Volkswagen Polo 2002-2005 Workshop Repair Manual PDF

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Volkswagen Polo 2002-2005 Workshop Repair Manual – PDF DOWNLOAD

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Volkswagen Polo 2002-2005 Workshop Repair Manual – PDF DOWNLOAD

Language : English
Pages : 6582
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Volkswagen Polo 2002-2005 Workshop Repair Manual – PDF DOWNLOAD

44 – Wheels, tyres, vehicle geometry 11
1 General notes on wheels and tyres (passenger cars) 11
2 Legislative and technical conditions for converting wheel and tyre combinations 13
2 1 Legislative conditions for converting wheel and tyre combinations 13
2 2 Technical conditions for converting wheel and tyre combinations 13
2 3 Additional wheel housing extensions (flaps) 14
2 4 “Series 80” tyres 14
2 5 Vehicles with Plus running gear 14
3 Documents and codes/designations 16
3 1 New vehicle registration documents since 01 10 2005 16
3 2 COC document (EEC Certificate of Conformity) 17
3 3 Official type designations 17
3 4 EU general type approval number, sales type and sales or trade designation 18
4 Useful information regarding tyres 20
4 1 Identification markings on the tyre sidewall 20
4 2 Explanation of tyre markings 21
4 3 Speed ratings for tyres 22
4 4 Undulations 23
4 5 Tyre storage 24
4 6 Tyre ageing 24
4 7 Winter tyres 25
4 8 Winter tyres with speed symbol “V” 26
4 9 Extra Load (XL) V winter tyres 27
4 10 Maximum speeds for V and Extra Load (XL) winter tyres 27
4 11 Reinforced and Extra Load (XL) tyres 28
4 12 Snow chains 28
5 Tyre wear/ mileage for passenger car tyres 30
5 1 General 30
5 2 Requirements to be met by tyres 30
5 3 Wear behaviour of high-speed tyres 31
5 4 Factors influencing the service life of a tyre 31
5 5 Driving style 31
5 6 Tyre maintenance 32
5 7 Evenly worn tyres 33
5 8 Measuring tread depth 34
5 9 One-sided wear 34
5 10 Outer shoulder wear 37
5 11 Wear in middle of tyre 37
5 12 Diagonal washout 39
6 Tyre noise 40
6 1 General notes on tyre noise 40
6 2 Saw-tooth wear 40
6 3 Flat spots (from locking wheels) 41
7 Rough running caused by wheels/tyres 43
7 1 Causes of rough running 43
7 2 Balancing wheels 43
7 3 Conducting a road test before balancing wheels 43
7 4 Balancing wheels on stationary wheel balancing machine 44
7 5 Vibration control system -VAS 6230- 46
7 6 Finish balancer 46
7 7 Radial and lateral runout of wheels and tyres 47
7 8 Checking radial and lateral runout on wheels and tyres with tyre gauge -V A G 1435- 47
7 9 Checking radial and lateral runout on wheel rim 48
7 10 Matching 49
7 11 Flat spots caused by storage or handling 50
8 Vehicle pulls to one side 52
8 1 General 52
8 2 Conicity 52
8 3 Remedies when vehicle pulls to one side 53
8 4 Strategic rotation of wheels for non-directional tyres 54
8 5 Strategic rotation of wheels having unidirectional tyres 55
9 Tyre damage 57
9 1 General information 57
9 2 Construction of a radial belted tyre 57
9 3 Impact damage 58
9 4 Cuts 59
9 5 Damage caused by foreign bodies 59
9 6 Loss of air from tyre 60
9 7 Tyre pressure 60
9 8 Tyre damage due to insufficient tyre pressure 61
9 9 Rising tyre temperature caused by insufficient inflation pressure 62
9 10 Tyre damage due to fitting error (fitting damage) 63
10 Tyres with run-flat properties 65
10 1 General 65
10 2 Design and identification 66
10 3 Retrofitting/requirements when using run-flat tyres 66
10 4 Repairs 67
11 Rolling resistance optimised tyres 68
12 Facts about disc-type wheels (passenger cars) 69
12 1 Design of disc-type wheel 69
12 2 Data on wheel rims 69
12 3 Wheel rims – pitch circle diameter 70
12 4 Split rim composite wheels 70
12 5 Alloy wheels with exchangeable trim elements 70
12 6 Alloy wheels with exchangeable trim elements (Zaragoza) 71
12 6 1 Tools 71
12 6 2 Materials 72
12 6 3 Installing trim element 72
12 6 4 Removing trim element 74
12 7 Hub cover for alloy wheels with open threaded connections 75
12 8 Care and maintenance of alloy wheel rims 75
12 9 Restoring alloy wheels 76
12 10 The valve 77
13 Fitting and removing wheels 78
13 1 Rotating wheels 78
13 2 Instructions for changing or fitting wheels 78
13 3 Revised wheel bolts for Sharan from model year 2001 80
13 4 Notes on use of temporary spare wheels 80
14 Lupo 3L, Lupo FSI, Lupo GTI from model year 1999 82
14 1 Lupo 3L, type 6E model year 1999 to model year 2006 82
14 2 Wheel allocation for Lupo 3L, type 6E model year 1999 to model year 2006 83
14 2 1 4 J x 14 83
14 2 2 41/2 J x 14 83
14 2 3 5 J x 14 84
14 3 Lupo FSI, type 6E model year 2001 to model year 2006 84
14 4 Wheel allocation for Lupo FSI, type 6E model year 2001 to model year 2006 85
14 4 1 5 J x 14 85
14 4 2 6 J x 14 86
14 5 Lupo GTI, type 6ES model year 2001 to model year 2006 87
14 6 Wheel allocation for Lupo GTI, type 6ES model year 2001 to model year 2006 88
14 6 1 6 J x 14 88
14 6 2 61/2 J x 15 89
15 Lupo model year 1999 to model year 2005 90
15 1 Lupo, type 6X model year 1999 to model year 2005 90
15 2 Wheel allocation for Lupo, type 6X model year 1999 to model year 2005 92
15 2 1 41/2 J x 13 92
15 2 2 51/2 J x 13 93
15 2 3 6 J x 14 94
15 2 4 6 J x 15 96
16 Fox from model year 2005 98
16 1 Fox, type 5Z model year 2005 to model year 2012 98
16 2 Wheel allocation for Fox, type 5Z model year 2005 to model year 2012 99
16 2 1 5 J x 14 100
16 2 2 6 J x 14 100
16 2 3 6 J x 15 102
17 Polo model year 1995 to model year 2001 105
17 1 Polo, type 6N up to and including 07 95 105
17 2 Wheel allocation for Polo, type 6N up to and including 07 95 106
17 2 1 41/2 J x 13 106
17 2 2 51/2 J x 13 107
17 3 Polo, type 6N from 08 95 up to and including model year 1996 108
17 4 Polo, type 6N from model year 1997 to model year 1999 109
17 5 Wheel allocation for Polo, type 6N from 08 95 to model year 1999 110
17 5 1 41/2 J x 13 111
17 5 2 51/2 J x 13 111
17 5 3 6 J x 14 112
17 5 4 6 J x 15 113
17 6 Polo, type 6N from model year 2000 to model year 2001 115
17 7 Wheel allocation for Polo, type 6N from model year 2000 to model year 2001 116
17 7 1 41/2 J x 13 117
17 7 2 51/2 J x 13 117
17 7 3 6 J x 14 118
17 7 4 6 J x 15 119
18 Polo Classic model year 1996 to model year 2002 122
18 1 Polo Classic, type 6KV model year 1996 to model year 2002 122
18 2 Wheel allocation for Polo Classic, type 6KV model year 1996 to model year 2002 124
18 2 1 51/2 J x 13 124
18 2 2 6 J x 14 125
18 2 3 6 J x 15 126
19 Polo Variant model year 1998 to model year 2002 128
19 1 Polo Variant type 6KV model year 1998 to model year 2002 128
19 2 Wheel allocation for Polo Variant type 6KV model year 1998 to model year 2002 130
19 2 1 51/2 J x 13 130
19 2 2 6 J x 14 131
19 2 3 6 J x 15 132
20 Polo from model year 2002 134
20 1 Polo, type 9N model year 2002 to model year 2008 134
20 2 Polo, type 9N model year 2009 137
20 3 Wheel allocation for Polo, type 9N model year 2002 to model year 2009 141
20 3 1 5 J x 13 141
20 3 2 5 J x 14 142
20 3 3 6 J x 14 142
20 3 4 6 J x 15 144
20 3 5 61/2 J x 16 offset 38 145
20 3 6 61/2 J x 16 offset 43 145
20 3 7 71/2 J x 17 offset 38 148
21 Polo Fun model year 2004 to model year 2005 149
21 1 Polo Fun, type 9N model year 2004 to model year 2005 149
21 2 Wheel allocation for Polo Fun, type 9N model year 2004 to model year 2005 150
21 2 1 6 J x 15 150
21 2 2 71/2 J x 17 150
22 CrossPolo from model year 2006 152
22 1 CrossPolo, type 9N model year 2006 to model year 2009 152
22 2 Wheel allocation for CrossPolo, type 9N model year 2006 to model year 2009 153
22 2 1 6 J x 15 153
22 2 2 71/2 J x 17 153
23 Polo BlueMotion from model year 2007 155
23 1 Polo BlueMotion, type 9N model year 2007 to model year 2009 155
23 2 Wheel allocation for Polo BlueMotion, type 9N model year 2007 to model year 2009 156
23 2 1 5 J x 14 156
24 Polo GTI from model year 2006 158
24 1 Polo GTI, type 9N model year 2006 to model year 2009 158
24 2 Wheel allocation for Polo GTI, type 9N model year 2006 to model year 2009 159
24 2 1 6 J x 15 159
24 2 2 61/2 J x 16 offset 38 160
24 2 3 61/2 J x 16 offset 43 160
24 2 4 7 J x 17 offset 38 162
24 2 5 71/2 J x 17 offset 38 163
25 Polo GTI Cup Edition from model year 2007 164
25 1 Polo GTI Cup Edition, type 9N model year 2007 to model year 2009 164
25 2 Wheel allocation for Polo GTI Cup Edition, type 9N model year 2007 to model year 2009 165
25 2 1 61/2 J x 16 offset 42 165
25 2 2 61/2 J x 16 offset 43 166
25 2 3 7 J x 17 offset 38 167
25 2 4 71/2 J x 17 offset 38 168
26 Polo saloon/sedan model year 2004 to model year 2005 169
26 1 Polo saloon/sedan, type 9N model year 2004 to model year 2005 169
26 2 Wheel allocation for Polo saloon/sedan, type 9N model year 2004 to model year 2005 171
26 2 1 5 J x 14 171
26 2 2 6 J x 14 171
26 2 3 6 J x 15 173
26 2 4 61/2 J x 16 174
27 Golf model year 1992 to model year 1998 176
27 1 Golf type 1HX0, Golf Syncro 1HX1, Golf type 1H 176
27 2 Wheel allocation for Golf type 1HX0, Golf Syncro 1HX1, Golf type 1H 180
27 2 1 51/2 J x 13 180
27 2 2 6 J x 14 181
27 2 3 6 J x 15 183
27 2 4 61/2 J x 15 186
27 2 5 7 J x 16 189
28 Golf model year 1998 to model year 2004, Golf R32, Golf Anniversary GTI 190
28 1 Golf, Golf 4Motion, type 1J model year 1998 to model year 2004 190
28 2 Wheel allocation for Golf, Golf 4Motion, type 1J model year 1998 to model year 2004 193
28 2 1 6 J x 14 193
28 2 2 6 J x 15 194
28 2 3 51/2 J x 16 197
28 2 4 61/2 J x 16 198
28 2 5 7 J x 17 202
28 2 6 71/2 J x 17 204
28 3 Conditions for fitting 17″ wheels and tyres to Golf model year 1998 to model year 2004 205
28 4 Golf R32, type 1J model year 2003 to model year 2005 206
28 5 Wheel allocation for Golf R32, type 1J model year 2003 to model year 2005 206
28 5 1 51/2 J x 17 207
28 5 2 71/2 J x 17 207
28 5 3 71/2 J x 18 207
28 6 Golf Anniversary GTI, type 1J model year 2002 208
28 7 Wheel allocation for Golf Anniversary GTI, type 1J model year 2002 208
28 7 1 51/2 J x 16 209
28 7 2 61/2 J x 16 209
28 7 3 7 J x 17 211
28 7 4 71/2 J x 18 212
28 8 Conditions for fitting 17″ and 18″ wheels and tyres of Golf Anniversary GTI 213
29 Golf model year 2004 to model year 2009 214
29 1 Golf, Golf 4Motion, type 1K model year 2004 to model year 2006 214
29 2 Golf, Golf 4Motion, type 1K model year 2007 to model year 2009 217
29 3 Wheel allocation for Golf, Golf 4Motion, type 1K model year 2004 to model year 2009 221
29 3 1 6 J x 15 221
29 3 2 61/2 J x 15 222
29 3 3 6 J x 16 223
29 3 4 61/2 J x 16 223
29 3 5 6 J x 17 227
29 3 6 7 J x 17 228
29 3 7 71/2 J x 17 230
29 3 8 71/2 J x 18 231
30 Golf BlueMotion model year 2008 to model year 2009 234
30 1 Golf BlueMotion, type 1K model year 2008 to model year 2009 234
30 2 Wheel allocation for Golf BlueMotion, type 1K model year 2008 to model year 2009 235
30 2 1 6 J x 15 235
30 2 2 61/2 J x 15 236
30 2 3 61/2 J x 16 237
31 Golf GTI model year 2005 to model year 2009 242
31 1 Golf GTI, type 1K model year 2005 to model year 2008 242
31 2 Golf GTI, type 1K model year 2009 243
31 3 Wheel allocation for Golf GTI, type 1K model year 2005 to model year 2009 245
31 3 1 6 J x 16 245
31 3 2 61/2 J x 16 245
31 3 3 6 J x 17 249
31 3 4 7 J x 17 250
31 3 5 71/2 J x 17 252
31 3 6 71/2 J x 18 253
32 Pirelli Golf model year 2008 to model year 2009 256
32 1 Pirelli Golf, type 1K model year 2008 to model year 2009 256
32 2 Wheel allocation for Pirelli Golf, type 1K model year 2008 to model year 2009 257
32 2 1 6 J x 16 257
32 2 2 61/2 J x 16 258
32 2 3 6 J x 17 262
32 2 4 7 J x 17 262
32 2 5 71/2 J x 17 265
32 2 6 71/2 J x 18 266
33 Golf R32 model year 2006 to model year 2009 269
33 1 Golf R32, type 1K model year 2006 to model year 2009 269
33 2 Wheel allocation for Golf R32, type 1K model year 2006 to model year 2009 270
33 2 1 6 J x 17 270
33 2 2 7 J x 17 271
33 2 3 71/2 J x 18 273
34 CrossGolf from model year 2007 276
34 1 CrossGolf, type 1KP model year 2007 to model year 2009 276
34 2 Wheel allocation for CrossGolf, type 1KP model year 2007 to model year 2009 279
34 2 1 6 J x 15 279
34 2 2 61/2 J x 15 280
34 2 3 6 J x 16 281
34 2 4 61/2 J x 16 282
34 2 5 6 J x 17 286
34 2 6 7 J x 17 offset 47 286
34 2 7 7 J x 17 offset 54 287
34 2 8 71/2 J x 17 289
35 Golf Plus from model year 2005 290
35 1 Golf Plus, type 1KP model year 2005 to model year 2006 290
35 2 Golf Plus, type 1KP model year 2007 to model year 2009 292
35 3 Wheel allocation for Golf Plus, type 1KP model year 2005 to model year 2009 295
35 3 1 6 J x 15 296
35 3 2 61/2 J x 15 296
35 3 3 6 J x 16 297
35 3 4 61/2 J x 16 298
35 3 5 6 J x 17 302
35 3 6 7 J x 17 303
35 3 7 71/2 J x 18 305
36 Golf Plus BlueMotion from model year 2008 308
36 1 Golf Plus BlueMotion, type 1KP model year 2008 to model year 2009 308
36 2 Wheel allocation for Golf Plus BlueMotion, type 1KP model year 2008 to model year 2009 309
36 2 1 6 J x 15 309
36 2 2 61/2 J x 15 310
36 2 3 61/2 J x 16 311
37 Golf Variant model year 1994 to model year 1998 316
37 1 Golf Variant type 1HX0, Golf Variant Syncro type 1HX1, Golf Variant type 1H 316
37 2 Wheel allocation for Golf Variant type 1HX0, Golf Variant Syncro type 1HX1, Golf Variant type 1H 319
37 2 1 51/2 J x 13 320
37 2 2 6 J x 14 320
37 2 3 6 J x 15 323
37 2 4 61/2 J x 15 326
38 Golf Variant model year 1999 to model year 2006, Bora Variant model year 1999 to model year 2005 327
38 1 Golf Variant, Golf Variant 4Motion, Bora Variant, Bora Variant 4Motion, type 1J 327
38 2 Wheel allocation for Golf Variant, Golf Variant 4Motion, Bora Variant, Bora Variant 4Motion, type 1J 330
38 2 1 6 J x 15 330
38 2 2 51/2 J x 16 333
38 2 3 61/2 J x 16 334
38 2 4 7 J x 17 338
38 2 5 71/2 J x 17 340
38 3 Conditions for fitting 17″ wheels and tyres 341
39 Golf Variant model year 2007 to model year 2010 342
39 1 Golf Variant, Golf Variant 4Motion; type 1KM model year 2007 to model year 2008 342
39 2 Golf Variant, Golf Variant 4Motion; type 1KM model year 2009 to model year 2010 345
39 3 Wheel allocation for Golf Variant, Golf Variant 4Motion; type 1KM model year 2007 to model year 2010 348
39 3 1 6 J x 15 348
39 3 2 61/2 J x 15 349
39 3 3 6 J x 16 350
39 3 4 61/2 J x 16 351
39 3 5 7 J x 17 355
39 3 6 71/2 J x 18 357
40 Golf Variant BlueMotion model year 2008 to model year 2010 360
40 1 Golf Variant BlueMotion, type 1KM model year 2008 to model year 2010 360
40 2 Wheel allocation for Golf Variant BlueMotion, type 1KM model year 2008 to model year 2010 361
40 2 1 6 J x 15 361
40 2 2 61/2 J x 15 362
40 2 3 61/2 J x 16 363
41 Jetta Model Year 2006 to Model Year 2011 368
41 1 Jetta, type 1KM model year 2006 368
41 2 Jetta, type 1KM model year 2007 to model year 2008 370
41 3 Jetta, type 1KM model year 2009 to model year 2011 373
41 4 Wheel allocation for Jetta, type 1KM model year 2006 to model year 2011 380
41 4 1 6 J x 15 380
41 4 2 61/2 J x 15 381
41 4 3 6 J x 16 382
41 4 4 61/2 J x 16 383
41 4 5 7 J x 17 388
41 4 6 71/2 J x 17 391
41 4 7 71/2 J x 18 392
42 Jetta BlueMotion from Model year 2008 397
42 1 Jetta BlueMotion, type 1KM model year 2008 to model year 2011 397
42 2 Wheel allocation for Jetta BlueMotion, type 1KM model year 2008 to model year 2011 398
42 2 1 6 J x 15 398
42 2 2 61/2 J x 15 399
42 2 3 6 J x 16 400
42 2 4 61/2 J x 16 401
43 Golf cabriolet model year 1994 to model year 1997 407
43 1 Golf cabriolet type 1EX0 model year 1994 to model year 1997 407
43 2 Wheel allocation for Golf cabriolet, type 1EX0 from model year 1994 to model year 1997 408
43 2 1 6 J x 14 409
43 2 2 6 J x 15 410
43 2 3 61/2 J x 16 410
44 Golf cabriolet model year 1998 to model year 2002 412
44 1 Golf cabriolet; type 1E from model year 1998 to model year 2002 412
44 2 Wheel allocation for Golf cabriolet; type 1E from model year 1998 to model year 2002 413
44 2 1 6 J x 14 413
44 2 2 6 J x 15 415
44 2 3 61/2 J x 16 417
45 Vento from model year 1992 to model year 1998 418
45 1 Vento; type 1HX0, 1H 418
45 2 Wheel allocation for Vento; type 1HX0, 1H 420
45 2 1 51/2 J x 13 420
45 2 2 6 J x 14 421
45 2 3 6 J x 15 423
45 2 4 61/2 J x 15 425
46 Bora model year 1999 to model year 2005 429
46 1 Bora, Bora 4Motion, type 1J model year 1999 to model year 2005 429
46 2 Wheel allocation for Bora, Bora 4Motion, type 1J model year 1999 to model year 2005 432
46 2 1 6 J x 15 432
46 2 2 51/2 J x 16 435
46 2 3 61/2 J x 16 435
46 2 4 7 J x 17 440
46 2 5 71/2 J x 17 442
46 3 Conditions for fitting 17″ wheels and tyres 443
47 New Beetle from model year 1999 444
47 1 New Beetle, type 9C model year 1999 to model year 2010 444
47 2 Wheel allocation for New Beetle, type 9C model year 1999 to model year 2010 447
47 2 1 6 J x 15 447
47 2 2 51/2 J x 16 449
47 2 3 61/2 J x 16 450
47 2 4 7 J x 17 455
47 2 5 71/2 J x 17 458
47 3 Conditions for fitting 17″ wheels and tyres 458
48 New Beetle Cabriolet from model year 2003 460
48 1 New Beetle Cabriolet, type 1Y model year 2003 to model year 2010 460
48 2 Wheel allocation for New Beetle Cabriolet, type 1Y model year 2003 to model year 2010 462
48 2 1 6 J x 15 462
48 2 2 51/2 J x 16 464
48 2 3 61/2 J x 16 465
48 2 4 7 J x 17 470
48 2 5 71/2 J x 17 473
48 3 Conditions for fitting 17″ wheels and tyres 473
49 New Beetle RSi 475
49 1 New Beetle RSi, type 9CR from model year 2001 475
49 2 Wheel allocation for New Beetle RSi, type 9CR from model year 2001 476
49 2 1 7 J x 16 476
49 2 2 9 x 18 476
50 Passat model year 1994 to model year 1997 478
50 1 Passat, type 35l model year 1994 to model year 1997 478
50 2 Wheel allocation for Passat, type 35l model year 1994 to model year 1997 480
50 2 1 6 J x 14 480
50 2 2 6 J x 15 482
51 Passat model year 1997 to model year 2005 486
51 1 Passat, Passat Variant, type 3B model year 1997 to model year 2000 486
51 2 Passat, Passat Variant, type 3B model year 1997 to model year 2000 488
51 2 1 6 J x 15 488
51 2 2 7 J x 15 489
51 2 3 7 J x 16 490
51 3 Passat, Passat Variant, type 3BG model year 2001 to model year 2005 491
51 4 Wheel allocation for Passat, Passat Variant, type 3BG model year 2001 to model year 2005 492
51 4 1 6 J x 15 493
51 4 2 7 J x 15 494
51 4 3 6 J x 16 494
51 4 4 7 J x 16 495
51 4 5 7 J x 17 497
51 5 Passat W8 4Motion, type 3BS model year 2002 to model year 2005 498
51 6 Wheel allocation for Passat W8 4Motion, type 3BS model year 2002 to model year 2005 499
51 6 1 7 J x 16 499
51 6 2 6 J x 17 500
51 6 3 71/2 J x 17 500
51 7 Passat Protect, type 3BL model year 2002 to model year 2005 501
51 8 Wheel allocation for Passat Protect, type 3BL model year 2002 to model year 2005 502
51 8 1 6 J x 16 502
51 8 2 7 J x 16 502
52 Passat saloon from model year 2006 504
52 1 Passat saloon, type 3C model year 2006 504
52 2 Passat saloon, type 3C model year 2007 to model year 2008 507
52 3 Passat saloon, type 3C model year 2009 515
52 4 Passat saloon, type 3C model year 2010 to model year 2011 522
52 5 Wheel allocation for Passat saloon, type 3C model year 2006 to model year 2011 526
52 5 1 61/2 J x 16 526
52 5 2 7 J x 16 527
52 5 3 6 J x 17 529
52 5 4 71/2 J x 17 529
52 5 5 8 J x 18 532
53 Passat saloon BlueMotion from model year 2008 535
53 1 Passat saloon BlueMotion, type 3C model year 2008 to model year 2009 535
53 2 Passat saloon BlueMotion, type 3C model year 2010 to model year 2011 537
53 3 Wheel allocation for Passat saloon BlueMotion, type 3C model year 2008 to model year 2011 538
53 3 1 61/2 J x 16 538
53 3 2 7 J x 16 539
53 3 3 6 J x 17 541
53 3 4 71/2 J x 17 541
53 3 5 8 J x 18 544
54 Passat Variant from model year 2006 547
54 1 Passat Variant, type 3C model year 2006 547
54 2 Passat Variant, type 3C model year 2007 to model year 2008 551
54 3 Passat Variant, type 3C model year 2009 561
54 4 Passat Variant, type 3C model year 2010 to model year 2011 569
54 5 Wheel allocation for Passat Variant, type 3C model year 2006 to model year 2011 573
54 5 1 61/2 J x 16 573
54 5 2 7 J x 16 574
54 5 3 6 J x 17 576
54 5 4 71/2 J x 17 576
54 5 5 8 J x 18 579
55 Passat Variant BlueMotion from model year 2008 582
55 1 Passat Variant BlueMotion, type 3C model year 2008 to model year 2009 582
55 2 Passat Variant BlueMotion, type 3C model year 2010 to model year 2011 584
55 3 Wheel allocation for Passat Variant BlueMotion, type 3C model year 2008 to model year 2011 585
55 3 1 61/2 J x 16 585
55 3 2 7 J x 16 586
55 3 3 6 J x 17 588
55 3 4 71/2 J x 17 588
55 3 5 8 J x 18 591
56 Passat R36 from model year 2008 594
56 1 Passat R36, type 3C model year 2008 to model year 2009 594
56 2 Passat R36, type 3C model year 2010 to model year 2011 596
56 3 Wheel allocation for Passat R36, type 3C model year 2008 to model year 2011 597
56 3 1 6 J x 17 597
56 3 2 71/2 J x 17 597
56 3 3 8 J x 18 600
56 3 4 8 J x 19 601
57 Sharan from model year 1996 603
57 1 Sharan, Sharan Syncro, type 7M model year 1996 to model year 2000 603
57 2 Wheel allocation for Sharan, Sharan Syncro Type 7M model year 1996 to model year 2000 606
57 2 1 6 J x 15 606
57 2 2 7 J x 15 607
57 2 3 7 J x 16 608
57 3 Sharan, Sharan 4Motion, type 7M model year 2001 608
57 4 Wheel allocation for Sharan, Sharan 4Motion, type 7M model year 2001 611
57 4 1 6 J x 15 611
57 4 2 7 J x 15 611
57 4 3 6 J x 16 612
57 4 4 7 J x 16 613
57 5 Sharan, Sharan 4Motion, type 7M model year 2002 to model year 2010 615
57 6 Wheel allocation for Sharan, Sharan 4Motion, type 7M model year 2002 to model year 2010 616
57 6 1 6 J x 16 617
57 6 2 7 J x 16 617
57 6 3 7 J x 17 619
58 Sharan BlueMotion from model year 2009 621
58 1 Sharan BlueMotion, type 7M model year 2009 to model year 2010 621
58 2 Wheel allocation for Sharan BlueMotion, type 7M model year 2009 to model year 2010 622
58 2 1 6 J x 16 622
59 Touareg from model year 2003 624
59 1 Touareg, type 7L, model year 2003 to model year 2010 624
59 2 Wheel allocation for Touareg, type 7L model year 2003 to model year 2010 628
59 2 1 7 J x 16 628
59 2 2 71/2 J x 17 629
59 2 3 8 J x 18 630
59 2 4 9 J x 19 632
59 2 5 9 J x 20 634
59 2 6 91/2 J x 20 636
60 Touareg R50 from model year 2008 637
60 1 Touareg R50, type 7L model year 2008 to model year 2010 637
60 2 Wheel allocation for Touareg R50, type 7L model year 2008 to model year 2010 638
60 2 1 9 J x 19 638
60 2 2 9 J x 20 640
60 2 3 91/2 J x 20 641
60 2 4 10 J x 21 641
61 Breakdown set for VW Vehicles 643
62 Temporary spare tyres and wheels for VW vehicles 644
63 Recommended summer tyres 646
63 1 Summer tyres for Lupo 3L model year 1999 to model year 2005 646
63 2 Summer tyres for Lupo FSI model year 1999 to model year 2005 646
63 3 Summer tyres for Lupo GTI model year 1999 to model year 2005 646
63 4 Summer tyres for Lupo model year 1999 to model year 2005 646
63 5 Summer tyres for Fox from model year 2005 647
63 6 Summer tyres for Polo model year 1995 to model year 2001 647
63 7 Summer tyres for Polo saloon/sedan model year 2004 to model year 2005 648
63 8 Summer tyres for Polo Classic model year 1996 to model year 2002 648
63 9 Summer tyres for Polo Variant model year 1998 to model year 2002 649
63 10 Summer tyres for Polo from model year 2002 649
63 11 Summer tyres for Polo Fun model year 2004 to model year 2005 650
63 12 Summer tyres for CrossPolo from model year 2006 650
63 13 Summer tyres for Polo BlueMotion from model year 2007 651
63 14 Summer tyres for Polo GTI from model year 2007 651
63 15 Summer tyres for Polo GTI Cup Edition from model year 2007 651
63 16 Summer tyres for Golf, Vento model year 1992 to model year 1998 651
63 17 Summer tyres for Golf Variant model year 1994 to model year 1998 652
63 18 Summer tyres for Golf cabriolet model year 1994 to model year 1997 653
63 19 Summer tyres for Golf, Golf 4Motion model year 1998 to model year 2004 653
63 20 Summer tyres for Golf model year 2004 to model year 2009 654
63 21 Summer tyres for Golf BlueMotion model year 2008 to model year 2009 656
63 22 Summer tyres for Golf GTI model year 2005 to model year 2009 656
63 23 Summer tyres for Pirelli Golf model year 2008 to model year 2009 656
63 24 Summer tyres for Golf R32 model year 2006 to model year 2009 657
63 25 Summer tyres for CrossGolf from model year 2007 657
63 26 Summer tyres for Golf Plus from model year 2005 658
63 27 Summer tyres for Golf Plus BlueMotion from model year 2008 659
63 28 Summer tyres for Bora, Bora 4Motion model year 1999 to model year 2005 659
63 29 Summer tyres for Golf Variant, Golf Variant 4Motion model year 1999 to model year 2006, Bora Variant, Bora Variant 4Motion model year 1999 to model year 2005 660
63 30 Summer tyres for Golf R32 661
63 31 Summer tyres for Golf Anniversary GTI 662
63 32 Summer tyres for Golf Variant model year 2007 to model year 2010 662
63 33 Summer tyres for Golf Variant BlueMotion from model year 2008 663
63 34 Summer tyres for Jetta Model Year 2006 to Model Year 2011 663
63 35 Summer tyres for Jetta BlueMotion Model Year 2008 to Model Year 2011 665
63 36 Summer tyres for Golf cabriolet model year 1998 to model year 2002 666
63 37 Summer tyres for New Beetle from model year 1999 667
63 38 Summer tyres for New Beetle Cabriolet from model year 2003 668
63 39 Summer tyres for New Beetle RSi 668
63 40 Summer tyres for Passat model year 1994 to model year 1997 669
63 41 Summer tyres for Passat model year 1997 to model year 2005 669
63 42 Summer tyres for Passat W8 670
63 43 Summer tyres for Passat Protect 670
63 44 Summer tyres for Passat saloon from model year 2006 670
63 45 Summer tyres for Passat saloon BlueMotion from model year 2008 671
63 46 Summer tyres for Passat Variant from model year 2006 672
63 47 Summer tyres for Passat Variant BlueMotion from model year 2008 673
63 48 Summer tyres for Passat R36 from model year 2008 674
63 49 Summer tyres for Sharan from model year 1996 675
63 50 Summer tyres for Sharan BlueMotion from model year 2009 675
63 51 Summer tyres for Touareg model year 2008 to model year 2010 676
63 52 Summer tyres for Touareg R50 model year 2008 to model year 2010 676
64 Recommended all-season tyres 677
64 1 All-season tyres Lupo model year 1999 to model year 2005 677
64 2 All-season tyres Polo model year 1995 to model year 2001 677
64 3 All-season tyres for Polo from model year 2002 677
64 4 All-season tyres Polo saloon/sedan model year 2004 to model year 2005 678
64 5 All-season tyres Golf, Vento model year 1992 to model year 1998 678
64 6 All-season tyres Golf Variant model year 1994 to model year 1998 678
64 7 All-season tyres Golf cabriolet model year 1994 to model year 1997 678
64 8 All-season tyres Golf, Golf 4Motion model year 1998 to model year 2004 678
64 9 All-season tyres for Golf model year 2004 to model year 2009 679
64 10 All-season tyres for CrossGolf from model year 2007 679
64 11 All-season tyres for Golf Plus from model year 2005 680
64 12 All-season tyres Bora, Bora 4Motion model year 1999 to model year 2005 680
64 13 All-season tyres Golf Variant, Golf Variant 4Motion model year 1999 to model year 2006, Bora Variant, Bora Variant 4Motion model year 1999 to model year 2005 681
64 14 All-season tyres Golf Variant model year 2007 to model year 2010 681
64 15 All-season tyres Jetta Model Year 2006 to Model Year 2011 681
64 16 All-season tyres Golf cabriolet model year 1998 to model year 2002 682
64 17 All-season tyres for New Beetle from model year 1999 682
64 18 All-season tyres for New Beetle Cabriolet from model year 2003 683
64 19 All-season tyres Passat model year 1997 to model year 2005 683
64 20 All-season tyres for Passat W8 683
64 21 All-season tyres for Passat saloon from model year 2006 684
64 22 All-season tyres for Passat saloon BlueMotion from model year 2008 684
64 23 All-season tyres for Passat Variant from model year 2006 684
64 24 All-season tyres for Passat Variant BlueMotion from model year 2008 684
64 25 All-season tyres for Passat R36 from model year 2008 685
64 26 All-season tyres for Touareg model year 2003 to model year 2010 685
65 Recommended winter tyres 686
65 1 Winter tyres Lupo 3L model year 1999 to model year 2005 686
65 2 Winter tyres Lupo FSI model year 1999 to model year 2005 686
65 3 Winter tyres Lupo GTI model year 1999 to model year 2005 686
65 4 Winter tyres Lupo model year 1999 to model year 2005 687
65 5 Winter tyres for Fox from model year 2005 687
65 6 Winter tyres Polo model year 1995 to model year 2001 687
65 7 Winter tyres for Polo from model year 2002 688
65 8 Winter tyres for Polo Fun model year 2004 to model year 2006 688
65 9 Winter tyres for CrossPolo from model year 2006 688
65 10 Winter tyres for Polo BlueMotion from model year 2007 688
65 11 Winter tyres for Polo GTI from model year 2007 689
65 12 Winter tyres for Polo GTI Cup Edition from model year 2007 689
65 13 Winter tyres Polo saloon/sedan model year 2004 to model year 2005 689
65 14 Winter tyres Polo Classic model year 1996 to model year 2002 689
65 15 Winter tyres Polo Variant model year 1998 to model year 2002 690
65 16 Winter tyres Golf, Vento model year 1992 to model year 1998 690
65 17 Winter tyres Golf Variant model year 1994 to model year 1998 691
65 18 Winter tyres Golf cabriolet model year 1994 to model year 1997 691
65 19 Winter tyres Golf, Golf 4Motion model year 1998 to model year 2004 691
65 20 Winter tyres for Golf model year 2004 to model year 2009 692
65 21 Winter tyres for Golf BlueMotion model year 2004 to model year 2009 693
65 22 Winter tyres for Golf GTI model year 2005 to model year 2009 693
65 23 Winter tyres for Pirelli Golf model year 2008 to model year 2009 693
65 24 Winter tyres for Golf R32 model year 2006 to model year 2009 694
65 25 Winter tyres for CrossGolf from model year 2007 694
65 26 Winter tyres for Golf Plus from model year 2005 694
65 27 Winter tyres for Golf Plus BlueMotion from model year 2008 695
65 28 Winter tyres Bora, Bora 4Motion model year 1999 to model year 2005 695
65 29 Winter tyres Golf Variant, Golf Variant 4Motion model year 1999 to model year 2006, Bora Variant, Bora Variant 4Motion model year 1999 to model year 2005 696
65 30 Winter tyres for Golf 32 696
65 31 Winter tyres for Golf Anniversary GTI 696
65 32 Winter tyres Golf Variant model year 2007 to model year 2010 697
65 33 Winter tyres for Golf Variant BlueMotion model year 2008 to model year 2010 697
65 34 Winter tyres Jetta Model Year 2006 to Model Year 2011 698
65 35 Winter tyres Jetta BlueMotion Model Year 2008 to Model Year 2011 698
65 36 Winter tyres Golf cabriolet model year 1998 to model year 2002 698
65 37 Winter tyres for New Beetle from model year 1999 699
65 38 Winter tyres for New Beetle Cabriolet from model year 2003 699
65 39 Winter tyres for New Beetle RSi 700
65 40 Winter tyres Passat model year 1994 to model year 1997 700
65 41 Winter tyres Passat model year 1997 to model year 2005 700
65 42 Winter tyres for Passat W8 701
65 43 Winter tyres for Passat Protect 701
65 44 Winter tyres for Passat saloon from model year 2006 701
65 45 Winter tyres for Passat saloon BlueMotion from model year 2008 702
65 46 Winter tyres for Passat Variant from model year 2006 702
65 47 Winter tyres for Passat Variant BlueMotion from model year 2008 703
65 48 Winter tyres for Passat R36 from model year 2008 703
65 49 Winter tyres for Sharan from model year 1996 704
65 50 Winter tyres for Sharan BlueMotion from model year 2009 704
65 51 Winter tyres for Touareg model year 2003 to model year 2010 704
65 52 Winter tyres for Touareg R50 model year 2008 to model year 2010 704
00 – Technical data 714
1 General notes on wheels and tyres (passenger cars) 714
1 1 Legislative conditions for converting wheel and tyre combinations 715
1 2 Technical conditions for converting wheel and tyre combinations 716
1 3 Official type designations 716
1 3 1 Official type approval, sales or trade designation 716
1 4 General information 718
1 4 1 Special models 718
1 4 2 Vehicles with Plus running gear 718
1 4 3 Speed ratings for tyres 719
1 4 4 “Series 80” tyres 720
1 4 5 Wheel bolts – torque settings 720
1 4 6 Revised wheel bolts for Sharan from model year 2001 720
1 4 7 Wheel rims – pitch circle diameter 721
1 4 8 Data on wheel rims 721
1 4 9 Split rim wheels 722
1 4 10 Alloy wheels with exchangeable trim elements 722
2 Facts about wheels and tyres (passenger cars) 723
2 1 Tyre wear/ mileage 723
2 1 1 General information 723
2 1 2 Requirements to be met by tyres 723
2 1 3 Wear behaviour of high-speed tyres 724
2 1 4 Factors influencing the service life of a tyre 724
2 1 5 Driving style 725
2 1 6 Tyre maintenance 726
2 1 7 Evenly worn tyres 727
2 1 8 Measuring tread depth 727
2 1 9 One-sided wear 728
2 1 10 Wear in middle of tyre 730
2 1 11 Diagonal washout 731
2 2 Tyre noise 732
2 2 1 General notes on tyre noise 732
2 2 2 Saw-tooth wear 733
2 2 3 Flat spots (from locking wheels) 734
2 3 Rough running caused by wheels/tyres 735
2 3 1 Causes of rough running 735
2 3 2 Balancing wheels 735
2 3 3 Conducting a road test before balancing wheels 735
2 3 4 Balancing wheels on stationary wheel balancing machine 736
2 3 5 Vibration control system -VAS 6230- 737
