« seal 3621
2 5 2 Vehicles with »new« seal 3624
2 6 Checking hydraulic compensation elements 3626
2 7 Renewing valve stem seals with cylinder head installed 3627
2 8 Renewing valve stem seals with cylinder head removed 3631
2 9 Valves 3636
2 9 1 Valve dimensions 3636
2 9 2 Reworking valve seats 3636
2 9 3 Checking valve guides 3636
2 9 4 Checking valves 3638
17 – Lubrication 3639
1 Engine oil: 3639
1 1 Oil capacities 3639
1 2 Checking engine oil level 3639
2 Parts of lubrication system 3640
2 1 Assembly overview – oil pump, sump 3640
2 2 Removing and installing oil level and oil temperature sender -G266- 3643
2 3 Removing and installing oil sump 3643
2 4 Removing and installing oil pump 3649
3 Oil filter bracket and engine oil cooler 3651
3 1 Assembly overview – oil filter bracket and engine oil cooler 3651
3 2 Removing and installing oil filter bracket with engine oil cooler 3653
3 3 Removing and installing oil pressure switch -F1- 3656
3 4 Checking oil pressure switch -F1- 3657
3 5 Checking oil pressure 3659
19 – Cooling 3661
1 Parts of cooling system 3661
1 1 Assembly overview – parts of cooling system, body side 3661
1 2 Assembly overview – parts of cooling system, engine side 3662
1 3 Assembly overview – coolant pump and thermostat 3664
1 4 Coolant hose connection diagram 3664
2 Repairing cooling system 3667
2 1 Removing and installing cowling together with radiator fan -V7- and radiator fan on right of radiator -V35- 3667
2 2 Removing and installing radiator 3668
2 3 Removing and installing coolant pump 3669
2 4 Removing and installing 4/2-way valve with thermostat 3671
2 4 1 Removing 4/2-way valve with thermostat 3672
2 4 2 Installing 4/2-way valve with thermostat 3677
2 5 Draining and adding coolant 3681
2 5 1 Draining 3682
2 5 2 Filling 3684
2 6 Coolant pipes, coolant temperature sender 3687
2 6 1 Removing and installing front coolant pipe 3687
2 6 2 Removing and installing upper front coolant pipe 3692
2 6 3 Removing and installing left coolant pipe 3693
2 6 4 Removing and installing right coolant pipe 3696
2 6 5 Removing and installing coolant temperature sender -G62- 3698
2 6 6 Removing and installing radiator outlet coolant temperature sender -G83- 3700
2 7 Checking cooling system for leaks 3701
20 – Fuel supply system 3704
1 Safety regulations for working on fuel supply 3704
2 Rules for cleanliness 3705
3 Procedure in event of misfuelling 3706
3 1 Procedure for 1st scenario 3706
3 2 Procedure for 2nd scenario 3707
4 Parts of fuel supply system 3710
4 1 Fuel tank, vehicles with front-wheel drive 3710
4 1 1 Assembly overview – fuel tank, all vehicles apart from Jetta from MY 2011 3710
4 1 2 Removing and installing fuel tank, all vehicles apart from Jetta from MY 2011 3712
4 1 3 Assembly overview – fuel tank, only Jetta from MY 2011 3714
4 1 4 Removing and installing fuel tank, only Jetta from MY 2011 3716
4 2 Fuel tank, vehicles with four-wheel drive 3719
4 2 1 Assembly overview – fuel tank 3719
4 2 2 Removing and installing fuel tank 3721
4 2 3 Removing and installing fuel gauge sender 2 -G169- 3725
4 2 4 Removing and installing suction-jet pump 3727
4 3 Emptying fuel tank 3728
4 3 1 Emptying fuel tank when fuel pump is intact 3728
4 3 2 Emptying fuel tank if it is more than 3/4 full 3730
4 3 3 Emptying fuel tank if it is less than 3/4 full 3731
4 4 Removing and installing fuel delivery unit 3732
4 5 Removing and installing fuel gauge sender 3734
5 Repairing fuel supply 3735
5 1 Assembly overview – fuel filter 3735
5 1 1 Upper part of fuel filter 3737
5 2 Removing and installing upper part of fuel filter 3738
5 3 Removing and installing fuel filter 3741
5 4 Checking fuel system pressurisation pump -G6- 3742
5 4 1 Checking delivery pressure of fuel pump 3742
5 4 2 Checking fuel delivery rate of fuel system pressurisation pump -G6- 3743
5 4 3 Checking voltage supply of fuel system pressurisation pump -G6- 3745
5 4 4 Checking current draw of fuel system pressurisation pump -G6- 3747
5 5 Checking supplementary fuel pump -V393- or fuel pump 2 -V277- (in-line electronic fuel pump) 3749
5 6 Removing and installing supplementary fuel pump -V393- or fuel pump 2 -V277- (in-line electronic fuel pump) 3751
5 7 Assembly overview – accelerator mechanism 3753
5 7 1 Removing and installing accelerator pedal module 3754
21 – Turbocharging/supercharging 3757
1 Turbocharger 3757
1 1 Safety precautions 3757
1 2 Rules for cleanliness 3757
1 3 Assembly overview – turbocharger 3758
1 4 Removing and installing turbocharger 3760
1 5 Changing vacuum unit with position sender for charge pressure positioner -G581- 3764
2 Charge air system 3772
2 1 Installing hose connections with corrugated pipe and hose clips 3772
2 2 Assembly overview – parts of charge air cooling 3773
2 3 Removing and installing charge air pressure sender -G31-/intake air temperature sender -G42- 3775
2 4 Removing and installing charge air cooler 3775
2 5 Checking charge air system for leaks 3777
2 6 Vacuum hose connection diagram 3781
2 7 Checking vacuum system 3781
2 7 1 Checking supply line, vacuum reservoir and non-return valve 3782
2 7 2 Checking control line to turbocharger 3783
2 7 3 Checking control line to vacuum unit for exhaust gas recirculation cooler changeover function 3784
23 – Mixture preparation – injection 3786
1 Diesel direct injection system 3786
1 1 Safety precautions 3786
1 2 Rules for cleanliness 3786
1 3 System layout 3787
2 High-pressure pump 3789
2 1 Assembly overview – high-pressure pump 3789
2 2 Removing and installing high-pressure pump 3791
2 3 Filling/bleeding fuel system 3795
2 4 Checking for leaks in the fuel system 3796
3 Injectors 3797
3 1 Assembly overview – injectors 3797
3 2 Carrying out adaptation for injector delivery calibration 3800
3 3 Checking for injectors sticking open 3801
3 4 Checking return flow rate of injectors with engine running 3802
3 5 Checking return flow rate of injectors at starter speed 3805
3 6 Removing and installing injectors 3807
3 7 Installing high-pressure lines 3811
3 8 Checking fuel pressure regulating valve -N276- 3813
3 9 Checking low pressure fuel system 3814
3 10 Removing and installing fuel pressure regulating valve -N276- 3817
3 11 Removing and installing fuel pressure sender -G247- 3819
3 12 Removing and installing fuel rail 3821
4 Intake manifold 3825
4 1 Assembly overview – intake manifold with attachments 3825
4 2 Removing and installing throttle valve module -J338- 3827
4 3 Removing and installing intake manifold 3828
5 Air filter 3833
5 1 Assembly overview – air filter 3833
5 2 Removing and installing air filter housing 3835
5 3 Removing and installing air mass meter -G70- 3837
5 4 Checking changeover flap for intake air preheater 3838
5 5 Removing and installing changeover flap for intake air preheater 3839
6 Lambda probe and pressure differential sender 3842
6 1 Removing and installing Lambda probe -G39-1 with Lambda probe heater -Z19-1 3842
6 2 Removing and installing pressure difference sender -G505-1 3843
7 Engine control unit -J623- 3845
7 1 Reading and clearing engine control unit fault memory 3845
7 2 Adapting functions and components 3845
7 3 Removing and installing engine control unit -J623- with no anti-theft device, all vehicles apart from Jetta from MY 2011 3846
7 4 Removing and installing engine control unit -J623- with anti-theft device, all vehicles apart from Jetta from MY 2011 3848
7 5 Removing and installing engine control unit -J623-, only Jetta from MY 2011 3852
7 5 1 Removing 3852
7 5 2 Installing 3853
26 – Exhaust system 3855
1 Front exhaust pipe with particulate filter 3855
1 1 Assembly overview – front exhaust pipe with particulate filter 3855
1 2 Removing and installing particulate filter 3858
2 Silencer 3865
2 1 Silencer, Jetta, Golf Variant 3865
2 1 1 Assembly overview – silencer, vehicles with front-wheel drive 3865
2 1 2 Assembly overview – silencer, vehicles with four-wheel drive 3866
2 2 Aligning exhaust system free of stress 3866
2 3 Installation position and specified torque of clamp 3867
3 Exhaust gas temperature regulation 3870
3 1 Assembly overview – exhaust gas temperature regulation 3870
3 2 Removing and installing exhaust gas temperature sender 1 -G235- 3871
3 3 Removing and installing exhaust gas temperature sender 3 -G495- 3873
3 4 Removing and installing exhaust gas temperature sender 4 -G648- 3875
4 Exhaust gas recirculation 3878
4 1 Assembly overview – exhaust gas recirculation 3878
4 2 Removing and installing exhaust gas recirculation cooler 3880
4 3 Checking changeover for exhaust gas recirculation cooler 3883
4 4 Checking exhaust gas recirculation cooler for leaks 3884
4 5 Cleaning exhaust gas recirculation system 3889
4 5 1 Initiating cleaning of exhaust gas recirculation system 3889
4 5 2 Cleaning connecting pipes and pipe union 3895
28 – Glow plug system 3897
1 Checking glow plug system 3897
1 1 Automatic glow period control unit -J179- 3897
1 2 Removing and installing glow plugs 3897
1 3 Removing and installing automatic glow period control unit -J179- 3900
D3E802B1C18 Body Repairs 3901
00 – Technical data 3907
1 Basic instructions 3907
2 Vehicle identification data 3908
2 1 Vehicle identification number 3908
2 2 Identification plate 3909
2 3 Vehicle data sticker 3910
3 Safety information 3911
4 Body work for which HV electrical system must be de-energised 3912
4 1 The following body work requires the HV electrical system to be de-energised 3912
5 Moulded foam inserts 3913
6 Galvanized body parts, high- and higher-strength and hot-formed body panels 3915
6 1 Installing 3915
6 2 Overview – NAR vehicles 3917
6 3 Overview – ROW vehicles 3920
7 Body panel gaps/shut lines 3923
7 1 Body – front 3923
7 2 Body – centre 3924
7 3 Body – rear 3925
8 Body dimensions 3926
8 1 Body – front 3926
8 2 Body – centre 3929
8 3 Body – rear 3936
8 4 Floor panel – front 3938
8 5 Floor panel – centre 3940
8 6 Floor panel – rear 3941
9 Contour correct surfaces 3943
10 Tools 3944
11 Alignment bracket set 3945
11 1 Overview 3945
11 2 Procedure for body structural damage on vehicles from Volkswagen 3945
12 Portal gauge 3946
50 – Body – front 3947
1 Renewing right bracket 3947
1 1 Tools 3947
1 2 Removing 3947
1 3 Installing 3949
1 3 1 Welding in 3949
2 Renewing left bracket 3951
2 1 Tools 3952
2 2 Removing 3952
2 3 Installing 3954
2 3 1 Preparing new part 3954
2 3 2 Welding in 3954
3 Renewing subframe 3956
3 1 Tools 3956
3 2 Removing 3956
3 3 Installing 3958
3 3 1 Preparing new part 3958
3 3 2 Welding in 3959
4 Renewing bumper bracket 3960
4 1 Tools 3961
4 2 Removing 3961
4 3 Installing 3962
4 3 1 Welding in 3962
5 Renewing upper wheel housing longitudinal member 3964
5 1 Tools 3965
5 2 Removing 3965
5 3 Installing 3968
5 3 1 Preparing new part 3968
5 3 2 Welding in 3969
6 Renewing front wheel housing 3975
6 1 Tools 3976
6 2 Removing 3976
6 3 Installing 3977
6 3 1 Preparing new parts 3977
6 3 2 Welding in 3979
7 Repairing threads for securing subframe (suspension subframe) 3981
7 1 Contents of thread repair kit 3983
7 2 Repairing threads 3983
7 2 1 Drilling threads 3983
7 2 2 Cutting thread 3984
7 2 3 Inserting thread insert 3985
8 Renewing front longitudinal member 3987
8 1 Tools 3988
8 2 Removing 3988
8 3 Installing 3990
8 3 1 Preparing new part 3990
8 3 2 Welding in 3991
9 Renewing front longitudinal member – part section 3994
9 1 Tools 3995
9 2 Removing 3995
9 3 Installing 3997
9 3 1 Preparing new part 3997
9 3 2 Welding in 3998
9 3 3 Shortening new longitudinal member with cover plate 4002
10 Renewing front right longitudinal member – part section 4006
10 1 Tools 4007
10 2 Removing 4007
10 3 Installing 4009
10 3 1 Preparing new part 4009
10 3 2 Welding in 4010
51 – Body – centre 4014
1 Renewing roof – vehicles with no sliding/tilting sunroof 4014
1 1 Tools 4015
1 2 Removing 4016
1 3 Installing 4018
1 3 1 Preparing new part 4019
1 3 2 Adjusting roof depth 4020
1 3 3 Bonding in 4021
1 3 4 Welding in 4027
2 Renewing roof – vehicles with sliding/tilting sunroof 4029
2 1 Tools 4030
2 2 Removing 4031
2 3 Installing 4034
2 3 1 Preparing new part 4035
2 3 2 Setting the depth dimension 4036
2 3 3 Bonding in 4037
2 3 4 Welding in 4043
3 Renewing roof side member 4046
3 1 Tools 4047
3 2 Removing 4047
3 3 Installing 4049
3 3 1 Preparing new part 4049
3 3 2 Moulded foam inserts 4050
3 3 3 Welding in 4051
4 Renewing front cross member for roof 4054
4 1 Tools 4055
4 2 Removing 4055
4 3 Installing 4056
4 3 1 Welding in 4056
5 Renewing roof reinforcement – vehicles for NAR, with no sliding/tilting sunroof 4058
5 1 Tools 4059
5 2 Removing 4059
5 3 Installing 4060
5 3 1 Welding in 4060
6 Renewing rear roof cross member 4062
6 1 Tools 4063
6 2 Removing 4063
6 3 Installing 4064
6 3 1 Welding in 4064
7 Renewing A-pillar 4066
7 1 Tools 4067
7 2 Removing 4067
7 3 Installing 4069
7 3 1 Preparing new part 4070
7 3 2 Moulded foam inserts 4071
7 3 3 Welding in 4072
8 Renewing A-pillar reinforcement – part section 4076
8 1 Tools 4077
8 2 Removing 4077
8 3 Installing 4078
8 3 1 Preparing new part 4079
8 3 2 Moulded foam inserts 4079
8 3 3 Welding in 4079
9 Renewing B-pillar 4083
9 1 Tools 4084
9 2 Removing 4084
9 3 Installing 4086
9 3 1 Preparing new part 4087
9 3 2 Marking area in which welding work is prohibited 4089
9 3 3 Moulded foam inserts 4089
9 3 4 Welding in 4090
10 Renewing B-pillar reinforcement, non-hybrid vehicles 4093
10 1 Tools 4094
10 2 Removing 4094
10 3 Installing 4096
10 3 1 Preparing new part 4096
10 3 2 Marking areas where no welding work may be carried out 4099
10 3 3 Welding in 4100
11 Renewing B-pillar reinforcement, hybrid vehicles 4103
11 1 Tools 4104
11 2 Removing 4104
11 3 Installing 4106
11 3 1 Preparing new part 4106
11 3 2 Marking areas where no welding work may be carried out 4109
11 3 3 Welding in 4110
12 Renewing inner B-pillar 4113
12 1 Tools 4114
12 2 Removing 4114
12 3 Installing 4115
12 3 1 Preparing new part 4115
12 3 2 Welding in 4116
13 Renewing side member 4118
13 1 Tools 4119
13 2 Removing 4119
13 3 Installing 4121
13 3 1 Preparing new part 4122
13 3 2 Moulded foam inserts 4123
13 3 3 Marking area in which welding work is prohibited 4124
13 3 4 Welding in 4125
14 Renewing front side member reinforcement, non-hybrid vehicles 4127
14 1 Tools 4128
14 2 Removing 4128
14 3 Installing 4129
14 3 1 Preparing new part 4130
14 3 2 Welding in 4130
15 Renewing front side member reinforcement, hybrid vehicles 4133
15 1 Tools 4134
15 2 Removing 4134
15 3 Installing 4135
15 3 1 Preparing new part 4136
15 3 2 Welding in 4136
16 Renewing rear side member reinforcement 4139
16 1 Tools 4140
16 2 Removing 4140
16 3 Installing 4141
16 3 1 Preparing new part 4142
16 3 2 Welding in 4142
17 Renewing outer mounting for seat cross member 4144
17 1 Tools 4145
17 2 Removing 4146
17 3 Installing 4147
17 3 1 Preparing new part 4147
17 3 2 Welding in 4148
18 Renewing inner mounting for seat cross member 4150
18 1 Tools 4150
18 2 Removing 4150
18 3 Installing 4152
18 3 1 Preparing new part 4152
18 3 2 Welding in 4153
19 Renewing seat middle cross member 4155
19 1 Tools 4155
19 2 Removing 4155
19 3 Installing 4157
19 3 1 Preparing new part 4157
19 3 2 Welding in 4158
53 – Body – rear 4160
1 Renewing cross panel 4160
1 1 Tools 4161
1 2 Removing 4161
1 3 Installing 4162
1 3 1 Preparing new part 4162
1 3 2 Welding in 4163
2 Renewing lock carrier 4165
2 1 Tools 4165
2 2 Removing 4165
2 3 Installing 4167
2 3 1 Welding in 4167
3 Renewing tail light mounting 4169
3 1 Tools 4170
3 2 Removing 4170
3 3 Installing 4171
3 3 1 Preparing new part 4171
3 3 2 Welding in 4171
4 Renewing tail light reinforcement, hybrid vehicles 4173
4 1 Tools 4174
4 2 Removing 4174
4 3 Installing 4175
4 3 1 Preparing new part 4175
4 3 2 Welding in 4175
5 Renewing luggage compartment floor 4177
5 1 Tools 4178
5 2 Removing 4179
5 3 Installing 4181
5 3 1 Preparing new part 4181
5 3 2 Moulded foam inserts 4183
5 3 3 Welding in 4183
6 Renewing C-pillar reinforcement – part section 4188
6 1 Tools 4189
6 2 Removing 4189
6 3 Installing 4190
6 3 1 Preparing new part 4190
6 3 2 Welding in 4191
7 Renewing rear longitudinal member – part section 4193
7 1 Tools 4194
7 2 Removing 4194
7 3 Installing 4195
7 3 1 Preparing new part 4195
7 3 2 Welding in 4196
8 Renewing rear longitudinal member – subpart 4198
8 1 Tools 4199
8 2 Removing 4199
8 3 Installing 4200
8 3 1 Preparing new part 4200
8 3 2 Welding in 4200
9 Renewing rear longitudinal member reinforcement, hybrid vehicles 4202
9 1 Tools 4203
9 2 Removing 4203
9 3 Installing 4204
9 3 1 Preparing new part 4204
9 3 2 Welding in 4205
10 Renewing rear battery mounting, hybrid vehicles 4208
10 1 Tools 4209
10 2 Removing 4209
10 3 Installing 4210
10 3 1 Preparing new part 4210
10 3 2 Welding in 4211
11 Renewing side panel – part section 4213
11 1 Tools 4214
11 2 Removing 4214
11 3 Installing 4217
11 3 1 Preparing new part 4218
11 3 2 Moulded foam inserts 4219
11 3 3 Welding in 4219
12 Renewing outer wheel housing liner 4224
12 1 Tools 4225
12 2 Removing 4225
12 3 Installing 4226
12 3 1 Preparing new part 4226
12 3 2 Welding in 4227
D3E802C2CF6 Running gear axles steering 4229
00 – Technical data 4237
1 Checklist for evaluating running gear of accident vehicles 4237
2 General information 4239
40 – Front suspension 4240
1 Evaluating accident vehicles 4240
2 Raising wheel suspension to unladen position 4241
3 Overview – front axle 4243
4 Assembly overview: subframe 4245
4 1 Repairing thread in longitudinal member 4246
4 2 Fixing position of subframe 4246
4 3 Lowering subframe 4249
4 4 Removing and installing subframe without steering rack 4253
4 5 Removing and installing subframe with hydraulic steering rack 4256
4 6 Removing and installing subframe with electromechanical steering rack 4263
4 7 Repairing subframe 4267
5 Assembly overview: front wheel suspension, suspension link 4277
5 1 Checking swivel joint 4278
5 2 Removing and installing swivel joint 4279
5 3 Removing and installing suspension link 4283
5 4 Removing and installing suspension link (left side of vehicles with dual clutch or automatic gearbox) 4284
5 5 Renewing front bonded rubber bush for suspension link 4289
5 6 Renewing rear bonded rubber bush for suspension link 4291
6 Assembly overview: wheel bearing 4294
6 1 Removing and installing wheel bearing unit 4295
6 2 Removing and installing wheel bearing housing 4298
7 Assembly overview: anti-roll bar 4305
7 1 Removing and installing anti-roll bar 4305
8 Assembly overview: suspension strut 4310
8 1 Removing and installing suspension strut 4311
8 2 Repairing suspension strut 4317
9 Removing and installing drive shafts 4320
9 1 Loosening and tightening twelve-point head bolt, with ribbing, securing drive shaft 4320
9 2 Loosening and tightening twelve-point head bolt, without ribbing, securing drive shaft 4321
9 3 Removing and installing drive shaft with constant velocity joint 4323
9 4 Removing and installing right drive shaft with (push-on) constant velocity slip joint 4326
9 5 Removing and installing drive shafts with triple roller joint AAR2600i 4332
9 6 Removing and installing drive shafts with triple roller joint AAR3300i 4336
10 Repairing drive shafts – overview of drive shafts 4341
10 1 Heat shield for drive shafts 4342
11 Assembly overview: drive shaft with VL100 constant velocity joint 4343
11 1 Dismantling and assembling drive shaft with VL100 constant velocity joint 4345
11 2 Checking outer constant velocity joint 4349
11 3 Checking inner constant velocity joint 4350
12 Assembly overview: drive shaft with VL107 constant velocity joint 4353
12 1 Dismantling and assembling drive shaft with VL107 constant velocity joint 4355
13 Assembly overview: drive shaft with VL107 constant velocity slip joint (push-on) 4360
13 1 Dismantling and assembling drive shaft with VL107 (push-on) constant velocity slip joint 4361
14 Assembly overview: drive shaft with triple roller joint AAR2600i 4365
14 1 Dismantling and assembling drive shaft with triple roller joint AAR2600i 4367
15 Assembly overview: drive shaft with triple roller joint AAR3300i 4372
15 1 Dismantling and assembling drive shaft with triple roller joint AAR3300i 4374
42 – Rear suspension 4380
1 Evaluating accident vehicles 4380
2 Rear axle in unladen position (torsion beam rear axle) 4381
3 Overview of rear axle (torsion beam rear axle) 4383
4 Assembly overview: axle beam, subframe, cross piece (torsion beam rear axle) 4385
4 1 Removing and installing axle assembly 4386
4 2 Removing and installing bonded rubber bush for axle beam 4390
4 3 Removing and installing cross piece 4394
4 4 Removing and installing bonded rubber bush for cross piece 4396
5 Assembly overview – plate for axle beam, torsion beam rear axle 4399
5 1 Removing plate for axle beam 4399
5 2 Installing plate for axle beam 4400
6 Assembly overview: wheel suspension (torsion beam rear axle) 4406
6 1 Removing and installing coil spring 4407
7 Assembly overview: shock absorbers (torsion beam rear axle) 4409
7 1 Removing and installing shock absorbers 4410
8 Assembly overview: wheel bearings, drum brake (torsion beam rear axle) 4412
8 1 Removing and installing wheel hub with wheel bearing, vehicles with drum brakes 4413
9 Assembly overview: wheel bearings, disc brake (torsion beam rear axle) 4417
9 1 Removing and installing wheel hub with wheel bearing, vehicles with disc brakes 4418
10 Rear axle in unladen position (multi-link rear suspension) 4421
11 Overview of rear axle (multi-link rear suspension) 4424
12 Assembly overview: subframe, transverse link, track rod (multi-link rear suspension) 4425
12 1 Assembly overview: rear left vehicle level sender -G76- 4427
12 2 Removing and installing rear left vehicle level sender -G76- 4427
12 3 Fixing position of subframe 4428
12 4 Lowering rear axle 4429
12 5 Removing and installing rear axle 4432
12 6 Removing and installing upper transverse link 4435
12 7 Removing and installing lower transverse link 4437
12 8 Removing and installing track rod 4439
13 Assembly overview: wheel bearing housing, trailing arm (multi-link rear suspension) 4442
13 1 Removing and installing wheel bearing housing 4443
13 2 Renewing bonded rubber bush for wheel bearing housing 4446
13 3 Removing and installing wheel bearing/wheel hub unit 4449
13 4 Removing and installing trailing arm with mounting bracket 4452
13 5 Repairing trailing arm 4456
14 Assembly overview: shock absorber, coil spring (multi-link rear suspension) 4460
14 1 Removing and installing coil spring 4460
14 2 Removing and installing shock absorbers 4462
14 3 Repairing shock absorber 4464
15 Assembly overview: anti-roll bar (multi-link rear suspension) 4466
15 1 Removing and installing anti-roll bar 4466
16 Assembly overview: subframe attachments, BlueMotion vehicles 4469
16 1 Removing and installing shield for rear axle 4470
44 – Wheels, tyres, vehicle geometry 4472
1 Evaluating accident vehicles 4472
2 Specified torque for fitting wheels 4473
3 Fitting wheel and tyre 4474
3 1 General information 4474
3 2 Fittings instructions 4474
4 Removing and fitting tyres (wheels with tyre pressure monitoring) 4476
4 1 Notes on safety and conditions for removing and fitting tyres (wheels with tyre pressure monitoring) 4476
4 2 Wheel change 4476
4 3 Fittings instructions 4477
4 4 Pressing tyre off wheel rim 4478
4 5 Removing tyre from wheel 4479
4 6 Fitting tyre to wheel rim 4479
5 Removing and fitting tyres with run-flat properties to wheel rims 4481
5 1 Safety information 4481
5 2 Fittings instructions 4481
5 3 Pressing tyre off wheel rim 4482
5 4 Removing tyre from wheel 4483
5 5 Fitting tyre to wheel rim 4484
6 Tyre pressure monitor display 4487
6 1 General information 4487
7 Tyre Pressure Monitoring System (TPMS) 4489
7 1 Assembly overview: tyre pressure sensor 4489
7 2 Removing and installing tyre pressure sensor 4490
8 Vehicle alignment check 4491
8 1 General information for vehicles with torsion beam rear axle 4491
8 2 General information for vehicles with multi-link rear suspension 4493
8 3 Conditions for testing 4494
8 4 Checking trailing arm of axle beam (torsion beam rear axle) using VAS 241 001 4495
8 5 Checking trailing arm of axle beam (torsion beam rear axle) using VAS 801 4497
8 6 Test preparations 4500
8 7 Vehicle alignment specifications for vehicles with torsion beam rear axle 4500
8 8 Vehicle alignment specifications for vehicles with multi-link rear suspension 4502
8 9 Transverse vehicle inclination “zero position” 4504
8 10 Overview – wheel alignment procedure 4504
8 11 Correcting front axle camber 4505
8 12 Checking torsion beam rear axle camber 4507
8 13 Adjusting multi-link rear suspension camber 4507
8 14 Checking torsion beam rear axle toe 4508
8 15 Adjusting multi-link rear suspension toe 4509
8 16 Adjusting front axle toe 4509
8 17 Basic setting of steering angle sensor -G85- 4510
8 18 Vehicle data sticker 4510
9 Wheels, tyres 4512
9 1 Models with breakdown set 4512
9 2 Removing a tyre 4512
9 3 Fitting a new tyre 4512
9 4 Tyre sealant disposal 4513
10 Instructions for changing or fitting wheels 4514
10 1 Fitting wheels 4515
11 Protecting wheel centring seat against corrosion 4516
12 Vibration due to wheels/tyres – causes and rectification 4517
12 1 Causes of rough running 4517
12 2 Balancing wheels 4517
12 3 Conducting a road test before balancing wheels 4517
12 4 Balancing wheels on stationary wheel balancing machine 4518
12 5 Vibration control system -VAS 6230 A- 4520
12 6 Finish balancer 4520
12 7 Radial and lateral runout of wheels and tyres 4521
12 8 Checking radial and lateral runout on wheels and tyres with tyre gauge -V A G 1435- 4521
12 9 Checking radial and lateral run-out on wheel rim 4522
12 10 Matching 4523
12 11 Flat spots caused by storage or handling 4524
48 – Steering 4526
1 Evaluating accident vehicles 4526
2 General repair instructions 4527
2 1 Steering rack 4527
2 2 Gaskets and seals 4527
2 3 Nuts and bolts 4527
2 4 Electrical components 4528
2 5 Guided Fault Finding, vehicle self-diagnosis and Test Instruments 4528
3 Assembly overview – airbag and steering wheel 4529
3 1 Removing and installing airbag and steering wheel 4529
4 Assembly overview: steering column, left-hand drive 4532
4 1 Removing and installing steering column 4532
4 2 Handling and transporting steering column 4540
4 3 Checking steering column for damage 4541
5 Assembly overview: steering column, right-hand drive 4543
5 1 Removing and installing steering column, right-hand drive vehicle 4543
5 2 Handling and transporting steering column 4552
5 3 Checking steering column for damage 4553
6 Electromechanical steering rack, LHD vehicle 4554
6 1 Assembly overview – electromechanical steering rack for LHD vehicle 4554
6 2 Removing and installing steering rack, left-hand drive vehicle 4556
7 Electromechanical steering rack, RHD vehicle 4564
7 1 Assembly overview – electromechanical steering rack for RHD vehicle 4564
7 2 Removing and installing steering rack, right-hand drive vehicle 4565
8 Repairing electromechanical steering rack 4572
8 1 Assembly overview: electromechanical steering rack 4572
8 2 Removing and installing track rod 4573
8 3 Removing and installing track rod ball joint 4576
8 4 Removing and installing boot 4577
8 5 Checking play, security and boots of track rod ends 4580
8 6 Checking and adjusting track rod length 4580
8 7 Allocation of track rod ball joints 4581
9 Assembly overview: hydraulic power steering 4582
9 1 Removing and installing power-assisted steering rack 4583
10 Repairing hydraulic power-assisted steering rack 4589
10 1 Assembly overview: power-assisted steering rack 4589
10 2 Removing and installing track rod 4590
10 3 Removing and installing track rod ball joint 4593
10 4 Removing and installing boot 4594
10 5 Checking play, security and boots of track rod ends 4596
10 6 Checking and adjusting left track rod length 4596
10 7 Allocation of track rod ball joints 4597
11 Vane pump, 4-cylinder petrol engine 4598
11 1 Assembly overview: vane pump, 4-cylinder petrol engine 4598
11 2 Removing and installing vane pump, 4-cylinder petrol engine 4599
12 Vane pump, 5-cylinder petrol engine 4602
12 1 Checking vane pump delivery pressure, 5-cylinder petrol engine 4602
12 2 Assembly overview: vane pump, 5-cylinder petrol engine 4605
12 3 Removing and installing vane pump, 5-cylinder petrol engine 4606
13 Assembly overview: hydraulic lines, 4-cylinder petrol engine 4610
14 Assembly overview: hydraulic lines, 5-cylinder petrol engine 4612
15 Assembly overview: power steering reservoir, 4-cylinder petrol engine 4614
16 Assembly overview: power steering reservoir, 5-cylinder petrol engine 4615
17 Checking power steering fluid level 4616
18 Bleeding steering system and checking for leaks 4617
18 1 Bleeding steering system 4617
18 2 Check steering system for leaks 4617
D3E802C2CF7 Brake systems 4618
00 – Technical data 4622
1 Identification 4622
1 1 Allocation of PR number – brakes 4622
1 1 1 PR number 4622
1 1 2 Front brakes 4622
1 1 3 Front brakes for North America 4623
1 1 4 Rear brakes, twist-beam rear axle 4623
1 1 5 Rear brakes, multi-link rear axle 4623
2 Technical data 4624
2 1 Technical data for brakes 4624
2 1 1 Brake master cylinder and brake servo 4624
2 1 2 Front brakes 4624
2 1 3 Rear brakes 4625
3 Brake test 4627
3 1 General information 4627
3 2 Checking vehicles with front-wheel drive 4627
45 – Anti-lock brake system 4628
1 General information 4628
1 1 Repair instructions for repair work on ABS 4628
1 2 Vehicle diagnosis, testing and information system 4629
2 Fitting location overview 4631
2 1 Fitting location overview – ABS 4631
2 1 1 ABS Mark 70 (ABS/TCS) 4631
2 1 2 ABS Mark 70 (ABS/TCS) (RHD vehicle) 4632
2 2 Fitting location overview – ABS/ESP 4634
2 2 1 ABS Mark 60 EC, North America 4634
2 2 2 ABS Mark 60 EC, as of 09/2010, North America 4636
2 2 3 ABS Mark 60 EC, vehicles with electromechanical power-assisted steering, North America 4638
2 2 4 ABS Mark 60 EC, vehicles with electromechanical power-assisted steering 4639
3 Fault display via warning lamps 4641
3 1 ABS/TCS, North America 4641
3 2 ABS/TCS, RHD vehicles 4642
3 3 ABS/EDL/TCS/ESP 4644
3 4 ABS/EDL/TCS/ESP North America as of 9/2010 4646
3 5 ABS/EDL/TCS/ESP 4648
4 Control unit and hydraulic unit 4652
4 1 Assembly overview – control unit and hydraulic unit 4652
4 1 1 Assembly overview – ABS Mark 70 (ABS/TCS), LHD vehicles 4652
4 1 2 Assembly overview – ABS Mark 70 (ABS/TCS), RHD vehicles 4655
4 1 3 Assembly overview – ABS Mark 60 EC (ABS/EDL/TCS/ESP), LHD vehicles 4656
4 1 4 Assembly overview – ABS Mark 60 EC (ABS/EDL/TCS/ESP), RHD vehicles 4658
4 2 Removing and installing ABS control unit -J104- and ABS hydraulic unit -N55- 4660
4 2 1 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) 4660
4 2 2 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) 4667
4 2 3 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) 4674
4 2 4 Removing and installing ABS control unit -J104- and ABS hydraulic unit -N55-, RHD vehicles with ABS Mark 70 (ABS/TCS) 4683
4 2 5 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) 4690
4 2 6 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) 4697
4 2 7 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) 4703
4 2 8 Removing and installing ABS control unit -J104- and ABS hydraulic unit -N55-, ABS Mark 60 EC (ABS/EDL/TCS/ESP) 4712
4 2 9 Removing and installing ABS control unit -J104- and ABS hydraulic unit -N55-, hybrid vehicles and ABS Mark 60 EC (ABS/EDL/TCS/ESP) 4720
4 3 Separating control unit from hydraulic unit 4727
4 3 1 Separating ABS control unit -J104- from ABS hydraulic unit -N55-, ABS Mark 70 (ABS/TCS) 4727
4 3 2 Separating ABS control unit -J104- from ABS hydraulic unit -N55-, ABS Mark 60 EC (ABS/EDL/TCS/ESP) 4729
4 4 Fitting control unit to hydraulic unit 4730
4 4 1 Installing ABS control unit -J104- to ABS hydraulic unit -N55-, ABS Mark 70 (ABS/TCS) 4730
4 4 2 Installing ABS control unit -J104- to ABS hydraulic unit -N55-, ABS Mark 60 EC (ABS/EDL/TCS/ESP) 4731
4 5 Connecting brake lines to hydraulic unit 4734
4 5 1 Connecting brake lines to ABS hydraulic unit -N55-, LHD vehicles with ABS Mark 70 (ABS/TCS) 4734
4 5 2 Connecting brake lines to ABS hydraulic unit -N55-, RHD vehicles with ABS Mark 70 (ABS/TCS) 4735
4 5 3 Connecting brake lines to ABS hydraulic unit -N55-, RHD vehicles with ABS Mark 60 EC (ABS/EDL/TCS/ESP) 4736
4 5 4 Connecting brake lines to ABS hydraulic unit -N55-, LHD vehicles with ABS Mark 60 EC (ABS/EDL/TCS/ESP) 4737
5 Sensors 4739
5 1 Assembly overview – speed sensor on front axle 4739
5 1 1 Assembly overview – speed sensor on front axle 4739
5 2 Assembly overview – speed sensor on rear axle 4740
5 2 1 Assembly overview – speed sensor on rear axle, torsion beam rear suspension with drum brakes 4740
5 2 2 Assembly overview – speed sensor on rear axle, torsion beam rear suspension with disc brakes 4741
5 2 3 Assembly overview – speed sensor on rear axle, multi-link rear suspension 4742
5 3 Removing and installing speed sensors on front axle -G45-/-G47- 4742
5 3 1 Removing and installing speed sensor on front axle 4742
5 4 Removing and installing speed sensors on rear axle -G44-/-G46- 4743
5 4 1 Removing and installing speed sensor on torsion beam rear suspension with drum brake 4743
5 4 2 Removing and installing speed sensor on torsion beam rear suspension with disc brake 4744
5 4 3 Removing and installing speed sensor on multi-link rear suspension 4745
5 5 Removing and installing yaw rate sender and lateral acceleration sender 4745
6 Removing and installing parts of ESP system 4747
6 1 Assembly overview – vehicles with steering angle sensor -G85- on steering column 4747
6 2 Removing and installing steering angle sensor -G85- on steering column 4748
6 3 Vehicles with electromechanical power steering 4749
6 4 Vehicles with steering angle sensor -G85- on steering rack 4749
46 – Brakes – mechanism 4751
1 Front brakes 4751
1 1 Assembly overview – front brakes 4751
1 1 1 Assembly overview – front brakes, FS III without brake pad wear indicator 4751
1 1 2 Assembly overview – front brakes, FS III with brake pad wear indicator 4753
1 1 3 Assembly overview – front brakes, FN3 15/16 inch without brake pad wear indicator 4755
1 1 4 Assembly overview – front brakes, FN3 15/16 inch with brake pad wear indicator 4757
1 2 Removing and installing brake pads or linings 4758
1 2 1 Removing and installing brake pads, brake caliper FS III 4758
1 2 2 Removing and installing brake pads, brake caliper FN 3 4761
1 3 Removing and installing brake caliper 4764
1 3 1 Removing and installing brake caliper, FS III brake caliper 4764
1 3 2 Removing and installing brake caliper, FS III brake caliper 4767
1 4 Removing and installing brake carrier 4771
1 4 1 Removing and installing brake carrier, brake caliper FN 3 4771
1 5 Replace brake disc 4773
1 5 1 Removing and installing brake disc, brake caliper FS III 4773
1 5 2 Removing and installing brake disc, brake caliper FN 3 4775
1 6 Removing and installing brake splash plate 4778
1 6 1 Removing and installing cover plate, brake caliper FS III 4778
1 6 2 Removing and installing splash plate, brake caliper FN 3 4779
2 Rear brakes 4782
2 1 Assembly overview – rear brakes 4782
2 1 1 Assembly overview – drum brake 4782
2 1 2 Assembly overview – brake drum 4784
2 1 4 Assembly overview – torsion beam rear suspension, rear brakes, Bosch ZOH BIR 38 4786
2 1 5 Assembly overview – torsion beam rear suspension, rear brakes, CI 38 4788
2 1 6 Assembly overview – multi-link rear suspension, rear brakes, Bosch ZOH BIR 38 4791
2 1 7 Assembly overview – multi-link rear suspension, rear brakes, CI 38 4794
2 2 Removing and installing brake pads or linings 4796
2 2 1 Removing and installing brake pads; Rear brakes, Bosch ZOH BIR 38 4796
2 2 2 Removing and installing brake pads; Rear brakes, CI 38 4799
2 3 Removing and installing brake caliper 4803
2 3 1 Removing and installing brake caliper; Rear brakes, Bosch ZOH BIR 38 4803
2 3 2 Removing and installing brake caliper; Rear brakes, CI 38 4806
2 3 3 Removing and installing wheel brake cylinder, drum brakes 4811
2 4 Removing and installing brake carrier 4813
2 4 1 Removing and installing backplate for drum brakes 4813
2 4 2 Removing and installing brake carrier for disc brakes 4815
2 5 Removing and installing brake disc 4817
2 5 1 Removing and installing brake disc 4817
2 5 2 Removing and installing brake drum 4819
2 6 Removing and installing brake shoes 4821
2 7 Retracting drum brakes 4823
2 8 Removing and installing brake splash plate 4824
2 8 1 Removing and installing splash plate for brakes, twist-beam rear axle 4824
2 8 2 Removing and installing splash plate for brakes, multi-link rear axle 4825
3 Handbrake 4828
3 1 Assembly overview – parking brake 4828
3 2 Removing and installing handbrake lever 4829
3 3 Removing and installing rear brake cable 4832
3 3 1 Removing and installing rear brake cable, drum brakes 4832
3 3 2 Removing and installing rear brake cable, disc brakes on torsion beam rear suspension 4836
3 3 3 Removing and installing brake cable, disc brakes on multi-link rear suspension 4839
3 4 Adjusting parking brake 4842
3 4 1 Adjusting handbrake, drum brakes 4842
3 4 2 Adjusting handbrake, disc brakes 4843
3 5 Removing and installing handbrake lever trim 4845
4 Brake pedal 4848
4 1 Assembly overview – brake pedal 4848
4 1 1 Assembly overview – brake pedal, left-hand drive 4848
4 1 2 Assembly overview – brake pedal, right-hand drive 4849
4 2 Removing and installing mounting bracket 4851
4 2 1 Removing and installing mounting bracket, left-hand drive 4851
4 2 2 Removing and installing mounting bracket, right-hand drive 4853
4 2 3 Removing and installing mounting bracket, hybrid vehicles 4856
4 3 Separating brake pedal from brake servo 4862
4 4 Connecting brake pedal to brake servo 4864
4 5 Removing and installing brake pedal 4864
4 5 1 Removing and installing brake pedal, LHD 4864
4 5 2 Removing and installing brake pedal, RHD 4865
47 – Brakes – hydraulics 4867
1 Front brake caliper 4867
1 1 Assembly overview – front brake caliper 4867
1 1 1 Assembly overview – front brake caliper, brake caliper FS III 4867
1 1 2 Assembly overview – front brake caliper, brake caliper FN 3 4868
1 2 Removing and installing brake caliper piston 4868
1 2 1 Removing and installing brake caliper piston, brake caliper piston FS III 4868
1 2 2 Removing and installing brake caliper piston, brake caliper piston FN 3 4871
2 Rear brake caliper 4874
2 1 Assembly overview – rear brake caliper 4874
2 1 1 Assembly overview – rear brake caliper, rear brakes, Bosch ZOH BIR 38 4874
2 1 2 Assembly overview – rear brake caliper, rear brakes, CI 38 4875
2 2 Removing and installing brake caliper piston 4876
2 2 1 Removing and installing brake caliper piston; Rear brakes, Bosch ZOH BIR 38 4876
2 2 2 Removing and installing brake caliper piston; Rear brakes, CI 38 4878
2 2 3 Pre-bleeding brake caliper 4880
3 Brake servo and brake master cylinder 4881
3 1 Assembly overview – brake servo/brake master cylinder 4881
3 1 1 Assembly overview – brake servo/brake master cylinder, left-hand drive 4881
3 1 2 Assembly overview – brake servo/brake master cylinder, right-hand drive 4884
3 2 Removing and installing brake light switch 4886
3 2 1 Removing and installing brake light switch -F-, LHD vehicles with 5-cyl petrol engine 4886
3 2 2 Removing and installing brake light switch -F-, LHD vehicles with 4-cyl petrol engine 4887
3 2 3 Removing and installing brake light switch -F-, LHD vehicles with 4-cyl diesel engine 4888
3 2 4 Removing and installing brake light switch -F-, right-hand drive 4890
3 2 5 Removing and installing brake light switch -F-, hybrid vehicles 4890
3 3 Removing and installing brake fluid reservoir 4891
3 3 1 Removing and installing brake fluid reservoir, LHD vehicles 4891
3 3 2 Removing and installing brake fluid reservoir, RHD vehicles 4895
3 3 3 Removing and installing brake fluid reservoir, hybrid vehicles 4898
3 4 Removing and installing brake master cylinder 4901
3 4 1 Removing and installing brake master cylinder, LHD vehicles with 5-cyl petrol engine 4901
3 4 2 Removing and installing brake master cylinder, LHD vehicles with 4-cyl petrol engine 4907
3 4 3 Removing and installing brake master cylinder, LHD vehicles with 4-cyl diesel engine 4912
3 4 4 Removing and installing brake master cylinder, RHD vehicles with 4-cyl petrol engine 4918
3 4 5 Removing and installing brake master cylinder, hybrid vehicles 4923
3 4 6 Removing and installing brake master cylinder, RHD vehicles with 4-cyl petrol engine 4927
3 5 Removing and installing brake servo 4935
3 5 1 Removing and installing brake servo, LHD vehicles with 5-cyl petrol engine 4935
3 5 2 Removing and installing brake servo, LHD vehicles with 4-cyl petrol engine 4944
3 5 3 Removing and installing brake servo, LHD vehicles with 4-cyl diesel engine 4951
3 5 4 Removing and installing brake servo, RHD vehicles with 4-cyl petrol engine 4958
3 5 5 Removing and installing brake servo, hybrid vehicles 4968
3 5 6 Removing and installing brake servo, RHD vehicles with 4-cyl diesel engine 4976
4 Vacuum system 4988
4 1 Assembly overview – vacuum pump 4988
4 1 1 Vacuum pump for brake servo (2 5 l petrol engine) 4988
4 1 2 Vacuum pump for brake servo (vehicles with 2 0 l petrol engine) 4988
4 1 3 Vacuum pump for brake servo (vehicles with diesel engine) 4989
4 2 Checking vacuum system 4989
4 2 1 Instructions 4989
4 2 2 Connecting vacuum gauge for brake servo -VAS 6721- 4990
4 2 3 Checking vacuum generation 4991
4 2 4 Checking for leaks 4992
4 2 5 Vacuum generation with manual vacuum pump -VAS 6213- 4993
4 3 Checking non-return valve 4994
4 4 Removing and installing vacuum sender -G608- 4994
4 5 Assembly overview – electric vacuum pump 4995
4 5 1 Assembly overview – vacuum pump for brakes -V192-, vehicles with petrol engine 4995
4 5 2 Assembly overview – vacuum pump for brakes -V192-, hybrid vehicles 4997
4 6 Removing and installing vacuum pump 4997
4 6 1 Removing and installing vacuum pump for brakes -V192-, vehicles with petrol engine 4997
4 6 2 Removing and installing vacuum pump for brakes -V192-, hybrid vehicles 4999
4 7 Removing and installing brake servo pressure sensor 5000
5 Brake lines 5001
5 1 Repairing brake lines 5001
5 1 1 Assembly overview – flanging tool 5001
5 1 2 Work instructions 5002
6 Hydraulic system 5006
6 1 General notes on brake fluid 5006
6 1 1 General information 5006
6 1 2 Changing brake fluid 5008
6 2 Pre-bleeding hydraulic system 5009
6 3 Bleeding hydraulic system following standard procedure 5011
6 4 Subsequent bleeding of hydraulic system 5014
6 5 Testing for leaks 5015
6 5 1 Test prerequisites: 5015
6 5 2 Checking wheel brake cylinder for leaks 5015
D3E802C2CFB General body repairs interior 5017
00 – Technical data 5023
1 Safety information 5023
1 1 Safety measures when working on vehicles with a start/stop system 5024
1 2 Safety measures when working with pyrotechnic components 5025
1 3 Storage, transportation and disposal of airbag, belt tensioner and battery isolator units (pyrotechnic components) 5026
1 4 Additional safety regulations for side airbag 5027
1 5 Additional safety instructions for curtain airbag 5027
1 6 Safety regulations for crash sensors (pressure sensors) for front side airbags 5028
1 7 Additional safety instructions for repair work on seat occupied recognition for front passenger airbag deactivation – country-specific 5028
1 8 Measures for seat occupied recognition for front passenger airbag deactivation following an accident – country-specific 5029
1 9 Renewing pyrotechnic, electrical and mechanical components of the restraint system after an accident 5029
1 10 Checking airbag securing parts after an accident 5031
1 11 Accident without airbag triggering 5031
1 12 Checking seat belts 5032
1 13 Check belt webbing 5032
1 14 Checking inertia reel (locking mechanism) 5033
1 15 Visually checking belt buckle 5033
1 16 Check operation of belt buckle 5033
1 17 Checking belt relays, and buckle tongues 5034
1 18 Checking securing parts and anchorage points after an accident 5034
1 19 Checking child seat anchors after an accident 5034
1 20 Safety instructions for automatic anti-dazzle interior mirror 5035
2 Repair notes 5036
2 1 Contact corrosion 5036
2 2 Pipe/wire routing and attachment 5036
68 – Interior equipment 5037
1 Compartments/covers 5037
1 1 Removing and installing storage compartment 5037
1 2 Removing and installing steering column trim 5037
1 3 Removing and installing left dash panel cover on driver side 5039
1 4 Removing and installing glove compartment 5040
1 5 Removing and installing glove compartment lock cylinder 5042
1 6 Removing and installing decorative trim on glove compartment 5043
1 7 Removing and installing spectacles holder 5044
2 Equipment 5046
2 1 Removing and installing sun visor 5046
2 2 Removing and installing roof grab handle 5047
2 3 Removing and installing roof grab handle bracket 5049
3 Centre console 5050
3 1 Removing and installing »Basic« centre console 5050
3 2 Removing and installing »Comfort and Highline« centre console 5054
3 3 Removing and installing rear trim of »Comfort and Highline« centre console 5058
3 4 Removing and installing rear trim bracket of »Comfort and Highline« centre console 5060
3 5 Removing and installing lid of rear storage compartment of centre console, »Comfort and Highline« 5061
3 6 Removing and installing centre console securing bracket 5061
3 6 1 Assembly overview – securing bracket 5061
3 6 2 Removing and installing front securing bracket 5062
3 6 3 Removing and installing middle securing bracket 5063
3 6 4 Removing and installing support 5063
3 6 5 Removing and installing rear fastenings 5064
4 On inside 5065
4 1 Assembly overview – interior mirror 5065
4 1 1 Assembly overview – interior mirror, »Basic« version 5065
4 1 2 Assembly overview – interior mirror, »with rain sensor« 5066
4 1 3 Assembly overview – interior mirror, »with rain sensor and front camera« 5067
4 2 Removing and installing interior mirror 5068
4 2 1 Removing and installing »Basic« interior mirror 5068
4 2 2 Removing and installing interior mirror, »with rain sensor« 5069
4 2 3 Removing and installing interior mirror, »with rain sensor and front camera« 5071
4 3 Repairing interior mirror retaining plate 5074
4 3 1 Repairing interior mirror retaining plate, »Basic« version 5074
4 3 2 Repairing interior mirror retaining plate, »with rain sensor« 5076
4 3 3 Repairing interior mirror retaining plate, »with rain sensor and front camera« 5077
4 4 Automatic anti-dazzle interior mirror – functional description 5077
69 – Passenger protection 5079
1 Seat belts 5079
1 1 Assembly overview – front three-point seat belt 5079
1 2 Assembly overview – rear three-point seat belt 5081
1 3 Removing and installing front three-point seat belt 5081
1 4 Removing and installing rear outer three-point seat belt 5087
1 5 Removing and installing rear centre three-point seat belt 5089
1 6 Removing and installing front belt height adjuster 5092
1 7 Removing and installing front belt buckle with belt switch -E24-/-E25- 5096
1 8 Removing and installing rear double belt buckle 5099
2 Child seat anchors 5101
2 1 Points to check 5101
2 2 Child seat anchors in rear shelf 5101
3 Airbag system 5102
3 1 Overview of fitting locations – airbag system 5102
3 2 Adapting components 5103
4 Airbag control unit 5104
4 1 Assembly overview – airbag control unit 5104
4 2 Removing and installing airbag control unit -J234- 5104
5 Driver’s airbag 5107
5 1 Removing and installing driver side airbag igniter -N95- 5107
6 Front passenger side airbag 5111
6 1 “Advanced Airbag System” (only for USA/Canada) 5111
6 2 Removing and installing front passenger airbag unit with front passenger side airbag igniter 1 -N131-/-N132- 5111
6 3 Removing and installing key-operated switch to deactivate front passenger side airbag -E224- 5115
7 Side airbags 5117
7 1 Removing and installing front side airbag with side airbag igniter -N199-/-N200- 5117
7 2 Removing and installing side airbag with rear side airbag igniter -N201-/-N202- 5119
8 Curtain airbags 5122
8 1 Removing and installing curtain airbag with curtain airbag igniter -N251-/-N252- 5122
9 Airbag crash sensors 5128
9 1 Removing and installing front airbag crash sensor, driver side -G283- (USA) 5128
9 2 Front airbag crash sensor, front passenger side -G284- (USA) 5130
9 3 Removing and installing side airbag crash sensor, driver side -G179- 5131
9 4 Removing and installing side airbag crash sensor, front passenger side -G180- 5135
9 5 Removing and installing rear side airbag crash sensor, driver side -G256- 5135
9 6 Removing and installing rear side-airbag crash sensor, front passenger side -G257- 5138
10 Seat belt verification 5139
10 1 Removing and installing Seat occupied sensor, front passenger side -G128- 5139
10 2 Removing and installing seat occupied sensor, front passenger side -G128-, from model year 2012 ▶ 5143
11 Seat occupied recognition (USA) 5149
11 1 Safety precautions for when working on seat occupied recognition 5149
11 2 Procedure after an accident when belt tensioner and/or airbag was triggered 5149
11 3 Assembly overview – front seat “Basic” 5150
11 4 Assembly overview – front seat “Comfort” 5152
11 5 Assembly overview – front seat “Sport” 5153
11 6 Removing and installing seat occupied recognition sensor 5154
11 7 Removing and installing seat occupied recognition control unit -J706- 5164
11 8 Removing and installing bracket for seat occupied recognition control unit -J706- 5167
11 9 Importers reporting obligation 5169
70 – Trim, insulation 5171
1 Door trims 5171
1 1 Tools 5171
1 2 Removing and installing driver door trim 5172
1 3 Removing and installing front passenger door trim 5176
1 4 Removing and installing front door trim bracket 5180
1 4 1 Installing 5182
1 5 Removing and installing rear door trim 5182
1 6 Removing and installing rear door trim bracket 5186
1 7 Removing and installing front inner mirror cover 5188
2 Dash panel 5190
2 1 Removing and installing covers on side of dash panel 5190
2 2 Removing and installing dash panel insert trim, with left and middle dash panel vents 5191
2 3 Removing and installing dash panel vents on right 5194
2 4 Removing and installing left decorative trim panel on driver side 5195
2 5 Removing and installing middle trim of dash panel (vehicles without Climatronic) 5196
2 6 Removing and installing trim in middle of dash panel (vehicles with Climatronic) 5197
2 7 Removing and installing dash panel 5199
2 8 Deformation elements for dash panel USA 5207
2 9 Aligning dash panel in vehicle 5208
3 Dash panel central tube 5211
3 1 Assembly overview – dash panel central tube 5211
3 2 Removing and installing dash panel central tube 5212
3 3 Removing and installing bracket for dash panel central tube, LHD vehicles 5216
4 Interior trims 5218
4 1 Removing and installing upper A-pillar trim 5218
4 2 Removing and installing centre A-pillar trim 5219
4 3 Removing and installing lower A-pillar trim on driver side 5221
4 4 Removing and installing lower A-pillar trim on front passenger side 5222
4 5 Releasing and securing upper B-pillar trim 5224
4 6 Removing and installing upper B-pillar trim 5226
4 7 Removing and installing lower B-pillar trim 5229
4 8 Removing and installing C-pillar trim 5231
4 9 Removing and installing sill panel moulding 5233
4 10 Removing and installing wheel housing trim for vehicles with side airbag 5235
4 11 Removing and installing wheel housing trim for vehicles without side airbag 5236
4 12 Removing and installing rear shelf 5238
4 13 Removing and installing rear shelf USA 5240
5 Luggage compartment trims 5243
5 1 Removing and installing luggage compartment floor covering 5243
5 2 Removing and installing luggage compartment floor covering, hybrid vehicles 5244
5 3 Removing and installing rear panel trim 5245
5 4 Removing and installing high-voltage battery cover, hybrid vehicles 5247
5 5 Removing and installing luggage compartment side trim 5249
5 6 Removing and installing side panel trim in luggage compartment, hybrid vehicles 5251
5 7 Removing and installing rear lid trim 5254
6 Roof trims 5257
6 1 Detaching and fastening moulded headliner 5257
6 2 Removing and installing moulded headlining 5260
6 3 Removing and installing insulation/roof reinforcements 5265
72 – Seat frames 5271
1 Front seats 5271
1 1 Assembly overview – front seat 5271
1 1 1 Assembly overview – manual front seat, NAR 5271
1 1 2 Assembly overview – semi-electric front seat, NAR 5273
1 2 Assembly overview – seat pan 5275
1 2 1 Assembly overview – manual seat pan, NAR 5275
1 2 2 Assembly overview – semi-electric seat pan, NAR 5276
1 3 Assembly overview – seat height adjustment 5277
1 4 Removing and installing front seat 5277
1 5 Removing and installing backrest adjusting lever 5282
1 6 Removing and installing lumbar adjustment lever 5283
1 7 Removing and installing left trim on seat without height adjustment 5283
1 8 Removing and installing left trim on seat with manual height adjustment 5285
1 9 Removing and installing left trim on seat with electrical height adjustment 5287
1 10 Removing and installing right trim on seat 5290
1 11 Removing and installing front seat drawer together with mounting 5291
1 12 Removing and installing front seat bar and operating lever 5292
1 13 Removing and installing bar of electrically adjustable seat 5293
1 14 Removing and installing head restraint guides 5295
1 15 Removing and installing backrest 5296
1 16 Removing and installing manually adjustable lumbar support frame 5298
1 17 Removing and installing fire extinguisher holder 5300
1 18 Removing and installing fire extinguisher holder on seat frame 5301
1 19 Removing and installing drive for backrest adjustment (electrically adjustable seat) 5302
2 Rear seats 5303
2 1 Removing and installing rear bench seat 5303
2 2 Removing and installing rear seat backrest 5304
2 3 Removing and installing backrest release mechanism 5307
2 4 Removing and installing side padding with side airbag 5308
2 5 Removing head restraint guides 5311
74 – Seat – padding, covers 5313
1 Front seat covers and padding 5313
1 1 Removing and installing seat pan cover and padding 5313
1 2 Removing and installing backrest cover and padding 5319
2 Rear seat covers and padding 5326
2 1 Removing and installing bench seat cover and padding 5326
2 2 Removing and installing cover and padding for 1/3 backrest 5330
2 3 Removing and installing cover and padding for 2/3-section of backrest 5334
2 4 Removing and installing through loading unit with centre armrest 5338
D3E802DF89D General body repairs exterior 5342
50 – Body – front 5350
1 Lock carrier 5350
1 1 Tools 5350
1 2 Lock carrier – add-on parts 5350
1 2 1 Assembly overview for RoW (rest of world) 5350
1 2 2 Assembly overview for NAR 5352
1 3 Service position 5354
1 3 1 Moving to service position 5354
1 3 2 Moving from service position 5355
1 4 Removing and installing lock carrier with attachments 5357
1 4 1 Removing 5357
1 4 2 Installing 5358
1 5 Removing and installing pressure hoses 5360
1 5 1 Pressure hose with plug-in connector 5360
1 5 2 Pressure hose with corrugated pipe connection and hose clip 5361
2 Wings 5363
2 1 Tools 5363
2 2 Assembly overview – front wing 5363
2 3 Removing and installing front wing 5364
2 3 1 Removing 5364
2 3 2 Installing 5366
2 4 Insulation and foam elements for wing and wing end plate 5367
2 5 Wing end plate 5367
2 6 Removing and installing wing bracket 5368
2 6 1 Removing 5368
2 6 2 Installing 5369
3 Plenum chamber cover 5370
3 1 Assembly overview – plenum chamber cover 5370
3 2 Removing and installing plenum chamber covers 5370
3 2 1 Removing 5370
3 2 2 Installing 5372
4 Underbody cladding 5374
4 1 Tools 5374
4 2 Assembly overview – underbody cladding 5374
4 3 Rear right underbody cladding 5375
5 Bulkhead 5377
5 1 Tools 5377
5 2 Materials 5377
5 3 Assembly overview – bulkhead 5378
6 Tunnel cross-piece 5379
6 1 Tools 5379
6 2 Assembly overview – tunnel cross-piece 5379
55 – Bonnet, rear lid 5381
1 Bonnet 5381
1 1 Tools 5381
1 2 Assembly overview – bonnet 5381
1 3 Removing and installing bonnet 5382
1 3 1 Removing 5382
1 3 2 Installing 5383
1 4 Removing and installing bonnet hinge 5384
1 4 1 Removing 5384
1 4 2 Installing 5385
1 5 Removing and installing insulation 5386
1 5 1 Removing 5386
1 5 2 Installing 5387
1 6 Assembly overview – seals 5388
1 7 Removing and installing bonnet stay 5389
1 7 1 Removing 5389
1 7 2 Installing 5390
1 8 Assembly overview – bonnet lock and release components 5391
1 9 Removing and installing bonnet lock 5392
1 9 1 Removing 5392
1 9 2 Installing 5394
1 10 Removing and installing Bowden cable 5395
1 11 Removing and installing striker pin 5396
1 11 1 Removing 5396
1 11 2 Installing 5397
1 12 Removing and installing release lever 5398
1 12 1 Removing 5398
1 12 2 Installing 5399
1 13 Adjusting bonnet 5401
1 13 1 Adjusting bonnet lock 5402
1 13 2 Adjusting striker pin 5402
2 Rear lid 5404
2 1 Tools 5404
2 2 Assembly overview – rear lid 5404
2 3 Removing and installing rear lid 5405
2 3 1 Removing 5405
2 3 2 Installing 5406
2 4 Assembly overview – gas strut 5406
2 5 Removing and installing gas strut 5407
2 5 1 Removing 5407
2 5 2 Installing 5408
2 6 Releasing gas from gas strut 5409
2 7 Assembly overview – rear lid hinge 5410
2 8 Removing and installing rear lid hinge 5411
2 8 1 Removing 5411
2 8 2 Installing 5412
2 9 Removing and installing hinge covers 5412
2 10 Removing and installing striker plate 5414
2 10 1 Removing 5414
2 10 2 Installing 5414
2 11 Adjusting rear lid 5415
2 11 1 Adjusting striker plate 5416
2 12 Removing and installing rear lid handle release button -E234- 5416
2 12 1 Removing 5416
2 12 2 Installing 5417
2 13 Removing and installing bonnet lock 5417
2 13 1 Removing 5417
2 13 2 Installing 5418
