Volkswagen Phaeton 2001-2008 Repair Manual – PDF DOWNLOAD

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Volkswagen Phaeton 2001-2008 Repair Manual – PDF DOWNLOAD

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Volkswagen Phaeton 2001-2008 Repair Manual – PDF DOWNLOAD

Language : English
Pages : 6705
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Volkswagen Phaeton 2001-2008 Repair Manual – PDF DOWNLOAD

00053148720 Wheels and Tyres Guide Standard 1
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
10053202020 Body Repairs 510
00 – Technical data 516
1 Vehicle identification data 516
2 Body dimensions 517
2 1 Body – front 517
2 2 Body – centre 520
2 3 Body – rear 525
2 4 Floor group – front 527
2 5 Floor group – centre 529
2 6 Floor group – rear 530
3 Body panel gaps/shut lines 532
3 1 Body – front 532
3 2 Body – rear 533
4 Moulded foam elements 534
5 Strengthened steel body panels 539
6 Galvanized body parts 540
7 Alignment bracket set 541
8 Portal gauge 542
50 – Body – front 544
1 Renewing mounting bracket for subframe 544
1 1 Removing 544
1 2 Installing 545
1 2 1 Welding in 545
2 Renewing headlight carrier 547
2 1 Removing 547
2 1 1 Cutting locations 547
2 1 2 Replacement part 548
3 Renewing extension of upper longitudinal member 549
3 1 Removing 549
3 1 1 Cutting locations 550
4 Reinforcement plate for wheel housing 552
4 1 Removing 552
4 1 1 Cutting locations 552
5 Renewing connecting plate for wheel housing 554
5 1 Removing 554
5 1 1 Cutting locations 554
6 Renewing reinforcement for wheel housing 556
6 1 Removing 556
6 1 1 Cutting locations 556
7 End plate for wheel housing 558
7 1 Removing 558
7 1 1 Cutting locations 558
8 Repairing threads for securing subframe (suspension subframe) 561
8 1 Tools 562
8 2 Contents of thread repair kit 562
8 3 Contents of thread repair kit 563
8 4 Repairing thread 564
8 4 1 Drilling thread 564
8 4 2 Cutting thread 565
8 4 3 Inserting thread insert 565
9 Renewing front wheel housing 567
9 1 Removing 567
10 Renewing front longitudinal member 569
10 1 Removing 569
10 1 3 Welding in 571
11 Renewing front part of longitudinal member – subpart 573
11 1 Removing 573
11 1 1 Cutting locations on left longitudinal member 573
11 1 2 Cutting locations on right longitudinal member 574
51 – Body – centre 577
1 Renewing roof 577
1 1 Removing 577
1 1 1 Cutting locations 578
2 Renewing roof 581
2 1 Removing 582
2 2 Installing 583
2 2 1 Preparing replacement part 583
2 2 2 Checking depth of middle section of roof 585
2 2 3 Bonding middle section of roof 586
2 2 4 Welding in 591
3 Renewing front roof cross member 593
3 1 Removing 593
3 1 1 Cutting locations 593
4 Renewing middle roof cross member 595
4 1 Removing 595
4 1 1 Cutting locations 595
5 Renewing rear roof cross member 597
5 1 Removing 597
5 1 1 Cutting locations 597
6 Renewing A-pillar 599
6 1 Removing 599
6 1 1 Cutting locations 600
6 1 2 Replacement parts 601
7 Renewing reinforcement for side panel 603
7 1 Removing 603
7 1 1 Cutting locations 604
8 Renewing outer B-pillar 606
8 1 Outer B-pillar 607
8 1 1 Cutting locations 608
8 1 2 Replacement parts 609
9 Renewing B-pillar reinforcement 610
9 1 Removing 610
9 1 1 Cutting locations 610
10 Renewing outer side member 612
10 1 Removing 613
10 1 1 Cutting locations 614
10 1 2 Replacement parts 615
10 1 3 Preparing replacement part 616
10 1 4 Welding in 617
11 Renewing side member reinforcement 618
11 1 Removing 618
11 1 1 Cutting locations 619
11 1 2 Replacement parts 619
12 Renewing side member reinforcement 621
12 1 Removing 621
12 2 Installing 624
12 2 1 Preparing replacement part 624
12 2 2 Moulded foam elements 625
12 2 3 Welding in 625
13 Renewing web plate for side member 627
13 1 Removing 627
13 1 1 Cutting locations 627
14 Renewing web plate for side member 629
14 1 Removing 629
14 2 Installing 632
14 2 1 Preparing replacement part 632
14 2 2 Welding in 633
15 Renewing seat anchor bracket in sill 635
15 1 Removing 635
15 2 Installing 636
15 2 1 Preparing replacement part 636
15 2 2 Welding in 636
16 Renewing floor panel – part section 637
16 1 Removing 637
16 2 Installing 639
16 2 1 Preparing replacement part 639
16 2 2 Welding in 640
17 Renewing front seat cross member 641
17 1 Removing 641
17 2 Installing 642
17 2 1 Preparing replacement part 642
17 2 2 Welding in 643
18 Renewing rear seat cross member 644
18 1 Removing 644
18 2 Installing 645
18 2 1 Preparing replacement part 645
18 2 2 Welding in 646
19 Renewing rear seat rail mounting bracket 647
19 1 Removing 647
19 2 Installing 648
19 2 1 Preparing replacement part 648
19 2 2 Welding in 648
53 – Body – rear 649
1 Renewing reinforcing for rear cross panel 649
1 1 Removing 649
1 1 1 Cutting locations 649
2 Renewing rear cross panel 651
2 1 Removing 651
2 1 1 Cutting locations 651
3 Renewing tail light mounting 653
3 1 Removing 653
3 1 1 Cutting locations 653
4 Renewing side panel 655
4 1 Removing 656
4 1 1 Cutting locations 656
4 1 2 Replacement parts 657
4 1 3 Foam insulation 657
5 Renewing spare wheel well 659
5 1 Removing 659
5 1 2 Bonding in 660
6 Renewing luggage compartment floor, part section 662
6 1 Removing 662
6 1 1 Cutting locations 662
6 1 2 Replacement part 663
7 Renewing rear longitudinal member 664
7 1 Removing 664
7 1 1 Cutting locations 664
7 1 2 Replacement parts 665
D3E8045FFDD Fuel supply system Petrol engines 666
00 – Technical data 670
1 Identification 670
1 1 Engine number, engine data 670
2 Safety instructions 671
2 1 Safety precautions when working on fuel supply system 671
2 2 Safety precautions during road tests in which testing and measuring equipment is used 673
3 General repair notes 674
3 1 Cleanliness specifications for working on the auxiliary heater and fuel system 674
20 – Fuel supply system 675
1 Fuel tank 675
1 1 Assembly overview – fuel tank 675
1 2 Removing and installing fuel tank 677
1 3 Emptying fuel tank 680
1 3 1 Emptying fuel tank when fuel pump is defective 680
1 3 2 Emptying fuel tank when fuel pump is intact 683
2 Fuel delivery unit, fuel gauge sender 686
2 1 Assembly overview – fuel delivery unit, fuel gauge sender 686
2 1 1 Assembly overview – fuel delivery unit/fuel gauge sender and suction-jet pump, left side 686
2 1 2 Assembly overview – fuel delivery unit/fuel gauge sender and suction-jet pump, right side 688
2 2 Removing and installing fuel delivery unit/fuel gauge sender 690
2 2 1 Removing and installing fuel delivery unit/fuel gauge sender, right side 691
2 2 2 Removing and installing fuel delivery unit/fuel gauge sender, left side 694
2 2 3 Schematic diagram of fuel lines and components in fuel tank 698
3 Separating push-on couplings 700
4 Activated charcoal filter system 704
4 1 Assembly overview – activated charcoal filter system 705
4 2 Checking fuel tank breather 706
5 Accelerator mechanism 709
5 1 Assembly overview – accelerator module 709
6 Fuel pump 711
6 1 Checking fuel pump 711
6 1 1 Checking fuel pressure 712
6 1 2 Checking holding pressure 714
6 1 3 Checking non-return valves of fuel pump 1 -V276- and fuel pump 2 -V277- 716
6 1 4 Checking fuel delivery rate 719
6 1 5 Checking current draw of pumps 722
D3E8045FFF7 Wheels and Tyres Guide 723
44 – Wheels, tyres, vehicle geometry 727
1 Wheel and tyre combination 727
1 1 General 727
1 2 Explanations regarding world regions 728
1 3 Phaeton, model year 2003 to model year 2009 – short and long wheelbase (type 3D) 729
1 4 Phaeton, model year 2010 to model year 2013 – short and long wheelbase (types 3D and 3d) 732
1 5 Phaeton, as of model year 2014 – short and long wheelbase (types 3D and 3d) 735
2 Wheel allocation 738
2 1 71/2 J x 16 738
2 2 71/2 J x 17 738
2 3 71/2 J x 18 740
2 4 81/2 J x 18 740
2 5 81/2 J x 19 offset 38 742
2 6 81/2 J x 19 offset 45 743
2 7 9 J x 19 offset 35 743
2 8 9 J x 19 offset 40 744
2 9 9 J x 20 745
3 Recommended summer tyres, worldwide except North America 746
4 Recommended all-season tyres, North America 747
5 Recommended winter tyres, worldwide except North America 748
6 Recommended temporary spare tyres and wheels 749
D3E8046D49A Wheels and Tyres Guide – General Information 750
44 – Wheels, tyres, vehicle geometry 758
1 Instructions on using the guide 758
1 1 Overview 758
1 1 1 Wheels and Tyres Guide – General Information 758
1 1 2 Wheels and Tyres Guide – Vehicle-specific section 758
1 2 General information 758
1 3 Notes 759
1 4 Determining correct wheel and tyre combinations, according to NEDC with tyre package 760
1 4 1 Determining the required tyre package via PR number 760
1 4 2 Determining the required tyre package via version key in the vehicle registration certificate part 1 760
1 5 Determining correct wheel and tyre combinations according to WLTP 761
1 5 1 Vehicle registration certificate part 1 761
1 5 2 COC document, item 0 10 763
1 6 NEDC, WLTP and RDE 763
1 6 1 What are NEDC, WLTP and RDE? 763
1 6 2 What are the differences between WLTP and RDE? 763
1 6 3 Since when are WLTP and RDE valid? 763
1 7 Definition of tyre package 763
1 8 Explanations regarding world regions 764
2 Legislative and technical conditions 766
2 1 Legislative conditions 766
2 1 1 Permissible wheel and tyre combinations in Germany 766
2 1 2 Vehicles with Tyre Pressure Monitoring System 766
2 2 Technical conditions 767
2 3 Load-carrying capacity depending on vehicle speed, winter tyres 767
2 4 Vehicle registration documents since 01 10 2005 769
2 5 COC document (EEC Certificate of Conformity) 770
2 6 EU general type approval number, sales type and sales or trade designation 770
3 Wheel change 773
3 1 Fitting instructions 773
3 2 Protecting wheel centring seat against corrosion 776
3 3 Fitting wheels 776
3 4 Position of anti-theft wheel bolts for steel wheels 777
4 Fitting tyre 779
4 1 Pressing tyre off wheel rim 779
4 2 Removing tyre sealant 780
4 3 Removing tyre from wheel 780
4 3 1 Removing tyres, wheels without and with tyre pressure monitoring 780
4 3 2 Removing tyres, run-flat tyres, ultra-high-performance tyres 782
4 4 Ensuring proper assembly temperature for tyres 784
4 5 Fitting tyre 785
4 5 1 Mounting tyre, wheels without and with tyre pressure monitoring 785
4 5 2 Mounting tyre, run-flat tyres, ultra-high performance tyres 787
4 6 Matching wheel rims and tyres 789
4 7 Checking radial and lateral runout of wheels and tyres 790
4 7 1 Checking radial and lateral runout of wheels and tyres, tolerances 790
4 7 2 Checking radial and lateral runout on wheels and tyres with tyre gauge 791
4 8 Matching wheels and tyres 792
4 9 Balancing wheel 793
4 9 1 Conditions 793
4 9 2 Balancing wheel on stationary wheel balancer 793
4 9 3 Balancing wheel with finish balancer 796
4 9 4 Checking radial and lateral run-out on wheel rim 797
4 10 Tyre sealant disposal 798
5 Tyre Pressure Monitoring System 799
5 1 System description – Tyre Pressure Monitoring System 799
5 1 1 System description – Tyre Pressure Monitoring System with indirect measurement (Tyre Pressure Loss Indicator) 799
5 1 2 System description – Tyre Pressure Monitoring System with direct measurement (with tyre pressure sensor) 801
5 1 3 Button behaviour – Tyre Pressure Monitoring System with direct measurement (with tyre pressure sensor) 801
5 1 4 System description – Tyre Pressure Monitoring System, Tyre Pressure Monitoring System (TPMS) with autolocation 802
5 2 Overview of fitting locations – Tyre Pressure Monitoring System 803
5 2 1 Overview of fitting locations – Tyre Pressure Monitoring System (TPMS) with autolocation 803
5 2 2 Overview of fitting locations – Tyre Pressure Monitoring System, Trigger 804
5 2 3 Overview of fitting locations – Tyre Pressure Monitoring System, Autolocation 806
5 3 Assembly overview – tyre pressure sensor 807
5 3 1 Assembly overview – tyre pressure sensor, tyre pressure sensor with valve 807
5 3 2 Assembly overview – tyre pressure sensor, tyre pressure sensor without valve, version 1 809
5 3 3 Assembly overview – tyre pressure sensor, tyre pressure sensor without valve, version 2 811
5 4 Removing and installing tyre pressure sensor -G222-/-G223-/-G224-/-G225- 812
5 4 1 Removing and installing tyre pressure sensor, tyre pressure sensor with valve 812
5 4 2 Removing and installing tyre pressure sensor, tyre pressure sensor without valve, version 1 (customer service version) 813
5 4 3 Removing and installing tyre pressure sensor, tyre pressure sensor without valve, version 1 (production version) 815
5 4 4 Removing and installing tyre pressure sensor -G222-/-G223-/-G224-/-G225-, version 2 818
5 5 Removing and installing Tyre Pressure Monitoring System control unit -J502- 820
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 821
5 5 2 Removing and installing tyre Tyre Pressure Monitoring System control unit, Passat 2011, Passat Estate 2011 823
5 5 3 Removing and installing Tyre Pressure Monitoring System control unit, CC 2010, CC 2012, Passat CC 2009 823
5 5 4 Removing and installing Tyre Pressure Monitoring System control unit, Phaeton 2003 823
5 5 5 Removing and installing Tyre Pressure Monitoring System control unit -J502-, Touran 2016 823
5 5 6 Removing and installing Tyre Pressure Monitoring System control unit -J502-, Tiguan 2008 824
5 5 7 Removing and installing Tyre Pressure Monitoring System control unit -J502-, Tiguan 2016, Tiguan 2017 (BW2), Tiguan 2021 825
5 5 8 Removing and installing Tyre Pressure Monitoring System control unit, up to model year 2014, Touareg 2010 826
5 5 9 Removing and installing Tyre Pressure Monitoring System control unit, as of model year 2015, Touareg 2015 827
5 5 10 Removing and installing Tyre Pressure Monitoring System control unit, Touareg 2018 828
5 5 11 Removing and installing bracket for Tyre Pressure Monitoring System control unit, Touareg 2015 829
5 6 Removing and installing tyre pressure monitor sender unit in wheel housing 829
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 829
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 830
5 6 3 Removing and installing sender unit for Tyre Pressure Monitoring System in wheel housing, Phaeton 2003 831
6 Wheel bolts 832
6 1 Wheel bolts, versions 832
6 2 Wheel bolts, anti-theft wheel bolt 834
6 3 Wheel bolts, adapter sets for anti-theft wheel bolts 834
7 Information on tyres 837
7 1 Identification markings on the tyre sidewall 837
7 2 Tyre dimension 839
7 3 Load rating code/load index (LI) 839
7 4 Speed rating code 840
7 5 EU tyre label 840
7 5 1 EU tyre label, summary 840
7 5 2 EU tyre label, objectives 841
7 5 3 EU tyre label, categories 842
7 6 Structure of a radial belted tyre 846
7 6 1 Cross section of a radial belted tyre 846
7 6 2 Run-flat tyres, structure and identification of a SST tyre 847
7 6 3 Run-flat tyres, seal inside technology 849
7 7 Run-flat tyre, SST (Self Supporting Tyre) 852
7 7 1 Run-flat tyres – general information 852
7 7 2 Run-flat tyres, retrofitting/requirements when using run-flat tyres 853
7 7 3 Run-flat tyres, repair work 853
7 8 Tyre storage 853
7 9 Reinforced and Extra Load (XL) tyres 854
7 10 M+S tyres 855
7 11 Winter tyres with speed symbol V 857
7 12 All-season tyres 858
7 13 Optimised rolling resistance tyres 859
7 14 Tyre ageing 859
7 15 Tyres with flange protection 861
7 16 Tyre sizes for vehicles with all-wheel drive 861
7 17 Increase in temperature due to insufficient tyre pressure 861
8 Tyre sealant 863
8 1 Models with breakdown set 863
8 2 Storage life 863
8 3 Disposal 863
9 Information about wheels (rims) 864
9 1 Structure of wheel (rim) 864
9 2 Identification 865
9 3 Composite wheels 866
9 4 Care and maintenance of alloy wheel rims 866
9 5 Restoring alloy wheels 866
9 6 Removing and installing hub cover for alloy wheels with open threaded connection 867
9 7 Renewing trim elements 868
9 7 1 Renewing trim elements, bonded trim elements 868
9 7 2 Renewing trim elements, bolted trim elements 872
9 8 Removing and installing valve 873
9 8 1 Removing and installing valve, description of the valve 873
9 8 2 Removing and installing valve, rubber valve 874
9 8 3 Removing and installing valve, metal valve 875
10 Handling problems 877
10 1 Rolling noise 877
10 1 1 General notes on tyre noise 877
10 1 2 Flat spots (from locking wheels) 878
10 2 Vehicle pulls to one side 879
10 2 1 General information 879
10 2 2 Conicity 879
10 2 3 Remedies when vehicle pulls to one side 881
10 2 4 Strategic rotation of wheels for non-directional tyres 882
10 2 5 Strategic rotation of wheels having unidirectional tyres 883
10 3 Vibration 884
10 3 1 Vibration, causes for vibration 884
10 3 2 Vibration, conducting a road test before balancing wheels 884
10 3 3 Vibration, vibration control system 884
10 4 Eliminating flat spots caused by storage or handling 885
11 Evaluating tyres 887
11 1 Flat spots caused by storage or handling 887
11 2 Undulations 887
11 3 Saw-tooth wear 888
11 4 Flat spots caused by hard braking 888
11 5 Swellings in the tyre sidewall 888
11 6 Cuts 890
11 7 Damage caused by foreign bodies 890
11 8 Stripped profile 891
11 9 Tyre damage due to insufficient tyre pressure 891
11 10 Checking tyres 892
11 11 Damage caused when fitting 893
12 Tyre wear 895
12 1 Factors influencing the service life of tyres 895
12 2 Saw-tooth wear 896
12 3 Wear behaviour of high-speed tyres 897
12 4 Measuring tread depth 897
12 5 One-sided wear 898
12 6 Outer shoulder wear 900
12 7 Diagonal washout 901
12 8 Wear in middle of tyre 902
12 9 Permissible deviation in tread depth 902
13 Overview of components 903
13 1 Assembly overview – wheel 903
14 Snow chains 906
14 1 Assembly and use of snow chains 906
15 Regular and temporary spare wheels, recommended temporary spare tyres 907
15 1 Spare wheel with yellow sticker 907
15 2 Temporary spare wheels and recommended temporary spare tyres 908
15 2 1 Atlas 2017 908
15 2 2 Golf 2013, e-Golf 2014 908
15 2 3 Golf 2017, e-Golf 2017 908
15 2 4 Golf SV 2015 908
15 2 5 Golf Variant 2014 909
15 2 6 Golf Variant 2017 909
15 2 7 Golf 2018 (AU2/BX6) 909
15 2 8 Jetta 2018 909
15 2 9 Taos 2021 910
D3E80404AD4 Fuel supply system Diesel engines 911
00 – Technical data 915
1 Engine data 915
2 Safety precautions 916
2 1 Safety precautions when working on fuel supply system 916
3 General repair notes 918
3 1 Rules for cleanliness 918
20 – Fuel supply system 919
1 Procedure when filling with incorrect fuel 919
1 1 Step 1 (Engine was started with incorrect fuel) 919
1 2 Step 2 (Engine was not started with incorrect fuel) 919
1 3 Step 3 (There are metal particles in fuel delivery unit and fuel tank) 920
1 4 Step 4 (There are no metal particles in fuel delivery unit and fuel tank) 920
1 5 Step 5 (There are metal particles in high-pressure pump) 921
1 6 Step 6 (There are no metal particles in high-pressure pump) 921
2 Fuel tank 922
2 1 Assembly overview – fuel tank 922
2 1 1 Assembly overview – fuel tank 922
2 1 2 Assembly overview – components on right-hand side in fuel tank 924
2 1 3 Assembly overview – components on left-hand side in fuel tank 926
2 1 4 Schematic diagram of fuel lines and components in fuel tank 927
2 2 Removing and installing fuel tank 929
2 3 Emptying fuel tank 930
3 Fuel delivery unit, fuel gauge sender 933
3 1 Removing and installing fuel delivery unit, fuel gauge sender 933
3 1 1 Removing and installing fuel pump 1 -V276-, fuel gauge sender and suction-jet pump on right side 933
3 1 2 Removing and installing fuel pump 2 -V277-, fuel gauge sender and suction-jet pump on left side 936
4 Push-on connectors 939
4 1 Detaching push-on couplings 939
5 Fuel cooler 943
5 1 Removing and installing fuel cooler 943
6 Fuel filter 944
6 1 Assembly overview – fuel filter 944
6 1 1 Assembly overview – fuel filter, engine codes BMK, CARA, CEXA, CEXB 944
6 1 2 Assembly overview – fuel filter, engine code AJS 945
6 2 Removing and installing fuel filter 947
6 2 1 Removing and installing fuel filter, engine code AJS 947
6 3 Fuel hoses in engine compartment, engine code AJS 948
7 Accelerator mechanism 950
7 1 Assembly overview – accelerator module 950
8 Fuel pump 951
8 1 Checking fuel pump 951
8 1 1 Checking fuel pressure of fuel pumps -V276-/-V277- 951
8 1 2 Checking fuel pressure of supplementary fuel pump -V393- 959
8 1 3 Checking fuel delivery rate of supplementary fuel pump -V393- 962
8 1 4 Checking tandem pump and fuel pump, engine code AJS 966
8 2 Removing and installing fuel pump 968
8 2 1 Removing and installing tandem pump and fuel pump, engine code AJS 968
8 3 Assembly overview – supplementary fuel pump -V393-, engine codes CARA, CEXA, CEXB 970
D3E8049715C Wheels and Tyres Guide 972
00 – Technical data 980
1 General notes on wheels and tyres (passenger cars) 980
1 1 Legislative conditions for converting wheel and tyre combinations 981
1 2 Technical conditions for converting wheel and tyre combinations 982
1 3 Official type designations 982
1 3 1 Official type approval, sales or trade designation 982
1 4 General information 984
1 4 1 Special models 984
1 4 2 Vehicles with Plus running gear 984
1 4 3 Speed ratings for tyres 985
1 4 4 “Series 80” tyres 986
1 4 5 Wheel bolts – torque settings 986
1 4 6 Revised wheel bolts for Sharan from model year 2001 986
1 4 7 Wheel rims – pitch circle diameter 987
1 4 8 Data on wheel rims 987
1 4 9 Split rim wheels 988
1 4 10 Alloy wheels with exchangeable trim elements 988
2 Facts about wheels and tyres (passenger cars) 989
2 1 Tyre wear/ mileage 989
2 1 1 General information 989
2 1 2 Requirements to be met by tyres 989
2 1 3 Wear behaviour of high-speed tyres 990
2 1 4 Factors influencing the service life of a tyre 990
2 1 5 Driving style 991
2 1 6 Tyre maintenance 992
2 1 7 Evenly worn tyres 993
2 1 8 Measuring tread depth 993
2 1 9 One-sided wear 994
2 1 10 Wear in middle of tyre 996
2 1 11 Diagonal washout 997
2 2 Tyre noise 998
2 2 1 General notes on tyre noise 998
2 2 2 Saw-tooth wear 999
2 2 3 Flat spots (from locking wheels) 1000
2 3 Rough running caused by wheels/tyres 1001
2 3 1 Causes of rough running 1001
2 3 2 Balancing wheels 1001
2 3 3 Conducting a road test before balancing wheels 1001
2 3 4 Balancing wheels on stationary wheel balancing machine 1002
2 3 5 Vibration control system -VAS 6230- 1003
2 3 6 Finish balancer 1004
2 3 7 Radial and lateral runout of wheels and tyres 1005
2 3 8 Checking radial and lateral runout on wheels and tyres with tyre gauge -V A G 1435- 1005
2 3 9 Checking radial and lateral runout on wheel 1007
2 3 10 Matching 1007
2 3 11 Flat spots caused by storage or handling 1009
2 4 Vehicle pulls to one side 1010
2 4 1 General information 1010
2 4 2 Conicity 1010
2 4 3 Remedies when vehicle pulls to one side 1012
2 4 4 Strategic rotation of wheels for non-directional tyres 1013
2 4 5 Strategic rotation of wheels having unidirectional tyres 1014
2 4 6 Tyres with a red spot 1014
2 5 Tyre damage 1015
2 5 1 General information 1015
2 5 2 Construction of a radial belted tyre 1016
2 5 3 Impact damage 1016
2 5 4 Cuts 1018
2 5 5 Damage caused by foreign bodies 1018
2 5 6 Loss of air from tyre 1019
2 5 7 Tyre pressure 1019
2 5 8 Tyre damage due to insufficient tyre pressure 1019
2 5 9 Rising tyre temperature caused by insufficient inflation pressure 1021
2 5 10 Tyre damage due to fitting error (fitting damage) 1022
2 6 Facts about wheels and tyres 1024
2 6 1 Identification markings on the tyre sidewall 1024
2 6 2 Explanation of tyre markings 1026
2 6 3 Undulations 1027
2 6 4 The valve 1028
2 6 5 Tyre storage 1029
2 6 6 Tyre ageing 1029
2 6 7 Care and maintenance of alloy wheel rims 1030
2 6 8 Rotating wheels 1031
2 6 9 Instructions for changing or fitting wheels 1031
2 6 10 Tyres with flange protection 1032
2 6 11 Notes on use of temporary spare wheels 1033
2 6 12 M+S tyres 1034
2 6 13 Winter tyres with speed symbol “V” 1035
2 6 14 Extra Load (XL) V winter tyres 1035
2 6 15 Reinforced and Extra Load (XL) tyres 1038
2 6 16 Snow chains 1038
44 – Wheels, tyres, vehicle geometry 1039
1 Lupo 3L, Lupo FSI, Lupo GTI from model year 1999 1039
1 1 Lupo 3L, type 6E model year 1999 to model year 2006 1039
1 2 Wheel allocation for Lupo 3L, type 6E model year 1999 to model year 2006 1040
1 2 1 4 J x 14 1040
1 2 2 41/2 J x 14 1041
1 2 3 5 J x 14 1041
1 3 Lupo FSI, type 6E model year 2001 to model year 2006 1041
1 4 Wheel allocation for Lupo FSI, type 6E model year 2001 to model year 2006 1042
1 4 1 5 J x 14 1042
1 4 2 6 J x 14 1043
1 5 Lupo GTI, type 6ES model year 2001 to model year 2006 1045
1 6 Wheel allocation for Lupo GTI, type 6ES model year 2001 to model year 2006 1046
1 6 1 6 J x 14 1046
1 6 2 61/2 J x 15 1047
2 Lupo model year 1999 to model year 2005 1049
2 1 Lupo, type 6X model year 1999 to model year 2005 1049
2 2 Wheel allocation for Lupo, type 6X model year 1999 to model year 2005 1051
2 2 1 41/2 J x 13 1051
2 2 2 51/2 J x 13 1052
2 2 3 6 J x 14 1054
2 2 4 6 J x 15 1057
3 Fox model year 2006 1059
3 1 Fox, type 5Z model year 2006 1059
3 2 Wheel allocation for Fox, type 5Z model year 2006 1060
3 2 1 5 J x 14 1060
3 2 2 6 J x 14 1061
3 2 3 6 J x 15 1063
4 Polo model year 1995 to model year 2002 1066
4 1 Polo, type 6N up to and including 07 95 1066
4 2 Wheel allocation for Polo, type 6N up to and including 07 95 1067
4 2 1 41/2 J x 13 1067
4 2 2 51/2 J x 13 1068
4 3 Polo, type 6N from 08 95 up to and including model year 1996 1069
4 4 Polo, type 6N from model year 1997 to model year 1999 1070
4 5 Wheel allocation for Polo, type 6N from 08 95 to model year 1999 1072
4 5 1 41/2 J x 13 1072
4 5 2 51/2 J x 13 1073
4 5 3 6 J x 14 1074
4 5 4 6 J x 15 1076
4 6 Polo, type 6N from model year 2000 to model year 2002 1078
4 7 Wheel allocation for Polo, type 6N from model year 2000 to model year 2002 1079
4 7 1 41/2 J x 13 1079
4 7 2 51/2 J x 13 1080
4 7 3 6 J x 14 1081
4 7 4 6 J x 15 1083
5 Polo from model year 2002 1086
5 1 Polo, type 9N model year 2002 to model year 2006 1086
5 2 Wheel allocation for Polo, type 9N model year 2002 to model year 2006 1088
5 2 1 5 J x 13 1089
5 2 2 5 J x 14 1089
5 2 3 6 J x 14 1090
5 2 4 6 J x 15 1091
5 2 5 61/2 J x 16 1093
6 Polo Fun from model year 2004 1097
6 1 Polo Fun, type 9N model year 2002 to model year 2006 1097
6 2 Wheel allocation for Polo Fun, type 9N model year 2004 to model year 2006 1098
6 2 1 6 J x 15 1098
6 2 2 71/2 J x 17 1099
7 Polo Classic model year 1996 to model year 2002 1100
7 1 Polo Classic, type 6KV model year 1996 to model year 2002 1100
7 2 Wheel allocation for Polo Classic, type 6KV model year 1996 to model year 2002 1102
7 2 1 51/2 J x 13 1102
7 2 2 6 J x 14 1103
7 2 3 6 J x 15 1105
8 Polo estate model year 1998 to model year 2002 1107
8 1 Polo estate type 6KV model year 1998 to model year 2002 1107
8 2 Wheel allocation for Polo estate type 6KV model year 1998 to model year 2002 1109
8 2 1 51/2 J x 13 1109
8 2 2 6 J x 14 1110
8 2 3 6 J x 15 1112
9 Polo saloon/sedan model year 2004 to model year 2005 1114
9 1 Polo saloon/sedan, type 9N model year 2004 to model year 2005 1114
9 2 Wheel allocation for Polo saloon/sedan, type 9N model year 2004 to model year 2005 1116
9 2 1 5 J x 14 1116
9 2 2 6 J x 14 1116
9 2 3 6 J x 15 1118
9 2 4 61/2 J x 16 1120
10 Golf model year 1992 to model year 1998 1122
10 1 Golf type 1HX0, Golf Syncro 1HX1, Golf type 1H 1122
10 2 Wheel allocation for Golf type 1HX0, Golf Syncro 1HX1, Golf type 1H 1125
10 2 1 51/2 J x 13 1126
10 2 2 6 J x 14 1127
10 2 3 6 J x 15 1131
10 2 4 61/2 J x 15 1135
10 2 5 7 J x 16 1139
11 Golf model year 1998 to model year 2004, Golf R32, Golf Anniversary GTI 1140
11 1 Golf, Golf 4Motion, type 1J model year 1998 to model year 2004 1140
11 2 Wheel allocation for Golf, Golf 4Motion, type 1J model year 1998 to model year 2004 1143
11 2 1 6 J x 14 1143
11 2 2 6 J x 15 1144
11 2 3 51/2 J x 16 1149
11 2 4 61/2 J x 16 1150
11 2 5 7 J x 17 1156
11 2 6 71/2 J x 17 1159
11 3 Conditions for fitting 17″ wheels and tyres to Golf model year 1998 to model year 2004 1159
11 4 Golf R32, type 1J model year 2003 to model year 2005 1160
11 5 Wheel allocation for Golf R32, type 1J model year 2003 to model year 2005 1161
11 5 1 51/2 J x 17 1161
11 5 2 71/2 J x 17 1162
11 5 3 71/2 J x 18 1163
11 6 Golf Anniversary GTI, type 1J model year 2002 1163
11 7 Wheel allocation for Golf Anniversary GTI, type 1J model year 2002 1164
11 7 1 51/2 J x 16 1164
11 7 2 61/2 J x 16 1165
11 7 3 7 J x 17 1167
11 7 4 71/2 J x 18 1169
11 8 Conditions for fitting 17″ and 18″ wheels and tyres of Golf Anniversary GTI 1170
12 Golf from model year 2004 1172
12 1 Golf, Golf 4Motion, type 1K model year 2004 to model year 2006 1172
12 2 Wheel allocation for Golf, Golf 4Motion, type 1K model year 2004 to model year 2006 1174
12 2 1 6 J x 15 1174
12 2 2 61/2 J x 15 1175
12 2 3 6 J x 16 1176
12 2 4 61/2 J x 16 1177
12 2 5 7 J x 17 1179
12 2 6 71/2 J x 17 1182
12 2 7 71/2 J x 18 1182
12 3 Golf GTI, type 1K model year 2005 to model year 2006 1183
12 4 Wheel allocation for Golf GTI, type 1K model year 2005 to model year 2006 1184
12 4 1 6 J x 16 1184
12 4 2 61/2 J x 16 1185
12 4 3 6 J x 17 1186
12 4 4 7 J x 17 1187
12 4 5 71/2 J x 17 1190
12 4 6 71/2 J x 18 1190
13 Golf Plus from model year 2005 1192
13 1 Golf Plus, type 1KP model year 2005 to model year 2006 1192
13 2 Wheel allocation for Golf Plus, type 1KP model year 2005 to model year 2006 1194
13 2 1 6 J x 15 1194
13 2 2 61/2 J x 15 1195
13 2 3 6 J x 16 1196
13 2 4 61/2 J x 16 1197
13 2 5 7 J x 17 1199
13 2 6 71/2 J x 18 1202
14 Golf estate model year 1994 to model year 1998 1204
14 1 Golf estate type 1HX0, Golf estate Syncro type 1HX1, Golf estate type 1H 1204
14 2 Wheel allocation for Golf estate type 1HX0, Golf estate Syncro type 1HX1, Golf estate type 1H 1207
14 2 1 51/2 J x 13 1207
14 2 2 6 J x 14 1208
14 2 3 6 J x 15 1213
14 2 4 61/2 J x 15 1217
15 Golf estate model year 1999 to model year 2006, Bora estate model year 1999 to model year 2005 1218
15 1 Golf estate, Golf estate 4Motion, Bora estate, Bora estate 4Motion, type 1J 1218
15 2 Wheel allocation for Golf estate, Golf estate 4Motion, Bora estate, Bora estate 4Motion, type 1J 1221
15 2 1 6 J x 15 1221
15 2 2 51/2 J x 16 1225
15 2 3 61/2 J x 16 1226
15 2 4 7 J x 17 1232
15 2 5 71/2 J x 17 1235
15 3 Conditions for fitting 17″ wheels and tyres 1236
16 Golf cabriolet model year 1994 to model year 1997 1238
16 1 Golf cabriolet type 1EX0 model year 1994 to model year 1997 1238
16 2 Wheel allocation for Golf cabriolet, type 1EX0 from model year 1994 to model year 1997 1239
16 2 1 6 J x 14 1240
16 2 2 6 J x 15 1241
16 2 3 61/2 J x 16 1242
17 Golf cabriolet model year 1998 to model year 2002 1244
17 1 Golf cabriolet; type 1E from model year 1998 to model year 2002 1244
17 2 Wheel allocation for Golf cabriolet; type 1E from model year 1998 to model year 2002 1245
17 2 1 6 J x 14 1245
17 2 2 6 J x 15 1248
17 2 3 61/2 J x 16 1250
18 Vento from model year 1992 to model year 1998 1251
18 1 Vento; type 1HX0, 1H 1251
18 2 Wheel allocation for Vento; type 1HX0, 1H 1253
18 2 1 51/2 J x 13 1253
18 2 2 6 J x 14 1255
18 2 3 6 J x 15 1258
18 2 4 61/2 J x 15 1261
19 Bora model year 1999 to model year 2005 1267
19 1 Bora, Bora 4Motion, type 1J model year 1999 to model year 2005 1267
19 2 Wheel allocation for Bora, Bora 4Motion, type 1J model year 1999 to model year 2005 1270
19 2 1 6 J x 15 1270
19 2 2 51/2 J x 16 1274
19 2 3 61/2 J x 16 1275
19 2 4 7 J x 17 1281
19 2 5 71/2 J x 17 1284
19 3 Conditions for fitting 17″ wheels and tyres 1285
20 Jetta from model year 2006 1287
20 1 Jetta, type 1KM from model year 2006 1287
20 2 Wheel allocation for Jetta, type 1KM from model year 2006 1289
20 2 1 6 J x 15 1289
20 2 2 61/2 J x 15 1290
20 2 3 6 J x 16 1290
20 2 4 61/2 J x 16 1291
20 2 5 7 J x 17 1293
21 New Beetle from model year 1999 1297
21 1 New Beetle, type 9C model year 1999 to model year 2006 1297
21 2 Wheel allocation for New Beetle, type 9C model year 1999 to model year 2006 1300
21 2 1 6 J x 15 1300
21 2 2 51/2 J x 16 1303
21 2 3 61/2 J x 16 1304
21 2 4 7 J x 17 1309
21 2 5 71/2 J x 17 1312
21 3 Conditions for fitting 17″ wheels and tyres 1313
22 New Beetle Cabriolet from model year 2003 1315
22 1 New Beetle Cabriolet, type 1Y, model year 2003 to model year 2006 1315
22 2 Wheel allocation for New Beetle Cabriolet, type 1Y model year 2003 to model year 2006 1317
22 2 1 6 J x 15 1317
22 2 2 51/2 J x 16 1320
22 2 3 61/2 J x 16 1321
22 2 4 7 J x 17 1325
22 2 5 71/2 J x 17 1329
22 3 Conditions for fitting 17″ wheels and tyres 1329
23 New Beetle RSi 1331
23 1 New Beetle RSi, type 9CR from model year 2001 1331
23 2 Wheel allocation for New Beetle RSi, type 9CR from model year 2001 1332
23 2 1 7 J x 16 1332
23 2 2 9 x 18 1333
24 Touran from model year 2003 1334
24 1 Touran, type 1T, model year 2003 to model year 2006 1334
24 2 Wheel allocation for Touran, type 1T model year 2003 to model year 2006 1337
24 2 1 6 J x 15 1337
24 2 2 61/2 J x 15 1338
24 2 3 6 J x 16 1339
24 2 4 61/2 J x 16 1340
24 2 5 7 J x 17 1342
25 Passat model year 1994 to model year 1997 1343
25 1 Passat, type 35l model year 1994 to model year 1997 1343
25 2 Wheel allocation for Passat, type 35l model year 1994 to model year 1997 1345
25 2 1 6 J x 14 1345
25 2 2 6 J x 15 1348
26 Passat model year 1997 to model year 2006 1353
26 1 Passat, Passat estate, type 3B model year 1997 to model year 2000 1353
26 2 Passat, Passat estate, type 3B model year 1997 to model year 2000 1355
