Volkswagen Jetta 2011 & Jetta 2013 Repair Manual PDF

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Volkswagen Jetta 2011 & Jetta 2013 Repair Manual – PDF DOWNLOAD

FILE DETAILS:

Volkswagen Jetta 2011 & Jetta 2013 Repair Manual – PDF DOWNLOAD 

Language : English
Pages : 13014
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Volkswagen Jetta 2011 & Jetta 2013 Repair Manual – PDF DOWNLOAD 

00 – Technical data 7
1 Basic instructions 7
2 Vehicle identification data 8
2 1 Vehicle identification number 8
2 2 Identification plate 9
2 3 Vehicle data sticker 10
3 Safety information 11
4 Body work for which HV electrical system must be de-energised 12
4 1 The following body work requires the HV electrical system to be de-energised 12
5 Moulded foam inserts 13
6 Galvanized body parts, high- and higher-strength and hot-formed body panels 15
6 1 Installing 15
6 2 Overview – NAR vehicles 17
6 3 Overview – ROW vehicles 20
7 Body panel gaps/shut lines 23
7 1 Body – front 23
7 2 Body – centre 24
7 3 Body – rear 25
8 Body dimensions 26
8 1 Body – front 26
8 2 Body – centre 29
8 3 Body – rear 36
8 4 Floor panel – front 38
8 5 Floor panel – centre 40
8 6 Floor panel – rear 41
9 Contour correct surfaces 43
10 Tools 44
11 Alignment bracket set 45
11 1 Overview 45
11 2 Procedure for body structural damage on vehicles from Volkswagen 45
12 Portal gauge 46
50 – Body – front 47
1 Renewing right bracket 47
1 1 Tools 47
1 2 Removing 47
1 3 Installing 49
1 3 1 Welding in 49
2 Renewing left bracket 51
2 1 Tools 52
2 2 Removing 52
2 3 Installing 54
2 3 1 Preparing new part 54
2 3 2 Welding in 54
3 Renewing subframe 56
3 1 Tools 56
3 2 Removing 56
3 3 Installing 58
3 3 1 Preparing new part 58
3 3 2 Welding in 59
4 Renewing bumper bracket 60
4 1 Tools 61
4 2 Removing 61
4 3 Installing 62
4 3 1 Welding in 62
5 Renewing upper wheel housing longitudinal member 64
5 1 Tools 65
5 2 Removing 65
5 3 Installing 68
5 3 1 Preparing new part 68
5 3 2 Welding in 69
6 Renewing front wheel housing 75
6 1 Tools 76
6 2 Removing 76
6 3 Installing 77
6 3 1 Preparing new parts 77
6 3 2 Welding in 79
7 Repairing threads for securing subframe (suspension subframe) 81
7 1 Contents of thread repair kit 83
7 2 Repairing threads 83
7 2 1 Drilling threads 83
7 2 2 Cutting thread 84
7 2 3 Inserting thread insert 85
8 Renewing front longitudinal member 87
8 1 Tools 88
8 2 Removing 88
8 3 Installing 90
8 3 1 Preparing new part 90
8 3 2 Welding in 91
9 Renewing front longitudinal member – part section 94
9 1 Tools 95
9 2 Removing 95
9 3 Installing 97
9 3 1 Preparing new part 97
9 3 2 Welding in 98
9 3 3 Shortening new longitudinal member with cover plate 102
10 Renewing front right longitudinal member – part section 106
10 1 Tools 107
10 2 Removing 107
10 3 Installing 109
10 3 1 Preparing new part 109
10 3 2 Welding in 110
51 – Body – centre 114
1 Renewing roof – vehicles with no sliding/tilting sunroof 114
1 1 Tools 115
1 2 Removing 116
1 3 Installing 118
1 3 1 Preparing new part 119
1 3 2 Adjusting roof depth 120
1 3 3 Bonding in 121
1 3 4 Welding in 127
2 Renewing roof – vehicles with sliding/tilting sunroof 129
2 1 Tools 130
2 2 Removing 131
2 3 Installing 134
2 3 1 Preparing new part 135
2 3 2 Setting the depth dimension 136
2 3 3 Bonding in 137
2 3 4 Welding in 143
3 Renewing roof side member 146
3 1 Tools 147
3 2 Removing 147
3 3 Installing 149
3 3 1 Preparing new part 149
3 3 2 Moulded foam inserts 150
3 3 3 Welding in 151
4 Renewing front cross member for roof 154
4 1 Tools 155
4 2 Removing 155
4 3 Installing 156
4 3 1 Welding in 156
5 Renewing roof reinforcement – vehicles for NAR, with no sliding/tilting sunroof 158
5 1 Tools 159
5 2 Removing 159
5 3 Installing 160
5 3 1 Welding in 160
6 Renewing rear roof cross member 162
6 1 Tools 163
6 2 Removing 163
6 3 Installing 164
6 3 1 Welding in 164
7 Renewing A-pillar 166
7 1 Tools 167
7 2 Removing 167
7 3 Installing 169
7 3 1 Preparing new part 170
7 3 2 Moulded foam inserts 171
7 3 3 Welding in 172
8 Renewing A-pillar reinforcement – part section 176
8 1 Tools 177
8 2 Removing 177
8 3 Installing 178
8 3 1 Preparing new part 179
8 3 2 Moulded foam inserts 179
8 3 3 Welding in 179
9 Renewing B-pillar 183
9 1 Tools 184
9 2 Removing 184
9 3 Installing 186
9 3 1 Preparing new part 187
9 3 2 Marking area in which welding work is prohibited 189
9 3 3 Moulded foam inserts 189
9 3 4 Welding in 190
10 Renewing B-pillar reinforcement, non-hybrid vehicles 193
10 1 Tools 194
10 2 Removing 194
10 3 Installing 196
10 3 1 Preparing new part 196
10 3 2 Marking areas where no welding work may be carried out 199
10 3 3 Welding in 200
11 Renewing B-pillar reinforcement, hybrid vehicles 203
11 1 Tools 204
11 2 Removing 204
11 3 Installing 206
11 3 1 Preparing new part 206
11 3 2 Marking areas where no welding work may be carried out 209
11 3 3 Welding in 210
12 Renewing inner B-pillar 213
12 1 Tools 214
12 2 Removing 214
12 3 Installing 215
12 3 1 Preparing new part 215
12 3 2 Welding in 216
13 Renewing side member 218
13 1 Tools 219
13 2 Removing 219
13 3 Installing 221
13 3 1 Preparing new part 222
13 3 2 Moulded foam inserts 223
13 3 3 Marking area in which welding work is prohibited 224
13 3 4 Welding in 225
14 Renewing front side member reinforcement, non-hybrid vehicles 227
14 1 Tools 228
14 2 Removing 228
14 3 Installing 229
14 3 1 Preparing new part 230
14 3 2 Welding in 230
15 Renewing front side member reinforcement, hybrid vehicles 233
15 1 Tools 234
15 2 Removing 234
15 3 Installing 235
15 3 1 Preparing new part 236
15 3 2 Welding in 236
16 Renewing rear side member reinforcement 239
16 1 Tools 240
16 2 Removing 240
16 3 Installing 241
16 3 1 Preparing new part 242
16 3 2 Welding in 242
17 Renewing outer mounting for seat cross member 244
17 1 Tools 245
17 2 Removing 246
17 3 Installing 247
17 3 1 Preparing new part 247
17 3 2 Welding in 248
18 Renewing inner mounting for seat cross member 250
18 1 Tools 250
18 2 Removing 250
18 3 Installing 252
18 3 1 Preparing new part 252
18 3 2 Welding in 253
19 Renewing seat middle cross member 255
19 1 Tools 255
19 2 Removing 255
19 3 Installing 257
19 3 1 Preparing new part 257
19 3 2 Welding in 258
53 – Body – rear 260
1 Renewing cross panel 260
1 1 Tools 261
1 2 Removing 261
1 3 Installing 262
1 3 1 Preparing new part 262
1 3 2 Welding in 263
2 Renewing lock carrier 265
2 1 Tools 265
2 2 Removing 265
2 3 Installing 267
2 3 1 Welding in 267
3 Renewing tail light mounting 269
3 1 Tools 270
3 2 Removing 270
3 3 Installing 271
3 3 1 Preparing new part 271
3 3 2 Welding in 271
4 Renewing tail light reinforcement, hybrid vehicles 273
4 1 Tools 274
4 2 Removing 274
4 3 Installing 275
4 3 1 Preparing new part 275
4 3 2 Welding in 275
5 Renewing luggage compartment floor 277
5 1 Tools 278
5 2 Removing 279
5 3 Installing 281
5 3 1 Preparing new part 281
5 3 2 Moulded foam inserts 283
5 3 3 Welding in 283
6 Renewing C-pillar reinforcement – part section 288
6 1 Tools 289
6 2 Removing 289
6 3 Installing 290
6 3 1 Preparing new part 290
6 3 2 Welding in 291
7 Renewing rear longitudinal member – part section 293
7 1 Tools 294
7 2 Removing 294
7 3 Installing 295
7 3 1 Preparing new part 295
7 3 2 Welding in 296
8 Renewing rear longitudinal member – subpart 298
8 1 Tools 299
8 2 Removing 299
8 3 Installing 300
8 3 1 Preparing new part 300
8 3 2 Welding in 300
9 Renewing rear longitudinal member reinforcement, hybrid vehicles 302
9 1 Tools 303
9 2 Removing 303
9 3 Installing 304
9 3 1 Preparing new part 304
9 3 2 Welding in 305
10 Renewing rear battery mounting, hybrid vehicles 308
10 1 Tools 309
10 2 Removing 309
10 3 Installing 310
10 3 1 Preparing new part 310
10 3 2 Welding in 311
11 Renewing side panel – part section 313
11 1 Tools 314
11 2 Removing 314
11 3 Installing 317
11 3 1 Preparing new part 318
11 3 2 Moulded foam inserts 319
11 3 3 Welding in 319
12 Renewing outer wheel housing liner 324
12 1 Tools 325
12 2 Removing 325
12 3 Installing 326
12 3 1 Preparing new part 326
12 3 2 Welding in 327
27 – Starter, current supply, CCS 333
1 Battery 333
1 1 Fundamentals for batteries 333
1 2 Battery load test 333
1 2 1 Battery with »standard« colour indicator 334
1 2 2 Battery with »enhanced« colour indicator 334
1 2 3 Absorbent glass mat battery 335
1 2 4 Lithium ion battery 335
1 3 Warning notices and safety regulations 335
1 3 1 Dangers when handling vehicle batteries 335
1 3 2 Safety markings on battery 336
1 3 3 Working on airbag system 337
1 4 Battery load test 337
2 Checking battery 339
2 1 Checking the various types of batteries 339
2 1 1 Checking a battery with colour indicator 339
2 1 2 Absorbent glass mat battery 339
2 2 Inspection 340
2 3 Information about battery replacement and battery gas venting 341
2 4 Checking colour indicator in battery cover 342
2 4 1 Checking colour indicator, “3-colour” 342
2 4 2 Checking colour indicator, “2-colour” 343
2 5 Battery tester with printer -VAS 6161- 344
2 5 1 Description of battery tester with printer -VAS 6161- 345
2 5 2 Perform battery test with battery tester with printer -VAS 6161- 345
2 5 3 Genuine Volkswagen battery test 347
2 5 4 “Non”-VW battery test 347
2 5 5 Carrying out stock maintenance 348
2 5 6 Comments concerning test print out 348
2 5 7 Assessing test results 349
2 6 Midtronics -MCR340V- battery tester only for USA/Canada vehicles 349
2 6 1 General description 350
2 6 2 Performing battery test with Midtronics -MCR340V- battery tester 351
2 6 3 Assessing test results 352
2 6 4 Dealing with problems with Midtronics -MCR340V- battery tester 352
2 7 Current draw test 353
3 Charging the battery 355
3 1 Battery charger -VAS 5095 A- 355
3 1 1 Description of battery charger -VAS 5095 A- 356
3 1 2 Charging battery with battery charger -VAS 5095 A- 357
3 1 3 Charging totally discharged battery with battery charger -VAS 5095 A- 358
3 1 4 Charging battery in support mode with battery charger -VAS 5095A- 359
3 1 5 Charging battery in trickle charge mode with battery charger -VAS 5095 A- 361
3 2 Battery charger -VAS 5900- 362
3 2 1 Description of battery charger -VAS 5900- 362
3 2 2 Charging battery with battery charger -VAS 5900- 363
3 2 3 Charging battery in service mode with battery charger -VAS 5900- 366
3 2 4 Charging totally discharged batteries with battery charger -VAS 5900- 369
3 2 5 Charging battery in support mode with battery charger -VAS 5900- 371
3 2 6 Charging battery in trickle charge mode with battery charger -VAS 5900- 373
3 3 Battery charger -VAS 5900 A- 374
3 3 1 General description – battery charger -VAS 5900 A- 374
3 3 2 Charging battery with battery charger -VAS 5900 A- 376
3 3 3 Charging totally discharged battery with battery charger -VAS 5900 A- 377
3 3 4 Charging battery in support mode with battery charger -VAS 5900 A- 380
3 3 5 Mains supply mode with battery charger -VAS 5900 A- 382
3 4 Battery charger -VAS 5903- 383
3 4 1 Description of battery charger -VAS 5903- 384
3 4 2 Charging battery with battery charger -VAS 5903- 384
3 4 3 Charging battery in refresh charge mode with battery charger -VAS 5903- 387
3 4 4 Charging totally discharged battery with battery charger -VAS 5903- 390
3 4 5 Charging battery in support mode with battery charger -VAS 5903- 392
3 4 6 Charging battery in trickle charge mode with battery charger -VAS 5903- 394
3 5 Battery charger -VAS 5906- 395
3 5 1 General description 395
3 5 2 Charging battery with battery charger -VAS 5906- 396
3 6 Battery charger -VAS 5908- 398
3 6 1 General description – battery charger -VAS 5908- 398
3 6 2 Auto mode on battery charger -VAS 5908- 400
3 6 3 Charging battery with battery charger -VAS 5908- 401
3 6 4 Charging battery in support mode with battery charger -VAS 5908- 403
3 6 5 VAS I-CHECK current draw test with battery charger -VAS 5908- 405
3 7 Midtronics -INC 940- battery charger only for USA/Canada 407
3 7 1 General description of Midtronics -INC 940- battery tester 407
3 7 2 Charging battery 408
3 7 3 Dealing with problems with Midtronics -INC 940- battery tester 410
3 8 Solar charger module -VAS 6102B- 411
3 8 1 Charging battery in trickle charge mode with solar panel -VAS 6102B- 411
3 9 Totally discharged batteries 412
4 Cruise control system (CCS) 414
4 1 Activating and deactivating cruise control system (CCS) 414
90 – Gauges, instruments 415
92 – Windscreen wash/wipe system 416
1 Washer fluid line hose couplings 416
1 1 Windscreen and rear window washer system 416
1 2 Headlight washer system 417
2 Hose repair 418
2 1 General description 418
2 2 Repairing smooth pipe 418
2 3 Repairing corrugated pipe 418
3 Distinguishing features of jointless wiper blades 421
94 – Lights, bulbs, switches – exterior 422
1 Operation and safety notes for gas discharge lamps 422
96 – Lights, bulbs, switches – interior 425
1 12 V socket 425
1 1 Removing and installing 12 V socket 425
1 2 Removing and installing socket illumination bulb -L42- 425
2 Cigarette lighter -U1- 426
2 1 General description 426
2 2 Assembly overview 427
2 3 Removing and installing cigarette lighter socket 428
2 4 Removing and installing cigarette lighter illumination bulb -L28- 431
97 – Wiring 433
1 Vehicle diagnosis, testing and information systems 433
1 1 Connecting vehicle diagnostic tester 433
1 2 Connecting vehicle diagnostic tester Golf Model Year 1998 – 2003 435
2 Repairs to wiring harnesses and connectors 436
2 1 General notes concerning repairs to vehicle electrical system 436
2 2 Wiring harness repair set 438
2 2 1 Wiring harness repair set -VAS 1978- 438
2 2 2 Upgrade kit -VAS 1978/50- 438
2 2 3 Wiring harness repair set -VAS 1978A- 439
2 2 4 Release tool set -VAS 1978/35- 439
2 3 Tool descriptions 440
2 3 1 Special pliers with insert 440
2 3 2 Release tools for contacts 441
2 3 3 Assembly tools for single wire seals 441
2 3 4 Wire stripper -VAS 1978/3- 441
2 3 5 Hot air blower 220 V/50 Hz -VAS 1978/14- 443
2 3 6 Crimping pliers -VAS 1978/1A- 443
2 4 Repairing wiring harnesses 445
2 4 1 Repairs to airbag and belt tensioner wiring 445
2 4 2 Repairing CAN bus wiring 447
2 4 3 Repair of Flexray wires with sheath 448
2 4 4 Repair of Flexray wires without sheath 449
2 4 5 Renewal of aerial wiring 450
2 4 6 Repairing 0 13 mm2/0 35 mm2/0 5 mm2 wire 452
2 4 7 Repair of 10 mm2 or 16 mm2 wire with single butt connector 457
2 4 8 Repair of 2 5 mm2, 4 mm2 or 6 mm2 aluminium wire with single butt connector 464
2 4 9 Wiring open circuit with one repair position 470
2 4 10 Wiring open circuit with two repair positions 473
2 5 Repairing fibre optic cables 475
2 5 1 Preparing fibre optic cable 476
2 5 2 Detaching fibre optic cable from cable harness connector 483
2 6 Repair of aerial wires 484
2 6 1 Repair set, aerial cable VAS 6720 484
2 7 Repairs to contact housings and connectors 496
2 7 1 Notes on repairs to contact housings and connectors 496
2 7 2 Repairs to contacts in contact housings 496
2 7 3 Fitting single wire seals 498
2 7 4 Repairs to contact housings using cut-and-clamp method 501
2 8 Releasing and dismantling contact housings 502
2 8 1 Notes on releasing and dismantling contact housings 502
2 8 2 Secondary locking element 502
2 8 3 Primary locking element 503
2 8 4 Round connector systems 504
2 8 5 Flat connector systems 505
2 8 6 Special connector systems 507
3 Contact surface cleaning set -VAS 6410- 510
3 1 Using contact surface cleaning set -VAS 6410- 510
3 1 1 Repairing ring terminals 510
3 1 2 Repairing threaded connections 512
3 1 3 Cleaning battery clamp and battery terminal 514
3 1 4 Anti-corrosion treatment 516
4 Renewing lambda probe 518
4 1 Renewing LSF Lambda probe (4-pin) 518
4 2 Renewing LSU Lambda probe (6-pin) 519
4 3 Types of protective tube on universal lambda probes 520
5 Exhaust gas temperature sensor 522
27 – Starter, current supply, CCS 531
1 Battery 531
1 1 Types of battery 531
1 2 Battery – general notes 531
1 2 1 Warning notices and safety regulations 531
1 2 2 Battery terminal connection 531
1 2 3 Battery recharging or jump start on vehicles with start/stop system 531
1 3 Assembly overview – battery 532
1 3 1 Assembly overview – battery -A- in engine compartment 532
1 3 2 Assembly overview – battery -A- in luggage compartment, high-voltage vehicle 533
1 4 Removing and installing battery 534
1 4 1 Removing and installing battery -A- in engine compartment 534
1 4 2 Removing and installing battery -A- in luggage compartment, high-voltage vehicle 535
1 4 3 Adapting battery -A- 536
1 5 Disconnecting and reconnecting battery 537
1 5 1 Disconnecting battery -A- in engine compartment 537
1 5 2 Reconnecting battery -A- in engine compartment 538
1 5 3 Disconnecting battery -A- in luggage compartment, high-voltage vehicle 539
1 5 4 Reconnecting battery -A- in luggage compartment, high-voltage vehicle 540
1 6 Removing and installing battery tray 541
1 6 1 Removing and installing battery tray in engine compartment 541
1 6 2 Removing and installing battery tray in luggage compartment, high-voltage vehicle 541
1 7 Checking battery 542
1 8 Charging battery 542
1 9 Removing and installing earth wire with battery monitor control unit -J367- 542
1 9 1 Battery monitoring control unit -J367- 542
1 9 2 Renewing and commissioning battery monitor control unit -J367- 543
1 9 3 Removing and installing battery monitor control unit -J367- in engine compartment 543
1 9 4 Removing and installing battery monitor control unit -J367- in luggage compartment, high-voltage vehicle 544
2 Alternator 546
2 1 Assembly overview – alternator 546
2 1 1 Assembly overview – alternator, 1 2 l petrol engine, 77 kW 546
2 1 2 Assembly overview – alternator, 1 4 l petrol engine, 90/110/118 kW 547
2 1 3 Assembly overview – alternator, 1 6 l petrol engine, 77 kW 548
2 1 4 Assembly overview – alternator, 2 0 l petrol engine, 85 kW 549
2 1 5 Assembly overview – alternator, 2 0 l petrol engine, 147 kW 550
2 1 6 Assembly overview – alternator, 2 5 l petrol engine, 125 kW 551
2 1 7 Assembly overview – alternator, 1 8 l petrol engine, 125 kW 552
2 1 8 Assembly overview – alternator, 1 6 l diesel engine, 77 kW 553
2 1 9 Assembly overview – alternator, 2 0 l diesel engine, 81/103 kW 554
2 2 Removing and installing alternator 556
2 2 1 Removing and installing alternator -C-, 1 2 l, 77 kW petrol engine 556
2 2 2 Removing and installing alternator -C-, 1 4 l, 90/110/118 kW petrol engines 558
2 2 3 Removing and installing alternator -C-, 1 6 l, 77 kW petrol engine 561
2 2 4 Removing and installing alternator -C-, 2 0 l, 85 kW petrol engine 563
2 2 5 Removing and installing alternator -C-, 2 0 l, 147 kW petrol engine 565
2 2 6 Removing and installing alternator -C-, 2 5 l, 125 kW petrol engine 568
2 2 7 Removing and installing alternator -C-, 1 8 l, 125 kW petrol engine 571
2 2 8 Removing and installing alternator -C-, 1 6 l, 77 kW diesel engine 573
2 2 9 Removing and installing alternator -C-, 2 0 l, 81/103 kW diesel engines 576
2 3 Checking alternator 579
2 4 Checking poly V-belt 579
2 5 Removing and installing poly V-belt pulley 579
2 5 1 Removing and installing poly V-belt pulley, without freewheel 579
2 5 2 Removing and installing Bosch poly V-belt pulley with freewheel 580
2 5 3 Removing and installing Valeo poly V-belt pulley with freewheel 582
2 6 Removing and installing voltage regulator 585
2 6 1 Removing and installing Bosch voltage regulator -C1- 585
2 6 2 Removing and installing Valeo voltage regulator -C1- 585
3 Starter 588
3 1 Assembly overview – starter 588
3 1 1 Assembly overview – starter, automatic gearbox or dual clutch gearbox 588
3 1 2 Assembly overview – starter, manual gearbox 589
3 1 3 Assembly overview – starter, 1 8 l petrol engine and automatic gearbox 590
3 2 Removing and installing starter 591
3 2 1 Removing and installing starter, 1 6 l petrol engine, 77 kW, automatic gearbox 591
3 2 2 Removing and installing starter, 2 0 l petrol engine, 85 kW, automatic gearbox 594
3 2 3 Removing and installing starter, 2 5 l petrol engine, 125 kW, automatic gearbox 596
3 2 4 Removing and installing starter, 1 8 l petrol engine, 125 kW, automatic gearbox 599
3 2 5 Removing and installing starter, 1 2 l petrol engine, 77 kW, dual clutch gearbox 601
3 2 6 Removing and installing starter, 1 4 l petrol engine, 90/110/118 kW, dual clutch gearbox 604
3 2 7 Removing and installing starter, 2 0 l petrol engine, 85 kW, dual clutch gearbox 606
3 2 8 Removing and installing starter, 2 0 l petrol engine, 147 kW, dual clutch gearbox 608
3 2 9 Removing and installing starter, 1 6 l diesel engine, 77 kW, dual clutch gearbox 610
3 2 10 Removing and installing starter, 2 0 l diesel engine, 81/103 kW, dual clutch gearbox 612
3 2 11 Removing and installing starter, 1 2 l petrol engine, 77 kW, manual gearbox 614
3 2 12 Removing and installing starter, 1 4 l petrol engine, 90/110/118 kW, manual gearbox 616
3 2 13 Removing and installing starter, 1 6 l petrol engine, 77 kW, manual gearbox 619
3 2 14 Removing and installing starter, 2 0 l petrol engine, 85 kW, manual gearbox 621
3 2 15 Removing and installing starter, 2 0 l petrol engine, 147 kW, manual gearbox 623
3 2 16 Removing and installing starter, 2 5 l petrol engine, 125 kW, manual gearbox 625
3 2 17 Removing and installing starter, 1 6 l diesel engine, 77 kW, manual gearbox 627
3 2 18 Removing and installing starter, 2 0 l diesel engine, 81/103 kW, manual gearbox 630
3 3 Checking starter 632
4 Cruise control system (CCS) 633
5 Start/Stop system 634
5 1 Safety precautions when working on vehicles with start/stop system 634
5 2 General description – start/stop system 634
5 3 Removing and installing voltage stabiliser 636
5 3 1 Removing and installing ( left-hand drive models) voltage stabiliser -J532- 636
5 3 2 Removing and installing (right-hand drive models) voltage stabiliser -J532- 636
90 – Gauges, instruments 638
1 Dash panel insert 638
1 1 Assembly overview – dash panel insert 638
1 1 1 Overview – dash panel insert 638
1 1 2 Assembly overview – dash panel insert 638
1 1 3 Warning lamp symbols in dash panel insert, High version 639
1 1 4 Warning lamp symbols in dash panel insert, petrol engine, Low version 641
1 1 5 Warning lamp symbols in dash panel insert, diesel engine, Low version 642
1 2 Removing and installing dash panel insert 643
1 2 1 Renewing dash panel insert 643
1 2 2 Removing and installing dash panel insert 643
1 3 Multi-pin connector pin assignment on dash panel insert 644
1 4 Removing and installing ambient temperature sensor -G17- 644
2 Horn 646
2 1 Assembly overview – horn 646
2 2 Removing and installing horn 646
92 – Windscreen wash/wipe system 648
1 Windscreen wiper system 648
1 1 Assembly overview – windscreen wiper system 648
1 2 Moving wipers to service position 649
1 2 1 Moving wipers to service position 649
1 2 2 Deactivating wiper motor control unit -J400- APP function 649
1 3 Removing and installing wiper blade 649
1 4 Removing and installing windscreen wiper arms 650
1 5 Adjusting windscreen wiper arms 651
1 6 Removing and installing windscreen wiper motor -V- 653
1 6 1 Removing wiper frame with linkage and wiper motor -V- 653
1 6 2 Removing and installing windscreen wiper motor -V- 653
1 7 Removing and installing rain and light sensor -G397- 655
1 7 1 Repairing rain and light sensor -G397- (made by TRW) 657
2 Windscreen washer system 659
2 1 Assembly overview – windscreen washer system 659
2 2 Removing and installing washer fluid reservoir 660
2 2 1 Removing and installing filler neck 660
2 2 2 Removing and installing washer fluid reservoir 661
2 3 Removing and installing windscreen washer fluid level sender -G33- 661
2 4 Removing and installing windscreen washer pump -V5- 662
2 5 Removing and installing washer jets 663
2 6 Adjusting spray jets 663
3 Headlight washer system 664
3 1 Assembly overview – headlight washer system 664
3 2 Removing and installing headlight washer system pump -V11- 664
3 3 Removing and installing washer jets 665
3 4 Adjusting spray jets 666
3 5 Removing and installing pop-up cylinder 666
4 Washer fluid lines 668
4 1 Repairing washer fluid lines 668
94 – Lights, bulbs, switches – exterior 669
1 Headlight 669
1 1 Operation and safety notes for gas discharge bulbs 669
1 2 Assembly overview – headlight 672
1 2 1 Overview – headlights, halogen bulbs, halogen headlights 672
1 2 2 Overview – headlights, gas discharge bulbs, cornering light, Xenon headlights 672
1 2 3 Assembly overview – headlights, halogen bulbs, halogen headlights 673
1 2 4 Assembly overview – headlights, gas discharge bulbs, cornering light, Xenon headlights 675
1 3 Removing and installing headlight 676
1 4 Adjusting headlights 677
1 4 1 Adjusting headlights, headlight with halogen bulb 677
1 4 2 Adjusting headlights, Xenon headlights 677
1 4 3 Performing basic settings for Xenon headlights 678
1 5 Adjusting headlight installation position 678
1 6 Removing and installing front turn signal bulb 679
1 6 1 Removing and installing front turn signal bulb, headlight with halogen bulb 679
1 6 2 Removing and installing front turn signal bulb, Xenon headlights 680
1 7 Installing repair kit for headlight housing 681
1 7 1 Repairing outer retaining tab 681
1 7 2 Repairing centre retaining tab 682
1 7 3 Repairing inner retaining tab 683
1 7 4 Repairing lower retaining tab 684
1 8 Changing headlights over from driving on right to driving on left 685
1 9 Changing headlights over from driving on left to driving on right 686
1 10 Removing and installing headlight range control actuator 687
1 10 1 Removing and installing headlight range control actuator 687
1 10 2 Checking headlight range control actuator 688
1 11 Renewing headlight dipped beam bulb 689
1 12 Renewing headlight main beam bulb 689
1 13 Removing and installing gas discharge bulb 690
1 14 Removing and installing bulb for daytime running light/side light 692
1 14 1 Removing and installing bulb for daytime running light 692
1 14 2 Removing and installing side light bulb 693
1 15 Removing and installing daytime running light 694
1 15 1 Removing and installing LED module for daytime running light and side light 694
1 16 Removing and installing headlight screen adjustment solenoid 695
1 16 1 Removing and installing headlight screen adjustment solenoid 695
1 16 2 Testing headlight screen adjustment solenoid 695
1 17 Removing and installing swivel module position sensor 695
1 17 1 Removing and installing swivel module position sensor 695
1 17 2 Checking swivel module position sensor 695
1 18 Removing and installing static cornering light bulb 696
1 19 Removing and installing gas discharge bulb control unit 697
1 20 Removing and installing power output module for headlight 698
1 20 1 Removing and installing power output module for headlight 698
1 20 2 Checking power output module for headlight 698
2 Fog lights 700
2 1 Assembly overview – fog lights 700
2 1 1 Assembly overview – fog lights, Jetta 700
2 1 2 Assembly overview – fog lights, Jetta GLI 701
2 2 Removing and installing fog light 701
2 2 1 Removing and installing fog light, Jetta 701
2 2 2 Removing and installing fog light, Jetta GLI 702
2 3 Removing and installing fog light bulb 703
2 3 1 Removing and installing fog light bulb, Jetta 703
2 3 2 Removing and installing fog light bulb, Jetta GLI 703
2 4 Adjusting fog lights 704
3 Side marker light 705
3 1 Removing and installing side marker light bulb 705
4 Lights in exterior mirror 707
4 1 Assembly overview – lights in exterior mirror 707
4 2 Removing and installing turn signal repeater bulb 707
4 3 Removing and installing entry light in exterior mirror 708
5 Tail lights 709
5 1 Assembly overview – tail lights in body 709
5 1 1 Assembly overview – tail lights in vehicle body (bulbs) 709
5 1 2 Assembly overview – tail lights in vehicle body (LEDs) 711
5 2 Assembly overview – tail lights in rear lid 712
5 2 1 Assembly overview – tail lights in rear lid (bulbs) 712
5 2 2 Assembly overview – tail lights in rear lid (LEDs) 712
5 3 Removing and installing bulb carrier 713
5 3 1 Removing and installing tail light bulb carrier, tail light in body 713
5 3 2 Removing and installing tail light bulb carrier, tail light in rear lid 714
5 4 Removing and installing tail light in rear lid 714
5 5 Removing and installing tail light in body 715
5 6 Removing and installing tail light bulb 715
5 7 Removing and installing rear fog light bulb 716
5 8 Removing and installing bulb for brake light and tail light 716
5 9 Removing and installing reversing light bulb 717
5 9 1 Removing and installing reversing light bulb (conventional bulb) 717
5 9 2 Removing and installing reversing light bulb (LED) 717
5 10 Removing and installing turn signal bulb 718
5 10 1 Removing and installing turn signal bulb (conventional bulb) 718
5 10 2 Removing and installing turn signal bulb (LED) 718
6 High-level brake light 720
6 1 Assembly overview – high-level brake light 720
6 2 Removing and installing high-level brake light 720
6 3 Removing and installing high-level brake light bulb -M25- 721
7 Number plate light 722
7 1 Removing and installing number plate light 722
7 1 1 Removing and installing number plate lights, bolted fitting 722
7 1 2 Removing and installing number plate lights, clipped fitting 722
8 Entry and start authorisation 723
8 1 Assembly overview – entry and start authorisation system 723
8 1 1 Overview – entry and start authorisation system 723
8 1 2 Assembly overview – entry and start authorisation system 724
8 2 Removing and installing entry and start authorisation control unit -J518- 725
8 2 1 Removing and installing (left-hand drive models) entry and start authorisation control unit -J518- 725
8 2 2 Removing and installing entry and start authorisation control unit -J518-, right-hand drive 726
8 2 3 Coding entry and start authorisation control unit -J518- 727
8 3 Removing and installing interior aerial for entry and start authorisation 728
8 3 1 Removing and installing interior aerial 1 for entry and start authorisation -R138- 728
8 3 2 Removing and installing interior aerial 2 for entry and start authorisation -R139- 728
8 4 Removing and installing front passenger side aerial for entry and start authorisation 729
8 4 1 Removing and installing front passenger side door exterior handle 729
8 5 Removing and installing driver side aerial for entry and start authorisation 729
8 5 1 Removing and installing driver side door exterior handle 729
8 6 Removing and installing luggage compartment aerial for entry and start authorisation -R137- 730
8 7 Removing and installing rear bumper aerial for entry and start authorisation -R136- 730
8 8 Checking entry and start system aerials and sensors 731
8 8 1 Checking driver side aerial for entry and start authorisation -R134- 731
8 8 2 Checking front passenger side aerial for entry and start authorisation -R135- 732
8 8 3 Checking rear bumper aerial for entry and start authorisation -R136- 732
8 8 4 Checking luggage compartment aerial for entry and start authorisation -R137- 732
8 8 5 Checking interior aerial 1 for entry and start authorisation -R138- 733
8 8 6 Checking interior aerial 2 for entry and start authorisation -R139- 733
8 8 7 Checking driver door exterior handle touch sensor -G415- 733
8 8 8 Checking front passenger door exterior handle touch sensor -G416- 734
8 9 Removing and installing entry and start authorisation switch 734
9 Steering column switch module 735
9 1 Assembly overview – steering column switch module 735
9 1 1 Assembly overview – steering column switch module, Valeo 735
9 1 2 Assembly overview – steering column switch module, Kostal 737
9 1 3 Assembly overview – steering column switch module, KESSY 737
9 2 Removing and installing steering column electronics control unit -J527- 739
9 2 1 Removing and installing steering column electronics control unit -J527-, Valeo 739
9 2 2 Removing and installing steering column electronics control unit -J527-, Kostal 740
9 2 3 Coding steering column electronics control unit -J527- 741
9 3 Removing and installing steering column combination switch -E595- 742
9 3 1 Removing and installing steering column combination switch -E595-, Valeo 742
9 3 2 Removing and installing steering column combination switch -E595-, Valeo with KESSY 744
9 3 3 Removing and installing steering column combination switch -E595-, Kostal 746
9 3 4 Removing and installing steering column combination switch -E595-, Kostal with KESSY 749
9 4 Removing and installing steering column switch base 751
9 4 1 Removing and installing steering column switch base, Valeo 751
9 4 2 Removing and installing steering column switch base, Valeo with KESSY 753
9 4 3 Removing and installing steering column switch base, Kostal 755
9 4 4 Removing and installing steering column switch base, Kostal with KESSY 757
9 5 Removing and installing electronic steering column lock control unit -J764- 759
9 5 1 Removing and installing electronic steering column lock control unit -J764- 759
9 5 2 Renewing electronic steering column lock control unit -J764- 760
9 6 Removing and installing ignition/starter switch -D- 761
9 6 1 Removing and installing ignition/starter switch -D- 761
9 6 2 Checking ignition/starter switch -D- 762
9 6 3 Removing and installing steering lock housing 762
9 6 4 Removing and installing lock cylinder 763
9 7 Removing and installing ignition key withdrawal lock solenoid -N376- 764
10 Parking aid 766
10 1 Assembly overview – parking aid 766
10 1 1 General description 766
10 1 2 Assembly overview – parking aid 767
10 2 Removing and installing parking aid control unit -J446- 769
10 2 1 Removing and installing parking aid control unit -J446-, left-hand drive vehicle 769
10 2 2 Removing and installing parking aid control unit -J446-, right-hand drive vehicle 770
10 2 3 Coding parking aid control unit -J446- 770
10 2 4 Adapting optical presentation of parking aid control unit -J446- 770
10 2 5 Parking aid control unit -J446-, final control diagnosis for parking aid 771
10 3 Removing and installing front parking aid warning buzzer -H22- 771
10 3 1 Removing and installing front parking aid warning buzzer -H22- 771
10 3 2 Adjusting volume of front parking aid warning buzzer -H22- 772
10 3 3 Adjusting pitch of front parking aid warning buzzer -H22- 772
10 4 Removing and installing rear parking aid warning buzzer -H15- 773
10 4 1 Removing and installing rear parking aid warning buzzer -H15- 773
10 4 2 Adjusting volume of rear parking aid warning buzzer -H15- 773
10 4 3 Adjusting pitch of rear parking aid warning buzzer pitch -H15- 773
10 5 Removing and installing front parking aid senders 774
10 5 1 Removing and installing front parking aid senders 774
10 5 2 Bonding sender retainer in front bumper cover 776
10 5 3 Renewing front parking aid senders 777
10 5 4 Repairing sender retainer in front bumper cover 778
10 5 5 Checking front parking aid sender 778
10 6 Removing and installing rear parking aid senders 778
10 6 1 Removing and installing rear parking aid senders 778
10 6 2 Bonding sender retainer in rear bumper cover 780
10 6 3 Renewing parking aid senders 781
10 6 4 Repairing sender retainers in rear bumper cover 782
10 6 5 Testing parking aid senders 782
11 Main beam assist 783
11 1 Overview – main beam assist 783
11 2 Overview of fitting locations – main beam assist 783
11 3 Removing and installing main beam assist control unit -J844- 784
11 4 Renewing main beam assist control unit -J844- 785
11 5 Coding main beam assist control unit -J844- 785
11 6 Removing and installing light sensor -G399- 785
12 Automatic headlight range control 787
12 1 Assembly overview – automatic headlight range control 787
12 2 Removing and installing cornering light and headlight range control unit -J745- 788
12 2 1 Removing and installing cornering light and headlight range control unit -J745- 788
12 2 2 Coding cornering light and headlight range control unit -J745- 789
12 2 3 Renewing cornering light and headlight range control unit -J745- 789
12 2 4 Making basic headlight setting 789
13 Towing bracket 790
13 1 Assembly overview – towing bracket socket 790
13 2 Removing and installing trailer detector control unit -J345- 790
13 3 Removing and installing trailer socket -U10- 791
96 – Lights, bulbs, switches – interior 793
1 Lights 793
1 1 Overview of fitting locations – lights in dash panel 793
1 2 Overview of fitting locations – lights in luggage compartment 795
1 3 Overview of fitting locations – lights in roof trim 796
1 4 Removing and installing glove compartment light -W6- 796
1 5 Removing and installing central locking SAFELOCK function warning lamp -K133- 798
1 6 Removing and installing luggage compartment light -W3- 799
1 7 Removing and installing illuminated vanity mirrors 800
1 8 Renewing bulb of front interior light -W1- 801
1 9 Removing and installing centre reading lights 803
1 10 Replacing bulb of rear interior light -W43- 803
2 Controls 806
2 1 Overview of fitting locations – controls in dash panel 807
2 2 Overview of fitting locations – controls in front doors 808
2 3 Fitting locations overview – controls in rear doors 809
2 4 Fitting locations overview – controls in centre console 810
2 5 Fitting locations overview – controls in roof trim 811
2 6 Removing and installing light switch -E1- 811
2 6 1 Checking light switch -E1- 812
2 7 Removing and installing regulator for switch and instrument illumination -E20- 813
2 7 1 Checking switch and instrument illumination regulator -E20- 813
2 8 Removing and installing key-operated switch to deactivate front passenger side airbag -E224- 814
2 9 Removing and installing tyre pressure monitor display button -E492- 815
2 10 Removing and installing rear central switch for interior locking -E286- 815
2 11 Removing and installing driver side interior locking button for central locking system -E308- 816
2 12 Removing and installing front passenger side interior locking button for central locking system -E309- 817
2 13 Removing and installing remote release button for fuel filler flap and rear lid -E463- 818
2 14 Removing and installing start/stop operating mode switch -E693- 819
2 15 Removing and installing TCS and ESP button -E256- 820
2 16 Removing and installing parking aid button -E266- 821
2 17 Removing and installing the starter button -E378- 823
2 18 Removing and installing button for electric drive -E656-, high-voltage vehicle 824
2 19 Removing and installing warning lamp for airbag deactivated on front passenger side -K145- 825
2 20 Removing and installing hazard warning light button -E229- 826
2 21 Removing and installing glove compartment light switch -E26- 827
2 22 Removing and installing mirror adjustment switch -E43- 827
2 23 Removing and installing operating unit for window regulator in driver door -E512- 828
2 24 Removing and installing window regulator switch in front passenger door -E107- 829
2 25 Removing and installing interior monitoring deactivation switch -E267- 831
2 26 Removing and installing rear window regulator switch in door 832
2 27 Removing and installing rear lid contact switch 833
2 27 1 Removing and installing rear lid locking unit -F256- 833
2 28 Removing and installing button 1 for tilting roof -E582- 833
2 29 Removing and installing front interior light/reading light 834
2 29 1 Removing and installing front interior light -W1-, vehicle with no sliding sunroof 834
2 29 2 Removing and installing front interior light -W1-, vehicle with sliding sunroof 835
2 30 Removing and installing rear interior light/reading light 836
2 30 1 Removing and installing rear interior light -W43- 836
2 31 Removing and installing garage door operating unit -E284- 837
3 Immobiliser 839
3 1 Overview – immobiliser 839
3 2 Immobiliser control unit -J362- 840
3 2 1 Removing and installing immobiliser control unit -J362- 840
3 2 2 Adapting immobiliser control unit -J362- 840
3 2 3 New identity on renewing all components 840
3 2 4 Online system test 840
3 3 Immobiliser reader coil -D2- 841
3 4 Ignition key 841
3 4 1 Ignition key – variable code transponder 841
3 4 2 Loss of an ignition key 841
3 4 3 Adapting ignition key to immobiliser 842
3 4 4 Checking ignition key with remote control 842
4 Anti-theft alarm system 843
4 1 Assembly overview – interior monitor 843
4 2 Activating and deactivating anti-theft alarm system 844
4 3 Central locking and anti-theft alarm system aerial -R47- 845
4 4 Removing and installing alarm horn -H12- 845
4 5 Removing and installing interior monitoring sensor -G273- 846
4 6 Removing and installing bonnet contact switch -F266- 846
4 7 Adaptations of anti-theft alarm system 846
4 7 1 Adapting alarm delay on opening driver door 846
4 7 2 Adapting country setting for alarm horn -H12- 847
5 Cigarette lighter, socket 848
5 1 Removing and installing AC/DC converter with socket 848
97 – Wiring 851
1 Relay carriers, fuse holders, electronics boxes 851
1 1 Fitting locations overview – relay carriers, fuse holders, electronics boxes 851
1 2 Removing and installing electronics box (E-box) 852
1 3 Removing and installing relay and fuse holder in electronics box 853
1 4 Removing and installing relay and fuse holder behind dash panel on driver side 854
1 4 1 Removing and installing fuse holder behind dash panel on driver side 854
1 4 2 Removing and installing onboard supply control unit -J519- 855
1 5 Removing and installing fuse holder on battery -A-, high-voltage vehicle 856
2 Control units 857
2 1 Fitting locations overview – control units 857
2 2 Removing and installing onboard supply control unit -J519- 858
2 2 1 Description of onboard supply control unit -J519- 858
2 2 2 Removing and installing onboard supply control unit -J519-, High version 860
2 2 3 Removing and installing onboard supply control unit -J519-, Low version 861
2 2 4 Renewing onboard supply control unit -J519- 861
2 2 5 Final control diagnosis of onboard supply control unit -J519- 862
2 2 6 Coding onboard supply control unit -J519- 863
2 2 7 Deactivating factory mode of onboard supply control unit -J519- 863
2 2 8 Adapting remote control key 864
2 2 9 Checking remote control unit key 864
2 2 10 Coding rain and light sensor -G397- 864
2 3 Removing and installing data bus diagnostic interface -J533- 865
2 3 1 Description of data bus diagnostic interface -J533- 865
2 3 2 Renewing data bus diagnostic interface -J533- 865
2 3 3 Removing and installing data bus diagnostic interface -J533-, LHD, High version 866
2 3 4 Removing and installing data bus diagnostic interface -J533-, RHD, High version 866
2 3 5 Coding data bus diagnostic interface -J533- 867
2 3 6 Checking bus activity of data bus diagnostic interface -J533- 867
2 3 7 Adapting bus subscriber of data bus diagnostic interface -J533- 868
2 4 Removing and installing garage door operation control unit -J530- 868
3 Connectors 869
3 1 Separating left door connector 869
3 1 1 Separating A-pillar door connector 869
3 1 2 Separating B-pillar door connector 869
3 2 Separating right door connector 870
3 2 1 Separating A-pillar door connector 870
3 2 2 Separating B-pillar door connector 870
3 3 Repairing electrical wiring harnesses and plug-in connections 870
4 Vehicle diagnostic, testing and information systems 871
00 – Technical data 880
1 Checklist for evaluating running gear of accident vehicles 880
2 General information 882
40 – Front suspension 883
1 Evaluating accident vehicles 883
2 Raising wheel suspension to unladen position 884
3 Overview – front axle 886
4 Assembly overview: subframe 888
4 1 Repairing thread in longitudinal member 889
4 2 Fixing position of subframe 889
4 3 Lowering subframe 892
4 4 Removing and installing subframe without steering rack 896
4 5 Removing and installing subframe with hydraulic steering rack 899
4 6 Removing and installing subframe with electromechanical steering rack 906
4 7 Repairing subframe 910
5 Assembly overview: front wheel suspension, suspension link 920
5 1 Checking swivel joint 921
5 2 Removing and installing swivel joint 922
5 3 Removing and installing suspension link 926
5 4 Removing and installing suspension link (left side of vehicles with dual clutch or automatic gearbox) 927
5 5 Renewing front bonded rubber bush for suspension link 932
5 6 Renewing rear bonded rubber bush for suspension link 934
6 Assembly overview: wheel bearing 937
6 1 Removing and installing wheel bearing unit 938
6 2 Removing and installing wheel bearing housing 941
7 Assembly overview: anti-roll bar 948
7 1 Removing and installing anti-roll bar 948
8 Assembly overview: suspension strut 953
8 1 Removing and installing suspension strut 954
8 2 Repairing suspension strut 960
9 Removing and installing drive shafts 963
9 1 Loosening and tightening twelve-point head bolt, with ribbing, securing drive shaft 963
9 2 Loosening and tightening twelve-point head bolt, without ribbing, securing drive shaft 964
9 3 Removing and installing drive shaft with constant velocity joint 966
9 4 Removing and installing right drive shaft with (push-on) constant velocity slip joint 969
9 5 Removing and installing drive shafts with triple roller joint AAR2600i 975
9 6 Removing and installing drive shafts with triple roller joint AAR3300i 979
10 Repairing drive shafts – overview of drive shafts 984
10 1 Heat shield for drive shafts 985
11 Assembly overview: drive shaft with VL100 constant velocity joint 986
11 1 Dismantling and assembling drive shaft with VL100 constant velocity joint 988
11 2 Checking outer constant velocity joint 992
11 3 Checking inner constant velocity joint 993
12 Assembly overview: drive shaft with VL107 constant velocity joint 996
12 1 Dismantling and assembling drive shaft with VL107 constant velocity joint 998
13 Assembly overview: drive shaft with VL107 constant velocity slip joint (push-on) 1003
13 1 Dismantling and assembling drive shaft with VL107 (push-on) constant velocity slip joint 1004
14 Assembly overview: drive shaft with triple roller joint AAR2600i 1008
14 1 Dismantling and assembling drive shaft with triple roller joint AAR2600i 1010
15 Assembly overview: drive shaft with triple roller joint AAR3300i 1015
15 1 Dismantling and assembling drive shaft with triple roller joint AAR3300i 1017
42 – Rear suspension 1023
1 Evaluating accident vehicles 1023
2 Rear axle in unladen position (torsion beam rear axle) 1024
3 Overview of rear axle (torsion beam rear axle) 1026
4 Assembly overview: axle beam, subframe, cross piece (torsion beam rear axle) 1028
4 1 Removing and installing axle assembly 1029
4 2 Removing and installing bonded rubber bush for axle beam 1033
4 3 Removing and installing cross piece 1037
4 4 Removing and installing bonded rubber bush for cross piece 1039
5 Assembly overview – plate for axle beam, torsion beam rear axle 1042
5 1 Removing plate for axle beam 1042
5 2 Installing plate for axle beam 1043
6 Assembly overview: wheel suspension (torsion beam rear axle) 1049
6 1 Removing and installing coil spring 1050
7 Assembly overview: shock absorbers (torsion beam rear axle) 1052
7 1 Removing and installing shock absorbers 1053
8 Assembly overview: wheel bearings, drum brake (torsion beam rear axle) 1055
8 1 Removing and installing wheel hub with wheel bearing, vehicles with drum brakes 1056
9 Assembly overview: wheel bearings, disc brake (torsion beam rear axle) 1060
9 1 Removing and installing wheel hub with wheel bearing, vehicles with disc brakes 1061
10 Rear axle in unladen position (multi-link rear suspension) 1064
11 Overview of rear axle (multi-link rear suspension) 1067
12 Assembly overview: subframe, transverse link, track rod (multi-link rear suspension) 1068
12 1 Assembly overview: rear left vehicle level sender -G76- 1070
12 2 Removing and installing rear left vehicle level sender -G76- 1070
12 3 Fixing position of subframe 1071
12 4 Lowering rear axle 1072
12 5 Removing and installing rear axle 1075
12 6 Removing and installing upper transverse link 1078
12 7 Removing and installing lower transverse link 1080
12 8 Removing and installing track rod 1082
13 Assembly overview: wheel bearing housing, trailing arm (multi-link rear suspension) 1085
13 1 Removing and installing wheel bearing housing 1086
13 2 Renewing bonded rubber bush for wheel bearing housing 1089
13 3 Removing and installing wheel bearing/wheel hub unit 1092
13 4 Removing and installing trailing arm with mounting bracket 1095
13 5 Repairing trailing arm 1099
14 Assembly overview: shock absorber, coil spring (multi-link rear suspension) 1103
14 1 Removing and installing coil spring 1103
14 2 Removing and installing shock absorbers 1105
14 3 Repairing shock absorber 1107
15 Assembly overview: anti-roll bar (multi-link rear suspension) 1109
15 1 Removing and installing anti-roll bar 1109
16 Assembly overview: subframe attachments, BlueMotion vehicles 1112
16 1 Removing and installing shield for rear axle 1113
44 – Wheels, tyres, vehicle geometry 1115
1 Evaluating accident vehicles 1115
2 Specified torque for fitting wheels 1116
3 Fitting wheel and tyre 1117
3 1 General information 1117
3 2 Fittings instructions 1117
4 Removing and fitting tyres (wheels with tyre pressure monitoring) 1119
4 1 Notes on safety and conditions for removing and fitting tyres (wheels with tyre pressure monitoring) 1119
4 2 Wheel change 1119
4 3 Fittings instructions 1120
4 4 Pressing tyre off wheel rim 1121
4 5 Removing tyre from wheel 1122
4 6 Fitting tyre to wheel rim 1122
5 Removing and fitting tyres with run-flat properties to wheel rims 1124
5 1 Safety information 1124
5 2 Fittings instructions 1124
5 3 Pressing tyre off wheel rim 1125
5 4 Removing tyre from wheel 1126
5 5 Fitting tyre to wheel rim 1127
6 Tyre pressure monitor display 1130
6 1 General information 1130
7 Tyre Pressure Monitoring System (TPMS) 1132
7 1 Assembly overview: tyre pressure sensor 1132
7 2 Removing and installing tyre pressure sensor 1133
8 Vehicle alignment check 1134
8 1 General information for vehicles with torsion beam rear axle 1134
8 2 General information for vehicles with multi-link rear suspension 1136
8 3 Conditions for testing 1137
8 4 Checking trailing arm of axle beam (torsion beam rear axle) using VAS 241 001 1138
8 5 Checking trailing arm of axle beam (torsion beam rear axle) using VAS 801 1140
8 6 Test preparations 1143
8 7 Vehicle alignment specifications for vehicles with torsion beam rear axle 1143
8 8 Vehicle alignment specifications for vehicles with multi-link rear suspension 1145
8 9 Transverse vehicle inclination “zero position” 1147
8 10 Overview – wheel alignment procedure 1147
8 11 Correcting front axle camber 1148
8 12 Checking torsion beam rear axle camber 1150
8 13 Adjusting multi-link rear suspension camber 1150
8 14 Checking torsion beam rear axle toe 1151
8 15 Adjusting multi-link rear suspension toe 1152
8 16 Adjusting front axle toe 1152
8 17 Basic setting of steering angle sensor -G85- 1153
8 18 Vehicle data sticker 1153
9 Wheels, tyres 1155
9 1 Models with breakdown set 1155
9 2 Removing a tyre 1155
9 3 Fitting a new tyre 1155
9 4 Tyre sealant disposal 1156
10 Instructions for changing or fitting wheels 1157
10 1 Fitting wheels 1158
11 Protecting wheel centring seat against corrosion 1159
12 Vibration due to wheels/tyres – causes and rectification 1160
12 1 Causes of rough running 1160
12 2 Balancing wheels 1160
12 3 Conducting a road test before balancing wheels 1160
12 4 Balancing wheels on stationary wheel balancing machine 1161
12 5 Vibration control system -VAS 6230 A- 1163
12 6 Finish balancer 1163
12 7 Radial and lateral runout of wheels and tyres 1164
12 8 Checking radial and lateral runout on wheels and tyres with tyre gauge -V A G 1435- 1164
12 9 Checking radial and lateral run-out on wheel rim 1165
12 10 Matching 1166
12 11 Flat spots caused by storage or handling 1167
48 – Steering 1169
1 Evaluating accident vehicles 1169
2 General repair instructions 1170
2 1 Steering rack 1170
2 2 Gaskets and seals 1170
2 3 Nuts and bolts 1170
2 4 Electrical components 1171
2 5 Guided Fault Finding, vehicle self-diagnosis and Test Instruments 1171
3 Assembly overview – airbag and steering wheel 1172
3 1 Removing and installing airbag and steering wheel 1172
4 Assembly overview: steering column, left-hand drive 1175
4 1 Removing and installing steering column 1175
4 2 Handling and transporting steering column 1183
4 3 Checking steering column for damage 1184
5 Assembly overview: steering column, right-hand drive 1186
5 1 Removing and installing steering column, right-hand drive vehicle 1186
5 2 Handling and transporting steering column 1195
5 3 Checking steering column for damage 1196
6 Electromechanical steering rack, LHD vehicle 1197
6 1 Assembly overview – electromechanical steering rack for LHD vehicle 1197
6 2 Removing and installing steering rack, left-hand drive vehicle 1199
7 Electromechanical steering rack, RHD vehicle 1207
7 1 Assembly overview – electromechanical steering rack for RHD vehicle 1207
7 2 Removing and installing steering rack, right-hand drive vehicle 1208
8 Repairing electromechanical steering rack 1215
8 1 Assembly overview: electromechanical steering rack 1215
8 2 Removing and installing track rod 1216
8 3 Removing and installing track rod ball joint 1219
8 4 Removing and installing boot 1220
8 5 Checking play, security and boots of track rod ends 1223
8 6 Checking and adjusting track rod length 1223
8 7 Allocation of track rod ball joints 1224
9 Assembly overview: hydraulic power steering 1225
9 1 Removing and installing power-assisted steering rack 1226
10 Repairing hydraulic power-assisted steering rack 1232
10 1 Assembly overview: power-assisted steering rack 1232
10 2 Removing and installing track rod 1233
10 3 Removing and installing track rod ball joint 1236
10 4 Removing and installing boot 1237
10 5 Checking play, security and boots of track rod ends 1239
10 6 Checking and adjusting left track rod length 1239
10 7 Allocation of track rod ball joints 1240
11 Vane pump, 4-cylinder petrol engine 1241
11 1 Assembly overview: vane pump, 4-cylinder petrol engine 1241
11 2 Removing and installing vane pump, 4-cylinder petrol engine 1242
12 Vane pump, 5-cylinder petrol engine 1245
12 1 Checking vane pump delivery pressure, 5-cylinder petrol engine 1245
12 2 Assembly overview: vane pump, 5-cylinder petrol engine 1248
12 3 Removing and installing vane pump, 5-cylinder petrol engine 1249
13 Assembly overview: hydraulic lines, 4-cylinder petrol engine 1253
14 Assembly overview: hydraulic lines, 5-cylinder petrol engine 1255
15 Assembly overview: power steering reservoir, 4-cylinder petrol engine 1257
16 Assembly overview: power steering reservoir, 5-cylinder petrol engine 1258
17 Checking power steering fluid level 1259
18 Bleeding steering system and checking for leaks 1260
18 1 Bleeding steering system 1260
18 2 Check steering system for leaks 1260
00 – Technical data 1265
1 Identification 1265
1 1 Allocation of PR number – brakes 1265
1 1 1 PR number 1265
1 1 2 Front brakes 1265
1 1 3 Front brakes for North America 1266
1 1 4 Rear brakes, twist-beam rear axle 1266
1 1 5 Rear brakes, multi-link rear axle 1266
2 Technical data 1267
2 1 Technical data for brakes 1267
2 1 1 Brake master cylinder and brake servo 1267
2 1 2 Front brakes 1267
2 1 3 Rear brakes 1268
3 Brake test 1270
3 1 General information 1270
3 2 Checking vehicles with front-wheel drive 1270
45 – Anti-lock brake system 1271
1 General information 1271
1 1 Repair instructions for repair work on ABS 1271
1 2 Vehicle diagnosis, testing and information system 1272
2 Fitting location overview 1274
2 1 Fitting location overview – ABS 1274
2 1 1 ABS Mark 70 (ABS/TCS) 1274
2 1 2 ABS Mark 70 (ABS/TCS) (RHD vehicle) 1275
2 2 Fitting location overview – ABS/ESP 1277
2 2 1 ABS Mark 60 EC, North America 1277
2 2 2 ABS Mark 60 EC, as of 09/2010, North America 1279
2 2 3 ABS Mark 60 EC, vehicles with electromechanical power-assisted steering, North America 1281
2 2 4 ABS Mark 60 EC, vehicles with electromechanical power-assisted steering 1282
3 Fault display via warning lamps 1284
3 1 ABS/TCS, North America 1284
3 2 ABS/TCS, RHD vehicles 1285
3 3 ABS/EDL/TCS/ESP 1287
3 4 ABS/EDL/TCS/ESP North America as of 9/2010 1289
3 5 ABS/EDL/TCS/ESP 1291
4 Control unit and hydraulic unit 1295
4 1 Assembly overview – control unit and hydraulic unit 1295
4 1 1 Assembly overview – ABS Mark 70 (ABS/TCS), LHD vehicles 1295
4 1 2 Assembly overview – ABS Mark 70 (ABS/TCS), RHD vehicles 1298
4 1 3 Assembly overview – ABS Mark 60 EC (ABS/EDL/TCS/ESP), LHD vehicles 1299
4 1 4 Assembly overview – ABS Mark 60 EC (ABS/EDL/TCS/ESP), RHD vehicles 1301
4 2 Removing and installing ABS control unit -J104- and ABS hydraulic unit -N55- 1303
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) 1303
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) 1310
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) 1317
4 2 4 Removing and installing ABS control unit -J104- and ABS hydraulic unit -N55-, RHD vehicles with ABS Mark 70 (ABS/TCS) 1326
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) 1333
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) 1340
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) 1346
4 2 8 Removing and installing ABS control unit -J104- and ABS hydraulic unit -N55-, ABS Mark 60 EC (ABS/EDL/TCS/ESP) 1355
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) 1363
4 3 Separating control unit from hydraulic unit 1370
4 3 1 Separating ABS control unit -J104- from ABS hydraulic unit -N55-, ABS Mark 70 (ABS/TCS) 1370
4 3 2 Separating ABS control unit -J104- from ABS hydraulic unit -N55-, ABS Mark 60 EC (ABS/EDL/TCS/ESP) 1372
4 4 Fitting control unit to hydraulic unit 1373
4 4 1 Installing ABS control unit -J104- to ABS hydraulic unit -N55-, ABS Mark 70 (ABS/TCS) 1373
4 4 2 Installing ABS control unit -J104- to ABS hydraulic unit -N55-, ABS Mark 60 EC (ABS/EDL/TCS/ESP) 1374
4 5 Connecting brake lines to hydraulic unit 1377
4 5 1 Connecting brake lines to ABS hydraulic unit -N55-, LHD vehicles with ABS Mark 70 (ABS/TCS) 1377
4 5 2 Connecting brake lines to ABS hydraulic unit -N55-, RHD vehicles with ABS Mark 70 (ABS/TCS) 1378
4 5 3 Connecting brake lines to ABS hydraulic unit -N55-, RHD vehicles with ABS Mark 60 EC (ABS/EDL/TCS/ESP) 1379
4 5 4 Connecting brake lines to ABS hydraulic unit -N55-, LHD vehicles with ABS Mark 60 EC (ABS/EDL/TCS/ESP) 1380
5 Sensors 1382
5 1 Assembly overview – speed sensor on front axle 1382
5 1 1 Assembly overview – speed sensor on front axle 1382
5 2 Assembly overview – speed sensor on rear axle 1383
5 2 1 Assembly overview – speed sensor on rear axle, torsion beam rear suspension with drum brakes 1383
5 2 2 Assembly overview – speed sensor on rear axle, torsion beam rear suspension with disc brakes 1384
5 2 3 Assembly overview – speed sensor on rear axle, multi-link rear suspension 1385
5 3 Removing and installing speed sensors on front axle -G45-/-G47- 1385
5 3 1 Removing and installing speed sensor on front axle 1385
5 4 Removing and installing speed sensors on rear axle -G44-/-G46- 1386
5 4 1 Removing and installing speed sensor on torsion beam rear suspension with drum brake 1386
5 4 2 Removing and installing speed sensor on torsion beam rear suspension with disc brake 1387
5 4 3 Removing and installing speed sensor on multi-link rear suspension 1388
5 5 Removing and installing yaw rate sender and lateral acceleration sender 1388
6 Removing and installing parts of ESP system 1390
6 1 Assembly overview – vehicles with steering angle sensor -G85- on steering column 1390
6 2 Removing and installing steering angle sensor -G85- on steering column 1391
6 3 Vehicles with electromechanical power steering 1392
6 4 Vehicles with steering angle sensor -G85- on steering rack 1392
46 – Brakes – mechanism 1394
1 Front brakes 1394
1 1 Assembly overview – front brakes 1394
