Volkswagen Polo 2022 Repair Manual – PDF DOWNLOAD

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Volkswagen Polo 2022 Repair Manual – PDF DOWNLOAD

FILE DETAILS:

Volkswagen Polo 2022 Repair Manual – PDF DOWNLOAD

Language : English
Pages : 7524
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Volkswagen Polo 2022 Repair Manual – PDF DOWNLOAD

D3E8046D49A Wheels and Tyres Guide – General Information 1
44 – Wheels, tyres, vehicle geometry 9
1 Instructions on using the guide 9
1 1 Overview 9
1 1 1 Wheels and Tyres Guide – General Information 9
1 1 2 Wheels and Tyres Guide – Vehicle-specific section 9
1 2 General information 9
1 3 Notes 10
1 4 Determining correct wheel and tyre combinations, according to NEDC with tyre package 11
1 4 1 Determining the required tyre package via PR number 11
1 4 2 Determining the required tyre package via version key in the vehicle registration certificate part 1 11
1 5 Determining correct wheel and tyre combinations according to WLTP 12
1 5 1 Vehicle registration certificate part 1 12
1 5 2 COC document, item 0 10 14
1 6 NEDC, WLTP and RDE 14
1 6 1 What are NEDC, WLTP and RDE? 14
1 6 2 What are the differences between WLTP and RDE? 14
1 6 3 Since when are WLTP and RDE valid? 14
1 7 Definition of tyre package 14
1 8 Explanations regarding world regions 15
2 Legislative and technical conditions 17
2 1 Legislative conditions 17
2 1 1 Permissible wheel and tyre combinations in Germany 17
2 1 2 Vehicles with Tyre Pressure Monitoring System 17
2 2 Technical conditions 18
2 3 Load-carrying capacity depending on vehicle speed, winter tyres 18
2 4 Vehicle registration documents since 01 10 2005 20
2 5 COC document (EEC Certificate of Conformity) 21
2 6 EU general type approval number, sales type and sales or trade designation 21
3 Wheel change 24
3 1 Fitting instructions 24
3 2 Protecting wheel centring seat against corrosion 27
3 3 Fitting wheels 27
3 4 Position of anti-theft wheel bolts for steel wheels 28
4 Fitting tyre 30
4 1 Pressing tyre off wheel rim 30
4 2 Removing tyre sealant 31
4 3 Removing tyre from wheel 31
4 3 1 Removing tyres, wheels without and with tyre pressure monitoring 31
4 3 2 Removing tyres, run-flat tyres, ultra-high-performance tyres 33
4 4 Ensuring proper assembly temperature for tyres 35
4 5 Fitting tyre 36
4 5 1 Mounting tyre, wheels without and with tyre pressure monitoring 36
4 5 2 Mounting tyre, run-flat tyres, ultra-high performance tyres 38
4 6 Matching wheel rims and tyres 40
4 7 Checking radial and lateral runout of wheels and tyres 41
4 7 1 Checking radial and lateral runout of wheels and tyres, tolerances 41
4 7 2 Checking radial and lateral runout on wheels and tyres with tyre gauge 42
4 8 Matching wheels and tyres 43
4 9 Balancing wheel 44
4 9 1 Conditions 44
4 9 2 Balancing wheel on stationary wheel balancer 44
4 9 3 Balancing wheel with finish balancer 47
4 9 4 Checking radial and lateral run-out on wheel rim 48
4 10 Tyre sealant disposal 49
5 Tyre Pressure Monitoring System 50
5 1 System description – Tyre Pressure Monitoring System 50
5 1 1 System description – Tyre Pressure Monitoring System with indirect measurement (Tyre Pressure Loss Indicator) 50
5 1 2 System description – Tyre Pressure Monitoring System with direct measurement (with tyre pressure sensor) 52
5 1 3 Button behaviour – Tyre Pressure Monitoring System with direct measurement (with tyre pressure sensor) 52
5 1 4 System description – Tyre Pressure Monitoring System, Tyre Pressure Monitoring System (TPMS) with autolocation 53
5 2 Overview of fitting locations – Tyre Pressure Monitoring System 54
5 2 1 Overview of fitting locations – Tyre Pressure Monitoring System (TPMS) with autolocation 54
5 2 2 Overview of fitting locations – Tyre Pressure Monitoring System, Trigger 55
5 2 3 Overview of fitting locations – Tyre Pressure Monitoring System, Autolocation 57
5 3 Assembly overview – tyre pressure sensor 58
5 3 1 Assembly overview – tyre pressure sensor, tyre pressure sensor with valve 58
5 3 2 Assembly overview – tyre pressure sensor, tyre pressure sensor without valve, version 1 60
5 3 3 Assembly overview – tyre pressure sensor, tyre pressure sensor without valve, version 2 62
5 4 Removing and installing tyre pressure sensor -G222-/-G223-/-G224-/-G225- 63
5 4 1 Removing and installing tyre pressure sensor, tyre pressure sensor with valve 63
5 4 2 Removing and installing tyre pressure sensor, tyre pressure sensor without valve, version 1 (customer service version) 64
5 4 3 Removing and installing tyre pressure sensor, tyre pressure sensor without valve, version 1 (production version) 66
5 4 4 Removing and installing tyre pressure sensor -G222-/-G223-/-G224-/-G225-, version 2 69
5 5 Removing and installing Tyre Pressure Monitoring System control unit -J502- 71
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 72
5 5 2 Removing and installing tyre Tyre Pressure Monitoring System control unit, Passat 2011, Passat Estate 2011 74
5 5 3 Removing and installing Tyre Pressure Monitoring System control unit, CC 2010, CC 2012, Passat CC 2009 74
5 5 4 Removing and installing Tyre Pressure Monitoring System control unit, Phaeton 2003 74
5 5 5 Removing and installing Tyre Pressure Monitoring System control unit -J502-, Touran 2016 74
5 5 6 Removing and installing Tyre Pressure Monitoring System control unit -J502-, Tiguan 2008 75
5 5 7 Removing and installing Tyre Pressure Monitoring System control unit -J502-, Tiguan 2016, Tiguan 2017 (BW2), Tiguan 2021 76
5 5 8 Removing and installing Tyre Pressure Monitoring System control unit, up to model year 2014, Touareg 2010 77
5 5 9 Removing and installing Tyre Pressure Monitoring System control unit, as of model year 2015, Touareg 2015 78
5 5 10 Removing and installing Tyre Pressure Monitoring System control unit, Touareg 2018 79
5 5 11 Removing and installing bracket for Tyre Pressure Monitoring System control unit, Touareg 2015 80
5 6 Removing and installing tyre pressure monitor sender unit in wheel housing 80
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 80
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 81
5 6 3 Removing and installing sender unit for Tyre Pressure Monitoring System in wheel housing, Phaeton 2003 82
6 Wheel bolts 83
6 1 Wheel bolts, versions 83
6 2 Wheel bolts, anti-theft wheel bolt 85
6 3 Wheel bolts, adapter sets for anti-theft wheel bolts 85
7 Information on tyres 88
7 1 Identification markings on the tyre sidewall 88
7 2 Tyre dimension 90
7 3 Load rating code/load index (LI) 90
7 4 Speed rating code 91
7 5 EU tyre label 91
7 5 1 EU tyre label, summary 91
7 5 2 EU tyre label, objectives 92
7 5 3 EU tyre label, categories 93
7 6 Structure of a radial belted tyre 97
7 6 1 Cross section of a radial belted tyre 97