26 2 1 6 J x 15 1355
26 2 2 7 J x 15 1357
26 2 3 7 J x 16 1358
26 3 Passat, Passat estate, type 3BG model year 2001 to model year 2006 1359
26 4 Wheel allocation for Passat, Passat estate, type 3BG model year 2001 to model year 2006 1361
26 4 1 6 J x 15 1361
26 4 2 7 J x 15 1362
26 4 3 6 J x 16 1364
26 4 4 7 J x 16 1365
26 4 5 7 J x 17 1367
26 5 Passat W8 4Motion, type 3BS model year 2002 to model year 2005 1368
26 6 Wheel allocation for Passat W8 4Motion, type 3BS model year 2002 to model year 2005 1369
26 6 1 7 J x 16 1370
26 6 2 6 J x 17 1370
26 6 3 71/2 J x 17 1371
26 7 Passat Protect, type 3BL model year 2002 to model year 2005 1371
26 8 Wheel allocation for Passat Protect, type 3BL model year 2002 to model year 2005 1372
26 8 1 6 J x 16 1373
26 8 2 7 J x 16 1373
27 Passat from model year 2006 1375
27 1 Passat, type 3C from model year 2006 1375
27 2 Wheel allocation for Passat, type 3C from model year 2006 1377
27 2 1 61/2 J x 16 1378
27 2 2 7 J x 16 1378
27 2 3 6 J x 17 1380
27 2 4 71/2 J x 17 1380
27 2 5 8 J x 18 1383
28 Phaeton from model year 2003 1385
28 1 Phaeton, type 3D, model year 2003 to model year 2006 – short and long wheelbase 1385
28 2 Wheel allocation for Phaeton, type 3D model year 2003 to model year 2006 – short and long wheelbase 1387
28 2 1 71/2 J x 16 1388
28 2 2 71/2 J x 17 1388
28 2 3 71/2 J x 18 1390
28 2 4 81/2 J x 18 1390
28 2 5 81/2 J x 19 1392
28 2 6 9 J x 19 1392
29 Sharan from model year 1996 1393
29 1 Sharan, Sharan Syncro, type 7M model year 1996 to model year 2000 1393
29 2 Wheel allocation for Sharan, Sharan Syncro Type 7M model year 1996 to model year 2000 1396
29 2 1 6 J x 15 1396
29 2 2 7 J x 15 1396
29 2 3 7 J x 16 1397
29 3 Sharan, Sharan 4Motion, type 7M model year 2001 1398
29 4 Wheel allocation for Sharan, Sharan 4Motion, type 7M model year 2001 1400
29 4 1 6 J x 15 1400
29 4 2 7 J x 15 1401
29 4 3 6 J x 16 1402
29 4 4 7 J x 16 1403
29 5 Sharan, Sharan 4Motion, type 7M model year 2002 to model year 2006 1406
29 6 Wheel allocation for Sharan, Sharan 4Motion, type 7M model year 2002 to model year 2006 1408
29 6 1 6 J x 16 1408
29 6 2 7 J x 16 1409
29 6 3 7 J x 17 1412
30 Touareg from model year 2003 1413
30 1 Touareg, type 7L, model year 2003 to model year 2006 1413
30 2 Wheel allocation for Touareg, type 7L model year 2003 to model year 2006 1416
30 2 1 7 J x 16 1416
30 2 2 71/2 J x 17 1417
30 2 3 8 J x 18 1418
30 2 4 9 J x 19 1421
30 2 5 9 J x 20 1425
30 2 6 91/2 J x 20 1426
31 Breakdown set for VW Vehicles 1427
32 Temporary spare tyres and wheels for VW vehicles 1428
33 Approved makes of summer tyres for initial fitting 1431
33 1 Summer tyres for Lupo 3L from model year 1999 1431
33 2 Summer tyres for Lupo FSI from model year 1999 1431
33 3 Summer tyres for Lupo GTI from model year 1999 1431
33 4 Summer tyres for Lupo model year 1999 to model year 2005 1431
33 5 Summer tyres for Fox from model year 2006 1431
33 6 Summer tyres for Polo, model year 1995 to model year 2002 1432
33 7 Summer tyres for Polo from model year 2002 1433
33 8 Summer tyres for Polo saloon/sedan from model year 2004 1433
33 9 Summer tyres for Polo Fun from model year 2004 1434
33 10 Summer tyres for Polo Classic model year 1996 to model year 2002 1434
33 11 Summer tyres for Polo estate model year 1998 to model year 2002 1435
33 12 Summer tyres for Golf, Vento model year 1992 to model year 1998 1435
33 13 Summer tyres for Golf estate model year 1994 to model year 1998 1436
33 14 Summer tyres for Golf cabriolet model year 1994 to model year 1997 1436
33 15 Summer tyres for Golf, Golf 4Motion model year 1998 to model year 2004 1437
33 16 Summer tyres for Bora, Bora 4Motion model year 1999 to model year 2005 1438
33 17 Summer tyres for Golf estate, Golf estate 4Motion model year 1999 to model year 2006, Bora estate, Bora estate 4Motion model year 1999 to model year 2005 1439
33 18 Summer tyres for Golf R32 1439
33 19 Summer tyres for Golf Anniversary GTI 1440
33 20 Summer tyres for Golf Cabriolet, model year 1998 to model year 2002 1440
33 21 Summer tyres for New Beetle from model year 1999 1441
33 22 Summer tyres for New Beetle Cabriolet from model year 2003 1442
33 23 Summer tyres for New Beetle RSi 1443
33 24 Summer tyres for Golf from model year 2004 1443
33 25 Summer tyres for Golf GTI from model year 2005 1444
33 26 Summer tyres for Golf Plus from model year 2005 1444
33 27 Summer tyres for Jetta from model year 2006 1445
33 28 Summer tyres for Touran from model year 2003 1445
33 29 Summer tyres for Passat model year 1994 to model year 1997 1446
33 30 Summer tyres for Passat model year 1997 to model year 2006 1446
33 31 Summer tyres for Passat W8 1447
33 32 Summer tyres for Passat Protect 1447
33 33 Summer tyres for Passat from model year 2006 1447
33 34 Summer tyres for Phaeton from model year 2003 1448
33 35 Summer tyres for Sharan from model year 1996 1448
33 36 Summer tyres for Touareg from model year 2003 1449
34 Approved makes of all-season tyres for initial fitting 1450
34 1 All-season tyres for Lupo, model year 1999 to model year 2005 1450
34 2 All-season tyres Polo model year 1995 to model year 2002 1450
34 3 All-season tyres from model year 2002 1450
34 4 Summer tyres for Polo saloon/sedan from model year 2004 1450
34 5 All-season tyres Golf, Vento model year 1992 to model year 1998 1450
34 6 All-season tyres Golf estate model year 1994 to model year 1998 1450
34 7 All-season tyres Golf cabriolet model year 1994 to model year 1997 1451
34 8 All-season tyres Golf, Golf 4Motion model year 1998 to model year 2004 1451
34 9 All-season tyres Bora, Bora 4Motion model year 1999 to model year 2005 1451
34 10 All-season tyres Golf estate, Golf estate 4Motion model year 1999 to model year 2006, Bora estate, Bora estate 4Motion model year 1999 to model year 2005 1452
34 11 All-season tyres Golf cabriolet model year 1998 to model year 2002 1452
34 12 All-weather tyres New Beetle from model year 1999 1452
34 13 All-weather tyres New Beetle Cabriolet from model year 2003 1452
34 14 All-weather tyres Golf from model year 2004 1453
34 15 All-season tyres for Golf Plus from model year 2005 1453
34 16 All-season tyres for Jetta from model year 2006 1453
34 17 All-weather tyres Touran from model year 2003 1454
34 18 All-season tyres for Passat, model year 1997 to model year 2006 1454
34 19 All-season tyres for Passat W8 1454
34 20 All-weather tyres Passat from model year 2006 1454
34 21 All-weather tyres Phaeton from model year 2003 1455
34 22 All-weather tyres Touareg from model year 2003 1455
35 Approved makes of winter tyres for initial fitting 1456
35 1 Winter tyres for Lupo 3L from model year 1999 1456
35 2 Winter tyres for Lupo FSI from model year 1999 1456
35 3 Winter tyres for Lupo GTI from model year 1999 1456
35 4 Winter tyres Lupo model year 1999 to model year 2005 1456
35 5 Winter tyres for Fox from model year 2006 1456
35 6 Winter tyres for Polo model year 1995 to model year 2002 1457
35 7 Winter tyres Polo from model year 2002 1457
35 8 Summer tyres for Polo saloon/sedan from model year 2004 1457
35 9 Summer tyres for Polo Fun from model year 2004 1458
35 10 Winter tyres Polo Classic model year 1996 to model year 2002 1458
35 11 Winter tyres Polo estate model year 1998 to model year 2002 1458
35 12 Winter tyres Golf, Vento model year 1992 to model year 1998 1459
35 13 Winter tyres Golf estate model year 1994 to model year 1998 1459
35 14 Winter tyres Golf cabriolet model year 1994 to model year 1997 1459
35 15 Winter tyres Golf, Golf 4Motion model year 1998 to model year 2004 1460
35 16 Winter tyres Bora, Bora 4Motion model year 1999 to model year 2005 1460
35 17 Winter tyres Golf estate, Golf estate 4Motion model year 1999 to model year 2006, Bora estate, Bora estate 4Motion model year 1999 to model year 2005 1461
35 18 Winter tyres for Golf R32 1461
35 19 Winter tyres for Golf Anniversary GTI 1461
35 20 Winter tyres Golf cabriolet model year 1998 to model year 2002 1461
35 21 Winter tyres New Beetle from model year 1999 1462
35 22 Winter tyres New Beetle Cabriolet from model year 2003 1462
35 23 Winter tyres for New Beetle RSi 1463
35 24 Winter tyres Golf from model year 2004 1463
35 25 Winter tyres for Golf GTI from model year 2005 1463
35 26 Winter tyres for Golf Plus from model year 2005 1463
35 27 Winter tyres for Jetta from model year 2006 1463
35 28 Winter tyres Touran from model year 2003 1464
35 29 Winter tyres for Passat model year 1994 to model year 1997 1464
35 30 Winter tyres for Passat model year 1997 to model year 2006 1464
35 31 Winter tyres for Passat W8 1465
35 32 Winter tyres for Passat Protect 1465
35 33 Winter tyres Passat from model year 2006 1465
35 34 Winter tyres Phaeton from model year 2003 1465
35 35 Winter tyres Sharan from model year 1996 1466
35 36 Winter tyres Touareg from model year 2003 1466
36 Approved makes of offroad tyres for initial fitting 1467
36 1 Offroad tyres for Touareg from model year 2003 1467
D4B807E3B5B Body Repairs General Body Repairs 1468
1 Safety instructions 1472
1 1 Part removal 1472
1 2 Battery and welding operation 1472
1 3 Electronic control unit 1472
1 3 1 Processing of the electronic control unit after repair dueto a traffic accident 1472
1 4 Paint, glass, soft pad and trim 1473
1 5 Fuel tank or fuel delivery pipeline 1473
1 6 Air conditioner 1473
1 6 1 Remedial measures: 1473
1 7 Airbag System 1474
1 8 Check the seat belts 1474
1 8 1 Belt body 1475
1 8 2 Automatic retractor (locking function) 1475
1 8 3 Visual inspection of the seat belt buckle 1476
1 8 4 Seat belt buckle function 1476
1 8 5 Seat belt guide member and tongue 1477
1 8 6 Fixing piece and fixing point 1477
1 9 Safety specifications for the seat belt tensioner 1477
1 10 Body repair on a vehicle equipped with the seat belt tensioners 1478
1 10 1 The following vehicles have been equipped with: 1478
1 11 Perform cutting off, correcting and/or leveling on a vehicleequipped with airbags 1479
1 12 Remove the front seats with a side airbag 1479
2 Basic instruction 1480
2 1 Diagnosis of the accident vehicle 1480
2 2 Condition of the body and/or the parts for delivery to thepainting workshop 1480
2 3 Correction 1480
2 4 Cutting 1480
2 5 Body-cut part and part section 1480
2 6 Original connection 1481
2 7 Galvanized body parts 1481
2 8 Remove the rest part 1481
2 9 New parts 1481
2 10 Parts 1481
2 11 Molded foam plastic pads 1482
3 Symbolic interpretation 1483
3 1 Symbolic interpretation for welding 1483
3 2 Symbolic interpretation for the operation method 1483
3 2 1 Grinding 1484
3 2 2 Thinning 1484
3 2 3 Punching 1484
3 2 4 Drilling 1485
3 2 5 Polishing 1485
3 2 6 Cavity corrosion protection 1485
3 2 7 Bonding 1486
3 2 8 Precise sealing 1486
4 Body repair tools 1487
4 1 Flaring tool -V A G 1317- 1487
4 2 Punching pliers -V A G 1329- 1487
4 3 Basic equipment -V A G 1366/3- 1487
4 4 Bottom protection layer spray gun -V A G 1379- 1488
4 5 Electric blower -V A G 1416- 1488
4 6 Door tensioner -V A G 1438- 1488
4 7 Body equipment component -V A G 1439- 1489
4 8 Pneumatic cutting knife -V A G 1523 A- 1489
4 9 Air chisel -V A G 1577- 1489
4 10 Edge closing iron block -V A G 1585- 1490
4 11 Welding fume ventilator -V A G 1586- 1490
4 12 Welding spot releasing device -V A G 1731- 1490
4 13 Pneumatic spray gun -V A G 1761/1- 1491
4 14 Pneumatic punching and thinning pliers -VAS 1996- 1491
4 15 Pneumatic adhesive spray gun -V A G 2005- 1491
4 16 Door hinge correction tool 1492
4 17 Hose kit 5023 for the inert gas protection welding 1492
4 18 Angle grinder -VAS 5174- 1492
4 19 Angle grinder -VAS 5175- 1493
4 20 Wire brush -VAS 5182- 1493
5 Body bonding 1494
5 1 Transporter 1991 → 1494
5 1 1 Separation process: 1494
5 1 2 Bonding process: 1494
5 2 Bonding types 1494
5 2 1 Bonding-strong 1494
5 2 2 Bonding-spot welding 1495
5 3 Repair method for replacing the parts 1495
5 3 1 Spot welding and bonding 1495
5 3 2 Plug welding and bonding (if spot welding is impossible) 1495
5 3 3 Welding fume ventilator 1496
5 3 4 Preparations 1496
5 3 5 Trimming 1496
6 Corrosion protection measures 1497
6 1 Corrosion protection 1497
7 Waste disposal instructions 1498
7 1 Waste disposal 1498
7 2 Air pressure tappet exhaust 1498
7 3 Airbag 1499
7 3 1 Waste disposal 1499
8 Contact corrosion protection 1500
8 1 Connection of aluminum alloy/magnesium alloy with steel 1500
9 Steel plate repair 1501
9 1 High-strength body plate 1501
9 2 Galvanized body parts 1501
9 2 1 Preparations 1501
9 2 2 Part cutting 1502
9 2 3 Connection process 1502
9 3 Welding on the galvanized body steel plate 1502
9 3 1 Inert gas protection plug welding SG of the galvanized steelplate 1502
9 3 2 Resistance pressure spot welding RP of the galvanized steelplate 1503
9 3 3 Welding transformer 1503
9 3 4 Welding clamp 1503
9 4 Tearing test 1503
10 Aluminum repair 1504
10 1 Painting 1504
10 2 Surface treatment 1504
10 3 Leveling 1505
10 4 Temperature control for heating 1505
11 Plastic repair method 1506
11 1 Material 1506
11 2 Repairing the pit 1507
11 3 Repairing the scratch 1508
11 4 Repair the crack 1510
11 5 Repairing the small hole (the diameter is more than 30 mm) 1511
11 6 Plastic repair (glass fibre material) 1512
11 7 Repair process 1513
11 7 1 Repairing the breakage position 1513
11 7 2 Repairing the surface damage 1515
12 Glass repair 1516
12 1 Repairing the windshield 1516
12 1 1 Premises 1516
12 1 2 Required special tools, operating equipment, testing instrumentsand auxiliary tools 1517
12 1 3 Repair description 1518
D4B80796BA2 Wheels and Tyres Guide General Information 1522
44 – Wheels, tyres, vehicle geometry 1526
1 Instructions on using the guide 1526
1 1 Overview 1526
1 1 1 Wheels and Tyres Guide – General Information 1526
1 1 2 Wheels and Tyres Guide – Vehicle-specific Section 1526
1 2 General information 1526
1 3 Notes 1527
1 4 Explanations regarding world regions 1528
1 5 Definition of tyre package 1528
1 6 Procedure for determining the required tyre package 1529
1 6 1 Determining the required tyre package via PR number 1529
1 6 2 Determining the required tyre package via version key in the vehicle registration certificate part 1 1529
1 7 Vehicle registration certificate part 1 1530
2 Legislative and technical conditions 1532
2 1 Legislative conditions 1532
2 1 1 Permissible wheel and tyre combinations in Germany 1532
2 1 2 Vehicles with Tyre Pressure Monitoring System 1532
2 2 Technical conditions 1533
2 3 Load-carrying capacity depending on vehicle speed, winter tyres 1533
2 4 Vehicle registration documents since 1 10 2005 1535
2 5 COC document (EEC Certificate of Conformity) 1536
2 6 EU general type approval number, sales type and sales or trade designation 1536
3 Wheel change 1538
3 1 Fitting instructions 1538
3 2 Protecting wheel centring seat against corrosion 1541
3 3 Fitting wheels 1542
3 4 Position of anti-theft wheel bolts for steel wheels 1542
4 Fitting tyre 1543
4 1 Pressing tyre off wheel rim 1543
4 2 Removing tyre sealant 1543
4 3 Removing tyre from wheel 1544
4 3 1 Removing tyres, wheels without and with tyre pressure monitoring 1544
4 3 2 Removing tyres, run-flat tyres, ultra-high-performance tyres 1545
4 4 Ensuring proper assembly temperature for tyres 1547
4 5 Mounting tyre 1548
4 5 1 Mounting tyre, wheels without and with tyre pressure monitoring 1548
4 5 2 Mounting tyre, run-flat tyres, ultra-high performance tyres 1550
4 6 Matching wheel rims and tyres 1553
4 7 Checking radial and lateral runout of wheels and tyres 1554
4 7 1 Checking radial and lateral runout of wheels and tyres, tolerances 1554
4 7 2 Checking radial and lateral runout on wheels and tyres with tyre gauge 1554
4 8 Matching wheels and tyres 1555
4 9 Balancing wheel 1556
4 9 1 Conditions 1556
4 9 2 Balancing wheel on stationary wheel balancer 1557
4 9 3 Balancing wheel with finish balancer 1560
4 9 4 Checking radial and lateral run-out on wheel rim 1561
4 10 Tyre sealant disposal 1562
5 Tyre pressure monitoring system 1563
5 1 System description – tyre pressure monitoring system 1563
5 1 1 System description – tyre pressure monitoring system with indirect measurement (Tyre Pressure Loss Indicator) 1563
5 1 2 System description – tyre pressure monitoring system with direct measurement (Tyre Pressure Monitoring System) 1564
5 1 3 System description – tyre pressure monitoring system, tyre pressure monitoring system (TPMS) with autolocation 1565
5 2 Overview of fitting locations – tyre pressure monitor system 1565
5 2 1 Overview of fitting locations – Tyre Pressure Monitoring System (TPMS) with autolocation 1565
5 3 Assembly overview – tyre pressure sensor 1567
5 3 1 Assembly overview – tyre pressure sensor, tyre pressure sensor with valve 1567
5 3 2 Assembly overview – tyre pressure sensor, tyre pressure sensor without valve, version 1 1568
5 3 3 Assembly overview – tyre pressure sensor, tyre pressure sensor without valve, version 2 1569
5 4 Removing and installing tyre pressure sensor -G222-/-G223-/-G224-/-G225- 1570
5 4 1 Removing and installing tyre pressure sensor, tyre pressure sensor with valve 1570
5 4 2 Removing and installing tyre pressure sensor, tyre pressure sensor without valve, version 1 (customer service version) 1571
5 4 3 Removing and installing tyre pressure sensor, tyre pressure sensor without valve, version 1 (production version) 1572
5 4 4 Removing and installing tyre pressure sensor -G222-/-G223-/-G224-/-G225-, version 2 1574
5 5 Removing and installing tyre pressure monitor control unit -J502- 1577
5 5 1 Removing and installing Tyre Pressure Monitoring System control unit -J502-, Arteon 2018, Passat 2015, Passat Estate 2015 1577
5 5 2 Removing and installing tyre pressure monitoring system control unit -J502-, Touran 1578
6 Wheel bolts 1580
6 1 Wheel bolts, versions 1580
6 2 Wheel bolts, anti-theft wheel bolt 1581
6 3 Wheel bolts, adapter sets for anti-theft wheel bolts 1581
7 Information on tyres 1584
7 1 Identification markings on the tyre sidewall 1584
7 2 Tyre dimension 1586
7 3 Load rating code/load index (LI) 1586
7 4 Speed rating code 1587
7 5 EU tyre label 1587
7 5 1 EU tyre label, summary 1587
7 5 2 EU tyre label, objectives 1588
7 5 3 EU tyre label, categories 1589
7 6 Structure of a radial belted tyre 1592
7 6 1 Cross section of a radial belted tyre 1592
7 6 2 Run-flat tyres, structure and identification of a SST tyre 1593
7 6 3 Run-flat tyres, seal inside technology 1594
7 7 Run-flat tyre, SST (Self Supporting Tyre) 1596
7 7 1 Run-flat tyres – general information 1596
7 7 2 Run-flat tyres, retrofitting/requirements when using run-flat tyres 1597
7 7 3 Run-flat tyres, repair work 1598
7 8 Tyre storage 1598
7 9 Reinforced and Extra Load (XL) tyres 1598
7 10 Winter tyres 1599
7 11 Winter tyres with speed symbol V 1601
7 12 Rolling resistance optimised tyres 1602
7 13 Tyre ageing 1602
7 14 Tyres with flange protection 1604
7 15 Tyre sizes for vehicles with four-wheel drive 1604
7 16 Increase in temperature due to insufficient tyre pressure 1605
8 Tyre sealant 1606
8 1 Models with breakdown set 1606
8 2 Storage life 1606
8 3 Waste disposal 1606
9 Information on wheel rims 1607
9 1 Structure of wheel rim 1607
9 2 Identification 1608
9 3 Composite wheels 1608
9 4 Care and maintenance of alloy wheel rims 1608
9 5 Restoring alloy wheels 1609
9 6 Removing and installing hub cover for alloy wheels with open threaded connection 1609
9 7 Renewing trim elements 1610
9 7 1 Renewing trim elements, bonded trim elements 1610
9 7 2 Renewing trim elements, bolted trim elements 1614
9 8 Removing and installing valve 1616
9 8 1 Removing and installing valve, description of the valve 1616
9 8 2 Removing and installing valve, rubber valve 1616
9 8 3 Removing and installing valve, metal valve 1617
10 Handling problems 1619
10 1 Rolling noise 1619
10 1 1 General notes on tyre noise 1619
10 1 2 Flat spots (from locking wheels) 1620
10 2 Vehicle pulls to one side 1621
10 2 1 General information 1621
10 2 2 Conicity 1621
10 2 3 Remedies when vehicle pulls to one side 1622
10 2 4 Strategic rotation of wheels for non-directional tyres 1623
10 2 5 Strategic rotation of wheels having unidirectional tyres 1624
10 3 Vibration 1625
10 3 1 Vibration, causes for vibration 1625
10 3 2 Vibration, conducting a road test before balancing wheels 1625
10 3 3 Vibration, vibration control system 1626
10 4 Eliminating flat spots caused by storage or handling 1626
11 Evaluating tyres 1628
11 1 Flat spots caused by storage or handling 1628
11 2 Undulations 1628
11 3 Saw-tooth wear 1629
11 4 Flat spots caused by hard braking 1629
11 5 Swellings in the tyre sidewall 1629
11 6 Cuts 1631
11 7 Damage caused by foreign bodies 1631
11 8 Stripped profile 1631
11 9 Tyre damage due to insufficient tyre pressure 1632
11 10 Checking tyres 1632
11 11 Damage caused when fitting 1633
12 Tyre wear 1635
12 1 Factors influencing the service life of tyres 1635
12 2 Saw-tooth wear 1636
12 3 Wear behaviour of high-speed tyres 1636
12 4 Measuring tread depth 1637
12 5 One-sided wear 1637
12 6 Outer shoulder wear 1640
12 7 Diagonal washout 1641
12 8 Wear in middle of tyre 1641
12 9 Permissible deviation in tread depth 1642
13 Exploded view of components 1643
13 1 Assembly overview – wheel 1643
14 Snow chains 1645
14 1 Assembly and use of snow chains 1645
15 Regular and temporary spare wheels, recommended temporary spare tyres 1646
15 1 Spare wheel with yellow sticker 1646
15 2 Temporary spare wheels and recommended temporary spare tyres 1647
15 2 1 Arteon 2018 1647
15 2 2 Atlas 2017 1647
15 2 3 Golf 2013, e-Golf 2014 1647
15 2 4 Golf 2017, e-Golf 2017 1647
15 2 5 Golf SV 2015 1648
15 2 6 Golf Estate 2014 1648
15 2 7 Golf Estate 2017 1648
15 2 8 Passat 2015, Passat Estate 2015 1648
15 2 9 Polo 2018 1649
15 2 10 Tiguan 2016 1649
D4B802605A6 General information Paint passenger vehicles 1650
00 – Technical data 1656
1 Safety information 1656
1 1 Safety precautions when painting natural gas-powered vehicles 1656
1 2 Safety precautions when painting electric drive vehicles 1657
2 General information 1658
2 1 Paintwork structure of a factory finish 1658
2 2 Paint structure of service department finish 1661
2 2 1 Paintwork structure, base coat 1661
2 2 2 Paintwork structure, metallic effect 1664
2 3 Fundamental approach to dealing with areas sanded through to the substrate (bare metal surface) 1666
2 4 Reduced paint structure in engine compartment and inside of bonnet 1666
2 5 Instructions for work on underbody and stone chip protection 1666
2 6 Work instruction for window flange area 1668
2 7 Pre-treatment of bonded surfaces when renewing laser-welded roofs 1670
2 8 Corrosion protection measures for wing surface in contact with wheel housing liner 1674
2 9 Notes on treating corroded fold areas 1675
2 10 Corrosion protection for body components, add-on components and welded components 1677
2 11 Painting parking aid sensor 1678
2 12 ACC – Adaptive Cruise Control 1680
2 13 Instructions for painting bumper cover in area of lane change assist control unit 1680
3 Genuine products 1682
3 1 Paint products in customer service 1682
3 2 General application instructions for repair and painting systems 1683
3 2 1 Aqua Premium – application instructions for water-based products 1683
3 2 2 Setting gloss level of HS clear coats and HS top coats with matting additive 1686
3 2 3 Setting gloss level of 2-pack HS clear coats with 2-pack clear coat, matt 1696
3 2 4 Repair paintwork system for matt-finished vehicles 1698
3 2 5 Paintwork system for plastic components 1703
3 2 6 Aqua Premium system, blending system for 2-stage colours 1711
3 2 7 Aqua Premium system, blending system for 3-stage colours 1720
3 2 8 Aqua Premium system, product preparation for processing 1727
3 2 9 Aquaplus design and multi-colour painting 1734
3 2 10 Processing instructions for paint with limited hiding power 1739
3 3 Filler 1739
3 3 1 2-pack steel filler set 1739
3 3 2 2-pack fine filler 1743
3 3 3 2-pack fine filler, flexible 1747
3 3 4 2-pack spray filler 1750
3 3 5 2-pack IR premium filler 1756
3 3 6 2-pack epoxy resin filler 1761
3 4 Priming metal 1765
3 4 1 1-pack anti-corrosion wash primer 1765
3 4 2 1-pack wash primer 1770
3 4 3 2-pack wash primer 1775
3 5 Priming plastic materials 1781
3 5 1 Adhesion promoter (transparent) 1781
3 6 Surfacer 1785
3 6 1 2-pack HS Vario surfacer 1785
3 6 2 2-pack HS premium surfacer 1795
3 6 3 2-pack HS Performance surfacer 1804
3 6 4 2-pack primer surfacer for plastics 1813
3 6 5 2-pack HS wet-on-wet surfacer 1819
3 6 6 2-pack base filler, professional 1829
3 7 Top coats 1846
3 7 1 2-pack HS top coat 1846
3 7 2 Aquaplus system, uni (solid-colour) and metallic colours 1855
3 7 3 Aquaplus system (pearlescent and heliochrome) 1863
3 7 4 Aquaplus blending system 1871
3 7 5 Aqua Premium system 1877
3 7 6 Aqua Premium blending system 1890
3 7 7 Aqua Premium system (painting rims) 1897
3 8 Clear coats 1906
3 8 1 2-pack HS clear coat 1906
3 8 2 2-pack MS matt clear coat 1913
3 8 3 2-pack HS Vario clear coat 1919
3 8 4 2-pack HS optimum clear coat 1927
3 8 5 2-pack HS optimum plus clear coat 1933
3 8 6 2-pack HS brilliant clear coat 1938
3 8 7 2-pack HS brilliant plus clear coat 1943
3 8 8 2-pack HS Performance clear coat 1949
3 8 9 Blender 1955
3 9 Hardener 1960
3 9 1 2-pack HS hardener 1960
3 9 2 2-pack VHS hardeners and 2-pack VHS Performance hardeners 1964
3 9 3 Hardener for 2-pack primer surfacer 1968
3 9 4 Aqua Premium hardener 1968
3 10 Thinners 1969
3 10 1 2-pack thinner 1969
3 10 2 HS spot thinner 1972
3 10 3 Demineralised water 1974
3 11 Anti-corrosion materials 1975
3 11 1 Anti-corrosion wax 1975
3 11 2 Cavity sealant 1976
3 11 3 Anti-corrosion wax (in aerosol can) 1979
3 12 Underseal 1980
3 12 1 Permanent underseal -D 314 D36 M2-, grey 1980
3 12 2 Permanent underseal -D 314 D37 M2-, black 1983
3 12 3 Permanent underseal -D 314 D38 M2-, light 1986
3 12 4 Underseal -D 314 D39 A3-, black 1989
3 13 Stone deflector 1991
3 13 1 Stone chip guard -AKR 311 KD1 05- 1991
3 13 2 Stone chip guard -AKR 311 KD1 10- 1993
3 14 Wax-based underseal 2000
3 14 1 Wax-based underseal -D 316 D38 A2- 2000
3 14 2 Wax-based underseal -D 316 000 A1- 2002
3 14 3 Spray wax -D 322 100 M2- 2004
3 15 Sealing materials 2005
3 15 1 Polyurethane adhesive sealant (bonding compound) 2005
3 15 2 Sprayable sealant 2008
3 15 3 Adhesive sealant 2011
3 16 Cleaning agents 2013
3 16 1 Silicone remover 2013
3 16 2 Cleaner for plastics 2015
3 16 3 Cleaner for plastics, anti-static 2016
3 16 4 Industrial dirt remover 2016
3 17 SprayMax system 2018
3 17 1 1-pack anti-corrosion primer 2018
3 17 2 1-pack test paint 2022
3 17 3 1-pack clear coat 2025
3 17 4 1-pack wash primer 2028
3 17 5 1-pack Fill Clean spray can -LLS MAX 099-/1-pack Fill Clean spray can -LLS MAX 100- – Aquaplus system 2033
3 17 6 1-pack fill clean spray can -LLS MAX 112-, Aqua Premium system 2040
3 17 7 2-pack surfacer 2048
3 17 8 2-pack HS Performance surfacer 2055
3 17 9 2-pack clear coat 2063
3 17 10 2-pack epoxy primer surfacer 2068
3 17 11 2-pack wash primer 2074
3 17 12 Silicone remover -LLS MAX 007- 2080
3 17 13 Slow-drying silicone remover -LLS MAX 008- 2082
3 17 14 Blender 2085
3 17 15 Adhesion promoter 2087
3 18 Additional materials 2091
3 18 1 Matting additive -ALN 775 106- 2091
3 18 2 Matting additive -LVM 769 810 A2- 2098
3 18 3 Texture additive 2101
3 18 4 Blending additive for Aquaplus 2107
3 18 5 Additive for Aqua Premium 2108
4 Workshop equipment 2109
4 1 Tools 2109
4 1 1 Spray can filling device -VAS 6425- 2109
4 1 2 Paint thickness tester -VAS 6272- 2110
4 1 3 Paint thickness tester -VAS 6197- 2111
4 1 4 Paint thickness tester -VAS 5278- 2111
4 1 5 Stone chip tester -VAS 5102A- 2112
4 1 6 Pneumatic brush grinder set -VAS 6446- 2113
4 1 7 Brush grinder set -VAS 6776- 2113
4 1 8 Suction feed spray-gun -V A G 1538- 2115
4 1 9 Infrared heater -VAS 6873- 2116
4 1 10 Stand -VAS 6873/1- 2116
4 1 11 Infrared heater -VAS 6874- 2117
4 1 12 Infrared heater -VAS 6875- 2118
4 1 13 Infrared heater -VAS 6876- 2118
4 1 14 Infrared heater -VAS 6877- 2119
4 1 15 Infrared heater -VAS 6878- 2120
4 1 16 Infrared heater -VAS 6879- 2121
4 2 Tack cloths 2121
4 2 1 Tack cloth -VAS 6177- 2121
4 2 2 Buffing cloth, white -VAS 6176- 2122
D4B8027068B Air conditioning systems with refrigerant R134a General information 2123
00 – Technical data 2129
1 Safety information 2129
1 1 Safety precautions when working on air conditioning systems 2129
1 2 Safety precautions when working on high-voltage system 2130
1 3 Safety precautions when working in the vicinity of high-voltage components 2130
1 4 Safety precautions when tow-starting or towing 2131
2 Repair instructions 2132
2 1 Rules for cleanliness when working on high-voltage system 2132
3 General information on air conditioning 2133
3 1 Other reference material 2133
3 2 Basics of air conditioning technology 2133
3 2 1 Physical principles: 2133
3 2 2 Heat always flows from a warmer to a colder substance 2134
3 2 3 Pressure and boiling point 2134
3 3 Vapour pressure table for refrigerant R134a 2135
3 4 Refrigerant R134a 2136
3 4 1 Physical data of refrigerant R134a 2136
3 4 2 Critical point 2136
3 4 3 Environmental aspects of refrigerant R134a 2137
3 5 Properties of refrigerant R134a 2137
3 5 1 Trade names and designations 2137
3 5 2 Colour 2137
3 5 3 Vapour pressure 2137
3 5 4 Physical properties of R134a 2138
3 5 5 Effects on metal 2138
3 5 6 Critical temperature and critical pressure 2138
3 5 7 Union 2138
3 5 8 Charge factor 2138
3 5 9 Detecting leaks 2138
3 6 Refrigerant oil 2139
3 6 1 Properties of refrigerant oil 2139
3 7 Comfort 2140
3 7 1 Environmental aspects 2140
3 8 How air conditioning works 2141
3 9 General work safety 2141
3 9 1 Product characteristics 2141
3 9 2 Handling refrigerants 2142
3 9 3 Wear safety goggles 2142
3 9 4 Wear protective gloves and apron 2142
3 9 5 Do not allow liquid refrigerant to come in contact with the skin 2142
3 9 6 Do not breath in refrigerant vapour 2142
3 9 7 Absolutely NO SMOKING 2142
3 9 8 Welding and soldering on refrigeration systems 2142
3 9 9 Pungent smell 2143
3 9 10 First aid 2143
3 9 11 Handling pressure vessels 2143
3 9 12 Do not heat up above 50°C 2143
3 9 13 Do not expose to uncontrolled heat 2143
3 9 14 Seal empty tanks/containers 2143
3 9 15 Safety instructions for using extraction and charging equipment 2144
3 10 Safety measures when working on vehicles with air conditioning and when working with refrigerant R134a 2144
3 11 Basics for working on refrigerant circuit 2145
3 11 1 O-ring 2146
3 11 2 Before operating the air conditioning system after recharging with refrigerant 2147
4 General information on refrigerant circuit 2148
4 1 Components of refrigerant circuit 2148
4 1 1 Distribution of the refrigerant circuit components and their influence on the high-pressure and low-pressure sides 2148
4 1 2 Air conditioning system compressor with magnetic clutch: 2148
4 1 3 Air conditioner compressor without magnetic clutch 2149
4 1 4 Air conditioner compressor without magnetic clutch, with elastic drive coupling 2150
4 1 5 Electrical air conditioner compressor for high-voltage system 2151
4 1 6 Condenser 2152
4 1 7 evaporator 2152
4 1 8 Reservoir 2153
4 1 9 Restrictor 2153
4 1 10 Receiver 2154
4 1 11 Expansion valve 2155
4 1 12 O-ring 2156
4 1 13 Pipes and hoses of refrigerant circuit 2156
4 1 14 High-pressure safety valve 2156
4 2 Design of refrigerant circuit 2159
4 2 1 Refrigerant circuit with expansion valve and evaporator 2159
4 2 2 Refrigerant circuit with restrictor and reservoir 2159
4 3 Evacuation and charging valves for quick-release couplings of air conditioner service station on refrigerant circuit 2160
4 3 1 Evacuation and charging valve with Schrader valve 2160
4 3 2 Extraction and charging valve, high-pressure side 2161
4 3 3 Extraction and charging valve, low-pressure side 2162
4 4 Switches and senders in refrigerant circuit and related connections 2162
4 4 1 High-pressure switch for air conditioning system -F23- 2162
4 4 2 High-pressure switch for magnetic clutch -F118- 2163
4 4 3 Low-pressure switch for air conditioning system -F73- 2163
4 4 4 Connections with valve for switches in refrigerant circuit 2164
4 4 5 Air conditioning system pressure switch -F129- 2164
4 4 6 High-pressure sender -G65- 2165
4 4 7 Refrigerant pressure and temperature sender -G395- 2166
4 4 8 Air conditioner compressor regulating valve -N280- 2166
4 5 Electrical components not installed in refrigerant circuit 2167
4 5 1 Control and regulating unit for air conditioning system -J127- 2167
4 5 2 Radiator fan control unit -J293- 2167
4 5 3 Radiator fan control unit -J293- 2168
4 5 4 Temperature switch for evaporator -E33- 2169
4 5 5 Evaporator output temperature sender -G263- or evaporator temperature sensor -G308- 2169
4 6 Pressures and temperatures in refrigerant circuit 2170
4 7 Refrigerant circuit with expansion valve 2170
4 8 Refrigerant circuit with restrictor and reservoir 2172
4 9 Test and measurement work that can be performed using a pressure gauge 2174
4 9 1 Pressure gauges enable the following test and measurement work 2174
4 10 Air conditioner service and recycling equipment 2175
4 10 1 Classification of extraction and charging devices in groups 2175
