Volkswagen Passat 1994 & Passat Variant 1994 Workshop Manual PDF

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Volkswagen Passat 1994 & Passat Variant 1994 Workshop Manual – PDF DOWNLOAD

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Volkswagen Passat 1994 & Passat Variant 1994 Workshop Manual – PDF DOWNLOAD 

Language : English
Pages : 4541
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Volkswagen Passat 1994 & Passat Variant 1994 Workshop Manual – PDF DOWNLOAD 

PAS53201020 Body Repairs 1
00 – Technical data 5
1 Vehicle identification data 5
1 1 Type plate and vehicle identification number 5
1 2 Vehicle data plate 5
2 Body dimensions 6
2 1 Floor group – front 6
2 2 Floor group – front 8
2 3 Floor group – rear 9
2 4 Body – front 10
2 5 Body – centre 14
2 6 Body – rear (saloon) 17
2 7 Body – rear (estate) 18
3 Alignment jig 19
3 1 Overview 19
4 Galvanized body parts 26
4 1 Passat estate 27
50 – Body – front 28
1 Renewing front wheel housing 28
1 1 Removing 28
1 1 1 Cutting locations 29
1 1 2 Replacement parts 29
1 1 3 Welding in 30
2 Renewing front longitudinal member – partial renewal 32
2 1 Removing 32
2 1 1 Cutting locations 32
2 1 2 Right longitudinal member 33
2 1 3 Replacement parts 33
2 1 4 Welding in 33
2 1 5 Right longitudinal member 34
3 Renewing forward section of front longitudinal member – partial renewal 35
3 1 Removing 35
3 1 1 Cutting locations 35
3 1 2 Replacement parts 36
3 1 3 Welding in 37
51 – Body – centre 39
1 Renewing roof (saloon) 39
1 1 Removing 39
1 1 1 Cutting locations 39
2 Renewing roof (estate) 42
2 1 Removing 42
2 1 1 Cutting locations 42
3 Renewing A-pillar 45
3 1 Removing 45
3 1 1 Cutting locations 45
3 1 2 Replacement parts 46
3 1 3 Welding in 46
4 Renewing outer side member 47
4 1 Removing 47
4 1 1 Cutting locations 47
4 1 2 Replacement part 48
4 1 3 Welding in 48
5 Renewing outer side member – partial renewal 49
5 1 Removing 49
5 1 1 Cutting locations 49
5 1 2 Replacement part 50
6 Renewing inner side member 51
6 1 Removing 51
6 1 1 Cutting locations 51
6 1 2 Replacement part 52
7 Renewing floor panel 53
7 1 Removing 53
7 1 1 Cutting locations 53
7 1 2 Part section repair 54
7 1 3 Replacement parts 55
7 1 4 Welding in 55
7 1 5 Weld pin position measurements 58
53 – Body – rear 59
1 Renewing rear cross panel (saloon) 59
1 1 Removing 59
1 1 1 Cutting locations 59
1 1 2 Replacement part 60
2 Renewing rear cross panel (estate) 61
2 1 Removing 61
2 1 1 Cutting locations 61
2 1 2 Replacement part 62
3 Renewing luggage compartment floor, partial renewal (saloon) 63
3 1 Removing 63
3 1 1 Cutting locations 63
3 1 2 Replacement part 63
3 1 3 Welding in 64
4 Renewing luggage compartment floor, partial renewal (estate) 65
4 1 Removing 65
4 1 1 Cutting locations 65
4 1 2 Replacement part 66
4 1 3 Welding in 66
5 Renewing rear longitudinal member – partial renewal (saloon) 67
5 1 Removing 67
5 1 1 Cutting locations 67
5 1 2 Left longitudinal member 68
5 1 3 Right longitudinal member 69
5 1 4 Replacement parts 69
5 1 5 Welding in 70
6 Renewing rear longitudinal member – partial renewal (estate) 71
6 1 Removing 71
6 1 1 Cutting locations 71
6 1 2 Replacement part 72
6 1 3 Welding in 72
7 Renewing side panel (saloon) 73
7 1 Removing 73
7 1 1 Cutting locations 73
7 1 2 Replacement parts 74
7 1 3 Welding in 74
8 Renewing side panel (estate) 76
8 1 Removing 76
8 1 1 Cutting locations 76
8 1 2 Replacement part 77
8 1 3 Welding in 77
9 Renewing side panel, partial renewal (saloon) 78
9 1 Removing 78
9 1 1 Cutting locations 78
9 1 2 Replacement parts 79
9 1 3 Welding in 79
10 Renewing side panel, partial renewal (estate) 80
10 1 Removing 80
10 1 1 Cutting locations 80
10 1 2 Replacement part 81
10 1 3 Welding in 81
11 Renewing outer wheel housing liner 82
11 1 Removing 82
11 1 1 Cutting locations 82
11 1 2 Replacement part 83
11 1 3 Welding in 83
00050505020 Electrical system 84
01 – Self-diagnosis 90
1 Vehicle diagnosis, testing and information systems 90
1 1 Connecting vehicle diagnosis, testing and information system -VAS 5051A- 90
2 Immobilizer self-diagnosis 92
2 1 Performing immobilizer self-diagnosis 92
2 1 1 Initiating immobilizer self-diagnosis 92
2 1 2 Overview of functions available in self-diagnosis 93
2 1 3 Read fault memory 94
2 1 4 Erase fault memory 95
2 1 5 End output 96
2 2 Fault table 96
2 3 Measured value blocks 99
2 3 1 Read measured value block 99
2 3 2 Overview of selectable display groups; significance of display zones and display possibilities 99
2 4 Coding immobilizer control unit -J362- 100
3 Guided functions for immobilizer 102
3 1 Observe additional information and perquisites for “online request with GeKo-VW” 102
3 2 Online system test 103
3 3 Adaptation of ignition keys 103
3 4 Adaption after changing engine control unit 104
3 5 Adapting immobilizer 104
27 – Starter, current supply, CCS 105
1 Battery 105
1 1 Battery handling instructions 105
1 2 Removing and installing battery 105
1 2 3 Checking battery is seated securely 107
1 3 Visual check 107
1 4 Checking electrolyte level 107
1 4 1 Electrolyte level too low 108
1 4 2 Electrolyte level too high 108
1 4 3 Batteries with central gas venting 109
1 5 No load voltage measurement 109
1 6 Checking specific gravity of all cells 110
1 6 1 Deviations in electrolyte density 111
1 7 Battery load test 112
1 8 Charging battery 113
1 8 1 Performing battery charging 114
1 8 2 Procedures for totally discharged batteries 114
1 8 3 Charging prerequisites for totally discharged batteries 114
1 9 Quick charging/starting boost 114
2 Starter 115
2 1 Removing and installing starter 115
2 1 1 Securing starter for 1 8 l / 2 0 l petrol injection and 1 9 l diesel engines 116
2 1 2 Securing starter, 2 8 l petrol injection engine with a manual gearbox 117
2 1 3 Securing starter, vehicles with an automatic gearbox 117
3 Alternator with poly-V-belt 119
3 1 4-cylinder diesel or fuel injected petrol engine with no air conditioner compressor 119
3 2 4-cylinder diesel engine with air conditioner compressor 120
3 3 4-cylinder fuel injection petrol engine with air conditioner compressor 121
3 4 6-cylinder fuel injection petrol engine with air conditioner compressor 122
3 5 Removing and installing poly-V-belt, 4-cylinder engine 124
3 5 1 Belt drive with no tensioning roller 124
3 5 2 Belt drive with tensioning roller 125
3 5 3 Removing poly-V-belt 125
3 5 4 Installing poly-V-belt 125
3 6 Removing and installing poly-V-belt, 6-cylinder engine 126
3 7 Checking alternator carbon brushes 127
3 8 Renewing poly-V-belt pulley on alternator 127
3 9 Removing and installing poly-V-belt pulley with freewheel 128
3 9 1 Installing poly-V-belt pulley with freewheel 128
90 – Gauges, instruments 129
1 Dash panel insert 129
1 1 Removing and installing dash panel insert 129
1 1 1 Removing individual instruments 129
1 1 2 Removing entire dash panel insert 129
2 Repairing dash panel insert 131
2 1 Vehicles with rev counter and digital clock 131
2 2 Vehicles with multifunction indicator (MFI) 132
2 2 1 Checking voltage supply 135
2 2 2 Checking output voltage 136
2 3 Checking LED 138
2 4 Installing speedometer (G54) 139
91 – Radio, telephone, navigation 141
1 Radio systems 141
1 1 Radio system “alpha” 141
1 2 Radio system “beta” 142
1 3 Radio system “gamma” and “gamma with CD changer” 143
1 4 Removing and installing radio 144
1 4 1 Removing: 145
1 4 2 Installing: 145
1 4 3 Securing aerial cable to radio unit 145
1 5 Activating anti-theft coding on radio 146
1 6 Removing and installing cassette storage box 146
1 6 1 Removing and installing bulb for illumination 146
1 7 Fitting location of CD changer 146
1 7 1 Passat Variant 146
1 7 2 Passat saloon 147
2 Aerial system 148
2 1 Roof aerial 148
3 Suppression measures 149
4 Loudspeaker system 150
4 1 Removing and installing front right treble loudspeaker 151
4 1 1 Removing: 151
4 1 2 Installing: 151
4 2 Removing and installing front left treble loudspeaker 152
4 2 1 Removing: 152
4 2 2 Installing: 152
4 3 Removing and installing rear bass loudspeaker 152
4 4 Removing and installing rear treble loudspeaker 152
4 4 1 Removing: 153
4 4 2 Installing: 153
4 5 Removing and installing front bass loudspeakers 153
4 5 1 Removing: 153
4 5 2 Installing: 153
92 – Windscreen wash/wipe system 154
1 Windscreen wiper system 154
1 1 Assembly overview – windscreen wiper system 154
1 2 Setting park position 155
1 3 Adjusting wiper blade park position 155
1 4 Removing and installing wiper blade rubber insert 155
2 Windscreen washer system 156
2 1 Assembly overview – windscreen washer system 156
2 2 Adjusting washer spray jets 156
2 3 Connection to windscreen washer pump 157
3 Rear window wipe/wash system 158
3 1 Assembly overview – rear window wipe/wash system 158
3 2 Adjusting rear window wiper park position 158
3 3 Adjusting washer spray jet 159
4 Headlight washer system 160
4 1 Assembly overview – headlight washer system 160
4 2 Adjusting washer spray jets 160
94 – Lights, bulbs, switches – exterior 161
1 Headlight 161
1 1 Removing and installing headlight housing 161
1 1 1 Removing radiator grille 161
1 1 2 Removing trim cover next to headlight 161
1 1 3 Removing front trim 162
1 1 4 Removing headlight housing 162
1 1 5 Removing sealing cap on headlight 162
1 2 Removing headlight bulbs 162
1 3 Removing and installing headlight range control motor 163
1 3 1 Removing 163
1 3 2 Installing 163
1 4 Adjusting headlights 163
2 Front fog lights 165
2 1 Removing or adjusting fog light 165
2 1 1 Removing 165
2 1 2 Adjusting 165
2 2 Removing and installing fog light bulb 166
3 Front turn signals 167
3 1 Removing front turn signals 167
3 2 Removing and installing turn signal bulb 167
4 Side mounted repeater turn signals 168
4 1 Removing and installing side mounted repeater turn signal 168
5 Number plate lights 169
5 1 Removing and installing registration plate light 169
5 2 Replacing number plate light bulb 169
6 Tail lights 170
6 1 Removing and installing tail light on saloon 170
6 2 Removing and installing tail light on Variant 170
7 Steering column switch and ignition and starter switch 172
7 1 Assembly overview – steering wheel 172
7 2 Removing and installing cover 173
7 2 1 Removing 173
7 2 2 Installing: 173
7 3 Removing and installing horn button 174
7 3 1 Removing 174
7 3 2 Installing: 174
7 4 Removing and installing horn button on vehicles with a driver airbag 174
7 4 1 Removing 174
7 4 2 Installing: 174
7 5 Contact ring for horn plate 175
7 6 Removing and installing steering lock housing 175
7 7 Removing and installing turn signal and windscreen wiper switches 175
7 8 Removing and installing lock cylinder 176
7 9 Pin assignment on steering column switch 176
7 9 2 B – 5-pin connector 176
7 9 3 C – 5-pin connector 176
7 9 4 D – 4-pin connector 177
7 10 Pin assignment at connector for multifunction indicator (MFI) and cruise control system (CCS) (at steering lock housing) 177
7 10 2 B – 4-pin connector, switch for CCS 177
96 – Lights, bulbs, switches – interior 178
1 Cruise control system (CCS) 178
1 1 Assembly overview – cruise control system (CCS) 178
1 2 Removing control element 179
1 3 Adjusting control element 180
1 4 Removing and installing breather valve 180
1 5 Removing and installing vacuum pump for automatic distance control system -V18- 180
1 6 Checking vacuum system for leaks 180
2 Anti-theft alarm system (ATA) 181
2 1 Removing alarm system warning lamp -K95- 182
2 2 Removing and installing contact switch in rear lid lock cylinder for anti-theft alarm system and central locking system -F124- 182
2 3 Removing and installing anti-theft alarm and vermin repellent system contact switch -F120- 182
2 4 Removing and installing anti-theft alarm system horn -H8- 183
2 5 Removing and installing anti-theft alarm system control unit -J284- 183
3 Interior lights and switches 184
3 1 Removing and installing light switch 184
3 1 1 Removing headlight range control regulator -E102- 184
3 2 Removing combi-warning lamp 184
3 3 Removing and installing interior light 185
3 3 1 Replacing interior light bulb 185
3 4 Replacing front passenger reading light bulb 185
3 5 Removing and installing luggage compartment light -W3-, Variant 186
3 6 Removing and installing luggage compartment light -W3-, saloon 186
3 7 Removing and installing luggage compartment light switch 186
3 8 Removing and installing rear reading lights 186
3 9 Removing and installing sliding sunroof switch -E8- 187
3 10 Removing and installing door contact switch 187
3 11 Removing and installing electric window switch 187
3 12 Removing and installing mirror adjustment switch -E43- with mirror adjustment change-over switch -E48- 188
4 Immobilizer 189
4 1 Removing and installing immobilizer 189
4 2 Removing and installing immobilizer control unit -J362- 189
4 3 Removing and installing immobilizer reader coil -D2- 190
4 4 Transponder 190
4 5 Retrofitting fuel shut-off valve control unit -J366- 190
4 6 Installing fuel shut-off valve control unit -J366- 191
4 7 Adapting fuel shut-off valve control unit to immobilizer control unit 193
4 8 Functional check of immobilizer 193
97 – Wiring 194
1 Relay plate 194
1 1 Removing and installing relay plate 194
1 2 Removing and installing multi-pin connector on back of relay plate 194
1 2 1 Removing multi-pin connector 194
00050505120 Heating air conditioner 196
01 – Self diagnosis 200
1 – Self diagnosis of Climatronic 200
1 1 – Self diagnosis of Climatronic 200
1 2 – Function 200
1 3 – Technical data of self diagnosis 201
1 4 – Test prerequisites for self diagnosis 201
1 5 – Connecting fault reader V A G 1551 and selecting function 201
1 6 – Chart of functions that can be selected 203
1 7 – Interrogating fault memory 203
1 8 – Fault table 204
1 9 – Final control diagnosis 208
1 10 – Read measured value block 211
1 11 – Erasing fault memory, ending output 215
80 – Heating 217
1 – Servicing heating system 217
1 1 – Servicing heating system 217
2 – Dismantling and assembling heater 227
2 1 – Dismantling and assembling heater 227
3 – Installing and adjusting cables 229
3 1 – Installing and adjusting cables 229
4 – Dismantling and assembling heated air and fresh air controls 234
4 1 – Dismantling and assembling heated air and fresh air controls 234
5 – Servicing electronic heater controls – Thermotronic 235
5 1 – Servicing electronic heater controls – Thermotronic 235
87 – Air conditioning 241
1 – Notes on repair work to vehicles with air conditioning and on handling refrigerant 241
1 1 – Notes on repair work to vehicles with air conditioning and on handling refrigerant 241
1 2 – Safety precautions for work on vehicles with air conditioning and when handling refrigerant R134a 241
1 3 – Service work on the air conditioner which can only be carried out in specially-equipped workshops 243
2 – Air conditioner with manual controls 245
2 1 – Air conditioner with manual controls 245
2 2 – Servicing air conditioning and heating – Passenger compartment 245
2 3 – Servicing air conditioning and heating – Engine compartment 254
2 4 – Installing and adjusting cables 263
2 5 – Vacuum hose connection diagram 267
2 6 – Removing and installing compressor bracket – 4 Cyl petrol engine 270
2 7 – Removing and installing compressor bracket – 6 Cyl petrol engine 273
2 8 – Removing and installing compressor bracket – Turbo Diesel engine 277
3 – Climatronic – air conditioner with automatic regulation 280
3 1 – Climatronic – air conditioner with automatic regulation 280
3 2 – Control and function of the control and display unit 280
3 3 – Servicing Climatronic – passenger compartment 282
3 4 – Servicing Climatronic – engine compartment 294
3 5 – Checking and adjusting end position of installed temperature flap positioning motor 300
3 6 – Vacuum hose connection diagram 301
00050505220 Digifant Injection and Ignition System 307
01 – Self diagnosis, Electrical check 311
1 – Self diagnosis 311
1 1 – Self diagnosis 311
1 2 – Function 311
1 3 – Technical data of self diagnosis 311
1 4 – Connecting fault reader V A G 1551 and selecting engine electronics control unit 312
1 5 – Interrogating and erasing fault memory 312
1 6 – Fault table 314
1 7 – Final control diagnosis 315
2 – Electrical check 317
2 1 – Electrical check 317
2 2 – Wiring and component check with test box V A G 1598 317
24 – Mixture preparation, Injection 324
1 – Digifant injection and ignition system 324
1 1 – Digifant injection and ignition system 324
1 2 – Fitting locations overview 324
1 3 – Servicing injection part 326
1 4 – Safety precautions 344
1 5 – Rules for cleanliness 344
1 6 – Technical data 344
1 7 – Idling check 345
1 8 – Checking idling stabilization 347
1 9 – Checking Lambda probe and Lambda control 348
1 10 – Checking engine operating mode 350
1 11 – Checking throttle valve potentiometer 351
1 12 – Matching automatic gearbox control unit and throttle valve potentiometer to one another 352
1 13 – Checking coolant temperature sender 352
1 14 – Checking intake air temperature sender 353
1 15 – Checking air mass meter potentiometer 354
1 16 – Checking control unit voltage supply 354
1 17 – Checking fuel pressure regulator and holding pressure 355
1 18 – Removing and installing injectors 357
1 19 – Checking injectors 358
1 20 – Checking intake air system for leaks (unmetered air) 360
1 21 – Checking intake air preheating 361
1 22 – Basic throttle valve setting 362
1 23 – Checking and adjusting throttle closing damper 362
1 24 – Vacuum hose connection diagram 363
28 – Ignition system 367
1 – Digifant injection and ignition system 367
1 1 – Digifant injection and ignition system 367
1 2 – Servicing ignition part 367
1 3 – Safety precautions 370
1 4 – Test data, spark plugs 371
1 5 – Installing distributor 371
1 6 – Checking ignition timing control 372
1 7 – Checking Hall sender 373
1 8 – Checking ignition transformer 374
1 9 – Checking ignition transformer output stage 374
00050505320 4 cyl fuel injection engine (2 valve) Mechanics 376
00 – Technical data 380
1 – Technical data 380
1 1 – Technical data 380
1 2 – Engine number 380
1 3 – Engine data 380
10 – Removing and installing engine 382
1 – Removing and installing engine 382
1 1 – Removing and installing engine 382
1 2 – Notes on removing 382
1 3 – Notes on installing 384
1 4 – Tightening torques 385
1 5 – Assembly mountings 385
1 6 – Aligning engine and gearbox 388
1 7 – Renewing engine carrier rubber mounting 389
1 8 – Additional information and removal instructions for vehicles with air conditioner 390
13 – Crankshaft group 392
1 – Dismantling and assembling engine 392
1 1 – Dismantling and assembling engine 392
1 2 – Removing and installing ribbed belt 405
1 3 – Removing and installing toothed belt 408
2 – Removing and installing sealing flanges and flywheel/drive plate 411
2 1 – Removing and installing sealing flanges and flywheel/drive plate 411
2 2 – Renewing crankshaft oil seal – pulley end – 413
2 3 – Removing and installing drive plate 415
3 – Removing and installing crankshaft 418
3 1 – Removing and installing crankshaft 418
3 2 – Crankshaft dimensions 420
4 – Dismantling and assembling pistons and conrods 421
4 1 – Dismantling and assembling pistons and conrods 421
4 2 – Piston and cylinder dimensions 427
15 – Cylinder head, Valve gear 428
1 – Removing and installing cylinder head 428
1 1 – Removing and installing cylinder head 428
1 2 – Removing and installing cylinder head 432
1 3 – Checking compressions 433
2 – Servicing valve gear 434
2 1 – Servicing valve gear 434
2 2 – Reworking valve seats 442
2 3 – Removing and installing camshaft oil seal 443
2 4 – Removing and installing camshaft 445
2 5 – Checking hydraulic bucket tappets 447
2 6 – Checking valve guides 447
2 7 – Renewing valve guides 448
2 8 – Renewing valve stem seals 448
17 – Lubrication 450
1 – Removing and installing parts of the lubrication system 450
1 1 – Removing and installing parts of the lubrication system 450
1 2 – Checking oil pressure and oil pressure switch 458
19 – Cooling system 460
1 – Removing and installing parts of cooling system 460
1 1 – Removing and installing parts of cooling system 460
1 2 – Parts of cooling system body side 461
1 3 – Parts of cooling system – engine side 465
1 4 – Dismantling and assembling coolant pump 468
1 5 – Draining and filling cooling system 469
1 6 – Removing and installing radiator and radiator fan 471
1 7 – Checking radiator fan run-on 472
20 – Fuel supply system 473
1 – Removing and installing parts of fuel supply system 473
1 1 – Removing and installing parts of fuel supply system 473
1 2 – Removing and installing fuel tank with its attachments and fuel filter, front wheel drive 474
1 3 – Removing and installing fuel tank with its attachments and fuel filter, four wheel drive 479
1 4 – Safety precautions when working on the fuel supply system 484
1 5 – Rules for cleanliness 484
1 6 – Adjusting throttle cable 485
1 7 – Removing and installing fuel delivery unit 487
1 8 – Checking fuel pump 488
1 9 – Removing and installing parts of activated charcoal filter system 494
1 10 – Checking activated charcoal filter shut-off valve 497
26 – Exhaust system 498
1 – Removing and installing parts of exhaust system, front wheel drive 498
1 1 – Removing and installing parts of exhaust system, front wheel drive 498
1 2 – Exhaust manifold, front exhaust pipe and catalyst with attachments – Engine codes AAM, ABS, ADZ 499
1 3 – Exhaust manifold, front exhaust pipe and catalyst with attachments – Engine codes 2E, ADY, AGG 501
1 4 – Silencer with mountings – Engine code AAM 504
1 5 – Silencer with mountings – Engine codes ABS, 2E, ADY, AGG 508
2 – Removing and installing parts of exhaust system, four wheel drive 511
2 1 – Removing and installing parts of exhaust system, four wheel drive 511
2 2 – Exhaust manifold, front exhaust pipe and catalyst with attachments 512
2 3 – Removing and installing front exhaust pipe 515
2 4 – Silencer with mountings 517
