Volkswagen Passat CC 2009 Workshop Manual – PDF DOWNLOAD

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Volkswagen Passat CC 2009 Workshop Manual – PDF DOWNLOAD

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Volkswagen Passat CC 2009 Workshop Manual – PDF DOWNLOAD

Language : English
Pages : 15539
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Volkswagen Passat CC 2009 Workshop Manual – PDF DOWNLOAD 

44 – Wheels, tyres, vehicle geometry 9
1 General notes on wheels and tyres (passenger cars) 9
2 Legislative and technical conditions for converting wheel and tyre combinations 11
2 1 Legislative conditions for converting wheel and tyre combinations 11
2 2 Technical conditions for converting wheel and tyre combinations 11
2 3 Additional wheel housing extensions (flaps) 12
2 4 „Series 80“ tyres 12
3 Documents and codes/designations 13
3 1 New vehicle registration documents since 01 10 2005 13
3 2 COC document (EEC Certificate of Conformity) 14
3 3 EU general type approval number, sales type and sales or trade designation 14
4 Useful information regarding tyres 16
4 1 Identification markings on the tyre sidewall 16
4 2 Explanation of tyre markings 17
4 3 Speed ratings for tyres 18
4 4 Undulations 19
4 5 Tyre storage 20
4 6 Tyre ageing 20
4 7 Tyre sizes for vehicles with four-wheel drive 22
4 8 Winter tyres 22
4 9 Winter tyres with speed symbol „V“ 23
4 10 Extra Load (XL) V winter tyres 24
4 11 Maximum speeds for V and Extra Load (XL) winter tyres 24
4 12 Reinforced and Extra Load (XL) tyres 25
4 13 Snow chains 25
5 Tyre wear/ mileage for passenger car tyres 27
5 1 General 27
5 2 Requirements to be met by tyres 27
5 3 Wear behaviour of high-speed tyres 28
5 4 Factors influencing the service life of a tyre 28
5 5 Driving style 28
5 6 Tyre maintenance 29
5 7 Evenly worn tyres 30
5 8 Measuring tread depth 31
5 9 One-sided wear 31
5 10 Outer shoulder wear 34
5 11 Wear in middle of tyre 34
5 12 Diagonal washout 36
6 Tyre noise 37
6 1 General notes on tyre noise 37
6 2 Saw-tooth wear 37
6 3 Flat spots (from locking wheels) 38
7 Vehicle pulls to one side 40
7 1 General 40
7 2 Conicity 40
7 3 Remedies when vehicle pulls to one side 41
7 4 Strategic rotation of wheels for non-directional tyres 42
7 5 Strategic rotation of wheels having unidirectional tyres 43
8 Tyre damage 45
8 1 General information 45
8 2 Construction of a radial belted tyre 46
8 3 Impact damage 46
8 4 Cuts 48
8 5 Damage caused by foreign bodies 48
8 6 Loss of air from tyre 48
8 7 Tyre pressure 48
8 8 Tyre damage due to insufficient tyre pressure 49
8 9 Rising tyre temperature caused by insufficient inflation pressure 50
8 10 Tyre damage due to fitting error (fitting damage) 51
9 Tyres with run-flat properties 53
9 1 General 53
9 2 Design and identification 54
9 3 Retrofitting/requirements when using run-flat tyres 54
9 4 Repairs 55
10 Rolling resistance optimised tyres 56
11 Facts about disc-type wheels (passenger cars) 57
11 1 Design of disc-type wheel 57
11 2 Data on wheel rims 57
11 3 Wheel rims – pitch circle diameter 58
11 4 Split rim composite wheels 58
11 5 Alloy wheels with exchangeable trim elements 58
11 6 Alloy wheels with exchangeable trim elements (Zaragoza) 59
11 6 1 Tools 59
11 6 2 Materials 60
11 6 3 Installing trim element 60
11 6 4 Removing trim element 62
11 7 Care and maintenance of alloy wheel rims 63
11 8 Restoring alloy wheels 63
11 9 The valve 65
12 Notes on use of temporary spare wheels 66
13 Fox from model year 2006 67
13 1 Fox, type 5Z model year 2006 to model year 2012 67
13 2 Wheel allocation for Fox, type 5Z model year 2006 to model year 2012 68
13 2 1 5 J x 14 69
13 2 2 6 J x 14 69
13 2 3 6 J x 15 71
14 up! from model year 2012 74
14 1 Advance information about up! Model year 2012 74
15 Polo from model year 2010 75
15 1 Polo, type 6R model year 2010 to model year 2012 75
15 2 Wheel allocation for Polo, type 6R model year 2010 to model year 2012 77
15 2 1 5 J x 14 77
15 2 2 6 J x 15 offset 38 78
15 2 3 6 J x 15 offset 40 78
15 2 4 7 J x 16 79
15 2 5 7 J x 17 80
16 Polo BlueMotion from model year 2010 81
16 1 Polo BlueMotion, type 6R model year 2010 to model year 2012 81
16 2 Wheel allocation for Polo BlueMotion, type 6R model year 2010 to model year 2012 82
16 2 1 51/2 J x 15 82
16 2 2 6 J x 15 offset 38 83
16 2 3 6 J x 15 offset 40 83
17 CrossPolo from model year 2011 85
17 1 CrossPolo, type 6R model year 2011 to model year 2012 85
17 2 Wheel allocation CrossPolo, type 6R model year 2011 to model year 2012 87
17 2 1 5 J x 14 87
17 2 2 6 J x 15 offset 38 88
17 2 3 6 J x 15 offset 40 88
17 2 4 7 J x 16 89
17 2 5 7 J x 17 90
17 2 6 71/2 J x 17 91
18 Polo GTI from model year 2011 92
18 1 Polo GTI, type 6R model year 2011 to model year 2012 92
18 2 Wheel allocation Polo GTI, type 6R model year 2011 to model year 2012 93
18 2 1 6 J x 15 offset 38 93
18 2 2 6 J x 15 offset 40 93
18 2 3 7 J x 16 94
18 2 4 7 J x 17 95
19 Golf from model year 2009 96
19 1 Golf, Golf 4Motion, sales type 5K model year 2009 to model year 2012 96
19 2 Wheel allocation for Golf, Golf 4Motion, sales type 5K model year 2009 to model year 2012 100
19 2 1 6 J x 15 100
19 2 2 61/2 J x 15 101
19 2 3 6 J x 16 102
19 2 4 61/2 J x 16 103
19 2 5 6 J x 17 108
19 2 6 7 J x 17 109
19 2 7 71/2 J x 17 112
19 2 8 71/2 J x 18 114
20 Golf BlueMotion from model year 2009 118
20 1 Golf BlueMotion, sales type 5K model year 2009 to model year 2012 118
20 2 Wheel allocation for Golf BlueMotion, sales type 5K model year 2009 to model year 2012 120
20 2 1 6 J x 15 120
20 2 2 61/2 J x 15 121
20 2 3 61/2 J x 16 122
21 Golf GTD from model year 2010 128
21 1 Golf GTD, sales type 5K, model year 2010 to model year 2012 128
21 2 Wheel allocation for Golf GTD, type 5K model year 2010 to model year 2012 130
21 2 1 6 J x 16 130
21 2 2 61/2 J x 16 130
21 2 3 6 J x 17 135
21 2 4 7 J x 17 136
21 2 5 71/2 J x 17 139
21 2 6 71/2 J x 18 141
22 Golf GTI from model year 2010 145
22 1 Golf GTI, sales type 5K, model year 2010 to model year 2012 145
22 2 Wheel allocation for Golf GTI, type 5K model year 2010 to model year 2012 147
22 2 1 6 J x 16 147
22 2 2 61/2 J x 16 148
22 2 3 6 J x 17 153
22 2 4 7 J x 17 153
22 2 5 71/2 J x 17 157
22 2 6 71/2 J x 18 158
22 2 7 71/2 J x 19 161
23 Golf R from model year 2010 163
23 1 Golf R, sales type 5K model year 2010 163
23 2 Golf R, sales type 5K model year 2011 to model year 2012 164
23 3 Wheel allocation for Golf R, type 5K model year 2010 to model year 2012 165
23 3 1 6 J x 17 166
23 3 2 7 J x 17 166
23 3 3 71/2 J x 17 166
23 3 4 71/2 J x 18 168
23 3 5 8 J x 19 171
24 CrossGolf from model year 2011 173
24 1 CrossGolf, sales type 521 model year 2011 to model year 2012 173
24 2 Wheel allocation CrossGolf, sales type 521 model year 2011 to model year 2012 176
24 2 1 6 J x 15 176
24 2 2 61/2 J x 15 177
24 2 3 6 J x 16 178
24 2 4 61/2 J x 16 179
24 2 5 6 J x 17 184
24 2 6 7 J x 17 offset 47 185
24 2 7 7 J x 17 offset 54 185
24 2 8 71/2 J x 17 189
25 Golf Cabriolet from model year 2012 190
25 1 Golf Cabriolet, sales type 517 from model year 2012 190
25 2 Wheel allocation Golf Cabriolet, sales type 517 from model year 2012 192
25 2 1 6 J x 15 192
25 2 2 61/2 J x 15 193
25 2 3 6 J x 16 194
25 2 4 61/2 J x 16 195
25 2 5 6 J x 17 200
25 2 6 7 J x 17 201
25 2 7 71/2 J x 17 204
25 2 8 71/2 J x 18 206
26 Golf Plus from model year 2009 210
26 1 Golf Plus, sales type 521 model year 2009 to model year 2011 210
26 2 Golf Plus, sales type 521 model year 2012 215
26 3 Wheel allocation for Golf Plus, sales type 521 model year 2009 to model year 2012 219
26 3 1 6 J x 15 219
26 3 2 61/2 J x 15 220
26 3 3 6 J x 16 221
26 3 4 61/2 J x 16 221
26 3 5 6 J x 17 226
26 3 6 7 J x 17 227
26 3 7 71/2 J x 17 230
26 3 8 71/2 J x 18 232
27 Golf Plus BlueMotion from model year 2010 236
27 1 Golf Plus BlueMotion, sales type 521, model year 2010 to model year 2012 236
27 2 Wheel allocation for Golf Plus BlueMotion, sales type 521, model year 2010 to model year 2012 238
27 2 1 6 J x 15 238
27 2 2 61/2 J x 15 239
27 2 3 6 J x 16 240
27 2 4 61/2 J x 16 241
28 Golf Variant from model year 2010 247
28 1 Golf Variant, Golf Variant 4Motion, sales type AJ5 model year 2010 to model year 2012 247
28 2 Wheel allocation for Golf Variant, Golf Variant 4Motion, sales type AJ5 model year 2010 to model year 2012 253
28 2 1 6 J x 15 253
28 2 2 61/2 J x 15 254
28 2 3 6 J x 16 255
28 2 4 61/2 J x 16 256
28 2 5 6 J x 17 261
28 2 6 7 J x 17 262
28 2 7 71/2 J x 17 265
28 2 8 71/2 J x 18 267
29 Golf Variant BlueMotion from model year 2010 271
29 1 Golf Variant BlueMotion, sales type AJ5, model year 2010 to model year 2012 271
29 2 Wheel allocation for Golf Variant BlueMotion, sales type AJ5, model year 2010 to model year 2012 272
29 2 1 6 J x 15 272
29 2 2 61/2 J x 15 273
29 2 3 6 J x 16 274
29 2 4 61/2 J x 16 275
30 Jetta from model year 2011 281
30 1 Jetta, sales type 162 model year 2011 to model year 2012 281
30 2 Wheel allocation Jetta, sales type 162 model year 2011 284
30 2 1 6 J x 15 284
30 2 2 61/2 J x 15 285
30 2 3 6 J x 16 286
30 2 4 61/2 J x 16 287
30 2 5 7 J x 17 292
30 2 6 71/2 J x 17 296
30 2 7 71/2 J x 18 297
31 Jetta from model year 2011 (NAR) 301
31 1 Jetta, sales type 162 from model year 2011 (NAR) 301
31 2 Wheel allocation for Jetta, sales type 162 from model year 2011 (NAR) 303
31 2 1 6 J x 15 303
31 2 2 61/2 J x 15 303
31 2 3 6 J x 16 305
31 2 4 61/2 J x 16 305
31 2 5 7 J x 17 310
31 2 6 71/2 J x 17 314
31 2 7 71/2 J x 18 315
32 Beetle from model year 2012 319
32 1 Beetle, sales type 5C1, from model year 2012 319
32 2 Beetle, sales type 5C1, from model year 2012 320
32 2 1 61/2 J x 16 321
32 2 2 7 J x 17 321
32 2 3 8 J x 18 323
32 2 4 8 J x 19 324
33 Scirocco from model year 2009 325
33 1 Scirocco, sales type 137, model year 2009 to model year 2011 325
33 2 Scirocco, sales type 137 model year 2012 328
33 3 Wheel allocation for Scirocco, sales type 137 model year 2009 to model year 2012 330
33 3 1 61/2 J x 16 330
33 3 2 61/2 J x 17 330
33 3 3 7 J x 17 331
33 3 4 8 J x 17 331
33 3 5 8 J x 18 333
33 3 6 8 J x 19 334
34 Scirocco R from model year 2010 336
34 1 Scirocco R, sales type 137, model year 2010 to model year 2011 336
34 2 Scirocco R, sales type 137 model year 2012 337
34 3 Wheel allocation for Scirocco R, sales type 137, model year 2010 to model year 2012 338
34 3 1 61/2 J x 17 339
34 3 2 7 J x 17 339
34 3 3 8 J x 17 339
34 3 4 8 J x 18 341
34 3 5 8 J x 19 343
35 Touran from model year 2003 344
35 1 Touran, type 1T model year 2003 to model year 2006 344
35 2 Touran, type 1T model year 2007 to model year 2010 347
35 3 Touran, type 1T and type 1t model year 2011 to model year 2012 352
35 4 Wheel allocation Touran, type 1T and type 1t model year 2003 to model year 2012 357
35 4 1 6 J x 15 357
35 4 2 61/2 J x 15 358
35 4 3 6 J x 16 359
35 4 4 61/2 J x 16 359
35 4 5 6 J x 17 365
35 4 6 7 J x 17 365
35 4 7 71/2 J x 18 366
36 CrossTouran from model year 2008 367
36 1 CrossTouran, type 1T model year 2008 to model year 2009 367
36 2 CrossTouran, type 1T and type 1t model year 2010 to model year 2012 370
36 3 Wheel allocation CrossTouran, type 1T and type 1t model year 2008 to model year 2012 374
36 3 1 6 J x 15 374
36 3 2 6 J x 16 375
36 3 3 61/2 J x 17 375
36 3 4 8 J x 17 376
37 Touran BlueMotion from model year 2009 377
37 1 Touran BlueMotion, type 1T and type 1t model year 2009 to model year 2012 377
37 2 Wheel allocation Touran BlueMotion, type 1T and type 1t model year 2009 to model year 2012 379
37 2 1 6 J x 15 379
37 2 2 61/2 J x 15 380
37 2 3 6 J x 16 381
37 2 4 61/2 J x 16 381
38 Tiguan from model year 2008 387
38 1 Tiguan, type 5N model year 2008 to model year 2011 387
38 2 Tiguan, type 5N, model year 2012 388
38 3 Wheel allocation for Tiguan, type 5N model year 2008 to model year 2012 390
38 3 1 6 1/2 J x 16 390
38 3 2 61/2 J x 17 392
38 3 3 7 J x 17 392
38 3 4 7 J x 18 393
38 3 5 9 J x 19 394
39 Eos from model year 2006 395
39 1 Eos, type 1F from model year 2006 395
39 2 Eos, type 1F model year 2007 to model year 2012 396
39 3 Wheel allocation for Eos, type 1F model year 2006 to model year 2012 399
39 3 1 61/2 J x 16 399
39 3 2 7 J x 16 400
39 3 3 6 J x 17 402
39 3 4 71/2 J x 17 403
39 3 5 8 J x 18 406
40 Passat saloon from model year 2011 409
40 1 Passat saloon, sales type 362 model year 2011 to model year 2012 409
40 2 Wheel allocation Passat saloon, sales type 362 model year 2011 to model year 2012 414
40 2 1 61/2 J x 16 415
40 2 2 7 J x 16 415
40 2 3 6 J x 17 416
40 2 4 61/2 J x 17 417
40 2 5 71/2 J x 17 417
40 2 6 8 J x 18 418
41 Passat Variant from model year 2011 420
41 1 Passat estate, sales type 365 model year 2011 to model year 2012 420
41 2 Wheel allocation Passat estate, sales type 365 model year 2011 to model year 2012 425
41 2 1 61/2 J x 16 425
41 2 2 7 J x 16 426
41 2 3 6 J x 17 427
41 2 4 61/2 J x 17 427
41 2 5 71/2 J x 17 428
41 2 6 8 J x 18 429
42 Passat CC from model year 2009, CC from model year 2010 431
42 1 Passat CC, sales type 357 model year 2009 431
42 2 Passat CC, CC, sales type 357 model year 2010 to model year 2012 433
42 3 Wheel allocation Passat CC, CC, sales type 357 model year 2009 to model year 2012 434
42 3 1 61/2 J x 17 434
42 3 2 8 J x 17 435
42 3 3 8 J x 18 436
42 3 4 8 J x 19 438
43 Phaeton from model year 2003 439
43 1 Phaeton, type 3D, model year 2003 to model year 2009 – short and long wheelbase 439
43 2 Phaeton, type 3D and type 3d, model year 2010 to model year 2012 – short and long wheelbase 442
43 3 Wheel allocation for Phaeton, type 3D and type 3d, model year 2003 to model year 2012 – short and long wheelbase 444
43 3 1 71/2 J x 16 444
43 3 2 71/2 J x 17 444
43 3 3 71/2 J x 18 446
43 3 4 81/2 J x 18 446
43 3 5 81/2 J x 19 offset 38 448
43 3 6 81/2 J x 19 offset 45 449
43 3 7 9 J x 19 offset 35 449
43 3 8 9 J x 19 offset 40 450
43 3 9 9 J x 20 450
44 Sharan from model year 2011 452
44 1 Sharan, Sharan 4Motion, type 7N model year 2011 to model year 2012 452
44 2 Wheel allocation Sharan, Sharan 4Motion, type 7N model year 2011 to model year 2012 454
44 2 1 6 1/2 J x 16 454
44 2 2 7 J x 17 455
44 2 3 71/2 J x 18 455
45 Touareg from model year 2010 457
45 1 Touareg, type 7P and type 7p, model year 2010 to model year 2012 457
45 2 Wheel allocation for Touareg, type 7P and type 7p, model year 2010 to model year 2012 459
45 2 1 71/2 J x 17 459
45 2 2 8 J x 18 460
45 2 3 81/2 J x 19 461
45 2 4 9 J x 20 461
45 2 5 91/2 J x 21 462
46 Touareg hybrid from model year 2011 464
46 1 Touareg hybrid, type 7PH and type 7pH, model year 2011 to model year 2012 464
46 2 Wheel allocation Touareg hybrid, type 7PH and type 7pH, model year 2011 to model year 2012 465
46 2 1 8 J x 18 465
46 2 2 81/2 J x 19 466
47 Breakdown set for VW Vehicles 468
48 Temporary spare tyres and wheels for VW vehicles 469
49 Recommended summer tyres 470
49 1 Summer tyres for Fox from model year 2006 470
49 2 Summer tyres for Polo from model year 2010 470
49 3 Summer tyres for Polo BlueMotion from model year 2010 471
49 4 Summer tyres for CrossPolo from model year 2011 472
49 5 Summer tyres for Polo GTI from model year 2011 472
49 6 Summer tyres for Golf from model year 2009 473
49 7 Summer tyres for Golf BlueMotion from model year 2009 474
49 8 Summer tyres for Golf GTD from model year 2009 475
49 9 Summer tyres for Golf GTI from model year 2009 475
49 10 Summer tyres for Golf R from model year 2010 476
49 11 Summer tyres for CrossGolf from model year 2011 477
49 12 Summer tyres Golf Cabriolet from model year 2012 478
49 13 Summer tyres for Golf Plus from model year 2009 479
49 14 Summer tyres for Golf Plus BlueMotion from model year 2010 480
49 15 Summer tyres for Golf Variant from model year 2010 481
49 16 Summer tyres for Golf Variant BlueMotion from model year 2010 482
49 17 Summer tyres for Jetta from model year 2011 483
49 18 Summer tyres for Beetle from model year 2012 485
49 19 Summer tyres for Scirocco from model year 2009 485
49 20 Summer tyres for Scirocco R from model year 2010 485
49 21 Summer tyres for Touran from model year 2003 486
49 22 Summer tyres for Touran BlueMotion from model year 2009 486
49 23 Summer tyres for CrossTouran from model year 2008 487
49 24 Summer tyres for Tiguan from model year 2008 487
49 25 Summer tyres for Eos from model year 2006 488
49 26 Summer tyres for Passat saloon from model year 2011 488
49 27 Summer tyres for Passat Variant from model year 2011 489
49 28 Summer tyres Passat CC from model year 2009, CC from model year 2010 490
49 29 Summer tyres for Sharan from model year 2011 490
49 30 Summer tyres for Phaeton from model year 2003 490
49 31 Summer tyres for Touareg from model year 2010 491
49 32 Summer tyres for Touareg hybrid from model year 2011 491
50 Recommended all-season tyres 492
50 1 All-season tyres for Polo from model year 2010 492
50 2 All-season tyres for Polo BlueMotion from model year 2010 492
50 3 All-season tyres for CrossPolo from model year 2011 492
50 4 All-season tyres for Polo GTI from model year 2011 493
50 5 All-season tyres for Golf from model year 2009 493
50 6 All-season tyres for CrossGolf from model year 2011 493
50 7 All-weather tyres Golf Cabriolet from model year 2012 494
50 8 All-season tyres for Golf Plus from model year 2009 494
50 9 All-season tyres for Golf Variant from model year 2010 495
50 10 All-season tyres for Jetta from model year 2011 495
50 11 All-season tyres for Jetta from model year 2011 (NAR) 495
50 12 All-season tyres for Touran from model year 2003 496
50 13 All-season tyres for Beetle from model year 2012 496
50 14 All-season tyres for Tiguan from model year 2008 496
50 15 All-season tyres for Eos from model year 2006 496
50 16 All-season tyres for Passat saloon from model year 2011 497
50 17 All-season tyres for Passat Variant from model year 2011 497
50 18 All-season tyres Passat CC from model year 2009, CC from model year 2010 497
50 19 All-season tyres for Sharan from model year 2011 498
50 20 All-season tyres for Phaeton from model year 2003 498
50 21 All-season tyres for Touareg from model year 2010 498
50 22 All-season tyres Touareg hybrid from model year 2010 498
51 Recommended winter tyres 500
51 1 Winter tyres for Fox from model year 2006 500
51 2 Winter tyres for Polo from model year 2010 500
51 3 Winter tyres for Polo BlueMotion from model year 2010 501
51 4 Winter tyres for CrossPolo from model year 2011 501
51 5 Winter tyres for Polo GTI from model year 2011 501
51 6 Winter tyres for Golf from model year 2009 501
51 7 Winter tyres for Golf BlueMotion from model year 2009 502
51 8 Winter tyres for Golf GTD from model year 2009 502
51 9 Winter tyres for Golf GTI from model year 2009 502
51 10 Winter tyres for Golf R from model year 2010 502
51 11 Winter tyres for CrossGolf from model year 20011 503
51 12 Winter tyres Golf Cabriolet from model year 2012 503
51 13 Winter tyres for Golf Plus from model year 2009 503
51 14 Winter tyres for Golf Plus BlueMotion from model year 2010 504
51 15 Winter tyres for Golf Variant from model year 2010 504
51 16 Winter tyres for Golf Variant BlueMotion from model year 2010 504
51 17 Winter tyres for Jetta from model year 2011 505
51 18 Winter tyres for Beetle from model year 2012 505
51 19 Winter tyres for Scirocco from model year 2009 505
51 20 Winter tyres for Scirocco R from model year 2010 505
51 21 Winter tyres for Touran from model year 2003 506
51 22 Winter tyres for Touran BlueMotion from model year 2009 506
51 23 Winter tyres for CrossTouran from model year 2008 506
51 24 Winter tyres for Tiguan from model year 2008 507
51 25 Winter tyres for Eos from model year 2006 507
51 26 Winter tyres for Passat saloon from model year 2011 507
51 27 Winter tyres for Passat Variant from model year 2011 507
51 28 Winter tyres Passat CC from model year 2009, CC from model year 2010 508
51 29 Winter tyres for Sharan from model year 2011 508
51 30 Winter tyres for Phaeton from model year 2003 508
51 31 Winter tyres for Touareg from model year 2010 508
51 32 Winter tyres Touareg hybrid from model year 2010 509
00 – Technical data 514
1 Safety information 514
1 1 Safety regulations for working on fuel supply 514
1 2 Safety precautions when using testers and measuring instruments during a road test 514
1 3 Safety precautions when working on vehicles with a start/stop system 515
2 Identification 516
2 1 Engine number/engine data 516
3 General information 517
3 1 Rules for cleanliness when working on auxiliary/supplementary heater and fuel system 517
4 Repair notes 518
4 1 Routing and attaching lines 518
4 2 General repair instructions 518
20 – Fuel supply system 519
1 Fuel 519
1 1 Assembly overview – fuel tank 519
1 1 1 Assembly overview – fuel tank, vehicles with front-wheel drive 519
1 1 2 Assembly overview – fuel tank, vehicles with front-wheel drive with engine codes CBFA, CCTA, CNNA 521
1 1 3 Assembly overview – fuel tank, vehicles with four-wheel drive 523
1 1 4 Assembly overview – fuel tank, vehicles with four-wheel drive with engine code CNNA 525
1 2 Emptying fuel tank 527
1 2 1 Emptying fuel tank when fuel pump is intact 527
1 2 2 Emptying fuel tank if it is more than 3/4 full 530
1 2 3 Emptying fuel tank with fuel tank less than 3/4 full, vehicles with front-wheel drive 531
1 2 4 Emptying fuel tank with fuel tank less than 3/4 full, vehicles with four-wheel drive 534
1 3 Removing and installing fuel tank 539
1 3 1 Removing and installing fuel tank – vehicles with front-wheel drive 539
1 3 2 Removing and installing fuel tank – vehicles with four-wheel drive 544
2 Fuel delivery unit, fuel gauge sender 554
2 1 Assembly overview – fuel delivery unit/fuel gauge sender 554
2 1 1 Assembly overview – fuel delivery unit/fuel gauge sender 554
2 1 2 Assembly overview – fuel delivery unit/fuel gauge sender, vehicles with auxiliary heater 555
2 2 Removing and installing fuel delivery unit, fuel gauge sender 556
2 2 1 Removing and installing fuel delivery unit, fuel gauge sender 556
2 2 2 Removing and installing fuel line for auxiliary/supplementary heater 561
3 Plug-in connectors 564
3 1 Separating plug-in connectors 564
4 Fuel filter 568
5 Activated charcoal filter with fuel tank leak detection 569
5 1 Assembly overview – activated charcoal filter system 569
5 1 1 Assembly overview – activated charcoal filter system for engine codes CCTA, CBFA, CNNA 569
5 1 2 Assembly overview – activated charcoal filter system, vehicles with additional filter and engine codes CBFA, CCTA 570
5 2 Removing and installing activated charcoal filter 570
5 3 Checking fuel system for leaks 571
5 3 1 Checking fuel system for leaks 571
5 3 2 Leak detection in fuel system 575
5 3 3 Schematic overview of activated charcoal filter system 576
5 3 4 Checking vacuum supply of fuel system diagnostic pump -V144- 577
6 Activated charcoal filter without fuel tank leak detection 579
6 1 Assembly overview – activated charcoal filter system 579
6 2 Removing and installing activated charcoal filter 579
6 3 Checking fuel tank breather 580
7 Accelerator pedal 583
7 1 Assembly overview – accelerator module 583
7 2 Removing and installing accelerator pedal module -GX2- 583
8 Fuel pump 586
8 1 Checking fuel system pressurisation pump -G6- 586
8 1 1 Checking function and voltage supply 586
8 1 2 Checking fuel pressure 589
8 1 3 Checking fuel pressure during vehicle operation, engine codes CCZB, CDAA, CDAB 594
8 1 4 Checking holding pressure 597
8 1 5 Checking fuel delivery rate, engine codes CKMA, CCTA, CBFA, CAVD, CTHD, CZDA 601
8 1 6 Checking fuel delivery rate, engine codes BWS, CCZB, CDAA, CDAB, CNNA 609
8 1 7 Checking current consumption 616
8 2 Removing and installing suction-jet pump 619
9 Senders and sensors 624
9 1 Removing and installing fuel gauge sender -G- 624
9 2 Removing and installing fuel gauge sender 2 -G169- 625
00 – Technical data 633
1 Safety information 633
1 1 Safety regulations for working on fuel supply 633
1 2 Safety measures when working on vehicles with a start/stop system 634
1 3 Safety precautions when using testers and measuring instruments during a road test 634
1 4 Safety precautions when working on the SCR system 634
2 Identification 636
2 1 Engine number/engine data 636
3 General information 637
3 1 Rules for cleanliness when working on auxiliary/supplementary heater and fuel system 637
4 Repair notes 638
4 1 Pipe/wire routing and attachment 638
4 2 General repair instructions 638
20 – Fuel supply system 639
1 Procedure should vehicle be misfueled 639
1 1 Step 1, engine was started with incorrect fuel 639
1 2 Step 2, engine was not started with incorrect fuel 641
1 3 Step 3, there are metal particles in fuel delivery unit and fuel tank 643
1 4 Step 4, there are no metal particles in fuel delivery unit or fuel tank 644
1 5 Step 5, there are metal particles in high-pressure pump 645
1 6 Step 6, there are no metal particles in high-pressure pump 645
2 Fuel 646
2 1 Assembly overview – fuel tank 646
2 1 1 Assembly overview – fuel tank, vehicles with front-wheel drive 646
2 1 2 Assembly overview – fuel tank, vehicles with four-wheel drive 648
2 2 Emptying fuel tank 649
2 2 1 Emptying fuel tank when fuel pump is intact 649
2 2 2 Emptying fuel tank if it is more than 3/4 full 651
2 2 3 Emptying fuel tank with fuel tank less than 3/4 full, vehicles with front-wheel drive 652
2 2 4 Emptying fuel tank with fuel tank less than 3/4 full, vehicles with four-wheel drive 653
2 3 Removing and installing fuel tank 657
2 3 1 Removing and installing fuel tank – vehicles with front-wheel drive 657
2 3 2 Removing and installing fuel tank – vehicles with four-wheel drive 661
3 Fuel delivery unit, fuel gauge sender 667
3 1 Assembly overview – fuel delivery unit/fuel gauge sender 667
3 1 1 Assembly overview – fuel delivery unit/fuel gauge sender 667
3 1 2 Assembly overview – fuel delivery unit/fuel gauge sender, vehicles with auxiliary heater 669
3 2 Removing and installing fuel delivery unit, fuel gauge sender 669
3 2 1 Removing and installing fuel delivery unit, fuel gauge sender 669
3 2 2 Removing and installing fuel line for auxiliary/supplementary heater 672
3 3 Removing and installing fuel gauge sender -G- 674
3 4 Removing and installing fuel gauge sender 2 -G169- 675
4 Plug-in connectors 678
4 1 Separating plug-in connectors 678
5 Fuel filter 682
5 1 Assembly overview – fuel filter 682
5 1 1 Assembly overview – fuel filter, engine codes CAYC, CFFA, CFFB, CFGB, CLLA, CFGC 682
5 1 2 Assembly overview – fuel filter, engine codes CUVC, CUWA 683
5 2 Removing and installing fuel filter 684
5 2 1 Removing and installing fuel filter, engine codes CAYC, CFFA, CFFB, CFGB, CLLA, CFGC 684
5 2 2 Removing and installing fuel filter, engine codes CUVC, CUWA 685
5 3 Fuel hoses in the engine compartment 688
6 Accelerator pedal 689
6 1 Assembly overview – accelerator module 689
6 2 Removing and installing accelerator pedal module -GX2- 689
7 Fuel pump 692
7 1 Checking fuel system pressurisation pump -G6- 692
7 1 1 Checking fuel pressure, engine codes CUVC, CUWA 692
7 1 2 Checking fuel delivery rate, engine codes CUVC, CUWA 698
7 1 3 Checking delivery pressure and fuel delivery quantity of fuel system pressurisation pump -G6-, engine codes CFFA, CFFB, CFGB, CLLA, CFGC 705
7 1 4 Delivery pressure of fuel pump, engine code CAYC 712
7 1 5 Checking delivery rate of fuel pump, engine code CAYC 716
7 1 6 Checking current consumption of fuel system pressurisation pump -G6- 719
7 1 7 Checking voltage supply of fuel system pressurisation pump -G6- 721
7 2 Removing and installing suction-jet pump 723
00 – Technical data 732
1 Identification 732
1 1 Engine number/engine data 732
1 1 1 Engine number 732
1 1 2 Engine data 732
2 Safety information 734
2 1 Safety regulations for working on fuel supply 734
2 2 Safety precautions when using testers and measuring instruments during a road test 734
2 3 Safety measures when working on vehicles with a start/stop system 735
2 4 Safety precautions when working on the cooling system 735
2 5 Safety precautions when working on the SCR system 735
2 6 Safety precautions when working on exhaust system 736
3 Repair instructions 738
3 1 Rules for cleanliness 738
3 2 Foreign objects in engine 738
3 3 Checking vacuum system 738
10 – Removing and installing engine 739
1 Removing and installing motor 739
1 1 Removing motor 739
1 1 1 Removing engine, Golf Cabriolet 739
1 1 2 Removing engine, CC 747
1 2 Separating engine and gearbox 762
1 2 1 Separating engine and gearbox, manual gearbox 762
1 2 2 Separating engine and gearbox, dual-clutch gearbox 764
1 3 Securing engine on engine and gearbox support 767
1 4 Installing engine 769
1 4 1 Notes on installing 769
2 Assembly mountings 773
2 1 Assembly overview – assembly mountings 773
2 2 Supporting engine in installation position 774
2 2 1 Supporting engine in installation position, Golf Cabriolet 774
2 2 2 Supporting engine in installation position, CC 776
2 3 Adjusting assembly mountings 779
3 Engine cover panel 781
3 1 Removing and installing engine cover 781
13 – Crankshaft group 783
1 Cylinder block (pulley end) 783
1 1 Assembly overview – poly V-belt drive 783
1 1 1 Assembly overview – poly V-belt drive with tensioning element and air conditioner compressor 783
1 1 2 Assembly overview – poly V-belt drive with tensioning roller and air conditioner compressor 784
1 1 3 Assembly overview – poly V-belt drive without air conditioner compressor 786
1 2 Removing and installing poly-V belt 787
1 2 1 Removing and installing poly V-belt (poly V-belt drive with tensioning element and air-conditioning compressor) 787
1 2 2 Removing and installing poly V-belt (poly V-belt drive with tensioning roller and air-conditioning compressor) 789
1 2 3 Removing and installing poly V-belt (poly V-belt drive without air conditioner compressor) 791
1 3 Removing and installing tensioner for poly V-belt 792
1 4 Removing and installing bracket for ancillaries 792
1 5 Removing and installing engine bracket 795
1 5 1 Removing and installing engine bracket, Golf Cabriolet 795
1 5 2 Removing and installing engine bracket, CC 798
1 6 Assembly overview – cylinder block (pulley end) 803
1 7 Removing and installing sealing flange on pulley end 805
1 8 Renewing crankshaft oil seal – belt pulley end 808
2 Cylinder block, gearbox end 812
2 1 Assembly overview – cylinder block, gearbox end 812
2 2 Removing and installing flywheel 813
2 3 Removing and installing sealing flange on gearbox side 815
2 3 1 Pressing out sealing flange with sender wheel 816
2 3 2 Pressing in sealing flange with sender wheel 818
3 Crankshaft 828
3 1 Assembly overview – crankshaft 828
3 2 Renewing needle bearing in crankshaft 829
3 3 Crankshaft dimensions 832
4 Pistons and conrods 833
4 1 Assembly overview – pistons and conrods 833
4 1 1 Piston and cylinder dimensions 838
4 2 Measuring piston projection at TDC 838
4 2 1 Cylinder head gasket identification 840
4 3 Separating new conrod 840
4 4 Checking radial clearance of conrods 841
15 – Cylinder head, valve gear 842
1 Cylinder head 842
1 1 Assembly overview – cylinder head 842
1 2 Removing and installing cylinder head 846
1 3 Assembly overview – cylinder head cover 856
1 4 Removing and installing cylinder head cover 858
1 4 1 Renewing seals for injectors 861
1 5 Removing and installing vacuum pump 862
1 6 Checking compression 864
2 Toothed belt drive 867
2 1 Assembly overview – toothed belt 867
2 2 Removing and installing toothed belt 869
2 2 1 Removing and installing toothed belt, tensioning roller A 872
2 2 2 Removing and installing toothed belt, tensioning roller B 882
3 Valve gear 892
3 1 Assembly overview – valve gear 892
3 2 Measuring axial play of camshaft 894
3 3 Measuring radial play of camshaft 895
3 4 Removing and installing camshaft oil seal 896
3 4 1 Vehicles with »old« seal 896
3 4 2 Vehicles with »new« seal 899
3 5 Removing and installing camshaft 903
3 6 Checking hydraulic compensation elements 912
3 7 Removing and installing valve stem seals 913
3 7 1 Removing and installing valve stem seals with cylinder head installed 913
3 7 2 Removing and installing valve stem seals with cylinder head removed 917
4 Inlet and exhaust valves 922
4 1 Valve dimensions 922
4 2 Reworking valve seats 922
4 3 Checking valve guides 922
4 4 Checking valves 924
17 – Lubrication 925
1 Sump, oil pump 925
1 1 Assembly overview – sump/oil pump 925
1 1 1 Assembly overview – sump / oil pump, engine code CFHC 925
1 1 2 Assembly overview – sump/oil pump, engine codes CFFA, CFFB, CFGB, CFGC, CLLA 928
1 2 Removing and installing sump 931
1 3 Removing and installing oil level and oil temperature sender 935
1 4 Removing and installing oil pump 937
1 5 Engine oil: 938
1 5 1 Oil capacities 938
1 5 2 Checking engine oil level 938
2 Engine oil cooler 940
2 1 Assembly overview – engine oil cooler 940
2 2 Removing and installing engine oil cooler 941
3 Oil filter, oil pressure switch 944
3 1 Assembly overview – oil filter 944
3 2 Removing and installing oil filter housing 945
3 3 Removing and installing oil pressure switch 949
3 4 Checking oil pressure and oil pressure switch 950
3 4 1 Checking oil pressure 950
3 4 2 Checking oil pressure switch 951
4 Balancer shaft module 953
4 1 Assembly overview – balancer shaft module 953
4 2 Removing and installing balance shaft module 956
4 2 1 Removing balancer shaft module 956
4 2 2 Installing a previously used balancer shaft module again 958
4 2 3 Installing a new balancer shaft module 961
19 – Cooling 966
1 Cooling system/coolant 966
1 1 Coolant hose connection diagram 966
1 2 Checking cooling system for leaks 967
1 3 Draining and adding coolant 971
1 3 1 Draining 973
1 3 2 Filling 975
2 Coolant pump, regulation of cooling system 978
2 1 Assembly overview – coolant pump, thermostat 978
2 2 Removing and installing coolant pump 978
2 3 Removing and installing 4/2-way valve with thermostat 980
2 4 Electric coolant pump 986
2 4 1 Assembly overview – electric coolant pump 986
2 4 2 Removing and installing electric coolant pump 987
2 5 Removing and installing coolant temperature sender 991
2 5 1 Removing and installing coolant temperature sender -G62- 991
2 5 2 Removing and installing radiator outlet coolant temperature sender -G83- 993
3 Coolant pipes 996
3 1 Assembly overview – coolant pipes 996
3 2 Removing and installing coolant pipes 998
3 2 1 Removing and installing front coolant pipe 998
3 2 2 Removing and installing upper front coolant pipe 1003
3 2 3 Removing and installing left coolant pipe 1004
3 2 4 Removing and installing right coolant pipe 1007
4 Radiator, radiator fan 1010
4 1 Assembly overview – radiator/radiator fan 1010
4 2 Removing and installing radiator 1010
4 3 Removing and installing radiator cowl with radiator fan 1013
4 4 Removing and installing radiator fan 1014
21 – Turbocharging/supercharging 1016
1 Turbocharger 1016
1 1 Assembly overview – turbocharger 1016
1 2 Removing and installing turbocharger 1018
1 3 Renewing vacuum unit for turbocharger 1026
2 Charge air system 1033
2 1 Assembly overview – charge air system 1033
2 2 Removing and installing charge air cooler 1034
2 3 Assembly overview – charge-air hose connections 1036
2 4 Removing and installing charge pressure sender 1037
2 5 Checking charge air system for leaks 1038
23 – Mixture preparation – injection 1042
1 Injection system 1042
1 1 Schematic overview – fuel system 1042
1 2 Filling/bleeding fuel system 1044
1 3 Checking fuel system for leaks 1045
2 Injectors/high-pressure accumulator (rail) 1046
2 1 Assembly overview – injectors 1046
2 2 Adapting correction values for injectors 1049
2 3 Testing jammed-open injectors 1050
2 4 Removing and installing injectors 1052
2 5 Removing and installing fuel rail 1056
2 6 Removing and installing high-pressure lines 1060
3 High-pressure pump 1065
3 1 Assembly overview – high-pressure pump 1065
3 2 Removing and installing high-pressure pump 1067
4 Senders and sensors 1073
4 1 Checking fuel pressure regulating valve 1073
4 2 Removing and installing fuel pressure regulating valve 1074
4 3 Removing and installing fuel pressure sender 1076
4 4 Removing and installing air mass meter 1079
4 5 Removing and installing NOx sender 2 -G687- 1080
4 6 Removing and installing differential pressure sensor 1080
4 6 1 Removing and installing pressure differential sender -G505- 1080
5 Lambda probe 1082
5 1 Removing and installing Lambda probe 1082
6 Vacuum system 1084
6 1 Vacuum hose connection diagram 1084
6 2 Checking vacuum system 1085
6 2 1 Checking supply line, vacuum reservoir and non-return valve 1085
6 2 2 Checking control line to turbocharger 1086
7 Air filter 1088
7 1 Assembly overview – air filter housing 1088
7 2 Removing and installing air filter housing 1090
8 Intake manifold 1093
8 1 Assembly overview – intake manifold 1093
8 2 Removing and installing intake manifold 1094
8 3 Removing and installing throttle valve module 1099
9 Engine control unit 1101
9 1 Removing and installing engine control unit 1101
9 1 1 Removing and installing engine control unit 1101
9 1 2 Removing and installing engine (motor) control unit -J623- with protective housing 1102
26 – Exhaust system 1106
1 Exhaust pipes and silencers 1106
1 1 Assembly overview – silencers 1106
1 1 1 Assembly overview – silencer, Golf Cabriolet 1106
1 1 2 Assembly overview – silencer, CC 1107
1 1 3 Assembly overview – silencer, CC with SCR system 1108
1 2 Aligning exhaust system free of stress 1109
1 3 Installation position of clamp 1110
2 Emission control 1112
2 1 Assembly overview – emission control 1112
2 1 1 Assembly overview – front exhaust pipe with particulate filter 1112
2 1 2 Assembly overview – front exhaust pipe with catalytic converter 1114
2 2 Removing and installing particulate filter 1115
2 3 Removing and installing catalytic converter 1124
3 SCR system (selective catalytic reduction) 1130
3 1 Assembly overview – tank for reducing agent 1130
3 2 Draining reducing agent tank 1131
3 3 Removing and installing reducing agent tank 1135
3 4 Assembly overview – delivery module for reducing agent 1138
3 5 Removing and installing heater element (heater cup) 1140
3 6 Assembly overview – reducing agent supply line 1145
3 7 Removing and installing reducing agent supply line 1146
3 8 Removing and installing injector for reducing agent 1149
4 Exhaust gas temperature regulation 1151
4 1 Assembly overview – exhaust gas temperature regulation 1151
4 2 Removing and installing parts of exhaust gas temperature regulation 1153
4 2 1 Removing and installing exhaust gas temperature sender 1 -G235- 1153
4 2 2 Removing and installing exhaust gas temperature sender 3 -G495- 1155
4 2 3 Removing and installing exhaust gas temperature sender 4 -G648- 1157
5 Exhaust gas recirculation 1160
5 1 Assembly overview – exhaust gas recirculation 1160
5 2 Checking changeover for exhaust gas recirculation cooler 1162
5 3 Removing and installing exhaust gas recirculation cooler 1162
5 4 Checking exhaust gas recirculation cooler for leaks 1165
5 5 Cleaning exhaust gas recirculation system 1171
5 5 1 Initiating cleaning of exhaust gas recirculation system 1171
5 5 2 Cleaning connecting pipes and pipe union 1177
28 – Glow plug system 1179
1 Glow plug system 1179
1 1 Removing and installing glow plug 1179
1 2 Removing and installing automatic glow period control unit 1181
1 3 Removing and installing Hall sender 1182
1 4 Removing and installing engine speed sender 1183
00 – Technical data 1192
1 Safety information 1192
1 1 Safety precautions when using testers and measuring instruments during a road test 1192
1 2 Safety measures when working on vehicles with a start/stop system 1193
1 3 All-wheel drive – notes on performance test 1193
2 Identification 1194
2 1 Gearbox identification 1194
2 1 1 Gearbox identification, front-wheel drive 1194
2 1 2 Gearbox identification, all-wheel drive 1195
3 Technical data 1197
3 1 Allocation gearbox – engine 1197
3 1 1 Allocation gearbox – engine, Golf, Golf Estate, manual gearbox 02Q 1197
3 1 2 Allocation gearbox – engine, Golf, manual gearbox 02Q with front differential lock 1198
3 1 3 Allocation gearbox – engine, CC, Passat, Golf, Golf estate, manual gearbox 0FB 1199
3 1 4 Allocation gearbox – engine, Scirocco, manual gearbox 0FB 1199
3 1 5 Allocation gearbox – engine, Scirocco, manual gearbox 02Q 1200
3 1 6 Allocation gearbox – engine, Golf Cabriolet, manual gearbox 02Q 1201
3 1 7 Allocation gearbox – engine, CC, manual gearbox 02Q 1202
3 1 8 Allocation gearbox – engine, Passat, manual gearbox 02Q 1203
3 1 9 Allocation gearbox – engine, Passat, manual gearbox 0BB 1205
3 1 10 Allocation gearbox – engine, Golf four-wheel drive, Golf Estate four-wheel drive, manual gearbox 02Q 1205
3 1 11 Allocation gearbox – engine, CC, all-wheel drive, manual gearbox 02Q 1206
3 1 12 Allocation gearbox – engine, Passat, four-wheel drive, manual gearbox 02Q 1207
3 2 Capacities 1207
3 2 1 Capacity, manual gearbox 1207
3 2 2 Capacity, bevel box 1207
3 2 3 Capacities, front differential lock 1207
3 3 Calculation of gear ratios 1208
4 Overview – power transmission 1209
4 1 Overview – power transmission, front-wheel drive 1209
4 2 Overview – power transmission, all-wheel drive 1210
5 Electrical components 1213
5 1 Overview of fitting locations – electrical components 1213
5 1 1 Overview of fitting locations – electrical components, front differential lock 1213
5 1 2 Overview of fitting locations – electrical components, manual gearbox 1213
5 1 3 Overview of fitting locations – electrical components, clutch mechanism 1214
6 Repair instructions 1216
6 1 General repair notes 1216
30 – Clutch 1220
1 Clutch mechanism 1220
1 1 Overview of fitting locations – clutch mechanism 1220
1 2 Assembly overview – pedal cluster 1221
1 2 1 Assembly overview – pedal cluster, CC, Scirocco, Golf Cabriolet, Passat 1221
1 2 2 Assembly overview – pedal cluster, Golf, Golf Estate 1224
1 3 Assembly overview – clutch hydraulics 1227
1 3 1 Assembly overview – clutch hydraulics, CC, Scirocco, Golf Cabriolet, Passat, LHD vehicles 1227
1 3 2 Assembly overview – clutch hydraulics, CC, Scirocco, Golf Cabriolet, Passat, RHD vehicles 1229
1 3 3 Assembly overview – clutch hydraulics, Golf, Golf Estate, LHD vehicles 1231
1 3 4 Assembly overview – clutch hydraulics, Golf, Golf Estate, RHD vehicles 1233
1 4 Assembly overview – clutch release mechanism 1235
1 5 Removing and installing bearing bush 1237
1 6 Checking clutch master cylinder and clutch slave cylinder 1238
1 7 Removing and installing clutch position sender -G476- 1239
1 7 1 Removing and installing clutch position sender -G476-, CC, Scirocco, Golf Cabriolet, Passat 1239
1 7 2 Removing and installing clutch position sender -G476-, Golf, Golf Estate 1245
1 8 Removing and installing return spring 1246
1 9 Removing and installing over-centre spring 1249
1 9 1 Removing and installing over-centre spring, Scirocco, Golf Cabriolet, LHD vehicles 1249
1 9 2 Removing and installing over-centre spring, Scirocco, Golf Cabriolet, RHD vehicles 1255
1 9 3 Removing and installing over-centre spring, CC, Passat 1260
1 9 4 Removing and installing over-centre spring, Golf, Golf Estate 1262
1 10 Removing and installing clutch pedal 1266
1 10 1 Removing and installing clutch pedal, Scirocco, Golf Cabriolet 1266
1 10 2 Removing and installing clutch pedal, CC, Passat 1267
1 10 3 Removing and installing clutch pedal, Golf, Golf Estate 1269
1 11 Removing and installing mounting bracket 1271
1 11 1 Removing and installing mounting bracket, Scirocco, Golf Cabriolet, LHD vehicles 1271
1 11 2 Removing and installing mounting bracket, Scirocco, Golf Cabriolet, RHD vehicles 1279
1 11 3 Removing and installing mounting bracket, CC, Passat 1287
1 11 4 Removing and installing mounting bracket, Golf, Golf Estate 1292
1 12 Removing and installing clutch master cylinder 1297
1 12 1 Removing and installing clutch master cylinder, CC, Scirocco, Golf Cabriolet, Passat 1297
1 12 2 Removing and installing clutch master cylinder, Golf, Golf Estate 1300
1 13 Removing and installing bleeder 1301
1 14 Removing and installing lines for clutch mechanism 1305
1 15 Removing and installing clutch slave cylinder together with release bearing 1309
1 16 Bleeding clutch mechanism 1311
1 17 Servicing clutch release mechanism 1312
2 Clutch 1314
2 1 Identifying different makes of clutch 1314
2 2 Assembly overview – clutch 1315
2 2 1 Assembly overview – clutch in conjunction with Sachs dual-mass flywheel 1315
2 2 2 Assembly overview – clutch in conjunction with LuK dual-mass flywheel 1316
2 2 3 Assembly overview – clutch with simple flywheel 1317
2 3 Removing and installing clutch 1318
2 3 1 Removing and installing clutch in conjunction with Sachs dual-mass flywheel 1318
2 3 2 Removing and installing clutch in conjunction with LuK dual-mass flywheel 1324
2 3 3 Removing and installing clutch in connection with simple flywheel 1328
34 – Controls, housing 1334
1 Selector mechanism 1334
1 1 Installation position – selector mechanism 1334
1 2 Overview – selector mechanism 1335
1 3 Assembly overview – gear knob and cover 1336
1 3 1 Assembly overview – gear knob and cover, CC, Scirocco, Golf Cabriolet, Passat 1336
1 3 2 Assembly overview – gear lever knob and cover, Golf, Golf Estate 1337
1 4 Assembly overview – gear lever and selector housing, CC, Scirocco, Golf Cabriolet, Passat 1338
1 5 Assembly overview – selector cables, CC, Scirocco, Golf Cabriolet, Passat 1340
1 6 Assembly overview – selector mechanism, Golf, Golf Estate 1342
1 7 Removing and installing gear knob 1344
1 7 1 Removing and installing gear knob, Scirocco, Golf Cabriolet 1344
1 7 2 Removing and installing gear knob, CC, Passat 1347
1 7 3 Removing and installing gear knob, Golf, Golf Estate 1349
1 8 Dismantling and assembling selector mechanism 1351
1 9 Removing and installing selector mechanism 1357
1 10 Removing and installing gear selector cable and gate selector cable 1363
1 11 Repairing selector mechanism 1366
1 12 Adjusting selector mechanism 1371
1 13 Checking selector mechanism 1376
2 Removing and installing gearbox 1377
2 1 Distinguishing between different types of turbo diesel engines 1377
2 2 Removing gearbox 1378
2 2 1 Removing gearbox, Golf, Golf Estate, front-wheel drive vehicle with turbo diesel engine 1378
2 2 2 Removing gearbox, Golf, Golf Estate, front-wheel drive vehicle with petrol engine 1387
2 2 3 Removing gearbox, Golf, Golf Estate, four-wheel drive 1400
2 2 4 Removing gearbox, Golf Cabriolet, vehicles with turbo diesel engine, engine lifting eyes »next to each other« on engine 1410
2 2 5 Removing gearbox, CC and Golf Cabriolet, vehicles with turbo diesel engine, engine lifting eyes fitted »diagonally« on engine 1424
2 2 6 Removing gearbox, CC, Golf Cabriolet with 2 0 l petrol engine, Passat with 1 8 l petrol engine, Scirocco with petrol engine 1438
2 2 7 Removing gearbox, CC, Passat, vehicles with turbo diesel engine, front-wheel drive, Scirocco, vehicles with turbo diesel engine, engine lifting eyes »next to each other« on engine 1453
2 2 8 Removing gearbox, CC, Passat, vehicles with turbo diesel engine, four-wheel drive 1468
2 3 Installing gearbox 1484
2 3 1 Installing gearbox, Golf, Golf Estate, front-wheel drive vehicle with turbo diesel engine 1485
2 3 2 Installing gearbox, Golf, Golf Estate, front-wheel drive vehicle with petrol engine 1492
2 3 3 Installing gearbox, Golf, Golf Estate, four-wheel drive 1502
2 3 4 Installing gearbox, CC and Golf Cabriolet, vehicles with turbo diesel engine, engine lifting eyes fitted »diagonally« on engine 1511
2 3 5 Installing gearbox, CC with 2 0 l petrol engine, Passat with 1 8 l petrol engine, Scirocco with petrol engine, Golf Cabriolet 1522
2 3 6 Installing gearbox, CC, Passat, vehicles with turbo diesel engine, front-wheel drive, Scirocco, Golf Cabriolet, vehicles with turbo diesel engine, engine lifting eyes »next to each other« on engine 1533
2 3 7 Installing gearbox, CC, Passat, vehicles with turbo diesel engine, four-wheel drive 1546
2 4 Specified torques for gearbox 1558
3 Assembly mountings 1559
3 1 Assembly overview – assembly mountings 1559
4 Bevel box 1563
4 1 Assembly overview – bevel box 1563
4 2 Bevel box differences, Golf and Golf estate 1565
4 3 Removing bevel box 1566
4 3 1 Removing bevel box CC, Passat 1566
4 3 2 Removing bevel box Golf and Golf estate 1571
4 4 Installing bevel box 1579
4 4 1 Installing bevel box CC, Passat 1579
4 4 2 Installing bevel box Golf and Golf estate 1583
5 Front differential lock 1589
5 1 Assembly overview – front differential lock 1589
5 2 Allocation of front differential lock 1589
5 3 Removing front differential lock 1589
5 4 Installing front differential lock 1593
6 Gearbox transport 1597
6 1 Gearbox transport 1597
6 2 Transporting front differential lock 1598
7 Gear oil 1599
7 1 Distinguishing between different manual gearbox types when filling oil 1599
7 2 Checking gear oil level 1599
7 2 1 Checking gear oil level, gearboxes “with” oil filler plug 1599
7 2 2 Checking gear oil level, gearboxes “without” oil filler plug 1600
7 2 3 Draining and filling gear oil (only for gearboxes “without” oil filler plug) 1600
7 2 4 Specified torque for oil filler and oil drain plugs 1602
8 Securing to engine and gearbox support 1604
8 1 Installing manual gearbox to engine and gearbox support 1604
8 2 Installing bevel box or front differential lock to engine and gearbox support 1605
9 Dismantling and assembling gearbox 1607
9 1 Schematic overview – gearbox 1607
9 1 1 Schematic overview – gearbox, front-wheel drive 1607
9 1 2 Schematic overview – front differential lock 1608
9 1 3 Schematic overview – gearbox, all-wheel drive 1609
9 2 Assembly overview – gearbox 1610
9 2 1 Assembly overview – gearbox, front-wheel drive 1610
9 2 2 Assembly overview – gearbox for four-wheel drive and gearbox for front-wheel drive with front differential lock 1611
9 3 Assembly overview – gearbox housing and selector mechanism 1612
9 4 Assembly overview – selector unit 1614
9 5 Assembly overview – shafts, differential, selector mechanism 1615
9 5 1 Assembly overview – shafts, differential, selector mechanism, front-wheel drive 1615
9 5 2 Assembly overview – shafts, differential, gear selector, all-wheel drive and front-wheel drive with front differential lock 1617
9 6 Assembly overview – selector forks 1619
9 7 Renewing selector shaft seal 1620
9 8 Dismantling and assembling gearbox 1622
9 8 1 Dismantling gearbox 1622
9 8 2 Assembling gearbox 1633
10 Gearbox housing, clutch housing 1645
10 1 Assembly overview – gearbox housing 1645
10 2 Assembly overview – clutch housing 1647
10 3 Repairing gearbox housing 1649
10 4 Repairing clutch housing 1658
35 – Gears, shafts 1662
1 Input shaft 1662
1 1 Assembly overview – input shaft 1662
1 2 Dismantling and assembling input shaft 1663
1 3 Renewing input shaft seal 1668
2 Output shaft 1671
2 1 Assembly overview – output shaft 1671
2 1 1 Assembly overview – output shaft for 1st to 4th gears 1671
2 1 2 Gearbox with reinforcement measures 1675
2 1 3 Assembly overview – output shaft for 5th, 6th and reverse gears 1677
2 2 Dismantling and assembling output shaft 1679
2 2 1 Dismantling and assembling output shaft for 1st to 4th gears 1679
2 2 2 Dismantling and assembling 1st to 4th gear output shaft, Scirocco, only manual gearbox 02Q 1696
2 2 3 Assembling 1st to 4th gear output shaft – up to gearbox date 25 10 9, only with manual gearbox 02Q 1707
2 2 4 Assembling 1st to 4th gear output shaft, from gearbox date 26 10 9, to gearbox date 24 05 0, only with manual gearbox 02Q 1713
2 2 5 Assembling 1st to 4th gear output shaft, from gearbox date 25 05 0 >, only with manual gearbox 02Q 1720
2 2 6 Dismantling and assembling output shaft for 5th, 6th and reverse gears 1726
2 3 Adjusting output shaft 1738
2 3 1 Adjusting output shaft for 1st to 4th gears 1738
2 3 2 Adjusting output shaft for 5th, 6th and reverse gears 1743
39 – Final drive – differential 1749
1 Oil seals 1749
1 1 Overview of fitting locations – oil seals 1749
1 2 Renewing left seal 1751
1 2 1 Renewing oil seal for left flange shaft 1751
1 3 Renewing right seal 1755
1 3 1 Renewing oil seal for right flange shaft, front-wheel drive 1755
1 3 2 Renewing oil seal for right flange shaft, front-wheel drive with front differential lock 1758
1 3 3 Renewing oil seal for right flange shaft, four-wheel drive 1762
1 3 4 Renewing right seal on manual gearbox, between manual gearbox and bevel box or between manual gearbox and front differential lock 1767
2 Differential 1770
2 1 Assembly overview – differential 1770
2 1 1 Assembly overview – differential, front-wheel drive 1770
2 1 2 Assembly overview – differential, four-wheel drive and front-wheel drive with front differential lock 1772
2 2 Dismantling and assembling differential 1775
2 2 1 Dismantling and assembling differential, front-wheel drive 1775
2 2 2 Dismantling and assembling differential, four-wheel drive, front-wheel drive with front differential lock 1782
2 3 Adjusting differential 1789
3 Adjustment overview 1793
4 Components of bevel box 1794
4 1 Assembly overview – components of bevel box 1794
4 1 1 Assembly overview – components of bevel box, “0AV” 1794
4 1 2 Assembly overview – components of bevel box, “0CN” 1797
4 2 Renewing bevel box seals 1800
4 2 1 Renewing seal between gearbox and bevel box with bevel box removed 1800
4 2 2 Renewing output flange oil seal, bevel box “0AV” (bevel box removed) 1801
4 2 3 Renewing output flange oil seal, bevel box “0CN” (bevel box removed) 1816
4 3 Renewing output flange and redetermining thickness of shim 1827
4 4 Renewing needle bearing (polygon bearing) and oil seal for right flange shaft 1828
5 Components of front differential lock 1833
5 1 Assembly overview – components of front differential lock 1833
5 2 Checking function 1835
5 3 Removing and installing pump -V181- 1835
5 4 Removing and installing coupling for front differential lock 1837
5 5 Removing and installing differential lock control unit -J647- 1837
5 6 Renewing seals for front differential lock 1838
5 6 1 Renewing seal between front differential lock and manual gearbox on front differential lock 1838
5 6 2 Renewing seal for right flange shaft in front differential lock 1840
5 7 Renewing ball bearing for flange shaft 1842
6 Gear oil 1845
6 1 Checking gear oil level 1845
6 1 1 Checking gear oil level in bevel box 1845
6 1 2 Topping up gear oil in bevel box 1846
7 Oil for front differential lock 1852
7 1 Checking oil level for front differential lock 1852
7 2 Draining and filling oil for front differential lock 1853
44 – Wheels, tyres, vehicle geometry 1865
1 Instructions on using the guide 1865
1 1 Overview 1865
1 1 1 Wheels and Tyres Guide – General Information 1865
1 1 2 Wheels and Tyres Guide – Vehicle-specific section 1865
1 2 General information 1865
1 3 Notes 1866
1 4 Determining correct wheel and tyre combinations, according to NEDC with tyre package 1867
1 4 1 Determining the required tyre package via PR number 1867
1 4 2 Determining the required tyre package via version key in the vehicle registration certificate part 1 1867
1 5 Determining correct wheel and tyre combinations according to WLTP 1868
1 5 1 Vehicle registration certificate part 1 1868
1 5 2 COC document, item 0 10 1870
1 6 NEDC, WLTP and RDE 1870
1 6 1 What are NEDC, WLTP and RDE? 1870
1 6 2 What are the differences between WLTP and RDE? 1870
1 6 3 Since when are WLTP and RDE valid? 1870
1 7 Definition of tyre package 1870
1 8 Explanations regarding world regions 1871
2 Legislative and technical conditions 1873
2 1 Legislative conditions 1873
2 1 1 Permissible wheel and tyre combinations in Germany 1873
2 1 2 Vehicles with Tyre Pressure Monitoring System 1873
2 2 Technical conditions 1874
2 3 Load-carrying capacity depending on vehicle speed, winter tyres 1874
2 4 Vehicle registration documents since 01 10 2005 1876
2 5 COC document (EEC Certificate of Conformity) 1877
2 6 EU general type approval number, sales type and sales or trade designation 1877
3 Wheel change 1880
3 1 Fitting instructions 1880
3 2 Protecting wheel centring seat against corrosion 1883
3 3 Fitting wheels 1883
3 4 Position of anti-theft wheel bolts for steel wheels 1884
4 Fitting tyre 1886
4 1 Pressing tyre off wheel rim 1886
4 2 Removing tyre sealant 1887
4 3 Removing tyre from wheel 1887
4 3 1 Removing tyres, wheels without and with tyre pressure monitoring 1887
4 3 2 Removing tyres, run-flat tyres, ultra-high-performance tyres 1889
4 4 Ensuring proper assembly temperature for tyres 1891
4 5 Fitting tyre 1892
4 5 1 Mounting tyre, wheels without and with tyre pressure monitoring 1892
4 5 2 Mounting tyre, run-flat tyres, ultra-high performance tyres 1894
4 6 Matching wheel rims and tyres 1896
4 7 Checking radial and lateral runout of wheels and tyres 1897
4 7 1 Checking radial and lateral runout of wheels and tyres, tolerances 1897
4 7 2 Checking radial and lateral runout on wheels and tyres with tyre gauge 1898
4 8 Matching wheels and tyres 1899
4 9 Balancing wheel 1900
4 9 1 Conditions 1900
4 9 2 Balancing wheel on stationary wheel balancer 1900
4 9 3 Balancing wheel with finish balancer 1903
4 9 4 Checking radial and lateral run-out on wheel rim 1904
4 10 Tyre sealant disposal 1905
5 Tyre Pressure Monitoring System 1906
5 1 System description – Tyre Pressure Monitoring System 1906
5 1 1 System description – Tyre Pressure Monitoring System with indirect measurement (Tyre Pressure Loss Indicator) 1906
5 1 2 System description – Tyre Pressure Monitoring System with direct measurement (with tyre pressure sensor) 1908
5 1 3 Button behaviour – Tyre Pressure Monitoring System with direct measurement (with tyre pressure sensor) 1908
5 1 4 System description – Tyre Pressure Monitoring System, Tyre Pressure Monitoring System (TPMS) with autolocation 1909
5 2 Overview of fitting locations – Tyre Pressure Monitoring System 1910
5 2 1 Overview of fitting locations – Tyre Pressure Monitoring System (TPMS) with autolocation 1910
5 2 2 Overview of fitting locations – Tyre Pressure Monitoring System, Trigger 1911
5 2 3 Overview of fitting locations – Tyre Pressure Monitoring System, Autolocation 1913
5 3 Assembly overview – tyre pressure sensor 1914
5 3 1 Assembly overview – tyre pressure sensor, tyre pressure sensor with valve 1914
5 3 2 Assembly overview – tyre pressure sensor, tyre pressure sensor without valve, version 1 1916
5 3 3 Assembly overview – tyre pressure sensor, tyre pressure sensor without valve, version 2 1918
5 4 Removing and installing tyre pressure sensor -G222-/-G223-/-G224-/-G225- 1919
5 4 1 Removing and installing tyre pressure sensor, tyre pressure sensor with valve 1919
5 4 2 Removing and installing tyre pressure sensor, tyre pressure sensor without valve, version 1 (customer service version) 1920
5 4 3 Removing and installing tyre pressure sensor, tyre pressure sensor without valve, version 1 (production version) 1922
5 4 4 Removing and installing tyre pressure sensor -G222-/-G223-/-G224-/-G225-, version 2 1925
5 5 Removing and installing Tyre Pressure Monitoring System control unit -J502- 1927
5 5 1 Removing and installing Tyre Pressure Monitoring System control unit -J502-, Arteon 2018, Arteon 2021, Arteon Shooting Brake 2021, Passat 2015, Passat Estate 2015, Passat 2019, Passat Estate 2019 1928
5 5 2 Removing and installing tyre Tyre Pressure Monitoring System control unit, Passat 2011, Passat Estate 2011 1930
5 5 3 Removing and installing Tyre Pressure Monitoring System control unit, CC 2010, CC 2012, Passat CC 2009 1930
5 5 4 Removing and installing Tyre Pressure Monitoring System control unit, Phaeton 2003 1930
5 5 5 Removing and installing Tyre Pressure Monitoring System control unit -J502-, Touran 2016 1930
5 5 6 Removing and installing Tyre Pressure Monitoring System control unit -J502-, Tiguan 2008 1931
5 5 7 Removing and installing Tyre Pressure Monitoring System control unit -J502-, Tiguan 2016, Tiguan 2017 (BW2), Tiguan 2021 1932
5 5 8 Removing and installing Tyre Pressure Monitoring System control unit, up to model year 2014, Touareg 2010 1933
5 5 9 Removing and installing Tyre Pressure Monitoring System control unit, as of model year 2015, Touareg 2015 1934
5 5 10 Removing and installing Tyre Pressure Monitoring System control unit, Touareg 2018 1935
5 5 11 Removing and installing bracket for Tyre Pressure Monitoring System control unit, Touareg 2015 1936
5 6 Removing and installing tyre pressure monitor sender unit in wheel housing 1936
5 6 1 Removing and installing sender unit for Tyre Pressure Monitoring System in front left/front right wheel housing -G431/G432-, Touareg 2010, Touareg 2015 1936
5 6 2 Removing and installing sender unit for Tyre Pressure Monitoring System in rear left/rear right wheel housing -G433/G434-, Touareg 2010, Touareg 2015 1937
5 6 3 Removing and installing sender unit for Tyre Pressure Monitoring System in wheel housing, Phaeton 2003 1938
6 Wheel bolts 1939
6 1 Wheel bolts, versions 1939
6 2 Wheel bolts, anti-theft wheel bolt 1941
6 3 Wheel bolts, adapter sets for anti-theft wheel bolts 1941
7 Information on tyres 1944
7 1 Identification markings on the tyre sidewall 1944
7 2 Tyre dimension 1946
7 3 Load rating code/load index (LI) 1946
7 4 Speed rating code 1947
7 5 EU tyre label 1947
7 5 1 EU tyre label, summary 1947
7 5 2 EU tyre label, objectives 1948
7 5 3 EU tyre label, categories 1949
7 6 Structure of a radial belted tyre 1953
7 6 1 Cross section of a radial belted tyre 1953
7 6 2 Run-flat tyres, structure and identification of a SST tyre 1954
7 6 3 Run-flat tyres, seal inside technology 1956
7 7 Run-flat tyre, SST (Self Supporting Tyre) 1959
7 7 1 Run-flat tyres – general information 1959
7 7 2 Run-flat tyres, retrofitting/requirements when using run-flat tyres 1960
7 7 3 Run-flat tyres, repair work 1960
7 8 Tyre storage 1960
7 9 Reinforced and Extra Load (XL) tyres 1961
7 10 M+S tyres 1962
7 11 Winter tyres with speed symbol V 1964
7 12 All-season tyres 1965
7 13 Optimised rolling resistance tyres 1966
7 14 Tyre ageing 1966
7 15 Tyres with flange protection 1968
7 16 Tyre sizes for vehicles with all-wheel drive 1968
7 17 Increase in temperature due to insufficient tyre pressure 1968
8 Tyre sealant 1970
8 1 Models with breakdown set 1970
8 2 Storage life 1970
8 3 Disposal 1970
9 Information about wheels (rims) 1971
9 1 Structure of wheel (rim) 1971
9 2 Identification 1972
9 3 Composite wheels 1973
9 4 Care and maintenance of alloy wheel rims 1973
9 5 Restoring alloy wheels 1973
9 6 Removing and installing hub cover for alloy wheels with open threaded connection 1974
9 7 Renewing trim elements 1975
9 7 1 Renewing trim elements, bonded trim elements 1975
9 7 2 Renewing trim elements, bolted trim elements 1979
9 8 Removing and installing valve 1980
9 8 1 Removing and installing valve, description of the valve 1980
9 8 2 Removing and installing valve, rubber valve 1981
9 8 3 Removing and installing valve, metal valve 1982
10 Handling problems 1984
10 1 Rolling noise 1984
10 1 1 General notes on tyre noise 1984
10 1 2 Flat spots (from locking wheels) 1985
10 2 Vehicle pulls to one side 1986
10 2 1 General information 1986
10 2 2 Conicity 1986
10 2 3 Remedies when vehicle pulls to one side 1988
10 2 4 Strategic rotation of wheels for non-directional tyres 1989
10 2 5 Strategic rotation of wheels having unidirectional tyres 1990