4 10 2 Charging devices that do not require a permit 2175
4 11 Notes to repairs on refrigerant circuit 2176
5 Laws and regulations 2177
5 1 Laws and regulations 2177
5 2 Recycling and refuse law 2182
5 2 1 Disposal of refrigerant and refrigerant machine oil 2182
5 3 Converting R12 refrigerant circuits to R134a refrigerant circuits and servicing them (retrofitting) 2183
5 4 Maintaining records on refrigerant 2183
6 Refrigerant circuit 2184
6 1 Important repair notes on air conditioning 2184
6 2 Converting refrigerant circuits from R12 refrigerant to R134a 2184
7 Working with the air conditioner service station 2185
7 1 Important instructions for working with the air conditioner service station 2185
7 2 Connecting a air conditioner service station for measuring and testing 2186
7 3 Drain the refrigerant circuit using the air conditioner service station 2187
7 4 Evacuating refrigerant circuit using air conditioner service station 2187
7 5 Filling refrigerant circuit with air conditioner service station 2189
7 6 Bringing air conditioning system into service after charging 2190
7 7 Charging the container in the air conditioning service station with refrigerant 2190
7 8 Emptying air conditioner service station 2191
8 Detecting leaks in refrigerant circuit 2192
8 1 Leak detection in refrigerant circuit using compressed air or nitrogen 2193
8 2 Searching for leaks in refrigerant circuits using leak detector -V A G 1796- 2194
8 3 Detecting leaks in refrigerant circuit using leak detecting system -VAS 6196- or leak detecting system -VAS 6201- or a later model 2195
9 Clearing refrigerant circuit of contaminants 2203
9 1 Vehicles with high-voltage system (hybrid vehicles) 2203
9 2 Blowing through refrigerant circuit with compressed air and nitrogen 2204
9 2 1 Flushing refrigerant circuit 2206
9 3 Flushing refrigerant circuit with refrigerant R134a 2206
9 3 1 Principle circuit diagrams for various purging circuits 2214
9 3 2 Purging electrical air conditioner compressor 2220
9 3 3 Adapters for setting up flushing circuits 2224
10 Clearing refrigerant circuit of contaminants, commercial vehicles 2238
10 1 Vehicles with high-voltage system 2238
10 2 Flushing refrigerant circuit with refrigerant R134a 2239
10 3 Adapters for setting up flushing circuits 2239
10 4 Procedure for setting up and flushing refrigerant circuit, Amarok 2023 ► 2243
10 5 Procedure for setting up and flushing refrigerant circuit, Amarok 2010 ► 2243
10 5 1 Connection diagram for flushing circuit 2243
10 5 2 Procedure for setting up and flushing refrigerant circuit 2244
10 6 Procedure for setting up and flushing refrigerant circuit, Caddy 2004 ► 2249
10 6 1 Connection diagram for flushing circuit 2249
10 6 2 Procedure for setting up and flushing refrigerant circuit 2250
10 7 Procedure for setting up and flushing refrigerant circuit, Crafter ►2017 2256
10 7 1 Connection diagram for flushing circuit, vehicles with one evaporator 2256
10 7 2 Connection diagram for flushing circuit, vehicles with second evaporator 2257
10 7 3 Procedure for setting up and flushing refrigerant circuit, vehicles with one evaporator 2258
10 7 4 Procedure for setting up and flushing refrigerant circuit, vehicles with second evaporator 2265
10 8 Procedure for setting up and flushing refrigerant circuit, Crafter 2017 ► or MAN TGE ►, Crafter Grand California ► 2273
10 8 1 Connection diagram for flushing circuit, vehicles with one evaporator 2274
10 8 2 Connection diagram for flushing circuit, vehicles with second evaporator 2275
10 8 3 Procedure for setting up and flushing refrigerant circuit, vehicles with one evaporator 2276
10 8 4 Procedure for setting up and flushing refrigerant circuit, vehicles with second evaporator 2281
10 9 Procedure for setting up and flushing refrigerant circuit, Transporter 2016 ►, Transporter 2020 ► 2290
10 9 1 Connection diagram for flushing circuit, vehicles with one evaporator 2290
10 9 2 Connection diagram for flushing circuit, vehicles with second evaporator 2291
10 9 3 Procedure for setting up and flushing refrigerant circuit, vehicles with one evaporator 2292
10 9 4 Procedure for setting up and flushing refrigerant circuit, vehicles with second evaporator 2297
11 Complaints 2306
11 1 Possible complaints about refrigerant circuit 2306
11 1 1 Conditions for testing: 2306
11 1 2 Possible complaints 2306
11 2 Odours from heater and air conditioning unit 2307
11 2 1 Does the odour emanate from the evaporator or heat exchanger? 2307
11 2 2 Ultrasonic air conditioner cleaning unit -VAS 6189A- 2308
11 2 3 Spraying the evaporator with the suction feed spray-gun -V A G 1538- and spray lance 2309
12 Connecting the air conditioning service station 2310
12 1 For vehicles that have connections on both low-pressure and high-pressure sides of refrigerant circuit 2310
12 1 1 Connecting a air conditioner service station for measuring and testing 2310
13 Checking pressures on vehicles 2311
13 1 Checking pressures in the refrigerant circuit (using a air conditioning service station) 2311
13 1 1 Conditions for testing 2311
13 1 2 Checking pressures 2312
13 1 3 Continuation of checking pressures 2314
13 2 Checking systems with a restrictor and collector (with internally regulated air conditioner compressor) 2315
13 2 1 Specifications: 2315
13 3 Checking systems with an expansion valve and reservoir (with internally regulated air conditioner compressor) 2319
13 3 1 Specifications: 2319
13 4 Checking systems with an expansion valve and reservoir (without regulated air conditioner compressor) 2324
13 4 1 Conditions for testing 2324
13 4 2 Check 2324
13 4 3 Specified values 2324
13 5 Checking systems with a restrictor and reservoir and air conditioner compressor regulating valve -N280- (with externally regulated air conditioner compressor) 2325
13 5 1 Specifications: 2325
13 6 Checking systems with an expansion valve, receiver and air conditioner compressor regulating valve -N280- (with externally regulated air conditioner compressor) 2330
13 6 1 Specifications: 2330
13 7 With expansion valve, receiver and electrical air conditioner compressor 2341
14 Renewing components 2342
14 1 In the event of leaking or damaged components (apart from the air conditioner compressor, receiver or reservoir) 2343
14 1 1 If the refrigerant circuit was completely empty 2343
14 1 2 If there is still refrigerant in the refrigerant circuit 2345
14 2 Renew the air conditioner compressor 2345
14 2 1 Without needing to flush refrigerant circuit of contaminants (cleaning), e g in cases of external damage after an accident 2345
14 2 2 Leaks or internal damage (e g noises or lack of power) 2347
14 3 Replace receiver or reservoir and restrictor 2347
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 2347
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 2349
15 Testing equipment and tools 2350
15 1 List of test equipment, tools and materials 2350
15 1 1 Tools and materials available from regional sales centre or importer 2350
15 1 2 Tools and materials commercially available 2351
15 1 3 Tools and materials available from regional sales centre or importer 2352
15 1 4 Tools and materials commercially available 2358
K0058950120 12 cylinder injection engine 2361
00 – Technical data 2367
1 Engine number 2367
2 Engine data 2368
10 – Removing and installing engine 2369
1 Removing and installing engine 2369
1 1 Removing engine 2371
1 2 Securing engine on engine and gearbox support -VAS 6095- 2381
1 3 Installing engine 2382
1 4 Specified torques 2384
2 Assembly mountings 2385
2 1 Assembly overview – assembly mountings 2385
2 2 Supporting engine in installation position 2386
2 3 Removing and installing engine carrier 2388
2 4 Removing and installing left engine mounting 2390
2 5 Removing and installing right engine mounting 2391
2 6 Removing and installing left engine support 2392
2 7 Removing and installing right engine support 2392
13 – Crankshaft group 2394
1 Assembly overview – dismantling and assembling engine 2394
1 1 Removing and installing poly V-belt 2396
2 Removing and installing sealing flange and drive plate 2398
2 1 Renewing crankshaft oil seal, vibration damper end 2400
2 2 Removing and installing drive plate 2401
2 3 Renewing crankshaft oil seal – drive plate side 2403
15 – Cylinder head, valve gear 2405
1 Cylinder heads 2405
1 1 Assembly overview – cylinder bank 1 2406
1 2 Assembly overview – cylinder bank 2 2409
1 3 Removing and installing cylinder head cover (cylinder banks 1 and 2) 2411
1 4 Removing and installing cylinder head (cylinder banks 1 and 2) 2413
1 4 1 Removing 2414
1 4 2 Installing 2418
1 5 Checking compression 2420
2 Chain drive 2423
2 1 Parts of chain drive system – engine codes BAN and BAP 2423
2 2 Parts of chain drive system – engine codes BRN, BRP and BTT 2427
2 3 Adjusting valve timing – engine codes BAN and BAP 2429
2 4 Adjusting valve timing, engine codes BRN, BRP and BTT 2438
3 Valve gear 2448
3 1 Valve gear (cylinder bank 1 and 2) – assembly overview 2448
3 2 Reworking valve seats 2453
3 3 Removing and installing camshaft control valves 2454
3 4 Removing and installing camshafts 2456
3 4 1 Removing 2457
3 4 2 Installing 2461
3 5 Checking valve guides 2465
3 6 Renewing valve stem seals 2465
17 – Lubrication 2468
1 Parts of lubrication system 2468
1 1 Engine oil 2468
1 2 Oil capacities 2469
1 3 Checking engine oil level 2469
1 4 Assembly overview – sump (vehicles with engine codes BAN and BAP) 2470
1 5 Assembly overview – sump (vehicles with engine codes BRN, BRP and BTT) 2473
1 6 Removing and installing lower part of sump 2474
1 7 Removing and installing upper part of sump 2476
1 8 Assembly overview – oil pump 2480
1 9 Removing and installing oil pump 2482
1 10 Assembly overview – oil filter housing (vehicles with engine codes BAN and BAP) 2484
1 11 Assembly overview – oil filter housing (vehicles with engine codes BRN, BRP and BTT) 2485
1 12 Checking oil pressure and oil pressure switch 2487
19 – Cooling 2489
1 Parts of cooling system 2489
1 1 Assembly overview – radiator 2490
1 2 Assembly overview – fans 2492
1 3 Assembly overview – parts of cooling system, body side 2492
1 4 Assembly overview – cooling system, engine side, top 2493
1 5 Assembly overview – cooling system, engine side, rear and side 2494
1 6 Parts of cooling system engine side, front 2496
1 7 Coolant hose schematic diagram 2497
1 8 Draining and filling coolant 2499
1 9 Removing and installing radiator 2503
1 10 Removing and installing coolant pump 2505
1 11 Checking cooling system for leaks 2507
20 – Fuel supply system 2509
1 Parts of fuel supply system 2509
1 1 Safety precautions when working on fuel supply system 2509
1 2 Rules for cleanliness 2510
1 3 Assembly overview – fuel tank with fuel filter 2510
1 4 Assembly overview – right side fuel delivery unit, fuel gauge sender and suction-jet pump 2512
1 5 Assembly overview – left side fuel delivery unit, fuel gauge sender and suction-jet pump 2514
1 6 Schematic diagram of fuel lines and components in fuel tank 2516
1 7 Emptying fuel tank 2518
1 8 Removing and installing fuel delivery unit, fuel gauge sender and suction-jet pump, right side 2520
1 9 Removing and installing fuel delivery unit, fuel gauge sender and suction-jet pump, left side 2524
1 10 Removing and installing fuel tank with attachments and fuel filter 2528
1 10 1 Removing 2529
1 10 2 Installing 2531
1 11 Checking fuel pumps 2531
1 11 1 Checking delivery rate 2534
1 11 2 Checking current draw of pumps 2536
1 11 3 Checking fuel pump non-return valves 2537
2 Electronic power control (EPC) 2540
2 1 Function of EPC system 2540
2 2 Assembly overview – accelerator mechanism 2540
3 Activated charcoal filter system (vehicles with engine code BAN and BRN) 2542
3 1 Function of activated charcoal filter system 2542
3 2 Assembly overview – activated charcoal filter system 2542
3 3 Checking activated charcoal filter system for leaks 2544
3 3 1 If vacuum builds up: 2545
3 3 2 If vacuum does not build up: 2546
4 Activated charcoal filter system (vehicles with engine code BAP and BRP) 2547
4 1 Function of activated charcoal filter system 2547
4 2 Assembly overview – activated charcoal filter system 2548
24 – Mixture preparation – injection 2550
1 Injection system 2550
1 1 General notes on injection 2550
1 2 Safety precautions 2551
1 3 Rules for cleanliness 2551
1 4 Assembly overview – intake manifold (vehicles with engine codes BAN and BAP) 2552
1 5 Assembly overview – upper part of intake manifold (vehicles with engine codes BRN, BRP and BTT) 2554
1 6 Assembly overview – lower part of intake manifold (vehicles with engine codes BRN, BRP and BTT) 2556
1 7 Assembly overview – fuel rail with injectors 2556
1 8 Assembly overview – air filter 2558
1 9 Technical data 2559
2 Lambda probes 2560
2 1 Removing and installing Lambda probe -G39- and Lambda probe 2 -G108- 2560
2 2 Removing and installing Lambda probe 3 -G285- and Lambda probe 4 -G286- 2563
2 3 Removing and installing Lambda probe after catalytic converter -G130- 2564
2 4 Removing and installing Lambda probe 2 after catalytic converter -G131- 2565
2 5 Removing and installing Lambda probe 3 after catalytic converter -G287- and Lambda probe 4 after catalytic converter -G288- 2567
3 Checking components 2570
3 1 Checking injectors 2570
3 2 Checking fuel pressure regulator and holding pressure 2572
4 Engine control units 2577
4 1 Removing and installing engine control units 2577
26 – Exhaust system 2578
1 Parts of the exhaust system 2578
1 1 Assembly overview – cylinder bank 1 exhaust manifold with starter catalytic converters and attachments 2580
1 2 Removing and installing starter catalytic converter for exhaust bank 1 of cylinders 1 … 3 2582
1 3 Removing and installing starter catalytic converter for exhaust bank 2 of cylinders 4 … 6 2582
1 4 Removing and installing exhaust manifold for exhaust bank 1 of cylinders 1 … 3 2583
1 5 Removing and installing exhaust manifold for exhaust bank 2 of cylinders 4 … 6 2583
1 6 Assembly overview – cylinder bank 2 exhaust manifold with starter catalytic converters and attachments 2584
1 7 Removing and installing starter catalytic converter for exhaust bank 3 of cylinders 7 … 9 2587
1 8 Removing and installing starter catalytic converter for exhaust bank 4 of cylinders 10 … 12 2587
1 9 Removing and installing exhaust manifold for exhaust bank 3 of cylinders 7 … 9 2588
1 10 Removing and installing exhaust manifold for exhaust bank 4 of cylinders 10 … 12 2588
1 11 Aligning starter catalytic converter with exhaust pipes 2589
1 12 Assembly overview – silencers with mountings 2590
2 Secondary air system 2593
2 1 Function of the secondary air system 2593
2 2 Assembly overview – secondary air system on body side 2594
2 3 Assembly overview – secondary air system on engine side 2595
2 4 Checking combination valves (vehicles with engine codes BAN and BAP) 2596
28 – Ignition system 2598
1 Repairing ignition system 2598
1 1 Assembly overview – ignition system 2598
1 2 Safety precautions 2600
1 3 Test data, spark plugs 2600
1 4 Removing and installing ignition coils with final output stages, engine codes BAN and BAP 2601
1 5 Removing and installing ignition coils with final output stages, engine codes BRN, BRP and BTT 2604
K0058950220 6 cylinder injection engine 2607
00 – Technical data 2613
1 Technical data 2613
1 1 Engine number 2613
1 2 Engine data 2613
10 – Removing and installing engine 2615
1 Removing and installing engine 2615
1 1 Removing engine 2616
1 1 1 Removing engine and gearbox without subframe 2623
1 2 Securing engine on engine and gearbox support -VAS 6095- 2626
1 3 Installing engine 2627
1 3 1 Additional information and assembly work for vehicles with air conditioner 2630
13 – Crankshaft group 2631
1 Dismantling and assembling engine 2631
1 1 Part I: assembly overview – chain drive 2632
1 2 Part II: assembly overview – cylinder block 2635
1 3 Removing and installing vibration damper 2637
1 4 Removing and installing engine bracket and engine mounting on left or right side 2638
1 5 Removing and installing poly V-belt 2640
2 Sealing flange and dual-mass flywheel 2642
2 1 Assembly overview 2642
2 2 Removing and installing seal, flywheel end 2643
2 3 Removing and installing flywheel 2645
2 4 Removing and installing drive plate 2646
2 5 Renewing crankshaft oil seal, vibration damper end 2647
2 6 Renewing crankshaft sealing flange -vibration damper side- 2649
3 Pistons and conrods 2652
3 1 Assembly overview 2652
3 2 Separating new conrod 2653
3 3 Checking piston and cylinder 2653
3 3 1 Installing piston 2655
3 4 Piston and cylinder dimensions 2655
4 Crankshaft 2656
4 1 Assembly overview 2656
4 2 Fitting sender wheel to crankshaft 2657
4 3 Allocation of crankshaft bearing shells (classification) 2658
15 – Cylinder head, valve gear 2660
1 Cylinder head 2660
1 1 Assembly overview 2660
1 2 Removing and installing cylinder head 2664
1 3 Checking valve timing 2668
1 4 Installing timing chain for intermediate shaft drive and camshaft drive 2670
1 5 Installing camshaft adjuster with timing chain for camshaft drive 2676
1 6 Removing and installing cylinder head cover 2680
1 7 Assembly overview – cover part 2683
1 7 1 Installing cover seals 2685
1 7 2 Preparing cylinder head gasket for fitting cover 2685
1 8 Checking compression 2686
2 Valve gear 2688
2 1 Assembly overview – valve gear 2688
2 2 Removing and installing camshaft control valves 2691
2 3 Removing and installing camshafts 2694
2 3 1 Removing 2695
2 4 Renewing valve stem seals 2699
2 4 2 Camshaft identification 2703
2 5 Checking valve guides 2703
2 6 Reworking valve seats 2703
17 – Lubrication 2707
1 Parts of lubrication system 2707
1 1 Engine oil 2707
1 2 Assembly overview 2707
1 2 1 Removing and installing oil spray jet 2709
1 2 2 Removing and installing oil non-return valve 2710
1 3 Assembly overview – dismantling and assembling oil filter housing 2710
1 4 Assembly overview – dismantling and assembling oil pump 2712
1 5 Removing and installing sump 2713
1 6 Checking oil pressure and oil pressure switch 2716
1 6 1 Checking oil pressure switch 2718
1 6 2 Checking oil pressure 2719
19 – Cooling 2720
1 Parts of cooling system 2720
1 1 Assembly overview – radiator 2721
1 2 Assembly overview – removing and installing fan 2722
1 3 Assembly overview – parts of cooling system, body side 2723
1 4 Assembly overview – thermostat housing 2724
1 5 Assembly overview – parts of cooling system, engine side 2725
1 6 Coolant hose schematic diagram 2726
1 7 Draining and filling coolant 2727
1 8 Removing and installing radiator 2730
1 9 Removing and installing coolant pump 2731
20 – Fuel supply system 2732
1 Parts of fuel supply system 2732
1 1 Assembly overview – fuel tank with attachments and fuel filter 2732
1 2 Dismantling and assembling right side fuel delivery unit, fuel gauge sender and suction-jet pump 2734
1 3 Assembly overview – fuel delivery unit, fuel gauge sender and suction jet pump on left side 2736
1 4 Schematic diagram of fuel lines and components in fuel tank 2738
1 5 Safety precautions when working on fuel supply system 2740
1 6 Rules for cleanliness 2740
1 7 Emptying fuel tank 2740
1 8 Removing and installing fuel delivery unit, fuel gauge sender and suction-jet pump, right side 2743
1 9 Removing and installing fuel delivery unit, fuel gauge sender and suction-jet pump, left side 2746
1 10 Removing and installing fuel tank with attachments and fuel filter 2749
1 11 Checking fuel pumps 2751
1 11 1 Checking delivery rate of both fuel pumps 2753
1 11 2 Checking delivery quantity of right pump 2755
1 11 3 Checking delivery quantity of left pump 2756
1 11 4 Checking current draw of pumps 2756
1 11 5 Checking fuel pump non-return valves 2757
1 11 6 Checking non-return valve of right pump 2758
1 11 7 Checking non-return valve of left pump 2759
2 Activated charcoal filter system 2760
2 1 Assembly overview – parts of activated charcoal filter system 2760
2 2 Checking activated charcoal filter system for leaks 2762
3 Checking electronic power control (EPC) 2765
24 – Mixture preparation – injection 2767
1 Injection system 2767
1 1 General notes on injection 2767
1 2 Assembly overview – intake manifold 2767
1 3 Assembly overview – fuel rail 2769
1 4 Assembly overview – air filter 2770
1 5 Safety precautions 2770
1 6 Rules for cleanliness 2771
1 7 Technical data 2771
2 Checking components 2773
2 1 Checking injectors 2773
2 1 1 Checking injectors for leaks and quantity injected 2774
2 2 Checking fuel pressure regulator and holding pressure 2775
3 Engine control unit 2779
3 1 Removing and installing engine control unit 2779
3 2 Reading and erasing engine control unit fault memory 2779
26 – Exhaust system 2781
1 Parts of exhaust system 2781
1 1 Assembly overview – exhaust manifold with starter catalytic converters and attachments 2782
1 2 Exhaust pipes with main catalytic converters and silencers with mountings 2784
1 3 Removing and installing exhaust manifolds and exhaust pipes with starter catalytic converters 2786
2 Secondary air system 2788
2 1 Assembly overview – parts of secondary air system 2788
2 2 Checking combination valve 2790
28 – Ignition system 2792
1 Ignition system 2792
1 1 Assembly overview – parts of ignition system 2792
1 2 Safety precautions 2794
1 3 Removing and installing ignition coils with output stage 2794
1 4 Test data, spark plugs 2796
K0058950320 Running gear Axles Steering Front and four wheel drive 2797
00 – Technical data 2803
1 Checklist for evaluating running gear of accident vehicles 2803
2 General information 2805
40 – Front suspension 2806
1 Appraisal of accident vehicles 2806
2 Repairing front wheel suspension 2807
2 1 Overview – front axle 2807
2 2 Raising wheel suspension to unladen position 2808
3 Assembly overview -A- – mounting bracket, upper suspension link, air suspension strut and wheel bearing housing 2810
3 1 Removing and installing air suspension strut 2812
3 2 Charging air suspension strut 2816
3 3 Removing and installing mounting bracket 2818
3 4 Removing and installing upper suspension links 2819
3 5 Renewing bonded rubber bushings for upper suspension links 2821
3 6 Removing and installing wheel bearing housing 2822
3 7 Assembly overview of wheel suspension up to model year 2007 2825
3 8 Assembly overview of wheel suspension up to model year 2008 2826
3 9 Removing and installing wheel bearing unit up to model year 2007 2827
3 10 Removing and installing wheel bearing unit from model year 2008 2830
4 Assembly overview -B- – Subframe, lower suspension link and anti-roll bar 2832
4 1 Removing and installing subframe 2834
4 2 Renewing front bonded rubber bushes in subframe 2836
4 3 Renewing rear bonded rubber bushes in subframe 2839
4 4 Renewing rear hydraulic bonded rubber bushes in subframe 2842
4 5 Removing and installing anti-roll bar 2845
4 6 Removing and installing track control link 2847
4 7 Renewing outer bush for track control link 2850
4 8 Renewing inner bush for track control link 2851
4 9 Removing and installing guide link 2853
4 10 Renewing guide link bushes 2854
5 Overview – drive shafts 2859
5 1 Heat shields for drive shafts 2859
5 2 Removing and installing drive shafts 2862
6 I: Assembly overview: drive shaft with triple roller joint AAR 2900 2864
6 1 Dismantling and assembling triple roller joint AAR 2900 2866
6 2 Checking outer constant velocity joint 2872
7 II: Assembly overview: drive shaft with triple roller joint AAR 3300i 2874
7 1 Dismantling and assembling triple roller joint AAR 3300i 2875
7 2 Repairing outer constant velocity joint 2881
42 – Rear suspension 2882
1 Appraisal of accident vehicles 2882
2 Repairing rear axle, front and four-wheel drive 2883
3 I: Assembly overview: subframe 2884
3 1 Removing and installing subframe 2886
3 2 Renewing front bonded rubber bushes in subframe 2888
3 3 Renewing rear bonded rubber bushes in subframe 2890
4 II: Assembly overview: Suspension link, track rod, air suspension strut 2894
4 1 Removing and installing air suspension strut 2896
4 2 Charging air suspension strut 2898
4 3 Removing and installing anti-roll bar 2900
4 4 Removing and installing upper links 2902
4 5 Removing and installing track rod 2905
4 6 Removing and installing coupling rod for anti-roll bar to lower suspension link 2906
4 7 Removing and installing coupling rod for track rod to lower suspension link 2907
4 8 Removing and installing lower suspension link 2908
5 III: Assembly overview: wheel bearing 2913
5 1 Removing and installing wheel bearing housing 2914
5 2 Removing and installing wheel bearing unit 2917
5 3 Renewing wheel bearing up to model year 2007 2920
5 4 Installing wheel bearing housing bonded rubber bush 2924
6 IV: Assembly overview: Drive shaft 2926
6 1 Removing and installing jointed shaft 2927
7 Repairing drive shafts 2932
7 1 Repairing inner constant velocity joint 2933
7 2 Checking inner constant velocity joint 2937
7 3 Repairing outer constant velocity joint 2939
7 4 Checking outer constant velocity joint 2940
43 – Self-levelling suspension 2942
1 Appraisal of accident vehicles 2942
2 Jacking mode 2943
3 Repairing self-levelling suspension 2944
3 1 Fault finding, air suspension strut and self-levelling suspension 2944
3 2 Self-levelling suspension components and fitting locations 2946
3 3 Removing and installing adaptive suspension control unit -J197- 2948
3 4 Removing and installing front vehicle level senders -G78 G289- 2949
3 5 Removing and installing front wheel acceleration senders -G337 G338- 2950
3 6 Removing and installing front body acceleration senders -G341 G342- 2951
3 7 Removing and installing rear vehicle level senders -G76 G77- 2951
3 8 Removing and installing rear wheel acceleration senders -G339 G340- 2952
3 9 Removing and installing rear body acceleration sender -G343- 2953
3 10 Repairing air line 2954
3 11 Assembly overview: air supply unit with solenoid valve block 2954
3 12 Removing and installing air supply unit 2955
3 13 Identification of pipes on solenoid valve block 2957
3 14 Removing and installing solenoid valve block 2957
3 15 Basic settings for self-levelling suspension 2958
3 16 Measuring ride height 2959
44 – Wheels, tyres, vehicle geometry 2960
1 Appraisal of accident vehicles 2960
2 Torque settings for wheel bolts and tyre assembly 2961
2 1 Specified torque for wheel bolts 2961
3 Fitting wheel and tyre 2962
3 1 General information 2962
3 2 Fittings instructions 2962
4 Removing and fitting tyres (wheels with tyre pressure monitoring) 2964
4 1 Notes on safety and conditions for removing and fitting tyres (wheels with tyre pressure monitoring) 2964
4 2 Wheel change 2964
4 3 Pressing tyre off wheel rim 2965
4 4 Removing tyre from wheel 2966
4 5 Fitting tyre to wheel rim 2966
5 Wheel alignment 2968
5 1 General notes on wheel alignment 2968
5 2 Models with electronic stabilisation program 2969
5 3 Vehicle data sticker 2969
5 4 Test prerequisites: 2970
5 5 Test preparations 2970
5 6 Wheel runout compensation 2971
5 7 Overview – wheel alignment procedure 2971
5 8 Wheel alignment specifications 2972
5 9 Averaging front axle camber 2973
5 10 Adjusting camber on rear axle 2974
5 11 Adjusting toe at rear axle 2975
5 12 Adjusting toe-in curve at front wheels 2975
5 13 Raising vehicle 2976
5 14 Adjusting toe constant “S” 2976
5 15 Adjusting front axle toe 2977
6 Fitting suspension blocks 2978
6 1 Fitting suspension blocks to front axle 2978
6 2 Fitting suspension blocks to rear axle 2979
7 Setting tyre pressure control when stationary, generation 1 2980
7 1 Removing and installing tyre pressure sensor and metal valve 2980
7 2 Removing and installing tyre pressure sensor 2981
7 3 Storing current tyre inflation pressure 2982
8 Repairing tyre pressure monitor, 2nd generation 2983
8 1 Component overview – tyre pressure monitor 2983
8 2 Assembly overview – tyre pressure sensor, version 1 2984
8 3 Assembly overview – tyre pressure sensor, version 2 2985
8 4 Removing and installing tyre pressure sensor, version 1 2985
8 5 Removing and installing tyre pressure sensor, version 2 2986
8 6 Removing and installing metal valve 2987
8 7 Removing and installing tyre pressure monitor sender unit in front left wheel housing -G431- 2988
8 8 Removing and installing tyre pressure monitor sender unit in front right wheel housing -G432- 2989
8 9 Removing and installing tyre pressure monitor sender unit in rear left wheel housing -G433- 2990
8 10 Removing and installing tyre pressure monitor sender unit in rear right wheel housing -G434- 2991
8 11 Removing and installing tyre pressure monitor aerial -R207- 2992
8 12 Removing and installing tyre pressure monitor control unit -J502- 2993
9 Wheels, tyres 2994
9 1 Models with breakdown set 2994
9 2 Tyre sealant 2994
9 3 Removing a tyre 2994
9 4 Fitting a new tyre 2995
9 5 Tyre sealant disposal 2995
10 Instructions for changing or fitting wheels 2996
10 1 Fitting wheels 2997
11 Protecting wheel centring seat against corrosion 2998
12 Rough running due to wheels/tyres – causes and rectification 2999
12 1 Causes of rough running 2999
12 2 Balancing wheels 2999
12 3 Conducting a road test before balancing wheels 2999
12 4 Balancing wheels on stationary wheel balancing machine 3000
12 5 Vibration control system -VAS 6230 A- 3003
12 6 Finish balancer 3003
12 7 Radial and lateral runout of wheels and tyres 3004
12 8 Checking radial and lateral runout on wheels and tyres with tyre gauge -V A G 1435- 3004
12 9 Checking radial and lateral runout on wheel rim 3005
12 10 Matching 3006
12 11 Flat spots caused by storage or handling 3007
13 Automatic Distance Control (ADC) 3009
13 1 General information on ADC 3009
13 2 Adjustment procedure 3009
14 Adaptive Cruise Control (ACC) 3013
14 1 General information on ACC calibration 3013
14 2 ACC calibration during vehicle alignment 3013
14 3 ACC calibration without prior vehicle alignment 3015
15 Front camera for driver assistance system R242 3018
15 1 Adjusting the front camera for driver assistance system R242 3018
48 – Steering 3026
1 Appraisal of accident vehicles 3026
2 Steering column 3027
2 1 Removing and installing steering column 3027
3 Assembly overview – steering box 3030
3 1 Removing and installing power steering, models with V6 petrol engine 3031
3 2 Removing and installing power steering, models with V6 diesel engine 3034
3 3 Removing and installing power steering, models with V8 petrol engine 3037
3 4 Removing and installing power steering, models with V10 diesel engine 3040
3 5 Removing and installing power steering, models with W12 petrol engine 3043
4 Repairing power steering 3047
4 1 Removing and installing track rods 3047
5 Vane pump 3050
5 1 Checking vane pump delivery pressure, V6 petrol engine 3050
5 2 Assembly overview – vane pump, V6 petrol engine 3053
5 3 Removing and installing vane pump, V6 petrol engine 3054
5 4 Checking vane pump delivery pressure, V6 diesel engine 3056
5 5 Assembly overview – vane pump, V6 diesel engine 3059
5 6 Removing and installing vane pump, V6 diesel engine 3060
5 7 Checking vane pump delivery pressure, V8 petrol engine 3063
5 8 Assembly overview – vane pump, V8 petrol engine 3065
5 9 Removing and installing vane pump, V8 petrol engine 3066
5 10 Checking vane pump delivery pressure, V10 diesel engine 3069
5 11 Assembly overview – vane pump, V10 diesel engine 3071
5 12 Removing and installing vane pump, V10 diesel engine 3072
5 13 Checking vane pump delivery pressure, W12 petrol engine 3074
5 14 Assembly overview – vane pump, W12 petrol engine 3077
5 15 Removing and installing vane pump, W12 petrol engine 3077
5 15 1 Calculating shim thickness 3081
5 16 Checking power steering fluid level 3081
5 17 Bleeding steering system 3082
5 18 Checking steering system for leaks 3083
K0058950420 Brake systems 3084
00 – Technical data 3088
1 Brake allocation via PR No 3088
1 1 Front brakes 3088
1 2 Rear brakes (disc brakes) 3088
2 Technical data for brakes 3089
2 1 Brake master cylinder and brake servo 3089
2 2 Front brakes 3089
2 3 Rear brakes 3091
2 4 Evaluating the ceramic brake disc 3092
2 4 1 Optical characteristics of the ceramic brake disc 3093
2 4 2 Surface cracks in the cooling channel ribs 3094
2 4 4 Edge fractures 3095
2 4 5 Material broken off the ceramic brake disc 3095
2 4 6 Crack leading to the cooling channel 3095
3 Determining the degree of wear on the ceramic brake disc 3096
3 1 Determining wear by checking the thickness of the brake disc 3097
3 2 Determining wear by weighing the brake disc 3098
3 3 Determining the wear at the wear indicators 3099
4 Brake test 3100
4 1 General 3100
4 2 Test for vehicles with front-wheel drive 3100
4 3 Test for vehicles with four-wheel drive 3100
45 – Anti-lock brake system 3101
1 General notes for anti-lock brake system (ABS) 3101
2 Notes for repair work on anti-lock brake system 3102
3 Connecting -VAS 5051- and selecting functions 3103
4 Electrical/electronic components and locations 3105
5 Fault display via warning lamps 3107
6 Assembly overview – hydraulic unit, brake servo/brake master cylinder 3110
6 1 Removing and installing control unit and hydraulic unit 3112
6 1 1 Removing 3113
6 1 2 Installing 3114
6 2 Removing and installing brake pressure sender -G201- 3114
6 2 1 Installing 3114