1 1 1 Assembly overview – front brakes, FS III without brake pad wear indicator 1394
1 1 2 Assembly overview – front brakes, FS III with brake pad wear indicator 1396
1 1 3 Assembly overview – front brakes, FN3 15/16 inch without brake pad wear indicator 1398
1 1 4 Assembly overview – front brakes, FN3 15/16 inch with brake pad wear indicator 1400
1 2 Removing and installing brake pads or linings 1401
1 2 1 Removing and installing brake pads, brake caliper FS III 1401
1 2 2 Removing and installing brake pads, brake caliper FN 3 1404
1 3 Removing and installing brake caliper 1407
1 3 1 Removing and installing brake caliper, FS III brake caliper 1407
1 3 2 Removing and installing brake caliper, FS III brake caliper 1410
1 4 Removing and installing brake carrier 1414
1 4 1 Removing and installing brake carrier, brake caliper FN 3 1414
1 5 Replace brake disc 1416
1 5 1 Removing and installing brake disc, brake caliper FS III 1416
1 5 2 Removing and installing brake disc, brake caliper FN 3 1418
1 6 Removing and installing brake splash plate 1421
1 6 1 Removing and installing cover plate, brake caliper FS III 1421
1 6 2 Removing and installing splash plate, brake caliper FN 3 1422
2 Rear brakes 1425
2 1 Assembly overview – rear brakes 1425
2 1 1 Assembly overview – drum brake 1425
2 1 2 Assembly overview – brake drum 1427
2 1 4 Assembly overview – torsion beam rear suspension, rear brakes, Bosch ZOH BIR 38 1429
2 1 5 Assembly overview – torsion beam rear suspension, rear brakes, CI 38 1431
2 1 6 Assembly overview – multi-link rear suspension, rear brakes, Bosch ZOH BIR 38 1434
2 1 7 Assembly overview – multi-link rear suspension, rear brakes, CI 38 1437
2 2 Removing and installing brake pads or linings 1439
2 2 1 Removing and installing brake pads; Rear brakes, Bosch ZOH BIR 38 1439
2 2 2 Removing and installing brake pads; Rear brakes, CI 38 1442
2 3 Removing and installing brake caliper 1446
2 3 1 Removing and installing brake caliper; Rear brakes, Bosch ZOH BIR 38 1446
2 3 2 Removing and installing brake caliper; Rear brakes, CI 38 1449
2 3 3 Removing and installing wheel brake cylinder, drum brakes 1454
2 4 Removing and installing brake carrier 1456
2 4 1 Removing and installing backplate for drum brakes 1456
2 4 2 Removing and installing brake carrier for disc brakes 1458
2 5 Removing and installing brake disc 1460
2 5 1 Removing and installing brake disc 1460
2 5 2 Removing and installing brake drum 1462
2 6 Removing and installing brake shoes 1464
2 7 Retracting drum brakes 1466
2 8 Removing and installing brake splash plate 1467
2 8 1 Removing and installing splash plate for brakes, twist-beam rear axle 1467
2 8 2 Removing and installing splash plate for brakes, multi-link rear axle 1468
3 Handbrake 1471
3 1 Assembly overview – parking brake 1471
3 2 Removing and installing handbrake lever 1472
3 3 Removing and installing rear brake cable 1475
3 3 1 Removing and installing rear brake cable, drum brakes 1475
3 3 2 Removing and installing rear brake cable, disc brakes on torsion beam rear suspension 1479
3 3 3 Removing and installing brake cable, disc brakes on multi-link rear suspension 1482
3 4 Adjusting parking brake 1485
3 4 1 Adjusting handbrake, drum brakes 1485
3 4 2 Adjusting handbrake, disc brakes 1486
3 5 Removing and installing handbrake lever trim 1488
4 Brake pedal 1491
4 1 Assembly overview – brake pedal 1491
4 1 1 Assembly overview – brake pedal, left-hand drive 1491
4 1 2 Assembly overview – brake pedal, right-hand drive 1492
4 2 Removing and installing mounting bracket 1494
4 2 1 Removing and installing mounting bracket, left-hand drive 1494
4 2 2 Removing and installing mounting bracket, right-hand drive 1496
4 2 3 Removing and installing mounting bracket, hybrid vehicles 1499
4 3 Separating brake pedal from brake servo 1505
4 4 Connecting brake pedal to brake servo 1507
4 5 Removing and installing brake pedal 1507
4 5 1 Removing and installing brake pedal, LHD 1507
4 5 2 Removing and installing brake pedal, RHD 1508
47 – Brakes – hydraulics 1510
1 Front brake caliper 1510
1 1 Assembly overview – front brake caliper 1510
1 1 1 Assembly overview – front brake caliper, brake caliper FS III 1510
1 1 2 Assembly overview – front brake caliper, brake caliper FN 3 1511
1 2 Removing and installing brake caliper piston 1511
1 2 1 Removing and installing brake caliper piston, brake caliper piston FS III 1511
1 2 2 Removing and installing brake caliper piston, brake caliper piston FN 3 1514
2 Rear brake caliper 1517
2 1 Assembly overview – rear brake caliper 1517
2 1 1 Assembly overview – rear brake caliper, rear brakes, Bosch ZOH BIR 38 1517
2 1 2 Assembly overview – rear brake caliper, rear brakes, CI 38 1518
2 2 Removing and installing brake caliper piston 1519
2 2 1 Removing and installing brake caliper piston; Rear brakes, Bosch ZOH BIR 38 1519
2 2 2 Removing and installing brake caliper piston; Rear brakes, CI 38 1521
2 2 3 Pre-bleeding brake caliper 1523
3 Brake servo and brake master cylinder 1524
3 1 Assembly overview – brake servo/brake master cylinder 1524
3 1 1 Assembly overview – brake servo/brake master cylinder, left-hand drive 1524
3 1 2 Assembly overview – brake servo/brake master cylinder, right-hand drive 1527
3 2 Removing and installing brake light switch 1529
3 2 1 Removing and installing brake light switch -F-, LHD vehicles with 5-cyl petrol engine 1529
3 2 2 Removing and installing brake light switch -F-, LHD vehicles with 4-cyl petrol engine 1530
3 2 3 Removing and installing brake light switch -F-, LHD vehicles with 4-cyl diesel engine 1531
3 2 4 Removing and installing brake light switch -F-, right-hand drive 1533
3 2 5 Removing and installing brake light switch -F-, hybrid vehicles 1533
3 3 Removing and installing brake fluid reservoir 1534
3 3 1 Removing and installing brake fluid reservoir, LHD vehicles 1534
3 3 2 Removing and installing brake fluid reservoir, RHD vehicles 1538
3 3 3 Removing and installing brake fluid reservoir, hybrid vehicles 1541
3 4 Removing and installing brake master cylinder 1544
3 4 1 Removing and installing brake master cylinder, LHD vehicles with 5-cyl petrol engine 1544
3 4 2 Removing and installing brake master cylinder, LHD vehicles with 4-cyl petrol engine 1550
3 4 3 Removing and installing brake master cylinder, LHD vehicles with 4-cyl diesel engine 1555
3 4 4 Removing and installing brake master cylinder, RHD vehicles with 4-cyl petrol engine 1561
3 4 5 Removing and installing brake master cylinder, hybrid vehicles 1566
3 4 6 Removing and installing brake master cylinder, RHD vehicles with 4-cyl petrol engine 1570
3 5 Removing and installing brake servo 1578
3 5 1 Removing and installing brake servo, LHD vehicles with 5-cyl petrol engine 1578
3 5 2 Removing and installing brake servo, LHD vehicles with 4-cyl petrol engine 1587
3 5 3 Removing and installing brake servo, LHD vehicles with 4-cyl diesel engine 1594
3 5 4 Removing and installing brake servo, RHD vehicles with 4-cyl petrol engine 1601
3 5 5 Removing and installing brake servo, hybrid vehicles 1611
3 5 6 Removing and installing brake servo, RHD vehicles with 4-cyl diesel engine 1619
4 Vacuum system 1631
4 1 Assembly overview – vacuum pump 1631
4 1 1 Vacuum pump for brake servo (2 5 l petrol engine) 1631
4 1 2 Vacuum pump for brake servo (vehicles with 2 0 l petrol engine) 1631
4 1 3 Vacuum pump for brake servo (vehicles with diesel engine) 1632
4 2 Checking vacuum system 1632
4 2 1 Instructions 1632
4 2 2 Connecting vacuum gauge for brake servo -VAS 6721- 1633
4 2 3 Checking vacuum generation 1634
4 2 4 Checking for leaks 1635
4 2 5 Vacuum generation with manual vacuum pump -VAS 6213- 1636
4 3 Checking non-return valve 1637
4 4 Removing and installing vacuum sender -G608- 1637
4 5 Assembly overview – electric vacuum pump 1638
4 5 1 Assembly overview – vacuum pump for brakes -V192-, vehicles with petrol engine 1638
4 5 2 Assembly overview – vacuum pump for brakes -V192-, hybrid vehicles 1640
4 6 Removing and installing vacuum pump 1640
4 6 1 Removing and installing vacuum pump for brakes -V192-, vehicles with petrol engine 1640
4 6 2 Removing and installing vacuum pump for brakes -V192-, hybrid vehicles 1642
4 7 Removing and installing brake servo pressure sensor 1643
5 Brake lines 1644
5 1 Repairing brake lines 1644
5 1 1 Assembly overview – flanging tool 1644
5 1 2 Work instructions 1645
6 Hydraulic system 1649
6 1 General notes on brake fluid 1649
6 1 1 General information 1649
6 1 2 Changing brake fluid 1651
6 2 Pre-bleeding hydraulic system 1652
6 3 Bleeding hydraulic system following standard procedure 1654
6 4 Subsequent bleeding of hydraulic system 1657
6 5 Testing for leaks 1658
6 5 1 Test prerequisites: 1658
6 5 2 Checking wheel brake cylinder for leaks 1658
50 – Body – front 1668
1 Lock carrier 1668
1 1 Tools 1668
1 2 Lock carrier – add-on parts 1668
1 2 1 Assembly overview for RoW (rest of world) 1668
1 2 2 Assembly overview for NAR 1670
1 3 Service position 1672
1 3 1 Moving to service position 1672
1 3 2 Moving from service position 1673
1 4 Removing and installing lock carrier with attachments 1675
1 4 1 Removing 1675
1 4 2 Installing 1676
1 5 Removing and installing pressure hoses 1678
1 5 1 Pressure hose with plug-in connector 1678
1 5 2 Pressure hose with corrugated pipe connection and hose clip 1679
2 Wings 1681
2 1 Tools 1681
2 2 Assembly overview – front wing 1681
2 3 Removing and installing front wing 1682
2 3 1 Removing 1682
2 3 2 Installing 1684
2 4 Insulation and foam elements for wing and wing end plate 1685
2 5 Wing end plate 1685
2 6 Removing and installing wing bracket 1686
2 6 1 Removing 1686
2 6 2 Installing 1687
3 Plenum chamber cover 1688
3 1 Assembly overview – plenum chamber cover 1688
3 2 Removing and installing plenum chamber covers 1688
3 2 1 Removing 1688
3 2 2 Installing 1690
4 Underbody cladding 1692
4 1 Tools 1692
4 2 Assembly overview – underbody cladding 1692
4 3 Rear right underbody cladding 1693
5 Bulkhead 1695
5 1 Tools 1695
5 2 Materials 1695
5 3 Assembly overview – bulkhead 1696
6 Tunnel cross-piece 1697
6 1 Tools 1697
6 2 Assembly overview – tunnel cross-piece 1697
55 – Bonnet, rear lid 1699
1 Bonnet 1699
1 1 Tools 1699
1 2 Assembly overview – bonnet 1699
1 3 Removing and installing bonnet 1700
1 3 1 Removing 1700
1 3 2 Installing 1701
1 4 Removing and installing bonnet hinge 1702
1 4 1 Removing 1702
1 4 2 Installing 1703
1 5 Removing and installing insulation 1704
1 5 1 Removing 1704
1 5 2 Installing 1705
1 6 Assembly overview – seals 1706
1 7 Removing and installing bonnet stay 1707
1 7 1 Removing 1707
1 7 2 Installing 1708
1 8 Assembly overview – bonnet lock and release components 1709
1 9 Removing and installing bonnet lock 1710
1 9 1 Removing 1710
1 9 2 Installing 1712
1 10 Removing and installing Bowden cable 1713
1 11 Removing and installing striker pin 1714
1 11 1 Removing 1714
1 11 2 Installing 1715
1 12 Removing and installing release lever 1716
1 12 1 Removing 1716
1 12 2 Installing 1717
1 13 Adjusting bonnet 1719
1 13 1 Adjusting bonnet lock 1720
1 13 2 Adjusting striker pin 1720
2 Rear lid 1722
2 1 Tools 1722
2 2 Assembly overview – rear lid 1722
2 3 Removing and installing rear lid 1723
2 3 1 Removing 1723
2 3 2 Installing 1724
2 4 Assembly overview – gas strut 1724
2 5 Removing and installing gas strut 1725
2 5 1 Removing 1725
2 5 2 Installing 1726
2 6 Releasing gas from gas strut 1727
2 7 Assembly overview – rear lid hinge 1728
2 8 Removing and installing rear lid hinge 1729
2 8 1 Removing 1729
2 8 2 Installing 1730
2 9 Removing and installing hinge covers 1730
2 10 Removing and installing striker plate 1732
2 10 1 Removing 1732
2 10 2 Installing 1732
2 11 Adjusting rear lid 1733
2 11 1 Adjusting striker plate 1734
2 12 Removing and installing rear lid handle release button -E234- 1734
2 12 1 Removing 1734
2 12 2 Installing 1735
2 13 Removing and installing bonnet lock 1735
2 13 1 Removing 1735
2 13 2 Installing 1736
2 14 Rear lid seal 1737
2 15 Removing and installing rear lid seal 1738
2 15 1 Removing 1738
2 15 2 Installing 1738
2 16 Number plate carrier 1739
3 Tank flap unit 1741
3 1 Tools 1741
3 2 Assembly overview – tank flap unit 1741
3 3 Removing and installing tank flap unit 1742
3 3 1 Removing 1742
3 3 2 Installing 1743
3 4 Removing and installing tank filler flap locking motor -V155- 1745
3 4 1 Removing 1745
3 4 2 Installing 1746
57 – Front doors, door components, central locking 1747
1 Rear door 1747
1 1 Tools 1747
1 2 Assembly overview – door hinges 1748
1 3 Removing and installing door 1750
1 3 1 Removing 1750
1 3 2 Installing 1751
1 4 Installing after renewing A-pillar 1752
1 5 Door alignment 1753
1 5 1 Door alignment – shut lines and flushness 1753
1 5 2 Adjusting striker pin 1755
2 Door components 1756
2 1 Tools 1756
2 2 Assembly overview – front door 1756
2 3 Removing and installing door cover 1758
2 3 1 Removing 1758
2 3 2 Installing 1759
2 4 Removing and installing door retaining strap 1760
2 4 1 Removing 1760
2 4 2 Installing 1761
2 5 Removing and installing striker pin 1761
2 5 1 Removing 1761
2 5 2 Installing 1762
2 6 Assembly overview – door handle and door lock 1762
2 7 Removing and installing lock cylinder cover cap 1764
2 7 1 Removing 1764
2 7 2 Installing 1764
2 8 Removing and installing lock cylinder 1765
2 8 1 Removing 1765
2 8 2 Installing 1766
2 9 Removing and installing cover cap (without lock cylinder) 1768
2 9 1 Tools 1768
2 9 2 Removing 1768
2 9 3 Installing 1770
2 10 Removing and installing door handle 1771
2 10 1 Removing 1771
2 10 2 Installing 1772
2 11 Removing and installing door lock 1773
2 11 1 Removing 1773
2 11 2 Installing 1774
2 12 Removing and installing mounting bracket 1776
2 12 1 Removing 1776
2 12 2 Installing 1777
2 13 Removing and installing inner window slot seal 1778
2 13 1 Removing 1778
2 13 2 Installing 1779
2 14 Removing and installing outer window slot seal 1781
2 14 1 Removing 1781
2 14 2 Installing 1782
2 15 Removing and installing inner door seal 1782
2 15 1 Removing 1783
2 15 2 Installing 1784
2 16 Removing and installing outer door seal 1785
2 16 1 Removing 1785
2 16 2 Installing 1785
2 17 Assembly overview – insulation 1786
3 Central locking 1788
3 1 Fitting location overview – central locking components 1788
3 2 Adapting keys with remote control 1790
3 3 Assembly overview – battery for folding key with remote control 1790
3 4 Removing and installing battery for folding key with remote control 1791
3 4 1 Removing 1791
3 4 2 Installing 1792
3 5 Assembly overview – battery for folding key with cover cap 1793
3 6 Removing and installing battery for folding key with cover cap 1794
3 6 1 Removing 1794
3 6 2 Installing 1794
58 – Rear doors, door components 1796
1 Rear door 1796
1 1 Tools 1796
1 2 Assembly overview – door hinges 1797
1 3 Removing and installing door 1799
1 3 1 Removing 1799
1 3 2 Installing 1800
1 4 Installing after renewing B-pillar 1801
1 5 Door alignment 1802
1 5 1 Door alignment – shut lines and flushness 1802
1 5 2 Adjusting striker pin 1803
2 Door components 1804
2 1 Tools 1804
2 2 Assembly overview – rear door 1804
2 3 Removing and installing cover 1806
2 3 1 Removing 1806
2 3 2 Installing 1807
2 4 Removing and installing door retaining strap 1808
2 4 1 Removing 1808
2 4 2 Installing 1809
2 5 Removing and installing striker pin 1809
2 5 1 Removing 1809
2 5 2 Installing 1810
2 6 Assembly overview – door handle and door lock 1810
2 7 Removing and installing cap 1811
2 7 1 Tools 1811
2 7 2 Removing 1812
2 7 3 Installing 1813
2 8 Removing and installing door handle 1814
2 8 1 Removing 1814
2 8 2 Installing 1815
2 9 Removing and installing door lock 1816
2 9 1 Removing 1816
2 9 2 Installing 1818
2 10 Removing and installing mounting bracket 1819
2 10 1 Removing 1819
2 10 2 Installing 1820
2 11 Removing and installing inner window slot seal 1821
2 11 1 Removing 1821
2 11 2 Installing 1822
2 12 Removing and installing outer window slot seal 1823
2 12 1 Distinguishing different versions 1823
2 12 2 Removing 1824
2 12 3 Installing 1825
2 13 Removing and installing inner door seal 1826
2 13 1 Removing 1827
2 13 2 Installing 1828
2 14 Removing and installing outer door seal 1829
2 14 1 Distinguishing different versions 1829
2 14 2 Removing 1830
2 14 3 Installing 1830
2 15 Assembly overview – insulation 1831
60 – Sunroof 1833
1 Sunroof with glass panel 1833
1 1 Tools 1833
1 2 Functional check 1833
1 3 Assembly overview 1834
1 4 Removing and installing sliding/tilting sunroof glass panel 1836
1 4 1 Removing 1836
1 4 2 Installing 1836
1 5 Height-adjustment of glass panel 1837
1 6 Checking parallel running of glass panel 1839
1 7 Adjusting parallel running of glass panel 1840
1 8 Renewing panel seal 1840
1 9 Removing and installing wind deflector 1841
1 9 1 Removing 1841
1 9 2 Installing 1841
1 10 Removing and installing sliding headliner 1842
1 10 1 Removing 1842
1 10 2 Installing 1843
1 11 Removing and installing sliding/tilting sunroof drive 1843
1 11 1 Removing 1843
1 11 2 Installing 1843
1 12 Setting drive for sliding/tilting sunroof to zero position 1844
1 13 Performing programming run for drive for sliding/tilting sunroof 1844
1 14 Removing pre-selector control for sliding/tilting sunroof 1845
1 14 1 Removing 1845
1 14 2 Installing 1845
1 15 Removing and installing carrier unit 1845
1 15 1 Removing 1845
1 15 2 Installing 1846
1 16 Cleaning water drain hoses 1848
1 16 1 Front water drain hoses 1848
1 16 2 Rear water drain hoses 1848
63 – Bumpers 1850
1 Front bumper cover 1850
1 1 Tools 1850
1 2 Repairing front bumper cover 1850
1 3 Installing brackets for parking aid system 1850
1 3 1 Tools 1850
1 3 2 Materials 1851
1 3 3 Installing brackets 1851
1 3 4 Minimum curing period 1855
1 4 Assembly overview – front bumper cover 1855
1 5 Removing and installing front bumper cover 1856
1 5 1 Removing 1856
1 5 2 Installing 1857
1 6 Front bumper cover add-on parts 1858
1 7 Installing front number plate carrier 1859
1 8 Assembly overview – guides for front bumper cover 1860
1 9 Assembly overview – front bumper carrier 1861
2 Rear bumper cover 1863
2 1 Tools 1863
2 2 Repairing rear bumper cover 1863
2 3 Installing brackets for parking aid system 1863
2 3 1 Tools 1863
2 3 2 Materials 1864
2 3 3 Installing brackets 1864
2 3 4 Minimum curing period 1868
2 4 Assembly overview – rear bumper cover 1868
2 5 Removing and installing rear bumper cover 1869
2 5 1 Removing 1869
2 5 2 Installing 1870
2 6 Assembly overview – guides for rear bumper cover 1871
2 7 Assembly overview – rear bumper carrier 1871
2 8 Assembly overview – towing bracket 1872
64 – Glazing 1874
1 Flush bonded windows 1874
1 1 Tools 1874
1 2 Materials 1875
1 3 Repairing windscreen 1876
1 4 Assembly overview – windscreen 1876
1 5 Remove windscreen 1877
1 6 Install windscreen 1879
1 7 Assembly overview – rear window 1879
1 8 Removing undamaged rear window 1880
1 9 Removing broken rear window 1882
1 10 Installing rear window 1882
1 11 Preparing old undamaged window for glazing 1883
1 11 1 Cutting back adhesive bead 1883
1 12 Preparing new window without precoating for glazing 1884
1 13 Preparing body flange for glazing 1884
1 14 Fitting instructions 1885
1 15 Minimum curing period 1886
1 16 Touching up paint damage 1887
1 17 Removing soiling caused by adhesive sealant 1887
2 Front door window 1888
2 1 Tools 1888
2 2 Assembly overview – front door window 1888
2 3 Removing and installing door window 1889
2 3 1 Removing 1889
2 3 2 Installing 1891
2 4 Removing and installing window regulator motor 1895
2 4 1 Removing and installing window regulator motor, equipment level High (AW1) 1895
2 4 2 Removing and installing window regulator motor, equipment level Low (AW0) 1898
2 5 Removing and installing window regulator 1901
2 5 1 Removing 1901
2 5 2 Installing 1902
2 6 Removing and installing window channel 1903
2 6 1 Removing 1903
2 6 2 Installing 1904
3 Rear door window 1906
3 1 Tools 1906
3 2 Assembly overview – rear door windows 1906
3 3 Removing and installing door window 1907
3 3 1 Removing 1907
3 3 2 Installing 1910
3 4 Removing and installing window regulator motor 1911
3 4 1 Removing and installing window regulator motor, equipment level High (AW1) 1911
3 4 2 Removing and installing window regulator motor, equipment level Low (AW0) 1913
3 5 Removing and installing window regulator 1916
3 5 1 Removing 1916
3 5 2 Installing 1917
3 6 Removing and installing window channel 1918
3 6 1 Removing 1918
3 6 2 Installing 1919
3 7 Removing and installing fixed door-window 1920
3 7 1 Removing 1920
3 7 2 Installing 1922
66 – Exterior equipment 1924
1 Wheel housing liner 1924
1 1 Tools 1924
1 2 Assembly overview – front wheel housing liner 1924
1 3 Removing and installing front wheel housing liner 1925
1 3 1 Removing 1925
1 3 2 Installing 1926
1 4 Assembly overview – rear wheel housing liner 1927
1 5 Removing and installing rear wheel housing liner 1928
1 5 1 Removing 1928
1 5 2 Installing 1929
2 Exterior mirror 1932
2 1 Tools 1932
2 2 Assembly overview – exterior mirror (manual operation) 1932
2 3 Assembly overview – exterior mirror, electrically operated, without turn signal repeater 1933
2 4 Assembly overview – exterior mirror, electrically operated, with turn signal repeater 1934
2 5 Removing and installing mirror glass 1936
2 5 1 Removing 1936
2 5 2 Installing 1937
2 6 Removing and installing exterior mirror trim, without turn signal repeater 1937
2 6 1 Removing 1937
2 6 2 Installing 1938
2 7 Removing and installing exterior mirror trim, with turn signal repeater 1939
2 8 Removing and installing exterior mirror housing, without turn signal repeater 1941
2 8 1 Removing 1941
2 8 2 Installing 1941
2 9 Removing and installing exterior mirror housing, with turn signal repeater 1942
2 10 Removing and installing adjustment unit with motor for exterior mirror 1944
2 10 1 Removing 1944
2 10 2 Installing 1945
2 11 Removing and installing assembly bracket 1947
2 12 Removing and installing exterior mirror (manual operation) 1948
2 12 1 Removing 1948
2 12 2 Installing 1950
2 13 Removing and installing exterior mirror (electrical operation) 1952
2 13 1 Removing 1952
2 13 2 Installing 1954
3 Radiator grille 1957
3 1 Tools 1957
3 2 Removing and installing radiator grille 1957
3 2 1 Removing 1957
3 2 2 Installing 1958
3 3 Removing and installing emblem 1959
3 3 1 Removing 1959
3 3 2 Installing 1961
4 Rear spoiler 1964
4 1 Removing and installing rear spoiler 1964
5 Mouldings and trims 1971
5 1 Water deflector 1971
5 1 1 Tools 1971
5 1 2 Assembly overview 1971
5 1 3 Removing 1972
5 1 4 Installing 1973
5 2 Assembly overview – side member cover 1975
5 3 Assembly overview – B-pillar trim 1976
5 4 Removing and installing B-pillar trim 1977
5 4 1 Removing 1977
5 4 2 Installing 1978
5 5 Side member extension 1979
5 5 1 Removing 1980
5 5 2 Dimensions for securing screws 1980
5 5 3 Installing 1982
6 Lettering 1984
6 1 Tools 1984
6 2 Installation instructions for lettering and emblems 1984
6 3 Dimensions – lettering on rear lid 1985
6 3 1 Lettering for model designation 1985
6 3 2 Lettering for engine type 1985
6 3 3 Lettering for additional designation 1986
6 3 4 “GLI” lettering 1986
6 3 5 Lettering “HYBRID” and “SPORT” 1987
6 4 Dimensions – lettering on wing 1987
6 4 1 Lettering “HYBRID” 1987
6 4 2 Lettering “MATCH”, “LIFE”, “sochiEDITION” 1988
7 Noise insulation 1989
7 1 Assembly overview – noise insulation 1989
7 1 1 Assembly overview – noise insulation, petrol engine 1989
7 1 2 Assembly overview – noise insulation for diesel engines 1990
7 1 3 Assembly overview – skid plate 1990
7 2 Removing and installing noise insulation 1991
7 2 1 Removing and installing noise insulation, petrol engine 1991
7 2 2 Removing and installing noise insulation, diesel engine 1992
7 2 3 Removing and installing skid plate 1993
00 – Technical data 1999
1 Safety information 1999
1 1 Safety regulations for working on fuel supply 1999
1 2 Safety precautions when using testers and measuring instruments during a road test 1999
1 3 Safety measures when working on vehicles with a start/stop system 2000
1 4 Safety precautions when working on vehicles with high-voltage system 2000
1 5 Safety precautions when working in the vicinity of high-voltage components 2001
2 Identification 2002
2 1 Engine number/engine data 2002
3 General information 2004
3 1 Rules for cleanliness when working on auxiliary/supplementary heater and fuel system 2004
4 Repair notes 2005
4 1 Routing and attachment of lines 2005
4 2 General repair instructions 2005
20 – Fuel supply system 2006
1 Fuel 2006
1 1 Assembly overview – fuel tank 2006
1 1 1 Assembly overview – fuel tank, vehicles with externally fitted fuel filter 2006
1 1 2 Assembly overview – fuel filter, vehicles with fuel filter integrated into flange of fuel delivery unit 2008
1 1 3 Assembly overview – fuel tank, hybrid vehicles 2010
1 2 Emptying fuel tank 2011
1 2 1 Emptying fuel tank when fuel pump is intact 2011
1 2 2 Emptying fuel tank if it is more than 3/4 full 2016
1 2 3 Emptying fuel tank if it is less than 3/4 full 2018
1 3 Removing and installing fuel tank 2022
2 Fuel delivery unit, fuel gauge sender 2027
2 1 Assembly overview – fuel delivery unit/fuel gauge sender 2027
2 1 1 Assembly overview – fuel delivery unit, vehicles with externally fitted fuel filter 2027
2 1 2 Assembly overview – fuel delivery unit, vehicles with fuel filter integrated into flange of fuel delivery unit 2029
2 1 3 Assembly overview – fuel delivery unit, hybrid vehicles 2030
2 2 Removing and installing fuel delivery unit, fuel gauge sender 2031
2 2 1 Removing and installing fuel delivery unit, fuel gauge sender 2031
2 2 2 Removing and installing fuel delivery unit, hybrid vehicles 2035
2 3 Removing and installing fuel gauge sender -G- 2041
2 3 1 Removing and installing fuel gauge sender 2041
2 3 2 Removing and installing fuel gauge sender -G-, hybrid 2042
3 Lines 2043
3 1 Removing and installing fuel lines 2043
4 Plug-in connectors 2047
4 1 Separating plug-in connectors 2047
5 Fuel filter 2051
5 1 Assembly overview – fuel filter 2051
5 1 1 Assembly overview – fuel filter, vehicles with externally fitted fuel filter 2051
5 1 2 Assembly overview – fuel filter, fuel filter integrated into flange of fuel delivery unit 2052
5 2 Removing and installing fuel filter 2052
5 2 1 Removing and installing fuel filter, vehicles with externally fitted fuel filter 2052
5 2 2 Removing and installing fuel filter, vehicles with fuel filter integrated into flange of fuel delivery unit 2053
6 Activated charcoal filter system 2054
6 1 Connection diagram – activated charcoal filter system 2054
6 1 1 Connection diagram – activated charcoal filter system, activated charcoal filter fitted in engine compartment 2054
6 1 2 Connection diagram – activated charcoal filter system, activated charcoal filter fitted in rear on right 2056
6 2 Assembly overview – activated charcoal filter system 2057
6 2 1 Assembly overview – Activated charcoal filter system, activated charcoal filter fitted in engine compartment 2057
6 2 2 Assembly overview – activated charcoal filter system, activated charcoal filter fitted in rear on right 2059
6 3 Assembly overview – diagnostic pump 2061
6 4 Removing and installing fuel system diagnosis pump 2062
6 5 Removing and installing activated charcoal filter 2063
6 5 1 Removing and installing activated charcoal filter, activated charcoal filter fitted in engine compartment 2063
6 5 2 Removing and installing activated charcoal filter, activated charcoal filter fitted in rear on right 2063
6 6 Checking fuel tank breather 2063
6 7 Checking fuel system for leaks 2068
7 Accelerator pedal 2072
7 1 Assembly overview – accelerator module 2072
7 2 Removing and installing accelerator module with accelerator position sender -G79-/-G185- 2072
8 Fuel pump 2075
8 1 Checking fuel system pressurisation pump -G6- 2075
8 1 1 Checking operation and power supply of fuel pump, vehicles with fuel pump control unit -J538- 2075
8 1 2 Checking operation and power supply of fuel pump, vehicles without fuel pump control unit -J538- 2079
8 1 3 Checking fuel pressure, vehicles with externally fitted fuel filter 2083
8 1 4 Checking fuel pressure, vehicles with fuel filter integrated into flange of fuel delivery unit 2088
8 1 5 Checking holding pressure, vehicles with externally fitted fuel filter 2092
8 1 6 Checking holding pressure, vehicles with fuel filter integrated into flange of fuel delivery unit 2097
8 1 7 Checking fuel delivery rate, vehicles with externally fitted fuel filter 2100
8 1 8 Checking fuel delivery rate, vehicles with fuel filter integrated into flange of fuel delivery unit 2108
8 1 9 Checking current consumption 2115
44 – Wheels, tyres, vehicle geometry 2122
1 General notes on using the “Wheels and Tyres Guide” 2122
1 1 General information 2122
1 2 Explanations regarding world regions 2123
1 3 Definition of tyre package 2124
1 4 Procedure for determining the required tyre package 2124
1 4 1 Determining the required tyre package via PR number 2124
1 4 2 Determining the required tyre package via version key in the vehicle registration certificate part 1 2125
2 Notes on the vehicle registration certificate 2126
2 1 Vehicle registration certificate part 1 2126
2 2 Version key, D2 2126
3 Wheel and tyre combinations without tyre package 2128
3 1 Jetta, model year 2011 to model year 2013 (sales type 162) 2128
3 2 Jetta – as of model year 2014 (sales type 162, 163) 2131
3 3 Jetta Hybrid – as of model year 2014 (sales type 162, 163) 2139
3 4 Jetta – from model year 2011 (North America – sales type 162, 163) 2143
3 5 Jetta Hybrid – from model year 2013 (North America – sales type 162, 163) 2145
3 6 Jetta Russia – model year 2011 to model year 2014 (sales type AV2) 2147
3 7 Jetta Russia – from model year 2015 (sales type AV3) 2148
4 Wheel and tyre combinations depending on tyre packages 2150
4 1 Type approval no (K): e1*2007/46*0539*18 2150
4 2 Type approval no (K): e1*2007/46*0539*19 to e1*2007/46*0539*20 2151
4 3 Type approval no (K): e1*2007/46*0539*21 to e1*2007/46*0539*22 2153
4 4 Type approval No (K): e1*2007/46*0539*23 2155
4 5 Changing to other wheel and tyre combinations 2157
5 Wheel allocation 2159
5 1 6 J x 15 offset 47 2159
5 2 61/2 J x 15 offset 50 2160
5 3 6 J x 16 offset 50 2161
5 4 61/2 J x 16 offset 50 2162
5 5 6 J x 17 offset 48 5 2167
5 6 7 J x 17 offset 54 2168
5 7 71/2 J x 17 offset 51 2172
5 8 71/2 J x 18 offset 51 2174
6 Recommended summer tyres 2179
6 1 Recommended summer tyres, Jetta worldwide except India, Indonesia, Japan, Mexico, North America, Scandinavia, South Africa, South America, South Korea, Taiwan 2179
6 2 Recommended summer tyres, Jetta Hybrid worldwide except North America 2181
6 3 Recommended summer tyres, Jetta Mexico, South America 2181
6 4 Recommended summer tyres, Jetta Indonesia, Japan, Scandinavia, South Africa, South Korea 2182
6 5 Recommended summer tyres, Jetta Taiwan 2182
6 6 Recommended summer tyres, Jetta India 2182
6 7 Recommended summer tyres, Jetta North America 2182
6 8 Recommended summer tyres, Jetta Hybrid North America 2183
6 9 Recommended summer tyres, Jetta Russia 2183
7 Recommended all-season tyres 2184
7 1 Recommended all-season tyres, Jetta worldwide except North America 2184
7 2 Recommended all-season tyres, Jetta North America 2184
7 3 Recommended all-season tyres, Jetta Hybrid North America 2184
8 Recommended winter tyres, worldwide except North America 2186
9 Recommended temporary spare tyres and wheels 2187
00 – Technical data 2194
1 Safety information 2194
1 1 Safety regulations for working on fuel supply 2194
1 2 Safety measures when working on vehicles with a start/stop system 2194
1 3 Safety precautions when using testers and measuring instruments during a road test 2195
1 4 Safety precautions when working on ignition system 2195
1 5 Safety precautions when working on the cooling system 2195
2 Identification 2196
2 1 Engine number/engine data 2196
3 Repair instructions 2198
3 1 Rules for cleanliness 2198
3 2 Foreign bodies in engine 2198
3 3 Contact corrosion 2198
3 4 Routing and attachment of lines 2198
3 5 Fitting radiator and condensers 2199
10 – Removing and installing engine 2200
1 Removing and installing engine 2200
1 1 Removing engine 2200
1 2 Separating engine and gearbox 2212
1 2 1 Separating engine and gearbox, vehicles with manual gearbox 2212
1 2 2 Separating engine and gearbox, vehicles with automatic gearbox 2213
1 3 Securing engine on engine and gearbox support 2216
1 4 Installing engine 2218
2 Assembly mountings 2222
2 1 Assembly overview – assembly mountings 2222
2 2 Supporting engine in installation position 2225
2 3 Removing and installing engine mounting 2228
2 4 Removing and installing gearbox mounting 2229
2 5 Removing and installing pendulum support 2231
2 6 Checking adjustment of assembly mountings 2232
2 7 Adjusting assembly mountings 2233
13 – Crankshaft group 2236
1 Cylinder block (pulley end) 2236
1 1 Assembly overview – poly V-belt drive 2236
1 1 1 Assembly overview – poly V-belt drive, vehicles without air conditioner compressor 2236
1 1 2 Assembly overview – poly V-belt drive, vehicles with air conditioner compressor 2238
1 2 Removing and installing poly-V belt 2240
1 2 1 Removing and installing poly V-belt, vehicles without air conditioner compressor 2240
1 2 2 Removing and installing poly V-belt, vehicles with air conditioner compressor 2243
1 3 Removing and installing tensioner for poly V-belt 2245
1 3 1 Removing and installing tensioner for poly V-belt, vehicles without air conditioner compressor 2245
1 3 2 Removing and installing tensioner for poly V-belt, vehicles with air conditioner compressor 2245
1 4 Removing and installing vibration damper 2246
1 5 Removing and installing engine support 2247
1 6 Renewing crankshaft oil seal for pulley end 2250
2 Cylinder block, gearbox end 2254
2 1 Assembly overview – cylinder block, gearbox end 2254
2 1 1 Assembly overview – cylinder block, gearbox end, vehicles with manual gearbox 2254
2 1 2 Assembly overview – cylinder block, gearbox end, vehicles with automatic gearbox 2256
2 2 Removing and installing flywheel 2258
2 3 Removing and installing drive plate 2259
2 4 Removing and installing sealing flange on gearbox side 2262
3 Crankshaft 2275
3 1 Renewing needle bearing in crankshaft 2275
3 2 Measuring axial clearance of crankshaft 2277
4 Pistons and conrods 2279
4 1 Assembly overview – pistons and conrods 2279
4 2 Removing and installing pistons 2283
4 3 Checking pistons and cylinder bores 2284
4 4 Separating new conrod 2286
4 5 Checking radial clearance of conrods 2287
4 6 Removing and installing oil spray jets 2288
15 – Cylinder head, valve gear 2290
1 Cylinder head 2290
1 1 Assembly overview – cylinder head 2290
1 2 Assembly overview – camshaft housing 2292
1 3 Removing and installing cylinder head 2294
1 4 Removing and installing camshaft housing 2298
1 5 Checking compression 2301
2 Toothed belt drive 2304
2 1 Assembly overview – toothed belt cover 2304
2 2 Assembly overview – toothed belt 2304
2 3 Checking valve timing 2306
2 4 Removing toothed belt from camshaft 2312
2 5 Removing and installing toothed belt 2327
3 Valve gear 2347
3 1 Assembly overview – valve gear 2347
3 1 1 Assembly overview – valves 2347
3 2 Removing and installing camshaft adjuster 2349
3 2 1 Removing and installing camshaft adjuster for inlet camshafts 2349
3 2 2 Removing and installing toothed belt pulley 2353
3 3 Measuring axial play of camshaft 2356
3 4 Removing and installing camshaft oil seal 2357
3 4 1 Removing and installing camshaft oil seal, inlet camshaft, pulley end 2357
3 4 2 Removing and installing camshaft oil seal, exhaust camshaft, pulley end 2359
3 4 3 Removing and installing camshaft oil seal, exhaust camshaft, gearbox end 2361
3 5 Removing and installing camshaft control valve 1 -N205- 2363
3 6 Removing and installing valve stem oil seals 2364
3 6 1 Removing and installing valve stem seals (cylinder head installed) 2364
3 6 2 Removing and installing valve stem seals (cylinder head removed) 2369
4 Inlet and exhaust valves 2374
4 1 Checking valve guides 2374
4 2 Checking valves 2375
4 3 Valve dimensions 2375
17 – Lubrication 2376
1 Sump, oil pump 2376
1 1 Assembly overview – sump/oil pump 2376
1 2 Removing and installing lower part of sump 2380
1 3 Removing and installing oil pump 2383
1 4 Removing and installing upper part of sump 2385
1 5 Engine oil: 2391
2 Engine oil cooler 2392
2 1 Assembly overview – engine oil cooler 2392
2 2 Removing and installing engine oil cooler 2392
3 Crankcase ventilation 2394
3 1 Assembly overview – crankcase breather system 2394
3 2 Removing and installing oil separator 2395
4 Oil filter, oil pressure switch 2398
4 1 Assembly overview – oil filter/oil pressure switch 2398
4 2 Removing and installing oil pressure switch -F1- 2398
4 3 Checking oil pressure 2399
4 4 Removing and installing oil filter housing 2402
19 – Cooling 2403
1 Cooling system/coolant 2403
1 1 Connection diagram – coolant hoses 2403
1 2 Draining and adding coolant 2404
1 3 Checking cooling system for leaks 2411
2 Coolant pump, regulation of cooling system 2414
2 1 Assembly overview –coolant pump, thermostat 2414
2 2 Assembly overview – coolant temperature sender 2417
2 3 Removing and installing coolant pump 2418
2 4 Removing and installing toothed belt pulley for coolant pump 2421
2 5 Removing and installing thermostat 2423
2 5 1 Removing and installing thermostat for large cooling circuit 2423
2 5 2 Removing and installing thermostat for small cooling circuit 2425
2 6 Removing and installing coolant temperature sender -G62- 2427
2 7 Removing and installing radiator outlet coolant temperature sender -G83- 2428
3 Coolant pipes 2430
3 1 Assembly overview – coolant pipes 2430
3 2 Removing and installing coolant pipes 2430
4 Radiator, radiator fan 2433
4 1 Assembly overview – radiator/radiator fan 2433
4 2 Assembly overview – radiator cowl and radiator fan 2434
4 3 Removing and installing radiator 2435
4 4 Removing and installing radiator cowl 2438
4 5 Removing and installing radiator fan 2439
24 – Mixture preparation – injection 2440
1 Injection system 2440
1 1 Overview of fitting locations – injection system 2440
1 2 Assembly overview – fuel system 2444
2 Injectors 2447
2 1 Assembly overview – fuel rail with injectors 2447
2 2 Removing and installing fuel rail 2447
2 3 Removing and installing injectors 2449
2 4 Checking injectors 2450
2 5 Cleaning injectors 2454
3 Air filter 2456
3 1 Assembly overview – air filter housing 2456
3 2 Removing and installing air filter housing 2457
4 Intake manifold 2459
4 1 Assembly overview – intake manifold 2459
4 2 Removing and installing intake manifold 2461
4 3 Removing and installing throttle valve module -GX3- 2463
4 4 Cleaning throttle valve module -GX3- 2464
5 Senders and sensors 2466
5 1 Removing and installing intake manifold sender -GX9- 2466
6 Engine/motor control unit 2467
6 1 Removing and installing engine control unit -J623- 2467
6 1 1 Removing and installing engine control unit -J623- (with metal locking plate) 2467
6 1 2 Removing and installing engine control unit -J623- (with protective housing) 2470
7 Lambda probe 2475
7 1 Assembly overview – lambda probe 2475
7 2 Removing and installing lambda probe 2476
7 2 1 Removing and installing Lambda probe 1 before catalytic converter -GX10- 2476
7 2 2 Removing and installing Lambda probe 1 after catalytic converter -GX7- 2477
26 – Exhaust system 2479
1 Exhaust pipes and silencers 2479
1 1 Assembly overview – silencers 2479
1 1 1 Assembly overview – silencers, Golf 2479
1 1 2 Assembly overview – silencers, Golf Estate 2482
1 2 Separating exhaust pipes from silencers 2486
1 2 1 Separating exhaust pipes/silencers, Golf 2486
1 2 2 Separating exhaust pipes from silencers, Golf Estate 2487
1 3 Removing and installing silencer 2488
1 3 1 Removing and installing front silencer 2488
1 3 2 Removing and installing rear silencer, Golf 2489
1 3 3 Removing and installing rear silencer, Golf Estate 2491
1 4 Aligning exhaust system free of stress 2492
1 4 1 Aligning exhaust system free of stress 2492
1 4 2 Align end exhaust pipes 2493
1 5 Checking exhaust system for leaks 2493
2 Emission control 2494
2 1 Assembly overview – emission control 2494
2 2 Removing and installing catalytic converter 2497
28 – Ignition system 2500
1 Ignition system 2500
1 1 Assembly overview – ignition system 2500
1 2 Test data, spark plugs 2502
1 3 Removing and installing ignition coils with output stage 2502
1 4 Removing and installing knock sensor 2504
1 5 Removing and installing Hall sender 2505
1 6 Removing and installing engine speed sender -G28- 2506
00 – Technical data 2512
1 Safety information 2512
1 1 Safety measures when working on vehicles with a start/stop system 2512
1 2 Safety precautions when using testers and measuring instruments during a road test 2512
1 3 General safety provisions 2512
2 Identification 2514
2 1 Gearbox identification 2514
3 Repair instructions 2516
3 1 General repair instructions 2516
4 Technical data 2520
4 1 Capacities 2520
4 2 Allocation gearbox – motor 2520
4 3 Calculation of gear ratios 2520
5 Overview – power transmission 2521
5 1 Overview – power transmission – front-wheel drive 2521
6 Electrical components 2523
6 1 Overview of fitting locations – electrical components 2523
6 1 1 Overview of fitting locations – electrical components, manual gearbox 2523
6 1 2 Overview of fitting locations – electrical components, clutch mechanism 2523
30 – Clutch 2525
1 Clutch mechanism 2525
1 1 Assembly overview – pedal cluster 2525
1 2 Assembly overview – clutch hydraulics 2527
1 3 Assembly overview – clutch release mechanism 2530
1 4 Removing and installing clutch pedal 2531
1 5 Removing and installing bearing bush 2532
1 6 Removing and installing over-centre spring 2534
1 7 Removing and installing return spring 2537
1 8 Removing and installing mounting bracket 2540
1 9 Checking clutch master cylinder and clutch slave cylinder 2545
1 10 Removing and installing clutch master cylinder 2547
1 11 Removing and installing clutch slave cylinder 2548
1 12 Removing and installing lines for clutch mechanism 2550
1 13 Bleeding clutch mechanism 2552
1 14 Removing and installing clutch position sender -G476- 2554
1 15 Repairing clutch release mechanism 2555
2 Clutch 2557
2 1 Assembly overview – clutch 2557
2 2 Removing and installing clutch 2557
34 – Controls, housing 2563
1 Selector mechanism 2563
1 1 Installation position – selector mechanism 2563
1 2 Assembly overview – gear knob and cover 2564
1 3 Assembly overview – selector mechanism 2565
1 4 Removing and installing gear knob 2571
1 5 Removing and installing selector mechanism 2572
1 6 Adjusting selector mechanism 2576
1 7 Checking selector mechanism 2579
1 8 Renewing selector shaft seal 2579
2 Removing and installing gearbox 2581
2 1 Specified torques for gearbox 2581
2 2 Removing gearbox 2581
2 3 Installing gearbox 2595
3 Assembly mountings 2604
3 1 Assembly overview – assembly mountings 2604
3 1 1 Assembly overview – assembly mountings, gearbox bracket is secured to gearbox at »side« 2604
3 1 2 Assembly overview – assembly mountings, gearbox support is secured to gearbox on »top« 2605
4 Gearbox transport 2608
5 Dismantling and assembling gearbox 2610
5 1 Schematic overview – gearbox 2610
5 2 Assembly overview – gearbox 2610
5 3 Assembly overview – cover for gearbox housing and 5th gear 2611
5 4 Assembly overview – selector unit 2613
5 5 Assembly overview – input shaft, output shafts, differential, selector rods 2614
5 6 Assembly overview – selector forks 2616
5 7 Repairing selector forks 2617
5 8 Repairing selector unit 2622
5 9 Dismantling and assembling gearbox 2624
6 Gearbox housing, clutch housing 2637
6 1 Assembly overview – clutch housing 2637
6 2 Assembly overview – gearbox housing and clutch housing 2637
6 3 Repairing clutch housing 2639
7 Securing to engine and gearbox support 2642
8 Gear oil 2644
8 1 Checking gear oil level 2644
35 – Gears, shafts 2646
1 Input shaft 2646
1 1 Assembly overview – input shaft 2646
1 2 Dismantling and assembling input shaft 2648
1 3 Renewing input shaft seal 2662
2 Output shaft 2664
2 1 Assembly overview – output shaft 2664
2 2 Dismantling and assembling output shaft 2667
39 – Final drive – differential 2676
1 Oil seals 2676
1 1 Overview of fitting locations – oil seals 2676
1 2 Renewing left seal 2676
1 3 Renewing right seal 2679
2 Differential 2684
2 1 Assembly overview – differential 2684
2 2 Dismantling and assembling differential 2686
2 3 Adjusting differential 2695
00 – Technical data 2706
1 Introduction 2706
2 Acoustic considerations during vehicle development 2707
2 1 Vibration insulation film 2707
2 2 Insulation 2708
3 General procedure for identifying noises 2710
3 1 General procedure 2710
3 2 Identifying a noise 2710
3 2 1 Localising origin of noise 2710
3 2 2 Identifying the type of noise 2711
3 2 3 Identifying the point in time when the noise occurs 2711
3 2 4 Identifying the noise by definition or designation 2711
3 3 Aid for localising noise by means of audio recordings (frequencies) 2711
3 3 1 Preparing an audio CD with downloaded files 2712
3 3 2 List of audio tracks 2712
3 3 3 Conditions for testing 2712
3 3 4 Conditions for performing the audio test 2713
3 4 Checklist 2713
4 Volkswagen equipment for localising noises 2717
4 1 Ultrasonic tester -VAG 1842- 2717
4 1 1 Design of the ultrasonic tester -VAG 1842- 2717
4 1 2 Example of procedure for identifying noises using ultrasound 2717
4 2 Borescope -VAS 6748A- 2721
4 2 1 Design of the borescope -VAS 6748A- 2721
4 2 2 Procedure for identifying noises using the borescope 2722
5 Attachments 2723
5 1 Checklist 2723
5 2 Designations for noises 2725
00 – Technical data 2732
1 — Change history — 2732
2 Introduction 2734
3 List of Suppliers 2735
3 1 3M do Brasil 2735
3 2 Brascola Ltda 2735
3 3 Castrol Brasil Ltda 2735
3 4 Cia Brasileira de Petróleo Ipiranga 2735
3 5 Chemours 2735
3 6 Chevron Brasil S/A 2735
3 7 Cremer S A Prod Têxteis e Cirúrgicos 2735
3 8 Dow Corning do Brasil Ltda 2735
3 9 Elf Lubrificantes do Brasil 2735
3 10 ExxonMobil 2735
3 11 Henkel do Brasil Ltda 2735
3 12 Klüber Lubrification Lubrificantes Especiais Ltda 2735
3 13 Loctite Brasil Ltda 2735
3 14 Lumobrás Imp Com Ind Ltda 2735
3 15 Motul Synthetic Lubricants 2735
3 16 Ocean Indústria Química 2735
3 17 Pentosin do Brasil Ltda 2736
3 18 Petrobras Distr S/A 2736
3 19 Shell Brasil S/A 2736
3 20 Sika S/A 2736
3 21 Solplás – Ind de Plásticos Ltda 2736
3 22 Solvay Química 2736
3 23 Three Bond do Brasil Ind e Com Ltda 2736
3 24 Total Lubrificantes Brasil Ltda 2736
3 25 Tutela Lubrificantes S/A 2736
3 26 Valvoline Lubrificantes Internacionais Ltda 2736
4 Work Instructions for Handling Chemicals 2737
4 1 Handling of Solvents 2737
4 2 Work instruction – Flammable material handling 2739
4 3 Handling used engine oil 2740
4 4 General guidelines on the storage of chemicals 2741
5 List of authorized products 2742
5 1 Polyurethane-based sealing adhesive 2742
5 2 High-resistance locking adhesive 2742
5 3 Low viscosity lock adhesive 2742
5 4 Sealing adhesive 2742
5 5 Self-adhesive PVC tape 2742
5 6 Double-sided adhesive tape 2742
5 7 Refrigerant gas – R134a 2743
5 8 Underbody coating 2743
5 9 Lubricating engine oil as per VW 502 00 and VW 505 00 standards 2743
5 10 Lubricating engine oil as per VW 507 00 standard 2743
5 11 Lubricating engine oil as per VW 508 88 and VW 509 99 standards 2744
5 12 Lubricating oil for manual gearbox and steering rack – SAE 90, MIL-L-2105B, API – GL5 2744
5 13 Lubricating oil for manual gearbox – SAE 80, MIL-L-2105, API – GL4 2744
5 14 Tire assembly paste 2744
5 15 Biodegradable degreasing product 2744
5 16 Grease remover spray 2745
6 List of fractionated products 2746
6 1 -000 096 319 D- Polishing material (chromium and aluminium) 2746
6 2 -032 198 561- Additional seal 2746
6 3 -AMV 188 001 02- Adhesive silicone 2747
6 4 -AMV 188 200 03- Sealing paste 2747
6 5 -AMV 189 300- Activating agent 2748
6 6 -AMV 189 400- Sealing compound 2748
6 7 Liquid sealant -D 000 600 A2- 2748
6 8 -D 001 210 M2- Universal adhesive 2749
6 9 -D 002 000 A2-Adhesive remover 2749
6 10 -D 004 660 M2- Adhesive set 2749
6 11 -D 007 000 A2- Spray silicone 2750
6 12 -D 009 200 02- Glass primer 2750
6 13 -D 009 401 04- Cleaning solution 2751
6 14 -D 009 500 25- Applicator 2751
6 15 Liquid sealant -D 154 000 A1- 2752
6 16 Liquid sealant -D 154 100 A1- 2752
6 17 -D 154 102 A1- Sealing compound 2752
6 18 -D 154 103 A1- Adhesive silicone 2753
6 19 -D 169 300 M1- Window adhesive 2753
6 20 -D 169 300 M2- Window adhesive 2753
6 21 -D 172 090 A2- Adhesive 2754
6 22 -D 174 003 M2- Silicone sealant 2754
6 23 -D 176 404 A3- Adhesive silicone 2755
6 24 -D 176 204 R2- Adhesive silicone 2755
6 25 -D 176 404 M2- Adhesive silicone 2755
6 26 -D 176 501 A1- Adhesive silicone 2755
6 27 -D 180 KU1 A1- 2-component adhesive for plastic 2756
6 28 -D 180 KU2 A1- 2-component adhesive for plastic 2756
6 29 -D 181 220 A1- Activating agent 2757
6 30 -D 181 655 A1- Activating agent 2757
6 31 -D 181 802 M1- Glass primer 2757
6 32 Liquid sealant -D 185 400 A2- 2758
6 33 Liquid sealant -D 185 400 A3- 2758
6 34 Liquid sealant -D 185 410 A2- 2758
6 35 -D 185 520 A2- Sealing compound 2758
6 36 -D 190 MKD A3- Assembly adhesive 2759
6 37 Liquid sealant -D 192 100 A2- 2759
6 38 -D 195 850 A1- Cleaning solution 2759
6 39 -D 316 D38 A2- Protective wax 2760
6 40 -D 322 000 A2- Wachs-spray 2760
6 41 -D 322 100 M2- Wachs-spray 2760
6 42 -D 330 KD2 A1- Cavity spray 2761
6 43 -D 366 PR1 A1- Plastic primer 2761
6 44 -D 454 300 A2- Sealing compound 2761
6 45 -D 469 101 A3- Gluing and sealing compound 2762
6 46 -D 822 150 A1- Plastic surfacer 2762
6 47 -G 000 100- Coupling teeth lubricant compound 2762
6 48 -G 000 115 A2- Spray lubricant 2763
6 49 -G 000 150- Consistent lubricating paste 2763
6 50 -G 000 405 A2- Silicone paste 2763
6 51 -G 000 450 02- Lubrication paste 2764
6 52 -G 000 650- Consistent lubricating paste 2765
6 53 -G 052 109 A2- Assembly paste 2765
6 54 -G 052 112 A3- High temperature paste 2765
6 55 -G 052 128 A1- Thrust ring sealing grease 2766
6 56 -G 052 133 A2- Lubricating paste for high temperatures 2766
6 57 -G 052 135 A1- Lubricating oil 2766
6 58 -G 052 142 A2- Polyurethane lubricating compound 2767
6 59 -G 052 150 A2- Lithium lubricating paste 2767
6 60 -G 052 168 A1- Steering box lubricant 2768
6 61 -G 052 172 A1- Special lubricant 2768
6 62 -G 052 172 M2- Special lubricant 2768
6 63 -G 052 181 A4- Lubricating paste for constant velocity joints 2769
6 64 -G 052 528 A2- Lubricating paste for constant velocity joints 2769
6 65 -G 052 565 A1- Silicone paste 2769
6 66 -G 052 723 A2- Moly paste 2770
6 67 -G 052 735 A2- Multi-purpose grease 2770
6 68 -G 052 738 A2- Lubricating paste for constant velocity joints 2770
6 69 -G 052 738 A3- Thrust ring sealing grease 2771
6 70 -G 052 745 A3- Lubricating paste for low temperature 2771
6 71 -G 052 751 A1- Molybdenum pasta 2771
6 72 -G 052 778 A2- Spray lubricant 2772
6 73 -G 052 817 A1- Contact grease 2772
6 74 -G 055 128 A1- Thrust ring sealing grease 2772
6 75 -G 060 567 A2- Special lubricant 2773
6 76 -G 060 735 A2- Multi-purpose grease 2773
6 77 -G 060 751 A2- Consistent lubricating paste 2773
6 78 -G 065 567 A2- Cleaning solution 2774
6 79 -G 070 528 R2- Lubricating paste for constant velocity joints 2774
6 80 -G 294 421 A1- Lubricating oil for assembly 2774
1 Safety instructions 2779
1 1 Part removal 2779
1 2 Battery and welding operation 2779
1 3 Electronic control unit 2779
1 3 1 Processing of the electronic control unit after repair dueto a traffic accident 2779
1 4 Paint, glass, soft pad and trim 2780
1 5 Fuel tank or fuel delivery pipeline 2780
1 6 Air conditioner 2780
1 6 1 Remedial measures: 2780
1 7 Airbag System 2781
1 8 Check the seat belts 2781
1 8 1 Belt body 2782
1 8 2 Automatic retractor (locking function) 2782
1 8 3 Visual inspection of the seat belt buckle 2783
1 8 4 Seat belt buckle function 2783
1 8 5 Seat belt guide member and tongue 2784
1 8 6 Fixing piece and fixing point 2784
1 9 Safety specifications for the seat belt tensioner 2784
1 10 Body repair on a vehicle equipped with the seat belt tensioners 2785
1 10 1 The following vehicles have been equipped with: 2785
1 11 Perform cutting off, correcting and/or leveling on a vehicleequipped with airbags 2786
1 12 Remove the front seats with a side airbag 2786
2 Basic instruction 2787
2 1 Diagnosis of the accident vehicle 2787
2 2 Condition of the body and/or the parts for delivery to thepainting workshop 2787
2 3 Correction 2787
2 4 Cutting 2787
2 5 Body-cut part and part section 2787
2 6 Original connection 2788
2 7 Galvanized body parts 2788
2 8 Remove the rest part 2788
2 9 New parts 2788
2 10 Parts 2788
2 11 Molded foam plastic pads 2789
3 Symbolic interpretation 2790
3 1 Symbolic interpretation for welding 2790
3 2 Symbolic interpretation for the operation method 2790
3 2 1 Grinding 2791
3 2 2 Thinning 2791
3 2 3 Punching 2791
3 2 4 Drilling 2792
3 2 5 Polishing 2792
3 2 6 Cavity corrosion protection 2792
3 2 7 Bonding 2793
3 2 8 Precise sealing 2793
4 Body repair tools 2794
4 1 Flaring tool -V A G 1317- 2794
4 2 Punching pliers -V A G 1329- 2794
4 3 Basic equipment -V A G 1366/3- 2794
4 4 Bottom protection layer spray gun -V A G 1379- 2795
4 5 Electric blower -V A G 1416- 2795
4 6 Door tensioner -V A G 1438- 2795
4 7 Body equipment component -V A G 1439- 2796
4 8 Pneumatic cutting knife -V A G 1523 A- 2796
4 9 Air chisel -V A G 1577- 2796
4 10 Edge closing iron block -V A G 1585- 2797
4 11 Welding fume ventilator -V A G 1586- 2797
4 12 Welding spot releasing device -V A G 1731- 2797
4 13 Pneumatic spray gun -V A G 1761/1- 2798
4 14 Pneumatic punching and thinning pliers -VAS 1996- 2798
4 15 Pneumatic adhesive spray gun -V A G 2005- 2798
4 16 Door hinge correction tool 2799
4 17 Hose kit 5023 for the inert gas protection welding 2799
4 18 Angle grinder -VAS 5174- 2799
4 19 Angle grinder -VAS 5175- 2800
4 20 Wire brush -VAS 5182- 2800
5 Body bonding 2801
5 1 Transporter 1991 → 2801
5 1 1 Separation process: 2801
5 1 2 Bonding process: 2801
5 2 Bonding types 2801
5 2 1 Bonding-strong 2801
5 2 2 Bonding-spot welding 2802
5 3 Repair method for replacing the parts 2802
5 3 1 Spot welding and bonding 2802
5 3 2 Plug welding and bonding (if spot welding is impossible) 2802
5 3 3 Welding fume ventilator 2803
5 3 4 Preparations 2803
5 3 5 Trimming 2803
6 Corrosion protection measures 2804
6 1 Corrosion protection 2804
7 Waste disposal instructions 2805
7 1 Waste disposal 2805
7 2 Air pressure tappet exhaust 2805
7 3 Airbag 2806
7 3 1 Waste disposal 2806
8 Contact corrosion protection 2807
8 1 Connection of aluminum alloy/magnesium alloy with steel 2807
9 Steel plate repair 2808
9 1 High-strength body plate 2808
9 2 Galvanized body parts 2808
9 2 1 Preparations 2808
9 2 2 Part cutting 2809
9 2 3 Connection process 2809
9 3 Welding on the galvanized body steel plate 2809
9 3 1 Inert gas protection plug welding SG of the galvanized steelplate 2809
9 3 2 Resistance pressure spot welding RP of the galvanized steelplate 2810
9 3 3 Welding transformer 2810
9 3 4 Welding clamp 2810
9 4 Tearing test 2810
10 Aluminum repair 2811
10 1 Painting 2811
10 2 Surface treatment 2811
10 3 Leveling 2812
10 4 Temperature control for heating 2812
11 Plastic repair method 2813
11 1 Material 2813
11 2 Repairing the pit 2814
11 3 Repairing the scratch 2815
11 4 Repair the crack 2817
11 5 Repairing the small hole (the diameter is more than 30 mm) 2818
11 6 Plastic repair (glass fibre material) 2819
11 7 Repair process 2820
11 7 1 Repairing the breakage position 2820
11 7 2 Repairing the surface damage 2822
12 Glass repair 2823
12 1 Repairing the windshield 2823
12 1 1 Premises 2823
12 1 2 Required special tools, operating equipment, testing instrumentsand auxiliary tools 2824
12 1 3 Repair description 2825
00 – Technical data 2835
1 Safety information 2835
1 1 Safety precautions when working on air conditioning systems 2835
1 2 Safety measures when working on vehicles with a start/stop system 2835
1 3 Safety precautions when using testers and measuring instruments during a road test 2836
1 4 Safety precautions when working on the cooling system 2836
1 5 Safety precautions when handling refrigerants 2836
1 6 Safety precautions for working on vehicles with auxiliary/supplementary heater 2837
2 General information 2839
2 1 Type plates 2839
2 1 1 Identification plate with capacities for refrigerant R134a and refrigerant oil 2839
2 1 2 Identification plate with capacities for refrigerant R1234yf and refrigerant oil 2839
2 2 Notes concerning odours in air conditioned vehicles 2840
2 3 Notes for vehicles with start-stop system 2841
2 4 Notes on dust and pollen filter 2842
3 Repair instructions 2843
3 1 Rules for cleanliness 2843
3 2 Nuts and bolts 2843
3 3 Routing and attachment of lines 2844
3 4 Fitting radiators and condensers 2844
3 5 Checking heater output 2844
3 6 Checking cooling output 2847
3 7 Working on refrigerant circuit 2849
3 8 Paint work on vehicles with air conditioning system 2850
3 9 Refrigerant circuit seals 2850
3 10 General repair instructions 2850
4 Technical data 2852
4 1 Refrigerant capacity 2852
4 2 Refrigerant oil capacities 2852
4 3 Oil distribution 2852
80 – Heating 2854
1 Overview of fitting locations – heating 2854
1 1 Overview of fitting locations – components not located in passenger compartment 2854
1 1 1 Overview of fitting locations – components not located in passenger compartment 2854
1 2 Overview of fitting locations – components located in front section of passenger compartment 2855
2 Heater 2856
2 1 Assembly overview – heater unit 2856
3 Control motors 2862
3 1 Overview of fitting locations – control motors at front 2862
3 2 Removing and installing fresh air and air recirculation flap control motor -V154- 2862
4 Air duct 2864
5 Operating and display unit 2865
5 1 Overview of operating and display unit 2865
6 Other controlling and regulating components 2867
87 – Air conditioning system 2868
1 Overview of fitting locations – air conditioning system 2868
1 1 Overview of fitting locations – components not located in passenger compartment 2868
1 1 1 Overview of fitting locations – components not located in passenger compartment 2868
1 2 Overview of fitting locations – components located in front section of passenger compartment 2870
2 Refrigerant circuit 2873
2 1 System overview – refrigerant circuit 2873
2 2 Assembly overview – condenser 2875
2 3 Removing and installing refrigerant circuit pressure sender -G805- 2877
2 4 Removing and installing refrigerant line with internal heat exchanger 2878
2 5 Removing and installing expansion valve 2882
2 6 Removing and installing condenser 2887
2 7 Removing and installing desiccant bag or cartridge 2891
2 8 Removing and installing damper weight for refrigerant line, low-pressure side 2895
2 9 Removing and installing evacuating and charging valves on low and high-pressure side 2896
2 10 Removing and installing refrigerant line from condenser to evaporator 2899
2 11 Removing and installing refrigerant line from condenser to air conditioner compressor 2902
2 12 Removing and installing refrigerant line from air conditioner compressor to evaporator 2905
3 Air conditioner compressor 2908
3 1 Assembly overview – drive unit of air conditioner compressor 2908
3 2 Assembly overview – pulley 2910
3 2 1 Assembly overview – pulley, Denso air conditioner compressor 2910
3 2 2 Assembly overview – belt pulley, Sanden air conditioner compressor 2910
3 3 Removing air conditioner compressor from and installing on bracket 2912