2 3 6 Finish balancer 738
2 3 7 Radial and lateral runout of wheels and tyres 739
2 3 8 Checking radial and lateral runout on wheels and tyres with tyre gauge -V A G 1435- 739
2 3 9 Checking radial and lateral runout on wheel 741
2 3 10 Matching 741
2 3 11 Flat spots caused by storage or handling 743
2 4 Vehicle pulls to one side 744
2 4 1 General information 744
2 4 2 Conicity 744
2 4 3 Remedies when vehicle pulls to one side 746
2 4 4 Strategic rotation of wheels for non-directional tyres 747
2 4 5 Strategic rotation of wheels having unidirectional tyres 748
2 4 6 Tyres with a red spot 748
2 5 Tyre damage 749
2 5 1 General information 749
2 5 2 Construction of a radial belted tyre 750
2 5 3 Impact damage 750
2 5 4 Cuts 752
2 5 5 Damage caused by foreign bodies 752
2 5 6 Loss of air from tyre 753
2 5 7 Tyre pressure 753
2 5 8 Tyre damage due to insufficient tyre pressure 753
2 5 9 Rising tyre temperature caused by insufficient inflation pressure 755
2 5 10 Tyre damage due to fitting error (fitting damage) 756
2 6 Facts about wheels and tyres 758
2 6 1 Identification markings on the tyre sidewall 758
2 6 2 Explanation of tyre markings 760
2 6 3 Undulations 761
2 6 4 The valve 762
2 6 5 Tyre storage 763
2 6 6 Tyre ageing 763
2 6 7 Care and maintenance of alloy wheel rims 764
2 6 8 Rotating wheels 765
2 6 9 Instructions for changing or fitting wheels 765
2 6 10 Tyres with flange protection 766
2 6 11 Notes on use of temporary spare wheels 767
2 6 12 M+S tyres 768
2 6 13 Winter tyres with speed symbol “V” 769
2 6 14 Extra Load (XL) V winter tyres 769
2 6 15 Reinforced and Extra Load (XL) tyres 772
2 6 16 Snow chains 772
44 – Wheels, tyres, vehicle geometry 773
1 Lupo 3L, Lupo FSI, Lupo GTI from model year 1999 773
1 1 Lupo 3L, type 6E model year 1999 to model year 2006 773
1 2 Wheel allocation for Lupo 3L, type 6E model year 1999 to model year 2006 774
1 2 1 4 J x 14 774
1 2 2 41/2 J x 14 775
1 2 3 5 J x 14 775
1 3 Lupo FSI, type 6E model year 2001 to model year 2006 775
1 4 Wheel allocation for Lupo FSI, type 6E model year 2001 to model year 2006 776
1 4 1 5 J x 14 776
1 4 2 6 J x 14 777
1 5 Lupo GTI, type 6ES model year 2001 to model year 2006 779
1 6 Wheel allocation for Lupo GTI, type 6ES model year 2001 to model year 2006 780
1 6 1 6 J x 14 780
1 6 2 61/2 J x 15 781
2 Lupo model year 1999 to model year 2005 783
2 1 Lupo, type 6X model year 1999 to model year 2005 783
2 2 Wheel allocation for Lupo, type 6X model year 1999 to model year 2005 785
2 2 1 41/2 J x 13 785
2 2 2 51/2 J x 13 786
2 2 3 6 J x 14 788
2 2 4 6 J x 15 791
3 Fox model year 2006 793
3 1 Fox, type 5Z model year 2006 793
3 2 Wheel allocation for Fox, type 5Z model year 2006 794
3 2 1 5 J x 14 794
3 2 2 6 J x 14 795
3 2 3 6 J x 15 797
4 Polo model year 1995 to model year 2002 800
4 1 Polo, type 6N up to and including 07 95 800
4 2 Wheel allocation for Polo, type 6N up to and including 07 95 801
4 2 1 41/2 J x 13 801
4 2 2 51/2 J x 13 802
4 3 Polo, type 6N from 08 95 up to and including model year 1996 803
4 4 Polo, type 6N from model year 1997 to model year 1999 804
4 5 Wheel allocation for Polo, type 6N from 08 95 to model year 1999 806
4 5 1 41/2 J x 13 806
4 5 2 51/2 J x 13 807
4 5 3 6 J x 14 808
4 5 4 6 J x 15 810
4 6 Polo, type 6N from model year 2000 to model year 2002 812
4 7 Wheel allocation for Polo, type 6N from model year 2000 to model year 2002 813
4 7 1 41/2 J x 13 813
4 7 2 51/2 J x 13 814
4 7 3 6 J x 14 815
4 7 4 6 J x 15 817
5 Polo from model year 2002 820
5 1 Polo, type 9N model year 2002 to model year 2006 820
5 2 Wheel allocation for Polo, type 9N model year 2002 to model year 2006 822
5 2 1 5 J x 13 823
5 2 2 5 J x 14 823
5 2 3 6 J x 14 824
5 2 4 6 J x 15 825
5 2 5 61/2 J x 16 827
6 Polo Fun from model year 2004 831
6 1 Polo Fun, type 9N model year 2002 to model year 2006 831
6 2 Wheel allocation for Polo Fun, type 9N model year 2004 to model year 2006 832
6 2 1 6 J x 15 832
6 2 2 71/2 J x 17 833
7 Polo Classic model year 1996 to model year 2002 834
7 1 Polo Classic, type 6KV model year 1996 to model year 2002 834
7 2 Wheel allocation for Polo Classic, type 6KV model year 1996 to model year 2002 836
7 2 1 51/2 J x 13 836
7 2 2 6 J x 14 837
7 2 3 6 J x 15 839
8 Polo estate model year 1998 to model year 2002 841
8 1 Polo estate type 6KV model year 1998 to model year 2002 841
8 2 Wheel allocation for Polo estate type 6KV model year 1998 to model year 2002 843
8 2 1 51/2 J x 13 843
8 2 2 6 J x 14 844
8 2 3 6 J x 15 846
9 Polo saloon/sedan model year 2004 to model year 2005 848
9 1 Polo saloon/sedan, type 9N model year 2004 to model year 2005 848
9 2 Wheel allocation for Polo saloon/sedan, type 9N model year 2004 to model year 2005 850
9 2 1 5 J x 14 850
9 2 2 6 J x 14 850
9 2 3 6 J x 15 852
9 2 4 61/2 J x 16 854
10 Golf model year 1992 to model year 1998 856
10 1 Golf type 1HX0, Golf Syncro 1HX1, Golf type 1H 856
10 2 Wheel allocation for Golf type 1HX0, Golf Syncro 1HX1, Golf type 1H 859
10 2 1 51/2 J x 13 860
10 2 2 6 J x 14 861
10 2 3 6 J x 15 865
10 2 4 61/2 J x 15 869
10 2 5 7 J x 16 873
11 Golf model year 1998 to model year 2004, Golf R32, Golf Anniversary GTI 874
11 1 Golf, Golf 4Motion, type 1J model year 1998 to model year 2004 874
11 2 Wheel allocation for Golf, Golf 4Motion, type 1J model year 1998 to model year 2004 877
11 2 1 6 J x 14 877
11 2 2 6 J x 15 878
11 2 3 51/2 J x 16 883
11 2 4 61/2 J x 16 884
11 2 5 7 J x 17 890
11 2 6 71/2 J x 17 893
11 3 Conditions for fitting 17″ wheels and tyres to Golf model year 1998 to model year 2004 893
11 4 Golf R32, type 1J model year 2003 to model year 2005 894
11 5 Wheel allocation for Golf R32, type 1J model year 2003 to model year 2005 895
11 5 1 51/2 J x 17 895
11 5 2 71/2 J x 17 896
11 5 3 71/2 J x 18 897
11 6 Golf Anniversary GTI, type 1J model year 2002 897
11 7 Wheel allocation for Golf Anniversary GTI, type 1J model year 2002 898
11 7 1 51/2 J x 16 898
11 7 2 61/2 J x 16 899
11 7 3 7 J x 17 901
11 7 4 71/2 J x 18 903
11 8 Conditions for fitting 17″ and 18″ wheels and tyres of Golf Anniversary GTI 904
12 Golf from model year 2004 906
12 1 Golf, Golf 4Motion, type 1K model year 2004 to model year 2006 906
12 2 Wheel allocation for Golf, Golf 4Motion, type 1K model year 2004 to model year 2006 908
12 2 1 6 J x 15 908
12 2 2 61/2 J x 15 909
12 2 3 6 J x 16 910
12 2 4 61/2 J x 16 911
12 2 5 7 J x 17 913
12 2 6 71/2 J x 17 916
12 2 7 71/2 J x 18 916
12 3 Golf GTI, type 1K model year 2005 to model year 2006 917
12 4 Wheel allocation for Golf GTI, type 1K model year 2005 to model year 2006 918
12 4 1 6 J x 16 918
12 4 2 61/2 J x 16 919
12 4 3 6 J x 17 920
12 4 4 7 J x 17 921
12 4 5 71/2 J x 17 924
12 4 6 71/2 J x 18 924
13 Golf Plus from model year 2005 926
13 1 Golf Plus, type 1KP model year 2005 to model year 2006 926
13 2 Wheel allocation for Golf Plus, type 1KP model year 2005 to model year 2006 928
13 2 1 6 J x 15 928
13 2 2 61/2 J x 15 929
13 2 3 6 J x 16 930
13 2 4 61/2 J x 16 931
13 2 5 7 J x 17 933
13 2 6 71/2 J x 18 936
14 Golf estate model year 1994 to model year 1998 938
14 1 Golf estate type 1HX0, Golf estate Syncro type 1HX1, Golf estate type 1H 938
14 2 Wheel allocation for Golf estate type 1HX0, Golf estate Syncro type 1HX1, Golf estate type 1H 941
14 2 1 51/2 J x 13 941
14 2 2 6 J x 14 942
14 2 3 6 J x 15 947
14 2 4 61/2 J x 15 951
15 Golf estate model year 1999 to model year 2006, Bora estate model year 1999 to model year 2005 952
15 1 Golf estate, Golf estate 4Motion, Bora estate, Bora estate 4Motion, type 1J 952
15 2 Wheel allocation for Golf estate, Golf estate 4Motion, Bora estate, Bora estate 4Motion, type 1J 955
15 2 1 6 J x 15 955
15 2 2 51/2 J x 16 959
15 2 3 61/2 J x 16 960
15 2 4 7 J x 17 966
15 2 5 71/2 J x 17 969
15 3 Conditions for fitting 17″ wheels and tyres 970
16 Golf cabriolet model year 1994 to model year 1997 972
16 1 Golf cabriolet type 1EX0 model year 1994 to model year 1997 972
16 2 Wheel allocation for Golf cabriolet, type 1EX0 from model year 1994 to model year 1997 973
16 2 1 6 J x 14 974
16 2 2 6 J x 15 975
16 2 3 61/2 J x 16 976
17 Golf cabriolet model year 1998 to model year 2002 978
17 1 Golf cabriolet; type 1E from model year 1998 to model year 2002 978
17 2 Wheel allocation for Golf cabriolet; type 1E from model year 1998 to model year 2002 979
17 2 1 6 J x 14 979
17 2 2 6 J x 15 982
17 2 3 61/2 J x 16 984
18 Vento from model year 1992 to model year 1998 985
18 1 Vento; type 1HX0, 1H 985
18 2 Wheel allocation for Vento; type 1HX0, 1H 987
18 2 1 51/2 J x 13 987
18 2 2 6 J x 14 989
18 2 3 6 J x 15 992
18 2 4 61/2 J x 15 995
19 Bora model year 1999 to model year 2005 1001
19 1 Bora, Bora 4Motion, type 1J model year 1999 to model year 2005 1001
19 2 Wheel allocation for Bora, Bora 4Motion, type 1J model year 1999 to model year 2005 1004
19 2 1 6 J x 15 1004
19 2 2 51/2 J x 16 1008
19 2 3 61/2 J x 16 1009
19 2 4 7 J x 17 1015
19 2 5 71/2 J x 17 1018
19 3 Conditions for fitting 17″ wheels and tyres 1019
20 Jetta from model year 2006 1021
20 1 Jetta, type 1KM from model year 2006 1021
20 2 Wheel allocation for Jetta, type 1KM from model year 2006 1023
20 2 1 6 J x 15 1023
20 2 2 61/2 J x 15 1024
20 2 3 6 J x 16 1024
20 2 4 61/2 J x 16 1025
20 2 5 7 J x 17 1027
21 New Beetle from model year 1999 1031
21 1 New Beetle, type 9C model year 1999 to model year 2006 1031
21 2 Wheel allocation for New Beetle, type 9C model year 1999 to model year 2006 1034
21 2 1 6 J x 15 1034
21 2 2 51/2 J x 16 1037
21 2 3 61/2 J x 16 1038
21 2 4 7 J x 17 1043
21 2 5 71/2 J x 17 1046
21 3 Conditions for fitting 17″ wheels and tyres 1047
22 New Beetle Cabriolet from model year 2003 1049
22 1 New Beetle Cabriolet, type 1Y, model year 2003 to model year 2006 1049
22 2 Wheel allocation for New Beetle Cabriolet, type 1Y model year 2003 to model year 2006 1051
22 2 1 6 J x 15 1051
22 2 2 51/2 J x 16 1054
22 2 3 61/2 J x 16 1055
22 2 4 7 J x 17 1059
22 2 5 71/2 J x 17 1063
22 3 Conditions for fitting 17″ wheels and tyres 1063
23 New Beetle RSi 1065
23 1 New Beetle RSi, type 9CR from model year 2001 1065
23 2 Wheel allocation for New Beetle RSi, type 9CR from model year 2001 1066
23 2 1 7 J x 16 1066
23 2 2 9 x 18 1067
24 Touran from model year 2003 1068
24 1 Touran, type 1T, model year 2003 to model year 2006 1068
24 2 Wheel allocation for Touran, type 1T model year 2003 to model year 2006 1071
24 2 1 6 J x 15 1071
24 2 2 61/2 J x 15 1072
24 2 3 6 J x 16 1073
24 2 4 61/2 J x 16 1074
24 2 5 7 J x 17 1076
25 Passat model year 1994 to model year 1997 1077
25 1 Passat, type 35l model year 1994 to model year 1997 1077
25 2 Wheel allocation for Passat, type 35l model year 1994 to model year 1997 1079
25 2 1 6 J x 14 1079
25 2 2 6 J x 15 1082
26 Passat model year 1997 to model year 2006 1087
26 1 Passat, Passat estate, type 3B model year 1997 to model year 2000 1087
26 2 Passat, Passat estate, type 3B model year 1997 to model year 2000 1089
26 2 1 6 J x 15 1089
26 2 2 7 J x 15 1091
26 2 3 7 J x 16 1092
26 3 Passat, Passat estate, type 3BG model year 2001 to model year 2006 1093
26 4 Wheel allocation for Passat, Passat estate, type 3BG model year 2001 to model year 2006 1095
26 4 1 6 J x 15 1095
26 4 2 7 J x 15 1096
26 4 3 6 J x 16 1098
26 4 4 7 J x 16 1099
26 4 5 7 J x 17 1101
26 5 Passat W8 4Motion, type 3BS model year 2002 to model year 2005 1102
26 6 Wheel allocation for Passat W8 4Motion, type 3BS model year 2002 to model year 2005 1103
26 6 1 7 J x 16 1104
26 6 2 6 J x 17 1104
26 6 3 71/2 J x 17 1105
26 7 Passat Protect, type 3BL model year 2002 to model year 2005 1105
26 8 Wheel allocation for Passat Protect, type 3BL model year 2002 to model year 2005 1106
26 8 1 6 J x 16 1107
26 8 2 7 J x 16 1107
27 Passat from model year 2006 1109
27 1 Passat, type 3C from model year 2006 1109
27 2 Wheel allocation for Passat, type 3C from model year 2006 1111
27 2 1 61/2 J x 16 1112
27 2 2 7 J x 16 1112
27 2 3 6 J x 17 1114
27 2 4 71/2 J x 17 1114
27 2 5 8 J x 18 1117
28 Phaeton from model year 2003 1119
28 1 Phaeton, type 3D, model year 2003 to model year 2006 – short and long wheelbase 1119
28 2 Wheel allocation for Phaeton, type 3D model year 2003 to model year 2006 – short and long wheelbase 1121
28 2 1 71/2 J x 16 1122
28 2 2 71/2 J x 17 1122
28 2 3 71/2 J x 18 1124
28 2 4 81/2 J x 18 1124
28 2 5 81/2 J x 19 1126
28 2 6 9 J x 19 1126
29 Sharan from model year 1996 1127
29 1 Sharan, Sharan Syncro, type 7M model year 1996 to model year 2000 1127
29 2 Wheel allocation for Sharan, Sharan Syncro Type 7M model year 1996 to model year 2000 1130
29 2 1 6 J x 15 1130
29 2 2 7 J x 15 1130
29 2 3 7 J x 16 1131
29 3 Sharan, Sharan 4Motion, type 7M model year 2001 1132
29 4 Wheel allocation for Sharan, Sharan 4Motion, type 7M model year 2001 1134
29 4 1 6 J x 15 1134
29 4 2 7 J x 15 1135
29 4 3 6 J x 16 1136
29 4 4 7 J x 16 1137
29 5 Sharan, Sharan 4Motion, type 7M model year 2002 to model year 2006 1140
29 6 Wheel allocation for Sharan, Sharan 4Motion, type 7M model year 2002 to model year 2006 1142
29 6 1 6 J x 16 1142
29 6 2 7 J x 16 1143
29 6 3 7 J x 17 1146
30 Touareg from model year 2003 1147
30 1 Touareg, type 7L, model year 2003 to model year 2006 1147
30 2 Wheel allocation for Touareg, type 7L model year 2003 to model year 2006 1150
30 2 1 7 J x 16 1150
30 2 2 71/2 J x 17 1151
30 2 3 8 J x 18 1152
30 2 4 9 J x 19 1155
30 2 5 9 J x 20 1159
30 2 6 91/2 J x 20 1160
31 Breakdown set for VW Vehicles 1161
32 Temporary spare tyres and wheels for VW vehicles 1162
33 Approved makes of summer tyres for initial fitting 1165
33 1 Summer tyres for Lupo 3L from model year 1999 1165
33 2 Summer tyres for Lupo FSI from model year 1999 1165
33 3 Summer tyres for Lupo GTI from model year 1999 1165
33 4 Summer tyres for Lupo model year 1999 to model year 2005 1165
33 5 Summer tyres for Fox from model year 2006 1165
33 6 Summer tyres for Polo, model year 1995 to model year 2002 1166
33 7 Summer tyres for Polo from model year 2002 1167
33 8 Summer tyres for Polo saloon/sedan from model year 2004 1167
33 9 Summer tyres for Polo Fun from model year 2004 1168
33 10 Summer tyres for Polo Classic model year 1996 to model year 2002 1168
33 11 Summer tyres for Polo estate model year 1998 to model year 2002 1169
33 12 Summer tyres for Golf, Vento model year 1992 to model year 1998 1169
33 13 Summer tyres for Golf estate model year 1994 to model year 1998 1170
33 14 Summer tyres for Golf cabriolet model year 1994 to model year 1997 1170
33 15 Summer tyres for Golf, Golf 4Motion model year 1998 to model year 2004 1171
33 16 Summer tyres for Bora, Bora 4Motion model year 1999 to model year 2005 1172
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 1173
33 18 Summer tyres for Golf R32 1173
33 19 Summer tyres for Golf Anniversary GTI 1174
33 20 Summer tyres for Golf Cabriolet, model year 1998 to model year 2002 1174
33 21 Summer tyres for New Beetle from model year 1999 1175
33 22 Summer tyres for New Beetle Cabriolet from model year 2003 1176
33 23 Summer tyres for New Beetle RSi 1177
33 24 Summer tyres for Golf from model year 2004 1177
33 25 Summer tyres for Golf GTI from model year 2005 1178
33 26 Summer tyres for Golf Plus from model year 2005 1178
33 27 Summer tyres for Jetta from model year 2006 1179
33 28 Summer tyres for Touran from model year 2003 1179
33 29 Summer tyres for Passat model year 1994 to model year 1997 1180
33 30 Summer tyres for Passat model year 1997 to model year 2006 1180
33 31 Summer tyres for Passat W8 1181
33 32 Summer tyres for Passat Protect 1181
33 33 Summer tyres for Passat from model year 2006 1181
33 34 Summer tyres for Phaeton from model year 2003 1182
33 35 Summer tyres for Sharan from model year 1996 1182
33 36 Summer tyres for Touareg from model year 2003 1183
34 Approved makes of all-season tyres for initial fitting 1184
34 1 All-season tyres for Lupo, model year 1999 to model year 2005 1184
34 2 All-season tyres Polo model year 1995 to model year 2002 1184
34 3 All-season tyres from model year 2002 1184
34 4 Summer tyres for Polo saloon/sedan from model year 2004 1184
34 5 All-season tyres Golf, Vento model year 1992 to model year 1998 1184
34 6 All-season tyres Golf estate model year 1994 to model year 1998 1184
34 7 All-season tyres Golf cabriolet model year 1994 to model year 1997 1185
34 8 All-season tyres Golf, Golf 4Motion model year 1998 to model year 2004 1185
34 9 All-season tyres Bora, Bora 4Motion model year 1999 to model year 2005 1185
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 1186
34 11 All-season tyres Golf cabriolet model year 1998 to model year 2002 1186
34 12 All-weather tyres New Beetle from model year 1999 1186
34 13 All-weather tyres New Beetle Cabriolet from model year 2003 1186
34 14 All-weather tyres Golf from model year 2004 1187
34 15 All-season tyres for Golf Plus from model year 2005 1187
34 16 All-season tyres for Jetta from model year 2006 1187
34 17 All-weather tyres Touran from model year 2003 1188
34 18 All-season tyres for Passat, model year 1997 to model year 2006 1188
34 19 All-season tyres for Passat W8 1188
34 20 All-weather tyres Passat from model year 2006 1188
34 21 All-weather tyres Phaeton from model year 2003 1189
34 22 All-weather tyres Touareg from model year 2003 1189
35 Approved makes of winter tyres for initial fitting 1190
35 1 Winter tyres for Lupo 3L from model year 1999 1190
35 2 Winter tyres for Lupo FSI from model year 1999 1190
35 3 Winter tyres for Lupo GTI from model year 1999 1190
35 4 Winter tyres Lupo model year 1999 to model year 2005 1190
35 5 Winter tyres for Fox from model year 2006 1190
35 6 Winter tyres for Polo model year 1995 to model year 2002 1191
35 7 Winter tyres Polo from model year 2002 1191
35 8 Summer tyres for Polo saloon/sedan from model year 2004 1191
35 9 Summer tyres for Polo Fun from model year 2004 1192
35 10 Winter tyres Polo Classic model year 1996 to model year 2002 1192
35 11 Winter tyres Polo estate model year 1998 to model year 2002 1192
35 12 Winter tyres Golf, Vento model year 1992 to model year 1998 1193
35 13 Winter tyres Golf estate model year 1994 to model year 1998 1193
35 14 Winter tyres Golf cabriolet model year 1994 to model year 1997 1193
35 15 Winter tyres Golf, Golf 4Motion model year 1998 to model year 2004 1194
35 16 Winter tyres Bora, Bora 4Motion model year 1999 to model year 2005 1194
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 1195
35 18 Winter tyres for Golf R32 1195
35 19 Winter tyres for Golf Anniversary GTI 1195
35 20 Winter tyres Golf cabriolet model year 1998 to model year 2002 1195
35 21 Winter tyres New Beetle from model year 1999 1196
35 22 Winter tyres New Beetle Cabriolet from model year 2003 1196
35 23 Winter tyres for New Beetle RSi 1197
35 24 Winter tyres Golf from model year 2004 1197
35 25 Winter tyres for Golf GTI from model year 2005 1197
35 26 Winter tyres for Golf Plus from model year 2005 1197
35 27 Winter tyres for Jetta from model year 2006 1197
35 28 Winter tyres Touran from model year 2003 1198
35 29 Winter tyres for Passat model year 1994 to model year 1997 1198
35 30 Winter tyres for Passat model year 1997 to model year 2006 1198
35 31 Winter tyres for Passat W8 1199
35 32 Winter tyres for Passat Protect 1199
35 33 Winter tyres Passat from model year 2006 1199
35 34 Winter tyres Phaeton from model year 2003 1199
35 35 Winter tyres Sharan from model year 1996 1200
35 36 Winter tyres Touareg from model year 2003 1200
36 Approved makes of offroad tyres for initial fitting 1201
36 1 Offroad tyres for Touareg from model year 2003 1201
00 – Technical data 1208
1 Technical data 1208
1 1 Engine number 1208
1 2 Engine data 1208
10 – Removing and installing engine 1209
1 Removing and installing engine 1209
1 1 Removing 1210
1 2 Installing 1212
1 3 Torque settings 1214
1 4 Additional notes and assembly work for vehicles with air conditioner 1215
13 – Crankshaft group 1217
1 Dismantling and assembling engine 1217
1 1 Assembly overview – parts l and ll 1217
1 2 Part I Assembly overview – belt drive 1219
1 3 Part II: Assembly overview – chain drive system 1220
1 4 Removing and installing poly V-belt 1222
1 4 1 Poly V-belt routing 1223
1 5 Removing and installing valve timing housing 1223
2 Cylinder block, sealing flange 1227
2 1 Assembly overview 1227
2 2 Renewing crankshaft oil seal – belt pulley end 1229
2 3 Poly V-belt pulley securing bolt tightening procedure 1230
2 4 Characteristics of the sealing flange and the assembly device -T10017- and -T10134- 1233
2 5 Renewing crankshaft sealing flange – flywheel end (assembly tool -T10134-) 1234
2 5 1 Pressing sealing flange with sender wheel off crankshaft 1235
2 5 2 Pressing sealing flange with sender wheel onto crankshaft 1236
2 5 3 A – Assembling sealing flange with sender wheel on assembly appliance -T10134- 1237
2 5 4 B – Attaching assembling tool -T10134- with sealing flange to crankshaft flange 1238
2 5 5 C – Bolting assembly tool -T10134- onto crankshaft flange 1239
2 5 6 D – Pressing sender wheel onto crankshaft flange using assembly tool -T10134- 1240
2 5 7 E – Checking sender wheel installation position on crankshaft 1240
2 5 8 F – Re-pressing sender wheel 1241
2 6 Renewing crankshaft sealing flange – flywheel end (assembly tool -T10017-) 1242
2 6 1 Pressing sealing flange with sender wheel off crankshaft 1243
2 6 2 Pressing sealing flange with sender wheel onto crankshaft 1244
2 6 3 A-Assembling sealing flange with sender wheel on assembly appliance -T10017- 1244
2 6 4 B-Assembling appliance -T10017- with sealing flange on crankshaft flange 1246
2 6 5 C-Fitting assembly appliance -T10017- onto crankshaft flange 1247
2 6 6 D-Pressing sender wheel onto crankshaft flange with assembly appliance -T10017- 1248
2 6 7 E – Checking sender wheel installation position on crankshaft 1248
2 6 8 F – Pressing sender wheel 1249
2 7 Crankshaft dimensions 1249
3 Pistons and conrods 1251
3 1 Assembly overview 1251
3 2 Checking piston 1252
3 3 Checking cylinder bores 1253
3 4 Piston and cylinder dimensions 1253
15 – Cylinder head, valve gear 1254
1 Cylinder head 1254
1 1 Assembly overview 1254
1 2 Checking valve timing 1257
1 3 Adjusting valve timing 1258
1 4 Removing and installing timing chain and chain drive for oil pump 1262
1 5 Removing and installing camshaft housing 1270
1 6 Removing and installing cylinder head 1274
1 7 Checking compression 1277
2 Valve gear 1279
2 1 Assembly overview 1279
2 2 Checking camshaft axial clearance 1281
2 3 Reworking valve seats 1281
2 4 Checking valve guides 1283
2 5 Renewing valve stem seals 1283
17 – Lubrication 1286
1 Parts of lubrication system 1286
1 1 Engine oil 1286
1 2 Assembly overview 1286
1 3 Removing and installing sump 1289
1 4 Removing and installing oil pump 1290
1 5 Checking oil pressure and oil pressure switch 1292
19 – Cooling 1295
1 Parts of cooling system 1295
1 1 Assembly overview – parts of cooling system, body side 1295
1 2 Assembly overview – parts of cooling system, engine side 1297
1 3 Coolant hose schematic diagram 1299
1 4 Draining and filling coolant 1300
1 5 Removing and installing radiator 1302
1 6 Removing and installing coolant pump 1303
20 – Fuel supply system 1306
1 Parts of fuel supply system 1306
1 1 Assembly overview – fuel tank with attachments 1306
1 2 Safety precautions when working on fuel supply system 1309
1 3 Rules for cleanliness 1309
1 4 Removing and installing fuel delivery unit 1309
1 5 Removing and installing fuel gauge sender G 1311
1 6 Removing and installing fuel tank 1312
1 7 Assembly overview – fuel filter with attachments 1314
1 8 Removing and installing fuel filter 1315
1 9 Crash fuel shut-off 1316
1 10 Checking fuel pump 1316
1 11 Bleeding fuel system 1321
2 Electronic power control (EPC) 1324
2 1 Assembly overview 1324
3 Activated charcoal filter system 1325
3 1 Assembly overview 1325
3 2 Checking fuel tank breather 1326
24 – Mixture preparation – injection 1327
1 Injection system 1327
1 1 General notes on injection 1327
1 2 Assembly overview – intake manifold 1327
1 3 Assembly overview – fuel rail with injectors 1329
1 4 Removing and installing injectors 1329
1 5 Assembly overview – air filter 1330
1 6 Removing and installing air filter housing 1332
1 7 Cleaning throttle valve module -J338- 1333
1 8 Safety precautions 1334
1 9 Rules for cleanliness 1335
1 10 Technical data 1335
2 Checking components 1336
2 1 Checking injectors for leaks and quantity injected 1336
2 1 1 Checking for leaks 1336
2 1 2 Checking quantity injected 1337
2 2 Checking fuel pressure regulator and holding pressure 1338
3 Engine control unit -J623- 1341
3 1 Removing and installing engine control unit -J623- 1341
3 2 Vehicles with anti-theft secured engine control unit -J623- 1341
26 – Exhaust system 1343
1 Parts of the exhaust system 1343
1 1 Assembly overview – catalytic converters and attachments 1343
1 2 Assembly overview – silencers with mountings 1345
28 – Ignition system 1346
1 Ignition system 1346
1 1 Assembly overview – ignition system 1346
1 2 Removing and installing ignition coils with output stage 1347
1 3 Safety precautions 1348
1 4 Spark plug test data 1349
1 Safety instructions 1354
1 1 Part removal 1354
1 2 Battery and welding operation 1354
1 3 Electronic control unit 1354
1 3 1 Processing of the electronic control unit after repair dueto a traffic accident 1354
1 4 Paint, glass, soft pad and trim 1355
1 5 Fuel tank or fuel delivery pipeline 1355
1 6 Air conditioner 1355
1 6 1 Remedial measures: 1355
1 7 Airbag System 1356
1 8 Check the seat belts 1356
1 8 1 Belt body 1357
1 8 2 Automatic retractor (locking function) 1357
1 8 3 Visual inspection of the seat belt buckle 1358
1 8 4 Seat belt buckle function 1358
1 8 5 Seat belt guide member and tongue 1359
1 8 6 Fixing piece and fixing point 1359
1 9 Safety specifications for the seat belt tensioner 1359
1 10 Body repair on a vehicle equipped with the seat belt tensioners 1360
1 10 1 The following vehicles have been equipped with: 1360
1 11 Perform cutting off, correcting and/or leveling on a vehicleequipped with airbags 1361
1 12 Remove the front seats with a side airbag 1361
2 Basic instruction 1362
2 1 Diagnosis of the accident vehicle 1362
2 2 Condition of the body and/or the parts for delivery to thepainting workshop 1362
2 3 Correction 1362
2 4 Cutting 1362
2 5 Body-cut part and part section 1362
2 6 Original connection 1363
2 7 Galvanized body parts 1363
2 8 Remove the rest part 1363
2 9 New parts 1363
2 10 Parts 1363
2 11 Molded foam plastic pads 1364
3 Symbolic interpretation 1365
3 1 Symbolic interpretation for welding 1365
3 2 Symbolic interpretation for the operation method 1365
3 2 1 Grinding 1366
3 2 2 Thinning 1366
3 2 3 Punching 1366
3 2 4 Drilling 1367
3 2 5 Polishing 1367
3 2 6 Cavity corrosion protection 1367
3 2 7 Bonding 1368
3 2 8 Precise sealing 1368
4 Body repair tools 1369
4 1 Flaring tool -V A G 1317- 1369
4 2 Punching pliers -V A G 1329- 1369
4 3 Basic equipment -V A G 1366/3- 1369
4 4 Bottom protection layer spray gun -V A G 1379- 1370
4 5 Electric blower -V A G 1416- 1370
4 6 Door tensioner -V A G 1438- 1370
4 7 Body equipment component -V A G 1439- 1371
4 8 Pneumatic cutting knife -V A G 1523 A- 1371
4 9 Air chisel -V A G 1577- 1371
4 10 Edge closing iron block -V A G 1585- 1372
4 11 Welding fume ventilator -V A G 1586- 1372
4 12 Welding spot releasing device -V A G 1731- 1372
4 13 Pneumatic spray gun -V A G 1761/1- 1373
4 14 Pneumatic punching and thinning pliers -VAS 1996- 1373
4 15 Pneumatic adhesive spray gun -V A G 2005- 1373
4 16 Door hinge correction tool 1374
4 17 Hose kit 5023 for the inert gas protection welding 1374
4 18 Angle grinder -VAS 5174- 1374
4 19 Angle grinder -VAS 5175- 1375
4 20 Wire brush -VAS 5182- 1375
5 Body bonding 1376
5 1 Transporter 1991 → 1376
5 1 1 Separation process: 1376
5 1 2 Bonding process: 1376
5 2 Bonding types 1376
5 2 1 Bonding-strong 1376
5 2 2 Bonding-spot welding 1377
5 3 Repair method for replacing the parts 1377
5 3 1 Spot welding and bonding 1377
5 3 2 Plug welding and bonding (if spot welding is impossible) 1377
5 3 3 Welding fume ventilator 1378
5 3 4 Preparations 1378
5 3 5 Trimming 1378
6 Corrosion protection measures 1379
6 1 Corrosion protection 1379
7 Waste disposal instructions 1380
7 1 Waste disposal 1380
7 2 Air pressure tappet exhaust 1380
7 3 Airbag 1381
7 3 1 Waste disposal 1381
8 Contact corrosion protection 1382
8 1 Connection of aluminum alloy/magnesium alloy with steel 1382
9 Steel plate repair 1383
9 1 High-strength body plate 1383
9 2 Galvanized body parts 1383
9 2 1 Preparations 1383
9 2 2 Part cutting 1384
9 2 3 Connection process 1384
9 3 Welding on the galvanized body steel plate 1384
9 3 1 Inert gas protection plug welding SG of the galvanized steelplate 1384
9 3 2 Resistance pressure spot welding RP of the galvanized steelplate 1385
9 3 3 Welding transformer 1385
9 3 4 Welding clamp 1385
9 4 Tearing test 1385
10 Aluminum repair 1386
10 1 Painting 1386
10 2 Surface treatment 1386
10 3 Leveling 1387
10 4 Temperature control for heating 1387
11 Plastic repair method 1388
11 1 Material 1388
11 2 Repairing the pit 1389
11 3 Repairing the scratch 1390
11 4 Repair the crack 1392
11 5 Repairing the small hole (the diameter is more than 30 mm) 1393
11 6 Plastic repair (glass fibre material) 1394
11 7 Repair process 1395
11 7 1 Repairing the breakage position 1395
11 7 2 Repairing the surface damage 1397
12 Glass repair 1398
12 1 Repairing the windshield 1398
12 1 1 Premises 1398
12 1 2 Required special tools, operating equipment, testing instrumentsand auxiliary tools 1399
12 1 3 Repair description 1400
00 – Technical data 1410
1 Safety information 1410
1 1 Safety precautions when painting natural gas-powered vehicles 1410
1 2 Safety precautions when painting electric drive vehicles 1411
2 General information 1412
2 1 Paintwork structure of a factory finish 1412
2 2 Paint structure of service department finish 1415
2 2 1 Paintwork structure, base coat 1415
2 2 2 Paintwork structure, metallic effect 1418
2 3 Fundamental approach to dealing with areas sanded through to the substrate (bare metal surface) 1420
2 4 Reduced paint structure in engine compartment and inside of bonnet 1420
2 5 Instructions for work on underbody and stone chip protection 1420
2 6 Work instruction for window flange area 1422
2 7 Pre-treatment of bonded surfaces when renewing laser-welded roofs 1424
2 8 Corrosion protection measures for wing surface in contact with wheel housing liner 1428
2 9 Notes on treating corroded fold areas 1429
2 10 Corrosion protection for body components, add-on components and welded components 1431
2 11 Painting parking aid sensor 1432
2 12 ACC – Adaptive Cruise Control 1434
2 13 Instructions for painting bumper cover in area of lane change assist control unit 1434
3 Genuine products 1436
3 1 Paint products in customer service 1436
3 2 General application instructions for repair and painting systems 1437
3 2 1 Aqua Premium – application instructions for water-based products 1437
3 2 2 Setting gloss level of HS clear coats and HS top coats with matting additive 1440
3 2 3 Setting gloss level of 2-pack HS clear coats with 2-pack clear coat, matt 1450
3 2 4 Repair paintwork system for matt-finished vehicles 1452
3 2 5 Paintwork system for plastic components 1457
3 2 6 Aqua Premium system, blending system for 2-stage colours 1465
3 2 7 Aqua Premium system, blending system for 3-stage colours 1474
3 2 8 Aqua Premium system, product preparation for processing 1481
3 2 9 Aquaplus design and multi-colour painting 1488
3 2 10 Processing instructions for paint with limited hiding power 1493
3 3 Filler 1493
3 3 1 2-pack steel filler set 1493
3 3 2 2-pack fine filler 1497
3 3 3 2-pack fine filler, flexible 1501
3 3 4 2-pack spray filler 1504
3 3 5 2-pack IR premium filler 1510
3 3 6 2-pack epoxy resin filler 1515
3 4 Priming metal 1519
3 4 1 1-pack anti-corrosion wash primer 1519
3 4 2 1-pack wash primer 1524
3 4 3 2-pack wash primer 1529
3 5 Priming plastic materials 1535
3 5 1 Adhesion promoter (transparent) 1535
3 6 Surfacer 1539
3 6 1 2-pack HS Vario surfacer 1539
3 6 2 2-pack HS premium surfacer 1549
3 6 3 2-pack HS Performance surfacer 1558
3 6 4 2-pack primer surfacer for plastics 1567
3 6 5 2-pack HS wet-on-wet surfacer 1573
3 6 6 2-pack base filler, professional 1583
3 7 Top coats 1600
3 7 1 2-pack HS top coat 1600
3 7 2 Aquaplus system, uni (solid-colour) and metallic colours 1609
3 7 3 Aquaplus system (pearlescent and heliochrome) 1617
3 7 4 Aquaplus blending system 1625
3 7 5 Aqua Premium system 1631
3 7 6 Aqua Premium blending system 1644
3 7 7 Aqua Premium system (painting rims) 1651
3 8 Clear coats 1660
3 8 1 2-pack HS clear coat 1660
3 8 2 2-pack MS matt clear coat 1667