10 3 Vibration 1991
10 3 1 Vibration, causes for vibration 1991
10 3 2 Vibration, conducting a road test before balancing wheels 1991
10 3 3 Vibration, vibration control system 1991
10 4 Eliminating flat spots caused by storage or handling 1992
11 Evaluating tyres 1994
11 1 Flat spots caused by storage or handling 1994
11 2 Undulations 1994
11 3 Saw-tooth wear 1995
11 4 Flat spots caused by hard braking 1995
11 5 Swellings in the tyre sidewall 1995
11 6 Cuts 1997
11 7 Damage caused by foreign bodies 1997
11 8 Stripped profile 1998
11 9 Tyre damage due to insufficient tyre pressure 1998
11 10 Checking tyres 1999
11 11 Damage caused when fitting 2000
12 Tyre wear 2002
12 1 Factors influencing the service life of tyres 2002
12 2 Saw-tooth wear 2003
12 3 Wear behaviour of high-speed tyres 2004
12 4 Measuring tread depth 2004
12 5 One-sided wear 2005
12 6 Outer shoulder wear 2007
12 7 Diagonal washout 2008
12 8 Wear in middle of tyre 2009
12 9 Permissible deviation in tread depth 2009
13 Overview of components 2010
13 1 Assembly overview – wheel 2010
14 Snow chains 2013
14 1 Assembly and use of snow chains 2013
15 Regular and temporary spare wheels, recommended temporary spare tyres 2014
15 1 Spare wheel with yellow sticker 2014
15 2 Temporary spare wheels and recommended temporary spare tyres 2015
15 2 1 Atlas 2017 2015
15 2 2 Golf 2013, e-Golf 2014 2015
15 2 3 Golf 2017, e-Golf 2017 2015
15 2 4 Golf SV 2015 2015
15 2 5 Golf Variant 2014 2016
15 2 6 Golf Variant 2017 2016
15 2 7 Golf 2018 (AU2/BX6) 2016
15 2 8 Jetta 2018 2016
15 2 9 Taos 2021 2017
00 – Technical data 2024
1 Identification 2024
1 1 Engine number, engine data 2024
2 Safety instructions 2026
2 1 Safety precautions when working on fuel supply system 2026
2 1 1 Releasing pressure in high-pressure area 2027
2 2 Safety precautions when working on cooling system 2027
2 3 Safety precautions when working on ignition system 2028
3 Repair instructions 2030
3 1 Rules for cleanliness 2030
10 – Removing and installing engine 2031
1 Removing and installing engine 2031
1 1 Removing engine 2031
1 2 Installing engine 2040
2 Assembly mountings 2044
2 1 Assembly overview – assembly mountings 2044
13 – Crankshaft group 2046
1 Cylinder block (pulley end) 2046
1 1 Assembly overview – poly V-belt drive 2046
1 2 Assembly overview – cylinder block (pulley end) 2048
1 3 Removing and installing poly V-belt 2051
1 3 1 Poly V-belt routing 2052
1 4 Removing and installing ancillary bracket 2053
1 5 Removing and installing poly V-belt pulley 2054
1 6 Renewing crankshaft oil seal – belt pulley end 2056
2 Cylinder block, gearbox end 2060
2 1 Assembly overview – cylinder block, gearbox end 2060
2 2 Removing and installing sealing flange on gearbox side 2061
2 2 1 Pressing sealing flange with sender wheel off crankshaft 2062
2 2 2 Pressing sealing flange with sender wheel onto crankshaft 2063
2 2 3 A – Assembling seal with sender wheel on assembly tool -T10134- 2063
2 2 4 B – Attaching assembling tool -T10134- with sealing flange on crankshaft flange 2065
2 2 5 C – Bolting assembly tool -T10134- onto crankshaft flange 2066
2 2 6 D – Pressing sender wheel onto crankshaft flange using assembly tool -T10134- 2067
2 2 8 F – Re-pressing sender wheel 2068
3 Crankshaft 2070
3 1 Assembly overview – crankshaft 2070
3 2 Renewing needle bearing in crankshaft 2071
3 3 Crankshaft dimensions 2072
4 Pistons and conrods 2073
4 1 Assembly overview – pistons and conrods 2073
4 2 Checking piston and cylinder bore 2075
4 2 1 Checking piston 2075
4 2 2 Checking cylinder bores 2076
4 3 Separating new conrod 2076
4 4 Removing and installing pistons 2076
4 5 Removing and installing oil spray jets 2077
15 – Cylinder head, valve gear 2079
1 Cylinder head 2079
1 1 Assembly overview – cylinder head 2079
1 2 Removing and installing cylinder head 2082
1 2 1 Removing 2082
1 2 2 Installing 2083
1 3 Removing and installing camshaft housing 2084
1 3 1 Removing 2086
1 3 2 Installing 2087
1 4 Checking compression 2090
2 Cover for timing chain 2093
2 1 Removing and installing valve timing housing 2093
3 Chain drive 2097
3 1 Removing and installing timing chain and chain drive for oil pump 2097
3 2 Checking valve timing 2105
3 3 Adjusting valve timing 2108
3 4 Checking timing chain 2115
4 Valve gear 2123
4 1 Assembly overview – valve gear 2123
4 2 Measuring axial clearance of camshaft 2124
4 3 Removing and installing valve stem seals 2125
4 3 1 Removing 2126
4 3 2 Installing 2127
5 Inlet and exhaust valves 2128
5 1 Reworking valve seats 2128
5 2 Checking valve guides 2129
17 – Lubrication 2130
1 Sump, oil pump 2130
1 1 Assembly overview – sump / oil pump 2130
1 2 Engine oil 2133
1 3 Removing and installing oil sump 2133
1 4 Removing and installing oil pump 2135
2 Oil filter, oil pressure switch 2138
2 1 Checking oil pressure and oil pressure switch 2138
19 – Cooling 2140
1 Cooling system, coolant 2140
1 1 Coolant hose schematic diagram 2140
1 2 Assembly overview – engine preheater 2142
1 3 Removing and installing engine preheater heater element -Z97- 2143
1 4 Checking cooling system for leaks 2145
1 5 Draining and filling coolant 2147
2 Coolant pump, regulation of cooling system 2153
2 1 Assembly overview – coolant pump, thermostat 2153
2 2 Electric coolant pump 2155
2 3 Removing and installing coolant pump 2156
2 4 Removing and installing coolant pump pulley 2163
3 Radiator, radiator fan 2171
3 1 Assembly overview – radiator/radiator fan 2171
3 2 Removing and installing radiator 2172
3 3 Removing and installing radiator cowling 2174
3 4 Removing and installing radiator module 2175
21 – Turbocharging/supercharging 2176
1 Turbocharger 2176
1 1 Assembly overview – turbocharger 2176
1 2 Removing and installing turbocharger 2180
1 3 Checking vacuum unit for turbocharger 2185
1 4 Adjusting vacuum unit for turbocharger 2187
1 5 Renewing vacuum unit for turbocharger 2192
2 Charge air system 2195
2 1 Assembly overview – charge air system 2195
2 1 1 Fitting hose connections with plug-in connectors 2197
2 2 Removing and installing charge air cooler 2198
2 3 Checking charge air system for leaks 2202
3 Supercharger 2205
3 1 Assembly overview – supercharger 2205
3 2 Removing and installing supercharger 2207
3 3 Removing and installing drive unit seal for supercharger 2214
24 – Mixture preparation – injection 2218
1 Injectors 2218
1 1 Assembly overview – fuel rail with injectors 2218
1 2 Removing and installing injectors 2220
1 3 Renewing seals on injectors 2222
2 Air filter 2227
2 1 Assembly overview – air filter housing 2227
2 2 Removing and installing air filter housing 2228
3 Intake manifold 2229
3 1 Assembly overview – intake manifold 2229
3 2 Removing and installing throttle valve module 2234
3 3 Cleaning throttle valve module 2236
3 4 Removing and installing regulating flap control unit 2237
4 Senders and sensors 2240
4 1 Checking fuel pressure sender 2240
5 Engine control unit 2244
5 1 Removing and installing engine control unit 2244
5 2 Removing and installing engine control unit with protective housing 2245
6 High-pressure pump 2248
6 1 Assembly overview – high-pressure pump 2248
6 2 Removing and installing high-pressure pump 2249
26 – Exhaust system 2253
1 Exhaust pipes, silencers 2253
1 1 Assembly overview – silencers 2253
1 2 Removing and installing front exhaust pipe 2255
1 3 Separating exhaust pipes, silencers 2256
1 4 Aligning exhaust system free of stress 2258
1 5 Installation position of clamp 2259
2 Cleansing exhaust emissions 2260
2 1 Assembly overview – emission control 2260
2 2 Removing and installing catalytic converter 2261
28 – Ignition system 2264
1 Ignition system 2264
1 1 Assembly overview – ignition system 2264
1 2 Test data, spark plugs 2265
1 3 Removing and installing ignition coils with output stage 2265
1 4 Removing and installing engine speed sender 2267
00 – Technical data 2273
1 Safety information 2273
1 1 Safety regulations for working on fuel supply 2273
1 2 Safety precautions when working on vehicles with a start/stop system 2273
1 3 Safety precautions when using testers and measuring instruments during a road test 2273
2 Identification 2275
2 1 Engine number/engine data 2275
3 General information 2276
3 1 Rules for cleanliness when working on auxiliary/supplementary heater and fuel system 2276
20 – Fuel supply system 2277
1 Fuel 2277
1 1 Assembly overview – fuel tank 2277
1 2 Removing and installing fuel tank 2278
1 3 Emptying fuel tank 2283
1 3 1 Emptying fuel tank when fuel pump is intact 2283
1 3 2 Emptying fuel tank if it is more than 3/4 full 2285
1 3 3 Emptying fuel tank if it is less than 3/4 full 2286
2 Fuel delivery unit, fuel gauge sender 2289
2 1 Removing and installing fuel delivery unit, fuel gauge sender 2289
2 2 Removing and installing fuel gauge sender 2293
2 2 1 Removing and installing fuel gauge sender -G- 2293
3 Separating plug-in connectors 2295
4 Fuel filter 2299
5 Activated charcoal filter system 2300
5 1 Assembly overview – activated charcoal filter system 2300
5 2 Checking fuel tank breather 2301
6 Accelerator pedal 2304
6 1 Assembly overview – accelerator module 2304
6 2 Removing and installing accelerator pedal module 2304
7 Fuel pump 2306
7 1 Checking fuel pump 2306
7 1 1 Checking function and voltage supply 2306
7 1 2 Checking fuel pressure 2309
7 1 3 Checking holding pressure 2311
7 1 4 Checking fuel delivery rate 2315
7 1 5 Checking current consumption 2323
00 – Technical data 2330
1 Safety information 2330
1 1 Safety regulations for working on fuel supply 2330
1 2 Safety precautions when working on vehicles with a start/stop system 2331
1 3 Safety precautions when using testers and measuring instruments during a road test 2331
1 4 Safety precautions when working on the SCR system 2331
2 Identification 2333
2 1 Engine number/engine data 2333
3 General information 2334
3 1 Rules for cleanliness when working on auxiliary/supplementary heater and fuel system 2334
20 – Fuel supply system 2335
1 Procedure should vehicle be misfueled 2335
1 1 Step 1: engine was started with incorrect fuel 2335
1 2 Step 2: engine was not started with incorrect fuel 2336
1 3 Step 3: swarf in fuel delivery unit and fuel tank 2337
1 4 Step 4: no swarf in fuel delivery unit or fuel tank 2338
1 5 Step 5: swarf in high-pressure pump 2338
1 6 Step 6: swarf in high-pressure pump 2339
2 Fuel 2340
2 1 Assembly overview – fuel tank 2340
2 1 1 Assembly overview – fuel tank, vehicles with front-wheel drive 2340
2 1 2 Assembly overview – fuel tank, vehicles with four-wheel drive 2343
2 2 Removing and installing fuel tank 2345
2 2 1 Removing and installing fuel tank – vehicles with front-wheel drive 2345
2 2 2 Removing and installing fuel tank – vehicles with four-wheel drive 2348
2 3 Emptying fuel tank 2352
2 3 1 Emptying fuel tank when fuel pump is intact 2352
2 3 2 Emptying fuel tank if it is more than 3/4 full 2355
2 3 3 Emptying fuel tank with fuel tank less than 3/4 full, vehicles with front-wheel drive 2356
2 3 4 Emptying fuel tank with fuel tank less than 3/4 full, vehicles with four-wheel drive 2358
3 Fuel delivery unit, fuel gauge sender 2362
3 1 Assembly overview – fuel delivery unit/fuel gauge sender 2362
3 2 Removing and installing fuel delivery unit, fuel gauge sender 2363
3 2 1 Removing and installing fuel delivery unit/fuel gauge, engine codes CBAA, CBAB, CBAC, CBBB 2363
3 2 2 Removing and installing fuel delivery unit/fuel gauge, engine codes CFFA, CFFB, CFGB, CLLA 2365
3 3 Removing and installing fuel gauge sender 2369
3 3 1 Removing and installing fuel gauge sender -G-, engine codes CBAA, CBAB, CBAC, CBBB 2369
3 3 2 Removing and installing fuel gauge sender -G-, engine codes CFFA, CFFB, CFGB, CLLA 2370
3 3 3 Removing and installing fuel gauge sender 2 -G169- 2371
4 Separating plug-in connectors 2374
5 Fuel filter 2378
5 1 Assembly overview – fuel filter 2378
5 1 1 Assembly overview – fuel filter, engine codes CBAA, CBAB, CBAC, CBBB 2378
5 1 2 Assembly overview – fuel filter, engine codes CFFA, CFFB, CFGB, CLLA 2379
5 1 3 Assembly overview – upper part of fuel filter 2380
5 1 4 Fuel hoses in the engine compartment 2381
5 2 Removing and installing fuel filter 2382
5 2 1 Removing and installing fuel filters, engine codes CBAA, CBAB, CBBB, CBAC 2382
5 2 2 Removing and installing fuel filter, engine codes CFFA, CFFB, CFGB, CLLA 2382
5 2 3 Removing and installing upper part of fuel filter, engine codes CBAA, CBAB, CBAC, CBBB 2383
6 Accelerator pedal 2387
6 1 Assembly overview – accelerator module 2387
6 2 Removing and installing accelerator pedal module 2387
7 Fuel pump 2391
7 1 Checking fuel pump 2391
7 1 1 Checking delivery pressure and fuel delivery quantity of fuel system pressurisation pump -G6-, CFFA, CFFB, CFGB, CLLA 2391
7 1 2 Checking delivery pressure of the fuel pump, engine codes CBAA, CBAB, CBBB, CBAC 2397
7 1 3 Checking supplementary fuel pump -V393- or fuel pump 2 -V277-, engine codes CBAA, CBAB, CBBB, CBAC 2399
7 1 4 Checking fuel delivery rate of fuel system pressurisation pump -G6-, engine codes CBAA, CBAB, CBBB, CBAC 2401
7 1 5 Checking voltage supply of fuel pump, engine codes CBAA, CBAB, CBBB, CBAC 2404
7 1 6 Checking current draw of fuel pump, engine codes CBAA, CBAB, CBBB, CBAC 2405
7 1 7 Checking current draw of fuel pump -G6-, engine codes CFFA, CFFB, CFGB, CLLA 2407
7 1 8 Checking voltage supply of fuel pump -G6-, engine codes CFFA, CFFB, CFGB, CLLA 2409
7 2 Removing and installing fuel pump 2410
7 2 1 Removing and installing supplementary fuel pump -V393- or fuel pump 2 -V277- 2410
7 3 Removing and installing suction-jet pump 2412
00 – Technical data 2420
1 Safety information 2420
1 1 Safety regulations for working on fuel supply 2420
1 2 Safety precautions when using testers and measuring instruments during a road test 2421
1 3 Safety precautions when working on the cooling system 2421
1 4 Safety precautions when working on ignition system 2422
2 Identification 2424
2 1 Engine number/engine data 2424
3 Repair instructions 2426
3 1 Rules for cleanliness 2426
3 2 Foreign objects in engine 2426
10 – Removing and installing engine 2427
1 Removing and installing engine 2427
1 1 Removing engine 2427
1 1 1 Removing engine, Sharan 2427
1 1 2 Removing engine, Passat, CC and Golf Cabriolet 2441
1 2 Separating engine and gearbox 2456
1 3 Securing engine on engine and gearbox support 2457
1 4 Installing engine 2459
2 Assembly mountings 2461
2 1 Assembly overview – assembly mountings 2461
2 1 1 Assembly overview – assembly mountings, Sharan 2461
2 1 2 Assembly overview – assembly mountings, Passat, CC and Golf Cabriolet 2463
2 2 Supporting engine in installation position 2465
2 2 1 Supporting engine in installation position, Sharan 2465
2 2 2 Supporting engine in installation location, Passat and CC 2468
2 2 3 Supporting engine in installation position, Golf Cabriolet 2471
2 3 Checking adjustment of assembly mountings 2473
2 4 Adjusting assembly mountings 2473
3 Engine cover panel 2477
3 1 Removing and installing engine cover 2477
13 – Crankshaft group 2478
1 Cylinder block (pulley end) 2478
1 1 Assembly overview – poly V-belt drive 2478
1 2 Removing and installing poly-V belt 2481
1 3 Removing and installing tensioner for poly V-belt 2482
1 4 Removing and installing bracket for ancillaries 2485
1 5 Removing and installing vibration damper 2487
1 6 Renewing oil seal for vibration damper 2495
2 Cylinder block, gearbox end 2498
2 1 Assembly overview – cylinder block, gearbox end 2498
2 2 Removing and installing flywheel 2499
2 3 Removing and installing sealing flange on gearbox side 2501
2 3 1 Removing and installing sealing flange on gearbox side, version A sealing lip faces outwards 2501
2 3 2 Removing and installing sealing flange on gearbox side, version B sealing lip faces engine 2505
3 Crankshaft 2510
3 1 Assembly overview – crankshaft 2510
3 2 Renewing needle bearing in crankshaft 2512
3 3 Crankshaft dimensions 2514
3 4 Measuring axial clearance of crankshaft 2515
3 5 Measuring radial clearance of crankshaft 2516
3 6 Allocation of main bearing shells 2516
3 7 Removing and installing sender wheel 2517
4 Balancer shaft 2519
4 1 Assembly overview – balance shaft 2519
4 2 Removing and installing balance shaft for inlet camshaft 2522
4 3 Removing and installing balance shaft for exhaust camshaft 2526
5 Pistons and conrods 2530
5 1 Assembly overview – pistons and conrods 2530
5 2 Removing and installing pistons 2534
5 3 Checking pistons and cylinder bores 2536
5 4 Separating new conrod 2539
5 5 Checking radial clearance of conrods 2539
15 – Cylinder head, valve gear 2541
1 Cylinder head 2541
1 1 Assembly overview – cylinder head 2541
1 2 Renewing oil non-return valve in cylinder head 2545
1 3 Removing and installing cylinder head 2546
1 3 1 Removing and installing cylinder head 2547
1 3 2 Removing and installing cylinder head and camshaft timing chain 2574
1 4 Checking compression 2587
1 5 Removing and installing vacuum pump 2589
2 Cover for timing chain 2591
2 1 Assembly overview – cover for timing chain 2591
2 2 Removing and installing upper timing chain cover 2594
2 3 Removing and installing timing chain cover (bottom) 2596
3 Chain drive 2604
3 1 Assembly overview – camshaft timing chains 2604
3 2 Removing and installing camshaft timing chain 2606
3 3 Removing and installing drive chain for balance shaft 2623
3 4 Checking valve timing 2623
4 Valve gear 2626
4 1 Assembly overview – valve gear 2626
4 2 Removing and installing camshaft 2629
4 3 Removing and installing camshaft control valve 1 -N205- 2649
4 4 Measuring axial play of camshaft 2650
4 5 Removing and installing valve stem seals 2651
5 Inlet and exhaust valves 2657
5 1 Checking valve guides 2657
17 – Lubrication 2659
1 Sump, oil pump 2659
1 1 Assembly overview – sump/oil pump 2659
1 2 Removing and installing lower part of sump 2662
1 3 Removing and installing upper part of sump 2665
1 4 Removing and installing oil pump 2670
1 5 Engine oil: 2673
2 Engine oil cooler 2675
2 1 Removing and installing engine oil cooler 2675
3 Crankcase ventilation 2677
3 1 Removing and installing oil separator 2677
4 Oil filter, oil pressure switch 2678
4 1 Assembly overview – oil filter/oil pressure switch 2678
4 1 1 Assembly overview – oil filter/oil pressure switch, engine codes CCTA, CBFA 2678
4 1 2 Assembly overview – oil filter/oil pressure switch, engine codes CCZA, CCZB, CDAA, CDAB 2680
4 2 Removing and installing oil pressure switch 2682
4 2 1 Removing and installing oil pressure switch F1 (blue), engine codes CCZA, CCZB, CDAA, CDAB 2682
4 2 2 Removing and installing oil pressure switch for reduced oil pressure F378 (brown), engine codes CCZA, CCZB, CDAA, CDAB 2683
4 3 Checking oil pressure and oil pressure switch 2683
4 3 1 Checking oil pressure and oil pressure switch, engine codes CCZA, CCZB, CDAA, CDAB 2684
4 3 2 Checking oil pressure and oil pressure switch, engine codes CCTA, CBFA 2686
4 4 Removing and installing oil pressure control valve, engine codes CCZA, CCZB, CDAA, CDAB 2688
19 – Cooling 2690
1 Cooling system/coolant 2690
1 1 Connection diagram – coolant hoses 2690
1 2 Draining and adding coolant 2691
1 3 Checking cooling system for leaks 2698
2 Coolant pump, regulation of cooling system 2702
2 1 Assembly overview – coolant pump, thermostat 2702
2 2 Assembly overview – electric coolant pump 2705
2 3 Removing and installing continued coolant circulation pump -V51- 2706
2 4 Removing and installing coolant pump with thermostat housing 2708
2 5 Removing and installing coolant pump on thermostat housing 2710
2 6 Removing and installing toothed belt for coolant pump 2713
2 7 Renewing oil seal for coolant pump drive 2716
2 8 Removing and installing thermostat 2717
2 9 Removing and installing coolant temperature sender -G62- 2720
3 Coolant pipes 2723
3 1 Assembly overview – coolant pipes 2723
3 2 Removing and installing front coolant pipes 2723
3 3 Removing and installing small coolant pipe 2726
4 Radiator, radiator fan 2729
4 1 Assembly overview – radiator/radiator fan 2729
4 1 1 Assembly overview – radiator/radiator fan, Sharan 2729
4 1 2 Assembly overview – radiator and radiator fan, Passat, CC and Golf Cabriolet 2730
4 2 Removing and installing radiator 2731
4 2 1 Removing and installing radiator, Sharan 2731
4 2 2 Removing and installing radiator, Passat, CC and Golf Cabriolet 2734
4 3 Removing and installing radiator cowl 2735
4 4 Removing and installing radiator fan -V7- and radiator fan 2 -V177- 2737
21 – Turbocharging/supercharging 2738
1 Turbocharger 2738
1 1 Overview – turbocharger 2738
1 2 Assembly overview – turbocharger, part I for engine codes CDAA, CDAB 2739
1 3 Assembly overview – turbocharger, part I for engine codes CBFA, CCTA, CCZA, CCZB 2741
1 4 Assembly overview – turbocharger, part II 2742
1 5 Assembly overview – turbocharger, part III 2743
1 6 Assembly overview – turbocharger, part IV 2745
1 7 Removing and installing turbocharger 2746
1 8 Checking vacuum unit for turbocharger 2755
1 9 Adjusting vacuum unit for turbocharger 2756
1 10 Renewing vacuum unit for turbocharger 2761
2 Charge air system 2763
2 1 Assembly overview – charge-air hose connections 2763
2 2 Assembly overview – charge air system 2765
2 3 Schematic overview – charge air system 2765
2 4 Removing and installing charge air cooler 2766
2 4 1 Removing and installing charge air cooler, Passat, CC and Sharan 2766
2 4 2 Removing and installing charge air cooler, Golf Cabriolet 2769
2 5 Checking charge air system for leaks 2771
24 – Mixture preparation – injection 2775
1 Injection system 2775
1 1 Overview of fitting locations – injection system 2775
2 Injectors 2782
2 1 Assembly overview – fuel rail with injectors 2782
2 2 Removing and installing injectors 2784
2 3 Renewing seals on injectors 2788
2 4 Cleaning injectors 2790
3 High-pressure pump 2793
3 1 Assembly overview – high-pressure pump 2793
3 2 Removing and installing high-pressure pump 2795
4 Senders and sensors 2798
4 1 Assembly overview – actuator for structure-borne sound and control unit for structure-borne sound, Golf Cabriolet 2798
4 2 Removing and installing air mass meter -G70- 2798
4 3 Removing and installing fuel pressure sender -G247- 2799
4 4 Checking fuel pressure sender -G247- 2801
5 Intake manifold 2805
5 1 Assembly overview – intake manifold 2805
5 2 Removing and installing intake manifold with fuel rail 2807
5 2 1 Disconnecting fuel rail from intake manifold 2814
5 3 Removing and installing throttle valve module -J338- 2815
5 4 Cleaning throttle valve module -J338- 2816
5 5 Checking intake manifold change-over 2818
6 Air filter 2820
6 1 Assembly overview – air filter housing 2820
6 2 Removing and installing air filter housing 2822
7 Engine control unit 2823
7 1 Removing and installing engine control unit 2823
7 1 1 Removing and installing engine control unit, Sharan 2823
7 1 2 Removing and installing engine control unit, Passat, CC and Golf Cabriolet 2824
7 2 Removing and installing engine control unit with protective housing 2826
7 2 1 Removing and installing engine control unit with protective housing, Sharan 2826
7 2 2 Removing and installing engine control unit with protective housing, Passat, CC and Golf Cabriolet 2828
26 – Exhaust system 2832
1 Exhaust pipes and silencers 2832
1 1 Assembly overview – silencers 2832
1 1 1 Assembly overview – silencers, Sharan 2832
1 1 2 Assembly overview – silencers, Passat and CC with front-wheel drive 2833
1 1 3 Assembly overview – silencers, Passat with all-wheel drive 2834
1 1 4 Assembly overview – silencers, Golf Cabriolet 2836
1 2 Separating exhaust pipes from silencers 2838
1 2 1 Separating exhaust pipes/silencers, Sharan 2838
1 2 2 Separating exhaust pipes/silencers, Passat and CC with front-wheel drive 2839
1 2 3 Separating exhaust pipes and silencers, Passat with all-wheel drive 2841
1 2 4 Separating exhaust pipes/silencers, Golf Cabriolet 2843
1 3 Aligning exhaust system free of stress 2844
1 3 1 Aligning exhaust system free of stress, Sharan 2844
1 3 2 Aligning exhaust system free of stress, Passat, CC and Golf Cabriolet 2846
1 4 Installation position of clamp 2847
1 5 Checking exhaust system for leaks 2848
2 Emission control 2850
2 1 Assembly overview – emission control 2850
2 1 1 Assembly overview – exhaust gas treatment, Sharan 2850
2 1 2 Assembly overview – cleansing exhaust emissions, Passat, CC and Golf Cabriolet 2852
2 2 Removing and installing catalytic converter 2854
2 2 1 Removing and installing catalytic converter, Passat, CC and Golf Cabriolet 2854
2 2 2 Removing and installing catalytic converter, Sharan 2857
3 Exhaust manifold 2860
4 Secondary air system – engine code CBFA 2861
4 1 Assembly overview – secondary air system 2861
4 2 Removing and installing secondary air pump motor -V101- 2861
4 3 Removing and installing secondary air inlet valve -N112- 2862
28 – Ignition system 2864
1 Ignition system 2864
1 1 Assembly overview – ignition system 2864
1 2 Removing and installing ignition coils with output stage 2865
1 3 Removing and installing knock sensor I -G61- 2866
1 4 Removing and installing engine speed sender -G28- 2867
1 5 Test data, spark plugs 2868
00 – Technical data 2874
1 Identification 2874
1 1 Gearbox identification 2874
1 1 1 Identification on gearbox 2874
1 1 2 Reading gearbox code letters 2875
2 General information 2877
2 1 Allocation gearbox – engine 2877
2 1 1 Golf Cabriolet 2012 ► 2877
2 1 2 CC 2012 ► 2877
2 1 3 Passat 2011 ► 2877
2 1 4 Tiguan 2008 ► 2878
2 2 Capacities 2878
3 Safety information 2879
3 1 General safety provisions 2879
3 2 Safety measures when working on vehicles with a start/stop system 2879
3 3 Notes on tow-starting/towing 2880
4 Repair notes 2881
4 1 General repair instructions 2881
4 1 1 General information 2881
4 1 3 Oil filter change – »Yes or no?« 2882
4 2 Gaskets and seals 2883
4 3 Nuts and bolts 2883
5 Electrical components 2884
5 1 Overview of fitting locations – electrical components 2884
30 – Clutch 2886
1 Clutch 2886
1 1 Assembly overview – dual clutch 2886
1 2 Removing and installing clutch end cover 2888
1 3 Removing dual clutch 2894
1 4 Installing dual clutch 2895
34 – Controls, housing 2901
1 Mechatronic unit 2901
1 1 Removing and installing mechatronic unit for dual clutch gearbox -J743- 2901
1 1 1 Removing and installing mechatronic unit for dual clutch gearbox -J743-, gearbox installed 2901
1 1 2 Removing and installing mechatronic unit for dual clutch gearbox -J743-, gearbox removed 2911
1 1 3 Renewing securing clip on vehicle connector 2919
1 2 Removing and installing gearbox input speed sender -G182- and clutch temperature sender -G509- 2920
2 Selector mechanism 2922
2 1 Assembly overview – selector mechanism 2922
2 2 Emergency release from position P 2923
2 3 Removing and installing selector lever handle 2924
2 3 1 Removing and installing handle 2924
2 3 2 Moving push button in the handle to installation position 2925
2 4 Removing and installing selector mechanism 2927
2 4 1 Removing and installing selector mechanism with selector housing 2927
2 4 2 Removing and installing selector mechanism without selector housing 2929
2 5 Checking selector mechanism 2931
2 6 Checking and adjusting selector lever cable 2932
2 7 Renewing oil seal for selector shaft 2934
3 Removing and installing gearbox 2937
3 1 Distinguishing between different types of engines, Golf Cabriolet 2012 ►, Tiguan 2008 ►, CC 2012 ► 2937
3 1 1 Distinguishing between different types of diesel engines, Golf Cabriolet 2012 ►, CC 2012 ►, vehicles with front-wheel drive 2937
3 1 2 Distinguishing between different types of 1 4 l petrol engines, Tiguan 2008 ► 2937
3 2 Removing gearbox 2939
3 2 3 Removing gearbox, Golf Cabriolet with 2 0 l petrol engine 2953
3 2 4 Removing gearbox, Passat 2011 ►, CC 2012 ► with 2 0 l petrol engine, front-wheel drive 2959
3 2 5 Removing gearbox, Passat 2011 ► with 2 0 l petrol engine, all-wheel drive 2965
3 2 6 Removing gearbox, Passat 2011 ► with diesel engine, front-wheel drive 2974
3 2 9 Removing gearbox, Passat 2011 ►, CC 2012 ► with diesel engine, all-wheel drive 3002
3 2 10 Removing gearbox, Passat 2011 ►, CC 2012 ► with 3 6 l – V6 petrol engine, all-wheel drive 3012
3 2 11 Removing gearbox, Tiguan 2008 ► with 1 4 l – 118 kW petrol engine, engine lifting eyes »at rear« of engine 3020
3 3 Installing gearbox 3036
3 4 Specified torques for gearbox 3041
4 Transporting gearbox 3043
5 Installing to engine and gearbox support 3044
6 Bevel box 3045
6 1 Removing bevel box 3045
6 1 1 Removing bevel box, CC 2012 ►, Passat 2011 ►, with diesel engine 3045
6 1 2 Removing bevel box, CC 2012 ►, Passat 2011 ► with 3 6 l – V6 petrol engine 3050
6 1 3 Removing bevel box, Passat 2011 ► with 2 0 l petrol engine 3054
6 2 Installing bevel box 3058
6 2 1 Installing bevel box, CC 2012 ►, Passat 2011 ►, with diesel engine 3058
6 2 2 Installing bevel box, CC 2012 ►, Passat 2011 ► with 3 6 l – V6 petrol engine 3059
6 2 3 Installing bevel box, Passat 2011 ► with 2 0 l petrol engine 3061
7 Dismantling and assembling gearbox 3063
7 1 Assembly overview – gearbox 3063
8 Gear oil circuit 3066
8 1 Removing and installing gear oil cooler 3066
8 2 Removing and installing gear oil pump 3068
8 3 Removing and installing gear oil filter 3072
9 Gear oil 3074
9 1 Checking gear oil level 3074
9 2 Draining and filling gear oil 3077
35 – Gears, shafts 3081
1 Currently, no repairs can be made to gears and shafts 3081
39 – Final drive – differential 3082
1 Final drive seals 3082
1 1 Overview of fitting locations – seals 3082
1 2 Renewing left oil seal 3082
1 3 Renewing right oil seal 3086
1 3 1 Renewing right oil seal, front wheel drive 3086
1 3 2 Renewing right oil seal, all-wheel drive 3089
2 Bevel box 3091
2 1 Assembly overview – bevel box 3091
2 2 Removing and installing right flange shaft 3092
2 3 Renewing needle bearing (polygon bearing) for right output shaft drive flange 3094
2 4 Renewing output flange and redetermining thickness of shim, bevel box removed 3096
2 5 Renewing seal on gearbox between bevel box and gearbox 3105
2 6 Renewing seal for right flange shaft on outside of bevel box 3107
2 7 Renewing seal on bevel box between gearbox and bevel box 3107
2 8 Renewing oil seal for drive flange and bevel box 3109
3 Gear oil 3120
3 1 Checking gear oil level 3120
3 1 1 Checking gear oil in bevel box 3120
3 1 2 Filling gear oil in bevel box 3120
00 – Technical data 3128
1 Identification 3128
1 1 Gearbox identification 3128
2 Overview – power transmission 3129
3 Technical data 3130
3 1 Allocation gearbox – engine 3130
3 1 1 CC 2012 ► 3130
3 1 2 Golf Cabriolet 2012 ► 3130
3 1 3 Passat 2011 ► 3130
3 2 Capacities 3130
4 Safety information 3132
4 1 General safety provisions 3132
4 2 Safety measures when working on vehicles with a start/stop system 3132
5 Repair notes 3133
5 1 General repair instructions 3133
5 1 1 Tools 3133
5 1 2 Gearbox 3133
5 1 3 Bearing 3135
5 1 4 Oil 3135
5 1 5 Initiating basic setting 3135
5 2 Gaskets and seals 3136
5 3 Nuts and bolts 3136
30 – Clutch 3137
1 Clutch 3137
1 1 Assembly overview – dual clutch 3137
1 1 1 Assembly overview – dual clutch, gearboxes made up to 05 2011 3137
1 1 2 Assembly overview – dual clutch, gearboxes made as of 06 2011 3139
1 2 Removing and installing the dual clutch 3140
1 2 1 Removing dual clutch 3140
1 2 2 Installing dual clutch 3145
1 3 Renewing input shaft seal 3150
1 3 1 Renewing outer seals 3150
1 3 2 Renewing inner seals 3152
2 Clutch operation 3154
2 1 Assembly overview – clutch engagement 3154
2 1 1 Assembly overview – clutch engagement, gearboxes made up to 05 2011 3154
2 1 2 Assembly overview – clutch engagement, gearboxes made as of 06 2011 3155
2 2 Removing and installing clutch engagement 3156
2 2 1 Removing and installing clutch engagement, gearboxes made up to 05 2011 3156
2 2 2 Removing and installing clutch engagement, gearboxes made from 06 2011 onwards 3159
2 3 Adjusting clutch engagement 3163
2 3 1 Adjusting clutch engagement, gearboxes up to 05 2011 3163
2 3 2 Adjusting clutch engagement, gearboxes as of 06 2011 3174
34 – Controls, housing 3186
1 Mechatronic unit 3186
1 1 Overview – mechatronic unit 3186
1 2 Removing and installing mechatronic unit 3189
1 2 1 Removing mechatronic unit 3189
1 2 2 Moving mechatronic unit into »removal position« by hand 3200
1 2 3 Installing mechatronic unit 3202
1 3 Renewing clutch actuator 3209
1 4 Renewing control unit for mechatronic unit for dual clutch gearbox -J743- 3215
2 Selector mechanism 3220
2 1 Assembly overview – selector mechanism 3220
2 2 Emergency release from position P 3221
2 3 Removing and installing selector lever handle 3221
2 3 1 Removing and installing handle 3221
2 3 2 Moving push-button in the handle to installation position 3223
2 4 Removing and installing selector mechanism 3225
2 4 1 Removing and installing selector mechanism with selector housing 3225
2 4 2 Removing and installing selector mechanism without selector housing 3227
2 5 Checking selector mechanism 3228
2 6 Checking and adjusting selector lever cable 3229
3 Removing and installing gearbox 3232
3 1 Distinguishing between different types of 1 4 l petrol engines, Golf Cabriolet, CC 3232
3 2 Removing gearbox 3233
3 2 1 Removing gearbox; Passat 2011► 1 4 l – 90 and 118 kW petrol engine and 1 4 l – 110 kW Eco-Fuel engine 3233
3 2 2 Removing gearbox; CC 2012 ► 1,4 l – 118 kW petrol engine, engine lifting eyes »at rear« of engine 3240
3 2 4 Removing gearbox; CC 2012 ►, Passat 2011 ► 1 8 l – 112 and 118 kW – petrol engine 3252
3 2 5 Removing gearbox, Passat 2011 ► with 1 6 l – 77 kW diesel engine 3259
3 2 6 Removing gearbox; Golf Cabriolet 2012 ► 1,4 l – 90 and 118 kW petrol engine, engine lifting eyes »at rear« of engine 3268
3 3 Install gearbox 3281
3 4 Specified torques for gearbox 3284
3 4 1 1 4 l petrol engine 3284
3 4 2 1 8 l petrol engine 3285
3 4 3 1 6 l diesel engine 3286
4 Transporting gearbox 3287
5 Installing to engine and gearbox support 3288
6 Dismantling and assembling gearbox 3289
6 1 Schematic overview – gearbox 3289
6 2 Dismantling and assembling gearbox 3290
6 2 1 Dismantling gearbox 3290
6 2 2 Assembling gearbox 3297
7 Gearbox housing, clutch housing 3308
7 1 Repairing gearbox housing 3308
7 2 Repairing clutch housing 3311
8 Gear oil 3315
8 1 Draining and filling gear oil 3315
8 2 Draining and filling hydraulic fluid for mechatronic unit 3318
35 – Gears, shafts 3321
1 Input shaft 3321
1 1 Dismantling and assembling input shaft 3321
1 1 1 Dismantling and assembling outer input shaft 3321
2 Output shaft 3325
2 1 Assembly overview – output shaft 3325
2 1 1 Assembly overview – output shaft 1 3325
2 1 2 Assembly overview – output shaft 2 3327
2 1 3 Assembly overview – output shaft 3 3328
2 2 Dismantling and assembling output shaft 1 3329
2 2 1 Dismantling output shaft 1 partially 3329
2 2 2 Dismantling output shaft 1 completely 3330
2 2 3 Assembling output shaft 1 3332
2 2 4 Dismantling and assembling locking collars and synchro-hubs of output shaft 1 3337
2 3 Dismantling and assembling output shaft 2 3338
2 3 1 Dismantling output shaft 2 3338
2 3 2 Assembling output shaft 2 3340
2 3 3 Dismantling and assembling locking collars and synchro-hubs of output shaft 2 3344
2 4 Dismantling and assembling output shaft 3 3344
2 4 1 Dismantling output shaft 3 3344
2 4 2 Assembling output shaft 3 3346
2 4 3 Dismantling and assembling locking collar and synchro-hub of output shaft 3 3348
2 5 Determining shims 3348
2 5 1 Notes on gearbox adjustment 3348
2 5 2 Calculating shims for clutch housing 3350
2 5 3 Calculating shims for gearbox housing 3362
3 Parking lock 3382
3 1 Removing and installing cover for parking lock 3382
3 2 Removing and installing parking lock 3383
39 – Final drive – differential 3385
1 Final drive seals 3385
1 1 Overview of fitting locations – seals 3385
1 2 Renewing seal for right flange shaft 3385
1 3 Renewing oil seal for left flange shaft 3388
00 – Technical data 3397
1 Safety information 3397
1 1 Safety measures when working with pyrotechnic components 3398
1 2 Safety instructions for belt tensioners 3399
1 3 Storage, transportation and disposal of airbag, belt tensioner and battery isolator units (pyrotechnic components) 3399
1 4 Checking seat belts 3399
1 5 Safety instructions for airbag 3400
1 6 Additional safety instructions for curtain airbag 3400
1 7 Renewing pyrotechnic, electrical and mechanical components of the restraint system after an accident 3400
1 7 1 Accident with airbag triggering 3400
1 7 2 Accident not involving triggering of airbag 3401
1 8 Deactivating the airbag 3401
68 – Interior equipment 3402
1 Storage compartments/covers 3402
1 1 Removing and installing headliner storage compartment 3402
1 2 Removing and installing steering column trim 3403
1 3 Removing and installing dash panel cover on driver’s side 3404
1 3 1 Removing and installing dash panel cover on driver’s side 3404
1 3 2 Removing and installing cover in driver footwell 3406
1 4 Removing and installing glove compartment 3407
1 5 Removing and installing glove compartment opener 3409
2 Equipment 3410
2 1 Removing and installing roof grab handle 3410
2 2 Removing and installing sun visor 3411
3 Centre console 3414
3 1 Removing and installing centre console 3414
3 2 Removing and installing centre console front storage compartment 3419
3 3 Removing and installing rear centre console trim 3420
3 4 Removing and installing centre console side trims 3422
3 5 Removing and installing centre console storage compartment 3423
3 6 Removing and installing centre console extension 3424
3 7 Removing and installing centre armrest 3427
3 8 Removing and installing centre armrest storage compartment 3428
3 9 Removing and installing upper part of centre armrest 3430
4 Interior mirror 3432
4 1 Assembly overview – interior mirror 3432
4 1 1 Assembly overview – interior mirror »with rain sensor, manually dimmable« 3432
4 1 2 Assembly overview – interior mirror »with rain sensor, automatically dimmable« 3433
4 2 Removing and installing interior mirror 3434
4 2 1 Removing and installing interior mirror »with rain sensor, manually dimmable« 3434
4 2 2 Removing and installing interior mirror »with rain sensor, automatically dimmable« 3436
4 2 3 Removing and installing interior mirror in vehicles with a multifunction camera 3438
4 2 4 Removing and installing rain sensor cover 3439
4 2 5 Repairing interior mirror retaining plate 3441
69 – Passenger protection 3443
1 Seat belts 3443
1 1 Assembly overview – front three-point seat belt 3443
1 1 1 Assembly overview – front three-point seat belt, excluding USA and Canada vehicles 3443
1 1 2 Assembly overview – front three-point seat belt, USA and Canada vehicles only 3445
1 2 Removing and installing front 3-point seat belt 3445
1 2 1 Removing and installing front three-point seat belt, excluding USA and Canada vehicles 3445
1 2 2 Removing and installing front three-point seat belt, USA and Canada vehicles only 3447
1 3 Removing and installing belt height adjustment 3449
1 4 Removing and installing front belt buckle 3450
1 5 Assembly overview – rear outer seat belt 3452
1 6 Removing and installing rear outer three-point seat belt 3452
1 7 Removing and installing rear middle three-point seat belt 3454
1 8 Removing and installing rear belt buckle 3455
2 Child seat anchors 3458
2 1 Testing after accident 3458
3 Airbag control unit 3459
3 1 Removing and installing airbag control unit 3459
4 Driver’s airbag 3462
4 1 Removing and installing airbag unit with igniter 3462
4 2 Removing and installing return spring with slip ring (coil connector) 3465
5 Front passenger side airbag 3466
5 1 Removing and installing front passenger side airbag unit with igniter 3466
6 Side airbags 3468
6 1 Removing and installing front side airbag with igniter 3468
6 2 Removing and installing rear side airbag with igniter 3469
7 Curtain airbags 3472
7 1 Removing and installing curtain airbag with igniter 3472
8 Airbag crash sensors 3475
8 1 Removing and installing front airbag crash sensor 3475
8 1 1 Removing and installing front airbag crash sensor for driver side -G283-, USA and Canada vehicles only 3475
8 1 2 Removing and installing front airbag crash sensor for front passenger side -G284-, USA and Canada vehicles only 3476
8 2 Removing and installing front side airbag crash sensor 3478
8 2 1 Removing and installing side airbag crash sensor on driver side 3478
8 2 2 Removing and installing side airbag crash sensor on front passenger side 3482
8 3 Removing and installing rear side airbag crash sensor 3487
8 3 1 Removing and installing rear left side airbag crash sensor 3487
8 3 2 Removing and installing right rear side airbag crash sensor 3488
9 Seat belt verification 3490
9 1 Removing and installing seat occupied sensor 3490
10 Seat occupied recognition 3495
10 1 Installation location overview – seat occupied recognition system 3495
10 2 Removing and installing seat occupied recognition 3496
10 2 1 Safety precautions for when working on seat occupied recognition 3497
10 2 2 Procedure after an accident when belt tensioner and/or airbag was triggered 3497
10 2 3 Removing and installing seat occupied recognition 3498
10 2 4 Removing and installing seat position sensor 3501
10 2 5 Importer’s reporting obligation 3502
70 – Trim, insulation 3503
1 Door trims 3503
1 1 Removing and installing door trim at front 3503
1 2 Removing and installing rear door trim 3507
2 Dash panel 3511
2 1 Removing and installing dash panel 3511
2 2 Removing and installing dash panel decorative trim 3519
2 2 1 Removing and installing front passenger side decorative trim 3519
2 2 2 Removing and installing dash panel insert decorative trim 3520
2 2 3 Removing and installing analogue clock 3521
2 2 4 Removing and installing analogue clock holder 3523
2 3 Removing and installing dash panel side cover 3525
3 Dash panel central tube 3527
3 1 Removing and installing dash panel central tube 3527
4 Interior trims 3532
4 1 Removing and installing A-pillar trim 3532
4 1 1 Removing and installing upper A-pillar trim 3532
4 1 2 Removing and installing lower A-pillar trim on driver side 3533
4 1 3 Removing and installing lower A-pillar trim on front passenger side 3534
4 1 4 Removing and installing centre A-pillar trim 3535
4 2 Removing and installing B-pillar trim 3536
4 2 1 Removing and installing B-pillar trim 3536
4 2 2 Detaching and attaching B-pillar trim 3538
4 2 3 Removing and installing lower B-pillar trim 3540
4 3 Removing and installing C-pillar trim 3541
4 3 1 Removing and installing C-pillar trim without roller sunblind 3541
4 3 2 Removing and installing C-pillar trim with roller sunblind 3543
4 3 3 Removing and installing lower C-pillar trim 3544
4 4 Removing and installing rear shelf 3547
4 4 1 Removing and installing rear shelf without roller sunblind 3547
4 4 2 Removing and installing rear shelf with roller sunblind 3549
4 5 Removing and installing sill moulding 3552
4 5 1 Removing and installing non-illuminated sill panel mouldings 3552
4 5 2 Removing and installing illuminated sill panel mouldings 3555
4 6 Removing and installing foot rest 3558
4 6 1 Removing and installing foot rest cover 3559
4 6 2 Removing and installing foot rest bracket 3560
5 Luggage compartment trims 3561
5 1 Removing and installing lock carrier trim 3561
5 2 Removing and installing load compartment side trim 3562
5 3 Removing and installing rear lid trim 3563
6 Roof trims 3566
6 1 Removing and installing moulded headliner 3566
6 1 1 Removing and installing moulded headliner 3566
6 1 2 Detaching and fastening moulded headliner 3568
6 2 Mounting roof reinforcement on body 3571
6 2 1 Mounting roof reinforcement on body, vehicles without panorama sunroof 3571
6 2 2 Mounting roof reinforcement on body, vehicles with panorama sunroof 3575
72 – Seat frames 3580
1 Front seats 3580
1 1 Removing and installing front seat 3580
1 1 1 Removing and installing seat 3583
1 1 2 Removing and installing right trim on seat 3586
1 1 3 Removing and installing left trim on seat with manual height adjustment 3586
1 1 4 Removing and installing left trim on seat with electrical height adjustment 3589
1 1 5 Removing and installing seat ventilation switch -E655- 3591
1 1 6 Removing and installing front seat fan -V268- 3592
1 1 7 Removing and installing front seat backrest fan -V269- 3594
1 2 Removing and installing front backrest 3596
1 2 1 Removing and installing backrest 3597
1 2 2 Removing and installing backrest adjustment wheel 3600
1 2 3 Removing and installing lumbar adjustment lever 3600
1 2 4 Removing and installing manually adjustable lumbar support frame 3601
1 2 5 Removing and installing backrest adjustment drive of electrically adjustable seat 3602
1 2 6 Removing and installing lumbar support of electrically adjustable seat 3603
1 3 Removing and installing head restraint 3605
1 4 Dismantling and assembling seat pan 3607
1 4 1 Removing and installing front seat bar and operating lever 3608
1 4 2 Removing and installing bar of electrically adjustable seat 3609
1 4 3 Removing and installing longitudinal seat adjustment of electrically adjustable seat 3610
1 4 4 Removing and installing seat pan of electrically adjustable seat 3612
1 4 5 Removing and installing rake adjustment of electrically adjustable seat 3614
1 4 6 Removing and installing height adjustment of electrically adjustable seat 3615
1 4 7 Removing and installing electrically adjustable seat control unit 3617
2 Rear seats 3619
2 1 Removing and installing bench seat / individual seats 3619
2 2 Removing and installing rear seat backrest 3620
2 2 1 Removing and installing split rear seat backrest 3620
2 2 2 Removing and installing one-piece rear seat backrest 3622
2 3 Removing and installing centre armrest 3624
2 3 1 Removing and installing centre armrest 3625
2 3 2 Removing and installing centre armrest drink holder 3626
2 3 3 Removing and installing centre console storage compartment (4-seater) 3627
74 – Seat – padding, covers 3629
1 Front seat covers and padding 3629
1 1 Removing and installing seat cover and seat cushion for seat pan 3629
1 2 Removing and installing backrest cover and cushion 3635
1 3 Renewing heater elements of seat heating 3640
2 Rear seat covers and padding 3641
2 1 Removing and installing cover and cushion 3641
2 1 1 Removing and installing seat cover and seat cushion for bench seat (4-seater) 3641
2 1 2 Removing and installing seat cover and seat cushion for bench seat (5-seater) 3642
2 1 3 Removing and installing seat cover and seat cushion for “2/3” bench seat (5-seater) 3645
2 1 4 Removing and installing seat cover and seat cushion for “1/3” bench seat (5-seater) 3648
2 1 5 Removing and installing backrest cover and cushion (4-seater) 3651
00 – Technical data 3659
1 Safety information 3659
1 1 General safety provisions 3659
1 2 Safety precautions when using testers and measuring instruments during a road test 3660
1 3 Safety measures when working on vehicles with a start/stop system 3661
2 Identification 3662
2 1 Identification of final drive 3662
2 1 1 Final drive code 02D/0BS/0AY 3662
2 1 2 Final drive code 0CQ/0CR/0BR 3662
3 Repair instructions 3664
3 1 General repair instructions 3664
3 1 1 General information 3664
3 1 2 Oil 3664
3 1 3 Locking devices 3664
3 1 4 Bearings 3664
3 1 5 Shims 3665
3 2 Gaskets and seals 3665
3 3 Nuts and bolts 3665
4 Technical data 3667
4 1 Capacities 3667
4 1 1 Capacities, final drive 0BS 3667
4 1 2 Capacities, final drive 0AY 3667
4 1 3 Capacities, final drive 0CQ 3667
4 1 4 Capacities, final drive 0CR 3668
4 1 5 Capacities, final drive 0BR 3668
5 Electrical components 3669
5 1 Overview of fitting locations – electrical components 3669
5 1 1 Overview of fitting locations – electrical components, rear final drive “0BS” with all-wheel drive coupling generation IV 3669
5 1 2 Overview of fitting locations – electrical components, rear final drive “0CQ/0CR/0AY/0BR” with all-wheel drive coupling generation V and VI 3669
39 – Final drive – rear differential 3671
1 Final drive 3671
1 1 Assembly overview – final drive 3671
1 1 1 Assembly overview – final drive 3671
1 2 Removing and installing final drive 3672
1 2 1 Removing and installing final drive, CC 2012 ►, Passat 2011 ►, Passat Estate 2011 ► 3672
1 2 2 Removing and installing final drive, Golf 2013 ►, Golf 2017 ► 3682
1 2 3 Removing and installing final drive, Golf Estate 2014 ►, Golf Estate 2017 ► 3693
1 2 4 Removing and installing final drive, Passat 2015 ►, Passat Estate 2015 ►, Arteon 2018 ►, Passat 2019 ►, Passat Estate 2019 ► 3704
1 2 5 Removing and installing rear final drive, Sharan 2016 ► 3714
1 2 6 Removing and installing final drive, Tiguan ► 3719
1 2 7 Removing and installing final drive, T-Roc 2018 ►, T-Roc 2022 ►, T-Roc Cabriolet 2022 ► 3731
1 2 8 Removing and installing final drive, Tarek Russia 2022 ► 3742
2 Assembly mountings 3753
2 1 Assembly overview – assembly mountings 3753
2 1 1 Assembly overview – subframe, rear final drive 0BS, 0CR, 0AY 3753
2 1 2 Assembly overview – subframe, rear final drive 0CQ, 0BR 3755
2 2 Removing and installing bonded rubber bush 3756
2 2 1 Removing and installing bonded rubber bush, rear final drive 0BS, 0CR, 0AY 3756
2 2 2 Removing and installing bonded rubber bush, rear final drove 0CQ, 0BR 3758
3 Gear oil 3765
3 1 Overview of fitting locations – oil drain and inspection plugs 3765
3 1 1 Overview of fitting locations – oil drain and inspection plugs, T-Roc 2018 ►, T-Roc 2022 ►, T-Roc Cabriolet 2022 ► 3765
3 1 2 Overview of fitting locations – drain and inspection plugs, Tarek Russia 2022 ► 3765
3 2 Checking gear oil level 3766
4 Oil seals 3769
4 1 Overview of fitting locations – oil seals 3769
4 2 Renewing right seal 3769
4 2 1 Renewing right oil seal, rear final drive 0BS 3769
4 2 2 Renewing right oil seal, rear final drive 0CQ, 0CR, 0AY, 0BR 3773
4 3 Renewing left seal 3776
4 3 1 Renewing left oil seal, rear final drive 0BS 3776
4 3 2 Renewing left oil seal, rear final drive 0CQ, 0CR, 0AY, 0BR 3780
4 4 Renewing input shaft seal 3783
4 4 1 Renewing input shaft seal 3783
5 All-wheel drive coupling 3792
5 1 Assembly overview – all-wheel drive coupling 3792
5 1 1 Assembly overview – all-wheel drive coupling, generation IV 3792
5 1 2 Assembly overview – all-wheel drive coupling, generation V and generation VI 3794
5 2 Checking function 3796
5 3 Checking fluid level in all-wheel drive coupling 3796
5 4 Draining and filling high performance fluid for all-wheel drive coupling 3797
5 5 Removing and installing all-wheel drive coupling pump -V181- 3800
5 5 1 Removing and installing all-wheel drive coupling pump -V181-, generation IV 3800
5 5 2 Removing and installing all-wheel drive coupling pump -V181-, generation V and generation VI 3802
5 6 Removing and installing all-wheel drive coupling 3806
5 6 1 Removing and installing all-wheel drive coupling, generation IV 3806
5 6 2 Removing and installing all-wheel drive coupling, generation V 3813
5 6 3 Removing and installing all-wheel drive coupling, generation VI 3821
5 7 Removing and installing four-wheel drive control unit -J492- 3829
5 7 1 Removing and installing all-wheel drive control unit -J492-, generation IV 3829
5 7 2 Removing and installing all-wheel drive control unit -J492-, generation V 3832
5 7 3 Removing and installing all-wheel drive control unit -J492-, generation VI 3833
6 Propshaft 3836
6 1 Assembly overview – propshaft 3836
6 1 1 Assembly overview – propshaft, CC 2012 ►, Passat ►, Passat Estate ►, Golf ►, Golf Estate ►, Tiguan ►, Arteon ► 3836
6 1 2 Assembly overview – propshaft, Sharan 2016 ► 3838
6 1 3 Assembly overview – propshaft, T-Roc 2018 ►, T-Roc 2022 ►, T-Roc Cabriolet 2022 ► 3839
6 1 4 Assembly overview – propshaft, Tarek Russia 2022 ► 3840
6 2 Removing and installing propshaft 3842
6 2 1 Removing and installing propshaft, CC 2012 ►, Passat 2011 ►, Passat Estate 2011 ► 3842
6 2 2 Removing and installing propshaft, Golf 2013 ►, Golf Estate 2014 ►, Golf 2017 ►, Golf Estate 2017 ► 3847
6 2 3 Removing and installing propshaft, Passat 2015 ►, Passat Estate 2015 ►, Arteon, Passat 2019 ►, Passat Estate 2019 ► 3852
6 2 4 Removing and installing propshaft, Sharan 2016 ► 3859
6 2 5 Removing and installing propshaft, Tiguan ► 3865
6 2 6 Removing and installing propshaft, T-Roc 2018 ►, T-Roc 2022 ►, T-Roc Cabriolet 2022 ► 3872
6 2 7 Removing and installing propshaft, Tarek Russia 2022 ► 3879
6 3 Removing and installing front flexible coupling 3886
6 4 Removing and installing rear flexible coupling 3889
00 – Technical data 3903
1 Identification 3903
1 1 Gearbox identification 3903
1 2 Identification of bevel box 3904
2 General information 3905
2 1 Allocation gearbox – engine 3905
2 2 Capacities 3905
3 Safety information 3906
3 1 General safety provisions 3906
3 2 Notes on tow-starting/towing 3906
4 Repair notes 3907
4 1 General repair instructions 3907
4 2 Gaskets and seals 3908
4 3 Nuts and bolts 3908
5 Electrical components 3909
5 1 Overview of fitting locations – electrical components 3909
32 – Torque converter 3914
1 Torque converter 3914
1 1 Assembly overview – torque converter 3914
1 2 Removing and installing torque converter 3915
1 3 Draining torque converter 3915
1 4 Removing and installing torque converter radial shaft seal 3916
37 – Controls, housing 3918
1 Selector mechanism 3918
1 1 Assembly overview – selector mechanism 3918
1 2 Emergency release from position »P« 3919
1 3 Removing and installing selector lever handle 3919
1 3 1 Removing and installing handle 3919
1 3 2 Moving push-button in the handle to installation position 3921
1 4 Removing and installing selector mechanism 3923
1 4 1 Removing and installing selector mechanism with selector housing 3923
1 4 2 Removing and installing selector mechanism without selector housing 3925
1 5 Checking selector mechanism 3927
1 6 Checking and adjusting selector lever cable 3928
1 7 Removing and installing multifunction switch 3930
1 8 Adjusting multifunction switch 3932
1 9 Renewing selector shaft seal 3933
2 Removing and installing gearbox 3935
2 1 Removing gearbox 3935
2 1 1 Removing gearbox, CC with front-wheel drive 3935
2 1 2 Removing gearbox, CC with all-wheel drive 3942
2 2 Installing gearbox 3950
2 2 1 Installing gearbox, CC with front-wheel drive 3950
2 2 2 Installing gearbox, CC with all-wheel drive 3950
2 3 Specified torques 3951
3 Transporting gearbox 3953
4 Securing to engine and gearbox support 3954
5 Bevel box 3956
5 1 Removing bevel box 3956
5 2 Installing bevel box 3959
6 ATF circuit 3962
6 1 Assembly overview – ATF cooler 3962
6 2 Removing and installing ATF cooler 3963
7 ATF 3965
7 1 Checking ATF level 3965
7 2 Draining and filling ATF 3968
38 – Gears, control 3970
1 ATF system 3970
1 1 Removing and installing sump 3970
1 2 Removing and installing ATF strainer 3971
2 Valve body 3973
2 1 Assembly overview – valve body 3973
2 2 Removing and installing valve body 3975
2 2 1 Wire routing, connectors, connections and retainer on valve body 3982
2 2 2 Removing and installing wiring harness for solenoid valves 3984
2 2 3 Removing and installing sender wiring harness 3985
2 2 4 Removing and installing gearbox input speed sender -G182- 3985
2 2 5 Removing and installing gearbox output speed sender -G195- 3986
2 2 6 Specified torques 3986
39 – Final drive – differential 3988
1 Final drive seals 3988
1 1 Renewing oil seal for left flange shaft 3988
1 2 Renewing seal for right flange shaft 3990
1 2 1 Renewing oil seal for right flange shaft, front-wheel drive 3990
1 2 2 Renewing oil seal for right flange shaft, all-wheel drive 3990
2 Bevel box 3994
2 1 Assembly overview – bevel box 3994
2 1 1 Removing and installing right flange shaft 3996
2 1 2 Renewing needle bearing (polygon bearing) for right flange shaft 3997
2 1 3 Renewing output flange and redetermining thickness of shim (bevel box removed) 3999
2 2 Renewing bevel box seals 4009
2 2 1 Renewing seal for right flange shaft on outside of bevel box 4009
2 2 2 Renewing seal on bevel box between gearbox and bevel box 4010
2 2 3 Renewing oil seal for propshaft drive flange at bevel box 4011
3 Gear oil 4016
3 1 Checking gear oil level 4016
3 1 1 Checking gear oil in bevel box 4016
3 1 2 Filling gear oil in bevel box 4016
44 – Wheels, tyres, vehicle geometry 4023
1 General notes on using the Wheels and Tyres Guide 4023
1 1 General information 4023
1 2 Explanations regarding world regions 4024
1 3 Definition of tyre package 4025
1 4 Procedure for determining the required tyre package 4025
1 4 1 Determining the required tyre package via PR number 4025
1 4 2 Determining the required tyre package via version key in the vehicle registration certificate part 1 4026
2 Notes on the vehicle registration certificate 4027
2 1 Vehicle registration certificate part 1 4027
2 2 Version key, D2 4027
3 Wheel and tyre combinations without tyre package 4029
3 1 Passat CC, model year 2009 (sales type 357/358) 4029
3 2 Passat CC, CC, from model year 2010 (sales type 357/358) 4030
4 Wheel and tyre combinations depending on tyre packages 4035
4 1 Type approval number (K): e1*2001/116*0468*18 to e1*2001/116*0468*21 4035
4 2 Changing to other wheel and tyre combinations 4036
5 Wheel allocation 4038
5 1 61/2 J x 17 offset 39 4038
5 2 7 J x 17 offset 33 4038
5 3 8 J x 17 offset 41 4039
5 4 8 J x 18 offset 41 4040
5 5 8 J x 19 offset 41 4042
6 Recommended summer tyres, except North America and China 4044
7 Recommended all-season tyres 4045
7 1 Recommended all-season tyres, except North America and China 4045
7 2 Recommended all-season tyres, North America 4045
8 Recommended winter tyres, except North America and China 4046
9 Recommended temporary spare tyres and wheels 4047
00 – Technical data 4054
1 Identification 4054
1 1 Engine number/engine data 4054
1 1 1 Engine number 4054
1 1 2 Engine data 4054
2 Safety information 4056
2 1 Safety regulations for working on fuel supply 4056
2 2 Safety precautions when using testers and measuring instruments during a road test 4056
2 3 Safety measures when working on vehicles with a start/stop system 4057
2 4 Safety precautions when working on the cooling system 4057
2 5 Safety precautions when working on the SCR system 4057
2 6 Safety precautions when working on exhaust system 4058
3 Repair instructions 4060
3 1 Rules for cleanliness 4060
3 1 1 When working on fuel supply/injection system 4060
3 1 2 When working on turbocharger 4060
3 2 Foreign bodies in engine 4061
3 3 Checking vacuum system 4061
10 – Removing and installing engine 4062
1 Removing and installing engine 4062
1 1 Removing engine 4062
1 1 1 Removing engine, Golf, Golf Plus, Touran, Scirocco and Tiguan 4062
1 1 2 Removing engine, Passat, Eos and CC 4071
1 2 Separating engine and gearbox 4086
1 2 1 Separating engine from gearbox 4086
1 2 2 Separating engine from dual clutch gearbox 4089
1 3 Securing engine on engine and gearbox support 4091
1 4 Installing engine 4092
1 4 1 Notes on installing 4092
2 Assembly mountings 4096
2 1 Assembly overview – assembly mountings 4096
2 1 1 Assembly overview – assembly mounting for Golf, Golf Plus, Touran, Passat, Eos, Scirocco and CC 4096
2 1 2 Assembly overview – assembly mountings, Tiguan 4097
2 2 Supporting engine in installation position 4098
2 2 1 Supporting engine in installation position, Golf and Scirocco 4098
2 2 2 Supporting engine in installation position, Tiguan 4101
2 2 3 Supporting engine in installation position, Golf Plus 4103
2 2 4 Supporting engine in installation position, Touran 4106
2 2 5 Supporting engine in installation position, Passat, Eos and CC 4109
2 3 Adjusting assembly mountings 4113
2 3 1 Adjusting assembly mounting, Golf and Scirocco 4113
2 3 2 Adjusting assembly mountings, Tiguan 4115
2 3 3 Adjusting assembly mounting, Golf Plus 4117
2 3 4 Adjusting assembly mountings, Touran 4119
2 3 5 Adjusting assembly mounting, Passat, Eos and CC 4121
3 Engine cover panel 4123
3 1 Removing and installing engine cover 4123
13 – Crankshaft group 4125
1 Cylinder block, pulley end 4125
1 1 Assembly overview – poly V-belt drive 4125
1 1 1 Assembly overview – poly V-belt drive with tensioning element and air conditioner compressor 4125
1 1 2 Assembly overview – poly V-belt drive with tensioning roller and air conditioner compressor 4126
1 1 3 Assembly overview – poly V-belt drive 4128
1 2 Removing and installing poly-V belt 4129
1 2 1 Removing and installing poly V-belt with tensioning element and air conditioner compressor 4129
1 2 2 Removing and installing poly V-belt with tensioning roller and air conditioner compressor 4131
1 2 3 Removing and installing poly V-belt without air conditioner compressor 4133
1 3 Removing and installing poly V-belt tensioner 4134
1 3 1 Removing and installing poly V-belt tensioner 4134
1 4 Removing and installing bracket for ancillaries 4135
1 5 Removing and installing engine bracket 4137
1 5 1 Removing and installing engine bracket, Golf and Scirocco 4137
1 5 2 Removing and installing engine bracket, Tiguan 4140
1 5 3 Removing and installing engine bracket, Golf Plus 4143
1 5 4 Removing and installing engine bracket, Touran 4146
1 5 5 Removing and installing engine bracket, Passat, Eos and CC 4150
1 6 Assembly overview – cylinder block, pulley end 4153
1 6 1 Assembly overview – cylinder block, pulley end 4153
1 6 2 Assembly overview – crankcase 4155
1 7 Renewing crankshaft oil seal (pulley end) 4157
1 8 Removing and installing sealing flange, pulley end 4158
2 Cylinder block, gearbox end 4162
2 1 Assembly overview – cylinder block, gearbox end 4162
2 2 Removing and installing flywheel 4163
2 3 Removing and installing sealing flange on gearbox side 4165
2 3 1 Pressing out sealing flange with sender wheel 4165
2 3 2 Pressing in sealing flange with sender wheel 4166
3 Crankshaft 4175
3 1 Assembly overview – crankshaft 4175
3 2 Renewing needle bearing in crankshaft 4176
3 3 Crankshaft dimensions 4178
4 Pistons and conrods 4179
4 1 Assembly overview – pistons and conrods 4179
4 1 1 Assembly overview – pistons and conrods 4179
4 1 2 Piston and cylinder dimensions 4183
4 1 3 Bearing shells – installation position 4183
4 1 4 Piston and cylinder dimensions 4184
4 2 Separating new conrod 4184
4 3 Measuring piston projection at TDC 4185
4 3 1 Cylinder head gasket identification 4187
4 4 Checking radial clearance of conrods 4187
15 – Cylinder head, valve gear 4188
1 Cylinder head 4188
1 1 Assembly overview – cylinder head 4188
1 2 Removing and installing cylinder head 4192
1 3 Removing and installing cylinder head cover 4203
1 3 1 Removing and installing cylinder head cover 4203
1 3 2 Renewing seals for injectors 4206
1 4 Assembly overview – cylinder head cover 4207
1 5 Removing and installing vacuum pump 4209
1 6 Checking compression 4210
2 Toothed belt drive 4212
2 1 Assembly overview – toothed belt 4212
2 2 Removing and installing toothed belt 4214
2 2 1 Removing and installing toothed belt, tensioning roller A 4216
2 2 2 Removing and installing toothed belt, tensioning roller B 4225
3 Valve gear 4236
3 1 Assembly overview – valve gear 4236
3 2 Measuring axial play of camshaft 4238
3 3 Measuring radial clearance of camshaft 4239
3 4 Removing and installing camshaft 4240
3 5 Removing and installing camshaft oil seal 4248
3 5 1 Vehicles with »old« seal 4248
3 5 2 Vehicles with »new« seal 4250
3 6 Checking hydraulic compensation elements 4252