3 4 Removing and installing air conditioner compressor 2914
3 5 Checking high-pressure safety valve on air conditioner compressor 2918
3 6 Removing and installing pulley 2920
3 6 1 Removing and installing Denso belt pulley 2920
3 6 2 Removing and installing Sanden belt pulley 2922
4 Control motors 2923
4 1 Overview of fitting locations – control motors at front 2923
4 1 1 Overview of fitting locations – front control motors, air conditioning system with electric and manual controls 2923
4 1 2 Overview of fitting locations – front control motors, Climatronic 2924
4 2 Removing and installing temperature flap control motor -V68- 2925
4 3 Removing and installing defroster flap control motor -V107- 2927
4 4 Removing and installing air recirculation flap control motor -V113- 2929
4 5 Removing and installing left temperature flap control motor -V158- 2931
4 6 Removing and installing right temperature flap control motor -V159- 2933
4 7 Removing and installing fresh air/air recirculation, air flow flap control motor -V425- 2935
4 8 Removing and installing front air distribution flap control motor -V426- 2937
4 9 Removing and installing air distribution flap control motor -V428- 2939
4 10 Removing and installing air distribution flap actuator 2941
4 10 1 Removing and installing front air distribution flap actuation unit, heater and air conditioning system with electric/manual controls 2941
4 10 2 Removing and installing front air distribution flap actuation unit, Climatronic 2943
5 Front heater and air conditioning unit 2945
5 1 Assembly overview – add-on parts of heater and air conditioning unit and of air intake box 2945
5 2 Assembly overview – flaps and partitions in air distribution housing 2947
5 3 Assembly overview – heater and air conditioning unit 2950
5 4 Assembly overview – evaporator housing 2954
5 5 Removing and installing evaporator 2955
5 6 Checking auxiliary air heater element -Z35- 2957
5 7 Removing and installing auxiliary air heater element -Z35- 2958
5 8 Removing and installing heater and air conditioning unit 2959
5 9 Removing and installing bracket for heater and air conditioning unit 2966
5 10 Dismantling and assembling heater and air conditioning unit 2968
5 11 Removing and installing air distribution housing 2970
5 12 Removing and installing dust and pollen filter 2970
5 13 Removing and installing fresh air blower -V2- 2973
5 14 Removing and installing fresh air blower control unit -J126- 2974
5 15 Removing and installing heat exchanger 2974
5 16 Removing and installing coolant pipes on heat exchanger 2980
5 17 Removing and installing evaporator temperature sensor -G308- 2982
5 18 Removing and installing condensation drain 2983
5 19 Checking condensation drain 2986
6 Air duct 2988
6 1 Assembly overview – air duct and air distribution in passenger compartment 2988
6 2 Removing and installing driver side footwell vents 2989
6 3 Removing and installing front passenger side footwell vents 2990
6 4 Removing and installing rear footwell vent 2992
6 5 Removing and installing air ducts 2993
6 6 Removing and installing forced ventilation for passenger compartment 2994
6 6 1 Removing and installing forced ventilation for passenger compartment 2994
6 7 Checking forced ventilation for passenger compartment 2995
6 8 Removing and installing fresh air intake 2995
6 9 Removing and installing cover for fresh air intake 2997
6 10 Removing and installing intake duct 2997
6 11 Removing and installing air duct for defroster vent 2999
6 12 Removing and installing air duct for centre dash panel vent 2999
7 Operating and display unit 3001
7 1 Overview of fitting locations – operating and display unit 3001
7 1 1 Overview of fitting locations – operating and display unit, air conditioning system with electric/manual controls 3001
7 1 2 Overview of fitting locations – operating and display unit, Climatronic 3003
7 2 Removing and installing operating and display unit 3005
8 Other controlling and regulating components 3008
8 1 Removing and installing sunlight penetration photosensor -G107- 3008
8 2 Working principles of air quality sensor -G238- 3009
8 3 Removing and installing air quality sensor -G238- 3010
8 4 Removing and installing ambient temperature sensor -G17- 3011
8 5 Removing and installing humidity sender for air conditioning system -G260- 3011
8 6 Removing and installing left vent temperature sender -G150- 3012
8 7 Removing and installing right vent temperature sender -G151- 3013
8 8 Removing and installing footwell vent temperature sender -G192- 3014
00 – Technical data 3022
1 Safety information 3022
1 1 Safety precautions when using testers and measuring instruments during a road test 3022
1 2 Safety measures when working on vehicles with a start/stop system 3023
2 Identification 3024
2 1 Gearbox identification 3024
2 1 1 Gearbox identification, front-wheel drive 3024
2 1 2 Gearbox identification, all-wheel drive 3025
3 Repair notes 3027
3 1 General repair instructions 3027
4 Technical data 3031
4 1 Capacities 3031
4 2 Allocation gearbox – motor 3031
4 3 Calculation of gear ratios 3032
5 Overview – power transmission 3033
5 1 Overview – power transmission – front-wheel drive 3033
6 Electrical components 3035
6 1 Overview of fitting locations – electrical components 3035
6 1 1 Overview of fitting locations – electrical components, front differential lock 3035
6 1 2 Overview of fitting locations – electrical components, manual gearbox 3035
6 1 3 Overview of fitting locations – electrical components, clutch mechanism 3036
30 – Clutch 3037
1 Clutch mechanism 3037
1 1 Assembly overview – pedal cluster 3037
1 2 Assembly overview – clutch hydraulics 3039
1 2 1 Assembly overview – clutch hydraulics, left-hand drive 3039
1 2 2 Assembly overview – clutch hydraulics, right-hand drive 3042
1 3 Assembly overview – clutch release mechanism 3044
1 4 Removing and installing clutch pedal 3045
1 5 Removing and installing over-centre spring 3047
1 6 Removing and installing return spring 3051
1 7 Removing and installing mounting bracket 3054
1 8 Removing and installing bearing bush 3060
1 9 Removing and installing clutch master cylinder 3061
1 10 Removing and installing clutch slave cylinder together with release bearing 3062
1 11 Removing and installing lines for clutch mechanism 3063
1 12 Removing and installing bleeder 3066
1 13 Bleeding clutch mechanism 3068
1 14 Checking clutch master cylinder and clutch slave cylinder 3070
1 15 Removing and installing clutch position sender -G476- 3070
1 16 Repairing clutch release mechanism 3071
2 Clutch 3073
2 1 Determining make of clutch 3073
2 2 Assembly overview – clutch 3074
2 2 1 Assembly overview – clutch in conjunction with Sachs dual-mass flywheel 3074
2 2 2 Assembly overview – clutch in conjunction with LuK dual-mass flywheel 3075
2 2 3 Assembly overview – clutch with simple flywheel 3076
2 3 Removing and installing clutch 3077
2 3 1 Removing and installing clutch in conjunction with Sachs dual-mass flywheel 3077
2 3 2 Removing and installing clutch in conjunction with LuK dual-mass flywheel 3083
2 3 3 Removing and installing clutch in connection with simple flywheel 3087
34 – Controls, housing 3093
1 Bevel box 3093
1 1 Assembly overview – bevel box 3093
1 2 Removing bevel box 3095
1 3 Installing bevel box 3104
2 Selector mechanism 3110
2 1 Installation position – selector mechanism 3110
2 2 Assembly overview – gear knob and cover 3110
2 3 Assembly overview – selector mechanism 3111
2 4 Removing and installing gear knob 3113
2 5 Removing and installing selector mechanism 3115
2 6 Adjusting selector mechanism 3125
2 7 Checking selector mechanism 3128
2 8 Renewing selector shaft seal 3129
3 Removing and installing gearbox 3131
3 1 Specified torques for gearbox 3131
3 2 Removing gearbox 3131
3 2 1 Removing gearbox, vehicles with diesel engine 3131
3 2 2 Removing gearbox, vehicles with petrol engine and front-wheel drive 3144
3 3 Installing gearbox 3161
3 3 1 Installing gearbox, vehicles with turbo diesel engine 3161
3 3 2 Installing gearbox, vehicles with petrol engine and front-wheel drive 3168
4 Assembly mountings 3177
4 1 Assembly overview – assembly mountings 3177
5 Front differential lock 3181
5 1 Assembly overview – front differential lock 3181
5 2 Allocation of front differential lock 3181
5 3 Removing front differential lock 3181
5 4 Installing front differential lock 3185
6 Transporting gearbox 3189
6 1 Transporting gearbox 3189
6 2 Transporting front differential lock 3190
7 Dismantling and assembling gearbox 3191
7 1 Schematic overview – gearbox 3191
7 1 1 Schematic overview – gearbox, front-wheel drive 3191
7 1 2 Schematic overview – front differential lock 3192
7 2 Assembly overview – gearbox 3193
7 2 1 Assembly overview – gearbox, front-wheel drive 3193
7 2 2 Assembly overview – gearbox for four-wheel drive and gearbox for front-wheel drive with front differential lock 3194
7 3 Assembly overview – gearbox housing and selector mechanism 3195
7 4 Assembly overview – selector unit 3197
7 5 Assembly overview – input shaft, output shafts, differential, selector rods 3198
7 5 1 Assembly overview – input shaft, output shafts, differential, selector rods, front-wheel drive 3198
7 5 2 Assembly overview – shafts, differential, selector shafts, all-wheel drive and front-wheel drive with front differential lock 3200
7 6 Assembly overview – selector forks 3202
7 7 Renewing selector shaft seal 3203
7 8 Dismantling and assembling gearbox 3205
8 Gearbox housing, clutch housing 3228
8 1 Assembly overview – gearbox housing 3228
8 2 Assembly overview – clutch housing 3230
8 3 Repairing gearbox housing 3232
8 4 Repairing clutch housing 3241
9 Securing to engine and gearbox support 3245
9 1 Installing manual gearbox to engine and gearbox support 3245
9 2 Installing bevel box or front differential lock to engine and gearbox support 3246
10 Gear oil 3248
10 1 Distinguishing between different manual gearbox types when filling oil 3248
10 2 Checking gear oil level 3248
10 2 1 Checking gear oil level, gearboxes “with” oil filler plug 3248
10 2 2 Checking gear oil level, gearboxes “without” oil filler plug 3249
10 2 3 Draining and filling gear oil 3250
10 2 4 Specified torque for oil filler and oil drain plugs 3252
35 – Gears, shafts 3253
1 Input shaft 3253
1 1 Assembly overview – input shaft 3253
1 2 Dismantling and assembling input shaft 3254
1 3 Renewing input shaft seal 3260
2 Output shaft 3262
2 1 Assembly overview – output shaft 3262
2 1 1 Assembly overview – output shaft for 1st to 4th gears 3262
2 1 2 Assembly overview – output shaft for 5th, 6th and reverse gear 3267
2 2 Dismantling and assembling output shaft 3269
2 2 1 Dismantling and assembling output shaft for 1st to 4th gears 3269
2 2 2 Dismantling and assembling output shaft for 5th, 6th and reverse gears 3287
2 3 Adjusting output shaft 3300
2 3 1 Adjusting output shaft for 1st to 4th gears 3300
2 3 2 Adjusting output shaft for 5th, 6th and reverse gears 3306
39 – Final drive – differential 3312
1 Checking gear oil level 3312
1 1 Checking gear oil level in bevel box 3312
1 2 Topping up gear oil in bevel box 3313
2 Oil seals 3318
2 1 Overview of fitting locations – oil seals 3318
2 2 Renewing left seal 3320
2 3 Renewing right seal 3323
2 3 1 Renewing right oil seal, front wheel drive 3323
2 3 2 Renewing oil seal for right flange shaft, front-wheel drive with front differential lock 3326
2 3 3 Renewing right oil seal, all-wheel drive 3331
2 3 4 Renew right seal on the manual gearbox, between gearbox and bevel box 3336
3 Differential 3339
3 1 Assembly overview – differential 3339
3 1 1 Assembly overview – differential, front-wheel drive 3339
3 1 2 Assembly overview – differential, four-wheel drive and front-wheel drive with front differential lock 3341
3 2 Dismantling and assembling differential 3344
3 2 1 Dismantling and assembling differential, front-wheel drive 3344
3 2 2 Dismantling and assembling differential, four-wheel drive, front-wheel drive with front differential lock 3350
3 3 Adjusting differential 3358
4 Adjustment overview 3363
5 Components of bevel box 3364
5 1 Assembly overview – components of bevel box 3364
5 2 Renewing output flange and redetermining thickness of shim 3366
5 3 Renewing needle bearing (polygon bearing) and oil seal for right flange shaft 3367
5 4 Renewing bevel box seals 3371
5 4 1 Renewing seal between gearbox and bevel box with bevel box removed 3371
5 4 2 Renewing oil seal for drive flange and bevel box 3373
6 Components of front differential lock 3385
6 1 Assembly overview – components of front differential lock 3385
6 2 Checking function 3387
6 3 Removing and installing pump -V181- 3387
6 4 Removing and installing coupling for front differential lock 3388
6 5 Removing and installing differential lock control unit – J647- 3388
6 6 Renewing seals for front differential lock 3389
6 6 1 Renewing seal between front differential lock and manual gearbox on front differential lock 3389
6 6 2 Renewing seal for right flange shaft in front differential lock 3391
6 7 Renewing ball bearing for flange shaft 3393
7 Oil for front differential lock 3397
7 1 Checking oil level for front differential lock 3397
7 2 Draining and filling oil for front differential lock 3398
00 – Technical data 3406
1 Safety information 3406
1 1 General safety provisions 3406
1 2 Safety measures when working on vehicles with a start/stop system 3406
1 3 Safety precautions when using testers and measuring instruments during a road test 3407
1 4 Safety precautions when tow-starting or towing 3407
2 Identification 3408
2 1 Gearbox identification 3408
3 Repair instructions 3409
3 1 General information 3409
3 2 Rules for cleanliness 3409
3 3 General repair instructions 3409
3 4 Gaskets and seals 3410
3 5 Nuts and bolts 3411
4 Technical data 3412
4 1 Capacities 3412
4 2 Allocation gearbox – motor 3412
5 Electrical components 3413
5 1 Overview of fitting locations – electrical components 3413
5 1 1 Overview of fitting locations – electrical components, gearbox control system 3413
5 1 2 Overview of fitting locations – electrical components, selector mechanism 3413
5 1 3 Overview of fitting locations – electrical components, front differential lock 3414
30 – Clutch 3416
1 Clutch 3416
1 1 Assembly overview – dual clutch 3416
1 2 Removing and installing clutch end cover 3416
1 3 Removing dual clutch 3421
1 4 Installing dual clutch 3425
34 – Controls, housing 3436
1 Mechatronic unit 3436
1 1 Assembly overview – mechatronic unit 3436
1 2 Removing and installing oil sump 3437
1 3 Removing and installing mechatronic unit 3441
2 Selector mechanism 3444
2 1 Assembly overview – selector lever handle 3444
2 2 Assembly overview – selector mechanism 3444
2 3 Manual release from position P 3446
2 4 Removing and installing selector lever handle 3447
2 5 Moving push-button in the handle to installation position 3451
2 6 Removing and installing selector mechanism 3452
2 7 Checking selector mechanism 3454
2 8 Checking and adjusting selector lever cable 3455
2 9 Renewing selector shaft seal 3457
3 Removing and installing gearbox 3460
3 1 Specified torques for gearbox 3460
3 2 Removing gearbox 3460
3 3 Installing gearbox 3470
4 Assembly mountings 3476
4 1 Assembly overview – assembly mountings 3476
5 Gearbox transport 3477
5 1 Gearbox transport 3477
5 2 Transporting front differential lock 3478
6 Securing to engine and gearbox support 3479
6 1 Securing to engine and gearbox support 3479
6 2 Securing front differential lock to engine and gearbox support 3480
7 Gear oil circuit 3482
7 1 Assembly overview – gear oil circuit 3482
7 2 Removing and installing gear oil cooler 3482
7 3 Removing and installing gear oil filter 3485
7 4 Removing and installing motor for auxiliary hydraulic pump 1 for gearbox oil -V475- 3487
8 Gear oil 3490
8 1 Overview of oil drain and inspection plugs 3490
8 2 Tools for gear oil change 3490
8 3 Checking gear oil level 3493
8 4 Draining and filling gear oil 3495
9 Front differential lock 3499
9 1 Assembly overview – front differential lock 3499
9 2 Removing front differential lock 3499
9 3 Installing front differential lock 3503
9 4 Removing and installing differential lock control unit -J647- 3506
35 – Gears, shafts 3507
1 Currently, no repairs can be made to gears and shafts 3507
39 – Final drive – differential 3508
1 Seals 3508
1 1 Overview of fitting locations – oil seals 3508
1 2 Renewing left seal 3508
1 3 Renewing right seal 3511
2 Components of front differential lock 3514
2 1 Assembly overview – components of front differential lock 3514
2 2 Removing and installing coupling for front differential lock 3516
2 3 Removing and installing pump for front differential lock 3516
2 4 Checking function 3517
2 5 Renewing seals for front differential lock 3518
2 5 1 Renewing outer seal on right of front differential lock 3518
2 5 2 Renewing seal between front differential lock and gearbox on front differential lock 3522
2 5 3 Renewing seal for right flange shaft in front differential lock 3524
2 6 Renewing ball bearing for flange shaft 3526
2 7 Checking oil level 3528
2 8 Draining and filling oil for front differential lock 3530
00 – Technical data 3542
1 Safety information 3542
1 1 Safety regulations for working on fuel supply 3542
1 2 Safety measures when working on vehicles with start/stop system 3542
1 3 Safety precautions when using testers and measuring instruments during a road test 3543
1 4 Safety precautions when working on the cooling system 3543
1 5 Safety precautions when working on ignition system 3543
2 Identification 3544
2 1 Engine number/engine data 3544
3 Repair instructions 3546
3 1 Rules for cleanliness 3546
3 2 General notes 3546
3 3 General repair notes 3546
3 4 Foreign bodies in engine 3547
3 5 Contact corrosion 3547
3 6 Routing and attachment of lines 3547
3 7 Installing radiators and condensers 3547
3 8 Checking vacuum system 3547
10 – Removing and installing engine 3549
1 Removing and installing engine 3549
1 1 Removing engine 3549
1 2 Separating engine and gearbox 3564
1 2 1 Separating engine and gearbox, vehicles with manual gearbox 3564
1 2 2 Separating engine and gearbox, vehicles with dual clutch gearbox 3567
1 3 Securing engine on engine and gearbox support 3570
1 4 Installing engine 3573
2 Assembly mountings 3577
2 1 Assembly overview – assembly mountings 3577
2 2 Removing and installing engine mounting 3579
2 3 Removing and installing gearbox mounting 3579
2 4 Removing and installing pendulum support 3581
2 5 Supporting engine in installation position 3582
2 6 Adjusting assembly mountings 3587
2 7 Checking adjustment of assembly mountings 3588
3 Engine cover panel 3590
3 1 Removing and installing engine cover 3590
13 – Crankshaft group 3591
1 Cylinder block, pulley end 3591
1 1 Assembly overview – cylinder block, pulley end 3591
1 2 Removing and installing poly-V belt 3594
1 3 Removing and installing poly V-belt tensioner 3596
1 4 Removing and installing vibration damper 3596
1 5 Removing and installing bracket for ancillaries 3603
1 6 Removing and installing engine support 3606
2 Cylinder block, gearbox end 3608
2 1 Assembly overview – cylinder block, gearbox end 3608
2 2 Removing and installing flywheel 3609
2 3 Removing and installing sealing flange on gearbox side 3610
3 Crankshaft 3616
3 1 Assembly overview – crankshaft 3616
3 2 Crankshaft dimensions 3618
3 3 Allocation of main bearing shells 3618
3 4 Renewing needle bearing in crankshaft 3620
3 5 Measuring axial clearance of crankshaft 3623
3 6 Measuring radial clearance of crankshaft 3624
3 7 Removing and installing sender wheel 3625
4 Balance shaft 3627
4 1 Assembly overview – balance shaft 3627
4 2 Removing and installing balance shaft 3628
4 2 1 Removing and installing inlet side balance shaft 3628
4 2 2 Removing and installing exhaust side balance shaft 3631
4 2 3 Renewing oil seal for balance shaft (inlet side) 3633
5 Pistons and conrods 3635
5 1 Assembly overview – pistons and conrods 3635
5 2 Removing and installing pistons 3637
5 3 Checking piston and cylinder bore 3638
5 3 1 Checking piston and cylinder bore 3638
5 4 Separating new conrod 3641
5 5 Checking radial clearance of conrods 3642
15 – Cylinder head, valve gear 3643
1 Cylinder head 3643
1 1 Assembly overview – cylinder head 3643
1 2 Assembly overview – camshaft housing 3646
1 3 Removing and installing cylinder head 3648
1 4 Removing and installing vacuum pump 3655
1 5 Checking compression 3657
2 Timing chain cover 3660
2 1 Assembly overview – timing chain cover 3660
2 2 Removing and installing timing chain cover 3663
2 2 1 Removing and installing upper timing chain cover 3663
2 2 2 Removing and installing timing chain cover (bottom) 3666
2 3 Renewing seal for vibration damper 3671
3 Chain drive 3674
3 1 Assembly overview – camshaft timing chains 3674
3 1 1 Assembly overview – camshaft timing chains 3674
3 2 Assembly overview – drive chain for balance shaft 3678
3 3 Removing and installing camshaft timing chain 3681
3 3 1 Removing and installing camshaft timing chain 3681
3 4 Removing and installing drive chain for balance shaft 3697
3 5 Checking chain elongation 3697
3 6 Checking valve timing 3698
4 Valve gear 3701
4 1 Assembly overview – valve gear 3701
4 2 Removing and installing camshaft 3704
4 2 1 Removing and installing camshaft 3704
4 3 Removing and installing camshaft control valve 1 -N205- 3724
4 4 Removing and installing exhaust camshaft control valve 1 -N318- 3724
4 5 Removing and installing valve stem oil seals 3724
4 5 1 Removing and installing valve stem seals (cylinder head installed) 3724
4 5 2 Removing and installing valve stem seals (cylinder head removed) 3731
5 Inlet and exhaust valves 3737
5 1 Checking valve guides 3737
5 2 Checking valves 3738
5 3 Valve dimensions 3738
17 – Lubrication 3739
1 Sump, oil pump 3739
1 1 Assembly overview – sump/oil pump 3739
1 2 Engine oil 3742
1 3 Removing and installing lower part of sump 3743
1 3 1 Removing and installing bottom section of sump, plastic sump 3743
1 3 2 Removing and installing bottom section of sump, sheet-metal sump 3745
1 4 Removing and installing upper part of sump 3747
1 5 Removing and installing oil pump 3752
1 6 Removing and installing oil level and oil temperature sender -G266- 3755
2 Engine oil cooler 3757
2 1 Assembly overview – engine oil cooler 3757
2 2 Removing and installing engine oil cooler 3757
2 3 Removing and installing mechanical switching valve 3759
3 Crankcase breather 3760
3 1 Assembly overview – crankcase breather system 3760
3 2 Removing and installing oil separator 3761
4 Oil filter, oil pressure switch 3762
4 1 Assembly overview – oil filter 3762
4 2 Assembly overview – oil pressure switches/oil pressure control 3762
4 3 Removing and installing oil pressure switch -F1- 3764
4 4 Removing and installing oil pressure switch for reduced oil pressure -F378- 3765
4 5 Removing and installing stage 3 oil pressure switch -F447- 3766
4 6 Checking oil pressure 3768
4 6 1 Checking engine oil pressure 3768
4 6 2 Checking oil pressure for piston spray jets 3770
4 7 Removing and installing piston cooling jet control valve -N522- 3772
4 8 Removing and installing valve for oil pressure control -N428- 3772
19 – Cooling 3774
1 Cooling system/coolant 3774
1 1 Connection diagram – coolant hoses 3774
1 1 1 Connection diagram – coolant hoses, vehicles with manual gearbox 3774
1 1 2 Coolant hose schematic diagram, vehicles with dual clutch gearbox, without circulation pump -V55- 3776
1 1 3 Coolant hose schematic diagram, vehicles with dual clutch gearbox, with circulation pump -V55- 3778
1 1 4 Coolant hose schematic diagram, vehicles with dual clutch gearbox and auxiliary radiator 3780
1 2 Checking cooling system for leaks 3781
1 3 Draining and filling cooling system 3784
2 Coolant pump, regulation of cooling system 3792
2 1 Assembly overview –coolant pump, thermostat 3792
2 2 Assembly overview – electric coolant pump 3795
2 2 1 Assembly overview – auxiliary pump for heating -V488-, coolant shut-off valve -N82- 3795
2 2 2 Assembly overview – coolant valve for gearbox -N488-, vehicles with 6-speed dual clutch gearbox or automatic gearbox 3795
2 2 3 Assembly overview – coolant valve for gearbox -N488-, vehicles with 7-speed dual clutch gearbox 3796
2 2 4 Assembly overview – gearbox oil cooling pump -V478- 3797
2 3 Assembly overview – coolant temperature sender 3798
2 4 Removing and installing electric coolant pump 3799
2 4 1 Removing and installing auxiliary pump for heating -V488- 3799
2 5 Removing and installing coolant valves 3802
2 5 1 Removing and installing coolant shut-off valve -N82- 3802
2 5 2 Removing and installing coolant valve for gearbox -N488-, vehicles with 6-speed dual clutch gearbox 3804
2 5 3 Removing and installing coolant valve for gearbox -N488-, vehicles with 7-speed dual clutch gearbox 3806
2 5 4 Removing and installing coolant valve for gearbox -N488-, vehicles with automatic gearbox 3807
2 6 Removing and installing coolant pump 3809
2 7 Removing and installing toothed belt for coolant pump 3812
2 8 Removing and installing actuator for engine temperature regulation -N493- 3815
2 9 Removing and installing coolant temperature sender -G62- 3817
2 10 Removing and installing radiator outlet coolant temperature sender -G83- 3818
3 Coolant pipes 3820
3 1 Assembly overview – coolant pipes 3820
3 2 Removing and installing coolant pipes 3820
3 2 1 Removing and installing front coolant pipes 3820
3 3 Removing and installing upper coolant pipes 3822
3 4 Removing and installing coolant pipes for gearbox 3823
4 Radiator, radiator fan 3826
4 1 Assembly overview – radiator/radiator fan 3826
4 2 Assembly overview – auxiliary radiator 3828
4 3 Assembly overview – radiator cowl and radiator fans 3829
4 4 Removing and installing radiator 3830
4 5 Removing and installing radiator cowl 3832
4 6 Removing and installing radiator fan 3834
4 6 1 Removing and installing radiator fan -V7- 3834
4 6 2 Removing and installing radiator fan -V177- 3834
4 7 Removing and installing auxiliary radiator 3835
21 – Turbocharging/supercharging 3838
1 Turbocharger 3838
1 1 Assembly overview – turbocharger 3838
1 2 Removing and installing turbocharger 3841
1 3 Adjusting charge pressure positioner -V465- 3847
1 4 Removing and installing turbocharger air recirculation valve -N249- 3849
2 Charge air system 3850
2 1 Assembly overview – charge air system 3850
2 2 Assembly overview – hose connections for charge air system 3852
2 3 Removing and installing charge air cooler 3852
2 4 Removing and installing charge pressure sender -G31- 3855
2 5 Checking charge air system for leaks 3856
2 6 Removing and installing air intake pipe 3858
2 6 1 Removing and installing air intake pipe between turbocharger and charge air cooler 3858
2 6 2 Removing and installing air intake pipe between charge air cooler and intake manifold 3859
24 – Mixture preparation – injection 3861
1 Injection system 3861
1 1 Overview of fitting locations – injection system 3861
1 1 1 Overview of fitting locations – engine compartment 3861
1 1 2 Overview of fitting locations – injection system, components in vehicle 3865
1 1 3 Overview of fitting locations – engine, top 3872
1 1 4 Overview of fitting locations – engine, inlet side 3873
1 1 5 Overview of fitting locations – engine, pulley side 3875
1 1 6 Overview of fitting locations – engine, gearbox side 3875
1 2 Reducing fuel pressure in high-pressure section 3876
2 Injectors 3878
2 1 Assembly overview – fuel rail with injectors 3878
2 1 1 Assembly overview – fuel rail with injectors, direct injection 3878
2 1 2 Assembly overview – fuel rail with injectors, indirect injection 3879
2 2 Removing and installing fuel rail 3880
2 3 Removing and installing injectors 3881
2 3 1 Removing and installing injectors, direct injection 3881
2 3 2 Removing and installing injectors, indirect injection 3886
2 4 Renewing seals on injector 3889
2 5 Cleaning injectors 3892
3 Air filter 3894
3 1 Assembly overview – air filter housing 3894
3 2 Removing and installing air filter housing 3896
3 3 Removing and installing air guide on lock carrier 3898
4 Intake manifold 3900
4 1 Assembly overview – intake manifold 3900
4 2 Assembly overview – lower part of intake manifold with fuel rail 3902
4 2 1 Assembly overview – lower part of intake manifold with fuel rail, direct injection 3902
4 3 Removing and installing intake manifold 3904
4 4 Removing and installing throttle valve module -GX3- 3911
4 5 Cleaning throttle valve module 3913
4 6 Checking intake manifold change-over function 3914
5 Senders and sensors 3917
5 1 Assembly overview – actuator for structure-borne sound and control unit for structure-borne sound 3917
5 2 Removing and installing fuel pressure sender -G247- 3919
5 3 Checking fuel pressure sender -G247- 3921
5 4 Removing and installing fuel pressure sender for low-pressure -G410- 3925
5 5 Removing and installing intake manifold sender -GX9- 3927
6 Engine/motor control unit 3928
6 1 Assembly overview – motor control unit 3928
6 2 Removing and installing motor control unit -J623- 3928
6 2 1 Removing and installing engine control unit -J623- without protective housing 3928
6 2 2 Removing and installing engine control unit -J623- with protective housing 3930
7 High-pressure pump 3934
7 1 Assembly overview – high-pressure pump 3934
7 2 Removing and installing high-pressure pump 3936
7 3 Removing and installing high-pressure pipe 3941
8 Lambda probe 3945
8 1 Assembly overview – lambda probe 3945
8 2 Removing and installing lambda probe 3946
8 2 1 Removing and installing Lambda probe 1 before catalytic converter -GX10- 3946
8 2 2 Removing and installing Lambda probe 1 after catalytic converter -GX7- 3947
26 – Exhaust system 3950
1 Exhaust pipes and silencers 3950
1 1 Assembly overview – silencers 3950
1 1 1 Silencer 3950
1 2 Separating exhaust pipes from silencers 3952
1 2 1 Separating exhaust pipes from silencers 3952
1 3 Removing and installing silencer 3955
1 3 1 Removing and installing silencer 3955
1 4 Aligning exhaust system free of stress 3956
1 5 Checking exhaust system for leaks 3957
1 6 Installation position of clamp 3958
1 6 1 Installation position of front clamping sleeve 3958
1 6 2 Installation position of rear clamp 3958
1 6 3 Specified torque for clamp 3959
2 Emission control 3960
2 1 Assembly overview – emission control 3960
2 1 1 Assembly overview – emission control, without particulate filter 3960
2 1 2 Assembly overview – emission control, with particulate filter 3962
2 2 Removing and installing catalytic converter 3965
2 3 Removing and installing particulate filter 3971
3 Secondary air system 3972
3 1 Assembly overview – secondary air system 3972
3 2 Removing and installing secondary air pump motor -V101- 3972
3 3 Removing and installing secondary air inlet valve -N112- 3973
28 – Ignition system 3975
1 Ignition system 3975
1 1 Assembly overview – ignition system 3975
1 2 Test data – spark plugs 3977
1 3 Removing and installing ignition coils with output stage 3977
1 4 Removing and installing knock sensor 1 -G61- 3979
1 5 Removing and installing Hall sender 3980
1 5 1 Removing and installing Hall sender -G40- 3980
1 5 2 Removing and installing Hall sender 3 -G300- 3981
1 6 Removing and installing engine speed sender -G28- 3981
00 – Technical data 3987
1 Identification of gearbox 3987
1 1 Location on gearbox 3987
1 2 Identification code, assembly allocation and capacities 3988
2 Overview – power transmission 3989
3 Calculating overall gear ratio “i” 3991
4 General repair instructions 3992
4 1 Components 3992
4 1 1 Gearbox 3992
4 1 2 O-rings, seals and gaskets 3992
4 1 3 Sealant 3993
4 1 4 Locking devices 3993
4 1 5 Nuts and bolts 3994
4 1 6 Bearings 3994
4 1 7 Shims 3995
4 1 8 Synchro-rings 3995
4 1 9 Gear wheels 3996
4 1 10 Synchromeshed gears 3996
4 1 11 Clutch 3996
30 – Clutch 3997
1 Fault finding, power transmission 3997
2 Repairing clutch mechanism 3998
2 1 Overview 3998
2 2 Assembly overview – pedal cluster 3998
2 3 Removing and installing over-centre spring (left-hand drive) 4000
2 3 1 Removing 4001
2 3 2 Installing 4004
2 3 3 Specified torques 4006
2 4 Removing and installing over-centre spring (right-hand drive) 4006
2 4 1 Removing 4007
2 4 2 Installing 4010
2 4 3 Specified torques 4012
2 5 Removing and installing clutch pedal (LHD) 4012
2 5 1 Removing 4013
2 5 2 Installing 4016
2 5 3 Specified torques 4019
2 6 Removing and installing clutch pedal (RHD) 4019
2 6 1 Removing 4020
2 6 2 Installing 4023
2 6 3 Specified torques 4026
2 7 Removing and installing mounting bracket (LHD) 4026
2 7 1 Removing 4027
2 7 2 Installing 4031
2 7 3 Specified torques 4033
2 8 Removing and installing mounting bracket (RHD) 4033
2 8 1 Removing 4034
2 8 2 Installing 4039
2 8 3 Specified torques 4041
2 9 Removing and installing clutch master cylinder 4041
2 9 1 Removing 4041
2 9 2 Installing 4042
2 10 Removing and installing clutch position sender -G476- 4043
2 10 1 Removing 4044
2 10 2 Installing 4046
2 11 Assembly overview – hydraulics (LHD) 4047
2 12 Assembly overview – hydraulics (RHD) 4049
2 13 Removing and installing clutch slave cylinder 4051
2 13 1 Removing 4051
2 13 2 Installing 4053
3 Bleeding clutch mechanism 4054
4 Repairing clutch release mechanism 4056
4 1 Assembly overview – clutch release mechanism 4056
4 2 Removing and installing clutch release lever, release bearing and guide sleeve 4057
5 Repairing clutch 4059
34 – Controls, housing 4065
1 Repairing selector mechanism 4065
1 1 Installation position of selector mechanism 4065
1 2 Overview of selector mechanism 4066
1 3 Assembly overview – gear knob and cover 4066
1 4 Removing and installing gaiter with gear knob and noise insulation 4067
1 5 Assembly overview – Gear lever and selector housing 4069
1 5 1 Dismantling and assembling selector mechanism 4071
1 6 Assembly overview – selector cables 4079
1 7 Removing cable end-piece from relay lever and installing 4084
1 8 Removing and installing selector mechanism 4086
1 8 1 Removing selector mechanism 4086
1 8 2 Installing selector mechanism 4090
1 9 Removing and installing gear selector cable and gate selector cable 4094
1 9 1 Removing 4094
1 9 2 Installing 4095
1 10 Adjusting selector mechanism 4096
1 10 1 Function 4099
2 Removing and installing gearbox, Jetta 2011 ► 4100
2 1 Removing gearbox, Jetta 2011 with 1 2 l engine and 1 4 l engine 4100
2 2 Installing gearbox, Jetta 2011 with 1 2 l engine and 1 4 l engine 4113
2 2 1 Specified torques 4121
3 Transporting gearbox 4123
4 Checking gear oil 4125
5 Securing to engine and gearbox support 4127
6 Dismantling and assembling gearbox 4129
6 1 Overview – gearbox 4129
6 2 Assembly overview 4129
6 3 Assembly overview – Removing and installing cover for gearbox housing and 5th and 6th gears 4130
6 4 Assembly overview – removing and installing clutch housing 4132
6 5 Assembly overview – removing and installing input shaft, output shaft, differential, selector mechanism and selector forks 4133
6 6 Assembly sequence 4135
6 6 1 Dismantling gearbox 4139
6 6 2 Assembling gearbox 4147
7 Repairing gearbox housing and clutch housing 4159
8 Assembly overview – gearbox housing cover 4163
9 Repairing gearbox housing cover 4165
10 Repairing selector unit 4168
11 Dismantling and assembling selector forks 4171
35 – Gears, shafts 4177
1 Input shaft 4177
1 1 Dismantling and assembling input shaft 4177
2 Output shaft 4191
2 1 Dismantling and assembling output shaft 4191
39 – Final drive – differential 4202
1 Renewing flange shaft oil seals with gearbox installed 4202
1 1 Renewing oil seal for left flange shaft 4202
1 1 1 Removing 4202
1 1 2 Installing 4203
1 2 Renewing seal for right flange shaft 4204
1 2 1 Removing 4205
1 2 2 Installing 4205
2 Differential 4207
2 1 Dismantling and assembling differential 4207
2 2 Adjusting differential 4215
2 2 1 Determining thickness of shim 4218
00 – Technical data 4223
1 Identification of gearbox 4223
1 1 Location on gearbox 4223
1 2 Identification code, assembly allocation and capacities 4223
2 Overview – power transmission 4225
3 Calculating overall gear ratio “i” 4227
4 General repair instructions 4228
4 1 Components 4228
4 1 1 Gearbox 4228
4 1 2 O-rings, seals, gaskets and sealants 4228
4 1 5 Bearings 4230
4 1 7 Synchro-rings 4230
4 1 8 Gears, synchro-hubs, sleeves for needle bearings 4230
4 1 9 Synchromeshed gears 4231
4 1 10 Clutch 4231
30 – Clutch 4232
1 Fault finding, power transmission 4232
2 Repairing clutch mechanism 4233
2 1 Overview 4233
2 2 Assembly overview – pedal cluster 4234
2 3 Removing and installing over-centre spring 4235
2 3 1 Removing 4236
2 3 2 Installing 4238
2 3 3 Specified torques 4240
2 4 Removing and installing clutch pedal 4240
2 4 1 Removing 4241
2 4 2 Installing 4244
2 4 3 Specified torques 4246
2 5 Removing and installing mounting bracket 4246
2 5 1 Removing 4247
2 5 2 Installing 4250
2 5 3 Specified torques 4252
2 6 Removing and installing clutch master cylinder 4252
2 6 1 Removing 4252
2 6 2 Installing 4253
2 7 Removing and installing clutch position sender -G476- 4254
2 7 1 Removing 4254
2 7 2 Installing 4256
2 8 Assembly overview – hydraulics (LHD) 4256
2 9 Assembly overview – hydraulics (RHD) 4259
2 10 Removing and installing clutch slave cylinder 4260
2 10 1 Removing 4260
2 10 2 Installing 4261
3 Bleeding clutch mechanism 4263
4 Repairing clutch release mechanism 4265
4 1 Assembly overview – clutch release mechanism 4265
4 2 Removing and installing clutch release lever, release bearing and guide sleeve 4266
5 Repairing clutch 4267
34 – Controls, housing 4270
1 Repairing selector mechanism 4270
1 1 Installation position of selector mechanism 4270
1 2 Overview of selector mechanism 4271
1 3 Assembly overview – gear knob and cover 4272
1 4 Removing and installing gaiter with gear knob and noise insulation 4272
1 5 Assembly overview – selector lever and selector housing (up to 10 06) 4274
1 6 Assembly overview – selector lever and selector housing (from 11 06) 4276
1 6 1 Dismantling and assembling selector mechanism 4278
1 7 Assembly overview – Selector cables 4283
1 8 Removing and installing selector mechanism 4287
1 8 1 Removing 4287
1 9 Removing and installing gear selector cable and gate selector cable 4291
1 9 1 Removing 4291
1 9 2 Installing 4292
1 10 Adjusting selector mechanism 4293
1 10 1 Function 4295
1 11 Plastic relay lever 4295
2 Removing and installing gearbox, Jetta 2011 ► 4299
2 1 Removing gearbox, Jetta 2011 with 1 6 l engine and 2 0 l engine 4299
2 2 Installing gearbox, Jetta 2011 with 1 6 l engine and 2 0 l engine 4308
2 2 1 Specified torques 4314
3 Transporting gearbox 4316
4 Checking gear oil 4318
5 Dismantling and assembling gearbox 4320
5 1 Overview – gearbox 4320
5 2 Assembly overview 4321
5 3 Assembly overview – removing and installing cover for gearbox housing and 5th gear 4322
5 4 Assembly overview – removing and installing clutch housing 4323
5 5 Assembly overview – removing and installing input shaft, output shaft, differential, selector mechanism and selector forks 4324
5 6 Dismantling and assembling procedure 4325
5 6 1 Dismantling gearbox 4328
5 6 2 Assembling gearbox 4331
6 Repairing gearbox housing and clutch housing 4336
7 Repairing selector unit 4341
8 Dismantling and assembling selector forks 4344
35 – Gears, shafts 4349
1 Input shaft 4349
1 1 Dismantling and assembling input shaft 4349
2 Output shaft 4360
2 1 Dismantling and assembling output shaft 4360
39 – Final drive – rear differential 4368
1 Renewing flange shaft oil seals with gearbox installed 4368
1 1 Renewing oil seal for left flange shaft 4368
1 1 1 Removing 4368
1 1 2 Installing 4369
1 2 Renewing seal for right flange shaft 4370
1 2 1 Removing 4370
1 2 2 Installing 4371
2 Differential 4372
2 1 Dismantling and assembling differential 4372
2 2 Adjusting differential 4380
2 2 1 Determining shim S2 4383
00 – Technical data 4388
1 Safety information 4388
1 1 General safety provisions 4388
1 2 Safety measures when working on vehicles with a start/stop system 4388
1 3 Safety precautions when using testers and measuring instruments during a road test 4389
2 Identification of gearbox 4390
3 Overview – power transmission 4391
4 Code, engine allocation 4392
5 Capacities 4393
6 Notes on tow-starting/towing 4394
7 General repair instructions 4395
7 1 Tools 4395
7 2 Gearbox 4395
7 3 Working with vehicle diagnostic testers 4400
7 3 1 Adapting installation information 4400
7 3 2 Reading measured values for mandatory reporting 4400
7 3 3 Initiating basic adjustment 4400
30 – Clutch 4402
1 Removing and installing dual clutch, gearboxes made up to 05 2011 4402
1 1 Assembly overview – dual clutch, gearboxes manufactured up to 05 2011 4402
1 2 Removing dual clutch, gearboxes manufactured up to 05 2011 4404
1 3 Adjusting position of engagement bearings for clutches “K 1” and “K 2”, gearboxes made up to 05 2011 4408
1 4 Installing dual clutch, gearboxes made as of 05 2011 4420
2 Removing and installing dual clutch, gearboxes made from 06 2011 onwards 4427
2 1 Assembly overview – dual clutch, gearboxes made as of 06 2011 4427
2 2 Removing dual clutch, gearboxes made as of 06 2011 4429
2 3 Adjusting position of engagement bearings for clutches “K 1” and “K 2”, gearboxes made as of 06 2011 4433
2 4 Installing dual clutch, gearbox date from 06 2011 4445
3 Removing and installing oil seals at clutch end 4452
34 – Controls, housing 4455
1 Gear oil 4455
1 1 Renewing gear oil 4455
1 2 Draining and filling hydraulic fluid for mechatronic unit 4459
2 Selector mechanism 4462
2 1 Overview – selector mechanism in vehicles up to 02 2009 4462
2 2 Removing and installing selector lever cable – vehicles up to 02 2009 4464
2 3 Overview of selector mechanism – vehicles from 03 2009 onwards 4472
2 4 Removing and installing selector mechanism – vehicles as of 03 2009 4473
2 4 1 Removing and installing selector mechanism with selector housing 4473
2 4 2 Removing and installing selector mechanism without selector housing 4477
2 5 Checking selector lever cable 4480
2 6 Adjusting selector lever cable 4480
2 7 Emergency release of selector lever 4483
2 8 Removing and installing selector lever knob 4483
2 9 Moving push-button in the handle to installation position 4486
2 9 1 Handle with push-button on side 4486
2 9 2 Handle with front push-button 4486
2 10 Checking selector mechanism 4487
3 Mechatronic unit for dual clutch gearbox -J743- 4489
3 1 Safety note on mechatronic unit for dual clutch gearbox -J743- 4489
3 2 Overview – mechatronic unit 4490
3 3 Removing mechatronic unit for dual clutch gearbox -J743- with gearbox installed 4491
3 4 Moving mechatronic unit for dual clutch gearbox -J743- into »removal position« by hand 4502
3 5 Installing mechatronic unit for dual clutch gearbox -J743- 4506
3 6 View of selector forks with mechatronic unit removed 4512
3 7 Renewing clutch actuator 4513
4 Removing and installing gearbox 4519
4 1 Removing gearbox 4519
4 1 1 Removing gearbox, vehicles with TFSI engine (EA111) 4519
4 1 2 Removing gearbox, vehicles with TFSI engine (EA211) 4529
4 2 Installing gearbox 4536
4 3 Specified torques 4540
4 3 1 Assembly mountings 4540
4 3 2 Gearbox to TFSI engine (EA 111) 4540
4 3 3 Gearbox to TFSI engine (EA 211) 4541
4 3 4 Engine: 1 6 l/77 kW TDI common rail 4542
5 Transporting gearbox and securing to assembly stand 4543
35 – Gears, shafts 4547
1 Dismantling and assembling gears and shafts 4547
2 Parking lock 4548
2 1 Removing and installing cover for parking lock 4548
2 2 Removing and installing parking lock 4549
39 – Final drive – front differential 4551
1 Oil seals 4551
1 1 Overview of fitting locations – seals 4551
1 2 Renewing oil seal for right stub shaft 4552
1 3 Renewing oil seal for left stub shaft 4554
1 4 Renewing seal for right flange shaft 4557
1 5 Renewing oil seal for left flange shaft 4560
00 – Technical data 4569
1 General repair notes 4569
1 1 Torque converter 4569
1 2 ATF 4569
1 3 Automatic gearbox control unit -J217- with ⇒ fuzzy logic 4569
1 4 Control units in vehicle 4569
1 5 Information on “09G gearbox” 4569
1 6 Tools 4569
1 7 Gearbox 4570
1 8 Gaskets, seals and oil 4571
1 9 Nuts and bolts 4571
1 10 Electrical components 4572
1 11 Guided fault finding, vehicle self-diagnosis and testing 4572
1 12 Safety precautions 4572
2 Gearbox identification 4573
2 1 Gearbox codes 4573
3 Capacities 4574
3 1 Planetary gearbox and final drive 4574
4 Code – engine allocation 4575
32 – Torque converter 4576
1 Assembly overview – torque converter 4576
1 1 Removing and installing torque converter 4577
1 2 Checking torque converter 4577
1 3 Draining torque converter 4578
1 4 Removing and installing torque converter oil seal 4578
37 – Controls, housing 4580
1 Connecting »tester« 4580
2 Electrical and electronic components and their locations 4581
3 Multifunction switch -F125- 4586
3 1 Removing multifunction switch -F125- 4586
3 2 Installing multifunction switch -F125- 4587
3 3 Adjusting multifunction switch -F125- 4588
4 Selector mechanism 4590
4 1 Overview – selector mechanism, vehicles 4590
4 2 Removing and installing selector mechanism – vehicles 4591
4 2 1 Removing and installing selector mechanism with selector housing 4591
4 2 2 Removing and installing selector mechanism without selector housing 4594
4 3 Checking selector lever cable 4597
4 4 Adjusting selector lever cable 4598
4 5 Emergency release of selector lever 4599
4 6 Removing and installing selector lever knob 4600
4 7 Moving push button to installation position in the handle 4603
4 7 1 Handle with pushbutton on side 4603
4 7 2 Handle with front pushbutton 4603
4 8 Checking selector mechanism 4604
4 8 1 Selector lever in “P” position and ignition switched on 4604
4 8 2 Selector lever in “N” position and ignition switched on 4605
4 8 3 Selector lever in position “Tiptronic” 4605
4 8 4 Ignition and light switched on 4605
4 8 5 Selector lever position display 4605
5 Removing and installing gearbox, Jetta 2011 ► 4606
5 1 Removing gearbox, Jetta 2011 with 1 6 l – 77 kW engine 4606
5 2 Removing gearbox, Jetta 2011 with 2 0 l – 85 kW engine 4614
5 3 Removing gearbox, Jetta 2011 with 2 5 l – 125 kW engine 4623
5 4 Installing gearbox, Jetta 2011 4634
5 5 Torque settings, gearbox to engine 4636
5 5 1 Torque settings, Jetta 2011 with 1 6 l – 77 kW engine 4636
5 5 2 Torque settings, Jetta 2011 with 2 0 l – 85 kW engine 4638
5 5 3 Torque settings, Jetta 2011 with 2 5 l – 125 kW engine 4639
6 Transporting gearbox 4640
7 Attaching gearbox on engine and gearbox support 4641
8 ATF cooler 4643
8 1 Assembly overview – ATF cooler 4643
9 Checking ATF level and topping up 4644
9 1 Checking ATF level 4646
9 2 Topping up ATF 4647
9 3 Draining and filling ATF 4648
38 – Gears, control 4650
1 Renewing oil seal for selector shaft 4650
2 Oil pan 4651
2 1 Removing and installing oil pan 4651
2 1 1 Removing 4651
2 1 2 Installing 4652
3 ATF strainer 4654
3 1 Removing and installing ATF strainer 4654
3 1 1 Removing 4654
3 1 2 Installing 4654
4 Valve body 4655
4 1 Assembly overview 4655
4 1 1 Specified torques 4658
4 1 2 Wire routing, connectors, connections and retainer on valve body 4658
4 2 Removing and installing valve body 4660
4 2 1 Removing 4661
4 2 2 Installing 4665
4 3 Removing and installing wiring harness for solenoid valves (14-pin connector) 4668
4 3 1 Removing 4668
4 3 2 Installing 4669
4 4 Removing and installing wiring harness for sender (8-pin connector) 4669
4 4 1 Removing 4669
4 4 2 Installing 4669
4 5 Removing and installing gearbox input speed sender -G182- 4670
4 5 1 Removing 4670
4 5 2 Installing 4670
4 6 Removing and installing gearbox output speed sender -G195- 4670
4 6 1 Removing 4670
4 6 2 Installing 4671
39 – Final drive – differential 4672
1 Renewing oil seals for flange shafts 4672
1 1 Overview of fitting locations – seals 4672
1 2 Renewing oil seal for left flange shaft 4672
1 3 Renewing seal for right flange shaft 4674
80 – Heating 4681
1 Repairing heating system 4681
1 1 Heating, passenger compartment (Jetta 2011►) 4681
1 2 Removing fresh air blower -V2- 4682
1 2 1 Removing 4682
1 3 Removing and installing fresh air blower series resistor with overheating fuse -N24- 4683
1 4 Removing and installing dust and pollen filter 4684
1 4 1 Removing and installing dust and pollen filter 4684
1 4 2 Removing and installing filter element for fresh air intake 4684
1 5 Removing vent (Jetta 2011►) 4685
1 5 1 Removing and installing trim for front left dash panel vent and centre vent 4685
1 5 2 Removing and installing dash panel vents on right 4687
1 5 3 Removing and installing right and left rear footwell air ducts 4688
1 5 4 Removing right footwell vent 4689
1 5 5 Removing and installing left footwell vent 4689
1 6 Removing and installing controls for heated and fresh air 4690
1 7 Connectors on controls for heated and fresh air 4691
1 7 1 Pin assignment for multi-pin connectors on back of controls for heated and fresh air 4691
1 8 Removing and installing flexible shaft for air distribution 4692
1 8 1 Check 4692
1 9 Removing and installing Bowden cable for temperature flap 4693
1 9 1 Removing 4693
1 9 2 Installing 4693
1 10 Removing and installing fresh air and air recirculation flap control motor -V154- 4694
1 10 1 Removing 4694
1 10 2 Installing 4694
1 11 A 4694
1 11 1 A 4694
1 12 Removing and installing heat exchanger 4694
1 12 1 Removing 4695
1 12 2 Installing 4696
1 13 Removing and installing auxiliary air heater element -Z35-, vehicles ► 1K-7M 119 726 4698
1 13 1 Removing 4698
1 13 2 Installing 4698
1 14 Checking, removing and installing auxiliary air heater element -Z35-, vehicles 1K-7M 119 727 ► 4699
1 14 1 Checking auxiliary air heater element -Z35- with peripherals 4699
1 14 2 Checking auxiliary air heater element -Z35- 4699
1 14 3 Conditions for testing 4699
1 14 4 Test sequence 4699
1 14 5 Removing and installing 4700
1 15 Checking ventilation 4701
1 15 1 Check 4701
1 16 Removing and installing air intake grille 4701
1 16 1 Removing 4701
1 16 2 Installing 4702
1 17 Removing and installing heater unit 4702
1 17 1 Removing 4703
2 Dismantling and assembling heater unit 4706
2 1 Dismantling and assembling heater unit 4706
2 2 Removing and installing air distribution housing 4707
2 2 1 Removing 4707
2 2 2 Installing 4708
2 3 Dismantling and assembling heater unit 4708
2 3 1 Dismantling 4708
2 3 2 Installing 4709
2 4 Removing and installing air distribution flap actuator 4709
2 4 1 Removing 4709
2 5 Removing and installing temperature flap actuator 4709
2 5 1 Removing 4709
2 5 2 Installing 4710
2 6 Removing and installing air distribution housing lever 4710
87 – Air conditioning system 4712
1 Notes on repair work to vehicles with air conditioning and on handling refrigerant 4712
2 Notes for vehicles with a start/stop system 4713
3 Overview of fitting locations – air conditioning system 4714
3 1 Overview of fitting locations – components not located in passenger compartment 4714
4 Air conditioning system with manual controls 4716
4 1 Air conditioning and heating – passenger compartment 4716
4 2 Removing and installing heater and air conditioner unit (manually operated air conditioning system) 4717
4 2 1 Removing 4718
4 3 Dismantling and assembling heater and air conditioning unit (manually operated air conditioning system) 4722
4 4 Removing and installing heating and air conditioning system controls (manually operated air conditioning system) 4723
4 4 1 Removing 4723
4 4 2 Installing 4724
4 5 Connectors on controls for heating and air conditioning system (manually operated air conditioning system) 4724
4 5 1 Pin assignment for multi-pin connectors on back of controls for heating and air conditioning system (manually operated air conditioning system) 4724
4 6 Removing and installing flexible shaft 4725
4 6 1 Removing 4725
4 6 2 Check 4725
4 7 Checking condensation drain hose on heater and air conditioner unit 4726
4 8 Removing and installing air recirculation flap control motor -V113- 4726
4 8 1 Removing 4726
4 8 2 Installing 4726
4 9 Removing and installing temperature flap control motor -V68- 4726
4 9 1 Removing 4726
4 9 2 Installing 4727
4 10 Removing and installing footwell vent temperature sender -G192- 4728
4 10 1 Removing 4728
4 10 2 Installing 4729
4 11 Removing and installing centre vent temperature sender -G191- 4729
4 11 1 Removing 4729
4 11 2 Installing 4729
5 Climatronic air conditioning with automatic regulation 4730
5 1 Procedure when checking and adjusting components 4730
5 2 Function of operating and display unit for Climatronic air conditioning system -E87- 4731
5 3 Removing and installing operating and display unit for Climatronic air conditioning system -E87- with Climatronic control unit -J255- 4732
5 3 1 Removing 4732
5 3 2 Installing 4733
5 4 Connectors on Climatronic control unit -J255- 4733
5 4 1 Pin assignment for multi-pin connectors A, B and C on back of Climatronic control unit -J255- 4733
5 5 Climatronic – passenger compartment 4734
5 6 Removing and installing fresh air blower control unit -J126- 4737
5 6 1 Removing 4737
5 6 2 Installing 4737
5 7 Removing and installing heater and air conditioning unit (Climatronic) 4737
5 7 1 Removing 4738
5 8 Dismantling and assembling heater and air conditioning unit 4742
5 9 Dismantling and assembling evaporator housing 4743
5 10 Removing and installing left footwell vent temperature sender -G261- 4744
5 10 1 Removing 4744
5 10 2 Installing 4745
5 11 Removing and installing right footwell vent temperature sender -G262- 4745
5 11 1 Removing 4745
5 11 2 Installing 4745
5 12 Removing and installing evaporator temperature sensor -G308- 4745
5 12 1 Removing 4745
5 12 2 Installing 4746
5 13 Removing left vent temperature sender -G150- and right vent temperature sender -G151- 4746
5 14 Removing sunlight penetration photosensor -G107- or sunlight penetration photosensor 2 -G134- 4746
5 14 1 Removing sunlight penetration photosensor -G107- or sunlight penetration photosensor 2 -G134- 4747
5 14 2 Removing sunlight penetration photosensor -G107- or sunlight penetration photosensor 2 -G134-, Jetta 2010▶ 4747
5 15 Checking condensation drain hose on heater and air conditioner unit 4747
5 16 Renewing control motors for air conditioning regulation 4747
5 17 Removing and installing fresh air and air recirculation flap control motor -V154- 4748
5 17 1 Removing 4748
5 17 2 Installing 4748
5 18 Removing and installing air flow flap control motor -V71- or fresh air/air recirculation, air flow flap control motor -V425- 4748
5 18 1 Removing 4748
5 18 2 Installing 4749
5 19 Removing and installing defroster flap control motor -V107- 4749
5 19 1 Removing 4749
5 19 2 Installing 4750
5 20 Removing and installing left temperature flap control motor -V158- 4750
5 20 1 Removing 4750
5 20 2 Installing 4751
5 21 Removing and installing right temperature flap control motor -V159- 4751
5 21 1 Removing 4751
5 21 2 Installing 4751
5 22 Removing and installing centre flap control motor -V70- 4752
5 22 1 Removing 4752
5 22 2 Installing 4752
6 Ancillary bracket for air conditioner compressor 4753
6 1 Removing and installing ancillary bracket for air conditioner compressor (Jetta 2011►) 4753
6 2 Removing and installing ancillary bracket for air conditioner compressor, engine codes BRM, BXE 4753
6 3 Removing and installing ancillary bracket for air conditioner compressor, engine codes BGP and BGQ 4755
6 4 Removing and installing ancillary bracket for air conditioner compressor, engine codes BPY, BWA, BSE, BSF, BLR, BLY 4757
7 Repair work on refrigerant circuit which may be performed only in appropriate workshops by specially trained mechanics 4760
7 1 Testing equipment and tools 4760
7 2 Renewing refrigerant circuit components 4762
7 2 1 Renewing components of refrigerant circuit (Golf Estate 2007►, Golf Estate 2010► and Jetta 2005►) 4762
7 2 2 Renewing refrigerant circuit components 4763
7 3 Removing high-pressure sender -G65- 4763
7 4 Removing and installing receiver with desiccant cartridge from Showa (FUJIKOKI) 4764
7 4 1 Removing 4764
7 4 2 Installing 4765
7 5 Removing and installing receiver with dryer (Modine dryer and strainer) 4765
7 5 1 Removing 4766
7 6 Air conditioner compressor 4767
7 6 1 Removing and installing air conditioner compressor 4767
7 6 2 Removing and installing electrical air conditioner compressor -V470-, engine codes CNLA and CRJA (hybrid) 4770
7 7 Compressor run-in 4771
7 8 Notes on installing air conditioner compressor 4771
7 9 Checking high-pressure safety valve on air conditioner compressor 4772
7 10 Expansion valve, function and removing 4773
7 10 1 Function 4775
7 11 Removing and installing evaporator 4775
7 12 A 4776
7 13 Removing and installing condenser (Jetta 2011►) 4776
7 14 Notes on installing air conditioner compressor 4778
7 14 1 Installing 4778
8 Capacities 4780
8 1 Refrigerant R134a 4780
8 2 Refrigerant oil 4780
8 2 1 Oil distribution 4781
00 – Technical data 4786
1 Repair instructions 4786
1 1 General repair instructions 4786
1 2 Notes on repair of CAN bus wiring 4786
91 – Communication 4787
1 Infotainment system 4787
1 1 Removing and installing magnetic field sender for compass 4787
2 Sound system 4788
2 1 Overview – Sound system 4788
2 1 1 Overview – sound system, 4 loudspeakers 4788
2 1 2 Overview – sound system, 6 loudspeakers 4790
2 1 3 Overview – sound system, 8 loudspeakers 4791
2 1 4 Overview – sound system, Volkswagen Sound 4792
2 1 5 Overview – sound system, Branded Sound 4793
2 2 Overview of fitting locations – sound system 4794
2 3 Removing and installing digital sound package control unit/amplifier 4794
2 3 1 Removing and installing amplifier -R12- 4794
2 4 Removing and installing rear treble loudspeakers -R14-/-R16- 4795
2 5 Removing and installing front treble loudspeakers -R20-/-R22- 4796
2 6 Removing and installing rear bass loudspeakers -R15-/-R17- 4797
2 7 Removing and installing front bass loudspeakers -R21-/-R23- 4798
2 8 Removing and installing subwoofer -R211- 4798
2 9 Connector pin assignment 4799
3 Aerial systems 4803
3 1 Overview – aerial systems 4803
3 2 Overview of fitting locations – aerial systems 4803
3 3 Removing and installing frequency modulation (FM) frequency filter R178/R179 4804
3 3 1 Removing and installing frequency modulation (FM) frequency filter in negative wire -R178- 4804
3 3 2 Removing and installing frequency modulation (FM) frequency filter in positive wire -R179- 4805
3 4 Removing and installing aerial amplifier 4805
3 5 Removing and installing roof aerial -RX5- 4806
3 6 Removing and installing aerials for vehicle location system 4807
4 Radio 4809
4 1 Overview – Radio 4809
4 2 Overview of fitting locations – radio 4827
4 3 Assembly overview – radio 4829
4 4 Removing and installing radio 4829
4 5 Connector pin assignment 4831
4 5 1 Connector pin assignment, RCD 210 4831
4 5 2 Connector pin assignment, RCD 030+ 4833
4 5 3 Connector pin assignment, RCD 310 4835
4 5 4 Connector pin assignment, RCD 300+ 4837
4 5 5 Connector pin assignment, Premium 8 4840
4 5 6 Connector pin assignment, RCD 510 4842
4 5 7 Connector pin assignment, RCD 510+ 4845
4 5 8 Connector pin assignment, RCD 320G 4848
5 Telephone system 4851
5 1 Components of telephone system 4851
5 1 1 Overview – telephone system, UTP High with Bluetooth 4851
5 1 2 Overview – telephone system, UTP Premium with Bluetooth and audio streaming 4852
5 1 3 Overview – telephone system, UTP in radio RNS 315 4853
5 1 4 Overview – telephone, UMI 4854
5 2 Overview of fitting locations – telephone system 4856
5 2 1 Overview of fitting locations – telephone system 4856
5 2 2 Overview of fitting locations – telephone system, UMI 4858
5 3 Removing and installing telephone microphone -R38- 4858
