Volkswagen New Beetle Cabrio 2010 Repair Manual – PDF DOWNLOAD

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Volkswagen New Beetle Cabrio 2010 Repair Manual – PDF DOWNLOAD

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Volkswagen New Beetle Cabrio 2010 Repair Manual – PDF DOWNLOAD 

Language : English
Pages : 5659
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Volkswagen New Beetle Cabrio 2010 Repair Manual – PDF DOWNLOAD 

00053148620 Wheels and Tyres Guide Archive 1
44 – Wheels, tyres, vehicle geometry 11
1 General notes on wheels and tyres (passenger cars) 11
2 Legislative and technical conditions for converting wheel and tyre combinations 13
2 1 Legislative conditions for converting wheel and tyre combinations 13
2 2 Technical conditions for converting wheel and tyre combinations 13
2 3 Additional wheel housing extensions (flaps) 14
2 4 “Series 80” tyres 14
2 5 Vehicles with Plus running gear 14
3 Documents and codes/designations 16
3 1 New vehicle registration documents since 01 10 2005 16
3 2 COC document (EEC Certificate of Conformity) 17
3 3 Official type designations 17
3 4 EU general type approval number, sales type and sales or trade designation 18
4 Useful information regarding tyres 20
4 1 Identification markings on the tyre sidewall 20
4 2 Explanation of tyre markings 21
4 3 Speed ratings for tyres 22
4 4 Undulations 23
4 5 Tyre storage 24
4 6 Tyre ageing 24
4 7 Winter tyres 25
4 8 Winter tyres with speed symbol “V” 26
4 9 Extra Load (XL) V winter tyres 27
4 10 Maximum speeds for V and Extra Load (XL) winter tyres 27
4 11 Reinforced and Extra Load (XL) tyres 28
4 12 Snow chains 28
5 Tyre wear/ mileage for passenger car tyres 30
5 1 General 30
5 2 Requirements to be met by tyres 30
5 3 Wear behaviour of high-speed tyres 31
5 4 Factors influencing the service life of a tyre 31
5 5 Driving style 31
5 6 Tyre maintenance 32
5 7 Evenly worn tyres 33
5 8 Measuring tread depth 34
5 9 One-sided wear 34
5 10 Outer shoulder wear 37
5 11 Wear in middle of tyre 37
5 12 Diagonal washout 39
6 Tyre noise 40
6 1 General notes on tyre noise 40
6 2 Saw-tooth wear 40
6 3 Flat spots (from locking wheels) 41
7 Rough running caused by wheels/tyres 43
7 1 Causes of rough running 43
7 2 Balancing wheels 43
7 3 Conducting a road test before balancing wheels 43
7 4 Balancing wheels on stationary wheel balancing machine 44
7 5 Vibration control system -VAS 6230- 46
7 6 Finish balancer 46
7 7 Radial and lateral runout of wheels and tyres 47
7 8 Checking radial and lateral runout on wheels and tyres with tyre gauge -V A G 1435- 47
7 9 Checking radial and lateral runout on wheel rim 48
7 10 Matching 49
7 11 Flat spots caused by storage or handling 50
8 Vehicle pulls to one side 52
8 1 General 52
8 2 Conicity 52
8 3 Remedies when vehicle pulls to one side 53
8 4 Strategic rotation of wheels for non-directional tyres 54
8 5 Strategic rotation of wheels having unidirectional tyres 55
9 Tyre damage 57
9 1 General information 57
9 2 Construction of a radial belted tyre 57
9 3 Impact damage 58
9 4 Cuts 59
9 5 Damage caused by foreign bodies 59
9 6 Loss of air from tyre 60
9 7 Tyre pressure 60
9 8 Tyre damage due to insufficient tyre pressure 61
9 9 Rising tyre temperature caused by insufficient inflation pressure 62
9 10 Tyre damage due to fitting error (fitting damage) 63
10 Tyres with run-flat properties 65
10 1 General 65
10 2 Design and identification 66
10 3 Retrofitting/requirements when using run-flat tyres 66
10 4 Repairs 67
11 Rolling resistance optimised tyres 68
12 Facts about disc-type wheels (passenger cars) 69
12 1 Design of disc-type wheel 69
12 2 Data on wheel rims 69
12 3 Wheel rims – pitch circle diameter 70
12 4 Split rim composite wheels 70
12 5 Alloy wheels with exchangeable trim elements 70
12 6 Alloy wheels with exchangeable trim elements (Zaragoza) 71
12 6 1 Tools 71
12 6 2 Materials 72
12 6 3 Installing trim element 72
12 6 4 Removing trim element 74
12 7 Hub cover for alloy wheels with open threaded connections 75
12 8 Care and maintenance of alloy wheel rims 75
12 9 Restoring alloy wheels 76
12 10 The valve 77
13 Fitting and removing wheels 78
13 1 Rotating wheels 78
13 2 Instructions for changing or fitting wheels 78
13 3 Revised wheel bolts for Sharan from model year 2001 80
13 4 Notes on use of temporary spare wheels 80
14 Lupo 3L, Lupo FSI, Lupo GTI from model year 1999 82
14 1 Lupo 3L, type 6E model year 1999 to model year 2006 82
14 2 Wheel allocation for Lupo 3L, type 6E model year 1999 to model year 2006 83
14 2 1 4 J x 14 83
14 2 2 41/2 J x 14 83
14 2 3 5 J x 14 84
14 3 Lupo FSI, type 6E model year 2001 to model year 2006 84
14 4 Wheel allocation for Lupo FSI, type 6E model year 2001 to model year 2006 85
14 4 1 5 J x 14 85
14 4 2 6 J x 14 86
14 5 Lupo GTI, type 6ES model year 2001 to model year 2006 87
14 6 Wheel allocation for Lupo GTI, type 6ES model year 2001 to model year 2006 88
14 6 1 6 J x 14 88
14 6 2 61/2 J x 15 89
15 Lupo model year 1999 to model year 2005 90
15 1 Lupo, type 6X model year 1999 to model year 2005 90
15 2 Wheel allocation for Lupo, type 6X model year 1999 to model year 2005 92
15 2 1 41/2 J x 13 92
15 2 2 51/2 J x 13 93
15 2 3 6 J x 14 94
15 2 4 6 J x 15 96
16 Fox from model year 2005 98
16 1 Fox, type 5Z model year 2005 to model year 2012 98
16 2 Wheel allocation for Fox, type 5Z model year 2005 to model year 2012 99
16 2 1 5 J x 14 100
16 2 2 6 J x 14 100
16 2 3 6 J x 15 102
17 Polo model year 1995 to model year 2001 105
17 1 Polo, type 6N up to and including 07 95 105
17 2 Wheel allocation for Polo, type 6N up to and including 07 95 106
17 2 1 41/2 J x 13 106
17 2 2 51/2 J x 13 107
17 3 Polo, type 6N from 08 95 up to and including model year 1996 108
17 4 Polo, type 6N from model year 1997 to model year 1999 109
17 5 Wheel allocation for Polo, type 6N from 08 95 to model year 1999 110
17 5 1 41/2 J x 13 111
17 5 2 51/2 J x 13 111
17 5 3 6 J x 14 112
17 5 4 6 J x 15 113
17 6 Polo, type 6N from model year 2000 to model year 2001 115
17 7 Wheel allocation for Polo, type 6N from model year 2000 to model year 2001 116
17 7 1 41/2 J x 13 117
17 7 2 51/2 J x 13 117
17 7 3 6 J x 14 118
17 7 4 6 J x 15 119
18 Polo Classic model year 1996 to model year 2002 122
18 1 Polo Classic, type 6KV model year 1996 to model year 2002 122
18 2 Wheel allocation for Polo Classic, type 6KV model year 1996 to model year 2002 124
18 2 1 51/2 J x 13 124
18 2 2 6 J x 14 125
18 2 3 6 J x 15 126
19 Polo Variant model year 1998 to model year 2002 128
19 1 Polo Variant type 6KV model year 1998 to model year 2002 128
19 2 Wheel allocation for Polo Variant type 6KV model year 1998 to model year 2002 130
19 2 1 51/2 J x 13 130
19 2 2 6 J x 14 131
19 2 3 6 J x 15 132
20 Polo from model year 2002 134
20 1 Polo, type 9N model year 2002 to model year 2008 134
20 2 Polo, type 9N model year 2009 137
20 3 Wheel allocation for Polo, type 9N model year 2002 to model year 2009 141
20 3 1 5 J x 13 141
20 3 2 5 J x 14 142
20 3 3 6 J x 14 142
20 3 4 6 J x 15 144
20 3 5 61/2 J x 16 offset 38 145
20 3 6 61/2 J x 16 offset 43 145
20 3 7 71/2 J x 17 offset 38 148
21 Polo Fun model year 2004 to model year 2005 149
21 1 Polo Fun, type 9N model year 2004 to model year 2005 149
21 2 Wheel allocation for Polo Fun, type 9N model year 2004 to model year 2005 150
21 2 1 6 J x 15 150
21 2 2 71/2 J x 17 150
22 CrossPolo from model year 2006 152
22 1 CrossPolo, type 9N model year 2006 to model year 2009 152
22 2 Wheel allocation for CrossPolo, type 9N model year 2006 to model year 2009 153
22 2 1 6 J x 15 153
22 2 2 71/2 J x 17 153
23 Polo BlueMotion from model year 2007 155
23 1 Polo BlueMotion, type 9N model year 2007 to model year 2009 155
23 2 Wheel allocation for Polo BlueMotion, type 9N model year 2007 to model year 2009 156
23 2 1 5 J x 14 156
24 Polo GTI from model year 2006 158
24 1 Polo GTI, type 9N model year 2006 to model year 2009 158
24 2 Wheel allocation for Polo GTI, type 9N model year 2006 to model year 2009 159
24 2 1 6 J x 15 159
24 2 2 61/2 J x 16 offset 38 160
24 2 3 61/2 J x 16 offset 43 160
24 2 4 7 J x 17 offset 38 162
24 2 5 71/2 J x 17 offset 38 163
25 Polo GTI Cup Edition from model year 2007 164
25 1 Polo GTI Cup Edition, type 9N model year 2007 to model year 2009 164
25 2 Wheel allocation for Polo GTI Cup Edition, type 9N model year 2007 to model year 2009 165
25 2 1 61/2 J x 16 offset 42 165
25 2 2 61/2 J x 16 offset 43 166
25 2 3 7 J x 17 offset 38 167
25 2 4 71/2 J x 17 offset 38 168
26 Polo saloon/sedan model year 2004 to model year 2005 169
26 1 Polo saloon/sedan, type 9N model year 2004 to model year 2005 169
26 2 Wheel allocation for Polo saloon/sedan, type 9N model year 2004 to model year 2005 171
26 2 1 5 J x 14 171
26 2 2 6 J x 14 171
26 2 3 6 J x 15 173
26 2 4 61/2 J x 16 174
27 Golf model year 1992 to model year 1998 176
27 1 Golf type 1HX0, Golf Syncro 1HX1, Golf type 1H 176
27 2 Wheel allocation for Golf type 1HX0, Golf Syncro 1HX1, Golf type 1H 180
27 2 1 51/2 J x 13 180
27 2 2 6 J x 14 181
27 2 3 6 J x 15 183
27 2 4 61/2 J x 15 186
27 2 5 7 J x 16 189
28 Golf model year 1998 to model year 2004, Golf R32, Golf Anniversary GTI 190
28 1 Golf, Golf 4Motion, type 1J model year 1998 to model year 2004 190
28 2 Wheel allocation for Golf, Golf 4Motion, type 1J model year 1998 to model year 2004 193
28 2 1 6 J x 14 193
28 2 2 6 J x 15 194
28 2 3 51/2 J x 16 197
28 2 4 61/2 J x 16 198
28 2 5 7 J x 17 202
28 2 6 71/2 J x 17 204
28 3 Conditions for fitting 17″ wheels and tyres to Golf model year 1998 to model year 2004 205
28 4 Golf R32, type 1J model year 2003 to model year 2005 206
28 5 Wheel allocation for Golf R32, type 1J model year 2003 to model year 2005 206
28 5 1 51/2 J x 17 207
28 5 2 71/2 J x 17 207
28 5 3 71/2 J x 18 207
28 6 Golf Anniversary GTI, type 1J model year 2002 208
28 7 Wheel allocation for Golf Anniversary GTI, type 1J model year 2002 208
28 7 1 51/2 J x 16 209
28 7 2 61/2 J x 16 209
28 7 3 7 J x 17 211
28 7 4 71/2 J x 18 212
28 8 Conditions for fitting 17″ and 18″ wheels and tyres of Golf Anniversary GTI 213
29 Golf model year 2004 to model year 2009 214
29 1 Golf, Golf 4Motion, type 1K model year 2004 to model year 2006 214
29 2 Golf, Golf 4Motion, type 1K model year 2007 to model year 2009 217
29 3 Wheel allocation for Golf, Golf 4Motion, type 1K model year 2004 to model year 2009 221
29 3 1 6 J x 15 221
29 3 2 61/2 J x 15 222
29 3 3 6 J x 16 223
29 3 4 61/2 J x 16 223
29 3 5 6 J x 17 227
29 3 6 7 J x 17 228
29 3 7 71/2 J x 17 230
29 3 8 71/2 J x 18 231
30 Golf BlueMotion model year 2008 to model year 2009 234
30 1 Golf BlueMotion, type 1K model year 2008 to model year 2009 234
30 2 Wheel allocation for Golf BlueMotion, type 1K model year 2008 to model year 2009 235
30 2 1 6 J x 15 235
30 2 2 61/2 J x 15 236
30 2 3 61/2 J x 16 237
31 Golf GTI model year 2005 to model year 2009 242
31 1 Golf GTI, type 1K model year 2005 to model year 2008 242
31 2 Golf GTI, type 1K model year 2009 243
31 3 Wheel allocation for Golf GTI, type 1K model year 2005 to model year 2009 245
31 3 1 6 J x 16 245
31 3 2 61/2 J x 16 245
31 3 3 6 J x 17 249
31 3 4 7 J x 17 250
31 3 5 71/2 J x 17 252
31 3 6 71/2 J x 18 253
32 Pirelli Golf model year 2008 to model year 2009 256
32 1 Pirelli Golf, type 1K model year 2008 to model year 2009 256
32 2 Wheel allocation for Pirelli Golf, type 1K model year 2008 to model year 2009 257
32 2 1 6 J x 16 257
32 2 2 61/2 J x 16 258
32 2 3 6 J x 17 262
32 2 4 7 J x 17 262
32 2 5 71/2 J x 17 265
32 2 6 71/2 J x 18 266
33 Golf R32 model year 2006 to model year 2009 269
33 1 Golf R32, type 1K model year 2006 to model year 2009 269
33 2 Wheel allocation for Golf R32, type 1K model year 2006 to model year 2009 270
33 2 1 6 J x 17 270
33 2 2 7 J x 17 271
33 2 3 71/2 J x 18 273
34 CrossGolf from model year 2007 276
34 1 CrossGolf, type 1KP model year 2007 to model year 2009 276
34 2 Wheel allocation for CrossGolf, type 1KP model year 2007 to model year 2009 279
34 2 1 6 J x 15 279
34 2 2 61/2 J x 15 280
34 2 3 6 J x 16 281
34 2 4 61/2 J x 16 282
34 2 5 6 J x 17 286
34 2 6 7 J x 17 offset 47 286
34 2 7 7 J x 17 offset 54 287
34 2 8 71/2 J x 17 289
35 Golf Plus from model year 2005 290
35 1 Golf Plus, type 1KP model year 2005 to model year 2006 290
35 2 Golf Plus, type 1KP model year 2007 to model year 2009 292
35 3 Wheel allocation for Golf Plus, type 1KP model year 2005 to model year 2009 295
35 3 1 6 J x 15 296
35 3 2 61/2 J x 15 296
35 3 3 6 J x 16 297
35 3 4 61/2 J x 16 298
35 3 5 6 J x 17 302
35 3 6 7 J x 17 303
35 3 7 71/2 J x 18 305
36 Golf Plus BlueMotion from model year 2008 308
36 1 Golf Plus BlueMotion, type 1KP model year 2008 to model year 2009 308
36 2 Wheel allocation for Golf Plus BlueMotion, type 1KP model year 2008 to model year 2009 309
36 2 1 6 J x 15 309
36 2 2 61/2 J x 15 310
36 2 3 61/2 J x 16 311
37 Golf Variant model year 1994 to model year 1998 316
37 1 Golf Variant type 1HX0, Golf Variant Syncro type 1HX1, Golf Variant type 1H 316
37 2 Wheel allocation for Golf Variant type 1HX0, Golf Variant Syncro type 1HX1, Golf Variant type 1H 319
37 2 1 51/2 J x 13 320
37 2 2 6 J x 14 320
37 2 3 6 J x 15 323
37 2 4 61/2 J x 15 326
38 Golf Variant model year 1999 to model year 2006, Bora Variant model year 1999 to model year 2005 327
38 1 Golf Variant, Golf Variant 4Motion, Bora Variant, Bora Variant 4Motion, type 1J 327
38 2 Wheel allocation for Golf Variant, Golf Variant 4Motion, Bora Variant, Bora Variant 4Motion, type 1J 330
38 2 1 6 J x 15 330
38 2 2 51/2 J x 16 333
38 2 3 61/2 J x 16 334
38 2 4 7 J x 17 338
38 2 5 71/2 J x 17 340
38 3 Conditions for fitting 17″ wheels and tyres 341
39 Golf Variant model year 2007 to model year 2010 342
39 1 Golf Variant, Golf Variant 4Motion; type 1KM model year 2007 to model year 2008 342
39 2 Golf Variant, Golf Variant 4Motion; type 1KM model year 2009 to model year 2010 345
39 3 Wheel allocation for Golf Variant, Golf Variant 4Motion; type 1KM model year 2007 to model year 2010 348
39 3 1 6 J x 15 348
39 3 2 61/2 J x 15 349
39 3 3 6 J x 16 350
39 3 4 61/2 J x 16 351
39 3 5 7 J x 17 355
39 3 6 71/2 J x 18 357
40 Golf Variant BlueMotion model year 2008 to model year 2010 360
40 1 Golf Variant BlueMotion, type 1KM model year 2008 to model year 2010 360
40 2 Wheel allocation for Golf Variant BlueMotion, type 1KM model year 2008 to model year 2010 361
40 2 1 6 J x 15 361
40 2 2 61/2 J x 15 362
40 2 3 61/2 J x 16 363
41 Jetta Model Year 2006 to Model Year 2011 368
41 1 Jetta, type 1KM model year 2006 368
41 2 Jetta, type 1KM model year 2007 to model year 2008 370
41 3 Jetta, type 1KM model year 2009 to model year 2011 373
41 4 Wheel allocation for Jetta, type 1KM model year 2006 to model year 2011 380
41 4 1 6 J x 15 380
41 4 2 61/2 J x 15 381
41 4 3 6 J x 16 382
41 4 4 61/2 J x 16 383
41 4 5 7 J x 17 388
41 4 6 71/2 J x 17 391
41 4 7 71/2 J x 18 392
42 Jetta BlueMotion from Model year 2008 397
42 1 Jetta BlueMotion, type 1KM model year 2008 to model year 2011 397
42 2 Wheel allocation for Jetta BlueMotion, type 1KM model year 2008 to model year 2011 398
42 2 1 6 J x 15 398
42 2 2 61/2 J x 15 399
42 2 3 6 J x 16 400
42 2 4 61/2 J x 16 401
43 Golf cabriolet model year 1994 to model year 1997 407
43 1 Golf cabriolet type 1EX0 model year 1994 to model year 1997 407
43 2 Wheel allocation for Golf cabriolet, type 1EX0 from model year 1994 to model year 1997 408
43 2 1 6 J x 14 409
43 2 2 6 J x 15 410
43 2 3 61/2 J x 16 410
44 Golf cabriolet model year 1998 to model year 2002 412
44 1 Golf cabriolet; type 1E from model year 1998 to model year 2002 412
44 2 Wheel allocation for Golf cabriolet; type 1E from model year 1998 to model year 2002 413
44 2 1 6 J x 14 413
44 2 2 6 J x 15 415
44 2 3 61/2 J x 16 417
45 Vento from model year 1992 to model year 1998 418
45 1 Vento; type 1HX0, 1H 418
45 2 Wheel allocation for Vento; type 1HX0, 1H 420
45 2 1 51/2 J x 13 420
45 2 2 6 J x 14 421
45 2 3 6 J x 15 423
45 2 4 61/2 J x 15 425
46 Bora model year 1999 to model year 2005 429
46 1 Bora, Bora 4Motion, type 1J model year 1999 to model year 2005 429
46 2 Wheel allocation for Bora, Bora 4Motion, type 1J model year 1999 to model year 2005 432
46 2 1 6 J x 15 432
46 2 2 51/2 J x 16 435
46 2 3 61/2 J x 16 435
46 2 4 7 J x 17 440
46 2 5 71/2 J x 17 442
46 3 Conditions for fitting 17″ wheels and tyres 443
47 New Beetle from model year 1999 444
47 1 New Beetle, type 9C model year 1999 to model year 2010 444
47 2 Wheel allocation for New Beetle, type 9C model year 1999 to model year 2010 447
47 2 1 6 J x 15 447
47 2 2 51/2 J x 16 449
47 2 3 61/2 J x 16 450
47 2 4 7 J x 17 455
47 2 5 71/2 J x 17 458
47 3 Conditions for fitting 17″ wheels and tyres 458
48 New Beetle Cabriolet from model year 2003 460
48 1 New Beetle Cabriolet, type 1Y model year 2003 to model year 2010 460
48 2 Wheel allocation for New Beetle Cabriolet, type 1Y model year 2003 to model year 2010 462
48 2 1 6 J x 15 462
48 2 2 51/2 J x 16 464
48 2 3 61/2 J x 16 465
48 2 4 7 J x 17 470
48 2 5 71/2 J x 17 473
48 3 Conditions for fitting 17″ wheels and tyres 473
49 New Beetle RSi 475
49 1 New Beetle RSi, type 9CR from model year 2001 475
49 2 Wheel allocation for New Beetle RSi, type 9CR from model year 2001 476
49 2 1 7 J x 16 476
49 2 2 9 x 18 476
50 Passat model year 1994 to model year 1997 478
50 1 Passat, type 35l model year 1994 to model year 1997 478
50 2 Wheel allocation for Passat, type 35l model year 1994 to model year 1997 480
50 2 1 6 J x 14 480
50 2 2 6 J x 15 482
51 Passat model year 1997 to model year 2005 486
51 1 Passat, Passat Variant, type 3B model year 1997 to model year 2000 486
51 2 Passat, Passat Variant, type 3B model year 1997 to model year 2000 488
51 2 1 6 J x 15 488
51 2 2 7 J x 15 489
51 2 3 7 J x 16 490
51 3 Passat, Passat Variant, type 3BG model year 2001 to model year 2005 491
51 4 Wheel allocation for Passat, Passat Variant, type 3BG model year 2001 to model year 2005 492
51 4 1 6 J x 15 493
51 4 2 7 J x 15 494
51 4 3 6 J x 16 494
51 4 4 7 J x 16 495
51 4 5 7 J x 17 497
51 5 Passat W8 4Motion, type 3BS model year 2002 to model year 2005 498
51 6 Wheel allocation for Passat W8 4Motion, type 3BS model year 2002 to model year 2005 499
51 6 1 7 J x 16 499
51 6 2 6 J x 17 500
51 6 3 71/2 J x 17 500
51 7 Passat Protect, type 3BL model year 2002 to model year 2005 501
51 8 Wheel allocation for Passat Protect, type 3BL model year 2002 to model year 2005 502
51 8 1 6 J x 16 502
51 8 2 7 J x 16 502
52 Passat saloon from model year 2006 504
52 1 Passat saloon, type 3C model year 2006 504
52 2 Passat saloon, type 3C model year 2007 to model year 2008 507
52 3 Passat saloon, type 3C model year 2009 515
52 4 Passat saloon, type 3C model year 2010 to model year 2011 522
52 5 Wheel allocation for Passat saloon, type 3C model year 2006 to model year 2011 526
52 5 1 61/2 J x 16 526
52 5 2 7 J x 16 527
52 5 3 6 J x 17 529
52 5 4 71/2 J x 17 529
52 5 5 8 J x 18 532
53 Passat saloon BlueMotion from model year 2008 535
53 1 Passat saloon BlueMotion, type 3C model year 2008 to model year 2009 535
53 2 Passat saloon BlueMotion, type 3C model year 2010 to model year 2011 537
53 3 Wheel allocation for Passat saloon BlueMotion, type 3C model year 2008 to model year 2011 538
53 3 1 61/2 J x 16 538
53 3 2 7 J x 16 539
53 3 3 6 J x 17 541
53 3 4 71/2 J x 17 541
53 3 5 8 J x 18 544
54 Passat Variant from model year 2006 547
54 1 Passat Variant, type 3C model year 2006 547
54 2 Passat Variant, type 3C model year 2007 to model year 2008 551
54 3 Passat Variant, type 3C model year 2009 561
54 4 Passat Variant, type 3C model year 2010 to model year 2011 569
54 5 Wheel allocation for Passat Variant, type 3C model year 2006 to model year 2011 573
54 5 1 61/2 J x 16 573
54 5 2 7 J x 16 574
54 5 3 6 J x 17 576
54 5 4 71/2 J x 17 576
54 5 5 8 J x 18 579
55 Passat Variant BlueMotion from model year 2008 582
55 1 Passat Variant BlueMotion, type 3C model year 2008 to model year 2009 582
55 2 Passat Variant BlueMotion, type 3C model year 2010 to model year 2011 584
55 3 Wheel allocation for Passat Variant BlueMotion, type 3C model year 2008 to model year 2011 585
55 3 1 61/2 J x 16 585
55 3 2 7 J x 16 586
55 3 3 6 J x 17 588
55 3 4 71/2 J x 17 588
55 3 5 8 J x 18 591
56 Passat R36 from model year 2008 594
56 1 Passat R36, type 3C model year 2008 to model year 2009 594
56 2 Passat R36, type 3C model year 2010 to model year 2011 596
56 3 Wheel allocation for Passat R36, type 3C model year 2008 to model year 2011 597
56 3 1 6 J x 17 597
56 3 2 71/2 J x 17 597
56 3 3 8 J x 18 600
56 3 4 8 J x 19 601
57 Sharan from model year 1996 603
57 1 Sharan, Sharan Syncro, type 7M model year 1996 to model year 2000 603
57 2 Wheel allocation for Sharan, Sharan Syncro Type 7M model year 1996 to model year 2000 606
57 2 1 6 J x 15 606
57 2 2 7 J x 15 607
57 2 3 7 J x 16 608
57 3 Sharan, Sharan 4Motion, type 7M model year 2001 608
57 4 Wheel allocation for Sharan, Sharan 4Motion, type 7M model year 2001 611
57 4 1 6 J x 15 611
57 4 2 7 J x 15 611
57 4 3 6 J x 16 612
57 4 4 7 J x 16 613
57 5 Sharan, Sharan 4Motion, type 7M model year 2002 to model year 2010 615
57 6 Wheel allocation for Sharan, Sharan 4Motion, type 7M model year 2002 to model year 2010 616
57 6 1 6 J x 16 617
57 6 2 7 J x 16 617
57 6 3 7 J x 17 619
58 Sharan BlueMotion from model year 2009 621
58 1 Sharan BlueMotion, type 7M model year 2009 to model year 2010 621
58 2 Wheel allocation for Sharan BlueMotion, type 7M model year 2009 to model year 2010 622
58 2 1 6 J x 16 622
59 Touareg from model year 2003 624
59 1 Touareg, type 7L, model year 2003 to model year 2010 624
59 2 Wheel allocation for Touareg, type 7L model year 2003 to model year 2010 628
59 2 1 7 J x 16 628
59 2 2 71/2 J x 17 629
59 2 3 8 J x 18 630
59 2 4 9 J x 19 632
59 2 5 9 J x 20 634
59 2 6 91/2 J x 20 636
60 Touareg R50 from model year 2008 637
60 1 Touareg R50, type 7L model year 2008 to model year 2010 637
60 2 Wheel allocation for Touareg R50, type 7L model year 2008 to model year 2010 638
60 2 1 9 J x 19 638
60 2 2 9 J x 20 640
60 2 3 91/2 J x 20 641
60 2 4 10 J x 21 641
61 Breakdown set for VW Vehicles 643
62 Temporary spare tyres and wheels for VW vehicles 644
63 Recommended summer tyres 646
63 1 Summer tyres for Lupo 3L model year 1999 to model year 2005 646
63 2 Summer tyres for Lupo FSI model year 1999 to model year 2005 646
63 3 Summer tyres for Lupo GTI model year 1999 to model year 2005 646
63 4 Summer tyres for Lupo model year 1999 to model year 2005 646
63 5 Summer tyres for Fox from model year 2005 647
63 6 Summer tyres for Polo model year 1995 to model year 2001 647
63 7 Summer tyres for Polo saloon/sedan model year 2004 to model year 2005 648
63 8 Summer tyres for Polo Classic model year 1996 to model year 2002 648
63 9 Summer tyres for Polo Variant model year 1998 to model year 2002 649
63 10 Summer tyres for Polo from model year 2002 649
63 11 Summer tyres for Polo Fun model year 2004 to model year 2005 650
63 12 Summer tyres for CrossPolo from model year 2006 650
63 13 Summer tyres for Polo BlueMotion from model year 2007 651
63 14 Summer tyres for Polo GTI from model year 2007 651
63 15 Summer tyres for Polo GTI Cup Edition from model year 2007 651
63 16 Summer tyres for Golf, Vento model year 1992 to model year 1998 651
63 17 Summer tyres for Golf Variant model year 1994 to model year 1998 652
63 18 Summer tyres for Golf cabriolet model year 1994 to model year 1997 653
63 19 Summer tyres for Golf, Golf 4Motion model year 1998 to model year 2004 653
63 20 Summer tyres for Golf model year 2004 to model year 2009 654
63 21 Summer tyres for Golf BlueMotion model year 2008 to model year 2009 656
63 22 Summer tyres for Golf GTI model year 2005 to model year 2009 656
63 23 Summer tyres for Pirelli Golf model year 2008 to model year 2009 656
63 24 Summer tyres for Golf R32 model year 2006 to model year 2009 657
63 25 Summer tyres for CrossGolf from model year 2007 657
63 26 Summer tyres for Golf Plus from model year 2005 658
63 27 Summer tyres for Golf Plus BlueMotion from model year 2008 659
63 28 Summer tyres for Bora, Bora 4Motion model year 1999 to model year 2005 659
63 29 Summer tyres for Golf Variant, Golf Variant 4Motion model year 1999 to model year 2006, Bora Variant, Bora Variant 4Motion model year 1999 to model year 2005 660
63 30 Summer tyres for Golf R32 661
63 31 Summer tyres for Golf Anniversary GTI 662
63 32 Summer tyres for Golf Variant model year 2007 to model year 2010 662
63 33 Summer tyres for Golf Variant BlueMotion from model year 2008 663
63 34 Summer tyres for Jetta Model Year 2006 to Model Year 2011 663
63 35 Summer tyres for Jetta BlueMotion Model Year 2008 to Model Year 2011 665
63 36 Summer tyres for Golf cabriolet model year 1998 to model year 2002 666
63 37 Summer tyres for New Beetle from model year 1999 667
63 38 Summer tyres for New Beetle Cabriolet from model year 2003 668
63 39 Summer tyres for New Beetle RSi 668
63 40 Summer tyres for Passat model year 1994 to model year 1997 669