7 Removing and installing parts of ABS system on front and rear axle 3116
7 1 Removing and installing parts of ABS system on front axle 3116
7 1 1 Removing and installing speed sensor on front axle 3116
7 1 2 Removing 3116
7 1 3 Installing 3117
7 2 Removing and installing parts of ABS system on rear axle 3117
7 2 1 Removing and installing speed sensor on rear axle 3118
7 2 2 Removing 3118
7 2 3 Installing 3118
8 Removing and installing parts of ESP system 3119
8 1 Removing and installing lateral acceleration sender -G200- and yaw rate sender -G202- 3119
8 1 1 Removing 3119
8 1 2 Installing 3119
8 2 Removing and installing steering angle sender -G85- 3120
46 – Brakes – mechanism 3121
1 Repairing front brakes 3121
1 1 Assembly overview – front brakes FN -2 3121
1 2 Removing and installing brake pads/linings 3122
1 2 1 Removing 3122
1 2 2 Installing 3124
1 3 Removing and installing brake caliper 3125
1 3 1 Removing 3126
1 3 2 Installing 3126
1 4 Assembly overview – front brake 2FNR 42 AL 3127
1 5 Removing and installing brake pads/linings 3128
1 5 1 Removing 3129
1 5 2 Installing 3130
1 6 Removing and installing brake caliper 3131
1 6 1 Removing 3132
1 6 2 Installing 3133
1 7 Assembly overview – front brake, Brembo 18″ 3134
1 8 Removing and installing brake pads/linings 3135
1 8 1 Removing 3135
1 8 2 Installing 3136
1 9 Removing and installing brake caliper 3138
1 9 1 Removing 3139
1 9 2 Installing 3139
1 10 Assembly overview – ceramic front brake 3140
1 11 Removing and installing brake pads, ceramic brake 3141
1 11 1 Removing 3142
1 11 2 Installing 3143
1 12 Removing and installing brake caliper of ceramic brake 3144
1 12 1 Removing 3145
1 12 2 Installing 3146
2 Repairing rear brakes (disc brakes) 3147
2 1 Removing and installing brake pads/linings 3148
2 1 1 Removing 3148
2 1 2 Installing 3150
2 2 Removing and installing brake caliper 3151
2 2 1 Removing 3151
2 2 2 Installing 3152
2 3 Adjusting parking brake 3152
3 Assembly overview – parking brake pedal 3154
3 1 Removing and installing parking brake pedal 3154
3 1 1 Removing 3154
3 1 2 Installing 3155
3 2 Removing and installing release handle 3156
3 2 1 Removing 3156
3 2 2 Installing 3157
4 Brake cables 3158
4 1 Removing and installing rear brake cables 3158
4 1 1 Removing 3158
4 1 2 Installing 3159
4 2 Removing and installing front brake cable 3160
4 2 1 Removing 3160
4 2 2 Installing 3161
4 3 Removing and installing release cable 3161
4 3 1 Installing 3163
5 Assembly overview – brake pedal (LHD) 3164
5 1 Separating brake pedal from brake servo 3164
5 1 1 Clipping brake pedal to brake servo 3166
5 2 Removing and installing brake pedal (left-hand drive vehicles) 3166
5 2 1 Removing 3166
5 2 2 Installing 3166
5 2 3 Clipping brake pedal to brake servo 3166
5 3 Removing and installing brake light switch -F- and brake pedal switch -F47- 3167
5 3 1 Brake light switch up to week 22 07 of 2006 3167
5 3 2 Brake light switch from week 22 07 of 2006 3168
5 3 3 Brake light switch from model year 09 3169
47 – Brakes – hydraulics 3172
1 Repairing front brake calipers 3172
1 1 Assembly overview – brake caliper HP2 3172
1 1 1 Removing and installing HP2 brake caliper piston 3172
1 2 Assembly overview – brake caliper 2FNR 42 AL 3174
1 2 1 Removing and installing 2FNR 42 AL brake caliper piston 3175
1 3 Assembly overview – brake caliper, Brembo 18″ 3178
1 3 1 Removing and installing 18″ brake caliper piston, Brembo 3179
1 4 Assembly overview – brake caliper of ceramic brake 3181
1 4 1 Removing and installing brake caliper piston (ceramic brake) 3183
2 Repairing rear brake calipers 3185
2 1 Assembly overview – rear brake caliper 3185
2 1 1 Removing and installing rear brake caliper piston 3186
2 1 2 Pre-bleeding brake caliper 3188
3 Pressurised leak test 3189
4 Bleeding brake system 3190
4 1 Bleeding (normal) 3190
4 2 Subsequent bleeding 3191
4 3 Changing brake fluid 3191
5 Assembly overview – brake servo/brake master cylinder 3192
5 1 Removing and installing potentiometer for brake servo diaphragm travel -G420- 3193
5 1 1 Removing 3193
5 1 2 Installing 3194
5 2 Removing and installing ACC trip switch in brake servo, pressure detected -F318- 3194
5 2 1 Removing 3194
5 2 2 Installing 3196
6 Brake servo vacuum supply 3197
6 1 Overview of vacuum hoses 3197
6 1 1 Vacuum hose with non-return valve for V6 petrol engine and manual gearbox 3197
6 1 2 Vacuum hose with non-return valve for V6 petrol engine and automatic gearbox 3197
6 1 3 Vacuum hose with vacuum booster for W12 petrol engine 3197
6 2 Assembly overview – vacuum pump for brakes -V192- 3198
6 3 Removing and installing vacuum pump for brakes -V192- 3199
6 3 1 Removing 3199
6 3 2 Installing 3199
6 4 Removing and installing brake servo pressure sensor -G294- 3199
6 4 1 Removing 3199
6 4 2 Installing 3199
7 Brake master cylinder 3200
7 1 Removing and installing brake master cylinder 3200
7 1 1 Removing 3200
7 1 2 Installing 3202
8 Brake servo 3204
8 1 Removing and installing brake servo 3204
8 1 1 Removing 3204
8 1 2 Installing 3206
9 Repairing brake lines 3208
9 1 Assembly overview – flanging tool 3210
9 2 Work instructions 3210
K0058950520 5 speed automatic gearbox 01L all wheel drive 3213
00 – Technical data 3217
1 Gearbox identification 3217
2 Notes on 5-speed automatic gearbox four wheel drive 01L 3218
3 Code letters, engine allocation 3219
4 Capacities 3220
4 1 Planetary gearbox 3220
4 2 Front final drive 3220
4 3 Transfer box 3220
5 General repair notes 3221
5 1 »Vorsprung durch Technik« 3221
5 2 Special tools 3222
5 3 Gearbox 3222
5 4 Electrical components 3223
5 5 Seals and sealing rings 3223
5 6 Locking devices 3224
5 7 Nuts and bolts 3224
5 8 Guided fault finding, vehicle self-diagnosis and testing 3224
5 9 Emergency release of selector mechanism 3224
5 10 Bearing 3224
5 11 Oil 3225
32 – Torque converter 3226
1 Torque converter 3226
1 1 Installing torque converter 3226
1 2 Secure torque converter to prevent it from falling out 3227
1 3 Checking torque converter 3227
1 4 Removing and installing torque converter oil seal 3227
1 4 1 Removing 3228
1 4 2 Installing 3228
1 5 Draining torque converter 3228
37 – Controls, housing 3230
1 Connecting -VAS 5051- and selecting functions 3230
2 Electrical and electronic components and their locations 3232
3 Renewing multifunction switch -F125- 3238
3 1 Removing 3238
3 2 Installing 3238
4 Repairing selector mechanism 3239
4 1 Checking selector mechanism 3239
4 1 1 Selector lever in “P” position and ignition switched on 3239
4 1 2 Selector lever in “N” position and ignition switched on 3239
4 1 3 Selector lever in position “D”, ignition and lights switched on 3239
4 1 4 Selector lever position display 3240
4 2 Removing and installing selector lever handle 3240
4 2 1 Removing 3240
4 2 2 Installing 3240
4 3 Removing and installing selector mechanism 3241
4 3 1 Removing 3241
4 3 2 Installing 3244
4 3 3 Specified torques 3246
4 4 Dismantling and assembling selector mechanism 3246
4 5 Checking and adjusting selector lever cable 3247
4 5 1 Checking selector lever cable 3248
4 6 Adjusting selector lever cable 3249
4 6 1 Adjusting selector lever to selector cover gate 3250
4 6 2 Adjusting selector lever cable at selector mechanism 3250
4 7 Removing and installing selector lever cable 3251
4 7 1 Removing 3251
4 7 2 Installing 3252
4 7 3 Specified torques 3254
4 8 Releasing selector lever without electrical current (emergency release) 3254
5 Removing and installing gearbox 3256
5 1 Removing gearbox 3256
5 2 Installing gearbox 3256
5 3 Specified torques 3256
5 4 Removing and installing gearbox mounting 3258
5 4 1 Removing gearbox mountings 3259
5 4 2 Removing and installing gearbox mountings from gearbox supports 3261
5 4 3 Installing gearbox mounting 3261
6 Checking ATF level and topping up 3263
6 1 Checking ATF level 3263
6 2 Topping up ATF 3266
6 3 Renewing ATF 3266
6 4 Filling empty additional ATF cooler 3268
7 Schematic overview – power train, four wheel drive 3270
7 1 Position of selector elements 3270
8 ATF lines and ATF cooler 3272
8 1 Removing and installing ATF lines and ATF cooler 3272
8 1 3 Removing 3273
8 1 4 Installing 3274
8 2 Cleaning ATF lines and ATF cooler 3275
38 – Gears, control 3276
1 Overview – valve body 3276
2 Removing and installing oil pan 3279
2 1 Removing 3279
2 2 Installing 3279
3 Removing and installing ATF strainer 3281
3 1 Removing 3281
3 2 Installing 3281
4 Removing and installing valve body 3282
4 1 Removing 3282
4 2 Installing 3282
4 3 Removing and installing wiring harness in gearbox 3283
4 3 1 Removing 3283
4 3 2 Installing 3284
4 4 Renewing gear oil temperature sender (ATF) -G93- 3284
4 4 1 Removing 3284
4 4 2 Installing 3284
5 Renewing oil seal for selector shaft 3285
5 1 Removing 3285
5 2 Installing 3285
39 – Final drive – front differential 3287
1 Overview – gear oil in front final drive 3287
1 1 Checking and topping up gear oil level in front final drive 3287
1 2 Filling front final drive with gear oil following repair 3288
2 Assembly overview – front final drive 3290
2 1 Removing and installing left flange shaft 3292
2 2 Renewing oil seal for left flange shaft 3294
2 3 Removing and installing drive wheel for speedometer sender -G22- 3294
2 4 Renewing ball bearing for left flange shaft 3294
2 5 Removing and installing right flange shaft 3294
2 6 Renewing seal for right flange shaft 3295
2 7 Renewing O-ring on final drive cover 3296
3 Assembly overview – gear oil drain and inspection plugs in transfer box 3298
3 1 Checking and replenishing gear oil level in transfer box 3298
3 2 Changing gear oil in transfer box or replenishing oil after repairs 3299
4 Assembly overview – transfer box 3301
4 1 Removing and installing rear flange shaft 3304
4 2 Renewing seal for rear flange shaft 3305
4 3 Removing and installing transfer box 3305
4 4 Removing and installing intermediate flange for front axle drive 3305
4 5 Renewing twin-lip oil seal in intermediate flange for front axle drive 3306
4 6 Renewing twin-lip oil seal in output pinion 3306
4 7 Renewing needle bearing for spur gear 2 3306
K0058950620 5 speed automatic gearbox 01V 3307
00 – Technical data 3313
1 Gearbox identification 3313
1 1 Location of code letters on gearbox 3313
2 Notes on 5-speed automatic gearbox 01V 3314
2 1 Torque converter 3314
2 2 Gearbox 3314
3 Code letters, engine allocations 3315
4 Capacities 3316
4 1 Planetary gear 3316
4 2 Front final drive 3316
5 General repair instructions 3317
5 1 Special tools 3317
5 2 Gearbox 3317
5 3 ATF lines 3317
5 4 Seals and sealing rings 3318
5 5 Bolts and nuts 3318
5 6 Locking devices 3319
5 7 Bearings 3319
5 8 Shims 3319
5 9 Valve chest 3319
5 10 Guided fault finding, vehicle self-diagnosis and testing 3319
5 11 “Vorsprung durch Technik” 3320
32 – Torque converter 3321
1 Torque converter 3321
1 1 Identification of torque converter 3321
1 2 Checking torque converter 3322
1 3 Removing and installing torque converter oil seal 3322
1 3 1 Removing 3322
1 3 2 Installing 3323
1 4 Draining torque converter 3323
1 5 Installing torque converter 3324
37 – Controls, housing 3325
1 Connecting -VAS 5051- and selecting functions 3325
1 1 Connecting -VAS 5051- 3325
2 Electrical and electronic components and their locations 3327
3 Repairing shift mechanism 3332
3 1 Removing and installing selector lever handle 3332
3 1 1 Removing 3332
3 1 2 Installing 3332
3 2 Removing and installing shift mechanism 3333
3 2 1 Removing 3333
3 2 2 Installing 3335
3 2 3 Torque settings 3337
3 3 Dismantling and assembling shift mechanism 3337
3 4 Releasing selector lever without electrical current 3339
3 5 Checking and adjusting selector lever cable 3340
3 5 1 Checking 3340
3 5 2 Adjusting 3341
3 6 Removing and installing selector lever cable 3342
3 6 1 Removing 3342
3 6 2 Installing 3343
3 6 3 Torque settings 3344
4 Removing and installing gearbox 3345
4 1 Removing gearbox 3345
4 2 Installing gearbox 3352
4 3 Torque settings 3356
4 4 Transporting automatic gearbox 3356
4 5 Securing gearbox to assembly stand 3357
4 6 Removing and installing gearbox support with damper weight and gearbox mounting 3359
4 6 1 Removing 3359
4 6 2 Installing 3361
4 6 3 Installation position of damper weight 3363
5 Checking ATF level and topping up 3364
5 1 Checking ATF level 3364
5 1 1 Torque settings 3365
5 2 Topping up ATF 3366
5 3 Renewing ATF 3366
6 Overview – power transmission, front-wheel drive 3369
6 1 Position of selector elements 3369
7 ATF lines and ATF cooler 3371
7 1 Removing and installing ATF lines and ATF cooler 3371
7 2 Removing 3371
7 3 Installing 3373
7 4 Installation position of ATF lines 3373
7 5 Torque settings 3373
7 6 Cleaning ATF pipes and ATF cooler 3374
38 – Gears, control 3375
1 Overview – valve chest 3375
2 Removing and installing oil pan 3379
2 1 Removing 3379
2 2 Installing 3380
3 Removing and installing ATF strainer 3381
3 1 Removing 3381
3 2 Installing 3381
4 Removing and installing valve chest 3382
4 1 Removing 3382
4 2 Installing 3384
5 Removing and installing internal oil pipe 3387
5 1 Removing 3387
5 2 Installing 3387
6 Renewing gearbox speed sender -G38- or gearbox output speed sender -G195- 3389
6 1 Removing 3389
6 2 Installing 3389
7 Removing and installing gearbox input speed sender -G182- 3391
7 1 Removing 3391
7 2 Installing 3391
8 Removing and installing wiring harness in gearbox 3392
8 1 Removing 3392
8 2 Installing 3392
9 Renewing gearbox oil temperature sender (ATF) -G93- 3393
10 Renewing multifunction switch -F125- 3394
10 1 Removing 3394
10 2 Installing 3394
11 Renewing oil seal for selector shaft 3395
11 1 Removing 3395
11 2 Installing 3396
39 – Final drive – differential 3397
1 Checking oil in front final drive 3397
2 Repairing front final drive 3399
2 1 Assembly overview 3399
3 Renewing oil seal for right flanged shaft 3401
3 1 Removing 3401
3 2 Installing 3402
4 Renewing oil seal for left flanged shaft 3404
4 1 Removing left flanged shaft 3405
4 2 Removing oil seal 3406
4 3 Removing deep groove ball bearing 3407
4 4 Installing deep groove ball bearing 3407
4 5 Installing oil seal 3407
4 6 Installing left flange shaft 3408
5 Renewing front final drive/gearbox housing seal 3410
5 1 Removing 3410
5 2 Installing 3411
6 Renewing O-ring on cover for front final drive 3414
6 1 Removing 3414
6 2 Installing 3415
7 Renewing gasket for front final drive 3416
7 1 Removing 3416
7 2 Installing 3417
8 Definitions 3418
K0058950720 6 speed manual gearbox 01E 0A1 3421
00 – Technical data 3425
1 Gearbox identification 3425
1 1 Location on gearbox 3425
1 2 Identification code, assembly allocation, ratios, capacities 3426
2 Overview – power transmission 3427
2 1 Designation 3427
2 1 1 Gears 3428
3 Calculating overall gear ratio “i” 3429
4 General repair instructions 3430
4 1 Components 3430
4 1 1 Gearbox 3430
4 1 2 Seals and sealing rings 3430
4 1 3 Locking devices 3431
4 1 4 Nuts and bolts 3431
4 1 5 Bearings 3431
4 1 6 Shims 3431
4 1 7 Synchronizer rings 3431
4 1 8 Gear wheels 3432
4 1 9 Synchromeshed gears 3432
30 – Clutch 3433
1 Repairing clutch mechanism 3433
1 1 Assembly overview – pedal cluster 3434
1 2 Removing and installing over-centre spring 3435
1 2 1 Removing 3435
1 2 2 Installing 3435
1 3 Removing and installing clutch pedal 3436
1 3 1 Removing 3436
1 3 2 Installing 3437
1 3 3 Removing, installing and adjusting clutch pedal switch -F36- 3438
1 3 4 Removing and installing clutch pedal switch -F71- 3439
1 4 Removing and installing mounting bracket 3439
1 4 1 Removing 3440
1 4 2 Installing 3442
1 5 Assembly overview – hydraulic system 3442
1 6 Removing and installing master cylinder 3445
1 6 1 Removing 3446
1 6 2 Installing 3446
1 7 Bleeding clutch system 3447
2 Repairing clutch release mechanism 3449
2 1 Removing and installing slave cylinder 3452
2 1 1 Removing 3452
2 1 2 Installing 3452
3 Repairing clutch 3454
3 1 Resetting adjusting ring of self-adjusting pressure plate 3456
34 – Controls, housing 3459
1 Repairing selector mechanism 3459
1 1 Installation position of selector mechanism 3459
1 2 Removing and installing selector lever knob and cover 3462
1 3 Repairing selector lever and selector lever housing 3463
1 4 Assembly overview – removing and installing selector cables 3465
1 5 Removing and installing selector mechanism 3466
1 5 1 Removing 3466
1 5 2 Installing 3468
1 5 3 Torque settings 3468
1 6 Removing and installing cable locking devices 3469
1 6 1 Removing 3469
1 6 2 Installing 3469
1 7 Adjusting selector mechanism 3470
1 7 1 Functional check 3473
1 7 2 Torque settings 3473
1 8 Additional adjustment of selector mechanism 3473
1 8 1 Torque settings 3475
2 Removing and installing gearbox 3476
2 1 Removing gearbox 3477
2 2 Transporting gearbox 3482
2 3 Installing gearbox 3482
2 3 1 Torque settings 3487
2 4 Removing and installing gearbox support with damper weight and gearbox mounting 3487
2 4 1 Removing 3487
2 4 2 Installing 3488
3 Checking gear oil 3490
4 Dismantling and assembling gearbox 3491
4 1 Assembly overview 3491
4 2 Removing and installing manual gearbox and end cover 3492
4 3 Removing and installing 5th and 6th gear 3493
4 4 Removing and installing input shaft, pinion shaft and gear selector mechanism, gearbox side 3495
4 5 Assembly sequence 3496
4 5 1 Removing 3499
4 5 2 Installing 3505
5 Repairing end cover 3513
6 Repairing bearing plate 3520
6 1 Redetermining shim S4 3524
6 1 1 A – Determining thickness of shim when renewing bearing plate 3525
6 1 2 B – Determining thickness of shim when renewing needle bearing for 1st gear 3525
6 1 3 C – Determining shim when items 4 8 are renewed 3525
6 1 4 Available shims for S4 3526
7 Repairing gearbox housing 3527
7 1 Renewing selector shaft oil seal with gearbox removed but not dismantled 3534
7 1 1 Removing 3535
7 1 2 Installing 3536
7 2 Dismantling and assembling selector shaft complete 3536
35 – Gears, shafts 3539
1 Dismantling and assembling input shaft 3539
2 Dismantling and assembling pinion shaft 3545
39 – Final drive – differential 3555
1 Renewing oil seals for flange shafts 3555
2 Differential 3557
2 1 Removing and installing differential 3557
2 2 Dismantling and assembling differential 3558
3 Adjusting pinion shaft and crown wheel 3567
3 1 Adjustment and marking of drive pinion sets 3567
3 2 Position of shims 3568
3 3 Adjustment overview 3568
3 4 Recommended sequence for new adjustment pinion drive set 3569
3 5 Adjusting pinion shaft 3569
3 5 1 Total shim thickness “Stotal” Determining (S3 plus S4) 3570
3 5 2 Determining thickness of temporary shim S3* 3571
3 5 3 Determining dimension “e” 3572
3 5 4 Determining thickness of shim S3 3573
3 5 5 Available shims for S3 3573
3 5 6 Determining thickness of shim S4 3574
3 5 7 Available shims for S4 3574
3 5 8 Carry out check measurement – checking dimension “r” 3574
3 6 Adjusting crown wheel 3574
3 6 1 Determining thickness of shim S1 3578
3 6 2 Adjusting backlash 3578
3 6 3 Calculating average backlash 3579
3 6 4 Determining thickness of shim S2 3579
3 6 5 Available shims for S2 3579
3 6 6 Determining thickness of shim S1 3580
3 6 7 Available shims for S1 3580
K0058950820 Electrical system 3581
27 – Starter, current supply, CCS 3589
1 Battery 3589
1 1 Fundamentals for batteries 3589
1 2 Types of battery 3589
1 3 Warning notices and safety regulations 3589
1 4 Battery terminal connection 3589
2 Checking battery 3590
3 Charging battery 3591
4 Disconnecting and reconnecting battery 3592
4 1 Disconnecting and reconnecting batteries, vehicles with two-battery concept 3592
4 1 1 Sequence for disconnecting batteries 3592
4 1 2 Disconnecting battery on right in luggage compartment 3592
4 1 3 Disconnecting battery on left in luggage compartment 3593
4 1 4 Sequence for connecting batteries 3594
4 1 5 Connecting battery on left in luggage compartment 3594
4 1 6 Connecting battery on right in luggage compartment 3595
4 1 7 Steps after connecting battery 3595
4 2 Disconnecting and reconnecting batteries, vehicles with electric power latching 3596
4 2 1 Sequence for disconnecting batteries 3596
5 Removing and installing battery 3598
5 1 Removing and installing battery on right in luggage compartment 3598
5 2 Removing and installing battery on left in luggage compartment 3600
6 Battery isolation relay -J7- 3605
6 1 Removing and installing battery isolation relay -J7- 3605
7 Pyrotechnic battery isolator 3607
7 1 Overview of fitting locations 3607
7 2 Safety precautions when working on pyrotechnical battery isolator 3608
7 3 Disposal of pyrotechnical battery isolation units 3608
7 4 Removing and installing pyrotechnical battery isolator 3608
8 Removing and installing battery monitor control unit -J367- 3611
8 1 Removing and installing battery temperature sensor -G331- on right in luggage compartment 3612
9 Starter, vehicles with automatic gearbox 3613
9 1 Checking starter -B- 3613
9 2 Starter, vehicles with 3 2 l, 177 kW injection engine, automatic gearbox AL420-6Q 3613
9 2 1 Assembly overview 3613
9 2 2 Removing and installing starter, vehicles with 3 2 l, 177 kW injection engine, automatic gearbox AL420-6Q 3614
9 3 Starter, vehicles with 3 6 l, 206 kW injection engine, automatic gearbox AL420-6Q 3616
9 3 1 Assembly overview 3616
9 3 2 Removing and installing starter, vehicles with 3 6 l, 206 kW injection engine, automatic gearbox AL420-6Q 3617
9 4 Starter, vehicles with 4 2 l, 246 kW injection engine, automatic gearbox AL420-6Q 3619
9 4 1 Assembly overview 3619
9 4 2 Removing and installing starter, vehicles with 4 2 l, 246 kW injection engine, automatic gearbox AL420-6Q 3621
9 5 Starter, vehicles with 6 0 l, 331 kW injection engine, automatic gearbox 5HP24 QU 3624
9 5 1 Assembly overview 3624
9 5 2 Removing and installing starter, vehicles with 6 0 l, 331 kW injection engine, automatic gearbox 5HP24 QU 3624
9 6 Starter, vehicles with 3 0 l, 176 kW TDI engine, automatic gearbox AL420-6Q 3626
9 6 1 Assembly overview 3626
9 6 2 Removing and installing starter, vehicles with 3 0 l, 176 kW TDI engine, automatic gearbox AL420-6Q 3627
9 7 Starter, vehicles with 4 9 l, 230 kW TDI engine, automatic gearbox AL750-6A 3628
9 7 1 Assembly overview 3628
9 7 2 Removing and installing starter, vehicles with 4 9 l, 230 kW TDI engine, automatic gearbox AL750-6A 3630
10 Alternator 3634
10 1 Characteristics of alternators 3634
10 2 Securing B+ (battery positive) wire to alternator 3635
10 3 Checking poly V-belt 3635
10 4 Alternator, 3 2 l injection engine 3635
10 4 1 Assembly overview 3635
10 4 2 Removing and installing alternator, 3 2 l injection engine 3637
10 5 Alternator, 3 6 l injection engine 3639
10 5 1 Assembly overview 3639
10 5 2 Removing and installing alternator, 3 6 l injection engine 3641
10 6 Alternator, 4 2 l injection engine 3643
10 6 1 Assembly overview 3643
10 6 2 Removing and installing alternator, 4 2 l injection engine 3644
10 7 Alternator, 6 0 l injection engine 3647
10 7 1 Assembly overview 3647
10 7 2 Removing and installing alternator, 6 0 l injection engine 3648
10 8 Alternator, 3 0 l TDI engine 3650
10 8 1 Assembly overview 3650
10 8 2 Removing and installing alternator, 3 0 l TDI engine 3651
10 9 Alternator, 4 9 l TDI engine 3654
10 9 1 Assembly overview – alternator with hard rubber disc coupling 3654
10 9 2 Assembly overview – alternator with elastic coupling 3656
10 9 3 Removing and installing alternator, 4 9 l TDI engine 3657
10 10 Removing and installing poly V-belt pulley on alternator 3660
10 11 Removing and installing poly V-belt pulley with freewheel from alternator, 4 9 l TDI engine 3662
11 Cruise control system (CCS) 3664
12 Adaptive cruise control (ACC) 3665
12 1 Assembly overview – Automatic adaptive cruise control 3665
12 1 2 Assembly overview – adaptive cruise control, variant 2 3665
12 2 Removing and installing automatic distance control unit 3666
12 2 1 Removing and installing adaptive cruise control unit -J428-, variant 1 3666
12 2 2 Removing and installing adaptive cruise control unit -J428-, variant 2 3667
12 3 Calibrating adaptive cruise control sensor -G550- 3668
12 4 Initialising adaptive cruise control 3669
12 5 Removing and installing brake servo control unit -J539- 3669
90 – Gauges, instruments 3671
1 Dash panel insert 3671
1 1 Renewing dash panel insert 3671
1 2 Coding dash panel insert 3671
1 3 Removing and installing dash panel insert 3671
1 4 Description of back of dash panel insert 3673
1 5 Pin assignment of connectors on dash panel insert 3674
1 6 Warning lamp symbols in dash panel insert 3674
2 Service interval display 3676
2 1 Resetting service interval display 3676
92 – Windscreen wash/wipe system 3677
1 Windscreen wiper system 3677
1 1 General description 3677
1 2 Assembly overview – windscreen wiper system 3677
1 3 Removing and installing windscreen wiper system 3678
1 3 1 Removing windscreen wiper system 3679
1 3 2 Removing wiper arms 3679
1 3 3 Removing plenum chamber cover 3680
1 3 4 Removing cowl panel 3680
1 3 5 Removing wiper frame on driver side 3680
1 3 6 Installing wiper frame on driver side 3681
1 3 7 Removing wiper motor from driver side wiper frame 3682
1 3 8 Installing wiper motor in driver side wiper frame 3682
1 3 9 Removing wiper frame on front passenger side 3684
1 3 10 Removing wiper motor from wiper frame 3684
1 3 11 Installing wiper motor in front passenger side wiper frame 3684
1 4 Adjusting wiper blade park position 3686
1 5 Removing and installing joint-free wiper blades 3687
1 6 Rain and light sensor -G397- 3688
1 6 1 Removing and installing rain and light sensor -G397- 3688
1 6 2 Testing rain and light sensor -G397- 3690
1 6 3 Coding rain and light sensor -G397- 3690
2 Windscreen washer system 3691
2 1 Assembly overview – windscreen washer system 3691
2 2 Removing and installing washer fluid reservoir 3692
2 2 1 Removing and installing washer fluid reservoir 3692
2 2 2 Removing and installing filler pipe for windscreen and headlight washer system reservoir 3693
2 3 Removing and installing windscreen washer pump -V5- 3694
2 4 Removing and installing windscreen washer fluid level sender -G33- 3695
2 5 Removing and installing windscreen washer system spray jets 3695
2 6 Checking spray jets for windscreen washer system 3696
3 Headlight washer system 3697
3 1 Assembly overview – headlight washer system 3697
3 2 Removing and installing headlight washer system pump -V11- 3699
3 3 Removing and installing spray jet pop-up cylinders 3699
3 4 Removing and installing spray jet assembly 3701
3 5 Checking and adjusting washer jets 3701
3 6 Bleeding headlight washer system 3702
4 Washer fluid line hose couplings 3703
5 Hose repair 3704
94 – Lights, bulbs, switches – exterior 3705
1 Operation and safety notes for gas discharge bulbs 3705
2 Headlight with gas discharge bulb 3708
2 1 General description 3708
2 2 Assembly overview, headlights with a gas discharge bulb 3708
2 3 Removing and installing headlight 3710
2 4 Adjusting headlight installation position 3712
2 5 Renewing gas discharge headlight bulb 3714
2 5 1 Renewing dipped beam gas discharge bulb 3714
2 5 2 Renewing main beam bulb 3715
2 5 3 Renewing side light bulb 3716
2 5 4 Renewing turn signal bulb 3717
2 6 Removing and installing headlight range control motor 3718
2 7 Removing and installing headlight range control unit 3720
2 8 Removing and installing vehicle level sender 3721
2 9 Coding control unit for headlight range control 3721
2 10 Converting headlights for use when driving on the left or right 3722
2 10 1 Converting headlights designed for driving on the right to driving on the left 3722
2 10 2 Converting headlights designed for driving on the left to driving on the right 3724
2 11 Adjusting headlights 3725
3 Headlights with two gas discharge bulbs 3726
3 1 General description 3726
3 2 Assembly overview – Headlights with two gas discharge bulbs 3726
3 3 Removing and installing headlight 3728
3 4 Adjusting headlight installation position 3730
3 5 Renewing bulbs in headlights with two gas discharge bulbs 3731
3 5 1 Renewing dipped beam gas discharge bulb 3731
3 5 2 Renewing main beam gas discharge bulb 3733
3 5 3 Renewing side light bulb 3734
3 5 4 Renewing turn signal bulb 3735
3 6 Removing and installing headlight range control motor 3736
3 7 Removing and installing headlight range control unit 3737
3 8 Removing and installing main beam headlight range control unit 3737
3 9 Removing and installing vehicle level sender 3738
3 10 Coding control unit for headlight range control 3739
3 11 Adjusting headlights 3739
4 Headlights with gas discharge bulb and cornering light (VARILIS headlights), vehicles up to calendar week 22/2010 (model year ► 2011) 3740
4 1 General description 3740
4 2 Assembly overview – headlights with gas discharge bulbs and cornering lights 3741
4 3 Removing and installing headlight 3743
4 4 Adjusting headlight installation position 3746
4 5 Renewing gas discharge bulbs and cornering light bulbs in headlights 3746
4 5 1 Renewing gas discharge bulb 3746
4 5 2 Renewing cornering light bulb (static cornering light) 3748
4 5 3 Renewing turn signal bulb 3749
4 6 Daytime running lights and side light control unit 3751
4 6 1 Removing and installing control unit for daytime running light and side light 3751
4 7 Gas discharge bulb control unit 3751
4 7 1 Removing and installing gas discharge bulb control unit 3751
4 8 Power output module for headlight 3752
4 8 1 Removing and installing power output module for headlight 3752
4 9 Headlight range control unit -J431- 3754
4 9 1 Removing and installing headlight range control unit -J431- 3754
4 9 2 Coding control unit for headlight range control 3754
4 10 Headlight range control motor 3754
4 10 1 Removing and installing headlight range control motor 3754
4 11 Dynamic cornering light control motor 3756
4 11 1 Checking dynamic cornering light control motor 3756
4 12 Swivel module position sensor 3756
4 12 1 Checking swivel module position sensor 3757
4 13 Headlight screen adjustment solenoid 3757
4 13 1 Removing and installing headlight screen adjustment solenoid 3757
4 13 2 Testing headlight screen adjustment solenoid 3757
4 14 Removing and installing vehicle level sender 3757
4 15 LED module for daytime running light and side light 3757
4 16 Adjusting headlights 3758
5 Headlights with dynamic main beam control, vehicles up to calendar week 22/2010 (model year ► 2011) 3759
5 1 General description 3759
5 2 Removing and installing headlight 3759
5 3 Assembly overview – gas discharge headlights with dynamic main beam regulation 3762
5 4 Adjusting headlight installation position 3763
5 5 Renewing gas discharge bulbs and cornering light bulbs in headlights 3764
5 5 1 Renewing gas discharge bulb 3764
5 5 2 Renewing cornering light bulb (static cornering light) 3766
5 5 3 Renewing turn signal bulb 3767
5 6 Daytime running lights and side light control unit 3769
5 6 1 Removing and installing control unit for daytime running light and side light 3769
5 7 Gas discharge bulb control unit 3769
5 7 1 Removing and installing gas discharge bulb control unit 3769
5 8 Power output module for headlight 3770
5 8 1 Removing and installing power output module for headlight 3770
5 9 Headlight range control unit -J431- 3772
5 9 1 Removing and installing headlight range control unit -J431- 3772
5 9 2 Coding control unit for headlight range control 3772
5 10 Headlight range control motor 3772
5 10 1 Removing and installing headlight range control motor 3772
5 11 Dynamic cornering light control motor 3774
5 11 1 Checking dynamic cornering light control motor 3774
5 12 Swivel module position sensor 3774
5 12 1 Checking swivel module position sensor 3775
5 13 Headlight screen adjustment solenoid 3775
5 13 1 Removing and installing headlight screen adjustment solenoid 3775
5 13 2 Testing headlight screen adjustment solenoid 3775
5 13 3 Removing and installing vehicle level sender 3775
5 14 LED module for daytime running light and side light 3775
5 15 Adjusting headlights 3776
6 Headlights with gas discharge bulb, vehicles as of calendar week 22/2010 (model year 2011 ►) 3777
6 1 General description 3777
6 2 Assembly overview – headlight 3778
6 3 Removing and installing headlight 3780
6 4 Adjusting headlights 3781
6 5 Adjusting headlight installation position 3781
6 6 Removing and installing front turn signal bulb -M5-/-M7- 3781
6 7 Removing and installing headlight range control motor -V48-/-V49- 3782
6 8 Removing and installing gas discharge bulb -L13-/-L14- 3784
6 9 Removing and installing LED modules for daytime running light and side light -L176-/-L177- 3785
6 10 Removing and installing bulbs for static cornering light -L148-/-L149- 3786
6 11 Removing and installing control unit for daytime running light and side light -J860-/-J861- 3786
6 12 Removing and installing gas discharge bulb control unit -J343-/-J344- 3787
6 13 Removing and installing output module for headlight -J667-/-J668- 3788
6 14 Removing and installing turn signal control unit 3789
6 15 Removing and installing control unit for cornering light and headlight range control -J745- 3789
6 16 Removing and installing headlight screen adjustment solenoid 3790
6 17 Removing and installing dynamic cornering light control motor -V318-/-V319- 3790
6 18 Removing and installing swivel module position sensor -G474-/-G475- 3790