7 6 2 Run-flat tyres, structure and identification of a SST tyre 98
7 6 3 Run-flat tyres, seal inside technology 100
7 7 Run-flat tyre, SST (Self Supporting Tyre) 103
7 7 1 Run-flat tyres – general information 103
7 7 2 Run-flat tyres, retrofitting/requirements when using run-flat tyres 104
7 7 3 Run-flat tyres, repair work 104
7 8 Tyre storage 104
7 9 Reinforced and Extra Load (XL) tyres 105
7 10 M+S tyres 106
7 11 Winter tyres with speed symbol V 108
7 12 All-season tyres 109
7 13 Optimised rolling resistance tyres 110
7 14 Tyre ageing 110
7 15 Tyres with flange protection 112
7 16 Tyre sizes for vehicles with all-wheel drive 112
7 17 Increase in temperature due to insufficient tyre pressure 112
8 Tyre sealant 114
8 1 Models with breakdown set 114
8 2 Storage life 114
8 3 Disposal 114
9 Information about wheels (rims) 115
9 1 Structure of wheel (rim) 115
9 2 Identification 116
9 3 Composite wheels 117
9 4 Care and maintenance of alloy wheel rims 117
9 5 Restoring alloy wheels 117
9 6 Removing and installing hub cover for alloy wheels with open threaded connection 118
9 7 Renewing trim elements 119
9 7 1 Renewing trim elements, bonded trim elements 119
9 7 2 Renewing trim elements, bolted trim elements 123
9 8 Removing and installing valve 124
9 8 1 Removing and installing valve, description of the valve 124
9 8 2 Removing and installing valve, rubber valve 125
9 8 3 Removing and installing valve, metal valve 126
10 Handling problems 128
10 1 Rolling noise 128
10 1 1 General notes on tyre noise 128
10 1 2 Flat spots (from locking wheels) 129
10 2 Vehicle pulls to one side 130
10 2 1 General information 130
10 2 2 Conicity 130
10 2 3 Remedies when vehicle pulls to one side 132
10 2 4 Strategic rotation of wheels for non-directional tyres 133
10 2 5 Strategic rotation of wheels having unidirectional tyres 134
10 3 Vibration 135
10 3 1 Vibration, causes for vibration 135
10 3 2 Vibration, conducting a road test before balancing wheels 135
10 3 3 Vibration, vibration control system 135
10 4 Eliminating flat spots caused by storage or handling 136
11 Evaluating tyres 138
11 1 Flat spots caused by storage or handling 138
11 2 Undulations 138
11 3 Saw-tooth wear 139
11 4 Flat spots caused by hard braking 139
11 5 Swellings in the tyre sidewall 139
11 6 Cuts 141
11 7 Damage caused by foreign bodies 141
11 8 Stripped profile 142
11 9 Tyre damage due to insufficient tyre pressure 142
11 10 Checking tyres 143
11 11 Damage caused when fitting 144
12 Tyre wear 146
12 1 Factors influencing the service life of tyres 146
12 2 Saw-tooth wear 147
12 3 Wear behaviour of high-speed tyres 148
12 4 Measuring tread depth 148
12 5 One-sided wear 149
12 6 Outer shoulder wear 151
12 7 Diagonal washout 152
12 8 Wear in middle of tyre 153
12 9 Permissible deviation in tread depth 153
13 Overview of components 154
13 1 Assembly overview – wheel 154
14 Snow chains 157
14 1 Assembly and use of snow chains 157
15 Regular and temporary spare wheels, recommended temporary spare tyres 158
15 1 Spare wheel with yellow sticker 158
15 2 Temporary spare wheels and recommended temporary spare tyres 159
15 2 1 Atlas 2017 159
15 2 2 Golf 2013, e-Golf 2014 159
15 2 3 Golf 2017, e-Golf 2017 159
15 2 4 Golf SV 2015 159
15 2 5 Golf Variant 2014 160
15 2 6 Golf Variant 2017 160
15 2 7 Golf 2018 (AU2/BX6) 160
15 2 8 Jetta 2018 160
15 2 9 Taos 2021 161
D4B80A21EAB 3 cyl diesel direct injection engine (1 0l 4V TSI EA211 evo) 162
00 – Technical data 170
1 Safety and repair instructions 170
1 1 Safety information 170
1 2 Repair instructions 170
2 Identification 171
2 1 Engine identification 171
2 2 Engine data 172
2 2 1 Engine data DLAA 172
2 2 2 Engine data DLAB 173
2 2 3 Engine data DLAC 173
3 Electrical components 175
3 1 Starting diagnosis 175
4 Technical data 177
4 1 Test and adjustment values 177
10 – Removing and installing engine 182
1 Safety and repair instructions 182
1 1 Safety information 182
1 2 Repair instructions 182
2 Removing and installing engine 183
2 1 Removing engine 183
2 2 Separating engine and gearbox 193
2 2 1 Separating engine and gearbox, vehicles with manual gearbox 193
2 2 2 Separating engine and gearbox, vehicles with direct shift gearbox 194
2 3 Securing engine on engine and gearbox support 196
2 4 Installing engine 198
3 Assembly mountings 201
3 1 Assembly overview – assembly mountings, Golf 201
3 1 1 Assembly overview – assembly mountings 201
3 2 Assembly overview – assembly mountings, Polo, T-Roc, T-Cross, Taigo 204
3 2 1 Assembly overview – assembly mountings 204
3 3 Removing and installing engine mounting 207
3 4 Removing and installing gearbox mountings, Golf 208
3 4 1 Removing and installing gearbox mounting 208
3 5 Removing and installing gearbox mountings, Polo, T-Roc, T-Cross, Taigo 209
3 5 1 Removing and installing gearbox mountings 209
3 6 Removing and installing pendulum support 210
3 7 Supporting engine in installation position, Golf 210
3 7 1 Supporting engine in installation position 210
3 8 Supporting engine in installation position, Polo 212
3 8 1 Supporting engine in installation position 212
3 9 Supporting engine in installation position, T-Roc 213
3 9 1 Supporting engine in installation position 213
3 10 Supporting engine in installation position, T-Cross, Taigo 216
3 10 1 Supporting engine in installation position 216
3 11 Checking and adjusting assembly mountings 217
13 – Crankshaft group 221
1 Safety and repair instructions 221
1 1 Safety information 221
1 2 Repair instructions 221
2 Cylinder block (pulley end) 222
2 1 Assembly overview – poly V-belt drive 222
2 1 1 Assembly overview – poly V-belt drive, with alternator 222
2 1 2 Assembly overview – poly V-belt drive, with starter-alternator 222
2 2 Removing and installing poly-V belt 223
2 2 1 Removing and installing poly-V belt 223
2 2 2 Removing and installing poly V-belt, with starter-alternator 225
2 3 Removing and installing tensioner for poly V-belt 226
2 3 1 Removing and installing tensioner for poly V-belt 226
2 3 2 Removing and installing tensioning device for poly V-belt, with starter-alternator 227
2 4 Removing and installing vibration damper 228
2 5 Removing and installing engine support 230
2 6 Renewing crankshaft oil seal for pulley end 231
2 7 Removing and installing sealing flange, pulley end 234
3 Cylinder block, gearbox end 236
3 1 Assembly overview – cylinder block, gearbox end 236
3 2 Removing and installing flywheel 238
3 2 1 Removing and installing flywheel 238
3 2 2 Removing and installing intermediate plate 241
3 2 3 Removing and installing intermediate plate 241
3 3 Removing and installing sealing flange (gearbox end) 242
4 Crankshaft 251
4 1 Renewing needle bearing in crankshaft 251
4 2 Measuring axial clearance of crankshaft 252