2 14 Rear lid seal 5419
2 15 Removing and installing rear lid seal 5420
2 15 1 Removing 5420
2 15 2 Installing 5420
2 16 Number plate carrier 5421
3 Tank flap unit 5423
3 1 Tools 5423
3 2 Assembly overview – tank flap unit 5423
3 3 Removing and installing tank flap unit 5424
3 3 1 Removing 5424
3 3 2 Installing 5425
3 4 Removing and installing tank filler flap locking motor -V155- 5427
3 4 1 Removing 5427
3 4 2 Installing 5428
57 – Front doors, door components, central locking 5429
1 Rear door 5429
1 1 Tools 5429
1 2 Assembly overview – door hinges 5430
1 3 Removing and installing door 5432
1 3 1 Removing 5432
1 3 2 Installing 5433
1 4 Installing after renewing A-pillar 5434
1 5 Door alignment 5435
1 5 1 Door alignment – shut lines and flushness 5435
1 5 2 Adjusting striker pin 5437
2 Door components 5438
2 1 Tools 5438
2 2 Assembly overview – front door 5438
2 3 Removing and installing door cover 5440
2 3 1 Removing 5440
2 3 2 Installing 5441
2 4 Removing and installing door retaining strap 5442
2 4 1 Removing 5442
2 4 2 Installing 5443
2 5 Removing and installing striker pin 5443
2 5 1 Removing 5443
2 5 2 Installing 5444
2 6 Assembly overview – door handle and door lock 5444
2 7 Removing and installing lock cylinder cover cap 5446
2 7 1 Removing 5446
2 7 2 Installing 5446
2 8 Removing and installing lock cylinder 5447
2 8 1 Removing 5447
2 8 2 Installing 5448
2 9 Removing and installing cover cap (without lock cylinder) 5450
2 9 1 Tools 5450
2 9 2 Removing 5450
2 9 3 Installing 5452
2 10 Removing and installing door handle 5453
2 10 1 Removing 5453
2 10 2 Installing 5454
2 11 Removing and installing door lock 5455
2 11 1 Removing 5455
2 11 2 Installing 5456
2 12 Removing and installing mounting bracket 5458
2 12 1 Removing 5458
2 12 2 Installing 5459
2 13 Removing and installing inner window slot seal 5460
2 13 1 Removing 5460
2 13 2 Installing 5461
2 14 Removing and installing outer window slot seal 5463
2 14 1 Removing 5463
2 14 2 Installing 5464
2 15 Removing and installing inner door seal 5464
2 15 1 Removing 5465
2 15 2 Installing 5466
2 16 Removing and installing outer door seal 5467
2 16 1 Removing 5467
2 16 2 Installing 5467
2 17 Assembly overview – insulation 5468
3 Central locking 5470
3 1 Fitting location overview – central locking components 5470
3 2 Adapting keys with remote control 5472
3 3 Assembly overview – battery for folding key with remote control 5472
3 4 Removing and installing battery for folding key with remote control 5473
3 4 1 Removing 5473
3 4 2 Installing 5474
3 5 Assembly overview – battery for folding key with cover cap 5475
3 6 Removing and installing battery for folding key with cover cap 5476
3 6 1 Removing 5476
3 6 2 Installing 5476
58 – Rear doors, door components 5478
1 Rear door 5478
1 1 Tools 5478
1 2 Assembly overview – door hinges 5479
1 3 Removing and installing door 5481
1 3 1 Removing 5481
1 3 2 Installing 5482
1 4 Installing after renewing B-pillar 5483
1 5 Door alignment 5484
1 5 1 Door alignment – shut lines and flushness 5484
1 5 2 Adjusting striker pin 5485
2 Door components 5486
2 1 Tools 5486
2 2 Assembly overview – rear door 5486
2 3 Removing and installing cover 5488
2 3 1 Removing 5488
2 3 2 Installing 5489
2 4 Removing and installing door retaining strap 5490
2 4 1 Removing 5490
2 4 2 Installing 5491
2 5 Removing and installing striker pin 5491
2 5 1 Removing 5491
2 5 2 Installing 5492
2 6 Assembly overview – door handle and door lock 5492
2 7 Removing and installing cap 5493
2 7 1 Tools 5493
2 7 2 Removing 5494
2 7 3 Installing 5495
2 8 Removing and installing door handle 5496
2 8 1 Removing 5496
2 8 2 Installing 5497
2 9 Removing and installing door lock 5498
2 9 1 Removing 5498
2 9 2 Installing 5500
2 10 Removing and installing mounting bracket 5501
2 10 1 Removing 5501
2 10 2 Installing 5502
2 11 Removing and installing inner window slot seal 5503
2 11 1 Removing 5503
2 11 2 Installing 5504
2 12 Removing and installing outer window slot seal 5505
2 12 1 Distinguishing different versions 5505
2 12 2 Removing 5506
2 12 3 Installing 5507
2 13 Removing and installing inner door seal 5508
2 13 1 Removing 5509
2 13 2 Installing 5510
2 14 Removing and installing outer door seal 5511
2 14 1 Distinguishing different versions 5511
2 14 2 Removing 5512
2 14 3 Installing 5512
2 15 Assembly overview – insulation 5513
60 – Sunroof 5515
1 Sunroof with glass panel 5515
1 1 Tools 5515
1 2 Functional check 5515
1 3 Assembly overview 5516
1 4 Removing and installing sliding/tilting sunroof glass panel 5518
1 4 1 Removing 5518
1 4 2 Installing 5518
1 5 Height-adjustment of glass panel 5519
1 6 Checking parallel running of glass panel 5521
1 7 Adjusting parallel running of glass panel 5522
1 8 Renewing panel seal 5522
1 9 Removing and installing wind deflector 5523
1 9 1 Removing 5523
1 9 2 Installing 5523
1 10 Removing and installing sliding headliner 5524
1 10 1 Removing 5524
1 10 2 Installing 5525
1 11 Removing and installing sliding/tilting sunroof drive 5525
1 11 1 Removing 5525
1 11 2 Installing 5525
1 12 Setting drive for sliding/tilting sunroof to zero position 5526
1 13 Performing programming run for drive for sliding/tilting sunroof 5526
1 14 Removing pre-selector control for sliding/tilting sunroof 5527
1 14 1 Removing 5527
1 14 2 Installing 5527
1 15 Removing and installing carrier unit 5527
1 15 1 Removing 5527
1 15 2 Installing 5528
1 16 Cleaning water drain hoses 5530
1 16 1 Front water drain hoses 5530
1 16 2 Rear water drain hoses 5530
63 – Bumpers 5532
1 Front bumper cover 5532
1 1 Tools 5532
1 2 Repairing front bumper cover 5532
1 3 Installing brackets for parking aid system 5532
1 3 1 Tools 5532
1 3 2 Materials 5533
1 3 3 Installing brackets 5533
1 3 4 Minimum curing period 5537
1 4 Assembly overview – front bumper cover 5537
1 5 Removing and installing front bumper cover 5538
1 5 1 Removing 5538
1 5 2 Installing 5539
1 6 Front bumper cover add-on parts 5540
1 7 Installing front number plate carrier 5541
1 8 Assembly overview – guides for front bumper cover 5542
1 9 Assembly overview – front bumper carrier 5543
2 Rear bumper cover 5545
2 1 Tools 5545
2 2 Repairing rear bumper cover 5545
2 3 Installing brackets for parking aid system 5545
2 3 1 Tools 5545
2 3 2 Materials 5546
2 3 3 Installing brackets 5546
2 3 4 Minimum curing period 5550
2 4 Assembly overview – rear bumper cover 5550
2 5 Removing and installing rear bumper cover 5551
2 5 1 Removing 5551
2 5 2 Installing 5552
2 6 Assembly overview – guides for rear bumper cover 5553
2 7 Assembly overview – rear bumper carrier 5553
2 8 Assembly overview – towing bracket 5554
64 – Glazing 5556
1 Flush bonded windows 5556
1 1 Tools 5556
1 2 Materials 5557
1 3 Repairing windscreen 5558
1 4 Assembly overview – windscreen 5558
1 5 Remove windscreen 5559
1 6 Install windscreen 5561
1 7 Assembly overview – rear window 5561
1 8 Removing undamaged rear window 5562
1 9 Removing broken rear window 5564
1 10 Installing rear window 5564
1 11 Preparing old undamaged window for glazing 5565
1 11 1 Cutting back adhesive bead 5565
1 12 Preparing new window without precoating for glazing 5566
1 13 Preparing body flange for glazing 5566
1 14 Fitting instructions 5567
1 15 Minimum curing period 5568
1 16 Touching up paint damage 5569
1 17 Removing soiling caused by adhesive sealant 5569
2 Front door window 5570
2 1 Tools 5570
2 2 Assembly overview – front door window 5570
2 3 Removing and installing door window 5571
2 3 1 Removing 5571
2 3 2 Installing 5573
2 4 Removing and installing window regulator motor 5577
2 4 1 Removing and installing window regulator motor, equipment level High (AW1) 5577
2 4 2 Removing and installing window regulator motor, equipment level Low (AW0) 5580
2 5 Removing and installing window regulator 5583
2 5 1 Removing 5583
2 5 2 Installing 5584
2 6 Removing and installing window channel 5585
2 6 1 Removing 5585
2 6 2 Installing 5586
3 Rear door window 5588
3 1 Tools 5588
3 2 Assembly overview – rear door windows 5588
3 3 Removing and installing door window 5589
3 3 1 Removing 5589
3 3 2 Installing 5592
3 4 Removing and installing window regulator motor 5593
3 4 1 Removing and installing window regulator motor, equipment level High (AW1) 5593
3 4 2 Removing and installing window regulator motor, equipment level Low (AW0) 5595
3 5 Removing and installing window regulator 5598
3 5 1 Removing 5598
3 5 2 Installing 5599
3 6 Removing and installing window channel 5600
3 6 1 Removing 5600
3 6 2 Installing 5601
3 7 Removing and installing fixed door-window 5602
3 7 1 Removing 5602
3 7 2 Installing 5604
66 – Exterior equipment 5606
1 Wheel housing liner 5606
1 1 Tools 5606
1 2 Assembly overview – front wheel housing liner 5606
1 3 Removing and installing front wheel housing liner 5607
1 3 1 Removing 5607
1 3 2 Installing 5608
1 4 Assembly overview – rear wheel housing liner 5609
1 5 Removing and installing rear wheel housing liner 5610
1 5 1 Removing 5610
1 5 2 Installing 5611
2 Exterior mirror 5614
2 1 Tools 5614
2 2 Assembly overview – exterior mirror (manual operation) 5614
2 3 Assembly overview – exterior mirror, electrically operated, without turn signal repeater 5615
2 4 Assembly overview – exterior mirror, electrically operated, with turn signal repeater 5616
2 5 Removing and installing mirror glass 5618
2 5 1 Removing 5618
2 5 2 Installing 5619
2 6 Removing and installing exterior mirror trim, without turn signal repeater 5619
2 6 1 Removing 5619
2 6 2 Installing 5620
2 7 Removing and installing exterior mirror trim, with turn signal repeater 5621
2 8 Removing and installing exterior mirror housing, without turn signal repeater 5623
2 8 1 Removing 5623
2 8 2 Installing 5623
2 9 Removing and installing exterior mirror housing, with turn signal repeater 5624
2 10 Removing and installing adjustment unit with motor for exterior mirror 5626
2 10 1 Removing 5626
2 10 2 Installing 5627
2 11 Removing and installing assembly bracket 5629
2 12 Removing and installing exterior mirror (manual operation) 5630
2 12 1 Removing 5630
2 12 2 Installing 5632
2 13 Removing and installing exterior mirror (electrical operation) 5634
2 13 1 Removing 5634
2 13 2 Installing 5636
3 Radiator grille 5639
3 1 Tools 5639
3 2 Removing and installing radiator grille 5639
3 2 1 Removing 5639
3 2 2 Installing 5640
3 3 Removing and installing emblem 5641
3 3 1 Removing 5641
3 3 2 Installing 5643
4 Rear spoiler 5646
4 1 Removing and installing rear spoiler 5646
5 Mouldings and trims 5653
5 1 Water deflector 5653
5 1 1 Tools 5653
5 1 2 Assembly overview 5653
5 1 3 Removing 5654
5 1 4 Installing 5655
5 2 Assembly overview – side member cover 5657
5 3 Assembly overview – B-pillar trim 5658
5 4 Removing and installing B-pillar trim 5659
5 4 1 Removing 5659
5 4 2 Installing 5660
5 5 Side member extension 5661
5 5 1 Removing 5662
5 5 2 Dimensions for securing screws 5662
5 5 3 Installing 5664
6 Lettering 5666
6 1 Tools 5666
6 2 Installation instructions for lettering and emblems 5666
6 3 Dimensions – lettering on rear lid 5667
6 3 1 Lettering for model designation 5667
6 3 2 Lettering for engine type 5667
6 3 3 Lettering for additional designation 5668
6 3 4 “GLI” lettering 5668
6 3 5 Lettering “HYBRID” and “SPORT” 5669
6 4 Dimensions – lettering on wing 5669
6 4 1 Lettering “HYBRID” 5669
6 4 2 Lettering “MATCH”, “LIFE”, “sochiEDITION” 5670
7 Noise insulation 5671
7 1 Assembly overview – noise insulation 5671
7 1 1 Assembly overview – noise insulation, petrol engine 5671
7 1 2 Assembly overview – noise insulation for diesel engines 5672
7 1 3 Assembly overview – skid plate 5672
7 2 Removing and installing noise insulation 5673
7 2 1 Removing and installing noise insulation, petrol engine 5673
7 2 2 Removing and installing noise insulation, diesel engine 5674
7 2 3 Removing and installing skid plate 5675
D3E8046D49A Wheels and Tyres Guide – General Information 5677
44 – Wheels, tyres, vehicle geometry 5685
1 Instructions on using the guide 5685
1 1 Overview 5685
1 1 1 Wheels and Tyres Guide – General Information 5685
1 1 2 Wheels and Tyres Guide – Vehicle-specific section 5685
1 2 General information 5685
1 3 Notes 5686
1 4 Determining correct wheel and tyre combinations, according to NEDC with tyre package 5687
1 4 1 Determining the required tyre package via PR number 5687
1 4 2 Determining the required tyre package via version key in the vehicle registration certificate part 1 5687
1 5 Determining correct wheel and tyre combinations according to WLTP 5688
1 5 1 Vehicle registration certificate part 1 5688
1 5 2 COC document, item 0 10 5690
1 6 NEDC, WLTP and RDE 5690
1 6 1 What are NEDC, WLTP and RDE? 5690
1 6 2 What are the differences between WLTP and RDE? 5690
1 6 3 Since when are WLTP and RDE valid? 5690
1 7 Definition of tyre package 5690
1 8 Explanations regarding world regions 5691
2 Legislative and technical conditions 5693
2 1 Legislative conditions 5693
2 1 1 Permissible wheel and tyre combinations in Germany 5693
2 1 2 Vehicles with Tyre Pressure Monitoring System 5693
2 2 Technical conditions 5694
2 3 Load-carrying capacity depending on vehicle speed, winter tyres 5694
2 4 Vehicle registration documents since 01 10 2005 5696
2 5 COC document (EEC Certificate of Conformity) 5697
2 6 EU general type approval number, sales type and sales or trade designation 5697
3 Wheel change 5700
3 1 Fitting instructions 5700
3 2 Protecting wheel centring seat against corrosion 5703
3 3 Fitting wheels 5703
3 4 Position of anti-theft wheel bolts for steel wheels 5704
4 Fitting tyre 5706
4 1 Pressing tyre off wheel rim 5706
4 2 Removing tyre sealant 5707
4 3 Removing tyre from wheel 5707
4 3 1 Removing tyres, wheels without and with tyre pressure monitoring 5707
4 3 2 Removing tyres, run-flat tyres, ultra-high-performance tyres 5709
4 4 Ensuring proper assembly temperature for tyres 5711
4 5 Fitting tyre 5712
4 5 1 Mounting tyre, wheels without and with tyre pressure monitoring 5712
4 5 2 Mounting tyre, run-flat tyres, ultra-high performance tyres 5714
4 6 Matching wheel rims and tyres 5716
4 7 Checking radial and lateral runout of wheels and tyres 5717
4 7 1 Checking radial and lateral runout of wheels and tyres, tolerances 5717
4 7 2 Checking radial and lateral runout on wheels and tyres with tyre gauge 5718
4 8 Matching wheels and tyres 5719
4 9 Balancing wheel 5720
4 9 1 Conditions 5720
4 9 2 Balancing wheel on stationary wheel balancer 5720
4 9 3 Balancing wheel with finish balancer 5723
4 9 4 Checking radial and lateral run-out on wheel rim 5724
4 10 Tyre sealant disposal 5725
5 Tyre Pressure Monitoring System 5726
5 1 System description – Tyre Pressure Monitoring System 5726
5 1 1 System description – Tyre Pressure Monitoring System with indirect measurement (Tyre Pressure Loss Indicator) 5726
5 1 2 System description – Tyre Pressure Monitoring System with direct measurement (with tyre pressure sensor) 5728
5 1 3 Button behaviour – Tyre Pressure Monitoring System with direct measurement (with tyre pressure sensor) 5728
5 1 4 System description – Tyre Pressure Monitoring System, Tyre Pressure Monitoring System (TPMS) with autolocation 5729
5 2 Overview of fitting locations – Tyre Pressure Monitoring System 5730
5 2 1 Overview of fitting locations – Tyre Pressure Monitoring System (TPMS) with autolocation 5730
5 2 2 Overview of fitting locations – Tyre Pressure Monitoring System, Trigger 5731
5 2 3 Overview of fitting locations – Tyre Pressure Monitoring System, Autolocation 5733
5 3 Assembly overview – tyre pressure sensor 5734
5 3 1 Assembly overview – tyre pressure sensor, tyre pressure sensor with valve 5734
5 3 2 Assembly overview – tyre pressure sensor, tyre pressure sensor without valve, version 1 5736
5 3 3 Assembly overview – tyre pressure sensor, tyre pressure sensor without valve, version 2 5738
5 4 Removing and installing tyre pressure sensor -G222-/-G223-/-G224-/-G225- 5739
5 4 1 Removing and installing tyre pressure sensor, tyre pressure sensor with valve 5739
5 4 2 Removing and installing tyre pressure sensor, tyre pressure sensor without valve, version 1 (customer service version) 5740
5 4 3 Removing and installing tyre pressure sensor, tyre pressure sensor without valve, version 1 (production version) 5742
5 4 4 Removing and installing tyre pressure sensor -G222-/-G223-/-G224-/-G225-, version 2 5745
5 5 Removing and installing Tyre Pressure Monitoring System control unit -J502- 5747
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 5748
5 5 2 Removing and installing tyre Tyre Pressure Monitoring System control unit, Passat 2011, Passat Estate 2011 5750
5 5 3 Removing and installing Tyre Pressure Monitoring System control unit, CC 2010, CC 2012, Passat CC 2009 5750
5 5 4 Removing and installing Tyre Pressure Monitoring System control unit, Phaeton 2003 5750
5 5 5 Removing and installing Tyre Pressure Monitoring System control unit -J502-, Touran 2016 5750
5 5 6 Removing and installing Tyre Pressure Monitoring System control unit -J502-, Tiguan 2008 5751
5 5 7 Removing and installing Tyre Pressure Monitoring System control unit -J502-, Tiguan 2016, Tiguan 2017 (BW2), Tiguan 2021 5752
5 5 8 Removing and installing Tyre Pressure Monitoring System control unit, up to model year 2014, Touareg 2010 5753
5 5 9 Removing and installing Tyre Pressure Monitoring System control unit, as of model year 2015, Touareg 2015 5754
5 5 10 Removing and installing Tyre Pressure Monitoring System control unit, Touareg 2018 5755
5 5 11 Removing and installing bracket for Tyre Pressure Monitoring System control unit, Touareg 2015 5756
5 6 Removing and installing tyre pressure monitor sender unit in wheel housing 5756
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 5756
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 5757
5 6 3 Removing and installing sender unit for Tyre Pressure Monitoring System in wheel housing, Phaeton 2003 5758
6 Wheel bolts 5759
6 1 Wheel bolts, versions 5759
6 2 Wheel bolts, anti-theft wheel bolt 5761
6 3 Wheel bolts, adapter sets for anti-theft wheel bolts 5761
7 Information on tyres 5764
7 1 Identification markings on the tyre sidewall 5764
7 2 Tyre dimension 5766
7 3 Load rating code/load index (LI) 5766
7 4 Speed rating code 5767
7 5 EU tyre label 5767
7 5 1 EU tyre label, summary 5767
7 5 2 EU tyre label, objectives 5768
7 5 3 EU tyre label, categories 5769
7 6 Structure of a radial belted tyre 5773
7 6 1 Cross section of a radial belted tyre 5773
7 6 2 Run-flat tyres, structure and identification of a SST tyre 5774
7 6 3 Run-flat tyres, seal inside technology 5776
7 7 Run-flat tyre, SST (Self Supporting Tyre) 5779
7 7 1 Run-flat tyres – general information 5779
7 7 2 Run-flat tyres, retrofitting/requirements when using run-flat tyres 5780
7 7 3 Run-flat tyres, repair work 5780
7 8 Tyre storage 5780
7 9 Reinforced and Extra Load (XL) tyres 5781
7 10 M+S tyres 5782
7 11 Winter tyres with speed symbol V 5784
7 12 All-season tyres 5785
7 13 Optimised rolling resistance tyres 5786
7 14 Tyre ageing 5786
7 15 Tyres with flange protection 5788
7 16 Tyre sizes for vehicles with all-wheel drive 5788
7 17 Increase in temperature due to insufficient tyre pressure 5788
8 Tyre sealant 5790
8 1 Models with breakdown set 5790
8 2 Storage life 5790
8 3 Disposal 5790
9 Information about wheels (rims) 5791
9 1 Structure of wheel (rim) 5791
9 2 Identification 5792
9 3 Composite wheels 5793
9 4 Care and maintenance of alloy wheel rims 5793
9 5 Restoring alloy wheels 5793
9 6 Removing and installing hub cover for alloy wheels with open threaded connection 5794
9 7 Renewing trim elements 5795
9 7 1 Renewing trim elements, bonded trim elements 5795
9 7 2 Renewing trim elements, bolted trim elements 5799
9 8 Removing and installing valve 5800
9 8 1 Removing and installing valve, description of the valve 5800
9 8 2 Removing and installing valve, rubber valve 5801
9 8 3 Removing and installing valve, metal valve 5802
10 Handling problems 5804
10 1 Rolling noise 5804
10 1 1 General notes on tyre noise 5804
10 1 2 Flat spots (from locking wheels) 5805
10 2 Vehicle pulls to one side 5806
10 2 1 General information 5806
10 2 2 Conicity 5806
10 2 3 Remedies when vehicle pulls to one side 5808
10 2 4 Strategic rotation of wheels for non-directional tyres 5809
10 2 5 Strategic rotation of wheels having unidirectional tyres 5810
10 3 Vibration 5811
10 3 1 Vibration, causes for vibration 5811
10 3 2 Vibration, conducting a road test before balancing wheels 5811
10 3 3 Vibration, vibration control system 5811
10 4 Eliminating flat spots caused by storage or handling 5812
11 Evaluating tyres 5814
11 1 Flat spots caused by storage or handling 5814
11 2 Undulations 5814
11 3 Saw-tooth wear 5815
11 4 Flat spots caused by hard braking 5815
11 5 Swellings in the tyre sidewall 5815
11 6 Cuts 5817
11 7 Damage caused by foreign bodies 5817
11 8 Stripped profile 5818
11 9 Tyre damage due to insufficient tyre pressure 5818
11 10 Checking tyres 5819
11 11 Damage caused when fitting 5820
12 Tyre wear 5822
12 1 Factors influencing the service life of tyres 5822
12 2 Saw-tooth wear 5823
12 3 Wear behaviour of high-speed tyres 5824
12 4 Measuring tread depth 5824
12 5 One-sided wear 5825
12 6 Outer shoulder wear 5827
12 7 Diagonal washout 5828
12 8 Wear in middle of tyre 5829
12 9 Permissible deviation in tread depth 5829
13 Overview of components 5830
13 1 Assembly overview – wheel 5830
14 Snow chains 5833
14 1 Assembly and use of snow chains 5833
15 Regular and temporary spare wheels, recommended temporary spare tyres 5834
15 1 Spare wheel with yellow sticker 5834
15 2 Temporary spare wheels and recommended temporary spare tyres 5835
15 2 1 Atlas 2017 5835
15 2 2 Golf 2013, e-Golf 2014 5835
15 2 3 Golf 2017, e-Golf 2017 5835
15 2 4 Golf SV 2015 5835
15 2 5 Golf Variant 2014 5836
15 2 6 Golf Variant 2017 5836
15 2 7 Golf 2018 (AU2/BX6) 5836
15 2 8 Jetta 2018 5836
15 2 9 Taos 2021 5837
D3E80500BF9 Fuel supply system petrol engines 5838
00 – Technical data 5842
1 Safety information 5842
1 1 Safety regulations for working on fuel supply 5842
1 2 Safety precautions when using testers and measuring instruments during a road test 5842
1 3 Safety measures when working on vehicles with a start/stop system 5843
1 4 Safety precautions when working on vehicles with high-voltage system 5843
1 5 Safety precautions when working in the vicinity of high-voltage components 5844
2 Identification 5845
2 1 Engine number/engine data 5845
3 General information 5847
3 1 Rules for cleanliness when working on auxiliary/supplementary heater and fuel system 5847
4 Repair notes 5848
4 1 Routing and attachment of lines 5848
4 2 General repair instructions 5848
20 – Fuel supply system 5849
1 Fuel 5849
1 1 Assembly overview – fuel tank 5849
1 1 1 Assembly overview – fuel tank, vehicles with externally fitted fuel filter 5849
1 1 2 Assembly overview – fuel filter, vehicles with fuel filter integrated into flange of fuel delivery unit 5851
1 1 3 Assembly overview – fuel tank, hybrid vehicles 5853
1 2 Emptying fuel tank 5854
1 2 1 Emptying fuel tank when fuel pump is intact 5854
1 2 2 Emptying fuel tank if it is more than 3/4 full 5859
1 2 3 Emptying fuel tank if it is less than 3/4 full 5861
1 3 Removing and installing fuel tank 5865
2 Fuel delivery unit, fuel gauge sender 5870
2 1 Assembly overview – fuel delivery unit/fuel gauge sender 5870
2 1 1 Assembly overview – fuel delivery unit, vehicles with externally fitted fuel filter 5870
2 1 2 Assembly overview – fuel delivery unit, vehicles with fuel filter integrated into flange of fuel delivery unit 5872
2 1 3 Assembly overview – fuel delivery unit, hybrid vehicles 5873
2 2 Removing and installing fuel delivery unit, fuel gauge sender 5874
2 2 1 Removing and installing fuel delivery unit, fuel gauge sender 5874
2 2 2 Removing and installing fuel delivery unit, hybrid vehicles 5878
2 3 Removing and installing fuel gauge sender -G- 5884
2 3 1 Removing and installing fuel gauge sender 5884
2 3 2 Removing and installing fuel gauge sender -G-, hybrid 5885
3 Lines 5886
3 1 Removing and installing fuel lines 5886
4 Plug-in connectors 5890
4 1 Separating plug-in connectors 5890
5 Fuel filter 5894
5 1 Assembly overview – fuel filter 5894
5 1 1 Assembly overview – fuel filter, vehicles with externally fitted fuel filter 5894
5 1 2 Assembly overview – fuel filter, fuel filter integrated into flange of fuel delivery unit 5895
5 2 Removing and installing fuel filter 5895
5 2 1 Removing and installing fuel filter, vehicles with externally fitted fuel filter 5895
5 2 2 Removing and installing fuel filter, vehicles with fuel filter integrated into flange of fuel delivery unit 5896
6 Activated charcoal filter system 5897
6 1 Connection diagram – activated charcoal filter system 5897
6 1 1 Connection diagram – activated charcoal filter system, activated charcoal filter fitted in engine compartment 5897
6 1 2 Connection diagram – activated charcoal filter system, activated charcoal filter fitted in rear on right 5899
6 2 Assembly overview – activated charcoal filter system 5900
6 2 1 Assembly overview – Activated charcoal filter system, activated charcoal filter fitted in engine compartment 5900
6 2 2 Assembly overview – activated charcoal filter system, activated charcoal filter fitted in rear on right 5902
6 3 Assembly overview – diagnostic pump 5904
6 4 Removing and installing fuel system diagnosis pump 5905
6 5 Removing and installing activated charcoal filter 5906
6 5 1 Removing and installing activated charcoal filter, activated charcoal filter fitted in engine compartment 5906
6 5 2 Removing and installing activated charcoal filter, activated charcoal filter fitted in rear on right 5906
6 6 Checking fuel tank breather 5906
6 7 Checking fuel system for leaks 5911
7 Accelerator pedal 5915
7 1 Assembly overview – accelerator module 5915
7 2 Removing and installing accelerator module with accelerator position sender -G79-/-G185- 5915
8 Fuel pump 5918
8 1 Checking fuel system pressurisation pump -G6- 5918
8 1 1 Checking operation and power supply of fuel pump, vehicles with fuel pump control unit -J538- 5918
8 1 2 Checking operation and power supply of fuel pump, vehicles without fuel pump control unit -J538- 5922
8 1 3 Checking fuel pressure, vehicles with externally fitted fuel filter 5926
8 1 4 Checking fuel pressure, vehicles with fuel filter integrated into flange of fuel delivery unit 5931
8 1 5 Checking holding pressure, vehicles with externally fitted fuel filter 5935
8 1 6 Checking holding pressure, vehicles with fuel filter integrated into flange of fuel delivery unit 5940
8 1 7 Checking fuel delivery rate, vehicles with externally fitted fuel filter 5943
8 1 8 Checking fuel delivery rate, vehicles with fuel filter integrated into flange of fuel delivery unit 5951
8 1 9 Checking current consumption 5958
D3E80461396 Wheels and Tyres Guide 5961
44 – Wheels, tyres, vehicle geometry 5965
1 General notes on using the “Wheels and Tyres Guide” 5965
1 1 General information 5965
1 2 Explanations regarding world regions 5966
1 3 Definition of tyre package 5967
1 4 Procedure for determining the required tyre package 5967
1 4 1 Determining the required tyre package via PR number 5967
1 4 2 Determining the required tyre package via version key in the vehicle registration certificate part 1 5968
2 Notes on the vehicle registration certificate 5969
2 1 Vehicle registration certificate part 1 5969
2 2 Version key, D2 5969
3 Wheel and tyre combinations without tyre package 5971
3 1 Jetta, model year 2011 to model year 2013 (sales type 162) 5971
3 2 Jetta – as of model year 2014 (sales type 162, 163) 5974
3 3 Jetta Hybrid – as of model year 2014 (sales type 162, 163) 5982
3 4 Jetta – from model year 2011 (North America – sales type 162, 163) 5986
3 5 Jetta Hybrid – from model year 2013 (North America – sales type 162, 163) 5988
3 6 Jetta Russia – model year 2011 to model year 2014 (sales type AV2) 5990
3 7 Jetta Russia – from model year 2015 (sales type AV3) 5991
4 Wheel and tyre combinations depending on tyre packages 5993
4 1 Type approval no (K): e1*2007/46*0539*18 5993
4 2 Type approval no (K): e1*2007/46*0539*19 to e1*2007/46*0539*20 5994
4 3 Type approval no (K): e1*2007/46*0539*21 to e1*2007/46*0539*22 5996
4 4 Type approval No (K): e1*2007/46*0539*23 5998
4 5 Changing to other wheel and tyre combinations 6000
5 Wheel allocation 6002
5 1 6 J x 15 offset 47 6002
5 2 61/2 J x 15 offset 50 6003
5 3 6 J x 16 offset 50 6004
5 4 61/2 J x 16 offset 50 6005
5 5 6 J x 17 offset 48 5 6010
5 6 7 J x 17 offset 54 6011
5 7 71/2 J x 17 offset 51 6015
5 8 71/2 J x 18 offset 51 6017
6 Recommended summer tyres 6022
6 1 Recommended summer tyres, Jetta worldwide except India, Indonesia, Japan, Mexico, North America, Scandinavia, South Africa, South America, South Korea, Taiwan 6022
6 2 Recommended summer tyres, Jetta Hybrid worldwide except North America 6024
6 3 Recommended summer tyres, Jetta Mexico, South America 6024
6 4 Recommended summer tyres, Jetta Indonesia, Japan, Scandinavia, South Africa, South Korea 6025
6 5 Recommended summer tyres, Jetta Taiwan 6025
6 6 Recommended summer tyres, Jetta India 6025
6 7 Recommended summer tyres, Jetta North America 6025
6 8 Recommended summer tyres, Jetta Hybrid North America 6026
6 9 Recommended summer tyres, Jetta Russia 6026
7 Recommended all-season tyres 6027
7 1 Recommended all-season tyres, Jetta worldwide except North America 6027
7 2 Recommended all-season tyres, Jetta North America 6027
7 3 Recommended all-season tyres, Jetta Hybrid North America 6027
8 Recommended winter tyres, worldwide except North America 6029
9 Recommended temporary spare tyres and wheels 6030
D4B802AD6C1 4 cylinder injection engine (1 8 l 2 0 l TFSI engine EA 888 generation III) 6031
00 – Technical data 6037
1 Safety information 6037
1 1 Safety regulations for working on fuel supply 6037
1 2 Safety measures when working on vehicles with a start/stop system 6037
1 3 Safety precautions when using testers and measuring instruments during a road test 6038
1 4 Safety precautions when working on the cooling system 6038
1 5 Safety precautions when working on ignition system 6038
2 Identification 6039
2 1 Engine number/engine data 6039
3 Repair instructions 6041
3 1 Rules for cleanliness 6041
3 2 General notes 6041
3 3 General repair notes 6042
3 4 Checking vacuum system 6042
10 – Removing and installing engine 6044
1 Removing and installing engine 6044
1 1 Removing engine 6044
1 2 Separating engine and gearbox 6056
1 3 Securing engine on engine and gearbox support 6058
1 4 Installing engine 6060
2 Assembly mountings 6064
2 1 Assembly overview – assembly mountings 6064
2 2 Removing and installing engine mounting 6067
2 3 Removing and installing gearbox mounting 6069
2 4 Removing and installing pendulum support 6070
2 5 Supporting engine in installation position 6071
2 6 Adjusting assembly mountings 6080
2 7 Checking adjustment of assembly mountings 6082
3 Engine cover panel 6083
3 1 Removing and installing engine cover 6083
13 – Crankshaft group 6084
1 Cylinder block (pulley end) 6084
1 1 Assembly overview – cylinder block (pulley end) 6084
1 2 Removing and installing poly-V belt 6086
1 3 Removing and installing tensioner for poly V-belt 6088
1 4 Removing and installing vibration damper 6088
1 5 Removing and installing bracket for ancillaries 6096
1 6 Removing and installing engine support 6100
2 Cylinder block, gearbox end 6102
2 1 Assembly overview – cylinder block, gearbox end 6102
2 2 Assembly overview – drive plate 6103
2 3 Removing and installing drive plate 6104
2 4 Removing and installing flywheel 6106
2 5 Removing and installing sealing flange on gearbox side 6108
2 5 1 Removing and installing sealing flange on gearbox side, version A sealing lip faces outwards 6109
2 5 2 Removing and installing sealing flange on gearbox side, version B sealing lip faces engine 6112
3 Crankshaft 6117
3 1 Assembly overview – crankshaft 6117
3 2 Crankshaft dimensions 6119
3 3 Allocation of main bearing shells 6119
3 4 Renewing needle bearing in crankshaft 6121
3 5 Measuring axial clearance of crankshaft 6124
3 6 Measuring radial clearance of crankshaft 6125
3 7 Removing and installing sender wheel 6126
4 Balancer shaft 6128
4 1 Assembly overview – balance shaft 6128
4 2 Removing and installing balance shaft 6129
4 2 1 Removing and installing balance shaft, inlet side 6129
4 2 2 Removing and installing balance shaft, exhaust side 6132
4 3 Renewing oil seal for balance shaft (inlet side) 6134
5 Pistons and conrods 6136
5 1 Assembly overview – pistons and conrods 6136
5 2 Removing and installing pistons 6138
5 3 Checking pistons and cylinder bores 6139
5 4 Separating new conrod 6141
5 5 Checking radial clearance of conrods 6142
15 – Cylinder head, valve gear 6144
1 Cylinder head 6144
1 1 Assembly overview – cylinder head 6144
1 2 Assembly overview – camshaft housing 6147
1 3 Removing and installing cylinder head 6149
1 4 Removing and installing vacuum pump 6154
1 5 Checking compression 6156
2 Cover for timing chain 6159
2 1 Assembly overview – cover for timing chain 6159
2 2 Removing and installing timing chain cover 6162
2 2 1 Removing and installing upper timing chain cover 6162
2 2 2 Removing and installing timing chain cover (bottom) 6164
2 3 Renewing seal for vibration damper 6170
3 Chain drive 6174
3 1 Assembly overview – camshaft timing chains 6174
3 2 Assembly overview – drive chain for balance shaft 6178
3 3 Removing and installing camshaft timing chain 6181
3 4 Removing and installing drive chain for balance shaft 6198
3 5 Checking timing chain 6198
3 6 Checking valve timing 6199
4 Valve gear 6203
4 1 Assembly overview – valve gear 6203
4 2 Removing and installing camshaft 6205
4 3 Removing and installing camshaft control valve 1 -N205- 6222
4 4 Removing and installing valve stem seals 6223
4 4 1 Removing and installing valve stem seals (cylinder head installed) 6223
4 4 2 Removing and installing valve stem seals (cylinder head removed) 6229
5 Inlet and exhaust valves 6236
5 1 Checking valve guides 6236
5 2 Checking valves 6237
5 3 Valve dimensions 6237
17 – Lubrication 6238
1 Sump, oil pump 6238
1 1 Assembly overview – sump/oil pump 6238
1 2 Engine oil: 6241
1 3 Removing and installing lower part of sump 6241
1 4 Removing and installing upper part of sump 6244
1 5 Removing and installing oil pump 6249
1 6 Removing and installing oil level and oil temperature sender -G266- 6251
2 Engine oil cooler 6253
2 1 Assembly overview – engine oil cooler 6253
2 2 Removing and installing engine oil cooler 6253
2 3 Removing and installing mechanical switching valve 6255
3 Crankcase ventilation 6256
3 1 Assembly overview – crankcase breather system 6256
3 2 Removing and installing oil separator 6257
4 Oil filter, oil pressure switch 6258
4 1 Assembly overview – oil filter 6258
4 2 Assembly overview – oil pressure switches/oil pressure control 6258
4 3 Removing and installing oil pressure switch -F1- 6259
4 4 Removing and installing oil pressure switch for reduced oil pressure -F378- 6261
4 5 Checking oil pressure and oil pressure switch 6262
4 6 Removing and installing oil pressure regulating valve -N428- 6265
19 – Cooling 6267
1 Cooling system/coolant 6267
1 1 Connection diagram – coolant hoses 6267
1 1 1 Coolant hose schematic diagram, cooling system without auxiliary radiator 6267
1 1 2 Coolant hose schematic diagram, cooling system with auxiliary radiator 6268
1 2 Checking cooling system for leaks 6269
1 3 Draining and adding coolant 6272
2 Coolant pump, regulation of cooling system 6280
2 1 Assembly overview – coolant pump, thermostat 6280
2 2 Assembly overview – electric coolant pump 6282
2 3 Assembly overview – coolant temperature sender 6283
2 4 Removing and installing continued coolant circulation pump -V51- 6284
2 5 Removing and installing coolant pump 6287
2 6 Removing and installing toothed belt for coolant pump 6288
2 7 Removing and installing thermostat housing 6291
2 8 Removing and installing coolant temperature sender -G62- 6294
2 9 Removing and installing radiator outlet coolant temperature sender -G83- 6295
3 Coolant pipes 6297
3 1 Assembly overview – coolant pipes 6297
3 2 Removing and installing coolant pipes 6297
3 3 Removing and installing upper coolant pipes 6299
4 Radiator, radiator fan 6301
4 1 Assembly overview – radiator/radiator fan 6301
4 2 Assembly overview – radiator cowl and radiator fan 6302
4 3 Assembly overview – radiator blind 6303
4 3 1 Assembly overview – radiator blind 6303
4 3 2 Assembly overview – components of radiator blind 6305
4 4 Removing and installing radiator 6306
4 5 Removing and installing radiator cowl 6307
4 6 Removing and installing radiator fan 6308
4 7 Removing and installing auxiliary radiator 6308
4 8 Removing and installing radiator blind 6310
4 9 Removing and installing radiator blind control motor -V544- 6312
21 – Turbocharging/supercharging 6318
1 Turbocharger 6318
1 1 Assembly overview – turbocharger 6318
1 1 1 Assembly overview – turbocharger, Mahle charge pressure positioner -V465- 6318
1 1 2 Assembly overview – turbocharger, Cooper charge pressure positioner -V465- 6321
1 2 Removing and installing turbocharger 6324
2 Charge air system 6334
2 1 Assembly overview – charge air system 6334
2 2 Removing and installing charge air cooler 6336
2 3 Removing and installing charge pressure sender -G31- 6338
2 4 Checking charge air system for leaks 6338
24 – Mixture preparation – injection 6341
1 Injection system 6341
1 1 Overview of fitting locations – injection system 6341
2 Injectors 6345
2 1 Assembly overview – fuel rail with injectors 6345
2 2 Removing and installing fuel rail 6347
2 3 Removing and installing injectors 6348
2 4 Renewing seals on injectors 6350
2 5 Cleaning injectors 6353
3 Air filter 6356
3 1 Assembly overview – air filter housing 6356
3 2 Removing and installing air filter housing 6358
4 Intake manifold 6360
4 1 Assembly overview – intake manifold 6360
4 2 Removing and installing intake manifold 6362
4 3 Removing and installing throttle valve module -GX3- 6368
4 4 Cleaning throttle valve module -GX3- 6369
5 Senders and sensors 6371
5 1 Assembly overview – actuator for structure-borne sound and control unit for structure-borne sound 6371
5 2 Control unit for structure-borne sound -J869- and actuator for structure-borne sound -R214- 6372
5 2 1 Removing and installing control unit for structure-borne sound -J869- 6372
5 2 2 Removing and installing actuator for structure-borne sound -R214- 6372
5 3 Removing and installing fuel pressure sender -G247- 6373
5 4 Checking fuel pressure sender -G247- 6375
5 5 Removing and installing intake manifold sender -GX9- 6378
6 Engine control unit 6379
6 1 Removing and installing engine control unit -J623- 6379
6 1 1 Removing and installing engine control unit -J623- without protective housing 6379
6 1 2 Removing and installing engine (motor) control unit -J623- with protective housing 6380
7 High-pressure pump 6383
7 1 Assembly overview – high-pressure pump 6383
7 2 Removing and installing high-pressure pump 6385
8 Lambda probe 6389
8 1 Assembly overview – Lambda probe 6389
8 2 Removing and installing Lambda probe 1 before catalytic converter -GX10- 6389
8 3 Removing and installing Lambda probe 1 after catalytic converter -GX7- 6391
26 – Exhaust system 6393
1 Exhaust pipes and silencers 6393
1 1 Assembly overview – silencers 6393
1 2 Removing and installing rear silencer 6394
1 3 Aligning exhaust system free of stress 6396
1 4 Checking exhaust system for leaks 6397
1 5 Installation position of clamp 6397
2 Emission control 6400
2 1 Assembly overview – emission control 6400
2 2 Removing and installing catalytic converter 6400
3 Secondary air system 6405
3 1 Assembly overview – secondary air system 6405
3 2 Removing and installing secondary air pump motor -V101- 6407
3 3 Removing and installing secondary air inlet valve -N112- 6407
28 – Ignition system 6409
1 Ignition system 6409
1 1 Assembly overview – ignition system 6409
1 2 Test data, spark plugs 6410
1 3 Removing and installing ignition coils with output stage 6411
1 4 Removing and installing knock sensor 1 -G61- 6412
1 5 Removing and installing Hall sender 6414
1 6 Removing and installing engine speed sender -G28- 6414
D4B803D28E8 4 cylinder injection engine (2 0 l engine) 6416
00 – Technical data 6422
1 Safety instructions 6422
1 1 Safety precautions when working on fuel supply system 6422
1 2 Safety precautions during road tests in which test and measuring equipment is used 6423
1 3 Safety precautions when working on ignition system 6423
1 4 Safety precautions when working on cooling system 6424
2 Identification 6425
2 1 Engine number, engine data 6425
3 Repair instructions 6427
3 1 Rules for cleanliness 6427
3 2 Foreign objects in engine 6427
3 3 Contact corrosion 6427
3 4 Routing and securing lines 6427
3 5 Installing coolers, condensers and radiators 6427
10 – Removing and installing engine 6429
1 Removing and installing engine 6429
1 1 Removing engine 6429
1 2 Securing engine on engine and gearbox support 6435
1 3 Installing engine 6436
2 Assembly mountings 6440
2 1 Assembly overview – assembly mountings 6440
2 2 Removing and installing engine mountings 6441
2 3 Supporting engine in installation position 6445
2 4 Adjusting assembly mountings 6448
2 5 Checking adjustment of assembly mountings 6450
13 – Crankshaft group 6451
1 Cylinder block (pulley end) 6451
1 1 Assembly overview – cylinder block (pulley end) 6451
1 2 Removing and installing poly V-belt 6452
1 3 Renewing crankshaft oil seal – belt pulley end 6454
1 4 Removing and installing sealing flange on pulley end 6457
2 Cylinder block, gearbox end 6460
2 1 Assembly overview – cylinder block, gearbox end 6460
2 2 Removing and installing drive plate 6461
3 Crankshaft 6463
3 1 Assembly overview – crankshaft 6463
3 2 Crankshaft dimensions 6465
4 Pistons and conrods 6466
4 1 Assembly overview – pistons and conrods 6466
4 2 Separating new conrod 6467
4 3 Checking piston and cylinder bore 6468
15 – Cylinder head, valve gear 6471
1 Cylinder head 6471
1 1 Assembly overview – cylinder head 6471
1 2 Removing and installing cylinder head 6473
1 3 Checking compression 6477
2 Toothed belt drive 6480
2 1 Assembly overview – toothed belt 6480
2 2 Removing and installing toothed belt 6482
2 3 Checking tensioning device for toothed belt drive 6486
3 Valve gear 6488
3 1 Assembly overview – valve gear 6488
3 2 Removing and installing camshaft oil seal 6491
3 3 Removing and installing camshaft 6493
3 4 Checking hydraulic compensation elements 6495
3 5 Removing and installing valve stem seals 6496
4 Inlet and exhaust valves 6499
4 1 Reworking valve seats 6499
4 2 Checking valve guides 6500
4 3 Renewing valve guides 6501
17 – Lubrication 6503
1 Sump, oil pump 6503
1 1 Assembly overview – sump and oil pump 6503
1 2 Engine oil 6504
1 3 Removing and installing oil sump 6505
1 4 Removing and installing oil pump 6509
2 Oil filter, oil pressure switch 6511
2 1 Checking oil pressure and oil pressure switch 6511
2 2 Removing and installing oil filter housing 6512
19 – Cooling 6515
1 Cooling system, coolant 6515
1 1 Coolant hose schematic diagram 6515
1 2 Assembly overview – engine preheater 6516
1 3 Checking cooling system for leaks 6516
1 4 Draining and filling coolant 6518
2 Coolant pump, regulation of cooling system 6524
2 1 Assembly overview – coolant pump, thermostat 6524
2 2 Removing and installing coolant pump 6526
2 3 Removing and installing thermostat 6527
3 Radiator and radiator fan 6529
3 1 Assembly overview – radiator and radiator fan 6529
3 2 Removing and installing radiator 6531
3 3 Removing and installing radiator fan -V7- and radiator fan 2 -V177- 6532
24 – Mixture preparation – injection 6534
1 Injection system 6534
1 1 Overview of fitting locations – injection system 6534
1 2 Filling and bleeding fuel system 6535
2 Injectors 6538
2 1 Removing and installing fuel rail 6538
2 2 Removing and installing injectors 6539
2 3 Checking injectors 6540
3 Air filter 6544
3 1 Assembly overview – air filter housing 6544
4 Intake manifold 6546
4 1 Assembly overview – intake manifold 6546
4 2 Assembly overview – lower part of intake manifold with fuel rail 6547
4 3 Removing and installing intake manifold with fuel rail 6548
5 Senders and sensors 6550
5 1 Checking fuel pressure sender 6550
6 Engine control unit 6553
6 1 Removing and installing engine control unit 6553
26 – Exhaust system 6556
1 Exhaust pipes, silencers 6556
1 1 Assembly overview – silencers 6556
1 2 Separating exhaust pipes, silencers 6557
1 3 Installation position of clamp 6559
1 4 Aligning exhaust system free of stress 6560
2 Emission control 6562
2 1 Assembly overview – emission control 6562
28 – Ignition system 6565
1 Ignition system 6565
1 1 Assembly overview – ignition system 6565
1 2 Test data, spark plugs 6566
D4B804EDF88 5 cylinder injection engine (2 5 l engine 4 valve) 6567
00 – Technical data 6573
1 Safety instructions 6573
1 1 Safety precautions when working on fuel supply system 6573
1 2 Safety precautions during road tests in which test and measuring equipment is used 6574
1 3 Safety precautions when working on cooling system 6574
1 4 Safety precautions when working on ignition system 6575
2 Identification 6576
2 1 Engine number, engine data 6576
3 General notes 6578
3 1 Numbering of cylinders 6578
4 Repair instructions 6579
4 1 Rules for cleanliness 6579
4 2 Foreign objects in engine 6579
10 – Removing and installing engine 6580
1 Removing and installing engine 6580
1 1 Removing engine 6580
1 2 Separating engine and gearbox 6587
1 2 1 Vehicles with automatic gearbox 6587
1 2 2 Vehicles with manual gearbox 6590
1 3 Securing engine on engine and gearbox support 6592
1 4 Installing engine 6594
2 Assembly mountings 6596
2 1 Assembly overview – assembly mountings 6596
2 2 Removing and installing engine mountings 6596
2 3 Supporting engine in installation position 6602
2 4 Adjusting assembly mountings 6607
2 5 Checking adjustment of assembly mountings (engine and gearbox mountings) 6611
3 Engine cover panel 6612
13 – Crankshaft group 6613
1 Cylinder block (pulley end) 6613
1 1 Assembly overview – poly V-belt drive 6613
1 2 Removing and installing poly V-belt 6616
1 3 Removing and installing tensioner for poly V-belt 6618
1 3 1 Removing and installing tensioner for air conditioner compressor poly V-belt 6618
1 3 2 Removing and installing tensioner for poly V-belt for alternator, vane pump and coolant pump 6618
1 4 Removing and installing vibration damper 6618
1 5 Removing and installing ancillary bracket 6620
1 6 Removing and installing engine bracket 6622
1 7 Renewing crankshaft oil seal – belt pulley end 6622
2 Cylinder block, gearbox end 6626
2 1 Assembly overview – cylinder block, gearbox end 6626
2 2 Assembly overview – drive plate 6627
2 3 Assembly overview – flywheel 6628
2 4 Removing and installing drive plate 6628
2 5 Removing and installing flywheel 6629
2 6 Renewing crankshaft oil seal – gearbox end 6630
2 7 Removing and installing sealing flange on gearbox side 6632
3 Crankshaft 6636
3 1 Assembly overview – crankshaft 6636
3 2 Locking crankshaft 6637
3 3 Crankshaft dimensions 6639
3 4 Allocation of main bearing shells 6640
3 5 Measuring axial clearance of crankshaft 6640
3 6 Measuring radial clearance of crankshaft 6641
4 Pistons and conrods 6642
4 1 Assembly overview – pistons and conrods 6642
4 2 Removing and installing pistons 6644
4 3 Checking piston and cylinder bore 6645
4 4 Separating new conrod 6647
15 – Cylinder head, valve gear 6649
1 Cylinder head 6649
1 1 Assembly overview – cylinder head 6649
1 2 Assembly overview – cylinder head cover 6651
1 3 Removing and installing cylinder head 6653
1 4 Removing and installing cylinder head cover 6658
1 5 Removing and installing vacuum pump 6659
1 6 Checking compression 6661
2 Cover for timing chain 6663
2 1 Removing and installing cover for timing chain 6663
2 2 Renewing oil seal for timing chain cover 6666
3 Chain drive 6669
3 1 Assembly overview – camshaft timing chains 6669
3 2 Assembly overview – timing chain 6670
3 3 Exploded view – drive chain for valve gear 6671
3 4 Checking valve timing 6672
3 5 Adjusting valve timing 6673
4 Valve gear 6680
4 1 Assembly overview – valve gear 6680
4 2 Removing and installing camshaft 6682
4 3 Removing and installing valve stem seals 6686
5 Inlet and exhaust valves 6691
5 1 Checking valve guides 6691
5 2 Valve dimensions 6691
17 – Lubrication 6692
1 Sump, oil pump 6692
1 1 Engine oil 6692
1 2 Assembly overview – sump and oil pump 6692
1 3 Removing and installing bottom section of sump 6694
1 4 Removing and installing top section of sump 6696
1 5 Removing and installing oil pump 6699
2 Oil filter, oil pressure switch 6704
2 1 Assembly overview – oil filter housing, oil pressure switch 6704
2 2 Draining oil filter housing 6706
2 3 Checking oil pressure and oil pressure switch 6707
2 3 1 Checking oil pressure, vehicles with engine codes CBTA, CBUA 6707
2 3 2 Checking oil pressure, vehicles with engine code CCCA 6708
2 3 3 Checking oil pressure switch, vehicles with engine codes CBTA, CBUA 6710
2 3 4 Checking oil pressure switch, vehicles with engine code CCCA 6713
2 4 Removing and installing oil filter housing 6713
19 – Cooling 6714
1 Cooling system, coolant 6714
1 1 Coolant hose schematic diagram 6714
1 2 Assembly overview – engine preheater 6716
1 3 Checking cooling system for leaks 6716
1 4 Draining and filling coolant 6718
2 Coolant pump, regulation of cooling system 6726
2 1 Assembly overview – coolant pump, thermostat 6726
2 2 Removing and installing coolant pump 6730
2 3 Removing and installing thermostat 6736
3 Radiator and radiator fan 6739
3 1 Assembly overview – radiator and radiator fan 6739
3 2 Removing and installing radiator 6741
3 3 Removing and installing radiator cowl 6743
3 4 Removing and installing radiator fan 6744
3 4 1 Removing and installing radiator fan -V7- 6744
3 4 2 Removing and installing radiator fan -V177- 6744
24 – Mixture preparation – injection 6745
1 Injection system 6745
1 1 Overview of fitting locations – injection system 6745
1 2 Filling and bleeding fuel system 6746
2 Injectors 6750
2 1 Assembly overview – fuel rail with injectors 6750
2 2 Removing and installing injectors 6750
2 3 Checking injectors 6752
3 Air filter 6757
3 1 Assembly overview – air filter housing 6757
3 2 Removing and installing air filter housing 6758
4 Intake manifold 6759
4 1 Assembly overview – intake manifold 6759
4 2 Removing and installing throttle valve module -J338- 6760
4 3 Removing and installing intake manifold 6761
5 Engine control unit 6765
5 1 Removing and installing engine control unit -J623- 6765
5 2 Removing and installing engine control unit -J623- with protective housing 6766
26 – Exhaust system 6769
1 Exhaust pipes, silencers 6769
1 1 Assembly overview – silencers 6769
1 2 Removing and installing silencer 6770
1 3 Aligning exhaust system free of tension 6772
2 Emission control 6774
2 1 Assembly overview – emission control 6774
2 1 1 Assembly overview – emission control, engine codes CBTA, CCCA 6774
2 1 2 Assembly overview – emission control, engine code CBUA 6776
2 2 Removing and installing catalytic converter 6778
3 Secondary air system 6781
3 1 Assembly overview – secondary air system 6781
3 2 Removing and installing secondary air pump motor -V101- 6782
3 3 Checking secondary air inlet valve 6783
4 Exhaust manifold 6785
4 1 Assembly overview – exhaust manifold 6785
28 – Ignition system 6786
1 Ignition system 6786
1 1 Assembly overview – ignition system 6786
1 2 Removing and installing ignition coils with output stage 6788
1 3 Removing and installing knock sensor I -G61- 6789
1 4 Test data, spark plugs 6790
D4B804F73F5 4 cyl injection engine (2 0 l engine EA 888 chain drive) 6791
00 – Technical data 6797
1 Safety information 6797
1 1 Safety regulations for working on fuel supply 6797
1 2 Safety precautions when using testers and measuring instruments during a road test 6797
1 3 Safety precautions when working on the cooling system 6798
1 4 Safety precautions when working on ignition system 6798
2 Identification 6799
2 1 Engine number/engine data 6799
3 Repair notes 6801
3 1 Rules for cleanliness 6801
3 2 Foreign objects in engine 6801
3 3 Contact corrosion 6801
3 4 Routing and attachment of lines 6801
3 5 Fitting radiator and condensers 6802
10 – Removing and installing engine 6803
1 Removing and installing engine 6803
1 1 Removing engine 6803
1 2 Separating engine and gearbox 6812
1 3 Securing engine on engine and gearbox support 6814
1 4 Installing engine 6815
2 Assembly mountings 6818
2 1 Assembly overview – assembly mountings 6818
2 2 Removing and installing engine mounting 6820
2 3 Supporting engine in installation position 6824
2 4 Adjusting assembly mountings 6828
2 5 Checking adjustment of assembly mountings (engine and gearbox mountings) 6830
3 Engine cover panel 6831
3 1 Removing and installing engine cover 6831
13 – Crankshaft group 6832
1 Cylinder block (pulley end) 6832
1 1 Assembly overview – poly V-belt drive 6832
1 2 Removing and installing poly-V belt 6834
1 3 Removing and installing tensioner for poly V-belt 6835
1 4 Removing and installing vibration damper 6839
1 5 Renewing seal for vibration damper 6840
1 6 Removing and installing bracket for ancillaries 6842
2 Cylinder block, gearbox end 6845
2 1 Assembly overview – cylinder block, gearbox end 6845
2 2 Removing and installing flywheel 6846
2 3 Removing and installing sealing flange on gearbox side 6848
2 3 1 Removing and installing sealing flange on gearbox side, version A (sealing lip faces air side) 6848
2 3 2 Removing and installing sealing flange on gearbox side, version B (sealing lip faces oil side) 6851
3 Crankshaft 6854
3 1 Assembly overview – crankshaft 6854
3 2 Crankshaft dimensions 6855
3 3 Allocation of main bearing shells 6856
3 4 Renewing needle bearing in crankshaft 6857
3 5 Measuring axial clearance of crankshaft 6859
3 6 Measuring radial clearance of crankshaft 6860
3 7 Removing and installing sender wheel 6861
4 Pistons and conrods 6862
4 1 Assembly overview – pistons and conrods 6862
4 2 Checking pistons and cylinder bores 6863
4 3 Separating new conrod 6866
15 – Cylinder head, valve gear 6867
1 Cylinder head 6867
1 1 Assembly overview – cylinder head 6867
1 2 Removing and installing cylinder head 6871
1 3 Removing and installing vacuum pump 6887
1 4 Checking compression 6888
2 Cover for timing chain 6891
2 1 Assembly overview – cover for timing chain 6891
2 2 Removing and installing upper timing chain cover 6892
2 3 Removing and installing timing chain cover (bottom) 6894
3 Chain drive 6902
3 1 Assembly overview – camshaft timing chains 6902
3 2 Assembly overview – drive chain for balance shaft 6903
3 3 Removing and installing camshaft timing chain 6905
3 4 Removing and installing drive chain for balance shaft 6917
3 5 Removing and installing balance shaft for inlet camshaft 6920
3 6 Removing and installing balance shaft for exhaust camshaft 6923
3 7 Checking valve timing 6926
4 Valve gear 6928
4 1 Assembly overview – valve gear 6928
4 2 Measuring axial play of camshaft 6929
4 3 Removing and installing camshaft 6930
4 4 Removing and installing camshaft control valve 1 -N205- 6938
4 5 Removing and installing valve stem seals 6939
5 Inlet and exhaust valves 6944
5 1 Checking valve guides 6944
5 2 Valve dimensions 6945
17 – Lubrication 6946
1 Sump, oil pump 6946
1 1 Assembly overview – sump/oil pump 6946
1 2 Engine oil: 6949
1 3 Removing and installing lower part of sump 6950
1 4 Removing and installing upper part of sump 6952
1 5 Removing and installing oil pump 6957
2 Crankcase ventilation 6960
2 1 Removing and installing oil separator 6960
3 Oil filter, oil pressure switch 6961
3 1 Assembly overview – oil filter housing, oil pressure switch -F1- 6961
3 2 Assembly overview – oil filter housing, oil pressure switch -F22- and oil pressure switch for reduced oil pressure -F378- 6962
3 3 Removing and installing engine oil cooler 6963
3 4 Checking oil pressure and oil pressure switch -F1- 6964
3 5 Checking oil pressure and oil pressure switch for reduced oil pressure -F378- 6967
3 6 Removing and installing oil pressure switch -F22- 6971
3 7 Removing and installing oil pressure switch for reduced oil pressure -F378- 6972
3 8 Removing and installing oil pressure regulating valve -N428- 6973
19 – Cooling 6975
1 Cooling system/coolant 6975
1 1 Connection diagram – coolant hoses 6975
1 1 1 Coolant hose schematic diagram, vehicles with manual gearbox 6975
1 1 2 Coolant hose schematic diagram, vehicles with dual clutch gearbox 6976
1 2 Checking cooling system for leaks 6977
1 3 Draining and adding coolant 6979
2 Coolant pump, regulation of cooling system 6985
2 1 Assembly overview – coolant pump, thermostat 6985
2 2 Assembly overview – electric coolant pump 6987
2 3 Removing and installing electric coolant pump 6987
2 4 Removing and installing coolant pump 6988
2 5 Removing and installing thermostat 6989
2 6 Removing and installing toothed belt for coolant pump 6992
2 7 Renewing seal for coolant pump drive 6995
2 8 Removing and installing coolant temperature sender -G62- 6996
3 Coolant pipes 7000
3 1 Assembly overview – coolant pipes 7000
3 2 Removing and installing front coolant pipes 7001
3 3 Removing and installing small coolant pipe 7004
4 Radiator, radiator fan 7006
4 1 Assembly overview – radiator/radiator fan 7006
4 2 Removing and installing radiator 7007
4 3 Removing and installing radiator cowl with radiator fan 7008
4 4 Removing and installing radiator fan -V7- and radiator fan 2 -V177- 7010
21 – Turbocharging/supercharging 7011
1 Exhaust turbocharger 7011
1 1 Assembly overview – turbocharger 7011
1 1 1 Part I 7012