6 19 Removing and installing control motor for VARILIS headlight -V446-/-V447- 3790
6 20 Removing and installing control motor sender for VARILIS headlight -G695-/-G696- 3790
7 Fog lights 3791
7 1 Removing and installing fog light 3791
7 2 Removing and installing fog light bulb 3792
7 3 Adjusting fog lights 3792
8 Front side marker light bulb 3793
8 1 Removing and installing side marking light bulb 3793
9 Turn signal repeater bulb and entry light in exterior mirror 3794
9 1 Removing and installing turn signal repeater 3794
9 2 Removing and installing entry light in exterior mirror 3794
10 Tail light cluster with LED 3796
10 1 Tail light (tail light cluster) with LEDs in side panel 3796
10 1 1 Assembly overview – tail light (tail light cluster) with LEDs in side panel 3796
10 1 2 Removing and installing tail light (tail light cluster) with light diodes in side panel 3797
10 2 Tail light (tail light cluster) in rear lid 3798
10 2 1 Assembly overview – tail light (tail light cluster) in rear lid 3798
10 2 2 Removing and installing tail light (tail light cluster) in rear lid 3799
10 2 3 Removing and installing reversing light bulb 3800
10 3 Tail light (tail light cluster) gaps and shut lines 3801
10 4 Checking tail light (tail light cluster) function 3802
11 Number plate light 3804
11 1 Number plate light -X- 3804
11 1 1 Removing and installing number plate light 3804
11 2 Luminescent number plate 3805
11 2 1 Removing and installing luminescent number plate 3805
12 High-level brake lights (additional brake lights) 3807
12 1 Removing and installing additional brake light 3807
12 2 Removing and installing bulb carrier 3807
13 Steering column switch 3809
13 1 Assembly overview – steering column switch 3809
13 2 Removing and installing steering column switch 3811
13 3 Dismantling and assembling steering column switch 3813
13 4 Pin assignment on steering column switch 3815
13 5 Coding steering column electronics control unit -J527- 3816
14 Entry and start authorisation 3818
14 1 Emergency release 3818
14 2 Entry and start authorisation switch -E415- 3818
14 2 1 Removing and installing entry and start authorisation switch -E415- 3819
14 2 2 Checking entry and start authorisation switch -E415- 3820
14 3 Entry and start authorisation button -E408- 3820
14 3 1 Removing and installing entry and start authorisation button -E408- 3821
14 3 2 Pin assignment for entry and start authorisation button -E408- 3821
14 3 3 Checking entry and start authorisation button -E408- 3821
14 4 Entry and start authorisation control unit -J518- 3822
14 4 1 Removing and installing entry and start authorisation control unit -J518- 3822
14 4 2 Renewing entry and start authorisation control unit -J518- 3823
14 4 3 Coding entry and start authorisation control unit -J518- 3823
14 4 4 Checking entry and start authorisation control unit -J518- 3824
14 5 Assembly overview of entry and start authorisation aerials 3824
14 6 Removing and installing entry and start authorisation aerials 3826
14 6 1 Removing and installing driver side aerial for entry and start authorisation -R134- 3826
14 6 2 Removing and installing front passenger side aerial for entry and start authorisation -R135- 3826
14 6 3 Rear bumper aerial for entry and start authorisation -R136- 3826
14 6 4 Removing and installing luggage compartment aerial for entry and start authorisation -R137- 3827
14 6 5 Removing and installing interior aerial 1 for entry and start authorisation -R138- 3827
14 6 6 Removing and installing interior aerial 2 for entry and start authorisation -R139- 3828
14 6 7 Removing and installing interior aerial 3 for entry and start authorisation -R154- 3829
14 7 Adapting aerial parameters for entry and start authorisation aerials 3829
15 Parking aid (PDC) 3831
15 1 General description 3831
15 2 Assembly overview – parking aid 3831
15 3 Parking aid control unit -J446- 3833
15 3 1 Removing and installing parking aid control unit -J446- 3833
15 3 2 Checking parking aid control unit -J446- 3833
15 3 3 Adapting deactivation speed of parking aid 3833
15 3 4 Adapting masking area for attachments 3834
15 4 Front parking aid senders 3834
15 4 1 Removing and installing front parking aid senders 3834
15 5 Rear parking aid senders 3835
15 5 1 Removing and installing rear parking aid sender 3835
15 6 Front parking aid display 3836
15 6 1 Removing and installing front parking aid display 3836
15 7 Rear parking aid display -Y15- 3837
15 7 1 Removing and installing rear parking aid display -Y15- 3837
15 8 Parking aid warning buzzer 3837
15 8 1 Removing and installing rear parking aid warning buzzer -H15- 3837
15 8 2 Adjusting volume of rear parking aid warning buzzer -H15- 3838
15 8 3 Removing and installing front parking aid warning buzzer -H22- 3838
15 8 4 Adjusting volume of front parking aid warning buzzer -H22- 3839
16 Lane change assist (Side Assist) 3840
16 1 General description 3840
16 2 Removing and installing lane change assist control unit with radar sensor 3840
16 3 Removing and installing lane change assist warning lamps in exterior mirror 3841
16 4 Calibrating lane change assist 3842
16 4 1 Measurement location 3842
16 4 2 Preparatory measures for calibration 3843
16 4 3 Calibrating lane change assist control unit -J769-/-J770- 3847
16 5 Lane change assist control unit final control diagnosis 3849
16 6 Coding lane change assist control unit 3849
17 Reverse camera (Rear Assist) 3850
17 1 General description 3850
17 2 Assembly overview – reversing camera system 3850
17 3 Removing and installing reversing camera 3851
17 4 Reversing camera system control unit -J772- 3852
17 4 1 Removing and installing reversing camera system control unit -J772- 3852
17 4 2 Coding reversing camera system control unit -J772- 3853
17 5 Calibrating reversing camera system 3853
17 5 1 Preparatory work for calibration: 3853
17 5 2 Calibrating reversing camera system 3856
18 Front camera for driver assist systems -R242- 3858
18 1 General description 3858
18 2 Removing and installing front camera for driver assist systems -R242- 3858
18 3 Calibrating front camera for driver assist systems -R242- 3859
18 4 Coding camera control unit -J852- 3859
18 5 Removing and installing windscreen heater for lane departure warning 3859
19 Tyre pressure monitor (TPM) from 2007 onwards 3860
19 1 Tyre pressure monitor control unit -J502- 3861
19 1 1 Removing and installing tyre pressure monitor control unit -J502- 3861
19 1 2 Coding tyre pressure monitor control unit -J502- 3861
19 2 Tyre pressure sensors 3862
19 2 1 Removing and installing tyre pressure sensors 3862
19 3 Transmitter units in wheel housing 3862
19 3 1 Removing and installing transmitter units in wheel housing 3862
19 4 Tyre pressure monitor aerial -R207- 3863
19 4 1 Removing and installing tyre pressure monitor aerial -R207- 3863
96 – Lights, bulbs, switches – interior 3864
1 Interior lights and switches 3864
1 1 Rear left footwell light -L106- or rear right footwell light -L107- 3864
1 1 1 Removing and installing rear left footwell light -L106- or rear right footwell light -L107- 3864
2 Lights and switches in dash panel 3865
2 1 Light switch -E1- 3865
2 1 1 Removing and installing light switch -E1- 3865
2 2 Switches and instruments illumination regulator -E20- and trip recorder zeroing switch -E123- 3865
2 2 1 Removing and installing switches and instruments illumination regulator -E20- and trip recorder zeroing switch -E123- 3865
2 3 Rear roller blind switch -E149- and parking aid button -E266- 3866
2 3 1 Removing and installing rear roller blind switch -E149- and parking aid button -E266- 3866
2 4 Glove compartment light -W6- 3867
2 4 1 Removing and installing glove compartment light -W6- 3867
2 5 Glove compartment light switch -E26- 3868
2 5 1 Removing and installing glove compartment light switch -E26- 3868
2 6 Steering column adjustment switch -E167- 3869
2 6 1 Removing and installing steering column adjustment switch -E167- 3869
2 7 Front left footwell lighting bulb -L151- or front right footwell light bulb -L152- 3869
2 7 1 Removing and installing front left footwell lighting bulb -L151- and front right footwell lighting bulb -L152- 3869
2 8 Radio controlled clock -Y8- 3870
2 8 1 Removing and installing the radio controlled clock -Y8- 3870
2 9 Light conductor for front left sill panel moulding ambient lighting -W67- and light conductor for front right sill panel moulding ambient lighting -W68- 3871
2 9 1 General notes 3871
2 9 2 Removing and installing light conductor for front left sill panel moulding ambient lighting -W67- and light conductor for front right sill panel moulding ambient lighting -W68- 3871
2 9 3 Removing and installing control unit for ambient lighting of front sill panel strips -J967- 3872
2 10 Light conductor for rear left sill panel moulding ambient lighting -W69- and light conductor for rear right sill panel moulding ambient lighting -W70- 3872
2 10 1 General notes 3872
2 10 2 Removing and installing light conductor for rear left sill panel moulding ambient lighting -W69- and light conductor for rear right sill panel moulding ambient lighting -W70- 3873
2 10 3 Removing and installing control unit 2 for ambient lighting of rear sill panel strips -J968- 3873
3 Lights and switches in front doors 3875
3 1 Central switch for window regulators in driver door -E189-, rear lid remote release button -E233- and fuel tank flap release button -E319- 3875
3 1 1 Removing and installing the central switch for window regulators in driver door -E189-, rear lid remote release button -E233- and fuel tank flap release button -E319- 3875
3 2 Front right window regulator switch -E41- 3876
3 2 1 Removing and installing front right window regulator switch -E41- 3876
3 3 Front interior locking buttons for central locking system -E308- and -E309- 3876
3 3 1 Removing and installing front interior locking buttons for central locking system -E308- and -E309- 3877
3 4 Door opener lighting -L108- and -L109- 3878
3 4 1 Removing and installing door opener lighting -L108- and -L109- 3878
3 5 Front door contact switch 3879
3 5 1 Removing and installing driver door contact switch -F2- or front passenger door contact switch -F3- 3879
3 6 Front left entry light -W31- or front right entry light -W32- 3879
3 6 1 Removing and installing rear left entry light -W31- or rear right entry light -W32- 3879
3 7 Door warning lamps -W30- and -W36- 3880
3 7 1 Removing and installing door warning lamps -W30- and -W36- 3881
4 Lights and switches in rear doors 3882
4 1 Rear window regulator switches -E52- and -E54- 3882
4 1 1 Removing and installing rear window regulator switches -E52- and -E54- 3882
4 2 Rear interior locking buttons for central locking system -E310- and -E311- 3882
4 2 1 Removing and installing rear interior locking buttons for central locking system -E310- and -E311- 3883
4 3 Rear door opener lighting -L110- and -L111- 3884
4 3 1 Removing and installing rear door opener lighting -L110- and -L111- 3884
4 4 Rear door contact switch 3885
4 4 1 Removing and installing rear left door contact switch -F10- or rear right door contact switch -F11- 3885
4 5 Rear entry lights -W33- and -W34- 3885
4 5 1 Removing and installing rear entry lights -W33- and -W34- 3885
4 6 Rear door warning lamps -W37- and -W38- 3886
4 6 1 Removing and installing rear door warning lamps -W37- and -W38- 3886
5 Lights and switches in luggage compartment 3888
5 1 Luggage compartment lights -W18- and -W35- 3888
5 1 1 Removing and installing luggage compartment lights -W18- and -W35- 3888
5 2 Luggage compartment light switch -F5- 3889
5 2 1 Removing and installing luggage compartment light switch -F5- 3889
5 3 Rear lid closing button, in rear lid -E406- 3889
5 3 1 Removing and installing button for closing rear lid in rear lid -E406- 3889
6 Lights and switches in roof trim 3891
6 1 Front interior light -W1- 3891
6 1 1 Removing and installing front interior light -W1- 3891
6 2 Front reading lights -W19- and -W13- 3893
6 2 1 Removing and installing front reading lights -W19- and -W13- 3893
6 3 Sunroof switch -E8- 3894
6 3 1 Removing and installing sliding sunroof switch -E8- 3894
6 4 Rear interior and reading lights 3894
6 4 1 Removing and installing rear interior and reading lights 3894
6 5 Rear interior light buttons -E327- and -E329- 3896
6 5 1 Removing and installing rear interior light button -E327- and rear reading light button -E329- 3896
6 6 Garage door opener 3896
6 6 1 Removing and installing garage door operation control unit -J530- 3896
6 7 Switch unit in roof module 3897
6 7 1 Removing and installing the switch unit in the roof module 3897
7 Lights and switches in centre console 3899
7 1 Mirror adjustment switch -E43- with mirror adjustment change-over switch -E48- 3899
7 1 1 Removing and installing mirror adjustment switch -E43- with mirror adjustment change-over switch -E48- 3899
7 2 Key operated switch to deactivate front passenger side airbag -E224- 3899
7 2 1 Removing and installing key-operated switch to deactivate front passenger side airbag -E224- 3899
7 3 Starter button -E408- 3900
7 3 1 Removing and installing the starter button -E408- 3900
7 4 Switch unit for front seat heating/front seat ventilation with button for damping, ESP and level control in the centre console 3900
7 4 1 Removing and installing the switch unit for front seat heating/front seat ventilation with button for damping, ESP and level control in the centre console 3901
7 5 Switch unit for memory and seat heating/seat ventilation for rear seats in the 4-seat version 3901
7 5 1 Removing and installing the switch unit for memory and seat heating/seat ventilation for rear seats in the 4-seat version 3901
7 6 Switch unit for adjustable rear seat, 4-seater 3902
7 6 1 Removing and installing the switch unit for rear seat adjustment in the 4-seat version 3902
7 7 Switch unit for height-adjustment of lumbar support of rear seat, 5-seater 3903
7 7 1 Removing and installing the switch unit for height-adjustment of rear seat lumbar support in the 5-seat version 3903
8 Cigarette lighter 3904
8 1 Cigarette lighter -U1- 3904
9 Horn 3905
9 1 Treble tone horn -H2- 3905
9 1 1 Removing and installing treble horn -H2-, variant 1 3905
9 1 2 Removing and installing treble horn -H2-, variant 2 3905
9 2 Bass tone horn -H7- 3906
9 2 1 Removing and installing bass horn -H7-, variant 1 3906
9 2 2 Removing and installing bass horn -H7-, variant 2 3906
97 – Wiring 3908
1 Vehicle diagnosis, testing and information systems 3908
2 Fuse holder 3909
2 1 Fuse holder under dash panel on left 3909
2 1 1 Removing and installing fuse holder on left beneath dash panel 3909
2 2 Pre-fuse box in luggage compartment on left 3909
2 2 1 Removing and installing pre-fuse on left in luggage compartment 3910
2 3 Thermal fuse box on driver side 3912
2 3 1 Removing and installing thermal fuse box on driver’s side 3912
3 Relay carrier 3914
3 1 Relay carrier in front right footwell 3914
3 1 1 Removing and installing relay carrier in front right footwell 3914
4 Electronics boxes 3916
4 1 E-box on left in luggage compartment 3916
4 1 1 Removing and installing E-box on left in luggage compartment (vehicles ► 05 03) 3916
4 1 2 Removing and installing E-box on left in luggage compartment (vehicles 06 03 ►) 3917
4 2 E-box on right in plenum chamber 3918
4 2 1 Removing and installing E-box in plenum chamber on right 3918
5 Control units 3921
5 1 Onboard supply control unit 3921
5 1 1 Removing and installing onboard supply control unit 3921
5 1 2 Replacing onboard power supply control unit 3922
5 2 Roof electronics control unit 3923
5 2 1 Removing and installing the roof electronics control unit 3923
6 Wiring harness and connector repairs 3924
K0058950920 Communication 3925
91 – Communication 3931
1 Communication systems 3931
1 1 General description 3931
2 Removing and installing control unit for front display and information control panel 3932
2 1 Removing and installing control unit for front display and information control panel 3932
2 2 Removing and installing control unit for front display and information control panel 3932
2 2 1 Removing: 3932
2 2 2 Installing: 3936
3 Control unit for front display and information control panel, vehicles ► 10 08 3938
3 1 General notes 3938
3 2 Fault finding 3939
3 3 Overview of control unit for front display and information control panel, vehicles ► 10 08 3939
3 4 Overview of multi-pin connectors of control unit for front display and information control panel, vehicles ► 10 08 3942
3 4 7 Connectors 7 and 8, aerial connections on control unit for front information display and operating unit 3946
3 5 Replacing the optical fibre conductor 3946
3 5 1 General notes 3947
3 5 2 Replacing the optical fibre conductor between the navigation control unit and the front information control unit 3947
3 5 3 Replacing the optical fibre conductor between the navigation control unit and the front information control unit and the rear information control unit 3950
3 5 4 Deleting and interrogating the fault memory after replacing an optical fibre conductor 3956
3 6 Adapting components, communication system 3957
4 Control unit for front display and information control panel, vehicles 11 08 ► 3958
4 1 General notes 3958
4 2 Overview of control unit for front display and information control panel, vehicles 11 08 ► 3959
4 3 Overview of multi-pin connectors of control unit for front display and information control panel, vehicles 11 08 ► 3961
4 3 6 8-pin multi-pin connector 6, CAN 3963
4 4 Anti-theft coding 3965
4 4 1 Deactivating anti-theft coding 3966
4 5 Removing and installing external Bluetooth module for navigation 3967
4 5 1 Removing 3967
4 5 2 Installing 3967
4 6 Adapting components, communication system 3968
5 Sound system amplifier 3969
5 1 “Standard sound system” amplifier for vehicles ► 10 08 3969
5 1 1 General description of the “Standard sound system” 3969
5 1 2 Fault finding 3969
5 1 3 Characteristic feature of “Standard sound system” 3969
5 1 4 Overview of “Standard sound system” 3969
5 1 5 Overview of multi-pin connectors on amplifier for “Standard sound system” 3971
5 2 “Premium sound system” amplifier for vehicles ► 10 08 3973
5 2 1 General description of the “Premium sound system” 3973
5 2 2 Characteristic feature of “Premium sound system” 3973
5 2 3 Overview of “Premium sound system” 3973
5 2 4 Overview of multi-pin connectors on amplifier for “Premium sound system” 3975
5 3 “Dynaudio sound system” amplifier for vehicles 11 08 ► 3976
5 4 Removing and installing amplifier 3977
5 4 1 Removing the amplifier from the left of the luggage compartment: 3977
5 4 2 Installing the amplifier on the left of the luggage compartment: 3981
5 4 3 Removing the amplifier from the right of the luggage compartment: 3981
5 4 4 Installing the amplifier on the right of the luggage compartment: 3982
6 TV system with analogue TV tuner or analogue television reception 3984
6 1 Fault finding 3984
6 2 Removing and installing TV tuner 3984
6 2 1 Removing: 3984
6 2 2 Installing: 3985
6 3 Pin assignment of 54-pin connector for TV tuner 3986
7 TV system with digital TV tuner for digital television (DVB-T) 3988
7 1 General notes 3988
7 1 1 Fault finding 3988
7 2 Removing and installing the digital TV tuner 3988
7 2 1 Removing 3989
7 2 2 Installing 3990
7 3 Programming the remote control for the digital TV tuner 3990
7 4 Changing remote control batteries 3991
7 5 Fuse for the digital TV tuner 3991
8 TV system with hybrid tuner for analogue reception and digital television (DVB-T) 3993
8 1 Fault finding 3993
8 2 Removing and installing TV tuner 3993
8 2 1 Removing: 3993
8 2 2 Installing: 3994
8 3 Pin assignment of 54-pin connector for TV tuner 3995
9 Navigation system with CD drive control unit 3997
9 1 General notes 3997
9 2 Fault finding 3997
9 3 Removing and installing navigation with CD drive control unit 3997
9 3 2 Removing: 3998
9 3 3 Installing: 3998
9 4 Overview of navigation system with CD drive control unit 3999
10 Multi-media system (Rear Seat DVD) 4000
10 1 General notes 4000
10 1 1 Fault finding 4000
10 2 Overview of multi-media system 4000
10 2 1 System overview of multi-media system 4002
10 3 System component connection assignments 4003
10 3 2 Multimedia display control unit 4003
10 4 Relays and fuses for the multi-media system 4004
10 5 Removing and installing multimedia DVD changer 4005
10 5 1 Removing multi-media system in luggage compartment 4005
10 5 2 Installing 4006
10 6 Removing and installing the display unit control unit 4007
10 6 1 Removing 4007
10 6 2 Installing 4007
10 7 Removing and installing multimedia control unit 4007
10 7 1 Removing 4008
10 7 2 Installing 4008
10 8 Removing and installing multimedia display units 4008
10 8 1 Removing 4008
10 8 2 Installing 4009
10 9 Removing and installing additional connections unit for video and audio 4009
10 9 1 Removing 4009
10 9 2 Installing 4010
11 Multi-media system (Rear Seat DVD), models 2012 ▶ 4011
11 1 General notes 4011
11 1 1 Fault finding 4011
11 2 Overview of multi-media system 4011
11 2 1 System overview of multi-media system 4013
11 3 Removing and installing multimedia system module in luggage compartment 4014
11 3 1 Overview of multimedia system module 4014
11 3 2 Removing multimedia system module in luggage compartment 4015
11 3 3 Installing multimedia system module in luggage compartment 4016
11 3 4 Routing wires on multimedia system module 4016
11 4 Removing and installing multimedia system control unit -J650- 4018
11 4 1 Removing: 4018
11 4 2 Installing: 4019
11 5 Removing and installing control unit for multimedia display units -J744- 4019
11 5 1 Removing: 4019
11 5 2 Installing: 4020
11 6 Removing and installing DVD changer -R162- 4021
11 6 1 Removing: 4021
11 6 2 Installing: 4021
11 7 Removing and installing battery monitoring control unit -J367- and suppression filter -C10- 4023
11 7 1 Removing: 4023
11 7 2 Installing: 4023
11 8 Removing and installing multi-media display units 4023
11 8 1 Removing: 4023
11 8 2 Installing: 4024
11 9 Removing and installing additional connections unit for audio and video -R176- 4025
11 9 1 Removing: 4025
11 9 2 Installing: 4025
11 10 Relays and fuses for the multi-media system 4025
12 Telematics system (only for vehicles for USA and Canada) 4027
12 1 General notes 4027
12 1 1 Fault finding 4028
12 2 Overview of telematics system 4028
12 3 Removing and installing telematics operating unit 4029
12 3 2 Removing 4029
12 3 3 Installing 4029
12 3 4 Description of functions of telematics operating unit buttons 4029
12 4 Removing and installing telematics control unit 4030
12 4 1 Removing: 4030
12 4 2 Installing: 4031
12 4 3 Configuring system with telematics central control centre 4032
12 5 Fault finding on telematics system 4036
12 5 1 Evaluating reactions of warning lamps in operating unit 4036
12 5 2 Evaluating messages from the telematics system in conjunction with reactions of the warning lamps 4036
12 6 Coding telematics system 4038
12 7 Deactivating transport mode 4038
13 CD changer 4039
13 1 CD changer, vehicles ►10 08 4039
13 1 1 General notes 4039
13 1 2 Fault finding 4039
13 1 3 Removing and installing CD changer 4039
13 2 CD changer, vehicles 11 08 ► 4041
13 2 1 General notes 4041
13 2 2 Fault finding 4041
13 2 3 Removing and installing CD changer 4041
14 Multimedia system control unit for vehicles 11 08 ► 4044
14 1 General notes 4044
14 2 Overview of multimedia system control unit 4044
14 3 Removing and installing multimedia control unit 4045
14 3 1 Removing: 4046
14 3 2 Installing: 4046
15 Connection for external audio sources 4047
15 1 General notes 4047
15 2 Removing and installing connection for external audio sources 4047
15 2 1 Removing: 4047
15 2 2 Installing: 4048
15 3 Contact assignment on connection for external audio sources 4048
16 Loudspeaker system 4049
16 1 General description 4049
16 2 Overview of loudspeaker system 4049
16 3 Removing and installing front bass loudspeakers 4050
16 3 1 Removing: 4050
16 3 2 Installing: 4051
16 4 Removing and installing front mid-bass loudspeakers 4051
16 4 1 Removing: 4051
16 4 2 Installing: 4051
16 5 Removing and installing front mid-range loudspeakers 4052
16 5 1 Removing: 4052
16 5 2 Installing: 4052
16 6 Removing and installing front treble loudspeakers 4052
16 6 1 Removing: 4053
16 6 2 Installing: 4053
16 7 Removing and installing rear bass loudspeakers 4053
16 7 1 Removing: 4054
16 7 2 Installing: 4054
16 8 Removing and installing rear mid-range loudspeakers 4054
16 8 1 Removing: 4054
16 8 2 Installing: 4055
17 Aerial systems 4056
17 1 General notes 4056
17 2 Overview of aerial system for vehicles ► 10 08 4056
17 3 Overview of aerial system for vehicles 11 08 ► in conjunction with radio navigation system “RNS 810” 4058
17 4 Overview of aerial system in vehicles 11 08 ► in conjunction with radio system “RCD 810” 4059
17 5 Overview of connections on aerial modules for vehicles 11 08 ► 4060
17 6 Removing and installing aerial amplifier 4061
17 6 2 Installing: 4062
17 7 Removing and installing aerial module for telephone and navigation 4062
17 7 1 Removing: 4062
17 7 2 Installing: 4063
17 8 Removing and installing roof aerial 4063
17 8 1 Removing: 4063
17 8 2 Installing: 4064
17 9 Renewal of aerial wiring 4064
18 Telephone system 4065
18 1 Telephone system for vehicles ► 10 2008 4065
18 1 1 General notes 4065
18 1 2 Fault finding 4065
18 1 3 Overview of telephone system 4065
18 1 4 Removing and installing telephone control unit and operating electronics control unit 4067
18 1 5 Multi-pin connectors on telephone and telematics control unit -J526- 4070
18 1 6 Removing and installing telephone microphone 4072
18 1 7 Removing and installing telephone bracket 4073
18 1 8 Adapting the wireless second handset to the mobile telephone (pairing process) 4074
18 1 9 Adapting the second handset to the mobile telephone (pairing process) ► 11 2008 4075
18 2 Telephone system for vehicles 11 2008 ► 4076
18 2 1 General notes 4076
18 2 2 Overview of telephone system “UHV Premium light” with Bluetooth technology 4076
18 2 3 Adapting the wireless second handset to the mobile telephone (pairing process) 11 2008 ► 4078
19 Multifunction steering wheel up to 05 2010 4079
19 1 General notes 4079
19 2 Fault finding 4079
19 2 1 Fault finding 4079
19 3 Removing and installing steering wheel multifunction buttons 4079
19 3 1 Removing: 4079
19 3 2 Installing: 4080
19 4 Removing and installing multifunction steering wheel control unit 4081
19 4 1 Removing: 4081
19 4 2 Installing: 4082
19 5 Adapting multifunction steering wheel components 4083
20 Multifunction steering wheel from 05 2010 4084
20 1 General notes 4084
20 2 Fault finding 4084
20 2 1 Fault finding 4084
20 3 Removing and installing steering wheel multifunction buttons 4084
20 3 1 Removing: 4084
20 3 2 Installing: 4086
20 4 Removing and installing multifunction steering wheel control unit 4086
20 4 1 Removing: 4086
20 4 2 Installing: 4087
20 5 Adapting multifunction steering wheel components 4087
21 Operating and display unit, rear 4088
21 1 General notes 4088
21 2 Removing and installing touchpad control unit -J929- 4088
21 3 Removing and installing display unit control unit -J146- 4089
21 3 1 Removing and installing display unit control unit -J146-, 5-seater 4089
21 3 2 Removing and installing display unit control unit -J146-, 4-seater 4090
21 4 Removing and installing battery for touchscreen control 4092
22 Notes on operating mobile telephones and two-way radios 4094
22 1 General notes 4094
22 1 1 Mobile telephones or portable two-way radios may not be used in the vehicle without a separate external aerial 4094
22 1 2 The installation and operation of two-way radios with a transmitting power above 10 watts for the radio communication services listed in the table are permitted only under the following conditions: 4094
22 2 Notes on performing repair work 4095
22 2 1 Transmitting power and possible fitting locations 4095
22 2 2 Voltage supply 4095
22 2 3 Aerial and aerial wiring 4096
22 2 4 Further additional installations 4096
22 3 Overview of battery, transmitter and receiver unit, fuse and wiring harness 4096
22 4 Transmitting power and aerial fitting locations 4097
22 4 1 Phaeton 2003 ► 4097
23 Suppression measures 4098
23 1 Suppression measures 4098
K0058951020 Heating air conditioning 4099
00 – Technical data 4105
1 Notes on safety 4105
1 1 Safety precautions when working on air conditioning systems 4105
1 2 Safety measures for when working on vehicles with a start-stop system 4105
1 3 Safety precautions when working on cooling system 4105
2 General notes 4107
2 1 Notes concerning odours in air conditioned vehicles 4107
2 2 Notes for vehicles with start-stop system 4107
3 Repair notes 4108
3 1 Working on refrigerant circuit 4108
3 2 Refrigerant circuit seals 4108
4 Technical data 4109
4 1 Capacities for refrigerant R134a 4109
4 2 Refrigerant oil 4109
4 3 Oil distribution 4109
80 – Heating 4110
1 Heating 4110
87 – Air conditioning system 4111
1 Overview of fitting locations – air conditioning system 4111
1 1 Overview of fitting locations – components not located in passenger compartment 4111
2 Refrigerant circuit 4115
2 1 System overview – refrigerant circuit 4115
2 2 Removing and installing condenser 4116
2 3 Removing and installing restrictor 4117
2 4 Removing and installing refrigerant pressure and temperature sender -G395- 4118
2 5 Quick release coupling 4120
2 6 Removing and installing evacuating and charging valves on low and high-pressure side 4123
2 7 Removing and installing drier 4125
3 Air conditioner compressor 4128
3 1 Removing and installing air conditioner compressor 4128
3 2 Removing and installing freewheel on air conditioner compressor 4132
3 2 1 Removing and installing freewheel on air conditioner compressor, vehicles without Gates coupling 4132
3 2 2 Removing and installing freewheel on air conditioner compressor, vehicles with Gates coupling 4133
3 3 Checking excess pressure relief valve on air conditioner compressor 4135
3 4 Ancillary bracket 4135
3 4 1 Removing and installing air conditioner compressor with ancillary bracket: engine codes AYT and BKL 4136
3 4 2 Removing and installing air conditioner compressor with ancillary bracket: engine codes BGH and BGJ 4138
3 4 3 Removing and installing air conditioner compressor with ancillary bracket: engine codes BMK, CARA, CEXA and CEXB 4140
3 4 4 Removing and installing air conditioner compressor, engine code AJS 4142
3 4 5 Removing and installing air conditioner compressor with ancillary bracket: engine codes BAN, BAP, BRN and BTT 4144
4 Control motors 4148
4 1 Overview of fitting locations – front control motors 4148
4 2 Removing and installing air flow flap control motor -V71- 4150
4 3 Removing and installing defroster flap control motor -V107- 4151
4 4 Removing and installing left footwell flap control motor -V108- 4151
4 4 1 Installing 4152
4 4 2 Changing position of shaft of control motor 4152
4 5 Removing and installing right footwell flap control motor -V109- 4152
4 6 Removing and installing air recirculation flap control motor -V113- 4153
4 7 Removing and installing front cold air flap control motor -V197- 4154
4 7 1 Installing 4154
4 8 Removing and installing front warm air flap control motor -V198- 4155
4 9 Removing and installing front right defroster and chest vent shut-off flap control motor -V199- 4155
4 10 Removing and installing front left defroster and chest vent shut-off flap control motor -V200- 4156
4 11 Removing and installing rear right centre console warm air flap control motor -V201- and rear left centre console warm air flap control motor -V202- 4156
4 12 Removing and installing rear right centre console cold air flap control motor -V203- and rear left centre console cold air flap control motor -V204- 4157
4 13 Removing and installing right defroster and chest vent flap control motor -V205- 4157
4 13 1 Removing 4157
4 13 2 Installing 4158
4 14 Removing and installing left defroster and chest vent flap control motor -V206- 4158
4 14 1 Removing 4158
4 14 2 Installing 4158
4 15 Removing and installing right B-pillar and footwell shut-off flap control motor -V211- 4158
4 16 Removing and installing left B-pillar and footwell shut-off flap control motor -V212- 4159
4 16 1 Installing 4159
5 Front heater and air conditioning unit 4160
5 1 Assembly overview – distribution box in rear left or right footwell 4160
5 2 Removing and installing heater and air conditioning unit 4161
5 3 Removing and installing evaporator temperature sensor -G308- 4166
5 4 Dismantling and assembling air distribution housing 4166
5 5 Removing and installing evaporator 4167
5 5 1 Removing 4167
5 5 2 Installing 4168
5 6 Dismantling and assembling lower part of housing 4169
5 7 Assembly overview – evaporator and covers in plenum chamber 4171
5 8 Checking, removing and installing water drain hose with valve 4172
5 8 1 Removing water drain hose with valve 4172
5 8 2 Installing 4174
5 8 3 Checking 4174
5 9 Removing and installing dust and pollen filter 4175
5 10 Removing and installing fresh air blower -V2- 4175
5 10 1 Removing 4175
5 10 2 Installing 4176