3 8 3 2-pack HS Vario clear coat 1673
3 8 4 2-pack HS optimum clear coat 1681
3 8 5 2-pack HS optimum plus clear coat 1687
3 8 6 2-pack HS brilliant clear coat 1692
3 8 7 2-pack HS brilliant plus clear coat 1697
3 8 8 2-pack HS Performance clear coat 1703
3 8 9 Blender 1709
3 9 Hardener 1714
3 9 1 2-pack HS hardener 1714
3 9 2 2-pack VHS hardeners and 2-pack VHS Performance hardeners 1718
3 9 3 Hardener for 2-pack primer surfacer 1722
3 9 4 Aqua Premium hardener 1722
3 10 Thinners 1723
3 10 1 2-pack thinner 1723
3 10 2 HS spot thinner 1726
3 10 3 Demineralised water 1728
3 11 Anti-corrosion materials 1729
3 11 1 Anti-corrosion wax 1729
3 11 2 Cavity sealant 1730
3 11 3 Anti-corrosion wax (in aerosol can) 1733
3 12 Underseal 1734
3 12 1 Permanent underseal -D 314 D36 M2-, grey 1734
3 12 2 Permanent underseal -D 314 D37 M2-, black 1737
3 12 3 Permanent underseal -D 314 D38 M2-, light 1740
3 12 4 Underseal -D 314 D39 A3-, black 1743
3 13 Stone deflector 1745
3 13 1 Stone chip guard -AKR 311 KD1 05- 1745
3 13 2 Stone chip guard -AKR 311 KD1 10- 1747
3 14 Wax-based underseal 1754
3 14 1 Wax-based underseal -D 316 D38 A2- 1754
3 14 2 Wax-based underseal -D 316 000 A1- 1756
3 14 3 Spray wax -D 322 100 M2- 1758
3 15 Sealing materials 1759
3 15 1 Polyurethane adhesive sealant (bonding compound) 1759
3 15 2 Sprayable sealant 1762
3 15 3 Adhesive sealant 1765
3 16 Cleaning agents 1767
3 16 1 Silicone remover 1767
3 16 2 Cleaner for plastics 1769
3 16 3 Cleaner for plastics, anti-static 1770
3 16 4 Industrial dirt remover 1770
3 17 SprayMax system 1772
3 17 1 1-pack anti-corrosion primer 1772
3 17 2 1-pack test paint 1776
3 17 3 1-pack clear coat 1779
3 17 4 1-pack wash primer 1782
3 17 5 1-pack Fill Clean spray can -LLS MAX 099-/1-pack Fill Clean spray can -LLS MAX 100- – Aquaplus system 1787
3 17 6 1-pack fill clean spray can -LLS MAX 112-, Aqua Premium system 1794
3 17 7 2-pack surfacer 1802
3 17 8 2-pack HS Performance surfacer 1809
3 17 9 2-pack clear coat 1817
3 17 10 2-pack epoxy primer surfacer 1822
3 17 11 2-pack wash primer 1828
3 17 12 Silicone remover -LLS MAX 007- 1834
3 17 13 Slow-drying silicone remover -LLS MAX 008- 1836
3 17 14 Blender 1839
3 17 15 Adhesion promoter 1841
3 18 Additional materials 1845
3 18 1 Matting additive -ALN 775 106- 1845
3 18 2 Matting additive -LVM 769 810 A2- 1852
3 18 3 Texture additive 1855
3 18 4 Blending additive for Aquaplus 1861
3 18 5 Additive for Aqua Premium 1862
4 Workshop equipment 1863
4 1 Tools 1863
4 1 1 Spray can filling device -VAS 6425- 1863
4 1 2 Paint thickness tester -VAS 6272- 1864
4 1 3 Paint thickness tester -VAS 6197- 1865
4 1 4 Paint thickness tester -VAS 5278- 1865
4 1 5 Stone chip tester -VAS 5102A- 1866
4 1 6 Pneumatic brush grinder set -VAS 6446- 1867
4 1 7 Brush grinder set -VAS 6776- 1867
4 1 8 Suction feed spray-gun -V A G 1538- 1869
4 1 9 Infrared heater -VAS 6873- 1870
4 1 10 Stand -VAS 6873/1- 1870
4 1 11 Infrared heater -VAS 6874- 1871
4 1 12 Infrared heater -VAS 6875- 1872
4 1 13 Infrared heater -VAS 6876- 1872
4 1 14 Infrared heater -VAS 6877- 1873
4 1 15 Infrared heater -VAS 6878- 1874
4 1 16 Infrared heater -VAS 6879- 1875
4 2 Tack cloths 1875
4 2 1 Tack cloth -VAS 6177- 1875
4 2 2 Buffing cloth, white -VAS 6176- 1876
00 – Technical data 1883
1 Technical data 1883
1 1 Engine number 1883
1 2 Engine data 1883
10 – Removing and installing engine 1885
1 Removing and installing engine 1885
1 1 Removing engine 1885
1 2 Securing engine to assembly stand 1891
1 3 Notes on installing 1892
1 4 Assembly mountings 1893
1 5 Additional information and assembly work for vehicles with air conditioner 1894
13 – Crankshaft group 1895
1 Dismantling and assembling engine 1895
1 1 Assembly overview – toothed belt drive 1895
1 2 Assembly overview – crankcase 1897
1 3 Removing and installing poly V-belt 1898
1 3 1 Belt drive with tensioning roller 1898
1 3 2 Belt drive without tensioning roller 1900
2 Sealing flange and flywheel 1902
2 1 Assembly overview – sealing flange and flywheel, engine codes AMF, BAY, BNM, BNV 1902
2 2 Assembly overview – sealing flange and flywheel, engine codes BMS, BWB 1904
2 3 Renewing crankshaft oil seal – pulley end 1905
2 3 1 Removing 1905
2 3 2 Installing 1906
2 4 Removing and installing sealing flange – pulley end 1906
2 4 1 Removing 1907
2 4 2 Installing 1908
2 5 Renewing crankshaft sealing flange – flywheel end, engine codes BMS, BWB 1909
2 5 1 Pressing out sealing flange with sender wheel 1910
2 5 2 Pressing in sealing flange with sender wheel 1911
2 5 3 A – Assembling seal with sender wheel on assembly tool -T10134- 1912
2 5 4 B – Attaching assembling tool -T10134- with sealing flange on crankshaft flange 1913
2 5 5 C – Bolting assembly tool -T10134- onto crankshaft flange 1914
2 5 6 D – Pressing sender wheel onto crankshaft flange using assembly tool -T10134- 1915
2 5 7 E – Checking sender wheel installation position on crankshaft 1915
2 5 8 F – Re-pressing sender wheel 1916
2 6 Removing and installing engine speed sender -G28-, engine codes BMS, BWB 1916
3 Balancer shaft and retaining frame 1918
3 1 Assembly overview – balancer shaft and retaining frame 1918
3 2 Removing and installing balancer shaft 1920
4 Crankshaft 1925
4 1 Assembly overview – crankshaft 1925
4 2 Crankshaft dimensions 1926
5 Pistons and conrods 1928
5 1 Assembly overview – pistons and conrods 1928
5 2 Separating new conrods 1930
5 3 Checking pistons, piston rings and cylinder bores 1930
5 4 Checking piston projection at TDC 1932
5 5 Piston and cylinder dimensions 1933
15 – Cylinder head, valve gear 1934
1 Cylinder head 1934
1 1 Assembly overview – cylinder head 1934
1 2 Removing, installing and tensioning toothed belt 1938
1 2 1 Vehicles with friction-damped belt tensioning system 1938
1 2 2 Vehicles with hydraulic belt tensioning system 1942
1 3 Removing and installing cylinder head 1948
1 3 1 Removing 1949
1 3 2 Installing 1951
1 4 Checking compression 1952
2 Valve gear 1955
2 1 Assembly overview – valve gear 1955
2 2 Reworking valve seats 1958
2 3 Checking valve guides 1960
2 4 Renewing valve stem seals 1960
2 5 Removing and installing camshaft 1962
2 6 Removing and installing camshaft oil seal 1966
17 – Lubrication 1969
1 Engine oil 1969
1 1 Oil capacities 1969
1 2 Checking engine oil level 1969
2 Parts of lubrication system 1970
2 1 Assembly overview – parts of lubrication system 1970
2 2 Assembly overview – oil filter bracket 1973
2 3 Removing and installing oil sump 1974
2 4 Checking oil pressure and oil pressure switch 1975
19 – Cooling 1978
1 Removing and installing parts of cooling system 1978
1 1 Assembly overview – parts of cooling system, body side 1978
1 2 Assembly overview – parts of cooling system, engine side 1980
1 3 Coolant hose schematic diagram 1981
1 3 1 Engine code AMF 1981
1 3 2 Engine codes BAY, BNM, BNV, BWB 1982
1 3 3 Engine code BMS 1983
1 4 Draining and filling coolant 1983
1 4 1 Draining 1984
1 4 2 Filling 1985
1 5 Removing and installing radiator 1987
1 6 Removing and installing coolant pump 1988
1 7 Removing and installing thermostat 1990
1 8 Checking cooling system for leaks 1991
1 9 Checking engine oil cooler for leaks 1993
20 – Fuel supply system 1996
1 Removing and installing parts of fuel supply system 1996
1 1 Safety precautions when working on fuel supply system 1997
1 2 Rules for cleanliness 1997
1 3 Assembly overview – fuel tank with attachments 1998
1 4 Removing and installing fuel tank 2000
1 5 Assembly overview – fuel filter 2001
1 5 1 Engine codes AMF, BAY, BNM 2001
1 5 2 Engine codes BMS, BNV, BWB 2003
1 6 Removing and installing fuel cooler 2004
1 7 Removing and installing fuel delivery unit 2004
1 8 Removing and installing fuel gauge sender -G- 2006
1 9 Checking fuel pump 2006
1 10 Assembly overview – accelerator mechanism 2007
1 11 Checking tandem pump 2008
1 11 1 Checking delivery pressure 2008
1 11 2 Checking for internal leaks 2011
1 12 Removing and installing tandem pump 2012
21 – Turbocharging/supercharging 2015
1 Charge air system with turbocharger 2015
1 1 Safety precautions 2015
1 2 Rules for cleanliness 2016
1 3 Installing hose connections with connector couplings 2016
1 4 Hose connections with spring band ring 2017
1 5 Assembly overview – turbocharger 2017
1 5 1 Engine code AMF 2018
1 5 2 Engine codes BAY, BNM, BNV 2020
1 5 3 Engine codes BMS, BWB 2021
1 6 Removing and installing turbocharger, engine codes BMS, BWB 2022
1 7 Assembly overview – parts of charge air cooling 2024
1 7 1 Engine codes AMF, BAY, BNM, BNV 2025
1 7 2 Engine codes BMS, BWB 2026
1 8 Checking charge air system for leaks 2026
23 – Mixture preparation – injection 2029
1 Repairing diesel direct injection system 2029
1 1 Safety precautions 2029
1 2 Rules for cleanliness 2030
1 3 Assembly overview – intake manifold with intake manifold flap 2030
1 3 1 Engine code AMF 2030
1 3 2 Engine codes BAY, BNM, BNV 2032
1 3 3 Engine codes BMS, BWB 2033
1 4 Assembly overview – air filter 2034
1 5 Assembly overview – unit injector 2034
1 6 Removing and installing unit injector 2036
1 7 Adjusting non-contact gap of unit injectors 2038
1 8 Removing and installing O-rings for unit injector 2038
2 Engine control unit 2041
2 1 Removing and installing engine control unit 2041
2 2 Removing and installing anti-theft engine control unit, engine codes AMF, BAY, BNM, BNV 2041
2 3 Removing and installing anti-theft engine control unit, engine codes BMS, BWB 2043
2 4 Reading and clearing engine control unit event memory 2044
2 5 Adapting functions and components 2045
26 – Exhaust system 2047
1 Exhaust system 2047
1 1 Assembly overview – front exhaust pipe with catalytic converter and silencer 2047
1 2 Assembly overview – front exhaust pipe with particulate filter 2049
1 3 Assembly overview – silencer, vehicles with particulate filter 2050
1 4 Removing and installing front exhaust pipe with particulate filter 2051
1 4 1 Removing 2051
1 4 2 Installing 2052
1 5 Aligning exhaust system free of stress 2052
2 Exhaust gas recirculation system 2055
2 1 Assembly overview – parts of exhaust gas recirculation system, engine code AMF 2055
2 2 Assembly overview – parts of exhaust gas recirculation system, engine codes BAY, BNM, BNV 2056
2 3 Assembly overview – parts of exhaust gas recirculation system, engine codes BMS, BWB 2057
2 4 Assembly overview – exhaust gas recirculation cooler, engine codes BMS, BWB 2058
2 5 Removing and installing exhaust gas recirculation cooler, engine codes BMS, BWB 2059
2 6 Vacuum hose assembly 2060
2 6 1 Vacuum hose schematic diagram 2060
2 6 2 Vacuum hose schematic diagram, engine codes BMS, BWB 2060
28 – Glow plug system 2062
1 Checking glow plug system 2062
1 1 Removing, installing and checking glow plugs 2062
1 2 Characteristics of ceramic glow plugs 2063
1 3 Removing, installing and checking ceramic glow pin plugs 2063
27 – Starter, current supply, CCS 2072
1 Battery 2072
1 1 Fundamentals for batteries 2072
1 2 Battery load test 2072
1 2 1 Battery with »standard« colour indicator 2073
1 2 2 Battery with »enhanced« colour indicator 2073
1 2 3 Absorbent glass mat battery 2074
1 2 4 Lithium ion battery 2074
1 3 Warning notices and safety regulations 2074
1 3 1 Dangers when handling vehicle batteries 2074
1 3 2 Safety markings on battery 2075
1 3 3 Working on airbag system 2076
1 4 Battery load test 2076
2 Checking battery 2078
2 1 Checking the various types of batteries 2078
2 1 1 Checking a battery with colour indicator 2078
2 1 2 Absorbent glass mat battery 2078
2 2 Visual inspection 2079
2 3 Information about battery replacement and battery gas venting 2080
2 4 Checking colour indicator in battery cover 2081
2 4 1 Checking colour indicator, “3-colour” 2081
2 4 2 Checking colour indicator, “2-colour” 2082
2 5 Current draw test 2083
3 Charging the battery 2085
3 1 Totally discharged batteries 2085
4 Cruise control system (CCS) 2087
4 1 Activating and deactivating cruise control system (CCS) 2087
90 – Gauges, instruments 2088
92 – Windscreen wash/wipe system 2089
1 Washer fluid line hose couplings 2089
1 1 Windscreen and rear window washer system 2089
1 2 Headlight washer system 2090
2 Hose repair 2091
2 1 General description 2091
2 2 Repairing smooth pipe 2091
2 3 Repairing corrugated pipe 2091
3 Distinguishing features of jointless wiper blades 2094
94 – Lights, bulbs, switches – exterior 2095
1 Operation and safety notes for gas discharge lamps 2095
96 – Lights, bulbs, switches – interior 2098
1 12 V socket 2098
1 1 Removing and installing 12 V socket 2098
1 2 Removing and installing socket illumination bulb -L42- 2098
2 Cigarette lighter -U1- 2099
2 1 General description 2099
2 2 Assembly overview 2100
2 3 Removing and installing cigarette lighter socket 2101
2 4 Removing and installing cigarette lighter illumination bulb -L28- 2104
97 – Wiring 2106
1 Vehicle diagnostic, testing and information systems 2106
1 1 Connecting vehicle diagnostic tester 2106
1 2 Connecting vehicle diagnostic tester Golf Model Year 1998 – 2003 2108
2 Repairs to wiring harnesses and connectors 2109
2 1 General notes concerning repairs to vehicle electrical system 2109
2 2 Wiring harness repair set 2111
2 2 1 Wiring harness repair set -VAS 1978- 2111
2 2 2 Upgrade kit -VAS 1978/50- 2111
2 2 3 Wiring harness repair set -VAS 1978A- 2112
2 2 4 Release tool set -VAS 1978/35- 2112
2 3 Tool descriptions 2113
2 3 1 Special pliers with insert 2113
2 3 2 Release tools for contacts 2114
2 3 3 Assembly tools for single wire seals 2114
2 3 4 Wire stripper -VAS 1978/3- 2114
2 3 5 Hot air blower 220 V/50 Hz -VAS 1978/14- 2116
2 3 6 Crimping pliers -VAS 1978/1A- 2116
2 4 Repairing wiring harnesses 2118
2 4 1 Repairs to airbag and belt tensioner wiring 2118
2 4 2 Repairing CAN bus wiring 2120
2 4 3 Repair of Flexray wires with sheath 2121
2 4 4 Repair of Flexray wires without sheath 2122
2 4 5 Renewal of aerial wiring 2123
2 4 6 Repairing 0 13 mm2/0 35 mm2/0 5 mm2 wire 2125
2 4 7 Repair of 10 mm2 or 16 mm2 wire with single butt connector 2130
2 4 8 Repair of 2 5 mm2, 4 mm2 or 6 mm2 aluminium wire with single butt connector 2137
2 4 9 Wiring open circuit with one repair position 2143
2 4 10 Wiring open circuit with two repair positions 2146
2 5 Repairing fibre optic cables 2148
2 5 1 Preparing fibre optic cable 2149
2 5 2 Detaching fibre optic cable from cable harness connector 2156
2 6 Repair of aerial wires 2157
2 6 1 Repair set, aerial cable VAS 6720 2157
2 7 Repairs to contact housings and connectors 2169
2 7 1 Notes on repairs to contact housings and connectors 2169
2 7 2 Repairs to contacts in contact housings 2169
2 7 3 Fitting single wire seals 2171
2 7 4 Repairs to contact housings using cut-and-clamp method 2174
2 8 Releasing and dismantling contact housings 2175
2 8 1 Notes on releasing and dismantling contact housings 2175
2 8 2 Secondary locking element 2175
2 8 3 Primary locking element 2176
2 8 4 Round connector systems 2177
2 8 5 Flat connector systems 2178
2 8 6 Special connector systems 2180
3 Contact surface cleaning set -VAS 6410- 2183
3 1 Using contact surface cleaning set -VAS 6410- 2183
3 1 1 Servicing ring terminals 2183
3 1 2 Servicing screw connections 2185
3 1 3 Cleaning battery clamp and battery terminal 2187
3 1 4 Anti-corrosion treatment 2189
4 Renewing lambda probe 2191
4 1 Renewing LSF Lambda probe (4-pin) 2191
4 2 Renewing LSU Lambda probe (6-pin) 2192
4 3 Types of protective tube on universal lambda probes 2193
5 Exhaust gas temperature sensor 2195
00 – Technical data 2200
1 Identification of gearbox 2200
1 1 Location on gearbox 2200
1 2 Identification codes, assembly allocation, capacities, Polo 2002 ► 2201
1 3 Identification codes, assembly allocation, capacities, Polo 2010 ► 2204
2 Overview – power transmission 2206
3 General repair instructions 2208
3 1 Gearbox 2208
3 2 Gaskets and seals 2208
3 3 Sealant 2208
3 4 Locking devices 2209
3 5 Nuts and bolts 2209
3 6 Bearings 2209
3 7 Shims 2210
3 8 Synchro-rings 2210
3 9 Gear wheels 2210
3 10 Synchromeshed gears 2210
3 11 Clutch 2211
4 Safety precautions for vehicles with a start-stop system 2212
5 Electrical components 2213
5 1 Overview of fitting locations – electrical components 2213
5 1 1 Overview of fitting locations – electrical components, manual gearbox 2213
5 1 2 Overview of fitting locations – electrical components, clutch mechanism 2214
30 – Clutch 2215
1 Repairing clutch mechanism 2215
1 1 Overview – clutch actuation 2215
1 2 Assembly overview – pedal cluster, Polo 2002 ► 2215
1 3 Assembly overview – pedal cluster, Polo 2010 ► 2217
1 4 Distinguishing between clutch pedal switches -F36- 2219
1 5 Removing and installing clutch pedal switch -F36- with rectangular housing 2220
1 5 1 Removing clutch pedal switch 2220
1 5 2 Installing clutch pedal switch 2220
1 6 Removing and installing clutch pedal switch -F36- with round housing 2220
1 6 1 Removing clutch pedal switch 2220
1 6 2 Installing clutch pedal switch 2221
1 7 Removing and installing over-centre spring – Polo 2002 ► 2223
1 7 1 Removing 2224
1 7 2 Installing 2224
1 8 Removing and installing mounting bracket, Polo 2002 ► 2225
1 8 1 Removing 2225
1 8 2 Installing 2227
1 8 3 Specified torques 2228
1 9 Removing and installing mounting bracket with master cylinder, Polo 2010 ► 2228
1 9 1 Removing 2229
1 9 2 Installing 2232
1 10 Removing and installing clutch pedal – Polo 2002 ► 2233
1 10 1 Removing 2233
1 10 2 Installing 2234
1 10 3 Specified torque 2234
1 11 Removing and installing clutch pedal with over-centre spring, Polo 2010 ► left-hand drive vehicles 2234
1 11 1 Removing 2235
1 11 2 Installing 2236
1 12 Removing and installing clutch pedal with extension spring, Polo 2010 ► left-hand drive vehicles 2238
1 12 1 Removing 2239
1 12 2 Installing 2240
1 13 Removing and installing clutch pedal – Polo 2010 ► right-hand drive 2241
1 13 1 Removing 2242
1 13 2 Installing 2243
1 14 Assembly overview – hydraulics (left-hand drive vehicles) 2245
1 15 Assembly overview – hydraulics (right-hand drive vehicles) 2248
1 16 Removing and installing master cylinder, Polo 2002 ► 2250
1 16 1 Removing 2250
1 16 2 Installing 2252
1 16 3 Specified torques 2253
1 17 Removing and installing master cylinder, Polo 2010 ► 2253
1 17 1 Removing 2253
1 17 2 Installing 2254
1 18 Removing and installing slave cylinder 2254
1 18 1 Removing 2254
1 18 2 Installing 2255
1 19 Bleeding clutch system 2255
2 Servicing clutch release mechanism 2257
3 Repairing clutch 2260
34 – Controls, housing 2264
1 Repairing selector mechanism 2264
1 1 Installation position of selector mechanism 2264
1 2 Overview of selector mechanism 2265
1 3 Assembly overview – gear knob and cover, Polo 2002 ► 2265
1 4 Removing and installing gear knob and cover, Polo 2002 ► 2266
1 5 Assembly overview – gear knob and cover, Polo 2010 ► 2269
1 6 Removing and installing gear knob and cover, Polo 2010 ► 2269
1 7 Servicing gear lever and selector housing (through 05/ 06) 2271
1 7 1 Removing and installing securing clip and spring 2273
1 8 Servicing gear lever and selector housing (from 06 06) 2274
1 9 Installing base plate to selector housing 2276
1 10 Assembly overview – removing and installing selector cables 2276
1 11 Removing and installing selector mechanism 2282
1 11 1 Removing 2282
1 11 2 Installing 2285
1 11 3 Specified torques 2287
1 12 Adjusting selector mechanism 2287
1 12 1 Function 2290
2 Removing and installing gearbox, Polo 2002 ► 2291
2 1 Removing gearbox 2291
2 2 Installing gearbox 2298
2 2 1 Specified torques 2303
3 Removing and installing gearbox, Polo 2010 ► 2307
3 1 Removing gearbox 2307
3 2 Installing gearbox 2317
3 2 1 Specified torques 2327
4 Gearbox transport 2329
5 Checking gearbox oil 2330
6 Dismantling and assembling gearbox 2331
6 1 Overview – gearbox 2331
6 2 Assembly overview 2331
6 3 Assembly overview – removing and installing cover for gearbox housing and 5th gear 2332
6 4 Assembly overview – removing and installing gearbox housing and selector mechanism 2334
6 5 Assembly overview – removing and installing input shaft, output shaft, differential and selector forks 2335
6 6 Assembly sequence – removing and installing cover for gearbox housing and 5th gear 2337
6 6 1 Removing 2337
6 6 2 Installing 2342
6 7 Assembly sequence – Dismantling and assembling gearbox completely 2342
6 7 1 Removing 2342
6 7 2 Installing 2349
6 7 3 Installing 5th gear 2354
7 Repairing gearbox housing and clutch housing 2359
8 Dismantling and assembling selector mechanism on gearbox side (selector shaft can be removed from selector mechanism cover) 2366
9 Dismantling and assembling selector mechanism on gearbox side (selector shaft cannot be removed from selector mechanism cover) 2370
10 Dismantling and assembling selector forks 2372
35 – Gears, shafts 2378
1 Input shaft 2378
1 1 Dismantling and assembling input shaft 2378
1 2 Adjusting input shaft 2386
1 2 1 Determining thickness of shim 2388
1 2 2 Carrying out check measurement 2389
2 Output shaft 2390
2 1 Dismantling and assembling output shaft 2390
2 2 Adjusting output shaft 2405
2 2 1 Determining thickness of shim 2406
3 Reverse shaft 2408
3 1 Dismantling and assembling reverse shaft 2408
39 – Final drive – differential 2411
1 Renewing flange shaft oil seals with gearbox installed 2411
1 1 Renewing oil seal for left flange shaft 2411
1 1 1 Removing 2411
1 1 2 Installing 2413
1 2 Distinguishing seals for right flange shaft 2413
1 3 Renewing seal (two-part seal and sleeve for right flange shaft) 2414
1 3 1 Removing 2414
1 3 2 Installing 2416
1 4 Renewing seal and sleeve together (one-piece seal and sleeve for right flange shaft) 2416
1 4 1 Removing 2417
1 4 2 Installing 2418
2 Adjustment overview 2420
3 Differential 2421
3 1 Dismantling and assembling differential 2421
3 2 Adjusting differential 2431
3 2 1 Determining thickness of shim 2432
00 – Technical data 2438
1 Gearbox identification 2438
1 1 Location on gearbox 2438
1 2 Identification codes, assembly allocation, capacities, Polo 2002 ► 2438
1 3 Identification codes, assembly allocation, capacities, Polo 2010 ► 2450
2 Overview – power transmission 2452
3 General repair notes 2454
3 1 Contact corrosion! 2454
3 2 Special tools 2454
3 3 Gearbox 2454
3 4 Seals and sealing rings 2454
3 5 Sealant 2455
3 6 Locking devices 2455
3 7 Nuts and bolts 2455
3 8 Bearings 2455
3 9 Shims 2456
3 10 Synchro-rings 2456
3 11 Gear wheels 2456
3 12 Synchromeshed gears 2456
3 13 Clutch 2456
4 Safety measures for vehicles with start/stop system 2457
30 – Clutch 2458
1 Repairing clutch mechanism 2458
1 1 Overview – clutch actuation 2458
1 2 Assembly overview – pedal cluster, Polo 2002 ► 2459
1 3 Assembly overview – pedal cluster, Polo 2010 ► 2460
1 4 Distinguishing between clutch pedal switches -F36- 2462
1 5 Removing and installing, adjusting clutch pedal switch -F36- with round housing 2462
1 5 1 Removing clutch pedal switch 2462
1 5 2 Installing clutch pedal switch 2462
1 6 Removing and installing clutch pedal switch -F36- with round housing 2463
1 6 1 Removing clutch pedal switch 2463
1 7 Removing and installing over-centre spring, Polo 2002 ► 2464
1 7 1 Removing 2465
1 7 2 Installing 2465
1 8 Removing and installing mounting bracket, Polo 2002 ► 2466
1 8 1 Installing 2468
1 8 2 Specified torques 2468
1 9 Removing and installing mounting bracket with master cylinder, Polo 2010 ► 2468
1 9 1 Removing 2469
1 9 2 Installing 2471
1 10 Removing and installing clutch pedal, Polo 2002 ► 2472
1 10 1 Removing 2473
1 10 2 Installing 2473
1 10 3 Torque setting 2474
1 11 Removing and installing clutch pedal with over-centre spring, Polo 2010 ► LHD 2474
1 11 1 Removing 2474
1 11 2 Installing 2475
1 12 Removing and installing clutch pedal with extension spring, Polo 2010 ► LHD 2477
1 12 1 Removing 2477
1 12 2 Installing 2478
1 13 Removing and installing clutch pedal, Polo 2010 ► RHD 2479
1 13 1 Removing 2480
1 13 2 Installing 2481
1 14 Assembly overview – hydraulics (LHD) 2482
1 15 Assembly overview – hydraulics (RHD) 2485
1 16 Removing and installing master cylinder, Polo 2002 ► 2487
1 16 1 Removing 2487
1 16 2 Installing 2489
1 16 3 Specified torques 2489
1 17 Removing and installing master cylinder, Polo 2010 ► 2489
1 17 1 Removing 2490
1 17 2 Installing 2490
1 18 Removing and installing slave cylinder 2490
1 18 1 Removing 2491
1 18 2 Installing 2491
1 19 Bleeding clutch system 2491
2 Repairing clutch release mechanism 2493
3 Repairing clutch 2495
34 – Controls, housing 2498
1 Repairing selector mechanism 2498
1 1 Installation position of selector mechanism 2498
1 2 Overview of selector mechanism 2499
1 3 Assembly overview – selector lever knob and cover, Polo 2002 ► 2500
1 4 Removing and installing gear knob and cover, Polo 2002 ► 2500
1 5 Assembly overview – selector lever knob and cover, Polo 2010 ► 2502
1 6 Removing and installing gear knob and cover, Polo 2010 ► 2503
1 7 Repairing gear lever and selector housing (through 05 06) 2504
1 8 Repairing gear lever and selector housing (from 06 06) 2506
1 9 Assembly overview – removing and installing selector cables 2508
1 10 Removing and installing selector mechanism 2512
1 10 1 Removing 2512
1 10 2 Installing 2515
1 10 3 Specified torques 2516
1 11 Adjusting selector mechanism 2516
1 11 1 Functional check 2519
2 Removing and installing gearbox, Polo 2002 ► with petrol engine 2520
2 1 Removing gearbox 2521
2 2 Installing gearbox 2526
2 2 1 Specified torques 2530
3 Removing and installing gearbox, Polo 2002 ► with 4-cyl diesel engine 2533
3 1 Removing gearbox 2534
3 2 Installing gearbox 2539
3 2 1 Specified torques 2543
4 Removing and installing gearbox, Polo 2002 ► with 3-cylinder TDI engine 2545
4 1 Removing gearbox 2546
4 2 Installing gearbox 2552
4 2 1 Specified torques 2557
5 Removing and installing gearbox, Polo 2010 ► 2559
5 1 Removing gearbox 2560
5 2 Installing gearbox 2566
5 2 1 Specified torques 2570
6 Transporting gearbox 2573
7 Checking gear oil 2574
8 Dismantling and assembling gearbox 2576
8 1 Overview – gearbox 2576
8 2 Assembly overview 2577
8 3 Assembly overview – removing and installing cover for gearbox housing and 5th gear 2578
8 4 Assembly overview – removing and installing clutch housing 2579
8 5 Assembly overview – removing and installing input shaft, output shaft, differential, selector mechanism and selector forks 2580
8 6 Dismantling and assembling procedure 2581
8 6 1 Modifying gearbox support -3221- 2584
8 6 2 Dismantling 2585
8 6 3 Assembling 2587
9 Repairing gearbox housing and clutch housing 2592
10 Repairing selector unit 2597
11 Dismantling and assembling selector forks 2600
35 – Gears, shafts 2605
1 Dismantling and assembling input shaft 2605
2 Dismantling and assembling output shaft 2616
39 – Final drive – differential 2623
1 Renewing flange shaft oil seals with gearbox installed 2623
1 1 Renewing oil seal for left flange shaft 2623
1 1 1 Removing 2623
1 1 2 Installing 2625
1 2 Renewing seal for right flange shaft 2625
1 2 1 Removing 2626
1 2 2 Installing 2627
2 Differential 2628
2 1 Dismantling and assembling differential 2628
2 1 1 One-piece thrust bearing and tapered roller bearing for differential modified from gearbox date 06 05 2 2636
2 2 Adjusting differential 2637
2 2 1 Determining shim S2 2642
00 – Technical data 2649
1 Checklist for evaluating running gear of accident vehicles 2649
2 General information 2651
40 – Front suspension 2652
1 Appraisal of accident vehicles 2652
2 Servicing front suspension 2653
2 1 Overview – front axle 2653
2 2 Raising wheel suspension to unladen position 2654
3 Assembly overview: subframe made of aluminium, anti-roll bar, suspension links 2657
3 1 Repairing threads in longitudinal member 2659
3 2 Fixing position of subframe 2660
3 3 Checking swivel joint 2662
3 4 Removing and installing swivel joint 2662
3 5 Installation position of swivel joints 2665
3 6 Removing and installing suspension link 2665
3 7 Removing and installing suspension bracket 2667
3 8 Renewing bonded rubber bush for suspension bracket 2669
3 9 Removing and installing subframe 2672
3 10 Removing and installing anti-roll bar, vehicles with power steering 2675
3 11 Removing and installing rubber bush for anti-roll bar 2677
4 Assembly overview: subframe made of steel, anti-roll bar, suspension links 2681
4 1 Repairing threads in longitudinal member 2683
4 2 Fixing position of subframe 2683
4 3 Checking swivel joint 2685
4 4 Removing and installing swivel joint 2686
4 5 Installation position of swivel joints 2688
4 6 Removing and installing suspension link 2689
4 6 1 Removing and installing suspension link, vehicles with manual gearbox 2689
4 6 2 Removing and installing suspension link, vehicles with automatic or dual clutch gearbox 2691
4 7 Renewing front bonded rubber bush for suspension link 2694
4 8 Renewing rear bonded rubber bush for suspension link 2697
4 9 Removing and installing subframe 2699
4 10 Removing and installing anti-roll bar 2701
4 11 Removing and installing rubber bush for anti-roll bar 2703
5 Assembly overview: wheel bearing 2706
5 1 Removing and installing front wheel hub with wheel bearing, 13″ running gear 2708
5 2 Removing and installing front wheel hub with wheel bearing, 14″ and 15″ running gear 2713
6 Assembly overview: suspension strut 2719
6 1 Vehicle data sticker 2720
6 2 Removing and installing suspension strut 2720
6 3 Repairing front coil spring suspension strut 2726
7 Removing and installing drive shafts 2729
7 1 Removing and installing drive shaft with constant velocity joint 2729
7 2 Removing and installing drive shaft with triple roller joint AAR 2000 (bolted on) 2732
7 3 Removing and installing drive shafts with triple roller joint AAR 2000i (inserted) 2734
8 Repairing drive shaft – overview of drive shafts 2739
8 1 Heat shields for drive shafts 2741
9 Assembly overview: drive shaft with VL90 or VL100 constant velocity joint 2742
9 1 Dismantling and assembling drive shaft with VL90 or VL100 constant velocity joint 2744
9 2 Checking outer constant velocity joint 2748
9 3 Checking inner constant velocity joint 2749
10 Assembly overview: drive shaft with VL107 constant velocity joint 2752
10 1 Dismantling and assembling drive shaft with VL107 constant velocity joint 2754
11 Assembly overview: drive shaft with triple roller joint AAR 2000/100 (bolted-on) 2759
11 1 Dismantling and assembling drive shaft with triple roller joint 2761
12 Assembly overview: drive shaft with triple roller joint AAR 2000/108 (bolted-on) 2767
12 1 Dismantling and assembling drive shaft with triple roller joint 2768
13 Assembly overview: drive shaft with triple roller joint AAR 2000i (inserted) 2769
13 1 Dismantling and assembling drive shaft with triple roller joint AAR2000i 2771
42 – Rear suspension 2776
1 Appraisal of accident vehicles 2776
2 Repairing rear axle 2777
2 1 Rear axle in unladen position 2777
2 2 Removing and installing rear axle 2779
2 3 Assembly overview – rear axle beam, drum brake 2783
2 4 Assembly overview – axle beam (disc brakes) 2786
2 5 Removing and installing bonded rubber bush 2788
2 6 Removing and installing spring 2791
2 7 Removing and installing shock absorber 2792
2 8 Assembly overview – shock absorber on vehicle with front-wheel drive 2793
3 Repairing wheel bearing, drum brake 2796
3 1 Assembly overview – wheel bearing 2796
3 2 Removing and installing wheel bearing/hub unit on vehicles with drum brakes 2797
4 Repairing wheel bearing (disc brake) 2800
4 1 Assembly overview – wheel bearing 2800
4 2 Removing and installing wheel bearing/wheel hub on vehicles with disc brakes 2801
44 – Wheels, tyres, vehicle geometry 2804
1 Appraisal of accident vehicles 2804
2 Specified torque for wheel bolts 2805
3 Fitting wheel and tyre 2806
3 1 General information 2806
3 2 Fittings instructions 2806
4 Removing and fitting tyres with run-flat properties to wheel rims 2808
4 1 Notes on safety and prerequisites 2808
4 2 Fittings instructions 2808
4 3 Pressing tyre off wheel rim 2809
4 4 Removing tyre from wheel 2810
4 5 Fitting tyre to wheel rim 2811
5 Tyre Pressure Loss Indicator (TPLI) 2814
6 Vehicle alignment check 2816
6 1 General information 2816
6 2 Conditions for testing 2817
6 3 Test preparations 2818
6 4 Vehicle data sticker 2818
6 5 Wheel alignment specifications 2818
6 6 Transverse vehicle inclination “zero position” 2820
6 7 Overview – wheel alignment procedure 2820
6 8 Adjusting camber at front wheels, subframe made of aluminium 2821
6 9 Correcting front axle camber, subframe made of steel 2822
6 10 Check rear axle camber 2824
6 11 Check rear axle toe 2824
6 12 Adjusting front axle toe 2824
6 13 Checking left and right-hand wheel lock 2824
7 Wheels, tyres 2826
7 1 Models with breakdown set 2826
7 2 Tyre sealant 2826
7 3 Removing a tyre 2826
7 4 Fitting a new tyre 2827
7 5 Tyre sealant disposal 2827