5 4 Removing and installing telephone bracket -R126- 4859
5 5 Removing and installing telephone transmitter and receiver unit 4860
5 6 Removing and installing mobile telephone operating electronics control unit -J412-, UMI 4861
5 6 1 Removing and installing mobile telephone operating electronics control unit -J412-, UMI control unit at glove compartment 4861
5 6 2 Removing and installing mobile telephone operating electronics control unit -J412-, UMI control unit in centre console 4862
5 7 Removing and installing operating unit for preparation for mobile phone 4864
5 8 Connector pin assignment 4865
6 Navigation system 4870
6 1 Overview – navigation system 4870
6 2 Overview of fitting locations – navigation system 4878
6 3 Connector pin assignment 4879
6 3 1 Connector pin assignment, RNS 315 4879
6 3 2 Connector pin assignment, RNS 315+ 4880
6 3 3 Connector pin assignment, RNS 510 4883
6 4 Removing and installing navigation system 4886
6 4 1 Removing and installing control unit with display for radio and navigation -J503- 4886
6 5 Removing and installing control unit for vehicle location system 4888
7 Reversing camera system 4889
7 1 Components of reversing camera system 4889
7 2 Overview of fitting locations – reversing camera system 4889
7 3 Removing and installing reversing camera -R189- 4890
8 Multifunction steering wheel 4892
8 1 Layout – multi-function steering wheel 4892
8 2 Overview – multifunction steering wheel 4892
8 3 Removing and installing steering wheel multifunction buttons -E441-/-E440- 4893
8 4 Removing and installing Tiptronic switch in steering wheel -E439-/-E438- 4894
9 Connection for external multimedia devices 4896
9 1 Overview – connection for external multimedia devices 4896
9 1 1 Overview – connection for external audio sources -R199-, AUX-IN 4896
9 1 2 Overview – multimedia system control unit -J650- 4898
9 1 4 Overview – multimedia system control unit -J650-, UMI 4900
9 2 Connectors, connection for external multimedia devices 4902
9 2 2 Connector of connection 2 for external audio sources -R231-, USB socket 4903
9 3 Removing and installing connection for external audio sources -R199- 4906
9 3 1 Removing and installing connection for external audio sources -R199-, centre console storage compartment 4906
9 3 2 Removing and installing connection 2 for external audio sources -R231-, USB socket 4907
9 3 3 Removing and installing multimedia system control unit -J650-, control unit on glove compartment 4908
9 3 4 Removing and installing multimedia system control unit -J650-, control unit in centre console 4909
9 3 5 Removing and installing multimedia system control unit -J650-, UMI control unit at glove compartment 4910
9 3 6 Removing and installing multimedia system control unit -J650-, UMI control unit in centre console 4911
9 3 7 Removing and installing connection for adapter cable specific to end device 4913
10 Mobile online services 4915
10 1 Overview – Mobile Online Services 4915
10 2 Overview of fitting locations – mobile online services 4916
10 3 Connectors of control unit for emergency call module and communication unit -J949- 4916
10 4 Removing and installing control unit for emergency call module and communication unit -J949- 4917
00 – Technical data 4925
1 Basic instructions 4925
2 Vehicle identification data 4926
2 1 Vehicle identification number 4926
2 2 Type plate 4927
2 3 Vehicle data sticker 4928
3 Safety information 4929
4 Body work for which voltage system must be de-energised 4930
4 1 The high-voltage system must be de-energised before carrying out the body work described below 4930
5 Moulded foam inserts 4931
6 Galvanized body parts, high- and higher-strength and hot-formed body panels 4933
6 1 Installing 4933
6 2 Overview of vehicle »NAR« 4935
6 3 Overview of vehicle »ROW (Rest of the World)« 4938
7 Body panel gaps/shut lines 4941
7 1 Body, front 4941
7 2 Body, centre 4942
7 3 Body, rear 4943
8 Body dimensions 4944
8 1 Body, front 4944
8 2 Body, centre 4947
8 3 Body, rear 4954
8 4 Floor panel – front 4956
8 5 Floor panel – centre 4958
8 6 Floor panel – rear 4959
9 Contour correct surfaces 4961
10 Tools 4962
11 Measurement and alignment systems, alignment bracket set 4963
11 1 Setup overview of complete body 4963
11 2 Procedure for structural damage on body 4964
12 Measurement and alignment systems, portal gauge 4965
12 1 Setup overview of complete body 4965
50 – Body – front 4967
1 Renewing right bracket 4967
1 1 Tools 4967
1 2 Removing 4967
1 3 Installing 4969
1 3 1 Welding in 4969
2 Renewing left bracket 4971
2 1 Tools 4972
2 2 Removing 4972
2 3 Installing 4974
2 3 1 Preparing new part 4974
2 3 2 Welding in 4975
3 Renewing subframe 4976
3 1 Tools 4976
3 2 Removing 4976
3 3 Installing 4978
3 3 1 Preparing new part 4978
3 3 2 Welding in 4979
4 Renewing bumper bracket 4980
4 1 Tools 4981
4 2 Removing 4981
4 3 Installing 4982
4 3 1 Welding in 4982
5 Renewing upper wheel housing longitudinal member 4984
5 1 Tools 4985
5 2 Removing 4985
5 3 Installing 4988
5 3 1 Preparing new part 4988
5 3 2 Welding in 4989
6 Renewing front wheel housing 4995
6 1 Tools 4996
6 2 Removing 4996
6 3 Installing 4997
6 3 1 Preparing new parts 4997
6 3 2 Welding in 4999
7 Repairing threads for securing subframe 5001
7 1 Contents of thread repair kit 5003
7 2 Repairing threads 5003
7 2 1 Drilling threads 5003
7 2 2 Cutting thread 5004
7 2 3 Inserting thread insert 5005
8 Renewing front longitudinal member 5007
8 1 Tools 5008
8 2 Removing 5008
8 3 Installing 5010
8 3 1 Preparing new part 5010
8 3 2 Welding in 5011
9 Renewing front longitudinal member – part section 5014
9 1 Tools 5015
9 2 Removing 5015
9 3 Installing 5017
9 3 1 Preparing new part 5017
9 3 2 Welding in 5018
9 3 3 Shortening new longitudinal member with cover plate 5022
10 Renewing front right longitudinal member – part section 5026
10 1 Tools 5027
10 2 Removing 5027
10 3 Installing 5029
10 3 1 Preparing new part 5029
10 3 2 Welding in 5030
51 – Body – centre 5034
1 Renewing roof – vehicles with no sliding/tilting sunroof 5034
1 1 Tools 5035
1 2 Removing 5036
1 3 Installing 5039
1 3 1 Preparing new part 5039
1 3 2 Adjusting roof depth 5041
1 3 3 Bonding in 5042
1 3 4 Welding in 5048
2 Renewing roof – vehicles with sliding/tilting sunroof 5050
2 1 Tools 5051
2 2 Removing 5052
2 3 Installing 5056
2 3 1 Preparing new part 5056
2 3 2 Setting the depth dimension 5058
2 3 3 Bonding in 5059
2 3 4 Welding in 5065
3 Renewing roof side member 5068
3 1 Tools 5069
3 2 Removing 5069
3 3 Installing 5071
3 3 1 Preparing new part 5071
3 3 2 Moulded foam inserts 5072
3 3 3 Welding in 5073
4 Renewing front cross member for roof 5076
4 1 Tools 5077
4 2 Removing 5077
4 3 Installing 5078
4 3 1 Welding in 5078
5 Renewing roof reinforcement – vehicles for NAR, with no sliding/tilting sunroof 5080
5 1 Tools 5081
5 2 Removing 5081
5 3 Installing 5082
5 3 1 Welding in 5082
6 Renewing rear roof cross member 5084
6 1 Tools 5085
6 2 Removing 5085
6 3 Installing 5086
6 3 1 Welding in 5086
7 Renewing intermediate plate, hybrid vehicles 5088
7 1 Tools 5089
7 2 Removing 5089
7 3 Installing 5090
7 3 1 Preparing new part 5090
7 3 2 Welding in 5091
8 Renewing A-pillar 5093
8 1 Tools 5094
8 2 Removing 5094
8 3 Installing 5096
8 3 1 Preparing new part 5097
8 3 2 Moulded foam inserts 5098
8 3 3 Welding in 5099
9 Renewing A-pillar reinforcement – part section 5103
9 1 Tools 5104
9 2 Removing 5104
9 3 Installing 5105
9 3 1 Preparing new part 5106
9 3 2 Moulded foam inserts 5106
9 3 3 Welding in 5106
10 Renewing B-pillar 5110
10 1 Tools 5111
10 2 Removing 5111
10 3 Installing 5113
10 3 1 Preparing new part 5114
10 3 2 Marking area in which welding work is prohibited 5116
10 3 3 Moulded foam inserts 5116
10 3 4 Welding in 5117
11 Renewing B-pillar reinforcement, non-hybrid vehicles 5120
11 1 Tools 5121
11 2 Removing 5121
11 3 Installing 5123
11 3 1 Preparing new part 5123
11 3 2 Marking areas where no welding work may be carried out 5126
11 3 3 Welding in 5127
12 Renewing B-pillar reinforcement, hybrid vehicles 5130
12 1 Tools 5131
12 2 Removing 5131
12 3 Installing 5133
12 3 1 Preparing new part 5133
12 3 2 Marking areas where no welding work may be carried out 5136
12 3 3 Welding in 5137
13 Renewing inner B-pillar 5140
13 1 Tools 5141
13 2 Removing 5141
13 3 Installing 5142
13 3 1 Preparing new part 5142
13 3 2 Welding in 5143
14 Renewing side member 5145
14 1 Tools 5146
14 2 Removing 5146
14 3 Installing 5148
14 3 1 Preparing new part 5149
14 3 2 Moulded foam inserts 5150
14 3 3 Marking area in which welding work is prohibited 5151
14 3 4 Welding in 5152
15 Renewing front side member reinforcement, non-hybrid vehicles 5154
15 1 Tools 5155
15 2 Removing 5155
15 3 Installing 5156
15 3 1 Preparing new part 5157
15 3 2 Welding in 5157
16 Renewing front side member reinforcement, hybrid vehicles 5160
16 1 Tools 5161
16 2 Removing 5161
16 3 Installing 5162
16 3 1 Preparing new part 5163
16 3 2 Welding in 5163
17 Renewing rear side member reinforcement 5166
17 1 Tools 5167
17 2 Removing 5167
17 3 Installing 5168
17 3 1 Preparing new part 5169
17 3 2 Welding in 5169
18 Renewing outer mounting for seat cross member 5171
18 1 Tools 5172
18 2 Removing 5173
18 3 Installing 5174
18 3 1 Preparing new part 5174
18 3 2 Welding in 5175
19 Renewing inner mounting for seat cross member 5177
19 1 Tools 5177
19 2 Removing 5177
19 3 Installing 5179
19 3 1 Preparing new part 5179
19 3 2 Welding in 5180
20 Renewing seat middle cross member 5182
20 1 Tools 5182
20 2 Removing 5182
20 3 Installing 5184
20 3 1 Preparing new part 5184
20 3 2 Welding in 5185
53 – Body – rear 5187
1 Renewing cross panel 5187
1 1 Tools 5188
1 2 Removing 5188
1 3 Installing 5189
1 3 1 Preparing new part 5189
1 3 2 Welding in 5191
2 Renewing lock carrier 5193
2 1 Tools 5193
2 2 Removing 5193
2 3 Installing 5195
2 3 1 Welding in 5195
3 Renewing tail light mounting 5197
3 1 Tools 5198
3 2 Removing 5198
3 3 Installing 5199
3 3 1 Preparing new part 5199
3 3 2 Welding in 5199
4 Renewing tail light reinforcement, hybrid vehicles 5201
4 1 Tools 5202
4 2 Removing 5202
4 3 Installing 5203
4 3 1 Preparing new part 5204
4 3 2 Welding in 5204
5 Renewing luggage compartment floor 5206
5 1 Tools 5207
5 2 Removing 5208
5 3 Installing 5210
5 3 1 Preparing new part 5210
5 3 2 Moulded foam inserts 5212
5 3 3 Welding in 5212
6 Renewing C-pillar reinforcement – part section 5217
6 1 Tools 5218
6 2 Removing 5218
6 3 Installing 5219
6 3 1 Preparing new part 5219
6 3 2 Welding in 5220
7 Renewing rear longitudinal member – part section 5222
7 1 Tools 5223
7 2 Removing 5223
7 3 Installing 5224
7 3 1 Preparing new part 5224
7 3 2 Welding in 5225
8 Renewing rear longitudinal member – subpart 5227
8 1 Tools 5228
8 2 Removing 5228
8 3 Installing 5229
8 3 1 Preparing new part 5229
8 3 2 Welding in 5229
9 Renewing rear longitudinal member reinforcement, hybrid vehicles 5231
9 1 Tools 5232
9 2 Removing 5232
9 3 Installing 5233
9 3 1 Preparing new part 5233
9 3 2 Welding in 5234
10 Renewing rear battery mounting, hybrid vehicles 5237
10 1 Tools 5238
10 2 Removing 5238
10 3 Installing 5239
10 3 1 Preparing new part 5239
10 3 2 Welding in 5240
11 Renewing side panel – part section 5242
11 1 Tools 5243
11 2 Removing 5243
11 3 Installing 5246
11 3 1 Preparing new part 5247
11 3 2 Moulded foam inserts 5248
11 3 3 Welding in 5248
12 Renewing outer wheel housing liner 5253
12 1 Tools 5254
12 2 Removing 5254
12 3 Installing 5255
12 3 1 Preparing new part 5255
12 3 2 Welding in 5256
00 – Technical data 5264
1 Safety information 5264
1 1 Safety precautions when working on high-voltage system 5264
1 2 Safety precautions when working in the vicinity of high-voltage components 5265
1 3 Safety measures when working on vehicles with a start/stop system 5265
1 4 Safety precautions when working on subframe 5265
2 Evaluating accident vehicles 5266
2 1 Check list for evaluating running gear on accident vehicles 5266
3 Repair instructions 5268
3 1 Steering rack 5268
3 2 Gaskets and seals 5268
3 3 Nuts and bolts 5268
3 4 Electrical components 5269
3 5 Raising suspension to unladen position (vehicles with coil springs) 5269
3 5 1 Raising wheel bearing assembly to unladen position (vehicles with coil springs), front axle 5269
3 5 2 Raising wheel bearing assembly to unladen position (vehicles with coil springs), rear axle 5271
40 – Front suspension 5274
1 Front axle 5274
1 1 Overview of fitting locations – front axle 5274
2 Subframe 5276
2 1 Assembly overview – subframe 5276
2 2 Fixing position of subframe 5278
2 3 Lowering subframe 5281
2 4 Removing and installing subframe without steering rack 5284
2 5 Removing and installing subframe with steering rack 5288
2 5 1 Removing and installing subframe with steering rack, hydraulic steering 5288
2 5 2 Removing and installing subframe with steering rack, electromechanical steering 5295
2 6 Repairing subframe 5300
2 7 Repairing thread in longitudinal member 5309
3 Anti-roll bar 5310
3 1 Assembly overview – anti-roll bar 5310
3 2 Removing and installing anti-roll bar 5310
4 Suspension strut, upper suspension link 5315
4 1 Assembly overview – suspension strut, upper suspension link 5315
4 2 Removing and installing suspension strut 5316
4 3 Repairing suspension strut 5322
5 Lower suspension link, swivel joint 5325
5 1 Assembly overview – lower suspension link, swivel joint 5325
5 2 Removing and installing lower suspension link 5327
5 2 1 Removing and installing lower suspension link, Basic 5327
5 2 2 Removing and installing lower suspension link, left side of vehicles with automatic or dual clutch gearbox 5328
5 3 Checking swivel joint 5333
5 4 Removing and installing swivel joint 5333
5 5 Renewing bonded rubber bush for lower suspension link 5337
5 5 1 Renewing bonded rubber bush for lower suspension link, front bonded rubber bush 5337
5 5 2 Renewing bonded rubber bush for lower suspension link, rear bonded rubber bush 5340
6 Wheel bearing 5342
6 1 Assembly overview – wheel bearing 5342
6 2 Removing and installing wheel bearing housing 5344
6 3 Removing and installing wheel bearing unit 5349
7 Drive shaft 5354
7 1 Overview – drive shaft 5354
7 2 Assembly overview – drive shaft 5355
7 2 1 Assembly overview – drive shaft, constant velocity joint VL100 5355
7 2 2 Assembly overview – drive shaft, constant velocity joint VL107 5358
7 2 3 Assembly overview – drive shaft with push-on constant velocity joint VL107 5360
7 2 4 Assembly overview – drive shaft, triple roller joint AAR2600i 5362
7 2 5 Assembly overview – drive shaft, triple roller joint AAR3300i 5364
7 3 Removing and installing drive shaft 5365
7 3 1 Removing and installing drive shaft, constant velocity joints VL100 and VL107 5365
7 3 2 Removing and installing drive shaft, right drive shaft with push-on constant velocity joint 5369
7 3 3 Removing and installing drive shaft, triple roller joint AAR2600i 5375
7 3 4 Removing and installing drive shaft, triple roller joint AAR3300i 5379
7 4 Loosening and tightening threaded connections of drive shaft 5383
7 4 1 Loosening and tightening drive shaft bolt, twelve-point head bolt with ribbing 5383
7 4 2 Loosening and tightening drive shaft bolt, twelve-point head bolt without ribbing 5385
7 5 Removing and installing drive shaft heat shield 5387
7 6 Dismantling and assembling drive shaft 5387
7 6 1 Dismantling and assembling drive shaft, constant velocity joint VL100 5387
7 6 2 Dismantling and assembling drive shaft, constant velocity joint VL107 5392
7 6 3 Dismantling and assembling drive shaft, push-on constant velocity joint VL107 5396
7 6 4 Dismantling and assembling drive shaft, triple roller joint AAR2600i 5399
7 6 5 Dismantling and assembling drive shaft, triple roller joint AAR3300i 5404
7 7 Checking outer constant velocity joint 5409
7 8 Checking inner constant velocity joint 5410
42 – Rear suspension 5413
1 Rear axle 5413
1 1 Overview – rear axle 5413
1 2 Lowering rear axle 5414
1 3 Removing and installing rear axle 5416
1 4 Removing and installing shield for rear axle 5420
2 Subframe 5422
2 1 Assembly overview – subframe 5422
2 2 Assembly overview – add-on parts for subframe 5424
2 3 Fixing position of subframe 5424
3 Anti-roll bar 5427
3 1 Assembly overview – anti-roll bar 5427
3 2 Removing and installing anti-roll bar 5427
4 Suspension link, track rod 5430
4 1 Removing and installing upper transverse link 5430
4 2 Removing and installing lower transverse link 5431
4 3 Removing and installing track rod 5433
5 Suspension strut, shock absorber, spring 5436
5 1 Assembly overview – suspension strut, shock absorber, spring 5436
5 2 Removing and installing shock absorbers 5436
5 3 Repairing shock absorber 5438
5 4 Removing and installing spring 5440
6 Wheel bearing assembly, trailing arm 5444
6 1 Assembly overview – wheel bearing 5444
6 2 Removing and installing wheel bearing housing 5445
6 3 Removing and installing wheel bearing unit 5448
6 4 Renewing bonded rubber bush for wheel bearing housing 5451
6 5 Removing and installing trailing arm with mounting bracket 5454
6 6 Repairing trailing arm 5457
43 – Self-levelling suspension 5461
1 Vehicle level sender 5461
1 1 Assembly overview – rear vehicle level senders 5461
1 2 Removing and installing rear vehicle level senders -G76-/-G77- 5461
44 – Wheels, tyres, vehicle geometry 5463
1 Wheels, tyres 5463
1 1 Specified torques for wheel bolts 5463
1 2 Pressing tyre off wheel rim 5463
1 3 Removing tyre from wheel 5464
1 4 Fitting tyre 5464
1 5 Wheel change 5465
1 5 1 Wheel change, protecting wheel centring seat against corrosion 5465
1 5 2 Wheel change, installation requirements 5465
1 5 3 Wheel change, installation instructions for wheel change 5467
1 5 4 Wheel change, wheel installation 5468
1 6 Removing and fitting tyres with run-flat properties to wheel rims 5468
1 6 1 Removing and fitting tyres with run-flat properties to wheel rims, safety instructions 5468
1 6 2 Removing and fitting tyres with run-flat properties to wheel rims, installation requirements 5469
1 6 3 Removing and fitting tyres with run-flat properties to wheel rims, pressing tyre off wheel rim 5470
1 6 4 Removing and fitting tyres with run-flat properties to wheel rims, removing tyre from wheel 5471
1 6 5 Removing and fitting tyres with run-flat properties to wheel rims, fitting tyre to wheel rim 5472
1 7 Tyre sealant disposal 5474
1 8 Models with breakdown set 5474
2 Tyre Pressure Monitoring System 5476
2 1 System description – Tyre Pressure Monitoring System 5476
2 2 Assembly overview – tyre pressure sensor 5477
2 3 Removing and installing tyre pressure sensor -G222-/-G223-/-G224-/-G225- 5478
2 4 Changing tyres on vehicles with tyre pressure monitoring system 5479
2 4 1 Notes on safety and conditions for removing and fitting tyres (wheels with tyre pressure monitoring) 5479
2 4 2 Wheel change 5480
2 4 3 Fittings instructions 5481
2 4 4 Removing tyre from wheel 5482
2 4 5 Fitting tyre to wheel rim 5482
3 Wheel alignment 5484
3 1 Notes for wheel alignment 5484
3 2 Conditions for testing 5484
3 3 Test preparations 5485
3 4 Specifications for wheel alignment 5486
3 5 Wheel alignment procedure 5488
3 6 Necessity of wheel alignment 5489
3 7 Transverse vehicle inclination “zero position” 5491
3 8 Adjusting camber at front wheels 5491
3 9 Adjusting camber on rear axle 5492
3 10 Adjusting toe at rear axle 5493
3 11 Adjusting front axle toe 5494
3 12 Vehicle data sticker 5495
3 13 Steering angle sender -G85- basic setting 5496
4 Vibration due to wheels/tyres – causes and rectification 5497
4 1 Causes of rough running 5497
4 2 Conducting a road test before balancing wheels 5497
4 3 Balancing wheel 5498
4 3 1 Balancing wheel, conditions 5498
4 3 2 Balancing wheel, balancing wheel on stationary wheel balancer 5498
4 3 3 Balancing wheel, balancing wheel with finish balancer 5500
4 4 Vibration control system 5501
4 5 Checking radial and lateral runout of wheels and tyres 5501
4 5 1 Checking radial and lateral runout of wheels and tyres, tolerances 5501
4 5 2 Checking radial and lateral runout on wheels and tyres with tyre gauge 5502
4 6 Checking radial and lateral run-out on wheel rim 5502
4 7 Matching wheels and tyres 5503
4 8 Determining flat spots on tyres 5504
5 Adaptive cruise control 5506
5 1 Calibrating adaptive cruise control 5506
48 – Steering 5512
1 Steering wheel 5512
1 1 Assembly overview – steering wheel 5512
1 2 Removing and installing steering wheel 5512
2 Steering column 5515
2 1 Assembly overview – steering column 5515
2 1 1 Assembly overview – steering column, left-hand drive 5515
2 1 2 Assembly overview – steering column, right-hand drive 5517
2 2 Checking steering column for damage 5517
2 3 Handling and transporting steering column 5518
2 4 Removing and installing steering column 5519
2 4 1 Removing and installing steering column, left-hand drive vehicle 5519
2 4 2 Removing and installing steering column, right-hand drive vehicle 5526
3 Steering rack 5535
3 1 Assembly overview – steering rack 5535
3 1 1 Assembly overview – steering rack, hydraulic steering rack 5535
3 1 2 Assembly overview – steering rack, electromechanical steering rack, left-hand drive vehicle 5536
3 1 3 Assembly overview – steering rack, electromechanical steering rack, right-hand drive vehicle 5538
3 2 Removing and installing steering rack 5540
3 2 1 Removing and installing steering rack, hydraulic steering 5540
3 2 2 Removing and installing steering rack, electromechanical steering rack, LHD vehicles 5546
3 2 3 Removing and installing steering rack, electromechanical steering rack, RHD vehicles 5553
3 3 Removing and installing boot 5559
3 3 1 Removing and installing boot, hydraulic steering 5559
3 3 2 Removing and installing boot, electromechanical steering 5561
3 4 Removing and installing track rod 5564
3 4 1 Removing and installing track rod, hydraulic steering 5564
3 4 2 Removing and installing track rod, electromechanical steering 5567
3 5 Removing and installing track rod ball joint 5570
3 6 Repairing steering rack 5572
3 6 1 Repairing steering rack, hydraulic steering 5572
3 6 2 Repairing steering rack, electromechanical steering 5574
4 Sensors 5575
4 1 Removing and installing steering angle sender -G85- 5575
4 1 1 Removing and installing steering angle sender -G85-, without electromechanical power steering 5575
4 1 2 Removing and installing steering angle sender -G85-, with electromechanical power steering 5576
5 Hydraulic power steering 5577
5 1 Assembly overview – hydraulic lines, reservoir 5577
5 1 1 Assembly overview – hydraulic lines, 4-cylinder petrol engine 5577
5 1 2 Assembly overview – hydraulic lines, reservoir, 4-cylinder petrol engine 5579
5 1 3 Assembly overview – hydraulic lines, 5-cylinder petrol engine 5580
5 1 4 Assembly overview – hydraulic lines, reservoir, 5-cylinder petrol engine 5581
5 2 Assembly overview – vane pump 5582
5 2 1 Assembly overview – vane pump, 4-cylinder petrol engine 5582
5 2 2 Assembly overview – vane pump, 5-cylinder petrol engine 5583
5 3 Checking hydraulic fluid level of power steering 5584
5 4 Bleeding steering system after repairs 5585
5 5 Check steering for leaks 5585
5 6 Checking delivery pressure of vane pump 5586
5 7 Removing and installing vane pump 5589
5 7 1 Removing and installing vane pump, 4-cylinder petrol engine 5589
5 7 2 Removing and installing vane pump, 5-cylinder petrol engine 5592
00 – Technical data 5599
1 Safety information 5599
1 1 Safety precautions when working on high-voltage system 5599
1 2 Safety precautions when working in the vicinity of high-voltage components 5600
1 3 Safety measures when working on vehicles with a start/stop system 5600
1 4 Safety precautions when using test and measuring instruments during a road test 5600
2 Identification 5601
2 1 Allocation of PR number – brakes 5601
2 1 1 PR number 5601
2 1 2 Front brakes 5601
2 1 3 Rear brakes, torsion beam rear axle 5601
2 1 4 Rear brakes, multi-link rear suspension 5602
3 Technical data 5603
3 1 Technical data for brakes 5603
3 1 1 Brake master cylinder and brake servo 5603
4 Brake test 5606
4 1 General information 5606
4 2 Checking vehicles with front-wheel drive 5606
45 – Anti-lock brake system 5607
1 General information 5607
1 1 Repair instructions for repair work on ABS 5607
1 2 Vehicle diagnosis, testing and information system 5609
2 Overview of fitting locations 5611
2 1 Fitting location overview – ABS 5611
2 1 1 ABS Mark 70, ABS/TCS 5611
2 1 2 ABS Mark 70 (ABS/TCS) (right-hand drive vehicles) 5612
2 2 Overview of fitting locations – ABS/ESP 5614
2 2 1 ABS Mark 60 EC, North America 5614
2 2 2 ABS Mark 60 EC, vehicles with electromechanical power steering, North America 5616
2 2 3 ABS Mark 60 EC, vehicles with electromechanical power steering 5617
3 Control unit and hydraulic unit 5619
3 1 Assembly overview – control unit and hydraulic unit 5619
3 1 1 Assembly overview – ABS Mark 70 (ABS/TCS), left-hand drive vehicles 5619
3 1 2 Assembly overview – ABS Mark 70 (ABS/TCS), right-hand drive vehicles 5622
3 1 3 Assembly overview – ABS Mark 60 EC (ABS/EDL/TCS/ESP), left-hand drive vehicles 5623
3 1 4 Assembly overview – ABS Mark 60 EC (ABS/EDL/TCS/ESP), right-hand drive vehicles 5625
3 2 Removing and installing ABS control unit -J104- and ABS hydraulic unit -N55- 5627
3 2 1 Removing and installing ABS control unit -J104- and ABS hydraulic unit -N55-, left-hand drive vehicles with petrol engines 5627
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 5634
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 5643
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 5651
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) 5662
3 2 6 Removing and installing ABS control unit -J104- and ABS hydraulic unit -N55-, left-hand drive vehicles with diesel engine 5671
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 5678
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 5687
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 5696
3 2 10 Removing and installing ABS control unit -J104- and ABS hydraulic unit -N55-, ABS Mark 60 EC (ABS/EDL/TCS/ESP) 5706
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) 5715
3 3 Separating control unit from hydraulic unit 5724
3 3 1 Separating ABS control unit -J104- from ABS hydraulic unit -N55-, ABS Mark 70 (ABS/TCS) 5724
3 3 2 Separating ABS control unit -J104- from ABS hydraulic unit -N55-, ABS Mark 60 EC (ABS/EDL/TCS/ESP) 5726
3 4 Fitting control unit to hydraulic unit 5727
3 4 1 Installing ABS control unit -J104- to ABS hydraulic unit -N55-, ABS Mark 70 (ABS/TCS) 5727
3 4 2 Installing ABS control unit -J104- to ABS hydraulic unit -N55-, ABS Mark 60 EC (ABS/EDL/TCS/ESP) 5729
3 5 Connecting brake lines to hydraulic unit 5732
3 5 1 Connecting brake lines to ABS hydraulic unit -N55-, left-hand drive vehicles 5732
3 5 2 Connecting brake lines to ABS hydraulic unit -N55-, right-hand drive vehicles 5733
4 Sensors 5735
4 1 Assembly overview – speed sensor on front axle 5735
4 1 1 Assembly overview – speed sensor on front axle 5735
4 2 Assembly overview – speed sensor on rear axle 5736
4 2 1 Assembly overview – speed sensor on rear axle, semi-independent suspension 5736
4 2 2 Assembly overview – speed sensor on rear axle, multi-link rear suspension 5737
4 3 Removing and installing yaw rate sender and lateral acceleration sender 5737
4 4 Assembly overview – sensors and actuators 5738
4 4 1 Assembly overview – steering angle sender -G85- 5738
4 5 Removing and installing speed sensors on front axle -G45-/-G47- 5738
4 5 1 Removing and installing speed sensor on front axle 5738
4 6 Removing and installing speed sensors on rear axle -G44-/-G46- 5739
4 6 1 Removing and installing speed sensor on semi-independent suspension 5739
4 6 2 Removing and installing speed sensor on multi-link rear suspension 5740
46 – Brakes – mechanism 5741
1 Front brakes 5741
1 1 Assembly overview – front brakes 5741
1 1 1 Assembly overview – front brakes, FS III without brake pad wear indicator 5741
1 1 2 Assembly overview – front brakes, FS III with brake pad wear indicator 5743
1 1 3 Assembly overview – front brakes, FN3 15/16 inch without brake pad wear indicator 5745
1 1 4 Assembly overview – front brakes, FN3 15/16 inch with brake pad wear indicator 5747
1 2 Removing and installing brake pads/linings 5748
1 2 1 Removing and installing brake pads, brake caliper FS III 5748
1 2 2 Removing and installing brake pads, brake caliper FN 3 5751
1 3 Removing and installing brake caliper 5754
1 3 1 Removing and installing brake caliper, FS III brake caliper 5754
1 3 2 Removing and installing brake caliper, FN 3 brake caliper 5757
1 4 Removing and installing brake carrier 5761
1 4 1 Removing and installing brake carrier, brake caliper FN 3 5761
1 5 Replace brake disc 5763
1 5 1 Removing and installing brake disc, brake caliper FS III 5763
1 5 2 Removing and installing brake disc, brake caliper FN 3 5765
1 6 Removing and installing brake splash plate 5768
1 6 1 Removing and installing cover plate, brake caliper FS III 5768
1 6 2 Removing and installing splash plate, brake caliper FN 3 5769
2 Rear brakes 5772
2 1 Assembly overview – rear brakes 5772
2 1 1 Assembly overview – torsion beam rear suspension, rear brakes, Bosch ZOH BIR 38 5772
2 1 2 Assembly overview – torsion beam rear suspension, rear brakes, CI 38 5775
2 1 3 Assembly overview – multi-link rear suspension, rear brakes, Bosch ZOH BIR 38 5777
2 1 4 Assembly overview – multi-link rear suspension, rear brakes, CI 38 5780
2 2 Removing and installing brake pads/linings 5782
2 2 1 Removing and installing brake pads; Rear brakes, Bosch ZOH BIR 38 5782
2 2 2 Removing and installing brake pads; Rear brakes, CI 38 5785
2 3 Removing and installing brake caliper 5789
2 3 1 Removing and installing brake caliper; Rear brakes, Bosch ZOH BIR 38 5789
2 3 2 Removing and installing brake caliper; Rear brakes, CI 38 5792
2 4 Removing and installing brake carrier 5796
2 5 Removing and installing brake disc 5798
2 6 Removing and installing brake splash plate 5800
2 6 1 Removing and installing splash plate for brakes, torsion beam rear axle 5800
2 6 2 Removing and installing splash plate for brakes, multi-link rear axle 5802
3 Parking brake 5805
3 1 Assembly overview – parking brake 5805
3 2 Removing and installing handbrake lever 5806
3 3 Adjusting parking brake 5809
3 4 Removing and installing rear brake cable 5810
3 4 1 Removing and installing rear brake cable on semi-independent suspension 5810
3 4 2 Removing and installing rear brake cable on multi-link rear suspension 5814
4 Brake pedal 5817
4 1 Assembly overview – brake pedal 5817
4 1 1 Assembly overview – brake pedal, left-hand drive 5817
4 1 2 Assembly overview – brake pedal, right-hand drive 5818
4 2 Removing and installing mounting bracket 5820
4 2 1 Removing and installing mounting bracket, left-hand drive 5820
4 2 2 Removing and installing mounting bracket, RHD 5822
4 2 3 Removing and installing mounting bracket, hybrid vehicles 5825
4 3 Separating brake pedal from brake servo 5831
4 4 Connecting brake pedal to brake servo 5832
4 5 Removing and installing brake pedal 5833
4 5 1 Removing and installing brake pedal, left-hand drive vehicles 5833
4 5 2 Removing and installing brake pedal, right-hand drive vehicles 5834
47 – Brakes – hydraulics 5835
1 Front brake caliper 5835
1 1 Assembly overview – front brake caliper 5835
1 1 1 Assembly overview – front brake caliper, brake caliper FS III 5835
1 1 2 Assembly overview – front brake caliper, brake caliper FN 3 5836
1 2 Removing and installing brake caliper piston 5837
1 2 1 Removing and installing brake caliper piston, brake caliper piston FS III 5837
1 2 2 Removing and installing brake caliper piston, brake caliper piston FN 3 5839
2 Rear brake caliper 5843
2 1 Assembly overview – rear brake caliper 5843
2 1 1 Assembly overview – rear brake caliper, rear brakes, Bosch ZOH BIR 38 5843
2 1 2 Assembly overview – rear brake caliper, rear brakes, CI 38 5844
2 2 Removing and installing brake caliper piston 5846
2 2 1 Removing and installing brake caliper piston; Rear brakes, Bosch ZOH BIR 38 5846
2 2 2 Removing and installing brake caliper piston; Rear brakes, CI 38 5848
3 Brake servo and brake master cylinder 5851
3 1 Assembly overview – brake servo/brake master cylinder 5851
3 1 1 Assembly overview – brake servo/brake master cylinder, left-hand drive vehicles 5851
3 1 2 Assembly overview – brake servo/brake master cylinder, right-hand drive 5854
3 2 Removing and installing brake light switch 5855
3 2 1 Removing and installing brake light switch -F-, left-hand drive vehicles with petrol engine 5855
3 2 2 Removing and installing brake light switch -F-, left-hand drive vehicles with diesel engine 5856
3 2 3 Removing and installing brake light switch -F-, right-hand drive 5857
3 2 4 Removing and installing brake light switch -F-, hybrid vehicles 5858
3 3 Removing and installing brake servo 5859
3 3 1 Removing and installing brake servo, left-hand drive vehicles with petrol engine 5859
3 3 2 Removing and installing brake servo, left-hand drive vehicles with diesel engine 5863
3 3 3 Removing and installing brake servo, right-hand drive vehicles with petrol engine 5868
3 3 4 Removing and installing brake servo, right-hand drive with diesel engine 5878
3 3 5 Removing and installing brake servo, hybrid vehicles 5889
3 4 Removing and installing brake master cylinder 5897
3 4 1 Removing and installing brake master cylinder, left-hand drive vehicles with petrol engine 5897
3 4 2 Removing and installing brake master cylinder, left-hand drive vehicles with diesel engine 5901
3 4 3 Removing and installing brake master cylinder, right-hand drive vehicles with petrol engine 5905
3 4 4 Removing and installing brake master cylinder, right-hand drive vehicles with diesel engine 5911
3 4 5 Removing and installing brake master cylinder, hybrid vehicles 5918
3 5 Removing and installing brake fluid reservoir 5923
3 5 1 Removing and installing brake fluid reservoir, left-hand drive vehicles 5923
3 5 2 Removing and installing brake fluid reservoir, right-hand drive vehicles 5925
3 5 3 Removing and installing brake fluid reservoir, hybrid vehicles 5928
4 Vacuum system 5932
4 1 Assembly overview – electric vacuum pump 5932
4 1 1 Assembly overview – electric vacuum pump, vehicles with 1 2 l petrol engine 5932
4 1 2 Assembly overview – electric vacuum pump, vehicles with 1 4 l – 118 kW petrol engine 5934
4 1 3 Assembly overview – electric vacuum pump, vehicles with 1 4 l – 110 kW petrol engine 5935
4 1 4 Assembly overview – electric vacuum pump, vehicles with 2 0 l petrol engine 5936
4 1 5 Assembly overview – electric vacuum pump, vehicles with hybrid powertrain 5937
4 2 Assembly overview – vacuum pump 5938
4 2 1 Assembly overview – vacuum pump, vehicles with 1 8 l – 125 kW and 2 0 l – 155 kW petrol engine 5938
4 2 2 Assembly overview – vacuum pump, vehicles with 2 0 l diesel engine 5939
4 2 3 Assembly overview – vacuum pump, vehicles with 2 5 l diesel engine 5939
4 3 Checking non-return valve 5940
4 4 Removing and installing brake servo pressure sensor 5940
4 5 Removing and installing vacuum sender -G608- 5940
4 6 Checking vacuum system 5941
4 6 1 Instructions 5941
4 6 2 Connecting vacuum gauge for brake servo -VAS 6721- 5942
4 6 3 Checking vacuum generation 5943
4 6 4 Checking for leaks 5944
4 6 5 Vacuum generation with manual vacuum pump -VAS 6213- 5945
4 7 Removing and installing electric vacuum pump 5946
4 7 1 Removing and installing electric vacuum pump, vehicles with 1 2 l and 1 4 l petrol engine 5946
4 7 2 Removing and installing electric vacuum pump, vehicles with 2 0 l petrol engine 5947
4 7 3 Removing and installing electric vacuum pump, vehicles with hybrid powertrain 5948
5 Brake lines 5951
5 1 Repairing brake lines 5951
5 1 1 Assembly overview – flanging tool 5951
5 1 2 Work instructions 5952
6 Hydraulic system 5956
6 1 General notes on brake fluid 5956
6 1 1 General information 5956
6 1 2 Changing brake fluid 5958
6 2 Pre-bleeding hydraulic system 5959
6 3 Bleeding hydraulic system following standard procedure 5961
6 4 Subsequent bleeding of hydraulic system 5964
6 5 Testing for leaks 5965
6 5 1 Prerequisites for testing: 5965
50 – Body – front 5972
1 Lock carrier 5972
1 1 Assembly overview – lock carrier 5972
1 1 1 Assembly overview – lock carrier, RoW (rest of world) 5972
1 1 2 Assembly overview – lock carrier, North American Region 5974
1 2 Removing and installing lock carrier 5975
1 3 Moving to and back from service position 5978
2 Wings 5982
2 1 Assembly overview – wing 5982
2 1 1 Assembly overview – wing 5982
2 1 2 Assembly overview – insulation, foam sections and end plate 5983
2 1 3 Assembly overview – end plate 5983
2 2 Removing and installing wing 5984
2 3 Removing and installing wing bracket 5986
3 Bulkhead 5987
3 1 Assembly overview – plenum chamber bulkhead 5987
3 2 Assembly overview – plenum chamber cover 5988
3 3 Removing and installing plenum chamber bulkhead 5989
3 4 Removing and installing plenum chamber cover 5991
55 – Bonnet, rear lid 5995
1 Bonnet 5995
1 1 Assembly overview – bonnet 5995
1 2 Assembly overview – Bowden cable 5996
1 3 Removing and installing bonnet 5997
1 4 Adjusting bonnet 5998
1 5 Removing and installing bonnet lock 6001
1 6 Removing and installing bonnet release lever 6004
1 7 Removing and installing striker pin 6005
1 8 Removing and installing hinges 6006
1 9 Removing and installing insulation 6007
1 9 1 Removing and installing insulation 6007
1 9 2 Removing and installing seals 6009
1 10 Removing and installing Bowden cable 6010
1 11 Removing and installing support rod 6011
2 Rear lid 6013
2 1 Assembly overview – rear lid 6013
2 2 Assembly overview – hinge 6014
2 3 Assembly overview – gas strut 6015
2 4 Assembly overview – number plate carrier 6015
2 5 Removing and installing rear lid 6016
2 6 Adjusting rear lid 6017
2 7 Removing and installing bonnet lock 6020
2 8 Removing and installing operating mechanism 6021
2 9 Removing and installing hinges 6022
2 10 Removing and installing striker pin 6025
2 11 Removing and installing rear lid seal 6026
2 12 Removing and installing gas strut 6027
2 13 Releasing gas from gas strut 6028
3 Tank flap unit 6029
3 1 Assembly overview – tank flap unit 6029
3 2 Removing and installing tank flap unit 6029
3 2 1 Removing and installing tank flap unit 6029
3 2 2 Removing and installing tank flap unit (Russia and Malaysia) 6031
57 – Front doors, door components, central locking 6035
1 Door 6035
1 1 Removing and installing inner door seal 6035
1 2 Removing and installing outer door seal 6036
1 3 Removing and installing door 6037
1 4 Adjusting door 6039
1 5 Adjusting striker pin 6041
1 6 Removing and installing door hinge 6042
1 7 Removing and installing door arrester 6043
2 Door components 6046
2 1 Assembly overview – door hinge 6046
2 2 Assembly overview – door components 6048
2 3 Assembly overview – door handle and door lock 6049
2 4 Assembly overview – insulation 6050
2 5 Removing and installing window regulator motor 6051
2 5 1 Removing and installing window regulator motor, equipment level High (AW1) 6051
2 5 2 Removing and installing window regulator motor, equipment level Low (AW0) 6053
2 6 Removing and installing window regulator 6055
2 7 Removing and installing inner door cover 6057
2 8 Removing and installing striker pin 6058
2 9 Removing and installing door handle 6059
2 10 Removing and installing door handle bracket 6061
2 11 Removing and installing door lock 6063
2 12 Removing and installing window channel 6066
2 13 Removing and installing inner window slot seal 6068
2 14 Removing and installing outer window slot seal 6070
2 15 Removing and installing lock cylinder 6071
2 16 Removing and installing cap on door handle 6074
2 16 1 Removing and installing cap for door handle, with lock cylinder 6074
2 16 2 Removing and installing cap for door handle, without lock cylinder 6075
3 Central locking 6078
3 1 Overview of fitting locations – central locking 6078
3 2 Assembly overview – ignition key 6080
3 2 1 Assembly overview – battery for ignition key with remote control 6080
3 2 2 Assembly overview – battery for ignition key with cap 6081
3 3 Removing and installing ignition key battery 6082
3 3 1 Removing and installing ignition key battery 6082
3 3 2 Removing and installing battery for ignition key with cap 6083
3 4 Removing and installing tank filler flap locking motor -V155- 6083
58 – Rear doors, door components 6086
1 Door 6086
1 1 Assembly overview – door 6086
1 2 Removing and installing door 6087
1 3 Adjusting door 6089
1 4 Adjusting striker pin 6091
1 5 Removing and installing door hinges 6091
1 6 Removing and installing door arrester 6093
1 7 Removing and installing outer door seal 6095
1 8 Removing and installing inner door seal 6096
2 Door components 6098
2 1 Assembly overview – door components 6098
2 2 Assembly overview – door handle and door lock 6100
2 3 Assembly overview – insulation 6101
2 4 Removing and installing window regulator motor 6101
2 4 1 Removing and installing window regulator motor, equipment level High (AW1) 6101
2 4 2 Removing and installing window regulator motor, equipment level Low (AW0) 6103
2 5 Removing and installing window regulator 6105
2 6 Removing and installing inner door cover 6107
2 7 Removing and installing striker pin 6108
2 8 Removing and installing door handle 6108
2 9 Removing and installing door handle bracket 6110
2 10 Removing and installing door lock 6112
2 11 Removing and installing window channel 6115
2 12 Removing and installing outer window slot seal 6117
2 13 Removing and installing inner window slot seal 6118
2 14 Removing and installing cap on door handle 6119
60 – Sunroof 6123
1 Sliding sunroof 6123
1 1 Assembly overview – sliding sunroof 6123
1 2 Removing and installing glass panel 6124
1 3 Removing and installing wind deflector 6126
1 4 Adjusting sunroof panel 6127
1 5 Checking parallel running of glass panel 6129
1 6 Adjusting parallel running of glass panel 6129
1 7 Removing and installing sliding sunroof seals 6130
1 8 Removing and installing sliding headliner 6130
1 9 Removing and installing sliding sunroof adjustment control unit -J245- 6131
1 10 Adapting sliding sunroof adjustment control unit -J245- 6132
1 11 Removing and installing sliding sunroof frame 6132
2 Water drain hoses 6135
2 1 Cleaning water drainage hoses 6135
63 – Bumpers 6137
1 Bumper, front 6137
1 1 Assembly overview – bumper cover 6137
1 1 1 Assembly overview – bumper cover 6137
1 1 2 Assembly overview – add-on parts 6138
1 1 3 Assembly overview – guides 6140
1 2 Assembly overview – impact bar 6141
1 3 Removing and installing bumper cover 6141
1 4 Installing front number plate carrier 6144
1 5 Repairing bumper cover 6145
1 6 Installing holder for parking aid sender 6145
2 Bumper, rear 6151
2 1 Assembly overview – bumper cover 6151
2 1 1 Assembly overview – bumper cover 6151
2 1 2 Assembly overview – add-on parts 6152
2 1 3 Assembly overview – guides 6153
2 2 Assembly overview – impact bar 6154
2 3 Removing and installing bumper cover 6154
2 4 Repairing bumper cover 6157
2 5 Installing holder for parking aid sender 6157
64 – Glazing 6162
1 Repair notes 6162
1 1 Minimum curing periods for bonded windows 6162
1 2 Window repair 6162
1 3 Installation instructions for bonded windows 6164
1 4 Preparing old undamaged windows for fitting 6165
1 5 Preparing new windows for installing 6165
1 6 Preparing body flange for fitting 6166
1 7 Cleaning off excess adhesive 6167
2 Windscreen 6168
2 1 Assembly overview – windscreen 6168
2 2 Removing and installing windscreen 6169
2 2 1 Removing and installing windscreen 6169
2 2 2 Removing broken windscreen 6172
3 Rear windscreen 6173
3 1 Assembly overview – rear window 6173
3 2 Removing and installing rear window 6173
3 2 1 Removing and installing rear window 6173
3 2 2 Removing broken rear window 6176
4 Door windows 6177
4 1 Assembly overview – front door window 6177
4 2 Assembly overview – rear door window 6178
4 3 Removing and installing front door window 6178
4 4 Removing and installing rear door window 6182
4 5 Removing and installing fixed rear door window 6186
66 – Exterior equipment 6189
1 Radiator grille and front trim 6189
1 1 Assembly overview – radiator grille 6189
1 2 Removing and installing radiator grille 6189
2 Spoiler 6192
2 1 Removing and installing spoiler 6192
3 Mouldings, trims, extensions 6198
3 1 Assembly overview – covers 6198
3 2 Assembly overview – side member trim 6200
3 3 Assembly overview – water deflector 6200
3 4 Assembly overview – B-pillar trim 6202
3 5 Removing and installing trim strip 6202
3 6 Removing and installing cover 6204
3 7 Removing and installing entry moulding 6205
3 8 Removing and installing side member trim 6208
3 8 1 Removing and installing side member trim 6208
3 8 2 ‏Removing and installing side member trim, GLI 6212
3 9 Removing and installing water deflector 6217
3 10 Removing and installing B-pillar trim 6221
4 Noise insulation 6223
4 1 Assembly overview – noise insulation 6223
4 1 1 Assembly overview – noise insulation, petrol engine 6223
4 1 2 Assembly overview – noise insulation for diesel engines 6224
4 1 3 Assembly overview – skid plate 6224
4 2 Removing and installing noise insulation 6225
4 2 1 Removing and installing noise insulation, petrol engine 6225
4 2 2 Removing and installing noise insulation, diesel engine 6226
4 2 3 Removing and installing underbody guard 6227
5 Underbody cladding 6229
5 1 Overview of fitting locations – underbody cladding 6229
5 1 1 Assembly overview – underbody cladding, front 6229
5 1 2 Assembly overview – underbody cladding, rear 6230
5 2 Assembly overview – bracing on underbody 6232
5 3 Removing and installing underbody cladding 6232
5 3 1 Removing and installing underbody cladding, front 6232
5 3 2 Removing and installing underbody cladding, rear 6234
5 4 Removing and installing tunnel cross-piece 6235
6 Exterior mirror 6238
6 1 Assembly overview – exterior mirror 6238
6 1 1 Assembly overview – exterior mirror, manual operation 6238
6 1 2 Assembly overview – exterior mirror, electric operation 6239
6 2 Removing and installing exterior mirror 6241
6 2 1 Removing and installing exterior mirror, manually operated 6241
6 2 2 Removing and installing exterior mirror, electrically operated 6243
6 3 Removing and installing mirror glass 6246
6 4 Removing and installing mirror adjustment unit 6248
6 5 Removing and installing mirror cover 6250
6 5 1 Removing and installing mirror cover, exterior mirror without turn signal repeater 6250
6 5 2 Removing and installing mirror housing, exterior mirror with turn signal repeater 6251
6 6 Removing and installing mirror trim 6253
6 6 1 Removing and installing mirror trim, exterior mirror without turn signal repeater 6253
6 6 2 Removing and installing mirror trim, exterior mirror with turn signal repeater 6254
7 Wheel housing liner 6257
7 1 Assembly overview – front wheel housing liner 6257
7 2 Assembly overview – rear wheel housing liner 6258
7 3 Removing and installing front wheel housing liner 6258
7 4 Removing and installing rear wheel housing liner 6260
8 Lettering and badges 6263
8 1 Assembly overview – lettering and badges 6263
8 2 Dimensions – lettering and badges on rear 6264
8 2 1 Dimensions for lettering, model designation 6264
8 2 2 Dimensions for lettering, engine type 6264
8 2 3 Dimensions for lettering, additional designations 6265
8 2 4 Dimensions for “GLI” lettering 6265
8 2 5 Dimensions for “HYBRID” and “SPORT” lettering 6266
8 2 6 Removing and installing badge on rear lid 6266
8 3 Dimensions – lettering and badges on sides 6268
8 3 1 Dimensions – lettering on wing “MATCH”, “LIFE” and “sochiEDITION” 6268
8 3 2 Dimensions – lettering on wing, “GTI” 6268
8 3 3 Dimensions – lettering on wing, “HYBRID” 6269
8 3 4 Dimensions – lettering on wing, “AVENUE” 6269
8 4 Removing and installing badges at vehicle front 6269
8 5 Removing and installing lettering 6270
9 Support tool 6272
9 1 Assembly overview – towing bracket 6272
9 2 Removing and installing towing bracket 6272
00 – Technical data 6279
1 Explanation of symbols 6279
1 1 Sanding 6279
1 2 Seam seals 6279
1 3 Cavity sealing 6281
2 Paint structure 6282
2 1 Structure of factory finish, cathodic dip primer 6282
2 2 Structure of factory finish, filler-primer 6283
2 3 Structure of factory finish, base coat 6285
2 4 Structure of factory finish, clear coat 6288
3 Areas exposed to stone chipping 6291
3 1 Body areas exposed to stone chipping 6291
4 Masking areas 6292
4 1 Masking areas, front body 6292
4 2 Masking areas, middle body 6296
4 3 Masking areas, rear body 6297
5 Seam seals 6299
5 1 Seam seals, front body 6299
5 2 Seam seals, middle body 6304
5 3 Seam seals, rear body 6307
6 Undercoating 6317
6 1 Undercoated areas, front body 6317
6 2 Undercoated areas, middle body 6318
6 3 Undercoated areas, rear body 6319
7 Cavity sealing 6321
7 1 Cavity sealing, overview of body 6321
7 2 Cavity sealing, front body 6322
7 3 Cavity sealing, middle body 6322
7 4 Cavity sealing, rear body 6326
00 – Technical data 6337
1 Safety information 6337
1 1 Safety measures when working on vehicles with a start/stop system 6337
1 2 Safety precautions when using testers and measuring instruments during a road test 6337
1 3 Operation and safety notes for gas discharge lamps 6338
2 Repair notes 6340
2 1 Contact corrosion 6340
2 2 Routing and attachment of lines 6340
3 Battery 6341
3 1 Types of battery 6341
3 2 Battery – general notes 6341
3 2 1 Warning notices and safety regulations 6341
3 2 2 Battery terminal connection 6341
3 2 3 Battery recharging or jump start on vehicles with Start/Stop system 6341
27 – Starter, current supply, CCS 6342
1 Battery 6342
1 1 Assembly overview – battery 6342
1 1 1 Assembly overview – battery, without battery monitor control unit 6342
1 1 2 Assembly overview – battery, with battery monitor control unit 6344
1 1 3 Assembly overview – battery, high-voltage vehicle 6345
1 2 Removing and installing battery 6345
1 2 1 Removing and installing battery in engine compartment 6345
1 2 2 Removing and installing battery in luggage compartment, high-voltage vehicle 6347
1 2 3 Adapting battery 6348
1 3 Disconnecting and connecting battery 6348
1 3 1 Disconnecting and connecting battery, in engine compartment 6348
1 3 2 Disconnecting and connecting battery in luggage compartment, high-voltage vehicle 6350
1 4 Removing and installing battery tray 6352
1 4 1 Removing and installing battery tray in engine compartment 6352
1 4 2 Removing and installing battery tray in luggage compartment, high-voltage vehicle 6353
1 5 Checking battery 6354
1 6 Charging battery 6354
1 7 Removing and installing earth wire with battery monitor control unit -J367- 6354
1 7 1 Battery monitor control unit -J367- 6354
1 7 2 Renewing and commissioning battery monitor control unit -J367- 6354
1 7 3 Removing and installing battery monitor control unit -J367- in engine compartment 6355
1 7 4 Removing and installing battery monitor control unit -J367- in luggage compartment, high-voltage vehicle 6356
1 8 Adapting battery monitor control unit -J367- 6357
2 Alternator 6358
2 1 Assembly overview – alternator 6358
2 1 1 Assembly overview – alternator without sliding bushes 6358
2 1 2 Assembly overview – alternator with sliding bushes 6359
2 2 Removing and installing alternator 6360
2 2 1 Removing and installing alternator, vehicles with 1 2 l TSI engine 6360
2 2 2 Removing and installing alternator, vehicles with 1 4 l TSI engine 6362
2 2 3 Removing and installing alternator, vehicles with 1 6 l petrol engine 6365
2 2 4 Removing and installing alternator, vehicles with 2 0 l indirect injection engine 6367
2 2 5 Removing and installing alternator, vehicles with 1 8 l/2 0 l TSI engine 6369
2 2 6 Removing and installing alternator -C-, vehicles with 2 5 l petrol engine 6372
2 2 7 Removing and installing alternator, vehicles with diesel engine 6374
2 3 Checking alternator 6376
2 4 Checking poly V-belt 6376
2 5 Removing and installing poly V-belt pulley 6377
2 5 1 Removing and installing poly V-belt pulley, without freewheel 6377
2 5 2 Removing and installing Bosch poly V-belt pulley with freewheel 6378
2 5 3 Removing and installing Valeo poly V-belt pulley with freewheel 6379
2 5 4 Removing and installing poly V-belt pulley, decoupler pulley with freewheel 6382
2 6 Removing and installing voltage regulator 6384
2 6 1 Removing and installing Bosch voltage regulator -C1- 6384
2 6 2 Removing and installing Valeo voltage regulator -C1- 6385
3 Starter motor 6388
3 1 Assembly overview – starter 6388
3 1 1 Exploded view – starter (vehicles with manual gearbox) 6388
3 1 2 Assembly overview – starter, vehicles with automatic gearbox 6389
3 1 3 Assembly overview – starter (vehicles with dual clutch gearbox) 6390
3 2 Removing and installing starter motor 6390
3 2 1 Removing and installing starter, vehicle with manual gearbox 6390
3 2 2 Removing and installing starter, vehicles with automatic gearbox 6393
3 2 3 Removing and installing starter, vehicles with dual clutch gearbox 6396
3 3 Checking starter 6397
4 Cruise control system (CCS) 6398
5 Start/stop system 6399
5 1 General description – start/stop system 6399
5 2 Removing and installing voltage stabiliser 6401
5 2 1 Removing and installing voltage stabiliser -J532-, left-hand drive 6401
5 2 2 Removing and installing voltage stabiliser -J532-, right-hand drive models 6401
6 Adaptive cruise control 6402
6 1 Overview of fitting locations – adaptive cruise control 6402
6 1 1 Overview of fitting locations – adaptive cruise control 6402
6 2 Removing and installing automatic distance control unit 6403
6 2 1 Removing and installing adaptive cruise control unit -J428- together with retaining plate 6403
6 2 2 Removing and installing adaptive cruise control unit -J428-, with mounting plate 6404
6 2 3 Removing adaptive cruise control unit -J428- from and installing to adapter frame 6404
6 3 Calibrating adaptive cruise control 6406
90 – Gauges, instruments 6407
1 Dash panel insert 6407
1 1 Assembly overview – dash panel insert 6407
1 2 Removing and installing dash panel insert -KX2- 6408
1 2 1 Renewing dash panel insert -KX2- 6408
1 2 2 Removing and installing dash panel insert -KX2- 6408
1 3 Multi-pin connector pin assignment on dash panel insert 6409
1 4 Removing and installing ambient temperature sensor 6410
2 Horn 6411
2 1 Assembly overview – horn 6411
2 2 Removing and installing treble horn -H2- and bass horn -H7- 6411
92 – Windscreen wash/wipe system 6413
1 windscreen wiper system 6413
1 1 Assembly overview – windscreen wiper system 6413
1 2 Moving wipers to service position 6414
1 2 1 Moving wipers to service position 6414
1 2 2 Deactivating wiper motor control unit -J400- APP function 6414
1 3 Removing and installing wiper blade 6414
1 4 Removing and installing wiper arms 6415
1 5 Adjusting wiper arms 6417
1 6 Removing and installing wiper motor -V- 6418
1 6 1 Removing wiper frame with linkage and wiper motor -V- 6418
1 6 2 Removing and installing wiper motor -V- 6419
1 7 Removing and installing rain and light sensor 6421
1 8 Repairing rain and light sensor 6423
2 Windscreen washer system 6425
2 1 Assembly overview – windscreen washer system 6425
2 2 Removing and installing washer fluid reservoir 6426
2 2 1 Removing and installing filler neck 6426
2 2 2 Removing and installing washer fluid reservoir 6427
2 3 Removing and installing windscreen washer fluid level sender 6427
2 4 Removing and installing windscreen washer pump 6428
2 5 Removing and installing washer jets 6429
2 6 Adjusting spray jets 6429
3 Headlight washer system 6430
3 1 Assembly overview – headlight washer system 6430
3 2 Removing and installing headlight washer system pump -V11- 6430
3 3 Removing and installing washer jets 6431
3 4 Adjusting spray jets 6432
3 5 Removing and installing pop-up cylinder 6432
4 Washer fluid lines 6434
4 1 Repairing washer fluid lines 6434
94 – Lights, bulbs, switches – exterior 6435
1 Headlights 6436
1 1 Assembly overview – headlight 6436
1 1 1 Overview – headlights, halogen bulbs, halogen headlights 6437
1 1 2 Overview – headlights, gas discharge bulbs, cornering light, xenon headlights 6437
1 1 3 Assembly overview – headlights, dual halogen headlights, up to model year 2017 6437
1 1 4 Assembly overview – headlights, dual halogen headlights, as of model year 2017 6439
1 1 5 Assembly overview – headlights, gas discharge bulbs, cornering light, xenon headlights 6441
1 2 Removing and installing headlight 6442
1 3 Adjusting headlights 6443
1 3 1 Adjusting headlights, dual halogen headlights 6443
1 3 2 Adjusting headlights, xenon headlight 6443
1 3 3 Carrying out basic setting, xenon headlight 6444
1 4 Adjusting headlight installation position 6444
1 5 Removing and installing front turn signal bulb -M5-/-M7- 6445
1 5 1 Removing and installing front turn signal bulb, dual halogen headlights 6445
1 5 2 Removing and installing front turn signal bulb, xenon headlight 6446
1 6 Installing repair kit for headlight housing 6448
1 6 1 Repairing outer retaining tab 6448
1 6 2 Repairing centre retaining tab 6449
1 6 3 Repairing inner retaining tab 6450
1 6 4 Repairing lower retaining tab 6451
1 7 Converting headlights from driving on right to driving on left 6452
1 7 1 Changing headlights over from driving on right to driving on left (dual halogen headlights) 6452
1 7 2 Converting headlights from driving on right to driving on left, xenon headlights 6453
1 8 Converting headlights from driving on left to driving on right 6453
1 8 1 Changing headlights over from driving on left to driving on right (dual halogen headlights) 6453
1 8 2 Converting headlights from driving on left to driving on right, xenon headlights 6454
1 9 Removing and installing headlight range control motor -V48-/-V49- 6455
1 9 1 Headlight range control motor -V48-/-V49-, dual halogen headlights 6455
1 9 2 Headlight range control motor -V48-/-V49-, xenon headlights 6455
1 10 Removing and installing dipped beam bulb 6456
1 11 Removing and installing headlight main beam bulb -M30-/-M32- 6457
1 12 Removing and installing gas discharge bulb -L13-/-L14- 6458
1 13 Removing and installing side light bulb -M1-/-M3- 6460
1 14 Removing and installing daytime running light bulb -L174-/-L175- 6461
1 14 1 Removing and installing daytime running light bulb -L174-/-L175-, dual halogen headlights, up to model year 2017 6461
1 14 2 Removing and installing daytime running light bulb -L174-/-L175-, dual halogen headlights, as of model year 2017 6463
1 14 3 Removing and installing daytime running light bulb -L174-/-L175-, xenon headlights 6463
1 15 Removing and installing daytime running light 6463
1 15 1 Removing and installing LED module for daytime running light and side light, dual halogen headlights, as of model year 2017 6463
1 15 2 Removing and installing LED module for daytime running light and side light, xenon headlights 6463
1 16 Removing and installing headlight screen adjustment solenoid 6464
1 16 1 Removing and installing headlight screen adjustment solenoid 6464
1 16 2 Testing headlight screen adjustment solenoid 6464
1 17 Removing and installing swivel module position sensor -G474-/-G475- 6464
1 17 1 Removing and installing swivel module position sensor 6464
1 17 2 Checking swivel module position sensor 6464
1 18 Removing and installing bulbs for cornering light -L148-/-L149- 6464
1 19 Removing and installing gas discharge bulb control unit -J343-/-J344- 6466
1 20 Removing and installing output module for headlight -J667-/-J668- 6466
1 20 1 Removing and installing output module for headlights 6466
1 20 2 Checking power output module for headlight 6467