63 41 Summer tyres for Passat model year 1997 to model year 2005 669
63 42 Summer tyres for Passat W8 670
63 43 Summer tyres for Passat Protect 670
63 44 Summer tyres for Passat saloon from model year 2006 670
63 45 Summer tyres for Passat saloon BlueMotion from model year 2008 671
63 46 Summer tyres for Passat Variant from model year 2006 672
63 47 Summer tyres for Passat Variant BlueMotion from model year 2008 673
63 48 Summer tyres for Passat R36 from model year 2008 674
63 49 Summer tyres for Sharan from model year 1996 675
63 50 Summer tyres for Sharan BlueMotion from model year 2009 675
63 51 Summer tyres for Touareg model year 2008 to model year 2010 676
63 52 Summer tyres for Touareg R50 model year 2008 to model year 2010 676
64 Recommended all-season tyres 677
64 1 All-season tyres Lupo model year 1999 to model year 2005 677
64 2 All-season tyres Polo model year 1995 to model year 2001 677
64 3 All-season tyres for Polo from model year 2002 677
64 4 All-season tyres Polo saloon/sedan model year 2004 to model year 2005 678
64 5 All-season tyres Golf, Vento model year 1992 to model year 1998 678
64 6 All-season tyres Golf Variant model year 1994 to model year 1998 678
64 7 All-season tyres Golf cabriolet model year 1994 to model year 1997 678
64 8 All-season tyres Golf, Golf 4Motion model year 1998 to model year 2004 678
64 9 All-season tyres for Golf model year 2004 to model year 2009 679
64 10 All-season tyres for CrossGolf from model year 2007 679
64 11 All-season tyres for Golf Plus from model year 2005 680
64 12 All-season tyres Bora, Bora 4Motion model year 1999 to model year 2005 680
64 13 All-season tyres Golf Variant, Golf Variant 4Motion model year 1999 to model year 2006, Bora Variant, Bora Variant 4Motion model year 1999 to model year 2005 681
64 14 All-season tyres Golf Variant model year 2007 to model year 2010 681
64 15 All-season tyres Jetta Model Year 2006 to Model Year 2011 681
64 16 All-season tyres Golf cabriolet model year 1998 to model year 2002 682
64 17 All-season tyres for New Beetle from model year 1999 682
64 18 All-season tyres for New Beetle Cabriolet from model year 2003 683
64 19 All-season tyres Passat model year 1997 to model year 2005 683
64 20 All-season tyres for Passat W8 683
64 21 All-season tyres for Passat saloon from model year 2006 684
64 22 All-season tyres for Passat saloon BlueMotion from model year 2008 684
64 23 All-season tyres for Passat Variant from model year 2006 684
64 24 All-season tyres for Passat Variant BlueMotion from model year 2008 684
64 25 All-season tyres for Passat R36 from model year 2008 685
64 26 All-season tyres for Touareg model year 2003 to model year 2010 685
65 Recommended winter tyres 686
65 1 Winter tyres Lupo 3L model year 1999 to model year 2005 686
65 2 Winter tyres Lupo FSI model year 1999 to model year 2005 686
65 3 Winter tyres Lupo GTI model year 1999 to model year 2005 686
65 4 Winter tyres Lupo model year 1999 to model year 2005 687
65 5 Winter tyres for Fox from model year 2005 687
65 6 Winter tyres Polo model year 1995 to model year 2001 687
65 7 Winter tyres for Polo from model year 2002 688
65 8 Winter tyres for Polo Fun model year 2004 to model year 2006 688
65 9 Winter tyres for CrossPolo from model year 2006 688
65 10 Winter tyres for Polo BlueMotion from model year 2007 688
65 11 Winter tyres for Polo GTI from model year 2007 689
65 12 Winter tyres for Polo GTI Cup Edition from model year 2007 689
65 13 Winter tyres Polo saloon/sedan model year 2004 to model year 2005 689
65 14 Winter tyres Polo Classic model year 1996 to model year 2002 689
65 15 Winter tyres Polo Variant model year 1998 to model year 2002 690
65 16 Winter tyres Golf, Vento model year 1992 to model year 1998 690
65 17 Winter tyres Golf Variant model year 1994 to model year 1998 691
65 18 Winter tyres Golf cabriolet model year 1994 to model year 1997 691
65 19 Winter tyres Golf, Golf 4Motion model year 1998 to model year 2004 691
65 20 Winter tyres for Golf model year 2004 to model year 2009 692
65 21 Winter tyres for Golf BlueMotion model year 2004 to model year 2009 693
65 22 Winter tyres for Golf GTI model year 2005 to model year 2009 693
65 23 Winter tyres for Pirelli Golf model year 2008 to model year 2009 693
65 24 Winter tyres for Golf R32 model year 2006 to model year 2009 694
65 25 Winter tyres for CrossGolf from model year 2007 694
65 26 Winter tyres for Golf Plus from model year 2005 694
65 27 Winter tyres for Golf Plus BlueMotion from model year 2008 695
65 28 Winter tyres Bora, Bora 4Motion model year 1999 to model year 2005 695
65 29 Winter tyres Golf Variant, Golf Variant 4Motion model year 1999 to model year 2006, Bora Variant, Bora Variant 4Motion model year 1999 to model year 2005 696
65 30 Winter tyres for Golf 32 696
65 31 Winter tyres for Golf Anniversary GTI 696
65 32 Winter tyres Golf Variant model year 2007 to model year 2010 697
65 33 Winter tyres for Golf Variant BlueMotion model year 2008 to model year 2010 697
65 34 Winter tyres Jetta Model Year 2006 to Model Year 2011 698
65 35 Winter tyres Jetta BlueMotion Model Year 2008 to Model Year 2011 698
65 36 Winter tyres Golf cabriolet model year 1998 to model year 2002 698
65 37 Winter tyres for New Beetle from model year 1999 699
65 38 Winter tyres for New Beetle Cabriolet from model year 2003 699
65 39 Winter tyres for New Beetle RSi 700
65 40 Winter tyres Passat model year 1994 to model year 1997 700
65 41 Winter tyres Passat model year 1997 to model year 2005 700
65 42 Winter tyres for Passat W8 701
65 43 Winter tyres for Passat Protect 701
65 44 Winter tyres for Passat saloon from model year 2006 701
65 45 Winter tyres for Passat saloon BlueMotion from model year 2008 702
65 46 Winter tyres for Passat Variant from model year 2006 702
65 47 Winter tyres for Passat Variant BlueMotion from model year 2008 703
65 48 Winter tyres for Passat R36 from model year 2008 703
65 49 Winter tyres for Sharan from model year 1996 704
65 50 Winter tyres for Sharan BlueMotion from model year 2009 704
65 51 Winter tyres for Touareg model year 2003 to model year 2010 704
65 52 Winter tyres for Touareg R50 model year 2008 to model year 2010 704
00053426020 Guide for using trailers up to market entry 2016 706
00 – Technical data 714
1 Foreword 714
1 1 Legal requirements outside Germany 714
2 Technical prerequisites 715
2 1 Factory fitted towing attachment 715
2 2 Retrofitted towing attachment 715
2 3 Ball head 715
2 4 Trailer socket 715
2 4 1 »7-pin« trailer socket 715
2 4 2 »13-pin« trailer socket 716
2 5 Trailer detector control unit -J345- 716
2 5 1 Retrofitting trailer detector control unit -J345- 716
2 5 2 Coding trailer detector control unit -J345- 717
2 6 Engine cooling 717
2 7 Exterior mirror 717
2 8 Uprated shock absorbers and coil springs 718
3 Notes on operation and driving 719
4 General information 720
4 1 Towing attachment type plate 720
4 2 Weight of vehicle and trailer combination 720
4 3 Tachograph 720
5 Drawbar load details 721
6 Legal requirements 722
7 Beetle 2012 ► 723
8 Bora 1999 ►, Bora Variant 1999 ► 724
9 Eos 2006 ► 726
10 Fox 2004 ► 727
11 Golf 1992 ►, Golf Variant 1994 ► 728
12 Golf Cabriolet 1994 ► 730
13 Golf 1998 ►, Golf Estate 1999 ► 731
13 1 Golf R32 732
13 2 Celebration GTI 732
13 3 Golf Bi Fuel 733
14 Golf 2004 ► 734
15 Golf Plus 2005 ► 736
16 Golf Variant 2007 ► 738
17 Golf 2009 ► 739
18 Golf Plus 2009 ►, CrossGolf 2009 ► 741
18 1 Golf Plus 741
18 2 Cross Golf 742
19 Golf Estate 2010 ► 743
20 Golf Cabriolet 2012 ► 744
21 Golf 2013 ► 746
22 Golf Estate 2014 ►, Golf Alltrack 2015 ► 749
22 1 Golf Estate 749
22 2 Golf Alltrack 750
23 e-Golf 2014 ► 752
24 Golf SV 2015 ► 753
25 Jetta 2005 ► 755
26 Jetta 2011 ► 757
27 Jetta 2015 ► 759
28 Lupo 3L, Lupo FSI, Lupo GTI 1999 ► 761
29 Lupo 1999 ► 762
30 New Beetle 1999 ► 763
31 New Beetle RSi 765
32 New Beetle Cabriolet 2003 ► 766
33 Passat saloon, estate 1994 ► 767
33 1 Passat Syncro 768
33 1 1 Increase in trailer load 769
34 Passat Saloon, Estate 1997 ► 770
35 Passat Saloon, Estate 2001 ► 771
36 Passat W8 2002 ► 772
37 Passat Saloon 2006 ► 773
38 Passat Estate 2006 ► 775
39 Passat CC 2009 ►; CC 2010 ►; CC 2012 ► 777
40 Passat saloon 2011 ► 780
41 Passat Estate 2011 ►, Passat Alltrack 2012 ► 782
41 1 Passat Estate 782
41 2 Passat Alltrack 784
42 Passat Saloon 2015 ► 785
43 Passat Estate, Passat Alltrack 2015 ► 788
43 1 Passat Estate 2015 ► 788
43 2 Passat Alltrack 2015 ► 790
44 Phaeton 2003 ► 791
45 Polo 1995 ► 792
46 Polo Classic 1996 ► 793
47 Polo Variant 1998 ► 794
48 Polo 2002 ►, Polo Fun 2004 ► 795
48 1 Polo 795
48 2 Polo Fun 796
48 2 1 Retrofitting a towing bracket 797
49 Polo saloon 2004 ► 798
50 Polo 2010 ►, CrossPolo 2010 ► 799
50 1 Polo 799
50 2 CrossPolo 800
51 Polo 2014 ►, CrossPolo 2014 ► 801
51 1 Polo 801
51 2 CrossPolo 802
51 3 Polo GTI 803
52 Scirocco 2009 ► 805
53 Scirocco 2015 ► 806
54 Sharan 1996 ► 807
54 1 Retrofitting towing bracket on Sharan BlueMotion 808
55 Sharan 2011 ► 809
56 Tiguan 2008 ► 810
56 1 Tiguan Trend & Fun/Sport & Style 810
56 2 Tiguan Track & Field/Track & Style 811
57 Touran 2003 ► 814
58 CrossTouran 816
59 Touareg 2003 ► 818
60 Touareg 2010 ► 819
61 Touareg 2015 ► 820
62 up! 2012 ► 821
63 e-up! 2014 ► 822
64 Vento 1992 ► 823
D3E801C764E Running gear axles steering 824
00 – Technical data 830
1 Technical data 830
1 1 Running gear 830
1 2 Wheels, tyres 830
40 – Front suspension 831
1 Electrical/electronic components and locations 831
1 1 Vehicle level sender on vehicles with dynamic headlight range control – general notes 831
1 2 Front left vehicle level sender -G78- on front axle 832
1 3 Rear left vehicle level sender -G76- on rear axle 833
2 Torque settings for front axle 835
3 Repairing front suspension 838
3 1 Overview – front axle 838
3 2 I: Assembly overview: subframe, anti-roll bar and suspension link 839
3 3 Checking swivel joint 841
3 4 Removing and installing swivel joint 842
3 4 1 Removing 842
3 4 2 Installing 844
3 5 Removing and installing suspension link 844
3 5 1 Removing 845
3 5 2 Installing 846
3 6 Renewing bonded rubber bush for suspension link 846
3 7 Removing and installing subframe 849
3 7 1 Removing 850
3 7 2 Installing 851
3 8 Renewing bonded rubber bushes in subframe 852
3 9 Repairing threads in longitudinal member 853
3 9 1 VAS thread repair set 853
3 10 II: Assembly overview: wheel bearing 854
3 11 Removing and installing front wheel bearing with wheel bearing housing installed 860
3 11 1 Removing 861
3 11 2 Pulling out wheel hub 862
3 11 3 Pulling out wheel bearing 862
3 11 5 Pressing in wheel bearing 863
3 11 6 Press in wheel hub 864
3 12 III: Assembly overview: coil spring strut 864
3 13 Removing and installing suspension strut 865
3 13 1 Removing 865
3 13 2 Installing 867
3 14 Repairing front suspension strut 867
3 14 1 Removing coil spring 869
3 14 2 Installing coil spring 869
4 Repairing drive shafts 870
4 1 Overview – drive shafts 870
4 2 Removing and installing constant velocity joint shaft and triple roller joint shaft AAR 2000 and AAR 2900 871
4 2 1 Removing 871
4 2 2 Installing 873
4 3 Removing and installing triple roller joint drive shaft AAR 3300i 874
4 3 1 Removing 875
4 3 2 Installing 876
4 4 I – Repairing front drive shaft with constant velocity joint 878
4 5 Removing, checking and installing outer constant velocity joint 884
4 5 1 Removing 884
4 5 2 Installing 885
4 6 Removing, checking and installing inner constant velocity joint 885
4 6 1 Removing 885
4 6 2 Installing 886
4 7 II – Repairing front drive shaft with triple roller joint AAR 2000 887
4 8 Dismantling and assembling triple roller joint 890
4 8 1 Dismantling 890
4 8 2 Assembling 891
4 9 IV – Repairing front drive shaft with triple roller joint AAR 2900 892
4 10 Dismantling and assembling triple roller joint AAR 2900 896
4 10 1 Dismantling 896
4 10 2 Assembling 898
4 11 IV – Repairing drive shaft with triple roller joint AAR 3300i 900
4 12 Dismantling and assembling triple roller joint AAR 3300i 904
4 12 1 Dismantling 904
4 12 2 Assembling 904
42 – Rear suspension 906
1 Rear axle in unladen position 906
2 Torque settings for rear axle 908
3 Repairing rear axle 909
3 1 Removing and installing rear axle 909
3 1 1 Removing 909
3 1 2 Installing 911
3 2 Assembly overview – rear axle beam 912
3 3 Removing and installing bonded rubber bush 915
3 3 1 Removing left bonded rubber bush 916
3 3 2 Installing left bonded rubber bush 916
3 3 3 Removing right bonded rubber bush 917
3 3 4 Installing right bonded rubber bush 918
3 3 5 Continuation for both sides 918
3 4 Removing and installing hydraulic bonded rubber bush 919
3 4 1 Removing 921
3 4 2 Installing 923
3 5 Removing and installing spring/shock absorber 925
3 5 1 Removing spring 926
3 5 2 Installing spring 926
3 5 3 Removing shock absorber 926
3 5 4 Installing shock absorber 927
3 6 Assembly overview – shock absorber on vehicle with front-wheel drive 927
4 Repairing wheel bearing 929
4 1 Repairing wheel bearing, front-wheel drive vehicles 929
4 2 Removing and installing wheel bearing/wheel hub on vehicles with disc brakes 930
4 2 1 Removing 930
4 2 2 Installing 932
44 – Wheels, tyres, vehicle geometry 933
1 Specified torque for wheel bolts 933
2 Protecting wheel centring seat against corrosion 934
3 Wheels, tyres 935
3 1 Models with breakdown set 935
3 1 1 Tyre sealant 935
3 2 Removing a tyre 935
3 2 1 Tyre sealant disposal 936
3 2 2 Fitting a new tyre 936
4 Wheel alignment 937
4 1 General 937
4 1 1 Wheel alignment is necessary if: 937
4 2 Test prerequisites: 938
4 3 Test preparations 938
4 3 1 Transverse vehicle inclination “zero position” 939
4 4 Vehicle data sticker 939
4 5 Wheel alignment specifications 940
4 5 1 Specification for front axle (front-wheel drive) 940
4 5 2 Rear axle specifications in front-wheel drive vehicles 941
4 5 3 Overview – wheel alignment procedure 942
4 6 Adjusting camber at front axle 942
4 7 Adjusting camber on rear axle 943
4 8 Adjusting toe setting on rear axle (front-wheel drive vehicles) 943
4 9 Adjusting front axle toe 944
4 10 Checking left and right-hand wheel lock 944
48 – Steering 946
1 Connecting -VAS 5051 A- and selecting functions 946
2 Torque settings for steering system 948
2 1 Torque settings for steering column 948
2 2 Torque settings for steering rack 949
2 3 Torque settings for vane pump 949
2 4 Torque settings for pressure line/suction hose to engine 950
2 5 Torque settings for pressure line fixtures on manual and automatic gearboxes 952
3 Steering column 955
3 1 Removing and installing steering column 955
3 1 1 Removing 955
3 1 2 Installing steering column 959
3 2 Checking steering column for damage 962
3 2 1 Checking function 962
3 3 Removing and installing steering lock housing 963
3 3 1 Removing 963
3 3 2 Installing 963
3 4 Assembly overview – steering column cross member for New Beetle saloon 964
3 5 Assembly overview – steering column cross member for New Beetle Cabriolet 965
3 6 Steering column variations 966
3 6 1 Distinguishing features of steering columns 967
3 7 Removing and installing locking cable for ignition with key removal lock 968
3 7 1 Unhooking 968
3 7 2 Fitting 969
3 8 Checking ignition key removal lock 969
4 Repairing power steering 970
4 1 Removing and installing power-assisted steering rack 970
4 1 1 Removing 971
4 1 2 Installing 973
4 2 Assembly overview – power steering rack (LHD) 974
4 3 Assembly overview – power steering rack (RHD) 976
4 4 Removing and installing track rod 978
4 4 1 Removing 978
4 4 2 Installing 979
4 4 3 Installing boots 979
4 5 Revised track rod ball joints 979
4 6 Revised track rods 980
4 7 Checking play, tightness and bellows of track rod ball joints 980
4 8 Determining centre position of steering rack 981
4 9 Adjusting steering rack 981
5 Bottom-mounted vane pump 982
5 1 Assembly overview 982
5 2 Checking delivery pressure of vane pump 983
5 3 Removing and installing vane pump 985
5 3 1 Removing 987
5 3 2 Installing 988
6 Top-mounted vane pump 989
6 1 Assembly overview 989
6 2 Checking delivery pressure of vane pump 990
6 3 Removing and installing vane pump 993
6 3 1 Removing 994
6 3 2 Installing 996
7 Top-mounted vane pump (vehicles with 2 5 l 5-cylinder engine) 997
7 1 Assembly overview 997
7 2 Checking delivery pressure of vane pump 998
7 3 Removing and installing vane pump 1000
7 3 1 Removing 1001
7 3 2 Installing 1002
8 Vane pump, reservoir, hydraulic lines (vehicles with 1 4 l engine) 1003
8 1 Assembly overview 1003
8 1 1 Installing reservoir 1004
8 1 2 Securing pressure line and suction hose on vehicles with no air conditioner 1005
8 1 3 Securing pressure line and suction hose on vehicles with air conditioner 1006
9 Vane pump, reservoir, hydraulic lines (vehicles with 1 6 l, 1 8 l, 2 0 l or TDI engine) 1007
9 1 Assembly overview 1007
9 1 1 Installing reservoir 1008
9 1 2 Securing pressure line and suction hose on vehicles with 1 6 l engine 1009
9 1 3 Securing pressure line and suction hose on vehicles with TDI engine and air conditioner 1010
9 1 4 Securing pressure line and suction hose on vehicles with 2 0 l or TDI engine with no air conditioner and vehicles with 1 8 l turbo engine with air conditioner 1011
9 1 5 Securing pressure line and suction hose on vehicles with 2 0 l engine with air conditioner and vehicles with 1 8 l turbo engine with no air conditioner 1012
9 1 6 Securing pressure line and suction hose on vehicles with TDI unit injector engine 1013
10 Vane pump, reservoir, hydraulic lines (vehicles with 2 3 l V5 engine) 1014
10 1 Assembly overview 1014
10 1 1 Installing reservoir 1015
10 1 2 Securing pressure line and suction hose 1016
11 Vane pump, reservoir, hydraulic lines (vehicles with 2 5 l 5-cyl engine) 1017
11 1 Assembly overview 1017
11 1 1 Installing reservoir 1018
11 1 2 Securing pressure line and suction hose 1019
12 Securing pressure line on manual and automatic gearboxes 1020
12 1 Securing pressure line on 5-speed manual gearbox 02T 1020
12 2 Securing pressure line on 5-speed manual gearbox 02J 1021
12 3 Securing pressure line on 5-speed manual gearbox 0A4 1023
12 4 Securing pressure line on 6-speed manual gearbox 02M 1025
12 5 Securing pressure line on automatic gearbox 01M 1026
12 6 Assembly overview: vane pump with hydraulic lines (vehicles with automatic gearbox 09G) 1027
12 6 1 Securing pressure line and suction hose on vane pump 1029
12 6 2 Securing pressure line and return hose on automatic gearbox 09G 1030
12 6 3 Securing pressure line and suction hose on automatic gearbox 09G (vehicles with 2 5 l 5-cyl engine) 1031
12 7 Assembly overview: vane pump with hydraulic lines (vehicles with dual clutch gearbox 02E) 1031
12 7 1 Securing pressure line and suction hose on vane pump on vehicles with dual clutch gearbox 02E and 74 kW TDI unit injector engine 1033
12 7 2 Securing pressure line and suction hose on dual clutch gearbox 02E 1034
13 Bleeding steering system, checking for leaks and checking fluid level 1035
13 1 Bleeding steering system 1035
13 2 Checking steering system for leaks 1035
13 3 Checking power steering fluid level 1036
D3E801F2B16 Electrical system General information 1037
27 – Starter, current supply, CCS 1041
1 Battery 1041
1 1 Fundamentals for batteries 1041
1 2 Battery load test 1041
1 2 1 Battery with »standard« colour indicator 1042
1 2 2 Battery with »enhanced« colour indicator 1042
1 2 3 Absorbent glass mat battery 1043
1 2 4 Lithium ion battery 1043
1 3 Warning notices and safety regulations 1043
1 3 1 Dangers when handling vehicle batteries 1043
1 3 2 Safety markings on battery 1044
1 3 3 Working on airbag system 1045
1 4 Battery load test 1045
2 Checking battery 1047
2 1 Checking the various types of batteries 1047
2 1 1 Checking a battery with colour indicator 1047
2 1 2 Absorbent glass mat battery 1047
2 2 Inspection 1048
2 3 Information about battery replacement and battery gas venting 1049
2 4 Checking colour indicator in battery cover 1050
2 4 1 Checking colour indicator, “3-colour” 1050
2 4 2 Checking colour indicator, “2-colour” 1051
2 5 Battery tester with printer -VAS 6161- 1052
2 5 1 Description of battery tester with printer -VAS 6161- 1053
2 5 2 Perform battery test with battery tester with printer -VAS 6161- 1053
2 5 3 Genuine Volkswagen battery test 1055
2 5 4 “Non”-VW battery test 1055
2 5 5 Carrying out stock maintenance 1056
2 5 6 Comments concerning test print out 1056
2 5 7 Assessing test results 1057
2 6 Midtronics -MCR340V- battery tester only for USA/Canada vehicles 1057
2 6 1 General description 1058
2 6 2 Performing battery test with Midtronics -MCR340V- battery tester 1059
2 6 3 Assessing test results 1060
2 6 4 Dealing with problems with Midtronics -MCR340V- battery tester 1060
2 7 Current draw test 1061
3 Charging the battery 1063
3 1 Battery charger -VAS 5095 A- 1063
3 1 1 Description of battery charger -VAS 5095 A- 1064
3 1 2 Charging battery with battery charger -VAS 5095 A- 1065
3 1 3 Charging totally discharged battery with battery charger -VAS 5095 A- 1066
3 1 4 Charging battery in support mode with battery charger -VAS 5095A- 1067
3 1 5 Charging battery in trickle charge mode with battery charger -VAS 5095 A- 1069
3 2 Battery charger -VAS 5900- 1070
3 2 1 Description of battery charger -VAS 5900- 1070
3 2 2 Charging battery with battery charger -VAS 5900- 1071
3 2 3 Charging battery in service mode with battery charger -VAS 5900- 1074
3 2 4 Charging totally discharged batteries with battery charger -VAS 5900- 1077
3 2 5 Charging battery in support mode with battery charger -VAS 5900- 1079
3 2 6 Charging battery in trickle charge mode with battery charger -VAS 5900- 1081
3 3 Battery charger -VAS 5900 A- 1082
3 3 1 General description – battery charger -VAS 5900 A- 1082
3 3 2 Charging battery with battery charger -VAS 5900 A- 1084
3 3 3 Charging totally discharged battery with battery charger -VAS 5900 A- 1085
3 3 4 Charging battery in support mode with battery charger -VAS 5900 A- 1088
3 3 5 Mains supply mode with battery charger -VAS 5900 A- 1090
3 4 Battery charger -VAS 5903- 1091
3 4 1 Description of battery charger -VAS 5903- 1092
3 4 2 Charging battery with battery charger -VAS 5903- 1092
3 4 3 Charging battery in refresh charge mode with battery charger -VAS 5903- 1095
3 4 4 Charging totally discharged battery with battery charger -VAS 5903- 1098
3 4 5 Charging battery in support mode with battery charger -VAS 5903- 1100
3 4 6 Charging battery in trickle charge mode with battery charger -VAS 5903- 1102
3 5 Battery charger -VAS 5906- 1103
3 5 1 General description 1103
3 5 2 Charging battery with battery charger -VAS 5906- 1104
3 6 Battery charger -VAS 5908- 1106
3 6 1 General description – battery charger -VAS 5908- 1106
3 6 2 Auto mode on battery charger -VAS 5908- 1108
3 6 3 Charging battery with battery charger -VAS 5908- 1109
3 6 4 Charging battery in support mode with battery charger -VAS 5908- 1111
3 6 5 VAS I-CHECK current draw test with battery charger -VAS 5908- 1113
3 7 Midtronics -INC 940- battery charger only for USA/Canada 1115
3 7 1 General description of Midtronics -INC 940- battery tester 1115
3 7 2 Charging battery 1116
3 7 3 Dealing with problems with Midtronics -INC 940- battery tester 1118
3 8 Solar charger module -VAS 6102B- 1119
3 8 1 Charging battery in trickle charge mode with solar panel -VAS 6102B- 1119
3 9 Totally discharged batteries 1120
4 Cruise control system (CCS) 1122
4 1 Activating and deactivating cruise control system (CCS) 1122
90 – Gauges, instruments 1123
92 – Windscreen wash/wipe system 1124
1 Washer fluid line hose couplings 1124
1 1 Windscreen and rear window washer system 1124
1 2 Headlight washer system 1125
2 Hose repair 1126
2 1 General description 1126
2 2 Repairing smooth pipe 1126
2 3 Repairing corrugated pipe 1126
3 Distinguishing features of jointless wiper blades 1129
94 – Lights, bulbs, switches – exterior 1130
1 Operation and safety notes for gas discharge lamps 1130
96 – Lights, bulbs, switches – interior 1133
1 12 V socket 1133
1 1 Removing and installing 12 V socket 1133
1 2 Removing and installing socket illumination bulb -L42- 1133
2 Cigarette lighter -U1- 1134
2 1 General description 1134
2 2 Assembly overview 1135
2 3 Removing and installing cigarette lighter socket 1136
2 4 Removing and installing cigarette lighter illumination bulb -L28- 1139
97 – Wiring 1141
1 Vehicle diagnosis, testing and information systems 1141
1 1 Connecting vehicle diagnostic tester 1141
1 2 Connecting vehicle diagnostic tester Golf Model Year 1998 – 2003 1143
2 Repairs to wiring harnesses and connectors 1144
2 1 General notes concerning repairs to vehicle electrical system 1144
2 2 Wiring harness repair set 1146
2 2 1 Wiring harness repair set -VAS 1978- 1146
2 2 2 Upgrade kit -VAS 1978/50- 1146
2 2 3 Wiring harness repair set -VAS 1978A- 1147
2 2 4 Release tool set -VAS 1978/35- 1147
2 3 Tool descriptions 1148
2 3 1 Special pliers with insert 1148
2 3 2 Release tools for contacts 1149
2 3 3 Assembly tools for single wire seals 1149
2 3 4 Wire stripper -VAS 1978/3- 1149
2 3 5 Hot air blower 220 V/50 Hz -VAS 1978/14- 1151