00050505420 Mono Motronic Injection and Ignition system 519
01 – Self diagnosis, Electrical check 523
1 – Self diagnosis 523
1 1 – Self diagnosis 523
1 2 – Function 523
1 3 – Technical data of self diagnosis 523
1 4 – Connecting fault reader V A G 1551 and selecting engine electronics control unit 524
1 5 – Interrogating fault memory 525
1 6 – Fault table 525
1 7 – Erasing fault memory 528
1 8 – Final control diagnosis 529
2 – Electrical check 531
2 1 – Electrical check 531
2 2 – Wiring and component check with test box V A G 1598/18 531
2 3 – Test table 531
24 – Mixture preparation, Injection 536
1 – Mono-Motronic injection and ignition system 536
1 1 – Mono-Motronic injection and ignition system 536
1 2 – Fitting locations overview 536
1 3 – Servicing injection part 538
1 4 – Dismantling and assembling intake manifold 544
1 5 – Dismantling and assembling air cleaner and intake elbow 546
1 6 – Servicing injection unit 548
1 7 – Safety precautions 553
1 8 – Rules for cleanliness 553
1 9 – Technical data 553
1 10 – Idling speed check 554
1 11 – Checking Lambda probe 555
1 12 – Checking engine operating mode 556
1 13 – Checking throttle valve positioner 557
1 14 – Checking and adjusting idling switch 559
1 15 – Checking sender for throttle valve positioner 562
1 16 – Matching engine electronic control unit to electronic immobilizer 563
1 17 – Checking throttle valve potentiometer 564
1 18 – Checking coolant temperature sender 565
1 19 – Checking intake air temperature sender 566
1 20 – Checking speed signal 567
1 21 – Checking injector 567
1 22 – Checking fuel pressure regulator and holding pressure 569
1 23 – Checking intake air system for leaks (unmetered air) 571
1 24 – Checking intake air preheating 572
28 – Ignition system 574
1 – Mono-Motronic injection and ignition system 574
1 1 – Mono-Motronic injection and ignition system 574
1 2 – Servicing ignition part 574
1 3 – Safety precautions 577
1 4 – Adjustment data, Spark plugs 578
1 5 – Installing distributor 578
1 6 – Checking and adjusting ignition timing 579
1 7 – Checking ignition timing control 580
1 8 – Checking Hall sender 581
1 9 – Checking ignition transformer 582
1 10 – Checking ignition transformer output stage 582
00050505520 Automatic gearbox 096 584
00 – Technical data 590
1 – Identification of gearbox 590
1 1 – Identification of gearbox 590
2 – Code letters, gearbox allocation, ratios, equipment 591
2 1 – Code letters, gearbox allocation, ratios, equipment 591
3 – Capacities 593
3 1 – Capacities 593
4 – Repair instructions 593
4 1 – Repair instructions 593
01 – Self diagnosis, Electrical check 596
1 – Self-diagnosis function 596
1 1 – Self-diagnosis function 596
1 2 – Technical data of self-diagnosis 597
1 3 – Self-diagnosis – Guide 597
2 – Locations of electrical/electronic components 599
2 1 – Locations of electrical/electronic components 599
3 – Performing self-diagnosis 610
3 1 – Performing self-diagnosis 610
3 2 – Connecting fault reader V A G 1551 and selecting functions 610
3 3 – List of selectable functions 611
3 4 – Interrogating fault memory 612
3 5 – Fault table 612
3 6 – Erasing fault memory 616
3 7 – Initiating basic setting 617
3 8 – Read measured value block 618
3 9 – Test table 619
4 – Gearbox: Electrical test 625
4 1 – Gearbox: Electrical test 625
4 2 – Electrical check on multi-pin connector with 38 pins 626
4 3 – Test table 627
4 4 – Electrical check on multi-pin connector with 68 pins 631
4 5 – Test table 634
32 – Torque converter 638
1 – Torque converter 638
1 1 – Torque converter 638
1 2 – Identification of torque converter 638
1 3 – Draining torque converter 639
1 4 – Removing and installing torque converter oil seal 639
37 – Controls, Housing 640
1 – Servicing shift mechanism 640
1 1 – Servicing shift mechanism 640
1 2 – Checking shift mechanism 640
1 3 – Checking and adjusting selector lever cable 640
1 4 – Checking ignition key removal lock (vehicles with ignition key removal lock) 641
1 5 – Dismantling and assembling shift mechanism 642
1 6 – Dismantling and assembling shift mechanism (vehicles with ignition key removal lock) 651
1 7 – Dismantling and assembling selector lever (vehicles with ignition key removal lock) 658
1 8 – Removing and installing locking cable (vehicles with ignition key removal lock) 664
1 9 – Adjusting locking cable (vehicles with ignition key removal lock) 666
2 – Checking gearbox 667
2 1 – Checking gearbox 667
2 2 – Checking shift points 667
2 3 – Checking stall speed 667
2 4 – Measuring main pressure 667
2 5 – Fault finding table for “4-speed automatic gearbox” 667
3 – Removing and installing gearbox 667
3 1 – Removing and installing gearbox 667
4 – Checking and topping up ATF level 672
4 1 – Checking and topping up ATF level 672
4 2 – Checking ATF level 672
4 3 – Topping up ATF 673
5 – Gearbox with selector elements 674
5 1 – Gearbox with selector elements 674
5 2 – Position of selector elements 675
6 – Dismantling and assembling gearbox 676
6 1 – Dismantling and assembling gearbox 676
6 2 – Removing and installing ATF cooler and ATF filler tube 676
6 3 – Dismantling and assembling planetary gearbox -Overview- 677
6 4 – I – Removing and installing ATF pump to supporting tube 679
6 5 – II – Removing and installing reverse gear clutch -K2- to large sun gear 682
6 6 – III – Removing and installing free wheel and reverse gear brake -B1- 685
6 7 – IV – Planet carrier and gearbox housing with input gear and cover 687
6 8 – Dismantling and assembling planetary gearbox 689
6 9 – Overview of all planetary gearbox adjustments 701
6 10 – Adjusting planet carrier 702
6 11 – Adjusting reverse gear brake -B1- 707
6 12 – Adjusting clutch play between -K1- and -K2- 712
6 13 – Adjusting 2nd and 4th gear brake -B2- 717
38 – Gears, Hydraulic controls 721
1 – Dismantling and assembling ATF pump 721
1 1 – Dismantling and assembling ATF pump 721
2 – Dismantling and assembling free wheel with -B1- piston 724
2 1 – Dismantling and assembling free wheel with -B1- piston 724
3 – Dismantling and assembling 1st to 3rd gear clutch -K1- with turbine shaft 726
3 1 – Dismantling and assembling 1st to 3rd gear clutch -K1- with turbine shaft 726
4 – Dismantling and assembling reverse gear clutch -K2- 732
4 1 – Dismantling and assembling reverse gear clutch -K2- 732
5 – Dismantling and assembling 4th gear clutch -K3- with pump shaft 735
5 1 – Dismantling and assembling 4th gear clutch -K3- with pump shaft 735
6 – Removing and installing valve body 739
6 1 – Removing and installing valve body 739
7 – Dismantling and assembling parking lock 746
7 1 – Dismantling and assembling parking lock 746
39 – Final drive, Differential 752
1 – Checking oil in final drive 752
1 1 – Checking oil in final drive 752
2 – Removing and installing oil seal for drive flange 752
2 1 – Removing and installing oil seal for drive flange 752
3 – Dismantling and assembling final drive 755
3 1 – Dismantling and assembling final drive 755
3 2 – Repair overview of final drive 755
3 3 – Removing and installing input gear 757
3 4 – Removing and installing drive pinion 762
3 5 – Removing and installing differential 769
3 6 – Dismantling and assembling differential 777
4 – Adjusting final drive 783
4 1 – Adjusting final drive 783
4 2 – Overview of adjustments 783
4 3 – Adjustments to be completed after replacing individual components 785
4 4 – Adjusting drive pinion 785
4 5 – Adjusting input gear 788
4 6 – Adjusting differential 789
00050505620 Running gear self diagnosis 791
01 – Self diagnosis, Electrical check 795
1 – Self-diagnosis function 795
1 1 – Self-diagnosis function 795
1 2 – Distinguishing features of ABS and the ABS/EDL, Teves 04 795
1 3 – Function 797
1 4 – Technical data of self-diagnosis 797
1 5 – Safety precautions and fundamental points regarding fault finding 798
1 6 – Fault finding with fault reader V A G 1551 on ABS, Teves 04 (flow chart) 798
2 – Electrical/electronic components and fitting locations 800
2 1 – Electrical/electronic components and fitting locations 800
3 – Executing self diagnosis 804
3 1 – Executing self diagnosis 804
3 2 – Test prerequisites for self-diagnosis 804
3 3 – Connecting fault reader V A G 1551 and selecting function 805
3 4 – List of selectable functions 807
3 5 – Interrogating fault memory 807
3 6 – Notes on fault table 808
3 7 – Fault table 808
3 8 – Erasing fault memory, ending output 813
4 – Electrical check of the ABS and ABS/EDL 814
4 1 – Electrical check of the ABS and ABS/EDL 814
4 2 – Test prerequisites 814
4 3 – Contact assignment of multi-pin connector 815
4 4 – Test equipment and aids required: 817
4 5 – Notes on test table 818
4 6 – Test table 818
4 7 – Removing and installing control unit 831
4 8 – Adjusting brake light switch 831
5 – Self-diagnosis function 832
5 1 – Self-diagnosis function 832
5 2 – Distinguishing features of ABS Teves 20 GI and the ABS/EDL Teves 20 GI 832
5 3 – Function 834
5 4 – Technical data of self-diagnosis 834
5 5 – Safety precautions and fundamental points regarding fault finding 834
5 6 – Fault finding with fault reader V A G 1551 on ABS and ABS/EDL Teves 04 (flow chart) 835
6 – Electrical/electronic components and fitting locations 837
6 1 – Electrical/electronic components and fitting locations 837
7 – Faults displayed by warning lamps 841
7 1 – Faults displayed by warning lamps 841
7 2 – Vehicle with ABS/EDL has no EDL function 842
8 – Executing self diagnosis 842
8 1 – Executing self diagnosis 842
8 2 – Test prerequisites for self-diagnosis 842
8 3 – List of selectable functions 842
8 4 – Connecting fault reader V A G 1551 and selecting functions 842
8 5 – Interrogating fault memory 844
8 6 – Notes on fault table 845
8 7 – Fault table 846
8 8 – Erasing fault memory, ending output 848
8 9 – Coding control unit 849
8 10 – Reading measured value block 850
8 11 – Final control diagnosis 852
8 12 – Initiating basic setting 857
9 – Electrical check of the ABS and ABS/ EDL Teves 20 GI 863
9 1 – Electrical check of the ABS and ABS/ EDL Teves 20 GI 863
9 2 – Test prerequisites 863
9 3 – Multi-pin connector with contact assignment 863
9 4 – Test equipment and aids required: 865
9 5 – Notes on test table 865
9 6 – Test table 865
9 7 – Removing and installing control unit 869
9 8 – Adjusting brake light switch 871
00050505720 Running gear 872
00 – Technical data 878
1 Technical data 878
1 1 Running gear 878
1 2 Steering 878
1 3 Brakes 878
1 4 Wheels, tyres 880
40 – Front suspension 882
1 Repairing front suspension (basic running gear) 882
1 1 Removing and installing subframe, anti-roll bar and suspension link (basic running gear) 883
1 2 Checking suspension link (basic and Plus running gear) 886
1 3 Reworking cap nut in longitudinal member (basic and Plus running gear) 886
1 3 1 Combi bolts for subframe 887
1 4 Removing and installing wheel bearing, suspension strut, drive shaft (basic running gear) 887
1 5 Repairing front suspension strut (basic and Plus running gear) 891
2 Repairing front suspension (Plus running gear) 894
2 1 Removing and installing subframe, anti-roll bar and suspension link (Plus running gear) 895
2 2 Removing and installing suspension link (Plus running gear) 897
2 2 1 Removing 897
2 2 2 Installing 898
2 2 3 Torque settings 898
2 3 Removing and installing wheel bearing, suspension strut (Plus running gear) 899
2 4 Removing and installing drive shaft (Plus running gear) 901
2 4 1 Removing 901
2 4 2 Installing 902
2 5 Removing and installing drive shaft with triple roller joint 902
2 5 1 Removing right drive shaft 903
2 5 2 Removing left drive shaft 903
2 5 3 Installing 904
2 6 Wheel hubs with compressed splines, vehicles with Plus running gear 904
2 7 Removing and installing drive shafts on vehicles with compressed splines in the wheel hub 904
2 7 1 Removing 904
2 7 2 Installing 905
3 Repairing drive shaft 906
3 1 Repairing drive shaft with triple roller joint 911
3 2 Dismantling and assembling triple roller joint 913
3 2 1 Assembling 914
3 3 Checking outer constant velocity joint 916
3 3 1 Removing 916
3 3 2 Installing 917
3 4 Checking inner constant velocity joint 917
3 4 1 Installing 917
3 4 2 Checking function of constant velocity joint 918
42 – Rear suspension 919
1 Repairing rear axle (front-wheel drive vehicles) 919
1 1 Removing and installing bonded rubber bush 921
1 1 1 Removing 922
1 1 2 Installing 923
1 2 Reworking cap nut in longitudinal member (vehicles with front-wheel drive) 926
1 3 Revised weld studs for securing brake lines and hand brake cables 927
1 3 1 Rear axle for vehicles up to July 1994 927
1 3 2 Rear axle for vehicles from August 1994 928
1 4 Dismantling and assembling suspension strut (vehicles with front-wheel drive) 928
2 Repairing rear axle (vehicles with four-wheel drive) 932
2 1 Repairing rear drive shaft 937
2 2 Reworking cap nut in longitudinal member (vehicles with four-wheel drive) 939
2 3 Dismantling and assembling suspension strut (vehicles with four-wheel drive) 940
3 Repairing wheel bearing 943
3 1 Repairing wheel bearing, vehicles with front-wheel drive – drum brakes 943
3 2 Repairing wheel bearing, vehicles with front-wheel drive – disc brakes 947
3 3 Repairing wheel bearing, vehicles with four-wheel drive – disc brakes 950
44 – Wheels, tyres, vehicle geometry 954
1 Wheel alignment 954
1 1 Test requirements: 954
1 2 Vehicle alignment specifications (vehicles with front-wheel drive) 954
1 3 Wheel alignment specifications (vehicles with four-wheel drive) 955
1 4 Adjusting front wheel camber 956
1 5 Calculating the direction of travel: 956
45 – Anti-lock brake system 957
1 Anti-lock brake system (ABS) and anti-lock brake system with electronic differential lock (ABS/EDL) Teves 04 957
1 1 Notes for repairs on ABS, ABS/EDL 957
1 2 Removing and installing control unit 958
1 2 1 Removing 958
1 2 2 Installing 958
1 3 Removing and installing speed sensor and speed sensor rotor 958
2 Assembly overview – hydraulic unit, brake servo/brake master cylinder Teves 04 – LHD 959
2 1 Removing and installing hydraulic unit (LHD) 960
2 1 1 Removing 960
2 1 2 Installing 961
2 2 Removing and installing brake pedal position sender, LHD 961
2 2 1 Removing 961
2 2 2 Installing 962
3 Assembly overview – hydraulic unit, brake servo/brake master cylinder Teves 04 – RHD 963
3 1 Connecting brake lines from tandem brake master cylinder to hydraulic unit 965
3 2 Adjusting brake light switch -F- 966
3 3 Removing and installing brake pedal position sender, RHD 966
3 3 1 Removing 966
3 3 2 Installing 967
3 4 Removing and installing hydraulic unit, RHD 967
3 4 1 Removing 967
3 4 2 Installing 968
3 5 Removing and installing brake servo and tandem brake master cylinder, RHD 968
3 5 1 Removing 968
3 5 2 Installing 969
4 Anti-lock brake system (ABS) and anti-lock brake system with electronic differential lock (ABS/EDL) Teves 20 GI 970
4 1 General information on this ABS 970
4 2 Notes for repairs on ABS, ABS/EDL 970
4 3 Removing and installing control unit and hydraulic unit 971
4 3 1 Removing 972
4 3 2 Installing 973
5 Assembly overview – hydraulic unit, brake servo/brake master cylinder Teves 20 GI – LHD 974
6 Assembly overview – hydraulic unit, RHD 975
6 1 Connecting brake lines from tandem brake master cylinder to hydraulic unit 976
46 – Brakes – mechanism 977
1 Repairing front brakes 977
1 1 Repairing front brakes, Girling brake caliper 977
1 2 Removing and installing brake pads 979
1 2 1 Removing 979
1 2 2 Installing 979
1 3 Repairing front brakes, Teves/ATE 979
1 4 Removing and installing brake pads 981
1 4 1 Removing 981
1 4 2 Installing 982
2 Repairing rear brakes, drum brakes 984
2 1 Removing and installing rear brakes 984
2 2 Releasing brake shoe adjustment 985
2 3 Repairing rear brakes 985
2 4 Removing and installing brake shoes 987
2 4 1 Removing 987
2 4 2 Installing 988
2 5 Adjusting handbrake, drum brakes 988
3 Repairing rear brakes, disc brakes 989
3 1 Repairing Girling rear disc brakes, vehicles with front or four-wheel drive 989
3 2 Removing and installing brake pads 991
3 2 1 Removing 991
3 2 2 Installing 991
3 3 Adjusting handbrake, disc brakes 992
4 Assembly overview – handbrake lever 993
5 Removing and installing brake pedal/brake servo 995
5 1 Removing and installing brake pedal 996
5 1 1 Removing 996
5 1 2 Installing 996
47 – Brakes – hydraulics 997
1 Assembly overview – brake master cylinder/brake servo 997
2 Repairing Girling front brake calipers 999
2 1 Removing and installing piston for front brake caliper 1000
2 1 1 Removing 1000
2 1 2 Installing 1000
3 Repairing Teves/ATE front brake caliper 1002
4 Repairing rear brake caliper 1005
4 1 Removing and installing piston for rear brake caliper 1006
4 1 1 Removing 1006
4 1 2 Installing 1006
4 1 3 Pre-bleeding brake caliper 1007
5 Checking and adjusting brake pressure regulator 1008
5 1 Vehicles without ABS, vehicles with ABS, ABS/EDL, Teves 04 1008
5 2 Load dependent brake pressure regulator specifications 1008
5 2 1 Adjusting regulator 1009
6 Bleeding the brake system on vehicles with and without ABS or ABS/EDL 1010
6 1 Bleeding the brake system on vehicles with and without ABS or ABS/EDL 1010
6 1 1 Special point regarding vehicles with ABS/EDL 1010
6 1 2 Changing brake fluid 1010
6 2 Bleeding brake system with brake filling and bleeding unit -VW 1238/1- or -V A G 1238 B- 1011
6 3 Bleeding brake system without brake filling and bleeding unit 1011
48 – Steering 1013
1 Assembly overview – steering column, column tube, steering wheel and airbag steering wheel 1013
1 1 Removing and installing airbag module 1015
1 1 1 Removing 1015
1 1 2 Installing 1016
1 2 Removing and installing steering wheel with airbag 1016
1 2 1 Removing 1016
1 2 2 Installing steering wheel 1017
1 3 Removing and installing coil connector with slip ring 1017
1 4 Removing and installing column tube for height adjustable steering wheel 1018
2 Repairing power steering 1019
2 1 Checking pump delivery pressure 1019
2 2 Removing and installing power steering box 1019
2 2 1 Notes for working on power steering box 1019
2 2 2 Removing 1020
2 2 3 Installing 1021
2 3 Assembly overview – power steering box (TRW) 1021
2 4 Adjusting power steering box (TRW) 1023
2 5 Assembly overview – power steering box (ZF) 1024
2 6 Adjusting power steering box (ZF) 1026
2 7 Revised track rod ball joints 1026
2 8 Assembly overview, power steering box with heat shield (vehicles with 16V engine) 1027
2 9 Removing and installing track rod (TRW and ZF power steering box) 1029
2 9 1 Removing 1029
2 9 2 Installing 1030
2 9 3 Installing boot 1030
2 10 Checking and adjusting length of left track rod 1031
3 Assembly overview – vane pump, hydraulic lines, reservoir (vehicles with 4-cyl engines) 1032
3 1 Assembly overview – hydraulic lines, reservoir (vehicles with 4-cyl engines) 1033
3 2 Removing and installing power steering vane pump (vehicles with 4-cylinder engine) 1034
3 3 Removing and installing power steering vane pump (vehicles with 16V engine) 1035
3 4 Tensioning V-belt on vehicles with 4-cylinder engine 1036
4 Assembly overview – pressure line and cooling line (vehicles with VR6 engine) 1037
4 1 Removing and installing power steering vane pump (vehicles with VR6 engine) 1038
5 Assembly overview – hydraulic lines, power steering box (right-hand drive vehicles) 1040
00050505820 5 Speed manual gearbox 02A 1041
00 – Technical data 1045
1 – Gearbox identification 1045
1 1 – Gearbox identification 1045
1 2 – Code letters, gearbox allocation, ratios, capacities 1046
2 – Transmission layout 1049
2 1 – Transmission layout 1049
3 – Calculating overall ratio (i) 1051
3 1 – Calculating overall ratio (i) 1051
4 – General repair instructions 1051
4 1 – General repair instructions 1051
30 – Clutch 1053
1 – Servicing clutch control 1053
1 1 – Servicing clutch control 1053
1 2 – Assembly overview – Pedal cluster (LHD vehicles) 1054
1 3 – Removing and installing over-centre spring (LHD vehicles) 1057
1 4 – Removing and installing clutch pedal (LHD vehicles) 1058
1 5 – Assembly overview – Pedal cluster (RHD vehicles) 1058
1 6 – Removing and installing over-centre spring (RHD vehicles) 1061
1 7 – Removing and installing clutch pedal (RHD vehicles) 1061
1 8 – Assembly overview – Hydraulic system 1062
1 9 – Removing and installing master cylinder 1066
1 10 – Bleeding clutch system 1067
2 – Servicing clutch release mechanism 1068
2 1 – Servicing clutch release mechanism 1068
3 – Servicing clutch 1071
3 1 – Servicing clutch 1071
34 – Controls, Housing 1076
1 – Servicing gear selector mechanism 1076
1 1 – Servicing gear selector mechanism 1076
1 2 – Installation position of gear selector mechanism 1076
1 3 – Removing and installing gear selector cables 1079
1 4 – Removing and installing gear stick housing 1085
1 5 – Removing and installing gear stick 1089
1 6 – Adjusting gear selector mechanism 1093
2 – Removing and installing gearbox 1096
2 1 – Removing and installing gearbox 1096
2 2 – Removing and installing gearbox – Vehicles with 4 cylinder engine – 1096
2 3 – Removing and installing gearbox – Vehicles with 6 cylinder fuel injection engine – 1106
2 4 – Checking gearbox oil 1114
3 – Dismantling and assembling gearbox 1115
3 1 – Dismantling and assembling gearbox 1115
3 2 – Removing and installing cover for gearbox housing and 5th gear 1116
3 3 – Removing and installing gearbox housing and selector mechanism 1119
3 4 – Removing and installing input shaft, output shaft (pinion shaft), differential and selector forks 1122
3 5 – Dismantling and assembling sequence 1125
4 – Servicing gearbox housing and clutch housing 1142
4 1 – Servicing gearbox housing and clutch housing 1142
5 – Dismantling and assembling gearbox selector mechanism 1152
5 1 – Dismantling and assembling gearbox selector mechanism 1152
6 – Dismantling and assembling selector forks 1157
6 1 – Dismantling and assembling selector forks 1157
35 – Gears, Shafts 1163
1 – Dismantling and assembling input shaft 1163
1 1 – Dismantling and assembling input shaft 1163