5 Pistons and conrods 254
5 1 Assembly overview – pistons and conrods 254
5 2 Removing and installing pistons 255
5 3 Checking pistons and cylinder bores 257
5 4 Separating new conrod 259
5 5 Checking radial clearance of conrods 260
5 6 Removing and installing oil spray jets 261
5 7 Setting piston to TDC position 262
15 – Cylinder head, valve gear 267
1 Safety and repair instructions 267
1 1 Safety information 267
1 2 Repair instructions 267
2 Cylinder head 268
2 1 Assembly overview – cylinder head 268
2 2 Assembly overview – camshaft housing 269
2 3 Removing and installing cylinder head 271
2 4 Removing and installing camshaft housing 274
2 5 Checking compression 277
2 6 Checking cylinder head for distortion 278
3 Toothed belt drive 280
3 1 Assembly overview – toothed belt cover 280
3 2 Assembly overview – toothed belt 280
3 3 Removing and installing toothed belt guard 282
3 3 1 Removing and installing upper toothed belt guard 282
3 3 2 Removing and installing lower toothed belt guard 283
3 4 Removing and installing toothed belt 283
3 5 Preassembling and mounting test tool VAS 611 007 288
3 5 1 Preassembling test tool VAS 611 007 288
3 5 2 Mounting test tool VAS 611 007 291
3 5 3 Test tool VAS 611 007 electronic adaption and performing basic setting 294
3 6 Checking valve timing 295
3 7 Adjusting valve timing 297
4 Valve gear 307
4 1 Assembly overview – valve gear 307
4 2 Removing and installing camshaft oil seal 307
4 2 1 Removing and installing camshaft oil seal for inlet camshaft, belt pulley end 307
4 2 2 Removing and installing exhaust camshaft oil seal, pulley end 310
4 2 3 Removing and installing exhaust camshaft oil seal, gearbox end 311
4 3 Removing and installing camshaft adjuster 314
4 3 1 Removing and installing camshaft adjuster for inlet camshaft 314
4 3 2 Removing and installing camshaft adjuster for exhaust camshaft 316
4 4 Removing and installing inlet camshaft control valve 1 [N727] 319
4 5 Removing and installing exhaust camshaft control valve 1 [N318] 320
4 6 Removing and installing valve stem oil seals 320
4 6 1 Removing and installing valve stem seals (cylinder head installed) 320
4 6 2 Removing and installing valve stem seals (cylinder head removed) 326
4 7 Removing and installing holder for oil seal 330
4 8 Checking control valve 333
4 9 Removing and installing inlet camshaft control valve 1 [N727] 333
5 Inlet and exhaust valves 336
5 1 Checking valve guides 336
5 2 Checking valves 336
17 – Lubrication 337
1 Safety and repair instructions 337
1 1 Safety information 337
1 2 Repair instructions 337
2 Sump, oil pump 338
2 1 Assembly overview – sump/oil pump 338
2 2 Engine oil: 341
2 3 Removing and installing oil sump 341
2 4 Removing and installing oil pump 345
2 5 Removing and installing oil level and oil temperature sender [G266] 346
3 Engine oil cooler 348
3 1 Assembly overview – engine oil cooler 348
3 2 Removing and installing engine oil cooler 348
4 Crankcase ventilation 350
4 1 Assembly overview – crankcase breather system 350
4 2 Removing and installing oil separator 351
4 2 1 Removing and installing lower oil separator 351
4 2 2 Removing and installing upper oil separator 352
5 Oil filter, oil pressure switch 353
5 1 Assembly overview – oil filter/oil pressure switch 353
5 2 Removing and installing oil pressure sender G10 353
5 3 Checking oil pressure and oil pressure switch 355
5 4 Removing and installing oil filter 355
5 5 Removing and installing oil pressure regulating valve [N428] 355
5 6 Removing and installing piston cooling jet control valve [N522] 356
19 – Cooling 358
1 Safety and repair instructions 358
1 1 Safety information 358
1 2 Repair instructions 358
2 Cooling system/coolant 359
2 1 Connection diagram – coolant hoses 359
2 2 Checking cooling system for leaks 361
2 3 Checking filling quality of cooling system 363
2 4 Removing and installing coolant expansion tank 366
2 5 Draining coolant 367
2 6 Filling cooling system 369
2 7 Checking coolant level and topping up 371
2 8 Renewing cap 372
3 Coolant pump, regulation of cooling system 374
3 1 Assembly overview –coolant pump, thermostat 374
3 2 Assembly overview – electric coolant pump 375
3 3 Assembly overview – coolant temperature sender 375
3 4 Removing and installing electric coolant pump 376
3 5 Removing and installing coolant pump 378
3 6 Removing and installing toothed belt pulley for coolant pump 382
3 7 Removing and installing coolant temperature sender [G62] 384
3 8 Removing and installing radiator outlet coolant temperature sender [G83] 385
3 9 Removing and installing engine outlet coolant temperature sender [G82] 387
3 10 Removing and installing engine temperature regulation module [GX33] 388
3 11 Checking coolant pump 391
4 Coolant pipes 395
4 1 Assembly overview – coolant pipes 395
4 2 Removing and installing coolant pipes 395
4 2 1 Removing and installing front coolant pipe 395
4 2 2 Removing and installing left coolant pipe 396
4 2 3 Removing and installing upper coolant pipe 397
5 Radiator, radiator fan 399
5 1 Assembly overview – radiator, Golf 399
5 1 1 Assembly overview – radiator 399
5 2 Assembly overview – radiator, Polo, T-Cross, Taigo 400
5 2 1 Assembly overview – radiator 400
5 3 Assembly overview – radiator/radiator fan, T-Roc 401
5 3 1 Assembly overview – radiator/radiator fan 401
5 4 Assembly overview – radiator cowl and radiator fan 402
5 5 Assembly overview – radiator blind 403
5 6 Removing and installing radiator, Golf 406
5 6 1 Removing and installing radiator 406
5 7 Removing and installing radiator, Polo, Taigo 409
5 7 1 Removing and installing radiator 409
5 8 Removing and installing radiator, T-Cross 412
5 8 1 Removing and installing radiator, T-Cross 412
5 9 Removing and installing radiator, T-Roc 415
5 9 1 Removing and installing radiator 415
5 10 Removing and installing radiator cowl 417
5 11 Removing and installing radiator fan VX57 419
5 12 Removing and installing radiator blind 420
5 13 Removing and installing radiator blind control motor [V544] 421
21 – Turbocharging/supercharging 427
1 Safety and repair instructions 427
1 1 Safety information 427
1 2 Repair instructions 427
2 Turbocharger 428
2 1 Assembly overview – turbocharger 428
2 1 1 Assembly overview – turbocharger 428
2 1 2 Assembly overview – lines on turbocharger 430
2 2 Removing and installing turbocharger 431
2 3 Removing and installing charge pressure control module [GX34] 435
2 4 Removing and installing connection for turbocharger 436
3 Charge air system 438
3 1 Assembly overview – charge air system 438
3 2 Removing and installing charge air cooler 440
3 3 Removing and installing charge pressure sender [GX26] 441
3 4 Checking charge air system for leaks 441
3 5 Removing and installing air intake pipe 444