1 21 Removing and installing control unit for daytime running light and side light -J860-/-J861- 6467
2 Fog lights 6469
2 1 Assembly overview – fog lights 6469
2 1 1 Assembly overview – fog lights, Jetta 6469
2 1 2 Assembly overview – fog lights, Jetta GLI 6470
2 1 3 Assembly overview – fog lights, Jetta GLI, »model year 2015« 6471
2 2 Removing and installing fog light 6471
2 2 1 Removing and installing fog light, Jetta 6471
2 2 2 Removing and installing fog light, Jetta GLI 6473
2 2 3 Removing and installing fog light, Jetta GLI, »model year 2015« 6473
2 3 Removing and installing fog light bulb -L22-/-L23- 6474
2 3 1 Removing and installing fog light bulb 6474
2 4 Adjusting fog lights 6475
3 Side marker light 6476
3 1 Removing and installing side marking light bulb 6476
4 Lights in exterior mirror 6478
4 1 Assembly overview – lights in exterior mirror 6478
4 2 Removing and installing turn signal repeater bulb -L131-/-L132- 6479
4 3 Removing and installing entry light in exterior mirror 6480
5 Tail lights 6481
5 1 Assembly overview – tail lights in body 6481
5 1 1 Assembly overview – tail lights in vehicle body (bulbs) 6481
5 1 2 Assembly overview – tail lights in vehicle body (LEDs) 6482
5 2 Assembly overview – tail lights in rear lid 6483
5 2 1 Assembly overview – tail lights in rear lid (bulbs) 6483
5 2 2 Assembly overview – tail lights in rear lid (LEDs) 6484
5 3 Removing and installing bulb carrier 6485
5 3 1 Removing and installing tail light bulb carrier, tail light in body 6485
5 3 2 Removing and installing tail light bulb carrier, tail light in rear lid 6486
5 4 Removing and installing tail light in rear lid 6486
5 5 Removing and installing tail light 6487
5 6 Removing and installing tail light bulb -M2-/-M4- 6487
5 7 Removing and installing rear fog light 6488
5 8 Removing and installing brake and tail light bulb -M21-/-M22- 6488
5 9 Removing and installing reversing light bulb 6489
5 9 1 Removing and installing reversing light bulb (conventional bulb) 6489
5 9 2 Removing and installing reversing light bulb (LED) 6489
5 10 Removing and installing turn signal bulb 6490
5 10 1 Removing and installing turn signal bulb (conventional bulb) 6490
5 10 2 Removing and installing turn signal bulb (LED) 6490
6 High-level brake light 6492
6 1 Assembly overview – high-level brake light 6492
6 2 Removing and installing additional brake light 6492
6 3 Removing and installing high-level brake light 6493
7 Number plate light 6494
7 1 Removing and installing number plate light -X4-/-X5- 6494
7 2 Removing and installing bulb for number plate light -X4-/-X5- 6494
8 Entry and start authorisation system 6495
8 1 Overview of fitting locations – entry and start authorisation system 6495
8 1 1 Overview of fitting locations – entry and start authorisation system 6495
8 1 2 Overview – entry and start authorisation system 6497
8 2 Removing and installing entry and start authorisation control unit -J518- 6498
8 2 1 Removing and installing (left-hand drive models) entry and start authorisation control unit -J518- 6498
8 2 2 Removing and installing entry and start authorisation control unit -J518-, right-hand drive 6498
8 2 3 Coding entry and start authorisation control unit -J518- 6499
8 3 Removing and installing interior aerial 1 for entry and start authorisation -R138- 6500
8 4 Removing and installing interior aerial 2 for entry and start authorisation -R139- 6500
8 5 Removing and installing front passenger side aerial for entry and start system -R135- 6501
8 6 Removing and installing driver side aerial for entry and start system -R134- 6501
8 7 Removing and installing luggage compartment aerial for entry and start system -R137- 6501
8 8 Removing and installing rear bumper aerial for entry and start system -R136- 6502
8 9 Checking entry and start system aerials and sensors 6503
8 9 1 Checking driver side aerial for entry and start authorisation -R134- 6503
8 9 2 Checking front passenger side aerial for entry and start authorisation -R135- 6503
8 9 3 Checking rear bumper aerial for entry and start authorisation -R136- 6503
8 9 4 Checking luggage compartment aerial for entry and start authorisation -R137- 6503
8 9 5 Checking interior aerial 1 for entry and start authorisation -R138- 6504
8 9 6 Checking interior aerial 2 for entry and start authorisation -R139- 6504
8 9 7 Checking driver door exterior handle contact sensor -G415- 6504
8 9 8 Checking front passenger door exterior handle contact sensor -G416- 6504
9 Steering column switch module 6505
9 1 Assembly overview – steering column switch module 6505
9 1 1 Assembly overview – steering column switch module, Valeo 6505
9 1 2 Assembly overview – steering column switch module, Kostal 6507
9 1 3 Assembly overview – steering column switch module, interface for entry and start system 6507
9 2 Removing and installing steering column electronics control unit -J527- 6508
9 2 1 Removing and installing steering column electronics control unit -J527-, Valeo 6508
9 2 2 Removing and installing steering column electronics control unit -J527-, Kostal 6511
9 2 3 Coding steering column electronics control unit -J527- 6513
9 3 Removing and installing steering column combination switch 6513
9 3 1 Removing and installing steering column combination switch -E595-, Valeo 6513
9 3 2 Removing and installing steering column combination switch -E595-, Valeo, interface for entry and start system 6516
9 3 3 Removing and installing steering column combination switch -E595-, Kostal 6518
9 3 4 Removing and installing steering column combination switch -E595-, Kostal, interface for entry and start system 6521
9 4 Removing and installing base for steering column combination switch 6523
9 4 1 Removing and installing steering column switch base, Valeo 6523
9 4 2 Removing and installing steering column switch base, Valeo, interface for entry and start system 6525
9 4 3 Removing and installing steering column switch base, Kostal 6527
9 4 4 Removing and installing steering column switch base, Kostal, interface for entry and start system 6529
9 5 Removing and installing electronic steering column lock control unit -J764- 6531
9 5 1 Removing and installing electronic steering column lock control unit -J764- 6531
9 5 2 Renewing electronic steering column lock control unit -J764- 6532
9 6 Removing and installing ignition/starter switch 6532
9 7 Checking ignition/starter switch 6533
9 8 Removing and installing lock cylinder 6534
9 9 Removing and installing steering lock housing 6536
9 10 Removing and installing ignition key withdrawal lock solenoid -N376- 6536
10 Parking aid 6538
10 1 Assembly overview – parking aid 6538
10 1 1 Assembly overview – parking aid, left-hand drive vehicles 6538
10 1 2 Assembly overview – parking aid, right-hand drive vehicles 6540
10 2 Removing and installing parking aid control unit -J446- 6541
10 2 1 Removing and installing parking aid control unit -J446-, left-hand drive vehicle 6541
10 2 2 Removing and installing parking aid control unit -J446-, RHD vehicle 6542
10 3 Removing and installing front parking aid warning buzzer -H22- 6542
10 3 1 Removing and installing front parking aid warning buzzer -H22-, LHD vehicles 6542
10 3 2 Removing and installing front parking aid warning buzzer -H22-, RHD vehicles 6543
10 4 Removing and installing rear parking aid warning buzzer -H15- 6543
10 4 1 Removing and installing rear parking aid warning buzzer -H15- 6543
10 4 2 Adjusting volume of rear parking aid warning buzzer -H15- 6544
10 4 3 Adjusting pitch of rear parking aid warning buzzer pitch -H15- 6544
10 5 Removing and installing front parking aid senders 6544
10 5 1 Removing and installing front parking aid senders 6544
10 5 2 Bonding sender retainer in front bumper cover 6546
10 5 3 Renewing front parking aid senders 6547
10 5 4 Repairing sender retainer in front bumper cover 6548
10 6 Removing and installing rear parking aid senders 6548
10 6 1 Removing and installing rear parking aid senders 6548
10 6 2 Bonding sender retainer in rear bumper cover 6550
10 6 3 Renewing parking aid senders 6551
10 6 4 Repairing sender retainers in rear bumper cover 6552
11 Main beam assist 6553
11 1 Overview – main beam assist 6553
11 2 Overview of fitting locations – main beam assist 6553
11 3 Removing and installing main beam assist control unit -J844- 6554
11 4 Renewing main beam assist control unit -J844- 6555
11 5 Coding main beam assist control unit -J844- 6555
11 6 Removing and installing light sensor -G399- 6555
12 Automatic headlight range control 6556
12 1 Assembly overview – automatic headlight range control 6556
12 1 1 Assembly overview – automatic headlight range control, LHD vehicles 6556
12 1 2 Assembly overview – automatic headlight range control, RHD vehicles 6557
12 2 Removing and installing headlight range control unit 6557
12 2 1 Removing and installing control unit for cornering light and headlight range control -J745-, LHD vehicles 6557
12 2 2 Removing and installing control unit for cornering light and headlight range control -J745-, RHD vehicles 6558
13 Towing bracket 6559
13 1 Assembly overview – towing bracket socket 6559
13 2 Removing and installing trailer detector control unit -J345- 6559
13 3 Trailer socket 6560
14 Blind Spot Monitor 6562
14 1 Assembly overview – blind spot monitor 6562
14 2 Removing and installing warning lamp for Blind Spot Monitor -K303-/-K304- 6562
14 3 Removing and installing blind spot monitor control unit -J1086-/-J1087- 6563
14 4 Calibrating Blind Spot Monitor 6564
14 4 1 Measurement location 6564
14 4 2 Preparatory measures for calibration 6565
14 4 3 Calibrating blind spot monitor control unit -J1086-/-J1087- 6569
96 – Lights, bulbs, switches – interior 6571
1 Lights 6571
1 1 Overview of fitting locations – lights in dash panel 6571
1 2 Overview of fitting locations – lights in luggage compartment 6573
1 3 Overview of fitting locations – lights in roof trim 6574
1 4 Removing and installing glove compartment light -W6- 6574
1 5 Removing and installing Central locking SAFELOCK function warning lamp -K133- 6576
1 6 Removing and installing luggage compartment light -W3- 6577
1 7 Removing and installing illuminated vanity mirror -W20-/-W14- 6578
1 8 Renewing front interior light bulb -W1-/-W13-/-W19- 6579
1 9 Removing and installing centre reading lights 6581
1 10 Renewing bulb of rear interior light -W47-/-W48- 6581
2 Controls 6584
2 1 Overview of fitting locations – controls in dash panel 6585
2 2 Overview of fitting locations – controls in front doors 6586
2 3 Overview of fitting locations – controls in rear doors 6587
2 4 Overview of fitting locations – controls in centre console 6588
2 5 Overview of fitting locations – controls in roof trim 6589
2 6 Removing and installing rotary light switch -EX1- 6589
2 7 Removing and installing regulator for switch and instrument illumination -E20- 6591
2 8 Removing and installing tyre pressure monitor display button -E492- 6592
2 9 Removing and installing rear ear interior locking switch -E273-/-E274- 6593
2 10 Removing and installing driver side interior locking button for central locking system -E308- 6594
2 11 Removing and installing front passenger side interior locking button for central locking system -E309- 6595
2 12 Removing and installing remote release button for fuel filler flap and rear lid -E463- 6596
2 13 Removing and installing Start/Stop operation button -E693- 6597
2 14 Removing and installing TCS and ESP button -E256- 6598
2 15 Removing and installing parking aid button -E266- 6598
2 16 Removing and installing the starter button -E378- 6598
2 17 Removing and installing button for electric drive -E656-, high-voltage vehicle 6599
2 18 Removing and installing front passenger side airbag deactivated warning lamp -K145- 6599
2 19 Removing and installing hazard warning light button -E229- 6600
2 20 Removing and installing glove compartment light switch -E26- 6600
2 21 Removing and installing mirror adjustment switch -E43-/-E168- 6601
2 22 Removing and installing operating unit for window regulator in driver door -E512- 6602
2 23 Removing and installing window regulator switch in front passenger door -E107- 6603
2 24 Removing and installing interior monitoring deactivation switch -E267- 6605
2 25 Removing and installing rear window regulator button -E700-/-E705- 6606
2 26 Removing and installing rear lid contact switch 6607
2 26 1 Removing and installing rear lid locking unit -F256- 6607
2 27 Removing and installing sunroof button -E325- 6607
2 28 Removing and installing front interior light/reading light 6608
2 28 1 Removing and installing front interior light -W1-, vehicle with no sliding sunroof 6608
2 28 2 Removing and installing front interior light -W1-, vehicle with sliding sunroof 6609
2 29 Removing and installing rear interior light/reading light 6610
2 30 Removing and installing garage door operating unit -E284- 6611
3 Anti-theft alarm 6613
3 1 Assembly overview – interior monitor 6613
3 2 Activating and deactivating anti-theft alarm 6614
3 3 Central locking and anti-theft alarm system aerial -R47- 6615
3 4 Removing and installing alarm horn -H12- 6615
3 5 Removing and installing interior monitoring sensor -G273- 6616
3 6 Removing and installing bonnet contact switch -F266- 6616
3 7 Adaptations of anti-theft alarm system 6616
3 7 1 Adapting alarm delay on opening driver door 6616
3 7 2 Adapting country setting for alarm horn -H12- 6617
4 Immobiliser 6618
4 1 Removing and installing immobiliser control unit 6618
4 1 1 Overview – immobiliser, generation IV 6618
4 1 2 Removing and installing immobiliser control unit, 5th generation immobiliser 6619
4 1 3 Removing and installing immobiliser control unit -J362- 6619
4 1 4 Adapting immobiliser control unit -J362- 6619
4 1 5 New identity on renewing all components 6620
4 1 6 Online system test 6620
4 2 Removing and installing immobiliser reader coil 6620
4 3 Ignition key 6620
4 3 1 Removing and installing battery of ignition key with remote control 6620
4 3 2 Ignition key – variable code transponder 6620
4 3 3 Loss of an ignition key 6620
4 3 4 Adapting ignition key to immobilizer 6621
4 3 5 Checking ignition key with remote control 6621
5 Cigarette lighter, socket 6622
5 1 Removing and installing AC/DC converter with socket 6622
97 – Wiring 6625
1 Relay carriers, fuse holders, electronics boxes 6625
1 1 Overview of fitting locations – relay carriers, fuse holders, E-boxes 6625
1 2 Removing and installing electronics box (E-box) 6626
1 3 Removing and installing relay and fuse holder in electronics box 6627
1 4 Removing and installing relay and fuse holder behind dash panel on driver side 6628
1 4 1 Removing and installing fuse holder behind dash panel on driver side 6628
1 4 2 Removing and installing onboard supply control unit -J519- 6629
1 5 Removing and installing fuse holder on battery, high-voltage vehicle 6630
2 Select Control units 6631
2 1 Overview of fitting locations – control units 6631
2 2 Removing and installing onboard supply control unit -J519- 6632
2 2 1 Description of onboard supply control unit -J519- 6632
2 2 2 Removing and installing onboard supply control unit -J519-, High version 6634
2 2 3 Removing and installing onboard supply control unit -J519-, Low version 6635
2 2 4 Renewing onboard supply control unit -J519- 6636
2 2 5 Final control diagnosis of onboard supply control unit -J519- 6636
2 2 6 Coding onboard supply control unit -J519- 6637
2 2 7 Deactivating factory mode of onboard supply control unit -J519- 6637
2 2 8 Adapting remote control unit key 6637
2 2 9 Checking remote control unit key 6637
2 2 10 Coding rain and light sensor -G397- 6637
2 3 Removing and installing data bus diagnostic interface -J533- 6638
2 3 1 Description of data bus diagnostic interface -J533- 6638
2 3 2 Renewing data bus diagnostic interface -J533- 6638
2 3 3 Removing and installing data bus diagnostic interface -J533-, LHD, High version 6639
2 3 4 Removing and installing data bus diagnostic interface -J533-, RHD, High version 6639
2 3 5 Coding data bus diagnostic interface -J533- 6640
2 3 6 Checking bus activity of data bus diagnostic interface -J533- 6640
2 3 7 Adapting bus subscriber of data bus diagnostic interface -J533- 6640
2 4 Removing and installing garage door operation control unit 6640
3 Connectors 6641
3 1 Separating left door connector 6641
3 1 1 Separating A-pillar door connector 6641
3 1 2 Separating B-pillar door connector 6641
3 2 Separating right door connector 6642
3 2 1 Separating A-pillar door connector 6642
3 2 2 Separating B-pillar door connector 6642
3 3 Repairing electrical wiring harnesses and plug-in connections 6642
4 Releasing and dismantling connector housings 6643
5 Repairing aerial cables 6644
6 Fibre optic cables 6645
7 Vehicle diagnosis, testing and information systems 6646
00 – Technical data 6651
1 Repair instructions 6651
1 1 General repair instructions 6651
1 2 Notes on repair of CAN bus wiring 6651
91 – Communication 6652
1 Infotainment system 6652
1 1 Overview of fitting locations – Infotainment system 6652
1 2 Removing and installing magnetic field sender for compass 6652
2 Sound system 6654
2 1 Components of sound system 6654
2 1 1 Components of sound system, 4 loudspeakers 6654
2 1 2 Components of sound system, 6 loudspeakers 6656
2 1 3 Components of sound system, 8 loudspeakers 6657
2 1 4 Components of sound system, Volkswagen Sound 6658
2 1 5 Components of sound system, branded sound 6659
2 2 Overview of fitting locations – sound system 6660
2 3 Removing and installing amplifier -R12- for digital sound package 6660
2 3 1 Removing and installing amplifier -R12- 6660
2 3 2 Removing and installing retainer for amplifier -R12- 6661
2 4 Removing and installing rear treble loudspeakers -R14-/-R16- 6662
2 5 Removing and installing front treble loudspeakers -R20-/-R22- 6663
2 6 Removing and installing rear bass loudspeakers -R15-/-R17- 6663
2 7 Removing and installing front bass loudspeakers -R21-/-R23- 6664
2 8 Removing and installing subwoofer -R211- 6665
2 9 Pin assignments 6665
2 10 Renewing rotary knobs of display unit for front information display and operating unit control unit -J685- 6669
3 Aerial systems 6670
3 1 Components of aerial systems 6670
3 2 Overview of fitting locations – aerial systems 6670
3 3 Removing and installing frequency modulation (FM) frequency filter R178/R179 6671
3 3 1 Removing and installing frequency modulation (FM) frequency filter in negative wire -R178- 6671
3 3 2 Removing and installing frequency modulation (FM) frequency filter in positive wire -R179- 6672
3 4 Removing and installing aerial amplifier -R24-/aerial amplifier 2 -R111- 6672
3 5 Removing and installing roof aerial 6673
3 6 Removing and installing vehicle location system aerial 1 -R259- and vehicle location system aerial 2 -R260- 6674
4 Radio 6676
4 1 Components of radio system 6676
4 2 Overview of fitting locations – radio 6698
4 3 Assembly overview – radio 6700
4 4 Removing and installing radio 6700
4 4 1 Removing and installing radio, any versions except for Composition Colour and Composition Media 6700
4 4 2 Removing and installing radio, only Composition Colour and Composition Media 6702
4 5 Pin assignments 6704
4 5 1 Pin assignments, RCD 210 6704
4 5 2 Pin assignments, RCD 030+ 6706
4 5 3 Pin assignments, RCD 310 6708
4 5 4 Pin assignments, RCD 300+ 6710
4 5 5 Pin assignments, Premium 8 6713
4 5 6 Pin assignments, RCD 510 6715
4 5 7 Pin assignments, RCD 510+ 6718
4 5 8 Connector pin assignment, RCD 320G 6721
4 5 9 Connector pin assignment, RCD 330G 6723
4 5 10 Connector pin assignment, Composition Colour 6725
4 5 11 Connector pin assignment, Composition Media 6728
5 Telephone system 6731
5 1 Components of telephone system 6731
5 1 1 Components of telephone system, UTP High with Bluetooth 6731
5 1 2 Components of telephone system, UTP Premium with Bluetooth and audio streaming 6732
5 1 3 Components of telephone system, UTP in radio RNS 315 6733
5 1 4 Components of telephone, UMI 6734
5 1 5 Components of telephone, Bluetooth hands-free system 6736
5 1 6 Components of telephone, Bluetooth car phone online 6736
5 2 Overview of fitting locations – telephone system 6737
5 2 1 Overview of fitting locations – telephone system 6737
5 2 2 Overview of fitting locations – telephone system, UMI 6739
5 2 3 Overview of fitting locations – telephone system, Bluetooth hands-free system, Bluetooth car phone online 6739
5 3 Removing and installing telephone microphone -R38- 6740
5 4 Removing and installing telephone bracket -R126- 6740
5 5 Removing and installing telephone transmitter and receiver unit 6741
5 6 Removing and installing mobile telephone operating electronics control unit -J412-, UMI 6743
5 6 1 Removing and installing mobile telephone operating electronics control unit -J412-, UMI control unit on glove compartment 6743
5 6 2 Removing and installing mobile telephone operating electronics control unit -J412-, UMI control unit in centre console 6743
5 7 Removing and installing operating unit for preparation for mobile phone 6744
5 8 Pin assignments 6745
5 8 3 Connector pin assignment, Bluetooth hands-free system, Bluetooth car phone online 6748
6 Navigation system 6750
6 1 Components of navigation system 6750
6 1 4 Components of navigation system, Discover Media 6757
6 2 Overview of fitting locations – navigation system 6757
6 3 Pin assignments 6759
6 3 1 Pin assignments, RNS 315 6759
6 3 2 Pin assignments, RNS 315+ 6761
6 3 3 Pin assignments, RNS 510 6763
6 3 4 Connector pin assignment, Discover Media 6766
6 4 Removing and installing control unit for navigation system 6766
6 4 1 Removing and installing control unit with display for radio and navigation -J503- 6766
6 4 2 Removing and installing control unit for navigation system, Discover Media 6768
6 5 Removing and installing control unit for vehicle location system 6768
7 Reversing camera 6770
7 1 Components of reversing camera system 6770
7 2 Overview of fitting locations – reversing camera system 6770
7 3 Removing and installing reversing camera -R189- 6771
8 Multifunction steering wheel 6773
8 1 Components of multifunction steering wheel 6773
8 2 Assembly overview – multifunction steering wheel 6773
8 3 Removing and installing steering wheel multifunction buttons -E441-/-E440- 6774
8 4 Removing and installing Tiptronic switch in steering wheel -E439-/-E438- 6775
9 Connection for external multimedia devices 6777
9 1 Components of connection for external multimedia units 6777
9 1 1 Components of connection for external multimedia devices, AUX-IN socket 6777
9 1 3 Components of connection for external multimedia devices, multimedia system control unit -J650- 6779
9 1 4 Components of connection for external multimedia devices, multimedia system control unit -J650-, UMI 6780
9 1 5 Components of connection for external multimedia devices, USB connection holder -R193- 6782
9 1 6 Components of connection for external multimedia devices, connection for external audio sources -R199- 6782
9 2 Connectors, connection for external multimedia devices 6783
9 2 2 Connectors, connection for external multimedia devices, connection 2 for external audio sources -R231- 6784
9 3 Removing and installing connection for external multimedia devices 6789
9 3 1 Removing and installing connection for external multimedia devices, AUX-In socket 6789
9 3 2 Removing and installing connection for external multimedia devices, connection 2 for external audio sources -R231- 6790
9 3 3 Removing and installing connection for external multimedia devices, multimedia system control unit -J650- 6790
9 3 4 Removing and installing connection for external multimedia devices, multimedia system control unit -J650-, UMI in glove compartment 6791
9 3 5 Removing and installing connection for external multimedia devices, multimedia system control unit -J650-, UMI in centre console 6792
9 3 6 Removing and installing connection for external multimedia devices, USB connection retainer -R193- 6793
9 3 7 Removing and installing connection for external multimedia devices, connection for external audio sources -R199- 6793
10 Car-Net 6795
10 1 Components of Car-Net 6795
10 1 1 Components of Car-Net, apart from PR no NZ3 (ERA GLONASS emergency call) 6795
10 1 2 Components of Car-Net, only PR no NZ3 (ERA GLONASS emergency call) 6796
10 2 Overview of fitting locations – Car-Net services 6798
10 2 1 Overview of fitting locations – Car-Net services apart from PR no NZ3 (ERA GLONASS emergency call) 6798
10 2 2 Overview of fitting locations – Car-Net services only PR no NZ3 (ERA GLONASS emergency call) 6799
10 3 Removing and installing emergency call module control unit and communication unit -J949- 6799
10 4 Removing and installing emergency button -E276- 6800
10 5 Removing and installing loudspeaker for emergency call module -R335- 6800
10 6 Removing and installing suppression filter -C10- 6801
10 7 Connectors of emergency call module control unit and communication unit -J949- 6802
00 – Technical data 6811
1 Safety information 6811
1 1 Safety regulations for working on fuel supply 6811
1 2 Safety measures when working on vehicles with a start/stop system 6811
1 3 Safety precautions when using testers and measuring instruments during a road test 6812
1 4 Safety precautions when working on the cooling system 6812
1 5 Safety precautions when working on ignition system 6812
2 Identification 6813
2 1 Engine number/engine data 6813
3 Repair notes 6815
3 1 Rules for cleanliness 6815
3 2 Foreign bodies in engine 6815
3 3 Contact corrosion 6815
3 4 Routing and attachment of lines 6815
3 5 Fitting radiators and condensers 6816
10 – Removing and installing engine 6817
1 Removing and installing engine 6817
1 1 Removing engine 6817
1 2 Separating engine and gearbox 6830
1 3 Securing engine on engine and gearbox support 6832
1 4 Installing engine 6834
2 Assembly mountings 6838
2 1 Assembly overview – assembly mountings 6838
2 2 Removing and installing engine mounting 6841
2 3 Removing and installing gearbox mounting 6843
2 4 Removing and installing pendulum support 6844
2 5 Supporting engine in installation position 6845
2 6 Adjusting assembly mountings 6854
2 7 Checking adjustment of assembly mountings 6857
13 – Crankshaft group 6858
1 Cylinder block (pulley end) 6858
1 1 Assembly overview – poly V-belt drive 6858
1 1 1 Assembly overview – poly V-belt drive, vehicles without air conditioner compressor 6858
1 1 2 Assembly overview – poly V-belt drive, vehicles with air conditioner compressor 6860
1 2 Assembly overview – sealing flange, belt pulley end 6862
1 3 Removing and installing poly-V belt 6864
1 3 1 Removing and installing poly V-belt, vehicles without air conditioner compressor 6864
1 3 2 Removing and installing poly V-belt, vehicles with air conditioner compressor 6866
1 4 Removing and installing tensioner for poly V-belt 6868
1 5 Removing and installing vibration damper 6869
1 6 Removing and installing engine support 6871
1 7 Renewing crankshaft oil seal for pulley end 6874
1 8 Removing and installing sealing flange on pulley end 6877
2 Cylinder block, gearbox end 6880
2 1 Assembly overview – cylinder block, gearbox end 6880
2 2 Assembly overview – drive plate 6881
2 3 Removing and installing drive plate 6883
2 4 Removing and installing flywheel 6885
2 5 Removing and installing sealing flange on gearbox side 6886
3 Crankshaft 6897
3 1 Crankshaft dimensions 6897
3 2 Renewing needle bearing in crankshaft 6897
3 3 Measuring axial clearance of crankshaft 6900
4 Pistons and conrods 6902
4 1 Assembly overview – pistons and conrods 6902
4 2 Removing and installing pistons 6905
4 3 Checking pistons and cylinder bores 6906
4 4 Separating new conrod 6908
4 5 Checking radial clearance of conrods 6909
4 6 Removing and installing oil spray jets 6909
15 – Cylinder head, valve gear 6912
1 Cylinder head 6912
1 1 Assembly overview – cylinder head 6912
1 2 Assembly overview – camshaft housing 6914
1 2 1 Assembly overview – camshaft housing, vehicles without adjustable exhaust camshaft 6914
1 2 2 Assembly overview – camshaft housing, vehicles with adjustable exhaust camshaft 6916
1 3 Removing and installing cylinder head 6918
1 4 Removing and installing camshaft housing 6923
1 5 Checking compression 6928
2 Toothed belt drive 6931
2 1 Assembly overview – toothed belt cover 6931
2 2 Assembly overview – toothed belt 6932
2 2 1 Assembly overview – toothed belt, vehicles without adjustable exhaust camshaft 6932
2 2 2 Assembly overview – toothed belt, vehicles with adjustable exhaust camshaft 6934
2 3 Removing and installing toothed belt guard 6936
2 3 1 Removing and installing upper toothed belt guard 6936
2 3 2 Removing and installing lower toothed belt guard 6937
2 4 Removing and installing toothed belt 6937
2 4 1 Removing and installing toothed belt, vehicles without adjustable exhaust camshaft 6937
2 4 2 Removing and installing toothed belt, vehicles with adjustable exhaust camshaft 6944
2 5 Checking valve timing 6951
2 6 Adjusting valve timing 6958
2 6 1 Checking valve timing, vehicles without adjustable exhaust camshaft 6958
2 6 2 Checking valve timing, vehicles without adjustable exhaust camshaft 6966
2 7 Removing toothed belt from camshaft 6975
2 7 1 Removing toothed belt from camshaft, exhaust side with camshaft adjuster 6975
2 7 2 Removing toothed belt from camshaft, exhaust side with toothed belt pulley 6979
3 Valve gear 6985
3 1 Assembly overview – valve gear 6985
3 2 Measuring axial play of camshaft 6987
3 3 Removing and installing camshaft oil seal 6988
3 3 1 Removing and installing camshaft oil seal for inlet camshaft, belt pulley end 6988
3 3 2 Removing and installing exhaust camshaft oil seal, pulley end 6990
3 3 3 Removing and installing exhaust camshaft oil seal, gearbox end 6992
3 4 Removing and installing camshaft adjuster 6994
3 4 1 Removing and installing inlet camshaft adjuster, vehicles with adjustable exhaust camshaft 6994
3 4 2 Removing and installing inlet camshaft adjuster, vehicles without adjustable exhaust camshaft 7000
3 4 3 Removing and installing camshaft adjuster for exhaust camshaft 7005
3 5 Removing and installing camshaft control valve 1 -N205- 7011
3 6 Removing and installing exhaust camshaft control valve 1 -N318- 7012
3 7 Removing and installing valve stem oil seals 7013
3 7 1 Removing and installing valve stem seals (cylinder head installed) 7013
3 7 2 Removing and installing valve stem seals (cylinder head removed) 7018
3 8 Removing and installing toothed belt pulley 7023
4 Inlet and exhaust valves 7026
4 1 Checking valve guides 7026
4 2 Checking valves 7027
4 3 Valve dimensions 7027
17 – Lubrication 7028
1 Sump, oil pump 7028
1 1 Assembly overview – sump/oil pump 7028
1 2 Engine oil 7032
1 3 Removing and installing lower part of sump 7032
1 4 Removing and installing upper part of sump 7037
1 5 Removing and installing oil pump 7044
1 6 Removing and installing oil level and oil temperature sender -G266- 7045
2 Engine oil cooler 7047
2 1 Assembly overview – engine oil cooler 7047
2 2 Removing and installing engine oil cooler 7047
3 Crankcase breather 7049
3 1 Assembly overview – crankcase breather system 7049
3 2 Removing and installing oil separator 7050
4 Oil filter, oil pressure switch 7054
4 1 Assembly overview – oil filter/oil pressure switch 7054
4 2 Removing and installing oil pressure switch -F1- 7055
4 3 Removing and installing oil pressure switch for reduced oil pressure -F378- 7056
4 4 Checking oil pressure 7057
4 5 Removing and installing valve for oil pressure control -N428- 7059
19 – Cooling 7060
1 Cooling system/coolant 7060
1 1 Connection diagram – coolant hoses 7060
1 2 Assembly overview – engine preheater 7061
1 3 Checking cooling system for leaks 7062
1 4 Draining and adding coolant 7065
1 5 Removing and installing engine preheating element -Z97- 7074
2 Coolant pump, regulation of cooling system 7077
2 1 Assembly overview –coolant pump, thermostat 7077
2 2 Assembly overview – electric coolant pump 7080
2 3 Assembly overview – coolant temperature sender 7081
2 4 Removing and installing electric coolant pump 7082
2 4 1 Removing and installing charge air cooling pump -V188- 7082
2 5 Removing and installing coolant pump 7084
2 6 Removing and installing thermostat 7090
2 6 1 Removing and installing thermostat for main coolant circuit (radiator) 7090
2 6 2 Removing and installing thermostat for coolant circuit of cylinder block 7092
2 7 Removing and installing toothed belt pulley for coolant pump 7093
2 8 Removing and installing coolant temperature sender -G62- 7095
2 9 Removing and installing radiator outlet coolant temperature sender -G83- 7096
3 Coolant pipes 7098
3 1 Assembly overview – coolant pipes 7098
3 2 Removing and installing coolant pipes 7098
4 Radiator, radiator fan 7103
4 1 Assembly overview – radiator/radiator fan 7103
4 2 Assembly overview – radiator cowl and radiator fan 7105
4 3 Removing and installing radiator 7106
4 4 Removing and installing water radiator for charge air cooling circuit 7108
4 5 Removing and installing radiator cowl 7111
4 6 Removing and installing radiator fan -V7- 7113
4 7 Removing and installing radiator fan 2 -V177- 7114
21 – Turbocharging/supercharging 7115
1 Turbocharger 7115
1 1 Assembly overview – turbocharger 7115
1 1 1 Assembly overview – turbocharger, version 1 7115
1 1 2 Assembly overview – turbocharger, version 2 7116
1 1 3 Assembly overview – lines on turbocharger 7117
1 2 Removing and installing turbocharger 7119
1 3 Removing and installing charge pressure positioner -V465- 7125
1 3 1 Removing and installing charge pressure positioner -V465-, version 1 7125
1 3 2 Removing and installing charge pressure positioner -V465-, version 2 7127
1 4 Removing and installing connection for turbocharger 7129
2 Charge air system 7133
2 1 Assembly overview – charge air system 7133
2 2 Removing and installing charge air cooler 7136
2 3 Removing and installing charge pressure sender -GX26- 7139
2 4 Checking charge air system for leaks 7140
2 5 Removing and installing air intake pipe 7141
24 – Mixture preparation – injection 7144
1 Injection system 7144
1 1 Overview of fitting locations – injection system 7144
2 Injectors 7149
2 1 Assembly overview – fuel rail with injectors 7149
2 2 Removing and installing fuel rail 7151
2 3 Removing and installing injectors 7151
2 4 Cleaning injectors 7158
3 Air filter 7160
3 1 Assembly overview – air filter housing 7160
3 2 Removing and installing air filter housing 7161
3 3 Removing and installing resonator for intake air 7162
4 Intake manifold 7164
4 1 Assembly overview – intake manifold 7164
4 2 Removing and installing intake manifold 7166
4 3 Removing and installing throttle valve module -GX3- 7170
4 4 Cleaning throttle valve module -GX3- 7171
5 Senders and sensors 7173
5 1 Removing and installing fuel pressure sender -G247- 7173
5 2 Checking fuel pressure sender -G247- 7174
5 3 Removing and installing intake manifold sender -GX9- 7176
6 Engine/motor control unit 7178
6 1 Removing and installing engine/motor control unit -J623- 7178
6 1 1 Removing and installing engine control unit -J623- without protective housing 7178
6 1 2 Removing and installing engine (motor) control unit -J623- with protective housing 7179
7 High-pressure pump 7183
7 1 Assembly overview – high-pressure pump 7183
7 1 1 Assembly overview – high-pressure pump, Hitachi 7183
7 1 2 Assembly overview – high-pressure pump, Continental 7184
7 1 3 Assembly overview – high-pressure pump, Bosch 7186
7 2 Removing and installing high-pressure pump 7187
7 3 Removing and installing high-pressure pipe 7189
8 Lambda probe 7192
8 1 Assembly overview – lambda probe 7192
8 1 1 Assembly overview – lambda probe, engine codes CZCA, CZDA 7192
8 1 2 Assembly overview -lambda probe, engine code CZTA 7193
8 2 Removing and installing lambda probe 7194
8 2 1 Removing and installing Lambda probe 1 before catalytic converter -GX10- 7194
8 2 2 Removing and installing Lambda probe 1 after catalytic converter -GX7- 7196
26 – Exhaust system 7199
1 Exhaust pipes and silencers 7199
1 1 Assembly overview – silencers 7199
1 2 Separating exhaust pipes from silencers 7200
1 3 Removing and installing rear silencer 7201
1 4 Aligning exhaust system free of stress 7202
1 5 Checking exhaust system for leaks 7203
1 6 Installation position of clamp 7203
2 Emission control 7206
2 1 Assembly overview – emission control 7206
2 2 Removing and installing catalytic converter 7208
28 – Ignition system 7214
1 Ignition system 7214
1 1 Assembly overview – ignition system 7214
1 2 Test data, spark plugs 7216
1 3 Removing and installing ignition coils with output stage 7216
1 4 Removing and installing knock sensor 1 -G61- 7219
1 5 Removing and installing Hall sender 7219
1 5 1 Removing and installing Hall sender -G40- 7219
1 5 2 Removing and installing Hall sender 3 -G300- 7220
1 6 Removing and installing engine speed sender -G28- 7220
00 – Technical data 7229
1 Safety instructions 7229
1 1 Safety precautions when working on fuel supply system 7229
1 2 Safety precautions during road tests in which test and measuring equipment is used 7230
1 3 Safety precautions when working on ignition system 7230
1 4 Safety precautions when working on cooling system 7231
2 Identification 7232
2 1 Engine number, engine data 7232
3 Repair instructions 7234
3 1 Rules for cleanliness 7234
3 2 Foreign objects in engine 7234
3 3 Contact corrosion 7234
3 4 Routing and securing lines 7234
3 5 Installing coolers, condensers and radiators 7234
10 – Removing and installing engine 7236
1 Removing and installing engine 7236
1 1 Removing engine 7236
1 2 Separating engine and gearbox 7244
1 3 Securing engine on engine and gearbox support 7245
1 4 Installing engine 7247
2 Assembly mountings 7250
2 1 Assembly overview – assembly mountings 7250
2 2 Removing and installing engine mountings 7252
2 3 Supporting engine in installation position 7257
2 4 Adjusting assembly mountings 7263
2 5 Checking adjustment of assembly mountings (engine and gearbox mountings) 7265
3 Engine cover panel 7266
3 1 Removing and installing engine cover panel 7266
13 – Crankshaft group 7267
1 Cylinder block (pulley end) 7267
1 1 Assembly overview – poly V-belt drive 7267
1 2 Assembly overview – cylinder block (pulley end) 7270
1 3 Removing and installing poly V-belt 7272
1 4 Removing and installing vibration damper 7273
1 5 Removing and installing ancillary bracket 7277
1 6 Renewing crankshaft oil seal – belt pulley end 7278
2 Cylinder block, gearbox end 7282
2 1 Assembly overview – cylinder block, gearbox end 7282
2 2 Removing and installing sealing flange on gearbox side 7283
3 Crankshaft 7293
3 1 Assembly overview – crankshaft 7293
3 2 Crankshaft dimensions 7294
3 3 Renewing needle bearing in crankshaft 7294
4 Pistons and conrods 7297
4 1 Assembly overview – pistons and conrods 7297
4 2 Checking piston and cylinder bore 7299
4 3 Separating new conrod 7300
4 4 Removing and installing pistons 7301
4 5 Removing and installing oil spray jets 7302
15 – Cylinder head, valve gear 7304
1 Cylinder head 7304
1 1 Assembly overview – cylinder head 7304
1 2 Removing and installing cylinder head 7306
1 3 Removing and installing camshaft housing 7307
1 4 Checking compression 7313
2 Cover for timing chain 7316
2 1 Removing and installing valve timing housing 7316
3 Chain drive 7319
3 1 Removing and installing timing chain and chain drive for oil pump 7319
3 2 Checking timing chain 7326
3 3 Checking valve timing 7334
3 4 Adjusting valve timing 7337
4 Valve gear 7345
4 1 Assembly overview – valve gear 7345
4 2 Measuring axial play of camshaft 7346
4 3 Removing and installing valve stem seals 7347
5 Inlet and exhaust valves 7350
5 1 Reworking valve seats 7350
5 2 Checking valve guides 7351
17 – Lubrication 7353
1 Sump, oil pump 7353
1 1 Assembly overview – sump and oil pump 7353
1 2 Engine oil 7354
1 3 Removing and installing sump 7355
1 4 Removing and installing oil pump 7359
2 Oil filter, oil pressure switch 7362
2 1 Checking oil pressure and oil pressure switch 7362
19 – Cooling 7364
1 Cooling system, coolant 7364
1 1 Coolant hose schematic diagram 7364
1 2 Checking cooling system for leaks 7364
1 3 Draining and filling coolant 7366
2 Coolant pump, regulation of cooling system 7372
2 1 Assembly overview – thermostat 7372
2 2 Removing and installing coolant circulation pump -V50- 7373
2 3 Removing and installing coolant pump 7374
2 4 Removing and installing coolant pump pulley 7379
3 Radiator and radiator fan 7384
3 1 Assembly overview – radiator and radiator fan 7384
3 2 Removing and installing radiator 7386
3 3 Removing and installing radiator cowling 7387
3 4 Removing and installing radiator fan -V7- and radiator fan 2 -V177- 7387
21 – Turbocharging/supercharging 7389
1 Turbocharger 7389
1 1 Assembly overview – turbocharger 7389
1 2 Assembly overview – turbocharger air recirculation valve -N249- 7391
1 3 Removing and installing turbocharger 7391
1 4 Checking vacuum unit for turbocharger 7396
1 5 Adjusting vacuum unit for turbocharger 7397
1 6 Renewing vacuum unit for turbocharger 7402
2 Charge air system 7404
2 1 Assembly overview – charge air system 7404
2 2 Assembly overview – charge-air hose connections 7405
2 3 Removing and installing charge air cooler 7406
2 4 Checking charge air system for leaks 7408
3 Supercharger 7411
3 1 Assembly overview – supercharger 7411
3 2 Removing and installing supercharger 7412
3 3 Removing and installing supercharger input shaft seal 7419
24 – Mixture preparation – injection 7423
1 Injection system 7423
1 1 Releasing high pressure in fuel system 7423
2 Injectors 7424
2 1 Assembly overview – fuel rail with injectors 7424
2 2 Removing and installing injectors 7424
2 3 Renewing seals on injectors 7427
3 Air filter 7431
3 1 Assembly overview – air filter housing 7431
3 2 Removing and installing air filter housing 7432
4 Intake manifold 7433
4 1 Assembly overview – intake manifold 7433
4 2 Assembly overview – lower part of intake manifold with fuel rail 7435
4 3 Removing and installing lower part of intake manifold 7437
4 4 Removing and installing lower part of intake manifold with fuel rail 7437
4 5 Removing and installing throttle valve module -J338- 7438
4 6 Cleaning throttle valve module -J338- 7440
5 Senders and sensors 7442
5 1 Checking fuel pressure sender -G247- 7442
6 Engine control unit 7445
6 1 Removing and installing engine control unit -J623- without protective housing 7445
6 2 Removing and installing engine control unit -J623- with protective housing 7447
7 High-pressure pump 7450
7 1 Assembly overview – high-pressure pump 7450
7 2 Removing and installing high-pressure pump 7451
26 – Exhaust system 7455
1 Exhaust pipes, silencers 7455
1 1 Assembly overview – silencers 7455
1 2 Removing and installing front exhaust pipe 7456
1 3 Separating exhaust pipes, silencers 7458
1 4 Aligning exhaust system free of stress 7459
2 Emission control 7461
2 1 Assembly overview – emission control 7461
28 – Ignition system 7463
1 Ignition system 7463
1 1 Assembly overview – ignition system 7463
1 2 Test data, spark plugs 7464
1 3 Removing and installing ignition coils with output stage 7464
1 4 Removing and installing engine speed sender -G28- 7466
44 – Wheels, tyres, vehicle geometry 7472
1 General information 7472
2 Wheels, tyres 7473
2 1 Specified torques for wheel bolts 7473
3 Jetta 2019 — North America, South America, Mexico 7474
4 Wheel allocation 7475
4 1 61/2 J x 16 offset 46 7475
4 2 61/2 J x 16 offset 48 7475
4 3 7 J x 17 offset 46 7476
4 4 7 5 J x 18 offset 49 7477
5 Recommended all-season tyres 7479
5 1 Recommended all-season tyres, North America 7479
5 2 Recommended all-season tyres, Mexico and South America 7479
5 3 Recommended all-season tyres, South Korea 7480
5 4 Recommended all-season tyres, Russia 7480
00 – Technical data 7489
1 Safety information 7489
1 1 Safety precautions when working on the fuel supply system 7489
1 2 Safety measures when working on vehicles with start/stop system 7489
1 3 Safety precautions when using testers and measuring instruments during a road test 7490
1 4 Safety precautions when working on the cooling system 7490
1 5 Safety precautions when working on the ignition system 7490
1 6 Safety precautions when working on the exhaust system 7491
2 Identification 7492
2 1 Engine number/engine data 7492
3 Repair instructions 7494
3 1 Rules for cleanliness 7494
3 2 General information 7494
3 3 General repair instructions 7495
3 4 Foreign material in engine 7495
3 5 Contact corrosion 7495
3 6 Routing and attachment of lines 7495
3 7 Installing radiators and condensers 7495
3 8 Bolts and nuts 7496
3 9 Identification labels 7496
3 10 Using impact drivers 7496
3 11 Checking vacuum system 7497
10 – Removing and installing engine 7498
1 Removing and installing engine 7498
1 1 Removing engine 7498
1 2 Separating engine and gearbox 7514
1 3 Securing engine on engine and gearbox support 7516
1 4 Installing engine 7517
2 Assembly mountings 7522
2 1 Assembly overview – assembly mountings 7522
2 2 Removing and installing engine mounting 7525
2 3 Removing and installing gearbox mounting 7525
2 4 Removing and installing pendulum support 7528
2 5 Supporting engine in installation position 7529
2 5 1 Supporting engine in installation position, engine codes CZDA, CWLA, DSJA 7529
2 5 2 Supporting engine in installation position, engine codes DGXA and DJXA 7531
2 6 Adjusting assembly mountings 7538
2 7 Checking adjustment of assembly mountings 7541
13 – Crankshaft group 7542
1 Cylinder block, pulley end 7542
1 1 Assembly overview – poly V-belt drive 7542
1 1 1 Assembly overview – poly V-belt drive, vehicles without air conditioner compressor 7542
1 1 2 Assembly overview – poly V-belt drive, vehicles with air conditioner compressor 7544
1 2 Assembly overview – sealing flange, pulley end 7546
1 3 Removing and installing poly-V belt 7548
1 3 1 Removing and installing poly V-belt, vehicles without air conditioner compressor 7548
1 3 2 Removing and installing poly V-belt, vehicles with air conditioner compressor 7550
1 4 Removing and installing poly V-belt tensioner 7552
1 5 Removing and installing vibration damper 7553
1 6 Removing and installing engine support 7555
1 7 Renewing crankshaft oil seal (pulley end) 7558
1 8 Removing and installing sealing flange, pulley end 7561
2 Cylinder block, gearbox end 7565
2 1 Assembly overview – cylinder block, gearbox end, flywheel 7565
2 2 Assembly overview – cylinder block, gearbox end, drive plate 7566
2 3 Removing and installing flywheel 7568
2 4 Removing and installing drive plate 7569
2 5 Removing and installing sealing flange on gearbox side 7571
3 Crankshaft 7582
3 1 Crankshaft dimensions 7582
3 2 Renewing needle bearing in crankshaft 7582
3 3 Measuring axial clearance of crankshaft 7585
4 Pistons and conrods 7587
4 1 Assembly overview – pistons and conrods 7587
4 2 Removing and installing pistons 7591
4 3 Checking piston and cylinder bore 7592
4 4 Separating new conrod 7595
4 5 Checking radial clearance of conrods 7595
4 6 Removing and installing oil spray jets 7596
4 7 Setting piston to TDC position 7597
15 – Cylinder head, valve gear 7602
1 Cylinder head 7602
1 1 Assembly overview – cylinder head 7602
1 2 Assembly overview – camshaft housing 7605
1 2 1 Assembly overview – camshaft housing, vehicles without adjustable exhaust camshaft 7605
1 2 2 Assembly overview – camshaft housing, vehicles with adjustable exhaust camshaft 7607
1 2 3 Assembly overview – camshaft housing, vehicles with cylinder shut-off 7609
1 2 4 Camshaft housing – specified torque and tightening sequence 7611
1 3 Removing and installing cylinder head 7612
1 4 Removing and installing camshaft housing 7617
1 5 Checking compression 7621
2 Toothed belt drive 7624
2 1 Assembly overview – toothed belt cover 7624
2 2 Assembly overview – toothed belt 7625
2 2 1 Assembly overview – toothed belt, vehicles without adjustable exhaust camshaft 7625
2 2 2 Assembly overview – toothed belt, vehicles with adjustable exhaust camshaft 7627
2 3 Removing and installing toothed belt guard 7629
2 3 1 Removing and installing upper toothed belt guard 7629
2 3 2 Removing and installing lower toothed belt guard 7630
2 4 Removing and installing toothed belt 7630
2 4 1 Removing and installing toothed belt, vehicles without adjustable exhaust camshaft 7630
2 4 2 Removing and installing toothed belt, vehicles with adjustable exhaust camshaft 7636
2 5 Checking valve timing 7642
2 6 Adjusting valve timing 7649
2 6 1 Checking valve timing, vehicles without adjustable exhaust camshaft 7649
2 6 2 Checking valve timing, vehicles without adjustable exhaust camshaft 7658
2 7 Removing toothed belt from camshaft 7667
3 Valve gear 7671
3 1 Assembly overview – valve gear 7671
3 2 Measuring axial play of camshaft 7673
3 3 Removing and installing camshaft oil seal 7674
3 3 1 Removing and installing camshaft oil seal for inlet camshaft, belt pulley end 7674
3 3 2 Removing and installing exhaust camshaft oil seal, pulley end 7676
3 3 3 Removing and installing exhaust camshaft oil seal, gearbox end 7678
3 4 Removing and installing camshaft adjuster 7681
3 4 1 Removing and installing inlet camshaft adjuster, vehicles with adjustable exhaust camshaft 7681
3 4 2 Removing and installing inlet camshaft adjuster, vehicles without adjustable exhaust camshaft 7686
3 4 3 Removing and installing camshaft adjuster for exhaust camshaft 7692
3 5 Removing and installing camshaft control valve 1 -N205- 7698
3 6 Removing and installing exhaust camshaft control valve 1 -N318- 7698
3 7 Removing and installing valve stem oil seals 7699
3 7 1 Removing and installing valve stem seals (cylinder head installed) 7699
3 7 2 Removing and installing valve stem seals (cylinder head removed) 7704
3 8 Removing and installing toothed belt pulley 7708
3 9 Removing and installing cam actuators 7710
4 Inlet and exhaust valves 7713
4 1 Checking valve guides 7713
4 2 Checking valves 7714
4 3 Valve dimensions 7714
17 – Lubrication 7715
1 Sump, oil pump 7715
1 1 Assembly overview – sump/oil pump 7715
1 2 Engine oil 7719
1 3 Removing and installing lower part of sump 7719
1 4 Removing and installing upper part of sump 7725
1 5 Removing and installing oil pump 7732
1 6 Removing and installing oil level and oil temperature sender -G266- 7733
2 Engine oil cooler 7735
2 1 Assembly overview – engine oil cooler 7735
2 2 Removing and installing engine oil cooler 7735
3 Crankcase breather 7737
3 1 Assembly overview – crankcase breather system 7737
3 2 Removing and installing oil separator 7738
4 Oil filter, oil pressure switch 7742
4 1 Assembly overview – oil filter/oil pressure switches 7742
4 2 Removing and installing oil pressure switch -F1- 7743
4 3 Removing and installing oil pressure switch for reduced oil pressure -F378- 7745
4 4 Checking oil pressure 7746
4 5 Removing and installing valve for oil pressure control -N428- 7748
19 – Cooling 7749
1 Cooling system/coolant 7749
1 1 Connection diagram – coolant hoses 7749
1 2 Assembly overview – engine preheater 7750
1 3 Assembly overview – coolant expansion tank 7751
1 4 Checking cooling system for leaks 7752
1 5 Draining and filling cooling system 7755
1 6 Removing and installing coolant expansion tank 7764
2 Coolant pump, regulation of cooling system 7766
2 1 Assembly overview – coolant pump/thermostat 7766
2 2 Assembly overview – electric coolant pump 7769
2 3 Assembly overview – coolant temperature sender 7769
2 4 Removing and installing electric coolant pump 7770
2 5 Removing and installing coolant pump 7772
2 6 Removing and installing thermostat 7777
2 6 1 Removing and installing thermostat for main coolant circuit (radiator) 7777
2 6 2 Removing and installing thermostat for cylinder block coolant circuit 7779
2 7 Removing and installing toothed belt pulley for coolant pump 7780
2 7 1 Removing and installing toothed belt pulley for coolant pump, vehicles with cylinder shut-off 7780
2 7 2 Removing and installing toothed belt pulley for coolant pump, vehicles without cylinder shut-off 7785
2 8 Removing and installing coolant temperature sender -G62- 7786
2 9 Removing and installing radiator outlet coolant temperature sender -G83- 7787
2 10 Removing and installing engine preheating element -Z97- 7788
3 Coolant pipes 7791
3 1 Assembly overview – coolant pipes 7791
3 1 1 Assembly overview – coolant pipes, clipped version 7791
3 1 2 Assembly overview – coolant pipes, bolted version 7791
3 2 Removing and installing coolant pipes 7792
3 2 1 Removing and installing coolant pipe, clipped version 7792
3 2 2 Removing and installing coolant pipe, bolted version 7796
4 Radiator, radiator fan 7799
4 1 Assembly overview – radiator/radiator fan 7799
4 2 Assembly overview – radiator cowl and radiator fans 7801
4 2 1 Assembly overview – radiator cowl with one radiator fan 7801
4 2 2 Assembly overview – radiator cowl with 2 radiator fans 7802
4 3 Assembly overview – radiator blind 7803
4 3 1 Assembly overview – radiator blind 7803
4 3 2 Assembly overview – components of radiator blind 7805
4 4 Removing and installing radiator 7806
4 5 Removing and installing water radiator for charge air cooling circuit 7811
4 6 Removing and installing radiator cowl 7812
4 6 1 Removing and installing radiator cowl with radiator fan, vehicles with one radiator fan 7812
4 6 2 Removing and installing radiator cowl with radiator fan, version with 2 radiator fans 7813
4 7 Removing and installing radiator fan 7814
4 7 1 Removing and installing radiator fan -V7- 7814
4 7 2 Removing and installing radiator fan 2 -V177- 7814
4 8 Removing and installing radiator blind 7815
4 9 Removing and installing radiator blind control motor -V544- 7818
21 – Turbocharging/supercharging 7823
1 Turbocharger 7823
1 1 Assembly overview – turbocharger 7823
1 1 1 Assembly overview – turbocharger, version 1 7823
1 1 2 Assembly overview – turbocharger, version 2 7824
1 1 3 Assembly overview – lines on turbocharger 7825
1 2 Removing and installing turbocharger 7827
1 3 Removing and installing charge pressure positioner -V465- 7832
1 3 1 Removing and installing charge pressure positioner -V465-, version 1 7832
1 3 2 Removing and installing charge pressure positioner -V465-, version 2 7833
1 4 Removing and installing connection for turbocharger 7835
2 Charge air system 7838
2 1 Assembly overview – charge air system 7838
2 2 Removing and installing charge air cooler 7841
2 3 Removing and installing charge pressure sender -GX26- 7844
2 4 Checking charge air system for leaks 7844
2 5 Removing and installing air intake pipe 7846
24 – Mixture preparation – injection 7849
1 Injection system 7849
1 1 Overview of fitting locations – injection system 7849
1 1 1 Overview of fitting locations – engine compartment 7849
1 1 2 Overview of fitting locations – engine from above, without cam actuators 7851
1 1 3 Overview of fitting locations – engine from above, with cam actuators 7852
1 1 4 Overview of fitting locations – engine, inlet side 7854
1 1 5 Overview of fitting locations – engine, exhaust side 7854
2 Injectors 7856
2 1 Assembly overview – fuel rail with injectors 7856
2 2 Removing and installing fuel rail 7858
2 3 Removing and installing injectors 7858
2 4 Cleaning injectors 7864
3 Air filter 7867
3 1 Assembly overview – air filter housing 7867
3 1 1 Assembly overview – air filter housing, engine code CZDA, CWLA, DSJA 7867
3 1 2 Assembly overview – air filter housing, engine code DGXA, DJXA 7869
3 2 Removing and installing air filter housing 7871
3 2 1 Removing and installing air filter housing, engine codes CZDA, CWLA, DSJA 7871
3 2 2 Removing and installing air filter housing, engine codes DGXA, DJXA 7872
3 3 Removing and installing air duct on lock carrier 7875
3 4 Removing and installing resonator for intake air 7876
4 Intake manifold 7877
4 1 Assembly overview – intake manifold 7877
4 2 Removing and installing intake manifold 7879
4 2 1 Removing and installing intake manifold, coolant pipe clipped-on 7879
4 2 2 Removing and installing intake manifold, coolant pipe bolted-on 7882
4 3 Removing and installing throttle valve module -GX3- 7887
4 4 Cleaning throttle valve module -GX3- 7888
4 5 Removing and installing activated charcoal filter solenoid valve 1 -N80- 7889
5 Senders and sensors 7891
5 1 Removing and installing fuel pressure sender -G247- 7891
5 2 Checking fuel pressure sender -G247- 7892
5 3 Removing and installing intake manifold sender -GX9- 7894
6 Engine/motor control unit 7896
6 1 Removing and installing motor control unit -J623- 7896
6 1 1 Removing and installing engine control unit -J623- (with metal locking plate) 7896
6 1 2 Removing and installing engine control unit -J623- (with protective housing) 7899
7 High-pressure pump 7903
7 1 Assembly overview – high-pressure pump 7903
7 1 1 Assembly overview – high-pressure pump, Hitachi 7903
7 1 2 Assembly overview – high-pressure pump, Continental 7905
7 1 3 Assembly overview – high-pressure pump, Bosch 7906
7 1 4 Assembly overview – high-pressure pump, Magneti Marelli 7908
7 2 Removing and installing high-pressure pump 7909
7 3 Removing and installing high-pressure pipe 7912
8 Lambda probe 7914
8 1 Assembly overview – lambda probe 7914
8 1 1 Assembly overview – lambda probe, engine codes CZDA, DJXA, CWLA, DSJA 7914
8 1 2 Assembly overview -lambda probe, engine code DGXA 7915
8 2 Removing and installing lambda probe 7916
8 2 1 Removing and installing Lambda probe 1 before catalytic converter -GX10- 7916
8 2 2 Removing and installing Lambda probe 1 after catalytic converter -GX7- 7918
26 – Exhaust system 7921
1 Exhaust pipes and silencers 7921
1 1 Assembly overview – silencers 7921
1 1 1 Assembly overview – silencer, Jetta 2018►, vehicles with torsion beam axle 7921
1 1 2 Assembly overview – silencer, Jetta 2018►, vehicles with multi-link suspension 7922
1 1 3 Assembly overview – silencer, Jetta 2022► 7924
1 2 Assembly overview – front exhaust pipe 7926
1 2 1 Assembly overview – mounting for front exhaust pipe 7926
1 3 Separating exhaust pipes from silencers 7926
1 3 1 Separating exhaust pipes from silencers, Jetta 2018►, vehicles with torsion beam axle 7926
1 3 2 Separating exhaust pipes from silencers, Jetta 2018►, vehicles with multi-link suspension 7928
1 3 3 Separating exhaust pipes from silencers, Jetta 2022► 7929
1 4 Removing and installing silencer 7930
1 4 1 Removing and installing silencer, Jetta 2018►, vehicles with torsion beam axle 7930
1 4 2 Removing and installing silencer, Jetta 2018►, vehicles with multi-link suspension 7932
1 4 3 Removing and installing silencer, Jetta 2022► 7933
1 5 Aligning exhaust system free of stress 7935
1 6 Checking exhaust system for leaks 7937
1 7 Installation position of clamp 7937
1 8 Removing and installing bracket for front exhaust pipe 7938
2 Emission control 7940
2 1 Assembly overview – emission control 7940
2 2 Removing and installing catalytic converter 7943
2 3 Removing and installing particulate filter 7948
3 Secondary air system 7949
3 1 Assembly overview – secondary air system 7949
3 2 Removing and installing secondary air pump motor -V101- 7950
3 3 Removing and installing secondary air inlet valve -N112- 7951
28 – Ignition system 7954
1 Ignition system 7954
1 1 Assembly overview – ignition system 7954
1 2 Removing and installing ignition coils with output stage 7956
1 3 Removing and installing knock sensor 1 -G61- 7958
1 4 Removing and installing Hall sender 7959
1 4 1 Removing and installing Hall sender -G40- 7959
1 4 2 Removing and installing Hall sender 3 -G300- 7960
1 5 Removing and installing engine speed sender -G28- 7960
00 – Technical data 7966
1 Safety information 7966