2 – Adjusting input shaft 1174
2 1 – Adjusting input shaft 1174
2 2 – Table of adjustment shims 1175
2 3 – Carrying out check measurement 1177
3 – Dismantling and assembling output shaft (pinion shaft) 1178
3 1 – Dismantling and assembling output shaft (pinion shaft) 1178
4 – Adjusting output shaft 1202
4 1 – Adjusting output shaft 1202
5 – Dismantling and assembling reverse shaft 1205
5 1 – Dismantling and assembling reverse shaft 1205
39 – Final drive, Differential 1209
1 – Renewing flanged shaft oil seals (gearbox installed) 1209
1 1 – Renewing flanged shaft oil seals (gearbox installed) 1209
1 2 – Renewing oil seals on gearboxes without springs behind flanges 1209
1 3 – Renewing oil seal on gearboxes with springs behind flanges 1211
2 – Dismantling and assembling differential 1213
2 1 – Dismantling and assembling differential 1213
3 – Adjustment overview 1229
3 1 – Adjustment overview 1229
4 – Adjusting differential 1229
4 1 – Adjusting differential 1229
00050505920 4 Cyl diesel engine Mech 1232
00 – Technical data 1236
1 – Technical data 1236
1 1 – Technical data 1236
1 2 – Engine number 1236
1 3 – Engine data 1236
10 – Removing and installing engine 1237
1 – Removing and installing engine 1237
1 1 – Removing and installing engine 1237
1 2 – Notes on removing 1237
1 3 – Notes on installing 1239
1 4 – Tightening torques 1240
1 5 – Assembly mountings 1241
1 6 – Aligning engine and gearbox 1243
1 7 – Renewing engine carrier rubber mounting 1245
1 8 – Additional information and removal instructions for vehicles with air conditioner 1246
13 – Crankshaft group 1247
1 – Dismantling and assembling engine 1247
1 1 – Dismantling and assembling engine 1247
1 2 – Removing and installing ribbed belt 1261
1 3 – Removing and installing toothed belt 1264
1 4 – Checking semi-automatic toothed belt tensioning roller 1269
1 5 – Removing single part injection pump sprocket 1269
2 – Removing and installing sealing flanges and flywheel/drive plate 1271
2 1 – Removing and installing sealing flanges and flywheel/drive plate 1271
2 2 – Renewing crankshaft oil seal – pulley end – 1274
2 3 – Removing and installing drive plate 1275
3 – Removing and installing crankshaft 1278
3 1 – Removing and installing crankshaft 1278
3 2 – Crankshaft dimensions 1281
4 – Dismantling and assembling pistons and conrods 1282
4 1 – Dismantling and assembling pistons and conrods 1282
4 2 – Checking piston projection at TDC 1289
4 3 – Piston and cylinder dimensions 1290
15 – Cylinder head, Valve gear 1291
1 – Removing and installing cylinder head 1291
1 1 – Removing and installing cylinder head 1291
1 2 – Installing cylinder head 1298
1 3 – Checking compressions 1299
2 – Servicing valve gear 1302
2 1 – Servicing valve gear 1302
2 2 – Reworking valve seats 1308
2 3 – Checking valve guides 1310
2 4 – Renewing valve guides 1311
2 5 – Renewing valve stem seals 1311
2 6 – Removing and installing camshaft 1313
2 7 – Checking hydraulic bucket tappets 1314
2 8 – Replacing swirl chambers 1315
17 – Lubrication 1317
1 – Removing and installing parts of the lubrication system 1317
1 1 – Removing and installing parts of the lubrication system 1317
1 2 – Checking oil pressure and oil pressure switch 1324
1 3 – Removing and installing oil sump cap 1324
19 – Cooling system 1326
1 – Removing and installing parts of cooling system 1326
1 1 – Removing and installing parts of cooling system 1326
1 2 – Parts of cooling system body side 1327
1 3 – Parts of cooling system – engine side 1331
1 4 – Dismantling and assembling coolant pump 1334
1 5 – Draining and filling cooling system 1335
1 6 – Removing and installing radiator and radiator fan 1337
20 – Fuel supply system 1339
1 – Removing and installing parts of fuel supply system 1339
1 1 – Removing and installing parts of fuel supply system 1339
1 2 – Removing and installing fuel tank with its attachments 1340
1 3 – Safety precautions when working on the fuel supply system 1343
1 4 – Rules for cleanliness 1343
1 5 – Servicing accelerator mechanism 1344
1 6 – Servicing cold start accelerator (CSA) operating cable 1346
1 7 – Adjusting CSA operating cable 1347
21 – Charging 1348
1 – Charge air system with turbocharger 1348
1 1 – Charge air system with turbocharger 1348
1 2 – Removing and installing turbocharger with attachments 1348
1 3 – Removing and installing parts of charge air cooling system 1359
1 4 – Rules for cleanliness 1362
1 5 – Turbocharger hose/pipe connections 1363
1 6 – Removing and installing turbocharger 1365
1 7 – Checking turbocharger 1369
1 8 – Checking pressure unit for charge pressure regulating valve 1372
1 9 – Removing and installing pressure unit for charge pressure regulating valve 1373
26 – Exhaust system 1374
1 – Removing and installing parts of exhaust system 1374
1 1 – Removing and installing parts of exhaust system 1374
2 – Exhaust gas recirculation system, engine codes 1Z and AHU 1384
2 1 – Exhaust gas recirculation system, engine codes 1Z and AHU 1384
2 2 – Removing and installing parts of exhaust gas recirculation system 1385
2 3 – Checking exhaust gas recirculation valve (mechanical) 1386
2 4 – Vacuum hose connection diagram 1388
3 – Exhaust gas recirculation system, engine code AFN 1388
3 1 – Exhaust gas recirculation system, engine code AFN 1388
3 2 – Removing and installing parts of exhaust gas recirculation system 1389
3 3 – Vacuum hose connection diagram 1390
3 4 – Checking exhaust gas recirculation valve 1391
4 – Exhaust gas recirculation system, engine code AAZ 1393
4 1 – Exhaust gas recirculation system, engine code AAZ 1393
4 2 – Removing and installing parts of exhaust gas recirculation system 1393
4 3 – Exhaust gas recirculation system 1394
4 4 – Checking exhaust gas recirculation 1395
4 5 – Checking exhaust gas recirculation valve 1397
4 6 – Checking two-way valve 1397
4 7 – Checking engine temperature sender 1398
4 8 – Checking and adjusting partial throttle switch 1399
00050506020 Diesel injection and glow plug system 1401
01 – Self diagnosis 1405
1 – Self diagnosis 1405
1 1 – Self diagnosis 1405
1 2 – Function 1405
1 3 – Technical data of self diagnosis 1405
1 4 – Connecting fault reader V A G 1551 and selecting engine electronics control unit 1405
1 5 – Interrogating fault memory 1407
1 6 – Fault table 1408
1 7 – Erasing fault memory 1409
1 8 – Final control diagnosis 1410
1 9 – Reading measured value block 1414
23 – Mixture preparation, Injection 1416
1 – Servicing fuel injection system 1416
1 1 – Servicing fuel injection system 1416
1 2 – Injection pump with two-part sprocket 1420
1 3 – Servicing fuel filter 1422
1 4 – Rules for cleanliness 1423
1 5 – Checking fuel system for leaks 1424
1 6 – Actuator controlled, load-dependent injection timing 1425
1 7 – Removing and installing injection pump 1425
1 8 – Checking and adjusting injection pump timing 1432
1 9 – Checking valve timing 1436
1 10 – Adjusting idling speed, idling speed boost and engine governed speed 1437
1 11 – Residual volume basic setting 1440
1 12 – Idling speed boost actuator 1441
1 13 – Checking commencement of injection valve 1441
1 14 – Checking engine temperature sender 1442
1 15 – Resistance figures for engine temperature sender 1442
1 16 – Checking idling speed boost valve 1443
1 17 – Removing and installing injectors 1443
1 18 – Servicing injectors 1444
2 – Servicing injection pump 1446
2 1 – Servicing injection pump 1446
2 2 – Removing and installing throttle lever or return spring 1452
2 3 – Renewing pump cover throttle lever bush, pump cover gasket and throttle lever shaft O-ring 1456
2 4 – Renewing fuel delivery adjusting screw O-ring 1458
2 5 – Renewing idling speed boost shaft O-ring 1459
2 6 – Renewing injection timing device cover O-ring 1459
2 7 – Renewing CSA lever/cover O-ring 1460
2 8 – Sealing injection pump connections 1460
28 – Glow plug system 1462
1 – Checking glow plug system 1462
1 1 – Checking glow plug system 1462
1 2 – Checking glow plug current consumption with V A G 1315A 1462
1 3 – Checking glow plugs 1462
1 4 – Glow plugs with burned electrodes 1463
00050506120 Diesel direct injection and glow plug system 1464
01 – Self-diagnosis 1468
1 – Self diagnosis 1468
1 1 – Self diagnosis 1468
1 2 – Function 1468
1 3 – Technical data of self diagnosis 1468
1 4 – Connecting fault reader V A G 1551 and selecting engine electronics control unit 1469
1 5 – Interrogating fault memory 1470
1 6 – Fault table 1471
1 7 – Erasing fault memory 1477
1 8 – Final control diagnosis 1478
1 9 – Reading measured value block 1481
1 10 – Display group overview 1482
1 11 – Evaluating measured value blocks, engine codes 1Z and AHU 1484
1 12 – Evaluating measured value blocks, engine code AFN 1495
23 – Mixture preparation, Injection 1507
1 – Servicing Diesel direct injection system 1507
1 1 – Servicing Diesel direct injection system 1507
1 2 – Safety precautions 1507
1 3 – Rules for cleanliness 1507
1 4 – Fitting locations overview 1508
1 5 – Servicing injection pump 1512
1 6 – Servicing fuel filter 1516
1 7 – Servicing accelerator linkage 1518
1 8 – Setting engine to number 1 cylinder with engine removed 1520
1 9 – Removing, installing and adjusting accelerator position sender 1520
1 10 – Checking sender adjustment 1521
1 11 – Removing and installing injection pump 1522
1 12 – Dynamically checking and adjusting commencement of injection 1525
1 13 – Checking valve timing 1526
1 14 – Removing and installing injectors 1528
1 15 – Servicing injectors 1528
1 16 – Removing and installing fuel temperature sender 1529
1 17 – Renewing injection timing device cover O-ring 1529
1 18 – Wiring and component check with test box V A G 1598/18 1530
1 19 – Checking engine speed sender 1530
1 20 – Checking intake manifold pressure sender and altitude sender 1531
1 21 – Checking coolant temperature sender 1533
1 22 – Checking brake light switch and brake pedal switch 1535
1 23 – Checking intake manifold sender 1537
1 24 – Checking Diesel direct injection system current supply 1539
1 25 – Checking fuel temperature sender 1540
1 26 – Checking modulating piston movement sender and quantity adjuster 1541
1 27 – Checking needle lift sender 1544
1 28 – Checking injection adjuster control range 1545
1 29 – Checking charge pressure control 1547
1 30 – Hose connection diagram for charge pressure control, engine code AFN 1553
1 31 – Checking exhaust gas recirculation and air mass meter function 1554
1 32 – Checking speedometer sender 1558
1 33 – Checking accelerator position sender 1559
2 – Replacing, coding and matching engine control unit 1561
2 1 – Replacing, coding and matching engine control unit 1561
2 2 – Replacing engine control unit 1561
2 3 – Coding engine control unit 1561
2 4 – Matching engine electronic control unit to electronic immobilizer 1563
28 – Glow plug system 1565
1 – Checking glow plug system 1565
1 1 – Checking glow plug system 1565
1 2 – Checking glow plugs 1565
00050506220 General body repairs 1567
01 – Self-diagnosis 1575
1 Airbag system self-diagnosis 1575
1 1 Function 1575
1 2 Test prerequisites for self-diagnosis 1575
1 3 Connecting fault reader -V A G 1551- and selecting function 1575
1 4 Interrogating fault memory 1577
1 5 Fault table 1578
1 6 Fault table / rapid data transfer 1578
1 7 Erasing fault memory, ending output 1580
1 8 Disabling front passenger side airbag unit ▸ 09 94 1580
1 8 1 Deactivating front passenger airbag 1580
1 8 2 Activating front passenger airbag 1582
2 Airbag system self-diagnosis 10 94 ▸ 1584
2 1 Tools 1584
2 2 Function 1584
2 3 Connecting fault reader -V A G 1551- and selecting functions (interrogating equipment version) 1585
2 3 1 Test prerequisites for self-diagnosis 1585
2 3 2 Interrogating control unit version 1586
2 3 3 Interrogating fault memory 1587
2 3 4 Erasing fault memory 1588
2 3 5 End output 1588
2 3 6 Fault table 1589
2 4 Coding airbag control unit -J234- with fault reader -V A G 1551- 1590
2 5 Reading measured value block 1592
2 5 1 Display group 001 1592
2 5 2 Evaluating display group number 001 1593
2 5 3 Display group 003 1594
2 5 4 Evaluating display group number 003 1594
2 6 Disabling and activating front passenger side airbag unit (adaption) 10 94 ▸ 1595
2 6 1 Deactivating front passenger airbag 1595
2 6 2 Activating front passenger airbag 1598
2 7 Test box -VAS 5056- 1601
2 7 1 Connecting test box -VAS 5056- to driver airbag components 1602
2 7 2 Connecting test box -VAS 5056- to front passenger airbag components 1602
50 – Body – front 1604
1 Body – front 1604
1 1 Removing and installing lock carrier 1605
1 2 Removing and installing front wing 1605
1 2 1 Removing 1605
1 2 2 Notes on installation: 1606
55 – Bonnet, rear lid 1607
1 Bonnet 1607
1 1 Removing and installing bonnet lock cable 1607
2 Rear lid 1608
2 1 Removing and installing rear lid lock (saloon) 1608
2 2 Removing and installing rear lid lock (estate) 1609
2 3 Removing and installing lock cylinder 1610
2 4 Removing gas strut 1611
2 5 Releasing gas from gas strut 1611
2 6 Removing and installing springs 1611
2 6 1 Removing 1611
2 6 2 Installation instructions 1612
2 7 Adjusting lid (estate) 1612
2 8 Adjusting lid (saloon) 1613
57 – Front doors, door components, central locking 1615
1 Front door 1615
1 1 Repairing door 1615
1 2 Repairing door with electric window regulator 1616
1 3 Removing and installing door 1618
1 4 Removing and installing window regulator 1618
1 5 Removing door window 1618
1 6 Fitting door window to window regulator 1619
1 7 Removing and installing outer window guide 1619
1 7 1 Removing 1619
1 7 2 Installing 1620
1 8 Fitting rail to door window 1620
1 9 Removing inner door seal 1620
1 10 Removing and installing electrical window regulator 1621
1 10 1 Removing 1621
1 10 2 Installing 1621
1 11 Repairing electric window regulators 1621
1 12 Repairing door handle for central locking 1621
1 13 Removing and installing door handle 1622
1 13 1 Removing 1623
1 13 2 Installing 1623
1 14 Removing and installing interior actuation 1623
1 14 1 Removing 1623
1 14 2 Installing 1623
1 15 Maintaining single-key locking 1623
1 16 Repairing door lock with actuating components 1624
1 17 Removing and installing door lock with tolerance compensation 1625
1 17 1 Removing 1625
1 17 2 Installing 1626
2 Central locking 1627
2 1 Repairing central locking system (saloon) 1627
2 2 Repairing central locking system (estate) 1628
2 3 Installing dual pressure pump (saloon) 1629
2 4 Removing and installing positioning element for fuel tank flap 1629
2 4 1 Removing 1629
2 4 2 Installing 1629
2 5 Removing and installing front door positioning elements 1629
2 5 1 Removing 1629
2 5 2 Installing 1630
2 6 Removing and installing rear door positioning elements 1631
2 6 1 Removing 1631
2 6 2 Installing 1631
2 7 Functional check of central locking 1632
2 7 1 Checking locking mechanism 1632
2 7 2 Checking anti-theft device 1632
58 – Rear doors, door components 1634
1 Rear door 1634
1 1 Repairing door 1634
1 2 Removing and installing door 1635
1 2 1 Removing 1635
1 2 2 Installing 1635
1 3 Removing and installing window regulator 1636
1 3 1 Removing 1636
1 3 2 Installing 1636
1 4 Removing and installing door window 1636
1 4 1 Removing 1636
1 4 2 Installing 1636
1 5 Fitting door window to window regulator 1637
1 6 Removing and installing outer window guide 1637
1 6 1 Removing 1637
1 6 2 Installing 1637
1 7 Fitting rail to door window 1638
1 8 Repairing rear electric window regulators 1638
1 9 Removing and installing impact bar 1641
1 10 Repairing door lock with actuating components 1642
1 11 Removing and installing door handle 1642
1 11 1 Removing 1642
1 11 2 Installing 1643
1 12 Removing and installing door lock 1643
1 12 1 Removing 1643
1 12 2 Installing 1643
1 13 Removing and installing interior actuation 1644
1 13 1 Removing 1644
1 13 2 Installing 1644
1 14 Removing inner door seal 1644
60 – Sunroof 1645
1 Sliding/tilting sunroof 1645
1 1 Tools 1645
1 2 Assembly overview 1645
1 3 Removing and installing sliding/tilting sunroof panel 1647
1 3 1 Removing 1647
1 3 2 Installing 1647
1 4 Checking and adjusting parallel running 1648
1 5 Removing sliding headliner for sliding/tilting sunroof 1650
1 5 1 Removing 1650
1 5 2 Installing 1651
1 6 Adjusting sliding/tilting sunroof panel (height adjustment) 1651
1 7 Checking electric drive (zero position) 1651
1 8 Removing and installing sliding/tilting sunroof carrier unit 1652
1 8 1 Removing 1652
1 8 2 Installing 1655
1 9 Cleaning water drainage hoses 1656
1 9 1 Front water drainage hoses 1656
1 9 2 Rear water drainage hoses 1657
2 Sliding/tilting sunroof with glass panel 1658
2 1 Assembly overview 1658
2 2 Removing and installing sliding/tilting sunroof glass panel 1659
2 2 1 Removing 1659
2 2 2 Installing 1660
2 3 Adjusting panel seal 1660
2 4 Removing and installing sliding headliner 1661
2 4 1 Removing 1661
2 4 2 Installing 1662
2 5 Checking parallel running 1662
2 6 Adjusting parallel running 1662
2 7 Adjusting glass panel for sliding/tilting sunroof (height adjustment) 1663
2 8 Checking electric drive (zero position) 1663
2 9 Removing sliding/tilting sunroof carrier unit 1664
2 10 Cleaning water drainage hoses 1664
63 – Bumpers 1665
1 Front bumper 1665
1 1 Removing and installing front bumper 1665
1 2 Removing and installing air intake grille 1666
1 2 1 Removing 1666
1 2 2 Installing 1666
1 3 Removing and installing front bumper from longitudinal member 1666
1 3 1 Removing 1666
1 3 2 Installing 1667
2 Rear bumper 1668
2 1 Removing and installing rear bumper 1668
64 – Glazing 1669
1 Flush bonded windows 1669
1 1 Tools 1669
1 2 Materials 1670
1 3 Assembly overview – Windscreen 1671
1 4 Removing and installing windscreen 1672
1 4 1 Removing 1672
1 4 2 Installing 1673
1 4 3 Renewing window surround 1673
1 5 Removing and installing rear window (saloon) 1674
1 5 1 Removing broken rear window 1674
1 5 2 Removing undamaged rear window 1675
1 5 3 Installing rear window 1675
1 6 Removing and installing rear window (estate) 1676
1 6 1 Removing undamaged rear window 1676
1 6 2 Removing broken rear window 1678
1 6 3 Installing rear window 1678
1 7 Preparing old undamaged rear window for glazing 1678
1 8 Preparing new rear window for glazing 1679
1 9 Preparing body flange for glazing 1680
1 10 Installation instructions 1680
1 11 Curing time 1681
1 12 Touching up paint damage 1681
1 13 Cleaning off excess adhesive sealing material 1681
2 Windows secured with screws 1682
2 1 Removing and installing side window (saloon) 1682
2 2 Removing and installing side window (estate) 1683
66 – Exterior equipment 1684
1 Roof mouldings 1684
1 1 Roof moulding (saloon) 1684
1 2 Roof moulding (estate) 1685
1 2 1 Removing roof moulding (without roof rail) 1686
1 2 2 Removing roof moulding (with roof rail) 1686
1 2 3 Renewing clips 1686
2 Roof rails 1687
2 1 Removing and installing roof rails 1687
3 Front trim 1688
3 1 Removing and installing radiator grille 1688
4 Wheel housing liner 1689
5 Exterior mirror 1690
5 1 Tools 1690
5 2 Assembly overview 1690
6 Protective strips 1692
68 – Interior equipment 1693
1 Interior mirror 1693
1 1 Removing and installing interior mirror 1693
1 1 1 Removing 1693
1 1 2 Installing 1693
1 2 Repair method using glass-to-metal adhesive 1693
2 Luggage compartment cover 1695
2 1 Retrofitting luggage compartment cover (PR no 3U2) 1695
3 Retrofitting net partition 1696
3 1 Installing reinforcement plates and lashing eyes 1696
3 1 1 Installing top, front reinforcement plate 1697
3 1 2 Installing top, rear reinforcement plate 1697
3 1 3 Installing bottom, front lashing eye 1698
3 2 Widening openings for cover caps in trim panels 1698
3 2 1 Widening opening for cover cap in upper C-pillar trim 1698
3 2 2 Widening opening for cover cap in upper D-pillar trim 1699
3 3 Removing and installing net partition 1699
69 – Passenger protection 1701
1 Seat belts 1701
1 1 Safety regulations for belt tensioners 1701
1 2 Disposal of belt tensioner units 1701
1 3 Removing and installing front seat belts with belt tensioner 1701
1 4 Assembly overview – Belt reel with tensioner unit 1703
1 5 Removing and installing belt reel with tensioner unit 1703
1 5 1 Removing 1704
1 5 2 Installing 1704
1 6 Removing and installing belt height adjusters 1705
1 7 Removing front fitting 1705
1 8 Removing front belt buckle 1706
1 9 Removing and installing rear belt reel 1706
2 Inspecting seat belts 1707
2 1 Points to check 1707
2 1 1 Checking belt webbing 1707
2 1 2 Checking inertia reel (locking mechanism) 1708
2 1 3 Visually checking belt buckle 1709
2 1 4 Checking operation of belt buckle 1709
2 1 5 Checking belt anchors, belt guides and latch plates 1709
2 1 6 Checking securing parts and anchorage points 1709
3 Airbag 1711
3 1 Safety precautions when working on the airbag 1711
3 2 Disposal of airbag units 1712
3 3 Deactivating the airbag 1712
3 4 Renewing airbag units following an accident 1712
3 4 1 Accident involving triggering of airbag 1712
3 4 2 Accident not involving triggering of airbag 1713
3 5 Assembly overview – driver airbag unit 1713
3 6 Removing and installing driver airbag unit 1714
3 6 1 Removing 1714
3 6 2 Installing 1715
3 7 Removing and installing steering wheel 1716
3 7 1 Removing 1716
3 7 2 Installing 1717
3 8 Removing and installing return spring with slip ring 1717
3 8 1 Removing 1717
3 8 2 Installing 1717
3 9 Assembly overview – front passenger airbag unit 1717
3 10 Removing and installing front passenger airbag unit 1718
3 10 1 Removing 1718
3 10 2 Installing 1719
3 11 Removing mounting frame 1720
3 12 Removing and installing airbag control unit -J234- 1720
3 12 1 Removing 1720
3 12 2 Installing 1720
70 – Trim, insulation 1722
1 Dash panel 1722
1 1 Removing and installing dash panel 1722
1 1 1 Removing 1722
1 1 2 Installing 1723
1 2 Removing knee pad 1724
1 3 Removing and installing centre console 1725
1 3 1 Removing 1725
1 3 2 Installing 1726
1 4 Removing handle and trim of handbrake lever 1727