5 11 Removing and installing fresh air blower control unit -J126- 4176
5 11 1 Removing 4176
5 11 2 Installing 4177
5 12 Removing and installing heat exchanger 4177
5 12 1 Removing and installing left heat exchanger 4177
5 12 2 Removing and installing right heat exchanger 4181
5 13 Removing and installing pump-valve unit 4185
5 13 1 Removing and installing pump-valve unit, LHD vehicles 4185
5 13 2 Removing and installing pump-valve unit, RHD vehicles 4189
5 14 Checking condensation drainage 4193
5 15 Removing and installing condensate drain hose 4195
6 Air duct 4196
6 1 Assembly overview – air duct and air distribution in passenger compartment 4196
6 2 Removing and installing left design trim control motor -V207- 4198
6 2 1 Removing 4198
6 2 2 Installing 4198
6 3 Removing and installing left dash panel vent 4198
6 3 1 Removing 4198
6 3 2 Installing 4199
6 4 Removing and installing right design trim control motor -V209- 4199
6 4 1 Removing 4199
6 4 2 Installing 4199
6 5 Removing and installing right dash panel vent 4200
6 5 1 Removing 4200
6 5 2 Installing 4201
6 6 Removing and installing centre design trim control motor -V208- 4202
6 6 1 Removing 4202
6 6 2 Installing 4202
6 7 Removing and installing centre dash panel vent 4202
6 7 1 Removing 4202
6 7 2 Installing 4204
6 8 Removing and installing defroster vent panel 4204
6 9 Removing and installing air distribution housing in centre of dash panel 4205
6 9 1 Removing 4205
6 10 Assembly overview – air distribution housing in dash panel centre 4205
6 11 Renewing design trim bearings 4207
6 11 1 Assembly overview 4207
6 11 2 Removing and installing design trim bearings 4207
6 12 Assembly overview – fresh air blower 4208
6 13 Removing and installing intake duct with air flow flap 4210
6 13 1 Removing 4210
6 13 2 Installing 4210
6 14 Removing and installing rear vent 4211
6 15 Checking exhaust ventilation for passenger compartment 4212
6 15 1 Checking 4212
7 Operating and display unit 4213
7 1 Overview of operating and display unit 4213
7 1 1 Overview of operating and display unit, up to 10 2008 4213
7 1 2 Overview of operating and display unit, as of 11 2008 4214
7 2 Removing and installing Climatronic control unit -J255- 4216
7 3 Connectors on Climatronic control unit -J255- 4218
7 3 1 Pin assignment for multi-pin connectors A, B, C, D, E, F, G, H and J on back of Climatronic control unit 4218
7 4 Removing and installing rear operating and display unit 4225
7 4 1 Removing and installing rear information display and operating unit control unit -J524-, four-seater, up to week 22/2011 4225
7 4 2 Removing and installing rear operating and display unit, touch-screen operation, as of week 22/2011 4225
7 4 3 Removing and installing rear information display and operating unit control unit -J524-, five-seater, up to week 22/2011 4225
7 4 4 Removing and installing rear operating and display unit, touch-screen operation, as of week 22/2011 4226
8 Other controlling and regulating components 4227
8 1 Removing and installing ambient temperature sensor -G17- 4227
8 1 1 Removing 4227
8 1 2 Installing 4228
8 2 Removing and installing dash panel temperature sensor -G56- 4228
8 2 1 Removing 4228
8 2 2 Installing 4229
8 3 Removing and installing fresh air intake duct temperature sensor -G89- 4229
8 3 1 Removing 4229
8 3 2 Installing 4229
8 4 Removing and installing photo sensor 2 for sunlight penetration -G134- 4229
8 5 Removing and installing centre vent temperature sender -G191- 4230
8 5 1 Removing 4230
8 5 2 Installing 4230
8 6 Removing and installing air quality sensor -G238- 4231
8 7 Working principles of air quality sensor -G238- 4231
8 8 Removing and installing left heat exchanger temperature sensor -G306-/right heat exchanger temperature sensor -G307- 4233
8 8 1 Left heat exchanger temperature sensor -G306- 4233
8 8 2 Right heat exchanger temperature sensor -G307- 4233
8 9 Removing and installing rear left centre console temperature sensor -G311- and rear right centre console temperature sensor -G312- 4234
8 9 1 Removing 4234
8 9 2 Installing 4234
8 10 Removing and installing humidity sender -G355- 4234
8 11 Removing and installing rear left defroster button -E299- and rear right defroster button -E300- 4235
8 11 1 Removing 4235
8 11 2 Installing 4235
8 12 Removing and installing front left vent button -E301- 4236
8 12 1 Removing 4236
8 12 2 Installing 4237
8 13 Removing and installing vent buttons -E302-, -E303-, -E304- and -E305- in dash panel 4237
8 14 Removing and installing rear left vent button in centre console -E306- and rear right vent button in centre console -E307- 4240
8 14 1 Removing 4240
8 14 2 Installing 4240
8 15 Removing and installing driver side defroster button -E323- and front passenger side defroster button -E324- 4240
8 15 1 Removing 4240
8 15 2 Installing 4241
K0058951120 Auxiliary heater 4242
82 – Supplementary heating 4246
1 Auxiliary coolant heater Thermo Top Z/C B (petrol) or D (diesel) 4246
1 1 Safety precautions for working on vehicles with auxiliary heater 4246
1 2 Safety measures for when working on vehicles with a start-stop system 4247
1 3 Safety precautions when working on the fuel system 4247
2 Notes on general repairs on vehicles with auxiliary heaters 4248
3 Rules for cleanliness for working on the auxiliary heater and the fuel system 4249
4 Switching auxiliary coolant heater on and off 4250
4 1 Switching auxiliary coolant heater on and off, vehicles up to week 44/2008 4250
4 2 Switching auxiliary coolant heater on and off, vehicles from week 45/2008 4251
5 Repairing auxiliary coolant heater Thermo Top Z/C-B or -D, components overview 4253
5 1 Auxiliary coolant heater Thermo Top Z/C-B or -D 4253
5 2 Removing and installing remote control receiver for auxiliary coolant heater -R149- 4257
5 2 1 Removing 4257
5 2 2 Installing 4257
5 3 Add-on parts for auxiliary coolant heater 4257
6 Removing and installing auxiliary coolant heater Thermo Top Z/C-B or -D 4259
6 1 Auxiliary coolant heater Thermo Top Z/C-B or -D 4259
6 2 Removing and installing air intake silencer 4261
6 2 1 Removing 4261
6 2 2 Installing 4261
6 3 Removing and installing circulation pump -V55- 4261
6 3 1 Removing 4261
6 3 2 Installing 4262
6 4 Removing and installing auxiliary coolant heater bracket 4263
6 4 1 Removing 4263
6 4 2 Installing 4263
6 5 Dismantling and assembling auxiliary coolant heater Thermo Top Z/C-B or -D 4263
6 5 1 Removing and installing connector strip cover 4265
6 5 2 Connector strip assignment for auxiliary coolant heater 4265
6 5 3 Connector strip assignment for auxiliary coolant heater 4266
6 5 4 Removing and installing combustion air blower -V6- 4266
6 5 5 Removing 4266
6 5 6 Installing 4267
6 5 7 Removing and installing combustion chamber 4267
6 5 8 Removing 4267
6 5 9 Installing 4267
6 5 10 Removing and installing glow plug with flame monitor -Q8-, vehicles up to 01 2003 4268
6 5 11 Removing 4268
6 5 13 Removing and installing glow plug with flame monitor -Q8- from 02 2003 4268
6 5 14 Removing 4268
6 5 15 Installing 4269
6 5 16 Coolant temperature sender for heater -G241- 4269
7 Connecting auxiliary coolant heater into cooling circuit 4270
7 1 Engine codes: BMK, CARA, CARB and CEXA 4270
7 2 Engine codes BGH and BGJ 4271
7 3 Engine code: AJS 4272
7 4 Engine codes CHNA, CMVA and CPFA 4274
7 5 Engine codes BAN, BAP, BRN, BRP and BTT 4275
7 6 Engine codes AYT, BKL and BRK 4276
7 7 Removing and installing heater coolant shut-off valve -N279- 4276
7 7 1 Removing 4276
7 7 2 Installing 4277
8 Fuel supply for auxiliary coolant heaters Thermo Top Z/C-B or -D 4279
8 1 Fuel supply for auxiliary coolant heaters Thermo Top Z/C-B or -D 4279
8 1 1 Rules for cleanliness 4279
8 1 2 Fuel feed to Thermo Top Z/C-B or -D 4279
8 1 3 Removing and installing metering pump -V54- 4280
8 1 4 Removing 4281
8 1 5 Installing 4281
8 1 6 Checking the fuel delivery quantity of the metering pump -V54- 4281
8 1 7 Test prerequisites: 4282
8 1 8 Checking 4282
8 2 Regulation of auxiliary coolant heater Thermo Top Z/C-B 4284
8 2 1 Heating mode 4285
8 2 2 Switching off 4285
9 Functional description of “large” remote control 4286
10 Functional description of “small” remote control 4288
K0058951320 General body repairs interior 4290
68 – Interior equipment 4296
1 Interior mirror 4296
1 1 Automatic anti-dazzle interior mirror 4296
1 2 Tools 4296
1 2 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 4296
1 3 Removing and installing interior mirror 4296
1 3 1 Removing 4296
1 3 2 Installing 4298
2 Compartments, covers and trims 4299
2 1 Tools 4299
2 1 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 4299
2 2 Removing and installing centre console (4-seater) 4299
2 2 1 Assembly overview 4299
2 2 2 Removing 4300
2 2 3 Installing 4309
2 3 Removing and installing centre console (5-seater) 4309
2 3 1 Removing 4309
2 3 2 Installing 4315
2 4 Removing and installing front ashtray 4315
2 4 1 Removing 4315
2 4 2 Installing 4317
2 5 Removing and installing centre console front storage compartment (4-seater) 4317
2 5 1 Removing 4317
2 5 2 Installing 4318
2 6 Removing and installing centre console rear storage compartment (4-seater) 4318
2 6 1 Removing 4318
2 6 2 Installing 4319
2 7 Removing and installing drinks holder 4319
2 7 1 Removing 4319
2 7 2 Installing 4320
2 8 Removing and installing footwell cover (front passenger side) 4320
2 8 1 Removing 4320
2 8 2 Installing 4321
2 9 Removing and installing glove compartment 4321
2 9 1 Removing 4321
2 9 2 Installing 4323
2 10 Removing and installing footwell cover (driver side) 4323
2 10 1 Removing 4323
2 10 2 Installing 4325
2 11 Removing and installing fuse holder cover (driver side) 4325
2 11 1 Removing 4325
2 11 2 Installing 4328
2 12 Removing and installing covers on side of dash panel 4328
2 12 1 Removing 4328
2 12 2 Installing 4329
2 13 Removing and installing sun visor 4329
2 13 1 Removing 4329
2 13 2 Installing 4330
3 Grab handles 4331
3 1 Removing and installing roof grab handles 4331
3 1 1 Removing 4331
3 1 2 Installing 4331
69 – Passenger protection 4332
1 Seat belts 4332
1 1 Tools 4332
1 1 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 4332
1 2 Safety regulations for belt tensioners 4332
1 3 Disposal of belt tensioner units 4333
1 4 Removing and installing front seat belts with two inertia reels 4333
1 4 1 Assembly overview 4333
1 4 2 Removing 4334
1 4 3 Installing 4336
1 5 Removing and installing front seat belt 4337
1 5 1 Assembly overview 4337
1 5 2 Removing 4337
1 5 3 Installing 4338
1 6 Removing and installing belt height adjustment (electric) 4339
1 6 1 Removing 4339
1 6 2 Installing 4340
1 7 Removing and installing belt height adjustment (mechanical) 4340
1 7 1 Removing 4340
1 7 2 Installing 4341
1 8 Removing and installing front seat belt latch 4341
1 8 1 Removing 4341
1 8 2 Installing 4342
1 9 Separating multi-part buckle tongue 4343
1 10 Joining shoulder and lap belts 4345
1 11 Removing and installing rear seat belts (4-seater) 4350
1 11 1 Removing 4350
1 11 2 Installing 4351
1 12 Removing and installing rear outer seat belts (5-seater) 4351
1 12 1 Removing 4351
1 12 2 Installing 4352
1 13 Removing and installing centre seat belt (5-seater) 4352
1 13 1 Removing 4352
1 13 2 Installing 4353
1 14 Removing and installing rear belt latch (4-seater) 4354
1 14 1 Removing 4354
1 14 2 Installing 4355
1 15 Removing and installing rear belt latch (5-seater) 4355
1 15 1 Removing 4355
1 15 2 Installing 4356
2 Inspecting seat belts 4357
2 1 Points to check 4357
2 1 1 Checking belt webbing 4357
2 1 2 Checking inertia reel (locking mechanism) 4358
2 1 3 Visually checking belt buckle 4359
2 1 4 Checking operation of belt buckle 4359
2 1 5 Checking belt guide fittings and latch plates 4359
2 1 6 Checking securing parts and anchorage points 4359
2 1 7 Functional check of convenience shoulder belt inertia reel 4360
3 Checking child seat anchors (ISOFIX) after an accident 4361
3 1 Points to check 4361
4 Child seat anchor (USA, Canada) 4362
4 1 Removing and installing child seat anchor 4362
5 Airbag 4363
5 1 Overview of locations: airbag systems 4363
5 2 Safety precautions when working on airbag 4363
5 2 1 Additional safety precautions for the curtain airbag 4364
5 3 Disposal of airbag units 4364
5 4 Deactivating the airbag 4364
5 5 Renewing airbag units following an accident 4365
5 5 1 Accident involving triggering of airbag 4365
5 5 2 Accident not involving triggering of airbag 4365
5 6 Removing and installing airbag control unit -J234-, 2003► 2008 4365
5 6 1 Removing 4365
5 6 2 Installing 4367
5 7 Removing and installing airbag control unit -J234-, 2009► 4367
5 7 1 Removing 4368
5 7 2 Installing 4369
5 8 Removing and installing airbag unit on driver side, 2003► 2010 4369
5 8 1 Checking installed airbag module 4369
5 8 2 Removing 4372
5 8 3 Installing 4375
5 9 Removing and installing airbag unit on driver side, 2011► 4376
5 10 Removing and installing mounting plate for airbag unit on driver side, 2003►2010 4379
5 10 1 Removing 4379
5 10 2 Installing 4381
5 11 Removing and installing steering wheel 4381
5 11 1 Removing 4381
5 11 2 Installing 4382
5 12 Removing and installing front passenger airbag unit 4383
5 12 1 Checking installed airbag module 4383
5 12 2 Removing 4385
5 12 3 Installing 4386
5 13 Removing and installing driver and front passenger side airbag 4388
5 13 1 Removing 4388
5 13 2 Installing 4389
5 14 Removing and installing curtain airbag on driver and passenger side 4389
5 14 1 Removing 4390
5 14 2 Installing 4391
5 15 Removing and installing rear side-airbag 4391
5 15 1 Removing 4392
5 15 2 Installing 4394
5 16 Removing and installing seat occupied recognition system (USA) 4395
5 16 1 System overview 4395
5 16 2 Removing 4395
5 16 3 Installing 4400
5 17 Adapting components 4401
5 17 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 4401
6 Crash sensors 4402
6 1 Fitting locations overview: crash and side crash sensors 4402
6 2 Removing and installing front crash sensors 4402
6 2 1 Removing 4402
6 2 2 Installing 4403
6 3 Removing and installing front side crash sensors on floor 4405
6 3 1 Removing 4405
6 3 2 Installing 4406
6 4 Removing and installing rear floor side crash sensors 4407
6 4 1 Removing 4408
6 4 2 Installing 4409
70 – Trim, insulation 4411
1 Dash panel 4411
1 1 Removing and installing dash panel 4411
1 1 1 Removing 4411
1 1 2 Installing 4415
1 1 3 Height adjustment of dash panel (Z axis) 4419
1 1 4 Depth adjustment of dash panel (X axis) 4420
1 1 5 Width adjustment of dash panel (Y axis) 4421
2 Door trims 4423
2 1 Tools 4423
2 1 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 4423
2 2 Removing and installing front door trim on driver side 4423
2 2 1 Removing 4423
2 2 2 Installing 4426
2 3 Removing and installing front door trim on passenger side 4426
2 3 1 Removing 4426
2 3 2 Installing 4429
2 4 Removing and installing rear door trim 4429
2 4 1 Removing 4429
2 4 2 Installing 4435
2 5 Removing and installing ashtray in rear door 4435
2 5 1 Removing 4435
2 5 2 Installing 4435
3 Sun blinds 4436
3 1 Removing and installing side sun blind 4436
3 1 1 Removing 4436
3 1 2 Installing 4438
4 Pillar trims 4443
4 1 Tools 4443
4 2 Removing and installing upper A-pillar trim 4443
4 2 1 Removing 4443
4 2 2 Installing 4445
4 3 Removing and installing lower trim of A-pillar on front passenger side 4445
4 3 1 Removing 4445
4 3 2 Installing 4446
4 4 Removing and installing lower trim of A-pillar on driver side 4446
4 4 1 Removing 4446
4 4 2 Installing 4447
4 5 Removing and installing lower trim for A-pillar with illuminated lettering »Edition 6« 4448
4 5 1 Removing 4448
4 5 2 Installing 4449
4 6 Removing and installing upper B-pillar trim 4449
4 6 1 Removing 4449
4 6 2 Installing 4450
4 7 Removing and installing lower B-pillar trim 4451
4 7 1 Removing 4451
4 7 2 Installing 4452
4 8 Removing and installing upper C-pillar trim 4452
4 8 1 Removing 4452
4 8 2 Installing 4453
4 9 Removing and installing lower trim of C-pillar 4453
4 9 1 Removing 4454
4 9 2 Installing 4454
4 10 Removing and installing wheel housing trim 4455
4 10 1 Removing 4455
4 10 2 Installing 4456
5 Rear shelf 4457
5 1 Removing and installing upper part of rear shelf 4457
5 1 1 Removing 4457
5 1 2 Installing 4459
5 2 Removing and installing lower part of rear shelf 4459
5 2 1 Removing 4459
5 2 2 Installing 4461
6 Luggage compartment trims 4462
6 1 Tools 4462
6 1 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 4462
6 2 Removing and installing rear lock carrier cover 4462
6 2 1 Removing 4462
6 2 2 Installing 4463
6 3 Removing and installing rain channel moulding 4463
6 3 1 Removing 4463
6 3 2 Installing 4464
6 4 Removing and installing rear lid trim 4464
6 4 1 Removing 4464
6 4 2 Installing 4466
6 5 Removing and installing right storage compartment 4466
6 5 1 Removing 4467
6 5 2 Installing 4467
6 6 Removing and installing side panel trim for luggage compartment 4467
6 6 1 Removing 4468
6 6 2 Installing 4469
6 7 Removing and installing rear bulkhead trim 4469
6 7 1 Removing 4469
6 7 2 Installing 4471
7 Roof trims 4472
7 1 Tools 4472
7 1 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 4472
7 2 Removing and installing moulded headliner (vehicle with sliding/tilting sunroof) 4472
7 2 1 Removing 4472
7 2 2 Installing 4476
72 – Seat frames 4477
1 Front seats 4477
1 1 Tools 4477
1 1 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 4477
1 2 Removing and installing front seat 4478
1 2 1 Removing 4478
1 2 2 Installing 4481
1 3 Removing and installing seat trim 4482
1 3 1 Removing 4482
1 3 2 Installing 4484
1 4 Removing and installing seat switch unit 4484
1 4 1 Removing 4484
1 4 2 Installing 4485
1 5 Removing and installing seat control unit 4485
1 5 1 Removing 4486
1 5 2 Installing 4486
1 6 Removing and installing seat longitudinal adjustment 4487
1 6 1 Installing 4488
1 7 Removing and installing drive motor for seat longitudinal adjustment 4488
1 7 1 Removing 4488
1 7 2 Installing 4489
1 8 Removing and installing seat tilt angle adjustment 4490
1 8 1 Removing 4490
1 8 2 Installing 4491
1 9 Removing and installing seat depth adjustment 4491
1 9 1 Removing 4491
1 9 2 Installing 4492
1 10 Removing and installing seat height 4492
1 10 1 Removing 4492
1 10 2 Installing 4494
1 11 Removing and installing seat backrest 4494
1 11 1 Removing 4494
1 11 2 Installing 4495
1 12 Removing and installing lumbar support 4496
1 12 1 Removing 4496
1 12 2 Installing 4497
1 13 Removing and installing backrest cover, 18 / 16-way seat 4497
1 13 1 Removing 4497
1 13 2 Installing 4499
1 14 Removing and installing backrest cover, 12-way seat 4499
1 14 1 Removing 4500
1 14 2 Installing 4500
1 15 Removing and installing head restraint for seat 4500
1 15 1 Removing 4500
1 15 2 Installing 4502
2 Rear seats 4503
2 1 Tools 4503
2 1 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 4503
2 2 Removing and installing rear seat cushion, 10-way seat 4503
2 2 1 Removing 4503
2 2 2 Installing 4504
2 3 Removing and installing backrest, 10-way seat 4504
2 3 1 Removing 4504
2 3 2 Installing 4506
2 4 Removing and installing seat frame, 10-way seat 4507
2 4 1 Removing 4507
2 4 2 Installing 4508
2 5 Removing and installing control unit, 10-way seat 4508
2 5 1 Removing 4508
2 5 2 Installing 4509
2 6 Removing and installing head restraint for rear seat 4509
2 6 1 Removing 4509
2 6 2 Installing 4510
2 7 Removing and installing rear bench seat, 5-seater 4510
2 7 1 Removing 4510
2 7 2 Installing 4511
2 8 Removing and installing rear seat backrest, 5-seater 4513
2 8 1 Removing 4513
2 8 2 Installing 4515
74 – Seat – padding, covers 4517
1 Front seat covers and padding 4517
1 1 Tools 4517
1 1 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 4517
1 2 Removing and installing front seat cushion cover and padding, 18-way seat 4517
1 2 1 Removing 4517
1 2 2 Installing 4518
1 3 Removing and installing front seat backrest cover and padding, 18-way seat 4519
1 3 1 Removing 4519
1 3 2 Installing 4521
2 Rear seat covers and padding 4522
2 1 Tools 4522
2 1 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 4522
2 2 Removing and installing rear seat cover and padding, 10-way seat 4522
2 2 1 Removing 4522
2 2 2 Installing 4526
2 3 Removing and installing rear seat backrest cover and padding, 10-way seat 4526
2 3 1 Removing 4526
2 3 2 Installing 4532
2 4 Removing and installing centre armrest, 4-seater 4532
2 4 1 Removing 4532
2 4 2 Installing 4533
2 5 Removing and installing rear bench seat cover and padding, 5-seater 4533
2 5 1 Removing 4533
2 5 2 Installing 4537
2 6 Removing and installing rear bench seat backrest cover and padding, 5-seater 4537
2 6 1 Removing 4537
2 6 2 Installing 4540
2 7 Removing and installing centre armrest, 5-seater 4540
2 7 1 Removing 4540
2 7 2 Installing 4542
2 8 Removing and installing drinks holder in centre armrest, 5-seater 4542
2 8 1 Removing 4542
2 8 2 Installing 4545
2 9 Removing and installing centre head restraint, 5-seater 4545
2 9 1 Removing 4545
2 9 2 Installing 4546
2 10 Replacing rear seat heater elements 4546
76 – Gas, water, electricity 4548
1 Electrical components and units 4548
1 1 Removing and installing refrigerator (4-seater) 4548
1 1 1 Removing 4548
1 1 2 Installing 4550
1 2 Removing and installing refrigerator (5-seater) 4550
1 2 1 Removing 4550
1 2 2 Installing 4551
K0058951420 General body repairs interior 4552
50 – Body front 4560
1 – Body, front 4560
1 1 – Body, front 4560
1 2 – Tools 4560
1 3 – Electrical/electronic components and locations 4560
1 4 – Lock carrier – service position 4561
1 5 – Removing and installing lock carrier with attachments 4565
1 6 – Overview, lock carrier ancillaries 4570
1 7 – Installation notes for sensor for automatic distance control -ADC- 4572
1 8 – Removing and installing automatic distance control sensor -ADC- 4573
2 – Wings 4574
2 1 – Wings 4574
2 2 – Front wing – Assembly overview 4574
2 3 – Removing and installing front wing 4576
2 4 – Front wing, bolting sequence 4578
3 – Noise insulation 4579
3 1 – Noise insulation 4579
3 2 – Noise insulation – Assembly overview 4579
55 – Bonnet, Flaps 4581
1 – Contact corrosion! 4581
1 1 – Contact corrosion! 4581
2 – Bonnet 4582
2 1 – Bonnet 4582
2 2 – Assembly overview 4582
2 3 – Removing gas strut 4584
2 4 – Bonnet service position 4584
2 5 – Removing insulation 4585
3 – Bonnet locking and unlocking components 4586
3 1 – Bonnet locking and unlocking components 4586
3 2 – Assembly overview 4586
3 3 – Removing and installing bonnet lock 4588
3 4 – Adjusting bonnet and bonnet lock 4591
3 5 – Separating Bowden cable 4594
3 6 – Removing and installing release lever 4596
4 – Rear boot lid/tailgate 4598
4 1 – Rear boot lid/tailgate 4598
4 2 – Tools 4598
4 3 – Overview, aluminium hinge and hydraulic unit 4599
4 4 – Removing and installing hydraulic unit 4602
4 5 – Overview, steel hinge 4604
4 6 – Removing gas strut 4607
4 7 – Releasing gas from strut 4608
4 8 – Adjusting boot lid/tailgate 4608
4 9 – Basic adjustment of boot lid 4608
4 10 – Adjusting striker plate with lock cover removed 4611
4 11 – Adjusting striker plate with lock cover installed 4612
4 12 – Adjusting damper 4612
5 – Lock parts with servo boot lid opener 4613
5 1 – Lock parts with servo boot lid opener 4613
5 2 – Assembly overview 4614
5 3 – Removing and installing lock cylinder carrier 4616
5 4 – Removing and installing bonnet lock 4617
6 – Lock parts with basic boot lid opener 4618
6 1 – Lock parts with basic boot lid opener 4618
6 2 – Assembly overview 4618
6 3 – Removing and installing lock cylinder carrier 4621
6 4 – Removing and installing bonnet lock 4622
7 – Tank flap unit 4623
7 1 – Tank flap unit 4623
7 2 – Removing and installing tank flap unit 4623
57 – Front doors/Door components/Central locking system 4626
1 – Contact corrosion! 4626
1 1 – Contact corrosion! 4626
2 – Front door 4627
2 1 – Front door 4627
2 2 – Tools 4627
2 3 – Assembly overview 4628
2 4 – Removing and installing door 4632
2 5 – Adjusting door 4633
2 6 – Door handle and lock – Assembly overview 4634
2 7 – Removing and installing lock cylinder housing 4638
2 8 – Removing and installing door handle 4639
2 9 – Removing and installing door lock 4641
2 10 – Door seals 4646
2 11 – Removing and installing door inner seal 4646
2 12 – Removing and installing outer door seal 4647
2 13 – Door insulation 4648
2 14 – Removing and installing insulation 4650
2 15 – Matching ignition keys to radio remote control 4650
2 16 – Removing and installing batteries for the (folding) main key with radio remote control 4651
58 – Rear doors/Door components 4653
1 – Contact corrosion! 4653
1 1 – Contact corrosion! 4653
2 – Rear door 4654
2 1 – Rear door 4654
2 2 – Tools 4654
2 3 – Assembly overview 4655
2 4 – Removing and installing door 4659
2 5 – Adjusting door 4660
2 6 – Door handle and door lock – Assembly overview 4661
2 7 – Removing and installing door handle 4664
2 8 – Removing and installing door lock 4666
2 9 – Door seals 4670
2 10 – Removing and installing door inner seal 4671
2 11 – Removing and installing outer door seal 4671
2 12 – Door insulation 4673
2 13 – Removing and installing insulation 4676
60 – Sliding/tilting roof 4677
1 – Sliding/tilting sunroof with glass panel 4677
1 1 – Sliding/tilting sunroof with glass panel 4677
1 2 – Function 4677
1 3 – Assembly overview 4678
1 4 – Removing sliding/tilting roof glass panel 4682
1 5 – Installing sliding/tilting roof glass panel 4682
1 6 – Adjusting height of sliding/tilting roof glass panel 4683
1 7 – Checking parallel running of glass panel 4684
1 8 – Adjusting parallel running of glass panel 4685
1 9 – Renewing panel seal 4685
1 10 – Removing wind deflector 4686
1 11 – Adjusting wind deflector 4687
1 12 – Removing sunroof blind 4687
1 13 – Adjusting parallel running of sunroof blind 4688
1 14 – Removing drive for sliding/tilting roof 4689
1 15 – Adjusting drive for sliding/tilting roof (“0” position) 4690
1 16 – Removing drive for sunroof blind 4690
1 17 – Removing drive for wind deflector 4691
1 18 – Removing preselection control for sliding/tilting roof 4693
1 19 – Removing switch for sunroof blind 4694
1 20 – Removing and installing carrier unit 4696
1 21 – Operation without current 4698
1 22 – Cleaning water drain hoses 4700
1 23 – Adapting components of sliding/tilting sunroof 4701
2 – Sliding/tilting sunroof with solar panel 4702
2 1 – Sliding/tilting sunroof with solar panel 4702
2 2 – Function 4702
2 3 – Assembly overview 4704
2 4 – Removing sliding/tilting sunroof solar panel 4709
2 5 – Installing sliding/tilting sunroof solar panel 4709
2 6 – Adjusting sliding/tilting roof solar panel height 4710
2 7 – Checking parallel running of solar panel 4711
2 8 – Adjusting parallel running of solar panel 4712
2 9 – Renewing panel seal 4712
2 10 – Removing wind deflector 4713
2 11 – Adjusting wind deflector 4714
2 12 – Removing solar panel trim 4714
2 13 – Removing drive for sliding/tilting sunroof 4715
2 14 – Adjusting drive for sliding/tilting roof (zero position) 4716
2 15 – Removing drive for wind deflector 4717
2 16 – Removing preselection control for sliding/tilting roof 4718
2 17 – Removing DC-DC converter 4720
2 18 – Removing solar contact 4720
2 19 – Removing and installing carrier unit 4721
2 20 – Operation without current 4723
2 21 – Cleaning water drain hoses 4725
2 22 – Adapting components of sliding/tilting sunroof 4726
63 – Bumpers 4728
1 – Front bumper 4728
1 1 – Front bumper 4728
1 2 – Servicing bumper cover 4728
1 3 – Tools 4728
1 4 – Bumper cover, assembly overview 4729
1 5 – Removing and installing bumper cover 4732
1 6 – Front bumper attachments 4735
1 7 – Front bumper, substructure 4736
1 8 – Installation notes for automatic distance control -ADC- sensor 4739
1 9 – Removing and installing automatic distance control -ADC- sensor 4739
1 10 – Removing and installing bumper cover insert 4740
2 – Rear bumper 4740
2 1 – Rear bumper 4740
2 2 – Servicing bumper cover 4740
2 3 – Bumper cover – Assembly overview 4741
2 4 – Removing and installing bumper cover 4743
2 5 – Rear bumper attachments 4746
2 6 – Rear bumper, substructure 4748
64 – Glazing 4750
1 – Flush bonded windows 4750
1 1 – Flush bonded windows 4750
1 2 – Tools 4750
1 3 – Materials 4751
1 4 – Repairing windscreen 4752
1 5 – Windscreen – Assembly overview 4752
1 6 – Removing and installing plenum chamber cover 4754
1 7 – Removing windscreen 4758
1 8 – Installing windscreen 4765
1 9 – Rear window – Assembly overview 4765
1 10 – Removing undamaged rear window 4766
1 11 – Installing rear window 4768
1 12 – Preparing old undamaged window for glazing 4769
1 13 – Preparing new window for glazing 4771
1 14 – Preparing body flange for glazing 4772
1 15 – Installation instructions 4773
1 16 – Curing time 4774
1 17 – Touching up paint damage 4774
1 18 – Cleaning off surplus adhesive sealing material 4774
2 – Front door window 4775
2 1 – Front door window 4775
2 2 – Assembly overview 4775
2 3 – Removing and installing door window 4778
2 4 – Servicing electric window lifters 4780
2 5 – Removing and installing mounting plate 4781
3 – Rear door window 4786
3 1 – Rear door window 4786
3 2 – Assembly overview 4786
3 3 – Removing and installing door window 4789
3 4 – Servicing electric window lifters 4791
3 5 – Removing and installing mounting plate 4791
3 6 – Removing and installing window slot seal 4796
66 – Exterior equipment 4798
1 – Removing and installing wheel housing liner 4798
1 1 – Removing and installing wheel housing liner 4798
1 2 – Front wheel housing liner 4798
1 3 – Rear wheel housing liner 4799
2 – Rear view mirror 4800
2 1 – Rear view mirror 4800
2 2 – Tools 4800
2 3 – Assembly overview 4801
2 4 – Removing and installing mirror glass 4803
2 5 – Removing mirror housing 4803
2 6 – Removing and installing side turn signals 4804
2 7 – Removing entry light 4804
2 8 – Removing and installing exterior rear view mirror 4806
2 9 – Removing and installing cap 4807
3 – Roof mouldings 4808
3 1 – Roof mouldings 4808
3 2 – Roof moulding 4808
3 3 – Removing and installing securing clips for roof mouldings 4809
3 4 – Drop deflector 4810
3 5 – Water deflector 4811
4 – Radiator grille 4812
4 1 – Radiator grille 4812
4 2 – Removing and installing radiator grille 4812
5 – Protective strips 4814
5 1 – Protective strips 4814
5 2 – Assembly overview 4814
5 3 – Renewing side protective strips 4816
5 4 – Assembly overview, protective strips on wing and rear panel 4816
5 5 – Renewing protective strip insert 4818
5 6 – Cover strips 4819
6 – Sill trim 4820
6 1 – Sill trim 4820
6 2 – Sill protective strip 4820
6 3 – Sill panel strips 4821
6 4 – Renewing sill panel strips 4822
K0058951520 6 speed automatic gearbox 09F four wheel drive 4823
00 – Technical data 4827
1 Gearbox identification 4827
1 1 Location of code letters on gearbox 4827
2 Notes on the 6-speed automatic gearbox 09F, four-wheel drive 4828
2 1 Gearbox 4828
2 2 Torque converter 4828
2 3 Gear change point variations for grades 4828
2 4 Gearbox breathing – odour 4828
2 5 Guided fault finding, vehicle self-diagnosis and testing 4828
3 Code letters, engine allocations 4829
4 Capacities 4830
4 1 Planetary gearbox 4830
4 2 Front final drive 4830
4 3 Transfer box 4830
5 General repair notes 4831
5 1 Special tools 4831
5 2 Gearbox 4831
5 3 Electrical components 4832
5 4 Mechatronic unit 4832
5 5 Seals and sealing rings 4833
5 6 Locking devices 4833
5 7 Nuts and bolts 4834
5 8 Guided fault finding, vehicle self-diagnosis and testing 4834
5 9 Emergency release of selector mechanism 4834
32 – Torque converter 4835
1 Torque converter 4835
1 1 Secure torque converter to prevent it from falling out 4835
1 2 Identification of torque converter 4836
1 3 Checking torque converter 4836
1 4 Draining torque converter 4836
1 5 Removing and installing torque converter oil seal 4837
1 5 1 Removing 4837
1 5 2 Installing 4838
1 6 Installing torque converter 4838
37 – Controls, housing 4839
1 Connecting -VAS 5051- and selecting functions 4839
2 Repairing selector mechanism 4841
2 1 Checking selector mechanism 4841
2 1 1 Selector lever in “P” position and ignition switched on 4841
2 1 2 Selector lever in “N” position and ignition switched on 4841
2 1 3 Selector lever in position “D”, ignition and lights switched on 4841
2 1 4 Selector lever position display 4842
2 2 Removing and installing selector lever handle 4842
2 2 1 Removing 4842
2 2 2 Installing 4842
2 3 Removing and installing selector mechanism 4843
2 3 1 Removing 4843
2 3 2 Installing 4846
2 3 3 Torque settings 4848
2 4 Dismantling and assembling shift mechanism 4848
2 5 Checking and adjusting selector lever cable 4849
2 5 1 Checking selector lever cable 4849
2 6 Adjusting selector lever cable 4850
2 6 1 Adjusting selector lever to selector cover gate 4851
2 6 2 Adjusting selector lever cable at selector mechanism 4852
2 7 Removing and installing selector lever cable 4852
2 7 1 Removing 4852
2 7 2 Installing 4854
2 7 3 Torque settings 4855
2 8 Releasing selector lever without electrical current (emergency release) 4855
2 9 Renewing oil seal for selector shaft 4856
2 9 1 Removing 4856
2 9 2 Installing 4857
3 Removing and installing gearbox 4858
3 1 Removing gearbox 4859
3 2 Installing gearbox 4862
3 2 1 Torque settings 4865