3 7 Removing and installing valve stem oil seals 4253
3 7 1 Renewing valve stem seals with cylinder head installed 4253
3 7 2 Renewing valve stem seals with cylinder head removed 4257
4 Inlet and exhaust valves 4261
4 1 Valve dimensions 4261
4 2 Reworking valve seats 4261
4 3 Checking valve guides 4261
4 4 Checking valves 4263
17 – Lubrication 4264
1 Sump, oil pump 4264
1 1 Assembly overview – sump/oil pump 4264
1 1 1 Assembly overview – sump/oil pump, engine codes CFFA, CFFB, CFGB, CFGC, CFFD, CLLA, CLJA 4264
1 1 2 Assembly overview – sump/oil pump, engine codes CFHB, CFHC, CFHF, CFJA, CFJB, CLCA 4267
1 2 Removing and installing sump 4270
1 3 Removing and installing oil pump 4275
1 3 1 Removing and installing oil pump, engine codes CFFA, CFFB, CFGB, CFGC, CFFD, CLLA, CLJA 4275
1 3 2 Removing and installing oil pump, engine codes CFHB, CFHC, CFHF, CFJA, CFJB, CLCA 4277
1 4 Removing and installing oil level and oil temperature sender 4278
1 5 Engine oil 4279
1 5 1 Oil capacities 4279
1 5 2 Checking engine oil level 4279
2 Engine oil cooler 4280
2 1 Assembly overview – engine oil cooler 4280
2 2 Removing and installing engine oil cooler 4281
3 Oil filter, oil pressure switch 4285
3 1 Assembly overview – oil filter housing, oil pressure switch 4285
3 2 Removing and installing oil pressure switch 4286
3 3 Checking oil pressure 4287
3 4 Checking oil pressure and oil pressure switch 4288
3 5 Removing and installing oil filter housing 4289
4 Balance shaft module 4294
4 1 Assembly overview – balance shaft module 4294
4 2 Removing and installing balance shaft module 4297
4 2 1 Removing balancer shaft module 4297
4 2 2 Installing a new balancer shaft module 4299
4 2 3 Installing a previously used balancer shaft module again 4303
19 – Cooling 4307
1 Cooling system/coolant 4307
1 1 Coolant hose connection diagram 4307
1 2 Draining and filling cooling system 4308
1 2 1 Draining 4309
1 2 2 Filling 4312
1 3 Checking cooling system for leaks 4314
2 Coolant pump, regulation of cooling system 4319
2 1 Assembly overview –coolant pump, thermostat 4319
2 2 Removing and installing coolant pump 4319
2 3 Removing and installing 4/2-way valve with thermostat 4321
2 4 Removing and installing coolant temperature sender 4326
2 4 1 Removing and installing coolant temperature sender -G62- 4326
2 4 2 Removing and installing radiator outlet coolant temperature sender -G83- 4328
3 Coolant pipes 4330
3 1 Assembly overview – coolant pipes 4330
3 2 Removing and installing coolant pipes 4332
3 2 1 Removing and installing front coolant pipe 4332
3 2 2 Removing and installing upper front coolant pipe 4337
3 2 3 Removing and installing left coolant pipe 4338
3 2 4 Removing and installing right coolant pipe 4341
4 Radiator, radiator fan 4344
4 1 Assembly overview – radiator/radiator fan 4344
4 2 Removing and installing radiator 4344
4 3 Removing and installing radiator cowl with radiator fans 4346
21 – Turbocharging/supercharging 4348
1 Turbocharger 4348
1 1 Assembly overview – turbocharger 4348
1 2 Removing and installing turbocharger 4350
1 3 Renewing vacuum unit for turbocharger 4355
2 Charge air system 4362
2 1 Assembly overview – charge air system 4362
2 2 Assembly overview – hose connections for charge air system 4363
2 3 Removing and installing charge air cooler 4364
2 4 Removing and installing charge pressure sender 4366
2 5 Checking charge air system for leaks 4366
23 – Mixture preparation – injection 4370
1 Injection system 4370
1 1 Schematic overview – fuel system 4370
1 2 Filling/bleeding fuel system 4372
1 3 Checking fuel system for leaks 4373
2 Vacuum system 4374
2 1 Assembly overview – vacuum system 4374
2 2 Checking vacuum system 4374
2 2 1 Checking supply line, vacuum reservoir and non-return valve 4375
2 2 2 Checking control line to turbocharger 4376
2 2 3 Checking control line to vacuum unit for exhaust gas recirculation cooler changeover function 4377
3 Injectors/high-pressure reservoir (rail) 4379
3 1 Assembly overview – injectors 4379
3 2 Adapting correction values for injectors 4382
3 3 Checking open injectors 4383
3 4 Checking return flow rate of injectors with engine running 4385
3 5 Checking return flow rate of injectors at starter speed 4388
3 6 Removing and installing injectors 4390
3 7 Removing and installing high-pressure lines 4394
3 8 Removing and installing fuel rail 4396
4 Intake manifold 4400
4 1 Assembly overview – intake manifold 4400
4 2 Removing and installing intake manifold 4401
4 3 Removing and installing throttle valve module 4405
5 Air filter 4408
5 1 Assembly overview – air filter housing 4408
5 2 Removing and installing air filter housing 4410
6 Senders and sensors 4412
6 1 Checking fuel pressure regulating valve 4412
6 2 Removing and installing fuel pressure regulating valve 4413
6 3 Removing and installing fuel pressure sender 4415
6 4 Removing and installing fuel temperature sender -G81- 4418
6 5 Removing and installing differential pressure sensor 4419
6 6 Removing and installing air mass meter 4420
7 High-pressure pump 4422
7 1 Assembly overview – high-pressure pump 4422
7 2 Removing and installing high-pressure pump 4424
8 Lambda probe 4428
8 1 Removing and installing lambda probe 4428
9 Engine/motor control unit 4430
9 1 Removing and installing engine control unit 4430
9 1 1 Removing and installing engine control unit -J623-, Golf, Scirocco 4430
9 1 2 Removing and installing engine control unit -J623-, Golf Plus, Touran 4432
9 1 3 Adapting functions and components, Eos 4433
9 1 4 Removing and installing engine control unit -J623-, Tiguan 4433
9 1 5 Removing and installing engine control unit -J623-, Eos 4435
9 1 6 Removing and installing engine control unit -J623-, Passat and CC up to 10 2010 4436
9 1 7 Removing and installing engine control unit -J623-, CC from 11 2010 4438
9 2 Removing and installing engine control unit with protective housing 4440
9 2 1 Removing and installing engine control unit -J623- with protective housing, Golf, Scirocco 4440
9 2 2 Removing and installing engine control unit -J623- with protective housing, Golf Plus, Touran 4443
9 2 3 Removing and installing engine control unit -J623- with protective housing, Tiguan 4446
9 2 4 Removing and installing engine control unit -J623- with protective housing, Eos 4448
9 2 5 Removing and installing engine control unit -J623- with protective housing, Passat and CC up to 10 2010 4451
9 2 6 Removing and installing engine control unit -J623- with protective housing, CC from 11 2010 4453
26 – Exhaust system 4457
1 Exhaust pipes and silencers 4457
1 1 Assembly overview – silencers 4457
1 1 1 Assembly overview – silencers, Tiguan 4457
1 1 2 Assembly overview – silencers, vehicles with front-wheel drive, Golf, Golf Plus, Eos, Scirocco 4458
1 1 3 Assembly overview – silencer, vehicles with four-wheel drive, Golf 4459
1 1 4 Assembly overview – silencers; vehicles with SCR system 4460
1 1 5 Assembly overview – silencers, vehicles with front-wheel drive, Passat and CC with engine codes CFFA, CFFB, CFGB, CFGC 4461
1 1 6 Assembly overview – silencers, vehicles with front-wheel drive, Passat and CC with engine code CLLA 4462
1 1 7 Assembly overview – silencers, vehicles with four-wheel drive, Passat and CC with engine code CFGB, CFGC 4463
1 1 8 Assembly overview – silencers, Touran 4464
1 1 9 Assembly overview – silencers, vehicles with four-wheel drive, Passat and CC with engine codes CFFA, CFFB 4465
1 2 Aligning exhaust system free of stress 4466
1 3 Installation position of clamp 4467
2 Emission control 4469
2 1 Assembly overview – emission control 4469
2 1 1 Assembly overview – front exhaust pipe with particulate filter 4469
2 1 2 Assembly overview – front exhaust pipe with catalytic converter, engine codes CLCA, CLLA, CLJA 4472
2 2 Removing and installing particulate filter 4473
2 3 Removing and installing catalytic converter 4482
2 3 1 Removing and installing front exhaust pipe with catalytic converter, engine codes CLCA, CLLA, CLJA 4482
3 SCR system (selective catalytic reduction) 4488
3 1 Assembly overview – reducing agent tank 4488
3 2 Draining reducing agent tank 4489
3 3 Removing and installing reducing agent tank 4493
3 4 Assembly overview – reducing agent supply line 4496
3 5 Removing and installing reducing agent supply line 4497
3 6 Removing and installing injector for reducing agent 4500
3 7 Assembly overview – delivery module for reducing agent 4501
3 8 Removing and installing heater element (reservoir) 4503
4 Exhaust gas temperature regulation 4508
4 1 Assembly overview – exhaust gas temperature regulation 4508
4 2 Removing and installing exhaust gas temperature sender 4510
4 2 1 Removing and installing exhaust gas temperature sender 1 -G235- 4510
4 2 2 Removing and installing exhaust gas temperature sender 3 -G495- 4512
4 2 3 Removing and installing exhaust gas temperature sender 4 -G648- 4514
5 Exhaust gas recirculation 4516
5 1 Assembly overview – exhaust gas recirculation 4516
5 2 Removing and installing exhaust gas recirculation cooler 4518
5 3 Checking exhaust gas recirculation cooler change-over 4521
5 4 Checking exhaust gas recirculation cooler for leaks 4522
5 5 Cleaning exhaust gas recirculation system 4527
5 5 1 Initiating cleaning of exhaust gas recirculation system 4527
5 5 2 Cleaning connecting pipes and pipe union 4533
28 – Glow plug system 4535
1 Glow plug system 4535
1 1 Removing and installing glow plug 4535
1 2 Removing and installing automatic glow period control unit 4537
1 3 Removing and installing Hall sender 4538
1 4 Removing and installing engine speed sender 4540
00 – Technical data 4549
1 Identification 4549
1 1 Engine number/engine data 4549
2 General information 4551
2 1 Numbering of cylinders 4551
3 Safety information 4552
3 1 Safety precautions during work on fuel system 4552
3 2 Safety precautions when using testers and measuring instruments during a road test 4552
3 3 Safety precautions when working on the cooling system 4553
3 4 Safety precautions when working on ignition system 4553
4 Repair notes 4554
4 1 Rules for cleanliness 4554
4 2 Foreign objects in engine 4554
10 – Removing and installing engine 4555
1 Removing and installing engine 4555
1 1 Removing engine 4555
1 2 Separating engine and gearbox 4565
1 3 Securing engine on engine and gearbox support 4567
1 4 Installing engine 4569
2 Assembly mountings 4572
2 1 Assembly overview – assembly mountings 4572
2 2 Removing and installing engine mounting 4574
2 3 Adjusting assembly mountings 4576
2 4 Checking adjustment of assembly mountings (engine and gearbox mountings) 4581
13 – Crankshaft group 4582
1 Cylinder block (pulley end) 4582
1 1 Assembly overview – cylinder block (pulley end) 4582
1 2 Assembly overview – poly V-belt drive 4584
1 3 Removing and installing poly-V belt 4586
1 4 Removing and installing tensioner for poly V-belt 4587
1 5 Removing and installing vibration damper 4588
1 6 Removing and installing bracket for ancillaries 4589
1 7 Removing and installing sealing flange on pulley end 4590
2 Cylinder block, gearbox end 4593
2 1 Assembly overview – cylinder block, gearbox end 4593
2 2 Removing and installing flywheel 4593
2 3 Renewing crankshaft oil seal (gearbox end) 4595
3 Crankshaft 4598
3 1 Assembly overview – crankshaft 4598
3 2 Renewing needle bearing in crankshaft 4600
3 3 Crankshaft dimensions 4602
3 4 Measuring axial clearance of crankshaft 4602
3 5 Measuring radial clearance of crankshaft 4603
3 6 Allocation of main bearing shells 4604
3 6 1 Allocation of main bearing shells, up to and including manufacturing date 23 09 12 4604
3 6 2 Allocation of main bearing shells, from manufacturing date 24 09 12 4606
3 7 Removing and installing sender wheel 4608
4 Pistons and conrods 4610
4 1 Assembly overview – pistons and conrods 4610
4 2 Removing and installing pistons 4612
4 3 Checking pistons and cylinder bores 4616
4 4 Separating new conrod 4618
15 – Cylinder head, valve gear 4619
1 Cylinder head 4619
1 1 Assembly overview – cylinder head 4619
1 2 Removing and installing cylinder head 4621
1 3 Removing and installing cylinder head cover 4632
1 4 Assembly overview – vacuum pump 4634
1 5 Removing and installing vacuum pump 4634
1 6 Checking compression 4636
2 Cover for timing chain 4640
2 1 Assembly overview – cover for timing chain 4640
2 2 Removing and installing timing chain cover 4641
2 3 Removing and installing the camshaft control valve seal 4646
2 4 Assembly overview – valve timing housing 4647
3 Chain drive 4649
3 1 Assembly overview – camshaft timing chains 4649
3 2 Removing and installing camshaft timing chain 4652
3 3 Removing and installing chain drive sprocket for high-pressure pump 4656
3 4 Removing and installing timing chain and chain drive for oil pump 4658
3 5 Checking valve timing 4663
3 6 Adjusting valve timing 4666
4 Valve gear 4672
4 1 Assembly overview – valve gear 4672
4 2 Measuring axial play of camshaft 4675
4 3 Removing and installing camshaft 4675
4 4 Removing and installing camshaft adjuster 4681
4 5 Removing and installing camshaft control valve 4690
4 6 Removing and installing valve stem seals 4695
5 Inlet and exhaust valves 4699
5 1 Checking valve guides 4699
5 2 Reworking valve seats 4699
5 3 Valve dimensions 4701
17 – Lubrication 4703
1 Sump, oil pump 4703
1 1 Assembly overview – sump/oil pump 4703
1 2 Removing and installing oil spray jet 4705
1 3 Removing and installing oil pan 4706
1 4 Removing and installing oil pump 4709
1 5 Engine oil: 4715
2 Oil filter, oil pressure switch 4717
2 1 Assembly overview – oil filter housing, oil pressure switch 4717
2 2 Checking oil pressure and oil pressure switch 4719
19 – Cooling 4723
1 Cooling system/coolant 4723
1 1 Connection diagram – coolant hoses 4723
1 2 Checking cooling system for leaks 4724
1 3 Draining and adding coolant 4728
2 Coolant pump, regulation of cooling system 4734
2 1 Assembly overview – coolant pump, thermostat 4734
2 2 Removing and installing coolant pump 4736
2 3 Removing and installing thermostat 4740
2 4 Checking thermostat 4741
2 5 Removing and installing continued coolant circulation pump -V51- 4741
3 Radiator, radiator fan 4743
3 1 Assembly overview – radiator/radiator fan 4743
3 2 Removing and installing radiator 4745
3 3 Removing and installing radiator cowl with radiator fan 4748
3 4 Removing and installing radiator fan 4749
24 – Mixture preparation – injection 4750
1 Injection system 4750
1 1 Overview of fitting locations – injection system 4750
2 Injectors 4753
2 1 Assembly overview – fuel rail with injectors 4753
2 2 Removing and installing injectors 4757
2 3 Renewing seals on injectors 4761
3 Air filter 4766
3 1 Assembly overview – air filter housing 4766
3 2 Removing and installing air filter housing 4767
3 3 Checking intake air preheating 4767
4 Intake manifold 4769
4 1 Assembly overview – intake manifold 4769
4 2 Removing and installing lower part of intake manifold with fuel rail 4771
4 3 Removing and installing intake manifold upper part 4774
4 4 Removing and installing throttle valve module -J338- 4778
5 Senders and sensors 4780
5 1 Checking fuel pressure sender -G247- 4780
6 Engine control unit 4784
6 1 Removing and installing engine control unit -J623- 4784
6 2 Removing and installing engine (motor) control unit -J623- with protective housing 4785
7 High-pressure pump 4789
7 1 Assembly overview – high-pressure pump 4789
7 2 Removing and installing high-pressure pump 4790
8 Lambda probe 4796
8 1 Removing and installing lambda probe -G39- 4796
8 2 Removing and installing Lambda probe -G108- 4797
8 3 Removing and installing lambda probe after catalytic converter -G130- and lambda probe 2 after catalytic converter -G131- 4798
26 – Exhaust system 4801
1 Exhaust pipes and silencers 4801
1 1 Assembly overview – silencers 4801
1 2 Separating exhaust pipes from silencers 4803
1 3 Installation position of clamp 4805
2 Emission control 4807
2 1 Assembly overview – emission control 4807
2 2 Removing and installing catalytic converter 4809
3 Exhaust manifold 4813
3 1 Assembly overview – exhaust manifold 4813
3 2 Removing and installing exhaust manifold 4814
28 – Ignition system 4817
1 Ignition system 4817
1 1 Assembly overview – ignition system 4817
1 2 Removing and installing ignition coils with output stage 4819
1 3 Removing and installing engine speed sender -G28- 4821
1 4 Test data, spark plugs 4821
00 – Technical data 4829
1 Safety information 4829
1 1 Safety measures when working on vehicles with a start/stop system 4829
2 Identification 4830
2 1 Gearbox identification 4830
3 Technical data 4831
3 1 Allocation gearbox – engine 4831
3 1 1 Allocation gearbox – engine, Golf Cabriolet 4831
3 1 2 Allocation gearbox – engine, CC 4831
3 1 3 Allocation gearbox – engine, Golf, Golf Estate 4833
3 2 Capacities 4834
3 3 Calculation of gear ratios 4834
4 Overview – power transmission 4835
5 Electrical components 4837
5 1 Overview of fitting locations – electrical components 4837
5 1 1 Overview of fitting locations – electrical components, manual gearbox 4837
5 1 2 Overview of fitting locations – electrical components, clutch mechanism 4838
6 Repair instructions 4839
6 1 General repair instructions 4839
30 – Clutch 4842
1 Clutch operation 4842
1 1 Overview of fitting locations – clutch mechanism 4842
1 2 Assembly overview – pedal cluster 4844
1 2 1 Assembly overview – pedal cluster, CC, Golf Cabriolet 4844
1 2 2 Assembly overview – pedal cluster, Golf, Golf Estate 4846
1 3 Assembly overview – clutch hydraulics 4848
1 3 1 Assembly overview – clutch hydraulics, CC, Golf Cabriolet, LHD vehicles 4848
1 3 2 Assembly overview – clutch hydraulics, CC, Golf Cabriolet, RHD vehicles 4850
1 3 3 Assembly overview – clutch hydraulics, Golf, Golf Estate, LHD vehicles 4852
1 3 4 Assembly overview – clutch hydraulics, Golf, Golf Estate, RHD vehicles 4853
1 4 Assembly overview – clutch release mechanism 4854
1 5 Removing and installing bearing bush 4855
1 6 Checking clutch master cylinder and clutch slave cylinder 4856
1 7 Removing and installing clutch position sender -G476- 4856
1 7 1 Removing and installing clutch position sender -G476-, CC, Golf Cabriolet 4856
1 7 2 Removing and installing clutch position sender -G476-, Golf, Golf Estate 4858
1 8 Removing and installing return spring 4859
1 9 Removing and installing over-centre spring 4861
1 9 1 Removing and installing over-centre spring, Golf Cabriolet, left-hand drive 4861
1 9 2 Removing and installing over-centre spring, Golf Cabriolet, right-hand drive 4866
1 9 3 Removing and installing over-centre spring, CC 4870
1 9 4 Removing and installing over-centre spring, Golf, Golf Estate 4872
1 10 Removing and installing clutch pedal 4874
1 10 1 Removing and installing clutch pedal, Golf Cabriolet 4874
1 10 2 Removing and installing clutch pedal, CC 4876
1 10 3 Removing and installing clutch pedal, Golf, Golf Estate 4878
1 11 Removing and installing mounting bracket 4879
1 11 1 Removing and installing mounting bracket, Golf Cabriolet, LHD vehicles 4879
1 11 3 Removing and installing mounting bracket, CC 4890
1 11 4 Removing and installing mounting bracket, Golf, Golf Estate 4893
1 12 Removing and installing clutch master cylinder 4898
1 12 1 Removing and installing clutch master cylinder, CC, Golf Cabriolet 4898
1 12 2 Removing and installing clutch master cylinder, Golf, Golf Estate 4900
1 13 Removing and installing clutch slave cylinder 4901
1 13 1 Removing and installing clutch slave cylinder, CC, Golf Cabriolet 4901
1 13 2 Removing and installing clutch slave cylinder, Golf, Golf Estate 4904
1 14 Removing and installing lines for clutch mechanism 4906
1 15 Bleeding clutch mechanism 4908
1 16 Repairing clutch release mechanism 4910
2 Clutch 4912
2 1 Assembly overview – clutch 4912
2 1 1 Assembly overview – clutch in conjunction with Sachs dual-mass flywheel 4912
2 1 2 Assembly overview – clutch in conjunction with LuK dual-mass flywheel 4913
2 1 3 Assembly overview – clutch with simple flywheel 4914
2 2 Removing and installing clutch 4915
2 2 1 Removing and installing clutch in conjunction with Sachs dual-mass flywheel 4915
2 2 2 Removing and installing clutch in conjunction with LuK dual-mass flywheel 4918
2 2 3 Removing and installing clutch in connection with simple flywheel 4922
34 – Controls, housing 4927
1 Selector mechanism 4927
1 1 Installation position – selector mechanism 4927
1 2 Overview – selector mechanism 4929
1 3 Assembly overview – gear knob and cover 4930
1 3 1 Assembly overview – gear knob and cover, Golf Cabriolet, CC 4930
1 3 2 Assembly overview – gear lever knob and cover, Golf, Golf Estate 4931
1 4 Assembly overview – Gear lever and selector housing 4932
1 5 Assembly overview – Selector cables 4934
1 6 Assembly overview – selector mechanism 4936
1 7 Removing and installing gear knob 4937
1 7 1 Removing and installing gear knob, Golf Cabriolet 4937
1 7 2 Removing and installing gear knob, CC 4939
1 7 3 Removing and installing gear knob, Golf, Golf Estate 4941
1 8 Dismantling and assembling selector mechanism 4943
1 9 Removing and installing selector mechanism 4947
1 10 Removing and installing gear selector cable and gate selector cable 4952
1 11 Repairing selector mechanism 4955
1 12 Adjusting selector mechanism 4957
1 13 Checking selector mechanism 4961
2 Removing and installing gearbox 4962
2 1 Distinguishing between different types of 1 4 l petrol engine, Golf Cabriolet, CC 4962
2 2 Removing gearbox 4963
2 2 1 Removing gearbox, Golf Cabriolet, engine lifting eyes »at rear« of engine 4963
2 2 2 Removing gearbox, Golf Cabriolet, engine lifting eyes »at front« of engine 4973
2 2 3 Removing gearbox, CC, vehicles with 1 4 l petrol engine, engine lifting eyes »at rear« of engine 4983
2 2 4 Removing gearbox, CC, vehicles with 1 4 l petrol engine, engine lifting eyes »at front« of engine 4993
2 2 5 Removing gearbox, CC with 1 8 l petrol engine 5002
2 2 6 Removing gearbox, Golf, Golf Estate with petrol engine 5011
2 2 7 Removing gearbox, Golf, Golf Estate with turbo diesel engine 5021
2 3 Install gearbox 5033
2 3 1 Installing gearbox, Golf Cabriolet, engine lifting eyes »at rear« of engine 5033
2 3 2 Installing gearbox, CC, vehicles with 1 4 l petrol engine, engine lifting eyes »at rear« of engine 5040
2 3 3 Installing gearbox, CC, Golf Cabriolet, vehicles with 1 4 l petrol engine, engine lifting eyes »at front« of engine 5047
2 3 4 Installing gearbox, CC with 1 8 l petrol engine 5054
2 3 5 Installing gearbox, Golf, Golf Estate with petrol engine 5060
2 3 6 Installing gearbox, Golf, Golf Estate with turbo diesel engine 5066
2 4 Specified torques for gearbox 5074
2 4 1 Specified torques for gearbox, Golf Cabriolet, vehicles with 1 4 l petrol engine, engine lifting eyes »at rear« of engine 5074
2 4 2 Specified torques for gearbox, CC, vehicles with 1 4 l petrol engine, engine lifting eyes »at rear« of engine 5075
2 4 4 Specified torques for gearbox, Golf, Golf Estate, Golf Cabriolet, CC, vehicles with 1 4 l petrol engine, engine lifting eyes »at front« of engine 5075
3 Assembly mountings 5077
3 1 Assembly overview – assembly mountings 5077
4 Transporting gearbox 5079
5 Gear oil 5080
5 1 Checking gear oil level 5080
5 2 Draining and filling gear oil 5080
6 Installing to engine and gearbox support 5083
7 Dismantling and assembling gearbox 5084
7 1 Schematic overview – gearbox 5084
7 2 Assembly overview – gearbox 5086
7 3 Assembly overview – cover for gearbox housing and 5th/6th gear 5087
7 4 Assembly overview – gearbox housing and selector mechanism 5089
7 5 Assembly overview – selector unit 5091
7 6 Assembly overview – shafts, differential, selector mechanism 5092
7 7 Assembly overview – selector forks 5093
7 8 Repairing selector unit 5096
7 9 Renewing oil seal for selector shaft 5097
7 10 Repairing selector forks 5098
7 11 Removing cover for gearbox housing and 5th and 6th gears 5102
7 12 Dismantling and assembling gearbox 5109
7 13 Installing cover for gearbox housing and 5th and 6th gears 5122
8 Gearbox housing, clutch housing 5127
8 1 Assembly overview – gearbox housing and clutch housing 5127
8 2 Assembly overview – gearbox housing cover 5129
8 3 Repairing gearbox housing 5130
8 3 1 Identifying output shaft bearing in gearbox housing 5130
8 3 2 Removing and installing roller bearing without retaining ring 5131
8 3 3 Removing and installing roller bearing with retaining ring 5132
8 4 Repairing clutch housing 5135
8 5 Repairing gearbox housing cover 5136
35 – Gears, shafts 5140
1 Input shaft 5140
1 1 Assembly overview – input shaft 5140
1 2 Dismantling and assembling input shaft 5142
1 3 Adjusting input shaft 5147
1 4 Renewing input shaft seal 5152
2 Output shaft 5154
2 1 Assembly overview – output shaft 5154
2 2 Dismantling and assembling output shaft 5157
2 3 Adjusting output shaft 5167
3 Reverse shaft 5173
3 1 Assembly overview – reverse shaft 5173
3 2 Dismantling and assembling reverse shaft 5176
39 – Final drive – differential 5179
1 Oil seals 5179
1 1 Overview of fitting locations – seals 5179
1 2 Renewing left oil seal 5180
1 2 1 Renewing oil seal for left flange shaft 5180
1 3 Renewing right oil seal 5182
1 3 1 Renewing oil seal for right flange shaft 5182
2 Differential 5186
2 1 Assembly overview – differential 5186
2 2 Dismantling and assembling differential 5187
2 3 Adjusting differential 5193
3 Adjustment overview 5197
00 – Technical data 5204
1 Introduction 5204
2 Acoustic considerations during vehicle development 5205
2 1 Vibration insulation film 5205
2 2 Insulation 5206
3 General procedure for identifying noises 5208
3 1 General procedure 5208
3 2 Identifying a noise 5208
3 2 1 Localising origin of noise 5208
3 2 2 Identifying the type of noise 5209
3 2 3 Identifying the point in time when the noise occurs 5209
3 2 4 Identifying the noise by definition or designation 5209
3 3 Aid for localising noise by means of audio recordings (frequencies) 5209
3 3 1 Preparing an audio CD with downloaded files 5210
3 3 2 List of audio tracks 5210
3 3 3 Conditions for testing 5210
3 3 4 Conditions for performing the audio test 5211
3 4 Checklist 5211
4 Volkswagen equipment for localising noises 5215
4 1 Ultrasonic tester -VAG 1842- 5215
4 1 1 Design of the ultrasonic tester -VAG 1842- 5215
4 1 2 Example of procedure for identifying noises using ultrasound 5215
4 2 Borescope -VAS 6748A- 5219
4 2 1 Design of the borescope -VAS 6748A- 5219
4 2 2 Procedure for identifying noises using the borescope 5220
5 Attachments 5221
5 1 Checklist 5221
5 2 Designations for noises 5223
00 – Technical data 5230
1 General repair instructions 5230
1 1 Tools 5230
1 2 Gearbox 5230
1 3 Overview 5230
1 4 Seals 5231
1 5 ⇒ DSG® oil 5232
1 6 Oil filter change – »Yes or no?« 5232
1 7 Oil drain and inspection plug -A- 5232
1 8 Nuts and bolts 5233
1 9 Electrical components 5233
2 Fault finding 5234
2 1 General notes on fault finding 5234
2 2 Useful information about the “behaviour of the control unit in the event of a gearbox fault” 5234
2 3 Special notes on fault finding 5235
3 Identification of gearbox 5237
3 1 Reading gearbox code letters 5237
4 Code – engine allocation 5239
4 1 Golf Plus 2009 ► 5239
4 2 Golf Plus 2005 ► 5239
4 3 Golf 2009 ► 5240
4 4 Scirocco 2009 ► 5240
4 5 Golf 2004 ► 5240
4 6 Touran 2003 ► 5241
4 7 Passat 2006 ► 5242
4 8 Eos 2006 ► 5242
4 9 Passat CC 2009 ►; CC 2010 ► 5243
4 10 Sharan 2011 ► 5243
5 Capacity 5244
30 – Clutch 5245
1 Clutch 5245
1 1 Assembly overview – dual clutch 5245
1 2 Removing and installing clutch end cover 5247
1 3 Removing dual clutch 5253
1 4 Installing dual clutch 5254
34 – Controls, housing 5260
1 Electrical and electronic components and their locations ⇒ DSG® 5260
1 1 Removing and installing mechatronic unit for dual clutch gearbox -J743- (gearbox installed) 5260
1 2 Removing and installing mechatronic unit for dual clutch gearbox -J743- (gearbox removed) 5269
1 3 Removing and installing gearbox input speed sender -G182- and oil temperature sender in multi-plate clutch -G509- 5276
2 Removing and installing gear oil cooler 5277
3 Removing and installing oil pump 5280
4 Renewing selector shaft lever oil seal with gearbox removed 5284
5 Emergency release of selector lever 5286
6 Removing and installing selector lever handle 5287
6 1 Moving push-button in the handle to installation position 5289
6 1 1 Handle with push-button on side 5289
6 1 2 Handle with front push-button 5289
7 Selector mechanism up to 02 2009 5291
7 1 Overview of selector mechanism up to 02 2009 5291
7 2 Removing and installing selector lever cable up to 02 2009 5292
7 3 Checking selector lever cable 5299
7 4 Adjusting selector lever cable 5299
8 Checking selector mechanism 5301
8 1 Selector lever in “P” position and ignition switched on 5301
8 2 Selector lever in “N” position and ignition switched on 5301
8 3 Selector lever in position “Tiptronic” 5301
8 4 Ignition and light switched on 5301
8 5 Selector lever position indicator 5301
9 Selector mechanism from 03 2009 onwards 5302
9 1 Overview of selector mechanism in vehicles from 03 2009 onwards 5302
9 2 Removing and installing selector mechanism, from 03 2009 5303
9 2 1 Removing and installing selector mechanism with selector housing 5303
9 2 2 Removing and installing selector mechanism without selector housing 5305
10 Removing and installing gearbox 5307
10 1 Removing gearbox, Passat CC 2009 ►, CC 2010 ► with 2 0 l petrol engine 5307
10 2 Removing gearbox, Golf 2009 ►, Golf Plus 2009 ► with 2 0 l petrol engine 5316
10 3 Removing gearbox, Golf Plus 2005 ► with 1 4 l petrol engine 5325
10 4 Removing gearbox, Passat CC 2009 ►, CC 2010 ► diesel engine 5332
10 5 Removing gearbox, Passat CC 2009 ►, CC 2010 ► with diesel engine, all-wheel drive 5342
10 6 Removing gearbox, Golf Plus 2009 ► with 2 0 l diesel engine 5351
10 7 Removing gearbox, Golf 2009 ► 2 0 l diesel engine 5359
10 8 Removing gearbox, Passat CC 2009 ►, CC 2010 ► with 3 6 l – V6 engine (all-wheel drive) 5366
10 9 Removing gearbox, Golf 2004 ▸ with 1 9 l and 2 0 l diesel engine 5373
10 10 Removing gearbox, Golf 2004 ► with 125 kW – 2 0 l diesel engine 5380
10 11 Removing gearbox, Eos 2006 ►, with 3 2 and 3 6 l – V6 engine 5386
10 12 Removing gearbox, Golf 2004 ► with 1 4 l petrol engine 5393
10 13 Removing gearbox, Golf 2004 ► with 2 0 l petrol engine 5400
10 14 Removing gearbox, Golf 2004 ►, with 3 2 l – V6 engine (R32 all-wheel drive) 5405
10 15 Removing gearbox, Golf Plus 2005 ► with 1 9 l and 2 0 l diesel engine, with 2 0 l petrol engine 5414
10 16 Removing gearbox, Eos 2006 ► with 2 0 l petrol engine 5421
10 17 Removing gearbox, Eos 2005 ► with 2 0 l diesel engine 5428
10 18 Removing gearbox, Touran 2003 ► 5435
10 19 Removing gearbox, Passat 2006 ► with 2 0 l diesel engine 5443
10 20 Removing gearbox, Passat 2006 ► with 2 0 l petrol engine 5451
10 21 Removing gearbox, Passat 2006 ► with 3 6 l – V6 engine (all-wheel drive) 5456
10 22 Removing gearbox, Scirocco 2009 ► with 2 0 l diesel engine 5462
10 23 Removing gearbox, Scirocco 2009 ► with 2 0 l petrol engine 5471
10 24 Removing gearbox, Sharan 2011 ► with 2 0 l diesel engine 5480
10 25 Removing gearbox, Sharan 2011 ► with 1 8 l and 2 0 l petrol engine 5488
10 26 Removing gearbox, Sharan 2011 ► with 1 4 l petrol engine 5497
10 27 Install gearbox 5504
11 Torque settings »gearbox to engine« 5506
11 1 Torque settings (⇒ ELSA) 5506
11 1 1 Torque settings and note on engine mountings 5507
11 1 2 Torque settings and note on engine mountings 5508
11 1 3 Torque settings and note on engine mountings 5509
11 1 4 Torque settings and note on engine mountings 5511
11 1 5 Torque settings and note on engine mountings 5512
11 1 6 Torque settings and note on engine mountings 5513
12 Transporting gearbox and securing to assembly stand 5514
13 Removing and installing bevel box, Golf 2004 ► and Passat 2006 ► 5515
14 Removing and installing bevel box, Passat CC 2009 ►, CC 2010 ► with diesel engine 5520
14 1 Specified torques 5526
15 Removing and installing bevel box, Passat CC 2009 ►, CC 2010 ► with 3 6 l V6 engine 5528
16 Oil and oil filter 5532
16 1 Oil filter: renewing 5532
16 2 Checking oil level and topping up 5533
16 3 Draining and filling oil 5536
35 – Gears, shafts 5540
1 Currently, no repairs can be made to gears and shafts 5540
39 – Final drive – differential 5541
1 Overview – seals 5541
1 1 Renewing seals for right flange shaft or stub shaft – front-wheel drive 5542
2 Renewing oil seal for left flange shaft – front and all-wheel drive 5544
2 1 Renewing oil seal for right flange shaft – all-wheel drive 5545
2 2 Dismantling and assembling flange shaft 5547
3 Renewing oil seal for propshaft drive flange at bevel box 5549
4 Assembly overview – Flange shafts and seals on bevel box 5555
4 1 Renewing seal on gearbox between bevel box and gearbox 5556
4 2 Removing and installing right flange shaft 5557
4 3 Renewing seal for right flange shaft on outside of bevel box 5559
4 4 Renewing needle bearing (polygon bearing) for right output shaft drive flange 5560
4 5 Renewing seal on bevel box between gearbox and bevel box 5562
5 Checking and topping up gear oil in bevel box 5564
5 1 Checking gear oil in bevel box 5564
5 2 Topping up gear oil in bevel box 5565
00 – Technical data 5572
1 Identification 5572
1 1 Gearbox identification 5572
1 1 1 Identification on gearbox 5572
1 1 2 Reading gearbox code letters 5573
2 General information 5575
2 1 Allocation gearbox – engine 5575
2 1 1 Golf Cabriolet 2012 ► 5575
2 1 2 CC 2012 ► 5575
2 1 3 Passat 2011 ► 5575
2 1 4 Tiguan 2008 ► 5576
2 2 Capacities 5576
3 Safety information 5577
3 1 General safety provisions 5577
3 2 Safety measures when working on vehicles with a start/stop system 5577
3 3 Notes on tow-starting/towing 5578
4 Repair instructions 5579
4 1 General repair instructions 5579
4 1 1 General information 5579
4 1 3 Oil filter change – »Yes or no?« 5580
4 2 Gaskets and seals 5581
4 3 Nuts and bolts 5581
5 Electrical components 5582
5 1 Overview of fitting locations – electrical components 5582
30 – Clutch 5584
1 Clutch 5584
1 1 Assembly overview – dual clutch 5584
1 2 Removing and installing clutch end cover 5586
1 3 Removing dual clutch 5592
1 4 Installing dual clutch 5593
34 – Controls, housing 5599
1 Mechatronic unit 5599
1 1 Removing and installing mechatronic unit for dual clutch gearbox -J743- 5599
1 1 1 Removing and installing mechatronic unit for dual clutch gearbox -J743-, gearbox installed 5599
1 1 2 Removing and installing mechatronic unit for dual clutch gearbox -J743-, gearbox removed 5609
1 1 3 Renewing securing clip on vehicle connector 5617
1 2 Removing and installing gearbox input speed sender -G182- and clutch temperature sender -G509- 5618
2 Selector mechanism 5620
2 1 Assembly overview – selector mechanism 5620
2 2 Emergency release from position P 5621
2 3 Removing and installing selector lever handle 5622
2 3 1 Removing and installing handle 5622
2 3 2 Moving push-button in the handle to installation position 5623
2 4 Removing and installing selector mechanism 5625
2 4 1 Removing and installing selector mechanism with selector housing 5625
2 4 2 Removing and installing selector mechanism without selector housing 5627
2 5 Checking selector mechanism 5629
2 6 Checking and adjusting selector lever cable 5630
2 7 Renewing oil seal for selector shaft 5632
3 Removing and installing gearbox 5635
3 1 Distinguishing between different types of engines, Golf Cabriolet 2012 ►, Tiguan 2008 ►, CC 2012 ► 5635
3 1 1 Distinguishing between different types of diesel engines, Golf Cabriolet 2012 ►, CC 2012 ►, vehicles with front-wheel drive 5635
3 1 2 Distinguishing between different types of 1 4 l petrol engines, Tiguan 2008 ► 5635
3 2 Removing gearbox 5637
3 2 3 Removing gearbox, Golf Cabriolet with 2 0 l petrol engine 5651
3 2 4 Removing gearbox, Passat 2011 ►, CC 2012 ► with 2 0 l petrol engine, front-wheel drive 5657
3 2 5 Removing gearbox, Passat 2011 ► with 2 0 l petrol engine, all-wheel drive 5663
3 2 6 Removing gearbox, Passat 2011 ► with diesel engine, front-wheel drive 5672
3 2 9 Removing gearbox, Passat 2011 ►, CC 2012 ► with diesel engine, all-wheel drive 5700
3 2 10 Removing gearbox, Passat 2011 ►, CC 2012 ► with 3 6 l – V6 petrol engine, all-wheel drive 5710
3 2 11 Removing gearbox, Tiguan 2008 ► with 1 4 l – 118 kW petrol engine, engine lifting eyes »at rear« of engine 5718
3 3 Install gearbox 5735
3 4 Specified torques for gearbox 5740
4 Transporting gearbox 5742
5 Installing to engine and gearbox support 5743
6 Bevel box 5744
6 1 Removing bevel box 5744
6 1 1 Removing bevel box, CC 2012 ►, Passat 2011 ►, with diesel engine 5744
6 1 2 Removing bevel box, CC 2012 ►, Passat 2011 ► with 3 6 l – V6 petrol engine 5749
6 1 3 Removing bevel box, Passat 2011 ► with 2 0 l petrol engine 5753
6 2 Installing bevel box 5757
6 2 1 Installing bevel box, CC 2012 ►, Passat 2011 ►, with diesel engine 5757
6 2 2 Installing bevel box, CC 2012 ►, Passat 2011 ► with 3 6 l – V6 petrol engine 5758
6 2 3 Installing bevel box, Passat 2011 ► with 2 0 l petrol engine 5760
7 Dismantling and assembling gearbox 5762
7 1 Assembly overview – gearbox 5762
8 Gear oil circuit 5765
8 1 Removing and installing gear oil cooler 5765
8 2 Removing and installing gear oil pump 5767
8 3 Removing and installing gear oil filter 5771
9 Gear oil 5773
9 1 Checking gear oil level 5773
9 2 Draining and filling gear oil 5776
35 – Gears, shafts 5780
1 Currently, no repairs can be made to gears and shafts 5780
39 – Final drive – differential 5781
1 Final drive seals 5781
1 1 Overview of fitting locations – seals 5781
1 2 Renewing left oil seal 5781
1 3 Renewing right oil seal 5785
1 3 1 Renewing right oil seal, front wheel drive 5785
1 3 2 Renewing right oil seal, all-wheel drive 5788
2 Bevel box 5790
2 1 Assembly overview – bevel box 5790
2 2 Removing and installing right flange shaft 5791
2 3 Renewing needle bearing (polygon bearing) for right output shaft drive flange 5793
2 4 Renewing output flange and redetermining thickness of shim, bevel box removed 5795
2 5 Renewing seal on gearbox between bevel box and gearbox 5804
2 6 Renewing seal for right flange shaft on outside of bevel box 5806
2 7 Renewing seal on bevel box between gearbox and bevel box 5807
2 8 Renewing oil seal for drive flange and bevel box 5808
3 Gear oil 5821
3 1 Checking gear oil level 5821
3 1 1 Checking gear oil in bevel box 5821
3 1 2 Filling gear oil in bevel box 5821
00 – Technical data 5831
1 — Change history — 5831
2 Introduction 5833
3 List of Suppliers 5834
3 1 3M do Brasil 5834
3 2 Brascola Ltda 5834
3 3 Castrol Brasil Ltda 5834
3 4 Cia Brasileira de Petróleo Ipiranga 5834
3 5 Chemours 5834
3 6 Chevron Brasil S/A 5834
3 7 Cremer S A Prod Têxteis e Cirúrgicos 5834
3 8 Dow Corning do Brasil Ltda 5834
3 9 Elf Lubrificantes do Brasil 5834
3 10 ExxonMobil 5834
3 11 Henkel do Brasil Ltda 5834
3 12 Klüber Lubrification Lubrificantes Especiais Ltda 5834
3 13 Loctite Brasil Ltda 5834
3 14 Lumobrás Imp Com Ind Ltda 5834
3 15 Motul Synthetic Lubricants 5834
3 16 Ocean Indústria Química 5834
3 17 Pentosin do Brasil Ltda 5835
3 18 Petrobras Distr S/A 5835
3 19 Shell Brasil S/A 5835
3 20 Sika S/A 5835
3 21 Solplás – Ind de Plásticos Ltda 5835
3 22 Solvay Química 5835
3 23 Three Bond do Brasil Ind e Com Ltda 5835
3 24 Total Lubrificantes Brasil Ltda 5835
3 25 Tutela Lubrificantes S/A 5835
3 26 Valvoline Lubrificantes Internacionais Ltda 5835
4 Work Instructions for Handling Chemicals 5836
4 1 Handling of Solvents 5836
4 2 Work instruction – Flammable material handling 5838
4 3 Handling used engine oil 5839
4 4 General guidelines on the storage of chemicals 5840
5 List of authorized products 5841
5 1 Polyurethane-based sealing adhesive 5841
5 2 High-resistance locking adhesive 5841
5 3 Low viscosity lock adhesive 5841
5 4 Sealing adhesive 5841
5 5 Self-adhesive PVC tape 5841
5 6 Double-sided adhesive tape 5841
5 7 Refrigerant gas – R134a 5842
5 8 Underbody coating 5842
5 9 Lubricating engine oil as per VW 502 00 and VW 505 00 standards 5842
5 10 Lubricating engine oil as per VW 507 00 standard 5842
5 11 Lubricating engine oil as per VW 508 88 and VW 509 99 standards 5843
5 12 Lubricating oil for manual gearbox and steering rack – SAE 90, MIL-L-2105B, API – GL5 5843
5 13 Lubricating oil for manual gearbox – SAE 80, MIL-L-2105, API – GL4 5843
5 14 Tire assembly paste 5843
5 15 Biodegradable degreasing product 5843
5 16 Grease remover spray 5844
6 List of fractionated products 5845
6 1 -000 096 319 D- Polishing material (chromium and aluminium) 5845
6 2 -032 198 561- Additional seal 5845
6 3 -AMV 188 001 02- Adhesive silicone 5846
6 4 -AMV 188 200 03- Sealing paste 5846
6 5 -AMV 189 300- Activating agent 5847
6 6 -AMV 189 400- Sealing compound 5847
6 7 Liquid sealant -D 000 600 A2- 5847
6 8 -D 001 210 M2- Universal adhesive 5848
6 9 -D 002 000 A2-Adhesive remover 5848
6 10 -D 004 660 M2- Adhesive set 5848
6 11 -D 007 000 A2- Spray silicone 5849
6 12 -D 009 200 02- Glass primer 5849
6 13 -D 009 401 04- Cleaning solution 5850
6 14 -D 009 500 25- Applicator 5850
6 15 Liquid sealant -D 154 000 A1- 5851
6 16 Liquid sealant -D 154 100 A1- 5851
6 17 -D 154 102 A1- Sealing compound 5851
6 18 -D 154 103 A1- Adhesive silicone 5852
6 19 -D 169 300 M1- Window adhesive 5852
6 20 -D 169 300 M2- Window adhesive 5852
6 21 -D 172 090 A2- Adhesive 5853
6 22 -D 174 003 M2- Silicone sealant 5853
6 23 -D 176 404 A3- Adhesive silicone 5854
6 24 -D 176 204 R2- Adhesive silicone 5854
6 25 -D 176 404 M2- Adhesive silicone 5854
6 26 -D 176 501 A1- Adhesive silicone 5854
6 27 -D 180 KU1 A1- 2-component adhesive for plastic 5855
6 28 -D 180 KU2 A1- 2-component adhesive for plastic 5855
6 29 -D 181 220 A1- Activating agent 5856
6 30 -D 181 655 A1- Activating agent 5856
6 31 -D 181 802 M1- Glass primer 5856
6 32 Liquid sealant -D 185 400 A2- 5857
6 33 Liquid sealant -D 185 400 A3- 5857
6 34 Liquid sealant -D 185 410 A2- 5857
6 35 -D 185 520 A2- Sealing compound 5857
6 36 -D 190 MKD A3- Assembly adhesive 5858
6 37 Liquid sealant -D 192 100 A2- 5858
6 38 -D 195 850 A1- Cleaning solution 5858
6 39 -D 316 D38 A2- Protective wax 5859
6 40 -D 322 000 A2- Wachs-spray 5859
6 41 -D 322 100 M2- Wachs-spray 5859
6 42 -D 330 KD2 A1- Cavity spray 5860
6 43 -D 366 PR1 A1- Plastic primer 5860
6 44 -D 454 300 A2- Sealing compound 5860
6 45 -D 469 101 A3- Gluing and sealing compound 5861
6 46 -D 822 150 A1- Plastic surfacer 5861
6 47 -G 000 100- Coupling teeth lubricant compound 5861
6 48 -G 000 115 A2- Spray lubricant 5862
6 49 -G 000 150- Consistent lubricating paste 5862
6 50 -G 000 405 A2- Silicone paste 5862
6 51 -G 000 450 02- Lubrication paste 5863
6 52 -G 000 650- Consistent lubricating paste 5864
6 53 -G 052 109 A2- Assembly paste 5864
6 54 -G 052 112 A3- High temperature paste 5864
6 55 -G 052 128 A1- Thrust ring sealing grease 5865
6 56 -G 052 133 A2- Lubricating paste for high temperatures 5865
6 57 -G 052 135 A1- Lubricating oil 5865
6 58 -G 052 142 A2- Polyurethane lubricating compound 5866
6 59 -G 052 150 A2- Lithium lubricating paste 5866
6 60 -G 052 168 A1- Steering box lubricant 5867
6 61 -G 052 172 A1- Special lubricant 5867
6 62 -G 052 172 M2- Special lubricant 5867
6 63 -G 052 181 A4- Lubricating paste for constant velocity joints 5868
6 64 -G 052 528 A2- Lubricating paste for constant velocity joints 5868
6 65 -G 052 565 A1- Silicone paste 5868
6 66 -G 052 723 A2- Moly paste 5869
6 67 -G 052 735 A2- Multi-purpose grease 5869
6 68 -G 052 738 A2- Lubricating paste for constant velocity joints 5869
6 69 -G 052 738 A3- Thrust ring sealing grease 5870
6 70 -G 052 745 A3- Lubricating paste for low temperature 5870
6 71 -G 052 751 A1- Molybdenum pasta 5870
6 72 -G 052 778 A2- Spray lubricant 5871
6 73 -G 052 817 A1- Contact grease 5871
6 74 -G 055 128 A1- Thrust ring sealing grease 5871
6 75 -G 060 567 A2- Special lubricant 5872
6 76 -G 060 735 A2- Multi-purpose grease 5872
6 77 -G 060 751 A2- Consistent lubricating paste 5872
6 78 -G 065 567 A2- Cleaning solution 5873
6 79 -G 070 528 R2- Lubricating paste for constant velocity joints 5873
6 80 -G 294 421 A1- Lubricating oil for assembly 5873
1 Safety instructions 5878
1 1 Part removal 5878
1 2 Battery and welding operation 5878
1 3 Electronic control unit 5878
1 3 1 Processing of the electronic control unit after repair dueto a traffic accident 5878
1 4 Paint, glass, soft pad and trim 5879
1 5 Fuel tank or fuel delivery pipeline 5879
1 6 Air conditioner 5879
1 6 1 Remedial measures: 5879
1 7 Airbag System 5880
1 8 Check the seat belts 5880
1 8 1 Belt body 5881
1 8 2 Automatic retractor (locking function) 5881
1 8 3 Visual inspection of the seat belt buckle 5882
1 8 4 Seat belt buckle function 5882
1 8 5 Seat belt guide member and tongue 5883
1 8 6 Fixing piece and fixing point 5883
1 9 Safety specifications for the seat belt tensioner 5883
1 10 Body repair on a vehicle equipped with the seat belt tensioners 5884
1 10 1 The following vehicles have been equipped with: 5884
1 11 Perform cutting off, correcting and/or leveling on a vehicleequipped with airbags 5885
1 12 Remove the front seats with a side airbag 5885
2 Basic instruction 5886
2 1 Diagnosis of the accident vehicle 5886
2 2 Condition of the body and/or the parts for delivery to thepainting workshop 5886
2 3 Correction 5886
2 4 Cutting 5886
2 5 Body-cut part and part section 5886
2 6 Original connection 5887
2 7 Galvanized body parts 5887
2 8 Remove the rest part 5887
2 9 New parts 5887
2 10 Parts 5887
2 11 Molded foam plastic pads 5888
3 Symbolic interpretation 5889
3 1 Symbolic interpretation for welding 5889
3 2 Symbolic interpretation for the operation method 5889
3 2 1 Grinding 5890
3 2 2 Thinning 5890
3 2 3 Punching 5890
3 2 4 Drilling 5891
3 2 5 Polishing 5891
3 2 6 Cavity corrosion protection 5891
3 2 7 Bonding 5892
3 2 8 Precise sealing 5892
4 Body repair tools 5893
4 1 Flaring tool -V A G 1317- 5893
4 2 Punching pliers -V A G 1329- 5893
4 3 Basic equipment -V A G 1366/3- 5893
4 4 Bottom protection layer spray gun -V A G 1379- 5894
4 5 Electric blower -V A G 1416- 5894
4 6 Door tensioner -V A G 1438- 5894
4 7 Body equipment component -V A G 1439- 5895
4 8 Pneumatic cutting knife -V A G 1523 A- 5895
4 9 Air chisel -V A G 1577- 5895
4 10 Edge closing iron block -V A G 1585- 5896
4 11 Welding fume ventilator -V A G 1586- 5896
4 12 Welding spot releasing device -V A G 1731- 5896
4 13 Pneumatic spray gun -V A G 1761/1- 5897
4 14 Pneumatic punching and thinning pliers -VAS 1996- 5897
4 15 Pneumatic adhesive spray gun -V A G 2005- 5897
4 16 Door hinge correction tool 5898
4 17 Hose kit 5023 for the inert gas protection welding 5898
4 18 Angle grinder -VAS 5174- 5898
4 19 Angle grinder -VAS 5175- 5899
4 20 Wire brush -VAS 5182- 5899
5 Body bonding 5900
5 1 Transporter 1991 → 5900
5 1 1 Separation process: 5900
5 1 2 Bonding process: 5900
5 2 Bonding types 5900
5 2 1 Bonding-strong 5900
5 2 2 Bonding-spot welding 5901
5 3 Repair method for replacing the parts 5901
5 3 1 Spot welding and bonding 5901
5 3 2 Plug welding and bonding (if spot welding is impossible) 5901
5 3 3 Welding fume ventilator 5902
5 3 4 Preparations 5902
5 3 5 Trimming 5902
6 Corrosion protection measures 5903
6 1 Corrosion protection 5903
7 Waste disposal instructions 5904
7 1 Waste disposal 5904
7 2 Air pressure tappet exhaust 5904
7 3 Airbag 5905
7 3 1 Waste disposal 5905
8 Contact corrosion protection 5906
8 1 Connection of aluminum alloy/magnesium alloy with steel 5906
9 Steel plate repair 5907
9 1 High-strength body plate 5907
9 2 Galvanized body parts 5907
9 2 1 Preparations 5907
9 2 2 Part cutting 5908
9 2 3 Connection process 5908
9 3 Welding on the galvanized body steel plate 5908
9 3 1 Inert gas protection plug welding SG of the galvanized steelplate 5908
9 3 2 Resistance pressure spot welding RP of the galvanized steelplate 5909
9 3 3 Welding transformer 5909
9 3 4 Welding clamp 5909
9 4 Tearing test 5909
10 Aluminum repair 5910
10 1 Painting 5910
10 2 Surface treatment 5910
10 3 Leveling 5911
10 4 Temperature control for heating 5911
11 Plastic repair method 5912
11 1 Material 5912
11 2 Repairing the pit 5913
11 3 Repairing the scratch 5914
11 4 Repair the crack 5916
11 5 Repairing the small hole (the diameter is more than 30 mm) 5917
11 6 Plastic repair (glass fibre material) 5918
11 7 Repair process 5919
11 7 1 Repairing the breakage position 5919
11 7 2 Repairing the surface damage 5921
12 Glass repair 5922
12 1 Repairing the windshield 5922
12 1 1 Premises 5922
12 1 2 Required special tools, operating equipment, testing instrumentsand auxiliary tools 5923
12 1 3 Repair description 5924
00 – Technical data 5934
1 Safety information 5934
1 1 Safety precautions when working on air conditioning systems 5934
1 2 Safety precautions when handling refrigerants 5935
1 3 Safety measures when working on vehicles with a start/stop system 5935
1 4 Safety precautions when using air conditioner service stations 5935
1 5 Safety measures for working on vehicles with high-voltage system 5936
1 6 Safety precautions when working in the vicinity of high-voltage components 5937
1 7 Safety precautions when working on pressure vessels 5937
2 Laws and regulations 5938
2 1 Legal regulations and standards 5938
2 2 Charging refrigerant circuit with different refrigerants 5939
2 3 Occupational health and safety 5940
3 Repair notes 5941
3 1 Rules for cleanliness 5941
3 2 Refrigerant circuit seals 5941
3 3 Refrigerant and refrigerant oil 5942
3 3 1 Important repair notes for refrigerant and refrigerant oil 5942
3 3 2 Refrigerant oil 5943
3 4 Handling pressure vessels 5944
3 5 Handling refrigerants 5945
4 Identification 5947
4 1 Notice for refrigerant circuit 5947
5 Technical data 5948
5 1 Refrigerant capacity 5948
5 2 Refrigerant oil capacities 5948
5 3 Safety data sheets 5948
6 Basic technical and physical properties 5949
6 1 Basics of air conditioning technology 5949
6 1 1 Physical properties of air conditioning system 5949
6 1 2 Pressure and boiling point of refrigerant 5950
6 1 3 Vapour pressure table for refrigerant 5951
6 2 Physical properties 5953
6 2 1 Refrigerant R1234yf 5953
6 2 2 Potential risks with refrigerant R1234yf 5953
6 2 3 Physical and chemical properties of refrigerant R1234yf 5954
6 2 4 Critical point 5954
6 2 5 Environmental aspects of refrigerant R1234yf 5955
6 2 6 Trade names and designations of refrigerant R1234yf 5955
6 2 7 Colour and odour of R1234yf refrigerant 5956
6 2 8 Vapour pressure of R1234yf refrigerant 5956
6 2 9 Physical properties of R1234yf refrigerant 5956
6 2 10 How R1234yf refrigerant reacts to metals and plastics 5956
6 2 11 Critical temperature / critical pressure of R1234yf refrigerant 5957
6 2 12 Water content of R1234yf refrigerant 5957
6 2 13 Flammability / decomposition of R1234yf refrigerant 5957
6 2 14 Charge factor of refrigerant R1234yf 5957
6 2 15 Evidence of leaks in a refrigerant circuit with R1234yf refrigerant 5958
6 2 16 Analysis of refrigerant R1234yf 5958
6 2 17 Returning contaminated R1234yf refrigerant for analysis, processing or disposal 5959
6 3 Product characteristics 5960
6 4 Function and role of air conditioning system 5960
6 4 1 Principle of operation 5960
6 4 2 Comfort 5961
6 4 3 Environmental aspects 5961
6 5 Other reference material 5962
87 – Air conditioning system 5963
1 Refrigerant circuit 5963
1 1 System overview – refrigerant circuit 5963
1 1 1 System overview – refrigerant circuit with expansion valve and receiver 5963
1 1 2 System overview – refrigerant circuit with restrictor and reservoir 5965
1 1 3 System overview – refrigerant circuit with electrically driven air conditioner compressor (with and without battery cooling module) 5966
1 2 General description – components of refrigerant circuit 5969
1 2 1 Layout and function of refrigerant circuit 5969
1 2 2 Mechanical air conditioner compressor 5970
1 2 3 Electrical air conditioner compressor for hybrid vehicles 5973
1 2 4 Condenser 5976
1 2 5 evaporator 5977
1 2 6 Reservoir 5979
1 2 7 Heat exchanger for heat pump mode 5979
1 2 8 Liquid receiver 5980
1 2 9 Restrictor 5980
1 2 10 Receiver 5982
1 2 11 Expansion valve (with and without shut-off valve) 5984
1 2 12 Refrigerant shut-off valves 5986
1 2 13 Refrigerant line with internal heat exchanger 5988
1 2 14 Quick release couplings of refrigerant lines 5989
1 2 15 Seals 5990
1 2 16 Pipes and hoses in refrigerant circuit 5991
1 2 17 High-pressure safety valve 5991
1 2 18 Non-return valves 5993
1 2 19 Quick-release coupling connections in refrigerant circuit 5994
1 2 20 Connections with valve for switches in refrigerant circuit 5998
1 2 21 Pressure senders and switches in refrigerant circuit 5999
1 2 22 Refrigerant pressure and temperature sender 6000
1 2 23 Air conditioner compressor regulating valve -N280- 6003
1 2 24 Refrigerant temperature sender 6004
1 3 Possible complaints 6005
1 3 1 Prerequisites for investigating a complaint 6005
1 3 2 Possible complaints 6005
1 3 3 Odours from heater and air conditioning unit 6007
1 4 Investigating leaks 6009
1 4 1 General information about investigating leaks in the refrigerant circuit 6009
1 4 2 Searching for leaks in refrigerant circuits using an electronic leak detector 6010
1 4 3 Searching for leaks with UV leak detection system 6011
1 4 4 Detecting leaks in a vacuum test using air conditioner service station, or in a pressure test 6017
1 4 5 Detecting leaks in a pressure test (with nitrogen or compressed air) 6018
1 5 Renewing components 6020
1 5 1 General information about renewing components 6020
1 5 2 Renewing leaking or damaged components of empty refrigerant circuit (apart from air conditioner compressor and receiver) 6021
1 5 3 Renewing leaking or damaged components of charged refrigerant circuit (apart from air conditioner compressor and receiver) 6023
1 5 4 Renewing air conditioner compressor with no need to clean refrigerant circuit 6024
1 5 5 Renewing air conditioner compressor due to leaks or internal damage 6027
1 5 6 Renewing desiccant cartridge / receiver after cleaning refrigerant circuit 6028
1 5 7 Renewing receiver with no need to clean refrigerant circuit 6030
1 5 8 Renewing desiccant cartridge / desiccant bag with no need to clean refrigerant circuit 6031
1 6 Cleaning refrigerant circuit 6032
1 6 1 General information about cleaning refrigerant circuit 6032
1 6 2 Preparations for cleaning refrigerant circuit (flushing with R1234yf refrigerant) 6034
1 6 3 Refrigerant circuit cleaning procedure 6038
1 6 4 Principle circuit diagrams for cleaning (flushing circuits) – refrigerant circuit with expansion valve and receiver 6038
1 6 5 Principle circuit diagrams for cleaning (flushing circuits) – refrigerant circuit with restrictor and receiver (without high-voltage system) 6043
1 6 6 Adapters for setting up flushing circuits 6046
1 6 7 General information about blowing through with compressed air or nitrogen 6059
1 6 8 Blowing through refrigerant circuit with compressed air or nitrogen 6063
1 7 Checking pressures with pressure gauge 6064
1 7 1 Display on pressure gauges 6064
1 7 2 Pressure gauges enable the following test and measurement work 6065
2 Working with air conditioner service station 6068
2 1 Working with air conditioner service station 6069
2 2 Connecting air conditioner service station to refrigerant circuit 6071
2 3 Performing gas analysis of refrigerant 6074
2 4 Purging refrigerant circuit 6077
2 5 Evacuating refrigerant circuit 6080
2 6 Charging refrigerant circuit 6086
2 7 Bringing air conditioning system into service after charging 6089
2 8 Switching off air conditioner service station and separating from refrigerant circuit 6091
2 9 Charging refrigerant in reservoir 6093
2 10 Emptying air conditioner service station 6094
2 11 Cleaning electrical air conditioning compressor 6094
2 12 Cleaning refrigerant circuit 6097
2 13 Filling contaminated refrigerant in a recycling cylinder for analysis, processing or disposal 6100
2 13 1 Filling contaminated refrigerant into recycling cylinder using extraction unit -VAS 581 011- 6100
2 13 2 Filling contaminated refrigerant into recycling cylinder using extraction unit -VAS 581 007- 6101
2 14 Checking pressures 6105
2 14 1 General information on checking pressures in the refrigerant circuit 6105
2 14 2 Pressures and temperatures in refrigerant circuit 6107
2 14 3 Checking pressures in the refrigerant circuit with the ignition switched off 6111
2 14 4 Checking pressures with air conditioning system switched on – vehicles with mechanical air conditioning compressor 6118
2 14 5 Checking pressures with air conditioning system switched on – vehicles with electrical air conditioning compressor 6140
3 Testing equipment and tools 6193
3 1 Tools and materials available from distribution centre or importer 6193
3 2 Tools and materials available commercially 6193
44 – Wheels, tyres, vehicle geometry 6199
1 Instructions on using the guide 6199
1 1 Overview 6199
1 1 1 Wheels and Tyres Guide – General Information 6199
1 1 2 Wheels and Tyres Guide – Vehicle-specific Section 6199
1 2 General information 6199
1 3 Notes 6200
1 4 Explanations regarding world regions 6201
1 5 Definition of tyre package 6201
1 6 Procedure for determining the required tyre package 6202
1 6 1 Determining the required tyre package via PR number 6202
1 6 2 Determining the required tyre package via version key in the vehicle registration certificate part 1 6202
1 7 Vehicle registration certificate part 1 6203
2 Legislative and technical conditions 6205
2 1 Legislative conditions 6205
2 1 1 Permissible wheel and tyre combinations in Germany 6205
2 1 2 Vehicles with Tyre Pressure Monitoring System 6205
2 2 Technical conditions 6206
2 3 Load-carrying capacity depending on vehicle speed, winter tyres 6206
2 4 Vehicle registration documents since 1 10 2005 6208
2 5 COC document (EEC Certificate of Conformity) 6209
2 6 EU general type approval number, sales type and sales or trade designation 6209
3 Wheel change 6211
3 1 Fitting instructions 6211
3 2 Protecting wheel centring seat against corrosion 6214
3 3 Fitting wheels 6215
3 4 Position of anti-theft wheel bolts for steel wheels 6215
4 Fitting tyre 6216
4 1 Pressing tyre off wheel rim 6216
4 2 Removing tyre sealant 6216
4 3 Removing tyre from wheel 6217
4 3 1 Removing tyres, wheels without and with tyre pressure monitoring 6217
4 3 2 Removing tyres, run-flat tyres, ultra-high-performance tyres 6218
4 4 Ensuring proper assembly temperature for tyres 6220
4 5 Mounting tyre 6221
4 5 1 Mounting tyre, wheels without and with tyre pressure monitoring 6221
4 5 2 Mounting tyre, run-flat tyres, ultra-high performance tyres 6223
4 6 Matching wheel rims and tyres 6226
4 7 Checking radial and lateral runout of wheels and tyres 6227
4 7 1 Checking radial and lateral runout of wheels and tyres, tolerances 6227
4 7 2 Checking radial and lateral runout on wheels and tyres with tyre gauge 6227
4 8 Matching wheels and tyres 6228
4 9 Balancing wheel 6229
4 9 1 Conditions 6229
4 9 2 Balancing wheel on stationary wheel balancer 6230
4 9 3 Balancing wheel with finish balancer 6233
4 9 4 Checking radial and lateral run-out on wheel rim 6234
4 10 Tyre sealant disposal 6235
5 Tyre pressure monitoring system 6236
5 1 System description – tyre pressure monitoring system 6236
5 1 1 System description – tyre pressure monitoring system with indirect measurement (Tyre Pressure Loss Indicator) 6236
5 1 2 System description – tyre pressure monitoring system with direct measurement (Tyre Pressure Monitoring System) 6237
5 1 3 System description – tyre pressure monitoring system, tyre pressure monitoring system (TPMS) with autolocation 6238
5 2 Overview of fitting locations – tyre pressure monitor system 6238
5 2 1 Overview of fitting locations – Tyre Pressure Monitoring System (TPMS) with autolocation 6238
5 3 Assembly overview – tyre pressure sensor 6240
5 3 1 Assembly overview – tyre pressure sensor, tyre pressure sensor with valve 6240
5 3 2 Assembly overview – tyre pressure sensor, tyre pressure sensor without valve, version 1 6241
5 3 3 Assembly overview – tyre pressure sensor, tyre pressure sensor without valve, version 2 6242
5 4 Removing and installing tyre pressure sensor -G222-/-G223-/-G224-/-G225- 6243
5 4 1 Removing and installing tyre pressure sensor, tyre pressure sensor with valve 6243
5 4 2 Removing and installing tyre pressure sensor, tyre pressure sensor without valve, version 1 (customer service version) 6244
5 4 3 Removing and installing tyre pressure sensor, tyre pressure sensor without valve, version 1 (production version) 6245
5 4 4 Removing and installing tyre pressure sensor -G222-/-G223-/-G224-/-G225-, version 2 6247
5 5 Removing and installing tyre pressure monitor control unit -J502- 6250
5 5 1 Removing and installing Tyre Pressure Monitoring System control unit -J502-, Arteon 2018, Passat 2015, Passat Estate 2015 6250
5 5 2 Removing and installing tyre pressure monitoring system control unit -J502-, Touran 6251
6 Wheel bolts 6253
6 1 Wheel bolts, versions 6253
6 2 Wheel bolts, anti-theft wheel bolt 6254
6 3 Wheel bolts, adapter sets for anti-theft wheel bolts 6254
7 Information on tyres 6257
7 1 Identification markings on the tyre sidewall 6257
7 2 Tyre dimension 6259
7 3 Load rating code/load index (LI) 6259
7 4 Speed rating code 6260
7 5 EU tyre label 6260
7 5 1 EU tyre label, summary 6260
7 5 2 EU tyre label, objectives 6261
7 5 3 EU tyre label, categories 6262
7 6 Structure of a radial belted tyre 6265
7 6 1 Cross section of a radial belted tyre 6265
7 6 2 Run-flat tyres, structure and identification of a SST tyre 6266
7 6 3 Run-flat tyres, seal inside technology 6267
7 7 Run-flat tyre, SST (Self Supporting Tyre) 6269
7 7 1 Run-flat tyres – general information 6269
7 7 2 Run-flat tyres, retrofitting/requirements when using run-flat tyres 6270
7 7 3 Run-flat tyres, repair work 6271
7 8 Tyre storage 6271
7 9 Reinforced and Extra Load (XL) tyres 6271
7 10 Winter tyres 6272
7 11 Winter tyres with speed symbol V 6274
7 12 Rolling resistance optimised tyres 6275
7 13 Tyre ageing 6275
7 14 Tyres with flange protection 6277
7 15 Tyre sizes for vehicles with four-wheel drive 6277
7 16 Increase in temperature due to insufficient tyre pressure 6278
8 Tyre sealant 6279
8 1 Models with breakdown set 6279
8 2 Storage life 6279
8 3 Waste disposal 6279
9 Information on wheel rims 6280
9 1 Structure of wheel rim 6280
9 2 Identification 6281
9 3 Composite wheels 6281
9 4 Care and maintenance of alloy wheel rims 6281
9 5 Restoring alloy wheels 6282
9 6 Removing and installing hub cover for alloy wheels with open threaded connection 6282
9 7 Renewing trim elements 6283
9 7 1 Renewing trim elements, bonded trim elements 6283
9 7 2 Renewing trim elements, bolted trim elements 6287
9 8 Removing and installing valve 6289
9 8 1 Removing and installing valve, description of the valve 6289
9 8 2 Removing and installing valve, rubber valve 6289
9 8 3 Removing and installing valve, metal valve 6290
10 Handling problems 6292
10 1 Rolling noise 6292
10 1 1 General notes on tyre noise 6292
10 1 2 Flat spots (from locking wheels) 6293
10 2 Vehicle pulls to one side 6294
10 2 1 General information 6294
10 2 2 Conicity 6294
10 2 3 Remedies when vehicle pulls to one side 6295
10 2 4 Strategic rotation of wheels for non-directional tyres 6296