1 1 Safety regulations for working on fuel supply 7966
1 2 Safety precautions when using testers and measuring instruments during a road test 7966
1 3 Safety measures when working on vehicles with a start/stop system 7967
2 Identification 7968
2 1 Engine number/engine data 7968
3 General information 7969
3 1 Rules for cleanliness when working on auxiliary heater and fuel system 7969
4 Repair instructions 7970
4 1 Routing and attachment of lines 7970
4 2 General repair instructions 7970
20 – Fuel supply system 7971
1 Fuel 7971
1 1 Assembly overview – fuel tank 7971
1 1 1 Assembly overview – fuel tank, vehicles with multi-link rear suspension and front-wheel drive 7971
1 1 2 Assembly overview – fuel tank, vehicles with front-wheel drive and torsion beam axle 7973
1 1 3 Assembly overview – fuel tank, vehicles with front-wheel drive and Total Flex torsion beam axle 7975
1 1 4 Assembly overview – fuel tank, vehicles with fuel tank leak detection 7977
1 2 Removing and installing fuel tank 7979
1 2 1 Removing and installing fuel tank, vehicles with multi-link rear suspension 7979
1 2 2 Removing and installing fuel tank, vehicles with multi-link rear suspension and fuel tank leakage diagnosis function 7987
1 2 3 Removing and installing fuel tank, vehicles with torsion beam axle 7995
1 2 4 Removing and installing fuel tank, vehicles with torsion beam axle, engine codes CWVA, CWLA 8001
1 3 Emptying fuel tank 8008
1 3 1 Emptying fuel tank when fuel pump is intact 8008
1 3 2 Emptying fuel tank with fuel pump intact, engine codes CWVA, CWLA 8013
1 3 3 Emptying fuel tank if it is more than 3/4 full 8017
1 3 4 Emptying fuel tank if it is less than 3/4 full 8019
1 3 5 Emptying fuel tank with fuel tank less than 3/4 full, engine codes CWVA, CWLA 8023
2 Fuel delivery unit, fuel gauge sender 8027
2 1 Assembly overview – fuel delivery unit/fuel gauge sender 8027
2 1 1 Assembly overview – fuel delivery unit, vehicles with fuel filter integrated into flange of fuel delivery unit 8027
2 1 2 Assembly overview – fuel delivery unit, vehicles with externally fitted fuel filter 8029
2 2 Removing and installing fuel delivery unit, fuel gauge sender 8031
2 3 Removing and installing fuel gauge sender -G- 8037
3 Lines 8038
3 1 Removing and installing fuel lines 8038
4 Plug-in connectors 8043
4 1 Separating plug-in connectors 8043
5 Fuel filter 8049
5 1 Assembly overview – fuel filter 8049
5 1 1 Assembly overview – fuel filter, vehicles with externally fitted fuel filter 8049
5 1 2 Assembly overview – fuel filter, fuel filter integrated into flange of fuel delivery unit 8050
5 2 Removing and installing fuel filter 8050
5 2 1 Removing and installing fuel filter, vehicles with externally fitted fuel filter 8050
5 2 2 Removing and installing fuel filter, vehicles with fuel filter integrated into flange of fuel delivery unit 8051
6 Activated charcoal filter system 8052
6 1 Connection diagram – activated charcoal filter system 8052
6 1 1 Connection diagram – activated charcoal filter with fuel tank leak diagnosis 8052
6 1 2 Connection diagram – activated charcoal filter system with fuel tank leak detection module -GX36- and fuel tank shut-off valve -N288- 8053
6 1 3 Connection diagram – activated charcoal filter without fuel tank leak detection 8054
6 1 4 Connection diagram – activated charcoal filter system, engine compartment, vehicles with 1 5 l engine 8055
6 1 5 Connection diagram – activated charcoal filter system, engine compartment, vehicles with 1 4 l engine 8056
6 2 Assembly overview – activated charcoal filter system 8058
6 2 1 Assembly overview – activated charcoal filter system with fuel tank leak detection module -GX36-, version 1 8058
6 2 2 Assembly overview – activated charcoal filter system with fuel tank leak detection module -GX36-, version 2 8059
6 2 3 Assembly overview – activated charcoal filter system with fuel tank leak detection module -GX36- and fuel tank shut-off valve -N288- 8060
6 2 4 Assembly overview – activated charcoal filter without fuel tank leak diagnosis 8062
6 3 Removing and installing activated charcoal filter 8064
6 3 1 Removing and installing activated charcoal filter with fuel tank leak detection module -GX36-, version 1 8064
6 3 2 Removing and installing activated charcoal filter with fuel tank leak detection module -GX36-, version 2 8066
6 3 3 Removing and installing activated charcoal filter, with fuel tank leak detection module -GX36- and fuel tank shut-off valve -N288- 8067
6 3 4 Removing and installing activated charcoal filter without fuel tank leak diagnosis 8069
6 4 Removing and installing fuel system diagnosis pump 8070
6 4 1 Removing and installing fuel system diagnosis pump, version 1 8070
6 4 2 Removing and installing fuel system diagnosis pump, version 2 8070
6 4 3 Removing and installing fuel system diagnostic pump with fuel tank leak detection module -GX36- and fuel tank shut-off valve -N288- 8071
6 5 Removing and installing air filter for activated charcoal filter 8073
6 5 1 Removing and installing air filter for activated charcoal filter, version 1 8073
6 5 2 Removing and installing air filter for activated charcoal filter, version 2 8074
6 5 3 Removing and installing air filter for activated charcoal filter, with fuel tank leak detection module -GX36- and fuel tank shut-off valve -N288- 8074
6 6 Removing and installing fuel tank shut-off valve -N288- with tank pressure sensor -G400- 8076
6 7 Checking fuel tank breather 8076
6 8 Checking fuel system for leaks, vehicles with fuel tank leak diagnosis 8083
6 8 1 Checking fuel system for leaks, vehicles with fuel tank leak diagnosis with smoke tester -KLI 9210- 8083
6 8 2 Checking fuel system for leaks, vehicles with fuel tank leak diagnosis with smoke tester -VAS 523 005- 8087
7 Accelerator pedal 8096
7 1 Assembly overview – accelerator module 8096
7 2 Removing and installing accelerator module with accelerator position sender -G79-/-G185- 8096
8 Fuel pump 8098
8 1 Checking fuel system pressurisation pump -G6- 8098
8 1 1 Checking operation and power supply of fuel pump 8098
8 1 2 Checking function and voltage supply of fuel pump, vehicles with engine codes CWVA, CWLA, DGXA, DJXA 8103
8 1 3 Checking fuel pressure 8107
8 1 4 Checking fuel pressure, vehicles with engine codes CWVA, CWLA, DGXA, DJXA 8113
8 1 5 Checking holding pressure 8118
8 1 6 Checking holding pressure, vehicles with engine codes CWVA, CWLA, DGXA, DJXA 8123
8 1 7 Checking fuel delivery rate 8128
8 1 8 Checking delivery rate, vehicles with engine codes CWVA, CWLA, DGXA, DJXA 8136
8 2 Removing and installing fuel pump control unit -J538- 8145
00 – Technical data 8153
1 Safety information 8153
1 1 Safety measures when working on vehicles with a start/stop system 8153
1 2 Safety precautions when working on subframe 8153
2 Repair notes 8154
2 1 Leaks at shock absorbers 8154
2 2 Noises from shock absorbers 8154
2 3 Checking shock absorbers when removed 8155
2 4 Steering rack 8155
2 5 Gaskets and seals 8156
2 6 Nuts and bolts 8156
2 7 Electrical components 8156
2 8 Raising suspension to unladen position (vehicles with coil springs) 8157
2 8 1 Raising wheel bearing assembly to unladen position (vehicles with coil springs), front axle 8157
2 8 2 Raising wheel bearing assembly to unladen position (vehicles with coil springs), rear axle 8159
3 Evaluating accident vehicles 8162
3 1 Check list for evaluating running gear on accident vehicles 8162
4 Disposal 8164
4 1 Releasing gas and draining front gas-filled shock absorbers 8164
4 1 1 Releasing gas and draining front gas-filled shock absorbers, conventional shock absorbers 8164
4 1 2 Releasing gas and draining front gas-filled shock absorbers, DCC shock absorbers 8165
4 2 Releasing gas and draining rear gas-filled shock absorbers 8166
4 2 1 Releasing gas and draining rear gas-filled shock absorbers, conventional shock absorbers 8166
4 2 2 Releasing gas and draining rear gas-filled shock absorbers, DCC shock absorbers 8166
40 – Front suspension 8168
1 Front axle 8168
1 1 Overview of fitting locations – front axle 8168
2 Subframe 8171
2 1 Assembly overview – subframe 8171
2 2 Removing and installing subframe without steering rack 8171
2 3 Removing and installing subframe with steering rack 8177
2 4 Repairing subframe 8185
2 5 Repairing thread in longitudinal member 8196
2 6 Fixing subframe in position 8196
2 7 Lowering subframe 8200
3 Anti-roll bar 8206
3 1 Assembly overview – anti-roll bar 8206
3 2 Removing and installing anti-roll bar 8206
3 3 Removing and installing coupling rod 8212
4 Suspension strut, upper suspension link 8214
4 1 Assembly overview – suspension strut, upper suspension link 8214
4 2 Removing and installing suspension strut 8215
4 3 Repairing suspension strut 8226
5 Lower suspension link, swivel joint 8231
5 1 Assembly overview – lower suspension link, swivel joint 8231
5 2 Removing and installing lower suspension link 8232
5 2 1 Removing and installing lower suspension link, vehicles with manual gearbox or 7-speed dual clutch gearbox 8232
5 2 2 Removing and installing lower suspension link, vehicles with automatic gearbox 8235
5 3 Checking swivel joint 8239
5 4 Removing and installing swivel joint 8240
5 5 Renewing bonded rubber bush for lower suspension link 8246
5 5 1 Renewing front bonded rubber bush for lower suspension link 8246
5 5 2 Renewing rear bonded rubber bush for lower suspension link 8249
6 Wheel bearing 8254
6 1 Assembly overview – wheel bearing assembly 8254
6 2 Removing and installing wheel bearing housing 8254
6 3 Removing and installing wheel bearing unit 8260
7 Drive shaft 8265
7 1 Overview – drive shaft 8265
7 2 Assembly overview – drive shaft 8266
7 2 1 Assembly overview – drive shaft, constant velocity joint VL100 8266
7 2 2 Assembly overview – drive shaft, constant velocity joint VL107 8268
7 2 3 Assembly overview – drive shaft, triple roller joint AAR2600i 8270
7 2 4 Assembly overview – drive shaft, triple roller joint AAR3300i 8272
7 3 Removing and installing drive shaft 8274
7 3 1 Removing and installing drive shaft, constant velocity joints VL100 and VL107 8274
7 3 2 Removing and installing drive shaft, right drive shaft, constant velocity joint VL107, bolted 8279
7 3 3 Removing and installing drive shaft, triple roller joint 8283
7 4 Loosening and tightening threaded connections of drive shaft 8289
7 5 Removing and installing drive shaft heat shield 8290
7 6 Dismantling and assembling drive shaft 8290
7 6 1 Dismantling and assembling drive shaft, outer constant velocity joint 8290
7 6 2 Dismantling and assembling drive shaft, inner constant velocity joint 8294
7 6 3 Dismantling and assembling drive shaft, triple roller joint 8301
7 7 Checking outer constant velocity joint 8311
7 8 Checking inner constant velocity joint 8313
42 – Rear suspension 8316
1 Rear axle 8316
1 1 Overview – rear axle 8316
1 1 1 Overview – rear axle, torsion beam axle 8316
1 1 2 Overview – rear axle, multi-link suspension 8317
1 2 Lowering rear axle 8319
1 3 Removing and installing rear axle 8323
1 3 1 Removing and installing rear axle, torsion beam axle 8323
1 3 2 Removing and installing rear axle, multi-link suspension 8326
2 Axle beam 8332
2 1 Assembly overview – axle beam 8332
2 2 Renewing bonded rubber bush for axle beam 8332
3 Subframe 8341
3 1 Assembly overview – subframe 8341
3 2 Fixing subframe in position 8341
4 Anti-roll bar 8347
4 1 Assembly overview – anti-roll bar 8347
4 2 Removing and installing anti-roll bar 8347
4 3 Removing and installing coupling rod 8349
5 Suspension link, track rod 8352
5 1 Assembly overview – transverse link 8352
5 2 Assembly overview – track rod 8354
5 3 Removing and installing upper transverse link 8354
5 4 Removing and installing lower transverse link 8356
5 5 Removing and installing track rod 8358
6 Suspension strut, shock absorber, spring 8360
6 1 Assembly overview – suspension strut, shock absorber, spring 8360
6 1 1 Assembly overview – suspension strut, shock absorber, spring, torsion beam axle 8360
6 1 2 Assembly overview – suspension strut, shock absorber, spring, multi-link suspension 8361
6 2 Removing and installing shock absorber 8362
6 2 1 Removing and installing shock absorber, torsion beam axle 8362
6 2 2 Removing and installing shock absorbers, multi-link suspension 8365
6 3 Repairing shock absorber 8369
6 4 Removing and installing spring 8372
6 4 1 Removing and installing spring, torsion beam axle 8372
6 4 2 Removing and installing spring, multi-link suspension 8375
7 Wheel bearing assembly, trailing arm 8382
7 1 Assembly overview – wheel bearing assembly 8382
7 1 1 Assembly overview – wheel bearing assembly, torsion beam axle 8382
7 1 2 Assembly overview – wheel bearing assembly, multi-link suspension 8383
7 2 Assembly overview – trailing arm 8384
7 3 Removing and installing wheel bearing housing 8385
7 4 Removing and installing wheel bearing unit 8391
7 5 Renewing bonded rubber bush for wheel bearing housing 8396
7 6 Removing and installing trailing arm with mounting bracket 8400
7 7 Repairing trailing arm 8404
43 – Self-levelling suspension 8409
1 Electronic damping control 8409
1 1 Overview of fitting locations – electronically controlled damping system 8409
1 2 Removing and installing electronically controlled damping control unit -J250- 8411
1 3 Removing and installing front body acceleration senders -G341-/-G342- 8412
1 3 1 Removing and installing front left body acceleration sender -G341- 8412
1 3 2 Removing and installing front right body acceleration sender -G342- 8414
1 4 Removing and installing rear left body acceleration sender -G699- 8415
2 Vehicle level sender 8417
2 1 Assembly overview – front vehicle level senders 8417
2 2 Assembly overview – rear vehicle level senders 8418
2 2 1 Assembly overview – vehicle rear level sender, torsion beam axle 8418
2 2 2 Assembly overview – rear vehicle level senders, multi-link suspension 8419
2 3 Removing and installing front vehicle level senders -G78-/-G289- 8419
2 4 Removing and installing rear vehicle level senders -G76-/-G77- 8421
2 4 1 Removing and installing rear left vehicle level sender -G76-, torsion beam axle 8421
2 4 2 Removing and installing rear left vehicle level sender -G76-, multi-link suspension 8422
44 – Wheels, tyres, vehicle geometry 8424
1 Wheel alignment 8424
1 1 Notes for wheel alignment 8424
1 2 Prerequisites for wheel alignment 8425
1 3 Test preparations 8425
1 3 1 Test preparations, wheel alignment with no driver assist systems 8425
1 3 2 Test preparations, wheel alignment with driver assist systems 8427
1 4 Specifications for wheel alignment 8427
1 4 1 Specified values for wheel alignment, torsion beam axle 8427
1 4 2 Specified values for wheel alignment, multi-link suspension 8428
1 5 Wheel alignment procedure 8429
1 6 Necessity of wheel alignment 8431
1 6 1 Necessity of wheel alignment, torsion beam axle 8431
1 6 2 Necessity of wheel alignment, multi-link suspension 8432
1 7 Vehicle data sticker 8433
1 8 Adjusting camber at front wheels 8434
1 9 Adjusting camber on rear axle 8435
1 9 1 Adjusting camber at rear axle, torsion beam axle 8435
1 9 2 Adjusting camber at rear axle, multi-link suspension 8435
1 10 Adjusting toe at rear axle 8437
1 10 1 Adjusting toe at rear axle, torsion beam axle 8437
1 10 2 Adjusting toe on rear axle, multi-link suspension 8437
1 11 Adjusting front axle toe 8438
1 12 Wheel runout compensation 8440
1 13 Checking maximum steering wheel angle 8440
2 Adaptive cruise control 8442
2 1 Calibrating adaptive cruise control 8442
2 1 1 Calibrating adaptive cruise control – static calibration 8442
2 1 2 Calibrating adaptive cruise control – dynamic calibration 8446
3 Front camera for driver assist systems 8448
3 1 Calibrating front camera for assist systems 8448
48 – Steering 8456
1 Steering wheel 8456
1 1 Assembly overview – steering wheel 8456
1 2 Removing and installing steering wheel 8456
2 Steering column 8459
2 1 Assembly overview – steering column 8459
2 2 Checking steering column for damage 8460
2 3 Handling and transporting steering column 8461
2 4 Removing and installing steering column 8462
2 5 Removing and installing control unit for electronic steering column lock -J764- 8473
3 Steering rack 8475
3 1 Assembly overview – steering rack 8475
3 1 1 Assembly overview – steering rack 8475
3 1 2 Assembly overview – steering rack, track rods 8476
3 2 Removing and installing steering rack 8477
3 3 Removing and installing bellows 8487
3 4 Removing and installing track rod 8490
3 5 Removing and installing track rod ball joint 8495
3 6 Repairing steering rack 8497
3 6 1 Removing and installing threaded bush 8497
4 Sensors 8502
4 1 Removing and installing steering angle sender -G85- 8502
00 – Materials 8507
1 Safety information 8507
1 1 Safety measures when working on vehicles with a start/stop system 8507
1 2 Safety precautions when using testers and measuring instruments during a road test 8507
2 Identification 8508
2 1 Allocation of PR number – brakes 8508
2 1 1 Front brake 8508
2 1 2 Rear brake 8508
3 Technical data 8510
3 1 Technical data for brakes 8510
3 1 1 Brake master cylinder and brake servo 8510
3 1 2 Front brakes 8510
3 1 3 Rear brakes 8512
4 Brake test 8515
4 1 General information 8515
4 2 Checking vehicles with front-wheel drive 8515
4 3 Checking electromechanical parking brake 8515
45 – Anti-lock brake system 8517
1 General information 8517
2 Overview of fitting locations 8519
2 1 Overview of fitting locations – ABS/ESP 8519
3 Control unit and hydraulic unit 8522
3 1 Assembly overview – control unit and hydraulic unit 8522
3 2 Removing and installing ABS control unit -J104- and ABS hydraulic unit -N55- 8524
3 2 1 Removing and installing ABS control unit -J104-/ABS hydraulic unit -N55-, petrol engine 8524
3 2 2 Removing and installing ABS control unit -J104-/ABS hydraulic unit -N55-, diesel engine 8531
3 3 Separating control unit from hydraulic unit 8540
3 4 Fitting control unit to hydraulic unit 8541
3 5 Connecting brake lines to hydraulic unit 8543
4 Sensors 8545
4 1 Assembly overview – speed sensor on front axle 8545
4 2 Assembly overview – speed sensor on rear axle 8546
4 2 1 Assembly overview – speed sensor on rear axle 8546
4 3 Removing and installing ESP sensor unit -G419- 8546
4 4 Removing and installing speed sensors on front axle -G45-/-G47- 8546
4 5 Removing and installing speed sensors on rear axle -G44-/-G46- 8547
4 6 Checking ABS sensor ring 8549
46 – Brakes – mechanism 8551
1 Front brake 8551
1 1 Assembly overview – front brake 8551
1 1 1 Assembly overview – front brake 8551
1 2 Removing and installing brake pads 8553
1 3 Removing and installing brake caliper 8556
1 4 Removing and installing brake carrier 8558
1 5 Removing and installing brake disc 8560
1 6 Removing and installing brake splash plate 8563
2 Rear brake 8566
2 1 Assembly overview – rear brakes 8566
2 2 Removing and installing brake pads 8568
2 3 Removing and installing brake caliper 8574
3 Parking brake 8579
3 1 Overview of fitting locations – parking brake 8579
3 2 Removing and installing control unit for electromechanical parking brake -J540- 8581
3 3 Removing and installing parking brake motor -V282-/-V283- 8581
4 Brake pedal 8584
4 1 Assembly overview – brake pedal 8584
4 2 Removing and installing mounting bracket 8586
4 3 Separating brake pedal from brake servo 8589
4 4 Connecting brake pedal to brake servo 8590
4 5 Removing and installing brake pedal 8590
47 – Brakes – hydraulics 8592
1 Front brake caliper 8592
1 1 Assembly overview – front brake caliper 8592
1 2 Removing and installing brake caliper piston 8593
2 Rear brake caliper 8596
2 1 Assembly overview – rear brake caliper 8596
2 2 Removing and installing protective cap 8597
3 Brake servo and brake master cylinder 8601
3 1 Assembly overview – brake servo/brake master cylinder 8601
3 2 Removing and installing brake light switch 8604
3 3 Removing and installing brake servo 8605
3 4 Removing and installing brake master cylinder 8611
4 Vacuum system 8618
4 1 Assembly overview – vacuum pump 8618
4 2 Checking non-return valve 8618
4 3 Removing and installing vacuum sender -G608- 8619
4 4 Checking vacuum system 8620
4 4 1 Instructions for checking 8620
4 4 2 Connecting vacuum gauge for brake servo -VAS 6721- 8620
4 4 3 Checking vacuum generation 8622
4 4 4 Checking for leaks 8623
4 4 5 Vacuum generation with manual vacuum pump -VAS 6213- 8625
5 Brake lines 8626
5 1 Repairing brake lines 8626
5 1 1 Assembly overview – flanging tool 8626
5 1 2 Tools 8627
5 1 3 Instructions for use of flanging tool 8628
6 Hydraulic system 8632
6 1 General notes on brake fluid 8632
6 2 Pre-bleeding hydraulic system 8632
6 3 Bleeding hydraulic system following standard procedure 8635
6 4 Subsequent bleeding of hydraulic system 8636
6 5 Testing for leaks 8637
00 – Technical data 8642
1 Repair instructions 8642
1 1 General repair instructions 8642
1 2 Routing and attachment of lines 8642
1 3 Notes on repair of CAN bus wiring 8642
1 4 General information 8642
91 – Communication 8644
1 Infotainment system 8644
1 1 Overview of infotainment system 8644
1 1 1 Components of Infotainment system, Composition Colour version 8644
1 1 2 Components of Infotainment system, Composition Media and Discover Media versions 8645
1 1 3 Layout – infotainment system, Discover Pro version 8646
1 2 Overview of fitting locations – Infotainment system 8647
1 3 Removing and installing infotainment system display 8649
1 4 Removing and installing control unit 1 for information electronics -J794- 8650
1 5 Renewing rotary knobs of display unit for front information display and operating unit control unit -J685- 8652
2 Sound system 8654
2 1 Components of sound system 8654
2 2 Overview of fitting locations – sound system 8655
2 3 Removing and installing digital sound package control unit -J525- 8656
2 4 Removing and installing bracket for digital sound package control unit -J525- 8659
2 5 Removing and installing front treble loudspeakers -R20-/-R22- 8659
2 6 Removing and installing rear treble loudspeakers -R14-/-R16- 8660
2 6 1 Removing and installing rear treble loudspeakers -R14-/-R16- 8660
2 7 Removing and installing front bass loudspeakers -R21-/-R23- 8661
2 8 Removing and installing rear bass loudspeakers -R15-/-R17- 8663
2 8 1 Removing and installing rear bass loudspeakers -R15-/-R17- 8663
2 9 Removing and installing subwoofer -R211- 8665
3 Aerial systems 8667
3 1 Components of aerial systems 8667
3 2 Overview of fitting locations – aerial systems 8667
3 3 Removing and installing aerial module 8668
3 4 Removing and installing frequency modulation (FM) frequency filter in negative wire -R178- 8670
3 5 Removing and installing frequency modulation (FM) frequency filter in positive wire -R179- 8671
3 6 Removing and installing roof aerial 8672
3 7 LTE aerial 2 -R306- 8674
4 Removing and installing radio 8675
4 1 Removing and installing radio, Composition Colour 8675
4 2 Removing and installing radio, Composition Media and Discover Pro 8676
5 Telephone system 8677
5 1 Preparation for mobile telephone 8677
5 1 1 Mobile telephone preparation, Bluetooth hands-free system 8677
5 1 2 Preparation for mobile telephone, on-line Bluetooth hands-free system 8677
5 2 Overview of fitting locations – telephone system 8678
5 3 Removing and installing telephone microphone -R38- 8679
5 4 Removing and installing storage compartment with interface for mobile telephone -R265- 8680
6 Navigation system 8682
6 1 Overview of navigation system 8682
6 2 Overview of fitting locations – navigation system 8682
6 3 Removing and installing control unit for navigation system 8683
7 Multifunction steering wheel 8684
7 1 Overview of multifunction steering wheel 8684
7 2 Assembly overview – multifunction steering wheel 8684
7 3 Removing and installing multifunction buttons in steering wheel -E441-/-E440- 8685
7 4 Removing and installing Tiptronic switch in steering wheel -E439-/-E438- 8689
8 Connection for external multimedia devices 8691
8 1 Removing and installing connection for external multimedia devices, USB connection 1 -U41- in centre console storage compartment at front, variant 1 8691
8 2 Removing and installing connection for external multimedia devices, USB port in storage compartment of front centre console, variant 2 8692
9 Online services 8694
9 1 General information 8694
9 2 Overview of fitting locations – mobile online services 8694
9 3 Removing and installing emergency call module control unit and communication unit -J949- 8695
9 4 Removing and installing operating unit for preparation for mobile telephone -E508- 8696
9 5 Removing and installing battery for control unit for emergency call module 8697
00 – Technical data 8702
1 Safety information 8702
1 1 General safety provisions 8702
1 2 Safety measures when working on vehicles with a start/stop system 8702
1 3 Safety precautions when using testing and measuring instruments during a road test 8703
1 4 Safety precautions when tow-starting or towing 8703
2 Identification 8704
2 1 Gearbox identification 8704
2 2 Identification of torque converter 8704
3 Repair instructions 8706
3 1 Rules for cleanliness 8706
3 2 General information 8706
3 3 General repair instructions 8707
3 4 Gaskets and seals 8708
3 5 Nuts and bolts 8708
4 Technical data 8709
4 1 Capacities 8709
4 2 Allocation gearbox – motor 8709
5 Electrical components 8710
5 1 Overview of fitting locations – electrical components 8710
32 – Torque converter 8711
1 Torque converter 8711
1 1 Assembly overview – torque converter 8711
1 2 Removing and installing torque converter 8711
1 3 Draining torque converter 8712
1 4 Checking torque converter 8713
1 5 Removing and installing torque converter oil seal 8713
37 – Controls, housing 8716
1 ATF circuit 8716
1 1 Assembly overview – ATF circuit 8716
1 2 Removing and installing ATF cooler 8716
1 3 Renewing ATF cooler seals 8721
2 ATF 8726
2 1 Checking ATF level 8726
2 2 Draining and filling ATF 8728
3 Removing and installing gearbox 8731
3 1 Specified torques for gearbox 8731
3 2 Removing gearbox 8731
3 3 Installing gearbox 8742
4 Assembly mountings 8746
4 1 Assembly overview – assembly mountings 8746
5 Gearbox transport 8749
6 Securing to engine and gearbox support 8750
7 Selector mechanism 8752
7 1 Assembly overview – selector mechanism 8752
7 2 Checking selector mechanism 8754
7 3 Manual release from position P 8755
7 4 Removing and installing selector mechanism 8756
7 4 1 Removing and installing selector mechanism with selector lever cable 8756
7 4 2 Removing and installing selector mechanism without selector lever cable 8758
7 5 Removing and installing selector lever handle 8762
7 6 Moving push-button in the handle to installation position 8765
7 7 Removing and installing gear selector cable 8767
7 8 Checking and adjusting selector lever cable 8769
7 9 Renewing selector shaft seal 8771
38 – Gears, control 8775
1 Dismantling and assembling gearbox 8775
1 1 Assembly overview – gearbox 8775
2 ATF system 8776
2 1 Removing and installing sump 8776
3 Valve body 8780
3 1 Assembly overview – valve body 8780
3 2 Removing and installing wiring harness for senders and solenoid valves 8782
3 3 Removing and installing valve body 8785
3 3 1 Removing and installing valve body, gearbox installed 8785
3 3 2 Removing and installing valve body, gearbox removed 8789
3 4 Removing and installing gearbox input speed sender -G182- and gearbox output speed sender -G195- 8791
39 – Final drive – differential 8793
1 Seals 8793
1 1 Overview of fitting locations – oil seals 8793
1 2 Renewing left seal 8793
1 3 Renewing right seal 8796
2 Gearbox control system 8800
2 1 Removing and installing gearbox control unit 8800
00 – Technical data 8810
1 Safety information 8810
1 1 Safety measures when working on vehicles with a start/stop system 8810
50 – Body – front 8811
1 Lock carrier 8811
1 1 Assembly overview – lock carrier 8811
1 2 Removing and installing lock carrier 8811
1 3 Moving to and back from service position 8814
2 Wings 8819
2 1 Assembly overview – wing 8819
2 2 Removing and installing wing 8819
3 Bulkhead 8823
3 1 Assembly overview – bulkhead 8823
3 2 Assembly overview – plenum chamber cover 8823
3 3 Removing and installing bulkhead 8824
3 4 Removing and installing plenum chamber cover 8825
55 – Bonnet, rear lid 8828
1 Bonnet 8828
1 1 Assembly overview – bonnet 8828
1 2 Assembly overview – Bowden cable 8829
1 3 Removing and installing bonnet 8830
1 4 Adjusting bonnet 8831
1 5 Removing and installing bonnet lock 8837
1 6 Removing and installing bonnet lock operating lever 8840
1 7 Removing and installing striker pin 8841
1 8 Removing and installing hinges 8842
1 9 Removing and installing insulation 8844
1 10 Removing and installing Bowden cable 8845
1 11 Removing and installing bonnet stay 8848
2 Rear lid 8849
2 1 Assembly overview – rear lid 8849
2 2 Removing and installing rear lid 8850
2 3 Adjusting rear lid 8851
2 4 Removing and installing bonnet lock 8854
2 5 Removing and installing operating mechanism 8856
2 6 Removing and installing hinges 8857
2 7 Removing and installing striker pin 8858
2 8 Removing and installing rear lid seal 8859
3 Tank flap unit 8860
3 1 Assembly overview – tank flap unit 8860
3 2 Removing and installing tank flap unit 8861
3 3 Removing and installing fuel tank flap 8862
3 4 Removing and installing sealing collar 8862
57 – Front doors, door components, central locking 8864
1 Door 8864
1 1 Assembly overview – door 8864
1 2 Removing and installing inner door seal 8867
1 3 Removing and installing outer door seal 8869
1 4 Removing and installing door 8872
1 5 Adjusting door 8875
1 6 Adjusting striker pin 8878
1 7 Removing and installing door arrester 8879
2 Door components 8882
2 1 Assembly overview – door components 8882
2 2 Assembly overview – window regulator 8883
2 3 Assembly overview – door handle and door lock 8884
2 4 Removing and installing window regulator motor 8885
2 5 Removing and installing window regulator 8888
2 6 Removing and installing inner door cover 8889
2 7 Removing and installing striker pin 8891
2 8 Removing and installing door handle 8893
2 8 1 Removing and installing door handle 8893
2 8 2 Removing and installing door handle with keyless entry system 8895
2 9 Removing and installing mounting bracket 8897
2 10 Removing and installing door lock 8900
2 11 Removing and installing window channel 8904
2 12 Removing and installing window slot inner seal 8906
2 13 Removing and installing window slot outer seal 8907
2 14 Removing and installing lock cylinder 8909
2 15 Removing and installing cap on door handle 8912
2 15 1 Removing and installing cap with lock cylinder 8912
2 15 2 Removing and installing cap for door handle, without lock cylinder 8913
3 Central locking 8918
3 1 Overview of fitting locations – central locking system 8918
3 2 Removing and installing driver door control unit -J386- and front passenger door control unit -J387- 8920
3 3 Removing and installing rear left door control unit -J388- and rear right door control unit -J389- 8922
3 4 Removing and installing bonnet contact switch -F266- 8923
3 5 Removing and installing tank filler flap locking motor -V155- 8924
3 6 Removing and installing ignition key battery 8926
3 6 1 Removing and installing ignition key battery, mechanical ignition lock 8926
3 6 2 Removing and installing ignition key battery, electronic ignition lock 8928
3 7 Removing and installing cap on ignition key 8930
3 7 1 Removing and installing cap on ignition key, mechanical ignition lock 8930
3 7 2 Removing and installing cap on ignition key, electronic ignition lock 8931
58 – Rear doors, door components 8932
1 Door 8932
1 1 Assembly overview – door 8932
1 2 Removing and installing door 8935
1 3 Adjusting door 8938
1 4 Adjusting striker pin 8941
1 5 Removing and installing door arrester 8942
1 6 Removing and installing outer door seal 8944
1 7 Removing and installing inner door seal 8946
2 Door components 8949
2 1 Assembly overview – door components 8949
2 2 Assembly overview – window regulator 8950
2 3 Assembly overview – door handle and door lock 8951
2 4 Removing and installing window regulator motor 8952
2 5 Removing and installing window regulator 8955
2 6 Removing and installing inner door cover 8957
2 7 Removing and installing striker pin 8958
2 8 Removing and installing door handle 8959
2 9 Removing and installing mounting bracket 8961
2 10 Removing and installing door lock 8963
2 11 Removing and installing window channel 8967
2 12 Removing and installing window slot outer seal 8969
2 13 Removing and installing window slot inner seal 8970
2 14 Removing and installing cap on door handle 8971
60 – Sunroof 8976
1 Repair instructions 8976
1 1 Minimum drying time for adhesives 8976
1 2 Tools and materials required for removal and installation 8976
1 2 1 Tools required for removal and installation 8976
1 2 2 Materials required for removal and installation 8978
1 3 Preparing new sliding sunroof frame for installation 8979
1 4 Preparing body flange for installing 8981
1 5 Cleaning off excess adhesive 8982
2 Sliding sunroof 8983
2 1 Assembly overview – sliding sunroof 8983
2 2 Assembly overview – sunroof roller blind 8985
2 3 Assembly overview – wind deflector 8985
2 4 Assembly overview – adhesive beads on sliding sunroof 8986
2 4 1 Assembly overview – adhesive beads on sliding sunroof frame 8986
2 4 2 Assembly overview – adhesive bead on front trim for sliding sunroof 8987
2 5 Removing and installing sliding sunroof frame 8988
2 6 Removing and installing wind deflector 8992
2 7 Removing and installing glass panel 8993
2 8 Removing and installing front trim for sliding sunroof 8995
2 9 Removing and installing sliding sunroof adjustment control unit -J245- 8998
2 10 Removing and installing sliding sunroof seals 8999
2 10 1 Removing and installing inner seal for sliding sunroof frame 8999
2 10 2 Removing and installing outer seal for sliding sunroof frame 9000
2 10 3 Removing and installing front trim seal 9001
2 11 Removing and installing sunroof roller blind 9001
2 12 Removing and installing side trim 9009
2 13 Removing and installing sunroof motor -V1- 9009
2 14 Removing and installing tilt mechanism for sliding sunroof 9010
2 14 1 Removing and installing guide 9010
2 14 2 Removing and installing tilt mechanism 9011
2 14 3 Removing and installing guide rail for tilt mechanism 9013
2 15 Manual operation 9015
63 – Bumpers 9016
1 Bumper, front 9016
1 1 Assembly overview – bumper cover 9016
1 2 Assembly overview – bumper carrier 9018
1 3 Removing and installing bumper cover 9019
1 4 Repairing bumper cover 9021
1 5 Installing holder for parking aid sender 9021
1 6 Installing retainer for parking aid sender 9026
2 Bumper, rear 9031
2 1 Assembly overview – bumper cover 9031
2 1 1 Assembly overview – bumper cover 9031
2 1 2 Assembly overview – bumper cover, GLI 9033
2 2 Assembly overview – bumper carrier 9035
2 3 Removing and installing bumper cover 9035
2 4 Removing and installing add-on parts 9037
2 4 1 Removing and installing guide under tail light 9037
2 4 2 Removing and installing guide profile on side panel 9038
2 4 3 Removing and installing centre guide 9039
2 4 4 Removing and installing spoiler 9040
2 4 5 Removing and installing reflector 9040
2 5 Repairing bumper cover 9041
2 6 Removing and installing bumper carrier 9041
2 7 Installing holder for parking aid sender 9041
2 8 Installing retainer for parking aid sender 9046
64 – Glazing 9051
1 Repair instructions 9051
1 1 Minimum drying times for bonded windows 9051
1 2 Window repair 9051
1 3 Installation instructions for bonded windows 9052
1 4 Tools and materials required for removal and installation 9053
1 4 1 Tools required for removal and installation 9053
1 4 2 Materials required for removal and installation 9056
1 5 Preparing old undamaged windows for installing 9057
1 6 Preparing new windows for installing 9058
1 7 Preparing body flange for installing 9059
1 8 Cleaning off excess adhesive 9060
2 Windscreen 9061
2 1 Assembly overview – windscreen 9061
2 2 Removing and installing windscreen 9062
3 Rear windscreen 9065
3 1 Assembly overview – rear window 9065
3 2 Removing and installing rear window 9066
3 2 1 Removing and installing rear window 9066
3 2 2 Removing broken rear window 9068
4 Side windows 9070
4 1 Assembly overview – rear side windows 9070
4 2 Removing and installing rear side window 9071
4 2 1 Removing and installing rear side window 9071
4 2 2 Removing broken rear side window 9073
5 Door windows 9074
5 1 Assembly overview – front door window 9074
5 2 Assembly overview – rear door window 9074
5 3 Removing and installing front door window 9075
5 4 Removing and installing rear door window 9077
66 – Exterior equipment 9081
1 Radiator grille and front trim 9081
1 1 Assembly overview – radiator grille 9081
1 2 Removing and installing radiator grille 9082
2 Spoiler 9083
2 1 Assembly overview – spoiler 9083
2 2 Removing and installing spoiler 9083
3 Mouldings, trims, extensions 9087
3 1 Assembly overview – side member trim 9087
3 2 Assembly overview – water deflector 9088
3 3 Assembly overview – B-pillar trim 9088
3 4 Assembly overview – C-pillar trim 9089
3 5 Assembly overview – heat shield 9090
3 6 Removing and installing side member trim 9091
3 7 Removing and installing water deflector 9097
3 8 Removing and installing B-pillar trim on door 9098
3 8 1 Removing and installing B-pillar trim on front door 9098
3 8 2 Removing and installing B-pillar trim on rear door 9099
3 9 Removing and installing C-pillar trim on door 9101
3 10 Removing and installing heat shield 9103
3 10 1 Removing and installing tunnel heat shield 9103
3 10 2 Removing and installing fuel tank heat shield 9104
3 10 3 Removing and installing rear underbody heat shield 9104
3 10 4 Removing and installing rear silencer heat shield 9105
4 Noise insulation 9107
4 1 Assembly overview – noise insulation 9107
4 1 1 Assembly overview – short noise insulation 9107
4 1 2 Assembly overview – long noise insulation 9108
4 2 Assembly overview – skid plate 9108
5 Underbody cladding 9110
5 1 Overview of fitting locations – underbody cladding 9110
5 2 Assembly overview – bracing on underbody 9110
5 3 Removing and installing tunnel cross-piece 9111
5 3 1 Removing and installing front tunnel cross-piece 9111
5 3 2 Removing and installing rear tunnel cross-piece 9113
6 Decorative film / protective film 9115
6 1 Renewing protective films 9115
7 Exterior mirror 9118
7 1 Assembly overview – exterior mirror 9118
7 2 Removing and installing exterior mirror 9119
7 3 Removing and installing mirror glass 9122
7 4 Removing and installing mirror adjustment unit 9124
7 5 Removing and installing mirror cover 9126
7 6 Removing and installing mirror frame 9126
8 Wheel housing liner 9128
8 1 Assembly overview – front wheel housing liner 9128
8 2 Assembly overview – rear wheel housing liner 9129
8 3 Assembly overview – sill panel cover 9129
8 4 Removing and installing front wheel housing liner 9130
8 5 Removing and installing rear wheel housing liner 9131
8 6 Removing and installing side member cover 9133
9 Lettering and badges 9135
9 1 Dimensions – lettering and badges on rear 9135
9 2 Dimensions – lettering and badges on sides 9136
9 3 Removing and installing badges at front 9137
9 3 1 Removing and installing brand emblem, vehicles without adaptive cruise control unit -J428- 9137
9 3 2 Removing and installing brand emblem, vehicles with adaptive cruise control unit -J428- 9138
9 4 Removing and installing lettering 9139
9 5 Renewing lettering and badges at rear 9140
00 – Technical data 9146
1 Safety information 9146
1 1 Safety measures when working on vehicles with a start/stop system 9146
1 2 Safety precautions when using testers and measuring instruments during a road test 9146
2 Identification 9147
2 1 Gearbox identification 9147
3 Repair instructions 9148
3 1 General repair instructions 9148
4 Technical data 9151
4 1 Capacities 9151
4 2 Allocation gearbox – engine 9151
4 3 Calculation of gear ratios 9151
5 Overview – power transmission 9152
5 1 Overview – power transmission – front-wheel drive 9152
6 Electrical components 9154
6 1 Overview of fitting locations – electrical components 9154
6 1 1 Overview of fitting locations – electrical components, manual gearbox 9154
6 1 2 Overview of fitting locations – electrical components, clutch mechanism 9154
30 – Clutch 9155
1 Clutch operation 9155
1 1 Assembly overview – pedal cluster 9155
1 2 Assembly overview – clutch hydraulics 9158
1 2 1 Assembly overview – clutch hydraulics, left-hand drive 9158
1 2 2 Assembly overview – clutch hydraulics, right-hand drive 9160
1 3 Assembly overview – clutch release mechanism 9161
1 4 Removing and installing clutch pedal 9162
1 5 Removing and installing over-centre spring 9163
1 6 Removing and installing return spring 9165
1 7 Removing and installing mounting bracket 9168
1 8 Removing and installing bearing bush 9172
1 9 Removing and installing clutch master cylinder 9173
1 10 Removing and installing clutch slave cylinder 9173
1 11 Removing and installing lines for clutch mechanism 9175
1 12 Bleeding clutch mechanism 9177
1 13 Checking clutch master cylinder and clutch slave cylinder 9178
1 14 Removing and installing clutch position sender -G476- 9178
1 15 Repairing clutch release mechanism 9179
2 Clutch 9181
2 1 Assembly overview – clutch 9181
2 1 1 Assembly overview – clutch in conjunction with Sachs dual-mass flywheel 9181
2 1 2 Assembly overview – clutch in conjunction with LuK dual-mass flywheel 9182
2 1 3 Assembly overview – clutch with simple flywheel 9183
2 2 Removing and installing clutch 9184
2 2 1 Removing and installing clutch in conjunction with Sachs dual-mass flywheel 9184
2 2 2 Removing and installing clutch in conjunction with LuK dual-mass flywheel 9187
2 2 3 Removing and installing clutch in connection with simple flywheel 9191
34 – Controls, housing 9196
1 Selector mechanism 9196
1 1 Installation position – selector mechanism 9196
1 2 Assembly overview – gear knob and cover 9197
1 3 Assembly overview – selector mechanism 9198
1 4 Removing and installing gear knob 9199
1 5 Removing and installing selector mechanism 9201
1 6 Adjusting selector mechanism 9207
1 7 Checking selector mechanism 9210
1 8 Renewing oil seal for selector shaft 9210
2 Removing and installing gearbox 9212
2 1 Specified torques for gearbox 9212
2 2 Removing gearbox 9212
2 3 Install gearbox 9228
3 Assembly mountings 9237
3 1 Assembly overview – assembly mountings 9237
4 Transporting gearbox 9239
5 Dismantling and assembling gearbox 9240
5 1 Schematic overview – gearbox 9240
5 2 Assembly overview – cover for gearbox housing and 5th gear 9242
5 3 Assembly overview – gearbox housing and selector mechanism 9243
5 4 Assembly overview – selector unit 9244
5 5 Assembly overview – input shaft, output shafts, differential, selector rods 9245
5 6 Assembly overview – selector forks 9246
5 7 Repairing selector unit 9247
5 8 Repairing selector forks 9248
5 9 Removing cover for gearbox housing and 5th gear 9252
5 10 Dismantling and assembling gearbox 9258
5 11 Installing cover for gearbox housing and 5th gear 9270
6 Gearbox housing, clutch housing 9274
6 1 Assembly overview – gearbox housing 9274
6 2 Assembly overview – clutch housing 9276
6 3 Repairing gearbox housing 9277
6 3 1 Removing and installing input shaft bearings in gearbox housing 9277
6 3 2 Removing and installing output shaft bearings in gearbox housing 9279
6 3 3 Removing and installing differential bearings in gearbox housing 9282
6 4 Repairing clutch housing 9284
6 4 1 Removing and installing input shaft bearings in clutch housing 9284
6 4 2 Removing and installing output shaft bearings in clutch housing 9285
6 4 3 Removing and installing differential bearings in clutch housing 9287
7 Installing to engine and gearbox support 9290
8 Gear oil 9291
8 1 Checking gear oil level 9291
8 2 Draining and filling gear oil 9291
35 – Gears, shafts 9294
1 Input shaft 9294
1 1 Assembly overview – input shaft 9294
1 2 Dismantling and assembling input shaft 9297
1 3 Adjusting input shaft 9303
2 Output shaft 9308
2 1 Assembly overview – output shaft 9308
2 2 Dismantling and assembling output shaft 9311
2 3 Adjusting output shaft 9321
3 Reverse shaft 9328
3 1 Assembly overview – reverse shaft 9328
3 2 Dismantling and assembling reverse shaft 9329
39 – Final drive – differential 9332
1 Oil seals 9332
1 1 Overview of fitting locations – seals 9332
1 2 Renewing left oil seal 9333
1 3 Renewing right oil seal 9335
1 4 Renewing input shaft seal 9339
2 Differential 9341
2 1 Assembly overview – differential 9341
2 2 Dismantling and assembling differential 9342
2 3 Adjusting differential 9347
3 Adjustment overview 9351
00 – Technical data 9356
1 Safety information 9356
1 1 Safety measures when working on vehicles with a start/stop system 9356
1 2 Safety precautions when using testers and measuring instruments during a road test 9356
1 3 General safety provisions 9356
2 Identification 9358
2 1 Gearbox identification 9358
3 Repair instructions 9360
3 1 General repair instructions 9360
4 Technical data 9365
4 1 Capacities 9365
4 2 Allocation gearbox – motor 9365
4 3 Calculation of gear ratios 9365
5 Overview – power transmission 9367
5 1 Overview – power transmission – front-wheel drive 9367
6 Electrical components 9369
6 1 Overview of fitting locations – electrical components 9369
6 1 1 Overview of fitting locations – electrical components, manual gearbox 9369
6 1 2 Overview of fitting locations – electrical components, clutch mechanism 9370
30 – Clutch 9371
1 Clutch mechanism 9371
1 1 Assembly overview – pedal cluster 9371
1 2 Assembly overview – clutch hydraulics 9373
1 2 1 Assembly overview – clutch hydraulics, left-hand drive 9373
1 2 2 Assembly overview – clutch hydraulics, right-hand drive 9376
1 3 Assembly overview – clutch release mechanism 9377
1 4 Removing and installing clutch pedal 9379
1 5 Removing and installing over-centre spring 9381
1 6 Removing and installing return spring 9384
1 7 Removing and installing mounting bracket 9387
1 8 Removing and installing bearing bush 9392
1 9 Removing and installing clutch master cylinder 9394
1 10 Removing and installing clutch slave cylinder 9394
1 11 Removing and installing lines for clutch mechanism 9396
1 12 Bleeding clutch mechanism 9400
1 13 Checking clutch master cylinder and clutch slave cylinder 9401
1 14 Removing and installing clutch position sender -G476- 9401
1 15 Repairing clutch release mechanism 9402
2 Clutch 9404
2 1 Determining make of clutch 9404
2 2 Assembly overview – clutch 9405
2 2 1 Assembly overview – clutch in conjunction with Sachs dual-mass flywheel 9405
2 2 2 Assembly overview – clutch in conjunction with LuK dual-mass flywheel 9406
2 2 3 Assembly overview – clutch with simple flywheel 9407
2 3 Removing and installing clutch 9408
2 3 1 Removing and installing clutch in conjunction with Sachs dual-mass flywheel 9408
2 3 2 Removing and installing clutch in conjunction with LuK dual-mass flywheel 9413
2 3 3 Removing and installing clutch in connection with simple flywheel 9419
34 – Controls, housing 9424
1 Selector mechanism 9424
1 1 Installation position – selector mechanism 9424
1 2 Assembly overview – gear knob and cover 9425
1 3 Assembly overview – selector mechanism 9425
1 4 Removing and installing gear knob 9427
1 5 Removing and installing selector mechanism 9429
1 6 Adjusting selector mechanism 9435
1 7 Checking selector mechanism 9439
1 8 Renewing selector shaft seal 9439
2 Removing and installing gearbox 9441
2 1 Specified torques for gearbox 9441
2 2 Removing gearbox 9442
2 3 Installing gearbox 9452
3 Assembly mountings 9462
3 1 Assembly overview – assembly mountings 9462
4 Gearbox transport 9466
5 Dismantling and assembling gearbox 9468
5 1 Schematic overview – gearbox 9468
5 2 Assembly overview – cover for gearbox housing and 5th/6th gear 9469
5 3 Assembly overview – gearbox housing and selector mechanism 9471
5 4 Assembly overview – selector unit 9473
5 5 Assembly overview – input shaft, output shafts, differential, selector rods 9473
5 6 Assembly overview – selector forks 9475
5 6 1 Assembly overview – selector forks in conjunction with synchromeshed gear for reverse gear 9475
5 6 2 Assembly overview – selector forks in conjunction with locking collar for reverse gear 9477
5 7 Repairing selector unit 9478
5 8 Repairing selector forks 9479
5 9 Removing cover for gearbox housing and 5th and 6th gears 9484
5 10 Dismantling and assembling gearbox 9492
5 11 Installing cover for gearbox housing and 5th and 6th gears 9509
6 Gearbox housing, clutch housing 9519
6 1 Assembly overview – gearbox housing 9519
6 2 Assembly overview – clutch housing 9522
6 3 Assembly overview – gearbox housing cover 9524
6 4 Repairing gearbox housing 9525
6 4 1 Removing and installing input shaft bearings in gearbox housing 9525
6 4 2 Removing and installing output shaft bearings in gearbox housing 9526
6 4 3 Removing and installing differential bearings in gearbox housing 9531
6 5 Repairing clutch housing 9534
6 5 1 Removing and installing input shaft bearings in clutch housing 9534
6 5 2 Removing and installing output shaft bearings in clutch housing 9535
6 5 3 Removing and installing differential bearings in clutch housing 9537
6 6 Repairing gearbox housing cover 9539
7 Securing to engine and gearbox support 9543
8 Gear oil 9548
8 1 Checking gear oil level 9548
8 2 Draining and filling gear oil 9548
35 – Gears, shafts 9551
1 Input shaft 9551
1 1 Assembly overview – input shaft 9551
1 2 Dismantling and assembling input shaft 9553
1 3 Adjusting input shaft 9559
2 Output shaft 9565
2 1 Assembly overview – output shaft 9565
2 2 Dismantling and assembling output shaft 9568
2 3 Adjusting output shaft 9584
3 Reverse shaft 9591
3 1 Assembly overview – reverse shaft 9591
3 1 1 Assembly overview – reverse shaft with synchromeshed gear for reverse gear 9591
3 1 2 Assembly overview – reverse shaft with reverse gear locking collar 9592
3 2 Dismantling and assembling reverse shaft 9593
39 – Final drive – differential 9597
1 Oil seals 9597
1 1 Overview of fitting locations – oil seals 9597
1 2 Renewing left seal 9597
1 3 Renewing right seal 9600
1 4 Renewing input shaft seal 9605
2 Differential 9608
2 1 Assembly overview – differential 9608
2 2 Dismantling and assembling differential 9610
2 3 Adjusting differential 9619
3 Adjustment overview 9623
00 – Technical data 9628
1 Safety information 9628
1 1 General safety provisions 9628
1 2 Safety precautions when using testing and measuring instruments during a road test 9629
1 3 Safety precautions when tow-starting or towing 9629
2 Identification 9630
2 1 Gearbox identification 9630
2 2 Identification of torque converter 9630
3 Repair instructions 9632
3 1 General information 9632
3 2 Rules for cleanliness 9633
3 3 General repair instructions 9633
3 4 Gaskets and seals 9634
3 5 Nuts and bolts 9634
4 Technical data 9635
4 1 Capacities 9635
4 2 Allocation gearbox – motor 9635
32 – Torque converter 9636
1 Torque converter 9636
1 1 Assembly overview – torque converter 9636
1 2 Removing and installing torque converter 9637
1 3 Draining torque converter 9638
1 4 Checking torque converter 9639
1 5 Removing and installing torque converter oil seal 9639
37 – Controls, housing 9641
1 ATF circuit 9641
1 1 Assembly overview – ATF circuit 9641
1 2 Removing and installing ATF cooler 9641
1 2 1 Removing and installing ATF cooler, 1 6 l engine 9641
1 2 2 Removing and installing ATF cooler, 1 4 l engine 9644
2 ATF 9646
2 1 Checking ATF level 9646
2 2 Draining and filling ATF 9650
3 Removing and installing gearbox 9654
3 1 Specified torques for gearbox 9654
3 2 Removing gearbox 9655
3 2 1 Removing gearbox, vehicles with 1 4 l, 110 kW engine 9655
3 2 2 Removing gearbox, vehicles with 1 6 l, 81 kW engine 9666
3 3 Installing gearbox 9679
4 Gearbox transport 9683
5 Securing to engine and gearbox support 9685
6 Selector mechanism 9687
6 1 Assembly overview – selector mechanism 9687
6 2 Checking selector mechanism 9689
6 3 Manual release from position P 9690
6 4 Removing and installing selector mechanism 9691
6 4 1 Removing and installing selector mechanism with selector lever cable 9691
6 4 2 Removing and installing selector mechanism without selector lever cable 9695
6 5 Removing and installing selector lever handle 9699
6 6 Moving push-button in the handle to installation position 9702
6 7 Removing and installing gear selector cable 9704
6 8 Checking and adjusting selector lever cable 9708
6 9 Removing and installing multifunction switch 9710
6 10 Adjusting multifunction switch 9714
6 11 Renewing selector shaft seal 9715
38 – Gears, control 9717
1 ATF system 9717
1 1 Removing and installing sump 9717
1 2 Removing and installing ATF strainer 9719
2 Valve body 9721
2 1 Assembly overview – valve body 9721
2 2 Removing and installing valve body 9724
2 3 Removing and installing wiring harness for senders and solenoid valves 9726
2 4 Removing and installing gearbox input speed sender -G182- and gearbox output speed sender -G195- 9730
39 – Final drive – differential 9731
1 Seals 9731
1 1 Overview of fitting locations – oil seals 9731
1 2 Renewing left seal 9731
1 3 Renewing right seal 9734
2 Gearbox control system 9738
2 1 Removing and installing gearbox control unit 9738
00 – Technical data 9746
1 Safety instructions 9746
1 1 Safety precautions when working on fuel supply system 9746
1 2 Safety precautions during road tests in which test and measuring equipment is used 9746
1 3 Safety precautions when working on cooling system 9747
1 4 Safety precautions when working on ignition system 9747
2 Identification 9748
2 1 Engine number, engine data 9748
3 Repair instructions 9749
3 1 Rules for cleanliness 9749
3 2 Foreign objects in engine 9749
3 3 Contact corrosion 9749
3 4 Routing and securing lines 9750
3 5 Installing coolers, condensers and radiators 9750
10 – Removing and installing engine 9751
1 Removing and installing engine 9751
1 1 Removing engine 9751
1 2 Separating engine and gearbox 9756
1 2 1 Separating engine and gearbox, manual gearbox 9756
1 2 2 Separating engine and gearbox, vehicles with automatic gearbox 9758
1 3 Securing engine on engine and gearbox support 9760
1 4 Installing engine 9761
2 Assembly mountings 9764
2 1 Assembly overview – assembly mountings 9764
2 2 Removing and installing engine mountings 9766
2 3 Supporting engine in installation position 9770
2 4 Adjusting assembly mountings 9779
13 – Crankshaft group 9781
1 Cylinder block (pulley end) 9781
1 1 Assembly overview – poly V-belt drive 9781
1 2 Assembly overview – cylinder block (pulley end) 9782
1 3 Removing and installing poly V-belt 9785
1 4 Removing and installing tensioner for poly V-belt 9785
1 5 Removing and installing vibration damper 9786
1 6 Removing and installing ancillary bracket 9789
1 7 Renewing crankshaft oil seal – belt pulley end 9790
2 Cylinder block, gearbox end 9793
2 1 Assembly overview – cylinder block, gearbox end 9793
2 2 Removing and installing sealing flange on gearbox side 9794
3 Crankshaft 9803
3 1 Assembly overview – crankshaft 9803
3 2 Crankshaft dimensions 9804
4 Pistons and conrods 9805
4 1 Assembly overview – pistons and conrods 9805
4 2 Checking piston and cylinder bore 9806
15 – Cylinder head, valve gear 9808
1 Cylinder head 9808
1 1 Assembly overview – cylinder head 9808
1 2 Removing and installing cylinder head 9809
1 3 Removing and installing camshaft housing 9812
1 4 Checking compression 9814
2 Cover for timing chain 9817
2 1 Removing and installing valve timing housing (timing case) 9817
3 Chain drive 9820
3 1 Removing and installing timing chain and chain drive for oil pump 9820
3 2 Checking valve timing 9827
3 3 Adjusting valve timing 9828
4 Valve gear 9835
4 1 Assembly overview – valve gear 9835
4 2 Measuring axial play of camshaft 9837
4 3 Removing and installing valve stem seals 9837
5 Inlet and exhaust valves 9840
5 1 Reworking valve seats 9840
5 2 Checking valve guides 9842
5 3 Checking valves 9842
5 4 Valve dimensions 9843
17 – Lubrication 9844
1 Sump, oil pump 9844
1 1 Assembly overview – sump and oil pump 9844
1 2 Engine oil 9846
1 3 Removing and installing sump 9846
1 4 Removing and installing oil pump 9850
2 Oil filter, oil pressure switch 9853
2 1 Checking oil pressure and oil pressure switch 9853
19 – Cooling 9855
1 Cooling system, coolant 9855
1 1 Coolant hose schematic diagram 9855
1 2 Checking cooling system for leaks 9856
1 3 Draining and filling coolant 9858
2 Coolant pump, regulation of cooling system 9862
2 1 Assembly overview – coolant pump, thermostat 9862
2 2 Assembly overview – coolant temperature sender 9863
2 3 Removing and installing coolant pump 9865
3 Radiator and radiator fan 9868
3 1 Assembly overview – radiator and radiator fan 9868
3 2 Removing and installing radiator 9872
3 3 Removing and installing radiator cowling with radiator fan 9876
3 4 Removing and installing radiator fan -V7- and radiator fan 2 -V177- 9877
24 – Mixture preparation – injection 9878
1 Injection system 9878
1 1 Filling and bleeding fuel system 9878
2 Injectors 9881
2 1 Assembly overview – fuel rail with injectors 9881
2 2 Removing and installing injectors 9881
2 3 Checking injectors 9883
3 Air filter 9887
3 1 Assembly overview – air filter housing 9887
3 2 Removing and installing air filter housing 9888
4 Intake manifold 9889
4 1 Assembly overview – intake manifold 9889
4 2 Cleaning throttle valve module -J338- 9890
5 Engine control unit 9891
5 1 Removing and installing engine control unit -J623- 9891
26 – Exhaust system 9892
1 Exhaust pipes, silencers 9892
1 1 Assembly overview – silencers 9892
1 2 Removing and installing front exhaust pipe 9893
1 3 Removing and installing rear silencer 9894
1 4 Installation position of clamp 9896
2 Emission control 9898
2 1 Assembly overview – emission control 9898
28 – Ignition system 9900
1 Ignition system 9900
1 1 Assembly overview – ignition system 9900
1 2 Test data, spark plugs 9901
1 3 Removing and installing ignition coils with output stage 9901
1 4 Removing and installing engine speed sender -G28- 9902
00 – Technical data 9911
1 Safety information 9911
1 1 Safety regulations for working on fuel supply 9911
1 2 Safety precautions when using testers and measuring instruments during a road test 9912
1 3 Safety precautions when working on ignition system 9912
1 4 Safety precautions when working on the cooling system 9913
2 Identification 9914
2 1 Engine number/engine data 9914
3 Repair notes 9916
3 1 Rules for cleanliness 9916
3 2 Foreign bodies in engine 9916
3 3 Contact corrosion 9916
3 4 Routing and attachment of lines 9916
3 5 Fitting radiator and condensers 9916
10 – Removing and installing engine 9917
1 Removing and installing engine 9917
1 1 Removing engine 9917
1 2 Securing engine on engine and gearbox support 9927
1 3 Installing engine 9928
2 Assembly mountings 9931
2 1 Assembly overview – assembly mountings 9931
2 2 Removing and installing engine mounting 9933
2 3 Supporting engine in installation position 9942
2 4 Adjusting assembly mountings 9949
2 5 Checking adjustment of assembly mountings 9951
13 – Crankshaft group 9952
1 Cylinder block (pulley end) 9952
1 1 Assembly overview – poly V-belt drive 9952
1 2 Assembly overview – cylinder block (pulley end) 9953
1 3 Removing and installing poly-V belt 9956
1 4 Removing and installing vibration damper 9956
1 5 Removing and installing bracket for ancillaries 9960
1 6 Renewing crankshaft oil seal – pulley end 9962
2 Cylinder block, gearbox end 9965
2 1 Assembly overview – cylinder block, gearbox end 9965
2 2 Removing and installing sealing flange on gearbox side 9966