8 Instructions for changing or fitting wheels 2828
8 1 Fitting wheels 2829
9 Protecting wheel centring seat against corrosion 2830
10 Vibration due to wheels/tyres – causes and rectification 2831
10 1 Causes of rough running 2831
10 2 Balancing wheels 2831
10 3 Conducting a road test before balancing wheels 2831
10 4 Balancing wheels on stationary wheel balancing machine 2832
10 5 Vibration control system -VAS 6230- 2834
10 6 Finish balancer 2834
10 7 Radial and lateral runout of wheels and tyres 2835
10 8 Checking radial and lateral runout on wheels and tyres with tyre gauge -V A G 1435- 2835
10 9 Checking radial and lateral run-out on wheel rim 2836
10 10 Matching 2837
10 11 Flat spots caused by storage or handling 2838
48 – Steering 2840
1 Appraisal of accident vehicles 2840
2 Electrical/electronic components and locations 2841
3 Steering column 2842
3 1 Removing and installing steering column 2842
3 2 Checking steering column for damage 2846
3 3 Removing and installing steering lock housing 2847
3 4 Assembly overview – cross member for steering column 2848
3 5 Removing and installing locking cable for ignition with key removal lock 2849
3 6 Checking ignition key removal lock 2850
3 7 Removing and installing mounting bracket 2850
3 8 Removing and installing strut 2851
4 Repairing mechanical (manual) steering rack 2853
4 1 Assembly overview – mechanical (manual) steering rack 2853
4 2 Removing and installing mechanical (manual) steering rack 2854
4 3 Dismantling and assembling mechanical steering rack 2858
4 4 Removing and installing track rod 2860
4 5 Checking play, security and boots of track rod ends 2861
4 6 Checking and adjusting left track rod length 2861
4 7 Allocation of track rod ball joints 2862
4 8 Determining centre position of steering rack 2862
4 9 Adjusting steering rack 2862
5 Repairing electrohydraulic power steering (TRW) 2864
5 1 Assembly overview – power steering rack (TRW) 2864
5 2 Removing and installing power steering rack (TRW) 2865
5 3 Removing and installing power steering sensor -G250- (TRW) 2872
5 4 Dismantling and assembling power steering rack (TRW) 2875
5 5 Removing and installing track rod (TRW) 2877
5 6 Checking play, tightness and bellows of track rod ball joints (TRW) 2878
5 7 Checking and adjusting length of left track rod (TRW) 2878
5 8 Allocation of track rod ball joints (TRW) 2879
5 9 Determining centre position of rack (TRW) 2879
5 10 Adjusting steering rack (TRW) 2880
5 11 Checking delivery pressure of motor/pump unit (TRW) 2880
5 12 Removing and installing motor/pump unit (TRW) 2883
5 13 Assembly overview – motor/pump unit (TRW) 2887
5 14 Renewing reservoir of motor/pump unit (TRW) 2888
6 Repairing electrohydraulic power steering (Koyo) 2892
6 1 Assembly overview – power steering rack (Koyo) 2892
6 2 Removing and installing power steering rack (Koyo) 2893
6 3 Removing and installing power steering sensor -G250- ( Koyo) 2899
6 4 Dismantling and assembling power steering rack (Koyo) 2902
6 5 Removing and installing track rod (Koyo) 2904
6 6 Checking play, tightness and bellows of track rod ball joints (Koyo) 2905
6 7 Checking and adjusting length of left track rod (Koyo) 2905
6 8 Allocation of track rod ball joints (Koyo) 2906
6 9 Determining centre position of rack (Koyo) 2906
6 10 Adjusting steering rack (Koyo) 2907
6 11 Checking delivery pressure of motor/pump unit (Koyo) 2907
6 12 Removing and installing motor/pump unit (Koyo) 2909
6 13 Assembly overview – motor/pump unit (Koyo) 2913
6 14 Renewing reservoir of motor/pump unit (Koyo) 2914
7 Bleeding steering system, checking for leaks and checking fluid level 2918
7 1 Bleeding steering system 2918
7 2 Checking steering system for leaks 2918
7 3 Checking hydraulic fluid level of power steering 2919
00 – Technical data 2925
1 Brake allocation via PR No 2925
1 1 Front brakes 2925
1 2 Rear brakes 2926
1 2 1 Disc brakes up to model year 2004 2926
1 2 2 Drum brakes up to model year 2004 2926
1 2 3 Disc brakes from model year 2005 2926
1 2 4 Drum brakes from model year 2005 2926
2 Technical data for brakes 2928
2 1 Brake master cylinder and brake servo 2928
2 2 Front brakes 2928
2 3 Rear brakes 2929
3 Brake test 2931
3 1 General 2931
3 2 Test for vehicles with front-wheel drive 2931
45 – Anti-lock brake system 2932
1 General notes for anti-lock brake system (ABS) 2932
1 1 ABS Mark 60 2932
1 2 ABS Bosch 5 7 2933
1 3 Bosch 8 0 from model year 2005 2934
2 Notes for repair work on anti-lock brake system 2936
3 Connecting -VAS 5051- and selecting functions 2937
4 Electrical/electronic components and locations 2939
4 1 ABS Mark 60 (ABS, ABS/EDL/TCS) 2939
4 2 ABS Bosch 5 7 (ABS/EDL/TCS/ESP) 2940
4 3 ABS Mark 8 0 (ABS, ABS/TCS) 2942
4 4 ABS Bosch 8 0 (ABS/EDL/TCS/ESP) 2943
5 Fault display via warning lamps 2945
6 Assembly overview – hydraulic unit, brake servo/brake master cylinder 2947
6 1 ABS Mark 60 2947
6 1 2 Removing control unit and hydraulic unit 2950
6 1 3 Unscrewing control unit from hydraulic unit 2954
6 1 4 Installing new control unit 2955
6 1 5 Installing control unit and hydraulic unit 2956
6 2 ABS/EDL/TCS/ESP Bosch 5 7 2957
6 2 2 Removing control unit and hydraulic unit 2961
6 2 3 Unscrewing control unit from hydraulic unit 2964
6 2 4 Installing new control unit 2965
6 2 5 Installing control unit and hydraulic unit 2965
6 2 6 Removing and installing brake pressure sender -G201- 2966
6 3 Bosch 8 0 ABS, ABS/TCS 2966
6 3 1 Connecting brake lines from brake master cylinder to hydraulic unit 2968
6 3 2 Removing control unit and hydraulic unit 2970
6 3 3 Installing control unit and hydraulic unit 2973
6 4 Bosch 8 0 ABS/EDL/TCS/ESP 2974
6 4 1 Connecting brake lines from brake master cylinder to hydraulic unit 2976
6 4 2 Removing control unit and hydraulic unit 2977
6 4 3 Installing control unit and hydraulic unit 2981
7 Removing and installing parts of ABS system on front and rear axle 2982
7 1 Removing and installing parts of ABS system on front axle 2982
7 1 1 Removing and installing speed sensor on front axle 2982
7 1 2 Removing and installing front speed sensor lines, Mark 60 2983
7 1 3 Removing and installing front speed sensor lines, Bosch 5 7 2985
7 1 4 Removing and installing front speed sensor lines, Bosch 8 0 2988
7 2 Removing and installing parts of anti-lock brake system on rear axle (vehicles with drum brakes) 2989
7 2 1 Removing and installing speed sensor on rear axle (drum brakes) 2990
7 2 2 Removing and installing rear speed sensor wires 2991
7 3 Removing and installing parts of anti-lock brake system on rear axle (vehicles with disc brakes) 2992
7 3 1 Removing and installing speed sensor on rear axle 2993
7 3 2 Removing and installing rear speed sensor wires 2994
8 Removing and installing parts of ESP system 2996
8 1 Removing and installing yaw rate sender -G202- and lateral acceleration sender -G200- 2996
8 1 1 Removing 2996
8 1 2 Installing 2996
8 2 Removing and installing steering angle sender -G85- 2997
46 – Brakes – mechanism 2998
1 Repairing front brakes 2998
1 1 Repairing front brakes, brake caliper FS II 2998
1 2 Removing and installing brake pads, brake caliper FS II 2999
1 2 1 Removing 3000
1 2 2 Installing 3000
1 3 Removing and installing brake caliper FS II 3001
1 3 1 Removing 3002
1 3 2 Installing 3002
1 4 Repairing front brakes, FS III brake caliper 3004
1 5 Removing and installing brake pads, brake caliper FS III 3005
1 5 1 Removing 3006
1 5 2 Installing 3006
1 6 Removing and installing brake caliper FS III 3007
1 6 1 Removing 3008
1 6 2 Installing 3008
1 7 Repairing front brakes, brake caliper C 54-II 3010
1 8 Removing and installing brake pads, brake caliper C 54-II 3011
1 8 1 Removing 3012
1 8 2 Installing 3013
1 9 Removing and installing brake caliper C 54-II 3013
1 9 1 Removing 3014
1 9 2 Installing 3014
1 10 Repairing front brakes, FN 3 brake caliper 3015
1 11 Removing and installing brake pads, brake caliper FN 3 3017
1 11 1 Removing 3017
1 11 2 Installing 3019
1 12 Removing and installing brake caliper FN 3 3020
1 12 1 Removing 3020
1 12 2 Installing 3021
2 Repairing rear brakes (drum brakes) 3022
2 1 Removing and installing rear brakes 3022
2 2 Resetting brake 3024
2 3 Repairing rear brakes 3024
2 3 1 Checking wheel brake cylinder for leaks 3025
2 4 Removing and installing brake shoes 3025
2 4 1 Removing 3026
2 4 2 Installing 3027
3 Repairing rear brakes (disc brakes) 3028
3 1 Removing and installing brake pads/linings 3030
3 1 1 Removing 3030
3 1 2 Installing 3031
3 2 Removing and installing brake caliper 3032
3 2 1 Removing 3033
3 2 2 Installing 3033
4 Assembly overview – handbrake lever 3035
4 1 Removing and installing handbrake cable (drum brakes) 3035
4 1 1 Removing 3035
4 1 2 Installing 3036
4 2 Adjusting handbrake 3037
4 3 Removing and installing handbrake cable (disc brakes) 3037
4 3 1 Removing 3037
4 3 2 Installing 3039
4 4 Adjusting handbrake 3039
5 Assembly overview – brake pedal 3041
5 1 Separating brake pedal from brake servo 3041
5 1 1 Clipping brake pedal to brake servo 3042
5 2 Removing and installing pedal cluster 3043
5 2 1 Removing 3043
5 2 2 Installing 3043
5 3 Removing and installing brake pedal 3043
5 3 1 Removing 3043
5 3 2 Installing 3044
5 4 Removing and installing brake light switch -F- and brake pedal switch -F47- 3045
5 4 1 Brake light switch up to week 45 of 2006 3045
5 4 2 Brake light switch from week 45 of 2006 3046
47 – Brakes – hydraulics 3047
1 Repairing front brake caliper 3047
1 1 Repairing brake caliper FS II 3047
1 2 Removing and installing piston for brake caliper FS II 3047
1 2 1 Removing 3048
1 2 2 Installing 3049
1 3 Repairing brake caliper FS III 3049
1 4 Removing and installing piston for brake caliper FS III 3050
1 4 1 Removing 3051
1 4 2 Installing 3051
1 5 Repairing brake caliper C 54-II 3052
1 6 Removing and installing piston for brake caliper C 54-II 3053
1 6 1 Removing 3054
1 6 2 Installing 3054
1 7 Repairing brake caliper FN 3 3055
1 8 Removing and installing piston for brake caliper FN 3 3056
1 8 1 Removing 3057
1 8 2 Installing 3058
2 Repairing rear brake caliper 3060
2 1 Removing and installing rear brake caliper piston 3061
2 1 1 Removing 3061
2 1 2 Installing 3062
2 1 3 Pre-bleeding brake caliper 3062
3 Pressurised leak test 3063
3 1 Test prerequisites: 3063
4 Assembly overview – brake pressure regulator 3064
5 Checking and adjusting brake pressure regulator 3065
5 1 Checking and adjusting pressure 3065
5 1 1 Specifications for load dependent brake pressure regulator 3066
5 1 2 Adjusting regulator 3066
6 Bleeding brake system 3067
6 1 Bleeding brake system using brake filling and bleeding unit -VAS 5234- or -V A G 1869- 3067
6 1 1 Pre-bleeding: 3068
6 1 2 Bleeding (normal): 3068
6 1 3 Subsequent bleeding 3069
6 2 Changing brake fluid 3069
7 Assembly overview – brake servo/brake master cylinder 3070
7 1 Overview – vacuum pump for brake servo (diesel vehicles) 3071
7 1 1 Exhauster pump for 4-cylinder diesel engines with distributor-type injection pump 3071
7 1 2 Exhauster pump for 3-cylinder diesel engines 3072
7 1 3 Exhauster pump for 4-cylinder diesel engines with unit injector 3073
7 2 Checking non-return valve: 3073
8 Removing and installing brake master cylinder 3074
8 1 Removing 3074
8 2 Installing 3075
9 Removing and installing brake servo 3076
9 1 Removing 3076
9 2 Installing 3078
10 Repairing brake lines 3079
10 1 Assembly overview – flanging tool 3079
10 2 Work instructions 3080
00 – Technical data 3089
1 Technical data 3089
1 1 Engine number 3089
1 2 Engine data 3089
10 – Removing and installing engine 3091
1 Removing and installing engine 3091
1 1 Removing engine 3093
1 2 Securing engine to assembly stand 3095
1 3 Installing engine 3095
1 4 Specified torques 3098
1 5 Assembly mountings 3098
1 6 Additional information and assembly work for vehicles with air conditioner 3099
13 – Crankshaft group 3100
1 Dismantling and assembling engine 3100
1 1 Assembly overview – parts l and ll 3100
1 2 Assembly overview – part I, belt drive 3102
1 3 Assembly overview – part II, cylinder block 3103
1 4 Removing and installing poly-V belt 3105
2 Cylinder block, sealing flange 3107
2 1 Assembly overview 3107
2 2 Pulling needle bearing out of and driving into crankshaft 3108
2 3 Renewing crankshaft oil seal – belt pulley end 3109
2 4 Poly V-belt pulley securing bolt tightening procedure 3111
2 5 Removing and installing drive plate 3112
2 6 Characteristics of the sealing flange and the assembly device -T10017- and -T10134- 3114
2 7 Renewing crankshaft sealing flange – flywheel end (assembly tool -T10134-) 3114
2 7 1 Pressing sealing flange with sender wheel off crankshaft 3115
2 7 2 Pressing sealing flange with sender wheel onto crankshaft 3116
2 7 3 A – Assemble seal with sender wheel on assembly tool -T10134- 3117
2 7 4 B – Fitting assembly tool -T10134- with sealing flange to crankshaft flange 3118
2 7 5 C – Screwing assembly tool -T10134- on crankshaft flange 3119
2 7 6 D – Pressing sender wheel onto crankshaft flange using assembly tool -T10134- 3120
2 7 7 E – Checking sender wheel installation position on crankshaft 3120
2 7 8 f) Re-pressing sender wheel 3121
2 8 Renewing crankshaft sealing flange – flywheel end (assembly tool -T10017-) 3122
2 8 1 Pressing sealing flange with sender wheel off crankshaft 3123
2 8 2 Pressing sealing flange with sender wheel onto crankshaft 3124
2 8 3 A-Assembling sealing flange with sender wheel on assembly appliance -T10017- 3124
2 8 4 B-Assembling appliance -T10017- with sealing flange on crankshaft flange 3126
2 8 5 C-Fitting assembly appliance -T10017- onto crankshaft flange 3127
2 8 6 D-Pressing sender wheel onto crankshaft flange with assembly appliance -T10017- 3128
2 8 7 E – Checking sender wheel installation position on crankshaft 3128
2 8 8 f) Re-pressing sender wheel 3129
2 9 Crankshaft dimensions 3129
3 Pistons and conrods 3131
3 1 Assembly overview 3131
3 2 Piston and cylinder dimensions 3134
15 – Cylinder head, valve gear 3135
1 Cylinder head 3135
1 1 Assembly overview 3135
1 2 Checking valve timing 3137
1 3 Removing, installing and tensioning toothed belt 3138
1 3 1 Removing 3139
1 3 2 Installing 3141
1 4 Checking semi-automatic toothed belt tensioner 3143
1 5 Removing and installing camshaft housing 3147
1 5 1 Removing 3147
1 5 2 Installing 3148
1 6 Removing and installing cylinder head 3149
1 6 1 Removing 3151
1 6 2 Installing 3153
1 7 Checking compression 3154
2 Valve gear 3156
2 1 Assembly overview 3156
2 2 Reworking valve seats 3159
2 3 Renewing camshaft oil seals 3160
2 4 Checking valve guides 3162
2 5 Renewing valve stem seals 3163
17 – Lubrication 3165
1 Parts of lubrication system 3165
1 1 Engine oil: 3165
1 2 Assembly overview 3165
1 3 Removing and installing oil sump 3168
1 4 Removing and installing oil pump 3169
1 5 Checking oil pressure and oil pressure switch 3172
19 – Cooling 3174
1 Parts of cooling system 3174
1 1 Assembly overview – parts of cooling system, body side 3174
1 2 Assembly overview – parts of cooling system, body side 3176
1 3 Assembly overview – parts of cooling system, engine side 3177
1 4 Connection diagram for coolant hoses 3179
1 5 Connection diagram for coolant hoses 3179
1 6 Draining and adding coolant 3181
1 7 Removing and installing radiator 3184
1 8 Removing and installing coolant pump 3186
20 – Fuel supply system 3188
1 Parts of fuel supply system 3188
1 1 Assembly overview – fuel tank with attachments 3188
1 2 Safety regulations for working on fuel supply 3191
1 3 Rules for cleanliness 3192
1 4 Removing and installing fuel delivery unit 3192
1 4 1 Removing 3192
1 4 2 Installing 3193
1 5 Removing and installing fuel gauge sender 3194
1 6 Removing and installing fuel tank 3194
1 6 1 Removing 3195
1 6 2 Installing 3196
1 7 Crash fuel shut-off 3196
1 8 Checking fuel pump (engine codes AUA, AUB, BBY, BBZ, BKY and BUD) 3196
1 8 1 Checking function and voltage supply 3199
1 8 2 Checking fuel pressure 3200
1 8 3 Checking holding pressure 3201
1 8 4 Checking fuel delivery rate 3202
1 8 5 Checking current consumption 3205
1 9 Checking fuel pump (engine code CGGB) 3205
1 9 1 Checking function and voltage supply 3206
1 9 2 Checking fuel pressure 3208
1 9 3 Checking holding pressure 3209
1 9 4 Checking fuel delivery rate 3210
1 9 5 Checking current consumption 3211
1 10 Bleeding fuel system 3212
2 Electronic power control (EPC) 3215
2 1 Assembly overview 3215
3 Activated charcoal filter system 3216
3 1 Assembly overview – parts of activated charcoal filter system 3216
3 2 Checking fuel tank breather 3217
24 – Mixture preparation – injection 3218
1 Injection system 3218
1 1 General notes on injection 3218
1 2 Assembly overview – parts of injection system 3218
1 3 Assembly overview – intake manifold 3220
1 4 Assembly overview – intake manifold 3221
1 5 Assembly overview – fuel rail with injectors 3223
1 6 Assembly overview – air filter 3223
1 6 1 Removing and installing air filter housing 3225
1 7 Assembly overview – air filter 3225
1 8 Removing and installing air filter housing 3227
1 9 Cleaning throttle valve module -J338- 3228
1 10 Checking injectors 3229
1 11 Checking intake air preheating 3230
1 12 Safety precautions 3231
1 13 Rules for cleanliness 3232
1 14 Technical data 3233
2 Engine control unit -J623- 3234
2 1 Removing and installing engine (motor) control unit -J623- 3234
2 2 Removing and installing anti-theft engine control unit -J623- 3234
2 3 Removing and installing anti-theft engine control unit -J623- (engine codes BUD and CGGB) 3236
26 – Exhaust system 3238
1 Parts of the exhaust system 3238
1 1 Assembly overview – front exhaust system with attachments 3238
1 2 Assembly overview – front exhaust system with attachments 3240
1 3 Assembly overview – silencers with mountings 3242
2 Exhaust gas recirculation system 3243
2 1 Assembly overview 3243
28 – Ignition system 3245
1 Ignition system 3245
1 1 General notes on ignition system 3245
1 2 Assembly overview – parts of ignition system 3245
1 3 Safety precautions 3247
1 4 Test data, spark plugs 3248
00 – Technical data 3256
1 Technical data 3256
1 1 Engine number 3256
10 – Removing and installing engine 3258
1 Removing and installing engine 3258
1 1 Removing 3259
1 2 Installing 3263
1 3 Specified torques 3264
13 – Crankshaft group 3266
1 Dismantling and assembling engine 3266
1 1 Assembly overview – part I, belt drive 3266
1 2 Assembly overview – part II, chain drive, engine codes AWY, BMD, BBM 3267
1 3 Assembly overview – part II, chain drive, engine codes AZQ, BME, BZG 3270
1 4 Removing and installing poly V-belt 3272
1 5 Removing and installing valve timing housing 3274
2 Cylinder block, seals 3279
2 1 Assembly overview 3279
2 2 Renewing crankshaft oil seal – belt pulley end 3280
2 3 Renewing crankshaft oil seal – flywheel end 3282
15 – Cylinder head, valve gear 3285
1 Cylinder head 3285
1 1 Assembly overview – engine codes AWY, BMD, BBM 3285
1 2 Removing and installing cylinder head, engine codes AWY, BMD, BBM 3287
1 3 Assembly overview – engine codes AZQ, BME, BZG 3290
1 4 Removing and installing cylinder head, engine codes AZQ, BME, BZG 3293
1 5 Removing and installing camshaft housing, engine codes AZQ, BME, BZG 3296
1 5 1 Removing camshaft housing 3298
1 5 2 Installing camshaft housing 3299
1 6 Checking valve timing, engine codes AWY, BMD, BBM 3300
1 7 Checking valve timing, engine codes AZQ, BME, BZG 3302
1 8 Removing and installing timing chain and drive chain for oil pump, engine codes AWY, BMD, BBM 3304
1 9 Adjusting valve timing, engine codes AWY, BMD, BBM 3306
1 10 Removing and installing timing chain and drive chain for oil pump, engine codes AZQ, BME, BZG 3309
1 11 Adjusting valve timing, engine codes AZQ, BME, BZG 3313
1 12 Checking compression 3316
2 Valve gear 3319
2 1 Assembly overview – engine codes AWY, BMD, BBM 3319
2 2 Assembly overview – engine codes AZQ, BME, BZG 3321
2 3 Checking camshaft axial clearance 3324
2 4 Reworking valve seats 3324
2 4 1 Two valves per cylinder, engine codes AWY, BMD, BBM 3325
2 4 2 Four valves per cylinder, engine codes AZQ, BME, BZG 3326
2 5 Checking valve guides 3327
2 6 Renewing valve stem seals 3328
17 – Lubrication 3332
1 Parts of lubrication system 3332
1 1 Engine oil 3332
1 2 Assembly overview 3332
1 3 Assembly overview – oil filter 3335
1 4 Removing and installing oil filter element 3335
1 5 Removing and installing oil sump 3336
1 6 Checking oil pressure and oil pressure switch 3337
19 – Cooling 3339
1 Parts of cooling system 3339
1 1 Assembly overview – parts of cooling system, body side (radiator with two fans) 3339
1 2 Assembly overview – parts of cooling system, body side (radiator with one fan) 3341
1 3 Assembly overview – parts of cooling system, engine side 3342
1 4 Draining and filling coolant 3343
1 5 Removing and installing radiator 3345
1 6 Removing and installing coolant pump 3347
20 – Fuel supply system 3349
1 Parts of fuel supply system 3349
1 1 Assembly overview – fuel tank with attachments 3349
1 2 Safety precautions when working on fuel supply system 3352
1 3 Rules for cleanliness 3353
1 4 Removing and installing fuel delivery unit 3353
1 5 Removing and installing fuel gauge sender -G- 3355
1 6 Removing and installing fuel tank 3355
1 7 Crash fuel shut-off 3357
1 8 Checking fuel pump 3357
1 9 Bleeding fuel system 3365
2 Activated charcoal filter system 3368
2 1 Function 3368
2 2 Assembly overview 3368
2 3 Checking fuel tank breather 3369
3 Electronic power control (EPC) 3371
3 1 Assembly overview 3371
24 – Mixture preparation – injection 3372
1 Injection system 3372
1 1 Assembly overview – parts of injection system 3372
1 2 Assembly overview – intake manifold, engine codes AWY, BMD, BBM 3374
1 3 Assembly overview – intake manifold, engine codes AZQ, BME, BZG 3375
1 4 Assembly overview – fuel rail with injectors, engine code AWY 3376
1 5 Assembly overview – fuel rail with injectors, engine codes AZQ, BMD, BME, BBM, BZG 3377
1 6 Assembly overview – air filter, engine codes AWY, AZQ, BME 3377
1 7 Removing and installing air filter, engine codes AWY, AZQ, BME 3378
1 8 Assembly overview – air filter, engine codes BMD, BBM, BZG 3379
1 9 Removing and installing air filter, engine codes BMD, BBM, BZG 3380
1 10 Cleaning throttle valve module -J338- 3381
1 11 Safety precautions 3382
1 12 Rules for cleanliness 3383
1 13 Technical data 3384
2 Checking components 3385
2 1 Checking injectors 3385
2 2 Checking fuel pressure regulator and holding pressure 3389
2 3 Checking intake air preheating 3392
2 4 Check non-return valve for crankcase breather 3392
3 Engine control unit -J623- 3395
3 1 Removing and installing engine control unit -J623- 3395
3 2 Removing and installing anti-theft-secured engine control unit -J623- (►model year 2007) 3395
3 3 Vehicles with anti-theft secured engine control unit -J623- (model year 2007►) 3397
26 – Exhaust system 3399
1 Parts of the exhaust system 3399
1 1 Assembly overview – front exhaust system with attachments 3399
1 2 Assembly overview – silencers with mountings 3400
2 Exhaust gas recirculation system 3402
2 1 Assembly overview 3402
28 – Ignition system 3403
1 Ignition system 3403
1 1 Assembly overview – parts of ignition system 3403
1 2 Removing and installing ignition coils with output stage 3404
1 3 Safety precautions 3405
1 4 Test data, spark plugs 3406
00 – Technical data 3413
1 – Technical data 3413
1 1 – Technical data 3413
1 2 – Engine number 3413
1 3 – Engine data 3413
10 – Removing and installing engine 3414
1 – Removing and installing engine 3414
1 1 – Removing and installing engine 3414
1 2 – Notes on removing 3416
1 3 – Securing engine to assembly stand 3418
1 4 – Notes on installing 3418
1 5 – Tightening torques 3419
1 6 – Assembly mountings 3419
1 7 – Additional information and removal instructions for vehicles with air conditioner 3421
13 – Crankshaft group 3422
1 – Dismantling and assembling engine 3422
1 1 – Dismantling and assembling engine 3422
1 2 – Removing and installing ribbed belt 3434
2 – Removing and installing sealing flange and flywheel 3437
2 1 – Removing and installing sealing flange and flywheel 3437
2 2 – Renewing crankshaft oil seal -pulley end 3440
2 3 – Removing and installing sealing flange, pulley end 3443
3 – Removing and installing crankshaft 3446
3 1 – Removing and installing crankshaft 3446
3 2 – Crankshaft dimensions 3450
4 – Dismantling and assembling pistons and conrods 3451
4 1 – Dismantling and assembling pistons and conrods 3451
4 2 – Checking piston projection at TDC 3457
4 3 – Piston and cylinder dimensions 3458
15 – Cylinder head, Valve gear 3459
1 – Removing and installing cylinder head 3459
1 1 – Removing and installing cylinder head 3459
1 2 – Removing and installing cylinder head cover 3467
1 3 – Removing, installing and tensioning toothed belt 3469
1 4 – Removing and installing cylinder head 3476
1 5 – Checking compression pressures 3479
2 – Servicing valve gear 3481
2 1 – Servicing valve gear 3481
2 2 – Checking valve guides 3488
2 3 – Renewing valve stem seals 3490
2 4 – Removing and installing camshaft 3492
2 5 – Removing and installing camshaft oil seal 3496
17 – Lubrication 3498
1 – Removing and installing parts of the lubrication system 3498
1 1 – Removing and installing parts of the lubrication system 3498
1 2 – Removing and installing sump 3510
1 3 – Checking oil pressure and oil pressure switch 3512
19 – Cooling system 3514
1 – Removing and installing parts of cooling system 3514
1 1 – Removing and installing parts of cooling system 3514
1 2 – Parts of cooling system body side 3515
1 3 – Parts of cooling system engine side 3518
1 4 – Coolant hose connection diagram 3522
1 5 – Draining and filling cooling system 3524
1 6 – Removing and installing radiator 3527
1 7 – Removing and installing coolant pump 3528
1 8 – Removing and installing thermostat 3530
20 – Fuel supply system 3532
1 – Removing and installing parts of fuel supply system 3532
1 1 – Removing and installing parts of fuel supply system 3532
1 2 – Removing and installing fuel tank with its attachments 3533
1 3 – Servicing fuel filter 3538
1 4 – Safety precautions when working on the fuel supply system 3540
1 5 – Rules for cleanliness 3541
1 6 – Removing and installing fuel cooler 3541
1 7 – Removing and installing fuel tank 3542
1 8 – Removing and installing fuel delivery unit 3544
1 9 – Removing and installing fuel gauge sender 3546
1 10 – Checking fuel pump 3547
1 11 – Servicing accelerator mechanism 3549
1 12 – Checking tandem pump 3550
1 13 – Removing and installing tandem pump 3552
21 – Charging 3555
1 – Charge air system with turbocharger 3555
1 1 – Charge air system with turbocharger 3555
1 2 – Safety precautions 3555
1 3 – Rules for cleanliness 3555
1 4 – Removing and installing turbocharger with attachments 3555
1 5 – Removing and installing parts of charge air cooling 3564
23 – Mixture preparation, Injection 3568
1 – Servicing Diesel direct injection system 3568
1 1 – Servicing Diesel direct injection system 3568
1 2 – Safety precautions 3568
1 3 – Rules for cleanliness 3568
1 4 – Servicing intake manifold flap 3569
1 5 – Servicing unit injector 3572
1 6 – Removing and installing O rings for unit injector 3574
1 7 – Removing and installing unit injector 3576
2 – Engine control unit 3580
2 1 – Engine control unit 3580
2 2 – Interrogating and erasing engine control unit fault memory 3580
2 3 – Adapting functions and components 3581
2 4 – Removing and installing engine control unit 3581
26 – Exhaust system 3583
1 – Removing and installing parts of exhaust system 3583
1 1 – Removing and installing parts of exhaust system 3583
1 2 – Aligning exhaust system ensuring connections are stress-free 3585
2 – Exhaust gas recirculation system 3586
2 1 – Exhaust gas recirculation system 3586
2 2 – Removing and installing parts of exhaust gas recirculation system 3587
28 – Ignition system 3589
1 – Checking glow plug system 3589
1 1 – Checking glow plug system 3589
1 2 – Checking glow plugs 3590
00 – Technical data 3596
1 – Technical data 3596
1 1 – Technical data 3596
1 2 – Engine number 3596
1 3 – Engine data 3596
10 – Removing and installing engine 3598
1 – Removing and installing engine 3598
1 1 – Removing and installing engine 3598
1 2 – Notes on removing 3599
1 3 – Securing engine to assembly stand 3603
1 4 – Notes on installing 3603
1 5 – Tightening torques 3604
1 6 – Assembly mountings 3605
1 7 – Additional information and removal instructions for vehicles with air conditioner 3606
13 – Crankshaft group 3607
1 – Dismantling and assembling engine 3607
1 1 – Dismantling and assembling engine 3607
1 2 – Removing and installing ribbed belt 3614
1 3 – Checking semi-automatic toothed belt tensioning roller 3616
2 – Removing and installing sealing flange and flywheel 3617
2 1 – Removing and installing sealing flange and flywheel 3617
2 2 – Renewing crankshaft oil seal -pulley end 3621
2 3 – Removing and installing sealing flange, pulley end 3624
3 – Removing and installing crankshaft 3627
3 1 – Removing and installing crankshaft 3627
3 2 – Crankshaft dimensions 3630
4 – Dismantling and assembling pistons and conrods 3631
4 1 – Dismantling and assembling pistons and conrods 3631
4 2 – Checking piston projection at TDC 3637
4 3 – Piston and cylinder dimensions 3638
15 – Cylinder head, Valve gear 3639
1 – Removing and installing cylinder head 3639
1 1 – Removing and installing cylinder head 3639
1 2 – Removing, installing and tensioning toothed belt 3643
1 3 – Removing and installing cylinder head 3649
1 4 – Checking compression pressures 3655
2 – Servicing valve gear 3657
2 1 – Servicing valve gear 3657
2 2 – Reworking valve seats 3663
2 3 – Checking valve guides 3665
2 4 – Renewing valve stem seals 3666
2 5 – Removing and installing camshaft 3668
2 6 – Checking hydraulic bucket tappets 3671
17 – Lubrication 3673
1 – Removing and installing parts of the lubrication system 3673
1 1 – Removing and installing parts of the lubrication system 3673
1 2 – Removing and installing sump 3681
1 3 – Checking oil pressure and oil pressure switch 3684
19 – Cooling system 3687
1 – Removing and installing parts of cooling system 3687
1 1 – Removing and installing parts of cooling system 3687
1 2 – Parts of cooling system body side 3688
1 3 – Parts of cooling system engine side 3692
1 4 – Coolant hose connection diagram 3695
1 5 – Draining and filling cooling system 3697
1 6 – Removing and installing coolant pump 3700
1 7 – Removing and installing radiator 3702
1 8 – Removing and installing thermostat 3704
20 – Fuel supply system 3706
1 – Removing and installing parts of fuel supply system 3706
1 1 – Removing and installing parts of fuel supply system 3706
1 2 – Removing and installing fuel tank with its attachments 3707
1 3 – Servicing fuel filter 3712
1 4 – Safety precautions when working on the fuel supply system 3715
1 5 – Rules for cleanliness 3715
1 6 – Removing and installing fuel tank 3716
1 7 – Removing and installing fuel delivery unit 3718
1 8 – Removing and installing fuel gauge sender 3720
1 9 – Servicing accelerator mechanism 3721
23 – Mixture preparation, Injection 3722
1 – Servicing Diesel direct injection system 3722
1 1 – Servicing Diesel direct injection system 3722
1 2 – Safety precautions 3722
1 3 – Rules for cleanliness 3722
1 4 – Servicing injection pump 3723
1 5 – Dismantling and assembling intake manifold 3728
1 6 – Removing and installing injection pump 3730
1 7 – Removing and installing injectors 3735
1 8 – Checking injectors 3736
1 9 – Renewing injection timing device cover O-ring 3737
2 – Engine control unit 3738
2 1 – Engine control unit 3738
2 2 – Removing and installing engine control unit 3738
2 3 – Interrogating and erasing engine control unit fault memory 3738
2 4 – Adapting functions and components 3739
26 – Exhaust system 3741
1 – Removing and installing parts of exhaust system 3741
1 1 – Removing and installing parts of exhaust system 3741
1 2 – Dismantling and assembling exhaust system 3741
2 – Exhaust gas recirculation system 3745
2 1 – Exhaust gas recirculation system 3745
2 2 – Removing and installing parts of exhaust gas recirculation system 3746
2 3 – Connection diagram for vacuum hoses 3747
2 4 – Checking exhaust gas recirculation valve (mechanical) 3748
28 – Glow plug system 3749
1 – Checking glow plug system 3749
1 1 – Checking glow plug system 3749
1 2 – Checking glow plugs 3750
27 – Starter, current supply, CCS 3759
1 Battery 3759
1 1 Types of battery 3759
1 2 Warning notices and safety regulations 3759
1 3 Battery terminal connection 3759
2 Checking battery 3760
3 Charging battery 3761
4 Disconnecting and reconnecting batteries 3762
4 1 Disconnecting battery 3762
4 2 Connecting battery 3763
5 Removing and installing battery 3766
5 1 Removing battery 3766
5 2 Installing battery 3766