10 2 5 Strategic rotation of wheels having unidirectional tyres 6297
10 3 Vibration 6298
10 3 1 Vibration, causes for vibration 6298
10 3 2 Vibration, conducting a road test before balancing wheels 6298
10 3 3 Vibration, vibration control system 6299
10 4 Eliminating flat spots caused by storage or handling 6299
11 Evaluating tyres 6301
11 1 Flat spots caused by storage or handling 6301
11 2 Undulations 6301
11 3 Saw-tooth wear 6302
11 4 Flat spots caused by hard braking 6302
11 5 Swellings in the tyre sidewall 6302
11 6 Cuts 6304
11 7 Damage caused by foreign bodies 6304
11 8 Stripped profile 6304
11 9 Tyre damage due to insufficient tyre pressure 6305
11 10 Checking tyres 6305
11 11 Damage caused when fitting 6306
12 Tyre wear 6308
12 1 Factors influencing the service life of tyres 6308
12 2 Saw-tooth wear 6309
12 3 Wear behaviour of high-speed tyres 6309
12 4 Measuring tread depth 6310
12 5 One-sided wear 6310
12 6 Outer shoulder wear 6313
12 7 Diagonal washout 6314
12 8 Wear in middle of tyre 6314
12 9 Permissible deviation in tread depth 6315
13 Exploded view of components 6316
13 1 Assembly overview – wheel 6316
14 Snow chains 6318
14 1 Assembly and use of snow chains 6318
15 Regular and temporary spare wheels, recommended temporary spare tyres 6319
15 1 Spare wheel with yellow sticker 6319
15 2 Temporary spare wheels and recommended temporary spare tyres 6320
15 2 1 Arteon 2018 6320
15 2 2 Atlas 2017 6320
15 2 3 Golf 2013, e-Golf 2014 6320
15 2 4 Golf 2017, e-Golf 2017 6320
15 2 5 Golf SV 2015 6321
15 2 6 Golf Estate 2014 6321
15 2 7 Golf Estate 2017 6321
15 2 8 Passat 2015, Passat Estate 2015 6321
15 2 9 Polo 2018 6322
15 2 10 Tiguan 2016 6322
00 – Technical data 6329
1 Safety information 6329
1 1 Safety precautions when painting natural gas-powered vehicles 6329
1 2 Safety precautions when painting electric drive vehicles 6330
2 General information 6331
2 1 Paintwork structure of a factory finish 6331
2 2 Paint structure of service department finish 6334
2 2 1 Paintwork structure, base coat 6334
2 2 2 Paintwork structure, metallic effect 6337
2 3 Fundamental approach to dealing with areas sanded through to the substrate (bare metal surface) 6339
2 4 Reduced paint structure in engine compartment and inside of bonnet 6339
2 5 Instructions for work on underbody and stone chip protection 6339
2 6 Work instruction for window flange area 6341
2 7 Pre-treatment of bonded surfaces when renewing laser-welded roofs 6343
2 8 Corrosion protection measures for wing surface in contact with wheel housing liner 6347
2 9 Notes on treating corroded fold areas 6348
2 10 Corrosion protection for body components, add-on components and welded components 6350
2 11 Painting parking aid sensor 6351
2 12 ACC – Adaptive Cruise Control 6353
2 13 Instructions for painting bumper cover in area of lane change assist control unit 6353
3 Genuine products 6355
3 1 Paint products in customer service 6355
3 2 General application instructions for repair and painting systems 6356
3 2 1 Aqua Premium – application instructions for water-based products 6356
3 2 2 Setting gloss level of HS clear coats and HS top coats with matting additive 6359
3 2 3 Setting gloss level of 2-pack HS clear coats with 2-pack clear coat, matt 6369
3 2 4 Repair paintwork system for matt-finished vehicles 6371
3 2 5 Paintwork system for plastic components 6376
3 2 6 Aqua Premium system, blending system for 2-stage colours 6384
3 2 7 Aqua Premium system, blending system for 3-stage colours 6393
3 2 8 Aqua Premium system, product preparation for processing 6400
3 2 9 Aquaplus design and multi-colour painting 6407
3 2 10 Processing instructions for paint with limited hiding power 6412
3 3 Filler 6412
3 3 1 2-pack steel filler set 6412
3 3 2 2-pack fine filler 6416
3 3 3 2-pack fine filler, flexible 6420
3 3 4 2-pack spray filler 6423
3 3 5 2-pack IR premium filler 6429
3 3 6 2-pack epoxy resin filler 6434
3 4 Priming metal 6438
3 4 1 1-pack anti-corrosion wash primer 6438
3 4 2 1-pack wash primer 6443
3 4 3 2-pack wash primer 6448
3 5 Priming plastic materials 6454
3 5 1 Adhesion promoter (transparent) 6454
3 6 Surfacer 6458
3 6 1 2-pack HS Vario surfacer 6458
3 6 2 2-pack HS premium surfacer 6468
3 6 3 2-pack HS Performance surfacer 6477
3 6 4 2-pack primer surfacer for plastics 6486
3 6 5 2-pack HS wet-on-wet surfacer 6492
3 6 6 2-pack base filler, professional 6502
3 7 Top coats 6519
3 7 1 2-pack HS top coat 6519
3 7 2 Aquaplus system, uni (solid-colour) and metallic colours 6528
3 7 3 Aquaplus system (pearlescent and heliochrome) 6536
3 7 4 Aquaplus blending system 6544
3 7 5 Aqua Premium system 6550
3 7 6 Aqua Premium blending system 6563
3 7 7 Aqua Premium system (painting rims) 6570
3 8 Clear coats 6579
3 8 1 2-pack HS clear coat 6579
3 8 2 2-pack MS matt clear coat 6586
3 8 3 2-pack HS Vario clear coat 6592
3 8 4 2-pack HS optimum clear coat 6600
3 8 5 2-pack HS optimum plus clear coat 6606
3 8 6 2-pack HS brilliant clear coat 6611
3 8 7 2-pack HS brilliant plus clear coat 6616
3 8 8 2-pack HS Performance clear coat 6622
3 8 9 Blender 6628
3 9 Hardener 6633
3 9 1 2-pack HS hardener 6633
3 9 2 2-pack VHS hardeners and 2-pack VHS Performance hardeners 6637
3 9 3 Hardener for 2-pack primer surfacer 6641
3 9 4 Aqua Premium hardener 6641
3 10 Thinners 6642
3 10 1 2-pack thinner 6642
3 10 2 HS spot thinner 6645
3 10 3 Demineralised water 6647
3 11 Anti-corrosion materials 6648
3 11 1 Anti-corrosion wax 6648
3 11 2 Cavity sealant 6649
3 11 3 Anti-corrosion wax (in aerosol can) 6652
3 12 Underseal 6653
3 12 1 Permanent underseal -D 314 D36 M2-, grey 6653
3 12 2 Permanent underseal -D 314 D37 M2-, black 6656
3 12 3 Permanent underseal -D 314 D38 M2-, light 6659
3 12 4 Underseal -D 314 D39 A3-, black 6662
3 13 Stone deflector 6664
3 13 1 Stone chip guard -AKR 311 KD1 05- 6664
3 13 2 Stone chip guard -AKR 311 KD1 10- 6666
3 14 Wax-based underseal 6673
3 14 1 Wax-based underseal -D 316 D38 A2- 6673
3 14 2 Wax-based underseal -D 316 000 A1- 6675
3 14 3 Spray wax -D 322 100 M2- 6677
3 15 Sealing materials 6678
3 15 1 Polyurethane adhesive sealant (bonding compound) 6678
3 15 2 Sprayable sealant 6681
3 15 3 Adhesive sealant 6684
3 16 Cleaning agents 6686
3 16 1 Silicone remover 6686
3 16 2 Cleaner for plastics 6688
3 16 3 Cleaner for plastics, anti-static 6689
3 16 4 Industrial dirt remover 6689
3 17 SprayMax system 6691
3 17 1 1-pack anti-corrosion primer 6691
3 17 2 1-pack test paint 6695
3 17 3 1-pack clear coat 6698
3 17 4 1-pack wash primer 6701
3 17 5 1-pack Fill Clean spray can -LLS MAX 099-/1-pack Fill Clean spray can -LLS MAX 100- – Aquaplus system 6706
3 17 6 1-pack fill clean spray can -LLS MAX 112-, Aqua Premium system 6713
3 17 7 2-pack surfacer 6721
3 17 8 2-pack HS Performance surfacer 6728
3 17 9 2-pack clear coat 6736
3 17 10 2-pack epoxy primer surfacer 6741
3 17 11 2-pack wash primer 6747
3 17 12 Silicone remover -LLS MAX 007- 6753
3 17 13 Slow-drying silicone remover -LLS MAX 008- 6755
3 17 14 Blender 6758
3 17 15 Adhesion promoter 6760
3 18 Additional materials 6764
3 18 1 Matting additive -ALN 775 106- 6764
3 18 2 Matting additive -LVM 769 810 A2- 6771
3 18 3 Texture additive 6774
3 18 4 Blending additive for Aquaplus 6780
3 18 5 Additive for Aqua Premium 6781
4 Workshop equipment 6782
4 1 Tools 6782
4 1 1 Spray can filling device -VAS 6425- 6782
4 1 2 Paint thickness tester -VAS 6272- 6783
4 1 3 Paint thickness tester -VAS 6197- 6784
4 1 4 Paint thickness tester -VAS 5278- 6784
4 1 5 Stone chip tester -VAS 5102A- 6785
4 1 6 Pneumatic brush grinder set -VAS 6446- 6786
4 1 7 Brush grinder set -VAS 6776- 6786
4 1 8 Suction feed spray-gun -V A G 1538- 6788
4 1 9 Infrared heater -VAS 6873- 6789
4 1 10 Stand -VAS 6873/1- 6789
4 1 11 Infrared heater -VAS 6874- 6790
4 1 12 Infrared heater -VAS 6875- 6791
4 1 13 Infrared heater -VAS 6876- 6791
4 1 14 Infrared heater -VAS 6877- 6792
4 1 15 Infrared heater -VAS 6878- 6793
4 1 16 Infrared heater -VAS 6879- 6794
4 2 Tack cloths 6794
4 2 1 Tack cloth -VAS 6177- 6794
4 2 2 Buffing cloth, white -VAS 6176- 6795
00 – Technical data 6802
1 Safety information 6802
1 1 Safety regulations for working on fuel supply 6802
1 2 Safety measures when working on vehicles with a start/stop system 6802
1 3 Safety precautions when using testing and measuring instruments during a road test 6803
1 4 Safety precautions when working on the cooling system 6803
1 5 Safety precautions when working on ignition system 6803
2 Identification 6804
2 1 Engine number/engine data 6804
3 Repair instructions 6806
3 1 Rules for cleanliness 6806
3 2 General information 6806
3 3 General repair instructions 6806
3 3 1 General notes on injection 6806
3 3 2 General notes on ignition system 6807
3 3 3 General notes on charge air system 6807
3 4 Foreign bodies in engine 6808
3 5 Contact corrosion 6808
3 6 Routing and attachment of lines 6808
3 7 Fitting radiator and condensers 6808
3 8 Checking vacuum system 6808
10 – Removing and installing engine 6810
1 Removing and installing engine 6810
1 1 Removing engine 6810
1 1 1 Removing engine, Golf Cabriolet and Scirocco 6810
1 1 2 Removing engine, Sharan, CC, Tiguan 6823
1 1 3 Removing engine, T-Roc 6836
1 1 4 Removing engine, Golf 2020, Golf Estate 2021 6846
1 2 Separating engine and gearbox 6860
1 3 Securing engine on engine and gearbox support 6862
1 4 Installing engine 6864
2 Assembly mountings 6869
2 1 Assembly overview – assembly mountings 6869
2 1 1 Assembly overview – assembly mountings, Golf Cabriolet, Scirocco and CC 6869
2 1 2 Assembly overview – assembly mountings, Sharan and Tiguan 6872
2 1 3 Assembly overview – assembly mountings, T-Roc 6875
2 1 4 Assembly overview – assembly mountings, Golf 2020, Golf Estate 2021 6878
2 2 Removing and installing engine mounting 6881
2 2 1 Removing and installing engine mounting, Golf Cabriolet, Scirocco and CC 6881
2 2 2 Removing and installing engine mountings, Sharan and Tiguan 6883
2 2 3 Removing and installing engine mounting, T-Roc 6884
2 2 4 Removing and installing engine mounting, Golf 2020, Golf Estate 2021 6884
2 3 Removing and installing gearbox mounting 6886
2 4 Removing and installing pendulum support 6888
2 5 Supporting engine in installation position 6889
2 5 1 Supporting engine in installation position, Golf Cabriolet 6889
2 5 2 Supporting engine in installation position, Tiguan 6893
2 5 3 Supporting engine in installation position, Sharan 6897
2 5 4 Supporting engine in installation position, CC 6901
2 5 5 Supporting engine in installation position, Scirocco 6903
2 5 6 Supporting engine in installation position, T-Roc 6907
2 5 7 Supporting engine in installation position, Golf 2020, Golf Estate 2020 6911
2 6 Checking adjustment of assembly mountings 6917
2 7 Adjusting assembly mountings 6918
13 – Crankshaft group 6922
1 Cylinder block (pulley end) 6922
1 1 Assembly overview – poly V-belt drive 6922
1 1 1 Assembly overview – poly V-belt drive, vehicles without air conditioner compressor 6922
1 1 2 Assembly overview – poly V-belt drive, vehicles with air conditioner compressor 6924
1 2 Assembly overview – sealing flange, belt pulley end 6926
1 3 Removing and installing poly-V belt 6929
1 3 1 Removing and installing poly V-belt, vehicles without air conditioner compressor 6929
1 3 2 Removing and installing poly V-belt, vehicles with air conditioner compressor 6931
1 4 Removing and installing tensioner for poly V-belt 6933
1 4 1 Removing and installing tensioner for poly V-belt, vehicles without air conditioner compressor 6933
1 4 2 Removing and installing tensioner for poly V-belt, vehicles with air conditioner compressor 6933
1 5 Removing and installing vibration damper 6934
1 6 Removing and installing engine support 6936
1 7 Renewing crankshaft oil seal – pulley end 6939
1 8 Removing and installing sealing flange on pulley end 6942
2 Cylinder block, gearbox end 6946
2 1 Assembly overview – cylinder block, gearbox end 6946
2 2 Removing and installing flywheel 6947
2 3 Removing and installing sealing flange on gearbox side 6949
3 Crankshaft 6961
3 1 Renewing needle bearing in crankshaft 6961
3 2 Crankshaft dimensions 6964
3 3 Measuring axial clearance of crankshaft 6964
4 Pistons and conrods 6966
4 1 Assembly overview – pistons and conrods 6966
4 2 Removing and installing pistons 6969
4 3 Removing and installing oil spray jets 6970
4 4 Checking pistons and cylinder bores 6971
4 5 Checking radial clearance of conrods 6974
4 6 Separating new conrod 6974
4 7 Setting piston to TDC position 6975
15 – Cylinder head, valve gear 6980
1 Cylinder head 6980
1 1 Assembly overview – cylinder head 6980
1 2 Assembly overview – camshaft housing 6982
1 2 1 Assembly overview – camshaft housing, exhaust side with toothed belt pulley 6982
1 2 2 Assembly overview – camshaft housing, exhaust side with camshaft adjuster 6984
1 3 Removing and installing cylinder head 6986
1 4 Removing and installing camshaft housing 6991
1 5 Checking compression 6997
2 Toothed belt drive 6999
2 1 Assembly overview – toothed belt cover 6999
2 2 Assembly overview – toothed belt 7000
2 2 1 Assembly overview – toothed belt, exhaust side with toothed belt pulley 7000
2 2 2 Assembly overview – toothed belt, exhaust side with camshaft adjuster 7002
2 3 Removing and installing toothed belt guard 7004
2 3 1 Removing and installing upper toothed belt guard 7004
2 3 2 Removing and installing lower toothed belt guard 7005
2 4 Preassembling and installing valve timing tool 7006
2 4 1 Preassembling test tool -VAS 611 007- 7006
2 4 2 Installing test tool -VAS 611 007- 7009
2 4 3 Teaching-in test tool -VAS 611 007- electronically and performing basic setting 7012
2 5 Checking valve timing 7014
2 6 Adjusting valve timing 7017
2 7 Removing and installing toothed belt 7028
2 8 Removing toothed belt from camshaft 7035
3 Valve gear 7043
3 1 Assembly overview – valve gear 7043
3 2 Removing and installing camshaft oil seal 7045
3 2 1 Removing and installing camshaft oil seal, for inlet camshaft on belt pulley side, exhaust side with toothed belt sprocket 7045
3 2 2 Removing and installing camshaft oil seal, for inlet camshaft on belt pulley side, exhaust side with camshaft adjuster 7047
3 2 3 Removing and installing camshaft oil seal, for exhaust camshaft on belt pulley side, exhaust side with toothed belt sprocket 7050
3 2 4 Removing and installing camshaft oil seal, for exhaust camshaft on belt pulley side, exhaust side with camshaft adjuster 7052
3 2 5 Removing and installing camshaft oil seal, exhaust camshaft, gearbox end 7055
3 3 Removing and installing camshaft adjuster 7057
3 3 1 Removing and installing inlet side camshaft adjuster, exhaust side with toothed belt sprocket 7057
3 3 2 Removing and installing inlet side camshaft adjuster, exhaust side with camshaft adjuster 7064
3 3 3 Removing and installing camshaft adjuster, exhaust side 7070
3 4 Removing and installing toothed belt pulley 7077
3 5 Removing and installing camshaft control valve 1 -N205- 7082
3 5 1 Removing and installing camshaft control valve 1 -N205-, exhaust side with camshaft adjuster 7082
3 5 2 Removing and installing camshaft control valve 1 -N205-, exhaust side with toothed belt pulley 7083
3 6 Removing and installing exhaust camshaft control valve 1 -N318- 7083
3 7 Removing and installing valve stem oil seals 7084
3 7 1 Removing and installing valve stem seals (cylinder head installed) 7084
3 7 2 Removing and installing valve stem seals (cylinder head removed) 7090
4 Inlet and exhaust valves 7096
4 1 Checking valve guides 7096
4 2 Checking valves 7097
4 3 Valve dimensions 7097
17 – Lubrication 7098
1 Sump, oil pump 7098
1 1 Assembly overview – sump/oil pump 7098
1 2 Engine oil: 7102
1 3 Removing and installing lower part of sump 7102
1 4 Removing and installing upper part of sump 7108
1 5 Removing and installing oil pump 7112
1 6 Removing and installing oil level and oil temperature sender -G266- 7114
2 Engine oil cooler 7115
2 1 Assembly overview – engine oil cooler 7115
2 2 Removing and installing engine oil cooler 7115
3 Crankcase ventilation 7117
3 1 Assembly overview – crankcase breather system 7117
3 2 Removing and installing oil separator 7118
4 Oil filter, oil pressure switch 7122
4 1 Assembly overview – oil filter/oil pressure switch 7122
4 2 Removing and installing oil pressure switch -F1- 7124
4 3 Removing and installing oil pressure switch for reduced oil pressure -F378- 7125
4 4 Checking oil pressure 7126
4 5 Removing and installing oil pressure regulating valve -N428- 7128
19 – Cooling 7130
1 Cooling system/coolant 7130
1 1 Connection diagram – coolant hoses 7130
1 1 1 Connection diagram – coolant hoses, CC, Golf Cabriolet, Scirocco, Sharan and Tiguan 7130
1 1 2 Connection diagram – coolant hoses, T-Roc, Golf 2020, Golf Estate 2021 7131
1 2 Checking cooling system for leaks 7132
1 2 1 Checking cooling system for leaks, Golf Cabriolet 2012 >, CC 2012 >, Tiguan 2008 >, Scirocco 2015 >, Sharan 2016 > 7132
1 2 2 Checking cooling system for leaks, Golf 2020 >, Golf Estate 2021 >, T-Roc 7136
1 3 Draining and adding coolant 7140
2 Coolant pump, regulation of cooling system 7148
2 1 Assembly overview – coolant pump, thermostat 7148
2 2 Assembly overview – electric coolant pump 7151
2 3 Assembly overview – coolant temperature sender 7152
2 3 1 Assembly overview – coolant temperature sender, CC, Golf Cabriolet, Scirocco, Sharan and Tiguan 7152
2 3 2 Assembly overview – coolant temperature sender, T-Roc, Golf 2020 >, Golf Estate 2021 > 7153
2 4 Removing and installing electric coolant pump 7154
2 5 Removing and installing coolant pump 7156
2 6 Removing and installing thermostat 7162
2 6 1 Removing and installing thermostat for main coolant circuit (radiator) 7162
2 6 2 Removing and installing thermostat for cylinder block coolant circuit 7165
2 7 Removing and installing toothed belt pulley for coolant pump 7166
2 8 Removing and installing coolant temperature sender -G62- 7167
2 9 Removing and installing radiator outlet coolant temperature sender -G83- 7170
2 9 1 Removing and installing radiator outlet coolant temperature sender -G83-, Sharan, CC and Tiguan 7170
2 9 2 Removing and installing radiator outlet coolant temperature sender -G83-, Golf Cabriolet and Scirocco 7171
2 9 3 Removing and installing radiator outlet coolant temperature sender -G83-, T-Roc, Golf 2020 >, Golf Estate 2021 > 7172
3 Coolant pipes 7174
3 1 Assembly overview – coolant pipes 7174
3 2 Removing and installing coolant pipes 7174
4 Radiator, radiator fan 7179
4 1 Assembly overview – radiator/radiator fan 7179
4 1 1 Assembly overview – radiator and radiator fan, Golf Cabriolet, CC and Tiguan 7179
4 1 2 Assembly overview – radiator/radiator fan, Sharan 7181
4 1 3 Assembly overview – radiator/radiator fan, Scirocco 7184
4 1 4 Assembly overview – radiator/radiator fan, T-Roc, Golf 2020 >, Golf Estate 2021 > 7186
4 2 Assembly overview – radiator cowl and radiator fan 7188
4 2 1 Assembly overview – radiator cowl and radiator fan, Golf Cabriolet, CC and Tiguan 7188
4 2 2 Assembly overview – radiator cowl and radiator fan, Sharan 7189
4 2 3 Assembly overview – radiator cowl and radiator fan, Scirocco 7190
4 2 4 Assembly overview – radiator cowl and radiator fan, T-Roc, Golf 2020 >, Golf Estate 2021 > 7192
4 3 Removing and installing radiator 7192
4 3 1 Removing and installing radiator, Golf Cabriolet, CC, Scirocco and Tiguan 7192
4 3 2 Removing and installing radiator, Sharan 7194
4 3 3 Removing and installing radiator, T-Roc, Golf 2020 >, Golf Estate 2021 > 7196
4 4 Removing and installing water radiator for charge air cooling circuit 7199
4 4 1 Removing and installing water radiator for charge air cooling circuit, Golf Cabriolet, CC, Scirocco and Tiguan 7199
4 4 2 Removing and installing water radiator for charge air cooling circuit, Sharan 7202
4 4 3 Removing and installing water radiator for charge air cooling circuit, T-Roc, Golf 2020 >, Golf Estate 2021 > 7203
4 5 Removing and installing radiator cowl 7207
4 5 1 Removing and installing radiator cowl with radiator fan, CC and Tiguan 7207
4 5 2 Removing and installing radiator cowl with radiator fan, Golf Cabriolet and Scirocco 7209
4 5 3 Removing and installing radiator cowl with radiator fan, Sharan 7210
4 5 4 Removing and installing radiator cowl, T-Roc, Golf 2020 >, Golf Estate 2021 > 7211
4 6 Removing and installing radiator fan -V7- 7213
4 6 1 Removing and installing radiator fan -V7- and radiator fan 2 -V177-, Golf Cabriolet, Sharan, CC and Tiguan 7213
4 6 2 Removing and installing radiator fan -V7- and radiator fan 2 -V177-, Scirocco 7214
4 6 3 Removing and installing radiator fan -V7-, T-Roc, Golf 2020 >, Golf Estate 2021 > 7214
21 – Turbocharging/supercharging 7216
1 Turbocharger 7216
1 1 Assembly overview – turbocharger 7216
1 1 1 Assembly overview – turbocharger, version 1 7216
1 1 2 Assembly overview – turbocharger, version 2 7217
1 1 3 Assembly overview – lines on turbocharger 7219
1 2 Removing and installing turbocharger 7220
1 3 Removing and installing charge pressure positioner -V465- 7226
1 3 1 Removing and installing charge pressure positioner -V465-, version 1 7226
1 3 2 Removing and installing charge pressure positioner -V465-, version 2 7228
1 4 Removing and installing connection for turbocharger 7229
2 Charge air system 7233
2 1 Assembly overview – charge air system 7233
2 2 Removing and installing charge air cooler 7235
2 3 Removing and installing charge pressure sender -GX26- 7238
2 4 Checking charge air system for leaks 7239
2 5 Removing and installing air intake pipe 7241
24 – Mixture preparation – injection 7244
1 Injection system 7244
1 1 Overview of fitting locations – injection system 7244
2 Injectors 7249
2 1 Assembly overview – fuel rail with injectors 7249
2 1 1 Assembly overview – fuel rail with injectors, vehicles without particulate filter 7249
2 1 2 Assembly overview – fuel rail with injectors, vehicles with particulate filter 7251
2 2 Removing and installing fuel rail 7253
2 3 Removing and installing injectors 7254
2 3 1 Removing and installing injectors, vehicles without particulate filter 7254
2 3 2 Removing and installing injectors, vehicles with particulate filter 7261
2 4 Cleaning injectors 7268
3 Air filter 7270
3 1 Assembly overview – air filter housing 7270
3 1 1 Assembly overview – air filter housing, Sharan 2016 >, Tiguan 2008 >, CC 2012 >, T-Roc, Golf 2020 >, Golf Estate 2021 > 7270
3 1 2 Assembly overview – air filter housing, Golf Cabriolet and Scirocco 7271
3 2 Removing and installing air filter housing 7272
3 3 Removing and installing air guide on lock carrier 7274
3 4 Removing and installing resonator for intake air 7276
4 Intake manifold 7278
4 1 Assembly overview – intake manifold 7278
4 2 Removing and installing intake manifold 7281
4 3 Removing and installing throttle valve module -GX3- 7284
4 4 Cleaning throttle valve module -GX3- 7285
5 Senders and sensors 7287
5 1 Removing and installing intake manifold sender -GX9- 7287
5 2 Removing and installing fuel pressure sender -G247- 7287
5 3 Checking fuel pressure sender -G247- 7289
5 3 1 Checking fuel pressure sender -G247-, using pressure sensor tester -VAS 6394- and vehicle diagnostic tester 7289
5 3 2 Checking fuel pressure sender -G247-, using vehicle diagnostic tester 7291
5 4 Removing and installing exhaust gas pressure sensor 1 -G450- 7293
6 Engine/motor control unit 7295
6 1 Assembly overview – engine control unit -J623- 7295
6 1 1 Assembly overview – engine control unit -J623-, Golf 2020 >, Golf Estate 2021 > 7295
6 2 Removing and installing engine control unit -J623- 7296
6 2 1 Removing and installing engine control unit -J623-, Sharan and Tiguan 7296
6 2 2 Removing and installing engine control unit -J623-, Golf Cabriolet, Scirocco and CC 7298
6 2 3 Removing and installing engine control unit -J623-, Golf 2020 >, Golf Estate 2021 > 7301
6 3 Removing and installing engine (motor) control unit -J623- with protective housing 7302
6 3 1 Removing and installing engine control unit -J623- with protective housing, Sharan and Tiguan 7302
6 3 2 Removing and installing engine control unit -J623- with protective housing, Golf Cabriolet, Scirocco and CC 7306
6 3 3 Removing and installing engine control unit -J623- with protective housing, T-Roc 7312
6 3 4 Removing and installing engine control unit -J623- with protective housing, Golf 2020 >, Golf Estate 2021 > 7315
7 High-pressure pump 7319
7 1 Assembly overview – high-pressure pump 7319
7 1 1 Assembly overview – high-pressure pump, version 1 7319
7 1 2 Assembly overview – high-pressure pump, version 2 7321
7 1 3 Assembly overview – high-pressure pump, version 3 7323
7 2 Removing and installing high-pressure pump 7325
7 3 Removing and installing high-pressure pipe 7327
8 Lambda probe 7329
8 1 Assembly overview – Lambda probe 7329
8 2 Removing and installing lambda probe 7330
8 2 1 Removing and installing Lambda probe 1 before catalytic converter -GX10- 7330
8 2 2 Removing and installing Lambda probe 1 after catalytic converter -GX7- 7332
26 – Exhaust system 7335
1 Exhaust pipes and silencers 7335
1 1 Assembly overview – silencers 7335
1 1 1 Assembly overview – silencers, Golf Cabriolet and Scirocco 7335
1 1 2 Assembly overview – silencer, CC 7337
1 1 3 Assembly overview – silencers, Sharan 7339
1 1 4 Assembly overview – silencers, Tiguan 7341
1 1 5 Assembly overview – silencer, T-Roc, Golf 2020, Golf Estate 2021 7343
1 2 Separating exhaust pipes from silencers 7345
1 2 1 Separating exhaust pipes/silencers, CC 7345
1 2 2 Separating exhaust pipes/silencers, Tiguan, Sharan 7347
1 2 3 Separating exhaust pipes/silencers, Scirocco, Golf Cabriolet, Scirocco, Golf Cabriolet, T-Roc, Golf Golf Estate 7348
1 3 Removing and installing silencer 7349
1 3 1 Removing and installing silencer, Golf Cabriolet 7349
1 3 2 Removing and installing silencer, CC 7351
1 3 3 Removing and installing silencer, Tiguan 7353
1 3 4 Removing and installing silencer, Sharan 7354
1 3 5 Removing and installing silencers, Scirocco 7356
1 3 6 Removing and installing silencers, T-Roc, Golf, Golf Estate 7357
1 4 Installation position of clamp 7359
1 5 Aligning exhaust system free of stress 7360
1 5 1 Aligning exhaust system free of stress, Golf Cabriolet and Scirocco 7360
1 5 2 Align exhaust system such that it is not under stress, CC 7361
1 5 3 Aligning exhaust system free of stress, Tiguan 7362
1 5 4 Aligning exhaust system free of stress, Sharan 7364
1 5 5 Aligning exhaust system free of tension, T-Roc, Golf, Golf Estate 7365
1 6 Checking exhaust system for leaks 7366
2 Emission control 7367
2 1 Assembly overview – emission control 7367
2 2 Removing and installing catalytic converter 7369
2 3 Removing and installing particulate filter 7376
28 – Ignition system 7377
1 Ignition system 7377
1 1 Assembly overview – ignition system 7377
1 2 Removing and installing ignition coils with output stage 7379
1 3 Removing and installing knock sensor 1 -G61- 7382
1 4 Removing and installing Hall sender 7383
1 4 1 Removing and installing Hall sender -G40- 7383
1 4 2 Removing and installing Hall sender 3 -G300- 7383
1 5 Removing and installing engine speed sender -G28- 7384
00 – Technical data 7394
1 Safety information 7394
1 1 Safety regulations for working on fuel supply 7394
1 2 Safety measures when working on vehicles with a start/stop system 7394
1 3 Safety precautions when using testers and measuring instruments during a road test 7395
1 4 Safety precautions when working on the cooling system 7395
1 5 Safety precautions when working on the SCR system 7395
1 6 Safety precautions when working on exhaust system 7396
2 Identification 7398
2 1 Engine number/engine data 7398
3 Repair notes 7401
3 1 Rules for cleanliness 7401
3 2 Foreign objects in engine 7401
3 3 Contact corrosion 7401
3 4 Routing and attachment of lines 7402
3 5 Fitting radiator and condensers 7402
4 Technical data 7404
4 1 Coolant 7405
10 – Removing and installing engine 7407
1 Removing and installing engine 7407
1 1 Removing engine 7407
1 2 Separating engine and gearbox 7419
1 2 1 Separating engine and gearbox, vehicles with manual gearbox 7419
1 2 2 Separating engine and gearbox, vehicles with dual clutch gearbox 7421
1 3 Securing engine on engine and gearbox support 7424
1 4 Installing engine 7426
2 Assembly mountings 7431
2 1 Assembly overview – assembly mountings 7431
2 1 1 Assembly overview – assembly mountings, CC 7431
2 1 2 Assembly overview – assembly mountings, Sharan and Tiguan 7434
2 2 Removing and installing engine mounting 7437
2 2 1 Removing and installing engine mountings, Sharan and Tiguan 7437
2 2 2 Removing and installing engine mountings, CC 7438
2 3 Removing and installing gearbox mounting 7439
2 4 Removing and installing pendulum support 7441
2 5 Supporting engine in installation position 7442
2 5 1 Supporting engine in installation position, CC 7442
2 5 2 Supporting engine in installation position, Sharan 7445
2 5 3 Supporting engine in installation position, Tiguan 7449
2 6 Adjusting assembly mountings 7452
2 7 Checking adjustment of assembly mountings 7454
3 Engine cover panel 7455
3 1 Removing and installing engine cover 7455
13 – Crankshaft group 7456
1 Cylinder block (pulley end) 7456
1 1 Assembly overview – cylinder block (pulley end) 7456
1 2 Assembly overview – sealing flange, belt pulley end 7458
1 3 Removing and installing poly-V belt 7460
1 4 Removing and installing tensioner for poly V-belt 7461
1 5 Removing and installing vibration damper 7462
1 6 Removing and installing bracket for ancillaries 7463
1 7 Removing and installing engine support 7465
1 8 Removing and installing sealing flange on pulley end 7466
1 9 Renewing caps in cylinder block (pulley end) 7469
2 Cylinder block, gearbox end 7471
2 1 Assembly overview – cylinder block, gearbox end 7471
2 2 Removing and installing flywheel 7472
2 3 Removing and installing sealing flange on gearbox side 7475
2 4 Renewing caps in cylinder block (gearbox end) 7485
3 Crankshaft 7487
3 1 Assembly overview – crankshaft 7487
3 2 Crankshaft dimensions 7488
3 3 Renewing needle bearing in crankshaft 7489
3 4 Measuring axial clearance of crankshaft 7492
4 Pistons and conrods 7493
4 1 Assembly overview – pistons and conrods 7493
4 2 Removing and installing pistons 7497
4 3 Measuring piston projection at TDC 7498
4 4 Checking pistons and cylinder bores 7501
4 5 Checking radial clearance of conrods 7503
15 – Cylinder head, valve gear 7504
1 Cylinder head 7504
1 1 Assembly overview – cylinder head 7504
1 2 Assembly overview – cylinder head cover 7508
1 3 Removing and installing cylinder head 7510
1 4 Removing and installing cylinder head cover 7521
1 5 Removing and installing injector seals 7523
1 6 Removing and installing camshaft housing 7524
1 7 Checking compression 7531
2 Toothed belt drive 7534
2 1 Assembly overview – toothed belt cover 7534
2 2 Assembly overview – toothed belt 7534
2 3 Removing and installing toothed belt guard 7536
2 3 1 Removing and installing upper toothed belt guard, vehicles without SCR system 7536
2 3 2 Removing and installing upper toothed belt guard, vehicles with SCR 7538
2 3 3 Removing and installing lower toothed belt guard 7541
2 4 Removing and installing toothed belt 7543
2 5 Removing toothed belt from camshaft 7557
3 Valve gear 7563
3 1 Assembly overview – valve gear 7563
3 2 Measuring axial play of camshaft 7567
3 3 Removing and installing camshaft oil seal 7568
3 4 Removing and installing camshaft control valve 1 -N205- 7570
3 5 Removing and installing camshaft adjuster 7570
3 5 1 Removing and installing control valve for the camshaft adjuster 7574
3 6 Checking hydraulic compensation elements 7577
3 7 Removing and installing valve stem seals 7578
3 7 1 Removing and installing valve stem seals (cylinder head installed) 7578
3 7 2 Removing and installing valve stem seals (cylinder head removed) 7583
4 Inlet and exhaust valves 7589
4 1 Checking valve guides 7589
4 2 Checking valves 7590
4 3 Valve dimensions 7590
17 – Lubrication 7591
1 Sump, oil pump 7591
1 1 Assembly overview – sump/oil pump 7591
1 2 Removing and installing sump 7593
1 3 Engine oil: 7598
1 4 Removing and installing oil pump 7598
1 5 Removing and installing oil level and oil temperature sender -G266- 7599
2 Engine oil cooler 7601
3 Oil filter, oil pressure switch 7602
3 1 Assembly overview – oil filter housing, oil pressure switch 7602
3 2 Removing and installing oil pressure switch -F1- 7604
3 3 Removing and installing oil pressure switch for reduced oil pressure -F378- 7606
3 4 Checking oil pressure 7608
3 5 Removing and installing oil filter housing 7608
3 6 Removing and installing oil pressure regulating valve -N428- 7611
19 – Cooling 7613
1 Cooling system/coolant 7613
1 1 Connection diagram – coolant hoses 7613
1 1 1 Assembly overview – coolant hoses, vehicles without SCR system 7613
1 1 2 Coolant hose schematic diagram, vehicles with SCR system 7616
1 2 Checking cooling system for leaks 7618
1 3 Draining coolant 7621
1 3 1 Draining coolant, Sharan 7621
1 3 2 Draining coolant, Tiguan and CC 7623
1 4 Filling with coolant 7625
1 4 1 Filling with coolant without electric vacuum pump 7625
1 4 2 Filling coolant with electric vacuum pump -VAS 6096/2- 7630
1 5 Checking filling quality of cooling system 7638
1 6 Checking electric vacuum pump -VAS 6096/2- 7640
1 7 Flushing cooling system 7641
1 7 1 Flushing cooling system, quick reference guide 7663
2 Coolant pump, regulation of cooling system 7665
2 1 Assembly overview – coolant pump, thermostat 7665
2 1 1 Assembly overview – coolant pump/thermostat, version 1 7665
2 1 2 Assembly overview – coolant pump/thermostat, version 2 7667
2 2 Assembly overview – electric coolant pump 7669
2 2 1 Charge air cooling pump -V188- version 1, auxiliary pump for heating -V488-, version 1 7669
2 2 2 Charge air cooling pump -V188-, version 2 7670
2 2 3 Assembly overview – auxiliary pump for heating -V488-, version 2 7671
2 2 4 Assembly overview – charge air cooling pump -V188-, version 3 7672
2 2 5 Assembly overview – auxiliary pump for heating -V488-, version 3 7673
2 3 Assembly overview – coolant temperature sender 7674
2 4 Removing and installing electric coolant pump 7675
2 4 1 Removing and installing charge air cooling pump -V188-, versions 1 and 2 7675
2 4 2 Removing and installing auxiliary pump for heating -V488-, version 1 7677
2 4 3 Removing and installing charge air cooling pump -V188-, version 3 7679
2 4 4 Removing and installing auxiliary pump for heating -V488-, version 2 7682
2 4 5 Removing and installing auxiliary pump for heating -V488-, version 3 7685
2 5 Removing and installing coolant pump 7689
2 6 Removing and installing thermostat 7689
2 6 1 Removing and installing thermostat, version 1 7689
2 6 2 Removing and installing thermostat, version 2 7691
2 7 Checking thermostat 7693
2 8 Removing and installing coolant valve for cylinder head -N489- 7694
2 9 Removing and installing coolant temperature sender -G62- 7694
3 Coolant pipes 7697
3 1 Assembly overview – coolant pipes 7697
3 2 Removing and installing coolant pipes 7699
3 2 1 Removing and installing coolant pipes (top front) 7699
3 2 2 Removing and installing lower front coolant pipe 7700
3 2 3 Removing and installing coolant pipe (front left) 7703
3 2 4 Removing and installing left coolant pipes 7704
3 2 5 Removing and installing rear coolant pipe 7706
3 2 6 Removing and installing rear right coolant pipe 7707
3 2 7 Removing and installing front coolant connection 7711
4 Radiator, radiator fan 7713
4 1 Assembly overview – radiator/radiator fan 7713
4 1 1 Assembly overview – radiator/radiator fan, Tiguan and CC 7713
4 1 2 Assembly overview – radiator/radiator fan, Sharan 7715
4 2 Assembly overview – radiator cowl and radiator fan 7718
4 2 1 Assembly overview – radiator cowl, Sharan 7718
4 3 Removing and installing radiator 7719
4 3 1 Removing and installing radiator, Sharan 7719
4 3 2 Removing and installing radiator, Tiguan and CC 7724
4 4 Removing and installing water radiator for charge air cooling circuit 7725
4 4 1 Removing and installing water radiator for charge air cooling circuit, Tiguan and CC 7725
4 4 2 Removing and installing water radiator for charge air cooling circuit, Sharan 7728
4 5 Removing and installing radiator cowl 7730
4 5 1 Removing and installing radiator cowl with radiator fan, Sharan 7730
4 5 2 Removing and installing radiator cowl with radiator fan, Tiguan 7731
4 5 3 Removing and installing radiator cowl with radiator fan, CC 7732
4 6 Removing and installing radiator fan 7734
4 6 1 Removing and installing radiator fan, Sharan 7734
4 6 2 Removing and installing radiator fan, Tiguan and CC 7734
21 – Turbocharging/supercharging 7736
1 Turbocharger 7736
1 1 Assembly overview – turbocharger 7736
1 2 Removing and installing turbocharger 7739
1 3 Renewing vacuum unit for turbocharger 7745
1 4 Removing and installing connection for turbocharger 7751
2 Charge air system 7754
2 1 Assembly overview – charge air system 7754
2 2 Removing and installing charge pressure sender -G31- 7757
2 3 Checking charge air system for leaks 7757
2 4 Removing and installing air pipe 7760
2 5 Checking charge air cooler for leaks 7761
23 – Mixture preparation – injection 7767
1 Injection system 7767
1 1 Schematic overview – fuel system 7767
1 1 1 Schematic overview – fuel system, version 1 7767
1 1 2 Schematic overview – fuel system, version 2 7768
1 2 Overview of fitting locations – injection system 7769
1 2 1 Overview of fitting locations – engine compartment 7769
1 2 2 Overview of fitting locations – front view of engine 7772
1 2 3 Overview of fitting locations – rear view of engine, vehicles with SCR system 7772
1 2 4 Overview of fitting locations – electrical connectors 7774
1 3 Filling/bleeding fuel system 7775
1 4 Checking fuel system for leaks 7776
2 Vacuum system 7777
2 1 Connection diagram – vacuum system 7777
2 2 Checking vacuum system 7778
3 Injectors/high-pressure accumulator (rail) 7779
3 1 Assembly overview – injectors 7779
3 2 Assembly overview – fuel rail 7781
3 3 Adapting correction values for injectors 7782
3 4 Testing injectors 7783
3 5 Checking return flow rate of injectors with engine running 7784
3 6 Checking return flow rate of injectors at starter speed 7787
3 7 Testing jammed-open injectors 7789
3 8 Removing and installing injectors 7790
3 9 Removing and installing high-pressure lines 7794
3 9 1 Removing high-pressure pipe between fuel rail and high-pressure pump 7794
3 9 2 Installing high-pressure line 7794
3 10 Removing and installing fuel rail 7797
4 Air filter 7799
4 1 Assembly overview – air filter housing 7799
4 1 1 Assembly overview – air filter housing, CC 7799
4 1 2 Assembly overview – air filter housing, Sharan and Tiguan 7801
4 2 Removing and installing air filter housing 7803
4 2 1 Removing and installing air filter housing, CC 7803
4 2 2 Removing and installing air filter housing, Sharan and Tiguan 7806
4 2 3 Installing screw-type clips on air ducts 7809
5 Intake manifold 7810
5 1 Assembly overview – intake manifold 7810
5 2 Removing and installing intake manifold 7814
5 3 Removing and installing throttle valve module -J338- 7819
6 Senders and sensors 7822
6 1 Removing and installing fuel pressure regulating valve -N276- 7822
6 1 1 Versions of fuel pressure regulating valve -N276- 7822
6 1 2 Removing and installing fuel pressure regulating valve, version 1 7823
6 1 3 Removing and installing fuel pressure regulating valve -N276-, version 2 7824
6 2 Checking fuel pressure regulating valve -N276- 7826
6 3 Removing and installing fuel pressure sender -G247- 7828
6 4 Removing and installing air mass meter -G70- 7829
6 5 Removing and installing pressure differential sender -G505- 7831
6 6 Removing and installing exhaust gas pressure sensor 1 -G450- 7832
6 7 Removing and installing charge air temperature sender ahead of charge air cooler -G810- 7833
6 8 Removing and installing charge air temperature sender after charge air cooler -G811- 7834
6 9 Removing and installing fuel temperature sender -G81- 7834
6 10 Removing and installing control unit for NOx sender -GX30- 7836
6 11 Assembly overview – NOx sender control unit -GX30- 7839
7 Engine control unit 7841
7 1 Removing and installing engine control unit -J623- 7841
7 1 1 Removing and installing engine control unit -J623-, Sharan and Tiguan 7841
7 1 2 Removing and installing engine control unit -J623-, CC 7843
7 2 Removing and installing engine (motor) control unit -J623- with protective housing 7845
7 2 1 Removing and installing engine control unit -J623- with protective housing, Sharan and Tiguan 7845
7 2 2 Removing and installing engine control unit -J623- with protective housing, CC 7850
8 High-pressure pump 7857
8 1 Assembly overview – high-pressure pump 7857
8 2 Removing and installing high-pressure pump 7858
9 Lambda probe 7863
9 1 Assembly overview – Lambda probe 7863
9 1 1 Assembly overview – lambda probe; Sharan and Tiguan with SCR system 7863
9 1 2 Assembly overview – lambda probe, CC 7864
9 2 Removing and installing Lambda probe 7866
9 2 1 Removing and installing lambda probe 1 before catalytic converter -GX10-, Sharan and Tiguan 7866
9 2 2 Removing and installing lambda probe 1 before catalytic converter -GX10-, CC 7867
9 2 3 Removing and installing Lambda probe 1 after catalytic converter -GX7- 7869
26 – Exhaust system 7872
1 Exhaust pipes and silencers 7872
1 1 Assembly overview – silencers 7872
1 1 1 Assembly overview – silencers, Tiguan 7872
1 1 2 Assembly overview – silencers, Sharan 7874
1 1 3 Assembly overview – silencer, CC 7876
1 2 Removing and installing front exhaust pipe 7877
1 3 Separating exhaust pipes from silencers 7878
1 3 1 Separating exhaust pipes/silencers, Sharan, Tiguan 7878
1 3 2 Separating exhaust pipes/silencers, CC 7880
1 4 Removing and installing silencer 7881
1 4 1 Removing and installing silencer, Tiguan 7881
1 4 2 Removing and installing silencer, Sharan 7882
1 4 3 Removing and installing silencer, CC 7884
1 5 Aligning exhaust system free of stress 7885
1 5 1 Aligning exhaust system free of stress, Sharan 7885
1 5 2 Aligning exhaust system free of stress, Tiguan 7885
1 5 3 Align exhaust system such that it is not under stress, CC 7886
1 6 Checking exhaust system for leaks 7886
1 7 Installation position of clamp 7887
1 7 1 Installation position of clamp, Sharan 7887
1 7 2 Installation position of clamp, Tiguan 7888
1 7 3 Installation position of clamp, CC 7890
1 8 Assembly overview – front exhaust pipe 7891
1 8 1 Assembly overview – front exhaust pipe, Sharan and Tiguan 7891
1 8 2 Assembly overview – front exhaust pipe, CC 7893
1 9 Align end exhaust pipes 7894
2 Emission control 7895
2 1 Assembly overview – emission control 7895
2 1 1 Versions of emission control module 7895
2 1 2 Assembly overview – emission control, version 1 7896
2 1 3 Assembly overview – emission control, version 2 7898
2 2 Removing and installing emission control module 7901
2 2 1 Removing and installing emission control module, version 1 7901
2 2 2 Removing and installing emission control module, version 2 7911
2 3 Removing and installing catalytic converter 7919
2 4 Removing and installing exhaust flap control unit -J883- 7919
3 SCR system (selective catalytic reduction) 7921
3 1 Assembly overview – reducing agent tank 7921
3 1 1 Assembly overview – tank for reducing agent, Tiguan 7921
3 1 2 Assembly overview – tank for reducing agent, Sharan 7922
3 2 Assembly overview – reducing agent supply line 7924
3 2 1 Assembly overview – reducing agent supply line, Tiguan 7924
3 2 2 Assembly overview – reducing agent supply line, Sharan 7924
3 3 Assembly overview – delivery module for reducing agent 7925
3 4 Removing and installing reducing agent tank 7926
3 4 1 Removing and installing tank for reducing agent, Tiguan 7926
3 4 2 Removing and installing tank for reducing agent, Sharan 7929
3 5 Removing and installing front section of reducing agent supply line 7933
3 6 Removing and installing delivery module for reducing agent 7935
3 7 Removing and installing injector for reduction agent -N474- 7938
3 8 Removing and installing control unit for reducing-agent heater -J891- 7940
3 8 1 Removing and installing control unit for reducing-agent heater -J891-, Tiguan 7940
3 8 2 Removing and installing control unit for reducing-agent heater -J891-, Sharan 7942
3 9 Assembly overview – injector for reducing agent -N474- 7943
3 10 Draining reducing agent tank 7944
3 10 1 Emptying tank for reducing agent, Tiguan 7944
3 10 2 Emptying tank for reducing agent, Sharan 7948
3 11 Removing and installing rear section of reducing agent supply line 7952
3 11 1 Removing and installing rear section of reducing agent supply line, Sharan 7952
3 11 2 Removing and installing rear section of reducing agent supply line, Tiguan 7953
3 12 Disconnecting reducing agent supply line 7954
3 13 SCR – resetting learnt values 7957
4 Exhaust gas temperature regulation 7958
4 1 Assembly overview – exhaust gas temperature regulation 7958
4 1 1 Assembly overview – exhaust gas temperature regulation, vehicles with SCR system 7958
4 1 2 Assembly overview – exhaust gas temperature regulation, vehicles with emission control module, version 2 7960
4 2 Removing and installing exhaust gas temperature sender 1 -G235- 7962
4 3 Removing and installing exhaust gas temperature sender 2 -G448- 7964
4 3 1 Removing and installing exhaust gas temperature sender 2 -G448-, Sharan and Tiguan 7964
4 3 2 Removing and installing exhaust gas temperature sender 2 -G448-, CC 7968
4 4 Removing and installing exhaust gas temperature sender 3 -G495- 7971
4 4 1 Removing and installing exhaust gas temperature sender 3 -G495-, Sharan and Tiguan 7971
4 4 2 Removing and installing exhaust gas temperature sender 3 -G495-, CC 7973
4 5 Removing and installing exhaust gas temperature sender 4 -G648- 7976
4 5 1 Removing and installing exhaust gas temperature sender 4 -G648-, Sharan and Tiguan 7976
4 5 2 Removing and installing exhaust gas temperature sender 4 -G648-, CC 7978
5 Exhaust gas recirculation 7982
5 1 Assembly overview – exhaust gas recirculation 7982
5 2 Assembly overview – exhaust gas recirculation valve 1 -GX5- 7984
5 3 Removing and installing exhaust gas recirculation cooler 7985
5 4 Removing and installing exhaust gas recirculation valve 1 -GX5- 7988
5 5 Removing and installing exhaust gas recirculation valve 2 -GX6- 7990
5 6 Checking exhaust gas recirculation cooler for leaks 7991
28 – Glow plug system 7992
1 Glow plug system 7992
1 1 Assembly overview – glow plug system 7992
1 2 Removing and installing glow plug 7993
1 3 Removing and installing automatic glow period control unit -J179- 7997
1 4 Removing and installing Hall sender -G40- 7997
1 5 Removing and installing engine speed sender -G28- 7998
00 – Technical data 8006
1 Safety information 8006
1 1 Safety precautions when working on air conditioning systems 8006
1 2 Safety precautions when working on high-voltage system 8007
1 3 Safety precautions when working in the vicinity of high-voltage components 8007
1 4 Safety precautions when tow-starting or towing 8008
2 Repair instructions 8009
2 1 Rules for cleanliness when working on high-voltage system 8009
3 General information on air conditioning 8010
3 1 Other reference material 8010
3 2 Basics of air conditioning technology 8010
3 2 1 Physical principles: 8010
3 2 2 Heat always flows from a warmer to a colder substance 8011
3 2 3 Pressure and boiling point 8011
3 3 Vapour pressure table for refrigerant R134a 8012
3 4 Refrigerant R134a 8013
3 4 1 Physical data of refrigerant R134a 8013
3 4 2 Critical point 8013
3 4 3 Environmental aspects of refrigerant R134a 8014
3 5 Properties of refrigerant R134a 8014
3 5 1 Trade names and designations 8014
3 5 2 Colour 8014
3 5 3 Vapour pressure 8014
3 5 4 Physical properties of R134a 8015
3 5 5 Effects on metal 8015
3 5 6 Critical temperature and critical pressure 8015
3 5 7 Union 8015
3 5 8 Charge factor 8015
3 5 9 Detecting leaks 8015
3 6 Refrigerant oil 8016
3 6 1 Properties of refrigerant oil 8016
3 7 Comfort 8017
3 7 1 Environmental aspects 8017
3 8 How air conditioning works 8018
3 9 General work safety 8018
3 9 1 Product characteristics 8018
3 9 2 Handling refrigerants 8019
3 9 3 Wear safety goggles 8019
3 9 4 Wear protective gloves and apron 8019
3 9 5 Do not allow liquid refrigerant to come in contact with the skin 8019
3 9 6 Do not breath in refrigerant vapour 8019
3 9 7 Absolutely NO SMOKING 8019
3 9 8 Welding and soldering on refrigeration systems 8019
3 9 9 Pungent smell 8020
3 9 10 First aid 8020
3 9 11 Handling pressure vessels 8020
3 9 12 Do not heat up above 50°C 8020
3 9 13 Do not expose to uncontrolled heat 8020
3 9 14 Seal empty tanks/containers 8020
3 9 15 Safety instructions for using extraction and charging equipment 8021
3 10 Safety measures when working on vehicles with air conditioning and when working with refrigerant R134a 8021
3 11 Basics for working on refrigerant circuit 8022
3 11 1 O-ring 8023
3 11 2 Before operating the air conditioning system after recharging with refrigerant 8024
4 General information on refrigerant circuit 8025
4 1 Components of refrigerant circuit 8025
4 1 1 Distribution of the refrigerant circuit components and their influence on the high-pressure and low-pressure sides 8025
4 1 2 Air conditioning system compressor with magnetic clutch: 8025
4 1 3 Air conditioner compressor without magnetic clutch 8026
4 1 4 Air conditioner compressor without magnetic clutch, with elastic drive coupling 8027
4 1 5 Electrical air conditioner compressor for high-voltage system 8028
4 1 6 Condenser 8029
4 1 7 evaporator 8029
4 1 8 Reservoir 8030
4 1 9 Restrictor 8030
4 1 10 Receiver 8031
4 1 11 Expansion valve 8032
4 1 12 O-ring 8033
4 1 13 Pipes and hoses of refrigerant circuit 8033
4 1 14 High-pressure safety valve 8033
4 2 Design of refrigerant circuit 8036
4 2 1 Refrigerant circuit with expansion valve and evaporator 8036
4 2 2 Refrigerant circuit with restrictor and reservoir 8036
4 3 Evacuation and charging valves for quick-release couplings of air conditioner service station on refrigerant circuit 8037
4 3 1 Evacuation and charging valve with Schrader valve 8037
4 3 2 Extraction and charging valve, high-pressure side 8038
4 3 3 Extraction and charging valve, low-pressure side 8039
4 4 Switches and senders in refrigerant circuit and related connections 8039
4 4 1 High-pressure switch for air conditioning system -F23- 8039
4 4 2 High-pressure switch for magnetic clutch -F118- 8040
4 4 3 Low-pressure switch for air conditioning system -F73- 8040
4 4 4 Connections with valve for switches in refrigerant circuit 8041
4 4 5 Air conditioning system pressure switch -F129- 8041
4 4 6 High-pressure sender -G65- 8042
4 4 7 Refrigerant pressure and temperature sender -G395- 8043
4 4 8 Air conditioner compressor regulating valve -N280- 8043
4 5 Electrical components not installed in refrigerant circuit 8044
4 5 1 Control and regulating unit for air conditioning system -J127- 8044
4 5 2 Radiator fan control unit -J293- 8044
4 5 3 Radiator fan control unit -J293- 8045
4 5 4 Temperature switch for evaporator -E33- 8046
4 5 5 Evaporator output temperature sender -G263- or evaporator temperature sensor -G308- 8046
4 6 Pressures and temperatures in refrigerant circuit 8047
4 7 Refrigerant circuit with expansion valve 8047
4 8 Refrigerant circuit with restrictor and reservoir 8049
4 9 Test and measurement work that can be performed using a pressure gauge 8051
4 9 1 Pressure gauges enable the following test and measurement work 8051
4 10 Air conditioner service and recycling equipment 8052
4 10 1 Classification of extraction and charging devices in groups 8052
4 10 2 Charging devices that do not require a permit 8052
4 11 Notes to repairs on refrigerant circuit 8053
5 Laws and regulations 8054
5 1 Laws and regulations 8054
5 2 Recycling and refuse law 8059
5 2 1 Disposal of refrigerant and refrigerant machine oil 8059
5 3 Converting R12 refrigerant circuits to R134a refrigerant circuits and servicing them (retrofitting) 8060
5 4 Maintaining records on refrigerant 8060
6 Refrigerant circuit 8061
6 1 Important repair notes on air conditioning 8061
6 2 Converting refrigerant circuits from R12 refrigerant to R134a 8061
7 Working with the air conditioner service station 8062
7 1 Important instructions for working with the air conditioner service station 8062
7 2 Connecting a air conditioner service station for measuring and testing 8063
7 3 Drain the refrigerant circuit using the air conditioner service station 8064
7 4 Evacuating refrigerant circuit using air conditioner service station 8064
7 5 Filling refrigerant circuit with air conditioner service station 8066
7 6 Bringing air conditioning system into service after charging 8067
7 7 Charging the container in the air conditioning service station with refrigerant 8067
7 8 Emptying air conditioner service station 8068
8 Detecting leaks in refrigerant circuit 8069
8 1 Leak detection in refrigerant circuit using compressed air or nitrogen 8070
8 2 Searching for leaks in refrigerant circuits using leak detector -V A G 1796- 8071
8 3 Detecting leaks in refrigerant circuit using leak detecting system -VAS 6196- or leak detecting system -VAS 6201- or a later model 8072
9 Clearing refrigerant circuit of contaminants 8080
9 1 Vehicles with high-voltage system (hybrid vehicles) 8080
9 2 Blowing through refrigerant circuit with compressed air and nitrogen 8081
9 2 1 Flushing refrigerant circuit 8083
9 3 Flushing refrigerant circuit with refrigerant R134a 8083
9 3 1 Principle circuit diagrams for various purging circuits 8091
9 3 2 Purging electrical air conditioner compressor 8097
9 3 3 Adapters for setting up flushing circuits 8101
10 Clearing refrigerant circuit of contaminants, commercial vehicles 8115
10 1 Vehicles with high-voltage system 8115
10 2 Flushing refrigerant circuit with refrigerant R134a 8116
10 3 Adapters for setting up flushing circuits 8116
10 4 Procedure for setting up and flushing refrigerant circuit, Amarok 2023 ► 8120
10 5 Procedure for setting up and flushing refrigerant circuit, Amarok 2010 ► 8120
10 5 1 Connection diagram for flushing circuit 8120
10 5 2 Procedure for setting up and flushing refrigerant circuit 8121
10 6 Procedure for setting up and flushing refrigerant circuit, Caddy 2004 ► 8126
10 6 1 Connection diagram for flushing circuit 8126
10 6 2 Procedure for setting up and flushing refrigerant circuit 8127
10 7 Procedure for setting up and flushing refrigerant circuit, Crafter ►2017 8133
10 7 1 Connection diagram for flushing circuit, vehicles with one evaporator 8133
10 7 2 Connection diagram for flushing circuit, vehicles with second evaporator 8134
10 7 3 Procedure for setting up and flushing refrigerant circuit, vehicles with one evaporator 8135
10 7 4 Procedure for setting up and flushing refrigerant circuit, vehicles with second evaporator 8142
10 8 Procedure for setting up and flushing refrigerant circuit, Crafter 2017 ► or MAN TGE ►, Crafter Grand California ► 8150
10 8 1 Connection diagram for flushing circuit, vehicles with one evaporator 8151
10 8 2 Connection diagram for flushing circuit, vehicles with second evaporator 8152
10 8 3 Procedure for setting up and flushing refrigerant circuit, vehicles with one evaporator 8153
10 8 4 Procedure for setting up and flushing refrigerant circuit, vehicles with second evaporator 8158
10 9 Procedure for setting up and flushing refrigerant circuit, Transporter 2016 ►, Transporter 2020 ► 8167
10 9 1 Connection diagram for flushing circuit, vehicles with one evaporator 8167
10 9 2 Connection diagram for flushing circuit, vehicles with second evaporator 8168
10 9 3 Procedure for setting up and flushing refrigerant circuit, vehicles with one evaporator 8169
10 9 4 Procedure for setting up and flushing refrigerant circuit, vehicles with second evaporator 8174
11 Complaints 8183
11 1 Possible complaints about refrigerant circuit 8183
11 1 1 Conditions for testing: 8183
11 1 2 Possible complaints 8183
11 2 Odours from heater and air conditioning unit 8184
11 2 1 Does the odour emanate from the evaporator or heat exchanger? 8184
11 2 2 Ultrasonic air conditioner cleaning unit -VAS 6189A- 8185
11 2 3 Spraying the evaporator with the suction feed spray-gun -V A G 1538- and spray lance 8186
12 Connecting the air conditioning service station 8187
12 1 For vehicles that have connections on both low-pressure and high-pressure sides of refrigerant circuit 8187
12 1 1 Connecting a air conditioner service station for measuring and testing 8187
13 Checking pressures on vehicles 8188
13 1 Checking pressures in the refrigerant circuit (using a air conditioning service station) 8188
13 1 1 Conditions for testing 8188
13 1 2 Checking pressures 8189
13 1 3 Continuation of checking pressures 8191
13 2 Checking systems with a restrictor and collector (with internally regulated air conditioner compressor) 8192
13 2 1 Specifications: 8192
13 3 Checking systems with an expansion valve and reservoir (with internally regulated air conditioner compressor) 8196
13 3 1 Specifications: 8196
13 4 Checking systems with an expansion valve and reservoir (without regulated air conditioner compressor) 8201
13 4 1 Conditions for testing 8201
13 4 2 Check 8201
13 4 3 Specified values 8201
13 5 Checking systems with a restrictor and reservoir and air conditioner compressor regulating valve -N280- (with externally regulated air conditioner compressor) 8202
13 5 1 Specifications: 8202
13 6 Checking systems with an expansion valve, receiver and air conditioner compressor regulating valve -N280- (with externally regulated air conditioner compressor) 8207
13 6 1 Specifications: 8207
13 7 With expansion valve, receiver and electrical air conditioner compressor 8218
14 Renewing components 8219
14 1 In the event of leaking or damaged components (apart from the air conditioner compressor, receiver or reservoir) 8220
14 1 1 If the refrigerant circuit was completely empty 8220
14 1 2 If there is still refrigerant in the refrigerant circuit 8222
14 2 Renew the air conditioner compressor 8222
14 2 1 Without needing to flush refrigerant circuit of contaminants (cleaning), e g in cases of external damage after an accident 8222
14 2 2 Leaks or internal damage (e g noises or lack of power) 8224
14 3 Replace receiver or reservoir and restrictor 8224
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 8224
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 8226
15 Testing equipment and tools 8227
15 1 List of test equipment, tools and materials 8227
15 1 1 Tools and materials available from regional sales centre or importer 8227
15 1 2 Tools and materials commercially available 8228
15 1 3 Tools and materials available from regional sales centre or importer 8229
15 1 4 Tools and materials commercially available 8235
00 – Technical data 8244
1 Identification of gearbox 8244
2 Overview – power transmission 8245
3 Code, engine allocation 8246
3 1 Polo 2010 ► 8246
3 2 Touran 2003 ► 8246
3 3 Golf 2004 ► 8246
3 4 Passat CC 2009 ►; CC 2010 ► 8247
3 5 Passat 2006 ► 8247
3 6 Golf 2009 ► 8247
3 7 Golf Plus 2009 ► 8247
3 8 Golf Plus 2005 ►, Cross Golf 8248
3 9 Scirocco 2009 ► 8248
4 Capacities 8249
5 General repair instructions 8250
5 1 Tools 8250
5 2 Gearbox 8250
5 3 Anti-friction bearings 8252
5 4 Oil 8252
5 5 Working with tester 8252
5 5 1 Adapting installation information 8253
5 5 2 Reading measured values for mandatory reporting 8253
5 5 3 Initiating basic adjustment 8253
30 – Clutch 8254
1 Removing and installing dual clutch, gearboxes made up to 05 2011 8254
1 1 Assembly overview – dual clutch, gearboxes made up to 05 2011 8254
1 2 Removing dual clutch, gearboxes made up to 05 2011 8256
1 3 Adjusting position of engagement bearings for clutches “K 1” and “K 2”, gearboxes made up to 05 2011 8260
1 4 Installing dual clutch, gearboxes made as of 05 2011 8273
2 Removing and installing dual clutch, gearboxes made from 06 2011 onwards 8280
2 1 Assembly overview – dual clutch, gearboxes made as of 06 2011 8280
2 2 Removing dual clutch, gearboxes made as of 06 2011 8282
2 3 Adjusting position of engagement bearings for clutches “K 1” and “K 2”, gearboxes made as of 06 2011 8286
2 4 Installing dual clutch, gearbox date from 06 2011 8299
3 Removing and installing oil seals at clutch end 8306
34 – Controls, housing 8309
1 Emergency release of selector lever 8309
2 Removing and installing selector lever handle 8310
2 1 Moving push-button in the handle to installation position 8312
2 1 1 Handle with push-button on side 8312
2 1 2 Handle with front push-button 8312
3 Selector mechanism in vehicles up to 02 2009 8315
3 1 Overview of selector mechanism up to 02 2009 8315
3 2 Removing and installing selector lever cable up to 02 2009 8316
4 Selector mechanism from 03 2009 onwards 8323
4 1 Overview of selector mechanism in vehicles from 03 2009 onwards 8323
4 2 Removing and installing selector mechanism 8324
4 2 1 Removing and installing selector mechanism with selector housing 8324
4 2 2 Removing and installing selector mechanism without selector housing 8326
5 Checking selector mechanism 8328
5 1 Selector lever in “P” position and ignition switched on 8328
5 2 Selector lever in “N” position and ignition switched on 8328
5 3 Selector lever in position “Tiptronic” 8328
5 4 Ignition and light switched on 8328
5 5 Selector lever position indicator 8328
5 6 Checking and adjusting selector lever cable 8328
6 Safety note on mechatronic unit for dual clutch gearbox -J743- 8332
7 Overview – mechatronic unit 8333
8 Removing mechatronic unit for dual clutch gearbox -J743-; gearbox is installed 8335
9 Moving mechatronic unit for dual clutch gearbox -J743- into »removal position« by hand 8347
10 Installing mechatronic unit for dual clutch gearbox -J743- 8349
11 View on selector forks; mechatronic unit is removed 8357
12 Renewing clutch actuator 8358
13 Renewing control unit for mechatronic unit for dual clutch gearbox -J743- 8364
14 Removing and installing gearbox 8369
14 1 Notes on different vehicles, different gearboxes 8369
14 2 Removing gearbox, Golf 2009 ► and Golf Plus 2009 ►, 1 2 l – 63 and 77 kW petrol engine 8371
14 3 Removing gearbox, Golf 2009 ►, 1 8 l – 118 kW petrol engine 8379
14 4 Removing gearbox, Polo 2010 ►, 1 2 l – 63 and 77 kW petrol engine 8385
14 5 Removing gearbox, Polo 2010 ►, 1 4 l – 63 kW petrol engine 8390
14 6 Removing gearbox, Polo 2010 ►, 1 4 l – 103 kW petrol engine 8397
14 7 Removing gearbox, Polo 2010 ►, 1 6 l – 66 kW diesel engine 8401
14 8 Removing gearbox, Polo 2010 ►, 1 4 l – 132 kW petrol engine 8408
14 9 Removing gearbox with flange shafts; Touran 1 4 l – 103, 110 and 125 kW petrol engine (and 110 kW Eco-Fuel) 8414
14 10 Removing gearbox, Touran 1 6 l – 77 kW TDI engine 8420
14 11 Removing gearbox, Touran 1 9 l – 77 kW TDI engine 8426
14 12 Removing gearbox, Passat 2006 ► 1 4 l – 110 kW Eco-Fuel engine 8432
14 13 Removing gearbox, Passat 1 4 l – 90 and 110 kW petrol engine 8438
14 14 Removing gearbox, Passat 1 8 l – 90 and 118 kW petrol engine 8443
14 15 Removing gearbox, Golf Plus 2009 ►, 1 4 l – 90 kW and 118 kW petrol engine 8448
14 16 Removing gearbox, Golf Plus 2009 ►, 1 6 l – 75 kW petrol engine 8455