24 – Mixture preparation – injection 448
1 Safety and repair instructions 448
1 1 Safety information 448
1 2 Repair instructions 448
2 Injection system 449
2 1 Overview of fitting locations – injection system 449
2 1 1 Overview of fitting locations on engine (from above) 449
2 1 2 Overview of fitting locations – rear view of engine 451
2 1 3 Overview of fitting locations – front view of engine 451
3 Vacuum system 453
3 1 Assembly overview – vacuum system 453
3 2 Removing and installing vacuum line 453
4 Injectors 455
4 1 Assembly overview – fuel rail with injectors 455
4 2 Removing and installing fuel rail 457
4 3 Removing and installing injectors 457
4 4 Renewing seals on injectors 460
5 Air filter 464
5 1 Assembly overview – air filter housing 464
5 2 Removing and installing air filter housing 466
5 3 Removing and installing air guide on lock carrier, Golf 468
5 3 1 Removing and installing air duct on lock carrier 468
5 4 Removing and installing air guide on lock carrier, Polo, Taigo 469
5 4 1 Removing and installing air duct on lock carrier 469
5 5 Removing and installing air duct on lock carrier, T-Roc 470
5 5 1 Removing and installing air guide on lock carrier 470
5 6 Removing and installing air duct on lock carrier, T-Cross 471
5 6 1 Removing and installing air guide on lock carrier 471
6 Intake manifold 472
6 1 Assembly overview – intake manifold 472
6 2 Removing and installing intake manifold 474
6 3 Removing and installing throttle valve module [GX3] 475
6 4 Cleaning throttle valve module [GX3] 475
7 Senders and sensors 477
7 1 Removing and installing fuel pressure sender [G247] 477
7 2 Checking fuel pressure sender G247 478
7 3 Removing and installing intake manifold sender [GX9] 479
7 4 Removing and installing exhaust gas pressure sensor 1 [G450] 480
8 Engine/motor control unit 481
8 1 Assembly overview – engine/motor control unit 481
8 2 Removing and installing motor control unit [J623] 481
8 2 1 Removing and installing engine control unit without protective housing [J623] 481
8 2 2 Removing and installing engine control unit [J623] with protective housing 482
9 High-pressure pump 486
9 1 Assembly overview – high-pressure pump 486
9 2 Removing and installing high-pressure pump 487
9 3 Removing and installing high-pressure pipe 489
10 Lambda probe 491
10 1 Assembly overview – lambda probe 491
10 2 Removing and installing lambda probe 491
10 2 1 Removing and installing lambda probe 1 before catalytic converter GX10 491
10 2 2 Removing and installing lambda probe 1 after catalytic converter GX7 492
26 – Exhaust system 494
1 Safety and repair instructions 494
1 1 Safety information 494
1 2 Repair instructions 494
2 Exhaust pipes and silencers 495
2 1 Assembly overview – silencers, Golf, T-Roc 495
2 1 1 Assembly overview – silencers 495
2 2 Assembly overview – silencer, Polo, T-Cross, Taigo 495
2 2 1 Assembly overview – silencers 495
2 3 Separating exhaust pipes from silencers 496
2 4 Removing and installing front silencer 498
2 5 Removing and installing rear silencer, Golf, T-Roc 499
2 5 1 Removing and installing rear silencer 499
2 6 Removing and installing rear silencer, Polo, T-Cross, Taigo 501
2 6 1 Removing and installing rear silencer 501
2 7 Aligning exhaust system free of stress 502
2 8 Checking exhaust system for leaks 503
2 9 Installation position of clamp 503
3 Emission control 505
3 1 Assembly overview – emission control 505
3 2 Removing and installing catalytic converter 508
3 3 Removing and installing particulate filter 511
3 4 Removing and installing bracket of catalytic converter/front exhaust pipe 511
28 – Ignition system 514
1 Safety and repair instructions 514
1 1 Safety information 514
1 2 Repair instructions 514
2 Ignition system 515
2 1 Assembly overview – ignition system 515
2 2 Removing and installing ignition coil with output stage 517
2 3 Removing and installing knock sensor 1 [G61] 519
2 4 Removing and installing engine speed sender [G28] 520
2 5 Removing and installing inlet camshaft position sender [G1002] 522
2 6 Removing and installing exhaust camshaft position sender [G1003] 522
D4B805CB339 Manual for Troubleshooting and Diagnosing Noises 524
00 – Technical data 530
1 Introduction 530
2 Acoustic considerations during vehicle development 531
2 1 Vibration insulation film 531
2 2 Insulation 532
3 General procedure for identifying noises 534
3 1 General procedure 534
3 2 Identifying a noise 534
3 2 1 Localising origin of noise 534
3 2 2 Identifying the type of noise 535
3 2 3 Identifying the point in time when the noise occurs 535
3 2 4 Identifying the noise by definition or designation 535
3 3 Aid for localising noise by means of audio recordings (frequencies) 535
3 3 1 Preparing an audio CD with downloaded files 536
3 3 2 List of audio tracks 536
3 3 3 Conditions for testing 536
3 3 4 Conditions for performing the audio test 537
3 4 Checklist 537
4 Volkswagen equipment for localising noises 541
4 1 Ultrasonic tester -VAG 1842- 541
4 1 1 Design of the ultrasonic tester -VAG 1842- 541
4 1 2 Example of procedure for identifying noises using ultrasound 541
4 2 Borescope -VAS 6748A- 545
4 2 1 Design of the borescope -VAS 6748A- 545
4 2 2 Procedure for identifying noises using the borescope 546
5 Attachments 547
5 1 Checklist 547
5 2 Designations for noises 549
D4B805CD31D Manual on Localising the Ingress of Water 550
00 – Technical data 556
1 Introduction 556
2 Causes 557
2 1 Vehicle fluids 557
2 2 External factors 557
2 3 Components 557
3 Localising water ingress 561
3 1 Preparation by customer service advisor 561
3 2 Work performed by the mechanic 561
3 3 Examples of components causing water ingress 562
4 Tools for localising ingress point 564
5 Attachments 565
5 1 Checklist 565
D4B806AE0FE Removed 6 speed manual gearbox 0AJ 567
00 – Technical data 571
1 Safety information 571
2 Identification 572
3 Technical data 573
3 1 Capacities 573
4 Overview – power transmission 574
5 Electrical components 576
6 Repair notes 577
6 1 General repair instructions 577
30 – Clutch 581
1 Clutch mechanism 581
1 1 Assembly overview – clutch release mechanism 581
1 2 Repairing clutch release mechanism 583
2 Clutch 585
2 1 Assembly overview – clutch 585
2 1 1 Assembly overview – clutch in conjunction with Sachs dual-mass flywheel 585
2 1 2 Assembly overview – clutch in conjunction with LuK dual-mass flywheel 586
2 1 3 Assembly overview – clutch with simple flywheel 586
2 2 Removing and installing clutch 587
2 2 1 Removing and installing clutch in conjunction with Sachs dual-mass flywheel 587
2 2 2 Removing and installing clutch in conjunction with LuK dual-mass flywheel 592
2 2 3 Removing and installing clutch in connection with simple flywheel 597
34 – Controls, housing 603
1 Selector mechanism 603