3 3 Dismantling and assembling left and right gearbox supports 4867
3 3 1 Removing 4867
3 3 2 Installing 4868
3 3 3 Torque settings 4868
3 4 Transporting automatic gearbox 4868
4 Checking ATF level and topping up 4871
4 1 Checking ATF level 4871
4 2 Topping up ATF 4874
4 3 Renewing ATF 4874
4 4 Filling empty ATF cooler 4876
5 Overview – four-wheel drive power train 4878
5 1 Position of selector elements 4878
6 ATF lines and ATF cooler 4880
6 1 Removing and installing ATF pipes 4880
6 1 2 Removing 4880
6 1 3 Installing 4882
6 2 Removing and installing ATF cooler 4883
6 2 1 Removing 4884
6 2 2 Installing 4885
6 3 Removing and installing bracket for ATF cooler 4886
6 3 1 Removing 4886
6 3 2 Installing 4887
6 4 Cleaning ATF lines and ATF cooler 4887
38 – Gears, control 4889
1 Removing and installing oil pan 4889
1 1 Removing 4889
1 2 Installing 4890
2 Removing and installing ATF strainer 4891
2 1 Removing 4891
2 2 Installing 4891
3 Removing and installing mechatronic unit 4893
3 1 Removing 4893
3 2 Installing 4894
4 Removing and installing mechatronic unit wiring harness 4896
4 1 Removing 4896
4 2 Installing 4897
39 – Final drive – front differential 4898
1 Checking gear oil in front final drive and transfer box 4898
2 Renewing oil seals for flange shafts 4900
2 1 Renewing left flange shaft oil seal 4900
2 1 1 Removing 4900
2 1 2 Installing 4901
2 2 Renewing oil seal for right flange shaft 4902
2 2 1 Removing 4903
2 2 2 Installing 4903
2 2 3 Torque settings 4904
2 3 Definitions: 4904
K0058951620 6 speed automatic gearbox 09L all wheel drive 4908
00 – Technical data 4912
1 Gearbox identification 4912
2 Notes on 6-speed automatic gearbox 09L, four-wheel drive 4913
2 1 Gearbox 4913
2 2 Torque converter 4913
2 3 Gear change point variations for gradients 4913
3 Codes, engine allocations 4914
4 Capacities 4915
4 1 Planetary gearbox 4915
4 2 Front final drive 4915
4 3 Transfer box 4915
5 General repair notes 4916
5 1 Special tools 4916
5 2 Gearbox 4916
5 3 Electrical components 4917
5 4 Mechatronic unit 4917
5 5 Seals and sealing rings 4918
5 6 Locking devices 4918
5 7 Nuts and bolts 4919
5 8 Guided fault finding, vehicle self-diagnosis and testing 4919
5 9 Emergency release of selector mechanism 4919
32 – Torque converter 4920
1 Torque converter 4920
1 1 Securing torque converter to prevent it from falling out 4920
1 2 Identification of torque converter 4920
1 3 Checking torque converter 4920
1 4 Draining torque converter 4921
1 5 Removing and installing torque converter oil seal 4921
1 5 1 Removing 4922
1 5 2 Installing 4922
1 6 Installing torque converter 4922
37 – Controls, housing 4924
1 Connecting -VAS 5051- and selecting functions 4924
2 Electrical and electronic components and their locations 4926
3 Repairing selector mechanism 4928
3 1 Checking selector mechanism 4928
3 1 1 Selector lever in “P” position and ignition switched on 4928
3 1 2 Selector lever in “N” position and ignition switched on 4928
3 1 3 Selector lever in position “D”, ignition and lights switched on 4928
3 1 4 Selector lever position display 4929
3 2 Removing and installing selector lever handle 4929
3 2 1 Removing and installing handle, up to production date 10 2013 4929
3 2 2 Removing and installing handle, as of production date 11 2013 4930
3 2 3 Setting push button in handle to installation position, as of production date 11 2013 4932
3 3 Removing and installing selector mechanism 4933
3 3 1 Removing 4934
3 3 2 Installing 4936
3 3 3 Specified torques 4938
3 4 Dismantling and assembling selector mechanism 4938
3 5 Checking and adjusting selector lever cable 4940
3 6 Checking selector lever cable 4940
3 7 Adjusting selector lever cable 4940
3 8 Adjusting support bracket on gearbox 4941
3 8 1 Adjusting support bracket on gearbox, selector mechanism up to index “M” 4943
3 8 2 Adjusting support bracket on gearbox, selector mechanism from index “N” 4943
3 8 3 Adjusting support bracket on gearbox, selector mechanism from index “T” 4944
3 9 Adjusting selector lever to selector cover gate 4944
3 10 Adjusting selector lever cable at selector mechanism 4944
3 11 Removing and installing selector lever cable 4944
3 11 1 Removing 4945
3 11 2 Installing 4947
3 12 Releasing selector lever without electrical current (emergency release) 4948
3 13 Renewing oil seal for selector shaft 4949
3 13 1 Removing 4949
3 13 2 Installing 4950
4 Removing and installing gearbox 4951
4 1 Removing and installing gearbox, vehicles with 6 and 8-cylinder engines 4951
4 1 1 Removing gearbox 4951
4 1 2 Installing gearbox 4953
4 1 3 Specified torques 4956
4 2 Dismantling and assembling left and right gearbox supports 4957
4 2 1 Removing 4958
4 2 2 Installing 4960
4 2 3 Specified torques 4960
4 3 Transporting automatic gearbox 4960
4 4 Removing and installing gearbox, vehicles with V6 TDI engine 4962
4 4 1 Removing gearbox 4964
4 4 2 Installing gearbox 4972
4 4 3 Specified torques 4974
5 Checking ATF level and topping up 4975
5 1 Checking ATF level 4975
5 2 Topping up ATF 4978
5 3 Renewing ATF 4978
5 4 Filling empty additional ATF cooler 4980
6 Overview – all-wheel drive power train 4981
6 1 Position of selector elements 4981
7 Removing and installing ATF lines, ATF cooler and additional ATF cooler 4983
7 1 Installation position for ATF lines, ATF cooler and additional ATF cooler 4983
7 2 Assembly overview 4983
7 3 Removing and installing ATF lines from gearbox to ATF cooler 4985
7 3 1 Removing 4986
7 3 2 Installing 4986
7 4 Removing and installing ATF cooler 4988
7 4 1 Removing 4989
7 4 2 Installing 4990
7 5 Removing and installing bracket for ATF cooler 4990
7 5 1 Removing 4991
7 5 2 Installing 4991
7 5 3 Specified torques 4991
7 6 Removing and installing additional ATF cooler 4992
7 6 1 Removing 4992
7 6 2 Installing 4992
7 7 Removing and installing thermostat 4993
7 7 1 Removing 4993
7 7 2 Installing 4993
7 8 Cleaning ATF lines and ATF cooler 4994
38 – Gears, control 4997
1 Removing and installing sump 4997
1 1 Removing 4997
1 2 Installing 4998
2 Removing and installing ATF strainer 4999
2 1 Removing 4999
2 2 Installing 4999
3 Removing and installing mechatronic unit 5001
3 1 Removing 5001
3 2 Installing 5002
4 Removing and installing mechatronic unit wiring harness 5005
4 1 Removing 5005
4 2 Installing 5006
39 – Final drive – front differential 5007
1 Checking oil in front final drive 5007
2 Checking gear oil in front transfer box 5009
3 Renewing seal for right flange shaft 5010
3 1 Removing 5010
3 2 Installing 5011
3 3 Specified torques 5012
4 Renewing left flange with bearing 5013
4 1 Removing 5013
4 2 Installing 5014
4 3 Specified torques 5015
5 Definitions: 5016
K0058951720 10 cylinder diesel engine 5020
00 – Technical data 5026
1 Technical data 5026
1 1 Engine number 5026
1 2 Engine data 5026
10 – Removing and installing engine 5027
1 Removing and installing engine 5027
1 1 Removing engine 5027
1 1 1 Removing engine from scissor-type assembly platform -VAS 6131- 5038
1 2 Notes on installing 5039
1 3 Specified torques 5039
13 – Crankshaft group 5040
1 Dismantling and assembling engine 5040
1 1 Assembly overview – components in the V space 5040
1 2 Assembly overview – gear train assembly 5042
1 3 Removing and installing gear train assembly 5043
1 3 1 Removing 5043
1 3 2 Installing 5044
1 4 Removing and installing drive plate 5046
1 4 1 Loosening and tightening drive plate 5046
1 4 2 Installing drive plate 5046
2 Balancer shaft 5047
2 1 Assembly overview – balancer shaft 5047
3 Crankshaft 5048
3 1 Assembly overview – crankshaft 5048
3 2 Removing and installing bearing saddle for crankshaft 5049
3 3 Crankshaft dimensions 5051
4 Sealing flanges, seals and vibration dampers 5052
4 1 Assembly overview – front sealing flange and vibration damper 5052
4 2 Renewing crankshaft oil seal, vibration damper end 5053
4 3 Crankshaft oil seal – engine timing end 5054
4 4 Alternator shaft oil seal 5056
5 Valve timing housing 5059
5 1 Assembly overview – valve timing housing 5059
6 Pistons and conrods 5061
6 1 Assembly overview – pistons and conrods 5061
6 2 Checking piston projection at TDC 5062
6 3 Piston and cylinder dimensions 5062
6 4 Piston rings, cylinder bore and piston installation position 5063
15 – Cylinder head, valve gear 5065
1 Cylinder head 5065
1 1 Assembly overview – cylinder head 5065
1 2 Removing and installing camshaft compensating gear and drive gear wheel 5067
1 3 Checking valve timing 5072
1 4 Adjusting valve timing 5072
1 5 Removing and installing cylinder heads 5075
1 5 1 Removing 5076
1 6 Checking compression 5077
2 Valve gear 5080
2 1 Assembly overview – valve gear 5080
2 2 Reworking valve seats 5083
2 3 Checking valve guides 5084
2 4 Renewing valve stem seals 5084
2 5 Removing and installing camshaft 5086
17 – Lubrication 5088
1 Engine oil 5088
1 1 Oil capacities 5088
1 2 Checking engine oil level 5088
2 Oil sump 5089
2 1 Assembly overview – lower part of sump 5089
2 2 Assembly overview – upper part of sump 5090
2 3 Applying sealant 5091
2 3 1 Sealing contour of lower and upper part of sump 5091
3 Assembly overview – oil filter housing 5092
4 Assembly overview – oil pump 5093
5 Checking oil pressure 5094
5 1 Assembly overview – oil pressure switch 5094
5 2 Check oil pressure in V space and and oil pressure switch 5095
5 3 Checking oil pressure at front of engine 5096
6 Assembly overview – oil supply lines 5097
6 1 Oil supply line for turbocharger of cylinder bank 1 5097
6 2 Oil supply line for turbocharger of cylinder bank 2 5098
19 – Cooling 5100
1 Parts of cooling system 5100
1 1 Assembly overview – radiator 5100
1 2 Removing and installing fan support 5101
1 2 1 Removing 5101
1 2 2 Installing 5102
1 3 Assembly overview – fans 5102
1 4 Parts of cooling system, body side 5103
1 5 Checking cooling system for leaks 5104
1 6 Removing and installing coolant connection 5105
1 7 Assembly overview – thermostat housing 5105
1 8 Parts of cooling system – engine side and at top 5107
1 9 Coolant hose schematic diagram 5108
1 10 Draining and filling coolant 5109
1 10 1 Draining 5109
1 10 2 Filling 5110
1 10 3 Procedure 5111
1 11 Removing and installing radiator 5111
1 11 1 Removing 5112
1 11 2 Installing 5112
1 12 Assembly overview – coolant pump 5112
1 12 1 Removing 5113
1 12 2 Installing 5115
21 – Turbocharging/supercharging 5116
1 Charge air system with turbocharger 5116
1 1 Removing and installing turbocharger with attachments 5116
1 2 Removing and installing parts of charge air cooling 5118
1 3 Rules for cleanliness 5118
23 – Mixture preparation – injection 5120
1 Repairing diesel direct injection system 5120
1 1 Safety precautions 5120
1 2 Rules for cleanliness 5121
1 3 Removing and installing intake manifold 5121
1 4 Assembly overview – intake connecting pipe 5122
1 5 Assembly overview – unit injector 5123
1 6 Removing and installing unit injector 5124
1 7 Checking and adjusting position of pump plungers in unit injectors 5126
1 8 Removing and installing O-rings for unit injector 5128
1 9 Assembly overview – air filter 5129
2 Engine control units 5131
2 1 Reading and deleting engine control unit fault memory 5131
2 2 Adapting functions and components 5132
2 3 Removing and installing engine control units 5132
26 – Exhaust system 5134
1 Removing and installing parts of exhaust system 5134
1 1 Removing and installing exhaust manifold 5134
1 2 Front exhaust pipe and catalytic converter with attachments 5136
1 3 Silencer with mountings 5137
2 Exhaust gas recirculation system 5139
2 1 Assembly overview – parts of exhaust gas recirculation 5139
2 2 Checking exhaust gas recirculation valve (mechanical) 5140
2 3 Vacuum hose schematic diagram 5141
28 – Glow plug system 5143
1 Removing, installing and checking glow plugs 5143
K0058951820 8 cylinder injection engine 5145
00 – Technical data 5151
1 Engine number 5151
2 Engine data 5152
3 Numbering of cylinders 5153
10 – Removing and installing engine 5154
1 Removing and installing engine 5154
1 1 Securing engine to assembly stand 5161
1 2 Installing engine 5162
2 Assembly mountings 5166
2 1 Assembly overview – assembly mountings 5166
2 2 Supporting engine in installation position 5167
2 3 Removing and installing engine mounting 5169
2 4 Removing and installing engine bracket or engine mounting 5170
13 – Crankshaft group 5172
1 Dismantling and assembling engine 5172
1 1 Part I: assembly overview – toothed belt drive 5173
1 2 Assembly overview – part II, cylinder block 5175
1 3 Removing and installing poly-V belt 5176
1 4 Checking alignment of poly V-belt 5176
2 Assembly overview – sealing flanges and drive plate 5178
2 1 Removing and installing sealing flange at drive plate end 5180
2 2 Removing and installing drive plate 5181
2 3 Renewing crankshaft oil seal, vibration damper end 5183
15 – Cylinder head, valve gear 5185
1 Assembly overview – cylinder head 5185
1 1 Removing and installing cylinder head cover (right side) 5187
1 2 Removing and installing left cylinder head cover 5189
1 3 Removing, installing and tensioning toothed belt 5191
1 4 Removing and installing left cylinder head 5197
1 5 Removing and installing right cylinder head 5200
1 6 Checking compression 5203
2 Assembly overview – valve gear 5205
2 1 Camshafts, checking axial clearance 5208
2 2 Renewing camshaft oil seals 5209
2 3 Renewing Hall sender seals 5210
2 4 Removing and installing camshafts and camshaft adjusters – left cylinder head 5212
2 5 Removing and installing camshafts and camshaft adjusters – right cylinder head 5218
2 6 Removing and installing roller rocker finger 5223
2 7 Renewing valve stem seals 5224
2 8 Checking valve guides 5228
2 9 Reworking valve seats 5229
17 – Lubrication 5231
1 Removing and installing parts of lubrication system 5231
1 1 Engine oil 5231
1 2 Checking oil level 5232
1 3 Assembly overview – oil filter housing 5232
1 4 Removing and installing oil filter housing 5233
1 5 Assembly overview – sump 5234
1 6 Removing and installing lower part of sump 5235
1 7 Removing and installing upper part of sump 5237
1 8 Removing and installing oil level and oil temperature sender -G266- 5241
1 9 Assembly overview – dismantling and assembling oil pump 5242
1 9 1 Removing and installing oil pump 5243
1 9 2 Removing and installing drive chain for oil pump 5244
1 10 Checking oil pressure and oil pressure switch 5245
19 – Cooling 5248
1 Removing and installing parts of cooling system 5248
1 1 Assembly overview – radiator 5248
1 2 Assembly overview – radiator fan 5250
1 3 Parts of cooling system, body side 5251
1 4 Parts of cooling system – engine side, front 5252
1 5 Parts of cooling system – engine side, rear 5253
1 6 Parts of cooling system – engine side, right 5254
1 7 Coolant hose connection diagram 5255
1 8 Draining and adding coolant 5256
1 9 Removing and installing fan mounting with fans 5259
1 10 Removing and installing radiator fans 5260
1 11 Removing and installing radiator 5261
1 12 Removing and installing coolant pump and thermostat 5263
1 13 Checking cooling system for leaks 5265
20 – Fuel supply system 5266
1 Removing and installing parts of fuel supply system 5266
1 1 Assembly overview – fuel tank with attachments and fuel filter 5266
1 2 Assembly overview – right side fuel delivery unit, fuel gauge sender and suction-jet pump 5268
1 3 Assembly overview – left side fuel delivery unit, fuel gauge sender and suction-jet pump 5270
1 4 Schematic diagram of fuel lines and components in fuel tank 5272
1 5 Safety regulations for working on fuel supply 5273
1 6 Rules for cleanliness 5274
1 7 Emptying fuel tank 5274
1 8 Removing and installing fuel delivery unit, fuel gauge sender and suction-jet pump, right side 5277
1 9 Removing and installing fuel delivery unit, fuel gauge sender and suction-jet pump, left side 5280
1 10 Removing and installing fuel tank with attachments and fuel filter 5282
1 11 Checking fuel pumps 5285
1 11 1 Checking current draw of pumps 5290
1 11 2 Checking fuel pump non-return valves 5291
1 12 Checking electronic power control (EPC) 5293
1 12 1 Function of EPC system 5294
2 Activated charcoal filter system 5296
2 1 Assembly overview – parts of activated charcoal filter system 5296
2 2 Checking activated charcoal filter system for leaks 5298
2 2 1 If vacuum builds up: 5299
2 2 2 If vacuum does not build up: 5300
3 Activated charcoal filter system (vehicles with fuel system diagnostic pump -V144-) 5301
3 1 Assembly overview – parts of activated charcoal filter system 5301
24 – Mixture preparation – injection 5303
1 Repairing injection system 5303
1 1 Assembly overview – intake manifold 5303
1 2 Assembly overview – fuel rail with injectors 5305
1 3 Assembly overview – air filter 5306
1 4 Vacuum hoses on intake manifold 5307
1 5 Removing and installing intake air duct to throttle valve module -J338- 5307
1 6 Safety precautions 5310
1 7 Rules for cleanliness 5311
1 8 Technical data 5311
2 Checking components 5312
2 1 Checking injectors 5312
2 2 Checking fuel pressure regulator and holding pressure 5314
3 Engine (motor) control unit 5318
3 1 Removing and installing engine control unit 5318
3 2 Reading and erasing engine control unit fault memory 5318
26 – Exhaust system 5320
1 Exhaust manifold, catalytic converters and silencers with mountings 5320
1 1 Assembly overview – exhaust manifold with starter catalytic converters and attachments 5320
1 1 1 Aligning starter catalytic converter with exhaust pipe 5322
1 2 Removing and installing starter catalytic converter with exhaust pipe 5323
1 3 Assembly overview – silencers with mountings 5323
2 Lambda probes 5326
2 1 Removing and installing Lambda probe -G39- 5326
2 2 Removing and installing Lambda probe after catalytic converter -G130- 5327
2 3 Removing and installing Lambda probe 2 -G108- and Lambda probe 2 after catalytic converter -G131- 5328
3 Secondary air system 5330
3 1 Assembly overview – parts of secondary air system, vehicle side 5330
3 2 Assembly overview – parts of secondary air system, engine side 5331
28 – Ignition system 5333
1 Repairing ignition system 5333
1 1 Assembly overview – parts of ignition system 5333
1 2 Safety precautions 5334
1 3 Removing and installing ignition coils with output stage 5334
1 4 Test data, spark plugs 5336
K0058952220 6 cylinder diesel engine (3 0 l engine common rail) 5338
00 – Technical data 5344
1 Technical data 5344
1 1 Engine number 5344
1 2 Engine data 5344
10 – Removing and installing engine 5346
1 Removing and installing engine 5346
1 1 Removing engine 5346
1 1 1 Removing engine from scissor-type assembly platform -VAS 6131- 5356
1 2 Notes on installing 5358
1 3 Specified torques 5359
1 4 Front engine mounting 5359
13 – Crankshaft group 5361
1 Dismantling and assembling engine 5361
1 1 Assembly overview – poly V-belt drive 5363
1 2 Removing and installing poly V-belt 5366
1 3 Renewing crankshaft oil seal – belt pulley end 5367
1 4 Removing and installing front sealing flange 5369
1 5 Assembly overview – drive plate/dual-mass flywheel 5372
1 6 Removing and installing dual-mass flywheel 5373
1 7 Extracting and driving in needle roller bearing for dual-mass flywheel 5374
1 8 Removing and installing drive plate 5375
1 9 Renewing crankshaft oil seal on timing chain end 5376
1 10 Assembly overview – timing chain covers 5378
1 11 Removing and installing timing chain covers 5379
1 12 Assembly overview – balancer shaft 5386
1 13 Removing and installing balancer shaft 5387
2 Chain drive (engine code BMK) 5390
2 1 Assembly overview – drive chain for valve gear 5390
2 2 Removing and installing drive chain for valve gear 5391
2 3 Assembly overview – chain for balancer shaft and oil pump 5392
2 4 Removing and installing chain for balancer shaft and oil pump 5394
3 Chain drive (engine codes CARA, CEXA, CEXB) 5398
3 1 Assembly overview – drive chain for valve gear 5398
3 2 Removing and installing drive chain for valve gear 5399
3 3 Assembly overview – chain for balancer shaft and oil pump 5400
3 4 Removing and installing chain for balancer shaft and oil pump 5402
4 Removing and installing crankshaft 5406
4 1 Assembly overview – crankshaft 5406
4 2 Crankshaft dimensions 5408
4 3 Measuring axial clearance 5408
4 4 Measuring radial clearance 5409
5 Pistons and conrods 5410
5 1 Assembly overview – pistons and conrods 5410
5 2 Checking piston projection at TDC 5413
5 3 Piston and cylinder dimensions 5414
5 4 Checking radial clearance of conrods 5414
15 – Cylinder head, valve gear 5415
1 Cylinder head 5415
1 1 Assembly overview – cylinder head 5415
1 2 Assembly overview – cylinder head cover 5418
1 3 Removing and installing cylinder head cover 5421
1 4 Removing and installing cylinder head 5427
1 5 Checking compression 5434
1 6 Assembly overview – vacuum pump 5436
2 Valve gear 5438
2 1 Assembly overview – valve gear 5438
2 2 Checking axial clearance of camshafts 5439
2 3 Renewing camshaft oil seal 5440
2 4 Removing and installing camshafts 5443
2 5 Renewing valve stem seals 5447
2 6 Checking hydraulic valve compensation elements 5451
2 7 Valve dimensions 5453
2 8 Checking valve guides 5453
3 Chain drive for camshafts 5455
3 1 Camshaft timing chains (engine code BMK) 5455
3 1 1 Assembly overview – left camshaft timing chain 5455
3 1 2 Assembly overview – right camshaft timing chain 5456
3 1 3 Removing and installing camshaft timing chains 5457
3 1 4 Removing camshaft timing chains from camshafts 5465
3 2 Camshaft timing chains (engine codes CARA, CEXA, CEXB) 5474
3 2 1 Assembly overview – left camshaft timing chain 5474
3 2 2 Assembly overview – right camshaft timing chain 5476
3 2 3 Removing and installing camshaft timing chains 5477
3 2 4 Removing camshaft timing chains from camshafts 5484
17 – Lubrication 5494
1 Engine oil 5494
1 1 Oil capacities 5494
1 2 Checking engine oil level 5494
2 Parts of lubrication system 5495
2 1 Assembly overview – oil pump, lower part of sump 5495
2 2 Removing and installing lower part of sump 5496
2 3 Removing and installing oil pump 5498
2 4 Assembly overview – upper part of sump 5499
2 5 Removing and installing upper part of sump 5500
3 Oil cooler, pressure control valve and oil filter housing 5504
3 1 Assembly overview – oil cooler, pressure control valve, and oil filter housing 5504
3 2 Removing and installing oil cooler 5505
3 3 Removing and installing oil filter housing 5506
3 4 Removing and installing pressure control valve for crankcase breather system 5507
3 5 Removing and installing mounting plate for oil cooler, pressure control valve and oil filter housing 5508
3 6 Removing and installing oil pressure switch -F1-/oil pressure switch for reduced oil pressure -F378- 5509
3 7 Checking oil pressure and oil pressure switch 5510
19 – Cooling 5513
1 Parts of cooling system 5513
1 1 Assembly overview – radiator 5513
1 2 Removing and installing fan support 5514
1 3 Assembly overview – fans 5515
1 4 Checking cooling system for leaks 5516
1 5 Draining and filling coolant 5516
1 6 Assembly overview – coolant pump and thermostat 5520
1 7 Removing and installing coolant pump 5520
1 8 Removing and installing continued coolant circulation pump -V51- 5521
1 9 Removing and installing hose connection with thermostat 5522
1 10 Assembly overview – pump for exhaust gas recirculation cooler -V400- 5523
1 11 Removing and installingpump for exhaust gas recirculation cooler -V400- 5524
1 12 Assembly overview – coolant pipes 5525
1 13 Removing and installing coolant pipes 5528
1 13 1 Removing and installing upper coolant pipe 5528
1 13 2 Removing and installing left coolant pipe 5528
1 13 3 Removing and installing rear left coolant pipe on gearbox 5531
1 13 4 Removing and installing rear left coolant pipe 5531
1 13 5 Removing and installing rear left coolant pipe on supplementary cooler for exhaust gas recirculation 5532
1 13 6 Removing and installing upper left coolant pipe 5533
1 13 7 Removing and installing upper right coolant pipe 5533
1 13 8 Removing and installing rear coolant pipe 5534
1 14 Removing and installing coolant temperature sender -G62- 5535
21 – Turbocharging/supercharging 5537
1 Charge air system with turbocharger 5537
1 1 Rules for cleanliness 5537
1 2 Assembly overview – turbocharger (engine code BMK) 5537
1 3 Removing and installing turbocharger (engine code BMK) 5539
1 4 Assembly overview – turbocharger (engine codes CARA, CEXA und CEXB) 5541
1 5 Removing and installing turbocharger (engine codes CARA, CEXA und CEXB) 5543
1 6 Removing and installing turbocharger 1 control unit -J724- 5547
1 7 Assembly overview – parts of charge air cooling 5556
1 8 Removing and installing charge air cooler 5557
23 – Mixture preparation – injection 5559
1 Diesel direct injection system 5560
1 1 Safety precautions 5561
1 2 Rules for cleanliness and instructions for working on fuel system 5561
1 3 Schematic overview of fuel system (engine code BMK) 5562
1 4 Schematic overview of fuel system (engine codes CARA, CEXA und CEXB) 5564
1 5 Assembly overview – fuel system (engine code BMK) 5566
1 6 Assembly overview – fuel system (engine codes CARA, CEXA und CEXB) 5568
1 7 Assembly overview – intake manifold 5571
1 7 1 Engine code BMK 5571
1 7 2 Engine codes CARA, CEXA, CEXB 5573
1 8 Removing and installing intake manifold upper part 5575
1 8 1 Engine code BMK 5575
1 8 2 Engine codes CARA, CEXA, CEXB 5577
1 9 Removing and installing intake manifold flap motor -V157- or intake manifold flap 2 motor -V275- 5579
1 10 Removing and installing lower parts of intake manifold (engine code BMK) 5586
1 10 1 Removing and installing lower part of left intake manifold (engine code BMK) 5586
1 10 2 Removing and installing lower part of right intake manifold (engine code BMK) 5589
1 11 Removing and installing lower parts of intake manifold (engine codes CARA, CEXA und CEXB) 5592
1 11 1 Removing and installing lower part of left intake manifold 5592
1 11 2 Removing and installing lower part of right intake manifold 5594
1 12 Removing and installing injectors (piezo injectors) 5596
1 13 Checking fuel pressure regulating valve -N276- 5602
1 14 Removing and installing fuel pressure regulating valve -N276- 5602
1 15 Removing and installing fuel pressure sender -G247- 5604
1 16 Checking return flow rate of injectors (piezo injectors) with engine running 5605
1 17 Checking return flow rate of injectors (piezo injectors) at starting speed 5608
1 18 Checking for injectors sticking open (piezo injectors) 5609
1 19 Installing high-pressure lines 5610
1 20 Checking pressure retention valve in fuel return 5613
1 21 Assembly overview – toothed belt for high-pressure pump (engine code BMK) 5614
1 22 Removing and installing toothed belt for high-pressure pump (engine code BMK) 5616
1 23 Assembly overview – high-pressure pump (engine code BMK) 5620
1 24 Removing and installing high-pressure pump (engine code BMK) 5623
1 25 Assembly overview – toothed belt for high-pressure pump (engine codes CARA, CEXA, CEXB) 5626
1 26 Removing and installing toothed belt for high-pressure pump (engine codes CARA, CEXA, CEXB) 5627
1 27 Assembly overview – high-pressure pump (engine codes CARA, CEXA und CEXB) 5635
1 28 Removing and installing high-pressure pump (engine codes CARA, CEXA und CEXB) 5636
1 29 Bleeding fuel system 5637
1 30 Assembly overview – air filter 5638
1 30 1 Removing and installing air filter lower part 5639
2 Engine control unit 5641
2 1 Reading and clearing engine control unit fault memory 5641
2 2 Adapting functions and components 5642
2 3 Removing and installing engine control unit 5643
2 4 Fitting locations 5643
26 – Exhaust system 5646
1 Parts of the exhaust system 5646
1 1 Assembly overview – exhaust system 5646
1 2 Assembly overview – front exhaust pipe and catalytic converter 5649
1 3 Assembly overview – exhaust manifold and intermediate pipes 5650
2 Exhaust gas recirculation system, engine code BMK 5651
2 1 Assembly overview – exhaust gas recirculation system 5651
2 2 Checking mechanical exhaust gas recirculation valve 5652
2 3 Removing and installing mechanical exhaust gas recirculation valve 5653
2 4 Removing and installing exhaust gas recirculation cooler 5653
3 Exhaust gas recirculation, engine codes CARA, CEXA, CEXB 5655
3 1 Assembly overview – exhaust gas recirculation system 5655
3 2 Removing and installing exhaust gas recirculation control motor -V338- 5656
3 3 Removing and installing exhaust gas recirculation cooler 5657
3 4 Removing and installing exhaust gas recirculation temperature sensor -G98- 5659
28 – Glow plug system 5661
1 Glow plug system 5661
1 1 Glow plug characteristics 5661
1 2 Removing, installing and checking ceramic glow pin plugs 5661
1 3 Removing and installing metal glow plugs 5663
1 4 Checking metal glow plugs 5664
K0058952320 Repair manual 5 speed automatic gearbox 01L 5666
00 – Technical data 5670
1 Vorsprung durch Technik 5670
1 1 General repair instructions 5670
1 2 Special tools 5671
2 Rules for cleanliness when working on the automatic gearbox 5673
3 Frequently occurring faults 5674
3 1 No power transfer in reverse gear 5674
3 2 Hard jolt during shift, power transmission problems in 4th and 5th gear 5674
3 3 Power transfer problems in 4th and 5th gear, ATF pump squeaks 5675
3 4 No power transmitted in any gear 5675
3 5 Reverse gear delayed (about 5   6 seconds) after gear is selected 5676
32 – Torque converter 5677
1 Torque converter 5677
1 1 Checking clutch lining of torque converter clutch 5677
1 2 Draining torque converter 5677
1 3 Checking torque converter 5678
37 – Controls, housing 5679
1 Securing gearbox to assembly stand 5679
2 Dismantling and assembling planetary gearbox 5680
2 1 Component overview – planetary gearbox 5680
2 2 Dismantling and assembling planetary gearbox 5681
3 Dismantling and assembling clutch “F” with freewheel 5706
3 1 Component overview – clutch “F” with freewheel 5706
3 2 Dismantling clutch “F” 5707
3 3 Dismantling freewheel 5708
3 4 Assembling freewheel 5710
3 5 Assembling clutch “F” 5711
4 Dismantling and assembling body “I” 5715
4 1 Component overview – clutch “C” with sun shaft 5715
4 2 Dismantling and assembling clutch “C” with sun shaft 5716
4 3 Component overview – clutch “D” 5720
4 4 Component overview – clutch “E” 5722
4 5 Dismantling and assembling clutch “D/E” 5723
4 6 Component overview – planetary drive 5731
4 7 Dismantling and assembling planetary drive 5732
4 8 Assembling body “I” 5737
5 Dismantling and assembling body “II” 5740
5 1 Component overview – body “II” 5740
5 2 Dismantling body “II” 5741
5 3 Component overview – clutch “A” 5743
5 4 Dismantling and assembling clutch “A” 5744
5 5 Component overview – clutch “B” 5748
5 6 Dismantling and assembling clutch “B” 5749
5 7 Assembling body “II” 5754
6 Removing and installing selector shaft 5756
39 – Final drive – rear differential 5760
1 Repairing final drive, rear differential 5760
39 – Final drive – front differential 5761
1 Dismantling and assembling ATF supply unit 5761
1 1 Component overview – ATF supply unit 5761
1 2 Dismantling and assembling ATF supply unit 5762
1 3 Removing and installing stator shaft 5765
1 4 Checking flow control valve in ATF supply unit 5766
2 Removing and installing ATF pipes 5767
2 1 Removing and installing ATF pipes 5767
2 2 Removing and installing ATF xxx pipe for final drive 5768
3 Assessment of wear on gearbox components 5769
3 1 Assessment of wear by checking ATF for colour and contamination 5769
3 2 Clutch “F” with freewheel 5769
3 3 Clutch “C” with sun shaft 5772
3 4 Clutch “D” 5774
3 5 Clutch “E” 5776
3 6 Planetary drive 5778
3 7 Clutch “A” 5781
3 8 Clutch “B” 5783
3 9 ATF supply unit 5785
K0058952420 Servicing automatic gearbox 01V front wheel drive and all wheel drive 5787
00 – Technical data 5791
1 Vorsprung durch Technik 5791
2 Repair instructions 5792
2 1 General repair notes 5792
2 2 Special tools 5794
3 Rules for cleanliness when working on the automatic gearbox 5803
4 Frequently occurring faults 5804
4 1 No power transmitted in any gear 5804
4 2 Hard jolt during shift; individual gears slipping; shifts take too long 5805
4 3 Hard jolt during shift, power transmission problems in 4th and 5th gear 5806
4 4 ATF leaking between engine and gearbox 5806
4 5 Speed-dependent noise with vehicle moving 5807
32 – Torque converter 5808
1 Torque converter 5808
1 1 Checking torque converter lock-up clutch 5808
1 2 Draining torque converter 5810
1 3 Checking torque converter 5810
37 – Controls, housing 5812
1 Securing gearbox to assembly stand 5812
2 Dismantling and assembling planetary gearbox 5813
2 1 Component overview – planetary gearbox 5813
2 2 Dismantling and assembling planetary gearbox 5815
3 Dismantling and assembling body “I” 5846
3 1 Component overview – body “I” 5846
3 2 Dismantling body “I” 5847
3 3 Component overview – clutch “F” 5848
3 4 Dismantling and assembling clutch “F” 5849
3 5 Component overview – clutch “D/G” with freewheel 5852
3 6 Dismantling and assembling clutch “D/G” with freewheel 5854
3 7 Component overview – planet carrier “III” 5863
3 8 Dismantling and assembling planetary drive “III” 5865
3 9 Assembling body “I” 5865
4 Dismantling and assembling body “II” 5867
4 1 Component overview – body “II” 5867
4 2 Dismantling body “II” 5868
4 3 Component overview – clutch “B” 5869
4 4 Dismantling and assembling clutch “B” 5870
4 5 Component overview – clutch “A” 5874