14 17 Removing gearbox, Scirocco 2009 ►, 1 4 l – 118 kW TSI engine 8462
14 18 Removing gearbox, Golf 2009 ►, 1 6 l – 75 kW petrol engine 8469
14 19 Removing gearbox, Golf 2009 ►, 1 4 l – 90 or 118 kW petrol engine 8475
14 20 Removing gearbox, Golf 2004 ►, Golf Plus 2005 ► and Cross Golf 1 4 l – 90, 118 kW TSI engine 8482
14 21 Removing gearbox, Golf Plus 2009, 1 6 l – 77 kW diesel engine 8489
14 22 Removing gearbox, Golf 2009 1 6 l and 1 9 l – 77 kW diesel engine 8496
14 23 Removing gearbox, Golf 2004 and Golf Plus 2005 1 9 l – 77 kW TDI engine 8502
14 24 Removing gearbox, Passat CC 2009 ►, CC 2010 ►, Passat 2011 ► 1 4 l – 90, 110, 118 kW petrol engine and 1 4 l – 110 kW Eco-Fuel engine 8508
14 25 Removing gearbox, Passat CC 2009►, CC 2010►, 1 8 l – 90 and 118 kW petrol engine 8515
14 26 Removing gearbox, Golf Cabriolet 2012 ►, 1 4 l – 90 or 118 kW petrol engine 8521
14 27 Install gearbox 8527
14 28 Torque settings »Gearbox to engine« and notes on assembly mounting 8530
14 28 1 1 8 – 118 kW engine 8532
14 28 2 1 4 l – 63 kW petrol engine 8533
14 28 3 1 4 l – 103 kW petrol engine 8534
14 28 4 1 2 l and 1 4 l and 1 6 l engine 8535
14 28 5 1 6 l – 77 kW diesel engine 8536
14 28 6 1 9 l – 77 kW diesel engine and 1 6 l – 66 kW diesel engine 8537
15 Transporting gearbox and securing to assembly stand 8538
16 Gear oil 8540
16 1 Draining and filling gear oil 8540
16 2 Draining and filling hydraulic fluid for mechatronic unit 8542
35 – Gears, shafts 8546
1 Notes on gearbox disassembly 8546
1 1 Overview: gearbox disassembly 8546
2 Dismantling gearbox 8548
3 Assembling gearbox 8555
4 Dismantling and assembling gearbox housing 8566
5 Dismantling and assembling clutch housing 8570
6 Dismantling and assembling outer input shaft 8574
7 Dismantling and assembling inner input shaft 8576
8 Dismantling and assembling output shaft 1 – overview 8579
8 1 Dismantling output shaft 1 partially 8580
8 2 Dismantling output shaft 1 completely 8582
8 3 Assembling output shaft 1 8584
8 4 Dismantling and assembling locking collars and synchro-hubs of output shaft 1 8589
9 Dismantling and assembling output shaft 2 – overview 8590
9 1 Dismantling output shaft 2 8591
9 2 Assembling output shaft 2 8593
9 3 Dismantling and assembling locking collars and synchro-hubs of output shaft 2 8597
10 Dismantling and assembling output shaft 3 – overview 8598
10 1 Dismantling output shaft 3 8598
10 2 Assembling output shaft 3 8600
10 3 Dismantling and assembling locking collar and synchro-hub of output shaft 3 8602
11 Notes on gearbox adjustment 8603
11 1 Calculating shims for clutch housing 8604
12 Calculating shims for gearbox housing 8617
13 Parking lock 8637
13 1 Removing and installing cover for parking lock 8637
13 2 Removing and installing parking lock 8638
39 – Final drive – front differential 8640
1 Oil seals 8640
1 1 Renewing oil seal for right stub shaft 8640
1 2 Renewing oil seal for left stub shaft 8641
1 3 Renewing seal for right flange shaft 8643
1 4 Renewing oil seal for left flange shaft 8645
00 – Technical data 8657
1 Engine number 8657
2 Engine data 8658
10 – Removing and installing engine 8660
1 Removing and installing engine 8660
1 1 Removing engine 8661
1 2 Separating gearbox from engine and assembling 8675
1 3 Securing engine to assembly stand 8678
1 4 Installing engine 8679
2 Assembly mountings 8682
2 1 Assembly overview – assembly mountings (Golf, Eos, Passat, CC, Scirocco) 8682
2 2 Assembly overview – assembly mountings (Tiguan) 8684
2 3 Checking adjustment of assembly mountings 8686
2 4 Adjusting assembly mountings (Passat 2006 ▶, CC) 8686
2 5 Adjusting assembly mountings (Golf, Eos, Scirocco) 8691
2 6 Adjusting assembly mounting (Tiguan) 8696
13 – Crankshaft group 8701
1 Cylinder block (pulley end) 8701
1 1 Assembly overview – poly V-belt drive 8701
1 2 Removing and installing poly-V belt 8704
1 3 Removing and installing tensioner for poly V-belt (Passat 2006 ▶, CC) 8705
1 4 Removing and installing tensioner for poly V-belt (Golf, Eos, Scirocco) 8710
1 5 Removing and installing tensioner for poly V-belt (Tiguan) 8715
1 6 Removing and installing bracket for ancillaries 8719
1 7 Removing and installing vibration damper 8721
1 8 Renewing oil seal for vibration damper 8729
2 Cylinder block, gearbox end 8732
2 1 Assembly overview – sealing flange on gearbox side and dual-mass flywheel/drive plate 8732
2 2 Removing and installing dual-mass flywheel 8733
2 3 Removing and installing drive plate 8735
2 4 Removing and installing sealing flange on gearbox side 8737
2 4 1 Removing and installing sealing flange on gearbox side, version A sealing lip faces outwards 8738
2 4 2 Removing and installing sealing flange on gearbox side, version B sealing lip faces engine 8741
3 Crankshaft 8746
3 1 Assembly overview – crankshaft 8746
3 1 1 Removing and installing sender wheel 8748
3 1 2 Allocation of crankshaft bearing shells (classification) 8749
3 2 Pulling needle bearing out of and driving into crankshaft 8751
3 3 Crankshaft dimensions 8753
3 4 Measuring axial clearance of crankshaft 8753
3 5 Measuring radial clearance of crankshaft 8754
4 Pistons and conrods 8756
4 1 Assembly overview – pistons and conrods 8756
4 2 Removing and installing pistons 8760
4 3 Checking pistons and cylinder bores 8762
4 4 Separating new conrod 8764
4 5 Checking radial clearance of conrods 8765
15 – Cylinder head, valve gear 8766
1 Chain drive 8766
1 1 Assembly overview – timing chain covers 8766
1 2 Removing and installing camshaft control valve 1 -N205- 8769
1 3 Removing and installing upper timing chain cover 8769
1 4 Removing and installing lower timing chain cover (Passat, CC) 8772
1 5 Removing and installing lower timing chain cover (Golf, Eos, Scirocco) 8780
1 6 Removing and installing bottom timing chain cover (Tiguan) 8789
1 7 Camshaft timing chain – exploded view 8797
1 8 Removing and installing camshaft timing chain 8799
1 9 Assembly overview – drive chain for balance shaft 8816
1 10 Removing and installing drive chain for balance shaft 8819
1 11 Removing and installing inlet side balance shaft 8819
1 12 Removing and installing exhaust side balance shaft 8824
1 13 Checking valve timing 8827
2 Cylinder head 8830
2 1 Assembly overview – cylinder head 8830
2 2 Renewing oil non-return valve in cylinder head 8834
2 3 Removing and installing engine cover 8835
2 4 Removing and installing cylinder head 8836
2 4 1 Removing and installing cylinder head 8837
2 4 2 Removing and installing cylinder head and camshaft timing chain 8867
2 5 Checking compression 8883
2 6 Removing and installing vacuum pump 8885
3 Valve gear 8887
3 1 Assembly overview – valve gear 8887
3 2 Removing and installing camshaft 8890
3 3 Checking axial clearance of camshafts 8911
3 4 Renewing valve stem seals 8912
3 4 1 Removing and installing valve stem seals (cylinder head installed) 8912
3 4 2 Removing and installing valve stem seals (cylinder head removed) 8917
3 5 Checking valve guides 8923
17 – Lubrication 8925
1 Sump and oil pump 8925
1 1 Assembly overview – sump, oil pump 8925
1 2 Removing and installing coarse oil separator 8928
1 3 Removing and installing lower part of sump 8929
1 4 Removing and installing oil pump 8932
1 5 Removing and installing upper part of sump 8935
1 6 Removing and installing oil pressure control valve -N428- (engine codes CCZA, CCZB, CCZC, CCZD, CDAA, CDAB) 8940
2 Engine oil: 8942
3 Oil filter, engine oil cooler and oil pressure switch (engine codes CAWA, CAWB, CBFA, CCTA, CCTB, BZB, CGYA) 8944
3 1 Assembly overview – oil filter, engine oil cooler and oil pressure switch -F1- 8944
3 2 Removing and installing engine oil cooler 8945
3 3 Checking oil pressure and oil pressure switch 8947
4 Oil filter, engine oil cooler and oil pressure switch (engine codes CCZA, CCZB, CCZC, CCZD, CDAA, CDAB) 8950
4 1 Assembly overview – oil filter, engine oil cooler 8950
4 2 Removing and installing engine oil cooler 8952
4 3 Removing and installing oil pressure switch -F1- 8953
4 4 Removing and installing oil pressure switch for reduced oil pressure -F378- 8955
4 5 Checking oil pressure and oil pressure switch 8956
19 – Cooling 8961
1 Cooling system 8961
1 1 Coolant hose connection diagram 8961
1 2 Draining and adding coolant 8963
1 3 Checking cooling system for leaks 8971
2 Coolant pump, thermostat, coolant pipes 8975
2 1 Assembly overview – coolant pump, thermostat 8975
2 2 Removing and installing coolant pump with thermostat housing 8978
2 3 Detaching coolant pump from thermostat housing/attaching coolant pump to thermostat housing 8981
2 4 Removing and installing toothed belt for coolant pump 8984
2 5 Renewing oil seal for coolant pump drive 8987
2 6 Removing and installing thermostat 8989
2 7 Removing and installing coolant temperature sender -G62- 8992
2 8 Assembly overview – coolant pipes 8995
2 9 Removing and installing front coolant pipes 8996
2 10 Removing and installing small coolant pipe 9000
2 11 Continued coolant circulation pump -V51- – exploded view 9001
2 12 Removing and installing continued coolant circulation pump -V51- 9002
3 Radiator and radiator fans 9004
3 1 Assembly overview – radiator, fan cowl and radiator fan (Passat, CC, Golf, Eos, Scirocco) 9004
3 2 Installing radiator identification sensor -G611-, engine code CBFA 9005
3 3 Assembly overview – radiator, radiator cowl and radiator fan (Tiguan) 9006
3 4 Removing and installing radiator cowl 9008
3 5 Removing and installing radiator fan -V7- and radiator fan 2 -V177- 9010
3 6 Removing and installing radiator (Passat, CC, Golf, Eos, Scirocco) 9010
3 7 Removing and installing radiator (Tiguan) 9011
20 – Fuel supply system 9014
1 Safety precautions 9014
1 1 Safety regulations for working on fuel supply 9014
2 Rules for cleanliness 9016
3 Fuel tank (Passat, CC) 9017
3 1 Assembly overview – fuel tank (engine codes BZB, CAWA, CAWB, CGYA, CCZA, CCZB, CDAA, CDAB) 9017
3 2 Assembly overview – fuel tank (engine codes CBFA, CCTA, CCTB) 9019
3 3 Emptying fuel tank 9021
3 3 1 Emptying fuel tank when fuel pump is intact 9021
3 3 2 Emptying fuel tank if it is more than 3/4 full 9024
3 3 3 Emptying fuel tank if it is less than 3/4 full 9025
3 4 Removing and installing fuel tank 9026
3 4 1 Removing fuel tank 9026
3 4 2 Installing fuel tank 9030
4 Fuel tank (Golf, Scirocco) 9032
4 1 Assembly overview – fuel tank (engine codes BZB, CAWA, CAWB, CGYA, CCZA, CCZB, CDAA) 9032
4 2 Assembly overview – fuel tank (engine codes CBFA, CCTA, CCTB) 9034
4 3 Draining fuel tank (engine codes BZB, CAWA, CAWB, CGYA, CCZA, CCZB, CDAA) 9037
4 3 1 Emptying fuel tank when fuel pump is intact 9038
4 3 2 Emptying fuel tank if it is more than 3/4 full 9040
4 3 3 Emptying fuel tank if it is less than 3/4 full 9042
4 4 Emptying fuel tank (engine codes CBFA, CCTA, CCTB) 9044
4 5 Removing and installing fuel tank 9046
5 Fuel tank (Tiguan) 9050
5 1 Assembly overview – fuel tank 9050
5 2 Emptying fuel tank 9053
5 2 1 Emptying fuel tank when fuel pump is intact 9053
5 2 2 Emptying fuel tank if it is more than 3/4 full 9055
5 2 3 Emptying fuel tank if it is less than 3/4 full 9056
5 3 Removing and installing fuel tank 9057
6 Fuel tank (Eos) 9063
6 1 Assembly overview – fuel tank (engine codes CAWA, CAWB, CCZA, CCZB) 9063
6 2 Assembly overview – fuel tank (engine codes CBFA, CCTA, CCTB) 9066
6 3 Emptying fuel tank 9069
6 3 1 Emptying fuel tank when fuel pump is intact 9069
6 3 2 Emptying fuel tank if it is more than 3/4 full 9072
6 3 3 Emptying fuel tank if it is less than 3/4 full 9073
6 4 Removing and installing fuel tank 9075
6 4 1 Removing 9075
6 4 2 Installing fuel tank 9078
7 Repairing fuel supply (Passat, CC) 9079
7 1 Removing and installing fuel delivery unit 9079
7 2 Removing and installing fuel gauge sender -G- 9084
7 3 Checking fuel pump 9085
7 3 1 Checking function and voltage supply 9087
7 3 2 Checking fuel pressure 9090
7 3 3 Checking fuel pressure when the engine is running (engine codes CCZA, CCZB, CDAA, CDAB) 9092
7 3 4 Checking holding pressure 9095
7 3 5 Checking fuel delivery rate (engine codes CAWA, CAWB, CBFA, CCTA, CCTB, CGYA, BZB) 9096
7 3 6 Checking fuel delivery rate (engine codes CCZA, CCZB, CDAA, CDAB) 9101
7 3 7 Checking current consumption 9105
8 Repairing fuel supply system (Golf, Eos, Scirocco) 9107
8 1 Removing and installing fuel delivery unit 9107
8 2 Removing and installing fuel gauge sender -G- 9111
8 3 Checking fuel pump -G6- 9112
8 3 1 Checking function and voltage supply 9114
8 3 2 Checking fuel pressure 9117
8 3 3 Checking fuel pressure when the engine is running (engine codes CCZA, CCZB, CDAA, CDAB) 9120
8 3 4 Checking holding pressure 9122
8 3 5 Checking fuel delivery rate (engine codes CAWA, CAWB, CBFA, CCTA, CCTB, BZB, CGYA) 9125
8 3 6 Checking fuel delivery rate (engine codes CCZA, CCZB, CDAA, CDAB) 9132
8 3 7 Checking current consumption 9136
9 Repairing fuel supply (Tiguan) 9138
9 1 Removing and installing fuel delivery unit 9138
9 2 Removing and installing fuel gauge sender G 9143
9 3 Removing and installing suction-jet pump, fuel filter and pressure limitation valve 9144
9 4 Removing and installing fuel gauge sender 2 -G169- 9147
9 5 Removing and installing fuel pump control unit -J538- 9148
9 6 Checking fuel pump 9151
9 6 1 Checking function and voltage supply 9152
9 6 2 Checking fuel pressure 9154
9 6 3 Checking fuel pressure when the engine is running and vehicle is in gear (engine codes CCZA, CCZB, CCZC, CCZD) 9155
9 6 4 Checking holding pressure 9158
9 6 5 Checking fuel delivery rate (engine codes CAWA, CAWB, CCTA, CCTB) 9160
9 6 6 Checking fuel delivery rate (engine codes CCZA, CCZB, CCZC, CCZD) 9164
9 6 7 Checking current consumption 9168
10 Electronic power control (EPC) 9170
10 1 Assembly overview – accelerator module 9170
10 2 Removing and installing accelerator pedal module 9170
11 Activated charcoal filter system (Passat, CC, Tiguan) 9174
11 1 Assembly overview – activated charcoal filter system (engine codes BZB, CAWA, CAWB, CGYA, CCZA, CCZB, CCZC, CCZD, CDAA, CDAB) 9174
11 2 Assembly overview – activated charcoal filter system (engine codes CBFA, CCTA, CCTB) 9175
11 2 1 Assembly overview – activated charcoal filter system 9176
11 2 2 Assembly overview – activated charcoal filter system (vehicles with additional filter) 9176
11 3 Checking fuel tank breather (engine codes BZB, CAWA, CAWB, CGYA, CCZA, CCZB, CCZC, CCZD, CDAA, CDAB) 9177
11 4 Check fuel system for leaks (engine codes CBFA, CCTA, CCTB) 9179
11 4 1 Leak detection in fuel system 9184
11 4 2 Schematic overview of activated charcoal filter system 9186
11 4 3 Checking vacuum supply of fuel system diagnostic pump -V144- 9187
12 Activated charcoal filter system (Golf, Eos, Scirocco with engine codes CAWA, CAWB, BZB, CGYA, CCZA, CCZB, CDAA) 9189
12 1 Assembly overview – activated charcoal filter system 9189
12 2 Checking fuel tank breather 9190
13 Activated charcoal filter system (Golf, Eos with engine code CBFA, CCTA, CCTB) 9193
13 1 Overview of activated charcoal filter system 9193
13 2 Assembly overview – activated charcoal filter system (Golf) 9195
13 3 Assembly overview – activated charcoal filter system (Eos) 9196
13 4 Removing and installing activated charcoal filter 9197
13 5 Removing and installing fuel system diagnostic pump -V144- (Golf) 9199
13 6 Removing and installing fuel system diagnostic pump -V144- (Eos) 9200
13 7 Checking fuel system for leaks 9201
13 7 1 Leak detection in fuel system 9206
13 7 2 Schematic overview of activated charcoal filter system 9208
13 7 3 Checking vacuum supply of fuel system diagnostic pump -V144- 9209
21 – Turbocharging/supercharging 9212
1 Turbocharger 9212
1 1 Assembly overview – turbocharger 9212
1 1 1 Part I (engine codes BZB, CGYA, CDAA, CDAB) 9213
1 1 2 Part I (engine codes CAWA, CAWB, CBFA, CCTA, CCTB, CCZA, CCZB, CCZC, CCZD) 9214
1 1 3 Part II 9215
1 1 4 Part III 9216
1 1 5 Part IV 9218
1 1 6 Installation location of turbocharger air recirculation valve -N249- 9219
1 2 Fitting hose connections with plug-in connectors 9220
1 3 Removing and installing turbocharger 9221
1 4 Checking vacuum unit for turbocharger 9228
1 5 Adjusting turbocharger vacuum unit (engine codes BZB, CGYA, CDAA, CDAB) 9230
1 6 Removing and installing vacuum unit for turbocharger 9234
2 Charge air system 9236
2 1 Assembly overview – charge air cooling (Passat, CC, Tiguan, Eos) 9236
2 2 Assembly overview – charge air cooler (Golf, Scirocco) 9237
2 3 Assembly overview – sound generator (Golf, Scirocco) 9239
2 4 Actuator for structure-borne sound -R214- and control unit for structure-borne sound -J869- 9239
2 4 1 Assembly overview – actuator for structure-borne sound -R214- and control unit for structure-borne sound -J869- (left-hand drive vehicles) 9240
2 4 2 Assembly overview – actuator for structure-borne sound -R214- and control unit for structure-borne sound -J869- (right-hand drive vehicles) 9240
2 5 Turbocharging – overview 9241
2 6 Removing and installing charge air cooler (Golf, Eos) 9242
2 7 Removing and installing charge air cooler (Passat, CC, Scirocco) 9245
2 8 Removing and installing charge air cooler, Tiguan 9246
2 9 Removing and installing charge air duct to sound generator (Golf, Scirocco) 9247
2 10 Checking charge air system for leaks 9249
24 – Mixture preparation – injection 9252
1 Safety precautions and rules for cleanliness 9252
1 1 General information on self-diagnosis 9252
2 Injection system 9253
2 1 Technical data 9253
2 2 Overview of fitting locations 9253
2 3 Assembly overview – air filter 9259
2 4 Removing and installing air filter housing 9261
2 5 Removing and installing air filter element 9262
2 6 Removing and installing air mass meter -G70- 9263
2 7 Assembly overview – intake manifold 9264
2 8 Assembly overview – fuel rail 9266
2 9 Removing and installing intake manifold with fuel rail 9268
2 9 1 Removing and installing fuel rail 9276
2 10 Removing and installing injectors 9277
2 11 Renewing Teflon seal on injector 9281
2 12 Cleaning injectors 9284
2 13 Removing and installing fuel pressure sender -G247- 9285
2 14 Removing and installing throttle valve module -J338- 9287
2 15 Cleaning throttle valve module -J338- 9288
2 16 Assembly overview – high-pressure pump with fuel pressure regulating valve -N276- 9290
2 17 Removing and installing high-pressure pump 9292
3 Checking components 9295
3 1 Checking fuel pressure sender -G247- 9295
3 2 Checking intake manifold change-over 9298
4 Engine control unit -J623- (Passat, CC up to 11/10) 9301
4 1 Removing and installing engine control unit 9301
4 2 Removing and installing engine control unit with protective housing 9302
5 Engine control unit -J623- (Golf, Eos to 11/08) 9305
5 1 Removing and installing engine control unit 9305
5 2 Removing and installing engine control unit with protective housing 9305
6 Engine control unit -J623- (Golf, Eos, Scirocco from 11/08; CC from 11/10) 9310
6 1 Removing and installing engine control unit 9310
6 2 Removing and installing engine control unit with protective housing 9312
7 Engine control unit -J623- (Tiguan) 9316
7 1 Removing and installing engine control unit 9316
7 2 Removing and installing engine control unit with protective housing 9317
8 Engine control unit -J623- (Scirocco to 11/08) 9320
8 1 Removing and installing engine control unit 9320
8 2 Removing and installing engine control unit with protective housing 9321
26 – Exhaust system 9324
1 Exhaust system (Passat, CC) 9324
1 1 Assembly overview – exhaust system (engine codes BZB, CAWA, CAWB, CGYA) 9324
1 2 Assembly overview – exhaust system (engine codes CCTA, CCTB, CCZA, CDAA, CDAB) 9326
1 3 Assembly overview – exhaust system (engine code CBFA) 9328
1 4 Separating centre and rear silencers 9330
1 5 Aligning exhaust system free of stress 9332
1 6 Installation position and specified torque of clamp 9333
1 7 Removing and installing catalytic converters with front exhaust pipe 9335
1 8 Checking exhaust system for leaks 9338
2 Exhaust system (Golf, Eos, Scirocco) 9339
2 1 Assembly overview – exhaust system (engine code CAWB) 9339
2 2 Assembly overview – exhaust system (Golf 2004 ►, Eos, Scirocco, engine codes CCTA, CCZA, CCZB) 9341
2 3 Assembly overview – exhaust system (engine code CBFA) 9343
2 4 Assembly overview – exhaust system (Golf 2009►, engine codes CCZA, CCZB) 9345
2 5 Assembly overview – exhaust system (Golf 2009 ►, engine codes CCTA, CDAA) 9347
2 6 Separating centre and rear silencers 9349
2 7 Aligning exhaust system free of stress 9351
2 8 Installation position and specified torque of clamp 9352
2 9 Removing and installing catalytic converters with front exhaust pipe 9353
2 10 Checking exhaust system for leaks 9356
3 Exhaust system (Tiguan) 9357
3 1 Assembly overview – exhaust system (engine codes CCTA, CCTB, CCZA, CCZB, CCZC, CCZD) 9357
3 2 Assembly overview – exhaust system (engine codes CAWB, CCZA) 9359
3 3 Separating centre and rear silencers 9361
3 4 Aligning exhaust system free of stress 9362
3 5 Removing and installing catalytic converters with front exhaust pipe 9364
3 6 Installation position and specified torque of clamp 9369
3 7 Checking exhaust system for leaks 9370
4 Secondary air system – engine code CBFA 9371
4 1 Assembly overview – secondary air system 9371
4 2 Removing and installing secondary air pump motor -V101- 9371
4 3 Removing and installing secondary air inlet valve -N112- 9372
28 – Ignition system 9374
1 Repairing ignition system 9374
1 1 General notes on ignition system 9374
1 2 Safety precautions 9374
1 3 Assembly overview – ignition system 9375
1 4 Removing and installing ignition coils with output stage 9375
1 5 Removing and installing knock sensor 1 -G61- 9377
1 6 Removing and installing engine speed sender -G28- 9378
1 7 Test data, spark plugs 9379
00 – Technical data 9386
1 Identification 9386
1 1 Gearbox identification 9386
2 Identification codes, assembly allocation, ratios and capacities 9387
2 1 Identification codes, assembly allocation, ratios and capacities, Golf 2004 ► 9387
2 2 Identification codes, assembly allocation, ratios and capacities, Golf 2009 ► 9390
2 3 Identification codes, assembly allocation, ratios and capacities, Golf Plus 2005 ► 9391
2 4 Identification codes, assembly allocation, ratios and capacities, Golf Plus 2009 ► 9393
2 5 Identification codes, assembly allocation and capacities, Passat 2006 ► 9394
2 6 Identification code, assembly allocation, transmission ratios and capacities, Passat 2011 ► 9395
2 7 Identification codes, assembly allocation, gear ratios and capacities, Passat CC 2009 ► 9396
2 8 Identification codes, assembly allocation, gear ratios and capacities, CC 2010 ► 9397
2 9 Identification codes, assembly allocation and capacities, Eos 2006 ► 9398
2 10 Identification codes, assembly allocation, ratios and capacities, Scirocco 2009 ► 9398
2 11 Calculating overall gear ratio “i” 9399
3 Overview – power transmission 9400
4 General repair instructions 9402
5 Safety precautions 9405
5 1 Safety precautions for vehicles with a start-stop system 9405
30 – Clutch 9406
1 Clutch operation 9406
1 1 Overview – clutch actuation 9406
1 2 Assembly overview – pedal cluster 9408
1 3 Removing and installing over-centre spring 9410
1 3 1 Removing and installing over-centre spring – Golf 2004 ► 9410
1 3 2 Removing and installing over-centre spring – Golf 2009 ► left-hand drive and Scirocco 9414
1 3 3 Removing and installing over-centre spring – Golf 2009 ► right-hand drive 9419
1 3 4 Removing and installing over-centre spring, Golf Plus 9423
1 3 5 Removing and installing over-centre spring, Passat, Passat CC, CC and Eos 9428
1 4 Removing and installing clutch pedal 9430
1 4 1 Removing and installing clutch pedal, Golf 2004 ►, Golf 2009 ►, Golf Plus and Scirocco 9430
1 4 2 Removing and installing clutch pedal, Passat, Passat CC, CC and Eos 9431
1 5 Removing and installing mounting bracket 9433
1 5 1 Removing and installing mounting bracket, Golf 2004 ► 9433
1 5 2 Removing and installing mounting bracket – Golf 2009 ► left-hand drive and Scirocco 9438
1 5 4 Removing and installing mounting bracket, Golf Plus left-hand drive 9449
1 5 5 Removing and installing mounting bracket, Passat, Passat CC and CC 9454
1 5 6 Removing and installing mounting bracket, Eos 9458
1 6 Removing and installing master cylinder 9462
1 7 Removing and installing clutch position sender -G476- 9464
1 8 Assembly overview – hydraulics (LHD) 9467
1 9 Assembly overview – hydraulics (RHD) 9469
1 10 Removing and installing slave cylinder 9470
1 11 Bleeding clutch system 9472
2 Clutch release mechanism 9474
2 1 Assembly overview – clutch release mechanism 9474
2 2 Repairing clutch release mechanism 9475
3 Clutch 9476
3 1 Clutch in connection with dual mass flywheel 9476
3 1 1 Identifying make of clutch, vehicles with 1 9 l – 66 kW turbo diesel engine and vehicles with 1 9 l – 77 kW turbo diesel engine 9476
3 1 2 Assembly overview – “Sachs” clutch 9478
3 1 3 Removing and installing “Sachs” clutch 9479
3 1 4 Assembly overview – “LuK” clutch 9481
3 1 5 Removing and installing “LuK” clutch 9482
3 2 Clutch in connection with simple flywheel 9484
3 2 1 Assembly overview – clutch in connection with simple flywheel 9484
3 2 2 Removing and installing clutch in connection with simple flywheel 9486
34 – Controls, housing 9488
1 Selector mechanism 9488
1 1 Installation position of selector mechanism 9488
1 2 Overview – selector mechanism 9489
1 3 Assembly overview – gear knob and cover 9489
1 4 Removing and installing gear knob with gaiter and noise insulation 9491
1 4 1 Removing and installing gear knob with gaiter and noise insulation, Golf, Eos and Scirocco 9491
1 4 2 Removing and installing gear knob with gaiter and noise insulation, Golf Plus 9492
1 4 3 Removing and installing gear knob with gaiter and noise insulation, Passat, Passat CC and CC 9494
1 5 Assembly overview – Gear lever and selector housing 9496
1 5 1 Assembly overview – selector lever and selector housing (up to 10 06) 9496
1 5 2 Assembly overview – selector lever and selector housing (from 11 06) 9498
1 6 Dismantling and assembling selector mechanism (from 11 06) 9499
1 6 1 Attaching base plate 9503
1 7 Assembly overview – Selector cables 9504
1 7 1 Assembly overview – selector cables (cable support bracket and metal relay lever ) 9504
1 7 2 Assembly overview – selector cables (cable support bracket and plastic relay lever) 9507
1 8 Removing and installing selector mechanism 9512
1 9 Adjusting selector mechanism 9516
1 9 1 Checking selector mechanism 9519
2 Removing and installing gearbox 9520
2 1 Removing and installing gearbox, Golf 2004 ► 9520
2 1 1 Removing gearbox 9522
2 1 2 Install gearbox 9528
2 1 3 Specified torques 9533
2 2 Removing and installing gearbox, Golf 2009 ► with 1 4 l engine 9534
2 2 1 Removing gearbox 9537
2 2 2 Install gearbox 9544
2 2 3 Specified torques 9550
2 3 Removing and installing gearbox, Golf 2009 ► with 1 8 l engine 9551
2 3 1 Removing gearbox 9554
2 3 2 Install gearbox 9560
2 3 3 Specified torques 9568
2 4 Removing and installing gearbox, Golf Plus 2005 ► 9569
2 4 1 Removing gearbox 9571
2 4 2 Install gearbox 9577
2 4 3 Specified torques 9583
2 5 Removing and installing gearbox, Golf Plus 2009 ► 9584
2 5 1 Removing gearbox 9587
2 5 2 Install gearbox 9594
2 5 3 Specified torques 9600
2 6 Removing and installing gearbox, Passat 2006 ► 9601
2 6 1 Removing gearbox 9603
2 6 2 Install gearbox 9608
2 6 3 Specified torques 9615
2 7 Removing and installing gearbox, Passat 2011 ► with turbo diesel engine 9616
2 7 1 Removing gearbox 9619
2 7 2 Install gearbox 9624
2 7 3 Specified torques 9630
2 8 Removing and installing gearbox, Passat 2011 ► with 1 4 l petrol engine and CC with 1 4 l petrol engine 9631
2 8 1 Removing gearbox 9634
2 8 2 Install gearbox 9640
2 8 3 Specified torques 9647
2 9 Removing and installing gearbox, Passat 2011 ► with 1 8 l petrol engine, Passat CC and CC with 1 8 l petrol engine 9648
2 9 1 Removing gearbox 9651
2 9 2 Install gearbox 9657
2 9 3 Specified torques 9664
2 10 Removing and installing gearbox, Eos 9665
2 10 1 Removing gearbox 9667
2 10 2 Install gearbox 9672
2 10 3 Specified torques 9678
2 11 Removing and installing gearbox – Scirocco 9679
2 11 1 Removing gearbox 9681
2 11 2 Install gearbox 9689
2 11 3 Specified torques 9695
3 Transporting gearbox 9697
4 Assembly overview – assembly mountings 9698
5 Gear oil 9700
5 1 Checking and topping up gear oil 9700
5 1 1 Preparing 9700
5 1 2 Drain gear oil 9701
5 1 3 Fill with gear oil 9702
6 Dismantling and assembling gearbox 9703
6 1 Overview – gearbox 9703
6 2 Overview – dismantling and assembling gearbox 9704
6 3 Assembly overview – removing and installing cover for gearbox housing and 5th and 6th gears 9705
6 4 Assembly overview – removing and installing gearbox housing and selector mechanism 9708
6 5 Assembly overview – removing and installing input shaft, output shaft, differential and selector forks 9709
6 6 Assembly sequence – Removing and installing cover for gearbox housing and 5th and 6th gear 9710
6 6 1 Removing 9712
6 6 2 Installing 9716
6 7 Assembly sequence – Dismantling and assembling gearbox completely 9716
6 7 1 Removing 9719
6 7 2 Installing 9725
7 Gearbox housing and clutch housing 9737
7 1 Assembly overview – gearbox housing and clutch housing 9737
7 2 Repairing gearbox housing and clutch housing 9739
7 2 1 Identifying output shaft bearing in gearbox housing 9743
7 2 2 Removing and installing roller bearing without retaining ring 9743
7 2 3 Removing and installing roller bearing with retaining ring 9744
8 Gearbox housing cover 9748
8 1 Assembly overview – gearbox housing cover 9748
8 2 Repairing gearbox housing cover 9749
9 Selector unit 9752
9 1 Assembly overview – selector unit 9752
9 2 Repairing selector unit 9754
10 Selector forks 9756
10 1 Assembly overview – selector forks in connection with reverse synchromeshed gear -arrow- 9756
10 2 Assembly overview – selector forks in connection with reverse gear locking collar -arrow- 9757
10 3 Repairing selector forks 9759
35 – Gears, shafts 9763
1 Input shaft 9763
1 1 Assembly overview – input shaft 9763
1 2 Dismantling and assembling input shaft 9765
1 3 Adjusting input shaft 9771
1 4 Renewing input shaft seal 9776
2 Output shaft 9778
2 1 Assembly overview – output shaft 9778
2 2 Dismantling and assembling output shaft 9781
2 3 Adjusting output shaft 9791
3 Reverse shaft 9796
3 1 Assembly overview – reverse shaft with reverse synchromeshed gear -arrow- 9796
3 2 Assembly overview – reverse shaft with reverse gear locking collar -arrow- 9797
3 3 Dismantling and assembling reverse shaft 9799
39 – Final drive – differential 9802
1 Oil seals 9802
1 1 Renewing left flange shaft oil seal with gearbox installed 9802
1 1 1 Removing 9803
1 1 2 Installing 9804
1 1 3 Specified torque 9804
1 2 Distinguishing seals for right flange shaft 9804
1 3 Renewing right seal with manual gearbox installed (two-part seal for flange shaft and sleeve) 9804
1 3 1 Removing 9805
1 3 2 Installing 9807
1 3 3 Specified torque 9807
1 4 Renewing right seal and sleeve together with manual gearbox installed (one-piece seal and sleeve for flange shaft) 9807
1 4 1 Removing 9809
1 4 2 Installing 9810
1 4 3 Specified torque 9810
2 Adjustment overview 9811
3 Differential 9812
3 1 Assembly overview – differential 9812
3 2 Dismantling and assembling differential 9814
3 3 Adjusting differential 9819
00 – Technical data 9829
1 Identifying rear final drive 9829
2 Identification codes, assembly allocation, capacities, Golf 2004 ► 9830
3 Identification codes, assembly allocation, capacities, Passat 2006 ► 9832
3 1 Passat with rear final drive 02D/0AV 9832
3 2 Passat with rear final drive 01Z 9833
3 3 Passat with rear final drive 0BS 9834
4 Identification codes, assembly allocation, capacities, Tiguan 2008 ► 9835
5 Identification codes, assembly allocation, capacities, Passat CC, CC 2010 ► 9837
6 Identification codes, assembly allocation, capacities, Golf 2009 ► 9838
7 Identification codes, assembly allocation, capacities, Sharan 2011 ► 9839
8 General repair instructions 9840
8 1 Oil 9840
8 2 Components 9840
8 2 1 Rear final drive 9840
8 2 2 Guided Fault Finding, vehicle self-diagnosis and test instruments 9840
8 2 3 O-ring, seals, gaskets 9841
8 2 4 Locking devices 9841
8 2 5 Nuts and bolts 9842
8 2 6 Bearings 9842
8 2 7 Shims 9842
9 Genuine parts 9843
39 – Final drive – rear differential 9844
1 Propshaft – Golf 2004 ► up to calendar week 26/07 9844
1 1 Assembly overview – propshaft 9844
1 2 Removing and installing propshaft 9846
1 3 Repairing propshaft 9853
1 4 Removing and installing rear flexible coupling 9860
2 Propshaft – Golf 2004 ► from calendar week 27/07 onwards 9866
2 1 Assembly overview – propshaft 9866
2 2 Removing and installing propshaft 9868
3 Propshaft – Passat 2006 ► up to calendar week 26/07 9873
3 1 Removing and installing propshaft 9873
3 2 Removing and installing front propshaft tube with flexible coupling 9879
3 3 Removing and installing rear flexible coupling 9882
3 4 Repairing propshaft 9887
3 5 Specified torques 9894
4 Propshaft – Passat 2006 ► from calendar week 27/07 onwards 9895
4 1 Assembly overview – propshaft 9895
4 2 Removing and installing propshaft 9897
5 Propshaft Tiguan 2008 ► 9902
5 1 Assembly overview – propshaft 9902
5 2 Removing and installing propshaft 9904
5 3 Removing and installing rear flexible coupling 9909
6 Propshaft – Passat CC, CC 2010 ► and Golf 2009 ► 9914
6 1 Assembly overview – propshaft 9914
6 2 Removing and installing propshaft 9916
6 3 Removing and installing rear flexible coupling 9920
7 Propshaft – Sharan 2011 ► 9925
7 1 Assembly overview – propshaft 9925
7 2 Removing and installing propshaft 9927
7 3 Removing and installing rear flexible coupling 9931
8 Removing and installing rear final drive, Golf 2004 ► 9937
8 1 Removing rear final drive 9937
8 2 Installing rear final drive 9940
9 Removing and installing rear final drive, Passat 2006 ► 9941
9 1 Removing rear final drive 02D or 0AV 9941
9 2 Installing rear final drive 02D or 0AV 9944
9 3 Removing rear final drive 01Z 9947
9 4 Installing rear final drive 01Z 9951
10 Removing and installing rear final drive, Tiguan 2008 ► 9954
10 1 Removing 9954
10 2 Installing 9961
11 Removing and installing rear final drive, Passat CC, CC 2010 ► 9965
11 1 Removing 9965
11 2 Installing 9971
12 Removing and installing rear final drive, Golf 2009 ► 9975
12 1 Removing 9975
12 2 Installing 9980
13 Removing and installing rear final drive, Sharan 2011 ► 9985
14 Renewing bonded rubber bush on rear final drive 9989
14 1 Renewing bonded rubber bush on rear final drive, Passat with final drive 01Z, Tiguan 2008 ►, Passat CC, CC 2010 ► and Sharan 2011 ► 9989
14 2 Assembly overview – bonded rubber bushes 9989
14 3 Removing bonded rubber bush 9990
14 4 Installing bonded rubber bush 9993
14 5 Renewing bonded rubber bushes on rear final drive, Golf 2004 ► and Passat 2006 ► with final drive 02D/0AV and Golf 2009 ► 9994
14 6 Assembly overview – bonded rubber bushes 9994
14 7 Removing and installing bonded rubber bush 9995
15 Renewing flange shaft oil seals 10002
15 1 Removing flange shaft oil seal 10002
15 1 1 Removing right oil seal 10002
15 1 2 Removing left oil seal 10004
15 2 Installing flange shaft oil seal 10005
16 Renewing propshaft flange oil seal on rear final drive (final drive installed) 10007
16 1 Removing 10008
16 2 Installing 10011
16 2 1 Specified torque 10012
17 Checking function of all-wheel drive coupling “generation II” 10013
17 1 Checking function of all-wheel drive coupling – vehicles with manual gearbox 10013
17 1 1 Function check for engaged all-wheel drive coupling 10013
17 1 2 Function check for disengaged all-wheel drive coupling 10013
17 2 Checking function of all-wheel drive coupling – vehicles with dual clutch gearbox 10014
17 2 1 Function check for engaged all-wheel drive coupling 10014
17 2 2 Function check for disengaged all-wheel drive coupling 10015
17 3 Checking function of all-wheel drive coupling – vehicles with automatic gearbox 10016
17 3 1 Checking function 10016
18 Checking function of all-wheel drive coupling “generation IV” 10017
18 1 Checking function 10017
19 Electrical/electronic components and fitting locations 10018
19 1 Electrical and electronic components and their locations, Golf 2004 ► 10018
19 2 Electrical and electronic components and their locations, Passat 2006 ► 10020
19 3 Electrical and electronic components and their fitting locations, Tiguan 2008 ►, Passat CC, CC 2010 ►, Sharan 2011 ► and Golf 2009 ►, Generation IV 10022
19 4 Electrical and electronic components and their fitting locations, Tiguan 2008 ►, Sharan 2011 ►, Generation V 10023
20 Assembly overview – all-wheel drive control unit -J492-, Golf 2004 ► and Passat 2006 ► 10025
20 1 Removing and installing four-wheel drive control unit -J492- 10027
20 1 1 Removing four-wheel drive control unit -J492- 10027
20 1 2 Installing 10029
20 2 Removing and installing all-wheel drive coupling pump -V181- 10031
20 2 1 Removing 10032
20 2 2 Installing 10033
20 2 3 Specified torque 10035
21 Assembly overview – all-wheel drive control unit -J492-, Passat CC, CC 2010 ► and Golf 2009 ► 10036
21 1 Removing and installing four-wheel drive control unit -J492- 10038
21 1 1 Removing four-wheel drive control unit -J492- 10038
21 1 2 Installing 10039
21 2 Removing and installing all-wheel drive coupling pump -V181- 10041
21 2 1 Removing 10042
21 2 2 Installing 10043
21 2 3 Specified torque 10044
22 Assembly overview – all-wheel drive coupling, Golf 2004 ► and Passat 2006 ►, Passat CC, CC 2010 ► and Golf 2009 ► 10045
23 Removing and installing all-wheel drive coupling, Golf 2004 ► and Passat 2006 ► 10046
23 1 Removing all-wheel drive coupling 10046
23 2 Installing all-wheel drive coupling 10047
24 Removing and installing all-wheel drive coupling, Passat CC, CC 2010 ► and Golf 2009 ► 10049
24 1 Removing all-wheel drive coupling 10049
24 2 Installing all-wheel drive coupling 10053
25 Assembly overview – dismantling and assembling all-wheel drive coupling (generation II), Golf 2004 ► and Passat 2006 ► 10055
25 1 Renewing grooved ball bearing for all-wheel drive coupling 10058
26 Dismantling and assembling all-wheel drive coupling, generation IV, assembly overview, Passat CC, CC 2010 ►and Golf 2009 ► 10065
27 Removing and installing oil filter for all-wheel drive coupling, Golf 2004 ► and Passat 2006 ► 10068
27 1 Removing 10068
27 2 Installing 10068
28 All-wheel drive coupling, Tiguan 2008 ►, Sharan 2011 ► 10070
28 1 Checking function 10070
28 2 Assembly overview – all-wheel drive coupling 10070
28 2 1 Assembly overview – all-wheel drive coupling, generation IV, to week 44/13 10070
28 2 2 Assembly overview – all-wheel drive coupling, generation V, from week 45/13 10073
28 3 Removing and installing all-wheel drive coupling pump -V181- 10075
28 3 1 Removing and installing all-wheel drive coupling pump -V181-, generation IV, to week 44/13 10075
28 3 2 Removing and installing all-wheel drive coupling pump -V181-, generation V, from week 45/13 10077
28 4 Removing and installing all-wheel drive coupling 10080
28 4 1 Removing and installing all-wheel drive coupling, generation IV, to week 44/13 10080
28 4 2 Removing and installing all-wheel drive coupling, generation V, from week 45/13 10088
28 5 Removing and installing four-wheel drive control unit -J492- 10097
28 5 1 Removing and installing all-wheel drive control unit -J492-, generation IV, up to week 44/13 10097
28 5 2 Removing and installing all-wheel drive control unit -J492-, generation V, as of week 45/13 10101
29 Checking oil level or topping up oil in rear final drive, Golf 2004 ► and Passat 2006 ► 10102
29 1 Specified torques 10103
30 Checking oil level or topping up oil in rear final drive, Tiguan 2008 ►, Passat CC, CC 2010 ►, Sharan 2011 ► and Golf 2009 ► 10104
31 Checking oil level or topping up oil in all-wheel drive coupling, generation II, Golf 2004 ► and Passat 2006 ► 10106
31 1 Checking oil level in all-wheel drive coupling 10106
31 2 Replenishing oil in all-wheel drive coupling 10107
31 3 Draining and filling high performance fluid for all-wheel drive coupling 10109
32 Checking oil level or topping up oil in all-wheel drive coupling, generations IV + V, Tiguan 2008 ►, Passat CC, CC 2010 ►, Sharan 2011 ► and Golf 2009 ► 10113
32 1 Checking oil level in all-wheel drive coupling 10113
32 2 Replenishing oil in all-wheel drive coupling 10114
32 3 Draining and filling high performance fluid for all-wheel drive coupling 10115
68 – Interior equipment 10129
1 Interior mirror 10129
1 1 Automatic anti-dazzle interior mirror 10129
1 2 Removing and installing interior mirror with rain sensor 10129
1 2 1 Removing 10129
1 2 2 Installing 10130
1 3 Bonding on retaining plate for interior mirror with rain sensor 10130
1 3 1 Preparing windscreen 10130
1 3 2 Preparing detached or new mirror base 10131
1 3 3 Bonding mirror base 10131
1 3 4 Cleaning and removing excessive adhesive 10131
1 3 5 Installing rain sensor and mirror 10131
1 4 Removing and installing interior mirror 10131
1 4 1 Removing 10131
1 4 2 Installing 10132
1 5 Bonding on retaining plate for interior mirror without rain sensor 10132
1 5 1 Materials: 10132
1 6 Removing and installing interior mirror in vehicles with front camera for driver assist systems 10133
1 6 1 Removing 10133
1 6 2 Installing 10134
2 Compartments, covers and trims 10135
2 1 Tools 10135
2 1 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 10135
2 2 Removing and installing centre console, basic version, Passat 2006►, Passat Estate 2006► and Passat CC 2009► 10135
2 2 1 Removing 10136
2 2 2 Installing 10137
2 3 Removing and installing centre console, comfort version, Passat 2006►, Passat Estate 2006► and Passat CC 2009► 10138
2 3 1 Removing 10138
2 3 2 Installing 10140
2 4 Removing and installing centre console, CC 2010► 10141
2 4 1 Removing 10141
2 4 2 Installing 10143
2 5 Removing and installing footwell trim 10144
2 5 1 Removing 10144
2 5 2 Installing 10145
2 6 Removing and installing front ashtray or front storage tray, Passat 2006►, Passat Estate 2006► and Passat CC 2009► 10145
2 6 1 Removing 10145
2 6 2 Installing 10148
2 7 Removing and installing front ashtray or front storage tray, CC 2010► 10148
2 7 1 Removing 10148
2 7 2 Installing 10150
2 8 Removing and installing Infotainment surround, Passat 2006►, Passat Estate 2006► and Passat CC 2009► 10150
2 8 1 Removing 10150
2 8 2 Installing 10151
2 9 Removing and installing Infotainment surround, CC 2010► 10151
2 9 1 Removing 10151
2 9 2 Installing 10152
2 10 Removing and installing “Climatronic/Climatic” cover, Passat 2006►, Passat Estate 2006► and Passat CC 2009► 10152
2 10 1 Removing 10152
2 10 2 Installing 10153
2 11 Removing and installing “Climatronic/Climatic” cover, CC 2010► 10153
2 11 1 Removing 10153
2 11 2 Installing 10154
2 12 Removing and installing rear trim 10154
2 12 1 Removing 10154
2 12 2 Installing 10155
2 13 Removing and installing centre console air duct, Passat 2006►, Passat Estate 2006► and Passat CC 2009► 10155
2 13 1 Removing 10155
2 13 2 Installing 10156
2 14 Removing and installing centre console air duct, CC 2010► 10156
2 14 1 Removing 10156
2 14 2 Installing 10157
2 15 Removing and installing storage tray in centre console, basic version, Passat 2006►, Passat Estate 2006► and Passat CC 20 9► 10157
2 15 1 Removing 10157
2 15 2 Installing 10159
2 16 Removing and installing storage tray in centre console, comfort version, Passat 2006►, Passat Estate 2006► and Passat CC 009► 10159
2 16 1 Removing 10159
2 16 2 Installing 10160
2 17 Removing and installing storage tray in centre console, CC 2010► 10160
2 17 1 Removing 10160
2 17 2 Installing 10160
2 18 Removing and installing centre console extension, basic version, Passat 2006►, Passat Estate 2006► and Passat CC 2009► 10161
2 18 1 Removing 10161
2 18 2 Installing 10162
2 19 Removing and installing centre console extension, comfort version, Passat 2006►, Passat Estate 2006► and Passat CC 2009► 10163
2 19 1 Removing 10163
2 19 2 Installing 10164
2 20 Removing and installing centre console extension, CC 2010► 10165
2 20 1 Removing 10165
2 20 2 Installing 10166
2 21 Removing and installing centre console armrest 10167
2 21 1 Removing 10167
2 21 2 Installing 10168
2 22 Removing and installing armrest compartment 10168
2 22 1 Removing 10168
2 22 2 Installing 10170
2 23 Removing and installing upper part of armrest 10170
2 23 1 Removing 10170
2 23 2 Installing 10171
2 24 Removing and installing dash panel end trims 10171
2 24 1 Removing 10171
2 24 2 Installing 10172
2 25 Removing and installing steering column trim 10172
2 25 1 Removing 10172
2 25 2 Installing 10173
2 26 Removing and installing glove compartment 10173
2 26 1 Removing 10173
2 26 2 Installing 10174
2 27 Removing and installing glove compartment lock cylinder 10175
2 27 1 Removing 10175
2 27 2 Installing 10175
2 28 Removing and installing footwell cover on driver side 10176
2 28 1 Removing 10176
2 28 2 Installing 10176
2 29 Removing and installing centre dash panel trim, Passat 2006►, Passat Estate 2006► and Passat CC 2009► 10177
2 29 1 Removing 10177
2 29 2 Installing 10177
2 30 Removing and installing dash panel trim, front passenger side, Passat 2006►, Passat Estate 2006► and Passat CC 2009► 10177
2 30 1 Removing 10177
2 30 2 Installing 10178
2 31 Removing and installing dash panel trim, front passenger side, CC 2010► 10178
2 31 1 Removing 10178
2 31 2 Installing 10179
2 32 Removing and installing dash panel insert trim, Passat 2006►, Passat Estate 2006► and Passat CC 2009► 10179
2 32 1 Removing 10179
2 32 2 Installing 10180
2 33 Removing and installing dash panel insert trim, CC 2010► 10180
2 33 1 Removing 10180
2 33 2 Installing 10181
2 34 Removing and installing analogue clock, CC 2010► 10181
2 34 1 Removing 10181
2 34 2 Installing 10182
2 35 Removing and installing holder for analogue clock, CC 2010► 10182
2 35 1 Removing 10182
2 35 2 Installing 10183
2 36 Removing and installing centre storage compartment, Passat 2006►, Passat Estate 2006► and Passat CC 2009► 10183
2 36 1 Removing 10183
2 36 2 Installing 10184
2 37 Removing and installing centre storage cluster unit, Passat 2006►, Passat Estate 2006► and Passat CC 2009► 10184
2 37 1 Removing 10184
2 37 2 Installing 10185
2 38 Removing and installing dummy cover carrier, Passat 2006►, Passat Estate 2006► and Passat CC 2009► 10185
2 38 1 Removing 10185
2 38 2 Installing 10186
2 39 Removing and installing trim on driver side, Passat 2006►, Passat Estate 2006► and Passat CC 2009► 10186
2 39 1 Removing 10186
2 39 2 Installing 10187
2 40 Removing and installing trim on driver side, CC 2010► 10188
2 40 1 Removing 10188
2 40 2 Installing 10189
2 41 Removing and installing storage tray in moulded headliner 10189
2 41 1 Removing 10189
2 41 2 Installing 10190
2 42 Removing and installing bench seat storage compartment, Passat CC 2009► and CC 2010► 10190
2 43 Removing and installing single sun visor, Passat 2006► and Passat Estate 2006► 10191
2 43 1 Removing 10191
2 43 2 Installing 10192
2 44 Removing and installing double sun visor, Passat 2006► and Passat Estate 2006► 10193
2 44 1 Removing 10193
2 44 2 Installing 10194
2 45 Removing and installing sun visor, Passat CC 2009► and CC 2010► 10195
2 46 Removing and installing permit/pass holder 10199
2 46 1 Removing 10199
2 46 2 Installing 10200
3 Sill panel strip 10201
3 1 Removing and installing sill panel moulding 10201
3 1 1 Removing 10201
3 1 2 Installing 10202
3 2 Removing and installing illuminated sill panel mouldings 10203
3 2 1 Removing 10204
3 2 2 Installing 10205
3 3 Removing and installing wheel housing liner 10206
3 3 1 Removing 10206
3 3 2 Installing 10207
4 Grab handles 10209
4 1 Removing and installing roof grab handles 10209
4 1 1 Installing 10210
5 Rear shelf/roller sunblind 10211
5 1 Removing and installing rear shelf without roller sunblind, Passat 2006► 10211
5 1 1 Removing 10211
5 1 2 Installing 10212
5 2 Removing and installing rear shelf with roller sunblind, Passat 2006► 10212
5 2 1 Removing 10212
5 2 2 Installing 10213
5 3 Removing and installing roller sunblind, Passat 2006► 10214
5 3 1 Removing 10214
5 3 2 Installing 10216
5 4 Removing and installing rear shelf without roller sun blind, Passat CC 2009► and CC 2010► 10216
5 5 Removing and installing rear shelf with roller sun blind, Passat CC 2009► and CC 2010► 10218
5 6 Removing and installing roller sunblind, rear door trim 10221
5 6 1 Removing 10221
5 6 2 Installing 10223
6 Net partition 10225
6 1 Removing and installing net partition 10225
6 1 1 Removing 10225
6 1 2 Installing 10225
6 2 Removing and installing net partition mountings 10226
6 2 1 Removing 10226
6 2 2 Installing 10226
69 – Passenger protection 10227
1 Seat belts 10227
1 1 General safety regulations when working on airbag, belt tensioner and battery isolator units (pyrotechnic components) 10228
1 2 Special instructions for belt tensioners 10229
1 3 Storage, transportation and disposal of airbag, belt tensioner and battery isolator units (pyrotechnic components) 10229
1 4 Removing and installing front seat belts, Passat 2006► and Passat Estate 2006► 10229
1 4 1 Assembly overview 10229
1 4 2 Removing 10230
1 4 3 Installing 10232
1 5 Removing and installing front seat belts, Passat CC 2009► and CC 2010►, except USA and Canada vehicles 10232
1 6 Removing and installing front seat belts, Passat CC 2009► and CC 2010►, USA and Canada vehicles only 10235
1 7 Removing and installing front belt height adjuster, Passat 2006► and Passat Estate 2006► 10237
1 7 1 Removing 10237
1 7 2 Installing 10238
1 8 Removing and installing front belt height adjuster, Passat CC 2009► and CC 2010► 10239
1 9 Removing and installing front belt buckle 10239
1 9 1 Removing 10239
1 9 2 Installing 10240
1 10 Removing and installing rear outer seat belts with belt tensioners, Passat 2006► 10240
1 10 1 Assembly overview 10241
1 10 2 Removing 10241
1 10 3 Installing 10243
1 11 Removing and installing rear outer seat belts without belt tensioners, Passat 2006► 10243
1 11 1 Assembly overview 10244
1 11 2 Removing 10244
1 11 3 Installing 10245
1 12 Removing and installing rear seat belts, Passat CC 2009► and CC 2010► 10246
1 13 Removing and installing rear outer seat belts with belt tensioners, Passat Estate 2006► 10248
1 13 1 Assembly overview 10249
1 13 2 Removing 10249
1 13 3 Installing 10251
1 14 Removing and installing rear outer seat belts without belt tensioners, Passat Estate 2006► 10251
1 14 1 Assembly overview 10252
1 14 2 Removing 10252
1 14 3 Installing 10253
1 15 Removing and installing middle, rear seat belt 10254
1 15 1 Removing 10254
1 15 2 Installing 10255
1 16 Removing and installing rear double belt buckle 10255
1 16 1 Removing 10255
1 16 2 Installing 10256
1 17 Removing and installing rear belt buckles, Passat CC 2009► and CC 2010► 10256
2 Inspecting seat belts 10257
2 1 Points to check 10257
2 1 1 Checking belt webbing 10257
2 1 2 Checking inertia reel (locking mechanism) 10258
2 1 3 Visual inspection of belt buckle 10259
2 1 4 Checking function of belt buckle 10259
2 1 5 Check belt guide fittings and latch plates 10259
2 1 6 Checking securing parts and anchorage points 10259
3 Checking child seat anchors (ISOFIX) after an accident 10260
3 1 Points to check 10260
4 Airbag 10261
4 1 Tools 10261
4 1 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 10261
4 2 Overview of fitting locations – airbag systems, Passat 2006► 10262
4 3 General safety regulations when working on airbag, belt tensioner and battery isolator units (pyrotechnic components) 10264
4 4 Special instructions for driver and front passenger airbag 10265
4 5 Special instructions for curtain airbag modules 10265
4 6 Storage, transportation and disposal of airbag, belt tensioner and battery isolator units (pyrotechnic components) 10266
4 7 Deactivating the airbag 10266
4 8 Renewing airbag units following an accident 10266
4 8 1 Accident with airbag triggering 10266
4 8 2 Accident without airbag triggering 10267
4 9 Removing and installing airbag control unit -J234- 10267
4 9 1 Removing 10267
4 9 2 Installing 10268
4 10 Removing and installing airbag unit on driver side, Passat 2006► and Passat Estate 2006► 10269
4 10 1 Removing 10269
4 10 2 Installing 10271
4 11 Removing and installing airbag unit on driver side, Passat CC 2009► and CC 2010► 10272
4 12 Removing and installing airbag coil connector and return spring with slip ring -F138- 10276
4 13 Removing and installing airbag unit on front passenger side 10277
4 13 1 Removing 10277
4 13 2 Installing 10278
4 14 Removing and installing front side-airbag 10279
4 14 1 Removing 10280
4 14 2 Installing 10281
4 15 Removing and installing rear side-airbag 10281
4 15 1 Removing 10282
4 15 2 Installing 10283
4 16 Removing and installing curtain airbag, Passat 2006►, ►calendar week 44/2009 10283
4 16 1 Removing 10284
4 16 2 Installing 10285
4 17 Removing and installing curtain airbag, Passat 2006►, calendar week 44/2009► 10285
4 17 1 Removing 10286
4 17 2 Installing 10287
4 18 Removing and installing curtain airbag, Passat CC 2009► and CC 2010► 10288
4 19 Removing and installing curtain airbag, Passat Estate 2006►, ►calendar week 44/2009 10290
4 19 1 Removing 10290
4 19 2 Installing 10292
4 20 Removing and installing curtain airbag, Passat Estate 2006►, calendar week 45/2009► 10292
4 20 1 Removing 10293
4 20 2 Installing 10295
4 21 Removing and installing seat occupied sensor, front passenger side -G128- 10295
4 21 1 Removing 10296
4 21 2 Installing 10297
4 22 Adapting components 10301
5 Passat 2006► and Passat Variant 2006►: Seat occupied recognition for front passenger airbag deactivation 10302
5 1 Safety precautions when working on seat occupied recognition 10302
5 2 Procedure after an accident when belt tensioner and/or airbag was triggered 10302
5 3 Assembly overview – seat occupied recognition 10303
5 4 Components of repair kit for seat occupied recognition 10303
5 5 Removing components of seat occupied recognition (vehicles with manually operated seats) 10304
5 6 Installing repair kit for seat occupied recognition (vehicles with manually adjusted seats) 10306
5 7 Removing components of seat occupied recognition (vehicles with electrically operated seats) 10307
5 8 Installing repair kit for seat occupied recognition (vehicles with electrically operated seats) 10310
5 9 Importers reporting obligation 10311
6 Seat occupied recognition for front passenger airbag deactivation, Passat CC 2009► and CC 2010► 10312
6 1 Tools 10312
6 1 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 10312
6 2 Safety precautions when working on seat occupied recognition 10312
6 3 Procedure after an accident when belt tensioner and/or airbag was triggered 10313
6 4 Importers reporting obligation 10313
6 5 Assembly overview – seat occupied recognition 10313
6 6 Removing and installing seat occupied recognition 10315
6 7 Removing and installing seat position sensor 10318
7 Crash sensors 10320
7 1 Tools 10320
7 1 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 10320
7 2 Removing and installing front airbag crash sensor, driver side -G283- 10320
7 2 1 Removing 10320
7 2 2 Installing 10321
7 3 Removing and installing front airbag crash sensor for driver side -G283- (USA and Canada vehicles only) 10321
7 3 1 Removing 10321
7 3 2 Installing 10322
7 4 Removing and installing front airbag crash sensor for front passenger side -G284- (USA and Canada vehicles only) 10322
7 4 1 Removing 10323
7 4 2 Installing 10323
7 5 Removing and installing side-airbag crash sensor, driver side -G179- 10324
7 5 1 Removing (crash sensor installed on outside of assembly carrier) 10324
7 5 2 Installing (crash sensor installed on outside of assembly carrier) 10325
7 5 3 Removing (crash sensor installed on inside of assembly carrier) 10327
7 5 4 Installing (crash sensor installed on inside of assembly carrier) 10328
7 6 Removing and installing side-airbag crash sensor, front passenger side -G180- 10329
7 6 1 Removing (crash sensor installed on outside of assembly carrier) 10330
7 6 2 Installing (crash sensor installed on outside of assembly carrier) 10331
7 6 3 Removing (crash sensor installed on inside of assembly carrier) 10333
7 6 4 Installing (crash sensor installed on inside of assembly carrier) 10334
7 7 Removing and installing rear side-airbag crash sensor, driver side -G256- 10336
7 7 1 Removing 10336
7 7 2 Installing 10337
7 8 Removing and installing rear side-airbag crash sensor, front passenger side -G257- 10337
70 – Trim, insulation 10339
1 Dash panel 10339
1 1 Tools 10339
1 1 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 10339
1 2 Removing and installing dash panel, Passat 2006►, Passat Estate 2006► and Passat CC 2009► 10339
1 2 1 Removing 10339
1 2 2 Installing 10346
1 3 Removing and installing dash panel, CC 2010► 10346
1 3 1 Removing 10346
1 3 2 Installing 10352
1 4 Removing and installing assembly carrier 10352
2 Door trims, Passat 2006► and Passat Estate 2006► 10358
2 1 Tools 10358
2 1 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 10358
2 2 Removing and installing front door trim on driver side 10358
2 2 1 Removing 10358
2 2 2 Installing 10360
2 3 Removing and installing front door trim on front passenger side 10360
2 3 1 Removing 10360
2 3 2 Installing 10361
2 4 Removing and installing rear door trim 10361
2 4 1 Removing 10361
2 4 2 Installing 10363
2 5 Removing and installing roller sunblind, rear door trim 10363
2 6 Removing and installing window winder 10363
2 6 1 Removing 10363
2 6 2 Installing 10364
2 7 Removing and installing front loudspeaker trim 10364
2 7 1 Removing 10364
2 7 2 Installing 10365
3 Door trims, Passat CC 2009► and CC 2010► 10366
3 1 Tools 10366
3 1 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 10366
3 2 Removing and installing front door trim 10366
3 3 Removing and installing rear door trim 10370
4 Pillar trims 10375
4 1 Tools 10375
4 1 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 10375
4 2 Removing and installing upper A-pillar trim, Passat 2006► and Passat Estate 2006► 10375
4 2 1 Removing 10375
4 2 2 Installing 10376
4 3 Removing and installing upper A-pillar trim, Passat CC 2009► and CC 2010► 10376
4 4 Removing and installing centre A-pillar trim 10378
4 4 1 Removing 10378
4 4 2 Installing 10378
4 5 Removing and installing lower A-pillar trim 10379
4 5 1 Removing 10379
4 5 2 Installing 10380
4 6 Removing and installing upper B-pillar trim, Passat 2006► and Passat Estate 2006► 10380
4 6 1 Removing 10380
4 6 2 Installing 10382
4 7 Removing and installing upper B-pillar trim, Passat CC 2009► and CC 2010► 10383
4 8 Releasing upper B-pillar trim from and securing in mountings, Passat CC 2009► and CC 2010► 10385
4 9 Removing and installing lower B-pillar trim 10386
4 9 1 Removing 10386
4 9 2 Installing 10387
4 10 Removing and installing C-pillar trim, Passat 2006►, vehicles without roller sunblind 10387
4 10 1 Removing 10387
4 10 2 Installing 10388
4 11 Removing and installing C-pillar trim, Passat 2006►, vehicles with roller sunblind 10388
4 11 1 Removing 10389
4 11 2 Installing 10390
4 12 Removing and installing C-pillar trim, Passat CC 2009► and CC 2010►, vehicles without roller sunblind 10390
4 13 Removing and installing C-pillar trim, Passat CC 2009► and CC 2010►, vehicles with roller sunblind 10391
4 14 Removing and installing C-pillar trim, Passat Estate 2006► 10393
4 14 1 Removing 10393
4 14 2 Installing 10394
4 15 Removing and installing D-pillar trim, Passat Estate 2006► 10394
4 15 1 Removing 10394
4 15 2 Installing 10396
5 Rear lid trim 10397
5 1 Tools 10397
5 1 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 10397
5 2 Removing and installing warning triangle bracket, Passat 2006► 10398
5 2 1 Removing 10398
5 2 2 Installing 10399
5 3 Removing and installing rear lid trim, Passat 2006► 10399
5 3 1 Removing 10399
5 3 2 Installing 10400
5 4 Removing and installing rear lid trim, Passat CC 2009► and CC 2010► 10400
5 5 Removing and installing window frame trim, Passat Estate 2006► 10401
5 5 1 Removing 10401
5 5 2 Installing 10402
5 6 Removing and installing rear lid trim, Passat Estate 2006► 10402
5 6 1 Removing 10402
5 6 2 Installing 10403
5 7 Removing and installing warning triangle bracket, Passat Estate 2006► 10404
5 7 1 Removing 10404
5 7 2 Installing 10404
6 Load and luggage compartment trims 10405
6 1 Tools 10405
6 1 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 10405
6 2 Removing and installing lock carrier cover, Passat 2006► 10405
6 2 1 Removing 10405
6 2 2 Installing 10406
6 3 Removing and installing lock carrier cover, Passat Estate 2006► 10406
6 3 1 Removing 10406
6 3 2 Installing 10407
6 4 Removing and installing lock carrier cover, Passat CC 2009► and CC 2010► 10407
6 5 Removing and installing load and luggage compartment floor covering, Passat Estate 2006► 10408
6 5 1 Removing 10408
6 5 2 Installing 10409
6 6 Removing and installing left side trim of luggage compartment, Passat 2006► 10409
6 6 1 Removing 10409
6 6 2 Installing 10410
6 7 Removing and installing right side trim of luggage compartment, Passat 2006► 10411
6 7 1 Removing 10411
6 7 2 Installing 10412
6 8 Removing and installing left side trim of luggage compartment, Passat Estate 2006► 10412
6 8 1 Removing 10412
6 8 2 Installing 10414
6 9 Removing and installing right side trim of luggage compartment, Passat Estate 2006► 10414
6 9 1 Removing 10414
6 9 2 Installing 10416
6 10 Removing and installing side trim of luggage compartment, Passat CC 2009► and CC 2010► 10416
7 Rail system, Passat Estate 2006► 10418
7 1 Removing and installing retaining rails 10418
7 1 1 Removing 10418
7 1 2 Installing 10419
7 2 Removing and installing retainer and carrier for rail system 10419
7 2 1 Removing 10419
7 2 2 Installing 10421
8 Roof trims 10422
8 1 Tools 10422
8 2 Removing and installing roof end strip, Passat 2006► 10422
8 2 1 Removing 10422
8 2 2 Installing 10424
8 3 Removing and installing roof end strip, Passat Estate 2006► 10424
8 3 1 Removing 10424
8 3 2 Installing 10425
8 4 Lowering and installing moulded headliner, Passat 2006► 10425
8 4 1 Lowering 10425
8 4 2 Installing 10428
8 5 Removing and installing moulded headliner, Passat 2006► 10429
8 5 1 Removing 10429
8 5 2 Installing 10432
8 6 Removing and installing moulded headliner, Passat Estate 2006► 10433
8 6 1 Removing 10433
8 6 2 Installing 10435
8 7 Lowering and installing moulded headliner, Passat CC 2009► and CC 2010► 10435
8 8 Removing and installing moulded headliner, Passat CC 2009► and CC 2010► 10438
8 9 Removing and installing roof insulation/reinforcement, Passat 2006►, Passat CC 2009► and CC 2010► 10440
8 9 1 Removing 10440
8 9 2 Installing 10442
8 10 Removing and installing roof insulation/reinforcement, Passat Estate 2006► 10443
8 10 1 Removing 10443
8 10 2 Installing 10445
72 – Seat frames 10447
1 Front seats 10447
1 1 Tools 10447
1 1 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 10447
1 2 Removing and installing front seat 10449
1 2 1 Removing 10449
1 2 2 Installing 10451
1 3 Removing and installing seat cover cap 10452
1 3 1 Removing 10453
1 3 2 Installing 10453
1 4 Removing and installing lumbar support adjustment wheel 10453
1 4 1 Removing 10454
1 4 2 Installing 10454
1 5 Removing and installing seat height 10454