3 Crankshaft 9979
3 1 Assembly overview – crankshaft 9979
3 2 Crankshaft dimensions 9981
3 3 Renewing needle bearing in crankshaft 9981
4 Pistons and conrods 9984
4 1 Assembly overview – pistons and conrods 9984
4 2 Checking pistons and cylinder bores 9986
4 3 Separating new conrod 9988
15 – Cylinder head, valve gear 9990
1 Cylinder head 9990
1 1 Assembly overview – cylinder head 9990
1 2 Removing and installing cylinder head 9993
1 3 Removing and installing camshaft housing 9995
1 4 Checking compression 10003
2 Cover for timing chain 10005
2 1 Removing and installing valve timing housing (timing case) 10005
3 Chain drive 10010
3 1 Removing and installing timing chain and chain drive for oil pump 10010
3 2 Checking timing chain 10021
3 3 Checking valve timing 10027
3 4 Adjusting valve timing 10031
4 Valve gear 10042
4 1 Assembly overview – valve gear 10042
4 2 Measuring axial play of camshaft 10044
4 3 Removing and installing valve stem oil seals 10046
5 Inlet and exhaust valves 10049
5 1 Reworking valve seats 10049
5 2 Checking valve guides 10050
17 – Lubrication 10052
1 Sump, oil pump 10052
1 1 Assembly overview – sump/oil pump 10052
1 2 Engine oil: 10054
1 3 Removing and installing oil sump 10055
1 4 Removing and installing oil pump 10058
2 Oil filter, oil pressure switch 10061
2 1 Checking oil pressure and oil pressure switch 10061
19 – Cooling 10064
1 Cooling system/coolant 10064
1 1 Connection diagram – coolant hoses 10064
1 2 Checking cooling system for leaks 10065
1 3 Draining and adding coolant 10067
2 Coolant pump, regulation of cooling system 10073
2 1 Assembly overview – thermostat 10073
2 2 Removing and installing coolant circulation pump -V50- 10075
2 3 Removing and installing coolant pump 10076
3 Radiator, radiator fan 10080
3 1 Assembly overview – radiator/radiator fan 10080
3 2 Removing and installing radiator 10082
3 3 Removing and installing water radiator for charge air cooling circuit 10084
3 4 Removing and installing radiator cowl 10086
3 5 Removing and installing radiator fan -V7- and radiator fan 2 -V177- 10087
21 – Turbocharging/supercharging 10089
1 Turbocharger 10089
1 1 Assembly overview – turbocharger 10089
1 2 Assembly overview – turbocharger air recirculation valve -N249- 10091
1 3 Removing and installing turbocharger 10092
1 4 Checking vacuum unit for turbocharger 10099
1 5 Adjusting vacuum unit for turbocharger 10101
1 6 Renewing vacuum unit for turbocharger 10109
1 7 Removing and installing compressor housing and turbine housing 10113
2 Charge air system 10120
2 1 Assembly overview – charge air system 10120
24 – Mixture preparation – injection 10123
1 Injection system 10123
1 1 Releasing high pressure in fuel system 10123
2 Injectors 10124
2 1 Assembly overview – fuel rail with injectors 10124
2 2 Removing and installing injectors 10124
2 3 Renewing seals on injectors 10127
3 Air filter 10133
3 1 Assembly overview – air filter housing 10133
3 2 Removing and installing air filter housing 10133
4 Intake manifold 10135
4 1 Assembly overview – intake manifold 10135
4 2 Assembly overview – lower part of intake manifold with fuel rail 10137
4 3 Removing and installing intake manifold 10139
4 4 Removing and installing throttle valve module -J338- 10140
4 5 Cleaning throttle valve module -J338- 10144
5 Senders and sensors 10146
5 1 Checking fuel pressure sender -G247- 10146
6 Engine/motor control unit 10150
6 1 Removing and installing engine control unit -J623- without protective housing 10150
6 2 Removing and installing engine (motor) control unit -J623- with protective housing 10152
7 High-pressure pump 10158
7 1 Assembly overview – high-pressure pump 10158
7 2 Removing and installing high-pressure pump 10159
26 – Exhaust system 10164
1 Exhaust pipes and silencers 10164
1 1 Assembly overview – silencers 10164
1 2 Separating exhaust pipes from silencers 10165
1 3 Installation position of clamp 10167
1 4 Aligning exhaust system free of stress 10169
2 Emission control 10171
2 1 Assembly overview – emission control 10171
28 – Ignition system 10174
1 Ignition system 10174
1 1 Assembly overview – ignition system 10174
1 2 Test data, spark plugs 10176
1 3 Removing and installing ignition coils with output stage 10176
1 4 Removing and installing engine speed sender -G28- 10178
00 – Technical data 10186
1 Safety information 10186
1 1 Safety precautions when working on air conditioning systems 10186
1 2 Safety precautions when handling refrigerants 10187
1 3 Safety measures when working on vehicles with a start/stop system 10187
1 4 Safety precautions when using air conditioner service stations 10187
1 5 Safety measures for working on vehicles with high-voltage system 10188
1 6 Safety precautions when working in the vicinity of high-voltage components 10189
1 7 Safety precautions when working on pressure vessels 10189
2 Laws and regulations 10190
2 1 Legal regulations and standards 10190
2 2 Charging refrigerant circuit with different refrigerants 10191
2 3 Occupational health and safety 10192
3 Repair notes 10193
3 1 Rules for cleanliness 10193
3 2 Refrigerant circuit seals 10193
3 3 Refrigerant and refrigerant oil 10194
3 3 1 Important repair notes for refrigerant and refrigerant oil 10194
3 3 2 Refrigerant oil 10195
3 4 Handling pressure vessels 10196
3 5 Handling refrigerants 10197
4 Identification 10199
4 1 Notice for refrigerant circuit 10199
5 Technical data 10200
5 1 Refrigerant capacity 10200
5 2 Refrigerant oil capacities 10200
5 3 Safety data sheets 10200
6 Basic technical and physical properties 10201
6 1 Basics of air conditioning technology 10201
6 1 1 Physical properties of air conditioning system 10201
6 1 2 Pressure and boiling point of refrigerant 10202
6 1 3 Vapour pressure table for refrigerant 10203
6 2 Physical properties 10205
6 2 1 Refrigerant R1234yf 10205
6 2 2 Potential risks with refrigerant R1234yf 10205
6 2 3 Physical and chemical properties of refrigerant R1234yf 10206
6 2 4 Critical point 10206
6 2 5 Environmental aspects of refrigerant R1234yf 10207
6 2 6 Trade names and designations of refrigerant R1234yf 10207
6 2 7 Colour and odour of R1234yf refrigerant 10208
6 2 8 Vapour pressure of R1234yf refrigerant 10208
6 2 9 Physical properties of R1234yf refrigerant 10208
6 2 10 How R1234yf refrigerant reacts to metals and plastics 10208
6 2 11 Critical temperature / critical pressure of R1234yf refrigerant 10209
6 2 12 Water content of R1234yf refrigerant 10209
6 2 13 Flammability / decomposition of R1234yf refrigerant 10209
6 2 14 Charge factor of refrigerant R1234yf 10209
6 2 15 Evidence of leaks in a refrigerant circuit with R1234yf refrigerant 10210
6 2 16 Analysis of refrigerant R1234yf 10210
6 2 17 Returning contaminated R1234yf refrigerant for analysis, processing or disposal 10211
6 3 Product characteristics 10212
6 4 Function and role of air conditioning system 10212
6 4 1 Principle of operation 10212
6 4 2 Comfort 10213
6 4 3 Environmental aspects 10213
6 5 Other reference material 10214
87 – Air conditioning system 10215
1 Refrigerant circuit 10215
1 1 System overview – refrigerant circuit 10215
1 1 1 System overview – refrigerant circuit with expansion valve and receiver 10215
1 1 2 System overview – refrigerant circuit with restrictor and reservoir 10217
1 1 3 System overview – refrigerant circuit with electrically driven air conditioner compressor (with and without battery cooling module) 10218
1 2 General description – components of refrigerant circuit 10221
1 2 1 Layout and function of refrigerant circuit 10221
1 2 2 Mechanical air conditioner compressor 10222
1 2 3 Electrical air conditioner compressor for hybrid vehicles 10225
1 2 4 Condenser 10228
1 2 5 evaporator 10229
1 2 6 Reservoir 10231
1 2 7 Heat exchanger for heat pump mode 10231
1 2 8 Liquid receiver 10232
1 2 9 Restrictor 10232
1 2 10 Receiver 10234
1 2 11 Expansion valve (with and without shut-off valve) 10236
1 2 12 Refrigerant shut-off valves 10238
1 2 13 Refrigerant line with internal heat exchanger 10240
1 2 14 Quick release couplings of refrigerant lines 10241
1 2 15 Seals 10242
1 2 16 Pipes and hoses in refrigerant circuit 10243
1 2 17 High-pressure safety valve 10243
1 2 18 Non-return valves 10245
1 2 19 Quick-release coupling connections in refrigerant circuit 10246
1 2 20 Connections with valve for switches in refrigerant circuit 10250
1 2 21 Pressure senders and switches in refrigerant circuit 10251
1 2 22 Refrigerant pressure and temperature sender 10252
1 2 23 Air conditioner compressor regulating valve -N280- 10255
1 2 24 Refrigerant temperature sender 10256
1 3 Possible complaints 10257
1 3 1 Prerequisites for investigating a complaint 10257
1 3 2 Possible complaints 10257
1 3 3 Odours from heater and air conditioning unit 10259
1 4 Investigating leaks 10261
1 4 1 General information about investigating leaks in the refrigerant circuit 10261
1 4 2 Searching for leaks in refrigerant circuits using an electronic leak detector 10262
1 4 3 Searching for leaks with UV leak detection system 10263
1 4 4 Detecting leaks in a vacuum test using air conditioner service station, or in a pressure test 10269
1 4 5 Detecting leaks in a pressure test (with nitrogen or compressed air) 10270
1 5 Renewing components 10272
1 5 1 General information about renewing components 10272
1 5 2 Renewing leaking or damaged components of empty refrigerant circuit (apart from air conditioner compressor and receiver) 10273
1 5 3 Renewing leaking or damaged components of charged refrigerant circuit (apart from air conditioner compressor and receiver) 10275
1 5 4 Renewing air conditioner compressor with no need to clean refrigerant circuit 10276
1 5 5 Renewing air conditioner compressor due to leaks or internal damage 10279
1 5 6 Renewing desiccant cartridge / receiver after cleaning refrigerant circuit 10280
1 5 7 Renewing receiver with no need to clean refrigerant circuit 10282
1 5 8 Renewing desiccant cartridge / desiccant bag with no need to clean refrigerant circuit 10283
1 6 Cleaning refrigerant circuit 10284
1 6 1 General information about cleaning refrigerant circuit 10284
1 6 2 Preparations for cleaning refrigerant circuit (flushing with R1234yf refrigerant) 10286
1 6 3 Refrigerant circuit cleaning procedure 10290
1 6 4 Principle circuit diagrams for cleaning (flushing circuits) – refrigerant circuit with expansion valve and receiver 10290
1 6 5 Principle circuit diagrams for cleaning (flushing circuits) – refrigerant circuit with restrictor and receiver (without high-voltage system) 10295
1 6 6 Adapters for setting up flushing circuits 10298
1 6 7 General information about blowing through with compressed air or nitrogen 10311
1 6 8 Blowing through refrigerant circuit with compressed air or nitrogen 10315
1 7 Checking pressures with pressure gauge 10316
1 7 1 Display on pressure gauges 10316
1 7 2 Pressure gauges enable the following test and measurement work 10317
2 Working with air conditioner service station 10320
2 1 Working with air conditioner service station 10321
2 2 Connecting air conditioner service station to refrigerant circuit 10323
2 3 Performing gas analysis of refrigerant 10326
2 4 Purging refrigerant circuit 10329
2 5 Evacuating refrigerant circuit 10332
2 6 Charging refrigerant circuit 10338
2 7 Bringing air conditioning system into service after charging 10341
2 8 Switching off air conditioner service station and separating from refrigerant circuit 10343
2 9 Charging refrigerant in reservoir 10345
2 10 Emptying air conditioner service station 10346
2 11 Cleaning electrical air conditioning compressor 10346
2 12 Cleaning refrigerant circuit 10349
2 13 Filling contaminated refrigerant in a recycling cylinder for analysis, processing or disposal 10352
2 13 1 Filling contaminated refrigerant into recycling cylinder using extraction unit -VAS 581 011- 10352
2 13 2 Filling contaminated refrigerant into recycling cylinder using extraction unit -VAS 581 007- 10353
2 14 Checking pressures 10357
2 14 1 General information on checking pressures in the refrigerant circuit 10357
2 14 2 Pressures and temperatures in refrigerant circuit 10359
2 14 3 Checking pressures in the refrigerant circuit with the ignition switched off 10363
2 14 4 Checking pressures with air conditioning system switched on – vehicles with mechanical air conditioning compressor 10370
2 14 5 Checking pressures with air conditioning system switched on – vehicles with electrical air conditioning compressor 10392
3 Testing equipment and tools 10445
3 1 Tools and materials available from distribution centre or importer 10445
3 2 Tools and materials available commercially 10445
00 – Technical data 10455
1 Safety information 10455
1 1 Safety measures when working on vehicles with a start/stop system 10455
1 2 Safety precautions when using testers and measuring instruments during a road test 10455
2 Repair instructions 10456
2 1 Contact corrosion 10456
2 2 Routing and attachment of lines 10456
3 Battery 10457
3 1 Battery – general notes 10457
3 2 Types of battery 10457
27 – Starter, current supply, CCS 10458
1 Battery 10458
1 1 Assembly overview – battery 10458
1 2 Removing and installing battery 10460
1 3 Disconnecting and connecting battery 10463
1 4 Removing and installing battery tray 10465
1 5 Checking battery 10466
1 6 Charging battery 10466
1 7 Removing and installing earth wire with battery monitor control unit -J367- 10466
1 8 Adapting battery monitor control unit -J367- 10467
2 Alternator 10468
2 1 Assembly overview – alternator 10468
2 1 1 Assembly overview – alternator without sliding bushes 10468
2 1 2 Assembly overview – alternator with sliding bushes 10468
2 2 Removing and installing alternator 10469
2 2 1 Removing and installing alternator, 1 4 l TSI engine 10469
2 2 2 Removing and installing alternator, vehicles with 1 6 l MPI engine 10471
2 2 3 Removing and installing alternator, vehicles with 2 0 l TSI engine 10473
2 3 Checking alternator 10475
2 4 Removing and installing poly V-belt pulley 10476
2 4 1 Removing and installing poly V-belt pulley without freewheel 10476
2 4 2 Removing and installing poly V-belt pulley with freewheel, manufacturer Bosch 10477
2 4 3 Removing and installing poly V-belt pulley with freewheel, manufacturer Valeo 10479
2 4 4 Removing and installing decoupler pulley with freewheel 10482
2 5 Removing and installing voltage regulator 10485
2 5 1 Removing and installing voltage regulator, manufacturer Bosch 10485
2 5 2 Removing and installing voltage regulator, manufacturer Valeo 10487
3 Starter 10489
3 1 Assembly overview – starter 10489
3 1 1 Assembly overview – starter, vehicles with manual gearbox 10489
3 1 2 Assembly overview – starter, vehicles with 6-speed dual clutch gearbox 0D9, vehicles with 7-speed dual clutch gearbox 0GC 10489
3 1 3 Assembly overview – starter, vehicles with 6-speed automatic gearbox 10490
3 1 4 Assembly overview – starter, vehicles with 8-speed automatic gearbox 10491
3 2 Removing and installing starter 10492
3 2 1 Removing and installing starter, vehicle with manual gearbox 10492
3 2 2 Removing and installing starter, vehicles with 6-speed dual clutch gearbox 0D9, vehicles with 7-speed dual clutch gearbox 0CG 10494
3 2 3 Removing and installing starter, vehicles with 6-speed automatic gearbox 10497
3 2 4 Removing and installing starter, vehicles with 8-speed automatic gearbox 10499
4 Cruise control system (CCS) 10501
5 Start/stop system 10502
5 1 General description – start/stop system 10502
5 2 Overview of fitting locations – start/stop system 10502
90 – Gauges, instruments 10503
1 Dash panel insert 10503
1 1 Assembly overview – dash panel insert 10503
1 2 Removing and installing dash panel insert -KX2- 10504
1 2 1 Removing and installing dash panel insert -KX2-, dash panel insert with analogue instruments 10504
1 2 2 Removing and installing dash panel insert -KX2-, fully digital dash panel insert 10506
2 Horn 10509
2 1 Assembly overview – horn (8Y0) 10509
2 2 Removing and installing left horn -H33- 10509
2 3 Assembly overview – horn (8Y1) 10510
2 4 Removing and installing treble horn -H2- and bass horn -H7- 10511
92 – Windscreen wash/wipe system 10513
1 Windscreen wiper system 10513
1 1 Assembly overview – windscreen wiper system 10513
1 2 Moving wipers to service position 10515
1 3 Removing and installing wiper blade 10515
1 4 Removing and installing wiper arms 10516
1 5 Adjusting wiper arms 10518
1 6 Removing and installing wiper motor -V- 10519
1 7 Removing and installing rain and light sensor 10521
1 8 Repairing rain and light sensor 10523
1 8 1 Repairing rain and light sensor, TRW 10523
1 8 2 Repairing rain and light sensor, Valeo 10524
2 Windscreen washer system 10527
2 1 Assembly overview – windscreen washer system 10527
2 1 1 Assembly overview – windscreen washer system 10527
2 2 Removing and installing washer fluid reservoir 10528
2 3 Removing and installing windscreen washer fluid level sender 10530
2 4 Removing and installing windscreen washer pump 10531
2 5 Removing and installing spray jets 10532
2 6 Adjusting spray jets 10533
3 Washer fluid lines 10534
3 1 Repairing washer fluid lines 10534
94 – Lights, bulbs, switches – exterior 10535
1 Headlights 10535
1 1 Assembly overview – headlight 10535
1 1 1 Assembly overview – LED headlights 10535
1 2 Removing and installing headlight 10536
1 3 Adjusting headlights 10541
1 4 Adjusting headlight installation position 10541
1 5 Removing and installing front turn signal bulb -M5-/-M7- 10542
1 5 1 Removing and installing front turn signal bulb -M5-/-M7- (equipment version 1) 10542
1 5 2 Removing and installing front turn signal bulb -M5-/-M7- (equipment version 2) 10543
1 6 Removing and installing headlight range control motor -V48-/-V49- 10544
1 7 Removing and installing headlight dipped beam bulb 10544
1 8 Removing and installing headlight main beam bulb -M30-/-M32- 10544
1 9 Removing and installing side light bulb -M1-/-M3- 10544
1 10 Removing and installing LED modules for daytime running light and side light -L176-/-L177- 10544
1 11 Removing and installing bulbs for cornering light -L148-/-L149- 10545
1 12 Removing and installing output module for headlight -J667-/-J668- 10545
1 13 Removing and installing output module 1 for LED headlight -A31-/-A27- 10545
2 Fog light 10546
2 1 Assembly overview – fog lights 10546
2 1 1 Assembly overview – fog lights 10546
2 2 Removing and installing fog light 10546
2 2 1 Removing and installing fog light 10546
2 3 Removing and installing fog light bulb -L22-/-L23- 10547
2 4 Adjusting fog lights 10548
3 Lights in exterior mirror 10549
3 1 Assembly overview – lights in exterior mirror 10549
3 2 Removing and installing turn signal 10551
3 3 Removing and installing entry light in exterior mirror 10552
4 Tail light cluster 10554
4 1 Assembly overview – tail light cluster in body 10554
4 1 1 Assembly overview – tail light cluster in body 10554
4 2 Assembly overview – tail light clusters in rear lid 10555
4 2 1 Assembly overview – tail light clusters in rear lid 10555
4 3 Removing and installing tail light in rear lid 10557
4 3 1 Removing and installing tail light in rear lid 10557
4 4 Adjusting installation position of tail light 10558
4 4 1 Adjusting installation position of tail light 10558
4 5 Removing and installing tail light cluster 10559
4 5 1 Removing and installing tail light cluster 10559
4 6 Removing and installing tail light bulb -M2-/-M4- 10560
4 7 Removing and installing rear fog light bulb -L46-/-L47- 10560
4 8 Removing and installing brake and tail light bulb -M21-/-M22- 10560
4 9 Removing and installing reversing light bulb 10560
4 10 Removing and installing turn signal bulb 10560
5 High-level brake light 10562
5 1 Assembly overview – high-level brake light 10562
5 2 Removing and installing high-level brake light 10562
5 3 Removing and installing high-level brake light 10563
6 Number plate light 10564
6 1 Removing and installing number plate light -X4-/-X5- 10564
6 1 1 Removing and installing number plate light -X4-/-X5- 10564
6 2 Removing and installing bulb for number plate light -X4-/-X5- 10565
7 Entry and start authorisation system 10566
7 1 Overview of fitting locations – entry and start authorisation system 10566
7 1 1 Overview of fitting locations – entry and start authorisation system, NAR and Mexico (equipment version 1) 10566
7 1 2 Overview of fitting locations – entry and start authorisation system, equipment version 2 10567
7 2 Overview of fitting locations – keyless entry system 10568
7 2 1 Overview of fitting locations – front keyless entry system, NAR and Mexico (equipment version 1) 10568
7 2 2 Overview overview of fitting locations – front keyless entry system (equipment version 2) 10569
7 2 3 Overview of fitting locations – rear keyless entry system 10570
7 3 Removing and installing interface for entry and start system -J965- 10571
7 3 1 Removing and installing entry and start authorisation control unit -J965-, equipment version 2 10571
7 3 2 Removing and installing entry and start authorisation control unit -J965-, NAR and Mexico (equipment version 1) 10573
7 4 Removing and installing door exterior handle contact sensor -G415-/-G416- 10574
7 5 Removing and installing driver side aerial for entry and start system -R134- 10574
7 6 Removing and installing front passenger side aerial for entry and start system -R135- 10574
7 7 Removing and installing rear bumper aerial for entry and start system -R136- 10574
7 8 Removing and installing interior aerial 1 for entry and start system -R138- 10575
7 9 Removing and installing interior aerial 2 for entry and start system -R139- 10575
8 Steering column switch module 10577
8 1 Assembly overview – steering column switch module 10577
8 1 1 Assembly overview – steering column switch module, mechanical ignition lock 10577
8 1 2 Assembly overview – steering column switch module, electronic ignition lock 10578
8 2 Removing and installing lock cylinder 10579
8 3 Removing and installing ignition key withdrawal lock solenoid -N376- 10581
8 4 Removing and installing ignition/starter switch 10582
8 5 Removing and installing steering column switch module 10584
8 5 1 Removing and installing steering column switch module, Kostal 10584
8 5 2 Removing and installing steering column switch module, Valeo 10586
8 6 Removing and installing steering column electronics control unit -J527- 10590
8 6 1 Removing and installing steering column electronics control unit -J527-, Kostal 10590
8 6 2 Removing and installing steering column electronics control unit -J527-, Valeo 10593
8 7 Removing and installing turn signal switch -E2- 10596
8 7 1 Removing and installing turn signal switch -E2-, Kostal 10596
8 7 2 Removing and installing turn signal switch -E2-, Valeo 10597
8 8 Removing and installing cruise control system switch -E45- 10598
8 9 Removing and installing intermittent wiper switch -E22- 10598
8 10 Removing and installing immobiliser reader coil -D2- 10598
8 10 1 Removing and installing immobiliser reader coil -D2-, mechanical ignition lock 10598
8 10 2 Removing and installing immobiliser reader coil -D2-, electronic ignition lock 10598
8 11 Removing and installing base for steering column combination switch 10599
8 11 1 Removing and installing base for steering column combination switch, mechanical ignition lock 10599
8 11 2 Removing and installing base for steering column combination switch, electronic ignition lock 10599
8 12 Removing and installing steering lock housing 10599
96 – Lights, bulbs, switches – interior 10601
1 Lights 10601
1 1 Overview of fitting locations – lights in dash panel 10601
1 2 Overview of fitting locations – lights in front doors 10602
1 3 Overview of fitting locations – lights in centre console 10603
1 4 Overview of fitting locations – lights in luggage compartment 10604
1 4 1 Overview of fitting locations – lights in luggage compartment 10604
1 5 Overview of fitting locations – lights in roof trim 10605
1 5 1 Overview of fitting locations – lights in roof trim, without panorama roof 10605
1 5 2 Overview of fitting locations – lights in roof trim, with panorama roof 10606
1 6 Removing and installing front footwell light -K268-/-K269- 10607
1 6 1 Removing and installing front footwell light -K268-, driver side 10607
1 6 2 Removing and installing front footwell light -K269-, front passenger side 10608
1 7 Removing and installing light 1 for dash panel contour lighting -L243-/light 3 for dash panel contour lighting -L245- 10609
1 8 Removing and installing storage compartment illumination bulb -L120- 10609
1 9 Removing and installing Central locking SAFELOCK function warning lamp -K133- 10609
1 10 Removing and installing reflectors in door 10610
1 11 Removing and installing entry light -W92-/-W93- 10611
1 12 Removing and installing light 2 for driver door background lighting -W97-/light 2 for passenger door ambient lighting -W98- 10611
1 13 Removing and installing light for door ambient lighting -W86-/-W87- 10612
1 14 Removing and installing selector lever position display -Y26- 10612
1 15 Removing and installing luggage compartment light -W3- 10613
1 16 Removing and installing illuminated vanity mirror -W20-/-W14- 10614
1 17 Removing and installing bulb for illuminated vanity mirror -W20-/-W14- 10614
1 18 Removing and installing bulb for front interior light -W1- 10615
1 18 1 Removing and installing bulb for front interior light -W1- with incandescent bulbs 10615
1 18 2 Removing and installing light for front interior light -W1- with LED 10616
1 19 Removing and installing rear interior light/reading light 10617
1 19 1 Removing and installing rear interior light -WX2-, vehicles without panoramic sunroof 10617
1 19 2 Removing and installing rear interior light -W43-, vehicles with panoramic sunroof 10618
1 20 Removing and installing bulb for rear interior light -W43-, vehicles with panoramic sunroof 10620
1 20 1 Removing and installing bulb for rear interior light -W43- with incandescent bulbs 10620
1 20 2 Removing and installing light for rear interior light -W43- with LED 10621
1 21 Removing and installing bulb for rear reading light -W11-/-W12- 10621
1 22 Renewing bulb of rear interior light -W47-/-W48- 10621
2 Controls 10623
2 1 Overview of fitting locations – controls in dash panel 10623
2 2 Overview of fitting locations – controls in front doors 10624
2 3 Overview of fitting locations – controls in rear doors 10625
2 4 Overview of fitting locations – controls in centre console 10626
2 5 Overview of fitting locations – controls in luggage compartment 10627
2 6 Overview of fitting locations – controls in roof trim 10628
2 6 1 Overview of fitting locations – controls in roof trim, equipment version 1 10628
2 6 2 Overview of fitting locations – controls in roof trim, equipment version 2 10629
2 7 Removing and installing rotary light switch -EX1- 10630
2 8 Removing and installing TCS and ESP button -E256- 10631
2 9 Removing and installing parking aid button -E266- 10631
2 10 Removing and installing park assist steering button -E581- 10632
2 11 Removing and installing Start/Stop operation button -E693- 10632
2 12 Removing and installing driving mode selection button -E735- 10632
2 13 Removing and installing switch module in centre console -EX23-/-EX30- 10632
2 14 Removing and installing hazard warning light switch -EX3- 10634
2 15 Removing and installing buttons for seat heating -E653-/-E654- 10635
2 16 Removing and installing exterior mirror adjuster -EX11- 10635
2 17 Removing and installing operating unit for window regulator in driver door -E512- 10636
2 18 Removing and installing front passenger side window regulator button -E716- 10636
2 19 Removing and installing driver side interior locking button for central locking system -E308- 10637
2 20 Removing and installing rear lid remote release button -E233- 10638
2 21 Removing and installing door contact switch -F2-/-F3- 10638
2 22 Removing and installing rear window regulator button -E711-/-E713- 10639
2 23 Removing and installing rear door contact switches -F10-/-F11- 10639
2 24 Removing and installing electromechanical parking brake button -E538-/auto-hold button -E540- 10640
2 25 Removing and installing the starter button -E378- 10640
2 26 Removing and installing rear lid contact switch 10641
2 27 Removing and installing vanity mirror contact switch -F147-/-F148- 10641
2 28 Removing and installing sunroof button -E325- 10641
2 29 Removing and installing front interior light/reading light 10642
2 30 Removing and installing front reading light button -E633-/-E634- 10643
3 Anti-theft alarm system 10644
3 1 Assembly overview – interior monitor 10644
3 2 Removing and installing alarm horn/signal horn for anti-theft alarm system 10646
3 2 1 Removing and installing alarm horn -H12-, not including NAR 10646
3 2 2 Removing and installing anti-theft alarm system horn -H8-, only NAR 10647
3 3 Removing and installing anti-theft alarm sensor -G578- 10648
4 Front camera for driver assist systems 10650
4 1 Removing and installing front camera for driver assist systems 10650
5 Cigarette lighter, socket 10651
5 1 Removing and installing cigarette lighter -U1- 10651
5 2 Removing and installing socket illumination bulb -L42- 10651
5 3 Removing and installing rear cigarette lighter illumination bulb -L32- 10651
5 4 Removing and installing electric socket -U- 10651
97 – Wiring 10652
1 Relay carriers, fuse holders, electronics boxes 10652
1 1 Overview of fitting locations – relay carriers, fuse holders, electronics boxes 10652
1 1 1 Relay carriers, fuse carriers, electronics box (engine compartment) 10652
1 1 2 Relay carrier, fuse carrier in dash panel/A-pillar 10653
1 2 Removing and installing electronics box (E-box) 10654
1 3 Removing and installing relay and fuse holder in electronics box 10656
1 3 1 Removing and installing fuse holder B -SB- 10656
1 3 2 Removing and installing fuse holder A -SA- 10658
1 4 Removing and installing relay and fuse holder behind dash panel on driver side 10659
2 Select Control units 10660
2 1 Overview of fitting locations – control units 10660
2 2 Removing and installing onboard supply control unit -J519- 10660
2 3 Removing and installing data bus diagnostic interface -J533- 10662
2 4 Removing and installing bracket for onboard supply control unit -J519- 10663
3 Connectors 10665
3 1 Repairing electrical wiring harnesses and plug-in connections 10665
3 1 1 Repairs to wiring harnesses and connectors 10665
3 1 2 Repairing connector housings and electrical connectors 10665
4 Releasing and dismantling connector housings 10666
5 Repairing aerial wires 10667
6 Fibre optic cables 10668
7 Vehicle diagnosis, testing and information systems 10669
00 – Technical data 10678
1 Basic instructions 10678
1 1 Original joint 10678
1 2 Used joining techniques 10678
2 Vehicle identification data 10680
2 1 Vehicle identification number 10680
2 2 Type plate 10681
2 3 Vehicle data sticker 10682
3 Safety information 10684
4 Moulded foam inserts 10685
5 Galvanized body parts, high- and higher-strength and hot-formed body panels 10687
6 Laser welding 10690
7 Gaps/shut lines 10691
7 1 Body – front 10691
7 2 Body, centre 10693
7 3 Body, rear 10696
8 Body dimensions 10699
8 1 Body – front 10699
8 1 1 Body dimensions for front end 10699
8 1 2 Diagonals for windscreen aperture and vehicle front end 10700
8 2 Body, centre 10701
8 2 1 Body dimensions for door apertures 10701
8 2 2 Body dimensions between pillars 10702
8 3 Body, rear 10704
8 3 1 Body dimensions for rear window aperture 10704
8 3 2 Body dimension for rear lid aperture 10705
8 4 Body dimension for floor panel 10706
8 4 1 Floor panel, front 10706
8 4 2 Floor panel, centre 10707
8 4 3 Floor panel – rear, torsion beam axle 10708
8 4 4 Floor panel – rear, multi-link suspension 10709
9 Straightening bracket set 10711
10 Portal gauge 10712
50 – Body – front 10713
1 Overview of parts 10713
2 Renewing right bracket 10714
2 1 Tools 10715
2 2 Removing 10715
2 3 Installing 10716
2 3 1 Preparing new part 10716
2 3 2 Welding in 10718
3 Repairing threads for securing subframe 10720
3 1 Contents of thread repair kit 10721
3 2 Repairing threads 10722
3 2 1 Drilling threads 10722
3 2 2 Cutting thread 10723
3 2 3 Inserting thread insert 10724
4 Renewing mounting bracket for subframe 10726
4 1 Tools 10727
4 2 Removing 10727
4 3 Installing 10728
4 3 1 Preparing new part 10728
4 3 2 Welding in 10730
5 Renewing front longitudinal member cross panel 10732
5 1 Tools 10733
5 2 Removing 10733
5 3 Installing 10734
5 3 1 Preparing new part 10734
5 3 2 Welding in 10735
6 Renewing upper wheel housing longitudinal member 10737
6 1 Tools 10738
6 2 Removing 10738
6 3 Installing 10739
6 3 1 Preparing new part 10739
6 3 2 Welding in 10741
7 Renewing hinge reinforcement for bonnet 10744
7 1 Tools 10745
7 2 Removing 10745
7 3 Installing 10746
7 3 1 Preparing new part 10746
7 3 2 Welding in 10747
8 Renewing upper inner wheel housing longitudinal member 10749
8 1 Tools 10750
8 2 Removing 10750
8 3 Installing 10751
8 3 1 Preparing new part 10751
8 3 2 Welding in 10753
9 Renewing front wheel housing 10756
9 1 Tools 10757
9 2 Removing 10757
9 3 Installing 10758
9 3 1 Preparing new part 10758
9 3 2 Welding in 10760
10 Renewing front wheel housing (part section) 10763
10 1 Tools 10764
10 2 Removing 10764
10 3 Installing 10765
10 3 1 Preparing new part 10765
10 3 2 Welding in 10767
11 Renewing front longitudinal member 10769
11 1 Tools 10770
11 2 Removing 10770
11 3 Installing 10771
11 3 1 Preparing new part 10771
11 3 2 Welding in 10774
12 Renewing front longitudinal member (left part section) 10776
12 1 Tools 10777
12 2 Removing 10777
12 3 Installing 10779
12 3 1 Preparing new part 10779
12 3 2 Welding in 10781
13 Renewing front longitudinal member (right part section) 10783
13 1 Tools 10784
13 2 Removing 10784
13 3 Installing 10786
13 3 1 Preparing new part 10786
13 3 2 Welding in 10788
14 Renewing studs 10790
51 – Body – centre 10792
1 Overview of parts 10792
2 Renewing roof – vehicles without tilting sunroof 10793
2 1 Tools 10794
2 2 Removing 10794
2 3 Installing 10796
2 3 1 Preparing new part 10797
2 3 2 Adjusting roof depth 10799
2 3 3 Bonding roof 10800
2 3 4 Welding in 10805
3 Renewing roof – vehicles with tilting sunroof 10807
3 1 Tools 10808
3 2 Removing 10808
3 3 Installing 10810
3 3 1 Preparing new part 10811
3 3 2 Adjusting roof depth 10813
3 3 3 Bonding roof 10814
3 3 4 Welding in 10819
4 Renewing front cross member for roof 10822
4 1 Tools 10823
4 2 Removing 10823
4 3 Installing 10824
4 3 1 Preparing new part 10824
4 3 2 Welding in 10825
5 Renewing rear roof cross member 10828
5 1 Tools 10829
5 2 Removing 10829
5 3 Installing 10830
5 3 1 Preparing new part 10830
5 3 2 Welding in 10831
6 Renewing roof side member 10833
6 1 Tools 10834
6 2 Removing 10835
6 3 Installing 10836
6 3 1 Preparing new part 10836
6 3 2 Welding in 10838
7 Renewing A-pillar 10842
7 1 Tools 10843
7 2 Moulded foam inserts 10844
7 3 Removing 10844
7 4 Installing 10846
7 4 1 Preparing new part 10846
7 4 2 Welding in 10847
8 Renewing upper A-pillar reinforcement (part section) 10851
8 1 Tools 10852
8 2 Moulded foam inserts 10852
8 3 Removing 10852
8 4 Installing 10855
8 4 1 Preparing new parts 10855
8 4 2 Welding in 10859
9 Renewing A-pillar reinforcement 10863
9 1 Tools 10864
9 2 Moulded foam inserts 10864
9 3 Removing 10864
9 4 Installing 10865
9 4 1 Preparing new part 10866
9 4 2 Welding in 10867
10 Renewing B-pillar 10871
10 1 Tools 10873
10 2 Type plate 10873
10 3 Moulded foam inserts 10874
10 4 Removing 10874
10 5 Installing 10876
10 5 1 Preparing new part 10876
10 5 2 Welding in 10878
11 Renewing B-pillar reinforcement 10882
11 1 Tools 10883
11 2 Type plate 10883
11 3 Moulded foam inserts 10884
11 4 Removing 10884
11 5 Installing 10886
11 5 1 Preparing new part 10886
11 5 2 Welding in 10891
12 Renewing outer side member 10894
12 1 Tools 10895
12 2 Type plate 10895
12 3 Moulded foam inserts 10896
12 4 Removing 10896
12 5 Installing 10898
12 5 1 Preparing new part 10898
12 5 2 Welding in 10900
13 Renewing side member reinforcement 10904
13 1 Tools 10905
13 2 Moulded foam inserts 10905
13 3 Removing 10905
13 4 Installing 10907
13 4 1 Preparing new part 10907
13 4 2 Welding in 10909
14 Renewing inner mounting for seat inner cross member 10912
14 1 Tools 10913
14 2 Removing 10913
14 3 Installing 10914
14 3 1 Preparing new part 10914
14 3 2 Welding in 10915
15 Renewing seat cross member 10917
15 1 Tools 10918
15 2 Removing 10918
15 3 Installing 10919
15 3 1 Preparing new part 10919
15 3 2 Welding in 10920
16 Renewing outer mounting for seat outer cross member 10922
16 1 Tools 10923
16 2 Removing 10923
16 3 Installing 10925
16 3 1 Preparing new part 10925
16 3 2 Welding in 10926
17 Renewing tunnel reinforcement 10930
17 1 Tools 10931
17 2 Removing 10931
17 3 Installing 10933
17 3 1 Preparing new part 10933
17 3 2 Welding in 10934
53 – Body – rear 10937
1 Overview of parts 10937
2 Renewing rear cross panel 10938
2 1 Tools 10939
2 2 Removing 10939
2 3 Installing 10941
2 3 1 Preparing new part 10941
2 3 2 Welding in 10942
3 Renewing rear cross member 10945
3 1 Tools 10946
3 2 Removing 10946
3 3 Installing 10947
3 3 1 Preparing new part 10947
3 3 2 Welding in 10949
4 Renewing tail light mounting 10952
4 1 Tools 10953
4 2 Removing 10953
4 3 Installing 10954
4 3 1 Preparing new part 10954
4 3 2 Welding in 10955
5 Renewing luggage compartment floor 10957
5 1 Tools 10958
5 2 Moulded foam inserts 10958
5 3 Removing 10958
5 4 Installing 10959
5 4 1 Preparing new part 10960
5 4 2 Welding in 10962
6 Renewing floor panel 10965
6 1 Tools 10966
6 2 Removing 10966
6 3 Installing 10967
6 3 1 Preparing new part 10967
6 3 2 Welding in 10969
7 Renewing rear longitudinal member cross panel 10971
7 1 Tools 10972
7 2 Removing 10972
7 3 Installing 10973
7 3 1 Preparing new part 10973
7 3 2 Welding in 10974
8 Renewing rear longitudinal member (part section) 10976
8 1 Tools 10977
8 2 Removing 10977
8 3 Installing 10978
8 3 1 Preparing new part 10978
8 3 2 Welding in 10979
9 Renewing rear longitudinal member (part section – second part section of torsion beam axle) 10981
9 1 Tools 10982
9 2 Moulded foam inserts 10982
9 3 Removing 10982
9 4 Installing 10984
9 4 1 Preparing new part 10985
9 4 2 Welding in 10988
10 Renewing rear longitudinal member (part section – second part section of multi-link suspension) 10994
10 1 Tools 10995
10 2 Moulded foam inserts 10995
10 3 Removing 10995
10 4 Installing 10997
10 4 1 Preparing new part 10997
10 4 2 Welding in 11001
11 Permitted parting cuts on side panel 11008
12 Renewing side panel (part section) 11009
12 1 Tools 11010
12 2 Moulded foam inserts 11011
12 3 Removing 11011
12 4 Installing 11013
12 4 1 Preparing new part 11013
12 4 2 Welding in 11015
13 Renewing outer wheel housing liner 11019
13 1 Tools 11020
13 2 Moulded foam inserts 11020
13 3 Removing 11020
13 4 Installing 11022
13 4 1 Preparing new part 11022
13 4 2 Welding in 11024
14 Renewing C-pillar reinforcement 11028
14 1 Tools 11029
14 2 Removing 11029
14 3 Installing 11030
14 3 1 Preparing new part 11030
14 3 2 Welding in 11031
15 Renewing rear shock absorber mounting 11033
15 1 Tools 11034
15 2 Removing 11034
15 3 Installing 11035
15 3 1 Preparing new part 11035
15 3 2 Welding in 11036
16 Renewing lock reinforcement 11039
16 1 Tools 11040
16 2 Removing 11040
16 3 Installing 11042
16 3 1 Preparing new part 11042
16 3 2 Welding in 11043
00 – Technical data 11051
1 Safety information 11051
1 1 Safety precautions when working on air conditioning systems 11051
1 2 Safety precautions when handling refrigerants 11051
1 3 Safety measures when working on vehicles with start/stop system 11052
1 4 Safety precautions when working on cooling system 11052
1 5 Safety precautions for working on vehicles with auxiliary/supplementary heater 11052
1 6 Safety precautions when using testers and measuring instruments during a road test 11053
2 Identification 11055
2 1 Identification of heater and air conditioning unit 11055
2 1 1 Identification of heater and air conditioning unit made by Valeo 11055
2 1 2 Identification of Denso heater and air conditioning unit 11055
3 General information 11057
3 1 Notes concerning odours in air conditioned vehicles 11057
3 2 Notes for vehicles with start-stop system 11057
3 3 Type plates 11058
3 3 1 Type plates, refrigerant R1234yf 11058
3 3 2 Type plates, refrigerant R134a 11059
4 Repair notes 11060
4 1 Working on refrigerant circuit 11060
4 2 General repair instructions 11060
4 3 Refrigerant circuit seals 11061
4 4 Checking cooling output 11061
5 Technical data 11064
5 1 Refrigerant capacity 11064
5 2 Refrigerant oil capacities 11064
5 3 Oil distribution 11064
80 – Heating 11066
1 Heating system 11066
87 – Air conditioning system 11067
1 Overview of fitting locations – air conditioning system 11067
1 1 Overview of fitting locations – components not located in passenger compartment 11067
1 2 Overview of fitting locations – components located in front section of passenger compartment 11069
2 Refrigerant circuit 11072
2 1 System overview – refrigerant circuit 11072
2 2 Assembly overview – condenser 11074
2 3 Removing and installing refrigerant circuit pressure sender -G805- 11076
2 4 Removing and installing expansion valve 11078
2 5 Removing and installing condenser 11081
2 6 Removing and installing desiccant bag or cartridge 11084
2 6 1 Removing and installing desiccant bag or cartridge, Denso condenser 11084
2 6 2 Removing and installing desiccant bag or cartridge, Modine condenser 11088
2 6 3 Removing and installing desiccant bag or cartridge, Showa/Keihin condenser 11093
2 7 Removing and installing damper weight for refrigerant line, low-pressure side 11095
2 8 Removing and installing evacuating and charging valves on low and high-pressure side 11096
2 9 Removing and installing refrigerant line with internal heat exchanger 11098
2 10 Removing and installing refrigerant line from condenser to evaporator 11102
2 11 Removing and installing refrigerant line from air conditioner compressor to condenser 11105
2 12 Removing and installing refrigerant line from evaporator to air conditioner compressor 11108
2 13 Commissioning air conditioning system after filling refrigerant circuit 11111
3 Air conditioner compressor 11112
3 1 Assembly overview – air conditioner compressor 11112
3 1 1 Assembly overview – air conditioner compressor 11112
3 1 2 Assembly overview – air conditioner compressor, with air conditioning system magnetic clutch -N25- 11114
3 2 Assembly overview – pulley 11116
3 2 1 Assembly overview – pulley, Denso air conditioner compressor 11116
3 2 2 Assembly overview – belt pulley, Sanden air conditioner compressor 11117
3 2 3 Assembly overview – belt pulley, air conditioner compressor -VX81- with air conditioning system magnetic clutch -N25-, Denso 11119
3 2 4 Assembly overview – belt pulley, air conditioner compressor -VX81- with air conditioning system magnetic clutch -N25-, Sanden 11121
3 3 Removing air conditioner compressor from and installing on bracket 11123
3 4 Removing and installing air conditioner compressor 11125
3 5 Checking high-pressure safety valve on air conditioner compressor 11130
3 6 Removing and installing pulley 11131
3 6 1 Removing and installing belt pulley, Denso air conditioner compressor 11131
3 6 2 Removing and installing pulley, Sanden air conditioner condenser 11133
3 6 3 Removing and installing belt pulley, air conditioner compressor -VX81- with air conditioning system magnetic clutch -N25-, Denso 11133
3 6 4 Removing and installing belt pulley, air conditioner compressor -VX81- with air conditioning system magnetic clutch -N25-, Sanden 11137
4 Control motors 11140
4 1 Overview of fitting locations – control motors at front 11140
4 1 1 Overview of fitting locations – front control motors, air conditioning system with electric and manual controls 11140
4 1 2 Overview of fitting locations – front control motors, Climatronic 11141
4 2 Removing and installing temperature flap control motor -V68- 11142
4 3 Removing and installing defroster flap control motor -V107- 11144
4 4 Removing and installing air recirculation flap control motor -V113- 11146
4 5 Removing and installing left temperature flap control motor -V158- 11148
4 6 Removing and installing right temperature flap control motor -V159- 11150
4 7 Removing and installing fresh air/air recirculation, air flow flap control motor -V425- 11152
4 8 Removing and installing front air distribution flap control motor -V426- 11154
4 9 Removing and installing air distribution flap control motor -V428- 11156
4 10 Removing and installing air distribution flap adjustment unit 11158
4 10 1 Removing and installing front air distribution flap adjustment unit, electric/manual air conditioning system 11158
4 10 2 Removing and installing front air distribution flap adjustment unit, Climatronic 11160
5 Front heater and air conditioning unit 11162
5 1 Assembly overview – heater and air conditioning unit 11162
5 2 Assembly overview – add-on parts of heater and air conditioning unit and of air intake box 11167
5 3 Assembly overview – evaporator housing 11169
5 4 Assembly overview – flaps and partitions in air distribution housing 11170
5 5 Removing and installing evaporator 11173
5 6 Checking auxiliary air heater element -Z35- 11175
5 7 Removing and installing auxiliary air heater element -Z35- 11176
5 8 Removing and installing heater and air conditioning unit 11177
5 9 Removing and installing bracket for heater and air conditioning unit 11183
5 10 Dismantling and assembling heater and air conditioning unit 11185
5 11 Removing and installing air distribution housing 11187
5 12 Removing and installing dust and pollen filter 11187
5 13 Removing and installing fresh air blower -V2- 11190
5 14 Removing and installing fresh air blower control unit -J126- 11191
5 15 Removing and installing heat exchanger 11192
5 16 Removing and installing coolant pipes on heat exchanger 11198
5 17 Removing and installing evaporator temperature sensor -G308- 11199
5 18 Removing and installing condensation drain 11200
5 19 Checking condensation drain 11202
6 Air duct 11204
6 1 Assembly overview – air duct and air distribution in passenger compartment 11204
6 2 Removing and installing fresh air intake 11205
6 3 Removing and installing cover for fresh air intake 11207
6 4 Removing and installing intake duct 11207
6 5 Removing and installing driver side footwell vents 11208
6 6 Removing and installing front passenger side footwell vents 11209
6 7 Removing and installing rear footwell vent 11210
6 8 Checking forced ventilation for passenger compartment 11212
6 9 Removing and installing forced ventilation for passenger compartment 11212
6 10 Removing and installing air duct for defroster vent 11213
6 11 Removing and installing air duct for centre dash panel vent 11214
7 Operating and display unit 11215
7 1 Overview of fitting locations – operating and display unit 11215
7 1 1 Overview of fitting locations – operating and display unit, air conditioning system with electric/manual controls 11215
7 1 2 Overview of fitting locations – operating and display unit, Climatronic 11217
7 2 Removing and installing operating and display unit, front 11219
8 Other controlling and regulating components 11222
8 1 Removing and installing sunlight penetration photosensor -G107- 11222
8 2 Removing and installing air quality sensor -G238- 11223
8 3 Removing and installing ambient temperature sensor -G17- 11224
8 4 Removing and installing humidity sender for air conditioning system -G260- 11224
8 5 Removing and installing left vent temperature sender -G150- 11225
8 6 Removing and installing right vent temperature sender -G151- 11226
8 7 Removing and installing footwell vent temperature sender -G192- 11227
00 – Technical data 11237
1 Safety information 11237
1 1 Safety precautions when working on the fuel supply system 11237
1 2 Safety measures when working on vehicles with start/stop system 11237
1 3 Safety precautions when using testers and measuring instruments during a road test 11238
1 4 Safety precautions when working on the cooling system 11238
1 5 Safety precautions when working on the ignition system 11238
2 Identification 11239
2 1 Engine number/engine data 11239
3 Repair instructions 11242
3 1 Rules for cleanliness 11242
3 2 General information 11242
3 3 General repair instructions 11243
3 4 Foreign material in engine 11243
3 5 Contact corrosion 11243
3 6 Routing and attachment of lines 11243
3 7 Fitting radiators and condensers 11243
3 8 Bolts and nuts 11243
3 9 Identification labels 11244
3 10 Using impact drivers 11244
3 11 Checking vacuum system 11245
10 – Removing and installing engine 11246
1 Removing and installing engine 11246
1 1 Removing engine 11246
1 2 Separating engine and gearbox 11256
1 3 Securing engine on engine and gearbox support 11259
1 4 Installing engine 11261
2 Assembly mountings 11266
2 1 Assembly overview – assembly mountings 11266
2 2 Removing and installing engine mounting 11269
2 3 Removing and installing gearbox mounting 11270
2 4 Removing and installing pendulum support 11271
2 5 Supporting engine in installation position 11272
2 6 Adjusting assembly mountings 11277
2 7 Checking adjustment of assembly mountings 11279
3 Engine cover panel 11281
3 1 Removing and installing engine cover 11281
13 – Crankshaft group 11282
1 Cylinder block, pulley end 11282
1 1 Assembly overview – poly V-belt drive 11282
1 2 Assembly overview – sealing flange, pulley end 11284
1 3 Removing and installing poly-V belt 11286
1 4 Removing and installing poly V-belt tensioner 11288
1 5 Removing and installing vibration damper 11288
1 6 Removing and installing engine support 11292
1 7 Renewing crankshaft oil seal (pulley end) 11293
1 8 Removing and installing sealing flange, pulley end 11296
2 Cylinder block, gearbox end 11299
2 1 Assembly overview – cylinder block, gearbox end, flywheel 11299
2 2 Assembly overview – cylinder block, gearbox end, drive plate 11302
2 3 Removing and installing flywheel 11304
2 3 1 Removing and installing flywheel 11304
2 3 2 Preloading teeth in flywheel – vehicles with dual clutch gearbox 11306
2 4 Removing and installing drive plate 11306
2 5 Removing and installing sealing flange on gearbox side 11308
3 Crankshaft 11320
3 1 Renewing needle bearing in crankshaft 11320
3 2 Crankshaft dimensions 11322
3 3 Measuring axial clearance of crankshaft 11322
4 Pistons and conrods 11324
4 1 Assembly overview – pistons and conrods 11324
4 2 Removing and installing pistons 11328
4 3 Checking piston and cylinder bore 11329
4 4 Separating new conrod 11332
4 5 Checking radial clearance of conrods 11332
4 6 Removing and installing oil spray jets 11333
4 7 Setting piston to TDC position 11335
15 – Cylinder head, valve gear 11338
1 Cylinder head 11338
1 1 Assembly overview – cylinder head 11338
1 2 Assembly overview – camshaft housing 11340
1 3 Removing and installing cylinder head 11343
1 4 Removing and installing camshaft housing 11347
1 5 Checking compression 11353
2 Toothed belt drive 11356
2 1 Assembly overview – toothed belt cover 11356
2 2 Assembly overview – toothed belt 11357
2 3 Removing and installing toothed belt guard 11360
2 3 1 Removing and installing upper toothed belt guard 11360
2 3 2 Removing and installing lower toothed belt guard 11360
2 4 Removing and installing toothed belt 11361
2 5 Pre-assembling and fitting valve timing tool 11368
2 5 1 Preassembling valve timing tool 11368
2 5 2 Installing test tool -VAS 611 007- 11371
2 5 3 Teaching in test tool -VAS 611 007- electronically and performing basic setting 11374
2 6 Checking valve timing 11376
2 7 Adjusting valve timing 11379
2 8 Removing toothed belt from camshaft 11390
3 Valve gear 11394
3 1 Assembly overview – valve gear 11394
3 2 Removing and installing camshaft oil seal 11397
3 2 1 Removing and installing camshaft oil seal for holder of inlet camshaft control valve 1 -N727- 11397
3 2 2 Removing and installing camshaft oil seal for inlet camshaft, belt pulley end 11400
3 2 3 Removing and installing exhaust camshaft oil seal, pulley end 11404
3 2 4 Removing and installing exhaust camshaft oil seal, gearbox end 11406
3 3 Removing and installing camshaft adjuster 11409
3 3 1 Removing and installing camshaft adjuster, inlet side 11409
3 3 2 Removing and installing camshaft adjuster, exhaust side 11414
3 4 Removing and installing inlet camshaft control valve 1 -N727- 11419
3 5 Removing and installing exhaust camshaft control valve 1 -N318- 11420
3 6 Removing and installing valve stem oil seals 11421
3 6 1 Removing and installing valve stem seals (cylinder head installed) 11421
3 6 2 Removing and installing valve stem seals (cylinder head removed) 11428
3 7 Removing and installing retainer for oil seal 11435
4 Inlet and exhaust valves 11438
4 1 Checking valve guides 11438
4 2 Checking valves 11439
4 3 Valve dimensions 11439
17 – Lubrication 11440
1 Sump, oil pump 11440
1 1 Assembly overview – sump/oil pump 11440
1 2 Engine oil 11445
1 3 Removing and installing lower part of sump 11445
1 4 Removing and installing upper part of sump 11452
1 5 Removing and installing oil pump 11457
1 6 Removing and installing oil level and oil temperature sender -G266- 11459
2 Engine oil cooler 11461
2 1 Assembly overview – engine oil cooler 11461
2 2 Removing and installing engine oil cooler 11461
3 Crankcase breather 11463
3 1 Assembly overview – crankcase breather system 11463
3 2 Removing and installing oil separator 11465
3 2 1 Removing and installing control unit for active oil separation -J1240- 11465
3 2 2 Removing and installing oil separator (top) 11466
4 Oil filter, oil pressure switch 11468
4 1 Assembly overview – oil pressure switches/oil pressure control 11468
4 2 Removing and installing oil pressure sender -G10- 11468
4 3 Checking oil pressure and oil pressure switch 11470
4 4 Removing and installing oil filter housing 11470
4 5 Removing and installing valve for oil pressure control -N428- 11471
19 – Cooling 11472
1 Cooling system/coolant 11472
1 1 Connection diagram – coolant hoses 11472
1 2 Assembly overview – coolant expansion tank 11474
1 3 Checking cooling system for leaks 11475
1 4 Draining and filling cooling system 11479
1 5 Flushing cooling system 11487
1 6 Removing and installing coolant expansion tank 11502
2 Coolant pump, regulation of cooling system 11504
2 1 Assembly overview – coolant pump/thermostat 11504
2 2 Assembly overview – electric coolant pump 11506
2 3 Assembly overview – coolant temperature sender 11506
2 4 Removing and installing electric coolant pump 11507
2 5 Removing and installing coolant pump 11510
2 6 Removing and installing toothed belt pulley for coolant pump 11515
2 7 Removing and installing coolant temperature sender -G62- 11516
2 8 Removing and installing radiator outlet coolant temperature sender -G83- 11518
2 9 Removing and installing engine outlet coolant temperature sender -G82- 11520
2 10 Removing and installing engine temperature regulation module -GX33- 11522
2 11 Checking coolant pump 11526
3 Coolant pipes 11532
3 1 Assembly overview – coolant pipes 11532
3 2 Removing and installing coolant pipes 11534
3 2 1 Removing and installing left lower coolant pipe 11534
3 2 2 Removing and installing upper left coolant pipe 11536
3 2 3 Removing and installing upper front coolant pipe 11538
3 2 4 Removing and installing lower front coolant pipe 11540
4 Radiator, radiator fan 11543
4 1 Assembly overview – radiator, radiator fan 11543
4 2 Assembly overview – radiator cowl and radiator fans 11545
4 3 Removing and installing radiator 11546
4 4 Removing and installing water radiator for charge air cooling circuit 11549
4 5 Removing and installing radiator cowl 11553
4 6 Removing and installing radiator fan 11554
21 – Turbocharging/supercharging 11556
1 Turbocharger 11556
1 1 Assembly overview – turbocharger 11556
1 1 1 Assembly overview – turbocharger 11556
1 1 2 Assembly overview – lines on turbocharger 11558
1 2 Removing and installing turbocharger 11560
1 3 Removing and installing connection for turbocharger 11565
1 4 Removing and installing charge pressure control module -GX34- 11567
2 Charge air system 11569
2 1 Assembly overview – charge air system 11569
2 2 Removing and installing charge air cooler 11572
2 3 Removing and installing charge pressure sender -GX26- 11575
2 4 Checking charge air system for leaks 11576
2 5 Removing and installing air intake pipe 11579
2 5 1 Removing and installing air intake pipe between charge air cooler and turbocharger 11579
2 5 2 Removing and installing air intake pipe between charge air cooler and intake manifold 11582
2 6 Checking charge air cooler for leaks 11584
24 – Mixture preparation – injection 11590
1 Injection system 11590
1 1 Overview of fitting locations – injection system 11590
1 1 1 Overview of fitting locations – engine compartment 11590
1 1 2 Overview of fitting locations on engine (from above) 11593
1 1 3 Overview of fitting locations – engine, inlet side 11595
1 1 4 Overview of fitting locations – engine, exhaust side 11597
2 Vacuum system 11600
2 1 Assembly overview – vacuum system 11600
2 2 Checking vacuum system 11600
3 Air filter 11602
3 1 Assembly overview – air filter housing 11602
3 2 Removing and installing air filter housing 11604
3 3 Removing and installing air duct on lock carrier 11607
4 Intake manifold 11609
4 1 Assembly overview – intake manifold 11609
4 2 Removing and installing intake manifold 11612
4 3 Removing and installing throttle valve module -GX3- 11616
4 4 Cleaning throttle valve module -GX3- 11617
5 Injectors 11619
5 1 Assembly overview – fuel rail with injectors 11619
5 2 Removing and installing fuel rail 11621
5 3 Removing and installing injectors 11622
5 4 Cleaning injectors 11630
6 Senders and sensors 11632
6 1 Removing and installing intake manifold sender -GX9- 11632
6 2 Removing and installing fuel pressure sender -G247- 11633
6 3 Checking fuel pressure sender -G247- 11634
6 3 1 Checking fuel pressure sender -G247-, using pressure sensor tester -VAS 6394- and vehicle diagnostic tester 11634
6 3 2 Checking fuel pressure sender -G247-, using vehicle diagnostic tester 11636
6 4 Removing and installing exhaust gas pressure sensor 1 -G450- 11638
7 High-pressure pump 11640
7 1 Assembly overview – high-pressure pump 11640
7 2 Removing and installing high-pressure pump 11641
7 3 Removing and installing high-pressure pipe 11643
8 Lambda probe 11645
8 1 Assembly overview – lambda probe 11645
8 2 Removing and installing lambda probe 11646
8 2 1 Removing and installing Lambda probe 1 before catalytic converter -GX10- 11646
8 2 2 Removing and installing Lambda probe 1 after catalytic converter -GX7- 11647
9 Engine/motor control unit 11649
9 1 Assembly overview – motor control unit 11649
9 2 Removing and installing motor control unit -J623- 11649
26 – Exhaust system 11651
1 Exhaust pipes and silencers 11651
1 1 Assembly overview – silencers 11651
1 2 Assembly overview – front exhaust pipe 11654
1 2 1 Assembly overview – mounting for front exhaust pipe 11654
1 3 Removing and installing silencer 11655
1 4 Separating exhaust pipes from silencers 11657
1 5 Aligning exhaust system free of stress 11658
1 6 Checking exhaust system for leaks 11659
1 7 Installation position of clamp 11660
1 8 Removing and installing bracket for front exhaust pipe 11661
2 Emission control 11663
2 1 Assembly overview – emission control 11663
2 2 Removing and installing catalytic converter 11666
2 3 Removing and installing particulate filter 11670
3 Secondary air system 11671
3 1 Assembly overview – secondary air system 11671