4 6 Dismantling and assembling clutch “A” 5875
4 7 Component overview – clutch “E” 5879
4 8 Dismantling and assembling clutch “E” 5880
4 9 Assembling body “II” 5885
5 Dismantling and assembling clutch “C” 5888
5 1 Component overview – clutch “C” 5888
5 2 Dismantling and assembling clutch “C” 5889
38 – Gears, control 5894
1 Dismantling and assembling ATF supply unit 5894
1 1 Component overview – ATF supply unit 5894
1 2 Removing and installing complete ATF supply unit with gearbox assembled 5895
1 3 Removing ATF pump from housing for ATF supply unit and installing 5910
1 4 Removing and installing housing for ATF supply unit and stator shaft 5914
1 5 Removing and installing stator shaft 5918
1 6 Renewing oil seal for ATF pump 5919
2 Repair work on installed gearbox 5920
2 1 Removing and installing valve body 5920
2 2 Removing and installing internal oil pipe 5923
2 3 Removing and installing gearbox speed sender -G38- or gearbox output speed sender -G195- 5924
2 4 Removing and installing gearbox input speed sender -G182- gearboxes with hydraulic control “E17” 5925
2 5 Removing and installing gearbox input speed sender -G182- gearboxes with hydraulic control “E18/2” 5926
2 6 Removing and installing wiring harness in gearbox 5927
3 Assessment of wear on gearbox components 5929
3 1 Assessment of wear by checking ATF for colour and contamination 5929
3 2 Clutch “F” 5929
3 3 Clutch “D/G” with freewheel 5931
3 4 Planet carrier “III” 5934
3 5 Clutch “B” 5936
3 6 Clutch “A” 5938
3 7 Clutch “E” 5940
3 8 Clutch “C” 5943
3 9 ATF supply unit 5945
39 – Final drive – front differential 5949
1 Repairing front axle drive and transfer box 5949
1 1 Removing and installing transfer box with Torsen differential 5949
1 2 Component overview – front axle drive and transfer box 5949
1 3 Renewing oil seal on output flange for propshaft 5953
1 4 Renewing oil seal in intermediate flange for front axle drive 5953
1 5 Renewing oil seal in input pinion 5954
1 6 Renewing needle bearing for gear wheel 2 5955
K0058952520 Propshaft and rear final drive 5957
00 – Technical data 5961
1 3 different final drives 5961
1 1 Codes, engine allocations 5962
2 Capacities 5963
2 1 Rear final drive 5963
3 General repair notes 5964
3 1 Special tool 5964
3 2 Gaskets and seals 5964
3 3 Locking devices 5965
3 4 Nuts and bolts 5965
39 – Final drive – rear differential 5966
1 Propshaft and rear final drive 0AR 5966
1 1 Assembly overview – propshaft 5966
1 2 Removing and installing propshaft 5967
1 2 1 Removing 5968
1 2 2 Installing 5970
1 3 Adjusting propshaft 5973
1 4 Assembly overview – rear final drive 5974
1 5 Removing and installing rear final drive 5976
1 5 1 Removing 5976
1 5 2 Installing 5979
1 6 Checking gear oil in rear final drive 5981
1 7 Renewing flange shaft oil seals 5982
1 8 Renewing propshaft flange seal 5985
1 9 Measuring and marking radial run-out on propshaft flange 5991
2 Propshaft and rear final drive 01R 5994
2 1 Assembly overview – propshaft 5994
2 2 Removing and installing propshaft 5994
2 2 1 Removing 5995
2 2 2 Installing 5998
2 3 Adjusting propshaft 6000
2 4 Assembly overview – rear final drive 6001
2 5 Removing and installing rear final drive 6003
2 5 1 Removing 6003
2 5 2 Installing 6005
2 6 Checking gear oil in rear final drive 6007
2 7 Renewing flange shaft oil seals 6008
2 7 1 Removing 6009
2 7 2 Installing 6010
2 8 Renewing propshaft flange seal 6011
2 8 1 Removing 6012
2 8 2 Determining dimension “a” and dimension “b” 6013
2 8 3 Installing 6014
2 8 4 Checking dimension “a” and dimension “b” 6015
2 9 Measuring and marking radial run-out on propshaft flange 6017
2 10 Dismantling and assembling differential 6020
2 10 1 Adjusting sun wheel and planet pinion 6029
2 10 2 Table of shims 6030
2 11 Removing and installing differential 6030
2 11 1 Removing 6034
2 11 2 Installing 6034
2 12 Removing and installing, dismantling and assembling pinion shaft 6035
2 12 1 Setting friction torques 6048
2 13 Adjusting pinion shaft and crown wheel 6048
2 13 1 General information 6048
2 13 2 Adjustment and marking of final drive gear sets 6048
2 13 3 Position of shims 6049
2 13 4 Adjustment overview 6050
2 14 Recommended sequence for new adjustment of final drive gear set 6051
2 15 Adjusting drive pinion 6051
2 15 1 Determining thickness of shim “S3” 6052
2 15 2 Setting friction torques 6053
2 15 3 Determining thickness of shim “S3” 6055
2 15 4 Table of shims 6056
2 15 5 Setting friction torques 6056
2 15 6 Carry out check measurement – checking dimension “r” 6056
2 16 Adjusting crown wheel 6057
2 16 1 “Stotal” Determining (S1+ S2) 6060
2 16 2 Determining thickness of temporary shim S1 6060
2 16 3 Adjusting backlash 6061
2 16 4 Calculating average backlash 6061
2 16 5 Determining thickness of shim S2 6062
2 16 6 Table of shims 6062
2 16 7 Determining thickness of shim S1 6062
2 16 8 Table of shims 6062
2 16 9 Carrying out check measurement 6063
3 Propshaft and rear final drive 08Y 6064
3 1 Assembly overview – propshaft 6064
3 2 Removing and installing propshaft 6064
3 2 1 Removing 6066
3 2 2 Installing 6067
3 3 Adjusting propshaft 6070
3 4 Removing and installing rear final drive 6070
3 4 1 Removing 6071
3 4 2 Installing 6073
3 5 Checking gear oil in rear final drive 6075
3 6 Renewing oil seal for left flange shaft 6076
3 6 1 Removing 6078
3 6 2 Installing 6078
3 6 3 Renewing flange shaft dust cap 6079
3 7 Renewing seal for right flange shaft 6080
3 7 1 Removing 6080
3 7 2 Installing 6081
3 8 Renewing propshaft flange seal 6082
3 8 1 Removing 6084
3 8 2 Installing 6085
3 8 3 Renewing propshaft flange dust cap 6087
3 9 Measuring and marking radial run-out on propshaft flange 6087
K0058952620 6 cylinder injection engine (direct injection) 6091
00 – Technical data 6097
1 Identification 6097
1 1 Engine number/engine data 6097
2 General notes 6098
2 1 Numbering of cylinders 6098
3 Safety information 6099
3 1 Safety precautions during work on fuel system 6099
3 2 Safety precautions when using testers and measuring instruments during a road test 6099
3 3 Safety precautions when working on cooling system 6100
3 4 Safety precautions when working on ignition system 6100
4 Repair notes 6102
4 1 Rules for cleanliness 6102
4 2 Foreign objects in engine 6102
10 – Removing and installing engine 6103
1 Removing and installing engine 6103
1 1 Removing engine 6103
1 1 1 Removing engine and gearbox without subframe 6112
1 2 Securing engine on engine and gearbox support 6115
1 3 Installing engine 6117
13 – Crankshaft group 6121
1 Cylinder block (pulley end) 6121
1 1 Assembly overview – cylinder block (pulley end) 6121
1 2 Removing and installing engine bracket 6124
1 3 Removing and installing poly-V belt 6126
1 4 Removing and installing sealing flange on pulley end 6127
2 Cylinder block, gearbox end 6131
2 1 Assembly overview – cylinder block, gearbox end 6131
2 2 Renewing crankshaft oil seal (gearbox end) 6132
2 3 Removing and installing sealing flange on gearbox side 6133
2 4 Removing and installing drive plate 6136
2 5 Removing and installing bracket for ancillaries 6138
3 Crankshaft 6140
3 1 Assembly overview – crankshaft 6140
3 2 Removing and installing sender wheel 6141
3 3 Allocation of main bearing shells 6142
3 3 1 Allocation of main bearing shells, up to and including manufacturing date 23 09 12 6142
3 3 2 Allocation of main bearing shells, from manufacturing date 24 09 12 6144
4 Pistons and conrods 6147
4 1 Assembly overview – pistons and conrods 6147
4 2 Checking pistons and cylinder bores 6149
4 3 Removing and installing pistons 6150
4 3 1 Removing and installing pistons, engine code CHNA, CMVA 6150
4 3 2 Removing and installing pistons, engine code CPFA 6153
15 – Cylinder head, valve gear 6156
1 Cylinder head 6156
1 1 Assembly overview – cylinder head 6156
1 2 Assembly overview – vacuum pump 6159
1 3 Removing and installing cylinder head 6159
1 4 Removing and installing cylinder head cover 6167
1 5 Removing and installing vacuum pump 6168
1 6 Checking compression 6171
2 Cover for timing chain 6175
2 1 Assembly overview – cover for timing chain 6175
2 2 Installing timing chain cover seals 6176
2 3 Assembly overview – valve timing housing, engine code CHNA 6177
2 4 Assembly overview – valve timing housing, engine codes CMVA, CPFA 6178
3 Chain drive 6179
3 1 Assembly overview – camshaft timing chains 6179
3 2 Removing and installing camshaft timing chain 6181
3 3 Removing and installing chain drive sprocket for high-pressure pump 6184
3 4 Removing and installing chain drive for oil pump 6185
3 4 1 Removing and installing oil pump drive chain, 2-part sprocket 6186
3 4 2 Removing and installing oil pump drive chain, 1-part sprocket 6190
3 5 Checking valve timing 6195
4 Valve gear 6198
4 1 Assembly overview – valve gear 6198
4 2 Measuring axial play of camshaft 6200
4 3 Removing and installing camshaft control valve 6201
4 4 Removing and installing camshaft 6204
4 5 Camshaft identification 6211
4 6 Removing and installing camshaft adjuster 6211
4 7 Removing and installing valve stem seal 6216
5 Inlet and exhaust valves 6219
5 1 Valve dimensions 6219
5 2 Checking valve guides 6219
5 3 Reworking valve seats 6220
17 – Lubrication 6222
1 Sump, oil pump 6222
1 1 Assembly overview – sump/oil pump 6222
1 1 1 Assembly overview – sump/oil pump, engine code CHNA 6222
1 1 2 Assembly overview – sump/oil pump, engine code CMVA, CPFA 6224
1 2 Removing and installing oil sump 6227
1 3 Removing and installing oil pump 6229
1 3 1 Removing and installing oil pump, 2-part sprocket 6229
1 3 2 Removing and installing oil pump, 1-part sprocket 6235
1 4 Engine oil: 6239
2 Oil filter, oil pressure switch 6241
2 1 Assembly overview – oil filter housing, oil pressure switch 6241
2 2 Checking oil pressure and oil pressure switch 6243
3 Oil circuit 6246
3 1 Oil spray jets/nozzles 6246
19 – Cooling 6247
1 Cooling system/coolant 6247
1 1 Connection diagram – coolant hoses 6247
1 1 1 Coolant hose schematic diagram, vehicles with no auxiliary heater 6247
1 1 2 Coolant hose schematic diagram, vehicles with auxiliary heater 6248
1 2 Draining and adding coolant 6250
1 3 Checking cooling system for leaks 6253
2 Coolant pump, regulation of cooling system 6254
2 1 Assembly overview – coolant pump, thermostat 6254
2 2 Removing and installing coolant pump 6255
2 3 Removing and installing thermostat 6256
2 4 Checking thermostat 6258
3 Coolant pipes 6259
3 1 Assembly overview – coolant pipes 6259
3 1 1 Assembly overview – coolant pipes part I, vehicles without auxiliary heater 6259
3 1 2 Assembly overview – coolant pipes part II, vehicles without auxiliary heater 6261
3 1 3 Assembly overview – coolant pipes part I, vehicles with auxiliary heater 6262
3 1 4 Assembly overview – coolant pipes part II, vehicles with auxiliary heater 6263
4 Radiator, radiator fan 6264
4 1 Assembly overview – radiator/radiator fan 6264
4 2 Assembly overview – radiator cowl and radiator fan 6265
4 3 Removing and installing radiator cowl with radiator fan 6265
4 4 Removing and installing radiator fan 6267
4 5 Removing and installing radiator 6268
24 – Mixture preparation – injection 6271
1 Vacuum system 6271
1 1 Checking vacuum system 6271
1 1 1 Checking vacuum reservoir in intake manifold for leaks 6271
1 1 2 Checking vacuum unit for intake manifold flap 6272
2 Injectors 6274
2 1 Assembly overview – fuel rail with injectors 6274
2 1 1 Assembly overview – fuel rail with injectors, engine code CHNA 6274
2 1 2 Assembly overview – fuel rail with injectors, engine code CMVA, CPFA 6277
2 2 Assembly overview – injectors for cylinders 1, 3 and 5 6280
2 3 Assembly overview – injectors for cylinders 2, 4 and 6 6281
2 4 Removing and installing injectors 6281
2 5 Renewing seals on injectors 6284
3 High-pressure pump 6289
3 1 Assembly overview – high-pressure pump 6289
3 2 Removing and installing high-pressure pump 6290
4 Senders and sensors 6294
4 1 Checking fuel pressure sender -G247- 6294
5 Lambda probe 6297
5 1 Assembly overview – Lambda probe 6297
5 2 Removing and installing Lambda probe 6297
6 Intake manifold 6300
6 1 Assembly overview – intake manifold 6300
6 2 Removing and installing intake manifold upper part 6302
6 3 Removing and installing lower part of intake manifold with fuel rail 6305
7 Air filter 6310
7 1 Assembly overview – air filter housing 6310
7 1 1 Disconnecting connecting line to air suspension compressor 6311
8 Engine (motor) control unit 6312
8 1 Removing and installing engine control unit -J623- 6312
26 – Exhaust system 6313
1 Exhaust pipes, silencers 6313
1 1 Assembly overview – silencers 6313
1 2 Aligning exhaust system free of stress 6314
1 3 Separating exhaust pipes, silencers 6314
1 4 Installation position of clamp 6315
2 Exhaust gas cleaning 6316
2 1 Assembly overview – emission control 6316
2 2 Removing and installing starter catalytic converter 6317
3 Exhaust manifold 6319
3 1 Assembly overview – exhaust manifold 6319
28 – Ignition system 6320
1 Ignition system 6320
1 1 Assembly overview – ignition system 6320
1 2 Removing and installing ignition coils with output stage 6322
1 3 Removing and installing Hall sender 6324
1 4 Removing and installing engine speed sender -G28- 6325
1 5 Test data, spark plugs 6326
K0059101320 Electrical system General information 6328
27 – Starter, current supply, CCS 6334
1 Battery 6334
1 1 Fundamentals for batteries 6334
1 2 Battery load test 6334
1 2 1 Battery with »standard« colour indicator 6335
1 2 2 Battery with »enhanced« colour indicator 6335
1 2 3 Absorbent glass mat battery 6336
1 2 4 Lithium ion battery 6336
1 3 Warning notices and safety regulations 6336
1 3 1 Dangers when handling vehicle batteries 6336
1 3 2 Safety markings on battery 6337
1 3 3 Working on airbag system 6338
1 4 Battery load test 6338
2 Checking battery 6340
2 1 Checking the various types of batteries 6340
2 1 1 Checking a battery with colour indicator 6340
2 1 2 Absorbent glass mat battery 6340
2 2 Visual inspection 6341
2 3 Information about battery replacement and battery gas venting 6342
2 4 Checking colour indicator in battery cover 6343
2 4 1 Checking colour indicator, “3-colour” 6343
2 4 2 Checking colour indicator, “2-colour” 6344
2 5 Current draw test 6345
3 Charging the battery 6347
3 1 Totally discharged batteries 6347
4 Cruise control system (CCS) 6349
4 1 Activating and deactivating cruise control system (CCS) 6349
90 – Gauges, instruments 6350
92 – Windscreen wash/wipe system 6351
1 Washer fluid line hose couplings 6351
1 1 Windscreen and rear window washer system 6351
1 2 Headlight washer system 6352
2 Hose repair 6353
2 1 General description 6353
2 2 Repairing smooth pipe 6353
2 3 Repairing corrugated pipe 6353
3 Distinguishing features of jointless wiper blades 6356
94 – Lights, bulbs, switches – exterior 6357
1 Operation and safety notes for gas discharge lamps 6357
96 – Lights, bulbs, switches – interior 6360
1 12 V socket 6360
1 1 Removing and installing 12 V socket 6360
1 2 Removing and installing socket illumination bulb -L42- 6360
2 Cigarette lighter -U1- 6361
2 1 General description 6361
2 2 Assembly overview 6362
2 3 Removing and installing cigarette lighter socket 6363
2 4 Removing and installing cigarette lighter illumination bulb -L28- 6366
97 – Wiring 6368
1 Vehicle diagnostic, testing and information systems 6368
1 1 Connecting vehicle diagnostic tester 6368
1 2 Connecting vehicle diagnostic tester Golf Model Year 1998 – 2003 6370
2 Repairs to wiring harnesses and connectors 6371
2 1 General notes concerning repairs to vehicle electrical system 6371
2 2 Wiring harness repair set 6373
2 2 1 Wiring harness repair set -VAS 1978- 6373
2 2 2 Upgrade kit -VAS 1978/50- 6373
2 2 3 Wiring harness repair set -VAS 1978A- 6374
2 2 4 Release tool set -VAS 1978/35- 6374
2 3 Tool descriptions 6375
2 3 1 Special pliers with insert 6375
2 3 2 Release tools for contacts 6376
2 3 3 Assembly tools for single wire seals 6376
2 3 4 Wire stripper -VAS 1978/3- 6376
2 3 5 Hot air blower 220 V/50 Hz -VAS 1978/14- 6378
2 3 6 Crimping pliers -VAS 1978/1A- 6378
2 4 Repairing wiring harnesses 6380
2 4 1 Repairs to airbag and belt tensioner wiring 6380
2 4 2 Repairing CAN bus wiring 6382
2 4 3 Repair of Flexray wires with sheath 6383
2 4 4 Repair of Flexray wires without sheath 6384
2 4 5 Renewal of aerial wiring 6385
2 4 6 Repairing 0 13 mm2/0 35 mm2/0 5 mm2 wire 6387
2 4 7 Repair of 10 mm2 or 16 mm2 wire with single butt connector 6392
2 4 8 Repair of 2 5 mm2, 4 mm2 or 6 mm2 aluminium wire with single butt connector 6399
2 4 9 Wiring open circuit with one repair position 6405
2 4 10 Wiring open circuit with two repair positions 6408
2 5 Repairing fibre optic cables 6410
2 5 1 Preparing fibre optic cable 6411
2 5 2 Detaching fibre optic cable from cable harness connector 6418
2 6 Repair of aerial wires 6419
2 6 1 Repair set, aerial cable VAS 6720 6419
2 7 Repairs to contact housings and connectors 6431
2 7 1 Notes on repairs to contact housings and connectors 6431
2 7 2 Repairs to contacts in contact housings 6431
2 7 3 Fitting single wire seals 6433
2 7 4 Repairs to contact housings using cut-and-clamp method 6436
2 8 Releasing and dismantling contact housings 6437
2 8 1 Notes on releasing and dismantling contact housings 6437
2 8 2 Secondary locking element 6437
2 8 3 Primary locking element 6438
2 8 4 Round connector systems 6439
2 8 5 Flat connector systems 6440
2 8 6 Special connector systems 6442
3 Contact surface cleaning set -VAS 6410- 6445
3 1 Using contact surface cleaning set -VAS 6410- 6445
3 1 1 Servicing ring terminals 6445
3 1 2 Servicing screw connections 6447
3 1 3 Cleaning battery clamp and battery terminal 6449
3 1 4 Anti-corrosion treatment 6451
4 Renewing lambda probe 6453
4 1 Renewing LSF Lambda probe (4-pin) 6453
4 2 Renewing LSU Lambda probe (6-pin) 6454
4 3 Types of protective tube on universal lambda probes 6455
5 Exhaust gas temperature sensor 6457
K0258951420 General body repairs exterior 6458
50 – Body – front 6466
1 Lock carrier 6466
1 1 Tools 6466
1 2 Fitting locations of adaptive cruise control senders 6466
1 2 1 ACC sender on right -G259- / ACC sender on left -G258- 6466
1 2 2 ACC sensor -G550- 6467
1 3 Assembly overview – lock carrier, service position 6467
1 4 Service position 6469
1 4 1 Moving to service position 6469
1 4 2 Moving from service position 6470
1 5 Assembly overview – lock carrier with attachments 6471
1 6 Removing and installing lock carrier with add-on parts 6471
1 6 1 Removing 6471
1 6 2 Installing 6473
1 7 Assembly overview – lock carrier attaching parts 6474
1 8 Installation instructions for longitudinal members 6475
1 9 Installation instructions for vehicles with adaptive cruise control 6475
1 9 1 Installation instructions for ACC sender on right -G259- / ACC sender on left -G258- 6475
1 9 2 Installation instructions for the ACC sensor -G550- 6476
1 10 Removing and installing ACC senders 6476
1 10 1 Removing and installing ACC sender on right -G259- / ACC sender on left -G258- 6476
1 10 2 Removing and installing ACC sensor -G550- 6477
2 Wing 6478
2 1 Tools 6478
2 2 Assembly overview – front wing 6478
2 3 Removing and installing front wing 6480
2 3 1 Removing 6480
2 3 2 Installing 6481
2 4 Front wing – bolting sequence 6482
3 Noise insulation 6483
3 1 Tools 6483
3 2 Assembly overview – noise insulation in vehicles up to 05 2010 6483
3 3 Assembly overview – noise insulation in vehicles up to 06 2010 6484
55 – Bonnet, rear lid 6485
1 Contact corrosion! 6485
2 Bonnet 6486
2 1 Tools 6486
2 2 Assembly overview – bonnet of vehicles up to 05 2010 6486
2 3 Assembly overview – bonnet of vehicles up to 06 2010 6488
2 4 Removing gas strut 6489
2 5 Service position for bonnet 6489
2 6 Removing and installing insulation of vehicles up to 05 2010 6490
2 6 1 Removing 6490
2 6 2 Installing 6490
2 7 Removing and installing insulation of vehicles up to 06 2010 6490
2 7 1 Removing 6490
2 7 2 Installing 6492
3 Lock and release components of bonnet 6493
3 1 Assembly overview – bonnet lock and release components of vehicles up to 05 2010 6493
3 2 Assembly overview – bonnet lock and release components of vehicles up to 06 2010 6494
3 3 Removing and installing bonnet lock 6494
3 3 1 Removing 6494
3 3 2 Installing 6497
3 4 Adjusting bonnet and bonnet lock 6498
3 5 Detaching Bowden cable 6500
3 6 Removing and installing release lever 6500
3 6 1 Removing 6500
3 6 2 Installing 6502
4 Rear lid 6503
4 1 Tools 6503
4 2 Assembly overview – aluminium hinge and hydraulic unit 6504
4 3 Removing and installing hydraulic unit 6505
4 3 1 Removing 6505
4 3 2 Installing 6506
4 4 Assembly overview – steel hinge 6506
4 5 Removing gas strut 6507
4 6 Releasing gas from gas strut 6507
4 7 Adjusting rear lid 6507
4 8 Basic adjustment of rear lid 6507
4 9 Adjusting striker plate with lock cover removed 6509
4 10 Adjusting striker plate with lock cover installed 6509
4 11 Adjusting dampers 6510
5 Lock parts with servo rear lid opener 6511
5 1 Assembly overview – lock parts with servo rear lid opener 6511
5 2 Removing and installing lock cylinder carrier 6512
5 2 1 Removing 6512
5 2 2 Installing 6512
5 3 Removing and installing lid lock 6513
5 3 1 Removing 6513
5 3 2 Installing 6513
6 Lock parts with basic rear lid opener 6514
6 1 Assembly overview – lock parts with basic rear lid opener 6514
6 2 Removing and installing lock cylinder carrier 6515
6 2 1 Removing 6515
6 2 2 Installing 6515
6 3 Removing and installing lid lock 6516
6 3 1 Removing 6516
6 3 2 Installing 6516
7 Tank flap unit 6517
7 1 Tools 6517
7 2 Removing and installing tank flap unit 6517
57 – Front doors, door components, central locking 6519
1 Contact corrosion! 6519
2 Front door 6520
2 1 Tools 6520
2 2 Assembly overview – front door 6521
2 3 Removing and installing door 6523
2 3 1 Removing 6523
2 3 2 Installing 6524
2 4 Adjusting door 6524
2 5 Adjusting striker pin 6524
2 6 Assembly overview – door handle and door lock 6525
2 7 Removing and installing lock cylinder housing 6526
2 7 1 Removing 6526
2 7 2 Installing 6527
2 8 Removing and installing door handle 6528
2 8 1 Removing 6528
2 8 2 Installing 6528
2 9 Door handle with (Keyless Entry) cable routing 6530
2 10 Removing and installing door lock 6530
2 10 1 Removing 6531
2 10 2 Installing 6532
2 11 Assembly overview – door power latching motor (V 278) 6534
2 12 Door seals 6535
2 13 Removing and installing door inner seal 6536
2 13 1 Removing 6536
2 13 2 Installing 6536
2 14 Removing and installing door outer seal 6536
2 14 1 Removing 6536
2 14 2 Installing 6537
2 15 Door insulation 6538
2 16 Removing and installing insulation 6539
2 17 Adapting ignition keys to remote control 6540
2 18 Removing and installing batteries for folding main key with remote control system 6540
2 18 1 Removing 6540
2 18 2 Installing 6541
2 19 Assembly overview – batteries for main key (foldable) with remote control, vehicles from 01 2004 6541
2 20 Removing and installing batteries for folding main key with remote control system, vehicles from 01 2004 6542
2 20 1 Removing 6542
2 20 2 Installing 6543
2 21 Assembly overview – batteries for main key (foldable) with remote control, vehicles from 06 2010 6543
2 22 Removing and installing batteries for folding main key with remote control system, vehicles from 06 2010 6544
2 22 1 Removing 6544
2 22 2 Installing 6545
58 – Rear doors, door components 6546
1 Contact corrosion! 6546
2 Rear door 6547
2 1 Tools 6547
2 2 Assembly overview – rear door 6548
2 3 Removing and installing door 6549
2 3 1 Removing 6549
2 3 2 Installing 6550
2 4 Adjusting door 6550
2 5 Adjusting striker pin 6551
2 6 Assembly overview – door handle and door lock 6551
2 7 Removing and installing door handle 6553
2 7 1 Removing 6553
2 7 2 Installing 6553
2 8 Door handle with (Keyless Entry) cable routing 6555
2 9 Removing and installing door lock 6556
2 9 1 Removing 6556
2 9 2 Installing 6559
2 10 Assembly overview – door power latching motor (V 278) 6560
2 11 Door seals 6561
2 12 Removing and installing door inner seal 6562
2 12 1 Removing 6562
2 12 2 Installing 6562
2 13 Removing and installing door outer seal 6562
2 13 1 Removing 6562
2 13 2 Installing 6563
2 14 Door insulation 6564
2 15 Installing insulation 6565
60 – Sunroof 6566
1 Sunroof with glass panel 6566
1 1 Tools 6566
1 2 Function 6566
1 3 Assembly overview 6567
1 4 Removing sliding/tilting sunroof glass panel 6569
1 5 Installing sliding/tilting sunroof glass panel 6569
1 6 Adjusting height of sliding/tilting sunroof glass panel 6570
1 7 Checking parallel running of glass panel 6571
1 8 Adjusting parallel running of glass panel 6571
1 9 Renewing panel seal 6572
1 10 Removing and installing wind deflector 6572
1 10 1 Removing 6572
1 10 2 Installing 6573
1 11 Adjusting wind deflector 6573
1 12 Removing and installing sliding headliner 6573
1 12 1 Removing 6573
1 12 2 Installing 6574
1 13 Adjusting parallel running of sliding headliner 6574
1 14 Removing and installing sliding/tilting sunroof drive 6575
1 14 1 Removing 6575
1 14 2 Installing 6576
1 15 Adjusting drive for sliding/tilting sunroof (zero position) 6576
1 16 Removing and installing drive for sliding headliner 6577
1 16 1 Removing 6577
1 16 2 Installing 6578
1 17 Removing and installing wind deflector drive 6578
1 17 1 Removing 6578
1 17 2 Installing 6579
1 18 Removing and installing sliding/tilting sunroof automatic preselector 6579
1 18 1 Removing 6579
1 18 2 Installing 6580
1 19 Removing switches for sunroof roller blind 6581
1 19 1 Removing 6581
1 19 2 Installing 6582
1 20 Removing and installing carrier unit 6582
1 20 1 Removing 6582
1 20 2 Installing 6583
1 21 Operating without current 6584
1 22 Cleaning water drain hoses 6584
1 22 1 Front water drain hoses 6584
1 22 2 Rear water drain hoses 6586
1 23 Adapting components of sliding/tilting sunroof 6586
1 24 Coding sliding/tilting sunroof 6587
2 Remove sliding/tilting sunroof with solar panel 6588
2 1 Tools 6588
2 2 Function 6588
2 3 Assembly overview 6589
2 4 Removing sliding/tilting sunroof solar panel 6591
2 5 Installing sliding/tilting sunroof solar panel 6591
2 6 Adjusting sliding/tilting sunroof solar panel height 6592
2 7 Checking parallel running of solar panel 6593
2 8 Adjusting parallel running of solar panel 6593
2 9 Renewing panel seal 6594
2 10 Removing and installing wind deflector 6594
2 10 1 Removing 6594
2 10 2 Installing 6595
2 11 Adjusting wind deflector 6595
2 12 Removing and installing solar panel trim 6595
2 12 1 Removing 6595
2 12 2 Installing 6596
2 13 Removing and installing sliding/tilting sunroof drive 6596
2 13 1 Removing 6596
2 13 2 Installing 6597
2 14 Adjusting drive for sliding/tilting sunroof (zero position) 6597
2 15 Removing and installing wind deflector drive 6597
2 15 1 Removing 6597
2 15 2 Installing 6599
2 16 Removing and installing sliding/tilting sunroof automatic preselector 6599
2 16 1 Removing 6599
2 16 2 Installing 6600
2 17 Removing and installing DC-DC converter 6600
2 17 1 Removing 6600
2 17 2 Installing 6600
2 18 Removing solar contact 6600
2 19 Removing and installing carrier unit 6601
2 19 1 Removing 6601
2 19 2 Installing 6602
2 20 Operating without current 6603
2 21 Cleaning water drain hoses 6603
2 21 1 Front water drain hoses 6603
2 21 2 Rear water drain hoses 6605
2 22 Adapting components of sliding/tilting sunroof 6605
2 23 Coding sliding/tilting sunroof 6606
63 – Bumpers 6607
1 Front bumper cover of vehicles up to 05 2010 6607
1 1 Repairing front bumper cover 6607
1 2 Tools 6607
1 3 Assembly overview – front bumper cover 6607
1 4 Removing and installing front bumper cover 6608
1 4 1 Removing 6609
1 4 2 Installing 6610
1 5 Front bumper cover add-on parts 6611
1 6 Front bumper cover substructure parts 6612
1 7 Installation notes for ACC sensor on right -G259- / left -G 258- 6613
1 8 Removing and installing adaptive cruise control sensor -ACC- 6613
1 9 Removing and installing bumper cover insert 6614
1 10 Assembling bumper cover insert 6615
2 Front bumper cover of vehicles from 06 2010 6617
2 1 Repairing front bumper cover 6617
2 2 Tools 6617
2 3 Assembly overview – front bumper cover 6617
2 4 Removing and installing front bumper cover 6618
2 4 1 Removing 6619
2 4 2 Installing 6620
2 5 Front bumper cover add-on parts 6621
2 6 Front bumper cover substructure parts 6622
3 Rear bumper cover 6623
3 1 Repairing bumper cover 6623
3 2 Tools 6623
3 3 Assembly overview – rear bumper cover 6623
3 4 Removing and installing rear bumper cover 6625
3 4 1 Removing 6625
3 4 2 Installing 6626
3 5 Rear bumper cover add-on parts 6627
3 6 Rear bumper cover substructure parts 6628
3 7 Assembly overview – towing bracket 6628
64 – Glazing 6630
1 Flush bonded windows 6630
1 1 Tools 6630
1 2 Materials 6632
1 3 Repairing windscreen 6632
1 4 Assembly overview – windscreen 6632
1 5 Removing and installing plenum chamber cover 6634
1 5 1 Removing 6634
1 5 2 Installing 6635
1 6 Removing windscreen 6639
1 7 Installing windscreen 6640
1 8 Preparing windscreen with viewing window for chassis number for vehicles without chassis number 6641
1 9 Assembly overview – rear window 6641
1 10 Removing undamaged rear window 6643
1 11 Installing rear window 6644
1 12 Preparing a removed windscreen for glazing 6644
1 13 Preparing new window for glazing 6645
1 14 Preparing body flange for glazing 6646
1 15 Installation instructions 6646
1 16 Minimum curing period 6647
1 17 Touching up paint damage 6647
1 18 Cleaning off excess adhesive sealing material 6647
2 Front door windows 6649
2 1 Assembly overview – front door window 6649
2 2 Removing and installing door window 6650
2 2 1 Removing 6650
2 2 2 Installing 6651
2 3 Removing and installing electric window regulator 6651
2 3 1 Removing 6651
2 3 2 Installing 6652
2 4 Removing and installing assembly carrier 6652
2 4 1 Removing 6652
2 4 2 Installing 6654
2 5 Removing and installing window slot seal 6657
2 5 1 Removing 6657
2 5 2 Installing 6657
2 6 Removing and installing trim 6657
2 6 1 Removing 6657
2 6 2 Installing 6657
3 Rear door windows 6659
3 1 Assembly overview – rear door window 6659
3 2 Removing and installing door window 6660
3 2 1 Removing 6660
3 2 2 Installing 6661
3 3 Removing and installing electric window regulator 6661
3 3 1 Removing 6661
3 3 2 Installing 6662
3 4 Removing and installing assembly carrier 6662
3 4 1 Removing 6662
3 4 2 Installing 6664
3 5 Removing and installing window channel 6666
3 5 1 Removing 6666
3 5 2 Installing 6667
3 6 Removing and installing window slot seal 6668
3 6 1 Removing 6668
3 6 2 Installing 6668
3 7 Removing and installing trim 6668
3 7 1 Removing B-pillar trim 6668
3 7 2 Installing B-pillar trim 6668
3 7 3 Removing C-pillar trim 6669
3 7 4 Installing C-pillar trim 6669
66 – Exterior equipment 6670
1 Removing and installing wheel housing liner 6670
1 1 Front wheel housing liner 6670
1 2 Rear wheel housing liner 6671
2 Exterior mirror 6672
2 1 Tools 6672
2 2 Assembly overview – rear-view mirror 6672
2 3 Removing and installing mirror glass 6673
2 3 1 Removing 6673
2 3 2 Installing 6673
2 4 Removing and installing mirror housing 6673
2 4 1 Removing 6673
2 4 2 Installing 6674
2 5 Removing and installing side turn signal repeaters 6674
2 5 1 Removing 6674
2 5 2 Installing 6675
2 6 Removing and installing entry light 6675
2 6 1 Removing 6675
2 6 2 Installing 6675
2 7 Removing and installing warning lamp for lane change assist 6675
2 7 1 Removing 6675
2 7 2 Installing 6676
2 8 Assembly overview – rear-view mirror 6676
2 9 Removing and installing rear-view mirror 6677
2 9 1 Removing 6677
2 9 2 Installing 6677
2 10 Removing and installing cap 6677
2 10 1 Removing 6677
2 10 2 Installing 6678
3 Radiator grille of vehicles up to 05 2010 6679
3 1 Assembly overview – radiator grille 6679
3 2 Removing and installing radiator grille 6679
3 2 1 Removing 6679
3 2 2 Installing 6680
4 Radiator grille of vehicles from 06 2010 6681
4 1 Assembly overview – radiator grille 6681
4 2 Removing and installing radiator grille 6682
4 2 1 Removing 6682
4 2 2 Installing 6683
4 3 Removing and installing VW emblem on vehicles without adaptive cruise control 6684
4 3 1 Removing 6684
4 3 2 Installing 6685
4 4 Removing and installing VW emblem on vehicles with adaptive cruise control 6687
4 4 1 Removing 6687
4 4 2 Installing 6688
5 Roof mouldings 6690
5 1 Assembly overview – roof strip 6690
5 2 Removing and installing securing clips for roof moulding 6691
5 2 1 Removing 6691
5 2 2 Installing 6691
5 3 Assembly overview – drip channel 6691
5 4 Assembly overview – water deflector 6693
6 Protective strips 6694
6 1 Assembly overview – protective moulding 6694
6 2 Renewing protective side strips 6695
6 3 Assembly overview – trim strips on wing and side panel 6696
6 4 Renewing trim strip insert 6696
6 5 Assembly overview – cover strips 6697
7 Sill trim 6698
7 1 Assembly overview – sill protective strip 6698
7 2 Assembly overview – sill panel mouldings 6699
7 3 Renewing sill panel moulding 6700
8 Lettering 6701
8 1 Tools 6701
8 2 Installation instructions for lettering and emblems 6701
8 3 Rear lettering – dimensions 6701
8 4 Dimensions of Volkswagen R GmbH emblem 6703
8 4 1 Dimensions of Volkswagen R GmbH emblem, left wing 6703
8 4 2 Dimensions of Volkswagen R GmbH emblem, right wing 6704
VW Oil Approval 6705

S.V 27/01/2025