2 Removing and installing gearbox 604
3 Gearbox transport 605
4 Gear oil 607
5 Securing to engine and gearbox support 608
6 Dismantling and assembling gearbox 610
6 1 Overview – gearbox 610
6 2 Assembly overview – gearbox 610
6 3 Assembly overview – gearbox housing cover 611
6 4 Assembly overview – clutch housing 613
6 5 Assembly overview – shafts, differential, selector mechanism 614
6 6 Assembly overview – selector forks 616
6 7 Repairing selector forks 617
6 8 Dismantling and assembling gearbox 622
6 8 1 Dismantling gearbox 622
6 8 2 Assembling gearbox 634
7 Gearbox housing, clutch housing 644
7 1 Assembly overview – gearbox housing and clutch housing 644
7 2 Assembly overview – gearbox housing cover 646
7 3 Repairing gearbox housing 647
7 4 Repairing gearbox housing cover 648
35 – Gears, shafts 652
1 Input shaft 652
1 1 Assembly overview – input shaft 652
1 2 Dismantling and assembling input shaft 655
1 3 Renewing input shaft seal 668
2 Output shaft 671
2 1 Assembly overview – output shaft 671
2 2 Dismantling and assembling output shaft 674
39 – Final drive – differential 682
1 Oil seals 682
1 1 Overview of fitting locations – oil seals 682
2 Differential 683
2 1 Assembly overview – differential 683
2 2 Dismantling and assembling differential 685
2 3 Adjusting differential 691
D4B806DBAE8 Removed 5 speed manual gearbox 0AF 697
00 – Technical data 701
1 Safety information 701
2 Identification 702
3 Technical data 703
3 1 Allocation gearbox – engine 703
3 2 Capacities 703
4 Overview – power transmission 704
5 Electrical components 706
6 Repair instructions 707
6 1 General repair instructions 707
30 – Clutch 711
1 Clutch mechanism 711
1 1 Assembly overview – clutch release mechanism 711
1 2 Repairing clutch release mechanism 713
2 Clutch 715
2 1 Assembly overview – clutch 715
2 1 1 Assembly overview – clutch in conjunction with Sachs dual-mass flywheel 715
2 1 2 Assembly overview – clutch in conjunction with LuK dual-mass flywheel 716
2 1 3 Assembly overview – clutch with simple flywheel 716
2 2 Removing and installing clutch 717
2 2 1 Removing and installing clutch in conjunction with Sachs dual-mass flywheel 717
2 2 2 Removing and installing clutch in conjunction with LuK dual-mass flywheel 722
2 2 3 Removing and installing clutch in connection with simple flywheel 727
34 – Controls, housing 733
1 Selector mechanism 733
2 Removing and installing gearbox 734
3 Gearbox transport 735
4 Gear oil 736
5 Securing to engine and gearbox support 737
6 Dismantling and assembling gearbox 739
6 1 Schematic overview – gearbox 739
6 2 Assembly overview – gearbox 739
6 3 Assembly overview – gearbox housing cover 740
6 4 Assembly overview – clutch housing 742
6 5 Assembly overview – shafts, differential, selector mechanism 742
6 6 Assembly overview – selector forks 744
6 7 Repairing selector forks 745
6 8 Dismantling and assembling gearbox 750
6 8 1 Dismantling gearbox 750
6 8 2 Assembling gearbox 756
7 Gearbox housing, clutch housing 763
7 1 Assembly overview – gearbox housing and clutch housing 763
7 2 Repairing gearbox housing 765
7 3 Repairing clutch housing 766
35 – Gears, shafts 769
1 Input shaft 769
1 1 Assembly overview – input shaft 769
1 2 Dismantling and assembling input shaft 771
1 3 Renewing input shaft seal 785
2 Output shaft 788
2 1 Assembly overview – output shaft 788
2 2 Dismantling and assembling output shaft 791
39 – Final drive – differential 799
1 Oil seals 799
1 1 Overview of fitting locations – oil seals 799
2 Differential 800
2 1 Assembly overview – differential 800
2 2 Dismantling and assembling differential 802
2 3 Adjusting differential 810
D4B807A6D24 Installed 6 speed manual gearbox 0AJ 816
00 – Technical data 820
1 Safety information 820
1 1 Safety measures when working on vehicles with a start/stop system 820
2 Identification 821
2 1 Gearbox identification 821
3 Technical data 822
3 1 Allocation gearbox – engine 822
3 2 Capacities 822
4 Overview – power transmission 823
5 Electrical components 825
5 1 Overview of fitting locations – electrical components 825
5 1 1 Overview of fitting locations – electrical components, manual gearbox 825
5 1 2 Overview of fitting locations – electrical components, clutch mechanism 825
6 Repair instructions 827
6 1 General repair instructions 827
30 – Clutch 830
1 Clutch mechanism 830
1 1 Overview of fitting locations – clutch mechanism 830
1 2 Assembly overview – pedal cluster 831
1 3 Assembly overview – clutch hydraulics 833
1 4 Removing and installing bearing bush 835
1 5 Checking clutch master cylinder and clutch slave cylinder 836
1 6 Removing and installing clutch position sender -G476- 837
1 7 Removing and installing over-centre spring 839
1 8 Removing and installing clutch pedal 841
1 8 1 Removing and installing clutch pedal, LHD 841
1 8 2 Removing and installing clutch pedal, RHD 842
1 9 Removing and installing mounting bracket 844
1 10 Removing and installing master cylinder 847
1 11 Removing and installing clutch slave cylinder 848
1 12 Removing and installing lines for clutch mechanism 851
1 13 Bleeding clutch mechanism 853
2 Clutch 856
34 – Controls, housing 857
1 Selector mechanism 857
1 1 Installation position – selector mechanism 857
1 2 Assembly overview – gear knob and cover 858
1 3 Assembly overview – selector mechanism 859
1 4 Removing and installing gear knob 861
1 5 Removing and installing selector mechanism 863
1 6 Repairing selector mechanism 871
1 7 Adjusting selector mechanism 875
1 8 Checking selector mechanism 879
2 Removing and installing gearbox 880
2 1 Specified torques for gearbox 880
2 1 1 Specified torques for gearbox in vehicles with 1 0 l petrol engine 880
2 2 Removing gearbox 880
2 2 1 Removing gearbox, vehicles with 1 0 l petrol engine 880
2 3 Installing gearbox 889
2 3 1 Installing gearbox, vehicles with 1 0 l petrol engine 889
3 Assembly mountings 896
3 1 Assembly overview – assembly mountings 896
4 Gear oil 899
4 1 Checking gear oil level 899
5 Dismantling and assembling gearbox 901
5 1 Assembly overview – selector unit 901
5 2 Removing and installing selector unit with gearbox installed 902
5 2 1 Removing and installing selector unit with gearbox installed 902
5 2 2 Repairing selector unit 907
5 2 3 Renewing selector shaft seal 908
6 Gearbox housing, clutch housing 909
35 – Gears, shafts 910
1 Input shaft 910
2 Output shaft 911
39 – Final drive – differential 912
1 Oil seals 912
1 1 Overview of fitting locations – oil seals 912
1 2 Renewing left seal 912
1 2 1 Renewing oil seal for left flange shaft 912
1 3 Renewing right seal 915
1 3 1 Renewing oil seal for right flange shaft 915
2 Differential 920
D4B807B934F Fuel supply system diesel engines 921
00 – Technical data 925
1 Safety information 925
