Volkswagen Polo 2010-2015 Workshop Repair Manual PDF

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Volkswagen Polo 2010-2015 Workshop Repair Manual – PDF DOWNLOAD

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Volkswagen Polo 2010-2015 Workshop Repair Manual – PDF DOWNLOAD

Language : English
Pages : 23208
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Volkswagen Polo 2010-2015 Workshop Repair Manual – PDF DOWNLOAD

00053148720 Wheels and Tyres Guide Standard 1
44 – Wheels, tyres, vehicle geometry 9
1 General notes on wheels and tyres (passenger cars) 9
2 Legislative and technical conditions for converting wheel and tyre combinations 11
2 1 Legislative conditions for converting wheel and tyre combinations 11
2 2 Technical conditions for converting wheel and tyre combinations 11
2 3 Additional wheel housing extensions (flaps) 12
2 4 „Series 80“ tyres 12
3 Documents and codes/designations 13
3 1 New vehicle registration documents since 01 10 2005 13
3 2 COC document (EEC Certificate of Conformity) 14
3 3 EU general type approval number, sales type and sales or trade designation 14
4 Useful information regarding tyres 16
4 1 Identification markings on the tyre sidewall 16
4 2 Explanation of tyre markings 17
4 3 Speed ratings for tyres 18
4 4 Undulations 19
4 5 Tyre storage 20
4 6 Tyre ageing 20
4 7 Tyre sizes for vehicles with four-wheel drive 22
4 8 Winter tyres 22
4 9 Winter tyres with speed symbol „V“ 23
4 10 Extra Load (XL) V winter tyres 24
4 11 Maximum speeds for V and Extra Load (XL) winter tyres 24
4 12 Reinforced and Extra Load (XL) tyres 25
4 13 Snow chains 25
5 Tyre wear/ mileage for passenger car tyres 27
5 1 General 27
5 2 Requirements to be met by tyres 27
5 3 Wear behaviour of high-speed tyres 28
5 4 Factors influencing the service life of a tyre 28
5 5 Driving style 28
5 6 Tyre maintenance 29
5 7 Evenly worn tyres 30
5 8 Measuring tread depth 31
5 9 One-sided wear 31
5 10 Outer shoulder wear 34
5 11 Wear in middle of tyre 34
5 12 Diagonal washout 36
6 Tyre noise 37
6 1 General notes on tyre noise 37
6 2 Saw-tooth wear 37
6 3 Flat spots (from locking wheels) 38
7 Vehicle pulls to one side 40
7 1 General 40
7 2 Conicity 40
7 3 Remedies when vehicle pulls to one side 41
7 4 Strategic rotation of wheels for non-directional tyres 42
7 5 Strategic rotation of wheels having unidirectional tyres 43
8 Tyre damage 45
8 1 General information 45
8 2 Construction of a radial belted tyre 46
8 3 Impact damage 46
8 4 Cuts 48
8 5 Damage caused by foreign bodies 48
8 6 Loss of air from tyre 48
8 7 Tyre pressure 48
8 8 Tyre damage due to insufficient tyre pressure 49
8 9 Rising tyre temperature caused by insufficient inflation pressure 50
8 10 Tyre damage due to fitting error (fitting damage) 51
9 Tyres with run-flat properties 53
9 1 General 53
9 2 Design and identification 54
9 3 Retrofitting/requirements when using run-flat tyres 54
9 4 Repairs 55
10 Rolling resistance optimised tyres 56
11 Facts about disc-type wheels (passenger cars) 57
11 1 Design of disc-type wheel 57
11 2 Data on wheel rims 57
11 3 Wheel rims – pitch circle diameter 58
11 4 Split rim composite wheels 58
11 5 Alloy wheels with exchangeable trim elements 58
11 6 Alloy wheels with exchangeable trim elements (Zaragoza) 59
11 6 1 Tools 59
11 6 2 Materials 60
11 6 3 Installing trim element 60
11 6 4 Removing trim element 62
11 7 Care and maintenance of alloy wheel rims 63
11 8 Restoring alloy wheels 63
11 9 The valve 65
12 Notes on use of temporary spare wheels 66
13 Fox from model year 2006 67
13 1 Fox, type 5Z model year 2006 to model year 2012 67
13 2 Wheel allocation for Fox, type 5Z model year 2006 to model year 2012 68
13 2 1 5 J x 14 69
13 2 2 6 J x 14 69
13 2 3 6 J x 15 71
14 up! from model year 2012 74
14 1 Advance information about up! Model year 2012 74
15 Polo from model year 2010 75
15 1 Polo, type 6R model year 2010 to model year 2012 75
15 2 Wheel allocation for Polo, type 6R model year 2010 to model year 2012 77
15 2 1 5 J x 14 77
15 2 2 6 J x 15 offset 38 78
15 2 3 6 J x 15 offset 40 78
15 2 4 7 J x 16 79
15 2 5 7 J x 17 80
16 Polo BlueMotion from model year 2010 81
16 1 Polo BlueMotion, type 6R model year 2010 to model year 2012 81
16 2 Wheel allocation for Polo BlueMotion, type 6R model year 2010 to model year 2012 82
16 2 1 51/2 J x 15 82
16 2 2 6 J x 15 offset 38 83
16 2 3 6 J x 15 offset 40 83
17 CrossPolo from model year 2011 85
17 1 CrossPolo, type 6R model year 2011 to model year 2012 85
17 2 Wheel allocation CrossPolo, type 6R model year 2011 to model year 2012 87
17 2 1 5 J x 14 87
17 2 2 6 J x 15 offset 38 88
17 2 3 6 J x 15 offset 40 88
17 2 4 7 J x 16 89
17 2 5 7 J x 17 90
17 2 6 71/2 J x 17 91
18 Polo GTI from model year 2011 92
18 1 Polo GTI, type 6R model year 2011 to model year 2012 92
18 2 Wheel allocation Polo GTI, type 6R model year 2011 to model year 2012 93
18 2 1 6 J x 15 offset 38 93
18 2 2 6 J x 15 offset 40 93
18 2 3 7 J x 16 94
18 2 4 7 J x 17 95
19 Golf from model year 2009 96
19 1 Golf, Golf 4Motion, sales type 5K model year 2009 to model year 2012 96
19 2 Wheel allocation for Golf, Golf 4Motion, sales type 5K model year 2009 to model year 2012 100
19 2 1 6 J x 15 100
19 2 2 61/2 J x 15 101
19 2 3 6 J x 16 102
19 2 4 61/2 J x 16 103
19 2 5 6 J x 17 108
19 2 6 7 J x 17 109
19 2 7 71/2 J x 17 112
19 2 8 71/2 J x 18 114
20 Golf BlueMotion from model year 2009 118
20 1 Golf BlueMotion, sales type 5K model year 2009 to model year 2012 118
20 2 Wheel allocation for Golf BlueMotion, sales type 5K model year 2009 to model year 2012 120
20 2 1 6 J x 15 120
20 2 2 61/2 J x 15 121
20 2 3 61/2 J x 16 122
21 Golf GTD from model year 2010 128
21 1 Golf GTD, sales type 5K, model year 2010 to model year 2012 128
21 2 Wheel allocation for Golf GTD, type 5K model year 2010 to model year 2012 130
21 2 1 6 J x 16 130
21 2 2 61/2 J x 16 130
21 2 3 6 J x 17 135
21 2 4 7 J x 17 136
21 2 5 71/2 J x 17 139
21 2 6 71/2 J x 18 141
22 Golf GTI from model year 2010 145
22 1 Golf GTI, sales type 5K, model year 2010 to model year 2012 145
22 2 Wheel allocation for Golf GTI, type 5K model year 2010 to model year 2012 147
22 2 1 6 J x 16 147
22 2 2 61/2 J x 16 148
22 2 3 6 J x 17 153
22 2 4 7 J x 17 153
22 2 5 71/2 J x 17 157
22 2 6 71/2 J x 18 158
22 2 7 71/2 J x 19 161
23 Golf R from model year 2010 163
23 1 Golf R, sales type 5K model year 2010 163
23 2 Golf R, sales type 5K model year 2011 to model year 2012 164
23 3 Wheel allocation for Golf R, type 5K model year 2010 to model year 2012 165
23 3 1 6 J x 17 166
23 3 2 7 J x 17 166
23 3 3 71/2 J x 17 166
23 3 4 71/2 J x 18 168
23 3 5 8 J x 19 171
24 CrossGolf from model year 2011 173
24 1 CrossGolf, sales type 521 model year 2011 to model year 2012 173
24 2 Wheel allocation CrossGolf, sales type 521 model year 2011 to model year 2012 176
24 2 1 6 J x 15 176
24 2 2 61/2 J x 15 177
24 2 3 6 J x 16 178
24 2 4 61/2 J x 16 179
24 2 5 6 J x 17 184
24 2 6 7 J x 17 offset 47 185
24 2 7 7 J x 17 offset 54 185
24 2 8 71/2 J x 17 189
25 Golf Cabriolet from model year 2012 190
25 1 Golf Cabriolet, sales type 517 from model year 2012 190
25 2 Wheel allocation Golf Cabriolet, sales type 517 from model year 2012 192
25 2 1 6 J x 15 192
25 2 2 61/2 J x 15 193
25 2 3 6 J x 16 194
25 2 4 61/2 J x 16 195
25 2 5 6 J x 17 200
25 2 6 7 J x 17 201
25 2 7 71/2 J x 17 204
25 2 8 71/2 J x 18 206
26 Golf Plus from model year 2009 210
26 1 Golf Plus, sales type 521 model year 2009 to model year 2011 210
26 2 Golf Plus, sales type 521 model year 2012 215
26 3 Wheel allocation for Golf Plus, sales type 521 model year 2009 to model year 2012 219
26 3 1 6 J x 15 219
26 3 2 61/2 J x 15 220
26 3 3 6 J x 16 221
26 3 4 61/2 J x 16 221
26 3 5 6 J x 17 226
26 3 6 7 J x 17 227
26 3 7 71/2 J x 17 230
26 3 8 71/2 J x 18 232
27 Golf Plus BlueMotion from model year 2010 236
27 1 Golf Plus BlueMotion, sales type 521, model year 2010 to model year 2012 236
27 2 Wheel allocation for Golf Plus BlueMotion, sales type 521, model year 2010 to model year 2012 238
27 2 1 6 J x 15 238
27 2 2 61/2 J x 15 239
27 2 3 6 J x 16 240
27 2 4 61/2 J x 16 241
28 Golf Variant from model year 2010 247
28 1 Golf Variant, Golf Variant 4Motion, sales type AJ5 model year 2010 to model year 2012 247
28 2 Wheel allocation for Golf Variant, Golf Variant 4Motion, sales type AJ5 model year 2010 to model year 2012 253
28 2 1 6 J x 15 253
28 2 2 61/2 J x 15 254
28 2 3 6 J x 16 255
28 2 4 61/2 J x 16 256
28 2 5 6 J x 17 261
28 2 6 7 J x 17 262
28 2 7 71/2 J x 17 265
28 2 8 71/2 J x 18 267
29 Golf Variant BlueMotion from model year 2010 271
29 1 Golf Variant BlueMotion, sales type AJ5, model year 2010 to model year 2012 271
29 2 Wheel allocation for Golf Variant BlueMotion, sales type AJ5, model year 2010 to model year 2012 272
29 2 1 6 J x 15 272
29 2 2 61/2 J x 15 273
29 2 3 6 J x 16 274
29 2 4 61/2 J x 16 275
30 Jetta from model year 2011 281
30 1 Jetta, sales type 162 model year 2011 to model year 2012 281
30 2 Wheel allocation Jetta, sales type 162 model year 2011 284
30 2 1 6 J x 15 284
30 2 2 61/2 J x 15 285
30 2 3 6 J x 16 286
30 2 4 61/2 J x 16 287
30 2 5 7 J x 17 292
30 2 6 71/2 J x 17 296
30 2 7 71/2 J x 18 297
31 Jetta from model year 2011 (NAR) 301
31 1 Jetta, sales type 162 from model year 2011 (NAR) 301
31 2 Wheel allocation for Jetta, sales type 162 from model year 2011 (NAR) 303
31 2 1 6 J x 15 303
31 2 2 61/2 J x 15 303
31 2 3 6 J x 16 305
31 2 4 61/2 J x 16 305
31 2 5 7 J x 17 310
31 2 6 71/2 J x 17 314
31 2 7 71/2 J x 18 315
32 Beetle from model year 2012 319
32 1 Beetle, sales type 5C1, from model year 2012 319
32 2 Beetle, sales type 5C1, from model year 2012 320
32 2 1 61/2 J x 16 321
32 2 2 7 J x 17 321
32 2 3 8 J x 18 323
32 2 4 8 J x 19 324
33 Scirocco from model year 2009 325
33 1 Scirocco, sales type 137, model year 2009 to model year 2011 325
33 2 Scirocco, sales type 137 model year 2012 328
33 3 Wheel allocation for Scirocco, sales type 137 model year 2009 to model year 2012 330
33 3 1 61/2 J x 16 330
33 3 2 61/2 J x 17 330
33 3 3 7 J x 17 331
33 3 4 8 J x 17 331
33 3 5 8 J x 18 333
33 3 6 8 J x 19 334
34 Scirocco R from model year 2010 336
34 1 Scirocco R, sales type 137, model year 2010 to model year 2011 336
34 2 Scirocco R, sales type 137 model year 2012 337
34 3 Wheel allocation for Scirocco R, sales type 137, model year 2010 to model year 2012 338
34 3 1 61/2 J x 17 339
34 3 2 7 J x 17 339
34 3 3 8 J x 17 339
34 3 4 8 J x 18 341
34 3 5 8 J x 19 343
35 Touran from model year 2003 344
35 1 Touran, type 1T model year 2003 to model year 2006 344
35 2 Touran, type 1T model year 2007 to model year 2010 347
35 3 Touran, type 1T and type 1t model year 2011 to model year 2012 352
35 4 Wheel allocation Touran, type 1T and type 1t model year 2003 to model year 2012 357
35 4 1 6 J x 15 357
35 4 2 61/2 J x 15 358
35 4 3 6 J x 16 359
35 4 4 61/2 J x 16 359
35 4 5 6 J x 17 365
35 4 6 7 J x 17 365
35 4 7 71/2 J x 18 366
36 CrossTouran from model year 2008 367
36 1 CrossTouran, type 1T model year 2008 to model year 2009 367
36 2 CrossTouran, type 1T and type 1t model year 2010 to model year 2012 370
36 3 Wheel allocation CrossTouran, type 1T and type 1t model year 2008 to model year 2012 374
36 3 1 6 J x 15 374
36 3 2 6 J x 16 375
36 3 3 61/2 J x 17 375
36 3 4 8 J x 17 376
37 Touran BlueMotion from model year 2009 377
37 1 Touran BlueMotion, type 1T and type 1t model year 2009 to model year 2012 377
37 2 Wheel allocation Touran BlueMotion, type 1T and type 1t model year 2009 to model year 2012 379
37 2 1 6 J x 15 379
37 2 2 61/2 J x 15 380
37 2 3 6 J x 16 381
37 2 4 61/2 J x 16 381
38 Tiguan from model year 2008 387
38 1 Tiguan, type 5N model year 2008 to model year 2011 387
38 2 Tiguan, type 5N, model year 2012 388
38 3 Wheel allocation for Tiguan, type 5N model year 2008 to model year 2012 390
38 3 1 6 1/2 J x 16 390
38 3 2 61/2 J x 17 392
38 3 3 7 J x 17 392
38 3 4 7 J x 18 393
38 3 5 9 J x 19 394
39 Eos from model year 2006 395
39 1 Eos, type 1F from model year 2006 395
39 2 Eos, type 1F model year 2007 to model year 2012 396
39 3 Wheel allocation for Eos, type 1F model year 2006 to model year 2012 399
39 3 1 61/2 J x 16 399
39 3 2 7 J x 16 400
39 3 3 6 J x 17 402
39 3 4 71/2 J x 17 403
39 3 5 8 J x 18 406
40 Passat saloon from model year 2011 409
40 1 Passat saloon, sales type 362 model year 2011 to model year 2012 409
40 2 Wheel allocation Passat saloon, sales type 362 model year 2011 to model year 2012 414
40 2 1 61/2 J x 16 415
40 2 2 7 J x 16 415
40 2 3 6 J x 17 416
40 2 4 61/2 J x 17 417
40 2 5 71/2 J x 17 417
40 2 6 8 J x 18 418
41 Passat Variant from model year 2011 420
41 1 Passat estate, sales type 365 model year 2011 to model year 2012 420
41 2 Wheel allocation Passat estate, sales type 365 model year 2011 to model year 2012 425
41 2 1 61/2 J x 16 425
41 2 2 7 J x 16 426
41 2 3 6 J x 17 427
41 2 4 61/2 J x 17 427
41 2 5 71/2 J x 17 428
41 2 6 8 J x 18 429
42 Passat CC from model year 2009, CC from model year 2010 431
42 1 Passat CC, sales type 357 model year 2009 431
42 2 Passat CC, CC, sales type 357 model year 2010 to model year 2012 433
42 3 Wheel allocation Passat CC, CC, sales type 357 model year 2009 to model year 2012 434
42 3 1 61/2 J x 17 434
42 3 2 8 J x 17 435
42 3 3 8 J x 18 436
42 3 4 8 J x 19 438
43 Phaeton from model year 2003 439
43 1 Phaeton, type 3D, model year 2003 to model year 2009 – short and long wheelbase 439
43 2 Phaeton, type 3D and type 3d, model year 2010 to model year 2012 – short and long wheelbase 442
43 3 Wheel allocation for Phaeton, type 3D and type 3d, model year 2003 to model year 2012 – short and long wheelbase 444
43 3 1 71/2 J x 16 444
43 3 2 71/2 J x 17 444
43 3 3 71/2 J x 18 446
43 3 4 81/2 J x 18 446
43 3 5 81/2 J x 19 offset 38 448
43 3 6 81/2 J x 19 offset 45 449
43 3 7 9 J x 19 offset 35 449
43 3 8 9 J x 19 offset 40 450
43 3 9 9 J x 20 450
44 Sharan from model year 2011 452
44 1 Sharan, Sharan 4Motion, type 7N model year 2011 to model year 2012 452
44 2 Wheel allocation Sharan, Sharan 4Motion, type 7N model year 2011 to model year 2012 454
44 2 1 6 1/2 J x 16 454
44 2 2 7 J x 17 455
44 2 3 71/2 J x 18 455
45 Touareg from model year 2010 457
45 1 Touareg, type 7P and type 7p, model year 2010 to model year 2012 457
45 2 Wheel allocation for Touareg, type 7P and type 7p, model year 2010 to model year 2012 459
45 2 1 71/2 J x 17 459
45 2 2 8 J x 18 460
45 2 3 81/2 J x 19 461
45 2 4 9 J x 20 461
45 2 5 91/2 J x 21 462
46 Touareg hybrid from model year 2011 464
46 1 Touareg hybrid, type 7PH and type 7pH, model year 2011 to model year 2012 464
46 2 Wheel allocation Touareg hybrid, type 7PH and type 7pH, model year 2011 to model year 2012 465
46 2 1 8 J x 18 465
46 2 2 81/2 J x 19 466
47 Breakdown set for VW Vehicles 468
48 Temporary spare tyres and wheels for VW vehicles 469
49 Recommended summer tyres 470
49 1 Summer tyres for Fox from model year 2006 470
49 2 Summer tyres for Polo from model year 2010 470
49 3 Summer tyres for Polo BlueMotion from model year 2010 471
49 4 Summer tyres for CrossPolo from model year 2011 472
49 5 Summer tyres for Polo GTI from model year 2011 472
49 6 Summer tyres for Golf from model year 2009 473
49 7 Summer tyres for Golf BlueMotion from model year 2009 474
49 8 Summer tyres for Golf GTD from model year 2009 475
49 9 Summer tyres for Golf GTI from model year 2009 475
49 10 Summer tyres for Golf R from model year 2010 476
49 11 Summer tyres for CrossGolf from model year 2011 477
49 12 Summer tyres Golf Cabriolet from model year 2012 478
49 13 Summer tyres for Golf Plus from model year 2009 479
49 14 Summer tyres for Golf Plus BlueMotion from model year 2010 480
49 15 Summer tyres for Golf Variant from model year 2010 481
49 16 Summer tyres for Golf Variant BlueMotion from model year 2010 482
49 17 Summer tyres for Jetta from model year 2011 483
49 18 Summer tyres for Beetle from model year 2012 485
49 19 Summer tyres for Scirocco from model year 2009 485
49 20 Summer tyres for Scirocco R from model year 2010 485
49 21 Summer tyres for Touran from model year 2003 486
49 22 Summer tyres for Touran BlueMotion from model year 2009 486
49 23 Summer tyres for CrossTouran from model year 2008 487
49 24 Summer tyres for Tiguan from model year 2008 487
49 25 Summer tyres for Eos from model year 2006 488
49 26 Summer tyres for Passat saloon from model year 2011 488
49 27 Summer tyres for Passat Variant from model year 2011 489
49 28 Summer tyres Passat CC from model year 2009, CC from model year 2010 490
49 29 Summer tyres for Sharan from model year 2011 490
49 30 Summer tyres for Phaeton from model year 2003 490
49 31 Summer tyres for Touareg from model year 2010 491
49 32 Summer tyres for Touareg hybrid from model year 2011 491
50 Recommended all-season tyres 492
50 1 All-season tyres for Polo from model year 2010 492
50 2 All-season tyres for Polo BlueMotion from model year 2010 492
50 3 All-season tyres for CrossPolo from model year 2011 492
50 4 All-season tyres for Polo GTI from model year 2011 493
50 5 All-season tyres for Golf from model year 2009 493
50 6 All-season tyres for CrossGolf from model year 2011 493
50 7 All-weather tyres Golf Cabriolet from model year 2012 494
50 8 All-season tyres for Golf Plus from model year 2009 494
50 9 All-season tyres for Golf Variant from model year 2010 495
50 10 All-season tyres for Jetta from model year 2011 495
50 11 All-season tyres for Jetta from model year 2011 (NAR) 495
50 12 All-season tyres for Touran from model year 2003 496
50 13 All-season tyres for Beetle from model year 2012 496
50 14 All-season tyres for Tiguan from model year 2008 496
50 15 All-season tyres for Eos from model year 2006 496
50 16 All-season tyres for Passat saloon from model year 2011 497
50 17 All-season tyres for Passat Variant from model year 2011 497
50 18 All-season tyres Passat CC from model year 2009, CC from model year 2010 497
50 19 All-season tyres for Sharan from model year 2011 498
50 20 All-season tyres for Phaeton from model year 2003 498
50 21 All-season tyres for Touareg from model year 2010 498
50 22 All-season tyres Touareg hybrid from model year 2010 498
51 Recommended winter tyres 500
51 1 Winter tyres for Fox from model year 2006 500
51 2 Winter tyres for Polo from model year 2010 500
51 3 Winter tyres for Polo BlueMotion from model year 2010 501
51 4 Winter tyres for CrossPolo from model year 2011 501
51 5 Winter tyres for Polo GTI from model year 2011 501
51 6 Winter tyres for Golf from model year 2009 501
51 7 Winter tyres for Golf BlueMotion from model year 2009 502
51 8 Winter tyres for Golf GTD from model year 2009 502
51 9 Winter tyres for Golf GTI from model year 2009 502
51 10 Winter tyres for Golf R from model year 2010 502
51 11 Winter tyres for CrossGolf from model year 20011 503
51 12 Winter tyres Golf Cabriolet from model year 2012 503
51 13 Winter tyres for Golf Plus from model year 2009 503
51 14 Winter tyres for Golf Plus BlueMotion from model year 2010 504
51 15 Winter tyres for Golf Variant from model year 2010 504
51 16 Winter tyres for Golf Variant BlueMotion from model year 2010 504
51 17 Winter tyres for Jetta from model year 2011 505
51 18 Winter tyres for Beetle from model year 2012 505
51 19 Winter tyres for Scirocco from model year 2009 505
51 20 Winter tyres for Scirocco R from model year 2010 505
51 21 Winter tyres for Touran from model year 2003 506
51 22 Winter tyres for Touran BlueMotion from model year 2009 506
51 23 Winter tyres for CrossTouran from model year 2008 506
51 24 Winter tyres for Tiguan from model year 2008 507
51 25 Winter tyres for Eos from model year 2006 507
51 26 Winter tyres for Passat saloon from model year 2011 507
51 27 Winter tyres for Passat Variant from model year 2011 507
51 28 Winter tyres Passat CC from model year 2009, CC from model year 2010 508
51 29 Winter tyres for Sharan from model year 2011 508
51 30 Winter tyres for Phaeton from model year 2003 508
51 31 Winter tyres for Touareg from model year 2010 508
51 32 Winter tyres Touareg hybrid from model year 2010 509
BRA5R000820 Body Repairs 510
00 – Technical data 516
1 Vehicle identification data 516
1 1 Vehicle identification number 516
1 2 Chassis number – anti-corrosion protection 516
1 3 Identification plate 516
1 4 Destructive labels (only for Brazil) – VIS 517
1 5 Destructible labels (only for Brazil) – VIS – replacement 517
1 6 Vehicle identification tag 518
2 Body dimensions 519
2 1 Body, front section 519
2 2 Body – central section 522
2 2 1 Polo Hatch 522
2 2 2 Polo Sedan 527
2 3 Body, rear section 532
2 3 1 Polo Hatch 532
2 3 2 Polo Sedan 534
2 4 Lower section of the vehicle – front section 537
2 5 Lower section of the vehicle – rear section 539
3 Body foam parts/supports 541
4 Galvanized parts of the car body 542
5 High-strength body plat 543
6 Laser welding 544
7 Body clearance dimensions (Polo Hatch / Sedan ▶ 2006) 545
7 1 Body, front section 545
7 2 Body – rear section (Polo Hatch) 547
7 3 Body – rear section (Polo Sedan) 549
8 Body clearance dimensions (Polo Hatch / Sedan 2007 ▶) 551
8 1 Body, front section 551
8 2 Body – rear section (Polo Hatch) 553
8 3 Body – rear section (Polo Sedan) 555
9 Alignment platform 557
9 1 Overview (Hatch) 557
9 2 Overview (Sedan) 567
50 – Body – front 580
1 Engine support (right side) – replace 580
1 1 Tools 580
1 2 Remove 580
1 3 Install 581
1 3 1 Prepare the new part 581
1 3 2 Welding 582
2 Auxiliary frame support – replace 583
2 1 Tools 583
2 2 Remove 583
2 3 Install 584
2 3 1 Prepare the new part 584
2 3 2 Welding 584
3 Wheel arch upper longitudinal member – replace 586
3 1 Tools 586
3 2 Remove 586
3 3 Install 588
3 3 1 Prepare the new part 588
3 3 2 Welding 589
4 Wheel arch upper longitudinal member (► 2006) – replace 590
4 1 Tools 590
4 2 Remove 590
4 3 Install 592
4 3 1 Prepare the new part 592
4 3 2 Welding 592
5 Wheel arch upper longitudinal member (2007 ►) – replace 594
5 1 Tools 595
5 2 Remove 595
5 3 Install 596
5 3 1 Prepare the new part 596
5 3 2 Foam parts/supports 597
5 3 3 Welding 597
6 Front wheel arch – replace 599
6 1 Tools 599
6 2 Remove 599
6 3 Install 600
6 3 1 Prepare the new part 600
6 3 2 Welding 601
7 Front wheel arch (partial part) – replace 602
7 1 Tools 602
7 2 Remove 602
7 3 Install 603
7 3 1 Prepare the new part 603
7 3 2 Welding 604
8 Auxiliary frame support thread – repair 605
8 1 Tools 606
8 1 1 Composition of the Heli-coil M12x1 5 thread set -VAS 6058- 606
8 2 Thread repair 607
8 2 1 Perforating thread 607
8 2 2 Cutting the thread 608
8 2 3 Installing insert 608
9 Front longitudinal member – replace 610
9 1 Tools 611
9 2 Remove 611
9 3 Install 613
9 3 1 Prepare the new part 613
9 3 2 Welding 613
10 Front longitudinal member (partial part) – replace 616
10 1 Tools 616
10 2 Remove 616
10 3 Install 617
10 3 1 Prepare the new part 618
10 3 2 Welding 618
11 Front bumper support – replace 619
11 1 Tools 619
11 2 Remove 619
11 3 Install 621
11 3 1 Welding 621
51 – Body – centre 623
1 Roof – replace 623
1 1 Tools 623
1 2 Remove 624
1 3 Install 626
1 3 1 Prepare the new part 627
1 3 2 Adjust roof depth 630
1 3 3 Gluing the roof 632
1 3 5 Cut the roof cross member 636
2 Roof (Sedan) – replace 639
2 1 Tools 639
2 2 Remove 640
2 3 Install 642
2 3 1 Prepare the new part 643
2 3 2 Adjust roof depth 646
2 3 3 Gluing the roof 648
3 Front roof cross member (Sedan) – replace 655
3 1 Tools 655
3 2 Remove 655
3 3 Install 656
3 3 1 Welding 656
4 Centre roof cross member (Sedan) – replace 658
4 1 Tools 658
4 2 Remove 658
4 3 Install 659
4 3 1 Welding 659
5 Rear roof cross member (Sedan) – replace 661
5 1 Tools 661
5 2 Remove 661
5 3 Install 662
5 3 1 Prepare the new part 662
5 3 2 Welding 663
6 A-pillar (external section) – replace 664
6 1 Tools 664
6 2 Remove 664
6 3 Install 667
6 3 1 Prepare the new part 667
6 3 2 Welding 667
7 A-pillar (internal section) – replace 669
7 1 Tools 669
7 2 Remove 669
7 3 Install 673
7 3 1 Prepare the new part 673
7 3 2 Install foam parts/supports 674
7 3 3 Welding 674
8 B-pillar (external section) – replace 675
8 1 Tools 675
8 2 Remove 675
8 3 Install 678
8 3 1 Prepare the new part 678
8 3 2 Welding 679
9 B-pillar (internal section) – replace 680
9 1 Tools 680
9 2 Remove 680
9 3 Install 683
9 3 1 Prepare the new part 683
9 3 2 Welding 684
10 Lower longitudinal member (external section) – replace 685
10 1 Tools 685
10 2 Remove 686
10 3 Install 687
10 3 1 Prepare the new part 687
10 3 2 Welding 688
53 – Body – rear 689
1 Back panel – replace 689
1 1 Tools 689
1 2 Remove 689
1 3 Install 691
1 3 1 Prepare the new part 691
1 3 2 Welding 691
2 Back panel (Sedan) – replace 693
2 1 Tools 693
2 2 Remove 693
2 3 Install 695
2 3 1 Prepare the new part 695
2 3 2 Welding 696
3 Rear cross member – replace 697
3 1 Tools 697
3 2 Remove 697
3 3 Install 698
3 3 1 Welding 698
4 Rear cross member (Sedan) – replace 699
4 1 Tools 699
4 2 Remove 699
4 3 Install 700
4 3 1 Welding 700
5 Tail light housing – replace 701
5 1 Tools 701
5 2 Remove 701
5 3 Install 703
5 3 1 Prepare the new part 703
5 3 2 Welding 703
6 Tail light housing (Sedan) – replace 705
6 1 Tools 705
6 2 Remove 705
6 3 Install 707
6 3 1 Welding 707
7 Front longitudinal member (partial part) – replace 708
7 1 Tools 708
7 2 Remove 708
7 3 Install 711
7 3 1 Prepare the new part 711
7 3 2 Foam parts/supports 711
7 3 3 Welding 711
8 Rear longitudinal member (partial part – Sedan) – replace 713
8 1 Tools 713
8 2 Remove 713
8 3 Install 715
8 3 1 Prepare the new part 716
8 3 2 Foam parts/supports 716
8 3 3 Welding 716
9 External side panel (partial part) – replace 717
9 1 Tools 717
9 2 Remove 718
9 3 Install 720
9 3 1 Prepare the new part 720
9 3 2 Foam parts/supports 720
9 3 3 Welding 720
10 External side panel (partial part – Sedan) – replace 722
10 1 Tools 722
10 2 Remove 723
10 3 Install 725
10 3 1 Prepare the new part 725
10 3 2 Foam parts/supports 725
10 3 3 Welding 726
11 External rear wheel arch (partial part) – replace 727
11 1 Tools 727
11 2 Remove 727
11 3 Install 728
11 3 1 Prepare the new part 728
11 3 2 Welding 729
12 External rear wheel arch (partial part – Sedan) – replace 730
12 1 Tools 730
12 2 Remove 730
12 3 Install 732
12 3 1 Prepare the new part 732
12 3 2 Welding 732
13 Luggage compartment – replace 734
13 1 Tools 734
13 2 Remove 734
13 3 Install 735
13 3 1 Prepare the new part 736
13 3 2 Welding 736
14 Luggage compartment floor (Sedan) – replace 737
14 1 Tools 737
14 2 Remove 737
14 3 Install 738
14 3 1 Prepare the new part 739
14 3 2 Welding 739
15 Tow hook – replace 741
15 1 Tools 741
15 2 Remove 741
15 3 Install 742
15 3 1 Prepare the new part 742
15 3 2 Welding 743
16 Luggage compartment floor (partial part) – replace 744
16 1 Tools 744
16 2 Remove 744
16 3 Install 745
16 3 1 Prepare the new part 746
16 3 2 Welding 746
BRA5R035320 Troubleshooting Mechanical Transmission 747
30 – Clutch 751
1 Complaints related to clutch and clutch control 751
1 1 Checking the clutch drive 760
34 – Controls, housing 762
1 Complaints related to the selection mechanism 762
BRA5R035420 Wheels rim and tyre specifications 763
00 – Technical data 767
1 General notes on rims and tyres (vehicles and passengers) 767
1 1 Technical conditions for combining rims and tyres 767
1 2 General Remarks 768
1 2 1 Wheel bolts – Tightening torques 768
1 2 2 Wheel hole circle diameter 768
1 2 3 Wheel specifications 768
1 3 Protecting the wheel centering seat against corrosion 769
2 Curiosities about rims and tires (passenger vehicles) 771
2 1 Wear/tyre mileage 771
2 1 1 General Remarks 771
2 1 3 Wear behaviour of high speed tires 771
2 1 4 Factors that influence tyre durability 772
2 1 5 Driving style: 772
2 1 6 Tyre maintenance 773
2 1 7 Tyres with uniform wear 774
2 1 8 Measuring track depth 775
2 1 9 Unilateral wear 775
2 1 10 Wear on the outer shoulder 778
2 1 11 Wear on the center portion of the tyre 778
2 1 12 Diagonal abrasion 780
2 2 Rolling noises coming from the tyres 780
2 2 1 General notes about rolling noises 780
2 2 2 Wear occurrence in the shape of saw 781
2 2 3 Blockage points 782
2 3 Drive instability due to rim/tyre 783
2 3 1 Causes of drive instability 783
2 3 2 Wheel balancing 784
2 3 3 Perform a test drive before performing the wheel balancing 784
2 3 4 Wheel balancing with the static balancing machine 784
2 3 5 Radial and axial deviation of concentricity of rim/tyre assembly 786
2 3 6 Inspect the radial and axial deviations of the rim/tyre assemblywith the Tyre gauge -V A G 1435- 786
2 3 7 Inspect the radial and axial deviations of rim concentricity 787
2 3 8 Positioning of the tyre in relation to the rim 788
2 3 9 Tyre deformation 789
2 4 The vehicle deviates to one side 790
2 4 1 General Remarks 790
2 4 2 Conicity 790
2 4 3 Solution when the vehicle deviates to one side 791
2 4 4 Selective change of wheels for tyres without tread direction 792
2 4 5 Selective change of wheels for tyres with tread direction 794
2 5 Damages on the tyres 794
2 5 1 General recommendations 794
2 5 2 Structure of a radial tyre 795
2 5 3 Damages caused by crashes 796
2 5 4 Damages due to cut 796
2 5 5 Damages caused by strange bodies 797
2 5 6 Loss of air from the tyres 797
2 5 7 Air pressure 797
2 5 8 Damages to the tyres due to insufficient air pressure 798
2 5 9 Rise of temperature in tyres with insufficient air pressure 799
2 5 10 Damages to the tyres due to assembly failure (assembly damages) 800
2 6 Useful notes related to tyres and wheels 801
2 6 1 Inscriptions on the side wall of the tyre 801
2 6 2 Clarifications about tyre inscriptions 803
2 6 3 Contractions 804
2 6 5 Storage of tyres 805
2 6 6 Aging of tyres 806
2 6 7 Replacement of wheels 807
2 6 8 Notes related to assembly in case of replacement/assembly ofwheel 807
44 – Vehicle wheels, tyres, measurement 809
1 5Z Family ► 809
1 1 Features of the rims 809
1 1 1 5 J X 14 809
1 1 2 6J X 14 809
1 1 3 6J X 15 810
1 1 4 6 5J X 16 812
2 9A Family ► 814
2 1 Features of the rims 814
2 1 1 6J X 15 814
2 1 2 7J X 17 815
2 1 3 7 5J X 17 815
3 5U Family ► 817
3 1 Features of the wheels 817
3 1 1 5J X 13 817
3 1 2 6J X 14 817
3 1 3 6J X 15 818
3 1 4 6J X 16 819
3 1 5 7J X 16 819
4 5W Family ► 821
4 1 Features of the wheels 821
4 1 1 5J X 13 821
4 1 2 6J X 14 822
4 1 3 6J X 15 822
5 7X Family ► 824
5 1 Features of the wheels 824
5 1 1 5 5J X 14 824
6 9B Family ► 825
6 1 Features of the wheels 825
6 1 1 6J X 15 825
6 1 2 6 5J X 16 826
6 1 3 7J X 17 826
BRA5R035520 Electrical system General information 828
27 – Starter, current supply, CCS 832
1 Battery -A- 832
1 1 Important information concerning battery -A- 832
1 2 Battery -A- types 833
1 2 1 Low maintenance batteries 833
1 2 2 »Standard« battery with colour codes 833
1 2 3 »Enhanced« battery with colour codes 833
1 2 4 Sealed battery (AGM battery) 834
1 3 Warning notes and safety norms 834
1 3 1 Risks inherent to the handling of automotive batteries 834
1 3 2 Safety symbols on the Battery -A- 835
1 3 3 Airbag system work 836
1 4 Battery -A- connection terminals 837
2 Battery -A- – check 838
2 1 Battery -A- checking sequence 838
2 1 1 Battery with colour codes – test 838
2 1 2 Sealed battery (AGM battery) – test 839
2 2 Check visually 839
2 3 Battery degassing and replacement instructions 840
2 4 Check the Battery -A- with inspection window 840
2 4 1 Check the Battery -A- with battery inspection window “3 colours” 841
2 4 2 Check the Battery -A- with battery inspection window “2 colours” 841
2 5 Checking the low-maintenance Battery — 842
2 5 1 Checking the electrolyte level 842
2 5 2 Top it up with distilled water 844
2 5 3 Verifying the density of the electrolyte 844
2 6 Current consumption – test 846
2 7 Check the charge of the Battery -A- 847
2 7 1 Battery tester with printer -VAS 5097A- 848
2 7 2 Description of the battery testing device, with printer -VAS 5097A- 849
2 7 3 Check the battery -A- charge with the battery tester with printer -VAS 5097A- 849
2 7 4 Battery tester -VAS 6161- 853
2 7 5 Description of the Battery testing device -VAS 6161- 853
2 7 6 Checking the Battery -A- charge with the Battery tester -VAS 6161- 854
2 7 7 Testing in maintenance mode 855
2 7 8 Testing in warranty mode 856
2 7 9 Testing in technical assistance mode 857
2 7 10 Printed protocol information 858
2 8 Charge acceptance test 859
2 8 1 Charge acceptance test with the -VAS 6161- 859
2 8 2 Charge acceptance test with the -VAS 5097A- 859
2 9 Check the resting current of the battery 860
2 10 Check Battery -A- charging 863
2 11 Checking the resting voltage of batteries (unused or stored vehicles) 865
3 Battery -A- – charging 867
3 1 Cautions when handling Battery -A- chargers 867
3 2 Battery charger -VAS 5095A- 869
3 2 1 Description of the Battery charger -VAS 5095A- 869
3 2 2 Charging the Battery -A- with the Battery charger -VAS 5095A- 870
3 2 3 Charging a heavily drained Battery -A- with the Battery charger -VAS 5095A- 871
3 2 4 Auxiliary operations with the Battery charger -VAS 5095A- 872
3 2 5 Trickle charge with the Battery charger -VAS 5095A- 873
3 3 Battery charger -VAS 5900- 874
3 3 1 Description of the Battery charger -VAS 5900- 874
3 3 2 Charging the Battery -A- with the Battery charger -VAS 5900- 875
3 3 3 Servicing charge with the Battery charger -VAS 5900- 877
3 3 4 Charging a completely drained battery with the Battery charger -VAS 5900- 880
3 3 5 Auxiliary operations with the Battery charger -VAS 5900- 883
3 3 6 Trickle charge operational mode with the Battery charger -VAS 5900- 885
3 4 Battery charger -VAS 5900A- 886
3 4 1 Battery charger -VAS 5900A- 886
3 4 2 Battery charger -VAS 5900A- operation modes 887
3 5 Battery charger -VAS 5903- 888
3 5 1 Description of the Battery charger -VAS 5903- 888
3 5 2 Charging the Battery -A- with the Battery charger -VAS 5903- 889
3 5 3 Servicing charge with the Battery charger -VAS 5903- 891
3 5 4 Charging a heavily drained Battery -A- with Battery charger -VAS 5903- 894
3 5 5 Auxiliary operations with the Battery charger -VAS 5903- 897
3 5 6 Trickle charge operational mode with the Battery charger -VAS 5903- 899
3 6 Battery charger -VAS 5906- 899
3 6 1 Description of the Battery charger -VAS 5906- 900
3 6 2 Operation mode of the Battery charger -VAS 5906- 901
3 7 Battery charger -VAS 5908- 902
3 7 1 Battery charger -VAS 5908- – general description 902
3 7 2 Automatic mode with the battery charger -VAS 5908- 904
3 7 3 Charging batteries with the battery charger -VAS 5908- 905
3 7 4 Support function with the Battery charger -VAS 5908- 907
3 7 5 VAS I-CHECK current consumption test with the battery charger -VAS 5908- 909
3 8 Completely flat batteries 911
3 9 Battery (Delphi) – charging procedure 912
3 9 1 Completely flat batteries 913
3 9 2 Charging a single Battery -A- or “rapid charging” 913
3 9 3 Charging several batteries or “parallel charging” 913
3 9 4 Charging several batteries – charging in series or “slow charging” 914
3 9 5 Equalization of batteries 915
4 Speed regulator (GRA) 916
4 1 Speed regulator (GRA) – activating/deactivating 916
92 – Windscreen wash/wipe system 917
1 Washer hoses – connecting and disconnecting 917
2 Washer hoses – repair 919
2 1 Repairing smooth hoses 919
2 2 Repairing wrinkled hoses 919
94 – Lights, bulbs, switches – exterior 922
1 Adhere to the safety warnings and the application of gas-discharge lamps 922
96 – Lights, bulbs, switches – interior 925
1 12-V socket 925
1 1 12-V socket – remove and install 925
1 2 Socket box light bulb -L42- – remove and install 925
2 Lighter -U1- 926
2 1 General description 926
2 2 Assembly overview 927
2 3 Lighter socket – remove and install 928
2 4 Cigarette lighter light bulb -L28- – remove and install 931
97 – Wiring 933
1 Vehicle diagnostic, testing and information system 933
1 1 Vehicle Diagnosis, Measurement and Information System – connect 933
2 Harness and connection repairs 936
2 1 General notes on repair work on the electrical system of the vehicle 936
2 2 Harness repair kits 937
2 2 1 Wiring harness repair set -VAS 1978- 937
2 2 2 Complementary set -VAS 1978/50- 937
2 2 3 Wiring harness repair set -VAS 1978A- 938
2 2 4 Terminal removal tool kit -VAS 1978/35- 939
2 3 Description of tools 939
2 3 1 Cleaving pliers -VAS 1978/1- 939
2 3 2 Disassembly tool for terminals 940
2 3 3 Assembly tool for simple cable linings 940
2 3 4 Pliers for stripping cables -VAS 1978/3- 941
2 3 5 Hot air blower -VAS 1978/14- 942
2 3 6 Crimping pliers -VAS 1978/1A- 942
2 4 Harness repair 944
2 4 1 Repairing airbag and seat belt pre-tensioning cables 944
2 4 2 Repairing CAN-Bus system cables 946
2 4 3 Replacing antenna cables 946
2 4 4 Repairs of electrical connectors 0 13 mm2/0 35 mm2/0 5 mm2 948
2 4 5 Repairs of cables with 10 mm2 or 16 mm2 with individual top connectors 954
2 4 6 Repairs of aluminium cables with 2 5 mm2, 4 mm2 or 6 mm2 with individual top connectors 960
2 4 7 Interruption in cables with a repaired section 967
2 4 8 Interruption in cables with two repaired sections 969
2 5 Fibre optic cable repairs 971
2 5 1 Fibre optic cable – prepare 972
2 5 2 Fibre optic cable of the the cable set connector – separate 979
2 6 Aerial cable repairs 980
2 6 1 Repair kit, aerial cable VAS 6720 980
2 7 Repairing connector terminals and connectors 992
2 7 1 Notes regarding repair work on connector terminal and connectors 992
2 7 2 Repairing connector terminals 992
2 7 3 Assembly of simple cable linings 994
2 7 4 Repairing connectors with the cutting/compression technique 997
2 8 Unlocking and disassembling the terminals 998
2 8 1 Note regarding the unlocking and disassembly of the connectors 998
2 8 2 Secondary locking 998
2 8 3 Primary locking 999
2 8 4 Fastening systems for round terminals 1000
2 8 5 Fastening systems for flat terminals 1001
2 8 6 Fastening device for special terminals 1003
3 Electrical contact cleaning set -VAS 6410- 1006
3 1 Use of the Electrical contact cleaning set -VAS 6410- 1006
3 1 1 Maintenance of cable eyes 1006
3 1 2 Maintenance of bolted joints 1008
3 1 3 Clean battery terminals 1010
3 1 4 Preservation 1012
4 Lambda probe – replace 1014
4 1 LSF lambda probe (4 poles) – replace 1014
4 2 LSU lambda probe (6 poles) – replace 1015
4 3 Versions of the protection tube of unit lambda probes 1016
D3E801B26A2 4 cylinder common rail engine (1 6 l EA189) (1) 1018
00 – Technical data 1024
1 Identification 1024
1 1 Engine number/engine data 1024
1 1 1 Engine number 1024
1 1 2 Engine data 1024
2 Safety information 1026
2 1 Safety measures when working on fuel supply 1026
2 2 Safety precautions when using testers and measuring instruments during a road test 1027
2 3 Safety measures when working on vehicles with a start/stop system 1027
2 4 Safety precautions when working on the cooling system 1027
2 5 Safety precautions when working on exhaust system 1028
3 Repair notes 1029
3 1 Rules for cleanliness 1029
3 1 1 When working on fuel supply/injection system 1029
3 1 2 When working on turbocharger 1029
3 2 Checking vacuum system 1030
10 – Removing and installing engine 1031
1 Removing and installing engine 1031
1 1 Removing engine 1031
1 1 1 Removing engine, Golf, Golf Plus, Golf Cabriolet, Polo 1031
1 1 2 Removing engine, Passat 1045
1 1 3 Removing engine, Touran 1058
1 2 Separating engine and gearbox 1071
1 3 Securing engine on engine and gearbox support 1073
1 4 Installing engine 1074
1 4 1 Notes on installing, Golf, Golf Plus, Golf Cabriolet, Polo 1074
1 4 2 Notes on installing, Passat, Touran 1076
1 4 3 Installing engine 1078
2 Assembly mountings 1083
2 1 Assembly overview – assembly mountings 1083
2 1 1 Assembly overview – assembly mountings, Golf, Golf Plus, Passat, Touran 1083
2 1 2 Assembly overview – assembly mountings, Polo 1085
2 1 3 Removing and installing assembly mountings 1086
2 2 Supporting engine in installation position 1089
2 2 1 Supporting engine in installation position, Golf, Golf Cabriolet, Passat 1089
2 2 2 Supporting engine in installation position, Golf Plus 1091
2 2 3 Supporting engine in installation position, Touran 1093
2 2 4 Supporting engine in installation position, Polo 1094
2 3 Adjusting assembly mountings 1095
3 Engine cover panel 1099
3 1 Removing and installing engine cover 1099
13 – Crankshaft group 1100
1 Cylinder block (pulley end) 1100
1 1 Assembly overview – poly V-belt drive 1100
1 1 1 Assembly overview – poly V-belt drive with tensioning roller and air conditioner compressor 1100
1 1 2 Assembly overview – poly V-belt drive with tensioning element and air conditioner compressor 1102
1 1 3 Assembly overview – poly V-belt drive without air conditioner compressor 1103
1 2 Removing and installing poly-V belt 1103
1 2 1 Removing and installing poly V-belt, poly V-belt drive without air conditioner compressor 1103
1 2 2 Removing and installing poly V-belt, poly V-belt drive with tensioning roller and air-conditioning compressor 1104
1 2 3 Removing and installing poly V-belt, poly V-belt drive with tensioning element and air-conditioning compressor 1106
1 3 Removing and installing tensioner for poly V-belt 1107
1 4 Removing and installing vibration damper 1111
1 5 Removing and installing bracket for ancillaries 1112
1 6 Renewing crankshaft oil seal – belt pulley end 1114
1 7 Removing and installing sealing flange on pulley end 1115
1 8 Removing and installing engine bracket 1118
1 8 1 Removing and installing engine bracket, Golf, Golf Cabriolet, Passat 1118
1 8 2 Removing and installing engine bracket, Touran 1121
1 8 3 Removing and installing engine bracket, Golf Plus 1123
1 8 4 Removing and installing engine bracket, Polo 1129
2 Cylinder block, gearbox end 1133
2 1 Assembly overview – cylinder block, gearbox end 1133
2 2 Removing and installing flywheel 1134
2 3 Removing and installing sealing flange on gearbox side 1135
2 3 1 Pressing out sealing flange with sender wheel 1137
2 3 2 Pressing in sealing flange with sender wheel 1138
2 3 3 a) Securing seal with sender wheel on assembly tool -T10134- 1139
2 3 4 b) Securing assembling tool -T10134- with sealing flange on crankshaft flange 1140
2 3 5 c) Bolting assembly tool -T10134- onto crankshaft flange 1141
2 3 6 D – Pressing sender wheel onto crankshaft flange using assembly tool -T10134- 1142
2 3 7 e) Checking sender wheel installation position on crankshaft 1142
2 3 8 f) Re-pressing sender wheel 1143
3 Crankshaft 1145
3 1 Assembly overview – crankshaft 1145
3 2 Renewing needle bearing in crankshaft 1146
3 3 Crankshaft dimensions 1148
3 4 Measuring axial clearance of crankshaft 1148
3 5 Measuring radial clearance of crankshaft 1148
4 Pistons and conrods 1150
4 1 Assembly overview – pistons and conrods 1150
4 1 1 Piston and cylinder dimensions 1153
4 2 Removing and installing pistons 1153
4 3 Measuring piston projection at “TDC” 1154
4 4 Separating new conrod 1156
4 5 Checking radial clearance of conrods 1157
15 – Cylinder head, valve gear 1158
1 Cylinder head 1158
1 1 Assembly overview – cylinder head 1158
1 2 Removing and installing cylinder head 1161
1 2 1 Removing and installing cylinder head, Polo, Golf, Golf Plus, Golf Cabriolet, Touran 1161
1 2 2 Removing and installing cylinder head, Passat 1177
1 3 Assembly overview – cylinder head cover 1190
1 4 Removing and installing cylinder head cover 1191
1 4 1 Removing and installing injector seal in cylinder head cover 1197
1 5 Removing and installing vacuum pump 1199
1 6 Checking compression 1200
2 Toothed belt drive 1202
2 1 Assembly overview – toothed belt 1202
2 1 1 Assembly overview – toothed belt, Golf, Golf Plus, Golf Cabriolet, Passat, Touran 1202
2 1 2 Assembly overview – toothed belt, Polo 1204
2 2 Removing and installing toothed belt 1207
3 Valve gear 1222
3 1 Assembly overview – valve gear 1222
3 2 Measuring axial play of camshaft 1223
3 3 Measuring radial play of camshaft 1224
3 4 Removing and installing camshaft oil seal 1225
3 5 Removing and installing camshaft 1227
3 5 1 Removing 1229
3 5 2 Installing 1230
3 6 Checking hydraulic compensation elements 1234
3 7 Removing and installing valve stem seal 1235
3 7 1 Removing and installing valve stem seals with cylinder head installed 1235
3 7 2 Removing and installing valve stem seals with cylinder head removed 1239
4 Inlet and exhaust valves 1242
4 1 Valve dimensions 1242
4 2 Reworking valve seats 1242
4 3 Checking valve guides 1242
4 4 Checking valves 1242
17 – Lubrication 1243
1 Sump, oil pump 1243
1 1 Assembly overview – sump/oil pump 1243
1 2 Removing and installing sump 1245
1 3 Removing and installing oil level and oil temperature sender -G 266- 1250
1 4 Removing and installing oil pump 1251
1 5 Engine oil: 1252
1 5 1 Oil capacities 1252
2 Engine oil cooler 1254
2 1 Assembly overview – engine oil cooler 1254
2 2 Removing and installing engine oil cooler 1255
2 3 Checking engine oil cooler for leaks 1257
3 Oil filter, oil pressure switch 1260
3 1 Assembly overview – oil filter housing 1260
3 2 Removing and installing oil filter housing 1261
3 3 Checking oil pressure and oil pressure switch 1264
3 3 1 Checking oil pressure 1264
3 3 2 Checking oil pressure switch 1265
3 4 Removing and installing oil pressure switch -F1- 1267
4 Oil circuit 1269
4 1 Assembly overview – oil circuit 1269
4 1 1 Assembly overview – oil supply line, Golf, Golf Plus, Golf Cabriolet, Passat, Touran 1269
4 1 2 Assembly overview – oil supply line, Polo 1270
4 2 Removing and installing oil supply line 1271
4 2 1 Removing and installing oil supply line, Polo 1271
4 2 2 Removing and installing oil supply line, Golf, Golf Plus, Golf Cabriolet, Passat, Touran 1276
4 3 Oil spray jets/nozzles 1277
19 – Cooling 1278
1 Cooling system/coolant 1278
1 1 Coolant hose connection diagram 1278
1 1 1 Coolant hose schematic diagram (vehicles with auxiliary heater, Polo) 1278
1 1 2 Coolant hose schematic diagram (vehicles with 4/2 way valve, Polo) 1279
1 1 3 Schematic diagram for coolant hoses (vehicles with thermostat, Golf, Golf Plus, Passat) 1280
1 1 4 Coolant hose schematic diagram (vehicles with 4/2-way valve, Golf, Passat, Touran) 1281
1 2 Checking cooling system for leaks 1282
1 3 Draining and adding coolant 1284
1 3 1 Draining coolant 1284
1 3 2 Filling with coolant 1287
2 Coolant pump, regulation of cooling system 1289
2 1 Assembly overview – coolant pump, thermostat 1289
2 1 1 Assembly overview – coolant pump, thermostat 1289
2 1 2 Assembly overview – coolant pump / thermostat with 4/2-way valve 1291
2 2 Removing and installing coolant pump 1292
2 3 Removing and installing thermostat 1293
2 4 Checking thermostat 1296
2 5 Removing and installing 4/2-way valve with thermostat 1296
2 6 Electric coolant pump 1302
2 6 1 Removing and installing coolant circulation pump 2 -V178-, Polo 1302
2 6 2 Removing and installing coolant circulation pump 2 -V178-, Golf, Golf Plus, Golf Cabriolet, Passat, Touran 1304
2 7 Removing and installing coolant temperature sender 1306
2 7 1 Removing and installing coolant temperature sender -G62- 1306
2 7 2 Removing and installing radiator outlet coolant temperature sender -G83-, Golf, Golf Plus, Golf Cabriolet, Passat, Toura
1309
2 7 3 Removing and installing radiator outlet coolant temperature sender -G83-, Polo 1310
3 Coolant pipes 1311
3 1 Assembly overview – coolant pipes 1311
3 1 1 Assembly overview – coolant pipes, Golf, Golf Plus, Golf Cabriolet, Passat, Touran 1311
3 1 2 Assembly overview – coolant pipes, Polo 1312
3 2 Removing and installing coolant pipes 1313
3 2 1 Removing and installing front coolant pipe, Polo 1313
3 2 2 Removing and installing front coolant pipe, Golf, Golf Plus, Golf Cabriolet, Passat, Touran, vehicles with thermostat 1316
3 2 3 Removing and installing front coolant pipe, Golf, Golf Plus, Golf Cabriolet, Passat, Touran, vehicles with 4/2-way valve 1319
3 2 4 Removing and installing right coolant pipes, Polo 1323
3 2 5 Removing and installing right coolant pipe, Golf, Golf Plus, Golf Cabriolet, Passat, Touran 1325
3 2 6 Removing and installing right coolant pipes, Golf, Golf Plus, Golf Cabriolet, Passat, Touran, vehicles with auxiliary heater 1327
4 Radiator, radiator fan 1329
4 1 Assembly overview – radiator/radiator fan 1329
4 1 1 Assembly overview – radiator/radiator fan, Golf, Golf Plus, Golf Cabriolet, Passat, Touran 1329
4 1 2 Assembly overview – radiator/radiator fan, Polo 1330
4 2 Removing and installing radiator 1332
4 2 1 Removing and installing radiator, Golf, Golf Plus, Golf Cabriolet, Passat, Touran 1332
4 2 2 Removing and installing radiator, Polo 1333
4 3 Removing and installing radiator cowl with radiator fan 1337
4 3 1 Removing and installing radiator cowl with radiator fan -V7- and radiator fan 2 -V177-, Golf, Golf Plus, Golf Cabriolet, Passat, Touran 1337
4 3 2 Removing and installing radiator cowl with radiator fan -V7-, Polo 1339
21 – Turbocharging/supercharging 1341
1 Turbocharger 1341
1 1 Assembly overview – turbocharger 1341
1 1 1 Assembly overview – turbocharger, Golf, Golf Plus, Golf Cabriolet, Passat, Touran 1341
1 1 2 Assembly overview – turbocharger, Polo 1344
1 2 Removing and installing turbocharger 1347
1 2 1 Removing and installing turbocharger, Golf, Golf Cabriolet 1347
1 2 2 Removing and installing turbocharger, Golf Plus, Touran 1352
1 2 3 Removing and installing turbocharger, Passat 1357
1 2 4 Removing and installing turbocharger, Polo 1364
1 3 Renewing vacuum unit for turbocharger 1370
2 Charge air system 1378
2 1 Assembly overview – charge air system 1378
2 1 1 Assembly overview – charge air system, Golf, Golf Plus, Golf Cabriolet 1378
2 1 2 Assembly overview – charge air system, Passat, Touran 1379
2 1 3 Assembly overview – charge air system, Polo 1381
2 2 Removing and installing charge air cooler 1382
2 2 1 Removing and installing charge air cooler, Golf, Golf Plus, Golf Cabriolet 1382
2 2 2 Removing and installing charge air cooler, Passat, Touran 1384
2 2 3 Removing and installing charge air cooler, Polo 1385
2 3 Assembly overview – charge-air hose connections 1386
2 3 2 Hose connections with plug-in connectors 1386
2 3 3 Removing and installing charge air pipe »hot« side 1387
2 4 Checking charge air system for leaks 1389
23 – Mixture preparation – injection 1392
1 Injection system 1392
1 1 Schematic overview – fuel system 1392
1 1 1 Schematic overview – fuel system, Polo 1392
1 1 2 Schematic overview – fuel system, Golf, Golf Plus, Golf Cabriolet, Touran, Passat 2006 ▶ 1394
1 1 3 Schematic overview – fuel system, Passat 2011▶ 1395
1 2 Assembly overview – fuel system 1397
1 2 1 Assembly overview – fuel system, Polo, Golf, Golf Plus, Golf Cabriolet, Touran, Passat 2006 ► 1397
1 2 2 Assembly overview – fuel system, Passat 2011▶ 1402
1 2 3 Conversion of 0 5 bar low-pressure fuel system to 6 0 bar low-pressure fuel system 1406
1 3 Filling/bleeding fuel system 1409
1 4 Checking fuel system for leaks 1409
2 Vacuum system 1411
2 1 Connection diagram – vacuum system 1411
2 1 1 Assembly overview – vacuum system, Golf, Golf Plus, Golf Cabriolet, Touran, Passat 1411
2 1 2 Schematic diagram – vacuum system, Polo 1412
3 Injectors/high-pressure accumulator (rail) 1415
3 1 Assembly overview – injectors 1415
3 2 Adapting correction values for injectors 1416
3 3 Testing jammed-open injectors 1416
3 4 Check pressure retention valve in fuel return line 1418
3 5 Removing and installing injectors 1420
3 5 1 Removing 1422
3 5 2 Installing 1423
3 6 Removing and installing fuel rail 1425
3 7 Removing and installing high-pressure lines 1429
3 7 1 Removing high-pressure lines between fuel rail and injectors 1430
3 7 2 Removing high-pressure line between fuel rail and high-pressure pump 1431
3 7 3 Installing high-pressure lines 1432
4 High-pressure pump 1436
4 1 Assembly overview – high-pressure pump 1436
4 2 Removing and installing high-pressure pump 1437
5 Senders and sensors 1443
5 1 Removing and installing fuel pressure regulating valve -N 276- 1443
5 2 Checking fuel pressure regulating valve -N276- 1445
5 3 Removing and installing fuel pressure sender -G 247- 1446
5 4 Checking fuel pressure sender -G 247- 1448
5 5 Checking fuel metering valve -N 290- 1448
5 6 Removing and installing pressure differential sender -G505- 1449
5 6 1 Differentiating criteria 1449
5 6 2 Removing and installing pressure differential sender -G 505-, Golf, Golf Plus, Golf Cabriolet, Touran, Passat 1451
5 6 3 Removing and installing pressure differential sender -G 505-, Polo 1452
5 6 4 Removing and installing pressure differential sender -G 505-, Polo, right-hand drive 1453
6 Lambda probe 1455
6 1 Assembly overview – Lambda probe 1455
6 1 1 Assembly overview – lambda probe, Golf, Golf Plus, Touran, Passat 2006► 1455
6 1 2 Assembly overview – lambda probe, Golf Cabriolet, Passat 2011► 1457
6 1 3 Assembly overview – lambda probe, Polo 1458
6 2 Removing and installing Lambda probe 1459
6 2 1 Removing and installing lambda probe 1 before catalytic converter -GX10-, Golf, Golf Plus, Golf Cabriolet, Passat, Touran 1459
6 2 2 Removing and installing lambda probe 1 before catalytic converter -GX10-, Polo 1460
7 Air filter 1462
7 1 Assembly overview – air filter housing 1462
7 1 1 Assembly overview – air filter housing, Golf, Golf Plus, Golf Cabriolet, Touran, Passat 1462
7 1 2 Assembly overview – air filter housing, Polo 1463
7 2 Removing and installing air filter housing 1464
7 2 1 Removing and installing air filter housing, Golf, Golf Plus, Golf Cabriolet, Touran, Passat 1464
7 2 2 Removing and installing air filter housing, Polo 1465
8 Intake manifold 1468
8 1 Assembly overview – intake manifold 1468
8 1 1 Assembly overview – intake manifold, vehicles with intake manifold flap -V157- 1468
8 1 2 Assembly overview – intake manifold with attachments, vehicles without intake manifold flap 1469
8 2 Removing and installing intake manifold 1470
8 3 Removing and installing throttle valve module -J338- 1474
9 Engine control unit 1476
9 1 Removing and installing engine control unit 1476
9 1 1 Removing and installing engine control unit -J623-, Golf 1476
9 1 2 Removing and installing engine control unit -J623- with protective housing, Golf, Golf Cabriolet 1477
9 1 3 Removing and installing engine control unit -J623-, Golf Plus, Touran 1480
9 1 4 Removing and installing engine control unit -J623- with protective housing, Golf Plus, Touran 1481
9 1 5 Removing and installing engine control unit -J623-, Polo 1483
9 1 6 Removing and installing engine control unit -J623- with protective housing, Polo 1484
9 1 7 Removing and installing engine control unit -J623-, Passat 2006► 1485
9 1 8 Removing and installing engine control unit -J623- with protective housing, Passat 2006► 1486
9 1 9 Removing and installing engine control unit -J623- with protective housing, Passat 2011► 1488
26 – Exhaust system 1491
1 Exhaust pipes and silencers 1491
1 1 Assembly overview – silencers 1491
1 1 1 Assembly overview – silencer, Golf, Touran, Passat 2011 ► 1491
1 1 2 Assembly overview – silencer, Passat 2006► 1493
1 1 3 Assembly overview – silencers, Polo 1494
1 1 4 Separating exhaust system 1494
1 2 Aligning exhaust system free of stress 1496
1 2 1 Aligning exhaust system free of stress, Golf, Golf Cabriolet, Golf Plus, Touran, Passat 1496
1 2 2 Aligning exhaust system free of stress, Polo 1496
1 3 Installation position of clamp 1498
2 Emission control 1499
2 1 Assembly overview – emission control 1499
2 1 1 Assembly overview – front exhaust pipe with particulate filter, Golf, Golf Plus, Golf Cabriolet, Passat, Touran 1499
2 1 2 Assembly overview – front exhaust pipe with catalytic converter, Golf, Golf Plus, EU3 and EU4 vehicles 1501
2 1 3 Assembly overview – front exhaust pipe with particulate filter, Polo, left-hand drive 1503
2 1 4 Assembly overview – front exhaust pipe with particulate filter, Polo, right-hand drive 1505
2 2 Removing and installing particulate filter 1507
2 2 1 Removing and installing particle filter, Golf, Golf Plus, Golf Cabriolet, Touran, Passat 1507
2 2 2 Removing and installing particulate filter, Polo, left-hand drive 1514
2 2 3 Removing and installing particulate filter, Polo, right-hand drive 1521
2 3 Removing and installing catalytic converter 1528
2 3 1 Removing and installing catalytic converter, Golf, Golf Plus, EU3 vehicles 1528
3 Exhaust gas temperature regulation 1533
3 1 Assembly overview – exhaust gas temperature regulation 1533
3 1 1 Assembly overview – exhaust gas temperature regulation, Golf, Golf Plus, Golf Cabriolet, Touran, Passat 1533
3 1 2 Assembly overview – exhaust gas temperature regulation, Polo (LHD) 1534
3 1 3 Assembly overview – exhaust gas temperature regulation, Polo (RHD) 1535
3 2 Removing and installing parts of exhaust gas temperature regulation 1536
3 2 1 Removing and installing exhaust gas temperature sender 1 – G235- 1536
3 2 2 Removing and installing exhaust gas temperature sender 3 – G495- 1538
3 2 3 Removing and installing exhaust gas temperature sender 4 – G648- 1539
3 2 4 Removing and installing exhaust gas temperature sender 4 – G648-, Polo LHD vehicles 1541
3 2 5 Removing and installing exhaust gas temperature sender 3 – G495-, Polo LHD vehicles 1542
3 2 6 Removing and installing exhaust gas temperature sender 3 -G 495-, Polo RHD vehicles 1544
3 2 7 Removing and installing exhaust gas temperature sender 4 -G 648-, Polo RHD vehicles 1545
4 Exhaust gas recirculation 1547
4 1 Assembly overview – exhaust gas recirculation 1547
4 2 Checking changeover for exhaust gas recirculation cooler 1548
4 3 Removing and installing exhaust gas recirculation cooler 1549
4 3 1 Removing and installing exhaust gas recirculation cooler, Golf, Golf Plus, Golf Cabriolet, Touran, Passat 1549
4 3 2 Removing and installing exhaust gas recirculation cooler, Polo 1552
4 4 Checking exhaust gas recirculation cooler for leaks 1554
4 5 Cleaning exhaust gas recirculation system 1557
4 5 1 Initiating cleaning of exhaust gas recirculation system 1557
4 5 2 Cleaning connecting pipes and pipe union 1563
28 – Glow plug system 1564
1 Glow plug system 1564
1 1 Removing and installing glow plug 1564
1 2 Checking glow plugs 1566
1 3 Removing and installing Hall sender -G40- 1566
1 4 Removing and installing engine speed sender -G 28- 1568
D3E801B26A2 4 cylinder common rail engine (1 6 l EA189) 1570
00 – Technical data 1576
1 Identification 1576
1 1 Engine number/engine data 1576
1 1 1 Engine number 1576
1 1 2 Engine data 1576
2 Safety information 1578
2 1 Safety measures when working on fuel supply 1578
2 2 Safety precautions when using testers and measuring instruments during a road test 1579
2 3 Safety measures when working on vehicles with a start/stop system 1579
2 4 Safety precautions when working on the cooling system 1579
2 5 Safety precautions when working on exhaust system 1580
3 Repair notes 1581
3 1 Rules for cleanliness 1581
3 1 1 When working on fuel supply/injection system 1581
3 1 2 When working on turbocharger 1581
3 2 Checking vacuum system 1582
10 – Removing and installing engine 1583
1 Removing and installing engine 1583
1 1 Removing engine 1583
1 1 1 Removing engine, Golf, Golf Plus, Golf Cabriolet, Polo 1583
1 1 2 Removing engine, Passat 1597
1 1 3 Removing engine, Touran 1610
1 2 Separating engine and gearbox 1623
1 3 Securing engine on engine and gearbox support 1625
1 4 Installing engine 1626
1 4 1 Notes on installing, Golf, Golf Plus, Golf Cabriolet, Polo 1626
1 4 2 Notes on installing, Passat, Touran 1628
1 4 3 Installing engine 1630
2 Assembly mountings 1635
2 1 Assembly overview – assembly mountings 1635
2 1 1 Assembly overview – assembly mountings, Golf, Golf Plus, Passat, Touran 1635
2 1 2 Assembly overview – assembly mountings, Polo 1637
2 1 3 Removing and installing assembly mountings 1638
2 2 Supporting engine in installation position 1641
2 2 1 Supporting engine in installation position, Golf, Golf Cabriolet, Passat 1641
2 2 2 Supporting engine in installation position, Golf Plus 1643
2 2 3 Supporting engine in installation position, Touran 1645
2 2 4 Supporting engine in installation position, Polo 1646
2 3 Adjusting assembly mountings 1647
3 Engine cover panel 1651
3 1 Removing and installing engine cover 1651
13 – Crankshaft group 1652
1 Cylinder block (pulley end) 1652
1 1 Assembly overview – poly V-belt drive 1652
1 1 1 Assembly overview – poly V-belt drive with tensioning roller and air conditioner compressor 1652
1 1 2 Assembly overview – poly V-belt drive with tensioning element and air conditioner compressor 1654
1 1 3 Assembly overview – poly V-belt drive without air conditioner compressor 1655
1 2 Removing and installing poly-V belt 1655
1 2 1 Removing and installing poly V-belt, poly V-belt drive without air conditioner compressor 1655
1 2 2 Removing and installing poly V-belt, poly V-belt drive with tensioning roller and air-conditioning compressor 1656
1 2 3 Removing and installing poly V-belt, poly V-belt drive with tensioning element and air-conditioning compressor 1658
1 3 Removing and installing tensioner for poly V-belt 1659
1 4 Removing and installing vibration damper 1663
1 5 Removing and installing bracket for ancillaries 1664
1 6 Renewing crankshaft oil seal – belt pulley end 1666
1 7 Removing and installing sealing flange on pulley end 1667
1 8 Removing and installing engine bracket 1670
1 8 1 Removing and installing engine bracket, Golf, Golf Cabriolet, Passat 1670
1 8 2 Removing and installing engine bracket, Touran 1673
1 8 3 Removing and installing engine bracket, Golf Plus 1675
1 8 4 Removing and installing engine bracket, Polo 1681
2 Cylinder block, gearbox end 1685
2 1 Assembly overview – cylinder block, gearbox end 1685
2 2 Removing and installing flywheel 1686
2 3 Removing and installing sealing flange on gearbox side 1687
2 3 1 Pressing out sealing flange with sender wheel 1689
2 3 2 Pressing in sealing flange with sender wheel 1690
2 3 3 a) Securing seal with sender wheel on assembly tool -T10134- 1691
2 3 4 b) Securing assembling tool -T10134- with sealing flange on crankshaft flange 1692
2 3 5 c) Bolting assembly tool -T10134- onto crankshaft flange 1693
2 3 6 D – Pressing sender wheel onto crankshaft flange using assembly tool -T10134- 1694
2 3 7 e) Checking sender wheel installation position on crankshaft 1694
2 3 8 f) Re-pressing sender wheel 1695
3 Crankshaft 1697
3 1 Assembly overview – crankshaft 1697
3 2 Renewing needle bearing in crankshaft 1698
3 3 Crankshaft dimensions 1700
3 4 Measuring axial clearance of crankshaft 1700
3 5 Measuring radial clearance of crankshaft 1700
4 Pistons and conrods 1702
4 1 Assembly overview – pistons and conrods 1702
4 1 1 Piston and cylinder dimensions 1705
4 2 Removing and installing pistons 1705
4 3 Measuring piston projection at “TDC” 1706
4 4 Separating new conrod 1708
4 5 Checking radial clearance of conrods 1709
15 – Cylinder head, valve gear 1710
1 Cylinder head 1710
1 1 Assembly overview – cylinder head 1710
1 2 Removing and installing cylinder head 1713
1 2 1 Removing and installing cylinder head, Polo, Golf, Golf Plus, Golf Cabriolet, Touran 1713
1 2 2 Removing and installing cylinder head, Passat 1729
1 3 Assembly overview – cylinder head cover 1742
1 4 Removing and installing cylinder head cover 1743
1 4 1 Removing and installing injector seal in cylinder head cover 1749
1 5 Removing and installing vacuum pump 1751
1 6 Checking compression 1752
2 Toothed belt drive 1754
2 1 Assembly overview – toothed belt 1754
2 1 1 Assembly overview – toothed belt, Golf, Golf Plus, Golf Cabriolet, Passat, Touran 1754
2 1 2 Assembly overview – toothed belt, Polo 1756
2 2 Removing and installing toothed belt 1759
3 Valve gear 1774
3 1 Assembly overview – valve gear 1774
3 2 Measuring axial play of camshaft 1775
3 3 Measuring radial play of camshaft 1776
3 4 Removing and installing camshaft oil seal 1777
3 5 Removing and installing camshaft 1779
3 5 1 Removing 1781
3 5 2 Installing 1782
3 6 Checking hydraulic compensation elements 1786
3 7 Removing and installing valve stem seal 1787
3 7 1 Removing and installing valve stem seals with cylinder head installed 1787
3 7 2 Removing and installing valve stem seals with cylinder head removed 1791
4 Inlet and exhaust valves 1794
4 1 Valve dimensions 1794
4 2 Reworking valve seats 1794
4 3 Checking valve guides 1794
4 4 Checking valves 1794
17 – Lubrication 1795
1 Sump, oil pump 1795
1 1 Assembly overview – sump/oil pump 1795
1 2 Removing and installing sump 1797
1 3 Removing and installing oil level and oil temperature sender -G 266- 1802
1 4 Removing and installing oil pump 1803
1 5 Engine oil: 1804
1 5 1 Oil capacities 1804
2 Engine oil cooler 1806
2 1 Assembly overview – engine oil cooler 1806
2 2 Removing and installing engine oil cooler 1807
2 3 Checking engine oil cooler for leaks 1809
3 Oil filter, oil pressure switch 1812
3 1 Assembly overview – oil filter housing 1812
3 2 Removing and installing oil filter housing 1813
3 3 Checking oil pressure and oil pressure switch 1816
3 3 1 Checking oil pressure 1816
3 3 2 Checking oil pressure switch 1817
3 4 Removing and installing oil pressure switch -F1- 1819
4 Oil circuit 1821
4 1 Assembly overview – oil circuit 1821
4 1 1 Assembly overview – oil supply line, Golf, Golf Plus, Golf Cabriolet, Passat, Touran 1821
4 1 2 Assembly overview – oil supply line, Polo 1822
4 2 Removing and installing oil supply line 1823
4 2 1 Removing and installing oil supply line, Polo 1823
4 2 2 Removing and installing oil supply line, Golf, Golf Plus, Golf Cabriolet, Passat, Touran 1828
4 3 Oil spray jets/nozzles 1829
19 – Cooling 1830
1 Cooling system/coolant 1830
1 1 Coolant hose connection diagram 1830
1 1 1 Coolant hose schematic diagram (vehicles with auxiliary heater, Polo) 1830
1 1 2 Coolant hose schematic diagram (vehicles with 4/2 way valve, Polo) 1831
1 1 3 Schematic diagram for coolant hoses (vehicles with thermostat, Golf, Golf Plus, Passat) 1832
1 1 4 Coolant hose schematic diagram (vehicles with 4/2-way valve, Golf, Passat, Touran) 1833
1 2 Checking cooling system for leaks 1834
1 3 Draining and adding coolant 1836
1 3 1 Draining coolant 1836
1 3 2 Filling with coolant 1839
2 Coolant pump, regulation of cooling system 1841
2 1 Assembly overview – coolant pump, thermostat 1841
2 1 1 Assembly overview – coolant pump, thermostat 1841
2 1 2 Assembly overview – coolant pump / thermostat with 4/2-way valve 1843
2 2 Removing and installing coolant pump 1844
2 3 Removing and installing thermostat 1845
2 4 Checking thermostat 1848
2 5 Removing and installing 4/2-way valve with thermostat 1848
2 6 Electric coolant pump 1854
2 6 1 Removing and installing coolant circulation pump 2 -V178-, Polo 1854
2 6 2 Removing and installing coolant circulation pump 2 -V178-, Golf, Golf Plus, Golf Cabriolet, Passat, Touran 1856
2 7 Removing and installing coolant temperature sender 1858
2 7 1 Removing and installing coolant temperature sender -G62- 1858
2 7 2 Removing and installing radiator outlet coolant temperature sender -G83-, Golf, Golf Plus, Golf Cabriolet, Passat, Toura
1861
2 7 3 Removing and installing radiator outlet coolant temperature sender -G83-, Polo 1862
3 Coolant pipes 1863
3 1 Assembly overview – coolant pipes 1863
3 1 1 Assembly overview – coolant pipes, Golf, Golf Plus, Golf Cabriolet, Passat, Touran 1863
3 1 2 Assembly overview – coolant pipes, Polo 1864
3 2 Removing and installing coolant pipes 1865
3 2 1 Removing and installing front coolant pipe, Polo 1865
3 2 2 Removing and installing front coolant pipe, Golf, Golf Plus, Golf Cabriolet, Passat, Touran, vehicles with thermostat 1868
3 2 3 Removing and installing front coolant pipe, Golf, Golf Plus, Golf Cabriolet, Passat, Touran, vehicles with 4/2-way valve 1871
3 2 4 Removing and installing right coolant pipes, Polo 1875
3 2 5 Removing and installing right coolant pipe, Golf, Golf Plus, Golf Cabriolet, Passat, Touran 1877
3 2 6 Removing and installing right coolant pipes, Golf, Golf Plus, Golf Cabriolet, Passat, Touran, vehicles with auxiliary heater 1879
4 Radiator, radiator fan 1881
4 1 Assembly overview – radiator/radiator fan 1881
4 1 1 Assembly overview – radiator/radiator fan, Golf, Golf Plus, Golf Cabriolet, Passat, Touran 1881
4 1 2 Assembly overview – radiator/radiator fan, Polo 1882
4 2 Removing and installing radiator 1884
4 2 1 Removing and installing radiator, Golf, Golf Plus, Golf Cabriolet, Passat, Touran 1884
4 2 2 Removing and installing radiator, Polo 1885
4 3 Removing and installing radiator cowl with radiator fan 1889
4 3 1 Removing and installing radiator cowl with radiator fan -V7- and radiator fan 2 -V177-, Golf, Golf Plus, Golf Cabriolet, Passat, Touran 1889
4 3 2 Removing and installing radiator cowl with radiator fan -V7-, Polo 1891
21 – Turbocharging/supercharging 1893
1 Turbocharger 1893
1 1 Assembly overview – turbocharger 1893
1 1 1 Assembly overview – turbocharger, Golf, Golf Plus, Golf Cabriolet, Passat, Touran 1893
1 1 2 Assembly overview – turbocharger, Polo 1896
1 2 Removing and installing turbocharger 1899
1 2 1 Removing and installing turbocharger, Golf, Golf Cabriolet 1899
1 2 2 Removing and installing turbocharger, Golf Plus, Touran 1904
1 2 3 Removing and installing turbocharger, Passat 1909
1 2 4 Removing and installing turbocharger, Polo 1916
1 3 Renewing vacuum unit for turbocharger 1922
2 Charge air system 1930
2 1 Assembly overview – charge air system 1930
2 1 1 Assembly overview – charge air system, Golf, Golf Plus, Golf Cabriolet 1930
2 1 2 Assembly overview – charge air system, Passat, Touran 1931
2 1 3 Assembly overview – charge air system, Polo 1933
2 2 Removing and installing charge air cooler 1934
2 2 1 Removing and installing charge air cooler, Golf, Golf Plus, Golf Cabriolet 1934
2 2 2 Removing and installing charge air cooler, Passat, Touran 1936
2 2 3 Removing and installing charge air cooler, Polo 1937
2 3 Assembly overview – charge-air hose connections 1938
2 3 2 Hose connections with plug-in connectors 1938
2 3 3 Removing and installing charge air pipe »hot« side 1939
2 4 Checking charge air system for leaks 1941
23 – Mixture preparation – injection 1944
1 Injection system 1944
1 1 Schematic overview – fuel system 1944
1 1 1 Schematic overview – fuel system, Polo 1944
1 1 2 Schematic overview – fuel system, Golf, Golf Plus, Golf Cabriolet, Touran, Passat 2006 ▶ 1946
1 1 3 Schematic overview – fuel system, Passat 2011▶ 1947
1 2 Assembly overview – fuel system 1949
1 2 1 Assembly overview – fuel system, Polo, Golf, Golf Plus, Golf Cabriolet, Touran, Passat 2006 ► 1949
1 2 2 Assembly overview – fuel system, Passat 2011▶ 1954
1 2 3 Conversion of 0 5 bar low-pressure fuel system to 6 0 bar low-pressure fuel system 1958
1 3 Filling/bleeding fuel system 1961
1 4 Checking fuel system for leaks 1961
2 Vacuum system 1963
2 1 Connection diagram – vacuum system 1963
2 1 1 Assembly overview – vacuum system, Golf, Golf Plus, Golf Cabriolet, Touran, Passat 1963
2 1 2 Schematic diagram – vacuum system, Polo 1964
3 Injectors/high-pressure accumulator (rail) 1967
3 1 Assembly overview – injectors 1967
3 2 Adapting correction values for injectors 1968
3 3 Testing jammed-open injectors 1968
3 4 Check pressure retention valve in fuel return line 1970
3 5 Removing and installing injectors 1972
3 5 1 Removing 1974
3 5 2 Installing 1975
3 6 Removing and installing fuel rail 1977
3 7 Removing and installing high-pressure lines 1981
3 7 1 Removing high-pressure lines between fuel rail and injectors 1982
3 7 2 Removing high-pressure line between fuel rail and high-pressure pump 1983
3 7 3 Installing high-pressure lines 1984
4 High-pressure pump 1988
4 1 Assembly overview – high-pressure pump 1988
4 2 Removing and installing high-pressure pump 1989
5 Senders and sensors 1995
5 1 Removing and installing fuel pressure regulating valve -N 276- 1995
5 2 Checking fuel pressure regulating valve -N276- 1997
5 3 Removing and installing fuel pressure sender -G 247- 1998
5 4 Checking fuel pressure sender -G 247- 2000
5 5 Checking fuel metering valve -N 290- 2000
5 6 Removing and installing pressure differential sender -G505- 2001
5 6 1 Differentiating criteria 2001
5 6 2 Removing and installing pressure differential sender -G 505-, Golf, Golf Plus, Golf Cabriolet, Touran, Passat 2003
5 6 3 Removing and installing pressure differential sender -G 505-, Polo 2004
5 6 4 Removing and installing pressure differential sender -G 505-, Polo, right-hand drive 2005
6 Lambda probe 2007
6 1 Assembly overview – Lambda probe 2007
6 1 1 Assembly overview – lambda probe, Golf, Golf Plus, Touran, Passat 2006► 2007
6 1 2 Assembly overview – lambda probe, Golf Cabriolet, Passat 2011► 2009
6 1 3 Assembly overview – lambda probe, Polo 2010
6 2 Removing and installing Lambda probe 2011
6 2 1 Removing and installing lambda probe 1 before catalytic converter -GX10-, Golf, Golf Plus, Golf Cabriolet, Passat, Touran 2011
6 2 2 Removing and installing lambda probe 1 before catalytic converter -GX10-, Polo 2012
7 Air filter 2014
7 1 Assembly overview – air filter housing 2014
7 1 1 Assembly overview – air filter housing, Golf, Golf Plus, Golf Cabriolet, Touran, Passat 2014
7 1 2 Assembly overview – air filter housing, Polo 2015
7 2 Removing and installing air filter housing 2016
7 2 1 Removing and installing air filter housing, Golf, Golf Plus, Golf Cabriolet, Touran, Passat 2016
7 2 2 Removing and installing air filter housing, Polo 2017
8 Intake manifold 2020
8 1 Assembly overview – intake manifold 2020
8 1 1 Assembly overview – intake manifold, vehicles with intake manifold flap -V157- 2020
8 1 2 Assembly overview – intake manifold with attachments, vehicles without intake manifold flap 2021
8 2 Removing and installing intake manifold 2022
8 3 Removing and installing throttle valve module -J338- 2026
9 Engine control unit 2028
9 1 Removing and installing engine control unit 2028
9 1 1 Removing and installing engine control unit -J623-, Golf 2028
9 1 2 Removing and installing engine control unit -J623- with protective housing, Golf, Golf Cabriolet 2029
9 1 3 Removing and installing engine control unit -J623-, Golf Plus, Touran 2032
9 1 4 Removing and installing engine control unit -J623- with protective housing, Golf Plus, Touran 2033
9 1 5 Removing and installing engine control unit -J623-, Polo 2035
9 1 6 Removing and installing engine control unit -J623- with protective housing, Polo 2036
9 1 7 Removing and installing engine control unit -J623-, Passat 2006► 2037
9 1 8 Removing and installing engine control unit -J623- with protective housing, Passat 2006► 2038
9 1 9 Removing and installing engine control unit -J623- with protective housing, Passat 2011► 2040
26 – Exhaust system 2043
1 Exhaust pipes and silencers 2043
1 1 Assembly overview – silencers 2043
1 1 1 Assembly overview – silencer, Golf, Touran, Passat 2011 ► 2043
1 1 2 Assembly overview – silencer, Passat 2006► 2045
1 1 3 Assembly overview – silencers, Polo 2046
1 1 4 Separating exhaust system 2046
1 2 Aligning exhaust system free of stress 2048
1 2 1 Aligning exhaust system free of stress, Golf, Golf Cabriolet, Golf Plus, Touran, Passat 2048
1 2 2 Aligning exhaust system free of stress, Polo 2048
1 3 Installation position of clamp 2050
2 Emission control 2051
2 1 Assembly overview – emission control 2051
2 1 1 Assembly overview – front exhaust pipe with particulate filter, Golf, Golf Plus, Golf Cabriolet, Passat, Touran 2051
2 1 2 Assembly overview – front exhaust pipe with catalytic converter, Golf, Golf Plus, EU3 and EU4 vehicles 2053
2 1 3 Assembly overview – front exhaust pipe with particulate filter, Polo, left-hand drive 2055
2 1 4 Assembly overview – front exhaust pipe with particulate filter, Polo, right-hand drive 2057
2 2 Removing and installing particulate filter 2059
2 2 1 Removing and installing particle filter, Golf, Golf Plus, Golf Cabriolet, Touran, Passat 2059
2 2 2 Removing and installing particulate filter, Polo, left-hand drive 2066
2 2 3 Removing and installing particulate filter, Polo, right-hand drive 2073
2 3 Removing and installing catalytic converter 2080
2 3 1 Removing and installing catalytic converter, Golf, Golf Plus, EU3 vehicles 2080
3 Exhaust gas temperature regulation 2085
3 1 Assembly overview – exhaust gas temperature regulation 2085
3 1 1 Assembly overview – exhaust gas temperature regulation, Golf, Golf Plus, Golf Cabriolet, Touran, Passat 2085
3 1 2 Assembly overview – exhaust gas temperature regulation, Polo (LHD) 2086
3 1 3 Assembly overview – exhaust gas temperature regulation, Polo (RHD) 2087
3 2 Removing and installing parts of exhaust gas temperature regulation 2088
3 2 1 Removing and installing exhaust gas temperature sender 1 – G235- 2088
3 2 2 Removing and installing exhaust gas temperature sender 3 – G495- 2090
3 2 3 Removing and installing exhaust gas temperature sender 4 – G648- 2091
3 2 4 Removing and installing exhaust gas temperature sender 4 – G648-, Polo LHD vehicles 2093
3 2 5 Removing and installing exhaust gas temperature sender 3 – G495-, Polo LHD vehicles 2094
3 2 6 Removing and installing exhaust gas temperature sender 3 -G 495-, Polo RHD vehicles 2096
3 2 7 Removing and installing exhaust gas temperature sender 4 -G 648-, Polo RHD vehicles 2097
4 Exhaust gas recirculation 2099
4 1 Assembly overview – exhaust gas recirculation 2099
4 2 Checking changeover for exhaust gas recirculation cooler 2100
4 3 Removing and installing exhaust gas recirculation cooler 2101
4 3 1 Removing and installing exhaust gas recirculation cooler, Golf, Golf Plus, Golf Cabriolet, Touran, Passat 2101
4 3 2 Removing and installing exhaust gas recirculation cooler, Polo 2104
4 4 Checking exhaust gas recirculation cooler for leaks 2106
4 5 Cleaning exhaust gas recirculation system 2109
4 5 1 Initiating cleaning of exhaust gas recirculation system 2109
4 5 2 Cleaning connecting pipes and pipe union 2115
28 – Glow plug system 2116
1 Glow plug system 2116
1 1 Removing and installing glow plug 2116
1 2 Checking glow plugs 2118
1 3 Removing and installing Hall sender -G40- 2118
1 4 Removing and installing engine speed sender -G 28- 2120
D3E801E2B9F Communication 2122
91 – Communication 2126
1 Communication systems 2126
1 1 General notes 2126
1 2 Fault finding in communication systems 2126
2 Radio units and radio navigation systems in general 2127
2 1 Removing and installing radio units and radio navigation systems 2127
2 1 2 Removing: 2127
2 1 3 Installing: 2129
2 2 Adapting radio components 2130
2 3 Adapting radio navigation system components 2130
3 Radio system “RCD 210” 2131
3 1 Features of radio unit “RCD 210” 2131
3 2 General notes 2131
3 3 Fault finding 2132
3 4 Overview of radio system “RCD 210” 2132
3 5 Overview of connectors on radio “RCD 210” 2133
3 6 Anti-theft coding 2135
3 6 1 Determining anti-theft code of anti-theft coding via VAS tester and deactivating anti-theft coding 2135
4 Radio system “RCD 310” 2137
4 1 Features of radio unit “RCD 310” 2137
4 2 General notes 2137
4 3 Overview of radio system “RCD 310” 2138
4 4 Overview of connectors on radio “RCD 310” 2139
4 5 Anti-theft coding 2141
4 5 1 Deactivating anti-theft code of anti-theft coding 2141
5 Radio system “RCD 510” 2143
5 1 Features of radio unit “RCD 510” 2143
5 2 General notes 2144
5 3 Overview of radio system “RCD 510” 2144
5 4 Activating/deactivating transport lock for CD changer in “RCD 510” 2146
5 5 Overview of connectors on radio “RCD 510” 2147
5 6 Anti-theft coding 2150
5 6 1 Deactivating anti-theft code of anti-theft coding 2151
6 Radio navigation system “RNS 310” 2152
6 1 Features of radio navigation system “RNS 310” 2152
6 2 General notes 2153
6 3 Overview of radio navigation system “RNS 310” 2153
6 4 Overview of connectors on radio navigation system “RNS 310” 2155
6 5 Anti-theft coding 2157
6 5 1 Deactivating anti-theft coding 2158
7 Multimedia system control unit 2159
7 1 General notes 2159
7 2 Overview of “multimedia system control unit” 2159
7 3 Removing and installing multimedia control unit 2160
7 3 1 Removing: 2160
7 3 2 Installing: 2161
8 Loudspeaker systems 2162
8 1 Overview of loudspeaker system 2162
8 2 Removing and installing front bass loudspeakers 2163
8 2 1 Removing: 2163
8 2 2 Installing: 2164
8 3 Removing and installing rear bass loudspeakers 2164
8 3 1 Removing: 2164
8 3 2 Installing: 2165
8 4 Removing and installing front treble loudspeakers 2165
8 4 1 Removing: 2165
8 4 2 Installing: 2166
9 Telephone system 2167
9 1 General notes 2167
9 1 1 Preparation for mobile telephone “UTP with audio streaming” 2167
9 2 Preparation for mobile telephone “UTP with audio streaming” 2167
9 2 1 Overview of telephone system / telephone preparation 2167
9 3 Removing and installing telephone transmitter and receiver unit 2168
9 3 1 Removing: 2169
9 3 2 Installing: 2169
9 4 Removing and installing telephone system microphone 2169
9 4 1 Removing: 2169
9 4 2 Installing: 2170
9 5 Removing and installing telephone bracket 2170
9 5 1 Removing: 2170
9 5 2 Installing: 2171
10 Aerial systems 2172
10 1 General notes 2172
10 2 Overview of aerial systems 2172
10 2 1 Aerial preparation for single AM/FM aerial 2172
10 2 2 Aerial preparation for single AM/FM/FM2 aerial with diversity function 2174
10 2 3 Aerial system for vehicles with radio system “RCD 210” 2175
10 2 4 Aerial system for vehicles with radio system “RCD 310” 2176
10 2 5 Aerial system for vehicles with radio system “RCD 510” 2177
10 2 6 Aerial system for vehicles with radio navigation system “RNS 310” 2178
10 3 Removing and installing aerial modules 2179
10 3 1 Removing: 2179
10 3 2 Installing: 2180
10 4 Removing and installing roof aerial 2181
10 4 1 Removing: 2181
10 4 2 Installing 2181
10 5 Renewal of aerial wiring 2182
11 Multifunction steering wheel 2183
11 1 General notes 2183
11 1 1 Fault finding 2183
11 2 Removing and installing steering wheel operating unit 2183
11 2 1 Removing: 2183
11 2 2 Installing: 2183
11 3 Removing and installing multifunction steering wheel control unit 2184
11 3 1 Removing: 2184
11 3 2 Installing: 2184
11 4 Adapting multifunction steering wheel components 2184
12 Notes on operating mobile telephones and two-way radios 2185
12 1 General notes 2185
12 1 1 Mobile telephones or portable two-way radios may not be used in the vehicle without a separate external aerial 2185
12 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: 2185
12 2 Notes on performing repair work 2185
12 2 1 Transmitting power and possible fitting locations 2186
12 2 2 Voltage supply 2186
12 2 3 Aerial and aerial wiring 2186
12 2 4 Further additional installations 2187
12 3 Overview of battery, transmitter and receiver unit, fuse and wiring harness 2187
12 4 Transmitting power and aerial fitting locations 2188
12 4 1 Polo 2010 ► 2188
13 Suppression measures 2189
13 1 Implementation of suppression measures 2189
D3E801E54AC 3 cylinder injection engine (1 2 l engine 4V EA 111) 2190
00 – Technical data 2194
1 Technical data 2194
1 1 Engine number 2194
10 – Removing and installing engine 2195
1 Removing and installing engine 2195
1 1 Removing 2196
1 2 Installing 2200
1 3 Specified torques 2201
13 – Crankshaft group 2203
1 Dismantling and assembling engine 2203
1 1 Assembly overview – belt drive 2203
1 2 Assembly overview – chain drive 2204
1 3 Removing and installing poly V-belt 2207
1 4 Removing and installing valve timing housing 2208
2 Cylinder block, seals 2214
2 1 Assembly overview 2214
2 2 Renewing crankshaft oil seal – belt pulley end 2215
2 3 Renewing crankshaft oil seal – flywheel end 2217
15 – Cylinder head, valve gear 2220
1 Cylinder head 2220
1 1 Assembly overview 2220
1 2 Removing and installing cylinder head 2223
1 3 Removing and installing camshaft housing 2225
1 3 1 Removing camshaft housing 2227
1 3 2 Installing camshaft housing 2228
1 4 Checking valve timing 2229
1 5 Removing and installing timing chain and drive chain for oil pump 2231
1 6 Adjusting valve timing 2233
1 7 Checking compression 2235
2 Valve gear 2237
2 1 Assembly overview 2237
2 2 Checking camshaft axial clearance 2239
2 3 Reworking valve seats 2240
2 4 Checking valve guides 2241
2 5 Renewing valve stem seals 2241
17 – Lubrication 2245
1 Parts of lubrication system 2245
1 1 Engine oil 2245
1 2 Assembly overview 2245
1 3 Assembly overview – oil filter 2248
1 4 Removing and installing oil filter element 2248
1 5 Removing and installing oil sump 2249
1 6 Checking oil pressure and oil pressure switch 2250
19 – Cooling 2252
1 Parts of cooling system 2252
1 1 Assembly overview – parts of cooling system, body side 2252
1 2 Assembly overview – parts of cooling system, engine side 2254
1 3 Coolant hose schematic diagram 2255
1 4 Draining and filling coolant 2256
1 5 Removing and installing radiator 2258
1 6 Removing and installing coolant pump 2260
20 – Fuel supply system 2262
1 Parts of fuel supply system 2262
1 1 Assembly overview – fuel tank with attachments 2262
1 2 Safety precautions when working on fuel supply system 2265
1 3 Rules for cleanliness 2266
1 4 Removing and installing fuel delivery unit 2266
1 5 Removing and installing fuel gauge sender -G- 2268
1 6 Removing and installing fuel tank 2268
1 7 Crash fuel shut-off 2270
1 8 Checking fuel pump 2270
1 8 1 Checking function and voltage supply 2272
1 8 2 Checking fuel pressure 2274
1 8 3 Checking holding pressure 2275
1 8 4 Checking fuel delivery rate 2276
1 8 5 Checking current draw 2277
1 9 Bleeding fuel system 2278
2 Activated charcoal filter system 2281
2 1 Assembly overview 2281
2 2 Checking fuel tank breather 2282
3 Electronic power control (EPC) 2283
3 1 Assembly overview 2283
24 – Mixture preparation – injection 2284
1 Injection system 2284
1 1 Assembly overview – parts of injection system 2284
1 2 Assembly overview – intake manifold 2287
1 3 Assembly overview – fuel rail with injectors 2288
1 4 Assembly overview – air filter 2288
1 5 Removing and installing air filter 2289
1 6 Cleaning throttle valve module -J338- 2290
1 7 Checking injectors 2291
1 8 Safety precautions 2296
1 9 Rules for cleanliness 2297
1 10 Technical data 2298
2 Engine control unit -J623- 2299
2 1 Removing and installing engine control unit -J623- 2299
2 2 Vehicles with anti-theft secured engine control unit -J623- 2299
26 – Exhaust system 2301
1 Parts of the exhaust system 2301
1 1 Assembly overview – front exhaust system with attachments 2301
1 2 Assembly overview – silencers with mountings 2302
28 – Ignition system 2304
1 Ignition system 2304
1 1 Assembly overview – parts of ignition system 2304
1 2 Removing and installing ignition coils with output stage 2305
1 3 Safety precautions 2306
1 4 Test data, spark plugs 2307
D3E801E54D7 3 cylinder injection engine (1 2 l engine 2V EA 111) 2308
00 – Technical data 2312
1 Technical data 2312
1 1 Engine number 2312
10 – Removing and installing engine 2313
1 Removing and installing engine 2313
1 1 Removing 2314
1 2 Installing 2318
1 3 Specified torques 2319
13 – Crankshaft group 2321
1 Dismantling and assembling engine 2321
1 1 Assembly overview – belt drive 2321
1 2 Assembly overview – chain drive 2322
1 3 Removing and installing poly V-belt 2325
1 4 Removing and installing valve timing housing 2326
2 Cylinder block, seals 2331
2 1 Assembly overview 2331
2 2 Renewing crankshaft oil seal – belt pulley end 2332
2 3 Renewing crankshaft oil seal – flywheel end 2334
15 – Cylinder head, valve gear 2337
1 Cylinder head 2337
1 1 Assembly overview 2337
1 2 Removing and installing cylinder head 2339
1 3 Checking valve timing 2342
1 4 Removing and installing timing chain and drive chain for oil pump 2343
1 5 Adjusting valve timing 2345
1 6 Checking compression 2348
2 Valve gear 2351
2 1 Assembly overview 2351
2 2 Checking camshaft axial clearance 2353
2 3 Reworking valve seats 2353
2 4 Checking valve guides 2355
2 5 Renewing valve stem seals 2355
17 – Lubrication 2359
1 Parts of lubrication system 2359
1 1 Engine oil 2359
1 2 Assembly overview 2359
1 3 Assembly overview – oil filter 2362
1 4 Removing and installing oil filter element 2362
1 5 Removing and installing oil sump 2363
1 6 Checking oil pressure and oil pressure switch 2364
19 – Cooling 2366
1 Parts of cooling system 2366
1 1 Assembly overview – parts of cooling system, body side 2366
1 2 Assembly overview – parts of cooling system, engine side 2368
1 3 Coolant hose schematic diagram 2369
1 4 Draining and filling coolant 2370
1 5 Removing and installing radiator 2372
1 6 Removing and installing coolant pump 2374
20 – Fuel supply system 2376
1 Parts of fuel supply system 2376
1 1 Assembly overview – fuel tank with attachments 2376
1 2 Safety precautions when working on fuel supply system 2379
1 3 Rules for cleanliness 2379
1 4 Removing and installing fuel delivery unit 2380
1 5 Removing and installing fuel gauge sender -G- 2381
1 6 Removing and installing fuel tank 2382
1 7 Crash fuel shut-off 2384
1 8 Checking fuel pump 2384
1 8 1 Checking function and voltage supply 2386
1 8 2 Checking fuel pressure 2388
1 8 3 Checking holding pressure 2389
1 8 4 Checking fuel delivery rate 2390
1 8 5 Checking current draw 2391
1 9 Bleeding fuel system 2392
2 Activated charcoal filter system 2395
2 1 Assembly overview 2395
2 2 Checking fuel tank breather 2395
3 Electronic power control (EPC) 2397
3 1 Assembly overview 2397
24 – Mixture preparation – injection 2398
1 Injection system 2398
1 1 Assembly overview – parts of injection system 2398
1 2 Assembly overview – intake manifold 2401
1 3 Assembly overview – fuel rail with injectors 2402
1 4 Assembly overview – air filter 2402
1 5 Removing and installing air filter 2403
1 6 Cleaning throttle valve module -J338- 2404
1 7 Checking injectors 2405
1 8 Check non-return valve for crankcase breather 2408
1 9 Safety precautions 2410
1 10 Rules for cleanliness 2411
1 11 Technical data 2411
2 Engine control unit -J623- 2412
2 1 Removing and installing engine control unit -J623- 2412
2 2 Removing and installing anti-theft engine control unit -J623- 2412
26 – Exhaust system 2414
1 Parts of the exhaust system 2414
1 1 Assembly overview – front exhaust system with attachments 2414
1 2 Assembly overview – silencers with mountings 2416
28 – Ignition system 2417
1 Ignition system 2417
1 1 Assembly overview – parts of ignition system 2417
1 2 Removing and installing ignition coils with output stage 2418
1 3 Safety precautions 2419
1 4 Test data, spark plugs 2420
D3E801E817C Brake systems 2421
00 – Technical data 2425
1 Brake allocation via PR No 2425
1 1 Front brakes 2425
1 2 Rear brakes 2426
1 2 1 Disc brakes 2426
1 2 2 Drum brakes 2426
2 Technical data for brakes 2427
2 1 Brake master cylinder and brake booster 2427
2 2 Front brakes 2427
2 3 Rear brakes 2428
3 Brake test 2430
3 1 General 2430
3 2 Test for vehicles with front-wheel drive 2430
45 – Anti-lock brake system 2431
1 General notes for anti-lock brake system (ABS) 2431
1 1 Bosch 8 2 and 9 0 2431
2 Notes for repair work on anti-lock brake system 2433
3 Connecting -VAS 5051- and selecting functions 2434
4 Electrical/electronic components and locations 2436
4 1 Bosch 8 2; 9 0 ABS 2436
4 2 Bosch 8 2i; 9 0i ABS/EDL/TCS/ESP 2437
5 Fault display via warning lamps 2439
6 Assembly overview – hydraulic unit, brake booster/brake master cylinder 2441
6 1 Bosch 8 2; 9 0 ABS, LHD vehicles 2441
6 1 1 Connecting brake lines from brake master cylinder to hydraulic unit 2442
6 1 2 Removing control unit and hydraulic unit 2444
6 1 3 Unscrewing control unit from hydraulic unit 2448
6 1 4 Installing new control unit 2449
6 1 5 Installing control unit and hydraulic unit 2450
6 2 Bosch 8 2; 9 0 ABS, RHD vehicles 2450
6 2 1 Connecting brake lines from brake master cylinder to ABS hydraulic unit -N55- 2452
6 2 2 Removing control unit and hydraulic unit 2454
6 2 3 Unscrewing control unit from hydraulic unit 2457
6 2 4 Installing new control unit 2458
6 2 5 Installing control unit and hydraulic unit 2458
6 3 Bosch 8 2i; 9 0i ABS/EDL/TCS/ESP, LHD vehicles 2459
6 3 1 Connecting brake lines from brake master cylinder to hydraulic unit 2461
6 3 2 Removing control unit and hydraulic unit 2463
6 3 3 Unscrewing control unit from hydraulic unit 2468
6 3 4 Installing new control unit 2469
6 3 5 Installing control unit and hydraulic unit 2470
6 4 Bosch 8 2i; 9 0i ABS/EDL/TCS/ESP, RHD vehicles 2470
6 4 1 Connecting brake lines from brake master cylinder to ABS hydraulic unit -N55- 2472
6 4 2 Removing control unit and hydraulic unit 2474
6 4 3 Unscrewing control unit from hydraulic unit 2476
6 4 4 Installing new control unit 2477
6 4 5 Installing control unit and hydraulic unit 2478
7 Removing and installing parts of ABS system on front and rear axle 2480
7 1 Removing and installing parts of ABS system on front axle 2480
7 1 1 Removing and installing speed sensor on front axle 2481
7 2 Removing and installing parts of anti-lock brake system on rear axle (drum brakes) 2481
7 2 1 Removing and installing speed sensor on rear axle (drum brakes) 2483
7 3 Removing and installing parts of anti-lock brake system on rear axle (disc brakes) 2483
7 3 1 Removing and installing speed sensor on rear axle 2485
8 Removing and installing parts of ESP system 2486
8 1 Removing and installing yaw rate sender -G202- and lateral acceleration sender -G200- 2486
8 2 Removing and installing steering angle sender -G85- 2486
46 – Brakes – mechanism 2487
1 Repairing front brakes 2487
1 1 Repairing front brakes, FS III brake caliper 2487
1 2 Removing and installing brake pads, brake caliper FS III 2488
1 2 1 Removing 2489
1 2 2 Installing 2489
1 3 Removing and installing brake caliper FS III 2490
1 3 1 Removing 2491
1 3 2 Installing 2491
1 4 Repairing front brakes, FN 3 brake caliper 2492
1 5 Removing and installing brake pads, brake caliper FN 3 2494
1 5 1 Removing 2494
1 5 2 Installing 2496
1 6 Removing and installing brake caliper FN 3 2496
1 6 1 Removing 2497
1 6 2 Installing 2497
2 Repairing rear brakes (drum brakes) 2499
2 1 Removing and installing rear brakes 2500
2 2 Resetting brake 2501
2 3 Repairing rear brakes 2501
2 3 1 Checking wheel brake cylinder for leaks 2502
2 4 Removing and installing brake shoes 2503
2 4 1 Removing 2503
2 4 2 Installing 2504
3 Repairing rear brakes (disc brakes) 2506
3 1 Removing and installing brake pads/linings 2507
3 1 1 Removing 2507
3 1 2 Installing 2508
3 2 Removing and installing brake caliper 2510
3 2 1 Removing 2510
3 2 2 Installing 2511
4 Assembly overview – handbrake lever 2512
4 1 Removing and installing handbrake cable (drum brakes) 2513
4 1 1 Removing 2513
4 1 2 Installing 2514
4 2 Adjusting handbrake 2515
4 3 Removing and installing handbrake cable (disc brakes) 2516
4 3 1 Removing 2516
4 3 2 Installing 2517
4 4 Adjusting handbrake 2518
5 Assembly overview – brake pedal 2520
5 1 Assembly overview – brake pedal, left-hand drive 2520
5 1 1 Separating brake pedal from brake booster 2520
5 1 2 Clipping brake pedal to brake booster 2521
5 1 3 Removing pedal cluster 2522
5 1 4 Installing pedal cluster 2522
5 1 5 Removing brake pedal 2522
5 1 6 Installing brake pedal 2522
5 2 Assembly overview – brake pedal, right-hand drive 2523
5 2 1 Separating brake pedal from brake booster 2524
5 2 2 Clipping brake pedal to brake booster 2524
5 2 3 Removing pedal cluster 2525
5 2 4 Installing pedal cluster 2525
5 2 5 Removing brake pedal 2525
5 2 6 Installing brake pedal 2526
47 – Brakes – hydraulics 2527
1 Repairing front brake calipers 2527
1 1 Repairing FS III brake calipers 2527
1 2 Removing and installing brake caliper FS III 2527
1 2 1 Removing 2528
1 2 2 Installing 2528
1 3 Repairing FN 3 brake calipers 2529
1 4 Removing and installing brake caliper piston FN 3 2530
1 4 1 Removing 2531
1 4 2 Installing 2532
2 Repairing rear brake calipers 2534
2 1 Removing and installing rear brake caliper piston 2534
2 1 1 Removing 2535
2 1 2 Installing 2536
2 1 3 Pre-bleeding brake caliper 2536
3 Pressurised leak test 2537
3 1 Test prerequisites: 2537
4 Bleeding brake system 2538
4 1 Bleeding brake system with brake filling and bleeding equipment -VAS 5234- 2538
4 1 1 Pre-bleeding: 2539
4 1 2 Bleeding (normal): 2539
4 1 3 Subsequent bleeding 2539
4 2 Changing brake fluid 2540
5 Assembly overview – brake booster/brake master cylinder 2541
5 1 Assembly overview – brake booster/brake master cylinder (left-hand drive vehicle) 2541
5 2 Assembly overview – brake booster/brake master cylinder (right-hand drive vehicle) 2542
5 3 Vacuum pump for brake booster (vehicles with diesel engine) 2544
5 3 1 Vacuum pump for diesel engines 2544
5 4 Checking brake booster vacuum system 2544
5 4 1 Connecting vacuum gauge for brake booster -VAS 6721- 2545
5 4 2 Checking vacuum generation 2545
5 4 3 Checking for leaks 2546
5 5 Checking non-return valve 2548
5 6 Vacuum pump for brakes -V192- 2548
5 6 1 Assembly overview – vacuum pump for brakes -V192- 2548
5 6 2 Removing 2549
5 6 3 Installing 2550
5 7 Removing and installing brake booster pressure sensor -G294- 2550
5 8 Removing and installing brake light switch -F-, left-hand drive 2551
5 9 Removing and installing brake light switch -F-, right-hand drive 2551
6 Removing and installing brake master cylinder 2553
6 1 Removing and installing brake master cylinder, left-hand drive 2553
6 1 1 Removing 2553
6 1 2 Installing 2554
6 2 Removing and installing brake master cylinder, right-hand drive vehicle 2554
6 2 1 Removing 2555
6 2 2 Installing 2557
7 Removing and installing brake booster 2558
7 1 Removing and installing brake booster, left-hand drive 2558
7 1 1 Removing 2558
7 1 2 Installing 2561
7 2 Removing and installing brake booster, right-hand drive vehicle 2561
7 2 1 Removing 2562
7 2 2 Installing 2566
8 Repairing brake lines 2568
8 1 Assembly overview – flanging tool 2568
8 2 Work instructions 2569
D3E801EC45D Body Repairs 2572
00 – Technical data 2578
1 Vehicle identification data 2578
1 1 Vehicle identification number 2578
1 2 Identification plate 2579
1 3 Vehicle data sticker 2580
2 Safety instructions 2581
3 Moulded foam elements 2582
4 Galvanized body parts, high- and higher-strength and hot-formed body panels 2584
4 1 Body 2584
4 2 2-door 2586
4 3 4-door 2589
5 Laser welding 2592
6 Body panel gaps/shut lines 2593
6 1 Body – front 2593
6 2 Body – centre 2594
6 3 Body – rear 2596
7 Body dimensions 2597
7 1 Body – front 2597
7 2 Body – centre 2600
7 2 1 2-door vehicle 2602
7 2 2 4-door vehicle 2605
7 3 Body – rear 2610
7 4 Floor group – front 2613
7 5 Floor group – centre 2615
7 6 Floor group – rear 2616
8 Tools 2617
9 Alignment jig 2618
9 1 Overview 2618
10 Portal gauge 2619
10 1 2-door 2619
10 2 4-door 2620
50 – Body – front 2622
1 Renewing right engine mounting bracket 2622
1 1 Tools 2622
1 2 Removing 2622
1 3 Installing 2624
1 3 1 Preparing new part 2624
1 3 2 Welding in 2625
2 Renewing retaining bracket for subframe 2626
2 1 Tools 2626
2 2 Removing 2626
2 3 Installing 2627
2 3 1 Preparing new part 2628
2 3 2 Welding in 2628
3 Renewing front bumper bracket 2630
3 1 Tools 2631
3 2 Removing 2631
3 3 Installing 2632
3 3 1 Welding in 2632
4 Renewing upper wheel housing longitudinal member 2634
4 1 Tools 2635
4 2 Removing 2635
4 3 Installing 2637
4 3 1 Preparing new part 2637
4 3 2 Welding in 2639
5 Renewing front wheel housing 2642
5 1 Tools 2643
5 2 Removing 2643
5 3 Installing 2644
5 3 1 Preparing new part 2644
5 3 2 Welding in 2644
6 Repairing threads for securing subframe 2646
6 1 Contents of thread repair kit 2648
6 2 Repairing threads 2648
6 2 1 Drilling thread 2648
6 2 2 Cutting thread 2649
6 2 3 Inserting thread insert 2650
7 Renewing front left longitudinal member 2652
7 1 Tools 2653
7 2 Removing 2653
7 3 Installing 2655
7 3 1 Preparing new part 2655
7 3 2 Welding in 2657
8 Renewing front left longitudinal member – part section 2659
8 1 Tools 2660
8 2 Removing 2660
8 3 Installing 2661
8 3 1 Preparing new part 2662
8 3 2 Welding in 2662
9 Renewing front right longitudinal member 2664
9 1 Tools 2665
9 2 Removing 2665
9 3 Installing 2667
9 3 1 Preparing new part 2667
9 3 2 Welding in 2670
10 Renewing front right longitudinal member – part section 2672
10 1 Tools 2673
10 2 Removing 2673
10 3 Installing 2674
10 3 1 Preparing new part 2674
10 3 2 Welding in 2676
51 – Body – centre 2677
1 Renewing roof 2677
1 1 Tools 2678
1 2 Removing 2679
1 3 Installing 2682
1 3 1 Preparing new part 2682
1 3 2 Adjusting roof depth 2684
1 3 3 Bonding roof 2685
1 3 4 Welding in 2691
2 Renewing front roof cross member 2693
2 1 Tools 2693
2 2 Removing 2693
2 3 Installing 2695
2 3 1 Preparing new part 2695
2 3 2 Welding in 2695
3 Renewing roof reinforcement 2697
3 1 Tools 2697
3 2 Removing 2697
3 3 Installing 2699
3 3 1 Preparing new part 2699
3 3 2 Welding in 2700
4 Renewing rear roof cross member 2702
4 1 Tools 2702
4 2 Removing 2702
4 3 Installing 2704
4 3 1 Preparing new part 2704
4 3 2 Welding in 2705
5 Renewing A-pillar 2707
5 1 Tools 2708
5 2 Removing 2708
5 3 Installing 2710
5 3 1 Preparing new part 2711
5 3 2 Moulded foam elements 2713
5 3 3 Welding in 2714
6 Renewing A-pillar reinforcement 2718
6 1 Tools 2719
6 2 Removing 2719
6 3 Installing 2722
6 3 1 Preparing new part 2722
6 3 2 Moulded foam elements 2723
6 3 3 Welding in 2724
7 Renewing B-pillar – 4-door 2728
7 1 Tools 2729
7 2 Removing 2729
7 3 Installing 2730
7 3 1 Preparing new part 2731
7 3 2 Marking area where no welding work may be carried out 2733
7 3 3 Moulded foam elements 2734
7 3 4 Welding in 2735
8 Renewing B-pillar reinforcement – 4-door 2738
8 1 Tools 2739
8 2 Removing 2739
8 3 Installing 2742
8 3 1 Preparing new part 2742
8 3 2 Marking area where no welding work may be carried out 2747
8 3 3 Moulded foam elements 2747
8 3 4 Welding in 2748
9 Renewing B-pillar reinforcement – 2-door 2752
9 1 Tools 2753
9 2 Removing 2753
9 3 Installing 2755
9 3 1 Preparing new part 2755
9 3 2 Marking area where no welding work may be carried out 2761
9 3 3 Moulded foam elements 2762
9 3 4 Welding in 2763
10 Renewing outer side member – 4-door 2767
10 1 Tools 2768
10 2 Removing 2768
10 3 Installing 2770
10 3 1 Preparing new part 2771
10 3 2 Marking area where no welding work may be carried out 2773
10 3 3 Moulded foam elements 2774
10 3 4 Welding in 2775
11 Renewing outer side member – 2-door 2779
11 1 Tools 2780
11 2 Removing 2781
11 3 Installing 2782
11 3 1 Preparing new part 2782
11 3 2 Welding in 2784
12 Renewing gusset plate 2788
12 1 Tools 2788
12 2 Removing 2788
12 3 Installing 2789
12 3 1 Preparing new part 2790
12 3 2 Welding in 2790
13 Renewing seat cross member 2792
13 1 Tools 2792
13 2 Removing 2792
13 3 Installing 2794
13 3 1 Preparing new part 2794
13 3 2 Welding in 2796
53 – Body – rear 2797
1 Renewing rear cross panel 2797
1 1 Tools 2798
1 2 Removing 2798
1 3 Installing 2799
1 3 1 Preparing new part 2799
1 3 2 Welding in 2800
2 Renewing tail light mounting 2802
2 1 Tools 2803
2 2 Removing 2803
2 3 Installing 2804
2 3 1 Preparing new part 2804
2 3 2 Welding in 2805
3 Renewing cross panel member 2807
3 1 Tools 2808
3 2 Removing 2808
3 3 Installing 2809
3 3 1 Preparing new part 2809
3 3 2 Welding in 2810
4 Renewing luggage compartment floor 2812
4 1 Tools 2813
4 2 Removing 2813
4 3 Installing 2814
4 3 1 Preparing new part 2814
4 3 2 Moulded foam elements 2815
4 3 3 Welding in 2815
5 Renewing rear longitudinal member – part section 2817
5 1 Tools 2818
5 2 Removing 2818
5 3 Installing 2820
5 3 1 Preparing new part 2820
5 3 2 Welding in 2822
6 Renewing side panel, part section – 4-door 2823
6 1 Tools 2824
6 2 Removing 2824
6 3 Installing 2826
6 3 1 Preparing new part 2827
6 3 2 Moulded foam elements 2829
6 3 3 Welding in 2830
7 Renewing side panel – 2-door 2834
7 1 Tools 2835
7 2 Removing 2835
7 3 Installing 2837
7 3 1 Preparing new part 2838
7 3 2 Moulded foam elements 2840
7 3 3 Marking area where no welding work may be carried out 2841
7 3 4 Welding in 2842
8 Renewing outer wheel housing liner – part section 2846
8 1 Tools 2847
8 2 Removing 2847
8 3 Installing 2848
8 3 1 Preparing new part 2848
8 3 2 Welding in 2849
D3E801EC55C Heating air conditioner 2851
00 – Technical data 2855
1 General information 2855
1 1 Notes concerning odours in air conditioned vehicles 2855
1 2 Notes for vehicles with a start/stop system 2855
1 3 Notes on repair work to vehicles with air conditioning and on handling refrigerant 2856
1 4 Procedure when checking and adjusting components 2856
1 5 Type plates 2857
2 Safety information 2858
2 1 Safety precautions when handling refrigerants 2858
2 2 Safety measures when working on vehicles with a start/stop system 2858
3 Repair instructions 2859
3 1 Repair work on refrigerant circuit which may be performed only in appropriate workshops by specially trained mechanics 2859
4 Technical data 2861
4 1 Capacities for refrigerant R134a 2861
4 2 Refrigerant oil 2861
4 3 Oil distribution 2861
80 – Heating 2862
1 Overview of fitting locations – heating 2862
1 1 Overview of fitting locations – components located in front section of passenger compartment 2862
2 Heater 2864
2 1 Removing and installing fresh air blower -V2- 2864
2 2 Removing and installing fresh air blower series resistor with overheating fuse -N24- 2864
2 3 Removing and installing dust and pollen filter 2864
2 4 Removing and installing heater unit 2864
2 5 Dismantling and assembling heater unit 2866
2 6 Assembly overview – heat exchanger 2868
2 7 Removing and installing heat exchanger 2868
2 8 Removing and installing auxiliary air heater element -Z35- 2870
2 9 Checking auxiliary air heater element -Z35- 2871
3 Control motors 2875
3 1 Removing and installing air distribution flap actuator 2875
3 2 Removing and installing temperature flap actuator 2876
3 2 1 Removing and installing temperature flap actuator, left-hand drive vehicles 2876
3 2 2 Removing and installing temperature flap actuator, right-hand drive vehicles 2878
4 Air duct 2880
4 1 Removing and installing centre vent 2880
4 2 Removing vents on driver or front passenger sides 2880
4 3 Removing and installing left footwell vent 2880
4 4 Removing and installing right footwell vent 2880
4 5 Removing and installing rear air duct 2880
4 6 Checking forced ventilation for passenger compartment 2880
5 Operating and display unit 2881
5 1 Removing and installing operating and display unit 2881
5 2 Pin assignment for multi-pin connectors on back of controls for heated and fresh air 2882
5 3 Removing and installing flexible shafts, checking 2882
87 – Air conditioning system 2884
1 Overview of fitting locations – air conditioning system 2884
1 1 Overview of fitting locations – components located in front section of passenger compartment 2884