1 1 2 Part II 7013
1 1 3 Part III 7014
1 1 4 Part IV 7016
1 2 Removing and installing turbocharger 7017
1 3 Checking vacuum unit for turbocharger 7023
1 4 Renewing vacuum unit for turbocharger 7025
2 Charge air system 7027
2 1 Schematic overview – charge air system 7027
2 2 Assembly overview – charge air system 7028
2 3 Removing and installing charge air cooler 7029
2 4 Checking charge air system for leaks 7031
24 – Mixture preparation – injection 7035
1 Injection system 7035
1 1 Overview of fitting locations – injection system 7035
1 2 Releasing high pressure in fuel system 7041
2 Injectors 7042
2 1 Removing and installing injectors 7042
2 2 Renewing seals on injectors 7045
2 3 Cleaning injectors 7047
3 Air filter 7049
3 1 Assembly overview – air filter housing 7049
3 2 Removing and installing air filter housing 7050
3 3 Removing and installing air filter element 7052
4 Intake manifold 7055
4 1 Assembly overview – intake manifold 7055
4 2 Removing and installing intake manifold with fuel rail 7057
4 3 Removing and installing throttle valve module -J338- 7064
4 4 Cleaning throttle valve module -J338- 7066
4 5 Checking intake manifold change-over 7066
5 Senders and sensors 7069
5 1 Removing and installing fuel pressure sender -G247- 7069
5 2 Checking fuel pressure sender -G247- 7071
5 3 Removing and installing air mass meter 7073
6 Engine (motor) control unit 7075
6 1 Removing and installing engine (motor) control unit -J623- 7075
7 High-pressure pump 7077
7 1 Assembly overview – high-pressure pump 7077
7 2 Assembly overview – fuel rail with injectors 7078
7 3 Removing and installing high-pressure pump 7080
26 – Exhaust system 7084
1 Exhaust pipes and silencers 7084
1 1 Assembly overview – silencers 7084
1 2 Removing and installing front exhaust pipe 7086
1 3 Separating exhaust pipes from silencers 7088
1 4 Aligning exhaust system free of stress 7090
1 5 Check exhaust system for leaks 7092
2 Secondary air system 7093
2 1 Assembly overview – secondary air system 7093
2 2 Removing and installing secondary air pump motor -V101- 7093
2 3 Removing and installing secondary air inlet valve -N112- 7094
28 – Ignition system 7096
1 Ignition system 7096
1 1 Assembly overview – ignition system 7096
1 2 Test data, spark plugs 7097
1 3 Removing and installing ignition coils with output stage 7098
1 4 Removing and installing knock sensor 1 -G61- 7099
1 5 Removing and installing engine speed sender -G28- 7100
D4B805CB339 Manual for Troubleshooting and Diagnosing Noises 7102
00 – Technical data 7108
1 Introduction 7108
2 Acoustic considerations during vehicle development 7109
2 1 Vibration insulation film 7109
2 2 Insulation 7110
3 General procedure for identifying noises 7112
3 1 General procedure 7112
3 2 Identifying a noise 7112
3 2 1 Localising origin of noise 7112
3 2 2 Identifying the type of noise 7113
3 2 3 Identifying the point in time when the noise occurs 7113
3 2 4 Identifying the noise by definition or designation 7113
3 3 Aid for localising noise by means of audio recordings (frequencies) 7113
3 3 1 Preparing an audio CD with downloaded files 7114
3 3 2 List of audio tracks 7114
3 3 3 Conditions for testing 7114
3 3 4 Conditions for performing the audio test 7115
3 4 Checklist 7115
4 Volkswagen equipment for localising noises 7119
4 1 Ultrasonic tester -VAG 1842- 7119
4 1 1 Design of the ultrasonic tester -VAG 1842- 7119
4 1 2 Example of procedure for identifying noises using ultrasound 7119
4 2 Borescope -VAS 6748A- 7123
4 2 1 Design of the borescope -VAS 6748A- 7123
4 2 2 Procedure for identifying noises using the borescope 7124
5 Attachments 7125
5 1 Checklist 7125
5 2 Designations for noises 7127
D4B805EFA93 Fuel supply system Diesel engines 7128
00 – Technical data 7132
1 Safety instructions 7132
1 1 Safety precautions when working on fuel supply system 7132
1 2 Safety precautions during road tests in which test and measuring equipment is used 7132
1 3 Safety precautions when working on vehicles with a start/stop system 7133
2 Identification 7134
2 1 Engine number, engine data 7134
3 General notes 7135
3 1 Cleanliness specifications for working on the auxiliary/supplementary heater and fuel system 7135
4 Repair instructions 7136
4 1 Routing and securing lines 7136
4 2 General repair notes 7136
20 – Fuel supply system 7137
1 Procedure when filling with incorrect fuel 7137
2 Fuel tank 7144
2 1 Assembly overview – fuel tank 7144
2 2 Removing and installing fuel tank 7145
2 3 Emptying fuel tank 7150
2 3 1 Emptying fuel tank when fuel pump is intact 7150
2 3 2 Emptying fuel tank if it is more than 3/4 full 7152
2 3 3 Emptying fuel tank when less than 3/4 full, vehicles with front-wheel drive 7153
3 Fuel delivery unit, fuel gauge sender 7157
3 1 Assembly overview – fuel delivery unit and fuel gauge sender 7157
3 2 Removing and installing fuel delivery unit, fuel gauge sender 7158
3 3 Removing and installing fuel gauge sender -G- 7162
4 Wiring 7164
4 1 Removing and installing fuel lines 7164
5 Plug-in connectors 7169
5 1 Separating plug-in connectors 7169
6 Fuel filter 7173
6 1 Assembly overview – fuel filter 7173
6 1 1 Assembly overview – fuel filter, without water separator sender -G63- 7173
6 1 2 Assembly overview – fuel filter, vehicles with water separator sender -G63- 7175
6 2 Removing and installing fuel filter 7177
6 3 Fuel hoses in the engine compartment 7180
6 4 Drain water from fuel filter 7181
7 Accelerator mechanism 7182
7 1 Assembly overview – accelerator module 7182
7 2 Removing and installing accelerator module with accelerator position sender -G79-/-G185- 7182
8 Fuel pump 7185
8 1 Checking fuel system pressurisation pump -G6- 7185
8 1 1 Checking fuel pressure 7185
8 1 2 Checking fuel delivery rate 7190
9 Senders and sensors 7198
9 1 Removing and installing water separator sender -G63- 7198
D4B807DC77D Chemicals Manual 7200
00 – Technical data 7206
1 — Change history — 7206
2 Introduction 7208
3 List of Suppliers 7209
3 1 3M do Brasil 7209
3 2 Brascola Ltda 7209
3 3 Castrol Brasil Ltda 7209
3 4 Cia Brasileira de Petróleo Ipiranga 7209
3 5 Chemours 7209
3 6 Chevron Brasil S/A 7209
3 7 Cremer S A Prod Têxteis e Cirúrgicos 7209
3 8 Dow Corning do Brasil Ltda 7209
3 9 Elf Lubrificantes do Brasil 7209
3 10 ExxonMobil 7209
3 11 Henkel do Brasil Ltda 7209
3 12 Klüber Lubrification Lubrificantes Especiais Ltda 7209
3 13 Loctite Brasil Ltda 7209
3 14 Lumobrás Imp Com Ind Ltda 7209
3 15 Motul Synthetic Lubricants 7209
3 16 Ocean Indústria Química 7209
3 17 Pentosin do Brasil Ltda 7210
3 18 Petrobras Distr S/A 7210
3 19 Shell Brasil S/A 7210
3 20 Sika S/A 7210
3 21 Solplás – Ind de Plásticos Ltda 7210
3 22 Solvay Química 7210
3 23 Three Bond do Brasil Ind e Com Ltda 7210
3 24 Total Lubrificantes Brasil Ltda 7210
3 25 Tutela Lubrificantes S/A 7210
3 26 Valvoline Lubrificantes Internacionais Ltda 7210
4 Work Instructions for Handling Chemicals 7211
4 1 Handling of Solvents 7211
4 2 Work instruction – Flammable material handling 7213
4 3 Handling used engine oil 7214
4 4 General guidelines on the storage of chemicals 7215
5 List of authorized products 7216
5 1 Polyurethane-based sealing adhesive 7216
5 2 High-resistance locking adhesive 7216
5 3 Low viscosity lock adhesive 7216
5 4 Sealing adhesive 7216
5 5 Self-adhesive PVC tape 7216
5 6 Double-sided adhesive tape 7216
5 7 Refrigerant gas – R134a 7217
5 8 Underbody coating 7217
5 9 Lubricating engine oil as per VW 502 00 and VW 505 00 standards 7217
5 10 Lubricating engine oil as per VW 507 00 standard 7217
5 11 Lubricating engine oil as per VW 508 88 and VW 509 99 standards 7218
5 12 Lubricating oil for manual gearbox and steering rack – SAE 90, MIL-L-2105B, API – GL5 7218
5 13 Lubricating oil for manual gearbox – SAE 80, MIL-L-2105, API – GL4 7218
5 14 Tire assembly paste 7218
5 15 Biodegradable degreasing product 7218
5 16 Grease remover spray 7219
6 List of fractionated products 7220
6 1 -000 096 319 D- Polishing material (chromium and aluminium) 7220
6 2 -032 198 561- Additional seal 7220
6 3 -AMV 188 001 02- Adhesive silicone 7221
6 4 -AMV 188 200 03- Sealing paste 7221
6 5 -AMV 189 300- Activating agent 7222
6 6 -AMV 189 400- Sealing compound 7222
6 7 Liquid sealant -D 000 600 A2- 7222
6 8 -D 001 210 M2- Universal adhesive 7223
6 9 -D 002 000 A2-Adhesive remover 7223
6 10 -D 004 660 M2- Adhesive set 7223
6 11 -D 007 000 A2- Spray silicone 7224
6 12 -D 009 200 02- Glass primer 7224
6 13 -D 009 401 04- Cleaning solution 7225
6 14 -D 009 500 25- Applicator 7225
6 15 Liquid sealant -D 154 000 A1- 7226
6 16 Liquid sealant -D 154 100 A1- 7226
6 17 -D 154 102 A1- Sealing compound 7226
6 18 -D 154 103 A1- Adhesive silicone 7227
6 19 -D 169 300 M1- Window adhesive 7227
6 20 -D 169 300 M2- Window adhesive 7227
6 21 -D 172 090 A2- Adhesive 7228
6 22 -D 174 003 M2- Silicone sealant 7228
6 23 -D 176 404 A3- Adhesive silicone 7229
6 24 -D 176 204 R2- Adhesive silicone 7229
6 25 -D 176 404 M2- Adhesive silicone 7229
6 26 -D 176 501 A1- Adhesive silicone 7229
6 27 -D 180 KU1 A1- 2-component adhesive for plastic 7230
6 28 -D 180 KU2 A1- 2-component adhesive for plastic 7230
6 29 -D 181 220 A1- Activating agent 7231
6 30 -D 181 655 A1- Activating agent 7231
6 31 -D 181 802 M1- Glass primer 7231
6 32 Liquid sealant -D 185 400 A2- 7232
6 33 Liquid sealant -D 185 400 A3- 7232
6 34 Liquid sealant -D 185 410 A2- 7232
6 35 -D 185 520 A2- Sealing compound 7232
6 36 -D 190 MKD A3- Assembly adhesive 7233
6 37 Liquid sealant -D 192 100 A2- 7233
6 38 -D 195 850 A1- Cleaning solution 7233
6 39 -D 316 D38 A2- Protective wax 7234
6 40 -D 322 000 A2- Wachs-spray 7234
6 41 -D 322 100 M2- Wachs-spray 7234
6 42 -D 330 KD2 A1- Cavity spray 7235
6 43 -D 366 PR1 A1- Plastic primer 7235
6 44 -D 454 300 A2- Sealing compound 7235
6 45 -D 469 101 A3- Gluing and sealing compound 7236
6 46 -D 822 150 A1- Plastic surfacer 7236
6 47 -G 000 100- Coupling teeth lubricant compound 7236
6 48 -G 000 115 A2- Spray lubricant 7237
6 49 -G 000 150- Consistent lubricating paste 7237
6 50 -G 000 405 A2- Silicone paste 7237
6 51 -G 000 450 02- Lubrication paste 7238
6 52 -G 000 650- Consistent lubricating paste 7239
6 53 -G 052 109 A2- Assembly paste 7239
6 54 -G 052 112 A3- High temperature paste 7239
6 55 -G 052 128 A1- Thrust ring sealing grease 7240
6 56 -G 052 133 A2- Lubricating paste for high temperatures 7240
6 57 -G 052 135 A1- Lubricating oil 7240
6 58 -G 052 142 A2- Polyurethane lubricating compound 7241
6 59 -G 052 150 A2- Lithium lubricating paste 7241
6 60 -G 052 168 A1- Steering box lubricant 7242
6 61 -G 052 172 A1- Special lubricant 7242
6 62 -G 052 172 M2- Special lubricant 7242
6 63 -G 052 181 A4- Lubricating paste for constant velocity joints 7243
6 64 -G 052 528 A2- Lubricating paste for constant velocity joints 7243
6 65 -G 052 565 A1- Silicone paste 7243
6 66 -G 052 723 A2- Moly paste 7244
6 67 -G 052 735 A2- Multi-purpose grease 7244
6 68 -G 052 738 A2- Lubricating paste for constant velocity joints 7244
6 69 -G 052 738 A3- Thrust ring sealing grease 7245
6 70 -G 052 745 A3- Lubricating paste for low temperature 7245
6 71 -G 052 751 A1- Molybdenum pasta 7245
6 72 -G 052 778 A2- Spray lubricant 7246
6 73 -G 052 817 A1- Contact grease 7246
6 74 -G 055 128 A1- Thrust ring sealing grease 7246
6 75 -G 060 567 A2- Special lubricant 7247
6 76 -G 060 735 A2- Multi-purpose grease 7247
6 77 -G 060 751 A2- Consistent lubricating paste 7247
6 78 -G 065 567 A2- Cleaning solution 7248
6 79 -G 070 528 R2- Lubricating paste for constant velocity joints 7248
6 80 -G 294 421 A1- Lubricating oil for assembly 7248
D4B807E3B5B Body Repairs General Body Repairs 7249
1 Safety instructions 7253
1 1 Part removal 7253
1 2 Battery and welding operation 7253
1 3 Electronic control unit 7253
1 3 1 Processing of the electronic control unit after repair dueto a traffic accident 7253
1 4 Paint, glass, soft pad and trim 7254
1 5 Fuel tank or fuel delivery pipeline 7254
1 6 Air conditioner 7254
1 6 1 Remedial measures: 7254
1 7 Airbag System 7255
1 8 Check the seat belts 7255
1 8 1 Belt body 7256
1 8 2 Automatic retractor (locking function) 7256
1 8 3 Visual inspection of the seat belt buckle 7257
1 8 4 Seat belt buckle function 7257
1 8 5 Seat belt guide member and tongue 7258
1 8 6 Fixing piece and fixing point 7258
1 9 Safety specifications for the seat belt tensioner 7258
1 10 Body repair on a vehicle equipped with the seat belt tensioners 7259
1 10 1 The following vehicles have been equipped with: 7259
1 11 Perform cutting off, correcting and/or leveling on a vehicleequipped with airbags 7260
1 12 Remove the front seats with a side airbag 7260
2 Basic instruction 7261
2 1 Diagnosis of the accident vehicle 7261
2 2 Condition of the body and/or the parts for delivery to thepainting workshop 7261
2 3 Correction 7261
2 4 Cutting 7261
2 5 Body-cut part and part section 7261
2 6 Original connection 7262
2 7 Galvanized body parts 7262
2 8 Remove the rest part 7262
2 9 New parts 7262
2 10 Parts 7262
2 11 Molded foam plastic pads 7263
3 Symbolic interpretation 7264
3 1 Symbolic interpretation for welding 7264
3 2 Symbolic interpretation for the operation method 7264
3 2 1 Grinding 7265
3 2 2 Thinning 7265
3 2 3 Punching 7265
3 2 4 Drilling 7266
3 2 5 Polishing 7266
3 2 6 Cavity corrosion protection 7266
3 2 7 Bonding 7267
3 2 8 Precise sealing 7267
4 Body repair tools 7268
4 1 Flaring tool -V A G 1317- 7268
4 2 Punching pliers -V A G 1329- 7268
4 3 Basic equipment -V A G 1366/3- 7268
4 4 Bottom protection layer spray gun -V A G 1379- 7269
4 5 Electric blower -V A G 1416- 7269
4 6 Door tensioner -V A G 1438- 7269
4 7 Body equipment component -V A G 1439- 7270
4 8 Pneumatic cutting knife -V A G 1523 A- 7270
4 9 Air chisel -V A G 1577- 7270
4 10 Edge closing iron block -V A G 1585- 7271
4 11 Welding fume ventilator -V A G 1586- 7271
4 12 Welding spot releasing device -V A G 1731- 7271
4 13 Pneumatic spray gun -V A G 1761/1- 7272
4 14 Pneumatic punching and thinning pliers -VAS 1996- 7272
4 15 Pneumatic adhesive spray gun -V A G 2005- 7272
4 16 Door hinge correction tool 7273
4 17 Hose kit 5023 for the inert gas protection welding 7273
4 18 Angle grinder -VAS 5174- 7273
4 19 Angle grinder -VAS 5175- 7274
4 20 Wire brush -VAS 5182- 7274
5 Body bonding 7275
5 1 Transporter 1991 → 7275
5 1 1 Separation process: 7275
5 1 2 Bonding process: 7275
5 2 Bonding types 7275
5 2 1 Bonding-strong 7275
5 2 2 Bonding-spot welding 7276
5 3 Repair method for replacing the parts 7276
5 3 1 Spot welding and bonding 7276
5 3 2 Plug welding and bonding (if spot welding is impossible) 7276
5 3 3 Welding fume ventilator 7277
5 3 4 Preparations 7277
5 3 5 Trimming 7277
6 Corrosion protection measures 7278
6 1 Corrosion protection 7278
7 Waste disposal instructions 7279
7 1 Waste disposal 7279
7 2 Air pressure tappet exhaust 7279
7 3 Airbag 7280
7 3 1 Waste disposal 7280
8 Contact corrosion protection 7281
8 1 Connection of aluminum alloy/magnesium alloy with steel 7281
9 Steel plate repair 7282
9 1 High-strength body plate 7282
9 2 Galvanized body parts 7282
9 2 1 Preparations 7282
9 2 2 Part cutting 7283
9 2 3 Connection process 7283
9 3 Welding on the galvanized body steel plate 7283
9 3 1 Inert gas protection plug welding SG of the galvanized steelplate 7283
9 3 2 Resistance pressure spot welding RP of the galvanized steelplate 7284
9 3 3 Welding transformer 7284
9 3 4 Welding clamp 7284
9 4 Tearing test 7284
10 Aluminum repair 7285
10 1 Painting 7285
10 2 Surface treatment 7285
10 3 Leveling 7286
10 4 Temperature control for heating 7286
11 Plastic repair method 7287
11 1 Material 7287
11 2 Repairing the pit 7288
11 3 Repairing the scratch 7289
11 4 Repair the crack 7291
11 5 Repairing the small hole (the diameter is more than 30 mm) 7292
11 6 Plastic repair (glass fibre material) 7293
11 7 Repair process 7294
11 7 1 Repairing the breakage position 7294
11 7 2 Repairing the surface damage 7296
12 Glass repair 7297
12 1 Repairing the windshield 7297
12 1 1 Premises 7297
12 1 2 Required special tools, operating equipment, testing instrumentsand auxiliary tools 7298
12 1 3 Repair description 7299
D4B809DE5A0 High voltage system General information 7303
00 – Technical data 7307
1 Safety information 7307
1 1 Safety measures for working on vehicles with high-voltage system 7307
1 2 Safety precautions when working in the vicinity of high-voltage components 7308
1 3 Safety precautions when using testers and measuring instruments during a road test 7308
1 4 Safety precautions when working on the cooling system 7308
2 Repair instructions 7309
2 1 Contact corrosion 7309
2 2 Routing and attachment of lines 7309
2 3 Rules for cleanliness when working on high-voltage system 7309
93 – Electric drive systems 7311
1 Hazard classification for the high-voltage system 7311
1 1 General information 7311
1 2 Induction training/staff qualifications 7312
2 Identification features of high-voltage vehicles 7314
3 Working on high-voltage vehicles 7320
3 1 Personal protective equipment (PPE) 7320
3 2 Workshop procedure for high-voltage vehicles 7320
3 2 1 Workshop procedure for EIPs 7320
3 2 2 Workshop procedure for HVT 7321
3 2 3 Workshop procedure for HVE 7322
3 2 4 Certified de-energisation 7322
4 Quarantine arrangements 7323
5 Assessing accident-damaged vehicles 7327
5 1 General information 7327
5 2 Photographic documentation 7327
6 High-voltage battery 7332
6 1 Classifying high-voltage battery 7332
6 1 1 Fundamentals of classifying lithium-ion high-voltage batteries 7332
6 1 2 Classification of lithium-ion high-voltage batteries with aid of ODIS 7336
6 2 High-voltage battery handling and storage 7339
6 3 Packaging high-voltage batteries 7340
6 3 1 Packaging high-voltage battery, e-up! 7340
6 3 2 Packaging high-voltage battery, e-Golf 7348
6 4 Packaging critical high-voltage batteries with “Warning” status 7360
6 4 1 Packaging critical high-voltage batteries with “Warning” status, module 7360
6 4 2 Packaging critical high-voltage batteries with “Warning” status, Golf GTE / Passat GTE / Jetta Hybrid 7366
6 4 3 Packaging critical high-voltage batteries with “Warning” status, e-Golf / e-up! 7376
6 5 Supplementary information on opening and bonding high-voltage batteries 7383
D4B8026F80B 7 speed dual clutch gearbox 0CG 7400
00 – Technical data 7404
1 Identification 7404
1 1 Gearbox identification 7404
2 Safety information 7405
2 1 General safety provisions 7405
2 2 Safety precautions when working on high-voltage vehicles 7405
2 3 Safety precautions when using testers and measuring instruments during a road test 7407
2 4 Safety precautions when working on the mechatronic unit 7407
2 5 Notes on tow-starting/towing 7409
3 Repair notes 7410
3 1 General information 7410
3 2 Rules for cleanliness 7411
3 3 General repair instructions 7412
3 3 1 Working with tester 7414
4 Technical data 7417
4 1 Capacities 7417
4 2 Allocation gearbox – engine 7418
4 3 Calculation of gear ratios 7419
5 Overview – power transmission 7420
5 1 Overview – power transmission – front-wheel drive 7420
30 – Clutch 7421
1 Clutch operation 7421
1 1 Assembly overview – clutch engagement 7421
1 2 Removing and installing clutch engagement 7422
1 3 Adjusting clutch engagement 7425
2 Clutch 7438
2 1 Assembly overview – dual clutch 7438
2 2 Removing dual clutch 7440
2 3 Installing dual clutch 7444
2 4 Renewing input shaft seal 7448
2 5 Renewing oil seal for inner input shaft 7450
34 – Controls, housing 7453
1 Mechatronic unit 7453
1 1 Overview – mechatronic unit 7453
1 2 Removing and installing mechatronic unit 7455
1 3 Setting mechatronic unit to removal position by hand 7475
1 4 Renewing bellows with clutch actuator 7477
2 Selector mechanism 7482
2 1 Assembly overview – selector mechanism 7482
2 2 Emergency release from position P 7484
2 3 Removing and installing selector lever handle 7485
2 4 Moving push-button in the handle to installation position 7486
2 5 Removing and installing selector mechanism 7488
2 5 1 Removing and installing selector mechanism with selector housing 7488
2 5 2 Removing and installing selector mechanism without selector housing 7492
2 6 Checking selector mechanism 7496
2 7 Checking and adjusting selector lever cable 7497
2 8 Renewing selector shaft seal 7501
3 Removing and installing gearbox 7502
3 1 Removing gearbox 7502
3 2 Installing gearbox 7507
3 3 Specified torques for gearbox 7510
4 Assembly mountings 7511
4 1 Assembly overview – assembly mountings 7511
4 1 1 Removing and installing gearbox bracket 7512
5 Transporting gearbox 7520
6 Dismantling and assembling gearbox 7523
6 1 Schematic overview – gearbox 7523
6 2 Dismantling and assembling gearbox 7524
6 2 1 Dismantling gearbox 7524
6 2 2 Assembling gearbox 7533
7 Gearbox housing, clutch housing 7546
7 1 Assembly overview – gearbox housing 7546
7 2 Assembly overview – clutch housing 7547
7 3 Repairing gearbox housing 7548
7 4 Repairing clutch housing 7553
8 Securing to engine and gearbox support 7558
9 Gear oil 7560
9 1 Draining and filling gear oil 7560
9 2 Draining and filling hydraulic fluid for mechatronic unit 7565
35 – Gears, shafts 7569
1 Input shaft 7569
1 1 Dismantling and assembling input shaft 7569
1 1 1 Dismantling and assembling outer input shaft 7569
1 1 2 Dismantling and assembling inner input shaft 7572
2 Output shaft 7576
2 1 Assembly overview – output shaft 7576
2 1 1 Assembly overview – output shaft 1 7576
2 1 2 Assembly overview – output shaft 2 7578
2 1 3 Assembly overview – output shaft 3 7579
2 2 Dismantling and assembling output shaft 1 7580
2 2 1 Dismantling output shaft 1 partially 7580
2 2 2 Dismantling output shaft 1 completely 7581
2 2 3 Assembling output shaft 1 7585
2 2 4 Dismantling and assembling locking collars and synchro-hubs of output shaft 1 7592
2 3 Dismantling and assembling output shaft 2 7592
2 3 1 Dismantling output shaft 2 7592
2 3 2 Assembling output shaft 2 7596
2 3 3 Dismantling and assembling locking collars and synchro-hubs of output shaft 2 7602
2 4 Dismantling and assembling output shaft 3 7602
2 4 1 Dismantling output shaft 3 7602
2 4 2 Assembling output shaft 3 7605
2 4 3 Dismantling and assembling locking collar and synchro-hub of output shaft 3 7608
2 5 Adjusting output shaft 7608
2 5 1 Notes on gearbox adjustment 7608
2 5 2 Calculating shims for clutch housing 7609
2 5 3 Calculating shims for gearbox housing 7622
3 Parking lock 7643
3 1 Removing and installing cover for parking lock 7643
3 2 Removing and installing parking lock 7645
39 – Final drive – differential 7647
1 Oil seals 7647
1 1 Overview of fitting locations – seals 7647
1 2 Renewing left seal 7647
1 3 Renewing right oil seal 7651
D4B8026F810 4 cylinder direct injection engine (1 4 l engine 4 V EA 211 turbocharger hybrid) 7655
00 – Technical data 7661
1 Safety information 7661
1 1 Safety measures for working on vehicles with high-voltage system 7661
1 2 Safety regulations for working on fuel supply 7662
1 3 Safety precautions when using testers and measuring instruments during a road test 7662
1 4 Safety precautions when working on the cooling system 7663
1 5 Safety precautions when working on ignition system 7663
2 Identification 7664
2 1 Engine number/engine data 7664
3 Repair notes 7666
3 1 Rules for cleanliness 7666
3 2 Foreign bodies in engine 7666
3 3 Contact corrosion 7666
3 4 Routing and attachment of lines 7667
3 5 Fitting radiators and condensers 7667
3 6 Checking vacuum system 7667
10 – Removing and installing engine 7668
1 Removing and installing engine 7668
1 1 Removing engine 7668
1 2 Separating engine and gearbox 7683
1 3 Separating electric drive motor -V141- and engine 7688
1 4 Securing engine on engine and gearbox support 7698
1 5 Connecting electric drive motor -V141- and engine 7700
1 5 1 Connecting electric drive motor -V141- and engine, new electric drive motor -V141- 7700
1 5 2 Connecting electric drive motor -V141- and engine, reinstallation of previously removed electric drive motor -V141- 7712
1 6 Installing engine 7723
2 Assembly mountings 7729
2 1 Assembly overview – assembly mountings 7729
2 2 Removing and installing engine mounting 7732
2 3 Removing and installing gearbox mounting 7739
2 4 Removing and installing pendulum support 7746
2 5 Adjusting assembly mountings 7747
2 5 1 Adjusting assembly mounting, engine mounting 7747
2 5 2 Adjusting assembly mounting, gearbox mounting 7752
2 6 Checking adjustment of assembly mountings 7759
3 Engine cover panel 7761
3 1 Removing and installing engine cover 7761
13 – Crankshaft group 7762
1 Cylinder block (pulley end) 7762
1 1 Assembly overview – sealing flange, belt pulley end 7762
1 2 Removing and installing vibration damper 7763
1 3 Removing and installing engine bracket 7765
1 4 Renewing crankshaft oil seal for pulley end 7766
1 5 Removing and installing sealing flange on pulley end 7769
2 Cylinder block, gearbox end 7773
2 1 Assembly overview – cylinder block, gearbox end 7773
2 2 Removing and installing sealing flange on gearbox side 7776
3 Crankshaft 7789
3 1 Crankshaft dimensions 7789
3 2 Measuring axial clearance of crankshaft 7789
4 Pistons and conrods 7791
4 1 Assembly overview – pistons and conrods 7791
4 2 Removing and installing pistons 7794
4 3 Checking pistons and cylinder bores 7796
4 4 Checking radial clearance of conrods 7798
4 5 Removing and installing oil spray jets 7798
15 – Cylinder head, valve gear 7800
1 Cylinder head 7800
1 1 Assembly overview – cylinder head 7800
1 2 Assembly overview – camshaft housing 7802
1 3 Removing and installing cylinder head 7804
1 4 Removing and installing camshaft housing 7809
1 5 Checking compression 7815
2 Toothed belt drive 7817
2 1 Assembly overview – toothed belt cover 7817
2 2 Assembly overview – toothed belt 7817
2 3 Removing and installing toothed belt guard 7819
2 3 1 Removing and installing upper toothed belt guard 7819
2 3 2 Removing and installing lower toothed belt guard 7820
2 4 Removing and installing toothed belt 7820
2 5 Checking valve timing 7828
2 6 Adjusting valve timing 7835
2 7 Removing toothed belt from camshaft 7844
3 Valve gear 7850
3 1 Assembly overview – valve gear 7850
3 2 Measuring axial play of camshaft 7851
3 3 Removing and installing camshaft oil seal 7852
3 3 1 Removing and installing camshaft oil seal for inlet camshaft, belt pulley end 7852
3 3 2 Removing and installing exhaust camshaft oil seal, pulley end 7854
3 3 3 Removing and installing exhaust camshaft oil seal, gearbox side, type 1 7856
3 3 4 Removing and installing exhaust camshaft oil seal, gearbox side, type 2 7858
3 4 Removing and installing camshaft adjuster 7861
3 4 1 Removing and installing camshaft adjuster for inlet camshaft 7861
3 4 2 Removing and installing camshaft adjuster for exhaust camshaft 7866
3 5 Removing and installing camshaft control valve 1 -N205- 7872
3 6 Removing and installing exhaust camshaft control valve 1 -N318- 7873
3 7 Removing and installing valve stem oil seals 7874
3 7 1 Removing and installing valve stem seals (cylinder head installed) 7874
3 7 2 Removing and installing valve stem seals (cylinder head removed) 7878
4 Inlet and exhaust valves 7883
4 1 Checking valve guides 7883
4 2 Checking valves 7884
4 3 Valve dimensions 7884
17 – Lubrication 7885
1 Sump, oil pump 7885
1 1 Assembly overview – sump/oil pump 7885
1 2 Engine oil 7889
1 3 Removing and installing lower part of sump 7889
1 4 Removing and installing upper part of sump 7894
1 5 Removing and installing oil pump 7901
1 6 Removing and installing oil level and oil temperature sender -G266- 7903
2 Engine oil cooler 7904
2 1 Assembly overview – engine oil cooler 7904
2 2 Removing and installing engine oil cooler 7904
3 Crankcase breather 7906
3 1 Assembly overview – crankcase breather system 7906
3 2 Removing and installing oil separator 7907
4 Oil filter, oil pressure switch 7910
4 1 Assembly overview – oil filter/oil pressure switch 7910
4 2 Removing and installing oil pressure switch -F22- 7911
4 3 Removing and installing oil pressure switch for reduced oil pressure -F378- 7912
4 4 Checking oil pressure 7913
4 5 Removing and installing valve for oil pressure control -N428- 7915
19 – Cooling 7917
1 Cooling system/coolant 7917
1 1 Connection diagram – coolant hoses 7917
1 2 Checking cooling system for leaks 7918
1 3 Draining and adding coolant 7922
2 Coolant pump, regulation of cooling system 7931
2 1 Assembly overview –coolant pump, thermostat 7931
2 1 1 Assembly overview – coolant pump/thermostat, version 1 7931
2 1 2 Assembly overview – coolant pump/thermostat, version 2 7934
2 2 Assembly overview – electric coolant pump 7936
2 3 Assembly overview – coolant temperature sender 7937
2 4 Removing and installing electric coolant pump 7938
2 4 1 Removing and installing coolant pump for low-temperature circuit -V468- 7938
2 4 2 Removing and installing coolant pump for high temperature circuit -V467- 7941
2 5 Removing and installing coolant pump 7943
2 6 Removing and installing thermostat 7950
2 6 1 Removing and installing thermostat for main coolant circuit (radiator) 7950
2 6 2 Removing and installing thermostat for coolant circuit of cylinder block 7952
2 7 Removing and installing toothed belt pulley for coolant pump 7954
2 7 1 Removing and installing toothed belt pulley for coolant pump, type 1 7954
2 7 2 Removing and installing toothed belt pulley for coolant pump, type 2 7957
2 8 Removing and installing coolant temperature sender -G62- 7958
2 9 Removing and installing radiator outlet coolant temperature sender -G83- 7959
3 Coolant pipes 7961
3 1 Assembly overview – coolant pipes 7961
3 2 Removing and installing coolant pipes 7961
4 Radiator, radiator fan 7964
4 1 Assembly overview – radiator/radiator fan 7964
4 2 Removing and installing radiator 7966
4 3 Removing and installing radiator cowl 7968
4 4 Removing and installing radiator fan 7970
21 – Turbocharging/supercharging 7972
1 Turbocharger 7972
1 1 Assembly overview – turbocharger 7972
1 1 1 Assembly overview – turbocharger, version 1 7972
1 1 2 Assembly overview – turbocharger, version 2 7973
1 1 3 Assembly overview – lines on turbocharger 7974
1 2 Removing and installing turbocharger 7976
1 3 Removing and installing charge pressure positioner -V465- 7983
1 3 1 Removing and installing charge pressure positioner -V465-, version 1 7983
1 3 2 Removing and installing charge pressure positioner -V465-, version 2 7984
1 4 Removing and installing connection for turbocharger 7986
2 Charge air system 7990
2 1 Assembly overview – charge air system 7990
2 2 Removing and installing charge air cooler 7993
2 3 Removing and installing charge pressure sender -GX26- 7997
2 4 Checking charge air system for leaks 7997
2 5 Removing and installing air intake pipe 7999
24 – Mixture preparation – injection 8002
1 Injectors 8002
1 1 Assembly overview – fuel rail with injectors 8002
1 2 Removing and installing fuel rail 8004
1 3 Removing and installing injectors 8004
1 4 Cleaning injectors 8011
2 Air filter 8013
2 1 Assembly overview – air filter housing 8013
2 2 Removing and installing air filter housing 8015
2 3 Removing and installing resonator for intake air 8016
3 Intake manifold 8018
3 1 Assembly overview – intake manifold 8018
3 2 Removing and installing intake manifold 8020
3 3 Removing and installing throttle valve module -GX3- 8024
3 4 Cleaning throttle valve module -GX3- 8025
4 Senders and sensors 8027
4 1 Removing and installing fuel pressure sender -G247- 8027
4 2 Checking fuel pressure sender -G247- 8028
4 2 1 Checking fuel pressure sender -G247-, using pressure sensor tester -VAS 6394- and vehicle diagnostic tester 8028
4 2 2 Checking fuel pressure sender -G247-, using vehicle diagnostic tester 8030
4 3 Removing and installing intake manifold sender -GX9- 8032
5 Engine/motor control unit 8034
5 1 Removing and installing engine/motor control unit -J623- 8034
5 1 1 Removing and installing engine control unit -J623- without protective housing 8034
5 1 2 Removing and installing engine (motor) control unit -J623- with protective housing 8035
6 High-pressure pump 8038
6 1 Assembly overview – high-pressure pump 8038
6 2 Removing and installing high-pressure pump 8039
6 3 Removing and installing high-pressure pipe 8042
7 Lambda probe 8045
7 1 Assembly overview – lambda probe 8045
7 2 Removing and installing lambda probe 8047
7 2 1 Removing and installing Lambda probe 1 after catalytic converter -GX7- 8047
7 2 2 Removing and installing Lambda probe 1 before catalytic converter -GX10- 8048
7 2 3 Removing and installing Lambda probe 2 before catalytic converter -GX11- 8050
26 – Exhaust system 8053
1 Exhaust pipes and silencers 8053
1 1 Assembly overview – silencers 8053
1 2 Removing and installing rear silencer 8054
1 3 Aligning exhaust system free of stress 8056
1 4 Checking exhaust system for leaks 8057
1 5 Installation position of clamp 8057
2 Emission control 8061
2 1 Assembly overview – emission control 8061
2 2 Removing and installing catalytic converter 8063
3 Secondary air system 8069
3 1 Assembly overview – secondary air system 8069
3 2 Removing and installing secondary air pump motor -V101- 8070
3 3 Removing and installing secondary air inlet valve -N112- 8070
28 – Ignition system 8072
1 Ignition system 8072
1 1 Assembly overview – ignition system 8072
1 2 Test data, spark plugs 8074
1 3 Removing and installing ignition coils with output stage 8074
1 4 Removing and installing knock sensor 1 -G61- 8077
1 5 Removing and installing Hall sender 8078
1 5 1 Removing and installing Hall sender -G40- 8078
1 5 2 Removing and installing Hall sender 3 -G300- 8079
1 6 Removing and installing engine speed sender -G28- 8080
D4B8036C767 Communication 8083
00 – Technical data 8087
1 Repair instructions 8087
1 1 General repair instructions 8087
1 2 Notes on repair of CAN bus wiring 8087
91 – Communication 8088
1 Infotainment system 8088
1 1 Removing and installing magnetic field sender for compass 8088
2 Sound system 8089
2 1 Overview – Sound system 8089
2 1 1 Overview – sound system, 4 loudspeakers 8089
2 1 2 Overview – sound system, 6 loudspeakers 8091
2 1 3 Overview – sound system, 8 loudspeakers 8092
2 1 4 Overview – sound system, Volkswagen Sound 8093
2 1 5 Overview – sound system, Branded Sound 8094
2 2 Overview of fitting locations – sound system 8095
2 3 Removing and installing digital sound package control unit/amplifier 8095
2 3 1 Removing and installing amplifier -R12- 8095
2 4 Removing and installing rear treble loudspeakers -R14-/-R16- 8096
2 5 Removing and installing front treble loudspeakers -R20-/-R22- 8097
2 6 Removing and installing rear bass loudspeakers -R15-/-R17- 8098
2 7 Removing and installing front bass loudspeakers -R21-/-R23- 8099
2 8 Removing and installing subwoofer -R211- 8099
2 9 Connector pin assignment 8100
3 Aerial systems 8104
3 1 Overview – aerial systems 8104
3 2 Overview of fitting locations – aerial systems 8104
3 3 Removing and installing frequency modulation (FM) frequency filter R178/R179 8105
3 3 1 Removing and installing frequency modulation (FM) frequency filter in negative wire -R178- 8105
3 3 2 Removing and installing frequency modulation (FM) frequency filter in positive wire -R179- 8106
3 4 Removing and installing aerial amplifier 8106
3 5 Removing and installing roof aerial -RX5- 8107
3 6 Removing and installing aerials for vehicle location system 8108
4 Radio 8110
4 1 Overview – Radio 8110
4 2 Overview of fitting locations – radio 8128
4 3 Assembly overview – radio 8130
4 4 Removing and installing radio 8130
4 5 Connector pin assignment 8132
4 5 1 Connector pin assignment, RCD 210 8132
4 5 2 Connector pin assignment, RCD 030+ 8134
4 5 3 Connector pin assignment, RCD 310 8136
4 5 4 Connector pin assignment, RCD 300+ 8138
4 5 5 Connector pin assignment, Premium 8 8141
4 5 6 Connector pin assignment, RCD 510 8143
4 5 7 Connector pin assignment, RCD 510+ 8146
4 5 8 Connector pin assignment, RCD 320G 8149
5 Telephone system 8152
5 1 Components of telephone system 8152
5 1 1 Overview – telephone system, UTP High with Bluetooth 8152
5 1 2 Overview – telephone system, UTP Premium with Bluetooth and audio streaming 8153
5 1 3 Overview – telephone system, UTP in radio RNS 315 8154
5 1 4 Overview – telephone, UMI 8155
5 2 Overview of fitting locations – telephone system 8157
5 2 1 Overview of fitting locations – telephone system 8157
5 2 2 Overview of fitting locations – telephone system, UMI 8159
5 3 Removing and installing telephone microphone -R38- 8159
5 4 Removing and installing telephone bracket -R126- 8160
5 5 Removing and installing telephone transmitter and receiver unit 8161
5 6 Removing and installing mobile telephone operating electronics control unit -J412-, UMI 8162
5 6 1 Removing and installing mobile telephone operating electronics control unit -J412-, UMI control unit at glove compartment 8162
5 6 2 Removing and installing mobile telephone operating electronics control unit -J412-, UMI control unit in centre console 8163
5 7 Removing and installing operating unit for preparation for mobile phone 8165
5 8 Connector pin assignment 8166
6 Navigation system 8171
6 1 Overview – navigation system 8171
6 2 Overview of fitting locations – navigation system 8179
6 3 Connector pin assignment 8180
6 3 1 Connector pin assignment, RNS 315 8180
6 3 2 Connector pin assignment, RNS 315+ 8181
6 3 3 Connector pin assignment, RNS 510 8184
6 4 Removing and installing navigation system 8187
6 4 1 Removing and installing control unit with display for radio and navigation -J503- 8187
6 5 Removing and installing control unit for vehicle location system 8189
7 Reversing camera system 8190
7 1 Components of reversing camera system 8190
7 2 Overview of fitting locations – reversing camera system 8190
7 3 Removing and installing reversing camera -R189- 8191
8 Multifunction steering wheel 8193
8 1 Layout – multi-function steering wheel 8193
8 2 Overview – multifunction steering wheel 8193
8 3 Removing and installing steering wheel multifunction buttons -E441-/-E440- 8194
8 4 Removing and installing Tiptronic switch in steering wheel -E439-/-E438- 8195
9 Connection for external multimedia devices 8197
9 1 Overview – connection for external multimedia devices 8197
9 1 1 Overview – connection for external audio sources -R199-, AUX-IN 8197
9 1 2 Overview – multimedia system control unit -J650- 8199
9 1 4 Overview – multimedia system control unit -J650-, UMI 8201
9 2 Connectors, connection for external multimedia devices 8203
9 2 2 Connector of connection 2 for external audio sources -R231-, USB socket 8204
9 3 Removing and installing connection for external audio sources -R199- 8207
9 3 1 Removing and installing connection for external audio sources -R199-, centre console storage compartment 8207
9 3 2 Removing and installing connection 2 for external audio sources -R231-, USB socket 8208
9 3 3 Removing and installing multimedia system control unit -J650-, control unit on glove compartment 8209
9 3 4 Removing and installing multimedia system control unit -J650-, control unit in centre console 8210
9 3 5 Removing and installing multimedia system control unit -J650-, UMI control unit at glove compartment 8211
9 3 6 Removing and installing multimedia system control unit -J650-, UMI control unit in centre console 8212
9 3 7 Removing and installing connection for adapter cable specific to end device 8214
10 Mobile online services 8216
10 1 Overview – Mobile Online Services 8216
10 2 Overview of fitting locations – mobile online services 8217
10 3 Connectors of control unit for emergency call module and communication unit -J949- 8217
10 4 Removing and installing control unit for emergency call module and communication unit -J949- 8218
D4B8046B377 5 speed manual gearbox 0A4 8220
00 – Technical data 8224
1 Safety information 8224
1 1 Safety measures when working on vehicles with a start/stop system 8224
1 2 Safety precautions when using testers and measuring instruments during a road test 8224
2 Identification 8225
2 1 Gearbox identification 8225
3 Repair notes 8226
3 1 General repair instructions 8226
4 Technical data 8230
4 1 Capacities 8230
4 2 Allocation gearbox – engine 8230
4 3 Calculation of gear ratios 8232
5 Overview – power transmission 8234
5 1 Overview – power transmission – front-wheel drive 8234
6 Electrical components 8236
6 1 Overview of fitting locations – electrical components 8236
6 1 1 Overview of fitting locations – electrical components, manual gearbox 8236
6 1 2 Overview of fitting locations – electrical components, clutch mechanism 8237
30 – Clutch 8238
1 Clutch operation 8238
1 1 Assembly overview – pedal cluster 8238
1 2 Assembly overview – clutch hydraulics 8241
1 2 1 Assembly overview – clutch hydraulics, left-hand drive 8241
1 2 2 Assembly overview – clutch hydraulics, right-hand drive 8243
1 3 Assembly overview – clutch release mechanism 8245
1 4 Removing and installing clutch pedal 8246
1 5 Removing and installing over-centre spring 8251
1 6 Removing and installing mounting bracket 8256
1 7 Removing and installing clutch master cylinder 8262
1 8 Removing and installing clutch slave cylinder 8264
1 9 Bleeding clutch mechanism 8266
1 10 Checking clutch master cylinder and clutch slave cylinder 8268
1 11 Removing and installing clutch position sender -G476- 8268
1 12 Repairing clutch release mechanism 8271
2 Clutch 8273
2 1 Determining make of clutch 8273
2 2 Assembly overview – clutch 8274
2 2 1 Assembly overview – clutch in conjunction with Sachs dual-mass flywheel 8274
2 2 2 Assembly overview – clutch in conjunction with LuK dual-mass flywheel 8276
2 2 3 Assembly overview – clutch with simple flywheel 8277
2 3 Removing and installing clutch 8278
2 3 1 Removing and installing clutch in conjunction with Sachs dual-mass flywheel 8278
2 3 2 Removing and installing clutch in conjunction with LuK dual-mass flywheel 8280
2 3 3 Removing and installing clutch in connection with simple flywheel 8283
34 – Controls, housing 8288
1 Selector mechanism 8288
1 1 Installation position – selector mechanism 8288
1 2 Assembly overview – gear knob and cover 8290
1 3 Assembly overview – Gear lever and selector housing 8291
1 4 Assembly overview – Selector cables 8293
1 5 Removing and installing gear knob 8295
1 6 Removing and installing selector mechanism 8297
1 7 Adjusting selector mechanism 8302
1 8 Checking selector mechanism 8305
1 9 Removing and installing gear selector cable and gate selector cable 8305
1 10 Renewing oil seal for selector shaft 8307
1 11 Dismantling and assembling selector mechanism 8308
2 Removing and installing gearbox 8315
2 1 Specified torques for gearbox 8315
2 1 1 Specified torques for gearbox, vehicles with 2 0 l/85 kW engine 8315
2 1 2 Specified torques for gearbox, vehicles with 1 4 l and 1 8 l engine 8316
2 1 3 Specified torques for gearbox, vehicles with 2 5 l/125 kW engine 8316
2 1 4 Specified torques for gearbox, vehicles with turbo diesel engine 8317
2 2 Removing gearbox 8317
2 2 1 Removing gearbox, vehicles with 2 0 l, 85 kW engine 8317
2 2 2 Removing gearbox, vehicles with 1 4 l and 1 8 l engine 8328
2 2 3 Removing gearbox, vehicles with 2 5 l, 125 kW engine 8341
2 2 4 Removing gearbox, vehicles with turbo diesel engine 8352
2 3 Installing gearbox 8363
2 3 1 Installing gearbox, vehicles with 2 0 l, 85 kW engine 8363
2 3 2 Installing gearbox, vehicles with 1 4 l and 1 8 l engine 8370
2 3 3 Installing gearbox, vehicles with 2 5 l, 125 kW engine 8378
2 3 4 Installing gearbox, vehicles with turbo diesel engine 8384
3 Assembly mounting 8391
3 1 Assembly overview – assembly mountings 8391
4 Transporting gearbox 8393
5 Dismantling and assembling gearbox 8394
5 1 Schematic overview – gearbox 8394
5 2 Assembly overview – cover for gearbox housing and 5th gear 8396
5 3 Assembly overview – gearbox housing and selector mechanism 8397
5 4 Assembly overview – selector unit 8398
5 5 Assembly overview – input shaft, output shafts, differential, selector rods 8399
5 6 Assembly overview – selector forks 8400
5 7 Repairing selector unit 8401
5 8 Repairing selector forks 8402
5 9 Removing cover for gearbox housing and 5th gear 8406
5 10 Dismantling and assembling gearbox 8412
5 11 Installing cover for gearbox housing and 5th gear 8424
6 Gearbox housing, clutch housing 8429
6 1 Assembly overview – gearbox housing 8429
6 2 Assembly overview – clutch housing 8431
6 3 Repairing gearbox housing 8432
6 3 1 Removing and installing input shaft bearings in gearbox housing 8432
6 3 2 Removing and installing output shaft bearings in gearbox housing 8434
6 3 3 Removing and installing differential bearings in gearbox housing 8437
6 4 Repairing clutch housing 8439
6 4 1 Removing and installing input shaft bearings in clutch housing 8439
6 4 2 Removing and installing output shaft bearings in clutch housing 8440
6 4 3 Removing and installing differential bearings in clutch housing 8442
7 Installing to engine and gearbox support 8445
8 Gear oil 8446
8 1 Checking gear oil level 8446
8 2 Draining and filling gear oil 8446
35 – Gears, shafts 8449
1 Input shaft 8449
1 1 Assembly overview – input shaft 8449
1 2 Dismantling and assembling input shaft 8452
1 3 Adjusting input shaft 8457
2 Output shaft 8462
2 1 Assembly overview – output shaft 8462
2 2 Dismantling and assembling output shaft 8465
2 3 Adjusting output shaft 8473
3 Reverse shaft 8480
3 1 Assembly overview – reverse shaft 8480
3 2 Dismantling and assembling reverse shaft 8483
39 – Final drive – differential 8486
1 Oil seals 8486
1 1 Overview of fitting locations – seals 8486
1 2 Renewing left oil seal 8487
1 3 Renewing right oil seal 8489
1 4 Renewing input shaft seal 8493
2 Differential 8495
2 1 Assembly overview – differential 8495
2 2 Dismantling and assembling differential 8497
2 3 Adjusting differential 8502
3 Adjustment overview 8506
D4B8046B378 5 speed manual gearbox 0AF 8507
00 – Technical data 8511
1 Safety information 8511
1 1 Safety measures when working on vehicles with a start/stop system 8511
1 2 Safety precautions when using testers and measuring instruments during a road test 8511
2 Identification 8512
2 1 Gearbox identification 8512
3 Repair notes 8514
3 1 General repair instructions 8514
4 Technical data 8519
4 1 Allocation gearbox – engine 8519
4 2 Capacities 8519
4 3 Calculation of gear ratios 8519
5 Overview – power transmission 8520
5 1 Overview – power transmission – front-wheel drive 8520
6 Electrical components 8522
6 1 Overview of fitting locations – electrical components 8522
6 1 1 Overview of fitting locations – electrical components, manual gearbox 8522
6 1 2 Overview of fitting locations – electrical components, clutch mechanism 8523
30 – Clutch 8524
1 Clutch mechanism 8524
1 1 Overview of fitting locations – clutch mechanism 8524
1 2 Assembly overview – pedal cluster 8525
1 3 Assembly overview – clutch hydraulics 8527
1 3 1 Assembly overview – clutch hydraulics, left-hand drive 8527
1 3 2 Assembly overview – clutch hydraulics, right-hand drive 8530
1 4 Assembly overview – clutch release mechanism 8532
1 5 Removing and installing over-centre spring 8533
1 6 Removing and installing clutch pedal 8540
1 7 Removing and installing mounting bracket 8547
1 8 Removing and installing clutch master cylinder 8554
1 9 Removing and installing clutch slave cylinder 8557
1 10 Checking clutch master cylinder and clutch slave cylinder 8560
1 11 Removing and installing clutch position sender -G476- 8560
1 12 Bleeding clutch mechanism 8563
1 13 Repairing clutch release mechanism 8565
2 Clutch 8567
2 1 Assembly overview – clutch 8567
2 2 Removing and installing clutch 8567
34 – Controls, housing 8573
1 Selector mechanism 8573
1 1 Installation position – selector mechanism 8573
1 2 Assembly overview – selector mechanism 8574
1 3 Assembly overview – gear knob and cover 8575
1 4 Assembly overview – Gear lever and selector housing 8576
1 5 Assembly overview – selector cables 8578
1 6 Removing and installing gear knob 8582
1 7 Dismantling and assembling selector mechanism 8584
1 8 Removing and installing selector mechanism 8591
1 9 Removing and installing gear selector cable and gate selector cable 8599
1 10 Adjusting selector mechanism 8601
1 11 Checking selector mechanism 8604
1 12 Renewing selector shaft seal 8604
2 Removing and installing gearbox 8606
2 1 Removing gearbox 8606
2 2 Installing gearbox 8617
2 3 Specified torques for gearbox 8624
3 Assembly mountings 8627
3 1 Assembly overview – assembly mountings 8627
3 1 1 Assembly overview – assembly mountings; gearbox support secured to gearbox on »side« 8627
3 1 2 Assembly overview – assembly mountings; gearbox support secured to gearbox on »top« 8628
4 Transporting gearbox 8631
5 Gear oil 8633
5 1 Checking gear oil level 8633
6 Securing to engine and gearbox support 8635
7 Dismantling and assembling gearbox 8637
7 1 Schematic overview – gearbox 8637
7 2 Assembly overview – gearbox 8638
7 3 Assembly overview – cover for gearbox housing and 5th gear 8638
7 4 Assembly overview – clutch housing 8639
7 5 Assembly overview – input shaft, output shafts, differential, selector rods 8640
7 6 Assembly overview – selector unit 8642
7 7 Assembly overview – selector forks 8643
7 8 Repairing selector forks 8644
7 9 Repairing selector unit 8649
7 10 Dismantling and assembling gearbox 8650
8 Gearbox housing, clutch housing 8663
8 1 Assembly overview – gearbox housing and clutch housing 8663
8 2 Repairing gearbox housing 8665
8 3 Repairing clutch housing 8666
35 – Gears, shafts 8669
1 Input shaft 8669
1 1 Assembly overview – input shaft 8669
1 2 Dismantling and assembling input shaft 8671
1 3 Renewing input shaft seal 8683
2 Output shaft 8686
2 1 Assembly overview – output shaft 8686
2 2 Dismantling and assembling output shaft 8688
39 – Final drive – rear differential 8697
1 Seals 8697
1 1 Overview of fitting locations – seals 8697
1 2 Renewing left seal 8697
1 3 Renewing right seal 8700
2 Differential 8703
2 1 Assembly overview – differential 8703
2 2 Dismantling and assembling differential 8705
2 3 Adjusting differential 8714
D4B8046FD14 Body Repairs 8720
00 – Technical data 8726
1 Basic instructions 8726
2 Vehicle identification data 8727
2 1 Vehicle identification number 8727
2 2 Type plate 8728
2 3 Vehicle data sticker 8729
3 Safety information 8730
4 Body work for which voltage system must be de-energised 8731
4 1 The high-voltage system must be de-energised before carrying out the body work described below 8731
5 Moulded foam inserts 8732
6 Galvanized body parts, high- and higher-strength and hot-formed body panels 8734
6 1 Installing 8734
6 2 Overview of vehicle »NAR« 8736
6 3 Overview of vehicle »ROW (Rest of the World)« 8739
7 Body panel gaps/shut lines 8742
7 1 Body, front 8742
7 2 Body, centre 8743
7 3 Body, rear 8744
8 Body dimensions 8745
8 1 Body, front 8745
8 2 Body, centre 8748
8 3 Body, rear 8755
8 4 Floor panel – front 8757
8 5 Floor panel – centre 8759
8 6 Floor panel – rear 8760
9 Contour correct surfaces 8762
10 Tools 8763
11 Measurement and alignment systems, alignment bracket set 8764
11 1 Setup overview of complete body 8764
11 2 Procedure for structural damage on body 8765
12 Measurement and alignment systems, portal gauge 8766
12 1 Setup overview of complete body 8766
50 – Body – front 8768
1 Renewing right bracket 8768
1 1 Tools 8768
1 2 Removing 8768
1 3 Installing 8770
1 3 1 Welding in 8770
2 Renewing left bracket 8772
2 1 Tools 8773
2 2 Removing 8773
2 3 Installing 8775
2 3 1 Preparing new part 8775
2 3 2 Welding in 8776
3 Renewing subframe 8777
3 1 Tools 8777
3 2 Removing 8777
3 3 Installing 8779
3 3 1 Preparing new part 8779
3 3 2 Welding in 8780
4 Renewing bumper bracket 8781
4 1 Tools 8782
4 2 Removing 8782
4 3 Installing 8783
4 3 1 Welding in 8783
5 Renewing upper wheel housing longitudinal member 8785
5 1 Tools 8786
5 2 Removing 8786
5 3 Installing 8789
5 3 1 Preparing new part 8789
5 3 2 Welding in 8790
6 Renewing front wheel housing 8796
6 1 Tools 8797
6 2 Removing 8797
6 3 Installing 8798
6 3 1 Preparing new parts 8798
6 3 2 Welding in 8800
7 Repairing threads for securing subframe 8802
7 1 Contents of thread repair kit 8804
7 2 Repairing threads 8804
7 2 1 Drilling threads 8804
7 2 2 Cutting thread 8805
7 2 3 Inserting thread insert 8806
8 Renewing front longitudinal member 8808
8 1 Tools 8809
8 2 Removing 8809
8 3 Installing 8811
8 3 1 Preparing new part 8811
8 3 2 Welding in 8812
9 Renewing front longitudinal member – part section 8815
9 1 Tools 8816
9 2 Removing 8816
9 3 Installing 8818
9 3 1 Preparing new part 8818
9 3 2 Welding in 8819
9 3 3 Shortening new longitudinal member with cover plate 8823
10 Renewing front right longitudinal member – part section 8827
10 1 Tools 8828
10 2 Removing 8828
10 3 Installing 8830
10 3 1 Preparing new part 8830
10 3 2 Welding in 8831
51 – Body – centre 8835
1 Renewing roof – vehicles with no sliding/tilting sunroof 8835
1 1 Tools 8836
1 2 Removing 8837
1 3 Installing 8840
1 3 1 Preparing new part 8840
1 3 2 Adjusting roof depth 8842
1 3 3 Bonding in 8843
1 3 4 Welding in 8849
2 Renewing roof – vehicles with sliding/tilting sunroof 8851
2 1 Tools 8852
2 2 Removing 8853
2 3 Installing 8857
2 3 1 Preparing new part 8857
2 3 2 Setting the depth dimension 8859
2 3 3 Bonding in 8860
2 3 4 Welding in 8866
3 Renewing roof side member 8869
3 1 Tools 8870
3 2 Removing 8870
3 3 Installing 8872
3 3 1 Preparing new part 8872
3 3 2 Moulded foam inserts 8873
3 3 3 Welding in 8874
4 Renewing front cross member for roof 8877
4 1 Tools 8878
4 2 Removing 8878
4 3 Installing 8879
4 3 1 Welding in 8879
5 Renewing roof reinforcement – vehicles for NAR, with no sliding/tilting sunroof 8881
5 1 Tools 8882
5 2 Removing 8882
5 3 Installing 8883
5 3 1 Welding in 8883
6 Renewing rear roof cross member 8885
6 1 Tools 8886
6 2 Removing 8886
6 3 Installing 8887
6 3 1 Welding in 8887
7 Renewing intermediate plate, hybrid vehicles 8889
7 1 Tools 8890
7 2 Removing 8890
7 3 Installing 8891
7 3 1 Preparing new part 8891
7 3 2 Welding in 8892
8 Renewing A-pillar 8894
8 1 Tools 8895
8 2 Removing 8895
8 3 Installing 8897
8 3 1 Preparing new part 8898
8 3 2 Moulded foam inserts 8899
8 3 3 Welding in 8900
9 Renewing A-pillar reinforcement – part section 8904
9 1 Tools 8905
9 2 Removing 8905
9 3 Installing 8906
9 3 1 Preparing new part 8907
9 3 2 Moulded foam inserts 8907
9 3 3 Welding in 8907
10 Renewing B-pillar 8911
10 1 Tools 8912
10 2 Removing 8912
10 3 Installing 8914
10 3 1 Preparing new part 8915
10 3 2 Marking area in which welding work is prohibited 8917
10 3 3 Moulded foam inserts 8917
10 3 4 Welding in 8918
11 Renewing B-pillar reinforcement, non-hybrid vehicles 8921
11 1 Tools 8922
11 2 Removing 8922
11 3 Installing 8924
11 3 1 Preparing new part 8924
11 3 2 Marking areas where no welding work may be carried out 8927
11 3 3 Welding in 8928
12 Renewing B-pillar reinforcement, hybrid vehicles 8931
12 1 Tools 8932
12 2 Removing 8932
12 3 Installing 8934
12 3 1 Preparing new part 8934
12 3 2 Marking areas where no welding work may be carried out 8937
12 3 3 Welding in 8938
13 Renewing inner B-pillar 8941
13 1 Tools 8942
13 2 Removing 8942
13 3 Installing 8943
13 3 1 Preparing new part 8943
13 3 2 Welding in 8944
14 Renewing side member 8946
14 1 Tools 8947
14 2 Removing 8947
14 3 Installing 8949
14 3 1 Preparing new part 8950
14 3 2 Moulded foam inserts 8951
14 3 3 Marking area in which welding work is prohibited 8952
14 3 4 Welding in 8953
15 Renewing front side member reinforcement, non-hybrid vehicles 8955
15 1 Tools 8956
15 2 Removing 8956
15 3 Installing 8957
15 3 1 Preparing new part 8958
15 3 2 Welding in 8958
16 Renewing front side member reinforcement, hybrid vehicles 8961
16 1 Tools 8962
16 2 Removing 8962
16 3 Installing 8963
16 3 1 Preparing new part 8964
16 3 2 Welding in 8964
17 Renewing rear side member reinforcement 8967
17 1 Tools 8968
17 2 Removing 8968
17 3 Installing 8969
17 3 1 Preparing new part 8970
17 3 2 Welding in 8970
18 Renewing outer mounting for seat cross member 8972
18 1 Tools 8973
18 2 Removing 8974
18 3 Installing 8975
18 3 1 Preparing new part 8975
18 3 2 Welding in 8976
19 Renewing inner mounting for seat cross member 8978
19 1 Tools 8978
19 2 Removing 8978
19 3 Installing 8980
19 3 1 Preparing new part 8980
19 3 2 Welding in 8981
20 Renewing seat middle cross member 8983
20 1 Tools 8983
20 2 Removing 8983
20 3 Installing 8985
20 3 1 Preparing new part 8985
20 3 2 Welding in 8986
53 – Body – rear 8988
1 Renewing cross panel 8988
1 1 Tools 8989
1 2 Removing 8989
1 3 Installing 8990
1 3 1 Preparing new part 8990
1 3 2 Welding in 8992
2 Renewing lock carrier 8994
2 1 Tools 8994
2 2 Removing 8994
2 3 Installing 8996
2 3 1 Welding in 8996
3 Renewing tail light mounting 8998
3 1 Tools 8999
3 2 Removing 8999
3 3 Installing 9000
3 3 1 Preparing new part 9000
3 3 2 Welding in 9000
4 Renewing tail light reinforcement, hybrid vehicles 9002
4 1 Tools 9003
4 2 Removing 9003
4 3 Installing 9004
4 3 1 Preparing new part 9005
4 3 2 Welding in 9005
5 Renewing luggage compartment floor 9007
5 1 Tools 9008
5 2 Removing 9009
5 3 Installing 9011
5 3 1 Preparing new part 9011
5 3 2 Moulded foam inserts 9013
5 3 3 Welding in 9013
6 Renewing C-pillar reinforcement – part section 9018
6 1 Tools 9019
6 2 Removing 9019
6 3 Installing 9020
6 3 1 Preparing new part 9020
6 3 2 Welding in 9021
7 Renewing rear longitudinal member – part section 9023
7 1 Tools 9024
7 2 Removing 9024
7 3 Installing 9025
7 3 1 Preparing new part 9025
7 3 2 Welding in 9026
8 Renewing rear longitudinal member – subpart 9028
8 1 Tools 9029
8 2 Removing 9029
8 3 Installing 9030
8 3 1 Preparing new part 9030
8 3 2 Welding in 9030
9 Renewing rear longitudinal member reinforcement, hybrid vehicles 9032
9 1 Tools 9033
9 2 Removing 9033
9 3 Installing 9034
9 3 1 Preparing new part 9034
9 3 2 Welding in 9035
10 Renewing rear battery mounting, hybrid vehicles 9038
10 1 Tools 9039