2 3 6 Crimping pliers -VAS 1978/1A- 1151
2 4 Repairing wiring harnesses 1153
2 4 1 Repairs to airbag and belt tensioner wiring 1153
2 4 2 Repairing CAN bus wiring 1155
2 4 3 Repair of Flexray wires with sheath 1156
2 4 4 Repair of Flexray wires without sheath 1157
2 4 5 Renewal of aerial wiring 1158
2 4 6 Repairing 0 13 mm2/0 35 mm2/0 5 mm2 wire 1160
2 4 7 Repair of 10 mm2 or 16 mm2 wire with single butt connector 1165
2 4 8 Repair of 2 5 mm2, 4 mm2 or 6 mm2 aluminium wire with single butt connector 1172
2 4 9 Wiring open circuit with one repair position 1178
2 4 10 Wiring open circuit with two repair positions 1181
2 5 Repairing fibre optic cables 1183
2 5 1 Preparing fibre optic cable 1184
2 5 2 Detaching fibre optic cable from cable harness connector 1191
2 6 Repair of aerial wires 1192
2 6 1 Repair set, aerial cable VAS 6720 1192
2 7 Repairs to contact housings and connectors 1204
2 7 1 Notes on repairs to contact housings and connectors 1204
2 7 2 Repairs to contacts in contact housings 1204
2 7 3 Fitting single wire seals 1206
2 7 4 Repairs to contact housings using cut-and-clamp method 1209
2 8 Releasing and dismantling contact housings 1210
2 8 1 Notes on releasing and dismantling contact housings 1210
2 8 2 Secondary locking element 1210
2 8 3 Primary locking element 1211
2 8 4 Round connector systems 1212
2 8 5 Flat connector systems 1213
2 8 6 Special connector systems 1215
3 Contact surface cleaning set -VAS 6410- 1218
3 1 Using contact surface cleaning set -VAS 6410- 1218
3 1 1 Repairing ring terminals 1218
3 1 2 Repairing threaded connections 1220
3 1 3 Cleaning battery clamp and battery terminal 1222
3 1 4 Anti-corrosion treatment 1224
4 Renewing lambda probe 1226
4 1 Renewing LSF Lambda probe (4-pin) 1226
4 2 Renewing LSU Lambda probe (6-pin) 1227
4 3 Types of protective tube on universal lambda probes 1228
5 Exhaust gas temperature sensor 1230
D3E8049715C Wheels and Tyres Guide 1231
00 – Technical data 1239
1 General notes on wheels and tyres (passenger cars) 1239
1 1 Legislative conditions for converting wheel and tyre combinations 1240
1 2 Technical conditions for converting wheel and tyre combinations 1241
1 3 Official type designations 1241
1 3 1 Official type approval, sales or trade designation 1241
1 4 General information 1243
1 4 1 Special models 1243
1 4 2 Vehicles with Plus running gear 1243
1 4 3 Speed ratings for tyres 1244
1 4 4 “Series 80” tyres 1245
1 4 5 Wheel bolts – torque settings 1245
1 4 6 Revised wheel bolts for Sharan from model year 2001 1245
1 4 7 Wheel rims – pitch circle diameter 1246
1 4 8 Data on wheel rims 1246
1 4 9 Split rim wheels 1247
1 4 10 Alloy wheels with exchangeable trim elements 1247
2 Facts about wheels and tyres (passenger cars) 1248
2 1 Tyre wear/ mileage 1248
2 1 1 General information 1248
2 1 2 Requirements to be met by tyres 1248
2 1 3 Wear behaviour of high-speed tyres 1249
2 1 4 Factors influencing the service life of a tyre 1249
2 1 5 Driving style 1250
2 1 6 Tyre maintenance 1251
2 1 7 Evenly worn tyres 1252
2 1 8 Measuring tread depth 1252
2 1 9 One-sided wear 1253
2 1 10 Wear in middle of tyre 1255
2 1 11 Diagonal washout 1256
2 2 Tyre noise 1257
2 2 1 General notes on tyre noise 1257
2 2 2 Saw-tooth wear 1258
2 2 3 Flat spots (from locking wheels) 1259
2 3 Rough running caused by wheels/tyres 1260
2 3 1 Causes of rough running 1260
2 3 2 Balancing wheels 1260
2 3 3 Conducting a road test before balancing wheels 1260
2 3 4 Balancing wheels on stationary wheel balancing machine 1261
2 3 5 Vibration control system -VAS 6230- 1262
2 3 6 Finish balancer 1263
2 3 7 Radial and lateral runout of wheels and tyres 1264
2 3 8 Checking radial and lateral runout on wheels and tyres with tyre gauge -V A G 1435- 1264
2 3 9 Checking radial and lateral runout on wheel 1266
2 3 10 Matching 1266
2 3 11 Flat spots caused by storage or handling 1268
2 4 Vehicle pulls to one side 1269
2 4 1 General information 1269
2 4 2 Conicity 1269
2 4 3 Remedies when vehicle pulls to one side 1271
2 4 4 Strategic rotation of wheels for non-directional tyres 1272
2 4 5 Strategic rotation of wheels having unidirectional tyres 1273
2 4 6 Tyres with a red spot 1273
2 5 Tyre damage 1274
2 5 1 General information 1274
2 5 2 Construction of a radial belted tyre 1275
2 5 3 Impact damage 1275
2 5 4 Cuts 1277
2 5 5 Damage caused by foreign bodies 1277
2 5 6 Loss of air from tyre 1278
2 5 7 Tyre pressure 1278
2 5 8 Tyre damage due to insufficient tyre pressure 1278
2 5 9 Rising tyre temperature caused by insufficient inflation pressure 1280
2 5 10 Tyre damage due to fitting error (fitting damage) 1281
2 6 Facts about wheels and tyres 1283
2 6 1 Identification markings on the tyre sidewall 1283
2 6 2 Explanation of tyre markings 1285
2 6 3 Undulations 1286
2 6 4 The valve 1287
2 6 5 Tyre storage 1288
2 6 6 Tyre ageing 1288
2 6 7 Care and maintenance of alloy wheel rims 1289
2 6 8 Rotating wheels 1290
2 6 9 Instructions for changing or fitting wheels 1290
2 6 10 Tyres with flange protection 1291
2 6 11 Notes on use of temporary spare wheels 1292
2 6 12 M+S tyres 1293
2 6 13 Winter tyres with speed symbol “V” 1294
2 6 14 Extra Load (XL) V winter tyres 1294
2 6 15 Reinforced and Extra Load (XL) tyres 1297
2 6 16 Snow chains 1297
44 – Wheels, tyres, vehicle geometry 1298
1 Lupo 3L, Lupo FSI, Lupo GTI from model year 1999 1298
1 1 Lupo 3L, type 6E model year 1999 to model year 2006 1298
1 2 Wheel allocation for Lupo 3L, type 6E model year 1999 to model year 2006 1299
1 2 1 4 J x 14 1299
1 2 2 41/2 J x 14 1300
1 2 3 5 J x 14 1300
1 3 Lupo FSI, type 6E model year 2001 to model year 2006 1300
1 4 Wheel allocation for Lupo FSI, type 6E model year 2001 to model year 2006 1301
1 4 1 5 J x 14 1301
1 4 2 6 J x 14 1302
1 5 Lupo GTI, type 6ES model year 2001 to model year 2006 1304
1 6 Wheel allocation for Lupo GTI, type 6ES model year 2001 to model year 2006 1305
1 6 1 6 J x 14 1305
1 6 2 61/2 J x 15 1306
2 Lupo model year 1999 to model year 2005 1308
2 1 Lupo, type 6X model year 1999 to model year 2005 1308
2 2 Wheel allocation for Lupo, type 6X model year 1999 to model year 2005 1310
2 2 1 41/2 J x 13 1310
2 2 2 51/2 J x 13 1311
2 2 3 6 J x 14 1313
2 2 4 6 J x 15 1316
3 Fox model year 2006 1318
3 1 Fox, type 5Z model year 2006 1318
3 2 Wheel allocation for Fox, type 5Z model year 2006 1319
3 2 1 5 J x 14 1319
3 2 2 6 J x 14 1320
3 2 3 6 J x 15 1322
4 Polo model year 1995 to model year 2002 1325
4 1 Polo, type 6N up to and including 07 95 1325
4 2 Wheel allocation for Polo, type 6N up to and including 07 95 1326
4 2 1 41/2 J x 13 1326
4 2 2 51/2 J x 13 1327
4 3 Polo, type 6N from 08 95 up to and including model year 1996 1328
4 4 Polo, type 6N from model year 1997 to model year 1999 1329
4 5 Wheel allocation for Polo, type 6N from 08 95 to model year 1999 1331
4 5 1 41/2 J x 13 1331
4 5 2 51/2 J x 13 1332
4 5 3 6 J x 14 1333
4 5 4 6 J x 15 1335
4 6 Polo, type 6N from model year 2000 to model year 2002 1337
4 7 Wheel allocation for Polo, type 6N from model year 2000 to model year 2002 1338
4 7 1 41/2 J x 13 1338
4 7 2 51/2 J x 13 1339
4 7 3 6 J x 14 1340
4 7 4 6 J x 15 1342
5 Polo from model year 2002 1345
5 1 Polo, type 9N model year 2002 to model year 2006 1345
5 2 Wheel allocation for Polo, type 9N model year 2002 to model year 2006 1347
5 2 1 5 J x 13 1348
5 2 2 5 J x 14 1348
5 2 3 6 J x 14 1349
5 2 4 6 J x 15 1350
5 2 5 61/2 J x 16 1352
6 Polo Fun from model year 2004 1356
6 1 Polo Fun, type 9N model year 2002 to model year 2006 1356
6 2 Wheel allocation for Polo Fun, type 9N model year 2004 to model year 2006 1357
6 2 1 6 J x 15 1357
6 2 2 71/2 J x 17 1358
7 Polo Classic model year 1996 to model year 2002 1359
7 1 Polo Classic, type 6KV model year 1996 to model year 2002 1359
7 2 Wheel allocation for Polo Classic, type 6KV model year 1996 to model year 2002 1361
7 2 1 51/2 J x 13 1361
7 2 2 6 J x 14 1362
7 2 3 6 J x 15 1364
8 Polo estate model year 1998 to model year 2002 1366
8 1 Polo estate type 6KV model year 1998 to model year 2002 1366
8 2 Wheel allocation for Polo estate type 6KV model year 1998 to model year 2002 1368
8 2 1 51/2 J x 13 1368
8 2 2 6 J x 14 1369
8 2 3 6 J x 15 1371
9 Polo saloon/sedan model year 2004 to model year 2005 1373
9 1 Polo saloon/sedan, type 9N model year 2004 to model year 2005 1373
9 2 Wheel allocation for Polo saloon/sedan, type 9N model year 2004 to model year 2005 1375
9 2 1 5 J x 14 1375
9 2 2 6 J x 14 1375
9 2 3 6 J x 15 1377
9 2 4 61/2 J x 16 1379
10 Golf model year 1992 to model year 1998 1381
10 1 Golf type 1HX0, Golf Syncro 1HX1, Golf type 1H 1381
10 2 Wheel allocation for Golf type 1HX0, Golf Syncro 1HX1, Golf type 1H 1384
10 2 1 51/2 J x 13 1385
10 2 2 6 J x 14 1386
10 2 3 6 J x 15 1390
10 2 4 61/2 J x 15 1394
10 2 5 7 J x 16 1398
11 Golf model year 1998 to model year 2004, Golf R32, Golf Anniversary GTI 1399
11 1 Golf, Golf 4Motion, type 1J model year 1998 to model year 2004 1399
11 2 Wheel allocation for Golf, Golf 4Motion, type 1J model year 1998 to model year 2004 1402
11 2 1 6 J x 14 1402
11 2 2 6 J x 15 1403
11 2 3 51/2 J x 16 1408
11 2 4 61/2 J x 16 1409
11 2 5 7 J x 17 1415
11 2 6 71/2 J x 17 1418
11 3 Conditions for fitting 17″ wheels and tyres to Golf model year 1998 to model year 2004 1418
11 4 Golf R32, type 1J model year 2003 to model year 2005 1419
11 5 Wheel allocation for Golf R32, type 1J model year 2003 to model year 2005 1420
11 5 1 51/2 J x 17 1420
11 5 2 71/2 J x 17 1421
11 5 3 71/2 J x 18 1422
11 6 Golf Anniversary GTI, type 1J model year 2002 1422
11 7 Wheel allocation for Golf Anniversary GTI, type 1J model year 2002 1423
11 7 1 51/2 J x 16 1423
11 7 2 61/2 J x 16 1424
11 7 3 7 J x 17 1426
11 7 4 71/2 J x 18 1428
11 8 Conditions for fitting 17″ and 18″ wheels and tyres of Golf Anniversary GTI 1429
12 Golf from model year 2004 1431
12 1 Golf, Golf 4Motion, type 1K model year 2004 to model year 2006 1431
12 2 Wheel allocation for Golf, Golf 4Motion, type 1K model year 2004 to model year 2006 1433
12 2 1 6 J x 15 1433
12 2 2 61/2 J x 15 1434
12 2 3 6 J x 16 1435
12 2 4 61/2 J x 16 1436
12 2 5 7 J x 17 1438
12 2 6 71/2 J x 17 1441
12 2 7 71/2 J x 18 1441
12 3 Golf GTI, type 1K model year 2005 to model year 2006 1442
12 4 Wheel allocation for Golf GTI, type 1K model year 2005 to model year 2006 1443
12 4 1 6 J x 16 1443
12 4 2 61/2 J x 16 1444
12 4 3 6 J x 17 1445
12 4 4 7 J x 17 1446
12 4 5 71/2 J x 17 1449
12 4 6 71/2 J x 18 1449
13 Golf Plus from model year 2005 1451
13 1 Golf Plus, type 1KP model year 2005 to model year 2006 1451
13 2 Wheel allocation for Golf Plus, type 1KP model year 2005 to model year 2006 1453
13 2 1 6 J x 15 1453
13 2 2 61/2 J x 15 1454
13 2 3 6 J x 16 1455
13 2 4 61/2 J x 16 1456
13 2 5 7 J x 17 1458
13 2 6 71/2 J x 18 1461
14 Golf estate model year 1994 to model year 1998 1463
14 1 Golf estate type 1HX0, Golf estate Syncro type 1HX1, Golf estate type 1H 1463
14 2 Wheel allocation for Golf estate type 1HX0, Golf estate Syncro type 1HX1, Golf estate type 1H 1466
14 2 1 51/2 J x 13 1466
14 2 2 6 J x 14 1467
14 2 3 6 J x 15 1472
14 2 4 61/2 J x 15 1476
15 Golf estate model year 1999 to model year 2006, Bora estate model year 1999 to model year 2005 1477
15 1 Golf estate, Golf estate 4Motion, Bora estate, Bora estate 4Motion, type 1J 1477
15 2 Wheel allocation for Golf estate, Golf estate 4Motion, Bora estate, Bora estate 4Motion, type 1J 1480
15 2 1 6 J x 15 1480
15 2 2 51/2 J x 16 1484
15 2 3 61/2 J x 16 1485
15 2 4 7 J x 17 1491
15 2 5 71/2 J x 17 1494
15 3 Conditions for fitting 17″ wheels and tyres 1495
16 Golf cabriolet model year 1994 to model year 1997 1497
16 1 Golf cabriolet type 1EX0 model year 1994 to model year 1997 1497
16 2 Wheel allocation for Golf cabriolet, type 1EX0 from model year 1994 to model year 1997 1498
16 2 1 6 J x 14 1499
16 2 2 6 J x 15 1500
16 2 3 61/2 J x 16 1501
17 Golf cabriolet model year 1998 to model year 2002 1503
17 1 Golf cabriolet; type 1E from model year 1998 to model year 2002 1503
17 2 Wheel allocation for Golf cabriolet; type 1E from model year 1998 to model year 2002 1504
17 2 1 6 J x 14 1504
17 2 2 6 J x 15 1507
17 2 3 61/2 J x 16 1509
18 Vento from model year 1992 to model year 1998 1510
18 1 Vento; type 1HX0, 1H 1510
18 2 Wheel allocation for Vento; type 1HX0, 1H 1512
18 2 1 51/2 J x 13 1512
18 2 2 6 J x 14 1514
18 2 3 6 J x 15 1517
18 2 4 61/2 J x 15 1520
19 Bora model year 1999 to model year 2005 1526
19 1 Bora, Bora 4Motion, type 1J model year 1999 to model year 2005 1526
19 2 Wheel allocation for Bora, Bora 4Motion, type 1J model year 1999 to model year 2005 1529
19 2 1 6 J x 15 1529
19 2 2 51/2 J x 16 1533
19 2 3 61/2 J x 16 1534
19 2 4 7 J x 17 1540
19 2 5 71/2 J x 17 1543
19 3 Conditions for fitting 17″ wheels and tyres 1544
20 Jetta from model year 2006 1546
20 1 Jetta, type 1KM from model year 2006 1546
20 2 Wheel allocation for Jetta, type 1KM from model year 2006 1548
20 2 1 6 J x 15 1548
20 2 2 61/2 J x 15 1549
20 2 3 6 J x 16 1549
20 2 4 61/2 J x 16 1550
20 2 5 7 J x 17 1552
21 New Beetle from model year 1999 1556
21 1 New Beetle, type 9C model year 1999 to model year 2006 1556
21 2 Wheel allocation for New Beetle, type 9C model year 1999 to model year 2006 1559
21 2 1 6 J x 15 1559
21 2 2 51/2 J x 16 1562
21 2 3 61/2 J x 16 1563
21 2 4 7 J x 17 1568
21 2 5 71/2 J x 17 1571
21 3 Conditions for fitting 17″ wheels and tyres 1572
22 New Beetle Cabriolet from model year 2003 1574
22 1 New Beetle Cabriolet, type 1Y, model year 2003 to model year 2006 1574
22 2 Wheel allocation for New Beetle Cabriolet, type 1Y model year 2003 to model year 2006 1576
22 2 1 6 J x 15 1576
22 2 2 51/2 J x 16 1579
22 2 3 61/2 J x 16 1580
22 2 4 7 J x 17 1584
22 2 5 71/2 J x 17 1588
22 3 Conditions for fitting 17″ wheels and tyres 1588
23 New Beetle RSi 1590
23 1 New Beetle RSi, type 9CR from model year 2001 1590
23 2 Wheel allocation for New Beetle RSi, type 9CR from model year 2001 1591
23 2 1 7 J x 16 1591
23 2 2 9 x 18 1592
24 Touran from model year 2003 1593
24 1 Touran, type 1T, model year 2003 to model year 2006 1593
24 2 Wheel allocation for Touran, type 1T model year 2003 to model year 2006 1596
24 2 1 6 J x 15 1596
24 2 2 61/2 J x 15 1597
24 2 3 6 J x 16 1598
24 2 4 61/2 J x 16 1599
24 2 5 7 J x 17 1601
25 Passat model year 1994 to model year 1997 1602
25 1 Passat, type 35l model year 1994 to model year 1997 1602
25 2 Wheel allocation for Passat, type 35l model year 1994 to model year 1997 1604
25 2 1 6 J x 14 1604
25 2 2 6 J x 15 1607
26 Passat model year 1997 to model year 2006 1612
26 1 Passat, Passat estate, type 3B model year 1997 to model year 2000 1612
26 2 Passat, Passat estate, type 3B model year 1997 to model year 2000 1614
26 2 1 6 J x 15 1614
26 2 2 7 J x 15 1616
26 2 3 7 J x 16 1617
26 3 Passat, Passat estate, type 3BG model year 2001 to model year 2006 1618
26 4 Wheel allocation for Passat, Passat estate, type 3BG model year 2001 to model year 2006 1620
26 4 1 6 J x 15 1620
26 4 2 7 J x 15 1621
26 4 3 6 J x 16 1623
26 4 4 7 J x 16 1624
26 4 5 7 J x 17 1626
26 5 Passat W8 4Motion, type 3BS model year 2002 to model year 2005 1627
26 6 Wheel allocation for Passat W8 4Motion, type 3BS model year 2002 to model year 2005 1628
26 6 1 7 J x 16 1629
26 6 2 6 J x 17 1629
26 6 3 71/2 J x 17 1630
26 7 Passat Protect, type 3BL model year 2002 to model year 2005 1630
26 8 Wheel allocation for Passat Protect, type 3BL model year 2002 to model year 2005 1631
26 8 1 6 J x 16 1632
26 8 2 7 J x 16 1632
27 Passat from model year 2006 1634
27 1 Passat, type 3C from model year 2006 1634
27 2 Wheel allocation for Passat, type 3C from model year 2006 1636
27 2 1 61/2 J x 16 1637
27 2 2 7 J x 16 1637
27 2 3 6 J x 17 1639
27 2 4 71/2 J x 17 1639
27 2 5 8 J x 18 1642
28 Phaeton from model year 2003 1644
28 1 Phaeton, type 3D, model year 2003 to model year 2006 – short and long wheelbase 1644
28 2 Wheel allocation for Phaeton, type 3D model year 2003 to model year 2006 – short and long wheelbase 1646
28 2 1 71/2 J x 16 1647
28 2 2 71/2 J x 17 1647
28 2 3 71/2 J x 18 1649
28 2 4 81/2 J x 18 1649
28 2 5 81/2 J x 19 1651
28 2 6 9 J x 19 1651
29 Sharan from model year 1996 1652
29 1 Sharan, Sharan Syncro, type 7M model year 1996 to model year 2000 1652
29 2 Wheel allocation for Sharan, Sharan Syncro Type 7M model year 1996 to model year 2000 1655
29 2 1 6 J x 15 1655
29 2 2 7 J x 15 1655
29 2 3 7 J x 16 1656
29 3 Sharan, Sharan 4Motion, type 7M model year 2001 1657
29 4 Wheel allocation for Sharan, Sharan 4Motion, type 7M model year 2001 1659
29 4 1 6 J x 15 1659
29 4 2 7 J x 15 1660
29 4 3 6 J x 16 1661
29 4 4 7 J x 16 1662
29 5 Sharan, Sharan 4Motion, type 7M model year 2002 to model year 2006 1665
29 6 Wheel allocation for Sharan, Sharan 4Motion, type 7M model year 2002 to model year 2006 1667
29 6 1 6 J x 16 1667
29 6 2 7 J x 16 1668
29 6 3 7 J x 17 1671
30 Touareg from model year 2003 1672
30 1 Touareg, type 7L, model year 2003 to model year 2006 1672
30 2 Wheel allocation for Touareg, type 7L model year 2003 to model year 2006 1675
30 2 1 7 J x 16 1675
30 2 2 71/2 J x 17 1676
30 2 3 8 J x 18 1677
30 2 4 9 J x 19 1680
30 2 5 9 J x 20 1684
30 2 6 91/2 J x 20 1685
31 Breakdown set for VW Vehicles 1686
32 Temporary spare tyres and wheels for VW vehicles 1687
33 Approved makes of summer tyres for initial fitting 1690
33 1 Summer tyres for Lupo 3L from model year 1999 1690
33 2 Summer tyres for Lupo FSI from model year 1999 1690
33 3 Summer tyres for Lupo GTI from model year 1999 1690
33 4 Summer tyres for Lupo model year 1999 to model year 2005 1690
33 5 Summer tyres for Fox from model year 2006 1690
33 6 Summer tyres for Polo, model year 1995 to model year 2002 1691
33 7 Summer tyres for Polo from model year 2002 1692
33 8 Summer tyres for Polo saloon/sedan from model year 2004 1692
33 9 Summer tyres for Polo Fun from model year 2004 1693
33 10 Summer tyres for Polo Classic model year 1996 to model year 2002 1693
33 11 Summer tyres for Polo estate model year 1998 to model year 2002 1694
33 12 Summer tyres for Golf, Vento model year 1992 to model year 1998 1694
33 13 Summer tyres for Golf estate model year 1994 to model year 1998 1695
33 14 Summer tyres for Golf cabriolet model year 1994 to model year 1997 1695
33 15 Summer tyres for Golf, Golf 4Motion model year 1998 to model year 2004 1696
33 16 Summer tyres for Bora, Bora 4Motion model year 1999 to model year 2005 1697
33 17 Summer tyres for Golf estate, Golf estate 4Motion model year 1999 to model year 2006, Bora estate, Bora estate 4Motion model year 1999 to model year 2005 1698
33 18 Summer tyres for Golf R32 1698
33 19 Summer tyres for Golf Anniversary GTI 1699
33 20 Summer tyres for Golf Cabriolet, model year 1998 to model year 2002 1699
33 21 Summer tyres for New Beetle from model year 1999 1700
33 22 Summer tyres for New Beetle Cabriolet from model year 2003 1701
33 23 Summer tyres for New Beetle RSi 1702
33 24 Summer tyres for Golf from model year 2004 1702
33 25 Summer tyres for Golf GTI from model year 2005 1703
33 26 Summer tyres for Golf Plus from model year 2005 1703
33 27 Summer tyres for Jetta from model year 2006 1704
33 28 Summer tyres for Touran from model year 2003 1704
33 29 Summer tyres for Passat model year 1994 to model year 1997 1705
33 30 Summer tyres for Passat model year 1997 to model year 2006 1705
33 31 Summer tyres for Passat W8 1706
33 32 Summer tyres for Passat Protect 1706
33 33 Summer tyres for Passat from model year 2006 1706
33 34 Summer tyres for Phaeton from model year 2003 1707
33 35 Summer tyres for Sharan from model year 1996 1707
33 36 Summer tyres for Touareg from model year 2003 1708
34 Approved makes of all-season tyres for initial fitting 1709
34 1 All-season tyres for Lupo, model year 1999 to model year 2005 1709
34 2 All-season tyres Polo model year 1995 to model year 2002 1709
34 3 All-season tyres from model year 2002 1709
34 4 Summer tyres for Polo saloon/sedan from model year 2004 1709
34 5 All-season tyres Golf, Vento model year 1992 to model year 1998 1709
34 6 All-season tyres Golf estate model year 1994 to model year 1998 1709
34 7 All-season tyres Golf cabriolet model year 1994 to model year 1997 1710
34 8 All-season tyres Golf, Golf 4Motion model year 1998 to model year 2004 1710
34 9 All-season tyres Bora, Bora 4Motion model year 1999 to model year 2005 1710
34 10 All-season tyres Golf estate, Golf estate 4Motion model year 1999 to model year 2006, Bora estate, Bora estate 4Motion model year 1999 to model year 2005 1711
34 11 All-season tyres Golf cabriolet model year 1998 to model year 2002 1711
34 12 All-weather tyres New Beetle from model year 1999 1711
34 13 All-weather tyres New Beetle Cabriolet from model year 2003 1711
34 14 All-weather tyres Golf from model year 2004 1712
34 15 All-season tyres for Golf Plus from model year 2005 1712
34 16 All-season tyres for Jetta from model year 2006 1712
34 17 All-weather tyres Touran from model year 2003 1713
34 18 All-season tyres for Passat, model year 1997 to model year 2006 1713
34 19 All-season tyres for Passat W8 1713
34 20 All-weather tyres Passat from model year 2006 1713
34 21 All-weather tyres Phaeton from model year 2003 1714
34 22 All-weather tyres Touareg from model year 2003 1714
35 Approved makes of winter tyres for initial fitting 1715
35 1 Winter tyres for Lupo 3L from model year 1999 1715
35 2 Winter tyres for Lupo FSI from model year 1999 1715
35 3 Winter tyres for Lupo GTI from model year 1999 1715
35 4 Winter tyres Lupo model year 1999 to model year 2005 1715
35 5 Winter tyres for Fox from model year 2006 1715
35 6 Winter tyres for Polo model year 1995 to model year 2002 1716
35 7 Winter tyres Polo from model year 2002 1716
35 8 Summer tyres for Polo saloon/sedan from model year 2004 1716
35 9 Summer tyres for Polo Fun from model year 2004 1717
35 10 Winter tyres Polo Classic model year 1996 to model year 2002 1717
35 11 Winter tyres Polo estate model year 1998 to model year 2002 1717
35 12 Winter tyres Golf, Vento model year 1992 to model year 1998 1718
35 13 Winter tyres Golf estate model year 1994 to model year 1998 1718
35 14 Winter tyres Golf cabriolet model year 1994 to model year 1997 1718
35 15 Winter tyres Golf, Golf 4Motion model year 1998 to model year 2004 1719
35 16 Winter tyres Bora, Bora 4Motion model year 1999 to model year 2005 1719
35 17 Winter tyres Golf estate, Golf estate 4Motion model year 1999 to model year 2006, Bora estate, Bora estate 4Motion model year 1999 to model year 2005 1720
35 18 Winter tyres for Golf R32 1720
35 19 Winter tyres for Golf Anniversary GTI 1720
35 20 Winter tyres Golf cabriolet model year 1998 to model year 2002 1720
35 21 Winter tyres New Beetle from model year 1999 1721
35 22 Winter tyres New Beetle Cabriolet from model year 2003 1721
35 23 Winter tyres for New Beetle RSi 1722
35 24 Winter tyres Golf from model year 2004 1722
35 25 Winter tyres for Golf GTI from model year 2005 1722
35 26 Winter tyres for Golf Plus from model year 2005 1722
35 27 Winter tyres for Jetta from model year 2006 1722
35 28 Winter tyres Touran from model year 2003 1723
35 29 Winter tyres for Passat model year 1994 to model year 1997 1723
35 30 Winter tyres for Passat model year 1997 to model year 2006 1723
35 31 Winter tyres for Passat W8 1724
35 32 Winter tyres for Passat Protect 1724
35 33 Winter tyres Passat from model year 2006 1724
35 34 Winter tyres Phaeton from model year 2003 1724
35 35 Winter tyres Sharan from model year 1996 1725
35 36 Winter tyres Touareg from model year 2003 1725
36 Approved makes of offroad tyres for initial fitting 1726
36 1 Offroad tyres for Touareg from model year 2003 1726
D4B802605A6 General information Paint passenger vehicles 1727
00 – Technical data 1733
1 Safety information 1733
1 1 Safety precautions when painting natural gas-powered vehicles 1733
1 2 Safety precautions when painting electric drive vehicles 1734
2 General information 1735
2 1 Paintwork structure of a factory finish 1735
2 2 Paint structure of service department finish 1738
2 2 1 Paintwork structure, base coat 1738
2 2 2 Paintwork structure, metallic effect 1741
2 3 Fundamental approach to dealing with areas sanded through to the substrate (bare metal surface) 1743
2 4 Reduced paint structure in engine compartment and inside of bonnet 1743
2 5 Instructions for work on underbody and stone chip protection 1743
2 6 Work instruction for window flange area 1745
2 7 Pre-treatment of bonded surfaces when renewing laser-welded roofs 1747
2 8 Corrosion protection measures for wing surface in contact with wheel housing liner 1751
2 9 Notes on treating corroded fold areas 1752
2 10 Corrosion protection for body components, add-on components and welded components 1754
2 11 Painting parking aid sensor 1755
2 12 ACC – Adaptive Cruise Control 1757
2 13 Instructions for painting bumper cover in area of lane change assist control unit 1757
3 Genuine products 1759
3 1 Paint products in customer service 1759
3 2 General application instructions for repair and painting systems 1760