1 1 1 Overview of fitting locations – components inside of front passenger compartment, left-hand drive vehicles 2884
1 1 2 Overview of fitting locations – components inside of front passenger compartment, right-hand drive vehicles 2886
2 Refrigerant circuit 2888
2 1 Required special tools, workshop equipment, testers, measuring instruments and auxiliary items 2888
2 2 System overview – refrigerant circuit 2889
2 3 Removing and installing evacuating and charging valves on low and high-pressure side 2891
2 4 Removing and installing high-pressure sender -G65- 2892
2 5 Removing and installing condenser 2894
2 6 Removing and installing desiccant cartridge 2896
2 7 Removing and installing expansion valve 2898
3 Air conditioner compressor 2901
3 1 Assembly overview – drive unit of air conditioner compressor 2901
3 2 Assembly overview – Denso pulley 2902
3 3 Removing and installing air conditioner compressor 2902
3 4 Removing and installing air conditioning system magnetic clutch -N25- 2908
3 5 Checking high-pressure safety valve on air conditioner compressor 2909
3 6 Removing and installing ancillary bracket for air conditioner compressor 2910
4 Control motors 2911
4 1 Removing and installing temperature flap control motor -V68- 2911
4 1 1 Removing and installing temperature flap control motor -V68-, left-hand drive vehicles 2911
4 1 2 Removing and installing temperature flap control motor -V68-, right-hand drive vehicles 2912
4 2 Removing and installing centre flap control motor -V70- 2913
4 2 1 Removing and installing centre flap control motor -V70-, left-hand drive vehicles 2913
4 2 2 Removing and installing centre flap control motor -V70-, right-hand drive vehicles 2914
4 3 Removing and installing air flow flap control motor -V71- 2915
4 3 1 Removing and installing air flow flap control motor -V71-, left-hand drive vehicles 2915
4 3 2 Removing and installing air flow flap control motor -V71-, right-hand drive vehicles 2916
4 4 Removing and installing defroster flap control motor -V107- and temperature flap control motor -V68- 2917
4 4 1 Removing and installing defroster flap control motor -V107- and temperature flap control motor -V68-, LHD vehicles 2917
4 4 2 Removing and installing defroster flap control motor -V107- and temperature flap control motor -V68- 2919
4 5 Removing and installing fresh air and air recirculation flap control motor -V154- 2921
4 6 Locally manufacturing an adapter cable to activate control motors 2923
5 Front heater and air conditioning unit 2924
5 1 Removing and installing heater and air conditioning unit 2924
5 1 1 Removing and installing heater and air conditioning unit, left-hand drive vehicles 2924
5 1 2 Removing and installing heater and air conditioning unit, right-hand drive vehicles 2927
5 2 Dismantling and assembling heater and air conditioning unit 2929
5 2 1 Dismantling and assembling heater and air conditioning unit, LHD vehicles, Climatic and air conditioning system with electric/manual controls 2929
5 2 2 Dismantling and assembling heater and air conditioning unit, LHD vehicles, Climatronic 2931
5 2 3 Dismantling and assembling heater and air conditioning unit, RHD vehicles, Climatic and air conditioning system with electric/manual controls 2933
5 2 4 Dismantling and assembling heater and air conditioning unit, RHD vehicles, Climatronic 2935
5 3 Removing and installing fresh air blower -V2- 2937
5 3 1 Removing and installing fresh air blower -V2-, left-hand drive vehicles 2937
5 3 2 Removing and installing fresh air blower -V2-, right-hand drive vehicles 2938
5 4 Removing and installing fresh air blower series resistor with overheating fuse -N24- 2940
5 4 1 Removing and installing fresh air blower series resistor with overheating fuse -N24-, left-hand drive vehicles 2940
5 4 2 Removing and installing fresh air blower series resistor with overheating fuse -N24-, right-hand drive vehicles 2940
5 5 Removing and installing dust and pollen filter 2941
5 5 1 Removing and installing dust and pollen filter, left-hand drive vehicles 2941
5 5 2 Removing and installing dust and pollen filter, right-hand drive vehicles 2942
5 6 Dismantling and assembling evaporator housing 2943
5 6 1 Dismantling and assembling evaporator housing, left-hand drive vehicles 2943
5 6 2 Dismantling and assembling evaporator housing, right-hand drive vehicles 2944
5 7 Checking condensation drain 2945
5 8 Removing and installing fresh air blower control unit -J126- 2946
5 9 Removing and installing evaporator output temperature sender -G263- 2947
5 9 1 Removing and installing evaporator output temperature sender -G263-, LHD vehicles 2947
5 9 2 Removing and installing evaporator output temperature sender -G263-, RHD vehicles 2948
6 Air duct 2949
6 1 Removing and installing centre vent 2949
6 2 Removing vents on driver or front passenger sides 2949
6 3 Removing and installing left footwell vent 2950
6 3 1 Removing and installing left footwell vent, LHD vehicles 2950
6 3 2 Removing and installing left footwell vent, RHD vehicles 2950
6 4 Removing and installing right footwell vent 2951
6 4 1 Removing and installing right footwell vent, LHD vehicles 2951
6 4 2 Removing and installing right footwell vent, RHD vehicles 2951
6 5 Removing and installing rear air duct 2951
6 6 Checking forced ventilation for passenger compartment 2952
7 Operating and display unit 2953
7 1 Overview of fitting locations – operating and display unit 2953
7 1 1 Overview of fitting locations – operating and display unit, Climatic and air conditioning system with electric/manual controls 2953
7 1 2 Overview of fitting locations – operating and display unit, air conditioning system with electric/manual controls 2955
7 1 3 Overview of fitting locations – operating and display unit, Climatronic 2955
7 2 Removing and installing operating and display unit 2957
7 2 1 Removing and installing operating and display unit for Climatic and air conditioning system with electric/manual controls 2957
7 2 2 Removing and installing operating and display unit, Climatronic 2958
7 3 Multi-pin connector pin assignment on back of operating and display unit 2959
7 3 1 Multi-pin connector pin assignment on back of operating and display unit, Climatic 2959
7 3 2 Multi-pin connector pin assignment on back of operating and display unit, electric/manual air conditioning system 2960
7 3 3 Multi-pin connector pin assignment on back of operating and display unit, Climatronic 2961
7 4 Removing and installing flexible shaft 2962
8 Other controlling and regulating components 2963
8 1 Removing and installing centre vent temperature sender -G191- 2963
8 1 1 Removing and installing centre vent temperature sender -G191-, left-hand drive vehicles 2963
8 1 2 Removing and installing centre vent temperature sender -G191-, right-hand drive vehicles 2964
8 2 Removing and installing footwell vent temperature sender -G192- 2964
8 3 Removing and installing sunlight penetration photosensor -G107- 2964
8 4 Removing and installing radiator fan control unit -J293- 2965
8 4 1 Removing and installing radiator fan control unit -J293-, up to week 21/2011 2965
8 4 2 Removing and installing radiator fan control unit -J293-, as of week 22/2011 2966
D3E801ED67B Electrical system 2967
00 – Technical data 2975
1 Safety information 2975
1 1 Safety measures when working on vehicles with start/stop system 2975
1 2 Safety precautions when using test and measuring equipment during a road test 2975
1 3 Operation and safety notes for gas discharge lamps 2976
2 Repair notes 2978
2 1 Contact corrosion 2978
2 2 Routing and attachment of lines 2978
3 Battery 2979
3 1 Battery – general notes 2979
3 2 Types of battery 2979
27 – Starter, current supply, CCS 2980
1 Battery 2980
1 1 Warning notices and safety regulations 2980
1 2 Assembly overview – battery 2980
1 2 1 Assembly overview – battery, vehicles with starter battery in engine compartment 2980
1 2 2 Assembly overview – battery, vehicles with starter battery in luggage compartment 2985
1 3 Assembly overview – battery tray 2986
1 3 1 Assembly overview – battery tray, battery tray without heat shield 2986
1 3 2 Assembly overview – battery tray, battery tray with heat shield 2988
1 4 Battery load test 2990
1 5 Disconnecting and connecting battery 2990
1 5 1 Disconnecting and connecting battery, models with starter battery in engine compartment 2990
1 5 2 Disconnecting and connecting battery, models with starter battery in luggage compartment 2992
1 6 Removing and installing battery 2995
1 6 1 Removing and installing battery, vehicles with starter battery in engine compartment 2995
1 6 2 Removing and installing battery, vehicles with starter battery in luggage compartment 2998
1 7 Removing and installing battery tray 2999
1 7 1 Removing and installing battery tray, battery tray without heat shield 2999
1 7 2 Removing and installing battery tray, battery tray with heat shield 3000
1 8 Checking battery 3001
1 9 Charging battery 3001
1 10 Removing and installing earth wire with battery monitor control unit -J367- 3001
1 11 Removing and installing battery cut-off/battery isolator 3002
1 12 Adapting battery monitor control unit -J367- 3006
1 13 Removing and installing suppression filter -C24- 3006
2 Starter, vehicles with manual gearbox 3007
2 1 Checking starter 3007
2 2 Starter, vehicles with manual gearbox MQ200 3007
2 2 1 Assembly overview 3007
2 2 2 Removing and installing starter, vehicles with manual gearbox MQ200 3008
2 3 Starter, vehicles with manual gearbox MQ250 3011
2 3 1 Assembly overview 3011
2 3 2 Removing and installing starter, vehicles with manual gearbox MQ250 3012
2 4 Starter, vehicles with manual gearbox MQ350 3014
2 4 1 Assembly overview – starter, vehicles with manual gearbox MQ350 3015
2 4 2 Assembly overview – starter, vehicles with 2 0 l TSI engine with 162 kW, manual gearbox MQ350 3015
2 4 3 Removing and installing starter, vehicles with manual gearbox MQ350 3016
2 4 4 Removing and installing starter, vehicles with 2 0 l TSI engine with 162 kW, manual gearbox MQ350 3018
3 Starter, vehicles with dual clutch gearbox (DSG) 3021
3 1 Checking starter -B- 3021
3 2 Starter, vehicles with 1 6 l TDI engine, 7-speed dual clutch gearbox 0AM 3021
3 2 1 Assembly overview 3021
3 2 2 Removing and installing starter, vehicles with 1 6 l TDI engine, 7-speed dual clutch gearbox 0AM 3022
3 3 Starter, vehicles with 1 4 l 132 KW TSI engine, 7-speed dual clutch gearbox 0AM 3023
3 3 1 Assembly overview 3023
3 3 2 Removing and installing starter, vehicles with 1 4 l 132 KW TSI engine, 7-speed dual clutch gearbox 0AM 3024
3 4 Starter, vehicles with 1 4 l 103 KW TSI engine, 7-speed dual clutch gearbox 0AM 3026
3 4 1 Assembly overview 3026
3 4 2 Removing and installing starter, vehicles with 1 4 l 103 KW TSI engine, 7-speed dual clutch gearbox 0AM 3027
3 5 Starter, vehicles with 1 2 l 77 kW TSI engine, 7-speed dual clutch gearbox 0AM 3029
3 5 1 Assembly overview 3029
3 5 2 Removing and installing starter, vehicles with 1 2 l 77 kW TSI engine, 7-speed dual clutch gearbox 0AM 3030
4 Starter, vehicles with automatic gearbox 3033
4 1 Starter, vehicles with automatic gearbox 09G 3033
4 1 1 Assembly overview 3033
4 1 2 Vehicles with 6-speed automatic gearbox 09G 3034
5 Alternator 3037
5 1 Checking poly V-belt 3037
5 2 Checking alternator -C- 3037
5 3 Securing B+ (battery positive) wire to alternator 3037
5 4 Alternator, 1 2 l injection engine, 51 kW 3038
5 4 1 Assembly overview – alternator, 1 2 l injection engine, 51 kW 3038
5 4 2 Removing and installing alternator, 1 2 l, 51 kW MPI engine 3039
5 5 Alternator, 1 4 l, 63 kW injection engine 3043
5 5 1 Assembly overview – alternator, 1 4 l, 63 kW MPI engine 3043
5 5 2 Removing and installing alternator, 1 4 l, 63 kW injection engine 3044
5 6 Alternator, 1 2 l, 66 kW/77 kW TSI engine 3046
5 6 1 Assembly overview – alternator, 1 2 l, 66/77 kW TSI engine 3046
5 6 2 Removing and installing alternator, 1 2 l, 66/77 kW, TSI engine 3047
5 7 Alternator, 1 4 l, 103 KW TSI engine 3051
5 7 1 Assembly overview – alternator, 1 4 l, 103 KW TSI engine 3051
5 7 2 Removing and installing alternator, 1 4 l, 103 KW TSI engine 3052
5 8 Alternator, 1 4 l, 132 KW TSI engine 3055
5 8 1 Assembly overview – alternator, 1 4 l, 132 KW TSI engine 3055
5 8 2 Removing and installing alternator, 1 4 l, 132 KW TSI engine 3057
5 9 Alternator, 2 0 l, 162 KW TSI engine 3061
5 9 1 Assembly overview – alternator, 2 0 l, 162 kW TSI engine 3061
5 9 2 Removing and installing alternator, 2 0 l, 162 KW TSI engine 3062
5 10 Alternator 1 2 l TDI 3066
5 10 1 Assembly overview – alternator, 1 2 l TDI engine 3066
5 10 2 Removing and installing alternator, 1 2 l TDI engine 3068
5 11 Alternator, 1 6 l TDI engine 3071
5 11 1 Assembly overview – alternator, 1 6 l TDI engine 3071
5 11 2 Removing and installing alternator, 1 6 l TDI engine 3073
5 12 Removing and installing poly V-belt pulley on alternator 3076
5 12 1 Removing and installing poly V-belt pulley without freewheel 3076
5 12 2 Removing and installing poly V-belt pulley with freewheel, manufacturer: Bosch 3077
5 12 3 Removing and installing poly V-belt pulley with freewheel, manufacturer: Valeo 3080
5 13 Voltage regulator for alternator 3083
5 13 1 Removing and installing voltage regulator, manufacturer: Bosch 3083
5 13 2 Removing and installing voltage regulator, manufacturer: Valeo 3084
6 Cruise control system (CCS) 3087
7 Start/stop system 3088
7 1 General description 3088
7 2 Start/stop operation switch -E693- 3089
7 2 1 Removing and installing Start/Stop operation button -E693- 3089
7 3 Voltage stabiliser -J532- 3089
7 3 1 Removing and installing voltage stabiliser -J532- 3090
90 – Gauges, instruments 3091
1 Dash panel insert 3091
1 1 Renewing dash panel insert 3091
1 2 Removing and installing dash panel insert 3092
1 3 Description of back of dash panel insert 3093
1 4 Warning lamp symbols in dash panel insert, petrol engine 3093
1 5 Warning lamp symbols in dash panel insert, diesel engine 3094
2 Service interval display 3096
2 1 Resetting service interval display 3096
92 – Windscreen wash/wipe system 3097
1 Windscreen wiper system 3097
1 1 Assembly overview – windscreen wiper system 3097
1 2 Removing and installing wiper arms 3098
1 3 Removing wiper frame with linkage and wiper motor 3100
1 4 Removing wiper motor from wiper frame and installing 3102
1 5 Adjusting wiper blade park position 3104
1 6 Removing and installing joint-free wipers 3106
1 7 Removing and installing wiper blade of joint-free wiper 3107
1 8 Removing and installing rain and light sensor -G397- 3108
1 8 1 Removing and installing rain and light sensor -G397- 3108
1 8 2 Repairing rain and light sensor -G397- (made by TRW) 3111
1 8 3 Coding rain and light sensor -G397- 3112
2 Windscreen washer system 3113
2 1 Assembly overview – windscreen washer system 3113
2 2 Removing and installing windscreen washer system spray jets 3115
2 3 Adjusting spray jets for windscreen washer system 3116
2 4 Assembly overview – washer fluid reservoir 3116
2 4 1 Removing and installing windscreen washer system reservoir 3117
2 5 Removing and installing windscreen and rear window washer pump -V59- 3119
3 Rear window wiper system 3121
3 1 Assembly overview – rear window wiper system 3121
3 2 Removing and installing wiper arm 3122
3 3 Removing and installing rear window wiper motor -V12- 3123
3 4 Adjusting rear window wiper park position 3124
3 5 Removing and installing joint-free wiper 3125
4 Rear window washer system 3126
4 1 Assembly overview – rear window washer system 3126
4 2 Renewing spray jet 3126
4 3 Adjusting spray jet 3127
5 Headlight washer system 3128
5 1 Assembly overview – headlight washer system 3128
5 2 Removing and installing headlight washer system pump -V11- 3129
5 3 Removing and installing spray jet pop-up cylinders 3130
5 4 Removing and installing spray jet retainer 3131
5 5 Adjusting headlight washer system spray jets 3132
5 6 Bleeding headlight washer system 3132
6 Washer fluid line hose couplings 3134
7 Hose repair 3135
94 – Lights, bulbs, switches – exterior 3136
1 Operation and safety notes for gas discharge lamps 3136
2 H4 headlights 3139
2 1 Assembly overview – headlights with halogen bulb H4 3139
2 2 Removing and installing headlight 3140
2 2 1 Removing headlight 3140
2 2 2 Installing headlight 3142
2 3 Adjusting headlight installation position 3142
2 4 Renewing headlight bulbs 3144
2 4 1 Renewing dipped beam and main beam bulb 3144
2 4 2 Renewing side light bulb 3145
2 4 3 Renewing front turn signal bulb 3147
2 5 Removing and installing headlight range control motor 3148
2 6 Converting headlights for use when driving on the left or right (halogen headlight) 3151
2 6 1 Converting headlights designed for driving on the right to driving on the left 3151
2 6 2 Converting headlights designed for driving on the left to driving on the right 3153
2 7 Adjusting headlights 3154
3 H7 headlights 3155
3 1 Assembly overview – headlights with halogen bulb H7 3155
3 2 Removing and installing headlight 3157
3 2 1 Removing headlight 3157
3 2 2 Installing headlight 3158
3 3 Adjusting headlight installation position 3158
3 4 Renewing headlight bulbs 3159
3 4 1 Renewing dipped beam bulb 3159
3 4 2 Renewing side light bulb 3160
3 4 3 Renewing headlight main beam bulb 3162
3 4 4 Renewing front turn signal bulb 3163
3 5 Removing and installing headlight range control motor 3164
3 6 Converting headlights for use when driving on the left or right (halogen headlight H7) 3166
3 6 1 Converting headlights designed for driving on the right to driving on the left 3167
3 6 2 Converting headlights designed for driving on the left to driving on the right 3168
3 7 Adjusting headlights 3170
4 Headlights with gas discharge bulb 3171
4 1 General description 3171
4 2 Assembly overview 3171
4 3 Removing and installing headlight 3173
4 3 1 Removing headlight 3173
4 3 2 Installing headlight 3174
4 4 Adjusting headlight installation position 3175
4 5 Renewing gas discharge headlight bulb 3175
4 5 1 Renewing gas discharge bulb 3175
4 5 2 Renewing turn signal bulb 3177
4 5 3 Renewing side light bulb 3178
4 5 4 Renewing static cornering light bulb 3179
4 6 Headlight starter for gas discharge bulb 3180
4 6 1 Removing and installing headlight starter for gas discharge bulb 3181
4 7 Headlight range control unit -J431- 3182
4 7 1 Removing and installing headlight range control unit -J431- 3182
4 7 2 Coding headlight range control unit -J431- 3183
4 8 Headlight range control motor 3183
4 8 1 Removing and installing headlight range control motor 3183
4 9 Headlight screen adjustment solenoid 3184
4 9 1 Removing and installing headlight screen adjustment solenoid 3185
4 9 2 Testing headlight screen adjustment solenoid 3185
4 10 LED module for daytime running light and side light 3185
4 10 1 Removing and installing LED module for daytime running light and side light 3185
4 11 Converting headlights for use when driving on the left or right 3185
4 12 Repairing headlight retaining tabs 3185
4 13 Adjusting headlights 3185
5 Fog lights 3186
5 1 Assembly overview – fog lights 3186
5 2 Removing and installing fog light 3186
5 3 Removing and installing fog light bulb 3188
5 4 Adjusting fog lights 3189
6 Fog light Polo Cross (Polo Dune) 3190
6 1 Assembly overview – fog lights 3190
6 2 Removing and installing fog light 3190
6 3 Removing and installing fog light bulb 3191
6 4 Adjusting fog lights 3192
7 Daytime running light 3193
7 1 Removing and installing daytime running light bulb in fog light 3193
8 Tail light 3195
8 1 Assembly overview – tail light 3195
8 2 Removing and installing tail light cluster 3196
8 3 Removing and installing tail light cluster bulb carrier 3197
9 Number plate light 3199
9 1 Bolted number plate light -X- 3199
9 1 1 Removing and installing bolted number plate light 3199
9 1 2 Removing and installing number plate light bulb 3200
9 2 Clipped number plate light -X- 3201
9 2 1 Removing and installing clipped number plate light 3201
9 2 2 Removing and installing clipped number plate light bulb 3202
10 High-level brake light 3204
10 1 High-level brake light bulb -M25- 3204
10 1 1 General description – light bulb for high-level brake light -M25- 3204
10 1 2 Removing and installing high-level brake light bulb -M25-, Polo, Polo Cross 3204
10 1 3 Removing and installing high-level brake light bulb -M25-, Polo GTI, Polo Blue Motion, Polo GT 3206
11 Steering column switch 3209
11 1 Removing and installing steering column switch 3210
11 2 Removing and installing airbag coil connector and return ring with slip ring -F138- 3213
11 3 Basic setting of steering angle sensor -G85- 3215
12 Ignition/starter switch and lock cylinder 3216
12 1 Removing and installing lock cylinder 3216
12 2 Ignition/starter switch -D- 3218
12 2 1 Removing and installing ignition/starter switch -D-, up to 10/2009 3218
12 2 2 Pin assignment at ignition/starter switch -D- up to 10/2009 3220
12 2 3 Removing and installing ignition/starter switch -D-, as of 11/2009 3220
12 3 Removing and installing ignition key withdrawal lock solenoid -N376- 3222
13 Steering lock housing 3223
13 1 Removing and installing steering lock housing 3223
14 Parking aid 3226
14 1 Assembly overview 3226
14 2 Parking aid control unit -J446- 3227
14 2 1 Removing and installing parking aid control unit -J446- 3227
14 2 2 Parking aid control unit -J446- final control diagnosis 3228
14 2 3 Adapting parking aid control unit -J446- 3228
14 2 4 Coding parking aid control unit -J446- 3229
14 2 5 Pin assignment of parking aid control unit -J446- 3229
14 3 Parking aid warning buzzer -H15- 3229
14 3 1 Removing and installing parking aid warning buzzer -H15- 3229
14 4 Rear parking aid sender up to 07/2009 3230
14 4 1 Removing and installing rear parking aid senders 3230
14 4 2 Replacing individual sender retainers up to 07/2009 3232
14 5 Rear parking aid sender from 08/2009 onwards 3233
14 5 1 Removing and installing rear parking aid senders 3233
14 5 2 Replacing individual sender retainers 3235
14 6 Renewing parking aid senders 3236
14 6 1 Painting senders 3236
96 – Lights, bulbs, switches – interior 3238
1 Interior lights and switches 3238
1 1 Removing and installing interior monitoring switch -E183- 3238
2 Lights and switches in engine compartment 3240
2 1 Removing and installing bonnet contact switch -F266- 3240
3 Lights and switches in dash panel 3241
3 1 Removing and installing light switch -E1- 3241
3 2 Removing and installing headlight range control regulator -E102- and switch and instrument illumination regulator -E20- 3242
3 3 Buttons, switches and warning lamps in centre of dash panel 3243
3 3 1 Removing and installing buttons, switches and warning lamps in centre of dash panel 3243
3 4 Removing and installing petrol or gas fuel selection switch -E395- 3244
3 4 1 Removing and installing petrol or gas fuel selection switch -E395- (vehicles ▶ 01 2011) 3244
3 4 2 Removing and installing petrol or gas fuel selection switch -E395- (vehicles 01 2011▶) 3245
3 5 Removing and installing tyre pressure monitor display button -E492- 3245
3 6 Removing and installing key-operated switch to deactivate front passenger side airbag -E224- 3246
3 7 Removing and installing left footwell light -W9- and right footwell light -W10- 3247
3 7 1 Renewing footwell light bulb 3248
4 Lights and switches in doors 3249
4 1 Removing and installing window regulator switch in front passenger door -E107- 3249
4 2 Removing and installing switch module for driver side window regulator 3250
4 2 1 Removing and installing switch module for driver side window regulator, 2-door vehicle 3250
4 2 2 Removing and installing switch module for driver side window regulator, 4-door vehicle 3250
4 3 Removing and installing switch module for mirror adjustment on driver side 3251
4 4 Removing and installing driver side interior locking button for central locking system -E308- 3252
4 5 Components – front door locks 3253
4 6 Driver side interior locking warning lamp -K174- and central locking SAFELOCK function warning lamp on front passenger side -K204- 3253
5 Lights and switches in luggage compartment and rear lid 3255
5 1 Removing and installing luggage compartment light -W3- 3255
5 2 Removing and installing luggage compartment light switch -F5- 3256
6 Lights and switches in roof trim 3257
6 1 Removing and installing sliding sunroof adjustment regulator 3257
6 2 interior light with switch-off delay -W15- with reading lights and preparation for mobile telephone 3257
6 2 1 Removing and installing interior light with switch-off delay -W15- 3257
6 2 2 Renewing bulb in front interior light -W1- 3259
6 2 3 Renewing bulb in front passenger reading light -W13- and driver side reading light -W19- 3260
6 3 Interior light with switch-off delay feature -W15- and panorama venting/sliding glass sunroof 3262
6 3 1 Removing and installing front interior and reading light in vehicles with panoramic sunroof 3262
6 4 Rear interior light -W43- 3263
6 4 1 Removing and installing rear interior light -W43- 3263
6 4 2 Renewing bulb in rear interior light -W43- 3264
6 5 Removing and installing light for vanity mirror 3266
7 12 V socket 3268
8 Cigarette lighter -U1- 3269
9 Horn 3270
9 1 Removing and installing horn in vehicles with fog lights or daytime running lights 3270
9 2 Removing and installing horn in vehicles without fog lights or daytime running lights 3270
10 Immobiliser 3272
10 1 Immobiliser control unit -J362- 3272
10 1 1 Removing and installing immobiliser control unit -J362- 3272
10 1 2 Adapting immobiliser control unit -J362- 3272
10 2 Ignition key 3273
10 2 1 Loss of the ignition key 3273
10 2 2 Adapting ignition key 3273
10 3 New identity on renewing all components 3273
10 4 Fazit system test 3273
11 Anti-theft alarm system (ATAS) 3274
11 1 Activating and deactivating anti-theft alarm 3274
11 2 Removing and installing interior monitoring switch -E183- 3274
11 3 Removing and installing anti-theft alarm sensor -G578- 3275
11 3 1 Removing and installing anti-theft alarm sensor -G578- 3275
11 4 Alarm horn -H12- 3275
11 4 1 Removing and installing alarm horn -H12- 3276
97 – Wiring 3278
1 Vehicle diagnosis, testing and information systems 3278
2 Fuse holder 3279
2 1 Removing and installing fuse holder B -SB- on left in dash panel 3279
2 2 Removing and installing fuse holder A -SA- on left in engine compartment 3280
2 2 1 Removing and installing fuse holder A -SA- on left in engine compartment, vehicles with starter battery in engine compartment 3280
2 2 2 Removing and installing fuse holder A -SA- on left in engine compartment, vehicles with starter battery in luggage compartment 3282
2 3 Removing and installing bracket for fuse holder A -SA- 3284
3 Relay carrier 3287
3 1 Removing and installing relay carrier on left of dash panel 3287
4 Control units 3289
4 1 Onboard supply control unit -J519- 3289
4 1 1 Removing and installing onboard supply control unit -J519- 3290
4 2 Data bus diagnostic interface -J533- 3290
4 3 Trailer detector control unit -J345- 3290
4 3 1 Removing and installing trailer detector control unit -J345- 3292
4 3 2 Coding trailer detector control unit -J345- 3293
4 3 3 Adapting immobiliser control unit -J345- software 3293
5 Wiring harness and connector repairs 3294
D3E801EFD5E General body repairs exterior 3295
50 – Body – front 3303
1 Lock carrier 3303
1 1 Assembly overview – lock carrier 3303
1 2 Removing and installing lock carrier 3304
1 3 Moving to and back from service position 3306
1 4 Pressure hose with plug-in connector 3310
1 4 1 Releasing plug-in connector 3310
1 4 2 Engaging plug-in connector 3310
2 Wings 3311
2 1 Tools 3311
2 2 Front wing 3311
2 2 1 Assembly overview 3311
2 2 2 Removing 3313
2 2 3 Installing 3315
2 3 Insulation and foam elements for wing and web plate 3316
2 4 Removing and installing wing bracket 3317
3 Plenum chamber bulkhead 3318
3 1 Tools 3318
3 2 Assembly overview – plenum chamber bulkhead 3318
4 Plenum chamber cover 3320
4 1 Plenum chamber cover 3320
4 1 1 Assembly overview 3320
4 1 2 Removing 3321
4 1 3 Installing 3322
5 Noise insulation 3324
5 1 Tools 3324
5 2 Assembly overview – diesel noise insulation 3324
5 3 Assembly overview – long noise insulation 3326
5 4 Assembly overview – short noise insulation 3327
6 Underbody cladding 3328
6 1 Tools 3328
6 2 Assembly overview – underbody cladding 3328
7 Bulkhead 3330
7 1 Tools 3330
7 2 Materials 3331
7 3 Assembly overview – bulkhead 3331
8 Tunnel cross-piece 3332
8 1 Tools 3332
8 2 Assembly overview – tunnel cross-piece 3332
55 – Bonnet, rear lid 3333
1 Bonnet (hood) 3333
1 1 Tools 3333
1 2 Assembly overview – bonnet 3333
1 3 Removing and installing bonnet 3335
1 3 1 Removing 3335
1 3 2 Installing 3336
1 4 Removing and installing bonnet hinge 3336
1 4 1 Removing 3337
1 4 2 Installing 3338
1 5 Removing and installing insulation 3339
1 5 1 Removing 3339
1 5 2 Installing 3340
1 6 Removing and installing support rod 3341
1 7 Assembly overview – bonnet lock and release components 3342
1 8 Removing and installing lid lock – LHD vehicle 3343
1 8 1 Removing 3343
1 8 2 Installing 3344
1 9 Removing and installing lid lock – RHD vehicle 3345
1 9 1 Removing 3345
1 9 2 Installing 3346
1 10 Detaching Bowden cable 3347
1 11 Removing and installing striker pin 3348
1 12 Removing and installing release lever 3349
1 12 1 Assembly overview 3349
1 12 2 Removing and installing 3350
1 13 Adjusting bonnet 3351
1 13 1 Adjusting lid lock 3352
1 14 Adjusting striker pin 3353
2 Rear lid 3354
2 1 Tools 3354
2 2 Assembly overview – rear lid 3354
2 3 Removing and installing rear lid 3356
2 3 1 Removing 3356
2 3 2 Installing 3358
2 4 Assembly overview – gas strut 3359
2 5 Removing gas strut 3359
2 6 Releasing gas from gas strut 3361
2 7 Assembly overview – rear lid hinge 3361
2 8 Removing and installing rear lid hinge 3363
2 8 1 Removing 3363
2 8 2 Installing 3364
2 9 Removing and installing striker pin 3365
2 10 Removing and installing stop buffer 3366
2 11 Adjusting rear lid 3367
2 11 1 Adjusting striker pin 3368
2 11 2 Adjusting adjusting buffer 3368
2 12 Removing and installing bonnet lock 3370
2 12 1 Removing 3370
2 12 2 Installing 3371
2 13 Removing and installing release element 3372
2 13 1 Removing 3372
2 13 2 Installing 3373
2 14 Rear lid seal 3373
2 15 Removing and installing rear lid seal 3374
2 15 1 Removing 3374
2 15 2 Installing 3375
3 Tank flap unit 3376
3 1 Tools 3376
3 2 Assembly overview – tank flap unit and actuator 3376
3 3 Removing and installing tank flap unit 3378
3 3 1 Removing 3378
3 3 2 Installing 3379
3 4 Removing and installing actuator 3380
3 4 1 Removing 3380
3 4 2 Installing 3381
57 – Front doors, door components, central locking 3382
1 Rear door 3382
1 1 Tools 3382
1 2 Assembly overview – door hinges 3383
1 3 Removing and installing door 3384
1 3 1 Removing 3385
1 3 2 Installing 3386
1 4 Installing after renewing A-pillar 3387
1 5 Door alignment 3388
1 5 1 Door alignment – shut lines and flushness 3388
1 5 2 Adjusting striker pin 3389
2 Door components 3392
2 1 Tools 3392
2 2 Assembly overview – front door (2-door model) 3393
2 3 Assembly overview – front door (4-door model) 3394
2 4 Removing and installing cover (2-door model) 3395
2 4 1 Removing 3395
2 4 2 Installing 3396
2 5 Removing and installing cover (4-door model) 3397
2 5 1 Removing 3397
2 5 2 Installing 3398
2 6 Removing and installing door retaining strap 3399
2 7 Removing and installing striker pin 3400
2 8 Assembly overview – door handle and door lock 3400
2 9 Removing and installing lock cylinder cover cap 3401
2 9 1 Removing 3401
2 9 2 Installing 3402
2 10 Removing and installing lock cylinder 3402
2 10 1 Removing 3402
2 10 2 Installing 3404
2 11 Removing and installing cover cap (without lock cylinder) 3405
2 11 1 Tools 3405
2 11 2 Removing 3405
2 11 3 Installing 3407
2 12 Removing and installing door handle 3408
2 12 1 Removing 3409
2 12 2 Installing 3410
2 13 Removing and installing door lock 3410
2 13 1 Removing 3411
2 13 2 Installing 3412
2 14 Removing and installing mounting bracket 3414
2 14 1 Removing 3414
2 14 2 Installing 3415
2 15 Removing and installing window slot inner seal 3415
2 16 Removing and installing outer window slot seal (2-door model) 3416
2 16 1 Removing 3416
2 16 2 Installing 3418
2 17 Removing and installing outer window slot seal (4-door model) 3419
2 17 1 Removing 3419
2 17 2 Installing 3420
2 18 Removing and installing inner door seal 3420
2 19 Removing and installing door outer seal (2-door model) 3422
2 20 Removing and installing door outer seal (4-door model) 3423
2 21 Assembly overview – insulation (2-door model) 3424
2 22 Assembly overview – insulation (4-door model) 3425
3 Central locking 3426
3 1 Fitting location overview – central locking components 3426
3 2 Adapting keys with remote control 3427
3 3 Assembly overview – battery for folding key with remote control 3428
3 4 Removing and installing battery for folding key with remote control 3429
3 4 1 Removing 3429
3 4 2 Installing 3431
58 – Rear doors, door components 3432
1 Rear door 3432
1 1 Tools 3432
1 2 Assembly overview – door hinges 3433
1 3 Removing and installing door 3434
1 3 1 Removing 3435
1 3 2 Installing 3436
1 4 Installing after renewing B-pillar 3437
1 5 Door alignment 3438
1 5 1 Tool 3438
1 5 2 Door alignment – shut lines and flushness 3438
1 5 3 Adjusting striker pin 3440
2 Door components 3442
2 1 Tools 3442
2 2 Assembly overview – rear door 3443
2 3 Removing and installing cover 3444
2 4 Removing and installing door retaining strap 3445
2 5 Removing and installing striker pin 3446
2 6 Assembly overview – door handle and door lock 3446
2 7 Removing and installing cap 3447
2 7 1 Tools 3447
2 7 2 Removing 3448
2 7 3 Installing 3449
2 8 Removing and installing door handle 3450
2 8 1 Removing 3450
2 8 2 Installing 3452
2 9 Removing and installing door lock 3452
2 9 1 Removing 3453
2 9 2 Installing 3454
2 10 Removing and installing mounting bracket 3456
2 10 1 Removing 3456
2 10 2 Installing 3457
2 11 Removing and installing trim 3458
2 11 1 Removing 3458
2 11 2 Installing 3459
2 12 Removing and installing window slot inner seal 3460
2 13 Removing and installing window slot outer seal 3461
2 13 1 Removing 3461
2 13 2 Installing 3462
2 14 Removing and installing inner door seal 3462
2 15 Removing and installing outer door seal 3464
2 16 Assembly overview – insulation 3465
60 – Sunroof 3466
1 Panorama tilting sunroof 3466
1 1 Tools 3466
1 2 Function 3466
1 3 Panoramic sliding roof normalisation run 3468
1 4 Assembly overview – panorama tilting sunroof 3469
1 5 Removing glass panel for panorama tilting sunroof 3471
1 6 Removing glass panel when drive is defective 3473
1 7 Installing glass panel 3475
1 8 Adjusting glass panel (height adjustment) 3477
1 9 Removing and installing glass panel seal 3478
1 10 Removing and installing cover 3479
1 11 Removing and installing drive for panorama tilting sunroof glass panel 3480
1 11 1 Removing 3480
1 11 2 Installing 3481
1 12 Removing and installing panorama tilting sunroof switch 3482
1 13 Operating without current 3483
1 14 Removing and installing wind deflector 3484
1 14 1 Removing 3484
1 14 2 Installing 3485
1 15 Removing and installing interior seal 3486
1 16 Sun blind 3487
1 16 1 Assembly overview 3487
1 16 2 Removing sun blind 3488
1 16 3 Installing sun blind 3490
1 16 4 Removing and installing tension bow 3493
1 16 5 Installing pulling rib 3494
1 17 Removing and installing guide rails 3495
1 17 1 Removing 3495
1 17 2 Installing 3497
1 18 Cleaning water drainage hoses 3498
1 18 1 Tools 3498
1 18 2 Assembly overview 3499
1 18 3 Water drain hoses 3500
1 19 Assembly overview – assembly frame and trim 3501
1 20 Removing and installing assembly frame 3502
1 20 1 Minimum curing period 3502
1 20 2 Fitting instructions 3502
1 20 3 Cleaning in the event of dirt caused by adhesive sealant 3503
1 20 4 Touching up paint damage 3503
1 20 5 Materials 3503
1 20 6 Preparing body flange for bonding 3503
1 20 7 Preparing sliding sunroof frame for installation 3504
1 20 8 Removing assembly frame 3505
1 20 9 Installing assembly frame 3508
1 21 Removing and installing trim 3510
1 21 1 Minimum curing period 3510
1 21 2 Fitting instructions 3510
1 21 3 Cleaning in the event of dirt caused by adhesive sealant 3511
1 21 4 Materials 3511
1 21 5 Preparing front trim for installation 3511
1 21 6 Preparing sliding sunroof frame for installation of front trim 3512
1 21 7 Removing trim panel 3512
1 22 Installing trim panel 3518
63 – Bumpers 3520
1 Front bumper cover 3520
1 1 Tools 3520
1 2 Repairing front bumper cover 3520
1 3 Number plate carrier 3521
1 3 1 Installing number plate carrier 3521
1 4 Front bumper carrier and lateral guides 3522
1 4 1 Assembly overview 3522
2 Front bumper cover, Polo 3523
2 1 Front bumper cover 3523
2 1 1 Assembly overview 3523
2 1 2 Removing 3524
2 1 3 Installing 3526
2 1 4 Front bumper cover add-on parts 3528
2 2 Front bumper cover, Polo Blue Motion 3529
2 2 1 Assembly overview – front bumper cover, Polo Blue Motion 3529
2 2 2 Removing front bumper cover, Polo Blue Motion 3530
2 2 3 Installing front bumper cover, Polo Blue Motion 3532
2 2 4 Front bumper cover with attachments, Polo Blue Motion 3534
2 3 Front bumper cover, Cross Polo 3535
2 3 1 Assembly overview – front bumper cover, Cross Polo 3535
2 3 2 Removing front bumper cover, Cross Polo 3536
2 3 3 Installing front bumper cover, Cross Polo 3538
2 3 4 Front bumper cover – attachments, Cross Polo 3540
2 4 Front bumper cover, Polo »GTI« 3541
2 4 1 Assembly overview – front bumper cover, Polo »GTI« 3542
2 4 2 Removing front bumper cover, Polo »GTI« 3543
2 4 3 Installing front bumper cover, Polo »GTI« 3545
2 4 4 Add-on parts for front bumper cover, Polo »GTI« 3547
2 5 Front bumper cover, Polo »R-Line« 3548
2 5 1 Assembly overview – front bumper cover, Polo »R-Line« 3548
2 5 2 Removing front bumper cover, Polo »R-Line« 3549
2 5 3 Installing front bumper cover, Polo »R-Line« 3550
2 5 4 Front bumper cover, add-on parts – Polo »R-Line« 3551
3 Rear bumper cover 3553
3 1 Tools 3553
3 2 Repairing rear bumper cover 3553
3 3 Installing brackets for parking aid system 3553
3 3 1 Tools 3553
3 3 2 Materials 3554
3 3 3 Installing brackets 3554
3 3 4 Minimum curing period 3558
3 4 Number plate carrier 3559
3 4 1 Installing number plate carrier 3559
3 5 Rear bumper carrier and subassemblies 3560
4 Rear bumper cover, Polo 3561
4 1 Rear bumper cover 3561
4 1 1 Assembly overview 3561
4 1 2 Removing 3562
4 1 3 Installing 3563
4 2 Rear bumper cover, Polo Blue Motion 3564
4 2 1 Assembly overview – rear bumper cover, Polo Blue Motion 3564
4 2 2 Removing rear bumper cover, Polo Blue Motion 3565
4 2 3 Installing rear bumper cover, Polo Blue Motion 3566
4 2 4 Rear bumper cover with attachments, Polo Blue Motion 3567
4 3 Rear bumper cover, Cross Polo 3568
4 3 1 Assembly overview – rear bumper cover, Cross Polo 3568
4 3 2 Removing rear bumper cover, Cross Polo 3569
4 3 3 Installing rear bumper cover, Cross Polo 3570
4 3 4 Rear bumper cover – attachments, Cross Polo 3571
4 4 Rear bumper cover, Polo GTI, Blue GT 3572
4 4 1 Assembly overview – rear bumper cover, Polo GTI 3572
4 4 2 Removing rear bumper cover, Polo GTI 3573
4 4 3 Installing rear bumper cover, Polo GTI 3574
4 4 4 Add-on parts for rear bumper cover, Polo GTI 3575
4 5 Rear bumper cover – Polo »R-Line« 3575
4 5 1 Assembly overview – rear bumper cover – Polo »R-Line« 3576
4 5 2 Removing rear bumper cover – Polo »R-Line« 3577
4 5 3 Installing rear bumper cover – Polo »R-Line« 3578
4 5 4 Rear bumper cover, add-on parts – Polo »R-Line« 3579
5 Towing bracket 3580
5 1 Assembly overview – towing bracket 3580
64 – Glazing 3581
1 Flush bonded windows 3581
1 1 Tools 3581
1 2 Materials 3582
1 3 Assembly overview – windscreen 3583
1 4 Removing windscreen 3584
1 5 Installing windscreen 3585
1 6 Assembly overview – rear window 3585
1 7 Removing undamaged rear window 3587
1 8 Removing broken rear window 3588
1 9 Installing rear window 3589
1 10 Assembly overview – side window (2-door model) 3589
1 11 Removing undamaged side window (2-door model) 3590
1 12 Assembly overview – side window (4-door model) 3591
1 13 Removing undamaged side window (4-door model) 3593
1 14 Removing broken side window 3594
1 15 Installing side window 3594
1 16 Preparing old undamaged window for glazing 3595
1 16 1 Cutting back adhesive bead 3595
1 17 Preparing new window without precoating for glazing 3595
1 18 Preparing body flange for glazing 3596
1 19 Fitting instructions 3597
1 19 1 Installation instructions for all windows 3597
1 20 Minimum curing period 3597
1 21 Touching up paint damage 3598
1 22 Cleaning in the event of dirt caused by adhesive sealant 3598
2 Front door window 3599
2 1 Tools 3599
2 2 Assembly overview – front door window 3600
2 3 Removing and installing door window 3600
2 3 1 Removing 3600
2 3 2 Installing 3602
2 4 Removing and installing window regulator motor 3605
2 4 1 Removing 3605
2 4 2 Installing 3606
2 5 Installing and removing window regulators 3607
2 5 1 Removing 3607
2 5 2 Installing 3608
2 6 Removing and installing window channel 3609
2 6 1 Removing window channel 3609
2 6 2 Installing 3610
3 Rear door window 3612
3 1 Tools 3612
3 2 Assembly overview – rear door window 3613
3 3 Removing and installing door window 3613
3 3 1 Removing door window 3614
3 3 2 Installing door window 3616
3 4 Removing and installing window regulator motor 3617
3 4 1 Removing 3617
3 4 2 Installing 3618
3 5 Removing and installing manual drive 3619
3 6 Removing and installing window crank 3620
3 7 Installing and removing window regulators 3621
3 7 1 Removing 3621
3 7 2 Installing 3622
3 8 Removing and installing window channel 3622
3 8 1 Removing window channel 3623
3 8 2 Installing 3624
66 – Exterior equipment 3625
1 Wheel housing liner 3625
1 1 Tools 3625
1 2 Front wheel housing liner 3625
1 2 1 Assembly overview 3625
1 2 2 Removing 3627
1 2 3 Installing 3628
1 3 Rear wheel housing liner 3628
1 3 1 Assembly overview 3629
1 3 2 Removing 3630
1 3 3 Installing 3631
2 Exterior mirror 3633
2 1 Tools 3633
2 2 Assembly overview – exterior mirror 3633
2 3 Removing and installing mirror glass 3634
2 3 1 Removing 3635
2 3 2 Installing 3635
2 4 Removing and installing adjustment unit with motor 3636
2 4 1 Removing 3636
2 4 2 Installing 3636
2 5 Removing and installing mirror housing 3637
2 5 1 Removing 3637
2 5 2 Installing 3637
2 6 Removing and installing trim 3638
2 6 1 Removing 3638
2 6 2 Installing 3638
2 7 Removing and installing assembly bracket with side turn signal repeater 3639
2 7 1 Removing 3639
2 7 2 Installing 3640
2 8 Removing and installing exterior mirror (manual operation) 3640
2 8 1 Removing 3641
2 8 2 Installing 3643
2 9 Removing and installing exterior mirror (electric operation) 3644
2 9 1 Removing 3645
2 9 2 Installing 3647
3 Radiator grille 3649
3 1 Tools 3649
3 2 Removing and installing radiator grille 3649
3 2 1 Removing 3649
3 2 2 Installing 3651
3 3 Removing and installing emblem 3652
3 3 1 Removing 3652
3 3 2 Installing 3654
3 4 Removing and installing emblem on Polo Blue Motion 3656
3 4 1 Removing 3656
3 4 2 Installing 3658
3 5 Assembly overview – radiator grille, Polo »GTI« 3660
4 Mouldings and trims 3661
4 1 Tool 3661
4 2 Removing and installing A-pillar trim 3661
4 3 B-pillar trim 3663
4 3 1 Assembly overview 3663
4 3 2 Removing 3664
4 3 3 Installing 3665
4 4 Wing trim panel 3666
4 4 1 Wing trim panel assembly instructions 3666
4 4 2 Removing and installing wing trim panel 3666
4 5 Water deflector, Polo Blue Motion, Blue GT 3667
4 5 1 Assembly overview – water deflector 3667
4 5 2 Removing water deflector strip 3668
4 5 3 Installing water deflector strip 3669
4 6 Removing and installing cover strip 3670
5 Removing and installing roof railing 3672
5 1 Tools 3672
5 2 Roof railing 3672
5 2 1 Assembly overview – roof railing 3672
5 2 2 Removing and installing roof railing 3674
6 Roof spoiler 3675
6 1 Tools 3675
6 2 Materials 3676
6 3 Roof spoiler, Polo Blue Motion 3676
6 3 1 Assembly overview – roof spoiler, Polo Blue Motion 3676
6 3 2 Removing middle piece of roof spoiler, Polo Blue Motion 3678
6 3 3 Installing middle piece of roof spoiler, Polo Blue Motion 3679
6 3 4 Removing adapter 3680
6 3 5 Removing side piece of roof spoiler, Polo Blue Motion 3681
6 3 6 Installing side piece of roof spoiler, Polo Blue Motion 3683
6 4 Roof spoiler, Polo »GTI« 3685
6 4 1 Assembly overview – roof spoiler 3685
6 4 2 Removing roof spoiler 3685
6 4 3 Installing roof spoiler 3687
6 4 4 Removing adapter 3689
6 5 Roof spoiler, Polo Blue GT 3690
6 5 1 Assembly overview, roof spoiler, Polo Blue GT 3690
6 5 2 Removing side spoilers, Polo Blue GT 3691
6 5 3 Installing side spoilers, Polo Blue GT 3692
6 6 Roof spoiler, Polo “WRC” 3694
6 6 1 Assembly overview – roof spoiler 3694
6 6 2 Removing roof spoiler 3695
6 6 3 Installing roof spoiler 3696
7 Special add-on parts 3699
7 1 Assembly overview – Polo Blue Motion 3699
7 2 Assembly overview – Cross Polo 3701
7 3 Assembly overview – Polo »GTI« 3702
7 4 Assembly overview – Polo »R-Line« 3703
7 5 Assembly overview – Polo »WRC« 3704
7 6 Safety requirements 3704
7 7 Tools 3705
7 8 Materials 3706
7 9 Side member extension, Polo Blue Motion, Blue GT 3706
7 9 1 Assembly overview – side member extension 3706
7 9 2 Removing side member extension 3707
7 9 3 Installing side member extension 3709
7 9 4 Removing retaining rail 3711
7 9 5 Installing retaining rail 3712
7 10 Side member extension, Cross Polo 3713
7 10 1 Assembly overview – side member extension 3714
7 10 2 Removing side member extension 3715
7 10 3 Installing side member extension 3716
7 10 4 Removing retaining rail 3717
7 10 5 Installing retaining rail 3718
7 11 Side member extension, Polo »GTI« 3721
7 11 1 Assembly overview – side member extension 3721
7 11 2 Removing side member extension 3722
7 11 3 Installing side member extension 3723
7 11 4 Position of self-drilling screws for side member extension 3723
7 12 Front wheel housing trim, Cross Polo 3725
7 12 1 Removing front wheel housing trim 3726
7 12 2 Installing front wheel housing trim 3727
7 13 Rear wheel housing trim, Cross Polo 3728
7 13 1 Removing rear wheel housing trim 3728
7 13 2 Installing rear wheel housing trim 3729
7 14 Front door cover, Cross Polo 3730
7 14 1 Removing front door cover 3730
7 14 2 Installing front door cover 3731
7 14 3 Removing and installing front door adapter 3732
7 15 Rear door cover, Cross Polo 3733
7 15 1 Removing rear door cover 3733
7 15 2 Installing rear door cover 3734
7 15 3 Rear door adapter 3735
7 16 Wheel arch trim, rear door, Cross Polo 3736
7 16 1 Removing and installing wheel arch trim of rear door 3736
7 17 Preparing attachment for bonding 3737
7 18 Preparing body component for bonding 3737
7 19 Fitting instructions 3738
7 20 Minimum curing period 3738
7 21 Touching up paint damage 3739
7 22 Cleaning in the event of dirt caused by adhesive sealant 3739
7 23 Cleaning guidelines 3739
8 Lettering and emblems 3740
8 1 Fitting instructions 3740
8 2 Dimensions – lettering and emblems on rear lid 3741
8 2 1 Rear lettering – dimensions 3741
8 2 2 Rear lettering dimensions, Polo Blue Motion 3742
8 2 3 Dimensions of rear lettering Polo GTI 3745
8 2 4 Rear lettering dimensions, Polo Blue GT 3746
8 2 5 Dimensions of rear lettering Polo “WRC” 3747
8 3 Removing and installing emblems 3748
8 3 1 Removing and installing radiator grille emblem, Polo Blue GT 3748
8 3 2 Removing and installing radiator grille emblem, Polo “R” 3749
8 4 Side lettering 3750
8 4 1 Rear bumper cover, Cross Polo 3750
8 4 2 2-door model, B-pillar – special models 3751
8 4 3 4-door model, B-pillar – special models 3752
8 4 4 Wing – special models 3753
9 Scuff protection film 3754
9 1 Renewing scuff protection film, Polo »GTI« 3754
9 1 1 Tools 3754
9 1 2 Fitting instructions 3754
9 1 3 Renewing scuff protection film, Polo »GTI« 2-door vehicle 3754
9 1 4 Renewing scuff protection film, Polo »GTI« 4-door vehicle 3756
D3E801EFD42 General body repairs interior 3758
68 – Interior equipment 3764
1 Interior mirror 3764
1 1 Tools 3764
1 1 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 3764
1 2 Automatic anti-dazzle interior mirror 3764
1 3 Removing and installing interior mirror with rain and light sensor -G397- 3764
1 3 1 Removing 3764
1 3 2 Installing 3766
1 4 Bonding retaining plate for interior mirror with rain and light sensor -G397- 3766
1 4 1 Preparing windscreen 3766
1 4 2 Preparing detached or new retaining plate 3767
1 4 3 Bonding retaining plate 3767
1 4 4 Cleaning and removing excessive adhesive 3767
1 4 5 Installing rain sensor and mirror 3767
1 5 Removing and installing interior mirror 3767
1 5 1 Removing 3767
1 5 2 Installing 3768
1 6 Bonding on retaining plate for interior mirror without rain sensor 3768
1 6 1 Materials: 3768
2 Compartments, covers and trims 3770
2 1 Tools 3770
2 1 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 3770
2 2 Removing and installing centre console without armrest 3771
2 3 Removing and installing centre console with armrest 3773
2 4 Removing and installing support (vehicles with arm rest) 3776
2 5 Removing and installing rear cup holder (vehicles with arm rest) 3777
2 6 Removing and installing arm rest 3777
2 7 Removing and installing hand brake cover cap 3778
2 8 Removing and installing cover for centre console 3779
2 9 Removing and installing dash panel middle trims 3780
2 10 Removing and installing centre dash panel compartment 3782
2 11 Removing and installing centre dash panel storage compartment 3783
2 12 Removing and installing dash panel end trims 3784
2 13 Removing and installing glove compartment 3785
2 14 Removing and installing fuse box cover 3786
2 15 Removing and installing steering column trim 3787
2 16 Removing and installing sun visors 3788
3 Sill mouldings and wheel housing trims 3790
3 1 Removing and installing sill mouldings (4-door models) 3790
3 2 Removing and installing sill mouldings (2-door models) 3791
3 3 Removing and installing wheel housing trim (4-door models) 3791
4 Grab handles 3794
4 1 Removing and installing roof grab handle 3794
69 – Passenger protection 3796
1 Seat belts 3796
1 1 Tools 3796
1 1 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 3796
1 2 General safety regulations when working on airbag, belt tensioner and battery isolator units (pyrotechnic components) 3797
1 3 Special instructions for belt tensioners 3798
1 4 Storage, transportation and disposal of airbag, belt tensioner and battery isolator units (pyrotechnic components) 3798
1 5 Removing and installing front seat belt (4-door models) 3798
1 6 Removing and installing front seat belt (2-door models) 3800
1 7 Removing and installing belt anchor rail (2-door models) 3802
1 8 Removing and installing front belt height adjuster (4-door models) 3804
1 9 Removing and installing front belt height adjuster (2-door models) 3805
1 10 Removing and installing front belt buckle 3806
1 11 Removing and installing outer rear seat belts (4-door models) 3807
1 12 Removing and installing outer rear seat belts (2-door models) 3808
1 13 Removing and installing centre rear seat belts 3809
1 14 Removing and installing rear double belt buckle 3809
2 Inspecting seat belts 3811
2 1 Points to check 3811
2 1 1 Checking belt webbing 3811
2 1 2 Checking inertia reel (locking mechanism) 3812
2 1 3 Visually checking belt buckle 3813
2 1 4 Checking operation of belt buckle 3813
2 1 5 Checking belt guide fittings and latch plates 3813
2 1 6 Checking securing parts and anchorage points 3813
3 Checking child seat anchors (ISOFIX) after an accident 3814
3 1 Points to check 3814
4 Airbag 3815
4 1 Tools 3815
4 1 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 3815
4 2 General safety regulations when working on airbag, belt tensioner and battery isolator units (pyrotechnic components) 3816
4 3 Special instructions for driver and front passenger airbag 3817
4 4 Special instructions for curtain airbag modules 3817
4 5 Storage, transportation and disposal of airbag, belt tensioner and battery isolator units (pyrotechnic components) 3818
4 6 Renewing airbag units following an accident 3818
4 6 1 Accident with airbag triggering 3818
4 6 2 Accident without airbag triggering 3818
4 7 Removing and installing airbag control unit -J234- 3818
4 8 Removing and installing driver airbag unit 3819
4 9 Removing and installing return spring with slip ring 3822
4 10 Removing and installing front passenger airbag unit 3822
4 11 Removing and installing side airbag (vehicles with curtain airbag) 3825
4 12 Removing and installing side airbag (vehicles without curtain airbag) 3827
4 13 Removing and installing curtain airbag 3828
4 14 Removing and installing seat occupied sensor, front passenger side -G128- 3831
4 15 Adapting components 3834
5 Crash sensors 3835
5 1 Tools 3835
5 1 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 3835
5 2 Removing and installing side airbag crash sensor on driver side -G179- (4-door models) 3835
5 3 Removing and installing side airbag crash sensor on front passenger side -G180- (4-door models) 3836
5 4 Removing and installing side airbag crash sensor on driver side -G179- (2-door models) 3837
5 5 Removing and installing side airbag crash sensor on front passenger side -G180- (2-door models) 3839
5 6 Removing and installing rear side-airbag crash sensor, driver side -G256- 3840
5 7 Removing and installing rear side-airbag crash sensor, front passenger side -G257- 3841
70 – Trim, insulation 3843
1 Dash panel 3843
1 1 Tools 3843
1 1 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 3843
1 2 Removing and installing dash panel 3843
1 3 Removing and installing dash panel cross member 3849
2 Door and side trims 3858
2 1 Tools 3858
2 1 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 3858
2 2 Removing and installing front door trim (4-door models) 3858
2 3 Removing and installing door trim panel (2-door models) 3862
2 4 Removing and installing rear door trim 3867
2 5 Removing and installing front door trim cover 3871
2 6 Removing and installing side trim 3872
3 Pillar trims 3875
3 1 Tools 3875
3 1 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 3875
3 2 Removing and installing upper A-pillar trims 3875
3 3 Removing and installing lower A-pillar trim (driver side) 3876
3 4 Removing and installing lower A-pillar trim (passenger side) 3878
3 5 Releasing and securing upper B-pillar trims (4-door models) 3879
3 6 Removing and installing B-pillar trims (4-door models) 3880
3 7 Releasing and securing B-pillar trims (2-door models) 3882
3 8 Removing and installing B-pillar trims (2-door models) 3883
3 9 Removing and installing C-pillar trims (4-door models) 3884
3 10 Releasing and securing C-pillar trims (2-door models) 3887
3 11 Removing and installing C-pillar trims (2-door models) 3888
4 Rear lid trim 3891
4 1 Tools 3891
4 1 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 3891
4 2 Removing and installing rear lid trim 3891
5 Luggage compartment trims 3893
5 1 Tools 3893
5 1 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 3893
5 2 Removing and installing lock carrier cover 3893
5 3 Removing and installing luggage compartment floor covering 3894
5 4 Removing and installing luggage compartment cover side support 3895
5 5 Removing and installing mounting parts for variable luggage compartment floor 3897
5 6 Removing and installing luggage compartment side trim panel 3897
6 Roof trims 3899
6 1 Tools 3899
6 1 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 3899
6 2 Removing and installing roof end strip 3900
6 3 Removing and installing moulded headliner (4-door models) 3900
6 4 Removing and installing moulded headliner (2-door models) 3903
6 5 Removing and installing insulation and roof reinforcements 3905
72 – Seat frames 3908
1 Front seats 3908
1 1 Tools 3908
1 1 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 3908
1 2 Removing and installing front seat 3909
1 3 Removing and installing seat trim on sill side (seat without height adjustment) 3913
1 4 Removing and installing seat trim on sill side (seat with height adjustment) 3914
1 5 Removing and installing seat height adjustment operating lever 3916
1 6 Removing and installing seat trim on tunnel side 3917
1 7 Removing and installing mounting for drawer 3917
1 8 Removing and installing lumbar adjustment lever 3919
1 9 Removing head restraint guides 3919
1 10 Removing and installing front seat backrest 3921
2 Rear seats 3924
2 1 Tools 3924
2 2 Removing and installing rear seat 3924
2 3 Removing and installing backrest 3925
2 4 Removing head restraint guides 3927
2 5 Removing and installing backrest release mechanism 3928
74 – Seat – padding, covers 3930
1 Front seat covers and padding 3930
1 1 Tools 3930
1 2 Removing and installing front seat cushion cover and padding 3930
1 3 Removing and installing front seat backrest cover and padding 3933
2 Rear seat covers and padding 3935
2 1 Tools 3935
2 2 Removing and installing bench seat (split) cover and padding 3935
2 3 Removing and installing bench seat (continuous) cover and padding 3936
2 4 Removing and installing backrest cover and padding 3937
D3E801F2AEA Running gear axles steering 3941
00 – Technical data 3947
1 Checklist for evaluating running gear of accident vehicles 3947
2 General information 3949
40 – Front suspension 3950
1 Evaluating accident vehicles 3950
2 Repairing front wheel suspension 3951
2 1 Overview – front axle 3951
2 2 Raising wheel suspension to unladen position 3952
3 Subframe, anti-roll bar, suspension links 3955
3 1 Assembly overview: subframe, anti-roll bar, suspension links 3955
3 2 Repairing thread in longitudinal member 3957
3 3 Fixing position of subframe (all vehicles except for R WRC) 3957
3 4 Fixing position of subframe (R WRC) 3960
3 5 Removing and installing subframe 3962
3 6 Checking swivel joint 3964
3 7 Removing and installing swivel joint 3964
3 8 Installation position of swivel joints 3967
3 9 Removing and installing suspension link 3968
3 9 1 Removing and installing suspension link, vehicles with manual gearbox 3968
3 9 2 Removing and installing suspension link, vehicles with automatic or dual clutch gearbox 3970
3 10 Renewing front bonded rubber bush for suspension link 3973
3 11 Renewing rear bonded rubber bush for suspension link 3976
3 12 Removing and installing anti-roll bar 3978
3 13 Removing and installing rubber bush for anti-roll bar 3980
4 Assembly overview: wheel bearing 3983
4 1 Pulling out and pulling in wheel hub with wheel bearing 3984
4 2 Removing and installing wheel bearing housing 3989
5 Assembly overview: suspension strut 3993
5 1 Removing and installing suspension strut 3994
5 2 Repairing front suspension strut 3999
6 Removing and installing drive shafts 4003
6 1 Removing and installing drive shaft with constant velocity joint 4003
6 2 Removing and installing drive shaft with triple roller joint AAR 2000 (bolted-on) 4005
7 Repairing drive shafts – overview of drive shafts 4007
7 1 Heat shields for drive shafts 4008
8 Assembly overview: drive shaft with VL90 or VL100 constant velocity joint 4009
8 1 Dismantling and assembling drive shaft with VL90 or VL100 constant velocity joint 4011
8 2 Checking outer constant velocity joint 4016
8 3 Checking inner constant velocity joint 4017
9 Assembly overview: drive shaft with VL107 constant velocity joint 4019
9 1 Dismantling and assembling drive shaft with VL107 constant velocity joint 4021
10 Assembly overview: drive shaft with triple roller joint AAR 2000/108 4026
10 1 Dismantling and assembling drive shaft with triple roller joint AAR 2000/108 4028
42 – Rear suspension 4036
1 Evaluating accident vehicles 4036
2 Repairing rear axle 4037
2 1 Overview – rear axle 4037
2 2 Rear axle in unladen position 4039
3 Assembly overview: axle beam, drum brake 4041
3 1 Removing and installing rear axle 4043
3 2 Removing and installing bonded rubber bush 4047
3 3 Removing and installing coil spring, vehicles with small rear silencer 4053
3 4 Removing and installing coil spring, vehicles with large rear silencer 4054
4 Assembly overview: axle body, disc brake 4057
5 Assembly overview: shock absorber 4059
5 1 Removing and installing shock absorbers 4060
6 Assembly overview: wheel bearings, drum brake 4062
6 1 Removing and installing wheel hub with wheel bearing, vehicles with drum brakes 4063
7 Assembly overview: wheel bearings, disc brake 4066
7 1 Removing and installing wheel hub with wheel bearing, vehicles with disc brakes 4067
43 – Self-levelling suspension 4069
1 Assembly overview: rear left vehicle level sender -G76-, front-wheel drive 4069
1 1 Removing and installing rear left vehicle level sender -G76- 4069
44 – Wheels, tyres, vehicle geometry 4071
1 Evaluating accident vehicles 4071
2 Specified torques for wheel bolts 4072
3 Removing and fitting tyres with run-flat properties to wheel rims 4073
3 1 Notes on safety and prerequisites 4073
3 2 Fittings instructions 4073
3 3 Pressing tyre off wheel rim 4074
3 4 Removing tyre from wheel 4075
3 5 Fitting tyre to wheel rim 4076
4 Tyre pressure monitor display 4079
5 Vehicle alignment check 4081
5 1 General information 4081
5 2 Conditions for testing 4083
5 3 Test preparations 4083
5 4 Wheel alignment specifications 4084
5 5 Transverse vehicle inclination “zero position” 4086
5 6 Overview – wheel alignment procedure 4086
5 7 Correcting front axle camber 4087
5 8 Check rear axle camber 4088
5 9 Check rear axle toe 4088
5 10 Adjusting front axle toe 4089
5 11 Checking left and right-hand wheel lock 4089
5 12 Vehicle data sticker 4090
6 Wheels, tyres 4091
6 1 Models with breakdown set 4091
6 2 Tyre sealant 4091
6 3 Removing a tyre 4091
6 4 Fitting a new tyre 4092
6 5 Tyre sealant disposal 4092
7 Instructions for changing or fitting wheels 4093
7 1 Fitting wheels 4094
8 Protecting wheel centring seat against corrosion 4095
9 Wheel change, installation requirements 4096
10 Vibration due to wheels/tyres – causes and rectification 4098
10 1 Causes of rough running 4098
10 2 Balancing wheels 4098
10 3 Conducting a road test before balancing wheels 4099
10 4 Balancing wheels on stationary wheel balancing machine 4099
10 5 Vibration control system -VAS 6230 A- 4102
10 6 Finish balancer 4102
10 7 Radial and lateral runout of wheels and tyres 4103
10 8 Checking radial and lateral runout on wheels and tyres with tyre gauge -V A G 1435- 4103
10 9 Checking radial and lateral run-out on wheel rim 4104
10 10 Matching 4105
10 11 Flat spots caused by storage or handling 4106
48 – Steering 4108
1 Evaluating accident vehicles 4108
2 General repair instructions 4109
2 1 Steering rack 4109
2 2 Gaskets and seals 4109
2 3 Nuts and bolts 4109
2 4 Electrical components 4110
2 5 Guided fault finding, vehicle self-diagnosis and test instruments 4110
3 Steering column 4111
3 1 Removing and installing steering wheel 4111
3 2 Assembly overview: steering column, left-hand drive 4114
3 3 Removing and installing steering column, left-hand drive vehicle 4114
3 4 Assembly overview: steering column, right-hand drive 4119
3 5 Removing and installing steering column, right-hand drive vehicle 4120
3 6 Handling and transporting steering column 4125
4 Electro-hydraulic power steering 4127
4 1 Assembly overview for electrohydraulic power steering, left-hand drive vehicle 4127
4 2 Removing and installing power-assisted steering rack, left-hand drive vehicle 4128
4 3 Removing and installing power steering sensor -G250-, left-hand drive vehicle 4134
4 4 Assembly overview for electrohydraulic power steering, right-hand drive vehicle 4134
4 5 Removing and installing power steering rack, right-hand drive vehicle 4136
4 6 Removing and installing power steering sensor -G250-, right-hand drive vehicle 4141
5 Repairing power steering rack 4143
5 1 Assembly overview: power steering rack, left-hand drive vehicle 4143
5 2 Assembly overview: power steering rack, right-hand drive vehicle 4145
5 3 Removing and installing track rod 4147
5 4 Checking play, security and boots of track rod ends 4148
5 5 Checking and adjusting left track rod length 4148
5 6 Allocation of track rod ball joints 4149
5 7 Allocation of track rod ball joints for GTI and R WRC 4149
5 8 Determining centre position of steering rack 4150
5 9 Adjusting steering rack 4150
6 Motor/pump unit 4151
6 1 Assembly overview: engine pump unit 4151
6 2 Removing and installing motor/pump unit 4152
6 3 Renewing reservoir for motor/pump unit 4155
6 4 Checking delivery pressure of motor/pump unit 4157
7 Bleeding steering system, checking for leaks and checking fluid level 4161
7 1 Bleeding steering system 4161
7 2 Check steering system for leaks 4161
7 3 Checking hydraulic fluid level of power steering 4162
D3E802B1C57 4 cylinder injection engine (1 4 l engine BiFuel) Volkswagen R GmbH 4164
00 – Technical data 4170
1 Engine number 4170
2 Engine data 4171
01 – Self-diagnosis 4172
1 Reading fault memory for fuel system (LPG) 4172
1 1 Preparation to read fault memory 4172
1 2 Read fault memory 4172
1 3 Erasing fault memory 4173
10 – Removing and installing engine 4174
1 Removing and installing engine 4174
1 1 Removing engine 4176
1 2 Securing engine to assembly stand 4179
1 3 Installing engine 4179
1 4 Torque settings 4181
1 5 Assembly mountings 4182
1 6 Additional information and assembly work for vehicles with air conditioner 4183
13 – Crankshaft group 4184
1 Dismantling and assembling engine 4184
1 1 Assembly overview – parts l and ll 4184
1 2 Assembly overview – part I, belt drive 4186
1 3 Assembly overview – part II, cylinder block 4188
1 4 Removing and installing poly-V belt 4189
2 Cylinder block, sealing flange 4191
2 1 Assembly overview 4191
2 2 Renewing crankshaft oil seal – belt pulley end 4193
2 3 Poly V-belt pulley securing bolt tightening procedure 4194
2 4 Removing and installing drive plate 4195
2 5 Characteristics of the sealing flange and the assembly devices -T10017- and assembly device -T10134- 4197
2 6 Renewing crankshaft sealing flange – flywheel end (assembly tool -T10134-) 4198
2 6 1 Pressing sealing flange with sender wheel off crankshaft 4199
2 6 2 Pressing sealing flange with sender wheel onto crankshaft 4200
2 6 3 A – Assemble seal with sender wheel on assembly tool -T10134- 4200
2 6 4 B – Fitting assembly tool -T10134- with sealing flange to crankshaft flange 4202
2 6 5 C – Screwing assembly tool -T10134- on crankshaft flange 4203
2 6 6 D – Pressing sender wheel onto crankshaft flange using assembly tool -T10134- 4204
2 6 7 E – Checking sender wheel installation position on crankshaft 4204
2 6 8 f) Re-pressing sender wheel 4205
2 7 Renewing crankshaft sealing flange – flywheel end (assembly tool -T10017-) 4206
2 7 1 Pressing sealing flange with sender wheel off crankshaft 4207
2 7 2 Pressing sealing flange with sender wheel onto crankshaft 4208
2 7 3 A-Assembling sealing flange with sender wheel on assembly appliance -T10017- 4208
2 7 4 B – Fitting assembly tool -T10017- with sealing flange to crankshaft flange 4210
2 7 5 C – Screwing assembly tool -T10017- on crankshaft flange 4211
2 7 6 D – Pressing sender wheel onto crankshaft flange using assembly tool -T10017- 4211
2 7 7 E – Checking sender wheel installation position on crankshaft 4212
2 7 8 f) Re-pressing sender wheel 4213
2 8 Crankshaft dimensions 4213
3 Pistons and conrods 4215
3 1 Assembly overview 4215
3 2 Piston and cylinder dimensions 4218
15 – Cylinder head, valve gear 4219
1 Cylinder head 4219
1 1 Assembly overview 4219
1 2 Checking valve timing 4221
1 3 Removing, installing and tensioning toothed belt 4222
1 3 1 Removing 4223
1 3 2 Installing 4225
1 4 Checking semi-automatic toothed belt tensioner 4227
1 5 Removing and installing camshaft housing 4231
1 5 1 Removing 4231
1 5 2 Installing 4232
1 6 Removing and installing cylinder head 4233
1 6 1 Removing 4234
1 6 2 Installing 4236
1 7 Checking compression 4237
2 Valve gear 4239
2 1 Assembly overview 4239
2 2 Reworking valve seats 4242
2 3 Renewing camshaft oil seals 4243
2 4 Checking valve guides 4245
2 5 Renewing valve stem seals 4246
17 – Lubrication 4248
1 Parts of lubrication system 4248
1 1 Engine oil: 4248
1 2 Assembly overview 4248
1 3 Removing and installing oil sump 4250
1 4 Removing and installing oil pump 4252
1 5 Checking oil pressure and oil pressure switch 4255
19 – Cooling 4257
1 Parts of cooling system 4257
1 1 Assembly overview – parts of cooling system, body side 4257
1 2 Assembly overview – parts of cooling system, engine side 4259
1 2 1 Parts of cooling system – coolant controller side 4259
1 2 2 Parts of cooling system – coolant pump side 4260
1 3 Coolant hose connection diagram 4261
1 4 Draining and adding coolant 4262
1 5 Removing and installing radiator 4265
1 6 Removing and installing coolant pump 4267
20 – Fuel supply system 4269
1 Parts of fuel supply system 4269
1 1 Assembly overview – fuel tank with attachments 4269
1 2 Safety regulations for working on fuel supply 4272
1 3 Rules for cleanliness 4273
1 4 Removing and installing fuel delivery unit 4273
1 4 1 Removing 4274
1 4 2 Installing 4274
1 5 Removing and installing fuel gauge sender 4275
1 6 Removing and installing fuel tank 4275
1 6 1 Removing 4276
1 6 2 Installing 4277
1 7 Crash fuel shut-off 4277
1 8 Checking fuel pump 4277
1 8 1 Checking function and voltage supply 4280
1 8 2 Checking fuel pressure 4281
1 8 3 Checking holding pressure 4282
1 8 4 Checking fuel delivery rate 4283
1 8 5 Checking current consumption 4285
1 9 Bleeding fuel system 4285
1 10 Parts of fuel supply system (LPG) 4288
1 10 1 Emptying fuel tank (LPG) 4288
1 10 2 Emptying the gas line 4292
1 10 3 Assembly overview – gas tank (LPG) 4294
1 10 4 Removing and installing pressure relief valve 4295
1 10 5 Removing and installing inlet valve 4295
1 10 6 Removing and installing elbow on inlet valve 4296
1 10 7 Gas gauge sender -G707- 4297
1 10 8 Removing and installing fuel gauge sender 4298
1 10 9 Removing and installing gas tank valve -N495- 4298
1 10 10 Removing and installing fuel tank (LPG) 4299
2 Electronic power control (EPC) 4302
2 1 Assembly overview 4302
3 Activated charcoal filter system 4303
3 1 Assembly overview – parts of activated charcoal filter system 4303
3 2 Checking fuel tank breather 4304
24 – Mixture preparation – injection 4305
1 Injection system 4305
1 1 General notes on injection 4305
1 2 Assembly overview – parts of injection system 4305
1 3 Assembly overview – intake manifold 4308
1 4 Assembly overview – fuel rail with injectors 4309
1 5 Fuel rail, removing and installing gas rail 4309
1 5 1 Removing 4309
1 5 2 Installing 4310
1 6 Assembly overview – air filter 4310
1 7 Removing and installing air filter housing 4312
1 8 Cleaning throttle valve module -J338- 4313
1 9 Checking injectors 4313
1 10 Safety precautions 4315
1 11 Rules for cleanliness 4317
1 12 Technical data 4317
1 13 Removing and installing vaporiser on vehicles which can be operated with liquid gas 4317
1 13 1 Removing 4317
1 13 2 Installing 4319
2 Engine control unit -J623- 4320
2 1 Removing and installing engine (motor) control unit -J623- 4320
2 2 Removing and installing anti-theft engine control unit -J623- 4320
2 3 Removing and installing anti-theft engine control unit -J623- 4322
3 Gas mode control unit -J659- 4324
3 1 Removing and installing gas mode control unit -J659- 4324
3 1 1 Removing 4324
3 1 2 Installing 4324
3 2 Removing holder for gas mode control unit -J659- 4324
26 – Exhaust system 4326
1 Parts of the exhaust system 4326
1 1 Assembly overview – front exhaust system with attachments 4326
1 2 Assembly overview – silencers with mountings 4328
28 – Ignition system 4329
1 Ignition system 4329
1 1 General notes on ignition system 4329
1 2 Assembly overview – parts of ignition system 4329
1 3 Safety precautions 4330
1 4 Test data, spark plugs 4331
D3E803AE08F Fuel supply system petrol engines 4332
00 – Technical data 4336
1 Safety information 4336
1 1 Safety measures when working on fuel supply 4336
1 2 Safety precautions when using testers and measuring instruments during a road test 4336
1 3 Safety measures when working on vehicles with a start/stop system 4337
2 Identification 4338
2 1 Engine number/engine data 4338
3 General information 4339
3 1 Rules for cleanliness when working on auxiliary/supplementary heater and fuel system 4339
20 – Fuel supply system 4340
1 Fuel 4340
1 1 Assembly overview – fuel tank 4340
1 1 1 Assembly overview – fuel tank, hatchback 4340
1 1 2 Assembly overview – fuel tank, saloon 4342
1 2 Removing and installing fuel tank 4344
1 2 1 Removing and installing fuel tank, hatchback 4344
1 2 2 Removing and installing fuel tank, saloon 4349
1 3 Emptying fuel tank 4352
1 3 1 Emptying fuel tank when fuel pump is intact 4352
1 3 2 Emptying fuel tank if it is more than 3/4 full 4355
1 3 3 Emptying fuel tank if it is less than 3/4 full 4357
2 Fuel delivery unit, fuel gauge sender 4361
2 1 Assembly overview – fuel delivery unit/fuel gauge sender 4361
2 2 Removing and installing fuel delivery unit, fuel gauge sender 4362
2 3 Removing and installing fuel gauge sender -G- 4366
2 3 1 Removing and installing external fuel gauge sender -G- with two cable connections 4366
2 3 2 Removing and installing internal fuel gauge sender -G- 4367
3 Plug-in connectors 4369
3 1 Separating plug-in connectors 4369
4 Fuel filter 4374
4 1 Assembly overview – fuel filter 4374
4 2 Removing and installing fuel filter 4374
5 Activated charcoal filter system 4376
5 1 Assembly overview – activated charcoal filter system 4376
5 1 1 Assembly overview – activated charcoal filter, hatchback 4376
5 1 2 Assembly overview – activated charcoal filter, saloon 4377
5 2 Checking fuel tank breather 4377
6 Accelerator pedal 4382
6 1 Assembly overview – accelerator module 4382
7 Fuel pump 4383
7 1 Checking fuel system pressurisation pump -G6- 4383
7 1 1 Checking function and voltage supply 4383
7 1 2 Checking fuel pressure 4387
7 1 3 Checking holding pressure 4392
7 1 4 Checking fuel delivery rate 4397
7 1 5 Checking current consumption 4406
D3E804C6F70 Wheels and Tyres Specifications 4409
44 – Vehicle wheels, tyres, measurement 4413
1 9A Family ► 4413
1 1 Features of the rims 4413
1 1 1 6J X 15 4413
1 1 2 7J X 17 4414
1 1 3 7 5J X 17 4414
D3E804CADC9 4 cylinder direct injection engine (1 2 l engine 2V EA 111 turbocharger) 4416
00 – Technical data 4422
1 Engine number/engine data 4422
2 Safety precautions 4426
2 1 Safety regulations for working on fuel supply 4426
2 2 Releasing high pressure in fuel system 4427
2 3 Safety precautions when using testers and measuring instruments during a road test 4428
2 4 Safety precautions when working on the cooling system 4428
2 5 Safety precautions when working on ignition system 4429
3 General repair instructions 4430
3 1 Rules for cleanliness 4430
3 2 Foreign objects in engine 4430
3 3 Contact corrosion 4430
3 4 Routing and attachment of lines 4430
3 5 Fitting radiator and condensers 4431
10 – Removing and installing engine 4432
1 Removing and installing engine 4432
1 1 Removing engine 4432
1 1 1 Removing engine (Golf, Golf Plus, Golf Cabriolet) 4432
1 1 2 Removing engine (Touran) 4440
1 1 3 Removing engine (Polo) 4447
1 2 Installing engine 4455
1 2 1 Installing engine (Golf, Golf Plus, Golf Cabriolet) 4455
1 2 2 Installing engine (Touran) 4458
1 2 3 Installing engine (Polo) 4460
2 Assembly mountings 4463
2 1 Assembly overview – assembly mountings 4463
2 1 1 Assembly overview – assembly mountings (Golf, Golf Plus, Golf Cabriolet, Touran) 4463
2 1 2 Assembly overview – assembly mountings (Polo) 4464
13 – Crankshaft group 4466
1 Cylinder block (pulley end) 4466
1 1 Assembly overview – poly V-belt drive 4466
1 2 Removing and installing poly-V belt 4468
1 2 1 Removing and installing poly V-belt (vehicles with air-conditioning system) 4468
1 2 2 Removing and installing poly V-belt (vehicles without air-conditioning system) 4469
1 3 Removing and installing crankshaft pulley 4469
1 4 Renewing crankshaft oil seal – belt pulley end 4473
2 Cylinder block, gearbox end 4476
2 1 Assembly overview – cylinder block, gearbox end 4476
2 2 Removing and installing flywheel 4478
2 3 Removing and installing crankshaft sealing flange on gearbox side 4479
2 4 Removing and installing bracket for ancillaries 4486
2 4 1 Removing and installing ancillary bracket (top) 4486
2 4 2 Removing and installing ancillary bracket (bottom) 4489
3 Crankshaft 4491
3 1 Renewing needle bearing in crankshaft 4491
3 2 Measuring axial clearance of crankshaft 4493
3 3 Crankshaft dimensions 4494
4 Pistons and conrods 4495
4 1 Assembly overview – pistons and conrods 4495
4 2 Checking pistons and cylinder bores 4496
4 3 Removing and installing oil spray jets 4497
4 4 Separating new conrod 4498
15 – Cylinder head, valve gear 4500
1 Cylinder head 4500
1 1 Assembly overview – cylinder head 4500
1 2 Removing and installing cylinder head cover and camshaft 4503
1 3 Removing and installing cylinder head 4517
1 4 Checking compression 4523
2 Valve gear 4525
2 1 Assembly overview – valve gear 4525
2 2 Measuring axial play of camshaft 4527
2 3 Removing and installing valve stem seals 4528
3 Inlet and exhaust valves 4530
3 1 Checking valve guides 4530
3 2 Checking valves 4530
3 3 Valve dimensions 4532
3 4 Reworking valve seats 4532
4 Cover for timing chain 4533
4 1 Removing and installing top valve timing housing 4533
4 2 Removing and installing bottom valve timing housing 4536
5 Chain drive 4541
5 1 Assembly overview – timing chain 4541
5 2 Checking valve timing 4546
5 3 Adjusting valve timing 4548
5 4 Removing and installing timing chain 4557
5 5 Removing and installing timing chain and chain drive for oil pump 4566
17 – Lubrication 4570
1 Sump, oil pump 4570
1 1 Assembly overview – sump/oil pump 4570
1 2 Engine oil: 4574
1 3 Removing and installing sump 4574
1 4 Removing and installing oil pump 4579
2 Oil filter, oil pressure switch 4581
2 1 Assembly overview – oil filter 4581
2 2 Checking oil pressure and oil pressure switch 4582
2 3 Removing and installing non-return valve 4583
3 Engine oil cooler 4585
3 1 Removing and installing engine oil cooler 4585
4 Crankcase ventilation 4586
4 1 Assembly overview – crankcase breather system 4586
4 2 Removing and installing oil separator 4587
19 – Cooling 4590
1 Cooling system/coolant 4590
1 1 Coolant hose connection diagram 4590
1 2 Draining and adding coolant 4592
1 3 Checking cooling system for leaks 4596
2 Coolant pump, regulation of cooling system 4599
2 1 Assembly overview – thermostat 4599
2 2 Removing and installing coolant pump 4600
2 3 Removing and installing coolant circulation pump -V50- 4601
3 Radiator, radiator fan 4604
3 1 Assembly overview – radiator/radiator fan 4604
3 1 1 Assembly overview – radiator/radiator fan (Golf, Golf Plus, Touran, Golf Cabriolet) 4604
3 1 2 Assembly overview – radiator/radiator fan (Polo) 4606
3 2 Removing and installing radiator 4608
3 2 1 Removing and installing radiator (Golf, Golf Plus, Touran, Golf Cabriolet) 4608
3 2 2 Removing and installing radiator and low-temperature cooler (Polo) 4612
3 3 Removing and installing radiator fan -V7- 4615
3 3 1 Removing and installing radiator fan -V7- (Golf, Golf Plus, Touran, Golf Cabriolet) 4615
3 3 2 Removing and installing radiator fan -V7- (Polo) 4616
21 – Turbocharging/supercharging 4618
1 Exhaust turbocharger 4618
1 1 Assembly overview – turbocharger 4618
1 2 Removing and installing turbocharger 4620
1 3 Removing and installing charge pressure positioner -V465- 4626
2 Charge air system 4629
2 1 Assembly overview – charge air system 4629
2 1 1 Assembly overview – charge air system (Golf, Golf Plus, Touran, Golf Cabriolet) 4629
2 1 2 Assembly overview – charge air system (Polo) 4631
2 2 Removing and installing charge air cooler (intake manifold) 4633
24 – Mixture preparation – injection 4635
1 Injection system 4635
2 Air filter 4636
2 1 Assembly overview – air filter 4636
2 1 1 Assembly overview – air filter (Golf, Golf Plus, Touran, Golf Cabriolet) 4636
2 1 2 Assembly overview – air filter (Polo) 4637
2 2 Removing and installing air filter housing 4638
2 2 1 Removing and installing air filter housing (Golf, Golf Plus, Touran, Golf Cabriolet) 4638
2 2 2 Removing and installing air filter housing (Polo) 4639
3 Intake manifold 4640
3 1 Assembly overview – intake manifold 4640
3 2 Removing and installing intake manifold 4644
3 3 Removing and installing throttle valve module -J338- 4645
3 4 Cleaning throttle valve module -J338- 4647
4 Injectors 4649
4 1 Removing and installing injectors 4649
4 2 Renewing seals on injectors 4651
4 3 Cleaning injectors 4655
5 High-pressure pump 4657
5 1 Assembly overview – high-pressure pump 4657
5 2 Removing and installing high-pressure pump 4658
6 Senders and sensors 4662
6 1 Checking fuel pressure sender -G247- 4662
7 Engine control unit -J623- 4666
7 1 Removing and installing engine (motor) control unit -J623- 4666
7 1 1 Removing and installing engine control unit -J623- (Golf, Golf Cabriolet) 4666
7 1 2 Removing and installing engine control unit -J623- (Golf Plus, Touran) 4667
7 1 3 Removing and installing engine control unit -J623- (Polo) 4668
7 2 Removing and installing engine (motor) control unit -J623- with protective housing 4669
7 2 1 Removing and installing engine control unit -J623- with protective housing (Golf, Golf Cabriolet) 4669
7 2 2 Removing and installing engine control unit -J623- with protective housing (Golf Plus, Touran) 4672
7 2 3 Removing and installing engine control unit -J623- with protective housing (Polo) 4674
26 – Exhaust system 4676
1 Exhaust pipes and silencers 4676
1 1 Assembly overview – silencers 4676
1 1 1 Assembly overview – silencers (Golf, Golf Plus, Touran, Golf Cabriolet) 4676
1 1 2 Assembly overview – silencer (Polo) 4678
1 2 Separating exhaust pipes from silencers 4678
1 3 Installation position of clamp 4680
2 Exhaust gas cleaning 4682
2 1 Assembly overview – emission control 4682
2 1 1 Assembly overview – emission control (Golf, Golf Plus, Touran, Golf Cabriolet) 4682
2 1 2 Assembly overview – emission control (Polo) 4684
2 2 Removing and installing catalytic converter (Polo) 4686
28 – Ignition system 4688
1 Ignition system 4688
1 1 Assembly overview – ignition system 4688
1 2 Removing and installing engine speed sender -G28- 4690
1 3 Test data, spark plugs 4690
D3E804CBC09 Wheels and Tyres General information 4691
00 – Technical data 4695
1 General notes on rims and tyres (passenger vehicles) 4695
1 1 Technical conditions for combining rims and tyres 4696
1 2 Miscellaneous 4696
1 2 1 Wheel bolts – Tightening torques 4696
1 2 2 Wheel hole circle diameter 4696
1 2 3 Wheel specifications 4696
1 3 Remove the tyre from the arch 4698
1 4 Install the tyre in the arch 4698
1 5 Protecting the wheel centering seat against corrosion 4699
2 Curiosities about rims and tyres (passenger vehicles) 4701
2 1 Wear/tyre mileage 4701
2 1 1 Miscellaneous 4701
2 1 2 What a tyre must provide 4701
2 1 3 Wear behaviour of high speed tyres 4702
2 1 4 Factors that influence tyre durability 4702
2 1 5 Driving style: 4702
2 1 6 Tyre maintenance 4703
2 1 7 Tyres with uniform wear 4705
2 1 8 Measuring track depth 4705
2 1 9 Unilateral wear 4706
2 1 10 Wear on the outer shoulder 4709
2 1 11 Wear on the centre portion of the tyre 4710
2 1 12 Diagonal abrasion 4711
2 2 Rolling noises coming from the tyres 4711
2 2 1 General notes about rolling noises 4711
2 2 2 Wear occurrence in the shape of saw 4712
2 2 3 Blockage points 4714
2 3 Drive instability due to rim/tyre 4714
2 3 1 Causes of drive instability 4714
2 3 2 Wheel balancing 4715
2 3 3 Perform a test drive before performing the wheel balancing 4715
2 3 4 Wheel balancing with the static balancing machine 4716
2 3 5 Radial and axial deviation of concentricity of rim/tyre assembly 4717
2 3 6 Inspect the radial and axial deviations of the rim/tyre assembly with the Tyre gauge -V A G 1435- 4718
2 3 7 Inspect the radial and axial deviations of rim concentricity 4719
2 3 8 Positioning of the tyre in relation to the rim 4720
2 3 9 Tyre deformation 4721
2 4 The vehicle deviates to one side 4722
2 4 1 Miscellaneous 4722
2 4 2 Conicity 4722
2 4 3 Solution when the vehicle deviates to one side 4724
2 4 4 Selective change of wheels for tyres without tread direction 4725
2 4 5 Selective change of wheels for tyres with tread direction 4726
2 5 Damages on the tyres 4727
2 5 1 General guidelines 4727
2 5 2 Structure of a radial tyre 4727
2 5 3 Damages caused by crashes 4728
2 5 4 Damages due to cut 4730
2 5 5 Damages caused by strange bodies 4730
2 5 6 Loss of air from the tyres 4731
2 5 7 Air pressure 4731
2 5 8 Damages to the tyres due to insufficient air pressure 4732
2 5 9 Rise of temperature in tyres with insufficient air pressure 4733
2 5 10 Damages to the tyres due to assembly failure (assembly damages) 4734
2 6 Useful notes related to tyres and wheels 4736
2 6 1 Inscriptions on the side wall of the tyre 4736
2 6 2 Clarifications about tyre inscriptions 4738
2 6 3 Contractions 4739
2 6 4 Rubber valve 4740
2 6 5 Storage of tyres 4741
2 6 6 Aging of tyres 4741
2 6 7 Tyre rotation 4742
2 6 8 Notes related to assembly in case of replacement/assembly of wheel 4743
D3E8031B213 6 speed automatic gearbox 09G 4745
00 – Technical data 4749
1 General repair notes 4749
1 1 Gearbox 4749
1 2 Torque converter 4749
1 3 ATF 4749
1 4 Automatic gearbox control unit -J217- with ⇒ fuzzy logic 4749
1 5 Control units in vehicle 4749
1 6 Information on „09G gearbox“ 4749
1 7 Tools 4750
1 8 Gearbox 4750
1 9 Gaskets, seals and oil 4750
1 10 Nuts and bolts 4750
1 11 Electrical components 4751
1 12 Guided fault finding, vehicle self-diagnosis and testing 4751
2 Gearbox identification 4752
2 1 Gearbox codes 4752
3 Identification codes, engine allocation, Polo 2010 ► 4753
4 Capacities 4754
4 1 Planetary gearbox and final drive 4754
32 – Torque converter 4755
1 Torque converter 4755
1 1 Identification of torque converter 4755
1 2 Draining torque converter 4755
1 3 Removing and installing torque converter oil seal 4755
1 4 Installing torque converter 4756
37 – Controls, housing 4757
1 Connecting »tester« 4757
1 1 Connecting vehicle diagnosis, testing and informationsystem -VAS 5051- 4757
2 Electrical and electronic components and their locations 4758
3 Multifunction switch -F125- 4762
3 1 Removing multifunction switch -F125- 4762
3 2 Installing multifunction switch -F125- 4763
3 3 Adjusting multifunction switch -F125- 4764
4 Emergency release of selector lever 4766
5 Removing and installing selector lever handle 4767
6 Selector mechanism 4769
6 1 Assembly overview – selector mechanism 4769
6 2 Removing and installing selector lever and selector mechanismwith selector lever cable 4770
6 3 Checking selector lever cable 4771
6 4 Adjusting selector lever cable 4772
7 Checking selector mechanism 4774
7 1 Selector lever in „P“ position and ignition switchedon 4774
7 2 Selector lever in „N“ position and ignition switchedon 4774
7 3 Selector lever in position „Tiptronic“ 4774
7 4 Ignition and light switched on 4774
7 5 Selector lever position display 4774
8 Removing and installing gearbox; 1 6 l – 77 kW engine 4775
8 1 Specified torques 4782
9 Transporting gearbox 4784
10 Checking ATF level and topping up 4785
10 1 Checking ATF level 4786
10 2 Topping up ATF 4787
10 3 Draining and filling ATF 4787
11 ATF cooler 4789
11 1 Assembly overview – ATF cooler 4789
38 – Gears, control 4790
1 Renewing oil seal for selector shaft 4790
2 Removing and installing ATF pan 4791
2 1 Removing 4791
2 2 Installing 4792
3 Removing and installing ATF strainer 4794
3 1 Removing 4794
3 2 Installing 4794
4 Removing and installing valve body 4795
4 1 Overview – valve chest 4795
4 2 Removing valve body 4797
4 3 Installing valve body 4800
4 4 Wire routing, connectors, connections and retainer on valvebody 4802
4 5 Specified torques 4804
5 Removing and installing wiring harness for solenoid valvesand senders 4805
5 1 Removing 4805
5 2 Installing 4805
5 3 Removing and installing gearbox input speed sender -G182- 4805
5 4 Removing and installing gearbox output speed sender -G195- 4806
39 – Final drive – differential 4807
1 Renewing oil seals for flange shafts 4807
1 1 Renewing oil seal for left flange shaft 4807
1 2 Renewing seal for right flange shaft 4808
D3E8037C214 4 cylinder injection engine (1 6 l engine BiFuel) Volkswagen R GmbH 4811
00 – Technical data 4817
1 Technical data 4817
1 1 Engine number 4817
1 2 Engine data 4817
01 – Self-diagnosis 4818
1 Read event memory 4818
10 – Removing and installing engine 4819
1 Removing and installing engine 4819
1 1 Removing 4820
1 2 Installing 4823
1 3 Specified torques 4824
1 4 Additional information and assembly work for vehicles with air conditioner 4825
13 – Crankshaft group 4827
1 Dismantling and assembling engine 4827
1 1 Assembly overview – parts l and ll 4827
1 2 Assembly overview – part I, belt drive 4829
1 3 Assembly overview – part II, chain drive system 4830
1 4 Removing and installing poly-V belt 4832
1 4 1 Poly V-belt routing 4833
1 5 Removing and installing valve timing housing (timing case) 4833
1 6 Removing and installing bracket for ancillaries 4838
2 Cylinder block, sealing flange 4840
2 1 Assembly overview 4840
2 2 Removing and installing engine speed sender -G28- 4841
2 3 Renewing crankshaft oil seal, pulley end 4842
2 4 Removing and installing crankshaft pulley 4844
2 5 Renewing crankshaft sealing flange, flywheel end 4847
2 5 1 Pressing sealing flange with sender wheel off crankshaft 4848
2 5 2 Pressing sealing flange with sender wheel onto crankshaft 4849
2 5 3 A – Assemble seal with sender wheel on assembly tool -T10134- 4850
2 5 4 B – Fitting assembly tool -T10134- with sealing flange to crankshaft flange 4852
2 5 5 C – Bolting assembly tool -T10134- onto crankshaft flange 4853
2 5 6 D – Pressing sender wheel onto crankshaft flange using assembly tool -T10134- 4853
2 5 7 e) Checking sender wheel installation position on crankshaft 4853
2 5 8 f) Re-pressing sender wheel 4854
3 Crankshaft 4856
3 1 Assembly overview 4856
3 2 Crankshaft dimensions 4857
4 Pistons and conrods 4858
4 1 Assembly overview 4858
4 2 Checking piston 4859
4 3 Checking cylinder bores 4860
4 4 Piston and cylinder dimensions 4860
15 – Cylinder head, valve gear 4861
1 Cylinder head 4861
1 1 Engine differences 4861
1 2 Assembly overview – cylinder head 4862
1 2 1 Engine version -A- 4863
1 2 2 Engine version -B- 4865
1 3 Checking valve timing 4866
1 3 1 Engine version -A- 4867
1 3 2 Engine version -B- 4868
1 4 Adjusting valve timing 4871
1 4 1 Engine version -A- 4871
1 4 2 Engine version -B- 4876
1 5 Removing and installing timing chain and chain drive for oil pump 4881
1 5 1 Removing 4883
1 5 2 Installing 4885
1 6 Removing and installing camshaft housing 4888
1 6 1 Removing 4891
1 6 2 Installing 4893
1 7 Removing and installing cylinder head 4894
1 8 Checking compression 4899
2 Valve gear 4901
2 1 Assembly overview 4901
2 2 Checking camshaft axial clearance 4903
2 3 Reworking valve seats 4903
2 4 Checking valve guides 4904
2 5 Renewing valve stem seals 4905
17 – Lubrication 4908
1 Parts of lubrication system 4908
1 1 Engine oil: 4908
1 2 Assembly overview 4908
1 3 Removing and installing sump 4910
1 4 Removing and installing oil pump 4912
1 5 Checking oil pressure and oil pressure switch 4914
19 – Cooling 4917
1 Parts of cooling system 4917
1 1 Assembly overview – parts of cooling system, body side 4917
1 2 Assembly overview – parts of cooling system, engine side 4919
1 3 Coolant hose connection diagram 4922
1 4 Draining and adding coolant 4923
1 5 Checking cooling system for leaks 4926
1 6 Removing and installing cowling with radiator fan -V7- 4928
1 7 Removing and installing radiator fan -V7- 4929
1 8 Removing and installing radiator 4930
1 9 Removing and installing coolant pump 4932
20 – Fuel supply system 4936
1 Parts of fuel supply system 4936
1 1 Assembly overview – fuel tank with attachments 4936
1 1 1 Assembly overview – fuel tank 4936
1 2 Safety regulations for working on fuel supply 4939
1 3 Rules for cleanliness 4939
1 4 Emptying fuel tank 4940
1 4 1 Emptying fuel tank if it is more than 3/4 full 4940
1 4 2 Emptying fuel tank if it is less than 3/4 full 4942
1 5 Removing and installing fuel delivery unit 4944
1 6 Removing and installing external fuel gauge sender -G- with 2 cable connections 4947
1 7 Removing and installing interior fuel gauge sender -G- 4948
1 8 Removing and installing fuel tank 4949
1 9 Removing and installing fuel filter 4951
1 10 Crash fuel shut-off 4952
1 11 Checking fuel pump 4952
1 11 1 Checking function and voltage supply 4954
1 11 2 Checking fuel pressure 4956
1 11 3 Checking holding pressure 4958
1 11 4 Checking fuel delivery rate 4959
1 11 5 Checking current consumption 4961
1 12 Bleeding fuel system 4962
1 13 Parts of fuel supply system (LPG) 4964
1 13 1 Emptying fuel tank (LPG) 4964
1 13 2 Emptying the gas line 4968
1 13 3 Assembly overview – gas tank (LPG) 4971
1 13 4 Removing and installing pressure relief valve 4972
1 13 5 Removing and installing inlet valve 4973
1 13 6 Removing and installing elbow on inlet valve 4974
1 13 7 Gas gauge sender -G707- 4975
1 13 8 Removing and installing fuel gauge sender 4976
1 13 9 Removing and installing gas tank valve -N495- 4976
1 13 10 Removing and installing fuel tank (LPG) 4977
2 Electronic power control (EPC) 4980
2 1 Assembly overview 4980
3 Activated charcoal filter system 4981
3 1 Assembly overview 4981
3 1 1 Assembly overview – activated charcoal filter 4981
3 2 Checking fuel tank breather 4982
3 2 1 Checking activated charcoal filter 4982
24 – Mixture preparation – injection 4983
1 Injection system 4983
1 1 General notes on injection 4983
1 2 Assembly overview – intake manifold 4983
1 3 Assembly overview – fuel rail with injectors 4985
1 4 Removing and installing injectors 4985
1 5 Fuel rail, removing and installing gas rail 4986
1 5 1 Removing 4986
1 5 2 Installing 4987
1 6 Removing and installing gas injectors 4987
1 7 Removing and installing gas rail sensor -G401- 4988
1 8 Assembly overview – air filter 4989
1 9 Removing and installing air filter housing 4990
1 10 Cleaning throttle valve module -J338- 4991
1 11 Safety precautions 4992
1 12 Rules for cleanliness 4993
1 13 Technical data 4993
1 14 Renewing filter for LPG system 4993
1 14 1 Renewing the gas filter 4994
1 14 2 Renewing the paper filter on the vaporiser 4994
1 15 Removing and installing vaporiser on vehicles which can be operated with liquid gas 5002
1 15 1 Removing 5003
1 15 2 Installing 5004
2 Checking components 5006
2 1 Checking injectors for leaks and quantity injected 5006
2 1 1 Check for leaks 5006
2 1 2 Checking quantity injected 5007
3 Engine control unit -J623- 5009
3 1 Removing and installing engine (motor) control unit -J623- 5009
3 2 Vehicles with anti-theft secured engine control unit -J623- 5009
4 Gas mode control unit -J659- 5011
4 1 Removing and installing gas mode control unit -J659- 5011
4 1 1 Removing 5011
4 1 2 Installing 5011
4 2 Removing holder for gas mode control unit -J659- 5011
26 – Exhaust system 5013
1 Parts of the exhaust system 5013
1 1 Assembly overview – catalytic converters and attachments 5013
1 2 Assembly overview – silencers with mountings, hatchback 5015
1 3 Separating front and rear silencers 5015
28 – Ignition system 5018
1 Ignition system 5018
1 1 Assembly overview – ignition system 5018
1 2 Removing and installing ignition coils with output stage 5019
1 3 Safety precautions 5021
1 4 Test data, spark plugs 5022
D3E8043DC69 5 speed manual gearbox 0CF 5023
00 – Technical data 5027
1 Safety information 5027
1 1 Safety measures when working on vehicles with a start/stop system 5027
2 Identification 5028
2 1 Gearbox identification 5028
3 Repair instructions 5030
3 1 General repair instructions 5030
4 Technical data 5034
4 1 Allocation gearbox – engine 5034
4 1 1 Allocation gearbox – engine, up! 5034
4 1 2 Allocation of gearbox to engine – Polo, Ameo 5035
4 2 Capacities 5036
4 3 Calculation of gear ratios 5036
5 Overview – power transmission 5037
6 Electrical components 5039
6 1 Overview of fitting locations – electrical components 5039
6 1 1 Overview of fitting locations – electrical components, manual gearbox 5039
6 1 2 Overview of fitting locations – electrical components, clutch mechanism, up! 5039
6 1 3 Overview of fitting locations – electrical components, clutch mechanism, Polo 5040
30 – Clutch 5041
1 Clutch mechanism 5041
1 1 Overview of fitting locations – clutch mechanism 5041
1 1 1 Overview of fitting locations – clutch mechanism, up! 5041
1 1 2 Overview of fitting locations – clutch mechanism, Polo 5042
1 2 Assembly overview – pedal cluster 5043
1 2 1 Assembly overview – pedal cluster, up! 5043
1 2 2 Assembly overview – pedal cluster, Polo 5045
1 3 Assembly overview – clutch hydraulics 5047
1 3 1 Assembly overview – clutch hydraulics, up! 5047
1 3 2 Assembly overview – clutch hydraulics, Polo, LHD vehicles 5049
1 3 3 Assembly overview – clutch hydraulics, Polo RHD models, Ameo 5051
1 4 Assembly overview – clutch release mechanism 5053
1 5 Removing and installing bearing bush 5055
1 6 Removing and installing clutch pedal 5056
1 6 1 Removing and installing clutch pedal, up! 5056
1 6 2 Removing and installing clutch pedal, Polo, LHD vehicles 5056
1 6 3 Removing and installing clutch pedal, Ameo, Polo RHD models 5058
1 7 Removing and installing over-centre spring, Polo, Ameo 5059
1 8 Removing and installing extension spring 5061
1 8 1 Removing and installing extension spring, up! 5061
1 8 2 Removing and installing extension spring, Polo, Ameo 5063
1 9 Removing and installing mounting bracket 5063
1 9 1 Removing and installing mounting bracket, up! 5063
1 9 2 Removing and installing mounting bracket, Polo, Ameo 5068
1 10 Removing and installing clutch master cylinder 5074
1 10 1 Removing and installing clutch master cylinder, up! 5074
1 10 2 Removing and installing clutch master cylinder, Polo, Ameo 5075
1 11 Removing and installing clutch slave cylinder 5077
1 12 Removing and installing lines for clutch mechanism 5079
1 13 Bleeding clutch mechanism 5084
1 14 Removing and installing clutch pedal switch -F36- 5086
1 15 Checking clutch master cylinder and clutch slave cylinder 5087
1 16 Removing and installing clutch position sender -G476- 5089
1 16 1 Removing and installing clutch position sender -G476-, up! 5089
1 16 2 Removing and installing clutch position sender -G476-, Polo, Ameo 5089
1 17 Repairing clutch release mechanism 5092
2 Clutch 5094
2 1 Assembly overview – clutch 5094
2 2 Removing and installing clutch 5094
34 – Controls, housing 5100
1 Selector mechanism 5100
1 1 Installation position – selector mechanism 5100
1 2 Overview – selector mechanism 5101
1 3 Assembly overview – gear knob and cover 5102
1 4 Assembly overview – Gear lever and selector housing 5104
1 4 1 Assembly overview – gear lever and selector housing; gear lever is NOT “pushed down” to engage reverse gear 5104
1 4 2 Assembly overview – gear lever and selector housing; gear lever is “pushed down” to engage reverse gear 5106
1 5 Assembly overview – selector cables 5107
1 6 Removing and installing gear knob 5109
1 7 Emblem identification 5112
1 8 Removing and installing selector mechanism 5113
1 9 Repairing selector mechanism 5116
1 10 Adjusting selector mechanism 5122
1 11 Checking selector mechanism 5124
1 12 Dismantling and assembling selector mechanism 5125
1 12 1 Dismantling and assembling selector mechanism, – gear lever is NOT “pushed down” to engage reverse gear 5125
1 13 Removing and installing selector cable 5130
1 13 1 Removing and installing selector cable, – gear lever is NOT “pushed down” to engage reverse gear 5130
1 14 Renewing selector shaft seal 5132
2 Removing and installing gearbox 5134
2 1 Specified torques for gearbox 5134
2 2 Removing gearbox 5134
2 2 1 Removing gearbox, up! 5134
2 2 2 Removing gearbox, Polo 5142
2 3 Installing gearbox 5150
2 3 1 Installing gearbox, up! 5150
2 3 2 Installing gearbox, Polo 5156
2 3 3 Installing gearbox, Ameo, Polo IN 5161
3 Assembly mountings 5165
3 1 Assembly overview – assembly mountings 5165
3 1 1 Assembly overview – assembly mountings, up! 5165
3 1 2 Assembly overview – assembly mountings, Polo, Ameo 5167
4 Gearbox transport 5170
5 Dismantling and assembling gearbox 5172
5 1 Schematic overview – gearbox 5172
5 2 Assembly overview – gearbox 5172
5 3 Assembly overview – clutch housing 5173
5 4 Assembly overview – selector unit 5174
5 5 Assembly overview – shafts, differential, selector mechanism 5175
5 6 Removing and installing selector unit with gearbox installed 5177
5 7 Renewing selector shaft sleeve 5181
5 8 Dismantling and assembling gearbox 5182
6 Gearbox housing, clutch housing 5190
6 1 Assembly overview – gearbox housing and clutch housing 5190
7 Securing to engine and gearbox support 5193
8 Gear oil 5195
8 1 Checking gear oil level 5195
8 2 Draining and filling gear oil 5195
35 – Gears, shafts 5198
1 Input shaft 5198
1 1 Assembly overview – input shaft 5198
1 2 Dismantling and assembling input shaft 5200
1 3 Adjusting input shaft 5208
1 4 Renewing input shaft seal 5213
2 Output shaft 5216
2 1 Assembly overview – output shaft 5216
2 2 Dismantling and assembling output shaft 5219
2 3 Adjusting output shaft 5233
3 Reverse shaft 5239
3 1 Removing and installing reverse shaft 5239
39 – Final drive – differential 5240
1 Oil seals 5240
1 1 Overview of fitting locations – oil seals 5240
1 2 Renewing left seal 5240
1 2 1 Renewing seal for left drive shaft 5240
1 3 Renewing right seal 5243
1 3 1 Renewing seal for right drive shaft 5243
2 Differential 5244
2 1 Assembly overview – differential 5244
2 2 Dismantling and assembling differential 5246
2 3 Adjusting differential 5254
3 Adjustment overview 5260
D3E8044B8B0 4 cylinder diesel engine (1 6 l engine common rail) 5261
00 – Technical data 5267
1 Technical data 5267
1 1 Engine number 5267
1 2 Engine data 5267
10 – Removing and installing engine 5269
1 Removing and installing engine 5269
1 1 Removing and installing engine cover panel 5269
1 2 Removing engine 5270
1 3 Separating engine from gearbox 5278
1 4 Securing engine on engine and gearbox support 5280
1 5 Installing engine 5282
1 6 Notes on installing 5284
1 7 Assembly mountings 5286
1 8 Setting up support bracket 5287
13 – Crankshaft group 5290
1 Removing and installing poly V-belt 5290
1 1 Assembly overview – poly V-belt drive without air conditioningcompressor 5290
1 2 Assembly overview – poly V-belt drive with tensioning elementand air conditioner compressor 5291
1 3 Removing and installing poly V-belt without air conditionercompressor 5291
1 4 Removing and installing poly V-belt with tensioning element 5292
1 5 Removing and installing tensioning element for poly V-belt 5293
2 Dismantling and assembling engine 5297
2 1 Assembly overview – ancillary bracket 5297
2 2 Removing and installing ancillary bracket 5297
2 3 Removing and installing vibration damper 5299
2 4 Assembly overview – toothed belt drive 5300
2 5 Removing and installing engine bracket 5302
2 6 Assembly overview – crankcase 5307
3 Removing and installing sealing flange and flywheel 5309
3 1 Assembly overview – sealing flanges and flywheel 5309
3 2 Removing and installing dual-mass flywheel 5310
3 3 Renewing crankshaft sealing flange – flywheel end 5312
3 3 1 Pressing out sealing flange with sender wheel 5313
3 3 2 Pressing in sealing flange with sender wheel 5314
3 3 3 a) Securing seal with sender wheel on assembly tool -T10134- 5315
3 3 4 b) Securing assembling tool -T10134- with sealing flange on crankshaft flange 5316
3 3 5 c) Bolting assembly tool -T10134- onto crankshaft flange 5317
3 3 6 D – Pressing sender wheel onto crankshaft flange using assembly tool -T10134- 5318
3 3 7 E – Checking sender wheel installation position on crankshaft 5318
3 3 8 F – Re-pressing sender wheel 5319
3 4 Renewing crankshaft oil seal – pulley end 5320
3 5 Removing and installing sealing flange – pulley end 5321
4 Removing and installing engine speed sender -G28- 5324
5 Pistons and conrods 5326
5 1 Assembly overview – pistons and conrods 5326
5 2 Measuring piston projection at „TDC“ 5330
5 3 Piston and cylinder dimensions 5331
5 4 Measuring radial clearance of conrods 5331
6 Crankshaft 5333
6 1 Assembly overview – crankshaft 5333
6 1 1 Crankshaft dimensions 5333
6 1 2 Measuring axial clearance of crankshaft 5334
15 – Cylinder head, valve gear 5335
1 Cylinder head 5335
1 1 Assembly overview – cylinder head 5335
1 2 Removing and installing Hall sender -G40- 5337
1 3 Assembly overview – cylinder head cover 5340
1 4 Removing and installing cylinder head cover 5341
1 5 Removing and installing injector seal in cylinder head cover 5345
1 6 Removing, installing and tensioning toothed belts 5348
1 6 1 Differences between versions of tensioning roller 5350
1 6 2 Removing 5350
1 6 3 Installing (adjusting valve timing) 5356
1 7 Removing and installing cylinder head 5362
1 7 1 Removing 5366
1 7 2 Installing 5374
1 8 Removing and installing vacuum pump 5376
1 9 Checking compression 5376
2 Valve gear 5379
2 1 Assembly overview – valve gear 5379
2 2 Measuring axial clearance of camshaft 5380
2 3 Measuring radial clearance of camshafts 5381
2 4 Valves 5382
2 4 1 Valve dimensions 5382
2 4 2 Reworking valve seats 5382
2 4 3 Checking valve guides 5382
2 4 4 Renewing valve stem seals with cylinder head installed 5382
2 5 Renewing valve stem seals with cylinder head removed 5385
2 5 1 Checking valves 5388
2 6 Removing and installing camshafts 5388
2 6 1 Removing 5390
2 6 2 Installing 5391
2 7 Checking hydraulic compensation elements 5395
2 8 Removing and installing camshaft oil seal 5396
17 – Lubrication 5398
1 Engine oil 5398
1 1 Oil capacities 5398
1 2 Checking engine oil level 5398
2 Parts of lubrication system 5399
2 1 Assembly overview – oil pump, sump 5399
2 2 Removing and installing oil sump 5402
2 3 Removing and installing oil pump 5406
3 Oil filter bracket, oil pressure, engine oil cooler and oilsupply line 5407
3 1 Assembly overview – oil filter bracket and engine oil cooler 5407
3 2 Removing and installing oil filter bracket with engine oilcooler 5409
3 3 Removing and installing engine oil cooler 5412
3 4 Checking engine oil cooler for leaks 5415