10 2 Removing 9039
10 3 Installing 9040
10 3 1 Preparing new part 9040
10 3 2 Welding in 9041
11 Renewing side panel – part section 9043
11 1 Tools 9044
11 2 Removing 9044
11 3 Installing 9047
11 3 1 Preparing new part 9048
11 3 2 Moulded foam inserts 9049
11 3 3 Welding in 9049
12 Renewing outer wheel housing liner 9054
12 1 Tools 9055
12 2 Removing 9055
12 3 Installing 9056
12 3 1 Preparing new part 9056
12 3 2 Welding in 9057
D4B8046FED1 Running gear axles steering 9059
00 – Technical data 9065
1 Safety information 9065
1 1 Safety precautions when working on high-voltage system 9065
1 2 Safety precautions when working in the vicinity of high-voltage components 9066
1 3 Safety measures when working on vehicles with a start/stop system 9066
1 4 Safety precautions when working on subframe 9066
2 Evaluating accident vehicles 9067
2 1 Check list for evaluating running gear on accident vehicles 9067
3 Repair instructions 9069
3 1 Steering rack 9069
3 2 Gaskets and seals 9069
3 3 Nuts and bolts 9069
3 4 Electrical components 9070
3 5 Raising suspension to unladen position (vehicles with coil springs) 9070
3 5 1 Raising wheel bearing assembly to unladen position (vehicles with coil springs), front axle 9070
3 5 2 Raising wheel bearing assembly to unladen position (vehicles with coil springs), rear axle 9072
40 – Front suspension 9075
1 Front axle 9075
1 1 Overview of fitting locations – front axle 9075
2 Subframe 9077
2 1 Assembly overview – subframe 9077
2 2 Fixing position of subframe 9079
2 3 Lowering subframe 9082
2 4 Removing and installing subframe without steering rack 9085
2 5 Removing and installing subframe with steering rack 9089
2 5 1 Removing and installing subframe with steering rack, hydraulic steering 9089
2 5 2 Removing and installing subframe with steering rack, electromechanical steering 9096
2 6 Repairing subframe 9101
2 7 Repairing thread in longitudinal member 9110
3 Anti-roll bar 9111
3 1 Assembly overview – anti-roll bar 9111
3 2 Removing and installing anti-roll bar 9111
4 Suspension strut, upper suspension link 9116
4 1 Assembly overview – suspension strut, upper suspension link 9116
4 2 Removing and installing suspension strut 9117
4 3 Repairing suspension strut 9123
5 Lower suspension link, swivel joint 9126
5 1 Assembly overview – lower suspension link, swivel joint 9126
5 2 Removing and installing lower suspension link 9128
5 2 1 Removing and installing lower suspension link, Basic 9128
5 2 2 Removing and installing lower suspension link, left side of vehicles with automatic or dual clutch gearbox 9129
5 3 Checking swivel joint 9134
5 4 Removing and installing swivel joint 9134
5 5 Renewing bonded rubber bush for lower suspension link 9138
5 5 1 Renewing bonded rubber bush for lower suspension link, front bonded rubber bush 9138
5 5 2 Renewing bonded rubber bush for lower suspension link, rear bonded rubber bush 9141
6 Wheel bearing 9143
6 1 Assembly overview – wheel bearing 9143
6 2 Removing and installing wheel bearing housing 9145
6 3 Removing and installing wheel bearing unit 9150
7 Drive shaft 9155
7 1 Overview – drive shaft 9155
7 2 Assembly overview – drive shaft 9156
7 2 1 Assembly overview – drive shaft, constant velocity joint VL100 9156
7 2 2 Assembly overview – drive shaft, constant velocity joint VL107 9159
7 2 3 Assembly overview – drive shaft with push-on constant velocity joint VL107 9161
7 2 4 Assembly overview – drive shaft, triple roller joint AAR2600i 9163
7 2 5 Assembly overview – drive shaft, triple roller joint AAR3300i 9165
7 3 Removing and installing drive shaft 9166
7 3 1 Removing and installing drive shaft, constant velocity joints VL100 and VL107 9166
7 3 2 Removing and installing drive shaft, right drive shaft with push-on constant velocity joint 9170
7 3 3 Removing and installing drive shaft, triple roller joint AAR2600i 9176
7 3 4 Removing and installing drive shaft, triple roller joint AAR3300i 9180
7 4 Loosening and tightening threaded connections of drive shaft 9184
7 4 1 Loosening and tightening drive shaft bolt, twelve-point head bolt with ribbing 9184
7 4 2 Loosening and tightening drive shaft bolt, twelve-point head bolt without ribbing 9186
7 5 Removing and installing drive shaft heat shield 9188
7 6 Dismantling and assembling drive shaft 9188
7 6 1 Dismantling and assembling drive shaft, constant velocity joint VL100 9188
7 6 2 Dismantling and assembling drive shaft, constant velocity joint VL107 9193
7 6 3 Dismantling and assembling drive shaft, push-on constant velocity joint VL107 9197
7 6 4 Dismantling and assembling drive shaft, triple roller joint AAR2600i 9200
7 6 5 Dismantling and assembling drive shaft, triple roller joint AAR3300i 9205
7 7 Checking outer constant velocity joint 9210
7 8 Checking inner constant velocity joint 9211
42 – Rear suspension 9214
1 Rear axle 9214
1 1 Overview – rear axle 9214
1 2 Lowering rear axle 9215
1 3 Removing and installing rear axle 9217
1 4 Removing and installing shield for rear axle 9221
2 Subframe 9223
2 1 Assembly overview – subframe 9223
2 2 Assembly overview – add-on parts for subframe 9225
2 3 Fixing position of subframe 9225
3 Anti-roll bar 9228
3 1 Assembly overview – anti-roll bar 9228
3 2 Removing and installing anti-roll bar 9228
4 Suspension link, track rod 9231
4 1 Removing and installing upper transverse link 9231
4 2 Removing and installing lower transverse link 9232
4 3 Removing and installing track rod 9234
5 Suspension strut, shock absorber, spring 9237
5 1 Assembly overview – suspension strut, shock absorber, spring 9237
5 2 Removing and installing shock absorbers 9237
5 3 Repairing shock absorber 9239
5 4 Removing and installing spring 9241
6 Wheel bearing assembly, trailing arm 9245
6 1 Assembly overview – wheel bearing 9245
6 2 Removing and installing wheel bearing housing 9246
6 3 Removing and installing wheel bearing unit 9249
6 4 Renewing bonded rubber bush for wheel bearing housing 9252
6 5 Removing and installing trailing arm with mounting bracket 9255
6 6 Repairing trailing arm 9258
43 – Self-levelling suspension 9262
1 Vehicle level sender 9262
1 1 Assembly overview – rear vehicle level senders 9262
1 2 Removing and installing rear vehicle level senders -G76-/-G77- 9262
44 – Wheels, tyres, vehicle geometry 9264
1 Wheels, tyres 9264
1 1 Specified torques for wheel bolts 9264
1 2 Pressing tyre off wheel rim 9264
1 3 Removing tyre from wheel 9265
1 4 Fitting tyre 9265
1 5 Wheel change 9266
1 5 1 Wheel change, protecting wheel centring seat against corrosion 9266
1 5 2 Wheel change, installation requirements 9266
1 5 3 Wheel change, installation instructions for wheel change 9268
1 5 4 Wheel change, wheel installation 9269
1 6 Removing and fitting tyres with run-flat properties to wheel rims 9269
1 6 1 Removing and fitting tyres with run-flat properties to wheel rims, safety instructions 9269
1 6 2 Removing and fitting tyres with run-flat properties to wheel rims, installation requirements 9270
1 6 3 Removing and fitting tyres with run-flat properties to wheel rims, pressing tyre off wheel rim 9271
1 6 4 Removing and fitting tyres with run-flat properties to wheel rims, removing tyre from wheel 9272
1 6 5 Removing and fitting tyres with run-flat properties to wheel rims, fitting tyre to wheel rim 9273
1 7 Tyre sealant disposal 9275
1 8 Models with breakdown set 9275
2 Tyre Pressure Monitoring System 9277
2 1 System description – Tyre Pressure Monitoring System 9277
2 2 Assembly overview – tyre pressure sensor 9278
2 3 Removing and installing tyre pressure sensor -G222-/-G223-/-G224-/-G225- 9279
2 4 Changing tyres on vehicles with tyre pressure monitoring system 9280
2 4 1 Notes on safety and conditions for removing and fitting tyres (wheels with tyre pressure monitoring) 9280
2 4 2 Wheel change 9281
2 4 3 Fittings instructions 9282
2 4 4 Removing tyre from wheel 9283
2 4 5 Fitting tyre to wheel rim 9283
3 Wheel alignment 9285
3 1 Notes for wheel alignment 9285
3 2 Conditions for testing 9285
3 3 Test preparations 9286
3 4 Specifications for wheel alignment 9287
3 5 Wheel alignment procedure 9289
3 6 Necessity of wheel alignment 9290
3 7 Transverse vehicle inclination “zero position” 9292
3 8 Adjusting camber at front wheels 9292
3 9 Adjusting camber on rear axle 9293
3 10 Adjusting toe at rear axle 9294
3 11 Adjusting front axle toe 9295
3 12 Vehicle data sticker 9296
3 13 Steering angle sender -G85- basic setting 9297
4 Vibration due to wheels/tyres – causes and rectification 9298
4 1 Causes of rough running 9298
4 2 Conducting a road test before balancing wheels 9298
4 3 Balancing wheel 9299
4 3 1 Balancing wheel, conditions 9299
4 3 2 Balancing wheel, balancing wheel on stationary wheel balancer 9299
4 3 3 Balancing wheel, balancing wheel with finish balancer 9301
4 4 Vibration control system 9302
4 5 Checking radial and lateral runout of wheels and tyres 9302
4 5 1 Checking radial and lateral runout of wheels and tyres, tolerances 9302
4 5 2 Checking radial and lateral runout on wheels and tyres with tyre gauge 9303
4 6 Checking radial and lateral run-out on wheel rim 9303
4 7 Matching wheels and tyres 9304
4 8 Determining flat spots on tyres 9305
5 Adaptive cruise control 9307
5 1 Calibrating adaptive cruise control 9307
48 – Steering 9313
1 Steering wheel 9313
1 1 Assembly overview – steering wheel 9313
1 2 Removing and installing steering wheel 9313
2 Steering column 9316
2 1 Assembly overview – steering column 9316
2 1 1 Assembly overview – steering column, left-hand drive 9316
2 1 2 Assembly overview – steering column, right-hand drive 9318
2 2 Checking steering column for damage 9318
2 3 Handling and transporting steering column 9319
2 4 Removing and installing steering column 9320
2 4 1 Removing and installing steering column, left-hand drive vehicle 9320
2 4 2 Removing and installing steering column, right-hand drive vehicle 9327
3 Steering rack 9336
3 1 Assembly overview – steering rack 9336
3 1 1 Assembly overview – steering rack, hydraulic steering rack 9336
3 1 2 Assembly overview – steering rack, electromechanical steering rack, left-hand drive vehicle 9337
3 1 3 Assembly overview – steering rack, electromechanical steering rack, right-hand drive vehicle 9339
3 2 Removing and installing steering rack 9341
3 2 1 Removing and installing steering rack, hydraulic steering 9341
3 2 2 Removing and installing steering rack, electromechanical steering rack, LHD vehicles 9347
3 2 3 Removing and installing steering rack, electromechanical steering rack, RHD vehicles 9354
3 3 Removing and installing boot 9360
3 3 1 Removing and installing boot, hydraulic steering 9360
3 3 2 Removing and installing boot, electromechanical steering 9362
3 4 Removing and installing track rod 9365
3 4 1 Removing and installing track rod, hydraulic steering 9365
3 4 2 Removing and installing track rod, electromechanical steering 9368
3 5 Removing and installing track rod ball joint 9371
3 6 Repairing steering rack 9373
3 6 1 Repairing steering rack, hydraulic steering 9373
3 6 2 Repairing steering rack, electromechanical steering 9375
4 Sensors 9376
4 1 Removing and installing steering angle sender -G85- 9376
4 1 1 Removing and installing steering angle sender -G85-, without electromechanical power steering 9376
4 1 2 Removing and installing steering angle sender -G85-, with electromechanical power steering 9377
5 Hydraulic power steering 9378
5 1 Assembly overview – hydraulic lines, reservoir 9378
5 1 1 Assembly overview – hydraulic lines, 4-cylinder petrol engine 9378
5 1 2 Assembly overview – hydraulic lines, reservoir, 4-cylinder petrol engine 9380
5 1 3 Assembly overview – hydraulic lines, 5-cylinder petrol engine 9381
5 1 4 Assembly overview – hydraulic lines, reservoir, 5-cylinder petrol engine 9382
5 2 Assembly overview – vane pump 9383
5 2 1 Assembly overview – vane pump, 4-cylinder petrol engine 9383
5 2 2 Assembly overview – vane pump, 5-cylinder petrol engine 9384
5 3 Checking hydraulic fluid level of power steering 9385
5 4 Bleeding steering system after repairs 9386
5 5 Check steering for leaks 9386
5 6 Checking delivery pressure of vane pump 9387
5 7 Removing and installing vane pump 9390
5 7 1 Removing and installing vane pump, 4-cylinder petrol engine 9390
5 7 2 Removing and installing vane pump, 5-cylinder petrol engine 9393
D4B8046FED2 Brake system 9396
00 – Technical data 9400
1 Safety information 9400
1 1 Safety precautions when working on high-voltage system 9400
1 2 Safety precautions when working in the vicinity of high-voltage components 9401
1 3 Safety measures when working on vehicles with a start/stop system 9401
1 4 Safety precautions when using test and measuring instruments during a road test 9401
2 Identification 9402
2 1 Allocation of PR number – brakes 9402
2 1 1 PR number 9402
2 1 2 Front brakes 9402
2 1 3 Rear brakes, torsion beam rear axle 9402
2 1 4 Rear brakes, multi-link rear suspension 9403
3 Technical data 9404
3 1 Technical data for brakes 9404
3 1 1 Brake master cylinder and brake servo 9404
4 Brake test 9407
4 1 General information 9407
4 2 Checking vehicles with front-wheel drive 9407
45 – Anti-lock brake system 9408
1 General information 9408
1 1 Repair instructions for repair work on ABS 9408
1 2 Vehicle diagnosis, testing and information system 9410
2 Overview of fitting locations 9412
2 1 Fitting location overview – ABS 9412
2 1 1 ABS Mark 70, ABS/TCS 9412
2 1 2 ABS Mark 70 (ABS/TCS) (right-hand drive vehicles) 9413
2 2 Overview of fitting locations – ABS/ESP 9415
2 2 1 ABS Mark 60 EC, North America 9415
2 2 2 ABS Mark 60 EC, vehicles with electromechanical power steering, North America 9417
2 2 3 ABS Mark 60 EC, vehicles with electromechanical power steering 9418
3 Control unit and hydraulic unit 9420
3 1 Assembly overview – control unit and hydraulic unit 9420
3 1 1 Assembly overview – ABS Mark 70 (ABS/TCS), left-hand drive vehicles 9420
3 1 2 Assembly overview – ABS Mark 70 (ABS/TCS), right-hand drive vehicles 9423
3 1 3 Assembly overview – ABS Mark 60 EC (ABS/EDL/TCS/ESP), left-hand drive vehicles 9424
3 1 4 Assembly overview – ABS Mark 60 EC (ABS/EDL/TCS/ESP), right-hand drive vehicles 9426
3 2 Removing and installing ABS control unit -J104- and ABS hydraulic unit -N55- 9428
3 2 1 Removing and installing ABS control unit -J104- and ABS hydraulic unit -N55-, left-hand drive vehicles with petrol engines 9428
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 9435
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 9444
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 9452
3 2 5 Removing and installing ABS control unit -J104- and ABS hydraulic unit -N55-, right-hand drive vehicles with ABS Mark 70 (ABS/TCS) 9463
3 2 6 Removing and installing ABS control unit -J104- and ABS hydraulic unit -N55-, left-hand drive vehicles with diesel engine 9472
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 9479
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 9488
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 9497
3 2 10 Removing and installing ABS control unit -J104- and ABS hydraulic unit -N55-, ABS Mark 60 EC (ABS/EDL/TCS/ESP) 9507
3 2 11 Removing and installing ABS control unit -J104- and ABS hydraulic unit -N55-, hybrid vehicles and ABS Mark 60 EC (ABS/EDL/TCS/ESP) 9516
3 3 Separating control unit from hydraulic unit 9525
3 3 1 Separating ABS control unit -J104- from ABS hydraulic unit -N55-, ABS Mark 70 (ABS/TCS) 9525
3 3 2 Separating ABS control unit -J104- from ABS hydraulic unit -N55-, ABS Mark 60 EC (ABS/EDL/TCS/ESP) 9527
3 4 Fitting control unit to hydraulic unit 9528
3 4 1 Installing ABS control unit -J104- to ABS hydraulic unit -N55-, ABS Mark 70 (ABS/TCS) 9528
3 4 2 Installing ABS control unit -J104- to ABS hydraulic unit -N55-, ABS Mark 60 EC (ABS/EDL/TCS/ESP) 9530
3 5 Connecting brake lines to hydraulic unit 9533
3 5 1 Connecting brake lines to ABS hydraulic unit -N55-, left-hand drive vehicles 9533
3 5 2 Connecting brake lines to ABS hydraulic unit -N55-, right-hand drive vehicles 9534
4 Sensors 9536
4 1 Assembly overview – speed sensor on front axle 9536
4 1 1 Assembly overview – speed sensor on front axle 9536
4 2 Assembly overview – speed sensor on rear axle 9537
4 2 1 Assembly overview – speed sensor on rear axle, semi-independent suspension 9537
4 2 2 Assembly overview – speed sensor on rear axle, multi-link rear suspension 9538
4 3 Removing and installing yaw rate sender and lateral acceleration sender 9538
4 4 Assembly overview – sensors and actuators 9539
4 4 1 Assembly overview – steering angle sender -G85- 9539
4 5 Removing and installing speed sensors on front axle -G45-/-G47- 9539
4 5 1 Removing and installing speed sensor on front axle 9539
4 6 Removing and installing speed sensors on rear axle -G44-/-G46- 9540
4 6 1 Removing and installing speed sensor on semi-independent suspension 9540
4 6 2 Removing and installing speed sensor on multi-link rear suspension 9541
46 – Brakes – mechanism 9542
1 Front brakes 9542
1 1 Assembly overview – front brakes 9542
1 1 1 Assembly overview – front brakes, FS III without brake pad wear indicator 9542
1 1 2 Assembly overview – front brakes, FS III with brake pad wear indicator 9544
1 1 3 Assembly overview – front brakes, FN3 15/16 inch without brake pad wear indicator 9546
1 1 4 Assembly overview – front brakes, FN3 15/16 inch with brake pad wear indicator 9548
1 2 Removing and installing brake pads/linings 9549
1 2 1 Removing and installing brake pads, brake caliper FS III 9549
1 2 2 Removing and installing brake pads, brake caliper FN 3 9552
1 3 Removing and installing brake caliper 9555
1 3 1 Removing and installing brake caliper, FS III brake caliper 9555
1 3 2 Removing and installing brake caliper, FN 3 brake caliper 9558
1 4 Removing and installing brake carrier 9562
1 4 1 Removing and installing brake carrier, brake caliper FN 3 9562
1 5 Replace brake disc 9564
1 5 1 Removing and installing brake disc, brake caliper FS III 9564
1 5 2 Removing and installing brake disc, brake caliper FN 3 9566
1 6 Removing and installing brake splash plate 9569
1 6 1 Removing and installing cover plate, brake caliper FS III 9569
1 6 2 Removing and installing splash plate, brake caliper FN 3 9570
2 Rear brakes 9573
2 1 Assembly overview – rear brakes 9573
2 1 1 Assembly overview – torsion beam rear suspension, rear brakes, Bosch ZOH BIR 38 9573
2 1 2 Assembly overview – torsion beam rear suspension, rear brakes, CI 38 9576
2 1 3 Assembly overview – multi-link rear suspension, rear brakes, Bosch ZOH BIR 38 9578
2 1 4 Assembly overview – multi-link rear suspension, rear brakes, CI 38 9581
2 2 Removing and installing brake pads/linings 9583
2 2 1 Removing and installing brake pads; Rear brakes, Bosch ZOH BIR 38 9583
2 2 2 Removing and installing brake pads; Rear brakes, CI 38 9586
2 3 Removing and installing brake caliper 9590
2 3 1 Removing and installing brake caliper; Rear brakes, Bosch ZOH BIR 38 9590
2 3 2 Removing and installing brake caliper; Rear brakes, CI 38 9593
2 4 Removing and installing brake carrier 9597
2 5 Removing and installing brake disc 9599
2 6 Removing and installing brake splash plate 9601
2 6 1 Removing and installing splash plate for brakes, torsion beam rear axle 9601
2 6 2 Removing and installing splash plate for brakes, multi-link rear axle 9603
3 Parking brake 9606
3 1 Assembly overview – parking brake 9606
3 2 Removing and installing handbrake lever 9607
3 3 Adjusting parking brake 9610
3 4 Removing and installing rear brake cable 9611
3 4 1 Removing and installing rear brake cable on semi-independent suspension 9611
3 4 2 Removing and installing rear brake cable on multi-link rear suspension 9615
4 Brake pedal 9618
4 1 Assembly overview – brake pedal 9618
4 1 1 Assembly overview – brake pedal, left-hand drive 9618
4 1 2 Assembly overview – brake pedal, right-hand drive 9619
4 2 Removing and installing mounting bracket 9621
4 2 1 Removing and installing mounting bracket, left-hand drive 9621
4 2 2 Removing and installing mounting bracket, RHD 9623
4 2 3 Removing and installing mounting bracket, hybrid vehicles 9626
4 3 Separating brake pedal from brake servo 9632
4 4 Connecting brake pedal to brake servo 9633
4 5 Removing and installing brake pedal 9634
4 5 1 Removing and installing brake pedal, left-hand drive vehicles 9634
4 5 2 Removing and installing brake pedal, right-hand drive vehicles 9635
47 – Brakes – hydraulics 9636
1 Front brake caliper 9636
1 1 Assembly overview – front brake caliper 9636
1 1 1 Assembly overview – front brake caliper, brake caliper FS III 9636
1 1 2 Assembly overview – front brake caliper, brake caliper FN 3 9637
1 2 Removing and installing brake caliper piston 9638
1 2 1 Removing and installing brake caliper piston, brake caliper piston FS III 9638
1 2 2 Removing and installing brake caliper piston, brake caliper piston FN 3 9640
2 Rear brake caliper 9644
2 1 Assembly overview – rear brake caliper 9644
2 1 1 Assembly overview – rear brake caliper, rear brakes, Bosch ZOH BIR 38 9644
2 1 2 Assembly overview – rear brake caliper, rear brakes, CI 38 9645
2 2 Removing and installing brake caliper piston 9647
2 2 1 Removing and installing brake caliper piston; Rear brakes, Bosch ZOH BIR 38 9647
2 2 2 Removing and installing brake caliper piston; Rear brakes, CI 38 9649
3 Brake servo and brake master cylinder 9652
3 1 Assembly overview – brake servo/brake master cylinder 9652
3 1 1 Assembly overview – brake servo/brake master cylinder, left-hand drive vehicles 9652
3 1 2 Assembly overview – brake servo/brake master cylinder, right-hand drive 9655
3 2 Removing and installing brake light switch 9656
3 2 1 Removing and installing brake light switch -F-, left-hand drive vehicles with petrol engine 9656
3 2 2 Removing and installing brake light switch -F-, left-hand drive vehicles with diesel engine 9657
3 2 3 Removing and installing brake light switch -F-, right-hand drive 9658
3 2 4 Removing and installing brake light switch -F-, hybrid vehicles 9659
3 3 Removing and installing brake servo 9660
3 3 1 Removing and installing brake servo, left-hand drive vehicles with petrol engine 9660
3 3 2 Removing and installing brake servo, left-hand drive vehicles with diesel engine 9664
3 3 3 Removing and installing brake servo, right-hand drive vehicles with petrol engine 9669
3 3 4 Removing and installing brake servo, right-hand drive with diesel engine 9679
3 3 5 Removing and installing brake servo, hybrid vehicles 9690
3 4 Removing and installing brake master cylinder 9698
3 4 1 Removing and installing brake master cylinder, left-hand drive vehicles with petrol engine 9698
3 4 2 Removing and installing brake master cylinder, left-hand drive vehicles with diesel engine 9702
3 4 3 Removing and installing brake master cylinder, right-hand drive vehicles with petrol engine 9706
3 4 4 Removing and installing brake master cylinder, right-hand drive vehicles with diesel engine 9712
3 4 5 Removing and installing brake master cylinder, hybrid vehicles 9719
3 5 Removing and installing brake fluid reservoir 9724
3 5 1 Removing and installing brake fluid reservoir, left-hand drive vehicles 9724
3 5 2 Removing and installing brake fluid reservoir, right-hand drive vehicles 9726
3 5 3 Removing and installing brake fluid reservoir, hybrid vehicles 9729
4 Vacuum system 9733
4 1 Assembly overview – electric vacuum pump 9733
4 1 1 Assembly overview – electric vacuum pump, vehicles with 1 2 l petrol engine 9733
4 1 2 Assembly overview – electric vacuum pump, vehicles with 1 4 l – 118 kW petrol engine 9735
4 1 3 Assembly overview – electric vacuum pump, vehicles with 1 4 l – 110 kW petrol engine 9736
4 1 4 Assembly overview – electric vacuum pump, vehicles with 2 0 l petrol engine 9737
4 1 5 Assembly overview – electric vacuum pump, vehicles with hybrid powertrain 9738
4 2 Assembly overview – vacuum pump 9739
4 2 1 Assembly overview – vacuum pump, vehicles with 1 8 l – 125 kW and 2 0 l – 155 kW petrol engine 9739
4 2 2 Assembly overview – vacuum pump, vehicles with 2 0 l diesel engine 9740
4 2 3 Assembly overview – vacuum pump, vehicles with 2 5 l diesel engine 9740
4 3 Checking non-return valve 9741
4 4 Removing and installing brake servo pressure sensor 9741
4 5 Removing and installing vacuum sender -G608- 9741
4 6 Checking vacuum system 9742
4 6 1 Instructions 9742
4 6 2 Connecting vacuum gauge for brake servo -VAS 6721- 9743
4 6 3 Checking vacuum generation 9744
4 6 4 Checking for leaks 9745
4 6 5 Vacuum generation with manual vacuum pump -VAS 6213- 9746
4 7 Removing and installing electric vacuum pump 9747
4 7 1 Removing and installing electric vacuum pump, vehicles with 1 2 l and 1 4 l petrol engine 9747
4 7 2 Removing and installing electric vacuum pump, vehicles with 2 0 l petrol engine 9748
4 7 3 Removing and installing electric vacuum pump, vehicles with hybrid powertrain 9749
5 Brake lines 9752
5 1 Repairing brake lines 9752
5 1 1 Assembly overview – flanging tool 9752
5 1 2 Work instructions 9753
6 Hydraulic system 9757
6 1 General notes on brake fluid 9757
6 1 1 General information 9757
6 1 2 Changing brake fluid 9759
6 2 Pre-bleeding hydraulic system 9760
6 3 Bleeding hydraulic system following standard procedure 9762
6 4 Subsequent bleeding of hydraulic system 9765
6 5 Testing for leaks 9766
6 5 1 Prerequisites for testing: 9766
D4B8046FED3 6 speed manual gearbox 0AJ 9767
00 – Technical data 9771
1 Safety information 9771
1 1 Safety measures when working on vehicles with a start/stop system 9771
1 2 Safety precautions when using testers and measuring instruments during a road test 9771
2 Identification 9772
2 1 Gearbox identification 9772
3 Repair notes 9773
3 1 General repair instructions 9773
4 Technical data 9778
4 1 Capacities 9778
4 2 Allocation gearbox – engine 9778
4 3 Calculation of gear ratios 9779
5 Overview – power transmission 9780
5 1 Overview – power transmission – front-wheel drive 9780
6 Electrical components 9782
6 1 Overview of fitting locations – electrical components 9782
6 1 1 Overview of fitting locations – electrical components, manual gearbox 9782
6 1 2 Overview of fitting locations – electrical components, clutch mechanism 9783
30 – Clutch 9784
1 Clutch mechanism 9784
1 1 Assembly overview – pedal cluster 9784
1 2 Assembly overview – clutch hydraulics 9786
1 3 Assembly overview – clutch release mechanism 9789
1 4 Removing and installing clutch pedal 9790
1 5 Removing and installing over-centre spring 9793
1 6 Removing and installing mounting bracket 9795
1 7 Removing and installing clutch master cylinder 9801
1 8 Removing and installing clutch slave cylinder 9803
1 9 Bleeding clutch mechanism 9807
1 10 Checking clutch master cylinder and clutch slave cylinder 9808
1 11 Removing and installing clutch position sender -G476- 9808
1 12 Repairing clutch release mechanism 9811
2 Clutch 9814
2 1 Assembly overview – clutch 9814
2 2 Removing and installing clutch 9815
34 – Controls, housing 9821
1 Selector mechanism 9821
1 1 Installation position – selector mechanism 9821
1 2 Assembly overview – gear knob and cover 9822
1 3 Assembly overview – selector mechanism 9822
1 4 Removing and installing gear knob 9824
1 5 Removing and installing selector mechanism 9827
1 6 Adjusting selector mechanism 9836
1 7 Checking selector mechanism 9839
1 8 Repairing selector mechanism 9839
1 9 Renewing selector shaft seal 9841
2 Removing and installing gearbox 9843
2 1 Distinguishing between different types of engines 9843
2 2 Specified torques for gearbox 9844
2 2 1 Specified torques for gearbox with engine lifting eyes »at front« of engine 9844
2 2 2 Specified torques for gearbox with engine lifting eyes »at rear« of engine 9845
2 3 Removing gearbox 9846
2 3 1 Removing gearbox, engine lifting eyes »at rear« of engine 9846
2 3 2 Removing gearbox, engine lifting eyes »at front« of engine 9860
2 4 Installing gearbox 9873
3 Assembly mountings 9882
3 1 Assembly overview – assembly mountings 9882
4 Transporting gearbox 9885
5 Dismantling and assembling gearbox 9887
5 1 Schematic overview – gearbox 9887
5 2 Assembly overview – cover for gearbox housing and 5th/6th gear 9887
5 3 Assembly overview – selector unit 9889
5 4 Assembly overview – input shaft, output shafts, differential, selector rods 9891
5 5 Assembly overview – selector forks 9893
5 6 Repairing selector forks 9894
5 7 Dismantling and assembling gearbox 9899
6 Gearbox housing, clutch housing 9923
6 1 Assembly overview – clutch housing 9923
6 2 Assembly overview – gearbox housing and clutch housing 9923
6 3 Assembly overview – gearbox housing cover 9925
6 4 Repairing gearbox housing 9927
6 5 Repairing gearbox housing cover 9928
7 Securing to engine and gearbox support 9932
8 Gear oil 9934
8 1 Checking gear oil level 9934
35 – Gears, shafts 9936
1 Input shaft 9936
1 1 Assembly overview – input shaft 9936
1 2 Dismantling and assembling input shaft 9939
1 3 Renewing input shaft seal 9950
2 Output shaft 9952
2 1 Assembly overview – output shaft 9952
2 2 Dismantling and assembling output shaft 9955
39 – Final drive – differential 9963
1 Oil seals 9963
1 1 Overview of fitting locations – seals 9963
1 2 Renewing left seal 9963
1 3 Renewing right seal 9966
2 Differential 9970
2 1 Assembly overview – differential 9970
2 2 Dismantling and assembling differential 9972
2 3 Adjusting differential 9980
D4B8046FED4 6 speed dual clutch gearbox 02E 9985
00 – Technical data 9989
1 Safety information 9989
1 1 General safety provisions 9989
1 2 Safety measures when working on vehicles with a start/stop system 9989
1 3 Safety precautions when tow-starting or towing 9990
1 4 Safety precautions when using testers and measuring instruments during a road test 9990
2 Identification 9991
2 1 Gearbox identification 9991
3 Repair notes 9993
3 1 General information 9993
3 2 Safety functions of gearbox control unit 9993
3 3 Rules for cleanliness 9994
3 4 General repair instructions 9994
4 Technical data 9997
4 1 Capacities 9997
4 2 Allocation gearbox – engine 9997
5 Electrical components 9998
5 1 Overview of fitting locations – electrical components 9998
30 – Clutch 9999
1 Clutch 9999
1 1 Assembly overview – dual clutch 9999
1 2 Removing and installing clutch end cover 10001
1 3 Removing dual clutch 10006
1 4 Installing dual clutch 10008
34 – Controls, housing 10015
1 Mechatronic unit 10015
1 1 Removing and installing mechatronic unit 10015
1 1 1 Removing and installing mechatronic unit for dual clutch gearbox -J743-, gearbox installed 10015
1 1 2 Removing and installing mechatronic unit for dual clutch gearbox -J743-, gearbox removed 10027
1 2 Removing and installing gearbox input speed sender -G182- and oil temperature sender in multi-plate clutch -G509- 10036
2 Selector mechanism 10038
2 1 Assembly overview – selector mechanism 10038
2 2 Removing and installing selector mechanism 10039
2 2 1 Removing and installing selector mechanism with selector housing 10039
2 2 2 Removing and installing selector mechanism without selector housing 10042
2 3 Checking and adjusting selector lever cable 10045
2 4 Emergency release from position P 10047
2 5 Removing and installing selector lever handle 10048
2 6 Moving push button in the handle to installation position 10050
2 6 1 Moving push button in handle to installation position, handle with push button on side 10050
2 6 2 Moving push button in handle to installation position, handle with push button at front 10050
2 7 Checking selector mechanism 10052
2 8 Renewing oil seal for selector shaft 10053
3 Removing and installing gearbox 10056
3 1 Removing gearbox 10056
3 1 1 Removing gearbox, 2 0 l – 103 kW and 2 0 l – 110 kW – diesel engine 10056
3 1 2 Removing gearbox, 2 0 l – 155 kW petrol engine 10067
3 2 Installing gearbox 10078
3 2 1 Installing gearbox, 2 0 l – 103 kW and 2 0 l – 110 kW – diesel engine 10078
3 2 2 Installing gearbox, 2 0 l – 155 kW petrol engine 10080
3 3 Specified torques for gearbox 10083
4 Assembly mounting 10085
4 1 Assembly overview – assembly mountings 10085
5 Transporting gearbox 10087
6 Dismantling and assembling gearbox 10088
6 1 Assembly overview – gearbox 10088
7 Installing to engine and gearbox support 10092
8 Gear oil circuit 10093
8 1 Removing and installing gear oil cooler 10093
8 2 Removing and installing gear oil pump 10095
8 3 Removing and installing gear oil filter 10098
9 Gear oil 10101
9 1 Checking gear oil level 10101
9 2 Draining and filling gear oil 10104
35 – Gears, shafts 10108
1 Dismantling and assembling gears and shafts 10108
39 – Final drive – differential 10109
1 Oil seals 10109
1 1 Overview of fitting locations – seals 10109
1 2 Renewing left oil seal 10109
1 3 Renewing right oil seal 10112
D4B8046FED5 General body repairs exterior 10116
50 – Body – front 10122
1 Lock carrier 10122
1 1 Assembly overview – lock carrier 10122
1 1 1 Assembly overview – lock carrier, RoW (rest of world) 10122
1 1 2 Assembly overview – lock carrier, North American Region 10124
1 2 Removing and installing lock carrier 10125
1 3 Moving to and back from service position 10128
2 Wings 10132
2 1 Assembly overview – wing 10132
2 1 1 Assembly overview – wing 10132
2 1 2 Assembly overview – insulation, foam sections and end plate 10133
2 1 3 Assembly overview – end plate 10133
2 2 Removing and installing wing 10134
2 3 Removing and installing wing bracket 10136
3 Bulkhead 10137
3 1 Assembly overview – plenum chamber bulkhead 10137
3 2 Assembly overview – plenum chamber cover 10138
3 3 Removing and installing plenum chamber bulkhead 10139
3 4 Removing and installing plenum chamber cover 10141
55 – Bonnet, rear lid 10145
1 Bonnet 10145
1 1 Assembly overview – bonnet 10145
1 2 Assembly overview – Bowden cable 10146
1 3 Removing and installing bonnet 10147
1 4 Adjusting bonnet 10148
1 5 Removing and installing bonnet lock 10151
1 6 Removing and installing bonnet release lever 10154
1 7 Removing and installing striker pin 10155
1 8 Removing and installing hinges 10156
1 9 Removing and installing insulation 10157
1 9 1 Removing and installing insulation 10157
1 9 2 Removing and installing seals 10159
1 10 Removing and installing Bowden cable 10160
1 11 Removing and installing support rod 10161
2 Rear lid 10163
2 1 Assembly overview – rear lid 10163
2 2 Assembly overview – hinge 10164
2 3 Assembly overview – gas strut 10165
2 4 Assembly overview – number plate carrier 10165
2 5 Removing and installing rear lid 10166
2 6 Adjusting rear lid 10167
2 7 Removing and installing bonnet lock 10170
2 8 Removing and installing operating mechanism 10171
2 9 Removing and installing hinges 10172
2 10 Removing and installing striker pin 10175
2 11 Removing and installing rear lid seal 10176
2 12 Removing and installing gas strut 10177
2 13 Releasing gas from gas strut 10178
3 Tank flap unit 10179
3 1 Assembly overview – tank flap unit 10179
3 2 Removing and installing tank flap unit 10179
3 2 1 Removing and installing tank flap unit 10179
3 2 2 Removing and installing tank flap unit (Russia and Malaysia) 10181
57 – Front doors, door components, central locking 10185
1 Door 10185
1 1 Removing and installing inner door seal 10185
1 2 Removing and installing outer door seal 10186
1 3 Removing and installing door 10187
1 4 Adjusting door 10189
1 5 Adjusting striker pin 10191
1 6 Removing and installing door hinge 10192
1 7 Removing and installing door arrester 10193
2 Door components 10196
2 1 Assembly overview – door hinge 10196
2 2 Assembly overview – door components 10198
2 3 Assembly overview – door handle and door lock 10199
2 4 Assembly overview – insulation 10200
2 5 Removing and installing window regulator motor 10201
2 5 1 Removing and installing window regulator motor, equipment level High (AW1) 10201
2 5 2 Removing and installing window regulator motor, equipment level Low (AW0) 10203
2 6 Removing and installing window regulator 10205
2 7 Removing and installing inner door cover 10207
2 8 Removing and installing striker pin 10208
2 9 Removing and installing door handle 10209
2 10 Removing and installing door handle bracket 10211
2 11 Removing and installing door lock 10213
2 12 Removing and installing window channel 10216
2 13 Removing and installing inner window slot seal 10218
2 14 Removing and installing outer window slot seal 10220
2 15 Removing and installing lock cylinder 10221
2 16 Removing and installing cap on door handle 10224
2 16 1 Removing and installing cap for door handle, with lock cylinder 10224
2 16 2 Removing and installing cap for door handle, without lock cylinder 10225
3 Central locking 10228
3 1 Overview of fitting locations – central locking 10228
3 2 Assembly overview – ignition key 10230
3 2 1 Assembly overview – battery for ignition key with remote control 10230
3 2 2 Assembly overview – battery for ignition key with cap 10231
3 3 Removing and installing ignition key battery 10232
3 3 1 Removing and installing ignition key battery 10232
3 3 2 Removing and installing battery for ignition key with cap 10233
3 4 Removing and installing tank filler flap locking motor -V155- 10233
58 – Rear doors, door components 10236
1 Door 10236
1 1 Assembly overview – door 10236
1 2 Removing and installing door 10237
1 3 Adjusting door 10239
1 4 Adjusting striker pin 10241
1 5 Removing and installing door hinges 10241
1 6 Removing and installing door arrester 10243
1 7 Removing and installing outer door seal 10245
1 8 Removing and installing inner door seal 10246
2 Door components 10248
2 1 Assembly overview – door components 10248
2 2 Assembly overview – door handle and door lock 10250
2 3 Assembly overview – insulation 10251
2 4 Removing and installing window regulator motor 10251
2 4 1 Removing and installing window regulator motor, equipment level High (AW1) 10251
2 4 2 Removing and installing window regulator motor, equipment level Low (AW0) 10253
2 5 Removing and installing window regulator 10255
2 6 Removing and installing inner door cover 10257
2 7 Removing and installing striker pin 10258
2 8 Removing and installing door handle 10258
2 9 Removing and installing door handle bracket 10260
2 10 Removing and installing door lock 10262
2 11 Removing and installing window channel 10265
2 12 Removing and installing outer window slot seal 10267
2 13 Removing and installing inner window slot seal 10268
2 14 Removing and installing cap on door handle 10269
60 – Sunroof 10273
1 Sliding sunroof 10273
1 1 Assembly overview – sliding sunroof 10273
1 2 Removing and installing glass panel 10274
1 3 Removing and installing wind deflector 10276
1 4 Adjusting sunroof panel 10277
1 5 Checking parallel running of glass panel 10279
1 6 Adjusting parallel running of glass panel 10279
1 7 Removing and installing sliding sunroof seals 10280
1 8 Removing and installing sliding headliner 10280
1 9 Removing and installing sliding sunroof adjustment control unit -J245- 10281
1 10 Adapting sliding sunroof adjustment control unit -J245- 10282
1 11 Removing and installing sliding sunroof frame 10282
2 Water drain hoses 10285
2 1 Cleaning water drainage hoses 10285
63 – Bumpers 10287
1 Bumper, front 10287
1 1 Assembly overview – bumper cover 10287
1 1 1 Assembly overview – bumper cover 10287
1 1 2 Assembly overview – add-on parts 10288
1 1 3 Assembly overview – guides 10290
1 2 Assembly overview – impact bar 10291
1 3 Removing and installing bumper cover 10291
1 4 Installing front number plate carrier 10294
1 5 Repairing bumper cover 10295
1 6 Installing holder for parking aid sender 10295
2 Bumper, rear 10301
2 1 Assembly overview – bumper cover 10301
2 1 1 Assembly overview – bumper cover 10301
2 1 2 Assembly overview – add-on parts 10302
2 1 3 Assembly overview – guides 10303
2 2 Assembly overview – impact bar 10304
2 3 Removing and installing bumper cover 10304
2 4 Repairing bumper cover 10307
2 5 Installing holder for parking aid sender 10307
64 – Glazing 10312
1 Repair notes 10312
1 1 Minimum curing periods for bonded windows 10312
1 2 Window repair 10312
1 3 Installation instructions for bonded windows 10314
1 4 Preparing old undamaged windows for fitting 10315
1 5 Preparing new windows for installing 10315
1 6 Preparing body flange for fitting 10316
1 7 Cleaning off excess adhesive 10317
2 Windscreen 10318
2 1 Assembly overview – windscreen 10318
2 2 Removing and installing windscreen 10319
2 2 1 Removing and installing windscreen 10319
2 2 2 Removing broken windscreen 10322
3 Rear windscreen 10323
3 1 Assembly overview – rear window 10323
3 2 Removing and installing rear window 10323
3 2 1 Removing and installing rear window 10323
3 2 2 Removing broken rear window 10326
4 Door windows 10327
4 1 Assembly overview – front door window 10327
4 2 Assembly overview – rear door window 10328
4 3 Removing and installing front door window 10328
4 4 Removing and installing rear door window 10332
4 5 Removing and installing fixed rear door window 10336
66 – Exterior equipment 10339
1 Radiator grille and front trim 10339
1 1 Assembly overview – radiator grille 10339
1 2 Removing and installing radiator grille 10339
2 Spoiler 10342
2 1 Removing and installing spoiler 10342
3 Mouldings, trims, extensions 10348
3 1 Assembly overview – covers 10348
3 2 Assembly overview – side member trim 10350
3 3 Assembly overview – water deflector 10350
3 4 Assembly overview – B-pillar trim 10352
3 5 Removing and installing trim strip 10352
3 6 Removing and installing cover 10354
3 7 Removing and installing entry moulding 10355
3 8 Removing and installing side member trim 10358
3 8 1 Removing and installing side member trim 10358
3 8 2 ‏Removing and installing side member trim, GLI 10362
3 9 Removing and installing water deflector 10367
3 10 Removing and installing B-pillar trim 10371
4 Noise insulation 10373
4 1 Assembly overview – noise insulation 10373
4 1 1 Assembly overview – noise insulation, petrol engine 10373
4 1 2 Assembly overview – noise insulation for diesel engines 10374
4 1 3 Assembly overview – skid plate 10374
4 2 Removing and installing noise insulation 10375
4 2 1 Removing and installing noise insulation, petrol engine 10375
4 2 2 Removing and installing noise insulation, diesel engine 10376
4 2 3 Removing and installing underbody guard 10377
5 Underbody cladding 10379
5 1 Overview of fitting locations – underbody cladding 10379
5 1 1 Assembly overview – underbody cladding, front 10379
5 1 2 Assembly overview – underbody cladding, rear 10380
5 2 Assembly overview – bracing on underbody 10382
5 3 Removing and installing underbody cladding 10382
5 3 1 Removing and installing underbody cladding, front 10382
5 3 2 Removing and installing underbody cladding, rear 10384
5 4 Removing and installing tunnel cross-piece 10385
6 Exterior mirror 10388
6 1 Assembly overview – exterior mirror 10388
6 1 1 Assembly overview – exterior mirror, manual operation 10388
6 1 2 Assembly overview – exterior mirror, electric operation 10389
6 2 Removing and installing exterior mirror 10391
6 2 1 Removing and installing exterior mirror, manually operated 10391
6 2 2 Removing and installing exterior mirror, electrically operated 10393
6 3 Removing and installing mirror glass 10396
6 4 Removing and installing mirror adjustment unit 10398
6 5 Removing and installing mirror cover 10400
6 5 1 Removing and installing mirror cover, exterior mirror without turn signal repeater 10400
6 5 2 Removing and installing mirror housing, exterior mirror with turn signal repeater 10401
6 6 Removing and installing mirror trim 10403
6 6 1 Removing and installing mirror trim, exterior mirror without turn signal repeater 10403
6 6 2 Removing and installing mirror trim, exterior mirror with turn signal repeater 10404
7 Wheel housing liner 10407
7 1 Assembly overview – front wheel housing liner 10407
7 2 Assembly overview – rear wheel housing liner 10408
7 3 Removing and installing front wheel housing liner 10408
7 4 Removing and installing rear wheel housing liner 10410
8 Lettering and badges 10413
8 1 Assembly overview – lettering and badges 10413
8 2 Dimensions – lettering and badges on rear 10414
8 2 1 Dimensions for lettering, model designation 10414
8 2 2 Dimensions for lettering, engine type 10414
8 2 3 Dimensions for lettering, additional designations 10415
8 2 4 Dimensions for “GLI” lettering 10415
8 2 5 Dimensions for “HYBRID” and “SPORT” lettering 10416
8 2 6 Removing and installing badge on rear lid 10416
8 3 Dimensions – lettering and badges on sides 10418
8 3 1 Dimensions – lettering on wing “MATCH”, “LIFE” and “sochiEDITION” 10418
8 3 2 Dimensions – lettering on wing, “GTI” 10418
8 3 3 Dimensions – lettering on wing, “HYBRID” 10419
8 3 4 Dimensions – lettering on wing, “AVENUE” 10419
8 4 Removing and installing badges at vehicle front 10419
8 5 Removing and installing lettering 10420
9 Support tool 10422
9 1 Assembly overview – towing bracket 10422
9 2 Removing and installing towing bracket 10422
D4B8046FED6 Heating air conditioning system 10425
00 – Technical data 10431
1 Safety information 10431
1 1 Safety precautions when working on air conditioning systems 10431
1 2 Safety measures for working on vehicles with high-voltage system 10431
1 3 Safety precautions when working in the vicinity of high-voltage components 10432
1 4 Safety measures when working on vehicles with a start/stop system 10433
1 5 Safety precautions when using testers and measuring instruments during a road test 10433
1 6 Safety precautions when working on the cooling system 10433
1 7 Safety precautions when handling refrigerants 10433
1 8 Safety precautions for working on vehicles with auxiliary/supplementary heater 10434
2 General information 10436
2 1 Type plates 10436
2 1 1 Identification plate with capacities for refrigerant R134a and refrigerant oil 10436
2 1 2 Identification plate with capacities for refrigerant R1234yf and refrigerant oil 10436
2 2 Notes concerning odours in air conditioned vehicles 10437
2 3 Notes for vehicles with start-stop system 10438
2 4 Notes on dust and pollen filter 10439
3 Repair notes 10440
3 1 Rules for cleanliness 10440
3 2 Nuts and bolts 10440
3 3 Checking heater output 10441
3 4 Checking cooling output 10443
3 5 Working on refrigerant circuit 10445
3 6 Paint work on vehicles with air conditioning system 10446
3 7 Refrigerant circuit seals 10446
4 Technical data 10447
4 1 Refrigerant capacity 10447
4 2 Refrigerant oil capacities 10447
4 3 Oil distribution 10448
80 – Heating 10449
1 Overview of fitting locations – heating 10449
1 1 Overview of fitting locations – components not located in passenger compartment 10449
1 2 Overview of fitting locations – components located in front section of passenger compartment 10450
2 Heater 10451
2 1 Assembly overview – heater unit 10451
2 2 Removing and installing flexible shafts 10453
2 2 1 Removing and installing flexible shaft for air distribution 10453
2 2 2 Checking flexible shaft for air distribution 10454
2 2 3 Removing and installing Bowden cable for temperature flap 10455
3 Control motors 10458
3 1 Removing and installing fresh air and air recirculation flap control motor -V154- 10458
4 Air duct 10459
5 Operating and display unit 10460
5 1 Overview of operating and display unit 10460
5 2 Removing and installing operating and display unit 10462
5 2 1 Removing and installing front part of operating and display unit 10462
5 2 2 Removing and installing rear part of operating and display unit 10463
6 Other controlling and regulating components 10465
87 – Air conditioning system 10466
1 Overview of fitting locations – air conditioning system 10466
1 1 Overview of fitting locations – components not located in passenger compartment 10466
1 2 Overview of fitting locations – components located in front section of passenger compartment 10468
2 Refrigerant circuit 10471
2 1 System overview – refrigerant circuit 10471
2 2 Assembly overview – condenser 10473
2 3 Removing and installing high-pressure sender -G65- 10474
2 4 Removing and installing expansion valve 10475
2 5 Removing and installing condenser 10480
2 6 Removing and installing desiccant bag or cartridge 10483
2 7 Removing and installing evacuating and charging valves on low and high-pressure side 10486
2 8 Removing and installing refrigerant line from condenser to evaporator 10488
2 9 Removing and installing refrigerant line from condenser to air conditioner compressor 10492
2 9 1 Removing and installing refrigerant line from condenser to air conditioner compressor 10492
2 9 2 Removing and installing refrigerant line from condenser to electrical air conditioner compressor -V470- 10495
2 10 Removing and installing refrigerant line from air conditioner compressor to evaporator 10499
2 10 1 Removing and installing refrigerant line from air conditioner compressor to evaporator 10499
2 10 2 Removing and installing refrigerant line from electrical air conditioner compressor -V470- to evaporator 10503
3 Air conditioner compressor 10508
3 1 Assembly overview – drive unit of air conditioner compressor 10508
3 1 1 Assembly overview – air conditioner compressor 10508
3 1 2 Assembly overview – electrical air conditioner compressor -V470- 10508
3 2 Removing air conditioner compressor from and installing on bracket 10509
3 2 1 Removing air conditioner compressor from and installing on bracket 10509
3 2 2 Removing electrical air conditioner compressor -V470- from and attaching to bracket 10511
3 3 Removing and installing air conditioner compressor 10513
3 3 1 Removing and installing air conditioner compressor 10513
3 3 2 Removing and installing electrical air conditioner compressor -V470- 10519
3 4 Checking high-pressure safety valve on air conditioner compressor 10522
4 Control motors 10524
4 1 Overview of fitting locations – control motors at front 10524
4 1 1 Overview of fitting locations – front control motors, air conditioning system with electric and manual controls 10524
4 1 2 Overview of fitting locations – front control motors, Climatronic 10525
4 2 Removing and installing temperature flap control motor -V68- 10526
4 3 Removing and installing centre flap control motor -V70- 10528
4 4 Removing and installing defroster flap control motor -V107- 10529
4 5 Removing and installing air recirculation flap control motor -V113- 10531
4 6 Removing and installing left temperature flap control motor -V158- 10535
4 7 Removing and installing right temperature flap control motor -V159- 10537
4 8 Removing and installing fresh air/air recirculation, air flow flap control motor -V425- 10539
4 9 Removing and installing air distribution flap control motor -V428- 10542
5 Front heater and air conditioning unit 10543
5 1 Assembly overview – heater and air conditioning unit 10543
5 1 1 Assembly overview – heater and air conditioning unit, air conditioning system with electric/manual controls 10543
5 1 2 Assembly overview – heater and air conditioning unit, Climatronic 10545
5 2 Assembly overview – evaporator housing 10548
5 3 Removing and installing evaporator 10548
5 4 Checking auxiliary air heater element -Z35- 10550
5 5 Removing and installing auxiliary air heater element -Z35- 10553
5 5 1 Removing and installing auxiliary air heater element -Z35- (LHD) 10553
5 5 2 Removing and installing auxiliary air heater element -Z35- (RHD) 10555
5 6 Removing and installing heater and air conditioning unit 10557
5 7 Dismantling and assembling heater and air conditioning unit 10564
5 8 Removing and installing air distribution housing 10566
5 9 Removing and installing dust and pollen filter 10568
5 9 1 Removing and installing dust and pollen filter 10568
5 9 2 Removing and installing filter element for fresh air intake 10569
5 10 Removing and installing fresh air blower -V2- 10570
5 11 Removing and installing fresh air blower control unit -J126- 10571
5 12 Removing and installing heat exchanger 10572
5 12 1 Removing and installing heat exchanger, left-hand drive vehicles 10572
5 12 2 Removing and installing heat exchanger (RHD) 10579
5 13 Removing and installing coolant pipes on heat exchanger 10585
5 13 1 Removing and installing coolant pipes on heat exchanger, LHD vehicles 10585
5 13 2 Removing and installing coolant pipes on heat exchanger, RHD vehicles 10587
5 14 Removing and installing evaporator temperature sensor -G308- 10589
5 15 Removing and installing condensation drain 10590
5 16 Checking condensation drain 10590
5 17 Removing and installing baffle plate 10591
5 17 1 Removing and installing baffle plate, LHD vehicles 10591
5 17 2 Removing and installing baffle plate, RHD vehicles 10592
5 18 Removing and installing fresh air blower series resistor with overheating fuse -N24- 10592
6 Air duct 10594
6 1 Assembly overview – air duct and air distribution in passenger compartment 10594
6 2 Removing and installing driver side footwell vents 10596
6 2 1 Removing and installing driver side footwell vents, left-hand drive vehicles 10596
6 2 2 Removing and installing driver side footwell vents, right-hand drive vehicles 10596
6 3 Removing and installing front passenger side footwell vents 10597
6 3 1 Removing and installing front passenger side footwell vents, left-hand drive vehicles 10597
6 3 2 Removing and installing front passenger side footwell vents, right-hand drive vehicles 10598
6 4 Removing and installing rear footwell vent 10598
6 5 Installing plug in air duct to centre vent 10599
6 6 Removing and installing air ducts 10600
6 7 Removing and installing forced ventilation for passenger compartment 10601
6 8 Checking forced ventilation for passenger compartment 10602
6 9 Removing and installing fresh air intake 10602
6 10 Removing and installing intake duct 10603
6 11 Removing and installing air duct for defroster vent 10604
6 12 Removing and installing air duct for centre dash panel vent 10605
7 Operating and display unit 10606
7 1 Overview of operating and display unit 10606
7 1 1 Overview of control and display unit, air conditioning system with electric/manual controls 10606
7 1 2 Overview of operating and display unit, Climatronic 10608
7 2 Removing and installing operating and display unit 10610
8 Other controlling and regulating components 10613
8 1 Removing and installing sunlight penetration photosensor -G107- 10613
8 2 Working principles of air quality sensor -G238- 10614
8 3 Removing and installing air quality sensor -G238- 10616
8 4 Removing and installing ambient temperature sensor -G17- 10617
8 5 Removing and installing humidity sender for air conditioning system -G260- 10617
8 6 Removing and installing left vent temperature sender -G150- 10617
8 7 Removing and installing right vent temperature sender -G151- 10618
8 8 Removing and installing left footwell vent temperature sender -G261- 10619
8 9 Removing and installing right footwell vent temperature sender -G262- 10619
D4B8046FEDB Vehicle specific paint information 10621
00 – Technical data 10625
1 Explanation of symbols 10625
1 1 Sanding 10625
1 2 Seam seals 10625
1 3 Cavity sealing 10627
2 Paint structure 10628
2 1 Structure of factory finish, cathodic dip primer 10628
2 2 Structure of factory finish, filler-primer 10629
2 3 Structure of factory finish, base coat 10631
2 4 Structure of factory finish, clear coat 10634
3 Areas exposed to stone chipping 10637
3 1 Body areas exposed to stone chipping 10637
4 Masking areas 10638
4 1 Masking areas, front body 10638
4 2 Masking areas, middle body 10642
4 3 Masking areas, rear body 10643
5 Seam seals 10645
5 1 Seam seals, front body 10645
5 2 Seam seals, middle body 10650
5 3 Seam seals, rear body 10653
6 Undercoating 10663
6 1 Undercoated areas, front body 10663
6 2 Undercoated areas, middle body 10664
6 3 Undercoated areas, rear body 10665
7 Cavity sealing 10667
7 1 Cavity sealing, overview of body 10667
7 2 Cavity sealing, front body 10668
7 3 Cavity sealing, middle body 10668
7 4 Cavity sealing, rear body 10672
D4B8046FEDC Electrical system 10675
00 – Technical data 10683
1 Safety information 10683
1 1 Safety measures when working on vehicles with a start/stop system 10683
1 2 Safety precautions when using testers and measuring instruments during a road test 10683
1 3 Operation and safety notes for gas discharge lamps 10684
2 Repair notes 10686
2 1 Contact corrosion 10686
2 2 Routing and attachment of lines 10686
3 Battery 10687
3 1 Types of battery 10687
3 2 Battery – general notes 10687
3 2 1 Warning notices and safety regulations 10687
3 2 2 Battery terminal connection 10687
3 2 3 Battery recharging or jump start on vehicles with Start/Stop system 10687
27 – Starter, current supply, CCS 10688
1 Battery 10688
1 1 Assembly overview – battery 10688
1 1 1 Assembly overview – battery, without battery monitor control unit 10688
1 1 2 Assembly overview – battery, with battery monitor control unit 10690
1 1 3 Assembly overview – battery, high-voltage vehicle 10691
1 2 Removing and installing battery 10691
1 2 1 Removing and installing battery in engine compartment 10691
1 2 2 Removing and installing battery in luggage compartment, high-voltage vehicle 10693
1 2 3 Adapting battery 10694
1 3 Disconnecting and connecting battery 10694
1 3 1 Disconnecting and connecting battery, in engine compartment 10694
1 3 2 Disconnecting and connecting battery in luggage compartment, high-voltage vehicle 10696
1 4 Removing and installing battery tray 10698
1 4 1 Removing and installing battery tray in engine compartment 10698
1 4 2 Removing and installing battery tray in luggage compartment, high-voltage vehicle 10699
1 5 Checking battery 10700
1 6 Charging battery 10700
1 7 Removing and installing earth wire with battery monitor control unit -J367- 10700
1 7 1 Battery monitor control unit -J367- 10700
1 7 2 Renewing and commissioning battery monitor control unit -J367- 10700
1 7 3 Removing and installing battery monitor control unit -J367- in engine compartment 10701