1 1 Safety precautions when working on the fuel supply system 925
1 2 Safety measures when working on vehicles with a start/stop system 926
1 3 Safety precautions when using testers and measuring instruments during a road test 926
2 Identification 927
2 1 Engine number/engine data 927
3 General information 928
3 1 Rules for cleanliness when working on auxiliary heater and fuel system 928
4 Repair instructions 929
4 1 Rules for cleanliness 929
4 2 Foreign bodies in engine 929
4 3 Contact corrosion 929
4 4 Routing and attachment of lines 930
4 5 Fitting radiators and condensers 930
20 – Fuel supply system 931
1 Procedure in event of misfuelling 931
1 1 Procedure in event of misfuelling 931
1 1 1 Step 1, engine was started with incorrect fuel 931
1 1 2 Step 2, engine was not started with incorrect fuel 933
1 1 3 Step 3, there are metal particles in fuel delivery unit and fuel tank 935
1 1 4 Step 4, there are no metal particles in fuel delivery unit or fuel tank 936
1 1 5 Step 5, there are metal particles in high-pressure pump 938
1 1 6 Step 6, there are no metal particles in high-pressure pump 938
2 Fuel 939
2 1 Assembly overview – fuel tank 939
2 2 Draining fuel tank 940
2 2 1 Emptying fuel tank when fuel pump is intact 940
2 2 2 Emptying fuel tank if it is more than 3/4 full 941
2 2 3 Emptying fuel tank less than 3/4 full, vehicles with front-wheel drive 943
2 3 Removing and installing fuel tanks 946
3 Fuel delivery unit, fuel gauge sender 954
3 1 Assembly overview – fuel delivery unit/fuel gauge sender 954
3 2 Removing and installing fuel delivery unit, fuel gauge sender 957
3 3 Removing and installing fuel gauge sender -G- 961
3 4 Removing and installing assembly opening cover 962
4 Plug-in connectors 964
4 1 Disconnecting plug-in connectors 964
5 Fuel filter 970
5 1 Assembly overview – fuel filter 970
5 1 1 Assembly overview – fuel filter, version 1 970
5 1 2 Assembly overview – fuel filter, version 2 971
5 1 3 Assembly overview – fuel filter, vehicles with water separator sender -G63- 972
5 2 Removing and installing fuel filter 974
6 Accelerator mechanism 978
6 1 Assembly overview – accelerator pedal module 978
6 2 Removing and installing accelerator pedal module -GX2- 978
7 Fuel pump 980
7 1 Checking fuel system pressurisation pump -G6- 980
7 1 1 Checking fuel pressure 980
7 1 2 Checking fuel delivery rate 987
7 2 Removing and installing fuel pump control unit -J538- 995
8 Senders and sensors 997
8 1 Removing and installing water separator sender -G63- 997
9 Fuel lines 998
9 1 Removing and installing fuel line for auxiliary/supplementary heater 998
9 2 Removing and installing fuel lines 1000
9 3 Fuel hoses in the engine compartment 1006
D4B807C13D1 Installed 5 speed manual gearbox 0AF 1008
00 – Technical data 1012
1 Safety information 1012
1 1 Safety measures when working on vehicles with a start/stop system 1012
2 Identification 1013
2 1 Gearbox identification 1013
3 Repair instructions 1014
3 1 General repair instructions 1014
4 Technical data 1017
4 1 Allocation gearbox – engine 1017
4 2 Capacities 1017
5 Overview – power transmission 1018
6 Electrical components 1020
6 1 Overview of fitting locations – electrical components 1020
6 1 1 Overview of fitting locations – electrical components, manual gearbox 1020
6 1 2 Overview of fitting locations – electrical components, clutch mechanism 1021
30 – Clutch 1022
1 Clutch mechanism 1022
1 1 Overview of fitting locations – clutch mechanism 1022
1 2 Assembly overview – pedal cluster 1023
1 3 Assembly overview – clutch hydraulics 1025
1 4 Removing and installing bearing bush 1027
1 5 Removing and installing clutch position sender -G476- 1028
1 6 Removing and installing over-centre spring 1030
1 7 Removing and installing clutch pedal 1032
1 7 1 Removing and installing clutch pedal, LHD 1032
1 7 2 Removing and installing clutch pedal, RHD 1033
1 8 Removing and installing mounting bracket 1035
1 9 Checking clutch master cylinder and clutch slave cylinder 1038
1 10 Removing and installing master cylinder 1039
1 11 Removing and installing clutch slave cylinder 1040
1 12 Removing and installing lines for clutch mechanism 1043
1 13 Bleeding clutch mechanism 1046
2 Clutch 1048
34 – Controls, housing 1049
1 Selector mechanism 1049
1 1 Installation position – selector mechanism 1049
1 2 Assembly overview – gear knob and cover 1050
1 3 Assembly overview – selector mechanism 1051
1 4 Removing and installing gear knob 1053
1 5 Removing and installing selector mechanism 1055
1 6 Repairing selector mechanism 1058
1 7 Adjusting selector mechanism 1063
1 8 Checking selector mechanism 1066
2 Removing and installing gearbox 1068
2 1 Removing gearbox 1068
2 2 Installing gearbox 1077
2 3 Specified torques for gearbox 1080
3 Assembly mountings 1082
3 1 Assembly overview – assembly mountings 1082
4 Gearbox transport 1085
5 Gear oil 1086
5 1 Checking gear oil level 1086
5 2 Draining and filling gear oil 1087
6 Dismantling and assembling gearbox 1089
6 1 Assembly overview – selector unit 1089
6 2 Removing and installing selector unit with gearbox installed 1090
6 3 Repairing selector unit 1094
6 4 Renewing selector shaft seal 1096
7 Gearbox housing, clutch housing 1097
35 – Gears, shafts 1098
1 Input shaft 1098
2 Output shaft 1099
39 – Final drive – differential 1100
1 Oil seals 1100
1 1 Overview of fitting locations – oil seals 1100
1 2 Renewing left seal 1100
1 2 1 Renewing oil seal for left flange shaft 1100
1 3 Renewing right seal 1103
1 3 1 Renewing right oil seal (for right flange shaft) 1103
2 Differential 1107
D4B807E3B5B Body Repairs General Body Repairs 1108
1 Safety instructions 1112
1 1 Part removal 1112
1 2 Battery and welding operation 1112
1 3 Electronic control unit 1112
1 3 1 Processing of the electronic control unit after repair dueto a traffic accident 1112
1 4 Paint, glass, soft pad and trim 1113
1 5 Fuel tank or fuel delivery pipeline 1113
1 6 Air conditioner 1113
1 6 1 Remedial measures: 1113
1 7 Airbag System 1114
1 8 Check the seat belts 1114
1 8 1 Belt body 1115
1 8 2 Automatic retractor (locking function) 1115
1 8 3 Visual inspection of the seat belt buckle 1116
1 8 4 Seat belt buckle function 1116
1 8 5 Seat belt guide member and tongue 1117
1 8 6 Fixing piece and fixing point 1117
1 9 Safety specifications for the seat belt tensioner 1117
1 10 Body repair on a vehicle equipped with the seat belt tensioners 1118
1 10 1 The following vehicles have been equipped with: 1118
1 11 Perform cutting off, correcting and/or leveling on a vehicleequipped with airbags 1119
1 12 Remove the front seats with a side airbag 1119
2 Basic instruction 1120
2 1 Diagnosis of the accident vehicle 1120
2 2 Condition of the body and/or the parts for delivery to thepainting workshop 1120
2 3 Correction 1120