3 2 1 Aqua Premium – application instructions for water-based products 1760
3 2 2 Setting gloss level of HS clear coats and HS top coats with matting additive 1763
3 2 3 Setting gloss level of 2-pack HS clear coats with 2-pack clear coat, matt 1773
3 2 4 Repair paintwork system for matt-finished vehicles 1775
3 2 5 Paintwork system for plastic components 1780
3 2 6 Aqua Premium system, blending system for 2-stage colours 1788
3 2 7 Aqua Premium system, blending system for 3-stage colours 1797
3 2 8 Aqua Premium system, product preparation for processing 1804
3 2 9 Aquaplus design and multi-colour painting 1811
3 2 10 Processing instructions for paint with limited hiding power 1816
3 3 Filler 1816
3 3 1 2-pack steel filler set 1816
3 3 2 2-pack fine filler 1820
3 3 3 2-pack fine filler, flexible 1824
3 3 4 2-pack spray filler 1827
3 3 5 2-pack IR premium filler 1833
3 3 6 2-pack epoxy resin filler 1838
3 4 Priming metal 1842
3 4 1 1-pack anti-corrosion wash primer 1842
3 4 2 1-pack wash primer 1847
3 4 3 2-pack wash primer 1852
3 5 Priming plastic materials 1858
3 5 1 Adhesion promoter (transparent) 1858
3 6 Surfacer 1862
3 6 1 2-pack HS Vario surfacer 1862
3 6 2 2-pack HS premium surfacer 1872
3 6 3 2-pack HS Performance surfacer 1881
3 6 4 2-pack primer surfacer for plastics 1890
3 6 5 2-pack HS wet-on-wet surfacer 1896
3 6 6 2-pack base filler, professional 1906
3 7 Top coats 1923
3 7 1 2-pack HS top coat 1923
3 7 2 Aquaplus system, uni (solid-colour) and metallic colours 1932
3 7 3 Aquaplus system (pearlescent and heliochrome) 1940
3 7 4 Aquaplus blending system 1948
3 7 5 Aqua Premium system 1954
3 7 6 Aqua Premium blending system 1967
3 7 7 Aqua Premium system (painting rims) 1974
3 8 Clear coats 1983
3 8 1 2-pack HS clear coat 1983
3 8 2 2-pack MS matt clear coat 1990
3 8 3 2-pack HS Vario clear coat 1996
3 8 4 2-pack HS optimum clear coat 2004
3 8 5 2-pack HS optimum plus clear coat 2010
3 8 6 2-pack HS brilliant clear coat 2015
3 8 7 2-pack HS brilliant plus clear coat 2020
3 8 8 2-pack HS Performance clear coat 2026
3 8 9 Blender 2032
3 9 Hardener 2037
3 9 1 2-pack HS hardener 2037
3 9 2 2-pack VHS hardeners and 2-pack VHS Performance hardeners 2041
3 9 3 Hardener for 2-pack primer surfacer 2045
3 9 4 Aqua Premium hardener 2045
3 10 Thinners 2046
3 10 1 2-pack thinner 2046
3 10 2 HS spot thinner 2049
3 10 3 Demineralised water 2051
3 11 Anti-corrosion materials 2052
3 11 1 Anti-corrosion wax 2052
3 11 2 Cavity sealant 2053
3 11 3 Anti-corrosion wax (in aerosol can) 2056
3 12 Underseal 2057
3 12 1 Permanent underseal -D 314 D36 M2-, grey 2057
3 12 2 Permanent underseal -D 314 D37 M2-, black 2060
3 12 3 Permanent underseal -D 314 D38 M2-, light 2063
3 12 4 Underseal -D 314 D39 A3-, black 2066
3 13 Stone deflector 2068
3 13 1 Stone chip guard -AKR 311 KD1 05- 2068
3 13 2 Stone chip guard -AKR 311 KD1 10- 2070
3 14 Wax-based underseal 2077
3 14 1 Wax-based underseal -D 316 D38 A2- 2077
3 14 2 Wax-based underseal -D 316 000 A1- 2079
3 14 3 Spray wax -D 322 100 M2- 2081
3 15 Sealing materials 2082
3 15 1 Polyurethane adhesive sealant (bonding compound) 2082
3 15 2 Sprayable sealant 2085
3 15 3 Adhesive sealant 2088
3 16 Cleaning agents 2090
3 16 1 Silicone remover 2090
3 16 2 Cleaner for plastics 2092
3 16 3 Cleaner for plastics, anti-static 2093
3 16 4 Industrial dirt remover 2093
3 17 SprayMax system 2095
3 17 1 1-pack anti-corrosion primer 2095
3 17 2 1-pack test paint 2099
3 17 3 1-pack clear coat 2102
3 17 4 1-pack wash primer 2105
3 17 5 1-pack Fill Clean spray can -LLS MAX 099-/1-pack Fill Clean spray can -LLS MAX 100- – Aquaplus system 2110
3 17 6 1-pack fill clean spray can -LLS MAX 112-, Aqua Premium system 2117
3 17 7 2-pack surfacer 2125
3 17 8 2-pack HS Performance surfacer 2132
3 17 9 2-pack clear coat 2140
3 17 10 2-pack epoxy primer surfacer 2145
3 17 11 2-pack wash primer 2151
3 17 12 Silicone remover -LLS MAX 007- 2157
3 17 13 Slow-drying silicone remover -LLS MAX 008- 2159
3 17 14 Blender 2162
3 17 15 Adhesion promoter 2164
3 18 Additional materials 2168
3 18 1 Matting additive -ALN 775 106- 2168
3 18 2 Matting additive -LVM 769 810 A2- 2175
3 18 3 Texture additive 2178
3 18 4 Blending additive for Aquaplus 2184
3 18 5 Additive for Aqua Premium 2185
4 Workshop equipment 2186
4 1 Tools 2186
4 1 1 Spray can filling device -VAS 6425- 2186
4 1 2 Paint thickness tester -VAS 6272- 2187
4 1 3 Paint thickness tester -VAS 6197- 2188
4 1 4 Paint thickness tester -VAS 5278- 2188
4 1 5 Stone chip tester -VAS 5102A- 2189
4 1 6 Pneumatic brush grinder set -VAS 6446- 2190
4 1 7 Brush grinder set -VAS 6776- 2190
4 1 8 Suction feed spray-gun -V A G 1538- 2192
4 1 9 Infrared heater -VAS 6873- 2193
4 1 10 Stand -VAS 6873/1- 2193
4 1 11 Infrared heater -VAS 6874- 2194
4 1 12 Infrared heater -VAS 6875- 2195
4 1 13 Infrared heater -VAS 6876- 2195
4 1 14 Infrared heater -VAS 6877- 2196
4 1 15 Infrared heater -VAS 6878- 2197
4 1 16 Infrared heater -VAS 6879- 2198
4 2 Tack cloths 2198
4 2 1 Tack cloth -VAS 6177- 2198
4 2 2 Buffing cloth, white -VAS 6176- 2199
K0051505220 Motronic injection and ignition system (4 Cyl engine) AQY 2200
Title 2200
Manual Repair Groups 2201
Technical Bulletin No 1 2379
Contents 2202
01-1 General to self-diagnosis 2204
01-1 -Features of self-diagnosis 2204
01-3 -Technical data of self-diagnosis 2205
01-5 -Connecting fault reader V A G 1551 and selecting engine electronics control unit 2206
01-10 Fault memory 2208
01-10 -Interrogating and erasing fault memory 2208
01-15 Fault table: V A G codes and SAE P0 codes 2211
01-29 Fault table: Fault codes P1176 P1851 2218
01-38 Final control diagnosis 2222
01-38 -Performing final control diagnosis 2222
01-51 Readiness code 2229
01-52 -Read-out readiness code 2229
01-54 -Generating readiness code 2230
01-66 Measured value blocks 2236
01-66 -Safety precautions 2236
01-66 -Read measured value block 2236
01-70 Evaluating measured value block, Display group numbers 000 009 -Basic functions- 2238
01-87 Evaluating measured value block, Display groups 010 029 -Ignition- 2247
01-98 Evaluating measured value block, Display group 030 049 -Lambda regulation- 2252
01-114 Evaluating measured value block, Display groups 050 069 -Speed regulation- 2260
01-123 Evaluating measured value block, Display group 070 079 -Reducing emissions- 2265
01-125 Evaluating measured value block, Display group 080 100 -Readiness code- 2266
24-1 Servicing injection system 2267
24-1 -Fitting locations overview 2267
24-5 -General notes on injection 2269
24-7 -Removing and installing parts of the injection system 2270
24-15 -Dismantling and assembling air cleaner 2274
24-16 -Dismantling and assembling intake manifold – lower part 2274
24-19 -Safety precautions 2276
24-21 -Rules for cleanliness 2277
24-22 -Technical data 2277
24-23 Checking components 2278
24-23 -Checking Lambda probe heating for Lambda probe before catalyst 2278
24-29 -Checking Lambda probe heater for Lambda probe after catalytic converter 2281
24-35 -Checking air mass meter 2284
24-39 -Checking throttle valve control part 2286
24-61 -Checking coolant temperature sender 2297
24-71 -Checking intake air temperature sender 2302
24-79 -Checking engine speed sender 2306
24-82 -Checking injectors 2307
24-92 -Checking fuel pressure regulator and holding pressure 2312
24-97 -Checking intake air system for leaks (unmetered air) 2315
24-101 Checking functions 2317
24-101 -Idling check 2317
24-107 -Adapting idling speed 2320
24-111 -Checking Lambda probe and Lambda regulation before catalytic converter 2322
24-122 -Checking Lambda probe and Lambda regulator after catalytic converter 2327
24-130 -Checking Lambda probe ageing Lambda probe 1 2331
24-134 -Checking engine operating mode 2333
24-138 Engine control unit 2335
24-138 -Checking control unit voltage supply 2335
24-144 -Procedure after voltage supply open circuit 2338
24-146 -Replacing engine control unit 2339
24-149 -Coding engine control unit 2341
24-152 -Matching engine control unit to throttle valve control part 2342
24-157 -Matching engine control unit to electronic immobilizer 2345
24-160 Checking additional signals 2346
24-160 -Checking speed signal 2346
24-164 -Checking air conditioner compressor signal 2348
24-169 -Checking ignition retardation during gear selection 2351
24-174 -Checking driving range signal 2353
24-179 -Checking data bus 2356
24-191 -Checking signal from clutch pedal switch 2362
24-193 -Checking signal from brake light switch and brake pedal switch 2363
28-1 Servicing ignition system 2365
28-1 -General notes on ignition system 2365
28-2 -Removing and installing parts of the ignition 2365
28-5 -Safety precautions 2367
28-6 -Test data, spark plugs 2367
28-7 -Checking Hall sender 2368
28-9 -Checking ignition coils with output stage 2369
28-15 -Checking knock sensor 2372
28-22 -Checking misfire recognition 2375
K0051505320 Direct injection and glow plug system with distributor pump 2391
01 – Self-diagnosis, Electrical check 2395
1 – Self-diagnosis 2395
1 1 – Self-diagnosis 2395
1 2 – Function 2395
1 3 – Technical data of self-diagnosis 2395
1 4 – Connecting fault reader V A G 1551 and selecting engine electronics control unit 2396
2 – Fault memory 2398
2 1 – Fault memory 2398
2 2 – Interrogating fault memory 2398
2 3 – Fault table 2399
2 4 – Erasing fault memory 2408
3 – Final control diagnosis 2410
3 1 – Final control diagnosis 2410
3 2 – Performing final control diagnosis 2410
4 – Measured value blocks 2414
4 1 – Measured value blocks 2414
4 2 – Safety precautions 2414
4 3 – Reading measured value block 2414
4 4 – Evaluating measured value blocks, at idling speed 2415
4 5 – Evaluating read measured value block, at full throttle 2422
23 – Mixture preparation, Injection 2427
1 – Servicing Diesel direct injection system 2427
1 1 – Servicing Diesel direct injection system 2427
1 2 – Safety precautions 2427
1 3 – Rules for cleanliness 2427
1 4 – Fitting locations overview 2428
1 5 – Servicing injection pump 2432
1 6 – Servicing intake manifold flap 2437
1 7 – Removing and installing injection pump 2439
1 8 – Dynamically checking and adjusting commencement of injection 2445
1 9 – Removing and installing injectors 2447
1 10 – Checking injectors 2449
1 11 – Renewing gasket on metering unit cover 2449
2 – Checking components and functions 2450
2 1 – Checking components and functions 2450
2 2 – Checking Diesel direct injection system voltage supply 2450
2 3 – Checking engine speed sender 2451
2 4 – Checking intake manifold pressure sender and altitude sender 2452
2 5 – Checking coolant temperature sender 2454
2 6 – Checking brake light switch and brake pedal switch 2456
2 7 – Checking clutch pedal switch 2457
2 8 – Checking intake manifold sender 2459
2 9 – Checking fuel temperature sender 2461
2 10 – Checking modulating piston movement sender and quantity adjuster 2463
2 11 – Checking needle lift sender 2466
2 12 – Checking injection timing control range 2467
2 13 – Checking charge pressure control 2469
2 14 – Checking air mass meter 2472
2 15 – Checking intake manifold change-over 2474
3 – Checking additional signals 2476
3 1 – Checking additional signals 2476
3 2 – Checking speed signal 2476
3 3 – Checking accelerator position sender 2478
3 4 – Additional signals 2479
3 5 – Checking accelerator pedal position sender 2479
3 6 – Checking gear change signal from automatic gearbox 2480
3 7 – Checking signals from/to air conditioning system 2481
3 8 – Checking cruise control system (CCS) 2483
4 – Replacing, coding and matching engine control unit 2485
4 1 – Replacing, coding and matching engine control unit 2485
4 2 – Replacing engine control unit 2485
4 3 – Coding engine control unit 2486
4 4 – Matching engine control unit to electronic immobilizer 2487
4 5 – Checking data bus 2488
28 – Glow plug system 2495
1 – Checking glow plug system 2495
1 1 – Checking glow plug system 2495
1 2 – Checking glow plugs 2495
K0051505720 Running gear axles steering 2497
00 – Technical data 2503
1 – Technical data 2503
1 1 – Technical data 2503
1 2 – Running gear 2503
1 3 – Steering 2503
1 4 – Wheels, tyres 2503
2 – General notes: 2505
2 1 – General notes: 2505
3 – Fastening subframe to body 2505
3 1 – Fastening subframe to body 2505
3 2 – Repair of damaged threads 2505
4 – Environmentally-friendly disposal of fluid-filled components 2506
4 1 – Environmentally-friendly disposal of fluid-filled components 2506
4 2 – Releasing gas from front gas-filled shock absorber 2506
4 3 – Releasing gas in rear gas-filled shock absorber 2507
4 4 – Draining the power-assisted steering box 2509
5 – Checking the shock absorber 2510
5 1 – Checking the shock absorber 2510
5 2 – Leaks in shock absorbers 2510
5 3 – Noises from shock absorbers 2511
5 4 – Checking the shock absorber when removed 2511
5 5 – Testing the shock absorber on the shock tester 2511
40 – Front suspension 2514
1 – Assembly overview of subframe 2514
1 1 – Assembly overview of subframe 2514
1 2 – Repairing thread in longitudinal member 2514
1 3 – Overview of components 2515
1 4 – Removing and installing anti-roll bar 2524
1 5 – Vehicle levelling sender in vehicles with automatic headlight range control 2529
1 6 – Checking lower ball joint 2533
1 7 – Removing and installing ball joint 2534
1 8 – Removing and installing wishbone 2537
1 9 – Replacing bonded rubber bushes for wishbone 2538
1 10 – Removing and installing subframe 2543
1 11 – Replacing subframe bushes 2547
2 – Assembly overview: Wheel bearing 2550
2 1 – Assembly overview: Wheel bearing 2550
2 2 – Drive shaft/wheel hub splines 2551
2 3 – Pressing out and pressing in front wheel bearing with wheel bearing housing fitted 2559
2 4 – Removing and installing wheel bearing housing 2566
2 5 – Pressing out and pressing in front wheel bearing with wheel bearing housing fitted 2570
3 – Assembly overview: Suspension strut 2575
3 1 – Assembly overview: Suspension strut 2575
3 2 – Removing and installing suspension strut/coil spring 2579
4 – Drive shafts 2585
4 1 – Drive shafts 2585
4 2 – Removing and installing drive shaft 2585
4 3 – Servicing drive shaft with constant velocity joint 2587
4 4 – Checking outer constant velocity joint 2597
4 5 – Checking inner constant velocity joint 2598
4 6 – Repairing drive shaft with inner tripod joint 2603
4 7 – Dismantling and assembling inner tripod joint 2612
42 – Rear suspension 2616
1 – Servicing rear axle (front-wheel drive vehicles) 2616
1 1 – Servicing rear axle (front-wheel drive vehicles) 2616
1 2 – Removing and installing rear axle 2616
1 3 – Assembly overview rear axle beam 2619
1 4 – Removing and installing bonded rubber bush 2627
1 5 – Removing and installing shock absorber/spring 2629
1 6 – Assembly overview of shock absorber on FWD vehicles 2633
1 7 – Vehicle levelling sender in vehicles with automatic headlight range control 2635
2 – Servicing wheel bearing 2636
2 1 – Servicing wheel bearing 2636
2 2 – Servicing wheel bearing, front-wheel drive vehicles 2636
2 3 – Removing and installing wheel bearing/wheel hub unit 2638
3 – Servicing rear axle (vehicles with four-wheel drive) 2641
3 1 – Servicing rear axle (vehicles with four-wheel drive) 2641
3 2 – Overview for rear axle with four-wheel drive 2642
3 3 – Removing and installing spring 2644
3 4 – Removing and installing shock absorber 2649
3 5 – Removing and installing anti-roll bar 2651
3 6 – Checking exhaust system for leaks 2655
3 7 – Assembly overview of spring and shock absorber in vehicles with four-wheel drive 2655
4 – Assembly overview of longitudinal and transverse link 2658
4 1 – Assembly overview of longitudinal and transverse link 2658
4 2 – Vehicle levelling sender in vehicles with automatic headlight range control 2664
4 3 – Pressing in and pressing out wheel bearing 2665
4 4 – Removing and installing bearing for longitudinal link 2671
4 5 – Removing and installing ball bearings 2674
4 6 – Removing and installing longitudinal link 2677
4 7 – Removing and installing transverse link 2681
5 – Assembly overview of subframe with axle drive 2689
5 1 – Assembly overview of subframe with axle drive 2689
5 2 – Removing and installing subframe 2692
5 3 – Removing and installing bonded rubber bush for subframe 2696
5 4 – Removing and installing bonded rubber bush for final drive 2699
6 – Servicing drive shaft 2702
6 1 – Servicing drive shaft 2702
6 2 – Removing and installing drive shaft 2702
6 3 – Servicing drive shaft with constant velocity joint 2705
44 – Wheels, Tyres, Wheel alignment 2714
1 – Wheels and tyres 2714
1 1 – Wheels and tyres 2714
1 2 – Balancing wheels on the vehicle 2714
1 3 – Instructions for changing/fitting wheels 2715
2 – Vehicle alignment 2716
2 1 – Vehicle alignment 2716
2 2 – General notes 2716
2 3 – Specified values for vehicle alignment, standard running gear 2717
2 4 – Specified values for vehicle alignment, sports running gear (PQZ) 2718
2 5 – Specified values for vehicle alignment for the New Beetle RSi 2720
2 6 – Test requirements: 2720
2 7 – Measuring procedure 2721
2 8 – Checking rear axle camber (FWD vehicles) 2723
2 9 – Adjusting rear axle camber (vehicles with four-wheel drive) 2723
2 10 – Centring rear axle toe (vehicles with front-wheel drive) 2723
2 11 – Adjusting toe at rear axle for vehicles with four-wheel drive 2724
2 12 – Adjusting front axle camber 2724
2 13 – Adjusting toe at front axle 2725
48 – Steering 2726
1 – Airbag, steering wheel, steering column 2726
1 1 – Airbag, steering wheel, steering column 2726
1 2 – Removing and installing driver’s airbag unit 2726
1 3 – Servicing steering wheel 2731
1 4 – Removing and installing steering column 2732
1 5 – Removing and installing steering lock housing 2740
1 6 – Checking steering column for damage 2741
1 7 – Assembly overview, cross member for steering column 2743
1 8 – Differing steering columns 2745
2 – Servicing power assisted steering 2749
2 1 – Servicing power assisted steering 2749
2 2 – Removing and installing power assisted steering box 2749
2 3 – Assembly overview, power steering box (LHD) 2754
2 4 – Assembly overview, power steering box (RHD) 2758
2 5 – Assembly overview, power assisted steering box with heat shield (vehicles with four-wheel drive) 2761
2 6 – Removing and installing track rod 2762
2 7 – Modified track rod ball joints 2764
2 8 – Modified track rods 2765
2 9 – Checking play, security and boots on tie rod ends 2766
2 10 – Determining central position on rack 2766
2 11 – Adjusting steering box 2766
3 – Vane pump, reservoir, hydraulic pipes 2767
3 1 – Vane pump, reservoir, hydraulic pipes 2767
3 2 – Checking vane pump delivery pressure 2767
3 3 – Removing and installing vane pump; models with low mounted vane pumps 2774
3 4 – Assembly overview: Vane pump with hydraulic pipes/hoses 2778
3 5 – Assembly overview for low-mounted vane pump 2784
K0051506020 General body repairs interior 2787
68 – Interior equipment 2795
1 Interior mirror 2795
1 1 Automatic anti-dazzle interior mirror 2795
1 1 1 Function diagram 2795
1 2 Removing and installing interior mirror 2796
1 2 1 Removing 2796
1 2 2 Installing 2797
2 Compartments, covers and trims 2798
2 1 Assembly overview – centre console ► 01 01 2798
2 2 Removing and installing centre console ► 01 01 2798
2 2 1 Removing 2799
2 2 2 Installing 2802
2 3 Removing and installing drink holder or ashtray in centre console ► 01 01 2802
2 4 Assembly overview – centre console 02 01 ► 04 03 2803
2 5 Removing and installing centre console 02 01 ► 04 03 2804
2 5 1 Removing 2804
2 5 2 Installing 2807
2 6 Removing rear ashtray from centre console 02 01 ► 04 03 2808
2 7 Removing drink holder 02 01 ► 2808
2 8 Assembly overview – centre console 05 03 ► and Cabriolet 2808
2 9 Removing and installing centre console 05 03 ► and Cabriolet 2810
2 9 1 Removing 2811
2 9 2 Installing 2813
2 10 Removing rear ashtray from centre console 05 03 ► and Cabriolet 2813
2 10 1 Installing 2813
2 11 Removing and installing armrest padding 05 03 ► and Cabriolet 2813
2 11 1 Installing 2814
2 12 Removing trim under centre of dash panel 2814
2 13 Removing glove compartment 2815
2 14 Removing and installing glove compartment lock cylinder 2815
2 14 1 Removing 2816
2 14 2 Installing 2816
2 15 Removing and installing glove compartment lid 2817
2 15 1 Removing 2817
2 15 2 Installing 2817
2 16 Removing footwell cover (driver side) 2817
2 17 Removing trim under steering column 2818
2 18 Removing spectacles compartment 2819
2 18 1 Spectacles compartment above windscreen (in roof liner) 2819
2 18 2 Spectacles compartment (in roof liner), driver side 2819
2 19 Removing front centre armrest 2820
2 20 Removing and installing armrest clip 2820
2 20 1 Removing 2820
2 20 2 Installing 2820
2 21 Removing sun visor 2821
2 22 Removing sun visor (Cabriolet) 2821
2 23 Removing plenum chamber inner cover 2821
2 24 Removing and installing centre console stowage net (Mexico) 2823
2 24 1 Removing 2823
2 24 2 Installing 2823
2 25 Removing and installing trim of steering wheel clip 2823
2 25 1 Removing 2823
2 25 2 Installing 2824
3 Grab handles 2826
3 1 Removing grab handle (dash panel) 2826
3 2 Removing grab handle with mobile telephone retainer (dash panel) 2826
3 3 Removing grab handle (roof) 2827
3 4 Removing grab straps 2827
4 Sill mouldings 2828
4 1 Assembly overview – sill moulding 2828
4 2 Removing and installing sill moulding 2829
4 2 1 Removing 2829
4 2 2 Installing 2829
4 3 Assembly overview – sill moulding (Cabriolet) 2830
4 4 Removing and installing sill moulding (Cabriolet) 2831
4 4 1 Removing 2831
4 4 2 Installing 2831
69 – Passenger protection 2833
1 Seat belts 2833
1 1 Safety regulations for belt tensioners 2833
1 2 Assembly overview – front seat belt with belt tensioner 2833
1 3 Assembly overview – rear seat belts (Cabriolet) 2835
1 4 Assembly overview – front seat belt with belt tensioner (Cabriolet) 2835
1 5 Assembly overview – rear seat belt (Cabriolet) 2837
2 Seat belts – checking 2838
2 1 Installing and retrofitting LATCH system “”Lower Anchors and Tethers for Children (child seat securing system) (USA) 2841
2 1 1 Checking LATCH system (Lower Anchors and Tethers for Children = child seat securing system) 2841
2 1 2 LATCH system “Lower Anchors and Tethers for Children” (USA) 2842
3 Automatic roll-over protection (Cabriolet) 2843
3 1 Safety precautions and notes for working on automatic roll-over protection 2843
3 2 Assembly overview – automatic roll-over protection 2844
3 3 Removing and installing automatic roll-over protection 2846
3 3 1 Removing 2846
3 3 2 Installing 2847
3 4 Lowering automatic roll-over protection 2848
3 5 Lowering roll-over protection (Cabriolet roof closed) 2849
3 6 Removing and installing impact carrier 2850
4 Airbag 2851
4 1 Tools 2851
4 2 Detailed overview – airbag 2851
4 3 Component overview (Cabriolet) 2853
4 4 Safety precautions and notes when working on airbag 2854
4 5 Renewing airbag units following an accident 2855
4 5 1 Accident involving triggering of airbag 2856
4 5 2 Accident not involving triggering of airbag 2856
4 6 Assembly overview – driver airbag unit 2857
4 7 Removing and installing driver airbag unit 2858
4 7 1 Removing 2858
4 7 2 Installing 2860
4 8 Assembly overview – front passenger airbag unit 2861
4 9 Removing and installing front passenger airbag unit 2861
4 10 Assembly overview – steering wheel 2865
4 11 Removing and installing steering wheel 2865
4 11 1 Removing 2865
4 11 2 Installing 2866
4 12 Removing and installing return spring with slip ring 2866
4 12 1 Models with no ESP 2866
4 12 2 Models with ESP 2867
4 12 3 Continuation for all vehicles 2867
4 13 Removing and installing airbag control unit -J234- 2868
4 14 Assembly overview – side airbag for driver/front passenger side 2868
4 15 Removing and installing side airbag on driver/front passenger side 2869
4 16 Assembly overview – side airbag on driver/front passenger side, from 05 03 2872
4 17 Removing and installing side airbag for driver/front passenger side, from 05 03 2872
4 18 Assembly overview – side airbag sensor for driver/front passenger side 2875
4 19 Removing and installing side airbag sensor for driver/front passenger side 2875
4 20 Assembly overview – side airbag sensor for driver/front passenger side, from 05 03 2878
4 21 Removing and installing side airbag sensor for driver/front passenger side, from 05 03 (in lower part of B-pillar) 2878
4 22 Assembly overview – side airbag sensor for driver/front passenger side (Cabriolet) 2881
4 23 Removing and installing side airbag sensor for driver/front passenger side (Cabriolet) 2881
4 24 Assembly overview – driver airbag crash sensor -G283- and front passenger airbag crash sensor -G284- 2883
4 25 Removing and installing driver airbag crash sensor -G283- and front passenger airbag crash sensor -G284- 2883
4 26 Removing and installing front passenger airbag deactivation switch -E224-, 05 03 > 2885
4 26 1 Removing 2885
4 26 2 Installing 2885
4 27 Removing and installing front passenger airbag deactivation switch -E224- (Cabriolet) 2885
4 27 1 Removing 2885