3 5 Checking oil pressure and oil pressure switch 5417
3 5 1 Checking oil pressure switch 5418
3 5 2 Checking oil pressure 5419
3 6 Removing and installing oil pressure switch -F1- 5420
4 Oil supply line and turbocharger support 5421
4 1 Assembly overview – oil supply line and turbocharger support 5421
4 2 Removing and installing oil supply line and turbocharger support 5422
19 – Cooling 5426
1 Cooling system 5426
1 1 Assembly overview – parts of cooling system, body side 5427
1 2 Assembly overview – cowling with radiator fan -V7- 5429
1 3 Parts of cooling system, engine side 5430
1 4 Assembly overview – coolant pump and 4/2-way valve with thermostat 5431
1 5 Removing and installing 4/2-way valve with thermostat 5431
1 6 Coolant hose schematic diagram 5436
1 7 Removing and installing cowling with radiator fan -V7- 5437
1 8 Removing and installing radiator and detaching charge air coolerfrom radiator 5438
1 9 Removing and installing coolant temperature sender -G62- 5442
1 10 Removing and installing coolant temperature senderat radiator outlet -G83- 5443
1 11 Removing and installing coolant circulation pump 2 -V178- 5444
1 12 Removing and installing coolant pump 5445
1 13 Removing and installing front coolant pipe 5447
1 14 Removing and installing right coolant pipes 5450
2 Draining and replenishing coolant 5452
2 1 Draining and filling coolant 5452
2 1 1 Draining 5453
2 1 2 Filling 5455
2 2 Checking cooling system for leaks 5456
20 – Fuel supply system 5459
1 Safety precautions when working on fuel supply system 5459
2 Rules for cleanliness 5460
3 Repair instructions if tank has been filled with incorrectfuel 5461
3 1 Step 1 (Engine was started with incorrect fuel) 5461
3 2 Step 2 (Engine was not started with incorrect fuel) 5462
3 3 Step 3 (There are metal particles in fuel delivery unit andfuel tank) 5463
3 4 Step 4 (There are no metal particles in fuel delivery unitand fuel tank) 5464
3 5 Step 5 (There are metal particles in high-pressure pump) 5464
3 6 Step 6 (There are no metal particles in high-pressure pump) 5464
4 Emptying fuel tank 5465
4 1 Emptying fuel tank when fuel pump is intact 5465
4 2 Emptying fuel tank if it is more than 3/4 full 5468
4 3 Emptying fuel tank if it is less than 3/4 full 5469
5 Parts of fuel supply system 5471
5 1 Fuel tank 5471
5 1 1 Assembly overview – fuel tank 5471
5 1 2 Removing and installing fuel tank 5473
5 1 3 Removing 5474
5 1 4 Installing 5475
5 2 Removing and installing fuel delivery unit 5476
5 2 1 Removing 5476
5 2 2 Installing 5477
6 Fuel gauge sender – G 6- 5479
6 1 Removing and installing fuel gauge sender – G 6- in vehicles with 0 5 bar low-pressure fuel system 5479
6 2 Removing and installing fuel gauge sender – G 6-, vehicles with 6 0 bar low-pressure fuel system 5480
7 Repairing fuel supply 5481
7 1 Assembly overview – fuel filter 5481
7 2 Removing and installing fuel filter 5483
7 3 Assembly overview – accelerator mechanism 5483
8 Testing low-pressure fuel systems (fuel pump) 5485
8 1 Distinguishing features of the various low-pressure fuel systems 5485
8 2 Checking fuel pump, vehicles with 0 5 barlow-pressure fuel system 5488
8 2 1 Checking fuel system pressurisation pump – G 6- delivery rate 5488
8 2 2 Checking voltage supply of fuel system pressurisationpump – G 6- 5489
8 2 3 Checking current consumption of fuel system pressurisationpump -G6- 5490
8 3 Checking fuel pump, vehicles with 6 0 barlow-pressure fuel system 5491
8 3 1 Checking delivery pressure of fuel pump 5492
8 3 2 Checking fuel system pressurisation pump delivery rate 5496
8 3 3 Checking voltage supply of fuel system pressurisationpump 5499
8 3 4 Checking current consumption of fuel system pressurisationpump 5500
21 – Turbocharging/supercharging 5503
1 Charge air system with turbocharger 5503
1 1 Safety precautions 5503
1 2 Rules for cleanliness 5503
1 3 Assembly overview – turbocharger with attachments 5504
1 3 1 Tightening exhaust temperature sender 1 -G235- 5506
1 4 Removing and installing turbocharger 5507
1 5 Assembly overview – parts of charge air cooling 5511
1 6 Removing and installing charge air cooler 5513
1 7 Removing and installing charge air pipe »hot« side 5513
2 Checking charge air system 5515
2 1 Checking charge air system for leaks 5515
3 Vacuum system 5517
3 1 Vacuum hose schematic diagram 5517
3 2 Testing vacuum system 5518
23 – Mixture preparation – injection 5519
1 Safety precautions, rules for cleanliness, assembly instructions 5519
1 1 Safety precautions 5519
1 2 Rules for cleanliness 5519
1 3 Instructions for working on fuel system 5520
1 4 To avoid any risk of injuries to persons and/or the destructionof the injection and glow plug system, the following must be noted 5521
2 Mixture preparation, 1 6 l common rail 5522
2 1 System layouts 5522
2 1 1 System layout: vehicles with 0 5 bar low-pressure fuel system 5522
2 1 2 System layout: vehicles with 6 0 bar low-pressure fuel system 5524
2 2 Assembly overview – fuel system 5526
2 3 Assembly overview – installation position of clamp 5532
3 Removing and installing components of the diesel direct injectionsystem 5533
3 1 Removing and installing injectors 5533
3 1 1 Removing 5534
3 1 2 Installing 5536
3 2 Removing and installing high-pressure lines 5538
3 2 1 Removing high-pressure lines between high-pressure accumulatorand injectors 5539
3 2 2 Removing high-pressure line between high-pressure accumulatorand high-pressure pump 5540
3 2 3 Installing high-pressure lines 5541
3 3 Removing and installing high-pressure pump 5544
3 4 Removing and installing high-pressure accumulator 5548
3 5 Removing and installing fuel pressure regulating valve – N276- 5552
3 6 Removing and installing fuel pressure sender – G247- 5554
4 Filling/bleeding/checking the diesel direct injection system 5557
4 1 Filling/bleeding, checking high-pressure pump/fuel system 5557
4 1 1 Filling/bleeding high-pressure pump/fuel system 5557
4 1 2 Pressure testing high-pressure pump 5558
4 1 3 Checking return flow rate at high-pressure pump 5559
4 2 Checks on high-pressure accumulator 5561
4 2 1 Checking fuel pressure regulating valve – N276- 5561
4 2 2 Checking fuel pressure sender – G247- 5562
4 3 Checks on injector 5563
4 3 1 Checking return flow rate of injectors 5563
4 3 2 Checking injectors with vacuum 5564
4 4 Checking fuel system for leaks 5566
4 5 Check pressure retention valve in fuel return line 5567
5 Intake manifold 5569
5 1 Assembly overview – intake manifold with attachments (vehicleswith intake manifold flap -V157-) 5569
5 2 Assembly overview – intake manifold with attachments (vehicleswithout intake manifold flap) 5570
5 3 Removing and installing intake manifold (vehicles with intake manifold flap -V157-) 5571
5 4 Removing and installing intake manifold (vehicles without intake manifold flap -V157-) 5574
5 5 Removing and installing throttle valve module -J338- 5578
6 Air filter 5579
6 1 Assembly overview – air filter 5579
6 1 1 Removing and installing air filter housing 5580
7 Engine control unit 5582
7 1 Removing and installing engine control unit with no ant-theftprotection 5582
7 2 Removing and installing anti-theft engine control unit 5582
26 – Exhaust system 5584
1 Exhaust system 5584
1 1 Assembly overview – front exhaust pipe with catalytic converter 5584
1 2 Removing and installing catalytic converter 5585
1 2 1 Removing 5586
1 2 2 Installing 5590
1 3 Assembly overview – silencer 5590
1 3 1 Separating catalytic converter and silencer 5591
1 4 Aligning exhaust system free of stress 5592
2 Exhaust gas recirculation system 5594
2 1 Assembly overview – parts of exhaust gas recirculation system 5594
2 2 Checking changeover for exhaust gas recirculation cooler 5595
2 3 Removing and installing exhaust gas recirculation system 5596
28 – Glow plug system 5600
1 Removing, installing and checking glow plugs 5600
D3E8045B154 Wheels and Tyres Guide 5603
44 – Wheels, tyres, vehicle geometry 5607
1 Wheel and tyre combinations 5607
1 1 General 5607
1 2 Explanations regarding world regions 5608
1 3 Polo – model year 2010 to model year 2012 (type 6R) 5609
1 4 Polo – model year 2013 to model year 2014 (type 6R) 5612
1 5 Polo BlueMotion Technology – model year 2010 to model year 2014 (type 6R) 5614
1 6 Polo BlueMotion – model year 2010 to model year 2014 (type 6R) 5618
1 7 Polo BlueGT – model year 2013 to model year 2014 (type 6R) 5619
1 8 CrossPolo – model year 2011 to model year 2012 (type 6R) 5620
1 9 CrossPolo – model year 2013 to model year 2014 (type 6R) 5622
1 10 Polo GTI – model year 2011 to model year 2014 (type 6R) 5624
1 11 Polo R WRC – Model year 2014 (type 6R) 5626
2 Wheel allocation 5628
2 1 5 J x 14 5628
2 2 51/2 J x 15 5629
2 3 6 J x 15 offset 38 5629
2 4 6 J x 15 offset 40 5630
2 5 6 J x 16 5631
2 6 7 J x 16 5632
2 7 7 J x 17 5633
2 8 71/2 J x 17 5635
2 9 71/2 J x 18 5636
3 Recommended summer tyres 5637
3 1 Recommended summer tyres, worldwide except North America and China 5637
3 2 Recommended summer tyres, Japan, Indonesia, South Korea 5638
3 3 Recommended summer tyres, Russia, Ukraine 5638
4 Recommended all-season tyres, worldwide except North America and China 5639
5 Recommended winter tyres, worldwide except North America and China 5640
6 Recommended temporary spare tyres and wheels 5641
D3E8046D49A Wheels and Tyres Guide – General Information 5643
44 – Wheels, tyres, vehicle geometry 5651
1 Instructions on using the guide 5651
1 1 Overview 5651
1 1 1 Wheels and Tyres Guide – General Information 5651
1 1 2 Wheels and Tyres Guide – Vehicle-specific section 5651
1 2 General information 5651
1 3 Notes 5652
1 4 Determining correct wheel and tyre combinations, according to NEDC with tyre package 5653
1 4 1 Determining the required tyre package via PR number 5653
1 4 2 Determining the required tyre package via version key in the vehicle registration certificate part 1 5653
1 5 Determining correct wheel and tyre combinations according to WLTP 5654
1 5 1 Vehicle registration certificate part 1 5654
1 5 2 COC document, item 0 10 5656
1 6 NEDC, WLTP and RDE 5656
1 6 1 What are NEDC, WLTP and RDE? 5656
1 6 2 What are the differences between WLTP and RDE? 5656
1 6 3 Since when are WLTP and RDE valid? 5656
1 7 Definition of tyre package 5656
1 8 Explanations regarding world regions 5657
2 Legislative and technical conditions 5659
2 1 Legislative conditions 5659
2 1 1 Permissible wheel and tyre combinations in Germany 5659
2 1 2 Vehicles with Tyre Pressure Monitoring System 5659
2 2 Technical conditions 5660
2 3 Load-carrying capacity depending on vehicle speed, winter tyres 5660
2 4 Vehicle registration documents since 01 10 2005 5662
2 5 COC document (EEC Certificate of Conformity) 5663
2 6 EU general type approval number, sales type and sales or trade designation 5663
3 Wheel change 5666
3 1 Fitting instructions 5666
3 2 Protecting wheel centring seat against corrosion 5669
3 3 Fitting wheels 5669
3 4 Position of anti-theft wheel bolts for steel wheels 5670
4 Fitting tyre 5672
4 1 Pressing tyre off wheel rim 5672
4 2 Removing tyre sealant 5673
4 3 Removing tyre from wheel 5673
4 3 1 Removing tyres, wheels without and with tyre pressure monitoring 5673
4 3 2 Removing tyres, run-flat tyres, ultra-high-performance tyres 5675
4 4 Ensuring proper assembly temperature for tyres 5677
4 5 Fitting tyre 5678
4 5 1 Mounting tyre, wheels without and with tyre pressure monitoring 5678
4 5 2 Mounting tyre, run-flat tyres, ultra-high performance tyres 5680
4 6 Matching wheel rims and tyres 5682
4 7 Checking radial and lateral runout of wheels and tyres 5683
4 7 1 Checking radial and lateral runout of wheels and tyres, tolerances 5683
4 7 2 Checking radial and lateral runout on wheels and tyres with tyre gauge 5684
4 8 Matching wheels and tyres 5685
4 9 Balancing wheel 5686
4 9 1 Conditions 5686
4 9 2 Balancing wheel on stationary wheel balancer 5686
4 9 3 Balancing wheel with finish balancer 5689
4 9 4 Checking radial and lateral run-out on wheel rim 5690
4 10 Tyre sealant disposal 5691
5 Tyre Pressure Monitoring System 5692
5 1 System description – Tyre Pressure Monitoring System 5692
5 1 1 System description – Tyre Pressure Monitoring System with indirect measurement (Tyre Pressure Loss Indicator) 5692
5 1 2 System description – Tyre Pressure Monitoring System with direct measurement (with tyre pressure sensor) 5694
5 1 3 Button behaviour – Tyre Pressure Monitoring System with direct measurement (with tyre pressure sensor) 5694
5 1 4 System description – Tyre Pressure Monitoring System, Tyre Pressure Monitoring System (TPMS) with autolocation 5695
5 2 Overview of fitting locations – Tyre Pressure Monitoring System 5696
5 2 1 Overview of fitting locations – Tyre Pressure Monitoring System (TPMS) with autolocation 5696
5 2 2 Overview of fitting locations – Tyre Pressure Monitoring System, Trigger 5697
5 2 3 Overview of fitting locations – Tyre Pressure Monitoring System, Autolocation 5699
5 3 Assembly overview – tyre pressure sensor 5700
5 3 1 Assembly overview – tyre pressure sensor, tyre pressure sensor with valve 5700
5 3 2 Assembly overview – tyre pressure sensor, tyre pressure sensor without valve, version 1 5702
5 3 3 Assembly overview – tyre pressure sensor, tyre pressure sensor without valve, version 2 5704
5 4 Removing and installing tyre pressure sensor -G222-/-G223-/-G224-/-G225- 5705
5 4 1 Removing and installing tyre pressure sensor, tyre pressure sensor with valve 5705
5 4 2 Removing and installing tyre pressure sensor, tyre pressure sensor without valve, version 1 (customer service version) 5706
5 4 3 Removing and installing tyre pressure sensor, tyre pressure sensor without valve, version 1 (production version) 5708
5 4 4 Removing and installing tyre pressure sensor -G222-/-G223-/-G224-/-G225-, version 2 5711
5 5 Removing and installing Tyre Pressure Monitoring System control unit -J502- 5713
5 5 1 Removing and installing Tyre Pressure Monitoring System control unit -J502-, Arteon 2018, Arteon 2021, Arteon Shooting Brake 2021, Passat 2015, Passat Estate 2015, Passat 2019, Passat Estate 2019 5714
5 5 2 Removing and installing tyre Tyre Pressure Monitoring System control unit, Passat 2011, Passat Estate 2011 5716
5 5 3 Removing and installing Tyre Pressure Monitoring System control unit, CC 2010, CC 2012, Passat CC 2009 5716
5 5 4 Removing and installing Tyre Pressure Monitoring System control unit, Phaeton 2003 5716
5 5 5 Removing and installing Tyre Pressure Monitoring System control unit -J502-, Touran 2016 5716
5 5 6 Removing and installing Tyre Pressure Monitoring System control unit -J502-, Tiguan 2008 5717
5 5 7 Removing and installing Tyre Pressure Monitoring System control unit -J502-, Tiguan 2016, Tiguan 2017 (BW2), Tiguan 2021 5718
5 5 8 Removing and installing Tyre Pressure Monitoring System control unit, up to model year 2014, Touareg 2010 5719
5 5 9 Removing and installing Tyre Pressure Monitoring System control unit, as of model year 2015, Touareg 2015 5720
5 5 10 Removing and installing Tyre Pressure Monitoring System control unit, Touareg 2018 5721
5 5 11 Removing and installing bracket for Tyre Pressure Monitoring System control unit, Touareg 2015 5722
5 6 Removing and installing tyre pressure monitor sender unit in wheel housing 5722
5 6 1 Removing and installing sender unit for Tyre Pressure Monitoring System in front left/front right wheel housing -G431/G432-, Touareg 2010, Touareg 2015 5722
5 6 2 Removing and installing sender unit for Tyre Pressure Monitoring System in rear left/rear right wheel housing -G433/G434-, Touareg 2010, Touareg 2015 5723
5 6 3 Removing and installing sender unit for Tyre Pressure Monitoring System in wheel housing, Phaeton 2003 5724
6 Wheel bolts 5725
6 1 Wheel bolts, versions 5725
6 2 Wheel bolts, anti-theft wheel bolt 5727
6 3 Wheel bolts, adapter sets for anti-theft wheel bolts 5727
7 Information on tyres 5730
7 1 Identification markings on the tyre sidewall 5730
7 2 Tyre dimension 5732
7 3 Load rating code/load index (LI) 5732
7 4 Speed rating code 5733
7 5 EU tyre label 5733
7 5 1 EU tyre label, summary 5733
7 5 2 EU tyre label, objectives 5734
7 5 3 EU tyre label, categories 5735
7 6 Structure of a radial belted tyre 5739
7 6 1 Cross section of a radial belted tyre 5739
7 6 2 Run-flat tyres, structure and identification of a SST tyre 5740
7 6 3 Run-flat tyres, seal inside technology 5742
7 7 Run-flat tyre, SST (Self Supporting Tyre) 5745
7 7 1 Run-flat tyres – general information 5745
7 7 2 Run-flat tyres, retrofitting/requirements when using run-flat tyres 5746
7 7 3 Run-flat tyres, repair work 5746
7 8 Tyre storage 5746
7 9 Reinforced and Extra Load (XL) tyres 5747
7 10 M+S tyres 5748
7 11 Winter tyres with speed symbol V 5750
7 12 All-season tyres 5751
7 13 Optimised rolling resistance tyres 5752
7 14 Tyre ageing 5752
7 15 Tyres with flange protection 5754
7 16 Tyre sizes for vehicles with all-wheel drive 5754
7 17 Increase in temperature due to insufficient tyre pressure 5754
8 Tyre sealant 5756
8 1 Models with breakdown set 5756
8 2 Storage life 5756
8 3 Disposal 5756
9 Information about wheels (rims) 5757
9 1 Structure of wheel (rim) 5757
9 2 Identification 5758
9 3 Composite wheels 5759
9 4 Care and maintenance of alloy wheel rims 5759
9 5 Restoring alloy wheels 5759
9 6 Removing and installing hub cover for alloy wheels with open threaded connection 5760
9 7 Renewing trim elements 5761
9 7 1 Renewing trim elements, bonded trim elements 5761
9 7 2 Renewing trim elements, bolted trim elements 5765
9 8 Removing and installing valve 5766
9 8 1 Removing and installing valve, description of the valve 5766
9 8 2 Removing and installing valve, rubber valve 5767
9 8 3 Removing and installing valve, metal valve 5768
10 Handling problems 5770
10 1 Rolling noise 5770
10 1 1 General notes on tyre noise 5770
10 1 2 Flat spots (from locking wheels) 5771
10 2 Vehicle pulls to one side 5772
10 2 1 General information 5772
10 2 2 Conicity 5772
10 2 3 Remedies when vehicle pulls to one side 5774
10 2 4 Strategic rotation of wheels for non-directional tyres 5775
10 2 5 Strategic rotation of wheels having unidirectional tyres 5776
10 3 Vibration 5777
10 3 1 Vibration, causes for vibration 5777
10 3 2 Vibration, conducting a road test before balancing wheels 5777
10 3 3 Vibration, vibration control system 5777
10 4 Eliminating flat spots caused by storage or handling 5778
11 Evaluating tyres 5780
11 1 Flat spots caused by storage or handling 5780
11 2 Undulations 5780
11 3 Saw-tooth wear 5781
11 4 Flat spots caused by hard braking 5781
11 5 Swellings in the tyre sidewall 5781
11 6 Cuts 5783
11 7 Damage caused by foreign bodies 5783
11 8 Stripped profile 5784
11 9 Tyre damage due to insufficient tyre pressure 5784
11 10 Checking tyres 5785
11 11 Damage caused when fitting 5786
12 Tyre wear 5788
12 1 Factors influencing the service life of tyres 5788
12 2 Saw-tooth wear 5789
12 3 Wear behaviour of high-speed tyres 5790
12 4 Measuring tread depth 5790
12 5 One-sided wear 5791
12 6 Outer shoulder wear 5793
12 7 Diagonal washout 5794
12 8 Wear in middle of tyre 5795
12 9 Permissible deviation in tread depth 5795
13 Overview of components 5796
13 1 Assembly overview – wheel 5796
14 Snow chains 5799
14 1 Assembly and use of snow chains 5799
15 Regular and temporary spare wheels, recommended temporary spare tyres 5800
15 1 Spare wheel with yellow sticker 5800
15 2 Temporary spare wheels and recommended temporary spare tyres 5801
15 2 1 Atlas 2017 5801
15 2 2 Golf 2013, e-Golf 2014 5801
15 2 3 Golf 2017, e-Golf 2017 5801
15 2 4 Golf SV 2015 5801
15 2 5 Golf Variant 2014 5802
15 2 6 Golf Variant 2017 5802
15 2 7 Golf 2018 (AU2/BX6) 5802
15 2 8 Jetta 2018 5802
15 2 9 Taos 2021 5803
D3E80238FCE 6 speed manual gearbox 02U 5804
00 – Technical data 5808
1 Safety precautions for vehicles with a start-stop system 5808
2 Identification of gearbox 5809
2 1 Location on gearbox 5809
2 2 Identification code, assembly allocation, capacities 5809
3 Overview – power transmission 5811
4 Calculating overall gear ratio “i” 5813
5 General repair instructions 5814
5 1 Gearbox 5814
5 2 Gaskets and seals 5814
5 3 Sealant 5814
5 4 Locking devices 5815
5 5 Nuts and bolts 5815
5 6 Mountings 5815
5 7 Shims 5815
5 8 Synchro-rings 5816
5 9 Gear wheels 5816
5 10 Synchromeshed gears 5816
5 11 Clutch 5816
6 Electrical components 5817
6 1 Overview of fitting locations – electrical components 5817
6 1 1 Overview of fitting locations – electrical components, manual gearbox 5817
6 1 2 Overview of fitting locations – electrical components, clutch mechanism 5817
30 – Clutch 5819
1 Repairing clutch mechanism 5819
1 1 Overview – clutch actuation 5819
1 2 Assembly overview – pedal cluster 5820
1 3 Removing, installing and adjusting clutch pedal switch -F36- 5822
1 3 1 Removing clutch pedal switch 5822
1 4 Removing and installing mounting bracket with master cylinder 5823
1 4 1 Removing 5824
1 4 2 Installing 5825
1 5 Removing and installing clutch pedal with over-centre spring, LHD 5826
1 5 1 Removing 5827
1 5 2 Installing 5828
1 6 Removing and installing clutch pedal with extension spring, LHD 5829
1 6 1 Removing 5830
1 6 2 Installing 5831
1 7 Removing and installing clutch pedal, RHD 5832
1 7 1 Removing 5833
1 7 2 Installing 5834
1 8 Assembly overview – hydraulics (LHD) 5835
1 9 Assembly overview – hydraulics (RHD) 5837
1 10 Removing and installing master cylinder 5839
1 10 1 Removing 5839
1 10 2 Installing 5839
1 11 Removing and installing slave cylinder 5839
1 11 1 Removing 5840
1 11 2 Installing 5840
1 12 Bleeding clutch system 5840
2 Repairing clutch release mechanism 5842
3 Repairing clutch 5844
4 Renewing input shaft seal 5848
34 – Controls, housing 5850
1 Repairing selector mechanism 5850
1 1 Installation position of selector mechanism 5850
1 2 Overview of selector mechanism 5851
1 3 Assembly overview – gear knob and cover 5852
1 4 Removing and installing gear knob and cover 5852
1 5 Repairing gear lever and selector housing 5854
1 6 Assembly overview – removing and installing selector cables 5856
1 7 Removing and installing selector mechanism 5860
1 7 1 Removing 5860
1 7 2 Installing 5862
1 7 3 Specified torques 5863
1 8 Adjusting selector mechanism 5863
1 8 1 Function 5866
2 Removing and installing gearbox 5867
2 1 Removing gearbox 5870
2 2 Installing gearbox 5875
2 3 Specified torques 5879
3 Checking gear oil 5881
4 Dismantling and assembling gearbox 5883
4 1 Overview – gearbox 5883
4 2 Assembly overview 5884
4 3 Assembly overview – removing and installing cover for gearbox housing and 5th and 6th gear 5885
4 4 Assembly overview – removing and installing clutch housing 5887
4 5 Assembly overview – removing and installing input shaft, output shaft, differential, selector mechanism and selector forks 5888
4 6 Assembly sequence 5889
4 6 1 Modifying gearbox support -3221- 5893
4 6 2 Dismantling 5893
4 6 3 Installing 5899
5 Repairing gearbox housing and clutch housing 5906
6 Repairing gearbox housing cover 5911
7 Repairing selector unit 5914
8 Dismantling and assembling selector forks 5917
35 – Gears, shafts 5922
1 Input shaft 5922
1 1 Assembly overview – input shaft 5922
1 2 Dismantling and assembling input shaft 5925
2 Output shaft 5934
2 1 Assembly overview – output shaft 5934
2 2 Dismantling and assembling output shaft 5937
39 – Final drive – differential 5944
1 Renewing flange shaft oil seals with gearbox installed 5944
1 1 Renewing oil seal for left flange shaft 5944
1 1 1 Removing 5944
1 1 2 Installing 5946
1 2 Renewing seal for right flange shaft 5946
1 2 1 Removing 5947
1 2 2 Installing 5948
2 Differential 5950
2 1 Assembly overview – differential 5950
2 2 Dismantling and assembling differential 5952
2 3 Adjusting differential 5958
2 3 1 Determining shim S2 5962
D3E80270E6B 3 cylinder common rail engine (1 2 l EA189) 5963
00 – Technical data 5969
1 Technical data 5969
1 1 Engine number/engine data 5969
2 Safety information 5970
2 1 Safety measures when working on fuel supply 5970
2 2 Safety measures when working on vehicles with a start/stop system 5971
2 3 Safety precautions when using testers and measuring instruments during a road test 5971
2 4 Safety precautions when working on the cooling system 5971
2 5 Safety precautions when working on the SCR system 5971
2 6 Safety precautions when working on exhaust system 5972
3 General repair notes 5974
3 1 Rules for cleanliness 5974
3 1 1 When working on fuel supply/injection system 5974
3 1 2 When working on turbocharger 5974
10 – Removing and installing engine 5975
1 Removing and installing engine 5975
1 1 Removing engine 5975
1 2 Securing engine on engine and gearbox support 5983
1 3 Installing engine 5985
1 3 1 Notes on installing 5985
1 3 2 Additional information and assembly work for vehicles with air conditioner 5987
2 Assembly mountings 5988
2 1 Assembly overview – assembly mountings 5988
2 2 Supporting engine in installation position 5990
2 2 1 Installing support bracket (Polo) 5990
3 Engine cover panel 5992
13 – Crankshaft group 5993
1 Cylinder block (pulley end) 5993
1 1 Assembly overview – poly V-belt drive (vehicles without air conditioner compressor) 5993
1 2 Assembly overview – poly V-belt drive (vehicles with idler roller and air conditioner compressor) 5995
1 3 Assembly overview – poly V-belt drive (vehicles with tensioning element and air conditioner compressor) 5996
1 4 Removing and installing poly V-belt (vehicles without air conditioner compressor) 5996
1 5 Removing and installing poly V-belt (vehicles with idler roller) 5997
1 6 Removing and installing poly V-belt (vehicles with tensioning element) 5998
1 7 Removing and installing tensioner for poly V-belt 6000
1 7 1 Removing and installing tensioning element for poly V-belt 6000
1 8 Removing and installing vibration damper 6001
1 9 Ancillary bracket 6002
1 9 2 Ancillary bracket (removing and installing) 6002
1 10 Removing and installing sealing flange on pulley end 6004
1 10 1 Removing 6005
1 10 2 Installing 6006
2 Cylinder block, gearbox end 6008
2 1 Assembly overview – cylinder block, gearbox end 6008
2 2 Removing and installing flywheel 6009
2 3 Removing and installing sealing flange on gearbox side 6010
2 3 1 Pressing out sealing flange with sender wheel 6011
2 3 2 Pressing in sealing flange with sender wheel 6012
2 3 3 A – Assemble seal with sender wheel on assembly tool -T10134- 6013
2 3 4 B – Fitting assembly tool -T10134- with sealing flange to crankshaft flange 6015
2 3 5 C – Bolting assembly tool -T10134- onto crankshaft flange 6016
2 3 6 D – Pressing sender wheel onto crankshaft flange using assembly tool -T10134- 6016
2 3 7 E – Checking sender wheel installation position on crankshaft 6016
2 3 8 f) Re-pressing sender wheel 6018
3 Crankshaft 6019
3 1 Assembly overview – crankshaft 6019
3 2 Crankshaft dimensions 6020
3 3 Measuring axial clearance of crankshaft 6020
3 4 Measuring radial clearance of crankshaft 6021
4 Pistons and conrods 6022
4 1 Assembly overview – pistons and conrods 6022
4 2 Removing and installing pistons 6024
4 3 Measuring piston projection at “TDC” 6025
4 4 Checking pistons and cylinder bores 6026
4 4 3 Piston and cylinder dimensions 6028
4 5 Separating new conrods 6028
4 6 Measuring radial clearance of conrods 6028
15 – Cylinder head, valve gear 6030
1 Cylinder head 6030
1 1 Assembly overview – cylinder head cover 6030
1 2 Removing and installing cylinder head cover 6031
1 2 1 Removing cylinder head cover 6031
1 2 2 Fitting the cylinder head cover 6032
1 2 3 Removing and installing injector seal in cylinder head cover 6033
1 3 Assembly overview – cylinder head 6034
1 4 Removing and installing cylinder head 6036
1 4 1 Removing 6039
1 4 2 Installing 6045
1 5 Removing and installing vacuum pump 6048
1 6 Checking compression 6049
2 Toothed belt drive 6051
2 1 Assembly overview – toothed belt drive 6051
2 1 1 Removing and installing engine bracket 6053
2 2 Removing, installing and tensioning toothed belts 6056
2 2 1 Removing 6057
2 2 2 Installing (adjusting valve timing) 6060
3 Valve gear 6065
3 1 Assembly overview – valve gear 6065
3 2 Measuring axial clearance of camshaft 6066
3 3 Measuring radial clearance of camshafts 6067
3 4 Inlet and exhaust valves 6068
3 4 1 Valve dimensions 6068
3 4 2 Reworking valve seats 6068
3 4 3 Checking valve guides 6068
3 4 4 Renewing valve stem seals 6069
3 4 5 Renewing valve stem seals with cylinder head removed 6073
3 4 6 Checking valves 6076
3 5 Removing and installing camshafts 6077
3 5 1 Removing 6078
3 5 2 Installing 6079
3 6 Checking hydraulic compensation elements 6083
3 7 Removing and installing camshaft oil seal 6084
17 – Lubrication 6086
1 Sump 6086
1 1 Assembly overview – sump 6086
1 2 Removing and installing oil level and oil temperature sender -G266- 6088
1 3 Removing and installing sump 6089
1 4 Engine oil: 6093
1 4 1 Oil capacities 6093
2 Engine oil cooler 6094
2 1 Removing and installing engine oil cooler 6094
2 2 Checking engine oil cooler for leaks 6096
3 Oil filter, oil pressure switch 6099
3 1 Assembly overview – oil filter bracket and engine oil cooler 6099
3 2 Removing and installing oil filter bracket with engine oil cooler 6100
3 3 Checking oil pressure and oil pressure switch 6103
3 3 1 Checking oil pressure switch 6104
3 3 2 Checking oil pressure 6104
3 4 Removing and installing oil pressure switch -F1- 6105
4 Oil circuit 6106
4 1 Removing and installing oil supply line and oil return (turbocharger support) 6106
4 1 1 Assembly overview – oil supply line and oil return (turbocharger support) 6106
4 1 2 Removing and installing oil supply line and oil return (turbocharger support) 6107
4 2 Oil spray jet 6109
5 Balancer shaft module 6110
5 1 Assembly overview – balancer shaft module 6110
5 2 Removing and installing balance shaft module 6111
19 – Cooling 6114
1 Cooling system/coolant 6114
1 1 Coolant hose connection diagram 6114
1 2 Checking cooling system for leaks 6115
1 3 Draining and adding coolant 6117
1 3 1 Draining 6117
1 3 2 Filling with coolant 6118
1 3 3 Filling: Using cooling system charge unit -VAS 6096- only 6119
1 3 4 Topping up 6121
1 4 Cooling system – fitting locations 6121
1 4 1 Assembly overview – parts of cooling system, body side 6121
1 4 2 Parts of cooling system – engine side 6123
2 Coolant pump, regulation of cooling system 6125
2 1 Assembly overview – coolant pump and 4/2-way valve with thermostat 6125
2 2 Removing and installing 4/2-way valve with thermostat 6126
2 3 Removing and installing coolant pump 6130
3 Radiator, radiator fan 6133
3 1 Removing and installing radiator 6133
3 2 Assembly overview – with radiator fan -V7- 6135
3 3 Removing and installing cowling with radiator fan -V7- 6135
21 – Turbocharging/supercharging 6137
1 Turbocharger 6137
1 1 Assembly overview – turbocharger with attachments 6137
1 2 Removing and installing turbocharger 6139
1 2 1 Tightening exhaust gas temperature sender 1 -G235- 6144
2 Charge air system 6146
2 1 Assembly overview – charge air system 6146
2 2 Removing and installing charge air cooler 6147
2 3 Fitting charge air system hose connections 6148
2 3 2 Removing and installing charge air pipe »hot« side 6148
2 3 3 Removing and installing charge air pipe »cold« side 6149
2 4 Checking charge air system for leaks 6150
23 – Mixture preparation – injection 6153
1 Injection system 6153
1 1 Instructions for working on fuel system 6153
1 2 Schematic overview – fuel system 6154
1 3 Filling/bleeding fuel system 6156
1 4 Checking for leaks in the fuel system 6157
2 Vacuum system 6158
2 1 Vacuum hose connection diagram 6158
2 2 Checking vacuum system 6159
3 Injectors, fuel rail 6161
3 1 Assembly overview – injectors 6161
3 2 Adapting correction values for injectors 6163
3 3 Checking return flow rate of injectors with engine running 6163
3 4 Removing and installing injectors 6165
3 4 1 Removing 6167
3 4 2 Installing 6169
3 5 Removing and installing high-pressure lines 6170
3 6 Assembly overview – fuel rail 6174
3 7 Removing and installing fuel rail 6176
4 High-pressure pump 6181
4 1 Assembly overview – high-pressure pump 6181
4 2 Removing and installing high-pressure pump 6182
4 3 Checking vacuum at high-pressure fuel pump (venturi nozzle) 6187
4 4 Checking vacuum between high-pressure fuel pump (venturi nozzle) and injectors 6189
5 Senders and sensors 6192
5 1 Removing and installing fuel pressure regulating valve – N276- 6192
5 2 Checking fuel pressure regulating valve – N276- 6194
5 3 Removing and installing fuel pressure sender – G247- 6196
5 4 Removing and installing pressure differential sender – G 505- 6197
5 4 1 Removing and installing pressure differential sender – G 505- 6197
5 4 2 Removing and installing pressure differential sender – G 505- (right-hand drive vehicles) 6198
6 Lambda probe 6200
6 1 Assembly overview – lambda probe and exhaust temperature sensors 6200
6 2 Removing and installing Lambda probe -G39- with Lambda probe heater -Z19- 6200
7 Air filter 6202
7 1 Assembly overview – air filter 6202
7 2 Removing and installing air filter housing 6203
8 Intake manifold 6205
8 1 Assembly overview – intake manifold with attachments 6205
8 2 Removing and installing intake manifold 6205
9 Engine control unit 6209
9 1 Reading and deleting engine control unit event memory 6209
9 2 Adapting functions and components 6209
9 3 Removing and installing engine control unit with no ant-theft protection 6210
9 4 Removing and installing anti-theft engine control unit 6210
26 – Exhaust system 6212
1 Exhaust pipes and silencers 6212
1 1 Assembly overview – silencers 6212
1 2 Separating exhaust pipes from silencers 6212
1 3 Aligning exhaust system free of stress 6214
1 4 Installation position of clamp 6215
2 Emission control 6216
2 1 Assembly overview – particulate filter 6216
2 1 1 Assembly overview – particulate filter (LHD) 6216
2 1 2 Assembly overview – particulate filter (RHD) 6219
2 2 Removing and installing particulate filter 6221
2 2 1 Removing and installing particulate filter (LHD) 6221
2 2 2 Removing and installing particulate filter (RHD) 6227
3 Exhaust gas recirculation 6234
3 1 Assembly overview – exhaust gas recirculation 6234
3 2 Removing and installing exhaust gas recirculation cooler 6235
3 3 Checking changeover for exhaust gas recirculation cooler 6238
3 4 Checking exhaust gas recirculation cooler for leaks 6239
3 5 Cleaning exhaust gas recirculation system 6243
3 5 1 Initiating cleaning of exhaust gas recirculation system 6243
3 5 2 Cleaning connecting pipes and pipe union 6248
28 – Glow plug system 6249
1 Glow plug system 6249
1 1 Checking glow plug system 6249
1 2 Removing and installing ceramic glow pin plugs; carrying out resistor test 6249
1 3 Removing and installing Hall sender -G40- 6252
1 4 Removing and installing knock sensor -G61- 6254
1 4 1 Removing 6254
1 4 2 Installing 6255
1 5 Removing and installing engine speed sender -G28- 6255
D3E80452DD3 Body Repair General Information 6257
00 – Technical data 6261
1 Safety indications 6261
1 1 Components removal 6261
1 2 Battery, work with weld 6261
1 3 Electronic control units 6261
1 3 1 Procedures with electronic control units after bodywork repairs 6261
1 4 Paint, glasses, stuffing, linings 6262
1 5 Fuel tank or fuel line 6262
1 6 Air conditioning system 6262
1 6 1 Solution: 6262
1 7 Airbag System – Safety measures to work 6263
1 8 Airbag triggers after an accident – which should be replaced 6264
1 8 1 Accident with Airbag triggering 6264
1 8 2 Accident without airbag triggering 6264
1 9 Verification of safety belts 6264
1 9 1 Check the belt braid 6265
1 9 2 Check the automatic retractor (locking effect) 6266
1 9 3 Visual inspection of the belt latch 6266
1 9 4 Check the operation of the belt latch 6266
1 9 5 Check the belt guides and the latch tab 6267
1 9 6 Check the fastening parts and fastening points 6267
1 10 Safety measures for belt tensioner 6267
1 11 Vehicles works with belt tensioner 6268
1 12 Repair, alignment and/or bodywork works in vehicles with Airbag 6268
1 13 Removal of the front seats with side airbag 6269
2 Basic instructions 6270
2 1 Accident vehicles diagnosis 6270
2 2 Body supply condition and individual parts for painting 6270
2 3 Alignment 6270
2 4 Cuts for removal 6270
2 5 Body partial parts 6270
2 6 Original joint 6271
2 7 Body galvanized parts 6271
2 8 Removing the residues 6271
2 9 New parts 6271
3 Symbols explanation 6272
3 1 Symbols explanation to welding works 6272
3 2 Symbols explanation to work process 6272
3 2 6 Application of anti-corrosion fluid 6274
3 2 8 Sealing 6274
4 Tooling to the body repair 6275
4 1 Hole plier -VAG 1329- 6275
4 2 Fluid pulveriser -VAG 1379- or -EQ 7608- 6275
4 3 Hot air blower -VAG 1416- 6275
4 4 Adjustable straps -VAG 1438- 6275
4 5 Pneumatic saw -VAG 1523A- or -EQ 7415- 6276
4 6 Pneumatic hammer -VAG 1577- 6276
4 7 Welding points remover -VAG 1731- 6276
4 8 Adhesives Pneumatic Applicator for glass bonded -VAG 1761/1- or -EQ 7434- 6276
4 9 Pneumatic adhesive applicator -VAG 2005- 6277
5 Glued joints of the body 6278
5 1 Removal procedure: 6278
5 1 1 Bonding process: 6278
5 2 Bonding types 6279
5 3 Partial replacement repair solution 6279
5 3 1 RP spot welding and bonding 6279
5 3 2 Welding SG and paste (if unable to welding spot) 6279
5 3 3 Gases aspiration from welding 6279
5 3 4 Preparations 6280
5 3 5 Finishing works 6280
6 Corrosion protection measures 6281
6 1 Materials for corrosion protection prior to welding 6281
6 1 1 Zinc-based conductive paint 6281
6 2 Corrosion protection and special warranty against corrosion perforation 6281
7 Indications to residue disposal 6283
7 1 Residue elimination 6283
7 2 Support covers damper – unusable for disposal 6283
7 3 Airbag 6284
7 3 1 Disposal as waste 6284
8 Repair of steel plates 6285
8 1 Plate body of high strength 6285
8 2 Parts of the galvanized body 6285
8 2 1 Preparation 6285
8 2 2 Cutting process 6285
8 2 3 Joining techniques 6286
8 3 Welding work on galvanized plates 6286
8 3 1 MIG Welding of galvanized plates 6286
8 3 2 Bore welding of galvanized plates 6286
8 3 3 Posting test 6287
8 4 Repair body shop where there is no paint damage (Paintless dent repair) 6287
D3E8028728F 4 cyl injection engine with timing chain 6288
00 – Technical data 6294
1 Technical data 6294
1 1 Engine number 6294
1 2 Engine data 6294
10 – Removing and installing engine 6295
1 Removing and installing engine 6295
1 1 Removing engine 6297
1 2 Securing engine to assembly stand 6299
1 3 Installing engine 6299
1 4 Specified torques 6302
1 5 Assembly mountings 6302
1 6 Additional notes and assembly work for vehicles with air conditioner 6303
13 – Crankshaft group 6304
1 Dismantling and assembling engine 6304
1 1 Assembly overview – parts l and ll 6304
1 2 Part I Assembly overview – belt drive 6306
1 3 Part II: Assembly overview – chain drive system 6307
1 4 Removing and installing poly V-belt 6309
1 4 1 Poly V-belt routing 6310
1 5 Removing and installing valve timing housing 6310
2 Cylinder block, sealing flange 6314
2 1 Assembly overview 6314
2 2 Renewing crankshaft oil seal – belt pulley end 6315
2 3 Poly V-belt pulley securing bolt tightening procedure 6317
2 4 Characteristics of the sealing flange and the assembly device -T10134- 6319
2 5 Renewing crankshaft sealing flange – flywheel end (assembly tool -T10134-) 6320
2 5 1 Pressing sealing flange with sender wheel off crankshaft 6321
2 5 2 Pressing sealing flange with sender wheel onto crankshaft 6322
2 5 3 A – Assembling sealing flange with sender wheel on assembly appliance -T10134- 6322
2 5 4 B – Attaching assembling tool -T10134- with sealing flange to crankshaft flange 6324
2 5 5 C – Bolting assembly tool -T10134- onto crankshaft flange 6325
2 5 6 D – Pressing sender wheel onto crankshaft flange using assembly tool -T10134- 6326
2 5 7 E – Checking sender wheel installation position on crankshaft 6326
2 5 8 F – Re-pressing sender wheel 6327
3 Removing and installing crankshaft 6328
3 1 Exploded view crankshaft 6328
3 2 Crankshaft bearings 6329
3 3 Crankshaft dimensions 6329
4 Pistons and conrods 6330
4 1 Assembly overview 6330
4 2 Checking piston 6331
4 3 Checking cylinder bores 6332
4 4 Piston and cylinder dimensions 6332
15 – Cylinder head, valve gear 6333
1 Cylinder head 6333
1 1 Assembly overview 6333
1 2 Checking valve timing 6336
1 3 Adjusting valve timing 6337
1 4 Removing and installing timing chain and chain drive for oil pump 6341
1 5 Removing and installing camshaft housing 6349
1 6 Removing and installing cylinder head 6353
1 7 Checking compression 6356
2 Valve gear 6358
2 1 Assembly overview 6358
2 2 Checking camshaft axial clearance 6360
2 3 Reworking valve seats 6360
2 4 Checking valve guides 6361
2 5 Renewing valve stem seals 6362
17 – Lubrication 6364
1 Parts of lubrication system 6364
1 1 Engine oil 6364
1 2 Assembly overview 6364
1 3 Removing and installing sump 6366
1 4 Removing and installing oil pump 6368
1 5 Checking oil pressure and oil pressure switch 6370
19 – Cooling 6373
1 Parts of cooling system 6373
1 1 Assembly overview – parts of cooling system, body side 6373
1 2 Assembly overview – parts of cooling system, engine side 6375
1 3 Coolant hose schematic diagram 6377
1 4 Draining and filling coolant 6378
1 5 Removing and installing radiator 6380
1 6 Removing and installing coolant pump 6381
20 – Fuel supply system 6384
1 Parts of fuel supply system 6384
1 1 Assembly overview – fuel tank with attachments 6384
1 2 Safety precautions when working on fuel supply system 6387
1 3 Rules for cleanliness 6387
1 4 Removing and installing fuel delivery unit 6387
1 5 Removing and installing fuel gauge sender G 6389
1 6 Removing and installing fuel tank 6390
1 7 Assembly overview – fuel filter with attachments 6392
1 8 Removing and installing fuel filter 6393
1 9 Crash fuel shut-off 6394
1 10 Checking fuel pump 6394
1 11 Bleeding fuel system 6399
2 Electronic power control (EPC) 6402
2 1 Assembly overview 6402
3 Activated charcoal filter system 6403
3 1 Assembly overview 6403
3 2 Checking fuel tank breather 6404
24 – Mixture preparation – injection 6405
1 Injection system 6405
1 1 General notes on injection 6405
1 2 Assembly overview – intake manifold 6405
1 3 Assembly overview – fuel rail with injectors 6407
1 4 Removing and installing injectors 6407
1 5 Assembly overview – air filter 6408
1 6 Removing and installing air filter housing 6410
1 7 Cleaning throttle valve module -J338- 6411
1 8 Safety precautions 6412
1 9 Rules for cleanliness 6413
1 10 Technical data 6413
2 Checking components 6414
2 1 Checking injectors for leaks and quantity injected 6414
2 1 1 Checking for leaks 6414
2 1 2 Checking quantity injected 6415
2 2 Checking fuel pressure regulator and holding pressure 6416
3 Engine control unit -J623- 6419
3 1 Removing and installing engine control unit -J623- 6419
3 2 Vehicles with anti-theft secured engine control unit -J623- 6419
26 – Exhaust system 6421
1 Parts of the exhaust system 6421
1 1 Assembly overview – catalytic converters and attachments 6421
1 2 Assembly overview – silencers with mountings 6423
28 – Ignition system 6424
1 Ignition system 6424
1 1 Assembly overview – ignition system 6424
1 2 Removing and installing ignition coils with output stage 6425
1 3 Safety precautions 6426
1 4 Spark plug test data 6427
D3E80365602 Fuel supply system Diesel engines 6428
00 – Technical data 6432
1 Engine data 6432
2 Safety precautions 6433
2 1 Safety precautions when working on fuel supply system 6433
3 General repair notes 6435
3 1 Rules for cleanliness 6435
20 – Fuel supply system 6436
1 What to do if fuel tank filled with incorrect fuel 6436
1 1 Step 1 (Engine was started with incorrect fuel) 6436
1 2 Step 2 (Engine was not started with incorrect fuel) 6437
1 3 Step 3 (There are filings in fuel delivery unit and fuel tank) 6438
1 4 Step 4 (There are no filings in fuel delivery unit or fuel tank) 6439
1 5 Step 5 (There are filings in high-pressure pump) 6439
1 6 Step 6 (There are no filings in high-pressure pump) 6440
2 Fuel tank 6441
2 1 Assembly overview – fuel tank 6441
2 1 1 Assembly overview – fuel tank (CAYA, CAYB, CAYC) 6441
2 1 2 Assembly overview – fuel tank (CFWA) 6444
2 2 Removing, installing and checking breather valve 6447
2 3 Removing and installing fuel tank 6447
2 3 1 Removing and installing the fuel tank (CAYA, CAYB, CAYC) 6447
2 3 2 Removing and installing fuel tank (CFWA) 6450
2 4 Emptying fuel tank 6453
2 4 1 Emptying fuel tank when fuel pump is intact (CAYA, CAYB, CAYC) 6454
2 4 2 Emptying fuel tank when fuel pump is intact (CFWA) 6456
2 4 3 Emptying fuel tank when it is more than 3/4 full (CAYA, CAYB, CAYC) 6457
2 4 4 Emptying fuel tank if it is more than 3/4 full (CFWA) 6458
2 4 5 Emptying fuel tank when it is less than 3/4 full (CAYA, CAYB, CAYC) 6459
2 4 6 Emptying fuel tank if it is less than 3/4 full (CFWA) 6460
3 Fuel delivery unit, fuel gauge sender 6462
3 1 Assembly overview – fuel delivery unit/fuel gauge sender (CAYA, CAYB, CAYC) 6462
3 2 Removing and installing fuel delivery unit/fuel gauge sender 6463
3 2 1 Removing and installing the fuel delivery unit/fuel gauge sender (CAYA, CAYB, CAYC) 6463
3 2 2 Removing and installing fuel delivery unit/fuel gauge sender (CFWA) 6467
3 3 Fuel gauge sender (CAYA, CAYB, CAYC) 6472
3 3 1 Removing and installing fuel gauge -G- sender (CAYA, CAYB, CAYC) 6472
3 3 2 Checking fuel gauge -G- sender (CAYA, CAYB, CAYC) 6473
3 4 Fuel gauge sender (CFWA) 6475
3 4 1 Removing and installing fuel gauge sender -G6- (CFWA) 6475
4 Detaching push-on connectors 6477
5 Fuel filter 6480
5 1 Assembly overview – fuel filter 6480
5 1 1 Assembly overview – fuel filter (CAYA, CAYB, CAYC) 6480
5 1 2 Assembly overview – fuel filter (CFWA) 6481
5 2 Removing and installing fuel filter 6483
5 2 1 Removing and installing the fuel filter (CAYA, CAYB, CAYC) 6483
5 2 2 Bleeding fuel filter (CAYA, CAYB, CAYC) 6484
5 2 3 Removing and installing fuel filter (CFWA) 6485
5 3 Fuel hoses in the engine compartment (CFWA) 6487
6 Accelerator mechanism 6489
6 1 Assembly overview – accelerator module 6489
7 Fuel pump 6490
7 1 Checking fuel pump 6490
7 1 1 Checking fuel delivery rate of fuel system pressurisation pump -G6- (CAYA, CAYB, CAYC) 6490
7 1 5 Checking the current consumption of fuel pump for delivery rate -G6- (CAYA, CAYB, CAYC) 6500
7 1 6 Checking current consumption of the fuel pump for delivery rate -G6- (CFWA) 6502
7 1 7 Checking voltage supply of the fuel pump for delivery rate -G6- (CAYA, CAYB, CAYC) 6503
7 1 8 Checking current consumption of the fuel pump for delivery rate -G6- (CFWA) 6505
D4B802DF404 Air conditioning with refrigerant R134a 6507
00 – Technical data 6511
1 General information on air conditioning 6511
1 1 Basics of air conditioning 6511
1 1 1 Physical principles: 6511
1 1 2 Heat is always transferred from a warmer material to a cooler one 6512
1 1 3 Pressure and boiling point 6512
1 2 Vapour pressure table for R134a refrigerant gas 6513
1 3 R134a refrigerant gas 6514
1 3 1 Data on the physical properties of R134a refrigerant gas 6514
1 3 2 Critical point 6514
1 3 3 Environmental aspects related to R134a refrigerant gas 6515
1 4 Properties of R134a refrigerant gas 6515
1 4 1 Trade name and designations 6515
1 4 2 Colour 6515
1 4 3 Vapour pressure 6515
1 4 4 Physical characteristics of R134a 6516
1 4 5 Reaction with metals 6516
1 4 6 Critical temperature / Critical pressure 6516
1 4 7 Water content 6516
1 4 8 Combustion 6516
1 4 9 Filling factor 6516
1 4 10 Leak detection 6517
1 5 Refrigeration system oil 6517
1 5 1 Characteristics of refrigeration system oil 6517
1 6 Comfort 6518
1 7 Environmental aspects 6518
1 8 Air conditioning effects 6518
1 9 Safety at work 6519
1 9 1 Product characteristics 6519
1 9 2 Handling refrigerant gas 6519
1 9 3 Wear protective goggles 6520
1 9 4 Use protective gloves and apron 6520
1 9 5 Refrigerant gas should never come into contact with skin 6520
1 9 6 Never inhale refrigerant gas vapours 6520
1 9 7 Smoking is strictly prohibited 6520
1 9 8 Soldering work in refrigeration systems 6520
1 9 9 Active smell 6520
1 9 10 First Aid 6521
1 9 11 Handling of pressurized tanks 6521
1 9 12 Do not heat above 50 °C 6521
1 9 13 Monitor the heating process 6521
1 9 14 Close empty containers 6521
1 9 15 Safety measures related to handling refrigerant gas suction and filling equipment 6522
1 9 16 Safety measures related to the works to be performed in vehicles with air conditioning and the handling of R134a refrigerant gas 6522
2 General remarks on the refrigerant gas loop 6524
2 1 Refrigerant gas loop components 6524
2 1 1 Distribution of refrigerant gas loop components and their influence on the high and low pressure areas 6524
2 1 2 Air conditioning compressor with magnetic coupling: 6524
2 1 3 Air conditioning compressor without magnetic coupling 6525
2 1 4 Condenser 6526
2 1 5 Evaporator 6526
2 1 6 Collection tank 6527
2 1 7 Butterfly (restrictor) 6528
2 1 8 Liquid tank 6528
2 1 9 Expansion valve 6530
2 1 10 O-ring seals 6530
2 1 11 Rigid tubes and flexible tubes in the refrigerant gas loop 6531
2 1 12 Overpressure valve 6531
2 2 Refrigerant gas loop components 6532
2 2 1 Refrigerant gas loop with expansion valve and evaporator 6532
2 2 2 Refrigerant circuit with butterfly (restrictor) and collection tank 6532
2 3 Quick coupling connections in the refrigerant gas loop 6533
2 3 1 Suction and filling valve with Schrader valve 6533
2 3 2 Suction and filling valve, high pressure section 6534
2 3 3 Evacuating and charging valve, low pressure section 6534
2 4 Switches and sensors for the refrigerant circuit and their connections 6534
2 4 1 High pressure switch for air conditioning system -F23- 6535
2 4 2 High pressure switch for magnetic clutch -F118- 6535
2 4 3 Low pressure switch for air conditioning system -F73- 6535
2 4 4 Valve connections for switch in the refrigerant gas loop 6536
2 4 5 Air conditioning system pressure switch -F129- 6536
2 4 6 High pressure sender -G65- 6537
2 4 7 Refrigerant pressure and temperature sender -G395- 6537
2 4 8 Magnetic valve for liquid refrigerant circulation -N43- 6538
2 4 9 Air conditioner compressor regulating valve -N280- 6538
2 5 Electrical components not assembled in the refrigerant gas loop 6539
2 5 1 Control and regulating unit for air conditioning system -J127- 6539
2 5 2 Radiator fan control unit -J293- 6539
2 5 3 Temperature switch for evaporator -E33- 6540
2 5 4 Air outlet temperature sensor for the evaporator -G263- or Evaporator temperature sensor -G308- 6541
2 6 Pressures and temperatures in the refrigerant gas loop 6541
2 7 Refrigerant circuit with expansion valve 6541
2 8 Refrigerant circuit with butterfly (restrictor) and collection tank 6543
2 9 Checking and measuring work with a pressure gauge 6545
2 9 1 Pressure gauges may be used to carry out the following checking and measuring work: 6545
2 10 Notes on doing repair work on the refrigerant gas loop 6546
3 Legislation and standards 6547
3 1 Legislation and standards 6547
3 2 Regulations on recycling and disposal 6550
3 3 Disposal of cooling agent and cooling machine oils 6550
4 Using the climate control recovery, recycling, refilling, and cleaning equipment 6551
4 1 Important notes for using the Climate control recovery, recycling and refill set or EQ 7098 -VAS 6008- 6551
4 2 Connect the Climate control recovery, recycling and refill set or EQ 7098 -VAS 6008- 6552
4 3 Empty the refrigerant gas loop with the Climate control recovery, recycling and refill set or EQ 7098 -VAS 6008- 6553
4 3 1 Sucking out the refrigerant gas 6553
4 3 2 Remove the air from the refrigerant gas loop 6554
4 4 Fill the refrigerant gas loop with the Climate control recovery, recycling and refill set or EQ 7098 -VAS 6008- 6554
4 4 1 Filling refrigerant gas 6554
4 4 2 Activating the air conditioning after filling up the loop 6555
4 5 Introduce refrigerant gas into the tank of the Climate control recovery, recycling and refill set or EQ 7098 -VAS 6008- 6555
4 6 Emptying the tank of the Climate control recovery, recycling and refill set or EQ 7098 -VAS 6008- 6556
5 Checking pressure values in the refrigerant gas loop 6557
5 1 Checking pressure values 6558
5 2 Verification for vehicles with butterfly (throttle) and collection tank (air conditioning compressor with internal adjustment device) 6560
5 2 1 Nominal values 6560
5 3 Verification for vehicles with expansion valve and liquid loop / dryer (air conditioning compressor with internal adjustment device) 6563
5 3 1 Nominal values 6563
5 4 Verification for vehicles with expansion valve, liquid tank / dryer and Adjustment valve for the air conditioning compressor -N280- (with air conditioning compressor with external adjustment device) 6567
5 4 1 Nominal values 6567
5 5 Verification for vehicles with butterfly (throttle), collection tank and regulating valve for the air conditioning compressor -N280- (with air conditioning compressor with external adjustment device) 6576
5 5 1 Nominal values 6577
6 Detecting leaks in the refrigerant gas loop 6582
6 1 Detecting leaks in the refrigerant gas loop with the R134a air conditioning leak detector or EQ 7051 -VAG 1796- 6583
6 2 Detecting leaks in the refrigerant gas loop by pressurizing the system 6583
6 3 Detection of leaks in the refrigerant gas loop with the air conditioning recovery, recycling, recharging and cleaning set 6584
7 Cleaning the refrigerant gas loop 6587
7 1 Venting the refrigerant gas loop 6587
7 2 Washing the refrigerant gas loop with R134a refrigerant gas (clean) 6589
8 Problems 6595
8 1 Possible problems in the refrigerant circuit 6595
8 1 1 Checking conditions 6595
8 1 2 Possible problems 6595
9 Replacing components 6597
9 1 Leaking or damaged components (except the compressor, collection tank and liquid tank) 6597
9 1 1 A completely empty refrigerant circuit 6597
9 1 2 The loop still contains refrigerant gas 6598
9 2 Replace the air conditioning compressor 6598
9 2 1 Without any need to vent the refrigerant circuit with compressed air and nitrogen (for example, in case of external damage caused by an accident) 6598
9 2 2 Leakage or internal damage (such as noises or lack of power) 6599
9 3 Replace the liquid/collection tank and the butterfly (restrictor) 6599
9 3 1 After cleaning the refrigerant circuit or in case of impurities 6599
9 3 2 No need to clean, no leaks and no penetration of humidity and impurities in the refrigerant circuit 6600
10 Test equipment and tools 6601
10 1 List of test equipment, tools, and material 6601
10 2 Test equipment, tools, and material 6601
D4B803FC27E General body repairs interior 6604
00 – Technical data 6610
1 Safety information 6610
1 1 Safety measures when working with pyrotechnic components 6611
1 2 Storage, transportation and disposal of airbag, belt tensioner and battery isolator units (pyrotechnic components) 6612
1 3 Additional safety regulations for belt tensioners 6613
1 4 Additional safety regulations for driver airbag and front passenger airbag 6613
1 5 Additional safety instructions for curtain airbag 6614
1 6 Renewing pyrotechnic, electrical and mechanical components of the restraint system after an accident 6614
1 7 Accident without airbag triggering 6614
1 8 Checking seat belts 6614
1 9 Checking belt webbing 6615
1 10 Checking inertia reel (locking mechanism) 6616
1 11 Visually inspecting belt buckle 6616
1 12 Checking operation of belt buckle 6616
1 13 Checking belt guide fittings and latch plates 6617
1 14 Checking securing parts and anchorage points after an accident 6617
1 15 Checking child seat anchors after an accident 6617
68 – Interior equipment 6618
1 Compartments/covers 6618
1 1 Removing and installing fuse box cover 6618
1 2 Removing and installing upper steering column trim 6618
1 3 Removing and installing lower steering column trim 6619
1 4 Removing and installing glove compartment 6620
2 Equipment 6622
2 1 Removing and installing sun visor 6622
2 2 Removing and installing roof grab handle 6624
3 Centre console 6626
3 1 Removing and installing drinks holder 6626
3 2 Removing and installing parking brake cover cap 6627
3 3 Removing and installing trim for operating and display unit 6628
3 3 1 Removing and installing trim for operating and display unit, vehicles with Climatronic 6628
3 3 2 Removing and installing trim for operating and display unit, vehicles without Climatronic 6629
3 4 Removing and installing cover for centre console 6630
3 5 Removing and installing centre console 6631
3 5 1 Removing and installing centre console, centre console without armrest 6631
3 5 2 Removing and installing centre console, centre console with armrest 6634
3 6 Removing and installing centre console bracket 6637
4 Front centre armrest 6639
4 1 Removing and installing front centre armrest 6639
5 Interior mirror 6640
5 1 Removing and installing interior mirror 6640
5 1 1 Removing and installing manually operated anti-dazzle interior mirror 6640
5 1 2 Removing and installing interior mirror, interior mirror with rain and light sensor -G397- 6641
5 2 Removing and installing retaining plate 6642
5 2 1 Removing and installing retaining plate, manually adjustable interior mirror 6642
5 2 2 Removing and installing retaining plate, interior mirror with rain and light sensor -G397- 6644
69 – Passenger protection 6645
1 Seat belts 6645
1 1 Removing and installing front 3-point seat belt 6645
1 1 1 Removing and installing front 3-point seat belt, 2-door models 6645
1 1 2 Removing and installing front 3-point seat belt, 4-door models 6647
1 2 Removing and installing rear three-point seat belt 6650
1 2 1 Removing and installing rear outer three-point seat belt, 4-door models 6650
1 2 2 Removing and installing rear outer three-point seat belt, 2-door models 6651
1 2 3 Removing and installing rear middle three-point seat belt 6652
1 3 Removing and installing front belt end anchor 6653
1 4 Removing and installing belt height adjustment 6655
1 4 1 Removing and installing belt height adjuster, 2-door models 6655
1 4 2 Removing and installing belt height adjuster, 4-door models 6656
1 5 Removing and installing front belt buckle 6657
1 6 Removing and installing rear belt buckle 6659
2 Airbag control unit 6661
2 1 Removing and installing airbag control unit -J234- 6661
3 Driver side airbag 6663
3 1 Assembly overview – driver side airbag 6663
3 2 Removing and installing airbag unit with igniter 6664
3 2 1 Removing and installing airbag unit with igniter 6664
3 3 Removing and installing return spring with slip ring (coil connector) 6671
4 Front passenger side airbag 6673
4 1 Removing and installing front passenger side airbag unit with igniter 6673
5 Side airbags 6678
5 1 Removing and installing front side airbag with igniter 6678
5 1 1 Removing and installing front side airbag with igniter, vehicles without curtain airbag 6678
5 1 2 Removing and installing front side airbag with igniter, vehicles with curtain airbag 6679
6 Curtain airbags 6682
6 1 Removing and installing curtain airbag with igniter 6682
7 Airbag crash sensors 6685
7 1 Removing and installing side airbag crash sensor on driver side -G179-/side airbag crash sensor on front passenger side -G180- 6685
7 1 1 Removing and installing front side airbag crash sensor -G179-/-G180-, 2-door models 6685
7 1 2 Removing and installing front side airbag crash sensor -G179-/-G180-, 4-door models 6687
7 2 Removing and installing rear side airbag crash sensor on driver side -G256-/rear side airbag crash sensor on front passenger side -G257- 6690
8 Seat belt verification 6692
8 1 Removing and installing seat occupied sensor, front passenger side -G128- 6692
70 – Trim, insulation 6695
1 Front door trims 6695
1 1 Removing and installing door trim at front 6695
1 1 1 Removing and installing front door trim, 2-door models 6695
1 1 2 Removing and installing front door trim, 4-door models 6700
1 2 Removing and installing mirror cover trim 6704
2 Rear door trims 6707
2 1 Removing and installing rear door trim 6707
3 Dash panel 6712
3 1 Removing and installing mounting frame for radio/navigation system 6712
3 2 Removing and installing centre dash panel compartment 6712
3 3 Removing and installing mounting for storage compartment in centre dash panel 6714
3 4 Removing and installing dash panel end cover 6716
3 5 Removing and installing dash panel 6717
4 Dash panel central tube 6724
4 1 Removing and installing dash panel central tube 6724
5 Interior trims 6732
5 1 Removing and installing sill panel moulding 6732
5 1 1 Removing and installing sill panel mouldings, 2-door models 6732
5 1 2 Removing and installing sill panel mouldings, 4-door models 6732
5 2 Removing and installing A-pillar trim 6734
5 3 Detaching and attaching B-pillar trim 6738
5 3 1 Detaching and attaching B-pillar trim, 2-door models 6738
5 3 2 Detaching and attaching B-pillar trim, 4-door models 6739
5 4 Removing and installing B-pillar trim 6740
5 4 1 Removing and installing B-pillar trim, 2-door models 6740
5 4 2 Removing and installing B-pillar trim, 4-door models 6742
5 5 Releasing and securing C-pillar trim 6745
5 6 Removing and installing C-pillar trim 6748
5 6 1 Removing and installing C-pillar trim, 2-door models 6748
5 6 2 Removing and installing C-pillar trim, 4-door models 6750
5 7 Removing and installing side trim panel 6752
5 8 Removing and installing wheel housing trims 6754
6 Luggage compartment trims 6757
6 1 Removing and installing lower rear lid trim 6757
6 2 Removing and installing luggage compartment floor 6758
6 3 Removing and installing lock carrier trim 6759
6 4 Removing and installing rear shelf support 6760
6 5 Removing and installing support for variable luggage compartment floor 6762
6 6 Removing and installing luggage compartment side trim 6763
7 Roof trims 6765
7 1 Removing and installing roof end strip 6765
7 2 Removing and installing moulded headliner 6765
7 2 1 Removing and installing moulded headliner, 2-door models 6765
7 2 2 Removing and installing moulded headliner, 4-door models 6769
7 3 Mounting roof reinforcement on body 6772
72 – Seat frames 6776
1 Front seats 6776
1 1 Removing and installing front seat 6776
1 2 Removing and installing seat trim on tunnel side 6780
1 3 Removing and installing seat trim on sill side 6781
1 3 1 Removing and installing seat trim on sill side, seat without height adjustment 6781
1 3 2 Removing and installing seat trim on sill side, seat with height adjustment 6783
1 4 Removing and installing seat height adjustment operating lever 6786
1 5 Removing and installing lumbar support adjustment 6787
1 6 Removing and installing mounting for drawer 6788
1 7 Removing and installing front backrest 6790
1 8 Removing and installing head restraint guide 6793
2 Rear seats 6795
2 1 Removing and installing bench seat / individual seats 6795
2 2 Removing and installing rear seat backrest 6795
2 3 Removing and installing head restraint guide 6798
2 4 Removing and installing locking mechanism for rear seat backrest 6799
74 – Seat – padding, covers 6802
1 Front seat covers and padding 6802
1 1 Removing and installing seat cover and seat cushion for seat pan 6802
1 2 Removing and installing backrest cover and cushion 6805
2 Rear seat covers and padding 6807
2 1 Removing and installing bench seat cover and padding 6807
2 1 1 Removing and installing bench seat cover and padding, one-piece bench seat 6807
2 1 2 Removing and installing bench seat cover and padding, divided bench seat 6808
2 2 Removing and installing rear seat backrest cover and padding 6810
D4B804D7AF4 3 cylinder direct injection engine (1 0 l engine 4V EA 211 turbocharger) 6814
00 – Technical data 6820
1 Safety information 6820
1 1 Safety regulations for working on fuel supply 6820
1 2 Safety measures when working on vehicles with a start/stop system 6820
1 3 Safety precautions when using testers and measuring instruments during a road test 6821
1 4 Safety precautions when working on the cooling system 6821
1 5 Safety precautions when working on ignition system 6821
1 6 Safety precautions when working on exhaust system 6822
2 Marking 6823
2 1 Engine number/engine data 6823
3 Repair instructions 6831
3 1 Rules for cleanliness 6831
3 2 General information 6831
3 3 General repair instructions 6832
3 4 Foreign objects in engine 6832
3 5 Contact corrosion 6832
3 6 Routing and attachment of lines 6833
3 7 Fitting radiator and condensers 6833
3 8 Checking vacuum system 6833
10 – Removing and installing engine 6834
1 Removing and installing motor 6834
1 1 Removing motor 6834
1 1 1 Removing engine, Polo 2014 ►, Polo Saloon IN 2016 ►, Polo KH IN 2015 ► 6834
1 1 2 Removing engine, Golf, Golf Estate, SV, Touran 6847
1 1 3 Removing engine, up! 6862
1 1 4 Removing engine, Polo 2018, T-Cross 6872
1 1 5 Removing engine, T-Roc, T-Roc Cabrio 6882
1 2 Separating engine and gearbox 6891
1 2 1 Separating engine and gearbox, vehicles with manual gearbox, Golf, Golf Estate, Golf SV, Polo 2014 ►, Polo 2018 ►, T-Roc, T-Cross, Touran, T-Roc Cabrio, Polo Saloon IN 2016 ►, Polo KH IN 2015 ► 6891
1 2 2 Separating engine and gearbox, vehicles with dual clutch gearbox, Golf, Golf Estate, Golf SV, Polo 2014 ►, Polo 2018 ►, T-Roc, T-Cross, Touran, T-Roc Cabrio, Polo Saloon IN 2016 ►, Polo KH IN 2015 ► 6893
1 2 3 Separating engine and gearbox, up! 6895
1 3 Securing engine on engine and gearbox support 6897
1 4 Installing engine 6899
1 4 1 Removing engine, Golf, Golf Estate, Golf SV, Polo 2014 ►, Touran, Polo Saloon IN 2016 ►, Polo KH IN 2015 ► 6899
1 4 2 Installing engine, up! 6903
1 4 3 Installing engine, Polo 2018 ►, T-Cross 6907
1 4 4 Installing engine, T-Roc, T-Roc Cabrio 6909
2 Assembly mountings 6912
2 1 Assembly overview – assembly mountings 6912
2 1 1 Assembly overview – assembly mountings, Polo 2014 ►, Polo Saloon IN 2016 ►, Polo KH IN 2015 ► 6912
2 1 2 Assembly overview – assembly mountings, Golf, Golf Estate, Golf SV, Touran 6914
2 1 3 Assembly overview – assembly mountings, up! 6916
2 1 4 Assembly overview – assembly mountings, Polo 2018 ►, T-Roc, T-Cross, T-Roc Cabrio 6919
2 2 Removing and installing engine mounting 6922
2 2 1 Removing and installing engine mountings, Polo 2014 ►, Polo Saloon IN 2016 ►, Polo KH IN 2015 ► 6922
2 2 2 Removing and installing engine mounting, Golf, Golf Estate, Golf SV, Polo 2018 ►, T-Roc, T-Cross, Touran, T-Roc Cabrio 6924
2 2 3 Removing and installing engine mounting, up! 6925
2 3 Removing and installing gearbox mountings 6926
2 3 1 Removing and installing gearbox mountings, manual gearbox, Polo 2014 ►, Polo Saloon IN 2016 ►, Polo KH IN 2015 ► 6926
2 3 2 Removing and installing gearbox mounting, manual gearbox, Golf, Golf Estate, Golf SV, Polo 2018 ►, T-Roc, T-Cross, Touran, T-Roc Cabrio 6927
2 3 3 Removing and installing gearbox mountings, up! 6930
2 4 Removing and installing pendulum support 6931
2 4 1 Removing and installing pendulum support, Polo 2014 ►, Polo Saloon IN 2016 ►, Polo KH IN 2015 ► 6931
2 4 2 Removing and installing pendulum support, Golf, Golf Estate, Golf SV, Polo 2018 ►, T-Roc, T-Cross, Touran, T-Roc Cabrio 6932
2 4 3 Removing and installing pendulum support, up! 6933
2 5 Supporting engine in installation position 6934
2 5 1 Support engine in its installation position, Polo 2014 ►, Polo Saloon IN 2016 ►, Polo KH IN 2015 ► 6934
2 5 2 Supporting engine in installation position, Golf, Golf Estate, Golf SV 6936
2 5 3 Supporting up! engine in installation position, on right of camshaft housing 6941
2 5 4 Supporting engine in installation position, up!, on camshaft housing (left-side) 6945
2 5 5 Supporting engine in installation position, Polo 2018 ▶, manual gearbox 6949
2 5 6 Supporting engine in installation position, Polo 2018 ►, dual clutch gearbox 6951
2 5 7 Supporting engine in installation position, T-Roc, T-Roc Cabrio 6955
2 5 8 Supporting engine in installation position, T-Cross 6958
2 5 9 Supporting engine in installation position, Touran 6960
2 6 Adjusting assembly mountings 6968
2 6 1 Adjusting assembly mountings, Golf, Golf Estate, Golf SV, Polo 2018 ►, T-Roc, T-Cross, Touran, T-Roc Cabrio 6968
2 6 2 Adjusting assembly mountings, up! 6970
2 7 Checking adjustment of assembly mountings (engine and gearbox mountings) 6971
2 7 1 Checking adjustment of assembly mountings, Golf, Golf Estate, Golf SV, Polo 2018 ►, T-Roc, T-Cross, Touran, T-Roc Cabrio 6971
2 7 2 Checking assembly mounting settings, up! 6972
13 – Crankshaft group 6973
1 Cylinder block (pulley end) 6973
1 1 Assembly overview – poly V-belt drive 6973
1 1 1 Assembly overview – poly V-belt drive, vehicles without air conditioner compressor 6973
1 1 2 Assembly overview – poly V-belt drive, vehicles with air conditioner compressor 6975
1 2 Removing and installing poly-V belt 6977
1 2 1 Removing and installing poly V-belt, vehicles without air conditioner compressor 6977
1 2 2 Removing and installing poly V-belt, vehicles with air conditioner compressor 6979
1 3 Removing and installing tensioner for poly V-belt 6981
1 3 1 Removing and installing tensioner for poly V-belt, vehicles without air conditioner compressor 6981
1 3 2 Removing and installing tensioner for poly V-belt, vehicles with air conditioner compressor 6981
1 4 Removing and installing vibration damper 6982
1 5 Removing and installing engine support 6986
1 6 Renewing crankshaft oil seal – belt pulley end 6990
2 Cylinder block, gearbox end 6993
2 1 Assembly overview – cylinder block, gearbox end 6993
2 2 Removing and installing flywheel 6995
2 3 Removing and installing sealing flange on gearbox side 6997
3 Crankshaft 7008
3 1 Crankshaft dimensions 7008
3 2 Renewing needle bearing in crankshaft 7008
4 Pistons and conrods 7011
4 1 Assembly overview – pistons and conrods 7011
4 2 Removing and installing pistons 7014
4 3 Checking pistons and cylinder bores 7015
4 4 Separating new conrod 7017
4 5 Checking radial clearance of conrods 7018
4 6 Removing and installing oil spray jets 7018
4 7 Setting piston to TDC position 7020
15 – Cylinder head, valve gear 7024
1 Cylinder head 7024
1 1 Assembly overview – cylinder head 7024
1 2 Assembly overview – camshaft housing 7026
1 3 Removing and installing cylinder head 7029
1 4 Removing and installing camshaft housing 7032
1 5 Checking compression 7037
2 Toothed belt drive 7040
2 1 Assembly overview – toothed belt cover 7040
2 2 Assembly overview – toothed belt 7040
2 3 Removing and installing toothed belt 7042
2 4 Preassembling and installing test tool -VAS 611 007- 7049
2 4 1 Preassembling test tool -VAS 611 007- 7049
2 4 2 Installing test tool -VAS 611 007- 7052
2 4 3 Teaching-in test tool -VAS 611 007- electronically and performing basic setting 7055
2 5 Checking valve timing 7057
2 6 Adjusting valve timing 7060
2 7 Removing toothed belt from camshaft 7071
3 Valve gear 7079
3 1 Assembly overview – valve gear 7079
3 2 Measuring axial play of camshaft 7081
3 3 Removing and installing camshaft oil seal 7082
3 3 1 Removing and installing camshaft oil seal, inlet camshaft 7082
3 3 2 Removing and installing camshaft oil seal, exhaust camshaft, pulley end 7084
3 3 3 Removing and installing camshaft oil seal, exhaust camshaft, gearbox end 7086
3 4 Removing and installing camshaft adjuster 7089
3 4 1 Removing and installing camshaft adjuster for inlet camshaft 7089
3 4 2 Removing and installing camshaft adjuster for exhaust camshaft 7095
3 5 Removing and installing camshaft control valve 1 -N205- 7101
3 6 Removing and installing exhaust camshaft control valve 1 -N318- 7102
3 7 Removing and installing valve stem seals 7103
3 7 1 Removing and installing valve stem seals (cylinder head installed) 7103
3 7 2 Removing and installing valve stem seals (cylinder head removed) 7110
4 Inlet and exhaust valves 7116
4 1 Checking valve guides 7116
4 2 Checking valves 7117
4 3 Valve dimensions 7117
17 – Lubrication 7118
1 Sump, oil pump 7118
1 1 Assembly overview – sump/oil pump 7118
1 2 Engine oil: 7122
1 3 Removing and installing sump 7122
1 4 Removing and installing oil pump 7127
1 5 Removing and installing oil level and oil temperature sender -G266- 7129
2 Engine oil cooler 7131
2 1 Assembly overview – engine oil cooler 7131
2 2 Removing and installing engine oil cooler 7132
3 Crankcase ventilation 7133
3 1 Assembly overview – crankcase breather system 7133
3 2 Removing and installing oil separator 7134
4 Oil filter, oil pressure switch 7138
4 1 Assembly overview – oil filter/oil pressure switch 7138
4 2 Removing and installing oil pressure sender -G10- 7139
4 3 Checking oil pressure and oil pressure switch 7140
4 4 Removing and installing oil filter housing 7140
4 5 Removing and installing oil pressure regulating valve -N428- 7142
19 – Cooling 7144
1 Cooling system/coolant 7144
1 1 Connection diagram – coolant hoses 7144
1 2 Checking cooling system for leaks 7145
1 3 Draining and adding coolant 7150
1 3 1 Draining and adding coolant, Polo 2014 ►, Polo Saloon IN 2016 ►, Polo KH IN 2015 ► 7150
1 3 2 Draining and filling coolant, Golf 2013, Golf 2017, Golf Estate 2014, Golf Estate 2017, Golf SV 2015, Polo 2018 ►, T-Roc, T-Cross, Touran, T-Roc Cabrio 7159
1 3 3 Draining and adding coolant, up! 7169
2 Coolant pump, regulation of cooling system 7178
2 1 Assembly overview – coolant pump, thermostat 7178
2 2 Assembly overview – electric coolant pump 7181
2 3 Assembly overview – coolant temperature sender 7182
2 3 1 Assembly overview – coolant temperature sender, Polo 2014 ►, up!, Polo Saloon IN 2016 ►, Polo KH IN 2015 ► 7182
2 3 2 Assembly overview – coolant temperature sender, Golf, Golf Estate, Golf SV, Polo 2018 ►, T-Roc, T-Cross, Touran, T-Roc Cabrio 7182
2 4 Removing and installing electric coolant pump 7183
2 5 Removing and installing coolant pump 7186
2 6 Removing and installing thermostat 7190
2 6 1 Removing and installing thermostat for main coolant circuit (radiator) 7190
2 6 2 Removing and installing thermostat for cylinder block coolant circuit 7193
2 7 Removing and installing toothed belt pulley for coolant pump 7194
2 8 Removing and installing coolant temperature sender -G62- 7196
2 9 Removing and installing radiator outlet coolant temperature sender -G83- 7199
2 9 1 Removing and installing radiator outlet coolant temperature sender -G83-, Polo 2014 ►, Polo Saloon IN 2016 ►, Polo KH IN 2015 ► 7199
2 9 2 Removing and installing radiator outlet coolant temperature sender -G83-, Golf, Golf Estate, Golf SV, Polo 2018 ►, T-Roc, T-Cross, Touran, T-Roc Cabrio 7200
2 9 3 Removing and installing radiator outlet coolant temperature sender -G83-, up! 7202
3 Coolant pipes 7204
3 1 Assembly overview – coolant pipes 7204
3 2 Removing and installing coolant pipes 7204
4 Radiator, radiator fan 7207
4 1 Assembly overview – radiator/radiator fan 7207
4 1 1 Assembly overview – radiator/radiator fan, Polo 2014 ►, Polo Saloon IN 2016 ►, Polo KH IN 2015 ► 7207
4 1 2 Assembly overview – radiator/radiator fan, Golf, Golf Estate, Golf SV, Touran 7209
4 1 3 Assembly overview – radiator/radiator fan, up! 7211
4 1 4 Assembly overview – radiator/radiator fan, Polo 2018 ►, T-Cross 7214
4 1 5 Assembly overview – radiator/radiator fan, T-Roc, T-Roc Cabrio 7216
4 2 Assembly overview – radiator cowl and radiator fan 7217
4 2 1 Assembly overview – radiator cowl and radiator fan, Polo 2014 ►, Polo Saloon IN 2016 ►, Polo KH IN 2015 ► 7217
4 2 2 Assembly overview – radiator cowl and radiator fan, Golf, Golf Estate, Golf SV, Polo 2018 ►, T-Roc, T-Cross, Touran, T-Roc Cabrio 7217
4 2 3 Assembly overview – radiator cowl and radiator fan, up! 7218
4 3 Assembly overview – radiator blind 7219
4 3 1 Assembly overview – radiator blind 7219
4 3 2 Assembly overview – components of radiator blind 7221
4 4 Removing and installing radiator 7222
4 4 1 Removing and installing radiator, Polo 2014 ►, Polo Saloon IN 2016 ►, Polo KH IN 2015 ► 7222
4 4 2 Removing and installing radiator, Golf, Golf Estate, Golf SV, Touran 7226
4 4 3 Removing and installing radiator, up! 7227
4 4 4 Removing and installing radiator, Polo 2018 ► 7233
4 4 5 Removing and installing radiator, T-Roc, T-Roc Cabrio 7239
4 4 6 Removing and installing radiator, T-Cross 7242
4 5 Removing and installing water radiator for charge air cooling circuit 7247
4 5 1 Removing and installing water radiator for charge air cooling circuit, Golf, Golf Estate, Golf SV, Touran 7247
4 5 2 Removing and installing water radiator for charge air cooling circuit, up!, T-Roc, T-Roc Cabrio 7252
4 6 Removing and installing radiator cowl 7253
4 6 1 Removing and installing radiator cowl, Polo 2014 ►, Polo Saloon IN 2016 ►, Polo KH IN 2015 ► 7253
4 6 2 Removing and installing radiator cowl, Golf, Golf Estate, Golf SV, Touran 7255
4 6 3 Removing and installing radiator cowl, up! 7256
4 6 4 Removing and installing radiator cowl, Polo 2018 ►, T-Cross 7257
4 6 5 Removing and installing radiator cowl, T-Roc, T-Roc Cabrio 7259
4 7 Removing and installing radiator fan -V7- 7260
4 7 1 Removing and installing radiator fan -V7-, Polo 2014 ►, Polo Saloon IN 2016 ►, Polo KH IN 2015 ► 7260
4 7 2 Removing and installing radiator fan -V7-, Golf, Golf Estate, Golf SV, Polo 2018 ►, T-Roc, T-Cross, Touran, T-Roc Cabrio 7261
4 7 3 Removing and installing radiator fan -V7-, up! 7261
4 8 Removing and installing radiator blind 7262
4 9 Removing and installing radiator blind control motor -V544- 7264
21 – Turbocharging/supercharging 7270
1 Turbocharger 7270
1 1 Assembly overview – turbocharger 7270
1 2 Removing and installing turbocharger 7273
1 3 Removing and installing charge pressure positioner -V465- 7280
1 4 Removing and installing connection for turbocharger 7282
1 4 1 Removing and installing connection for turbocharger 7282
1 4 2 Removing and installing turbocharger connection, Polo 2014 ►, Polo Saloon IN 2016 ►, Polo KH IN 2015 ► 7284
2 Charge air system 7287
2 1 Assembly overview – charge air system 7287
2 2 Removing and installing charge air cooler 7289
2 2 1 Removing and installing charge air cooler, Polo, Golf, Golf Estate, Golf SV, T-Roc, T-Cross, Touran, T-Roc Cabrio 7289
2 2 2 Removing and installing charge air cooler, up! 7291
2 3 Removing and installing charge pressure sender -GX26- 7293
2 4 Checking charge air system for leaks 7294
2 5 Removing and installing air pipe 7296
24 – Mixture preparation – injection 7299
1 Injection system 7299
1 1 Overview of fitting locations – injection system 7299
1 1 1 Overview of fitting locations – engine compartment, Polo 2014 ►, Polo Saloon IN 2016 ►, Polo KH IN 2015 ► 7299
1 1 2 Overview of fitting locations – engine compartment, Golf, Golf Estate, Golf SV, Polo 2018 ►, T-Roc, T-Cross, Touran, T-Roc Cabrio 7302
1 1 3 Overview of fitting locations – engine compartment, up! 7305
1 1 4 Overview of fitting locations on engine (from above) 7307
1 1 5 Overview of fitting locations – engine from above, with particulate filter 7307
1 1 6 Overview of fitting locations – engine, rear 7309
1 1 7 Overview of fitting locations – engine, front 7310
2 Injectors 7312
2 1 Assembly overview – fuel rail with injectors 7312
2 2 Removing and installing fuel rail 7315
2 3 Removing and installing injectors 7316
2 3 1 Removing and installing injectors, version 1 7316
2 3 2 Removing and installing injectors, version 2 7323
2 4 Cleaning injectors 7331
3 Air filter 7333
3 1 Assembly overview – air filter housing 7333
3 1 1 Assembly overview – air filter housing, Polo 2014 ►, Polo Saloon IN 2016 ►, Polo KH IN 2015 ► 7333
3 1 2 Assembly overview – air filter housing, Golf, Golf Estate, Golf SV, T-Roc, Touran, T-Roc Cabrio 7334
3 1 3 Assembly overview – air filter housing, up! 7336
3 1 4 Assembly overview – air filter housing, Polo 2018 7337
3 1 5 Assembly overview – air filter housing, T-Cross 7339
3 2 Removing and installing air filter housing 7341
3 2 1 Removing and installing air filter housing, Golf, Golf Estate, Golf SV, Polo 2014 ►, Polo 2018 ►, T-Roc, T-Cross, Touran, T-Roc Cabrio, Polo Saloon IN 2016 ►, Polo KH IN 2015 ► 7341
3 2 2 Removing and installing air filter housing, up! 7342
3 3 Removing air duct on lock carrier 7344
3 3 1 Removing air duct on lock carrier, Golf, Golf Estate, Golf SV, Touran 7344
3 3 2 Removing air duct on lock carrier, Polo 2018 7345
3 3 3 Removing air duct on lock carrier, T-Roc, T-Roc Cabrio 7345
3 3 4 Removing air duct on lock carrier, T-Cross 7346
4 Intake manifold 7347
4 1 Assembly overview – intake manifold 7347
4 2 Removing and installing intake manifold 7349
4 2 1 Removing and installing intake manifold, Golf, Golf Estate, Golf SV, Polo 2014 ►, Polo 2018 ►, T-Roc, T-Cross, Touran, T-Roc Cabrio, Polo Saloon IN 2016 ►, Polo KH IN 2015 ► 7349
4 2 2 Removing and installing intake manifold, up! 7353
4 3 Removing and installing throttle valve module -GX3- 7356
4 4 Cleaning throttle valve module -GX3- 7358
5 Senders and sensors 7360
5 1 Assembly overview – actuator for structure-borne sound -R214- and control unit for structure-borne sound -J869- 7360
5 2 Removing and installing fuel pressure sender -G247- 7362
5 2 1 Removing and installing fuel pressure sender -G247-, Golf, Golf Estate, Golf SV, Polo 2014, Polo 2018, Touran, T-Roc, T-Cross, T-Roc Cabrio 7362
5 2 2 Removing and installing fuel pressure sender -G247-, up! 7363
5 3 Checking fuel pressure sender -G247- 7364
5 4 Removing and installing intake manifold sender -GX9- 7367
5 5 Removing and installing exhaust gas pressure sensor 1 -G450- 7367
6 Engine control unit 7370
6 1 Assembly overview – engine control unit 7370
6 1 1 Assembly overview – engine control unit, Polo 2014 ►, Polo Saloon IN 2016 ►, Polo KH IN 2015 ► 7370
6 1 2 Assembly overview – engine control unit, up! 7371
6 1 3 Assembly overview – engine control unit, Polo 2018 ►, T-Roc, T-Cross, Touran, T-Roc Cabrio 7371
6 2 Removing and installing engine control unit -J623- 7373
6 2 1 Removing and installing engine control unit -J623-, Polo 2014 ►, Polo Saloon IN 2016 ►, Polo KH IN 2015 ► 7373
6 2 2 Removing and installing engine control unit -J623-, up! 7374
6 2 3 Removing and installing engine control unit -J623- with protective housing, Golf, Golf Estate, Golf SV, Polo 2018 ►, T-Roc, T-Cross, Touran, T-Roc Cabrio 7376
6 2 4 Removing and installing engine control unit -J623- with metal locking plate, Golf, Golf Estate, Golf SV 7379
6 2 5 Removing engine control unit -J623- from protective housing, Golf, Golf Estate, Golf SV 7382
7 High-pressure pump 7384
7 1 Assembly overview – high-pressure pump 7384
7 2 Removing and installing high-pressure pump 7385
7 3 Removing and installing high-pressure pipe 7387
8 Lambda probe 7389
8 1 Assembly overview – Lambda probe 7389
8 2 Removing and installing Lambda probe 7390
26 – Exhaust system 7393
1 Exhaust pipes and silencers 7393
1 1 Assembly overview – silencers 7393
1 1 1 Assembly overview – silencers, Polo 2014 ►, Polo Saloon IN 2016 ►, Polo KH IN 2015 ► 7393
1 1 2 Assembly overview – silencer, Golf, Golf SV, T-Roc, Touran, T-Roc Cabrio 7394
1 1 3 Assembly overview silencers, Golf Estate 7397
1 1 4 Assembly overview – silencers, up! 7400
1 1 5 Assembly overview – silencers, Polo 2018 ►, T-Cross 7401
1 2 Separating exhaust pipes from silencers 7402
1 2 1 Separating exhaust pipes from silencers, Golf, Golf Estate, Golf SV, Polo 2014 ►, Polo 2018 ►, T-Roc, T-Cross, Touran, T-Roc Cabrio, Polo Saloon IN 2016 ►, Polo KH IN 2015 ► 7402
1 2 2 Separating exhaust pipes/silencers, up! 7404
1 3 Removing and installing silencer 7406
1 3 1 Removing and installing front silencer, Polo 2014 ►, Polo Saloon IN 2016 ►, Polo KH IN 2015 ► 7406
1 3 2 Removing and installing front silencer, Golf, Golf Estate, Golf SV, T-Roc, Touran, T-Roc Cabrio 7408
1 3 3 Removing and installing front silencer, Polo 2018 ►, T-Cross 7409
1 3 4 Removing and installing rear silencer, Polo 2014 ►, Polo Saloon IN 2016 ►, Polo KH IN 2015 ► 7410
1 3 5 Removing and installing rear silencer, Golf, Golf Estate, Golf SV, T-Roc, Touran, T-Roc Cabrio 7413
1 3 6 Removing and installing rear silencer, Polo 2018 ►, T-Cross 7415
1 3 7 Removing and installing silencer, up! 7416
1 3 8 Align end exhaust pipes 7418
1 4 Aligning exhaust system free of stress 7418
1 5 Checking exhaust system for leaks 7419
1 6 Installation position of clamp 7419
1 6 1 Installation position of clamp, Golf, Golf Estate, Golf SV, Polo 2014 ►, Polo 2018 ►, T-Roc, T-Cross, Touran, T-Roc Cabrio, Polo Saloon IN 2016 ►, Polo KH IN 2015 ► 7419
1 6 2 Installation position of clamp, up! 7421
2 Emission control 7423
2 1 Assembly overview – emission control 7423
2 1 1 Assembly overview – emission control, Polo 2014 ►, up!, Polo Saloon IN 2016 ►, Polo KH IN 2015 ► 7423
2 1 2 Assembly overview – emission control, Golf, Golf Estate, Golf SV, Polo 2018 ►, T-Roc, T-Cross, T-Roc Cabrio 7425
2 1 3 Assembly overview – emission control with petrol particulate filter, Golf, Golf Estate, Golf SV, Polo 2018 ►, T-Roc, T-Cross, Touran, T-Roc Cabrio 7428
2 2 Removing and installing catalytic converter 7431
2 3 Removing and installing particulate filter 7435
28 – Ignition system 7436
1 Ignition system 7436
1 1 Assembly overview – ignition system 7436
1 2 Removing and installing ignition coils with output stage 7438
1 3 Removing and installing knock sensor 1 -G61- 7441
1 4 Removing and installing Hall sender 7443
1 5 Removing and installing engine speed sender -G28- 7444
1 5 1 Removing and installing engine speed sender -G28-, Golf, Golf Estate, Golf SV, Polo 2014 ►, up!, T-Roc, Touran, T-Roc Cabrio 7444
1 5 2 Removing and installing engine speed sender -G28-, Polo 2018 ►, T-Cross 7446
D4B805CB339 Manual for Troubleshooting and Diagnosing Noises 7449
00 – Technical data 7455
1 Introduction 7455
2 Acoustic considerations during vehicle development 7456
2 1 Vibration insulation film 7456
2 2 Insulation 7457
3 General procedure for identifying noises 7459
3 1 General procedure 7459
3 2 Identifying a noise 7459
3 2 1 Localising origin of noise 7459
3 2 2 Identifying the type of noise 7460
3 2 3 Identifying the point in time when the noise occurs 7460
3 2 4 Identifying the noise by definition or designation 7460
3 3 Aid for localising noise by means of audio recordings (frequencies) 7460
3 3 1 Preparing an audio CD with downloaded files 7461
3 3 2 List of audio tracks 7461
3 3 3 Conditions for testing 7461
3 3 4 Conditions for performing the audio test 7462
3 4 Checklist 7462
4 Volkswagen equipment for localising noises 7466
4 1 Ultrasonic tester -VAG 1842- 7466
4 1 1 Design of the ultrasonic tester -VAG 1842- 7466
4 1 2 Example of procedure for identifying noises using ultrasound 7466
4 2 Borescope -VAS 6748A- 7470
4 2 1 Design of the borescope -VAS 6748A- 7470
4 2 2 Procedure for identifying noises using the borescope 7471
5 Attachments 7472
5 1 Checklist 7472
5 2 Designations for noises 7474
D4B807B63D7 Wheels and Tyres Guide 7475
44 – Wheels, tyres, vehicle geometry 7479
1 General notes on wheels and tyres (passenger cars) 7479
2 Legislative and technical conditions for converting wheel and tyre combinations 7481
2 1 Legislative conditions for converting wheel and tyre combinations 7481
2 2 Technical conditions for converting wheel and tyre combinations 7481
2 3 Additional wheel housing extensions (flaps) 7482
2 4 “Series 80” tyres 7482
3 Documents and codes/designations 7483
3 1 New vehicle registration documents since 01 10 2005 7483
3 2 COC document (EEC Certificate of Conformity) 7484
3 3 EU general type approval number, sales type and sales or trade designation 7484
4 Useful information regarding tyres 7486
4 1 Identification markings on the tyre sidewall 7486
4 2 Explanation of tyre markings 7488
4 3 Speed ratings for tyres 7489
4 4 Undulations 7490
4 5 Tyre storage 7491
4 6 Tyre ageing 7491
4 7 Tyre sizes for vehicles with four-wheel drive 7493
4 8 Winter tyres 7493
4 9 Winter tyres with speed symbol “V” 7494
4 10 Extra Load (XL) V winter tyres 7495
4 11 Maximum speeds for V and Extra Load (XL) winter tyres 7495
4 12 Reinforced and Extra Load (XL) tyres 7496
4 13 Snow chains 7496
5 Tyre wear/ mileage for passenger car tyres 7498
5 1 General 7498
5 2 Requirements to be met by tyres 7498
5 3 Wear behaviour of high-speed tyres 7499
5 4 Factors influencing the service life of a tyre 7499
5 5 Driving style 7499
5 6 Tyre maintenance 7500
5 7 Evenly worn tyres 7502
5 8 Measuring tread depth 7502
5 9 One-sided wear 7503
5 10 Outer shoulder wear 7506
5 11 Wear in middle of tyre 7507
5 12 Diagonal washout 7508
6 Tyre noise 7509
6 1 General notes on tyre noise 7509
6 2 Saw-tooth wear 7509
6 3 Flat spots (from locking wheels) 7511
7 Vehicle pulls to one side 7512
7 1 General 7512
7 2 Conicity 7512
7 3 Remedies when vehicle pulls to one side 7513
7 4 Strategic rotation of wheels for non-directional tyres 7514
7 5 Strategic rotation of wheels having unidirectional tyres 7515
8 Tyre damage 7517
8 1 General information 7517
8 2 Construction of a radial belted tyre 7517
8 3 Impact damage 7518
8 4 Cuts 7520
8 5 Damage caused by foreign bodies 7520
8 6 Loss of air from tyre 7520
8 7 Tyre pressure 7521
8 8 Tyre damage due to insufficient tyre pressure 7521
8 9 Rising tyre temperature caused by insufficient inflation pressure 7523
8 10 Tyre damage due to fitting error (fitting damage) 7524
9 Tyres with run-flat properties 7527
9 1 General 7527
9 2 Design and identification 7528
9 3 Retrofitting/requirements when using run-flat tyres 7528
9 4 Repairs 7529
10 Rolling resistance optimised tyres 7530
11 Facts about disc-type wheels (passenger cars) 7531
11 1 Design of disc-type wheel 7531
11 2 Data on wheel rims 7531
11 3 Wheel rims – pitch circle diameter 7532
11 4 Split rim composite wheels 7532
11 5 Alloy wheels with exchangeable trim elements 7532
11 6 Alloy wheels with exchangeable trim elements (Zaragoza) 7533
11 6 1 Tools 7533
11 6 2 Materials 7534
11 6 3 Installing trim element 7534
11 6 4 Removing trim element 7536
11 7 Care and maintenance of alloy wheel rims 7538
11 8 Restoring alloy wheels 7538
11 9 The valve 7539
12 Notes on use of temporary spare wheels 7541
13 Breakdown set for VW Vehicles 7542
14 Temporary spare tyres and wheels for VW vehicles 7543
15 Recommended summer tyres 7544
15 1 Recommended summer tyres, worldwide except North America and China 7544
16 Recommended all-season tyres 7546
16 1 Recommended all season tyres, worldwide except North America and China 7546
D4B807B63F6 4 cyl engine 7548
00 – Technical data 7554
1 Technical data 7554
1 1 Engine number 7554
1 2 Engine data 7554
10 – Removing and installing engine 7555
1 Removing and installing engine 7555
1 1 Removing 7556
1 2 Installing 7560
1 3 Torque settings 7561
1 4 Additional notes and assembly work for vehicles with air conditioner 7562
13 – Crankshaft group 7564
1 Dismantling and assembling engine 7564
1 1 Assembly overview – parts l and ll 7564
1 2 Part I Assembly overview – belt drive 7565
1 3 Part II: Assembly overview – chain drive system 7566
1 4 Removing and installing poly V-belt 7569
1 4 1 Poly V-belt routing 7570
1 5 Removing and installing valve timing housing 7570
2 Cylinder block, sealing flange 7575
2 1 Assembly overview 7575
2 2 Renewing crankshaft oil seal – belt pulley end 7577
2 3 Poly V-belt pulley securing bolt tightening procedure 7579
2 4 Characteristics of the sealing flange and the assembly device -T10134- 7583
2 5 Renewing crankshaft sealing flange – flywheel end (assembly tool -T10134-) 7584
2 5 1 Pressing sealing flange with sender wheel off crankshaft 7585
2 5 2 Pressing sealing flange with sender wheel onto crankshaft 7586
2 5 3 A – Assembling sealing flange with sender wheel on assembly appliance -T10134- 7586
2 5 4 B – Attaching assembling tool -T10134- with sealing flange to crankshaft flange 7589
2 5 5 C – Bolting assembly tool -T10134- onto crankshaft flange 7591
2 5 6 D – Pressing sender wheel onto crankshaft flange using assembly tool -T10134- 7591
2 5 7 E – Checking sender wheel installation position on crankshaft 7592
2 5 8 F – Re-pressing sender wheel 7593
3 Removing and installing crankshaft 7595
3 1 Exploded view crankshaft 7595
3 2 Crankshaft bearings 7597
3 3 Crankshaft dimensions 7597
4 Pistons and conrods 7598
4 1 Assembly overview 7598
4 2 Checking piston 7600
4 3 Checking cylinder bores 7601
4 4 Piston and cylinder dimensions 7602
15 – Cylinder head, valve gear 7603
1 Cylinder head 7603
1 1 Assembly overview 7603
1 2 Checking valve timing 7605
1 3 Adjusting valve timing 7608
1 4 Removing and installing timing chain and chain drive for oil pump 7614
1 5 Removing and installing camshaft housing 7623
1 6 Removing and installing cylinder head 7629
1 7 Checking compression 7633
2 Valve gear 7636
2 1 Assembly overview 7636
2 2 Checking camshaft axial clearance 7639
2 3 Reworking valve seats 7639
2 4 Checking valve guides 7641
2 5 Renewing valve stem seals 7642
17 – Lubrication 7645
1 Parts of lubrication system 7645
1 1 Engine oil 7645
1 2 Assembly overview 7645
1 3 Removing and installing sump 7648
1 4 Removing and installing oil pump 7650
1 5 Checking oil pressure and oil pressure switch 7652
19 – Cooling 7655
1 Parts of cooling system 7655
1 1 Assembly overview – parts of cooling system, body side 7655
1 2 Assembly overview – parts of cooling system, engine side 7657
1 3 Coolant hose schematic diagram 7659
1 4 Draining and filling coolant 7660
1 4 1 Draining and adding coolant 7660
1 5 Removing and installing radiator 7669
1 6 Removing and installing coolant pump 7671
20 – Fuel supply system 7673
1 Parts of fuel supply system 7673
1 1 Assembly overview – fuel tank with attachments 7673
1 2 Safety precautions when working on fuel supply system 7676
1 3 Rules for cleanliness 7677
1 4 Removing and installing fuel delivery unit 7677
1 5 Removing and installing fuel gauge sender G 7679
1 6 Removing and installing fuel tank 7680
1 7 Assembly overview – fuel filter with attachments 7682
1 8 Removing and installing fuel filter 7683
1 9 Crash fuel shut-off 7685
1 10 Checking fuel pump 7685
1 11 Bleeding fuel system 7691
2 Electronic power control (EPC) 7695
2 1 Assembly overview 7695
2 2 Removing and installing accelerator pedal module -GX2- 7695
3 Activated charcoal filter system 7698
3 1 Assembly overview 7698
3 2 Checking fuel tank breather 7699
24 – Mixture preparation – injection 7700
1 Injection system 7700
1 1 General notes on injection 7700
1 2 Assembly overview – intake manifold 7700
1 3 Removing and installing intake manifold 7701
1 4 Assembly overview – fuel rail with injectors 7704
1 5 Removing and installing injectors 7705
1 6 Assembly overview – air filter 7707
1 7 Removing and installing air filter housing 7709
1 8 Cleaning throttle valve module -J338- 7710
1 9 Safety precautions 7711
1 10 Rules for cleanliness 7712
1 11 Technical data 7713
2 Checking components 7714
2 1 Checking injectors for leaks and quantity injected 7714
2 1 1 Checking for leaks 7715
2 1 2 Checking quantity injected 7716
2 2 Checking fuel pressure regulator and holding pressure 7717
3 Engine control unit -J623- 7721
3 1 Removing and installing engine control unit -J623- 7721
3 2 Vehicles with anti-theft secured engine control unit -J623- 7722
26 – Exhaust system 7724
1 Parts of the exhaust system 7724
1 1 Assembly overview – catalytic converters and attachments 7724
1 2 Assembly overview – silencers with mountings 7726
28 – Ignition system 7728
1 Ignition system 7728
1 1 Assembly overview – ignition system 7728
1 2 Removing and installing ignition coils with output stage 7729
1 3 Safety precautions 7731
1 4 Spark plug test data 7732
D4B807B64CC 3 cylinder direct injection engine (1 0l engine 4V EA11 turbocharger) 7733
00 – Technical data 7741
1 Safety information 7741
1 1 Safety regulations for working on fuel supply 7741
1 2 Safety measures when working on vehicles with a start/stop system 7741
1 3 Safety precautions when using testers and measuring instruments during a road test 7742
1 4 Safety precautions when working on the cooling system 7742
1 5 Safety precautions when working on ignition system 7742
2 Identification 7743
2 1 Engine number/engine data 7743
3 Repair notes 7745
3 1 Rules for cleanliness 7745
3 2 General information 7745
3 3 General repair instructions 7746
3 4 Foreign objects in engine 7746
3 5 Contact corrosion 7746
3 6 Routing and attachment of lines 7747
3 7 Fitting radiator and condensers 7747
3 8 Checking vacuum system 7747
10 – Removing and installing engine 7748
1 Removing and installing engine 7748
1 1 Removing engine 7748
1 1 1 Removing engine, Polo 2014 ► 7748
1 1 2 Removing engine, Polo 2018 ► 7761
1 2 Separating engine and gearbox 7771
1 2 1 Separating engine and gearbox, vehicles with manual gearbox, Polo 2014 ►, Polo 2018 ► 7771
1 2 2 Separating engine and gearbox, vehicles with dual clutch gearbox, Polo 2014 ►, Polo 2018 ► 7772
1 3 Securing engine on engine and gearbox support 7774
1 4 Installing engine 7776
1 4 1 Removing engine, Polo 2014 ► 7776
1 4 2 Installing engine, Polo 2018 ► 7781
2 Assembly mountings 7784
2 1 Assembly overview – assembly mountings 7784
2 1 1 Assembly overview – assembly mountings, Polo 2014 ► 7784
2 1 2 Assembly overview – assembly mountings, Polo 2018 ► 7786
2 2 Removing and installing motor mounting 7789
2 2 1 Removing and installing engine mounting, Polo 2014 ► 7789
2 2 2 Removing and installing engine mounting, Polo 2018 ► 7791
2 3 Removing and installing gearbox mounting 7792
2 3 1 Removing and installing gearbox mounting, manual gearbox, Polo 2014 ► 7792
2 3 2 Removing and installing gearbox mountings, manual gearbox, Polo 2018 ► 7794
2 4 Removing and installing pendulum support 7796
2 4 1 Removing and installing pendulum support, Polo 2014 ► 7796
2 4 2 Removing and installing pendulum support, Polo 2018 ► 7797
2 5 Supporting engine in installation position 7798
2 5 1 Supporting engine in installation position, Polo 2014 ▶ 7798
2 5 2 Supporting engine in installation position, Polo 2018 ▶, manual gearbox 7800
2 5 3 Supporting engine in installation position, Polo 2018 ►, dual clutch gearbox 7802
2 6 Adjusting assembly mountings 7806
2 6 1 Removing assembly mountings, Polo 2018 ► 7806
2 7 Checking adjustment of assembly mountings (engine and gearbox mountings) 7809
2 7 1 Checking adjustment of assembly mountings , Polo 2018 ► 7809
13 – Crankshaft group 7810
1 Cylinder block (pulley end) 7810
1 1 Assembly overview – poly V-belt drive 7810
1 1 1 Assembly overview – poly V-belt drive, vehicles without air conditioner compressor 7810
1 1 2 Assembly overview – poly V-belt drive, vehicles with air conditioner compressor 7812
1 2 Removing and installing poly-V belt 7814
1 2 1 Removing and installing poly V-belt, vehicles without air conditioner compressor 7814
1 2 2 Removing and installing poly V-belt, vehicles with air conditioner compressor 7816
1 3 Removing and installing tensioner for poly V-belt 7818
1 3 1 Removing and installing tensioner for poly V-belt, vehicles without air conditioner compressor 7818
1 3 2 Removing and installing tensioner for poly V-belt, vehicles with air conditioner compressor 7818
1 4 Removing and installing vibration damper 7819
1 5 Removing and installing engine support 7822
1 6 Renewing crankshaft oil seal – belt pulley end 7826
2 Cylinder block, gearbox end 7830
2 1 Assembly overview – cylinder block, gearbox end 7830
2 2 Removing and installing flywheel 7832
2 3 Removing and installing sealing flange on gearbox side 7834
3 Crankshaft 7844
3 1 Crankshaft dimensions 7844
3 2 Renewing needle bearing in crankshaft 7844
4 Pistons and conrods 7847
4 1 Assembly overview – pistons and conrods 7847
4 2 Removing and installing pistons 7850
4 3 Checking pistons and cylinder bores 7851
4 4 Separating new conrod 7853
4 5 Checking radial clearance of conrods 7854
4 6 Removing and installing oil spray jets 7854
4 7 Setting piston to TDC position 7855
15 – Cylinder head, valve gear 7859
1 Cylinder head 7859
1 1 Assembly overview – cylinder head 7859
1 2 Assembly overview – camshaft housing 7861
1 3 Removing and installing cylinder head 7863
1 4 Removing and installing camshaft housing 7867
1 5 Checking compression 7871
2 Toothed belt drive 7873
2 1 Assembly overview – toothed belt cover 7873
2 2 Assembly overview – toothed belt 7873
2 3 Removing and installing toothed belt 7875
2 4 Preassembling and installing test tool -VAS 611 007- 7881
2 4 1 Preassembling test tool -VAS 611 007- 7881
2 4 2 Installing test tool -VAS 611 007- 7884
2 4 3 Teaching-in test tool -VAS 611 007- electronically and performing basic setting 7886
2 5 Checking valve timing 7889
2 6 Adjusting valve timing 7892
2 7 Removing toothed belt from camshaft 7901
3 Valve gear 7909
3 1 Assembly overview – valve gear 7909
3 2 Measuring axial play of camshaft 7911
3 3 Removing and installing camshaft oil seal 7912
3 3 1 Removing and installing camshaft oil seal, inlet camshaft 7912
3 3 2 Removing and installing camshaft oil seal, exhaust camshaft, pulley end 7914
3 3 3 Removing and installing camshaft oil seal, exhaust camshaft, gearbox end 7917
3 4 Removing and installing camshaft adjuster 7920
3 4 1 Removing and installing camshaft adjuster for inlet camshaft 7920
3 4 2 Removing and installing camshaft adjuster for exhaust camshaft 7925
3 5 Removing and installing camshaft control valve 1 -N205- 7931
3 6 Removing and installing exhaust camshaft control valve 1 -N318- 7932
3 7 Removing and installing valve stem seals 7934
3 7 1 Removing and installing valve stem seals (cylinder head installed) 7934
3 7 2 Removing and installing valve stem seals (cylinder head removed) 7940
4 Inlet and exhaust valves 7945
4 1 Checking valve guides 7945
4 2 Checking valves 7946
4 3 Valve dimensions 7946
17 – Lubrication 7947
1 Sump, oil pump 7947
1 1 Assembly overview – sump/oil pump 7947
1 2 Engine oil: 7951
1 3 Removing and installing sump 7951
1 4 Removing and installing oil pump 7957
1 5 Removing and installing oil level and oil temperature sender -G266- 7958
2 Engine oil cooler 7960
2 1 Assembly overview – engine oil cooler 7960
2 2 Removing and installing engine oil cooler 7960
3 Crankcase ventilation 7962
3 1 Assembly overview – crankcase breather system 7962
3 2 Removing and installing oil separator 7963
4 Oil filter, oil pressure switch 7967
4 1 Assembly overview – oil filter/oil pressure switch 7967
4 2 Removing and installing oil pressure sender -G10- 7968
4 3 Checking oil pressure and oil pressure switch 7969
4 4 Removing and installing oil filter housing 7969
4 5 Removing and installing oil pressure regulating valve -N428- 7970
19 – Cooling 7973
1 Cooling system/coolant 7973
1 1 Connection diagram – coolant hoses 7973
1 2 Checking cooling system for leaks 7974
1 3 Draining and adding coolant 7979
1 3 1 Draining and adding coolant, Polo 2014 ► 7979
1 3 2 Draining and filling coolant, Polo 2018 ► 7986
2 Coolant pump, regulation of cooling system 7994
2 1 Assembly overview – coolant pump, thermostat 7994
2 2 Assembly overview – electric coolant pump 7997
2 3 Assembly overview – coolant temperature sender 7998
2 3 1 Assembly overview – coolant temperature sender, Polo 2014 ► 7998
2 3 2 Assembly overview – coolant temperature sender, Polo 2018 ► 7998
2 4 Removing and installing electric coolant pump 7999
2 5 Removing and installing coolant pump 8002
2 6 Removing and installing thermostat 8007
2 6 1 Removing and installing thermostat for main coolant circuit (radiator) 8007
2 6 2 Removing and installing thermostat for cylinder block coolant circuit 8009
2 7 Removing and installing toothed belt pulley for coolant pump 8011
2 8 Removing and installing coolant temperature sender -G62- 8012
2 9 Removing and installing radiator outlet coolant temperature sender -G83- 8015
2 9 1 Removing and installing radiator outlet coolant temperature sender -G83-, Polo 2014 ► 8015
2 9 2 Removing and installing radiator outlet coolant temperature sender -G83-, Polo 2018 ► 8016
3 Coolant pipes 8019
3 1 Assembly overview – coolant pipes 8019
3 2 Removing and installing coolant pipes 8019
4 Radiator, radiator fan 8022
4 1 Assembly overview – radiator/radiator fan 8022
4 1 1 Assembly overview – radiator, radiator fan, Polo 2014 ► 8022
4 1 2 Assembly overview – radiator, radiator fan, Polo 2018 ► 8024
4 2 Assembly overview – radiator cowl and radiator fan 8025
4 2 1 Assembly overview – radiator cowl and radiator fan, Polo 2014 ► 8025
4 2 2 Assembly overview – radiator cowl and radiator fan, Polo 2018 ► 8026
4 3 Assembly overview – radiator blind 8027
4 3 1 Assembly overview – radiator blind 8027
4 3 2 Assembly overview – components of radiator blind 8029
4 4 Removing and installing radiator 8030
4 4 1 Removing and installing radiator, Polo 2014 ► 8030
4 4 2 Removing and installing radiator, Polo 2018 ► 8034
4 5 Removing and installing water radiator for charge air cooling circuit 8036
4 5 1 Removing and installing water radiator for charge air cooling circuit, Golf, Golf Estate, Golf SV 8036
4 6 Removing and installing radiator cowl 8041
4 6 1 Removing and installing radiator cowl, Polo 2014 ► 8041
4 6 2 Removing and installing radiator cowl, Polo 2018 ► 8043
4 7 Removing and installing radiator fan -V7- 8044
4 7 1 Removing and installing radiator fan -V7-, Polo 2014 ► 8044
4 7 2 Removing and installing radiator fan -V7-, Polo 2018 ► 8045
4 8 Removing and installing radiator blind 8046
4 9 Removing and installing radiator blind control motor -V544- 8048
20 – Fuel supply system 8054
1 Safety information 8054
1 1 Safety regulations for working on fuel supply 8054
1 2 Safety precautions when using testers and measuring instruments during a road test 8054
1 3 Safety measures when working on vehicles with a start/stop system 8055
2 Identification 8056
2 1 Engine number/engine data 8056
3 General information 8057
3 1 Rules for cleanliness when working on auxiliary/supplementary heater and fuel system 8057
4 Fuel 8058
4 1 Assembly overview – fuel tank 8058
4 1 1 Assembly overview – fuel tank, hatchback 8058
4 1 2 Assembly overview – fuel tank, saloon 8062
4 2 Emptying fuel tank 8065
4 2 1 Emptying fuel tank when fuel pump is intact 8065
4 2 2 Emptying fuel tank if it is more than 3/4 full 8070
4 2 3 Emptying fuel tank if it is less than 3/4 full 8072
4 3 Removing and installing fuel tank 8076
4 3 1 Removing and installing fuel tank, hatchback 8076
4 3 2 Removing and installing fuel tank, saloon 8082
5 Fuel delivery unit, fuel gauge sender 8088
5 1 Assembly overview – fuel delivery unit/fuel gauge sender 8088
5 1 1 Assembly overview – fuel delivery unit and fuel gauge sender, vehicles with union nut 8088