5 3 Removing and installing battery console (vehicles as of 04 05) 3767
6 Specified torques: battery 3771
7 Starter 3772
7 1 Checking starter -B- 3772
7 2 Removing and installing starter, manual gearbox 3772
7 2 1 Vehicles with 1 2 l 40 kW or 47 kW injection engine with manual gearbox 3772
7 2 2 Vehicles with 1 4 l 51 kW, 55 kW or 74 kW injection engine with manual gearbox 3773
7 2 3 Vehicles with a 1 4 l 59 kW injection engine and manual gearbox 3775
7 2 4 Vehicles with 1 4 l 63 kW FSI engine and manual gearbox 3776
7 2 5 Vehicles with 1 6 l 77 kW FSI engine and manual gearbox 3777
7 2 6 Vehicles with 1 8 l 110 kW turbo engine and manual gearbox 3779
7 2 7 Vehicles with 1 4 l 51 kW, 55 kW or 59 kW TDI engine and manual gearbox 3780
7 2 8 Vehicles with 1 9 l 47 kW SDI engine and manual gearbox 3782
7 2 9 Vehicles with 1 9 l 74 kW TDI engine and manual gearbox 3784
7 3 Removing and installing starter, automatic gearbox 3786
7 3 1 Vehicles with 4-speed automatic gearbox 001 3786
7 3 2 Vehicles with 6-speed automatic gearbox 09G 3787
8 Specified torques: starter 3790
9 Alternator, vehicles up to 03 05 3791
9 1 Securing battery positive wire to alternator 3791
9 2 Checking poly V-belt 3791
9 3 Checking alternator -C- 3791
9 3 1 Checking alternator -C- 3791
9 4 Alternator, 1 2 l 40 kW or 47 kW injection engine 3792
9 4 1 Assembly overview 3792
9 4 2 Removing and installing alternator, 1 2 l 40 kW or 47 kW injection engine 3793
9 5 Alternator, 1 4 l 55 kW or 74 kW injection engine 3795
9 5 1 Assembly overview 3795
9 5 3 Removing and installing alternator, 1 4 l 55 kW or 74 kW injection engine 3797
9 6 Alternator, 1 4 l 63 kW FSI engine 3800
9 6 1 Assembly overview 3800
9 6 2 Removing and installing alternator, 1 4 l 63 kW FSI engine 3801
9 7 Alternator, 1 6 l 77 kW injection engine 3803
9 7 1 Assembly overview – 1 6 l 77 kW injection engine 3803
9 7 2 Removing and installing alternator, 1 6 l 77 kW injection engine 3805
9 8 Alternator, 1 4 l 51 kW or 55 kW TDI engine 3807
9 8 1 Assembly overview 3807
9 8 2 Removing and installing alternator, 1 4 l 55 kW TDI engine 3808
9 9 Alternator, 1 9 l 47 kW SDI engine 3810
9 9 1 Assembly overview 3810
9 9 2 Removing and installing alternator, 1 9 l 47 kW SDI engine 3811
9 10 Alternator, 1 9 l 74 kW or 96 kW TDI engine 3814
9 10 1 Assembly overview 3814
9 10 3 Removing and installing alternator, 1 9 l 74 kW or 96 kW TDI engine 3815
9 11 Removing and installing poly V-belt pulley on alternator 3818
9 11 1 Removing and installing poly V-belt pulley with no freewheel 3818
9 11 2 Removing and installing poly V-belt pulley with a freewheel, manufacturer: Bosch 3819
9 11 3 Removing and installing poly V-belt pulley with a freewheel, manufacturer: Valeo 3820
9 12 Voltage regulator for alternator 3822
9 12 1 Removing and installing voltage regulator, manufacturer: Bosch 3823
9 12 2 Removing and installing voltage regulator, manufacturer: Valeo 3823
10 Alternator, vehicles as of 04 05 3826
10 1 Securing battery positive wire to alternator 3826
10 2 Checking poly V-belt 3826
10 3 Checking alternator -C- 3826
10 4 Alternator, 1 2 l 40 kW or 47 kW injection engine 3826
10 5 Alternator, 1 4 l 55 kW or 74 kW injection engine 3826
10 6 Alternator, 1 4 l 63 kW FSI engine 3826
10 7 Alternator, 1 6 l 77 kW injection engine 3826
10 7 1 Assembly overview – 1 6 l 77 kW injection engine 3826
10 7 2 Removing and installing alternator, 1 6 l 77 kW injection engine 3828
10 8 Alternator, 1 8 l 110 kW turbo engine 3830
10 8 1 Assembly overview 3830
10 8 3 Removing and installing alternator, 1 8 l 110 kW turbo engine 3832
10 9 Alternator, 1 4 l 51 kW, 55 kW or 59 kW TDI engine 3835
10 9 1 Assembly overview 3835
10 9 2 Removing and installing alternator, 1 4 l 51 kW, 55 kW or 59 kW TDI engine 3836
10 10 Alternator, 1 9 l 47 kW SDI engine 3838
10 11 Alternator, 1 9 l 74 kW or 96 kW TDI engine 3838
10 11 1 Assembly overview 3838
10 11 3 Removing and installing alternator, 1 9 l 74 kW or 96 kW TDI engine 3840
10 12 Removing and installing poly V-belt pulley on alternator 3843
10 13 Voltage regulator for alternator 3843
11 Alternator, vehicles as of 06 06 3844
11 1 Securing battery positive wire to alternator 3844
11 2 Checking poly V-belt 3844
11 3 Checking alternator -C- 3844
11 4 Alternator, 1 2 l 40 kW or 47 kW injection engine 3844
11 5 Alternator, 1 4 l 55 kW or 74 kW injection engine 3844
11 6 Alternator, 1 4 l 59 kW injection engine with air conditioning system 3844
11 6 1 Assembly overview 3844
11 6 3 Removing and installing alternator, 1 4 l 59 kW injection engine with air conditioning system 3846
11 7 Alternator, 1 4 l 59 kW injection engine with air no conditioning system 3848
11 7 1 Assembly overview 3848
11 7 3 Removing and installing alternator, 1 4 l 59 kW injection engine with no air conditioning system 3849
11 8 Alternator, 1 6 l 77 kW injection engine 3852
11 9 Alternator, 1 8 l 110 kW turbo engine 3852
11 10 Alternator, 1 4 l 51 kW or 59 kW TDI engine 3852
11 11 Alternator, 1 9 l 74 kW or 96 kW TDI engine 3852
11 12 Removing and installing poly V-belt pulley on alternator 3852
11 13 Voltage regulator for alternator 3852
12 Alternator, vehicles with diesel particulate filter 3854
12 1 Securing battery positive wire to alternator 3854
12 2 Checking poly V-belt 3854
12 3 Checking alternator -C- 3854
12 4 Alternator, 1 4 l 51 kW TDI engine with air conditioning system 3854
12 4 1 Assembly overview 3854
12 4 3 Removing and installing alternator, 1 4 l 51 kW TDI engine with air conditioning system 3856
12 5 Alternator, 1 4 l 51 kW TDI engine with no air conditioning system 3858
12 5 1 Assembly overview 3858
12 5 3 Removing and installing alternator, 1 4 l 51 kW TDI engine with no air conditioning system 3860
12 6 Alternator, 1 4 l 59 kW TDI engine with air conditioning system 3862
12 6 1 Assembly overview 3862
12 6 3 Removing and installing alternator, 1 4 l 59 kW TDI engine with air conditioning system 3864
12 7 Alternator, 1 4 l 59 kW TDI engine with no air conditioning system 3867
12 7 1 Assembly overview 3867
12 7 3 Removing and installing alternator, 1 4 l 59 kW TDI engine with no air conditioning system 3868
12 8 Alternator, 1 9 l 74 kW TDI engine with air conditioning system 3870
12 8 1 Assembly overview 3870
12 8 3 Removing and installing alternator, 1 9 l 74 kW TDI engine with air conditioning system 3872
12 9 Alternator, 1 9 l 74 kW TDI engine with no air conditioning system 3875
12 9 1 Assembly overview 3875
12 9 3 Removing and installing alternator, 1 9 l 74 kW TDI engine with no air conditioning system 3876
12 10 Removing and installing poly V-belt pulley on alternator 3879
12 11 Voltage regulator for alternator 3879
13 Cruise control system (CCS) 3880
13 1 Activating and deactivating cruise control system (CCS) 3880
90 – Gauges, instruments 3881
1 Dash panel insert 3881
1 1 Renewing dash panel insert 3881
1 2 Removing and installing dash panel insert 3882
1 3 Description of back of dash panel insert 3883
1 4 Warning lamp symbols in dash panel insert 3883
2 Service interval display 3885
2 1 Resetting service interval display 3885
92 – Windscreen wash/wipe system 3886
1 Windscreen wiper system 3886
1 1 Removing and installing windscreen wiper system 3886
1 1 1 Removing wiper arms 3886
1 1 2 Removing plenum chamber cover 3887
1 1 3 Removing bulkhead 3887
1 1 4 Removing wiper frame with linkage and windscreen wiper motor -V- 3888
1 1 5 Removing windscreen wiper motor -V- from wiper frame 3889
1 1 6 Installing windscreen wiper motor -V- in wiper frame 3889
1 1 7 Setting park position 3890
1 1 8 Installing wiper frame with linkage and windscreen wiper motor -V- 3890
1 1 9 Installing plenum chamber cover 3891
1 1 10 Installing wiper arms 3891
1 2 Adjusting wiper blade park position 3891
1 2 1 Vehicles ▸12 02 with windscreen wiper system 6Q1/6Q2 955 023 D and 6QE 955 023 3892
1 2 2 Vehicles 01 03 ▸ 08 03 3893
1 2 3 Vehicles 09 03 ▸ with windscreen wiper system 6Q1/6Q2 955 023 E 3893
1 3 Aerodynamic wiper 3894
1 3 2 Removing and installing wiper rubber blade on aero windscreen wiper 3894
1 4 Removing and installing rain sensor -G213- 3895
1 5 Fitting a new adhesive pad to the rain sensor (Valeo) 3896
1 5 1 Preparing windscreen 3897
1 5 2 Preparing rain sensor 3897
1 5 3 Bonding a new adhesive pad to the rain sensor 3897
1 5 4 Installing rain sensor 3899
2 Windscreen washer system 3901
2 1 Assembly overview – windscreen washer system 3901
2 2 Removing and installing reservoir for windscreen and headlight washer system 3903
2 3 Removing and installing windscreen and rear window washer pump -V59- 3904
2 4 Removing and installing windscreen washer fluid level sender -G33- 3905
2 5 Removing and installing windscreen washer jets 3906
2 6 Cleaning spray jets for front windscreen washer system 3906
2 7 Adjusting windscreen washer system washer jets 3906
3 Rear window wiper system 3907
3 1 Assembly overview – rear window wiper system 3907
3 2 Removing and installing rear window wiper 3907
3 2 1 Removing wiper arm 3907
3 2 2 Removing and installing rear window wiper motor 3908
3 3 Adjusting rear window wiper park position 3908
3 3 1 Vehicles up to 03 05 3908
3 3 2 Vehicles as of 04 05 3909
4 Rear window washer system 3910
4 1 Assembly overview – rear window washer system 3910
4 2 Removing and installing spray jet 3911
4 3 Cleaning spray jet 3911
4 4 Adjusting washer jet 3911
5 Headlight washer system 3912
5 1 Assembly overview – headlight washer system 3912
5 2 Removing and installing washer jet assembly 3914
5 3 Removing and installing pop-up washer spray jet cylinder, vehicles up to 03 05 3914
5 4 Removing and installing pop-up washer spray jet cylinder, vehicles as of 04 05 3915
5 5 Removing and installing headlight washer system pump -V11- 3916
5 6 Adjusting headlight washer system jets 3916
5 7 Bleeding headlight washer system 3916
6 Washer fluid line hose couplings 3917
7 Hose repair 3918
8 Specified torques for windscreen wash/wipe system 3919
94 – Lights, bulbs, switches – exterior 3920
1 Headlight, vehicles up to 03 05 3920
1 1 Assembly overview – headlight 3920
1 2 Removing and installing headlight 3921
1 3 Adjusting headlight installation position 3923
1 4 Renewing headlight bulbs 3924
1 4 1 Renewing side light bulb 3924
1 4 2 Renewing headlight dipped beam bulb 3926
1 4 3 Renewing headlight main beam bulb 3928
1 4 4 Renewing front turn signal bulb 3930
1 5 Headlight range control motor 3932
1 5 2 Removing and installing headlight range control motor (headlight manufacturer: Automotive Lighting) 3933
1 5 3 Removing and installing headlight range control motor (headlight manufacturer: Valeo) 3935
1 6 Repairing headlight retaining tabs 3937
1 6 1 Repairing upper retaining tab 3937
1 6 2 Repairing outer retaining tab 3938
1 7 Converting headlights for use when driving on the left or right 3939
1 7 1 Fitting conversion foil 3940
1 8 Adjusting headlight 3941
2 Headlight, vehicles as of 04 05 3942
2 1 Assembly overview – headlight 3942
2 2 Removing and installing headlight 3944
2 3 Adjusting headlight installation position 3945
2 4 Renewing headlight bulbs; headlight manufacturer: Hella 3947
2 4 1 Renewing side light bulb 3947
2 4 2 Renewing headlight dipped beam bulb 3949
2 4 3 Renewing headlight main beam bulb 3952
2 4 4 Renewing front turn signal bulb 3954
2 5 Renewing headlight bulbs; headlight manufacturer: Valeo 3956
2 5 1 Renewing side light bulb 3956
2 5 2 Renewing headlight dipped beam bulb 3957
2 5 3 Renewing headlight main beam bulb 3960
2 5 4 Renewing front turn signal bulb 3962
2 6 Headlight range control motor 3964
2 6 2 Removing and installing headlight range control motor (headlight manufacturer: Hella) 3965
2 6 3 Removing and installing headlight range control motor (headlight manufacturer: Valeo) 3968
2 7 Repairing headlight retaining tabs 3970
2 7 1 Repairing upper retaining tab 3970
2 7 2 Repairing side retaining tab 3971
2 7 3 Repairing lower retaining tab 3972
2 8 Converting headlights for use when driving on the left or right 3973
2 8 1 Converting headlights designed for driving on the right to driving on the left 3973
2 8 2 Converting headlights designed for driving on the left to driving on the right 3974
2 9 Adjusting headlight 3975
3 Front fog light, vehicles up to 03 05 3976
3 1 Fog lights (except Polo Fun) 3976
3 1 1 Removing and installing fog light 3976
3 1 2 Removing and installing left fog light bulb -L22- and right fog light bulb -L23- 3977
3 2 Fog lights (Polo Fun only) 3978
3 2 1 Removing and installing fog light 3978
3 2 2 Removing and installing left fog light bulb -L22- and right fog light bulb -L23- 3979
3 3 Adjusting fog light 3980
4 Front fog light, vehicles as of 04 05 3981
4 1 Fog lights (except Polo Cross/Dune) 3981
4 1 1 Removing and installing fog light 3981
4 1 2 Removing and installing left fog light bulb -L22- and right fog light bulb -L23- 3982
4 2 Fog light Polo Cross (Polo Dune) 3983
4 2 1 Removing and installing fog light 3983
4 2 2 Removing and installing left fog light bulb -L22- and right fog light bulb -L23- 3983
4 3 Adjusting fog light 3984
5 Side mounted repeater turn signals, vehicles up to 03 05 3985
5 1 Removing and installing side mounted repeater turn signal 3985
6 Mirror turn signal bulb in exterior mirror, vehicles from 04 05 3986
7 Tail lights, vehicles up to 03 05 3987
7 1 Assembly overview – tail lights 3987
7 2 Removing and installing tail light 3988
7 3 Removing and installing bulb holder 3989
8 Tail lights, vehicles as of 04 05 3990
8 1 Assembly overview – tail lights 3990
8 2 Removing and installing tail light 3990
8 3 Removing and installing bulb holder 3991
9 Additional brake light 3993
9 1 Additional brake light (except Polo GTI, Polo Blue Motion) 3993
9 1 1 Removing and installing additional brake light 3993
9 1 2 Removing and installing bulb holder 3994
9 2 Additional brake light (Polo GTI, Polo Blue Motion) 3994
10 Number plate lights 3996
10 1 Removing and installing number plate light -X- 3996
11 Steering column switch 3997
11 1 Removing and installing steering column switch 3998
11 2 Removing and installing airbag coil connector and return ring with slip ring -F138- 4000
11 3 Basic setting of steering angle sensor -G85- 4001
12 Ignition/starter switch and lock cylinder 4003
12 1 Removing and installing lock cylinder 4003
12 2 Ignition/starter switch -D- 4004
12 2 1 Removing and installing ignition/starter switch -D- 4005
12 2 2 Pin assignment for ignition/starter switch -D- 4005
13 Steering lock housing 4006
13 1 Removing and installing steering lock housing 4006
14 Parking aid, vehicles as of 04 05 4008
14 1 Assembly overview 4008
14 2 Parking aid control unit -J446- 4009
14 2 1 Removing and installing parking aid control unit -J446- 4009
14 2 2 Parking aid control unit -J446- final control diagnosis 4009
14 2 3 Adapting parking aid control unit -J446- 4010
14 2 4 Coding parking aid control unit -J446- 4010
14 2 5 Pin assignment of parking aid control unit -J446- 4011
14 3 Parking aid warning buzzer -H15- 4011
14 3 1 Removing and installing parking aid warning buzzer -H15- 4011
14 4 Rear parking aid senders 4011
14 4 1 Removing and installing rear parking aid sender 4011
14 4 2 Renewing bumper cover in cases of repair 4012
14 4 3 Renewing individual sender retainer in cases of repair 4012
14 4 4 Renewing individual sender in cases of repair 4013
15 Specified torques: lights, bulbs, switches – exterior 4014
15 1 Specified torques: headlight 4014
15 2 Specified torques: fog light 4014
15 3 Specified torques: tail light 4014
15 4 Specified torques: additional brake light 4014
15 5 Specified torques: steering column switch 4014
96 – Lights, bulbs, switches – interior 4015
1 Interior lights and switches 4015
1 1 Removing and installing interior monitoring deactivation switch -E267- 4015
2 Lights and switches in engine compartment 4016
2 1 Removing and installing bonnet contact switch -F266- 4016
3 Lights and switches in dash panel 4017
3 1 Removing and installing light switch -E1- 4017
3 2 Removing and installing headlight range control adjuster -E102- and switches and instruments lighting control -E20- 4018
3 3 Removing and installing switches, lights and regulators in centre of dash panel 4018
3 4 Removing and installing front passenger side airbag deactivation key switch -E224- 4020
4 Lights and switches in front doors 4021
4 1 Removing and installing switch module for driver side window lift 4021
4 2 Removing and installing window lift switch in passenger door -E107- 4021
4 3 Removing and installing switch module for driver side mirror adjustment 4022
4 4 Removing and installing driver side interior locking switch -E150- 4022
4 5 Removing and installing central locking deadlock function warning lamp -K133- 4023
4 6 Removing and installing left door warning lamp -M27- and right door warning lamp -M28- 4024
4 7 Removing and installing door contact switch 4025
5 Lights and switches in rear doors 4027
5 1 Removing and installing rear left window regulator switch in door -E52- 4027
5 2 Removing and installing rear right window regulator switch in door -E54- 4027
6 Lights and switches in luggage compartment 4028
6 1 Removing and installing luggage compartment light switch -F5- 4028
6 2 Removing and installing luggage compartment light -W3- 4028
7 Lights and switches in roof trim 4030
7 1 Front interior light -W1- 4030
7 1 1 Removing and installing front interior light -W1- 4030
7 1 2 Renewing bulb in front interior light -W1- 4031
7 2 Front interior light -W1- with reading lights and preparation for telephone 4032
7 2 1 Removing and installing front interior light -W1- 4032
7 2 2 Renewing bulb in front interior light -W- 4034
7 2 3 Renewing bulb in front passenger reading light -W13- and driver side reading light -W19- 4035
7 3 Front interior light -W1- with reading lights and regulator for sunroof 4036
7 3 1 Removing and installing front interior light -W1- 4036
7 3 2 Renewing bulb in front interior light -W1- 4037
7 3 3 Renewing bulb in front passenger reading light -W13- and driver side reading light -W19- 4038
7 3 4 Removing and installing sliding sunroof adjustment regulator -E139- 4039
7 4 Rear interior light -W43- 4040
7 4 1 Removing and installing rear interior light -W43- 4040
7 4 2 Renewing bulb in rear interior light -W43- 4041
7 5 Removing and installing illuminated vanity mirror 4041
8 Horn 4044
8 1 Single tone horn 4044
8 1 1 Removing and installing single tone horn 4044
8 1 2 Checking single tone horn 4045
8 2 Dual tone horn 4045
8 2 1 Removing and installing dual-tone horn 4045
8 2 2 Checking dual tone horn 4047
8 3 Horn plate -H- 4047
8 3 1 Removing and installing signal horn activation -H- 4047
8 3 2 Checking horn plate -H- 4048
9 Immobilizer 4049
9 1 Immobilizer control unit -J362- 4049
9 2 Immobilizer reader coil -D2- 4049
9 3 Ignition key 4049
9 3 1 Ignition key – variable code transponder 4049
9 3 2 Adapting ignition keys to the immobilizer 4050
9 3 3 Adapting ignition keys to the convenience system 4050
10 Anti-theft alarm system (ATA) 4051
10 1 Activating and deactivating anti-theft alarm system 4051
10 2 Removing and installing interior monitoring deactivation switch -E267- 4052
10 3 Anti-theft alarm ultrasonic sensor -G209- 4052
10 3 1 Removing and installing ATA ultrasonic sensor -G209- (vehicles without sliding sunroof) 4052
10 3 2 Removing and installing ATA ultrasonic sensor -G209- (vehicles with sliding sunroof) 4053
10 4 Central locking and anti-theft alarm system aerial -R47- 4054
10 5 Alarm horn -H12- 4055
10 5 1 Removing and installing alarm horn -H12- 4055
11 Specified torques: lights, bulbs, switches – interior 4056
11 1 Specified torques: horn or dual tone horn -H1- 4056
11 2 Specified torques: signal horn activation -H- 4056
11 3 Specified torques: alarm horn -H12- 4056
97 – Wiring 4057
1 Vehicle diagnosis, testing and information systems 4057
2 Fuse holder 4058
2 1 Removing and installing fuse holder 4058
2 2 Main fuse carrier, vehicles up to 03 05 4058
2 2 1 Removing and installing main fuse carrier (version 1) 4059
2 2 2 Removing and installing main fuse carrier (version 2) 4061
2 3 Main fuse carrier, vehicles as of 04 05 4063
2 3 1 Removing and installing main fuse carrier (version 1) 4064
2 3 2 Removing and installing main fuse carrier (version 2) 4067
3 Relay carrier 4071
3 1 Removing and installing relay carrier 4071
4 Potential distributor 4073
4 1 Removing and installing voltage distributor 4073
5 Connector points and compact connector 4074
5 1 A-pillar coupling station 4074
5 2 B-pillar coupling station 4074
5 3 Compact connector at bulkhead 4074
5 3 1 Removing/installing bulkhead connectors on engine end and releasing/locking compact connector on engine end 4075
5 3 2 Removing and installing compact connector 4076
6 Repairing connector on steering column switch 4078
6 1 Checking and renewing housing and contacts of 41-pin connector -T41- 4078
6 1 1 Checking 4078
6 1 3 Removing contacts and renewing connector housing 4078
6 1 4 Assembling connector housing 4080
6 1 5 Repairing wire with defective contact 4081
7 Control units 4082
7 1 Onboard supply control unit -J519- 4082
7 1 1 Removing and installing onboard supply control unit -J519- 4083
7 1 2 Renewing onboard supply control unit -J519- 4084
7 1 3 Coding onboard supply control unit -J519- 4084
7 1 4 Activating “comfort signaling/blinking” 4085
7 1 5 Adapting turn signal cycles for “tap signaling” 4085
7 2 Data bus diagnostic interface -J533- 4086
7 3 Convenience system central control unit -J393- 4086
7 3 1 Removing and installing convenience system central control unit -J393- 4087
7 3 2 Coding convenience system central control unit -J393- 4087
7 3 3 Checking anti-theft alarm 4087
8 Specified torques: wires/cables 4088
8 1 Specified torques: fuse holder 4088
8 2 Specified torques: main fuse carrier 4088
8 3 Specified torques: compact connector 4088
9 Wiring harness and connector repairs 4089
80 – Heating 4094
1 Repairing heating system 4094
1 1 Passenger compartment heating 4094
1 2 Removing fresh air blower -V2- 4095
1 2 1 Removing 4095
1 2 2 Installing 4096
1 3 Removing and installing fresh air blower series resistor with overheating fuse -N24- 4096
1 3 1 Removing 4096
1 4 Removing and installing dust and pollen filter 4097
1 4 1 Removing 4097
1 4 2 Installing 4098
1 5 Removing vents 4098
1 5 1 Removing centre vent from centre trim 4098
1 5 2 Installing 4099
1 5 3 Removing vents on driver or front passenger sides 4099
1 5 4 Removing 4100
1 5 5 Installing 4100
1 5 6 Removing left or right footwell vent 4100
1 6 Removing and installing rear footwell air duct 4100
1 6 1 Removing 4100
1 6 2 Installing 4101
1 7 Removing and installing controls for heated and fresh air 4101
1 7 1 Removing 4101
1 8 Connectors on controls for heated and fresh air 4102
1 8 1 Pin assignment for multi-pin connectors A and B on back of heated air and fresh air controls 4102
1 9 Removing and installing flexible shafts 4103
1 9 1 Removing 4103
1 9 2 Checking 4104
1 10 Checking ventilation 4104
1 10 1 Checking 4104
2 Removing and installing heater unit 4105
3 Dismantling and assembling heater unit 4107
3 1 Removing and installing air distribution flap actuator 4108
3 1 1 Removing 4108
3 1 2 Installing 4108
3 2 Removing and installing temperature flap actuator 4109
3 2 1 Removing 4109
3 3 Removing and installing fresh air/air recirculation flap control motor -V154- 4110
3 3 1 Removing 4110
3 3 2 Installing 4111
3 4 Assembly overview – heat exchanger 4111
3 5 Removing and installing heat exchanger 4112
3 6 Removing and installing auxiliary air heater element -Z35- 4114
3 7 Checking auxiliary air heater element -Z35- 4116
3 7 1 Checking auxiliary air heater element -Z35- with peripherals 4116
3 7 2 Checking auxiliary air heater element -Z35- 4116
3 7 3 Test conditions 4117
3 7 4 Test sequence 4117
87 – Air conditioning system 4120
1 Notes on repair work to vehicles with air conditioning and on handling refrigerant 4120
1 1 Notes concerning odours in air conditioned vehicles 4120
2 Air conditioning system with manual regulation “Climatic” 4121
2 1 Air conditioning and heating – passenger compartment 4121
2 2 Removing and installing heating and air conditioning controls, Climatic 4123
2 2 1 Removing 4123
2 2 2 Installing 4124
2 3 Connections on controls for heating and air conditioning, Climatic 4124
2 3 1 Pin assignment for multi-pin connectors A, B and C on back of controls for heating and air conditioning system, Climatic 4124
2 4 Removing and installing flexible shaft 4125
2 4 1 Removing 4125
2 4 2 Checking 4125
2 5 Removing and installing temperature flap control motor -V68- 4126
2 5 1 Removing 4126
2 5 2 Installing 4126
2 6 Climatic – engine compartment 4127
2 7 Checking water drain valve 4128
2 8 Checking high-pressure safety valve on air conditioner compressor 4128
2 9 Removing and installing high-pressure sender -G65- 4129
3 Automatic air conditioning system “Climatronic” 4130
3 1 Procedure when checking and adjusting components 4130
3 2 Function of operating and display unit for Climatronic air conditioning system -E87- with Climatronic control unit -J255- 4131
3 3 Removing and installing operating and display unit for Climatronic air conditioning system -E87- with Climatronic control unit -J255- 4132
3 3 1 Removing 4132
3 4 Connectors on Climatronic control unit -J255- 4133
3 4 1 Pin assignment for multi-pin connectors A, B and C on back of Climatronic control unit 4133
3 5 Climatronic – passenger compartment 4134
3 6 Removing and installing footwell vent temperature sender -G192- 4136
3 6 2 Installing 4136
3 7 Removing and installing evaporator out-flow temperature sender -G263- 4137
3 8 Removing and installing centre vent temperature sender -G191- 4137
3 8 2 Installing 4137
3 9 Removing and installing sunlight penetration photosensor -G107- 4138
3 9 2 Installing 4138
3 10 Removing and installing fresh air intake duct temperature sensor -G89- 4138
3 11 Removing and installing fresh air blower control unit -J126- 4139
3 12 Making adapter cable for control motor actuation up to WEEK 49/2003 4140
3 13 Making adapter cable for control motor actuation from WEEK 50/2003 4140
3 14 Removing and installing air flow flap control motor -V71- 4141
3 14 1 Removing 4141
3 14 2 Installing 4141
3 15 Removing and installing centre flap control motor -V70- 4142
3 15 1 Removing 4142
3 16 Removing and installing defroster flap control motor -V107- and temperature flap control motor -V68- 4143
3 16 1 Removing 4143
3 17 Climatronic – engine compartment 4145
4 Bracket for air conditioner compressor 4147
4 1 Removing and installing bracket for air conditioner compressor, engine codes: ATD, AXR, ASZ, BMT and BLT 4147
4 2 Removing and installing bracket for air conditioner compressor, engine codes: AMF, BAY, BMS, BNM, BNV and BWB 4149
4 3 Removing and installing bracket for air conditioner compressor, engine codes: AUA, AUB, BBY, BBZ, BKY and BUD 4151
4 4 Removing and installing poly V-belt pulley or air conditioning system magnetic clutch -N25- 4153
4 4 1 Removing and installing poly V-belt pulley, Denso air conditioner compressor 4153
5 Repair work on refrigerant circuit which may be performed only in appropriate workshops by specially trained mechanics 4155
5 1 Required special tools, workshop equipment, testers, measuring instruments and auxiliary items 4155
5 2 Removing and installing heater and air conditioning unit 4156
5 3 Dismantling and assembling heater and air conditioner unit “Climatic” 4158
5 4 Dismantling and assembling heater and air conditioning unit, “Climatronic” 4160
5 5 Renewing refrigerant circuit components 4161
5 6 Removing evacuating and charging valve, high-pressure side and low-pressure side 4164
5 6 1 Removing evacuation and charging valve, high-pressure side 4164
5 6 2 Removing evacuating and charging valve, low-pressure side 4165
5 7 Removing dryer cartridge 4166
5 7 1 Removing in vehicles up to 02 05 4167
5 7 2 Installing in vehicles up to 02 05 4167
5 7 3 Removing in vehicles from 03 05 4167
5 7 4 Installing in vehicles from 03 05 4169
5 7 5 Tasks of reservoir with dryer cartridge 4169
5 8 Dismantling and assembling evaporator housing 4170
5 9 Expansion valve, function and removal 4171
5 10 Removing and installing condenser 4172
5 11 Quick-release coupling 4174
5 12 Removing and installing air conditioner compressor 4176
5 12 1 Removing 4176
5 12 2 Installing 4180
5 13 Notes on installing air conditioner compressor 4181
5 13 1 Installing 4181
6 Capacities 4183
6 1 Refrigerant R134a 4183
6 2 Refrigerant oil 4183
6 2 1 Oil distribution 4183
91 – Communication 4188
1 Communication systems 4188
1 1 Fault finding 4188
2 Radio “ALPHA” ► 04 05 4189
2 1 General notes 4189
2 1 1 Fault finding 4189
2 2 Overview of radio system “ALPHA” 4189
2 3 Removing and installing radio unit “ALPHA” 4190
2 3 1 Removing: 4191
2 3 2 Installing: 4191
2 4 Overview of radio connectors 4192
2 4 1 Contact assignment of multi-pin connectors I, II, III on the rear of the radio 4192
2 5 Anti-theft coding 4192
2 5 1 Functional notes 4192
2 5 2 Deactivating anti-theft coding 4193
3 Radio “BETA” ► 04 05 4194
3 1 General notes 4194
3 1 1 Fault finding 4194
3 2 Overview of radio system “BETA” 4194
3 3 Removing and installing radio unit “BETA” 4195
3 3 1 Removing: 4196
3 3 2 Installing: 4196
3 4 Overview of radio connectors 4197
3 4 1 Contact assignment of multi-pin connectors I, II, III on the rear of the radio 4197
3 5 Anti-theft coding 4198
3 5 1 Functional notes 4198
3 5 2 Deactivating anti-theft coding 4199
3 6 Adapting radio components 4199
4 Radio “GAMMA” ► 04 05 4201
4 1 General notes 4201
4 1 1 Fault finding 4201
4 2 Overview of radio system “GAMMA” 4201
4 3 Removing and installing radio unit “GAMMA” 4202
4 3 1 Removing: 4203
4 3 2 Installing: 4203
4 4 Overview of radio connectors 4204
4 4 1 Contact assignment of multi-pin connectors I, II, III on the rear of the radio 4204
4 5 Anti-theft coding 4205
4 5 1 Functional notes 4205
4 5 2 Deactivating anti-theft coding 4206
4 6 Adapting radio components 4206
5 Radio “Volkswagen Individual” 4208
5 1 General notes 4208
5 1 1 Fault finding 4208
5 2 Wiring harness adapter set for radio “Volkswagen Individual” 4209
5 3 Overview of radio system “Volkswagen Individual” 4209
5 4 Removing and installing radio unit “Volkswagen Individual” 4210
5 4 1 Removing 4210
5 4 2 Installing 4211
5 5 Overview of connectors on radio “Volkswagen Individual” 4212
5 5 1 Contact assignment of multi-pin connectors I, II, III on the rear of the radio 4212
5 6 Anti-theft coding 4213
5 6 1 Deactivating anti-theft coding 4213
6 Radio navigation system (RNS) with multifunction display (MFD) ► 04 05 4215
6 1 General notes 4215
6 1 1 Fault finding 4215
6 2 Overview of “radio navigation system (RNS) with multifunction display (MFD)” 4215
6 3 Removing and installing radio navigation system 4217
6 3 1 Removing: 4217
6 3 2 Installing: 4218
6 4 Overview of radio navigation system connectors 4218
6 4 1 Contact assignment of 26-pin connector for navigation sensors 4219
6 4 3 Contact assignment of multi-pin connectors I, II, III on rear of radio navigation system 4220
6 5 Anti-theft coding 4221
6 5 1 Deactivating anti-theft coding 4222
6 6 Adapting navigation system components 4223
6 7 Adapting radio components 4223
7 Radio navigation system (RNS) with monochrome display 4225
7 1 General notes 4225
7 1 1 Fault finding 4226
7 2 Overview of “radio navigation system (RNS) with monochrome display” ► 04 05 4226
7 3 Overview of “radio navigation system (RNS) with monochrome display” 05 05 ► 4227
7 4 Removing and installing radio navigation system 4228
7 4 1 Removing: 4228
7 4 2 Installing: 4229
7 5 Overview of radio navigation system connectors 4229
7 5 1 Contact assignment of multi-pin connector l 4230
7 5 2 Contact assignment of multi-pin connector ll 4231
7 5 3 Contact assignment of multi-pin connector lll 4232
7 5 4 Contact assignment of multi-pin connector lV 4232
7 6 Anti-theft coding 4232
7 6 1 Deactivating anti-theft coding 4233
7 7 Adapting navigation system components 4233
7 8 Adapting radio components 4234
8 Radio system “RCD 200” 05 05 ► 4236
8 1 General description 4236
8 2 Fault finding 4236
8 3 Overview of radio system “RCD 200” 4237
8 4 Removing and installing radio “RCD 200” 4238
8 4 1 Removing: 4238
8 4 2 Installing: 4240
8 5 Overview of connectors on radio unit “RCD 200” 4240
8 6 Anti-theft coding 4243
8 6 1 Functional notes 4243
8 6 2 Deactivating anti-theft coding 4243
8 7 Adapting radio components 4244
9 CD changer and CD player 4246
9 1 General notes 4246
9 2 Removing and installing CD changer under front passenger seat 4246
9 2 1 Removing: 4246
9 2 2 Installing: 4247