4 27 2 Installing 2886
4 28 Assembly overview – underside of Passive Occupant Detection System (PODS), (USA) 2886
4 29 Assembly overview – upper side of Passive Occupant Detection System (PODS), (USA) 2887
4 30 Removing and installing Passive Occupant Detection System (PODS), (USA) 2887
4 30 1 Removing 2887
4 30 2 Installing 2891
70 – Trim, insulation 2893
1 Dash panel 2893
1 1 Tools 2893
1 2 Removing and installing dash panel 2893
1 2 1 Removing 2893
1 2 2 If fitted 2897
1 2 3 Models with no mobile telephone holder 2899
1 2 4 Models with mobile telephone holder 2899
1 2 5 Continued for all vehicles 2900
1 2 6 Installing 2902
2 Door trim 2904
2 1 Tools 2904
2 2 Assembly overview – front door trim 2904
2 3 Removing and installing front door trim 2905
2 3 1 Removing 2905
2 3 2 Removing window crank 2906
2 3 3 Installing 2906
2 4 Assembly overview – front door trim (Cabriolet) 2907
2 5 Removing and installing front door trim (Cabriolet) 2908
2 5 1 Removing 2908
2 5 2 Installing 2909
2 6 Repairing door trim 2909
2 7 Assembly overview – door trim 2910
2 8 Removing and installing upper part (shoulder) of door trim 2911
2 8 1 Removing 2911
2 8 2 Installing 2911
2 8 3 Replacing net and door storage compartment 2912
2 9 Assembly overview – door trim (Cabriolet) 2914
2 10 Removing and installing upper part (shoulder) of door trim (Cabriolet) 2915
2 10 1 Removing 2915
2 10 2 Installing 2915
3 Pillar and side trims 2916
3 1 Assembly overview – upper A-pillar trim 2916
3 2 Removing and installing upper A-pillar trim 2916
3 3 Removing and installing lower A-pillar trim 2917
3 3 1 Removing driver side 2917
3 3 2 Installing driver side 2918
3 3 3 Removing front passenger side 2918
3 3 4 Installing front passenger side 2918
3 4 Assembly overview – B-pillar trim 2918
3 5 Removing and installing B-pillar trim 2919
3 6 Assembly overview – C-pillar trim 2921
3 7 Removing and installing C-pillar trim 2921
3 8 Assembly overview – side trim 2923
3 9 Removing and installing side trim 2923
4 Pillar and side trims (Cabriolet) 2925
4 1 Assembly overview – A-pillar upper trim 2925
4 2 Removing and installing upper A-pillar trim 2925
4 3 Assembly overview – side trim 2927
4 4 Removing and installing side trim 2927
4 5 Assembly overview – side panel trim on Cabriolets with motorised folding roof, with large roof flaps and flap control motor 2930
4 6 Repairing side panel 2931
4 7 Assembly overview – flap module 2932
4 8 Removing and installing push rod 2933
4 8 1 Removing 2933
4 8 2 Installing 2933
4 9 Removing and installing large roof flap 2934
4 9 1 Removing 2934
4 9 2 Installing 2934
4 10 Removing and installing Bowden cable 2934
4 10 1 Removing 2934
4 10 2 Installing 2934
4 11 Removing and installing small roof flap 2935
4 11 1 Removing 2935
4 11 2 Installing 2935
4 12 Removing and installing flap positioning motor 2935
4 12 1 Removing 2935
4 12 2 Installing 2936
4 13 Removing and installing lever 2936
4 13 1 Removing 2936
4 13 2 Installing 2936
4 14 Removing and installing large and small trim 2936
4 14 1 Removing large cover 2936
4 14 2 Installing 2936
4 14 3 Removing smaller trim 2937
4 14 4 Installing 2937
4 15 Adjusting large and small trim 2937
4 15 1 Adjusting gap/shut line A 2937
4 15 2 Adjusting gap/shut line B 2938
4 15 3 Adjusting gap/shut lines C and D 2938
4 15 4 Adjusting height of trim A 2939
4 15 5 Adjusting height of trim B 2939
4 16 Assembly overview – Cabriolets with manually operated folding roof and motorised folding roof with no large roof flaps and flap control motor 2940
4 17 Repairing side panel 2941
4 17 1 Removing and installing shoulder (upper part) of door trim 2941
4 18 Assembly overview – flap module 2942
4 19 Removing and installing Bowden cable 2943
4 19 1 Removing 2943
4 19 2 Installing 2943
4 20 Removing and installing small roof flap 2943
4 20 1 Removing 2943
4 20 2 Installing 2943
4 21 Removing and installing flap positioning motor 2944
4 21 1 Removing 2944
4 21 2 Installing 2944
4 22 Removing and installing small trim 2944
4 22 1 Removing 2944
4 22 2 Installing 2944
4 23 Adjusting small trim 2944
4 23 1 Adjusting gap/shut lines C and D 2945
4 23 2 Adjusting height of trim B 2945
4 24 Removing and installing roll-over protection 2946
4 24 1 Removing 2947
4 24 2 Installing 2947
4 25 Removing and installing rear shelf 2948
4 25 1 Removing 2948
4 25 2 Installing 2948
4 26 Assembly overview water strip 2949
4 27 Removing and installing water strip 2949
4 27 1 Removing 2949
4 27 2 Installing 2950
5 Luggage compartment trims 2952
5 1 Assembly overview – luggage compartment side trim on left 2952
5 2 Assembly overview – luggage compartment side trim on right 2953
5 3 Removing and installing luggage compartment side trim on left or right 2953
5 4 Assembly overview – load sill cover 2955
5 5 Removing and installing load sill cover 2955
5 6 Assembly overview – luggage compartment trim on left (Cabriolet) 2957
5 7 Assembly overview – luggage compartment trim on right (Cabriolet) 2958
5 8 Removing and installing luggage compartment side trim on left or right (Cabriolet) 2958
5 9 Removing and installing luggage compartment side trim (Cabriolet) 2959
5 9 1 Removing 2959
5 9 2 Installing 2960
5 10 Assembly overview – load sill cover (Cabriolet) 2960
5 11 Removing and installing load sill cover (Cabriolet) 2961
5 12 Assembly overview – rear bulkhead trim (Cabriolet) 2963
5 13 Removing and installing rear bulkhead trim (Cabriolet) 2964
5 13 1 Removing 2964
5 13 2 Installing 2965
6 Tailgate/boot lid trim 2966
6 1 Assembly overview – rear lid upper trim 2966
6 2 Removing and installing rear lid upper trim 2966
6 2 1 Removing 2966
6 2 2 Installing 2967
6 3 Assembly overview – rear lid lower trim 2968
6 4 Removing and installing rear lid lower trim 2968
6 5 Assembly overview – rear lid lower trim 2970
6 6 Removing and installing rear lid lower trim 2970
6 6 1 Removing 2970
6 6 2 Installing 2972
6 7 Assembly overview – luggage compartment lid trim (Cabriolet) 2972
6 8 Removing and installing luggage compartment lid trim (Cabriolet) 2973
6 8 1 Removing 2973
6 8 2 Installing 2975
6 9 Assembly overview – luggage compartment lid trim (Cabriolet for USA) 2975
6 10 Removing and installing luggage compartment lid trim (Cabriolet for USA) 2976
6 10 1 Removing 2976
6 10 2 Installing 2978
7 Roof trims 2979
7 1 Tools 2979
7 2 Removing and installing moulded headliner 2979
7 2 1 Removing 2979
7 2 2 Installing 2985
7 3 Assembly overview – inner and outer trim for roof cross member (Cabriolet) 2986
7 4 Removing and installing inner and outer trim for roof cross member (Cabriolet) 2986
7 5 Assembly overview – roof cross member seal and retaining rail (Cabriolet) 2988
7 6 Removing and installing roof cross member seal and retaining rail (Cabriolet) 2988
72 – Seat frames 2990
1 Front seats 2990
1 1 Tools 2990
1 2 Removing and installing front seat 2990
1 2 1 Removing 2990
1 2 2 Installing 2994
1 3 Assembly overview – front backrest 2995
1 4 Removing and installing front backrest 2996
1 4 1 Removing 2996
1 4 2 Installing 2997
1 5 Removing and installing head restraint guides 2997
1 5 1 Removing 2997
1 5 2 Installing 2997
1 6 Assembly overview – seat height adjuster element 2997
1 7 Removing and installing seat height adjustment element 2998
1 7 1 Removing 2998
1 7 2 Installing 3000
1 8 Assembly overview – fire extinguisher bracket (front passenger side) 3001
1 9 Removing and installing fire extinguisher bracket on front passenger side 3002
1 9 1 Removing 3002
1 9 2 Installing 3002
1 10 Assembly overview – backrest frame ▸ 04 03 and (Cabriolet) 3003
1 11 Assembly overview – backrest frame 05 03 ► 3004
1 12 Removing and installing cable for adjusting seat longitudinally 3004
1 12 1 Removing 3004
1 12 2 Installing 3005
1 13 Removing and installing lumbar support frame 05 03 ► 3005
1 13 1 Removing 3005
1 13 2 Installing 3006
1 14 Removing and installing backrest release cable 05 03 ► 3007
1 14 1 Removing 3007
1 14 2 Installing 3007
2 Rear seats 3008
2 1 Removing and installing rear bench seat (one-piece) 3008
2 1 1 Removing 3008
2 1 2 Installing 3008
2 2 Removing and installing backrest (one-piece) 3009
2 2 1 Removing 3009
2 2 2 Installing 3009
2 3 Assembly overview – backrest locking device (one-piece backrest) 3010
2 4 Removing and installing backrest locking device (one-piece backrest) 3010
2 4 1 Removing 3010
2 4 2 Installing 3011
2 4 3 Adjusting locking hooks 3012
2 5 Removing and installing rear bench seat (two-piece) 3012
2 5 1 Removing 3012
2 5 2 Installing 3013
2 6 Removing and installing backrest (two-piece) 3013
2 6 1 Removing 3014
2 6 2 Installing 3014
2 7 Assembly overview – backrest locking device (two-piece backrest) 3015
2 8 Removing and installing right backrest locking device (two-piece backrest) 3015
2 8 1 Removing 3015
2 8 2 Installing 3016
2 8 3 Adjusting locking hooks 3017
2 9 Assembly overview – left backrest locking device (two-piece backrest) 3017
2 10 Removing and installing left backrest locking device (two-piece (split) backrest) 3018
2 10 1 Removing 3018
2 10 2 Installing 3019
2 10 3 Adjusting locking hooks 3020
2 11 Removing and installing rear bench seat (Cabriolet) 3020
2 11 1 Removing 3020
2 11 2 Installing 3021
2 12 Removing and installing backrest (Cabriolet) 3021
2 12 1 Removing 3021
2 12 2 Installing 3021
2 13 Assembly overview – through-loading aperture (Cabriolet) 3022
2 14 Removing and installing through loading aperture (Cabriolet) 3023
2 14 1 Removing 3023
2 14 2 Installing 3023
74 – Seat – padding, covers 3024
1 Front seat cover and padding 3024
1 1 Tools 3024
1 2 Removing and installing front seat cover and padding 3024
1 2 1 Removing 3025
1 2 2 Installing 3026
1 3 Removing and installing front backrest cover and padding 3026
1 3 1 Removing 3026
1 3 2 Installing 3029
1 4 Removing and installing cover and padding for front seat backrest 05 03 ► 3029
1 4 1 Removing 3029
1 4 2 Installing 3032
1 5 Removing seat heater element 3032
1 5 1 Models ► 04 03 and Cabriolet 3032
1 5 2 Models 05 03 ► 3032
1 6 Removing backrest heater element 3033
1 6 1 Removing 3033
2 Rear seat cover and padding 3035
2 1 Tools 3035
2 2 Assembly overview – cover and padding for bench seat 3035
2 3 Removing and installing cover and padding for rear bench seat 3037
2 3 1 Removing 3037
2 3 2 Installing 3037
2 3 3 Removing head restraint guides (one-piece bench seat) 3037
2 3 4 Installing head restraint guides (one-piece bench seat) 3038
2 3 5 Removing and installing head restraint guides (two-piece bench seat) 3038
2 4 Assembly overview – cover and padding for seat backrest (one-piece or right-hand side) 3038
2 5 Removing and installing cover and padding for seat backrest (one-piece or right-hand side) 3039
2 5 1 Removing 3039
2 5 2 Installing 3041
2 6 Assembly overview – cover and padding for left backrest 3042
2 7 Removing and installing cover and padding for left seat backrest 3042
2 7 1 Removing 3042
2 7 2 Installing 3044
2 8 Assembly overview – cover and padding for backrest (Cabriolet) 3045
2 9 Removing and installing cover and padding for seat backrest (Cabriolet) 3046
2 9 1 Removing 3046
2 9 2 Installing 3046
2 10 Assembly overview – cover and padding for bench seat (Cabriolet) 3047
2 10 1 Assembly overview 3047
2 11 Removing and installing cover and padding for bench seat (Cabriolet) 3048
2 11 1 Removing 3048
2 11 2 Installing 3048
K0051506120 General body repairs exterior 3049
50 – Body – front 3055
1 Body, front 3055
1 1 Tools 3055
1 2 Assembly overview – lock carrier 3055
1 3 Lock carrier – service position 3057
1 4 Assembly overview – front end 3059
1 5 Assembly overview – front wing 3061
1 6 Replacing anti-friction foil 3062
1 6 1 Materials: 3062
1 6 2 Bonnet anti-friction foil 3062
1 6 3 Rear lid anti-friction foil 3063
1 6 4 Anti-scratch film for front section of sill 3063
1 6 5 Anti-scratch film for rear section of sill 3063
1 6 6 General instructions 3064
1 6 7 Procedure for removing film 3064
1 7 Assembly overview – noise insulation 3064
1 7 1 Models with a petrol engine 3064
1 7 2 Vehicles with diesel engine 3066
1 7 3 Vehicles with petrol engine, Cabriolet 3066
1 8 Removing and installing plenum chamber cover 3068
1 9 Assembly overview – vibration damper, Cabriolet 3069
53 – Body – rear 3070
1 Body – rear 3070
1 1 Assembly overview – rear end 3070
1 2 Assembly overview – rear end, Cabriolet 3072
1 3 Assembly overview – rear wing 3074
1 4 Removing and installing diagonal struts 3076
1 4 1 Removing 3076
1 4 2 Installing 3077
55 – Bonnet, rear lid 3078
1 Bonnet 3078
1 1 Assembly overview 3078
1 2 Adjusting rear lid 3079
1 3 Removing and installing Bowden cable 3080
1 4 Removing and installing release lever 3081
1 4 1 Removing 3081
1 5 Removing, installing and adjusting bonnet lock 3082
2 Rear lid 3083
2 1 Assembly overview – rear lid 3083
2 2 Assembly overview – rear lid, Cabriolet 3084
2 2 1 Assembly overview 3084
2 3 Removing gas strut 3085
2 4 Removing gas strut, Cabriolet 3085
2 5 Releasing gas from gas strut 3086
2 6 Adjusting rear lid 3086
2 6 1 Adjusting lid hinge 3087
2 6 2 Adjusting lid limit stop 3087
2 7 Adjusting lid, Cabriolet 3088
2 7 1 Adjusting lid hinge stop 3088
2 8 Removing and installing lid lock 3088
2 9 Installing and removing lid lock 09 01 ► (USA) 3090
2 10 Removing and installing lid lock, Cabriolet 3091
2 11 Removing and installing motor carrier for remote release of rear lid 3092
2 11 1 Removing 3092
2 11 2 Installing 3093
2 12 Removing and installing motor carrier for rear lid remote release 09 01 ► (USA) 3093
2 12 1 Removing 3093
2 13 Removing and installing retaining plate with motor for remote release of rear lid, Cabriolet 3094
2 13 1 Removing 3094
2 13 2 Installing 3095
2 14 Removing and installing carrier with microswitch for rear lid, Cabriolet 3096
2 14 1 Removing 3096
2 14 2 Installing 3096
3 Tank flap unit 3097
3 1 Removing and installing tank flap unit 3097
3 1 1 Removing 3097
3 1 2 Installing 3097
3 2 Removing and installing fuel tank filler flap release motor 3098
3 2 1 Removing 3098
3 2 2 Installing 3098
57 – Front doors, door components, central locking 3099
1 Front door 3099
1 1 Tools 3099
1 2 Assembly overview – front door 3099
1 3 Assembly overview – front door, Cabriolet 3101
1 4 Removing and installing door 3103
1 5 Removing and installing door, Cabriolet 3106
1 5 1 Removing 3106
1 5 2 Installing 3108
1 6 Adjusting door 3108
1 7 Assembly overview – door handle and door lock 3109
1 8 Removing and installing lock cylinder housing 3110
1 8 1 Removing 3110
1 8 2 Installing 3111
1 9 Removing and installing door handle 3111
1 9 1 Removing 3111
1 9 2 Installing 3112
1 10 Removing and installing door lock 3112
1 10 1 Removing 3112
1 10 2 Installing 3115
1 11 Removing and installing door lock, Cabriolet 3117
1 11 1 Removing 3117
1 11 2 Installing 3118
1 12 Removing and installing bearing bracket 3119
1 12 1 Removing 3119
1 12 2 Installing 3120
1 13 Removing and installing locking knob for release rod 3120
1 13 1 Removing right door 3120
1 13 2 Installing right door 3121
1 13 3 Removing left door 3121
1 13 4 Installing left door 3121
1 14 Door seals, Cabriolet 3121
1 14 1 Assembly overview 3123
2 Central locking 3124
2 1 Assembly overview – central locking and convenience system 3124
60 – Sunroof 3127
1 Sliding/tilting sunroof 3127
1 1 Tools 3127
1 2 Function 3127
1 3 Assembly overview – sliding/tilting sunroof with glass panel 3127
1 4 Removing and installing sliding/tilting sunroof glass panel 3129
1 4 1 Removing 3129
1 4 2 Installing 3129
1 5 Adjusting height of sliding/tilting sunroof glass panel 3130
1 6 Adjusting panel seal 3131
1 7 Renewing panel seal 3131
1 8 Removing wind deflector 3131
1 9 Removing sliding headlining 3132
1 10 Removing sliding/tilting sunroof drive 3132
1 11 Adjusting drive for sliding/tilting sunroof (zero position) 3135
1 12 Removing pre-selector control for sliding/tilting sunroof 3136
1 13 Checking parallel running 3136
1 14 Adjusting parallel running 3137
1 15 Removing and installing carrier unit 3137
1 15 1 Removing 3137
1 15 2 Installing 3139
1 16 Removing coulisse guide 3139
1 17 Cleaning water drain hoses 3140
1 17 1 Front water drain hoses 3140
1 17 2 Rear water drain 3142
61 – Convertible roof, hardtop, canopy 3143
1 Convertible top 3143
1 1 Safety precautions when working on convertible roof 3143
1 1 1 Opening convertible roof by pressing open/close button 3143
1 1 2 Safety precautions when working on electric/hydraulic convertible roof 3143
1 2 Tools 3143
1 3 Assembly overview – electrical/hydraulic convertible roof 3144
1 4 Removing and installing electric/hydraulic convertible roof 3145
1 4 1 Removing 3145
1 4 2 Installing 3148
1 5 Removing and installing convertible roof cover, electric/hydraulic convertible roof 3148
1 5 1 Removing 3148
1 5 2 Installing 3154
1 6 Assembly overview – manual convertible roof 3155
1 7 Removing and installing manual convertible roof 3156
1 7 1 Removing 3156
1 7 2 Installing 3159
1 8 Removing and installing cover of manual convertible roof 3159
1 8 1 Removing 3159
1 8 2 Installing 3166
1 9 Removing and installing padding of electric/hydraulic and manual convertible roof 3173
1 9 1 Removing 3173
1 9 2 Installing 3175
1 10 Removing and installing convertible roof headliner of electric/hydraulic and manual convertible roof 3176
1 10 1 Removing 3176
1 10 2 Installing 3181
1 11 Assembly overview – convertible roof headliner, tensioning system ► 11 03 3186
1 12 Removing and installing convertible roof liner tensioning system ► 11 03 3188
1 12 1 Removing 3188
1 12 2 Installing 3190
1 13 Assembly overview – convertible roof headliner, tensioning system 12 03 ► 3193
1 14 Removing and installing convertible roof headliner tensioning system 12 03 ► 3195
1 14 1 Removing 3195
1 14 2 Installing 3197
1 15 Assembly overview – front locking mechanism for electric/hydraulic and manual convertible roof 3200
1 16 Removing and installing front convertible roof catch 3202
1 17 Assembly overview – rear locking mechanism for electrical/hydraulic convertible roof 3202
1 18 Assembly overview – rear locking mechanism for manual convertible roof 3204
2 Electrical/hydraulic top 3205
2 1 Assembly overview 3205
2 2 Filling and bleeding the hydraulic system 3205
2 2 1 Filling the hydraulic system 3206
2 2 2 Bleeding the hydraulic system 3206
2 3 Removing and installing hydraulic pump 3207
2 3 1 Removing 3207
2 3 2 Installing 3207
2 4 Assembly overview – impeller for hydraulic pump 3208
2 5 Removing and installing impeller for hydraulic pump 3208
2 5 1 Removing 3208
2 5 2 Installing 3210
2 6 Assembly overview – oil reservoir 3212
2 7 Removing and installing oil reservoir 3212
2 7 1 Removing 3212
2 7 2 Installing 3214
2 8 Assembly overview – hydraulic cylinder 3215
2 9 Removing and installing the hydraulic cylinder 3215
2 9 1 Removing 3215
2 9 2 Installing 3217
2 10 Removing and installing hydraulic hoses 3217
2 10 1 Removing 3218
2 10 2 Installing 3218
3 Manually operated convertible roof 3220
3 1 Assembly overview – manual convertible roof 3220
3 2 Assembly overview – dampers 3221
3 3 Removing and installing dampers 3221
3 3 1 Removing 3221
3 3 2 Installing 3222
4 Windscreen frame 3223
4 1 Assembly overview – windscreen frame, electric/hydraulic and manual convertible roof 3223
4 2 Removing and installing roof cross member seal and retaining rail for electrohydraulic and manually operated convertible roof 3223
4 2 1 Removing 3224
4 2 2 Installing 3224
63 – Bumpers 3225
1 Front bumper 3225
1 1 Assembly overview 3225
2 Rear bumper 3227
2 1 Assembly overview 3227
64 – Glazing 3229
1 Flush bonded windows 3229
1 1 Tools 3229
1 2 Materials 3231
1 3 Assembly overview – windscreen 3231
1 4 Removing windscreen 3232
1 5 Removing windscreen, Cabriolet 3234
1 6 Installing windscreen 3235
1 7 Removing and installing rain sensor 3235
1 7 1 Removing 3235
1 7 2 Installing 3235
1 8 Assembly overview – side window 3236
1 9 Removing undamaged side window 3237
1 10 Removing broken side window 3238
1 11 Installing side window 3238
1 12 Assembly overview – rear window 3238
1 13 Removing undamaged rear window 3239
1 14 Removing broken rear window 3241
1 15 Installing rear window 3241
1 16 Preparing old undamaged window for glazing 3241
1 17 Preparing new window for glazing 3242
1 18 Preparing body flange for glazing 3242
1 19 Installation instructions 3243
1 20 Minimum curing period 3243
1 21 Touching up paint damage 3243
1 22 Cleaning off excess adhesive sealing material 3244
2 Door windows 3245
2 1 Tools 3245
2 2 Assembly overview- front door window 3245
2 3 Removing front door window 3246
2 4 Adjusting door window 3247
2 5 Removing and installing assembly carrier 3247
2 5 1 Removing 3247
2 5 2 Installing 3249
2 6 Renewing window regulators 3251
2 7 Assembly overview – front door window, Cabriolet 3253
2 8 Removing and installing front door window, Cabriolet 3254
2 8 1 Removing 3254
2 8 2 Installing 3255
2 9 Adjusting front door window, Cabriolet 3255
2 9 1 Front to rear adjustment (X axis adjustment) 3256
2 9 2 Left and right adjustment (Y axis adjustment) 3256
2 9 3 Up and down adjustment (Z axis adjustment) 3257
2 9 4 Functional check 3258
2 10 Removing and installing assembly carrier, Cabriolet 3258
2 10 1 Removing 3258
2 10 2 Installing 3259
2 11 Removing and installing front window regulators, Cabriolet 3259
2 11 1 Assembly overview 3259
2 11 2 Removing 3260
2 11 3 Installing 3261
2 12 Renewing window regulator, Cabriolet 3261
2 13 Electric window regulator with convenience function (automatic opening and closing) and force limitation mechanism 3265
2 13 1 Function of window regulator with ignition switched on 3265
2 13 2 Function of window regulator with ignition switched off 3266
2 13 3 Setting automatic opening and closing 3266
2 14 Overcoming resistance with excess force limitation 3267
3 Side window, Cabriolet 3268
3 1 Assembly overview – side windows 3268
3 2 Removing and installing side window 3268
3 2 1 Removing 3268
3 2 2 Installing 3270
3 3 Adjusting side window 3270
3 3 1 Adjusting side inclination (distance) 3271
3 4 Removing and installing carrier plate 3274
3 4 1 Removing 3274
3 4 2 Installing 3274
3 5 Renewing window regulators 3274
3 6 Removing and installing window regulator motor 3276
3 6 1 Removing 3276
3 6 2 Installing 3276
66 – Exterior equipment 3277
1 Removing and installing wheel housing liner 3277
1 1 Front wheel housing liner 3277
1 2 Rear wheel housing liner 3278
2 Exterior mirror 3281
2 1 Tools 3281
2 2 Removing and installing mirror glass 3281
2 2 1 Removing 3281
2 2 2 Installing 3282
2 3 Removing and installing mirror housing 3282
2 3 1 New Beetle saloon ► 05 00 3282
2 3 2 New Beetle saloon 06 00 ► 3282
2 3 3 New Beetle Cabriolet 3282
2 3 4 Installing 3283
2 4 Removing and installing turn signal bulb 3283
2 4 1 Removing 3283
2 4 2 Installing 3284
2 5 Removing and installing rear view mirror 3284
2 5 1 New Beetle saloon ► 05 00 3285
2 5 2 New Beetle saloon 06 00 ► 3286
2 5 3 New Beetle Cabriolet 3287
2 5 4 Installing 3288
3 Roof mouldings 3289
3 1 Roof moulding 3289
4 Protective strips 3290
4 1 Renewing protective strips 3290
4 2 Replacing sill panel strips, Cabriolet 3291
4 3 Removing and installing convertible roof frame protective strip, Cabriolet 3292
4 3 1 Assembly overview 3292
4 3 2 Removing 3292
4 3 3 Installing 3294
5 Rear spoiler 3295
5 1 Assembly overview 3295
5 2 Function 3295
5 3 Raising and lowering the rear spoiler “manually” 3296
5 4 Removing and installing rear spoiler drive 3296
5 4 1 Removing 3296
5 4 2 Installing 3297
5 5 Removing and installing rear spoiler assembly 3297
5 5 1 Removing 3297
5 5 2 Installing 3298
5 6 Checking and adjusting parallel running 3299
5 6 1 Checking 3299
5 6 2 Adjusting 3300
5 7 Removing and installing cable lower guide tubes 3300
5 8 Lubricate rear spoiler rods 3301
6 Windbreak 3302
6 1 Removing and installing windbreak mounting 3302
6 1 1 Removing 3302
6 1 2 Installing 3302
6 2 Removing and installing rear windbreak mounting 3302
6 2 1 Removing 3302
6 2 2 Installing 3303
K0051506520 4 cylinder FI engine (1 6 l) mechanics AWH 3304
Title 3304
Manual Repair Groups 3305
Contents 3307
00-1 Technical data 3309
00-1 -Engine number 3309
00-2 -Engine data 3309
10-1 Removing and installing engine 3311
10-3 -Notes on removing 3312
10-9 -Securing engine to assembly stand 3315
10-10 -Notes on installing 3315
10-14 -Tightening torques 3317
10-15 -Assembly mountings 3318
10-16 -Additional information and removal instructions for vehicles with air conditioner 3318
13-1 Dismantling and assembling engine 3320
13-9 -Removing and installing ribbed belt 3324
13-12 -Removing, installing and tensioning toothed belt 3325
13-21 -Checking semi-automatic toothed belt tensioning roller 3330
13-22 Removing and installing sealing flange and pressure plate/drive plate 3330
13-25 -Renewing crankshaft oil seal -belt pulley end 3332
13-29 -Removing and installing front sealing flange 3334
13-33 -Removing and installing drive plate 3336
13-36 Removing and installing crankshaft 3337