1 7 4 Removing and installing battery monitor control unit -J367- in luggage compartment, high-voltage vehicle 10702
1 8 Adapting battery monitor control unit -J367- 10703
2 Alternator 10704
2 1 Assembly overview – alternator 10704
2 1 1 Assembly overview – alternator without sliding bushes 10704
2 1 2 Assembly overview – alternator with sliding bushes 10705
2 2 Removing and installing alternator 10706
2 2 1 Removing and installing alternator, vehicles with 1 2 l TSI engine 10706
2 2 2 Removing and installing alternator, vehicles with 1 4 l TSI engine 10708
2 2 3 Removing and installing alternator, vehicles with 1 6 l petrol engine 10711
2 2 4 Removing and installing alternator, vehicles with 2 0 l indirect injection engine 10713
2 2 5 Removing and installing alternator, vehicles with 1 8 l/2 0 l TSI engine 10715
2 2 6 Removing and installing alternator -C-, vehicles with 2 5 l petrol engine 10718
2 2 7 Removing and installing alternator, vehicles with diesel engine 10720
2 3 Checking alternator 10722
2 4 Checking poly V-belt 10722
2 5 Removing and installing poly V-belt pulley 10723
2 5 1 Removing and installing poly V-belt pulley, without freewheel 10723
2 5 2 Removing and installing Bosch poly V-belt pulley with freewheel 10724
2 5 3 Removing and installing Valeo poly V-belt pulley with freewheel 10725
2 5 4 Removing and installing poly V-belt pulley, decoupler pulley with freewheel 10728
2 6 Removing and installing voltage regulator 10730
2 6 1 Removing and installing Bosch voltage regulator -C1- 10730
2 6 2 Removing and installing Valeo voltage regulator -C1- 10731
3 Starter motor 10734
3 1 Assembly overview – starter 10734
3 1 1 Exploded view – starter (vehicles with manual gearbox) 10734
3 1 2 Assembly overview – starter, vehicles with automatic gearbox 10735
3 1 3 Assembly overview – starter (vehicles with dual clutch gearbox) 10736
3 2 Removing and installing starter motor 10736
3 2 1 Removing and installing starter, vehicle with manual gearbox 10736
3 2 2 Removing and installing starter, vehicles with automatic gearbox 10739
3 2 3 Removing and installing starter, vehicles with dual clutch gearbox 10742
3 3 Checking starter 10743
4 Cruise control system (CCS) 10744
5 Start/stop system 10745
5 1 General description – start/stop system 10745
5 2 Removing and installing voltage stabiliser 10747
5 2 1 Removing and installing voltage stabiliser -J532-, left-hand drive 10747
5 2 2 Removing and installing voltage stabiliser -J532-, right-hand drive models 10747
6 Adaptive cruise control 10748
6 1 Overview of fitting locations – adaptive cruise control 10748
6 1 1 Overview of fitting locations – adaptive cruise control 10748
6 2 Removing and installing automatic distance control unit 10749
6 2 1 Removing and installing adaptive cruise control unit -J428- together with retaining plate 10749
6 2 2 Removing and installing adaptive cruise control unit -J428-, with mounting plate 10750
6 2 3 Removing adaptive cruise control unit -J428- from and installing to adapter frame 10750
6 3 Calibrating adaptive cruise control 10752
90 – Gauges, instruments 10753
1 Dash panel insert 10753
1 1 Assembly overview – dash panel insert 10753
1 2 Removing and installing dash panel insert -KX2- 10754
1 2 1 Renewing dash panel insert -KX2- 10754
1 2 2 Removing and installing dash panel insert -KX2- 10754
1 3 Multi-pin connector pin assignment on dash panel insert 10755
1 4 Removing and installing ambient temperature sensor 10756
2 Horn 10757
2 1 Assembly overview – horn 10757
2 2 Removing and installing treble horn -H2- and bass horn -H7- 10757
92 – Windscreen wash/wipe system 10759
1 windscreen wiper system 10759
1 1 Assembly overview – windscreen wiper system 10759
1 2 Moving wipers to service position 10760
1 2 1 Moving wipers to service position 10760
1 2 2 Deactivating wiper motor control unit -J400- APP function 10760
1 3 Removing and installing wiper blade 10760
1 4 Removing and installing wiper arms 10761
1 5 Adjusting wiper arms 10763
1 6 Removing and installing wiper motor -V- 10764
1 6 1 Removing wiper frame with linkage and wiper motor -V- 10764
1 6 2 Removing and installing wiper motor -V- 10765
1 7 Removing and installing rain and light sensor 10767
1 8 Repairing rain and light sensor 10769
2 Windscreen washer system 10771
2 1 Assembly overview – windscreen washer system 10771
2 2 Removing and installing washer fluid reservoir 10772
2 2 1 Removing and installing filler neck 10772
2 2 2 Removing and installing washer fluid reservoir 10773
2 3 Removing and installing windscreen washer fluid level sender 10773
2 4 Removing and installing windscreen washer pump 10774
2 5 Removing and installing washer jets 10775
2 6 Adjusting spray jets 10775
3 Headlight washer system 10776
3 1 Assembly overview – headlight washer system 10776
3 2 Removing and installing headlight washer system pump -V11- 10776
3 3 Removing and installing washer jets 10777
3 4 Adjusting spray jets 10778
3 5 Removing and installing pop-up cylinder 10778
4 Washer fluid lines 10780
4 1 Repairing washer fluid lines 10780
94 – Lights, bulbs, switches – exterior 10781
1 Headlights 10782
1 1 Assembly overview – headlight 10782
1 1 1 Overview – headlights, halogen bulbs, halogen headlights 10783
1 1 2 Overview – headlights, gas discharge bulbs, cornering light, xenon headlights 10783
1 1 3 Assembly overview – headlights, dual halogen headlights, up to model year 2017 10783
1 1 4 Assembly overview – headlights, dual halogen headlights, as of model year 2017 10785
1 1 5 Assembly overview – headlights, gas discharge bulbs, cornering light, xenon headlights 10787
1 2 Removing and installing headlight 10788
1 3 Adjusting headlights 10789
1 3 1 Adjusting headlights, dual halogen headlights 10789
1 3 2 Adjusting headlights, xenon headlight 10789
1 3 3 Carrying out basic setting, xenon headlight 10790
1 4 Adjusting headlight installation position 10790
1 5 Removing and installing front turn signal bulb -M5-/-M7- 10791
1 5 1 Removing and installing front turn signal bulb, dual halogen headlights 10791
1 5 2 Removing and installing front turn signal bulb, xenon headlight 10792
1 6 Installing repair kit for headlight housing 10794
1 6 1 Repairing outer retaining tab 10794
1 6 2 Repairing centre retaining tab 10795
1 6 3 Repairing inner retaining tab 10796
1 6 4 Repairing lower retaining tab 10797
1 7 Converting headlights from driving on right to driving on left 10798
1 7 1 Changing headlights over from driving on right to driving on left (dual halogen headlights) 10798
1 7 2 Converting headlights from driving on right to driving on left, xenon headlights 10799
1 8 Converting headlights from driving on left to driving on right 10799
1 8 1 Changing headlights over from driving on left to driving on right (dual halogen headlights) 10799
1 8 2 Converting headlights from driving on left to driving on right, xenon headlights 10800
1 9 Removing and installing headlight range control motor -V48-/-V49- 10801
1 9 1 Headlight range control motor -V48-/-V49-, dual halogen headlights 10801
1 9 2 Headlight range control motor -V48-/-V49-, xenon headlights 10801
1 10 Removing and installing dipped beam bulb 10802
1 11 Removing and installing headlight main beam bulb -M30-/-M32- 10803
1 12 Removing and installing gas discharge bulb -L13-/-L14- 10804
1 13 Removing and installing side light bulb -M1-/-M3- 10806
1 14 Removing and installing daytime running light bulb -L174-/-L175- 10807
1 14 1 Removing and installing daytime running light bulb -L174-/-L175-, dual halogen headlights, up to model year 2017 10807
1 14 2 Removing and installing daytime running light bulb -L174-/-L175-, dual halogen headlights, as of model year 2017 10809
1 14 3 Removing and installing daytime running light bulb -L174-/-L175-, xenon headlights 10809
1 15 Removing and installing daytime running light 10809
1 15 1 Removing and installing LED module for daytime running light and side light, dual halogen headlights, as of model year 2017 10809
1 15 2 Removing and installing LED module for daytime running light and side light, xenon headlights 10809
1 16 Removing and installing headlight screen adjustment solenoid 10810
1 16 1 Removing and installing headlight screen adjustment solenoid 10810
1 16 2 Testing headlight screen adjustment solenoid 10810
1 17 Removing and installing swivel module position sensor -G474-/-G475- 10810
1 17 1 Removing and installing swivel module position sensor 10810
1 17 2 Checking swivel module position sensor 10810
1 18 Removing and installing bulbs for cornering light -L148-/-L149- 10810
1 19 Removing and installing gas discharge bulb control unit -J343-/-J344- 10812
1 20 Removing and installing output module for headlight -J667-/-J668- 10812
1 20 1 Removing and installing output module for headlights 10812
1 20 2 Checking power output module for headlight 10813
1 21 Removing and installing control unit for daytime running light and side light -J860-/-J861- 10813
2 Fog lights 10815
2 1 Assembly overview – fog lights 10815
2 1 1 Assembly overview – fog lights, Jetta 10815
2 1 2 Assembly overview – fog lights, Jetta GLI 10816
2 1 3 Assembly overview – fog lights, Jetta GLI, »model year 2015« 10817
2 2 Removing and installing fog light 10817
2 2 1 Removing and installing fog light, Jetta 10817
2 2 2 Removing and installing fog light, Jetta GLI 10819
2 2 3 Removing and installing fog light, Jetta GLI, »model year 2015« 10819
2 3 Removing and installing fog light bulb -L22-/-L23- 10820
2 3 1 Removing and installing fog light bulb 10820
2 4 Adjusting fog lights 10821
3 Side marker light 10822
3 1 Removing and installing side marking light bulb 10822
4 Lights in exterior mirror 10824
4 1 Assembly overview – lights in exterior mirror 10824
4 2 Removing and installing turn signal repeater bulb -L131-/-L132- 10825
4 3 Removing and installing entry light in exterior mirror 10826
5 Tail lights 10827
5 1 Assembly overview – tail lights in body 10827
5 1 1 Assembly overview – tail lights in vehicle body (bulbs) 10827
5 1 2 Assembly overview – tail lights in vehicle body (LEDs) 10828
5 2 Assembly overview – tail lights in rear lid 10829
5 2 1 Assembly overview – tail lights in rear lid (bulbs) 10829
5 2 2 Assembly overview – tail lights in rear lid (LEDs) 10830
5 3 Removing and installing bulb carrier 10831
5 3 1 Removing and installing tail light bulb carrier, tail light in body 10831
5 3 2 Removing and installing tail light bulb carrier, tail light in rear lid 10832
5 4 Removing and installing tail light in rear lid 10832
5 5 Removing and installing tail light 10833
5 6 Removing and installing tail light bulb -M2-/-M4- 10833
5 7 Removing and installing rear fog light 10834
5 8 Removing and installing brake and tail light bulb -M21-/-M22- 10834
5 9 Removing and installing reversing light bulb 10835
5 9 1 Removing and installing reversing light bulb (conventional bulb) 10835
5 9 2 Removing and installing reversing light bulb (LED) 10835
5 10 Removing and installing turn signal bulb 10836
5 10 1 Removing and installing turn signal bulb (conventional bulb) 10836
5 10 2 Removing and installing turn signal bulb (LED) 10836
6 High-level brake light 10838
6 1 Assembly overview – high-level brake light 10838
6 2 Removing and installing additional brake light 10838
6 3 Removing and installing high-level brake light 10839
7 Number plate light 10840
7 1 Removing and installing number plate light -X4-/-X5- 10840
7 2 Removing and installing bulb for number plate light -X4-/-X5- 10840
8 Entry and start authorisation system 10841
8 1 Overview of fitting locations – entry and start authorisation system 10841
8 1 1 Overview of fitting locations – entry and start authorisation system 10841
8 1 2 Overview – entry and start authorisation system 10843
8 2 Removing and installing entry and start authorisation control unit -J518- 10844
8 2 1 Removing and installing (left-hand drive models) entry and start authorisation control unit -J518- 10844
8 2 2 Removing and installing entry and start authorisation control unit -J518-, right-hand drive 10844
8 2 3 Coding entry and start authorisation control unit -J518- 10845
8 3 Removing and installing interior aerial 1 for entry and start authorisation -R138- 10846
8 4 Removing and installing interior aerial 2 for entry and start authorisation -R139- 10846
8 5 Removing and installing front passenger side aerial for entry and start system -R135- 10847
8 6 Removing and installing driver side aerial for entry and start system -R134- 10847
8 7 Removing and installing luggage compartment aerial for entry and start system -R137- 10847
8 8 Removing and installing rear bumper aerial for entry and start system -R136- 10848
8 9 Checking entry and start system aerials and sensors 10849
8 9 1 Checking driver side aerial for entry and start authorisation -R134- 10849
8 9 2 Checking front passenger side aerial for entry and start authorisation -R135- 10849
8 9 3 Checking rear bumper aerial for entry and start authorisation -R136- 10849
8 9 4 Checking luggage compartment aerial for entry and start authorisation -R137- 10849
8 9 5 Checking interior aerial 1 for entry and start authorisation -R138- 10850
8 9 6 Checking interior aerial 2 for entry and start authorisation -R139- 10850
8 9 7 Checking driver door exterior handle contact sensor -G415- 10850
8 9 8 Checking front passenger door exterior handle contact sensor -G416- 10850
9 Steering column switch module 10851
9 1 Assembly overview – steering column switch module 10851
9 1 1 Assembly overview – steering column switch module, Valeo 10851
9 1 2 Assembly overview – steering column switch module, Kostal 10853
9 1 3 Assembly overview – steering column switch module, interface for entry and start system 10853
9 2 Removing and installing steering column electronics control unit -J527- 10854
9 2 1 Removing and installing steering column electronics control unit -J527-, Valeo 10854
9 2 2 Removing and installing steering column electronics control unit -J527-, Kostal 10857
9 2 3 Coding steering column electronics control unit -J527- 10859
9 3 Removing and installing steering column combination switch 10859
9 3 1 Removing and installing steering column combination switch -E595-, Valeo 10859
9 3 2 Removing and installing steering column combination switch -E595-, Valeo, interface for entry and start system 10862
9 3 3 Removing and installing steering column combination switch -E595-, Kostal 10864
9 3 4 Removing and installing steering column combination switch -E595-, Kostal, interface for entry and start system 10867
9 4 Removing and installing base for steering column combination switch 10869
9 4 1 Removing and installing steering column switch base, Valeo 10869
9 4 2 Removing and installing steering column switch base, Valeo, interface for entry and start system 10871
9 4 3 Removing and installing steering column switch base, Kostal 10873
9 4 4 Removing and installing steering column switch base, Kostal, interface for entry and start system 10875
9 5 Removing and installing electronic steering column lock control unit -J764- 10877
9 5 1 Removing and installing electronic steering column lock control unit -J764- 10877
9 5 2 Renewing electronic steering column lock control unit -J764- 10878
9 6 Removing and installing ignition/starter switch 10878
9 7 Checking ignition/starter switch 10879
9 8 Removing and installing lock cylinder 10880
9 9 Removing and installing steering lock housing 10882
9 10 Removing and installing ignition key withdrawal lock solenoid -N376- 10882
10 Parking aid 10884
10 1 Assembly overview – parking aid 10884
10 1 1 Assembly overview – parking aid, left-hand drive vehicles 10884
10 1 2 Assembly overview – parking aid, right-hand drive vehicles 10886
10 2 Removing and installing parking aid control unit -J446- 10887
10 2 1 Removing and installing parking aid control unit -J446-, left-hand drive vehicle 10887
10 2 2 Removing and installing parking aid control unit -J446-, RHD vehicle 10888
10 3 Removing and installing front parking aid warning buzzer -H22- 10888
10 3 1 Removing and installing front parking aid warning buzzer -H22-, LHD vehicles 10888
10 3 2 Removing and installing front parking aid warning buzzer -H22-, RHD vehicles 10889
10 4 Removing and installing rear parking aid warning buzzer -H15- 10889
10 4 1 Removing and installing rear parking aid warning buzzer -H15- 10889
10 4 2 Adjusting volume of rear parking aid warning buzzer -H15- 10890
10 4 3 Adjusting pitch of rear parking aid warning buzzer pitch -H15- 10890
10 5 Removing and installing front parking aid senders 10890
10 5 1 Removing and installing front parking aid senders 10890
10 5 2 Bonding sender retainer in front bumper cover 10892
10 5 3 Renewing front parking aid senders 10893
10 5 4 Repairing sender retainer in front bumper cover 10894
10 6 Removing and installing rear parking aid senders 10894
10 6 1 Removing and installing rear parking aid senders 10894
10 6 2 Bonding sender retainer in rear bumper cover 10896
10 6 3 Renewing parking aid senders 10897
10 6 4 Repairing sender retainers in rear bumper cover 10898
11 Main beam assist 10899
11 1 Overview – main beam assist 10899
11 2 Overview of fitting locations – main beam assist 10899
11 3 Removing and installing main beam assist control unit -J844- 10900
11 4 Renewing main beam assist control unit -J844- 10901
11 5 Coding main beam assist control unit -J844- 10901
11 6 Removing and installing light sensor -G399- 10901
12 Automatic headlight range control 10902
12 1 Assembly overview – automatic headlight range control 10902
12 1 1 Assembly overview – automatic headlight range control, LHD vehicles 10902
12 1 2 Assembly overview – automatic headlight range control, RHD vehicles 10903
12 2 Removing and installing headlight range control unit 10903
12 2 1 Removing and installing control unit for cornering light and headlight range control -J745-, LHD vehicles 10903
12 2 2 Removing and installing control unit for cornering light and headlight range control -J745-, RHD vehicles 10904
13 Towing bracket 10905
13 1 Assembly overview – towing bracket socket 10905
13 2 Removing and installing trailer detector control unit -J345- 10905
13 3 Trailer socket 10906
14 Blind Spot Monitor 10908
14 1 Assembly overview – blind spot monitor 10908
14 2 Removing and installing warning lamp for Blind Spot Monitor -K303-/-K304- 10908
14 3 Removing and installing blind spot monitor control unit -J1086-/-J1087- 10909
14 4 Calibrating Blind Spot Monitor 10910
14 4 1 Measurement location 10910
14 4 2 Preparatory measures for calibration 10911
14 4 3 Calibrating blind spot monitor control unit -J1086-/-J1087- 10915
96 – Lights, bulbs, switches – interior 10917
1 Lights 10917
1 1 Overview of fitting locations – lights in dash panel 10917
1 2 Overview of fitting locations – lights in luggage compartment 10919
1 3 Overview of fitting locations – lights in roof trim 10920
1 4 Removing and installing glove compartment light -W6- 10920
1 5 Removing and installing Central locking SAFELOCK function warning lamp -K133- 10922
1 6 Removing and installing luggage compartment light -W3- 10923
1 7 Removing and installing illuminated vanity mirror -W20-/-W14- 10924
1 8 Renewing front interior light bulb -W1-/-W13-/-W19- 10925
1 9 Removing and installing centre reading lights 10927
1 10 Renewing bulb of rear interior light -W47-/-W48- 10927
2 Controls 10930
2 1 Overview of fitting locations – controls in dash panel 10931
2 2 Overview of fitting locations – controls in front doors 10932
2 3 Overview of fitting locations – controls in rear doors 10933
2 4 Overview of fitting locations – controls in centre console 10934
2 5 Overview of fitting locations – controls in roof trim 10935
2 6 Removing and installing rotary light switch -EX1- 10935
2 7 Removing and installing regulator for switch and instrument illumination -E20- 10937
2 8 Removing and installing tyre pressure monitor display button -E492- 10938
2 9 Removing and installing rear ear interior locking switch -E273-/-E274- 10939
2 10 Removing and installing driver side interior locking button for central locking system -E308- 10940
2 11 Removing and installing front passenger side interior locking button for central locking system -E309- 10941
2 12 Removing and installing remote release button for fuel filler flap and rear lid -E463- 10942
2 13 Removing and installing Start/Stop operation button -E693- 10943
2 14 Removing and installing TCS and ESP button -E256- 10944
2 15 Removing and installing parking aid button -E266- 10944
2 16 Removing and installing the starter button -E378- 10944
2 17 Removing and installing button for electric drive -E656-, high-voltage vehicle 10945
2 18 Removing and installing front passenger side airbag deactivated warning lamp -K145- 10945
2 19 Removing and installing hazard warning light button -E229- 10946
2 20 Removing and installing glove compartment light switch -E26- 10946
2 21 Removing and installing mirror adjustment switch -E43-/-E168- 10947
2 22 Removing and installing operating unit for window regulator in driver door -E512- 10948
2 23 Removing and installing window regulator switch in front passenger door -E107- 10949
2 24 Removing and installing interior monitoring deactivation switch -E267- 10951
2 25 Removing and installing rear window regulator button -E700-/-E705- 10952
2 26 Removing and installing rear lid contact switch 10953
2 26 1 Removing and installing rear lid locking unit -F256- 10953
2 27 Removing and installing sunroof button -E325- 10953
2 28 Removing and installing front interior light/reading light 10954
2 28 1 Removing and installing front interior light -W1-, vehicle with no sliding sunroof 10954
2 28 2 Removing and installing front interior light -W1-, vehicle with sliding sunroof 10955
2 29 Removing and installing rear interior light/reading light 10956
2 30 Removing and installing garage door operating unit -E284- 10957
3 Anti-theft alarm 10959
3 1 Assembly overview – interior monitor 10959
3 2 Activating and deactivating anti-theft alarm 10960
3 3 Central locking and anti-theft alarm system aerial -R47- 10961
3 4 Removing and installing alarm horn -H12- 10961
3 5 Removing and installing interior monitoring sensor -G273- 10962
3 6 Removing and installing bonnet contact switch -F266- 10962
3 7 Adaptations of anti-theft alarm system 10962
3 7 1 Adapting alarm delay on opening driver door 10962
3 7 2 Adapting country setting for alarm horn -H12- 10963
4 Immobiliser 10964
4 1 Removing and installing immobiliser control unit 10964
4 1 1 Overview – immobiliser, generation IV 10964
4 1 2 Removing and installing immobiliser control unit, 5th generation immobiliser 10965
4 1 3 Removing and installing immobiliser control unit -J362- 10965
4 1 4 Adapting immobiliser control unit -J362- 10965
4 1 5 New identity on renewing all components 10966
4 1 6 Online system test 10966
4 2 Removing and installing immobiliser reader coil 10966
4 3 Ignition key 10966
4 3 1 Removing and installing battery of ignition key with remote control 10966
4 3 2 Ignition key – variable code transponder 10966
4 3 3 Loss of an ignition key 10966
4 3 4 Adapting ignition key to immobilizer 10967
4 3 5 Checking ignition key with remote control 10967
5 Cigarette lighter, socket 10968
5 1 Removing and installing AC/DC converter with socket 10968
97 – Wiring 10971
1 Relay carriers, fuse holders, electronics boxes 10971
1 1 Overview of fitting locations – relay carriers, fuse holders, E-boxes 10971
1 2 Removing and installing electronics box (E-box) 10972
1 3 Removing and installing relay and fuse holder in electronics box 10973
1 4 Removing and installing relay and fuse holder behind dash panel on driver side 10974
1 4 1 Removing and installing fuse holder behind dash panel on driver side 10974
1 4 2 Removing and installing onboard supply control unit -J519- 10975
1 5 Removing and installing fuse holder on battery, high-voltage vehicle 10976
2 Select Control units 10977
2 1 Overview of fitting locations – control units 10977
2 2 Removing and installing onboard supply control unit -J519- 10978
2 2 1 Description of onboard supply control unit -J519- 10978
2 2 2 Removing and installing onboard supply control unit -J519-, High version 10980
2 2 3 Removing and installing onboard supply control unit -J519-, Low version 10981
2 2 4 Renewing onboard supply control unit -J519- 10982
2 2 5 Final control diagnosis of onboard supply control unit -J519- 10982
2 2 6 Coding onboard supply control unit -J519- 10983
2 2 7 Deactivating factory mode of onboard supply control unit -J519- 10983
2 2 8 Adapting remote control unit key 10983
2 2 9 Checking remote control unit key 10983
2 2 10 Coding rain and light sensor -G397- 10983
2 3 Removing and installing data bus diagnostic interface -J533- 10984
2 3 1 Description of data bus diagnostic interface -J533- 10984
2 3 2 Renewing data bus diagnostic interface -J533- 10984
2 3 3 Removing and installing data bus diagnostic interface -J533-, LHD, High version 10985
2 3 4 Removing and installing data bus diagnostic interface -J533-, RHD, High version 10985
2 3 5 Coding data bus diagnostic interface -J533- 10986
2 3 6 Checking bus activity of data bus diagnostic interface -J533- 10986
2 3 7 Adapting bus subscriber of data bus diagnostic interface -J533- 10986
2 4 Removing and installing garage door operation control unit 10986
3 Connectors 10987
3 1 Separating left door connector 10987
3 1 1 Separating A-pillar door connector 10987
3 1 2 Separating B-pillar door connector 10987
3 2 Separating right door connector 10988
3 2 1 Separating A-pillar door connector 10988
3 2 2 Separating B-pillar door connector 10988
3 3 Repairing electrical wiring harnesses and plug-in connections 10988
4 Releasing and dismantling connector housings 10989
5 Repairing aerial cables 10990
6 Fibre optic cables 10991
7 Vehicle diagnosis, testing and information systems 10992
D4B8046FEDD Communication 10993
00 – Technical data 10997
1 Repair instructions 10997
1 1 General repair instructions 10997
1 2 Notes on repair of CAN bus wiring 10997
91 – Communication 10998
1 Infotainment system 10998
1 1 Overview of fitting locations – Infotainment system 10998
1 2 Removing and installing magnetic field sender for compass 10998
2 Sound system 11000
2 1 Components of sound system 11000
2 1 1 Components of sound system, 4 loudspeakers 11000
2 1 2 Components of sound system, 6 loudspeakers 11002
2 1 3 Components of sound system, 8 loudspeakers 11003
2 1 4 Components of sound system, Volkswagen Sound 11004
2 1 5 Components of sound system, branded sound 11005
2 2 Overview of fitting locations – sound system 11006
2 3 Removing and installing amplifier -R12- for digital sound package 11006
2 3 1 Removing and installing amplifier -R12- 11006
2 3 2 Removing and installing retainer for amplifier -R12- 11007
2 4 Removing and installing rear treble loudspeakers -R14-/-R16- 11008
2 5 Removing and installing front treble loudspeakers -R20-/-R22- 11009
2 6 Removing and installing rear bass loudspeakers -R15-/-R17- 11009
2 7 Removing and installing front bass loudspeakers -R21-/-R23- 11010
2 8 Removing and installing subwoofer -R211- 11011
2 9 Pin assignments 11011
2 10 Renewing rotary knobs of display unit for front information display and operating unit control unit -J685- 11015
3 Aerial systems 11016
3 1 Components of aerial systems 11016
3 2 Overview of fitting locations – aerial systems 11016
3 3 Removing and installing frequency modulation (FM) frequency filter R178/R179 11017
3 3 1 Removing and installing frequency modulation (FM) frequency filter in negative wire -R178- 11017
3 3 2 Removing and installing frequency modulation (FM) frequency filter in positive wire -R179- 11018
3 4 Removing and installing aerial amplifier -R24-/aerial amplifier 2 -R111- 11018
3 5 Removing and installing roof aerial 11019
3 6 Removing and installing vehicle location system aerial 1 -R259- and vehicle location system aerial 2 -R260- 11020
4 Radio 11022
4 1 Components of radio system 11022
4 2 Overview of fitting locations – radio 11044
4 3 Assembly overview – radio 11046
4 4 Removing and installing radio 11046
4 4 1 Removing and installing radio, any versions except for Composition Colour and Composition Media 11046
4 4 2 Removing and installing radio, only Composition Colour and Composition Media 11048
4 5 Pin assignments 11050
4 5 1 Pin assignments, RCD 210 11050
4 5 2 Pin assignments, RCD 030+ 11052
4 5 3 Pin assignments, RCD 310 11054
4 5 4 Pin assignments, RCD 300+ 11056
4 5 5 Pin assignments, Premium 8 11059
4 5 6 Pin assignments, RCD 510 11061
4 5 7 Pin assignments, RCD 510+ 11064
4 5 8 Connector pin assignment, RCD 320G 11067
4 5 9 Connector pin assignment, RCD 330G 11069
4 5 10 Connector pin assignment, Composition Colour 11071
4 5 11 Connector pin assignment, Composition Media 11074
5 Telephone system 11077
5 1 Components of telephone system 11077
5 1 1 Components of telephone system, UTP High with Bluetooth 11077
5 1 2 Components of telephone system, UTP Premium with Bluetooth and audio streaming 11078
5 1 3 Components of telephone system, UTP in radio RNS 315 11079
5 1 4 Components of telephone, UMI 11080
5 1 5 Components of telephone, Bluetooth hands-free system 11082
5 1 6 Components of telephone, Bluetooth car phone online 11082
5 2 Overview of fitting locations – telephone system 11083
5 2 1 Overview of fitting locations – telephone system 11083
5 2 2 Overview of fitting locations – telephone system, UMI 11085
5 2 3 Overview of fitting locations – telephone system, Bluetooth hands-free system, Bluetooth car phone online 11085
5 3 Removing and installing telephone microphone -R38- 11086
5 4 Removing and installing telephone bracket -R126- 11086
5 5 Removing and installing telephone transmitter and receiver unit 11087
5 6 Removing and installing mobile telephone operating electronics control unit -J412-, UMI 11089
5 6 1 Removing and installing mobile telephone operating electronics control unit -J412-, UMI control unit on glove compartment 11089
5 6 2 Removing and installing mobile telephone operating electronics control unit -J412-, UMI control unit in centre console 11089
5 7 Removing and installing operating unit for preparation for mobile phone 11090
5 8 Pin assignments 11091
5 8 3 Connector pin assignment, Bluetooth hands-free system, Bluetooth car phone online 11094
6 Navigation system 11096
6 1 Components of navigation system 11096
6 1 4 Components of navigation system, Discover Media 11103
6 2 Overview of fitting locations – navigation system 11103
6 3 Pin assignments 11105
6 3 1 Pin assignments, RNS 315 11105
6 3 2 Pin assignments, RNS 315+ 11107
6 3 3 Pin assignments, RNS 510 11109
6 3 4 Connector pin assignment, Discover Media 11112
6 4 Removing and installing control unit for navigation system 11112
6 4 1 Removing and installing control unit with display for radio and navigation -J503- 11112
6 4 2 Removing and installing control unit for navigation system, Discover Media 11114
6 5 Removing and installing control unit for vehicle location system 11114
7 Reversing camera 11116
7 1 Components of reversing camera system 11116
7 2 Overview of fitting locations – reversing camera system 11116
7 3 Removing and installing reversing camera -R189- 11117
8 Multifunction steering wheel 11119
8 1 Components of multifunction steering wheel 11119
8 2 Assembly overview – multifunction steering wheel 11119
8 3 Removing and installing steering wheel multifunction buttons -E441-/-E440- 11120
8 4 Removing and installing Tiptronic switch in steering wheel -E439-/-E438- 11121
9 Connection for external multimedia devices 11123
9 1 Components of connection for external multimedia units 11123
9 1 1 Components of connection for external multimedia devices, AUX-IN socket 11123
9 1 3 Components of connection for external multimedia devices, multimedia system control unit -J650- 11125
9 1 4 Components of connection for external multimedia devices, multimedia system control unit -J650-, UMI 11126
9 1 5 Components of connection for external multimedia devices, USB connection holder -R193- 11128
9 1 6 Components of connection for external multimedia devices, connection for external audio sources -R199- 11128
9 2 Connectors, connection for external multimedia devices 11129
9 2 2 Connectors, connection for external multimedia devices, connection 2 for external audio sources -R231- 11130
9 3 Removing and installing connection for external multimedia devices 11135
9 3 1 Removing and installing connection for external multimedia devices, AUX-In socket 11135
9 3 2 Removing and installing connection for external multimedia devices, connection 2 for external audio sources -R231- 11136
9 3 3 Removing and installing connection for external multimedia devices, multimedia system control unit -J650- 11136
9 3 4 Removing and installing connection for external multimedia devices, multimedia system control unit -J650-, UMI in glove compartment 11137
9 3 5 Removing and installing connection for external multimedia devices, multimedia system control unit -J650-, UMI in centre console 11138
9 3 6 Removing and installing connection for external multimedia devices, USB connection retainer -R193- 11139
9 3 7 Removing and installing connection for external multimedia devices, connection for external audio sources -R199- 11139
10 Car-Net 11141
10 1 Components of Car-Net 11141
10 1 1 Components of Car-Net, apart from PR no NZ3 (ERA GLONASS emergency call) 11141
10 1 2 Components of Car-Net, only PR no NZ3 (ERA GLONASS emergency call) 11142
10 2 Overview of fitting locations – Car-Net services 11144
10 2 1 Overview of fitting locations – Car-Net services apart from PR no NZ3 (ERA GLONASS emergency call) 11144
10 2 2 Overview of fitting locations – Car-Net services only PR no NZ3 (ERA GLONASS emergency call) 11145
10 3 Removing and installing emergency call module control unit and communication unit -J949- 11145
10 4 Removing and installing emergency button -E276- 11146
10 5 Removing and installing loudspeaker for emergency call module -R335- 11146
10 6 Removing and installing suppression filter -C10- 11147
10 7 Connectors of emergency call module control unit and communication unit -J949- 11148
D4B8047B932 4 cylinder injection engine (1 2 l 4V EA211 turbocharger) 11151
00 – Technical data 11157
1 Safety information 11157
1 1 Safety regulations for working on fuel supply 11157
1 2 Safety measures when working on vehicles with a start/stop system 11157
1 3 Safety precautions when using testers and measuring instruments during a road test 11158
1 4 Safety precautions when working on the cooling system 11158
1 5 Safety precautions when working on ignition system 11158
2 Identification 11159
2 1 Engine number/engine data 11159
3 Repair notes 11160
3 1 Rules for cleanliness 11160
3 2 Foreign bodies in engine 11160
3 3 Contact corrosion 11160
3 4 Routing and attachment of lines 11160
3 5 Fitting radiator and condensers 11161
10 – Removing and installing engine 11162
1 Removing and installing engine 11162
1 1 Removing engine 11162
1 2 Separating engine and gearbox 11175
1 3 Securing engine on engine and gearbox support 11176
1 4 Installing engine 11178
2 Assembly mountings 11181
2 1 Assembly overview – assembly mountings 11181
2 2 Removing and installing engine mounting 11184
2 3 Removing and installing gearbox mounting 11186
2 4 Removing and installing pendulum support 11188
2 5 Supporting engine in installation position 11188
2 6 Adjusting assembly mountings 11198
2 7 Checking adjustment of assembly mountings 11200
13 – Crankshaft group 11201
1 Cylinder block (pulley end) 11201
1 1 Assembly overview – poly V-belt drive 11201
1 1 1 Assembly overview – poly V-belt drive, vehicles without air conditioner compressor 11201
1 1 2 Assembly overview – poly V-belt drive, vehicles with air conditioner compressor 11203
1 2 Removing and installing poly-V belt 11205
1 2 1 Removing and installing poly V-belt, vehicles without air conditioner compressor 11205
1 2 2 Removing and installing poly V-belt, vehicles with air conditioner compressor 11207
1 3 Removing and installing tensioner for poly V-belt 11208
1 4 Removing and installing vibration damper 11209
1 5 Removing and installing engine support 11211
1 6 Renewing crankshaft oil seal – pulley end 11213
2 Cylinder block, gearbox end 11217
2 1 Assembly overview – cylinder block, gearbox end 11217
2 2 Removing and installing flywheel 11218
2 3 Removing and installing sealing flange on gearbox side 11219
3 Crankshaft 11230
3 1 Crankshaft dimensions 11230
3 2 Renewing needle bearing in crankshaft 11230
3 3 Measuring axial clearance of crankshaft 11233
4 Pistons and conrods 11235
4 1 Assembly overview – pistons and conrods 11235
4 2 Removing and installing pistons 11238
4 3 Checking pistons and cylinder bores 11239
4 4 Separating new conrod 11242
4 5 Checking radial clearance of conrods 11242
4 6 Removing and installing oil spray jets 11243
15 – Cylinder head, valve gear 11245
1 Cylinder head 11245
1 1 Assembly overview – cylinder head 11245
1 2 Assembly overview – camshaft housing 11247
1 3 Removing and installing cylinder head 11249
1 4 Removing and installing camshaft housing 11254
1 5 Checking compression 11258
2 Toothed belt drive 11261
2 1 Assembly overview – toothed belt cover 11261
2 2 Assembly overview – toothed belt 11261
2 3 Removing and installing toothed belt guard 11263
2 3 1 Removing and installing upper toothed belt guard 11263
2 3 2 Removing and installing lower toothed belt guard 11264
2 4 Removing and installing toothed belt 11264
2 5 Checking valve timing 11270
2 6 Adjusting valve timing 11278
2 7 Removing toothed belt from camshaft 11285
3 Valve gear 11290
3 1 Assembly overview – valve gear 11290
3 2 Measuring axial play of camshaft 11291
3 3 Removing and installing camshaft oil seal 11292
3 3 1 Removing and installing camshaft oil seal for inlet camshaft, belt pulley end 11292
3 3 2 Removing and installing exhaust camshaft oil seal, pulley end 11294
3 3 3 Removing and installing exhaust camshaft oil seal, gearbox end 11296
3 4 Removing and installing camshaft adjuster 11299
3 5 Removing and installing camshaft control valve 1 -N205- 11302
3 6 Removing and installing valve stem oil seals 11303
3 6 1 Removing and installing valve stem seals (cylinder head installed) 11303
3 6 2 Removing and installing valve stem seals (cylinder head removed) 11307
3 7 Removing and installing toothed belt pulley 11311
4 Inlet and exhaust valves 11314
4 1 Checking valve guides 11314
4 2 Checking valves 11315
4 3 Valve dimensions 11315
17 – Lubrication 11316
1 Sump, oil pump 11316
1 1 Assembly overview – sump/oil pump 11316
1 2 Engine oil: 11320
1 3 Removing and installing oil sump 11321
1 4 Removing and installing oil pump 11326
1 5 Removing and installing oil level and oil temperature sender -G266- 11329
2 Engine oil cooler 11330
2 1 Assembly overview – engine oil cooler 11330
2 2 Removing and installing engine oil cooler 11330
3 Crankcase ventilation 11332
3 1 Assembly overview – crankcase breather system 11332
3 2 Removing and installing oil separator 11333
4 Oil filter, oil pressure switch 11337
4 1 Assembly overview – oil filter/oil pressure switch 11337
4 2 Removing and installing oil pressure switch for reduced oil pressure -F378- 11337
4 3 Checking oil pressure and oil pressure switch 11338
4 4 Removing and installing oil filter housing 11340
19 – Cooling 11342
1 Cooling system/coolant 11342
1 1 Connection diagram – coolant hoses 11342
1 2 Checking cooling system for leaks 11344
1 3 Draining and adding coolant 11346
2 Coolant pump, regulation of cooling system 11356
2 1 Assembly overview – coolant pump, thermostat 11356
2 2 Assembly overview – electric coolant pump 11359
2 3 Assembly overview – coolant temperature sender 11360
2 4 Removing and installing electric coolant pump 11361
2 5 Removing and installing coolant pump 11363
2 6 Removing and installing thermostat 11369
2 6 1 Removing and installing thermostat for large cooling circuit 11369
2 6 2 Removing and installing thermostat for small cooling circuit 11371
2 7 Removing and installing toothed belt pulley for coolant pump 11372
2 8 Removing and installing coolant temperature sender -G62- 11374
2 9 Removing and installing radiator outlet coolant temperature sender -G83- 11376
3 Coolant pipes 11377
3 1 Assembly overview – coolant pipes 11377
3 2 Removing and installing coolant pipes 11377
4 Radiator, radiator fan 11381
4 1 Assembly overview – radiator/radiator fan 11381
4 2 Assembly overview – radiator cowl and radiator fan 11383
4 3 Removing and installing radiator 11384
4 4 Removing and installing water radiator for charge air cooling circuit 11385
4 5 Removing and installing radiator cowl 11388
4 6 Removing and installing radiator fan 11390
4 6 1 Removing and installing radiator fan -V7- 11390
4 6 2 Removing and installing radiator fan -V177- 11391
21 – Turbocharging/supercharging 11393
1 Turbocharger 11393
1 1 Assembly overview – turbocharger 11393
1 2 Removing and installing turbocharger 11395
1 3 Removing and installing charge pressure positioner -V465- 11399
2 Charge air system 11401
2 1 Assembly overview – charge air system 11401
2 2 Removing and installing charge air cooler 11404
2 3 Removing and installing charge pressure sender -GX26- 11406
2 4 Checking charge air system for leaks 11407
2 5 Removing and installing air intake pipe 11409
24 – Mixture preparation – injection 11411
1 Injection system 11411
1 1 Overview of fitting locations – injection system 11411
2 Injectors 11415
2 1 Assembly overview – fuel rail with injectors 11415
2 2 Removing and installing fuel rail 11417
2 3 Removing and installing injectors 11417
2 4 Cleaning injectors 11424
3 Air filter 11426
3 1 Assembly overview – air filter housing 11426
3 2 Removing and installing air filter housing 11427
3 3 Removing and installing resonator for intake air 11429
4 Intake manifold 11431
4 1 Assembly overview – intake manifold 11431
4 2 Removing and installing intake manifold 11433
4 3 Removing and installing throttle valve module -GX3- 11436
4 4 Cleaning throttle valve module -GX3- 11437
5 Senders and sensors 11439
5 1 Removing and installing intake manifold sender -GX9- 11439
5 2 Removing and installing fuel pressure sender -G247- 11439
5 3 Checking fuel pressure sender -G247- 11441
6 Engine/motor control unit 11444
6 1 Removing and installing engine control unit -J623- 11444
6 1 1 Removing and installing engine control unit -J623- without protective housing 11444
6 1 2 Removing and installing engine (motor) control unit -J623- with protective housing 11445
7 High-pressure pump 11448
7 1 Assembly overview – high-pressure pump 11448
7 1 1 Assembly overview – high-pressure pump, Hitachi 11448
7 1 2 Assembly overview – high-pressure pump, Continental 11449
7 1 3 Assembly overview – high-pressure pump, Bosch 11451
7 2 Removing and installing high-pressure pump 11452
7 3 Removing and installing high-pressure pipe 11454
8 Lambda probe 11457
8 1 Assembly overview – Lambda probe 11457
8 2 Removing and installing lambda probe 11458
8 2 1 Removing and installing Lambda probe 1 before catalytic converter -GX10- 11458
8 2 2 Removing and installing Lambda probe 1 after catalytic converter -GX7- 11459
26 – Exhaust system 11462
1 Exhaust pipes and silencers 11462
1 1 Assembly overview – silencers 11462
1 2 Separating exhaust pipes from silencers 11462
1 3 Removing and installing rear silencer 11464
1 4 Aligning exhaust system free of stress 11465
1 5 Checking exhaust system for leaks 11466
1 6 Installation position of clamp 11467
2 Emission control 11469
2 1 Assembly overview – emission control 11469
2 2 Removing and installing catalytic converter 11471
28 – Ignition system 11476
1 Ignition system 11476
1 1 Assembly overview – ignition system 11476
1 2 Test data, spark plugs 11478
1 3 Removing and installing ignition coils with output stage 11478
1 4 Removing and installing knock sensor 1 -G61- 11481
1 5 Removing and installing Hall sender -G40- 11481
1 6 Removing and installing engine speed sender -G28- 11482
D4B8047B934 4 cylinder injection engine (1 4 l 4V EA211 turbocharger) 11484
00 – Technical data 11490
1 Safety information 11490
1 1 Safety regulations for working on fuel supply 11490
1 2 Safety measures when working on vehicles with a start/stop system 11490
1 3 Safety precautions when using testers and measuring instruments during a road test 11491
1 4 Safety precautions when working on the cooling system 11491
1 5 Safety precautions when working on ignition system 11491
2 Identification 11492
2 1 Engine number/engine data 11492
3 Repair notes 11494
3 1 Rules for cleanliness 11494
3 2 Foreign bodies in engine 11494
3 3 Contact corrosion 11494
3 4 Routing and attachment of lines 11494
3 5 Fitting radiators and condensers 11495
10 – Removing and installing engine 11496
1 Removing and installing engine 11496
1 1 Removing engine 11496
1 2 Separating engine and gearbox 11509
1 3 Securing engine on engine and gearbox support 11511
1 4 Installing engine 11513
2 Assembly mountings 11517
2 1 Assembly overview – assembly mountings 11517
2 2 Removing and installing engine mounting 11520
2 3 Removing and installing gearbox mounting 11522
2 4 Removing and installing pendulum support 11523
2 5 Supporting engine in installation position 11524
2 6 Adjusting assembly mountings 11533
2 7 Checking adjustment of assembly mountings 11536
13 – Crankshaft group 11537
1 Cylinder block (pulley end) 11537
1 1 Assembly overview – poly V-belt drive 11537
1 1 1 Assembly overview – poly V-belt drive, vehicles without air conditioner compressor 11537
1 1 2 Assembly overview – poly V-belt drive, vehicles with air conditioner compressor 11539
1 2 Assembly overview – sealing flange, belt pulley end 11541
1 3 Removing and installing poly-V belt 11543
1 3 1 Removing and installing poly V-belt, vehicles without air conditioner compressor 11543
1 3 2 Removing and installing poly V-belt, vehicles with air conditioner compressor 11545
1 4 Removing and installing tensioner for poly V-belt 11547
1 5 Removing and installing vibration damper 11548
1 6 Removing and installing engine support 11550
1 7 Renewing crankshaft oil seal for pulley end 11553
1 8 Removing and installing sealing flange on pulley end 11556
2 Cylinder block, gearbox end 11559
2 1 Assembly overview – cylinder block, gearbox end 11559
2 2 Assembly overview – drive plate 11560
2 3 Removing and installing drive plate 11562
2 4 Removing and installing flywheel 11564
2 5 Removing and installing sealing flange on gearbox side 11565
3 Crankshaft 11576
3 1 Crankshaft dimensions 11576
3 2 Renewing needle bearing in crankshaft 11576
3 3 Measuring axial clearance of crankshaft 11579
4 Pistons and conrods 11581
4 1 Assembly overview – pistons and conrods 11581
4 2 Removing and installing pistons 11584
4 3 Checking pistons and cylinder bores 11585
4 4 Separating new conrod 11587
4 5 Checking radial clearance of conrods 11588
4 6 Removing and installing oil spray jets 11588
15 – Cylinder head, valve gear 11591
1 Cylinder head 11591
1 1 Assembly overview – cylinder head 11591
1 2 Assembly overview – camshaft housing 11593
1 2 1 Assembly overview – camshaft housing, vehicles without adjustable exhaust camshaft 11593
1 2 2 Assembly overview – camshaft housing, vehicles with adjustable exhaust camshaft 11595
1 3 Removing and installing cylinder head 11597
1 4 Removing and installing camshaft housing 11602
1 5 Checking compression 11607
2 Toothed belt drive 11610
2 1 Assembly overview – toothed belt cover 11610
2 2 Assembly overview – toothed belt 11611
2 2 1 Assembly overview – toothed belt, vehicles without adjustable exhaust camshaft 11611
2 2 2 Assembly overview – toothed belt, vehicles with adjustable exhaust camshaft 11613
2 3 Removing and installing toothed belt guard 11615
2 3 1 Removing and installing upper toothed belt guard 11615
2 3 2 Removing and installing lower toothed belt guard 11616
2 4 Removing and installing toothed belt 11616
2 4 1 Removing and installing toothed belt, vehicles without adjustable exhaust camshaft 11616
2 4 2 Removing and installing toothed belt, vehicles with adjustable exhaust camshaft 11623
2 5 Checking valve timing 11630
2 6 Adjusting valve timing 11637
2 6 1 Checking valve timing, vehicles without adjustable exhaust camshaft 11637
2 6 2 Checking valve timing, vehicles without adjustable exhaust camshaft 11645
2 7 Removing toothed belt from camshaft 11654
2 7 1 Removing toothed belt from camshaft, exhaust side with camshaft adjuster 11654
2 7 2 Removing toothed belt from camshaft, exhaust side with toothed belt pulley 11658
3 Valve gear 11664
3 1 Assembly overview – valve gear 11664
3 2 Measuring axial play of camshaft 11666
3 3 Removing and installing camshaft oil seal 11667
3 3 1 Removing and installing camshaft oil seal for inlet camshaft, belt pulley end 11667
3 3 2 Removing and installing exhaust camshaft oil seal, pulley end 11669
3 3 3 Removing and installing exhaust camshaft oil seal, gearbox end 11671
3 4 Removing and installing camshaft adjuster 11673
3 4 1 Removing and installing inlet camshaft adjuster, vehicles with adjustable exhaust camshaft 11673
3 4 2 Removing and installing inlet camshaft adjuster, vehicles without adjustable exhaust camshaft 11679
3 4 3 Removing and installing camshaft adjuster for exhaust camshaft 11684
3 5 Removing and installing camshaft control valve 1 -N205- 11690
3 6 Removing and installing exhaust camshaft control valve 1 -N318- 11691
3 7 Removing and installing valve stem oil seals 11692
3 7 1 Removing and installing valve stem seals (cylinder head installed) 11692
3 7 2 Removing and installing valve stem seals (cylinder head removed) 11697
3 8 Removing and installing toothed belt pulley 11702
4 Inlet and exhaust valves 11705
4 1 Checking valve guides 11705
4 2 Checking valves 11706
4 3 Valve dimensions 11706
17 – Lubrication 11707
1 Sump, oil pump 11707
1 1 Assembly overview – sump/oil pump 11707
1 2 Engine oil 11711
1 3 Removing and installing lower part of sump 11711
1 4 Removing and installing upper part of sump 11716
1 5 Removing and installing oil pump 11723
1 6 Removing and installing oil level and oil temperature sender -G266- 11724
2 Engine oil cooler 11726
2 1 Assembly overview – engine oil cooler 11726
2 2 Removing and installing engine oil cooler 11726
3 Crankcase breather 11728
3 1 Assembly overview – crankcase breather system 11728
3 2 Removing and installing oil separator 11729
4 Oil filter, oil pressure switch 11733
4 1 Assembly overview – oil filter/oil pressure switch 11733
4 2 Removing and installing oil pressure switch -F1- 11734
4 3 Removing and installing oil pressure switch for reduced oil pressure -F378- 11735
4 4 Checking oil pressure 11736
4 5 Removing and installing valve for oil pressure control -N428- 11738
19 – Cooling 11739
1 Cooling system/coolant 11739
1 1 Connection diagram – coolant hoses 11739
1 2 Assembly overview – engine preheater 11740
1 3 Checking cooling system for leaks 11741
1 4 Draining and adding coolant 11744
1 5 Removing and installing engine preheating element -Z97- 11753
2 Coolant pump, regulation of cooling system 11756
2 1 Assembly overview –coolant pump, thermostat 11756
2 2 Assembly overview – electric coolant pump 11759
2 3 Assembly overview – coolant temperature sender 11760
2 4 Removing and installing electric coolant pump 11761
2 4 1 Removing and installing charge air cooling pump -V188- 11761
2 5 Removing and installing coolant pump 11763
2 6 Removing and installing thermostat 11769
2 6 1 Removing and installing thermostat for main coolant circuit (radiator) 11769
2 6 2 Removing and installing thermostat for coolant circuit of cylinder block 11771
2 7 Removing and installing toothed belt pulley for coolant pump 11772
2 8 Removing and installing coolant temperature sender -G62- 11774
2 9 Removing and installing radiator outlet coolant temperature sender -G83- 11775
3 Coolant pipes 11777
3 1 Assembly overview – coolant pipes 11777
3 2 Removing and installing coolant pipes 11777
4 Radiator, radiator fan 11782
4 1 Assembly overview – radiator/radiator fan 11782
4 2 Assembly overview – radiator cowl and radiator fan 11784
4 3 Removing and installing radiator 11785
4 4 Removing and installing water radiator for charge air cooling circuit 11787
4 5 Removing and installing radiator cowl 11790
4 6 Removing and installing radiator fan -V7- 11792
4 7 Removing and installing radiator fan 2 -V177- 11793
21 – Turbocharging/supercharging 11794
1 Turbocharger 11794
1 1 Assembly overview – turbocharger 11794
1 1 1 Assembly overview – turbocharger, version 1 11794
1 1 2 Assembly overview – turbocharger, version 2 11795
1 1 3 Assembly overview – lines on turbocharger 11796
1 2 Removing and installing turbocharger 11798
1 3 Removing and installing charge pressure positioner -V465- 11804
1 3 1 Removing and installing charge pressure positioner -V465-, version 1 11804
1 3 2 Removing and installing charge pressure positioner -V465-, version 2 11806
1 4 Removing and installing connection for turbocharger 11808
2 Charge air system 11812
2 1 Assembly overview – charge air system 11812
2 2 Removing and installing charge air cooler 11815
2 3 Removing and installing charge pressure sender -GX26- 11818
2 4 Checking charge air system for leaks 11819
2 5 Removing and installing air intake pipe 11820
24 – Mixture preparation – injection 11823
1 Injection system 11823
1 1 Overview of fitting locations – injection system 11823
2 Injectors 11828
2 1 Assembly overview – fuel rail with injectors 11828
2 2 Removing and installing fuel rail 11830
2 3 Removing and installing injectors 11830
2 4 Cleaning injectors 11837
3 Air filter 11839
3 1 Assembly overview – air filter housing 11839
3 2 Removing and installing air filter housing 11840
3 3 Removing and installing resonator for intake air 11841
4 Intake manifold 11843
4 1 Assembly overview – intake manifold 11843
4 2 Removing and installing intake manifold 11845
4 3 Removing and installing throttle valve module -GX3- 11849
4 4 Cleaning throttle valve module -GX3- 11850
5 Senders and sensors 11852
5 1 Removing and installing fuel pressure sender -G247- 11852
5 2 Checking fuel pressure sender -G247- 11853
5 3 Removing and installing intake manifold sender -GX9- 11855
6 Engine/motor control unit 11857
6 1 Removing and installing engine/motor control unit -J623- 11857
6 1 1 Removing and installing engine control unit -J623- without protective housing 11857
6 1 2 Removing and installing engine (motor) control unit -J623- with protective housing 11858
7 High-pressure pump 11862
7 1 Assembly overview – high-pressure pump 11862
7 1 1 Assembly overview – high-pressure pump, Hitachi 11862
7 1 2 Assembly overview – high-pressure pump, Continental 11863
7 1 3 Assembly overview – high-pressure pump, Bosch 11865
7 2 Removing and installing high-pressure pump 11866
7 3 Removing and installing high-pressure pipe 11868
8 Lambda probe 11871
8 1 Assembly overview – lambda probe 11871
8 1 1 Assembly overview – lambda probe, engine codes CZCA, CZDA 11871
8 1 2 Assembly overview -lambda probe, engine code CZTA 11872
8 2 Removing and installing lambda probe 11873
8 2 1 Removing and installing Lambda probe 1 before catalytic converter -GX10- 11873
8 2 2 Removing and installing Lambda probe 1 after catalytic converter -GX7- 11875
26 – Exhaust system 11878
1 Exhaust pipes and silencers 11878
1 1 Assembly overview – silencers 11878
1 2 Separating exhaust pipes from silencers 11879
1 3 Removing and installing rear silencer 11880
1 4 Aligning exhaust system free of stress 11881
1 5 Checking exhaust system for leaks 11882
1 6 Installation position of clamp 11882
2 Emission control 11885
2 1 Assembly overview – emission control 11885
2 2 Removing and installing catalytic converter 11887
28 – Ignition system 11893
1 Ignition system 11893
1 1 Assembly overview – ignition system 11893
1 2 Test data, spark plugs 11895
1 3 Removing and installing ignition coils with output stage 11895
1 4 Removing and installing knock sensor 1 -G61- 11898
1 5 Removing and installing Hall sender 11898
1 5 1 Removing and installing Hall sender -G40- 11898
1 5 2 Removing and installing Hall sender 3 -G300- 11899
1 6 Removing and installing engine speed sender -G28- 11899
D4B8048BC6A 4 cylinder injection engine (1 4 l direct injection engine turbocharger and supercharger) 11902
00 – Technical data 11908
1 Safety instructions 11908
1 1 Safety precautions when working on fuel supply system 11908
1 2 Safety precautions during road tests in which test and measuring equipment is used 11909
1 3 Safety precautions when working on ignition system 11909
1 4 Safety precautions when working on cooling system 11910
2 Identification 11911
2 1 Engine number, engine data 11911
3 Repair instructions 11913
3 1 Rules for cleanliness 11913
3 2 Foreign objects in engine 11913
3 3 Contact corrosion 11913
3 4 Routing and securing lines 11913
3 5 Installing coolers, condensers and radiators 11913
10 – Removing and installing engine 11915
1 Removing and installing engine 11915
1 1 Removing engine 11915
1 2 Separating engine and gearbox 11923
1 3 Securing engine on engine and gearbox support 11924
1 4 Installing engine 11926
2 Assembly mountings 11929
2 1 Assembly overview – assembly mountings 11929
2 2 Removing and installing engine mountings 11931
2 3 Supporting engine in installation position 11936
2 4 Adjusting assembly mountings 11942
2 5 Checking adjustment of assembly mountings (engine and gearbox mountings) 11944
3 Engine cover panel 11945
3 1 Removing and installing engine cover panel 11945
13 – Crankshaft group 11946
1 Cylinder block (pulley end) 11946