1 5 1 Assembly overview 10454
1 5 2 Removing 10455
1 5 3 Installing 10456
1 6 Removing and installing seat (electric) trim on face side 10456
1 6 1 Removing 10456
1 6 2 Installing 10457
1 7 Removing and installing seat (electric) trims 10457
1 7 1 Removing 10457
1 7 2 Installing 10459
1 8 Removing and installing seat (electric) trim holders 10459
1 8 1 Removing 10459
1 8 2 Installing 10460
1 9 Removing and installing seat (part electric) trim 10460
1 9 1 Removing 10460
1 9 2 Installing 10461
1 10 Removing and installing seat (height adjustable) trim 10461
1 10 1 Removing 10461
1 10 2 Installing 10462
1 11 Removing and installing trims on front passenger seat, seat with pass-through 10463
1 11 1 Removing 10463
1 11 2 Installing 10465
1 12 Removing and installing seat (part electric) trim holder and actuating lever 10465
1 12 1 Removing 10465
1 12 2 Installing 10466
1 13 Removing and installing seat trim (without height adjustment) 10466
1 13 1 Removing 10466
1 13 2 Installing 10467
1 14 Removing and installing seat (without height adjustment) trim holder 10467
1 14 1 Removing 10467
1 15 Removing and installing front seat backrest 10468
1 15 1 Removing 10468
1 15 2 Installing 10470
1 16 Removing and installing lumbar support (2-way, manual) 10471
1 16 1 Removing 10471
1 16 2 Installing 10472
1 17 Removing and installing electric seat control unit 10472
1 17 1 Removing 10472
1 17 2 Installing 10473
1 18 Removing and installing seat (electric/part electric) switch unit 10473
1 18 1 Removing 10473
1 18 2 Installing 10474
1 19 Removing and installing electric longitudinal seat adjustment 10474
1 19 1 Removing 10475
1 19 2 Installing 10476
1 20 Removing and installing seat pan on electrically adjustable seat 10476
1 20 1 Removing 10476
1 20 2 Installing 10477
1 21 Removing and installing rake adjustment on electrically adjustable seat 10478
1 21 1 Removing 10478
1 21 2 Installing 10479
1 22 Removing and installing height adjustment on electrically adjustable seat 10479
1 22 1 Removing 10480
1 22 2 Installing 10481
1 23 Removing and installing (electric) seat lumbar support 10481
1 23 1 Removing 10481
1 23 2 Installing 10483
1 24 Removing and installing drive for (electric) backrest adjustment 10484
1 25 Removing and installing head restraint 10484
1 26 Removing and installing seat ventilation switch -E655-, Passat CC 2009► and CC 2010► 10486
1 27 Removing and installing front seat fan -V268-, Passat CC 2009► and CC 2010► 10487
1 28 Removing and installing front seat backrest fan -V269-, Passat CC 2009► and CC 2010► 10490
2 Front sport seats, R36 10494
2 1 Tools 10494
2 1 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 10494
2 2 Removing and installing R36 sport seat 10496
2 2 1 Removing 10496
2 2 2 Installing 10498
2 3 Removing and installing R36 sport seat trim 10499
2 3 1 Removing 10499
2 3 2 Installing 10501
2 4 Removing and installing R36 sport seat backrest 10502
2 4 1 Removing 10502
2 4 2 Installing 10504
2 5 Removing and installing R36 sport seat switch unit 10504
2 5 1 Removing 10504
2 5 2 Installing 10506
2 6 Removing and installing R36 sport seat longitudinal adjustment 10506
2 6 1 Removing 10506
2 6 2 Installing 10509
2 7 Removing and installing seat pan for R36 sport seat 10509
2 7 1 Removing 10510
2 7 2 Installing 10511
2 8 Removing and installing R36 sport seat rake adjustment 10512
2 8 1 Removing 10512
2 8 2 Installing 10513
2 9 Removing and installing R36 sport seat height adjustment 10513
2 9 1 Removing 10513
2 9 2 Installing 10515
2 10 Pneumatic lumbar support, R36 leather sports seat 10515
2 10 1 Assembly overview – pneumatic lumbar support, R36 leather sports seat 10515
2 10 2 Removing pneumatic pump for R36 leather sport seat 10517
2 10 3 Installing pneumatic pump for R36 leather sport seat 10518
2 10 4 Removing valve blocks for R36 leather sport seat 10519
2 10 5 Installing valve blocks for R36 leather sport seat 10520
2 11 Removing and installing motor for backrest adjustment, R36 sport seat 10521
2 12 Removing and installing head restraint guides, R36 sport seat 10521
2 12 1 Removing 10521
2 12 2 Installing 10522
3 Rear seats 10523
3 1 Tools 10523
3 1 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 10523
3 2 Removing and installing bench seat, Passat 2006►, Passat CC 2009► and CC 2010► 10523
3 2 1 Removing 10523
3 2 2 Installing 10525
3 3 Removing and installing bench seat, Passat Estate 2006► 10526
3 3 1 Removing 10526
3 3 2 Installing 10527
3 4 Removing and installing left backrest segment 10527
3 4 1 Removing 10527
3 4 2 Installing 10528
3 5 Removing and installing right backrest segment 10528
3 5 1 Removing 10528
3 5 2 Installing 10529
3 6 Removing and installing fixed rear backrest, Passat CC 2009► and CC 2010► 10530
3 7 Removing and installing side padding with side-airbag 10531
3 7 1 Removing 10532
3 7 2 Installing 10533
3 8 Removing and installing side padding with no side-airbag 10533
3 8 1 Removing 10533
3 8 2 Installing 10534
3 9 Assembly overview – locking mechanism for rear seat backrest 10535
3 10 Removing and installing trim for locking mechanism 10536
3 11 Removing and installing lock cylinder for locking mechanism 10537
3 12 Removing and installing locking mechanism 10538
3 13 Removing and installing centre armrest 10539
3 13 1 Removing 10539
3 13 2 Installing 10540
3 14 Removing and installing centre armrest drink holder 10540
3 14 1 Removing 10540
3 14 2 Installing 10541
74 – Seat – padding, covers 10542
1 Front seat covers and padding 10542
1 1 Tools 10542
1 1 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 10542
1 2 Removing and installing front seat cushion cover and padding 10542
1 2 1 Removing 10543
1 2 2 Installing 10547
1 3 Removing and installing front seat backrest cover and padding (except Trendline) 10548
1 3 1 Removing 10548
1 3 2 Installing 10552
1 4 Removing and installing front seat backrest cover and padding (Trendline) 10553
1 4 1 Removing 10553
1 4 2 Installing 10555
1 5 Renewing heater elements of seat heating 10555
2 Covers and padding for R36 sport seat 10556
2 1 Tools 10556
2 1 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 10556
2 2 Removing and installing front seat cover and padding for R36 sports seat 10557
2 2 1 Removing 10557
2 2 2 Installing 10562
2 3 Removing and installing backrest cover and padding for R36 sports seat 10563
2 3 1 Removing 10563
2 3 2 Installing 10569
2 4 Renewing heater element for seat heater of R36 sport seat 10570
3 Rear seat covers and padding 10571
3 1 Tools 10571
3 1 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 10571
3 2 Removing and installing bench seat cover and padding, Passat 2006► 10571
3 2 1 Removing 10572
3 2 2 Installing 10573
3 3 Removing and installing bench seat cover and padding, Passat Estate 2006► 10574
3 3 1 Removing 10574
3 3 2 Installing 10577
3 4 Removing and installing bench seat cover and padding, Passat CC 2009► and CC 2010► 10577
3 4 1 Removing 10577
3 4 2 Installing 10580
3 5 Removing and installing cover and padding for bench seat with integrated child seat 10581
3 5 1 Removing 10581
3 5 2 Installing 10586
3 6 Removing and installing push button with trim for adjusting mechanism of child seat 10586
3 6 1 Removing 10586
3 6 2 Installing 10587
3 7 Removing and installing right backrest cover and padding 10588
3 7 1 Removing 10588
3 7 2 Installing 10591
3 8 Removing and installing left backrest cover and padding 10591
3 8 1 Removing 10591
3 8 2 Installing 10594
3 9 Removing and installing fixed rear backrest cover and padding, Passat CC 2009► and CC 2010► 10594
00 – Technical data 10604
1 Safety information 10604
1 1 Safety precautions when working on air conditioning systems 10604
1 2 Safety precautions when handling refrigerants 10604
1 3 Safety measures when working on vehicles with a start/stop system 10605
1 4 Safety precautions when working on the cooling system 10605
2 General information 10606
2 1 Notes concerning odours in air conditioned vehicles 10606
2 2 Notes for vehicles with start-stop system 10606
3 Repair notes 10607
3 1 Working on refrigerant circuit 10607
3 2 General repair instructions 10608
3 3 Refrigerant circuit seals 10608
4 Technical data 10609
4 1 Refrigerant capacity 10609
4 1 1 Capacities for refrigerant R1234yf 10609
4 1 2 Capacities for refrigerant R134a 10609
4 2 Refrigerant oil 10609
4 3 Oil distribution 10610
80 – Heating 10611
1 Heater 10611
1 1 Assembly overview – heater unit 10611
1 2 Removing and installing fresh air blower -V2- 10613
1 3 Checking fresh air blower -V2- 10614
1 4 Removing and installing fresh air blower series resistor with overheating fuse -N24- 10615
1 5 Removing and installing dust and pollen filter 10616
1 6 Removing and installing heat exchanger 10618
1 7 Removing and installing heater unit 10622
1 8 Dismantling and assembling heater unit 10626
1 9 Removing and installing auxiliary air heater element -Z35- 10627
2 Air duct 10631
2 1 Removing and installing centre vent, front 10631
2 2 Dismantling and assembling centre vent, front 10632
2 3 Removing vent on driver or front passenger side 10633
2 4 Removing and installing right footwell vent on front passenger side 10633
2 5 Removing and installing footwell vents on driver side 10634
2 6 Removing and installing rear footwell air duct 10634
2 7 Removing and installing air duct for rear vent 10635
2 8 Removing and installing rear vents 10635
2 9 Checking forced ventilation for passenger compartment 10637
2 10 Removing and installing forced ventilation for passenger compartment 10637
2 11 Removing and installing fresh air intake 10638
3 Control motors 10639
3 1 Removing and installing fresh air and air recirculation flap control motor -V154- 10639
3 2 Removing and installing air distribution flap actuator 10642
3 3 Removing and installing temperature flap actuator 10642
3 4 Removing and installing Bowden cable for temperature flap 10642
3 5 Removing and installing flexible shaft for air distribution 10643
4 Operating and display unit 10645
4 1 Removing and installing operating and display unit 10645
4 2 Multi-pin connector pin assignment on back of operating and display unit 10645
87 – Air conditioning system 10647
1 Overview of fitting locations – air conditioning system 10647
1 1 Overview of fitting locations – components not located in passenger compartment 10647
1 2 Overview of fitting locations – components located in front section of passenger compartment 10650
1 2 1 Overview of fitting locations – components inside of front passenger compartment, Climatic to WEEK 21/11 10650
1 2 2 Overview of fitting locations – components inside of front passenger compartment, manually controlled air conditioning system, as of WEEK 22/11 10652
1 2 3 Overview of fitting locations – components inside of front passenger compartment, Climatronic 10653
2 Refrigerant circuit 10657
2 1 Removing and installing high-pressure sender -G65- 10657
2 2 Removing and installing expansion valve 10658
2 3 Assembly overview – condenser 10662
2 4 Removing and installing condenser 10663
2 5 Removing and installing receiver 10666
2 5 1 Removing and installing receiver, Showa 10666
2 6 Removing and installing desiccant bag or cartridge 10669
2 6 1 Removing and installing desiccant cartridge, Passat 2006 ► 10669
2 6 2 Removing and installing desiccant cartridge, Passat CC 2009 ►, CC 2010 ► and CC 2012 10672
2 7 Removing and installing evacuating and charging valves on low and high-pressure side 10675
3 Air conditioner compressor 10678
3 1 Assembly overview – pulley 10678
3 1 1 Assembly overview – Denso pulley 10678
3 2 Removing air conditioning compressor from and installing on bracket 10679
3 3 Removing and installing air conditioner compressor bracket 10682
3 3 1 Removing and installing air conditioner compressor bracket, engine codes BKC, BKP, BLS, BMA, BMP, BMR, BUZ, BVE, BWV, BXE, CBAA, CBAB, CBAC and CBBB 10682
3 3 2 Removing and installing air conditioner compressor bracket, engine codes BUE, CAXA and CAXC 10683
3 3 3 Removing and installing air conditioner compressor bracket, engine codes BLF, BLP, BSE and BSF 10685
3 3 4 Removing and installing air conditioner compressor bracket, engine codes AXX, BLR, BLX, BLY, BPY, BVX, BVY, BVZ, BWA, BZB, CAWB, CBFA, CCTA, CCTB, CCZA, CCZB, CDAA, CDAB and CGYA 10686
3 3 5 Removing and installing air conditioner compressor bracket, engine codes AXZ, BLV and BWS 10688
3 3 6 Removing and installing air conditioner compressor bracket, engine codes CAYC, CBDC, CDGA, CFFB and CFGB 10690
3 3 7 Removing and installing air conditioner compressor bracket, Passat CC 2009 ►, CC 2010 ► and CC 2012 ► 10691
3 4 Removing and installing air conditioner compressor 10691
3 5 Checking high-pressure safety valve on air conditioner compressor 10695
3 6 Removing and installing pulley 10696
3 6 1 Removing and installing Zexel pulley 10696
3 6 2 Removing and installing Sanden pulley 10698
3 6 3 Removing and installing Denso pulley 10700
4 Front heater and air conditioning unit 10702
4 1 Removing and installing evaporator 10702
4 2 Dismantling and assembling evaporator housing 10703
4 3 Removing and installing heater and air conditioning unit 10704
4 3 1 Removing and installing heater and air conditioning unit, to WEEK 44/08 10704
4 3 2 Removing and installing heater and air conditioning unit, as of WEEK 45/08 10709
4 4 Dismantling and assembling heater and air conditioning unit 10714
4 4 1 Dismantling and assembling heater and air conditioning unit, Climatic 10714
4 4 2 Dismantling and assembling heater and air conditioning unit, manually regulated air conditioning system 10716
4 4 3 Dismantling and assembling heater and air conditioning unit, Climatronic 10718
4 5 Removing and installing fresh air blower -V2- 10719
4 6 Checking fresh air blower -V2- 10720
4 7 Removing and installing fresh air blower control unit -J126- 10721
4 8 Removing and installing condensation drain 10722
4 9 Checking condensation drain 10722
4 10 Removing and installing glove box cooling 10723
4 11 Removing and installing evaporator temperature sensor -G308- 10723
5 Air duct 10724
5 1 Removing and installing left vent temperature sender -G150- 10724
5 2 Removing and installing right vent temperature sender -G151- 10724
5 3 Removing and installing left footwell vent temperature sender -G261- 10725
5 4 Removing and installing right footwell vent temperature sender -G262- 10725
5 5 Removing and installing evaporator output temperature sender -G263- or evaporator temperature sensor -G308- 10725
5 6 Removing and installing centre vent temperature sender -G191- 10726
5 7 Removing and installing footwell vent temperature sender -G192- 10726
6 Operating and display unit 10727
6 1 Overview of operating and display unit 10727
6 1 1 Overview of operating and display unit, CC 2012 ►, Climatronic as of WEEK 22/2012 10727
6 1 2 Overview of operating and display unit, CC 2010 ► as of WEEK 45/11 10730
6 1 3 Overview of operating and display unit, Passat CC 2009 ►, CC 2010 ► to WEEK 44/11 10731
6 1 4 Overview of operating and display unit, Passat 2006 ► 10733
6 1 5 Overview of operating and display unit, manually controlled air conditioning system, from WEEK 22/11 to WEEK 26/12 10735
6 1 6 Overview of control and display unit, air conditioning system with electric and manual controls, as of WEEK 26/12 10736
6 1 7 Overview of operating and display unit for Climatic, Passat CC 2009 ►, CC 2010 ► 10738
6 1 8 Overview of operating and display unit for Climatic, Passat 2006 ► 10739
6 2 Removing and installing operating and display unit 10740
6 2 1 Removing and installing operating and display unit, as of WEEK 45/10 10740
6 2 2 Removing and installing operating and display unit, up to WEEK 44/10 10741
6 2 3 Removing and installing operating and display unit for Climatic 10741
6 3 Multi-pin connector pin assignment on Climatronic control unit -J255- 10742
6 3 1 Multi-pin connector pin assignment on Climatronic control unit -J255-, CC 2010 ► as of WEEK 45/11 10742
6 3 2 Multi-pin connector pin assignment on Climatronic control unit -J255-, Passat CC 2009 ►, CC 2010 ► to WEEK 44/11 10743
6 3 3 Multi-pin connector pin assignment on Climatronic control unit -J255-, Passat 2006 ► 10745
6 3 4 Multi-pin connector pin assignment on Climatronic control unit -J255-, manually controlled air conditioning system, as of WEEK 22/11 10747
6 3 5 Multi-pin connector pin assignment on Climatronic control unit -J255-, Climatic, to WEEK 21/11, Passat CC 2009 ► and CC 010 10749
6 3 6 Multi-pin connector pin assignment on Climatronic control unit -J255-, Climatic, Passat 2006 ► 10751
7 Control motors 10753
7 1 Removing and installing temperature flap control motor -V68- 10753
7 2 Removing and installing centre flap control motor -V70- or front air distribution flap control motor -V426- 10754
7 3 Removing and installing air flow flap control motor -V71- with potentiometer for air flow flap control motor -G113- 10755
7 4 Removing and installing defroster flap control motor -V107- 10758
7 5 Removing and installing air recirculation flap control motor -V113- 10759
7 6 Removing and installing fresh air/air recirculation, air flow flap control motor -V425- with potentiometer for fresh air/air recirculation, air flow flap control motor -G644- 10761
7 7 Removing and installing fresh air/air recirculation, air flow flap actuator 10762
7 8 Removing and installing left temperature flap control motor -V158- 10762
7 9 Removing and installing right temperature flap control motor -V159- 10764
7 9 1 Removing and installing right temperature flap control motor -V159-, to WEEK 44/08 10764
7 9 2 Removing and installing right temperature flap control motor -V159-, as of WEEK 45/08 10765
7 10 Removing and installing indirect ventilation flap control motor -V213- 10765
7 11 Removing and installing air distribution flap control motor -V428- 10766
7 11 1 Removing and installing air distribution flap servomotor -V428-, Passat 2006 ► 10766
7 11 2 Removing and installing air distribution flap control motor -V428-, Passat CC 2009 ► and CC 2010 ► 10767
7 12 Removing and installing flexible shaft 10767
8 Other controlling and regulating components 10769
8 1 Removing and installing sunlight penetration photosensor -G107- or sunlight penetration photosensor 2 -G134- 10769
8 2 Removing and installing air quality sensor -G238- 10770
8 3 Removing and installing ambient temperature sensor -G17- 10770
00 – Technical data 10776
1 General information 10776
1 1 Starting conditions for auxiliary/supplementary heater Thermo Top V/fleece 10776
1 1 1 Starting conditions for auxiliary/supplementary heater Thermo Top V/fleece (auxiliary/supplementary heater mode) 10776
1 1 2 Starting conditions for auxiliary/supplementary heater Thermo Top V/fleece (supplementary heater mode) 10776
1 2 Notes for vehicles with a start/stop system 10777
1 3 Rules for cleanliness when working on auxiliary/supplementary heater Thermo Top V/fleece and fuel system 10777
1 4 Type plates 10778
2 Safety information 10781
2 1 Safety precautions when working on vehicles equipped with auxiliary/supplementary heater Thermo Top V/fleece 10781
2 2 Safety measures when working on vehicles with a start/stop system 10781
2 3 Safety precautions during work on fuel system 10782
3 Repair instructions 10783
3 1 Notes on general repairs to vehicles equipped with auxiliary/supplementary heater Thermo Top V/fleece 10783
82 – Supplementary heating 10784
1 Auxiliary/supplementary heater Thermo Top V/fleece 10784
1 1 Overview of fitting locations – auxiliary/supplementary heater 10784
1 2 Assembly overview – auxiliary/supplementary heater, exterior 10787
1 3 Assembly overview – auxiliary/supplementary heater, interior 10788
1 3 1 Assembly overview – auxiliary/supplementary heater, interior, Passat 2006 ► and Passat CC 2009 ► 10788
1 3 2 Assembly overview – auxiliary/supplementary heater, interior, CC 2010 ►, CC 2012 ► 10790
1 4 Removing and installing auxiliary/supplementary heater Thermo Top V/fleece 10791
1 5 Dismantling and assembling auxiliary/supplementary heater Thermo Top V/fleece 10795
1 6 Removing and installing air intake silencer 10796
1 7 Removing and installing circulation pump -V55- 10797
1 8 Removing and installing silencer with bracket 10798
1 9 Removing and installing exhaust system 10799
1 10 Removing and installing auxiliary/supplementary heater bracket 10800
1 11 Removing and installing cover 10801
1 12 Removing and installing auxiliary heater control unit -J364- 10801
1 13 Removing and installing glow plug with flame monitor -Q8- 10802
1 13 1 Removing and installing glow plug with flame monitor -Q8-, Thermo Top V/fleece Passat 2006 ►, Passat CC 2009 ►, CC 2010 ► and CC 2012 ► 10802
1 13 2 Removing and installing glow plug with flame monitor -Q8-, Thermo Top fleece, CC 2010 ►, CC 2012 ► 10803
1 14 Removing and installing temperature sensor -G18- and overheating sensor -G189- 10804
1 15 Dismantling and assembling burner unit 10804
1 16 Connector pin assignment for auxiliary/supplementary heater Thermo Top V/fleece 10805
1 16 1 Connector pin assignment for auxiliary/supplementary heater Thermo Top V/fleece, Thermo Top V (auxiliary heater mode), Passat 2006 ► and Passat CC 2009 ► 10805
1 16 2 Connector pin assignment for auxiliary/supplementary heater Thermo Top V/fleece, Thermo Top V (supplementary heater mode), Passat 2006 ► and Passat CC 2009 ► 10807
1 16 3 Connector pin assignment for auxiliary/supplementary heater Thermo Top V/fleece, Thermo Top V/fleece (auxiliary heater mode), CC 2010 ►, CC 2012 ► 10809
1 16 4 Connector pin assignment for auxiliary/supplementary heater Thermo Top V/fleece, Thermo Top V/fleece (supplementary heater mode), CC 2010 ►, CC 2012 ► 10811
2 Coolant circuit with auxiliary/supplementary heater Thermo Top V/fleece 10813
2 1 Connection diagram – coolant hoses 10813
2 1 1 Schematic diagram – coolant hoses, supplementary heater, engine codes BKC, BLS and BXE 10813
2 1 2 Schematic diagram – coolant hoses, auxiliary heater, engine codes BLF and BLP 10815
2 1 3 Schematic diagram – coolant hoses, auxiliary heater, engine codes BKP, BMA, BVE, BMR, BUZ and BWV 10816
2 1 4 Schematic diagram – coolant hoses, auxiliary heater, engine code CAXA 10819
2 1 5 Schematic diagram – coolant hoses, auxiliary heater, engine codes BLR, BLX and BLY 10820
2 1 6 Schematic diagram – coolant hoses, auxiliary heater, engine codes BVX, BVY and BVZ 10821
2 1 7 Schematic diagram – coolant hoses, supplementary heater, engine code BMP 10822
2 1 8 Schematic diagram – coolant hoses, supplementary heater, engine codes CBAA, CBAB, CBBB and CBDC 10823
2 1 9 Schematic diagram – coolant hoses, supplementary heater, engine code AXZ 10824
2 1 10 Schematic diagram – coolant hoses, supplementary heater, engine codes BLV and BWS 10825
2 1 11 Schematic diagram – coolant hoses, engine codes CCZB and CDAA 10826
2 1 12 Schematic diagram – coolant hoses, engine codes CFFB and CFGB 10827
2 2 Removing and installing heater coolant shut-off valve 10827
2 2 1 Removing and installing heater coolant shut-off valve -N279-, vehicles with petrol engine 10827
3 Fuel supply system 10829
3 1 Overview of fitting locations – fuel supply system 10829
3 1 1 Extracting fuel from Thermo Top V/fleece 10830
3 2 Removing and installing metering pump -V54- 10831
3 2 1 Removing and installing metering pump -V54-, Passat 2006 ► and Passat CC 2009 ► 10831
3 2 2 Removing and installing metering pump -V54-, CC 2010 ►, CC 2012 ► 10832
3 2 3 Removing and installing metering pump -V54-, EcoFuel vehicles 10834
3 3 Checking fuel delivery rate 10835
4 Regulation of auxiliary/supplementary heater Thermo Top V/fleece 10838
4 1 Functional description 10838
4 1 1 Supplementary heater mode 10839
4 1 2 Auxiliary heater mode 10839
4 1 3 Switching off auxiliary/supplementary heater Thermo Top V/fleece 10841
5 Other controlling and regulating components 10842
5 1 Removing and installing ambient temperature sensor -G17- 10842
5 2 Removing and installing remote control receiver for auxiliary coolant heater -R149- for auxiliary/supplementary heater Thermo Top V/fleece 10842
5 2 1 Removing and installing remote control receiver for auxiliary coolant heater -R149- for auxiliary/supplementary heater Thermo Top V/fleece, Passat Saloon 2006 ►, Passat CC 2009 ►, CC 2010 ► and CC 2012 ► 10843
5 2 2 Removing and installing remote control receiver for auxiliary coolant heater -R149- for auxiliary/supplementary heater Thermo Top V/fleece, Passat Estate 2006 ► 10843
5 3 Functional description of remote control for auxiliary/supplementary heater Thermo Top V/fleece 10844
5 3 1 Functional description of remote control for auxiliary/supplementary heater Thermo Top V/fleece, “large” 10844
5 3 2 Functional description of remote control for auxiliary/supplementary heater Thermo Top V/fleece, Thermo Top V/fleece 10846
00 – Technical data 10854
1 Repair notes 10854
1 1 General repair instructions 10854
1 2 Tools 10854
1 3 Gearbox 10854
1 4 ⇒ ATF 10855
1 5 Automatic gearbox control unit -J217- with ⇒ fuzzy logic 10856
1 6 Control units in vehicle 10856
1 7 Gaskets and seals 10856
1 8 Nuts and bolts 10857
1 9 Electrical components 10857
2 Identification of gearbox 10858
3 Bevel box identification 10859
4 Identification codes, assembly allocation – Passat 10860
4 1 Identification codes, assembly allocation – Cars with front-wheel drive 10860
4 2 Identification codes, assembly allocation – Cars with all-wheel drive 10860
5 Identification codes, assembly allocation – Passat CC and CC 10861
5 1 Identification codes, assembly allocation – Cars with front-wheel drive 10861
5 2 Identification codes, assembly allocation – Cars with all-wheel drive 10861
6 Identification codes, assembly allocation – Tiguan 10862
6 1 Identification codes, assembly allocation – Cars with front-wheel drive 10862
6 2 Identification codes, assembly allocation – Cars with all-wheel drive 10862
7 Capacities 10863
7 1 6-speed automatic gearbox 09M, front-wheel drive 10863
7 2 6-speed automatic gearbox 09M, all-wheel drive 10863
7 3 Guided fault-finding, vehicle self-diagnosis and test instruments 10863
32 – Torque converter 10864
1 Torque converter 10864
1 1 Identification of torque converter 10864
1 2 Draining torque converter 10864
1 3 Removing and installing torque converter oil seal 10864
1 4 Installing torque converter 10865
37 – Controls, housing 10867
1 Connecting vehicle diagnostic tester and selecting functions 10867
2 Electrical and electronic components and their locations, Passat, Passat CC and CC 10868
3 Electrical and electronic components and their locations – Tiguan 10872
4 Removing, installing and adjusting multifunction switch -F125- 10876
4 1 Removing multifunction switch -F125- 10876
4 2 Installing multifunction switch -F125- 10877
4 3 Adjusting multifunction switch -F125- 10878
4 3 1 Adjustment prerequisites 10878
5 Emergency release of selector lever 10880
6 Removing and installing selector lever handle 10881
6 1 Moving push button in the handle to installation position 10883
6 1 1 Handle with push-button on side 10883
6 1 2 Handle with front push-button 10884
7 Selector mechanism, Passat, Passat CC, CC and Tiguan to week 44/09 10886
7 1 Overview – selector mechanism 10886
7 2 Removing and installing selector mechanism with selector lever 10887
7 3 Removing and installing gear selector cable 10887
7 4 Checking selector lever cable 10895
7 5 Adjusting selector lever cable 10895
7 6 Checking selector mechanism 10896
7 6 1 Selector lever in “P” position and ignition switched on 10896
7 6 2 Selector lever in “N” position and ignition switched on 10897
7 6 3 Selector lever in position “Tiptronic” 10897
7 6 4 Ignition and light switched on 10897
7 6 5 Selector lever position display 10897
8 Selector mechanism for Tiguan from week 45/09 10898
8 1 Overview – selector mechanism 10898
8 2 Removing and installing selector mechanism with selector housing 10899
8 3 Removing and installing selector mechanism without selector housing 10901
9 Removing and installing gearbox – Passat 10903
9 1 Removing and installing gearbox – vehicles with front-wheel drive 10903
9 2 Removing gearbox – vehicles with 3 6 l – 206 kW engine 10903
9 3 Installing gearbox – vehicles with 3 6 l – 206 kW engine 10911
9 3 1 Specified torques 10911
9 4 Removing and installing gearbox – vehicles with all-wheel drive 10912
9 5 Removing gearbox – vehicles with 3 6 l – 206 kW engine 10912
9 6 Installing gearbox – vehicles with 3 6 l – 206 kW engine 10919
9 6 1 Specified torques 10920
10 Removing and installing gearbox – Passat CC and CC 10922
10 1 Removing and installing gearbox – vehicles with front-wheel drive 10922
10 2 Removing gearbox – vehicles with 3 6 l – 206 kW engine 10922
10 3 Installing gearbox – vehicles with 3 6 l – 206 kW engine 10930
10 3 1 Specified torques 10930
10 4 Removing and installing gearbox – vehicles with all-wheel drive 10931
10 5 Removing gearbox – vehicles with 3 6 l – 206 kW engine 10931
10 6 Installing gearbox – vehicles with 3 6 l – 206 kW engine 10937
10 6 1 Specified torques 10938
11 Removing and installing gearbox – Tiguan 10940
11 1 Removing and installing gearbox – vehicles with front-wheel drive 10940
11 2 Removing gearbox – vehicles with 2 0 l – 147 kW TSFI engine 10940
11 3 Installing gearbox – vehicles with 2 0 l – 147 kW TSFI engine 10947
11 3 1 Specified torques 10948
11 4 Removing and installing gearbox – vehicles with all-wheel drive 10949
11 4 1 Removing gearbox – vehicles with 2 0 l – 103 kW TDI engine 10949
11 4 2 Installing gearbox – vehicles with 2 0 l – 103 kW TDI engine 10956
11 4 3 Specified torques 10957
11 5 Removing gearbox – vehicles with 2 0 l – 125/132/147 kW TSFI engine 10958
11 6 Installing gearbox – vehicles with 2 0 l – 125/132/147 kW TSFI engine 10965
11 6 1 Specified torques 10966
12 Transporting gearbox 10968
13 Assembly overview – ATF cooler – Passat 10969
13 1 Assembly overview for vehicles with 3 6 l 206 kW engine 10969
13 1 1 ATF lines 10970
14 Assembly overview – ATF cooler – Tiguan 10971
14 1 Removing and installing ATF cooler 10972
14 1 1 Removing 10972
14 1 2 Installing 10974
14 2 Renew “seal set for quick-release connection” 10975
14 2 1 Removing seal set 10976
14 2 2 Installing seal set 10976
15 Checking and topping up ATF level 10978
15 1 Check ATF level 10980
15 2 Topping up ATF 10981
15 3 Draining and filling ATF 10982
38 – Gears, control 10984
1 Renewing oil seal for selector shaft 10984
2 Removing and installing oil sump 10985
2 1 Removing 10985
2 2 Installing 10986
3 Removing and installing ATF strainer 10988
3 1 Removing 10988
3 2 Installing 10988
4 Removing and installing valve body 10989
4 1 Overview – valve chest 10989
4 2 Removing valve body 10991
4 3 Installing valve body 10994
4 3 1 Wire routing, connectors, connections and retainer on valve body 10996
4 4 Specified torques 10998
5 Removing and installing wiring harness for solenoid valves and senders 10999
5 1 Removing 10999
5 2 Installing 10999
5 3 Removing and installing gearbox input speed sender -G182- 10999
5 3 1 Removing 10999
5 3 2 Installing 11000
5 4 Removing and installing gearbox output speed sender -G195- 11000
5 4 1 Removing 11000
5 4 2 Installing 11000
39 – Final drive – front differential 11002
1 Renewing flange shaft oil seals 11002
1 1 Renewing left oil seal – front and all-wheel drive vehicles 11002
1 1 1 Removing left oil seal 11002
1 1 2 Installing left seal 11003
1 2 Renewing right oil seal – front-wheel drive vehicles 11004
1 2 1 Removing right oil seal 11004
1 2 2 Installing right seal 11004
1 3 Renewing right oil seal – all-wheel drive vehicles 11005
1 3 1 Removing small oil seal 11005
1 3 2 Removing large oil seal 11006
1 3 3 Installing small oil seal 11006
1 3 4 Installing large oil seal 11007
39 – Final drive – differential 11008
1 Removing and installing bevel box – Passat, Passat CC and CC 11008
1 1 Removing and installing bevel box – vehicles with 3 6 l – 206 kW engine 11008
1 1 1 Removing 11010
1 1 2 Installing 11014
2 Removing and installing bevel box – Tiguan 11018
2 1 Removing and installing bevel box – vehicles with 2 0 l – 103 kW TDI engine 11018
2 1 1 Removing 11020
2 1 2 Installing 11025
2 2 Removing and installing bevel box – vehicles with 2 0 l – 125/132/147 kW TSFI engine 11028
2 2 1 Removing 11028
2 2 2 Installing 11034
3 Repairing bevel box 11038
3 1 Bevel box – assembly overview 11038
4 Renewing seals on bevel box 11040
4 1 Renewing seals on left (between bevel box and gearbox) 11041
4 1 1 Removing seals 11041
4 1 2 Installing seals 11042
4 2 Renewing right seal (drive shaft side) 11043
4 2 1 Removing oil seal 11043
4 2 2 Installing oil seal 11044
4 3 Renewing output flange oil seal (bevel box removed) 11045
4 3 1 Removing 11048
4 3 2 Installing 11049
4 4 Renewing needle bearing (polygon bearing) for stub shaft 11050
5 Checking and topping up gear oil in bevel box 11054
5 1 Checking gear oil in bevel box 11055
5 2 Topping up gear oil in bevel box 11055
00 – Technical data 11063
1 Identification 11063
1 1 Engine number/engine data 11063
1 1 1 Engine number 11063
1 1 2 Engine data 11063
2 Safety information 11065
2 1 Safety precautions when working on fuel system 11065
2 2 Safety precautions when using testers and measuring instruments during a road test 11066
2 3 Safety measures when working on vehicles with a start/stop system 11066
2 4 Safety precautions when working on the cooling system 11066
2 5 Safety precautions when working on the SCR system 11067
2 6 Safety precautions when working on exhaust system 11067
3 Repair notes 11069
3 1 Rules for cleanliness 11069
3 2 Foreign objects in engine 11069
3 3 Checking vacuum system 11070
10 – Removing and installing engine 11071
1 Removing and installing engine 11071
1 1 Removing and installing engine 11071
1 1 1 Removing engine, Passat, Passat CC, Tiguan, Eos 11071
1 1 2 Removing engine, Golf, Golf Plus, Scirocco 11078
1 2 Securing engine on engine and gearbox support 11084
1 3 Installing engine 11085
1 3 1 Notes on installing, Passat, Passat CC, Tiguan and Eos 11085
1 3 2 Notes on installing, Golf, Golf Plus, Scirocco 11086
2 Assembly mountings 11089
2 1 Assembly overview – assembly mountings 11089
2 2 Supporting engine in installation position 11090
2 2 1 Supporting engine in installation position, Passat, Passat CC, Eos, Golf and Scirocco 11090
2 2 2 Supporting engine in installation position, Tiguan 11093
2 2 3 Supporting engine in installation position, Golf Plus 11095
2 3 Adjusting assembly mountings 11098
2 3 1 Adjusting assembly mountings, Passat, Passat CC, Eos, Golf and Scirocco 11098
2 3 2 Adjusting assembly mountings, Tiguan 11099
2 3 3 Adjusting assembly mountings, Golf Plus 11101
3 Engine cover panel 11103
3 1 Removing and installing engine cover 11103
13 – Crankshaft group 11104
1 Cylinder block (pulley end) 11104
1 1 Assembly overview – poly V-belt drive 11104
1 1 1 Assembly overview – poly V-belt drive with tensioning element and air conditioner compressor 11104
1 1 2 Assembly overview – poly V-belt drive with tensioning roller and air conditioner compressor 11106
1 1 3 Assembly overview – poly V-belt drive without air conditioner compressor 11108
1 2 Removing and installing poly-V belt 11108
1 2 1 Removing and installing poly V-belt with tensioning element and air conditioner compressor 11108
1 2 2 Removing and installing poly V-belt with tensioning roller and air conditioner compressor 11110
1 2 3 Removing and installing poly V-belt without air conditioner compressor 11111
1 3 Removing and installing tensioner for poly V-belt 11112
1 3 1 Removing and installing poly V-belt tensioner 11112
1 4 Removing and installing bracket for ancillaries 11113
1 5 Removing and installing engine bracket 11115
1 5 1 Removing and installing engine bracket, Passat, Passat CC, Eos, Golf and Scirocco 11115
1 5 2 Removing and installing engine bracket, Tiguan 11118
1 5 3 Removing and installing engine bracket, Golf Plus 11121
1 6 Assembly overview – cylinder block (pulley end) 11125
1 7 Removing and installing sealing flange on pulley end 11126
1 8 Renewing crankshaft oil seal – belt pulley end 11128
2 Cylinder block, gearbox end 11131
2 1 Assembly overview – cylinder block, gearbox end 11131
2 2 Removing and installing sealing flange on gearbox side 11132
2 2 1 Pressing out sealing flange with sender wheel 11133
2 2 2 Pressing in sealing flange with sender wheel 11134
2 2 3 A – Assembling seal with sender wheel on assembly tool -T10134- 11135
2 2 4 B – Fitting assembly tool -T10134- with sealing flange to crankshaft flange 11136
2 2 5 C – Screwing assembly tool -T10134- on crankshaft flange 11137
2 2 6 D – Pressing sender wheel onto crankshaft flange using assembly tool -T10134- 11138
2 2 7 E – Checking sender wheel installation position on crankshaft 11138
2 2 8 F – Re-pressing sender wheel 11139
3 Crankshaft 11141
3 1 Assembly overview – crankshaft 11141
3 2 Renewing needle bearing in crankshaft 11141
3 3 Crankshaft dimensions 11144
4 Pistons and conrods 11145
4 1 Assembly overview – pistons and conrods 11145
4 1 1 Assembly overview – pistons and conrods 11145
4 1 2 Piston and cylinder dimensions 11148
4 2 Measuring piston projection at TDC 11148
4 3 Separating new conrod 11149
15 – Cylinder head, valve gear 11151
1 Cylinder head 11151
1 1 Assembly overview – cylinder head 11151
1 2 Removing and installing cylinder head 11153
1 3 Assembly overview – cylinder head cover 11162
1 4 Removing and installing cylinder head cover 11163
1 5 Removing and installing vacuum pump 11166
1 6 Checking compression 11167
2 Toothed belt drive 11169
2 1 Assembly overview – toothed belt 11169
2 2 Removing and installing toothed belt 11171
3 Valve gear 11178
3 1 Assembly overview – valve gear 11178
3 2 Removing and installing camshaft oil seal 11179
3 2 1 Vehicles up to 08 09 11180
3 2 2 Vehicles from 09 09 11181
3 3 Removing and installing camshaft 11183
3 4 Removing and installing valve stem seals 11190
4 Inlet and exhaust valves 11195
4 1 Valve dimensions 11195
4 2 Reworking valve seats 11195
4 3 Checking valve guides 11195
17 – Lubrication 11196
1 Sump, oil pump 11196
1 1 Assembly overview – sump/oil pump 11196
1 1 1 Assembly overview – sump / oil pump, engine codes CBAA, CBAB, CBAC, CBBA, CBBB 11196
1 1 2 Assembly overview – sump / oil pump, engine codes CBDA, CBDC, CBDB, CJAA 11199
1 2 Removing and installing oil sump 11202
1 3 Removing and installing oil pump 11205
1 3 1 Removing and installing oil pump, engine codes CBAA, CBAB, CBAC, CBBA, CBBB 11205
1 4 Engine oil: 11206
1 4 1 Oil capacities, engine codes CBAA, CBAB, CBAC, CBBA, CBBB 11206
1 4 2 Oil capacities, engine codes CBDA, CBDB, CBDC, CJAA 11207
2 Engine oil cooler 11208
2 1 Assembly overview – engine oil cooler 11208
3 Oil filter, oil pressure switch 11210
3 1 Assembly overview – oil filter/oil pressure switch 11210
3 2 Removing and installing oil filter housing 11211
3 3 Checking oil pressure and oil pressure switch 11214
3 3 1 Checking oil pressure switch 11215
3 3 2 Checking oil pressure 11215
4 Oil circuit 11216
4 1 Removing and installing oil supply line for turbocharger 11216
5 Balancer shaft module 11218
5 1 Assembly overview – balancer shaft module 11218
5 2 Removing and installing balance shaft module 11221
5 2 1 Removing balancer shaft module 11221
5 2 2 Installing a new balancer shaft module 11222
5 2 3 Installing a previously used balancer shaft module again 11226
5 2 4 Renewing spur gear for crankshaft, engine codes CBAA, CBAB, CBAC, CBBA, CBBB 11228
19 – Cooling 11232
1 Cooling system/coolant 11232
1 1 Coolant hose connection diagram 11232
1 1 1 Coolant hose schematic diagram, vehicles with 4/2-way valve, engine codes CBAA, CBBB, CBAB, CBBA, CBDB, CBDC, CBAC, CBDA 11232
1 1 2 Coolant hose schematic diagram, vehicles without 4/2-way valve, engine codes CBAA, CBBB, CBAB, CBBA, CBDB, CBDC, CBAC, CBDA 11233
1 1 3 Coolant hose schematic diagram, engine code CJAA 11235
1 2 Checking cooling system for leaks 11236
1 2 1 Checking cooling system for leaks 11236
1 2 2 Checking oil cooler for leaks 11238
1 3 Draining and adding coolant 11240
1 3 1 Draining 11241
1 3 2 Filling 11243
1 4 Assembly overview – engine preheater 11244
1 4 1 Assembly overview – engine preheater 11244
1 4 2 Removing and installing engine preheater 11246
2 Coolant pump, regulation of cooling system 11248
2 1 Removing and installing coolant pump 11248
2 2 Removing and installing thermostat 11249
2 3 Removing and installing 4/2-way valve with thermostat 11251
3 Coolant pipes 11253
3 1 Assembly overview – coolant pipes 11253
3 1 1 Assembly overview – coolant pipes, engine side, engine codes CBAA, CBBB, CBAB, CBBA, CBDB, CBDC, CBAC, CBDA 11253
3 1 2 Assembly overview – coolant pipes, engine side, engine code CJAA 11254
3 1 3 Assembly overview – coolant pipes, gearbox side, engine code CJAA 11256
4 Radiator, radiator fan 11257
4 1 Assembly overview – radiator/radiator fan 11257
4 1 1 Assembly overview – radiator/radiator fan, engine codes CBAA, CBBB, CBAB, CBBA, CBDB, CBDC, CBAC, CBDA 11257
4 1 2 Assembly overview – radiator/radiator fan, engine code CJAA 11259
4 2 Removing and installing radiator 11260
4 3 Removing and installing radiator cowl with radiator fan 11261
21 – Turbocharging/supercharging 11262
1 Exhaust turbocharger 11262
1 1 Assembly overview – turbocharger 11262
1 1 1 Assembly overview – turbocharger, engine codes CBAA, CBBB, CBAB, CBBA, CBDB, CBDC, CBAC, CBDA 11262
1 1 2 Assembly overview – turbocharger, engine code CJAA 11264
1 2 Removing and installing turbocharger 11268
1 2 1 Removing and installing turbocharger, engine codes CBAA, CBBB, CBAB, CBBA, CBDB, CBDC, CBAC, CBDA 11268
1 2 2 Removing and installing turbocharger, engine code CJAA 11270
1 3 Renewing vacuum unit for turbocharger 11272
2 Charge air system 11280
2 1 Assembly overview – charge air system 11280
2 2 Assembly overview – charge-air hose connections 11282
2 2 1 Assembly overview – charge-air hose connections with plug-in connectors 11282
2 3 Checking charge air system for leaks 11283
23 – Mixture preparation – injection 11286
1 Injection system 11286
1 1 Schematic overview – fuel system 11286
1 2 Assembly overview – fuel system 11288
1 3 Filling/bleeding fuel system 11291
1 4 Checking fuel system for leaks 11292
2 Injectors/high-pressure accumulator (rail) 11293
2 1 Check pressure retention valve in fuel return line 11293
2 2 Removing and installing injectors 11294
2 2 1 Removing injectors 11294
2 2 2 Installing injectors 11297
2 3 Removing and installing high-pressure lines 11298
2 4 Removing and installing fuel rail 11300
3 Vacuum system 11304
3 1 Assembly overview – vacuum system 11304
3 1 1 Assembly overview – vacuum system, engine codes CBAA, CBBB, CBAB, CBBA, CBDB, CBDC, CBAC, CBDA 11304
3 1 2 Assembly overview – vacuum system, engine code CJAA 11305
3 2 Checking vacuum system 11305
3 2 1 Checking supply line, vacuum reservoir and non-return valve 11306
3 2 2 Checking control line to turbocharger 11307
3 2 3 Checking control line to vacuum unit for exhaust gas recirculation cooler changeover, engine codes CBAA, CBBB, CBAB, CBBA, CBDB, CBDC, CBAC, CBDA 11307
4 Air filter 11309
4 1 Assembly overview – air filter housing 11309
4 1 1 Assembly overview – air filter, engine codes CBAA, CBBB, CBAB, CBBA, CBDB, CBDC, CBAC, CBDA 11309
4 1 2 Assembly overview – air filter, engine code CJAA 11310
4 2 Removing and installing air filter housing 11311
4 3 Checking changeover flap for intake air preheating 11312
4 4 Removing and installing changeover flap for intake air preheating 11313
5 Intake manifold 11316
5 1 Assembly overview – intake manifold 11316
5 2 Removing and installing intake manifold 11316
6 Senders and sensors 11320
6 1 Checking fuel pressure regulating valve 11320
6 2 Removing and installing fuel pressure regulating valve -N276- 11321
6 3 Removing and installing fuel pressure sender 11323
6 4 Assembly overview – actuator for structure-borne sound and control unit for structure-borne sound 11324
6 4 1 Assembly overview – actuator for structure-borne sound -R214- and control unit for structure-borne sound -J869- (left-hand drive vehicles) 11324
6 4 2 Assembly overview – actuator for structure-borne sound -R214- and control unit for structure-borne sound -J869- (right-hand drive vehicles) 11325
7 High-pressure pump 11327
7 1 Removing and installing high-pressure pump 11327
8 Engine (motor) control unit 11331
8 1 Removing and installing engine control unit 11331
8 1 1 Removing and installing anti-theft engine control unit -J623-, Scirocco 11331
8 1 2 Removing and installing engine control unit -J623-, Scirocco 11333
8 1 3 Removing and installing anti-theft engine control unit -J623-, Passat, Passat CC and Tiguan 11334
8 1 4 Removing and installing engine control unit -J623-, Passat, Passat CC and Tiguan 11336
8 1 5 Removing and installing engine control unit, Golf Plus 11337
8 1 6 Removing and installing anti-theft engine control unit, Golf Plus 11338
8 1 7 Removing and installing engine control unit -J623-, Golf 11340
8 1 8 Removing and installing anti-theft engine control unit -J623-, Golf 11341
8 1 9 Removing and installing engine control unit, Eos 11344
8 1 10 Removing and installing anti-theft engine control unit, Eos 11345
9 Lambda probe 11349
9 1 Removing and installing lambda probe 11349
9 1 1 Removing and installing Lambda probe -G39- 11349
9 1 2 Removing and installing lambda probe after catalytic converter -G130-, engine code CJAA 11350
26 – Exhaust system 11353
1 Exhaust pipes and silencers 11353
1 1 Assembly overview – silencers 11353
1 1 1 Assembly overview – silencer, vehicles with front-wheel drive, Passat, Passat CC 11353
1 1 2 Assembly overview – silencer, vehicles with four-wheel drive, Passat, Passat CC 11355
1 1 3 Assembly overview – silencer, vehicles with SCR system, Passat, Passat CC 11356
1 1 4 Assembly overview – silencers, Tiguan 11357
1 1 5 Assembly overview – silencer, vehicles with front-wheel drive, Eos, Golf, Scirocco, Golf Plus 11358
1 1 6 Assembly overview – silencer, vehicles with four-wheel drive, Golf 11359
1 1 7 Assembly overview – silencer, engine code CJAA 11360
1 2 Separating exhaust pipes from silencers 11361
1 2 1 Separating and joining exhaust system, engine code CJAA 11361
1 2 2 Separating exhaust pipe/silencer, engine codes CBAA, CBBB, CBAB, CBBA, CBDB, CBDC, CBAC, CBDA 11362
1 3 Aligning exhaust system free of stress 11363
1 3 1 Aligning exhaust system free of stress, engine codes CBAA, CBBB, CBAB, CBBA, CBDB, CBDC, CBAC, CBDA 11363
1 3 2 Aligning exhaust system free of stress, engine code CJAA 11364
1 4 Check exhaust system for leaks 11365
1 5 Installation position of clamp 11366
2 Exhaust gas cleaning 11368
2 1 Assembly overview – emission control 11368
2 1 1 Assembly overview – front exhaust pipe with particulate filter, engine codes CBAA, CBBB, CBAB, CBBA, CBDB, CBDC, CBAC, CBDA 11368
2 1 2 Assembly overview – particulate filter with NOx storage catalytic converter, engine code CJAA 11371
2 1 3 Assembly overview – exhaust flap control unit -J883- with SCR catalytic converter 11374
2 1 5 Routing cables/lines of exhaust system components, engine code CJAA 11376
2 2 Removing and installing particulate filter 11378
2 2 1 Removing and installing particulate filter, engine codes CBAA, CBBB, CBAB, CBBA, CBDB, CBDC, CBAC, CBDA 11378
2 2 2 Removing and installing particulate filter, Tiguan with front-wheel drive 11382
2 3 Removing and installing particulate filter with NOx storage catalytic converter 11386
2 3 1 Removing particulate filter with NOx storage catalytic converter 11388
2 3 2 Installing particulate filter with NOx storage catalytic converter 11392
2 4 Removing and installing NOx storage catalytic converter 11394
3 SCR system (selective catalytic reduction) 11396
3 1 Assembly overview – tank for reducing agent 11396
3 2 Draining reducing agent tank 11397
3 3 Removing and installing reducing agent tank 11400
3 4 Assembly overview – delivery module for reducing agent 11402
3 5 Assembly overview – reducing agent delivery line 11404
3 6 Removing and installing reducing agent supply line 11405
3 7 Removing and installing injector for reducing agent 11407
3 8 Removing and installing heater element (heater cup) 11408
4 Exhaust gas recirculation 11413
4 1 Assembly overview – exhaust gas recirculation 11413
4 1 1 Assembly overview – exhaust gas recirculation system, engine codes CBAA, CBBB, CBAB, CBBA, CBDB, CBDC, CBAC, CBDA 11413
4 1 2 Assembly overview – exhaust gas recirculation system, engine code CJAA 11415
4 2 Removing and installing exhaust gas recirculation filter 11416
4 3 Removing and installing exhaust gas recirculation cooler 11418
4 4 Checking exhaust gas recirculation cooler for leaks 11422
4 5 Removing and installing temperature sensor for exhaust gas recirculation 11425
4 6 Cleaning exhaust gas recirculation system 11429
4 6 1 Initiating exhaust gas recirculation system cleaning procedure 11430
4 6 2 Cleaning exhaust gas recirculation valve -N18- and connecting pipe 11434
28 – Glow plug system 11436
1 Glow plug system 11436
1 1 Removing and installing automatic glow period control unit -J179- 11436
1 2 Removing and installing glow plug 11437
1 2 1 Removing and installing glow plugs, engine codes CBAA, CBBB, CBAB, CBBA, CBDB, CBDC, CBAC, CBDA 11437
1 2 2 Removing and installing glow plugs, engine code CJAA 11439
1 3 Removing and installing Hall sender 11444
1 3 1 Vehicles up to 12 2007 11445
1 3 2 Vehicles from 01 08 11446
1 4 Removing and installing engine speed sender 11448
00 – Technical data 11454
1 Repair instructions 11454
1 1 General information 11454
1 1 1 General information 11454
1 1 2 Suppression measures 11455
1 1 3 Mobile telephones or portable two-way radios without separate external aerial 11455
1 1 4 Installation and operation of two-way radios with a transmitting power above 10 watts 11455
1 1 5 Overview of battery, transmitter and receiver unit, fuse and wiring harness 11455
1 1 6 Transmitting power and aerial fitting locations 11456
1 2 General repair instructions 11457
1 2 1 Notes on performing repair work 11457
1 2 2 Fault finding in communication systems 11459
1 2 3 Adapting radio components 11459
1 2 4 Adapting radio navigation system components 11459
91 – Communication 11461
1 Radio/radio navigation systems -R-/-J503- 11461
1 1 Components of radio/radio navigation systems -R-/-J503- 11461
1 2 Overview of fitting locations – radio/radio navigation system -R-/-J503- 11489
1 2 1 Assembly overview – radio system “RCD 310” 11489
1 2 2 Assembly overview – radio system “RCD 510” 11491
1 2 3 Assembly overview – radio navigation system “RNS 300” 11493
1 2 4 Assembly overview – radio navigation system “RNS 310” 11495
1 2 5 Assembly overview – radio navigation system “RNS 315” 11496
1 2 6 Assembly overview – radio navigation system “RNS 510” 11498
1 2 7 Assembly overview – radio system “Premium Sound System”, for vehicles for USA and Canada 11500
1 2 8 Assembly overview – Composition Colour 11502
1 2 9 Assembly overview – Composition Media and Discover Media 11504
1 3 Removing and installing radio/radio navigation system -R-/-J503- 11505
1 4 Interface for external multimedia units -R215- 11507
1 5 Removing and installing magnetic field sender for compass -G197- 11509
1 6 Pin assignments 11510
1 6 1 Connector pin assignment, “RCD 310” 11511
1 6 2 Connector pin assignment, “RCD 510” 11513
1 6 3 Connector pin assignment, “RNS 300” 11516
1 6 4 Connector pin assignment, “RNS 310” 11518
1 6 5 Connector pin assignment, “RNS 315” 11520
1 6 6 Connector pin assignment, “RNS 510” 11523
1 6 7 Connector pin assignment, “Premium Sound System” 11527
2 Sound system 11531
2 1 Overview of fitting locations – sound system 11531
2 2 Removing and installing amplifier -R12- for digital sound package 11531
2 3 Removing and installing front bass loudspeakers -R21-/-R23- 11535
2 4 Removing and installing rear bass loudspeakers -R15-/-R17- 11536
2 5 Removing and installing front treble loudspeakers -R20-/-R22- 11537
2 6 Removing and installing rear treble loudspeakers -R14-/-R16- 11538
3 Aerial systems 11540
3 1 Overview of fitting locations – aerial systems 11540
3 1 1 Overview of aerial system in standard version 11540
3 1 2 Overview of aerial system in DAB version 11542
3 1 3 Overview of frequency filter and aerial amplifier 11543
3 2 Removing and installing aerial module -R108-/-R109- 11544
3 2 1 Removing and installing left frequency filter and aerial module -R108-/-R179- 11544
3 2 2 Removing and installing right frequency filter and aerial module -R109-/-R178- 11545
3 3 Removing and installing roof aerial -RX5- 11545
4 CD changer -R41- 11547
4 1 General information 11547
4 2 Removing and installing CD changer -R41- 11547
5 Telephone system 11550
5 1 Components of telephone system 11550
5 1 1 Components of telephone system 11550
5 1 2 Components of Composition Colour, Media and Discover Media 11550
5 2 Mobile telephone preparation 11551
5 2 1 Removing and installing operating unit for preparation for mobile phone 11551
5 2 2 Changing mobile phone cradle from old to new dash panel 11552
5 3 Overview of fitting locations – telephone system 11554
5 4 Removing and installing telephone microphone -R38- 11556
5 5 Removing and installing telephone bracket 11557
5 5 1 Removing and installing telephone bracket in centre console 11557
5 5 2 Removing and installing telephone bracket on dash panel 11558
5 6 Removing and installing telephone transmitter and receiver unit -R36-/-J412- 11560
6 Reversing camera 11561
6 1 Components of reversing camera system 11561
6 2 Overview of fitting locations – reversing camera system 11562
6 3 Removing and installing reversing camera -R189- 11562
6 4 Calibrating reversing camera 11563
6 5 Removing and installing reversing camera system control unit -J772- 11568
6 5 1 Removing and installing reversing camera system control unit -J772- 11568
6 5 2 Coding reversing camera system control unit -J772- 11568
6 6 Renewing video cable 11569
6 6 1 Preparation 11569
6 6 3 Renewing video cable connector strip 11570
7 Multifunction steering wheel 11571
7 1 Components of radio/radio navigation system on multifunction steering wheel -R-/-J503- 11571
7 2 Removing and installing multifunction buttons -E440-/-E441- 11572
8 Connection for external multimedia devices 11574
8 1 Components of connection for external multimedia units 11574
8 1 1 Overview – connection for external audio sources -R199-, AUX-IN 11574
8 1 2 Overview – interface for external multimedia units -R215- 11576
8 1 3 Overview – interface for external multimedia units -R215-, UMI 11578
8 2 Connectors, connection for external multimedia devices 11579
8 3 Removing and installing connection for external audio sources -R199- 11582
8 4 Removing and installing interface for external multimedia units -R215- 11583
8 4 1 Removing and installing interface for external multimedia units -R215-, glove compartment 11583
8 4 2 Removing and installing interface for external multimedia units -R215-, centre console 11584
8 4 3 Removing and installing interface for external multimedia units -R215-, UMI control unit in glove compartment 11585
8 4 4 Removing and installing interface for external multimedia units -R215-, UMI control unit in centre console 11585
9 Car-Net 11586
9 1 General information 11586
9 2 Overview of fitting locations – Car-Net services 11586
9 3 Removing and installing emergency call module control unit and communication unit -J949- 11587
9 4 Renewing control unit for emergency call module and communication unit -J949- 11589
9 5 Removing and installing emergency button -E276- 11589
00 – Technical data 11597
1 Engine number 11597
2 Engine data 11598
10 – Removing and installing engine 11599
1 Removing and installing engine 11599
1 1 Removing engine 11600
1 2 Securing engine on engine and gearbox support -VAS 6095- 11607
1 3 Installing engine 11608
1 4 Specified torques for assembly mounting 11610
13 – Crankshaft group 11612
1 Dismantling and assembling engine (engine code CDVA, BLV, BWS up to 01 2011) 11612
1 1 Part I 11614
1 2 Part II 11617
1 3 Removing and installing vibration damper (engine codes BWS, CDVA) 11618
1 4 Removing and installing vibration damper (engine code BLV) 11619
1 5 Removing and installing bracket for ancillaries 11621
1 6 Assembly overview – poly V-belt drive 11621
1 7 Removing and installing poly-V belt 11623
1 8 Removing and installing tensioner for poly V-belt 11624
2 Dismantling and assembling engine (engine code CNNA, BWS from 01 2011) 11626
2 1 Part I 11627
2 2 Part II 11629
2 3 Removing and installing vibration damper 11631
2 4 Removing and installing bracket for ancillaries 11631
2 5 Assembly overview – poly V-belt drive 11632
2 6 Removing and installing poly-V belt 11633
2 7 Removing and installing tensioner for poly V-belt 11634
3 Sealing flange and flywheel or drive plate 11636
3 1 Assembly overview – sealing flanges and flywheel 11636
3 2 Assembly overview – sealing flanges and drive plate 11638
3 3 Assembly overview – timing chain covers 11639
3 4 Removing and installing crankshaft seal on gearbox side 11639
3 5 Removing and installing sealing flange on gearbox side 11641
3 6 Removing and installing flywheel 11644
3 7 Removing and installing drive plate 11645
3 8 Renewing crankshaft sealing flange -vibration damper end- (engine code BLV) 11646
3 9 Renewing crankshaft sealing flange -vibration damper end- (engine code BWS, CDVA, CNNA) 11648
4 Assembly overview – crankshaft 11651
4 1 Fitting sender wheel to crankshaft 11652
4 2 Pulling needle bearing out of and driving into crankshaft 11653
4 3 Allocation of main bearing shells 11655
4 3 1 Allocation of main bearing shells, up to and including manufacturing date 23 09 12 11655
4 3 2 Allocation of main bearing shells, from manufacturing date 24 09 12 11657
5 Pistons and conrods 11660
5 1 Assembly overview – pistons and conrods 11660
5 2 Checking pistons, piston rings and cylinder bores 11661
5 2 1 Checking piston ring gap 11661
5 2 2 Checking ring-to-groove clearance 11661
5 2 3 Checking piston 11662
5 2 4 Checking cylinder bores 11662
5 2 5 Removing and installing pistons 11663
5 3 Piston and cylinder dimensions 11665
15 – Cylinder head, valve gear 11666
1 Cylinder head 11666
1 1 Assembly overview – cylinder head 11666
1 2 Removing and installing cylinder head 11669
1 3 Checking valve timing 11677
1 3 1 Checking valve timing (vehicles up to 11/2008) 11677
1 3 2 Checking valve timing (vehicles as of 11/2008) 11680
1 4 Removing and installing camshaft adjuster 11682
1 4 1 Removing and installing camshaft adjuster (vehicles to 11/2008) 11682
1 4 2 Removing and installing camshaft adjuster (vehicles from 11/2008) 11688
1 5 Removing and installing chain drive for oil pump 11694
1 5 1 Removing and installing oil pump drive chain, 1-part sprocket 11694
1 5 2 Removing and installing oil pump drive chain, 2-part sprocket 11700
1 6 Removing and installing camshaft drive timing chain 11705
1 7 Removing and installing chain drive sprocket for high-pressure pump 11708
1 8 Removing and installing cylinder head cover 11709
1 9 Assembly overview – mechanical vacuum pump 11712
1 10 Removing and installing mechanical vacuum pump 11713
1 11 Installing cover oil seals 11715
1 12 Checking compression 11716
2 Valve gear 11719
2 1 Assembly overview – valve gear 11719
2 2 Camshafts, checking axial clearance 11721
2 3 Assembly overview – valve timing housing (engine codes CDVA, BLV, BWS up to 01 2011) 11722
2 4 Assembly overview – valve timing housing (engine codes CNNA, BWS from 01 2011) 11723
2 5 Removing and installing camshaft control valves 11724
2 6 Removing and installing camshafts 11728
2 7 Camshaft identification 11735
2 8 Renewing valve stem seals 11735
2 9 Valve dimensions 11738
2 10 Checking valve guides 11738
2 11 Reworking valve seats 11739
17 – Lubrication 11741
1 Parts of lubrication system 11741
1 1 Engine oil: 11741
1 2 Assembly overview – oil sump, oil pump and oil filter bracket (engine code CDVA, BLV, BWS up to 01 2011) 11742
1 3 Assembly overview – oil sump, oil pump and oil filter bracket (engine code CNNA, BWS from 01 2011) 11744
1 4 Removing and installing oil spray jet 11745
1 5 Removing and installing sump 11746
1 6 Removing and installing oil pump 11748
1 6 1 Removing and installing oil pump, 1-part sprocket 11748
1 6 2 Removing and installing oil pump, 2-part sprocket 11753
1 7 Assembly overview – oil filter housing (engine codes CDVA, BWS up to 01 2011) 11757
1 8 Assembly overview – oil filter housing (engine codes CNNA, BWS from 01 2011) 11759
1 9 Assembly overview – oil filter housing (engine code BLV) 11760
1 10 Checking oil pressure and oil pressure switch (engine code CDVA, BLV, BWS up to 01 2011) 11762
1 11 Checking oil pressure and oil pressure switch (engine code CNNA, BWS from 01 2011) 11764
19 – Cooling 11768
1 Parts of cooling system 11768
1 1 Assembly overview – parts of cooling system, body side 11769
1 2 Assembly overview – cooling system, engine side 11770
1 3 Coolant hose connection diagram 11772
1 4 Draining and adding coolant 11773
1 5 Removing and installing fan mounting with fans 11776
1 6 Removing and installing radiator 11778
1 7 Removing and installing coolant pump 11780
1 8 Removing and installing thermostat 11783
1 9 Checking cooling system for leaks 11785
20 – Fuel supply system 11787
1 Safety precautions and rules for cleanliness 11787
1 1 Safety measures when working on fuel supply 11787
1 2 Releasing pressure in high-pressure area 11788
1 3 Rules for cleanliness 11789
2 Fuel tank (Passat CC with front-wheel drive) 11790
2 1 Assembly overview – fuel tank 11790
2 2 Emptying fuel tank 11792
2 2 1 Emptying fuel tank when fuel pump is intact 11792
2 2 2 Emptying fuel tank if it is more than 3/4 full 11794
2 2 3 Emptying fuel tank if it is less than 3/4 full 11795
2 3 Removing and installing fuel tank 11796
2 3 1 Removing fuel tank 11797
2 3 2 Installing fuel tank 11799
2 4 Removing and installing fuel gauge sender -G- 11799
3 Fuel tank (Passat CC with four-wheel drive) 11801
3 1 Assembly overview – fuel tank (engine code BWS) 11801
3 2 Assembly overview – fuel tank (engine code BLV, CNNA) 11804
3 3 Emptying fuel tank 11805
3 3 1 Emptying fuel tank when fuel pump is intact 11806
3 3 2 Emptying fuel tank if it is more than 3/4 full 11808
3 3 3 Emptying fuel tank if it is less than 3/4 full 11808
3 4 Removing and installing fuel tank 11811
3 4 1 Removing fuel tank 11811
3 4 2 Installing fuel tank 11815
3 5 Removing and installing fuel gauge sender 2 -G169- 11816
3 6 Removing and installing suction-jet pump 11819
4 Repairing fuel supply (Passat CC) 11821
4 1 Removing and installing fuel delivery unit 11821
4 1 1 Removing fuel pump unit 11822
4 1 2 Installing fuel pump unit 11824
4 2 Removing and installing fuel gauge sender -G- 11826
4 3 Checking fuel pump 11827
4 3 1 Checking function and voltage supply 11828
4 3 2 Checking fuel pressure 11831
4 3 3 Checking holding pressure 11832
4 3 4 Checking fuel delivery rate 11833
4 3 5 Checking current consumption 11836
5 Activated charcoal filter system (Passat CC with engine code BLV, CNNA) 11838
5 1 Function 11838
5 2 Assembly overview – activated charcoal filter system 11838