1 5 Removing and installing centre console extension 1728
1 5 1 Removing 1728
1 5 2 Installing 1729
1 6 Removing and installing driver stowage compartment 1729
1 6 1 Removing 1729
1 6 2 Installing 1730
1 7 Removing and installing passenger side storage compartment 1730
1 7 1 Removing 1730
1 7 2 Installing 1730
1 8 Removing glove box 1730
1 8 1 Removing 1730
1 8 2 Installing 1731
1 9 Repairing glove box lock 1732
2 Door trims 1733
2 1 Tools 1733
2 2 Assembly overview – Front door trim 1733
2 3 Removing and installing front door trim 1735
2 3 1 Removing 1735
2 3 2 Installing 1736
2 4 Assembly overview – rear door trim 1736
2 5 Removing and installing rear door trim 1738
2 5 1 Removing 1738
2 5 2 Installing 1739
2 6 Removing and installing door insulation film 1739
2 6 1 Removing 1740
2 6 2 Installing 1742
3 Trim 1743
3 1 Removing and installing upper A-pillar trim 1743
3 2 Removing and installing lower A-pillar trim 1744
3 3 Removing and installing B-pillar trim 1744
3 4 Removing and installing upper C-pillar trim 1745
3 5 Removing and installing lower C-pillar trim 1746
3 6 Removing and installing lower C-pillar padding 1748
3 7 Removing and installing D-pillar trim (saloon) 1749
3 8 Removing and installing D-pillar trim (estate) 1750
3 9 Removing and installing rear shelf and belt reel cover (saloon) 1751
3 10 Removing and installing belt guide 1752
3 10 1 Removing 1752
3 10 2 Installing 1752
3 11 Removing and installing front luggage compartment trim and belt reel cover (estate) 1752
3 12 Removing and installing rear luggage compartment trim (estate) 1754
3 13 Removing and installing side trim of luggage compartment (saloon) 1755
3 13 1 Removing trim 1755
3 14 Removing rear bumper carrier cover (saloon) 1756
3 15 Removing rear bumper carrier cover (estate) 1757
3 16 Removing and installing rear lid trim (estate) 1758
3 17 Removing and installing cap for rear lid hinges (estate) 1758
3 17 1 Removing 1758
3 17 2 Installing 1759
3 18 Removing and installing sill panel strip 1759
4 Roof trims 1760
4 1 Removing and installing moulded headliner (saloon) 1760
4 1 1 Removing 1760
4 1 2 Installing 1762
4 2 Removing and installing moulded headliner with sliding/tilting roof (saloon) 1762
4 2 1 Removing 1762
4 2 2 Installing 1765
4 3 Removing and installing moulded headliner (estate) 1765
4 4 Removing and installing moulded headliner with sliding/tilting roof (estate) 1766
4 4 1 Removing 1766
4 4 2 Installing 1769
4 5 Removing, installing, cutting section in roof insulation/reinforcement (RIR) 1770
4 5 1 Removing 1770
4 5 2 Installing 1770
72 – Seat frames 1772
1 Front seats 1772
1 1 Removing and installing seat 1772
1 1 1 Removing 1772
1 1 2 Installing 1772
1 2 Separating seat frame and backrest frame 1772
1 3 Repairing seat frame (normal and sport seat) 1773
1 4 Repairing seat frame with mechanical height adjustment 1775
1 5 Dismantling and assembling seat frame with mechanical height adjustment 1776
1 5 1 Dismantling 1776
1 5 2 Assembling 1779
1 6 Repairing seat frame with electric height adjustment 1779
1 7 Dismantling and assembling seat frame with electric height adjustment 1781
1 7 1 Dismantling 1781
1 7 2 Assembling 1784
1 8 Repairing backrest frame 1784
1 9 Renewing backrest frame 1785
2 Rear seats 1787
2 1 Removing and installing (split folding) bench seat and backrest 1787
2 1 1 Removing 1787
2 1 2 Installing 1787
3 Child bench seat 1788
3 1 Retrofitting child bench seat 1788
3 2 Modifying child bench seat 1790
74 – Seat – padding, covers 1792
1 Front seat covers and padding 1792
1 1 Assembly overview – Cover and padding for front seat part 1792
1 2 Removing and installing cover and padding for front seat part 1792
1 2 1 Removing 1792
1 2 2 Installing 1793
1 3 Assembly overview – Cover and padding for front seat part with height adjustment 1794
1 4 Removing and installing cover and padding for front seat part with height adjustment 1794
1 4 1 Removing 1794
1 4 2 Installing 1795
1 5 Removing and installing backrest cover and padding 1796
2 Rear seat covers and padding 1798
2 1 Removing and installing covers and padding for bench seat 1798
2 2 Removing and installing covers and padding for (split folding) backrest 1799
2 3 Removing and installing lock (backrest) 1801
2 4 Removing centre armrest 1801
2 5 Removing and installing padding clips 1802
2 5 1 Removing 1802
2 5 2 Installing 1802
00050506320 Motronic injection and ignition system (6 Cyl engine) 1803
01 – Self-diagnosis 1807
1 – General to self-diagnosis 1807
1 1 – General to self-diagnosis 1807
1 2 – Features of self-diagnosis 1807
1 3 – Technical data of self-diagnosis 1807
1 4 – Connecting fault reader V A G 1551 and selecting engine electronics control unit 1808
2 – Fault memory 1811
2 1 – Fault memory 1811
2 2 – Interrogating and erasing fault memory 1811
2 3 – Fault table 1813
2 4 – Fault code 00281 00525 1813
2 5 – Fault code 00527 00553 1816
2 6 – Fault code 00561 01177 1818
2 7 – Fault code 01242 65535 1821
3 – Final control diagnosis 1824
3 1 – Final control diagnosis 1824
3 2 – Performing final control diagnosis 1824
4 – Measured value blocks 1828
4 1 – Measured value blocks 1828
4 2 – Safety precautions 1828
4 3 – Read measured value block 1828
4 4 – Evaluating measured value blocks, display groups 001 – 003 1829
4 5 – Evaluating measured value blocks, display groups 004 – 099 1833
24 – Mixture preparation, Injection 1838
1 – Servicing injection system 1838
1 1 – Servicing injection system 1838
1 2 – Fitting locations overview 1838
1 3 – General notes on injection 1841
1 4 – Removing and installing parts of the injection system 1843
1 5 – Dismantling and assembling air cleaner 1846
1 6 – Dismantling and assembling fuel rail with injectors 1849
1 7 – Removing and installing throttle valve control part 1852
1 8 – Safety precautions 1857
1 9 – Rules for cleanliness 1858
1 10 – Technical data 1858
2 – Checking components 1858
2 1 – Checking components 1858
2 2 – Checking Lambda probe heating 1858
2 3 – Checking air mass meter 1861
2 4 – Checking throttle valve control part 1864
2 5 – Checking throttle valve potentiometer 1871
2 6 – Checking coolant temperature sender 1873
2 7 – Checking intake manifold temperature sender 1876
2 8 – Checking engine speed sender 1879
2 9 – Checking fuel pressure regulator and holding pressure 1880
2 10 – Checking intake air system for leaks (unmetered air) 1882
2 11 – Matching engine electronic control unit to electronic immobilizer 1883
2 12 – Removing and installing injectors 1884
2 13 – Checking injectors 1885
2 14 – Checking and adjusting throttle closing damper 1889
2 15 – Matching automatic gearbox control unit and throttle valve potentiometer to one another 1890
3 – Checking functions 1890
3 1 – Checking functions 1890
3 2 – Idling check 1890
3 3 – Checking Lambda control 1892
3 4 – Checking engine operating mode 1895
3 5 – Checking driving characteristics after a cold start 1897
4 – Engine control unit 1898
4 1 – Engine control unit 1898
4 2 – Checking control unit voltage supply 1898
4 3 – Procedure after voltage supply open circuit 1900
4 4 – Replacing engine control unit 1901
4 5 – Coding engine control unit 1901
4 6 – Matching engine control unit to throttle valve control part 1902
4 7 – Matching engine control unit to electronic immobilizer 1903
5 – Checking additional signals 1905
5 1 – Checking additional signals 1905
5 2 – Checking speed signal 1905
5 3 – Checking air conditioner compressor signal 1906
5 4 – Checking driving range signal 1908
28 – Ignition system 1910
1 – Servicing ignition 1910
1 1 – Servicing ignition 1910
1 2 – General notes on ignition system 1910
1 3 – Removing and installing parts of the ignition system 1911
1 4 – Safety precautions 1915
1 5 – Test data, spark plugs 1915
1 6 – Checking Hall sender 1915
1 7 – Checking ignition transformer 1917
1 8 – Checking knock sensors 1920
00050506420 6 cyl fuel injection engine Mechanics 1923
00 – Technical data 1927
1 – Technical data 1927
1 1 – Technical data 1927
1 2 – Engine number 1927
1 3 – Engine data 1927
10 – Removing and installing engine 1929
1 – Removing and installing engine 1929
1 1 – Removing and installing engine 1929
1 2 – Notes on removing 1930
1 3 – Notes on installing 1933
1 4 – Tightening torques 1935
1 5 – Assembly mountings 1935
1 6 – Aligning engine and gearbox 1936
1 7 – Renewing engine carrier rubber mounting 1938
1 8 – Additional information and removal instructions for vehicles with air conditioner 1939
13 – Crankshaft group 1941
1 – Dismantling and assembling engine 1941
1 1 – Dismantling and assembling engine 1941
1 2 – Removing and installing ribbed belt 1961
1 3 – Checking valve timing 1962
1 4 – Adjusting valve timing 1965
2 – Removing and installing sealing flanges and flywheel/drive plate 1972
2 1 – Removing and installing sealing flanges and flywheel/drive plate 1972
2 2 – Renewing crankshaft oil seal – vibration damper end – 1977
2 3 – Removing and installing drive plate 1978
3 – Removing and installing crankshaft 1980
3 1 – Removing and installing crankshaft 1980
4 – Dismantling and assembling pistons and conrods 1983
4 1 – Dismantling and assembling pistons and conrods 1983
4 2 – Piston and cylinder dimensions 1990
15 – Cylinder head, Valve gear 1991
1 – Removing and installing cylinder head 1991
1 1 – Removing and installing cylinder head 1991
1 2 – Removing and installing cylinder head cover 1998
1 3 – Installing cylinder head 1999
1 4 – Checking compressions 2000
2 – Servicing valve gear 2001
2 1 – Servicing valve gear 2001
2 2 – Reworking valve seats 2008
2 3 – Removing and installing camshafts 2009
2 4 – Checking hydraulic bucket tappets 2012
2 5 – Checking valve guides 2013
2 6 – Renewing valve guides 2013
2 7 – Renewing valve stem seals 2015
17 – Lubrication 2017
1 – Removing and installing parts of the lubrication system 2017
1 1 – Removing and installing parts of the lubrication system 2017
1 2 – Dismantling and assembling oil filter housing 2023
1 3 – Dismantling and assembling oil pump 2026
1 4 – Checking oil pressure and oil pressure switch 2029
19 – Cooling system 2031
1 – Removing and installing parts of cooling system 2031
1 1 – Removing and installing parts of cooling system 2031
1 2 – Parts of cooling system body side 2032
1 3 – Parts of cooling system engine side 2035
1 4 – Dismantling and assembling coolant thermostat housing 2039
1 5 – Draining and filling cooling system 2042
1 6 – Removing and installing radiator and radiator fan 2044
1 7 – Removing and installing coolant pump 2045
1 8 – Checking coolant continued circulation pump and radiator fan run-on 2048
20 – Fuel supply system 2050
1 – Removing and installing parts of fuel supply system 2050
1 1 – Removing and installing parts of fuel supply system 2050
1 2 – Removing and installing fuel tank with its attachments and fuel filter, front wheel drive 2051
1 3 – Removing and installing fuel tank with its attachments and fuel filter, four wheel drive 2057
1 4 – Safety precautions when working on the fuel supply system 2063
1 5 – Rules for cleanliness 2063
1 6 – Adjusting throttle cable 2064
1 7 – Removing and installing fuel delivery unit 2066
1 8 – Checking fuel pump 2068
1 9 – Removing and installing parts of the activated charcoal filter system 2074
1 10 – Checking fuel tank breather 2076
26 – Exhaust system 2079
1 – Removing and installing parts of exhaust system, front wheel drive 2079
1 1 – Removing and installing parts of exhaust system, front wheel drive 2079
1 2 – Exhaust manifold, front exhaust pipe and catalyst with attachments 2080
1 3 – Removing and installing parts of exhaust system, front wheel drive 2083
1 4 – Removing and installing parts of exhaust system, four wheel drive 2087
1 5 – Exhaust manifold, front exhaust pipe and catalyst with attachments 2088
1 6 – Silencer with mountings 2090
1 7 – Removing and installing front exhaust pipe and catalyst with attachments 2091
00050506520 4 Cyl fuel injection engine (4 valve) Mechanics 2092
00 – Technical data 2096
1 – Technical data 2096
1 1 – Technical data 2096
1 2 – Engine number 2096
1 3 – Engine data 2096
10 – Removing and installing engine 2097
1 – Removing and installing engine 2097
1 1 – Removing and installing engine 2097
1 2 – Notes on removing 2097
1 3 – Notes on installing 2098
1 4 – Tightening torques 2100
1 5 – Assembly mountings 2100
1 6 – Aligning engine and gearbox 2102
1 7 – Renewing engine carrier rubber mounting 2102
1 8 – Additional information and removal instructions for vehicles with air conditioner 2103
13 – Crankshaft group 2105
1 – Dismantling and assembling engine 2105
1 1 – Dismantling and assembling engine 2105
1 2 – Removing and installing ribbed belt 2115
1 3 – Removing and installing toothed belt 2116
1 4 – Checking semi-automatic toothed belt tensioning roller 2118
2 – Removing and installing sealing flange and flywheel 2119
2 1 – Removing and installing sealing flange and flywheel 2119
2 2 – Renewing crankshaft oil seal – pulley end – 2121
3 – Removing and installing crankshaft 2123
3 1 – Removing and installing crankshaft 2123
3 2 – Crankshaft dimensions 2125
4 – Dismantling and assembling pistons and conrods 2126
4 1 – Dismantling and assembling pistons and conrods 2126
4 2 – Piston and cylinder dimensions 2131
15 – Cylinder head, Valve gear 2132
1 – Removing and installing cylinder head 2132
1 1 – Removing and installing cylinder head 2132
1 2 – Removing and installing cylinder head 2135
1 3 – Checking compressions 2137
2 – Servicing valve gear 2138
2 1 – Servicing valve gear 2138
2 2 – Reworking valve seats 2143
2 3 – Removing and installing camshaft oil seal 2145
2 4 – Checking hydraulic bucket tappets 2146
2 5 – Removing and installing camshaft 2147
2 6 – Checking valve guides 2149
2 7 – Renewing valve guides 2149
2 8 – Renewing valve stem seals 2151
17 – Lubrication 2153
1 – Removing and installing parts of the lubrication system 2153
1 1 – Removing and installing parts of the lubrication system 2153
1 2 – Checking oil pressure and oil pressure switch 2160
19 – Cooling system 2162
1 – Removing and installing parts of cooling system 2162
1 1 – Removing and installing parts of cooling system 2162
1 2 – Parts of cooling system body side 2163
1 3 – Parts of cooling system – engine side 2166
1 4 – Dismantling and assembling coolant pump 2169
1 5 – Draining and filling cooling system 2170
1 6 – Removing and installing radiator and radiator fan 2172
20 – Fuel supply system 2174
1 – Removing and installing parts of fuel supply system 2174
1 1 – Removing and installing parts of fuel supply system 2174
1 2 – Removing and installing fuel tank with its attachments 2175
1 3 – Safety precautions when working on the fuel supply system 2181
1 4 – Rules for cleanliness 2181
1 5 – Adjusting throttle cable 2181
1 6 – Removing and installing fuel delivery unit 2182
1 7 – Checking fuel pump 2183
1 8 – Removing and installing parts of the activated charcoal filter system 2187
1 9 – Checking fuel tank breather 2189
26 – Exhaust system 2191
1 – Removing and installing parts of exhaust system 2191
1 1 – Removing and installing parts of exhaust system 2191
00050506620 Digifant injection and ignition system (4 valve) 2197
01 – Self diagnosis 2201
1 – Self diagnosis 2201
1 1 – Self diagnosis 2201
1 2 – Function 2201
1 3 – Technical data of self diagnosis 2201
1 4 – Connecting fault reader V A G 1551 and selecting engine electronics control unit 2202
1 5 – Interrogating and erasing fault memory 2203
1 6 – Fault table 2205
1 7 – Final control diagnosis 2207
1 8 – Read measured value block and basic settings 2211
1 9 – Display group overview 2211
24 – Mixture preparation, Injection 2214
1 – Digifant injection and ignition system 2214
1 1 – Digifant injection and ignition system 2214
1 2 – Fitting locations overview 2214
1 3 – Servicing injection part 2217
1 4 – Dismantling and assembling intake manifold upper part 2224
1 5 – Dismantling and assembling intake manifold lower part 2227
1 6 – Dismantling and assembling air cleaner 2229
1 7 – Safety precautions 2231
1 8 – Rules for cleanliness 2231
1 9 – Technical data 2231
1 10 – Performing basic setting 2232
1 11 – Checking Lambda probe and Lambda control 2233
1 12 – Checking idling stabilization 2236
1 13 – Checking engine operating mode 2237
1 14 – Checking throttle valve potentiometer 2238
1 15 – Checking coolant temperature sender 2241
1 16 – Checking intake air temperature sender 2244
1 17 – Checking engine speed sender 2246
1 18 – Checking and adjusting idling switch 2248
1 19 – Checking control unit voltage supply 2251
1 20 – Matching engine electronic control unit to electronic immobilizer 2253
1 21 – Checking Lambda probe heating 2254
1 22 – Checking starter signal 2255
1 23 – Checking injectors 2255
1 24 – Checking fuel pressure regulator and holding pressure 2258
1 25 – Checking intake air system for leaks (unmetered air) 2259
1 26 – Checking intake air preheating 2260
28 – Ignition system 2262
1 – Digifant injection and ignition system 2262
1 1 – Digifant injection and ignition system 2262
1 2 – Servicing ignition part 2262
1 3 – Dismantling and assembling distributor 2266
1 4 – Safety precautions 2267
1 5 – Test data, spark plugs 2268
1 6 – Checking ignition timing control 2268
1 7 – Checking No 1 Cyl recognition sender 2269
1 8 – Checking knock sensors 2270
1 9 – Checking ignition transformer 2271
1 10 – Checking ignition transformer output stage 2271
1 11 – Renewing rotor arm 2274
00050506720 5 Speed Manual Gearbox 02C four wheel drive 2275
00 – Technical data 2281
1 – Gearbox identification 2281
1 1 – Gearbox identification 2281
1 2 – Code letters, gearbox allocation, ratios, capacities 2282
2 – Rear final drive identification 2283
2 1 – Rear final drive identification 2283
2 2 – Code letters, assembly allocation, ratios, capacities 2283
3 – Transmission layout 2284
3 1 – Transmission layout 2284
4 – Calculating overall ratio (i) 2286
4 1 – Calculating overall ratio (i) 2286
4 2 – Notes on brake and performance tests and towing 2286
5 – General repair instructions 2286
5 1 – General repair instructions 2286
30 – Clutch 2289
1 – Servicing clutch control 2289
1 1 – Servicing clutch control 2289
1 2 – Assembly overview – Pedal cluster 2290
1 3 – Removing and installing over-centre spring 2293
1 4 – Removing and installing clutch pedal 2294
1 5 – Assembly overview – Hydraulic system 2294
1 6 – Removing and installing master cylinder 2297
1 7 – Bleeding clutch system 2298
2 – Servicing clutch release mechanism 2299
2 1 – Servicing clutch release mechanism 2299
3 – Servicing clutch 2302
3 1 – Servicing clutch 2302
34 – Controls, Housing 2306
1 – Servicing gear selector mechanism 2306
1 1 – Servicing gear selector mechanism 2306
1 2 – Installation position of gear selector mechanism 2306
1 3 – Removing and installing gear selector cables 2309
1 4 – Removing and installing gear stick housing 2315
1 5 – Removing and installing gear stick 2319
1 6 – Adjusting gear selector mechanism 2323
2 – Removing and installing gearbox 2326
2 1 – Removing and installing gearbox 2326
2 2 – Removing and installing gearbox and bevel box (Vehicles with 4 cylinder engine) 2326
2 3 – Removing and installing gearbox and bevel box (Vehicles with 6 cylinder fuel injection engine) 2337
3 – Removing and installing bevel box 2349
3 1 – Removing and installing bevel box 2349
4 – Checking oil in manual gearbox with bevel box 2360
4 1 – Checking oil in manual gearbox with bevel box 2360
5 – Dismantling and assembling gearbox 2361
5 1 – Dismantling and assembling gearbox 2361
5 2 – Removing and installing cover for gearbox housing and 5th gear 2362
5 3 – Removing and installing gearbox housing and selector mechanism 2365
5 4 – Removing and installing input shaft, output shaft (pinion shaft), differential and selector forks 2367
5 5 – Dismantling and assembling sequence 2369
6 – Servicing gearbox housing and clutch housing 2386
6 1 – Servicing gearbox housing and clutch housing 2386
7 – Dismantling and assembling gearbox selector mechanism 2394
7 1 – Dismantling and assembling gearbox selector mechanism 2394
8 – Dismantling and assembling selector forks 2399
8 1 – Dismantling and assembling selector forks 2399
35 – Gears, Shafts 2405
1 – Dismantling and assembling input shaft 2405
1 1 – Dismantling and assembling input shaft 2405
2 – Adjusting input shaft 2416
2 1 – Adjusting input shaft 2416
2 2 – Table of adjustment shims 2417
2 3 – Carrying out check measurement 2419
3 – Dismantling and assembling output shaft (pinion shaft) 2420
3 1 – Dismantling and assembling output shaft (pinion shaft) 2420
4 – Adjusting output shaft 2444
4 1 – Adjusting output shaft 2444
5 – Dismantling and assembling reverse shaft 2447
5 1 – Dismantling and assembling reverse shaft 2447
39 – Final drive, Differential rear 2451
1 – Renewing left-hand flange shaft or right-hand drive flange oil seals (gearbox installed) 2451
1 1 – Renewing left-hand flange shaft or right-hand drive flange oil seals (gearbox installed) 2451
1 2 – Renewing left-hand flange shaft oil seal 2451
1 3 – Renewing right-hand drive flange oil seal 2452
2 – Renewing bevel box output flange oil seal (bevel box removed) 2453
2 1 – Renewing bevel box output flange oil seal (bevel box removed) 2453
3 – Dismantling and assembling differential 2455
3 1 – Dismantling and assembling differential 2455
4 – Adjustment overview 2467
4 1 – Adjustment overview 2467
5 – Adjusting differential 2467
5 1 – Adjusting differential 2467
6 – Dismantling and assembling bevel box 2470
6 1 – Dismantling and assembling bevel box 2470
6 2 – Assembly overview 2470
6 3 – Dismantling and assembling sequence 2480
7 – Adjusting shaft bevel gear and bevel gear (gear set) 2490
7 1 – Adjusting shaft bevel gear and bevel gear (gear set) 2490
7 2 – General notes 2490
7 3 – Adjusting and marking of gear sets 2490
7 4 – Position of shims 2491
7 5 – Adjustment overview (bevel box) 2491