5 1 2 Assembly overview – fuel delivery unit and fuel gauge sender, vehicles with locking ring 8090
5 1 3 Assembly overview – fuel delivery unit/fuel gauge sender, vehicles with auxiliary heater 8091
5 2 Removing and installing fuel delivery unit, fuel gauge sender 8092
5 2 1 Removing and installing fuel delivery unit/fuel gauge sender, hatchback 8092
5 2 2 Removing and installing fuel line for auxiliary/supplementary heater 8097
5 2 3 Removing and installing fuel delivery unit/fuel gauge sender, saloon 8100
5 3 Removing and installing fuel gauge sender -G- 8105
6 Plug-in connectors 8109
6 1 Separating plug-in connectors 8109
7 Fuel filter 8115
7 1 Assembly overview – fuel filter 8115
7 2 Removing and installing fuel filter 8115
8 Activated charcoal filter system 8118
8 1 Assembly overview – activated charcoal filter system 8118
8 1 1 Assembly overview – activated charcoal filter, hatchback 8118
8 1 2 Assembly overview – activated charcoal filter, saloon 8118
8 2 Removing and installing activated charcoal filter 8119
8 2 1 Removing and installing activated charcoal filter, hatchback 8119
8 3 Checking fuel tank breather 8121
9 Accelerator pedal 8127
9 1 Assembly overview – accelerator module 8127
10 Fuel pump 8128
10 1 Checking fuel system pressurisation pump -G6- 8128
10 1 1 Checking function and voltage supply 8128
10 1 2 Checking function and voltage supply, vehicles with engine codes CWVA, CWVB, CHYA, CHYB 8133
10 1 3 Checking fuel pressure 8138
10 1 4 Checking fuel pressure, vehicles with engine codes CWVA, CWVB, CHYA, CHYB 8145
10 1 5 Checking holding pressure 8151
10 1 6 Checking holding pressure, vehicles with engine codes CWVA, CWVB, CHYA, CHYB 8158
10 1 7 Checking fuel delivery rate 8164
10 1 8 Checking delivery rate, vehicles with engine codes CWVA, CWVB, CHYA, CHYB 8175
10 1 9 Checking current consumption 8186
21 – Turbocharging/supercharging 8190
1 Exhaust turbocharger 8190
1 1 Assembly overview – turbocharger 8190
1 2 Removing and installing turbocharger 8193
1 3 Removing and installing charge pressure positioner -V465- 8199
1 4 Removing and installing connection for turbocharger 8200
2 Charge air system 8204
2 1 Assembly overview – charge air system 8204
2 2 Removing and installing charge air cooler 8206
2 2 1 Removing and installing charge air cooler 8206
2 3 Removing and installing charge pressure sender -GX26- 8208
2 4 Checking charge air system for leaks 8209
2 5 Removing and installing air pipe 8211
24 – Mixture preparation – injection 8213
1 Injection system 8213
1 1 Overview of fitting locations – injection system 8213
1 1 1 Overview of fitting locations – engine compartment, Polo 2014 ► 8213
1 1 2 Overview of fitting locations – engine compartment, Polo 2018 ► 8217
1 1 3 Overview of fitting locations on engine (from above) 8220
1 1 4 Overview of fitting locations – engine, rear 8221
1 1 5 Overview of fitting locations – engine, front 8222
2 Injectors 8224
2 1 Assembly overview – fuel rail with injectors 8224
2 2 Removing and installing fuel rail 8225
2 3 Removing and installing injectors 8226
2 4 Cleaning injectors 8233
3 Air filter 8235
3 1 Assembly overview – air filter housing 8235
3 1 1 Assembly overview – air filter housing, Polo 2014 ► 8235
3 1 2 Assembly overview – air filter housing, Polo 2018 ► 8236
3 2 Removing and installing air filter housing 8238
3 2 1 Removing and installing air filter housing, Polo 2014 ►, Polo 2018 ► 8238
4 Intake manifold 8240
4 1 Assembly overview – intake manifold 8240
4 2 Removing and installing intake manifold 8242
4 2 1 Removing and installing intake manifold, Polo 2014 ►, Polo 2018 ► 8242
4 3 Removing and installing throttle valve module -GX3- 8245
4 4 Cleaning throttle valve module -GX3- 8247
5 Senders and sensors 8249
5 1 Removing and installing fuel pressure sender -G247- 8249
5 2 Checking fuel pressure sender -G247- 8250
5 3 Removing and installing intake manifold sender -GX9- 8253
6 Engine (motor) control unit 8254
6 1 Assembly overview – engine control unit 8254
6 1 1 Assembly overview – engine control unit, Polo 2014 ► 8254
6 1 2 Assembly overview – engine control unit, Polo 2018 ► 8254
6 2 Removing and installing engine (motor) control unit -J623- 8255
6 2 1 Removing and installing engine control unit -J623-, Polo 2014 ► 8255
6 2 2 Removing and installing engine control unit -J623- with protective housing, Polo 2018 ► 8257
7 High-pressure pump 8261
7 1 Assembly overview – high-pressure pump 8261
7 2 Removing and installing high-pressure pump 8262
7 3 Removing and installing high-pressure pipe 8264
8 Lambda probe 8266
8 1 Assembly overview – Lambda probe 8266
8 2 Removing and installing Lambda probe 8267
26 – Exhaust system 8270
1 Exhaust pipes, silencers 8270
1 1 Assembly overview – silencers 8270
1 1 1 Assembly overview – silencers, Polo 2014 ► 8270
1 1 2 Assembly overview – silencer, Polo 2018 ► 8271
1 2 Separating exhaust pipes/silencers 8272
1 2 1 Separating exhaust pipes/silencers, Polo 2014 ►, Polo 2018 ► 8272
1 3 Removing and installing silencer 8274
1 3 1 Removing and installing front silencer, Polo 2014 ► 8274
1 3 2 Removing and installing front silencer, Polo 2018 ► 8275
1 3 3 Removing and installing rear silencer, Polo 2014 ► 8276
1 3 4 Removing and installing rear silencer, Polo 2018 ► 8279
1 3 5 Align end exhaust pipes 8280
1 4 Aligning exhaust system free of stress 8280
1 5 Check exhaust system for leaks 8281
1 6 Installation position of clamp 8282
1 6 1 Installation position of clamp, Polo 2014 ►, Polo 2018 ► 8282
2 Exhaust gas cleaning 8284
2 1 Assembly overview – emission control 8284
2 1 1 Assembly overview – emission control, Polo 2014 ► 8284
2 1 2 Assembly overview – emission control, Polo 2018 ► 8286
2 2 Removing and installing catalytic converter 8289
28 – Ignition system 8293
1 Ignition system 8293
1 1 Assembly overview – ignition system 8293
1 2 Removing and installing ignition coils with output stage 8295
1 3 Removing and installing knock sensor 1 -G61- 8298
1 4 Removing and installing Hall sender 8299
1 5 Removing and installing engine speed sender -G28- 8300
1 5 1 Removing and installing engine speed sender -G28-, Polo 2014 ► 8300
1 5 2 Removing and installing engine speed sender -G28-, Polo 2018 ► 8302
D4B807B75F3 Brakes 8305
00 – Technical data 8309
1 Brake allocation via PR No 8309
1 1 Front brakes 8309
1 2 Rear brakes 8310
1 2 1 Disc brakes 8310
1 2 2 Drum brakes 8310
2 Technical data for brakes 8311
2 1 Brake master cylinder and brake servo 8311
2 2 Front brakes 8311
2 2 1 Front brakes FS III 8311
2 2 2 Front brakes FN 3 8311
2 3 Rear brakes 8313
2 3 1 Rear brake (drum brake) 8313
2 3 2 Rear brakes (38″ brake disc) 8314
3 Brake test 8315
3 1 General 8315
3 2 Test for vehicles with front-wheel drive 8315
45 – Anti-lock brake system 8316
1 General notes for anti-lock brake system (ABS) 8316
1 1 Bosch 8 2 8316
2 Notes for repair work on anti-lock brake system 8318
3 Connecting -VAS 5051- and selecting functions 8319
4 Electrical/electronic components and locations 8321
4 1 Bosch 8 2 ABS 8321
4 2 Bosch 8 2i ABS/EDL/TCS/ESP 8322
5 Fault display via warning lamps 8325
6 Assembly overview – hydraulic unit, brake servo/brake master cylinder 8328
6 1 Bosch 8 2 ABS, left-hand drive 8328
6 1 1 Connecting brake lines from brake master cylinder to hydraulic unit 8330
6 1 2 Removing control unit and hydraulic unit 8331
6 1 3 Unscrewing control unit from hydraulic unit 8335
6 1 4 Installing new control unit 8336
6 1 5 Installing control unit and hydraulic unit 8338
6 2 Bosch 8 2 ABS, right-hand drive 8338
6 2 1 Connecting brake lines from brake master cylinder to ABS hydraulic unit -N55- 8340
6 2 2 Removing control unit and hydraulic unit 8341
6 2 3 Unscrewing control unit from hydraulic unit 8345
6 2 4 Installing new control unit 8346
6 2 5 Installing control unit and hydraulic unit 8347
6 3 Bosch 8 2i ABS/EDS/ASR/ESP, left-hand drive 8348
6 3 1 Connecting brake lines from brake master cylinder to hydraulic unit 8350
6 3 2 Removing control unit and hydraulic unit 8351
6 3 3 Unscrewing control unit from hydraulic unit 8356
6 3 4 Installing new control unit 8357
6 3 5 Installing control unit and hydraulic unit 8358
6 4 Bosch 8 2i ABS/EDS/ASR/ESP, right-hand drive 8358
6 4 1 Connecting brake lines from brake master cylinder to ABS hydraulic unit -N55- 8360
6 4 2 Removing control unit and hydraulic unit 8361
6 4 3 Unscrewing control unit from hydraulic unit 8365
6 4 4 Installing new control unit 8366
6 4 5 Installing control unit and hydraulic unit 8367
7 Removing and installing parts of ABS system on front and rear axle 8369
7 1 Removing and installing parts of ABS system on front axle 8369
7 1 1 Removing and installing speed sensor on front axle 8370
7 2 Removing and installing parts of anti-lock brake system on rear axle (drum brakes) 8370
7 2 1 Removing and installing speed sensor on rear axle (drum brakes) 8372
7 3 Removing and installing parts of anti-lock brake system on rear axle (disc brakes) 8372
7 3 1 Removing and installing speed sensor on rear axle 8374
8 Removing and installing parts of ESP system 8375
8 1 Removing and installing yaw rate sender -G202- and lateral acceleration sender -G200- 8375
8 2 Removing and installing steering angle sender -G85- 8375
46 – Brakes – mechanism 8376
1 Repairing front brakes 8376
1 1 Repairing front brakes, FS III brake caliper 8376
1 2 Removing and installing brake pads, brake caliper FS III 8378
1 2 1 Removing 8378
1 2 2 Installing 8379
1 3 Removing and installing brake caliper FS III 8380
1 3 1 Removing 8381
1 3 2 Installing 8381
1 4 Repairing front brakes, FN 3 brake caliper 8383
1 5 Removing and installing brake pads, brake caliper FN 3 8385
1 5 1 Removing 8385
1 5 2 Installing 8387
1 6 Removing and installing brake caliper FN 3 8388
1 6 1 Removing 8388
1 6 2 Installing 8389
2 Rear wheel brake until chassis number AAVZZZ6RZLU012824 (One shot (wedge) system) 8390
2 1 Rear wheel brake (One shot (wedge) system) – assembly overview 8390
2 2 Brake drum (One shot (wedge) system) – position 8392
2 3 Brake shoes (One shot – wedge – system) – remove and install 8392
3 Rear wheel brake as of chassis number AAVZZZ6RZLU012827 (Micrometer System) 8397
3 1 Assembly overview – rear brake, disc brake 8397
3 2 Assembly overview – rear wheel brake (Micrometric system) 8399
3 3 Removing and installing brake pads or linings 8401
3 4 Removing and installing brake caliper 8404
3 5 Remove and install brake shoes (Micrometric system) 8406
4 Handbrake 8418
4 1 Handbrake – assembly overview 8418
4 2 Handbrake cable (drum brake) – remove and install 8419
4 3 Handbrake (One shot (wedge) system) – adjust 8423
4 4 Handbrake (Micrometer system) – adjust 8425
5 Assembly overview – brake pedal 8427
5 1 Assembly overview – brake pedal, left-hand drive 8427
5 1 1 Separating brake pedal from brake servo 8427
5 1 2 Clipping brake pedal to brake servo 8428
5 1 3 Removing pedal cluster 8429
5 1 4 Installing pedal cluster 8430
5 1 5 Removing brake pedal 8430
5 1 6 Installing brake pedal 8430
5 2 Assembly overview – brake pedal, right-hand drive 8430
5 2 1 Separating brake pedal from brake servo 8431
5 2 2 Clipping brake pedal to brake servo 8432
5 2 3 Removing pedal cluster 8433
5 2 4 Installing pedal cluster 8433
5 2 5 Removing brake pedal 8434
5 2 6 Installing brake pedal 8434
47 – Brakes – hydraulics 8435
1 Repairing front brake calipers 8435
1 1 Repairing FS III brake calipers 8435
1 2 Removing and installing brake caliper FS III 8435
1 2 1 Removing 8436
1 2 2 Installing 8437
1 3 Repairing FN 3 brake calipers 8438
1 4 Removing and installing brake caliper piston FN 3 8438
1 4 1 Removing 8439
1 4 2 Installing 8440
2 Repairing rear brake calipers 8443
2 1 Removing and installing rear brake caliper piston 8444
2 1 1 Removing 8445
2 1 2 Installing 8446
2 1 3 Pre-bleeding brake caliper 8446
3 Pressurised leak test 8448
3 1 Test prerequisites: 8448
4 Bleeding brake system 8449
4 1 Bleeding brake system with brake filling and bleeding equipment -VAS 5234- 8449
4 1 1 Pre-bleeding: 8450
4 1 2 Bleeding (normal): 8450
4 1 3 Subsequent bleeding 8450
4 2 Changing brake fluid 8451
5 Assembly overview – brake servo/brake master cylinder 8452
5 1 Assembly overview – brake servo/brake master cylinder (left-hand drive vehicle) 8452
5 2 Assembly overview – brake servo/brake master cylinder (right-hand drive vehicle) 8454
5 3 Vacuum pump for brake servo (vehicles with diesel engine) 8456
5 3 1 Exhauster pump for 4-cylinder diesel engines 8456
5 4 Checking brake servo vacuum system 8457
5 4 1 Connecting vacuum gauge for brake servo -VAS 6721- 8457
5 4 2 Checking vacuum generation 8459
5 4 3 Checking for leaks 8460
5 4 4 Vacuum generation with manual vacuum pump -VAS 6213- 8462
5 5 Checking non-return valve 8462
5 6 Vacuum pump for brakes -V192- 8462
5 6 1 Assembly overview – vacuum pump for brakes -V192- 8462
5 6 2 Removing 8463
5 6 3 Installing 8464
5 7 Removing and installing brake servo pressure sensor -G294- 8464
5 8 Removing and installing brake light switch -F-, left-hand drive 8465
5 9 Removing and installing brake light switch -F-, right-hand drive 8466
6 Removing and installing brake master cylinder 8468
6 1 Removing and installing brake master cylinder, left-hand drive 8468
6 1 1 Removing 8468
6 1 2 Installing 8469
6 2 Removing and installing brake master cylinder, right-hand drive vehicle 8469
6 2 1 Removing 8470
6 2 2 Installing 8472
7 Removing and installing brake servo 8474
7 1 Removing and installing brake servo, left-hand drive 8474
7 1 1 Removing 8474
7 1 2 Installing 8477
7 2 Removing and installing brake servo, right-hand drive vehicle 8477
7 2 1 Removing 8478
7 2 2 Installing 8484
8 Repairing brake lines 8485
8 1 Assembly overview – flanging tool 8486
8 2 Work instructions 8487
D4B807B644A 6 speed automatic gearbox 09G 8490
00 – Technical data 8494
1 General repair notes 8494
1 1 Gearbox 8494
1 2 Torque converter 8494
1 3 ATF 8494
1 4 Automatic gearbox control unit -J217- with ⇒ Fuzzy logic 8494
1 5 Control units in vehicle 8494
1 6 Information on “09G gearbox” 8494
1 7 Tools 8495
1 8 Gearbox 8495
1 9 Gaskets, seals and oil 8495
1 10 Nuts and bolts 8496
1 11 Electrical components 8496
1 12 Guided fault finding, vehicle self-diagnosis and testing 8497
2 Gearbox identification 8498
2 1 Gearbox codes 8498
3 Code letters, engine allocation 8500
4 Capacities 8501
4 1 Planetary gearbox and final drive 8501
32 – Torque converter 8502
1 Torque converter 8502
1 1 Identification of torque converter 8502
1 2 Draining torque converter 8502
1 3 Removing and installing torque converter oil seal 8502
1 4 Installing torque converter 8503
37 – Controls, housing 8505
1 Connecting »tester« 8505
1 1 Connecting vehicle diagnosis, testing and information system -VAS 5051- 8505
2 Electrical and electronic components and their locations 8507
3 Multifunction switch -F125- 8512
3 1 Removing multifunction switch -F125- 8512
3 2 Installing multifunction switch -F125- 8514
3 3 Adjusting multifunction switch -F125- 8515
4 Selector mechanism 8517
4 1 Assembly overview – selector mechanism 8517
4 2 Emergency release of selector lever 8517
4 3 Removing and installing selector lever handle 8518
4 4 Moving push button to installation position in the handle 8522
4 5 Removing and installing selector lever and selector mechanism with selector lever cable 8524
4 6 Checking selector lever cable 8526
4 7 Adjusting selector lever cable 8527
5 Checking selector mechanism 8529
5 1 Selector lever in “P” position and ignition switched on 8529
5 2 Selector lever in “N” position and ignition switched on 8529
5 3 Selector lever in position “Tiptronic” 8529
5 4 Ignition and light switched on 8529
5 5 Selector lever position display 8529
6 Removing and installing gearbox 8530
6 1 Removing and installing gearbox, 1 6 l – 77 kW, petrol engine 8530
6 2 Removing and installing gearbox, 1 6 l – 81 kW, petrol engine 8540
6 3 Specified torques for gearbox 8540
6 3 1 1 6 l – 77 kW petrol engine 8540
6 3 2 1 6 l – 81 kW petrol engine 8542
7 Transporting gearbox 8543
8 Checking ATF level and topping up 8544
8 1 Checking ATF level 8545
8 2 Topping up ATF 8546
8 3 Draining and filling ATF 8547
9 ATF cooler 8549
9 1 Assembly overview – ATF cooler 8549
9 1 1 Assembly overview – ATF cooler, round version 8549
9 1 2 Assembly overview – ATF cooler, rectangular version 8549
9 2 Removing and installing ATF cooler 8550
9 2 1 Removing and installing ATF cooler, round version 8550
9 2 2 Removing and installing ATF cooler, rectangular version 8552
38 – Gears, control 8555
1 Renewing oil seal for selector shaft 8555
2 Removing and installing ATF pan 8556
2 1 Removing 8556
2 2 Installing 8557
3 Removing and installing ATF strainer 8559
3 1 Removing 8559
3 2 Installing 8559
4 Removing and installing valve body 8561
4 1 Overview – valve chest 8561
4 2 Removing valve body 8564
4 3 Installing valve body 8567
4 4 Wire routing, connectors, connections and retainer on valve body 8571
4 5 Specified torques 8572
5 Removing and installing wiring harness for solenoid valves and senders 8573
5 1 Removing 8573
5 2 Installing 8573
5 3 Removing and installing gearbox input speed sender -G182- 8573
5 4 Removing and installing gearbox output speed sender -G195- 8574
39 – Final drive – differential 8576
1 Renewing oil seals for flange shafts 8576
1 1 Renewing oil seal for left flange shaft 8576
1 2 Renewing seal for right flange shaft 8578
D4B807B645C 6 speed manual gearbox O2U 8581
00 – Technical data 8585
1 Safety instructions 8585
1 1 Safety precautions when working on vehicles with a Start/Stop system 8585
2 Identification 8586
2 1 Gearbox identification 8586
3 Technical data 8587
3 1 Allocation gearbox – engine 8587
3 2 Capacities 8587
3 3 Calculation of gear ratios 8587
4 Overview – power transmission 8588
5 Electrical components 8590
5 1 Overview of fitting locations – electrical components 8590
5 1 1 Overview of fitting locations – electrical components, manual gearbox 8590
5 1 2 Overview of fitting locations – electrical components, clutch mechanism 8590
6 Repair instructions 8591
6 1 General repair notes 8591
30 – Clutch 8594
1 Clutch operation 8594
1 1 Overview of fitting locations – clutch mechanism 8594
1 2 Assembly overview – pedal cluster 8596
1 3 Assembly overview – clutch hydraulics 8598
1 3 1 Assembly overview – clutch hydraulics, left-hand drive 8598
1 3 2 Assembly overview – clutch hydraulics, right-hand drive 8600
1 4 Assembly overview – clutch release mechanism 8601
1 5 Removing and installing bearing bush 8602
1 6 Checking clutch master cylinder and clutch slave cylinder 8602
1 7 Removing and installing clutch position sender -G476- 8602
1 8 Removing and installing over-centre spring 8604
1 9 Removing and installing extension spring 8606
1 10 Removing and installing clutch pedal 8606
1 10 1 Removing and installing clutch pedal, LHD 8606
1 10 2 Removing and installing clutch pedal, RHD 8607
1 11 Removing and installing mounting bracket 8608
1 12 Removing and installing clutch master cylinder 8611
1 13 Removing and installing clutch slave cylinder 8612
1 14 Removing and installing lines for clutch mechanism 8613
1 15 Bleeding clutch mechanism 8616
1 16 Repairing clutch release mechanism 8618
2 Clutch 8620
2 1 Assembly overview – clutch 8620
2 2 Removing and installing clutch 8621
34 – Controls, housing 8625
1 Selector mechanism 8625
1 1 Installation position – selector mechanism 8625
1 2 Assembly overview – gear knob and cover 8627
1 3 Assembly overview – selector mechanism 8628
1 4 Removing and installing gear knob 8629
1 5 Removing and installing selector mechanism 8631
1 6 Repairing selector mechanism 8634
1 7 Adjusting selector mechanism 8637
1 8 Checking selector mechanism 8639
2 Removing and installing gearbox 8640
2 1 Removing gearbox 8640
2 2 Installing gearbox 8648
2 3 Specified torques for gearbox 8653
3 Assembly mountings 8654
3 1 Assembly overview – assembly mountings 8654
4 Transporting gearbox 8656
5 Gear oil 8657
5 1 Checking gear oil level 8657
6 Installing to engine and gearbox support 8659
7 Dismantling and assembling gearbox 8661
7 1 Schematic overview – gearbox 8661
7 2 Assembly overview – gearbox 8662
7 3 Assembly overview – cover for gearbox housing and 5th/6th gear 8663
7 4 Assembly overview – clutch housing 8664
7 5 Assembly overview – shafts, differential, selector mechanism 8665
7 6 Assembly overview – selector unit 8666
7 7 Assembly overview – selector forks 8668
7 8 Repairing selector forks 8669
7 9 Repairing selector unit 8672
7 10 Renewing oil seal for selector shaft 8675
7 11 Dismantling and assembling gearbox 8675
8 Gearbox housing, clutch housing 8690
8 1 Assembly overview – gearbox housing and clutch housing 8690
8 2 Assembly overview – gearbox housing cover 8692
8 3 Repairing gearbox housing cover 8693
8 4 Repairing clutch housing 8694
35 – Gears, shafts 8697
1 Input shaft 8697
1 1 Assembly overview – input shaft 8697
1 2 Dismantling and assembling input shaft 8700
1 3 Renewing input shaft seal 8708
2 Output shaft 8710
2 1 Assembly overview – output shaft 8710
2 2 Dismantling and assembling output shaft 8712
39 – Final drive – differential 8718
1 Oil seals 8718
1 1 Overview of fitting locations – seals 8718
1 2 Renewing left oil seal 8719
1 2 1 Renewing oil seal for left flange shaft 8719
1 3 Renewing right oil seal 8721
1 3 1 Renewing oil seal for right flange shaft 8721
2 Differential 8724
2 1 Assembly overview – differential 8724
2 2 Dismantling and assembling differential 8725
2 3 Adjusting differential 8731
D4B807B6361 5 speed manual gearbox 02T 8736
00 – Technical data 8740
1 Identification 8740
1 1 Gearbox identification 8740
1 2 Prefix, correspondence, gearbox ratio, filling volume 8741
2 gearbox assembly scheme 8742
2 1 Nomenclature 8742
2 2 Gear ratios 8742
3 Gearbox ratio “i” 8744
3 1 Gearbox ratio “i” – calculation 8744
4 General repair instructions 8745
4 1 gearbox 8745
4 2 Gaskets and retainers 8745
4 3 Screws, nuts 8746
4 4 Roller Bearings 8746
4 5 Adjustment shims 8747
4 6 Synchronizer rings 8747
30 – Clutch 8748
1 Command system 8748
1 1 Command system – component overview 8748
1 2 Command pedals – assembly overview 8749
1 3 Clutch pedal switch -F36- – remove and install 8751
1 3 1 Clutch pedal switch -F36- with rectangular case – remove and install 8751
1 3 2 Clutch pedal switch -F36- with round case – remove and install 8752
1 4 Clutch pedal return spring – remove and install 8753
1 4 1 Removal 8753
1 4 2 Installation 8754
1 5 Clutch pedal support – remove and install 8755
1 5 1 Removal 8756
1 5 2 Installation 8757
1 6 Clutch pedal – remove install 8758
1 6 1 Removal 8758
1 6 2 Installation 8759
1 7 Hydraulic system – assembly overview 8759
1 8 Transmitting cylinder – clutch hydraulic drive – remove and install 8761
1 8 1 Removal 8762
1 8 2 Installation 8764
2 Clutch drive mechanism 8765
2 1 Clutch drive mechanism – assembly overview 8765
2 2 Clutch slave cylinder – remove and install 8768
2 2 1 Removal 8768
2 2 2 Installation 8768
2 3 Clutch drive mechanism – bleed 8769
3 Clutch 8771
3 1 Clutch – assembly overview 8771
3 2 Clutch – repair 8772
34 – Controls, housing 8776
1 Shift mechanism 8776
1 1 Shift mechanism – installation position 8776
1 2 Gearshift mechanism – component overview 8777
1 3 Handle and boot on the gear lever – assembly overview 8777
1 4 Handle and boot on the gear lever – remove and install 8778
1 4 1 Removal 8779
1 4 2 Installation 8779
1 5 Gearshift lever and mechanism – repair 8780
1 5 1 Gearshift lever and mechanism (version 1) – repair 8780
1 5 2 Gearshift lever and mechanism (version 2) – repair 8783
1 6 Drive cables – remove and install 8785
1 6 1 Drive cables (version 1) – remove and install 8785
1 6 2 Drive cables (version 2) – remove and install 8787
1 7 Gearshift mechanism – remove and install 8789
1 7 1 Removal 8790
1 7 2 Installation 8792
1 8 Gear selection mechanism – adjust 8793
1 8 1 Gear selection mechanism – adjust 8794
1 8 2 Gear selection mechanism – check operation 8796
2 gearbox – remove and install 8798
2 1 gearbox – remove and install 8798
2 1 1 Removal 8800
2 1 2 Installation 8810
2 1 3 Tightening torques 8817
2 2 Gearbox – transport 8821
3 Gearbox oil level 8823
3 1 Oil level – check 8823
3 2 Oil level – replenish 8824
4 gearbox – disassemble and assemble 8826
4 1 Gearbox – overview 8826
4 2 gearbox – assembly overview 8826
4 3 Gearbox housing cover and 5th gear 8827
4 4 Clutch housing 8828
4 5 Input shaft, planet pinion, differential, selection mechanism and selector forks 8829
4 6 Input shaft, planet pinion, differential, selection mechanism and selector forks – disassemble and assemble 8831
4 6 1 Disassembly 8833
4 6 2 Assembly 8836
5 Gearbox and clutch housings 8841
5 1 Gearbox and clutch housings – repair 8841
6 Gear selection mechanism – adjust 8847
6 1 Gear selection mechanism – disassemble and assemble 8847
7 Selector forks 8850
7 1 Selector forks – disassemble and assemble 8850
35 – Gears, shafts 8856
1 Input shaft 8856
1 1 Primary shaft – general overview of assembly 8856
1 2 Input shaft – disassemble and assemble 8858
2 Planet pinion 8870
2 1 Pinion shaft – general overview of assembly 8870
2 2 Planet pinion – disassemble and assemble 8873
39 – Final drive – differential 8881
1 Drive flange 8881
1 1 Left drive flange retainer (left side) – replace 8881
1 1 1 Removal 8882
1 1 2 Installation 8884
1 2 Drive flange retainer (right side) – replace 8885
1 2 1 Removal 8886
1 2 2 Installation 8887
2 Differential 8888
2 1 Differential – general overview of assembly 8888
2 2 Differential – disassemble and assemble 8890
2 3 Differential – adjust 8898
D4B807B6444 Running gear axles steering 8904
00 – Technical data 8910
1 Checklist for evaluating running gear of accident vehicles 8910
2 General information 8912
40 – Front suspension 8913
1 Evaluating accident vehicles 8913
2 Repairing front wheel suspension 8914
2 1 Overview – front axle 8914
2 2 Raising wheel suspension to unladen position 8915
3 Subframe, anti-roll bar, suspension links 8918
3 1 Assembly overview: subframe, anti-roll bar, suspension links 8918
3 2 Repairing thread in longitudinal member 8920
3 3 Fixing position of subframe 8920
3 4 Removing and installing subframe 8924
3 5 Checking swivel joint 8926
3 6 Removing and installing swivel joint 8927
3 7 Installation position of swivel joints 8931
3 8 Removing and installing suspension link 8931
3 9 Renewing front bonded rubber bush for suspension link 8934
3 10 Renewing rear bonded rubber bush for suspension link 8937
3 11 Removing and installing anti-roll bar 8939
3 12 Removing and installing rubber bush for anti-roll bar 8942
4 Assembly overview: wheel bearing 8944
4 1 Pulling out and pulling in wheel hub with wheel bearing 8946
4 2 Removing and installing wheel bearing housing 8952
5 Assembly overview: suspension strut 8956
5 1 Removing and installing suspension strut 8957
5 2 Repairing front suspension strut 8964
6 Removing and installing drive shafts 8968
6 1 Removing and installing drive shaft with constant velocity joint 8968
6 2 Removing and installing drive shaft with triple roller joint AAR 2000 (bolted-on) 8970
7 Repairing drive shafts – overview of drive shaft’s 8974
7 1 Heat shields for drive shafts 8974
8 Assembly overview: drive shaft with VL90 or VL100 constant velocity joint 8976
8 1 Dismantling and assembling drive shaft with VL90 or VL100 constant velocity joint 8978
8 2 Checking outer constant velocity joint 8985
8 3 Checking inner constant velocity joint 8986
9 Assembly overview: drive shaft with VL107 constant velocity joint 8990
9 1 Dismantling and assembling drive shaft with VL107 constant velocity joint 8992
10 Assembly overview: drive shaft with triple roller joint AAR 2000/108 8999
10 1 Dismantling and assembling drive shaft with triple roller joint AAR 2000/108 9001
42 – Rear suspension 9012
1 Evaluating accident vehicles 9012
2 Repairing rear axle 9013
2 1 Overview – rear axle 9013
2 2 Rear axle in unladen position 9014
3 Assembly overview: axle body, drum brake 9018
3 1 Removing and installing rear axle 9020
3 2 Removing and installing bonded rubber bush 9026
3 3 Removing and installing coil spring 9034
4 Assembly overview: axle body, disc brake 9036
5 Assembly overview: rear left vehicle level sender -G76-, front-wheel drive 9039
5 1 Removing and installing rear left vehicle level sender -G76- 9039
6 Assembly overview: shock absorber 9041
6 1 Removing and installing shock absorbers 9042
7 Assembly overview: wheel bearings, drum brake 9045
7 1 Removing and installing wheel hub with wheel bearing, vehicles with drum brakes 9046
8 Assembly overview: wheel bearings, disc brake 9049
8 1 Removing and installing wheel hub with wheel bearing, vehicles with disc brakes 9049
44 – Wheels, tyres, vehicle geometry 9053
1 Evaluating accident vehicles 9053
2 Specified torque for wheel bolts 9054
3 Removing and fitting tyres with run-flat properties to wheel rims 9055
3 1 Notes on safety and prerequisites 9055
3 2 Fittings instructions 9055
3 3 Pressing tyre off wheel rim 9056
3 4 Removing tyre from wheel 9057
3 5 Fitting tyre to wheel rim 9060
4 Tyre pressure monitor display 9063
5 Wheel alignment 9065
5 1 General 9065
5 2 Test prerequisites 9067
5 3 Test preparations 9067
5 4 Wheel alignment specifications 9068
5 5 Transverse vehicle inclination “zero position” 9069
5 6 Overview – wheel alignment procedure 9069
5 7 Correcting front axle camber 9071
5 8 Check rear axle camber 9072
5 9 Check rear axle toe 9072
5 10 Adjusting toe at front axle 9072
5 11 Checking left and right-hand wheel lock 9073
5 12 Vehicle data sticker 9074
6 Wheels, tyres 9076
6 1 Models with breakdown set 9076
6 2 Tyre sealant 9076
6 3 Removing a tyre 9076
6 4 Fitting a new tyre 9077
6 5 Tyre sealant disposal 9078
7 Instructions for changing or fitting wheels 9079
7 1 Fitting wheels 9080
8 Protecting wheel centring seat against corrosion 9082
9 Vibration due to wheels/tyres – causes and rectification 9083
9 1 Causes of vibration 9083
9 2 Balancing wheels 9083
9 3 Conducting a road test before balancing wheels 9084
9 4 Balancing wheels on stationary wheel balancing machine 9084
9 5 Vibration control system -VAS 6230- 9086
9 6 Finish balancer 9087
9 7 Radial and lateral run-out of wheels and tyres 9088
9 8 Checking radial and lateral run-out on wheels and tyres with tyre gauge -V A G 1435- 9088
9 9 Checking radial and lateral run-out on wheel rim 9089
9 10 Matching 9090
9 11 Flat spots caused by storage or handling 9091
48 – Steering 9093
1 Steering wheel 9093
1 1 Assembly overview – steering wheel 9093
1 2 Removing and installing steering wheel 9093
2 Steering column 9096
2 1 Assembly overview – steering column 9096
2 2 Removing and installing steering column 9098
2 3 Handling and transporting steering column 9110
2 4 Removing and installing intermediate steering shaft 9112
2 5 Repairing steering column 9113
2 6 Removing and installing power steering control unit -J500- 9114
2 6 1 Distinguishing features of left-hand and right-hand drive 9114
2 6 2 Removing and installing power steering control unit -J500-, left-hand drive vehicle 9114
2 6 3 Removing and installing power steering control unit -J500-, right-hand drive vehicle 9120
3 Steering rack 9126
3 1 Assembly overview – steering rack 9126
3 2 Removing and installing steering rack 9126
3 3 Repairing steering rack 9131
3 4 Removing and installing track rod 9132
3 5 Removing and installing track rod ball joint 9137
3 6 Adjusting steering rack 9139
4 Sensors 9140
4 1 Removing and installing steering angle sender -G85- 9140
D4B807C13CA 6 speed manual gearbox 0DQ 9141
00 – Technical data 9145
1 Safety instructions 9145
1 1 Safety precautions when working on vehicles with a Start/Stop system 9145
2 Identification 9146
2 1 Gearbox identification 9146
3 Technical data 9148
3 1 Allocation gearbox – engine 9148
3 2 Capacities 9148
3 3 Calculation of gear ratios 9148
4 Overview – power transmission 9149
5 Electrical components 9151
5 1 Overview of fitting locations – electrical components 9151
5 1 1 Overview of fitting locations – electrical components, manual gearbox 9151
5 1 2 Overview of fitting locations – electrical components, clutch mechanism 9151
6 Repair instructions 9153
6 1 General repair notes 9153
30 – Clutch 9157
1 Clutch operation 9157
1 1 Overview of fitting locations – clutch mechanism 9157
1 2 Assembly overview – pedal cluster 9158
1 3 Assembly overview – clutch hydraulics 9160
1 3 1 Assembly overview – clutch hydraulics, left-hand drive 9160
1 3 2 Assembly overview – clutch hydraulics, right-hand drive 9163
1 4 Assembly overview – clutch release mechanism 9165
1 5 Removing and installing bearing bush 9166
1 6 Checking clutch master cylinder and clutch slave cylinder 9167
1 7 Removing and installing clutch position sender -G476- 9167
1 8 Removing and installing over-centre spring 9169
1 9 Removing and installing extension spring 9171
1 10 Removing and installing clutch pedal 9171
1 10 1 Removing and installing clutch pedal, LHD 9171
1 10 2 Removing and installing clutch pedal, RHD 9172
1 11 Removing and installing mounting bracket 9173
1 12 Removing and installing clutch master cylinder 9179
1 13 Removing and installing clutch slave cylinder 9180
1 14 Removing and installing lines for clutch mechanism 9182
1 15 Bleeding clutch mechanism 9185
1 16 Repairing clutch release mechanism 9186
2 Clutch 9189
2 1 Assembly overview – clutch 9189
2 2 Removing and installing clutch 9189
34 – Controls, housing 9195
1 Selector mechanism 9195
1 1 Installation position – selector mechanism 9195
1 2 Assembly overview – gear knob and cover 9196
1 3 Assembly overview – selector mechanism 9197
1 4 Removing and installing gear knob 9199
1 5 Removing and installing selector mechanism 9201
1 6 Repairing selector mechanism 9206
1 7 Adjusting selector mechanism 9209
1 8 Checking selector mechanism 9212
2 Removing and installing gearbox 9213
2 1 Removing gearbox 9213
2 2 Installing gearbox 9224
2 3 Specified torques for gearbox 9230
3 Assembly mountings 9231
3 1 Assembly overview – assembly mountings 9231
4 Transporting gearbox 9234
5 Gear oil 9235
5 1 Checking gear oil level 9235
6 Installing to engine and gearbox support 9237
7 Dismantling and assembling gearbox 9239
7 1 Schematic overview – gearbox 9239
7 2 Assembly overview – gearbox 9240
7 3 Assembly overview – cover for gearbox housing and 5th/6th gear 9240
7 4 Assembly overview – clutch housing 9242
7 5 Assembly overview – shafts, differential, selector mechanism 9242
7 6 Assembly overview – selector unit 9244
7 7 Assembly overview – selector forks 9245
7 8 Repairing selector forks 9246
7 9 Repairing selector unit 9251
7 10 Renewing oil seal for selector shaft 9254
7 11 Dismantling and assembling gearbox 9255
8 Gearbox housing, clutch housing 9275
8 1 Assembly overview – gearbox housing and clutch housing 9275
8 2 Assembly overview – gearbox housing cover 9277
8 3 Repairing gearbox housing cover 9278
8 4 Repairing clutch housing 9279
35 – Gears, shafts 9282
1 Input shaft 9282
1 1 Assembly overview – input shaft 9282
1 2 Dismantling and assembling input shaft 9285
1 3 Renewing input shaft seal 9296
2 Output shaft 9298
2 1 Assembly overview – output shaft 9298
2 2 Dismantling and assembling output shaft 9301
39 – Final drive – differential 9309
1 Oil seals 9309
1 1 Overview of fitting locations – seals 9309
1 2 Renewing left oil seal 9309
1 2 1 Renewing oil seal for left flange shaft 9309
1 3 Renewing right oil seal 9313
1 3 1 Renewing oil seal for right flange shaft 9313
2 Differential 9316
2 1 Assembly overview – differential 9316
2 2 Dismantling and assembling differential 9318
2 3 Adjusting differential 9326
D4B807DC77D Chemicals Manual 9332
00 – Technical data 9338
1 — Change history — 9338
2 Introduction 9340
3 List of Suppliers 9341
3 1 3M do Brasil 9341
3 2 Brascola Ltda 9341
3 3 Castrol Brasil Ltda 9341
3 4 Cia Brasileira de Petróleo Ipiranga 9341
3 5 Chemours 9341
3 6 Chevron Brasil S/A 9341
3 7 Cremer S A Prod Têxteis e Cirúrgicos 9341
3 8 Dow Corning do Brasil Ltda 9341
3 9 Elf Lubrificantes do Brasil 9341
3 10 ExxonMobil 9341
3 11 Henkel do Brasil Ltda 9341
3 12 Klüber Lubrification Lubrificantes Especiais Ltda 9341
3 13 Loctite Brasil Ltda 9341
3 14 Lumobrás Imp Com Ind Ltda 9341
3 15 Motul Synthetic Lubricants 9341
3 16 Ocean Indústria Química 9341
3 17 Pentosin do Brasil Ltda 9342
3 18 Petrobras Distr S/A 9342
3 19 Shell Brasil S/A 9342
3 20 Sika S/A 9342
3 21 Solplás – Ind de Plásticos Ltda 9342
3 22 Solvay Química 9342
3 23 Three Bond do Brasil Ind e Com Ltda 9342
3 24 Total Lubrificantes Brasil Ltda 9342
3 25 Tutela Lubrificantes S/A 9342
3 26 Valvoline Lubrificantes Internacionais Ltda 9342
4 Work Instructions for Handling Chemicals 9343
4 1 Handling of Solvents 9343
4 2 Work instruction – Flammable material handling 9345
4 3 Handling used engine oil 9346
4 4 General guidelines on the storage of chemicals 9347
5 List of authorized products 9348
5 1 Polyurethane-based sealing adhesive 9348
5 2 High-resistance locking adhesive 9348
5 3 Low viscosity lock adhesive 9348
5 4 Sealing adhesive 9348
5 5 Self-adhesive PVC tape 9348
5 6 Double-sided adhesive tape 9348
5 7 Refrigerant gas – R134a 9349
5 8 Underbody coating 9349
5 9 Lubricating engine oil as per VW 502 00 and VW 505 00 standards 9349
5 10 Lubricating engine oil as per VW 507 00 standard 9349
5 11 Lubricating engine oil as per VW 508 88 and VW 509 99 standards 9350
5 12 Lubricating oil for manual gearbox and steering rack – SAE 90, MIL-L-2105B, API – GL5 9350
5 13 Lubricating oil for manual gearbox – SAE 80, MIL-L-2105, API – GL4 9350
5 14 Tire assembly paste 9350
5 15 Biodegradable degreasing product 9350
5 16 Grease remover spray 9351
6 List of fractionated products 9352
6 1 -000 096 319 D- Polishing material (chromium and aluminium) 9352
6 2 -032 198 561- Additional seal 9352
6 3 -AMV 188 001 02- Adhesive silicone 9353
6 4 -AMV 188 200 03- Sealing paste 9353
6 5 -AMV 189 300- Activating agent 9354
6 6 -AMV 189 400- Sealing compound 9354
6 7 Liquid sealant -D 000 600 A2- 9354
6 8 -D 001 210 M2- Universal adhesive 9355
6 9 -D 002 000 A2-Adhesive remover 9355
6 10 -D 004 660 M2- Adhesive set 9355
6 11 -D 007 000 A2- Spray silicone 9356
6 12 -D 009 200 02- Glass primer 9356
6 13 -D 009 401 04- Cleaning solution 9357
6 14 -D 009 500 25- Applicator 9357
6 15 Liquid sealant -D 154 000 A1- 9358
6 16 Liquid sealant -D 154 100 A1- 9358
6 17 -D 154 102 A1- Sealing compound 9358
6 18 -D 154 103 A1- Adhesive silicone 9359
6 19 -D 169 300 M1- Window adhesive 9359
6 20 -D 169 300 M2- Window adhesive 9359
6 21 -D 172 090 A2- Adhesive 9360
6 22 -D 174 003 M2- Silicone sealant 9360
6 23 -D 176 404 A3- Adhesive silicone 9361
6 24 -D 176 204 R2- Adhesive silicone 9361
6 25 -D 176 404 M2- Adhesive silicone 9361
6 26 -D 176 501 A1- Adhesive silicone 9361
6 27 -D 180 KU1 A1- 2-component adhesive for plastic 9362
6 28 -D 180 KU2 A1- 2-component adhesive for plastic 9362
6 29 -D 181 220 A1- Activating agent 9363
6 30 -D 181 655 A1- Activating agent 9363
6 31 -D 181 802 M1- Glass primer 9363
6 32 Liquid sealant -D 185 400 A2- 9364
6 33 Liquid sealant -D 185 400 A3- 9364
6 34 Liquid sealant -D 185 410 A2- 9364
6 35 -D 185 520 A2- Sealing compound 9364
6 36 -D 190 MKD A3- Assembly adhesive 9365
6 37 Liquid sealant -D 192 100 A2- 9365
6 38 -D 195 850 A1- Cleaning solution 9365
6 39 -D 316 D38 A2- Protective wax 9366
6 40 -D 322 000 A2- Wachs-spray 9366
6 41 -D 322 100 M2- Wachs-spray 9366
6 42 -D 330 KD2 A1- Cavity spray 9367
6 43 -D 366 PR1 A1- Plastic primer 9367
6 44 -D 454 300 A2- Sealing compound 9367
6 45 -D 469 101 A3- Gluing and sealing compound 9368
6 46 -D 822 150 A1- Plastic surfacer 9368
6 47 -G 000 100- Coupling teeth lubricant compound 9368
6 48 -G 000 115 A2- Spray lubricant 9369
6 49 -G 000 150- Consistent lubricating paste 9369
6 50 -G 000 405 A2- Silicone paste 9369
6 51 -G 000 450 02- Lubrication paste 9370
6 52 -G 000 650- Consistent lubricating paste 9371
6 53 -G 052 109 A2- Assembly paste 9371
6 54 -G 052 112 A3- High temperature paste 9371
6 55 -G 052 128 A1- Thrust ring sealing grease 9372
6 56 -G 052 133 A2- Lubricating paste for high temperatures 9372
6 57 -G 052 135 A1- Lubricating oil 9372
6 58 -G 052 142 A2- Polyurethane lubricating compound 9373
6 59 -G 052 150 A2- Lithium lubricating paste 9373
6 60 -G 052 168 A1- Steering box lubricant 9374
6 61 -G 052 172 A1- Special lubricant 9374
6 62 -G 052 172 M2- Special lubricant 9374
6 63 -G 052 181 A4- Lubricating paste for constant velocity joints 9375
6 64 -G 052 528 A2- Lubricating paste for constant velocity joints 9375
6 65 -G 052 565 A1- Silicone paste 9375
6 66 -G 052 723 A2- Moly paste 9376
6 67 -G 052 735 A2- Multi-purpose grease 9376
6 68 -G 052 738 A2- Lubricating paste for constant velocity joints 9376
6 69 -G 052 738 A3- Thrust ring sealing grease 9377
6 70 -G 052 745 A3- Lubricating paste for low temperature 9377
6 71 -G 052 751 A1- Molybdenum pasta 9377
6 72 -G 052 778 A2- Spray lubricant 9378
6 73 -G 052 817 A1- Contact grease 9378
6 74 -G 055 128 A1- Thrust ring sealing grease 9378
6 75 -G 060 567 A2- Special lubricant 9379
6 76 -G 060 735 A2- Multi-purpose grease 9379
6 77 -G 060 751 A2- Consistent lubricating paste 9379
6 78 -G 065 567 A2- Cleaning solution 9380
6 79 -G 070 528 R2- Lubricating paste for constant velocity joints 9380
6 80 -G 294 421 A1- Lubricating oil for assembly 9380
D4B807E3B5B Body Repairs General Body Repairs 9381
1 Safety instructions 9385
1 1 Part removal 9385
1 2 Battery and welding operation 9385
1 3 Electronic control unit 9385
1 3 1 Processing of the electronic control unit after repair dueto a traffic accident 9385
1 4 Paint, glass, soft pad and trim 9386
1 5 Fuel tank or fuel delivery pipeline 9386
1 6 Air conditioner 9386
1 6 1 Remedial measures: 9386
1 7 Airbag System 9387
1 8 Check the seat belts 9387
1 8 1 Belt body 9388
1 8 2 Automatic retractor (locking function) 9388
1 8 3 Visual inspection of the seat belt buckle 9389
1 8 4 Seat belt buckle function 9389
1 8 5 Seat belt guide member and tongue 9390
1 8 6 Fixing piece and fixing point 9390
1 9 Safety specifications for the seat belt tensioner 9390
1 10 Body repair on a vehicle equipped with the seat belt tensioners 9391
1 10 1 The following vehicles have been equipped with: 9391
1 11 Perform cutting off, correcting and/or leveling on a vehicleequipped with airbags 9392
1 12 Remove the front seats with a side airbag 9392
2 Basic instruction 9393
2 1 Diagnosis of the accident vehicle 9393
2 2 Condition of the body and/or the parts for delivery to thepainting workshop 9393
2 3 Correction 9393
2 4 Cutting 9393
2 5 Body-cut part and part section 9393
2 6 Original connection 9394
2 7 Galvanized body parts 9394
2 8 Remove the rest part 9394
2 9 New parts 9394
2 10 Parts 9394
2 11 Molded foam plastic pads 9395
3 Symbolic interpretation 9396
3 1 Symbolic interpretation for welding 9396
3 2 Symbolic interpretation for the operation method 9396
3 2 1 Grinding 9397
3 2 2 Thinning 9397
3 2 3 Punching 9397
3 2 4 Drilling 9398
3 2 5 Polishing 9398
3 2 6 Cavity corrosion protection 9398
3 2 7 Bonding 9399
3 2 8 Precise sealing 9399
4 Body repair tools 9400
4 1 Flaring tool -V A G 1317- 9400
4 2 Punching pliers -V A G 1329- 9400
4 3 Basic equipment -V A G 1366/3- 9400
4 4 Bottom protection layer spray gun -V A G 1379- 9401
4 5 Electric blower -V A G 1416- 9401
4 6 Door tensioner -V A G 1438- 9401
4 7 Body equipment component -V A G 1439- 9402
4 8 Pneumatic cutting knife -V A G 1523 A- 9402
4 9 Air chisel -V A G 1577- 9402
4 10 Edge closing iron block -V A G 1585- 9403
4 11 Welding fume ventilator -V A G 1586- 9403
4 12 Welding spot releasing device -V A G 1731- 9403
4 13 Pneumatic spray gun -V A G 1761/1- 9404
4 14 Pneumatic punching and thinning pliers -VAS 1996- 9404
4 15 Pneumatic adhesive spray gun -V A G 2005- 9404
4 16 Door hinge correction tool 9405
4 17 Hose kit 5023 for the inert gas protection welding 9405
4 18 Angle grinder -VAS 5174- 9405
4 19 Angle grinder -VAS 5175- 9406
4 20 Wire brush -VAS 5182- 9406
5 Body bonding 9407
5 1 Transporter 1991 → 9407
5 1 1 Separation process: 9407
5 1 2 Bonding process: 9407
5 2 Bonding types 9407
5 2 1 Bonding-strong 9407
5 2 2 Bonding-spot welding 9408
5 3 Repair method for replacing the parts 9408
5 3 1 Spot welding and bonding 9408
5 3 2 Plug welding and bonding (if spot welding is impossible) 9408
5 3 3 Welding fume ventilator 9409
5 3 4 Preparations 9409
5 3 5 Trimming 9409
6 Corrosion protection measures 9410
6 1 Corrosion protection 9410
7 Waste disposal instructions 9411
7 1 Waste disposal 9411
7 2 Air pressure tappet exhaust 9411
7 3 Airbag 9412
7 3 1 Waste disposal 9412
8 Contact corrosion protection 9413
8 1 Connection of aluminum alloy/magnesium alloy with steel 9413
9 Steel plate repair 9414
9 1 High-strength body plate 9414
9 2 Galvanized body parts 9414
9 2 1 Preparations 9414
9 2 2 Part cutting 9415
9 2 3 Connection process 9415
9 3 Welding on the galvanized body steel plate 9415
9 3 1 Inert gas protection plug welding SG of the galvanized steelplate 9415
9 3 2 Resistance pressure spot welding RP of the galvanized steelplate 9416
9 3 3 Welding transformer 9416
9 3 4 Welding clamp 9416
9 4 Tearing test 9416
10 Aluminum repair 9417
10 1 Painting 9417
10 2 Surface treatment 9417
10 3 Leveling 9418
10 4 Temperature control for heating 9418
11 Plastic repair method 9419
11 1 Material 9419
11 2 Repairing the pit 9420
11 3 Repairing the scratch 9421
11 4 Repair the crack 9423
11 5 Repairing the small hole (the diameter is more than 30 mm) 9424
11 6 Plastic repair (glass fibre material) 9425
11 7 Repair process 9426
11 7 1 Repairing the breakage position 9426
11 7 2 Repairing the surface damage 9428
12 Glass repair 9429
12 1 Repairing the windshield 9429
12 1 1 Premises 9429
12 1 2 Required special tools, operating equipment, testing instrumentsand auxiliary tools 9430
12 1 3 Repair description 9431
D4B807E182B Electrical system General information 9435
27 – Starter, current supply, CCS 9439
1 Battery -A- 9439
1 1 Important information concerning battery -A- 9439
1 2 Battery -A- types 9440
1 2 1 Low maintenance batteries 9440
1 2 2 Maintenance-free batteries 9440
1 2 3 VRLA Batteries (AGM – Absorbent Glass Mat) 9440
1 3 Warning notes and safety norms 9441
1 3 1 Risks inherent to the handling of automotive batteries 9441
1 3 2 Safety symbols on the Battery -A- 9441
1 4 Battery -A- connection terminals 9443
2 Battery -A- – check 9444
2 1 Battery -A- checking sequence 9444
2 2 Check visually 9444
2 3 Check the battery -A- with inspection window 9445
2 4 Check the battery -A- with battery inspection window “3 colours” 9446
2 5 Check the battery -A- with battery inspection window “2 colours” 9446
2 6 Checking the low-maintenance battery -A- 9447
2 6 1 Checking the electrolyte level 9447
2 6 2 Top it up with distilled water 9449
2 6 3 Verifying the density of the electrolyte 9449
2 7 Check the charge of the Battery -A- 9451
2 7 1 Battery tester with printer -VAS 5097A- 9451
2 7 2 Description of the battery testing device, with printer -VAS 5097A- 9452
2 7 3 Check the battery -A- charge with the battery tester with printer -VAS 5097A- 9453
2 7 4 Battery tester -VAS 6161- 9456
2 7 5 Description of the Battery testing device -VAS 6161- 9457
2 7 6 Checking the Battery -A- charge with the Battery tester -VAS 6161- 9457
2 7 7 Printed protocol information 9458
2 8 Charge acceptance test 9459
2 8 1 Charge acceptance test with the -VAS 6161- 9460
2 8 2 Charge acceptance test with the -VAS 5097A- 9460
2 9 Check the resting current of the battery 9461
2 10 Check the final battery charge 9464
2 11 Checking the resting voltage of batteries (unused or stored vehicles) 9466
3 Battery -A- – charging 9468
3 1 Battery charger -VAS 5095A- 9468
3 1 1 Description of the Battery charger -VAS 5095A- 9469
3 1 2 Charging the Battery -A- with the Battery charger -VAS 5095A- 9469
3 1 3 Charging a heavily drained Battery -A- with the Battery charger -VAS 5095A- 9470
3 1 4 Auxiliary operations with the Battery charger -VAS 5095A- 9471
3 1 5 Trickle charge with the Battery charger -VAS 5095A- 9473
3 2 Battery charger -VAS 5900- 9473
3 2 1 Description of the Battery charger -VAS 5900- 9474
3 2 2 Charging the Battery -A- with the Battery charger -VAS 5900- 9474
3 2 3 Servicing charge with the Battery charger -VAS 5900- 9477
3 2 4 Charging a completely drained battery with the Battery charger -VAS 5900- 9480
3 2 5 Auxiliary operations with the Battery charger -VAS 5900- 9482
3 2 6 Trickle charge operational mode with the Battery charger -VAS 5900- 9484
3 3 Battery charger -VAS 5900A- 9485
3 3 1 Battery charger -VAS 5900A- 9485
3 3 2 Battery charger -VAS 5900A- operation modes 9486
3 4 Battery charger -VAS 5903- 9487
3 4 1 Description of the Battery charger -VAS 5903- 9487
3 4 2 Charging the Battery -A- with the Battery charger -VAS 5903- 9488
3 4 3 Servicing charge with the Battery charger -VAS 5903- 9490
3 4 4 Charging a heavily drained Battery -A- with Battery charger -VAS 5903- 9493
3 4 5 Auxiliary operations with the Battery charger -VAS 5903- 9496
3 4 6 Trickle charge operational mode with the Battery charger -VAS 5903- 9498
3 5 Battery charger -VAS 5906- 9498
3 5 1 Description of the Battery charger -VAS 5906- 9499
3 5 2 Operation mode of the Battery charger -VAS 5906- 9500
3 6 Battery charger -VAS 5908- 9501
3 6 1 General description – battery charger -VAS 5908- 9501
3 6 2 Auto mode on battery charger -VAS 5908- 9503
3 6 3 Charging battery with battery charger -VAS 5908- 9504
3 6 4 Charging battery in support mode with battery charger -VAS 5908- 9506
3 6 5 VAS I-CHECK current draw test with battery charger -VAS 5908- 9508
3 7 Completely flat batteries 9510
3 8 Battery (Delphi) – charging procedure 9511
3 8 1 Completely flat batteries 9512
3 8 2 Charging a single Battery -A- or “rapid charging” 9512
3 8 3 Charging several batteries or “parallel charging” 9512
3 8 4 Charging several batteries – charging in series or “slow charging” 9513
3 8 5 Equalization of batteries 9514
4 Speed regulator (GRA) 9515
4 1 Speed regulator (GRA) – activating/deactivating 9515
92 – Windscreen wash/wipe system 9516
1 Washer hoses – connecting and disconnecting 9516
2 Washer hoses – repair 9518
2 1 Repairing smooth hoses 9518
2 2 Repairing wrinkled hoses 9518
94 – Lights, bulbs, switches – exterior 9521
1 Adhere to the safety warnings and the application of gas-discharge lamps 9521
97 – Wiring 9524
1 Vehicle diagnostic, testing and information system 9524
1 1 Vehicle Diagnosis, Measurement and Information System – connect 9524
2 Harness and connection repairs 9527
2 1 Harness repair kits 9527
2 1 1 Wiring harness repair set -VAS 1978- 9527
2 1 2 Complementary set -VAS 1978/50- 9527
2 1 3 Wiring harness repair set -VAS 1978A- 9528
2 2 Description of tools 9528
2 2 1 Cleaving pliers -VAS 1978/1- 9528
2 2 2 Disassembly tool for terminals 9529
2 2 3 Assembly tool for simple cable linings 9530
2 2 4 Pliers for stripping cables -VAS 1978/3- 9530
2 2 5 Hot air blower -VAS 1978/14- 9531
2 3 General notes on repair work on the electrical system of the vehicle 9532
2 4 Harness repair 9533
2 4 1 Notes on harness repair work 9534
2 4 2 Repairing airbag and seat belt pre-tensioning cables 9534
2 4 3 Repairing CAN-Bus system cables 9537
2 4 4 Replacing antenna cables 9537
2 4 5 Interruption in cables with a repaired section 9539
2 4 6 Interruption in cables with two repaired sections 9542
2 5 Repairing connector terminals and connectors 9545
2 5 1 Notes regarding repair work on connector terminal and connectors 9545
2 5 2 Repairing connector terminals 9545
2 5 3 Assembly of simple cable linings 9547
2 5 4 Repairing connectors with the cutting/compression technique 9550
2 6 Unlocking and disassembling the terminals 9551
2 6 1 Note regarding the unlocking and disassembly of the connectors 9551
2 6 2 Secondary locking 9551
2 6 3 Primary locking 9552
2 6 4 Fastening systems for round terminals 9553
2 6 5 Fastening systems for flat terminals 9554
2 6 6 Fastening device for special terminals 9556
D4B807E1949 Communication 9559
00 – Technical data 9563
1 Repair instructions 9563
1 1 General repair instructions 9563
1 2 Notes on repair of CAN bus wiring 9563
1 3 Transmitting power and aerial fitting locations 9563
91 – Communication 9565
1 Infotainment system 9565
1 1 Layout – infotainment system 9565
1 2 Overview of fitting locations – infotainment system 9567
1 3 Removing and installing display unit for front information display and operating unit control unit -J685- 9568
2 Sound system 9570
2 1 Overview of fitting locations – sound system 9570
2 2 Removing and installing front treble loudspeakers -R20-/-R22- 9570
2 3 Removing and installing rear bass loudspeakers -R15-/-R17- 9571
2 3 1 Removing and installing rear bass loudspeakers -R15-/-R17-, 2-door 9571
2 3 2 Removing and installing rear bass loudspeakers -R15-/-R17-, 4-door 9572
2 4 Removing and installing front bass loudspeakers -R21-/-R23- 9574
3 Aerial systems 9576
3 1 Overview of fitting locations – aerial systems 9576
3 2 Removing and installing aerial amplifiers -R24-/-R83- 9576
3 3 Removing and installing roof aerial -RX5- 9578
3 4 Removing and installing aerials -R11-/-R93-/-R183- 9579
4 Radio 9580
4 1 Overview – Radio 9580
4 2 Removing and installing radio display unit for front information display and operating unit control unit -J685- 9580
5 Telephone system 9582
5 1 Mobile telephone preparation 9582
5 1 1 Mobile telephone preparation, Bluetooth hands-free system 9582
5 1 2 Mobile telephone preparation, Bluetooth car phone online 9582
5 2 Overview of fitting locations – telephone system 9583
5 3 Removing and installing aerial amplifier for mobile telephone -R86- 9584
5 4 Removing and installing telephone microphone -R38- 9585
6 Multifunction steering wheel 9587
6 1 Layout multi-function steering wheel 9587
6 2 Overview – multifunction steering wheel 9587
6 3 Removing and installing steering wheel multifunction buttons -E441-/-E440- 9588
6 4 Removing and installing Tiptronic switch in steering wheel -E439-/-E438- 9592
7 Connection for external multimedia devices 9593
7 1 Overview of fitting locations – connection for external multimedia devices 9593
7 2 Removing and installing connection for external multimedia devices 9594
7 2 1 Removing and installing connection for external multimedia devices, USB connection retainer -R193- 9594
7 2 2 Removing and installing connection for external multimedia devices, connection for external audio sources -R199- 9594
7 3 Removing and installing interface for external multimedia devices -R215- 9595
D4B807E3326 Electrical system 9597
27 – Starter, current supply, CCS 9603
1 Battery 9603
1 1 Battery -A- – disconnect and connect 9604
1 1 1 Disconnect the Battery -A- (Version 1) 9605
1 1 2 Connect the Battery -A- (Version 1) 9606
1 1 3 Disconnect the Battery -A- (Version 2) 9608
1 1 4 Connect the Battery -A- (Version 2) 9609
1 1 5 Disconnect the Battery -A- (Versions 3 and 4) 9610
1 1 6 Connect the Battery -A- (Versions 3 and 4) 9611
1 1 7 Disconnect the Battery -A- (Version 5) 9613
1 1 8 Connect the Battery -A- (Version 5) 9614
1 1 9 Disconnect the Battery -A- (Version 6) 9615
1 1 10 Connect the Battery -A- (Version 6) 9616
1 2 Battery -A- – remove and install 9617
1 2 1 Remove the Battery -A- (Version 1) 9617
1 2 2 Install the Battery -A- (Version 1) 9618
1 2 3 Remove the Battery -A- (Version 2) 9619
1 2 4 Install the Battery -A- (Version 2) 9619
1 2 5 Remove the Battery -A- (Version 3) 9620
1 2 6 Install the Battery -A- (Version 3) 9621
1 2 7 Remove the Battery -A- (Version 4) 9623
1 2 8 Install the Battery -A- (Version 4) 9624
1 2 9 Remove the Battery -A- (Version 5) 9625
1 2 10 Install the Battery -A- (Versions 5 and 6) 9626
1 3 Battery -A- console – remove and install 9628
1 3 1 Battery -A- console (version 1) – remove and install 9628
1 3 2 Battery -A- console (version 2) – remove and install 9629
1 4 Tightening torques – battery 9630
2 Starting motor 9631
2 1 Starter -B- – remove and install 9631
2 1 1 Starter -B- for vehicles with 1 0l, 1 6l and 2 0l engines (ARA, BAH, BPA, CCRA, BBX, CFEA) 9632
2 1 2 Starter -B- for vehicles with 1 4l engines (BBZ, BBY, BKY) 9633
2 1 3 Starter -B- for vehicles with 1 4l engine (BAY) 9634
2 1 4 Starter -B- for vehicles with 1 9l engine (ASY) 9635
2 2 Starter -B- – (Manufacturer Valeo) – disassemble and assemble 9637
2 2 1 Magnetic switch – remove and install 9637
2 2 2 Armature and gearing pinion – remove and install 9638
2 3 Starter -B- – (Manufacturer Bosch) – disassemble and assemble 9642
2 3 1 Magnetic switch – remove and install 9643
2 3 2 Armature – remove and install 9645
2 3 3 Gearing pinion (Fastened on armature shaft) – remove and install 9648
2 3 4 Gearing pinion (Fastened on planetary shaft) – remove and install 9651
2 3 5 Bearing Bushing – remove and install 9654
2 4 Tightening torques – Starter 9656
3 Alternator 9657
3 1 Securing battery positive wire to alternator 9657
3 2 Checking poly V-belt 9657
3 3 Voltage regulator for alternator 9657
3 3 1 Removing and installing voltage regulator, manufacturer: Bosch 9657
3 3 2 Removing and installing voltage regulator, manufacturer: Valeo 9658
3 4 Checking alternator -C- 9660
3 5 Alternator, vehicles with 1 0 l TSI engine 9660
3 5 1 Assembly overview – alternator with sliding bushes 9660
3 5 2 Assembly overview – alternator without sliding bushes 9661
3 5 3 Removing and installing alternator, vehicles with 1 0 l TSI engine 9662
3 5 4 Removing and installing poly V-belt pulley without freewheel 9664
3 5 5 Removing and installing poly V-belt pulley with freewheel, manufacturer: Bosch 9665
3 5 6 Removing and installing poly V-belt pulley with freewheel, manufacturer: Valeo 9667
3 5 7 Removing and installing decoupler pulley with freewheel 9669
3 5 8 Removing and installing voltage regulator -C1-, manufacturer: Bosch 9671
3 5 9 Removing and installing voltage regulator -C1-, Valeo 9672
3 6 Alternator, 1 4 l 55 kW injection engine 9674
3 6 1 Assembly overview 9674
3 6 2 Compact bracket tightening sequence 9676
3 6 3 Removing and installing alternator, 1 4 l 55 kW injection engine 9676
3 6 4 Routing poly-V-belt, 1 4 l 55 kW injection engine 9680
3 7 Alternator, 1 4 l 63 kW FSI engine 9681
3 7 1 Assembly overview 9681
3 7 2 Removing and installing alternator, 1 4 l 63 kW FSI engine 9683
3 7 3 Routing poly V-belt, 1 4 l 63 kW FSI engine 9686
3 8 Alternator, 1 6 l 77 kW injection engine 9687
3 8 1 Assembly overview – 1 6 l 77 kW injection engine 9687
3 8 2 Removing and installing alternator, 1 6 l 77 kW injection engine 9689
3 8 3 Poly V-belt routing, 1 6 l 77 kW injection engine 9692
90 – Gauges, instruments 9694
1 Combined Instrument 9694
1 1 Locating defects and indicating faults 9694
1 2 Combined instrument -K- – replace 9695
1 3 Combined instrument -K- – remove and install 9697
1 3 1 Removal 9698
1 3 2 Installation 9699
1 4 Combined instrument -K- – description of rear part 9699
1 5 Combined instrument -K- – connector pinout 9700
1 6 Combined instrument -K- – control light symbols 9700
1 6 1 Version (12/07►) 9700
1 6 2 Version (07/06►) 9701
1 6 3 Version (► 07/06) 9702
2 Indication of Service Interval 9704
2 1 Service interval indication – reset to zero 9704
3 Cigarette lighter and 12V socket 9705
3 1 Cigarette lighter -U1- and 12V socket -U5- – general overview of assembly 9705
3 2 Cigarette lighter -U1- and 12V socket -U5- – remove and install 9705
3 2 1 Removal 9706
3 2 2 Installation 9708
92 – Windscreen wash/wipe system 9709
1 Windscreen wiper system 9709
1 1 Windscreen wiper system – assembly overview 9710
1 2 Windscreen wiper blade – remove and install 9711
1 2 1 Windscreen wiper blade 9711
1 2 2 Windscreen wiper blade – streamlined (version 1) 9712
1 2 3 Windscreen wiper blade – streamlined (version 2) 9713
1 3 Windscreen wiper blade and arm set – remove and install 9714
1 3 1 Removal 9714
1 3 2 Installation 9716
1 4 Windscreen wiper mechanism – remove and install 9716
1 4 1 Removal 9716
1 4 2 Installation 9717
1 5 Windscreen wiper motor -V- – disassemble and assemble 9717
1 5 1 Disassembly 9717
1 5 2 Assembly 9718
1 6 Windscreen wiper blade resting position – adjust 9719
1 6 1 Driver’s side 9720
1 6 2 Passenger’s side 9720
1 7 Blade application angle on the windscreen – adjust 9721
1 8 Tightening torque – Windscreen wiper system 9722
1 9 Rain sensor -G213- – remove and install 9723
1 9 1 Removal 9723
1 9 2 Installation 9724
1 10 Rain sensor and sunlight penetration photosensor -G397- – remove and install 9725
1 10 1 Removal 9725
1 10 2 Installation 9726
2 Windscreen washer system 9728
2 1 Windscreen washer system – assembly overview 9728
2 2 Reservoir for the windscreen and rear window washer system (version 1) – remove and install 9729
2 2 1 Removal 9729
2 2 2 Installation 9731
2 3 Reservoir for the windscreen and rear window washer system (version 2) – remove and install 9731
2 3 1 Removal 9732
2 3 2 Installation 9733
2 4 Windscreen and rear window washer pump -V59- – remove and install 9733
2 4 1 Removal 9733
2 4 2 Installation 9734
2 5 Tightening torque – windscreen and rear window washer system 9734
2 6 Windscreen washer system spray nozzles – replace 9734
2 6 1 Removal 9734
2 6 2 Installation 9734
2 7 Windscreen washer system spray nozzles – adjust 9735
2 7 1 Pre-adjusted washer jets (fan-type nozzles) 9735
3 Rear window wiper system 9737
3 1 Rear window wiper and washer system – assembly overview 9737
3 2 Rear window wiper arm – remove and install 9738
3 2 1 Removal 9738
3 2 2 Installation 9739
3 3 Rear window wiper motor -V12- – remove and install 9739
3 3 1 Removal 9739
3 3 2 Installation 9740
3 4 Tightening torques – rear window wiper system 9740
3 5 Rear window wiper blade resting position – adjust 9740
3 6 Rear window wiper blade – remove and install 9741
3 6 1 Rear window wiper blade (version 1) 9741
3 6 2 Rear window wiper blade (version 2) 9741
4 Rear window washer system 9743
4 1 Rear window washer system – assembly overview 9743
4 2 Rear window washer system spray nozzle – replace 9744
4 2 1 Removal 9744
4 2 2 Installation 9745
4 3 Rear window washer system spray nozzle – adjust 9745
94 – Lights, bulbs, switches – exterior 9747
1 Headlights 9747
1 1 Assembly overview – headlight 9747
1 1 1 Assembly overview – halogen headlights H7, version 1 9747
1 1 2 Assembly overview – halogen headlights H7, version 2 9749
1 1 3 Assembly overview – gas discharge headlight 9751
1 1 4 Assembly overview – LED headlights 9753
1 2 Removing and installing headlight 9755
1 3 Adjusting headlights 9757
1 3 1 Adjusting headlights, halogen headlights H7 9757
1 3 2 Adjusting headlights, gas discharge headlight 9757
1 3 3 Adjusting headlights, auxiliary headlight 9758
1 4 Adjusting headlight installation position 9758
1 5 Removing and installing front turn signal bulb -M5-/-M7- 9759
1 5 1 Removing and installing front turn signal bulb -M5-/-M7-, halogen headlights H7, version 1 9759
1 5 2 Removing and installing front turn signal bulb -M5-/-M7-, halogen headlights H7, version 2 9760
1 5 3 Removing and installing front turn signal bulb -M5-/-M7- (gas discharge headlights) 9762
1 5 4 Removing and installing front turn signal bulb -M5-/-M7-, LED headlights 9764
1 6 Installing repair kit for headlight housing 9765
1 7 Converting headlights from driving on right to driving on left 9767
1 7 1 Changing headlights over from driving on right to driving on left, left halogen headlight H7 9767
1 7 2 Changing headlights over from driving on right to driving on left, left gas discharge headlight 9768
1 7 3 Changing headlights over from driving on right to driving on left, left LED headlight 9769
1 7 4 Changing headlights over from driving on right to driving on left, right halogen headlight H7 9770
1 7 5 Changing headlights over from driving on right to driving on left, right gas discharge headlight 9771
1 7 6 Changing headlights over from driving on right to driving on left, right LED headlight 9771
1 8 Converting headlights from driving on left to driving on right 9773
1 8 1 Changing headlights over from driving on left to driving on right, left halogen headlight H7 9773
1 8 2 Changing headlights over from driving on left to driving on right, left gas discharge headlight 9774
1 8 3 Changing headlights over from driving on left to driving on right, left LED discharge headlight 9775
1 8 4 Changing headlights over from driving on left to driving on right, right halogen headlight H7 9776
1 8 5 Changing headlights over from driving on left to driving on right, right gas discharge headlight 9777
1 8 6 Changing headlights over from driving on left to driving on right, right LED headlight 9777
1 9 Removing and installing headlight range control motor -V48-/-V49- 9778
1 9 1 Removing and installing headlight range control motor -V48-/-V49-, halogen headlights H7, version 1 9778
1 9 2 Removing and installing headlight range control motor -V48-/-V49-, halogen headlights H7, version 2 9780
1 9 3 Removing and installing headlight range control motor -V48-/-V49- (gas discharge headlights) 9783
1 9 4 Headlight range control motors -V48-/-V49-, LED headlights 9785
1 10 Removing and installing headlight dipped beam bulb -M29-/-M31- 9788
1 10 1 Removing and installing headlight dipped beam bulb -M29-/-M31-, halogen headlights H7, version 1 9788
1 10 2 Removing and installing headlight dipped beam bulb -M29-/-M31-, halogen headlights H7, version 2 9790
1 10 3 Headlight dipped beam bulb -M29-/-M31-, LED headlights 9791
1 11 Removing and installing headlight main beam bulb -M30-/-M32- 9794
1 11 1 Removing and installing headlight main beam bulb -M30-/-M32-, halogen headlights H7, version 1 9794
1 11 2 Removing and installing main beam headlight bulb -M30-/-M32-, halogen headlights H7, version 2 9796
1 11 3 Headlight main beam bulb -M30-/-M32-, LED headlights 9797
1 12 Removing and installing gas discharge bulb -L13-/-L14- 9800
1 13 Removing and installing side light bulb -M1-/-M3- 9802
1 13 1 Removing and installing side light bulb -M1-/-M3-, halogen headlights H7, version 1 9802
1 13 2 Removing and installing side light bulb -M1-/-M3-, halogen headlights H7, version 2 9803
1 13 3 Removing and installing side light bulb -M1-/-M3-, gas discharge headlights 9805
1 14 Removing and installing daytime running light bulb -L174-/-L175- 9806
1 14 1 Removing and installing daytime running light bulb -L174-/-L175-, halogen headlights H7 9806
1 14 2 Removing and installing daytime running light bulb -L174-/-L175-, gas discharge headlights 9806
1 15 Removing and installing headlight screen adjustment solenoid -N395-/-N396- 9806
1 16 Removing and installing bulbs for cornering light -M51-/-M52- 9807
1 17 Removing and installing headlight starter for gas discharge light -J426-/-J427- 9808
1 18 Removing and installing LED modules for daytime running light and side light -L176-/-L177- 9810
1 19 Removing and installing starter unit for gas discharge bulb 9810
1 20 Removing and installing output module 1 for LED headlight -A27-/-A31- 9811
1 21 Removing and installing control unit for daytime running light and side light -J860-/-J861- 9812
2 Fog lights (►07/11) 9814
2 1 Fog lights – remove and install 9814
2 1 1 Removal 9814
2 1 2 Installation 9814
2 2 Left fog light lamp -L22- andRight fog light lamp -L23- – replace 9815
2 2 1 Removal 9815
2 2 2 Installation 9815
3 Side mounted repeater turn signals 9817
3 1 Removing and installing side mounted repeater turn signal 9817
4 Taillights 9819
4 1 Tail lights – assembly overview 9819
4 2 Removing and installing bulb carrier 9819
4 3 Removing and installing tail light 9820
5 Number plate light 9822
5 1 Removing and installing number plate light -X4-/-X5- 9822
5 2 Removing and installing bulb for number plate light -X4-/-X5- 9823
6 High level brake light 9825
6 1 Assembly overview – high-level brake light 9825
6 2 Removing and installing high-level brake light 9825
6 3 Removing and installing high-level brake light bulb -M25- 9828
7 Light switches on the instrument panel 9829
7 1 Light switch -E1- – remove and install 9829
7 1 1 Removal 9829
7 1 2 Installation 9830
7 2 Headlight reach adjustment control -E102- and/or Instrument switch and lighting adjustment -E20- – remove and install 9830
7 2 1 Removal 9830
7 2 2 Installation 9831
8 Automatic headlight range control 9832
8 1 Assembly overview – automatic headlight range control 9832
8 2 Removing and installing headlight range control unit -J431- 9832
9 Switch set 9834
9 1 Indicator and wiper/washer switches – remove and install 9834
9 1 1 Removal 9834
9 1 2 Installation 9835
9 2 Connectors pinout in the switch set for turn lights and window wipers/washers 9836
10 Steering column switch 9837
10 1 Removing and installing steering column switch 9837
10 2 Removing and installing airbag coil connector and return ring with slip ring -F138 – 9841
11 Ignition/starter switch and lock cylinder 9844
11 1 Removing and installing lock cylinder 9844
11 2 Ignition/starter switch -D- 9846
11 2 1 Removing and installing ignition/starter switch -D- 9846
11 2 2 Pin assignment for ignition/starter switch -D- 9847
11 3 Removing and installing ignition key withdrawal lock solenoid -N376- 9848
11 4 Steering lock housing 9849
11 4 1 Removing and installing steering lock housing 9849
12 Auxiliary parking system 9852
12 1 Locating defects and indicating faults 9852
12 2 Auxiliary parking system – assembly general view 9852
12 3 Control unit for Park Assist steering -J446- (Hatch) – remove and install 9854
12 3 1 Removal 9854
12 3 2 Installation 9855
12 4 Warning buzzer for rear parking aid -H15- (Hatch) – remove and install 9855
12 4 1 Removal 9855
12 4 2 Installation 9856
12 5 Control unit for Park Assist steering -J446- (Sedan) – remove and install 9856
12 5 1 Removal 9856
12 5 2 Installation 9856
12 6 Warning buzzer for rear parking aid -H15- (Sedan) – remove and install 9857
12 6 1 Removal 9857
12 6 2 Installation 9857
12 7 Parking aid sensor – remove and install 9857
12 7 1 Removal 9857
12 7 2 Installation 9858
96 – Lights, bulbs, switches – interior 9861
1 Lights and internal switches 9861
1 1 Interior monitoring deactivation switch -E267- (version 1) – remove and install 9861
1 1 1 Removal 9861
1 1 2 Installation 9862
1 2 Interior monitoring deactivation switch -E267- (version 2) – remove and install 9862
1 2 1 Removal 9862
1 2 2 Installation 9863
2 Lights and switches in the engine compartment 9864
2 1 Contact switch for bonnet -F266- – remove and install 9864
2 1 1 Removal 9864
2 1 2 Installation 9864
3 Switched on the instrument panel 9865
3 1 Dashboard switches – remove and install 9865
3 1 1 Removal 9866
3 1 2 Installation 9866
4 Front door lights and switches 9867
4 1 Front and rear window drive switches – remove and install 9867
4 1 1 Removal 9867
4 1 2 Installation 9868
4 2 Right front window drive switch -E41- – remove and install 9868
4 2 1 Removal 9868
4 2 2 Installation 9868
4 3 Rear-view mirror adjustment switch -E43- with switch for rear-view mirror adjustment -E48- – remove and install 9868
4 3 1 Removal 9868
4 3 2 Installation 9869
4 4 Front internal lighting switch (door contact) -E459- – remove and install 9869
5 Rear door lights and switches 9870
5 1 Power window drive switch on left rear door -E52- and/or Power window drive switch on right rear door -E54- – remove and install 9870
5 1 1 Removal 9870
5 1 2 Installation 9871
6 Lights and switches in luggage compartment 9872
6 1 Luggage compartment lighting switch -F5- – remove and install 9872
6 2 Luggage compartment lighting – remove and install 9872
6 2 1 Removal 9872
6 2 2 Installation 9873
6 3 Luggage Compartment lighting fixture -W3- – replace 9873
7 Roof lining lights and switches 9874
7 1 Internal front light -W1- 9874
7 1 1 Internal front light -W1- – remove and install 9874
7 1 2 Internal front light -W1- – replace lamp 9875
7 2 Front internal light -W1- with reading light 9876
7 2 1 Front internal light -W1- with reading light – remove and install 9876
7 2 2 Front internal light -W1- with sunroof – remove and install 9877
7 2 3 Sunroof sliding adjustment -E139- – remove and install 9878
7 2 4 Front internal light -W1- with reading light (version 1) – replace the lamp 9879
7 2 5 Front internal light -W1- with reading light (version 2) – replace the lamp 9880
7 2 6 Driver side reading light -W19- and/orPassenger side reading light -W13- (version 1) – replace the lamps 9881
7 2 7 Driver side reading light -W19- and/orPassenger side reading light -W13- (version 2) – replace the lamps 9883
7 3 Make-up mirror lighting – remove and install 9884
7 3 1 Removal 9884
7 3 2 Installation 9885
7 3 3 Make-up mirror lighting lamp -L31- – replace 9885
7 4 Internal rear light -W43- 9885
7 4 1 Internal rear light -W43- – remove and install 9885
7 4 2 Internal rear light -W43- – replace lamp 9886
8 Horns 9888
8 1 Treble tone horn -H2- – remove and install 9888
8 1 1 Removal 9888
8 1 2 Installation 9889
8 2 Treble tone horn -H2- and Bass tone horn -H7- – remove and install 9890
8 2 1 Removal 9890
8 2 2 Installation 9891
8 3 Horn actuator -H- 9891
9 Immobilizer 9892
9 1 Immobilizer control unit -J362- – replace 9892
9 2 Immobilizer reading coil -D2- – remove and install 9892
9 3 Ignition key – variable code transponder 9892
9 4 Ignition key – adapt to immobilizer 9892
9 5 Ignition key – replace battery 9893
10 Alarm system 9894
10 1 Locating defects and indicating faults 9894
10 2 Anti-theft alarm system – activate and deactivate 9895
10 3 Ultra-sound sensor for alarm system -G209- – remove and install 9895
10 3 1 On vehicles without sunroof 9896
10 3 2 On vehicles with sunroof 9896
10 4 Alarm system horn -H8- – remove and install 9897
10 4 1 Removal 9898
10 4 2 Installation 9898
97 – Wiring 9899
1 Relay carriers, fuse holders, electronics boxes 9899
1 1 Overview of fitting locations – relay carriers, fuse holders, electronics boxes 9899
1 2 Removing and installing electronics box (E-box) 9900
1 3 Removing and installing bracket for electronics box 9902
1 4 Removing and installing fuse holder C -SC- 9903
1 5 Removing and installing relay and fuse carrier 1 -SR1- 9905
2 Control units 9908
2 1 Overview of fitting locations – control units 9908
2 1 1 Overview of fitting locations – control units, front 9908
2 1 2 Overview of fitting locations – control units, rear 9908
2 2 Removing and installing onboard supply control unit -J519- 9909
2 3 Removing and installing data bus diagnostic interface -J533- 9911
3 Connectors 9912
3 1 Repairing electrical wiring harnesses and plug-in connections 9912
3 1 1 Repairs to wiring harnesses and connectors 9912
3 1 2 Repairing connector housings and electrical connectors 9912
4 Releasing and dismantling connector housings 9913
5 Repairing aerial cables 9914
6 Optical fibre conductor 9915
7 Vehicle diagnosis, testing and information systems 9916
D4B809E6584 General body repairs exterior 9917
50 – Body – front 9925
1 Lock carrier 9925
1 1 Assembly overview – lock carrier 9925
1 2 Removing and installing lock carrier 9926
1 3 Moving to and back from service position 9928
1 4 Releasing and engaging pressure hose with plug-in connector 9932
2 Wings 9933
2 1 Assembly overview – wing 9933
2 2 Assembly overview – insulation and foam elements 9934
2 3 Removing and installing wing 9934
2 4 Removing and installing wing bracket 9938
3 Bulkhead 9940
3 1 Assembly overview – plenum chamber bulkhead 9940
3 2 Assembly overview – plenum chamber bulkhead 9942
3 3 Assembly overview – plenum chamber cover 9943
3 4 Removing and installing plenum chamber bulkhead 9943
3 5 Removing and installing plenum chamber cover 9945
55 – Bonnet, rear lid 9948
1 Bonnet (hood) 9948
1 1 Assembly overview – bonnet 9948
1 2 Assembly overview – Bowden cable 9950
1 3 Assembly overview – bonnet release lever 9951
1 4 Removing and installing bonnet 9951
1 5 Adjusting bonnet 9954
1 6 Adjusting lid lock 9955
1 7 Adjusting striker pin 9956
1 8 Removing and installing bonnet lock 9956
1 8 1 Removing and installing lid lock, LHD vehicle 9956
1 8 2 Removing and installing lid lock, RHD vehicle 9959
1 9 Removing and installing bonnet release lever 9962
1 10 Removing and installing striker pin 9962
1 11 Removing and installing hinges 9963
1 12 Removing and installing insulation 9965
1 13 Removing and installing support rod 9968
1 14 Detaching Bowden cable 9969
2 Rear lid 9970
2 1 Assembly overview – rear lid 9970
2 2 Assembly overview – hinges 9972
2 3 Assembly overview – gas strut 9973
2 4 Removing and installing rear lid 9973
2 5 Removing and installing stop buffer 9977
2 6 Adjusting rear lid 9977
2 7 Adjusting striker pin 9979
2 8 Adjusting adjusting buffer 9980
2 9 Removing and installing bonnet lock 9982
2 10 Removing and installing operating mechanism 9984
2 11 Removing and installing hinges 9986
2 12 Removing and installing striker pin 9988
2 13 Removing and installing rear lid seal 9990
2 14 Removing and installing gas strut 9991
2 15 Releasing gas from gas strut 9993
3 Tank flap unit 9994
3 1 Assembly overview – tank flap unit 9994
3 2 Removing and installing tank flap unit 9994
3 3 Removing and installing actuator 9997
57 – Front doors, door components, central locking 9999
1 Door 9999
1 1 Assembly overview – door 9999
1 2 Removing and installing inner door seal 10001
1 3 Removing and installing outer door seal 10003
1 3 1 Removing and installing door outer seal, 2-door model 10003
1 3 2 Removing and installing door outer seal, 4-door model 10004
1 4 Removing and installing door 10005
1 5 Installing after renewing A-pillar 10007
1 6 Adjusting door 10009
1 7 Adjusting striker pin 10011
1 8 Removing and installing door arrester 10013
2 Door components 10015
2 1 Assembly overview – door components 10015
2 1 1 Assembly overview – door components, 2-door model 10015
2 1 2 Assembly overview – door components, 4-door model 10017
2 2 Assembly overview – door handle and door lock 10018
2 3 Assembly overview – insulation 10019
2 3 1 Assembly overview – insulation, 2-door model 10019
2 3 2 Assembly overview – insulation, 4-door model 10020
2 4 Removing and installing window regulator motor 10020
2 5 Removing and installing window regulator 10022
2 6 Removing and installing inner door cover 10025
2 6 1 Removing and installing inner door cover, 2-door model 10025
2 6 2 Removing and installing inner door cover, 4-door model 10027
2 7 Removing and installing striker pin 10028
2 8 Removing and installing lock cylinder cover cap 10029
2 9 Removing and installing lock cylinder 10030
2 10 Removing and installing cap without lock cylinder 10032
2 11 Removing and installing door handle 10036
2 12 Removing and installing mounting bracket 10038
2 13 Removing and installing door lock 10039
2 14 Removing and installing window channel 10044
2 15 Removing and installing window slot inner seal 10046
2 16 Removing and installing window slot outer seal 10047
2 16 1 Removing and installing outer window slot seal, 2-door model 10047
2 16 2 Removing and installing outer window slot seal, 4-door model 10049
3 Central locking 10051
3 1 Overview of fitting locations – central locking 10051
3 2 Removing and installing ignition key battery 10053
3 3 Adapting keys with remote control 10054
58 – Rear doors, door components 10055
1 Door 10055
1 1 Assembly overview – door 10055
1 2 Removing and installing inner door seal 10057
1 3 Removing and installing outer door seal 10059
1 4 Removing and installing door 10060
1 5 Installing after renewing B-pillar 10062
1 6 Adjusting door 10064
1 7 Adjusting striker pin 10067
1 8 Removing and installing door arrester 10068
2 Door components 10071
2 1 Assembly overview – door components 10071
2 2 Assembly overview – door handle and door lock 10073
2 3 Assembly overview – insulation 10074
2 4 Removing and installing window regulator motor 10074
2 5 Removing and installing window crank 10077
2 6 Removing and installing window crank mechanism 10077
2 7 Removing and installing window regulator 10079
2 8 Removing and installing inner door cover 10082
2 9 Removing and installing striker pin 10082
2 10 Removing and installing cap 10083
2 11 Removing and installing door handle 10087
2 12 Removing and installing mounting bracket 10089
2 13 Removing and installing door lock 10090
2 14 Removing and installing window channel 10094
2 15 Removing and installing window slot inner seal 10096
2 16 Removing and installing window slot outer seal 10097
60 – Sunroof 10099
1 Sliding sunroof 10099
1 1 Function 10099
1 2 Assembly overview – sliding sunroof 10101
1 3 Assembly overview – sunroof roller blind 10103
1 4 Assembly overview – sliding sunroof frame and front trim 10104
1 5 Removing and installing sliding sunroof frame 10105
1 5 1 Minimum curing period 10105
1 5 2 Fitting instructions 10106
1 5 3 Cleaning in the event of dirt caused by adhesive sealant 10106
1 5 4 Touching up paint damage 10106
1 5 5 Materials 10106
1 5 6 Preparing body flange for bonding 10107
1 5 7 Preparing sliding sunroof frame for installation 10107
1 5 8 Removing and installing sliding sunroof frame 10108
1 6 Removing and installing wind deflector 10115
1 7 Removing and installing glass panel 10116
1 8 Removing glass panel when drive is defective 10121
1 9 Adjusting glass panel 10122
1 10 Removing and installing guide plate 10124
1 11 Removing and installing front trim for sliding sunroof 10129
1 11 1 Minimum curing period 10129
1 11 2 Fitting instructions 10129
1 11 3 Cleaning in the event of dirt caused by adhesive sealant 10130
1 11 4 Materials 10130
1 11 5 Preparing front trim for installation 10130
1 11 6 Preparing sliding sunroof frame for installation of front trim 10131
1 11 7 Removing and installing front trim for sliding sunroof 10131
1 12 Removing and installing sliding sunroof adjustment control unit -J245- 10138
1 13 Removing and installing glass panel seal 10141
1 14 Removing and installing interior seal 10142
1 15 Removing and installing cover 10142
1 16 Removing and installing sunroof switch 10144
1 17 Removing and installing sunroof roller blind 10144
1 18 Removing and installing tension bow 10148
1 19 Adapting sliding sunroof adjustment control unit -J245- 10150
1 20 Operating without current 10152
2 Water drain hoses 10153
2 1 Assembly overview – water drainage hoses 10153
2 2 Cleaning water drainage hoses 10153
63 – Bumpers 10156
1 Bumper, front 10156
1 1 Assembly overview – bumper cover 10156
1 1 1 Assembly overview – bumper cover, Polo, »standard« equipment version 10156
1 1 2 Assembly overview – bumper cover, Polo BlueMotion 10158
1 1 3 Assembly overview – bumper cover, CrossPolo 10159
1 1 4 Assembly overview – bumper cover, Polo »GTI« 10160
1 1 5 Assembly overview – bumper cover, Polo »R-Line« 10161
1 2 Assembly overview – impact bar 10161
1 3 Assembly overview – add-on parts 10163
1 3 1 Assembly overview – add-on parts, Polo, »standard« equipment version 10163
1 3 2 Assembly overview – add-on parts, Polo »BlueMotion« 10164
1 3 3 Assembly overview – attachments, »Cross Polo« 10165
1 3 4 Assembly overview – add-on parts, Polo »GTI« 10166
1 3 5 Assembly overview – add-on parts, Polo »R-Line« 10168
1 4 Removing and installing bumper cover 10169
1 4 1 Removing and installing bumper cover, Polo, »standard« equipment version 10169
1 4 2 Removing and installing bumper cover, Polo BlueMotion 10173
1 4 3 Removing and installing bumper cover, CrossPolo 10177
1 4 4 Removing and installing bumper cover, Polo »GTI« 10181
1 4 5 Removing and installing bumper cover, Polo »R-Line« 10185
1 5 Installing number plate carrier 10188
1 6 Repairing bumper cover 10189
1 7 Installing brackets for parking aid system 10190
2 Bumper, rear 10195
2 1 Assembly overview – bumper cover 10195
2 1 1 Assembly overview – bumper cover, Polo, »standard« equipment version 10195
2 1 2 Assembly overview – bumper cover, Polo BlueMotion 10197
2 1 3 Assembly overview – bumper cover, CrossPolo 10198
2 1 4 Assembly overview – bumper cover, Polo GTI, Polo BlueGT 10199
2 1 5 Assembly overview – bumper cover, Polo »R-Line« 10200
2 2 Assembly overview – impact bar 10200
2 3 Assembly overview – add-on parts 10202
2 3 1 Assembly overview – add-on parts, Polo BlueMotion 10202
2 3 2 Assembly overview – attachments, Cross Polo 10203
2 3 3 Assembly overview – add-on parts, Polo GTI, Polo BlueGT 10204
2 3 4 Assembly overview – add-on parts, Polo »R-Line« 10204
2 4 Removing and installing bumper cover 10205
2 4 1 Removing and installing bumper cover, Polo, »standard« equipment version 10205
2 4 2 Removing and installing bumper cover, Polo »BlueMotion« 10208
2 4 3 Removing and installing bumper cover, CrossPolo 10211
2 4 4 Removing and installing bumper cover, Polo GTI, Polo BlueGT 10213
2 4 5 Removing and installing bumper cover, Polo »R-Line« 10216
2 5 Installing number plate carrier 10218
2 6 Repairing bumper cover 10219
2 7 Installing brackets for parking aid system 10220
64 – Glazing 10225
1 Repair instructions 10225
1 1 Minimum curing periods for bonded windows 10225
1 2 Installation instructions for bonded windows 10226
1 3 Preparing old undamaged windows for fitting 10227
1 4 Preparing new windows for installing 10227
1 5 Preparing body flange for fitting 10228
1 6 Cleaning off excess adhesive 10228
2 Windscreen 10229
2 1 Assembly overview – windscreen 10229
2 2 Removing and installing windscreen 10230
3 Rear windscreen 10235
3 1 Assembly overview – rear window 10235
3 2 Removing and installing rear window 10236
3 3 Removing broken rear window 10240
4 Side window 10241
4 1 Assembly overview – rear side windows 10241
4 1 1 Assembly overview – rear side window, 2-door model 10241
4 1 2 Assembly overview – rear side window, 4-door model 10242
4 2 Removing and installing rear side window 10243
4 2 1 Removing and installing rear side window, 2-door model 10243
4 2 2 Removing and installing rear side window, 4-door model 10246
4 3 Removing broken rear side window 10250
5 Door windows 10251
5 1 Assembly overview – front door window 10251
5 2 Assembly overview – rear door window 10252
5 3 Removing and installing front door window 10253
5 4 Removing and installing rear door window 10258
66 – Exterior equipment 10262
1 Radiator grille and front trim 10262
1 1 Assembly overview – radiator grille 10262
1 1 1 Assembly overview – radiator grille »GTI« 10262
1 1 2 Assembly overview – radiator grille 10263
1 2 Removing and installing radiator grille 10263
2 Spoiler 10267
2 1 Assembly overview – spoiler 10267
2 1 1 Assembly overview – spoiler, Polo »BlueMotion« 10267
2 1 2 Assembly overview – spoiler, Polo »GTI« 10268
2 1 3 Assembly overview – spoiler, Polo »Blue GT« 10269
2 1 4 Assembly overview – spoiler, Polo »R-Line« 10270
2 2 Removing and installing spoiler 10270
2 2 1 Removing and installing spoiler, Polo »BlueMotion« 10270
2 2 2 Removing and installing spoiler, Polo »GTI« 10274
2 2 3 Removing and installing spoiler, Polo »Blue GT«, Polo »R-Line« 10278
2 3 Removing adapter 10282
2 3 1 Removing adapter, Polo BlueMotion 10282
2 3 2 Removing adapter, Polo »GTI« 10284
2 4 Removing and installing side piece of spoiler 10286
2 4 1 Removing and installing side piece of spoiler, Polo »BlueMotion« 10286
2 4 2 Removing and installing side piece of spoiler, Polo »Blue GT« 10290
3 Mouldings, trims, extensions 10296
3 1 Assembly overview – side member trim 10296
3 1 1 Assembly overview – side member trim, Polo »BlueMotion«, Polo »Blue GT« 10296
3 1 2 Assembly overview – side member trim, Cross Polo 10298
3 1 3 Assembly overview – side member trim, Polo »GTI« 10299
3 2 Assembly overview – water deflector 10300
3 3 Assembly overview – B-pillar trim 10301
3 4 Removing and installing front door cover 10301
3 5 Removing and installing adapter for front door cover 10303
3 6 Removing and installing rear door cover 10305
3 7 Removing and installing adapter for rear door cover 10308
3 8 Removing and installing entry moulding 10310
3 8 1 Removing and installing step moulding, Polo, 2-door model 10310
3 8 2 Removing and installing step moulding, Polo, 4-door model 10311
3 9 Removing and installing side member trim 10314
3 9 1 Removing and installing side member trim, Polo »BlueMotion«, Polo »Blue GT« 10314
3 9 2 Removing and installing side member trim, Cross Polo 10318
3 9 3 Removing and installing side member trim, Polo »GTI« 10321
3 10 Removing and installing retaining strip for side member trim 10323
3 10 1 Removing and installing retaining strip for side member trim, Polo »BlueMotion«, Polo »Blue GT« 10323
3 10 2 Removing and installing retaining strip for side member trim, CrossPolo, Polo »GTI« 10325
3 11 Removing and installing water deflector 10331
3 12 Removing and installing A-pillar trim 10334
3 13 Removing and installing B-pillar trim 10336
3 14 Removing and installing C-pillar trim on door 10338
3 15 Wing trim panel 10339
3 16 Removing and installing front wheel arch trim 10341
3 17 Removing and installing rear wheel arch trim 10345
3 18 Removing and installing wheel arch trim of rear door 10349
4 Noise insulation 10353
4 1 Assembly overview – noise insulation 10353
4 1 1 Assembly overview – noise insulation, diesel engines 10353
4 1 2 Assembly overview – noise insulation, long version 10354
4 1 3 Assembly overview – noise insulation, short version 10355
5 Underbody cladding 10356
5 1 Assembly overview – underbody cladding 10356
5 2 Assembly overview – tunnel cross-piece 10357
6 Roof moulding and roof railing 10358
6 1 Assembly overview – roof railing 10358
6 2 Removing and installing roof railing 10358
7 Exterior mirror 10361
7 1 Assembly overview – exterior mirror 10361
7 2 Removing and installing exterior mirror 10362
7 2 1 Removing and installing exterior mirror, manually operated 10362
7 2 2 Removing and installing exterior mirror, electrically operated 10366
7 3 Removing and installing mirror glass 10369
7 4 Removing and installing mirror adjustment unit 10371
7 5 Removing and installing mirror cover 10373
7 6 Removing and installing mirror trim 10374
7 7 Removing and installing assembly bracket 10375
8 Wheel housing liner 10377
8 1 Assembly overview – front wheel housing liner 10377
8 2 Assembly overview – rear wheel housing liner 10378
8 3 Removing and installing front wheel housing liner 10378
8 4 Removing and installing rear wheel housing liner 10380
9 Lettering and emblems 10384
9 1 Dimensions – lettering and emblems on rear lid 10384
9 1 1 Dimensions – lettering and emblems on rear lid 10384
9 1 2 Dimensions – rear lettering, Polo “GTI” 10386
9 1 3 Dimensions – lettering and emblems on rear lid, Polo BlueMotion 10387
9 1 4 Dimensions – lettering and emblems on rear lid, Polo BlueGT 10388
9 2 Dimensions – lettering, rear door 10388
9 3 Dimensions – lettering and emblems, sides 10390
9 3 1 Side emblem on wing – “GTI” 10390
9 3 2 Side emblem on wing – special models 10390
9 4 Removing and installing badges at front 10392
9 4 1 Removing and installing emblems at vehicle front, not Polo BlueMotion, not Polo BlueGT 10392
9 4 2 Removing and installing emblems at vehicle front, Polo BlueMotion 10396
9 4 3 Removing and installing front emblems, Polo BlueGT 10400
9 4 4 Removing and installing emblems at vehicle front, Polo “R-Line” 10401
9 5 Removing and installing lettering and emblems 10401
10 Special add-on parts 10403
10 1 Repair instructions 10403
10 1 1 Safety requirements 10403
10 1 2 Preparing add-on part for installation 10403
10 1 3 Preparing body component 10404
10 1 4 Installation instructions for bonded add-on parts 10405
10 1 5 Minimum curing period for bonded add-on parts 10405
10 1 6 Cleaning off excess adhesive 10406
10 1 7 Cleaning guidelines 10406
10 2 Assembly overview – special add-on parts 10406
10 2 1 Assembly overview – special add-on parts, Polo BlueMotion 10406
10 2 2 Assembly overview – special add-on parts, Cross Polo 10408
10 2 3 Assembly overview – special add-on parts, Polo »GTI« 10409
10 2 4 Assembly overview – special add-on parts, Polo »R-Line« 10410
11 Towing bracket 10411
11 1 Assembly overview – towing bracket 10411
12 Heat shields 10412
12 1 Overview of fitting locations – heat shields 10412
12 2 Removing and installing underbody heat shield 10413
12 3 Removing and installing heat shield for centre exhaust system 10414
12 4 Removing and installing heat shield for rear silencer 10415
D4B8026CEF5 6 speed manual gearbox 0A8 10417
00 – Technical data 10421
1 Identification 10421
1 1 Gearbox identification 10421
2 Technical data 10422
2 1 Allocation gearbox – engine 10422
2 2 Capacities 10422
2 2 1 Capacity, manual gearbox 10422
2 3 Calculation of gear ratios 10422
3 Overview – power transmission 10423
4 Safety information 10425
4 1 Safety precautions when working on vehicles with a start/stop system 10425
5 Electrical components 10426
5 1 Overview of fitting locations – electrical components 10426
5 1 1 Overview of fitting locations – electrical components, manual gearbox 10426
5 1 2 Overview of fitting locations – electrical components, clutch mechanism 10426
6 Repair notes 10428
6 1 General repair instructions 10428
30 – Clutch 10431
1 Clutch operation 10431
1 1 Overview of fitting locations – clutch mechanism 10431
1 2 Assembly overview – pedal cluster 10433
1 3 Assembly overview – clutch hydraulics 10435
1 3 1 Assembly overview – clutch hydraulics, left-hand drive 10435
1 3 2 Assembly overview – clutch hydraulics, right-hand drive 10437
1 4 Assembly overview – clutch release mechanism 10439
1 5 Checking clutch master cylinder and clutch slave cylinder 10439
1 6 Removing and installing clutch position sender -G476- 10439
1 7 Removing and installing over-centre spring 10440
1 8 Removing and installing extension spring 10440
1 9 Removing and installing clutch pedal 10441
1 9 1 Removing and installing clutch pedal with over-centre spring, LHD 10441
1 9 2 Removing and installing clutch pedal with extension spring, LHD 10444
1 9 3 Removing and installing clutch pedal with extension spring or with over-centre spring, RHD vehicles 10445
1 10 Removing and installing mounting bracket 10447
1 11 Removing and installing clutch master cylinder 10451
1 12 Removing and installing bleeder 10453
1 13 Removing and installing lines for clutch mechanism 10454
1 14 Removing and installing clutch slave cylinder together with release bearing 10456
1 15 Bleeding clutch mechanism 10457
1 16 Removing and installing clutch pedal switch -F36- 10459
1 17 Repairing clutch release mechanism 10460
2 Clutch 10462
2 1 Assembly overview – clutch 10462
2 1 1 Assembly overview – “Sachs” clutch in connection with dual-mass flywheel 10462
2 1 2 Assembly overview – “LuK” clutch in connection with dual-mass flywheel 10463
2 1 3 Assembly overview – clutch with simple flywheel 10464
2 2 Removing and installing clutch 10465
2 2 1 Removing and installing clutch with “Sachs” dual-mass flywheel 10465
2 2 2 Removing and installing clutch with “LuK” dual-mass flywheel 10469
2 2 3 Removing and installing clutch in connection with simple flywheel 10473
34 – Controls, housing 10478
1 Selector mechanism 10478
1 1 Installation position – selector mechanism 10478
1 2 Overview – selector mechanism 10480
1 3 Assembly overview – gear knob and cover 10481
1 4 Assembly overview – Gear lever and selector housing 10482
1 5 Assembly overview – Selector cables 10483
1 6 Removing and installing gear knob 10486
1 7 Removing and installing selector mechanism 10487
1 8 Renewing oil seal for selector shaft 10490
1 9 Adjusting selector mechanism 10492
1 10 Checking selector mechanism 10494
2 Removing and installing gearbox 10495
2 1 Removing gearbox 10495
2 2 Installing gearbox 10505
2 3 Specified torques for gearbox 10511
3 Assembly mountings 10512
3 1 Assembly overview – assembly mountings 10512
4 Transporting gearbox 10513
5 Gear oil 10514
5 1 Distinguishing between different manual gearbox types when filling oil 10514
5 2 Checking gear oil level 10514
5 2 1 Checking gear oil level, gearboxes “with” oil filler plug 10514
5 2 2 Checking gear oil level, gearboxes “without” oil filler plug 10515
5 2 3 Draining and filling gear oil (only for gearboxes “without” oil filler plug) 10515
6 Installing to engine and gearbox support 10518
7 Dismantling and assembling gearbox 10519
7 1 Schematic overview – gearbox 10519
7 2 Overview – gearbox 10520
7 3 Assembly overview – gearbox housing and selector mechanism 10521
7 4 Assembly overview – selector unit 10523
7 5 Assembly overview – input shaft, output shafts, differential and selector rods 10524
7 6 Assembly overview – selector forks 10526
7 7 Dismantling and assembling gearbox 10526
8 Gearbox housing, clutch housing 10540
8 1 Assembly overview – gearbox housing 10540
8 2 Assembly overview – clutch housing 10542
8 3 Repairing gearbox housing 10543
8 4 Repairing clutch housing 10551
35 – Gears, shafts 10554
1 Input shaft 10554
1 1 Assembly overview – input shaft 10554
1 2 Dismantling and assembling input shaft 10555
1 3 Renewing input shaft seal 10559
2 Output shaft 10561
2 1 Assembly overview – output shaft 10561
2 1 1 Assembly overview – output shaft for 1st to 4th gears 10561
2 1 2 Assembly overview – output shaft for 5th, 6th and reverse gears 10564
2 2 Dismantling and assembling output shaft 10566
2 2 1 Dismantling and assembling output shaft for 1st through 4th gears 10566
2 2 2 Dismantling and assembling output shaft for 5th, 6th and reverse gears 10578
2 3 Adjusting output shaft 10587
2 3 1 Adjusting output shaft for 1st through 4th gears 10587
2 3 2 Adjusting output shaft for 5th, 6th and reverse gears 10592
39 – Final drive – differential 10598
1 Oil seals 10598
1 1 Overview of fitting locations – oil seals 10598
1 2 Renewing left oil seal 10599
1 2 1 Renewing oil seal for left flange shaft 10599
1 3 Renewing right oil seal 10602
1 3 1 Renewing oil seal for right flange shaft 10602
2 Differential 10605
2 1 Assembly overview – differential 10605
2 2 Dismantling and assembling differential 10607
2 3 Adjusting differential 10611
3 Adjustment overview 10615
D4B8026CF4D 4 cyl direct injection (1 4 l 4V EA 211 turbocharger) 10616
00 – Technical data 10622
1 Safety information 10622
1 1 Safety regulations for working on fuel supply 10622
1 2 Safety measures when working on vehicles with a start/stop system 10622
1 3 Safety precautions when using testers and measuring instruments during a road test 10623
1 4 Safety precautions when working on the cooling system 10623
1 5 Safety precautions when working on ignition system 10623
2 Identification 10624
2 1 Engine number/engine data 10624
3 Repair instructions 10626
3 1 Rules for cleanliness 10626
3 2 Foreign objects in engine 10626
3 3 Contact corrosion 10626
3 4 Routing and attachment of lines 10626
3 5 Fitting radiator and condensers 10627
10 – Removing and installing engine 10628
1 Removing and installing motor 10628
1 1 Removing motor 10628
1 2 Separating engine and gearbox 10640
1 3 Securing engine on engine and gearbox support 10642
1 4 Installing engine 10643
2 Assembly mountings 10646
2 1 Assembly overview – assembly mountings 10646
2 1 1 Assembly overview – assembly mountings, manual gearbox 10646
2 1 2 Assembly overview – assembly mountings, dual clutch gearbox 10649
2 2 Removing and installing engine mounting 10652
2 3 Removing and installing gearbox mountings 10654
2 4 Removing and installing pendulum support 10656
2 4 1 Removing and installing pendulum support, manual gearbox 10656
2 4 2 Removing and installing pendulum support, dual clutch gearbox 10657
2 5 Supporting engine in installation position 10658
2 5 1 Supporting engine in installation position, Polo 2010>, Polo 2014>, Polo Lim RUS 2016> 10658
2 5 2 Supporting engine in installation position, Polo Saloon RUS 2020> 10661
13 – Crankshaft group 10663
1 Cylinder block (pulley end) 10663
1 1 Assembly overview – poly V-belt drive 10663
1 1 1 Assembly overview – poly V-belt drive, vehicles without air conditioner compressor 10663
1 1 2 Assembly overview – poly V-belt drive, vehicles with air conditioner compressor 10664
1 2 Assembly overview – sealing flange, belt pulley end 10665
1 3 Removing and installing poly-V belt 10667
1 3 1 Removing and installing poly V-belt, vehicles without air conditioner compressor 10667
1 3 2 Removing and installing poly V-belt, vehicles with air conditioner compressor 10668
1 4 Removing and installing tensioner for poly V-belt 10670
1 4 1 Removing and installing tensioner for poly V-belt, vehicles without air conditioner compressor 10670
1 4 2 Removing and installing tensioner for poly V-belt, vehicles with air conditioner compressor 10671
1 5 Removing and installing vibration damper 10671
1 6 Removing and installing engine support 10673
1 7 Renewing crankshaft oil seal – belt pulley end 10677
1 8 Removing and installing sealing flange on pulley end 10680
2 Cylinder block, gearbox end 10684
2 1 Assembly overview – cylinder block, gearbox end 10684
2 2 Removing and installing flywheel 10686
2 3 Removing and installing sealing flange on gearbox side 10687
3 Crankshaft 10698
3 1 Crankshaft dimensions 10698
3 2 Renewing needle bearing in crankshaft 10698
3 3 Measuring axial clearance of crankshaft 10701
4 Pistons and conrods 10703
4 1 Assembly overview – pistons and conrods 10703
4 2 Removing and installing pistons 10706
4 3 Separating new conrod 10707
4 4 Removing and installing oil spray jets 10708
4 5 Checking pistons and cylinder bores 10709
4 6 Checking radial clearance of conrods 10712
4 7 Setting piston to TDC position 10712
15 – Cylinder head, valve gear 10717
1 Cylinder head 10717
1 1 Assembly overview – cylinder head 10717
1 2 Assembly overview – camshaft housing 10719
1 2 1 Assembly overview – camshaft housing, vehicles with Active Cylinder Management 10719
1 2 2 Assembly overview – camshaft housing, exhaust side with toothed belt pulley 10722
1 3 Removing and installing cylinder head 10724
1 4 Removing and installing camshaft housing 10729
1 5 Checking compression 10733
2 Toothed belt drive 10736
2 1 Assembly overview – toothed belt cover 10736
2 2 Assembly overview – toothed belt 10737
2 2 1 Assembly overview – toothed belt, exhaust side with camshaft adjuster 10737
2 2 2 Assembly overview – toothed belt, exhaust side with toothed belt pulley 10739
2 3 Removing and installing toothed belt guard 10741
2 3 1 Removing and installing upper toothed belt guard 10741
2 3 2 Removing and installing lower toothed belt guard 10742
2 4 Checking valve timing 10742
2 4 1 Checking valve timing, vehicles without ACT 10742
2 4 2 Checking valve timing, vehicles with ACT 10745
2 5 Preassembling and installing valve timing tool 10749
2 5 1 Preassembling test tool -VAS 611 007- without ACT 10749
2 5 2 Preassembling test tool -VAS 611 007- with ACT 10752
2 5 3 Mounting test tool -VAS 611 007- without ACT 10756
2 5 4 Mounting test tool -VAS 611 007- with ACT 10758
2 5 5 Teaching-in test tool -VAS 611 007- electronically and performing basic setting 10761
2 6 Adjusting valve timing 10764
2 6 1 Adjusting valve timing, vehicles without ACT 10764
2 6 2 Adjusting valve timing, vehicles with Active Cylinder Management 10775
2 7 Removing toothed belt from camshaft 10786
2 8 Removing and installing toothed belt 10793
3 Valve gear 10801
3 1 Assembly overview – valve gear 10801
3 2 Removing and installing camshaft oil seal 10803
3 2 1 Removing and installing camshaft oil seal, for inlet camshaft on belt pulley side, exhaust side with toothed belt sprocket 10803
3 2 2 Removing and installing camshaft oil seal, for inlet camshaft on belt pulley side, exhaust side with camshaft adjuster 10805
3 2 3 Removing and installing camshaft oil seal, for exhaust camshaft on belt pulley side, exhaust side with toothed belt sprocket 10807
3 2 4 Removing and installing camshaft oil seal, for exhaust camshaft on belt pulley side, exhaust side with camshaft adjuster 10810
3 2 5 Removing and installing exhaust camshaft oil seal, gearbox end, vehicles with Active Cylinder Management 10812
3 2 6 Removing and installing exhaust camshaft oil seal, gearbox end; exhaust side with toothed belt pulley on control end 10814
3 3 Removing and installing camshaft adjuster 10817
3 3 1 Removing and installing inlet side camshaft adjuster, exhaust side with camshaft adjuster 10817
3 3 2 Removing and installing inlet side camshaft adjuster, exhaust side with toothed belt sprocket 10823
3 3 3 Removing and installing camshaft adjuster for exhaust camshaft 10830
3 4 Removing and installing toothed belt pulley 10836
3 5 Removing and installing camshaft control valve 1 -N205- 10841
3 5 1 Removing and installing camshaft control valve 1 -N205-, vehicles with Active Cylinder Management 10841
3 5 2 Removing and installing camshaft control valve 1 -N205-, exhaust side with toothed belt pulley 10842
3 6 Removing and installing exhaust camshaft control valve 1 -N318- 10842
3 7 Removing and installing valve stem seals 10843
3 7 1 Removing and installing valve stem seals (cylinder head installed) 10843
3 7 2 Removing and installing valve stem seals (cylinder head removed) 10848
3 8 Removing and installing cam actuators 10853
3 8 1 Removing and installing exhaust cam actuator for cylinder 2 -N587- 10853
3 8 2 Removing and installing exhaust cam actuator for cylinder 3 -N595- 10854
3 8 3 Removing and installing inlet cam actuator for cylinder 2 -N583- 10856
3 8 4 Removing and installing inlet cam actuator for cylinder 3 -N591- 10858
4 Inlet and exhaust valves 10860
4 1 Checking valve guides 10860
4 2 Checking valves 10861
4 3 Valve dimensions 10861
17 – Lubrication 10862
1 Sump, oil pump 10862
1 1 Assembly overview – sump/oil pump 10862
1 2 Engine oil: 10866
1 3 Removing and installing lower part of sump 10866
1 4 Removing and installing upper part of sump 10872
1 5 Removing and installing oil pump 10876
1 6 Removing and installing oil level and oil temperature sender -G266- 10878
2 Engine oil cooler 10879
2 1 Assembly overview – engine oil cooler 10879
2 2 Removing and installing engine oil cooler 10879
3 Crankcase ventilation 10881
3 1 Assembly overview – crankcase breather system 10881
3 2 Removing and installing oil separator 10882
4 Oil filter, oil pressure switch 10885
4 1 Assembly overview – oil filter/oil pressure switch 10885