9 3 Removing and installing CD changer from centre console 4247
9 3 1 Removing: 4247
9 3 2 Installing: 4248
9 4 Removing and installing CD player 4248
9 4 1 Removing: 4249
9 4 2 Installing: 4249
9 4 3 Contact assignment of the multi-pin connectors on CD player 4249
10 Loudspeaker systems 4251
10 1 Loudspeaker systems ► 04 05 4251
10 1 1 Removing and installing front treble loudspeakers 4251
10 1 2 Removing and installing rear treble loudspeakers 4251
10 1 3 Removing and installing front and rear bass loudspeakers 4251
10 2 Loudspeaker systems 05 05 ► 4252
10 2 1 Removing and installing front treble loudspeakers 4252
10 2 2 Removing and installing front bass loudspeakers 4252
10 2 3 Removing and installing rear treble loudspeakers 4253
10 2 4 Removing and installing rear bass loudspeakers 4254
11 Telephone systems 4255
11 1 General notes 4255
11 2 Overview of preparation for mobile telephone 4255
11 3 Removing and installing telephone bracket 4256
11 3 1 Removing telephone bracket 4257
11 3 2 Installing telephone bracket 4258
11 4 Removing and installing telephone operating electronics control unit 4258
11 4 1 Removing: 4258
11 4 2 Installing: 4258
11 5 Removing and installing telephone microphone 4258
11 5 1 Removing and installing telephone microphone ► 04 05 4258
11 5 2 Removing and installing telephone microphone 05 05 ► 4259
12 Aerial systems 4260
12 1 General notes 4260
12 2 Overview of roof aerial for radio 4260
12 3 Overview of roof aerial for radio and telephone 4262
12 4 Overview of roof aerial for radio, telephone and navigation system 4263
12 5 Removing and installing aerial 4263
12 5 1 Removing: 4263
12 5 2 Installing: 4264
12 6 Renewal of aerial wiring 4264
13 Notes on operating mobile telephones and two-way radios 4265
13 1 General notes 4265
13 1 1 Mobile telephones or portable two-way radios may not be used in the vehicle without a separate external aerial 4265
13 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: 4265
13 2 Notes on performing repair work 4266
13 2 1 Transmitting power and possible fitting locations 4266
13 2 2 Voltage supply 4266
13 2 3 Aerial and aerial wiring 4266
13 2 4 Further additional installations 4267
13 3 Overview of battery, transmitter and receiver unit, fuse and wiring harness 4267
13 4 Transmitting power and aerial fitting locations 4268
13 4 1 Polo 2002 ► 4268
14 Suppression 4270
14 1 Suppression measures 4270
15 iPod cradle 4271
15 1 General description 4272
15 2 Notes on performing repair work 4272
15 3 Removing and installing iPod cradle 4272
15 3 1 Removing 4273
15 3 2 Installing 4274
15 3 3 Multi-pin connector 4, 12-pin, iPod cradle 4274
15 3 4 Removing and installing radio adapter cable 4274
15 4 Adapting iPod components 4275
1 Engine list 4281
2 Service work 4285
2 1 Information on LongLife service and time or distance dependent service 4285
2 1 1 Service identification 4285
2 1 2 LongLife service 4285
2 1 3 Time or distance dependent service 4286
2 1 4 Service interval display 4286
2 2 Service tables 4287
2 2 1 SERVICE INTERVALS 4288
2 2 2 VW ENGINE OIL STANDARDS 4289
2 2 3 FILTER CHANGE INTERVALS 4290
2 2 4 TOOTHED BELT CHANGE INTERVALS 4290
2 2 5 Spark plug change intervals 4291
2 3 Delivery inspection 4291
2 4 Oil change service 4293
2 5 Interval service 2008► 4294
2 6 Inspection ►2007 4296
2 7 Inspection service 2008► 4298
2 8 Time or distance dependent additional work 4300
2 9 Service intervals with market-specific deviations 4304
3 General information 4306
3 1 Stickers 4306
3 1 1 Attaching “Your next service” sticker 4306
3 1 3 Attaching hotline sticker 4307
3 2 Entries in service schedule 4307
3 3 Connecting vehicle diagnostic tester 4308
3 4 Raising vehicle with lifting platform or trolley jack 4309
3 4 1 Safety notes: 4310
3 4 2 Lifting points for lifting platform or trolley jack: 4310
3 5 Vehicle identification number 4311
3 6 Vehicle data sticker 4312
3 7 Countries where diesel has a high sulphur content 4312
3 8 Engine code and engine number 4313
3 9 RME fuel (biodiesel) 4313
3 10 Severe operating conditions 4314
3 11 Type plate 4314
4 Descriptions of work: 4316
4 1 Removable towing bracket: checking and cleaning if necessary 4317
4 2 Swivel joints and suspension link mountings: inspecting 4319
4 3 Automatic gearbox: checking ATF level 4320
4 4 Automatic gearbox: changing ATF (09G gearbox) 4320
4 5 Battery: checking battery terminal clamps for secure seating 4321
4 6 Battery: Checking using battery tester with printer VAS 5097A or VAS 6161 4322
4 7 Brake and clutch system: Changing brake fluid 4322
4 8 Brake fluid level: checking 4327
4 8 1 Procedure, brake fluid level (dependent upon lining/pad wear): checking 4327
4 9 Front passenger airbag: checking key switch and “On/Off function” 4328
4 10 Tyres: checking condition, wear pattern, tread depth, tyre pressure and age 4329
4 10 1 Checking condition 4329
4 10 2 Checking tyre wear pattern 4330
4 10 3 Checking tyre tread depth (including spare wheel) 4330
4 10 4 Tyre pressure (including spare wheel): Checking, correcting if necessary 4330
4 11 Brake system and shock absorbers: inspecting for leaks and damage 4338
4 12 Brakes, front and rear: checking thickness of brake pads and condition of brake discs 4339
4 12 1 Front brake pads: 4339
4 12 2 Rear brake pads: 4340
4 12 3 Rear drum brake pads: checking 4341
4 12 4 Brake discs: checking condition 4342
4 13 Electric windows: Carry out initialisation (activation) 4343
4 14 Vehicle system test: Carry out test 4343
4 15 Bonnet: greasing arrester 4344
4 16 Adding multi-purpose additive G17 4344
4 17 Boots: inspecting 4345
4 18 Checking expiry date of first-aid kit 4345
4 19 Interior and exterior body: inspecting for corrosion with doors and flaps open 4345
4 20 Poly V-belt: Checking tension, adjusting if necessary 4345
4 21 Poly V-belt: checking condition 4345
4 22 Checking number plate on vehicle bumper (Polo Cross) 4346
4 23 Fuel filter: Renewing (diesel engine) 4346
4 24 Fuel filter: Draining water (diesel engine) 4347
4 25 Cooling system: checking frost protection and coolant level 4349
4 25 1 Frost protection: checking, replenishing coolant additive if necessary 4349
4 25 2 Coolant level: checking, replenishing coolant if necessary 4350
4 25 3 Mixing ratio: 4351
4 26 Air filter: Cleaning housing and renewing filter element 4351
4 26 1 Air filter: Clean housing and renew filter element, engine codes BUD and BTS 4351
4 26 2 Air filter: Cleaning housing and renewing filter element, 1 4 l injection engines 4352
4 26 3 Air filter: Clean housing and renew filter element, engine codes: AWY, AZQ, BMD, BME and 4-cylinder FSI engines 4353
4 26 4 Air filter: Clean housing and renew filter element, diesel engines, 1 8 l 5-valve engines and engines with engine codes: BZG and BBM 4353
4 27 Engine oil level: Check, replenish engine oil if necessary 4354
4 28 Engine oil: Draining or extracting and replenishing; renewing oil filter 4355
4 28 1 Engine oil: draining or extracting 4355
4 28 2 Renewing oil filter 4357
4 28 3 Replenishing engine oil 4360
4 29 Engine and components in engine compartment: inspecting for leaks and damage (from above and below) 4361
4 30 Removing and installing engine cover panel -top- 4361
4 31 Removing and installing engine cover -bottom- (noise insulation) 4364
4 32 Road test: performing (driving behaviour, noises, air conditioner etc ) 4365
4 33 Wheel securing bolts: tightening to specified torque 4365
4 34 Radio/radio navigation system: entering PIN of anti-theft coding and storing local radio stations to station buttons 4367
4 35 Radio code: reading using vehicle diagnostic tester 4368
4 36 Tyre repair set: checking 4369
4 37 Tyre Pressure Loss Indicator: performing basic setting 4369
4 38 Manual gearbox/final drive: Checking oil level, replenishing oil if necessary 4370
4 39 Window wiper and washer system and headlight washer system: Checking function 4370
4 39 1 Anti-freeze concentration in window wiper and washer system: Checking and replenishing fluid if necessary 4370
4 39 2 Window wiper and washer system: Checking spray jet settings 4372
4 39 3 Headlight washer system: check jet setting 4374
4 39 4 Checking wiper blade park position 4374
4 39 5 Wiper blades: Check setting angle 4374
4 40 Wiper blade protection: removing 4375
4 40 1 Wiper blade protection, version 1: removing 4376
4 40 2 Wiper blade protection, version 2, removing 4377
4 40 3 Wiper blade protection, version 3 -transport wiper blade: changing 4378
4 41 Headlight adjustment: Check, adjust headlights if necessary 4378
4 41 1 Test requirements 4378
4 41 2 Checking headlight adjustment (using test screen without 15° setting line) 4380
4 41 3 Adjusting headlights 4381
4 41 4 Fog lights and other auxiliary lights: adjusting 4382
4 42 Sunroof: checking function, cleaning and greasing guide rails 4383
4 43 Service interval display: resetting 4383
4 43 1 Resetting service interval display with adjustment buttons for distance display and clock on dash panel insert 4384
4 43 2 Resetting service interval display using diagnostic tester 4385
4 44 Service interval display: recoding 4386
4 45 Track rod ends: checking clearance, firm seating and boots 4387
4 46 Dust and pollen filter: renew filter element 4388
4 47 Door arrester: grease 4388
4 48 Transportation device: Remove blocking pieces from front axle springs 4389
4 49 Recoding dash panel insert 4390
4 50 Clock: setting to correct time 4391
4 51 Underseal: inspecting for damage to underseal, underbody cladding, routing of lines and plugs 4391
4 52 Toothed belt and tensioning roller: Renew 4391
4 53 Camshaft drive toothed belt: Renewing (4-cylinder 5-valve petrol engine) 4392
4 54 Camshaft drive toothed belt: Check (4-cylinder petrol engine) not for engine code AXU 4392
4 55 Renewing spark plugs 4392
4 55 1 Spark plugs: renewing, engine codes BUD, BTS 4394
4 55 2 Spark plugs: renewing, engine codes AUA and AUB 4394
4 55 3 Renewing spark plugs, engine codes AWY, BBY, BBZ, AXU, AZQ, BMD, BME, BKY, BUD, BTS, BZG 4395
4 56 Diesel particulate filter: check 4399
5 Exhaust emissions test 4400
5 1 Exhaust emissions test for petrol engines 4400
5 2 Exhaust emissions test for diesel engines 4409
5 2 1 Exhaust emissions test for diesel engines without OBD with diesel tester V A G 1743 4409
5 2 2 Exhaust emissions test for diesel engines without OBD with emissions testing station VAS 6300 4416
5 2 3 Exhaust emissions test for diesel engines with OBD 4425
6 Glossary 4429
50 – Body – front 4439
1 Lock carrier 4439
1 1 Tools 4439
1 1 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 4439
1 2 Assembly overview – lock carrier > 03 05 4439
1 3 Lock carrier – service position > 03 05 4441
1 4 Removal and installation of lock carrier > 03 05 4442
1 4 1 Removal 4442
1 4 2 Installation 4443
1 5 Assembly overview – lock carrier 04 05 > 4444
1 6 Lock carrier – service position 04 05 > 4445
1 7 Removal and installation of lock carrier 04 05 > 4446
1 7 1 Removal 4446
1 7 2 Installation 4447
2 Wing 4449
2 1 Assembly overview – front wing 4449
2 2 Removal and installation of wing 4450
2 2 1 Removal 4450
2 2 2 Installation 4451
2 3 Removal and installation of closing piece 4452
2 3 1 Removal 4452
2 3 2 Installation 4452
2 4 Wing dimensions – Vehicles > 02 05 4452
2 5 Wing dimensions – Vehicles 03 05 > 4454
3 Noise insulation 4455
3 1 Assembly overview – noise insulation (petrol engine) 4455
3 2 Assembly overview – noise insulation (diesel engine) 4456
4 Cross panel 4457
4 1 Tools 4457
4 2 Materials 4457
4 3 Assembly overview – cross panel 4458
55 – Bonnet, rear lid 4459
1 Bonnet 4459
1 1 Tools 4459
1 2 Assembly overview – bonnet 4459
1 3 Removal and installation of bonnet 4461
1 3 1 Removal 4461
1 3 2 Installation 4462
1 4 Adjusting bonnet 4463
1 5 Removing gas-filled strut 4463
1 6 Removal and installation of Bowden cable 4464
1 6 1 Assembly overview 4464
1 6 2 Removal 4466
1 6 3 Installation 4467
1 7 Removal and installation of release lever 4467
1 7 1 Removal 4467
1 7 2 Installation 4468
1 8 Assembly overview – bonnet lock 4469
1 9 Removal and installation of lid lock 4469
1 9 2 Installation 4470
2 Rear lid 4471
2 1 Tools 4471
2 1 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 4471
2 2 Assembly overview 4471
2 3 Removing gas-filled strut 4473
2 4 Releasing gas from gas-filled strut 4473
2 5 Adjusting rear lid 4473
2 6 Removal and installation of lid lock 4475
2 6 1 Vehicles without central locking 4475
2 6 2 Vehicles with central locking 4477
3 Tank flap unit 4479
3 1 Removal and installation of tank flap unit 4479
57 – Front doors, door components, central locking 4481
1 Front door 4481
1 1 Tools 4481
1 2 Assembly overview 4481
1 3 Removal and installation of door 4484
1 4 Adjusting door 4484
1 4 1 Adjusting striker pin 4485
1 5 Assembly overview – door handle and door lock 4485
1 6 Removal and installation of lock cylinder housing 4487
1 6 2 Installation 4487
1 7 Removal and installation of door handle 4488
1 7 2 Installation 4488
1 8 Removal and installation of door lock 4489
1 8 2 Installation 4491
1 9 Removal and installation of locking knob for locking rod 4493
1 9 1 Removal 4493
1 9 3 Installing 4494
1 9 5 Removing 4494
1 9 7 Installing 4494
1 10 Door seals 4495
1 10 1 Assembly overview – door seals 4495
1 10 2 Removing inner door seal 4496
1 10 3 Installing interior door seal 4497
1 10 4 Removing outer door seals 4497
1 10 5 Installation of door outer seal 4499
2 Central locking 4501
2 1 Location overview – central locking components 4501
2 2 Removal of control unit for convenience system 4504
2 3 Adapting keys with remote control 4504
2 4 Removal and installation of battery for folding key with remote control 4504
2 4 2 Installation 4506
58 – Rear doors, door components 4507
1 Rear door 4507
1 1 Tools 4507
1 1 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 4507
1 2 Assembly overview 4508
1 3 Removal and installation of door 4509
1 4 Adjusting door 4510
1 5 Assembly overview – door handle and door lock 4510
1 6 Removal and installation of door handle 4512
1 6 1 Removal 4512
1 6 2 Installation 4512
1 7 Removal and installation of door lock 4514
1 7 1 Removal 4514
1 7 2 Installation 4517
1 8 Door seals 4520
1 8 1 Assembly overview – door seals 4520
1 8 2 Removing inner door seal 4521
1 8 3 Installing interior door seal 4522
1 8 4 Removing outer door seals 4522
1 8 5 Installation of door outer seal 4524
60 – Sunroof 4526
1 Sliding/tilting sunroof 4526
1 1 Function 4526
1 2 Assembly overview – sliding/tilting sunroof with glass panel 4526
1 3 Removal of sliding/tilting sunroof glass panel 4529
1 4 Installation of glass panel for sliding/tilting sunroof 4530
1 5 Adjusting sliding/tilting sunroof glass panel (height adjustment) 4530
1 6 Adjusting panel seal 4532
1 7 Renewing panel seal 4533
1 8 Removing wind deflector 4534
1 9 Removal and installation of sun blind 4534
1 10 Removing pre-selector switch for sliding/tilting sunroof (E 139) 4534
1 11 Removal of drive for sliding/tilting sunroof 4535
1 12 Adjusting drive for sliding/tilting sunroof (zero position) 4535
1 13 Checking parallel running 4535
1 14 Adjusting parallel running 4536
1 14 1 Zero position 4536
1 15 Removing guide plate 4536
1 16 Removal and installation of assembly unit 4537
1 16 1 Removal 4537
1 16 2 Installation 4538
1 17 Removal of guide with cable 4539
1 17 1 Installation instructions: 4539
1 18 Cleaning water drain hoses 4540
1 18 1 Front water drain hoses: 4540
1 18 2 Rear water drain hoses: 4540
63 – Bumpers 4542
1 Front bumper 4542
1 1 Tools 4542
1 2 Repairing front bumper cover 4542
2 Front bumper > 03 05 4544
2 1 Assembly overview – bumper cover > 03 05 4544
2 2 Removal and installation of bumper cover > 03 05 4545
2 3 Assembly overview – bumper carrier > 03 05 4546
3 Front bumper 04 05 > 4547
3 1 Assembly overview – front bumper 04 05 > 4547
3 2 Removal and installation of front bumper cover 04 05 > 4548
3 2 1 Removal 4548
3 2 2 Installation 4549
3 3 Front bumper attachments 04 05 > 4550
3 4 Front bumper attachments – Blue Motion and GT Rocket 4550
3 5 Assembly overview – front bumper carrier 04 05 > 4552
4 Front bumper, Polo Fun 4553
4 1 Assembly overview – bumper cover, Polo Fun 4553
4 2 Removal and installation of front bumper cover, Polo Fun 4554
4 3 Assembly overview – bumper carrier, Polo Fun 4555
5 Front bumper, Cross Polo 4556
5 1 Assembly overview – bumper cover, Cross Polo 4556
5 2 Removal and installation of bumper cover, Cross Polo 4557
5 3 Assembly overview – bumper carrier, Cross Polo 4558
6 Front bumper, Polo GTI Cup Edition 4559
6 1 Assembly overview – bumper cover, Polo GTI Cup Edition 4559
6 2 Removing and installing bumper cover, Polo GTI Cup Edition 4560
6 2 1 Removing 4560
6 2 2 Installing 4561
6 3 Bumper cover attachments, Polo GTI Cup Edition 4561
6 4 Assembly overview – bumper carrier, Polo GTI Cup Edition 4562
6 5 Assembly overview – dimensions for number plate attachment 4563
7 Rear bumper 4564
7 1 Tools 4564
7 2 Repairing rear bumper cover 4564
8 Rear bumper 4565
8 1 Assembly overview – rear bumper cover 4565
8 2 Assembly overview – rear bumper cover, Blue Motion and GT Rocket 4565
8 3 Removal and installation of rear bumper cover 4567
8 4 Assembly overview – bumper carrier 4568
9 Rear bumper, Polo Fun 4569
9 1 Assembly overview – bumper cover, Polo Fun 4569
9 2 Removal and installation of bumper cover, Polo Fun 4570
9 3 Assembly overview – bumper carrier, Polo Fun 4571
10 Rear bumper, Cross Polo 4572
10 1 Assembly overview – bumper cover, Cross Polo 4572
10 2 Removal and installation of bumper cover, Cross Polo 4573
10 3 Assembly overview – bumper carrier, Cross Polo 4574
10 4 Adapting bumper to wheel housing liner 4575
11 Rear bumper, Polo GTI Cup Edition 4576
11 1 Assembly overview – rear bumper cover, Polo GTI Cup Edition 4576
11 2 Removing and installing rear bumper cover, Polo GTI Cup Edition 4577
11 2 1 Removing 4577
11 2 2 Installing 4577
11 3 Rear bumper cover attachments, Polo GTI Cup Edition 4578
11 4 Assembly overview – bumper carrier, Polo GTI Cup Edition 4579
12 Towing bracket 4580
12 1 Assembly overview – towing bracket 4580
64 – Glazing 4581
1 Flush bonded windows 4581
1 1 Tools 4581
1 2 Materials 4582
1 3 Repairing windscreen 4583
1 4 Assembly overview – windscreen 4583
1 5 Removal and installation of plenum chamber cover 4585
1 5 1 Removal 4586
1 5 2 Installation 4587
1 6 Removing windscreen 4587
1 7 Installing windscreen 4588
1 8 Preparing windscreen with viewing hole for chassis number for vehicles without chassis number 4588
1 9 Assembly overview – side window (2-door) 4589
1 10 Removal of undamaged side window (2-door) 4589
1 11 Removal of damaged side window (2-door) 4590
1 12 Installation of side window (2-door) 4590
1 13 Assembly overview – side window (4-door) 4591
1 14 Removal of undamaged side window (4-door) 4591
1 15 Removal of damaged side window (4-door) 4592
1 16 Installation of side window (4-door) 4592
1 17 Assembly overview – rear window 4593
1 18 Removal of undamaged rear window 4593
1 19 Removal of broken rear window 4595
1 20 Installation of rear window 4595
1 21 Preparing old undamaged window for glazing 4595
1 22 Preparing new window with precoating for glazing 4596
1 22 1 Gaps for side window 4596
1 23 Preparing new window without precoating for glazing 4596
1 23 1 Dimensions for adhesive bead and primer at the top of the windscreen 4597
1 23 2 Dimensions for adhesive bead and primer at the bottom of the windscreen 4599
1 23 3 Dimensions for adhesive bead and primer at the sides of the windscreen 4600
1 24 Preparing body flange for glazing 4601
1 25 Installation instructions 4602
1 26 Minimum curing period 4602
1 27 Touching up paint damage 4603
1 28 Cleaning off excess adhesive sealing material 4603
2 Screw-fastened windows 4604
2 1 Removal and installation of vent wing 4604
2 2 Window seal 4605
2 3 Adjusting vent wing 4605
3 Door windows 4607
3 1 Tools 4607
3 2 Assembly overview – front door window 4608
3 3 Removing front door window 4609
3 4 Adjusting front door window 4610
3 5 Removal and installation of front and rear assembly carriers 4610
3 5 1 Removal 4610
3 5 2 Installation of assembly carrier 4612
3 6 Assembly overview – rear door window 4613
3 7 Removing rear door window 4616
3 8 Fitting rear door window to window lifter 4617
3 9 Removal and installation of assembly carrier 4617
3 9 2 Installation of assembly carrier 4619
3 10 Electric window regulator with convenience function (automatic opening and closing) and force limitation mechanism 4621
3 10 1 Function of window lifter with ignition switched on 4621
3 10 2 Function of window lifter with ignition switched off 4622
3 10 3 Setting automatic opening and closing 4622
3 11 Overcoming resistance with excess force limitation 4623
3 12 Removal and installation of window lifter motor in assembly carrier 4623
3 12 1 Removal 4623
3 12 3 Installation of assembly carrier with window lifter 4624
66 – Exterior equipment 4626
1 Removal and installation of wheel housing liner 4626
1 1 Front wheel housing liner 4626
1 1 1 Spoiler on wheel housing liner 4627
1 2 Rear wheel housing liner 4628
2 Exterior mirror 4629
2 1 Tools 4629
2 2 Assembly overview – exterior mirror (with electric actuation) > 02 05 4629
2 3 Assembly overview – exterior mirror (with manual actuation) > 02 05 4631
2 4 Removing mirror housing > 02 05 4631
2 5 Assembly overview – exterior mirror 03 05 > 4632
2 6 Removal and installation of mirror glass 03 05 > 4633
2 6 1 Removal 4634
2 6 2 Installation 4634
2 7 Removal and installation of mirror housing 03 05 > 4634
2 7 1 Removal 4634
2 7 2 Installation 4635
2 8 Removal and installation of cover with side turn signal repeaters 03 05 > 4635
2 8 1 Removal 4635
2 8 2 Installation 4635
2 9 Removal and installation of exterior mirror 03 05 > 4635
2 9 1 Removal 4636
2 9 2 Installation 4636
3 Radiator grille 4637
3 1 Tools 4637
3 2 Assembly overview – radiator grille > 03 50 4637
3 3 Removal and installation of radiator grille > 03 05 4638
3 3 1 Removal 4638
3 3 2 Installation 4638
3 4 Assembly overview – radiator grille 04 05 > 4639
3 5 Removal and installation of radiator grille 04 05 > 4640
3 5 1 Removal 4640
3 5 2 Installation 4641
3 6 Radiator grille, Polo Blue Motion 4642
3 6 1 Assembly overview 4642
3 6 2 Removing 4643
3 6 3 Installing 4644
4 Mouldings and trims 4645
4 1 Tools 4645
4 2 Renewing side protective strips 4645
4 3 Assembly overview – side member extension, Polo GTI 4647
4 4 Removing and installing side member extension, Polo GTI 4648
4 4 1 Removing 4648
4 4 2 Installing 4649
4 5 Removing and installing retaining strip for side member extension 4650
4 5 1 Removing 4650
4 5 2 Installing 4651
4 6 Assembly overview – wheel arch trims, Polo GTI Cup Edition and GT Rocket 4652
5 Roof edge spoiler 4653
5 1 Tools 4653
5 2 Materials 4653
5 3 Roof spoiler, Polo GTI and GT Rocket 4654
5 3 1 Assembly overview 4654
5 3 2 Removing 4655
5 3 3 Installing 4656
5 4 Assembly overview – roof spoiler, Polo GTI Cup Edition 4657
5 4 1 Assembly overview 4657
5 4 2 Removing centre roof spoiler 4657
5 4 3 Installing centre roof spoiler 4659
5 4 4 Removing left roof spoiler 4660
5 4 5 Installing left roof spoiler 4661
5 5 Roof spoiler, Polo Blue Motion 4662
5 5 1 Assembly overview 4662
5 5 2 Removing 4663
5 5 3 Installing 4664
5 6 Preparing body kit component for bonding 4665
5 7 Installation instructions 4665
5 8 Minimum curing period 4666
5 9 Touching up paint damage 4666
5 10 Cleaning off excess adhesive sealing material 4666
6 Special attachments 4667
6 1 Safety requirements 4667
6 2 Tools 4667
6 3 Materials 4667
6 4 Special attachments, Polo Fun 4668
6 4 1 Overview of parts – Polo Fun 4668
6 4 2 Assembly overview – side member extension and wheel arch trim 4669
6 4 3 Removing side member extension and wheel arch trim 4670
6 4 4 Installing side member extension 4671
6 4 5 Assembly overview – protective side strips 4671
6 4 6 Removing side protective mouldings 4672
6 4 7 Installation of side protective mouldings 4672
6 5 Special attachments, Cross Polo 4673
6 5 1 Overview of parts – Cross Polo 4673
6 5 2 Assembly overview – side member extension and wheel arch trim 4674
6 5 3 Removing side member extension and wheel arch trim 4675
6 5 4 Installing side member extension 4677
6 5 5 Installation of wheel housing trim 4678
6 5 6 Assembly overview – trim foil 4679
6 5 7 Removal of trim foil 4681
6 5 8 Installation of trim foil 4682
6 5 9 Assembly overview – protective side strips 4683
6 5 10 Removing side protective mouldings 4683
6 5 11 Installation of side protective mouldings 4685
6 6 Special attachments, Polo GTI Cup Edition 4686
6 6 1 Overview of parts – Polo GTI Cup Edition 4686
6 7 Special attachments, Polo Blue Motion 4687
6 7 1 Overview of parts – Polo Blue Motion 4687
6 8 Special attachments Polo GT Rocket 4688
6 8 1 Overview of parts – Polo GT Rocket 4688
6 9 Side member extension, Polo Blue Motion, GTI Cup Edition and GT Rocket 4689
6 9 1 Assembly overview 4689
6 9 2 Removing 4689
6 9 3 Installing 4691
6 10 Preparing body kit component for bonding 4692
6 11 Preparing body kit component for bonding 4692
6 12 Installation instructions 4692
6 13 Minimum curing period 4693
6 14 Touching up paint damage 4693
6 15 Cleaning off excess adhesive sealing material 4693
7 Roof rail 4694
7 1 Roof rail, Polo Fun 4694
7 1 1 Assembly overview 4694
7 1 2 Removing roof rail 4695
7 1 3 Installing 4695
7 2 Roof rail, Cross Polo 4696
7 2 1 Assembly overview 4696
7 2 2 Removing roof rail 4697
7 2 3 Installing roof rail 4697
8 Lettering 4699
8 1 Tools 4699
8 2 Attachment notes for lettering 4699
8 3 Rear lettering dimensions 4699
8 3 1 Rear lettering > 03 05 4699
8 3 2 Rear lettering 04 05 > 4701
8 4 Side lettering 4702
8 4 1 Cross Polo 4702
8 4 2 GT Rocket 4703
68 – Interior equipment 4710
1 Interior mirror 4710
1 1 Removing interior mirror 4710
1 2 Installing interior mirror 4710
1 3 Bonding retaining plate for interior mirror 4710
1 3 1 Materials 4710
1 4 Automatic anti-dazzle interior mirror 4711
1 5 Removing and installing interior mirror on vehicles with a rain sensor 4712
1 5 1 Removing 4712
1 5 2 Installing 4713
1 6 Bonding on interior mirror base with rain sensor 4713
1 6 1 Preparing windscreen 4714
1 6 2 Preparing detached or new mirror base 4714
1 6 3 Bonding mirror base 4714
1 6 4 Cleaning and removing excessive adhesive 4714
1 6 5 Installing rain sensor and mirror 4714
2 Compartments, covers and trims 4715
2 1 Removing and installing upper part of centre console 4715
2 1 1 Removing 4715
2 1 2 Installing 4716
2 2 Removing and installing lower part of centre console 4717
2 2 2 Installing 4718
2 3 Removing handbrake lever handle 4718
2 4 Removing driver side compartment 4718
2 5 Removing front passenger side compartment 4719
2 6 Removing glove compartment 4719
2 7 Removing sun visor 4720
2 8 Removing middle sun visor 4720
3 Sill panel trims 4721
3 1 Removing and installing sill panel trim (4-door) 4721
3 1 1 Assembly overview 4721
3 1 2 Removing 4721
3 1 3 Installing 4722
3 2 Removing and installing sill panel trim (2-door) 4722
3 2 1 Removing 4722
3 2 2 Installing 4723
4 Grab handles 4724
4 1 Removing roof grab handle 4724
69 – Passenger protection 4725
1 Seat belts 4725
1 1 Safety regulations for belt tensioners 4725
1 2 Disposal of belt tensioner units 4725
1 3 Checking belt tensioner 4725
1 4 Removing and installing seat belt with belt tensioner unit (4-door) 4725
1 4 1 Assembly overview 4725
1 4 2 Removing 4726
1 4 3 Installing 4727
1 5 Removing and installing seat belt with belt tensioner unit (2-door) 4728
1 5 1 Assembly overview 4728
1 5 2 Removing 4728
1 5 3 Installing 4729
1 6 Removing and installing belt height adjustment 4730
1 6 1 Assembly overview 4730
1 6 2 Removing 4730
1 6 3 Installing 4731
1 7 Removing front belt end anchor (4-door) 4731
1 8 Removing front belt anchor rail (2-door) 4731
1 9 Removing front belt buckle 4732
1 10 Removing and installing rear outer seat belts 4732
1 10 1 Assembly overview 4732
1 10 2 Removing 4733
1 10 3 Installing 4735
1 11 Removing and installing belt buckle and belt guide of middle rear 3rd three-point seat belt 4735
1 11 1 Removing 4735
1 11 2 Installing 4736
1 12 3 Removing and installing rear middle three-point seat belt 4736
1 12 1 Removing 4736
1 12 2 Installing 4737
1 13 Removing and installing lap belt and double buckle 4738
1 13 1 Removing 4738
1 13 2 Installing 4738
2 Inspecting seat belts 4739
2 1 Points to check 4739
2 1 1 Checking belt webbing 4739
2 1 2 Checking inertia reel (locking mechanism) 4740
2 1 3 Visually checking belt buckle 4741
2 1 4 Checking operation of belt buckle 4741
2 1 5 Checking belt relays and latch plate 4741
2 1 6 Checking securing parts and anchorage points 4741
3 Airbag 4742
3 1 Overview – installation locations 4742
3 2 Safety precautions when working on airbag 4742
3 3 Additional safety precautions for the curtain airbag 4743
3 4 Disposal of airbag units 4743
3 5 Deactivating the airbag 4743
3 6 Renewing airbag units following an accident 4744
3 6 1 Accident involving triggering of airbag 4744
3 6 2 Accident not involving triggering of airbag 4744
3 7 Removing and installing driver airbag unit 4745
3 7 1 Assembly overview 4745
3 7 2 Removing 4745
3 7 3 Installing 4746
3 8 Removing and installing steering wheel 4748
3 8 1 Assembly overview 4748
3 8 2 Removing 4748
3 8 3 Installing 4749
3 9 Removing and installing return spring with slip ring 4749
3 10 Removing and installing front passenger airbag unit 4750
3 10 1 Removing 4750
3 10 2 Installing 4752
3 11 Removing and installing airbag control unit (J234) 4754
3 12 Removing and installing driver and front passenger side airbag 4755
3 12 1 Removing 4755
3 12 2 Installing 4756
3 13 Removing and installing curtain airbag on driver and passenger side 4757
3 13 1 Removing 4757
3 13 2 Installing 4758
3 14 Removing and installing crash sensor for side airbag for driver or front passenger 4759
3 14 1 Removing 4759
3 14 2 Installing 4760
3 15 Removing and installing crash sensor for right curtain airbag 4761
3 15 1 Removing 4761
3 15 2 Installing 4762
3 16 Removing and installing crash sensor for left curtain airbag 4763
3 16 1 Removing 4763
3 16 2 Installing 4764
3 17 Adapting components 4764
70 – Trim, insulation 4765
1 Dash panel 4765
1 1 Tools 4765
1 2 Removing and installing dash panel 4765
1 2 1 Removing 4765
1 2 2 Installing 4770
1 3 Removing and installing dash panel cross member 4770
1 3 1 Removing 4770
1 3 2 Installing 4773
2 Door trims 4774
2 1 Tools 4774
2 1 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 4774
2 2 Removing and installing front door trim on driver side 4774
2 2 1 Removing 4774
2 2 2 Installing 4778
2 3 Removing and installing front door trim on passenger side 4779
2 3 1 Removing 4779
2 3 2 Installing 4783
2 4 Removing and installing rear door trim 4784
2 4 1 Removing 4785
2 4 2 Installing 4788
3 Pillar and side trims 4790
3 1 Tools 4790
3 1 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 4790
3 2 Removing and installing upper A-pillar trim 4790
3 2 1 Removing 4790
3 2 2 Installing 4791
3 3 Removing lower right A-pillar trim 4792
3 4 Removing lower left A-pillar trim 4793
3 5 Removing and installing lower B-pillar trim (4-door) 4793
3 5 1 Assembly overview 4793
3 5 2 Removing 4794
3 5 3 Installing 4795
3 6 Removing and installing upper B-pillar trim 4795
3 6 1 Removing 4795
3 6 2 Installing 4796
3 7 Removing and installing upper B-pillar trim (2-door) 4797
3 7 1 Removing 4797
3 7 2 Installing 4798
3 8 Removing and installing upper C-pillar trim (4-door) 4799
3 8 1 Removing 4799
3 8 2 Installing 4800
3 9 Removing and installing upper C-pillar trim (2-door) 4801
3 9 1 Removing 4801
3 9 2 Installing 4802
3 9 3 Removing trim strip 4804
3 10 Removing and installing lower C-pillar trim 4804
3 10 1 Removing 4804
3 10 2 Installing 4805
3 11 Removing and installing rear seat trim 4806
3 11 1 Removing 4806
3 11 2 Installing 4807
4 Luggage compartment trims 4809
4 1 Tools 4809
4 1 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 4809
4 2 Removing and installing support for luggage compartment cover 4809
4 2 1 Removing 4809
4 2 2 Installing 4810
4 3 Removing and installing luggage compartment floor trim 4810
4 3 1 Removing 4810
4 3 2 Installing 4811
4 4 Removing and installing left luggage compartment side trim 4811
4 4 1 Removing 4811
4 4 2 Installing 4812
4 5 Removing and installing right luggage compartment side trim 4812
4 5 1 Removing 4812
4 5 2 Installing 4813
4 6 Removing and installing rear lock carrier cover 4813
4 6 1 Removing 4813
4 6 2 Installing 4814
5 Rear lid trim 4816
5 1 Removing and installing lower rear lid trim 4816
5 1 1 Removing 4816
5 1 2 Installing 4816