7 6 – Recommended sequence for adjusting gear set 2492
7 7 – Determining shim “S4” thickness when replacing output flange 2492
7 8 – Adjusting shaft bevel gear 2493
7 9 – Adjusting bevel gear 2498
8 – Removing and installing propshaft 2501
8 1 – Removing and installing propshaft 2501
9 – Servicing propshaft 2505
9 1 – Servicing propshaft 2505
10 – Checking function of viscous coupling 2513
10 1 – Checking function of viscous coupling 2513
11 – Removing and installing viscous coupling 2513
11 1 – Removing and installing viscous coupling 2513
12 – Removing and installing viscous coupling oil seal in rear final drive (final drive installed) 2515
12 1 – Removing and installing viscous coupling oil seal in rear final drive (final drive installed) 2515
13 – Removing and installing drive flange oil seal (rear final drive installed) 2515
13 1 – Removing and installing drive flange oil seal (rear final drive installed) 2515
14 – Functional check of free-wheel 2517
14 1 – Functional check of free-wheel 2517
15 – Functional check of free-wheel lock 2517
15 1 – Functional check of free-wheel lock 2517
16 – Removing and installing rear final drive 2518
16 1 – Removing and installing rear final drive 2518
17 – Checking rear final drive oil 2521
17 1 – Checking rear final drive oil 2521
18 – Dismantling and assembling rear final drive 2522
18 1 – Dismantling and assembling rear final drive 2522
18 2 – Removing viscous coupling and rear axle housing from bevel gear housing 2534
18 3 – Servicing shaft bevel gear bearings 2536
18 4 – Pressing bevel gear off and on input shaft 2540
18 5 – Servicing bevel gear/input shaft bearings 2541
18 6 – Servicing differential bearings 2544
18 7 – Installing rear axle housing on bevel gear housing and building on viscous coupling 2546
19 – Dismantling and assembling differential and freewheel (assembly overview) 2550
19 1 – Dismantling and assembling differential and freewheel (assembly overview) 2550
20 – Dismantling and assembling differential (sequence) 2554
20 1 – Dismantling and assembling differential (sequence) 2554
21 – Removing and installing freewheel (sequence) 2555
21 1 – Removing and installing freewheel (sequence) 2555
22 – Dismantling and assembling freewheel (sequence) 2556
22 1 – Dismantling and assembling freewheel (sequence) 2556
23 – Adjusting bevel gear and shaft bevel gear (gear set) 2557
23 1 – Adjusting bevel gear and shaft bevel gear (gear set) 2557
23 2 – General notes 2557
23 3 – Adjusting and marking of gear sets 2558
23 4 – Position of shims 2559
23 5 – Adjustment overview (rear final drive) 2559
23 6 – Recommended sequence for adjusting gear set 2560
23 7 – Adjusting shaft bevel gear 2560
23 8 – Adjusting bevel gear 2564
00050506920 4 cyl fuel injection engine (cross flow cylinder head) 2568
00 – Technical data 2572
1 – Technical data 2572
1 1 – Technical data 2572
1 2 – Engine number 2572
1 3 – Engine data 2572
10 – Removing and installing engine 2574
1 – Removing and installing engine 2574
1 1 – Removing and installing engine 2574
1 2 – Notes on removing 2574
1 3 – Notes on installing 2576
1 4 – Tightening torques 2577
1 5 – Assembly mountings 2578
1 6 – Aligning engine and gearbox 2579
1 7 – Renewing engine carrier rubber mounting 2580
1 8 – Additional information and removal instructions for vehicles with air conditioner 2580
13 – Crankshaft group 2582
1 – Dismantling and assembling engine 2582
1 1 – Dismantling and assembling engine 2582
1 2 – Removing and installing ribbed belt 2593
1 3 – Removing and installing toothed belt 2596
2 – Removing and installing sealing flange and pressure plate/drive plate 2599
2 1 – Removing and installing sealing flange and pressure plate/drive plate 2599
2 2 – Renewing crankshaft oil seal – pulley end – 2602
2 3 – Removing and installing drive plate 2603
3 – Removing and installing crankshaft 2607
3 1 – Removing and installing crankshaft 2607
3 2 – Crankshaft dimensions 2609
4 – Dismantling and assembling pistons and conrods 2610
4 1 – Dismantling and assembling pistons and conrods 2610
4 2 – Piston and cylinder dimensions 2616
15 – Cylinder head, Valve gear 2617
1 – Removing and installing cylinder head 2617
1 1 – Removing and installing cylinder head 2617
1 2 – Removing and installing cylinder head 2624
1 3 – Checking compressions 2625
2 – Servicing valve gear 2627
2 1 – Servicing valve gear 2627
2 2 – Reworking valve seats 2633
2 3 – Removing and installing camshaft oil seal 2635
2 4 – Removing and installing camshaft 2636
2 5 – Checking hydraulic bucket tappets 2637
2 6 – Checking valve guides 2638
2 7 – Renewing valve guides 2639
2 8 – Renewing valve stem seals 2640
17 – Lubrication 2642
1 – Removing and installing parts of the lubrication system 2642
1 1 – Removing and installing parts of the lubrication system 2642
1 2 – Checking oil pressure and oil pressure switch 2648
19 – Cooling system 2649
1 – Removing and installing parts of cooling system 2649
1 1 – Removing and installing parts of cooling system 2649
1 2 – Parts of cooling system body side 2650
1 3 – Parts of cooling system – engine side 2653
1 4 – Dismantling and assembling coolant pump 2656
1 5 – Draining and filling cooling system 2657
1 6 – Removing and installing radiator and radiator fan 2659
20 – Fuel supply system 2661
1 – Removing and installing parts of fuel supply system 2661
1 1 – Removing and installing parts of fuel supply system 2661
1 2 – Removing and installing fuel tank with its attachments and fuel filter 2662
1 3 – Safety precautions when working on the fuel supply system 2667
1 4 – Rules for cleanliness 2668
1 5 – Adjusting throttle cable 2668
1 6 – Removing and installing fuel delivery unit 2670
1 7 – Checking fuel pump 2671
1 8 – Servicing the activated charcoal filter system 2676
1 9 – Checking fuel tank breather 2679
26 – Exhaust system 2682
1 – Removing and installing parts of exhaust system 2682
1 1 – Removing and installing parts of exhaust system 2682
00050507020 Motronic injection and ignition system (4 Cyl ) 2688
01 – Self diagnosis, Electrical check 2692
1 – Self diagnosis 2692
1 1 – Self diagnosis 2692
1 2 – Function 2692
1 3 – Technical data of self diagnosis 2692
1 4 – Connecting fault reader V A G 1551 and selecting engine electronics control unit 2693
1 5 – Interrogating fault memory 2694
1 6 – Fault table 2694
1 7 – Erasing fault memory 2700
1 8 – Final control diagnosis 2701
1 9 – Reading measuring value block 2704
1 10 – Display group overview 2704
2 – Electrical check 2706
2 1 – Electrical check 2706
2 2 – Wiring and component check with test box V A G 1598/18 2706
24 – Mixture preparation, Injection 2713
1 – Motronic injection and ignition system 2713
1 1 – Motronic injection and ignition system 2713
1 2 – Fitting locations overview 2713
1 3 – Servicing injection part 2716
1 4 – Dismantling and assembling intake manifold – upper part 2724
1 5 – Dismantling and assembling intake manifold – lower part 2727
1 6 – Dismantling and assembling air cleaner 2728
1 7 – Safety precautions 2729
1 8 – Rules for cleanliness 2730
1 9 – Technical data 2730
1 10 – Idling check 2730
1 11 – Checking idling stabilization 2731
1 12 – Checking Lambda probe and Lambda control 2733
1 13 – Checking engine operation 2735
1 14 – Checking throttle valve potentiometer 2736
1 15 – Matching automatic gearbox control unit and throttle valve potentiometer to one another 2737
1 16 – Checking intake manifold temperature sender 2738
1 17 – Checking coolant temperature sender 2739
1 18 – Checking speed signal 2740
1 19 – Matching engine electronic control unit to electronic immobilizer 2741
1 20 – Checking fuel pressure regulator and holding pressure 2742
1 21 – Checking injectors 2744
1 22 – Checking intake air system for leaks (outside air) 2746
1 23 – Checking intake air preheating 2747
28 – Ignition system 2749
1 – Motronic injection and ignition system 2749
1 1 – Motronic injection and ignition system 2749
1 2 – Servicing ignition part 2749
1 3 – Safety precautions 2753
1 4 – Test data, spark plugs 2753
1 5 – Installing distributor 2753
1 6 – Checking ignition transformer 2755
1 7 – Checking ignition transformer output stage 2756
1 8 – Checking Hall sender 2757
00050507120 Automatic gearbox 01M from January 1995 2759
00 – Technical data 2765
1 – Identification of gearbox 2765
1 1 – Identification of gearbox 2765
2 – Information on “Automatic gearbox 01M” 2766
2 1 – Information on “Automatic gearbox 01M” 2766
3 – Code letters, gearbox allocation, ratios, equipment 2766
3 1 – Code letters, gearbox allocation, ratios, equipment 2766
4 – Capacities 2769
4 1 – Capacities 2769
5 – Repair instructions 2769
5 1 – Repair instructions 2769
01 – Self diagnosis 2773
1 – Self-diagnosis function 2773
1 1 – Self-diagnosis function 2773
1 2 – Technical data of self-diagnosis 2774
1 3 – Self-diagnosis – Guide 2775
2 – Locations of electrical/electronic components 2776
2 1 – Locations of electrical/electronic components 2776
3 – Performing self-diagnosis 2788
3 1 – Performing self-diagnosis 2788
3 2 – Connecting fault reader V A G 1551 and selecting functions 2788
3 3 – List of selectable functions 2790
3 4 – Interrogating fault memory 2790
3 5 – Fault table 2791
3 6 – Erasing fault memory 2796
3 7 – Initiating basic setting 2797
3 8 – Read measured value block 2798
3 9 – Test table 2800
4 – Gearbox: Electrical test 2808
4 1 – Gearbox: Electrical test 2808
4 2 – Electrical check 2808
4 3 – Test table 2811
32 – Torque converter 2816
1 – Torque converter 2816
1 1 – Torque converter 2816
1 2 – Identification of torque converter 2816
1 3 – Torque converter allocation 2817
1 4 – Removing and installing torque converter oil seal 2819
1 5 – Draining torque converter 2820
37 – Controls, Housing 2822
1 – Servicing shift mechanism 2822
1 1 – Servicing shift mechanism 2822
1 2 – Checking shift mechanism 2822
1 3 – Checking and adjusting selector lever cable 2822
1 4 – Checking ignition key removal lock (vehicles with ignition key removal lock) 2823
1 5 – Dismantling and assembling selector mechanism 2823
1 6 – Dismantling and assembling shift mechanism (vehicles with ignition key removal lock) 2832
1 7 – Dismantling and assembling selector lever (vehicles with ignition key removal lock) 2839
1 8 – Removing and installing locking cable (vehicles with ignition key removal lock) 2845
1 9 – Adjusting locking cable (vehicles with ignition key removal lock) 2848
2 – Checking gearbox 2848
2 1 – Checking gearbox 2848
2 2 – Checking shift points 2849
2 3 – Checking stall speed 2849
2 4 – Measuring main pressure 2849
2 5 – Fault finding table for “4-speed automatic gearbox” 2849
3 – Removing and installing gearbox 2849
3 1 – Removing and installing gearbox 2849
3 2 – Removing and installing starter bush 2855
4 – Checking and topping up ATF level 2857
4 1 – Checking and topping up ATF level 2857
4 2 – Checking ATF level 2858
4 3 – Topping up ATF 2859
4 4 – Renewing ATF 2860
5 – Gearbox with selector elements 2861
5 1 – Gearbox with selector elements 2861
5 2 – Position of selector elements 2862
6 – Dismantling and assembling gearbox 2864
6 1 – Dismantling and assembling gearbox 2864
6 2 – Removing and installing ATF cooler and ATF filler tube 2864
6 3 – Dismantling and assembling planetary gearbox -Overview- 2866
6 4 – I – Removing and installing ATF pump to supporting tube 2867
6 5 – II – Removing and installing reverse gear clutch -K2- to large sun wheel 2870
6 6 – III – Removing and installing freewheel and reverse gear brake -B1- 2873
6 7 – IV – Planet carrier and gearbox housing with input gear and cover 2875
6 8 – Dismantling and assembling planetary gearbox 2877
6 9 – Overview of all planetary gearbox adjustments 2893
6 10 – Adjusting planet carrier 2894
6 11 – Adjusting reverse gear brake -B1- 2900
6 12 – Adjusting clutch play between -K1- and -K2- 2905
6 13 – Adjusting 2nd and 4th gear brake -B2- 2910
38 – Gears, Hydraulic controls 2916
1 – Dismantling and assembling ATF pump 2916
1 1 – Dismantling and assembling ATF pump 2916
2 – Dismantling and assembling freewheel with -B1- piston 2919
2 1 – Dismantling and assembling freewheel with -B1- piston 2919
3 – Dismantling and assembling 1st to 3rd gear clutch -K1- 2921
3 1 – Dismantling and assembling 1st to 3rd gear clutch -K1- 2921
4 – Dismantling and assembling reverse gear clutch -K2- 2926
4 1 – Dismantling and assembling reverse gear clutch -K2- 2926
5 – Dismantling and assembling 3rd and 4th gear clutch -K3- with turbine shaft 2929
5 1 – Dismantling and assembling 3rd and 4th gear clutch -K3- with turbine shaft 2929
6 – Removing and installing valve chest 2933
6 1 – Removing and installing valve chest 2933
7 – Dismantling and assembling parking lock 2942
7 1 – Dismantling and assembling parking lock 2942
39 – Final drive, Differential 2949
1 – Checking oil in final drive 2949
1 1 – Checking oil in final drive 2949
2 – Removing and installing oil seal for drive flange 2949
2 1 – Removing and installing oil seal for drive flange 2949
3 – Dismantling and assembling final drive 2952
3 1 – Dismantling and assembling final drive 2952
3 2 – Repair overview of final drive 2952
3 3 – Removing and installing input gear 2954
3 4 – Removing and installing drive pinion 2960
3 5 – Removing and installing differential 2970
3 6 – Dismantling and assembling differential 2979
4 – Adjusting final drive 2990
4 1 – Adjusting final drive 2990
4 2 – Overview of adjustments 2991
4 3 – Adjustments to be completed after replacing individual components 2992
4 4 – Adjusting drive pinion 2992
4 5 – Adjusting input gear 2994
4 6 – Adjusting differential 2996
5 – Definitions 2997
5 1 – Definitions 2997
00053148620 Wheels and Tyres Guide Archive 2999
44 – Wheels, tyres, vehicle geometry 3009
1 General notes on wheels and tyres (passenger cars) 3009
2 Legislative and technical conditions for converting wheel and tyre combinations 3011
2 1 Legislative conditions for converting wheel and tyre combinations 3011
2 2 Technical conditions for converting wheel and tyre combinations 3011
2 3 Additional wheel housing extensions (flaps) 3012
2 4 “Series 80” tyres 3012
2 5 Vehicles with Plus running gear 3012
3 Documents and codes/designations 3014
3 1 New vehicle registration documents since 01 10 2005 3014
3 2 COC document (EEC Certificate of Conformity) 3015
3 3 Official type designations 3015
3 4 EU general type approval number, sales type and sales or trade designation 3016
4 Useful information regarding tyres 3018
4 1 Identification markings on the tyre sidewall 3018
4 2 Explanation of tyre markings 3019
4 3 Speed ratings for tyres 3020
4 4 Undulations 3021
4 5 Tyre storage 3022
4 6 Tyre ageing 3022
4 7 Winter tyres 3023
4 8 Winter tyres with speed symbol “V” 3024
4 9 Extra Load (XL) V winter tyres 3025
4 10 Maximum speeds for V and Extra Load (XL) winter tyres 3025
4 11 Reinforced and Extra Load (XL) tyres 3026
4 12 Snow chains 3026
5 Tyre wear/ mileage for passenger car tyres 3028
5 1 General 3028
5 2 Requirements to be met by tyres 3028
5 3 Wear behaviour of high-speed tyres 3029
5 4 Factors influencing the service life of a tyre 3029
5 5 Driving style 3029
5 6 Tyre maintenance 3030
5 7 Evenly worn tyres 3031
5 8 Measuring tread depth 3032
5 9 One-sided wear 3032
5 10 Outer shoulder wear 3035
5 11 Wear in middle of tyre 3035
5 12 Diagonal washout 3037
6 Tyre noise 3038
6 1 General notes on tyre noise 3038
6 2 Saw-tooth wear 3038
6 3 Flat spots (from locking wheels) 3039
7 Rough running caused by wheels/tyres 3041
7 1 Causes of rough running 3041
7 2 Balancing wheels 3041
7 3 Conducting a road test before balancing wheels 3041
7 4 Balancing wheels on stationary wheel balancing machine 3042
7 5 Vibration control system -VAS 6230- 3044
7 6 Finish balancer 3044
7 7 Radial and lateral runout of wheels and tyres 3045
7 8 Checking radial and lateral runout on wheels and tyres with tyre gauge -V A G 1435- 3045
7 9 Checking radial and lateral runout on wheel rim 3046
7 10 Matching 3047
7 11 Flat spots caused by storage or handling 3048
8 Vehicle pulls to one side 3050
8 1 General 3050
8 2 Conicity 3050
8 3 Remedies when vehicle pulls to one side 3051
8 4 Strategic rotation of wheels for non-directional tyres 3052
8 5 Strategic rotation of wheels having unidirectional tyres 3053
9 Tyre damage 3055
9 1 General information 3055
9 2 Construction of a radial belted tyre 3055
9 3 Impact damage 3056
9 4 Cuts 3057
9 5 Damage caused by foreign bodies 3057
9 6 Loss of air from tyre 3058
9 7 Tyre pressure 3058
9 8 Tyre damage due to insufficient tyre pressure 3059
9 9 Rising tyre temperature caused by insufficient inflation pressure 3060
9 10 Tyre damage due to fitting error (fitting damage) 3061
10 Tyres with run-flat properties 3063
10 1 General 3063
10 2 Design and identification 3064
10 3 Retrofitting/requirements when using run-flat tyres 3064
10 4 Repairs 3065
11 Rolling resistance optimised tyres 3066
12 Facts about disc-type wheels (passenger cars) 3067
12 1 Design of disc-type wheel 3067
12 2 Data on wheel rims 3067
12 3 Wheel rims – pitch circle diameter 3068
12 4 Split rim composite wheels 3068
12 5 Alloy wheels with exchangeable trim elements 3068
12 6 Alloy wheels with exchangeable trim elements (Zaragoza) 3069
12 6 1 Tools 3069
12 6 2 Materials 3070
12 6 3 Installing trim element 3070
12 6 4 Removing trim element 3072
12 7 Hub cover for alloy wheels with open threaded connections 3073
12 8 Care and maintenance of alloy wheel rims 3073
12 9 Restoring alloy wheels 3074
12 10 The valve 3075
13 Fitting and removing wheels 3076
13 1 Rotating wheels 3076
13 2 Instructions for changing or fitting wheels 3076
13 3 Revised wheel bolts for Sharan from model year 2001 3078
13 4 Notes on use of temporary spare wheels 3078
14 Lupo 3L, Lupo FSI, Lupo GTI from model year 1999 3080
14 1 Lupo 3L, type 6E model year 1999 to model year 2006 3080
14 2 Wheel allocation for Lupo 3L, type 6E model year 1999 to model year 2006 3081
14 2 1 4 J x 14 3081
14 2 2 41/2 J x 14 3081
14 2 3 5 J x 14 3082
14 3 Lupo FSI, type 6E model year 2001 to model year 2006 3082
14 4 Wheel allocation for Lupo FSI, type 6E model year 2001 to model year 2006 3083
14 4 1 5 J x 14 3083
14 4 2 6 J x 14 3084
14 5 Lupo GTI, type 6ES model year 2001 to model year 2006 3085
14 6 Wheel allocation for Lupo GTI, type 6ES model year 2001 to model year 2006 3086
14 6 1 6 J x 14 3086
14 6 2 61/2 J x 15 3087
15 Lupo model year 1999 to model year 2005 3088
15 1 Lupo, type 6X model year 1999 to model year 2005 3088
15 2 Wheel allocation for Lupo, type 6X model year 1999 to model year 2005 3090
15 2 1 41/2 J x 13 3090
15 2 2 51/2 J x 13 3091
15 2 3 6 J x 14 3092
15 2 4 6 J x 15 3094
16 Fox from model year 2005 3096
16 1 Fox, type 5Z model year 2005 to model year 2012 3096
16 2 Wheel allocation for Fox, type 5Z model year 2005 to model year 2012 3097
16 2 1 5 J x 14 3098
16 2 2 6 J x 14 3098
16 2 3 6 J x 15 3100
17 Polo model year 1995 to model year 2001 3103
17 1 Polo, type 6N up to and including 07 95 3103
17 2 Wheel allocation for Polo, type 6N up to and including 07 95 3104
17 2 1 41/2 J x 13 3104
17 2 2 51/2 J x 13 3105
17 3 Polo, type 6N from 08 95 up to and including model year 1996 3106
17 4 Polo, type 6N from model year 1997 to model year 1999 3107
17 5 Wheel allocation for Polo, type 6N from 08 95 to model year 1999 3108
17 5 1 41/2 J x 13 3109
17 5 2 51/2 J x 13 3109
17 5 3 6 J x 14 3110
17 5 4 6 J x 15 3111
17 6 Polo, type 6N from model year 2000 to model year 2001 3113
17 7 Wheel allocation for Polo, type 6N from model year 2000 to model year 2001 3114
17 7 1 41/2 J x 13 3115
17 7 2 51/2 J x 13 3115
17 7 3 6 J x 14 3116
17 7 4 6 J x 15 3117
18 Polo Classic model year 1996 to model year 2002 3120
18 1 Polo Classic, type 6KV model year 1996 to model year 2002 3120
18 2 Wheel allocation for Polo Classic, type 6KV model year 1996 to model year 2002 3122
18 2 1 51/2 J x 13 3122
18 2 2 6 J x 14 3123
18 2 3 6 J x 15 3124
19 Polo Variant model year 1998 to model year 2002 3126
19 1 Polo Variant type 6KV model year 1998 to model year 2002 3126
19 2 Wheel allocation for Polo Variant type 6KV model year 1998 to model year 2002 3128
19 2 1 51/2 J x 13 3128
19 2 2 6 J x 14 3129
19 2 3 6 J x 15 3130
20 Polo from model year 2002 3132
20 1 Polo, type 9N model year 2002 to model year 2008 3132
20 2 Polo, type 9N model year 2009 3135
20 3 Wheel allocation for Polo, type 9N model year 2002 to model year 2009 3139
20 3 1 5 J x 13 3139
20 3 2 5 J x 14 3140
20 3 3 6 J x 14 3140
20 3 4 6 J x 15 3142
20 3 5 61/2 J x 16 offset 38 3143
20 3 6 61/2 J x 16 offset 43 3143
20 3 7 71/2 J x 17 offset 38 3146
21 Polo Fun model year 2004 to model year 2005 3147
21 1 Polo Fun, type 9N model year 2004 to model year 2005 3147
21 2 Wheel allocation for Polo Fun, type 9N model year 2004 to model year 2005 3148
21 2 1 6 J x 15 3148
21 2 2 71/2 J x 17 3148
22 CrossPolo from model year 2006 3150
22 1 CrossPolo, type 9N model year 2006 to model year 2009 3150
22 2 Wheel allocation for CrossPolo, type 9N model year 2006 to model year 2009 3151
22 2 1 6 J x 15 3151
22 2 2 71/2 J x 17 3151
23 Polo BlueMotion from model year 2007 3153
23 1 Polo BlueMotion, type 9N model year 2007 to model year 2009 3153
23 2 Wheel allocation for Polo BlueMotion, type 9N model year 2007 to model year 2009 3154
23 2 1 5 J x 14 3154
24 Polo GTI from model year 2006 3156
24 1 Polo GTI, type 9N model year 2006 to model year 2009 3156
24 2 Wheel allocation for Polo GTI, type 9N model year 2006 to model year 2009 3157
24 2 1 6 J x 15 3157
24 2 2 61/2 J x 16 offset 38 3158
24 2 3 61/2 J x 16 offset 43 3158
24 2 4 7 J x 17 offset 38 3160
24 2 5 71/2 J x 17 offset 38 3161
25 Polo GTI Cup Edition from model year 2007 3162
25 1 Polo GTI Cup Edition, type 9N model year 2007 to model year 2009 3162
25 2 Wheel allocation for Polo GTI Cup Edition, type 9N model year 2007 to model year 2009 3163
25 2 1 61/2 J x 16 offset 42 3163