5 3 Checking fuel system for leaks 11839
5 3 1 Leak detection in fuel system 11843
5 3 2 Schematic overview of activated charcoal filter system 11844
5 3 3 Checking vacuum supply of fuel system diagnostic pump -V144- 11845
6 Activated charcoal filter system (Passat CC with engine code BWS) 11847
6 1 Function 11847
6 2 Assembly overview – activated charcoal filter system 11847
6 3 Checking fuel tank breather 11848
7 Fuel tank (Eos) 11850
7 1 Assembly overview – fuel tank 11850
7 2 Emptying fuel tank 11852
7 2 1 Emptying fuel tank when fuel pump is intact 11853
7 2 2 Emptying fuel tank if it is more than 3/4 full 11854
7 2 3 Emptying fuel tank if it is less than 3/4 full 11855
7 3 Removing and installing fuel tank 11856
7 3 1 Removing 11857
7 3 2 Installing fuel tank 11858
8 Repairing fuel supply (Eos) 11860
8 1 Removing and installing fuel delivery unit 11860
8 2 Removing and installing fuel gauge sender -G- 11863
8 3 Checking fuel pump -G6- 11864
8 3 1 Checking function and voltage supply 11865
8 3 2 Checking fuel pressure 11868
8 3 3 Checking holding pressure 11870
8 3 4 Checking fuel delivery rate 11871
8 3 5 Checking current consumption 11874
9 Activated charcoal filter system (Eos) 11876
9 1 Assembly overview – activated charcoal filter system 11876
9 2 Checking fuel tank breather 11876
10 Electronic power control (EPC) 11879
10 1 Assembly overview – accelerator module 11879
10 2 Removing and installing accelerator pedal module 11879
24 – Mixture preparation – injection 11882
1 Injection system 11882
1 1 General notes on the injection system 11883
1 2 Rules for cleanliness 11883
1 3 Technical data 11883
1 4 Assembly overview – intake manifold 11884
1 5 Assembly overview – fuel rail with high-pressure pump and injectors 11885
1 6 Assembly overview – air filter 11888
1 7 Checking intake air preheating 11889
1 8 Removing and installing intake manifold upper part 11889
1 9 Removing and installing lower part of intake manifold with fuel rail 11892
1 10 Removing and installing high-pressure pump 11896
1 11 Checking fuel pressure sender -G247- 11899
1 12 Removing and installing injectors 11902
1 13 Renewing seals on injectors 11906
2 Engine control unit -J623- (Passat) 11910
2 1 Removing and installing engine (motor) control unit -J623- 11910
2 2 Removing and installing anti-theft engine control unit -J623- 11911
3 Engine control unit -J623- (Eos) 11914
3 1 Removing and installing engine control unit 11914
3 2 Removing and installing anti-theft engine control unit 11915
26 – Exhaust system 11919
1 Exhaust manifold, front exhaust pipes, catalytic converters and Lambda probes (engine codes BWS, CDVA) 11919
1 1 Assembly overview – exhaust manifold, front exhaust pipe with catalytic converters and front silencers 11921
1 2 Removing and installing exhaust manifold 11922
1 3 Removing and installing Lambda probe -G39- and Lambda probe 2 -G108- 11923
1 4 Removing and installing front exhaust pipes with catalytic converters and front silencers 11925
2 Exhaust manifolds, front exhaust pipes, catalytic converters and Lambda probes (engine code CNNA, BLV) 11928
2 1 Assembly overview – exhaust manifold, front exhaust pipe with catalytic converters and front silencers 11930
2 2 Removing and installing exhaust manifold 11931
2 3 Removing and installing Lambda probe -G39- and Lambda probe 2 -G108- 11932
2 4 Removing and installing front exhaust pipes with catalytic converters and front silencers (vehicles with four-wheel drive) 11934
2 5 Removing and installing front exhaust pipes with catalytic converters and front silencers (vehicles with front-wheel drive) 11936
3 Silencers with mountings (vehicles with four-wheel drive) 11939
3 1 Assembly overview – silencers with mountings 11939
3 1 1 Separating centre and rear silencers 11940
4 Silencers with mountings (Passat CC with front-wheel drive) 11943
4 1 Assembly overview – silencers with mountings 11943
4 1 1 Separating centre and rear silencers 11944
5 Silencer with mountings (Eos) 11946
5 1 Assembly overview – silencers with mountings 11946
5 2 Clamps 11947
5 3 Separating centre and rear silencers 11947
5 4 Aligning exhaust system free of stress 11948
28 – Ignition system 11950
1 Ignition system 11950
1 1 General notes on ignition system 11950
1 2 Assembly overview – ignition system 11950
1 3 Test data, spark plugs 11952
1 4 Removing and installing ignition coils with output stage 11952
50 – Body – front 11961
1 Lock carrier 11961
1 1 Assembly overview – lock carrier 11961
1 2 Assembly overview – air deflector elements on lock carrier 11962
1 2 1 Assembly overview – air deflector elements on lock carrier, to 01 2011 11962
1 2 2 Assembly overview – air deflector elements on lock carrier, as of 01 2011 11963
1 3 Service position 11963
1 4 Removing and installing lock carrier 11967
2 Wings 11970
2 1 Assembly overview – wing 11970
2 2 Removing and installing wing 11970
2 3 Removing and installing wing bracket 11973
3 Bulkhead 11974
3 1 Assembly overview – plenum chamber bulkhead 11974
3 2 Assembly overview – plenum chamber cover 11976
3 3 Removing and installing plenum chamber cover 11976
55 – Bonnet, rear lid 11980
1 Bonnet 11980
1 1 Assembly overview – bonnet 11980
1 2 Assembly overview – bonnet lock and release components 11982
1 3 Assembly overview – release lever and mounting bracket 11983
1 4 Removing and installing bonnet 11983
1 5 Removing and installing striker pin 11986
1 6 Adjusting bonnet 11986
1 6 1 Adjusting bonnet 11986
1 6 2 Adjusting lid lock 11987
1 6 3 Adjusting striker pin 11989
1 7 Removing and installing hinge 11989
1 8 Removing and installing insulation 11991
1 9 Removing and installing gas strut 11993
1 9 1 Removing and installing gas strut 11994
1 9 2 Releasing gas from gas strut 11994
1 10 Removing and installing bonnet lock and Bowden cable 11994
1 11 Removing and installing bonnet release lever 11998
2 Rear lid 12000
2 1 Assembly overview – rear lid 12000
2 2 Assembly overview – rear lid hinge 12001
2 3 Rear lid emergency release 12002
2 4 Removing and installing rear lid 12002
2 5 Adjusting rear lid 12004
2 5 1 Adjusting rear lid 12004
2 5 2 Adjusting adjusting buffer 12007
2 5 3 Adjusting striker pin 12008
2 6 Removing and installing hinge 12008
2 7 Removing and installing gas strut 12011
2 7 1 Removing and installing gas strut 12011
2 7 2 Releasing gas from gas strut 12013
2 8 Removing and installing operating mechanism 12013
2 9 Removing and installing rear lid lock 12015
2 9 1 Removing and installing rear lid lock 12015
2 9 2 Removing and installing striker pin 12017
2 9 3 Removing and installing stop buffer 12019
2 10 Removing and installing seal 12020
3 Tank flap unit 12022
3 1 Assembly overview – tank flap unit 12022
3 2 Removing and installing tank flap unit 12022
3 3 Removing and installing actuator 12024
57 – Front doors, door components, central locking 12026
1 Door 12026
1 1 Assembly overview – door hinges 12026
1 2 Removing and installing door 12027
1 3 Adjusting door 12029
1 4 Adjusting striker pin 12031
2 Components 12033
2 1 Assembly overview – components 12033
2 2 Assembly overview – insulation 12034
2 3 Assembly overview – door handle and door lock 12035
2 4 Removing and installing components 12036
2 4 1 Removing and installing subframe 12036
2 4 2 Removing and installing striker pin 12038
2 5 Removing and installing door handle 12039
2 5 1 Removing and installing 12039
2 5 2 Removing and installing lock cylinder cover cap 12042
2 5 3 Removing and installing lock cylinder 12043
2 5 4 Removing and installing mounting bracket 12045
2 5 5 Removing and installing retaining bracket 12047
2 6 Removing and installing door lock 12049
2 7 Removing and installing door seal 12052
2 7 1 Removing and installing inner door seal 12052
2 7 2 Removing and installing outer door seal 12054
3 Central locking 12059
3 1 Overview of fitting locations – central locking 12059
3 2 Assembly overview – ignition key battery 12061
3 3 Removing and installing ignition key battery 12061
58 – Rear doors, door components 12063
1 Door 12063
1 1 Assembly overview – door hinges 12063
1 2 Removing and installing door 12064
1 3 Adjusting door 12066
1 4 Adjusting striker pin 12068
2 Components 12071
2 1 Assembly overview – door components 12071
2 1 1 Assembly overview – rear door 12071
2 1 2 Assembly overview – insulation 12073
2 2 Assembly overview – door handle and door lock 12074
2 3 Removing and installing door components 12075
2 3 1 Removing and installing subframe 12075
2 3 2 Removing and installing striker pin 12077
2 4 Removing and installing door handle 12079
2 4 1 Removing and installing door handle 12080
2 4 2 Removing and installing cap 12082
2 4 3 Removing and installing lock cylinder housing 12082
2 4 4 Removing and installing mounting bracket 12084
2 4 5 Removing and installing retaining bracket 12087
2 5 Removing and installing door lock 12089
2 6 Removing and installing door seal 12092
2 6 1 Removing and installing inner door seal 12092
2 6 2 Removing and installing outer door seal 12094
60 – Sunroof 12099
1 Sliding sunroof 12099
1 1 Function 12099
1 2 Assembly overview – sliding sunroof 12099
1 3 Assembly overview – roller sun blind 12102
1 4 Assembly overview – seals 12103
1 5 Removing and installing sliding/tilting sunroof glass panel 12103
1 6 Removing and installing carrier unit 12105
1 7 Removing and installing sliding/tilting sunroof automatic preselector 12114
1 8 Adjusting glass panel 12114
1 8 1 Height-adjustment of glass panel 12114
1 8 2 Setting drive for sliding/tilting sunroof to zero position 12116
1 9 Removing and installing guide plate 12116
1 10 Removing and installing cable 12117
1 11 Removing and installing swivel mounting 12119
1 12 Removing and installing drive for panorama tilting sunroof glass panel 12120
1 12 1 Operating without current 12121
1 13 Removing and installing sliding headliner 12122
1 13 1 Removing and installing guide rails 12124
1 14 Removing and installing panel seal 12125
1 14 1 Removing and installing panel seals and retaining strip on glass panel 12125
1 14 2 Removing and installing seals on assembly frame 12126
63 – Bumpers 12127
1 Bumper, front 12127
1 1 Assembly overview – front bumper 12127
1 1 1 Assembly overview – front bumper, ► 01 2011 12127
1 1 2 Assembly overview – front bumper, 01 2011 ► 12128
1 1 3 Assembly overview – add-on parts, ► 01 2011 12130
1 1 4 Assembly overview – attachments 01 2011 ► 12130
1 1 5 Assembly overview – front bumper carrier, ► 01 2011 12132
1 1 6 Assembly overview – front bumper carrier, 01 2011 ► 12133
1 2 Removing and installing front bumper 12133
1 2 1 Removing and installing front bumper, ► 01 2011 12134
1 2 2 Removing and installing front bumper, 01 2011 ► 12136
1 3 Repairing bumper cover 12138
1 4 Installing bracket for parking aid system – vehicles ► 01 2011 12138
1 4 1 Tools 12138
1 4 2 Materials 12138
1 4 3 Installing brackets 12139
1 4 4 Minimum curing period 12141
1 5 Installing bracket for parking aid system – vehicles 01 2011 ► 12142
1 5 1 Tools 12142
1 5 2 Materials 12142
1 5 3 Installing brackets 12143
1 5 4 Minimum curing period 12146
2 Bumper, rear 12147
2 1 Assembly overview – rear bumper 12147
2 1 1 Assembly overview – rear bumper cover 12147
2 1 2 Assembly overview – add-on parts 12148
2 1 3 Assembly overview – guides for rear bumper cover, ► 01 2011 12150
2 1 4 Assembly overview – guides for rear bumper cover, 01 2011 ► 12151
2 1 5 Assembly overview – rear bumper cover bracket, vehicles with SCR system 12151
2 1 6 Assembly overview – rear bumper carrier, ► 01 2011 12153
2 1 7 Assembly overview – rear bumper carrier, 01 2011 ► 12154
2 2 Removing and installing rear bumper 12154
2 3 Repairing bumper cover 12156
2 4 Installing bracket for parking aid system – vehicles ► 01 2011 12156
2 4 1 Tools 12156
2 4 2 Materials 12157
2 4 3 Installing brackets 12157
2 4 4 Minimum curing period 12160
2 5 Installing bracket for parking aid system – vehicles 01 2011 ► 12161
2 5 1 Tools 12161
2 5 2 Materials 12161
2 5 3 Installing brackets 12162
2 5 4 Minimum curing period 12165
64 – Glazing 12166
1 Repair instructions 12166
1 1 Minimum curing periods for bonded windows 12166
1 2 Window repair 12167
1 3 Installation instructions for bonded windows 12167
1 3 1 Installation instructions for all windows 12167
1 3 2 Installation instructions for windscreen 12167
1 3 3 Installation instructions for rear window 12169
1 3 4 Materials 12170
1 4 Preparing old undamaged windows for glazing 12170
1 5 Preparing new windows for glazing 12171
1 6 Preparing body flange for glazing 12172
2 Windscreen 12174
2 1 Assembly overview – windscreen 12174
2 2 Removing and installing windscreen 12175
2 2 1 Removing and installing undamaged windscreen 12176
2 2 2 Removing broken windscreen 12179
3 Rear windscreen 12181
3 1 Assembly overview – rear window 12181
3 2 Removing and installing rear window 12181
3 2 1 Removing and installing undamaged rear window 12183
3 2 2 Removing broken rear window 12185
4 Door windows 12186
4 1 Assembly overview – front door window 12186
4 2 Assembly overview – rear door window 12187
4 3 Removing and installing front door window 12187
4 4 Removing and installing rear door window 12190
4 5 Removing and installing fixed rear door window 12192
4 6 Adjusting front door window 12194
4 6 1 Notes for adjustment 12195
4 6 2 Basic height adjustment 12196
4 6 3 Adjusting longitudinally 12198
4 6 4 Checking height, adjusting if necessary 12199
4 6 5 Adjusting inclination 12200
4 7 Adjusting rear door window 12201
4 7 1 Notes for adjustment 12202
4 7 2 Basic height adjustment 12202
4 7 3 Adjusting longitudinally 12204
4 7 4 Checking height, adjusting if necessary 12205
4 7 5 Adjusting inclination 12206
4 8 Adjusting fixed rear door window 12207
5 Window regulator 12209
5 1 Removing and installing front window regulator 12209
5 2 Removing and installing front window regulator motor 12213
5 3 Removing and installing rear window regulator 12213
5 4 Removing and installing rear window regulator motor 12217
6 Window channels and seals 12219
6 1 Removing and installing front window slot seal 12219
6 2 Removing and installing rear window slot strip 12220
66 – Exterior equipment 12222
1 Radiator grille and front trim 12222
1 1 Removing and installing radiator grille up to 01 2011 12222
1 2 Removing and installing radiator grille on vehicles from 01 2011 12223
2 Spoiler 12226
2 1 Assembly overview – spoiler 12226
2 1 1 Removing and installing spoiler 12226
3 Mouldings, trims, extensions 12232
3 1 Assembly overview – protective side strips on front and rear door 12232
3 2 Assembly overview – side member trim 12233
3 3 Assembly overview – trim on rear lid 12235
3 4 Assembly overview – wheel arch trims 12235
3 4 1 Assembly overview – wheel arch trims, vehicles to 01 2011 12236
3 4 2 Assembly overview – wheel arch trims, vehicles as of 01 2011 12237
3 5 Removing and installing edge moulding 12237
3 6 Removing and installing B-pillar trim 12239
3 6 1 Removing and installing bracket for B-pillar trim 12242
3 7 Removing and installing number plate carrier 12243
3 8 Removing and installing entry moulding 12245
3 9 Removing and installing protective side strip 12246
3 10 Removing and installing rear lid trim 12249
4 Noise insulation 12253
4 1 Assembly overview – short noise insulation 12253
4 2 Assembly overview – long noise insulation 12254
5 Underbody cover 12255
5 1 Assembly overview – underbody cladding 12255
5 2 Assembly overview – tunnel cross-piece 12255
6 Exterior mirror 12257
6 1 Assembly overview – exterior mirror 12257
6 2 Removing and installing mirror glass 12257
6 3 Removing and installing mirror cover 12260
6 3 1 Removing and installing mirror cover 12260
6 3 2 Removing and installing trim 12262
6 3 3 Removing and installing assembly bracket 12263
6 4 Removing and installing exterior mirror 12264
7 Wheel housing liner 12266
7 1 Assembly overview – front wheel housing liner 12266
7 2 Assembly overview – rear wheel housing liner 12267
7 3 Removing and installing front wheel housing liner 12267
7 4 Removing and installing rear wheel housing liner 12269
8 Lettering and emblems 12271
8 1 Dimensions for lettering 12271
8 1 1 Dimensions, lettering on rear 12272
8 1 2 Dimensions, wing lettering, »R Line« 12273
8 1 3 Dimensions, wing lettering, »Exclusive« 12274
8 2 Removing and installing emblems 12276
8 2 1 Removing and installing front emblem, to 01 2011 12276
8 2 2 Removing and installing front emblem, as of 01 2011 12276
8 2 3 Removing and installing emblem with decorative frame on vehicles with adaptive cruise control 12278
8 2 4 Removing and installing »R-Line« emblem in radiator grille 12278
9 Special add-on parts 12280
9 1 Assembly overview – special add-on parts 12280
10 Towing bracket 12281
10 1 Assembly overview – towing bracket 12281
10 1 1 Assembly overview – towing bracket with removable ball head 12281
10 1 2 Assembly overview – towing bracket with swivel-mounted ball head 12282
00 – Technical data 12289
1 Evaluating accident vehicles 12289
1 1 Check list for evaluating running gear on accident vehicles 12289
2 General information 12291
2 1 Tyre types 12291
3 Repair instructions 12292
3 1 Raising suspension to unladen position (vehicles with coil springs) 12292
3 1 1 Raising wheel bearing assembly to unladen position (vehicles with coil springs), front axle 12292
3 1 2 Raising wheel bearing to unladen position on vehicles with coil springs, rear axle, front-wheel drive 12294
3 1 3 Raising wheel bearing to unladen position on vehicles with coil springs, rear axle, four-wheel drive 12296
3 2 General information 12299
3 2 1 General information – lane departure warning 12299
3 3 General repair instructions 12300
3 4 Steering rack 12300
3 5 Gaskets and seals 12301
3 6 Nuts and bolts 12301
3 7 Electrical components 12301
3 8 Repairing damaged threads in longitudinal member (subframe to body) 12301
40 – Front suspension 12302
1 Front axle 12302
1 1 Overview – front axle 12302
2 Subframe 12303
2 1 Assembly overview – subframe 12303
2 2 Fixing position of subframe 12306
2 3 Lowering subframe 12308
2 4 Removing and installing subframe without steering rack 12312
2 5 Removing and installing subframe with steering rack 12316
2 6 Repairing subframe 12321
2 7 Removing and installing anti-roll bar 12329
3 Suspension strut, upper suspension link 12335
3 1 Assembly overview – suspension strut, upper suspension link 12335
3 1 1 Assembly overview – suspension strut, upper suspension link 12335
3 1 2 Assembly overview – suspension strut, upper suspension link, suspension strut for adaptive chassis control DCC 12337
3 2 Removing and installing suspension strut 12339
3 2 1 Removing and installing suspension strut 12339
3 2 2 Removing and installing suspension strut – suspension strut for adaptive chassis control DCC 12345
3 3 Repairing suspension strut 12353
4 Lower suspension link, swivel joint 12356
4 1 Checking swivel joint 12356
4 2 Removing and installing swivel joint 12356
4 3 Removing and installing lower suspension link 12360
4 3 1 Removing and installing lower suspension link 12360
4 3 2 Removing and installing lower suspension link, left side, for vehicles with automatic or dual clutch gearbox 12363
4 4 Renewing bonded rubber bush for lower suspension link 12368
4 5 Renewing mounting bracket with suspension link bush 12370
5 Wheel bearing 12373
5 1 Assembly overview – wheel bearing 12373
5 2 Removing and installing wheel bearing unit 12375
5 3 Removing and installing wheel bearing housing 12377
6 Drive shaft 12383
6 1 Overview – drive shaft 12383
6 2 Heat shields for drive shafts 12384
6 3 Assembly overview – drive shaft 12385
6 3 1 Assembly overview – drive shaft, constant velocity joint VL100 12385
6 3 2 Assembly overview – drive shaft, constant velocity joint VL107 12387
6 3 3 Assembly overview – drive shaft, triple roller joint AAR2600i 12389
6 3 4 Assembly overview – drive shaft, triple roller joint AAR3300i (pushed into gearbox or bolted onto flange shaft) 12391
6 3 5 Assembly overview – drive shaft, triple roller joint AAR3300i (pushed onto stub shaft) 12393
6 4 Loosening and tightening drive shaft threaded connection on wheel hub 12394
6 4 1 Loosening and tightening twelve-point head bolt, with ribbing, securing drive shaft 12394
6 4 2 Loosening and tightening twelve-point head bolt, without ribbing, securing drive shaft 12396
6 5 Removing and installing drive shaft 12398
6 5 1 Removing and installing drive shaft, constant velocity joint 12398
6 5 2 Removing and installing drive shafts, triple roller joint AAR3300i (bolted on) 12401
6 5 3 Removing and installing drive shafts, triple roller joint AAR2600i and AAR3300i (pushed into gearbox) 12405
6 5 4 Removing and installing drive shafts, triple roller joint AAR3300i (pushed onto gearbox stub shaft) 12409
6 6 Dismantling and assembling drive shaft 12415
6 6 1 Dismantling and assembling drive shaft, constant velocity joint VL100 12415
6 6 2 Dismantling and assembling drive shaft, constant velocity joint VL107 12420
6 6 3 Dismantling and assembling drive shaft, triple roller joint AAR2600i 12425
6 6 4 Dismantling and assembling drive shaft, triple roller joint AAR3300i (pushed into gearbox or bolted onto flange shaft) 12429
6 6 5 Dismantling and assembling drive shaft, triple roller joint AAR3300i (pushed onto stub shaft) 12434
6 7 Checking outer constant velocity joint 12439
6 8 Checking inner constant velocity joint 12440
42 – Rear suspension 12442
1 Rear axle 12442
1 1 Overview – rear axle 12442
1 1 1 Overview – rear axle, front-wheel drive 12442
1 1 2 Overview – rear axle, four-wheel drive 12445
1 2 Removing and installing rear axle 12446
1 2 1 Removing and installing rear axle, front-wheel drive 12446
1 2 2 Removing and installing rear axle, four-wheel drive 12450
2 Subframe 12455
2 1 Assembly overview – subframe 12455
2 1 1 Assembly overview – subframe, front-wheel drive 12455
2 1 2 Assembly overview – subframe, four-wheel drive 12456
2 2 Repairing subframe 12457
2 2 1 Repairing subframe, front-wheel drive 12457
2 2 2 Repairing subframe, all-wheel drive, up to week 21/2012 12461
2 2 3 Repairing subframe, all-wheel drive, from week 22/2012 12469
3 Suspension link, track rod 12483
3 1 Assembly overview – transverse link 12483
3 1 1 Assembly overview – transverse link, front-wheel drive 12483
3 1 2 Assembly overview – transverse link, four-wheel drive 12486
3 2 Removing and installing upper transverse link 12488
3 2 1 Removing and installing upper transverse link, front-wheel drive 12488
3 2 2 Removing and installing upper transverse link, four-wheel drive 12490
3 3 Removing and installing lower transverse link 12491
3 3 1 Removing and installing lower transverse link, front-wheel drive 12491
3 3 2 Removing and installing lower transverse link, four-wheel drive 12493
3 4 Removing and installing track rod 12495
3 4 1 Removing and installing track rod, front-wheel drive 12495
3 4 2 Removing and installing track rod, four-wheel drive 12498
3 4 3 Allocation of track rods to trailing arms, front- and four-wheel drive 12500
4 Wheel bearing housing, wheel bearing unit, trailing arm 12503
4 1 Assembly overview – wheel bearing housing, wheel bearing unit 12503
4 1 1 Assembly overview – wheel bearing housing, wheel bearing unit, front-wheel drive 12503
4 1 2 Assembly overview – wheel bearing housing, wheel bearing unit, four-wheel drive 12506
4 2 Removing and installing wheel bearing housing 12508
4 2 1 Removing and installing wheel bearing housing, front-wheel drive 12508
4 2 2 Removing and installing wheel bearing housing, four-wheel drive 12511
4 3 Renewing bonded rubber bush for wheel bearing housing 12515
4 3 1 Renewing bonded rubber bush for wheel bearing housing, front-wheel drive 12515
4 3 2 Renewing bonded rubber bush for wheel bearing housing, four-wheel drive 12518
4 4 Removing and installing wheel bearing unit 12521
4 4 1 Removing and installing wheel bearing unit, front-wheel drive 12521
4 4 2 Removing and installing wheel bearing unit, all wheel drive 12524
4 5 Removing and installing trailing arm with mounting bracket 12526
4 5 1 Removing and installing trailing arm with mounting bracket, front-wheel drive 12526
4 5 2 Removing and installing trailing arm with mounting bracket, four-wheel drive 12529
4 6 Repairing trailing arm 12533
4 6 1 Repairing trailing arm, front-wheel drive 12533
4 6 2 Repairing trailing arm, four-wheel drive 12535
5 Suspension strut, shock absorber, spring 12538
5 1 Assembly overview – suspension strut, shock absorber, spring 12538
5 1 1 Assembly overview – suspension strut, shock absorber, spring, front-wheel drive 12538
5 1 2 Assembly overview – suspension strut, shock absorber, spring, adaptive chassis control DCC, front-wheel drive 12540
5 1 3 Assembly overview – suspension strut, shock absorber, spring, four-wheel drive 12541
5 1 4 Assembly overview – suspension strut, shock absorber, spring, adaptive chassis control DCC, four-wheel drive 12542
5 2 Removing and installing spring 12543
5 2 1 Removing and installing spring, front-wheel drive 12543
5 2 2 Removing and installing spring, four-wheel drive 12544
5 3 Removing and installing shock absorbers 12546
5 3 1 Removing and installing shock absorbers, front-wheel drive 12546
5 3 2 Removing and installing shock absorbers, shock absorber for adaptive chassis control DCC, front-wheel drive 12548
5 3 3 Removing and installing shock absorbers, all wheel drive 12550
5 3 4 Removing and installing shock absorbers, shock absorber for adaptive chassis control DCC, four-wheel drive 12552
5 4 Repairing shock absorber 12555
5 4 1 Repairing shock absorbers, front-wheel drive 12555
5 4 2 Repairing shock absorbers, shock absorber for adaptive chassis control DCC, front-wheel drive 12557
5 4 3 Repairing shock absorbers, four-wheel drive 12558
5 4 4 Repairing shock absorbers, shock absorber for adaptive chassis control DCC, four-wheel drive 12560
6 Anti-roll bar 12563
6 1 Assembly overview – anti-roll bar 12563
6 1 1 Assembly overview – anti-roll bar, front-wheel drive 12563
6 1 2 Assembly overview – anti-roll bar, four-wheel drive 12564
6 2 Removing and installing anti-roll bar 12564
6 2 1 Removing and installing anti-roll bar, front-wheel drive 12564
6 2 2 Removing and installing anti-roll bar, four-wheel drive 12566
7 Drive shaft 12569
7 1 Assembly overview – drive shaft 12569
7 2 Loosening and tightening drive shaft threaded connection on wheel hub 12571
7 2 1 Loosening and tightening drive shaft threaded connection on wheel hub, twelve-point head bolt with ribbing 12571
7 2 2 Loosening and tightening drive shaft threaded connection on wheel hub, twelve-point head bolt without ribbing 12572
7 3 Removing and installing drive shaft 12574
7 4 Dismantling and assembling drive shaft 12578
7 5 Checking outer constant velocity joint 12582
7 6 Checking inner constant velocity joint 12583
43 – Self-levelling suspension 12585
1 Electronically controlled damping system 12585
1 1 Assembly overview – electronically controlled damping system 12585
1 1 1 Assembly overview – electronically controlled damping system 12585
1 1 2 Shock absorber damping adjustment button 12587
1 1 3 Cable routing left front axle 12588
1 1 4 Cable routing right front axle 12589
1 1 5 Cable routing rear axle 12590
1 2 Removing and installing electronically controlled damping control unit 12590
1 3 Re-adapting reference position (default position) 12591
1 4 Removing and installing front body acceleration senders 12591
1 4 1 Removing and installing front body acceleration senders – front left body acceleration sender 12591
1 4 2 Removing and installing front body acceleration senders – front right body acceleration sender 12592
1 4 3 Renewing bracket for front body acceleration sender 12593
1 5 Removing and installing rear body acceleration sender 12595
1 5 1 Removing and installing rear body acceleration sender, front-wheel drive 12595
1 5 2 Removing and installing rear body acceleration sender, four-wheel drive 12596
2 Vehicle level sender 12598
2 1 Assembly overview – front vehicle level senders 12598
2 1 1 Assembly overview – front vehicle level senders 12598
2 1 2 Assembly overview – front vehicle level senders, adaptive chassis control DCC 12600
2 2 Removing and installing front vehicle level senders 12601
2 2 1 Removing and installing front vehicle level senders 12601
2 2 2 Removing and installing front vehicle level senders, adaptive chassis control DCC 12602
2 3 Assembly overview – rear vehicle level senders 12604
2 3 1 Assembly overview – rear vehicle level sender, front-wheel drive 12604
2 3 2 Assembly overview – rear vehicle level senders, adaptive chassis control DCC, front-wheel drive 12606
2 3 3 Assembly overview – rear vehicle level senders, four-wheel drive 12607
2 3 4 Assembly overview – rear vehicle level senders, adaptive chassis control DCC, four-wheel drive 12608
2 4 Removing and installing rear vehicle level senders 12609
2 4 1 Removing and installing rear vehicle level senders, front-wheel drive 12609
2 4 2 Removing and installing rear vehicle level senders, adaptive chassis control DCC, front-wheel drive 12610
2 4 3 Removing and installing rear vehicle level senders, four-wheel drive 12610
2 4 4 Removing and installing rear vehicle level senders, adaptive chassis control DCC, four-wheel drive 12611
44 – Wheels, tyres, vehicle geometry 12612
1 Wheels, tyres 12612
1 1 Specified torques for wheel bolts 12612
1 2 Tyres with run-flat properties 12612
1 2 1 Self-sealing tyres 12612
1 3 Wheel change 12614
1 3 1 Notes on wheel change 12614
1 3 2 Wheel change, protecting wheel centring seat against corrosion 12615
1 3 3 Wheel change, installation instructions for wheel change 12616
1 3 4 Wheel change, wheel installation 12617
1 3 5 Wheel change, position of anti-theft wheel bolts for steel wheels 12617
1 4 Models with breakdown set 12618
1 5 Tyre sealant 12618
1 6 Pressing tyre off wheel rim 12618
1 7 Removing tyre from wheel 12619
1 8 Tyre sealant disposal 12620
1 9 Mounting tyre 12620
1 9 1 Installing tyre, installation requirements 12620
1 9 2 Installing tyre, inserting tyre valve 12621
2 Tyre Pressure Monitoring System 12622
2 1 Components overview – tyre pressure monitoring system 12622
2 1 1 Components overview – tyre pressure monitoring system, tyre pressure monitoring system (TPMS) with autolocation 12622
2 2 System description – Tyre Pressure Monitoring System 12623
2 2 1 System description – tyre pressure monitoring system, tyre pressure monitor display 12623
2 2 2 System description – tyre pressure monitoring system, tyre pressure monitor (TPM) 12625
2 2 3 System description – Tyre Pressure Monitoring System, Tyre Pressure Monitoring System (TPMS) with autolocation 12626
2 3 Removing and installing tyre pressure monitor control unit 12627
2 3 1 Removing and installing tyre pressure monitor control unit, tyre pressure monitoring system (TPMS) with autolocation 12627
2 3 2 Removing and installing tyre pressure monitor control unit, removing and installing bracket for tyre pressure monitor control unit 12627
2 4 Assembly overview – tyre pressure sensor 12628
2 4 1 Assembly overview – tyre pressure sensor, tyre pressure sensor with rubber valve 12628
2 4 2 Assembly overview – tyre pressure sensor, tyre pressure sensor with metal valve, version 1 12630
2 4 3 Assembly overview – tyre pressure sensor, tyre pressure sensor with metal valve, version 2 12631
2 5 Removing and installing tyre pressure sensor 12632
2 5 1 Removing and installing tyre pressure sensor, tyre pressure sensor with rubber valve 12632
2 5 2 Removing and installing tyre pressure sensor, tyre pressure sensor with metal valve, version 1 (customer service version) 12633
2 5 3 Removing and installing tyre pressure sensor, tyre pressure sensor with metal valve, version 1 (production version) 12634
2 5 4 Removing and installing tyre pressure sensor, tyre pressure sensor with metal valve, version 2 12636
2 6 Changing tyres on vehicles with tyre pressure monitoring system 12638
2 6 1 Notes and conditions for changing tyres on vehicles with tyre pressure monitoring system 12638
2 6 2 Changing tyres on vehicles with tyre pressure monitoring system, wheel change 12639
2 6 3 Changing tyres on vehicles with tyre pressure monitoring system, pressing tyre off wheel rim 12640
2 6 4 Changing tyres on vehicles with tyre pressure monitoring system, removing tyre from wheel rim 12640
2 6 5 Changing tyres on vehicles with tyre pressure monitoring system, fitting tyre to wheel rim 12641
2 7 Removing and installing metal valve body 12642
3 Wheel alignment 12644
3 1 Notes for wheel alignment 12644
3 2 Necessity of wheel alignment 12644
3 3 Conditions for testing 12645
3 4 Test preparations 12646
3 5 Specifications for wheel alignment 12647
3 6 Overview – wheel alignment procedure 12648
3 7 Adjusting camber at front wheels 12649
3 8 Adjusting camber on rear axle 12651
3 9 Adjusting toe at rear axle 12652
3 10 Adjusting front axle toe 12653
3 11 Steering angle sender – basic setting 12654
3 12 Vehicle data sticker 12654
4 Adaptive Cruise Control (ACC) 12655
4 1 Calibrating ACC 12655
4 1 1 Calibrating ACC, calibrating ACC during vehicle alignment 12655
4 1 2 Calibrating ACC, calibrating ACC without prior vehicle alignment 12658
5 Lane departure warning 12661
5 1 Calibrating lane departure warning 12661
6 Vibration due to wheels/tyres – causes and rectification 12668
6 1 Causes of rough running 12668
6 2 Conducting a road test before balancing wheels 12668
6 3 Balancing wheel 12669
6 3 1 Balancing wheel, conditions 12669
6 3 2 Balancing wheel, balancing wheel on stationary wheel balancer 12669
6 3 3 Balancing wheel, balancing wheel with finish balancer 12672
6 4 Vibration control system 12673
6 5 Checking radial and lateral runout of wheels and tyres 12673
6 5 1 Checking radial and lateral runout of wheels and tyres 12673
6 5 2 Checking radial and lateral runout on wheels and tyres with tyre gauge 12674
6 6 Checking radial and lateral run-out on wheel rim 12674
6 7 Matching wheels and tyres 12675
6 8 Determining flat spots on tyres 12676
48 – Steering 12678
1 Steering wheel 12678
1 1 Removing and installing steering wheel 12678
2 Steering column 12681
2 1 Assembly overview – steering column 12681
2 2 Removing and installing steering column 12682
2 2 1 Removing and installing steering column, removing and installing steering column 12682
2 2 2 Removing and installing steering column, removing and installing mounting bracket 12690
2 3 Handling and transporting steering column 12691
2 4 Checking steering column for damage 12692
2 5 Removing and installing ESL control unit 12693
3 Steering rack 12695
3 1 Assembly overview – steering rack 12695
3 1 1 Assembly overview – steering rack, left-hand drive 12695
3 1 2 Assembly overview – steering rack, right-hand drive 12697
3 2 Removing and installing steering rack 12698
3 2 1 Removing and installing steering rack, left-hand drive vehicle 12698
3 2 2 Removing and installing steering rack, RLD vehicle 12707
3 3 Repairing steering rack 12716
3 3 1 Repairing steering rack, left-hand drive 12716
3 3 2 Repairing steering rack, right-hand drive 12718
3 3 3 Repairing steering rack, renewing bonded rubber bush for steering rack 12718
3 4 Removing and installing track rod 12721
3 5 Removing and installing track rod ball joint 12724
3 6 Removing and installing bellows 12725
00 – Technical data 12733
1 Identification 12733
1 1 Allocation of PR number – brakes 12733
1 1 1 Front brakes 12733
1 1 2 Rear brakes 12733
2 Technical data 12735
2 1 Technical data for brakes 12735
2 1 1 Brake master cylinder and brake servo 12735
3 Brake test 12737
3 1 General information 12737
3 2 Checking vehicles with front-wheel drive 12737
3 3 Checking vehicles with four-wheel drive 12737
3 3 1 On a regulated roller dynamometer with contra-rotating rollers for four-wheel drive vehicles 12737
3 3 2 Without roller dynamometer for four-wheel drive vehicles 12738
3 4 Checking parking brake 12738
3 4 1 Checking vehicles with front-wheel drive: 12738
3 4 2 Checking vehicles with four-wheel drive: 12739
45 – Anti-lock brake system 12740
1 General information 12740
1 1 Repair instructions for repair work on ABS 12740
1 2 Vehicle diagnosis, testing and information system 12741
2 Fitting location overview 12743
3 Control unit and hydraulic unit 12745
3 1 Assembly overview 12745
3 2 Removing and installing control unit and hydraulic unit 12746
3 3 Connecting brake lines to hydraulic unit 12749
4 Sensors 12751
4 1 Assembly overview – speed sensor on front axle 12751
4 2 Removing and installing speed sensor on front axle 12752
4 3 Assembly overview – speed sensor on rear axle 12752
4 3 1 Assembly overview – front-wheel drive 12752
4 3 2 Assembly overview – four-wheel drive 12754
4 4 Removing and installing speed sensor on rear axle 12754
4 4 1 Front-wheel drive 12754
4 4 2 Four-wheel drive 12755
4 5 Removing and installing ESP sensor unit 12755
4 6 Removing and installing steering angle sender 12756
4 7 Removing and installing brake servo vacuum sender 12756
46 – Brakes – mechanism 12758
1 Front brakes 12758
1 1 Assembly overview – front brakes 12758
1 1 1 Assembly overview – front brakes FN 3 12758
1 1 2 Assembly overview – front brakes FNR-G 12760
1 1 3 Assembly overview- front brakes C60 12761
1 2 Removing and installing brake pads/linings 12763
1 2 1 Removing and installing brake pads, front brakes FN 3 12763
1 2 2 Removing and installing brake pads, front brakes FNR-G 12765
1 2 3 Removing and installing brake pads, front brakes C60 12768
1 3 Removing and installing brake caliper 12771
1 3 1 Removing and installing brake caliper FN3 12771
1 3 2 Removing and installing brake caliper FNR-G 12773
1 3 3 Removing and installing brake caliper C60 12774
2 Rear brakes 12777
2 1 Assembly overview – rear brakes 12777
2 2 Removing and installing brake pads/linings 12778
2 3 Removing and installing brake caliper 12781
3 Parking brake 12784
3 1 Fitting location overview – parking brake 12784
3 2 Removing and installing control unit 12785
3 3 Removing and installing parking brake motor 12785
4 Brake pedal 12788
4 1 Assembly overview – brake pedal 12788
4 2 Separating brake pedal from brake servo 12788
4 3 Connecting brake pedal to brake servo 12789
47 – Brakes – hydraulics 12790
1 Front brake calipers 12790
1 1 Assembly overview – front brake caliper 12790
1 1 1 Assembly overview – brake caliper FN3 12790
1 1 2 Assembly overview – brake caliper FNR-G 12791
1 1 3 Assembly overview – brake caliper C60 12792
1 2 Removing and installing brake caliper piston 12792
1 2 1 Removing and installing piston for brake caliper FN 3 12793
1 2 2 Removing and installing piston for FNR-G brake caliper 12795
1 2 3 Removing and installing piston for brake caliper C 60 12797
2 Rear brake calipers 12800
2 1 Assembly overview – rear brake caliper 12800
2 2 Removing and installing rear brake caliper piston 12801
2 2 1 Pre-bleeding brake caliper 12803
3 Brake servo and brake master cylinder 12804
3 1 Assembly overview – brake servo/brake master cylinder 12804
3 2 Removing and installing brake light switch 12805
3 3 Removing and installing brake master cylinder 12806
3 4 Removing and installing brake servo 12807
4 Vacuum system 12812
4 1 Assembly overview – vacuum pump 12812
4 1 1 Vacuum pump for brake servo (vehicles with diesel engine) 12812
4 1 2 Vacuum pump for brake servo (vehicles with petrol engine) 12813
4 2 Checking non-return valve 12813
4 3 Removing and installing brake servo pressure sensor 12813
4 4 Checking brake servo vacuum system 12814
4 4 1 Connecting vacuum gauge for brake servo -VAS 6721- 12814
4 4 2 Checking vacuum generation 12815
4 4 3 Checking for leaks 12816
5 Brake lines 12819
5 1 Repairing brake lines 12819
5 1 1 Assembly overview – flanging tool 12821
5 1 2 Work instructions 12821
6 Hydraulic system 12824
6 1 General notes on brake fluid 12824
6 1 1 Changing brake fluid 12824
6 2 Pre-bleeding hydraulic system 12824
6 3 Bleeding hydraulic system following standard procedure 12826
6 4 Subsequent bleeding of hydraulic system 12827
6 5 Testing for leaks 12827
6 5 1 Test prerequisites: 12827
00 – Technical data 12835
1 Vehicle identification data 12835
1 1 Vehicle identification number 12835
1 2 Type plate 12835
1 3 Vehicle data sticker 12836
2 Safety information 12837
3 Moulded foam inserts 12838
4 Galvanised body parts 12839
4 1 Vehicle body 12839
4 2 High- and higher-strength body panels 12840
4 3 Hot-formed body panels 12840
5 Laser welding 12842
6 Body panel gaps/shut lines 12843
6 1 Body, front 12843
6 2 Body, centre 12843
6 3 Body, rear 12844
7 Body dimensions 12845
7 1 Body, front 12845
7 2 Body, centre 12849
7 3 Body, rear 12857
7 4 Floor panel, front 12859
7 5 Floor panel, centre 12861
7 6 Floor panel, rear 12862
8 Alignment bracket set 12864
8 1 Overview 12864
9 Portal gauge 12865
9 1 Overview 12865
9 1 1 Front door aperture 12865
9 1 2 Rear door aperture 12866
50 – Body – front 12867
1 Renewing right bracket 12867
1 1 Tools 12867
1 2 Removing 12867
1 3 Installing 12869
1 3 1 Welding in 12869
2 Renewing left bracket 12871
2 1 Tools 12871
2 2 Removing 12871
2 3 Installing 12874
2 3 1 Preparing new part 12874
2 3 2 Welding in 12874
3 Renewing retaining bracket (for subframe) 12876
3 1 Tools 12876
3 2 Removing 12876
3 3 Installing 12878
3 3 1 Preparing new part 12878
3 3 2 Welding in 12879
4 Renewing bumper bracket 12880
4 1 Tools 12881
4 2 Removing 12881
4 3 Installing 12882
4 3 1 Welding in 12882
5 Renewing upper wheel housing longitudinal member 12884
5 1 Tools 12885
5 2 Removing 12885
5 3 Installing 12887
5 3 1 Preparing new part 12888
5 3 2 Welding in 12888
6 Renewing front wheel housing 12891
6 1 Tools 12892
6 2 Removing 12892
6 3 Installing 12894
6 3 1 Preparing new parts 12894
6 3 2 Welding in 12897
7 Renewing front longitudinal member 12903
7 1 Tools 12904
7 2 Removing 12904
7 3 Installing 12907
7 3 1 Preparing new part 12907
7 3 2 Welding in 12908
7 3 3 Shortening new longitudinal member with cover plate 12910
8 Renewing front longitudinal member – part section 12914
8 1 Tools 12915
8 2 Removing 12915
8 3 Installing 12918
8 3 1 Preparing new part 12918
8 3 2 Welding in 12919
8 3 3 Shortening new longitudinal member with cover plate 12923
9 Repairing threads for securing subframe (suspension subframe) 12927
9 1 Tools 12928
9 2 Contents of thread repair kit 12929
9 3 Repairing thread 12930
9 3 1 Drilling threads 12930
9 3 2 Cutting thread 12931
9 3 3 Inserting thread insert 12931
51 – Body – centre 12933
1 Renewing roof – vehicles with no panorama tilting sunroof 12933
1 1 Tools 12934
1 2 Removing 12935
1 3 Installing 12938
1 3 1 Preparing new part 12938
1 3 2 Adjusting roof depth 12941
1 3 3 Bonding roof 12941
1 3 4 Welding in 12948
2 Renewing roof – vehicles with panorama tilting sunroof 12950
2 1 Tools 12951
2 2 Removing 12952
2 3 Installing 12955
2 3 1 Preparing new part 12955
2 3 2 Adjusting roof depth 12958
2 3 3 Bonding roof 12958
2 3 4 Welding in 12965
3 Renewing roof side member 12967
3 1 Tools 12968
3 2 Removing 12968
3 3 Installing 12970
3 3 1 Preparing new part 12971
3 3 2 Moulded foam inserts 12972
3 3 3 Welding in 12973
4 Renewing front cross member for roof – vehicles with no panorama tilting sunroof 12976
4 1 Tools 12977
4 2 Removing 12977
4 3 Installing 12978
4 3 1 Welding in 12978
5 Renewing front cross member for roof – vehicles with panorama tilting sunroof 12980
5 1 Tools 12981
5 2 Removing 12981
5 3 Installing 12982
5 3 1 Preparing new part 12982
5 3 2 Welding in 12982
6 Renewing roof reinforcement, vehicles with panorama tilting sunroof 12984
6 1 Tools 12985
6 2 Removing 12985
6 3 Installing 12986
6 3 1 Welding in 12986
7 Renewing rear roof cross member 12989
7 1 Tools 12990
7 2 Removing 12990
7 3 Installing 12991
7 3 1 Welding in 12991
8 Renewing A-pillar 12993
8 1 Tools 12994
8 2 Removing 12994
8 3 Installing 12996
8 3 1 Preparing new part 12997
8 3 2 Moulded foam inserts 12998
8 3 3 Welding in 13000
9 Renewing A-pillar reinforcement 13002
9 1 Tools 13003
9 2 Removing 13003
9 3 Installing 13005
9 3 1 Preparing new part 13005
9 3 2 Moulded foam inserts 13006
9 3 3 Welding in 13006
10 Renewing B-pillar 13010
10 1 Tools 13010
10 2 Removing 13010
10 3 Installing 13014
10 3 1 Preparing new part 13015
10 3 2 Marking the area where no welding work may be carried out 13016
10 3 3 Moulded foam inserts 13017
10 3 4 Welding in 13018
11 Renewing inner B-pillar 13021
11 1 Tools 13022
11 2 Removing 13022
11 3 Installing 13023
11 3 1 Welding in 13023
12 Renewing B-pillar reinforcement 13025
12 1 Tools 13026
12 2 Removing 13026
12 3 Installing 13030
12 3 1 Preparing new part 13030
12 3 2 Marking the areas where no welding work may be carried out 13033
12 3 3 Moulded foam inserts 13036
12 3 4 Welding in 13037
13 Renewing side member 13040
13 1 Tools 13041
13 2 Removing 13041
13 3 Installing 13042
13 3 1 Preparing new part 13043
13 3 2 Marking the areas where no welding work may be carried out 13045
13 3 3 Moulded foam inserts 13045
13 3 4 Welding in 13046
14 Renewing front side member reinforcement 13049
14 1 Tools 13050
14 2 Removing 13050
14 3 Installing 13051
14 3 1 Preparing new part 13051
14 3 2 Welding in 13053
15 Renewing rear side member reinforcement 13056
15 1 Tools 13057
15 2 Removing 13057
15 3 Installing 13058
15 3 1 Welding in 13058
53 – Body – rear 13061
1 Renewing cross panel 13061
1 1 Tools 13062
1 2 Removing 13062
1 3 Installing 13066
1 3 1 Preparing new part 13066
1 3 2 Welding in 13067
2 Renewing lock carrier 13070
2 1 Tools 13070
2 2 Removing 13070
2 3 Installing 13071
2 3 1 Welding in 13071
3 Renewing tail light mounting 13073
3 1 Tools 13073
3 2 Removing 13073
3 3 Installing 13075
3 3 1 Preparing new part 13075
3 3 2 Welding in 13076
4 Renewing rear longitudinal member – part section 13079
4 1 Tools 13080
4 2 Removing 13080
4 3 Installing 13082
4 3 1 Preparing new part 13082
4 3 2 Welding in 13083
5 Renewing side panel – part section 13087
5 1 Tools 13088
5 2 Removing 13088
5 3 Installing 13090
5 3 1 Preparing new part 13091
5 3 2 Moulded foam inserts 13092
5 3 3 Welding in 13092
6 Renewing outer wheel housing liner 13095
6 1 Tools 13096
6 2 Removing 13096
6 3 Installing 13099
6 3 1 Welding in 13100
7 Renewing spare wheel well 13103
7 1 Removing 13104
7 2 Installing 13105
7 2 1 Preparing new part 13105
7 2 2 Bonding in 13106
00 – Technical data 13116
1 Battery 13116
1 1 Types of battery 13116
1 2 Battery – general notes 13116
1 3 Fundamental issues 13116
1 3 1 Warning notices and safety regulations 13116
27 – Starter, current supply, CCS 13117
1 Battery 13117
1 1 Assembly overview – battery 13117
1 1 1 Assembly overview – engine compartment 13117
1 1 2 Assembly overview – luggage compartment 13118
1 2 Removing and installing battery 13119
1 2 1 Battery in engine compartment 13119
1 2 2 Battery in luggage compartment 13121
1 3 Checking battery 13122
1 4 Disconnecting and connecting battery 13122
1 4 1 Battery in engine compartment 13122
1 4 2 Battery in luggage compartment 13124
1 5 Charging battery 13127
1 6 Removing and installing earth cable with battery monitor control unit J367 13127
1 7 Pyrotechnical battery isolator 13129
1 7 2 Safety precautions when working on pyrotechnical battery isolator 13130
1 7 3 Disposal of pyrotechnical battery isolation units 13130
1 7 4 Removing and installing pyrotechnical battery isolator 13130
1 8 Adapting battery monitor control unit J367 13132
2 Jump start point 13133
2 1 Assembly overview – jump-start terminal 13133
2 2 Removing and installing jump starting point 13133
3 Starter motor 13135
3 1 Assembly overview – starter 13135
3 1 1 Assembly overview – starter, 1 4 l TSI engine, manual gearbox 13135
3 1 2 Assembly overview – 1 8 l TSI engine, manual gearbox 13137
3 1 3 Assembly overview – 2 0 l TSI engine, manual gearbox 13138
3 1 4 Assembly overview – 2 0 l TDI engine, manual gearbox 13139
3 1 5 Assembly overview – 3 6 l FSI engine, dual clutch gearbox (DSG) 13140
3 1 6 Assembly overview – 2 0 l TDI engine, dual clutch gearbox (DSG) 13141
3 1 7 Assembly overview – 2 0 l TSI engine, dual clutch gearbox (DSG) 13142
3 1 8 Assembly overview – 3 6 l FSI engine, automatic gearbox 13143
3 2 Removing and installing starter motor 13144
3 2 1 Removing and installing starter -B-, 1 4 l TSI engine, manual gearbox 13144
3 2 2 Removing and installing starter, 1 8 l TSI engine, manual gearbox 13146
3 2 3 Removing and installing starter, 2 0l TSI engine, manual gearbox 13150
3 2 4 Removing and installing starter, 2 0 l TDI engine, manual gearbox 13152
3 2 5 Removing and installing starter, 3 6 l FSI engine, dual clutch gearbox (DSG) 13156
3 2 6 2 0 l TDI engine, dual clutch gearbox (DSG) 13160
3 2 7 Removing and installing starter, 2 0 l TSI engine, dual clutch gearbox (DSG) 13163
3 2 8 Removing and installing starter, 3 6 l FSI engine, automatic gearbox 13165
3 3 Checking starter 13170
4 Alternator 13171
4 1 Assembly overview – alternator 13171
4 1 1 Assembly overview – 1 8 l TSI engine 13171
4 1 2 Assembly overview – 2 0 l FSI engine 13173
4 1 3 Assembly overview – 2 0 l TSI engine 13174
4 1 4 Assembly overview – 2 0 l TDI engine 13175
4 1 5 Assembly overview – 2 0 l TDI engine, Common Rail 13176
4 1 6 Assembly overview – 3 6 l FSI engine 13177
4 2 Removing and installing alternator 13178
4 2 1 Removing and installing alternator, 1 8 l TSI engine 13178
4 2 2 Removing and installing alternator, 2 0 l FSI engine 13180
4 2 3 Removing and installing alternator, 2 0 l TSI engine 13183
4 2 4 Removing and installing alternator, 2 0 l TDI engine 13187
4 2 5 Removing and installing alternator, 2 0 l TDI common rail engine 13191
4 2 6 3 6 l FSI engine 13194
4 3 Checking alternator 13197
4 4 Checking poly V-belt 13197
4 5 Removing and installing poly V-belt pulley 13198
4 5 1 Removing and installing poly V-belt pulley without freewheel 13198
4 5 2 Removing and installing poly V-belt pulley with freewheel, manufacturer: Bosch 13199
4 5 3 Removing and installing poly V-belt pulley with freewheel, manufacturer: Valeo 13200
4 6 Removing and installing voltage regulator 13203
4 6 1 Removing and installing voltage regulator, manufacturer: Bosch 13203
4 6 2 Removing and installing voltage regulator, manufacturer: Valeo 13203
4 7 Securing B+ (battery positive) wire to alternator 13205
5 Start/stop system 13206
5 1 Components of start/stop system 13206
5 2 Removing and installing voltage stabiliser -J532- 13207
6 Cruise control system (CCS) 13209
6 1 General notes 13209
6 2 Activating and deactivating cruise control system (CCS) 13209
7 Adaptive cruise control (ACC) 13210
7 1 Installing adaptive cruise control 13210
7 2 Overview of fitting locations – adaptive cruise control 13210
7 3 Removing and installing adaptive cruise control unit 13211
7 4 Removing and installing adaptive cruise control button 13212
7 5 Calibrating adaptive cruise control 13212
7 5 1 General notes 13212
7 5 2 Initialising adaptive cruise control 13213
90 – Gauges, instruments 13214
1 Dash panel insert 13214
1 1 General description 13214
1 2 Assembly overview – dash panel insert 13216
1 2 1 Warning lamp symbols in dash panel insert 13216
1 2 2 Pin assignment of connections on dash panel insert 13219
1 2 3 Description of back of dash panel insert 13219
1 3 Removing and installing dash panel insert 13219
2 Clock 13221
2 1 Removing and installing clock 13221
3 Horn 13223
3 1 Assembly overview – horn 13223
3 1 1 Checking horn 13223
3 1 2 Horn plate 13223
3 2 Removing and installing horn 13224
92 – Windscreen wash/wipe system 13225
1 windscreen wiper system 13225
1 1 General description 13225
1 2 Assembly overview – windscreen wiper system 13225
1 3 Removing and installing wiper blade 13227
1 4 Renewing windscreen wiper rubber 13227
1 5 Removing and installing wiper arms 13229
1 6 Adjusting wiper arms 13229
1 7 Removing and installing wiper motor 13230
1 7 1 Removing windscreen wiper system 13230
1 7 2 Removing plenum chamber cover 13231
1 7 3 Removing wiper frame with linkage and wiper motor 13231
1 7 4 Removing windscreen wiper motor 13232
1 7 5 Installing windscreen wiper motor 13232
1 7 6 Installing windscreen wiper system 13234
1 7 7 Deactivating APP function of wiper motor 13234
1 7 8 Checking windscreen wiper system 13236
1 8 Removing and installing rain and light sensor 13236
1 8 1 Removing and installing rain and light sensor -G397-, version 1 13236
1 8 2 Removing and installing rain and light sensor, version 2 13238
1 8 3 Coding rain and light sensor -G397- 13240
2 Windscreen washer system 13241
2 1 General notes 13241
2 2 Assembly overview – windscreen washer system 13241
2 3 Removing and installing washer fluid reservoir 13243
2 3 1 General notes 13243
2 3 2 Removing and installing windscreen washer reservoir (single chamber version) 13243
2 3 3 Removing and installing upper part of reservoir for windscreen and headlight washer systems 13244
2 3 4 Removing and installing lower part of reservoir for windscreen and headlight washer systems 13246
2 4 Removing and installing windscreen washer pump 13247
2 5 Removing and installing windscreen washer fluid level sender 13248
2 6 Removing and installing washer jets 13248
2 7 Adjusting spray jets 13248
3 Headlight washer system 13249
3 1 General notes 13249
3 2 Assembly overview – headlight washer system 13249
3 3 Removing and installing headlight washer system pump 13250
3 3 1 Checking headlight washer system pump -V11- 13251
3 4 Removing and installing washer jets 13251
3 5 Adjusting spray jets 13251
3 6 Removing and installing pop-up cylinder 13251
3 7 Bleeding headlight washer system 13253
3 8 Adapting headlight washer system 13253
4 Washer fluid lines 13254
4 1 Headlight washer system 13254
4 2 Hose repair 13254
94 – Lights, bulbs, switches – exterior 13255
1 Headlights 13256
1 1 Assembly overview – headlight 13256
1 1 1 Headlights with halogen bulbs ► 01 2012 13256
1 1 2 Headlights with gas discharge bulbs and cornering lights ► 01 2012 13258
1 1 3 Headlights with halogen bulbs 01 2012 ► 13261
1 1 4 Headlights with gas discharge bulbs and cornering lights 01 2012 ► 13263
1 2 Removing and installing headlights -MX1-/-MX2- 13265
1 2 1 Removing and installing headlights -MX1-/-MX2- ► 01 2012 13265
1 2 2 Removing and installing headlights -MX1-/-MX2- 01 2012 ► 13266
1 3 Adjusting headlights -MX1-/-MX2- 13269
1 3 1 Halogen headlights 13269
1 3 2 Gas discharge headlights 13269
1 4 Adjusting headlight installation position 13269
1 5 Converting headlights for use when driving on the left or right 13271
1 5 1 Halogen headlights ► 01 2012 13271
1 5 2 Halogen headlights 01 2012 ► 13274
1 5 3 Gas discharge headlights 13278
1 6 Removing and installing headlight dipped beam bulb -M29-/-M31- 13278
1 6 1 Removing and installing dipped beam bulb -M29-/-M31- ► 01 2012 13278
1 6 2 Removing and installing dipped beam bulb -M29-/-M31- 01 2012 ► 13280
1 7 Removing and installing headlight main beam bulb -M30-/-M32- 13282
1 7 1 Removing and installing main beam bulb -M30-/-M32- ► 01 2012 13282
1 7 2 Removing and installing main beam bulb -M30-/-M32- 01 2012 ► 13284
1 8 Removing and installing static cornering light bulb 13285
1 8 1 Halogen headlights 13285
1 8 2 Gas discharge headlights 13287
1 9 Removing and installing side light bulb -M1-/-M3- 13289
1 9 1 Removing and installing side light bulb -M1-/-M3-► 01 2012 13289
1 9 2 Removing and installing side light bulb -M1-/-M3- 01 2012 ► 13290
1 10 Removing and installing turn signal bulb -M5-/-M7- 13292
1 10 1 Removing and installing turn signal bulb -M5-/-M7-, halogen headlight 01 2012 ► 13292
1 10 2 Removing and installing turn signal bulb -M5-/-M7-, gas discharge headlight 01 2012 ► 13293
1 11 Removing and installing headlight range control motor -V48-/-V49- 13295
1 11 1 Removing and installing headlight range control motor -V48-/-V49-, halogen headlight ► 01 2012 13295
1 11 2 Removing and installing headlight range control motor -V48-/-V49-, halogen headlight 01 2012 ► 13297
1 11 3 Removing and installing headlight range control motor -V48-/-V49-, headlights with gas discharge bulb 13298
1 12 Headlight holder 13298
1 12 1 Removing and installing headlight holder 13298
1 13 Repairing headlight retaining tabs 13299
1 13 1 General description 13299
1 13 2 Repairing inner retaining tab 13299
1 13 3 Repairing upper retaining tab 13300
1 13 4 Repairing rear retaining tab 13301
1 13 5 Repairing lower retaining tab 13302
1 14 Removing and installing gas discharge bulb 13303
1 15 Removing and installing bulb for daytime running light/side light 13306
1 16 Headlight holder 13308
1 16 1 Removing and installing headlight holder 13308
1 17 Dip beam screen motor -V294-/-V295- 13308
1 17 1 Removing and installing dipped beam screen 13308
1 17 2 Checking dipped beam screen motor 13308
1 18 Gas discharge bulb control unit -J343-/-J344- with power output module for headlight-J667-/-J668- 13308
1 18 1 Removing and installing gas discharge bulb control unit -J343-/-J344- with power output module for headlight -J667-/-J668- 13308
1 18 2 Coding gas discharge bulb control unit -J343-/-J344- with output module for headlight -J667-/-J668- 13310
1 19 Cornering light and headlight range control unit -J745- 13310
1 19 1 Removing and installing cornering light and headlight range control unit -J745- 13310
1 19 2 Coding cornering light and headlight range control unit -J745- 13311
1 20 Vehicle level sender 13311
1 20 1 Removing and installing vehicle level sender 13311
1 21 Removing and installing control unit for daytime running light and side light -J860-/-J861- 13312
2 Fog lights 13313
2 1 Assembly overview – fog lights 13313
2 2 Removing and installing fog light 13314
2 3 Removing and installing fog light bulb -L22-/-L23- 13315
2 4 Checking fog lights 13315
2 5 Adjusting fog lights 13316
3 Side marker light 13317
3 1 Removing and installing side marker bulb (for USA and Canada only) 13317
4 Front turn signal lamp 13319
4 1 Removing and installing front turn signal 13319
4 2 Removing and installing front turn signal bulb -M5-/-M7- 13320
4 3 Checking front turn signal 13321
5 Lights in exterior mirror 13322
5 1 Assembly overview – lights in exterior mirror 13322
5 2 Removing and installing turn signal repeater bulb -L131-/-L132- 13322
5 2 1 Removing and installing turn signal repeater bulb -L131-/-L132- 13322
5 2 2 Checking turn signal repeater bulb -L131-/-L132- 13323
5 3 Entry light in exterior mirror -W52-/-W53- 13323
5 3 1 Removing and installing entry light in exterior mirror -W52-/-W53- 13323
5 3 2 Renewing bulb for entry light in exterior mirror -W52-/-W53- 13324
5 3 3 Checking entry light in exterior mirror -W52-/-W53- 13325
6 Tail lights 13326
6 1 General notes 13326
6 2 Assembly overview – tail lights in rear lid 13326
6 2 1 Assembly overview – tail lights in rear lid ► 01 2012 13326
6 2 2 Assembly overview – tail lights in rear lid 01 2012 ► 13328
6 3 Assembly overview – tail lights in body 13329
6 3 1 Assembly overview – tail lights in body ► 01 2012 13329
6 3 2 Assembly overview – tail lights in body 01 2012 ► 13330
6 4 Removing and installing tail light -MX3-/-MX4- 13330
6 4 1 Removing and installing tail light -MX3-/-MX4- ► 01 2012 13330
6 4 2 Removing and installing tail light cluster -MX3-/-MX4- 01 2012 ► 13333
6 5 Removing and installing tail light cluster in rear lid -MX5-/-MX6- 13336
6 5 1 Removing and installing tail light cluster in rear lid -MX5-/-MX6- ► 01 2012 13336
6 5 2 Removing and installing tail light cluster in rear lid -MX5-/-MX6- 01 2012 ► 13341
6 6 Removing and installing brake and tail light bulb -M21-/-M22- 13344
6 7 Removing and installing rear turn signal bulb -M6-/-M8- 13345
7 High-level brake light 13347
7 1 General notes 13347
7 2 Removing and installing bulb for high-level brake light -M25- 13347
7 3 Checking high-level brake light bulb -M25- 13348
8 Number plate light 13349
8 1 Removing and installing number plate light -X- 13349
8 2 Checking number plate light -X- 13350
9 Steering column switch module (SCSM) 13351
9 1 Assembly overview – steering column switch module (SCSM) 13351
9 1 1 Assembly overview ► 10 2009 13351
9 1 2 Assembly overview 10 2009 ► 13352
9 2 Removing and installing steering column switch module (SCSM) 13353
9 2 1 Removing and installing ► 10 2009 13353
9 2 2 Removing and installing 10 2009 ► 13355
9 3 Removing and installing steering column electronics control unit 13358
9 3 1 Steering column electronics control unit -J527- ► 10 2009 13358
9 3 2 Steering column electronics control unit -J527- 10 2009 ► 13360
9 4 Airbag coil connector and return ring with slip ring -F138- ► 10 2009 13364
9 4 1 Removing and installing airbag coil connector and return ring with slip ring -F138- 13364
9 5 Segment sender for steering angle sender -G85- ► 10 2009 13365
9 5 1 Removing and installing segment sender for steering angle sensor 13365
10 Ignition/starter switch and lock cylinder 13367
10 1 Ignition/starter switch 13367
10 1 1 Removing and installing electronic ignition lock -D9- 13367
10 2 Lock cylinder 13367
11 Parking aid 13368
11 1 General description 13368
11 2 Assembly overview – parking aid 13369
11 3 Removing and installing parking aid control unit 13371
11 3 1 Removing and installing parking aid control unit -J446- ► 05 2008 13371
11 3 2 Removing and installing parking aid control unit -J446- 05 2008 ► 13372
11 4 Removing and installing front parking aid senders 13373
11 4 1 Removing and installing front parking aid senders in radiator grille 13373
11 4 2 Removing and installing front parking aid senders in bumper cover 13375
11 4 3 Checking front parking aid sender 13377
11 4 4 Renewing parking aid senders 13377
11 5 Removing and installing rear parking aid senders 13378
11 5 1 Removing and installing rear parking aid senders 13378
11 5 2 Checking rear parking aid senders 13379
11 5 3 Renewing parking aid senders 13380
11 6 Repairing sender retainers of parking aid in front bumper cover and in radiator grille 13380
11 6 1 Allocating sender retainers of parking aid to installation location in bumper cover and radiator grille 13380
11 6 2 Bonding sender retainers of parking aid in front bumper cover and in radiator grille 13381
11 7 Repairing parking aid sender retainers in rear bumper cover 13382
11 7 1 Painting parking aid sender retainers in rear bumper cover 13382
11 7 2 Allocating parking aid sender retainers to fitting location in rear bumper cover 13383
11 7 3 Removing and installing parking aid sender retainers in rear bumper cover 13383
11 8 Parking aid warning buzzer 13384
11 8 1 Removing and installing front parking aid warning buzzer -H22- 13384
11 8 2 Adjusting volume of front parking aid warning buzzer -H22- 13384
11 8 3 Adjusting pitch of front parking aid warning buzzer -H22- 13385
11 8 4 Removing and installing rear parking aid warning buzzer -H15- 13385
11 8 5 Adjusting volume of rear parking aid warning buzzer -H15- 13385
11 8 6 Adjusting pitch of rear parking aid warning buzzer -H15- 13386
12 Park assist steering 13387
12 1 General description 13387
12 2 Assembly overview – park assist steering 13388
12 3 Removing and installing park assist steering control unit 13390