2 4 Cutting 1120
2 5 Body-cut part and part section 1120
2 6 Original connection 1121
2 7 Galvanized body parts 1121
2 8 Remove the rest part 1121
2 9 New parts 1121
2 10 Parts 1121
2 11 Molded foam plastic pads 1122
3 Symbolic interpretation 1123
3 1 Symbolic interpretation for welding 1123
3 2 Symbolic interpretation for the operation method 1123
3 2 1 Grinding 1124
3 2 2 Thinning 1124
3 2 3 Punching 1124
3 2 4 Drilling 1125
3 2 5 Polishing 1125
3 2 6 Cavity corrosion protection 1125
3 2 7 Bonding 1126
3 2 8 Precise sealing 1126
4 Body repair tools 1127
4 1 Flaring tool -V A G 1317- 1127
4 2 Punching pliers -V A G 1329- 1127
4 3 Basic equipment -V A G 1366/3- 1127
4 4 Bottom protection layer spray gun -V A G 1379- 1128
4 5 Electric blower -V A G 1416- 1128
4 6 Door tensioner -V A G 1438- 1128
4 7 Body equipment component -V A G 1439- 1129
4 8 Pneumatic cutting knife -V A G 1523 A- 1129
4 9 Air chisel -V A G 1577- 1129
4 10 Edge closing iron block -V A G 1585- 1130
4 11 Welding fume ventilator -V A G 1586- 1130
4 12 Welding spot releasing device -V A G 1731- 1130
4 13 Pneumatic spray gun -V A G 1761/1- 1131
4 14 Pneumatic punching and thinning pliers -VAS 1996- 1131
4 15 Pneumatic adhesive spray gun -V A G 2005- 1131
4 16 Door hinge correction tool 1132
4 17 Hose kit 5023 for the inert gas protection welding 1132
4 18 Angle grinder -VAS 5174- 1132
4 19 Angle grinder -VAS 5175- 1133
4 20 Wire brush -VAS 5182- 1133
5 Body bonding 1134
5 1 Transporter 1991 → 1134
5 1 1 Separation process: 1134
5 1 2 Bonding process: 1134
5 2 Bonding types 1134
5 2 1 Bonding-strong 1134
5 2 2 Bonding-spot welding 1135
5 3 Repair method for replacing the parts 1135
5 3 1 Spot welding and bonding 1135
5 3 2 Plug welding and bonding (if spot welding is impossible) 1135
5 3 3 Welding fume ventilator 1136
5 3 4 Preparations 1136
5 3 5 Trimming 1136
6 Corrosion protection measures 1137
6 1 Corrosion protection 1137
7 Waste disposal instructions 1138
7 1 Waste disposal 1138
7 2 Air pressure tappet exhaust 1138
7 3 Airbag 1139
7 3 1 Waste disposal 1139
8 Contact corrosion protection 1140
8 1 Connection of aluminum alloy/magnesium alloy with steel 1140
9 Steel plate repair 1141
9 1 High-strength body plate 1141
9 2 Galvanized body parts 1141
9 2 1 Preparations 1141
9 2 2 Part cutting 1142
9 2 3 Connection process 1142
9 3 Welding on the galvanized body steel plate 1142
9 3 1 Inert gas protection plug welding SG of the galvanized steelplate 1142
9 3 2 Resistance pressure spot welding RP of the galvanized steelplate 1143
9 3 3 Welding transformer 1143
9 3 4 Welding clamp 1143
9 4 Tearing test 1143
10 Aluminum repair 1144
10 1 Painting 1144
10 2 Surface treatment 1144
10 3 Leveling 1145
10 4 Temperature control for heating 1145
11 Plastic repair method 1146
11 1 Material 1146
11 2 Repairing the pit 1147
11 3 Repairing the scratch 1148
11 4 Repair the crack 1150
11 5 Repairing the small hole (the diameter is more than 30 mm) 1151
11 6 Plastic repair (glass fibre material) 1152
11 7 Repair process 1153
11 7 1 Repairing the breakage position 1153
11 7 2 Repairing the surface damage 1155
12 Glass repair 1156
12 1 Repairing the windshield 1156
12 1 1 Premises 1156
12 1 2 Required special tools, operating equipment, testing instrumentsand auxiliary tools 1157
12 1 3 Repair description 1158
D4B808BCFF0 Fuel supply system natural gas engines 1162
00 – Technical data 1166
1 Safety information 1166
1 1 Safety precautions when working on the fuel supply system 1166
1 2 Safety precautions when using testers and measuring instruments during a road test 1166
1 3 Safety measures when working on vehicles with a start/stop system 1167
1 4 Safety precautions when working on vehicles with natural gas systems 1167
2 Identification 1170
2 1 Engine number/engine data 1170
3 General information 1171
3 1 Rules for cleanliness when working on auxiliary/supplementary heater and fuel system 1171
4 Repair instructions 1172
4 1 Routing and attachment of lines 1172
4 2 General repair instructions 1172
20 – Fuel supply system 1173
1 Fuel system 1173
1 1 Overview of fitting locations – fuel system 1173
1 1 1 Overview of fitting locations – fuel system, Polo with bivalent fuel system 1173
1 1 2 Overview of fitting locations – fuel system, Polo with monovalent fuel system 1175
1 1 3 Overview of fitting locations – fuel system, Golf and Golf Estate 1177
2 Fuel 1180
2 1 Assembly overview – fuel tank 1180
2 1 1 Assembly overview – fuel tank, Polo with bivalent fuel system 1180
2 1 2 Assembly overview – fuel tank, Polo with monovalent fuel system 1182
2 1 3 Assembly overview – fuel tank, Golf and Golf Estate 1184
2 2 Assembly overview – natural gas fuel tanks 1186
2 2 1 Assembly overview – natural gas fuel tanks 1 and 2, Polo 1186
2 2 2 Assembly overview – fuel tank 1 and 2, Golf and Golf Estate 1188
2 2 3 Assembly overview – natural gas fuel tank 3, Polo 1192
2 2 4 Assembly overview – natural gas fuel tank 3, Golf and Golf Estate 1194
2 3 Assembly overview – securing straps 1196
2 3 1 Assembly overview – securing straps, Polo, natural gas fuel tanks 1 and 2 1196
2 3 2 Assembly overview – securing straps, Golf and Golf Estate, natural gas fuel tanks 1 and 2 1197
2 3 3 Assembly overview – securing straps, Polo, natural gas fuel tank 3 1198
2 3 4 Assembly overview – securing straps, natural gas fuel tank 3, Golf and Golf Estate 1200
2 4 Assembly overview – tank shut-off mechanism 1202
2 4 1 Assembly overview – fuel tank shut-off valve, vehicles with steel tanks 1202
2 4 2 Assembly overview – fuel tank shut-off valve, vehicles with natural gas fuel tanks made of fibre composite material 1204
2 5 Assembly overview – filler neck 1206
2 5 1 Assembly overview – filler neck, Polo 1206
2 5 2 Assembly overview – filler neck, Golf and Golf Estate 1207
2 6 Assembly overview – mounting for natural gas fuel tanks 1209
2 6 1 Assembly overview – mounting for natural gas fuel tanks 1 and 2, Polo 1209
2 6 2 Assembly overview – mounting for natural gas fuel tanks 1 and 2, Golf 1211
2 6 3 Assembly overview – mounting for natural gas fuel tanks 1 and 2, Golf Estate 1213
2 6 4 Assembly overview – mounting for natural gas fuel tank 3, Polo 1215
2 6 5 Assembly overview – mounting for natural gas fuel tank 3, Golf and Golf Estate 1217
2 7 Assembly overview – high-pressure natural gas line 1221
2 7 1 Assembly overview – high-pressure natural gas line, Polo with bivalent fuel system 1221
2 7 2 Assembly overview – high-pressure natural gas line, Polo with monovalent fuel system 1222
2 7 3 Assembly overview – high-pressure natural gas line, Golf and Golf Estate 1224
2 8 Assembly overview – trims for natural gas fuel tanks 1224
2 8 1 Assembly overview – trims with turn clip for natural gas fuel tanks 1 and 2, Golf and Golf Estate 1224