25 2 2 61/2 J x 16 offset 43 3164
25 2 3 7 J x 17 offset 38 3165
25 2 4 71/2 J x 17 offset 38 3166
26 Polo saloon/sedan model year 2004 to model year 2005 3167
26 1 Polo saloon/sedan, type 9N model year 2004 to model year 2005 3167
26 2 Wheel allocation for Polo saloon/sedan, type 9N model year 2004 to model year 2005 3169
26 2 1 5 J x 14 3169
26 2 2 6 J x 14 3169
26 2 3 6 J x 15 3171
26 2 4 61/2 J x 16 3172
27 Golf model year 1992 to model year 1998 3174
27 1 Golf type 1HX0, Golf Syncro 1HX1, Golf type 1H 3174
27 2 Wheel allocation for Golf type 1HX0, Golf Syncro 1HX1, Golf type 1H 3178
27 2 1 51/2 J x 13 3178
27 2 2 6 J x 14 3179
27 2 3 6 J x 15 3181
27 2 4 61/2 J x 15 3184
27 2 5 7 J x 16 3187
28 Golf model year 1998 to model year 2004, Golf R32, Golf Anniversary GTI 3188
28 1 Golf, Golf 4Motion, type 1J model year 1998 to model year 2004 3188
28 2 Wheel allocation for Golf, Golf 4Motion, type 1J model year 1998 to model year 2004 3191
28 2 1 6 J x 14 3191
28 2 2 6 J x 15 3192
28 2 3 51/2 J x 16 3195
28 2 4 61/2 J x 16 3196
28 2 5 7 J x 17 3200
28 2 6 71/2 J x 17 3202
28 3 Conditions for fitting 17″ wheels and tyres to Golf model year 1998 to model year 2004 3203
28 4 Golf R32, type 1J model year 2003 to model year 2005 3204
28 5 Wheel allocation for Golf R32, type 1J model year 2003 to model year 2005 3204
28 5 1 51/2 J x 17 3205
28 5 2 71/2 J x 17 3205
28 5 3 71/2 J x 18 3205
28 6 Golf Anniversary GTI, type 1J model year 2002 3206
28 7 Wheel allocation for Golf Anniversary GTI, type 1J model year 2002 3206
28 7 1 51/2 J x 16 3207
28 7 2 61/2 J x 16 3207
28 7 3 7 J x 17 3209
28 7 4 71/2 J x 18 3210
28 8 Conditions for fitting 17″ and 18″ wheels and tyres of Golf Anniversary GTI 3211
29 Golf model year 2004 to model year 2009 3212
29 1 Golf, Golf 4Motion, type 1K model year 2004 to model year 2006 3212
29 2 Golf, Golf 4Motion, type 1K model year 2007 to model year 2009 3215
29 3 Wheel allocation for Golf, Golf 4Motion, type 1K model year 2004 to model year 2009 3219
29 3 1 6 J x 15 3219
29 3 2 61/2 J x 15 3220
29 3 3 6 J x 16 3221
29 3 4 61/2 J x 16 3221
29 3 5 6 J x 17 3225
29 3 6 7 J x 17 3226
29 3 7 71/2 J x 17 3228
29 3 8 71/2 J x 18 3229
30 Golf BlueMotion model year 2008 to model year 2009 3232
30 1 Golf BlueMotion, type 1K model year 2008 to model year 2009 3232
30 2 Wheel allocation for Golf BlueMotion, type 1K model year 2008 to model year 2009 3233
30 2 1 6 J x 15 3233
30 2 2 61/2 J x 15 3234
30 2 3 61/2 J x 16 3235
31 Golf GTI model year 2005 to model year 2009 3240
31 1 Golf GTI, type 1K model year 2005 to model year 2008 3240
31 2 Golf GTI, type 1K model year 2009 3241
31 3 Wheel allocation for Golf GTI, type 1K model year 2005 to model year 2009 3243
31 3 1 6 J x 16 3243
31 3 2 61/2 J x 16 3243
31 3 3 6 J x 17 3247
31 3 4 7 J x 17 3248
31 3 5 71/2 J x 17 3250
31 3 6 71/2 J x 18 3251
32 Pirelli Golf model year 2008 to model year 2009 3254
32 1 Pirelli Golf, type 1K model year 2008 to model year 2009 3254
32 2 Wheel allocation for Pirelli Golf, type 1K model year 2008 to model year 2009 3255
32 2 1 6 J x 16 3255
32 2 2 61/2 J x 16 3256
32 2 3 6 J x 17 3260
32 2 4 7 J x 17 3260
32 2 5 71/2 J x 17 3263
32 2 6 71/2 J x 18 3264
33 Golf R32 model year 2006 to model year 2009 3267
33 1 Golf R32, type 1K model year 2006 to model year 2009 3267
33 2 Wheel allocation for Golf R32, type 1K model year 2006 to model year 2009 3268
33 2 1 6 J x 17 3268
33 2 2 7 J x 17 3269
33 2 3 71/2 J x 18 3271
34 CrossGolf from model year 2007 3274
34 1 CrossGolf, type 1KP model year 2007 to model year 2009 3274
34 2 Wheel allocation for CrossGolf, type 1KP model year 2007 to model year 2009 3277
34 2 1 6 J x 15 3277
34 2 2 61/2 J x 15 3278
34 2 3 6 J x 16 3279
34 2 4 61/2 J x 16 3280
34 2 5 6 J x 17 3284
34 2 6 7 J x 17 offset 47 3284
34 2 7 7 J x 17 offset 54 3285
34 2 8 71/2 J x 17 3287
35 Golf Plus from model year 2005 3288
35 1 Golf Plus, type 1KP model year 2005 to model year 2006 3288
35 2 Golf Plus, type 1KP model year 2007 to model year 2009 3290
35 3 Wheel allocation for Golf Plus, type 1KP model year 2005 to model year 2009 3293
35 3 1 6 J x 15 3294
35 3 2 61/2 J x 15 3294
35 3 3 6 J x 16 3295
35 3 4 61/2 J x 16 3296
35 3 5 6 J x 17 3300
35 3 6 7 J x 17 3301
35 3 7 71/2 J x 18 3303
36 Golf Plus BlueMotion from model year 2008 3306
36 1 Golf Plus BlueMotion, type 1KP model year 2008 to model year 2009 3306
36 2 Wheel allocation for Golf Plus BlueMotion, type 1KP model year 2008 to model year 2009 3307
36 2 1 6 J x 15 3307
36 2 2 61/2 J x 15 3308
36 2 3 61/2 J x 16 3309
37 Golf Variant model year 1994 to model year 1998 3314
37 1 Golf Variant type 1HX0, Golf Variant Syncro type 1HX1, Golf Variant type 1H 3314
37 2 Wheel allocation for Golf Variant type 1HX0, Golf Variant Syncro type 1HX1, Golf Variant type 1H 3317
37 2 1 51/2 J x 13 3318
37 2 2 6 J x 14 3318
37 2 3 6 J x 15 3321
37 2 4 61/2 J x 15 3324
38 Golf Variant model year 1999 to model year 2006, Bora Variant model year 1999 to model year 2005 3325
38 1 Golf Variant, Golf Variant 4Motion, Bora Variant, Bora Variant 4Motion, type 1J 3325
38 2 Wheel allocation for Golf Variant, Golf Variant 4Motion, Bora Variant, Bora Variant 4Motion, type 1J 3328
38 2 1 6 J x 15 3328
38 2 2 51/2 J x 16 3331
38 2 3 61/2 J x 16 3332
38 2 4 7 J x 17 3336
38 2 5 71/2 J x 17 3338
38 3 Conditions for fitting 17″ wheels and tyres 3339
39 Golf Variant model year 2007 to model year 2010 3340
39 1 Golf Variant, Golf Variant 4Motion; type 1KM model year 2007 to model year 2008 3340
39 2 Golf Variant, Golf Variant 4Motion; type 1KM model year 2009 to model year 2010 3343
39 3 Wheel allocation for Golf Variant, Golf Variant 4Motion; type 1KM model year 2007 to model year 2010 3346
39 3 1 6 J x 15 3346
39 3 2 61/2 J x 15 3347
39 3 3 6 J x 16 3348
39 3 4 61/2 J x 16 3349
39 3 5 7 J x 17 3353
39 3 6 71/2 J x 18 3355
40 Golf Variant BlueMotion model year 2008 to model year 2010 3358
40 1 Golf Variant BlueMotion, type 1KM model year 2008 to model year 2010 3358
40 2 Wheel allocation for Golf Variant BlueMotion, type 1KM model year 2008 to model year 2010 3359
40 2 1 6 J x 15 3359
40 2 2 61/2 J x 15 3360
40 2 3 61/2 J x 16 3361
41 Jetta Model Year 2006 to Model Year 2011 3366
41 1 Jetta, type 1KM model year 2006 3366
41 2 Jetta, type 1KM model year 2007 to model year 2008 3368
41 3 Jetta, type 1KM model year 2009 to model year 2011 3371
41 4 Wheel allocation for Jetta, type 1KM model year 2006 to model year 2011 3378
41 4 1 6 J x 15 3378
41 4 2 61/2 J x 15 3379
41 4 3 6 J x 16 3380
41 4 4 61/2 J x 16 3381
41 4 5 7 J x 17 3386
41 4 6 71/2 J x 17 3389
41 4 7 71/2 J x 18 3390
42 Jetta BlueMotion from Model year 2008 3395
42 1 Jetta BlueMotion, type 1KM model year 2008 to model year 2011 3395
42 2 Wheel allocation for Jetta BlueMotion, type 1KM model year 2008 to model year 2011 3396
42 2 1 6 J x 15 3396
42 2 2 61/2 J x 15 3397
42 2 3 6 J x 16 3398
42 2 4 61/2 J x 16 3399
43 Golf cabriolet model year 1994 to model year 1997 3405
43 1 Golf cabriolet type 1EX0 model year 1994 to model year 1997 3405
43 2 Wheel allocation for Golf cabriolet, type 1EX0 from model year 1994 to model year 1997 3406
43 2 1 6 J x 14 3407
43 2 2 6 J x 15 3408
43 2 3 61/2 J x 16 3408
44 Golf cabriolet model year 1998 to model year 2002 3410
44 1 Golf cabriolet; type 1E from model year 1998 to model year 2002 3410
44 2 Wheel allocation for Golf cabriolet; type 1E from model year 1998 to model year 2002 3411
44 2 1 6 J x 14 3411
44 2 2 6 J x 15 3413
44 2 3 61/2 J x 16 3415
45 Vento from model year 1992 to model year 1998 3416
45 1 Vento; type 1HX0, 1H 3416
45 2 Wheel allocation for Vento; type 1HX0, 1H 3418
45 2 1 51/2 J x 13 3418
45 2 2 6 J x 14 3419
45 2 3 6 J x 15 3421
45 2 4 61/2 J x 15 3423
46 Bora model year 1999 to model year 2005 3427
46 1 Bora, Bora 4Motion, type 1J model year 1999 to model year 2005 3427
46 2 Wheel allocation for Bora, Bora 4Motion, type 1J model year 1999 to model year 2005 3430
46 2 1 6 J x 15 3430
46 2 2 51/2 J x 16 3433
46 2 3 61/2 J x 16 3433
46 2 4 7 J x 17 3438
46 2 5 71/2 J x 17 3440
46 3 Conditions for fitting 17″ wheels and tyres 3441
47 New Beetle from model year 1999 3442
47 1 New Beetle, type 9C model year 1999 to model year 2010 3442
47 2 Wheel allocation for New Beetle, type 9C model year 1999 to model year 2010 3445
47 2 1 6 J x 15 3445
47 2 2 51/2 J x 16 3447
47 2 3 61/2 J x 16 3448
47 2 4 7 J x 17 3453
47 2 5 71/2 J x 17 3456
47 3 Conditions for fitting 17″ wheels and tyres 3456
48 New Beetle Cabriolet from model year 2003 3458
48 1 New Beetle Cabriolet, type 1Y model year 2003 to model year 2010 3458
48 2 Wheel allocation for New Beetle Cabriolet, type 1Y model year 2003 to model year 2010 3460
48 2 1 6 J x 15 3460
48 2 2 51/2 J x 16 3462
48 2 3 61/2 J x 16 3463
48 2 4 7 J x 17 3468
48 2 5 71/2 J x 17 3471
48 3 Conditions for fitting 17″ wheels and tyres 3471
49 New Beetle RSi 3473
49 1 New Beetle RSi, type 9CR from model year 2001 3473
49 2 Wheel allocation for New Beetle RSi, type 9CR from model year 2001 3474
49 2 1 7 J x 16 3474
49 2 2 9 x 18 3474
50 Passat model year 1994 to model year 1997 3476
50 1 Passat, type 35l model year 1994 to model year 1997 3476
50 2 Wheel allocation for Passat, type 35l model year 1994 to model year 1997 3478
50 2 1 6 J x 14 3478
50 2 2 6 J x 15 3480
51 Passat model year 1997 to model year 2005 3484
51 1 Passat, Passat Variant, type 3B model year 1997 to model year 2000 3484
51 2 Passat, Passat Variant, type 3B model year 1997 to model year 2000 3486
51 2 1 6 J x 15 3486
51 2 2 7 J x 15 3487
51 2 3 7 J x 16 3488
51 3 Passat, Passat Variant, type 3BG model year 2001 to model year 2005 3489
51 4 Wheel allocation for Passat, Passat Variant, type 3BG model year 2001 to model year 2005 3490
51 4 1 6 J x 15 3491
51 4 2 7 J x 15 3492
51 4 3 6 J x 16 3492
51 4 4 7 J x 16 3493
51 4 5 7 J x 17 3495
51 5 Passat W8 4Motion, type 3BS model year 2002 to model year 2005 3496
51 6 Wheel allocation for Passat W8 4Motion, type 3BS model year 2002 to model year 2005 3497
51 6 1 7 J x 16 3497
51 6 2 6 J x 17 3498
51 6 3 71/2 J x 17 3498
51 7 Passat Protect, type 3BL model year 2002 to model year 2005 3499
51 8 Wheel allocation for Passat Protect, type 3BL model year 2002 to model year 2005 3500
51 8 1 6 J x 16 3500
51 8 2 7 J x 16 3500
52 Passat saloon from model year 2006 3502
52 1 Passat saloon, type 3C model year 2006 3502
52 2 Passat saloon, type 3C model year 2007 to model year 2008 3505
52 3 Passat saloon, type 3C model year 2009 3513
52 4 Passat saloon, type 3C model year 2010 to model year 2011 3520
52 5 Wheel allocation for Passat saloon, type 3C model year 2006 to model year 2011 3524
52 5 1 61/2 J x 16 3524
52 5 2 7 J x 16 3525
52 5 3 6 J x 17 3527
52 5 4 71/2 J x 17 3527
52 5 5 8 J x 18 3530
53 Passat saloon BlueMotion from model year 2008 3533
53 1 Passat saloon BlueMotion, type 3C model year 2008 to model year 2009 3533
53 2 Passat saloon BlueMotion, type 3C model year 2010 to model year 2011 3535
53 3 Wheel allocation for Passat saloon BlueMotion, type 3C model year 2008 to model year 2011 3536
53 3 1 61/2 J x 16 3536
53 3 2 7 J x 16 3537
53 3 3 6 J x 17 3539
53 3 4 71/2 J x 17 3539
53 3 5 8 J x 18 3542
54 Passat Variant from model year 2006 3545
54 1 Passat Variant, type 3C model year 2006 3545
54 2 Passat Variant, type 3C model year 2007 to model year 2008 3549
54 3 Passat Variant, type 3C model year 2009 3559
54 4 Passat Variant, type 3C model year 2010 to model year 2011 3567
54 5 Wheel allocation for Passat Variant, type 3C model year 2006 to model year 2011 3571
54 5 1 61/2 J x 16 3571
54 5 2 7 J x 16 3572
54 5 3 6 J x 17 3574
54 5 4 71/2 J x 17 3574
54 5 5 8 J x 18 3577
55 Passat Variant BlueMotion from model year 2008 3580
55 1 Passat Variant BlueMotion, type 3C model year 2008 to model year 2009 3580
55 2 Passat Variant BlueMotion, type 3C model year 2010 to model year 2011 3582
55 3 Wheel allocation for Passat Variant BlueMotion, type 3C model year 2008 to model year 2011 3583
55 3 1 61/2 J x 16 3583
55 3 2 7 J x 16 3584
55 3 3 6 J x 17 3586
55 3 4 71/2 J x 17 3586
55 3 5 8 J x 18 3589
56 Passat R36 from model year 2008 3592
56 1 Passat R36, type 3C model year 2008 to model year 2009 3592
56 2 Passat R36, type 3C model year 2010 to model year 2011 3594
56 3 Wheel allocation for Passat R36, type 3C model year 2008 to model year 2011 3595
56 3 1 6 J x 17 3595
56 3 2 71/2 J x 17 3595
56 3 3 8 J x 18 3598
56 3 4 8 J x 19 3599
57 Sharan from model year 1996 3601
57 1 Sharan, Sharan Syncro, type 7M model year 1996 to model year 2000 3601
57 2 Wheel allocation for Sharan, Sharan Syncro Type 7M model year 1996 to model year 2000 3604
57 2 1 6 J x 15 3604
57 2 2 7 J x 15 3605
57 2 3 7 J x 16 3606
57 3 Sharan, Sharan 4Motion, type 7M model year 2001 3606
57 4 Wheel allocation for Sharan, Sharan 4Motion, type 7M model year 2001 3609
57 4 1 6 J x 15 3609
57 4 2 7 J x 15 3609
57 4 3 6 J x 16 3610
57 4 4 7 J x 16 3611
57 5 Sharan, Sharan 4Motion, type 7M model year 2002 to model year 2010 3613
57 6 Wheel allocation for Sharan, Sharan 4Motion, type 7M model year 2002 to model year 2010 3614
57 6 1 6 J x 16 3615
57 6 2 7 J x 16 3615
57 6 3 7 J x 17 3617
58 Sharan BlueMotion from model year 2009 3619
58 1 Sharan BlueMotion, type 7M model year 2009 to model year 2010 3619
58 2 Wheel allocation for Sharan BlueMotion, type 7M model year 2009 to model year 2010 3620
58 2 1 6 J x 16 3620
59 Touareg from model year 2003 3622
59 1 Touareg, type 7L, model year 2003 to model year 2010 3622
59 2 Wheel allocation for Touareg, type 7L model year 2003 to model year 2010 3626
59 2 1 7 J x 16 3626
59 2 2 71/2 J x 17 3627
59 2 3 8 J x 18 3628
59 2 4 9 J x 19 3630
59 2 5 9 J x 20 3632
59 2 6 91/2 J x 20 3634
60 Touareg R50 from model year 2008 3635
60 1 Touareg R50, type 7L model year 2008 to model year 2010 3635
60 2 Wheel allocation for Touareg R50, type 7L model year 2008 to model year 2010 3636
60 2 1 9 J x 19 3636
60 2 2 9 J x 20 3638
60 2 3 91/2 J x 20 3639
60 2 4 10 J x 21 3639
61 Breakdown set for VW Vehicles 3641
62 Temporary spare tyres and wheels for VW vehicles 3642
63 Recommended summer tyres 3644
63 1 Summer tyres for Lupo 3L model year 1999 to model year 2005 3644
63 2 Summer tyres for Lupo FSI model year 1999 to model year 2005 3644
63 3 Summer tyres for Lupo GTI model year 1999 to model year 2005 3644
63 4 Summer tyres for Lupo model year 1999 to model year 2005 3644
63 5 Summer tyres for Fox from model year 2005 3645
63 6 Summer tyres for Polo model year 1995 to model year 2001 3645
63 7 Summer tyres for Polo saloon/sedan model year 2004 to model year 2005 3646
63 8 Summer tyres for Polo Classic model year 1996 to model year 2002 3646
63 9 Summer tyres for Polo Variant model year 1998 to model year 2002 3647
63 10 Summer tyres for Polo from model year 2002 3647
63 11 Summer tyres for Polo Fun model year 2004 to model year 2005 3648
63 12 Summer tyres for CrossPolo from model year 2006 3648
63 13 Summer tyres for Polo BlueMotion from model year 2007 3649
63 14 Summer tyres for Polo GTI from model year 2007 3649
63 15 Summer tyres for Polo GTI Cup Edition from model year 2007 3649
63 16 Summer tyres for Golf, Vento model year 1992 to model year 1998 3649
63 17 Summer tyres for Golf Variant model year 1994 to model year 1998 3650
63 18 Summer tyres for Golf cabriolet model year 1994 to model year 1997 3651
63 19 Summer tyres for Golf, Golf 4Motion model year 1998 to model year 2004 3651
63 20 Summer tyres for Golf model year 2004 to model year 2009 3652
63 21 Summer tyres for Golf BlueMotion model year 2008 to model year 2009 3654
63 22 Summer tyres for Golf GTI model year 2005 to model year 2009 3654
63 23 Summer tyres for Pirelli Golf model year 2008 to model year 2009 3654
63 24 Summer tyres for Golf R32 model year 2006 to model year 2009 3655
63 25 Summer tyres for CrossGolf from model year 2007 3655
63 26 Summer tyres for Golf Plus from model year 2005 3656
63 27 Summer tyres for Golf Plus BlueMotion from model year 2008 3657
63 28 Summer tyres for Bora, Bora 4Motion model year 1999 to model year 2005 3657
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 3658
63 30 Summer tyres for Golf R32 3659
63 31 Summer tyres for Golf Anniversary GTI 3660
63 32 Summer tyres for Golf Variant model year 2007 to model year 2010 3660
63 33 Summer tyres for Golf Variant BlueMotion from model year 2008 3661
63 34 Summer tyres for Jetta Model Year 2006 to Model Year 2011 3661
63 35 Summer tyres for Jetta BlueMotion Model Year 2008 to Model Year 2011 3663
63 36 Summer tyres for Golf cabriolet model year 1998 to model year 2002 3664
63 37 Summer tyres for New Beetle from model year 1999 3665
63 38 Summer tyres for New Beetle Cabriolet from model year 2003 3666
63 39 Summer tyres for New Beetle RSi 3666
63 40 Summer tyres for Passat model year 1994 to model year 1997 3667
63 41 Summer tyres for Passat model year 1997 to model year 2005 3667
63 42 Summer tyres for Passat W8 3668
63 43 Summer tyres for Passat Protect 3668
63 44 Summer tyres for Passat saloon from model year 2006 3668
63 45 Summer tyres for Passat saloon BlueMotion from model year 2008 3669
63 46 Summer tyres for Passat Variant from model year 2006 3670
63 47 Summer tyres for Passat Variant BlueMotion from model year 2008 3671
63 48 Summer tyres for Passat R36 from model year 2008 3672
63 49 Summer tyres for Sharan from model year 1996 3673
63 50 Summer tyres for Sharan BlueMotion from model year 2009 3673
63 51 Summer tyres for Touareg model year 2008 to model year 2010 3674
63 52 Summer tyres for Touareg R50 model year 2008 to model year 2010 3674
64 Recommended all-season tyres 3675
64 1 All-season tyres Lupo model year 1999 to model year 2005 3675
64 2 All-season tyres Polo model year 1995 to model year 2001 3675
64 3 All-season tyres for Polo from model year 2002 3675
64 4 All-season tyres Polo saloon/sedan model year 2004 to model year 2005 3676
64 5 All-season tyres Golf, Vento model year 1992 to model year 1998 3676
64 6 All-season tyres Golf Variant model year 1994 to model year 1998 3676
64 7 All-season tyres Golf cabriolet model year 1994 to model year 1997 3676
64 8 All-season tyres Golf, Golf 4Motion model year 1998 to model year 2004 3676
64 9 All-season tyres for Golf model year 2004 to model year 2009 3677
64 10 All-season tyres for CrossGolf from model year 2007 3677
64 11 All-season tyres for Golf Plus from model year 2005 3678
64 12 All-season tyres Bora, Bora 4Motion model year 1999 to model year 2005 3678
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 3679
64 14 All-season tyres Golf Variant model year 2007 to model year 2010 3679
64 15 All-season tyres Jetta Model Year 2006 to Model Year 2011 3679
64 16 All-season tyres Golf cabriolet model year 1998 to model year 2002 3680
64 17 All-season tyres for New Beetle from model year 1999 3680
64 18 All-season tyres for New Beetle Cabriolet from model year 2003 3681
64 19 All-season tyres Passat model year 1997 to model year 2005 3681
64 20 All-season tyres for Passat W8 3681
64 21 All-season tyres for Passat saloon from model year 2006 3682
64 22 All-season tyres for Passat saloon BlueMotion from model year 2008 3682
64 23 All-season tyres for Passat Variant from model year 2006 3682
64 24 All-season tyres for Passat Variant BlueMotion from model year 2008 3682
64 25 All-season tyres for Passat R36 from model year 2008 3683
64 26 All-season tyres for Touareg model year 2003 to model year 2010 3683
65 Recommended winter tyres 3684
65 1 Winter tyres Lupo 3L model year 1999 to model year 2005 3684
65 2 Winter tyres Lupo FSI model year 1999 to model year 2005 3684
65 3 Winter tyres Lupo GTI model year 1999 to model year 2005 3684
65 4 Winter tyres Lupo model year 1999 to model year 2005 3685
65 5 Winter tyres for Fox from model year 2005 3685
65 6 Winter tyres Polo model year 1995 to model year 2001 3685
65 7 Winter tyres for Polo from model year 2002 3686
65 8 Winter tyres for Polo Fun model year 2004 to model year 2006 3686
65 9 Winter tyres for CrossPolo from model year 2006 3686
65 10 Winter tyres for Polo BlueMotion from model year 2007 3686
65 11 Winter tyres for Polo GTI from model year 2007 3687
65 12 Winter tyres for Polo GTI Cup Edition from model year 2007 3687
65 13 Winter tyres Polo saloon/sedan model year 2004 to model year 2005 3687
65 14 Winter tyres Polo Classic model year 1996 to model year 2002 3687
65 15 Winter tyres Polo Variant model year 1998 to model year 2002 3688
65 16 Winter tyres Golf, Vento model year 1992 to model year 1998 3688
65 17 Winter tyres Golf Variant model year 1994 to model year 1998 3689
65 18 Winter tyres Golf cabriolet model year 1994 to model year 1997 3689
65 19 Winter tyres Golf, Golf 4Motion model year 1998 to model year 2004 3689
65 20 Winter tyres for Golf model year 2004 to model year 2009 3690
65 21 Winter tyres for Golf BlueMotion model year 2004 to model year 2009 3691
65 22 Winter tyres for Golf GTI model year 2005 to model year 2009 3691
65 23 Winter tyres for Pirelli Golf model year 2008 to model year 2009 3691
65 24 Winter tyres for Golf R32 model year 2006 to model year 2009 3692
65 25 Winter tyres for CrossGolf from model year 2007 3692
65 26 Winter tyres for Golf Plus from model year 2005 3692
65 27 Winter tyres for Golf Plus BlueMotion from model year 2008 3693
65 28 Winter tyres Bora, Bora 4Motion model year 1999 to model year 2005 3693
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 3694
65 30 Winter tyres for Golf 32 3694
65 31 Winter tyres for Golf Anniversary GTI 3694
65 32 Winter tyres Golf Variant model year 2007 to model year 2010 3695
65 33 Winter tyres for Golf Variant BlueMotion model year 2008 to model year 2010 3695
65 34 Winter tyres Jetta Model Year 2006 to Model Year 2011 3696
65 35 Winter tyres Jetta BlueMotion Model Year 2008 to Model Year 2011 3696