13-40 -Crankshaft dimensions 3339
13-41 Dismantling and assembling pistons and conrods 3340
13-49 -Piston and cylinder dimensions 3344
15-1 Removing and installing cylinder head 3345
15-6 -Removing and installing cylinder head 3347
15-12 -Checking compression pressures 3350
15-15 Servicing valve gear 3352
15-22 -Reworking valve seats 3355
15-26 -Replacing camshaft oil seal 3357
15-30 -Removing and installing camshaft 3359
15-34 -Checking hydraulic bucket tappets 3361
15-36 -Checking valve guides 3362
15-37 -Renewing valve guides 3363
15-39 -Renewing valve stem seals 3364
17-1 Removing and installing parts of the lubrication system 3366
17-11 -Removing and installing sump 3371
17-14 -Checking oil pressure and oil pressure switch 3372
19-1 Removing and installing parts of cooling system 3375
19-2 -Parts of cooling system body side 3375
19-7 -Parts of cooling system engine side 3378
19-10 -Coolant hose connection diagram 3379
19-11 -Draining and filling cooling system 3380
19-16 -Removing and installing radiator 3382
19-19 -Removing and installing coolant pump 3384
19-22 -Removing and installing thermostat 3385
19-24 -Electronically regulated cooling system 3386
19-25 -Checking electronically regulated cooling system 3387
20-1 Removing and installing parts of fuel supply system 3389
20-2 -Removing and installing fuel tank with its attachments and fuel filter 3389
20-8 -Safety precautions when working on the fuel supply system 3392
20-9 -Rules for cleanliness 3393
20-10 -Removing and installing fuel delivery unit 3393
20-13 -Removing and installing fuel gauge sender 3395
20-14 -Removing and installing fuel tank 3395
20-18 -Checking fuel pump 3397
20-20 -Crash fuel shut-off 3398
20-29 Checking electronic power control (EPC) 3403
20-30 -Function of EPC system 3403
20-32 -Checking electronic accelerator warning lamp 3404
20-33 -Checking accelerator pedal position sender 3405
20-39 Activated charcoal filter system 3408
20-39 -Function 3408
20-41 -Servicing parts of the activated charcoal filter system 3409
20-43 -Checking activated charcoal filter solenoid valve 1 3410
26-1 Removing and installing parts of exhaust system 3413
26-2 -Exhaust manifold, front exhaust pipe and catalytic converter with attachments 3413
26-6 -Silencer with mountings 3415
26-10 -Checking catalytic converter 3417
26-14 Secondary air system 3419
26-14 -Function 3419
26-15 -Removing and installing parts of the secondary air system 3420
26-19 -Checking secondary air system 3422
26-23 -Checking secondary air pump motor 3424
26-32 Exhaust gas recirculation system 3428
26-33 -Servicing parts of exhaust gas recirculation system 3429
26-36 -Checking potentiometer for exhaust gas recirculation (G212) 3430
K0051506720 Simos injection and ignition system 3433
01 – Self-diagnosis 3437
1 – General to self-diagnosis 3437
1 1 – General to self-diagnosis 3437
1 2 – Features of self-diagnosis 3437
1 3 – Technical data of self-diagnosis 3437
1 4 – Significance of EPC warning lamp (fault lamp for electronic accelerator) in dash panel insert 3438
1 5 – Connecting fault reader V A G 1551 and selecting engine control unit 3439
1 6 – Connecting vehicle diagnosis, testing and information system VAS 5051 and selecting engine control unit 3441
2 – Fault memory 3444
2 1 – Fault memory 3444
2 2 – Automatic test sequence for interrogating all fault memories 3444
2 3 – Interrogating and erasing engine control unit fault memory 3445
3 – Fault table: SAE P0 codes 3446
3 1 – Fault table: SAE P0 codes 3446
4 – Fault table: SAE P1 codes 3449
4 1 – Fault table: SAE P1 codes 3449
5 – Final control diagnosis 3455
5 1 – Final control diagnosis 3455
5 2 – Performing final control diagnosis 3455
6 – Measured value blocks 3461
6 1 – Measured value blocks 3461
6 2 – Safety precautions 3461
6 3 – Read measured value block 3461
7 – Evaluating measured value blocks, display groups 0 9 -Basic functions- 3462
7 1 – Evaluating measured value blocks, display groups 0 9 -Basic functions- 3462
8 – Evaluating measured value blocks, display groups 10 29 -Ignition- 3465
8 1 – Evaluating measured value blocks, display groups 10 29 -Ignition- 3465
9 – Evaluating measured value blocks, display groups 30 49 -Lambda regulation- 3468
9 1 – Evaluating measured value blocks, display groups 30 49 -Lambda regulation- 3468
10 – Evaluating measured value blocks, display groups 50 69 -Speed regulation- 3472
10 1 – Evaluating measured value blocks, display groups 50 69 -Speed regulation- 3472
11 – Evaluating measured value blocks, display groups 70 79 -Reducing emissions- 3475
11 1 – Evaluating measured value blocks, display groups 70 79 -Reducing emissions- 3475
11 2 – Evaluating measured value blocks, display groups 90 95 -Variable valve timing/variable intake manifold- 3476
12 – Evaluating measured value blocks, display groups 120 129 -Communication- 3477
12 1 – Evaluating measured value blocks, display groups 120 129 -Communication- 3477
12 2 – Evaluating measured value blocks, display groups 130 and 131 -Cooling- 3478
24 – Mixture preparation, Injection 3479
1 – Servicing injection system 3479
1 1 – Servicing injection system 3479
1 2 – Fitting locations overview 3479
1 3 – General notes on injection 3487
1 4 – Removing and installing parts of the injection system 3488
1 5 – Dismantling and assembling intake manifold – Upper part 3495
1 6 – Dismantling and assembling air cleaner 3497
1 7 – Dismantling and assembling fuel rail with injectors 3498
1 8 – Safety precautions 3499
1 9 – Rules for cleanliness 3500
1 10 – Technical data 3500
2 – Checking components 3500
2 1 – Checking components 3500
2 2 – Checking Lambda probe heating for Lambda probe before catalyst 3500
2 3 – Checking Lambda probe heating for Lambda probe after catalyst 3503
2 4 – Checking air mass meter 3506
2 5 – Checking intake air temperature sender 3509
2 6 – Checking throttle valve control part 3511
2 7 – Checking coolant temperature sender 3515
2 8 – Checking engine speed sender 3517
2 9 – Checking injectors 3519
2 10 – Checking fuel pressure regulator and holding pressure 3525
2 11 – Checking intake air system for leaks (unmetered air) 3527
3 – Checking functions 3528
3 1 – Checking functions 3528
3 2 – Idling check 3528
3 3 – Checking Lambda probe and Lambda regulation before catalyst 3530
3 4 – Checking Lambda probe and Lambda regulation after catalyst 3534
3 5 – Checking Lambda probe ageing Lambda probe 1 3538
3 6 – Checking engine operating mode 3539
3 7 – Checking intake manifold change-over 3540
4 – Engine control unit 3541
4 1 – Engine control unit 3541
4 2 – Function 3541
4 3 – Checking control unit voltage supply 3541
4 4 – Replacing engine control unit 3543
4 5 – Coding engine control unit 3544
4 6 – Coding variations of engine control unit 3545
4 7 – Erasing learnt values and adapting engine control unit to throttle valve control part and exhaust gas recirculation valve 3546
4 8 – Adapting engine control unit to electronic immobilizer 3548
5 – Checking additional signals 3549
5 1 – Checking additional signals 3549
5 2 – Checking speed signal 3549
5 3 – Checking engine speed signal 3551
5 4 – Checking signal from/to air conditioning system 3551
5 5 – Checking signal from clutch pedal switch 3555
5 6 – Checking signal from brake light switch and brake pedal switch 3557
5 7 – Checking signal from power steering pressure switch 3560
5 8 – Checking driving range signal 3561
5 9 – Checking data bus 3562
28 – Ignition system 3565
1 – Servicing ignition system 3565
1 1 – Servicing ignition system 3565
1 2 – General notes on ignition system 3565
1 3 – Removing and installing parts of the ignition system 3566
1 4 – Safety precautions 3569
1 5 – Test data, spark plugs 3569
1 6 – Checking Hall sender 3570
1 7 – Checking ignition coils with output stage 3571
1 8 – Checking knock sensor 3574
1 9 – Check misfiring recognition 3576
K0051506820 Simos Injection and Ignition System 3578
01 – Self-diagnosis 3582
1 – General to self-diagnosis 3582
1 1 – General to self-diagnosis 3582
1 2 – Features of self-diagnosis 3582
1 3 – Technical data of self-diagnosis 3582
1 4 – Significance of exhaust emissions warning lamp 3584
1 5 – Significance of EPC warning lamp (fault lamp for electric power control) in dash panel insert 3585
1 6 – Connecting fault reader 3586
2 – Fault memory 3589
2 1 – Fault memory 3589
2 2 – Automatic test sequence for interrogating all fault memories 3589
2 3 – Interrogating and erasing engine control unit fault memory 3590
3 – Fault table: SAE P0 and P2 codes 3591
3 1 – Fault table: SAE P0 and P2 codes 3591
4 – Fault table: SAE P1 and P3 codes 3596
4 1 – Fault table: SAE P1 and P3 codes 3596
5 – Final control diagnosis 3607
5 1 – Final control diagnosis 3607
5 2 – Performing final control diagnosis 3607
6 – Readiness code 3619
6 1 – Readiness code 3619
6 2 – Read readiness code 3619
6 3 – Generating readiness code 3620
7 – Measured value (data) blocks 3630
7 1 – Measured value (data) blocks 3630
7 2 – Safety precautions 3630
7 3 – Read measured value (data) block 3631
8 – Evaluating measured value blocks, display groups 0 9 -Basic functions- 3632
8 1 – Evaluating measured value blocks, display groups 0 9 -Basic functions- 3632
9 – Evaluating measured value blocks, display groups 10 29 -Ignition- 3636
9 1 – Evaluating measured value blocks, display groups 10 29 -Ignition- 3636
10 – Evaluating measured value blocks, display groups 30 49, 99 -Lambda regulation- 3640
10 1 – Evaluating measured value blocks, display groups 30 49, 99 -Lambda regulation- 3640
11 – Evaluating measured value blocks, display groups 50 69 -Revolution regulation- 3645
11 1 – Evaluating measured value blocks, display groups 50 69 -Revolution regulation- 3645
12 – Evaluating measured value blocks, display groups 70 79 -Reducing emissions- 3650
12 1 – Evaluating measured value blocks, display groups 70 79 -Reducing emissions- 3650
12 2 – Evaluating measured value blocks, display groups 90 95 -Variable valve timing/variable intake manifold change-over- 3651
13 – Evaluating measured value blocks, display group 100 -Readiness code- 3652
13 1 – Evaluating measured value blocks, display group 100 -Readiness code- 3652
14 – Evaluating measured value blocks, display groups 120 129 -Communication- 3652
14 1 – Evaluating measured value blocks, display groups 120 129 -Communication- 3652
24 – Mixture preparation, Injection 3654
1 – Servicing injection system 3654
1 1 – Servicing injection system 3654
1 2 – Fitting locations overview 3654
1 3 – General notes on injection 3664
1 4 – Removing and installing parts of the injection system 3665
1 5 – Dismantling and assembling intake manifold – Upper part 3673
1 6 – Dismantling and assembling air cleaner 3675
1 7 – Dismantling and assembling fuel rail with injectors 3676
1 8 – Safety precautions 3677
1 9 – Rules for cleanliness 3678
1 10 – Technical data 3678
2 – Checking components 3678
2 1 – Checking components 3678
2 2 – Checking Lambda probe heating for Lambda probe before catalytic converter 3678
2 3 – Checking Lambda probe heating for Lambda probe after catalytic converter 3682
2 4 – Check air mass meter 3685
2 5 – Check intake air temperature sender 3687
2 6 – Checking throttle valve control part 3690
2 7 – Check coolant temperature sender 3693
2 8 – Checking engine speed sender 3696
2 9 – Checking injectors 3698
2 10 – Checking fuel pressure regulator and holding pressure 3703
2 11 – Checking intake air system for leaks (unmetered air) 3705
3 – Checking functions 3706
3 1 – Checking functions 3706
3 2 – Idling check 3706
3 3 – Checking Lambda probe and Lambda regulation before catalytic converter 3708
3 4 – Checking Lambda probe and Lambda regulation after catalytic converter 3712
3 5 – Checking Lambda probe ageing Lambda probe 1 3715
3 6 – Checking engine operating condition 3717
3 7 – Checking variable intake manifold change-over 3719
4 – Engine control unit 3721
4 1 – Engine control unit 3721
4 2 – Function 3721
4 3 – Checking control unit voltage supply 3721
4 4 – Replace engine control unit 3725
4 5 – Coding engine control unit 3726
4 6 – Coding variations of engine control unit 3727
4 7 – Erasing learnt values and adapting engine control unit to throttle valve control part and exhaust gas recirculation valve 3728
4 8 – Learning kickdown switch points 3731
4 9 – Checking data bus matching resistor 3732
5 – Checking additional signals 3733
5 1 – Checking additional signals 3733
5 2 – Check vehicle speed signal 3733
5 3 – Checking signal from/to air conditioning system 3734
5 4 – Checking signal from clutch pedal switch 3738
5 5 – Checking signal from brake light switch and brake pedal switch 3739
5 6 – Checking signal from power steering pressure switch 3740
5 7 – Checking driving range signal 3742
28 – Ignition system 3744
1 – Servicing ignition system 3744
1 1 – Servicing ignition system 3744
1 2 – General notes on ignition system 3744
1 3 – Removing and installing parts of the ignition system 3745
1 4 – Safety precautions 3751
1 5 – Test data, spark plugs 3752
1 6 – Checking Hall sender 3753
1 7 – Checking ignition transformer 3756
1 8 – Checking knock sensor 3759
1 9 – Check misfiring detection 3765
K0051575920 Heating air conditioner 3767
80 – Heating 3771
1 Repairing heating system 3771
1 1 Passenger compartment heating – assembly overview 3771
1 2 Removing and installing fresh air blower -V2- and fresh air blower series resistor with overheating fuses -N24- 3773
1 3 Removing and installing intermediate piece and intermediate piece, defrost 3773
1 4 Removing connecting piece 3774
1 5 Removing and installing dust and pollen filter 3775
1 6 Removing vents 3777
1 6 1 Removing side window vent 3777
1 6 2 Removing vents 3777
1 6 3 Removing centre trim with centre vent 3778
1 7 Defroster channel 3779
1 7 1 Assembly overview 3779
1 7 2 Removing and installing 3780
1 8 Removing and installing controls for heated and fresh air 3781
1 9 Checking ventilation 3782
1 10 Removing and installing heater unit 3782
1 11 Removing and installing heat exchanger 3784
2 Dismantling and assembling heater unit 3788
2 1 Assembly overview 3788
2 2 Removing and installing fresh air and air recirculation flap control motor -V154- 3788
3 Dismantling and assembling heated air and fresh air controls 3790
4 Installing and adjusting cables 3791
4 1 Assembly overview 3791
4 2 Adjusting cable at temperature flap 3792
4 3 Adjusting cable at footwell/defroster flap 3792
4 4 Adjusting lever and cable at centre flap 3793
4 4 1 Adjusting lever at centre flap 3793
4 4 2 Adjusting cable at centre flap 3793
82 – Supplementary heating 3794
1 Glow plugs – supplementary heating 3794
1 1 Glow plugs – supplementary heating in coolant circuit 3794
87 – Air conditioning system 3795
1 Notes on repair work to vehicles with air conditioning and on handling refrigerant 3795
2 Air conditioning system with manual controls 3796
2 1 Air conditioning and heating – passenger compartment 3796
2 2 Air conditioning and heating system – engine compartment 3798
2 3 Removing and installing air conditioner compressor 3800
2 3 1 Removing air conditioner compressor downwards with refrigerant lines and hoses connected 3801
2 3 2 Removing air conditioner compressor upwards with refrigerant lines and hoses connected 3801
2 3 3 Installing 3802
2 4 Removing and installing refrigerant lines from air conditioner compressor 3802
2 5 Repairing air conditioning system magnetic clutch -N25- (made by Sanden) 3805
2 5 1 Removing and installing air conditioning system magnetic clutch -N25- 3806
2 5 2 Checking and adjusting clearance 3808
2 6 Checking water drain valve 3809
3 Ancillary bracket for air conditioner compressor 3810
3 1 Engine code: BCA 3810
3 1 1 Securing air conditioner compressor to body 3812
3 2 Engine codes: AQY, AVC, AWH, AWU, AYD, AZJ 3812
3 2 1 Securing air conditioner compressor to body 3815
3 3 Engine code: ATD 3816
3 3 1 Securing air conditioner compressor to body 3818
3 4 Engine code: AQN 3818
3 4 1 Securing air conditioner compressor to body 3820
3 5 Engine code: ALH 3820
3 5 1 Securing air conditioner compressor to body 3822
3 6 Engine codes: BPS, BPR 3823
3 6 1 Securing air conditioner compressor to body 3824
4 Repair work on refrigerant circuit that can only be carried out by suitable workshops with properly trained mechanics (specialist workshops for air conditioning systems) 3826
4 1 Repairing components in refrigerant circuit 3827
4 2 Removing evacuating and charging valve, low-pressure side 3830
4 3 Removing evacuation and charging valve, high-pressure side 3830
4 4 High-pressure safety valve on air conditioner compressor 3831
4 5 Receiver with dryer 3831
4 6 Expansion valve 3832
4 6 1 Assembly overview 3832
4 6 2 Removing 3833
4 7 Checking air conditioning system pressure switch -F129- 3835
4 7 1 Checking air conditioning system pressure switch -F129- 3835
4 7 2 Test conditions 3835
4 8 Checking high pressure sensor -G65- 3836
4 8 1 Testing high-pressure sender -G65- via engine control unit 3837
4 8 2 Checking high-pressure sender -G65- with ignition tester -V A G 1767- 3838
4 9 Removing and installing condenser 3842
4 10 Dismantling and assembling air conditioning unit 3843
4 11 Dismantling and assembling evaporator housing 3846
5 Capacities 3848
5 1 Refrigerant R134a 3848
5 2 Refrigerant oil 3848
5 2 1 Oil distribution 3848
K0051622920 Motronic Injection and Ignitio System (5 Cyl 4 Valve) 3849
01 – Self-diagnosis 3853
1 – General to self-diagnosis 3853
1 1 – General to self-diagnosis 3853
1 2 – Features of self-diagnosis 3853
1 3 – Significance of EPC warning lamp (fault lamp for electronic accelerator) in dash panel insert 3853
1 4 – Significance of exhaust emissions warning lamp 3854
1 5 – Technical data of self-diagnosis 3855
1 6 – Connecting fault reader 3856
2 – Fault memory 3859
2 1 – Fault memory 3859
2 2 – Interrogating and erasing fault memory 3859
3 – Fault table: From V A G code 16395 / SAE P0 or P2 codes 3861
3 1 – Fault table: From V A G code 16395 / SAE P0 or P2 codes 3861
4 – Fault table: from V A G code 17455 / SAE P1 and P3 codes 3867
4 1 – Fault table: from V A G code 17455 / SAE P1 and P3 codes 3867
5 – Final control diagnosis 3877
5 1 – Final control diagnosis 3877
5 2 – Performing final control diagnosis 3877
6 – Readiness code 3893
6 1 – Readiness code 3893
6 2 – Reading readiness code 3893
6 3 – Generating readiness code 3894
7 – Measured value blocks 3904
7 1 – Measured value blocks 3904
7 2 – Safety precautions 3904
7 3 – Read measured value block 3904
8 – Evaluating measured value blocks, display groups 0 8 -Basic functions- 3905
8 1 – Evaluating measured value blocks, display groups 0 8 -Basic functions- 3905
9 – Evaluating measured value blocks, display groups 10 29 -Ignition- 3910
9 1 – Evaluating measured value blocks, display groups 10 29 -Ignition- 3910
10 – Evaluating measured value blocks, display grps 30 33, 99 -Lambda regulation- 3913
10 1 – Evaluating measured value blocks, display grps 30 33, 99 -Lambda regulation- 3913
11 – Evaluating measured value blocks, display groups 50 69 -Speed regulation- 3917
11 1 – Evaluating measured value blocks, display groups 50 69 -Speed regulation- 3917
12 – Evaluating measured value blocks, display groups 70 78 -Reducing emissions- 3921
12 1 – Evaluating measured value blocks, display groups 70 78 -Reducing emissions- 3921
13 – Evaluating measured block values, display groups 90 95 -Performance improvement- 3922
13 1 – Evaluating measured block values, display groups 90 95 -Performance improvement- 3922
14 – Evaluating measured value blocks, display groups 120 126 -Communication- 3923
14 1 – Evaluating measured value blocks, display groups 120 126 -Communication- 3923
24 – Mixture preparation, Injection 3925
1 – Servicing injection system 3925
1 1 – Servicing injection system 3925
1 2 – Fitting locations overview 3925
1 3 – General notes on injection 3930
1 4 – Removing and installing parts of the injection system 3931
1 5 – Dismantling and assembling intake manifold 3940
1 6 – Dismantling and assembling fuel distributor 3943
1 7 – Dismantling and assembling air cleaner 3945
1 8 – Safety precautions 3947
1 9 – Rules for cleanliness 3949
1 10 – Technical data 3949
2 – Checking components 3950
2 1 – Checking components 3950
2 2 – Checking Lambda probe heating for Lambda probe before catalytic converter 3950
2 3 – Checking Lambda probe heating for Lambda probe after catalytic converter 3953
2 4 – Checking air mass meter 3956
2 5 – Checking throttle valve control part 3960
2 6 – Checking coolant temperature sender 3964
2 7 – Checking intake air temperature sender 3969
2 8 – Checking engine speed sender 3973
2 9 – Checking injectors 3975
2 10 – Checking fuel pressure regulator and holding pressure 3982
2 11 – Checking intake manifold change-over 3985
2 12 – Checking intake air system for leaks (unmetered air) 3986
3 – Checking functions 3988
3 1 – Checking functions 3988
3 2 – Idling check 3988
3 3 – Adapting idling speed 3989
3 4 – Checking Lambda probe and Lambda regulation before catalytic converter 3990
3 5 – Checking Lambda probe and Lambda regulation after catalytic converter 3993
3 6 – Checking Lambda probe ageing of Lambda probe 1 bank 1 3996
3 7 – Checking Lambda probe ageing Lambda probe after catalytic converter (trim regulation) 3997
3 8 – Checking engine operating mode 3998
4 – Engine control unit 4000
4 1 – Engine control unit 4000
4 2 – Checking control unit voltage supply 4000
4 3 – Procedure after voltage supply open circuit 4002
4 4 – Replacing engine control unit 4003
4 5 – Coding engine control unit 4004
4 6 – Erasing values learnt by engine electronics control unit 4005
4 7 – Adapting engine control unit to throttle valve control part 4006
4 8 – Learning kick-down point 4007
5 – Checking additional signals 4008
5 1 – Checking additional signals 4008
5 2 – Checking speed signal 4008
5 3 – Checking signal from/to air conditioning system 4009
5 4 – Checking signal from clutch pedal switch 4011
5 5 – Checking signal from brake light switch and brake pedal switch 4012
5 6 – Checking driving range signal 4013
5 7 – Checking kick-down point 4014
5 8 – Checking matching resistor of data bus 4015
28 – Glow plug system 4016
1 – Servicing ignition system 4016
1 1 – Servicing ignition system 4016
1 2 – General notes on ignition system 4016
1 3 – Removing and installing parts of the ignition system 4017
1 4 – Safety precautions 4022
1 5 – Test data, spark plugs 4023
1 6 – Checking Hall sender 4024
1 7 – Checking ignition coils with output stage 4027
1 8 – Checking knock sensor 4030
1 9 – Check misfiring detection 4034
K0051638920 02T 5 speed gearbox 4037
00 – Technical data 4041
1 – Gearbox identification 4041
1 1 – Gearbox identification 4041
1 2 – Identification code, assembly allocation, ratios, capacities 4042
2 – Power transmission diagram 4044
2 1 – Power transmission diagram 4044
3 – Calculating the demultiplication ratio “i” 4046
3 1 – Calculating the demultiplication ratio “i” 4046
4 – General notes on the repair 4046
4 1 – General notes on the repair 4046
30 – Clutch 4049
1 – Clutch mechanism: repairing 4049
1 1 – Clutch mechanism: repairing 4049
1 2 – General assembly diagram- pedal gear 4050
1 3 – Removing and installing neutral retaining spring 4054
1 4 – Clutch pedal: removing and installing 4056
1 5 – Assembly overview – hydraulics 4058
1 6 – Clutch pump: Removal and installation 4061
1 7 – Clutch pump: removal and installation 4065
1 8 – Pipe unit and hose: removal and installation 4067
1 9 – Bleed clutch system: 4069
2 – Declutching unit: repairing 4070
2 1 – Declutching unit: repairing 4070
3 – Repairing clutch 4073
3 1 – Repairing clutch 4073
34 – Controls, Housing 4078
1 – Servicing gear drive mechanism 4078
1 1 – Servicing gear drive mechanism 4078
1 2 – Gear drive mechanism mounting position 4078
1 3 – Gear lever dust cover and knob: removal and installation 4081
1 4 – Gear lever and protective cover: repairing 4083
1 5 – Drive mechanism cables: disassembly and reassembly; – general assembly diagram 4087
1 6 – Removing and installing gear selector mechanism 4090
1 7 – Gear drive mechanism: adjustment 4094
2 – Gearbox: removal and installation 4098
2 1 – Gearbox: removal and installation 4098
2 2 – Modifying support rail VW 457/1 4100
3 – Gear oil level: checking 4113
3 1 – Gear oil level: checking 4113
4 – Dismantling and assembling gearbox 4115
4 1 – Dismantling and assembling gearbox 4115
4 2 – Gearbox assembly overview 4115
4 3 – The installation and removal of the gearbox housing and 5th gear 4118
4 4 – Clutch housing: removing and installing 4121
4 5 – Input shaft, secondary shaft (thrust sprocket shaft), differential, drive mechanism and gearbox brackets: removing and installing 4123
4 6 – Installation sequence 4127
4 7 – Gearbox support 3221: modify 4129
5 – Repairing gearbox housing and clutch housing 4137
5 1 – Repairing gearbox housing and clutch housing 4137
6 – Gear drive mechanism: dismantling and assembling 4145