4 2 Removing and installing oil pressure switch -F1- 10886
4 3 Removing and installing oil pressure switch for reduced oil pressure -F378- 10888
4 4 Checking oil pressure 10888
4 5 Removing and installing oil pressure regulating valve -N428- 10891
19 – Cooling 10892
1 Cooling system/coolant 10892
1 1 Connection diagram – coolant hoses 10892
1 2 Checking cooling system for leaks 10896
1 3 Draining and adding coolant 10899
2 Coolant pump, regulation of cooling system 10908
2 1 Assembly overview – coolant pump, thermostat 10908
2 2 Assembly overview – electric coolant pump 10911
2 3 Assembly overview – coolant temperature sender 10912
2 4 Removing and installing electric coolant pump 10913
2 5 Removing and installing coolant pump 10915
2 6 Removing and installing thermostat 10921
2 6 1 Removing and installing thermostat for main coolant circuit (radiator) 10921
2 6 2 Removing and installing thermostat for cylinder block coolant circuit 10923
2 7 Removing and installing toothed belt pulley for coolant pump 10924
2 8 Removing and installing coolant temperature sender -G62- 10928
2 9 Removing and installing radiator outlet coolant temperature sender -G83- 10930
3 Coolant pipes 10933
3 1 Assembly overview – coolant pipes 10933
3 2 Removing and installing coolant pipes 10933
4 Radiator, radiator fan 10938
4 1 Assembly overview – radiator/radiator fan 10938
4 2 Assembly overview – radiator cowl and radiator fan 10940
4 3 Removing and installing radiator 10941
4 4 Removing and installing water radiator for charge air cooling circuit 10946
4 5 Removing and installing radiator cowl with radiator fan 10950
4 6 Removing and installing radiator fan -V7- 10951
21 – Turbocharging/supercharging 10954
1 Turbocharger 10954
1 1 Assembly overview – turbocharger 10954
1 1 1 Assembly overview – turbocharger, version 1 10954
1 1 2 Assembly overview – turbocharger, version 2 10955
1 1 3 Assembly overview – lines on turbocharger 10957
1 2 Removing and installing turbocharger 10958
1 3 Removing and installing charge pressure positioner -V465- 10964
1 3 1 Removing and installing charge pressure positioner -V465-, version 1 10964
1 3 2 Removing and installing charge pressure positioner -V465-, version 2 10965
1 4 Removing and installing connection for turbocharger 10966
2 Charge air system 10970
2 1 Assembly overview – charge air system 10970
2 2 Removing and installing charge air cooler 10972
2 3 Removing and installing charge pressure sender -GX26- 10975
2 4 Checking charge air system for leaks 10976
2 5 Removing and installing air pipe 10978
24 – Mixture preparation – injection 10981
1 Injection system 10981
1 1 Overview of fitting locations – injection system 10981
1 1 1 Overview of fitting locations – engine compartment, vehicles with Active Cylinder Management 10981
1 1 2 Overview of fitting locations – engine compartment, exhaust side with toothed belt pulley 10983
1 1 3 Engine (from above), vehicles with Active Cylinder Management 10985
1 1 4 Overview of fitting locations – front view of engine 10986
1 1 5 Overview of fitting locations – rear of engine 10987
2 Injectors 10989
2 1 Assembly overview – fuel rail with injectors 10989
2 2 Removing and installing fuel rail 10991
2 3 Removing and installing injectors 10992
2 4 Cleaning injectors 10998
3 Air filter 11000
3 1 Assembly overview – air filter housing 11000
3 2 Removing and installing air filter housing 11000
3 3 Removing and installing resonator for intake air 11002
4 Intake manifold 11003
4 1 Assembly overview – intake manifold 11003
4 2 Removing and installing intake manifold 11005
4 3 Removing and installing throttle valve module -GX3- 11009
4 4 Cleaning throttle valve module -GX3- 11011
5 Senders and sensors 11013
5 1 Removing and installing fuel pressure sender -G247- 11013
5 2 Checking fuel pressure sender -G247- 11014
5 2 1 Checking fuel pressure sender -G247-, using pressure sensor tester -VAS 6394- and vehicle diagnostic tester 11014
5 2 2 Checking fuel pressure sender -G247-, using vehicle diagnostic tester 11016
5 3 Removing and installing intake manifold sender -GX9- 11018
6 Engine control unit 11020
6 1 Removing and installing engine control unit -J623- 11020
6 1 1 Removing and installing engine control unit -J623-, Polo 2010>, Polo 2014>, Polo Lim RUS 2016> 11020
6 1 2 Removing and installing engine control unit -J623-, Polo Lim RUS 2020> 11021
6 2 Removing and installing engine (motor) control unit -J623- with protective housing 11022
7 High-pressure pump 11025
7 1 Assembly overview – high-pressure pump 11025
7 1 1 Assembly overview – high-pressure pump, version 1 11025
7 1 2 Assembly overview – high-pressure pump, version 2 11026
7 1 3 Assembly overview – high-pressure pump, version 3 11028
7 2 Removing and installing high-pressure pump 11030
7 3 Removing and installing high-pressure pipe 11032
8 Lambda probe 11033
8 1 Assembly overview – Lambda probe 11033
8 2 Removing and installing Lambda probe 11034
8 2 1 Removing and installing Lambda probe 1 before catalytic converter -GX10- 11034
8 2 2 Removing and installing Lambda probe 1 after catalytic converter -GX7- 11035
26 – Exhaust system 11038
1 Exhaust pipes and silencers 11038
1 1 Assembly overview – silencers 11038
1 1 1 Assembly overview – silencers, Polo 2010>, Polo 2014>, Polo Lim RUS 2016> 11038
1 1 2 Assembly overview – silencers, Polo Saloon RUS 2020> 11040
1 2 Separating exhaust pipes from silencers 11041
1 3 Removing and installing silencer 11042
1 3 1 Removing and installing silencers, Polo 2010>, Polo 2014>, Polo Lim RUS 2016> 11042
1 3 2 Removing and installing silencer, Polo Saloon RUS 2020> 11043
1 4 Aligning exhaust system free of stress 11045
1 5 Checking exhaust system for leaks 11046
2 Emission control 11047
2 1 Assembly overview – emission control 11047
2 2 Removing and installing catalytic converter 11049
28 – Ignition system 11054
1 Ignition system 11054
1 1 Assembly overview – ignition system 11054
1 2 Removing and installing ignition coils with output stage 11056
1 3 Removing and installing knock sensor 1 -G61- 11059
1 4 Removing and installing Hall sender 11060
1 4 1 Removing and installing Hall sender -G40- 11060
1 4 2 Removing and installing Hall sender 3 -G300- 11060
1 5 Removing and installing engine speed sender -G28- 11061
D4B8026F7C5 Chemicals Manual 11063
00 – Technical data 11073
1 Introduction 11073
2 List of Suppliers 11074
2 1 3M do Brasil 11074
2 2 Alba Adesivos Ind Com Ltda 11074
2 3 Brascola Ltda 11074
2 4 Castrol Brasil Ltda 11074
2 5 Cia Brasileira de Petróleo Ipiranga 11074
2 6 Chevron Brasil S/A 11074
2 7 Colauto – Adesivos e Massas Ltda 11074
2 8 Cremer S A Prod Têxteis e Cirúrgicos 11074
2 9 Dow Corning do Brasil Ltda 11074
2 10 Dow Automotive System 11074
2 11 Du Pont S/A 11074
2 12 Elf Lubrificantes do Brasil 11074
2 13 Esso Brasileira de Petróleo Ltda 11074
2 14 Formiquímica Com e Repres de Produtos Químicos Ltda 11074
2 15 Gratec System Indústria de Produtos Químicos Ltda 11074
2 16 Henkel do Brasil Ltda 11074
2 17 Klüber Lubrification Lubrificantes Especiais Ltda 11075
2 18 Loctite Brasil Ltda 11075
2 19 Lumobrás Imp Com Ind Ltda 11075
2 20 ExxonMobil do Brasil Ind Com Ltda 11075
2 21 Motul Synthetic Lubricants 11075
2 22 Nippondenso Compressores Ltda 11075
2 23 Pentosin do Brasil Ltda 11075
2 24 Petrobras Distr S/A 11075
2 25 Promax Prod Máximos S/A Indústria e Comércio 11075
2 26 Repsol – YPF S A Divisão Lubrificantes Brasil 11075
2 27 Quaker Chemical Industria e Comércio Ltda 11075
2 28 Shell Brasil S/A 11075
2 29 Sika S/A 11075
2 30 Solplás – Ind de Plásticos Ltda 11075
2 31 Solvay Química 11075
2 32 Three Bond do Brasil Ind e Com Ltda 11075
2 33 Total Lubrificantes Brasil Ltda 11076
2 34 Tutela Lubrificantes S/A 11076
2 35 Valvoline Lubrificantes Internacionais Ltda 11076
3 List of authorized products 11077
3 1 Assembly Adhesive 11077
3 2 Adhesive for polyurethane and polypropylene 11077
3 3 Resin adhesive 11077
3 4 Polyurethane-based sealing adhesive 11077
3 5 Instant adhesive 11077
3 6 Adhesive for sealing gaskets 11077
3 7 Permanent adhesive 11077
3 8 Adhesive for packings and linings 11078
3 9 Polyurethane adhesive 11078
3 10 Polyurethane adhesive 11078
3 11 Epoxy adhesive with 2 components 11078
3 12 Sealing adhesives for engines 11078
3 13 High-resistance locking adhesive 11078
3 14 Low viscosity lock adhesive 11078
3 15 Locking adhesive 11078
3 16 Locking adhesive for mechanical seals 11078
3 17 Medium torque locking adhesive 11079
3 18 Adhesive for plastic cap gaskets 11079
3 19 Metal-glass adhesive 11079
3 20 Sealing adhesive 11079
3 21 2-component adhesive 11079
3 22 Universal adhesive 11079
3 23 Additives for coolants – G11 11079
3 24 Additives for coolants – G13 11079
3 25 Additive for the windscreen/rear window washer reservoir 11079
3 26 Additives for petrol 11080
3 27 Activating agent for pre-laminated glass 11080
3 28 Silicone rubber 11080
3 29 Filling and acoustic isolation foam 11080
3 30 Polyurethane adhesive tape 11080
3 31 Cotton tape 11080
3 32 Self-adhesive PVC tape 11080
3 33 Transferable adhesive tape 11080
3 34 Sealing tape 11080
3 35 Double-sided adhesive tape 11081
3 36 Double-sided acrylic foam adhesive tape 11081
3 37 Medium density double-sided adhesive tape 11081
3 38 Hydraulic brake fluid (DOT 4) 11081
3 39 Automatic transmission fluid 11081
3 40 Refrigerant gas – R134a 11081
3 41 Multi-purpose grease 11081
3 42 Semi-fluid grease 11081
3 43 Multi-purpose grease 11082
3 44 Multi-purpose grease 11082
3 45 Special lubrication grease 11082
3 46 Polyalphaolefin-based low temperature grease 11082
3 47 Lubricating grease 11082
3 48 Complex grease 11082
3 49 Graphite grease 11082
3 50 Grease for front wheel cylinder support guide pin 11082
3 51 Grease for gearbox side seals 11083
3 52 Lubricating grease 11083
3 53 Grease for electrical contacts 11083
3 54 Polyurea grease 11083
3 55 High temperature grease 11083
3 56 Temperature resistant grease 11083
3 57 Lubricating grease 11083
3 58 Silicone based grease 11083
3 59 Windscreen adhesive set 11083
3 60 Windscreen adhesive set 11084
3 61 Glass adhesion kit 11084
3 62 Lithium-based lubricant 11084
3 63 Adhesive paste and grey sealant 11084
3 64 Adhesive material for glass 11084
3 65 Sealing compound 11084
3 66 Adhesive material for glass 11084
3 67 Silicone paste 11084
3 68 Mouldable paste for caulking 11084
3 69 Lubricating paste for high temperatures 11084
3 70 Lubricating paste for constant velocity joints 11085
3 71 Sealing compound 11085
3 72 Sealing compound 11085
3 73 Sealing compound 11085
3 74 Paste for bucket protection 11085
3 75 Sealing compound for engines 11085
3 76 Sealing compound 11085
3 77 Sealing compound for engine 11085
3 78 Nyogel 11085
3 79 Engine lubricant oil: Petrol, Ethanol – VW 501 01 11086
3 80 Engine lubricant oil: Petrol, Ethanol, Totalflex and NGV – VW 502 00 11086
3 81 Lubricating oil for diesel engines – VW 505 00 11087
3 82 Engine oil lubricant: Diesel – VW 507 00 11088
3 83 Engine lubricant oil: Petrol and Totalflex – VW 508 88 11088
3 84 Diesel engine lubricant oil – VW 509 99 11089
3 85 Lubricating oil for manual gearbox and steering box – SAE 90, MIL-L-2105B, API-GL5 11089
3 86 Lubricating oil for manual gearbox – SAE 80, MIL-L-2105, API-GL4 11089
3 87 Lubricating oil for manual gearbox – SAE 75W90 11090
3 88 Lubricating oil for manual gearbox – SAE 75W90 11090
3 89 Special oil 11090
3 90 Oil for manual gearbox 11090
3 91 Lubricating oil for manual gearbox – SAE 75W90 11090
3 92 Lubricating oil for manual gearbox – SAE 75W90 11090
3 93 Lubricating oil for manual gearbox – SAE 75W90 11090
3 94 Lubricating oil for manual gearbox – SAE 75W90 11090
3 95 Lubricating oil for manual gearbox – SAE 75W90 11091
3 96 Lubricating oil for power steering 11091
3 97 Lubricating oil for automatic gearbox and power steering 11091
3 98 Lubricating oil for the automatic gearbox differential – SAE 75W90 11091
3 99 VW ATF oil for power steering 11091
3 100 VW ATF oil for power steering 11091
3 101 ATF oil for automatic gearboxes 11091
3 102 VW ATF oil for power steering 11091
3 103 Oil for gear selection mechanism 11091
3 104 Air conditioning compressor oil – R 134a 11091
3 105 Oil for the air conditioning compressor 11091
3 106 Lubricating oil for assembly 11092
3 107 White lubricating grease 11092
3 108 Moly grease 11092
3 109 Molybdenum bisulphate lubricating grease 11092
3 110 Copper grease 11092
3 111 Silicon grease 11092
3 112 High temperature paste 11092
3 113 Primer 11092
3 114 Glass primer 11092
3 115 Adhesive remover 11092
3 116 Cleaning remover 11093
3 117 Corrosive paste 11093
3 118 Odourless solvent 11093
3 119 Cleaning solution 11093
3 120 Engine leak detection spray 11093
3 121 Cylinder lubricating spray 11093
3 122 Primer for polyurethane surface 11093
3 123 Adhesive sealant 11093
3 124 Mixing tube 11093
3 125 Liquid sealant 11094
3 126 Silicone sealant for engines 11094
3 127 Sealant for exhaust connections 11094
3 128 Teflon thread sealant 11094
4 Work Instructions for Handling Chemicals 11095
4 1 General considerations 11095
4 1 1 Solvent Handling 11095
4 1 2 Work instruction – Flammable material handling 11097
4 1 3 Handling used engine oil 11098
5 Application guide 11100
5 1 Application guide 11100
6 Repair Group 10 – Cylinders, cylinder block, support, protector 11108
6 1 Cylinder base gasket – lubricate 11108
6 2 Engine housing – seal 11109
6 3 Engine housing plugs – fasten 11110
6 4 Cylinder block plugs – fasten 11111
7 Repair Group 13 – Crankshaft group 11112
7 1 Crankshaft needle bearing 11112
7 2 Needle bearing of the fastening hollow screw for the flywheel 11113
7 3 Flywheel fastening screw – lock 11114
8 Repair Group 15 – Cylinder head, valve gear 11115
8 1 Intermediate shaft seal – lubricate for assembly 11115
8 2 Camshaft valve bearing cover (1st and 5th) – Seal 11116
8 3 Cylinder head sealing gasket – glue 11117
8 4 Lower rear threaded pins fastening the cylinder head – rear threaded pin (crankshaft) / lower front threaded pins (flywheel) – Seal 11118
8 5 Cylinder head cover – seal 11119
8 6 Cylinder head cover – seal 11120
8 7 Cylinder head cover – seal 11121
9 Repair Group 17 – Lubrication system 11122
9 1 Engine crankcase – Fill / top up oil level 11122
9 2 Junction between crankcase gaskets and crankshaft front and rear flange gasket – seal 11123
9 3 Engine crankcase – seal 11124
10 Repair Group 19 – Cooling system 11125
10 1 G11 cooling system – fill / adjust additive proportion 11125
10 2 G13 cooling system – fill / adjust additive proportion 11126
11 Repair Group 20 – Supply system – tank, fuel pump 11127
11 1 Fuel tank – add additive 11127
11 2 Accelerator pedal shaft – lubricate 11128
11 3 Accelerator pedal fastening – lubricate 11129
11 4 Accelerator cable and cable end – accelerator pedal fastening – lubricate 11130
12 Repair Group 26 – Exhaust system 11131
12 1 Exhaust connection – seal 11131
13 Repair Group – 28 – Ignition system, pre-ignition system 11132
13 1 Ignition coils with final power stage – lubricate 11132
14 Repair Group 30 – Clutch – control system 11133
14 1 Clutch pedal bung – lubricate 11133
14 2 Clutch control cable – lubricate 11134
14 3 Clutch fork, contact with bearing – lubricate 11135
14 4 Clutch fork bungs – lubricate 11136
14 5 Wing nut for clutch control cable adjustment – lubricate 11137
14 6 Sealing ring for the de-clutch bearing guide – lubricate for assembly 11138
14 7 Clutch cable – lubricate 11139
14 8 Clutch fork and clutch actuating lever – lubricate 11140
14 9 Clutch pedal fastening – lubricate 11141
14 10 Clutch actuating lever – lubricate 11142
14 11 Input shaft splines – lubricate 11143
14 12 Clutch pedal / clutch pedal bung – lubricate 11144
14 13 Pedal support – seal 11145
14 14 Clutch fork contact with the hydraulically activated cylinder of the gearbox clutch – lubricate 11146
14 15 Fastening flange for clutch slave cylinder – seal 11147
15 Repair Group – 34 – Drive, housing 11148
15 1 Linkage rod, front/rear section – lubricate 11148
15 2 Gear lever bearing 11149
15 3 Manual Gearbox – fill / top up level 11150
15 4 Manual gearbox – Fill / top up level 11151
15 5 Manual Gearbox – fill / top up level 11152
15 6 Manual Gearbox – fill / top up level 11153
15 7 Manual Gearbox – fill / top up level 11154
15 8 Plastic sleeves for the linkage rod coupling system / linkage rod / supports (on the gearbox) – lubricate 11155
15 9 Gear lever guide plate – lubricate 11156
15 10 Rubber shim for the clutch compartment cover – glue 11157
15 11 Clutch compartment cover – seal 11158
15 12 Linkage rod bellows for the gear lever assembly – fasten / seal 11159
15 13 Junction of cases and differential cover housing (transfer box / differential) – seal 11160
15 14 Gear lever handle – fasten 11161
15 15 Fastening screw for the rear support of the gearbox cushion – seal 11162
15 16 Gearbox cushion – lubricate 11163
15 17 Gear selection mechanism – fill up 11164
15 18 Electric connectors of the gear selection mechanism – apply Nyogel 11165
16 Repair Group 35 – Gears and shafts 11166
16 1 Input shaft splines – lubricate 11166
16 2 Fastening screw for the clutch assembly / 5th gear synchronizer – lock 11167
17 Repair Group – 37 – Drive, housing 11168
17 1 Planetary gear box (automatic gearbox) – fill / top up oil level 11168
17 2 Planetary gear box (automatic gearbox) – fill / top up oil level 11169
17 3 Planetary gear box (automatic gearbox) – fill / top up oil level 11170
18 Repair Group – 39 – Gearbox shafts, differential 11171
18 1 Gearbox side seals – lubricate 11171
18 2 Planetary and satellite gears – lubricate for assembly 11172
18 3 Automatic gearbox differential – top up oil level 11173
18 4 Differential cover with gearbox housing – seal 11174
19 Repair Group – 40 – Front suspension 11175
19 1 Constant velocity joint spline – lubricate 11175
19 2 Inner and outer constant velocity joint – lubricate 11176
19 3 Front wheel bearing mounting – lubricate 11177
19 4 Axle end – lubricate 11178
19 4 1 Front wheel hub seal – lubricate 11179
19 4 2 King pin bearing – lubricate 11180
19 4 3 Front axle beam – lubricate 11181
19 4 4 Suspension arms – lubricate 11182
19 4 5 Front wheel bearing – lubricate 11183
19 4 6 Passage hole for the speedometer cable in the wheel hub protector – seal 11184
20 Repair Group – 42 – Rear suspension 11185
20 1 Inner and outer constant velocity joint – lubricate 11185
20 2 Shaft end splines – lubricate 11186
20 3 Rear torsion bar – lubricate 11187
20 4 Rear wheel hub – lubricate 11188
20 5 Rear wheel hub seal – lubricate 11189
20 6 Rear wheel bearing – lubricate 11190
21 Repair Group – 46 – Brakes – Mechanical systems 11191
21 1 Rear wheel brake shoe ends – lubricate 11191
21 2 Handbrake cable terminal – lubricate 11192
21 3 Brake pedal safety pin – lubricate 11193
21 4 Securing pin for the operating rod of the master cylinder plunger – lubricate 11194
21 5 Securing pin of the handbrake lever – lubricate 11195
21 6 Handbrake ratchet – lubricate 11196
22 Repair Group – 47 – Brakes – Brake servo hydraulic system 11197
22 1 Brake system – fill / top up 11197
22 2 Guide pin for the support of the front disc brake cylinder (manufactured by Varga) – lubricate 11198
22 3 Fastening screw for the front disc brake cylinder housing – lock 11199
23 Repair Group – 48 – Steering 11200
23 1 Oil reservoir for the power steering system – Fill / top up oil level 11200
23 2 Oil reservoir for the power steering system – fill / top up oil level 11201
23 3 Steering box – Fill / top up level 11202
23 4 Steering box mechanism – lubricate 11203
23 5 Adapter (sleeve) for the upper steering shaft – lock 11204
24 Repair Group – 53 – Body – Rear section 11205
24 1 Bucket sealing membrane – glue 11205
24 2 Rear side panel – protect the paint 11206
25 Repair Group – 55 – Covers 11207
25 1 Bucket protective cover longitudinal member – glue the finishing 11207
25 2 Lower latch of the bonnet – lubricate 11208
25 3 Damper eyelet for the rear cover – lubricate 11209
26 Repair Group – 57 – Front doors / components / central lock 11210
26 1 Front door lock – lubricate 11210
26 2 Lock drive rod – lubricate 11211
26 3 Noise insulation for lock operating rod – glue 11212
26 4 Inner door seal – glue 11213
27 Repair Group – 58 – Rear doors / components 11214
27 1 Rear door lock – lubricate 11214
27 2 Side door lock – lubricate 11215
28 Repair Group – 64 – Windscreens, windows, window mechanism 11216
28 1 Door window activation mechanism – lubricate 11216
28 2 Vent window latch – lubricate 11217
28 3 Front door window support – lubricate 11218
28 4 Front door window activation mechanism – lubricate 11219
28 5 Window crank fastening screw – lock 11220
28 6 Windscreen, side window glass and rear window glass – glue 11221
28 7 Windscreen, side window glass and rear window glass – seal 11222
28 8 Glass – engrave chassis number 11223
28 9 Front and rear door window guide groove – glue 11224
28 10 Vent window – seal 11225
29 Repair Group – 66 – External equipment 11226
29 1 Roof rack fastening screws – lock 11226
30 Repair Group – 68 – Internal equipment 11227
30 1 Interior rearview mirror support – fasten 11227
31 Repair Group – 70 – Lining/insulation 11228
31 1 Door noise insulation – glue 11228
31 2 Noise insulation on rear side panel – glue 11229
31 3 Roof noise insulation – glue 11230
31 4 Door sealing membrane – glue 11231
32 Repair Group – 72 – Seat framework 11232
32 1 Front seat central sliding guide – lubricate 11232
32 2 Front seat side sliding guide – lubricate 11233
33 Repair Group – 87 – Air conditioning 11234
33 1 Air conditioning system – refill with gas 11234
33 2 Air conditioning system – refill with oil 11235
33 3 Air conditioning pressure switch – seal 11236
34 Repair Group – 92 – Windscreen, rear window and headlight wiper and washer 11237
34 1 Windscreen wiper operating rod – lubricate 11237
34 2 Windscreen/rear window washer water tank – fill 11238
35 Repair Group – 94 – Switches, lights, and external bulbs 11239
35 1 Contact blade for turn signal switch 11239
36 Repair Group – 97 – Cables and electrical harnesses 11240
36 1 Gaskets for the plastic covers that cover the electric harnesses – seal 11240
D4B8026F7C6 Painting Manual 11241
00 – Technical data 11245
1 Introduction 11245
2 Safety at the working area 11246
2 1 Product handling 11246
2 2 Wear individual protection equipment (IPE) 11246
2 3 Important safety items in the repainting workshop 11247
2 3 1 Fire extinguishers 11247
2 3 2 Ventilation 11248
2 4 Storage of chemicals 11248
2 4 1 Grounding 11248
2 4 2 Electrical Installations 11248
2 4 3 Location of the painting section 11248
2 5 Environment and disposal of paints 11248
2 5 1 Residues 11248
2 5 2 Paint leftovers 11249
2 5 3 Disposal of grout and empty packages 11249
2 5 4 Filters, cloths and papers 11249
2 5 5 Disposal of cans and drums 11249
2 5 6 Rain waters, sewage and earth 11249
2 5 7 Risk of chemicals 11249
3 Colours 11251
3 1 1995 line – Imported vehicles 11251
3 1 1 Solid colours 11251
3 1 2 Metallic colours 11251
3 1 3 Pearly colours 11252
3 2 1995 line – Domestically manufactured vehicles 11252
3 2 1 Solid colours 11252
3 2 2 Metallic colours 11252
3 2 3 Pearly colours 11252
3 3 1996 line – Imported vehicles 11253
3 3 1 Solid colours 11253
3 3 2 Metallic colours 11253
3 3 3 Pearly colours 11254
3 4 1996 line – Domestically manufactured vehicles 11254
3 4 1 Solid colours 11254
3 4 2 Metallic colours 11254
3 4 3 Pearly colours 11255
3 5 1997 line – Imported vehicles 11255
3 5 1 Solid colours 11255
3 5 2 Metallic colours 11255
3 5 3 Pearly colours 11256
3 6 1997 line – Domestically manufactured vehicles 11256
3 6 1 Solid colours 11256
3 6 2 Metallic colours 11257
3 6 3 Pearly colours 11257
3 7 1998 line – Imported vehicles 11257
3 7 1 Solid colours 11257
3 7 2 Metallic colours 11258
3 7 3 Pearly colours 11259
3 8 1998 line – Domestically manufactured vehicles 11260
3 8 1 Solid colours 11260
3 8 2 Metallic colours 11260
3 8 3 Pearly colours 11261
3 9 1999 line – Imported vehicles 11261
3 9 1 Solid colours 11261
3 9 2 Metallic colours 11262
3 9 3 Pearly colours 11263
3 10 1999 line – Domestically manufactured vehicles 11264
3 10 1 Solid colours 11264
3 10 2 Metallic colours 11264
3 10 3 Pearly colours 11265
3 11 2000 line – Imported vehicles 11265
3 11 1 Solid colours 11265
3 11 2 Metallic colours 11266
3 11 3 Pearly colours 11267
3 12 2000 line – Domestically manufactured vehicles 11267
3 12 1 Solid colours 11267
3 12 2 Metallic colours 11268
3 12 3 Pearly colours 11268
3 13 2001 line – Imported vehicles 11269
3 13 1 Solid colours 11269
3 13 2 Metallic colours 11269
3 13 3 Pearly colours 11270
3 14 2001 line – Domestically manufactured vehicles 11270
3 14 1 Solid colours 11270
3 14 2 Metallic colours 11271
3 14 3 Pearly colours 11272
3 15 2002 line – Imported vehicles 11272
3 15 1 Solid colours 11272
3 15 2 Metallic colours 11273
3 15 3 Pearly colours 11274
3 16 2002 line – Domestically manufactured vehicles 11275
3 16 1 Solid colours 11275
3 16 2 Metallic colours 11275
3 16 3 Pearly colours 11276
3 17 2003 line – Imported vehicles 11277
3 17 1 Solid colours 11277
3 17 2 Metallic colours 11277
3 17 3 Pearly colours 11277
3 18 2003 line – Domestically manufactured vehicles 11278
3 18 1 Solid colours 11278
3 18 2 Metallic colours 11279
3 18 3 Pearly colours 11279
3 19 2004 line – Imported vehicles 11280
3 19 1 Solid colours 11280
3 19 2 Metallic colours 11280
3 19 3 Pearly colours 11280
3 20 2004 line – Domestically manufactured vehicles 11281
3 20 1 Solid colours 11281
3 20 2 Metallic colours 11281
3 20 3 Pearly colours 11282
3 21 2005 line – Imported vehicles 11282
3 21 1 Solid colours 11282
3 21 2 Metallic colours 11283
3 21 3 Pearly colours 11283
3 22 2005 line – Domestically manufactured vehicles 11284
3 22 1 Solid colours 11284
3 22 2 Metallic colours 11285
3 22 3 Pearly colours 11285
3 23 2006 line – Imported vehicles 11286
3 23 1 Solid colours 11286
3 23 2 Metallic colours 11286
3 23 3 Pearly colours 11288
3 24 2006 line – Domestically manufactured vehicles 11288
3 24 1 Solid colours 11288
3 24 2 Metallic colours 11289
3 24 3 Pearly colours 11290
3 25 2007 line – Imported vehicles 11290
3 25 1 Solid colours 11290
3 25 2 Metallic colours 11291
3 25 3 Pearly colours 11293
3 26 2007 line – Domestically manufactured vehicles 11293
3 26 1 Solid colours 11293
3 26 2 Metallic colours 11294
3 26 3 Pearly colours 11294
3 27 2008 line – Imported vehicles 11295
3 27 1 Solid colours 11295
3 27 2 Metallic colours 11295
3 27 3 Pearly colours 11296
3 28 2008 line – Domestically manufactured vehicles 11297
3 28 1 Solid colours 11297
3 28 2 Metallic colours 11297
3 28 3 Pearly colours 11298
3 29 2009 line – Imported vehicles 11298
3 29 1 Solid colours 11298
3 29 2 Metallic colours 11300
3 29 3 Pearly colours 11302
3 30 2009 line – Domestically manufactured vehicles 11304
3 30 1 Solid colours 11304
3 30 2 Metallic colours 11305
3 30 3 Pearly colours 11307
3 31 2010 line – Imported vehicles 11307
3 31 1 Solid colours 11307
3 31 2 Metallic colours 11308
3 31 3 Pearly colours 11311
3 32 2010 line – Domestically manufactured vehicles 11312
3 32 1 Solid colours 11312
3 32 2 Metallic colours 11313
3 32 3 Pearly colours 11314
3 33 2011 line – Imported vehicles 11315
3 33 1 Solid colours 11315
3 33 2 Metallic colours 11316
3 33 3 Pearly colours 11320
3 34 2011 line – Domestically manufactured vehicles 11320
3 34 1 Solid colours 11320
3 34 2 Metallic colours 11321
3 34 3 Pearly colours 11323
3 35 2012 line – Imported vehicles 11323
3 35 1 Solid colours 11323
3 35 2 Metallic colours 11324
3 35 3 Pearly colours 11327
3 36 2012 line – Domestically manufactured vehicles 11327
3 36 1 Solid colours 11327
3 36 2 Metallic colours 11328
3 36 3 Pearly colours 11330
3 37 2013 line – Imported vehicles 11330
3 37 1 Solid colours 11330
3 37 2 Metallic colours 11331
3 37 3 Pearly colours 11334
3 38 2013 line – Domestically manufactured vehicles 11334
3 38 1 Solid colours 11334
3 38 2 Metallic colours 11336
3 38 3 Pearly colours 11337
3 39 2014 line – Imported vehicles 11337
3 39 1 Solid colours 11337
3 39 2 Metallic colours 11338
3 39 3 Pearly colours 11339
3 40 2014 line – Domestically manufactured vehicles 11340
3 40 1 Solid colours 11340
3 40 2 Metallic colours 11341
3 40 3 Pearly colours 11342
3 41 2015 line – Imported vehicles 11343
3 41 1 Solid colours 11343
3 41 2 Metallic colours 11344
3 41 3 Pearly colours 11347
3 42 2015 line – Domestically manufactured vehicles 11347
3 42 1 Solid colours 11347
3 42 2 Metallic colours 11348
3 42 3 Pearly colours 11350
3 42 4 Special colours 11350
3 43 2016 line – Imported vehicles 11350
3 43 1 Solid colours 11350
3 43 2 Metallic colours 11351
3 43 3 Pearly colours 11353
3 44 2016 line – Domestically manufactured vehicles 11354
3 44 1 Solid colours 11354
3 44 2 Metallic colours 11355
3 44 3 Pearly colours 11357
3 44 4 Special colours 11357
3 45 2017 line – Domestically manufactured vehicles 11358
3 45 1 Solid colours 11358
3 45 2 Metallic colours 11358
3 45 3 Pearly colours 11360
3 45 4 Special colours 11360
3 46 2017 line – Imported vehicles 11361
3 46 1 Solid colours 11361
3 46 2 Metallic colours 11361
3 46 3 Pearly colours 11364
3 47 2018 line – Domestically manufactured vehicles 11364
3 47 1 Solid colours 11364
3 47 2 Metallic colours 11365
3 47 3 Pearly colours 11367
3 47 4 Special colours 11367
3 48 2018 line – Imported vehicles 11368
3 48 1 Metallic colours 11368
3 48 2 Pearly colours 11369
3 49 2019 line – Domestically manufactured vehicles 11369
3 49 1 Solid colours 11369
3 49 2 Metallic colours 11370
3 49 3 Pearly colours 11372
3 50 2019 line – Imported vehicles 11372
3 50 1 Solid colours 11372
3 50 2 Metallic colours 11372
3 50 3 Pearly colours 11374
3 51 2020 line – Domestically manufactured vehicles 11374
3 51 1 Solid colours 11374
3 51 2 Metallic colours 11375
3 52 2020 line – Imported vehicles 11377
3 52 1 Solid colours 11377
3 52 2 Metallic colours 11377
3 52 3 Pearly colours 11379
3 53 2021 line – Domestically manufactured vehicles 11379
3 53 1 Solid colours 11379
3 53 2 Metallic colours 11380
3 54 2021 line – Imported vehicles 11381
3 54 1 Solid colours 11381
3 54 2 Metallic colours 11382
3 54 3 Pearly colours 11382
4 Special colours 11384
4 1 Special colours 11384
4 1 1 Fox Blackfox 2012 11384
4 1 2 Crossfox 11384
4 1 3 Crossfox 2012 ► 11385
4 1 4 Fox Extreme 11386
4 1 5 Fox Silverfox 2012 11387
4 1 6 Gol – Special fleet painting 11388
4 1 7 Gol Rallye (5W) 11389
4 1 8 Gol Vintage (5U) 11390
4 1 9 Golf GT 11392
4 1 10 Golf Silver Edition 11393
4 1 11 Golf Black Edition 2011 11394
4 1 12 Silver series Kombi 11394
4 1 13 Parati Track and Field (Generation IV) 11395
4 1 14 Parati Surf 11396
4 1 15 Parati Titan 11397
4 1 16 Saveiro Crossover (generation III) 11398
4 1 17 Saveiro Crossover (generation IV) 11399
4 1 18 Saveiro Titan 11400
4 1 19 Saveiro Surf 11401
4 1 20 Saveiro Trooper 2010 ► 11402
4 1 21 Saveiro Cross 2010 ► 11403
4 1 22 Saveiro basic 2013 ► 11404
4 1 23 Kombi Last Edition 2013 11405
4 1 24 Fox Pepper 2015 ► 11406
4 1 25 up! TSI 2016 ► 11407
4 1 26 speed up! TSI 2016 ► 11408
4 1 27 CrossFox — Urban White 2017 ► 11409
4 1 28 CrossFox — Camou Red 2018 11410
4 1 29 Up – Connect 2018 11411
4 1 30 Up – Pepper 2018 11412
4 1 31 Saveiro – Pepper 2018 11413
4 1 32 Polo Beats 11415
4 1 33 T-Cross Highline 11415
4 1 34 NIVUS – HERO 11416
5 Paints 11418
5 1 Basic composition of paints 11418
5 2 Types of paints 11418
6 Complements 11420
6 1 Thinners / Solvents / Diluents 11420
6 1 1 Basic composition 11420
6 1 2 Types of thinners 11420
6 2 Rust neutralizers 11420
6 3 Sealing and protection of the lower part of the vehicle 11420
6 4 Sanding control 11421
6 5 Primers 11421
6 5 1 PU Primer 11421
6 6 Polyester paste 11421
6 6 1 Body repair paste 11421
6 6 2 Polyurethane-based sealing adhesive (thread) 11421
6 6 3 Polyester Paste 11422
6 7 Abrasives 11422
6 7 1 Polishers 11422
7 Repainting 11423
7 1 Paint Repair 11423
7 1 1 General information 11423
7 2 Paint repair on steel plates and zinc-coated steel plates 11423
7 2 1 Solid paint – solid colours 11424
7 2 2 Double-layer paint (solid, metallic and pearly colours) 11425
7 2 3 Water-based double-layer paint (smooth, metallic and pearly colours) 11427
7 3 Paint repair on plastic parts 11429
7 3 1 Repainting of plastic components that require special care 11431
7 4 Spray guns and their use 11432
7 5 Paint dryers by irradiation 11436
7 6 Dryers based on air insufflation (water-based painting) 11437
8 Body sealing 11438
8 1 Materials 11438
8 1 1 Polyurethane-based sealing adhesive 11438
8 1 2 Body repair paste 11438
8 1 3 Paste for load bed protection 11439
8 2 Santana and Quantum 11439
8 3 Gol 1995 ► 11449
8 4 Gol 1999 ► and Parati 1999 ► – 5X and 5W 11458
8 5 Saveiro 2000 ► – 5X and 5W 11472
8 6 Gol, Voyage 2009 ► and Saveiro 2010 ► 11476
8 7 Fox and Spacefox 11511
8 8 Polo 11544
8 9 Golf 11577
9 Application of anti-corrosion fluid 11595
9 1 Anti-corrosive fluid 11595
9 2 Equipment 11595
9 3 Gol , Parati and Saveiro – 5X and 5W 11595
9 4 New Gol , Voyage 2009 ► Saveiro 2010 ► 11603
9 5 Fox and Spacefox 11616
9 6 Polo 11628
D4B8026F80A Running gear axles steering 11639
00 – Technical data 11645
1 Checklist for evaluating running gear of accident vehicles 11645
2 General information 11647
40 – Front suspension 11648
1 Evaluating accident vehicles 11648
2 Repairing front wheel suspension 11649
2 1 Overview – front axle 11649
2 2 Raising wheel suspension to unladen position 11650
3 Subframe, anti-roll bar, suspension links 11652
3 1 Assembly overview – subframe, anti-roll bar, suspension links 11652
3 2 Repairing thread in longitudinal member 11654
3 3 Fixing position of subframe 11654
3 4 Removing and installing subframe 11656
3 5 Checking swivel joint 11658
3 6 Removing and installing swivel joint 11658
3 7 Installation position of swivel joints 11661
3 8 Removing and installing suspension link 11661
3 9 Renewing front bonded rubber bush for suspension link 11663
3 10 Renewing rear bonded rubber bush for suspension link 11666
3 11 Removing and installing anti-roll bar 11668
3 12 Removing and installing rubber bush for anti-roll bar 11670
4 Assembly overview – wheel bearings 11673
4 1 Pulling out and pulling in wheel hub with wheel bearing 11674
4 2 Removing and installing wheel bearing housing 11678
5 Assembly overview – suspension strut 11682
5 1 Removing and installing suspension strut 11683
5 2 Repairing front suspension strut 11688
6 Removing and installing drive shafts 11692
6 1 Removing and installing drive shaft with constant velocityjoint 11692
6 2 Removing and installing drive shaft with triple roller jointAAR 2000 (bolted-on) 11694
7 Repairing drive shafts – overview of drive shafts 11696
7 1 Heat shields for drive shafts 11697
8 Assembly overview – drive shaft with VL90 or VL100 constantvelocity joint 11698
8 1 Dismantling and assembling drive shaft with VL90 or VL100 constantvelocity joint 11700
8 2 Checking outer constant velocity joint 11705
8 3 Checking inner constant velocity joint 11706
9 Assembly overview – drive shaft with VL107 constant velocityjoint 11708
9 1 Dismantling and assembling drive shaft with VL107 constantvelocity joint 11710
10 Assembly overview – drive shaft with triple roller joint AAR2000/108 11715
10 1 Dismantling and assembling drive shaft with triple roller jointAAR 2000/108 11717
42 – Rear suspension 11725
1 Evaluating accident vehicles 11725
2 Repairing rear axle 11726
2 1 Overview – rear axle 11726
2 2 Rear axle in unladen position 11728
3 Assembly overview – axle body, drum brake 11730
3 1 Removing and installing rear axle 11732
3 2 Removing and installing bonded rubber bush 11736
3 3 Removing and installing coil spring 11741
4 Assembly overview – axle body, disc brake 11743
5 Assembly overview – rear left vehicle level sender -G76-, front-wheel drive 11745
5 1 Removing and installing rear left vehicle level sender -G76- 11745
6 Assembly overview – shock absorber 11747
6 1 Removing and installing shock absorbers 11748
7 Assembly overview – wheel bearings, drum brake 11750
7 1 Removing and installing wheel hub with wheel bearing, vehicleswith drum brakes 11751
8 Assembly overview – wheel bearings, disc brake 11753
8 1 Removing and installing wheel hub with wheel bearing, vehicleswith disc brakes 11754
44 – Wheels, tyres, vehicle geometry 11756
1 Evaluating accident vehicles 11756
2 Specified tightening torque for wheel bolts 11757
3 Removing and fitting tyres with run-flat properties to wheelrims 11758
3 1 Notes on safety and prerequisites 11758
3 2 Fittings instructions 11758
3 3 Pressing tyre off wheel rim 11759
3 4 Removing tyre from wheel 11760
3 5 Fitting tyre to wheel rim 11761
4 Tyre pressure monitor display 11764
5 Wheel alignment 11766
5 1 General 11766
5 2 Test prerequisites 11767
5 3 Test preparations 11768
5 4 Wheel alignment specifications 11768
5 5 Transverse vehicle inclination „zero position“ 11770
5 6 Overview – wheel alignment procedure 11770
5 7 Correcting front axle camber 11771
5 8 Check rear axle camber 11772
5 9 Check rear axle toe 11772
5 10 Adjusting front axle toe 11773
5 11 Checking left and right-hand wheel lock 11773
5 12 Vehicle data sticker 11774
6 Wheels, tyres 11775
6 1 Models with breakdown set 11775
6 2 Tyre sealant 11775
6 3 Removing a tyre 11775
6 4 Fitting a new tyre 11776
6 5 Tyre sealant disposal 11776
7 Instructions for changing or fitting wheels 11777
7 1 Fitting wheels 11778
8 Protecting wheel centring seat against corrosion 11779
9 Rough running due to wheels/tyres – causes and rectification 11780
9 1 Causes of rough running 11780
9 2 Balancing wheels 11780
9 3 Conducting a road test before balancing wheels 11781
9 4 Balancing wheels on stationary wheel balancing machine 11781
9 5 Vibration control system -VAS 6230- 11783
9 6 Finish balancer 11783
9 7 Radial and lateral runout of wheels and tyres 11784
9 8 Checking radial and lateral runout on wheels and tyres with tyre gauge -V A G 1435- 11784
9 9 Checking radial and lateral run-out on wheel rim 11785
9 10 Matching 11786
9 11 Flat spots caused by storage or handling 11787
48 – Steering 11789
1 Evaluating accident vehicles 11789
2 General repair instructions 11790
2 1 Steering box 11790
2 2 Gaskets and seals 11790
2 3 Nuts and bolts 11790
2 4 Electrical components 11791
2 5 Guided fault finding, vehicle self-diagnosis and test instruments 11791
3 Steering column 11792
3 1 Removing and installing steering wheel 11792
3 2 Assembly overview – steering column, left-hand drive 11795
3 3 Removing and installing steering column, left-hand drive vehicle 11795
3 4 Assembly overview – steering column, right-hand drive vehicle 11800
3 5 Removing and installing steering column, right-hand drive vehicle 11801
3 6 Handling and transporting steering column 11806
4 Steering column CEPS (for South Africa only) 11808
4 1 Removing and installing steering wheel 11808
4 2 Assembly overview – steering column 11811
4 3 Removing and installing steering column 11811
4 4 Handling and transporting steering column 11818
5 Electro-hydraulic power steering 11819
5 1 Assembly overview for electro-hydraulic power steering, left-handdrive vehicle 11819
5 2 Removing and installing power steering box, left-hand drivevehicle 11820
5 3 Removing and installing power steering sensor -G250-, left-hand drive vehicle 11825
5 4 Assembly overview for electro-hydraulic power steering, right-handdrive vehicle 11826
5 5 Removing and installing power steering box, right-hand drivevehicle 11828
5 6 Removing and installing power steering sensor -G250-, right-hand drive vehicle 11833
6 Power steering CEPS (for South Africa only) 11835
6 1 Assembly overview – Steering box 11835
6 2 Removing and installing steering box 11836
7 Repairing power steering box 11839
7 1 Assembly overview – power steering box, left-hand drive vehicle 11839
7 2 Assembly overview – power steering box, right-hand drive vehicle 11840
7 3 Removing and installing track rod 11842
7 4 Checking play, tightness and bellows of track rod ball joints 11843
7 5 Checking and adjusting left track rod length 11843
7 6 Allocation of track rod ball joints 11844
7 7 Determining centre position of steering rack 11844
7 8 Adjusting steering box 11844
8 Repairing steering box CEPS (for South Africa only) 11846
8 1 Assembly overview: steering box 11846
8 2 Removing and installing track rod 11847
8 3 Checking play, tightness and bellows of track rod ball joints 11848
8 4 Checking and adjusting left track rod length 11848
8 5 Allocation of track rod ball joints 11849
8 6 Determining centre position of steering rack 11849
8 7 Adjusting steering box 11849
9 Motor/pump unit 11851
9 1 Assembly overview – motor/pump unit 11851
9 2 Removing and installing motor/pump unit 11852
9 3 Renewing motor/pump unit reservoir 11855
9 4 Checking delivery pressure of motor/pump unit 11857
10 Bleeding steering system, checking for leaks and checking fluidlevel 11861
10 1 Bleeding steering system 11861
10 2 Check steering system for leaks 11861
10 3 Checking hydraulic fluid level of power steering 11862
D4B8040D52F 3 cylinder injection engine (1 0 l engine 4 V EA 211) 11864
00 – Technical data 11870
1 Safety information 11870
1 1 Safety regulations for working on fuel supply 11870
1 2 Safety measures when working on vehicles with a start/stop system 11870
1 3 Safety precautions when using testers and measuring instruments during a road test 11871
1 4 Safety precautions when working on the cooling system 11871
1 5 Safety precautions when working on ignition system 11871
2 Identification 11872
2 1 Engine number/engine data 11872
3 Repair instructions 11873
3 1 Rules for cleanliness 11873
3 2 General information 11873
3 3 General repair instructions 11873
3 4 Foreign objects in engine 11874
3 5 Contact corrosion 11874
3 6 Routing and attachment of lines 11874
3 7 Fitting radiator and condensers 11874
3 8 Checking vacuum system 11874
10 – Removing and installing engine 11876
1 Removing and installing engine 11876
1 1 Removing engine 11876
1 1 1 Removing engine, Polo 2014, Ameo 11876
1 1 2 Removing engine, Polo 2018 11883
1 2 Separating engine and gearbox 11893
1 3 Securing engine on engine and gearbox support 11894
1 4 Installing engine 11896
1 4 1 Installing engine, Polo 2014, Ameo 11896
1 4 2 Installing engine, Polo 2018 11897
2 Assembly mountings 11901
2 1 Assembly overview – assembly mountings 11901
2 1 1 Assembly overview – assembly mountings, Polo 2014, Ameo 11901
2 1 2 Assembly overview – assembly mountings, Polo 2018 11903
2 2 Removing and installing engine mounting 11905
2 2 1 Removing and installing engine mounting, Polo 2014, Ameo 11905
2 2 2 Removing and installing engine mounting, Polo 2018 11906
2 3 Removing and installing gearbox mounting 11908
2 3 1 Removing and installing gearbox mounting, Polo 2014, Ameo 11908
2 3 2 Removing and installing gearbox mounting, Polo 2018 11909
2 4 Removing and installing pendulum support 11912
2 4 1 Removing and installing pendulum support, Polo 2014, Ameo 11912
2 4 2 Removing and installing pendulum support, Polo 2018 11913
2 5 Supporting engine in installation position 11914
2 5 1 Supporting engine in installation position, Polo 2014, Ameo 11914
2 5 2 Supporting engine in installation position, Polo 2018 11916
2 6 Adjusting assembly mountings 11918
2 7 Checking adjustment of assembly mountings (engine and gearbox mountings) 11919
13 – Crankshaft group 11920
1 Cylinder block (pulley end) 11920
1 1 Assembly overview – poly V-belt drive 11920
1 1 1 Assembly overview – poly V-belt drive, vehicles without air conditioner compressor 11920
1 1 2 Assembly overview – poly V-belt drive, Polo 2014, Ameo, vehicles with air conditioner compressor 11922
1 1 3 Assembly overview – poly V-belt drive, Polo 2018, vehicles with air conditioner compressor 11923
1 2 Assembly overview – cylinder block (pulley end) 11924
1 3 Removing and installing poly-V belt 11926
1 3 1 Removing and installing poly V-belt, Polo 2014, Ameo, vehicles with air conditioner compressor 11926
1 3 2 Removing and installing poly V-belt, Polo 2018, vehicles with air conditioner compressor 11928
1 3 3 Removing and installing poly V-belt, Polo 2014, Ameo, vehicles without air conditioner compressor 11929
1 3 4 Removing and installing poly V-belt, Polo 2018, vehicles without air conditioner compressor 11930
1 4 Removing and installing tensioner for poly V-belt 11931
1 4 1 Removing and installing tensioner for poly V-belt, vehicles without air conditioner compressor 11931
1 4 2 Removing and installing tensioner for poly V-belt, vehicles with air conditioner compressor 11933
1 5 Removing and installing engine support 11934
1 6 Renewing crankshaft oil seal – belt pulley end 11936
2 Cylinder block, gearbox end 11939
2 1 Assembly overview – cylinder block, gearbox end 11939
2 2 Removing and installing flywheel 11940
2 3 Removing and installing sealing flange on gearbox side 11941
3 Crankshaft 11949
3 1 Crankshaft dimensions 11949
4 Pistons and conrods 11950
4 1 Assembly overview – pistons and conrods 11950
4 2 Checking pistons and cylinder bores 11951
4 3 Separating new conrod 11953
4 4 Removing and installing oil spray jets 11954
4 5 Setting piston to TDC position 11955
15 – Cylinder head, valve gear 11957
1 Cylinder head 11957
1 1 Assembly overview – cylinder head 11957
1 2 Removing and installing cylinder head 11960
1 3 Removing and installing camshaft housing 11966
1 4 Checking compression 11969
2 Toothed belt drive 11973
2 1 Assembly overview – toothed belt cover 11973
2 2 Assembly overview – toothed belt 11974
2 3 Removing and installing toothed belt guard 11975
2 3 1 Removing and installing upper toothed belt guard 11975
2 3 2 Removing and installing lower toothed belt guard 11975
2 4 Removing and installing toothed belt 11976
2 5 Preassembling and installing valve timing tool 11983
2 5 1 Preassembling valve timing tool 11983
2 5 2 Installing test tool -VAS 611 007- 11986
2 5 3 Teaching in test tool -VAS 611 007- electronically and performing basic setting 11988
2 6 Checking valve timing 11990
2 7 Adjusting valve timing 11993
2 8 Removing toothed belt from camshaft 12002
3 Valve gear 12007
3 1 Assembly overview – valve gear 12007
3 2 Measuring axial play of camshaft 12008
3 3 Removing and installing camshaft oil seal 12009
3 3 1 Removing and installing camshaft oil seal, pulley end 12009
3 3 2 Removing and installing camshaft oil seal, gearbox end 12011
3 4 Removing and installing camshaft adjuster 12013
3 5 Removing and installing toothed belt pulley 12018
3 6 Removing and installing valve stem seals 12021
3 6 1 Removing and installing valve stem seals (cylinder head installed) 12021
3 6 2 Removing and installing valve stem seals (cylinder head removed) 12025
4 Inlet and exhaust valves 12029
4 1 Checking valve guides 12029
17 – Lubrication 12030
1 Sump, oil pump 12030
1 1 Assembly overview – sump/oil pump 12030
1 2 Engine oil: 12033
1 3 Removing and installing sump 12034
1 4 Removing and installing oil pump 12037
1 5 Removing and installing oil level and oil temperature sender -G266- 12039
2 Crankcase ventilation 12040
2 1 Assembly overview – crankcase breather system 12040
2 2 Removing and installing oil separator 12041
3 Oil filter, oil pressure switch 12044
3 1 Removing and installing oil pressure switch -F1- 12044
3 2 Checking oil pressure and oil pressure switch 12045
3 3 Removing and installing oil filter housing 12046
19 – Cooling 12048
1 Cooling system/coolant 12048
1 1 Connection diagram – coolant hoses 12048
1 1 1 Connection diagram – coolant hoses, Polo 2014, Ameo 12048
1 1 2 Connection diagram – coolant hoses, Polo 2018 12049
1 2 Checking cooling system for leaks 12049
1 3 Draining and adding coolant 12052
1 3 1 Draining coolant, Polo 2014, Ameo 12052
1 3 2 Filling coolant, Polo 2014, Ameo 12054
1 3 3 Draining and filling coolant, Polo 2018 12059
2 Coolant pump, regulation of cooling system 12066
2 1 Assembly overview – coolant pump 12066
2 2 Assembly overview – thermostat 12068
2 3 Removing and installing coolant pump 12070
2 4 Removing and installing thermostat 12074
2 4 1 Removing and installing thermostat (small circuit) 12074
2 4 2 Removing and installing thermostat (extended circuit) 12077
2 5 Removing and installing toothed belt for coolant pump 12080
2 6 Removing and installing toothed belt pulley for coolant pump 12083
2 7 Removing and installing coolant temperature sender -G62- 12084
3 Coolant pipes 12086
3 1 Assembly overview – coolant pipes 12086
3 1 1 Assembly overview – coolant pipes, Polo 2014, Ameo 12086
3 1 2 Assembly overview – coolant pipes, Polo 2018 12087
3 2 Removing and installing coolant pipes 12087
4 Radiator, radiator fan 12089
4 1 Assembly overview – radiator/radiator fan 12089
4 1 1 Assembly overview – radiator/radiator fan, Polo 2014, Ameo 12089
4 1 2 Assembly overview – radiator/radiator fan, Polo 2018 12091
4 2 Assembly overview – radiator cowl and radiator fan 12092
4 2 1 Assembly overview – radiator cowl and radiator fan, Polo 2014, Ameo 12092
4 2 2 Assembly overview – radiator cowl and radiator fan, Polo 2018 12093
4 3 Removing and installing radiator 12094
4 3 1 Removing and installing radiator, Polo 2014, Ameo 12094
4 3 2 Removing and installing radiator, Polo 2018 12097
4 4 Removing and installing radiator cowl with radiator fan 12102
4 4 1 Removing and installing radiator cowl with radiator fan, Polo 2014, Ameo 12102
4 4 2 Removing and installing radiator cowl with radiator fan, Polo 2018 12103
4 5 Removing and installing radiator fan -V7- 12104
4 5 1 Removing and installing radiator fan -V7-, Polo 2014, Ameo 12104
4 5 2 Removing and installing radiator fan -V7-, Polo 2018 12105
24 – Mixture preparation – injection 12106
1 Injection system 12106
1 1 Overview of fitting locations – injection system 12106
1 1 1 Overview of fitting locations – injection system, Polo 2014, Ameo 12106
1 1 2 Overview of fitting locations – injection system, Polo 2018 12109
1 2 Assembly overview – fuel system 12113
2 Injectors 12115
2 1 Assembly overview – fuel rail with injectors 12115
2 2 Removing and installing injectors 12115
2 3 Checking injectors 12117
2 4 Cleaning injectors 12122
3 Air filter 12124
3 1 Assembly overview – air filter housing 12124
3 1 1 Assembly overview – air filter housing, Polo 2014 12124
3 1 2 Assembly overview – air filter housing, Polo 2018, Ameo 12125
3 2 Removing and installing air filter housing 12127
3 2 1 Removing and installing air filter housing, Polo 2014 12127
3 2 2 Removing and installing air filter housing, Polo 2018, Ameo 12128
4 Intake manifold 12129
4 1 Assembly overview – intake manifold 12129
4 2 Removing and installing intake manifold 12130
4 3 Removing and installing throttle valve module -GX3- 12132
4 4 Cleaning throttle valve module -GX3- 12134
5 Senders and sensors 12135
5 1 Removing and installing intake manifold sender -GX9- 12135
6 Engine control unit 12137
6 1 Assembly overview – engine control unit 12137
6 2 Removing and installing engine (motor) control unit -J623- 12138
6 2 1 Removing and installing engine/motor control unit -J623-, Polo 2014, Ameo 12138
6 2 2 Removing and installing engine control unit -J623-, Polo 2018 12139
6 3 Removing and installing engine (motor) control unit -J623- with protective housing 12140
6 3 1 Removing and installing engine/motor control unit -J623- with protective housing, Polo 2014, Ameo 12140
6 3 2 Removing and installing engine control unit -J623- with protective housing, Polo 2018 12141
7 Lambda probe 12145
7 1 Assembly overview – Lambda probe 12145
7 2 Removing and installing Lambda probe 12146
7 2 1 Removing and installing lambda probe 1 before catalytic converter -GX10-, Polo 2014, Ameo 12146
7 2 2 Removing and installing lambda probe 1 after catalytic converter -GX7-, Polo 2014, Ameo 12148
7 2 3 Removing and installing lambda probe 1 before catalytic converter -GX10-, Polo 2018 12149
7 2 4 Removing and installing lambda probe 1 after catalytic converter -GX7-, Polo 2018 12151
26 – Exhaust system 12153
1 Exhaust pipes and silencers 12153
1 1 Assembly overview – silencers 12153
1 1 1 Assembly overview – silencers, Polo 2014, Ameo 12153
1 1 2 Assembly overview – silencer, Polo 2018 12155
1 2 Separating exhaust pipes from silencers 12156
1 3 Removing and installing silencer 12157
1 3 1 Removing and installing front silencer 12157
1 3 2 Removing and installing rear silencer 12158
1 4 Aligning exhaust system free of stress 12160
1 5 Checking exhaust system for leaks 12160
1 6 Installation position of clamp 12161
1 6 1 Installation position of clamp, Polo 2014, Ameo 12161
1 6 2 Installation position of clamp, Polo 2018 12162
2 Emission control 12163
2 1 Assembly overview – emission control 12163
2 1 1 Assembly overview – emission control, Polo 2014, Ameo 12163
2 1 2 Assembly overview – emission control, Polo 2018 12165
2 2 Removing and installing catalytic converter 12166
2 2 1 Removing and installing catalytic converter, Polo 2014, Ameo 12166
2 2 2 Removing and installing catalytic converter, Polo 2018 12169
28 – Ignition system 12172
1 Ignition system 12172
1 1 Assembly overview – ignition system 12172
1 2 Removing and installing ignition coils with output stage 12174
1 3 Removing and installing knock sensor 1 -G61- 12176
1 4 Removing and installing Hall sender -G40- 12177
1 5 Removing and installing engine speed sender -G28- 12178
1 5 1 Removing and installing engine speed sender -G28-, Polo 2014, Ameo 12178
1 5 2 Removing and installing engine speed sender -G28-, Polo 2018 12181
D4B8040D53E 4 cyl direct injection (1 2 l 4V EA 211 turbocharger) 12184
00 – Technical data 12190
1 Safety information 12190
1 1 Safety regulations for working on fuel supply 12190
1 2 Safety measures when working on vehicles with a start/stop system 12190
1 3 Safety precautions when using testers and measuring instruments during a road test 12191
1 4 Safety precautions when working on the cooling system 12191
1 5 Safety precautions when working on ignition system 12191
1 6 Identification 12192
1 6 1 Engine number/engine data 12192
2 Repair notes 12193
2 1 Rules for cleanliness 12193
2 2 Foreign objects in engine 12193
2 3 Contact corrosion 12193
2 4 Pipe/wire routing and attachment 12193
2 5 Fitting radiator and condensers 12194
10 – Removing and installing engine 12195
1 Removing and installing engine 12195
1 1 Removing engine 12195
1 2 Separating engine and gearbox 12205
1 3 Securing engine on engine and gearbox support 12206
1 4 Installing engine 12208
2 Assembly mountings 12211
2 1 Assembly overview – assembly mountings 12211
2 2 Supporting engine in installation position 12213
2 3 Removing and installing motor mounting 12216
2 4 Removing and installing gearbox mounting 12218
2 5 Removing and installing pendulum support 12219
13 – Crankshaft group 12221
1 Cylinder block (pulley end) 12221
1 1 Assembly overview – poly V-belt drive 12221
1 1 1 Assembly overview – poly V-belt drive, vehicles without air conditioner compressor 12221
1 1 2 Assembly overview – poly V-belt drive, vehicles with air conditioner compressor 12223
1 2 Removing and installing poly-V belt 12225
1 2 1 Removing and installing poly V-belt, vehicles without air conditioner compressor 12225
1 2 2 Removing and installing poly V-belt, vehicles with air conditioner compressor 12226
1 3 Removing and installing tensioner for poly V-belt 12228
1 3 1 Removing and installing tensioner for poly V-belt, vehicles without air conditioner compressor 12228
1 3 2 Removing and installing tensioner for poly V-belt, vehicles with air conditioner compressor 12228
1 4 Removing and installing vibration damper 12228
1 5 Removing and installing engine support 12229
1 6 Renewing crankshaft oil seal – belt pulley end 12232
2 Cylinder block, gearbox end 12235
2 1 Assembly overview – cylinder block, gearbox end 12235
2 2 Removing and installing flywheel 12236
2 3 Removing and installing sealing flange on gearbox side 12237
3 Crankshaft 12246
3 1 Crankshaft dimensions 12246
3 2 Measuring axial clearance of crankshaft 12246
3 3 Renewing needle bearing in crankshaft 12247
4 Pistons and conrods 12251
4 1 Assembly overview – pistons and conrods 12251
4 2 Separating new conrod 12253
4 3 Removing and installing pistons 12253
4 4 Removing and installing oil spray jets 12254
4 5 Checking pistons and cylinder bores 12255
4 6 Checking radial clearance of conrods 12256
15 – Cylinder head, valve gear 12258
1 Cylinder head 12258
1 1 Assembly overview – cylinder head 12258
1 2 Assembly overview – camshaft housing 12259
1 3 Removing and installing cylinder head 12261
1 4 Removing and installing camshaft housing 12265
1 5 Checking compression 12269
2 Toothed belt drive 12272
2 1 Assembly overview – toothed belt cover 12272
2 2 Assembly overview – toothed belt 12273
2 3 Checking valve timing 12274
2 4 Removing toothed belt from camshaft 12280
2 5 Removing and installing toothed belt 12292
3 Valve gear 12306
3 1 Assembly overview – valve gear 12306
3 2 Measuring axial play of camshaft 12308
3 3 Removing and installing camshaft adjuster 12309
3 4 Removing and installing toothed belt pulley 12312
3 5 Removing and installing camshaft oil seal 12314
3 5 1 Removing and installing camshaft oil seal for inlet camshaft, belt pulley end 12314
3 5 2 Removing and installing exhaust camshaft oil seal, pulley end 12316
3 5 3 Removing and installing exhaust camshaft oil seal, gearbox end 12318
3 6 Removing and installing camshaft control valve 1 -N205- 12319
3 7 Removing and installing valve stem seals 12320
3 7 1 Removing and installing valve stem seals (cylinder head installed) 12320
3 7 2 Removing and installing valve stem seals (cylinder head removed) 12325
4 Inlet and exhaust valves 12328
4 1 Checking valve guides 12328
4 2 Checking valves 12328
4 3 Valve dimensions 12329
17 – Lubrication 12330
1 Sump, oil pump 12330
1 1 Assembly overview – sump/oil pump 12330
1 2 Engine oil: 12334
1 3 Removing and installing oil sump 12334
1 4 Removing and installing oil pump 12338
1 5 Removing and installing oil level and oil temperature sender -G266- 12341
2 Engine oil cooler 12342
2 1 Assembly overview – engine oil cooler 12342
2 2 Removing and installing engine oil cooler 12342
3 Crankcase ventilation 12344
3 1 Assembly overview – crankcase breather system 12344
3 2 Removing and installing oil separator 12345
4 Oil filter, oil pressure switch 12348
4 1 Assembly overview – oil filter/oil pressure switch 12348
4 2 Removing and installing oil pressure switch for reduced oil pressure -F378- 12349
4 3 Checking oil pressure and oil pressure switch 12350
4 4 Removing and installing oil filter housing 12351
19 – Cooling 12353
1 Cooling system/coolant 12353
1 1 Connection diagram – coolant hoses 12353
1 2 Draining and adding coolant 12355
1 3 Checking cooling system for leaks 12360
2 Coolant pump, regulation of cooling system 12362
2 1 Assembly overview – coolant pump, thermostat 12362
2 2 Assembly overview – electric coolant pump 12364
2 3 Assembly overview – coolant temperature sender 12366
2 4 Removing and installing coolant pump 12367
2 5 Removing and installing toothed belt pulley for coolant pump 12371
2 6 Removing and installing thermostat 12372
2 6 1 Removing and installing thermostat for main coolant circuit (radiator) 12372
2 6 2 Removing and installing thermostat for cylinder block coolant circuit 12374
2 7 Removing and installing electric coolant pump 12375
2 7 1 Removing and installing charge air cooling pump -V188- 12375
2 8 Removing and installing coolant temperature sender -G62- 12377
2 9 Removing and installing radiator fan thermal switch -F18- 12379
3 Coolant pipes 12381
3 1 Assembly overview – coolant pipes 12381
3 2 Removing and installing coolant pipes 12381
4 Radiator, radiator fan 12385
4 1 Assembly overview – radiator/radiator fan 12385
4 2 Assembly overview – radiator cowl and radiator fan 12387
4 3 Removing and installing radiator 12388
4 4 Removing and installing water radiator for charge air cooling circuit 12391
4 5 Removing and installing radiator cowl 12394
4 6 Removing and installing radiator fan -V7- 12396
21 – Turbocharging/supercharging 12398
1 Exhaust turbocharger 12398
1 1 Assembly overview – turbocharger 12398
1 2 Removing and installing turbocharger 12400
1 3 Removing and installing charge pressure positioner -V465- 12404
1 4 Removing and installing connection for turbocharger 12405
2 Charge air system 12409
2 1 Assembly overview – charge air system 12409
2 2 Removing and installing air pipe 12411
2 3 Removing and installing charge pressure sender -GX26- 12412
2 4 Removing and installing charge air cooler 12412
2 5 Checking charge air system for leaks 12415
24 – Mixture preparation – injection 12418
1 Injection system 12418
1 1 Overview of fitting locations – injection system 12418
2 Air filter 12422
2 1 Assembly overview – air filter housing 12422
2 2 Removing and installing air filter housing 12423
2 3 Removing and installing resonator for intake air 12424
3 Intake manifold 12425
3 1 Assembly overview – intake manifold 12425
3 2 Removing and installing intake manifold 12427
3 3 Removing and installing throttle valve module -GX3- 12429
3 4 Cleaning throttle valve module -GX3- 12430
4 Injectors 12432
4 1 Assembly overview – fuel rail with injectors 12432
4 2 Removing and installing fuel rail 12433
4 3 Removing and installing injectors 12434
5 Senders and sensors 12439
5 1 Removing and installing intake manifold sender -GX9- 12439
5 2 Removing and installing fuel pressure sender -G247- 12439
5 3 Checking fuel pressure sender -G247- 12440
6 High-pressure pump 12443
6 1 Assembly overview – high-pressure pump 12443
6 2 Removing and installing high-pressure pump 12444
6 3 Removing and installing high-pressure pipe 12445
7 Lambda probe 12447
7 1 Assembly overview – Lambda probe 12447
7 2 Removing and installing Lambda probe 12448
7 2 1 Removing and installing Lambda probe 1 before catalytic converter -GX10- 12448
7 2 2 Removing and installing Lambda probe 1 after catalytic converter -GX7- 12449
8 Engine (motor) control unit 12451
8 1 Assembly overview – engine control unit 12451
8 2 Removing and installing engine (motor) control unit -J623- 12452
8 2 1 Removing and installing engine (motor) control unit -J623- 12452
8 2 2 Disconnecting engine control unit -J623- from protective housing 12453
26 – Exhaust system 12454
1 Exhaust pipes, silencers 12454
1 1 Assembly overview – silencers 12454
1 2 Separating exhaust pipes, silencers 12455
1 3 Removing and installing silencer 12457
1 3 1 Removing and installing front silencer 12457
1 3 2 Removing and installing rear silencer 12458
1 3 3 Align end exhaust pipes 12458
1 4 Aligning exhaust system free of tension 12459
1 5 Check exhaust system for leaks 12459
1 6 Installation position of clamp 12460
2 Exhaust gas cleaning 12461
2 1 Assembly overview – emission control 12461
2 2 Removing and installing catalytic converter 12462
28 – Ignition system 12467
1 Ignition system 12467
1 1 Assembly overview – ignition system 12467
1 2 Test data, spark plugs 12468
1 3 Removing and installing ignition coils with output stage 12468
1 4 Removing and installing knock sensor 1 -G61- 12470
1 5 Removing and installing Hall sender -G40- 12470
1 6 Removing and installing engine speed sender -G28- 12471
D4B8040D54E Communication 12473
00 – Technical data 12477
1 Repair instructions 12477
1 1 General repair instructions 12477
1 2 Notes on repair of CAN bus wiring 12477
1 3 Transmitting power and aerial fitting locations 12477
91 – Communication 12479
1 Infotainment system 12480
1 1 Layout – infotainment system 12480
1 2 Overview of fitting locations – infotainment system 12483
1 3 Removing and installing infotainment system display 12484
1 4 Removing and installing control unit for front display and information control panel -J685- 12486
1 5 Removing and installing information electronics control unit 1 -J794- 12487
2 Sound system 12489
2 1 Overview of fitting locations – sound system 12489
2 2 Removing and installing front treble loudspeakers -R20-/-R22- 12489
2 3 Removing and installing rear bass loudspeakers -R15-/-R17- 12490
2 3 1 Removing and installing rear bass loudspeakers -R15-/-R17-, 2-door 12490
2 3 2 Removing and installing rear bass loudspeakers -R15-/-R17-, 4-door 12491
2 4 Removing and installing front bass loudspeakers -R21-/-R23- 12492
3 Aerial systems 12494
3 1 Overview of fitting locations – aerial systems 12494
3 2 Removing and installing aerial module 12494
3 3 Removing and installing roof aerial 12496
3 4 Removing and installing radio aerial 2 -R93-/TV aerial 2 -R56- 12497
4 Radio 12498
4 1 Overview – Radio 12498
4 2 Removing and installing radio 12498
5 Telephone system 12499
5 1 Mobile telephone preparation 12499
5 1 1 Mobile telephone preparation, Bluetooth hands-free system 12499
5 1 2 Mobile telephone preparation, Bluetooth car phone online 12499
5 2 Overview of fitting locations – telephone system 12500
5 3 Removing and installing aerial amplifier for mobile telephone -R86- 12501
5 4 Removing and installing telephone microphone -R38- 12502
6 Multifunction steering wheel 12503
6 1 Components of multifunction steering wheel 12503
6 2 Overview – multifunction steering wheel 12503
6 3 Removing and installing steering wheel multifunction buttons -E441-/-E440- 12504
6 4 Removing and installing Tiptronic switch in steering wheel -E439-/-E438- 12507
7 Connection for external multimedia devices 12509
7 1 Overview of fitting locations – connection for external multimedia devices 12509
7 2 Removing and installing connection for external multimedia devices 12510
7 2 1 Removing and installing connection for external multimedia devices, USB connection retainer -R193- 12510
7 2 2 Removing and installing connection for external multimedia devices, connection for external audio sources -R199- 12510
7 3 Removing and installing interface for external multimedia devices -R215- 12511
8 Reversing camera system 12513
8 1 Components of reversing camera system 12513
8 2 Overview of fitting locations – reversing camera system 12513
8 3 Removing and installing reversing camera -R189- 12514
D4B8040D507 5 speed manual gearboxes 02T and 0DF 12515
00 – Technical data 12519
1 Safety information 12519
1 1 Safety measures when working on vehicles with a start/stop system 12519
2 Identification 12520
2 1 Gearbox identification 12520
3 Technical data 12522
3 1 Allocation gearbox – engine 12522
3 1 1 Allocation gearbox – engine, Polo, manual gearbox 02T 12522
3 1 2 Allocation gearbox – engine, Polo, manual gearbox 0DF 12522
3 1 3 Allocation gearbox – engine, up! 12522
3 2 Capacities 12523
3 3 Calculation of gear ratios 12523
4 Overview – power transmission 12524
5 Electrical components 12526
5 1 Overview of fitting locations – electrical components 12526
5 1 1 Overview of fitting locations – electrical components, manual gearbox, up! 12526
5 1 2 Overview of fitting locations – electrical components, manual gearbox, Polo 12526
5 1 3 Overview of fitting locations – electrical components, clutch mechanism, up! 12527
5 1 4 Overview of fitting locations – electrical components, clutch mechanism, Polo 12528
6 Repair instructions 12529
6 1 General repair instructions 12529
30 – Clutch 12533
1 Clutch mechanism 12533
1 1 Overview of fitting locations – clutch mechanism 12533
1 1 1 Overview of fitting locations – clutch mechanism, up! 12533
1 1 2 Overview of fitting locations – clutch mechanism, Polo 12534
1 2 Assembly overview – pedal cluster 12535
1 2 1 Assembly overview – pedal cluster, up! 12535
1 2 2 Assembly overview – pedal cluster, Polo 12537
1 3 Assembly overview – clutch hydraulics 12539
1 3 1 Assembly overview – clutch hydraulics, up! 12539
1 3 2 Assembly overview – clutch hydraulics, Polo, LHD vehicles 12541
1 3 3 Assembly overview – clutch hydraulics, Polo, RHD vehicles 12543
1 4 Assembly overview – clutch release mechanism 12545
1 5 Removing and installing bearing bush 12546
1 6 Removing and installing clutch pedal 12548
1 6 1 Removing and installing clutch pedal, up! 12548
1 6 2 Removing and installing clutch pedal, Polo, LHD vehicles 12548
1 6 3 Removing and installing clutch pedal, Polo, RHD vehicles 12549
1 7 Removing and installing over-centre spring 12551
1 8 Removing and installing extension spring 12553
1 8 1 Removing and installing extension spring, up! 12553
1 8 2 Removing and installing extension spring, Polo 12554
1 9 Removing and installing mounting bracket 12554
1 9 1 Removing and installing mounting bracket, up! 12554
1 9 2 Removing and installing mounting bracket, Polo 12560
1 10 Removing and installing clutch master cylinder 12565
1 10 1 Removing and installing clutch master cylinder, up! 12565
1 10 2 Removing and installing clutch master cylinder, Polo 12566
1 11 Removing and installing clutch slave cylinder 12567
1 11 1 Removing and installing clutch slave cylinder, up! 12567
1 11 2 Removing and installing clutch slave cylinder, Polo 12570
1 12 Checking clutch master cylinder and clutch slave cylinder 12572
1 13 Removing and installing lines for clutch mechanism 12573
1 14 Bleeding clutch mechanism 12578
1 15 Removing and installing clutch pedal switch -F36- 12579
1 16 Checking clutch master cylinder and clutch slave cylinder 12580
1 17 Removing and installing clutch position sender -G476- 12580
1 17 1 Removing and installing clutch position sender -G476-, up! 12580
1 17 2 Removing and installing clutch position sender -G476-, Polo 12581
1 18 Servicing clutch release mechanism 12583
2 Clutch 12586
2 1 Assembly overview – clutch 12586
2 2 Removing and installing clutch 12586
34 – Controls, housing 12592
1 Selector mechanism 12592
1 1 Installation position – selector mechanism 12592
1 2 Assembly overview – gear knob and cover 12593
1 3 Assembly overview – selector mechanism 12594
1 3 1 Assembly overview – selector mechanism, up! 12594
1 3 2 Assembly overview – selector mechanism, Polo 12596
1 4 Removing and installing gear knob 12598
1 5 Removing and installing selector mechanism 12601
1 6 Repairing selector mechanism 12604
1 7 Adjusting selector mechanism 12609
1 7 1 Adjusting selector mechanism, up! 12609
1 7 2 Adjusting selector mechanism, Polo 12612
1 8 Checking selector mechanism 12615
2 Removing and installing gearbox 12616
2 1 Differentiating between gearboxes, Polo 12616
2 2 Removing gearbox 12616
2 2 1 Removing gearbox, up! 12616
2 2 2 Removing gearbox, Polo 12624
2 3 Installing gearbox 12638
2 3 1 Installing gearbox, up! 12638
2 3 2 Installing gearbox, Polo 12644
2 4 Specified torques for gearbox 12651
2 4 1 Specified torques for gearbox, up! 12651
2 4 2 Specified torques for gearbox, Polo 12652
3 Assembly mountings 12653
3 1 Assembly overview – assembly mountings, up! 12653
3 2 Assembly overview – assembly mountings, Polo 12654
4 Gearbox transport 12657
5 Gear oil 12658
5 1 Checking gear oil level 12658
5 2 Draining and filling gear oil 12659
6 Securing to engine and gearbox support 12661
6 1 Securing to engine and gearbox support, gearboxes for up! 12661
6 2 Securing to engine and gearbox support, gearboxes for Polo 12662
7 Dismantling and assembling gearbox 12663
7 1 Schematic overview – gearbox 12663
7 1 1 Schematic overview – gearbox, manual gearbox 02T 12663
7 1 2 Schematic overview – gearbox, manual gearbox 0DF 12664
7 2 Assembly overview – gearbox 12665
7 3 Assembly overview – cover for gearbox housing and 5th gear 12666
7 4 Assembly overview – clutch housing 12668
7 4 1 Assembly overview – clutch housing, manual gearbox 02T 12668
7 4 2 Assembly overview – clutch housing, manual gearbox 0DF 12668
7 5 Assembly overview – shafts, differential, selector mechanism 12669
7 6 Assembly overview – selector unit 12671
7 6 1 Assembly overview – selector unit, up! 12671
7 6 2 Assembly overview – selector unit, Polo 12673
7 7 Assembly overview – selector forks 12674
7 8 Removing and installing selector unit with gearbox installed 12675
7 8 1 Removing and installing selector unit, up! 12675
7 8 2 Removing and installing selector unit, Polo 12681
7 9 Repairing selector forks 12684
7 10 Repairing selector unit 12689
7 11 Renewing selector shaft seal 12691
7 12 Dismantling and assembling gearbox 12693
8 Gearbox housing, clutch housing 12707
8 1 Assembly overview – gearbox housing and clutch housing 12707
8 1 1 Assembly overview – gearbox housing and clutch housing, manual gearbox 02T 12707
8 1 2 Assembly overview – gearbox housing and clutch housing, manual gearbox 0DF 12709
8 2 Repairing clutch housing 12711
35 – Gears, shafts 12714
1 Input shaft 12714
1 1 Assembly overview – input shaft 12714
1 2 Dismantling and assembling input shaft 12716
1 3 Renewing input shaft seal 12730
2 Output shaft 12732
2 1 Assembly overview – output shaft 12732
2 2 Dismantling and assembling output shaft 12735
39 – Final drive – differential 12743
1 Oil seals 12743
1 1 Overview of fitting locations – oil seals 12743
1 2 Renewing left seal 12744
1 2 1 Renewing oil seal for left flange shaft, manual gearbox 02T 12744
1 2 2 Renewing oil seal for left flange shaft, manual gearbox 0DF 12747
1 3 Renewing right seal 12749
1 3 1 Renewing oil seal for right flange shaft, manual gearbox 02T 12749
1 3 2 Renewing oil seal for right flange shaft, manual gearbox 0DF 12752
2 Differential 12755
2 1 Assembly overview – differential 12755
2 1 1 Assembly overview – differential housing, manual gearbox 02T 12755
2 1 2 Assembly overview – differential housing, manual gearbox 0DF 12757
2 2 Dismantling and assembling differential 12758
2 3 Adjusting differential 12766
D4B8040D543 Electrical system 12773
00 – Technical data 12781
1 Safety information 12781
1 1 Safety measures when working on vehicles with a start/stop system 12781
1 2 Safety precautions when using testers and measuring instruments during a road test 12781
1 3 Operation and safety notes for gas discharge lamps 12782
2 Repair notes 12784
2 1 Contact corrosion 12784
2 2 Routing and attachment of lines 12784
3 Battery 12785
3 1 Types of battery 12785
3 2 Battery – general notes 12785
27 – Starter, current supply, CCS 12786
1 Battery 12786
1 1 Assembly overview – battery 12786
1 1 1 Assembly overview – battery; battery in engine compartment 12786
1 1 2 Assembly overview – battery; battery in luggage compartment 12788
1 2 Assembly overview – battery isolator 12789
1 3 Removing and installing battery 12790
1 3 1 Removing and installing battery; battery in engine compartment 12790
1 3 2 Removing and installing battery, battery in luggage compartment 12792
1 4 Disconnecting and connecting battery 12795
1 4 1 Disconnecting and connecting battery; battery in engine compartment 12795
1 4 2 Disconnecting and connecting battery, battery in luggage compartment 12797
1 5 Removing and installing battery tray 12798
1 5 1 Removing and installing battery tray, battery in engine compartment 12798
1 5 2 Removing and installing battery tray, battery in luggage compartment 12799
1 6 Checking battery 12801
1 7 Charging battery 12801
1 8 Removing and installing earth wire with battery monitor control unit -J367- 12802
1 8 1 Removing and installing earth cable with battery monitor control unit -J367-, battery in engine compartment 12802
1 8 2 Removing and installing earth cable with battery monitor control unit -J367-, battery in luggage compartment 12803
1 9 Removing and installing battery isolator 12803
1 10 Adapting battery monitor control unit -J367- 12804
2 Jump start point 12805
2 1 Assembly overview – jump-start terminal 12805
2 2 Removing and installing jump starting point 12805
3 Alternator 12807
3 1 Assembly overview – alternator 12807
3 1 1 Assembly overview – alternator 12807
3 1 2 Assembly overview – alternator with decoupler pulley with freewheel 12808
3 1 3 Assembly overview – alternator without sliding bushes 12809
3 2 Removing and installing alternator 12810
3 2 1 Removing and installing alternator, vehicles with 1 0 l IDI engine 12810
3 2 2 Removing and installing alternator – vehicles with 1 0 l FSI engine 12811
3 2 3 Removing and installing alternator, vehicles with 1 2 l TSI engine 12812
3 2 4 Removing and installing alternator, vehicles with 1 2 l/81 KW TSI engine 12814
3 2 5 Removing and installing alternator, vehicles with 1 4 l/110 kW TSI engine 12816
3 2 6 Removing and installing alternator, vehicles with 1 4 l TDI engine 12818
3 2 7 Removing and installing alternator, vehicles with 1 8 l/141 KW TSI engine 12820
3 3 Checking alternator 12822
3 4 Checking poly V-belt 12822
3 5 Removing and installing poly V-belt pulley 12822
3 5 1 Removing and installing poly V-belt pulley without freewheel 12822
3 5 2 Removing and installing poly V-belt pulley with freewheel, manufacturer: Bosch 12823
3 5 3 Removing and installing poly V-belt pulley with freewheel, manufacturer: Valeo 12825
3 5 4 Removing and installing “decoupler pulley with freewheel” 12827
3 6 Removing and installing voltage regulator -C1- 12830
3 6 1 Removing and installing voltage regulator -C1-, Bosch, version 1 12830
3 6 2 Removing and installing voltage regulator -C1-, Bosch, version 2 12831
3 6 3 Removing and installing voltage regulator -C1-, Valeo 12832
4 Starter motor 12835
4 1 Assembly overview – starter 12835
4 1 1 Assembly overview – starter, vehicles with 5-speed manual gearbox, 0CF (MQ100-5F) 12835
4 1 2 Assembly overview – starter, vehicles with 5-speed manual gearbox, 0A4 (MQ250-5F) 12837
4 1 3 Assembly overview – starter, vehicles with 5-speed manual gearbox, 02T (MQ200-5F), 0DF (MQ250-5F) 12838
4 1 4 Assembly overview – starter, vehicles with 6-speed manual gearbox, 02U (MQ200-6F), 0DQ (MQ200-6F) 12839
4 1 5 Assembly overview – starter, vehicles with 6-speed manual gearbox, 0A8 (MQ350-6F) 12840
4 1 6 Assembly overview – starter, vehicles with 7-speed dual clutch gearbox, 0CW (DQ200-7F) 12841
4 2 Removing and installing starter 12842
4 2 1 Removing and installing starter, vehicles with 5-speed manual gearbox, 0CF (MQ100-5F) 12842
4 2 2 Removing and installing starter, vehicles with 5-speed manual gearbox, 04A (MQ250-5F) 12843
4 2 3 Removing and installing starter, vehicles with 5-speed manual gearbox, 02T (MQ200-5F), 0DF (MQ250-5F) 12845
4 2 4 Removing and installing starter, vehicles with 6-speed manual gearbox, 02U (MQ200-6F), 0DQ (MQ200-6F) 12846
4 2 5 Removing and installing starter, vehicles with 6-speed manual gearbox, 0A8 (MQ350-6F) 12848
4 2 6 Removing and installing starter, vehicles with 7-speed dual clutch gearbox, 0CW (DQ200-7F) 12849
4 3 Checking starter 12850
5 Cruise control system (CCS) 12851
6 Start/stop system 12852
6 1 General description – start/stop system 12852
7 Adaptive cruise control 12853
7 1 Overview of fitting locations – adaptive cruise control 12853
7 2 Removing and installing adaptive cruise control unit -J428- 12854
7 2 1 Removing and installing adaptive cruise control unit -J428- together with retaining plate 12854
7 2 2 Removing adaptive cruise control unit -J428- from and installing to retaining plate 12854
7 2 3 Removing adaptive cruise control unit -J428- from and installing to adapter frame 12856
7 3 Removing and installing trim for radar sensor 12857
7 4 Calibrating adaptive cruise control 12857
90 – Gauges, instruments 12859
1 Dash panel insert 12859
1 1 Assembly overview – dash panel insert 12859
1 2 Removing and installing dash panel insert -KX2- 12859
2 Horn 12862
2 1 Assembly overview – horn 12862
2 2 Removing and installing treble horn -H2- and bass horn -H7- 12863
2 2 1 Removing and installing treble horn -H2- 12863
2 2 2 Removing and installing bass horn -H7- 12863
2 2 3 Removing and installing bracket for horns 12863
92 – Windscreen wash/wipe system 12865
1 Windscreen wiper system 12865
1 1 Assembly overview – windscreen wiper system 12865
1 2 Moving wipers to service position 12866
1 3 Removing and installing wiper blade 12867
1 4 Removing and installing wiper arms 12868
1 5 Adjusting wiper arms 12869
1 6 Removing and installing wiper motor -V- 12870
1 7 Renewing wiper motor 12872
1 8 Removing and installing rain and light sensor 12874
2 Windscreen washer system 12877
2 1 Assembly overview – windscreen washer system 12877
2 2 Removing and installing washer fluid reservoir 12878
2 3 Removing and installing windscreen washer fluid level sender -G33- 12880
2 4 Removing and installing windscreen and rear window washer pump -V59- 12881
2 5 Removing and installing washer jets 12881
2 6 Adjusting spray jets 12882
3 Rear window wiper system 12883
3 1 Assembly overview – rear window wiper system 12883
3 2 Removing and installing wiper blade 12884
3 3 Removing and installing wiper arm 12884
3 4 Adjusting wiper arm 12885
3 5 Removing and installing rear window wiper motor -V12- 12886
4 Rear window washer system 12888
4 1 Assembly overview – rear window washer system 12888
4 2 Removing and installing washer fluid reservoir 12889
4 3 Removing and installing rear window washer pump 12889
4 4 Removing and installing spray jet 12889
4 5 Adjusting spray jet 12890
5 Headlight washer system 12891
5 1 Assembly overview – headlight washer system 12891
5 2 Removing and installing washer fluid reservoir 12892
5 3 Removing and installing headlight washer system pump -V11- 12892
5 4 Removing and installing washer jets 12893
5 5 Adjusting spray jets 12893
5 6 Removing and installing pop-up cylinder 12893
5 6 1 Removing and installing pop-up cylinder 12893
5 6 2 Removing and installing pop-up cylinder, Polo GTI 12894
6 Washer fluid lines 12896
6 1 Repairing washer fluid lines 12896
94 – Lights, bulbs, switches – exterior 12897
1 Headlights 12898
1 1 Assembly overview – headlight 12898
1 1 1 Assembly overview – halogen headlights H7, version 1 12898
1 1 2 Assembly overview – halogen headlights H7, version 2 12900
1 1 3 Assembly overview – gas discharge headlight 12902
1 1 4 Assembly overview – LED headlights 12904
1 2 Removing and installing headlight 12905
1 3 Adjusting headlights 12907
1 3 1 Adjusting headlights, halogen headlights H7 12907
1 3 2 Adjusting headlights, gas discharge headlight 12907
1 3 3 Adjusting headlights, auxiliary headlight 12907
1 4 Adjusting headlight installation position 12907
1 5 Removing and installing front turn signal bulb -M5-/-M7- 12908
1 5 1 Removing and installing front turn signal bulb -M5-/-M7-, halogen headlights H7, version 1 12908
1 5 2 Removing and installing front turn signal bulb -M5-/-M7-, halogen headlights H7, version 2 12909
1 5 3 Removing and installing front turn signal bulb -M5-/-M7- (gas discharge headlights) 12910
1 5 4 Removing and installing front turn signal bulb -M5-/-M7-, LED headlights 12912
1 6 Installing repair kit for headlight housing 12913
1 7 Converting headlights from driving on right to driving on left 12914
1 7 1 Changing headlights over from driving on right to driving on left, left halogen headlight H7 12914
1 7 2 Changing headlights over from driving on right to driving on left, left gas discharge headlight 12915
1 7 3 Changing headlights over from driving on right to driving on left, left LED headlight 12916
1 7 4 Changing headlights over from driving on right to driving on left, right halogen headlight H7 12917
1 7 5 Changing headlights over from driving on right to driving on left, right gas discharge headlight 12917
1 7 6 Changing headlights over from driving on right to driving on left, right LED headlight 12918
1 8 Converting headlights from driving on left to driving on right 12919
1 8 1 Changing headlights over from driving on left to driving on right, left halogen headlight H7 12919
1 8 2 Changing headlights over from driving on left to driving on right, left gas discharge headlight 12920
1 8 3 Changing headlights over from driving on left to driving on right, left LED discharge headlight 12921
1 8 4 Changing headlights over from driving on left to driving on right, right halogen headlight H7 12922
1 8 5 Changing headlights over from driving on left to driving on right, right gas discharge headlight 12922
1 8 6 Changing headlights over from driving on left to driving on right, right LED headlight 12923
1 9 Removing and installing headlight range control motor -V48-/-V49- 12924
1 9 1 Removing and installing headlight range control motor -V48-/-V49-, halogen headlights H7, version 1 12924
1 9 2 Removing and installing headlight range control motor -V48-/-V49-, halogen headlights H7, version 2 12925
1 9 3 Removing and installing headlight range control motor -V48-/-V49- (gas discharge headlights) 12928
1 9 4 Headlight range control motors -V48-/-V49-, LED headlights 12930
1 10 Removing and installing headlight dipped beam bulb -M29-/-M31- 12932
1 10 1 Removing and installing headlight dipped beam bulb -M29-/-M31-, halogen headlights H7, version 1 12932
1 10 2 Removing and installing headlight dipped beam bulb -M29-/-M31-, halogen headlights H7, version 2 12933
1 10 3 Headlight dipped beam bulb -M29-/-M31-, LED headlights 12935
1 11 Removing and installing headlight main beam bulb -M30-/-M32- 12936
1 11 1 Removing and installing main beam headlight bulb -M30-/-M32-, halogen headlights H7, version 1 12936
1 11 2 Removing and installing main beam headlight bulb -M30-/-M32-, halogen headlights H7, version 2 12938
1 11 3 Headlight main beam bulb -M30-/-M32-, LED headlights 12939
1 12 Removing and installing gas discharge bulb -L13-/-L14- 12941
1 13 Removing and installing side light bulb -M1-/-M3- 12942
1 13 1 Removing and installing side light bulb -M1-/-M3-, halogen headlights H7, version 1 12942
1 13 2 Removing and installing side light bulb -M1-/-M3-, halogen headlights H7, version 2 12944
1 13 3 Removing and installing side light bulb -M1-/-M3-, gas discharge headlights 12945
1 14 Removing and installing daytime running light bulb -L174-/-L175- 12946
1 14 1 Removing and installing daytime running light bulb -L174-/-L175-, halogen headlights H7 12946
1 14 2 Removing and installing daytime running light bulb -L174-/-L175-, gas discharge headlights 12946
1 15 Removing and installing headlight screen adjustment solenoid -N395-/-N396- 12946
1 16 Removing and installing bulbs for cornering light -M51-/-M52- 12947
1 17 Removing and installing headlight starter for gas discharge light -J426-/-J427- 12948
1 18 Removing and installing LED modules for daytime running light and side light -L176-/-L177- 12949
1 19 Removing and installing starter unit for gas discharge bulb 12949
1 20 Removing and installing output module 1 for LED headlight -A27-/-A31- 12950
1 21 Removing and installing control unit for daytime running light and side light -J860-/-J861- 12951
2 Fog lights 12952
2 1 Assembly overview – fog lights 12952
2 1 1 Assembly overview – fog lights 12952
2 1 2 Assembly overview – fog lights, Polo Cross 12953
2 1 3 Assembly overview – fog lights, Polo GTI 12954
2 2 Removing and installing fog light 12954
2 2 1 Removing and installing fog light 12954
2 2 2 Removing and installing fog lights, Polo Cross 12956
2 2 3 Removing and installing fog lights, Polo GTI 12957
2 3 Removing and installing fog light bulb -L22-/-L23- 12959
2 3 1 Removing and installing fog light bulb -L22-/-L23- 12959
2 3 2 Removing and installing fog light bulb -L22-/-L23-, “Cross” 12960
2 4 Adjusting fog lights 12960
3 Daytime running light 12961
3 1 Assembly overview – daytime running lights 12961
3 2 Removing and installing daytime running light bulb -L174-/-L175- 12962
3 2 1 Removing and installing daytime running light bulb -L174-/-L175-, halogen headlights H7 12962
3 2 2 Removing and installing daytime running light bulb -L174-/-L175-, gas discharge headlights 12963
4 Lights in exterior mirror 12964
4 1 Assembly overview – lights in exterior mirror 12964
4 2 Removing and installing turn signal 12965
4 3 Removing and installing turn signal repeater bulb -L131-/-L132- 12965
5 Tail lights 12966
5 1 Assembly overview – tail lights in body 12966
5 2 Removing and installing bulb carrier 12966
5 3 Removing and installing tail light cluster 12967
6 High-level brake light 12969
6 1 Assembly overview – high-level brake light 12969
6 2 Removing and installing high-level brake light 12970
6 2 1 Removing and installing high-level brake light 12970
6 2 2 Removing and installing high-level brake light, BlueMotion, GTI and R-Line 12971
6 3 Removing and installing bulb for high-level brake light -M25- 12972
7 Number plate light 12973
7 1 Removing and installing number plate light -X4-/-X5- 12973
7 2 Removing and installing bulb for number plate light -X4-/-X5- 12974
8 Steering column switch module 12975
8 1 Assembly overview – steering column switch module 12975
8 2 Removing and installing airbag coil connector and return ring with slip ring -F138- 12976
8 3 Removing and installing steering column combination switch -E595- 12978
8 4 Removing and installing turn signal switch -E2- 12980
8 5 Removing and installing cruise control system switch -E45- 12980
8 6 Removing and installing intermittent wiper switch -E22- 12981
8 7 Removing and installing ignition/starter switch -D- 12981
8 8 Removing and installing lock cylinder 12982
8 9 Removing and installing steering lock housing 12984
8 10 Removing and installing ignition key withdrawal lock solenoid -N376- 12986
9 Parking aid 12987
9 1 Assembly overview – parking aid 12987
9 1 1 Assembly overview – front parking aid system 12987
9 1 2 Assembly overview – rear parking aid system 12988
9 2 Removing and installing parking aid control unit -J446- 12988
9 3 Removing and installing front parking aid warning buzzer -H22- 12989
9 4 Removing and installing rear parking aid warning buzzer -H15- 12989
9 5 Removing and installing front parking aid senders 12990
9 6 Removing and installing rear parking aid senders 12991
10 Automatic headlight range control 12993
10 1 Assembly overview – automatic headlight range control 12993
10 2 Removing and installing headlight range control unit -J431- 12993
11 Towing bracket 12995
11 1 Assembly overview – towing bracket socket 12995
11 2 Removing and installing trailer detector control unit -J345- 12995
96 – Lights, bulbs, switches – interior 12997
1 Lights 12997
1 1 Overview of fitting locations – lights in dash panel 12997
1 2 Overview of fitting locations – lights in front doors 12999
1 3 Overview of fitting locations – lights in centre console 13000
1 4 Overview of fitting locations – lights in luggage compartment 13001
1 5 Overview of fitting locations – lights in roof trim 13002
1 6 Removing and installing footwell light -W9-/-W10- 13002
1 7 Removing and installing footwell light bulb -W9-/-W10- 13003
1 8 Removing and installing Central locking SAFELOCK function warning lamp -K133- 13004
1 9 Removing and installing selector lever position display -Y6- 13005
1 10 Removing and installing right luggage compartment light -W35- 13005
1 11 Removing and installing bulb for right luggage compartment light -W35- 13006
1 12 Removing and installing illuminated vanity mirror -W20-/-W14- 13007
1 13 Removing and installing bulb for illuminated vanity mirror -W20-/-W14- 13008
1 14 Removing and installing front interior light -WX1- 13009
1 14 1 Removing and installing front interior light -WX1-, vehicles without panorama sliding sunroof 13009
1 14 2 Removing and installing front interior light -WX1-, vehicles without panorama sliding sunroof 13010
1 15 Removing and installing bulb for front interior light -W13-/-W15-/-W19- 13012
1 15 1 Removing and installing bulb for interior light with switch-off delay -W15-, vehicles without panorama sliding sunroof 13012
1 15 2 Removing and installing bulb for interior light with switch-off delay -W15-, vehicles with panorama sliding sunroof 13013
1 15 3 Removing and installing reading light bulb -W13-/-W19-, vehicles without panorama sliding sunroof 13014
1 15 4 Removing and installing reading light bulb -W13-/-W19-, vehicles with panorama sliding sunroof 13015
1 16 Removing and installing rear interior light -WX2- 13015
1 17 Removing and installing bulb for rear centre reading light -W44- 13016
2 Controls 13019
2 1 Overview of fitting locations – controls in dash panel 13020
2 2 Overview of fitting locations – controls in front doors 13021
2 3 Overview of fitting locations – controls in rear doors 13022
2 4 Overview of fitting locations – controls in luggage compartment 13023
2 5 Overview of fitting locations – controls in roof trim 13024
2 6 Removing and installing rotary light switch -EX1- 13024
2 7 Removing and installing regulator for switch and instrument illumination -E20- 13025
2 8 Removing and installing headlight range control regulator -E102- 13026
2 9 Removing and installing heated seat regulator -E94-/-E95- 13026
2 10 Removing and installing TCS and ESP button -E256- 13027
2 11 Removing and installing Start/Stop operation button -E693- 13027
2 12 Heated rear window button -E230- 13027
2 13 Removing and installing hazard warning light button -E229- 13028
2 14 Removing and installing front passenger side airbag deactivated warning lamp -K145- 13028
2 15 Removing and installing parking aid button -E266- 13028
2 16 Removing and installing driving mode selection button -E735- 13029
2 17 Removing and installing buttons in dash panel 13029
2 18 Removing and installing operating unit for window regulator in driver door -E512- 13031
2 19 Removing and installing window regulator switch in front passenger door -E107- 13032
2 20 Removing and installing mirror adjustment switch -E43- 13032
2 21 Removing and installing driver side interior locking button for central locking system -E308- 13033
2 22 Removing and installing door contact switch -F2-/-F3- 13033
2 23 Removing and installing rear door contact switches -F10-/-F11- 13034
2 24 Removing and installing rear lid contact switch for anti-theft alarm -F123- 13034
2 25 Removing and installing rear window regulator switch in door -E52-/-E54- 13034
2 26 Removing and installing vanity mirror contact switch -F147-/-F148- 13035
3 Further lights and controls in vehicle interior 13036
3 1 Overview of fitting locations – further lights and controls in vehicle interior 13036
3 2 Removing and installing sunroof button -E325- 13036
3 3 Removing and installing tyre pressure monitor display button -E492- 13037
4 Anti-theft alarm 13038
4 1 Assembly overview – interior monitor 13038
4 2 Removing and installing alarm horn -H12- 13038
4 3 Activating and deactivating anti-theft alarm 13040
4 3 1 Deactivating anti-theft alarm system 13040
4 3 2 Activating anti-theft alarm system 13040
4 4 Removing and installing anti-theft alarm sensor -G578- 13040
4 5 Removing and installing button for deactivating interior monitoring and vehicle inclination sensor -E616- 13041
5 Immobiliser 13043
5 1 Removing and installing immobilizer control unit -J362- 13043
5 2 Removing and installing immobiliser reader coil -D2- 13043
6 Cigarette lighter, socket 13044
6 1 Removing and installing cigarette lighter -U1- 13044
6 2 Removing and installing 12 V socket 13044
97 – Wiring 13045
1 Relay carriers, fuse holders, electronics boxes 13045
1 1 Overview of fitting locations – relay carriers, fuse holders, E-boxes 13045
1 1 1 Overview of fitting locations – relay carriers, fuse holders, E-boxes 13045
1 1 2 Overview of fitting locations – relay carriers, fuse holders, electronics boxes, Polo GTI 13047
1 2 Removing and installing electronics box (E-box) 13047
1 2 1 Removing and installing electronics box (E-box) 13047
1 2 2 Removing and installing electronics box, Polo GTI 13049
1 3 Removing and installing bracket for electronics box 13050
1 3 1 Removing and installing bracket for electronics box 13050
1 3 2 Removing and installing bracket for electronics box, Polo GTI 13051
1 4 Removing and installing fuse holder C -SC- 13052
1 5 Removing and installing relay and fuse carrier 1 -SR1- 13054
2 Control units 13057
2 1 Overview of fitting locations – control units 13057
2 1 1 Overview of fitting locations – control units, front 13057
2 1 2 Fitting locations overview – control units, rear 13058
2 2 Removing and installing onboard supply control unit -J519- 13058
2 3 Removing and installing data bus diagnostic interface -J533- 13059
3 Connectors 13060
3 1 Repairing electrical wiring harnesses and plug-in connections 13060
3 1 1 Repairs to wiring harnesses and connectors 13060
3 1 2 Repairing connector housings and electrical connectors 13060
4 Releasing and dismantling connector housings 13061
5 Repairing aerial wires 13062
6 Fibre optic cables 13063
7 Vehicle diagnosis, testing and information systems 13064
8 Driving sound and engine sound 13065
8 1 Overview of fitting locations – driving sound and engine sound 13065
8 2 Removing and installing engine sound generator control unit -J943- 13066
D4B8040D547 3 cylinder common rail engine (1 4 l 4V turbocharger EA 288) 13067
00 – Technical data 13075
1 Safety information 13075
1 1 Safety regulations for working on fuel supply 13075
1 2 Safety measures when working on vehicles with start/stop system 13076
1 3 Safety precautions when using testers and measuring instruments during a road test 13077
1 4 Safety precautions when working on the cooling system 13077
1 5 Safety precautions when working on exhaust system 13077
2 Identification 13079
2 1 Motor number/motor data 13079
3 Repair instructions 13081
3 1 Rules for cleanliness 13081
3 2 Foreign objects in engine 13081
3 3 Contact corrosion 13081
3 4 Routing and attachment of lines 13082
3 5 Fitting radiator and condensers 13082
4 Technical data 13084
4 1 Coolant 13085
10 – Removing and installing engine 13087
1 Removing and installing engine 13087
1 1 Removing engine 13087
1 2 Separating engine and gearbox 13095
1 2 1 Separating engine and gearbox, vehicles with manual gearbox 13095
1 2 2 Separating engine and gearbox, vehicles with dual clutch gearbox 13097
1 3 Securing engine on engine and gearbox support 13100
1 4 Installing engine 13102
2 Assembly mountings 13106
2 1 Assembly overview – assembly mountings 13106
2 2 Supporting engine in installation position 13108
2 3 Removing and installing engine mounting 13110
2 4 Removing and installing gearbox mounting 13111
2 5 Removing and installing pendulum support 13112
3 Engine cover panel 13114
3 1 Removing and installing engine cover 13114
13 – Crankshaft group 13115
1 Cylinder block (pulley end) 13115
1 1 Assembly overview – poly V-belt drive 13115
1 2 Assembly overview – sealing flange, belt pulley end 13117
1 3 Removing and installing poly-V belt 13118
1 4 Removing and installing tensioner for poly V-belt 13119
1 5 Removing and installing vibration damper 13120
1 6 Removing and installing bracket for ancillaries 13121
1 6 1 Removing and installing bracket for high-pressure pump 13121
1 6 2 Removing and installing bracket for alternator 13122
1 7 Removing and installing engine support 13123
1 8 Removing and installing sealing flange on pulley end 13125
2 Cylinder block, gearbox end 13128
2 1 Assembly overview – cylinder block, gearbox end 13128
2 2 Removing and installing flywheel 13129
2 2 1 Preloading gear in flywheel – vehicles with dual clutch gearbox 13132
2 3 Removing and installing sealing flange on gearbox side 13132
3 Crankshaft 13145
3 1 Assembly overview – crankshaft 13145
3 2 Crankshaft dimensions 13147
3 3 Measuring axial clearance of crankshaft 13147
3 4 Renewing needle bearing in crankshaft 13148
4 Pistons and conrods 13151
4 1 Assembly overview – pistons and conrods 13151
4 2 Removing and installing pistons 13155
4 3 Measuring piston projection at TDC 13156
4 4 Checking pistons and cylinder bores 13159
4 5 Checking radial clearance of conrods 13161
15 – Cylinder head, valve gear 13162
1 Cylinder head 13162
1 1 Assembly overview – cylinder head 13162
1 2 Assembly overview – cylinder head cover 13166
1 3 Removing and installing cylinder head cover 13167
1 4 Removing and installing cylinder head 13169
1 5 Removing and installing injector seals 13177
1 6 Checking compression 13178
1 7 Removing and installing camshaft housing 13180
2 Toothed belt drive 13185
2 1 Assembly overview – toothed belt cover 13185
2 2 Assembly overview – toothed belt 13185
2 3 Removing and installing toothed belt guard 13187
2 3 1 Removing and installing upper toothed belt guard 13187
2 3 2 Removing and installing lower toothed belt guard 13188
2 4 Removing toothed belt from camshaft 13189
2 5 Removing and installing toothed belt 13193
3 Valve gear 13208
3 1 Assembly overview – valve gear 13208
3 2 Measuring axial play of camshaft 13210
3 3 Removing and installing camshaft oil seal 13211
3 4 Checking hydraulic compensation elements 13213
3 5 Removing and installing valve stem seals 13214
3 5 1 Removing and installing valve stem seals (cylinder head installed) 13214
3 5 2 Removing and installing valve stem seals (cylinder head removed) 13218
4 Inlet and exhaust valves 13223
4 1 Checking valve guides 13223
4 2 Checking valves 13224
4 3 Valve dimensions 13224
17 – Lubrication 13225
1 Sump, oil pump 13225
1 1 Assembly overview – sump/oil pump 13225
1 2 Engine oil: 13227
1 3 Removing and installing oil sump 13227
1 3 1 Removing and installing lower part of sump 13227
1 3 2 Removing and installing upper part of sump 13228
1 4 Removing and installing oil pump 13234
1 5 Removing and installing oil level and oil temperature sender -G266- 13238
2 Engine oil cooler 13240
3 Oil filter, oil pressure switch 13241
3 1 Assembly overview – oil filter housing, oil pressure switch 13241
3 2 Removing and installing oil pressure switch -F1- 13242
3 3 Checking oil pressure 13243
3 4 Removing and installing oil filter housing 13244
3 5 Removing and installing oil pressure regulating valve -N428- 13248
19 – Cooling 13250
1 Cooling system/coolant 13250
1 1 Connection diagram – coolant hoses 13250
1 2 Checking cooling system for leaks 13251
1 3 Draining coolant 13255
1 4 Filling with coolant 13256
1 4 1 Filling with coolant without electric vacuum pump 13256
1 4 2 Filling coolant with electric vacuum pump -VAS 6096/2- 13261
1 5 Checking filling quality of cooling system 13269
1 6 Checking electric vacuum pump -VAS 6096/2- 13271
1 7 Flushing cooling system 13272
1 7 1 Flushing cooling system, quick reference guide 13295
2 Coolant pump, regulation of cooling system 13297
2 1 Assembly overview – coolant pump, thermostat 13297
2 2 Assembly overview – coolant temperature sender 13299
2 3 Assembly overview – electric coolant pump 13300
2 4 Removing and installing coolant pump 13301
2 5 Removing and installing thermostat 13303
2 6 Removing and installing coolant valve for cylinder head -N489- 13304
2 7 Checking thermostat 13305
2 8 Removing and installing coolant temperature sender -G62- 13305
2 9 Removing and installing electric coolant pump 13307
2 9 1 Removing and installing auxiliary pump for heating -V488- 13307
2 9 2 Removing and installing charge air cooling pump -V188- 13309
3 Coolant pipes 13312
3 1 Assembly overview – coolant pipes 13312
4 Radiator, radiator fan 13313
4 1 Assembly overview – radiator/radiator fan 13313
4 2 Assembly overview – radiator cowl and radiator fan 13315
4 3 Removing and installing radiator 13316
4 4 Removing and installing radiator cowl 13322
4 5 Removing and installing radiator fan 13323
21 – Turbocharging/supercharging 13326
1 Turbocharger 13326
1 1 Assembly overview – turbocharger 13326
1 1 1 Assembly overview – turbocharger, engine codes CUTA, CUSA, CUSB 13326
1 1 2 Assembly overview – turbocharger, engine codes CYZA and CYZB 13328
1 2 Removing and installing turbocharger 13331
1 2 1 Removing and installing turbocharger, engine codes CUTA, CUSA, CUSB 13331
1 2 2 Removing and installing turbocharger, engine codes CYZA and CYZB 13335
1 3 Renewing vacuum unit for turbocharger 13339
1 3 1 Renewing turbocharger vacuum unit (engine codes CUSA, CUSB) 13339
1 3 2 Renewing turbocharger vacuum unit (engine codes CYZA, CYZB, CUTA) 13344
2 Charge air system 13350
2 1 Assembly overview – charge air system 13350
2 2 Removing and installing charge air cooler 13352
2 3 Removing and installing bracket for charge air cooler 13353
2 4 Removing and installing charge air temperature sender 13354
2 4 1 Removing and installing charge air temperature sender ahead of charge air cooler -G810- 13354
2 4 2 Removing and installing charge air temperature sender after charge air cooler -G811- 13355
2 5 Removing and installing charge pressure sender -G31- 13355
2 6 Checking charge air system for leaks 13356
2 7 Checking charge air cooler for leaks 13359
23 – Mixture preparation – injection 13365
1 Injection system 13365
1 1 Overview of fitting locations – injection system 13365
1 2 Schematic overview – fuel system 13369
1 3 Filling/bleeding fuel system 13370
1 4 Checking fuel system for leaks 13371
2 Vacuum system 13372
2 1 Connection diagram – vacuum system 13372
2 2 Checking vacuum system 13372
3 Injectors/high-pressure accumulator (rail) 13374
3 1 Assembly overview – injectors 13374
3 2 Assembly overview – fuel rail 13376
3 3 Removing and installing injectors 13377
3 4 Removing and installing high-pressure lines 13382
3 4 1 Removing high-pressure pipe between fuel rail and high-pressure pump 13382
3 4 2 Removing high-pressure line between fuel rail and injectors 13383
3 4 3 Installing high-pressure lines 13383
3 5 Testing jammed-open injectors 13385
3 6 Checking return flow rate of injectors with engine running 13387
3 7 Removing and installing fuel rail 13389
4 Air filter 13393
4 1 Assembly overview – air filter housing 13393
4 2 Removing and installing air filter housing 13395
5 Intake manifold 13397
5 1 Assembly overview – intake manifold 13397
5 2 Removing and installing throttle valve module -J338- 13397
5 3 Removing and installing intake manifold 13399
6 Senders and sensors 13405
6 1 Removing and installing fuel temperature sender -G81- 13405
6 2 Removing and installing air mass meter -G70- 13405
6 3 Removing and installing fuel pressure regulating valve -N276- 13407
6 4 Removing and installing fuel pressure sender -G247- 13408
6 5 Removing and installing pressure differential sender -G505- 13410
6 6 Removing and installing exhaust gas pressure sensor 1 -G450- 13411
7 Engine control unit 13413
7 1 Assembly overview – engine/motor control unit 13413
7 2 Removing and installing engine control unit -J623- 13414