65 36 Winter tyres Golf cabriolet model year 1998 to model year 2002 3696
65 37 Winter tyres for New Beetle from model year 1999 3697
65 38 Winter tyres for New Beetle Cabriolet from model year 2003 3697
65 39 Winter tyres for New Beetle RSi 3698
65 40 Winter tyres Passat model year 1994 to model year 1997 3698
65 41 Winter tyres Passat model year 1997 to model year 2005 3698
65 42 Winter tyres for Passat W8 3699
65 43 Winter tyres for Passat Protect 3699
65 44 Winter tyres for Passat saloon from model year 2006 3699
65 45 Winter tyres for Passat saloon BlueMotion from model year 2008 3700
65 46 Winter tyres for Passat Variant from model year 2006 3700
65 47 Winter tyres for Passat Variant BlueMotion from model year 2008 3701
65 48 Winter tyres for Passat R36 from model year 2008 3701
65 49 Winter tyres for Sharan from model year 1996 3702
65 50 Winter tyres for Sharan BlueMotion from model year 2009 3702
65 51 Winter tyres for Touareg model year 2003 to model year 2010 3702
65 52 Winter tyres for Touareg R50 model year 2008 to model year 2010 3702
00053201020 Body repairs Volkswagen cars Golf Vento Cabriolet Passat 94 Golf 98 3704
Contents 3706
1 Safety instructions 3708
1 1 Removing components 3708
1 2 Battery, welding work 3708
1 3 Electronic control units 3708
1 3 1 Procedure for handling electronic control units after accident repairs 3708
1 4 Paint, glass, upholstery, trim 3709
1 5 Fuel tank or fuel pipes 3709
1 6 Air conditioner 3709
1 6 1 Remedy: 3709
1 7 Airbag system 3710
1 8 Checking seat belts 3710
1 8 1 Checking belt webbing 3711
1 8 2 Checking inertia reel (locking effect) 3712
1 8 3 Belt lock – visual check 3712
1 8 4 Belt lock – functional check 3712
1 8 5 Checking belt guides and lock tongues 3713
1 8 6 Checking securing parts and anchorage points 3713
1 9 Safety regulations for belt tensioners 3713
1 10 Body repairs on vehicles fitted with belt tensioners 3714
1 10 1 The following list of vehicles are equipped with: 3715
1 11 Cutting, straightening and/or panel beating work on vehicles fitted with airbag 3715
1 12 Removing front seats with side airbag 3715
2 Fundamental instructions 3717
2 1 Diagnosis on accident vehicles 3717
2 2 Conditions in which body and/or parts are passed for painting 3717
2 3 Straightening 3717
2 4 Parting cuts 3717
2 5 Replacement body sub-parts and part sections 3718
2 6 Original joint 3718
2 7 Galvanized body parts 3718
2 8 Removing remaining material 3718
2 9 New parts 3719
2 10 Replacement parts 3719
3 Symbols 3720
3 1 Symbols for welding operations 3720
3 2 Symbols for working procedures 3720
3 2 1 Grind 3720
3 2 2 Offset 3721
3 2 3 Punch 3721
3 2 4 Drill 3721
3 2 5 Grind 3722
3 2 6 Cavity preservation 3722
3 2 7 Bond 3722
3 2 8 Seal 3722
4 Body repair tools 3723
4 1 Flanging tool V A G1317 3723
4 2 Hole punch V A G1329 3723
4 3 Basic equipment V A G1366/3 3723
4 4 Underseal spray gun V A G1379 3723
4 5 Hot air blower V A G1416 3724
4 6 Mechanical door tensioner V A G1438 3724
4 7 Body equipment trolley V A G1439 3724
4 8 Pneumatic sabre saw V A G1523A 3724
4 9 Pneumatic hammer V A G1577 3725
4 10 Fold crimping tool V A G1585 3725
4 11 Local exhaust ventilation unit V A G1586 3725
4 12 Spot weld breaker V A G1731 3725
4 13 Pneumatic cartridge gun V A G1761/1 3726
4 14 Pneumatic punch and offset tool VAS1996 3726
4 15 Pneumatic glue gun V A G2005 3726
4 16 Door hinge alignment tool 3726
4 17 Hose set 5023 3727
4 18 Angle grinder VAS5174 3727
4 19 Angle grinder VAS5175 3727
4 20 Wire brush VAS5182 3727
5 Body bonded joints 3728
5 1 Transporter 1991 ‰ 3728
5 1 1 Separating procedure: 3728
5 1 2 Bonding procedure: 3728
5 2 Types of bonded joints 3728
5 2 1 Joints bonded for strength 3728
5 2 2 Spot welded bonded joints 3728
5 3 Repair solutions for part section replacement 3729
5 3 1 RP spot welding and bonding 3729
5 3 2 SG welding and bonding (when spot welding is not possible) 3729
5 3 3 Extraction of welding fumes 3729
5 3 4 Preparation 3729
5 3 5 Supplementary work 3729
6 Anti-corrosion measures 3730
6 1 Anti-corrosion protection 3730
7 Disposal instructions 3731
7 1 Disposal 3731
7 2 Releasing gas from strut 3731
7 3 Airbag 3732
7 3 1 Disposal 3732
8 Contact corrosion protection 3733
8 1 Joining aluminium/magnesium and steel 3733
9 Steel sheet repairs 3734
9 1 Strengthened steel body panels 3734
9 2 Galvanized body parts 3735
9 2 1 Preparation 3735
9 2 2 Parting cuts 3735
9 2 3 Joint techniques 3735
9 3 Welding work on galvanized body panels 3735
9 3 1 SG inert gas welding of galvanized panels 3735
9 3 2 RP welding of galvanized panels 3736
9 3 3 Welding transformer 3736
9 3 4 Welding clamp 3736
9 4 Unbuttoning test 3736
10 Aluminium repairs 3737
10 1 Paint 3737
10 2 Surface preparation 3737
10 3 Removing dents 3738
10 4 Temperature regulation when heating 3738
11 Synthetic material repair procedures 3739
11 1 Materials 3739
11 2 Repairing dents 3741
11 3 Repairing scratches 3743
11 4 Repairing cracks (up to 100 mm in length) 3744
11 5 Repairing hole (up to 30 mm diameter) 3745
11 6 Synthetic material repair (glass fibre materials) 3746
11 7 Repair procedures 3747
11 7 1 Repairing rupture/hole 3747
11 7 2 Repairing damaged surfaces 3748
12 Glass repair 3749
12 1 Repairing windscreen 3749
12 1 1 Prerequisites 3749
12 1 2 Special tools, workshop equipment, testers, measuring instruments and auxiliary items requ 3750
12 1 3 Description of repair 3751
D3E8049715C Wheels and Tyres Guide 3754
00 – Technical data 3762
1 General notes on wheels and tyres (passenger cars) 3762
1 1 Legislative conditions for converting wheel and tyre combinations 3763
1 2 Technical conditions for converting wheel and tyre combinations 3764
1 3 Official type designations 3764
1 3 1 Official type approval, sales or trade designation 3764
1 4 General information 3766
1 4 1 Special models 3766
1 4 2 Vehicles with Plus running gear 3766
1 4 3 Speed ratings for tyres 3767
1 4 4 “Series 80” tyres 3768
1 4 5 Wheel bolts – torque settings 3768
1 4 6 Revised wheel bolts for Sharan from model year 2001 3768
1 4 7 Wheel rims – pitch circle diameter 3769
1 4 8 Data on wheel rims 3769
1 4 9 Split rim wheels 3770
1 4 10 Alloy wheels with exchangeable trim elements 3770
2 Facts about wheels and tyres (passenger cars) 3771
2 1 Tyre wear/ mileage 3771
2 1 1 General information 3771
2 1 2 Requirements to be met by tyres 3771
2 1 3 Wear behaviour of high-speed tyres 3772
2 1 4 Factors influencing the service life of a tyre 3772
2 1 5 Driving style 3773
2 1 6 Tyre maintenance 3774
2 1 7 Evenly worn tyres 3775
2 1 8 Measuring tread depth 3775
2 1 9 One-sided wear 3776
2 1 10 Wear in middle of tyre 3778
2 1 11 Diagonal washout 3779
2 2 Tyre noise 3780
2 2 1 General notes on tyre noise 3780
2 2 2 Saw-tooth wear 3781
2 2 3 Flat spots (from locking wheels) 3782
2 3 Rough running caused by wheels/tyres 3783
2 3 1 Causes of rough running 3783
2 3 2 Balancing wheels 3783
2 3 3 Conducting a road test before balancing wheels 3783
2 3 4 Balancing wheels on stationary wheel balancing machine 3784
2 3 5 Vibration control system -VAS 6230- 3785
2 3 6 Finish balancer 3786
2 3 7 Radial and lateral runout of wheels and tyres 3787
2 3 8 Checking radial and lateral runout on wheels and tyres with tyre gauge -V A G 1435- 3787
2 3 9 Checking radial and lateral runout on wheel 3789
2 3 10 Matching 3789
2 3 11 Flat spots caused by storage or handling 3791
2 4 Vehicle pulls to one side 3792
2 4 1 General information 3792
2 4 2 Conicity 3792
2 4 3 Remedies when vehicle pulls to one side 3794
2 4 4 Strategic rotation of wheels for non-directional tyres 3795
2 4 5 Strategic rotation of wheels having unidirectional tyres 3796
2 4 6 Tyres with a red spot 3796
2 5 Tyre damage 3797
2 5 1 General information 3797
2 5 2 Construction of a radial belted tyre 3798
2 5 3 Impact damage 3798
2 5 4 Cuts 3800
2 5 5 Damage caused by foreign bodies 3800
2 5 6 Loss of air from tyre 3801
2 5 7 Tyre pressure 3801
2 5 8 Tyre damage due to insufficient tyre pressure 3801
2 5 9 Rising tyre temperature caused by insufficient inflation pressure 3803
2 5 10 Tyre damage due to fitting error (fitting damage) 3804
2 6 Facts about wheels and tyres 3806
2 6 1 Identification markings on the tyre sidewall 3806
2 6 2 Explanation of tyre markings 3808
2 6 3 Undulations 3809
2 6 4 The valve 3810
2 6 5 Tyre storage 3811
2 6 6 Tyre ageing 3811
2 6 7 Care and maintenance of alloy wheel rims 3812
2 6 8 Rotating wheels 3813
2 6 9 Instructions for changing or fitting wheels 3813
2 6 10 Tyres with flange protection 3814
2 6 11 Notes on use of temporary spare wheels 3815
2 6 12 M+S tyres 3816
2 6 13 Winter tyres with speed symbol “V” 3817
2 6 14 Extra Load (XL) V winter tyres 3817
2 6 15 Reinforced and Extra Load (XL) tyres 3820
2 6 16 Snow chains 3820
44 – Wheels, tyres, vehicle geometry 3821
1 Lupo 3L, Lupo FSI, Lupo GTI from model year 1999 3821
1 1 Lupo 3L, type 6E model year 1999 to model year 2006 3821
1 2 Wheel allocation for Lupo 3L, type 6E model year 1999 to model year 2006 3822
1 2 1 4 J x 14 3822
1 2 2 41/2 J x 14 3823
1 2 3 5 J x 14 3823
1 3 Lupo FSI, type 6E model year 2001 to model year 2006 3823
1 4 Wheel allocation for Lupo FSI, type 6E model year 2001 to model year 2006 3824
1 4 1 5 J x 14 3824
1 4 2 6 J x 14 3825
1 5 Lupo GTI, type 6ES model year 2001 to model year 2006 3827
1 6 Wheel allocation for Lupo GTI, type 6ES model year 2001 to model year 2006 3828
1 6 1 6 J x 14 3828
1 6 2 61/2 J x 15 3829
2 Lupo model year 1999 to model year 2005 3831
2 1 Lupo, type 6X model year 1999 to model year 2005 3831
2 2 Wheel allocation for Lupo, type 6X model year 1999 to model year 2005 3833
2 2 1 41/2 J x 13 3833
2 2 2 51/2 J x 13 3834
2 2 3 6 J x 14 3836
2 2 4 6 J x 15 3839
3 Fox model year 2006 3841
3 1 Fox, type 5Z model year 2006 3841
3 2 Wheel allocation for Fox, type 5Z model year 2006 3842
3 2 1 5 J x 14 3842
3 2 2 6 J x 14 3843
3 2 3 6 J x 15 3845
4 Polo model year 1995 to model year 2002 3848
4 1 Polo, type 6N up to and including 07 95 3848
4 2 Wheel allocation for Polo, type 6N up to and including 07 95 3849
4 2 1 41/2 J x 13 3849
4 2 2 51/2 J x 13 3850
4 3 Polo, type 6N from 08 95 up to and including model year 1996 3851
4 4 Polo, type 6N from model year 1997 to model year 1999 3852
4 5 Wheel allocation for Polo, type 6N from 08 95 to model year 1999 3854
4 5 1 41/2 J x 13 3854
4 5 2 51/2 J x 13 3855
4 5 3 6 J x 14 3856
4 5 4 6 J x 15 3858
4 6 Polo, type 6N from model year 2000 to model year 2002 3860
4 7 Wheel allocation for Polo, type 6N from model year 2000 to model year 2002 3861
4 7 1 41/2 J x 13 3861
4 7 2 51/2 J x 13 3862
4 7 3 6 J x 14 3863
4 7 4 6 J x 15 3865
5 Polo from model year 2002 3868
5 1 Polo, type 9N model year 2002 to model year 2006 3868
5 2 Wheel allocation for Polo, type 9N model year 2002 to model year 2006 3870
5 2 1 5 J x 13 3871
5 2 2 5 J x 14 3871
5 2 3 6 J x 14 3872
5 2 4 6 J x 15 3873
5 2 5 61/2 J x 16 3875
6 Polo Fun from model year 2004 3879
6 1 Polo Fun, type 9N model year 2002 to model year 2006 3879
6 2 Wheel allocation for Polo Fun, type 9N model year 2004 to model year 2006 3880
6 2 1 6 J x 15 3880
6 2 2 71/2 J x 17 3881
7 Polo Classic model year 1996 to model year 2002 3882
7 1 Polo Classic, type 6KV model year 1996 to model year 2002 3882
7 2 Wheel allocation for Polo Classic, type 6KV model year 1996 to model year 2002 3884
7 2 1 51/2 J x 13 3884
7 2 2 6 J x 14 3885
7 2 3 6 J x 15 3887
8 Polo estate model year 1998 to model year 2002 3889
8 1 Polo estate type 6KV model year 1998 to model year 2002 3889
8 2 Wheel allocation for Polo estate type 6KV model year 1998 to model year 2002 3891
8 2 1 51/2 J x 13 3891
8 2 2 6 J x 14 3892
8 2 3 6 J x 15 3894
9 Polo saloon/sedan model year 2004 to model year 2005 3896
9 1 Polo saloon/sedan, type 9N model year 2004 to model year 2005 3896
9 2 Wheel allocation for Polo saloon/sedan, type 9N model year 2004 to model year 2005 3898
9 2 1 5 J x 14 3898
9 2 2 6 J x 14 3898
9 2 3 6 J x 15 3900
9 2 4 61/2 J x 16 3902
10 Golf model year 1992 to model year 1998 3904
10 1 Golf type 1HX0, Golf Syncro 1HX1, Golf type 1H 3904
10 2 Wheel allocation for Golf type 1HX0, Golf Syncro 1HX1, Golf type 1H 3907
10 2 1 51/2 J x 13 3908
10 2 2 6 J x 14 3909
10 2 3 6 J x 15 3913
10 2 4 61/2 J x 15 3917
10 2 5 7 J x 16 3921
11 Golf model year 1998 to model year 2004, Golf R32, Golf Anniversary GTI 3922
11 1 Golf, Golf 4Motion, type 1J model year 1998 to model year 2004 3922
11 2 Wheel allocation for Golf, Golf 4Motion, type 1J model year 1998 to model year 2004 3925
11 2 1 6 J x 14 3925
11 2 2 6 J x 15 3926
11 2 3 51/2 J x 16 3931
11 2 4 61/2 J x 16 3932
11 2 5 7 J x 17 3938
11 2 6 71/2 J x 17 3941
11 3 Conditions for fitting 17″ wheels and tyres to Golf model year 1998 to model year 2004 3941
11 4 Golf R32, type 1J model year 2003 to model year 2005 3942
11 5 Wheel allocation for Golf R32, type 1J model year 2003 to model year 2005 3943
11 5 1 51/2 J x 17 3943
11 5 2 71/2 J x 17 3944
11 5 3 71/2 J x 18 3945
11 6 Golf Anniversary GTI, type 1J model year 2002 3945
11 7 Wheel allocation for Golf Anniversary GTI, type 1J model year 2002 3946
11 7 1 51/2 J x 16 3946
11 7 2 61/2 J x 16 3947
11 7 3 7 J x 17 3949
11 7 4 71/2 J x 18 3951
11 8 Conditions for fitting 17″ and 18″ wheels and tyres of Golf Anniversary GTI 3952
12 Golf from model year 2004 3954
12 1 Golf, Golf 4Motion, type 1K model year 2004 to model year 2006 3954
12 2 Wheel allocation for Golf, Golf 4Motion, type 1K model year 2004 to model year 2006 3956
12 2 1 6 J x 15 3956
12 2 2 61/2 J x 15 3957
12 2 3 6 J x 16 3958
12 2 4 61/2 J x 16 3959
12 2 5 7 J x 17 3961
12 2 6 71/2 J x 17 3964
12 2 7 71/2 J x 18 3964
12 3 Golf GTI, type 1K model year 2005 to model year 2006 3965
12 4 Wheel allocation for Golf GTI, type 1K model year 2005 to model year 2006 3966
12 4 1 6 J x 16 3966
12 4 2 61/2 J x 16 3967
12 4 3 6 J x 17 3968
12 4 4 7 J x 17 3969
12 4 5 71/2 J x 17 3972
12 4 6 71/2 J x 18 3972
13 Golf Plus from model year 2005 3974
13 1 Golf Plus, type 1KP model year 2005 to model year 2006 3974
13 2 Wheel allocation for Golf Plus, type 1KP model year 2005 to model year 2006 3976
13 2 1 6 J x 15 3976
13 2 2 61/2 J x 15 3977
13 2 3 6 J x 16 3978
13 2 4 61/2 J x 16 3979
13 2 5 7 J x 17 3981
13 2 6 71/2 J x 18 3984
14 Golf estate model year 1994 to model year 1998 3986
14 1 Golf estate type 1HX0, Golf estate Syncro type 1HX1, Golf estate type 1H 3986
14 2 Wheel allocation for Golf estate type 1HX0, Golf estate Syncro type 1HX1, Golf estate type 1H 3989
14 2 1 51/2 J x 13 3989
14 2 2 6 J x 14 3990
14 2 3 6 J x 15 3995
14 2 4 61/2 J x 15 3999
15 Golf estate model year 1999 to model year 2006, Bora estate model year 1999 to model year 2005 4000
15 1 Golf estate, Golf estate 4Motion, Bora estate, Bora estate 4Motion, type 1J 4000
15 2 Wheel allocation for Golf estate, Golf estate 4Motion, Bora estate, Bora estate 4Motion, type 1J 4003
15 2 1 6 J x 15 4003
15 2 2 51/2 J x 16 4007
15 2 3 61/2 J x 16 4008
15 2 4 7 J x 17 4014
15 2 5 71/2 J x 17 4017
15 3 Conditions for fitting 17″ wheels and tyres 4018
16 Golf cabriolet model year 1994 to model year 1997 4020
16 1 Golf cabriolet type 1EX0 model year 1994 to model year 1997 4020
16 2 Wheel allocation for Golf cabriolet, type 1EX0 from model year 1994 to model year 1997 4021
16 2 1 6 J x 14 4022
16 2 2 6 J x 15 4023
16 2 3 61/2 J x 16 4024
17 Golf cabriolet model year 1998 to model year 2002 4026
17 1 Golf cabriolet; type 1E from model year 1998 to model year 2002 4026
17 2 Wheel allocation for Golf cabriolet; type 1E from model year 1998 to model year 2002 4027
17 2 1 6 J x 14 4027
17 2 2 6 J x 15 4030
17 2 3 61/2 J x 16 4032
18 Vento from model year 1992 to model year 1998 4033
18 1 Vento; type 1HX0, 1H 4033
18 2 Wheel allocation for Vento; type 1HX0, 1H 4035
18 2 1 51/2 J x 13 4035
18 2 2 6 J x 14 4037
18 2 3 6 J x 15 4040
18 2 4 61/2 J x 15 4043
19 Bora model year 1999 to model year 2005 4049
19 1 Bora, Bora 4Motion, type 1J model year 1999 to model year 2005 4049
19 2 Wheel allocation for Bora, Bora 4Motion, type 1J model year 1999 to model year 2005 4052
19 2 1 6 J x 15 4052
19 2 2 51/2 J x 16 4056
19 2 3 61/2 J x 16 4057
19 2 4 7 J x 17 4063
19 2 5 71/2 J x 17 4066
19 3 Conditions for fitting 17″ wheels and tyres 4067
20 Jetta from model year 2006 4069
20 1 Jetta, type 1KM from model year 2006 4069
20 2 Wheel allocation for Jetta, type 1KM from model year 2006 4071
20 2 1 6 J x 15 4071
20 2 2 61/2 J x 15 4072
20 2 3 6 J x 16 4072
20 2 4 61/2 J x 16 4073
20 2 5 7 J x 17 4075
21 New Beetle from model year 1999 4079
21 1 New Beetle, type 9C model year 1999 to model year 2006 4079
21 2 Wheel allocation for New Beetle, type 9C model year 1999 to model year 2006 4082
21 2 1 6 J x 15 4082
21 2 2 51/2 J x 16 4085
21 2 3 61/2 J x 16 4086
21 2 4 7 J x 17 4091
21 2 5 71/2 J x 17 4094
21 3 Conditions for fitting 17″ wheels and tyres 4095
22 New Beetle Cabriolet from model year 2003 4097
22 1 New Beetle Cabriolet, type 1Y, model year 2003 to model year 2006 4097
22 2 Wheel allocation for New Beetle Cabriolet, type 1Y model year 2003 to model year 2006 4099
22 2 1 6 J x 15 4099
22 2 2 51/2 J x 16 4102
22 2 3 61/2 J x 16 4103
22 2 4 7 J x 17 4107
22 2 5 71/2 J x 17 4111
22 3 Conditions for fitting 17″ wheels and tyres 4111
23 New Beetle RSi 4113
23 1 New Beetle RSi, type 9CR from model year 2001 4113
23 2 Wheel allocation for New Beetle RSi, type 9CR from model year 2001 4114
23 2 1 7 J x 16 4114
23 2 2 9 x 18 4115
24 Touran from model year 2003 4116
24 1 Touran, type 1T, model year 2003 to model year 2006 4116
24 2 Wheel allocation for Touran, type 1T model year 2003 to model year 2006 4119
24 2 1 6 J x 15 4119
24 2 2 61/2 J x 15 4120
24 2 3 6 J x 16 4121
24 2 4 61/2 J x 16 4122
24 2 5 7 J x 17 4124
25 Passat model year 1994 to model year 1997 4125
25 1 Passat, type 35l model year 1994 to model year 1997 4125
25 2 Wheel allocation for Passat, type 35l model year 1994 to model year 1997 4127
25 2 1 6 J x 14 4127
25 2 2 6 J x 15 4130
26 Passat model year 1997 to model year 2006 4135
26 1 Passat, Passat estate, type 3B model year 1997 to model year 2000 4135
26 2 Passat, Passat estate, type 3B model year 1997 to model year 2000 4137
26 2 1 6 J x 15 4137
26 2 2 7 J x 15 4139
26 2 3 7 J x 16 4140
26 3 Passat, Passat estate, type 3BG model year 2001 to model year 2006 4141
26 4 Wheel allocation for Passat, Passat estate, type 3BG model year 2001 to model year 2006 4143
26 4 1 6 J x 15 4143
26 4 2 7 J x 15 4144
26 4 3 6 J x 16 4146
26 4 4 7 J x 16 4147
26 4 5 7 J x 17 4149
26 5 Passat W8 4Motion, type 3BS model year 2002 to model year 2005 4150
26 6 Wheel allocation for Passat W8 4Motion, type 3BS model year 2002 to model year 2005 4151
26 6 1 7 J x 16 4152
26 6 2 6 J x 17 4152
26 6 3 71/2 J x 17 4153
26 7 Passat Protect, type 3BL model year 2002 to model year 2005 4153
26 8 Wheel allocation for Passat Protect, type 3BL model year 2002 to model year 2005 4154
26 8 1 6 J x 16 4155
26 8 2 7 J x 16 4155
27 Passat from model year 2006 4157
27 1 Passat, type 3C from model year 2006 4157
27 2 Wheel allocation for Passat, type 3C from model year 2006 4159
27 2 1 61/2 J x 16 4160
27 2 2 7 J x 16 4160
27 2 3 6 J x 17 4162
27 2 4 71/2 J x 17 4162
27 2 5 8 J x 18 4165
28 Phaeton from model year 2003 4167
28 1 Phaeton, type 3D, model year 2003 to model year 2006 – short and long wheelbase 4167
28 2 Wheel allocation for Phaeton, type 3D model year 2003 to model year 2006 – short and long wheelbase 4169
28 2 1 71/2 J x 16 4170
28 2 2 71/2 J x 17 4170
28 2 3 71/2 J x 18 4172
28 2 4 81/2 J x 18 4172
28 2 5 81/2 J x 19 4174
28 2 6 9 J x 19 4174
29 Sharan from model year 1996 4175
29 1 Sharan, Sharan Syncro, type 7M model year 1996 to model year 2000 4175
29 2 Wheel allocation for Sharan, Sharan Syncro Type 7M model year 1996 to model year 2000 4178
29 2 1 6 J x 15 4178
29 2 2 7 J x 15 4178
29 2 3 7 J x 16 4179
29 3 Sharan, Sharan 4Motion, type 7M model year 2001 4180
29 4 Wheel allocation for Sharan, Sharan 4Motion, type 7M model year 2001 4182
29 4 1 6 J x 15 4182
29 4 2 7 J x 15 4183
29 4 3 6 J x 16 4184
29 4 4 7 J x 16 4185
29 5 Sharan, Sharan 4Motion, type 7M model year 2002 to model year 2006 4188
29 6 Wheel allocation for Sharan, Sharan 4Motion, type 7M model year 2002 to model year 2006 4190
29 6 1 6 J x 16 4190
29 6 2 7 J x 16 4191
29 6 3 7 J x 17 4194
30 Touareg from model year 2003 4195
30 1 Touareg, type 7L, model year 2003 to model year 2006 4195
30 2 Wheel allocation for Touareg, type 7L model year 2003 to model year 2006 4198
30 2 1 7 J x 16 4198
30 2 2 71/2 J x 17 4199
30 2 3 8 J x 18 4200
30 2 4 9 J x 19 4203
30 2 5 9 J x 20 4207
30 2 6 91/2 J x 20 4208
31 Breakdown set for VW Vehicles 4209
32 Temporary spare tyres and wheels for VW vehicles 4210
33 Approved makes of summer tyres for initial fitting 4213
33 1 Summer tyres for Lupo 3L from model year 1999 4213
33 2 Summer tyres for Lupo FSI from model year 1999 4213
33 3 Summer tyres for Lupo GTI from model year 1999 4213
33 4 Summer tyres for Lupo model year 1999 to model year 2005 4213
33 5 Summer tyres for Fox from model year 2006 4213
33 6 Summer tyres for Polo, model year 1995 to model year 2002 4214
33 7 Summer tyres for Polo from model year 2002 4215
33 8 Summer tyres for Polo saloon/sedan from model year 2004 4215
33 9 Summer tyres for Polo Fun from model year 2004 4216
33 10 Summer tyres for Polo Classic model year 1996 to model year 2002 4216
33 11 Summer tyres for Polo estate model year 1998 to model year 2002 4217
33 12 Summer tyres for Golf, Vento model year 1992 to model year 1998 4217
33 13 Summer tyres for Golf estate model year 1994 to model year 1998 4218
33 14 Summer tyres for Golf cabriolet model year 1994 to model year 1997 4218
33 15 Summer tyres for Golf, Golf 4Motion model year 1998 to model year 2004 4219
33 16 Summer tyres for Bora, Bora 4Motion model year 1999 to model year 2005 4220