1 1 Assembly overview – poly V-belt drive 11946
1 2 Assembly overview – cylinder block (pulley end) 11949
1 3 Removing and installing poly V-belt 11951
1 4 Removing and installing vibration damper 11952
1 5 Removing and installing ancillary bracket 11956
1 6 Renewing crankshaft oil seal – belt pulley end 11957
2 Cylinder block, gearbox end 11961
2 1 Assembly overview – cylinder block, gearbox end 11961
2 2 Removing and installing sealing flange on gearbox side 11962
3 Crankshaft 11972
3 1 Assembly overview – crankshaft 11972
3 2 Crankshaft dimensions 11973
3 3 Renewing needle bearing in crankshaft 11973
4 Pistons and conrods 11976
4 1 Assembly overview – pistons and conrods 11976
4 2 Checking piston and cylinder bore 11978
4 3 Separating new conrod 11979
4 4 Removing and installing pistons 11980
4 5 Removing and installing oil spray jets 11981
15 – Cylinder head, valve gear 11983
1 Cylinder head 11983
1 1 Assembly overview – cylinder head 11983
1 2 Removing and installing cylinder head 11985
1 3 Removing and installing camshaft housing 11986
1 4 Checking compression 11992
2 Cover for timing chain 11995
2 1 Removing and installing valve timing housing 11995
3 Chain drive 11998
3 1 Removing and installing timing chain and chain drive for oil pump 11998
3 2 Checking timing chain 12005
3 3 Checking valve timing 12013
3 4 Adjusting valve timing 12016
4 Valve gear 12024
4 1 Assembly overview – valve gear 12024
4 2 Measuring axial play of camshaft 12025
4 3 Removing and installing valve stem seals 12026
5 Inlet and exhaust valves 12029
5 1 Reworking valve seats 12029
5 2 Checking valve guides 12030
17 – Lubrication 12032
1 Sump, oil pump 12032
1 1 Assembly overview – sump and oil pump 12032
1 2 Engine oil 12033
1 3 Removing and installing sump 12034
1 4 Removing and installing oil pump 12038
2 Oil filter, oil pressure switch 12041
2 1 Checking oil pressure and oil pressure switch 12041
19 – Cooling 12043
1 Cooling system, coolant 12043
1 1 Coolant hose schematic diagram 12043
1 2 Checking cooling system for leaks 12043
1 3 Draining and filling coolant 12045
2 Coolant pump, regulation of cooling system 12051
2 1 Assembly overview – thermostat 12051
2 2 Removing and installing coolant circulation pump -V50- 12052
2 3 Removing and installing coolant pump 12053
2 4 Removing and installing coolant pump pulley 12058
3 Radiator and radiator fan 12063
3 1 Assembly overview – radiator and radiator fan 12063
3 2 Removing and installing radiator 12065
3 3 Removing and installing radiator cowling 12066
3 4 Removing and installing radiator fan -V7- and radiator fan 2 -V177- 12066
21 – Turbocharging/supercharging 12068
1 Turbocharger 12068
1 1 Assembly overview – turbocharger 12068
1 2 Assembly overview – turbocharger air recirculation valve -N249- 12070
1 3 Removing and installing turbocharger 12070
1 4 Checking vacuum unit for turbocharger 12075
1 5 Adjusting vacuum unit for turbocharger 12076
1 6 Renewing vacuum unit for turbocharger 12081
2 Charge air system 12083
2 1 Assembly overview – charge air system 12083
2 2 Assembly overview – charge-air hose connections 12084
2 3 Removing and installing charge air cooler 12085
2 4 Checking charge air system for leaks 12087
3 Supercharger 12090
3 1 Assembly overview – supercharger 12090
3 2 Removing and installing supercharger 12091
3 3 Removing and installing supercharger input shaft seal 12098
24 – Mixture preparation – injection 12102
1 Injection system 12102
1 1 Releasing high pressure in fuel system 12102
2 Injectors 12103
2 1 Assembly overview – fuel rail with injectors 12103
2 2 Removing and installing injectors 12103
2 3 Renewing seals on injectors 12106
3 Air filter 12110
3 1 Assembly overview – air filter housing 12110
3 2 Removing and installing air filter housing 12111
4 Intake manifold 12112
4 1 Assembly overview – intake manifold 12112
4 2 Assembly overview – lower part of intake manifold with fuel rail 12114
4 3 Removing and installing lower part of intake manifold 12116
4 4 Removing and installing lower part of intake manifold with fuel rail 12116
4 5 Removing and installing throttle valve module -J338- 12117
4 6 Cleaning throttle valve module -J338- 12119
5 Senders and sensors 12121
5 1 Checking fuel pressure sender -G247- 12121
6 Engine control unit 12124
6 1 Removing and installing engine control unit -J623- without protective housing 12124
6 2 Removing and installing engine control unit -J623- with protective housing 12126
7 High-pressure pump 12129
7 1 Assembly overview – high-pressure pump 12129
7 2 Removing and installing high-pressure pump 12130
26 – Exhaust system 12134
1 Exhaust pipes, silencers 12134
1 1 Assembly overview – silencers 12134
1 2 Removing and installing front exhaust pipe 12135
1 3 Separating exhaust pipes, silencers 12137
1 4 Aligning exhaust system free of stress 12138
2 Emission control 12140
2 1 Assembly overview – emission control 12140
28 – Ignition system 12142
1 Ignition system 12142
1 1 Assembly overview – ignition system 12142
1 2 Test data, spark plugs 12143
1 3 Removing and installing ignition coils with output stage 12143
1 4 Removing and installing engine speed sender -G28- 12145
D4B8048BC56 4 cyl injection engine (1 2 l engine EA 111 turbocharger) 12147
00 – Technical data 12153
1 Safety information 12153
1 1 Safety precautions when working on fuel system 12153
1 2 Safety precautions when using testing and measuring instruments during a road test 12154
1 3 Safety precautions when working on ignition system 12154
1 4 Safety precautions when working on cooling system 12154
2 Identification 12155
2 1 Engine number/engine data 12155
3 General information 12156
3 1 Numbering of cylinders 12156
4 Repair instructions 12157
4 1 Rules for cleanliness 12157
4 2 Foreign objects in engine 12157
4 3 Contact corrosion 12157
4 4 Routing and attachment of lines 12157
4 5 Fitting radiator and condensers 12157
10 – Removing and installing engine 12159
1 Removing and installing engine 12159
1 1 Removing engine 12159
1 2 Separating engine and gearbox 12167
1 2 1 Vehicles with manual gearbox 12167
1 2 2 Vehicles with dual clutch gearbox 12167
1 3 Securing engine on engine and gearbox support 12169
1 4 Installing engine 12170
2 Assembly mountings 12172
2 1 Assembly overview – assembly mountings 12172
2 2 Removing and installing engine mounting 12174
2 3 Supporting engine in installation position 12180
2 4 Adjusting assembly mountings 12186
2 5 Checking adjustment of assembly mountings (engine and gearbox mountings) 12188
13 – Crankshaft group 12189
1 Cylinder block (pulley end) 12189
1 1 Assembly overview – poly V-belt drive 12189
1 1 1 Assembly overview – poly V-belt drive, without air conditioner compressor 12189
1 1 2 Assembly overview – poly V-belt drive, air conditioner compressor 12192
1 2 Assembly overview – cylinder block (pulley end) 12194
1 3 Removing and installing poly-V belt 12197
1 4 Removing and installing tensioner for poly V-belt 12199
1 4 1 Removing and installing tensioner for poly V-belt, with air conditioner 12199
1 4 2 Removing and installing tensioner for poly V-belt, without air conditioner 12199
1 5 Removing and installing vibration damper 12199
1 6 Removing and installing bracket for ancillaries 12202
1 6 1 Removing and installing upper ancillary bracket 12202
1 6 2 Removing and installing lower ancillary bracket 12204
1 7 Renewing crankshaft oil seal – belt pulley end 12205
2 Cylinder block, gearbox end 12209
2 1 Assembly overview – cylinder block, gearbox end 12209
2 2 Removing and installing sealing flange on gearbox side 12210
3 Crankshaft 12218
3 1 Crankshaft dimensions 12218
3 2 Renewing needle bearing in crankshaft 12218
4 Pistons and conrods 12220
4 1 Assembly overview – pistons and conrods 12220
4 2 Checking pistons and cylinder bores 12222
4 3 Separating new conrod 12223
4 4 Removing and installing oil spray jets 12224
15 – Cylinder head, valve gear 12225
1 Cylinder head 12225
1 1 Assembly overview – cylinder head 12225
1 2 Removing and installing cylinder head 12227
1 3 Removing and installing cylinder head cover 12230
1 4 Checking compression 12239
2 Cover for timing chain 12242
2 1 Removing and installing valve timing housing (timing case) 12242
2 1 1 Removing and installing upper valve timing housing 12242
2 1 2 Removing and installing lower valve timing housing 12244
3 Chain drive 12248
3 1 Removing and installing camshaft timing chain 12248
3 2 Removing and installing timing chain and chain drive for oil pump 12254
3 3 Checking valve timing 12255
3 4 Adjusting valve timing 12258
4 Valve gear 12265
4 1 Assembly overview – valve gear 12265
4 2 Measuring axial play of camshaft 12269
4 3 Removing and installing camshaft 12270
4 4 Removing and installing valve stem seals 12272
17 – Lubrication 12275
1 Sump, oil pump 12275
1 1 Assembly overview – sump/oil pump 12275
1 2 Engine oil: 12278
1 3 Removing and installing sump 12279
1 4 Removing and installing oil pump 12281
2 Engine oil cooler 12283
2 1 Removing and installing engine oil cooler 12283
3 Oil filter, oil pressure switch 12285
3 1 Checking oil pressure and oil pressure switch 12285
19 – Cooling 12287
1 Cooling system/coolant 12287
1 1 Connection diagram – coolant hoses 12287
1 2 Checking cooling system for leaks 12287
1 3 Draining and adding coolant 12289
2 Coolant pump, regulation of cooling system 12296
2 1 Assembly overview – thermostat 12296
2 2 Removing and installing coolant pump 12297
2 3 Removing and installing coolant pump pulley 12299
2 4 Removing and installing electric coolant pump 12300
2 4 1 Removing and installing coolant circulation pump -V50- 12300
3 Radiator, radiator fan 12302
3 1 Assembly overview – radiator/radiator fan 12302
3 2 Removing and installing radiator 12304
3 3 Removing and installing radiator cowl 12305
3 4 Removing and installing radiator fan 12306
21 – Turbocharging/supercharging 12308
1 Exhaust turbocharger 12308
1 1 Assembly overview – turbocharger 12308
1 1 1 Assembly overview – turbocharger 12308
1 1 2 Assembly overview – turbocharger with attachments 12310
1 2 Removing and installing turbocharger 12311
1 3 Removing and installing charge pressure positioner -V465- 12315
2 Charge air system 12317
2 1 Assembly overview – charge air system 12317
2 2 Removing and installing charge air cooler 12318
24 – Mixture preparation – injection 12321
1 Injection system 12321
1 1 Releasing high pressure in fuel system 12321
2 Injectors 12322
2 1 Removing and installing injectors 12322
2 2 Renewing seals on injectors 12325
2 3 Cleaning injectors 12328
3 Air filter 12329
3 1 Assembly overview – air filter housing 12329
3 2 Removing and installing air filter housing 12330
4 Intake manifold 12331
4 1 Assembly overview – intake manifold 12331
4 1 1 Assembly overview – intake manifold 12331
4 1 2 Assembly overview – intake manifold, vehicles with manual gearbox 12333
4 1 3 Assembly overview – intake manifold, vehicles with dual clutch gearbox 12334
4 2 Removing and installing intake manifold 12335
4 3 Removing and installing throttle valve module -J338- 12337
4 4 Cleaning throttle valve module 12339
5 Senders and sensors 12341
5 1 Checking fuel pressure sender -G247- 12341
6 Engine (motor) control unit 12344
6 1 Removing and installing engine (motor) control unit -J623- 12344
7 High-pressure pump 12346
7 1 Assembly overview – high-pressure pump 12346
7 2 Removing and installing high-pressure pump 12347
26 – Exhaust system 12350
1 Exhaust pipes and silencers 12350
1 1 Assembly overview – silencers 12350
1 2 Separating exhaust pipes from silencers 12351
1 3 Installation position of clamp 12353
1 4 Aligning exhaust system free of stress 12354
2 Exhaust gas cleaning 12355
2 1 Assembly overview – emission control 12355
28 – Ignition system 12357
1 Ignition system 12357
1 1 Assembly overview – ignition system 12357
1 2 Test data, spark plugs 12359
1 3 Removing and installing engine speed sender -G28- 12359
D4B80256F85 Hybrid electrical system 12360
93 – Electric drive systems 12364
1 General warnings for working on high-voltage system 12364
1 1 General warnings for working on high-voltage system 12364
1 2 Warning stickers 12368
2 Overview of fitting locations – high-voltage components 12370
3 Description of high-voltage system 12372
3 1 Operating modes for high-voltage vehicle 12372
3 1 1 Standstill 12372
3 1 2 Driving with electric motor 12372
3 1 3 Driving with combustion engine and electric motor 12373
3 1 4 Recuperation 12373
3 2 Maintenance connector for high-voltage system -TW- 12373
4 High-voltage battery unit 12375
4 1 General description – high-voltage battery unit 12375
4 2 Assembly overview – high-voltage battery 12375
4 3 Removing and installing high-voltage battery 12378
4 3 1 Visual inspection of hybrid battery unit -AX1- 12378
4 3 2 Removing and installing hybrid battery unit -AX1- 12378
4 3 3 Converting hybrid battery unit -AX1- from index D to index C, only USA 12386
4 4 Removing and installing battery regulation control unit 12387
4 5 Renewing battery regulation control unit 12394
4 6 Removing and installing battery fan 12395
4 7 Removing and installing air supply ducts for battery fan 12396
4 8 Charging high-voltage battery 12400
5 Power and control electronics for electric drive 12402
5 1 General description – power and control electronics for electric drive 12402
5 2 Fitting locations overview – power and control electronics for electric drive 12403
5 2 1 Assembly overview – power and control electronics for electric drive -JX1- 12403
5 3 Removing and installing power and control electronics for electric drive 12405
5 3 1 Visual inspection of power and control electronics for electric drive -JX1- 12405
5 3 2 Removing and installing power and control electronics for electric drive -JX1- 12405
5 3 3 Removing and installing fuse for electrical air conditioner compressor -V470- 12409
5 4 Renewing power and control electronics for electric drive 12411
6 Electric drive motor 12413
6 1 General description – electric drive motor 12413
6 2 Removing and installing electric drive motor 12413
6 2 1 Removing and installing electric drive motor -V141- 12413
6 2 2 Removing and installing drive motor rotor position sender 1 -G713- 12414
7 High-voltage cables 12415
7 1 General description – high-voltage cables 12415
7 2 Overview of fitting locations – high-voltage cables 12416
7 3 Removing and installing high-voltage wiring harness for high-voltage battery 12417
7 4 Removing and installing high-voltage wiring harness for drive motor 12421
7 5 Removing and installing high-voltage wire for electrical air conditioner compressor 12424
8 Cooling system for high-voltage system 12427
9 De-energising the high-voltage system 12428
10 Recommissioning high-voltage system 12429
11 Potential equalisation lines 12430
D4B80462D0C 4 cylinder injection engine (1 6 l engine MPI) 12432
00 – Technical data 12438
1 Safety instructions 12438
1 1 Safety precautions when working on fuel supply system 12438
1 2 Safety precautions during road tests in which test and measuring equipment is used 12438
1 3 Safety precautions when working on cooling system 12439
1 4 Safety precautions when working on ignition system 12439
2 Identification 12440
2 1 Engine number, engine data 12440
3 Repair instructions 12441
3 1 Rules for cleanliness 12441
3 2 Foreign objects in engine 12441
3 3 Contact corrosion 12441
3 4 Routing and securing lines 12442
3 5 Installing coolers, condensers and radiators 12442
10 – Removing and installing engine 12443
1 Removing and installing engine 12443
1 1 Removing engine 12443
1 2 Separating engine and gearbox 12448
1 2 1 Separating engine and gearbox, manual gearbox 12448
1 2 2 Separating engine and gearbox, vehicles with automatic gearbox 12450
1 3 Securing engine on engine and gearbox support 12452
1 4 Installing engine 12453
2 Assembly mountings 12456
2 1 Assembly overview – assembly mountings 12456
2 2 Removing and installing engine mountings 12458
2 3 Supporting engine in installation position 12462
2 4 Adjusting assembly mountings 12471
13 – Crankshaft group 12473
1 Cylinder block (pulley end) 12473
1 1 Assembly overview – poly V-belt drive 12473
1 2 Assembly overview – cylinder block (pulley end) 12474
1 3 Removing and installing poly V-belt 12477
1 4 Removing and installing tensioner for poly V-belt 12477
1 5 Removing and installing vibration damper 12478
1 6 Removing and installing ancillary bracket 12481
1 7 Renewing crankshaft oil seal – belt pulley end 12482
2 Cylinder block, gearbox end 12485
2 1 Assembly overview – cylinder block, gearbox end 12485
2 2 Removing and installing sealing flange on gearbox side 12486
3 Crankshaft 12495
3 1 Assembly overview – crankshaft 12495
3 2 Crankshaft dimensions 12496
4 Pistons and conrods 12497
4 1 Assembly overview – pistons and conrods 12497
4 2 Checking piston and cylinder bore 12498
15 – Cylinder head, valve gear 12500
1 Cylinder head 12500
1 1 Assembly overview – cylinder head 12500
1 2 Removing and installing cylinder head 12501
1 3 Removing and installing camshaft housing 12504
1 4 Checking compression 12506
2 Cover for timing chain 12509
2 1 Removing and installing valve timing housing (timing case) 12509
3 Chain drive 12512
3 1 Removing and installing timing chain and chain drive for oil pump 12512
3 2 Checking valve timing 12519
3 3 Adjusting valve timing 12520
4 Valve gear 12527
4 1 Assembly overview – valve gear 12527
4 2 Measuring axial play of camshaft 12529
4 3 Removing and installing valve stem seals 12529
5 Inlet and exhaust valves 12532
5 1 Reworking valve seats 12532
5 2 Checking valve guides 12534
5 3 Checking valves 12534
5 4 Valve dimensions 12535
17 – Lubrication 12536
1 Sump, oil pump 12536
1 1 Assembly overview – sump and oil pump 12536
1 2 Engine oil 12538
1 3 Removing and installing sump 12538
1 4 Removing and installing oil pump 12542
2 Oil filter, oil pressure switch 12545
2 1 Checking oil pressure and oil pressure switch 12545
19 – Cooling 12547
1 Cooling system, coolant 12547
1 1 Coolant hose schematic diagram 12547
1 2 Checking cooling system for leaks 12548
1 3 Draining and filling coolant 12550
2 Coolant pump, regulation of cooling system 12554
2 1 Assembly overview – coolant pump, thermostat 12554
2 2 Assembly overview – coolant temperature sender 12555
2 3 Removing and installing coolant pump 12557
3 Radiator and radiator fan 12560
3 1 Assembly overview – radiator and radiator fan 12560
3 2 Removing and installing radiator 12564
3 3 Removing and installing radiator cowling with radiator fan 12568
3 4 Removing and installing radiator fan -V7- and radiator fan 2 -V177- 12569
24 – Mixture preparation – injection 12570
1 Injection system 12570
1 1 Filling and bleeding fuel system 12570
2 Injectors 12573
2 1 Assembly overview – fuel rail with injectors 12573
2 2 Removing and installing injectors 12573
2 3 Checking injectors 12575
3 Air filter 12579
3 1 Assembly overview – air filter housing 12579
3 2 Removing and installing air filter housing 12580
4 Intake manifold 12581
4 1 Assembly overview – intake manifold 12581
4 2 Cleaning throttle valve module -J338- 12582
5 Engine control unit 12583
5 1 Removing and installing engine control unit -J623- 12583
26 – Exhaust system 12584
1 Exhaust pipes, silencers 12584
1 1 Assembly overview – silencers 12584
1 2 Removing and installing front exhaust pipe 12585
1 3 Removing and installing rear silencer 12586
1 4 Installation position of clamp 12588
2 Emission control 12590
2 1 Assembly overview – emission control 12590
28 – Ignition system 12592
1 Ignition system 12592
1 1 Assembly overview – ignition system 12592
1 2 Test data, spark plugs 12593
1 3 Removing and installing ignition coils with output stage 12593
1 4 Removing and installing engine speed sender -G28- 12594
D4B80471B44 6 speed manual gearbox 02Q 12597
00 – Technical data 12601
1 Identification 12601
1 1 Gearbox identification 12601
2 Safety information 12602
2 1 Safety precautions when using testing and measuring instruments during a road test 12602
2 2 Safety measures when working on vehicles with a start/stop system 12603
3 Repair instructions 12604
3 1 General repair instructions 12604
3 2 Contact corrosion 12607
4 Technical data 12608
4 1 Allocation gearbox – engine 12608
4 2 Capacities 12608
4 3 Calculation of gear ratios 12608
5 Overview – power transmission 12609
5 1 Overview – power transmission – front-wheel drive 12609
6 Electrical components 12611
6 1 Overview of fitting locations – electrical components 12611
6 1 1 Overview of fitting locations – electrical components, manual gearbox 12611
6 1 2 Overview of fitting locations – electrical components, clutch mechanism 12612
30 – Clutch 12613
1 Clutch mechanism 12613
1 1 Overview of fitting locations – clutch mechanism 12613
1 2 Assembly overview – pedal cluster 12615
1 3 Assembly overview – clutch hydraulics 12617
1 3 1 Assembly overview – clutch hydraulics, left-hand drive 12617
1 3 2 Assembly overview – clutch hydraulics, right-hand drive 12619
1 4 Assembly overview – clutch release mechanism 12622
1 5 Removing and installing over-centre spring 12623
1 6 Removing and installing clutch pedal 12628
1 7 Removing and installing mounting bracket 12634
1 8 Removing and installing clutch master cylinder 12640
1 9 Removing and installing clutch slave cylinder together with release bearing 12642
1 10 Removing and installing lines for clutch mechanism 12643
1 11 Removing and installing bleeder 12645
1 12 Checking clutch master cylinder and clutch slave cylinder 12646
1 13 Removing and installing clutch position sender -G476- 12646
1 14 Bleeding clutch mechanism 12649
2 Clutch 12651
2 1 Determining make of clutch 12651
2 2 Assembly overview – clutch 12652
2 2 1 Assembly overview – clutch in conjunction with Sachs dual-mass flywheel 12652
2 2 2 Assembly overview – clutch in conjunction with LuK dual-mass flywheel 12654
2 2 3 Assembly overview – clutch with simple flywheel 12655
2 3 Removing and installing clutch 12656
2 3 1 Removing and installing clutch in conjunction with Sachs dual-mass flywheel 12656
2 3 2 Removing and installing clutch in conjunction with LuK dual-mass flywheel 12660
2 3 3 Removing and installing clutch in connection with simple flywheel 12664
34 – Controls, housing 12669
1 Selector mechanism 12669
1 1 Installation position – selector mechanism 12669
1 2 Assembly overview – selector mechanism 12671
1 3 Assembly overview – gear knob and cover 12672
1 4 Assembly overview – Gear lever and selector housing 12673
1 5 Assembly overview – Selector cables 12675
1 6 Removing and installing gear knob 12677
1 7 Dismantling and assembling selector mechanism 12679
1 8 Removing and installing selector mechanism 12684
1 9 Removing and installing gear selector cable and gate selector cable 12690
1 10 Adjusting selector mechanism 12692
1 11 Checking selector mechanism 12694
1 12 Renewing selector shaft seal 12694
2 Removing and installing gearbox 12696
2 1 Removing gearbox 12696
2 2 Installing gearbox 12709
2 3 Specified torques for gearbox 12716
3 Assembly mountings 12718
3 1 Assembly overview – assembly mountings 12718
4 Transporting gearbox 12721
5 Dismantling and assembling gearbox 12722
5 1 Schematic overview – gearbox 12722
5 2 Assembly overview – gearbox 12723
5 3 Assembly overview – gearbox housing and selector mechanism 12724
5 4 Assembly overview – selector unit 12726
5 5 Assembly overview – input shaft, output shafts, differential, selector rods 12727
5 6 Assembly overview – selector forks 12729
5 7 Dismantling and assembling gearbox 12729
6 Gearbox housing, clutch housing 12744
6 1 Assembly overview – gearbox housing 12744
6 2 Assembly overview – clutch housing 12746
6 3 Repairing gearbox housing 12747
6 4 Repairing clutch housing 12754
7 Securing to engine and gearbox support 12757
8 Gear oil 12758
8 1 Checking gear oil level 12758
35 – Gears, shafts 12760
1 Input shaft 12760
1 1 Assembly overview – input shaft 12760
1 2 Dismantling and assembling input shaft 12761
1 3 Renewing input shaft seal 12765
2 Output shaft 12767
2 1 Assembly overview – output shaft 12767
2 1 1 Assembly overview – output shaft for 1st to 4th gears 12767
2 1 2 Assembly overview – output shaft for 5th, 6th and reverse gear 12771
2 2 Dismantling and assembling output shaft 12774
2 2 1 Dismantling and assembling output shaft for 1st to 4th gears 12774
2 2 2 Dismantling and assembling output shaft for 5th, 6th and reverse gears 12786
2 3 Adjusting output shaft 12796
2 3 1 Adjusting output shaft for 1st to 4th gears 12796
2 3 2 Adjusting output shaft for 5th, 6th and reverse gears 12801
39 – Final drive – differential 12807
1 Oil seals 12807
1 1 Overview of fitting locations – seals 12807
1 2 Renewing left seal 12808
1 3 Renewing right oil seal 12810
2 Differential 12814
2 1 Assembly overview – differential 12814
2 2 Dismantling and assembling differential 12816
2 3 Adjusting differential 12821
3 Adjustment overview 12825
D4B80471B50 General body repairs interior 12826
00 – Technical data 12832
1 Safety information 12832
1 1 Safety measures when working on vehicles with start/stop system 12833
1 2 Safety measures when working with pyrotechnic components 12834
1 3 Storage, transportation and disposal of airbag, belt tensioner and battery isolator units (pyrotechnic components) 12835
1 4 Additional safety regulations for side airbag 12836
1 5 Additional safety instructions for curtain airbag 12836
1 6 Safety regulations for crash sensors (pressure sensors) for front side airbags 12837
1 7 Additional safety instructions for repair work on seat occupied recognition for front passenger airbag deactivation – country-specific 12837
1 8 Measures for seat occupied recognition for front passenger airbag deactivation following an accident – country-specific 12838
1 9 Renewing pyrotechnic, electrical and mechanical components of the restraint system after an accident 12838
1 10 Checking airbag securing parts after an accident 12840
1 11 Accident without airbag triggering 12840
1 12 Checking seat belts 12841
1 13 Check belt webbing 12841
1 14 Checking inertia reel (locking mechanism) 12842
1 15 Visually checking belt buckle 12843
1 16 Check operation of belt buckle 12843
1 17 Checking belt relays, and buckle tongues 12843
1 18 Checking securing parts and anchorage points after an accident 12843
1 19 Checking child seat anchors after an accident 12844
1 20 Safety instructions for automatic anti-dazzle interior mirror 12844
2 Repair notes 12845
2 1 Contact corrosion 12845
2 2 Pipe/wire routing and attachment 12845
68 – Interior equipment 12846
1 Compartments/covers 12846
1 1 Overview of fitting locations – storage compartments/covers 12846
1 2 Removing and installing dash panel cover on driver side 12847
1 3 Removing and installing upper steering column trim 12849
1 4 Removing and installing lower steering column trim 12850
1 5 Removing and installing glove compartment opener 12851
1 6 Removing and installing glove compartment 12853
1 6 1 Removing and installing glove compartment 12853
1 6 2 Removing and installing decorative trim on glove compartment 12855
1 7 Removing and installing glove compartment cover 12857
1 8 Removing and installing headliner storage compartment 12857
2 Equipment 12860
2 1 Assembly overview – sun visors 12860
2 2 Removing and installing sun visor 12860
2 3 Removing and installing roof grab handle 12863
2 3 1 Removing and installing roof grab handle 12863
2 3 2 Removing and installing bracket for roof grab handle 12864
3 Centre console 12866
3 1 Assembly overview – securing bracket 12866
3 2 Removing and installing rear centre console trim 12866
3 3 Removing and installing centre console 12870
3 3 1 Removing and installing centre console, basic 12870
3 3 2 Removing and installing centre console, Comfort and Highline 12874
3 4 Removing and installing lid of rear storage compartment of centre console, »Comfort and Highline« 12879
3 5 Removing and installing centre console bracket 12880
3 5 1 Removing and installing front bracket for centre console 12880
3 5 2 Removing and installing middle bracket for centre console 12881
3 5 3 Removing and installing rear bracket for centre console, »Comfort and Highline« 12882
3 5 4 Removing and installing support 12883
4 On inside 12885
4 1 Assembly overview – interior mirror 12885
4 1 1 Assembly overview – interior mirror, »Basic« version 12885
4 1 2 Assembly overview – manually operated or automatic anti-dazzle interior mirror, with rain and light sensor and without front camera for driver assist systems 12886
4 1 3 Assembly overview – automatic anti-dazzle interior mirror, with rain and light sensor and front camera for driver assist systems 12886
4 2 Removing and installing interior mirror 12888
4 2 1 Removing and installing »Basic« interior mirror 12888
4 2 2 Removing and installing interior mirror, »with rain sensor« 12889
4 2 3 Removing and installing interior mirror, »with rain sensor and front camera« 12892
4 3 Repairing interior mirror retaining plate 12895
4 3 1 Repairing interior mirror retaining plate, »Basic« version 12895
4 3 2 Repairing interior mirror retaining plate, »with rain sensor« 12897
4 3 3 Repairing interior mirror retaining plate, »with rain sensor and front camera« 12899
69 – Passenger protection 12900
1 Seat belts 12900
1 1 Assembly overview – front three-point seat belt 12900
1 1 1 Assembly overview – vehicles without belt anchor tensioner 12900
1 1 2 Assembly overview – vehicles with belt anchor tensioner 12901
1 2 Assembly overview – rear three-point seat belt 12903
1 3 Removing and installing front three-point seat belt 12904
1 3 1 Vehicles without belt anchor tensioner 12905
1 3 2 Vehicles with belt anchor tensioner 12910
1 4 Removing and installing rear three-point seat belt 12915
1 4 1 Removing and installing rear outer three-point seat belt 12915
1 4 2 Removing and installing rear centre three-point seat belt 12919
1 5 Removing and installing belt height adjuster 12922
1 6 Removing and installing front belt buckle 12924
1 7 Removing and installing rear belt buckle 12928
2 Child seat anchors 12929
2 1 Points to check 12929
2 2 Child seat anchors in rear shelf 12929
3 Airbag system 12930
3 1 Overview of fitting locations – airbag system 12930
4 Airbag control unit 12932
4 1 Assembly overview – airbag control unit 12932
4 2 Removing and installing airbag control unit -J234- 12932
5 Driver’s airbag 12937
5 1 Assembly overview – driver side airbag 12937
5 2 Removing and installing airbag unit with igniter 12939
5 3 Removing and installing return spring with slip ring (coil connector) 12944
6 Front passenger side airbag 12945
6 1 “Advanced Airbag System” (only for North American Region/Canada) 12945
6 2 Removing and installing front passenger side airbag unit with igniter 12945
6 3 Removing and installing key-operated switch to deactivate front passenger side airbag 12950
7 Side airbags 12952
7 1 Removing and installing front side airbag with igniter 12952
7 2 Removing and installing rear side airbag with igniter 12954
8 Curtain airbags 12958
8 1 Removing and installing curtain airbag with igniter 12958
9 Airbag crash sensors 12964
9 1 Overview of fitting locations – airbag crash sensors 12964
9 2 Removing and installing front airbag crash sensor, driver side -G283- 12965
9 3 Removing and installing front airbag crash sensor, front passenger side -G284- 12968
9 4 Removing and installing front side airbag crash sensor -G179-/-G180- 12971
9 5 Removing and installing rear side airbag crash sensor -G256-/-G257- 12974
10 Seat belt verification 12978
10 1 Removing and installing Seat occupied sensor, front passenger side -G128- 12978
11 Seat occupied recognition 12982
11 1 Assembly overview – seat occupied recognition 12982
11 2 Removing and installing seat occupied recognition sensor 12984
11 3 Removing and installing seat occupied recognition control unit 12990
11 4 Removing and installing bracket for seat occupied recognition control unit -J706- 12993
11 5 Importers reporting obligation 12995
70 – Trim, insulation 12997
1 Front door trims 12997
1 1 Removing and installing front door trim 12997
1 1 1 Removing and installing front door trim, driver side 12997
1 1 2 Removing and installing front door trim, front passenger side 13002
1 1 3 Removing and installing bracket for front door trim 13006
1 2 Removing and installing mirror cover trim 13009
2 Rear door trims 13011
2 1 Removing and installing rear door trim 13011
2 1 1 Removing and installing rear door trims 13011
2 1 2 Removing and installing bracket for rear door trims 13014
3 Dash panel 13017
3 1 Assembly overview – dash panel 13017
3 2 Removing and installing dash panel end cover 13019
3 3 Removing and installing dash panel trim 13020
3 4 Removing and installing radio/navigation system mounting frame 13022
3 4 1 Removing and installing mounting frame for radio/navigation system, vehicles without Climatronic 13022
3 4 2 Removing and installing mounting frame for radio/navigation system, vehicles with Climatronic 13023
3 5 Removing and installing dash panel 13025
3 5 1 Aligning dash panel in vehicle 13032
3 6 Removing and installing outer dash panel vents 13035
3 7 Removing and installing dash panel insert trim 13036
4 Central tube for dash panel 13041
4 1 Assembly overview – central tube for dash panel 13041
4 2 Removing and installing central tube for dash panel 13043
4 2 1 Removing and installing bracket for dash panel central tube, left-hand drive vehicles 13048
4 3 Removing and installing impact absorber 13049
5 Interior trims 13052
5 1 Overview of fitting locations – interior trims 13052
5 2 Removing and installing sill panel moulding 13053
5 3 Removing and installing A-pillar trim 13055
5 3 1 Removing and installing upper A-pillar trim 13055
5 3 2 Removing and installing lower A-pillar trim on driver side 13057
5 3 3 Removing and installing lower A-pillar trim on front passenger side 13059
5 4 Removing and installing A-pillar gap cover 13061
5 5 Removing and installing B-pillar trim 13063
5 5 1 Releasing and securing upper B-pillar trim 13063
5 5 2 Removing and installing upper B-pillar trim 13065
5 5 3 Removing and installing lower B-pillar trim 13067
5 6 Removing and installing C-pillar trim 13069
5 7 Removing and installing wheel housing trims 13071
5 7 1 Removing and installing wheel housing trim, vehicles with side airbag 13071
5 7 2 Removing and installing wheel housing trim, vehicles without side airbag 13072
5 8 Removing and installing rear shelf 13074
5 8 1 Removing and installing rear shelf 13074
5 8 2 Removing and installing rear shelf, North American Region 13077
6 Luggage compartment trims 13079
6 1 Removing and installing lower rear lid trim 13079
6 2 Removing and installing luggage compartment side trim 13081
6 3 Removing and installing luggage compartment floor 13083
6 3 1 Removing and installing luggage compartment floor 13083
6 3 2 Removing and installing luggage compartment floor, hybrid vehicles 13084
6 4 Removing and installing lock carrier trim 13084
6 5 Removing and installing high-voltage battery cover, hybrid vehicles 13086
6 6 Removing and installing side panel trim in luggage compartment, hybrid vehicles 13089
7 Roof trims 13093
7 1 Removing and installing moulded headlining 13093
7 1 1 Removing and installing moulded headlining 13093
7 1 2 Detaching and fastening moulded headliner 13097
7 1 3 Removing and installing insulation/roof reinforcements 13101
72 – Seat frames 13107
1 Front seats 13107
1 1 Assembly overview – front seat 13107
1 1 1 Assembly overview – front seat, manual 13107
1 1 2 Assembly overview – front seat, semi-electric 13109
1 2 Assembly overview – front backrest 13111
1 3 Assembly overview – seat pan 13112
1 3 1 Assembly overview – seat pan, manual, North American Region 13112
1 3 2 Assembly overview – seat pan, partially electric, North American Region 13113
1 4 Assembly overview – seat height adjustment 13113
1 5 Removing and installing front seat 13114
1 6 Removing and installing lumbar support adjustment unit 13119
1 7 Removing and installing backrest adjustment unit 13120
1 8 Removing and installing front backrest 13122
1 9 Removing and installing seat trim on sill side 13124
1 9 1 Removing and installing seat trim on sill side, without height adjustment 13124
1 9 2 Removing and installing seat trim on sill side, manual height adjustment 13127
1 9 3 Removing and installing seat trim on sill side, electric height adjustment 13129
1 10 Removing and installing seat trim on tunnel side 13132
1 11 Removing and installing front seat drawer together with mounting 13132
1 12 Removing and installing front seat bar and operating lever 13134
1 13 Removing and installing bar of electrically adjustable seat 13135
1 14 Removing and installing head restraint guide 13137
1 15 Removing and installing lumbar support frame 13138
1 15 1 Removing and installing manually adjustable lumbar support frame 13138
1 15 2 Removing and installing electric lumbar support frame 13140
1 16 Removing and installing fire extinguisher holder 13142
1 17 Removing and installing fire extinguisher holder on seat frame 13142
1 18 Removing and installing drive for backrest adjustment (electrically adjustable seat) 13143
2 Rear seats 13144
2 1 Removing and installing bench seat/individual seats 13144
2 2 Removing and installing head restraint guide 13146
2 3 Removing and installing rear seat backrest 13147
2 4 Removing and installing locking mechanism for rear seat backrest 13149
2 5 Removing and installing side padding with side airbag 13151
74 – Seat – padding, covers 13154
1 Front seat covers and padding 13154
1 1 Removing and installing cover and padding for seat pan 13154
1 2 Removing and installing backrest cover and backrest padding 13159
2 Rear seat covers and padding 13166
2 1 Removing and installing covers and padding 13166
2 2 Removing and installing backrest cover and padding, 1/3 section 13170
2 3 Removing and installing backrest cover and padding, 2/3 section 13175
2 4 Removing and installing through loading unit with centre armrest 13179
D4B80472A2E 6 speed manual gearbox 02S 13183
00 – Technical data 13187
1 Safety information 13187
1 1 Safety measures when working on vehicles with a start/stop system 13187
1 2 Safety precautions when using testers and measuring instruments during a road test 13187
2 Identification 13189
2 1 Gearbox identification 13189
3 Repair notes 13190
3 1 General repair instructions 13190
4 Technical data 13194
4 1 Capacities 13194
4 2 Allocation gearbox – engine 13194
4 3 Calculation of gear ratios 13194
5 Overview – power transmission 13196
5 1 Overview – power transmission – front-wheel drive 13196
6 Electrical components 13198
6 1 Overview of fitting locations – electrical components 13198
6 1 1 Overview of fitting locations – electrical components, manual gearbox 13198
6 1 2 Overview of fitting locations – electrical components, clutch mechanism 13199
30 – Clutch 13200
1 Clutch operation 13200
1 1 Assembly overview – pedal cluster 13200
1 2 Assembly overview – clutch hydraulics 13203
1 2 1 Assembly overview – clutch hydraulics, left-hand drive 13203
1 2 2 Assembly overview – clutch hydraulics, right-hand drive 13205
1 3 Assembly overview – clutch release mechanism 13207
1 4 Removing and installing over-centre spring 13208
1 5 Removing and installing clutch pedal 13212
1 6 Removing and installing mounting bracket 13218
1 7 Removing and installing clutch master cylinder 13224
1 8 Removing and installing clutch slave cylinder 13226
1 9 Checking clutch master cylinder and clutch slave cylinder 13228
1 10 Removing and installing clutch position sender -G476- 13228
1 11 Bleeding clutch mechanism 13231
1 12 Repairing clutch release mechanism 13232
2 Clutch 13234
2 1 Determining make of clutch 13234
2 2 Assembly overview – clutch 13235
2 2 1 Assembly overview – clutch in conjunction with Sachs dual-mass flywheel 13235
2 2 2 Assembly overview – clutch in conjunction with LuK dual-mass flywheel 13237
2 2 3 Assembly overview – clutch with simple flywheel 13238
2 3 Removing and installing clutch 13239
2 3 1 Removing and installing clutch in conjunction with Sachs dual-mass flywheel 13239
2 3 2 Removing and installing clutch in conjunction with LuK dual-mass flywheel 13241
2 3 3 Removing and installing clutch in connection with simple flywheel 13244
34 – Controls, housing 13249
1 Selector mechanism 13249
1 1 Installation position – selector mechanism 13249
1 2 Assembly overview – gear knob and cover 13251
1 3 Assembly overview – Gear lever and selector housing 13252
1 4 Assembly overview – Selector cables 13254
1 5 Removing and installing gear knob 13256
1 6 Dismantling and assembling selector mechanism 13258
1 7 Removing and installing selector mechanism 13264
1 8 Removing and installing gear selector cable and gate selector cable 13269
1 9 Adjusting selector mechanism 13271
1 10 Checking selector mechanism 13273
1 11 Renewing oil seal for selector shaft 13274
2 Removing and installing gearbox 13276
2 1 Specified torques for gearbox 13276
2 2 Removing gearbox 13276
2 3 Installing gearbox 13287
3 Assembly mounting 13295
3 1 Assembly overview – assembly mountings 13295
4 Transporting gearbox 13297
5 Dismantling and assembling gearbox 13298
5 1 Schematic overview – gearbox 13298
5 2 Assembly overview – cover for gearbox housing and 5th/6th gear 13300
5 3 Assembly overview – gearbox housing and selector mechanism 13302
5 4 Assembly overview – selector unit 13304
5 5 Assembly overview – input shaft, output shafts, differential, selector rods 13305
5 6 Assembly overview – selector forks 13306
5 7 Repairing selector unit 13309
5 8 Repairing selector forks 13310
5 9 Removing cover for gearbox housing and 5th and 6th gears 13313
5 10 Dismantling and assembling gearbox 13319
5 11 Installing cover for gearbox housing and 5th and 6th gears 13333
6 Gearbox housing, clutch housing 13338
6 1 Assembly overview – gearbox housing 13338
6 2 Assembly overview – clutch housing 13340
6 3 Assembly overview – gearbox housing cover 13341
6 4 Repairing gearbox housing 13342
6 4 1 Removing and installing input shaft bearings in gearbox housing 13342
6 4 2 Removing and installing output shaft bearings in gearbox housing 13344
6 4 3 Removing and installing differential bearings in gearbox housing 13347
6 5 Repairing clutch housing 13349
6 5 1 Removing and installing input shaft bearings in clutch housing 13349
6 5 2 Removing and installing output shaft bearings in clutch housing 13350
6 5 3 Removing and installing differential bearings in clutch housing 13352
6 6 Repairing gearbox housing cover 13354
7 Installing to engine and gearbox support 13356
8 Gear oil 13357
8 1 Checking gear oil level 13357
8 2 Draining and filling gear oil 13357
35 – Gears, shafts 13360
1 Input shaft 13360
1 1 Assembly overview – input shaft 13360
1 2 Dismantling and assembling input shaft 13362
1 3 Adjusting input shaft 13366
2 Output shaft 13372
2 1 Assembly overview – output shaft 13372
2 2 Dismantling and assembling output shaft 13375
2 3 Adjusting output shaft 13385
3 Reverse shaft 13392
3 1 Assembly overview – reverse shaft 13392
3 2 Dismantling and assembling reverse shaft 13395
39 – Final drive – differential 13398
1 Oil seals 13398
1 1 Overview of fitting locations – seals 13398
1 2 Renewing left oil seal 13399
1 3 Renewing right oil seal 13401
1 4 Renewing input shaft seal 13405
2 Differential 13407
2 1 Assembly overview – differential 13407
2 2 Dismantling and assembling differential 13409
2 3 Adjusting differential 13414
3 Adjustment overview 13418
D4B80473A21 7 speed dual clutch gearbox 0AM 13419
00 – Technical data 13423
1 Safety information 13423
1 1 General safety provisions 13423
1 2 Safety measures when working on vehicles with a start/stop system 13423
1 3 Safety precautions when using testers and measuring instruments during a road test 13424
1 4 Safety precautions when working on the mechatronic unit 13424
1 5 Safety precautions when tow-starting or towing 13425
2 Identification 13426
2 1 Gearbox identification 13426
3 Repair notes 13427
3 1 General information 13427
3 2 General repair instructions 13429
3 3 Working with tester 13432
4 Technical data 13435
4 1 Capacities 13435
4 2 Allocation gearbox – engine 13436
5 Overview – power transmission 13438
30 – Clutch 13439
1 Clutch operation 13439
1 1 Assembly overview – clutch engagement 13439
1 2 Removing and installing clutch engagement 13440
1 3 Adjusting clutch engagement 13443
2 Clutch 13456
2 1 Assembly overview – dual clutch 13456
2 2 Removing dual clutch 13457
2 3 Installing dual clutch 13461
2 4 Renewing input shaft seal 13465
2 5 Renewing oil seal for inner input shaft 13467
34 – Controls, housing 13470
1 Mechatronic unit 13470
1 1 Assembly overview – mechatronic unit 13470
1 2 Removing and installing mechatronic unit 13471
1 3 Setting mechatronic unit to removal position by hand 13486
1 4 Renewing bellows with clutch actuator 13490
2 Selector mechanism 13495
2 1 Assembly overview – selector mechanism 13495
2 2 Emergency release from position P 13496
2 3 Removing and installing selector mechanism 13497
2 3 1 Removing and installing selector mechanism with selector housing 13497
2 3 2 Removing and installing selector mechanism without selector housing 13501
2 4 Checking and adjusting selector lever cable 13504
2 5 Removing and installing selector lever handle 13506
2 6 Moving push button in the handle to installation position 13509
2 6 1 Moving push button in handle to installation position, handle with push button on side 13509
2 6 2 Moving push button in handle to installation position, handle with push button at front 13509
2 7 Checking selector mechanism 13510
2 8 Renewing oil seal for selector shaft 13511
3 Removing and installing gearbox 13512
3 1 Removing gearbox 13512
3 1 1 Removing gearbox, vehicles with petrol engine 13512
3 1 2 Removing gearbox, vehicles with diesel engine 13524
3 2 Installing gearbox 13533
3 3 Specified torques for gearbox 13538
4 Transporting gearbox 13541
5 Dismantling and assembling gearbox 13544
5 1 Schematic overview – gearbox 13544
5 2 Dismantling and assembling gearbox 13545
5 2 1 Dismantling gearbox 13545
5 2 2 Assembling gearbox 13554
6 Gearbox housing, clutch housing 13567
6 1 Assembly overview – gearbox housing 13567
6 2 Assembly overview – clutch housing 13568
6 3 Repairing gearbox housing 13569
6 4 Repairing clutch housing 13574
7 Installing to engine and gearbox support 13579
8 Gear oil 13581
8 1 Draining and filling gear oil 13581
8 2 Draining and filling hydraulic fluid for mechatronic unit 13584
35 – Gears, shafts 13587
1 Input shaft 13587
1 1 Dismantling and assembling input shaft 13587
1 1 1 Dismantling and assembling outer input shaft 13587
1 1 2 Dismantling and assembling inner input shaft 13590
2 Output shaft 13594
2 1 Assembly overview – output shaft 13594
2 1 1 Assembly overview – output shaft 1 13594
2 1 2 Assembly overview – output shaft 2 13596
2 1 3 Assembly overview – output shaft 3 13597
2 2 Dismantling and assembling output shaft 1 13598
2 2 1 Dismantling output shaft 1 partially 13598
2 2 2 Dismantling output shaft 1 completely 13599
2 2 3 Assembling output shaft 1 13603
2 2 4 Dismantling and assembling locking collars and synchro-hubs of output shaft 1 13610
2 3 Dismantling and assembling output shaft 2 13610
2 3 1 Dismantling output shaft 2 13610
2 3 2 Assembling output shaft 2 13614
2 3 3 Dismantling and assembling locking collars and synchro-hubs of output shaft 2 13620
2 4 Dismantling and assembling output shaft 3 13620
2 4 1 Dismantling output shaft 3 13620
2 4 2 Assembling output shaft 3 13623
2 4 3 Dismantling and assembling locking collar and synchro-hub of output shaft 3 13626
2 5 Adjusting output shaft 13626
2 5 1 Notes on gearbox adjustment 13626
2 5 2 Calculating shims for clutch housing 13627
2 5 3 Calculating shims for gearbox housing 13640
3 Parking lock 13661
3 1 Removing and installing cover for parking lock 13661
3 2 Removing and installing parking lock 13662
39 – Final drive – front differential 13664
1 Oil seals 13664
1 1 Overview of fitting locations – seals 13664
1 2 Renewing left oil seal 13664
1 3 Renewing right oil seal 13668
D4B80473A22 6 speed automatic gearbox 09G 13672
00 – Technical data 13676
1 Safety information 13676
1 1 General safety provisions 13676
1 2 Safety precautions when using testers and measuring instruments during a road test 13676
1 3 Safety precautions when tow-starting or towing 13677
2 Identification 13678
2 1 Gearbox identification 13678
2 2 Identification of torque converter 13678
3 Repair notes 13679
3 1 General information 13679
3 2 Rules for cleanliness 13680
3 3 General repair instructions 13680
3 4 Gaskets and seals 13681
3 5 Nuts and bolts 13682
4 Technical data 13683
4 1 Capacities 13683
4 2 Allocation gearbox – engine 13683
5 Electrical components 13684
5 1 Overview of fitting locations – electrical components 13684
32 – Torque converter 13691
1 Torque converter 13691
1 1 Assembly overview – torque converter 13691
1 2 Removing and installing torque converter 13692
1 3 Checking torque converter 13693
1 4 Draining torque converter 13693
1 5 Removing and installing torque converter oil seal 13694
37 – Controls, housing 13696
1 Connecting vehicle diagnostic tester 13696
2 Selector mechanism 13697
2 1 Assembly overview – selector mechanism 13697
2 2 Removing and installing selector mechanism 13699
2 2 1 Removing and installing selector mechanism with selector housing 13699
2 2 2 Removing and installing selector mechanism without selector housing 13704
2 3 Checking and adjusting selector lever cable 13708
2 4 Emergency release from position P 13710
2 5 Removing and installing selector lever handle 13711
2 6 Moving push-button in the handle to installation position 13714
2 6 1 Moving push-button in handle to installation position, handle with push-button on side 13714
2 6 2 Moving push-button in handle to installation position, handle with push-button at front 13715
2 7 Checking selector mechanism 13716
2 8 Removing and installing multifunction switch 13717
2 9 Adjusting multifunction switch 13721
2 10 Renewing selector shaft seal 13723
3 Removing and installing gearbox 13725
3 1 Removing gearbox 13725
3 1 1 Removing gearbox, 1 4 l – 110 kW and 1 6 l – 81 kW engines 13725
3 1 2 Removing gearbox, 1 6 l – 77 kW engine 13739
3 1 3 Removing gearbox, 1 8 l – 125 kW engine 13752
3 1 4 Removing gearbox, 2 0 l – 85 kW engine 13767
3 1 5 Removing gearbox, 2 5 l – 125 kW engine 13781
3 2 Installing gearbox 13796
3 3 Specified torques for gearbox 13799
4 Transporting gearbox 13803
5 Securing to engine and gearbox support 13805
6 ATF circuit 13807
6 1 Assembly overview – ATF circuit 13807
6 1 1 Assembly overview – ATF circuit, ATF cooler with round design 13807
6 1 2 Assembly overview – ATF circuit, ATF cooler with rectangular design 13808
6 2 Removing and installing ATF cooler 13809
6 2 1 Removing and installing ATF cooler, vehicles with 1 8 l, 2 0 l, 2 5 l and 1 6 l – 77 kW engine 13809
6 2 2 Removing and installing ATF cooler, vehicles with 1 4 l and 1 6 l – 81 kW engine 13811
7 ATF 13815
7 1 Checking ATF level 13815
7 2 Draining and filling ATF 13819
38 – Gears, control 13823
1 ATF system 13823
1 1 Removing and installing oil pan 13823
1 2 Removing and installing ATF strainer 13825
1 2 1 Removing and installing ATF strainer, vehicles with 2nd generation gearbox 13825
1 2 2 Removing and installing ATF strainer, vehicles with 3rd generation gearbox 13827
2 Valve body 13828
2 1 Assembly overview – valve body 13828
2 1 1 Assembly overview – valve body, vehicles with 2nd generation gearbox 13828
2 1 2 Assembly overview – valve body, vehicles with 3r generation gearbox 13831
2 2 Wire routing, connectors, connections and retainers on valve body, vehicles with 2nd generation gearbox 13834
2 3 Removing and installing valve body 13835
2 3 1 Removing and installing valve body, vehicles with 2nd generation gearbox 13835
2 3 2 Removing and installing valve body, vehicles with 3rd generation gearbox 13844
2 4 Removing and installing wiring harness for senders and solenoid valves 13847
2 4 1 Removing and installing wiring harness for senders and solenoid valves, vehicles with 2nd generation gearbox 13847
2 4 2 Removing and installing wiring harness for senders and solenoid valves, vehicles with 3rd generation gearbox 13848
2 5 Removing and installing gearbox input speed sender -G182- and gearbox output speed sender -G195- 13851
2 5 1 Removing and installing gearbox input speed sender -G182- and gearbox output speed sender -G195-, vehicles with 2nd generation gearbox 13851
2 5 2 Removing and installing gearbox input speed sender -G182- and gearbox output speed sender -G195-, vehicles with 3rd generation gearbox 13852
39 – Final drive – differential 13854
1 Oil seals 13854
1 1 Overview of fitting locations – seals 13854
1 2 Renewing left seal 13854
1 3 Renewing right seal 13857
D4B80486CB7 4 cylinder injection engine (1 4 l direct injection engine turbocharger) 13861
00 – Technical data 13867
1 Safety information 13867
1 1 Safety regulations for working on fuel supply 13867
1 2 Safety precautions when using testers and measuring instruments during a road test 13868
1 3 Safety precautions when working on ignition system 13868
1 4 Safety precautions when working on the cooling system 13869
2 Identification 13870
2 1 Engine number/engine data 13870
3 Repair notes 13872
3 1 Rules for cleanliness 13872
3 2 Foreign bodies in engine 13872
3 3 Contact corrosion 13872
3 4 Routing and attachment of lines 13872
3 5 Fitting radiator and condensers 13872
10 – Removing and installing engine 13873
1 Removing and installing engine 13873
1 1 Removing engine 13873
1 2 Securing engine on engine and gearbox support 13883
1 3 Installing engine 13884
2 Assembly mountings 13887
2 1 Assembly overview – assembly mountings 13887
2 2 Removing and installing engine mounting 13889
2 3 Supporting engine in installation position 13898
2 4 Adjusting assembly mountings 13905
2 5 Checking adjustment of assembly mountings 13907
13 – Crankshaft group 13908
1 Cylinder block (pulley end) 13908
1 1 Assembly overview – poly V-belt drive 13908
1 2 Assembly overview – cylinder block (pulley end) 13909
1 3 Removing and installing poly-V belt 13912
1 4 Removing and installing vibration damper 13912
1 5 Removing and installing bracket for ancillaries 13916
1 6 Renewing crankshaft oil seal – pulley end 13918
2 Cylinder block, gearbox end 13921
2 1 Assembly overview – cylinder block, gearbox end 13921
2 2 Removing and installing sealing flange on gearbox side 13922
3 Crankshaft 13935
3 1 Assembly overview – crankshaft 13935
3 2 Crankshaft dimensions 13937
3 3 Renewing needle bearing in crankshaft 13937
4 Pistons and conrods 13940
4 1 Assembly overview – pistons and conrods 13940
4 2 Checking pistons and cylinder bores 13942
4 3 Separating new conrod 13944
15 – Cylinder head, valve gear 13946
1 Cylinder head 13946
1 1 Assembly overview – cylinder head 13946
1 2 Removing and installing cylinder head 13949
1 3 Removing and installing camshaft housing 13951
1 4 Checking compression 13959
2 Cover for timing chain 13961
2 1 Removing and installing valve timing housing (timing case) 13961
3 Chain drive 13966
3 1 Removing and installing timing chain and chain drive for oil pump 13966
3 2 Checking timing chain 13977
3 3 Checking valve timing 13983
3 4 Adjusting valve timing 13987
4 Valve gear 13998
4 1 Assembly overview – valve gear 13998
4 2 Measuring axial play of camshaft 14000
4 3 Removing and installing valve stem oil seals 14002
5 Inlet and exhaust valves 14005
5 1 Reworking valve seats 14005
5 2 Checking valve guides 14006
17 – Lubrication 14008
1 Sump, oil pump 14008
1 1 Assembly overview – sump/oil pump 14008
1 2 Engine oil: 14010
1 3 Removing and installing oil sump 14011
1 4 Removing and installing oil pump 14014
2 Oil filter, oil pressure switch 14017
2 1 Checking oil pressure and oil pressure switch 14017
19 – Cooling 14020
1 Cooling system/coolant 14020
1 1 Connection diagram – coolant hoses 14020
1 2 Checking cooling system for leaks 14021
1 3 Draining and adding coolant 14023
2 Coolant pump, regulation of cooling system 14029
2 1 Assembly overview – thermostat 14029
2 2 Removing and installing coolant circulation pump -V50- 14031
2 3 Removing and installing coolant pump 14032
3 Radiator, radiator fan 14036
3 1 Assembly overview – radiator/radiator fan 14036
3 2 Removing and installing radiator 14038
3 3 Removing and installing water radiator for charge air cooling circuit 14040
3 4 Removing and installing radiator cowl 14042
3 5 Removing and installing radiator fan -V7- and radiator fan 2 -V177- 14043
21 – Turbocharging/supercharging 14045
1 Turbocharger 14045
1 1 Assembly overview – turbocharger 14045
1 2 Assembly overview – turbocharger air recirculation valve -N249- 14047
1 3 Removing and installing turbocharger 14048
1 4 Checking vacuum unit for turbocharger 14055
1 5 Adjusting vacuum unit for turbocharger 14057
1 6 Renewing vacuum unit for turbocharger 14065
1 7 Removing and installing compressor housing and turbine housing 14069
2 Charge air system 14076
2 1 Assembly overview – charge air system 14076
24 – Mixture preparation – injection 14079
1 Injection system 14079
1 1 Releasing high pressure in fuel system 14079
2 Injectors 14080
2 1 Assembly overview – fuel rail with injectors 14080
2 2 Removing and installing injectors 14080
2 3 Renewing seals on injectors 14083
3 Air filter 14089
3 1 Assembly overview – air filter housing 14089
3 2 Removing and installing air filter housing 14089
4 Intake manifold 14091
4 1 Assembly overview – intake manifold 14091
4 2 Assembly overview – lower part of intake manifold with fuel rail 14093