6 1 – Gear drive mechanism: dismantling and assembling 4145
7 – Dismantling and assembling selector forks 4148
7 1 – Dismantling and assembling selector forks 4148
7 2 – Dismantling and assembling selector forks: Gearbox codes FNT, FLU, GEQ, GAH, GEW 4149
7 3 – Dismantling and assembling selector forks: Gearbox codes GSE, GSG 4155
35 – Gears, Shafts 4164
1 – Dismantling and assembling input shaft 4164
1 1 – Dismantling and assembling input shaft 4164
2 – Dismantling and assembling output shaft 4181
2 1 – Dismantling and assembling output shaft 4181
39 – Final drive, Differential 4195
1 – Oil seal for flanged shaft: renew 4195
1 1 – Oil seal for flanged shaft: renew 4195
1 2 – Renewing oil seal for left flanged shaft: Gearbox codes FNT, FLU, GAH 4195
1 3 – Renewing oil seal for left flanged shaft: Gearbox codes GEQ, GSE, GEW, GSG 4198
1 4 – Renewing oil seal for right flanged shaft: Gearbox codes FNT, FLU, GAH 4201
1 5 – Renewing oil seal for right flanged shaft: Gearbox codes GEQ, GSE, GEW, GSG 4204
2 – Dismantling and assembling differential 4206
2 1 – Dismantling and assembling differential 4206
2 2 – Dismantling and assembling differential: Gearbox codes: FNT, FLU, GAH 4206
2 3 – Dismantling and assembling differential: Gearbox codes: GEQ, GSE, GEW, GSG 4219
3 – Adjusting differential 4232
3 1 – Adjusting differential 4232
3 2 – Adjusting differential: Gearbox codes FNT, FLU, GAH 4232
3 3 – Adjusting differential: Gearbox codes GEQ, GSE, GEW, GSG 4237
K0051645920 Motronic injec a ignit system (4v Roller Rocker Finger) 4243
01 – Self-diagnosis 4247
1 – General to self-diagnosis 4247
1 1 – General to self-diagnosis 4247
1 2 – Features of self-diagnosis 4247
1 3 – Technical data of self-diagnosis 4247
1 4 – Significance of EPC warning lamp (fault lamp for electronic accelerator) in dash panel insert 4248
1 5 – Significance of exhaust emissions warning lamp 4249
1 6 – Connecting fault reader 4250
2 – Fault memory 4253
2 1 – Fault memory 4253
2 2 – Interrogating and erasing engine control unit fault memory 4253
2 3 – Test sequence 4254
3 – Fault table: SAE P0 codes 4255
3 1 – Fault table: SAE P0 codes 4255
4 – Fault table: SAE P1 codes 4262
4 1 – Fault table: SAE P1 codes 4262
5 – Final control diagnosis 4270
5 1 – Final control diagnosis 4270
5 2 – Performing final control diagnosis 4270
6 – Readiness code 4276
6 1 – Readiness code 4276
6 2 – Function 4276
6 3 – Reading off readiness code 4276
6 4 – Generate readiness code 4277
7 – Measured value blocks 4283
7 1 – Measured value blocks 4283
7 2 – Safety precautions 4283
7 3 – Read measured value block 4283
8 – Evaluating measured value blocks, display groups 0 9 -Basic functions- 4284
8 1 – Evaluating measured value blocks, display groups 0 9 -Basic functions- 4284
9 – Evaluating measured value blocks, display groups 10 29 -Ignition- 4288
9 1 – Evaluating measured value blocks, display groups 10 29 -Ignition- 4288
10 – Evaluating measured value blocks, display groups 30 49, 99 -Lambda regulation- 4292
10 1 – Evaluating measured value blocks, display groups 30 49, 99 -Lambda regulation- 4292
11 – Evaluating measured value blocks, display groups 50 69 -Speed regulation- 4297
11 1 – Evaluating measured value blocks, display groups 50 69 -Speed regulation- 4297
12 – Evaluating measured value blocks, display groups 70 79 -Reducing emissions- 4300
12 1 – Evaluating measured value blocks, display groups 70 79 -Reducing emissions- 4300
13 – Evaluating measured value blocks, display group 100 -Readiness code- 4302
13 1 – Evaluating measured value blocks, display group 100 -Readiness code- 4302
14 – Evaluating measured value blocks, display groups 120 129 -Communication- 4302
14 1 – Evaluating measured value blocks, display groups 120 129 -Communication- 4302
24 – Mixture preparation, Injection 4304
1 – Servicing injection system 4304
1 1 – Servicing injection system 4304
1 2 – Fitting locations overview 4304
1 3 – General notes on injection 4308
1 4 – Removing and installing parts of the injection system 4310
1 5 – Dismantling and assembling intake manifold 4323
1 6 – Dismantling and assembling fuel rail with injectors 4327
1 7 – Dismantling and assembling air cleaner 4330
1 8 – Dismantling and assembling the intake manifold 4332
1 9 – Safety precautions 4335
1 10 – Rules for cleanliness 4336
1 11 – Technical data 4337
2 – Checking components 4337
2 1 – Checking components 4337
2 2 – Checking Lambda probe heating for Lambda probe before catalytic converter 4337
2 3 – Checking Lambda probe heating for Lambda probe after catalytic converter 4340
2 4 – Checking throttle valve control part 4342
2 5 – Checking intake manifold pressure sender 4346
2 6 – Check intake air temperature sender 4347
2 7 – Check coolant temperature sender 4352
2 8 – Checking engine speed sender 4357
2 9 – Checking injectors 4359
2 10 – Checking fuel pressure regulator and holding pressure 4365
2 11 – Checking intake air system for leaks (unmetered air) 4368
2 12 – Checking intake air preheating 4369
3 – Checking functions 4370
3 1 – Checking functions 4370
3 2 – Idling check 4370
3 3 – Checking Lambda probe and Lambda regulation before catalytic converter 4372
3 4 – Check Lambda probe and Lambda regulation after catalytic converter 4375
3 5 – Checking Lambda probe ageing for Lambda probe before catalytic converter 4379
3 6 – Checking engine operating mode 4381
4 – Engine control unit 4383
4 1 – Engine control unit 4383
4 2 – Checking control unit voltage supply 4383
4 3 – Procedure after voltage supply open circuit 4385
4 4 – Replace engine control unit 4385
4 5 – Coding engine control unit 4387
4 6 – Coding variations of engine control unit 4388
4 7 – Erasing learnt values and adapting engine control unit to throttle valve control part and exhaust gas recirculation valve 4388
5 – Checking additional signals 4390
5 1 – Checking additional signals 4390
5 2 – Checking speed signal 4390
5 3 – Checking signal from/to air conditioning system 4392
5 4 – Checking signal from clutch pedal switch 4394
5 5 – Checking signal from brake light switch and brake pedal switch 4396
5 6 – Checking engine speed signal 4399
5 7 – Checking data bus 4400
28 – Ignition system 4402
1 – Servicing ignition system 4402
1 1 – Servicing ignition system 4402
1 2 – General notes on ignition system 4402
1 3 – Removing and installing parts of the ignition system 4403
1 4 – Safety precautions 4406
1 5 – Test data, spark plugs 4407
1 6 – Checking Hall sender 4407
1 7 – Checking ignition coils with final output stage 4409
1 8 – Checking knock sensor 4413
1 9 – Check misfiring recognition 4415
K0051652920 Self diagnosis for 6 speed automatic gearbox 09G 4418
01 – Self-diagnosis, Electrical check 4422
1 – Self-diagnosis function 4422
1 1 – Self-diagnosis function 4422
1 2 – Technical data of self-diagnosis 4423
2 – General notes on the repair 4423
2 1 – General notes on the repair 4423
3 – Electrical/electronic components and their locations 4425
3 1 – Electrical/electronic components and their locations 4425
4 – Performing self-diagnosis 4437
4 1 – Performing self-diagnosis 4437
4 2 – Safety precautions 4438
4 3 – Connecting VAS 5051 and selecting function 4438
4 4 – List of selectable functions 4440
4 5 – Interrogate fault memory 4441
4 6 – Fault table 4441
4 7 – Fault codes 00258 01236 4442
4 8 – Fault codes 16988 65535 4448
4 9 – Initiate basic setting 4458
4 10 – Erase fault memory 4459
4 11 – Code control unit 4460
4 12 – Read measured value (data) block 4460
4 13 – Test table 4463
5 – Gearbox: Electrical check 4473
5 1 – Gearbox: Electrical check 4473
5 2 – Test table 4475
K0051653220 General body repairs interior 4480
68 – Interior equipment 4484
1 – Interior mirror 4484
1 1 – Interior mirror 4484
1 2 – Removing and installing interior mirror 4484
1 3 – Bonding retaining plate for interior mirror 4485
2 – Compartments, covers and trimming 4486
2 1 – Compartments, covers and trimming 4486
2 2 – Removing and installing centre console 4486
2 3 – Removing trim below centre of dash panel 4498
2 4 – Removing glove box 4499
2 5 – Removing drivers side footwell cover 4500
2 6 – Removing trim under steering column 4500
2 7 – Removing sun visor 4502
2 8 – Removing plenum chamber inner cover 4502
3 – Grab handle 4504
3 1 – Grab handle 4504
3 2 – Removing grab handle (dash panel) 4504
3 3 – Removing hand hold (roof) 4504
3 4 – Removing hand hold straps 4505
4 – Sill panel trims 4506
4 1 – Sill panel trims 4506
4 2 – Removing and installing sill panel trim 4506
5 – Foot support 4508
5 1 – Foot support 4508
5 2 – Removing and installing foot support on driver’s side 4508
5 3 – Removing and installing foot support on front passenger’s side 4508
6 – Rear seat backrest reinforcement 4509
6 1 – Rear seat backrest reinforcement 4509
6 2 – Removing rear seat backrest reinforcement 4509
69 – Passenger protection 4510
1 – Seat belts 4510
1 1 – Seat belts 4510
1 2 – Safety regulations for belt tensioners 4510
1 3 – Front seat belt with belt tensioner – Assembly overview 4511
1 4 – Removing and installing rear seat belts 4515
2 – Inspecting seat belts 4516
2 1 – Inspecting seat belts 4516
3 – Airbag 4520
3 1 – Airbag 4520
3 2 – Tools 4520
3 3 – Locations overview 4521
3 4 – Safety precautions when working on the airbag 4522
3 5 – Replacing airbag units following an accident 4523
3 6 – Removing and installing driver’s airbag unit 4524
3 7 – Steering wheel – Assembly overview 4528
3 8 – Removing steering wheel 4529
3 9 – Removing and installing coil connector with slip ring 4529
3 10 – Removing and installing front passenger’s airbag unit 4532
3 11 – Removing and installing airbag control unit (J 234) 4534
3 12 – Removing and installing driver’s/front passenger’s side airbag 4536
3 13 – Removing and installing sensor for driver’s/front passenger’s side airbag 4539
70 – Trim/Insulation 4541
1 – Dash panel 4541
1 1 – Dash panel 4541
1 2 – Removing and installing dash panel 4541
2 – Door trims 4550
2 1 – Door trims 4550
2 2 – Tools 4550
2 3 – Removing and installing front door trim panel 4551
3 – Pillars and side trim panels 4553
3 1 – Pillars and side trim panels 4553
3 2 – Removing and installing A-pillar upper trim 4554
3 3 – Removing and installing A-pillar lower trim 4555
3 4 – Removing and installing B-pillar upper trim 4557
3 5 – Removing and installing C-pillar trim 4559
3 6 – Removing and installing side panel trim 4561
4 – Load and luggage compartment trim panels 4563
4 1 – Load and luggage compartment trim panels 4563
4 2 – Removing and installing luggage compartment side panel trim 4563
4 3 – Removing and installing load sill cover 4565
5 – Tailgate trim panels 4567
5 1 – Tailgate trim panels 4567
5 2 – Removing and installing tailgate upper trim 4567
5 3 – Removing and installing tailgate lower trim 4569
6 – Roof trims 4571
6 1 – Roof trims 4571
6 2 – Tools 4571
6 3 – Removing and installing moulded headliner 4572
72 – Seat frames 4580
1 – Front seats 4580
1 1 – Front seats 4580
1 2 – Removing and installing front seat 4580
1 3 – Removing and installing bucket seat 4581
1 4 – Adjusting seat height 4583
2 – Rear seats 4583
2 1 – Rear seats 4583
2 2 – Removing and installing rear seat cushion (single unit) 4584
2 3 – Removing and installing backrest 4585
74 – Seats – Upholstery, Covers 4586
1 – Front seat cover and padding 4586
1 1 – Front seat cover and padding 4586
1 2 – Removing and installing front seat cover and padding 4586
2 – Rear seat cover and padding 4587
2 1 – Rear seat cover and padding 4587
2 2 – Tools 4587
2 3 – Removing and installing seat cushion cover and padding 4588
2 4 – Removing and installing backrest cover and padding (single unit backrest or right-hand backrest) 4592
K0051653320 General body repairs exterior 4596
50 – Body front 4602
1 – Body front 4602
1 1 – Body front 4602
1 2 – Tools 4602
1 3 – Lock carrier – Assembly overview 4603
1 4 – Lock carrier – service position 4606
1 5 – Front part – Assembly overview 4607
1 6 – Front wing – Assembly overview 4610
1 7 – Noise insulation – Assembly overview 4613
1 8 – Removing and installing plenum chamber closing cover 4615
53 – Body rear 4616
1 – Body rear 4616
1 1 – Body rear 4616
1 2 – Rear part – Assembly overview 4616
1 3 – Rear wing – Assembly overview 4619
55 – Bonnet, Flaps 4623
1 – Bonnet 4623
1 1 – Bonnet 4623
1 2 – Assembly overview 4624
1 3 – Adjusting bonnet 4626
1 4 – Removing and installing bowden cable 4626
1 5 – Removing and installing release lever 4628
1 6 – Removing and installing bonnet lock 4629
2 – Tailgate 4631
2 1 – Tailgate 4631
2 2 – Assembly overview 4631
2 3 – Removing gas strut 4633
2 4 – Releasing gas from strut 4633
2 5 – Adjusting boot lid/tailgate 4634
2 6 – Removing and adjusting tailgate lock 4637
2 7 – Removing and installing tailgate remote release motor carrier 4640
3 – Tank flap unit 4641
3 1 – Tank flap unit 4641
3 2 – Removing and installing fuel tank filler flap unit 4641
3 3 – Removing and installing fuel tank filler flap release motor 4642
57 – Front doors/Door components/Central locking system 4644
1 – Front doors 4644
1 1 – Front doors 4644
1 2 – Tools 4644
1 3 – Assembly overview 4645
1 4 – Removing and installing door 4648
1 5 – Adjusting door 4652
1 6 – Door handle and lock – Assembly overview 4654
1 7 – Removing lock cylinder housing 4656
1 8 – Installing lock cylinder housing 4657
1 9 – Removing and installing door handle 4657
1 10 – Removing and installing door lock 4658
1 11 – Removing and installing bearing bracket 4664
1 12 – Removing and installing locking knob for release rod 4665
2 – Central locking 4667
2 1 – Central locking 4667
2 2 – Assembly overview for central locking and convenience systems 4668
63 – Bumpers 4673
1 – Front bumper 4673
1 1 – Front bumper 4673
1 2 – Assembly overview 4673
2 – Rear bumper 4677
2 1 – Rear bumper 4677
2 2 – Assembly overview 4677
2 3 – Removing and installing diffuser 4680
64 – Glazing 4681
1 – Flush bonded windows 4681
1 1 – Flush bonded windows 4681
1 2 – Tools 4681
1 3 – Materials 4682
1 4 – Windscreen – Assembly overview 4683
1 5 – Removing windscreen 4685
1 6 – Installing windscreen 4688
1 7 – Removing and installing rain sensor 4688
1 8 – Side window – Assembly overview 4690
1 9 – Removing undamaged side window 4691
1 10 – Removing broken side window 4693
1 11 – Installing side window 4693
1 12 – Rear window – Assembly overview 4694
1 13 – Removing undamaged rear window 4695
1 14 – Removing broken rear window 4697
1 15 – Installing rear window 4698
1 16 – Preparing old undamaged window for glazing 4698
1 17 – Preparing new window for glazing 4699
1 18 – Preparing body flange for glazing 4700
1 19 – Installation instructions 4701
1 20 – Minimum curing time 4702
1 21 – Touching up paint damage 4702
1 22 – Cleaning off surplus adhesive sealing material 4702
2 – Door windows 4702
2 1 – Door windows 4702
2 2 – Tools 4703
2 3 – Front door window – Assembly overview 4704
2 4 – Removing front door window 4707
2 5 – Adjusting door window 4708
2 6 – Removing and installing assembly carrier 4708
2 7 – Electric window lifter with convenience system (automatic opening and closing) with excess force limitation (roll-back) 4713
2 8 – Overriding difficulties in window upper area with force limitation system 4715
66 – Exterior equipment 4716
1 – Removing and installing wheel housing liner 4716
1 1 – Removing and installing wheel housing liner 4716
1 2 – Front wheel housing liner 4716
1 3 – Rear wheel housing liner 4717
2 – Rear view mirror 4718
2 1 – Rear view mirror 4718
2 2 – Tools 4718
2 3 – Removing and installing mirror glass 4718
2 4 – Removing mirror housing 4719
2 5 – Removing and installing exterior mirror 4720
3 – Roof mouldings 4723
3 1 – Roof mouldings 4723
3 2 – Roof moulding 4723
4 – Spoiler 4725
4 1 – Spoiler 4725
4 2 – Removing and installing roof spoiler 4725
4 3 – Removing and installing rear spoiler 4727
5 – Sill trim 4729
5 1 – Sill trim 4729
5 2 – Replacing sill trim 4729
K0051653620 Motronic inject and ignition system 6 cyl Injection engine 4734
01 – Self-diagnosis 4738
1 – General to self-diagnosis (engine) 4738
1 1 – General to self-diagnosis (engine) 4738
1 2 – Features of self-diagnosis 4738
1 3 – Significance of EPC warning lamp (fault lamp for electronic accelerator) in dash panel insert 4738
1 4 – Significance of exhaust emissions warning lamp 4739
1 5 – Technical data of self-diagnosis 4740
1 6 – Connecting fault reader V A G 1551 and selecting engine control unit 4741
1 7 – Connecting vehicle diagnosis, testing and information system VAS 5051 and selecting engine control unit 4744
2 – Fault memory 4747
2 1 – Fault memory 4747
2 2 – Interrogating and erasing fault memory 4747
3 – Fault table: from V A G code 16486 / SAE P0 codes 4749
3 1 – Fault table: from V A G code 16486 / SAE P0 codes 4749
3 2 – Characteristics of the New Beetle RSi 4749
3 3 – Fault table: from V A G code 16486 / SAE P0 codes 4752
4 – Fault table: from V A G code 17510 / SAE P1 codes 4758
4 1 – Fault table: from V A G code 17510 / SAE P1 codes 4758
4 2 – Characteristics of the New Beetle RSi 4758
4 3 – Fault table: from V A G code 17510 / SAE P1 codes 4761
5 – Final control diagnosis 4770
5 1 – Final control diagnosis 4770
5 2 – Performing final control diagnosis 4770
6 – Readiness code 4786
6 1 – Readiness code 4786
6 2 – Reading readiness code 4786
6 3 – Generating readiness code 4787
7 – Measured value blocks 4805
7 1 – Measured value blocks 4805
7 2 – Safety precautions 4805
7 3 – Read measured value block 4806
8 – Evaluating measured value blocks, display groups 0 6 -Basic functions- 4807
8 1 – Evaluating measured value blocks, display groups 0 6 -Basic functions- 4807
9 – Evaluating measured value blocks, display groups 10 29 -Ignition- 4810
9 1 – Evaluating measured value blocks, display groups 10 29 -Ignition- 4810
10 – Evaluating measured value blocks, display groups 30 33, 99 -Lambda regulation- 4813
10 1 – Evaluating measured value blocks, display groups 30 33, 99 -Lambda regulation- 4813
11 – Evaluating measured value blocks, display groups 50 69 -Speed regulation- 4819
11 1 – Evaluating measured value blocks, display groups 50 69 -Speed regulation- 4819
12 – Evaluating measured block values, display groups 91 95 -Performance improvement- 4822
12 1 – Evaluating measured block values, display groups 91 95 -Performance improvement- 4822
13 – Evaluating measured value block, display group 125 -Communication- 4823
13 1 – Evaluating measured value block, display group 125 -Communication- 4823
24 – Mixture preparation, Injection 4824
1 – Servicing injection system 4824
1 1 – Servicing injection system 4824
1 2 – Fitting locations overview 4824
1 3 – General notes on injection 4831
1 4 – Removing and installing parts of the injection system 4832
1 5 – Dismantling and assembling intake manifold 4845
1 6 – Dismantling and assembling fuel distributor 4849
1 7 – Dismantling and assembling air cleaner 4851
1 8 – Safety precautions 4853
1 9 – Rules for cleanliness 4855
1 10 – Technical data 4855
2 – Checking components 4855
2 1 – Checking components 4855
2 2 – Checking Lambda probe heating for Lambda probe before catalyst 4856
2 3 – Checking Lambda probe heating for Lambda probe after catalyst 4861
2 4 – Checking air mass meter 4867
2 5 – Checking throttle valve control part 4870
2 6 – Checking coolant temperature sender 4874
2 7 – Checking intake air temperature sender 4879
2 8 – Checking engine speed sender 4885
2 9 – Checking injectors 4886
2 10 – Checking fuel pressure regulator and holding pressure 4892
2 11 – Checking intake manifold change-over 4895
2 12 – Checking intake air system for leaks (unmetered air) 4897
3 – Checking functions 4898
3 1 – Checking functions 4898
3 2 – Idling check 4899
3 3 – Checking Lambda probe and Lambda regulation before catalyst 4900
3 4 – Checking Lambda probe and Lambda regulation after catalyst 4905
3 5 – Checking Lambda probe ageing of Lambda probe 1 bank 1 4908
3 6 – Checking Lambda probe ageing of Lambda probe 1 bank 2 4910
3 7 – Checking Lambda probe ageing Lambda probe after catalyst (trim regulation) 4911
3 8 – Checking engine operating mode 4913
3 9 – Checking Lambda probe ageing of Lambda probes 4914
4 – Engine control unit 4914
4 1 – Engine control unit 4914
4 2 – Checking control unit voltage supply 4915
4 3 – Procedure after voltage supply open circuit 4917
4 4 – Replacing engine control unit 4918
4 5 – Coding engine control unit 4919
4 6 – Matching engine control unit to electronic immobilizer 4920
4 7 – Adapting engine control unit to throttle valve control part 4921
5 – Checking additional signals 4923
5 1 – Checking additional signals 4923
5 2 – Checking speed signal 4923
5 3 – Checking signal from/to air conditioner 4925
5 4 – Checking signal from clutch pedal switch 4927
5 5 – Checking signal from brake light switch and brake pedal switch 4930
5 6 – Checking cruise control system (CCS) 4933
5 7 – Checking data bus 4934
28 – Ignition system 4936
1 – Servicing ignition system 4936
1 1 – Servicing ignition system 4936
1 2 – General notes on ignition system 4936
1 3 – Removing and installing parts of the ignition system 4937
1 4 – Safety precautions 4942
1 5 – Test data, spark plugs 4943
1 6 – Checking Hall sender 4943
1 7 – Checking ignition transformer 4945
1 8 – Checking knock sensor 4949
1 9 – Check misfiring recognition 4952
K0051654621 Engine Mechanical Fuel Injection and Ignition 4956
00 – General, Technical Data 4962
1 Technical Data 4962
1 1 Engine Number 4962
1 2 Engine Data 4962
10 – Engine – Assembly 4965
1 Engine, Removing and Installing 4965
1 1 Engine, Removing 4966
1 2 Engine, Securing to Assembly Stand 4971
1 3 Engine, Installing 4972
1 4 Tightening Specifications 4974
1 5 Engine and Transmission Mounts, Aligning 4975
1 6 Assembly Mounts, Tightening Specifications 4976
1 7 Air Conditioning, General Information and Assembly Work 4976
13 – Engine – Crankshaft, Cylinder Block 4978
1 Engine, Disassembling and Assembling 4978
1 1 Assembly Overview 4978
1 1 1 Part I 4979
1 1 2 Part II 4980
1 2 Ribbed Belt, Removing and Installing 4981
2 Sealing Flanges and Flywheel/Drive Plate 4983
2 1 Assembly Overview 4983
2 2 Crankshaft Oil Seal, Belt Pulley End, Replacing 4985
2 3 Sealing Flange, Belt Pulley End, Removing and Installing 4987
2 4 Drive Plate, Removing and Installing 4989
3 Crankshaft, Servicing 4991
3 1 Crankshaft, Assembly Overview 4991
3 2 Crankshaft Dimensions 4993
4 Piston and Connecting Rod, Servicing 4994
4 1 Piston and Connecting Rod, Assembly Overview 4994
4 1 1 Industrially Fractured Connecting Rods, Introducing Gradually 4994
4 1 2 Piston with Conventional Connecting Rod 4995
4 1 3 Piston with Industrially Fractured Connecting Rod 4998
4 2 Piston and Cylinder Dimensions 5001
15 – Engine – Cylinder head, Valvetrain 5002
1 Cylinder Head, Servicing 5002
1 1 Cylinder Head, Assembly Overview 5003
1 1 1 Engine Code APH 5003
1 1 2 Engine Codes AWP, AWV, BKF and BNU 5005
1 2 Toothed Belt, Removing, Installing and Tensioning 5007
1 3 Cylinder Head, Removing and Installing 5012
1 3 1 Removing 5012
1 3 2 Installing 5016
1 4 Compression, Checking 5018
2 Valve Gear, Servicing 5022
2 1 Valve Gear, Assembly Overview 5022
2 2 Camshaft Oil Seal, Replacing 5026
2 2 1 Oil Seals, General Information 5026
2 2 2 Intake Camshaft Seal on Camshaft Position Sensor, Replacing 5027
2 2 3 Exhaust Camshaft Seal on Camshaft Pulley, Replacing 5029
2 3 Hydraulic Lifters, Checking 5031
2 4 Camshafts, Removing and Installing 5031
2 4 1 Removing 5032
2 4 2 Installing 5034
2 5 Valve Stem Seals, Replacing 5036
2 6 Valve Guides, Checking 5039
2 7 Valve Seats, Reworking 5039
17 – Engine – Lubrication 5042
1 Lubrication System, Servicing 5042
1 1 Engine Oil 5042
1 2 Lubrication System, Assembly Overview 5044
1 2 1 Part I – Engines with One-Piece Oil Pan 5044
1 2 2 Part I – Engines with Two-Piece Oil Pan 5046
1 2 3 Part I – Engines with Oil Pan Guard 5048
1 2 4 Part II – Oil Filter Bracket 5050
1 3 Oil Pan, Removing and Installing 5051
1 4 Oil Pressure and Oil Pressure Switch, Checking 5054
19 – Engine – Cooling system 5057
1 Cooling System, Servicing 5057
1 1 Cooling System Components on Body, Assembly Overview 5058
1 2 Cooling System Components on Engine, Assembly Overview 5060
1 2 1 Engine Code APH 5060
1 2 2 Engine Codes AWP, AWV, BKF and BNU 5062
1 3 Coolant Hose Connection Diagram 5064
1 3 1 Engine Code APH 5064
1 3 2 Engine Codes AWP, AWV, BKF and BNU 5065
1 4 Cooling System, Draining and Filling 5066
1 5 Radiator, Removing and Installing 5070
1 5 1 Air Conditioning, General Information and Assembly Work 5071
1 6 Coolant Pump, Removing and Installing 5072
1 7 Thermostat, Removing and Installing 5073
1 8 After-Run Coolant Pump, Checking 5074
1 9 Coolant Fan, Checking 5076
20 – Fuel supply 5077
1 Fuel Supply System Components 5077
1 1 Fuel Supply System, Safety Precautions 5077
1 2 Clean Working Conditions 5078
1 3 Fuel Tank with Attachments and Fuel Filter, Assembly Overview 5079
1 3 1 Engine Codes APH, AWP, AWV, BKF and BNU 5079