3 2 Removing and installing secondary air pump motor -V101- 11673
3 3 Removing and installing secondary air inlet valve -N112- 11675
3 4 Removing and installing sender 1 for secondary air pressure -G609- 11676
28 – Ignition system 11677
1 Ignition system 11677
1 1 Assembly overview – ignition system 11677
1 2 Removing and installing ignition coils with output stage 11679
1 3 Removing and installing knock sensor 1 -G61- 11683
1 4 Removing and installing engine speed sender -G28- 11684
1 5 Removing and installing inlet camshaft position sender -G1002- 11685
1 6 Removing and installing exhaust camshaft position sender -G1003- 11686
00 – Technical data 11692
1 Explanation of symbols 11692
1 1 Sanding 11692
1 2 Seam sealing 11692
1 3 Cavity sealing 11695
2 Paintwork structure 11696
2 1 Structure of factory finish, surfacer 11696
2 2 Structure of factory finish, base coat 11696
2 3 Structure of factory finish, clear coat 11697
3 Areas exposed to stone chipping 11699
3 1 Areas of body exposed to stone chipping – general overview 11699
4 Masked sectors 11700
4 1 Masking areas, front of body 11700
4 2 Masking areas, rear of body 11701
5 Seam sealing 11703
5 1 Seam seals, front body 11703
5 2 Seam sealing: Front wheel housing 11705
5 3 Seam seals, A-pillar 11706
5 4 Seam seals, centre body 11708
5 5 Seam seals, roof 11709
5 6 Seam seals, rear wheel housing 11710
5 7 Seam seals, underbody 11711
5 8 Seam seals, rear cross panel 11713
6 Underseal 11716
6 1 Underseal, body – overview with differing layer thickness 11716
6 2 Underseal, front body 11717
6 3 Underseal, centre body 11717
6 4 Underseal, rear body 11719
7 Cavity sealing 11721
7 1 Cavity sealing, body – overview 11721
7 2 Cavity sealing, front body 11721
7 3 Cavity sealing, rear body 11722
7 4 Cavity sealing, doors 11723
00 – Technical data 11735
1 Safety information 11735
1 1 Safety precautions for working on vehicles with start-stop system 11735
1 2 Safety precautions when using testers and measuring instruments during a road test 11735
1 3 Safety precautions when working on the cooling system 11735
2 Repair notes 11736
2 1 Routing and attachment of lines 11736
2 2 Contact corrosion 11736
2 3 Bonding surfaces for self-adhesive components 11736
2 4 Secured threaded connections 11736
50 – Body – front 11737
1 Lock carrier 11737
1 1 Assembly overview – lock carrier 11737
1 2 Removing and installing lock carrier 11737
1 3 Moving to and back from service position 11740
2 Wings 11745
2 1 Assembly overview – wing 11745
2 2 Removing and installing wing 11745
3 Bulkhead 11748
3 1 Assembly overview – bulkhead 11748
3 2 Assembly overview – plenum chamber cover 11748
3 3 Removing and installing bulkhead 11749
3 4 Removing and installing plenum chamber cover 11750
55 – Bonnet, rear lid 11752
1 Bonnet 11752
1 1 Assembly overview – bonnet 11752
1 2 Assembly overview – Bowden cable 11753
1 3 Removing and installing bonnet 11755
1 4 Adjusting bonnet 11755
1 5 Removing and installing bonnet lock 11760
1 6 Removing and installing bonnet lock release lever 11763
1 7 Removing and installing striker pin 11764
1 8 Removing and installing hinges 11764
1 9 Removing and installing insulation 11765
1 10 Removing and installing Bowden cable 11767
1 11 Removing and installing bonnet stay 11769
2 Rear lid 11770
2 1 Assembly overview – rear lid 11770
2 2 Removing and installing rear lid 11772
2 3 Adjusting rear lid 11772
2 4 Removing and installing bonnet lock 11775
2 5 Removing and installing operating mechanism 11776
2 6 Removing and installing hinges 11777
2 7 Removing and installing striker pin 11777
2 8 Removing and installing rear lid seal 11779
3 Tank flap unit 11780
3 1 Assembly overview – tank flap unit 11780
3 2 Removing and installing tank flap unit 11781
3 3 Removing and installing fuel tank flap 11782
3 4 Removing and installing sealing collar 11782
57 – Front doors, door components, central locking 11784
1 Door 11784
1 1 Assembly overview – door 11784
1 2 Removing and installing inner door seal 11786
1 3 Removing and installing outer door seal 11788
1 4 Removing and installing door 11791
1 5 Adjusting door 11793
1 6 Adjusting striker pin 11796
1 7 Removing and installing door arrester 11797
2 Door components 11799
2 1 Assembly overview – door components 11799
2 2 Assembly overview – window regulator 11800
2 3 Assembly overview – door handle and door lock 11801
2 4 Removing and installing window regulator motor 11802
2 5 Removing and installing window regulator 11804
2 6 Removing and installing inner door cover 11806
2 7 Removing and installing striker pin 11808
2 8 Removing and installing door handle 11809
2 8 1 Removing and installing door handle 11809
2 8 2 Removing and installing door handle with keyless entry system 11810
2 9 Removing and installing mounting bracket 11812
2 10 Removing and installing door lock 11815
2 11 Removing and installing window channel 11819
2 12 Removing and installing window slot inner seal 11821
2 13 Removing and installing outer window slot seal 11822
2 14 Removing and installing lock cylinder 11823
2 15 Removing and installing cap on door handle 11825
2 15 1 Removing and installing cap with lock cylinder 11825
2 15 2 Removing and installing cap for door handle, without lock cylinder 11827
3 Central locking 11832
3 1 Overview of fitting locations – central locking system 11832
3 2 Removing and installing driver door control unit -J386- and front passenger door control unit -J387- 11834
3 3 Removing and installing rear left door control unit -J388- and rear right door control unit -J389- 11836
3 4 Removing and installing bonnet contact switch -F266- 11837
3 5 Removing and installing tank filler flap locking motor -V155- 11838
3 6 Removing and installing ignition key battery 11840
58 – Rear doors, door components 11841
1 Door 11841
1 1 Assembly overview – door 11841
1 2 Removing and installing door 11843
1 3 Adjusting door 11846
1 4 Adjusting striker pin 11849
1 5 Removing and installing door arrester 11850
1 6 Removing and installing outer door seal 11851
1 7 Removing and installing inner door seal 11853
2 Door components 11855
2 1 Assembly overview – door components 11855
2 2 Assembly overview – window regulator 11856
2 3 Assembly overview – door handle and door lock 11857
2 4 Removing and installing window regulator motor 11858
2 5 Removing and installing window regulator 11861
2 6 Removing and installing inner door cover 11862
2 7 Removing and installing striker pin 11863
2 8 Removing and installing door handle 11864
2 9 Removing and installing mounting bracket 11866
2 10 Removing and installing door lock 11867
2 11 Removing and installing window channel 11871
2 12 Removing and installing outer window slot seal 11873
2 13 Removing and installing window slot inner seal 11874
2 14 Removing and installing cap on door handle 11874
60 – Sunroof 11879
1 Repair notes 11879
1 1 Minimum drying time for adhesives 11879
1 2 Tools and materials required for removal and installation 11879
1 2 1 Tools required for removal and installation 11879
1 2 2 Materials required for removal and installation 11881
1 3 Preparing new sliding sunroof frame for installation 11882
1 4 Preparing body flange for installing 11884
1 5 Cleaning off excess adhesive 11885
2 Sliding sunroof 11886
2 1 Assembly overview – sliding sunroof 11886
2 2 Assembly overview – sunroof roller blind 11888
2 3 Assembly overview – wind deflector 11888
2 4 Assembly overview – adhesive beads on sliding sunroof 11889
2 4 1 Assembly overview – adhesive beads on sliding sunroof frame 11889
2 4 2 Assembly overview – adhesive bead on front trim for sliding sunroof 11890
2 5 Removing and installing sliding sunroof frame 11891
2 6 Removing and installing wind deflector 11895
2 7 Removing and installing glass panel 11896
2 8 Removing and installing front trim for sliding sunroof 11897
2 9 Removing and installing sliding sunroof adjustment control unit -J245- 11901
2 10 Removing and installing sliding sunroof seals 11901
2 10 1 Removing and installing inner seal for sliding sunroof frame 11901
2 10 2 Removing and installing outer seal for sliding sunroof frame 11902
2 10 3 Removing and installing front trim seal 11904
2 11 Removing and installing sunroof roller blind 11904
2 12 Removing and installing side trim 11911
2 13 Removing and installing sunroof motor -V1- 11911
2 14 Removing and installing tilt mechanism for sliding sunroof 11912
2 14 1 Removing and installing guide 11912
2 14 2 Removing and installing tilt mechanism 11913
2 14 3 Removing and installing guide rail for tilt mechanism 11915
2 15 Manual operation 11916
63 – Bumpers 11917
1 Bumper, front 11917
1 1 Assembly overview – bumper cover 11917
1 1 1 Assembly overview – bumper cover, standard 11917
1 1 2 Assembly overview – bumper cover, GLI 11918
1 2 Assembly overview – bumper carrier 11920
1 3 Removing and installing bumper cover 11920
1 4 Repairing bumper cover 11922
1 5 Installing holder for parking aid sender 11922
1 6 Installing retainer for parking aid sender 11927
2 Bumper, rear 11932
2 1 Assembly overview – bumper cover 11932
2 1 1 Assembly overview – bumper cover 11932
2 1 2 Assembly overview – bumper cover, GLI 11934
2 2 Assembly overview – bumper carrier 11936
2 3 Removing and installing bumper cover 11936
2 4 Removing and installing attachments 11938
2 4 1 Removing and installing guide under tail light 11938
2 4 2 Removing and installing guide profile on side panel 11939
2 4 3 Removing and installing centre guide 11939
2 4 4 Removing and installing spoiler 11940
2 4 5 Removing and installing reflector 11940
2 5 Repairing bumper cover 11941
2 6 Removing and installing bumper carrier 11941
2 7 Installing holder for parking aid sender 11941
2 8 Installing retainer for parking aid sender 11946
64 – Glazing 11951
1 Repair notes 11951
1 1 Minimum drying times for bonded windows 11951
1 2 Window repair 11951
1 3 Installation instructions for bonded windows 11952
1 4 Tools and materials required for removal and installation 11953
1 4 1 Tools required for removal and installation 11953
1 4 2 Materials required for removal and installation 11956
1 5 Preparing old undamaged windows for installing 11957
1 6 Preparing new windows for installing 11958
1 7 Preparing body flange for installing 11958
1 8 Cleaning off excess adhesive 11959
2 Windscreen 11961
2 1 Assembly overview – windscreen 11961
2 2 Removing and installing windscreen 11961
3 Rear windscreen 11965
3 1 Assembly overview – rear window 11965
3 2 Removing and installing rear window 11966
3 2 1 Removing and installing rear window 11966
3 2 2 Removing broken rear window 11968
4 Side window 11970
4 1 Assembly overview – rear side windows 11970
4 2 Removing and installing rear side window 11971
4 2 1 Removing and installing rear side window 11971
4 2 2 Removing broken rear side window 11973
5 Door windows 11974
5 1 Assembly overview – front door window 11974
5 2 Assembly overview – rear door window 11974
5 3 Removing and installing front door window 11975
5 4 Removing and installing rear door window 11977
66 – Exterior equipment 11980
1 Radiator grille and front trim 11980
1 1 Assembly overview – radiator grille 11980
1 2 Removing and installing radiator grille 11981
1 3 Removing and installing trim strip 11981
2 Spoiler 11983
2 1 Assembly overview – spoiler 11983
2 2 Removing and installing spoiler 11983
3 Mouldings, trims, extensions 11987
3 1 Assembly overview – side member trim 11987
3 2 Assembly overview – water deflector 11987
3 3 Assembly overview – B-pillar trim 11988
3 4 Assembly overview – C-pillar trim 11989
3 5 Removing and installing side member trim 11990
3 6 Removing and installing water deflector 11996
3 7 Removing and installing B-pillar trim on door 11997
3 7 1 Removing and installing B-pillar trim on front door 11997
3 7 2 Removing and installing B-pillar trim on rear door 11998
3 8 Removing and installing C-pillar trim on door 12000
4 Noise insulation 12002
4 1 Assembly overview – noise insulation 12002
4 1 1 Assembly overview – short noise insulation 12002
4 1 2 Assembly overview – long noise insulation 12002
4 2 Assembly overview – skid plate 12003
5 Underbody cladding 12005
5 1 Overview of fitting locations – underbody cladding 12005
5 2 Assembly overview – bracing on underbody 12005
5 3 Removing and installing tunnel cross-piece 12006
5 3 1 Removing and installing front tunnel cross-piece 12006
5 3 2 Removing and installing rear tunnel cross-piece 12007
6 Decorative film / protective film 12009
6 1 Renewing protective films 12009
7 Exterior mirror 12010
7 1 Assembly overview – exterior mirror 12010
7 2 Removing and installing exterior mirror 12011
7 3 Removing and installing mirror glass 12012
7 4 Removing and installing mirror adjustment unit 12013
7 5 Removing and installing mirror cover 12015
7 6 Removing and installing mirror frame 12015
8 Wheel housing liner 12017
8 1 Assembly overview – front wheel housing liner 12017
8 2 Assembly overview – rear wheel housing liner 12017
8 3 Assembly overview – sill panel cover 12018
8 4 Removing and installing front wheel housing liner 12019
8 5 Removing and installing rear wheel housing liner 12020
8 6 Removing and installing side member cover 12021
9 Lettering and badges 12023
9 1 Dimensions – lettering and badges on rear 12023
9 2 Dimensions – lettering and badges on sides 12024
9 2 1 Dimensions – lettering on wing 12024
9 2 2 Dimensions – badge on B-pillar, “Wolfsburg Edition” 12025
9 3 Removing and installing bonded lettering 12025
9 4 Removing and installing badges at front 12026
9 5 Renewing lettering and badges at rear 12027
9 6 Renewing lettering and badges on sides 12028
9 6 1 Fitting instructions 12028
9 6 2 Renewing lettering on wing 12028
9 6 3 Renewing badge on B-pillar 12029
9 7 Removing and installing lettering and badges for radiator grille 12030
10 Heat shields 12031
10 1 Overview of fitting locations – heat shields 12031
10 2 Removing and installing tunnel heat shield 12031
10 3 Removing and installing fuel tank heat shield 12032
10 4 Removing and installing rear underbody heat shield 12033
10 5 Removing and installing rear silencer heat shield 12034
00 – Technical data 12040
1 Repair notes 12040
1 1 General repair instructions 12040
1 2 Routing and attachment of lines 12040
1 3 Notes on repair of CAN bus wiring 12040
1 4 General information 12040
91 – Communication 12042
1 Infotainment system 12042
1 1 Overview of infotainment system 12042
1 1 1 Components of Infotainment system, Composition Colour version 12042
1 1 2 Components of Infotainment system, Composition Media and Discover Media versions 12043
1 1 3 Layout – infotainment system, Discover Pro version 12044
1 2 Overview of fitting locations – Infotainment system 12044
1 3 Removing and installing infotainment system display 12046
1 4 Removing and installing control unit 1 for information electronics -J794- 12047
1 5 Renewing rotary knobs of display unit for front information display and operating unit control unit -J685- 12048
2 Sound system 12050
2 1 Components of sound system 12050
2 2 Overview of fitting locations – sound system 12051
2 3 Removing and installing digital sound package control unit -J525- 12052
2 4 Removing and installing front treble loudspeakers -R20-/-R22- 12055
2 5 Removing and installing rear treble loudspeakers -R14-/-R16- 12055
2 5 1 Removing and installing rear treble loudspeakers -R14-/-R16- 12055
2 6 Removing and installing front loudspeaker -R2-/-R3- 12057
2 7 Removing and installing front bass loudspeakers -R21-/-R23- 12058
2 8 Removing and installing rear bass loudspeakers -R15-/-R17- 12060
2 8 1 Removing and installing rear bass loudspeakers -R15-/-R17- 12060
2 9 Removing and installing subwoofer -R211- 12062
3 Aerial systems 12064
3 1 Components of aerial systems 12064
3 2 Overview of fitting locations – aerial systems 12064
3 3 Removing and installing aerial module 12065
3 4 Removing and installing frequency modulation (FM) frequency filter in negative wire -R178- 12067
3 5 Removing and installing frequency modulation (FM) frequency filter in positive wire -R179- 12068
3 6 Removing and installing roof aerial 12069
3 7 Removing and installing LTE aerial 2 -R306- 12070
4 Removing and installing radio 12072
4 1 Removing and installing radio, Composition Colour 12072
4 2 Removing and installing radio, Composition Media and Discover Pro 12073
5 Telephone system 12074
5 1 Preparation for mobile telephone 12074
5 1 1 Mobile telephone preparation, Bluetooth hands-free system 12074
5 1 2 Preparation for mobile telephone, on-line Bluetooth hands-free system 12074
5 2 Overview of fitting locations – telephone system 12075
5 3 Removing and installing telephone microphone -R38- 12076
5 4 Removing and installing storage compartment with interface for mobile telephone -R265- 12077
6 Navigation system 12079
6 1 Overview of navigation system 12079
6 2 Overview of fitting locations – navigation system 12079
6 3 Removing and installing control unit for navigation system 12080
7 Multifunction steering wheel 12081
7 1 Overview of multifunction steering wheel 12081
7 2 Assembly overview – multifunction steering wheel 12081
7 3 Removing and installing multifunction buttons in steering wheel -E441-/-E440- 12082
7 4 Removing and installing Tiptronic switch in steering wheel -E439-/-E438- 12086
8 Connection for external multimedia devices 12088
8 1 Removing and installing connection for external multimedia devices, USB connection 1 -U41- in centre console storage compartment at front 12088
8 2 Removing and installing USB charging socket 1 -U37- 12089
9 Online services 12091
9 1 General description – Car-Net services 12091
9 2 Overview of fitting locations – mobile online services 12091
9 3 Removing and installing emergency call module control unit and communication unit -J949- 12093
9 4 Removing and installing operating unit for preparation for mobile telephone -E508- 12093
9 5 Removing and installing loudspeaker for emergency call module -R335- 12094
9 6 Removing and installing battery for control unit for emergency call module 12095
00 – Technical data 12101
1 Safety information 12101
1 1 Safety measures when working on vehicles with start/stop system 12101
1 2 Safety precautions when using testers and measuring instruments during a road test 12101
2 Repair instructions 12102
2 1 Rules for cleanliness 12102
2 2 General information 12102
2 3 Contact corrosion 12102
2 4 Routing and attachment of lines 12102
98 – Assist systems 12104
1 Fitting locations 12104
1 1 Overview of fitting locations – senders, sensors and control units in front section of vehicle 12104
1 2 Overview of fitting locations – senders, sensors and control units in centre section of vehicle 12105
1 3 Overview of fitting locations – senders, sensors and control units in rear section of vehicle 12105
2 Senders/sensors/control units 12107
2 1 Removing and installing adaptive cruise control unit -J428- 12107
2 2 Removing and installing parking aid control unit -J446- 12108
2 3 Removing and installing front parking aid warning buzzer -H22- 12109
2 4 Removing and installing rear parking aid warning buzzer -H15- 12110
2 5 Removing and installing front parking aid senders -G252-/-G253-/-G254-/-G255- 12110
2 6 Removing and installing rear parking aid senders -G203-/-G204-/-G205-/-G206- 12111
2 7 Removing and installing Blind Spot Monitor control unit -J1086-/-J1087- without GLI equipment 12112
2 8 Removing and installing Blind Spot Monitor control unit -J1086-/-J1087- with GLI equipment 12113
2 9 Removing and installing Blind Spot Monitor warning lamp in exterior mirror -K303-/-K304- 12115
2 10 Removing and installing front camera for driver assist systems -R242- 12115
2 11 Removing and installing reversing camera -R189- 12116
3 Adaptive cruise control 12117
3 1 Components of adaptive cruise control 12117
3 2 Assembly overview – Automatic adaptive cruise control 12117
3 3 Adjusting/calibrating adaptive cruise control unit 12118
3 3 1 Calibrating adaptive cruise control – static calibration 12118
3 3 2 Calibrating adaptive cruise control – dynamic calibration 12122
4 Parking aid / park assist steering / autonomous parking system 12124
4 1 Components of parking aid / park assist steering / autonomous parking system 12124
5 Blind Spot Monitor 12125
5 1 Assembly overview – Blind Spot Monitor 12125
6 Front camera for driver assist systems 12126
6 1 Components of front camera for assist systems 12126
6 2 Calibrating front camera for assist systems 12126
7 Reversing camera system 12135
7 1 Overview of reversing camera system 12135
00 – Technical data 12142
1 Safety information 12142
1 1 Safety measures when working on vehicles with a start/stop system 12142
1 2 Safety precautions when using testers and measuring instruments during a road test 12142
2 Repair notes 12143
2 1 Contact corrosion 12143
2 2 Routing and attachment of lines 12143
3 Battery 12144
3 1 Battery – general notes 12144
3 2 Types of battery 12144
27 – Starter, current supply, CCS 12145
1 Battery 12145
1 1 Assembly overview – battery 12145
1 2 Removing and installing battery 12147
1 3 Disconnecting and connecting battery 12150
1 4 Removing and installing battery tray 12152
1 5 Checking battery 12153
1 6 Charging battery 12153
1 7 Removing and installing earth wire with battery monitor control unit -J367- 12153
1 8 Adapting battery monitor control unit -J367- 12154
2 Alternator 12155
2 1 Assembly overview – alternator 12155
2 1 1 Assembly overview – alternator without sliding bushes 12155
2 1 2 Assembly overview – alternator with sliding bushes 12155
2 2 Removing and installing alternator 12156
2 2 1 Removing and installing alternator, 1 4 l TSI engine 12156
2 2 2 Removing and installing alternator, vehicles with 1 5 l TSI engine 12158
2 2 3 Removing and installing alternator, vehicles with 1 6 l MPI engine 12160
2 2 4 Removing and installing alternator, vehicles with 2 0 l TSI engine 12161
2 3 Checking alternator 12164
2 4 Removing and installing poly V-belt pulley 12164
2 4 1 Removing and installing poly V-belt pulley without freewheel 12164
2 4 2 Removing and installing poly V-belt pulley with freewheel, manufacturer Bosch 12166
2 4 3 Removing and installing poly V-belt pulley with freewheel, manufacturer Valeo 12168
2 4 4 Removing and installing decoupler pulley with freewheel 12170
2 5 Removing and installing voltage regulator 12174
2 5 1 Removing and installing voltage regulator, manufacturer Bosch 12174
2 5 2 Removing and installing voltage regulator, manufacturer Valeo 12175
3 Starter 12178
3 1 Assembly overview – starter 12178
3 1 1 Assembly overview – starter, vehicles with manual gearbox 12178
3 1 2 Assembly overview – starter, vehicles with 7-speed dual clutch gearbox, 0GC 12178
3 1 3 Assembly overview – starter, vehicles with 6-speed automatic gearbox 12179
3 1 4 Assembly overview – starter, vehicles with 8-speed automatic gearbox 12180
3 2 Removing and installing starter 12181
3 2 1 Removing and installing starter, vehicle with manual gearbox 12181
3 2 2 Removing and installing starter, vehicles with 7-speed dual clutch gearbox, 0CG 12183
3 2 3 Removing and installing starter, vehicles with 6-speed automatic gearbox 12185
3 2 4 Removing and installing starter, vehicles with 8-speed automatic gearbox 12188
4 Cruise control system (CCS) 12190
5 Start/stop system 12191
5 1 General description – start/stop system 12191
5 2 Overview of fitting locations – start/stop system 12191
90 – Gauges, instruments 12192
1 Dash panel insert 12192
1 1 Assembly overview – dash panel insert 12192
1 2 Removing and installing dash panel insert -KX2- 12192
1 2 1 Removing and installing dash panel insert -KX2-, equipment version 1 12192
1 2 2 Removing and installing dash panel insert -KX2-, equipment version 2 12194
2 Horn 12197
2 1 Assembly overview – horn (8Y1) 12197
2 2 Removing and installing treble horn -H2- and bass horn -H7- 12197
92 – Windscreen wash/wipe system 12199
1 Windscreen wiper system 12199
1 1 Assembly overview – windscreen wiper system 12199
1 2 Moving wipers to service position 12201
1 3 Removing and installing wiper blade 12201
1 4 Removing and installing wiper arms 12202
1 5 Adjusting wiper arms 12204
1 6 Removing and installing wiper motor -V- 12205
1 7 Removing and installing rain and light sensor 12207
1 8 Repairing rain and light sensor 12209
1 8 1 Repairing rain and light sensor, TRW 12209
1 8 2 Repairing rain and light sensor, Valeo 12210
2 Windscreen washer system 12213
2 1 Assembly overview – windscreen washer system 12213
2 1 1 Assembly overview – windscreen washer system 12213
2 2 Removing and installing washer fluid reservoir 12214
2 3 Removing and installing windscreen washer fluid level sender 12216
2 4 Removing and installing windscreen washer pump 12217
2 5 Removing and installing spray jets 12218
2 6 Adjusting spray jets 12219
3 Washer fluid lines 12220
3 1 Repairing washer fluid lines 12220
94 – Lights, bulbs, switches – exterior 12221
1 Headlights 12221
1 1 Assembly overview – headlight 12221
1 1 1 Assembly overview – headlight, LED headlight 12221
1 2 Assembly overview – daytime running lights 12222
1 2 1 Assembly overview – daytime running lights, LED headlight 12222
1 3 Removing and installing headlight 12223
1 4 Adjusting headlights 12228
1 5 Adjusting headlight installation position 12228
1 6 Removing and installing front turn signal bulb -M5-/-M7- 12229
1 6 1 Removing and installing front turn signal bulb -M5-/-M7- (equipment version 1) 12229
1 6 2 Removing and installing front turn signal bulb -M5-/-M7- (equipment version 2) 12230
1 7 Removing and installing headlight range control motor -V48-/-V49- 12231
1 8 Removing and installing headlight dipped beam bulb 12231
1 9 Removing and installing headlight main beam bulb -M30-/-M32- 12231
1 10 Removing and installing side light bulb -M1-/-M3- 12231
1 11 Removing and installing LED modules for daytime running light and side light -L176-/-L177- 12231
1 12 Removing and installing output module for headlight -J667-/-J668- 12232
1 13 Removing and installing output module 1 for LED headlight -A31-/-A27- 12232
1 14 Removing and installing daytime running lights 12232
1 14 1 Removing and installing daytime running light, LED headlight 12232
2 Lights in exterior mirror 12234
2 1 Assembly overview – lights in exterior mirror 12234
2 2 Removing and installing turn signal 12235
3 Tail light cluster 12238
3 1 Assembly overview – tail light cluster in body 12238
3 1 1 Assembly overview – tail light cluster in body 12238
3 2 Assembly overview – tail light clusters in rear lid 12239
3 2 1 Assembly overview – tail light clusters in rear lid 12239
3 3 Removing and installing tail light in rear lid 12241
3 3 1 Removing and installing tail light in rear lid 12241
3 4 Adjusting installation position of tail light 12242
3 4 1 Adjusting installation position of tail light 12242
3 5 Removing and installing tail light cluster 12243
3 5 1 Removing and installing tail light cluster 12243
3 6 Removing and installing tail light bulb -M2-/-M4- 12244
3 7 Removing and installing rear fog light bulb -L46-/-L47- 12244
3 8 Removing and installing brake and tail light bulb -M21-/-M22- 12244
3 9 Removing and installing reversing light bulb 12244
3 10 Removing and installing turn signal bulb 12244
4 High-level brake light 12246
4 1 Assembly overview – high-level brake light 12246
4 2 Removing and installing high-level brake light 12246
4 3 Removing and installing high-level brake light 12247
5 Number plate light 12248
5 1 Removing and installing number plate light -X4-/-X5- 12248
5 1 1 Removing and installing number plate light -X4-/-X5- 12248
5 2 Removing and installing bulb for number plate light -X4-/-X5- 12249
6 Entry and start authorisation system 12250
6 1 Overview of fitting locations – entry and start authorisation system 12250
6 1 1 Overview of fitting locations – entry and start authorisation system, NAR and Mexico (equipment version 1) 12250
6 1 2 Overview of fitting locations – entry and start authorisation system, equipment version 2 12251
6 2 Overview of fitting locations – keyless entry system 12252
6 2 1 Overview of fitting locations – front keyless entry system, NAR and Mexico (equipment version 1) 12252
6 2 2 Overview overview of fitting locations – front keyless entry system (equipment version 2) 12253
6 2 3 Overview of fitting locations – rear keyless entry system 12254
6 3 Removing and installing interface for entry and start system -J965- 12255
6 3 1 Removing and installing entry and start authorisation control unit -J965-, equipment version 2 12255
6 3 2 Removing and installing entry and start authorisation control unit -J965-, NAR and Mexico (equipment version 1) 12257
6 4 Removing and installing door exterior handle contact sensor -G415-/-G416- 12258
6 5 Removing and installing driver side aerial for entry and start system -R134- 12258
6 6 Removing and installing front passenger side aerial for entry and start system -R135- 12258
6 7 Removing and installing rear bumper aerial for entry and start system -R136- 12258
6 8 Removing and installing interior aerial 1 for entry and start system -R138- 12259
6 9 Removing and installing interior aerial 2 for entry and start system -R139- 12259
7 Steering column switch module 12261
7 1 Assembly overview – steering column switch module 12261
7 1 1 Assembly overview – steering column switch module, mechanical ignition lock 12261
7 1 2 Assembly overview – steering column switch module, electronic ignition lock 12262
7 2 Removing and installing lock cylinder 12263
7 3 Removing and installing ignition key withdrawal lock solenoid -N376- 12265
7 4 Removing and installing ignition/starter switch 12266
7 5 Removing and installing steering column switch module 12268
7 5 1 Removing and installing steering column switch module, Kostal 12268
7 5 2 Removing and installing steering column switch module, Valeo 12270
7 6 Removing and installing steering column electronics control unit -J527- 12274
7 6 1 Removing and installing steering column electronics control unit -J527-, Kostal 12274
7 6 2 Removing and installing steering column electronics control unit -J527-, Valeo 12277
7 7 Removing and installing turn signal switch -E2- 12280
7 7 1 Removing and installing turn signal switch -E2-, Kostal 12280
7 7 2 Removing and installing turn signal switch -E2-, Valeo 12281
7 8 Removing and installing cruise control system switch -E45- 12282
7 9 Removing and installing intermittent wiper switch -E22- 12282
7 10 Removing and installing immobiliser reader coil -D2- 12282
7 10 1 Removing and installing immobiliser reader coil -D2-, mechanical ignition lock 12282
7 10 2 Removing and installing immobiliser reader coil -D2-, electronic ignition lock 12282
7 11 Removing and installing base for steering column combination switch 12283
7 11 1 Removing and installing base for steering column combination switch, mechanical ignition lock 12283
7 11 2 Removing and installing base for steering column combination switch, electronic ignition lock 12283
7 12 Removing and installing steering lock housing 12283
96 – Lights, bulbs, switches – interior 12285
1 Lights 12285
1 1 Overview of fitting locations – lights in dash panel 12285
1 2 Overview of fitting locations – lights in front doors 12286
1 3 Overview of fitting locations – lights in centre console 12287
1 4 Overview of fitting locations – lights in luggage compartment 12288
1 4 1 Overview of fitting locations – lights in luggage compartment 12288
1 5 Overview of fitting locations – lights in roof trim 12289
1 5 1 Overview of fitting locations – lights in roof trim, without panorama roof 12289
1 5 2 Overview of fitting locations – lights in roof trim, with panorama roof 12290
1 6 Removing and installing front footwell light -K268-/-K269- 12291
1 6 1 Removing and installing front footwell light -K268-, driver side 12291
1 6 2 Removing and installing front footwell light -K269-, front passenger side 12292
1 7 Removing and installing light 1 for dash panel contour lighting -L243-/light 3 for dash panel contour lighting -L245- 12293
1 8 Removing and installing storage compartment illumination bulb -L120- 12293
1 9 Removing and installing Central locking SAFELOCK function warning lamp -K133- 12293
1 10 Removing and installing reflectors in door 12294
1 11 Removing and installing entry light -W92-/-W93- 12295
1 12 Removing and installing light for door ambient lighting -W86-/-W87- 12295
1 13 Removing and installing selector lever position display -Y26- 12295
1 14 Removing and installing luggage compartment light -W3- 12296
1 15 Removing and installing illuminated vanity mirror -W20-/-W14- 12296
1 16 Removing and installing bulb for illuminated vanity mirror -W20-/-W14- 12297
1 17 Removing and installing bulb for front interior light -W1- 12298
1 17 1 Removing and installing bulb for front interior light -W1- with incandescent bulbs 12298
1 17 2 Removing and installing light for front interior light -W1- with LED 12299
1 18 Rear interior light 12300
1 18 1 Removing and installing rear interior light -WX2-, vehicles without panoramic sunroof 12300
1 19 Removing and installing bulb for rear interior light -W43-, vehicles with panoramic sunroof 12302
1 19 1 Removing and installing bulb for rear interior light -W43- with incandescent bulbs 12302
1 19 2 Removing and installing light for rear interior light -W43- with LED 12303
1 20 Removing and installing bulb for rear reading light -W11-/-W12- 12303
1 21 Renewing bulb of rear interior light -W47-/-W48- 12303
2 Controls 12304
2 1 Overview of fitting locations – controls in dash panel 12304
2 2 Overview of fitting locations – controls in front doors 12305
2 3 Overview of fitting locations – controls in rear doors 12306
2 4 Overview of fitting locations – controls in centre console 12307
2 5 Overview of fitting locations – controls in luggage compartment 12308
2 6 Overview of fitting locations – controls in roof trim 12309
2 6 1 Overview of fitting locations – controls in roof trim, without panorama roof 12309
2 6 2 Overview of fitting locations – controls in roof trim, with panorama roof 12310
2 7 Removing and installing rotary light switch -EX1- 12311
2 8 Removing and installing TCS and ESP button -E256- 12312
2 9 Removing and installing parking aid button -E266- 12312
2 10 Removing and installing park assist steering button -E581- 12313
2 11 Removing and installing Start/Stop operation button -E693- 12313
2 12 Removing and installing driving mode selection button -E735- 12313
2 13 Removing and installing centre console switch module 12313
2 14 Removing and installing hazard warning light switch -EX3- 12315
2 15 Removing and installing buttons for seat heating -E653-/-E654- 12316
2 16 Removing and installing exterior mirror adjuster -EX11- 12316
2 17 Removing and installing operating unit for window regulator in driver door -E512- 12317
2 18 Removing and installing front passenger side window regulator button -E716- 12317
2 19 Removing and installing driver side interior locking button for central locking system -E308- 12318
2 20 Removing and installing rear lid remote release button -E233-/remote release button for fuel filler flap and rear lid -E463- 12319
2 21 Removing and installing door contact switch -F2-/-F3- 12319
2 22 Removing and installing rear window regulator button -E711-/-E713- 12320
2 23 Removing and installing rear door contact switches -F10-/-F11- 12320
2 24 Removing and installing electromechanical parking brake button -E538-/auto-hold button -E540- 12321
2 25 Removing and installing starter button -E378- 12321
2 26 Removing and installing rear lid contact switch 12322
2 27 Removing and installing vanity mirror contact switch -F147-/-F148- 12322
2 28 Removing and installing sunroof button -E325- 12322
2 29 Removing and installing front interior light/reading light 12323
2 30 Removing and installing front reading light button -E633-/-E634- 12324
3 Anti-theft alarm 12325
3 1 Assembly overview – interior monitor 12325
3 2 Removing and installing alarm horn/signal horn for anti-theft alarm system 12327
3 2 1 Removing and installing alarm horn -H12-, not including NAR 12327
3 2 2 Removing and installing anti-theft alarm system horn -H8-, only NAR 12328
3 3 Removing and installing anti-theft alarm sensor -G578- 12329
4 Cigarette lighter, socket 12331
4 1 Removing and installing cigarette lighter -U1- 12331
4 2 Removing and installing socket illumination bulb -L42- 12331
4 3 Removing and installing rear cigarette lighter illumination bulb -L32- 12331
4 4 Removing and installing 12 V socket -U5- 12331
97 – Wiring 12332
1 Relay carriers, fuse holders, electronics boxes 12332
1 1 Overview of fitting locations – relay carriers, fuse holders, electronics boxes 12332
1 1 1 Relay carriers, fuse carriers, electronics box (engine compartment) 12332
1 1 2 Relay carrier, fuse carrier in dash panel/A-pillar 12333
1 2 Removing and installing electronics box 12334
1 3 Removing and installing relay and fuse holder in electronics box 12336
1 3 1 Removing and installing fuse holder B -SB- 12336
1 3 2 Removing and installing fuse holder A -SA- 12338
1 4 Removing and installing relay and fuse holder behind dash panel on driver side 12339
2 Control units 12340
2 1 Overview of fitting locations – control units 12340
2 2 Removing and installing onboard supply control unit -J519- 12340
2 3 Removing and installing data bus diagnostic interface -J533- 12342
2 4 Removing and installing bracket for onboard supply control unit -J519- 12343
3 Connectors 12345
3 1 Repairing electrical wiring harnesses and plug-in connections 12345
3 1 1 Repairs to wiring harnesses and connectors 12345
3 1 2 Repairing connector housings and electrical connectors 12345
4 Releasing and dismantling connector housings 12346
5 Repairing aerial wires 12347
6 Fibre optic cables 12348
7 Vehicle diagnosis, testing and information systems 12349
00 – Technical data 12356
1 Safety information 12356
1 1 Safety measures when working on vehicles with start/stop system 12356
1 2 Safety precautions when working on subframe 12356
2 Repair notes 12357
2 1 Leaks at shock absorbers 12357
2 2 Noises from shock absorbers 12357
2 3 Checking shock absorbers when removed 12358
2 4 Steering rack 12358
2 5 Gaskets and seals 12359
2 6 Nuts and bolts 12359
2 7 Electrical components 12359
2 8 Raising suspension to unladen position (vehicles with coil springs) 12359
3 Assessing accident-damaged vehicles 12363
3 1 Check list for evaluating running gear on accident vehicles 12363
4 Disposal 12365
4 1 Releasing gas and draining front gas-filled shock absorbers 12365
4 1 1 Releasing gas and draining front gas-filled shock absorbers, conventional shock absorbers 12365
4 1 2 Releasing gas and draining front gas-filled shock absorbers, DCC shock absorbers 12366
4 2 Releasing gas and draining rear gas-filled shock absorbers 12367
40 – Front suspension 12368
1 Front axle 12368
1 1 Overview of fitting locations – front axle 12368
2 Subframe 12371
2 1 Assembly overview – subframe 12371
2 2 Removing and installing subframe without steering rack 12371
2 3 Removing and installing subframe with steering rack 12376
2 4 Repairing subframe 12384
2 5 Repairing thread in longitudinal member 12395
2 6 Fixing subframe in position 12395
2 7 Lowering subframe 12399
3 Anti-roll bar 12404
3 1 Assembly overview – anti-roll bar 12404
3 2 Removing and installing anti-roll bar 12404
3 3 Removing and installing coupling rod 12410
4 Suspension strut, upper suspension link 12411
4 1 Assembly overview – suspension strut, upper suspension link 12411
4 2 Removing and installing suspension strut 12412
4 3 Repairing suspension strut 12422
5 Lower suspension link, swivel joint 12427
5 1 Assembly overview – lower suspension link, swivel joint 12427
5 2 Removing and installing lower suspension link 12428
5 2 1 Removing and installing lower suspension link, vehicles with manual gearbox or 7-speed dual clutch gearbox 12428
5 2 2 Removing and installing lower suspension link, vehicles with automatic gearbox 12430
5 3 Checking swivel joint 12434
5 4 Removing and installing swivel joint 12435
5 5 Renewing bonded rubber bush for lower suspension link 12440
5 5 1 Renewing front bonded rubber bush for lower suspension link 12440
5 5 2 Renewing rear bonded rubber bush for lower suspension link 12443
6 Wheel bearing 12448
6 1 Assembly overview – wheel bearing assembly 12448
6 2 Removing and installing wheel bearing housing 12448
6 3 Removing and installing wheel bearing unit 12454
7 Drive shaft 12458
7 1 Overview – drive shaft 12458
7 2 Assembly overview – drive shaft 12459
7 2 1 Assembly overview – drive shaft, constant velocity joint VL100 12459
7 2 2 Assembly overview – drive shaft, constant velocity joint VL107 12461
7 2 3 Assembly overview – drive shaft, triple roller joint AAR2600i 12463
7 2 4 Assembly overview – drive shaft, triple roller joint AAR3300i 12465
7 3 Removing and installing drive shaft 12467
7 3 1 Removing and installing drive shaft, constant velocity joints VL100 and VL107 12467
7 3 2 Removing and installing drive shaft, right drive shaft, constant velocity joint VL107, bolted 12472
7 3 3 Removing and installing drive shaft, triple roller joint 12475
7 4 Loosening and tightening threaded connections of drive shaft 12480
7 5 Removing and installing drive shaft heat shield 12482
7 6 Dismantling and assembling drive shaft 12482
7 6 1 Dismantling and assembling drive shaft, outer constant velocity joint 12482
7 6 2 Dismantling and assembling drive shaft, inner constant velocity joint 12486
7 6 3 Dismantling and assembling drive shaft, triple roller joint 12492
7 7 Checking outer constant velocity joint 12501
7 8 Checking inner constant velocity joint 12503
42 – Rear suspension 12506
1 Rear axle 12506
1 1 Overview – rear axle 12506
1 1 1 Overview – rear axle, torsion beam axle 12506
1 1 2 Overview – rear axle, multi-link suspension 12507
1 2 Lowering rear axle 12509
1 3 Removing and installing rear axle 12512
1 3 1 Removing and installing rear axle, torsion beam axle 12512
1 3 2 Removing and installing rear axle, multi-link suspension 12515
2 Axle beam 12519
2 1 Assembly overview – axle beam 12519
2 2 Assembly overview – attachments for torsion beam axle 12519
2 3 Removing and installing stone deflector for axle beam 12521
2 3 1 Removing and installing centre stone deflector 12521
2 3 2 Removing and installing centre stone deflector 12521
2 4 Renewing bonded rubber bush for axle beam 12522
3 Subframe 12532
3 1 Assembly overview – subframe 12532
3 2 Fixing subframe in position 12532
4 Anti-roll bar 12538
4 1 Assembly overview – anti-roll bar 12538
4 2 Removing and installing anti-roll bar 12538
4 3 Removing and installing coupling rod 12539
5 Suspension link, track rod 12542
5 1 Assembly overview – transverse link 12542
5 2 Assembly overview – track rod 12544
5 3 Removing and installing upper transverse link 12544
5 4 Removing and installing lower transverse link 12545
5 5 Removing and installing track rod 12547
6 Suspension strut, shock absorber, spring 12549
6 1 Assembly overview – suspension strut, shock absorber, spring 12549
6 1 1 Assembly overview – suspension strut, shock absorber, spring, torsion beam axle 12549
6 1 2 Assembly overview – suspension strut, shock absorber, spring, multi-link suspension 12550
6 2 Removing and installing shock absorber 12551
6 2 1 Removing and installing shock absorber, torsion beam axle 12551
6 2 2 Removing and installing shock absorbers, multi-link suspension 12554
6 3 Repairing shock absorber 12557
6 4 Removing and installing spring 12559
6 4 1 Removing and installing spring, torsion beam axle 12559
6 4 2 Removing and installing spring, multi-link suspension 12562
7 Wheel bearing assembly, trailing arm 12569
7 1 Assembly overview – wheel bearing assembly 12569
7 1 1 Assembly overview – wheel bearing assembly, torsion beam axle 12569
7 1 2 Assembly overview – wheel bearing assembly, multi-link suspension 12570
7 2 Assembly overview – trailing arm 12571
7 3 Removing and installing wheel bearing housing 12572
7 4 Removing and installing wheel bearing unit 12577
7 5 Renewing bonded rubber bush for wheel bearing housing 12581
7 6 Removing and installing trailing arm with mounting bracket 12585
7 7 Repairing trailing arm 12589
43 – Self-levelling suspension 12595
1 Electronic damping control 12595
1 1 Overview of fitting locations – electronically controlled damping system 12595
1 2 Removing and installing electronically controlled damping control unit -J250- 12597
1 3 Removing and installing front body acceleration senders -G341-/-G342- 12598
1 3 1 Removing and installing front left body acceleration sender -G341- 12598
1 3 2 Removing and installing front right body acceleration sender -G342- 12599
1 4 Removing and installing rear left body acceleration sender -G699- 12601
2 Vehicle level sender 12602
2 1 Assembly overview – front vehicle level senders 12602
2 2 Assembly overview – rear vehicle level senders 12603
2 2 1 Assembly overview – vehicle rear level sender, torsion beam axle 12603
2 2 2 Assembly overview – rear vehicle level senders, multi-link suspension 12603
2 3 Removing and installing front vehicle level senders -G78-/-G289- 12604
2 4 Removing and installing rear vehicle level senders -G76-/-G77- 12606
2 4 1 Removing and installing rear left vehicle level sender -G76-, torsion beam axle 12606
2 4 2 Removing and installing rear left vehicle level sender -G76-, multi-link suspension 12606
44 – Wheels, tyres, vehicle geometry 12608
1 Wheel alignment 12608
1 1 Notes for wheel alignment 12608
1 2 Prerequisites for checking 12609
1 3 Preparations for testing 12609
1 3 1 Preparations for testing, wheel alignment with no driver assist systems 12609
1 3 2 Test preparations, wheel alignment with driver assist systems 12610
1 4 Specifications for wheel alignment 12611
1 4 1 Specified values for wheel alignment, torsion beam axle 12611
1 4 2 Specified values for wheel alignment, multi-link suspension 12612
1 5 Wheel alignment procedure 12613
1 6 Necessity of wheel alignment 12615
1 6 1 Necessity of wheel alignment, torsion beam axle 12615
1 6 2 Necessity of wheel alignment, multi-link suspension 12616
1 7 Vehicle data sticker 12616
1 8 Adjusting camber at front wheels 12617
1 9 Adjusting camber on rear axle 12618
1 9 1 Adjusting camber at rear axle, torsion beam axle 12618
1 9 2 Adjusting camber at rear axle, multi-link suspension 12619
1 10 Adjusting toe at rear axle 12620
1 10 1 Adjusting toe at rear axle, torsion beam axle 12620
1 10 2 Adjusting toe on rear axle, multi-link suspension 12620
1 11 Adjusting front axle toe 12621
1 12 Wheel runout compensation 12622
1 13 Checking maximum steering wheel angle 12622
2 Adaptive cruise control 12623
3 Front camera for driver assist systems 12624
48 – Steering 12625
1 Steering wheel 12625
1 1 Assembly overview – steering wheel 12625
1 2 Removing and installing steering wheel 12626
2 Steering column 12628
2 1 Assembly overview – steering column 12628
2 2 Checking steering column for damage 12629
2 3 Handling and transporting steering column 12630
2 4 Removing and installing steering column 12631
2 5 Removing and installing control unit for electronic steering column lock -J764- 12636
3 Steering rack 12639
3 1 Assembly overview – steering rack 12639
3 1 1 Assembly overview – steering rack 12639
3 1 2 Assembly overview – steering rack, track rods 12640
3 2 Removing and installing steering rack 12641
3 3 Removing and installing bellows 12650
3 4 Removing and installing track rod 12653
3 5 Removing and installing track rod ball joint 12657
3 6 Repairing steering rack 12659
3 6 1 Removing and installing threaded bush 12659
4 Sensors 12664
4 1 Removing and installing steering angle sender -G85- 12664
44 – Wheels, tyres, vehicle geometry 12669
1 General information 12669
2 Wheels, tyres 12670
2 1 Specified torques for wheel bolts 12670
3 Jetta 2019 — North America, South America, Mexico 12671
4 Wheel allocation 12672
4 1 61/2 J x 16 offset 46 12672
4 2 7 J x 17 offset 46 12673
4 3 7 J x 17 offset 49 12674
4 4 7 5 J x 18 offset 49 12675
5 Recommended all-season tyres 12677
5 1 Recommended all-season tyres, worldwide according to country-specific approval 12677
6 Recommended summer tyres 12678
6 1 Recommended summer tyres, worldwide according to country-specific approval 12678
00 – Technical data 12683
45 – Anti-lock brake system 12684
1 General notes 12684
1 1 Repair instructions for repair work on ABS 12684
2 Overview of fitting locations 12686
2 1 Overview of fitting locations – ABS/ESP 12686
3 Control unit and hydraulic unit 12689
3 1 Assembly overview – control unit and hydraulic unit 12689
3 2 Removing and installing ABS control unit -J104- and ABS hydraulic unit -N55- 12691
3 3 Separating control unit from hydraulic unit 12697
3 4 Fitting control unit to hydraulic unit 12699
3 5 Connecting brake lines to hydraulic unit 12700
4 Sensors 12702
4 1 Assembly overview – speed sensor on front axle 12702
4 2 Assembly overview – speed sensors on rear axle 12703
4 2 1 Assembly overview – speed sensors at rear, vehicles with torsion beam axle 12703
4 2 2 Assembly overview – speed sensor at rear, vehicles with multi-link rear suspension 12703
4 3 Removing and installing ESP sensor unit -G419- 12704
4 4 Removing and installing speed sensors on front axle -G45-/-G47- 12704
4 5 Removing and installing speed sensors on rear axle -G44-/-G46- 12705
4 5 1 Removing and installing speed sensor on rear axle -G44-/-G46-, vehicles with torsion beam axle 12705
4 5 2 Removing and installing speed sensor on rear axle -G44-/-G46-, vehicles with multi-link suspension 12706
4 6 Checking ABS sensor ring 12707
46 – Brakes – mechanism 12709
1 Front brake 12709
1 1 Assembly overview – front brake 12709
1 1 1 Assembly overview – front brake 12709
1 2 Removing and installing brake pads 12711
1 3 Removing and installing brake caliper 12713
1 4 Removing and installing brake carrier 12715
1 5 Removing and installing brake disc 12717
1 6 Removing and installing brake splash plate 12718
2 Rear brake 12720
2 1 Assembly overview – rear brakes 12720
2 2 Removing and installing brake pads 12722
2 3 Removing and installing brake caliper 12728
3 Parking brake 12733
3 1 Overview of fitting locations – parking brake 12733
3 2 Removing and installing control unit for electromechanical parking brake -J540- 12735
3 3 Removing and installing parking brake motor -V282-/-V283- 12735
4 Brake pedal 12738
4 1 Assembly overview – brake pedal 12738
4 2 Removing and installing mounting bracket 12740
4 3 Separating brake pedal from brake servo 12742
4 4 Connecting brake pedal to brake servo 12743
4 5 Removing and installing brake pedal 12744
47 – Brakes – hydraulics 12745
1 Front brake caliper 12745
1 1 Assembly overview – front brake caliper 12745
1 2 Removing and installing brake caliper piston 12746
2 Rear brake caliper 12750
2 1 Assembly overview – rear brake caliper 12750
2 2 Removing and installing protective cap 12750
3 Brake servo and brake master cylinder 12754
3 1 Assembly overview – brake servo/brake master cylinder 12754
3 2 Removing and installing brake light switch 12756
3 3 Removing and installing brake servo 12757
3 4 Removing and installing brake master cylinder 12764
4 Vacuum system 12769
4 1 Assembly overview – vacuum pump 12769
4 2 Checking non-return valve 12769
4 3 Removing and installing vacuum sender -G608- 12770
4 4 Checking vacuum system 12771
4 4 1 Instructions for checking 12771
4 4 2 Connecting vacuum gauge for brake servo -VAS 6721- 12771
4 4 3 Checking vacuum generation 12773
4 4 4 Checking for leaks 12774
4 4 5 Vacuum generation with manual vacuum pump -VAS 6213- 12776
5 Brake lines 12777
5 1 Repairing brake lines 12777
5 1 1 Assembly overview – flanging tool 12777
5 1 2 Instructions for use of flanging tool 12778
6 Hydraulic system 12781
6 1 General notes on brake fluid 12781
6 2 Pre-bleeding hydraulic system 12781
6 3 Bleeding hydraulic system following standard procedure 12784
6 4 Subsequent bleeding of hydraulic system 12785
6 5 Leak test 12786
00 – Technical data 12791
1 Safety information 12791
1 1 General safety provisions 12791
1 2 Safety measures when working on vehicles with a start/stop system 12792
1 3 Notes on tow-starting/towing 12792
1 4 Safety measures when using testers and measuring instruments during a road test 12792
2 Identification 12794
2 1 Gearbox identification 12794
2 1 1 Identification on gearbox 12794
2 1 2 Reading gearbox code letters 12794
3 Repair instructions 12797
3 1 General repair instructions 12797
3 1 1 General information 12797
3 2 Gaskets and seals 12798
3 3 Nuts and bolts 12799
4 Technical data 12800
4 1 Allocation gearbox – engine 12800
4 2 Capacities 12800
4 2 1 Capacities – dual clutch gearbox 12800
4 2 2 Capacities, front differential lock 12800
5 Electrical components 12801
5 1 Overview of fitting locations – electrical components 12801
5 1 1 Overview of fitting locations – gearbox control 12801
5 1 2 Overview of fitting locations – electrical components, front differential lock 12801
30 – Clutch 12803
1 Clutch 12803
1 1 Assembly overview – dual clutch 12803
1 2 Removing and installing clutch end cover 12805
1 3 Removing dual clutch 12810
1 4 Installing dual clutch 12812
34 – Controls, housing 12820
1 Mechatronic unit 12820
1 1 Assembly overview – mechatronic unit 12820
1 1 1 Renewing securing clip on vehicle connector 12824
1 2 Removing and installing sump 12825
1 3 Removing and installing mechatronic unit for dual clutch gearbox -J743- 12832
1 3 1 Removing and installing mechatronic unit for dual clutch gearbox -J743-, gearbox installed 12832
1 3 2 Removing and installing mechatronic unit for dual clutch gearbox -J743-, gearbox removed 12847
2 Selector mechanism 12855
2 1 Assembly overview – selector mechanism 12855
2 1 1 Assembly overview – selector mechanism, manufacturer ZF 12855
2 1 2 Assembly overview – selector mechanism, manufacturer ECS 12856
2 2 Manual release from position P 12858
2 3 Removing and installing selector lever handle 12858
2 4 Moving push-button in the handle to installation position 12862
2 5 Removing and installing selector mechanism 12864
2 6 Checking selector mechanism 12867
2 7 Checking and adjusting selector lever cable 12868
2 8 Renewing selector shaft seal 12870
3 Removing and installing gearbox 12873
3 1 Removing gearbox 12873
3 1 1 Removing gearbox, vehicles with petrol engine 12873
3 2 Installing gearbox 12884
3 3 Specified torques for gearbox 12889
4 Assembly mountings 12890
4 1 Assembly overview – assembly mountings 12890
5 Transporting gearbox 12894
5 1 Transporting gearbox 12894
5 2 Transporting front differential lock 12894
6 Dismantling and assembling gearbox 12896
6 1 Assembly overview – gearbox 12896
7 Securing to engine and gearbox support 12900
7 1 Installing gearbox to engine and gearbox support 12900
7 2 Securing front differential lock to engine and gearbox support 12901
8 Gear oil circuit 12903
8 1 Removing and installing gear oil cooler 12903
8 2 Removing and installing cover for gear oil pump 12906
8 3 Removing and installing gear oil pump 12908
8 4 Removing and installing gear oil filter 12910
9 Gear oil 12913
9 1 Checking gear oil level 12913
9 2 Draining and filling gear oil 12917
10 Front differential lock 12921
10 1 Assembly overview – front differential lock 12921
10 2 Removing front differential lock 12921
10 3 Installing front differential lock 12925
10 4 Removing and installing differential lock control unit -J647- 12927
35 – Gears, shafts 12929
1 Currently, no repairs can be made to gears and shafts 12929
39 – Final drive – differential 12930
1 Oil for front differential lock 12930
1 1 Checking oil level for front differential lock 12930
1 2 Draining and filling oil for front differential lock 12931
2 Oil seals 12936
2 1 Overview of fitting locations – seals 12936
2 2 Renewing left seal 12938
2 3 Renewing right seal 12942
2 3 1 Renewing right oil seal, front wheel drive 12942
2 3 2 Renewing outer seal on right of bevel box 12947
2 3 3 Renewing right seal on gearbox, between front differential lock and gearbox or between bevel box and gearbox 12948
2 3 4 Renewing seal on bevel box between bevel box and gearbox 12950
3 Components of front differential lock 12952
3 1 Assembly overview – components of front differential lock 12952
3 2 Checking function 12954
3 3 Removing and installing pump for front differential lock -V181- 12954
3 4 Removing and installing coupling for front differential lock 12956
3 5 Renewing seals for front differential lock 12956
3 5 1 Renewing outer seal on right of front differential lock 12956
3 5 2 Renewing seal between front differential lock and gearbox on front differential lock 12961
3 5 3 Renewing seal for right flange shaft in front differential lock 12963
3 6 Renewing ball bearing for flange shaft 12965
00 – Technical data 12972
1 Safety information 12972
1 1 Safety measures when working on vehicles with start/stop system 12972
1 2 Safety precautions when using testers and measuring instruments during a road test 12972
2 Repair instructions 12973
2 1 Rules for cleanliness 12973
2 2 General information 12973
2 3 Contact corrosion 12973
2 4 Routing and attachment of lines 12973
98 – Assist systems 12975
1 Fitting locations 12975
1 1 Overview of fitting locations – senders, sensors and control units in front section of vehicle 12975
1 2 Overview of fitting locations – senders, sensors and control units in centre section of vehicle 12976
1 3 Overview of fitting locations – senders, sensors and control units in rear section of vehicle 12976
2 Senders/sensors/control units 12978
2 1 Removing and installing adaptive cruise control unit -J428- 12978
2 2 Removing and installing parking aid control unit -J446- 12979
2 3 Removing and installing front parking aid warning buzzer -H22- 12980
2 4 Removing and installing rear parking aid warning buzzer -H15- 12981
2 5 Removing and installing front parking aid senders -G252-/-G253-/-G254-/-G255- 12981
2 6 Removing and installing rear parking aid senders -G203-/-G204-/-G205-/-G206- 12982
2 7 Removing and installing Blind Spot Monitor control unit -J1086-/-J1087- without GLI equipment 12983
2 8 Removing and installing Blind Spot Monitor control unit -J1086-/-J1087- with GLI equipment 12985
2 9 Removing and installing Blind Spot Monitor warning lamp in exterior mirror -K303-/-K304- 12986
2 10 Removing and installing front camera for driver assist systems -R242- 12986
2 11 Removing and installing reversing camera -R189- 12987
3 Adaptive cruise control 12988
3 1 Components of adaptive cruise control 12988
3 2 Assembly overview – Automatic adaptive cruise control 12988
3 3 Adjusting/calibrating adaptive cruise control unit 12989
3 3 1 Calibrating adaptive cruise control – static calibration 12989
3 3 2 Calibrating adaptive cruise control – dynamic calibration 12993
4 Parking aid / park assist steering / autonomous parking system 12995
4 1 Components of parking aid / park assist steering / autonomous parking system 12995
5 Blind Spot Monitor 12996
5 1 Assembly overview – Blind Spot Monitor 12996
5 2 Calibrating Blind Spot Monitor 12996
5 2 1 Measurement location 12996
5 2 2 Preparatory measures for calibration 12998
5 2 3 Calibrating blind spot monitor control unit -J1086-/-J1087- 13002
6 Front camera for driver assist systems 13005
6 1 Components of front camera for assist systems 13005
6 2 Calibrating front camera for assist systems 13005
7 Reversing camera system 13014
7 1 Ovrview of reversing camera system 13014