4 3 Removing and installing intake manifold 14095
4 4 Removing and installing throttle valve module -J338- 14096
4 5 Cleaning throttle valve module -J338- 14100
5 Senders and sensors 14102
5 1 Checking fuel pressure sender -G247- 14102
6 Engine/motor control unit 14106
6 1 Removing and installing engine control unit -J623- without protective housing 14106
6 2 Removing and installing engine (motor) control unit -J623- with protective housing 14108
7 High-pressure pump 14114
7 1 Assembly overview – high-pressure pump 14114
7 2 Removing and installing high-pressure pump 14115
26 – Exhaust system 14120
1 Exhaust pipes and silencers 14120
1 1 Assembly overview – silencers 14120
1 2 Separating exhaust pipes from silencers 14121
1 3 Installation position of clamp 14123
1 4 Aligning exhaust system free of stress 14125
2 Emission control 14127
2 1 Assembly overview – emission control 14127
28 – Ignition system 14130
1 Ignition system 14130
1 1 Assembly overview – ignition system 14130
1 2 Test data, spark plugs 14132
1 3 Removing and installing ignition coils with output stage 14132
1 4 Removing and installing engine speed sender -G28- 14134
D4B80609EAF Air conditioning systems with refrigerant R1234yf – General information 14136
00 – Technical data 14142
1 Safety information 14142
1 1 Safety precautions when working on air conditioning systems 14142
1 2 Safety precautions when handling refrigerants 14143
1 3 Safety measures when working on vehicles with a start/stop system 14143
1 4 Safety precautions when using air conditioner service stations 14143
1 5 Safety measures for working on vehicles with high-voltage system 14144
1 6 Safety precautions when working in the vicinity of high-voltage components 14145
1 7 Safety precautions when working on pressure vessels 14145
2 Laws and regulations 14146
2 1 Legal regulations and standards 14146
2 2 Charging refrigerant circuit with different refrigerants 14147
2 3 Occupational health and safety 14148
3 Repair notes 14149
3 1 Rules for cleanliness 14149
3 2 Refrigerant circuit seals 14149
3 3 Refrigerant and refrigerant oil 14150
3 3 1 Important repair notes for refrigerant and refrigerant oil 14150
3 3 2 Refrigerant oil 14151
3 4 Handling pressure vessels 14152
3 5 Handling refrigerants 14153
4 Identification 14155
4 1 Notice for refrigerant circuit 14155
5 Technical data 14156
5 1 Refrigerant capacity 14156
5 2 Refrigerant oil capacities 14156
5 3 Safety data sheets 14156
6 Basic technical and physical properties 14157
6 1 Basics of air conditioning technology 14157
6 1 1 Physical properties of air conditioning system 14157
6 1 2 Pressure and boiling point of refrigerant 14158
6 1 3 Vapour pressure table for refrigerant 14159
6 2 Physical properties 14161
6 2 1 Refrigerant R1234yf 14161
6 2 2 Potential risks with refrigerant R1234yf 14161
6 2 3 Physical and chemical properties of refrigerant R1234yf 14162
6 2 4 Critical point 14162
6 2 5 Environmental aspects of refrigerant R1234yf 14163
6 2 6 Trade names and designations of refrigerant R1234yf 14163
6 2 7 Colour and odour of R1234yf refrigerant 14164
6 2 8 Vapour pressure of R1234yf refrigerant 14164
6 2 9 Physical properties of R1234yf refrigerant 14164
6 2 10 How R1234yf refrigerant reacts to metals and plastics 14164
6 2 11 Critical temperature / critical pressure of R1234yf refrigerant 14165
6 2 12 Water content of R1234yf refrigerant 14165
6 2 13 Flammability / decomposition of R1234yf refrigerant 14165
6 2 14 Charge factor of refrigerant R1234yf 14165
6 2 15 Evidence of leaks in a refrigerant circuit with R1234yf refrigerant 14166
6 2 16 Analysis of refrigerant R1234yf 14166
6 2 17 Returning contaminated R1234yf refrigerant for analysis, processing or disposal 14167
6 3 Product characteristics 14168
6 4 Function and role of air conditioning system 14168
6 4 1 Principle of operation 14168
6 4 2 Comfort 14169
6 4 3 Environmental aspects 14169
6 5 Other reference material 14170
87 – Air conditioning system 14171
1 Refrigerant circuit 14171
1 1 System overview – refrigerant circuit 14171
1 1 1 System overview – refrigerant circuit with expansion valve and receiver 14171
1 1 2 System overview – refrigerant circuit with restrictor and reservoir 14173
1 1 3 System overview – refrigerant circuit with electrically driven air conditioner compressor (with and without battery cooling module) 14174
1 2 General description – components of refrigerant circuit 14177
1 2 1 Layout and function of refrigerant circuit 14177
1 2 2 Mechanical air conditioner compressor 14178
1 2 3 Electrical air conditioner compressor for hybrid vehicles 14181
1 2 4 Condenser 14184
1 2 5 evaporator 14185
1 2 6 Reservoir 14187
1 2 7 Heat exchanger for heat pump mode 14187
1 2 8 Liquid receiver 14188
1 2 9 Restrictor 14188
1 2 10 Receiver 14190
1 2 11 Expansion valve (with and without shut-off valve) 14192
1 2 12 Refrigerant shut-off valves 14194
1 2 13 Refrigerant line with internal heat exchanger 14196
1 2 14 Quick release couplings of refrigerant lines 14197
1 2 15 Seals 14198
1 2 16 Pipes and hoses in refrigerant circuit 14199
1 2 17 High-pressure safety valve 14199
1 2 18 Non-return valves 14201
1 2 19 Quick-release coupling connections in refrigerant circuit 14202
1 2 20 Connections with valve for switches in refrigerant circuit 14206
1 2 21 Pressure senders and switches in refrigerant circuit 14207
1 2 22 Refrigerant pressure and temperature sender 14208
1 2 23 Air conditioner compressor regulating valve -N280- 14211
1 2 24 Refrigerant temperature sender 14212
1 3 Possible complaints 14213
1 3 1 Prerequisites for investigating a complaint 14213
1 3 2 Possible complaints 14213
1 3 3 Odours from heater and air conditioning unit 14215
1 4 Investigating leaks 14217
1 4 1 General information about investigating leaks in the refrigerant circuit 14217
1 4 2 Searching for leaks in refrigerant circuits using an electronic leak detector 14218
1 4 3 Searching for leaks with UV leak detection system 14219
1 4 4 Detecting leaks in a vacuum test using air conditioner service station, or in a pressure test 14225
1 4 5 Detecting leaks in a pressure test (with nitrogen or compressed air) 14226
1 5 Renewing components 14228
1 5 1 General information about renewing components 14228
1 5 2 Renewing leaking or damaged components of empty refrigerant circuit (apart from air conditioner compressor and receiver) 14229
1 5 3 Renewing leaking or damaged components of charged refrigerant circuit (apart from air conditioner compressor and receiver) 14231
1 5 4 Renewing air conditioner compressor with no need to clean refrigerant circuit 14232
1 5 5 Renewing air conditioner compressor due to leaks or internal damage 14235
1 5 6 Renewing desiccant cartridge / receiver after cleaning refrigerant circuit 14236
1 5 7 Renewing receiver with no need to clean refrigerant circuit 14238
1 5 8 Renewing desiccant cartridge / desiccant bag with no need to clean refrigerant circuit 14239
1 6 Cleaning refrigerant circuit 14240
1 6 1 General information about cleaning refrigerant circuit 14240
1 6 2 Preparations for cleaning refrigerant circuit (flushing with R1234yf refrigerant) 14242
1 6 3 Refrigerant circuit cleaning procedure 14246
1 6 4 Principle circuit diagrams for cleaning (flushing circuits) – refrigerant circuit with expansion valve and receiver 14246
1 6 5 Principle circuit diagrams for cleaning (flushing circuits) – refrigerant circuit with restrictor and receiver (without high-voltage system) 14251
1 6 6 Adapters for setting up flushing circuits 14254
1 6 7 General information about blowing through with compressed air or nitrogen 14267
1 6 8 Blowing through refrigerant circuit with compressed air or nitrogen 14271
1 7 Checking pressures with pressure gauge 14272
1 7 1 Display on pressure gauges 14272
1 7 2 Pressure gauges enable the following test and measurement work 14273
2 Working with air conditioner service station 14276
2 1 Working with air conditioner service station 14277
2 2 Connecting air conditioner service station to refrigerant circuit 14279
2 3 Performing gas analysis of refrigerant 14282
2 4 Purging refrigerant circuit 14285
2 5 Evacuating refrigerant circuit 14288
2 6 Charging refrigerant circuit 14294
2 7 Bringing air conditioning system into service after charging 14297
2 8 Switching off air conditioner service station and separating from refrigerant circuit 14299
2 9 Charging refrigerant in reservoir 14301
2 10 Emptying air conditioner service station 14302
2 11 Cleaning electrical air conditioning compressor 14302
2 12 Cleaning refrigerant circuit 14305
2 13 Filling contaminated refrigerant in a recycling cylinder for analysis, processing or disposal 14308
2 13 1 Filling contaminated refrigerant into recycling cylinder using extraction unit -VAS 581 011- 14308
2 13 2 Filling contaminated refrigerant into recycling cylinder using extraction unit -VAS 581 007- 14309
2 14 Checking pressures 14313
2 14 1 General information on checking pressures in the refrigerant circuit 14313
2 14 2 Pressures and temperatures in refrigerant circuit 14315
2 14 3 Checking pressures in the refrigerant circuit with the ignition switched off 14319
2 14 4 Checking pressures with air conditioning system switched on – vehicles with mechanical air conditioning compressor 14326
2 14 5 Checking pressures with air conditioning system switched on – vehicles with electrical air conditioning compressor 14348
3 Testing equipment and tools 14401
3 1 Tools and materials available from distribution centre or importer 14401
3 2 Tools and materials available commercially 14401
D4B80743DC1 Heating air conditioner 14403
00 – Technical data 14409
1 Safety information 14409
1 1 Safety precautions when working on air conditioning systems 14409
1 2 Safety measures for working on vehicles with high-voltage system 14409
1 3 Safety precautions when working in the vicinity of high-voltage components 14410
1 4 Safety measures when working on vehicles with a start/stop system 14411
1 5 Safety precautions when using testers and measuring instruments during a road test 14411
1 6 Safety precautions when working on the cooling system 14411
1 7 Safety precautions when handling refrigerants 14411
1 8 Safety precautions for working on vehicles with auxiliary/supplementary heater 14412
2 General information 14414
2 1 Type plates 14414
2 1 1 Identification plate with capacities for refrigerant R134a and refrigerant oil 14414
2 2 Notes concerning odours in air conditioned vehicles 14414
2 3 Notes for vehicles with start-stop system 14415
2 4 Notes on dust and pollen filter 14416
3 Repair notes 14418
3 1 Rules for cleanliness 14418
3 2 Nuts and bolts 14418
3 3 Routing and attachment of lines 14419
3 4 Fitting radiators and condensers 14419
3 5 Checking heater output 14419
3 6 Checking cooling output 14422
3 7 Working on refrigerant circuit 14424
3 8 Paint work on vehicles with air conditioning system 14424
3 9 Refrigerant circuit seals 14425
4 Technical data 14426
4 1 Refrigerant capacity 14426
4 2 Refrigerant oil capacities 14426
4 3 Oil distribution 14427
80 – Heating 14428
1 Overview of fitting locations – heating 14428
1 1 Overview of fitting locations – components not located in passenger compartment 14428
1 2 Overview of fitting locations – components located in front section of passenger compartment 14429
2 Heater 14432
2 1 Assembly overview – heater unit 14432
2 2 Removing and installing heater unit 14433
2 3 Removing and installing flexible shafts 14439
2 3 1 Removing and installing flexible shafts for air distribution 14439
2 3 2 Removing and installing Bowden cable for temperature flap 14440
2 4 Removing and installing temperature flap actuator 14441
3 Control motors 14443
3 1 Removing and installing fresh air and air recirculation flap control motor -V154- 14443
4 Air duct system 14444
5 Operating and display unit 14445
5 1 Overview of operating and display unit 14445
5 2 Connectors on controls for heated and fresh air 14447
6 Other controlling and regulating components 14449
87 – Air conditioning system 14450
1 Overview of fitting locations – air conditioning system 14450
1 1 Overview of fitting locations – components not located in passenger compartment 14450
1 2 Overview of fitting locations – components located in front section of passenger compartment 14452
1 2 1 Air conditioning and heating system – components located in front section of passenger compartment 14452
1 2 2 Climatronic – components located in front section of passenger compartment 14454
2 Refrigerant circuit 14457
2 1 System overview – refrigerant circuit 14457
2 2 Assembly overview – condenser 14459
2 3 Removing and installing high-pressure sender -G65- 14460
2 4 Removing and installing expansion valve 14462
2 5 Removing and installing condenser 14465
2 6 Removing and installing desiccant bag or cartridge 14468
2 7 Removing and installing evacuating and charging valves on low and high-pressure side 14471
2 8 Removing and installing refrigerant line from air conditioner compressor to evaporator 14473
2 9 Removing and installing refrigerant line from condenser to air conditioner compressor 14477
2 9 1 Removing and installing refrigerant line from condenser to air conditioner compressor 14477
2 9 2 Removing and installing refrigerant line from condenser to electrical air conditioner compressor -V470- 14479
2 10 Removing and installing refrigerant line from air conditioner compressor to evaporator 14482
2 10 1 Removing and installing refrigerant line from air conditioner compressor to evaporator 14482
2 10 2 Removing and installing refrigerant line from electrical air conditioner compressor -V470- to evaporator 14485
3 Air conditioner compressor 14490
3 1 Assembly overview – drive unit of air conditioner compressor 14490
3 1 1 Assembly overview – air conditioner compressor 14490
3 1 2 Assembly overview – electrical air conditioner compressor -V470- 14490
3 2 Removing air conditioning compressor from and installing on bracket 14491
3 2 1 Removing air conditioning compressor from and installing on bracket 14491
3 2 2 Removing electrical air conditioner compressor -V470- from and attaching to bracket 14493
3 3 Removing and installing air conditioner compressor 14495
3 3 1 Removing and installing air conditioner compressor 14495
3 3 2 Removing and installing electrical air conditioner compressor -V470- 14500
3 4 Checking high-pressure safety valve on air conditioner compressor 14503
4 Control motors 14505
4 1 Overview of fitting locations – front control motors 14505
4 1 1 Overview of fitting locations – front control motors, air conditioning system with electric and manual controls 14505
4 1 2 Overview of fitting locations – front control motors, Climatronic 14506
4 2 Removing and installing temperature flap control motor -V68- 14507
4 3 Removing and installing centre flap control motor -V70- 14510
4 4 Removing and installing defroster flap control motor -V107- 14511
4 5 Removing and installing air recirculation flap control motor -V113- 14513
4 6 Removing and installing left temperature flap control motor -V158- 14517
4 7 Removing and installing right temperature flap control motor -V159- 14520
4 8 Removing and installing fresh air/air recirculation, air flow flap control motor -V425- 14522
4 9 Removing and installing air distribution flap control motor -V428- 14522
5 Front heater and air conditioning unit 14523
5 1 Assembly overview – heater and air conditioning unit 14523
5 1 1 Assembly overview – heater and air conditioning unit, air conditioner with manual controls 14523
5 1 2 Assembly overview – heater and air conditioning unit, Climatronic 14525
5 2 Assembly overview – evaporator housing 14528
5 3 Removing and installing evaporator 14528
5 4 Checking auxiliary air heater element -Z35- 14530
5 5 Removing and installing auxiliary air heater element -Z35- 14533
5 5 1 Removing and installing auxiliary air heater element -Z35- (LHD) 14533
5 5 2 Removing and installing auxiliary air heater element -Z35- (RHD) 14535
5 6 Removing and installing heater and air conditioning unit 14537
5 7 Dismantling and assembling heater and air conditioning unit 14544
5 8 Removing and installing air distribution housing 14545
5 8 1 Removing and installing air distribution housing 14545
5 8 2 Removing and installing air distribution housing lever 14547
5 9 Removing and installing dust and pollen filter 14549
5 10 Removing and installing fresh air blower -V2- 14550
5 11 Removing and installing fresh air blower control unit -J126- 14551
5 12 Removing and installing heat exchanger 14552
5 12 1 Removing and installing heat exchanger, left-hand drive vehicles 14552
5 12 2 Removing and installing heat exchanger (RHD) 14558
5 13 Removing and installing coolant pipes on heat exchanger 14564
5 13 1 Removing and installing coolant pipes on heat exchanger, LHD vehicles 14564
5 13 2 Removing and installing coolant pipes on heat exchanger, RHD vehicles 14566
5 14 Removing and installing evaporator temperature sensor -G308- 14568
5 15 Removing and installing condensation drain 14569
5 16 Checking condensation drain 14569
5 17 Removing and installing baffle plate 14570
5 17 1 Removing and installing baffle plate, LHD vehicles 14570
5 17 2 Removing and installing baffle plate, RHD vehicles 14571
5 18 Removing and installing fresh air blower series resistor with overheating fuse -N24- 14571
6 Air duct system 14573
6 1 Assembly overview – air duct and air distribution in passenger compartment 14573
6 2 Air intake and air outlet openings 14575
6 2 1 Removing and installing trim for left dash panel vent and centre vent 14575
6 2 2 Removing and installing right side vent 14577
6 3 Removing and installing driver side footwell vents 14578
6 3 1 Removing and installing driver side footwell vents, left-hand drive vehicles 14578
6 3 2 Removing and installing driver side footwell vents, right-hand drive vehicles 14579
6 4 Removing and installing front passenger side footwell vents 14579
6 4 1 Removing and installing front passenger side footwell vents, left-hand drive vehicles 14579
6 4 2 Removing and installing front passenger side footwell vents, right-hand drive vehicles 14580
6 5 Removing and installing rear footwell vent 14581
6 6 Installing plug in air duct to centre vent 14582
6 7 Removing and installing air ducts 14583
6 8 Removing and installing forced ventilation for passenger compartment 14583
6 9 Checking forced ventilation for passenger compartment 14584
6 10 Removing and installing fresh air intake 14585
6 11 Removing and installing air intake duct 14586
6 12 Removing and installing air duct for defroster vent 14587
6 13 Removing and installing air duct for centre dash panel vent 14588
7 Operating and display unit 14589
7 1 Overview of operating and display unit 14589
7 1 1 Overview of control and display unit, air conditioning system with electric/manual controls 14589
7 1 2 Overview of operating and display unit, Climatronic 14591
7 2 Removing and installing operating and display unit 14593
7 3 Procedure when checking and adjusting components 14595
7 4 Connectors on controls for heating and air conditioning system 14596
7 4 1 Connectors on controls for heating and air conditioning system (manually operated air conditioning system) 14596
7 4 2 Connectors on Climatronic control unit -J255- 14597
8 Other controlling and regulating components 14600
8 1 Removing sunlight penetration photosensor -G107- or sunlight penetration photosensor 2 -G134- 14600
8 2 Principle of operation of air quality sensor -G238- 14601
8 3 Removing and installing air quality sensor -G238- 14602
8 4 Removing and installing ambient temperature sensor -G17- 14603
8 5 Removing and installing left vent temperature sender -G150- 14604
8 6 Removing and installing right vent temperature sender -G151- 14604
8 7 Removing and installing footwell vent temperature sender -G192- 14605
8 8 Removing and installing left footwell vent temperature sender -G261- 14605
8 9 Removing and installing right footwell vent temperature sender -G262- 14605
D4B80796BA2 Wheels and Tyres Guide General Information 14607
44 – Wheels, tyres, vehicle geometry 14611
1 Instructions on using the guide 14611
1 1 Overview 14611
1 1 1 Wheels and Tyres Guide – General Information 14611
1 1 2 Wheels and Tyres Guide – Vehicle-specific Section 14611
1 2 General information 14611
1 3 Notes 14612
1 4 Explanations regarding world regions 14613
1 5 Definition of tyre package 14613
1 6 Procedure for determining the required tyre package 14614
1 6 1 Determining the required tyre package via PR number 14614
1 6 2 Determining the required tyre package via version key in the vehicle registration certificate part 1 14614
1 7 Vehicle registration certificate part 1 14615
2 Legislative and technical conditions 14617
2 1 Legislative conditions 14617
2 1 1 Permissible wheel and tyre combinations in Germany 14617
2 1 2 Vehicles with Tyre Pressure Monitoring System 14617
2 2 Technical conditions 14618
2 3 Load-carrying capacity depending on vehicle speed, winter tyres 14618
2 4 Vehicle registration documents since 1 10 2005 14620
2 5 COC document (EEC Certificate of Conformity) 14621
2 6 EU general type approval number, sales type and sales or trade designation 14621
3 Wheel change 14623
3 1 Fitting instructions 14623
3 2 Protecting wheel centring seat against corrosion 14626
3 3 Fitting wheels 14627
3 4 Position of anti-theft wheel bolts for steel wheels 14627
4 Fitting tyre 14628
4 1 Pressing tyre off wheel rim 14628
4 2 Removing tyre sealant 14628
4 3 Removing tyre from wheel 14629
4 3 1 Removing tyres, wheels without and with tyre pressure monitoring 14629
4 3 2 Removing tyres, run-flat tyres, ultra-high-performance tyres 14630
4 4 Ensuring proper assembly temperature for tyres 14632
4 5 Mounting tyre 14633
4 5 1 Mounting tyre, wheels without and with tyre pressure monitoring 14633
4 5 2 Mounting tyre, run-flat tyres, ultra-high performance tyres 14635
4 6 Matching wheel rims and tyres 14638
4 7 Checking radial and lateral runout of wheels and tyres 14639
4 7 1 Checking radial and lateral runout of wheels and tyres, tolerances 14639
4 7 2 Checking radial and lateral runout on wheels and tyres with tyre gauge 14639
4 8 Matching wheels and tyres 14640
4 9 Balancing wheel 14641
4 9 1 Conditions 14641
4 9 2 Balancing wheel on stationary wheel balancer 14642
4 9 3 Balancing wheel with finish balancer 14645
4 9 4 Checking radial and lateral run-out on wheel rim 14646
4 10 Tyre sealant disposal 14647
5 Tyre pressure monitoring system 14648
5 1 System description – tyre pressure monitoring system 14648
5 1 1 System description – tyre pressure monitoring system with indirect measurement (Tyre Pressure Loss Indicator) 14648
5 1 2 System description – tyre pressure monitoring system with direct measurement (Tyre Pressure Monitoring System) 14649
5 1 3 System description – tyre pressure monitoring system, tyre pressure monitoring system (TPMS) with autolocation 14650
5 2 Overview of fitting locations – tyre pressure monitor system 14650
5 2 1 Overview of fitting locations – Tyre Pressure Monitoring System (TPMS) with autolocation 14650
5 3 Assembly overview – tyre pressure sensor 14652
5 3 1 Assembly overview – tyre pressure sensor, tyre pressure sensor with valve 14652
5 3 2 Assembly overview – tyre pressure sensor, tyre pressure sensor without valve, version 1 14653
5 3 3 Assembly overview – tyre pressure sensor, tyre pressure sensor without valve, version 2 14654
5 4 Removing and installing tyre pressure sensor -G222-/-G223-/-G224-/-G225- 14655
5 4 1 Removing and installing tyre pressure sensor, tyre pressure sensor with valve 14655
5 4 2 Removing and installing tyre pressure sensor, tyre pressure sensor without valve, version 1 (customer service version) 14656
5 4 3 Removing and installing tyre pressure sensor, tyre pressure sensor without valve, version 1 (production version) 14657
5 4 4 Removing and installing tyre pressure sensor -G222-/-G223-/-G224-/-G225-, version 2 14659
5 5 Removing and installing tyre pressure monitor control unit -J502- 14662
5 5 1 Removing and installing Tyre Pressure Monitoring System control unit -J502-, Arteon 2018, Passat 2015, Passat Estate 2015 14662
5 5 2 Removing and installing tyre pressure monitoring system control unit -J502-, Touran 14663
6 Wheel bolts 14665
6 1 Wheel bolts, versions 14665
6 2 Wheel bolts, anti-theft wheel bolt 14666
6 3 Wheel bolts, adapter sets for anti-theft wheel bolts 14666
7 Information on tyres 14669
7 1 Identification markings on the tyre sidewall 14669
7 2 Tyre dimension 14671
7 3 Load rating code/load index (LI) 14671
7 4 Speed rating code 14672
7 5 EU tyre label 14672
7 5 1 EU tyre label, summary 14672
7 5 2 EU tyre label, objectives 14673
7 5 3 EU tyre label, categories 14674
7 6 Structure of a radial belted tyre 14677
7 6 1 Cross section of a radial belted tyre 14677
7 6 2 Run-flat tyres, structure and identification of a SST tyre 14678
7 6 3 Run-flat tyres, seal inside technology 14679
7 7 Run-flat tyre, SST (Self Supporting Tyre) 14681
7 7 1 Run-flat tyres – general information 14681
7 7 2 Run-flat tyres, retrofitting/requirements when using run-flat tyres 14682
7 7 3 Run-flat tyres, repair work 14683
7 8 Tyre storage 14683
7 9 Reinforced and Extra Load (XL) tyres 14683
7 10 Winter tyres 14684
7 11 Winter tyres with speed symbol V 14686
7 12 Rolling resistance optimised tyres 14687
7 13 Tyre ageing 14687
7 14 Tyres with flange protection 14689
7 15 Tyre sizes for vehicles with four-wheel drive 14689
7 16 Increase in temperature due to insufficient tyre pressure 14690
8 Tyre sealant 14691
8 1 Models with breakdown set 14691
8 2 Storage life 14691
8 3 Waste disposal 14691
9 Information on wheel rims 14692
9 1 Structure of wheel rim 14692
9 2 Identification 14693
9 3 Composite wheels 14693
9 4 Care and maintenance of alloy wheel rims 14693
9 5 Restoring alloy wheels 14694
9 6 Removing and installing hub cover for alloy wheels with open threaded connection 14694
9 7 Renewing trim elements 14695
9 7 1 Renewing trim elements, bonded trim elements 14695
9 7 2 Renewing trim elements, bolted trim elements 14699
9 8 Removing and installing valve 14701
9 8 1 Removing and installing valve, description of the valve 14701
9 8 2 Removing and installing valve, rubber valve 14701
9 8 3 Removing and installing valve, metal valve 14702
10 Handling problems 14704
10 1 Rolling noise 14704
10 1 1 General notes on tyre noise 14704
10 1 2 Flat spots (from locking wheels) 14705
10 2 Vehicle pulls to one side 14706
10 2 1 General information 14706
10 2 2 Conicity 14706
10 2 3 Remedies when vehicle pulls to one side 14707
10 2 4 Strategic rotation of wheels for non-directional tyres 14708
10 2 5 Strategic rotation of wheels having unidirectional tyres 14709
10 3 Vibration 14710
10 3 1 Vibration, causes for vibration 14710
10 3 2 Vibration, conducting a road test before balancing wheels 14710
10 3 3 Vibration, vibration control system 14711
10 4 Eliminating flat spots caused by storage or handling 14711
11 Evaluating tyres 14713
11 1 Flat spots caused by storage or handling 14713
11 2 Undulations 14713
11 3 Saw-tooth wear 14714
11 4 Flat spots caused by hard braking 14714
11 5 Swellings in the tyre sidewall 14714
11 6 Cuts 14716
11 7 Damage caused by foreign bodies 14716
11 8 Stripped profile 14716
11 9 Tyre damage due to insufficient tyre pressure 14717
11 10 Checking tyres 14717
11 11 Damage caused when fitting 14718
12 Tyre wear 14720
12 1 Factors influencing the service life of tyres 14720
12 2 Saw-tooth wear 14721
12 3 Wear behaviour of high-speed tyres 14721
12 4 Measuring tread depth 14722
12 5 One-sided wear 14722
12 6 Outer shoulder wear 14725
12 7 Diagonal washout 14726
12 8 Wear in middle of tyre 14726
12 9 Permissible deviation in tread depth 14727
13 Exploded view of components 14728
13 1 Assembly overview – wheel 14728
14 Snow chains 14730
14 1 Assembly and use of snow chains 14730
15 Regular and temporary spare wheels, recommended temporary spare tyres 14731
15 1 Spare wheel with yellow sticker 14731
15 2 Temporary spare wheels and recommended temporary spare tyres 14732
15 2 1 Arteon 2018 14732
15 2 2 Atlas 2017 14732
15 2 3 Golf 2013, e-Golf 2014 14732
15 2 4 Golf 2017, e-Golf 2017 14732
15 2 5 Golf SV 2015 14733
15 2 6 Golf Estate 2014 14733
15 2 7 Golf Estate 2017 14733
15 2 8 Passat 2015, Passat Estate 2015 14733
15 2 9 Polo 2018 14734
15 2 10 Tiguan 2016 14734
D4B802605A6 General information Paint passenger vehicles 14735
00 – Technical data 14741
1 Safety information 14741
1 1 Safety precautions when painting natural gas-powered vehicles 14741
1 2 Safety precautions when painting electric drive vehicles 14742
2 General information 14743
2 1 Paintwork structure of a factory finish 14743
2 2 Paint structure of service department finish 14746
2 2 1 Paintwork structure, base coat 14746
2 2 2 Paintwork structure, metallic effect 14749
2 3 Fundamental approach to dealing with areas sanded through to the substrate (bare metal surface) 14751
2 4 Reduced paint structure in engine compartment and inside of bonnet 14751
2 5 Instructions for work on underbody and stone chip protection 14751
2 6 Work instruction for window flange area 14753
2 7 Pre-treatment of bonded surfaces when renewing laser-welded roofs 14755
2 8 Corrosion protection measures for wing surface in contact with wheel housing liner 14759
2 9 Notes on treating corroded fold areas 14760
2 10 Corrosion protection for body components, add-on components and welded components 14762
2 11 Painting parking aid sensor 14763
2 12 ACC – Adaptive Cruise Control 14765
2 13 Instructions for painting bumper cover in area of lane change assist control unit 14765
3 Genuine products 14767
3 1 Paint products in customer service 14767
3 2 General application instructions for repair and painting systems 14768
3 2 1 Aqua Premium – application instructions for water-based products 14768
3 2 2 Setting gloss level of HS clear coats and HS top coats with matting additive 14771
3 2 3 Setting gloss level of 2-pack HS clear coats with 2-pack clear coat, matt 14781
3 2 4 Repair paintwork system for matt-finished vehicles 14783
3 2 5 Paintwork system for plastic components 14788
3 2 6 Aqua Premium system, blending system for 2-stage colours 14796
3 2 7 Aqua Premium system, blending system for 3-stage colours 14805
3 2 8 Aqua Premium system, product preparation for processing 14812
3 2 9 Aquaplus design and multi-colour painting 14819
3 2 10 Processing instructions for paint with limited hiding power 14824
3 3 Filler 14824
3 3 1 2-pack steel filler set 14824
3 3 2 2-pack fine filler 14828
3 3 3 2-pack fine filler, flexible 14832
3 3 4 2-pack spray filler 14835
3 3 5 2-pack IR premium filler 14841
3 3 6 2-pack epoxy resin filler 14846
3 4 Priming metal 14850
3 4 1 1-pack anti-corrosion wash primer 14850
3 4 2 1-pack wash primer 14855
3 4 3 2-pack wash primer 14860
3 5 Priming plastic materials 14866
3 5 1 Adhesion promoter (transparent) 14866
3 6 Surfacer 14870
3 6 1 2-pack HS Vario surfacer 14870
3 6 2 2-pack HS premium surfacer 14880
3 6 3 2-pack HS Performance surfacer 14889
3 6 4 2-pack primer surfacer for plastics 14898
3 6 5 2-pack HS wet-on-wet surfacer 14904
3 6 6 2-pack base filler, professional 14914
3 7 Top coats 14931
3 7 1 2-pack HS top coat 14931
3 7 2 Aquaplus system, uni (solid-colour) and metallic colours 14940
3 7 3 Aquaplus system (pearlescent and heliochrome) 14948
3 7 4 Aquaplus blending system 14956
3 7 5 Aqua Premium system 14962
3 7 6 Aqua Premium blending system 14975
3 7 7 Aqua Premium system (painting rims) 14982
3 8 Clear coats 14991
3 8 1 2-pack HS clear coat 14991
3 8 2 2-pack MS matt clear coat 14998
3 8 3 2-pack HS Vario clear coat 15004
3 8 4 2-pack HS optimum clear coat 15012
3 8 5 2-pack HS optimum plus clear coat 15018
3 8 6 2-pack HS brilliant clear coat 15023
3 8 7 2-pack HS brilliant plus clear coat 15028
3 8 8 2-pack HS Performance clear coat 15034
3 8 9 Blender 15040
3 9 Hardener 15045
3 9 1 2-pack HS hardener 15045
3 9 2 2-pack VHS hardeners and 2-pack VHS Performance hardeners 15049
3 9 3 Hardener for 2-pack primer surfacer 15053
3 9 4 Aqua Premium hardener 15053
3 10 Thinners 15054
3 10 1 2-pack thinner 15054
3 10 2 HS spot thinner 15057
3 10 3 Demineralised water 15059
3 11 Anti-corrosion materials 15060
3 11 1 Anti-corrosion wax 15060
3 11 2 Cavity sealant 15061
3 11 3 Anti-corrosion wax (in aerosol can) 15064
3 12 Underseal 15065
3 12 1 Permanent underseal -D 314 D36 M2-, grey 15065
3 12 2 Permanent underseal -D 314 D37 M2-, black 15068
3 12 3 Permanent underseal -D 314 D38 M2-, light 15071
3 12 4 Underseal -D 314 D39 A3-, black 15074
3 13 Stone deflector 15076
3 13 1 Stone chip guard -AKR 311 KD1 05- 15076
3 13 2 Stone chip guard -AKR 311 KD1 10- 15078
3 14 Wax-based underseal 15085
3 14 1 Wax-based underseal -D 316 D38 A2- 15085
3 14 2 Wax-based underseal -D 316 000 A1- 15087
3 14 3 Spray wax -D 322 100 M2- 15089
3 15 Sealing materials 15090
3 15 1 Polyurethane adhesive sealant (bonding compound) 15090
3 15 2 Sprayable sealant 15093
3 15 3 Adhesive sealant 15096
3 16 Cleaning agents 15098
3 16 1 Silicone remover 15098
3 16 2 Cleaner for plastics 15100
3 16 3 Cleaner for plastics, anti-static 15101
3 16 4 Industrial dirt remover 15101
3 17 SprayMax system 15103
3 17 1 1-pack anti-corrosion primer 15103
3 17 2 1-pack test paint 15107
3 17 3 1-pack clear coat 15110
3 17 4 1-pack wash primer 15113
3 17 5 1-pack Fill Clean spray can -LLS MAX 099-/1-pack Fill Clean spray can -LLS MAX 100- – Aquaplus system 15118
3 17 6 1-pack fill clean spray can -LLS MAX 112-, Aqua Premium system 15125
3 17 7 2-pack surfacer 15133
3 17 8 2-pack HS Performance surfacer 15140
3 17 9 2-pack clear coat 15148
3 17 10 2-pack epoxy primer surfacer 15153
3 17 11 2-pack wash primer 15159
3 17 12 Silicone remover -LLS MAX 007- 15165
3 17 13 Slow-drying silicone remover -LLS MAX 008- 15167
3 17 14 Blender 15170
3 17 15 Adhesion promoter 15172
3 18 Additional materials 15176
3 18 1 Matting additive -ALN 775 106- 15176
3 18 2 Matting additive -LVM 769 810 A2- 15183
3 18 3 Texture additive 15186
3 18 4 Blending additive for Aquaplus 15192
3 18 5 Additive for Aqua Premium 15193
4 Workshop equipment 15194
4 1 Tools 15194
4 1 1 Spray can filling device -VAS 6425- 15194
4 1 2 Paint thickness tester -VAS 6272- 15195
4 1 3 Paint thickness tester -VAS 6197- 15196
4 1 4 Paint thickness tester -VAS 5278- 15196
4 1 5 Stone chip tester -VAS 5102A- 15197
4 1 6 Pneumatic brush grinder set -VAS 6446- 15198
4 1 7 Brush grinder set -VAS 6776- 15198
4 1 8 Suction feed spray-gun -V A G 1538- 15200
4 1 9 Infrared heater -VAS 6873- 15201
4 1 10 Stand -VAS 6873/1- 15201
4 1 11 Infrared heater -VAS 6874- 15202
4 1 12 Infrared heater -VAS 6875- 15203
4 1 13 Infrared heater -VAS 6876- 15203
4 1 14 Infrared heater -VAS 6877- 15204
4 1 15 Infrared heater -VAS 6878- 15205
4 1 16 Infrared heater -VAS 6879- 15206
4 2 Tack cloths 15206
4 2 1 Tack cloth -VAS 6177- 15206
4 2 2 Buffing cloth, white -VAS 6176- 15207
D4B804587A1 4 cylinder common rail engine (2 0 l 4V turbocharger) 15208
00 – Technical data 15216
1 Safety information 15216
1 1 Safety regulations for working on fuel supply 15216
1 2 Safety measures when working on vehicles with a start/stop system 15217
1 3 Safety precautions when using testers and measuring instruments during a road test 15217
1 4 Safety precautions when working on the cooling system 15217
1 5 Safety precautions when working on SCR system 15218
2 Identification 15219
2 1 Engine number/engine data 15219
3 Repair instructions 15221
3 1 Rules for cleanliness 15221
3 2 Adapting learnt value for SCR system 15221
3 3 Foreign objects in engine 15221
3 4 Contact corrosion 15222
3 5 Routing and attachment of lines 15222
3 6 Fitting radiator and condensers 15222
4 Technical data 15223
4 1 Coolant 15223
10 – Removing and installing engine 15224
1 Removing and installing engine 15224
1 1 Removing engine 15224
1 2 Separating engine and gearbox 15234
1 3 Securing engine on engine and gearbox support 15235
1 4 Installing engine 15237
2 Assembly mountings 15241
2 1 Assembly overview – assembly mountings 15241
2 2 Removing and installing engine mounting 15243
2 3 Removing and installing gearbox mounting 15244
2 4 Removing and installing pendulum support 15245
2 5 Supporting engine in installation position 15246
2 6 Adjusting assembly mountings 15250
2 7 Checking adjustment of assembly mountings (engine and gearbox mountings) 15251
3 Engine cover panel 15252
3 1 Removing and installing engine cover 15252
13 – Crankshaft group 15253
1 Cylinder block (pulley end) 15253
1 1 Assembly overview – cylinder block (pulley end) 15253
1 2 Assembly overview – sealing flange, belt pulley end 15255
1 3 Removing and installing poly-V belt 15255
1 4 Removing and installing tensioner for poly V-belt 15257
1 5 Removing and installing vibration damper 15257
1 6 Removing and installing bracket for ancillaries 15258
1 7 Removing and installing engine support 15259
1 8 Removing and installing sealing flange on pulley end 15260
2 Cylinder block, gearbox end 15263
2 1 Assembly overview – cylinder block, gearbox end 15263
2 2 Removing and installing flywheel 15264
2 3 Removing and installing sealing flange on gearbox side 15265
3 Crankshaft 15274
3 1 Assembly overview – crankshaft 15274
3 2 Crankshaft dimensions 15275
3 3 Renewing needle bearing in crankshaft 15275
3 4 Measuring axial clearance of crankshaft 15277
4 Pistons and conrods 15279
4 1 Assembly overview – pistons and conrods 15279
4 2 Removing and installing pistons 15281
4 3 Measuring piston projection at TDC 15282
4 4 Checking pistons and cylinder bores 15284
4 5 Separating new conrod 15286
4 6 Checking radial clearance of conrods 15286
4 7 Removing and installing oil spray jets 15286
15 – Cylinder head, valve gear 15288
1 Cylinder head 15288
1 1 Assembly overview – cylinder head 15288
1 2 Assembly overview – cylinder head cover 15290
1 3 Removing and installing cylinder head 15292
1 4 Removing and installing cylinder head cover 15301
1 5 Removing and installing injector seals 15303
1 6 Removing and installing camshaft housing 15304
1 7 Checking compression 15309
2 Toothed belt drive 15311
2 1 Assembly overview – toothed belt cover 15311
2 2 Assembly overview – toothed belt 15312
2 3 Removing and installing toothed belt guard 15313
2 3 1 Removing and installing upper toothed belt guard 15313
2 3 2 Removing and installing lower toothed belt guard 15315
2 4 Removing and installing toothed belt 15316
2 5 Removing toothed belt from camshaft 15327
3 Valve gear 15332
3 1 Assembly overview – valve gear 15332
3 2 Measuring axial play of camshaft 15335
3 3 Removing and installing camshaft oil seal 15336
3 4 Removing and installing camshaft adjuster 15337
3 5 Removing and installing camshaft control valve 1 -N205- 15340
3 6 Removing control valve from and installing on inlet camshaft control valve 1 -N205- 15341
3 7 Checking hydraulic compensation elements 15343
3 8 Removing and installing valve stem seals 15344
3 8 1 Removing and installing valve stem seals (cylinder head installed) 15344
3 8 2 Removing and installing valve stem seals (cylinder head removed) 15347
4 Inlet and exhaust valves 15351
4 1 Checking valve guides 15351
4 2 Checking valves 15352
4 3 Valve dimensions 15352
17 – Lubrication 15353
1 Sump, oil pump 15353
1 1 Assembly overview – sump/oil pump 15353
1 1 1 Assembly overview – sump/oil pump, vehicles with two-piece sump 15353
1 1 2 Assembly overview – sump/oil pump, vehicles with one-piece sump 15356
1 2 Engine oil: 15358
1 3 Removing and installing sump 15358
1 4 Removing and installing lower part of sump 15361
1 5 Removing and installing upper part of sump 15365
1 6 Removing and installing oil pump 15369
1 7 Removing and installing oil level and oil temperature sender -G266- 15370
1 7 1 Removing and installing oil level and oil temperature sender -G266-, vehicles with two-piece sump 15370
1 7 2 Removing and installing oil level and oil temperature sender -G266-, vehicles with one-piece sump 15371
2 Engine oil cooler 15372
2 1 Removing and installing engine oil cooler 15372
3 Oil filter, oil pressure switch 15373
3 1 Assembly overview – oil filter housing, oil pressure switch 15373
3 2 Removing and installing oil pressure switch -F1- 15374
3 3 Removing and installing oil pressure switch for reduced oil pressure -F378- 15375
3 4 Checking oil pressure 15376
3 5 Removing and installing oil filter housing 15376
3 6 Removing and installing oil pressure regulating valve -N428- 15378
19 – Cooling 15380
1 Cooling system/coolant 15380
1 1 Connection diagram – coolant hoses 15380
1 1 1 Coolant hose schematic diagram, vehicles with SCR system 15380
1 1 2 Coolant hose schematic diagram, vehicles without SCR 15382
1 1 3 Coolant hose schematic diagram, vehicles without SCR and without exhaust gas recirculation valve 1 -GX5- 15384
1 2 Assembly overview – engine preheater 15386
1 3 Checking cooling system for leaks 15386
1 4 Draining coolant 15388
1 5 Filling with coolant 15390
1 5 1 Filling with coolant without electric vacuum pump 15390
1 5 2 Filling coolant with electric vacuum pump -VAS 6096/2- 15393
1 6 Checking electric vacuum pump -VAS 6096/2- 15399
1 7 Flushing cooling system 15399
1 8 Flushing cooling system, quick reference guide 15420
2 Coolant pump, regulation of cooling system 15422
2 1 Assembly overview – coolant pump, thermostat 15422
2 2 Assembly overview – electric coolant pump 15424
2 2 1 Assembly overview – charge air cooling pump -V188- and auxiliary pump for heating -V488-, version 1 15424
2 2 2 Assembly overview – charge air cooling pump -V188-, version 2 15425
2 2 3 Assembly overview – charge air cooling pump -V188-, version 3 15426
2 2 4 Assembly overview – auxiliary pump for heating -V488-, version 2 15427
2 2 5 Assembly overview – auxiliary pump for heating -V488-, version 3 15428
2 3 Assembly overview – coolant temperature sender 15429
2 3 1 Assembly overview – coolant temperature sender -G62- 15429
2 3 2 Assembly overview – radiator outlet coolant temperature sender -G83- 15430
2 4 Removing and installing electric coolant pump 15430
2 4 1 Removing and installing charge air cooling pump -V188-, version 1 and 2 15430
2 4 2 Removing and installing charge air cooling pump -V188-, version 3 15432
2 4 3 Removing and installing auxiliary pump for heating -V488-, version 1 15434
2 4 4 Removing and installing auxiliary pump for heating -V488-, version 2 15436
2 4 5 Removing and installing auxiliary pump for heating -V488-, version 3 15438
2 5 Removing and installing coolant pump 15441
2 6 Removing and installing thermostat 15442
2 7 Checking thermostat 15442
2 8 Removing and installing coolant valve for cylinder head -N489- 15443
2 9 Removing and installing coolant temperature sender -G62- 15443
2 10 Removing and installing radiator outlet coolant temperature sender -G83- 15444
3 Coolant pipes 15446
3 1 Assembly overview – coolant pipes 15446
3 2 Removing and installing coolant pipes 15447
3 2 1 Removing and installing coolant pipes (top front) 15447
3 2 2 Removing and installing lower front coolant pipe 15448
3 2 3 Removing and installing coolant pipe (front left) 15449
3 2 4 Removing and installing left coolant pipes 15450
3 2 5 Removing and installing rear coolant pipe 15452
3 2 6 Removing and installing rear right coolant pipe 15454
4 Radiator, radiator fan 15457
4 1 Assembly overview – radiator/radiator fan 15457
4 2 Removing and installing radiator 15459
4 3 Removing and installing water radiator for charge air cooling circuit 15460
4 4 Removing and installing radiator cowl with radiator fan 15463
4 5 Removing and installing radiator fan 15464
21 – Turbocharging/supercharging 15465
1 Exhaust turbocharger 15465
1 1 Assembly overview – turbocharger 15465
1 2 Removing and installing turbocharger 15467
1 3 Renewing vacuum unit for turbocharger 15470
1 4 Removing and installing connection for turbocharger 15475
2 Charge air system 15477
2 1 Assembly overview – charge air system 15477
2 2 Removing and installing charge pressure sender -G31- 15479
2 3 Checking charge air system for leaks 15479
23 – Mixture preparation – injection 15482
1 Injection system 15482
1 1 Schematic overview – fuel system 15482
1 2 Overview of fitting locations – injection system 15483
1 3 Filling/bleeding fuel system 15489
1 4 Checking fuel system for leaks 15489
2 Vacuum system 15490
2 1 Connection diagram – vacuum system 15490
2 2 Checking vacuum system 15491
3 Injectors/high-pressure accumulator (rail) 15492
3 1 Assembly overview – injectors 15492
3 2 Assembly overview – fuel rail 15494
3 3 Adapting correction values for injectors 15495
3 4 Testing injectors 15495
3 5 Checking return flow rate of injectors with engine running 15495
3 6 Checking return flow rate of injectors at starter speed 15498
3 7 Testing jammed-open injectors 15499
3 8 Removing and installing injectors 15500
3 9 Removing and installing high-pressure lines 15503
3 9 1 Removing high-pressure pipe between fuel rail and high-pressure pump 15503
3 9 2 Installing high-pressure line 15503
3 10 Removing and installing fuel rail 15505
4 Air filter 15507
4 1 Assembly overview – air filter housing 15507
4 2 Removing and installing air filter housing 15508
5 Intake manifold 15511
5 1 Assembly overview – intake manifold 15511
5 2 Removing and installing intake manifold 15513
5 3 Removing and installing throttle valve module -J338- 15516
6 Senders and sensors 15519
6 1 Removing and installing fuel pressure regulating valve -N276- 15519
6 1 1 Versions of fuel pressure regulating valve -N276- 15519
6 1 2 Removing and installing fuel pressure regulating valve, version 1 15520
6 1 3 Removing and installing fuel pressure regulating valve -N276-, version 2 15523
6 2 Checking fuel pressure regulating valve -N276- 15525
6 3 Removing and installing fuel pressure sender -G247- 15526
6 4 Removing and installing air mass meter -G70- 15527
6 5 Removing and installing pressure differential sender -G505- 15529
6 6 Removing and installing exhaust gas pressure sensor 1 -G450- 15530
6 7 Removing and installing NOx sender 2 -G687- 15531
6 8 Removing and installing control unit for NOx sender -GX30- 15533
6 8 1 Removing and installing control unit for NOx sender -GX30-, version secured with clips 15533
6 8 2 Removing and installing control unit for NOx sender -GX30-, version secured with bolts 15536
6 9 Removing and installing charge air temperature sender before charge air cooler -G810-/charge air temperature sender after charge air cooler -G811- 15538
6 10 Removing and installing fuel temperature sender -G81- 15539
6 11 Removing and installing temperature and pressure sender for low-pressure fuel system -GX20- 15540
7 Engine control unit 15542
7 1 Removing and installing engine (motor) control unit -J623- 15542
7 1 1 Removing and installing engine (motor) control unit -J623- 15542
7 1 2 Removing and installing engine (motor) control unit -J623- with protective housing 15543
8 High-pressure pump 15546
8 1 Assembly overview – high-pressure pump 15546
8 2 Removing and installing high-pressure pump 15546
9 Lambda probe 15550
9 1 Assembly overview – Lambda probe 15550
9 1 1 Assembly overview – Lambda probe; vehicles without SCR system 15550
9 1 2 Assembly overview – Lambda probe; vehicles with SCR system 15551
9 2 Removing and installing Lambda probe 15552
9 2 1 Removing and installing Lambda probe 1 before catalytic converter -GX10- 15552
9 2 2 Removing and installing Lambda probe after catalytic converter -G130- 15553
26 – Exhaust system 15556
1 Exhaust pipes and silencers 15556
1 1 Assembly overview – silencers 15556
1 2 Assembly overview – front exhaust pipe 15558
1 3 Removing and installing front exhaust pipe 15559
1 4 Separating exhaust pipes from silencers 15560
1 5 Removing and installing rear silencer 15561
1 6 Aligning exhaust system free of stress 15562
1 7 Checking exhaust system for leaks 15562
1 8 Installation position of clamp 15563
1 9 Align end exhaust pipes 15563
2 Exhaust gas cleaning 15565
2 1 Assembly overview – emission control 15565
2 2 Removing and installing emission control module 15567
2 3 Removing and installing exhaust flap control unit -J883- 15573
3 SCR system (selective catalytic reduction) 15575
3 1 Assembly overview – tank for reducing agent 15575
3 2 Assembly overview – reducing agent delivery line 15577
3 3 Assembly overview – delivery module for reducing agent 15578
3 4 Assembly overview – injector for reducing agent 15579
3 5 Removing and installing reducing agent tank 15580
3 6 Removing and installing reducing agent supply line 15582
3 6 1 Removing and installing front part of reducing agent supply line 15582
3 6 2 Removing and installing rear part of reducing agent supply line 15583
3 7 Disconnecting reducing agent supply line 15585
3 8 Removing and installing delivery module for reducing agent 15589
3 9 Removing and installing injector for reduction agent -N474- 15591
3 10 Removing and installing control unit for reducing-agent heater -J891- 15592
3 11 Draining reducing agent tank 15593
4 Exhaust gas temperature regulation 15596
4 1 Assembly overview – exhaust gas temperature regulation 15596
4 1 1 Assembly overview – exhaust gas temperature regulation, vehicles without SCR system 15596
4 1 2 Assembly overview – exhaust gas temperature regulation, vehicles with SCR system 15598
4 2 Removing and installing exhaust gas temperature sender 1 -G235- 15599
4 3 Removing and installing exhaust gas temperature sender 2 -G448- 15600
4 4 Removing and installing exhaust gas temperature sender 3 -G495- 15603
4 5 Removing and installing exhaust gas temperature sender 4 -G648- 15604
5 Exhaust gas recirculation 15607
5 1 Assembly overview – exhaust gas recirculation 15607
5 1 1 Assembly overview – exhaust gas recirculation 15607
5 1 2 Assembly overview – exhaust gas recirculation, vehicles for USA 15609
5 2 Assembly overview – exhaust gas recirculation valve 1 -GX5- 15611
5 3 Removing and installing exhaust gas recirculation cooler 15611
5 4 Checking exhaust gas recirculation cooler for leaks 15614
5 5 Removing and installing exhaust gas recirculation valve 1 -GX5- 15616
5 6 Removing and installing exhaust gas recirculation valve 2 -GX6- 15617
5 6 1 Removing and installing exhaust gas recirculation valve 2 -GX6- 15617
5 6 2 Removing and installing exhaust gas recirculation valve 2 -GX6-, vehicles for USA 15619
5 7 Removing and installing exhaust gas recirculation temperature sensor -G98- 15620
28 – Glow plug system 15622
1 Glow plug system 15622
1 1 Assembly overview – glow plug system 15622
1 2 Removing and installing glow plug 15624
1 3 Removing and installing automatic glow period control unit -J179- 15626
1 4 Removing and installing Hall sender -G40- 15627
1 5 Removing and installing engine speed sender -G28- 15627
D4B8027068B Air conditioning systems with refrigerant R134a General information 15629
00 – Technical data 15635
1 Safety information 15635
1 1 Safety precautions when working on air conditioning systems 15635
1 2 Safety precautions when working on high-voltage system 15636
1 3 Safety precautions when working in the vicinity of high-voltage components 15636
1 4 Safety precautions when tow-starting or towing 15637
2 Repair instructions 15638
2 1 Rules for cleanliness when working on high-voltage system 15638
3 General information on air conditioning 15639
3 1 Other reference material 15639
3 2 Basics of air conditioning technology 15639
3 2 1 Physical principles: 15639
3 2 2 Heat always flows from a warmer to a colder substance 15640
3 2 3 Pressure and boiling point 15640
3 3 Vapour pressure table for refrigerant R134a 15641
3 4 Refrigerant R134a 15642
3 4 1 Physical data of refrigerant R134a 15642
3 4 2 Critical point 15642
3 4 3 Environmental aspects of refrigerant R134a 15643
3 5 Properties of refrigerant R134a 15643
3 5 1 Trade names and designations 15643
3 5 2 Colour 15643
3 5 3 Vapour pressure 15643
3 5 4 Physical properties of R134a 15644
3 5 5 Effects on metal 15644
3 5 6 Critical temperature and critical pressure 15644
3 5 7 Union 15644
3 5 8 Charge factor 15644
3 5 9 Detecting leaks 15644
3 6 Refrigerant oil 15645
3 6 1 Properties of refrigerant oil 15645
3 7 Comfort 15646
3 7 1 Environmental aspects 15646
3 8 How air conditioning works 15647
3 9 General work safety 15647
3 9 1 Product characteristics 15647
3 9 2 Handling refrigerants 15648
3 9 3 Wear safety goggles 15648
3 9 4 Wear protective gloves and apron 15648
3 9 5 Do not allow liquid refrigerant to come in contact with the skin 15648
3 9 6 Do not breath in refrigerant vapour 15648
3 9 7 Absolutely NO SMOKING 15648
3 9 8 Welding and soldering on refrigeration systems 15648
3 9 9 Pungent smell 15649
3 9 10 First aid 15649
3 9 11 Handling pressure vessels 15649
3 9 12 Do not heat up above 50°C 15649
3 9 13 Do not expose to uncontrolled heat 15649
3 9 14 Seal empty tanks/containers 15649
3 9 15 Safety instructions for using extraction and charging equipment 15650
3 10 Safety measures when working on vehicles with air conditioning and when working with refrigerant R134a 15650
3 11 Basics for working on refrigerant circuit 15651
3 11 1 O-ring 15652
3 11 2 Before operating the air conditioning system after recharging with refrigerant 15653
4 General information on refrigerant circuit 15654
4 1 Components of refrigerant circuit 15654
4 1 1 Distribution of the refrigerant circuit components and their influence on the high-pressure and low-pressure sides 15654
4 1 2 Air conditioning system compressor with magnetic clutch: 15654
4 1 3 Air conditioner compressor without magnetic clutch 15655
4 1 4 Air conditioner compressor without magnetic clutch, with elastic drive coupling 15656
4 1 5 Electrical air conditioner compressor for high-voltage system 15657
4 1 6 Condenser 15658
4 1 7 evaporator 15658
4 1 8 Reservoir 15659
4 1 9 Restrictor 15659
4 1 10 Receiver 15660
4 1 11 Expansion valve 15661
4 1 12 O-ring 15662
4 1 13 Pipes and hoses of refrigerant circuit 15662
4 1 14 High-pressure safety valve 15662
4 2 Design of refrigerant circuit 15665
4 2 1 Refrigerant circuit with expansion valve and evaporator 15665
4 2 2 Refrigerant circuit with restrictor and reservoir 15665
4 3 Evacuation and charging valves for quick-release couplings of air conditioner service station on refrigerant circuit 15666
4 3 1 Evacuation and charging valve with Schrader valve 15666
4 3 2 Extraction and charging valve, high-pressure side 15667
4 3 3 Extraction and charging valve, low-pressure side 15668
4 4 Switches and senders in refrigerant circuit and related connections 15668
4 4 1 High-pressure switch for air conditioning system -F23- 15668
4 4 2 High-pressure switch for magnetic clutch -F118- 15669
4 4 3 Low-pressure switch for air conditioning system -F73- 15669
4 4 4 Connections with valve for switches in refrigerant circuit 15670
4 4 5 Air conditioning system pressure switch -F129- 15670
4 4 6 High-pressure sender -G65- 15671
4 4 7 Refrigerant pressure and temperature sender -G395- 15672
4 4 8 Air conditioner compressor regulating valve -N280- 15672
4 5 Electrical components not installed in refrigerant circuit 15673
4 5 1 Control and regulating unit for air conditioning system -J127- 15673
4 5 2 Radiator fan control unit -J293- 15673
4 5 3 Radiator fan control unit -J293- 15674
4 5 4 Temperature switch for evaporator -E33- 15675
4 5 5 Evaporator output temperature sender -G263- or evaporator temperature sensor -G308- 15675
4 6 Pressures and temperatures in refrigerant circuit 15676
4 7 Refrigerant circuit with expansion valve 15676
4 8 Refrigerant circuit with restrictor and reservoir 15678
4 9 Test and measurement work that can be performed using a pressure gauge 15680
4 9 1 Pressure gauges enable the following test and measurement work 15680
4 10 Air conditioner service and recycling equipment 15681
4 10 1 Classification of extraction and charging devices in groups 15681
4 10 2 Charging devices that do not require a permit 15681
4 11 Notes to repairs on refrigerant circuit 15682
5 Laws and regulations 15683
5 1 Laws and regulations 15683
5 2 Recycling and refuse law 15688
5 2 1 Disposal of refrigerant and refrigerant machine oil 15688
5 3 Converting R12 refrigerant circuits to R134a refrigerant circuits and servicing them (retrofitting) 15689
5 4 Maintaining records on refrigerant 15689
6 Refrigerant circuit 15690
6 1 Important repair notes on air conditioning 15690
6 2 Converting refrigerant circuits from R12 refrigerant to R134a 15690
7 Working with the air conditioner service station 15691
7 1 Important instructions for working with the air conditioner service station 15691
7 2 Connecting a air conditioner service station for measuring and testing 15692
7 3 Drain the refrigerant circuit using the air conditioner service station 15693
7 4 Evacuating refrigerant circuit using air conditioner service station 15693
7 5 Filling refrigerant circuit with air conditioner service station 15695
7 6 Bringing air conditioning system into service after charging 15696
7 7 Charging the container in the air conditioning service station with refrigerant 15696
7 8 Emptying air conditioner service station 15697
8 Detecting leaks in refrigerant circuit 15698
8 1 Leak detection in refrigerant circuit using compressed air or nitrogen 15699
8 2 Searching for leaks in refrigerant circuits using leak detector -V A G 1796- 15700
8 3 Detecting leaks in refrigerant circuit using leak detecting system -VAS 6196- or leak detecting system -VAS 6201- or a later model 15701
9 Clearing refrigerant circuit of contaminants 15709
9 1 Vehicles with high-voltage system (hybrid vehicles) 15709