1 4 Fuel Delivery Unit, Removing and Installing 5082
1 5 Fuel Level Sensor, Removing and Installing 5084
1 6 Fuel Tank, Removing and Installing 5084
1 7 Crash Fuel Shut-Off 5086
1 8 Fuel Pump, Checking 5087
2 Electronic Power Control, Servicing 5094
2 1 Electronic Power Control System, Function 5094
2 2 Electronic Power Control System, Assembly Overview 5095
3 EVAP System, Servicing 5096
3 1 Functional Description 5096
3 2 EVAP System Components, Engine Codes APH, AWP, AWV, BKF and BNU, Assembly Overview 5097
3 3 EVAP System, Connection Diagram 5098
3 4 Fuel Tank Breather Line, Engine Codes APH, AWP, AWV, BKF and BNU, Checking 5099
21 – Turbocharger, G-Charger 5100
1 Charge Air System with Turbocharger, Servicing 5100
1 1 Safety Precautions 5100
1 2 Clean Working Conditions 5101
1 3 Turbocharger with Attachments, Assembly Overview 5102
1 3 1 Part I 5102
1 3 2 Part II – Engine Code APH 5104
1 3 3 Part II – Engine Codes AWP, AWV, BKF and BNU 5105
1 4 Charge Air Cooler System Components, Assembly Overview 5106
1 5 Charge Pressure Control and Vacuum Control, Overview 5107
1 5 1 Engine Code APH 5107
1 5 2 Engine Codes AWP, AWV, BKF and BNU 5108
2 Charge Air System Components, Checking 5110
2 1 Charge Pressure Control, Checking 5110
2 1 1 Engine Codes APH, BKF and BNU 5110
2 1 2 Engine Codes AWP and AWV 5111
2 2 Charge Pressure Control Valve Pressure Unit, Checking 5111
2 3 Charge Pressure Bypass Valve, Checking 5112
24 – Multiport Fuel Injection (MFI) 5114
1 Injection System, Servicing 5114
1 1 Injection, General Information 5114
1 2 Safety Precautions 5115
1 3 Clean Working Conditions 5116
1 4 Component Locations, Overview 5116
1 4 1 Engines with Two Oxygen Sensors 5116
1 4 2 Engines with Three Oxygen Sensors 5118
1 5 Exhaust Gas Recirculation, Assembly Overview 5120
1 5 1 Engine Code APH 5120
1 5 2 Engine Codes AWP, AWV 5123
1 5 3 Engine Codes BKF and BNU 5125
1 6 Air Filter Assembly, Overview 5128
1 7 Fuel Rail with Injectors, Assembly Overview 5129
1 8 Technical Data 5129
2 Components, Checking 5131
2 1 Injectors, Checking Injection Quantity and for Leaks 5131
2 2 Fuel Pressure Regulator and Residual Pressure 5134
3 Engine Control Module 5137
3 1 Engine Control Module, Replacing 5137
3 2 Adapting Functions and Components 5138
3 3 Engine Control Module DTC Memory, Checking and Erasing 5140
26 – Exhaust system, Emission controls 5142
1 Exhaust System Components, Servicing 5142
1 1 Exhaust Manifold/Front Exhaust Pipe with Catalytic Converter and Attachments, Assembly Overview 5143
1 1 1 Engines with Two Oxygen Sensors 5143
1 1 2 Engines with Three Oxygen Sensors 5144
1 2 Muffler with Mounts, Assembly Overview 5145
2 Secondary Air Injection System 5147
2 1 Functional Description 5147
2 2 Secondary Air System Components, Assembly Overview 5148
2 3 Secondary Air System, Connection Diagram 5149
2 3 1 Engine Code APH 5149
2 3 2 Engine Codes AWP, AWV, BKF and BNU 5150
2 4 Combination Valve, Checking 5150
2 5 Combination Valve, Removing and Installing 5151
28 – Ignition/Glow plug System 5153
1 Ignition System, Servicing 5153
1 1 Ignition System, General Information 5153
1 2 Safety Precautions 5153
1 3 Ignition System Components, Assembly Overview 5155
1 4 Ignition Coils with Final Output Stage, Removing and Installing 5156
1 4 1 Engine Code APH 5156
1 4 2 Engine Codes AWP, AWV, BKF and BNU 5157
1 5 Spark Plug Test Data 5158
K0251572920 Electrical system 5159
27 – Starter, current supply, CCS 5167
1 Battery -A- 5167
1 1 Fundamentals for batteries -A- 5167
1 2 Types of battery 5167
1 2 1 Low maintenance battery -A- 5167
1 2 2 Maintenance-free battery -A- 5167
1 2 3 Absorbent glass mat battery 5168
1 2 4 Gel battery 5168
1 3 Warning notices and safety regulations 5168
1 3 1 Dangers when handling batteries -A- 5168
1 4 Battery terminal connection 5170
2 Checking battery -A- 5171
2 1 Visual check 5171
2 2 Test of colour display of magic eye 5172
2 2 1 Test of “3-colour” display (up to 03/08) 5172
2 2 2 Test of “2-colour” display (from 04/08 onwards) 5173
2 3 Checking low maintenance battery -A- 5174
2 3 1 Checking electrolyte level 5174
2 3 2 Replenishing with distilled water 5174
2 3 3 Checking specific gravity of electrolyte 5175
2 4 Checking no-load voltage of battery -A- (stock and stored vehicles) 5177
2 5 Battery test using battery tester with printer -VAS 5097 A- 5178
2 5 2 Battery load test 5179
2 5 3 Table showing low-temperature test current 5181
2 5 4 Results of battery load test 5182
2 5 6 Evaluation of test result 5182
2 6 Battery tester with printer -VAS 6161- 5183
2 6 2 Battery test 5184
2 6 3 Maintenance test 5185
2 6 4 Service test 5186
2 6 5 Guarantee test 5187
2 6 7 Evaluation of test result 5188
2 7 Current draw test 5189
3 Charging battery -A- 5191
3 1 Battery charger -VAS 5095 A- 5191
3 1 1 Description of battery charger -VAS 5095 A- 5192
3 1 2 Charging battery -A- 5192
3 1 3 Charging totally discharged battery -A- 5193
3 1 4 Support mode 5194
3 1 5 Trickle charging 5196
3 2 Battery charger -VAS 5900- 5197
3 2 1 Description of battery charger -VAS 5900- 5197
3 2 2 Charging battery -A- 5198
3 2 3 Service charging 5200
3 2 4 Charging totally discharged battery -A- 5202
3 2 5 Support mode 5204
3 2 6 Trickle charging 5207
3 3 Battery charger -VAS 5903- 5208
3 3 1 Description of battery charger -VAS 5903- 5209
3 3 2 Charging battery -A- 5209
3 3 3 Refresh charging 5211
3 3 4 Charging totally discharged battery -A- 5213
3 3 5 Support mode 5215
3 3 6 Trickle charging 5217
3 4 Battery charger -VAS 5906- 5218
3 4 2 Charging battery -A- 5220
3 5 Solar panel -VAS 6102 A- 5221
3 5 2 Trickle charging 5221
3 6 Totally discharged batteries -A- 5222
4 Disconnecting and connecting battery -A- 5224
4 1 Disconnecting battery -A- 5224
4 2 Connecting battery -A- 5225
5 Removing and installing battery -A- 5227
5 1 Vehicles with 4-cylinder engine (petrol/diesel) 5227
5 2 Vehicles with 5-cyl 2 5l petrol engine 5229
6 Starter -B- 5232
6 1 Removing and installing starter -B-, 4-cylinder engines (petrol/diesel) 5232
6 2 Removing and installing starter -B-, 5-cylinder petrol engine 5235
6 3 Specified torques: starter -B- 5237
7 Alternator -C- 5238
7 1 Assembly overview – 4-cyl 1 6l/1 8l/2 0l petrol engine 5238
7 2 Assembly overview – 5-cylinder petrol engine with power steering/air conditioner compressor 5239
7 3 4-cylinder diesel engine with power steering – Assembly overview 5240
7 4 Assembly overview – 4-cylinder diesel engine with power steering/air conditioner compressor 5241
7 5 Removing and installing alternator -C- 5242
7 5 1 Vehicles with 4-cylinder engine (petrol/diesel) 5242
7 5 2 Vehicles with 5-cyl 2 5l petrol engine 5243
7 6 Removing air conditioner compressor on vehicles with an air conditioning system 5246
7 7 Securing battery positive wire on alternator -C- 5247
7 8 Checking poly V-belt 5248
7 9 Removing and installing voltage regulator -C1- 5248
7 9 1 Removing and installing voltage regulator -C1- up to 04 99 5248
7 9 2 Removing and installing voltage regulator -C1- from 05 99 5249
7 10 Checking carbon brushes 5250
7 11 Removing and installing poly-V belt pulley on alternator -C- 5250
7 11 1 Removing and installing poly V-belt pulley without freewheel 5250
7 11 2 Removing and installing poly V-belt pulley with freewheel 5251
8 Cruise control system (CCS) 5254
8 1 Activating/deactivating cruise control system (CCS) 5254
8 2 CCS switch -E45- 5254
90 – Gauges, instruments 5255
1 Dash panel insert 5255
1 1 Renewing dash panel insert 5255
1 2 Removing and installing dash panel insert 5256
1 3 Installing adapter cable 5256
1 4 Warning lamp symbols in dash panel insert 5259
1 5 Multi-pin connector on dash panel insert up to 04 99 5261
1 6 Multi-pin connector on dash panel insert from 05 99 5264
2 Service interval display 5267
2 1 Service table 5267
2 2 Service interval display: resetting, up to 04 99 5267
2 3 Service interval display, from 05 99 5268
2 4 Service interval display: resetting, from 05 99 5269
92 – Windscreen wash/wipe system 5271
1 Windscreen wiper system 5271
1 1 Assembly overview – windscreen wiper system 5271
1 2 Removing and installing windscreen wiper system 5271
1 2 1 Removing wiper arms 5272
1 2 2 Remove plenum chamber cover 5273
1 2 3 Removing wiper frame with linkage and wiper motor -V- 5273
1 2 4 Removing wiper motor -V- from wiper frame 5274
1 2 5 Installing windscreen wiper motor -V- in wiper frame 5274
1 3 Adjusting wiper blade park position 5274
1 4 Removing and installing wiper rubber 5275
2 Window washer system 5277
2 1 Assembly overview – windscreen washer system 5277
2 2 Adjusting spray fields for window spray jets 5277
2 3 Removing and installing window washer system spray jet 5278
3 Headlight washer system 5279
3 1 Assembly overview – headlight washer system 5279
3 2 Removing and installing spray jet carrier with spray jets 5279
3 3 Removing and installing headlight washer system supplementary reservoir 5280
94 – Lights, bulbs, switches – exterior 5281
1 Headlight with halogen bulbs 5281
1 1 Assembly overview up to 06 05 5281
1 2 Assembly overview from 07 05 5282
1 3 Adjusting headlights 5282
1 4 Converting headlights from driving on the right to driving on the left and visa versa 5283
1 4 1 Vehicles, up to 06 05 5283
1 4 2 Vehicles from 07 05 5284
1 5 Removing and installing headlight, up to 06 05 5285
1 5 1 Removing and installing left headlight 5285
1 5 2 Removing and installing right headlight 5286
1 6 Removing and installing headlight, from 07 05  5286
1 7 Removing and installing headlight mounting plate, from 07 05 5288
1 8 Replacing bulbs up to 06 05 5289
1 8 1 Renewing dipped beam bulb 5289
1 8 2 Renewing main beam bulb 5290
1 8 3 Renewing side light bulb 5291
1 9 Replacing bulbs from 07 05 5292
1 9 1 Renewing dipped beam bulb 5292
1 9 2 Renewing main beam bulb 5293
1 9 3 Renewing side light bulb 5294
1 10 Removing and installing headlight range control motor, up to 06 05 5295
1 11 Removing and installing headlight range control motor, from 07 05 5296
2 Headlights with gas discharge bulbs 5298
2 1 Operation and safety notes for gas discharge bulbs 5298
2 2 Assembly overview 5300
2 3 Renewing bulbs 5302
2 3 1 Renewing gas discharge bulb 5302
2 3 2 Renewing main beam bulb 5304
2 3 3 Renewing side light bulb 5304
2 4 Removing and installing headlight 5305
2 5 Adjusting headlights 5305
2 5 1 Making basic headlight setting 5305
2 5 2 Adjustment lever for setting for driving on the left or right 5305
2 6 Removing and installing gas discharge bulb control unit 5306
2 7 Removing and installing front left vehicle level sender -G78- 5307
2 8 Removing and installing rear left vehicle level sender -G76-: 5308
2 9 Removing and installing headlight range control unit -J431- 5308
2 10 Removing and installing headlight range control motor 5309
3 Fog lights 5310
3 1 Removing and installing fog light, up to 11 99 5310
3 2 Removing and installing fog light, from 12 99 5310
3 3 Removing and installing fog light, from 07 05 5311
3 4 Adjusting fog light height adjustment 5312
3 4 1 Vehicles, up to 06 05 5312
3 4 2 Vehicles from 07 05 5312
3 5 Renewing fog light bulb 5313
3 5 1 Vehicles, up to 06 05 5313
3 5 2 Vehicles from 07 05 5314
4 Front turn signals 5315
4 1 Removing and installing front turn signals, up to 06 05 5315
4 2 Removing and installing front turn signals, from 07 05 5315
4 3 Renewing turn signal bulb 5317
4 3 1 Renewing bulb, vehicles up to 06 05 5317
4 3 2 Renewing bulb, vehicles from 07 05 5317
4 4 Removing and installing front turn signals (Sport Edition) 5318
4 5 Renewing turn signal bulb (Sport Edition) 5319
5 Side turn signals 5320
5 1 Removing and installing turn signal repeater 5320
5 2 Removing and installing turn signal lights (Sport Edition) 5321
5 3 Renewing turn signal bulb (Sport Edition) 5321
6 Turning signal lights in exterior mirror 5323
6 1 Removing and installing turn signal repeater bulb 5323
7 Tail lights 5325
7 1 Assembly overview up to 06 05 5325
7 2 Assembly overview from 07 05 5326
7 3 Removing and installing tail light, up to 06 05 5326
7 4 Removing and installing tail light, from 07 05 5327
7 5 Renewing tail light bulbs, up to 06 05 5330
7 6 Renewing tail light bulbs, from 07 05 5330
8 Reversing light 5333
8 1 Removing and installing reversing light, up to 06 05 5333
8 2 Removing and installing reversing light, from 07 05 5333
8 3 Renewing reversing light bulb, up to 06 05 5334
8 4 Renewing reversing light bulb, from 07 05 5335
9 Rear fog light 5336
9 1 Removing and installing rear fog light, up to 06 05 5336
9 2 Removing and installing rear fog light, from 07 05 5336
9 3 Renewing rear fog light bulb, up to 06 05 5336
9 4 Renewing rear fog light bulb, from 07 05 5337
10 Number plate lights 5338
10 1 Removing and installing number plate light, up to 06 05 5338
10 2 Removing and installing number plate light, from 07 05 5338
10 3 Renewing number plate light bulb, from 07 05 5339
11 Additional brake lights 5340
11 1 Removing and installing high-level brake light, limousine 5340
11 2 Removing and installing high-level brake light, Cabriolet, from 07 05 5340
12 Steering column switch 5342
12 1 Removing and installing steering column switch 5342
12 2 Pin assignment on steering column switch 5343
13 Ignition/starter switch -D- and lock cylinder 5345
13 1 Removing and installing lock cylinder 5345
13 2 Removing and installing ignition/starter switch -D- 5346
13 3 Pin assignment for ignition/starter switch -D- 5347
14 Parking aid 5348
14 1 General description 5348
14 2 Assembly overview – 4-channel parking aid 5348
14 3 Removing and installing parking aid control unit -J446- saloon 5349
14 4 Removing and installing parking aid control unit -J446- Cabriolet 5350
14 5 Coding parking aid control unit -J446- 5350
14 6 Adapting parking aid control unit -J446- 5351
14 7 Removing and installing rear parking aid senders 5351
14 8 Renewing rear parking aid senders 5353
14 9 Bonding sender bracket in bumper cover 5354
14 10 Testing parking aid senders 5355
14 11 Removing and installing rear parking aid warning buzzer -H15- – saloon 5356
14 12 Removing and installing rear parking aid warning buzzer -H15- convertible 5356
14 13 Checking rear parking aid warning buzzer -H15- 5357
96 – Lights, bulbs, switches – interior 5358
1 Interior lights and switches 5358
1 1 Removing and installing light switch -E1- 5358
1 2 Removing and installing headlight range control/illumination regulators 5359
1 3 Removing and installing window regulator switch, up to 05 08 5359
1 4 Removing and installing window regulator switch, up to 05 08 5360
1 5 Removing and installing mirror adjuster switch/change-over switches 5360
1 6 Removing and installing front passenger side interior locking switch -E198- 5361
1 7 Removing and installing tank filler flap/rear lid remote release switches 5362
1 8 Removing and installing adjustable rear spoiler switch -E127- 5362
1 9 Removing and installing hazard warning light switch -E3-/front passenger front airbag deactivated warning lamp -K145-, from 06 03 5364
1 10 Removing and installing switches in centre of dash panel 5364
1 11 Removing and installing door contact switch 5365
1 12 Removing and installing luggage compartment light switch -F5- 5366
1 13 Removing and installing bonnet contact switch -F266- 5366
1 14 Removing and installing front interior light -W1- 5366
1 15 Removing and installing glove compartment light -W6- 5367
1 16 Removing and installing illuminated vanity mirrors 5367
1 17 Removing and installing rear reading lights 5368
1 18 Removing and installing luggage compartment light -W3- 5369
1 19 Removing and installing door warning lamps 5369
1 20 Removing and installing convertible roof switch Cabriolet 5370
2 Immobiliser 5373
2 1 General description 5373
2 1 1 Immobiliser, 2nd generation 5373
2 1 2 Immobiliser, 3rd generation 5373
2 1 3 Immobiliser, 4th generation 5373
2 1 4 Immobiliser, 4th generation, with online connection and download capabilities 5374
2 2 Removing and installing immobiliser control unit -J362- 5374
2 3 Adapting immobiliser control unit -J362- 5374
2 3 1 Immobiliser, 2nd generation 5374
2 3 2 Immobiliser, 3rd generation 5375
2 3 3 Immobiliser, 4th generation 5375
2 3 4 Immobiliser, 4th generation, with online connection and download capabilities 5375
2 4 Immobiliser reader coil -D2- 5376
2 5 Ignition key 5376
2 6 Adapting ignition keys 5376
2 6 1 Immobiliser, 2nd generation 5376
2 6 2 Immobiliser, 3rd generation 5376
2 6 3 Immobiliser, 4th generation 5377
2 6 4 Immobiliser, 4th generation, with online connection and download capabilities 5377
3 Anti-theft alarm (ATA) and interior monitoring 5379
3 1 Assembly overview saloon 5379
3 2 Assembly overview Cabriolet 5381
3 3 Checking Cabriolet anti-theft alarm components 5382
3 4 Checking anti-theft alarm components 5382
3 5 Checking anti-theft alarm function 5383
3 6 Anti-theft alarm sensors saloon 5383
3 6 1 Removing and installing ATA ultrasonic sensors 5383
3 7 Anti-theft alarm sensors Cabriolet 5384
3 7 1 Removing and installing front interior monitor send and receive module 5384
3 7 2 Removing and installing rear interior monitor send and receive module 5385
3 7 3 Adapting sensor sensitivity 5386
3 8 Removing and installing interior monitoring switch -E183- 5386
3 8 1 Checking interior monitoring switch -E183- 5387
3 9 Removing and installing alarm horn -H12- 5387
3 9 1 Checking alarm horn -H12- 5388
4 Horn 5389
4 1 Removing and installing treble horn -H2- / bass horn -H7- 5389
97 – Wiring 5390
1 Vehicle diagnosis tester 5390
1 1 Connecting vehicle diagnostic tester 5390
2 Removing and installing fuse holder and relay carrier 5392
2 1 Removing and installing fuse holder on left of dash panel 5392
2 2 Removing and installing relay plate and 13-position relay carrier 5393
2 3 A-pillar coupling station 5393
2 4 Removing and installing fuse holder on battery -A- 5394
2 5 Removing and installing relay protective housing in engine compartment 5394
2 6 Removing and installing cable duct in engine compartment 5394
3 Control units 5396
3 1 Tyre pressure monitor control unit -J502- 5396
3 1 1 Removing and installing tyre pressure monitor control unit -J502- 5396
3 1 2 Coding tyre pressure monitor control unit -J502- 5397
3 2 Convenience system central control unit -J393- 5397
3 2 1 Removing and installing convenience system central control unit -J393- 5398
3 2 2 Adapting components convenience system central control unit -J393- 5398
3 2 3 Coding convenience system central control unit -J393- 5399
4 Repairs to wiring harnesses and connectors 5400
4 1 Notes on safety 5400
4 2 General notes concerning repairs to vehicle electrical system 5400
4 3 Notes on repairs to wiring harnesses and connectors 5401
4 4 Crimp connector 5402
4 5 CAN bus line repair 5404
4 6 Repairs to airbag and belt tensioner wiring 5404
4 7 Optical fibre lines (OFL) 5405
4 8 Wiring harness repair set -VAS 1978 B- 5405
4 9 Release tool set -VAS 1978/35- 5406
4 9 1 Secondary locks 5407
4 9 2 Primary locks 5408
4 9 3 Flat connector system 5408
4 9 4 Round connector systems 5409
4 9 5 Special connector systems 5410
4 9 6 Plug-in aid 5412
4 10 Crimping pliers -V A S 1978/9A- 5412
4 10 1 Fitting tool head 5413
4 10 2 Stripping off insulation 5413
4 10 3 Crimping 5414
5 Cleaning contact surfaces with contact surface cleaning set -VAS 6410- 5416
5 1 Repairing ring terminals 5416
5 2 Repairing threaded connections 5417
5 3 Cleaning battery terminals 5418
5 4 Anti-corrosion treatment 5419
6 Renewal of aerial wiring 5421
6 1 General description 5421
6 2 Assembly overview – aerial wire 5421
6 3 Installing a new aerial wire 5421
ONB53207020 New Beetle 1999 5423
Body Repairs New Beetle 1999> 5423
General Informations 5424
Safety instructions 5424
– Removing components 5424
– Battery, welding work 5424
– Electronic control units 5425
– Paint, glass, upholstery, trims 5426
– Fuel tank or fuel pipes 5426
– Air conditioner 5427
– Airbag system 5429
– Checking seat belts 5430
– Safety regulations for belt tensioners 5437
– Repairs on vehicles with belt tensioners 5438
– Cutting, straightening and/or bending operations on vehicles with airbag 5441
– Removing front seats with side airbag 5442
Basic instructions 5443
– Diagnosis on accident vehicles 5443
– Conditions in which body and/or parts are passed for painting 5444
– Straightening 5445
– Parting cuts 5445
– Replacement body sub–parts and part sections 5446
– Original joint 5447
– Galvanized body parts 5448
– Removing material remains 5449
– New parts 5449
– Service parts 5450
Symbols 5452
– Symbols for welding operations 5452
– Symbols for working procedures 5453
Body repair tools 5456
– Fold opener V A G 1317 5456
– Hole punch V A G 1329 5456
– Basic equipment V A G 1366/3 5457
– Underbody protection gun V A G 1379 5457
– Hot air blower V A G 1416 5458
– Door brace V A G 1438 5458
– Body equipment trolley V A G 1439 5459
– Body repair saw V A G 1523 A 5459
– Pneumatic hammer V A G 1577 5460
– Flanging tool V A G 1585 5460
– Welding smoke extractor V A G 1586 5461
– Welding spot breaker V A G 1731 5461
– Compressed air gun V A G 1761/1 5462
– Compressed air adhesive pistol V A G 2005 5463
– Straightening tool for door hinges 5463
– Hose packet 5023 5464
– Angle grinder VAS 5174 5464
– Angle grinder VAS 5175 5464
– Brush VAS 5182 5465
Materials for Body Repairs and General Body Repairs 5466
– Adhesives 5466
– Sealants 5471
– Locking fluids 5474
– Surface protection materials 5475
– Anti–corrosion materials 5476
– Chemical materials 5477
– Filling materials 5479
Bodywork – Bonded joints 5480
– Transporter 1991> 5480
– Audi 100 1991> 5481
– Audi 80 1992 > 5482
– Audi Convertible 1992 > 5485
-Types of bonded joints 5486
– Repair remedies when replacing parts 5487
Anti–corrosion measures 5491
– Anti–corrosion protection 5491
– Long–term body protection 5491
– Warranty information 5492
– Electrolytic galvanizing 5493
– Hot galvanizing 5494
Disposal information 5495
– Environment protection practised during production 5495
– Recycling 5498
– Plastics 5501
– Disposal 5505
– Releasing gas from strut 5507
– Airbag 5508
Repair procedures 5509
– Accident repairs 5509
Contact corrosion protection 5510
– Connections/joints of aluminium/magnesium and steel 5510
Sheet metal repairs 5512
– Strengthened steel body panels 5512
– Galvanized body parts 5514
– Welding work on galvanized body panels 5515
– Unbuttoning test 5518
Aluminium repairs 5519
– Paint 5520
– Surface preparation 5521
– Removing dents 5522
– Temperature regulation for heat treatments 5524
Procedures for repair of synthetic materials 5525
– Materials 5525
– Servicing dents 5527
– Servicing scratches 5529
– Servicing cracks (up to 100 mm long) 5531
– Servicing holes (up to 30 mm diameter) 5534
– Synthetic material repairs (glass fibre materials) 5537
– Repair procedure 5538
Repairing glass 5543
– Repairing windscreens 5543
00 Materials 5553
Vehicle identification data 5553
– Vehicle identification number 5553
– Identification plate 5553
– Vehicle data plate 5554
Safety notes 5555
Body foam insulation 5556
Galvanized body parts 5558
Body panel gaps/shut lines 5559
– Body front 5559
– Body rear 5560
Body dimensions 5561
– Body front 5561
– Body centre 5564
– Body rear 5567
– Floor group front 5570
– Floor group centre 5571
– Floor group rear 5572
50 Body front 5573
50 40 55 50 Engine console – Renewal 5573
– Right-hand engine console 5573
50 52 55 52 Intermediate piece – Renewal 5575
50 53 55 50 Wing connecting plate – Renewal 5577
50 60 55 00 Headlight mounting – Renewal 5579
50 72 55 52 Longitudinal member for upper wheel housing – Renewal 5581
50 74 55 00 Front wheel housing – Renewal 5585
50 75 55 50 Front wheel housing – Partial renewal 5587
50 79 55 00 Front longitudinal member – Renewal 5589
50 79 55 02 Front longitudinal member – Partial renewal 5592
50 80 55 00 Longitudinal member front part – Renewal 5595
51 Body centre 5598
51 03 55 00 Roof – Renewal 5598
51 07 55 50 Front roof cross member – Renewal 5602
51 09 55 50 Centre roof cross member – Renewal 5604
51 09 55 50 Rear roof cross member – Renewal 5606
51 37 55 00 A pillar – Renewal 5608
51 38 55 50 Reinforcement for A pillar – Renewal 5612
51 42 55 50 Reinforcement for B pillar – Renewal 5616
51 45 55 00 Outer side member – Renewal 5620
51 48 55 50 Centre side member – Renewal 5624
51 49 55 50 Side member reinforcement – Renewal 5627
– Includes: Web plate part section 5627
51 73 55 50 Floor plate – Partial renewal 5631
53 Body rear 5634
53 05 55 50 Rear cross panel – Renewal 5634
53 06 55 50 Corner reinforcement – Renewal 5638
– Encompasses: Cover plate, corner part and rear cross panel 5638
53 09 55 50 Rear lock carrier – Renewal 5640
– Encompasses: Rear cross panel 5640
53 13 55 00 Lower corner part – Renewal 5642
53 14 55 50 Cover plate – Renewal 5646
53 48 55 52 Rear longitudinal member – Partial renewal 5649
53 55 55 00 Side panel -Partial renewal- 5651
53 80 55 50 Spare wheel recess – Renewal 5656
53 80 55 52 Spare wheel well – Partial renewal 5658

S.V 26/01/2025