12 3 1 Removing and installing park assist steering control unit -J791- 13390
12 3 2 Coding park assist steering control unit -J791- 13390
12 4 Repairing park assist steering sender retainers in front bumper cover 13391
12 4 1 Allocating park assist steering sender retainers to fitting location in front bumper cover 13391
12 4 2 Bonding park assist steering sender retainers in front bumper cover 13391
12 5 Removing and installing front parking aid warning buzzer 13392
12 5 1 Removing and installing front parking aid warning buzzer -H22- 13392
12 5 2 Adjusting volume of front parking aid warning buzzer -H22- 13393
12 5 3 Adjusting pitch of front parking aid warning buzzer -H22- 13393
12 6 Removing and installing rear parking aid warning buzzer 13394
12 6 1 Removing and installing rear parking aid warning buzzer -H15- 13394
12 6 2 Adjusting volume of rear parking aid warning buzzer -H15- 13394
12 6 3 Adjusting pitch of rear parking aid warning buzzer -H15- 13394
13 Lane departure warning (Lane Assist) 13395
13 1 General description 13395
13 2 Assembly overview – lane departure warning 13396
13 3 Removing and installing lane departure warning control unit 13396
13 4 Removing and installing windscreen heater for lane departure warning 13397
13 5 Calibrating lane departure warning camera 13398
13 6 Coding lane departure warning control unit 13398
14 Entry and start authorisation 13399
14 1 Assembly overview – entry and start authorisation aerials and sensors 13399
14 1 1 Assembly overview – rear lid power opening sender -G750-/-G760-, Saloon 13401
14 2 General description 13401
14 3 Emergency starting when communication between ID sender and control unit is defective 13403
14 4 Electronic ignition lock -D9- 13403
14 4 1 Removing and installing electronic ignition lock -D9- 13403
14 5 Removing and installing control unit for terminal control and engine start -J942- 13403
14 5 1 Coding control unit for terminal control and engine start -J942- 13404
14 6 Convenience system central control unit -J393- 13404
14 6 1 Removing and installing convenience system central control unit -J393- 13404
14 7 Entry and start authorisation aerials and sensors 13405
14 7 1 Removing and installing driver side door exterior handle 13405
14 7 2 Removing and installing front passenger side door exterior handle 13406
14 7 3 Removing and installing rear left door exterior handle 13406
14 7 4 Removing and installing rear right door exterior handle 13407
14 7 5 Removing and installing rear bumper aerial for entry and start system -R136- 13407
14 7 6 Removing and installing interior aerial 1 for entry and start authorisation -R138- 13408
14 7 7 Removing and installing interior aerial 2 for entry and start authorisation -R139- 13409
14 7 8 Removing and installing interior aerial 3 for entry and start authorisation -R154- 13410
14 7 9 Removing and installing luggage compartment aerial for entry and start authorisation -R137- 13411
14 8 Checking entry and start system aerials and sensors 13412
14 8 1 Checking driver side aerial for entry and start authorisation -R134- 13412
14 8 2 Checking front passenger side aerial for entry and start authorisation -R135- 13413
14 8 3 Checking rear bumper aerial for entry and start authorisation -R136- 13413
14 8 4 Checking luggage compartment aerial for entry and start authorisation -R137- 13413
14 8 5 Checking interior aerial 1 for entry and start authorisation -R138- 13414
14 8 6 Checking interior aerial 2 for entry and start authorisation -R139- 13414
14 8 7 Checking interior aerial 3 for entry and start authorisation -R154- 13414
14 8 8 Checking driver door exterior handle contact sensor -G415- 13414
14 8 9 Checking front passenger door exterior handle contact sensor -G416- 13415
14 8 10 Checking rear left door exterior handle contact sensor -G417- 13415
14 8 11 Checking rear right door exterior door handle contact sensor -G418- 13415
14 9 Removing and installing rear lid power opening sender -G750-/-G760- 13416
14 10 Adapting entry and start authorisation functions 13417
14 10 1 Feedback for unlocking via entry and start authorisation system 13417
14 10 2 Adapting feedback for locking via entry and start authorisation system 13417
96 – Lights, bulbs, switches – interior 13418
1 Lights 13418
1 1 Overview of fitting locations – lights in dash panel 13418
1 2 Overview of fitting locations – lights in front doors 13420
1 3 Overview of fitting locations – lights in rear doors 13421
1 4 Overview of fitting locations – lights in luggage compartment 13422
1 5 Overview of fitting locations – lights in roof trim 13423
1 6 Removing and installing glove compartment light -W6- 13423
1 7 Removing and installing bulb for glove compartment light -W6- 13424
1 8 Removing and installing footwell light -W9-/-W10- 13424
1 9 Removing and installing footwell light bulb -W9-/-W10- 13425
1 10 Removing and installing front passenger side airbag deactivated warning lamp -K145- 13426
1 11 Central locking SAFELOCK function warning lamp -K133- 13427
1 11 1 Removing and installing Central locking SAFELOCK function warning lamp -K133- 13427
1 11 2 Checkingcentral locking SAFELOCK function warning lamp -K133- 13428
1 12 Removing and installing entry light -W31-/-W32-/-W33-/-W34- 13428
1 13 Removing and installing luggage compartment light -W3- 13429
1 14 Removing and installing bulb for luggage compartment light -W3- 13430
1 15 Removing and installing cigarette lighter illumination bulb -L28- 13431
1 16 Removing and installing illuminated vanity mirror -W20-/-W14- 13431
1 17 Removing and installing vanity mirror light bulb -L31-  13432
1 18 Removing and installing front interior light -WX1- 13432
1 18 1 Removing and installing front interior light -WX1- 13433
1 18 2 Removing and installing front reading lights button -E457- and -E458- 13434
1 18 3 Removing and installing button 1 for tilting roof -E582- 13434
1 19 Removing and installing centre reading light -W39-/-W40- 13435
1 20 Removing and installing rear interior light -WX2- 13436
1 21 Removing and installing bulb for rear reading light -W11-/-W12- 13437
1 22 Removing and installing light conductor for front sill panel moulding ambient lighting -W67-/-W68- 13438
2 Controls 13441
2 1 Fitting locations overview – controls in dash panel 13442
2 2 Fitting locations overview – controls in front doors 13444
2 3 Fitting locations overview – controls in rear doors 13445
2 4 Fitting locations overview – controls in centre console 13446
2 5 Fitting locations overview – controls in luggage compartment 13447
2 6 Fitting locations overview – controls in roof trim 13448
2 7 Removing and installing light switch -E1- 13448
2 8 Removing and installing headlight range control regulator -E102- and switch and instrument illumination regulator -E20- 13449
2 9 Removing and installing electronic ignition lock -D9- 13450
2 10 Removing and installing hazard warning light switch -E3- 13452
2 10 1 Removing and installing hazard warning light switch -E3- ►01 2012 13452
2 10 2 Removing and installing hazard warning light switch -E3- 01 2012► 13454
2 11 Removing and installing glove compartment light switch -E26- 13455
2 12 Removing and installing driver side switch module 13456
2 13 Removing and installing front left window regulator switch -E40- 13457
2 14 Removing and installing rear left window regulator switch in driver door -E53- 13457
2 15 Removing and installing rear right window regulator switch in driver door -E55- 13457
2 16 Removing and installing front right window regulator switch in driver door -E81- 13458
2 17 Removing and installing childproof lock button -E318- 13458
2 18 Removing and installing mirror adjustment switch -E43- 13458
2 19 Removing and installing driver side interior locking button for central locking system -E308- 13459
2 20 Removing and installing rear window regulator switch -E52-/-E54- 13460
2 21 Removing and installing remote release button for fuel filler flap and rear lid -E463- 13461
2 22 Removing and installing key-operated switch to block release of rear lid remote -E232- 13461
2 23 Removing and installing window regulator switch in front passenger door -E107- 13462
2 24 Removing and installing electromechanical parking brake button -E538- 13463
2 24 1 Removing and installing electromechanical parking brake button -E538- ▶ 01/2012 13463
2 24 2 Removing and installing electromechanical parking brake button -E538- 01/2012 ▶ 13465
2 25 Removing and installing auto-hold button -E540- 13465
2 26 Removing and installing Tyre Pressure Monitoring System button -E226- 13465
2 27 Removing and installing TCS and ESP button -E256- 13465
2 28 Removing and installing shock absorber damping adjustment button -E387- 13465
2 29 Removing and installing rear roller blind switch -E149- 13465
2 30 Removing and installing parking aid button -E266- 13465
2 31 Removing and installing park assist steering button -E581- 13465
2 32 Removing and installing switch module in centre console -EX23-/-EX30- 13466
2 32 1 Removing and installing centre console switch module -EX23-/-EX30- Vehicles ► 01 2012 13466
2 32 2 Removing and installing centre console switch module -EX23-/-EX30- Vehicles 01 2012 ► 13467
2 33 Removing and installing luggage compartment light switch -F5- 13468
2 34 Removing and installing rear lid locking unit -F256- 13469
2 34 1 Rear lid lock unit -F256- 13469
2 35 Removing and installing vanity mirror contact switch -F147-/-F148- 13469
2 36 Removing and installing front interior light button -E326-, reading light button -E457-/-E458- 13470
2 37 Removing and installing rear reading light button -E454-/-E455- 13470
2 38 Removing and installing interior monitoring deactivation switch -E267- and deactivation button for vehicle inclination sender -E360- 13470
2 39 Removing and installing bonnet contact switch -F266- 13471
2 40 Removing and installing garage door operating unit -E284- 13472
3 Immobiliser 13473
3 1 General description 13473
3 2 Immobiliser control unit -J362- 13474
3 2 1 Adapting immobiliser control unit -J362- 13474
3 3 Immobiliser reader unit -D1- 13475
3 4 Ignition key 13475
3 5 Online system test 13476
4 Anti-theft alarm (ATA) 13477
4 1 General description 13477
4 2 Assembly overview – anti-theft alarm (ATA) 13478
4 3 Activating and deactivating anti-theft alarm 13479
4 4 Interior monitoring sensor -G273- 13480
4 5 Interior monitor send and receive module 1 -G303- 13480
4 5 1 Removing and installing interior monitor send and receive module 1 -G303- 13480
4 6 Vehicle inclination sender -G384- 13482
4 7 Central locking and anti-theft alarm system aerial -R47- 13482
4 8 Reading alarm sources of anti-theft alarm 13482
4 9 Adapting alarm delay on opening driver door 13483
4 10 Adapting sensitivity of interior monitoring system 13483
4 11 Adapting sensitivity of inclination sensor 13483
4 12 Alarm horn -H12- 13484
4 12 1 Removing and installing alarm horn -H12- 13484
4 12 2 Checking alarm horn -H12- 13485
4 12 3 Reading alarm sources of alarm horn 13485
4 12 4 Adapting country setting for intelligent alarm horn 13486
5 Lights and controls in front doors 13487
5 1 Components – front door locks 13487
6 Lights and controls in rear doors 13488
6 1 Components – rear door locks 13488
7 Lights and controls in the roof trim 13489
7 1 Automatic anti-dazzle interior mirror -Y7- 13489
7 1 1 Removing and installing automatic anti-dazzle interior mirror -Y7- 13489
8 Lights and controls in the centre console 13490
8 1 Removing and installing front ashtray illumination bulb 13490
8 2 Removing and installing cigarette lighter -U1- 13490
8 3 Removing and installing storage compartment illumination bulb -L120- 13490
8 4 Removing and installing DC/AC converter with socket, 12 V-230 V -U13- 13492
9 Lane change assist 13495
9 1 Removing and installing lane change assist warning lamp in exterior mirror -K233-/-K234- 13495
9 2 Removing and installing lane change assist control unit -J769-/-J770- 13496
9 3 Calibrating lane change assist 13497
9 4 Calibrating lane change assist control unit -J769-/-J770- 13502
97 – Wiring 13505
1 Vehicle diagnosis, testing and information systems 13505
2 Relay carriers, fuse holders, electronics boxes 13506
2 1 Removing and installing fuse holder in dash panel 13506
2 2 Removing and installing electronics box in dash panel 13507
2 3 Relay carrier on left of dash panel 13508
2 3 1 Removing and installing relay carrier on left of dash panel 13508
2 4 Relay carrier on onboard supply control unit -J519- 13510
2 4 1 Removing and installing onboard supply control unit -J519- 13510
2 5 Removing and installing electronics box on left side of engine compartment 13511
2 6 Main fuse box 13515
3 Select Control units 13516
3 1 On-board supply control unit -J519- 13516
3 1 1 General description 13516
3 1 2 Removing and installing onboard supply control unit -J519- 13517
3 1 3 Coding onboard supply control unit -J519- 13517
3 1 4 Onboard supply control unit -J519- final control diagnosis 13518
3 1 5 Adaption of main beam for automatic headlight control 13519
3 1 6 Adaption of delay for automatic headlight control 13520
3 1 7 Adapting footwell lighting dimmer value 13520
3 1 8 Adapting Coming Home time 13520
3 1 9 Adapting Leaving Home time 13521
3 1 10 Adapting headlight washer system 13521
3 1 11 Adapting heater switch-off time for rear window and exterior mirrors 13521
3 1 12 Coding/decoding daytime running lights 13522
3 2 Data bus diagnostic interface -J533- 13522
3 2 1 General description 13522
3 2 2 Renewing data bus diagnostic interface -J533- 13523
3 2 3 Removing and installing data bus diagnostic interface -J533- 13523
3 2 4 Coding data bus diagnostic interface -J533- 13524
3 2 5 Checking bus activity 13524
3 2 6 Checking bus participants 13524
3 3 Convenience system central control unit -J393- 13525
3 3 1 General description 13525
3 3 2 Removing and installing convenience system central control unit -J393- 13527
3 3 3 Renewing and/or coding convenience system central control unit -J393- 13528
3 3 4 Updating convenience system central control unit -J393- 13529
3 3 5 Convenience system central control unit -J393- final control diagnosis 13529
3 3 6 Reading alarm sources of anti-theft alarm 13530
3 3 7 Reading alarm sources of alarm horn 13530
3 4 Driver door control unit -J386- 13531
3 4 1 Removing and installing driver door control unit -J386- 13531
3 4 2 Coding driver door control unit -J386- 13531
3 5 Front passenger door control unit -J387- 13532
3 5 1 Removing and installing front passenger door control unit -J387- 13532
3 5 2 Coding front passenger door control unit -J387- 13532
3 6 Rear left door control unit -J388- 13533
3 6 1 Removing and installing rear left door control unit -J388- 13533
3 6 2 Coding rear left door control unit -J388- 13533
3 7 Rear right door control unit -J389- 13534
3 7 1 Removing and installing rear right door control unit -J389- 13534
3 7 2 Coding rear right door control unit -J389- 13534
3 8 Trailer detector control unit -J345- 13534
3 8 1 Removing and installing trailer detector control unit -J345- 13535
3 8 2 Coding trailer detector control unit -J345- 13536
3 8 3 Adapting immobiliser control unit -J345- software 13536
4 Connectors 13538
4 1 Repairing electrical wiring harnesses and plug-in connections 13538
27 – Starter, current supply, CCS 13545
1 Battery 13545
1 1 Fundamentals for batteries 13545
1 2 Battery load test 13545
1 2 1 Battery with »standard« colour indicator 13546
1 2 2 Battery with »enhanced« colour indicator 13546
1 2 3 Absorbent glass mat battery 13547
1 2 4 Lithium ion battery 13547
1 3 Warning notices and safety regulations 13547
1 3 1 Dangers when handling vehicle batteries 13547
1 3 2 Safety markings on battery 13548
1 3 3 Working on airbag system 13549
1 4 Battery load test 13549
2 Checking battery 13551
2 1 Checking the various types of batteries 13551
2 1 1 Checking a battery with colour indicator 13551
2 1 2 Absorbent glass mat battery 13551
2 2 Visual inspection 13552
2 3 Information about battery replacement and battery gas venting 13553
2 4 Checking colour indicator in battery cover 13554
2 4 1 Checking colour indicator, “3-colour” 13554
2 4 2 Checking colour indicator, “2-colour” 13555
2 5 Current draw test 13556
3 Charging the battery 13558
3 1 Totally discharged batteries 13558
4 Cruise control system (CCS) 13560
4 1 Activating and deactivating cruise control system (CCS) 13560
90 – Gauges, instruments 13561
92 – Windscreen wash/wipe system 13562
1 Washer fluid line hose couplings 13562
1 1 Windscreen and rear window washer system 13562
1 2 Headlight washer system 13563
2 Hose repair 13564
2 1 General description 13564
2 2 Repairing smooth pipe 13564
2 3 Repairing corrugated pipe 13564
3 Distinguishing features of jointless wiper blades 13567
94 – Lights, bulbs, switches – exterior 13568
1 Operation and safety notes for gas discharge lamps 13568
96 – Lights, bulbs, switches – interior 13571
1 12 V socket 13571
1 1 Removing and installing 12 V socket 13571
1 2 Removing and installing socket illumination bulb -L42- 13571
2 Cigarette lighter -U1- 13572
2 1 General description 13572
2 2 Assembly overview 13573
2 3 Removing and installing cigarette lighter socket 13574
2 4 Removing and installing cigarette lighter illumination bulb -L28- 13577
97 – Wiring 13579
1 Vehicle diagnostic, testing and information systems 13579
1 1 Connecting vehicle diagnostic tester 13579
1 2 Connecting vehicle diagnostic tester Golf Model Year 1998 – 2003 13581
2 Repairs to wiring harnesses and connectors 13582
2 1 General notes concerning repairs to vehicle electrical system 13582
2 2 Wiring harness repair set 13584
2 2 1 Wiring harness repair set -VAS 1978- 13584
2 2 2 Upgrade kit -VAS 1978/50- 13584
2 2 3 Wiring harness repair set -VAS 1978A- 13585
2 2 4 Release tool set -VAS 1978/35- 13585
2 3 Tool descriptions 13586
2 3 1 Special pliers with insert 13586
2 3 2 Release tools for contacts 13587
2 3 3 Assembly tools for single wire seals 13587
2 3 4 Wire stripper -VAS 1978/3- 13587
2 3 5 Hot air blower 220 V/50 Hz -VAS 1978/14- 13589
2 3 6 Crimping pliers -VAS 1978/1A- 13589
2 4 Repairing wiring harnesses 13591
2 4 1 Repairs to airbag and belt tensioner wiring 13591
2 4 2 Repairing CAN bus wiring 13593
2 4 3 Repair of Flexray wires with sheath 13594
2 4 4 Repair of Flexray wires without sheath 13595
2 4 5 Renewal of aerial wiring 13596
2 4 6 Repairing 0 13 mm2/0 35 mm2/0 5 mm2 wire 13598
2 4 7 Repair of 10 mm2 or 16 mm2 wire with single butt connector 13603
2 4 8 Repair of 2 5 mm2, 4 mm2 or 6 mm2 aluminium wire with single butt connector 13610
2 4 9 Wiring open circuit with one repair position 13616
2 4 10 Wiring open circuit with two repair positions 13619
2 5 Repairing fibre optic cables 13621
2 5 1 Preparing fibre optic cable 13622
2 5 2 Detaching fibre optic cable from cable harness connector 13629
2 6 Repair of aerial wires 13630
2 6 1 Repair set, aerial cable VAS 6720 13630
2 7 Repairs to contact housings and connectors 13642
2 7 1 Notes on repairs to contact housings and connectors 13642
2 7 2 Repairs to contacts in contact housings 13642
2 7 3 Fitting single wire seals 13644
2 7 4 Repairs to contact housings using cut-and-clamp method 13647
2 8 Releasing and dismantling contact housings 13648
2 8 1 Notes on releasing and dismantling contact housings 13648
2 8 2 Secondary locking element 13648
2 8 3 Primary locking element 13649
2 8 4 Round connector systems 13650
2 8 5 Flat connector systems 13651
2 8 6 Special connector systems 13653
3 Contact surface cleaning set -VAS 6410- 13656
3 1 Using contact surface cleaning set -VAS 6410- 13656
3 1 1 Servicing ring terminals 13656
3 1 2 Servicing screw connections 13658
3 1 3 Cleaning battery clamp and battery terminal 13660
3 1 4 Anti-corrosion treatment 13662
4 Renewing lambda probe 13664
4 1 Renewing LSF Lambda probe (4-pin) 13664
4 2 Renewing LSU Lambda probe (6-pin) 13665
4 3 Types of protective tube on universal lambda probes 13666
5 Exhaust gas temperature sensor 13668
00 – Technical data 13677
1 Engine number/engine data 13677
2 Safety precautions 13681
2 1 Safety regulations for working on fuel supply 13681
2 2 Safety precautions when working on ignition system 13681
2 3 Releasing pressure in high-pressure area 13682
3 General repair instructions 13683
3 1 Rules for cleanliness 13683
10 – Removing and installing engine 13684
1 Removing and installing motor 13684
1 1 Removing engine (Golf Plus, Eos, Scirocco, Golf, Touran, Golf Cabriolet) 13684
1 2 Installing engine (Golf Plus, Eos, Scirocco, Golf, Touran, Golf Cabriolet) 13694
1 3 Removing engine (Tiguan) 13696
1 4 Installing engine (Tiguan) 13704
1 5 Removing engine (Polo) 13707
1 6 Installing engine (Polo) 13715
1 7 Removing engine (Sharan) 13716
1 8 Installing engine (Sharan) 13724
1 9 Removing engine (Passat, Passat CC) 13726
1 10 Installing engine (Passat, Passat CC) 13736
2 Assembly mountings 13740
2 1 Assembly overview – assembly mountings (Touran, Golf Plus, Eos, Scirocco, Golf, Golf Cabriolet) 13740
2 2 Assembly overview – assembly mountings (Tiguan) 13741
2 3 Assembly overview – assembly mountings (Polo) 13742
2 4 Assembly overview – assembly mountings (Sharan) 13743
2 5 Assembly overview – assembly mountings (Passat, Passat CC) 13743
13 – Crankshaft group 13745
1 Cylinder block (pulley end) 13745
1 1 Assembly overview – poly V-belt drive 13747
1 2 Assembly overview – cylinder block, belt pulley end 13749
1 3 Removing and installing poly V-belt (Golf Plus, Eos, Scirocco, Golf, Touran, Polo, Sharan, Passat, Passat CC, Golf Cabriolet) 13751
1 3 1 Poly V-belt routing 13753
1 4 Removing and installing poly V-belt (Tiguan) 13754
1 4 1 Poly V-belt routing 13755
1 5 Removing and installing bracket for ancillaries 13756
1 6 Renewing crankshaft oil seal – pulley end 13757
1 7 Removing and installing crankshaft pulley 13759
2 Cylinder block, gearbox end 13763
2 1 Assembly overview – cylinder block, gearbox end 13763
2 2 Removing and installing sealing flange on gearbox side 13765
2 2 1 Pressing sealing flange with sender wheel off crankshaft 13765
2 2 2 Pressing sealing flange with sender wheel onto crankshaft 13766
2 2 3 A – Assemble seal with sender wheel on assembly tool -T10134- 13767
2 2 4 B – Fitting assembly tool -T10134- with sealing flange to crankshaft flange 13769
2 2 5 C – Screwing assembly tool -T10134- on crankshaft flange 13770
2 2 6 D – Pressing sender wheel onto crankshaft flange using assembly tool -T10134- 13770
2 2 8 f) Re-pressing sender wheel 13772
3 Crankshaft 13773
3 1 Assembly overview – crankshaft 13773
3 2 Pulling needle bearing out of and driving into crankshaft 13774
3 3 Crankshaft dimensions 13776
4 Pistons and conrods 13777
4 1 Assembly overview – pistons and conrods 13777
4 2 Checking piston 13779
4 3 Checking cylinder bores 13780
4 4 Separating new conrod 13780
4 5 Removing and installing pistons 13780
4 6 Removing and installing oil spray jets 13781
15 – Cylinder head, valve gear 13783
1 Cylinder head 13783
1 1 Assembly overview – cylinder head 13783
1 2 Removing and installing camshaft housing 13786
1 2 1 Removing 13787
1 2 2 Installing 13789
1 3 Removing and installing cylinder head 13792
1 3 1 Removing 13792
1 3 2 Installing 13793
1 4 Checking compression 13794
2 Valve gear 13797
2 1 Assembly overview – valve gear 13797
2 2 Measuring axial clearance of camshaft 13799
2 3 Reworking valve seats 13799
2 4 Checking valve guides 13801
2 5 Removing and installing valve stem seals 13801
2 5 1 Removing 13802
2 5 2 Installing 13803
3 Cover for timing chain 13804
3 1 Removing and installing valve timing housing (Eos, Golf Plus, Scirocco, Golf, Polo, Sharan, Golf Cabriolet) 13804
3 1 1 Removing 13805
3 1 2 Installing 13807
3 2 Removing and installing valve timing housing (Touran, Tiguan) 13808
3 2 1 Removing 13811
3 2 2 Installing 13813
3 3 Removing and installing valve timing housing (Passat CC, Passat) 13814
4 Chain drive 13819
4 1 Checking valve timing 13819
4 2 Adjusting valve timing 13821
4 3 Checking timing chain 13828
4 4 Removing and installing timing chain and chain drive for oil pump 13835
17 – Lubrication 13844
1 Sump, oil pump 13844
1 1 Engine oil: 13844
1 2 Assembly overview – sump, oil pump 13844
1 3 Removing and installing sump 13847
1 4 Removing and installing oil pump 13851
2 Oil filter, oil pressure switch 13854
2 1 Checking oil pressure and oil pressure switch 13854
19 – Cooling 13856
1 Cooling system/coolant 13856
1 1 Coolant hose schematic diagram (Golf Plus, Eos, Scirocco, Golf, Touran, Polo, Golf Cabriolet) 13857
1 2 Schematic diagram for coolant hoses (Tiguan) 13858
1 3 Schematic diagram for coolant hoses (Sharan) 13859
1 4 Coolant hose schematic diagram (Passat, Passat CC) 13860
1 5 Draining and filling with coolant (Golf Plus, Eos, Scirocco, Golf, Touran, Tiguan, Golf Cabriolet) 13861
1 6 Draining and filling coolant (Polo) 13865
1 7 Draining and filling coolant (Sharan) 13869
1 8 Draining and filling coolant (Passat, Passat CC) 13874
1 9 Checking cooling system for leaks (Polo, Touran, Golf Plus, Eos, Scirocco, Golf, Golf Cabriolet) 13880
1 10 Checking cooling system for leaks (Sharan, Tiguan) 13882
1 11 Checking cooling system for leaks (Passat, Passat CC) 13884
2 Coolant pump, regulation of cooling system 13887
2 1 Assembly overview – thermostat 13887
2 2 Assembly overview – thermostat (Passat, Passat CC) 13889
2 3 Removing and installing coolant pump (Polo, Touran, Golf Plus, Eos, Tiguan, Scirocco, Golf, Golf Cabriolet) 13890
2 4 Removing and installing coolant pump belt pulley (Polo, Touran, Golf Plus, Eos, Tiguan, Scirocco, Golf, Golf Cabriolet) 13894
2 5 Removing and installing coolant circulation pump -V50- (Polo, Touran, Golf Plus, Eos, Tiguan, Scirocco, Golf, Golf Cabriolet) 13899
2 6 Removing and installing coolant pump (Sharan) 13901
2 7 Removing and installing coolant pump belt pulley (Sharan) 13906
2 8 Removing and installing coolant circulation pump -V50- (Sharan) 13910
2 9 Removing and installing coolant pump belt pulley (Passat, Passat CC) 13912
2 10 Removing and installing coolant pump (Passat, Passat CC) 13918
2 11 Removing and installing coolant circulation pump -V50- (Passat, Passat CC) 13925
2 12 Assembly overview – heater element for engine preheater -Z97- (Passat, Passat CC) 13927
2 13 Removing and installing heater element for engine preheater -Z97- (Passat, Passat CC) 13929
3 Radiator, radiator fan 13932
3 1 Assembly overview – radiator/radiator fan (Eos, Golf Plus, Scirocco, Golf, Touran, Golf Cabriolet) 13932
3 2 Assembly overview – parts of cooling system, body side (Tiguan) 13934
3 3 Assembly overview – radiator/radiator fan (Polo) 13936
3 4 Assembly overview – radiator/radiator fan (Sharan) 13937
3 5 Assembly overview – radiator/radiator fan (Passat, Passat CC) 13938
3 6 Removing and installing radiator fan -V7- and radiator fan 2 -V177- (Eos, Golf Plus, Scirocco, Golf, Touran, Golf Cabriolet) 13939
3 7 Removing and installing radiator fan -V7- and radiator fan 2 -V177- (Polo) 13940
3 8 Removing and installing radiator, radiator fan -V7- and radiator fan 2 -V177- (Sharan) 13941
3 9 Removing and installing radiator (Passat, Passat CC) 13943
3 10 Removing and installing fan cowling (Passat, Passat CC) 13946
3 11 Removing and installing radiator fan -V7- and radiator fan 2 -V177- (Passat, Passat CC) 13947
3 12 Removing and installing radiator (Golf Plus, Eos, Scirocco, Golf, Touran, Golf Cabriolet) 13948
3 13 Removing and installing radiator and radiator fan -V7- (Tiguan) 13949
3 14 Removing and installing radiator with charge air cooler (Polo) 13951
21 – Turbocharging/supercharging 13954
1 Turbocharger 13954
1 1 Assembly overview – turbocharger 13954
1 2 Removing and installing turbocharger 13958
1 3 Checking vacuum unit for turbocharger 13963
1 4 Removing and installing vacuum unit for turbocharger 13965
1 5 Adjusting vacuum unit for turbocharger 13967
2 Compressor 13973
2 1 Assembly overview – supercharger 13973
2 2 Removing and installing supercharger 13975
2 3 Removing and installing supercharger (Tiguan with four-wheel drive) 13983
2 4 Removing and installing drive unit seal for supercharger 13991
3 Charge air system 13995
3 1 Assembly overview – charge air system (Eos, Golf Plus, Golf, Touran, Scirocco, Tiguan, Sharan, Golf Cabriolet) 13996
3 2 Assembly overview – charge air system (Polo) 13997
3 3 Assembly overview – charge air system (Passat, Passat CC) 13998
3 4 Fitting hose connections with plug-in connectors 13999
3 5 Checking charge air system for leaks 14000
3 6 Removing and installing charge air cooler (Eos, Golf Plus, Golf, Golf Cabriolet, Touran) 14003
3 7 Removing and installing charge air cooler, Sharan 14005
3 8 Removing and installing charge air cooler (Scirocco) 14007
3 9 Removing and installing charge air cooler, Tiguan 14009
3 10 Removing and installing charge air cooler (Passat, Passat CC) 14011
24 – Mixture preparation – injection 14016
1 Air filter 14016
1 1 Assembly overview – air filter 14016
1 2 Assembly overview – air filter (Polo) 14017
1 3 Removing and installing air filter housing 14018
1 4 Removing and installing air filter housing (Polo) 14019
2 Intake manifold 14020
2 1 Assembly overview – intake manifold 14020
2 2 Removing and installing regulating flap control unit -J808- and throttle valve module -J338- 14025
2 3 Cleaning throttle valve module -J338- 14027
3 Injectors 14029
3 1 Assembly overview – fuel rail with injectors 14029
3 2 Removing and installing injectors 14031
3 3 Renewing seals on injectors 14034
4 Senders and sensors 14038
4 1 Checking fuel pressure sender 14038
4 2 Actuator for structure-borne sound -R214- and control unit for structure-borne sound -J869- (Polo, left-hand drive) 14041
4 3 Assembly overview – actuator for structure-borne sound -R214- and control unit for structure-borne sound -J869- (Polo, right-hand drive) 14043
5 High-pressure pump 14044
5 1 Assembly overview – high-pressure pump 14044
5 2 Removing and installing high-pressure pump 14045
6 Engine control unit -J623- 14049
6 1 Removing and installing engine control unit -J623- (Golf Plus, Touran) 14049
6 2 Removing and installing engine control unit -J623- with protective housing (Golf Plus, Touran) 14051
6 3 Removing and installing engine control unit -J623- (Eos) 14053
6 4 Removing and installing engine control unit -J623- with protective housing (Eos► 10 2008) 14054
6 5 Removing and installing engine control unit -J623- (Tiguan) 14056
6 6 Removing and installing engine control unit -J623- with protective housing (Tiguan) 14057
6 7 Removing and installing engine control unit -J623- (Scirocco) 14059
6 8 Removing and installing engine control unit -J623- with protective housing (Scirocco► 09 2008) 14060
6 9 Removing and installing engine control unit -J623- (Golf, Golf Cabriolet) 14062
6 10 Removing and installing engine control unit -J623- (Passat, Passat CC) 14063
6 11 Removing and installing engine control unit -J623- with protective housing (Golf, Eos 11 2008►, Scirocco 10 2008►, Passat, Passat CC, Golf Cabriolet) 14064
6 12 Removing and installing engine control unit -J623- (Polo) 14067
6 13 Removing and installing engine control unit -J623- with protective housing (Polo) 14068
6 14 Removing and installing engine control unit -J623- (Sharan) 14069
6 15 Removing and installing engine control unit -J623- with protective housing (Sharan) 14070
26 – Exhaust system 14072
1 Exhaust pipes and silencers 14072
1 1 Assembly overview – silencer (Golf Plus, Eos, Scirocco, Golf, Touran, Golf Cabriolet) 14073
1 2 Assembly overview – silencers (Tiguan) 14074
1 3 Assembly overview – silencers (Polo) 14075
1 4 Assembly overview – silencers (Sharan) 14076
1 5 Assembly overview – silencer (Passat, Passat CC) 14077
1 6 Removing and installing front exhaust pipe (Tiguan with four-wheel drive) 14078
1 7 Removing and installing front exhaust pipe (Golf Plus, Eos, Scirocco, Golf, Tiguan, Touran, Golf Cabriolet) 14079
1 8 Removing and installing front exhaust pipe (Sharan) 14080
1 9 Removing and installing (Passat, Passat CC) 14081
1 10 Separating exhaust pipes, silencers (Tiguan) 14083
1 11 Separating exhaust pipes/silencers (Golf Plus, Eos, Scirocco, Golf, Touran, Golf Cabriolet) 14084
1 12 Separating exhaust pipes, silencers (Polo) 14086
1 13 Separating exhaust pipes, silencers (Sharan) 14087
1 14 Separating exhaust pipes/silencers (Passat, Passat CC) 14088
1 15 Aligning exhaust system free of stress (Passat, Passat CC) 14090
1 16 Installation position of clamp 14091
2 Emission control 14092
2 1 Assembly overview – exhaust gas treatment (Golf Plus, Eos, Scirocco, Golf, Touran, Tiguan, Golf Cabriolet) 14092
2 2 Assembly overview – exhaust gas treatment (Tiguan with four-wheel drive) 14094
2 3 Assembly overview – exhaust gas treatment (Polo) 14096
2 4 Assembly overview – exhaust gas treatment (Sharan) 14097
2 5 Assembly overview – exhaust gas treatment (Passat, Passat CC) 14098
2 6 Removing and installing catalytic converter (Polo) 14100
2 7 Removing and installing (Passat, Passat CC) 14101
28 – Ignition system 14104
1 Ignition system 14104
1 1 Assembly overview – ignition system 14104
1 2 Removing and installing ignition coils with output stage 14105
1 3 Removing and installing engine speed sender -G28- 14107
1 4 Test data, spark plugs 14109
00 – Technical data 14116
1 General repair notes 14116
1 1 Gearbox 14116
1 2 Torque converter 14116
1 3 ATF 14116
1 4 Automatic gearbox control unit -J217- with ⇒ fuzzy logic 14116
1 5 Control units in vehicle 14116
1 6 Information on “09G gearbox” 14116
1 7 Tools 14117
1 8 Gearbox 14117
1 9 Gaskets, seals and oil 14118
1 10 Nuts and bolts 14118
1 11 Electrical components 14119
1 12 Guided fault finding, vehicle self-diagnosis and test instruments 14119
2 Capacities 14120
2 1 Planetary gearbox and final drive 14120
3 Code – engine allocation 14121
3 1 Gearbox codes 14121
4 Golf 2004 ► 14122
5 Golf Plus 2005 ► 14123
6 Golf 2009 ► 14124
7 Touran 2003 ► 14125
8 Passat 2006 ► 14126
9 Passat CC 2009 ►, CC 2010 ► 14127
32 – Torque converter 14128
1 Proper handling and installation of torque converter 14128
1 1 Identification of torque converter 14128
1 2 Draining torque converter 14128
1 3 Removing and installing torque converter oil seal 14129
1 4 Installing torque converter 14130
37 – Controls, housing 14131
1 Connecting »tester« 14131
1 1 Connecting vehicle diagnosis, testing and information system -VAS 5051- 14131
2 Electrical and electronic components and their locations 14133
3 Multifunction switch -F125- 14138
3 1 Removing multifunction switch -F125- 14138
3 2 Installing multifunction switch -F125- 14139
3 3 Adjusting multifunction switch -F125- 14140
3 3 1 Adjustment prerequisites 14141
4 Emergency release of selector lever 14142
5 Removing and installing selector lever handle 14143
5 1 Moving pushbutton to installation position in the handle 14145
5 1 1 Handle with pushbutton on side 14145
5 1 2 Handle with front pushbutton 14145
6 Selector mechanism up to 02 2009 14148
6 1 Overview of selector mechanism up to 02 2009 14148
6 2 Removing and installing selector mechanism with selector lever 14149
6 3 Removing and installing selector lever cable 14149
6 4 Checking selector lever cable 14157
6 5 Adjusting selector lever cable 14158
7 Selector mechanism from 03 2009 onwards 14160
7 1 Overview – selector mechanism 14160
7 2 Removing and installing selector mechanism with selector housing 14161
7 3 Removing and installing selector mechanism without selector housing 14163
8 Checking selector mechanism 14165
8 1 Selector lever in “P” position and ignition switched on 14165
8 2 Selector lever in “N” position and ignition switched on 14165
8 3 Selector lever in position “Tiptronic” 14165
8 4 Ignition and light switched on 14165
8 5 Selector lever position display 14165
9 Removing and installing gearbox, Golf 2004 ► 14166
9 1 Removing gearbox, Golf 2004 with 1 6 l – 75 kW, 1 6 l – 85 kW (FSI) and 2 0 l – 110 kW (FSI) engines 14166
9 2 Installing gearbox, Golf 2004 with 1 6 l – 75 kW, 1 6 l – 85 kW (FSI) and 2 0 l – 110 kW (FSI) engines 14172
9 3 Removing gearbox, Golf 2004 with 2 5 l – 110 kW and 125 kW engines 14172
9 4 Installing gearbox, Golf 2004 with 2 5 l – 110 kW and 125 engines 14180
9 5 Torque settings, gearbox to engine 14181
9 5 1 Torque settings, Golf 2004 with 1 6 l – 75 kW and 2 0 l – 110 kW (FSI) engines 14181
9 5 2 Torque settings, Golf 2004 with 1 6 l – 85 kW (FSI) engine 14182
9 5 3 Specified torques, Golf 2004 with 2 5 l – 110 kW and 125 kW engines 14183
10 Removing and installing gearbox, Golf Plus 2005 ► 14185
10 1 Removing gearbox, Golf Plus 2005 14185
10 2 Installing gearbox, Golf Plus 2005 14191
10 3 Torque settings, gearbox to engine 14192
10 3 1 Torque settings, Golf Plus 2005 with 1 6 l – 75 kW and 2 0 l – 110 kW (FSI) engines 14192
10 3 2 Torque settings, Golf Plus 2005 with 1 6 l – 85 kW (FSI) engine 14194
10 3 3 Torque settings, Golf Plus 2005 with 2 5 l – 110 kW engine 14195
11 Removing and installing gearbox, Touran 2003 ► 14196
11 1 Removing gearbox, Touran 2003 14196
11 2 Installing gearbox, Touran 2003 14200
11 3 Torque settings, gearbox to engine 14201
11 3 1 Torque settings, Touran 2003 with 1 6 l – 85 kW (FSI) engine 14201
11 3 2 Torque settings, Touran 2003 with 2 0 l – 85 kW (FSI) and 1 8 l – 110 kW (FSI) engines 14202
11 3 3 Torque settings, Touran 2003 with 2 0 l – 110 kW (FSI) engine 14203
12 Removing and installing gearbox, Passat 2003 ► 14204
12 1 Removing gearbox, Passat with 1 6 l – 85 kW and 2 0 l – 110 kW engines 14204
12 2 Installing gearbox, Passat with 1 6 l – 85 kW and 2 0 l – 110 kW engines 14210
12 3 Torque settings, gearbox to engine 14211
12 3 1 Specified torques for 1 6 l – 85 kW engine 14211
12 3 2 Specified torques for 2 0 l – 110 kW engine 14212
12 4 Removing gearbox, Passat with 1 8 l – 118 kW and 2 0 l – 147 kW engines 14212
12 5 Installing gearbox, Passat with 1 8 l – 118 kW and 2 0 l – 147 kW engines 14218
12 6 Torque settings, gearbox to engine 14219
12 6 1 Specified torques for 1 8 l 118 kW TFSI engine 14219
12 6 2 Specified torques for 2 0 l 147 kW TFSI engine 14220
13 Removing and installing gearbox, Passat CC 2009 ►, CC 2010 ► 14221
13 1 Removing gearbox, Passat CC 2009, CC 2010 with 2 0 l 147 kW TFSI engine 14221
13 2 Installing gearbox, Passat CC 2009, CC 2010 with 2 0 l 147 kW TFSI engine 14229
13 3 Torque settings, gearbox to engine 14230
13 3 1 Specified torques for 2 0 l 147 kW TFSI engine 14230
14 Removing and installing gearbox, Golf 2009 ► 14232
14 1 Removing gearbox, Golf 2009 with 2 5 l – 125 kW engine 14232
14 2 Installing gearbox, Golf 2009 with 2 5 l – 125 kW engine 14240
14 3 Torque settings, Golf 2009 with 2 5 l – 125 kW engine 14241
15 Transporting gearbox 14243
16 ATF cooler for 1 6 l – 85 kW and 2 0 l – 110 kW engines 14244
16 1 Assembly overview – ATF cooler 14244
17 ATF lines, ATF water cooler and additional ATF cooler, Passat with 2 0 l TFSI engine 14245
17 1 Overview 14245
17 1 1 ATF lines on gearbox 14246
17 1 2 External ATF heat exchanger 14247
17 1 3 ATF lines 14248
17 1 4 Additional ATF cooler 14249
18 Checking ATF level and topping up 14250
18 1 Checking ATF level 14252
18 2 Topping up ATF 14253
18 3 Draining and filling ATF 14254
38 – Gears, control 14256
1 Renewing oil seal for selector shaft 14256
2 Removing and installing ATF pan 14257
2 1 Removing 14257
2 2 Installing 14258
3 Removing and installing ATF strainer 14260
3 1 Removing 14260
3 2 Installing 14260
4 Removing and installing valve body 14261
4 1 Overview – valve chest 14261
4 2 Removing valve body 14263
4 3 Installing valve body 14266
4 3 1 Wire routing, connectors, connections and retainer on valve body 14268
4 4 Specified torques 14270
5 Removing and installing wiring harness for solenoid valves and senders 14271
5 1 Removing 14271
5 2 Installing 14271
6 Removing and installing gearbox input speed sender -G182- 14272
6 1 Removing 14272
6 2 Installing 14272
7 Removing and installing gearbox output speed sender -G195- 14273
7 1 Removing 14273
7 2 Installing 14273
39 – Final drive – differential 14274
1 Renewing oil seals for flange shafts 14274
1 1 Renewing oil seal for left flange shaft 14274
1 2 Renewing seal for right flange shaft 14275
00 – Technical data 14286
1 Front-wheel drive – gearbox identification 14286
1 1 Location on gearbox 14286
1 2 Front-wheel drive – identification codes, assembly allocation and capacities, Golf 2004 ► 14287
1 3 Front-wheel drive – identification codes, assembly allocation and capacities, Golf 2009 ► 14290
1 4 Identification codes, assembly allocation, capacities, Golf Plus 2005 ► 14292
1 5 Identification codes, assembly allocation, capacities, Golf Plus 2009 ► 14293
1 6 Front-wheel drive – identification codes, assembly allocation and capacities, Passat 2006 ► 14294
1 7 Identification codes, assembly allocation, capacities, Passat CC 2009 ► 14297
1 8 Identification codes, assembly allocation and capacities, front-wheel drive CC 2010 ► 14298
1 9 Identification codes, assembly allocation, capacities, Eos 2006 ► 14300
1 10 Identification codes, assembly allocation and capacities, Scirocco 2009 ► 14302
1 11 Identification codes, assembly allocation, capacities, Touran 2003 ► 14304
2 All-wheel drive – gearbox identification 14308
2 1 Location on gearbox 14308
2 2 All-wheel drive – identification codes, assembly allocation, capacities – Golf 2005 ► 14309
2 3 All-wheel drive – identification codes, assembly allocation, capacities – Golf 2009 ► 14313
2 4 All-wheel drive – identification codes, assembly allocation, capacities – Passat 2006 ► 14314
2 5 All-wheel drive – identification codes, assembly allocation and capacities – CC 2010 ► 14315
3 Front-wheel drive – Overview power transmission 14317
4 Overview – all-wheel drive power train 14319
5 Calculating overall gear ratio “i” 14321
6 All-wheel drive – notes on performance test 14322
7 General repair instructions 14323
7 1 Contact corrosion 14323
7 2 Special tool 14323
7 3 Front-wheel drive – gearbox 14323
7 4 four-wheel drive – gearbox 14323
7 5 Gaskets, seals 14324
7 6 Sealant 14324
7 7 Locking devices 14325
7 8 Nuts and bolts 14325
7 9 Bearings 14325
7 10 Shims 14326
7 11 Synchro-rings 14326
7 12 Gear wheels 14326
7 13 Synchromeshed gears 14326
7 14 Clutch 14327
8 Safety precautions for vehicles with a start-stop system 14328
30 – Clutch 14329
1 Repairing clutch mechanism 14329
1 1 Overview 14329
1 2 Touran to 05 03 only: Assembly overview – pedal cluster with clutch pedal switch -F36- 14330
1 3 Touran as of 06 03, Golf, Golf Plus, Passat, Passat CC, CC, Eos and Scirocco: Assembly overview – pedal cluster 14332
1 4 Removing and installing over-centre spring 14335
1 4 1 Removing and installing over-centre spring – Golf 2004 ► 14335
1 4 2 Removing and installing over-centre spring – Golf 2009 ► left-hand drive and Scirocco 14340
1 4 3 Removing and installing over-centre spring – Golf 2009 ► right-hand drive 14345
1 4 4 Removing and installing over-centre spring, Golf Plus 14350
1 4 5 Removing and installing over-centre spring, Passat, Passat CC, CC, Touran to approx 05 03 and Eos 14355
1 5 Removing and installing over-centre spring with mounting bracket installed (Touran from approx 06 03) 14357
1 6 Removing and installing clutch pedal 14360
1 6 1 Removing and installing clutch pedal, Golf 2004 ►, Golf 2009 ►, Golf Plus, Touran from approx 06 03 and Scirocco 14360
1 6 2 Removing and installing clutch pedal, Passat, Passat CC, CC, Touran to approx 05 03 and Eos 14362
1 7 Removing and installing mounting bracket, Golf 2004 ► 14364
1 7 1 Removing 14365
1 7 2 Installing 14370
1 7 3 Specified torques 14372
1 8 Removing and installing mounting bracket – Golf 2009 ► left-hand drive and Scirocco 14372
1 8 1 Removing 14372
1 8 2 Installing 14377
1 8 3 Specified torques 14378
1 9 Removing and installing mounting bracket, Golf Plus left-hand drive 14378
1 9 1 Removing 14379
1 9 2 Installing 14384
1 9 3 Specified torques 14385
1 10 Removing and installing mounting bracket, Golf 2009 ► RHD and Golf Plus RHD 14385
1 10 1 Removing 14386
1 10 2 Installing 14390
1 10 3 Specified torques 14393
1 11 Removing and installing master cylinder 14393
1 11 1 Removing 14393
1 11 2 Installing 14394
1 12 Assembly overview – hydraulics (left-hand drive vehicles) 14395
1 13 Assembly overview – hydraulics (right-hand drive vehicles) 14398
1 14 Touran: Removing and installing clutch pedal switch -F36- 14400
1 14 1 Removing 14400
1 14 2 Installing 14401
1 15 Removing and installing mounting bracket (all Tourans) 14402
1 15 1 Removing 14404
1 15 2 Installing 14410
1 15 3 Specified torques 14413
1 16 Touran: removing and installing master cylinder with mounting bracket removed (to 05 03) 14413
1 16 1 Removing 14413
1 16 2 Installing 14414
1 17 Removing and installing mounting bracket, Passat, Passat CC and CC 14415
1 17 1 Removing 14416
1 17 2 Installing 14418
1 17 3 Specified torques 14419
1 18 Removing and installing mounting bracket, Eos 14419
1 18 1 Removing 14420
1 18 2 Installing 14422
1 18 3 Specified torques 14424
2 Removing and installing clutch position sender -G476- 14425
2 1 Removing 14425
2 2 Installing 14428
3 Bleeding clutch system 14430
4 Servicing clutch release mechanism 14432
4 1 Assembly overview 14432
4 2 Removing line and bleeder from and installing on slave cylinder 14433
4 3 Removing and installing slave cylinder with release bearing 14434
4 3 1 Removing 14434
4 3 2 Installing 14435
4 4 Removing and installing line for clutch mechanism 14436
4 4 1 Removing 14436
4 4 2 Installing 14438
5 Servicing clutch, in conjunction with dual-mass flywheel 14440
5 1 Identifying make of clutch, vehicles with 2 0 l – 100 kW turbo diesel engine and vehicles with 2 0 l – 103 kW turbo diesel engine 14440
5 2 Removing and installing “Sachs” clutch 14442
5 2 1 Removing 14442
5 2 2 Installing 14442
5 3 Repairing “Sachs” clutch 14445
5 4 Removing and installing “LuK” clutch 14446
5 4 1 Removing 14446
5 4 2 Installing 14446
5 5 Servicing LuK clutch 14450
6 Servicing clutch, in conjunction with one-piece flywheel 14451
34 – Controls, housing 14455
1 Repairing selector mechanism 14455
1 1 Installation position of selector mechanism 14455
1 2 Overview of selector mechanism 14456
1 3 Assembly overview – gear knob and cover 14456
1 4 Removing and installing gaiter with gear knob and noise insulation, Golf, Eos and Scirocco 14458
1 5 Removing and installing gaiter with gear knob and noise insulation, Golf Plus 14460
1 6 Removing and installing gaiter with gear knob, Touran 14462
1 7 Removing and installing gaiter with gear knob and noise insulation, Passat, Passat CC and CC 14463
1 8 Repairing gear lever and selector housing (to 10 06) 14466
1 9 Repairing gear lever and selector housing (from 11 06) 14469
1 9 1 Dismantling and assembling selector mechanism 14471
1 9 2 Installing base plate to selector housing 14476
1 10 Assembly overview – removing and installing selector cables 14477
1 11 Removing and installing selector mechanism 14483
1 11 1 Removing 14483
1 11 2 Installing 14487
1 11 3 Specified torques 14489
1 12 Adjusting selector mechanism 14489
1 13 Function 14492
2 Plastic relay lever 14493
3 Touran, identifying gearbox for removal and installation 14497
4 Touran, removing and installing gearbox to gearbox date 31 10 4 (gearbox with stub shaft on right) 14499
4 1 Removing gearbox 14499
4 2 Installing gearbox 14506
4 2 1 Specified torques 14513
5 Touran, difference between removing and installing gearbox from gearbox date 01 11 4 (gearbox with right flange shaft) 14515
6 Touran, removing and installing gearbox (to 11 06 = vehicles with small headlights, from 12 06 to 05 10 = vehicles with large headlights with curvature) 14517
6 1 Removing gearbox 14517
6 2 Installing gearbox 14528
6 2 1 Specified torques 14536
7 Touran, removing and installing gearbox (from 06 10 = vehicles with large headlights without curvature) 14538
7 1 Removing gearbox 14538
7 2 Installing gearbox 14550
7 2 1 Specified torques 14560
8 Removing and installing gearbox, Golf 2004 ► front-wheel drive 14563
8 1 Removing gearbox 14563
8 2 Installing gearbox 14575
8 2 1 Specified torques 14584
9 Removing and installing gearbox, Golf 2009 ► front-wheel drive with turbo diesel engine 14586
9 1 Removing gearbox 14586
9 2 Installing gearbox 14598
9 2 1 Specified torques 14608
10 Removing and installing gearbox, Golf 2009 ► front-wheel drive with petrol engine 14610
10 1 Removing gearbox 14610
10 2 Installing gearbox 14622
10 2 1 Specified torques 14632
11 Removing and installing gearbox, Golf 2004 ► all-wheel drive 14634
11 1 Removing and installing gearbox in vehicles with turbo diesel engine 14634
11 1 1 Removing gearbox 14634
11 1 2 Installing gearbox 14646
11 1 3 Specified torques 14655
11 2 Removing and installing gearbox, vehicles with 6-cylinder petrol engine 14658
11 2 1 Removing gearbox 14659
11 2 2 Installing gearbox 14670
11 2 3 Specified torques 14679
12 Removing and installing gearbox, Golf 2009 ► all-wheel drive 14681
12 1 Removing gearbox 14682
12 2 Installing gearbox 14695
12 2 1 Specified torques 14707
13 Removing and installing gearbox, Golf Plus 2005 ► 14710
13 1 Removing gearbox 14710
13 2 Installing gearbox 14722
13 2 1 Specified torques 14730
14 Removing and installing gearbox, Golf Plus 2009 ► 14733
14 1 Removing gearbox 14734
14 2 Installing gearbox 14747
14 2 1 Specified torques 14757
15 Removing and installing gearbox, Passat 2006 ► front-wheel drive 14760
15 1 Removing gearbox 14760
15 2 Installing gearbox 14772
15 2 1 Specified torques 14780
16 Removing and installing gearbox, Passat 2006 ► all-wheel drive 14782
16 1 Removing gearbox 14782
16 2 Installing gearbox 14794
16 2 1 Specified torques 14804
17 Removing and installing gearbox, Passat CC front-wheel drive and CC front-wheel drive, with turbo diesel engine 14807
17 1 Removing gearbox 14807
17 2 Installing gearbox 14819
17 2 1 Specified torques 14829
18 Removing and installing gearbox, Passat CC front-wheel drive and CC front-wheel drive, with petrol engine 14832
18 1 Removing gearbox 14832
18 2 Installing gearbox 14844
18 2 1 Specified torques 14854
19 Removing and installing gearbox, CC all-wheel drive 14856
19 1 Removing gearbox 14857
19 2 Installing gearbox 14870
19 2 1 Specified torques 14882
20 Removing and installing gearbox, Eos 14885
20 1 Removing gearbox 14886
20 2 Installing gearbox 14896
20 2 1 Specified torques 14904
21 Removing and installing gearbox, Scirocco with petrol engine 14906
21 1 Removing gearbox 14906
21 2 Installing gearbox 14917
21 2 1 Specified torques 14927
22 Removing and installing gearbox in Scirocco with turbo diesel engine 14929
22 1 Removing gearbox 14929
22 2 Installing gearbox 14940
22 2 1 Specified torques 14951
23 Gearbox transport 14953
23 1 Front-wheel drive – transporting gearbox 14953
23 2 All-wheel drive – transporting gearbox 14954
24 Checking gearbox oil 14956
25 Removing and installing bevel box, vehicles with 6-cylinder petrol engine and vehicles with turbo diesel engine without particulate filter 14958
25 1 Removing bevel box 14958
25 2 Installing bevel box 14965
25 2 1 Specified torques 14970
26 Removing and installing bevel box, vehicles with turbo diesel engine and particulate filter, to approx 10  09 14971
26 1 Removing bevel box 14972
26 2 Installing bevel box 14979
26 2 1 Specified torques 14982
27 Removing and installing bevel box, vehicles with turbo diesel engine and particulate filter, from approx 11  09 14984
27 1 Removing bevel box 14984
27 2 Installing bevel box 14989
27 2 1 Specified torques 14992
28 Checking or topping up gear oil in bevel box 14993
28 1 Checking gear oil in bevel box 14993
28 2 Topping up gear oil in bevel box 14995
28 2 1 Specified torque 14999
29 Dismantling and assembling gearbox 15000
29 1 Overview – gearbox, front-wheel drive, Golf 2004 ► and Touran 15000
29 2 Overview – gearbox, front-wheel drive, Golf 2009 ►, Golf Plus, Passat, Passat CC, CC, Eos and Scirocco 15000
29 3 Overview – gearbox, all-wheel drive 15001
29 4 Assembly overview – front-wheel drive 15002
29 5 Assembly overview – all-wheel drive 15004
29 6 Assembly overview – removing and installing gearbox housing and selector unit 15006
29 7 Assembly overview – front-wheel drive – removing and installing input shaft, output shafts, differential and selector rods; Touran and Golf 2004 ► 15008
29 8 Assembly overview – front-wheel drive – removing and installing input shaft, output shafts, differential and selector rods; Golf 2009 ►, Golf Plus, Passat, Passat CC, CC and Eos and Scirocco 15010
29 9 All-wheel drive – removing and installing input shaft, output shafts, differential, bevel box and selector rods 15012
29 10 Installation position of shafts and selector rods in gearbox 15014
29 11 Securing to engine and gearbox support 15014
29 12 Assembly order, gearbox »without« circlip -A- for input shaft cover made from sheet metal 15016
29 12 1 Removing 15017
29 12 2 Installing 15024
29 13 Assembly order: I = gearbox »with« circlip -A- for input shaft cover made from sheet metal; II = gearbox with input shaft cover made from plastic 15032
29 13 1 Removing 15033
29 13 2 Installing 15040
30 Repairing gearbox housing 15050
31 Front-wheel drive – servicing clutch housing 15061
32 four-wheel drive – repairing clutch housing 15065
33 Repairing selector unit 15069
33 1 Renewing selector shaft seal 15071
34 Repairing selector forks 15074
35 – Gears, shafts 15077
1 Input shaft 15077
1 1 Assembly overview – input shaft 15077
1 2 Dismantling and assembling input shaft 15079
1 2 1 Modification in area of deep groove ball bearing 15083
1 3 Renewing input shaft seal 15085
1 3 1 Procedure 15085
2 Output shaft for 1st to 4th gears 15087
2 1 Assembly overview – output shaft for 1st to 4th gears 15087
2 2 Dismantling and assembling output shaft for 1st to 4th gears 15090
2 2 1 Distinguishing 1st/2nd gear synchronisation, distinguishing 3rd gear synchronisation 15098
2 2 2 Assembling 1st to 4th gear output shaft up to gearbox date 25 10 9 15100
2 2 3 Assembling 1st to 4th gear output shaft – from gearbox date 26 10 9 up to gearbox date 24 05 0 15106
2 2 4 Assembling 1st to 4th gear output shaft – from gearbox date 25 05 0 onwards 15112
2 3 Adjusting output shaft for 1st to 4th gears 15119
2 3 1 Determining thickness of shim 15122
2 3 2 Table of shims 15123
2 3 3 Carrying out check measurement 15123
3 Output shaft for 5th and 6th gears and reverse gear 15125
3 1 Assembly overview – output shaft for 5th, 6th and reverse gears 15125
3 2 Dismantling and assembling output shaft for 5th, 6th and reverse gears 15127
3 3 Adjusting output shaft for 5th, 6th and reverse gears 15138
3 3 1 Determining thickness of shim 15141
3 3 2 Table of shims 15142
3 3 3 Carrying out check measurement 15142
39 – Final drive – differential 15144
1 Front-wheel drive – renewing seals for flange shafts or stub shaft with gearbox installed 15144
1 1 Renewing oil seal for left flange shaft 15144
1 1 1 Removing 15144
1 1 2 Installing 15145
1 2 Identifying gearbox to renew right oil seal, Golf and Touran 15146
1 3 Renewing stub shaft seal – Golf and Touran to gearbox manufacture date 31 10 4 15146
1 3 1 Removing 15147
1 3 2 Installing 15147
1 4 Renewing oil seal for right flange shaft, Golf and Touran from gearbox manufacture date 01 11 4, Golf Plus, Passat, Passat CC, CC, Eos and Scirocco 15148
1 4 1 Removing 15148
1 4 2 Installing 15149
2 All-wheel drive – renewing flange shaft oil seals with gearbox and bevel box installed 15151
2 1 Renewing oil seal for left flange shaft 15151
2 2 Renewing seal for right flange shaft 15151
2 2 1 Removing 15151
2 2 2 Installing 15152
3 Renewing seal between gearbox and bevel box, in gearbox 15154
4 Assembly overview – seals, flange shaft mount and output flange mount in bevel box 15156
5 Renewing seal between gearbox and bevel box with bevel box removed 15159
6 Renewing bevel box output flange oil seal (bevel box removed) 15161
7 Renewing output flange and redetermining thickness of shim (bevel box removed) 15172
8 Renewing polygon needle bearing and seal on right flange shaft 15173
8 1 Removing 15173
8 2 Installing 15175
9 Adjustment overview – manual gearbox 15177
10 Differential 15178
10 1 Front-wheel drive – dismantling and assembling differential 15178
10 2 All-wheel drive – dismantling and assembling differential 15186
10 3 Adjusting differential 15194
10 3 1 Determining thickness of shim 15196
00 – Technical data 15204
1 General repair instructions 15204
1 1 Tools 15204
1 2 Gearbox 15204
1 3 Overview 15204
1 4 Seals 15205
1 5 ⇒ DSG® oil 15206
1 6 Oil filter change – »Yes or no?« 15206
1 7 Oil drain and inspection plug -A- 15206
1 8 Nuts and bolts 15207
1 9 Electrical components 15207
2 Fault finding 15208
2 1 General notes on fault finding 15208
2 2 Useful information about the “behaviour of the control unit in the event of a gearbox fault” 15208
2 3 Special notes on fault finding 15209
3 Identification of gearbox 15211
3 1 Reading gearbox code letters 15211
4 Code – engine allocation 15213
4 1 Golf Plus 2009 ► 15213
4 2 Golf Plus 2005 ► 15213
4 3 Golf 2009 ► 15214
4 4 Scirocco 2009 ► 15214
4 5 Golf 2004 ► 15214
4 6 Touran 2003 ► 15215
4 7 Passat 2006 ► 15216
4 8 Eos 2006 ► 15216
4 9 Passat CC 2009 ►; CC 2010 ► 15217
4 10 Sharan 2011 ► 15217
5 Capacity 15218
30 – Clutch 15219
1 Clutch 15219
1 1 Assembly overview – dual clutch 15219
1 2 Removing and installing clutch end cover 15221
1 3 Removing dual clutch 15227
1 4 Installing dual clutch 15228
34 – Controls, housing 15234
1 Electrical and electronic components and their locations ⇒ DSG® 15234
1 1 Removing and installing mechatronic unit for dual clutch gearbox -J743- (gearbox installed) 15234
1 2 Removing and installing mechatronic unit for dual clutch gearbox -J743- (gearbox removed) 15243
1 3 Removing and installing gearbox input speed sender -G182- and oil temperature sender in multi-plate clutch -G509- 15250
2 Removing and installing gear oil cooler 15251
3 Removing and installing oil pump 15254
4 Renewing selector shaft lever oil seal with gearbox removed 15258
5 Emergency release of selector lever 15260
6 Removing and installing selector lever handle 15261
6 1 Moving push-button in the handle to installation position 15263
6 1 1 Handle with push-button on side 15263
6 1 2 Handle with front push-button 15263
7 Selector mechanism up to 02 2009 15265
7 1 Overview of selector mechanism up to 02 2009 15265
7 2 Removing and installing selector lever cable up to 02 2009 15266
7 3 Checking selector lever cable 15273
7 4 Adjusting selector lever cable 15273
8 Checking selector mechanism 15275
8 1 Selector lever in “P” position and ignition switched on 15275
8 2 Selector lever in “N” position and ignition switched on 15275
8 3 Selector lever in position “Tiptronic” 15275
8 4 Ignition and light switched on 15275
8 5 Selector lever position indicator 15275
9 Selector mechanism from 03 2009 onwards 15276
9 1 Overview of selector mechanism in vehicles from 03 2009 onwards 15276
9 2 Removing and installing selector mechanism, from 03 2009 15277
9 2 1 Removing and installing selector mechanism with selector housing 15277
9 2 2 Removing and installing selector mechanism without selector housing 15279
10 Removing and installing gearbox 15281
10 1 Removing gearbox, Passat CC 2009 ►, CC 2010 ► with 2 0 l petrol engine 15281
10 2 Removing gearbox, Golf 2009 ►, Golf Plus 2009 ► with 2 0 l petrol engine 15288
10 3 Removing gearbox, Golf Plus 2005 ► with 1 4 l petrol engine 15297
10 4 Removing gearbox, Passat CC 2009 ►, CC 2010 ► diesel engine 15304
10 5 Removing gearbox, Passat CC 2009 ►, CC 2010 ► with diesel engine, all-wheel drive 15314
10 6 Removing gearbox, Golf Plus 2009 ► with 2 0 l diesel engine 15323
10 7 Removing gearbox, Golf 2009 ► 2 0 l diesel engine 15331
10 8 Removing gearbox, Passat CC 2009 ►, CC 2010 ► with 3 6 l – V6 engine (all-wheel drive) 15338
10 9 Removing gearbox, Golf 2004 ▸ with 1 9 l and 2 0 l diesel engine 15345
10 10 Removing gearbox, Golf 2004 ► with 125 kW – 2 0 l diesel engine 15352
10 11 Removing gearbox, Eos 2006 ►, with 3 2 and 3 6 l – V6 engine 15358
10 12 Removing gearbox, Golf 2004 ► with 1 4 l petrol engine 15365
10 13 Removing gearbox, Golf 2004 ► with 2 0 l petrol engine 15372
10 14 Removing gearbox, Golf 2004 ►, with 3 2 l – V6 engine (R32 all-wheel drive) 15377
10 15 Removing gearbox, Golf Plus 2005 ► with 1 9 l and 2 0 l diesel engine, with 2 0 l petrol engine 15386
10 16 Removing gearbox, Eos 2006 ► with 2 0 l petrol engine 15393
10 17 Removing gearbox, Eos 2005 ► with 2 0 l diesel engine 15400
10 18 Removing gearbox, Touran 2003 ► 15407
10 19 Removing gearbox, Passat 2006 ► with 2 0 l diesel engine 15415
10 20 Removing gearbox, Passat 2006 ► with 2 0 l petrol engine 15423
10 21 Removing gearbox, Passat 2006 ► with 3 6 l – V6 engine (all-wheel drive) 15428
10 22 Removing gearbox, Scirocco 2009 ► with 2 0 l diesel engine 15434
10 23 Removing gearbox, Scirocco 2009 ► with 2 0 l petrol engine 15443
10 24 Removing gearbox, Sharan 2011 ► with 2 0 l diesel engine 15452
10 25 Removing gearbox, Sharan 2011 ► with 1 8 l and 2 0 l petrol engine 15460
10 26 Removing gearbox, Sharan 2011 ► with 1 4 l petrol engine 15469
10 27 Install gearbox 15476
11 Torque settings »gearbox to engine« 15478
11 1 Torque settings (⇒ ELSA) 15478
11 1 1 Torque settings and note on engine mountings 15479
11 1 2 Torque settings and note on engine mountings 15480
11 1 3 Torque settings and note on engine mountings 15481
11 1 4 Torque settings and note on engine mountings 15483
11 1 5 Torque settings and note on engine mountings 15484
11 1 6 Torque settings and note on engine mountings 15485
12 Transporting gearbox and securing to assembly stand 15486
13 Removing and installing bevel box, Golf 2004 ► and Passat 2006 ► 15487
14 Removing and installing bevel box, Passat CC 2009 ►, CC 2010 ► with diesel engine 15492
14 1 Specified torques 15498
15 Removing and installing bevel box, Passat CC 2009 ►, CC 2010 ► with 3 6 l V6 engine 15500
16 Oil and oil filter 15504
16 1 Oil filter: renewing 15504
16 2 Checking oil level and topping up 15505
16 3 Draining and filling oil 15508
35 – Gears, shafts 15512
1 Currently, no repairs can be made to gears and shafts 15512
39 – Final drive – differential 15513
1 Overview – seals 15513
1 1 Renewing seals for right flange shaft or stub shaft – front-wheel drive 15514
2 Renewing oil seal for left flange shaft – front and all-wheel drive 15516
2 1 Renewing oil seal for right flange shaft – all-wheel drive 15517
2 2 Dismantling and assembling flange shaft 15519
3 Renewing oil seal for propshaft drive flange at bevel box 15521
4 Assembly overview – Flange shafts and seals on bevel box 15527
4 1 Renewing seal on gearbox between bevel box and gearbox 15528
4 2 Removing and installing right flange shaft 15529
4 3 Renewing seal for right flange shaft on outside of bevel box 15531
4 4 Renewing needle bearing (polygon bearing) for right output shaft drive flange 15532
4 5 Renewing seal on bevel box between gearbox and bevel box 15534
5 Checking and topping up gear oil in bevel box 15536
5 1 Checking gear oil in bevel box 15536
5 2 Topping up gear oil in bevel box 15537