9 2 Blowing through refrigerant circuit with compressed air and nitrogen 15710
9 2 1 Flushing refrigerant circuit 15712
9 3 Flushing refrigerant circuit with refrigerant R134a 15712
9 3 1 Principle circuit diagrams for various purging circuits 15720
9 3 2 Purging electrical air conditioner compressor 15726
9 3 3 Adapters for setting up flushing circuits 15730
10 Clearing refrigerant circuit of contaminants, commercial vehicles 15744
10 1 Vehicles with high-voltage system 15744
10 2 Flushing refrigerant circuit with refrigerant R134a 15745
10 3 Adapters for setting up flushing circuits 15745
10 4 Procedure for setting up and flushing refrigerant circuit, Amarok 2023 ► 15749
10 5 Procedure for setting up and flushing refrigerant circuit, Amarok 2010 ► 15749
10 5 1 Connection diagram for flushing circuit 15749
10 5 2 Procedure for setting up and flushing refrigerant circuit 15750
10 6 Procedure for setting up and flushing refrigerant circuit, Caddy 2004 ► 15755
10 6 1 Connection diagram for flushing circuit 15755
10 6 2 Procedure for setting up and flushing refrigerant circuit 15756
10 7 Procedure for setting up and flushing refrigerant circuit, Crafter ►2017 15762
10 7 1 Connection diagram for flushing circuit, vehicles with one evaporator 15762
10 7 2 Connection diagram for flushing circuit, vehicles with second evaporator 15763
10 7 3 Procedure for setting up and flushing refrigerant circuit, vehicles with one evaporator 15764
10 7 4 Procedure for setting up and flushing refrigerant circuit, vehicles with second evaporator 15771
10 8 Procedure for setting up and flushing refrigerant circuit, Crafter 2017 ► or MAN TGE ►, Crafter Grand California ► 15779
10 8 1 Connection diagram for flushing circuit, vehicles with one evaporator 15780
10 8 2 Connection diagram for flushing circuit, vehicles with second evaporator 15781
10 8 3 Procedure for setting up and flushing refrigerant circuit, vehicles with one evaporator 15782
10 8 4 Procedure for setting up and flushing refrigerant circuit, vehicles with second evaporator 15787
10 9 Procedure for setting up and flushing refrigerant circuit, Transporter 2016 ►, Transporter 2020 ► 15796
10 9 1 Connection diagram for flushing circuit, vehicles with one evaporator 15796
10 9 2 Connection diagram for flushing circuit, vehicles with second evaporator 15797
10 9 3 Procedure for setting up and flushing refrigerant circuit, vehicles with one evaporator 15798
10 9 4 Procedure for setting up and flushing refrigerant circuit, vehicles with second evaporator 15803
11 Complaints 15812
11 1 Possible complaints about refrigerant circuit 15812
11 1 1 Conditions for testing: 15812
11 1 2 Possible complaints 15812
11 2 Odours from heater and air conditioning unit 15813
11 2 1 Does the odour emanate from the evaporator or heat exchanger? 15813
11 2 2 Ultrasonic air conditioner cleaning unit -VAS 6189A- 15814
11 2 3 Spraying the evaporator with the suction feed spray-gun -V A G 1538- and spray lance 15815
12 Connecting the air conditioning service station 15816
12 1 For vehicles that have connections on both low-pressure and high-pressure sides of refrigerant circuit 15816
12 1 1 Connecting a air conditioner service station for measuring and testing 15816
13 Checking pressures on vehicles 15817
13 1 Checking pressures in the refrigerant circuit (using a air conditioning service station) 15817
13 1 1 Conditions for testing 15817
13 1 2 Checking pressures 15818
13 1 3 Continuation of checking pressures 15820
13 2 Checking systems with a restrictor and collector (with internally regulated air conditioner compressor) 15821
13 2 1 Specifications: 15821
13 3 Checking systems with an expansion valve and reservoir (with internally regulated air conditioner compressor) 15825
13 3 1 Specifications: 15825
13 4 Checking systems with an expansion valve and reservoir (without regulated air conditioner compressor) 15830
13 4 1 Conditions for testing 15830
13 4 2 Check 15830
13 4 3 Specified values 15830
13 5 Checking systems with a restrictor and reservoir and air conditioner compressor regulating valve -N280- (with externally regulated air conditioner compressor) 15831
13 5 1 Specifications: 15831
13 6 Checking systems with an expansion valve, receiver and air conditioner compressor regulating valve -N280- (with externally regulated air conditioner compressor) 15836
13 6 1 Specifications: 15836
13 7 With expansion valve, receiver and electrical air conditioner compressor 15847
14 Renewing components 15848
14 1 In the event of leaking or damaged components (apart from the air conditioner compressor, receiver or reservoir) 15849
14 1 1 If the refrigerant circuit was completely empty 15849
14 1 2 If there is still refrigerant in the refrigerant circuit 15851
14 2 Renew the air conditioner compressor 15851
14 2 1 Without needing to flush refrigerant circuit of contaminants (cleaning), e g in cases of external damage after an accident 15851
14 2 2 Leaks or internal damage (e g noises or lack of power) 15853
14 3 Replace receiver or reservoir and restrictor 15853
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 15853
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 15855
15 Testing equipment and tools 15856
15 1 List of test equipment, tools and materials 15856
15 1 1 Tools and materials available from regional sales centre or importer 15856
15 1 2 Tools and materials commercially available 15857
15 1 3 Tools and materials available from regional sales centre or importer 15858
15 1 4 Tools and materials commercially available 15864
MEX5R005120 5 cylinder injection engine (2 5 l engine 4 valve) 15867
00 – Technical data 15873
1 Technical data 15873
1 1 Engine number 15873
1 2 Engine data 15873
10 – Removing and installing engine 15875
1 Removing and installing engine 15875
1 1 Removing engine – Jetta up to MY 2010 and Golf Variant 15875
1 2 Removing engine – Jetta from MY 2011 15880
1 3 Securing engine to assembly stand 15887
1 4 Installing engine – Jetta up to MY 2010 and Golf Variant 15890
1 5 Installing engine – Jetta from MY 2011 15891
1 6 Assembly mountings- specified torques 15893
13 – Crankshaft group 15894
1 Dismantling and assembling engine 15894
1 1 Assembly overview – add-on parts 15894
1 1 1 Part I – Poly V-belts (engine codes BGP, BGQ and BTK) 15897
1 1 2 Part II – Poly V-belts (engine codes CBTA, CBUA and CCCA) – Jetta up to MY 2010 and Golf Variant 15899
1 1 3 Part III – Poly V-belts (engine codes CBTA, CBUA and CCCA) – Jetta from MY 2011 15902
1 1 4 Part IV – Engine rear 15904
1 1 5 Part IV – Engine front/side – Jetta up to MY 2010 and Golf Variant 15905
1 1 6 Engine front/side – Jetta from MY 2011 15907
1 2 Assembly overview – chain drive 15908
1 2 1 Overview 15909
1 2 2 Timing chain 15910
1 2 3 Drive chain for valve gear 15911
1 3 Removing and installing poly V-belt 15912
1 3 1 Removing and installing poly V-belt – Jetta up to MY 2010 and Golf Variant 15912
1 3 2 Removing and installing poly V-belt – Jetta from MY 2011 15913
1 4 Removing and installing exhauster pump for brake servo 15915
2 Sealing flange and flywheel or drive plate 15918
2 1 Assembly overview 15918
2 2 Renewing crankshaft sealing flange – belt pulley end 15919
2 3 Removing and installing valve timing housing 15922
2 4 Removing and installing seal on gearbox side 15925
2 5 Removing and installing drive plate 15926
3 Crankshaft 15928
3 1 Assembly overview – crankshaft 15928
3 2 Crankshaft dimensions 15929
3 3 Locking crankshaft 15930
3 3 1 Locking crankshaft to check/adjust timing 15932
4 Pistons and conrods 15934
4 1 Assembly overview – pistons and conrods 15934
4 2 Separating new conrod 15935
4 3 Checking pistons, piston rings and cylinder bores 15936
4 4 Piston and cylinder dimensions 15938
15 – Cylinder head, valve gear 15939
1 Cylinder head 15939
1 1 Assembly overview 15939
1 2 Removing and installing cylinder head cover 15941
1 3 Removing and installing chain guard cover 15942
1 4 Renewing chain guard cover seal 15946
1 5 Checking valve timing 15948
1 6 Adjusting valve timing 15949
1 7 Removing and installing cylinder head 15953
1 8 Checking compression 15958
2 Valve gear 15960
2 1 Assembly overview – valve gear 15960
2 2 Valve dimensions 15962
2 3 Checking valve guides 15962
2 4 Renewing valve stem seals 15963
2 5 Removing and installing camshafts 15966
17 – Lubrication 15971
1 Parts of lubrication system 15971
1 1 Engine oil 15971
1 2 Assembly overview – parts of lubrication system – Jetta up to MY 2010 and Golf Variant 15972
1 3 Assembly overview – parts of lubrication system – Jetta from MY 2011 15974
1 4 Oil filter bracket with attachments – Assembly overview – Jetta up to MY 2010 and Golf Variant 15976
1 5 Oil filter bracket with attachments – Assembly overview – Jetta from MY 2011 15977
1 6 Draining oil filter housing 15979
1 7 Removing and installing lower part of sump 15979
1 8 Removing and installing upper part of sump 15981
1 9 Removing and installing oil pump, engine codes BGP, BGQ and BTK 15984
1 10 Removing and installing oil pump, engine codes CBTA, CBUA and CCCA 15987
1 11 Checking oil pressure and oil pressure switch – Jetta up to MY 2010 and Golf Variant 15991
19 – Cooling 15994
1 Cooling system components – Jetta up to MY 2010 and Golf Variant 15994
1 1 Assembly overview – parts of cooling system, engine side 15995
1 2 Assembly overview – parts of cooling system, body side 15998
1 3 Coolant hose schematic diagram 15999
1 4 Draining and filling coolant 16001
1 5 Removing and installing coolant pump 16004
1 6 Removing and installing thermostat 16008
1 7 Removing and installing radiator fan -V7- and radiator fan 2 -V177- 16010
1 8 Removing and installing radiator 16011
1 9 Checking cooling system for leaks 16013
2 Cooling system components – Jetta from MY 2011 16016
2 1 Assembly overview – parts of cooling system, engine side 16017
2 2 Assembly overview – parts of cooling system, body side 16020
2 3 Coolant hose schematic diagram 16021
2 4 Assembly overview – engine preheater 16022
2 5 Draining and filling coolant 16023
2 6 Removing and installing coolant pump 16026
2 7 Removing and installing thermostat 16030
2 8 Removing and installing radiator fan -V7- and radiator fan 2 -V177- 16032
2 9 Removing and installing radiator 16033
2 10 Checking cooling system for leaks 16034
20 – Fuel supply system 16037
1 Parts of fuel supply system 16037
1 1 Safety precautions when working on fuel supply system 16037
1 2 Rules for cleanliness 16038
1 3 Assembly overview – fuel tank, engine codes BGP, BGQ, CBTA, CBUA 16038
1 4 Assembly overview – fuel tank, engine codes BTK, CCCA 16041
1 5 Emptying fuel tank 16043
1 5 1 Draining fuel tank when fuel pump is intact 16043
1 5 2 Draining fuel tank in event of faulty fuel pump, engine codes BGP, BGQ, CBTA, CBUA 16045
1 5 3 Draining fuel tank in event of faulty fuel pump, engine codes BTK, CCCA 16046
1 6 Removing and installing fuel delivery unit 16048
1 7 Removing and installing fuel gauge sender -G- 16050
1 8 Removing and installing fuel tank – Jetta up to MY 2010 and Golf Variant 16052
1 9 Removing and installing fuel tank – Jetta from MY 2011 16055
1 10 Assembly overview – fuel filter with attachments 16059
1 11 Removing and installing fuel filter 16060
1 12 Checking fuel pump 16061
1 12 1 Checking function and voltage supply 16062
1 12 2 Checking delivery rate 16063
1 12 3 Checking current draw 16066
1 12 4 Checking non-return valve for fuel pump 16067
1 13 Bleeding fuel system 16069
2 Electronic power control (EPC) 16072
2 1 Function of EPC system 16072
2 2 Assembly overview – accelerator module 16072
2 3 Removing and installing accelerator module 16073
2 3 1 Pulling connector from and fitting it onto accelerator module 16075
3 Activated charcoal filter system – Jetta up to MY 2010 and Golf Variant with engine codes BGP, BGQ, CBTA, CBUA 16077
3 1 Function 16077
3 2 Overview of activated charcoal filter system – vehicles to MY 2009 16077
3 3 Overview of activated charcoal filter system – vehicles from MY 2010 16079
3 4 Assembly overview: activated charcoal filter system 16080
3 5 Removing and installing activated charcoal filter 16081
3 6 Removing and installing fuel system diagnostic pump -V144- 16082
3 7 Checking fuel system for leaks 16082
3 7 1 Gross leak detection in fuel system 16087
3 7 2 Schematic overview of activated charcoal filter system 16088
3 7 3 Checking vacuum supply of fuel system diagnostic pump -V144- 16089
4 Activated charcoal filter system – Jetta from MY 2011 with engine code CBTA, CBUA 16091
4 1 Function 16091
4 2 Overview of activated charcoal filter system 16091
4 3 Assembly overview: activated charcoal filter system 16093
4 4 Removing and installing activated charcoal filter 16094
4 5 Removing and installing fuel system diagnostic pump -V144- 16094
4 6 Checking fuel system for leaks 16095
4 6 1 Gross leak detection in fuel system 16100
5 Activated charcoal filter system, engine codes BTK, CCCA 16102
5 1 Function 16102
5 2 Assembly overview – activated charcoal filter system 16102
5 3 Checking fuel tank breather 16103
24 – Mixture preparation – injection 16106
1 Injection system 16106
1 1 General notes on injection 16106
1 2 Safety precautions 16107
1 3 Rules for cleanliness 16108
1 4 Technical data 16108
1 5 Overview of fitting locations 16109
1 6 Assembly overview – intake manifold with attachments, engine codes BGP and BGQ 16112
1 7 Assembly overview – intake manifold with attachments, Jetta up to MY 2010 and Golf Variant with engine codes CBTA and CBUA 16113
1 8 Assembly overview – intake manifold with attachments, Jetta up to MY 2010 and Golf Variant with engine codes BTK and CCCA 16114
1 9 Assembly overview – intake manifold with attachments, Jetta from MY 2011 16115
1 10 Assembly overview – fuel rail with injectors 16116
1 11 Assembly overview – air filter 16116
1 12 Removing and installing engine cover with air filter 16118
1 13 Removing and installing throttle valve module -J338- 16118
1 14 Removing and installing intake manifold 16120
1 15 Removing and installing injectors 16124
2 Checking components 16126
2 1 Checking injectors for leaks and quantity injected 16126
2 2 Checking fuel pressure regulator and holding pressure 16129
3 Engine control unit 16132
3 1 Reading and erasing engine control unit fault memory 16132
3 2 Removing and installing engine control unit – up to 10 2008 16133
3 2 1 Removing and installing engine control unit without theft protection 16133
3 2 2 Removing and installing engine control unit with theft protection 16133
3 3 Removing and installing engine control unit – from 11 2008 for Jetta up to MY 2010 and Golf Variant 16136
3 3 1 Removing and installing engine control unit without theft protection 16136
3 3 2 Removing and installing engine control unit with theft protection 16138
3 4 Removing and installing engine control unit – Jetta from MY 2011 16140
26 – Exhaust system 16143
1 Parts of the exhaust system 16143
1 1 Assembly overview – exhaust manifold with attachments, Jetta up to MY 2010 and Golf Variant 16145
1 2 Assembly overview – exhaust manifold with attachments, Jetta from MY 2011 16146
1 3 Assembly overview – front exhaust pipe with catalytic converter and attachments, engine codes BGP, BTK, CBTA, CCCA 16147
1 4 Assembly overview – front exhaust pipe with catalytic converter and attachments, engine codes BGQ, CBUA and Jetta from MY 2011 with CCCA and automatic gearbox 16149
1 5 Assembly overview – silencers with mountings 16151
1 6 Removing and installing front exhaust pipe with catalytic converter 16151
1 7 Separating and joining centre and rear silencers 16153
1 8 Aligning exhaust system free of stress 16154
2 Secondary air system 16156
2 1 Function 16156
2 2 Assembly overview – secondary air system 16156
2 3 Removing and installing secondary air pump motor -V101- 16158
2 4 Checking secondary air inlet valve -N112- 16158
28 – Ignition system 16160
1 Ignition system 16160
1 1 General notes on ignition system 16160
1 2 Safety precautions 16160
1 3 Assembly overview – ignition system 16160
1 4 Removing and installing ignition coils with output stage 16162
1 5 Test data, spark plugs 16163
MEX5R005320 6 speed automatic gearbox 09G 16164
00 – Technical data 16168
1 General repair notes 16168
1 1 Torque converter 16168
1 2 ATF 16168
1 3 Automatic gearbox control unit -J217- with ⇒ fuzzy logic 16168
1 4 Control units in vehicle 16168
1 5 Information on “09G gearbox” 16168
1 6 Tools 16168
1 7 Gearbox 16169
1 8 Gaskets, seals and oil 16170
1 9 Nuts and bolts 16170
1 10 Electrical components 16171
1 11 Guided fault finding, vehicle self-diagnosis and testing 16171
1 12 Safety precautions 16171
2 Gearbox identification 16172
2 1 Gearbox codes 16172
3 Capacities 16173
3 1 Planetary gearbox and final drive 16173
4 Code – engine allocation 16174
32 – Torque converter 16175
1 Assembly overview – torque converter 16175
1 1 Removing and installing torque converter 16176
1 2 Checking torque converter 16176
1 3 Draining torque converter 16177
1 4 Removing and installing torque converter oil seal 16177
37 – Controls, housing 16179
1 Connecting »tester« 16179
2 Electrical and electronic components and their locations 16180
3 Multifunction switch -F125- 16185
3 1 Removing multifunction switch -F125- 16185
3 2 Installing multifunction switch -F125- 16186
3 3 Adjusting multifunction switch -F125- 16187
4 Selector mechanism up to 02 2009 16189
4 1 Overview of selector mechanism up to 02 2009 16189
4 2 Removing and installing selector mechanism with selector lever up to 02 2009 16190
4 3 Removing and installing selector lever cable up to 02 2009 16192
4 4 Checking selector lever cable 16200
4 5 Adjusting selector lever cable 16201
4 6 Emergency release of selector lever 16202
4 7 Removing and installing selector lever knob 16203
4 8 Moving push button to installation position in the handle 16205
4 8 1 Handle with pushbutton on side 16205
4 8 2 Handle with front pushbutton 16205
4 9 Checking selector mechanism 16207
4 9 1 Selector lever in “P” position and ignition switched on 16207
4 9 2 Selector lever in “N” position and ignition switched on 16207
4 9 3 Selector lever in position “Tiptronic” 16208
4 9 4 Ignition and light switched on 16208
4 9 5 Selector lever position display 16208
5 Selector mechanism from 03 2009 onwards 16209
5 1 Overview of selector mechanism in vehicles from 03 2009 onwards 16209
5 2 Removing and installing selector mechanism – vehicles as of 03 2009 16210
5 2 1 Removing and installing selector mechanism with selector housing 16210
5 2 2 Removing and installing selector mechanism without selector housing 16213
6 Removing and installing gearbox, Jetta 2005 ►, Bora 2006 ►, Golf Estate 2007 ►, Jetta Wagon 2008 ► 16217
6 1 Removing gearbox, vehicles with 1 6 l – 75 kW; 2 0 l – 85 kW; and 2 0 l – 110 kW engines 16217
6 2 Installing gearbox, vehicles with 1 6 l – 75 kW; 2 0 l – 85 kW; and 2 0 l – 110 kW engines 16224
6 3 Removing gearbox, vehicles with 2 5 l – 110 kW and 2 5 l – 125 kW engines 16226
6 4 Installing gearbox, vehicles with 2 5 l – 110 kW and 2 5 l – 125 kW engines 16233
6 5 Torque settings, gearbox to engine 16235
6 5 1 Torque settings, vehicles with 1 6 l – 75 kW; 2 0 l – 85 kW; and 2 0 l – 110 kW engines 16235
6 5 2 Torque settings, vehicles with 2 5 l – 110 kW and 2 5 l – 125 kW engines 16236
7 Removing and installing gearbox, Jetta 2011 ► 16237
7 1 Removing gearbox, Jetta 2011 with 1 6 l – 77 kW engine 16237
7 2 Removing gearbox, Jetta 2011 with 2 0 l – 85 kW engine 16245
7 3 Removing gearbox, Jetta 2011 with 2 5 l – 125 kW engine 16254
7 4 Installing gearbox, Jetta 2011 16265
7 5 Torque settings, gearbox to engine 16267
7 5 1 Torque settings, Jetta 2011 with 1 6 l – 77 kW engine 16267
7 5 2 Torque settings, Jetta 2011 with 2 0 l – 85 kW engine 16269
7 5 3 Torque settings, Jetta 2011 with 2 5 l – 125 kW engine 16270
8 Transporting gearbox 16271
9 Attaching gearbox on engine and gearbox support 16272
10 ATF cooler 16274
10 1 ATF cooler, round design – assembly view 16274
10 2 ATF cooler, rectangular design – assembly view 16275
10 2 1 Removing and installing ATF cooler, rectangular design 16275
11 Checking ATF level and topping up 16278
11 1 Checking ATF level 16280
11 2 Topping up ATF 16281
11 3 Draining and filling ATF 16282
38 – Gears, control 16284
1 Renewing oil seal for selector shaft 16284
2 Sump 16285
2 1 Removing and installing sump 16285
2 1 1 Removing 16285
2 1 2 Installing 16286
3 ATF strainer 16288
3 1 Removing and installing ATF strainer 16288
3 1 1 Removing 16288
3 1 2 Installing 16288
4 Valve body 16289
4 1 Assembly overview 16289
4 1 1 Specified torques 16292
4 1 2 Wire routing, connectors, connections and retainer on valve body 16292
4 2 Removing and installing valve body 16294
4 2 1 Removing 16295
4 2 2 Installing 16299
4 3 Removing and installing wiring harness for solenoid valves (14-pin connector) 16302
4 3 1 Removing 16302
4 3 2 Installing 16303
4 4 Removing and installing wiring harness for sender (8-pin connector) 16303
4 4 1 Removing 16303
4 4 2 Installing 16303
4 5 Removing and installing gearbox input speed sender -G182- 16304
4 5 1 Removing 16304
4 5 2 Installing 16304
4 6 Removing and installing gearbox output speed sender -G195- 16304
4 6 1 Removing 16304
4 6 2 Installing 16305
39 – Final drive – differential 16306
1 Renewing oil seals for flange shafts 16306
1 1 Overview of fitting locations – seals 16306
1 2 Renewing oil seal for left flange shaft 16306
1 3 Renewing seal for right flange shaft 16308
MEX5R006320 5 speed manual gearbox 0A4 16311
00 – Technical data 16315
1 Identification of gearbox 16315
1 1 Location on gearbox 16315
1 2 Identification code, assembly allocation and capacities 16316
2 Overview – power transmission 16320
3 Calculating overall gear ratio “i” 16322
4 General repair instructions 16323
4 1 Components 16323
4 1 1 Gearbox 16323
4 1 2 O-rings, seals, gaskets and sealants 16323
4 1 3 Locking devices 16324
4 1 5 Mountings 16324
4 1 7 Synchro-rings 16325
4 1 8 Gears, synchro-hubs, inner races for needle bearings 16325
4 1 9 Synchromeshed gears 16325
4 1 10 Clutch 16325
5 Safety precautions 16327
5 1 Safety precautions for vehicles with a start-stop system 16327
30 – Clutch 16328
1 Repairing clutch mechanism 16328
1 1 Overview 16328
1 2 Assembly overview – pedal cluster 16329
1 3 Removing and installing over-centre spring 16330
1 3 1 Removing 16330
1 3 2 Installing 16333
1 3 3 Specified torques 16335
1 4 Removing and installing clutch pedal 16335
1 4 1 Removing 16335
1 4 2 Installing 16338
1 4 3 Specified torques 16340
1 5 Removing and installing mounting bracket 16340
1 5 1 Removing 16341
1 5 2 Installing 16344
1 5 3 Specified torques 16346
1 6 Removing and installing clutch master cylinder 16346
1 6 1 Removing 16346
1 6 2 Installing 16347
1 7 Removing and installing clutch position sender -G476- 16348
1 7 1 Removing 16348
1 7 2 Installing 16350
1 8 Assembly overview – hydraulics (LHD) 16351
1 9 Assembly overview – hydraulics (RHD) 16354
1 10 Removing and installing clutch slave cylinder 16355
1 10 1 Removing 16356
1 10 2 Installing 16357
1 10 3 Specified torques 16357
1 11 Bleeding clutch system 16358
2 Repairing clutch release mechanism 16360
3 Repairing clutch, in conjunction with dual-mass flywheel 16362
3 1 Determining clutch manufacturer 16362
3 2 Removing and installing Sachs clutch 16364
3 2 1 Removing 16364
3 2 2 Installing 16364
3 3 Repairing Sachs clutch 16365
3 4 Removing and installing LuK clutch 16366
3 4 1 Removing 16366
3 4 2 Installing 16366
3 5 Repairing LuK clutch 16368
4 Repairing clutch, in conjunction with one-piece flywheel 16370
34 – Controls, housing 16373
1 Repairing selector mechanism 16373
1 1 Installation position of selector mechanism 16373
1 2 Overview of selector mechanism 16374
1 3 Removing and installing gear knob and cover 16375
1 4 Removing and installing gaiter with gear knob and noise insulation 16376
1 4 1 Installing 16377
1 5 Repairing gear lever and selector housing (through 10 06) 16377
1 6 Repairing gear lever and selector housing (from 11 06) 16380
1 6 1 Dismantling and assembling selector mechanism 16381
1 7 Assembly overview – removing and installing selector cables 16386
1 8 Plastic relay lever 16390
1 9 Removing and installing selector mechanism 16393
1 9 1 Removing 16393
1 9 2 Installing 16395
1 10 Removing and installing gear selector cable and gate selector cable 16396
1 10 1 Removing 16396
1 10 2 Installing 16397
1 11 Adjusting selector mechanism 16398
1 11 1 Function 16400
2 Removing and installing gearbox, Jetta 2005 ►, Bora 2006 ►, Golf Variant 2007 ►, Bora Sportwagen 2008 ►, Golf Variant 2010 ► 16401
2 1 Removing gearbox 16403
2 2 Install gearbox 16410
2 2 1 Specified torques 16416
3 Removing and installing gearbox, Jetta 2011 ► 16417
3 1 Removing gearbox, Jetta 2011 with 2 0 l – 85 kW engine 16417
3 2 Installing gearbox, Jetta 2011 with 2 0 l – 85 kW engine 16427
3 2 1 Specified torques 16434
3 3 Removing gearbox, Jetta 2011 with 2 5 l – 125 kW engine 16434
3 4 Installing gearbox, Jetta 2011 with 2 5 l – 125 kW engine 16445
3 4 1 Specified torques 16452
3 5 Removing gearbox, Jetta 2011 with 1 8 l – 125 kW engine 16452
3 6 Installing gearbox, Jetta 2011 with 1 8 l – 125 kW engine 16465
3 6 1 Specified torques 16473
3 7 Removing gearbox, Jetta 2011 with turbo diesel engine 16474
3 8 Installing gearbox, Jetta 2011 with turbo diesel engine 16484
3 8 1 Specified torques 16491
4 Assembly mountings 16492
4 1 Assembly overview – assembly mountings 16492
5 Transporting gearbox 16494
6 Checking and topping up gear oil 16495
6 1 Preparing 16495
6 2 Drain gear oil 16496
6 3 Fill with gear oil 16497
7 Dismantling and assembling gearbox 16498
7 1 Overview – gearbox 16498
7 2 Assembly overview 16499
7 3 Removing and installing cover for gearbox housing and 5th gear 16500
7 4 Removing and installing gearbox housing and selector mechanism 16501
7 5 Removing and installing input shaft, output shaft, differential and selector forks 16503
7 6 Assembly sequence – removing and installing cover for gearbox housing and 5th gear 16504
7 6 1 Removing cover for gearbox housing and 5th gear 16506
7 6 2 Installing cover for gearbox housing and 5th gear 16509
7 7 Assembly sequence – Dismantling and assembling gearbox completely 16510
7 7 1 Dismantling gearbox 16513
7 7 2 Assembling gearbox 16518
8 Repairing gearbox housing and clutch housing 16525
9 Repairing selector unit 16531
10 Dismantling and assembling selector forks 16534
35 – Gears, shafts 16539
1 Input shaft 16539
1 1 Dismantling and assembling input shaft 16539
1 2 Adjusting input shaft 16547
1 2 1 Determining thickness of shim 16550
1 2 2 Carrying out check measurement 16551
1 3 Renewing input shaft seal 16551
2 Output shaft 16554
2 1 Dismantling and assembling output shaft 16554
2 2 Adjusting output shaft 16567
2 2 1 Determining thickness of shim 16570
3 Reverse shaft 16572
3 1 Dismantling and assembling reverse shaft 16572
39 – Final drive – differential 16575
1 Oil seals 16575
1 1 Overview of fitting locations – seals 16575
1 2 Renewing oil seal for left flange shaft 16575
1 2 1 Removing 16576
1 2 2 Installing 16577
1 2 3 Specified torque 16577
1 3 Distinguishing seals for right flange shaft 16577
1 4 Renewing seal (two-part seal and sleeve for right flange shaft) 16578
1 4 1 Removing 16579
1 4 2 Installing 16580
1 4 3 Specified torque 16580
1 5 Renewing seal and sleeve together (one-piece seal and sleeve for right flange shaft) 16580
1 5 1 Removing 16581
1 5 2 Installing 16582
1 5 3 Specified torque 16583
2 Adjustment overview 16584
3 Differential 16585
3 1 Dismantling and assembling differential 16585
3 2 Adjusting differential 16593
3 2 1 Determining thickness of shim 16594
MEX5R006620 6 speed dual clutch gearbox 02E 16596
00 – Technical data 16600
1 General repair notes 16600
1 1 Tools 16601
1 2 Gearbox 16601
1 3 Overview 16601
1 4 O-rings, seals and gaskets 16602
1 5 Dual clutch gearbox oil 16603
1 5 2 Oil filter change – »Yes or no?« 16603
1 5 3 Oil and fault finding via oil level check 16604
1 6 Nuts and bolts 16604
1 7 Electrical components 16605
2 Fault finding 16606
2 1 General notes on fault finding 16606
2 2 Useful information about the “behaviour of the control unit in the event of a gearbox fault” 16606
2 3 Special notes on fault finding 16607
2 3 1 Selector lever position display – no “R” 16607
2 3 2 Touch function does not work – no gear change 16607
2 3 3 »Power transfer« inadequate – possibly insufficient fluid 16607
2 3 4 No faults have been saved 16607
2 3 5 Faults have been saved 16607
2 3 6 If there are faults »not caused by the gearbox« 16607
3 Gearbox identification 16609
3 1 Reading gearbox code letters 16609
4 Code – engine allocation 16612
4 1 Identification code 16612
5 Capacity 16613
30 – Clutch 16614
1 Assembly overview – dual clutch 16614
2 Removing and installing dual clutch 16617
2 1 Removing clutch end cover 16617
2 2 Installing clutch end cover 16619
2 2 1 Installing clutch end covers supplied without bush 16620
2 2 2 Installing clutch end covers supplied with bush 16622
2 3 Removing dual clutch 16623
2 4 Installing and adjusting the dual clutch 16625
34 – Controls, housing 16632
1 Electrical and electronic components for the dual clutch gearbox and their locations 16632
1 1 Removing and installing mechatronic unit for dual clutch gearbox -J743- (gearbox installed) 16632
1 1 1 Removing mechatronic unit (gearbox installed) 16633
1 1 2 Installing mechatronic unit (gearbox installed) 16639
1 2 Removing and installing mechatronic unit for dual clutch gearbox -J743- (gearbox removed) 16645
1 2 1 Removing mechatronic unit (gearbox removed) 16645
1 2 2 Installing mechatronic unit (gearbox removed) 16651
1 3 Removing and installing gearbox input speed sender -G182- and oil temperature sender in multi-plate clutch -G509- 16654
2 Removing and installing gear oil cooler 16656
2 1 Removing gear oil cooler 16656
2 2 Installing gear oil cooler 16658
3 Removing and installing oil pump 16659
3 1 Removing oil pump 16659
3 2 Installing oil pump 16661
4 Renew seal on selector shaft lever 16663
5 Selector mechanism 16665
5 1 Overview – selector mechanism in vehicles up to 02 2009 16665
5 2 Removing and installing selector lever cable – vehicles up to 02 2009 16666
5 3 Overview of selector mechanism – vehicles from 03 2009 onwards 16674
5 4 Removing and installing selector mechanism – vehicles as of 03 2009 16675
5 4 1 Removing and installing selector mechanism with selector housing 16675
5 4 2 Removing and installing selector mechanism without selector housing 16678
5 5 Checking selector lever cable 16681
5 6 Adjusting selector lever cable 16681
5 7 Emergency release of selector lever 16683
5 8 Removing and installing selector lever knob 16683
5 9 Moving button to installation position in knob 16686
5 9 1 Knob with button on side 16686
5 9 2 Knob with button at front 16686
5 10 Checking selector mechanism 16687
6 Removing and installing gearbox, Jetta 2005 ►, Golf Variant 2007 ► and Golf Variant 2010 ► 16689
6 1 Removing gearbox 16689
6 2 Installing gearbox 16700
6 3 Specified torques 16703
7 Removing and installing gearbox, Jetta 2011 ► 16706
7 1 Removing gearbox, Jetta 2011 with 2 0 l – 103 kW diesel engine 16706
7 2 Installing gearbox, Jetta 2011 with 2 0 l – 103 kW diesel engine 16718
7 3 Removing gearbox, Jetta 2011 with 2 0 l – 147 kW petrol engine 16720
7 4 Installing gearbox, Jetta 2011 with 2 0 l – 147 kW petrol engine 16733
7 5 Specified torques 16735
8 Transporting gearbox and securing to assembly stand 16737
9 Oil and oil filter 16738
9 1 Renewing oil filter 16738
9 2 Checking oil level and topping up 16739
9 3 Draining and filling oil 16742
35 – Gears, shafts 16746
1 Currently, no repairs can be made to gears and shafts 16746
39 – Final drive – differential 16747
1 Renewing seals for flange shaft or stub shaft 16747
1 1 Overview of fitting locations- seals 16747
1 2 Renewing oil seal for left flange shaft 16748
1 2 1 Removing 16749
1 2 2 Installing 16749
1 3 Renewing seals for right flange shaft or stub shaft 16750
1 3 1 Removing 16751
1 3 2 Installing 16752
MEX5R006920 6 speed manual gearbox 02Q 16754
00 – Technical data 16760
1 Gearbox identification – front-wheel drive 16760
1 1 Location on gearbox 16760
1 2 Identification code, assembly allocation and capacities – front-wheel drive 16761
2 Gearbox identification – all-wheel drive 16766
2 1 Location on gearbox 16766
2 2 Identification code, assembly allocation and capacities – all-wheel drive 16767
3 Overview – power transmission – front-wheel drive 16769
4 Overview – power transmission – all-wheel drive 16771
5 Calculating overall gear ratio “i” 16773
6 All-wheel drive – notes on performance test 16774
7 General repair instructions 16775
7 1 Safety precautions for vehicles with a start-stop system 16775
7 2 Contact corrosion 16775
7 3 Special tool 16775
7 4 Components 16775
7 4 1 Gearbox 16775
7 4 2 O-rings, seals, gaskets and sealants 16776
7 4 3 Locking devices 16777
7 4 4 Nuts and bolts 16777
7 4 5 Bearings 16778
7 4 6 Shims 16778
7 4 7 Synchro-rings 16779
7 4 8 Gears, synchro-hubs, sleeves for needle bearings 16779
7 4 9 Synchromeshed gears 16779
7 4 10 Clutch 16779
30 – Clutch 16781
1 Fault finding, power transmission 16781
2 Repairing clutch mechanism 16782
2 1 Overview 16782
2 2 Assembly overview – pedal cluster 16782
2 3 Removing and installing over-centre spring 16784
2 3 1 Removing 16784
2 3 2 Installing 16787
2 3 3 Specified torques 16790
2 4 Removing and installing clutch pedal 16790
2 4 1 Removing 16791
2 4 2 Installing 16794
2 4 3 Specified torques 16797
2 5 Removing and installing mounting bracket 16797
2 5 1 Removing 16798
2 5 2 Installing 16802
2 5 3 Specified torques 16805
2 6 Removing and installing clutch master cylinder 16805
2 6 1 Removing 16805
2 6 2 Installing 16806
2 7 Removing and installing clutch position sender -G476- 16807
2 7 1 Removing 16808
2 7 2 Installing 16810
2 8 Assembly overview – hydraulics (LHD) 16811
2 9 Assembly overview – hydraulics (RHD) 16814
2 10 Bleeding clutch mechanism 16816
3 Repairing clutch release mechanism 16819
3 1 Removing and installing pipe/hose assembly and bleeder on clutch slave cylinder 16821
3 2 Removing and installing clutch slave cylinder together with release bearing 16822
3 3 Removing and installing pipe/hose line or pipe 16824
3 4 Renewing input shaft seal 16826
4 Repairing clutch – vehicles with diesel engine 16829
4 1 Determining clutch manufacturer 16830
4 2 Removing and installing “Sachs” clutch 16831
4 3 Repairing “Sachs” clutch 16835
4 4 Removing and installing “LuK” clutch 16836
4 5 Repairing “LuK” clutch 16840
5 Repairing clutch – vehicles with petrol engine 16841
5 1 Repairing clutch 16842
5 2 Removing and installing clutch 16842
34 – Controls, housing 16847
1 Repairing selector mechanism 16847
1 1 Installation position of selector mechanism 16847
1 2 Overview of selector mechanism 16848
1 3 Assembly overview – gear knob and cover 16848
1 4 Removing and installing gaiter with gear knob and noise insulation 16849
1 4 1 Removing 16850
1 4 2 Installing 16851
1 5 Assembly overview – selector lever and selector housing (up to 10 06) 16851
1 6 Assembly overview – selector lever and selector housing (from 11 06) 16854
1 6 1 Dismantling and assembling selector mechanism 16856
1 7 Assembly overview – selector cables 16863
1 8 Plastic relay lever 16868
1 9 Removing and installing selector mechanism 16873
1 9 1 Removing 16873
1 9 2 Installing 16876
1 10 Removing and installing gear selector cable and gate selector cable 16878
1 10 1 Removing 16878
1 10 2 Installing 16880
1 11 Adjusting selector mechanism 16881
1 11 1 Function 16884
2 Removing and installing gearbox, Jetta 2005 ►, Golf Estate 2007 ►, Golf Estate 2010 ► vehicles with diesel engine and front-wheel drive 16885
2 1 Removing gearbox 16885
2 2 Installing gearbox 16901
2 3 Specified torques 16912
3 Removing and installing gearbox, Jetta 2005 ►, Golf Estate 2007 ►, Golf Estate 2010 ► vehicles with petrol engine and front-wheel drive 16914
3 1 Removing gearbox 16914
3 2 Installing gearbox 16929
3 3 Specified torques 16940
4 Removing and installing gearbox, Jetta 2011 ► vehicles with diesel engine and vehicles with petrol engine 16942
4 1 Removing gearbox 16942
4 2 Installing gearbox 16958
4 3 Specified torques 16968
5 Removing and installing gearbox, Jetta 2005 ►, Golf Estate 2007 ►, Golf Estate 2010 ► vehicles with all-wheel drive 16970
5 1 Removing and installing gearbox in vehicles with turbo diesel engine 16970
5 1 1 Removing gearbox 16972
5 1 2 Installing gearbox 16987
5 1 3 Specified torques 16999
6 Transporting gearbox 17002
6 1 Front-wheel drive – transporting gearbox 17002
6 2 All-wheel drive – transporting gearbox 17003
7 Secure gearbox on engine and gearbox support 17005
8 Checking gear oil 17007
8 1 Checking gear oil level, gearboxes with oil filler plug 17007
8 2 Checking gear oil level, gearboxes without oil filler plug 17008
8 3 Draining and filling gear oil (only for gearboxes “without” oil filler plug) 17008
8 4 Specified torque for oil filler and oil drain plugs 17010
9 Removing and installing bevel box 17012
9 1 Removing and installing bevel box, vehicles with turbo diesel engine without particulate filter 17012
9 1 1 Removing bevel box 17012
9 1 2 Installing bevel box 17018
9 1 3 Specified torques 17023
9 2 Removing and installing bevel box, vehicles with turbo diesel engine and particulate filter, to approx 10 09 17023
9 2 1 Removing bevel box 17024
9 2 2 Installing bevel box 17033
9 2 3 Specified torques 17037
9 3 Removing and installing bevel box, vehicles with turbo diesel engine and particulate filter, from approx 11 09 17038
9 3 1 Removing bevel box 17039
9 3 2 Installing bevel box 17044
9 3 3 Specified torques 17047
10 Checking or topping up gear oil in bevel box 17048
10 1 Checking gear oil in bevel box 17049
10 2 Topping up gear oil in bevel box 17050
10 2 1 Specified torque 17053
11 Dismantling and assembling gearbox 17055
11 1 Front-wheel drive – gearbox overview 17055
11 2 Overview – gearbox, all-wheel drive 17055
11 3 Assembly overview – front-wheel drive 17056
11 4 Assembly overview – all-wheel drive 17058
11 5 Assembly overview – removing and installing gearbox housing and selector mechanism 17060
11 6 Assembly overview, front-wheel drive – removing and installing input shaft, output shafts, differential and selector rods 17063
11 6 1 Installation position of shafts and selector rods in gearbox 17065
11 7 Assembly overview, four-wheel drive – removing and installing input shaft, output shafts, differential, bevel box and selector rods 17065
11 8 Assembly order, gearbox »without« circlip -A- for input shaft cover made from sheet metal 17067
11 8 1 Dismantling gearbox 17070
11 8 2 Assembling gearbox 17077
11 9 Assembly sequence: I = gearbox »with« circlip -A- for input shaft cover made of sheet metal; II = gearbox with input shaft cover made of plastic 17086
11 9 1 Dismantling gearbox 17089
11 9 2 Assembling gearbox 17096
12 Repairing gearbox housing 17107
13 Repairing clutch housing 17119
14 Repairing selector unit 17124
14 1 Renewing selector shaft seal 17126
15 Repairing selector forks 17129
35 – Gears, shafts 17132
1 Input shaft 17132
1 1 Assembly overview – input shaft 17132
1 2 Dismantling and assembling input shaft 17134
1 2 1 Modification in area of deep groove ball bearing 17139
2 Output shaft for 1st to 4th gears 17141
2 1 Assembly overview – output shaft for 1st to 4th gears 17141
2 2 Dismantling and assembling output shaft for 1st to 4th gears 17144
2 2 1 Distinguishing 1st/2nd gear synchronisation, distinguishing 3rd gear synchronisation 17152
2 2 2 Assembling 1st to 4th gear output shaft up to gearbox date 25 10 9 17154
2 2 3 Assembling 1st to 4th gear output shaft – from gearbox date 26 10 9 up to gearbox date 24 05 0 17160
2 2 4 Assembling 1st to 4th gear output shaft – from gearbox date 25 05 0 onwards 17166
2 3 Adjusting output shaft for 1st to 4th gears 17173
2 3 1 Determining thickness of shim 17177
2 3 2 Table of shims 17177
2 3 3 Carrying out check measurement 17178
3 Output shaft for 5th, 6th and reverse gears 17179
3 1 Assembly overview – output shaft for 5th, 6th and reverse gears 17179
3 2 Dismantling and assembling output shaft for 5th, 6th and reverse gears 17181
3 3 Adjusting output shaft for 5th, 6th and reverse gears 17193
3 3 1 Determining thickness of shim 17197
3 3 2 Table of shims 17197
3 3 3 Carrying out check measurement 17198
39 – Final drive – differential 17199
1 Front-wheel drive – renewing flange shaft seals with manual gearbox installed 17199
1 1 Renewing oil seal for left flange shaft 17199
1 1 1 Removing 17200
1 1 2 Installing 17200
1 2 Renewing seal for right flange shaft 17201
1 2 1 Removing 17202
1 2 2 Installing 17203
2 Four-wheel drive – renewing flange shaft seals and bevel box (manual gearbox installed) 17205
2 1 Renewing oil seal for left flange shaft 17205
2 2 Renewing seal for right flange shaft 17205
2 2 1 Removing 17206
2 2 2 Installing 17208
2 3 Renewing bevel box seal with manual gearbox installed 17209
3 Assembly overview – seals, flange shaft mounting and output flange mounting in bevel box 17212
3 1 Removing and installing bevel box (with manual gearbox removed) 17215
3 2 Renewing seal on bevel box between manual gearbox and bevel box 17217
3 3 Renewing bevel box output flange oil seal (bevel box removed) 17218
3 4 Renewing output flange and redetermining thickness of shim (bevel box removed) 17230
3 5 Renewing polygon needle bearing and seal on right flange shaft 17231
3 5 1 Removing 17233
3 5 2 Installing 17236
4 Adjustment overview 17238
5 Differential 17239
5 1 Front-wheel drive – dismantling and assembling differential 17239
5 2 All-wheel drive – dismantling and assembling differential 17247
5 3 Adjusting differential 17256
5 3 1 Determining thickness of shim 17259
MEX5R007520 6 speed manual gearbox 02S 17261
00 – Technical data 17265
1 Gearbox identification 17265
1 1 Location on gearbox 17265
1 2 Identification code, assembly allocation and capacities 17265
2 Overview – power transmission 17268
3 Calculating overall gear ratio “i” 17270
4 General repair notes 17271
4 1 Components 17271
4 1 1 Gearbox 17271
4 1 2 O-rings, seals, gaskets and sealants 17271
4 1 5 Bearings 17272
4 1 7 Synchro-rings 17273
4 1 8 Gears and synchro-hubs 17273
4 1 9 Synchromeshed gears 17273
4 1 10 Clutch 17274
30 – Clutch 17275
1 Fault finding, power transmission 17275
2 Repairing clutch mechanism 17276
2 1 Overview 17276
2 2 Assembly overview – pedal cluster 17277
2 3 Removing and installing over-centre spring 17278
2 3 1 Removing 17278
2 3 2 Installing 17281
2 3 3 Specified torques 17283
2 4 Removing and installing clutch pedal 17283
2 4 1 Removing 17284
2 4 2 Installing 17286
2 4 3 Specified torques 17289
2 5 Removing and installing mounting bracket 17289
2 5 1 Removing 17290
2 5 2 Installing 17293
2 5 3 Specified torques 17295
2 6 Removing and installing clutch master cylinder 17295
2 6 1 Removing 17295
2 6 2 Installing 17296
2 7 Removing and installing clutch position sender -G476- 17297
2 7 1 Removing 17297
2 7 2 Installing 17299
2 8 Assembly overview – hydraulics (LHD) 17300
2 9 Assembly overview – hydraulics (RHD) 17303
2 10 Removing and installing clutch slave cylinder 17304
2 10 1 Removing 17305
2 10 2 Installing 17306
2 10 3 Specified torques 17306
2 11 Bleeding clutch mechanism 17307
3 Repairing clutch release mechanism 17309
4 Repairing clutch, in conjunction with dual-mass flywheel 17311
4 1 Determining clutch manufacturer 17311
4 2 Removing and installing “Sachs” clutch 17313
4 2 1 Removing 17313
4 2 2 Installing 17313
4 3 Repairing “Sachs” clutch 17314
4 4 Removing and installing “LuK” clutch 17315
4 4 1 Removing 17315
4 4 2 Installing 17315
4 5 Repairing “LuK” clutch 17317
5 Repairing clutch, in conjunction with one-piece flywheel 17319
34 – Controls, housing 17322
1 Repairing selector mechanism 17322
1 1 Installation position of selector mechanism 17322
1 2 Overview of selector mechanism 17323
1 3 Assembly overview – gear lever knob and cover 17324
1 4 Removing and installing gaiter with gear knob and noise insulation 17325
1 4 1 Installing 17326
1 5 Assembly overview – selector lever and selector housing (up to 10 06) 17326
1 6 Assembly overview – selector lever and selector housing (from 11 06) 17329
1 6 1 Dismantling and assembling selector mechanism 17330
1 7 Assembly overview – selector cables (cable support bracket and metal relay lever ) 17335
1 8 Assembly overview – selector cables (cable support bracket and plastic relay lever) 17339
1 9 Removing and installing selector mechanism 17344
1 9 1 Removing 17344
1 10 Removing and installing gear selector cable and gate selector cable 17348
1 10 1 Removing 17348
1 10 2 Installing 17349
1 11 Adjusting selector mechanism 17350
1 11 1 Functional check 17352
2 Removing and installing gearbox, Jetta 2005 ►, Golf Variant 2007 ►, Golf Variant 2010 ►  17354
2 1 Removing gearbox 17354
2 2 Installing gearbox 17361
2 2 1 Specified torques 17367
3 Removing and installing gearbox, Jetta 2011 ► 17369
3 1 Removing gearbox 17369
3 2 Installing gearbox 17380
3 2 1 Specified torques 17388
4 Transporting gearbox 17389
5 Checking and topping up gear oil 17390
5 1 Preparation 17390
5 2 Draining gear oil 17391
5 3 Filling with gear oil 17392
6 Dismantling and assembling gearbox 17393
6 1 Overview – gearbox 17393
6 2 Assembly overview – dismantling and assembling gearbox 17394
6 3 Assembly overview – Removing and installing cover for gearbox housing and 5th and 6th gears 17395
6 4 Assembly overview – removing and installing gearbox housing and selector mechanism 17398
6 5 Assembly overview – removing and installing input shaft, output shaft, differential and selector forks 17399
6 6 Assembly sequence – Removing and installing cover for gearbox housing and 5th and 6th gear 17400
6 6 1 Removing cover for gearbox housing and 5th and 6th gears 17402
6 6 2 Installing cover for gearbox housing and 5th and 6th gears 17406
6 7 Assembly sequence – Dismantling and assembling gearbox completely 17406
6 7 1 Dismantling gearbox 17410
6 7 2 Assembling gearbox 17416
7 Repairing gearbox housing and clutch housing 17427
8 Repairing gearbox housing cover 17434
9 Repairing selector unit 17438
10 Selector forks 17441
10 1 Assembly overview – selector forks in connection with reverse synchromeshed gear -arrow- 17441
10 2 Assembly overview – selector forks in connection with reverse gear locking collar -arrow- 17443
10 3 Repairing selector forks 17444
35 – Gears, shafts 17448
1 Input shaft 17448
1 1 Dismantling and assembling input shaft 17448
1 2 Adjusting input shaft 17457
1 2 1 Determining thickness of shim 17459
1 2 2 Carrying out check measurement 17461
2 Output shaft 17462
2 1 Dismantling and assembling output shaft 17462
2 2 Adjusting output shaft 17475
2 2 1 Determining thickness of shim 17478
3 Reverse shaft 17480
3 1 Assembly overview – reverse shaft with reverse synchromeshed gear -arrow- 17480
3 2 Assembly overview – reverse shaft with reverse gear locking collar -arrow- 17481
3 3 Dismantling and assembling reverse shaft 17483
39 – Final drive – differential 17486
1 Renewing flange shaft oil seals with gearbox installed 17486
1 1 Renewing oil seal for left flange shaft with gearbox installed 17486
1 1 1 Removing 17486
1 1 3 Torque setting 17488
1 2 Distinguishing seals for right flange shaft 17488
1 3 Renewing right seal with gearbox installed (two-part seal for flange shaft and sleeve) 17488
1 3 1 Removing 17489
1 3 3 Torque setting 17491
1 4 Renewing right seal and sleeve together with gearbox installed (one-piece seal and sleeve for flange shaft) 17491
1 4 1 Removing 17492
1 4 2 Installing 17493
1 4 3 Torque setting 17493
2 Adjustment overview 17494
3 Differential 17495
3 1 Dismantling and assembling differential 17495
3 2 Adjusting differential 17503
3 2 1 Determining thickness of shim 17504
MEX5R008520 7 speed dual clutch gearbox 0AM 17506
00 – Technical data 17510
1 Identification of gearbox 17510
2 Overview – power transmission 17511
3 Code, engine allocation 17512
4 Capacities 17513
5 Safety information 17514
5 1 General safety provisions 17514
5 2 Safety measures when working on vehicles with a start/stop system 17514
5 3 Safety precautions when using testers and measuring instruments during a road test 17515
6 Notes on tow-starting/towing 17516
7 General repair instructions 17517
7 1 Tools 17517
7 2 Gearbox 17517
7 3 Working with vehicle diagnostic testers 17522
7 3 1 Adapting installation information 17522
7 3 2 Reading measured values for mandatory reporting 17522
7 3 3 Initiating basic adjustment 17522
30 – Clutch 17524
1 Removing and installing dual clutch, gearboxes made up to 05 2011 17524
1 1 Assembly overview – dual clutch, gearboxes manufactured up to 05 2011 17524
1 2 Removing dual clutch, gearboxes manufactured up to 05 2011 17526
1 3 Adjusting position of engagement bearings for clutches “K 1” and “K 2”, gearboxes made up to 05 2011 17530
1 4 Installing dual clutch, gearboxes made as of 05 2011 17542
2 Removing and installing dual clutch, gearboxes made from 06 2011 onwards 17549
2 1 Assembly overview – dual clutch, gearboxes made as of 06 2011 17549
2 2 Removing dual clutch, gearboxes made as of 06 2011 17551
2 3 Adjusting position of engagement bearings for clutches “K 1” and “K 2”, gearboxes made as of 06 2011 17555
2 4 Installing dual clutch, gearbox date from 06 2011 17568
3 Removing and installing oil seals at clutch end 17574
34 – Controls, housing 17577
1 Gear oil 17577
1 1 Renewing gear oil 17577
1 2 Draining and filling hydraulic fluid for mechatronic unit 17581
2 Selector mechanism 17584
2 1 Overview – selector mechanism in vehicles up to 02 2009 17584
2 2 Removing and installing selector lever cable – vehicles up to 02 2009 17586
2 3 Overview of selector mechanism – vehicles from 03 2009 onwards 17594
2 4 Removing and installing selector mechanism – vehicles as of 03 2009 17595
2 4 1 Removing and installing selector mechanism with selector housing 17595
2 4 2 Removing and installing selector mechanism without selector housing 17599
2 5 Checking selector lever cable 17602
2 6 Adjusting selector lever cable 17602
2 7 Emergency release of selector lever 17605
2 8 Removing and installing selector lever knob 17605
2 9 Moving push-button in the handle to installation position 17608
2 9 1 Handle with push-button on side 17608
2 9 2 Handle with front push-button 17608
2 10 Checking selector mechanism 17609
3 Mechatronic unit for dual clutch gearbox -J743- 17611
3 1 Safety note on mechatronic unit for dual clutch gearbox -J743- 17611
3 2 Overview – mechatronic unit 17612
3 3 Removing mechatronic unit for dual clutch gearbox -J743- with gearbox installed 17613
3 4 Moving mechatronic unit for dual clutch gearbox -J743- into »removal position« by hand 17624
3 5 Installing mechatronic unit for dual clutch gearbox -J743- 17628
3 6 View of selector forks with mechatronic unit removed 17634
3 7 Renewing clutch actuator 17635
4 Removing and installing gearbox, Jetta 2005 ►, Golf Variant 2007 ►, Golf Variant 2010 ► 17641
4 1 Information about gearboxes with different output shafts 17641
4 2 Removing gearbox, vehicles with 1 2 l/77 kW TSI engine, 1 4 l/90 kW TFSI engine, and 1 4 l/118 kW TSI engine 17641
4 3 Removing gearbox, vehicles with 1 6 l/75 kW MPI engine 17650
4 4 Removing gearbox – vehicles with 1 9 l/77 kW TDI PD engine 17660
4 5 Removing gearbox – vehicles with 1 6 l/77 kW TDI CR engine 17668
4 6 Installing gearbox, Jetta 2005 ►, Golf Variant 2007 ►, Golf Variant 2010 ► 17676
4 7 Torque settings »Gearbox to engine« and notes on assembly mounting 17680
4 7 1 Engines: 1 2 l/77 kW TSI, 1 4 l/90 kW TFSI, 1 4 l/118 kW TSI and 1 6 l/75 kW MPI 17681
4 7 2 Engine: 1 9 l/77 kW TDI PD 17683
4 7 3 Engine: 1 6 l/77 kW TDI common rail 17684
5 Removing and installing gearbox, Jetta 2011 ► 17685
5 1 Removing gearbox, Jetta 2011 with 1 2 l/77 kW TSI engine, 1 4 l/90 kW TFSI engine, and 1 4 l/118 kW TSI engine 17685
5 2 Removing gearbox, Jetta 2011 with 1 6 l/77 kW TDI CR engine 17696
5 3 Installing gearbox, Jetta 2011 17705
5 4 Specified torques 17709
5 4 1 Engines: 1 2 l/77 kW TSI, 1 4 l/90 kW TFSI, and 1 4 l/118 kW TSI 17709
5 4 2 Engine: 1 6 l/77 kW TDI common rail 17711
6 Transporting gearbox and securing to assembly stand 17712
35 – Gears, shafts 17716
1 Dismantling and assembling gears and shafts 17716
2 Parking lock 17717
2 1 Removing and installing cover for parking lock 17717
2 2 Removing and installing parking lock 17718
39 – Final drive – front differential 17720
1 Oil seals 17720
1 1 Overview of fitting locations – seals 17720
1 2 Renewing oil seal for right stub shaft 17721
1 3 Renewing oil seal for left stub shaft 17723
1 4 Renewing seal for right flange shaft 17726
1 5 Renewing oil seal for left flange shaft 17729
MEX5R009620 6 speed manual gearbox 0AJ 17734
00 – Technical data 17738
1 Identification of gearbox 17738
1 1 Location on gearbox 17738
1 2 Identification code, assembly allocation and capacities 17739
2 Overview – power transmission 17741
3 Calculating overall gear ratio “i” 17743
4 General repair instructions 17744
4 1 Components 17744
4 1 1 Gearbox 17744
4 1 2 O-rings, seals and gaskets 17744
4 1 3 Sealant 17744
4 1 4 Locking devices 17745
4 1 5 Nuts and bolts 17746
4 1 6 Mountings 17746
4 1 7 Shims 17747
4 1 8 Synchro-rings 17747
4 1 9 Gear wheels 17748
4 1 10 Synchromeshed gears 17748
4 1 11 Clutch 17748
30 – Clutch 17749
1 Fault finding, power transmission 17749
2 Repairing clutch mechanism 17750
2 1 Overview 17750
2 2 Assembly overview – pedal cluster 17750
2 3 Removing and installing over-centre spring (left-hand drive) 17752
2 3 1 Removing 17753
2 3 2 Installing 17756
2 3 3 Specified torques 17758
2 4 Removing and installing over-centre spring (right-hand drive) 17758
2 4 1 Removing 17759
2 4 2 Installing 17762
2 4 3 Specified torques 17764
2 5 Removing and installing clutch pedal (LHD) 17764
2 5 1 Removing 17765
2 5 2 Installing 17768
2 5 3 Specified torques 17771
2 6 Removing and installing clutch pedal (RHD) 17771
2 6 1 Removing 17772
2 6 2 Installing 17775
2 6 3 Specified torques 17778
2 7 Removing and installing mounting bracket (LHD) 17778
2 7 1 Removing 17779
2 7 2 Installing 17783
2 7 3 Specified torques 17785
2 8 Removing and installing mounting bracket (RHD) 17785
2 8 1 Removing 17786
2 8 2 Installing 17791
2 8 3 Specified torques 17793
2 9 Removing and installing clutch master cylinder 17793
2 9 1 Removing 17793
2 9 2 Installing 17794
2 10 Removing and installing clutch position sender -G476- 17795
2 10 1 Removing 17796
2 10 2 Installing 17798
2 11 Assembly overview – hydraulics (LHD) 17799
2 12 Assembly overview – hydraulics (RHD) 17801
2 13 Removing and installing clutch slave cylinder 17803
2 13 1 Removing 17803
2 13 2 Installing 17805
3 Bleeding clutch mechanism 17806
4 Repairing clutch release mechanism 17808
4 1 Assembly overview – clutch release mechanism 17808
4 2 Removing and installing clutch release lever, release bearing and guide sleeve 17809
5 Repairing clutch 17811
34 – Controls, housing 17817
1 Repairing selector mechanism 17817
1 1 Installation position of selector mechanism 17817
1 2 Overview of selector mechanism 17818
1 3 Assembly overview – gear knob and cover 17818
1 4 Removing and installing gaiter with gear knob and noise insulation 17819
1 5 Assembly overview – Gear lever and selector housing 17821
1 5 1 Dismantling and assembling selector mechanism 17823
1 6 Assembly overview – selector cables 17831
1 7 Removing cable end-piece from relay lever and installing 17836
1 8 Removing and installing selector mechanism 17838
1 8 1 Removing selector mechanism 17838
1 8 2 Installing selector mechanism 17842
1 9 Removing and installing gear selector cable and gate selector cable 17846
1 9 1 Removing 17846
1 9 2 Installing 17847
1 10 Adjusting selector mechanism 17848
1 10 1 Function 17851
2 Removing and installing gearbox, Jetta 2005 ►, Golf Variant 2007 ► and Golf Variant 2010 ► 17852
2 1 Removing gearbox 17852
2 2 Installing gearbox 17864
2 2 1 Specified torques 17871
3 Removing and installing gearbox, Jetta 2011 ► 17873
3 1 Removing gearbox, Jetta 2011 with 1 2 l engine and 1 4 l engine 17873
3 2 Installing gearbox, Jetta 2011 with 1 2 l engine and 1 4 l engine 17886
3 2 1 Specified torques 17894
4 Transporting gearbox 17896
5 Checking gear oil 17898
6 Dismantling and assembling gearbox 17900
6 1 Overview – gearbox 17900
6 2 Assembly overview 17900
6 3 Assembly overview – Removing and installing cover for gearbox housing and 5th and 6th gears 17901
6 4 Assembly overview – removing and installing clutch housing 17903
6 5 Assembly overview – removing and installing input shaft, output shaft, differential, selector mechanism and selector forks 17904
6 6 Assembly sequence 17906
6 6 1 Dismantling gearbox 17910
6 6 2 Assembling gearbox 17917
7 Repairing gearbox housing and clutch housing 17929
8 Repairing gearbox housing cover 17933
9 Repairing selector unit 17936
10 Dismantling and assembling selector forks 17939
35 – Gears, shafts 17945
1 Input shaft 17945
1 1 Dismantling and assembling input shaft 17945
2 Output shaft 17959
2 1 Dismantling and assembling output shaft 17959
39 – Final drive – differential 17970
1 Renewing flange shaft oil seals with gearbox installed 17970
1 1 Renewing oil seal for left flange shaft 17970
1 1 1 Removing 17970
1 1 2 Installing 17971
1 2 Renewing seal for right flange shaft 17972
1 2 1 Removing 17973
1 2 2 Installing 17973
2 Differential 17975
2 1 Dismantling and assembling differential 17975
2 2 Adjusting differential 17983
2 2 1 Determining thickness of shim 17986