7 3 Removing and installing engine (motor) control unit -J623- with protective housing 13415
8 High-pressure pump 13417
8 1 Assembly overview – high-pressure pump 13417
8 2 Removing and installing high-pressure pump 13419
9 Lambda probe 13425
9 1 Assembly overview – Lambda probe 13425
9 2 Removing and installing Lambda probe 13426
9 2 1 Removing and installing Lambda probe 1 before catalytic converter -GX10- 13426
9 2 2 Removing and installing Lambda probe 1 after catalytic converter -GX7- 13428
26 – Exhaust system 13431
1 Exhaust pipes and silencers 13431
1 1 Assembly overview – silencers 13431
1 2 Separating exhaust pipes from silencers 13432
1 3 Removing and installing silencer 13434
1 4 Removing and installing front exhaust pipe 13435
1 5 Aligning exhaust system free of stress 13437
1 6 Installation position of clamp 13438
1 7 Align end exhaust pipes 13439
1 8 Checking exhaust system for leaks 13439
2 Emission control 13440
2 1 Assembly overview – emission control 13440
2 1 1 Assembly overview – emission control, engine codes CUTA, CUSA, CUSB 13440
2 1 2 Assembly overview – emission control system, engine codes CYZA and CYZB 13442
2 2 Removing and installing emission control module 13443
2 3 Removing and installing particulate filter 13449
2 4 Removing and installing exhaust flap control unit -J883- 13452
3 Exhaust gas temperature regulation 13454
3 1 Assembly overview – exhaust gas temperature regulation 13454
3 2 Removing and installing exhaust gas temperature sender 13456
3 2 1 Removing and installing exhaust gas temperature sender 1 -G235- 13456
3 2 2 Removing and installing exhaust gas temperature sender 3 -G495- 13457
3 2 3 Removing and installing exhaust gas temperature sender, vehicles with engine codes CYZA and CYZB 13459
4 Exhaust gas recirculation 13461
4 1 Assembly overview – exhaust gas recirculation 13461
4 1 1 Assembly overview – exhaust gas recirculation, low pressure 13461
4 1 2 Assembly overview – exhaust gas recirculation, high pressure 13463
4 1 3 Assembly overview – exhaust gas recirculation, vehicles with engine code CYZA and CYZB 13465
4 2 Removing and installing exhaust gas recirculation cooler 13467
4 2 1 Removing and installing exhaust gas recirculation cooler, high pressure 13467
4 2 2 Removing and installing exhaust gas recirculation cooler, low pressure 13470
4 2 3 Removing and installing exhaust gas recirculation cooler, vehicles with engine codes CYZA and CYZB 13471
4 3 Removing and installing exhaust gas recirculation control motor -V338- 13473
4 4 Removing and installing exhaust gas recirculation control motor 2 -V339- 13475
4 5 Checking exhaust gas recirculation cooler for leaks 13477
28 – Glow plug system 13478
1 Glow plug system 13478
1 1 Assembly overview – glow plug system 13478
1 2 Removing and installing glow plug 13479
1 3 Removing and installing automatic glow period control unit -J179- 13483
1 4 Removing and installing knock sensor 1 -G61- 13483
1 5 Removing and installing Hall sender -G40- 13484
1 6 Removing and installing engine speed sender -G28- 13485
D4B8040D563 General body repairs exterior 13487
50 – Body – front 13495
1 Lock carrier 13495
1 1 Assembly overview – lock carrier 13495
1 2 Removing and installing lock carrier 13496
1 3 Moving to and back from service position 13499
1 4 Releasing and engaging pressure hose with plug-in connector 13503
2 Wings 13505
2 1 Assembly overview – wing 13505
2 2 Assembly overview – insulation and foam elements 13506
2 3 Removing and installing wing 13507
2 4 Removing and installing wing bracket 13510
3 Bulkhead 13513
3 1 Assembly overview – bulkhead 13513
3 2 Assembly overview – plenum chamber bulkhead 13514
3 3 Assembly overview – plenum chamber cover 13515
3 4 Removing and installing plenum chamber bulkhead 13516
3 5 Removing and installing plenum chamber cover 13517
55 – Bonnet, rear lid 13521
1 Bonnet 13521
1 1 Assembly overview – bonnet 13521
1 2 Assembly overview – Bowden cable 13522
1 3 Assembly overview – bonnet release lever 13523
1 4 Removing and installing bonnet 13524
1 5 Adjusting bonnet 13527
1 6 Adjusting bonnet lock 13528
1 7 Adjusting striker pin 13528
1 8 Removing and installing rear lid lock 13529
1 8 1 Removing and installing lid lock, LHD vehicle 13529
1 8 2 Removing and installing lid lock, RHD vehicle 13532
1 9 Removing and installing bonnet lock operating lever 13534
1 10 Removing and installing striker pin 13535
1 11 Removing and installing hinges 13536
1 12 Removing and installing insulation 13538
1 13 Removing and installing bonnet stay 13540
1 14 Detaching Bowden cable 13541
2 Rear lid 13543
2 1 Assembly overview – rear lid 13543
2 2 Assembly overview – hinges 13544
2 3 Assembly overview – gas strut 13545
2 4 Removing and installing rear lid 13546
2 5 Removing and installing stop buffer 13549
2 6 Adjusting rear lid 13550
2 7 Adjusting striker pin 13552
2 8 Adjusting adjusting buffer 13554
2 9 Removing and installing rear lid lock 13555
2 10 Removing and installing operating mechanism 13557
2 11 Removing and installing hinges 13559
2 12 Removing and installing striker pin 13561
2 13 Removing and installing rear lid seal 13563
2 14 Removing and installing gas strut 13564
2 15 Releasing gas from gas strut 13566
3 Tank flap unit 13567
3 1 Assembly overview – tank flap unit 13567
3 2 Removing and installing tank flap unit 13567
3 3 Removing and installing actuator 13569
57 – Front doors, door components, central locking 13572
1 Door 13572
1 1 Assembly overview – door 13572
1 2 Removing and installing inner door seal 13574
1 3 Removing and installing outer door seal 13576
1 3 1 Removing and installing door outer seal, 2-door model 13576
1 3 2 Removing and installing door outer seal, 4-door model 13577
1 4 Removing and installing door 13578
1 5 Installing after renewing A-pillar 13580
1 6 Adjusting door 13582
1 7 Adjusting striker pin 13584
1 8 Removing and installing door arrester 13586
2 Door components 13588
2 1 Assembly overview – door components 13588
2 1 1 Assembly overview – door components, 2-door model 13588
2 1 2 Assembly overview – door components, 4-door model 13589
2 2 Assembly overview – door handle and door lock 13591
2 3 Assembly overview – insulation 13592
2 3 1 Assembly overview – insulation, 2-door model 13592
2 3 2 Assembly overview – insulation, 4-door model 13592
2 4 Removing and installing window regulator motor 13593
2 5 Removing and installing window regulator 13595
2 6 Removing and installing inner door cover 13598
2 6 1 Removing and installing inner door cover, 2-door model 13598
2 6 2 Removing and installing inner door cover, 4-door model 13599
2 7 Removing and installing striker pin 13601
2 8 Removing and installing lock cylinder cover cap 13602
2 9 Removing and installing lock cylinder 13603
2 10 Removing and installing cap without lock cylinder 13606
2 11 Removing and installing door handle 13609
2 12 Removing and installing mounting bracket 13611
2 13 Removing and installing door lock 13613
2 14 Removing and installing window channel 13617
2 15 Removing and installing window slot inner seal 13620
2 16 Removing and installing window slot outer seal 13621
2 16 1 Removing and installing outer window slot seal, 2-door model 13621
2 16 2 Removing and installing outer window slot seal, 4-door model 13623
3 Central locking 13625
3 1 Overview of fitting locations – central locking system 13625
3 2 Removing and installing ignition key battery 13627
3 3 Adapting keys with remote control 13629
58 – Rear doors, door components 13630
1 Door 13630
1 1 Assembly overview – door 13630
1 2 Removing and installing inner door seal 13632
1 3 Removing and installing outer door seal 13634
1 4 Removing and installing door 13634
1 5 Installing after renewing B-pillar 13637
1 6 Adjusting door 13639
1 7 Adjusting striker pin 13642
1 8 Removing and installing door arrester 13643
2 Door components 13646
2 1 Assembly overview – door components 13646
2 2 Assembly overview – door handle and door lock 13647
2 3 Assembly overview – insulation 13648
2 4 Removing and installing window regulator motor 13649
2 5 Removing and installing window crank 13651
2 6 Removing and installing window crank mechanism 13652
2 7 Removing and installing window regulator 13654
2 8 Removing and installing inner door cover 13656
2 9 Removing and installing striker pin 13657
2 10 Removing and installing cap 13658
2 11 Removing and installing door handle 13661
2 12 Removing and installing mounting bracket 13663
2 13 Removing and installing door lock 13665
2 14 Removing and installing window channel 13668
2 15 Removing and installing window slot inner seal 13671
2 16 Removing and installing window slot outer seal 13671
60 – Sunroof 13674
1 Sliding sunroof 13674
1 1 Functional check 13674
1 2 Assembly overview – sliding sunroof 13676
1 3 Assembly overview – sunroof roller blind 13678
1 4 Assembly overview – sliding sunroof frame and front trim 13679
1 5 Removing and installing sliding sunroof frame 13680
1 5 1 Minimum curing period 13680
1 5 2 Fitting instructions 13680
1 5 3 Removing soiling caused by adhesive sealant 13681
1 5 4 Touching up paint damage 13681
1 5 5 Materials 13681
1 5 6 Preparing body flange for bonding 13682
1 5 7 Preparing sliding sunroof frame for installation 13683
1 5 8 Removing and installing sliding sunroof frame 13685
1 6 Removing and installing wind deflector 13691
1 7 Removing and installing glass panel 13693
1 8 Removing glass panel when drive is defective 13697
1 9 Adjusting glass panel 13699
1 10 Removing and installing slotted guide 13701
1 11 Removing and installing front trim for sliding sunroof 13706
1 11 1 Minimum curing period 13706
1 11 2 Fitting instructions 13706
1 11 3 Removing soiling caused by adhesive sealant 13706
1 11 4 Materials 13707
1 11 5 Preparing front trim for installation 13707
1 11 6 Preparing sliding sunroof frame for installation of front trim 13709
1 11 7 Removing and installing front trim for sliding sunroof 13710
1 12 Removing and installing sliding sunroof adjustment control unit -J245- 13715
1 13 Removing and installing glass panel seal 13718
1 14 Removing and installing interior seal 13719
1 15 Removing and installing cover 13720
1 16 Removing and installing sunroof switch 13722
1 17 Removing and installing sunroof roller blind 13722
1 18 Removing and installing tension bow 13726
1 19 Adapting sliding sunroof adjustment control unit -J245- 13729
1 20 Manual operation 13730
2 Water drain hoses 13731
2 1 Assembly overview – water drain hoses 13731
2 2 Cleaning water drain hoses 13731
63 – Bumpers 13734
1 Bumper, front 13734
1 1 Assembly overview – bumper cover 13734
1 1 1 Assembly overview – bumper cover, Polo, »standard« equipment version 13734
1 1 2 Assembly overview – bumper cover, Polo BlueMotion 13735
1 1 3 Assembly overview – bumper cover, CrossPolo 13736
1 1 4 Assembly overview – bumper cover, Polo »GTI« 13737
1 1 5 Assembly overview – bumper cover, Polo »R-Line« 13738
1 2 Assembly overview – bumper carrier 13739
1 3 Assembly overview – add-on parts 13740
1 3 1 Assembly overview – add-on parts, Polo, »standard« equipment version 13740
1 3 2 Assembly overview – add-on parts, Polo »BlueMotion« 13741
1 3 3 Assembly overview – attachments, »Cross Polo« 13743
1 3 4 Assembly overview – add-on parts, Polo »GTI« 13745
1 3 5 Assembly overview – add-on parts, Polo »R-Line« 13747
1 4 Removing and installing bumper cover 13749
1 4 1 Removing and installing bumper cover, Polo, »standard« equipment version 13749
1 4 2 Removing and installing bumper cover, Polo BlueMotion 13753
1 4 3 Removing and installing bumper cover, CrossPolo 13757
1 4 4 Removing and installing bumper cover, Polo »GTI« 13761
1 4 5 Removing and installing bumper cover, Polo »R-Line« 13765
1 5 Installing number plate carrier 13768
1 6 Repairing bumper cover 13769
1 7 Installing brackets for parking aid system 13770
2 Bumper, rear 13775
2 1 Assembly overview – bumper cover 13775
2 1 1 Assembly overview – bumper cover, Polo, »standard« equipment version 13775
2 1 2 Assembly overview – bumper cover, Polo BlueMotion 13776
2 1 3 Assembly overview – bumper cover, CrossPolo 13777
2 1 4 Assembly overview – bumper cover, Polo GTI, Polo BlueGT 13778
2 1 5 Assembly overview – bumper cover, Polo »R-Line« 13779
2 2 Assembly overview – bumper carrier 13780
2 3 Assembly overview – add-on parts 13781
2 3 1 Assembly overview – add-on parts, Polo BlueMotion 13781
2 3 2 Assembly overview – attachments, Cross Polo 13782
2 3 3 Assembly overview – add-on parts, Polo GTI, Polo BlueGT 13783
2 3 4 Assembly overview – add-on parts, Polo »R-Line« 13784
2 4 Removing and installing bumper cover 13785
2 4 1 Removing and installing bumper cover, Polo, »standard« equipment version 13785
2 4 2 Removing and installing bumper cover, Polo »BlueMotion« 13788
2 4 3 Removing and installing bumper cover, CrossPolo 13791
2 4 4 Removing and installing bumper cover, Polo GTI, Polo BlueGT 13793
2 4 5 Removing and installing bumper cover, Polo »R-Line« 13796
2 5 Installing number plate carrier 13798
2 6 Repairing bumper cover 13799
2 7 Installing brackets for parking aid system 13800
64 – Glazing 13805
1 Repair instructions 13805
1 1 Minimum drying times for bonded windows 13805
1 2 Installation instructions for bonded windows 13805
1 3 Preparing old undamaged windows for installing 13807
1 4 Preparing new windows for installing 13807
1 5 Preparing body flange for installing 13808
1 6 Cleaning off excess adhesive 13809
2 Windscreen 13810
2 1 Assembly overview – windscreen 13810
2 2 Removing and installing windscreen 13811
3 Rear windscreen 13816
3 1 Assembly overview – rear window 13816
3 2 Removing and installing rear window 13816
3 3 Removing broken rear window 13821
4 Side windows 13822
4 1 Assembly overview – rear side windows 13822
4 1 1 Assembly overview – rear side window, 2-door model 13822
4 1 2 Assembly overview – rear side window, 4-door model 13822
4 2 Removing and installing rear side window 13823
4 2 1 Removing and installing rear side window, 2-door model 13823
4 2 2 Removing and installing rear side window, 4-door model 13827
4 3 Removing broken rear side window 13832
5 Door windows 13833
5 1 Assembly overview – front door window 13833
5 2 Assembly overview – rear door window 13833
5 3 Removing and installing front door window 13834
5 4 Removing and installing rear door window 13839
66 – Exterior equipment 13844
1 Radiator grille and front trim 13844
1 1 Assembly overview – radiator grille 13844
1 1 1 Assembly overview – radiator grille »GTI« 13844
1 1 2 Assembly overview – radiator grille 13845
1 2 Removing and installing radiator grille 13845
2 Spoiler 13849
2 1 Assembly overview – spoiler 13849
2 1 1 Assembly overview – spoiler, Polo »BlueMotion« 13849
2 1 2 Assembly overview – spoiler, Polo »GTI« 13849
2 1 3 Assembly overview – spoiler, Polo »Blue GT« 13850
2 1 4 Assembly overview – spoiler, Polo »R-Line« 13851
2 2 Removing and installing spoiler 13852
2 2 1 Removing and installing spoiler, Polo »BlueMotion« 13852
2 2 2 Removing and installing spoiler, Polo »GTI« 13856
2 2 3 Removing and installing spoiler, Polo »Blue GT«, Polo »R-Line« 13860
2 3 Removing adapter 13865
2 3 1 Removing adapter, Polo BlueMotion 13865
2 3 2 Removing adapter, Polo »GTI« 13867
2 4 Removing and installing side piece of spoiler 13869
2 4 1 Removing and installing side piece of spoiler, Polo »BlueMotion« 13869
2 4 2 Removing and installing side piece of spoiler, Polo »Blue GT« 13873
3 Mouldings, trims, extensions 13879
3 1 Assembly overview – side member trim 13879
3 1 1 Assembly overview – side member trim, Polo »BlueMotion«, Polo »Blue GT« 13879
3 1 2 Assembly overview – side member trim, Cross Polo 13880
3 1 3 Assembly overview – side member trim, Polo »GTI« 13881
3 2 Assembly overview – water deflector 13882
3 3 Assembly overview – B-pillar trim 13883
3 4 Removing and installing front door cover 13884
3 5 Removing and installing adapter for front door cover 13886
3 6 Removing and installing rear door cover 13888
3 7 Removing and installing adapter for rear door cover 13891
3 8 Removing and installing step moulding 13893
3 8 1 Removing and installing step moulding, Polo, 2-door model 13893
3 8 2 Removing and installing step moulding, Polo, 4-door model 13894
3 9 Removing and installing side member trim 13897
3 9 1 Removing and installing side member trim, Polo »BlueMotion«, Polo »Blue GT« 13897
3 9 2 Removing and installing side member trim, Cross Polo 13901
3 9 3 Removing and installing side member trim, Polo »GTI« 13904
3 10 Removing and installing retaining strip for side member trim 13906
3 10 1 Removing and installing retaining strip for side member trim, Polo »BlueMotion«, Polo »Blue GT« 13906
3 10 2 Removing and installing retaining strip for side member trim, CrossPolo, Polo »GTI« 13908
3 11 Removing and installing water deflector 13914
3 12 Removing and installing A-pillar trim 13917
3 13 Removing and installing B-pillar trim 13918
3 14 Removing and installing C-pillar trim on door 13920
3 15 Wing trim panel 13922
3 16 Removing and installing front wheel arch trim 13924
3 17 Removing and installing rear wheel arch trim 13928
3 18 Removing and installing wheel arch trim of rear door 13932
4 Noise insulation 13936
4 1 Assembly overview – noise insulation 13936
4 1 1 Assembly overview – noise insulation, diesel engines 13936
4 1 2 Assembly overview – noise insulation, long version 13937
4 1 3 Assembly overview – noise insulation, short version 13937
5 Underbody cladding 13939
5 1 Assembly overview – underbody cladding 13939
5 2 Assembly overview – tunnel cross-piece 13939
6 Roof moulding and roof railing 13941
6 1 Assembly overview – roof railing 13941
6 2 Removing and installing roof railing 13941
7 Exterior mirror 13944
7 1 Assembly overview – exterior mirror 13944
7 2 Removing and installing exterior mirror 13945
7 2 1 Removing and installing exterior mirror, manually operated 13945
7 2 2 Removing and installing exterior mirror, electrically operated 13949
7 3 Removing and installing mirror glass 13953
7 4 Removing and installing mirror adjustment unit 13955
7 5 Removing and installing mirror cover 13956
7 6 Removing and installing mirror frame 13957
7 7 Removing and installing assembly bracket 13959
8 Wheel housing liner 13961
8 1 Assembly overview – front wheel housing liner 13961
8 2 Assembly overview – rear wheel housing liner 13962
8 3 Removing and installing front wheel housing liner 13962
8 4 Removing and installing rear wheel housing liner 13964
9 Lettering and badges 13968
9 1 Dimensions – lettering and emblems on rear lid 13968
9 1 1 Dimensions – lettering and emblems on rear lid 13968
9 1 2 Dimensions – rear lettering, Polo “GTI” 13969
9 1 3 Dimensions – lettering and emblems on rear lid, Polo BlueMotion 13969
9 1 4 Dimensions – lettering and emblems on rear lid, Polo BlueGT 13970
9 2 Dimensions – lettering, rear door 13971
9 3 Dimensions – lettering and emblems, sides 13972
9 3 1 Side emblem on wing – “GTI” 13972
9 3 2 Side emblem on wing – special models 13973
9 4 Removing and installing badges at front 13974
9 4 1 Removing and installing emblems at vehicle front, not Polo BlueMotion, not Polo BlueGT 13974
9 4 2 Removing and installing emblems at vehicle front, Polo BlueMotion 13978
9 4 3 Removing and installing front emblems, Polo BlueGT 13982
9 4 4 Removing and installing emblems at vehicle front, Polo “R-Line” 13983
9 5 Removing and installing lettering and emblems 13984
10 Special add-on parts 13986
10 1 Repair instructions 13986
10 1 1 Safety requirements 13986
10 1 2 Preparing add-on part for installation 13986
10 1 3 Preparing body component 13987
10 1 4 Installation instructions for bonded add-on parts 13988
10 1 5 Minimum curing period for bonded add-on parts 13988
10 1 6 Cleaning off excess adhesive 13989
10 1 7 Cleaning guidelines 13989
10 2 Assembly overview – special add-on parts 13989
10 2 1 Assembly overview – special add-on parts, Polo BlueMotion 13989
10 2 2 Assembly overview – special add-on parts, Cross Polo 13990
10 2 3 Assembly overview – special add-on parts, Polo »GTI« 13991
10 2 4 Assembly overview – special add-on parts, Polo »R-Line« 13992
11 Towing bracket 13994
11 1 Assembly overview – towing bracket 13994
12 Heat shields 13995
12 1 Overview of fitting locations – heat shields 13995
12 2 Removing and installing underbody heat shield 13995
12 3 Removing and installing heat shield for centre exhaust system 13996
12 4 Removing and installing heat shield for rear silencer 13997
D4B8040F7AA 5 speed manual gearbox 0A4 14000
00 – Technical data 14004
1 Safety information 14004
1 1 Safety measures when working on vehicles with a start/stop system 14004
2 Identification 14005
2 1 Gearbox identification 14005
3 Technical data 14007
3 1 Allocation gearbox – engine 14007
3 2 Capacities 14008
3 3 Calculation of gear ratios 14008
4 Overview – power transmission 14009
5 Electrical components 14011
5 1 Overview of fitting locations – electrical components 14011
5 1 1 Overview of fitting locations – electrical components, manual gearbox 14011
5 1 2 Overview of fitting locations – electrical components, clutch mechanism 14012
6 Repair instructions 14013
6 1 General repair instructions 14013
30 – Clutch 14017
1 Clutch mechanism 14017
1 1 Overview of fitting locations – clutch mechanism 14017
1 2 Assembly overview – pedal cluster 14018
1 3 Assembly overview – clutch hydraulics 14020
1 3 1 Assembly overview – clutch hydraulics, left-hand drive 14020
1 3 2 Assembly overview – clutch hydraulics, right-hand drive 14022
1 4 Assembly overview – clutch release mechanism 14024
1 5 Removing and installing bearing bush 14026
1 6 Checking clutch master cylinder and clutch slave cylinder 14027
1 7 Removing and installing clutch position sender -G476- 14028
1 8 Removing and installing over-centre spring 14030
1 9 Removing and installing extension spring 14032
1 10 Removing and installing clutch pedal 14032
1 10 1 Removing and installing clutch pedal, LHD 14032
1 10 2 Removing and installing clutch pedal, RHD 14034
1 11 Removing and installing mounting bracket 14035
1 12 Removing and installing clutch master cylinder 14041
1 13 Removing and installing clutch slave cylinder 14042
1 14 Removing and installing lines for clutch mechanism 14045
1 15 Bleeding clutch mechanism 14048
1 16 Repairing clutch release mechanism 14050
2 Clutch 14052
2 1 Assembly overview – clutch 14052
2 1 1 Assembly overview – clutch in conjunction with Sachs dual-mass flywheel 14052
2 1 2 Assembly overview – clutch in conjunction with LuK dual-mass flywheel 14053
2 1 3 Assembly overview – clutch with simple flywheel 14054
2 2 Removing and installing clutch 14055
2 2 1 Removing and installing clutch in conjunction with Sachs dual-mass flywheel 14055
2 2 2 Removing and installing clutch in conjunction with LuK dual-mass flywheel 14060
2 2 3 Removing and installing clutch in connection with simple flywheel 14064
34 – Controls, housing 14070
1 Selector mechanism 14070
1 1 Installation position – selector mechanism 14070
1 2 Assembly overview – gear knob and cover 14071
1 3 Assembly overview – selector mechanism 14072
1 4 Removing and installing gear knob 14074
1 5 Removing and installing selector mechanism 14076
1 6 Repairing selector mechanism 14079
1 7 Adjusting selector mechanism 14083
1 8 Checking selector mechanism 14087
2 Removing and installing gearbox 14088
2 1 Removing gearbox 14088
2 2 Installing gearbox 14098
2 3 Specified torques for gearbox 14106
3 Assembly mountings 14107
3 1 Assembly overview – assembly mountings 14107
4 Gearbox transport 14110
5 Gear oil 14112
5 1 Checking gear oil level 14112
5 2 Draining and filling gear oil 14112
6 Securing to engine and gearbox support 14115
7 Dismantling and assembling gearbox 14117
7 1 Schematic overview – gearbox 14117
7 2 Assembly overview – gearbox 14118
7 3 Assembly overview – cover for gearbox housing and 5th gear 14119
7 4 Assembly overview – gearbox housing and selector mechanism 14121
7 5 Assembly overview – selector unit 14123
7 6 Assembly overview – shafts, differential, selector mechanism 14124
7 7 Assembly overview – selector forks 14125
7 8 Removing and installing selector unit with gearbox installed 14126
7 9 Repairing selector unit 14129
7 10 Renewing selector shaft seal 14130
7 11 Repairing selector forks 14131
7 12 Removing cover for gearbox housing and 5th gear 14136
7 13 Dismantling and assembling gearbox 14143
7 14 Installing cover for gearbox housing and 5th gear 14157
8 Gearbox housing, clutch housing 14162
8 1 Assembly overview – gearbox housing and clutch housing 14162
8 2 Repairing gearbox housing 14165
8 2 1 Identifying output shaft bearing in gearbox housing 14165
8 2 2 Removing and installing roller bearing without retaining ring 14166
8 2 3 Removing and installing roller bearing with retaining ring 14168
8 3 Repairing clutch housing 14171
35 – Gears, shafts 14173
1 Input shaft 14173
1 1 Assembly overview – input shaft 14173
1 2 Dismantling and assembling input shaft 14175
1 3 Adjusting input shaft 14183
1 4 Renewing input shaft seal 14188
2 Output shaft 14191
2 1 Assembly overview – output shaft 14191
2 2 Dismantling and assembling output shaft 14194
2 3 Adjusting output shaft 14208
3 Reverse shaft 14213
3 1 Assembly overview – reverse shaft 14213
3 2 Dismantling and assembling reverse shaft 14213
39 – Final drive – differential 14217
1 Oil seals 14217
1 1 Overview of fitting locations – oil seals 14217
1 2 Renewing left seal 14217
1 2 1 Renewing oil seal for left flange shaft 14217
1 3 Renewing right seal 14221
1 3 1 Renewing oil seal for right flange shaft 14221
2 Differential 14226
2 1 Assembly overview – differential 14226
2 2 Dismantling and assembling differential 14228
2 3 Adjusting differential 14234
3 Adjustment overview 14238
D4B8041A9DE 6 speed manual gearbox 0A8 14239
00 – Technical data 14243
1 Safety information 14243
1 1 Safety precautions when working on vehicles with a start/stop system 14243
2 Identification 14244
2 1 Gearbox identification 14244
3 Technical data 14245
3 1 Allocation gearbox – engine 14245
3 2 Capacities 14245
3 2 1 Capacity, manual gearbox 14245
3 3 Calculation of gear ratios 14245
4 Overview – power transmission 14246
5 Electrical components 14248
5 1 Overview of fitting locations – electrical components 14248
5 1 1 Overview of fitting locations – electrical components, manual gearbox 14248
5 1 2 Overview of fitting locations – electrical components, clutch mechanism 14248
6 Repair notes 14249
6 1 General repair instructions 14249
30 – Clutch 14252
1 Clutch operation 14252
1 1 Overview of fitting locations – clutch mechanism 14252
1 2 Assembly overview – pedal cluster 14254
1 3 Assembly overview – clutch hydraulics 14256
1 3 1 Assembly overview – clutch hydraulics, left-hand drive 14256
1 3 2 Assembly overview – clutch hydraulics, right-hand drive 14258
1 4 Assembly overview – clutch release mechanism 14260
1 5 Removing and installing bearing bush 14261
1 6 Checking clutch master cylinder and clutch slave cylinder 14262
1 7 Removing and installing clutch position sender -G476- 14262
1 8 Removing and installing over-centre spring 14264
1 9 Removing and installing extension spring 14265
1 10 Removing and installing clutch pedal 14265
1 10 1 Removing and installing clutch pedal, LHD 14265
1 10 2 Removing and installing clutch pedal, RHD 14266
1 11 Removing and installing mounting bracket 14267
1 12 Removing and installing clutch master cylinder 14271
1 13 Removing and installing bleeder 14272
1 14 Removing and installing lines for clutch mechanism 14273
1 15 Removing and installing clutch slave cylinder together with release bearing 14276
1 16 Bleeding clutch mechanism 14277
1 17 Repairing clutch release mechanism 14278
2 Clutch 14280
2 1 Assembly overview – clutch 14280
2 1 1 Assembly overview – clutch in conjunction with Sachs dual-mass flywheel 14280
2 1 2 Assembly overview – clutch in conjunction with LuK dual-mass flywheel 14281
2 1 3 Assembly overview – clutch with simple flywheel 14282
2 2 Removing and installing clutch 14283
2 2 1 Removing and installing clutch in conjunction with Sachs dual-mass flywheel 14283
2 2 2 Removing and installing clutch in conjunction with LuK dual-mass flywheel 14287
2 2 3 Removing and installing clutch in connection with simple flywheel 14292
34 – Controls, housing 14296
1 Selector mechanism 14296
1 1 Installation position – selector mechanism 14296
1 2 Assembly overview – gear knob and cover 14298
1 3 Assembly overview – selector mechanism 14299
1 4 Removing and installing gear knob 14301
1 5 Removing and installing selector mechanism 14302
1 6 Repairing selector mechanism 14305
1 7 Adjusting selector mechanism 14307
1 8 Checking selector mechanism 14309
2 Removing and installing gearbox 14310
2 1 Removing gearbox 14310
2 1 1 Removing gearbox, vehicles with 1 4 l engine 14310
2 1 2 Removing gearbox, vehicles with 1 8 l engine 14319
2 2 Installing gearbox 14331
2 3 Specified torques for gearbox 14338
3 Assembly mountings 14339
3 1 Assembly overview – assembly mountings 14339
4 Transporting gearbox 14340
5 Gear oil 14341
5 1 Distinguishing between different manual gearbox types when filling oil 14341
5 2 Checking gear oil level 14341
5 2 1 Checking gear oil level, gearboxes “with” oil filler plug 14341
5 2 2 Checking gear oil level, gearboxes “without” oil filler plug 14342
5 2 3 Draining an adding gear oil, manual gearbox “without” oil filler plug 14342
6 Installing to engine and gearbox support 14345
7 Dismantling and assembling gearbox 14346
7 1 Schematic overview – gearbox 14346
7 2 Assembly overview – gearbox 14347
7 3 Assembly overview – gearbox housing and selector mechanism 14348
7 4 Assembly overview – selector unit 14350
7 5 Assembly overview – shafts, differential, selector mechanism 14351
7 6 Assembly overview – selector forks 14353
7 7 Renewing oil seal for selector shaft 14353
7 8 Removing and installing selector unit with gearbox installed 14355
7 9 Dismantling and assembling gearbox 14358
8 Gearbox housing, clutch housing 14373
8 1 Assembly overview – gearbox housing 14373
8 2 Assembly overview – clutch housing 14375
8 3 Repairing gearbox housing 14376
8 4 Repairing clutch housing 14384
35 – Gears, shafts 14386
1 Input shaft 14386
1 1 Assembly overview – input shaft 14386
1 2 Dismantling and assembling input shaft 14387
1 3 Renewing input shaft seal 14391
2 Output shaft 14393
2 1 Assembly overview – output shaft 14393
2 1 1 Assembly overview – output shaft for 1st to 4th gears 14393
2 1 2 Assembly overview – output shaft for 5th, 6th and reverse gears 14396
2 2 Dismantling and assembling output shaft 14398
2 2 1 Dismantling and assembling output shaft for 1st through 4th gears 14398
2 2 2 Dismantling and assembling output shaft for 5th, 6th and reverse gears 14410
2 3 Adjusting output shaft 14419
2 3 1 Adjusting output shaft for 1st through 4th gears 14419
2 3 2 Adjusting output shaft for 5th, 6th and reverse gears 14424
39 – Final drive – differential 14430
1 Seals 14430
1 1 Overview of fitting locations – seals 14430
1 2 Renewing left oil seal 14431
1 2 1 Renewing oil seal for left flange shaft 14431
1 3 Renewing right oil seal 14433
1 3 1 Renewing oil seal for right flange shaft 14433
2 Differential 14437
2 1 Assembly overview – differential 14437
2 2 Dismantling and assembling differential 14439
2 3 Adjusting differential 14443
3 Adjustment overview 14448
D4B8042C9AB 4 cylinder injection engine (1 6 l engine 4 V EA 211) 14449
00 – Technical data 14455
1 Safety information 14455
1 1 Safety regulations for working on fuel supply 14455
1 2 Safety measures when working on vehicles with a start/stop system 14455
1 3 Safety precautions for when using test instruments and measuring equipment during a road test 14456
1 4 Safety precautions when working on ignition system 14456
1 5 Safety precautions when working on exhaust system 14456
1 6 Safety precautions when working on the cooling system 14457
2 Identification 14458
2 1 Engine number/engine data 14458
3 Repair instructions 14460
3 1 Rules for cleanliness 14460
3 2 General information 14460
3 3 General repair notes 14460
3 4 Foreign bodies in engine 14461
3 5 Contact corrosion 14461
3 6 Routing and attachment of lines 14461
3 7 Fitting radiator and condensers 14461
3 8 Checking vacuum system 14461
10 – Removing and installing engine 14463
1 Removing and installing engine 14463
1 1 Removing engine 14463
1 1 1 Removing engine, Golf 2013>, Golf SV 2015>, Golf Estate 2014>, Golf 2017>, Polo 2018>, Polo 2022>, Golf 2020>, Taigun 2022>, Virtus 2022> 14463
1 1 2 Removing engine, Polo 2014>, Polo Saloon RUS 2016> 14477
1 1 3 Removing engine, Polo Saloon RUS 2020 14489
1 2 Separating engine and gearbox 14500
1 2 1 Separating engine and gearbox, vehicles with manual gearbox 14500
1 2 2 Separating engine and gearbox, vehicles with automatic gearbox 14502
1 3 Securing engine on engine and gearbox support 14504
1 4 Installing engine 14506
1 4 1 Installing engine, Golf 2013>, Golf SV 2015>, Golf Estate 2014>, Golf 2017>, Polo 2018>, Polo 2022>, Golf 2020>, Taigun 2022>, Virtus 2022> 14506
1 4 2 Installing engine, Polo 2014>, Polo Saloon RUS 2016> 14510
1 4 3 Installing engine, Polo Saloon RUS 2020> 14512
2 Assembly mountings 14517
2 1 Assembly overview – assembly mountings 14517
2 1 1 Assembly overview – assembly mountings, Golf 2013>, Golf Estate 2014>, Golf SV 2015>, Polo 2018>, Polo 2022>, Golf 2017>, Golf 2020>, Taigun 2022>, Virtus 2022> 14517
2 1 2 Assembly overview – assembly mountings, Polo 2014>, Polo Saloon RUS 2016>, manual gearbox 14519
2 1 3 Assembly overview – assembly mountings, Polo 2014>, Polo Saloon RUS 2016>, automatic gearbox 14522
2 1 4 Assembly overview – assembly mountings, Polo Saloon RUS 2020> 14525
2 2 Supporting engine in installation position 14529
2 2 1 Supporting engine in installation position, Golf 2013>, Golf Estate 2014>, Golf SV 2015>, Golf 2017>, Polo 2018>, Polo 2022>, Golf 2020>, Virtus 2022> 14529
2 2 2 Supporting engine in installation position, Polo 2014>, Polo Saloon RUS 2016> 14535
2 2 3 Supporting engine in installation position, Polo Saloon RUS 2020> 14538
2 3 Removing and installing engine mounting 14540
2 3 1 Removing and installing engine mounting, Golf 2013>, Golf Estate 2014>, Golf SV 2015>, Golf 2017>, Polo 2018>, Polo 2022>, Golf 2020>, Taigun 2022>, Virtus 2022> 14540
2 3 2 Removing and installing engine mounting, Polo 2014>, Polo Saloon RUS 2016> 14542
2 3 3 Removing and installing engine mounting, Polo Saloon RUS 2020> 14544
2 4 Removing and installing gearbox mounting 14545
2 4 1 Removing and installing gearbox mounting, Golf 2013>, Golf Estate 2014>, Golf SV 2015>, Golf 2017>, Polo 2018>, Polo 2022>, Golf 2020>, Taigun 2022>, Virtus 2022> 14545
2 4 2 Removing and installing gearbox mounting, Polo 2014>, Polo Saloon RUS 2016> 14547
2 4 3 Removing and installing gearbox mounting, Polo Saloon RUS 2020> 14549
2 5 Removing and installing pendulum support 14550
2 5 1 Removing and installing pendulum support, Golf 2013>, Golf Estate 2014>, Golf SV 2015>, Golf 2017>, Polo 2018>, Polo 2022>, Golf 2020>, Taigun 2022>, Virtus 2022> 14550
2 5 2 Removing and installing pendulum support, manual gearbox, Polo 2014>, Polo Saloon RUS 2016> 14551
2 5 3 Removing and installing pendulum support, automatic gearbox, Polo 2014>, Polo Saloon RUS 2016> 14552
2 5 4 Removing and installing pendulum support, Polo Saloon RUS 2020> 14553
2 6 Checking adjustment of assembly mountings 14554
2 6 1 Checking adjustment of assembly mountings, Golf 2013>, Golf Estate 2014>, Golf SV 2015>, Golf 2017>, Polo 2018>, Polo 2022>, Golf 2020>, Virtus 2022> 14554
2 6 2 Checking adjustment of assembly mountings, Polo 2014>, Polo Saloon RUS 2016>, Polo Saloon RUS 2020> 14555
2 7 Adjusting assembly mountings 14556
2 7 1 Adjusting assembly mountings, Golf 2013>, Golf Estate 2014>, Golf SV 2015>, Golf 2017>, Polo 2018>, Polo 2022>, Golf 2020>, Taigun 2022>, Virtus 2022> 14556
2 7 2 Adjusting assembly mountings, Polo Saloon RUS 2020> 14559
13 – Crankshaft group 14562
1 Cylinder block (pulley end) 14562
1 1 Assembly overview – poly V-belt drive 14562
1 1 1 Assembly overview – poly V-belt drive, vehicles without air conditioner compressor, Golf 2013>, Golf Estate 2014>, Golf SV 2015>, Golf 2017>, Polo Saloon RUS 2020>, Golf 2020> 14562
1 1 2 Assembly overview – poly V-belt drive, vehicles without air conditioner compressor, Polo 2014, Polo Saloon RUS 2016>, Polo 2018>, Polo 2022> 14564
1 1 3 Assembly overview – poly V-belt drive, vehicles with air conditioner compressor, Golf 2013>, Golf Estate 2014>, Golf SV 2015>, Golf 2017>, Golf 2020>, Taigun 2022> 14566
1 1 4 Assembly overview – poly V-belt drive, vehicles with air conditioner compressor, Polo 2014>, Polo Saloon RUS 2016>, Polo 2018>, Polo 2022>, Polo Saloon RUS 2020>, Virtus 2022> 14568
1 2 Removing and installing poly-V belt 14569
1 2 1 Removing and installing poly-V belt, vehicles without air conditioner compressor, Golf 2013>, Golf Estate 2014>, Golf SV 2015>, Golf 2017>, Polo Saloon RUS 2020>, Golf 2020> 14569
1 2 2 Removing and installing poly V-belt, vehicles without air conditioner compressor, Polo 2014> Polo Saloon RUS 2016>, Polo 2018>, Polo 2022>, Polo Saloon RUS 2020> 14572
1 2 3 Removing and installing poly-V belt, vehicles with air conditioner compressor, Golf 2013>, Golf Estate 2014>, Golf SV 2015>, Golf 2017>, Golf 2020>, Taigun 2022> 14573
1 2 4 Removing and installing poly V-belt, vehicles with air conditioner compressor, Polo 2014> Polo Saloon RUS 2016>, Polo 2018>, Polo 2022>, Polo Saloon RUS 2020>, Virtus 2022> 14575
1 3 Removing and installing tensioner for poly V-belt 14576
1 3 1 Removing and installing tensioner for poly V-belt, vehicles without air conditioner compressor 14576
1 3 2 Removing and installing tensioner for poly V-belt, vehicles with air conditioner compressor 14577
1 4 Removing and installing vibration damper 14578
1 5 Removing and installing engine support 14580
1 5 1 Removing and installing engine support, Golf 2013>, Golf 2017>, Golf SV 2015>, Golf Estate 2014>, Polo 2014>, Polo 2018>, Polo 2022>, Polo Saloon RUS 2016>, Golf 2020>, Taigun 2022>, Virtus 2022> 14580
1 5 2 Removing and installing engine support, Polo Saloon RUS 2020> 14583
1 6 Renewing crankshaft oil seal – pulley end 14587
2 Cylinder block, gearbox end 14590
2 1 Assembly overview – cylinder block, gearbox end 14590
2 1 1 Assembly overview – cylinder block, gearbox end, vehicles with manual gearbox 14590
2 1 2 Assembly overview – cylinder block, gearbox end, vehicles with automatic gearbox 14592
2 2 Removing and installing flywheel 14594
2 3 Removing and installing drive plate 14596
2 4 Removing and installing sealing flange on gearbox side 14599
3 Crankshaft 14611
3 1 Measuring axial clearance of crankshaft 14611
4 Pistons and conrods 14613
4 1 Assembly overview – pistons and conrods 14613
4 2 Removing and installing pistons 14617
4 3 Checking pistons and cylinder bores 14618
4 4 Separating new conrod 14620
4 5 Checking radial clearance of conrods 14621
4 6 Removing and installing oil spray jets 14622
4 7 Setting piston to TDC position 14623
15 – Cylinder head, valve gear 14626
1 Cylinder head 14626
1 1 Assembly overview – cylinder head 14626
1 2 Assembly overview – camshaft housing 14628
1 3 Removing and installing cylinder head 14630
1 4 Removing and installing camshaft housing 14634
1 5 Checking compression 14637
2 Toothed belt drive 14640
2 1 Assembly overview – toothed belt cover 14640
2 2 Assembly overview – toothed belt 14640
2 3 Removing and installing toothed belt guard 14642
2 3 1 Removing and installing upper toothed belt guard 14642
2 3 2 Removing and installing lower toothed belt guard 14643
2 4 Removing and installing toothed belt 14643
2 5 Preassembling and installing valve timing tool 14649
2 5 1 Preassembling valve timing tool 14649
2 5 2 Installing test tool -VAS 611 007- 14653
2 5 3 Teaching in test tool -VAS 611 007- electronically and performing basic setting 14655
2 6 Checking valve timing 14658
2 7 Adjusting valve timing 14662
2 8 Removing toothed belt from camshaft 14673
3 Valve gear 14678
3 1 Assembly overview – valve gear 14678
3 1 1 Assembly overview – valves 14678
3 2 Removing and installing camshaft adjuster 14680
3 3 Removing and installing toothed belt pulley 14685
3 4 Measuring axial play of camshaft 14690
3 5 Removing and installing camshaft oil seal 14691
3 5 1 Removing and installing camshaft oil seal, inlet camshaft, pulley end 14691
3 5 2 Removing and installing camshaft oil seal, exhaust camshaft, pulley end 14693
3 5 3 Removing and installing camshaft oil seal, exhaust camshaft, gearbox end 14695
3 6 Removing and installing camshaft control valve 1 -N205- 14697
3 7 Removing and installing valve stem oil seals 14698
3 7 1 Removing and installing valve stem seals (cylinder head installed) 14698
3 7 2 Removing and installing valve stem seals (cylinder head removed) 14703
4 Inlet and exhaust valves 14708
4 1 Checking valve guides 14708
4 2 Checking valves 14709
4 3 Valve dimensions 14709
17 – Lubrication 14710
1 Sump, oil pump 14710
1 1 Assembly overview – sump/oil pump 14710
1 2 Removing and installing lower part of sump 14713
1 3 Removing and installing oil pump 14719
1 4 Removing and installing upper part of sump 14721
1 5 Engine oil: 14726
2 Engine oil cooler 14727
2 1 Assembly overview – engine oil cooler 14727
2 2 Removing and installing engine oil cooler 14727
3 Crankcase ventilation 14729
3 1 Assembly overview – crankcase breather system 14729
3 2 Removing and installing oil separator 14730
4 Oil filter, oil pressure switch 14733
4 1 Assembly overview – oil filter/oil pressure switch 14733
4 2 Removing and installing oil pressure switch -F1- 14733
4 3 Checking oil pressure 14735
4 4 Removing and installing oil filter housing 14736
19 – Cooling 14738
1 Cooling system/coolant 14738
1 1 Connection diagram – coolant hoses 14738
1 1 1 Connection diagram – coolant hoses 14738
1 1 2 Connection diagram – coolant hoses 14740
1 2 Draining and adding coolant 14741
1 3 Checking cooling system for leaks 14750
2 Coolant pump, regulation of cooling system 14754
2 1 Assembly overview – coolant pump, thermostat 14754
2 2 Assembly overview – coolant temperature sender 14757
2 3 Removing and installing coolant pump 14758
2 4 Removing and installing toothed belt pulley for coolant pump 14762
2 5 Removing and installing thermostat 14763
2 5 1 Removing and installing thermostat for main coolant circuit (radiator) 14763
2 5 2 Removing and installing thermostat for cylinder block coolant circuit 14766
2 6 Removing and installing coolant temperature sender -G62- 14767
2 7 Removing and installing radiator outlet coolant temperature sender -G83- 14768
3 Coolant pipes 14770
3 1 Assembly overview – coolant pipes 14770
3 2 Removing and installing coolant pipes 14770
4 Radiator, radiator fan 14773
4 1 Assembly overview – radiator/radiator fan 14773
4 1 1 Assembly overview – radiator/radiator fan Golf 2013>, Golf 2017>, Golf SV 2015>, Golf Estate 2014>, Polo 2014>, Polo 2018>, Polo 2022>, Polo Saloon RUS 2016>, Taigun 2022>, Virtus 2022> 14773
4 1 2 Assembly overview – radiator/radiator fan, Polo Saloon RUS 2020> 14775
4 1 3 Assembly overview – radiator/radiator fan, Golf 2020> 14776
4 2 Assembly overview – radiator cowl and radiator fan 14777
4 2 1 Assembly overview – radiator cowl and radiator fan, Golf 2013>, Golf 2017>, Golf SV 2015>, Golf Estate 2014>, Polo 2014>, Polo 2018>, Polo 2022>, Polo Saloon RUS 2016>, Golf 2020>, Taigun 2022>, Virtus 2022> 14777
4 2 2 Assembly overview – radiator cowl and radiator fan, Polo Saloon RUS 2020> 14778
4 3 Removing and installing radiator 14779
4 3 1 Removing and installing radiator, Polo 2014>, Polo Saloon RUS 2016> 14779
4 3 2 Removing and installing radiator, Golf 2013>, Golf Estate 2014>, Golf SV 2015>, Golf 2017>, Polo 2018>, Polo 2022>, Golf 2020>, Taigun 2022>, Virtus 2022> 14782
4 3 3 Removing and installing radiator, Polo Saloon RUS 2020> 14789
4 4 Removing and installing radiator cowl 14792
4 4 1 Removing and installing radiator cowl, Golf 2013>, Golf 2017>, Golf SV 2015>, Golf Estate 2014>, Polo 2014>, Polo 2018>, Polo 2022>, Polo Saloon RUS 2016>, Golf 2020>, Taigun 2022>, Virtus 2022> 14792
4 4 2 Removing and installing radiator cowl, Polo Saloon RUS 2020> 14793
4 5 Removing and installing radiator fan -V7- 14794
4 5 1 Removing and installing radiator fan -V7-, Golf 2013>, Golf 2017>, Golf SV 2015>, Golf Estate 2014>, Polo 2014>, Polo 2018>, Polo 2022>, Polo Saloon RUS 2016>, Golf 2020>, Taigun 2022>, Virtus 2022> 14795
4 5 2 Removing and installing radiator fan -V7-, Polo Saloon RUS 2020> 14795
24 – Mixture preparation – injection 14798
1 Injection system 14798
1 1 Overview of fitting locations – injection system 14798
1 2 Assembly overview – fuel system 14804
2 Injectors 14807
2 1 Assembly overview – fuel rail with injectors 14807
2 2 Removing and installing fuel rail 14807
2 3 Removing and installing injectors 14810
2 4 Checking injectors 14811
2 5 Cleaning injectors 14815
3 Air filter 14817
3 1 Assembly overview – air filter housing 14817
3 2 Removing and installing air filter housing 14819
4 Intake manifold 14822
4 1 Assembly overview – intake manifold 14822
4 1 1 Assembly overview – intake manifold, Golf 2013>, Golf 2017>, Golf SV 2015>, Golf Estate 2014>, Polo 2014>, Polo 2018>, Polo 2022>, Polo Saloon RUS 2016>, Golf 2020> 14822
4 1 2 Assembly overview – intake manifold Polo Saloon RUS 2020>, Taigun 2022>, Virtus 2022> 14824
4 2 Removing and installing intake manifold 14826
4 3 Removing and installing throttle valve module -GX3- 14829
4 4 Cleaning throttle valve module -GX3- 14829
5 Senders and sensors 14831
5 1 Removing and installing intake manifold sender -GX9- 14831
6 Engine/motor control unit 14832
6 1 Removing and installing engine control unit -J623- 14832
6 1 1 Removing and installing engine control unit -J623-, engine control unit with metal locking plate, Golf 2013>, Golf Estate 2014>, Golf SV 2015>, Golf 2017>; 2018>, Polo 2018>, Polo 2022>, Golf 2020>, Virtus 2022> 14832
6 1 2 Removing and installing engine control unit -J623-, engine control unit with protective housing, Golf 2013>, Golf Estate 2014>, Golf SV 2015>, Golf 2017>, Polo 2018>, Polo 2022>, Taigun 2022> 14835
6 1 3 Removing and installing engine control unit -J623-, engine control unit with protective housing, Polo 2014>, Polo Saloon RUS 2016> 14839
6 1 4 Removing and installing engine control unit -J623-, without protective housing, Polo 2014> Polo Saloon RUS 2016> 14841
6 1 5 Removing and installing engine control unit -J623- without protective housing, Polo Saloon RUS 2020> 14842
7 Lambda probe 14844
7 1 Assembly overview – Lambda probe 14844
7 2 Removing and installing lambda probe 14845
7 2 1 Removing and installing lambda probe 1 before catalytic converter -GX10-/lambda probe 1 after catalytic converter -GX7- 14845
26 – Exhaust system 14848
1 Exhaust pipes and silencers 14848
1 1 Assembly overview – silencers 14848
1 1 1 Assembly overview – silencers, Golf 2013>, Golf SV 2015>, Golf 2017>, Golf 2020> 14848
1 1 2 Assembly overview – silencers, Golf Estate 2014> 14851
1 1 3 Assembly overview – silencers, Polo 2014>, Polo Saloon RUS 2016>, Polo 2018>, Polo 2022> 14854
1 1 4 Assembly overview – silencer, Polo Saloon RUS 2020>, Taigun 2022>, Virtus 2022> 14856
1 2 Separating exhaust pipes from silencers 14858
1 2 1 Separating exhaust pipes from silencers, Polo 2014>, Polo Saloon RUS 2016>, Golf 2013>, Golf SV 2015>, Golf 2017, Polo Saloon RUS 2020>, Golf 2020>, Taigun 2022>, Virtus 2022> 14858
1 2 2 Separating exhaust pipes from silencers, Golf Estate 2014, Polo 2018, Polo 2022> 14859
1 3 Removing and installing silencer 14860
1 3 1 Removing and installing front silencer, Golf 2013>, Golf Estate 2014>, Golf SV 2015>, Golf 2017>, Golf 2020> 14860
1 3 2 Removing and installing rear silencer, Golf 2013>, Golf 2017>, Golf SV 2015>, Golf 2020> 14861
1 3 3 Removing and installing rear silencer, Golf Estate 2014 14863
1 3 4 Removing and installing silencers, Polo 2014>, Polo Saloon 2016>, Polo 2018>, Polo 2022> 14864
1 3 5 Removing and installing silencer, Polo Saloon RUS 2020>, Taigun 2022>, Virtus 2022> 14866
1 4 Aligning exhaust system free of stress 14867
1 4 1 Aligning exhaust system free of stress 14867
1 4 2 Align end exhaust pipes 14867
1 5 Checking exhaust system for leaks 14868
2 Emission control 14869
2 1 Assembly overview – emission control 14869
2 1 1 Assembly overview – emission control, Golf 2013>, Golf 2017>, Golf SV 2015>, Golf Estate 2014, Golf 2020>, Taigun 2022>, Virtus 2022> 14869
2 1 2 Assembly overview – emission control, Polo 2014>, Polo Saloon RUS 2016>, Polo 2018>, Polo 2022>, Polo Saloon RUS 2020> 14871
2 2 Removing and installing catalytic converter 14873
28 – Ignition system 14877
1 Ignition system 14877
1 1 Assembly overview – ignition system 14877
1 2 Removing and installing ignition coils with output stage 14879
1 3 Removing and installing knock sensor 1 -G61- 14881
1 4 Removing and installing Hall sender 14883
1 5 Removing and installing engine speed sender -G28- 14883
D4B8042CA11 6 speed automatic gearbox 09G 14886
00 – Technical data 14890
1 Safety information 14890
1 1 General safety provisions 14890
1 2 Safety precautions when using testers and measuring instruments during a road test 14891
1 3 Safety precautions when tow-starting or towing 14891
2 Identification 14892
2 1 Gearbox identification 14892
2 2 Identification of torque converter 14892
3 Repair instructions 14893
3 1 General information 14893
3 2 Rules for cleanliness 14893
3 3 General repair instructions 14894
3 4 Gaskets and seals 14895
3 5 Nuts and bolts 14895
4 Technical data 14896
4 1 Allocation gearbox – engine 14896
4 1 1 Golf 2013 ►, Golf Variant 2014 ►, Golf SV 2015 ► 14896
4 1 2 Polo 2014 ► 14896
4 1 3 Golf 2017 ►, Golf Estate 2017 ► 14896
4 2 Capacities 14896
32 – Torque converter 14897
1 Torque converter 14897
1 1 Assembly overview – torque converter 14897
1 2 Draining torque converter 14898
1 3 Removing and installing torque converter oil seal 14898
1 4 Removing and installing torque converter 14900
1 5 Checking torque converter 14901
37 – Controls, housing 14902
1 ATF circuit 14902
1 1 Assembly overview – ATF circuit 14902
1 2 Removing and installing ATF cooler 14903
1 2 1 Removing and installing ATF cooler, Golf 2013 ►, Golf Estate 2014 ►, Golf SV 2015 ►, Golf 2017 ►, Golf Estate 2017 ► 14903
1 2 2 Removing and installing ATF cooler, Polo 2014 ► 14904
2 ATF 14907
2 1 Checking ATF level 14907
2 2 Draining and filling ATF 14910
3 Removing and installing gearbox 14914
3 1 Removing gearbox 14914
3 1 1 Removing engine, Golf 2013 ►, Golf Estate 2014 ►, Golf SV 2015 ►, Golf 2017 ►, Golf Estate 2017 ► 14914
3 1 2 Removing gearbox, Polo 2014 ► 14924
3 2 Installing gearbox 14925
3 3 Specified torques for gearbox 14928
4 Transporting gearbox 14929
5 Securing to engine and gearbox support 14930
6 Selector mechanism 14932
6 1 Assembly overview – selector mechanism 14932
6 2 Emergency release from position P 14934
6 2 1 Manual release mechanism from position P, Golf 2013 ►, Golf Estate 2014 ►, Golf 2017 ►, Golf Estate 2017 ► 14934
6 2 2 Emergency release from position P, Polo 2014 ►, Golf SV 2015 ► 14935
6 3 Removing and installing selector lever handle 14936
6 3 1 Removing and installing selector lever handle, Golf 2013 ►, Golf Estate 2014 ►, Golf 2017 ►, Golf Estate 2017 ► 14936
6 3 2 Removing and installing selector lever handle, Polo 2014 ►, Golf Sportsvan 2015 ► 14938
6 4 Moving push-button in the handle to installation position 14940
6 5 Removing and installing selector mechanism 14943
6 5 1 Removing and installing selector mechanism with selector lever cable 14943
6 5 2 Removing and installing selector mechanism without selector lever cable 14945
6 6 Removing and installing gear selector cable 14948
6 7 Checking selector mechanism 14950
6 8 Checking and adjusting selector lever cable 14951
6 9 Removing and installing multifunction switch 14953
6 10 Adjusting multifunction switch 14956
6 11 Renewing selector shaft seal 14957
38 – Gears, control 14959
1 ATF system 14959
1 1 Removing and installing sump 14959
1 2 Removing and installing ATF strainer 14960
2 Valve body 14962
2 1 Assembly overview – valve body 14962
2 1 1 Removing and installing wiring harness for senders and solenoid valves 14965
2 1 2 Removing and installing gearbox input speed sender -G182- and gearbox output speed sender -G195- 14967
2 2 Removing and installing valve body 14967
39 – Final drive – differential 14970
1 Oil seals 14970
1 1 Renewing left seal 14970
1 2 Renewing right oil seal 14972
2 Gearbox control system 14975
2 1 Removing and installing gearbox control unit 14975
D4B8046FECF 4 cylinder injection engine (1 6 l engine) 14977
00 – Technical data 14983
1 Identification 14983
1 1 Engine number, engine data 14983
2 Safety instructions 14984
2 1 Safety precautions when working on fuel supply system 14984
2 2 Safety precautions when working on vehicles with a Start/Stop system 14984
2 3 Safety precautions during road tests in which test and measuring equipment is used 14984
2 4 Safety precautions when working on ignition system 14985
2 5 Safety precautions when working on cooling system 14985
3 Repair instructions 14986
3 1 Rules for cleanliness 14986
3 2 Foreign objects in engine 14986
3 3 Contact corrosion 14986
3 4 Routing and securing lines 14986
3 5 Installing coolers, condensers and radiators 14987
10 – Removing and installing engine 14988
1 Removing and installing engine 14988
1 1 Removing engine 14988
1 2 Separating engine and gearbox 14996
1 2 1 Separating engine and gearbox, vehicles with manual gearbox 14996
1 2 2 Separating engine and gearbox, vehicles with automatic gearbox 14998
1 3 Securing engine on engine and gearbox support 15001
1 4 Installing engine 15002
2 Assembly mountings 15006
2 1 Assembly overview – assembly mountings 15006
2 1 1 Assembly overview – assembly mountings, manual gearbox 15006
2 1 2 Assembly overview – assembly mountings, automatic gearbox 15008
2 2 Supporting engine in installation position 15011
2 3 Removing and installing engine mountings 15014
2 4 Removing and installing gearbox mounting 15016
2 5 Removing and installing pendulum support 15017
2 5 1 Removing and installing pendulum support, manual gearbox 15017
2 5 2 Removing and installing pendulum support, automatic gearbox 15018
13 – Crankshaft group 15020
1 Cylinder block (pulley end) 15020
1 1 Assembly overview – poly V-belt drive 15020
1 1 1 Assembly overview – poly V-belt drive, vehicles without air conditioner compressor 15020
1 1 2 Assembly overview – poly V-belt drive, vehicles with air conditioner compressor 15022
1 2 Removing and installing poly V-belt 15024
1 2 1 Removing and installing poly V-belt, vehicles without air conditioner compressor 15024
1 2 2 Removing and installing poly V-belt, vehicles with air conditioner compressor 15025
1 3 Removing and installing tensioner for poly V-belt 15026
1 3 1 Removing and installing tensioner for poly V-belt, vehicles with air conditioner compressor 15026
1 4 Removing and installing vibration damper 15026
1 5 Removing and installing engine support 15027
1 6 Renewing crankshaft oil seal – belt pulley end 15030
2 Cylinder block, gearbox end 15034
2 1 Assembly overview – cylinder block, gearbox end 15034
2 1 1 Assembly overview – cylinder block, gearbox end, vehicles with manual gearbox 15034
2 1 2 Assembly overview – cylinder block, gearbox end, vehicles with automatic gearbox 15036
2 2 Removing and installing flywheel 15037
2 3 Removing and installing drive plate 15038
2 4 Removing and installing sealing flange on gearbox side 15040
3 Crankshaft 15050
3 1 Measuring axial clearance of crankshaft 15050
4 Pistons and conrods 15052
4 1 Assembly overview – pistons and conrods 15052
4 2 Removing and installing pistons 15054
4 3 Removing and installing oil spray jets 15055
4 4 Checking pistons and cylinder bores 15056
4 5 Separating new conrod 15057
4 6 Checking radial clearance of conrods 15058
15 – Cylinder head, valve gear 15059
1 Cylinder head 15059
1 1 Assembly overview – cylinder head 15059
1 2 Assembly overview – camshaft housing 15061
1 3 Removing and installing cylinder head 15062
1 4 Removing and installing camshaft housing 15065
1 5 Checking compression 15067
2 Toothed belt drive 15070
2 1 Assembly overview – toothed belt cover 15070
2 2 Assembly overview – toothed belt 15071
2 3 Checking valve timing 15072
2 4 Removing toothed belt from camshaft 15076
2 5 Removing and installing toothed belt 15089
3 Valve gear 15104
3 1 Assembly overview – valve gear 15104
3 1 1 Assembly overview – valves 15104
3 2 Removing and installing camshaft adjuster 15105
3 3 Measuring axial play of camshaft 15105
3 4 Removing and installing camshaft oil seal 15106
3 4 1 Removing and installing camshaft oil seal, inlet camshaft, pulley end 15106
3 4 2 Removing and installing camshaft oil seal, exhaust camshaft, pulley end 15108
3 4 3 Removing and installing camshaft oil seal, exhaust camshaft, gearbox end 15109
3 5 Removing and installing inlet camshaft control valve 1 -N205- 15112
3 6 Removing and installing valve stem seals 15112
3 6 1 Removing and installing valve stem seals (cylinder head installed) 15112
3 6 2 Removing and installing valve stem seals (cylinder head removed) 15116
4 Inlet and exhaust valves 15120
4 1 Checking valve guides 15120
4 2 Checking valves 15120
4 3 Valve dimensions 15121
17 – Lubrication 15122
1 Sump, oil pump 15122
1 1 Assembly overview – sump and oil pump 15122
1 2 Removing and installing lower part of sump 15125
1 3 Removing and installing oil pump 15127
1 4 Removing and installing upper part of sump 15129
1 5 Engine oil 15132
2 Engine oil cooler 15133
2 1 Assembly overview – engine oil cooler 15133
2 2 Removing and installing engine oil cooler 15133
3 Crankcase breather 15135
3 1 Assembly overview – crankcase breather system 15135
3 2 Removing and installing oil separator 15136
4 Oil filter, oil pressure switch 15138
4 1 Assembly overview – oil filter/oil pressure switch 15138
4 2 Removing and installing oil pressure switch -F1- 15138
4 3 Checking oil pressure 15139
4 4 Removing and installing oil filter housing 15141
19 – Cooling 15142
1 Cooling system, coolant 15142
1 1 Coolant hose schematic diagram 15142
1 2 Draining and filling coolant 15144
1 3 Checking cooling system for leaks 15148
2 Coolant pump, regulation of cooling system 15151
2 1 Assembly overview – coolant pump, thermostat 15151
2 2 Assembly overview – coolant temperature sender 15153
2 3 Removing and installing coolant pump 15155
2 4 Removing and installing toothed belt pulley for coolant pump 15158
2 5 Removing and installing thermostat 15159
2 5 1 Removing and installing thermostat for large cooling circuit 15159
2 5 2 Removing and installing thermostat for small cooling circuit 15161
2 6 Removing and installing coolant temperature sender -G62- 15162
2 7 Removing and installing coolant temperature sender at radiator outlet -G83- 15163
3 Coolant pipes 15165
3 1 Assembly overview – coolant pipes 15165
3 2 Removing and installing coolant pipes 15165
4 Radiator and radiator fan 15168
4 1 Assembly overview – radiator and radiator fan 15168
4 2 Assembly overview – radiator cowl and radiator fan 15169
4 3 Removing and installing radiator 15170
4 4 Removing and installing radiator cowling 15173
4 5 Removing and installing radiator fan 15174
24 – Mixture preparation – injection 15175
1 Injection system 15175
1 1 Installation location overview – injection system 15175
1 2 Assembly overview – fuel system 15179
2 Air filter 15181
2 1 Assembly overview – air filter housing 15181
2 2 Removing and installing air filter housing 15181
3 Intake manifold 15183
3 1 Assembly overview – intake manifold 15183
3 2 Removing and installing intake manifold 15184
3 3 Removing and installing throttle valve module -GX3- 15186
3 4 Cleaning throttle valve module -GX3- 15187
4 Injectors 15188
4 1 Assembly overview – fuel rail with injectors 15188
4 2 Removing and installing fuel rail 15188
4 3 Removing and installing injectors 15191
4 4 Checking injectors 15191
4 5 Cleaning injectors 15195
5 Senders and sensors 15197
5 1 Removing and installing intake manifold sender -GX9- 15197
6 Lambda probe 15198
6 1 Assembly overview – Lambda probe 15198
6 2 Removing and installing lambda probe 1 before catalytic converter -GX10-/lambda probe 1 after catalytic converter -GX7- 15198
7 Engine control unit 15201
7 1 Removing and installing engine control unit -J623- 15201
7 2 Removing and installing engine control unit -J623- with protective housing 15202
26 – Exhaust system 15204
1 Exhaust pipes, silencers 15204
1 1 Assembly overview – silencers 15204
1 2 Removing and installing silencer 15205
1 3 Separating exhaust pipes, silencers 15206
1 4 Aligning exhaust system free of stress 15207
1 4 1 Aligning exhaust system free of stress 15207
1 4 2 Align end exhaust pipes 15207
1 5 Checking exhaust system for leaks 15208
2 Emission control 15209
2 1 Assembly overview – emission control 15209
2 2 Removing and installing catalytic converter 15210
28 – Ignition system 15212
1 Ignition system 15212
1 1 Assembly overview – ignition system 15212
1 2 Test data, spark plugs 15213
1 3 Removing and installing ignition coils with output stage 15213
1 4 Removing and installing knock sensor 15215
1 5 Removing and installing Hall sender 15216
1 6 Removing and installing engine speed sender -G28- 15217
D4B8049DB61 4 cyl direct injection engine (1 8 l 4 V EA 888 Gen III turbocharger chain drive) 15219
00 – Technical data 15225
1 Safety information 15225
1 1 Safety regulations for working on fuel supply 15225
1 2 Safety measures when working on vehicles with a start/stop system 15225
1 3 Safety precautions when using testers and measuring instruments during a road test 15226
1 4 Safety precautions when working on ignition system 15226
1 5 Safety precautions when working on the cooling system 15226
1 6 Safety precautions when working on exhaust system 15227
2 Identification 15228
2 1 Engine number/engine data 15228
3 Repair instructions 15230
3 1 Rules for cleanliness 15230
3 2 Foreign objects in engine 15230
3 3 Contact corrosion 15230
3 4 Routing and attachment of lines 15230
3 5 Fitting radiator and condensers 15231
3 6 Checking vacuum system 15231
10 – Removing and installing engine 15232
1 Removing and installing engine 15232
1 1 Removing engine 15232
1 2 Separating engine and gearbox 15249
1 2 1 Separating engine and gearbox, vehicles with manual gearbox 15249
1 2 2 Separating engine and gearbox, vehicles with dual clutch gearbox 15251
1 3 Securing engine on engine and gearbox support 15254
1 4 Installing engine 15257
2 Assembly mountings 15260
2 1 Assembly overview – assembly mountings 15260
2 2 Removing and installing engine mounting 15262
2 3 Removing and installing gearbox mounting 15264
2 4 Removing and installing pendulum support 15267
2 4 1 Removing and installing pendulum support, manual gearbox 15267
2 4 2 Removing and installing pendulum support, dual clutch gearbox 15268
2 5 Supporting engine in installation position 15270
3 Engine cover panel 15275
3 1 Removing and installing engine cover 15275
13 – Crankshaft group 15276
1 Cylinder block (pulley end) 15276
1 1 Assembly overview – cylinder block (pulley end) 15276
1 2 Removing and installing poly-V belt 15279
1 3 Removing and installing tensioner for poly V-belt 15280
1 4 Removing and installing vibration damper 15281
1 5 Removing and installing bracket for ancillaries 15288
1 6 Renewing seal for vibration damper 15291
1 7 Removing and installing engine support 15294
2 Cylinder block, gearbox end 15296
2 1 Assembly overview – cylinder block, gearbox end 15296
2 2 Removing and installing flywheel 15297
2 3 Removing and installing sealing flange on gearbox side 15299
3 Crankshaft 15304
3 1 Assembly overview – crankshaft 15304
3 2 Crankshaft dimensions 15306
3 3 Allocation of main bearing shells 15306
3 4 Renewing needle bearing in crankshaft 15308
3 5 Measuring axial clearance of crankshaft 15310
3 6 Measuring radial clearance of crankshaft 15311
3 7 Removing and installing sender wheel 15312
4 Balancer shaft 15314
4 1 Assembly overview – balance shaft 15314
4 2 Removing and installing balance shaft 15315
4 2 1 Removing and installing inlet side balance shaft 15315
4 2 2 Removing and installing exhaust side balance shaft 15318
4 3 Renewing oil seal for balance shaft (inlet side) 15320
5 Pistons and conrods 15322
5 1 Assembly overview – pistons and conrods 15322
5 2 Removing and installing pistons 15326
5 3 Removing and installing oil spray jets 15328
5 4 Checking pistons and cylinder bores 15329
5 5 Separating new conrod 15332
5 6 Checking radial clearance of conrods 15332
15 – Cylinder head, valve gear 15334
1 Cylinder head 15334
1 1 Assembly overview – cylinder head 15334
1 2 Removing and installing cylinder head 15337
1 3 Removing and installing vacuum pump 15344
1 4 Checking compression 15346
2 Cover for timing chain 15349
2 1 Assembly overview – cover for timing chain 15349
2 2 Removing and installing camshaft control valve 1 -N205- and exhaust camshaft control valve 1 -N318- 15351
2 3 Removing and installing timing chain cover 15351
2 3 1 Removing and installing upper timing chain cover 15351
2 3 2 Removing and installing timing chain cover (bottom) 15353
3 Chain drive 15358
3 1 Assembly overview – camshaft timing chains 15358
3 2 Removing and installing camshaft timing chain 15361
3 3 Assembly overview – drive chain for balance shaft 15377
3 4 Removing and installing drive chain for balance shaft 15380
3 5 Checking timing chain 15380
3 6 Checking valve timing 15381
4 Valve gear 15384
4 1 Assembly overview – valve gear 15384
4 2 Removing and installing camshaft 15389
4 3 Installing ball for sliding piece 15406
4 4 Removing and installing valve stem seals 15407
4 4 1 Removing and installing valve stem seals (cylinder head installed) 15407
4 4 2 Removing and installing valve stem seals (cylinder head removed) 15413
5 Inlet and exhaust valves 15418
5 1 Checking valve guides 15418
5 2 Checking valves 15419
5 3 Valve dimensions 15419
17 – Lubrication 15420
1 Sump, oil pump 15420
1 1 Assembly overview – sump/oil pump 15420
1 2 Removing and installing oil level and oil temperature sender -G266- 15423
1 3 Removing and installing lower part of sump 15424
1 3 1 Removing and installing bottom section of sump, plastic sump 15424
1 3 2 Removing and installing bottom section of sump, sheet-metal sump 15426
1 4 Removing and installing oil pump 15430
1 5 Removing and installing upper part of sump 15433
1 6 Engine oil: 15439
2 Engine oil cooler 15440
2 1 Assembly overview – engine oil cooler 15440
2 2 Removing and installing engine oil cooler 15440
2 3 Removing and installing mechanical switching valve 15442
3 Crankcase ventilation 15443
3 1 Assembly overview – crankcase breather system 15443
3 2 Removing and installing oil separator 15444
4 Oil filter, oil pressure switch 15445
4 1 Assembly overview – oil filter 15445
4 2 Assembly overview – oil pressure switches/oil pressure control 15445
4 3 Removing and installing piston cooling jet control valve -N522- 15447
4 4 Removing and installing oil pressure regulating valve -N428- 15447
4 5 Removing and installing oil pressure switch 15449
4 5 1 Removing and installing oil pressure switch -F1- 15449
4 5 2 Removing and installing oil pressure switch for reduced oil pressure -F378- 15450
4 5 3 Removing and installing stage 3 oil pressure switch -F447- 15451
4 6 Checking oil pressure 15453
4 6 1 Checking engine oil pressure 15453
4 6 2 Checking oil pressure and oil spray jets 15456
19 – Cooling 15458
1 Cooling system/coolant 15458
1 1 Connection diagram – coolant hoses 15458
1 1 1 Vehicles with manual gearbox 15458
1 1 2 Vehicles with dual clutch gearbox 15460
1 2 Draining and adding coolant 15461
1 3 Checking cooling system for leaks 15469
1 4 Flushing cooling system 15472
1 4 1 Flushing cooling system 15472
1 4 2 Flushing cooling system, quick reference guide 15494
2 Coolant pump, regulation of cooling system 15496
2 1 Assembly overview – coolant pump, thermostat 15496
2 2 Assembly overview – electric coolant pump 15498
2 3 Assembly overview – coolant temperature sender 15500
2 4 Removing and installing toothed belt for coolant pump 15501
2 5 Removing and installing coolant pump 15504
2 6 Removing and installing auxiliary pump for heating -V488- 15508
2 7 Removing and installing coolant shut-off valve -N82- 15512
2 8 Removing and installing coolant valve for gearbox -N488-, vehicles with dual clutch gearbox 15514
2 9 Removing and installing actuator for engine temperature regulation -N493- 15516
2 10 Removing and installing coolant temperature sender -G62- 15518
2 11 Removing and installing radiator outlet coolant temperature sender -G83- 15520
3 Coolant pipes 15522
3 1 Assembly overview – coolant pipes 15522
3 2 Removing and installing front coolant pipe 15522
3 3 Removing and installing upper coolant pipes 15524
4 Radiator, radiator fan 15527
4 1 Assembly overview – radiator/radiator fan 15527
4 2 Removing and installing radiator 15528
4 3 Removing and installing radiator cowl with radiator fan 15532
4 4 Removing and installing radiator fan 15536
21 – Turbocharging/supercharging 15537
1 Turbocharger 15537
1 1 Assembly overview – turbocharger 15537
1 2 Removing and installing turbocharger 15541
1 3 Removing and installing charge pressure positioner -V465- 15545
1 4 Adjusting charge pressure positioner -V465- 15546
2 Charge air system 15549
2 1 Assembly overview – charge air system 15549
2 2 Assembly overview – charge-air hose connections 15551
2 2 1 Hose connections with grooved unions 15551
2 2 2 Hose connections with plug-in connectors 15552
2 3 Removing and installing charge air cooler 15553
2 4 Removing and installing charge pressure sender -G31- 15554
2 5 Checking charge air system for leaks 15555
24 – Mixture preparation – injection 15558
1 Injection system 15558
1 1 Overview of fitting locations – injection system 15558
2 Injectors 15567
2 1 Assembly overview – fuel rail with injectors 15567
2 1 1 Assembly overview – fuel rail with injectors, direct injection 15567
2 1 2 Assembly overview – fuel rail with injectors, indirect injection 15568
2 2 Removing and installing fuel rail 15569
2 3 Removing and installing injectors 15570
2 3 1 Removing and installing injectors, direct injection 15570
2 3 2 Removing and installing injectors, indirect injection 15574
2 4 Renewing seals on injectors 15576
2 5 Cleaning injectors 15579
3 Air filter 15581
3 1 Assembly overview – air filter housing 15581
3 2 Removing and installing air filter housing 15582
4 Intake manifold 15583
4 1 Assembly overview – intake manifold 15583
4 2 Removing and installing intake manifold 15585
4 3 Removing and installing throttle valve module -GX3- 15591
4 4 Cleaning throttle valve module 15593
5 Senders and sensors 15595
5 1 Assembly overview – actuator for structure-borne sound -R214- and control unit for structure-borne sound -J869- 15595
5 1 1 Assembly overview – actuator for structure-borne sound -R214- and control unit for structure-borne sound -J869-, Polo, LHD vehicles 15595
5 1 2 Assembly overview – actuator for structure-borne sound -R214- and control unit for structure-borne sound -J869-, Polo, RHD vehicles 15596
5 2 Removing and installing fuel pressure sender -G247- 15597
5 3 Checking fuel pressure sender -G247- 15600
5 4 Removing and installing fuel pressure sender for low-pressure -G410- 15603
5 5 Removing and installing intake manifold sender -GX9- 15604
6 Engine control unit 15605
6 1 Removing and installing engine control unit -J623- 15605
7 High-pressure pump 15607
7 1 Assembly overview – high-pressure pump 15607
7 2 Removing and installing high-pressure pump 15609
7 3 Removing and installing high-pressure pipe 15613
8 Lambda probe 15617
8 1 Assembly overview – Lambda probe 15617
8 2 Removing and installing Lambda probe 15618
8 2 1 Removing and installing Lambda probe 1 before catalytic converter -GX10- 15618
8 2 2 Removing and installing Lambda probe 1 after catalytic converter -GX7- 15619
26 – Exhaust system 15621
1 Exhaust pipes and silencers 15621
1 1 Assembly overview – silencers 15621
1 2 Separating exhaust pipes from silencers 15622
1 3 Aligning exhaust system free of stress 15623
1 4 Checking exhaust system for leaks 15624
2 Emission control 15625
2 1 Assembly overview – emission control 15625
2 2 Removing and installing catalytic converter 15627
28 – Ignition system 15632
1 Ignition system 15632
1 1 Assembly overview – ignition system 15632
1 2 Test data, spark plugs 15634
1 3 Removing and installing ignition coils with output stage 15634
1 4 Removing and installing knock sensor 1 -G61- 15637
1 5 Removing and installing Hall sender 15638
1 5 1 Removing and installing Hall sender -G40- 15638
1 5 2 Removing and installing Hall sender 3 -G300- 15638
1 6 Removing and installing engine speed sender -G28- 15639
D4B8078EDD8 Heating air conditioner 15640
00 – Technical data 15646
1 General notes 15646
1 1 Notes concerning odours in air conditioned vehicles 15646
1 2 Notes for vehicles with a start-stop system 15646
1 3 Notes on repair work to vehicles with air conditioning and on handling refrigerant 15647
1 4 Procedure for checking and adjusting components 15647
1 5 Identification plates 15647
2 Notes on safety 15649
2 1 Safety precautions when handling refrigerants 15649
2 2 Safety measures for when working on vehicles with a start-stop system 15650
3 Repair notes 15651
3 1 Repair work on refrigerant circuit which may be performed only in appropriate workshops by specially trained mechanics 15651
4 Technical data 15653
4 1 Capacities for refrigerant R134a 15653
4 2 Refrigerant machine oil 15653
4 3 Oil distribution 15654
80 – Heating 15655
1 Overview of fitting locations – heating 15655
1 1 Overview of fitting locations – components not located in passenger compartment 15655
1 1 1 Overview of fitting locations – components not located in passenger compartment (LHD) 15655
1 1 2 Overview of fitting locations – components not located in passenger compartment (RHD) 15656
1 2 Overview of fitting locations – components located in front section of passenger compartment 15657
1 2 1 Overview of fitting locations – components inside of front passenger compartment, LHD vehicles 15657
1 2 2 Overview of fitting locations – components inside of front passenger compartment, RHD vehicles 15659
2 Heater unit 15660
2 1 Assembly overview – heater unit 15660
2 2 Removing and installing fresh air blower -V2- 15662
2 3 Removing and installing fresh air blower series resistor with overheating fuse -N24- 15662
2 4 Removing and installing dust and pollen filter 15662
2 5 Removing and installing heat exchanger 15662
2 6 Removing and installing heater unit 15662
2 7 Dismantling and assembling heater unit 15662
2 8 Checking auxiliary air heater element -Z35- 15664
2 9 Removing and installing auxiliary air heater element -Z35- 15664
2 10 Removing and installing flexible shafts 15664
3 Control motors 15665
3 1 Overview of fitting locations – front control motors 15665
3 1 1 Overview of fitting locations – front control motors, LHD vehicles 15665
3 1 2 Overview of fitting locations – front control motors, RHD vehicles 15665
3 2 Removing and installing air distribution flap actuator 15666
3 3 Removing and installing temperature flap actuator 15668
3 3 1 Removing and installing temperature flap actuator (LHD) 15668
3 3 2 Removing and installing temperature flap actuator (RHD) 15670
3 4 Removing and installing fresh air and air recirculation flap control motor -V154- 15671
4 Air duct 15672
4 1 Assembly overview – air duct and air distribution in passenger compartment 15672
4 2 Removing and installing centre vent at front 15672
4 3 Removing and installing right or left vent 15672
4 4 Removing and installing driver side footwell vents 15672
4 5 Removing and installing front passenger side footwell vents 15672
4 6 Removing and installing rear air duct 15672
4 7 Checking exhaust ventilation for passenger compartment 15672
4 8 Removing and installing exhaust ventilation for passenger compartment 15673
4 9 Removing and installing fresh air intake 15673
4 10 Removing and installing air duct for defroster vent 15673
4 11 Removing and installing air duct for centre vent 15673
5 Operating and display unit 15674
5 1 Exploded view of fitting locations – operating and display unit 15674
5 2 Removing and installing operating and display unit 15675
5 3 Pin assignment for multi-pin connectors on back of operating and display unit, heated and fresh air 15676
6 Other controlling and regulating components 15677
6 1 Removing and installing ambient temperature sensor -G17- 15677
87 – Air conditioning system 15678
1 Overview of fitting locations – air conditioning system 15678
1 1 Overview of fitting locations – components not located in passenger compartment 15678
1 1 1 Overview of fitting locations – components not located in passenger compartment (LHD) 15678
1 1 2 Overview of fitting locations – components not located in passenger compartment (RHD) 15680
1 2 Overview of fitting locations – components located in front section of passenger compartment 15682
1 2 1 Overview of fitting locations – components inside of front passenger compartment, LHD vehicles with A/C system with electric/manual controls 15682
1 2 2 Overview of fitting locations – components located in front section of passenger compartment, RHD vehicles, air conditioning system with electric/manual controls 15684
1 2 3 Overview of fitting locations – components inside of front passenger compartment, LHD vehicles, Climatronic 15686
1 2 4 Overview of fitting locations – components inside of front passenger compartment, RHD vehicles, Climatronic 15688
2 Refrigerant circuit 15692
2 1 System overview – refrigerant circuit 15692
2 2 Assembly overview – condenser 15694
2 3 Removing and installing evacuating and charging valves on low and high-pressure side 15696
2 4 Removing and installing high-pressure sender -G65- 15698
2 5 Removing and installing condenser 15700
2 6 Removing and installing desiccant bag or cartridge 15701
2 7 Removing and installing expansion valve 15704
3 Air conditioner compressor 15707
3 1 Assembly overview – drive unit of air conditioner compressor 15707
3 2 Assembly overview – belt pulley 15708
3 3 Removing air conditioner compressor from and installing on bracket 15708
3 4 Removing and installing air conditioner compressor 15710
3 5 Removing and installing belt pulley 15714
3 6 Checking excess pressure relief valve on air conditioner compressor 15715
4 Control motors 15717
4 1 Overview of fitting locations – front control motors 15717
4 1 1 Overview of fitting locations – front control motors, air conditioning system with electric/manual controls, LHD vehicles 15717
4 1 2 Overview of fitting locations – front control motors, air conditioning system with electric/manual controls, RHD vehicles 15718
4 1 3 Fitting locations overview – front control motors, Climatronic (LHD) 15719
4 1 4 Overview of fitting locations – front control motors, Climatronic (RHD) 15720
4 2 Removing and installing temperature flap control motor -V68- 15721
4 2 1 Removing and installing temperature flap control motor -V68- (LHD) 15721
4 2 2 Removing and installing temperature flap control motor -V68- (RHD) 15723
4 3 Removing and installing defroster flap control motor -V107-/temperature flap control motor -V68- 15724
4 3 1 Removing and installing defroster flap control motor -V107-/temperature flap control motor -V68-, LHD vehicles 15724
4 3 2 Removing and installing defroster flap control motor -V107-/temperature flap control motor -V68-, RHD vehicles 15727
4 4 Removing and installing fresh air and air recirculation flap control motor -V154- 15729
4 5 Removing and installing fresh air/recirculated air, air flow flap control motor -V425- 15731
4 5 1 Removing and installing fresh air/recirculated air, air flow flap control motor -V425- (LHD) 15731
4 5 2 Removing and installing fresh air/recirculated air, air flow flap control motor -V425- (RHD) 15733
4 6 Removing and installing air distribution flap control motor -V428- 15734
4 6 1 Removing and installing air distribution flap control motor -V428-, LHD vehicles 15734
4 6 2 Removing and installing air distribution flap control motor -V428-, RHD vehicles 15735
4 7 Locally manufacturing an adapter cable to activate control motors 15737
5 Front heater and air conditioning unit 15738
5 1 Assembly overview – heater and air conditioning unit 15738
5 1 1 Assembly overview – heater and air conditioning unit, air conditioning system with electric/manual controls, LHD vehicles 15738
5 1 2 Assembly overview – heater and air conditioning unit, air conditioning system with electric/manual controls, RHD vehicles 15740
5 1 3 Assembly overview – heater and air conditioning unit, Climatronic (LHD) 15742
5 1 4 Assembly overview – heater and air conditioning unit, Climatronic (RHD) 15744
5 2 Removing and installing heater and air conditioning unit 15747
5 2 1 Removing and installing heater and air conditioning unit (LHD) 15747
5 2 2 Removing and installing heater and air conditioning unit, right-hand drive vehicles 15749
5 3 Dismantling and assembling heater and air conditioning unit 15751
5 4 Removing and installing fresh air blower -V2- 15753
5 4 1 Removing and installing fresh air blower -V2- (LHD) 15753
5 4 2 Removing and installing fresh air blower -V2- (RHD) 15755
5 5 Removing and installing fresh air blower series resistor with overheating fuse -N24- 15756
5 5 1 Removing and installing fresh air blower series resistor with overheating fuse -N24-, LHD vehicles 15756
5 5 2 Removing and installing fresh air blower series resistor with overheating fuse -N24-, RHD vehicles 15757
5 6 Removing and installing dust and pollen filter 15758
5 6 1 Removing and installing dust and pollen filter (LHD) 15758
5 6 2 Removing and installing dust and pollen filter (RHD) 15759
5 7 Dismantling and assembling evaporator housing 15760
5 7 1 Dismantling and assembling evaporator housing, LHD vehicles 15760
5 7 2 Dismantling and assembling evaporator housing, RHD vehicles 15761
5 8 Checking auxiliary air heater element -Z35- 15762
5 9 Removing and installing auxiliary air heater element -Z35- 15766
5 10 Checking condensation drainage 15767
5 11 Removing and installing fresh air blower control unit -J126- 15767
5 11 1 Removing and installing fresh air blower control unit -J126- (LHD) 15767
5 11 2 Removing and installing fresh air blower control unit -J126- (RHD) 15768
5 12 Removing and installing heat exchanger 15769
5 13 Removing and installing evaporator temperature sensor -G308- 15772
5 13 1 Removing and installing evaporator temperature sensor -G308- (LHD) 15772
5 13 2 Removing and installing evaporator temperature sensor -G308- (RHD) 15773
5 14 Removing and installing flexible shaft 15774
6 Air duct 15775
6 1 Assembly overview – air duct and air distribution in passenger compartment 15775
6 2 Removing and installing centre vent at front 15776
6 3 Removing and installing right or left vent 15777
6 4 Removing and installing driver side footwell vents 15777
6 4 1 Removing and installing driver side footwell vents (LHD) 15777
6 4 2 Removing and installing driver side footwell vents (RHD) 15778
6 5 Removing and installing front passenger side footwell vents 15778
6 5 1 Removing and installing front passenger side footwell vents (LHD) 15778
6 5 2 Removing and installing front passenger side footwell vents (RHD) 15779
6 6 Removing and installing rear footwell vent 15779
6 7 Removing and installing exhaust ventilation for passenger compartment 15780
6 8 Checking exhaust ventilation for passenger compartment 15781
6 9 Removing and installing fresh air intake 15782
6 9 1 Removing and installing fresh air intake (LHD) 15782
6 9 2 Removing and installing fresh air intake (RHD) 15783
6 10 Removing and installing air duct for defroster vent 15784
6 11 Removing and installing air duct for centre vent 15785
7 Operating and display unit 15786
7 1 Exploded view of fitting locations – operating and display unit 15786
7 1 1 Overview of fitting locations – operating and display unit, air conditioning system with electric/manual controls 15786
7 1 2 Overview of fitting locations – operating and display unit, Climatronic 15787
7 2 Removing and installing operating and display unit 15789
7 2 1 Removing and installing operating and display unit, air conditioning system with electric/manual controls 15789
7 2 2 Removing and installing operating and display unit, Climatronic 15790
7 3 Multi-pin connector pin assignment on back of operating and display unit 15792
7 3 1 Multi-pin connector pin assignment on back of operating and display unit, A/C system with electric/manual controls 15792
7 3 2 Multi-pin connector pin assignment on back of operating and display unit, Climatronic 15792
8 Other controlling and regulating components 15793
8 1 Removing and installing sunlight penetration photosensor -G107- 15793
8 2 Removing and installing centre vent temperature sender -G191- 15794
8 2 1 Removing and installing centre vent temperature sender -G191-, LHD vehicles 15794
8 2 2 Removing and installing centre vent temperature sender -G191-, RHD vehicles 15794
8 3 Removing and installing footwell vent temperature sender -G192- 15795
8 4 Removing and installing radiator fan control unit -J293- 15795
8 5 Removing and installing ambient temperature sensor -G17- 15797
D4B80403DE3 Body Repairs 15798
00 – Technical data 15804
1 Basic instructions 15804
2 Vehicle identification data 15805
2 1 Vehicle identification number 15805
2 2 Type plate 15806
2 3 Vehicle data sticker 15807
3 Safety information 15808
4 Moulded foam inserts 15809
5 Galvanized body parts, high- and higher-strength and hot-formed body panels 15811
5 1 Installing 15811
5 2 2-door models 15813
5 3 4-door models 15816
6 Laser welding 15819
7 Body panel gaps/shut lines 15820
7 1 Body – front 15820
7 2 Body – centre 15821
7 3 Body – rear 15823
8 Body dimensions 15824
8 1 Body – front 15824
8 2 Body – centre 15827
8 2 1 2-door models 15829
8 2 2 4-door models 15832
8 3 Body – rear 15837
8 4 Floor panel – front 15840
8 5 Floor panel – centre 15842
8 6 Floor panel – rear 15843
9 Tools 15844
10 Alignment jig 15845
10 1 Overview 15845
11 Portal gauge 15846
11 1 2-door models 15846
11 2 4-door models 15847
50 – Body – front 15849
1 Renewing right engine mounting bracket 15849
1 1 Tools 15849
1 2 Removing 15849
1 3 Installing 15851
1 3 1 Preparing replacement part 15851
1 3 2 Welding in 15852
2 Renewing mounting bracket for subframe 15853
2 1 Tools 15853
2 2 Removing 15853
2 3 Installing 15854
2 3 1 Preparing replacement part 15855
2 3 2 Welding in 15855
3 Renewing front bumper bracket 15857
3 1 Tools 15858
3 2 Removing 15858
3 3 Installing 15859
3 3 1 Welding in 15859
4 Renewing upper wheel housing longitudinal member 15861
4 1 Tools 15862
4 2 Removing 15862
4 3 Installing 15864
4 3 1 Preparing replacement part 15864
4 3 2 Welding in 15866
5 Renewing front wheel housing 15869
5 1 Tools 15870
5 2 Removing 15870
5 3 Installing 15871
5 3 1 Preparing replacement part 15871
5 3 2 Welding in 15871
6 Repairing threads for securing subframe 15873
6 1 Contents of thread repair kit 15875
6 2 Repairing threads 15875
6 2 1 Drilling thread 15875
6 2 2 Cutting thread 15876
6 2 3 Inserting thread insert 15877
7 Renewing front left longitudinal member 15879
7 1 Tools 15880
7 2 Removing 15880
7 3 Installing 15882
7 3 1 Preparing replacement part 15882
7 3 2 Welding in 15884
8 Renewing front left longitudinal member – part section 15886
8 1 Tools 15887
8 2 Removing 15887
8 3 Installing 15888
8 3 1 Preparing replacement part 15889
8 3 2 Welding in 15889
9 Renewing front right longitudinal member 15891
9 1 Tools 15892
9 2 Removing 15892
9 3 Installing 15894
9 3 1 Preparing replacement part 15894
9 3 2 Welding in 15897
10 Renewing front right longitudinal member – part section 15899
10 1 Tools 15900
10 2 Removing 15900
10 3 Installing 15901
10 3 1 Preparing replacement part 15901
10 3 2 Welding in 15903
51 – Body – centre 15904
1 Renewing roof 15904
1 1 Tools 15905
1 2 Removing 15906
1 3 Installing 15909
1 3 1 Preparing replacement part 15909
1 3 2 Adjusting roof depth 15911
1 3 3 Bonding roof 15912
1 3 4 Welding in 15918
2 Renewing front cross member for roof 15920
2 1 Tools 15920
2 2 Removing 15920
2 3 Installing 15922
2 3 1 Preparing replacement part 15922
2 3 2 Welding in 15922
3 Renewing roof reinforcement 15924
3 1 Tools 15924
3 2 Removing 15924
3 3 Installing 15926
3 3 1 Preparing replacement part 15926
3 3 2 Welding in 15927
4 Renewing rear roof cross member 15929
4 1 Tools 15929
4 2 Removing 15929
4 3 Installing 15931
4 3 1 Preparing replacement part 15931
4 3 2 Welding in 15932
5 Renewing A-pillar 15934
5 1 Tools 15935
5 2 Removing 15935
5 3 Installing 15937
5 3 1 Preparing replacement part 15938
5 3 2 Moulded foam inserts 15940
5 3 3 Welding in 15941
6 Renewing A-pillar reinforcement 15945
6 1 Tools 15946
6 2 Removing 15946
6 3 Installing 15949
6 3 1 Preparing replacement part 15949
6 3 2 Moulded foam inserts 15950
6 3 3 Welding in 15951
7 Renewing B-pillar – 4-door 15955
7 1 Tools 15956
7 2 Removing 15957
7 3 Installing 15958
7 3 1 Preparing replacement part 15959
7 3 2 Moulded foam inserts 15961
7 3 3 Welding in 15961
8 Renewing B-pillar reinforcement – 4-door 15963
8 1 Tools 15964
8 2 Removing 15964
8 3 Installing 15966
8 3 1 Preparing replacement part 15967
8 3 2 Marking area in which welding work is prohibited 15968
8 3 3 Moulded foam inserts 15969
8 3 4 Welding in 15969
9 Renewing B-pillar reinforcement, 4-door model, part section 15972
9 1 Tools 15973
9 2 Removing 15973
9 3 Installing 15977
9 3 1 Preparing replacement part 15977
9 3 2 Marking area in which welding work is prohibited 15980
9 3 3 Moulded foam inserts 15980
9 3 4 Welding in 15980
10 Renewing B-pillar reinforcement – 2-door 15985
10 1 Tools 15986
10 2 Removing 15986
10 3 Installing 15988
10 3 1 Preparing replacement part 15988
10 3 2 Marking area in which welding work is prohibited 15994
10 3 3 Moulded foam inserts 15995
10 3 4 Welding in 15996
11 Renewing outer side member – 4-door 16000
11 1 Tools 16001
11 2 Removing 16001
11 3 Installing 16003
11 3 1 Preparing replacement part 16004
11 3 2 Marking area in which welding work is prohibited 16006
11 3 3 Moulded foam inserts 16007
11 3 4 Welding in 16008
12 Renewing outer side member – 2-door 16012
12 1 Tools 16013
12 2 Removing 16014
12 3 Installing 16015
12 3 1 Preparing replacement part 16015
12 3 2 Welding in 16017
13 Renewing gusset plate 16021
13 1 Tools 16021
13 2 Removing 16021
13 3 Installing 16022
13 3 1 Preparing replacement part 16023
13 3 2 Welding in 16023
14 Renewing seat cross member 16025
14 1 Tools 16025
14 2 Removing 16025
14 3 Installing 16027
14 3 1 Preparing replacement part 16027
14 3 2 Welding in 16029
53 – Body – rear 16030
1 Renewing rear cross panel 16030
1 1 Tools 16031
1 2 Removing 16031
1 3 Installing 16032
1 3 1 Preparing replacement part 16032
1 3 2 Welding in 16033
2 Renewing tail light mounting 16035
2 1 Tools 16036
2 2 Removing 16036
2 3 Installing 16037
2 3 1 Preparing replacement part 16037
2 3 2 Welding in 16038
3 Renewing cross panel member 16040
3 1 Tools 16041
3 2 Removing 16041
3 3 Installing 16042
3 3 1 Preparing replacement part 16042
3 3 2 Welding in 16043
4 Renewing luggage compartment floor 16045
4 1 Tools 16046
4 2 Removing 16046
4 3 Installing 16047
4 3 1 Preparing replacement part 16047
4 3 2 Moulded foam inserts 16048
4 3 3 Welding in 16048
5 Renewing rear longitudinal member – part section 16050
5 1 Tools 16051
5 2 Removing 16051
5 3 Installing 16053
5 3 1 Preparing replacement part 16053
5 3 2 Welding in 16055
6 Renewing side panel, part section – 4-door 16056
6 1 Tools 16057
6 2 Removing 16057
6 3 Installing 16059
6 3 1 Preparing replacement part 16060
6 3 2 Moulded foam inserts 16062
6 3 3 Welding in 16063
7 Renewing side panel – 2-door 16067
7 1 Tools 16068
7 2 Removing 16068
7 3 Installing 16070
7 3 1 Preparing replacement part 16071
7 3 2 Moulded foam inserts 16073
7 3 3 Marking area in which welding work is prohibited 16074
7 3 4 Welding in 16075
8 Renewing outer wheel housing liner – part section 16079
8 1 Tools 16080
8 2 Removing 16081
8 3 Installing 16082
8 3 1 Preparing replacement part 16082
8 3 2 Welding in 16083
D4B80403F7A 6 speed manual gearboxes 02U and 0DQ 16085
00 – Technical data 16089
1 Safety information 16089
1 1 Safety measures when working on vehicles with start/stop system 16089
2 Identification 16090
2 1 Gearbox identification 16090
3 Technical data 16092
3 1 Allocation gearbox – engine 16092
3 1 1 Allocation gearbox – engine, manual gearbox 02U 16092
3 1 2 Allocation gearbox – engine, manual gearbox 0DQ 16092
3 2 Capacities 16093
3 3 Calculation of gear ratios 16093
4 Overview – power transmission 16094
5 Electrical components 16096
5 1 Overview of fitting locations – electrical components 16096
5 1 1 Overview of fitting locations – electrical components, manual gearbox 16096
5 1 2 Overview of fitting locations – electrical components, clutch mechanism 16096
6 Repair instructions 16098
6 1 General repair instructions 16098
30 – Clutch 16102
1 Clutch mechanism 16102
1 1 Overview of fitting locations – clutch mechanism 16102
1 2 Assembly overview – pedal cluster 16103
1 3 Assembly overview – clutch hydraulics 16105
1 3 1 Assembly overview – clutch hydraulics, left-hand drive 16105
1 3 2 Assembly overview – clutch hydraulics, right-hand drive 16107
1 4 Assembly overview – clutch release mechanism 16109
1 5 Removing and installing bearing bush 16110
1 6 Checking clutch master cylinder and clutch slave cylinder 16112
1 7 Removing and installing clutch position sender -G476- 16112
1 8 Removing and installing over-centre spring 16114
1 9 Removing and installing extension spring 16116
1 10 Removing and installing clutch pedal 16116
1 10 1 Removing and installing clutch pedal, LHD 16116
1 10 2 Removing and installing clutch pedal, RHD 16117
1 11 Removing and installing mounting bracket 16119
1 12 Removing and installing clutch master cylinder 16124
1 13 Removing and installing clutch slave cylinder 16125
1 14 Removing and installing lines for clutch mechanism 16127
1 15 Bleeding clutch mechanism 16131
1 16 Checking clutch master cylinder and clutch slave cylinder 16133
1 17 Servicing clutch release mechanism 16134
2 Clutch 16136
2 1 Assembly overview – clutch 16136
2 2 Removing and installing clutch 16136
34 – Controls, housing 16142
1 Selector mechanism 16142
1 1 Installation position – selector mechanism 16142
1 2 Assembly overview – gear knob and cover 16143
1 3 Assembly overview – selector mechanism 16144
1 4 Removing and installing gear knob 16146
1 5 Removing and installing selector mechanism 16148
1 6 Repairing selector mechanism 16152
1 7 Adjusting selector mechanism 16156
1 8 Checking selector mechanism 16159
2 Removing and installing gearbox 16160
2 1 Differentiating between gearboxes 16160
2 2 Removing gearbox 16160
2 3 Installing gearbox 16175
2 4 Specified torques for gearbox 16183
3 Assembly mountings 16184
3 1 Assembly overview – assembly mountings 16184
4 Gearbox transport 16187
5 Gear oil 16188
5 1 Checking gear oil level 16188
5 2 Draining and filling gear oil 16189
6 Securing to engine and gearbox support 16191
7 Dismantling and assembling gearbox 16192
7 1 Schematic overview – gearbox 16192
7 2 Assembly overview – gearbox 16193
7 3 Assembly overview – cover for gearbox housing and 5th/6th gear 16193
7 4 Assembly overview – clutch housing 16195
7 4 1 Assembly overview – clutch housing, manual gearbox 02U 16195
7 4 2 Assembly overview – clutch housing, manual gearbox 0DQ 16196
7 5 Assembly overview – shafts, differential, selector mechanism 16197
7 6 Assembly overview – selector unit 16199
7 7 Assembly overview – selector forks 16200
7 8 Repairing selector forks 16201
7 9 Repairing selector unit 16206
7 10 Renewing selector shaft seal 16208
7 11 Dismantling and assembling gearbox 16209
8 Gearbox housing, clutch housing 16232
8 1 Assembly overview – gearbox housing and clutch housing 16232
8 1 1 Assembly overview – gearbox housing and clutch housing, manual gearbox 02U 16232
8 1 2 Assembly overview – gearbox housing and clutch housing, manual gearbox 0DQ 16234
8 2 Assembly overview – gearbox housing cover 16236
8 3 Repairing gearbox housing cover 16237
8 4 Servicing clutch housing 16240
35 – Gears, shafts 16243
1 Input shaft 16243
1 1 Assembly overview – input shaft 16243
1 2 Dismantling and assembling input shaft 16246
1 3 Renewing input shaft seal 16258
2 Output shaft 16260
2 1 Assembly overview – output shaft 16260
2 2 Dismantling and assembling output shaft 16263
39 – Final drive – differential 16271
1 Oil seals 16271
1 1 Overview of fitting locations – oil seals 16271
1 2 Renewing left seal 16272
1 2 1 Renewing oil seal for left flange shaft, manual gearbox 02U 16272
1 2 2 Renewing oil seal for left flange shaft, manual gearbox 0DQ 16275
1 3 Renewing right seal 16278
1 3 1 Renewing oil seal for right flange shaft, manual gearbox 02U 16278
1 3 2 Renewing oil seal for right flange shaft, manual gearbox 0DQ 16280
2 Differential 16284
2 1 Assembly overview – differential 16284
2 1 1 Assembly overview – differential housing, manual gearbox 02U 16284
2 1 2 Assembly overview – differential housing, manual gearbox 0DQ 16286
2 2 Dismantling and assembling differential 16287
2 3 Adjusting differential 16297
D4B80403F9C Fuel supply system diesel engines 16304
00 – Technical data 16308
1 Safety information 16308
1 1 Safety regulations for working on fuel supply 16308
1 2 Safety precautions when using testers and measuring instruments during a road test 16309
1 3 Safety measures when working on vehicles with a start/stop system 16309
2 Identification 16311
2 1 Engine number/engine data 16311
3 General information 16312
3 1 Rules for cleanliness when working on auxiliary/supplementary heater and fuel system 16312
20 – Fuel supply system 16313
1 Procedure in event of misfuelling 16313
1 1 Step 1 (Engine was started with incorrect fuel) 16313
1 2 Step 2 (Engine was not started with incorrect fuel) 16315
1 3 Step 3 (There are filings in fuel delivery unit and fuel tank) 16318
1 4 Step 4 (There are no filings in fuel delivery unit and fuel tank) 16318
1 5 Step 5 (There are filings in high-pressure pump) 16319
1 6 Step 6 (There are no filings in high-pressure pump) 16319
2 Fuel 16321
2 1 Assembly overview – fuel tank 16321
2 1 1 Assembly overview – fuel tank 16321
2 2 Removing and installing fuel tank 16322
2 2 1 Removing and installing fuel tank 16322
2 3 Emptying fuel tank 16329
2 3 1 Emptying fuel tank when fuel pump is intact 16329
2 3 2 Emptying fuel tank if it is more than 3/4 full 16331
2 3 3 Emptying fuel tank if it is less than 3/4 full 16332
3 Fuel delivery unit, fuel gauge sender 16335
3 1 Assembly overview – fuel delivery unit/fuel gauge sender 16335
3 2 Removing and installing fuel delivery unit, fuel gauge sender 16336
3 3 Removing and installing fuel gauge sender -G- 16341
4 Plug-in connectors 16343
4 1 Separating plug-in connectors 16343
5 Fuel filter 16347
5 1 Assembly overview – fuel filter 16347
5 2 Removing and installing fuel filter 16348
5 3 Fuel hoses in the engine compartment 16349
6 Accelerator pedal 16350
6 1 Assembly overview – accelerator module 16350
7 Fuel pump 16351
7 1 Checking fuel system pressurisation pump -G6- 16351
7 1 1 Checking fuel pressure 16351
7 1 2 Checking fuel delivery rate 16356
D4B80403F9D Brake system 16365
00 – Technical data 16369
1 Notes on safety 16369
1 1 Safety precautions during a road test using test and measuring equipment 16369
1 2 Safety precautions when working on vehicles with Start/Stop system 16370
2 Identification 16371
2 1 Allocation of PR number – brakes 16371
2 1 1 Front brakes 16371
2 1 2 Rear brakes 16371
3 Technical data 16373
3 1 Technical data for brakes 16373
3 1 1 Brake master cylinder and brake servo 16373
4 Brake test 16376
4 1 General information 16376
4 2 Checking vehicles with front-wheel drive 16376
45 – Anti-lock brake system 16377
1 General information 16377
1 1 Repair instructions for repair work on ABS 16377
1 2 Vehicle diagnosis, testing and information system 16378
2 Overview of fitting locations 16381
2 1 Overview of fitting locations – ABS/ESP 16381
3 Control unit and hydraulic unit 16383
3 1 Assembly overview – control unit and hydraulic unit 16383
3 1 1 Assembly overview – control unit and hydraulic unit, LHD vehicles, ABS/ESP 16383
3 1 2 Assembly overview – control unit and hydraulic unit, RHD vehicles, ABS 16386
3 1 3 Assembly overview – control unit and hydraulic unit, RHD vehicles, ABS/ESP 16388
3 2 Removing and installing ABS control unit -J104-/ABS hydraulic unit -N55- 16389
3 2 1 Removing and installing control unit and hydraulic unit, LHD vehicles, ABS/ESP 16389
3 2 2 Removing and installing control unit and hydraulic unit, RHD vehicles, ABS 16393
3 2 3 Removing and installing control unit and hydraulic unit, RHD vehicles, ABS/ESP 16397
3 3 Separating control unit from hydraulic unit 16400
3 4 Fitting control unit to hydraulic unit 16401
3 5 Connecting brake lines to hydraulic unit 16403
3 5 2 Connecting brake lines to hydraulic unit, right-hand drive 16403
4 Sensors 16405
4 1 Assembly overview – speed sensor on front axle 16405
4 2 Assembly overview – speed sensor on rear axle 16406
4 2 1 Assembly overview – speed sensor on rear axle, drum brake 16406
4 2 2 Assembly overview – speed sensor on rear axle, disc brake 16408
4 3 Removing and installing ESP sensor unit -G419- 16409
4 4 Removing and installing speed sensors on front axle -G45-/-G47- 16409
4 5 Removing and installing speed sensors on rear axle -G44-/-G46- 16410
4 5 1 Removing and installing speed sensors on rear axle -G44-/-G46-, drum brake 16410
4 5 2 Removing and installing speed sensors on rear axle -G44-/-G46-, disc brake 16410
4 6 Removing and installing steering angle sender -G85- 16411
46 – Brakes – mechanism 16412
1 Front brakes 16412
1 1 Assembly overview – front brakes 16412
1 1 1 Assembly overview – front brake, FS III brake caliper 16412
1 1 2 Assembly overview – front brake,FN 3 brake caliper 16414
1 2 Removing and installing brake pads or linings 16416
1 2 1 Removing and installing brake pads, brake caliper FS III 16416
1 2 2 Removing and installing brake pads, brake caliper FN 3 16418
1 3 Removing and installing brake caliper 16421
1 3 1 Removing and installing brake caliper, FS III brake caliper 16421
1 3 2 Removing and installing brake caliper, FN 3 brake caliper 16423
2 Rear brakes 16426
2 1 Assembly overview – rear brakes 16426
2 1 1 Assembly overview – rear brake, drum brake 16426
2 1 2 Assembly overview – rear brake, disc brake 16429
2 2 Removing and installing brake pads or linings 16431
2 3 Removing and installing brake caliper 16434
2 4 Removing and installing brake shoes 16435
2 5 Retracting drum brakes 16438
3 Handbrake 16439
3 1 Assembly overview – parking brake 16439
3 2 Adjusting parking brake 16440
3 2 1 Adjusting handbrake, drum brakes 16440
3 2 2 Adjusting handbrake, disc brakes 16441
3 3 Removing and installing rear brake cable 16442
3 3 1 Removing and installing rear brake cable, drum brakes 16442
3 3 2 Removing and installing rear brake cable, disc brake 16445
4 Brake pedal 16448
4 1 Assembly overview – brake pedal 16448
4 1 1 Assembly overview – brake pedal, left-hand drive 16448
4 1 2 Assembly overview – brake pedal, right-hand drive 16449
4 2 Removing and installing mounting bracket 16451
4 2 1 Removing and installing mounting bracket, left-hand drive 16451
4 2 2 Removing and installing mounting bracket, right-hand drive 16451
4 3 Separating brake pedal from brake servo 16452
4 4 Connecting brake pedal to brake servo 16453
4 5 Removing and installing brake pedal 16454
4 5 1 Removing and installing brake pedal, LHD 16454
4 5 2 Removing and installing brake pedal, RHD 16454
47 – Brakes – hydraulics 16455
1 Front brake caliper 16455
1 1 Assembly overview – front brake caliper 16455
1 1 1 Assembly overview – front brake caliper, brake caliper FS III 16455
1 1 2 Assembly overview – front brake caliper, brake caliper FN 3 16456
1 2 Removing and installing brake caliper piston 16456
1 2 1 Removing and installing brake caliper piston, FS III brake caliper 16456
1 2 2 Removing and installing brake caliper piston, brake caliper FN 3 16458
2 Rear brake caliper 16462
2 1 Assembly overview – rear brake caliper 16462
2 2 Removing and installing brake caliper piston 16463
3 Brake servo and brake master cylinder 16465
3 1 Assembly overview – brake servo/brake master cylinder 16465
3 1 1 Assembly overview – brake servo/brake master cylinder, left-hand drive 16465
3 1 2 Assembly overview – brake servo/brake master cylinder, right-hand drive 16467
3 2 Removing and installing brake light switch 16468
3 2 1 Removing and installing brake light switch, left-hand drive 16468
3 2 2 Removing and installing brake light switch, right-hand drive 16469
3 3 Removing and installing brake servo 16470
3 3 1 Removing and installing brake servo, LHD vehicles, 3-cyl 1 0 l petrol engine 16470
3 3 2 Removing and installing brake servo, LHD vehicles, 4-cyl 1 2 l petrol engine 16474
3 3 3 Removing and installing brake servo, LHD vehicles, 4-cyl 1 8l petrol engine 16479
3 3 4 Removing and installing brake servo, LHD vehicles, 3-cyl 1 4 l diesel engine 16485
3 3 5 Removing and installing brake servo, RHD vehicles, 3-cyl 1 0 l petrol engine 16490
3 3 6 Removing and installing brake servo, RHD vehicles, 4-cyl 1 2 l/1 4 l/1 6 l petrol engine 16496
3 3 7 Removing and installing brake servo, RHD vehicles, 4-cyl 1 8 l petrol engine 16502
3 4 Removing and installing brake master cylinder 16508
3 4 1 Removing and installing brake master cylinder, left-hand drive 16508
3 4 2 Removing and installing brake master cylinder, right-hand drive 16512
4 Vacuum system 16516
4 1 Assembly overview – vacuum pump 16516