5 2 Removing and installing upper rear lid trim 4817
5 2 1 Removing 4817
5 2 2 Installing 4818
6 Roof trims 4820
6 1 Removing and installing moulded headliner (vehicles without sunroof) 4820
6 1 1 Assembly overview 4820
6 1 2 Removing 4820
6 1 3 Installing 4823
6 2 Removing and installing moulded headliner (vehicles with sunroof) 4824
6 2 1 Removing 4824
6 2 2 Installing 4827
7 Removing and installing roof insulation/reinforcement 4829
7 1 Removing 4829
7 2 Installing 4830
72 – Seat frames 4832
1 Front seats 4832
1 1 Tools 4832
1 1 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 4832
1 2 Removing and installing front seat 4832
1 2 1 Removing 4832
1 2 2 Installing 4834
1 3 Removing and installing front seat trim (basic) 4836
1 3 1 Assembly overview – front seat 4836
1 3 2 Removing 4836
1 3 3 Installing 4837
1 4 Removing and installing front seat trim (with parallel height adjustment) 4838
1 4 1 Assembly overview – front seat 4838
1 4 2 Removing 4838
1 4 3 Installing 4839
1 5 Removing and installing drawer on driver and passenger side 4839
1 5 1 Removing 4839
1 5 2 Installing 4840
1 6 Removing and installing front backrest 4840
1 6 1 Assembly overview – front seat 4840
1 6 2 Removing 4841
1 6 3 Installing 4842
1 7 Removing and installing parallel height adjustment 4842
1 7 1 Removing 4842
1 7 2 Installing 4843
1 8 Removing and installing cable and Bowden cable for locking backrest 4843
1 8 1 Assembly overview 4843
1 8 2 Removing 4844
1 8 3 Installing 4845
1 9 Removing head restraint guides 4846
2 Rear seats 4848
2 1 Removing (divided) bench seat 4848
2 2 Removing and installing (divided) backrest 4848
2 2 1 Removing 4848
2 2 2 Installing 4850
2 3 Removing and installing (one-piece) backrest 4850
2 3 1 Removing 4850
2 3 2 Installing 4851
74 – Seat – padding, covers 4852
1 Front seat covers and padding 4852
1 1 Tools 4852
1 1 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 4852
1 2 Removing and installing front seat cover and padding 4852
1 2 1 Assembly overview 4852
1 2 2 Removing 4853
1 2 3 Installing 4854
1 3 Removing and installing front backrest cover and padding 4855
1 3 1 Assembly overview 4855
1 3 2 Removing 4855
1 3 3 Installing 4857
2 Seat heater elements 4858
2 1 Removing seat heater element 4858
2 2 Removing backrest heater element 4858
2 2 1 Removing 4858
2 2 2 Installing 4859
3 Rear seat covers and padding 4860
3 1 Tools 4860
3 2 Removing and installing cover and padding for (one-piece) bench seat 4860
3 2 1 Installing 4861
3 3 Removing and installing cover and padding for (one-piece) backrest 4861
3 3 1 Removing 4861
3 3 2 Installing 4862
3 4 Removing and installing covers and padding for (divided) backrest 4862
3 4 1 Removing 4862
3 4 2 Installing 4863
00 – Technical data 4870
1 Technical data 4870
1 1 Engine number 4870
1 2 Engine data 4870
10 – Removing and installing engine 4871
1 Removing and installing engine 4871
1 1 Removing 4872
1 2 Installing 4874
1 3 Specified torques 4876
1 4 Additional information and assembly work for vehicles with air conditioner 4877
13 – Crankshaft group 4879
1 Dismantling and assembling engine 4879
1 1 Assembly overview – parts l and ll 4879
1 2 Assembly overview – part I, belt drive 4881
1 3 Part II: assembly overview – chain drive system 4882
1 4 Removing and installing poly V-belt 4884
1 4 1 Poly V-belt routing 4885
1 5 Removing and installing valve timing housing (timing case) 4885
2 Cylinder block, sealing flange 4889
2 1 Assembly overview 4889
2 2 Renewing crankshaft oil seal – pulley end 4891
2 3 Poly V-belt pulley securing bolt tightening procedure 4892
2 4 Renewing crankshaft sealing flange – flywheel end 4895
2 4 1 Pressing sealing flange with sender wheel off crankshaft 4896
2 4 2 Pressing sealing flange with sender wheel onto crankshaft 4897
2 4 3 A-Assembling sealing flange with sender wheel on assembly appliance -T10017- 4898
2 4 4 B-Assembling appliance -T10017- with sealing flange on crankshaft flange 4899
2 4 5 C-Fitting assembly appliance -T10017- onto crankshaft flange 4900
2 4 6 D-Pressing sender wheel onto crankshaft flange with assembly appliance -T10017- 4901
2 4 7 E – Checking sender wheel installation position on crankshaft 4901
2 4 8 F – Re-pressing sender wheel 4902
2 5 Crankshaft dimensions 4902
3 Pistons and conrods 4904
3 1 Assembly overview 4904
3 2 Checking piston 4905
3 3 Checking cylinder bores 4906
3 4 Piston and cylinder dimensions 4906
15 – Cylinder head, valve gear 4907
1 Cylinder head 4907
1 1 Assembly overview 4907
1 2 Checking valve timing 4910
1 3 Adjusting valve timing 4911
1 4 Removing and installing timing chain and chain drive for oil pump 4915
1 5 Removing and installing camshaft housing 4922
1 5 1 Removing 4924
1 5 2 Installing 4925
1 6 Removing and installing cylinder head 4926
1 7 Checking compression 4929
2 Valve gear 4931
2 1 Assembly overview 4931
2 2 Checking camshaft axial clearance 4933
2 3 Reworking valve seats 4933
2 4 Checking valve guides 4935
2 5 Renewing valve stem seals 4935
17 – Lubrication 4938
1 Parts of lubrication system 4938
1 1 Engine oil 4938
1 2 Assembly overview 4938
1 3 Removing and installing sump 4941
1 4 Removing and installing oil pump 4942
1 5 Checking oil pressure and oil pressure switch 4944
19 – Cooling 4947
1 Parts of cooling system 4947
1 1 Assembly overview – parts of cooling system, body side 4947
1 2 Assembly overview – parts of cooling system, engine side 4949
1 3 Coolant hose schematic diagram 4951
1 4 Draining and filling coolant 4952
1 5 Removing and installing radiator 4954
1 6 Removing and installing coolant pump 4955
20 – Fuel supply system 4958
1 Safety precautions 4958
1 1 Safety precautions when working on fuel supply system 4958
1 2 Releasing pressure in high-pressure area 4959
2 Parts of fuel supply system 4960
2 1 Assembly overview – fuel tank with attachments 4960
2 2 Safety precautions when working on fuel supply system 4963
2 3 Rules for cleanliness 4963
2 4 Removing and installing fuel delivery unit 4963
2 5 Removing and installing fuel gauge sender G 4965
2 6 Removing and installing fuel tank 4966
2 7 Crash fuel shut-off 4968
2 8 Checking fuel pump 4968
3 Electronic power control (EPC) 4975
3 1 Function of EPC system 4975
3 2 Assembly overview 4975
4 Activated charcoal filter system 4977
4 1 Function 4977
4 2 Assembly overview 4977
4 3 Checking fuel tank breather 4978
24 – Mixture preparation – injection 4980
1 Injection system 4980
1 1 General notes on injection 4980
1 2 Assembly overview – intake manifold 4980
1 3 Assembly overview – fuel rail with injectors 4983
1 4 Checking vacuum reservoir in intake manifold for leaks 4984
1 5 Assembly overview – air filter 4985
1 6 Removing and installing air filter 4986
1 7 Cleaning throttle valve module -J338- 4986
1 8 Removing and installing injectors 4987
1 8 1 Removing 4988
1 8 2 Installing 4989
1 9 Removing and installing high-pressure pump 4990
1 10 Safety precautions 4992
1 11 Rules for cleanliness 4993
1 12 Technical data 4993
2 Checking components 4995
2 1 Checking intake air preheating 4995
3 Engine control unit -J623- 4996
3 1 Removing and installing engine control unit -J623- 4996
3 2 Removing and installing anti-theft engine control unit -J623- (vehicles ► model year 2007) 4996
3 3 Removing and installing anti-theft engine control unit -J623- (vehicles model year 2007▸) 4998
26 – Exhaust system 5000
1 Parts of the exhaust system 5000
1 1 Assembly overview – catalytic converters and attachments 5000
1 2 Assembly overview – silencers with mountings 5002
2 Exhaust gas recirculation system 5003
2 1 Assembly overview – exhaust gas recirculation system 5003
2 2 Removing and installing exhaust gas recirculation valve N18 5004
28 – Ignition system 5006
1 Ignition system 5006
1 1 Assembly overview – ignition system 5006
1 2 Removing and installing ignition coils with output stage 5007
1 3 Safety precautions 5008
1 4 Test data, spark plugs 5009
00 – Technical data 5016
1 Technical data 5016
1 1 Engine number 5016
1 2 Engine data 5016
10 – Removing and installing engine 5017
1 Removing and installing engine 5017
1 1 Removing engine 5017
1 2 Securing engine to assembly stand 5021
1 3 Notes on installing 5022
1 4 Assembly mountings 5023
1 5 Additional notes and assembly work for vehicles with air conditioner 5024
13 – Crankshaft group 5025
1 Dismantling and assembling engine 5025
1 1 Assembly overview – toothed belt drive 5025
1 2 Assembly overview – poly V-belt drive 5026
1 2 1 Vehicles with no air conditioner 5026
1 2 2 Vehicles with air conditioner 5027
1 3 Removing and installing poly V-belt 5028
1 4 Assembly overview – crankcase 5030
2 Sealing flange and flywheel 5032
2 1 Assembly overview – sealing flange and flywheel, engine codes ASZ, ATD, AXR, BLT 5032
2 2 Assembly overview – sealing flange and flywheel, engine code BMT 5034
2 3 Renewing crankshaft oil seal – belt pulley end 5035
2 3 1 Removing 5035
2 3 2 Installing 5036
2 4 Removing and installing sealing flange – belt pulley end 5036
2 4 1 Removing 5037
2 4 2 Installing 5038
2 5 Renewing crankshaft sealing flange – flywheel end, engine code BMT 5038
2 5 1 Pressing out sealing flange with sender wheel 5039
2 5 2 Pressing in sealing flange with sender wheel 5040
2 5 3 A – Assembling sealing flange with sender wheel on assembly appliance -T10134- 5041
2 5 4 B – Attaching assembling tool -T10134- with sealing flange to crankshaft flange 5042
2 5 5 C – Bolting assembly tool -T10134- onto crankshaft flange 5043
2 5 6 D – Pressing sender wheel onto crankshaft flange using assembly tool -T10134- 5044
2 5 7 E – Checking sender wheel installation position on crankshaft 5044
2 5 8 F – Pressing sender wheel on fully 5045
2 6 Removing and installing engine speed sender -G28-, engine code BMT 5045
3 Crankshaft 5047
3 1 Assembly overview – crankshaft 5047
3 2 Crankshaft dimensions 5048
4 Pistons and conrods 5050
4 1 Assembly overview – pistons and conrods 5050
4 2 Separating new conrods 5051
4 2 1 Separating new conrod 5051
4 3 Checking pistons, piston rings and cylinder bores 5052
4 4 Checking piston projection at TDC 5053
4 5 Piston and cylinder dimensions 5055
15 – Cylinder head, valve gear 5056
1 Cylinder head 5056
1 1 Assembly overview – cylinder head 5056
1 2 Removing and installing cylinder head cover 5059
1 3 Removing, installing and tensioning toothed belt 5060
1 3 1 Removing 5062
1 3 2 Installing 5065
1 4 Removing and installing cylinder head 5069
1 4 1 Removing 5070
1 4 2 Installing 5072
1 5 Checking compression 5073
2 Valve gear 5076
2 1 Assembly overview – valve gear 5076
2 2 Checking valve guides 5079
2 2 1 Test procedure 5079
2 3 Renewing valve stem oil seals 5080
2 3 1 Removing 5080
2 3 2 Installing 5081
2 4 Removing and installing camshaft 5081
2 4 1 Removing 5082
2 4 2 Installing 5084
2 5 Removing and installing camshaft oil seal 5085
2 5 1 Removing 5086
2 5 2 Installing 5087
17 – Lubrication 5088
1 Engine oil 5088
1 1 Oil capacities 5088
1 2 Checking engine oil level 5088
2 Parts of lubrication system 5089
2 1 Assembly overview – parts of lubrication system 5089
2 2 Removing and installing sump 5090
2 3 Assembly overview – oil filter bracket 5092
2 4 Checking oil pressure and oil pressure switch 5093
2 5 Assembly overview – oil supply line 5094
2 6 Removing and installing oil supply line 5095
19 – Cooling 5098
1 Parts of cooling system 5098
1 1 Assembly overview – parts of cooling system, body side 5099
1 1 1 Vehicles with two radiator fans 5099
1 1 2 Vehicles with one radiator fan 5101
1 2 Assembly overview – parts of cooling system, engine side 5102
1 3 Coolant hose schematic diagram 5103
1 3 1 Engine code ASZ 5103
1 3 2 Engine code ATD 5104
1 3 3 Engine codes AXR, BLT 5105
1 3 4 Engine code BMT 5106
1 4 Draining and filling coolant 5107
1 4 1 Draining 5107
1 4 2 Filling 5108
1 5 Removing and installing radiator 5109
1 6 Removing and installing coolant pump 5111
1 7 Removing and installing thermostat 5112
1 7 1 Removing 5113
1 7 2 Installing 5114
1 8 Checking cooling system for leaks 5114
1 9 Checking oil cooler for leaks 5116
20 – Fuel supply system 5119
1 Removing and installing parts of fuel supply system 5119
1 1 Safety precautions when working on fuel supply system 5119
1 2 Rules for cleanliness 5120
1 3 Assembly overview – fuel tank with attachments 5120
1 4 Assembly overview – fuel filter 5123
1 5 Removing and installing fuel cooler 5124
1 5 1 Removing 5124
1 5 2 Installing 5124
1 6 Removing and installing fuel tank 5125
1 6 1 Removing 5125
1 6 2 Installing 5126
1 7 Removing and installing fuel delivery unit 5126
1 7 1 Removing 5127
1 7 2 Installing 5128
1 8 Removing and installing fuel gauge sender -G- 5128
1 8 1 Removing 5128
1 8 2 Installing 5128
1 9 Checking fuel pump 5129
1 9 1 Test prerequisites 5129
1 9 2 Checking function and voltage supply 5129
1 9 3 Checking current draw of fuel pump 5129
1 10 Assembly overview – accelerator mechanism 5130
1 11 Checking tandem pump 5131
1 11 1 Checking delivery pressure 5131
1 11 2 Checking for internal leaks 5133
1 12 Removing and installing tandem pump 5134
1 12 1 Removing 5135
1 12 2 Installing 5136
21 – Turbocharging/supercharging 5138
1 Charge air system with turbocharger 5138
1 1 Safety precautions 5138
1 2 Rules for cleanliness 5139
1 3 Disconnecting and reconnecting hose connections with push-in connectors 5139
1 4 Hose connections with spring band ring 5140
1 5 Assembly overview – turbocharger with attachments 5140
1 5 1 Engine codes ASZ, ATD 5141
1 5 2 Engine codes AXR, BLT 5142
1 5 3 Engine code BMT 5144
1 6 Removing and installing turbocharger, engine code BMT 5145
1 7 Assembly overview – parts of charge air cooling 5147
1 7 1 Engine codes ASZ, ATD, AXR, BLT 5147
1 7 2 Engine code BMT 5149
1 8 Checking charge air system for leaks 5149
23 – Mixture preparation – injection 5152
1 Repairing diesel direct injection system 5152
1 1 Safety precautions 5152
1 2 Rules for cleanliness 5153
1 3 Assembly overview – intake manifold with intake manifold flap 5153
1 3 1 Engine codes ASZ, ATD 5153
1 3 2 Engine codes AXR, BLT 5155
1 3 3 Engine code BMT 5156
1 4 Assembly overview – air filter 5157
1 5 Assembly overview – unit injector 5157
1 6 Removing and installing unit injector O-rings 5158
1 6 1 Removing 5159
1 6 2 Installing 5159
1 7 Removing and installing unit injector 5160
1 7 1 Removing 5160
1 7 2 Installing 5161
2 Engine control unit 5164
2 1 Reading and clearing engine control unit fault memory 5164
2 2 Adapting functions and components 5164
2 3 Removing and installing engine control unit 5165
2 3 1 Removing and installing engine control unit with no ant-theft protection 5165
2 3 2 Removing and installing anti-theft engine control unit 5166
2 3 3 Removing and installing anti-theft engine control unit (engine code BMT) 5168
26 – Exhaust system 5170
1 Exhaust system 5170
1 1 Assembly overview – front exhaust pipe with catalytic converter and silencers 5172
1 2 Assembly overview – front exhaust pipe with particulate filter 5173
1 3 Assembly overview – silencer (vehicle with particulate filter) 5175
1 4 Removing and installing front exhaust pipe with particulate filter 5175
1 4 1 Removing 5176
1 4 2 Installing 5178
1 5 Aligning exhaust system stress free 5178
2 Exhaust gas recirculation system 5180
2 1 Assembly overview – parts of exhaust gas recirculation 5180
2 1 1 Engine codes ASZ, ATD 5180
2 1 2 Engine codes AXR, BLT 5182
2 1 3 Engine code BMT 5183
2 2 Assembly overview – exhaust gas recirculation cooler, engine code BMT 5184
2 3 Removing and installing exhaust gas recirculation cooler, engine code BMT 5185
2 4 Schematic diagram for vacuum hoses 5186
28 – Glow plug system 5187
1 Checking glow plug system 5187
1 1 Removing, installing and checking glow plugs 5187
1 2 Characteristics of ceramic glow plugs 5188
1 3 Removing, installing and checking ceramic glow plugs 5188
00 – Technical data 5195
1 Gearbox identification 5195
1 1 Location on gearbox 5195
1 2 Identification code, assembly allocation and capacities 5195
2 Overview – power transmission 5198
3 Calculating overall gear ratio “i” 5200
4 General repair notes 5201
4 1 Contact corrosion! 5201
4 2 Repair instructions 5201
4 2 1 Special tools 5201
4 2 2 Gearbox 5201
4 2 3 Seals and sealing rings 5201
4 2 4 Sealant 5202
4 2 6 Nuts and bolts 5202
4 2 7 Bearings 5202
4 2 8 Shims 5203
4 2 9 Synchro-rings 5203
4 2 10 Gear wheels 5203
4 2 11 Synchromeshed gears 5203
4 2 12 Clutch 5203
30 – Clutch 5204
1 Repairing clutch mechanism 5204
1 1 Overview 5204
1 2 Assembly overview – pedal cluster 5205
1 3 Distinguishing between clutch pedal switches -F36- 5206
1 4 Removing and installing clutch pedal switch -F36- with rectangular housing 5206
1 4 1 Removing 5206
1 4 2 Installing and adjusting new clutch pedal switch 5207
1 5 Removing and installing clutch pedal switch -F36- with round housing 5207
1 5 1 Removing clutch pedal switch 5207
1 6 Removing and installing over-centre spring 5208
1 6 1 Removing 5208
1 6 2 Installing 5208
1 7 Removing and installing mounting bracket 5209
1 7 1 Removing 5210
1 7 2 Installing 5212
1 7 3 Specified torques 5212
1 8 Removing and installing clutch pedal 5212
1 8 1 Removing 5213
1 8 2 Installing 5213
1 8 3 Torque setting 5214
1 9 Assembly overview – hydraulics (LHD) 5214
1 10 Assembly overview – hydraulics (RHD) 5216
1 11 Removing and installing master cylinder 5218
1 11 1 Removing 5219
1 11 2 Installing 5220
1 11 3 Specified torques 5220
1 12 Bleeding clutch system 5220
2 Repairing clutch release mechanism 5222
2 1 Removing pipe/hose line and bleeder from and installing on slave cylinder 5223
2 2 Removing and installing slave cylinder with release bearing 5223
2 2 1 Removing 5223
2 2 2 Installing 5224
2 3 Removing and installing pipe/hose line 5224
2 3 1 Removing 5225
2 3 2 Installing 5226
2 4 Renewing input shaft seal 5226
2 4 1 Procedure 5227
3 Repairing clutch 5229
34 – Controls, housing 5232
1 Repairing selector mechanism 5232
1 1 Installation position of selector mechanism 5232
1 2 Removing and installing gear knob and cover 5234
1 3 Removing and installing gaiter with selector lever knob and, if present, noise insulation 5234
1 3 1 Installing 5235
1 4 Repairing gear lever and selector housing (through 05 06) 5236
1 5 Repairing gear lever and selector housing (from 06 06) 5238
1 6 Assembly overview – removing and installing selector cables 5240
1 7 Removing and installing selector mechanism 5242
1 7 1 Removing 5242
1 7 2 Installing 5244
1 7 3 Specified torques 5245
1 8 Adjusting selector mechanism 5245
1 9 Functional check 5247
2 Removing and installing gearbox 5249
2 1 Removing gearbox 5251
2 1 1 Transporting gearbox 5256
2 2 Installing gearbox 5256
2 2 1 Specified torques 5261
3 Checking gear oil 5262
4 Dismantling and assembling gearbox 5264
4 1 Overview – gearbox 5264
4 2 Assembly overview 5264
4 3 Assembly overview – removing and installing gearbox housing and selector unit 5266
4 4 Removing and installing input shaft, output shafts, differential and selector rods – Assembly overview 5268
4 5 Installing to engine and gearbox support 5269
4 6 Assembly order, gearbox »without« retaining ring -A- for input shaft sealing cover 5270
4 6 1 Removing 5272
4 6 2 Installing 5276
4 7 Assembly order, gearbox »with« retaining ring -A- for input shaft sealing cover 5280
4 7 1 Removing 5282
4 7 2 Installing 5286
5 Repairing gearbox housing 5291
6 Repairing clutch housing 5302
7 Repairing selector unit 5306
8 Repairing selector forks 5309
35 – Gears, shafts 5312
1 Input shaft 5312
1 1 Dismantling and assembling input shaft 5312
1 1 1 Modification in area of deep groove ball bearing 5317
2 Output shaft for 1st through 4th gears 5319
2 1 Dismantling and assembling output shaft for 1st through 4th gears 5319
2 2 Adjusting output shaft for 1st through 4th gears 5331
2 2 1 Determining thickness of shim 5334
2 2 2 Table of shims 5335
2 2 3 Carrying out check measurement 5335
3 Output shaft for 5th, 6th and reverse gears 5337
3 1 Dismantling and assembling output shaft for 5th, 6th and reverse gears 5337
3 2 Adjusting output shaft for 5th, 6th and reverse gears 5347
3 2 1 Determining thickness of shim 5350
3 2 2 Table of shims 5351
3 2 3 Carrying out check measurement 5351
39 – Final drive – differential 5353
1 Renewing flange shaft oil seals with gearbox installed 5353
1 1 Renewing oil seal for left flange shaft 5353
1 1 1 Removing 5353
1 1 2 Installing 5354
1 2 Renewing seal for right flange shaft 5354
1 2 1 Removing 5355
1 2 2 Installing 5356
2 Adjustment overview 5357
3 Differential 5358
3 1 Dismantling and assembling differential 5358
3 2 Adjusting differential 5363
3 2 1 Determining thickness of shim 5366
00 – Technical data 5374
1 Technical data 5374
1 1 Engine number 5374
1 2 Engine data 5374
10 – Removing and installing engine 5375
1 Removing and installing engine 5375
1 1 Removing engine 5375
1 2 Securing engine to assembly stand 5379
1 3 Installing engine 5381
1 4 Assembly mountings 5383
13 – Crankshaft group 5384
1 Dismantling and assembling engine 5384
1 1 Assembly overview 5384
1 1 1 Part I 5386
1 1 2 Part II 5387
1 2 Removing and installing poly V-belt 5388
2 Sealing flange and flywheel 5390
2 1 Renewing crankshaft oil seal – pulley end 5391
2 2 Removing and installing sealing flange – pulley end 5393
2 3 Removing and installing flywheel 5396
2 4 Removing and installing crankshaft sealing flange – flywheel end 5397
3 Crankshaft 5399
3 1 Assembly overview – crankshaft 5399
3 2 Crankshaft dimensions 5400
4 Pistons and conrods 5402
4 1 Assembly overview – pistons and conrods 5402
4 1 1 Bearing shells – installation position 5403
4 2 Checking pistons, piston rings and cylinder bores 5403
4 3 Piston and cylinder dimensions 5405
15 – Cylinder head, valve gear 5406
1 Cylinder head 5406
1 1 Assembly overview – cylinder head 5406
1 2 Removing, installing and tensioning toothed belts 5408
1 2 1 Removing 5409
1 2 2 Installing 5411
1 3 Removing and installing cylinder head 5413
1 3 1 Removing 5415
1 3 2 Installing 5416
1 4 Checking compression 5417
2 Valve gear 5420
2 1 Assembly overview – valve gear 5421
2 2 Valve dimensions 5423
2 3 Reworking valve seats 5423
2 4 Renewing camshaft oil seals 5425
2 4 1 Removing and installing oil seal on camshaft toothed belt pulley 5425
2 4 2 Removing and installing oil seal on Hall sender 5427
2 5 Checking hydraulic bucket tappets 5429
2 6 Removing and installing camshafts 5429
2 6 1 Removing 5430
2 6 2 Installing 5432
2 7 Checking valve guides 5434
2 8 Renewing valve stem seals 5434
17 – Lubrication 5437
1 Parts of lubrication system 5437
1 1 Engine oil 5437
1 2 Assembly overview – parts of lubrication system 5437
1 3 Assembly overview – oil filter bracket 5439
1 4 Removing and installing sump 5440
1 5 Checking oil pressure and oil pressure switch 5443
19 – Cooling 5446
1 Parts of cooling system 5446
1 1 Parts of cooling system, body side 5446
1 2 Parts of cooling system – engine side 5447
1 3 Coolant hose schematic diagram 5449
1 4 Draining and filling coolant 5450
1 5 Removing and installing radiator 5453
1 6 Removing and installing coolant pump 5455
1 7 Removing and installing thermostat 5456
20 – Fuel supply system 5459
1 Fuel tank 5459
1 1 Safety precautions when working on fuel supply system 5459
1 2 Rules for cleanliness 5459
1 3 Assembly overview – fuel tank with attachments 5460
1 4 Removing and installing fuel tank 5462
1 4 1 Removing 5463
1 4 2 Installing 5464
2 Repairing fuel supply system 5465
2 1 Safety precautions when working on fuel supply system 5465
2 2 Rules for cleanliness 5465
2 3 Assembly overview – fuel delivery unit 5466
2 4 Removing and installing fuel delivery unit 5466
2 5 Removing and installing fuel gauge sender -G- 5468
2 6 Checking fuel pump 5468
2 6 1 Checking function and voltage supply 5470
2 6 2 Checking delivery rate 5472
2 6 3 Checking fuel pump non-return valve 5474
3 Electronic power control (EPC) 5476
3 1 Assembly overview 5476
4 Activated charcoal filter system 5478
4 1 Function 5478
4 2 Assembly overview – parts of activated charcoal filter system 5478
4 3 Schematic diagram of activated charcoal filter system 5480
4 4 Checking fuel tank breather 5480
21 – Turbocharging/supercharging 5482
1 Turbocharger 5482
1 1 Rules for cleanliness 5482
1 2 Assembly overview part 1 – turbocharger 5483
1 3 Assembly overview part 2 – turbocharger 5485
1 4 Removing and installing turbocharger 5485
2 Charge air system 5491
2 1 Assembly overview – charge air cooler 5491
2 2 Schematic diagram of turbocharging system 5492
2 3 Checking charge pressure regulating valve vacuum unit 5492
2 4 Checking overrun shut-off valve 5493
2 5 Checking charge air system for leaks 5494
24 – Mixture preparation – injection 5496
1 Injection system 5496
1 1 General notes on injection 5496
1 2 Safety precautions 5496
1 3 Rules for cleanliness 5497
1 4 Technical data 5497
1 5 Assembly overview – intake manifold 5498
1 6 Assembly overview – fuel rail with injectors 5499
1 7 Assembly overview – air filter 5500
1 8 Removing and installing intake manifold 5500
2 Checking components 5502
2 1 Checking injectors 5502
2 2 Checking fuel pressure regulator and holding pressure 5504
3 Engine control unit 5508
3 1 Removing and installing engine control unit 5508
3 2 Removing and installing anti-theft engine control unit 5508
26 – Exhaust system 5511
1 Parts of exhaust system 5511
1 1 Assembly overview – exhaust system 5511
1 2 Separating centre and rear silencers 5513
1 3 Removing and installing front exhaust pipe with catalytic converter 5514
2 Secondary air system 5516
2 1 Function 5516
2 2 Assembly overview – secondary air system 5516
2 3 Removing and installing secondary air pump motor -V101- 5517
2 4 Checking combination valve 5517
28 – Ignition system 5519
1 Repairing ignition system 5519
1 1 General notes on ignition system 5519
1 2 Safety precautions 5519
1 3 Assembly overview – parts of ignition system 5519
1 4 Removing and installing ignition coils with output stage 5521
1 5 Spark plug test data 5522
00 – Technical data 5529
1 Suggestions and criticism, general repair notes 5529
1 1 Suggestions and criticism of this workshop manual 5529
1 2 General repair notes 5530
1 3 Tools 5530
1 4 Gearbox 5530
1 5 ATF 5531
1 6 Seals and sealing rings 5532
1 7 Nuts and bolts 5532
1 8 Locking devices 5533
1 9 Bearing 5533
1 10 Piston rings 5533
1 11 Inner plates 5533
1 12 Shims 5533
1 13 Clutches 5534
1 14 Brakes 5534
1 15 Valve body 5534
1 16 Electrical components 5534
1 17 Guided fault finding, vehicle self-diagnosis and testing 5535
2 Fault finding for the automatic 4-speed gearbox 5536
2 1 Vehicle cannot drive forwards or backwards 5536
2 2 Vehicle will not drive forwards 5537
2 3 Vehicle will not reverse 5537
2 4 Gearbox oily 5537
2 5 Oil or ATF leaks around torque converter 5537
2 6 Visible fouling of ATF and/or engine coolant 5538
2 7 ATF level too low, final drive oil level too high (or vice versa) – no external leaks in gearbox 5538
2 8 Gearbox oily only near breather – no other external leaks in gearbox 5538
2 9 ATF escaping from breather (only for longitudinally installed gearbox 01N) 5538
2 10 Selector mechanism does not move freely 5538
2 11 Not all selector lever positions can be selected; selected drive ranges do not function 5539
2 12 Parking lock does not engage 5539
2 13 Parking lock disengages »with a jolt« (selector lever sometimes difficult to move from „P“ to „R“) 5539
2 14 Final drive noisy 5539
2 15 Performance – jolting in neutral or during certain engine and gearbox movements 5540
2 16 Engine speed drops when driving range is selected 5540
2 17 Vehicle does not start at all or also starts in „R-D-3-2-1“ 5540
2 18 Vehicle does not start or engine stalls after a short time 5541
2 19 Selector lever can be moved from „N“ or „P“ without brake being operated 5541
2 20 Selector lever cannot be moved from „N“ or „P“ although brake is operated 5541
2 21 Shifts occur sporadically or not at all 5541
2 22 All shifts are »hard or jolting« 5542
2 23 One particular shift is »hard or jolting« 5543
2 24 Shift from 3rd to 4th gear takes »too long« in vehicles through 12 92 having economy/sport switch 5543
2 25 Shifts take »too long« 5543
2 26 Hard shifts immediately after repair 5544
2 27 Gearbox downshifts at constant vehicle speed without apparent reason 5544
2 28 Gearbox does not downshift for kickdown 5544
2 29 Gearbox does not shift until it warms up 5545
2 30 Gearbox switches to emergency running 5545
2 31 Selector lever position „1“, gearbox does not shift to 1st gear (no power transfer in 1st gear) 5545
2 32 Selector lever position „D“, „3“ or „2“, gearbox does not shift to 1st gear 5546
2 33 Selector lever position „D“, „3“ or „2“, automatic gearbox does not shift to 2nd gear (no power transfer) 5546
2 34 Selector lever position „D“ or „3“ does not shift to 3rd gear, hydraulic (3H) 5546
2 34 1 Automatic gearboxes through manufacture date 12 92 5546
2 34 2 Automatic gearboxes from manufacture date 01 95 5546
2 34 3 Automatic gearbox 001 5546
2 35 Selector lever position „D“ or „3“ does not shift to 3rd gear, mechanical (3M) 5547
2 35 1 Automatic gearboxes through manufacture date 12 92, not gearbox 001 5547
2 35 2 Automatic gearboxes from manufacture date 01 95 and gearbox 001 5547
2 36 Selector lever position „D“ or „3“ does not shift to 3rd gear (not gearbox 001) 5547
2 36 1 Automatic gearboxes from manufacture date 01 93 through 12 94 5547
2 37 Selector lever position „D“ does not shift to 4th gear 5547
2 37 1 Automatic gearboxes from manufacture date 01 93 through 12 94 5547
2 38 Selector lever position „D“ does not shift to 4th gear, mechanical (4M) 5548
2 38 1 Automatic gearboxes from manufacture date 01 95 and gearbox 001 5548
2 39 Selector lever position „R“, automatic gearbox does not shift to reverse gear 5548
3 Gearbox identification 5549
3 1 Location on gearbox 5549
4 Identification codes, engine allocation, ratios, equipment 5550
5 Capacity 5551
5 1 Planetary gearbox and final drive 5551
32 – Torque converter 5552
1 Torque converter 5552
1 1 Identification of torque converter 5552
1 2 Draining torque converter 5552
1 3 Removing and installing torque converter oil seal 5553
1 4 Installing torque converter 5554
37 – Controls, housing 5555
1 Connecting Volkswagen tester and selecting functions 5555
2 Carry out basic setting 5557
3 Electrical and electronic components and their locations 5558
3 1 Components in vehicle 5558
3 2 Components on gearbox 5560
3 3 Adjusting multifunction switch -F125- 5562
3 4 Removing and installing senders -G38- and -G68- 5562
3 5 Removing and installing wiring harness 5563
4 Repairing selector mechanism 5565
4 1 Checking selector mechanism 5565
4 2 Checking and adjusting selector lever cable 5566
4 2 1 Checking 5566
4 2 2 Adjusting 5566
4 3 Checking operation of the ignition key withdrawal lock 5566
4 4 Dismantling and assembling selector mechanism 5567
4 5 Removing and installing selector lever lock solenoid -N110- 5570
4 5 1 Removing 5570
4 5 2 Installing 5571
4 6 Removing and installing selector lever cable 5571
4 6 1 Removing 5571
4 6 2 Installing 5572
4 7 Removing and installing selector lever 5573
4 7 1 Installing 5575
4 8 Removing and installing locking cable 5576
4 8 1 Removing 5576
4 8 2 Installing 5577
4 9 Adjusting locking cable 5577
5 Removing and installing gearbox 5579
5 1 Removing gearbox 5580
5 2 Transporting automatic gearbox 5585
5 3 Installing gearbox 5586
5 4 Specified torques 5587
6 Checking ATF level and topping up 5588
6 1 Checking ATF level 5589
6 2 Topping up ATF 5591
6 3 Draining and filling ATF 5591
7 Gearbox with selector elements 5593
7 1 Position of selector elements 5593
7 2 Position of selector elements 5594
8 Dismantling and assembling gearbox 5597
8 1 Removing and installing ATF cooler and ATF filler tube 5597
8 2 Overview – dismantling and assembling planetary gearbox 5597
8 3 I – Removing and installing ATF pump up to large sun gear 5598
8 4 II – Removing and installing gearbox housing cover up to input gear 5600
8 4 1 Installation position of shim -F- and needle thrust bearings in planetary gearbox 5602
8 5 Dismantling and assembling planetary gearbox 5602
8 5 1 Dismantling planetary gearbox 5604
8 5 2 Assembling planetary gearbox 5610
8 6 Overview – all planetary gearbox adjustments 5616
8 7 Adjusting reverse gear brake -B1- 5617
8 7 2 Measurement to check reverse gear brake -B1- 5619
8 8 Adjusting 2nd and 4th gear brake -B2- 5619
8 9 Adjusting clutch play 5621
8 9 1 Adjusting clutch play between -K1- and ATF pump 5622
8 9 2 Adjusting clutch play between -K2- and ATF pump 5623
8 9 3 Checking dimension for clutch play 5624
38 – Gears, control 5626
1 Dismantling and assembling ATF pump 5626
2 Dismantling and assembling freewheel 5628