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 4221
33 18 Summer tyres for Golf R32 4221
33 19 Summer tyres for Golf Anniversary GTI 4222
33 20 Summer tyres for Golf Cabriolet, model year 1998 to model year 2002 4222
33 21 Summer tyres for New Beetle from model year 1999 4223
33 22 Summer tyres for New Beetle Cabriolet from model year 2003 4224
33 23 Summer tyres for New Beetle RSi 4225
33 24 Summer tyres for Golf from model year 2004 4225
33 25 Summer tyres for Golf GTI from model year 2005 4226
33 26 Summer tyres for Golf Plus from model year 2005 4226
33 27 Summer tyres for Jetta from model year 2006 4227
33 28 Summer tyres for Touran from model year 2003 4227
33 29 Summer tyres for Passat model year 1994 to model year 1997 4228
33 30 Summer tyres for Passat model year 1997 to model year 2006 4228
33 31 Summer tyres for Passat W8 4229
33 32 Summer tyres for Passat Protect 4229
33 33 Summer tyres for Passat from model year 2006 4229
33 34 Summer tyres for Phaeton from model year 2003 4230
33 35 Summer tyres for Sharan from model year 1996 4230
33 36 Summer tyres for Touareg from model year 2003 4231
34 Approved makes of all-season tyres for initial fitting 4232
34 1 All-season tyres for Lupo, model year 1999 to model year 2005 4232
34 2 All-season tyres Polo model year 1995 to model year 2002 4232
34 3 All-season tyres from model year 2002 4232
34 4 Summer tyres for Polo saloon/sedan from model year 2004 4232
34 5 All-season tyres Golf, Vento model year 1992 to model year 1998 4232
34 6 All-season tyres Golf estate model year 1994 to model year 1998 4232
34 7 All-season tyres Golf cabriolet model year 1994 to model year 1997 4233
34 8 All-season tyres Golf, Golf 4Motion model year 1998 to model year 2004 4233
34 9 All-season tyres Bora, Bora 4Motion model year 1999 to model year 2005 4233
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 4234
34 11 All-season tyres Golf cabriolet model year 1998 to model year 2002 4234
34 12 All-weather tyres New Beetle from model year 1999 4234
34 13 All-weather tyres New Beetle Cabriolet from model year 2003 4234
34 14 All-weather tyres Golf from model year 2004 4235
34 15 All-season tyres for Golf Plus from model year 2005 4235
34 16 All-season tyres for Jetta from model year 2006 4235
34 17 All-weather tyres Touran from model year 2003 4236
34 18 All-season tyres for Passat, model year 1997 to model year 2006 4236
34 19 All-season tyres for Passat W8 4236
34 20 All-weather tyres Passat from model year 2006 4236
34 21 All-weather tyres Phaeton from model year 2003 4237
34 22 All-weather tyres Touareg from model year 2003 4237
35 Approved makes of winter tyres for initial fitting 4238
35 1 Winter tyres for Lupo 3L from model year 1999 4238
35 2 Winter tyres for Lupo FSI from model year 1999 4238
35 3 Winter tyres for Lupo GTI from model year 1999 4238
35 4 Winter tyres Lupo model year 1999 to model year 2005 4238
35 5 Winter tyres for Fox from model year 2006 4238
35 6 Winter tyres for Polo model year 1995 to model year 2002 4239
35 7 Winter tyres Polo from model year 2002 4239
35 8 Summer tyres for Polo saloon/sedan from model year 2004 4239
35 9 Summer tyres for Polo Fun from model year 2004 4240
35 10 Winter tyres Polo Classic model year 1996 to model year 2002 4240
35 11 Winter tyres Polo estate model year 1998 to model year 2002 4240
35 12 Winter tyres Golf, Vento model year 1992 to model year 1998 4241
35 13 Winter tyres Golf estate model year 1994 to model year 1998 4241
35 14 Winter tyres Golf cabriolet model year 1994 to model year 1997 4241
35 15 Winter tyres Golf, Golf 4Motion model year 1998 to model year 2004 4242
35 16 Winter tyres Bora, Bora 4Motion model year 1999 to model year 2005 4242
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 4243
35 18 Winter tyres for Golf R32 4243
35 19 Winter tyres for Golf Anniversary GTI 4243
35 20 Winter tyres Golf cabriolet model year 1998 to model year 2002 4243
35 21 Winter tyres New Beetle from model year 1999 4244
35 22 Winter tyres New Beetle Cabriolet from model year 2003 4244
35 23 Winter tyres for New Beetle RSi 4245
35 24 Winter tyres Golf from model year 2004 4245
35 25 Winter tyres for Golf GTI from model year 2005 4245
35 26 Winter tyres for Golf Plus from model year 2005 4245
35 27 Winter tyres for Jetta from model year 2006 4245
35 28 Winter tyres Touran from model year 2003 4246
35 29 Winter tyres for Passat model year 1994 to model year 1997 4246
35 30 Winter tyres for Passat model year 1997 to model year 2006 4246
35 31 Winter tyres for Passat W8 4247
35 32 Winter tyres for Passat Protect 4247
35 33 Winter tyres Passat from model year 2006 4247
35 34 Winter tyres Phaeton from model year 2003 4247
35 35 Winter tyres Sharan from model year 1996 4248
35 36 Winter tyres Touareg from model year 2003 4248
36 Approved makes of offroad tyres for initial fitting 4249
36 1 Offroad tyres for Touareg from model year 2003 4249
D4B807E3B5B Body Repairs General Body Repairs 4250
1 Safety instructions 4254
1 1 Part removal 4254
1 2 Battery and welding operation 4254
1 3 Electronic control unit 4254
1 3 1 Processing of the electronic control unit after repair dueto a traffic accident 4254
1 4 Paint, glass, soft pad and trim 4255
1 5 Fuel tank or fuel delivery pipeline 4255
1 6 Air conditioner 4255
1 6 1 Remedial measures: 4255
1 7 Airbag System 4256
1 8 Check the seat belts 4256
1 8 1 Belt body 4257
1 8 2 Automatic retractor (locking function) 4257
1 8 3 Visual inspection of the seat belt buckle 4258
1 8 4 Seat belt buckle function 4258
1 8 5 Seat belt guide member and tongue 4259
1 8 6 Fixing piece and fixing point 4259
1 9 Safety specifications for the seat belt tensioner 4259
1 10 Body repair on a vehicle equipped with the seat belt tensioners 4260
1 10 1 The following vehicles have been equipped with: 4260
1 11 Perform cutting off, correcting and/or leveling on a vehicleequipped with airbags 4261
1 12 Remove the front seats with a side airbag 4261
2 Basic instruction 4262
2 1 Diagnosis of the accident vehicle 4262
2 2 Condition of the body and/or the parts for delivery to thepainting workshop 4262
2 3 Correction 4262
2 4 Cutting 4262
2 5 Body-cut part and part section 4262
2 6 Original connection 4263
2 7 Galvanized body parts 4263
2 8 Remove the rest part 4263
2 9 New parts 4263
2 10 Parts 4263
2 11 Molded foam plastic pads 4264
3 Symbolic interpretation 4265
3 1 Symbolic interpretation for welding 4265
3 2 Symbolic interpretation for the operation method 4265
3 2 1 Grinding 4266
3 2 2 Thinning 4266
3 2 3 Punching 4266
3 2 4 Drilling 4267
3 2 5 Polishing 4267
3 2 6 Cavity corrosion protection 4267
3 2 7 Bonding 4268
3 2 8 Precise sealing 4268
4 Body repair tools 4269
4 1 Flaring tool -V A G 1317- 4269
4 2 Punching pliers -V A G 1329- 4269
4 3 Basic equipment -V A G 1366/3- 4269
4 4 Bottom protection layer spray gun -V A G 1379- 4270
4 5 Electric blower -V A G 1416- 4270
4 6 Door tensioner -V A G 1438- 4270
4 7 Body equipment component -V A G 1439- 4271
4 8 Pneumatic cutting knife -V A G 1523 A- 4271
4 9 Air chisel -V A G 1577- 4271
4 10 Edge closing iron block -V A G 1585- 4272
4 11 Welding fume ventilator -V A G 1586- 4272
4 12 Welding spot releasing device -V A G 1731- 4272
4 13 Pneumatic spray gun -V A G 1761/1- 4273
4 14 Pneumatic punching and thinning pliers -VAS 1996- 4273
4 15 Pneumatic adhesive spray gun -V A G 2005- 4273
4 16 Door hinge correction tool 4274
4 17 Hose kit 5023 for the inert gas protection welding 4274
4 18 Angle grinder -VAS 5174- 4274
4 19 Angle grinder -VAS 5175- 4275
4 20 Wire brush -VAS 5182- 4275
5 Body bonding 4276
5 1 Transporter 1991 → 4276
5 1 1 Separation process: 4276
5 1 2 Bonding process: 4276
5 2 Bonding types 4276
5 2 1 Bonding-strong 4276
5 2 2 Bonding-spot welding 4277
5 3 Repair method for replacing the parts 4277
5 3 1 Spot welding and bonding 4277
5 3 2 Plug welding and bonding (if spot welding is impossible) 4277
5 3 3 Welding fume ventilator 4278
5 3 4 Preparations 4278
5 3 5 Trimming 4278
6 Corrosion protection measures 4279
6 1 Corrosion protection 4279
7 Waste disposal instructions 4280
7 1 Waste disposal 4280
7 2 Air pressure tappet exhaust 4280
7 3 Airbag 4281
7 3 1 Waste disposal 4281
8 Contact corrosion protection 4282
8 1 Connection of aluminum alloy/magnesium alloy with steel 4282
9 Steel plate repair 4283
9 1 High-strength body plate 4283
9 2 Galvanized body parts 4283
9 2 1 Preparations 4283
9 2 2 Part cutting 4284
9 2 3 Connection process 4284
9 3 Welding on the galvanized body steel plate 4284
9 3 1 Inert gas protection plug welding SG of the galvanized steelplate 4284
9 3 2 Resistance pressure spot welding RP of the galvanized steelplate 4285
9 3 3 Welding transformer 4285
9 3 4 Welding clamp 4285
9 4 Tearing test 4285
10 Aluminum repair 4286
10 1 Painting 4286
10 2 Surface treatment 4286
10 3 Leveling 4287
10 4 Temperature control for heating 4287
11 Plastic repair method 4288
11 1 Material 4288
11 2 Repairing the pit 4289
11 3 Repairing the scratch 4290
11 4 Repair the crack 4292
11 5 Repairing the small hole (the diameter is more than 30 mm) 4293
11 6 Plastic repair (glass fibre material) 4294
11 7 Repair process 4295
11 7 1 Repairing the breakage position 4295
11 7 2 Repairing the surface damage 4297
12 Glass repair 4298
12 1 Repairing the windshield 4298
12 1 1 Premises 4298
12 1 2 Required special tools, operating equipment, testing instrumentsand auxiliary tools 4299
12 1 3 Repair description 4300
D4B8027068B Air conditioning systems with refrigerant R134a General information 4304
00 – Technical data 4310
1 Safety information 4310
1 1 Safety precautions when working on air conditioning systems 4310
1 2 Safety precautions when working on high-voltage system 4311
1 3 Safety precautions when working in the vicinity of high-voltage components 4311
1 4 Safety precautions when tow-starting or towing 4312
2 Repair instructions 4313
2 1 Rules for cleanliness when working on high-voltage system 4313
3 General information on air conditioning 4314
3 1 Other reference material 4314
3 2 Basics of air conditioning technology 4314
3 2 1 Physical principles: 4314
3 2 2 Heat always flows from a warmer to a colder substance 4315
3 2 3 Pressure and boiling point 4315
3 3 Vapour pressure table for refrigerant R134a 4316
3 4 Refrigerant R134a 4317
3 4 1 Physical data of refrigerant R134a 4317
3 4 2 Critical point 4317
3 4 3 Environmental aspects of refrigerant R134a 4318
3 5 Properties of refrigerant R134a 4318
3 5 1 Trade names and designations 4318
3 5 2 Colour 4318
3 5 3 Vapour pressure 4318
3 5 4 Physical properties of R134a 4319
3 5 5 Effects on metal 4319
3 5 6 Critical temperature and critical pressure 4319
3 5 7 Union 4319
3 5 8 Charge factor 4319
3 5 9 Detecting leaks 4319
3 6 Refrigerant oil 4320
3 6 1 Properties of refrigerant oil 4320
3 7 Comfort 4321
3 7 1 Environmental aspects 4321
3 8 How air conditioning works 4322
3 9 General work safety 4322
3 9 1 Product characteristics 4322
3 9 2 Handling refrigerants 4323
3 9 3 Wear safety goggles 4323
3 9 4 Wear protective gloves and apron 4323
3 9 5 Do not allow liquid refrigerant to come in contact with the skin 4323
3 9 6 Do not breath in refrigerant vapour 4323
3 9 7 Absolutely NO SMOKING 4323
3 9 8 Welding and soldering on refrigeration systems 4323
3 9 9 Pungent smell 4324
3 9 10 First aid 4324
3 9 11 Handling pressure vessels 4324
3 9 12 Do not heat up above 50°C 4324
3 9 13 Do not expose to uncontrolled heat 4324
3 9 14 Seal empty tanks/containers 4324
3 9 15 Safety instructions for using extraction and charging equipment 4325
3 10 Safety measures when working on vehicles with air conditioning and when working with refrigerant R134a 4325
3 11 Basics for working on refrigerant circuit 4326
3 11 1 O-ring 4327
3 11 2 Before operating the air conditioning system after recharging with refrigerant 4328
4 General information on refrigerant circuit 4329
4 1 Components of refrigerant circuit 4329
4 1 1 Distribution of the refrigerant circuit components and their influence on the high-pressure and low-pressure sides 4329
4 1 2 Air conditioning system compressor with magnetic clutch: 4329
4 1 3 Air conditioner compressor without magnetic clutch 4330
4 1 4 Air conditioner compressor without magnetic clutch, with elastic drive coupling 4331
4 1 5 Electrical air conditioner compressor for high-voltage system 4332
4 1 6 Condenser 4333
4 1 7 evaporator 4333
4 1 8 Reservoir 4334
4 1 9 Restrictor 4334
4 1 10 Receiver 4335
4 1 11 Expansion valve 4336
4 1 12 O-ring 4337
4 1 13 Pipes and hoses of refrigerant circuit 4337
4 1 14 High-pressure safety valve 4337
4 2 Design of refrigerant circuit 4340
4 2 1 Refrigerant circuit with expansion valve and evaporator 4340
4 2 2 Refrigerant circuit with restrictor and reservoir 4340
4 3 Evacuation and charging valves for quick-release couplings of air conditioner service station on refrigerant circuit 4341
4 3 1 Evacuation and charging valve with Schrader valve 4341
4 3 2 Extraction and charging valve, high-pressure side 4342
4 3 3 Extraction and charging valve, low-pressure side 4343
4 4 Switches and senders in refrigerant circuit and related connections 4343
4 4 1 High-pressure switch for air conditioning system -F23- 4343
4 4 2 High-pressure switch for magnetic clutch -F118- 4344
4 4 3 Low-pressure switch for air conditioning system -F73- 4344
4 4 4 Connections with valve for switches in refrigerant circuit 4345
4 4 5 Air conditioning system pressure switch -F129- 4345
4 4 6 High-pressure sender -G65- 4346
4 4 7 Refrigerant pressure and temperature sender -G395- 4347
4 4 8 Air conditioner compressor regulating valve -N280- 4347
4 5 Electrical components not installed in refrigerant circuit 4348
4 5 1 Control and regulating unit for air conditioning system -J127- 4348
4 5 2 Radiator fan control unit -J293- 4348
4 5 3 Radiator fan control unit -J293- 4349
4 5 4 Temperature switch for evaporator -E33- 4350
4 5 5 Evaporator output temperature sender -G263- or evaporator temperature sensor -G308- 4350
4 6 Pressures and temperatures in refrigerant circuit 4351
4 7 Refrigerant circuit with expansion valve 4351
4 8 Refrigerant circuit with restrictor and reservoir 4353
4 9 Test and measurement work that can be performed using a pressure gauge 4355
4 9 1 Pressure gauges enable the following test and measurement work 4355
4 10 Air conditioner service and recycling equipment 4356
4 10 1 Classification of extraction and charging devices in groups 4356
4 10 2 Charging devices that do not require a permit 4356
4 11 Notes to repairs on refrigerant circuit 4357
5 Laws and regulations 4358
5 1 Laws and regulations 4358
5 2 Recycling and refuse law 4363
5 2 1 Disposal of refrigerant and refrigerant machine oil 4363
5 3 Converting R12 refrigerant circuits to R134a refrigerant circuits and servicing them (retrofitting) 4364
5 4 Maintaining records on refrigerant 4364
6 Refrigerant circuit 4365
6 1 Important repair notes on air conditioning 4365
6 2 Converting refrigerant circuits from R12 refrigerant to R134a 4365
7 Working with the air conditioner service station 4366
7 1 Important instructions for working with the air conditioner service station 4366
7 2 Connecting a air conditioner service station for measuring and testing 4367
7 3 Drain the refrigerant circuit using the air conditioner service station 4368
7 4 Evacuating refrigerant circuit using air conditioner service station 4368
7 5 Filling refrigerant circuit with air conditioner service station 4370
7 6 Bringing air conditioning system into service after charging 4371
7 7 Charging the container in the air conditioning service station with refrigerant 4371
7 8 Emptying air conditioner service station 4372
8 Detecting leaks in refrigerant circuit 4373
8 1 Leak detection in refrigerant circuit using compressed air or nitrogen 4374
8 2 Searching for leaks in refrigerant circuits using leak detector -V A G 1796- 4375
8 3 Detecting leaks in refrigerant circuit using leak detecting system -VAS 6196- or leak detecting system -VAS 6201- or a later model 4376
9 Clearing refrigerant circuit of contaminants 4384
9 1 Vehicles with high-voltage system (hybrid vehicles) 4384
9 2 Blowing through refrigerant circuit with compressed air and nitrogen 4385
9 2 1 Flushing refrigerant circuit 4387
9 3 Flushing refrigerant circuit with refrigerant R134a 4387
9 3 1 Principle circuit diagrams for various purging circuits 4395
9 3 2 Purging electrical air conditioner compressor 4401
9 3 3 Adapters for setting up flushing circuits 4405
10 Clearing refrigerant circuit of contaminants, commercial vehicles 4419
10 1 Vehicles with high-voltage system 4419
10 2 Flushing refrigerant circuit with refrigerant R134a 4420
10 3 Adapters for setting up flushing circuits 4420
10 4 Procedure for setting up and flushing refrigerant circuit, Amarok 2023 ► 4424
10 5 Procedure for setting up and flushing refrigerant circuit, Amarok 2010 ► 4424
10 5 1 Connection diagram for flushing circuit 4424
10 5 2 Procedure for setting up and flushing refrigerant circuit 4425
10 6 Procedure for setting up and flushing refrigerant circuit, Caddy 2004 ► 4430
10 6 1 Connection diagram for flushing circuit 4430
10 6 2 Procedure for setting up and flushing refrigerant circuit 4431
10 7 Procedure for setting up and flushing refrigerant circuit, Crafter ►2017 4437
10 7 1 Connection diagram for flushing circuit, vehicles with one evaporator 4437
10 7 2 Connection diagram for flushing circuit, vehicles with second evaporator 4438
10 7 3 Procedure for setting up and flushing refrigerant circuit, vehicles with one evaporator 4439
10 7 4 Procedure for setting up and flushing refrigerant circuit, vehicles with second evaporator 4446
10 8 Procedure for setting up and flushing refrigerant circuit, Crafter 2017 ► or MAN TGE ►, Crafter Grand California ► 4454
10 8 1 Connection diagram for flushing circuit, vehicles with one evaporator 4455
10 8 2 Connection diagram for flushing circuit, vehicles with second evaporator 4456
10 8 3 Procedure for setting up and flushing refrigerant circuit, vehicles with one evaporator 4457
10 8 4 Procedure for setting up and flushing refrigerant circuit, vehicles with second evaporator 4462
10 9 Procedure for setting up and flushing refrigerant circuit, Transporter 2016 ►, Transporter 2020 ► 4471
10 9 1 Connection diagram for flushing circuit, vehicles with one evaporator 4471
10 9 2 Connection diagram for flushing circuit, vehicles with second evaporator 4472
10 9 3 Procedure for setting up and flushing refrigerant circuit, vehicles with one evaporator 4473
10 9 4 Procedure for setting up and flushing refrigerant circuit, vehicles with second evaporator 4478
11 Complaints 4487
11 1 Possible complaints about refrigerant circuit 4487
11 1 1 Conditions for testing: 4487
11 1 2 Possible complaints 4487
11 2 Odours from heater and air conditioning unit 4488
11 2 1 Does the odour emanate from the evaporator or heat exchanger? 4488
11 2 2 Ultrasonic air conditioner cleaning unit -VAS 6189A- 4489
11 2 3 Spraying the evaporator with the suction feed spray-gun -V A G 1538- and spray lance 4490
12 Connecting the air conditioning service station 4491
12 1 For vehicles that have connections on both low-pressure and high-pressure sides of refrigerant circuit 4491
12 1 1 Connecting a air conditioner service station for measuring and testing 4491
13 Checking pressures on vehicles 4492
13 1 Checking pressures in the refrigerant circuit (using a air conditioning service station) 4492
13 1 1 Conditions for testing 4492
13 1 2 Checking pressures 4493
13 1 3 Continuation of checking pressures 4495
13 2 Checking systems with a restrictor and collector (with internally regulated air conditioner compressor) 4496
13 2 1 Specifications: 4496
13 3 Checking systems with an expansion valve and reservoir (with internally regulated air conditioner compressor) 4500
13 3 1 Specifications: 4500
13 4 Checking systems with an expansion valve and reservoir (without regulated air conditioner compressor) 4505
13 4 1 Conditions for testing 4505
13 4 2 Check 4505
13 4 3 Specified values 4505
13 5 Checking systems with a restrictor and reservoir and air conditioner compressor regulating valve -N280- (with externally regulated air conditioner compressor) 4506
13 5 1 Specifications: 4506
13 6 Checking systems with an expansion valve, receiver and air conditioner compressor regulating valve -N280- (with externally regulated air conditioner compressor) 4511
13 6 1 Specifications: 4511
13 7 With expansion valve, receiver and electrical air conditioner compressor 4522
14 Renewing components 4523
14 1 In the event of leaking or damaged components (apart from the air conditioner compressor, receiver or reservoir) 4524
14 1 1 If the refrigerant circuit was completely empty 4524
14 1 2 If there is still refrigerant in the refrigerant circuit 4526
14 2 Renew the air conditioner compressor 4526
14 2 1 Without needing to flush refrigerant circuit of contaminants (cleaning), e g in cases of external damage after an accident 4526
14 2 2 Leaks or internal damage (e g noises or lack of power) 4528
14 3 Replace receiver or reservoir and restrictor 4528
14 3 1 After flushing contaminants from refrigerant circuit, e g due to moisture intrusion (because refrigerant circuit was open for a longer period of time) or due to soiling 4528
14 3 2 Without needing to flush contaminants from refrigerant circuit (e g damage in an accident); no refrigerant has escaped and no moisture or dirt has entered refrigerant circuit 4530
15 Testing equipment and tools 4531
15 1 List of test equipment, tools and materials 4531
15 1 1 Tools and materials available from regional sales centre or importer 4531
15 1 2 Tools and materials commercially available 4532
15 1 3 Tools and materials available from regional sales centre or importer 4533
15 1 4 Tools and materials commercially available 4539

S.V 29/01/2025