4 1 1 Assembly overview – vacuum pump, mechanical vacuum pump 16516
4 1 2 Assembly overview – vacuum pump for brakes -V192- 16516
4 2 Checking non-return valve 16517
4 3 Removing and installing brake servo pressure sensor 16518
4 4 Checking vacuum system 16518
4 4 1 Connecting brake servo tester -VAS 6721- 16519
4 4 2 Checking vacuum generation 16520
4 4 3 Checking for leaks 16521
4 5 Removing and installing electrical vacuum pump for brakes 16523
5 Brake lines 16525
5 1 Repairing brake lines 16525
5 1 1 Assembly overview – flanging tool 16527
5 1 2 Work instructions 16527
6 Hydraulic system 16530
6 1 General notes on brake fluid 16530
6 2 Pre-bleeding hydraulic system 16530
6 3 Bleeding hydraulic system following standard procedure 16531
6 4 Subsequent bleeding of hydraulic system 16532
6 5 Testing for leaks 16533
D4B80403F9E Wheels and Tyres Guide 16535
44 – Wheels, tyres, vehicle geometry 16539
1 General notes on using the “Wheels and Tyres Guide” 16539
1 1 General information 16539
1 2 Explanations regarding world regions 16540
1 3 Definition of tyre package 16541
1 4 Procedure for determining the required tyre package 16541
1 4 1 Determining the required tyre package via PR number 16541
1 4 2 Determining the required tyre package via version key in the vehicle registration certificate part 1 16542
2 Notes on the vehicle registration certificate 16543
2 1 Vehicle registration certificate part 1 16543
2 2 Version key, D2 16543
3 Wheel and tyre combinations without tyre package 16545
3 1 Polo – from model year 2014, sales type 6C 16545
3 2 Polo BlueMotion – from model year 2015, sales type 6C 16546
3 3 Cross Polo – model year 2014, sales type 6C 16548
4 Wheel and tyre combinations depending on tyre packages 16551
4 1 Type Approval No (K): e1*2001/116*0510*23 16551
4 2 Type Approval No (K): e1*2001/116*0510*24 16552
4 3 Type Approval No (K): e1*2001/116*0510*25 16554
4 4 Type approval number (K): e1*2001/116*0510*26 to e1*2001/116*0510*29 16556
4 5 Changing to other wheel and tyre combinations 16559
5 Wheel allocation 16561
5 1 5 J x 14 offset 35 16561
5 2 5 1/2 J x 15 offset 38 16562
5 3 6 J x 15 offset 38 16562
5 4 6 J x 15 offset 40 16563
5 5 6 J x 16 offset 40 16565
5 6 7 J x 16 offset 46 16566
5 7 7 J x 17 offset 46 16568
5 8 71/2 J x 17 offset 38 16570
5 9 71/2 J x 17 offset 44 16570
6 Recommended summer tyres 16572
6 1 Recommended summer tyres, worldwide except North America and China 16572
6 2 Recommended summer tyres, Japan, Indonesia, South Korea 16572
7 Recommended all-season tyres, worldwide except North America and China 16573
8 Recommended winter tyres, worldwide except North America and China 16574
9 Recommended temporary spare tyres and wheels 16575
D4B80423DFE 4 cylinder injection engine (1 4 l direct injection engine turbocharger) 16576
00 – Technical data 16582
1 Identification 16582
1 1 Engine number, engine data 16582
2 Safety instructions 16583
2 1 Safety precautions when working on fuel supply system 16583
2 2 Safety precautions when working on vehicles with a Start/Stop system 16583
2 3 Safety precautions during road tests in which test and measuring equipment is used 16584
2 4 Safety precautions when working on cooling system 16584
2 5 Safety precautions when working on ignition system 16584
3 Repair instructions 16585
3 1 Rules for cleanliness 16585
3 2 Foreign objects in engine 16585
3 3 Contact corrosion 16585
3 4 Routing and securing lines 16585
3 5 Installing coolers, condensers and radiators 16586
10 – Removing and installing engine 16587
1 Removing and installing engine 16587
1 1 Removing engine 16587
1 2 Separating engine and gearbox 16596
1 3 Securing engine on engine and gearbox support 16598
1 4 Installing engine 16599
2 Assembly mountings 16602
2 1 Assembly overview – assembly mountings 16602
2 1 1 Assembly overview – assembly mountings, manual gearbox 16602
2 1 2 Assembly overview – assembly mountings, dual clutch gearbox 16604
2 2 Supporting engine in installation position 16607
2 3 Removing and installing engine mountings 16610
2 4 Removing and installing gearbox mounting 16612
2 5 Removing and installing pendulum support 16613
2 5 1 Removing and installing pendulum support, manual gearbox 16613
2 5 2 Removing and installing pendulum support, dual clutch gearbox 16614
13 – Crankshaft group 16616
1 Cylinder block (pulley end) 16616
1 1 Assembly overview – poly V-belt drive 16616
1 1 1 Assembly overview – poly V-belt drive, vehicles without air conditioner compressor 16616
1 1 2 Assembly overview – poly V-belt drive, vehicles with air conditioner compressor 16618
1 2 Assembly overview – Sealing flange, belt pulley end 16619
1 3 Removing and installing poly V-belt 16620
1 3 1 Removing and installing poly V-belt, vehicles without air conditioner compressor 16620
1 3 2 Removing and installing poly V-belt, vehicles with air conditioner compressor 16621
1 4 Removing and installing tensioner for poly V-belt 16623
1 4 1 Removing and installing tensioner for poly V-belt, vehicles without air conditioner compressor 16623
1 4 2 Removing and installing tensioner for poly V-belt, vehicles with air conditioner compressor 16623
1 5 Removing and installing vibration damper 16623
1 6 Removing and installing engine support 16624
1 7 Renewing crankshaft oil seal – belt pulley end 16628
1 8 Removing and installing sealing flange on pulley end 16630
2 Cylinder block, gearbox end 16633
2 1 Assembly overview – cylinder block, gearbox end 16633
2 2 Removing and installing flywheel 16634
2 3 Removing and installing sealing flange on gearbox side 16635
3 Crankshaft 16644
3 1 Renewing needle bearing in crankshaft 16644
3 2 Crankshaft dimensions 16645
3 3 Measuring axial clearance of crankshaft 16645
4 Pistons and conrods 16647
4 1 Assembly overview – pistons and conrods 16647
4 2 Separating new conrod 16649
4 3 Removing and installing pistons 16649
4 4 Removing and installing oil spray jets 16650
4 5 Checking piston and cylinder bore 16651
4 6 Checking radial clearance of conrods 16652
15 – Cylinder head, valve gear 16653
1 Toothed belt drive 16653
1 1 Assembly overview – toothed belt cover 16653
1 2 Assembly overview – toothed belt 16654
1 3 Checking valve timing 16655
1 4 Detaching toothed belt from camshaft 16661
1 5 Removing and installing toothed belt 16675
2 Cylinder head 16690
2 1 Assembly overview – cylinder head 16690
2 2 Assembly overview – camshaft housing 16692
2 3 Removing and installing cylinder head 16693
2 4 Removing and installing camshaft housing 16697
2 5 Checking compression 16701
3 Valve gear 16704
3 1 Assembly overview – valve gear 16704
3 1 1 Assembly overview – valves 16704
3 2 Removing and installing camshaft control valve 1 -N205-/-N318- 16705
3 3 Removing and installing cam actuators 16706
3 3 2 Removing and installing exhaust cam actuator for cylinder 2 -N587- 16706
3 3 3 Removing and installing exhaust cam actuator for cylinder 3 -N595- 16707
3 3 4 Removing and installing inlet cam actuator for cylinder 2 -N583- 16708
3 3 5 Removing and installing inlet cam actuator for cylinder 3 -N591- 16709
3 4 Removing and installing camshaft adjuster 16709
3 5 Measuring axial play of camshaft 16710
3 6 Removing and installing camshaft oil seal 16711
3 6 1 Removing and installing camshaft oil seal for inlet camshaft, belt pulley end 16711
3 6 2 Removing and installing exhaust camshaft oil seal, pulley end 16712
3 6 3 Removing and installing exhaust camshaft oil seal, gearbox end 16714
3 7 Removing and installing valve stem seals 16716
3 7 1 Removing and installing valve stem oil seals (cylinder head installed) 16716
3 7 2 Removing and installing valve stem oil seals (cylinder head removed) 16721
4 Inlet and exhaust valves 16725
4 1 Checking valve guides 16725
4 2 Checking valves 16725
4 3 Valve dimensions 16726
17 – Lubrication 16727
1 Sump, oil pump 16727
1 1 Assembly overview – sump, oil pump 16727
1 2 Removing and installing oil level and oil temperature sender -G266- 16730
1 3 Removing and installing lower part of sump 16730
1 4 Removing and installing oil pump 16733
1 5 Removing and installing upper part of sump 16734
1 6 Engine oil 16737
2 Engine oil cooler 16738
2 1 Assembly overview – engine oil cooler 16738
2 2 Removing and installing engine oil cooler 16738
3 Crankcase breather 16740
3 1 Assembly overview – crankcase breather system 16740
3 2 Removing and installing oil separator 16741
4 Oil filter, oil pressure switch 16743
4 1 Assembly overview – oil filter/oil pressure switch 16743
4 2 Removing and installing oil pressure switch -F1- 16744
4 3 Removing and installing oil pressure switch for reduced oil pressure -F378- 16745
4 4 Removing and installing oil pressure regulating valve -N428- 16746
4 5 Checking oil pressure 16747
19 – Cooling 16750
1 Cooling system, coolant 16750
1 1 Coolant hose schematic diagram 16750
1 2 Draining and filling coolant 16753
1 3 Checking cooling system for leaks 16759
2 Coolant pump, regulation of cooling system 16762
2 1 Assembly overview – coolant pump, thermostat 16762
2 2 Assembly overview – electric coolant pump 16764
2 3 Assembly overview – coolant temperature sender 16766
2 4 Removing and installing coolant pump 16767
2 5 Removing and installing toothed belt pulley for coolant pump 16771
2 6 Removing and installing thermostat 16775
2 6 1 Removing and installing thermostat for large cooling circuit 16775
2 6 2 Removing and installing thermostat for small cooling circuit 16777
2 7 Removing and installing electric coolant pump 16778
2 7 1 Removing and installing charge air cooling pump -V188- 16778
2 8 Removing and installing coolant temperature sender -G62- 16780
2 9 Removing and installing coolant temperature sender at radiator outlet -G83- 16781
3 Coolant pipes 16783
3 1 Assembly overview – coolant pipes 16783
3 2 Removing and installing coolant pipes 16783
4 Radiator, radiator fan 16787
4 1 Assembly overview – radiator/radiator fan 16787
4 2 Assembly overview – radiator cowl and radiator fan 16789
4 3 Removing and installing radiator 16791
4 4 Removing and installing cooler for charge air cooling circuit 16794
4 5 Removing and installing radiator cowling with radiator fan 16798
4 6 Removing and installing radiator fan -V7- 16799
21 – Turbocharging/supercharging 16801
1 Turbocharger 16801
1 1 Assembly overview – turbocharger 16801
1 2 Removing and installing turbocharger 16803
1 3 Removing and installing charge pressure positioner -V465- 16807
1 3 1 Removing and installing charge pressure positioner -V465-, version 1 16807
1 3 2 Removing and installing charge pressure positioner -V465-, version 2 16808
2 Charge air system 16811
2 1 Assembly overview – charge air system 16811
2 2 Removing and installing charge pressure sender -GX26- 16813
2 3 Removing and installing charge air cooler 16813
2 4 Checking charge air system for leaks 16815
24 – Mixture preparation – injection 16817
1 Injection system 16817
1 1 Overview of fitting locations – injection system 16817
1 2 Releasing high pressure in fuel system 16820
2 Air filter 16822
2 1 Assembly overview – air filter housing 16822
2 2 Removing and installing air filter housing 16823
3 Intake manifold 16824
3 1 Assembly overview – intake manifold 16824
3 2 Removing and installing intake manifold 16826
3 3 Removing and installing throttle valve module -GX3- 16828
3 4 Cleaning throttle valve module -GX3- 16830
4 Injectors 16831
4 1 Assembly overview – fuel rail with injectors 16831
4 2 Removing and installing fuel rail 16832
4 3 Removing and installing injectors 16833
4 4 Cleaning injectors 16837
5 Senders and sensors 16839
5 1 Removing and installing intake manifold sender -GX9- 16839
5 2 Removing and installing fuel pressure sender -G247- 16839
5 3 Checking fuel pressure sender -G247- 16840
6 High-pressure pump 16844
6 1 Assembly overview – high-pressure pump 16844
6 2 Removing and installing high-pressure pump 16845
6 3 Removing and installing high-pressure pipe 16846
7 Lambda probe 16848
7 1 Assembly overview – Lambda probe 16848
7 2 Removing and installing Lambda probe 16849
7 2 1 Removing and installing lambda probe 1 before catalytic converter -GX10-/lambda probe 1 after catalytic converter -GX7- 16849
8 Engine control unit 16851
8 1 Removing and installing engine control unit -J623- 16851
8 2 Removing and installing engine control unit -J623- with protective housing 16852
26 – Exhaust system 16854
1 Exhaust pipes, silencers 16854
1 1 Assembly overview – silencers 16854
1 2 Removing and installing silencer 16855
1 3 Separating exhaust pipes, silencers 16856
1 4 Aligning exhaust system free of stress 16857
1 4 1 Aligning exhaust system free of stress 16857
1 4 2 Align end exhaust pipes 16858
1 5 Checking exhaust system for leaks 16858
2 Emission control 16859
2 1 Assembly overview – emission control 16859
2 2 Removing and installing catalytic converter 16860
28 – Ignition system 16865
1 Ignition system 16865
1 1 Assembly overview – ignition system 16865
1 2 Test data, spark plugs 16866
1 3 Removing and installing ignition coils with output stage 16866
1 4 Removing and installing knock sensor 1 -G61- 16868
1 5 Removing and installing Hall sender 16869
1 5 1 Removing and installing Hall sender -G40- 16869
1 5 2 Removing and installing Hall sender 3 -G300- 16870
1 6 Removing and installing engine speed sender -G28- 16871
D4B80609EAF Air conditioning systems with refrigerant R1234yf – General information 16873
00 – Technical data 16879
1 Safety information 16879
1 1 Safety precautions when working on air conditioning systems 16879
1 2 Safety precautions when handling refrigerants 16880
1 3 Safety measures when working on vehicles with a start/stop system 16880
1 4 Safety precautions when using air conditioner service stations 16880
1 5 Safety measures for working on vehicles with high-voltage system 16881
1 6 Safety precautions when working in the vicinity of high-voltage components 16882
1 7 Safety precautions when working on pressure vessels 16882
2 Laws and regulations 16883
2 1 Legal regulations and standards 16883
2 2 Charging refrigerant circuit with different refrigerants 16884
2 3 Occupational health and safety 16885
3 Repair notes 16886
3 1 Rules for cleanliness 16886
3 2 Refrigerant circuit seals 16886
3 3 Refrigerant and refrigerant oil 16887
3 3 1 Important repair notes for refrigerant and refrigerant oil 16887
3 3 2 Refrigerant oil 16888
3 4 Handling pressure vessels 16889
3 5 Handling refrigerants 16890
4 Identification 16892
4 1 Notice for refrigerant circuit 16892
5 Technical data 16893
5 1 Refrigerant capacity 16893
5 2 Refrigerant oil capacities 16893
5 3 Safety data sheets 16893
6 Basic technical and physical properties 16894
6 1 Basics of air conditioning technology 16894
6 1 1 Physical properties of air conditioning system 16894
6 1 2 Pressure and boiling point of refrigerant 16895
6 1 3 Vapour pressure table for refrigerant 16896
6 2 Physical properties 16898
6 2 1 Refrigerant R1234yf 16898
6 2 2 Potential risks with refrigerant R1234yf 16898
6 2 3 Physical and chemical properties of refrigerant R1234yf 16899
6 2 4 Critical point 16899
6 2 5 Environmental aspects of refrigerant R1234yf 16900
6 2 6 Trade names and designations of refrigerant R1234yf 16900
6 2 7 Colour and odour of R1234yf refrigerant 16901
6 2 8 Vapour pressure of R1234yf refrigerant 16901
6 2 9 Physical properties of R1234yf refrigerant 16901
6 2 10 How R1234yf refrigerant reacts to metals and plastics 16901
6 2 11 Critical temperature / critical pressure of R1234yf refrigerant 16902
6 2 12 Water content of R1234yf refrigerant 16902
6 2 13 Flammability / decomposition of R1234yf refrigerant 16902
6 2 14 Charge factor of refrigerant R1234yf 16902
6 2 15 Evidence of leaks in a refrigerant circuit with R1234yf refrigerant 16903
6 2 16 Analysis of refrigerant R1234yf 16903
6 2 17 Returning contaminated R1234yf refrigerant for analysis, processing or disposal 16904
6 3 Product characteristics 16905
6 4 Function and role of air conditioning system 16905
6 4 1 Principle of operation 16905
6 4 2 Comfort 16906
6 4 3 Environmental aspects 16906
6 5 Other reference material 16907
87 – Air conditioning system 16908
1 Refrigerant circuit 16908
1 1 System overview – refrigerant circuit 16908
1 1 1 System overview – refrigerant circuit with expansion valve and receiver 16908
1 1 2 System overview – refrigerant circuit with restrictor and reservoir 16910
1 1 3 System overview – refrigerant circuit with electrically driven air conditioner compressor (with and without battery cooling module) 16911
1 2 General description – components of refrigerant circuit 16914
1 2 1 Layout and function of refrigerant circuit 16914
1 2 2 Mechanical air conditioner compressor 16915
1 2 3 Electrical air conditioner compressor for hybrid vehicles 16918
1 2 4 Condenser 16921
1 2 5 evaporator 16922
1 2 6 Reservoir 16924
1 2 7 Heat exchanger for heat pump mode 16924
1 2 8 Liquid receiver 16925
1 2 9 Restrictor 16925
1 2 10 Receiver 16927
1 2 11 Expansion valve (with and without shut-off valve) 16929
1 2 12 Refrigerant shut-off valves 16931
1 2 13 Refrigerant line with internal heat exchanger 16933
1 2 14 Quick release couplings of refrigerant lines 16934
1 2 15 Seals 16935
1 2 16 Pipes and hoses in refrigerant circuit 16936
1 2 17 High-pressure safety valve 16936
1 2 18 Non-return valves 16938
1 2 19 Quick-release coupling connections in refrigerant circuit 16939
1 2 20 Connections with valve for switches in refrigerant circuit 16943
1 2 21 Pressure senders and switches in refrigerant circuit 16944
1 2 22 Refrigerant pressure and temperature sender 16945
1 2 23 Air conditioner compressor regulating valve -N280- 16948
1 2 24 Refrigerant temperature sender 16949
1 3 Possible complaints 16950
1 3 1 Prerequisites for investigating a complaint 16950
1 3 2 Possible complaints 16950
1 3 3 Odours from heater and air conditioning unit 16952
1 4 Investigating leaks 16954
1 4 1 General information about investigating leaks in the refrigerant circuit 16954
1 4 2 Searching for leaks in refrigerant circuits using an electronic leak detector 16955
1 4 3 Searching for leaks with UV leak detection system 16956
1 4 4 Detecting leaks in a vacuum test using air conditioner service station, or in a pressure test 16962
1 4 5 Detecting leaks in a pressure test (with nitrogen or compressed air) 16963
1 5 Renewing components 16965
1 5 1 General information about renewing components 16965
1 5 2 Renewing leaking or damaged components of empty refrigerant circuit (apart from air conditioner compressor and receiver) 16966
1 5 3 Renewing leaking or damaged components of charged refrigerant circuit (apart from air conditioner compressor and receiver) 16968
1 5 4 Renewing air conditioner compressor with no need to clean refrigerant circuit 16969
1 5 5 Renewing air conditioner compressor due to leaks or internal damage 16972
1 5 6 Renewing desiccant cartridge / receiver after cleaning refrigerant circuit 16973
1 5 7 Renewing receiver with no need to clean refrigerant circuit 16975
1 5 8 Renewing desiccant cartridge / desiccant bag with no need to clean refrigerant circuit 16976
1 6 Cleaning refrigerant circuit 16977
1 6 1 General information about cleaning refrigerant circuit 16977
1 6 2 Preparations for cleaning refrigerant circuit (flushing with R1234yf refrigerant) 16979
1 6 3 Refrigerant circuit cleaning procedure 16983
1 6 4 Principle circuit diagrams for cleaning (flushing circuits) – refrigerant circuit with expansion valve and receiver 16983
1 6 5 Principle circuit diagrams for cleaning (flushing circuits) – refrigerant circuit with restrictor and receiver (without high-voltage system) 16988
1 6 6 Adapters for setting up flushing circuits 16991
1 6 7 General information about blowing through with compressed air or nitrogen 17004
1 6 8 Blowing through refrigerant circuit with compressed air or nitrogen 17008
1 7 Checking pressures with pressure gauge 17009
1 7 1 Display on pressure gauges 17009
1 7 2 Pressure gauges enable the following test and measurement work 17010
2 Working with air conditioner service station 17013
2 1 Working with air conditioner service station 17014
2 2 Connecting air conditioner service station to refrigerant circuit 17016
2 3 Performing gas analysis of refrigerant 17019
2 4 Purging refrigerant circuit 17022
2 5 Evacuating refrigerant circuit 17025
2 6 Charging refrigerant circuit 17031
2 7 Bringing air conditioning system into service after charging 17034
2 8 Switching off air conditioner service station and separating from refrigerant circuit 17036
2 9 Charging refrigerant in reservoir 17038
2 10 Emptying air conditioner service station 17039
2 11 Cleaning electrical air conditioning compressor 17039
2 12 Cleaning refrigerant circuit 17042
2 13 Filling contaminated refrigerant in a recycling cylinder for analysis, processing or disposal 17045
2 13 1 Filling contaminated refrigerant into recycling cylinder using extraction unit -VAS 581 011- 17045
2 13 2 Filling contaminated refrigerant into recycling cylinder using extraction unit -VAS 581 007- 17046
2 14 Checking pressures 17050
2 14 1 General information on checking pressures in the refrigerant circuit 17050
2 14 2 Pressures and temperatures in refrigerant circuit 17052
2 14 3 Checking pressures in the refrigerant circuit with the ignition switched off 17056
2 14 4 Checking pressures with air conditioning system switched on – vehicles with mechanical air conditioning compressor 17063
2 14 5 Checking pressures with air conditioning system switched on – vehicles with electrical air conditioning compressor 17085
3 Testing equipment and tools 17138
3 1 Tools and materials available from distribution centre or importer 17138
3 2 Tools and materials available commercially 17138
D4B80788C82 General body repairs exterior 17140
50 – Body – front 17148
1 Lock carrier 17148
1 1 Assembly overview – lock carrier 17148
1 2 Removing and installing lock carrier 17149
1 3 Moving to and back from service position 17152
1 4 Releasing and engaging pressure hose with plug-in connector 17156
2 Wings 17158
2 1 Assembly overview – wing 17158
2 2 Assembly overview – insulation and foam elements 17159
2 3 Removing and installing wing 17160
2 4 Removing and installing wing bracket 17163
3 Bulkhead 17166
3 1 Assembly overview – plenum chamber bulkhead 17166
3 2 Assembly overview – plenum chamber bulkhead 17167
3 3 Assembly overview – plenum chamber cover 17168
3 4 Removing and installing plenum chamber bulkhead 17169
3 5 Removing and installing plenum chamber cover 17170
55 – Bonnet, rear lid 17174
1 Bonnet (hood) 17174
1 1 Assembly overview – bonnet 17174
1 2 Assembly overview – Bowden cable 17175
1 3 Assembly overview – bonnet release lever 17176
1 4 Removing and installing bonnet 17177
1 5 Adjusting bonnet 17180
1 6 Adjusting lid lock 17181
1 7 Adjusting striker pin 17181
1 8 Removing and installing bonnet lock 17182
1 8 1 Removing and installing lid lock, LHD vehicle 17182
1 8 2 Removing and installing lid lock, RHD vehicle 17185
1 9 Removing and installing bonnet release lever 17187
1 10 Removing and installing striker pin 17188
1 11 Removing and installing hinges 17189
1 12 Removing and installing insulation 17191
1 13 Removing and installing support rod 17193
1 14 Detaching Bowden cable 17194
2 Rear lid 17196
2 1 Assembly overview – rear lid 17196
2 2 Assembly overview – hinges 17197
2 3 Assembly overview – gas strut 17198
2 4 Removing and installing rear lid 17199
2 5 Removing and installing stop buffer 17202
2 6 Adjusting rear lid 17203
2 7 Adjusting striker pin 17205
2 8 Adjusting adjusting buffer 17207
2 9 Removing and installing rear lid lock 17208
2 10 Removing and installing operating mechanism 17210
2 11 Removing and installing hinges 17212
2 12 Removing and installing striker pin 17214
2 13 Removing and installing rear lid seal 17216
2 14 Removing and installing gas strut 17217
2 15 Releasing gas from gas strut 17219
3 Tank flap unit 17220
3 1 Assembly overview – tank flap unit 17220
3 2 Removing and installing tank flap unit 17220
3 3 Removing and installing fuel tank flap 17223
57 – Front doors, door components, central locking 17225
1 Door 17225
1 1 Assembly overview – door 17225
1 2 Removing and installing inner door seal 17227
1 3 Removing and installing outer door seal 17229
1 3 1 Removing and installing door outer seal, 2-door model 17229
1 3 2 Removing and installing door outer seal, 4-door model 17230
1 4 Removing and installing door 17231
1 5 Installing after renewing A-pillar 17233
1 6 Adjusting door 17235
1 7 Adjusting striker pin 17237
1 8 Removing and installing door arrester 17239
2 Door components 17241
2 1 Assembly overview – door components 17241
2 1 1 Assembly overview – door components, 2-door model 17241
2 1 2 Assembly overview – door components, 4-door model 17242
2 2 Assembly overview – door handle and door lock 17244
2 3 Assembly overview – insulation 17245
2 3 1 Assembly overview – insulation, 2-door model 17245
2 3 2 Assembly overview – insulation, 4-door model 17245
2 4 Removing and installing window regulator motor 17246
2 5 Removing and installing window regulator 17248
2 6 Removing and installing inner door cover 17251
2 6 1 Removing and installing inner door cover, 2-door model 17251
2 6 2 Removing and installing inner door cover, 4-door model 17252
2 7 Removing and installing striker pin 17254
2 8 Removing and installing lock cylinder cover cap 17255
2 9 Removing and installing lock cylinder 17256
2 10 Removing and installing cap without lock cylinder 17259
2 11 Removing and installing door handle 17262
2 12 Removing and installing mounting bracket 17264
2 13 Removing and installing door lock 17266
2 14 Removing and installing window channel 17270
2 15 Removing and installing window slot inner seal 17273
2 16 Removing and installing window slot outer seal 17274
2 16 1 Removing and installing outer window slot seal, 2-door model 17274
2 16 2 Removing and installing outer window slot seal, 4-door model 17276
3 Central locking 17278
3 1 Overview of fitting locations – central locking 17278
3 2 Removing and installing ignition key battery 17280
3 3 Adapting keys with remote control 17282
3 4 Removing and installing tank filler flap locking motor -V155- 17282
58 – Rear doors, door components 17284
1 Door 17284
1 1 Assembly overview – door 17284
1 2 Removing and installing inner door seal 17286
1 3 Removing and installing outer door seal 17288
1 4 Removing and installing door 17288
1 5 Installing after renewing B-pillar 17291
1 6 Adjusting door 17293
1 7 Adjusting striker pin 17296
1 8 Removing and installing door arrester 17297
2 Door components 17300
2 1 Assembly overview – door components 17300
2 2 Assembly overview – door handle and door lock 17301
2 3 Assembly overview – insulation 17302
2 4 Removing and installing window regulator motor 17303
2 5 Removing and installing window crank 17305
2 6 Removing and installing window crank mechanism 17306
2 7 Removing and installing window regulator 17308
2 8 Removing and installing inner door cover 17310
2 9 Removing and installing striker pin 17311
2 10 Removing and installing cap 17312
2 11 Removing and installing door handle 17315
2 12 Removing and installing mounting bracket 17317
2 13 Removing and installing door lock 17319
2 14 Removing and installing window channel 17322
2 15 Removing and installing window slot inner seal 17325
2 16 Removing and installing window slot outer seal 17325
60 – Sunroof 17328
1 Sliding sunroof 17328
1 1 Function 17328
1 2 Assembly overview – sliding sunroof 17330
1 3 Assembly overview – sunroof roller blind 17332
1 4 Assembly overview – sliding sunroof frame and front trim 17333
1 5 Removing and installing sliding sunroof frame 17334
1 5 1 Minimum curing period 17334
1 5 2 Fitting instructions 17334
1 5 3 Cleaning in the event of dirt caused by adhesive sealant 17335
1 5 4 Touching up paint damage 17335
1 5 5 Materials 17335
1 5 6 Preparing body flange for bonding 17336
1 5 7 Preparing sliding sunroof frame for installation 17337
1 5 8 Removing and installing sliding sunroof frame 17338
1 6 Removing and installing wind deflector 17345
1 7 Removing and installing glass panel 17346
1 8 Removing glass panel when drive is defective 17350
1 9 Adjusting glass panel 17352
1 10 Removing and installing guide plate 17354
1 11 Removing and installing front trim for sliding sunroof 17359
1 11 1 Minimum curing period 17359
1 11 2 Fitting instructions 17359
1 11 3 Cleaning in the event of dirt caused by adhesive sealant 17360
1 11 4 Materials 17360
1 11 5 Preparing front trim for installation 17360
1 11 6 Preparing sliding sunroof frame for installation of front trim 17361
1 11 7 Removing and installing front trim for sliding sunroof 17362
1 12 Removing and installing sliding sunroof adjustment control unit -J245- 17369
1 13 Removing and installing glass panel seal 17371
1 14 Removing and installing interior seal 17372
1 15 Removing and installing cover 17373
1 16 Removing and installing sunroof switch 17375
1 17 Removing and installing sunroof roller blind 17375
1 18 Removing and installing tension bow 17379
1 19 Adapting sliding sunroof adjustment control unit -J245- 17382
1 20 Operating without current 17383
2 Water drain hoses 17384
2 1 Assembly overview – water drainage hoses 17384
2 2 Cleaning water drainage hoses 17384
63 – Bumpers 17387
1 Bumper, front 17387
1 1 Assembly overview – bumper cover 17387
1 1 1 Assembly overview – bumper cover, Polo, »standard« equipment version 17387
1 1 2 Assembly overview – bumper cover, Polo BlueMotion 17388
1 1 3 Assembly overview – bumper cover, CrossPolo 17389
1 1 4 Assembly overview – bumper cover, Polo »GTI« 17390
1 1 5 Assembly overview – bumper cover, Polo »R-Line« 17391
1 2 Assembly overview – impact bar 17392
1 3 Assembly overview – add-on parts 17393
1 3 1 Assembly overview – add-on parts, Polo, »standard« equipment version 17393
1 3 2 Assembly overview – add-on parts, Polo »BlueMotion« 17394
1 3 3 Assembly overview – attachments, »Cross Polo« 17396
1 3 4 Assembly overview – add-on parts, Polo »GTI« 17398
1 3 5 Assembly overview – add-on parts, Polo »R-Line« 17400
1 4 Removing and installing bumper cover 17402
1 4 1 Removing and installing bumper cover, Polo, »standard« equipment version 17402
1 4 2 Removing and installing bumper cover, Polo BlueMotion 17406
1 4 3 Removing and installing bumper cover, CrossPolo 17410
1 4 4 Removing and installing bumper cover, Polo »GTI« 17414
1 4 5 Removing and installing bumper cover, Polo »R-Line« 17418
1 5 Installing number plate carrier 17421
1 6 Repairing bumper cover 17422
1 7 Installing brackets for parking aid system 17423
2 Bumper, rear 17428
2 1 Assembly overview – bumper cover 17428
2 1 1 Assembly overview – bumper cover, Polo, »standard« equipment version 17428
2 1 2 Assembly overview – bumper cover, Polo BlueMotion 17429
2 1 3 Assembly overview – bumper cover, CrossPolo 17430
2 1 4 Assembly overview – bumper cover, Polo GTI, Polo BlueGT 17431
2 1 5 Assembly overview – bumper cover, Polo »R-Line« 17432
2 2 Assembly overview – impact bar 17433
2 3 Assembly overview – add-on parts 17434
2 3 1 Assembly overview – add-on parts, Polo BlueMotion 17434
2 3 2 Assembly overview – attachments, Cross Polo 17435
2 3 3 Assembly overview – add-on parts, Polo GTI, Polo BlueGT 17436
2 3 4 Assembly overview – add-on parts, Polo »R-Line« 17437
2 4 Removing and installing bumper cover 17438
2 4 1 Removing and installing bumper cover, Polo, »standard« equipment version 17438
2 4 2 Removing and installing bumper cover, Polo »BlueMotion« 17441
2 4 3 Removing and installing bumper cover, CrossPolo 17444
2 4 4 Removing and installing bumper cover, Polo GTI, Polo BlueGT 17446
2 4 5 Removing and installing bumper cover, Polo »R-Line« 17449
2 5 Installing number plate carrier 17451
2 6 Repairing bumper cover 17452
2 7 Installing brackets for parking aid system 17453
64 – Glazing 17458
1 Repair instructions 17458
1 1 Minimum curing periods for bonded windows 17458
1 2 Installation instructions for bonded windows 17458
1 3 Preparing old undamaged windows for fitting 17460
1 4 Preparing new windows for installing 17460
1 5 Preparing body flange for fitting 17461
1 6 Cleaning off excess adhesive 17462
2 Windscreen 17463
2 1 Assembly overview – windscreen 17463
2 2 Removing and installing windscreen 17464
3 Rear windscreen 17469
3 1 Assembly overview – rear window 17469
3 2 Removing and installing rear window 17469
3 3 Removing broken rear window 17474
4 Side window 17475
4 1 Assembly overview – rear side windows 17475
4 1 1 Assembly overview – rear side window, 2-door model 17475
4 1 2 Assembly overview – rear side window, 4-door model 17475
4 2 Removing and installing rear side window 17476
4 2 1 Removing and installing rear side window, 2-door model 17476
4 2 2 Removing and installing rear side window, 4-door model 17480
4 3 Removing broken rear side window 17485
5 Door windows 17486
5 1 Assembly overview – front door window 17486
5 2 Assembly overview – rear door window 17486
5 3 Removing and installing front door window 17487
5 4 Removing and installing rear door window 17492
66 – Exterior equipment 17497
1 Radiator grille and front trim 17497
1 1 Assembly overview – radiator grille 17497
1 1 1 Assembly overview – radiator grille »GTI« 17497
1 1 2 Assembly overview – radiator grille 17498
1 2 Removing and installing radiator grille 17498
2 Spoiler 17502
2 1 Assembly overview – spoiler 17502
2 1 1 Assembly overview – spoiler, Polo »BlueMotion« 17502
2 1 2 Assembly overview – spoiler, Polo »GTI« 17502
2 1 3 Assembly overview – spoiler, Polo »Blue GT« 17503
2 1 4 Assembly overview – spoiler, Polo »R-Line« 17504
2 2 Removing and installing spoiler 17505
2 2 1 Removing and installing spoiler, Polo »BlueMotion« 17505
2 2 2 Removing and installing spoiler, Polo »GTI« 17509
2 2 3 Removing and installing spoiler, Polo »Blue GT«, Polo »R-Line« 17513
2 3 Removing adapter 17518
2 3 1 Removing adapter, Polo BlueMotion 17518
2 3 2 Removing adapter, Polo »GTI« 17520
2 4 Removing and installing side piece of spoiler 17522
2 4 1 Removing and installing side piece of spoiler, Polo »BlueMotion« 17522
2 4 2 Removing and installing side piece of spoiler, Polo »Blue GT« 17526
3 Mouldings, trims, extensions 17532
3 1 Assembly overview – side member trim 17532
3 1 1 Assembly overview – side member trim, Polo »BlueMotion«, Polo »Blue GT« 17532
3 1 2 Assembly overview – side member trim, Cross Polo 17533
3 1 3 Assembly overview – side member trim, Polo »GTI« 17534
3 2 Assembly overview – water deflector 17535
3 3 Assembly overview – B-pillar trim 17536
3 4 Removing and installing front door cover 17537
3 5 Removing and installing adapter for front door cover 17539
3 6 Removing and installing rear door cover 17541
3 7 Removing and installing adapter for rear door cover 17544
3 8 Removing and installing entry moulding 17546
3 8 1 Removing and installing step moulding, Polo, 2-door model 17546
3 8 2 Removing and installing step moulding, Polo, 4-door model 17547
3 9 Removing and installing side member trim 17550
3 9 1 Removing and installing side member trim, Polo »BlueMotion«, Polo »Blue GT« 17550
3 9 2 Removing and installing side member trim, Cross Polo 17554
3 9 3 Removing and installing side member trim, Polo »GTI« 17557
3 10 Removing and installing retaining strip for side member trim 17559
3 10 1 Removing and installing retaining strip for side member trim, Polo »BlueMotion«, Polo »Blue GT« 17559
3 10 2 Removing and installing retaining strip for side member trim, CrossPolo, Polo »GTI« 17561
3 11 Removing and installing water deflector 17567
3 12 Removing and installing A-pillar trim 17570
3 13 Removing and installing B-pillar trim 17571
3 14 Removing and installing C-pillar trim on door 17573
3 15 Wing trim panel 17575
3 16 Removing and installing front wheel arch trim 17577
3 17 Removing and installing rear wheel arch trim 17581
3 18 Removing and installing wheel arch trim of rear door 17585
4 Noise insulation 17589
4 1 Assembly overview – noise insulation 17589
4 1 1 Assembly overview – noise insulation, diesel engines 17589
4 1 2 Assembly overview – noise insulation, long version 17590
4 1 3 Assembly overview – noise insulation, short version 17590
5 Underbody cladding 17592
5 1 Assembly overview – underbody cladding 17592
5 2 Assembly overview – tunnel cross-piece 17592
6 Roof moulding and roof railing 17594
6 1 Assembly overview – roof railing 17594
6 2 Removing and installing roof railing 17594
7 Exterior mirror 17597
7 1 Assembly overview – exterior mirror 17597
7 2 Removing and installing exterior mirror 17598
7 2 1 Removing and installing exterior mirror, manually operated 17598
7 2 2 Removing and installing exterior mirror, electrically operated 17602
7 3 Removing and installing mirror glass 17606
7 4 Removing and installing mirror adjustment unit 17608
7 5 Removing and installing mirror cover 17609
7 6 Removing and installing mirror trim 17610
7 7 Removing and installing assembly bracket 17612
8 Wheel housing liner 17614
8 1 Assembly overview – front wheel housing liner 17614
8 2 Assembly overview – rear wheel housing liner 17615
8 3 Removing and installing front wheel housing liner 17615
8 4 Removing and installing rear wheel housing liner 17617
9 Lettering and emblems 17621
9 1 Dimensions – lettering and emblems on rear lid 17621
9 1 1 Dimensions – lettering and emblems on rear lid 17621
9 1 2 Dimensions – rear lettering, Polo “GTI” 17622
9 1 3 Dimensions – lettering and emblems on rear lid, Polo BlueMotion 17622
9 1 4 Dimensions – lettering and emblems on rear lid, Polo BlueGT 17623
9 2 Dimensions – lettering, rear door 17624
9 3 Dimensions – lettering and emblems, sides 17625
9 3 1 Side emblem on wing – “GTI” 17625
9 3 2 Side emblem on wing – special models 17626
9 4 Removing and installing badges at front 17627
9 4 1 Removing and installing emblems at vehicle front, not Polo BlueMotion, not Polo BlueGT 17627
9 4 2 Removing and installing emblems at vehicle front, Polo BlueMotion 17631
9 4 3 Removing and installing front emblems, Polo BlueGT 17635
9 4 4 Removing and installing emblems at vehicle front, Polo “R-Line” 17636
9 5 Removing and installing lettering and emblems 17637
10 Special add-on parts 17639
10 1 Repair instructions 17639
10 1 1 Safety requirements 17639
10 1 2 Preparing add-on part for installation 17639
10 1 3 Preparing body component 17640
10 1 4 Installation instructions for bonded add-on parts 17641
10 1 5 Minimum curing period for bonded add-on parts 17641
10 1 6 Cleaning off excess adhesive 17642
10 1 7 Cleaning guidelines 17642
10 2 Assembly overview – special add-on parts 17642
10 2 1 Assembly overview – special add-on parts, Polo BlueMotion 17642
10 2 2 Assembly overview – special add-on parts, Cross Polo 17643
10 2 3 Assembly overview – special add-on parts, Polo »GTI« 17644
10 2 4 Assembly overview – special add-on parts, Polo »R-Line« 17645
11 Towing bracket 17647
11 1 Assembly overview – towing bracket 17647
12 Heat shields 17648
12 1 Overview of fitting locations – heat shields 17648
12 2 Removing and installing underbody heat shield 17648
12 3 Removing and installing heat shield for centre exhaust system 17649
12 4 Removing and installing heat shield for rear silencer 17650
D4B80788C87 General body repairs interior 17653
00 – Technical data 17659
1 Safety information 17659
1 1 Safety measures when working with pyrotechnic components 17661
1 2 Storage, transportation and disposal of airbag, belt tensioner and battery isolator units (pyrotechnic components) 17662
1 3 Additional safety regulations for belt tensioners 17662
1 4 Additional safety regulations for driver airbag and front passenger airbag 17663
1 5 Additional safety instructions for curtain airbag 17663
1 6 Renewing pyrotechnic, electrical and mechanical components of the restraint system after an accident 17663
1 7 Accident without airbag triggering 17663
1 8 Checking seat belts 17664
1 9 Checking belt webbing 17664
1 10 Checking inertia reel (locking mechanism) 17665
1 11 Visually inspecting belt buckle 17666
1 12 Checking operation of belt buckle 17666
1 13 Checking belt guide fittings and latch plates 17666
1 14 Checking securing parts and anchorage points after an accident 17666
1 15 Checking child seat anchors after an accident 17667
68 – Interior equipment 17668
1 Compartments/covers 17668
1 1 Removing and installing fuse box cover 17668
1 2 Removing and installing upper steering column trim 17668
1 3 Removing and installing lower steering column trim 17669
1 4 Removing and installing glove compartment 17670
2 Equipment 17672
2 1 Removing and installing sun visor 17672
2 2 Removing and installing roof grab handle 17674
3 Centre console 17676
3 1 Removing and installing drinks holder 17676
3 2 Removing and installing parking brake cover cap 17677
3 3 Removing and installing trim for operating and display unit 17678
3 3 1 Removing and installing trim for operating and display unit, vehicles with Climatronic 17678
3 3 2 Removing and installing trim for operating and display unit, vehicles without Climatronic 17679
3 4 Removing and installing cover for centre console 17680
3 5 Removing and installing centre console 17681
3 5 1 Removing and installing centre console, centre console without armrest 17681
3 5 2 Removing and installing centre console, centre console with armrest 17685
3 6 Removing and installing centre console bracket 17688
4 Front centre armrest 17689
4 1 Removing and installing front centre armrest 17689
5 Interior mirror 17690
5 1 Removing and installing interior mirror 17690
5 1 1 Removing and installing manually operated anti-dazzle interior mirror 17690
5 1 2 Removing and installing interior mirror, interior mirror with rain and light sensor -G397- 17691
5 2 Removing and installing retaining plate 17692
5 2 1 Removing and installing retaining plate, manually adjustable interior mirror 17692
5 2 2 Removing and installing retaining plate, interior mirror with rain and light sensor -G397- 17694
69 – Passenger protection 17695
1 Seat belts 17695
1 1 Removing and installing front 3-point seat belt 17695
1 1 1 Removing and installing front 3-point seat belt, 2-door models 17695
1 1 2 Removing and installing front 3-point seat belt, 4-door models 17698
1 2 Removing and installing rear three-point seat belt 17701
1 2 1 Removing and installing rear outer three-point seat belt, 4-door models 17701
1 2 2 Removing and installing rear outer three-point seat belt, 2-door models 17702
1 2 3 Removing and installing rear middle three-point seat belt 17703
1 3 Removing and installing front belt end anchor 17704
1 4 Removing and installing belt height adjustment 17707
1 4 1 Removing and installing belt height adjuster, 2-door models 17707
1 4 2 Removing and installing belt height adjuster, 4-door models 17709
1 5 Removing and installing front belt buckle 17710
1 6 Removing and installing rear belt buckle 17711
2 Airbag control unit 17713
2 1 Removing and installing airbag control unit -J234- 17713
3 Driver side airbag 17715
3 1 Assembly overview – driver side airbag 17715
3 2 Removing and installing airbag unit with igniter 17717
3 2 1 Removing and installing airbag unit with igniter 17717
3 3 Removing and installing return spring with slip ring (coil connector) 17724
4 Front passenger side airbag 17726
4 1 Removing and installing front passenger side airbag unit with igniter 17726
5 Side airbags 17731
5 1 Removing and installing front side airbag with igniter 17731
5 1 1 Removing and installing front side airbag with igniter, vehicles without curtain airbag 17731
5 1 2 Removing and installing front side airbag with igniter, vehicles with curtain airbag 17732
6 Curtain airbags 17735
6 1 Removing and installing curtain airbag with igniter 17735
7 Airbag crash sensors 17738
7 1 Removing and installing side airbag crash sensor on driver side -G179-/side airbag crash sensor on front passenger side -G180- 17738
7 1 1 Removing and installing front side airbag crash sensor -G179-/-G180-, 2-door models 17738
7 1 2 Removing and installing front side airbag crash sensor -G179-/-G180-, 4-door models 17740
7 2 Removing and installing rear side airbag crash sensor on driver side -G256-/rear side airbag crash sensor on front passenger side -G257- 17742
8 Seat belt verification 17745
8 1 Removing and installing seat occupied sensor, front passenger side -G128- 17745
70 – Trim, insulation 17748
1 Front door trims 17748
1 1 Removing and installing door trim at front 17748
1 1 1 Removing and installing front door trim, 2-door models 17748
1 1 2 Removing and installing front door trim, 4-door models 17753
1 2 Removing and installing mirror cover trim 17757
2 Rear door trims 17760
2 1 Removing and installing rear door trim 17760
3 Dash panel 17766
3 1 Removing and installing mounting frame for radio/navigation system 17766
3 2 Removing and installing centre dash panel compartment 17766
3 3 Removing and installing mounting for storage compartment in centre dash panel 17768
3 4 Removing and installing dash panel end cover 17770
3 5 Removing and installing dash panel 17771
4 Dash panel central tube 17779
4 1 Removing and installing dash panel central tube 17779
5 Interior trims 17787
5 1 Removing and installing sill panel moulding 17787
5 1 1 Removing and installing sill panel mouldings, 2-door models 17787
5 1 2 Removing and installing sill panel mouldings, 4-door models 17788
5 2 Removing and installing A-pillar trim 17790
5 3 Detaching and attaching B-pillar trim 17794
5 3 1 Detaching and attaching B-pillar trim, 2-door models 17794
5 3 2 Detaching and attaching B-pillar trim, 4-door models 17795
5 4 Removing and installing B-pillar trim 17796
5 4 1 Removing and installing B-pillar trim, 2-door models 17796
5 4 2 Removing and installing B-pillar trim, 4-door models 17799
5 5 Releasing and securing C-pillar trim 17801
5 6 Removing and installing C-pillar trim 17804
5 6 1 Removing and installing C-pillar trim, 2-door models 17804
5 6 2 Removing and installing C-pillar trim, 4-door models 17807
5 7 Removing and installing side trim panel 17809
5 8 Removing and installing wheel housing trims 17811
5 9 Floor lining – remove and install 17813
5 9 1 Removal 17813
5 9 2 Installation 17814
6 Luggage compartment trims 17815
6 1 Removing and installing lower rear lid trim 17815
6 2 Removing and installing luggage compartment floor 17816
6 3 Removing and installing lock carrier trim 17817
6 4 Removing and installing rear shelf support 17818
6 5 Removing and installing support for variable luggage compartment floor 17821
6 6 Removing and installing luggage compartment side trim 17822
7 Roof trims 17824
7 1 Removing and installing roof end strip 17824
7 2 Removing and installing moulded headliner 17824
7 2 1 Removing and installing moulded headliner, 2-door models 17824
7 2 2 Removing and installing moulded headliner, 4-door models 17828
7 3 Mounting roof reinforcement on body 17832
72 – Seat frames 17836
1 Front seats 17836
1 1 Removing and installing front seat 17836
1 2 Removing and installing seat trim on tunnel side 17840
1 3 Removing and installing seat trim on sill side 17841
1 3 1 Removing and installing seat trim on sill side, seat without height adjustment 17841
1 3 2 Removing and installing seat trim on sill side, seat with height adjustment 17843
1 4 Removing and installing seat height adjustment operating lever 17847
1 5 Removing and installing lumbar support adjustment 17847
1 6 Removing and installing mounting for drawer 17848
1 7 Removing and installing front backrest 17850
1 8 Removing and installing head restraint guide 17853
2 Rear seats 17855
2 1 Removing and installing bench seat / individual seats 17855
2 2 Removing and installing rear seat backrest 17855
2 3 Removing and installing head restraint guide 17859
2 4 Removing and installing locking mechanism for rear seat backrest 17860
74 – Seat – padding, covers 17863
1 Front seat covers and padding 17863
1 1 Removing and installing seat cover and seat cushion for seat pan 17863
1 2 Removing and installing backrest cover and cushion 17866
2 Rear seat covers and padding 17868
2 1 Removing and installing bench seat cover and padding 17868
2 1 1 Removing and installing bench seat cover and padding, one-piece bench seat 17868
2 1 2 Removing and installing bench seat cover and padding, divided bench seat 17869
2 2 Removing and installing rear seat backrest cover and padding 17871
D4B80789DE4 Air conditioning with refrigerant R134a 17875
00 – Technical data 17879
1 General information on air conditioning 17879
1 1 Basics of air conditioning 17879
1 1 1 Physical principles: 17879
1 1 2 Heat is always transferred from a warmer material to a cooler one 17880
1 1 3 Pressure and boiling point 17880
1 2 Vapour pressure table for R134a refrigerant gas 17881
1 3 R134a refrigerant gas 17882
1 3 1 Data on the physical properties of R134a refrigerant gas 17882
1 3 2 Critical point 17882
1 3 3 Environmental aspects related to R134a refrigerant gas 17883
1 4 Properties of R134a refrigerant gas 17883
1 4 1 Trade name and designations 17883
1 4 2 Colour 17883
1 4 3 Vapour pressure 17883
1 4 4 Physical characteristics of R134a 17884
1 4 5 Reaction with metals 17884
1 4 6 Critical temperature / Critical pressure 17884
1 4 7 Water content 17884
1 4 8 Combustion 17884
1 4 9 Filling factor 17884
1 4 10 Leak detection 17885
1 5 Refrigeration system oil 17885
1 5 1 Characteristics of refrigeration system oil 17885
1 6 Comfort 17886
1 7 Environmental aspects 17886
1 8 Air conditioning effects 17886
1 9 Safety at work 17887
1 9 1 Product characteristics 17887
1 9 2 Handling refrigerant gas 17887
1 9 3 Wear protective goggles 17888
1 9 4 Use protective gloves and apron 17888
1 9 5 Refrigerant gas should never come into contact with skin 17888
1 9 6 Never inhale refrigerant gas vapours 17888
1 9 7 Smoking is strictly prohibited 17888
1 9 8 Soldering work in refrigeration systems 17888
1 9 9 Active smell 17888
1 9 10 First Aid 17889
1 9 11 Handling of pressurized tanks 17889
1 9 12 Do not heat above 50 °C 17889
1 9 13 Monitor the heating process 17889
1 9 14 Close empty containers 17889
1 9 15 Safety measures related to handling refrigerant gas suction and filling equipment 17890
1 9 16 Safety measures related to the works to be performed in vehicles with air conditioning and the handling of R134a refrigerant gas 17890
2 General remarks on the refrigerant gas loop 17892
2 1 Refrigerant gas loop components 17892
2 1 1 Distribution of refrigerant gas loop components and their influence on the high and low pressure areas 17892
2 1 2 Air conditioning compressor with magnetic coupling: 17892
2 1 3 Air conditioning compressor without magnetic coupling 17893
2 1 4 Condenser 17894
2 1 5 Evaporator 17894
2 1 6 Collection tank 17895
2 1 7 Butterfly (throttle) 17896
2 1 8 Liquid tank 17896
2 1 9 Expansion valve 17898
2 1 10 O-ring seals 17898
2 1 11 Rigid tubes and flexible tubes in the refrigerant gas loop 17899
2 1 12 Overpressure valve 17899
2 2 Refrigerant gas loop components 17900
2 2 1 Refrigerant gas loop with expansion valve and evaporator 17900
2 2 2 Refrigerant gas loop with butterfly (throttle) and collection tank 17900
2 3 Quick coupling connections in the refrigerant gas loop 17901
2 3 1 Suction and filling valve with Schrader valve 17901
2 3 2 Suction and filling valve, high pressure section 17902
2 3 3 Suction and filling valve, low pressure section 17902
2 4 Switches and sensors for the refrigerant gas loop and their connections 17902
2 4 1 Air conditioning high pressure switch -F23- 17903
2 4 2 High pressure switch for magnetic coupling -F118- 17903
2 4 3 Air conditioning low pressure switch -F73- 17903
2 4 4 Valve connections for switch in the refrigerant gas loop 17904
2 4 5 Air conditioning pressure switch -F129- 17904
2 4 6 High pressure sensor -G65- 17905
2 4 7 Pressure and temperature sensor for the refrigerant gas -G395- 17905
2 4 8 Magnetic valve for refrigerant fluid circulation -N43- 17906
2 4 9 Adjustment valve for the air conditioning compressor -N280- 17906
2 5 Electrical components not assembled in the refrigerant gas loop 17907
2 5 1 Air conditioning adjustment and control unit -J127- 17907
2 5 2 Radiator fan control unit -J293- 17907
2 5 3 Evaporator temperature switch -E33- 17908
2 5 4 Air outlet temperature sensor for the evaporator -G263- or Evaporator temperature sensor -G308- 17909
2 6 Pressures and temperatures in the refrigerant gas loop 17909
2 7 Refrigerant gas loop with expansion valve 17909
2 8 Refrigerant gas loop with butterfly (throttle) and collection tank 17911
2 9 Checking and measuring work with a pressure gauge 17913
2 9 1 Pressure gauges may be used to carry out the following checking and measuring work: 17913
2 10 Notes on doing repair work on the refrigerant gas loop 17914
3 Legislation and standards 17915
3 1 Legislation and standards 17915
3 2 Regulations on recycling and disposal 17918
3 3 Disposal of cooling agent and cooling machine oils 17918
4 Using the climate control recovery, recycling, refilling, and cleaning equipment 17919
4 1 Important notes for using the Climate control recovery, recycling and refill set or EQ 7098 -VAS 6008- 17919
4 2 Connect the Climate control recovery, recycling and refill set or EQ 7098 -VAS 6008- 17920
4 3 Empty the refrigerant gas loop with the Climate control recovery, recycling and refill set or EQ 7098 -VAS 6008- 17921
4 3 1 Sucking out the refrigerant gas 17921
4 3 2 Remove the air from the refrigerant gas loop 17922
4 4 Fill the refrigerant gas loop with the Climate control recovery, recycling and refill set or EQ 7098 -VAS 6008- 17922
4 4 1 Filling refrigerant gas 17922
4 4 2 Activating the air conditioning after filling up the loop 17923
4 5 Introduce refrigerant gas into the tank of the Climate control recovery, recycling and refill set or EQ 7098 -VAS 6008- 17923
4 6 Emptying the tank of the Climate control recovery, recycling and refill set or EQ 7098 -VAS 6008- 17924
5 Checking pressure values in the refrigerant gas loop 17925
5 1 Checking pressure values 17926
5 2 Verification for vehicles with butterfly (throttle) and collection tank (air conditioning compressor with internal adjustment device) 17928
5 2 1 Nominal values 17928
5 3 Verification for vehicles with expansion valve and liquid loop / dryer (air conditioning compressor with internal adjustment device) 17931
5 3 1 Nominal values 17931
5 4 Verification for vehicles with expansion valve, liquid tank / dryer and Adjustment valve for the air conditioning compressor -N280- (with air conditioning compressor with external adjustment device) 17935
5 4 1 Nominal values 17935
5 5 Verification for vehicles with butterfly (throttle), collection tank and regulating valve for the air conditioning compressor -N280- (with air conditioning compressor with external adjustment device) 17944
5 5 1 Nominal values 17945
6 Detecting leaks in the refrigerant gas loop 17950
6 1 Detecting leaks in the refrigerant gas loop with the R134a air conditioning leak detector or EQ 7051 -VAG 1796- 17951
6 2 Detecting leaks in the refrigerant gas loop by pressurizing the system 17951
6 3 Detection of leaks in the refrigerant gas loop with the air conditioning recovery, recycling, recharging and cleaning set 17952
7 Cleaning the refrigerant gas loop 17955
7 1 Venting the refrigerant gas loop 17955
7 2 Washing the refrigerant gas loop with R134a refrigerant gas (clean) 17957
8 Problems 17963
8 1 Possible problems in the refrigerant gas loop 17963
8 1 1 Checking conditions 17963
8 1 2 Possible problems 17963
9 Replacing components 17965
9 1 Leaking or damaged components (except the compressor, collection tank and liquid tank) 17965
9 1 1 A completely empty refrigerant gas loop 17965
9 1 2 The loop still contains refrigerant gas 17966
9 2 Replace the air conditioning compressor 17966
9 2 1 Without any need to vent the refrigerant gas circuit with compressed air and nitrogen (for example, in case of external damage caused by an accident) 17966
9 2 2 Leakage or internal damage (such as noises or lack of power) 17967
9 3 Replace the liquid/collection tank and the butterfly (throttle) 17967
9 3 1 After cleaning the refrigerant gas loop or in case of impurities 17968
9 3 2 No need to clean, no leaks and no penetration of humidity and impurities in the refrigerant gas loop 17968
10 Test equipment and tools 17970
10 1 List of test equipment, tools, and material 17970
10 2 Test equipment, tools, and material 17970
D4B80796BA2 Wheels and Tyres Guide General Information 17973
44 – Wheels, tyres, vehicle geometry 17977
1 Instructions on using the guide 17977
1 1 Overview 17977
1 1 1 Wheels and Tyres Guide – General Information 17977
1 1 2 Wheels and Tyres Guide – Vehicle-specific Section 17977
1 2 General information 17977
1 3 Notes 17978
1 4 Explanations regarding world regions 17979
1 5 Definition of tyre package 17979
1 6 Procedure for determining the required tyre package 17980
1 6 1 Determining the required tyre package via PR number 17980
1 6 2 Determining the required tyre package via version key in the vehicle registration certificate part 1 17980
1 7 Vehicle registration certificate part 1 17981
2 Legislative and technical conditions 17983
2 1 Legislative conditions 17983
2 1 1 Permissible wheel and tyre combinations in Germany 17983
2 1 2 Vehicles with Tyre Pressure Monitoring System 17983
2 2 Technical conditions 17984
2 3 Load-carrying capacity depending on vehicle speed, winter tyres 17984
2 4 Vehicle registration documents since 1 10 2005 17986
2 5 COC document (EEC Certificate of Conformity) 17987
2 6 EU general type approval number, sales type and sales or trade designation 17987
3 Wheel change 17989
3 1 Fitting instructions 17989
3 2 Protecting wheel centring seat against corrosion 17992
3 3 Fitting wheels 17993
3 4 Position of anti-theft wheel bolts for steel wheels 17993
4 Fitting tyre 17994
4 1 Pressing tyre off wheel rim 17994
4 2 Removing tyre sealant 17994
4 3 Removing tyre from wheel 17995
4 3 1 Removing tyres, wheels without and with tyre pressure monitoring 17995
4 3 2 Removing tyres, run-flat tyres, ultra-high-performance tyres 17996
4 4 Ensuring proper assembly temperature for tyres 17998
4 5 Mounting tyre 17999
4 5 1 Mounting tyre, wheels without and with tyre pressure monitoring 17999
4 5 2 Mounting tyre, run-flat tyres, ultra-high performance tyres 18001
4 6 Matching wheel rims and tyres 18004
4 7 Checking radial and lateral runout of wheels and tyres 18005
4 7 1 Checking radial and lateral runout of wheels and tyres, tolerances 18005
4 7 2 Checking radial and lateral runout on wheels and tyres with tyre gauge 18005
4 8 Matching wheels and tyres 18006
4 9 Balancing wheel 18007
4 9 1 Conditions 18007
4 9 2 Balancing wheel on stationary wheel balancer 18008
4 9 3 Balancing wheel with finish balancer 18011
4 9 4 Checking radial and lateral run-out on wheel rim 18012
4 10 Tyre sealant disposal 18013
5 Tyre pressure monitoring system 18014
5 1 System description – tyre pressure monitoring system 18014
5 1 1 System description – tyre pressure monitoring system with indirect measurement (Tyre Pressure Loss Indicator) 18014
5 1 2 System description – tyre pressure monitoring system with direct measurement (Tyre Pressure Monitoring System) 18015
5 1 3 System description – tyre pressure monitoring system, tyre pressure monitoring system (TPMS) with autolocation 18016
5 2 Overview of fitting locations – tyre pressure monitor system 18016
5 2 1 Overview of fitting locations – Tyre Pressure Monitoring System (TPMS) with autolocation 18016
5 3 Assembly overview – tyre pressure sensor 18018
5 3 1 Assembly overview – tyre pressure sensor, tyre pressure sensor with valve 18018
5 3 2 Assembly overview – tyre pressure sensor, tyre pressure sensor without valve, version 1 18019
5 3 3 Assembly overview – tyre pressure sensor, tyre pressure sensor without valve, version 2 18020
5 4 Removing and installing tyre pressure sensor -G222-/-G223-/-G224-/-G225- 18021
5 4 1 Removing and installing tyre pressure sensor, tyre pressure sensor with valve 18021
5 4 2 Removing and installing tyre pressure sensor, tyre pressure sensor without valve, version 1 (customer service version) 18022
5 4 3 Removing and installing tyre pressure sensor, tyre pressure sensor without valve, version 1 (production version) 18023
5 4 4 Removing and installing tyre pressure sensor -G222-/-G223-/-G224-/-G225-, version 2 18025
5 5 Removing and installing tyre pressure monitor control unit -J502- 18028
5 5 1 Removing and installing Tyre Pressure Monitoring System control unit -J502-, Arteon 2018, Passat 2015, Passat Estate 2015 18028
5 5 2 Removing and installing tyre pressure monitoring system control unit -J502-, Touran 18029
6 Wheel bolts 18031
6 1 Wheel bolts, versions 18031
6 2 Wheel bolts, anti-theft wheel bolt 18032
6 3 Wheel bolts, adapter sets for anti-theft wheel bolts 18032
7 Information on tyres 18035
7 1 Identification markings on the tyre sidewall 18035
7 2 Tyre dimension 18037
7 3 Load rating code/load index (LI) 18037
7 4 Speed rating code 18038
7 5 EU tyre label 18038
7 5 1 EU tyre label, summary 18038
7 5 2 EU tyre label, objectives 18039
7 5 3 EU tyre label, categories 18040
7 6 Structure of a radial belted tyre 18043
7 6 1 Cross section of a radial belted tyre 18043
7 6 2 Run-flat tyres, structure and identification of a SST tyre 18044
7 6 3 Run-flat tyres, seal inside technology 18045
7 7 Run-flat tyre, SST (Self Supporting Tyre) 18047
7 7 1 Run-flat tyres – general information 18047
7 7 2 Run-flat tyres, retrofitting/requirements when using run-flat tyres 18048
7 7 3 Run-flat tyres, repair work 18049
7 8 Tyre storage 18049
7 9 Reinforced and Extra Load (XL) tyres 18049
7 10 Winter tyres 18050
7 11 Winter tyres with speed symbol V 18052
7 12 Rolling resistance optimised tyres 18053
7 13 Tyre ageing 18053
7 14 Tyres with flange protection 18055
7 15 Tyre sizes for vehicles with four-wheel drive 18055
7 16 Increase in temperature due to insufficient tyre pressure 18056
8 Tyre sealant 18057
8 1 Models with breakdown set 18057
8 2 Storage life 18057
8 3 Waste disposal 18057
9 Information on wheel rims 18058
9 1 Structure of wheel rim 18058
9 2 Identification 18059
9 3 Composite wheels 18059
9 4 Care and maintenance of alloy wheel rims 18059
9 5 Restoring alloy wheels 18060
9 6 Removing and installing hub cover for alloy wheels with open threaded connection 18060
9 7 Renewing trim elements 18061
9 7 1 Renewing trim elements, bonded trim elements 18061
9 7 2 Renewing trim elements, bolted trim elements 18065
9 8 Removing and installing valve 18067
9 8 1 Removing and installing valve, description of the valve 18067
9 8 2 Removing and installing valve, rubber valve 18067
9 8 3 Removing and installing valve, metal valve 18068
10 Handling problems 18070
10 1 Rolling noise 18070
10 1 1 General notes on tyre noise 18070
10 1 2 Flat spots (from locking wheels) 18071
10 2 Vehicle pulls to one side 18072
10 2 1 General information 18072
10 2 2 Conicity 18072
10 2 3 Remedies when vehicle pulls to one side 18073
10 2 4 Strategic rotation of wheels for non-directional tyres 18074
10 2 5 Strategic rotation of wheels having unidirectional tyres 18075
10 3 Vibration 18076
10 3 1 Vibration, causes for vibration 18076
10 3 2 Vibration, conducting a road test before balancing wheels 18076
10 3 3 Vibration, vibration control system 18077
10 4 Eliminating flat spots caused by storage or handling 18077
11 Evaluating tyres 18079
11 1 Flat spots caused by storage or handling 18079
11 2 Undulations 18079
11 3 Saw-tooth wear 18080
11 4 Flat spots caused by hard braking 18080
11 5 Swellings in the tyre sidewall 18080
11 6 Cuts 18082
11 7 Damage caused by foreign bodies 18082
11 8 Stripped profile 18082
11 9 Tyre damage due to insufficient tyre pressure 18083
11 10 Checking tyres 18083
11 11 Damage caused when fitting 18084
12 Tyre wear 18086
12 1 Factors influencing the service life of tyres 18086
12 2 Saw-tooth wear 18087
12 3 Wear behaviour of high-speed tyres 18087
12 4 Measuring tread depth 18088
12 5 One-sided wear 18088
12 6 Outer shoulder wear 18091
12 7 Diagonal washout 18092
12 8 Wear in middle of tyre 18092
12 9 Permissible deviation in tread depth 18093
13 Exploded view of components 18094
13 1 Assembly overview – wheel 18094
14 Snow chains 18096
14 1 Assembly and use of snow chains 18096
15 Regular and temporary spare wheels, recommended temporary spare tyres 18097
15 1 Spare wheel with yellow sticker 18097
15 2 Temporary spare wheels and recommended temporary spare tyres 18098
15 2 1 Arteon 2018 18098
15 2 2 Atlas 2017 18098
15 2 3 Golf 2013, e-Golf 2014 18098
15 2 4 Golf 2017, e-Golf 2017 18098
15 2 5 Golf SV 2015 18099
15 2 6 Golf Estate 2014 18099
15 2 7 Golf Estate 2017 18099
15 2 8 Passat 2015, Passat Estate 2015 18099
15 2 9 Polo 2018 18100
15 2 10 Tiguan 2016 18100
D4B802605A6 General information Paint passenger vehicles 18101
00 – Technical data 18107
1 Safety information 18107
1 1 Safety precautions when painting natural gas-powered vehicles 18107
1 2 Safety precautions when painting electric drive vehicles 18108
2 General information 18109
2 1 Paintwork structure of a factory finish 18109
2 2 Paint structure of service department finish 18112
2 2 1 Paintwork structure, base coat 18112
2 2 2 Paintwork structure, metallic effect 18115
2 3 Fundamental approach to dealing with areas sanded through to the substrate (bare metal surface) 18117
2 4 Reduced paint structure in engine compartment and inside of bonnet 18117
2 5 Instructions for work on underbody and stone chip protection 18117
2 6 Work instruction for window flange area 18119
2 7 Pre-treatment of bonded surfaces when renewing laser-welded roofs 18121
2 8 Corrosion protection measures for wing surface in contact with wheel housing liner 18125
2 9 Notes on treating corroded fold areas 18126
2 10 Corrosion protection for body components, add-on components and welded components 18128
2 11 Painting parking aid sensor 18129
2 12 ACC – Adaptive Cruise Control 18131
2 13 Instructions for painting bumper cover in area of lane change assist control unit 18131
3 Genuine products 18133
3 1 Paint products in customer service 18133
3 2 General application instructions for repair and painting systems 18134
3 2 1 Aqua Premium – application instructions for water-based products 18134
3 2 2 Setting gloss level of HS clear coats and HS top coats with matting additive 18137
3 2 3 Setting gloss level of 2-pack HS clear coats with 2-pack clear coat, matt 18147
3 2 4 Repair paintwork system for matt-finished vehicles 18149
3 2 5 Paintwork system for plastic components 18154
3 2 6 Aqua Premium system, blending system for 2-stage colours 18162
3 2 7 Aqua Premium system, blending system for 3-stage colours 18171
3 2 8 Aqua Premium system, product preparation for processing 18178
3 2 9 Aquaplus design and multi-colour painting 18185
3 2 10 Processing instructions for paint with limited hiding power 18190
3 3 Filler 18190
3 3 1 2-pack steel filler set 18190
3 3 2 2-pack fine filler 18194
3 3 3 2-pack fine filler, flexible 18198
3 3 4 2-pack spray filler 18201
3 3 5 2-pack IR premium filler 18207
3 3 6 2-pack epoxy resin filler 18212
3 4 Priming metal 18216
3 4 1 1-pack anti-corrosion wash primer 18216
3 4 2 1-pack wash primer 18221
3 4 3 2-pack wash primer 18226
3 5 Priming plastic materials 18232
3 5 1 Adhesion promoter (transparent) 18232
3 6 Surfacer 18236
3 6 1 2-pack HS Vario surfacer 18236
3 6 2 2-pack HS premium surfacer 18246
3 6 3 2-pack HS Performance surfacer 18255
3 6 4 2-pack primer surfacer for plastics 18264
3 6 5 2-pack HS wet-on-wet surfacer 18270
3 6 6 2-pack base filler, professional 18280
3 7 Top coats 18297
3 7 1 2-pack HS top coat 18297
3 7 2 Aquaplus system, uni (solid-colour) and metallic colours 18306
3 7 3 Aquaplus system (pearlescent and heliochrome) 18314
3 7 4 Aquaplus blending system 18322
3 7 5 Aqua Premium system 18328
3 7 6 Aqua Premium blending system 18341
3 7 7 Aqua Premium system (painting rims) 18348
3 8 Clear coats 18357
3 8 1 2-pack HS clear coat 18357
3 8 2 2-pack MS matt clear coat 18364
3 8 3 2-pack HS Vario clear coat 18370
3 8 4 2-pack HS optimum clear coat 18378
3 8 5 2-pack HS optimum plus clear coat 18384
3 8 6 2-pack HS brilliant clear coat 18389
3 8 7 2-pack HS brilliant plus clear coat 18394
3 8 8 2-pack HS Performance clear coat 18400
3 8 9 Blender 18406
3 9 Hardener 18411
3 9 1 2-pack HS hardener 18411
3 9 2 2-pack VHS hardeners and 2-pack VHS Performance hardeners 18415
3 9 3 Hardener for 2-pack primer surfacer 18419
3 9 4 Aqua Premium hardener 18419
3 10 Thinners 18420
3 10 1 2-pack thinner 18420
3 10 2 HS spot thinner 18423
3 10 3 Demineralised water 18425
3 11 Anti-corrosion materials 18426
3 11 1 Anti-corrosion wax 18426
3 11 2 Cavity sealant 18427
3 11 3 Anti-corrosion wax (in aerosol can) 18430
3 12 Underseal 18431
3 12 1 Permanent underseal -D 314 D36 M2-, grey 18431
3 12 2 Permanent underseal -D 314 D37 M2-, black 18434
3 12 3 Permanent underseal -D 314 D38 M2-, light 18437
3 12 4 Underseal -D 314 D39 A3-, black 18440
3 13 Stone deflector 18442
3 13 1 Stone chip guard -AKR 311 KD1 05- 18442
3 13 2 Stone chip guard -AKR 311 KD1 10- 18444
3 14 Wax-based underseal 18451
3 14 1 Wax-based underseal -D 316 D38 A2- 18451
3 14 2 Wax-based underseal -D 316 000 A1- 18453
3 14 3 Spray wax -D 322 100 M2- 18455
3 15 Sealing materials 18456
3 15 1 Polyurethane adhesive sealant (bonding compound) 18456
3 15 2 Sprayable sealant 18459
3 15 3 Adhesive sealant 18462
3 16 Cleaning agents 18464
3 16 1 Silicone remover 18464
3 16 2 Cleaner for plastics 18466
3 16 3 Cleaner for plastics, anti-static 18467
3 16 4 Industrial dirt remover 18467
3 17 SprayMax system 18469
3 17 1 1-pack anti-corrosion primer 18469
3 17 2 1-pack test paint 18473
3 17 3 1-pack clear coat 18476
3 17 4 1-pack wash primer 18479
3 17 5 1-pack Fill Clean spray can -LLS MAX 099-/1-pack Fill Clean spray can -LLS MAX 100- – Aquaplus system 18484
3 17 6 1-pack fill clean spray can -LLS MAX 112-, Aqua Premium system 18491
3 17 7 2-pack surfacer 18499
3 17 8 2-pack HS Performance surfacer 18506
3 17 9 2-pack clear coat 18514
3 17 10 2-pack epoxy primer surfacer 18519
3 17 11 2-pack wash primer 18525
3 17 12 Silicone remover -LLS MAX 007- 18531
3 17 13 Slow-drying silicone remover -LLS MAX 008- 18533
3 17 14 Blender 18536
3 17 15 Adhesion promoter 18538
3 18 Additional materials 18542
3 18 1 Matting additive -ALN 775 106- 18542
3 18 2 Matting additive -LVM 769 810 A2- 18549
3 18 3 Texture additive 18552
3 18 4 Blending additive for Aquaplus 18558
3 18 5 Additive for Aqua Premium 18559
4 Workshop equipment 18560
4 1 Tools 18560
4 1 1 Spray can filling device -VAS 6425- 18560
4 1 2 Paint thickness tester -VAS 6272- 18561
4 1 3 Paint thickness tester -VAS 6197- 18562
4 1 4 Paint thickness tester -VAS 5278- 18562
4 1 5 Stone chip tester -VAS 5102A- 18563
4 1 6 Pneumatic brush grinder set -VAS 6446- 18564
4 1 7 Brush grinder set -VAS 6776- 18564
4 1 8 Suction feed spray-gun -V A G 1538- 18566
4 1 9 Infrared heater -VAS 6873- 18567
4 1 10 Stand -VAS 6873/1- 18567
4 1 11 Infrared heater -VAS 6874- 18568
4 1 12 Infrared heater -VAS 6875- 18569
4 1 13 Infrared heater -VAS 6876- 18569
4 1 14 Infrared heater -VAS 6877- 18570
4 1 15 Infrared heater -VAS 6878- 18571
4 1 16 Infrared heater -VAS 6879- 18572
4 2 Tack cloths 18572
4 2 1 Tack cloth -VAS 6177- 18572
4 2 2 Buffing cloth, white -VAS 6176- 18573
D4B802791D7 4 cylinder direct injection engine (1 2 l engine 4V EA 211 turbocharger) 18574
00 – Technical data 18580
1 Safety information 18580
1 1 Safety regulations for working on fuel supply 18580
1 2 Safety measures when working on vehicles with a start/stop system 18580
1 3 Safety precautions for when using test instruments and measuring equipment during a road test 18581
1 4 Safety precautions when working on the cooling system 18581
1 5 Safety precautions when working on ignition system 18581
2 Identification 18582
2 1 Engine number/engine data 18582
3 Repair instructions 18584
3 1 Rules for cleanliness 18584
3 2 General information 18584
3 3 General repair notes 18585
3 4 Foreign objects in engine 18585
3 5 Contact corrosion 18585
3 6 Routing and attachment of lines 18585
3 7 Fitting radiator and condensers 18585
3 8 Checking vacuum system 18585
10 – Removing and installing engine 18587
1 Removing and installing engine 18587
1 1 Removing engine 18587
1 1 1 Removing engine, Golf, Golf Estate, Golf SV, Touran 18587
1 1 2 Removing engine, Golf Cabriolet 18600
1 1 3 Removing engine, Polo 18612
1 2 Separating engine and gearbox 18625
1 3 Securing engine on engine and gearbox support 18626
1 4 Installing engine 18628
2 Assembly mountings 18632
2 1 Assembly overview – assembly mountings 18632
2 1 1 Assembly overview – assembly mountings, Golf, Golf Estate, Golf SV, Touran 18632
2 1 2 Assembly overview – assembly mountings, Golf Cabriolet 18634
2 1 3 Assembly overview – assembly mountings, Polo with dual clutch gearbox 18636
2 1 4 Assembly overview – assembly mountings, Polo with manual gearbox 18639
2 2 Removing and installing engine mounting 18642
2 2 1 Removing and installing engine mounting, Golf, Golf Estate, Golf SV, Touran 18642
2 2 2 Removing and installing engine mounting, Golf Cabriolet 18643
2 2 3 Removing and installing engine mounting, Polo 18645
2 3 Removing and installing gearbox mounting 18648
2 3 1 Removing and installing gearbox mounting, Golf, Golf Estate, Golf SV, Touran, Golf Cabriolet 18648
2 3 2 Removing and installing gearbox mountings, Polo 18650
2 4 Removing and installing pendulum support 18652
2 4 1 Removing and installing pendulum support, Golf, Golf Estate, Golf SV, Touran, Golf Cabriolet 18652
2 4 2 Removing and installing pendulum support, Polo 18653
2 5 Supporting engine in installation position 18656
2 5 1 Supporting engine in installation position, Golf, Golf Estate, Golf SV 18656
2 5 2 Supporting engine in installation position, Touran 18662
2 5 3 Supporting engine in installation position, Golf Cabriolet 18668
2 5 4 Supporting engine in installation position, Polo 18672
2 6 Adjusting assembly mountings 18675
2 7 Checking adjustment of assembly mountings 18677
2 7 1 Checking adjustment of assembly mountings, Golf, Golf Estate, Golf SV, Touran 18677
2 7 2 Checking assembly mounting settings, Golf Cabriolet 18678
2 7 3 Checking assembly mounting settings, Polo 18678
13 – Crankshaft group 18680
1 Cylinder block (pulley end) 18680
1 1 Assembly overview – poly V-belt drive 18680
1 1 1 Assembly overview – poly V-belt drive, vehicles without air conditioner compressor 18680
1 1 2 Assembly overview – poly V-belt drive, vehicles with air conditioner compressor 18682
1 2 Removing and installing poly-V belt 18684
1 2 1 Removing and installing poly V-belt, vehicles without air conditioner compressor 18684
1 2 2 Removing and installing poly V-belt, vehicles with air conditioner compressor 18686
1 3 Removing and installing tensioner for poly V-belt 18688
1 4 Removing and installing vibration damper 18688
1 5 Removing and installing engine support 18691
1 6 Renewing crankshaft oil seal – belt pulley end 18694
2 Cylinder block, gearbox end 18698
2 1 Assembly overview – cylinder block, gearbox end 18698
2 2 Removing and installing flywheel 18699
2 3 Removing and installing sealing flange on gearbox side 18701
3 Crankshaft 18713
3 1 Crankshaft dimensions 18713
3 2 Measuring axial clearance of crankshaft 18713
3 3 Renewing needle bearing in crankshaft 18714
4 Pistons and conrods 18718
4 1 Assembly overview – pistons and conrods 18718
4 2 Removing and installing pistons 18720
4 3 Checking pistons and cylinder bores 18722
4 4 Separating new conrod 18724
4 5 Checking radial clearance of conrods 18724
4 6 Removing and installing oil spray jets 18725
4 7 Setting piston to TDC position 18726
15 – Cylinder head, valve gear 18731
1 Cylinder head 18731
1 1 Assembly overview – cylinder head 18731
1 2 Assembly overview – camshaft housing 18733
1 3 Removing and installing cylinder head 18735
1 4 Removing and installing camshaft housing 18740
1 5 Checking compression 18744
2 Toothed belt drive 18747
2 1 Assembly overview – toothed belt cover 18747
2 2 Assembly overview – toothed belt 18747
2 3 Removing and installing toothed belt guard 18749
2 3 1 Removing and installing upper toothed belt guard 18749
2 3 2 Removing and installing lower toothed belt guard 18750
2 4 Preassembling and installing valve timing tool 18751
2 4 1 Preassembling test tool -VAS 611 007- 18751
2 4 2 Installing test tool -VAS 611 007- 18754
2 4 3 Teaching-in test tool -VAS 611 007- electronically and performing basic setting 18758
2 5 Removing and installing toothed belt 18761
2 6 Checking valve timing 18767
2 7 Adjusting valve timing 18769
2 8 Removing toothed belt from camshaft 18780
3 Valve gear 18786
3 1 Assembly overview – valve gear 18786
3 2 Measuring axial play of camshaft 18788
3 3 Removing and installing camshaft adjuster 18789
3 4 Removing and installing toothed belt pulley 18794
3 5 Removing and installing camshaft oil seal 18797
3 5 1 Removing and installing camshaft oil seal for inlet camshaft, belt pulley end 18797
3 5 2 Removing and installing exhaust camshaft oil seal, pulley end 18800
3 5 3 Removing and installing exhaust camshaft oil seal, gearbox end 18801
3 6 Removing and installing camshaft control valve 1 -N205- 18804
3 7 Removing and installing valve stem seals 18805
3 7 1 Removing and installing valve stem seals (cylinder head installed) 18805
3 7 2 Removing and installing valve stem seals (cylinder head removed) 18810
4 Inlet and exhaust valves 18816
4 1 Checking valve guides 18816
4 2 Checking valves 18817
4 3 Valve dimensions 18817
17 – Lubrication 18818
1 Sump, oil pump 18818
1 1 Assembly overview – sump/oil pump 18818
1 2 Engine oil: 18823
1 3 Removing and installing sump 18823
1 4 Removing and installing oil pump 18830
1 5 Removing and installing oil level and oil temperature sender -G266- 18833
2 Engine oil cooler 18834
2 1 Assembly overview – engine oil cooler 18834
2 2 Removing and installing engine oil cooler 18834
3 Crankcase ventilation 18836
3 1 Assembly overview – crankcase breather system 18836
3 2 Removing and installing oil separator 18837
4 Oil filter, oil pressure switch 18840
4 1 Assembly overview – oil filter/oil pressure switch 18840
4 2 Removing and installing oil pressure switch for reduced oil pressure -F378- 18841
4 3 Checking oil pressure and oil pressure switch 18842
4 4 Removing and installing oil filter housing 18844
19 – Cooling 18845
1 Cooling system/coolant 18845
1 1 Connection diagram – coolant hoses 18845
1 1 1 Connection diagram – coolant hoses 18845
1 1 2 Connection diagram – coolant hoses, vehicles with engine preheating element -Z97- 18848
1 2 Checking cooling system for leaks 18849
1 3 Draining and adding coolant 18853
2 Coolant pump, regulation of cooling system 18865
2 1 Assembly overview – coolant pump, thermostat 18865
2 2 Assembly overview – electric coolant pump 18868
2 3 Assembly overview – coolant temperature sender 18869
2 3 1 Assembly overview – coolant temperature sender, Golf, Golf Estate, Golf SV, Touran, Golf Cabriolet 18869
2 3 2 Assembly overview – coolant temperature sender, Polo 18870
2 4 Removing and installing electric coolant pump 18871
2 5 Removing and installing coolant pump 18873
2 6 Removing and installing thermostat 18879
2 6 1 Removing and installing thermostat for main coolant circuit 18879
2 6 2 Removing and installing thermostat for cylinder block coolant circuit 18881
2 7 Removing and installing toothed belt pulley for coolant pump 18882
2 8 Removing and installing coolant temperature sender -G62- 18884
2 9 Removing and installing radiator outlet coolant temperature sender -G83- 18885
2 10 Removing and installing radiator fan thermal switch -F18- 18886
3 Coolant pipes 18888
3 1 Assembly overview – coolant pipes 18888
3 2 Removing and installing coolant pipes 18888
4 Radiator, radiator fan 18893
4 1 Assembly overview – radiator/radiator fan 18893
4 1 1 Assembly overview – radiator/radiator fan, Golf, Golf Estate, Golf SV, Touran, version 1 18893
4 1 2 Assembly overview – radiator/radiator fan, Golf, Golf Estate, Golf SV, Touran, version 2 18895
4 1 3 Assembly overview – radiator/radiator fan, Golf Cabriolet 18897
4 1 4 Assembly overview – radiator/radiator fan, Polo 18899
4 1 5 Plug-in connectors of coolant hoses 18901
4 1 6 Coolant hoses with pretensioned spring-type clips 18901
4 2 Assembly overview – radiator cowl and radiator fan 18902
4 2 1 Assembly overview – radiator cowl and radiator fan, Golf, Golf Estate, Golf SV, Touran 18902
4 2 2 Assembly overview – radiator cowl and radiator fan, Golf Cabriolet 18903
4 2 3 Assembly overview – radiator cowl and radiator fan, Polo 18904
4 3 Removing and installing radiator 18905
4 3 1 Removing and installing radiator, Golf, Golf Estate, Golf SV, Touran version 1 18905
4 3 2 Removing and installing radiator, Golf, Golf Estate, Golf SV, Touran version 2 18908
4 3 3 Removing and installing radiator, Golf Cabriolet 18911
4 3 4 Removing and installing radiator, Polo 18912
4 4 Removing and installing water radiator for charge air cooling circuit 18915
4 4 1 Removing and installing water radiator for charge air cooling circuit, Golf, Golf Estate, SV, Touran version 1 18915
4 4 2 Removing and installing water radiator for charge air cooling circuit, Golf, Golf Estate, SV, Touran version 2 18920
4 4 3 Removing and installing water radiator for charge air cooling circuit, Golf Cabriolet 18920
4 4 4 Removing and installing water radiator for charge air cooling circuit, Polo 18922
4 5 Removing and installing radiator cowl 18925
4 5 1 Removing and installing radiator cowl, Golf, Golf Estate, Golf SV, Touran 18925
4 5 2 Removing and installing radiator cowl, Golf Cabriolet 18927
4 5 3 Removing and installing radiator cowl, Polo 18929
4 6 Removing and installing radiator fan -V7- 18932
4 6 1 Removing and installing radiator fan, Golf, Golf Estate, Golf SV, Touran 18932
4 6 2 Removing and installing radiator fan, Golf Cabriolet 18932
4 6 3 Removing and installing radiator fan -V7-, Polo 18933
21 – Turbocharging/supercharging 18935
1 Turbocharger 18935
1 1 Assembly overview – turbocharger 18935
1 1 1 Assembly overview – turbocharger 18935
1 1 2 Assembly overview – lines on turbocharger 18936
1 2 Removing and installing turbocharger 18938
1 3 Removing and installing charge pressure positioner -V465- 18942
1 4 Removing and installing connection for turbocharger 18943
2 Charge air system 18947
2 1 Assembly overview – charge air system 18947
2 2 Removing and installing charge air cooler 18949
2 3 Removing and installing charge pressure sender -GX26- 18952
2 4 Checking charge air system for leaks 18953
2 5 Removing and installing air pipe 18956
24 – Mixture preparation – injection 18959
1 Injection system 18959
1 1 Overview of fitting locations – injection system 18959
1 1 1 Overview of fitting locations – engine compartment, Golf, Golf Estate, Golf SV, Touran 18959
1 1 2 Overview of fitting locations – engine compartment, Golf Cabriolet 18961
1 1 3 Overview of fitting locations – engine compartment, Polo 18963
1 1 4 Overview of fitting locations – front view of engine 18965
1 1 5 Overview of fitting locations – rear view of engine 18966
2 Air filter 18968
2 1 Assembly overview – air filter housing 18968
2 1 1 Assembly overview – air filter housing, Golf, Golf Estate, Golf SV, Touran 18968
2 1 2 Assembly overview – air filter housing, Golf Cabriolet 18969
2 1 3 Assembly overview – air filter housing, Polo 18970
2 2 Removing and installing air filter housing 18971
2 3 Removing and installing resonator for intake air 18973
3 Intake manifold 18974
3 1 Assembly overview – intake manifold 18974
3 2 Removing and installing intake manifold 18977
3 3 Removing and installing throttle valve module -GX3- 18979
3 4 Cleaning throttle valve module -GX3- 18980
4 Injectors 18982
4 1 Assembly overview – fuel rail with injectors 18982
4 2 Removing and installing fuel rail 18984
4 3 Removing and installing injectors 18985
4 3 1 Removing and installing injectors, Bosch 18985
4 3 2 Removing and installing injectors, Continental 18992
4 4 Cleaning injectors 18999
5 Senders and sensors 19001
5 1 Removing and installing intake manifold sender -GX9- 19001
5 2 Removing and installing fuel pressure sender -G247- 19001
5 3 Checking fuel pressure sender -G247- 19003
6 High-pressure pump 19005
6 1 Assembly overview – high-pressure pump 19005
6 2 Removing and installing high-pressure pump 19007
6 3 Removing and installing high-pressure pipe 19009
7 Lambda probe 19012
7 1 Assembly overview – Lambda probe 19012
7 2 Removing and installing Lambda probe 19013
7 2 1 Removing and installing Lambda probe 1 before catalytic converter -GX10- 19013
7 2 2 Removing and installing Lambda probe 1 after catalytic converter -GX7- 19014
8 Engine control unit 19016
8 1 Removing and installing engine control unit -J623- 19016
8 1 1 Removing and installing engine control unit -J623- (with metal locking plate) 19016
8 1 2 Removing and installing engine control unit -J623- (with protective housing) 19019
8 1 3 Removing and installing engine control unit -J623- without protective housing, Golf Cabriolet 19022
8 1 4 Removing and installing engine control unit -J623- with protective housing, Golf Cabriolet 19024
8 1 5 Removing and installing engine control unit -J623-, Polo 19029
8 1 6 Disconnecting engine control unit -J623- from protective housing, Polo 19030
8 2 Assembly overview – engine/motor control unit 19031
26 – Exhaust system 19032
1 Exhaust pipes and silencers 19032
1 1 Assembly overview – silencers 19032
1 1 1 Assembly overview – silencers, Golf Saloon, Golf SV 19032
1 1 2 Assembly overview – silencers, Golf Estate 19034
1 1 3 Assembly overview – silencers, Touran 19037
1 1 4 Assembly overview – silencers, Golf Cabriolet 19040
1 1 5 Assembly overview – silencers, Polo 19042
1 2 Separating exhaust pipes from silencers 19044
1 2 1 Separating exhaust pipes, silencers, Golf Saloon, Golf SV 19044
1 2 2 Separating exhaust pipes/silencers, estate 19045
1 2 3 Separating exhaust pipes/silencers, Touran 19046
1 2 4 Separating exhaust pipes/silencers, Golf Cabriolet 19047
1 2 5 Separating exhaust pipes/silencers, Polo 19049
1 3 Removing and installing silencer 19050
1 3 1 Removing and installing front silencer, Golf, Golf Estate, Golf SV, Touran 19050
1 3 2 Removing and installing rear silencer, Golf, Golf Estate, Golf SV 19051
1 3 3 Removing and installing rear silencer, Touran 19053
1 3 4 Removing and installing silencer, Golf Cabriolet 19054
1 3 5 Removing and installing front silencer, Polo 19056
1 3 6 Removing and installing rear silencer, Polo 19057
1 4 Aligning exhaust system free of stress 19058
1 5 Checking exhaust system for leaks 19059
1 6 Installation position of clamp 19059
2 Emission control 19061
2 1 Assembly overview – emission control 19061
2 1 1 Assembly overview – emission control, Golf, Golf Estate, Golf SV, Touran, Golf Cabriolet 19061
2 1 2 Assembly overview – exhaust gas treatment, Polo 19063
2 2 Removing and installing catalytic converter 19066
2 2 1 Removing and installing catalytic converter, Golf, Golf Estate, Golf SV, Touran, Golf Cabriolet 19066
2 2 2 Removing and installing catalytic converter, Polo 19070
28 – Ignition system 19077
1 Ignition system 19077
1 1 Assembly overview – ignition system 19077
1 2 Removing and installing ignition coils with output stage 19079
1 3 Removing and installing knock sensor 1 -G61- 19081
1 4 Removing and installing Hall sender 19082
1 5 Removing and installing engine speed sender -G28- 19082
D4B802791F6 7 speed dual clutch gearbox 0CW 19084
00 – Technical data 19088
1 Safety information 19088
1 1 General safety provisions 19088
1 2 Safety measures when working on vehicles with a start/stop system 19088
1 3 Safety precautions when using testers and measuring instruments during a road test 19089
1 4 Safety precautions when tow-starting or towing 19089
2 Identification 19090
2 1 Gearbox identification 19090
3 Repair notes 19091
3 1 General information 19091
3 2 General repair instructions 19092
3 3 Gaskets, seals 19093
3 4 Nuts and bolts 19093
4 Technical data 19095
4 1 Capacities 19095
5 Overview – power transmission 19097
5 1 Overview – power transmission – front-wheel drive 19097
30 – Clutch 19098
1 Clutch mechanism 19098
1 1 Assembly overview – clutch engagement mechanism 19098
1 2 Removing and installing clutch engagement mechanism 19100
1 3 Adjusting clutch engagement mechanism 19104
2 Clutch 19120
2 1 Assembly overview – dual clutch 19120
2 2 Removing dual clutch 19122
2 3 Installing dual clutch 19127
2 4 Renewing input shaft seal 19133
2 5 Renewing oil seal for inner input shaft 19135
34 – Controls, housing 19138
1 Mechatronic unit 19138
1 1 Assembly overview – mechatronic unit 19138
1 2 Removing and installing mechatronic unit 19140
1 3 Moving mechatronic unit for dual clutch gearbox -J743- into removal position by hand 19157
1 4 Renewing clutch actuator piston 19159
1 5 Renewing control unit for mechatronic unit for dual clutch gearbox -J743- 19165
2 Selector mechanism 19171
2 1 Assembly overview – selector mechanism 19171
2 1 1 Assembly overview – selector mechanism, manufacturer ZF 19171
2 1 2 Assembly overview – selector mechanism, manufacturer ECS 19173
2 2 Manual release from position P 19175
2 2 1 Manual release mechanism from position P, Golf 2013 ►, Golf Estate 2014 ►, Golf 2017 ►, Golf Estate 2017 ► 19175
2 2 2 Manual release from position P, Polo 2014 ► 19176
2 2 3 Emergency release from position P, Golf SV 2015 ►, Golf SV 2018 ► 19177
2 2 4 Manual release mechanism from position P, Passat 2015 ►, Passat Estate 2015 ►, Passat 2019 ►, Passat Estate 2019 ► 19178
2 2 5 Manual release from position P, Touran 2016 ► 19179
2 2 6 Manual release from position P, Polo, Taigo, Virtbus 19180
2 2 7 Emergency release from position P, T-Roc, T-Roc Cabriolet 19181
2 3 Removing and installing selector lever handle 19182
2 3 1 Removing and installing selector lever handle, Golf 2013 ►, Golf Estate 2014 ►, Golf 2017 ►, Golf Estate 2017 ► 19182
2 3 2 Removing and installing selector lever handle, Passat 2015 ►, Passat Estate 2015 ►, Passat 2019 ►, Passat Estate 2019 ► 19185
2 3 3 Removing and installing selector lever handle, Polo, Taigo, Virtbus, Golf SV 2015 ►, Golf SV 2018 ► 19189
2 3 4 Removing and installing selector lever handle, Touran 2016 ► 19192
2 3 5 Removing and installing selector lever handle, T-Roc 2018 ►, T-Roc Cabriolet 2020 ► 19195
2 4 Bringing interlock button in handle into installation position 19198
2 5 Removing and installing selector mechanism 19201
2 5 1 Removing and installing selector mechanism with selector lever cable 19201
2 5 2 Removing and installing selector mechanism without selector lever cable, manufacturer ZF 19204
2 5 3 Removing and installing selector mechanism without selector lever cable, manufacturer ECS 19207
2 6 Adjusting selector mechanism 19210
2 7 Removing and installing gear selector cable 19215
2 7 1 Removing and installing selector lever cable, manufacturer ZF 19215
2 7 2 Removing and installing selector lever cable, manufacturer ECS 19219
2 8 Checking selector mechanism 19221
2 9 Checking and adjusting selector lever cable 19223
2 10 Renewing selector shaft seal 19225
3 Removing and installing gearbox 19226
3 1 Removing gearbox 19226
3 1 1 Removing gearbox, Golf 2013 ►, Golf Estate 2014 ►, Golf SV 2015 ►, Golf 2017 ►, Golf Estate 2017 ►, Golf SV 2018 ►, vehicles with 1 0 l, 1 2 l and 1 4 l petrol engines and 1 4 l natural gas engine 19226
3 1 2 Removing gearbox, Golf 2013 ►, Golf Estate 2014 ►, Golf 2017 ►, Golf Estate 2017 ►, vehicles with diesel engine 19233
3 1 3 Removing gearbox, Golf SV 2015 ►, Golf SV 2018 ►, vehicles with diesel engine 19239
3 1 4 Removing gearbox, Polo 2014 ►, vehicles with 1 0 l, 1 2 l and 1 4 l petrol engine 19246
3 1 5 Removing gearbox, Polo 2014 ►, vehicles with diesel engine 19254
3 1 6 Removing gearbox, Passat 2015 ►, Passat Estate 2015 ►, Passat 2019 ►, Passat Estate 2019 ►, vehicles with diesel engine 19261
3 1 7 Removing gearbox, Polo 2014 ►, vehicles with 1 8 l petrol engine 19267
3 1 8 Removing gearbox, Passat 2015 ►, Passat estate 2015 ►, Passat 2019 ►, vehicles with 1 4 l petrol engine 19274
3 1 9 Removing gearbox, Passat 2015 ►, Passat Estate 2015 ►, vehicles with 1 8 l petrol engine 19280
3 1 10 Removing gearbox, Touran 2016 ►, vehicles with 1 4 l petrol engine 19287
3 1 11 Removing gearbox, Touran 2016 ►, vehicles with diesel engine 19293
3 1 12 Removing gearbox, Touran 2016 ►, vehicles with 1 8 l petrol engine 19300
3 1 13 Removing gearbox, Golf 2017 ►, Golf Estate 2017 ►, Golf SV 2018 ►, vehicles with 1 5 l petrol engine 19306
3 1 14 Removing gearbox, Polo, vehicles with 1 0 l petrol engine 19313
3 1 15 Removing gearbox, T-Roc, T-Roc Cabriolet, vehicles with 1 5 l petrol engine 19321
3 1 16 Removing gearbox, Polo 2018 ►, vehicles with diesel engine 19328
3 1 17 Removing gearbox, Passat 2015 ►, Passat estate 2015 ►, Passat 2019 ►, Passat estate 2019 ►, vehicles with 1 5 l petrol engine 19334
3 1 18 Removing gearbox, Touran 2016 ►, vehicles with 1 5 l petrol engine 19340
3 1 19 Removing gearbox, Polo 2018 ►, Polo 2022 ►, Virtbus, Taigo vehicles with 1 5 l petrol engine 19347
3 2 Installing gearbox 19353
3 3 Specified torques for gearbox 19359
4 Assembly mountings 19361
4 1 Assembly overview – assembly mountings 19361
4 1 1 Assembly overview – assembly mountings, Golf, Golf Estate, Golf SV, Passat, Passat Estate, Touran, T-Roc, T-Roc Cabriolet, Polo, Virtbus, Taigo 19361
4 1 2 Assembly overview – assembly mountings, Polo 2014 ► 19363
5 Gearbox transport 19365
6 Securing to engine and gearbox support 19367
7 Gear oil 19370
7 1 Draining and filling gear oil 19370
7 2 Draining and filling hydraulic fluid for mechatronic unit 19373
35 – Gears, shafts 19377
1 Parking lock 19377
1 1 Removing and installing cover for parking lock 19377
1 2 Removing and installing parking lock 19378
39 – Final drive – differential 19380
1 Oil seals 19380
1 1 Overview of fitting locations – oil seals 19380
1 2 Renewing left seal 19380
1 3 Renewing right seal 19384
1 3 1 Renewing right oil seal, gearboxes with flange shaft 19384
1 3 2 Renewing right oil seal, gearboxes with stub shaft 19389
D4B804021C9 Fuel supply system petrol engines 19392
00 – Technical data 19396
1 Safety information 19396
1 1 Safety regulations for working on fuel supply 19396
1 2 Safety precautions when using testers and measuring instruments during a road test 19396
1 3 Safety measures when working on vehicles with start/stop system 19397
2 Identification 19398
2 1 Engine number/engine data 19398
3 General information 19399
3 1 Rules for cleanliness when working on auxiliary/supplementary heater and fuel system 19399
20 – Fuel supply system 19400
1 Fuel 19400
1 1 Assembly overview – fuel tank 19400
1 1 1 Assembly overview – fuel tank, hatchback 19400
1 1 2 Assembly overview – fuel tank, saloon 19404
1 2 Emptying fuel tank 19407
1 2 1 Emptying fuel tank when fuel pump is intact 19407
1 2 2 Emptying fuel tank if it is more than 3/4 full 19412
1 2 3 Emptying fuel tank if it is less than 3/4 full 19415
1 3 Removing and installing fuel tank 19419
1 3 1 Removing and installing fuel tank, hatchback 19419
1 3 2 Removing and installing fuel tank, saloon 19424
2 Fuel delivery unit, fuel gauge sender 19430
2 1 Assembly overview – fuel delivery unit/fuel gauge sender 19430
2 1 1 Assembly overview – fuel delivery unit and fuel gauge sender, vehicles with union nut 19430
2 1 2 Assembly overview – fuel delivery unit and fuel gauge sender, vehicles with locking ring 19432
2 1 3 Assembly overview – fuel delivery unit/fuel gauge sender, vehicles with auxiliary heater 19434
2 2 Removing and installing fuel delivery unit, fuel gauge sender 19435
2 2 1 Removing and installing fuel delivery unit/fuel gauge sender, hatchback 19435
2 2 2 Removing and installing fuel line for auxiliary/supplementary heater 19440
2 2 3 Removing and installing fuel delivery unit/fuel gauge sender, saloon 19442
2 3 Removing and installing fuel gauge sender -G- 19447
3 Plug-in connectors 19451
3 1 Separating plug-in connectors 19451
4 Fuel filter 19458
4 1 Assembly overview – fuel filter 19458
4 2 Removing and installing fuel filter 19458
5 Activated charcoal filter system 19461
5 1 Assembly overview – activated charcoal filter system 19461
5 1 1 Assembly overview – activated charcoal filter, hatchback 19461
5 1 2 Assembly overview – activated charcoal filter, saloon 19461
5 1 3 Assembly overview – activated charcoal filter, 1 4 l engine 19462
5 1 4 Assembly overview – activated charcoal filter, 1 6 l engine 19463
5 2 Removing and installing activated charcoal filter 19464
5 2 1 Removing and installing activated charcoal filter, hatchback 19464
5 2 2 Removing and installing activated charcoal filter, Saloon 19466
5 3 Checking fuel tank breather 19466
6 Accelerator pedal 19472
6 1 Assembly overview – accelerator module 19472
6 2 Removing and installing accelerator pedal module -GX2- 19472
7 Fuel pump 19475
7 1 Checking fuel system pressurisation pump -G6- 19475
7 1 1 Checking function and voltage supply 19475
7 1 2 Checking function and voltage supply, vehicles with engine codes CWVA, CWVB, CHYA, CHYB 19480
7 1 3 Checking fuel pressure 19485
7 1 4 Checking fuel pressure, vehicles with engine codes CWVA, CWVB, CHYA, CHYB 19492
7 1 5 Checking holding pressure 19499
7 1 6 Checking holding pressure, vehicles with engine codes CWVA, CWVB, CHYA, CHYB 19506
7 1 7 Checking fuel delivery rate 19514
7 1 8 Checking delivery rate, vehicles with engine codes CWVA, CWVB, CHYA, CHYB 19526
7 1 9 Checking current consumption 19537
D4B804021DC Heating air conditioner 19541
00 – Technical data 19547
1 Safety information 19547
1 1 Safety precautions when working on air conditioning systems 19547
1 2 Safety precautions when handling refrigerants 19547
1 3 Safety measures when working on vehicles with a start/stop system 19548
1 4 Safety precautions when working on the cooling system 19548
2 General information 19549
2 1 Notes concerning odours in air conditioned vehicles 19549
2 2 Notes for vehicles with a start/stop system 19549
2 3 Type plates 19550
3 Repair instructions 19552
3 1 Working on refrigerant circuit 19552
3 2 General repair instructions 19552
3 3 Refrigerant circuit seals 19552
4 Technical data 19554
4 1 Refrigerant capacity 19554
4 1 1 Capacities for refrigerant R134a 19554
4 1 2 Capacities for refrigerant R1234yf 19554
4 2 Refrigerant oil capacities 19554
4 2 1 Refrigerant oil capacities, refrigerant R134a 19554
4 2 2 Refrigerant oil capacities, refrigerant R1234yf 19555
4 3 Oil distribution 19555
80 – Heating 19556
1 Overview of fitting locations – heating 19556
1 1 Overview of fitting locations – components not located in passenger compartment 19556
1 1 1 Overview of fitting locations – components not located in passenger compartment, left-hand drive vehicles 19556
1 1 2 Overview of fitting locations – components not located in passenger compartment, right-hand drive vehicles 19557
1 2 Overview of fitting locations – components located in front section of passenger compartment 19558
1 2 1 Overview of fitting locations – components inside of front passenger compartment, left-hand drive vehicles 19558
1 2 2 Overview of fitting locations – components inside of front passenger compartment, right-hand drive vehicles 19559
2 Heater 19561
2 1 Assembly overview – heater unit 19561
2 2 Removing and installing fresh air blower -V2- 19563
2 3 Removing and installing fresh air blower series resistor with overheating fuse -N24- 19563
2 4 Removing and installing dust and pollen filter 19563
2 5 Removing and installing heat exchanger 19563
2 6 Removing and installing heater unit 19563
2 7 Dismantling and assembling heater unit 19563
2 8 Checking auxiliary air heater element -Z35- 19565
2 9 Removing and installing auxiliary air heater element -Z35- 19565
2 10 Removing and installing flexible shafts 19565
3 Control motors 19566
3 1 Overview of fitting locations – front control motors 19566
3 1 1 Overview of fitting locations – front control motors, LHD vehicles 19566
3 1 2 Overview of fitting locations – front control motors, RHD vehicles 19567
3 2 Removing and installing air distribution flap actuator 19567
3 3 Removing and installing temperature flap actuator 19569
3 3 1 Removing and installing temperature flap actuator, left-hand drive vehicles 19569
3 3 2 Removing and installing temperature flap actuator, right-hand drive vehicles 19571
3 4 Removing and installing fresh air and air recirculation flap control motor -V154- 19572
4 Air duct 19573
4 1 Assembly overview – air duct and air distribution in passenger compartment 19573
4 2 Removing and installing centre vent at front 19573
4 3 Removing and installing right or left vent 19573
4 4 Removing and installing driver side footwell vents 19573
4 5 Removing and installing front passenger side footwell vents 19573
4 6 Removing and installing rear air duct 19573
4 7 Checking forced ventilation for passenger compartment 19573
4 8 Removing and installing forced ventilation for passenger compartment 19574
4 9 Removing and installing fresh air intake 19574
4 10 Removing and installing air duct for defroster vent 19574
4 11 Removing and installing air duct for centre vent 19574
5 Operating and display unit 19575
5 1 Overview of fitting locations – operating and display unit 19575
5 2 Removing and installing operating and display unit 19575
5 3 Pin assignment for multi-pin connectors on back of operating and display unit, heated and fresh air 19576
6 Other controlling and regulating components 19577
6 1 Removing and installing ambient temperature sensor -G17- 19577
87 – Air conditioning system 19578
1 Overview of fitting locations – air conditioning system 19578
1 1 Overview of fitting locations – components not located in passenger compartment 19578
1 1 1 Overview of fitting locations – components not located in passenger compartment, left-hand drive vehicles 19578
1 1 2 Overview of fitting locations – components not located in passenger compartment, right-hand drive vehicles 19580
1 2 Overview of fitting locations – components located in front section of passenger compartment 19582
1 2 1 Overview of fitting locations – components in front passenger compartment, left-hand drive vehicles with electric/manual air conditioning system 19582
1 2 2 Overview of fitting locations – components located in front section of passenger compartment, RHD vehicles, air conditioning system with electric/manual controls 19584
1 2 3 Overview of fitting locations – components inside front passenger compartment, left-hand drive vehicles with Climatronic 19586
1 2 4 Overview of fitting locations – components inside front passenger compartment, right-hand drive vehicles with Climatronic 19588
2 Refrigerant circuit 19591
2 1 System overview – refrigerant circuit 19591
2 2 Assembly overview – condenser 19594
2 3 Removing and installing evacuating and charging valves on low and high-pressure side 19596
2 4 Removing and installing high-pressure sender -G65- 19598
2 5 Removing and installing condenser 19600
2 6 Removing and installing desiccant bag or cartridge 19603
2 7 Removing and installing expansion valve 19606
3 Air conditioner compressor 19610
3 1 Assembly overview – drive unit of air conditioner compressor 19610
3 2 Assembly overview – pulley 19611
3 3 Removing air conditioning compressor from and installing on bracket 19612
3 4 Removing and installing air conditioner compressor 19613
3 5 Removing and installing pulley 19619
3 6 Checking high-pressure safety valve on air conditioner compressor 19620
4 Control motors 19621
4 1 Overview of fitting locations – front control motors 19621
4 1 1 Overview of fitting locations – front control motors, air conditioning system with electric/manual controls, left-hand drive vehicles 19621
4 1 2 Overview of fitting locations – front control motors, air conditioning system with electric/manual controls, right-hand drive vehicles 19623
4 1 3 Overview of fitting locations – front control motors, Climatronic, left-hand drive vehicles 19624
4 1 4 Overview of fitting locations – front control motors, Climatronic, right-hand drive vehicles 19625
4 2 Removing and installing temperature flap control motor -V68- 19625
4 2 1 Removing and installing temperature flap control motor -V68-, left-hand drive vehicles 19625
4 2 2 Removing and installing temperature flap control motor -V68-, right-hand drive vehicles 19626
4 3 Removing and installing defroster flap control motor -V107-/temperature flap control motor -V68- 19627
4 3 1 Removing and installing defroster flap control motor -V107-/temperature flap control motor -V68-, left-hand drive vehicles 19627
4 3 2 Removing and installing defroster flap control motor -V107-/temperature flap control motor -V68-, right-hand drive vehicles 19629
4 4 Removing and installing fresh air and air recirculation flap control motor -V154- 19631
4 5 Removing and installing fresh air/air recirculation, air flow flap control motor -V425- 19632
4 5 1 Removing and installing fresh air/air recirculation, air flow flap control motor -V425-, left-hand drive vehicles 19632
4 5 2 Removing and installing fresh air/air recirculation, air flow flap control motor -V425-, RHD vehicles 19633
4 6 Removing and installing air distribution flap control motor -V428- 19634
4 6 1 Removing and installing air distribution flap control motor -V428-, left-hand drive vehicles 19634
4 6 2 Removing and installing air distribution flap control motor -V428-, right-hand drive vehicles 19635
4 7 Locally manufacturing an adapter cable to activate control motors 19636
5 Front heater and air conditioning unit 19638
5 1 Assembly overview – heater and air conditioning unit 19638
5 1 1 Assembly overview – heater and air conditioning unit, electric/manual air conditioning system, left-hand drive vehicles 19638