3 Dismantling and assembling 1st to 3rd gear clutch -K1- 5629
4 Dismantling and assembling reverse gear clutch -K2- 5632
5 Dismantling and assembling 3rd and 4th gear clutch -K3- 5634
6 Dismantling and assembling reverse gear brake -B1- 5637
7 Dismantling and assembling piston for 2nd and 4th gear brake -B2- 5639
8 Removing and installing valve body 5641
9 Dismantling and assembling parking lock 5644
39 – Final drive – differential 5647
1 Renewing oil seals for flange shafts 5647
1 1 Removing and installing left flange shaft 5647
1 2 Removing and installing right flange shaft 5648
2 Dismantling and assembling final drive 5650
2 1 Overview – final drive repair 5650
2 2 Removing and installing differential 5651
2 3 Removing and installing pinion shaft 5652
2 4 Dismantling and assembling differential 5655
3 Adjusting final drive 5660
3 1 Overview of adjustments 5660
3 2 Adjustments to be completed after renewing individual components 5660
3 3 Adjusting differential 5661
3 3 1 Table of shims: 5663
3 4 Adjusting pinion shaft 5663
4 Definitions: 5666
00 – Technical data 5675
1 Technical data 5675
1 1 Engine number 5675
1 2 Engine data 5675
10 – Removing and installing engine 5676
1 Removing and installing engine 5676
1 1 Removing 5677
1 2 Installing 5679
1 3 Specified torques 5681
1 4 Additional information and assembly work for vehicles with air conditioner 5682
13 – Crankshaft group 5684
1 Dismantling and assembling engine 5684
1 1 Assembly overview – parts l and ll 5684
1 2 Assembly overview – part I, belt drive 5686
1 3 Part II: assembly overview – chain drive system 5687
1 4 Removing and installing poly V-belt 5689
1 4 1 Poly V-belt routing 5690
1 5 Removing and installing valve timing housing (timing case) 5690
2 Cylinder block, sealing flange 5694
2 1 Assembly overview 5694
2 2 Renewing crankshaft oil seal – pulley end 5696
2 3 Poly V-belt pulley securing bolt tightening procedure 5697
2 4 Characteristics of the sealing flange and the assembly device -T10017- and -T10134- 5700
2 5 Renewing crankshaft sealing flange – flywheel end (assembly tool -T10134-) 5701
2 5 1 Pressing sealing flange with sender wheel off crankshaft 5702
2 5 2 Pressing sealing flange with sender wheel onto crankshaft 5703
2 5 3 A – Assembling seal with sender wheel on assembly tool -T10134- 5704
2 5 4 B – Attaching assembling tool -T10134- with sealing flange on crankshaft flange 5705
2 5 5 C – Bolting assembly tool -T10134- onto crankshaft flange 5706
2 5 6 D – Pressing sender wheel onto crankshaft flange using assembly tool -T10134- 5707
2 5 7 E – Checking sender wheel installation position on crankshaft 5707
2 5 8 F – Re-pressing sender wheel 5708
2 6 Renewing crankshaft sealing flange – flywheel end (assembly tool -T10017-) 5709
2 6 1 Pressing sealing flange with sender wheel off crankshaft 5710
2 6 2 Pressing sealing flange with sender wheel onto crankshaft 5711
2 6 3 A-Assembling sealing flange with sender wheel on assembly appliance -T10017- 5711
2 6 4 B-Assembling appliance -T10017- with sealing flange on crankshaft flange 5713
2 6 5 C-Fitting assembly appliance -T10017- onto crankshaft flange 5714
2 6 6 D-Pressing sender wheel onto crankshaft flange with assembly appliance -T10017- 5715
2 6 7 E – Checking sender wheel installation position on crankshaft 5715
2 6 8 Re-pressing sender wheel F 5716
2 7 Crankshaft dimensions 5716
3 Pistons and conrods 5718
3 1 Assembly overview 5718
3 2 Checking piston 5719
3 3 Checking cylinder bores 5720
3 4 Piston and cylinder dimensions 5720
15 – Cylinder head, valve gear 5721
1 Cylinder head 5721
1 1 Assembly overview 5721
1 2 Checking valve timing 5724
1 3 Adjusting valve timing 5725
1 4 Removing and installing timing chain and chain drive for oil pump 5729
1 5 Removing and installing camshaft housing 5737
1 6 Removing and installing cylinder head 5741
1 7 Checking compression 5744
2 Valve gear 5746
2 1 Assembly overview 5746
2 2 Checking camshaft axial clearance 5748
2 3 Reworking valve seats 5748
2 4 Checking valve guides 5750
2 5 Renewing valve stem seals 5750
17 – Lubrication 5753
1 Parts of lubrication system 5753
1 1 Engine oil 5753
1 2 Assembly overview 5753
1 3 Removing and installing oil sump 5756
1 4 Removing and installing oil pump 5757
1 5 Checking oil pressure and oil pressure switch 5759
19 – Cooling 5762
1 Parts of cooling system 5762
1 1 Assembly overview – parts of cooling system, body side 5762
1 2 Assembly overview – parts of cooling system, engine side 5764
1 3 Coolant hose schematic diagram 5766
1 4 Draining and filling coolant 5767
1 5 Removing and installing radiator 5770
1 6 Removing and installing coolant pump 5772
20 – Fuel supply system 5775
1 Parts of fuel supply system 5775
1 1 Assembly overview – fuel tank with attachments 5775
1 2 Safety precautions when working on fuel supply system 5778
1 3 Rules for cleanliness 5778
1 4 Removing and installing fuel delivery unit 5778
1 5 Removing and installing fuel gauge sender G 5780
1 6 Removing and installing fuel tank 5781
1 7 Assembly overview – fuel filter with attachments 5783
1 8 Removing and installing fuel filter 5784
1 9 Crash fuel shut-off 5785
1 10 Checking fuel pump 5785
1 11 Bleeding fuel system 5790
2 Electronic power control (EPC) 5793
2 1 Assembly overview 5793
3 Activated charcoal filter system 5794
3 1 Assembly overview 5794
3 2 Checking fuel tank breather 5795
24 – Mixture preparation – injection 5796
1 Injection system 5796
1 1 General notes on injection 5796
1 2 Assembly overview – intake manifold 5796
1 3 Assembly overview – fuel rail with injectors 5798
1 4 Removing and installing injectors 5798
1 5 Assembly overview – air filter 5799
1 6 Removing and installing air filter housing 5801
1 7 Cleaning throttle valve module -J338- 5802
1 8 Safety precautions 5803
1 9 Rules for cleanliness 5804
1 10 Technical data 5804
2 Checking components 5805
2 1 Checking injectors for leaks and quantity injected 5805
2 1 1 Checking for leaks 5805
2 1 2 Checking quantity injected 5806
2 2 Checking fuel pressure regulator and holding pressure 5807
3 Engine control unit -J623- 5810
3 1 Removing and installing engine control unit -J623- 5810
3 2 Removing and installing engine control unit -J623- with protective housing 5810
26 – Exhaust system 5812
1 Parts of the exhaust system 5812
1 1 Assembly overview – catalytic converters and attachments 5812
1 2 Assembly overview – silencers with mountings 5814
28 – Ignition system 5815
1 Ignition system 5815
1 1 Assembly overview – ignition system 5815
1 2 Removing and installing ignition coils with output stage 5816
1 3 Safety precautions 5817
1 4 Test data, spark plugs 5818
00 – Technical data 5823
1 Suggestions and criticism, general repair notes 5823
1 1 Suggestions and criticism of this workshop manual 5823
1 2 General repair notes 5824
1 3 Gearbox 5824
1 4 Torque converter 5824
1 5 ATF 5824
1 6 Automatic gearbox control unit -J217- with ⇒ fuzzy logic 5824
1 7 Control units in vehicle 5824
1 8 Information on “09G gearbox” 5824
1 9 Tools 5824
1 10 Gearbox 5825
1 11 Gaskets, seals and oil 5826
1 12 Nuts and bolts 5826
1 13 Electrical components 5826
1 14 Guided fault finding, vehicle self-diagnosis and testing 5827
2 Gearbox identification 5828
2 1 Gearbox codes 5828
3 Capacities 5829
3 1 Planetary gearbox and final drive 5829
4 Identification codes, engine allocation, Polo 2002 ▸ 5830
32 – Torque converter 5831
1 Torque converter 5831
1 1 Identification of torque converter 5831
1 2 Draining torque converter 5831
1 3 Removing and installing torque converter oil seal 5831
1 4 Installing torque converter 5832
37 – Controls, housing 5833
1 Connecting “tester” 5833
1 1 Connecting vehicle diagnosis, testing and information system -VAS 5051- 5833
2 Electrical and electronic components and their locations 5835
3 Multifunction switch -F125- 5839
3 1 Removing multifunction switch -F125- 5839
3 2 Installing multifunction switch -F125- 5840
3 3 Adjusting multifunction switch -F125- 5841
3 3 1 Adjustment prerequisites 5841
4 Repairing selector mechanism 5843
4 1 Assembly overview – selector mechanism 5843
4 2 Removing and installing selector mechanism 5844
4 2 1 Removing 5845
4 2 2 Installing 5847
4 3 Removing and installing selector lever handle 5847
4 4 Removing and installing selector lever cable 5848
4 4 1 Removing 5848
4 4 2 Installing 5850
4 5 Checking selector lever cable 5850
4 6 Adjusting selector lever cable 5851
4 7 Checking selector mechanism 5852
4 7 1 Selector lever in “P” position and ignition switched on 5852
4 7 2 Selector lever in “N” position and ignition switched on 5852
4 7 3 Selector lever in position “Tiptronic” 5852
4 7 4 Ignition and light switched on 5852
4 7 5 Selector lever position display 5852
4 8 Removing and installing selector lever lock solenoid -N110- 5853
4 8 1 Removing 5853
4 8 2 Installing 5855
4 9 Removing and installing locking cable 5855
4 9 1 Removing 5855
4 9 2 Installing 5856
4 9 3 Installation position of locking cable 5857
4 10 Adjusting locking cable 5858
4 11 Checking operation of the ignition key withdrawal lock 5859
5 Removing and installing gearbox 5861
5 1 Removing gearbox, Polo 2002 with 1 4 l – 59 kW engine 5861
5 2 Installing gearbox, Polo 2002 with 1 4 l – 59 kW engine 5870
5 2 1 Torque settings 5871
5 3 Removing gearbox, Polo 2002 with 1 6 l – 77 kW engine 5872
5 4 Installing gearbox, Polo 2002 with 1 6 l – 77 kW engine 5880
5 4 1 Torque settings 5880
6 Transporting gearbox 5882
7 Checking ATF level and topping up 5883
7 1 Checking ATF level 5884
7 2 Topping up ATF 5885
7 3 Draining and filling ATF 5886
8 ATF cooler 5887
8 1 Assembly overview – ATF cooler 5887
38 – Gears, control 5888
1 Renewing oil seal for selector shaft 5888
2 Removing and installing ATF pan 5889
2 1 Removing 5889
2 2 Installing 5890
3 Removing and installing ATF strainer 5892
3 1 Removing 5892
3 2 Installing 5892
4 Removing and installing valve body 5893
4 1 Overview – valve chest 5893
4 2 Removing valve body 5895
4 3 Installing valve body 5898
4 3 1 Wire routing, connectors, connections and retainer on valve body 5900
4 4 Torque settings 5902
5 Removing and installing wiring harness for solenoid valves and senders 5903
5 1 Removing 5903
5 2 Installing 5903
5 3 Removing and installing gearbox input speed sender -G182- 5903
5 3 1 Removing 5903
5 3 2 Installing 5904
5 4 Removing and installing gearbox output speed sender -G195- 5904
5 4 1 Removing 5904
5 4 2 Installing 5904
39 – Final drive – differential 5906
1 Renewing oil seals for flange shafts 5906
1 1 Renewing oil seal for flange shaft 5906
1 1 1 Removing flange shaft oil seal 5906
1 1 2 Installing flange shaft oil seal 5908
00 – Technical data 5915
1 Technical data 5915
1 1 Engine number 5915
1 2 Engine data 5915
10 – Removing and installing engine 5916
1 Removing and installing engine 5916
1 1 Removing engine 5916
1 2 Securing engine to assembly stand 5920
1 3 Installing engine 5922
1 4 Assembly mountings 5924
13 – Crankshaft group 5925
1 Dismantling and assembling engine 5925
1 1 Assembly overview 5925
1 1 1 Part I 5927
1 1 2 Part II 5928
1 2 Removing and installing poly V-belt 5929
2 Sealing flange and flywheel 5931
2 1 Renewing crankshaft oil seal – pulley end 5932
2 2 Removing and installing sealing flange – pulley end 5934
2 3 Removing and installing flywheel 5936
2 4 Removing and installing crankshaft sealing flange – flywheel end 5937
3 Crankshaft 5939
3 1 Assembly overview – crankshaft 5939
3 2 Crankshaft dimensions 5940
4 Pistons and conrods 5942
4 1 Assembly overview – pistons and conrods 5942
4 1 1 Bearing shells – installation position 5943
4 2 Checking pistons, piston rings and cylinder bores 5943
4 3 Piston and cylinder dimensions 5945
15 – Cylinder head, valve gear 5946
1 Cylinder head 5946
1 1 Assembly overview – cylinder head 5946
1 2 Removing, installing and tensioning toothed belt 5948
1 2 1 Removing 5949
1 2 2 Installing 5951
1 3 Removing and installing cylinder head 5953
1 3 1 Removing 5955
1 3 2 Installing 5956
1 4 Checking compression 5957
2 Valve gear 5960
2 1 Assembly overview – valve gear 5961
2 2 Valve dimensions 5963
2 3 Reworking valve seats 5963
2 4 Renewing camshaft oil seals 5965
2 4 1 Removing and installing oil seal on camshaft toothed belt pulley 5965
2 4 2 Removing and installing oil seal on Hall sender 5967
2 5 Checking hydraulic bucket tappets 5969
2 6 Removing and installing camshafts 5969
2 6 1 Removing 5970
2 6 2 Installing 5972
2 7 Checking valve guides 5974
2 8 Renewing valve stem seals 5974
17 – Lubrication 5977
1 Parts of lubrication system 5977
1 1 Engine oil 5977
1 2 Assembly overview – parts of lubrication system 5977
1 3 Assembly overview – oil filter bracket 5979
1 4 Removing and installing oil sump 5980
1 5 Checking oil pressure and oil pressure switch 5983
19 – Cooling 5986
1 Parts of cooling system 5986
1 1 Parts of cooling system – body side 5986
1 2 Parts of cooling system – engine side 5987
1 3 Coolant hose schematic diagram 5990
1 4 Draining and filling coolant 5991
1 5 Removing and installing radiator 5994
1 6 Removing and installing coolant pump 5996
1 7 Removing and installing thermostat 5997
20 – Fuel supply system 5999
1 Fuel tank 5999
1 1 Safety precautions when working on fuel supply system 5999
1 2 Rules for cleanliness 5999
1 3 Assembly overview – fuel tank with attachments 6000
1 4 Removing and installing fuel tank 6002
1 4 1 Removing 6003
1 4 2 Installing 6004
2 Repairing fuel supply system 6005
2 1 Safety precautions when working on fuel supply system 6005
2 2 Rules for cleanliness 6005
2 3 Assembly overview – fuel delivery unit 6006
2 4 Removing and installing fuel delivery unit 6006
2 5 Removing and installing fuel gauge sender -G- 6008
2 6 Checking fuel pump 6008
2 6 1 Checking function and voltage supply 6010
2 6 2 Checking delivery rate 6012
2 6 3 Checking non-return valve for fuel pump 6014
3 Electronic power control (EPC) 6016
3 1 Assembly overview 6016
4 Activated charcoal filter system 6018
4 1 Function 6018
4 2 Assembly overview – parts of activated charcoal filter system 6018
4 3 Overview of activated charcoal filter system 6020
4 4 Checking fuel tank breather 6020
21 – Turbocharging/supercharging 6022
1 Turbocharger 6022
1 1 Rules for cleanliness 6022
1 2 Assembly overview part 1 – turbocharger 6023
1 3 Assembly overview part 2 – turbocharger 6025
1 4 Removing and installing turbocharger 6025
2 Charge air system 6031
2 1 Assembly overview – charge air cooler 6031
2 2 Schematic diagram of turbocharging system 6032
2 3 Checking vacuum unit for charge pressure control valve 6032
2 4 Checking overrun shut-off valve 6033
2 5 Checking charge air system for leaks 6034
24 – Mixture preparation – injection 6036
1 Injection system 6036
1 1 General notes on injection 6036
1 2 Safety precautions 6036
1 3 Rules for cleanliness 6037
1 4 Technical data 6037
1 5 Assembly overview – intake manifold 6038
1 6 Assembly overview – fuel rail with injectors 6039
1 7 Assembly overview – air filter 6040
1 8 Removing and installing intake manifold 6040
2 Checking components 6042
2 1 Checking injectors 6042
2 2 Checking fuel pressure regulator and holding pressure 6044
3 Engine control unit 6048
3 1 Removing and installing engine control unit 6048
3 2 Removing and installing anti-theft engine control unit 6048
26 – Exhaust system 6051
1 Parts of exhaust system 6051
1 1 Assembly overview – exhaust system 6051
1 2 Separating centre and rear silencers 6053
1 3 Removing and installing front exhaust pipe with catalytic converter 6054
2 Secondary air system 6056
2 1 Function 6056
2 2 Assembly overview – secondary air system 6056
2 3 Removing and installing secondary air pump motor -V101- 6057
2 4 Checking combination valve 6057
28 – Ignition system 6059
1 Repairing ignition system 6059
1 1 General notes on ignition system 6059
1 2 Safety precautions 6059
1 3 Assembly overview – parts of the ignition 6059
1 4 Removing and installing ignition coils with output stage 6061
1 5 Test data, spark plugs 6062
00 – Technical data 6067
1 Identification of gearbox 6067
1 1 Location on gearbox 6067
1 2 Identification code, assembly allocation and capacities 6067
2 Overview – power transmission 6069
3 Calculating overall gear ratio “i” 6071
4 General repair instructions 6072
4 1 Gearbox 6072
4 1 1 Gearbox 6072
4 2 Gaskets and seals 6072
4 3 Sealant 6072
4 4 Locking devices 6073
4 5 Nuts and bolts 6073
4 6 Mountings 6073
4 7 Shims 6073
4 8 Synchro-rings 6074
4 9 Gear wheels 6074
4 10 Synchromeshed gears 6074
4 11 Clutch 6074
30 – Clutch 6075
1 Fault finding, power transmission 6075
2 Repairing clutch mechanism 6076
2 1 Overview – clutch actuation 6076
2 2 Assembly overview – pedal cluster 6077
2 3 Distinguishing between clutch pedal switches -F36- 6078
2 4 Removing and installing clutch pedal switch -F36- with rectangular housing 6078
2 4 1 Removing 6078
2 4 2 Installing and adjusting new clutch pedal switch 6078
2 5 Removing and installing clutch pedal switch -F36- with round housing 6079
2 5 1 Removing 6079
2 5 2 Installing and adjusting 6079
2 6 Removing and installing over-centre spring 6079
2 6 1 Removing 6080
2 6 2 Installing 6080
2 7 Removing and installing mounting bracket for clutch pedal 6081
2 7 1 Removing 6082
2 7 2 Installing 6084
2 7 3 Specified torques 6084
2 8 Removing and installing clutch pedal 6084
2 8 1 Removing 6085
2 8 2 Installing 6085
2 8 3 Specified torque 6085
2 9 Assembly overview – hydraulics – LHD 6085
2 10 Assembly overview – hydraulics – RHD 6088
2 11 Removing and installing master cylinder 6090
2 11 1 Removing 6091
2 11 2 Installing 6092
2 11 3 Specified torques 6092
2 12 Removing and installing slave cylinder 6092
2 12 1 Removing 6093
2 12 2 Installing 6093
2 12 3 Specified torques 6094
2 13 Bleeding clutch mechanism 6094
3 Repairing clutch release mechanism 6096
4 Repairing clutch 6098
34 – Controls, housing 6101
1 Fault finding, power transmission 6101
2 Repairing selector mechanism 6102
2 1 Installation position of selector mechanism 6102
2 2 Overview of selector mechanism 6103
2 3 Assembly overview – gear knob and cover 6104
2 4 Removing and installing gaiter with selector lever knob and, if present, noise insulation 6104
2 5 Repairing gear lever and selector housing (through 05 06) 6106
2 6 Repairing gear lever and selector housing (from 06 06) 6108
2 7 Assembly overview – removing and installing selector cables 6110
2 8 Removing and installing selector mechanism 6114
2 8 1 Removing 6114
2 8 2 Installing 6116
2 8 3 Specified torques 6118
2 9 Adjusting selector mechanism 6118
2 9 1 Function 6120
3 Removing and installing gearbox 6122
3 1 Removing gearbox 6123
3 2 Transporting gearbox 6128
3 3 Install gearbox 6128
3 3 1 Specified torques 6133
4 Checking gear oil 6134
5 Dismantling and assembling gearbox 6135
5 1 Overview – gearbox 6135
5 2 Assembly overview 6135
5 3 Assembly overview – removing and installing cover for gearbox housing and 5th gear 6137
5 4 Assembly overview – removing and installing gearbox housing and selector mechanism 6139
5 5 Assembly overview – removing and installing input shaft, output shaft, differential and selector forks 6140
5 6 Assembly sequence – removing and installing cover for gearbox housing and 5th gear 6141
5 6 1 Removing 6143
5 6 2 Installing 6146
5 7 Assembly sequence – Dismantling and assembling gearbox completely 6147
5 7 1 Removing 6149
5 7 2 Installing 6154
6 Repairing gearbox housing and clutch housing 6160
7 Dismantling and assembling selector mechanism on gearbox side (selector shaft can be removed from selector mechanism cover) 6166
8 Dismantling and assembling selector mechanism on gearbox side (selector shaft cannot be removed from selector mechanism cover) 6170
9 Dismantling and assembling selector forks 6172
35 – Gears, shafts 6177
1 Input shaft 6177
1 1 Dismantling and assembling input shaft 6177
1 2 Modification in springs for 5th gear synchronisation from gearbox date 05111 6184
1 3 Adjusting input shaft 6184
1 3 1 Table of shims 6186
1 3 2 Carrying out check measurement 6188
2 Output shaft 6189
2 1 Dismantling and assembling output shaft 6189
2 2 Adjusting output shaft 6202
2 2 1 Determining thickness of shim 6204
3 Reverse shaft 6206
3 1 Dismantling and assembling reverse shaft 6206
39 – Final drive – differential 6210
1 Renewing flange shaft oil seals with gearbox installed 6210
1 1 Renewing oil seal for left flange shaft 6210
1 1 1 Removing 6210
1 1 2 Installing 6211
1 1 3 Specified torques: 6212
1 2 Distinguishing seals for right flange shaft 6212
1 3 Renewing seal (two-part seal and sleeve for right flange shaft) 6212
1 3 1 Removing 6213
1 3 2 Installing 6214
1 3 3 Specified torque 6215
1 4 Renewing seal and sleeve together (one-piece seal and sleeve for right flange shaft) 6215
1 4 1 Removing 6217
1 4 2 Installing 6217
1 4 3 Specified torque 6218
2 Adjustment overview 6219
3 Differential 6220
3 1 Dismantling and assembling differential 6220
3 2 Adjusting differential 6228
3 2 1 Determining thickness of shim 6230
00 – Technical data 6237
1 Vehicle identification data 6237
1 1 Vehicle identification number 6237
1 2 Identification plate 6237
1 3 Vehicle data sticker 6237
2 Body dimensions 6238
2 1 Body – front 6238
2 2 Body – centre 6241
2 2 1 2-door vehicle 6241
2 2 2 4-door vehicle 6244
2 3 Body – rear 6248
2 4 Floor group – front 6250
2 5 Floor group – rear 6252
3 Moulded foam elements 6254
4 Galvanized body parts 6255
5 Strengthened steel body panels 6256
6 Laser welding 6257
7 Body panel gaps/shut lines 6258
7 1 Body – front 6258
7 2 Body – rear 6260
8 Alignment jig 6262
8 1 Overview 6262
50 – Body – front 6273
1 Renewing engine console (right) 6273
1 1 Tools 6273
1 2 Removing 6274
1 3 Installing 6275
1 3 1 Preparing replacement part 6275
1 3 2 Welding in 6275
2 Renewing wing connecting plate 6276
2 1 Tools 6276
2 2 Removing 6277
2 3 Installing 6278
2 3 1 Preparing replacement part 6278
2 3 2 Welding in 6278
3 Renewing upper wheel housing longitudinal member ►02 2005 6279
3 1 Tools 6279
3 2 Removing 6279
3 3 Installing 6281
3 3 1 Preparing replacement part 6281
3 3 2 Welding in 6281
4 Renewing upper wheel housing longitudinal member 03 2005 ► 6282
4 1 Tools 6282
4 2 Removing 6283
4 3 Installing 6285
4 3 1 Preparing replacement part 6285
4 3 2 Moulded foam elements 6285
4 3 3 Welding in 6285
5 Renewing front wheel housing 6287
5 1 Tools 6287
5 2 Removing 6287
5 3 Installing 6288
5 3 1 Preparing replacement part 6288
5 3 2 Welding in 6289
6 Renewing front wheel housing – part section 6290
6 1 Tools 6290
6 2 Removing 6290
6 3 Installing 6292
6 3 1 Preparing replacement part 6292
6 3 2 Welding in 6292
7 Renewing front longitudinal member 6293
7 1 Tools 6294
7 2 Removing 6294
7 3 Installing 6295
7 3 1 Preparing replacement part 6295
7 3 2 Welding in 6296
8 Renewing front longitudinal member – part section 6299
8 1 Tools 6299
8 2 Removing 6299
8 3 Installing 6300
8 3 1 Preparing replacement part 6300
8 3 2 Welding in 6301
9 Renewing front section of longitudinal member 6302
9 1 Removing 6302
9 2 Installing 6303
9 2 1 Welding in 6303
51 – Body – centre 6305
1 Renewing roof 6305
1 1 Tools 6305
1 1 1 Removing 6306
1 2 Installing 6307
1 2 1 Preparing replacement part 6307
1 2 2 Adjusting roof depth 6312
1 2 3 Bonding roof 6313
1 2 4 Welding in 6316
1 2 5 Bonding roof cross member 6317
2 Renewing roof with roof railing 6319
2 1 Tools 6319
2 1 1 Removing 6320
2 2 Installing 6322
2 2 1 Preparing replacement part 6322
2 2 2 Adjusting roof depth 6327
2 2 3 Bonding roof 6328
2 2 4 Welding in 6337
3 Renewing front roof cross member 6339
3 1 Tools 6339
3 2 Removing 6339
3 3 Installing 6340
3 3 1 Welding in 6340
4 Renewing roof reinforcement 6342
4 1 Removing 6342
4 2 Installing 6343
4 2 1 Welding in 6343
5 Renewing rear roof cross member 6344
5 1 Removing 6344
5 2 Installing 6345
5 2 1 Preparing replacement part 6345
5 2 2 Welding in 6345
6 Renewing A-pillar 6346
6 1 Tools 6346
6 2 Removing 6347
6 3 Installing 6349
6 3 1 Preparing replacement part 6349
6 3 2 Welding in 6350
7 Renewing inner A-pillar 6352
7 1 Tools 6352
7 2 Removing 6352
7 3 Installing 6355
7 3 1 Preparing replacement part 6355
7 3 2 Foam insulation 6355
7 3 3 Welding in 6355
8 Renewing B-pillar (4-door) 6357
8 1 Tools 6357
8 2 Removing 6358
8 3 Installing 6358
8 3 1 Preparing replacement part 6358
8 3 2 Welding in 6360
9 Renewing inner B-pillar (2-door) 6362
9 1 Tools 6362
9 2 Removing 6362
9 3 Installing 6364
9 3 1 Preparing replacement part 6364
9 3 2 Welding in 6365
10 Renewing inner B-pillar (4-door) 6366
10 1 Removing 6366
10 2 Installing 6368
10 2 1 Preparing replacement part 6368
10 2 2 Welding in 6368
11 Renewing outer side member (2-door) 6370
11 1 Tools 6370
11 2 Removing 6370
11 3 Installing 6371
11 3 1 Preparing replacement part 6371
11 3 2 Welding in 6372
12 Renewing outer side member (4-door) 6374
12 1 Tools 6374
12 2 Removing 6374
12 3 Installing 6375
12 3 1 Preparing replacement part 6375
12 3 2 Welding in 6377
13 Renewing side member reinforcement 6379
13 1 Tools 6379
13 2 Removing 6379
13 3 Installing 6381
13 3 1 Preparing replacement part 6381
13 3 2 Welding in 6381
14 Renewing floor panel – part section 6383
14 1 Tools 6383
14 2 Removing 6384
14 3 Installing 6385
14 3 1 Preparing replacement part 6385
14 3 2 Welding in 6386
53 – Body – rear 6388
1 Renewing rear cross panel 6388
1 1 Tools 6388
1 2 Removing 6388
1 3 Installing 6390
1 3 1 Preparing replacement part 6390
1 3 2 Welding in 6390
2 Renewing inner lock carrier 6391
2 1 Tools 6391
2 2 Removing 6391
2 3 Installing 6392
2 3 1 Welding in 6392
3 Renewing tail light mounting 6393
3 1 Tools 6393
3 2 Removing 6394
3 3 Installing 6395
3 3 1 Preparing replacement part 6395
3 3 2 Welding in 6395
4 Renewing towing eye 6396
4 1 Removing 6396
4 2 Installing 6397
4 2 1 Preparing replacement part 6397
4 2 2 Welding in 6397
5 Renewing rear longitudinal member – part section 6398
5 1 Removing 6398
5 2 Installing 6399
5 2 1 Preparing replacement part 6399
5 2 2 Moulded foam elements 6400
5 2 3 Welding in 6400
6 Renewing side panel – part section (2-door) 6401
6 1 Tools 6401
6 2 Removing 6402
6 3 Installing 6404
6 3 1 Preparing replacement part 6404
6 3 2 Welding in 6405
7 Renewing side panel – part section (4-door) 6407
7 1 Tools 6407
7 2 Removing 6408
7 3 Installing 6410
7 3 1 Preparing replacement part 6410
7 3 2 Moulded foam elements 6410
7 3 3 Welding in 6411
8 Renewing outer wheel housing liner – part section 6413
8 1 Tools 6413
8 2 Removing 6413
8 3 Installing 6414
8 3 1 Preparing replacement part 6414
8 3 2 Welding in 6415
9 Renewing spare wheel well 6416
9 1 Removing 6416
9 2 Installing 6417
9 2 1 Preparing replacement part 6417
9 2 2 Welding in 6417
10 Renewing spare wheel well – part section 6418
10 1 Removing 6418
10 2 Installing 6419
10 2 1 Preparing replacement part 6419
10 2 2 Welding in 6419
00 – Technical data 6426
1 Technical data 6426
1 1 Engine number 6426
1 2 Engine data 6426
10 – Removing and installing engine 6427
1 Removing and installing engine 6427
1 1 Notes on removing 6428
1 2 Securing engine to assembly stand 6432
1 3 Notes on installing 6432
1 3 1 Torque settings 6433
1 4 Assembly mounting 6433
1 4 1 Additional information and removal instructions for vehicles with air conditioner 6434
13 – Crankshaft group 6435
1 Dismantling and assembling engine 6435
1 1 Assembly overview 6435
1 1 1 Part I 6437
1 1 2 Part II 6438
1 2 Removing and installing poly V-belt 6439
1 2 1 Removing poly V-belt 6440
1 2 2 Installing poly V-belt 6440
2 Removing and installing front sealing flange 6442
2 1 Exploded view sealing flanges and flywheel or drive plate 6442
2 2 Renewing crankshaft oil seal 6443
2 2 1 Removing 6443
2 2 2 Installing 6444
2 3 Removing and installing front sealing flange 6445
2 3 1 Removing 6446
2 3 2 Installing 6447
3 Dismantling and assembling pistons and conrods 6449
3 1 Assembly overview – Pistons and conrods 6449
3 1 1 Conventional conrods 6449
3 1 2 Industrially cracked conrods 6451
3 2 Checking pistons, piston rings and cylinder bores 6452
3 3 Piston and cylinder dimensions 6454
4 Removing and installing crankshaft 6455
4 1 Exploded view crankshaft 6455
4 2 Colour identification 6456
4 3 Crankshaft dimensions 6457
15 – Cylinder head, Valve gear 6458
1 Removing and installing cylinder head 6458
1 1 Exploded view cylinder head 6458
1 2 Removing, installing and tensioning toothed belt 6460
1 2 1 Removing 6460
1 2 2 Installing 6462
1 3 Checking semi-automatic toothed belt tensioning roller 6464
1 4 Removing and installing cylinder head 6464
1 4 1 Removing 6465
1 4 2 Installing 6467
1 5 Checking compression 6468
2 Repairing valve gear 6471
2 1 Exploded view valve gear 6471
2 2 Reworking valve seats 6473
2 3 Renewing camshaft oil seal 6475
2 3 1 Removing 6475
2 3 2 Installing 6476
2 4 Removing and installing camshaft 6477
2 4 1 Removing 6478
2 4 2 Installing 6479
2 5 Checking hydraulic bucket tappets 6480
2 6 Checking valve guides 6481
2 7 Renewing valve guides 6481
2 8 Renewing valve stem seals 6482
17 – Lubrication 6486
1 Removing and installing parts of lubrication system 6486
1 1 Engine oil 6486
1 2 Assembly overview – Parts of lubrication system 6487
1 3 Assembly overview – Oil filter bracket 6489
1 4 Removing and installing sump 6490
1 4 1 Removing 6490
1 4 2 Installing 6491
1 5 Checking oil pressure and oil pressure switch 6492
19 – Cooling system 6495
1 Removing and installing parts of cooling system 6495
1 1 Assembly overview – parts of cooling system – engine side 6495
1 2 Assembly overview – parts of cooling system – body side 6498
1 3 Draining and filling coolant 6499
1 3 1 Draining 6499
1 3 2 Filling with coolant 6501
1 4 Removing and installing coolant pump 6502
1 5 Removing and installing thermostat 6503
1 6 Removing and installing radiator fan -V7- and radiator fan 2 -V177- 6505
1 7 Removing and installing radiator 6506
1 8 Checking cooling system for leaks 6507
20 – Fuel supply system 6510
1 Parts of fuel system 6510
1 1 Assembly overview – fuel tank with attachments 6510
1 2 Safety precautions when working on fuel supply system 6513
1 3 Rules for cleanliness 6514
1 4 Removing and installing fuel delivery unit 6514
1 4 1 Removing 6514
1 4 2 Installing 6515
1 5 Removing and installing fuel gauge sender 6516
1 6 Removing and installing fuel tank 6516
1 6 1 Removing 6517
1 6 2 Installing 6518
1 7 Crash fuel shut-off 6518
1 8 Checking fuel pump 6518
1 8 1 Checking delivery rate 6522
1 8 2 Checking fuel pump non-return valve 6524
2 Active charcoal filter system 6526
2 1 Assembly overview – parts of active charcoal filter system 6526
2 2 Checking fuel tank breather 6527
3 Electronic power control (EPC) 6529
3 1 Assembly overview 6529
24 – Mixture preparation, Injection 6531
1 Repairing ignition system 6531
1 1 General notes on ignition system 6531
1 2 Safety precautions 6531
1 3 Assembly overview – ignition system 6531
1 4 Spark plugs 6532
2 Engine control unit 6533
2 1 Removing and installing anti-theft engine control unit 6533
2 1 1 Removing 6533
2 1 2 Installing 6534
2 2 Reading and erasing engine control unit fault memory 6535
26 – Exhaust system 6536
1 Removing and installing parts of exhaust system 6536
1 1 Front exhaust pipe and catalytic converter with attachments 6536
1 2 Silencer with mountings 6538
1 3 Separating middle and rear silencers 6538
1 4 Aligning exhaust system stress free 6539
28 – Ignition system 6541
1 Repairing injection system 6541
1 1 General notes on injection 6541
1 2 Safety precautions 6542
1 3 Rules for cleanliness 6542
1 4 Technical data 6543
1 5 Dismantling and assembling intake manifold – upper part 6543
1 6 Dismantling and assembling intake manifold – lower part 6545
1 7 Fuel rail 6546
1 8 Dismantling and assembling air cleaner 6547
1 9 Removing and installing intake manifold 6547
1 10 Removing and installing fuel rail with intake manifold flaps 6548
1 10 1 Removing 6548
1 10 2 Installing 6549
1 11 Removing and installing injectors 6550
1 11 1 Removing 6550
1 11 2 Installing 6551
1 12 Renewing Teflon seal on injector 6552
1 13 Cleaning throttle valve module -J338- 6554
30 – Clutch 6559
1 Complaints regarding clutch and clutch mechanism 6559
1 1 Checking clutch mechanism (slave cylinder is bolted from outside on clutch housing) 6565
1 2 Checking clutch mechanism (slave cylinder is located inside clutch housing) 6566
34 – Controls, housing 6568
1 Complaints regarding the selector mechanism 6568
30 – Clutch 6573
1 Complaints regarding clutch and clutch mechanism 6573
1 1 Checking clutch mechanism (slave cylinder is bolted from outside on clutch housing) 6579
1 2 Checking clutch mechanism (slave cylinder is located inside clutch housing) 6580
34 – Controls, housing 6582
1 Complaints regarding the selector mechanism 6582

S.V 03/02/2025