5 1 2 Assembly overview – heater and air conditioning unit, electric/manual air conditioning system, right-hand drive vehicles 19640
5 1 3 Assembly overview – heater and air conditioning unit, Climatronic (LHD vehicles) 19642
5 1 4 Assembly overview – heater and air conditioning unit, Climatronic (RHD vehicles) 19644
5 2 Assembly overview – evaporator housing 19647
5 3 Removing and installing evaporator 19648
5 4 Removing and installing heater and air conditioning unit 19648
5 4 1 Removing and installing heater and air conditioning unit, left-hand drive vehicles 19648
5 4 2 Removing and installing heater and air conditioning unit, right-hand drive vehicles 19652
5 5 Dismantling and assembling heater and air conditioning unit 19655
5 6 Removing and installing fresh air blower -V2- 19657
5 6 1 Removing and installing fresh air blower -V2-, left-hand drive vehicles 19657
5 6 2 Removing and installing fresh air blower -V2-, right-hand drive vehicles 19658
5 7 Removing and installing fresh air blower series resistor with overheating fuse -N24- 19660
5 7 1 Removing and installing fresh air blower series resistor with overheating fuse -N24-, left-hand drive vehicles 19660
5 7 2 Removing and installing fresh air blower series resistor with overheating fuse -N24-, right-hand drive vehicles 19660
5 8 Removing and installing dust and pollen filter 19661
5 8 1 Removing and installing dust and pollen filter, left-hand drive vehicles 19661
5 8 2 Removing and installing dust and pollen filter, right-hand drive vehicles 19661
5 9 Dismantling and assembling evaporator housing 19662
5 10 Checking auxiliary air heater element -Z35- 19663
5 11 Removing and installing auxiliary air heater element -Z35- 19666
5 12 Checking condensation drain 19667
5 13 Removing and installing fresh air blower control unit -J126- 19667
5 13 1 Removing and installing fresh air blower control unit -J126-, left-hand drive vehicles 19667
5 13 2 Removing and installing fresh air blower control unit -J126-, right-hand drive vehicles 19668
5 14 Removing and installing heat exchanger 19669
5 15 Removing and installing evaporator temperature sensor -G308- 19673
5 15 1 Removing and installing evaporator temperature sensor -G308-, left-hand drive vehicles 19673
5 15 2 Removing and installing evaporator temperature sensor -G308-, right-hand drive vehicles 19674
5 16 Removing and installing flexible shaft 19675
6 Air duct 19676
6 1 Assembly overview – air duct and air distribution in passenger compartment 19676
6 2 Removing and installing centre vent at front 19677
6 3 Removing and installing right or left vent 19678
6 4 Removing and installing driver side footwell vents 19678
6 4 1 Removing and installing driver side footwell vents, left-hand drive vehicles 19678
6 4 2 Removing and installing driver side footwell vents, right-hand drive vehicles 19679
6 5 Removing and installing front passenger side footwell vents 19679
6 5 1 Removing and installing front passenger side footwell vents, left-hand drive vehicles 19679
6 5 2 Removing and installing front passenger side footwell vents, right-hand drive vehicles 19679
6 6 Removing and installing rear footwell vent 19680
6 7 Removing and installing forced ventilation for passenger compartment 19680
6 8 Checking forced ventilation for passenger compartment 19681
6 9 Removing and installing fresh air intake 19682
6 9 1 Removing and installing fresh air intake, left-hand drive vehicles 19682
6 9 2 Removing and installing fresh air intake , right-hand drive vehicles 19683
6 10 Removing and installing air duct for defroster vent 19684
6 11 Removing and installing air duct for centre vent 19684
7 Operating and display unit 19685
7 1 Overview of fitting locations – operating and display unit 19685
7 1 1 Overview of fitting locations – operating and display unit, air conditioning system with electric/manual controls 19685
7 1 2 Overview of fitting locations – operating and display unit, Climatronic 19686
7 2 Removing and installing operating and display unit 19687
7 2 1 Removing and installing operating and display unit, air conditioning system with electric/manual controls 19687
7 2 2 Removing and installing operating and display unit, Climatronic 19688
7 3 Multi-pin connector pin assignment on back of operating and display unit 19689
7 3 1 Multi-pin connector pin assignment on back of operating and display unit, electric/manual air conditioning system 19689
7 3 2 Multi-pin connector pin assignment on back of operating and display unit, Climatronic 19689
8 Other controlling and regulating components 19690
8 1 Removing and installing sunlight penetration photosensor -G107- 19690
8 2 Removing and installing centre vent temperature sender -G191- 19691
8 2 1 Removing and installing centre vent temperature sender -G191-, left-hand drive vehicles 19691
8 2 2 Removing and installing centre vent temperature sender -G191-, right-hand drive vehicles 19691
8 3 Removing and installing footwell vent temperature sender -G192- 19692
8 4 Removing and installing radiator fan control unit -J293- 19692
8 5 Removing and installing ambient temperature sensor -G17- 19693
D4B804088FD Running gear axles steering 19694
00 – Technical data 19700
1 Evaluating accident vehicles 19700
1 1 Checklist for evaluating running gear on accident vehicles 19700
2 Safety information 19702
2 1 Safety measures when working on vehicles with a start/stop system 19702
2 2 Safety precautions when working on subframe 19702
3 Repair instructions 19703
3 1 Steering rack 19703
3 2 Gaskets and seals 19703
3 3 Nuts and bolts 19703
3 4 Repairing damaged threads in longitudinal member (subframe to body) 19703
3 5 Electrical components 19704
3 6 Raising suspension to unladen position (vehicles with coil springs) 19704
3 6 1 Raising wheel bearing assembly to unladen position (vehicles with coil springs), front axle 19704
3 6 2 Raising wheel bearing assembly to unladen position (vehicles with coil springs), rear axle 19706
40 – Front suspension 19709
1 Front axle 19709
1 1 Overview – front axle 19709
2 Subframe 19710
2 1 Assembly overview – subframe 19710
2 2 Fixing position of subframe 19712
2 3 Removing and installing subframe without steering rack 19714
2 4 Removing and installing subframe with steering rack 19716
2 5 Removing and installing anti-roll bar 19718
2 6 Renewing anti-roll bar bushes 19720
3 Suspension strut, upper suspension link 19723
3 1 Assembly overview – suspension strut, upper suspension link 19723
3 1 1 Assembly overview – suspension strut, upper suspension link, basic version of running gear 19723
3 1 2 Assembly overview – suspension strut, upper suspension link, “Sport Select” running gear 19725
3 2 Removing and installing suspension strut 19726
3 2 1 Removing and installing suspension strut, basic version of running gear 19726
3 2 2 Removing and installing suspension strut, “Sport Select” running gear 19732
3 3 Repairing suspension strut 19740
4 Lower suspension link, swivel joint 19744
4 1 Removing and installing lower suspension link 19744
4 1 1 Removing and installing lower suspension link, vehicles with manual gearbox 19744
4 1 2 Removing and installing lower suspension link, vehicles with automatic or dual clutch gearbox 19746
4 2 Checking swivel joint 19749
4 3 Removing and installing swivel joint 19749
4 4 Renewing front bonded rubber bush for lower suspension link 19752
4 5 Renewing rear bonded rubber bush for lower suspension link 19755
5 Wheel bearing 19758
5 1 Assembly overview – wheel bearing 19758
5 2 Removing and installing wheel bearing housing 19759
5 3 Removing and installing wheel bearing unit 19761
6 Drive shaft 19770
6 1 Overview – drive shaft 19770
6 2 Assembly overview – drive shaft 19771
6 2 1 Assembly overview – drive shaft, joint body TS1800 19771
6 2 2 Assembly overview – drive shaft, constant velocity joints VL90 and VL100 19773
6 2 3 Assembly overview – drive shaft, constant velocity joint VL107, threaded connection 19775
6 2 4 Assembly overview – drive shaft, constant velocity joint VL107, plug-in connection 19777
6 3 Removing and installing drive shaft 19779
6 3 1 Removing and installing drive shaft, joint body TS1800 19779
6 3 2 Removing and installing drive shaft, constant velocity joint, threaded connection 19783
6 3 3 Removing and installing drive shaft, constant velocity joint, plug-in connection 19786
6 4 Removing and installing joint body 19791
6 5 Removing and installing drive shaft heat shield 19795
6 6 Dismantling and assembling drive shaft 19795
6 6 1 Dismantling and assembling drive shaft, joint body TS1800 19795
6 6 2 Dismantling and assembling drive shaft, constant velocity joints VL90 and VL100 19800
6 6 3 Dismantling and assembling drive shaft, constant velocity joint VL107, threaded connection 19806
6 6 4 Dismantling and assembling drive shaft, constant velocity joint VL107, plug-in connection 19812
6 7 Checking outer constant velocity joint 19817
6 8 Checking inner constant velocity joint 19818
42 – Rear suspension 19820
1 Rear axle 19820
1 1 Overview – rear axle 19820
1 2 Removing and installing rear axle 19822
2 Axle beam 19826
2 1 Assembly overview – axle beam 19826
2 1 1 Assembly overview – axle beam, drum brake 19826
2 1 2 Assembly overview – axle beam, disc brake 19828
2 2 Renewing bonded rubber bush for axle beam 19830
3 Suspension strut, shock absorber, spring 19836
3 1 Assembly overview – suspension strut, shock absorber, spring 19836
3 1 1 Assembly overview – suspension strut/shock absorber, spring, basic version of running gear 19836
3 1 2 Assembly overview – suspension strut/shock absorber, spring, “Sport Select” running gear 19837
3 2 Removing and installing shock absorbers 19838
3 2 1 Removing and installing shock absorber, basic version of running gear 19838
3 2 2 Removing and installing shock absorber, “Sport Select” running gear 19839
3 3 Repairing shock absorber 19841
3 3 1 Repairing shock absorber, basic version of running gear 19841
3 3 2 Repairing shock absorber, “Sport Select” running gear 19842
3 4 Removing and installing spring 19845
3 4 1 Removing and installing spring, vehicles with small rear silencer 19845
3 4 2 Removing and installing spring, vehicles with large rear silencer 19846
4 Wheel bearing assembly, trailing arm 19848
4 1 Assembly overview – wheel bearing 19848
4 1 1 Assembly overview – wheel bearings, drum brake 19848
4 1 2 Assembly overview – wheel bearings, disc brake 19849
4 2 Removing and installing wheel bearing unit 19850
4 2 1 Removing and installing wheel bearing unit, vehicles with drum brake 19850
4 2 2 Removing and installing wheel bearing unit, vehicles with disc brake 19852
43 – Self-levelling suspension 19854
1 Electronically controlled damping system 19854
1 1 Assembly overview – electronically controlled damping system 19854
1 2 Removing and installing electronically controlled damping control unit -J250- 19854
2 Vehicle level sender 19856
2 1 Assembly overview – rear vehicle level senders 19856
2 2 Removing and installing rear vehicle level senders -G76-/-G77- 19856
44 – Wheels, tyres, vehicle geometry 19858
1 Wheels, tyres 19858
1 1 Pressing tyre off wheel rim 19858
1 2 Removing tyre from wheel 19858
1 3 Mounting tyre 19859
1 4 Wheel change 19859
1 4 1 Wheel change, protecting wheel centring seat against corrosion 19859
1 4 2 Wheel change, installation requirements 19860
1 4 3 Wheel change, installation instructions for wheel change 19861
1 4 4 Wheel change, wheel installation 19862
1 5 Specified torques for wheel bolts 19863
1 6 Tyre sealant 19863
1 7 Tyre sealant disposal 19863
1 8 Models with breakdown set 19863
2 Tyre pressure monitoring system 19864
2 1 System description – tyre pressure monitoring system 19864
3 Wheel alignment 19866
3 1 Notes for wheel alignment 19866
3 2 Conditions for testing 19866
3 3 Test preparations 19867
3 3 1 Test preparations, wheel alignment with no driver assist systems 19867
3 3 2 Test preparations, wheel alignment with driver assist systems 19869
3 4 Specifications for wheel alignment 19869
3 5 Wheel alignment procedure 19871
3 6 Necessity of wheel alignment 19872
3 7 Vehicle data sticker 19873
3 8 Adjusting camber at front wheels 19873
3 9 Adjusting camber on rear axle 19874
3 10 Adjusting toe at rear axle 19875
3 11 Adjusting front axle toe 19875
3 12 Checking maximum wheel lock 19875
4 Vibration due to wheels/tyres – causes and rectification 19877
4 1 Causes of rough running 19877
4 2 Conducting a road test before balancing wheels 19877
4 3 Balancing wheel 19878
4 3 1 Balancing wheel, conditions 19878
4 3 2 Balancing wheel, balancing wheel on stationary wheel balancer 19878
4 3 3 Balancing wheel, balancing wheel with finish balancer 19881
4 4 Vibration control system 19882
4 5 Checking radial and lateral runout of wheels and tyres 19882
4 5 1 Checking radial and lateral runout of wheels and tyres, tolerances 19882
4 5 2 Checking radial and lateral runout on wheels and tyres with tyre gauge 19883
4 6 Checking radial and lateral run-out on wheel rim 19883
4 7 Matching wheels and tyres 19884
4 8 Determining flat spots on tyres 19885
5 Adaptive cruise control 19887
5 1 Calibrating adaptive cruise control 19887
48 – Steering 19893
1 Steering wheel 19893
1 1 Assembly overview – steering wheel 19893
1 2 Removing and installing steering wheel 19893
2 Steering column 19896
2 1 Assembly overview – steering column 19896
2 2 Removing and installing steering column 19897
2 3 Handling and transporting steering column 19906
2 4 Removing and installing intermediate steering shaft 19908
2 5 Repairing steering column 19909
2 6 Removing and installing power steering control unit -J500- 19910
2 6 1 Distinguishing features of left-hand and right-hand drive 19910
2 6 2 Removing and installing power steering control unit -J500-, left-hand drive vehicle 19910
2 6 3 Removing and installing power steering control unit -J500-, right-hand drive vehicle 19914
3 Steering rack 19920
3 1 Assembly overview – steering rack 19920
3 2 Removing and installing steering rack 19921
3 3 Repairing steering rack 19924
3 4 Removing and installing track rod 19926
3 5 Removing and installing track rod ball joint 19929
3 6 Adjusting steering rack 19930
4 Sensors 19931
4 1 Removing and installing steering angle sender -G85- 19931
D4B8027068B Air conditioning systems with refrigerant R134a General information 19932
00 – Technical data 19938
1 Safety information 19938
1 1 Safety precautions when working on air conditioning systems 19938
1 2 Safety precautions when working on high-voltage system 19939
1 3 Safety precautions when working in the vicinity of high-voltage components 19939
1 4 Safety precautions when tow-starting or towing 19940
2 Repair instructions 19941
2 1 Rules for cleanliness when working on high-voltage system 19941
3 General information on air conditioning 19942
3 1 Other reference material 19942
3 2 Basics of air conditioning technology 19942
3 2 1 Physical principles: 19942
3 2 2 Heat always flows from a warmer to a colder substance 19943
3 2 3 Pressure and boiling point 19943
3 3 Vapour pressure table for refrigerant R134a 19944
3 4 Refrigerant R134a 19945
3 4 1 Physical data of refrigerant R134a 19945
3 4 2 Critical point 19945
3 4 3 Environmental aspects of refrigerant R134a 19946
3 5 Properties of refrigerant R134a 19946
3 5 1 Trade names and designations 19946
3 5 2 Colour 19946
3 5 3 Vapour pressure 19946
3 5 4 Physical properties of R134a 19947
3 5 5 Effects on metal 19947
3 5 6 Critical temperature and critical pressure 19947
3 5 7 Union 19947
3 5 8 Charge factor 19947
3 5 9 Detecting leaks 19947
3 6 Refrigerant oil 19948
3 6 1 Properties of refrigerant oil 19948
3 7 Comfort 19949
3 7 1 Environmental aspects 19949
3 8 How air conditioning works 19950
3 9 General work safety 19950
3 9 1 Product characteristics 19950
3 9 2 Handling refrigerants 19951
3 9 3 Wear safety goggles 19951
3 9 4 Wear protective gloves and apron 19951
3 9 5 Do not allow liquid refrigerant to come in contact with the skin 19951
3 9 6 Do not breath in refrigerant vapour 19951
3 9 7 Absolutely NO SMOKING 19951
3 9 8 Welding and soldering on refrigeration systems 19951
3 9 9 Pungent smell 19952
3 9 10 First aid 19952
3 9 11 Handling pressure vessels 19952
3 9 12 Do not heat up above 50°C 19952
3 9 13 Do not expose to uncontrolled heat 19952
3 9 14 Seal empty tanks/containers 19952
3 9 15 Safety instructions for using extraction and charging equipment 19953
3 10 Safety measures when working on vehicles with air conditioning and when working with refrigerant R134a 19953
3 11 Basics for working on refrigerant circuit 19954
3 11 1 O-ring 19955
3 11 2 Before operating the air conditioning system after recharging with refrigerant 19956
4 General information on refrigerant circuit 19957
4 1 Components of refrigerant circuit 19957
4 1 1 Distribution of the refrigerant circuit components and their influence on the high-pressure and low-pressure sides 19957
4 1 2 Air conditioning system compressor with magnetic clutch: 19957
4 1 3 Air conditioner compressor without magnetic clutch 19958
4 1 4 Air conditioner compressor without magnetic clutch, with elastic drive coupling 19959
4 1 5 Electrical air conditioner compressor for high-voltage system 19960
4 1 6 Condenser 19961
4 1 7 evaporator 19961
4 1 8 Reservoir 19962
4 1 9 Restrictor 19962
4 1 10 Receiver 19963
4 1 11 Expansion valve 19964
4 1 12 O-ring 19965
4 1 13 Pipes and hoses of refrigerant circuit 19965
4 1 14 High-pressure safety valve 19965
4 2 Design of refrigerant circuit 19968
4 2 1 Refrigerant circuit with expansion valve and evaporator 19968
4 2 2 Refrigerant circuit with restrictor and reservoir 19968
4 3 Evacuation and charging valves for quick-release couplings of air conditioner service station on refrigerant circuit 19969
4 3 1 Evacuation and charging valve with Schrader valve 19969
4 3 2 Extraction and charging valve, high-pressure side 19970
4 3 3 Extraction and charging valve, low-pressure side 19971
4 4 Switches and senders in refrigerant circuit and related connections 19971
4 4 1 High-pressure switch for air conditioning system -F23- 19971
4 4 2 High-pressure switch for magnetic clutch -F118- 19972
4 4 3 Low-pressure switch for air conditioning system -F73- 19972
4 4 4 Connections with valve for switches in refrigerant circuit 19973
4 4 5 Air conditioning system pressure switch -F129- 19973
4 4 6 High-pressure sender -G65- 19974
4 4 7 Refrigerant pressure and temperature sender -G395- 19975
4 4 8 Air conditioner compressor regulating valve -N280- 19975
4 5 Electrical components not installed in refrigerant circuit 19976
4 5 1 Control and regulating unit for air conditioning system -J127- 19976
4 5 2 Radiator fan control unit -J293- 19976
4 5 3 Radiator fan control unit -J293- 19977
4 5 4 Temperature switch for evaporator -E33- 19978
4 5 5 Evaporator output temperature sender -G263- or evaporator temperature sensor -G308- 19978
4 6 Pressures and temperatures in refrigerant circuit 19979
4 7 Refrigerant circuit with expansion valve 19979
4 8 Refrigerant circuit with restrictor and reservoir 19981
4 9 Test and measurement work that can be performed using a pressure gauge 19983
4 9 1 Pressure gauges enable the following test and measurement work 19983
4 10 Air conditioner service and recycling equipment 19984
4 10 1 Classification of extraction and charging devices in groups 19984
4 10 2 Charging devices that do not require a permit 19984
4 11 Notes to repairs on refrigerant circuit 19985
5 Laws and regulations 19986
5 1 Laws and regulations 19986
5 2 Recycling and refuse law 19991
5 2 1 Disposal of refrigerant and refrigerant machine oil 19991
5 3 Converting R12 refrigerant circuits to R134a refrigerant circuits and servicing them (retrofitting) 19992
5 4 Maintaining records on refrigerant 19992
6 Refrigerant circuit 19993
6 1 Important repair notes on air conditioning 19993
6 2 Converting refrigerant circuits from R12 refrigerant to R134a 19993
7 Working with the air conditioner service station 19994
7 1 Important instructions for working with the air conditioner service station 19994
7 2 Connecting a air conditioner service station for measuring and testing 19995
7 3 Drain the refrigerant circuit using the air conditioner service station 19996
7 4 Evacuating refrigerant circuit using air conditioner service station 19996
7 5 Filling refrigerant circuit with air conditioner service station 19998
7 6 Bringing air conditioning system into service after charging 19999
7 7 Charging the container in the air conditioning service station with refrigerant 19999
7 8 Emptying air conditioner service station 20000
8 Detecting leaks in refrigerant circuit 20001
8 1 Leak detection in refrigerant circuit using compressed air or nitrogen 20002
8 2 Searching for leaks in refrigerant circuits using leak detector -V A G 1796- 20003
8 3 Detecting leaks in refrigerant circuit using leak detecting system -VAS 6196- or leak detecting system -VAS 6201- or a later model 20004
9 Clearing refrigerant circuit of contaminants 20012
9 1 Vehicles with high-voltage system (hybrid vehicles) 20012
9 2 Blowing through refrigerant circuit with compressed air and nitrogen 20013
9 2 1 Flushing refrigerant circuit 20015
9 3 Flushing refrigerant circuit with refrigerant R134a 20015
9 3 1 Principle circuit diagrams for various purging circuits 20023
9 3 2 Purging electrical air conditioner compressor 20029
9 3 3 Adapters for setting up flushing circuits 20033
10 Clearing refrigerant circuit of contaminants, commercial vehicles 20047
10 1 Vehicles with high-voltage system 20047
10 2 Flushing refrigerant circuit with refrigerant R134a 20048
10 3 Adapters for setting up flushing circuits 20048
10 4 Procedure for setting up and flushing refrigerant circuit, Amarok 2023 ► 20052
10 5 Procedure for setting up and flushing refrigerant circuit, Amarok 2010 ► 20052
10 5 1 Connection diagram for flushing circuit 20052
10 5 2 Procedure for setting up and flushing refrigerant circuit 20053
10 6 Procedure for setting up and flushing refrigerant circuit, Caddy 2004 ► 20058
10 6 1 Connection diagram for flushing circuit 20058
10 6 2 Procedure for setting up and flushing refrigerant circuit 20059
10 7 Procedure for setting up and flushing refrigerant circuit, Crafter ►2017 20065
10 7 1 Connection diagram for flushing circuit, vehicles with one evaporator 20065
10 7 2 Connection diagram for flushing circuit, vehicles with second evaporator 20066
10 7 3 Procedure for setting up and flushing refrigerant circuit, vehicles with one evaporator 20067
10 7 4 Procedure for setting up and flushing refrigerant circuit, vehicles with second evaporator 20074
10 8 Procedure for setting up and flushing refrigerant circuit, Crafter 2017 ► or MAN TGE ►, Crafter Grand California ► 20082
10 8 1 Connection diagram for flushing circuit, vehicles with one evaporator 20083
10 8 2 Connection diagram for flushing circuit, vehicles with second evaporator 20084
10 8 3 Procedure for setting up and flushing refrigerant circuit, vehicles with one evaporator 20085
10 8 4 Procedure for setting up and flushing refrigerant circuit, vehicles with second evaporator 20090
10 9 Procedure for setting up and flushing refrigerant circuit, Transporter 2016 ►, Transporter 2020 ► 20099
10 9 1 Connection diagram for flushing circuit, vehicles with one evaporator 20099
10 9 2 Connection diagram for flushing circuit, vehicles with second evaporator 20100
10 9 3 Procedure for setting up and flushing refrigerant circuit, vehicles with one evaporator 20101
10 9 4 Procedure for setting up and flushing refrigerant circuit, vehicles with second evaporator 20106
11 Complaints 20115
11 1 Possible complaints about refrigerant circuit 20115
11 1 1 Conditions for testing: 20115
11 1 2 Possible complaints 20115
11 2 Odours from heater and air conditioning unit 20116
11 2 1 Does the odour emanate from the evaporator or heat exchanger? 20116
11 2 2 Ultrasonic air conditioner cleaning unit -VAS 6189A- 20117
11 2 3 Spraying the evaporator with the suction feed spray-gun -V A G 1538- and spray lance 20118
12 Connecting the air conditioning service station 20119
12 1 For vehicles that have connections on both low-pressure and high-pressure sides of refrigerant circuit 20119
12 1 1 Connecting a air conditioner service station for measuring and testing 20119
13 Checking pressures on vehicles 20120
13 1 Checking pressures in the refrigerant circuit (using a air conditioning service station) 20120
13 1 1 Conditions for testing 20120
13 1 2 Checking pressures 20121
13 1 3 Continuation of checking pressures 20123
13 2 Checking systems with a restrictor and collector (with internally regulated air conditioner compressor) 20124
13 2 1 Specifications: 20124
13 3 Checking systems with an expansion valve and reservoir (with internally regulated air conditioner compressor) 20128
13 3 1 Specifications: 20128
13 4 Checking systems with an expansion valve and reservoir (without regulated air conditioner compressor) 20133
13 4 1 Conditions for testing 20133
13 4 2 Check 20133
13 4 3 Specified values 20133
13 5 Checking systems with a restrictor and reservoir and air conditioner compressor regulating valve -N280- (with externally regulated air conditioner compressor) 20134
13 5 1 Specifications: 20134
13 6 Checking systems with an expansion valve, receiver and air conditioner compressor regulating valve -N280- (with externally regulated air conditioner compressor) 20139
13 6 1 Specifications: 20139
13 7 With expansion valve, receiver and electrical air conditioner compressor 20150
14 Renewing components 20151
14 1 In the event of leaking or damaged components (apart from the air conditioner compressor, receiver or reservoir) 20152
14 1 1 If the refrigerant circuit was completely empty 20152
14 1 2 If there is still refrigerant in the refrigerant circuit 20154
14 2 Renew the air conditioner compressor 20154
14 2 1 Without needing to flush refrigerant circuit of contaminants (cleaning), e g in cases of external damage after an accident 20154
14 2 2 Leaks or internal damage (e g noises or lack of power) 20156
14 3 Replace receiver or reservoir and restrictor 20156
14 3 1 After flushing contaminants from refrigerant circuit, e g due to moisture intrusion (because refrigerant circuit was open for a longer period of time) or due to soiling 20156
14 3 2 Without needing to flush contaminants from refrigerant circuit (e g damage in an accident); no refrigerant has escaped and no moisture or dirt has entered refrigerant circuit 20158
15 Testing equipment and tools 20159
15 1 List of test equipment, tools and materials 20159
15 1 1 Tools and materials available from regional sales centre or importer 20159
15 1 2 Tools and materials commercially available 20160
15 1 3 Tools and materials available from regional sales centre or importer 20161
15 1 4 Tools and materials commercially available 20167
D4B80335321 4 cyl direct injection engine (2 0 l 4V turbocharger toothed belt drive) 20170
00 – Technical data 20176
1 Engine number, engine data 20176
2 Safety precautions 20177
2 1 Safety precautions when working on fuel supply system 20177
2 2 Safety precautions when working on ignition system 20177
2 3 Releasing pressure in high-pressure area 20178
3 General repair notes 20180
3 1 Rules for cleanliness 20180
3 2 Foreign objects in engine 20180
10 – Removing and installing engine 20181
1 Removing and installing engine 20181
1 1 Removing engine 20181
1 2 Separating engine and gearbox 20190
1 3 Securing engine on engine and gearbox support 20191
1 4 Installing engine 20193
2 Assembly mountings 20196
2 1 Assembly overview – assembly mountings 20196
2 2 Removing and installing engine mounting 20197
2 3 Removing and installing gearbox mounting 20198
2 4 Removing and installing pendulum support 20201
2 5 Supporting engine in installation position 20201
3 Engine cover panel 20204
3 1 Removing and installing engine cover panel 20204
13 – Crankshaft group 20205
1 Cylinder block (pulley end) 20205
1 1 Assembly overview – poly V-belt drive 20205
1 2 Assembly overview – sealing flange, pulley end 20206
1 3 Removing and installing poly V-belt 20207
1 4 Removing and installing tensioner for poly V-belt 20209
1 5 Removing and installing bracket for ancillaries 20209
1 6 Removing and installing vibration damper 20210
1 7 Renewing crankshaft oil seal – belt pulley end 20211
1 8 Removing and installing sealing flange on pulley end 20213
2 Cylinder block, gearbox end 20217
2 1 Assembly overview – cylinder block, gearbox end 20217
2 2 Removing and installing flywheel 20218
2 3 Removing and installing sealing flange on gearbox side 20219
3 Crankshaft 20222
3 1 Assembly overview – crankshaft 20222
3 2 Crankshaft dimensions 20224
3 3 Measuring axial clearance of crankshaft 20224
3 4 Measuring radial clearance of crankshaft 20225
3 5 Removing and installing drive chain sprocket 20226
4 Pistons and conrods 20229
4 1 Assembly overview – pistons and conrods 20229
4 2 Removing and installing pistons 20230
4 3 Checking piston and cylinder bore 20232
4 4 Checking radial clearance of conrods 20233
15 – Cylinder head, valve gear 20235
1 Cylinder head 20235
1 1 Assembly overview – cylinder head 20235
1 2 Removing and installing cylinder head 20237
1 3 Removing and installing cylinder head cover 20243
1 4 Checking compression 20245
1 5 Removing and installing vacuum pump 20246
2 Toothed belt drive 20248
2 1 Assembly overview – toothed belt 20248
2 2 Removing and installing toothed belt 20249
3 Valve gear 20254
3 1 Assembly overview – valve gear 20254
3 2 Measuring axial play of camshaft 20256
3 3 Measuring radial play of camshaft 20257
3 4 Removing and installing camshaft oil seal 20258
3 5 Removing and installing camshaft adjuster 20260
3 6 Removing and installing inlet camshaft control valve 1 -N205- 20264
3 7 Removing and installing camshaft 20265
3 8 Removing and installing valve stem seals 20269
3 8 1 Renewing valve stem seals with cylinder head installed 20269
3 8 2 Renewing valve stem seals with cylinder head removed 20273
4 Inlet and exhaust valves 20278
4 1 Checking valve guides 20278
4 2 Checking valves 20279
4 3 Valve dimensions 20279
17 – Lubrication 20280
1 Sump, oil pump 20280
1 1 Assembly overview – sump, oil pump 20280
1 2 Engine oil 20281
1 3 Removing and installing sump 20281
1 4 Removing and installing oil level and oil temperature sender -G266- 20285
2 Engine oil cooler 20286
2 1 Removing and installing engine oil cooler 20286
3 Oil filter, oil pressure switch 20288
3 1 Assembly overview – oil filter housing, oil pressure switch 20288
3 2 Draining oil filter housing 20289
3 3 Removing and installing oil filter housing 20291
3 4 Removing and installing oil pressure switch -F1- 20291
3 5 Checking oil pressure and oil pressure switch 20293
4 Balancer shaft module 20295
4 1 Assembly overview – balancer shaft module 20295
4 2 Removing and installing balance shaft module 20296
19 – Cooling 20302
1 Cooling system, coolant 20302
1 1 Coolant hose schematic diagram 20302
1 2 Draining and filling coolant 20303
1 3 Checking cooling system for leaks 20308
2 Coolant pump, regulation of cooling system 20310
2 1 Assembly overview – coolant pump, thermostat 20310
2 2 Assembly overview – electric coolant pump 20311
2 3 Removing and installing continued coolant circulation pump -V51- 20311
2 4 Removing and installing coolant pump 20312
2 5 Removing and installing thermostat 20313
2 6 Removing and installing coolant temperature sender -G62- 20314
2 7 Removing and installing coolant temperature sender at radiator outlet -G83- 20315
3 Coolant pipes 20317
3 1 Assembly overview – coolant pipes 20317
3 2 Removing and installing coolant pipes 20318
3 3 Removing and installing front right coolant pipe 20320
4 Radiator, radiator fan 20322
4 1 Assembly overview – radiator, radiator fan 20322
4 2 Removing and installing radiator 20323
4 3 Removing and installing radiator cowling with radiator fan 20325
4 4 Removing and installing radiator fan 20327
21 – Turbocharging/supercharging 20328
1 Turbocharger 20328
1 1 Assembly overview – turbocharger 20328
1 2 Removing and installing turbocharger 20331
1 3 Checking vacuum unit for turbocharger 20336
1 4 Renewing vacuum unit for turbocharger 20338
1 5 Adjusting vacuum unit for turbocharger 20338
2 Charge air system 20343
2 1 Schematic overview – charge air system 20343
2 2 Assembly overview – charge air system 20344
2 3 Assembly overview – charge-air hose connections 20346
2 3 2 Hose connections with plug-in connectors 20346
2 4 Removing and installing charge air cooler 20347
2 5 Removing and installing charge pressure sender -G31- 20348
2 6 Checking charge air system for leaks 20348
24 – Mixture preparation – injection 20351
1 Injection system 20351
1 1 Overview of fitting locations – injection system 20351
2 Air filter 20360
2 1 Assembly overview – air filter housing 20360
2 2 Removing and installing air filter housing 20361
3 Intake manifold 20363
3 1 Assembly overview – intake manifold 20363
3 2 Assembly overview – intake manifold with fuel rail 20365
3 3 Removing and installing intake manifold with fuel rail 20366
3 4 Removing and installing throttle valve module -J338- 20369
3 5 Cleaning throttle valve module 20371
3 6 Removing and installing intake manifold flap motor -V157- 20372
3 7 Checking intake manifold change-over 20373
3 8 Checking double non-return valve 20375
4 High-pressure pump 20377
4 1 Assembly overview – high-pressure pump 20377
4 2 Removing and installing high-pressure pump 20378
5 Injectors 20380
5 1 Removing and installing fuel rail 20380
5 2 Removing and installing injectors 20381
5 3 Renewing seals on injectors 20384
5 4 Cleaning injectors 20386
6 Senders and sensors 20388
6 1 Assembly overview – actuator for structure-borne sound -R214- and control unit for structure-borne sound -J869- 20388
6 2 Removing and installing air mass meter -G70- 20389
6 3 Removing and installing fuel pressure sender -G247- 20389
6 4 Checking fuel pressure sender -G247- 20391
7 Lambda probe 20394
7 1 Assembly overview – Lambda probe 20394
7 2 Removing and installing Lambda probe -G39- 20394
7 3 Removing and installing Lambda probe after catalytic converter -G130- 20396
8 Engine control unit 20398
8 1 Removing and installing engine control unit -J623- 20398
26 – Exhaust system 20400
1 Exhaust pipes, silencers 20400
1 1 Assembly overview – silencers 20400
1 2 Separating exhaust pipes, silencers 20401
1 3 Aligning exhaust system free of stress 20402
1 4 Checking exhaust system for leaks 20403
2 Emission control 20404
2 1 Assembly overview – emission control 20404
2 2 Removing and installing catalytic converter 20405
3 Exhaust manifold 20408
28 – Ignition system 20409
1 Ignition system 20409
1 1 Assembly overview – ignition system 20409
1 2 Test data, spark plugs 20410
1 3 Removing and installing ignition coils with output stage 20411
1 4 Removing and installing knock sensor 1 -G61- 20412
1 5 Removing and installing knock sensor 2 -G66- 20413
1 6 Removing and installing Hall sender -G40- 20414
1 7 Removing and installing engine speed sender -G28- 20414
D4B80372446 Vehicle specific paint information 20416
00 – Technical data 20420
1 Explanation of symbols 20420
1 1 Sanding 20420
1 2 Seam sealing 20420
1 3 Cavity sealing 20422
2 Paint structure 20423
2 1 Structure of factory finish, cathodic dip primer 20423
2 2 Structure of factory finish, undercoat 20425
2 3 Structure of factory finish, base coat 20427
2 4 Structure of factory finish, clear coat 20431
3 Areas exposed to stone chipping 20433
3 1 Body areas exposed to stone chipping 20433
4 Masked sectors 20435
4 1 Masking areas, front body 20435
4 2 Masking areas, middle body 20439
4 3 Masking areas, rear body 20440
5 Seam sealing 20447
5 1 Seam seals, front body 20447
5 2 Seam seals, middle body 20454
5 3 Seam seals, rear body 20462
6 Underseal 20470
6 1 Undersealed areas, body overview indicating differing coat thicknesses 20470
6 2 Undersealed areas 20471
7 Cavity sealing 20476
7 1 Cavity sealing, overview of body 20476
7 2 Cavity sealing, front body 20477
7 3 Cavity sealing, middle body 20477
7 4 Cavity sealing, rear body 20480
8 Contrasting colours 20483
8 1 Contrasting colours, CrossPolo 20483
8 2 Contrasting colours, CrossPolo, Urban White 20484
8 3 Contrasting colours, Polo WRC 20485
8 4 Contrasting colours, Polo Fresh 20486
8 5 Contrasting colours, Polo Black Edition/Silver Edition 20487
8 6 Contrasting colours, Polo BlueGT 20488
8 7 Contrasting colours, Polo Match 20489
D4D8081B13E General Paint Passenger vehicles information 20490
00 – Technical data 20496
1 Safety information 20496
1 1 Safety measures when working on vehicles with a start/stop system 20496
50 – Body – front 20497
1 Lock carrier 20497
1 1 Assembly overview – lock carrier 20497
1 2 Removing and installing lock carrier 20499
1 2 1 Removing and installing lock carrier 20499
1 2 2 Removing and installing assembly frame 20502
1 3 Moving to and back from service position 20504
2 Wings 20508
2 1 Assembly overview – wing 20508
2 2 Removing and installing wing 20508
3 Bulkhead 20513
3 1 Assembly overview – plenum chamber bulkhead 20513
3 2 Assembly overview – plenum chamber cover 20513
3 3 Removing and installing plenum chamber bulkhead 20514
3 4 Removing and installing plenum chamber cover 20515
55 – Bonnet, rear lid 20519
1 Bonnet 20519
1 1 Assembly overview – bonnet 20519
1 2 Assembly overview – Bowden cable 20520
1 3 Removing and installing bonnet 20521
1 4 Adjusting bonnet 20524
1 5 Removing and installing bonnet lock 20531
1 5 1 Removing and installing left bonnet lock 20531
1 5 2 Removing and installing right bonnet lock 20533
1 6 Removing and installing bonnet release lever 20536
1 6 1 Removing and installing bonnet release lever 20536
1 6 2 Removing and installing release lever on lock cylinder 20537
1 7 Removing and installing striker pin 20539
1 8 Removing and installing hinges 20540
1 9 Renewing hinges 20542
1 10 Removing and installing insulation 20544
1 11 Removing and installing support rod 20545
1 12 Removing and installing Bowden cable 20547
1 12 1 Removing and installing Bowden cable to mounting bracket 20547
1 12 2 Removing and installing Bowden cable from right bonnet lock to release lever 20549
1 12 3 Removing and installing Bowden cable from left bonnet lock to release lever 20550
1 12 4 Removing and installing Bowden cable coupling with Bowden cables 20553
2 Rear lid 20555
2 1 Assembly overview – rear lid 20555
2 2 Removing and installing rear lid 20557
2 3 Adjusting rear lid 20560
2 4 Removing and installing bonnet lock 20567
2 5 Removing and installing operating mechanism 20569
2 5 1 Removing and installing handle, without reversing camera 20569
2 5 2 Removing and installing handle, with reversing camera 20572
2 6 Removing and installing hinges 20574
2 7 Removing and installing striker pin 20577
2 8 Removing and installing rear lid seal 20578
2 9 Removing and installing gas strut 20580
2 10 Releasing gas from gas strut 20581
3 Tank flap unit 20583
3 1 Assembly overview – tank flap unit 20583
3 2 Removing and installing tank flap unit 20583
3 3 Removing and installing fuel tank flap 20586
57 – Front doors, door components, central locking 20588
1 Door 20588
1 1 Assembly overview – door 20588
1 2 Removing and installing inner door seal 20591
1 3 Removing and installing outer door seal 20593
1 3 1 Removing and installing door outer seal, 4-door model 20593
1 3 2 Removing and installing door outer seal, 2-door model 20594
1 4 Removing and installing door 20595
1 5 Adjusting door 20599
1 6 Adjusting striker pin 20601
1 7 Removing and installing door arrester 20603
2 Door components 20606
2 1 Assembly overview – door components 20606
2 2 Assembly overview – window regulator 20608
2 3 Assembly overview – door handle and door lock 20608
2 4 Removing and installing window regulator motor 20609
2 5 Removing and installing window regulator 20612
2 6 Removing and installing inner door cover 20615
2 7 Removing and installing striker pin 20617
2 8 Removing and installing cap on door handle 20619
2 8 1 Removing and installing cap for door handle, for lock cylinder 20619
2 8 2 Removing and installing cap for door handle, without lock cylinder 20621
2 9 Removing and installing lock cylinder 20625
2 10 Removing and installing door handle 20628
2 11 Removing and installing door handle bracket 20630
2 12 Removing and installing door lock 20632
2 13 Removing and installing window channel 20637
2 14 Removing and installing outer window slot seal 20640
2 15 Removing and installing inner window slot seal 20642
3 Central locking 20643
3 1 Overview of fitting locations – central locking 20643
3 2 Removing and installing ignition key battery 20645
3 3 Removing and installing cap on ignition key 20647
3 4 Removing and installing tank filler flap locking motor -V155- 20648
58 – Rear doors, door components 20650
1 Door 20650
1 1 Assembly overview – door 20650
1 2 Removing and installing door 20653
1 3 Adjusting door 20656
1 4 Adjusting striker pin 20658
1 5 Removing and installing door arrester 20660
1 6 Removing and installing inner door seal 20662
1 7 Removing and installing outer door seal 20664
2 Door components 20666
2 1 Assembly overview – door components 20666
2 2 Assembly overview – window regulator 20668
2 3 Assembly overview – door handle and door lock 20668
2 4 Removing and installing window regulator motor 20669
2 5 Removing and installing window regulator 20672
2 6 Removing and installing window crank 20675
2 7 Removing and installing inner door cover 20678
2 8 Removing and installing striker pin 20680
2 9 Removing and installing cap on door handle 20682
2 10 Removing and installing door handle 20686
2 11 Removing and installing door handle bracket 20688
2 12 Removing and installing door lock 20691
2 13 Removing and installing window channel 20695
2 14 Removing and installing outer window slot seal 20698
2 15 Removing and installing inner window slot seal 20699
60 – Sunroof 20701
1 Sliding sunroof 20701
1 1 Assembly overview – sliding sunroof 20701
1 2 Assembly overview – sunroof roller blind 20703
1 3 Removing and installing sliding sunroof frame 20703
1 4 Removing and installing wind deflector 20711
1 5 Removing and installing glass panel 20713
1 6 Adjusting sunroof panel 20718
1 7 Removing and installing front trim for sliding sunroof 20719
1 8 Removing and installing -J245- sliding sunroof adjustment control unit 20721
1 9 Removing and installing sunroof motor -V1- 20723
1 10 Operating without current 20726
1 11 Removing and installing sliding sunroof seals 20727
1 11 1 Removing and installing seal for sliding sunroof frame 20727
1 11 2 Removing and installing glass panel seal 20728
1 12 Removing and installing sunroof roller blind 20729
1 13 Programming sliding sunroof adjustment control unit -J245- 20735
63 – Bumpers 20737
1 Bumper, front 20737
1 1 Assembly overview – bumper cover 20737
1 2 Assembly overview – impact bar 20739
1 3 Removing and installing bumper cover 20739
1 4 Repairing bumper cover 20743
1 5 Installing holder for parking aid sender 20743
1 6 Installing retainer for parking aid sender 20748
2 Bumper, rear 20753
2 1 Assembly overview – bumper cover 20753
2 2 Assembly overview – impact bar 20754
2 3 Removing and installing bumper cover 20755
2 4 Removing and installing impact bar 20758
2 5 Repairing bumper cover 20760
2 6 Installing holder for parking aid sender 20760
2 7 Installing retainer for parking aid sender 20764
64 – Glazing 20769
1 Repair notes 20769
1 1 Minimum curing periods for bonded windows 20769
1 2 Window repair 20769
1 3 Installation instructions for bonded windows 20770
1 3 1 Fitting instructions 20770
1 3 2 Materials 20771
1 4 Preparing old undamaged windows for fitting 20772
1 5 Preparing new windows for installing 20772
1 6 Preparing body flange for fitting 20775
1 7 Cleaning off excess adhesive 20776
2 Windscreen 20777
2 1 Assembly overview – windscreen 20777
2 2 Removing and installing windscreen 20778
2 2 1 Removing and installing windscreen 20778
2 2 2 Removing broken windscreen 20785
3 Rear windscreen 20786
3 1 Assembly overview – rear window 20786
3 2 Removing and installing rear window 20787
3 2 1 Removing and installing rear window 20787
3 2 2 Removing broken rear window 20790
4 Side window 20791
4 1 Assembly overview – rear side windows 20791
4 2 Removing and installing rear side window 20792
4 2 1 Removing and installing rear side window 20792
4 2 2 Removing broken rear side window 20795
5 Door windows 20796
5 1 Assembly overview – front door window 20796
5 2 Assembly overview – rear door window 20796
5 3 Removing and installing front door window 20797
5 4 Removing and installing rear door window 20801
66 – Exterior equipment 20805
1 Radiator grille and front trim 20805
1 1 Assembly overview – radiator grille 20805
1 2 Removing and installing radiator grille 20806
2 Mouldings, trims, extensions 20808
2 1 Removing and installing A-pillar trim 20808
2 2 Removing and installing B-pillar trim on door 20809
2 2 1 Removing and installing B-pillar trim on front door 20809
2 2 2 Removing and installing B-pillar trim on rear door 20811
2 3 Removing and installing C-pillar trim on door 20812
2 4 Removing and installing entry moulding 20815
2 4 1 Fitting instructions 20815
2 4 2 Removing and installing outer step moulding 20815
3 Noise insulation 20817
3 1 Assembly overview – noise insulation 20817
3 1 1 Assembly overview – short noise insulation 20817
3 1 2 Assembly overview – long noise insulation 20818
3 1 3 Assembly overview – skid plate 20818
4 Underbody cladding 20820
4 1 Overview of fitting locations – underbody cladding 20820
4 1 1 Overview of fitting locations – underbody cladding, petrol/diesel 20820
4 2 Removing and installing underbody cladding 20820
4 3 Removing and installing centre underbody panels 20822
4 3 1 Removing and installing centre underbody cladding 20822
4 3 2 Removing and installing short centre underbody cladding 20823
4 4 Removing and installing rear underbody panel 20824
4 4 1 Removing and installing rear underbody cladding – petrol/diesel 20825
5 Exterior mirror 20827
5 1 Assembly overview – exterior mirror 20827
5 2 Removing and installing exterior mirror 20828
5 2 1 Removing and installing exterior mirror, electric adjustment 20828
5 2 2 Removing and installing exterior mirror, manual adjustment 20831
5 3 Removing and installing mirror glass 20833
5 4 Removing and installing mirror adjustment unit 20835
5 5 Removing and installing mirror cover 20837
5 6 Removing and installing mirror trim 20838
5 7 Removing and installing turn signal 20839
6 Wheel housing liner 20841
6 1 Assembly overview – front wheel housing liner 20841
6 2 Assembly overview – rear wheel housing liner 20842
6 3 Removing and installing front wheel housing liner 20842
6 4 Removing and installing rear wheel housing liner 20844
7 Trim film and protective film 20846
7 1 Renewing decorative film and protective film 20846
7 1 1 Fitting instructions 20846
7 2 Decorative film dimensions 20847
7 3 Renewing decorative film 20847
8 Lettering and emblems 20850
8 1 Dimensions – lettering and emblems on rear 20850
8 1 1 Dimensions – lettering on rear 20851
8 1 2 Dimensions of lettering “GTI” on rear 20852
8 2 Dimensions – lettering and emblems on sides 20852
8 2 1 Dimensions – lettering on wing 20852
8 2 2 Dimensions – badge on B-pillar 20853
8 3 Removing and installing lettering and emblems for radiator grille 20854
8 3 1 Removing and installing brand emblem on radiator grille, vehicles without adaptive cruise control unit 20854
8 3 2 Removing and installing brand emblem on radiator grille, vehicles with adaptive cruise control unit -J428- 20855
8 4 Renewing lettering and badges at rear 20857
9 Towing bracket 20858
9 1 Assembly overview – towing bracket 20858
9 2 Removing and installing towing bracket 20859
10 Heat shields 20862
10 1 Overview of fitting locations – heat shields 20862
10 2 Removing and installing underbody heat shield 20862
10 3 Removing and installing heat shield for centre exhaust system 20863
10 4 Removing and installing heat shield for rear silencer 20864
D4D8088B280 General information Paint passenger vehicles 20867
00 – Technical data 20871
1 Safety information 20871
1 1 Safety precautions when painting natural gas-powered vehicles 20871
1 2 Safety precautions when painting electric drive vehicles 20872
2 General information 20873
2 1 Paintwork structure of a factory finish 20873
2 2 Paint structure of service department finish 20876
2 3 Fundamental approach to dealing with areas sanded through to the substrate (bare metal surface) 20879
2 4 Reduced paint structure in engine compartment and inside of bonnet 20879
2 5 Instructions for work on underbody and stone chip protection 20880
2 6 Work instruction for window flange area 20882
2 7 Pre-treatment of bonded surfaces when renewing laser-welded roofs 20883
2 8 Corrosion protection measures for wing surface in contact with wheel housing liner 20887
2 9 Notes on treating corroded fold areas 20888
2 10 Corrosion protection for body components, add-on components and welded components 20890
2 11 Painting parking aid sensor 20891
2 12 ACC – Adaptive Cruise Control 20893
2 13 Instructions for painting bumper cover in area of lane change assist control unit 20893
3 Genuine products 20895
3 1 Paint products in customer service 20895
3 2 General application instructions for repair and painting systems 20896
3 2 1 Aqua Premium – application instructions for water-based products 20896
3 2 2 Setting gloss level of HS clear coats and HS top coats with matting additive 20899
3 2 3 Setting gloss level of 2-pack HS clear coats with 2-pack clear coat, matt 20909
3 2 4 Repair paintwork system for matt-finished vehicles 20911
3 2 5 Paintwork system for plastic components 20916
3 2 6 Aqua Premium system, blending system for 2-stage colours 20924
3 2 7 Aqua Premium system, blending system for 3-stage colours 20931
3 2 8 Aquaplus design and multi-colour painting 20939
3 2 9 Processing instructions for paint with limited hiding power 20943
3 3 Filler 20944
3 3 1 2-pack steel filler set 20944
3 3 2 2-pack fine filler 20947
3 3 3 2-pack fine filler, flexible 20952
3 3 4 2-pack spray filler 20955
3 3 5 2-pack IR premium filler 20961
3 3 6 2-pack diamond aluminium filler 20966
3 4 Priming metal 20969
3 4 1 1-pack anti-corrosion wash primer 20969
3 4 2 1-pack wash primer 20974
3 4 3 2-pack wash primer 20979
3 5 Priming plastic materials 20985
3 5 1 Adhesion promoter (transparent) 20985
3 6 Surfacer 20989
3 6 1 2-pack HS Vario surfacer 20989
3 6 2 2-pack HS premium surfacer 21000
3 6 3 2-pack HS mixture surfacer 21008
3 6 4 2-pack HS Performance surfacer 21024
3 6 5 2-pack primer surfacer for plastics 21034
3 6 6 2-pack HS wet-on-wet surfacer 21040
3 7 Top coats 21050
3 7 1 2-pack HS top coat 21050
3 7 2 Aquaplus system, uni (solid-colour) and metallic colours 21059
3 7 3 Aquaplus system (pearlescent and heliochrome) 21067
3 7 4 Aquaplus blending system 21075
3 7 5 Aqua Premium system 21081
3 7 6 Aqua Premium blending system 21093
3 7 7 Aqua Premium system (painting rims) 21101
3 8 Clear coats 21109
3 8 1 2-pack HS clear coat 21109
3 8 2 2-pack MS matt clear coat 21116
3 8 3 2-pack HS Vario clear coat 21122
3 8 4 2-pack HS optimum clear coat 21129
3 8 5 2-pack HS optimum plus clear coat 21135
3 8 6 2-pack HS brilliant clear coat 21140
3 8 7 2-pack HS brilliant plus clear coat 21145
3 8 8 2-pack HS Performance clear coat 21151
3 8 9 Blender 21157
3 9 Hardener 21162
3 9 1 2-pack HS hardener 21162
3 9 2 2-pack VHS hardeners and 2-pack VHS Performance hardeners 21166
3 9 3 Hardener for 2-pack primer surfacer 21170
3 9 4 Aqua Premium hardener 21170
3 10 Thinners 21171
3 10 1 2-pack thinner 21171
3 10 2 HS spot thinner 21174
3 10 3 Demineralised water 21176
3 11 Anti-corrosion materials 21177
3 11 1 Anti-corrosion wax 21177
3 11 2 Cavity sealant 21178
3 11 3 Anti-corrosion wax (in aerosol can) 21181
3 12 Underseal 21182
3 12 1 Permanent underseal -D 314 D36 M2-, grey 21182
3 12 2 Permanent underseal -D 314 D37 M2-, black 21185
3 12 3 Permanent underseal -D 314 D38 M2-, light 21188
3 12 4 Underseal -D 314 D39 A3-, black 21191
3 13 Stone chip guard 21193
3 13 1 Stone chip guard -AKR 311 KD1 05- 21193
3 13 2 Stone chip guard -AKR 311 KD1 10- 21195
3 14 Wax-based underseal 21202
3 14 1 Wax-based underseal -D 316 D38 A2- 21202
3 14 2 Wax-based underseal -D 316 000 A1- 21204
3 14 3 Spray wax -D 322 100 M2- 21206
3 15 Sealing materials 21207
3 15 1 Polyurethane adhesive sealant (bonding compound) 21207
3 15 2 Sprayable sealant 21210
3 15 3 Adhesive sealant 21213
3 16 Cleaning agents 21215
3 16 1 Silicone remover 21215
3 16 2 Cleaner for plastics 21217
3 16 3 Cleaner for plastics, anti-static 21218
3 16 4 Industrial dirt remover 21219
3 17 SprayMax system 21220
3 17 1 1-pack anti-corrosion primer 21220
3 17 2 1-pack test paint 21224
3 17 3 1-pack clear coat 21227
3 17 4 1-pack wash primer 21230
3 17 5 1-pack Fill Clean spray can -LLS MAX 099-/1-pack Fill Clean spray can -LLS MAX 100- – Aquaplus system 21235
3 17 6 1-pack fill clean spray can -LLS MAX 112-, Aqua Premium system 21242
3 17 7 2-pack surfacer 21250
3 17 8 2-pack clear coat 21257
3 17 9 2-pack epoxy primer surfacer 21262
3 17 10 2-pack wash primer 21268
3 17 11 Silicone remover -LLS MAX 007- 21274
3 17 12 Slow-drying silicone remover -LLS MAX 008- 21276
3 17 13 Blender 21279
3 17 14 Adhesion promoter 21281
3 18 Additional materials 21285
3 18 1 Matting additive -ALN 775 106- 21285
3 18 2 Matting additive -LVM 769 810 A2- 21292
3 18 3 Texture additive 21295
3 18 4 Blending additive for Aquaplus 21301
3 18 5 Additive for Aqua Premium 21302
4 Workshop equipment 21303
4 1 Tools 21303
4 1 1 Spray can filling device -VAS 6425- 21303
4 1 2 Paint thickness tester -VAS 6272- 21304
4 1 3 Paint thickness tester -VAS 6197- 21305
4 1 4 Paint thickness tester -VAS 5278- 21305
4 1 5 Stone chip tester -VAS 5102A- 21306
4 1 6 Pneumatic brush grinder set -VAS 6446- 21307
4 1 7 Brush grinder set -VAS 6776- 21307
4 1 8 Suction feed spray-gun -V A G 1538- 21309
4 1 9 Infrared heater -VAS 6873- 21310
4 1 10 Stand -VAS 6873/1- 21310
4 1 11 Infrared heater -VAS 6874- 21311
4 1 12 Infrared heater -VAS 6875- 21312
4 1 13 Infrared heater -VAS 6876- 21312
4 1 14 Infrared heater -VAS 6877- 21313
4 1 15 Infrared heater -VAS 6878- 21314
4 1 16 Infrared heater -VAS 6879- 21315
4 2 Tack cloths 21315
4 2 1 Tack cloth -VAS 6177- 21315
4 2 2 Buffing cloth, white -VAS 6176- 21316
4 2 3 Professional cleaning cloth -VAS 6006- 21316
D4D808660C2 Body Repairs 21318
00 – Technical data 21324
1 Basic instructions 21324
2 Vehicle identification data 21325
2 1 Vehicle identification number 21325
2 2 Type plate 21325
2 3 Vehicle data sticker 21326
3 Safety information 21328
4 Moulded foam inserts 21329
5 Galvanized body parts, high- and higher-strength and hot-formed body panels 21331
5 1 Installing 21331
5 2 2-door models 21332
5 3 4-door models 21335
6 Laser welding 21339
7 Body panel gaps/shut lines 21340
7 1 Body – front 21340
7 2 Body – centre 21341
7 3 Body – rear 21342
8 Body dimensions 21344
8 1 Body – front 21344
8 2 Body – centre 21347
8 2 1 2-door models 21349
8 2 2 4-door models 21352
8 3 Body – rear 21357
8 4 Floor panel – front 21360
8 5 Floor panel – centre 21362
8 6 Floor panel – rear 21363
9 Tools 21365
10 Alignment jig 21366
10 1 Overview 21366
11 Portal gauge 21367
11 1 2-door models 21367
11 2 4-door models 21367
50 – Body – front 21370
1 Renewing right engine mounting bracket 21370
1 1 Tools 21370
1 2 Removing 21370
1 3 Installing 21372
1 3 1 Preparing replacement part 21372
1 3 2 Welding in 21372
2 Renewing mounting bracket for subframe 21374
2 1 Tools 21374
2 2 Removing 21374
2 3 Installing 21376
2 3 1 Preparing replacement part 21376
2 3 2 Welding in 21376
3 Renewing front bumper bracket 21378
3 1 Tools 21379
3 2 Removing 21379
3 3 Installing 21380
3 3 1 Welding in 21380
4 Renewing upper wheel housing longitudinal member 21382
4 1 Tools 21383
4 2 Removing 21383
4 3 Installing 21385
4 3 1 Preparing replacement part 21385
4 3 2 Welding in 21386
5 Renewing front wheel housing 21390
5 1 Tools 21391
5 2 Removing 21391
5 3 Installing 21392
5 3 1 Preparing replacement part 21392
5 3 2 Welding in 21392
6 Repairing threads for securing subframe 21394
6 1 Contents of thread repair kit 21395
6 2 Repairing threads 21396
6 2 1 Drilling thread 21396
6 2 2 Cutting thread 21397
6 2 3 Inserting thread insert 21398
7 Renewing front left longitudinal member 21400
7 1 Tools 21401
7 2 Removing 21401
7 3 Installing 21403
7 3 1 Preparing replacement part 21403
7 3 2 Welding in 21404
8 Renewing front left longitudinal member – part section 21407
8 1 Tools 21409
8 2 Removing 21409
8 3 Installing 21410
8 3 1 Preparing replacement part 21411
8 3 2 Welding in 21411
9 Renewing front right longitudinal member 21413
9 1 Tools 21414
9 2 Removing 21414
9 3 Installing 21416
9 3 1 Preparing replacement part 21416
9 3 2 Welding in 21418
10 Renewing front right longitudinal member – part section 21421
10 1 Tools 21422
10 2 Removing 21423
10 3 Installing 21424
10 3 1 Preparing replacement part 21424
10 3 2 Welding in 21425
51 – Body – centre 21427
1 Renewing roof 21427
1 1 Tools 21428
1 2 Removing 21429
1 3 Installing 21432
1 3 1 Preparing replacement part 21432
1 3 2 Adjusting roof depth 21433
1 3 3 Bonding roof 21435
1 3 4 Welding in 21442
2 Renewing front cross member for roof 21444
2 1 Tools 21444
2 2 Removing 21444
2 3 Installing 21446
2 3 1 Preparing replacement part 21446
2 3 2 Welding in 21446
3 Renewing roof reinforcement 21448
3 1 Tools 21448
3 2 Removing 21448
3 3 Installing 21450
3 3 1 Preparing replacement part 21450
3 3 2 Welding in 21451
4 Renewing rear roof cross member 21453
4 1 Tools 21453
4 2 Removing 21453
4 3 Installing 21455
4 3 1 Preparing replacement part 21455
4 3 2 Welding in 21456
5 Renewing A-pillar 21458
5 1 Tools 21459
5 2 Removing 21459
5 3 Installing 21461
5 3 1 Preparing replacement part 21462
5 3 2 Moulded foam inserts 21463
5 3 3 Welding in 21464
6 Renewing A-pillar reinforcement 21469
6 1 Tools 21470
6 2 Removing 21470
6 3 Installing 21474
6 3 1 Preparing replacement part 21474
6 3 2 Moulded foam inserts 21475
6 3 3 Welding in 21475
7 Renewing B-pillar – 4-door 21480
7 1 Tools 21482
7 2 Removing 21482
7 3 Installing 21484
7 3 1 Preparing replacement part 21485
7 3 2 Moulded foam inserts 21486
7 3 3 Welding in 21486
8 Renewing B-pillar reinforcement – 4-door 21489
8 1 Tools 21490
8 2 Removing 21490
8 3 Installing 21492
8 3 1 Preparing replacement part 21493
8 3 2 Marking area in which welding work is prohibited 21494
8 3 3 Moulded foam inserts 21495
8 3 4 Welding in 21495
9 Renewing B-pillar reinforcement, 4-door model, part section 21498
9 1 Tools 21499
9 2 Removing 21499
9 3 Installing 21503
9 3 1 Preparing replacement part 21503
9 3 2 Marking area in which welding work is prohibited 21505
9 3 3 Moulded foam inserts 21506
9 3 4 Welding in 21506
10 Renewing B-pillar reinforcement – 2-door 21512
10 1 Tools 21513
10 2 Removing 21513
10 3 Installing 21515
10 3 1 Preparing replacement part 21515
10 3 2 Marking area in which welding work is prohibited 21520
10 3 3 Moulded foam inserts 21521
10 3 4 Welding in 21522
11 Renewing outer side member – 4-door 21527
11 1 Tools 21529
11 2 Removing 21529
11 3 Installing 21531
11 3 1 Preparing replacement part 21532
11 3 2 Marking area in which welding work is prohibited 21533
11 3 3 Moulded foam inserts 21534
11 3 4 Welding in 21535
12 Renewing outer side member – 2-door 21540
12 1 Tools 21542
12 2 Removing 21542
12 3 Installing 21543
12 3 1 Preparing replacement part 21543
12 3 2 Welding in 21544
13 Renewing gusset plate 21549
13 1 Tools 21549
13 2 Removing 21549
13 3 Installing 21551
13 3 1 Preparing replacement part 21551
13 3 2 Welding in 21551
14 Renewing seat cross member 21553
14 1 Tools 21553
14 2 Removing 21553
14 3 Installing 21555
14 3 1 Preparing replacement part 21555
14 3 2 Welding in 21556
53 – Body – rear 21558
1 Renewing rear cross panel 21558
1 1 Tools 21559
1 2 Removing 21559
1 3 Installing 21560
1 3 1 Preparing replacement part 21560
1 3 2 Welding in 21561
2 Renewing tail light mounting 21563
2 1 Tools 21564
2 2 Removing 21564
2 3 Installing 21565
2 3 1 Preparing replacement part 21565
2 3 2 Welding in 21566
3 Renewing cross panel member 21568
3 1 Tools 21569
3 2 Removing 21569
3 3 Installing 21570
3 3 1 Preparing replacement part 21570
3 3 2 Welding in 21571
4 Renewing luggage compartment floor 21573
4 1 Tools 21574
4 2 Removing 21574
4 3 Installing 21575
4 3 1 Preparing replacement part 21575
4 3 2 Moulded foam inserts 21576
4 3 3 Welding in 21576
5 Renewing rear longitudinal member – part section 21578
5 1 Tools 21579
5 2 Removing 21579
5 3 Installing 21581
5 3 1 Preparing replacement part 21581
5 3 2 Welding in 21582
6 Renewing side panel, part section – 4-door 21584
6 1 Tools 21585
6 2 Removing 21585
6 3 Installing 21587
6 3 1 Preparing replacement part 21588
6 3 2 Moulded foam inserts 21589
6 3 3 Welding in 21590
7 Renewing side panel – 2-door 21595
7 1 Tools 21596
7 2 Removing 21596
7 3 Installing 21598
7 3 1 Preparing replacement part 21599
7 3 2 Moulded foam inserts 21600
7 3 3 Marking area in which welding work is prohibited 21601
7 3 4 Welding in 21602
8 Renewing outer wheel housing liner – part section 21607
8 1 Tools 21608
8 2 Removing 21608
8 3 Installing 21610
8 3 1 Preparing replacement part 21610
8 3 2 Welding in 21611
K0058895220 7 speed dual clutch gearbox 0AM 21613
00 – Technical data 21619
1 Identification of gearbox 21619
2 Overview – power transmission 21620
3 Code, engine allocation 21621
3 1 Polo 2010 ► 21621
3 2 Touran 2003 ► 21621
3 3 Golf 2004 ► 21621
3 4 Passat CC 2009 ►; CC 2010 ► 21622
3 5 Passat 2006 ► 21622
3 6 Golf 2009 ► 21622
3 7 Golf Plus 2009 ► 21622
3 8 Golf Plus 2005 ►, Cross Golf 21623
3 9 Scirocco 2009 ► 21623
4 Capacities 21624
5 General repair instructions 21625
5 1 Tools 21625
5 2 Gearbox 21625
5 3 Anti-friction bearings 21627
5 4 Oil 21627
5 5 Working with tester 21627
5 5 1 Adapting installation information 21628
5 5 2 Reading measured values for mandatory reporting 21628
5 5 3 Initiating basic adjustment 21628
30 – Clutch 21629
1 Removing and installing dual clutch, gearboxes made up to 05 2011 21629
1 1 Assembly overview – dual clutch, gearboxes made up to 05 2011 21629
1 2 Removing dual clutch, gearboxes made up to 05 2011 21631
1 3 Adjusting position of engagement bearings for clutches “K 1” and “K 2”, gearboxes made up to 05 2011 21635
1 4 Installing dual clutch, gearboxes made as of 05 2011 21648
2 Removing and installing dual clutch, gearboxes made from 06 2011 onwards 21655
2 1 Assembly overview – dual clutch, gearboxes made as of 06 2011 21655
2 2 Removing dual clutch, gearboxes made as of 06 2011 21657
2 3 Adjusting position of engagement bearings for clutches “K 1” and “K 2”, gearboxes made as of 06 2011 21661
2 4 Installing dual clutch, gearbox date from 06 2011 21674
3 Removing and installing oil seals at clutch end 21681
34 – Controls, housing 21684
1 Emergency release of selector lever 21684
2 Removing and installing selector lever handle 21685
2 1 Moving push-button in the handle to installation position 21687
2 1 1 Handle with push-button on side 21687
2 1 2 Handle with front push-button 21687
3 Selector mechanism in vehicles up to 02 2009 21690
3 1 Overview of selector mechanism up to 02 2009 21690
3 2 Removing and installing selector lever cable up to 02 2009 21691
4 Selector mechanism from 03 2009 onwards 21698
4 1 Overview of selector mechanism in vehicles from 03 2009 onwards 21698
4 2 Removing and installing selector mechanism 21699
4 2 1 Removing and installing selector mechanism with selector housing 21699
4 2 2 Removing and installing selector mechanism without selector housing 21701
5 Checking selector mechanism 21703
5 1 Selector lever in “P” position and ignition switched on 21703
5 2 Selector lever in “N” position and ignition switched on 21703
5 3 Selector lever in position “Tiptronic” 21703
5 4 Ignition and light switched on 21703
5 5 Selector lever position indicator 21703
5 6 Checking and adjusting selector lever cable 21703
6 Safety note on mechatronic unit for dual clutch gearbox -J743- 21707
7 Overview – mechatronic unit 21708
8 Removing mechatronic unit for dual clutch gearbox -J743-; gearbox is installed 21710
9 Moving mechatronic unit for dual clutch gearbox -J743- into »removal position« by hand 21722
10 Installing mechatronic unit for dual clutch gearbox -J743- 21724
11 View on selector forks; mechatronic unit is removed 21732
12 Renewing clutch actuator 21733
13 Renewing control unit for mechatronic unit for dual clutch gearbox -J743- 21739
14 Removing and installing gearbox 21744
14 1 Notes on different vehicles, different gearboxes 21744
14 2 Removing gearbox, Golf 2009 ► and Golf Plus 2009 ►, 1 2 l – 63 and 77 kW petrol engine 21746
14 3 Removing gearbox, Golf 2009 ►, 1 8 l – 118 kW petrol engine 21754
14 4 Removing gearbox, Polo 2010 ►, 1 2 l – 63 and 77 kW petrol engine 21760
14 5 Removing gearbox, Polo 2010 ►, 1 4 l – 63 kW petrol engine 21765
14 6 Removing gearbox, Polo 2010 ►, 1 4 l – 103 kW petrol engine 21772
14 7 Removing gearbox, Polo 2010 ►, 1 6 l – 66 kW diesel engine 21776
14 8 Removing gearbox, Polo 2010 ►, 1 4 l – 132 kW petrol engine 21783
14 9 Removing gearbox with flange shafts; Touran 1 4 l – 103, 110 and 125 kW petrol engine (and 110 kW Eco-Fuel) 21789
14 10 Removing gearbox, Touran 1 6 l – 77 kW TDI engine 21795
14 11 Removing gearbox, Touran 1 9 l – 77 kW TDI engine 21801
14 12 Removing gearbox, Passat 2006 ► 1 4 l – 110 kW Eco-Fuel engine 21807
14 13 Removing gearbox, Passat 1 4 l – 90 and 110 kW petrol engine 21813
14 14 Removing gearbox, Passat 1 8 l – 90 and 118 kW petrol engine 21818
14 15 Removing gearbox, Golf Plus 2009 ►, 1 4 l – 90 kW and 118 kW petrol engine 21823
14 16 Removing gearbox, Golf Plus 2009 ►, 1 6 l – 75 kW petrol engine 21830
14 17 Removing gearbox, Scirocco 2009 ►, 1 4 l – 118 kW TSI engine 21837
14 18 Removing gearbox, Golf 2009 ►, 1 6 l – 75 kW petrol engine 21844
14 19 Removing gearbox, Golf 2009 ►, 1 4 l – 90 or 118 kW petrol engine 21850
14 20 Removing gearbox, Golf 2004 ►, Golf Plus 2005 ► and Cross Golf 1 4 l – 90, 118 kW TSI engine 21857
14 21 Removing gearbox, Golf Plus 2009, 1 6 l – 77 kW diesel engine 21864
14 22 Removing gearbox, Golf 2009 1 6 l and 1 9 l – 77 kW diesel engine 21871
14 23 Removing gearbox, Golf 2004 and Golf Plus 2005 1 9 l – 77 kW TDI engine 21877
14 24 Removing gearbox, Passat CC 2009 ►, CC 2010 ►, Passat 2011 ► 1 4 l – 90, 110, 118 kW petrol engine and 1 4 l – 110 kW Eco-Fuel engine 21883
14 25 Removing gearbox, Passat CC 2009►, CC 2010►, 1 8 l – 90 and 118 kW petrol engine 21890
14 26 Removing gearbox, Golf Cabriolet 2012 ►, 1 4 l – 90 or 118 kW petrol engine 21896
14 27 Install gearbox 21902
14 28 Torque settings »Gearbox to engine« and notes on assembly mounting 21905
14 28 1 1 8 – 118 kW engine 21907
14 28 2 1 4 l – 63 kW petrol engine 21908
14 28 3 1 4 l – 103 kW petrol engine 21909
14 28 4 1 2 l and 1 4 l and 1 6 l engine 21910
14 28 5 1 6 l – 77 kW diesel engine 21911
14 28 6 1 9 l – 77 kW diesel engine and 1 6 l – 66 kW diesel engine 21912
15 Transporting gearbox and securing to assembly stand 21913
16 Gear oil 21915
16 1 Draining and filling gear oil 21915
16 2 Draining and filling hydraulic fluid for mechatronic unit 21917
35 – Gears, shafts 21921
1 Notes on gearbox disassembly 21921
1 1 Overview: gearbox disassembly 21921
2 Dismantling gearbox 21923
3 Assembling gearbox 21930
4 Dismantling and assembling gearbox housing 21941
5 Dismantling and assembling clutch housing 21945
6 Dismantling and assembling outer input shaft 21949
7 Dismantling and assembling inner input shaft 21951
8 Dismantling and assembling output shaft 1 – overview 21954
8 1 Dismantling output shaft 1 partially 21955
8 2 Dismantling output shaft 1 completely 21957
8 3 Assembling output shaft 1 21959
8 4 Dismantling and assembling locking collars and synchro-hubs of output shaft 1 21964
9 Dismantling and assembling output shaft 2 – overview 21965
9 1 Dismantling output shaft 2 21966
9 2 Assembling output shaft 2 21968
9 3 Dismantling and assembling locking collars and synchro-hubs of output shaft 2 21972
10 Dismantling and assembling output shaft 3 – overview 21973
10 1 Dismantling output shaft 3 21973
10 2 Assembling output shaft 3 21975
10 3 Dismantling and assembling locking collar and synchro-hub of output shaft 3 21977
11 Notes on gearbox adjustment 21978
11 1 Calculating shims for clutch housing 21979
12 Calculating shims for gearbox housing 21992
13 Parking lock 22012
13 1 Removing and installing cover for parking lock 22012
13 2 Removing and installing parking lock 22013
39 – Final drive – front differential 22015
1 Oil seals 22015
1 1 Renewing oil seal for right stub shaft 22015
1 2 Renewing oil seal for left stub shaft 22016
1 3 Renewing seal for right flange shaft 22018
1 4 Renewing oil seal for left flange shaft 22020
K0059101320 Electrical system General information 22024
27 – Starter, current supply, CCS 22030
1 Battery 22030
1 1 Fundamentals for batteries 22030
1 2 Battery load test 22030
1 2 1 Battery with »standard« colour indicator 22031
1 2 2 Battery with »enhanced« colour indicator 22031
1 2 3 Absorbent glass mat battery 22032
1 2 4 Lithium ion battery 22032
1 3 Warning notices and safety regulations 22032
1 3 1 Dangers when handling vehicle batteries 22032
1 3 2 Safety markings on battery 22033
1 3 3 Working on airbag system 22034
1 4 Battery load test 22034
2 Checking battery 22036
2 1 Checking the various types of batteries 22036
2 1 1 Checking a battery with colour indicator 22036
2 1 2 Absorbent glass mat battery 22036
2 2 Visual inspection 22037
2 3 Information about battery replacement and battery gas venting 22038
2 4 Checking colour indicator in battery cover 22039
2 4 1 Checking colour indicator, “3-colour” 22039
2 4 2 Checking colour indicator, “2-colour” 22040
2 5 Current draw test 22041
3 Charging the battery 22043
3 1 Totally discharged batteries 22043
4 Cruise control system (CCS) 22045
4 1 Activating and deactivating cruise control system (CCS) 22045
90 – Gauges, instruments 22046
92 – Windscreen wash/wipe system 22047
1 Washer fluid line hose couplings 22047
1 1 Windscreen and rear window washer system 22047
1 2 Headlight washer system 22048
2 Hose repair 22049
2 1 General description 22049
2 2 Repairing smooth pipe 22049
2 3 Repairing corrugated pipe 22049
3 Distinguishing features of jointless wiper blades 22052
94 – Lights, bulbs, switches – exterior 22053
1 Operation and safety notes for gas discharge lamps 22053
96 – Lights, bulbs, switches – interior 22056
1 12 V socket 22056
1 1 Removing and installing 12 V socket 22056
1 2 Removing and installing socket illumination bulb -L42- 22056
2 Cigarette lighter -U1- 22057
2 1 General description 22057
2 2 Assembly overview 22058
2 3 Removing and installing cigarette lighter socket 22059
2 4 Removing and installing cigarette lighter illumination bulb -L28- 22062
97 – Wiring 22064
1 Vehicle diagnostic, testing and information systems 22064
1 1 Connecting vehicle diagnostic tester 22064
1 2 Connecting vehicle diagnostic tester Golf Model Year 1998 – 2003 22066
2 Repairs to wiring harnesses and connectors 22067
2 1 General notes concerning repairs to vehicle electrical system 22067
2 2 Wiring harness repair set 22069
2 2 1 Wiring harness repair set -VAS 1978- 22069
2 2 2 Upgrade kit -VAS 1978/50- 22069
2 2 3 Wiring harness repair set -VAS 1978A- 22070
2 2 4 Release tool set -VAS 1978/35- 22070
2 3 Tool descriptions 22071
2 3 1 Special pliers with insert 22071
2 3 2 Release tools for contacts 22072
2 3 3 Assembly tools for single wire seals 22072
2 3 4 Wire stripper -VAS 1978/3- 22072
2 3 5 Hot air blower 220 V/50 Hz -VAS 1978/14- 22074
2 3 6 Crimping pliers -VAS 1978/1A- 22074
2 4 Repairing wiring harnesses 22076
2 4 1 Repairs to airbag and belt tensioner wiring 22076
2 4 2 Repairing CAN bus wiring 22078
2 4 3 Repair of Flexray wires with sheath 22079
2 4 4 Repair of Flexray wires without sheath 22080
2 4 5 Renewal of aerial wiring 22081
2 4 6 Repairing 0 13 mm2/0 35 mm2/0 5 mm2 wire 22083
2 4 7 Repair of 10 mm2 or 16 mm2 wire with single butt connector 22088
2 4 8 Repair of 2 5 mm2, 4 mm2 or 6 mm2 aluminium wire with single butt connector 22095
2 4 9 Wiring open circuit with one repair position 22101
2 4 10 Wiring open circuit with two repair positions 22104
2 5 Repairing fibre optic cables 22106
2 5 1 Preparing fibre optic cable 22107
2 5 2 Detaching fibre optic cable from cable harness connector 22114
2 6 Repair of aerial wires 22115
2 6 1 Repair set, aerial cable VAS 6720 22115
2 7 Repairs to contact housings and connectors 22127
2 7 1 Notes on repairs to contact housings and connectors 22127
2 7 2 Repairs to contacts in contact housings 22127
2 7 3 Fitting single wire seals 22129
2 7 4 Repairs to contact housings using cut-and-clamp method 22132
2 8 Releasing and dismantling contact housings 22133
2 8 1 Notes on releasing and dismantling contact housings 22133
2 8 2 Secondary locking element 22133
2 8 3 Primary locking element 22134
2 8 4 Round connector systems 22135
2 8 5 Flat connector systems 22136
2 8 6 Special connector systems 22138
3 Contact surface cleaning set -VAS 6410- 22141
3 1 Using contact surface cleaning set -VAS 6410- 22141
3 1 1 Servicing ring terminals 22141
3 1 2 Servicing screw connections 22143
3 1 3 Cleaning battery clamp and battery terminal 22145
3 1 4 Anti-corrosion treatment 22147
4 Renewing lambda probe 22149
4 1 Renewing LSF Lambda probe (4-pin) 22149
4 2 Renewing LSU Lambda probe (6-pin) 22150
4 3 Types of protective tube on universal lambda probes 22151
5 Exhaust gas temperature sensor 22153
K0059111420 4 cylinder direct injection engine (1 4 l EA 111 turbocharger supercharger) 22154
00 – Technical data 22162
1 Engine number/engine data 22162
2 Safety precautions 22166
2 1 Safety regulations for working on fuel supply 22166
2 2 Safety precautions when working on ignition system 22166
2 3 Releasing pressure in high-pressure area 22167
3 General repair instructions 22168
3 1 Rules for cleanliness 22168
10 – Removing and installing engine 22169
1 Removing and installing motor 22169
1 1 Removing engine (Golf Plus, Eos, Scirocco, Golf, Touran, Golf Cabriolet) 22169
1 2 Installing engine (Golf Plus, Eos, Scirocco, Golf, Touran, Golf Cabriolet) 22179
1 3 Removing engine (Tiguan) 22181
1 4 Installing engine (Tiguan) 22189
1 5 Removing engine (Polo) 22192
1 6 Installing engine (Polo) 22200
1 7 Removing engine (Sharan) 22201
1 8 Installing engine (Sharan) 22209
1 9 Removing engine (Passat, Passat CC) 22211
1 10 Installing engine (Passat, Passat CC) 22221
2 Assembly mountings 22225
2 1 Assembly overview – assembly mountings (Touran, Golf Plus, Eos, Scirocco, Golf, Golf Cabriolet) 22225
2 2 Assembly overview – assembly mountings (Tiguan) 22226
2 3 Assembly overview – assembly mountings (Polo) 22227
2 4 Assembly overview – assembly mountings (Sharan) 22228
2 5 Assembly overview – assembly mountings (Passat, Passat CC) 22228
13 – Crankshaft group 22230
1 Cylinder block (pulley end) 22230
1 1 Assembly overview – poly V-belt drive 22232
1 2 Assembly overview – cylinder block, belt pulley end 22234
1 3 Removing and installing poly V-belt (Golf Plus, Eos, Scirocco, Golf, Touran, Polo, Sharan, Passat, Passat CC, Golf Cabriolet) 22236
1 3 1 Poly V-belt routing 22238
1 4 Removing and installing poly V-belt (Tiguan) 22239
1 4 1 Poly V-belt routing 22240
1 5 Removing and installing bracket for ancillaries 22241
1 6 Renewing crankshaft oil seal – pulley end 22242
1 7 Removing and installing crankshaft pulley 22244
2 Cylinder block, gearbox end 22248
2 1 Assembly overview – cylinder block, gearbox end 22248
2 2 Removing and installing sealing flange on gearbox side 22250
2 2 1 Pressing sealing flange with sender wheel off crankshaft 22250
2 2 2 Pressing sealing flange with sender wheel onto crankshaft 22251
2 2 3 A – Assemble seal with sender wheel on assembly tool -T10134- 22252
2 2 4 B – Fitting assembly tool -T10134- with sealing flange to crankshaft flange 22254
2 2 5 C – Screwing assembly tool -T10134- on crankshaft flange 22255
2 2 6 D – Pressing sender wheel onto crankshaft flange using assembly tool -T10134- 22255
2 2 8 f) Re-pressing sender wheel 22257
3 Crankshaft 22258
3 1 Assembly overview – crankshaft 22258
3 2 Pulling needle bearing out of and driving into crankshaft 22259
3 3 Crankshaft dimensions 22261
4 Pistons and conrods 22262
4 1 Assembly overview – pistons and conrods 22262
4 2 Checking piston 22264
4 3 Checking cylinder bores 22265
4 4 Separating new conrod 22265
4 5 Removing and installing pistons 22265
4 6 Removing and installing oil spray jets 22266
15 – Cylinder head, valve gear 22268
1 Cylinder head 22268
1 1 Assembly overview – cylinder head 22268
1 2 Removing and installing camshaft housing 22271
1 2 1 Removing 22272
1 2 2 Installing 22274
1 3 Removing and installing cylinder head 22277
1 3 1 Removing 22277
1 3 2 Installing 22278
1 4 Checking compression 22279
2 Valve gear 22282
2 1 Assembly overview – valve gear 22282
2 2 Measuring axial clearance of camshaft 22284
2 3 Reworking valve seats 22284
2 4 Checking valve guides 22286
2 5 Removing and installing valve stem seals 22286
2 5 1 Removing 22287
2 5 2 Installing 22288
3 Cover for timing chain 22289
3 1 Removing and installing valve timing housing (Eos, Golf Plus, Scirocco, Golf, Polo, Sharan, Golf Cabriolet) 22289
3 1 1 Removing 22290
3 1 2 Installing 22292
3 2 Removing and installing valve timing housing (Touran, Tiguan) 22293
3 2 1 Removing 22296
3 2 2 Installing 22298
3 3 Removing and installing valve timing housing (Passat CC, Passat) 22299
4 Chain drive 22304
4 1 Checking valve timing 22304
4 2 Adjusting valve timing 22306
4 3 Checking timing chain 22313
4 4 Removing and installing timing chain and chain drive for oil pump 22320
17 – Lubrication 22329
1 Sump, oil pump 22329
1 1 Engine oil: 22329
1 2 Assembly overview – sump, oil pump 22329
1 3 Removing and installing sump 22332
1 4 Removing and installing oil pump 22336
2 Oil filter, oil pressure switch 22339
2 1 Checking oil pressure and oil pressure switch 22339
19 – Cooling 22341
1 Cooling system/coolant 22341
1 1 Coolant hose schematic diagram (Golf Plus, Eos, Scirocco, Golf, Touran, Polo, Golf Cabriolet) 22342
1 2 Schematic diagram for coolant hoses (Tiguan) 22343
1 3 Schematic diagram for coolant hoses (Sharan) 22344
1 4 Coolant hose schematic diagram (Passat, Passat CC) 22345
1 5 Draining and filling with coolant (Golf Plus, Eos, Scirocco, Golf, Touran, Tiguan, Golf Cabriolet) 22346
1 6 Draining and filling coolant (Polo) 22350
1 7 Draining and filling coolant (Sharan) 22354
1 8 Draining and filling coolant (Passat, Passat CC) 22359
1 9 Checking cooling system for leaks (Polo, Touran, Golf Plus, Eos, Scirocco, Golf, Golf Cabriolet) 22365
1 10 Checking cooling system for leaks (Sharan, Tiguan) 22367
1 11 Checking cooling system for leaks (Passat, Passat CC) 22369
2 Coolant pump, regulation of cooling system 22372
2 1 Assembly overview – thermostat 22372
2 2 Assembly overview – thermostat (Passat, Passat CC) 22374
2 3 Removing and installing coolant pump (Polo, Touran, Golf Plus, Eos, Tiguan, Scirocco, Golf, Golf Cabriolet) 22375
2 4 Removing and installing coolant pump belt pulley (Polo, Touran, Golf Plus, Eos, Tiguan, Scirocco, Golf, Golf Cabriolet) 22379
2 5 Removing and installing coolant circulation pump -V50- (Polo, Touran, Golf Plus, Eos, Tiguan, Scirocco, Golf, Golf Cabriolet) 22384
2 6 Removing and installing coolant pump (Sharan) 22386
2 7 Removing and installing coolant pump belt pulley (Sharan) 22391
2 8 Removing and installing coolant circulation pump -V50- (Sharan) 22395
2 9 Removing and installing coolant pump belt pulley (Passat, Passat CC) 22397
2 10 Removing and installing coolant pump (Passat, Passat CC) 22403
2 11 Removing and installing coolant circulation pump -V50- (Passat, Passat CC) 22410
2 12 Assembly overview – heater element for engine preheater -Z97- (Passat, Passat CC) 22412
2 13 Removing and installing heater element for engine preheater -Z97- (Passat, Passat CC) 22414
3 Radiator, radiator fan 22417
3 1 Assembly overview – radiator/radiator fan (Eos, Golf Plus, Scirocco, Golf, Touran, Golf Cabriolet) 22417
3 2 Assembly overview – parts of cooling system, body side (Tiguan) 22419
3 3 Assembly overview – radiator/radiator fan (Polo) 22421
3 4 Assembly overview – radiator/radiator fan (Sharan) 22422
3 5 Assembly overview – radiator/radiator fan (Passat, Passat CC) 22423
3 6 Removing and installing radiator fan -V7- and radiator fan 2 -V177- (Eos, Golf Plus, Scirocco, Golf, Touran, Golf Cabriolet) 22424
3 7 Removing and installing radiator fan -V7- and radiator fan 2 -V177- (Polo) 22425
3 8 Removing and installing radiator, radiator fan -V7- and radiator fan 2 -V177- (Sharan) 22426
3 9 Removing and installing radiator (Passat, Passat CC) 22428
3 10 Removing and installing fan cowling (Passat, Passat CC) 22431
3 11 Removing and installing radiator fan -V7- and radiator fan 2 -V177- (Passat, Passat CC) 22432
3 12 Removing and installing radiator (Golf Plus, Eos, Scirocco, Golf, Touran, Golf Cabriolet) 22433
3 13 Removing and installing radiator and radiator fan -V7- (Tiguan) 22434
3 14 Removing and installing radiator with charge air cooler (Polo) 22436
21 – Turbocharging/supercharging 22439
1 Turbocharger 22439
1 1 Assembly overview – turbocharger 22439
1 2 Removing and installing turbocharger 22443
1 3 Checking vacuum unit for turbocharger 22448
1 4 Removing and installing vacuum unit for turbocharger 22450
1 5 Adjusting vacuum unit for turbocharger 22452
2 Compressor 22458
2 1 Assembly overview – supercharger 22458
2 2 Removing and installing supercharger 22460
2 3 Removing and installing supercharger (Tiguan with four-wheel drive) 22468
2 4 Removing and installing drive unit seal for supercharger 22476
3 Charge air system 22480
3 1 Assembly overview – charge air system (Eos, Golf Plus, Golf, Touran, Scirocco, Tiguan, Sharan, Golf Cabriolet) 22481
3 2 Assembly overview – charge air system (Polo) 22482
3 3 Assembly overview – charge air system (Passat, Passat CC) 22483
3 4 Fitting hose connections with plug-in connectors 22484
3 5 Checking charge air system for leaks 22485
3 6 Removing and installing charge air cooler (Eos, Golf Plus, Golf, Golf Cabriolet, Touran) 22488
3 7 Removing and installing charge air cooler, Sharan 22490
3 8 Removing and installing charge air cooler (Scirocco) 22492
3 9 Removing and installing charge air cooler, Tiguan 22494
3 10 Removing and installing charge air cooler (Passat, Passat CC) 22496
24 – Mixture preparation – injection 22501
1 Air filter 22501
1 1 Assembly overview – air filter 22501
1 2 Assembly overview – air filter (Polo) 22502
1 3 Removing and installing air filter housing 22503
1 4 Removing and installing air filter housing (Polo) 22504
2 Intake manifold 22505
2 1 Assembly overview – intake manifold 22505
2 2 Removing and installing regulating flap control unit -J808- and throttle valve module -J338- 22510
2 3 Cleaning throttle valve module -J338- 22512
3 Injectors 22514
3 1 Assembly overview – fuel rail with injectors 22514
3 2 Removing and installing injectors 22516
3 3 Renewing seals on injectors 22519
4 Senders and sensors 22523
4 1 Checking fuel pressure sender 22523
4 2 Actuator for structure-borne sound -R214- and control unit for structure-borne sound -J869- (Polo, left-hand drive) 22526
4 3 Assembly overview – actuator for structure-borne sound -R214- and control unit for structure-borne sound -J869- (Polo, right-hand drive) 22528
5 High-pressure pump 22529
5 1 Assembly overview – high-pressure pump 22529
5 2 Removing and installing high-pressure pump 22530
6 Engine control unit -J623- 22534
6 1 Removing and installing engine control unit -J623- (Golf Plus, Touran) 22534
6 2 Removing and installing engine control unit -J623- with protective housing (Golf Plus, Touran) 22536
6 3 Removing and installing engine control unit -J623- (Eos) 22538
6 4 Removing and installing engine control unit -J623- with protective housing (Eos► 10 2008) 22539
6 5 Removing and installing engine control unit -J623- (Tiguan) 22541
6 6 Removing and installing engine control unit -J623- with protective housing (Tiguan) 22542
6 7 Removing and installing engine control unit -J623- (Scirocco) 22544
6 8 Removing and installing engine control unit -J623- with protective housing (Scirocco► 09 2008) 22545
6 9 Removing and installing engine control unit -J623- (Golf, Golf Cabriolet) 22547
6 10 Removing and installing engine control unit -J623- (Passat, Passat CC) 22548
6 11 Removing and installing engine control unit -J623- with protective housing (Golf, Eos 11 2008►, Scirocco 10 2008►, Passat, Passat CC, Golf Cabriolet) 22549
6 12 Removing and installing engine control unit -J623- (Polo) 22552
6 13 Removing and installing engine control unit -J623- with protective housing (Polo) 22553
6 14 Removing and installing engine control unit -J623- (Sharan) 22554
6 15 Removing and installing engine control unit -J623- with protective housing (Sharan) 22555
26 – Exhaust system 22557
1 Exhaust pipes and silencers 22557
1 1 Assembly overview – silencer (Golf Plus, Eos, Scirocco, Golf, Touran, Golf Cabriolet) 22558
1 2 Assembly overview – silencers (Tiguan) 22559
1 3 Assembly overview – silencers (Polo) 22560
1 4 Assembly overview – silencers (Sharan) 22561
1 5 Assembly overview – silencer (Passat, Passat CC) 22562
1 6 Removing and installing front exhaust pipe (Tiguan with four-wheel drive) 22563
1 7 Removing and installing front exhaust pipe (Golf Plus, Eos, Scirocco, Golf, Tiguan, Touran, Golf Cabriolet) 22564
1 8 Removing and installing front exhaust pipe (Sharan) 22565
1 9 Removing and installing (Passat, Passat CC) 22566
1 10 Separating exhaust pipes, silencers (Tiguan) 22568
1 11 Separating exhaust pipes/silencers (Golf Plus, Eos, Scirocco, Golf, Touran, Golf Cabriolet) 22569
1 12 Separating exhaust pipes, silencers (Polo) 22571
1 13 Separating exhaust pipes, silencers (Sharan) 22572
1 14 Separating exhaust pipes/silencers (Passat, Passat CC) 22573
1 15 Aligning exhaust system free of stress (Passat, Passat CC) 22575
1 16 Installation position of clamp 22576
2 Emission control 22577
2 1 Assembly overview – exhaust gas treatment (Golf Plus, Eos, Scirocco, Golf, Touran, Tiguan, Golf Cabriolet) 22577
2 2 Assembly overview – exhaust gas treatment (Tiguan with four-wheel drive) 22579
2 3 Assembly overview – exhaust gas treatment (Polo) 22581
2 4 Assembly overview – exhaust gas treatment (Sharan) 22582
2 5 Assembly overview – exhaust gas treatment (Passat, Passat CC) 22583
2 6 Removing and installing catalytic converter (Polo) 22585
2 7 Removing and installing (Passat, Passat CC) 22586
28 – Ignition system 22589
1 Ignition system 22589
1 1 Assembly overview – ignition system 22589
1 2 Removing and installing ignition coils with output stage 22590
1 3 Removing and installing engine speed sender -G28- 22592
1 4 Test data, spark plugs 22594
P0050308920 5 speed manual gearbox 02R 22595
00 – Technical data 22599
1 Identification of gearbox 22599
1 1 Location on gearbox 22599
1 2 Identification codes, assembly allocation, capacities, Polo 2002 ► 22600
1 3 Identification codes, assembly allocation, capacities, Polo 2010 ► 22603
2 Overview – power transmission 22605
3 General repair instructions 22607
3 1 Gearbox 22607
3 2 Gaskets and seals 22607
3 3 Sealant 22607
3 4 Locking devices 22608
3 5 Nuts and bolts 22608
3 6 Bearings 22608
3 7 Shims 22609
3 8 Synchro-rings 22609
3 9 Gear wheels 22609
3 10 Synchromeshed gears 22609
3 11 Clutch 22610
4 Safety precautions for vehicles with a start-stop system 22611
5 Electrical components 22612
5 1 Overview of fitting locations – electrical components 22612
5 1 1 Overview of fitting locations – electrical components, manual gearbox 22612
5 1 2 Overview of fitting locations – electrical components, clutch mechanism 22613
30 – Clutch 22614
1 Repairing clutch mechanism 22614
1 1 Overview – clutch actuation 22614
1 2 Assembly overview – pedal cluster, Polo 2002 ► 22614
1 3 Assembly overview – pedal cluster, Polo 2010 ► 22616
1 4 Distinguishing between clutch pedal switches -F36- 22618
1 5 Removing and installing clutch pedal switch -F36- with rectangular housing 22619
1 5 1 Removing clutch pedal switch 22619
1 5 2 Installing clutch pedal switch 22619
1 6 Removing and installing clutch pedal switch -F36- with round housing 22619
1 6 1 Removing clutch pedal switch 22619
1 6 2 Installing clutch pedal switch 22620
1 7 Removing and installing over-centre spring – Polo 2002 ► 22622
1 7 1 Removing 22623
1 7 2 Installing 22623
1 8 Removing and installing mounting bracket, Polo 2002 ► 22624
1 8 1 Removing 22624
1 8 2 Installing 22626
1 8 3 Specified torques 22627
1 9 Removing and installing mounting bracket with master cylinder, Polo 2010 ► 22627
1 9 1 Removing 22628
1 9 2 Installing 22631
1 10 Removing and installing clutch pedal – Polo 2002 ► 22632
1 10 1 Removing 22632
1 10 2 Installing 22633
1 10 3 Specified torque 22633
1 11 Removing and installing clutch pedal with over-centre spring, Polo 2010 ► left-hand drive vehicles 22633
1 11 1 Removing 22634
1 11 2 Installing 22635
1 12 Removing and installing clutch pedal with extension spring, Polo 2010 ► left-hand drive vehicles 22637
1 12 1 Removing 22638
1 12 2 Installing 22639
1 13 Removing and installing clutch pedal – Polo 2010 ► right-hand drive 22640
1 13 1 Removing 22641
1 13 2 Installing 22642
1 14 Assembly overview – hydraulics (left-hand drive vehicles) 22644
1 15 Assembly overview – hydraulics (right-hand drive vehicles) 22647
1 16 Removing and installing master cylinder, Polo 2002 ► 22649
1 16 1 Removing 22649
1 16 2 Installing 22651
1 16 3 Specified torques 22652
1 17 Removing and installing master cylinder, Polo 2010 ► 22652
1 17 1 Removing 22652
1 17 2 Installing 22653
1 18 Removing and installing slave cylinder 22653
1 18 1 Removing 22653
1 18 2 Installing 22654
1 19 Bleeding clutch system 22654
2 Servicing clutch release mechanism 22656
3 Repairing clutch 22659
34 – Controls, housing 22663
1 Repairing selector mechanism 22663
1 1 Installation position of selector mechanism 22663
1 2 Overview of selector mechanism 22664
1 3 Assembly overview – gear knob and cover, Polo 2002 ► 22664
1 4 Removing and installing gear knob and cover, Polo 2002 ► 22665
1 5 Assembly overview – gear knob and cover, Polo 2010 ► 22668
1 6 Removing and installing gear knob and cover, Polo 2010 ► 22668
1 7 Servicing gear lever and selector housing (through 05/ 06) 22670
1 7 1 Removing and installing securing clip and spring 22672
1 8 Servicing gear lever and selector housing (from 06 06) 22673
1 9 Installing base plate to selector housing 22675
1 10 Assembly overview – removing and installing selector cables 22675
1 11 Removing and installing selector mechanism 22681
1 11 1 Removing 22681
1 11 2 Installing 22684
1 11 3 Specified torques 22686
1 12 Adjusting selector mechanism 22686
1 12 1 Function 22689
2 Removing and installing gearbox, Polo 2002 ► 22690
2 1 Removing gearbox 22690
2 2 Installing gearbox 22697
2 2 1 Specified torques 22702
3 Removing and installing gearbox, Polo 2010 ► 22706
3 1 Removing gearbox 22706
3 2 Installing gearbox 22716
3 2 1 Specified torques 22726
4 Gearbox transport 22728
5 Checking gearbox oil 22729
6 Dismantling and assembling gearbox 22730
6 1 Overview – gearbox 22730
6 2 Assembly overview 22730
6 3 Assembly overview – removing and installing cover for gearbox housing and 5th gear 22731
6 4 Assembly overview – removing and installing gearbox housing and selector mechanism 22733
6 5 Assembly overview – removing and installing input shaft, output shaft, differential and selector forks 22734
6 6 Assembly sequence – removing and installing cover for gearbox housing and 5th gear 22736
6 6 1 Removing 22736
6 6 2 Installing 22741
6 7 Assembly sequence – Dismantling and assembling gearbox completely 22741
6 7 1 Removing 22741
6 7 2 Installing 22748
6 7 3 Installing 5th gear 22753
7 Repairing gearbox housing and clutch housing 22758
8 Dismantling and assembling selector mechanism on gearbox side (selector shaft can be removed from selector mechanism cover) 22765
9 Dismantling and assembling selector mechanism on gearbox side (selector shaft cannot be removed from selector mechanism cover) 22769
10 Dismantling and assembling selector forks 22771
35 – Gears, shafts 22777
1 Input shaft 22777
1 1 Dismantling and assembling input shaft 22777
1 2 Adjusting input shaft 22785
1 2 1 Determining thickness of shim 22787
1 2 2 Carrying out check measurement 22788
2 Output shaft 22789
2 1 Dismantling and assembling output shaft 22789
2 2 Adjusting output shaft 22804
2 2 1 Determining thickness of shim 22805
3 Reverse shaft 22807
3 1 Dismantling and assembling reverse shaft 22807
39 – Final drive – differential 22810
1 Renewing flange shaft oil seals with gearbox installed 22810
1 1 Renewing oil seal for left flange shaft 22810
1 1 1 Removing 22810
1 1 2 Installing 22812
1 2 Distinguishing seals for right flange shaft 22812
1 3 Renewing seal (two-part seal and sleeve for right flange shaft) 22813
1 3 1 Removing 22813
1 3 2 Installing 22815
1 4 Renewing seal and sleeve together (one-piece seal and sleeve for right flange shaft) 22815
1 4 1 Removing 22816
1 4 2 Installing 22817
2 Adjustment overview 22819
3 Differential 22820
3 1 Dismantling and assembling differential 22820
3 2 Adjusting differential 22830
3 2 1 Determining thickness of shim 22831
P0050312920 5 speed manual gearbox 02T 22833
00 – Technical data 22837
1 Gearbox identification 22837
1 1 Location on gearbox 22837
1 2 Identification codes, assembly allocation, capacities, Polo 2002 ► 22837
1 3 Identification codes, assembly allocation, capacities, Polo 2010 ► 22849
2 Overview – power transmission 22851
3 General repair notes 22853
3 1 Contact corrosion! 22853
3 2 Special tools 22853
3 3 Gearbox 22853
3 4 Seals and sealing rings 22853
3 5 Sealant 22854
3 6 Locking devices 22854
3 7 Nuts and bolts 22854
3 8 Bearings 22854
3 9 Shims 22855
3 10 Synchro-rings 22855
3 11 Gear wheels 22855
3 12 Synchromeshed gears 22855
3 13 Clutch 22855
4 Safety measures for vehicles with start/stop system 22856
30 – Clutch 22857
1 Repairing clutch mechanism 22857
1 1 Overview – clutch actuation 22857
1 2 Assembly overview – pedal cluster, Polo 2002 ► 22858
1 3 Assembly overview – pedal cluster, Polo 2010 ► 22859
1 4 Distinguishing between clutch pedal switches -F36- 22861
1 5 Removing and installing, adjusting clutch pedal switch -F36- with round housing 22861
1 5 1 Removing clutch pedal switch 22861
1 5 2 Installing clutch pedal switch 22861
1 6 Removing and installing clutch pedal switch -F36- with round housing 22862
1 6 1 Removing clutch pedal switch 22862
1 7 Removing and installing over-centre spring, Polo 2002 ► 22863
1 7 1 Removing 22864
1 7 2 Installing 22864
1 8 Removing and installing mounting bracket, Polo 2002 ► 22865
1 8 1 Installing 22867
1 8 2 Specified torques 22867
1 9 Removing and installing mounting bracket with master cylinder, Polo 2010 ► 22867
1 9 1 Removing 22868
1 9 2 Installing 22870
1 10 Removing and installing clutch pedal, Polo 2002 ► 22871
1 10 1 Removing 22872
1 10 2 Installing 22872
1 10 3 Torque setting 22873
1 11 Removing and installing clutch pedal with over-centre spring, Polo 2010 ► LHD 22873
1 11 1 Removing 22873
1 11 2 Installing 22874
1 12 Removing and installing clutch pedal with extension spring, Polo 2010 ► LHD 22876
1 12 1 Removing 22876
1 12 2 Installing 22877
1 13 Removing and installing clutch pedal, Polo 2010 ► RHD 22878
1 13 1 Removing 22879
1 13 2 Installing 22880
1 14 Assembly overview – hydraulics (LHD) 22881
1 15 Assembly overview – hydraulics (RHD) 22884
1 16 Removing and installing master cylinder, Polo 2002 ► 22886
1 16 1 Removing 22886
1 16 2 Installing 22888
1 16 3 Specified torques 22888
1 17 Removing and installing master cylinder, Polo 2010 ► 22888
1 17 1 Removing 22889
1 17 2 Installing 22889
1 18 Removing and installing slave cylinder 22889
1 18 1 Removing 22890
1 18 2 Installing 22890
1 19 Bleeding clutch system 22890
2 Repairing clutch release mechanism 22892
3 Repairing clutch 22894
34 – Controls, housing 22897
1 Repairing selector mechanism 22897
1 1 Installation position of selector mechanism 22897
1 2 Overview of selector mechanism 22898
1 3 Assembly overview – selector lever knob and cover, Polo 2002 ► 22899
1 4 Removing and installing gear knob and cover, Polo 2002 ► 22899
1 5 Assembly overview – selector lever knob and cover, Polo 2010 ► 22901
1 6 Removing and installing gear knob and cover, Polo 2010 ► 22902
1 7 Repairing gear lever and selector housing (through 05 06) 22903
1 8 Repairing gear lever and selector housing (from 06 06) 22905
1 9 Assembly overview – removing and installing selector cables 22907
1 10 Removing and installing selector mechanism 22911
1 10 1 Removing 22911
1 10 2 Installing 22914
1 10 3 Specified torques 22915
1 11 Adjusting selector mechanism 22915
1 11 1 Functional check 22918
2 Removing and installing gearbox, Polo 2002 ► with petrol engine 22919
2 1 Removing gearbox 22920
2 2 Installing gearbox 22925
2 2 1 Specified torques 22929
3 Removing and installing gearbox, Polo 2002 ► with 4-cyl diesel engine 22932
3 1 Removing gearbox 22933
3 2 Installing gearbox 22938
3 2 1 Specified torques 22942
4 Removing and installing gearbox, Polo 2002 ► with 3-cylinder TDI engine 22944
4 1 Removing gearbox 22945
4 2 Installing gearbox 22951
4 2 1 Specified torques 22956
5 Removing and installing gearbox, Polo 2010 ► 22958
5 1 Removing gearbox 22959
5 2 Installing gearbox 22965
5 2 1 Specified torques 22969
6 Transporting gearbox 22972
7 Checking gear oil 22973
8 Dismantling and assembling gearbox 22975
8 1 Overview – gearbox 22975
8 2 Assembly overview 22976
8 3 Assembly overview – removing and installing cover for gearbox housing and 5th gear 22977
8 4 Assembly overview – removing and installing clutch housing 22978
8 5 Assembly overview – removing and installing input shaft, output shaft, differential, selector mechanism and selector forks 22979
8 6 Dismantling and assembling procedure 22980
8 6 1 Modifying gearbox support -3221- 22983
8 6 2 Dismantling 22984
8 6 3 Assembling 22986
9 Repairing gearbox housing and clutch housing 22991
10 Repairing selector unit 22996
11 Dismantling and assembling selector forks 22999
35 – Gears, shafts 23004
1 Dismantling and assembling input shaft 23004
2 Dismantling and assembling output shaft 23015
39 – Final drive – differential 23022
1 Renewing flange shaft oil seals with gearbox installed 23022
1 1 Renewing oil seal for left flange shaft 23022
1 1 1 Removing 23022
1 1 2 Installing 23024
1 2 Renewing seal for right flange shaft 23024
1 2 1 Removing 23025
1 2 2 Installing 23026
2 Differential 23027
2 1 Dismantling and assembling differential 23027
2 1 1 One-piece thrust bearing and tapered roller bearing for differential modified from gearbox date 06 05 2 23035
2 2 Adjusting differential 23036
2 2 1 Determining shim S2 23041
P0050325920 4 cyl injection engine (toothed belt drive) 23042
00 – Technical data 23048
1 Technical data 23048
1 1 Engine number 23048
1 2 Engine data 23048
10 – Removing and installing engine 23050
1 Removing and installing engine 23050
1 1 Removing engine 23052
1 2 Securing engine to assembly stand 23054
1 3 Installing engine 23054
1 4 Specified torques 23057
1 5 Assembly mountings 23057
1 6 Additional information and assembly work for vehicles with air conditioner 23058
13 – Crankshaft group 23059
1 Dismantling and assembling engine 23059
1 1 Assembly overview – parts l and ll 23059
1 2 Assembly overview – part I, belt drive 23061
1 3 Assembly overview – part II, cylinder block 23062
1 4 Removing and installing poly-V belt 23064
2 Cylinder block, sealing flange 23066
2 1 Assembly overview 23066
2 2 Pulling needle bearing out of and driving into crankshaft 23067
2 3 Renewing crankshaft oil seal – belt pulley end 23068
2 4 Poly V-belt pulley securing bolt tightening procedure 23070
2 5 Removing and installing drive plate 23071
2 6 Characteristics of the sealing flange and the assembly device -T10017- and -T10134- 23073
2 7 Renewing crankshaft sealing flange – flywheel end (assembly tool -T10134-) 23073
2 7 1 Pressing sealing flange with sender wheel off crankshaft 23074
2 7 2 Pressing sealing flange with sender wheel onto crankshaft 23075
2 7 3 A – Assemble seal with sender wheel on assembly tool -T10134- 23076
2 7 4 B – Fitting assembly tool -T10134- with sealing flange to crankshaft flange 23077
2 7 5 C – Screwing assembly tool -T10134- on crankshaft flange 23078
2 7 6 D – Pressing sender wheel onto crankshaft flange using assembly tool -T10134- 23079
2 7 7 E – Checking sender wheel installation position on crankshaft 23079
2 7 8 f) Re-pressing sender wheel 23080
2 8 Renewing crankshaft sealing flange – flywheel end (assembly tool -T10017-) 23081
2 8 1 Pressing sealing flange with sender wheel off crankshaft 23082
2 8 2 Pressing sealing flange with sender wheel onto crankshaft 23083
2 8 3 A-Assembling sealing flange with sender wheel on assembly appliance -T10017- 23083
2 8 4 B-Assembling appliance -T10017- with sealing flange on crankshaft flange 23085
2 8 5 C-Fitting assembly appliance -T10017- onto crankshaft flange 23086
2 8 6 D-Pressing sender wheel onto crankshaft flange with assembly appliance -T10017- 23087
2 8 7 E – Checking sender wheel installation position on crankshaft 23087
2 8 8 f) Re-pressing sender wheel 23088
2 9 Crankshaft dimensions 23088
3 Pistons and conrods 23090
3 1 Assembly overview 23090
3 2 Piston and cylinder dimensions 23093
15 – Cylinder head, valve gear 23094
1 Cylinder head 23094
1 1 Assembly overview 23094
1 2 Checking valve timing 23096
1 3 Removing, installing and tensioning toothed belt 23097
1 3 1 Removing 23098
1 3 2 Installing 23100
1 4 Checking semi-automatic toothed belt tensioner 23102
1 5 Removing and installing camshaft housing 23106
1 5 1 Removing 23106
1 5 2 Installing 23107
1 6 Removing and installing cylinder head 23108
1 6 1 Removing 23110
1 6 2 Installing 23112
1 7 Checking compression 23113
2 Valve gear 23115
2 1 Assembly overview 23115
2 2 Reworking valve seats 23118
2 3 Renewing camshaft oil seals 23119
2 4 Checking valve guides 23121
2 5 Renewing valve stem seals 23122
17 – Lubrication 23124
1 Parts of lubrication system 23124
1 1 Engine oil: 23124
1 2 Assembly overview 23124
1 3 Removing and installing oil sump 23127
1 4 Removing and installing oil pump 23128
1 5 Checking oil pressure and oil pressure switch 23131
19 – Cooling 23133
1 Parts of cooling system 23133
1 1 Assembly overview – parts of cooling system, body side 23133
1 2 Assembly overview – parts of cooling system, body side 23135
1 3 Assembly overview – parts of cooling system, engine side 23136
1 4 Connection diagram for coolant hoses 23138
1 5 Connection diagram for coolant hoses 23138
1 6 Draining and adding coolant 23140
1 7 Removing and installing radiator 23143
1 8 Removing and installing coolant pump 23145
20 – Fuel supply system 23147
1 Parts of fuel supply system 23147
1 1 Assembly overview – fuel tank with attachments 23147
1 2 Safety regulations for working on fuel supply 23150
1 3 Rules for cleanliness 23151
1 4 Removing and installing fuel delivery unit 23151
1 4 1 Removing 23151
1 4 2 Installing 23152
1 5 Removing and installing fuel gauge sender 23153
1 6 Removing and installing fuel tank 23153
1 6 1 Removing 23154
1 6 2 Installing 23155
1 7 Crash fuel shut-off 23155
1 8 Checking fuel pump (engine codes AUA, AUB, BBY, BBZ, BKY and BUD) 23155
1 8 1 Checking function and voltage supply 23158
1 8 2 Checking fuel pressure 23159
1 8 3 Checking holding pressure 23160
1 8 4 Checking fuel delivery rate 23161
1 8 5 Checking current consumption 23164
1 9 Checking fuel pump (engine code CGGB) 23164
1 9 1 Checking function and voltage supply 23165
1 9 2 Checking fuel pressure 23167
1 9 3 Checking holding pressure 23168
1 9 4 Checking fuel delivery rate 23169
1 9 5 Checking current consumption 23170
1 10 Bleeding fuel system 23171
2 Electronic power control (EPC) 23174
2 1 Assembly overview 23174
3 Activated charcoal filter system 23175
3 1 Assembly overview – parts of activated charcoal filter system 23175
3 2 Checking fuel tank breather 23176
24 – Mixture preparation – injection 23177
1 Injection system 23177
1 1 General notes on injection 23177
1 2 Assembly overview – parts of injection system 23177
1 3 Assembly overview – intake manifold 23179
1 4 Assembly overview – intake manifold 23180
1 5 Assembly overview – fuel rail with injectors 23182
1 6 Assembly overview – air filter 23182
1 6 1 Removing and installing air filter housing 23184
1 7 Assembly overview – air filter 23184
1 8 Removing and installing air filter housing 23186
1 9 Cleaning throttle valve module -J338- 23187
1 10 Checking injectors 23188
1 11 Checking intake air preheating 23189
1 12 Safety precautions 23190
1 13 Rules for cleanliness 23191
1 14 Technical data 23192
2 Engine control unit -J623- 23193
2 1 Removing and installing engine (motor) control unit -J623- 23193
2 2 Removing and installing anti-theft engine control unit -J623- 23193
2 3 Removing and installing anti-theft engine control unit -J623- (engine codes BUD and CGGB) 23195
26 – Exhaust system 23197
1 Parts of the exhaust system 23197
1 1 Assembly overview – front exhaust system with attachments 23197
1 2 Assembly overview – front exhaust system with attachments 23199
1 3 Assembly overview – silencers with mountings 23201
2 Exhaust gas recirculation system 23202
2 1 Assembly overview 23202
28 – Ignition system 23204
1 Ignition system 23204
1 1 General notes on ignition system 23204
1 2 Assembly overview – parts of ignition system 23204
1 3 Safety precautions 23206
1 4 Test data, spark plugs 23207