2 8 2 Assembly overview – trims with turn clip for natural gas fuel tanks 3, Golf and Golf Estate 1225
2 9 Removing and installing fuel tanks 1226
2 9 1 Removing and installing (petrol) fuel tank, Polo with monovalent fuel system 1226
2 9 2 Removing and installing (petrol) fuel tank, Polo with bivalent fuel system 1232
2 9 3 Removing and installing (petrol) fuel tank, Golf and Golf Estate 1241
2 9 4 Lowering (petrol) fuel tank, Golf and Golf Estate 1247
2 10 Draining fuel tank 1251
2 10 1 Emptying fuel tank when fuel pump is intact 1251
2 10 2 Emptying fuel tank if it is more than 3/4 full 1254
2 10 3 Emptying fuel tank if less than 3/4 full, Polo with bivalent fuel system 1256
2 11 Removing and installing solenoid of fuel tank shut-off valve 1260
2 11 1 Removing and installing solenoid of fuel tank shut-off valve -N361-/-N362-, Polo 1260
2 11 2 Removing and installing solenoid of fuel tank shut-off valve -N361-/-N362-, Golf and Golf Estate 1265
2 11 3 Removing and installing solenoid of fuel tank shut-off valve 3 -N363-, natural gas fuel tank 3 1270
2 12 Removing and installing fuel tank shut-off valve 1276
2 13 Removing and installing filler connection 1283
2 13 1 Removing filling connection at top on filler neck, Polo 1283
2 13 2 Removing and installing filling connection with high-pressure natural gas line, Polo 1287
2 13 3 Removing and installing filling connection, Golf and Golf Estate 1292
2 14 Removing and installing natural gas fuel tanks 1298
2 14 1 Removing and installing natural gas fuel tanks 1 and 2 together with mounting, Polo 1298
2 14 2 Removing natural gas fuel tanks 1 and 2 from and installing to mounting, Polo 1311
2 14 3 Removing and installing natural gas fuel tank 3, Polo 1322
2 14 4 Removing and installing natural gas fuel tanks 1 and 2 together with mounting, Golf and Golf Estate 1331
2 14 5 Removing natural gas fuel tanks 1 and 2 from and installing to mounting, Golf and Golf Estate 1343
2 14 6 Removing and installing natural gas fuel tank 3 together with mounting, Golf and Golf Estate 1350
2 14 7 Removing natural gas fuel tank 3 from mounting, Golf and Golf Estate 1363
2 14 8 Aligning natural gas fuel tanks 1 and 2 with mounting, Golf and Golf Estate 1371
2 14 9 Aligning natural gas fuel tank 3 to mounting, Polo 1373
2 14 10 Reusing natural gas fuel tanks made of composite material, natural gas fuel tanks 1 and 2 Golf and Golf Estate 1376
2 14 11 Checking for leaks from natural gas fuel tank after removing and installing tank shut-off valve, steel tank 1378
2 15 Determining residual pressure in natural gas fuel tank 1381
2 15 1 Checking and converting adapter for natural gas counterpressure check 1381
2 15 2 Self-test of cooling system tester -V A G 1274 B- 1384
2 15 3 Determining residual pressure in natural gas fuel tank 1388
2 16 Discharging natural gas fuel tanks 1393
2 17 Aligning securing strap pads 1404
2 17 1 Aligning securing strap pads, natural gas fuel tanks 1 and 2 made of composite material, Golf and Golf Estate 1404
2 18 Closing fuel tank shut-off valves by mechanical means 1406
2 18 1 Closing fuel tank shut-off valves by mechanical means, Polo 1406
2 18 2 Closing fuel tank shut-off valves by mechanical means, Golf and Golf Estate 1409
2 19 Releasing pressure in high-pressure natural gas line 1414
2 20 Preparing high-pressure natural gas line for installation 1417
2 21 Removing and installing high-pressure natural gas line 1418
2 21 1 Removing and installing high-pressure natural gas line, Polo with monovalent fuel system 1418
2 21 2 Removing and installing high-pressure natural gas line, Polo with bivalent fuel system 1423
2 21 3 Removing and installing high-pressure natural gas line, Golf and Golf Estate 1427
3 Fuel delivery unit, fuel gauge sender 1434
3 1 Assembly overview – fuel delivery unit/fuel gauge sender 1434
3 1 1 Assembly overview – fuel delivery unit/fuel gauge sender, Polo 1434
3 1 2 Assembly overview – fuel delivery unit/fuel gauge sender, Golf and Golf Estate 1436
3 2 Removing and installing fuel delivery unit, fuel gauge sender 1439
3 3 Removing and installing fuel gauge sender -G- 1444
3 3 1 Removing and installing fuel gauge sender -G-, Polo 1444
3 3 2 Removing and installing fuel gauge sender -G-, Golf and Golf Estate 1445
3 4 Removing and installing assembly opening cover 1446
4 Plug-in connectors 1447
4 1 Disconnecting plug-in connectors 1447
5 Fuel filter 1454
6 Activated charcoal filter system 1455
6 1 Connection diagram – activated charcoal filter system 1455
6 1 1 Connection diagram – activated charcoal filter system, engine compartment, vehicles with 1 5 l engine from model year 2020 1455
6 1 2 Connection diagram – activated charcoal filter system, engine compartment, vehicles with 1 0 l engine from model year 2020 1456
6 2 Assembly overview – activated charcoal filter system 1457
6 3 Removing and installing activated charcoal filter 1459
6 4 Checking fuel tank breather 1461
7 Accelerator mechanism 1469
7 1 Assembly overview – accelerator pedal module 1469
7 2 Removing and installing accelerator pedal module -GX2- 1469
8 Fuel pump 1471
8 1 Checking fuel system pressurisation pump -G6- 1471
8 1 1 Checking low pressure fuel system 1471
8 1 2 Measuring pressure at fuel delivery unit -GX1- 1474
8 1 3 Checking delivery rate of fuel system pressurisation pump -G6- in engine compartment 1477
8 1 4 Measuring fuel delivery rate at fuel delivery unit -GX1- 1480
8 1 5 Connecting test instrument adapter for voltage measurement at fuel delivery unit 1483
8 1 6 Connecting remote control 1485
8 2 Removing and installing fuel pump control unit -J538- 1487
8 2 1 Removing and installing fuel pump control unit -J538-, Polo 1487
8 2 2 Removing and installing fuel pump control unit -J538-, Golf and Golf Estate 1488
9 Wiring 1490
9 1 Removing and installing fuel lines 1490
9 2 Removing and installing fuel line for auxiliary/supplementary heater 1496
D4B808C8895 Removed 6 speed manual gearbox 0DQ 1498
00 – Technical data 1502
1 Identification 1502
2 Technical data 1503
2 1 Capacities 1503
3 Overview – power transmission 1504
4 Electrical components 1506
4 1 Overview of fitting locations – electrical components 1506
5 Repair notes 1507
5 1 General repair notes 1507
30 – Clutch 1511
1 Clutch mechanism 1511
1 1 Assembly overview – clutch release mechanism 1511
1 2 Servicing clutch release mechanism 1512
2 Clutch 1515
2 1 Assembly overview – clutch 1515
2 2 Removing and installing clutch 1515
34 – Controls, housing 1521
1 Selector mechanism 1521
2 Removing and installing gearbox 1522
3 Gearbox transport 1523
4 Gear oil 1524
5 Securing to engine and gearbox support 1525
6 Dismantling and assembling gearbox 1526
6 1 Schematic overview – gearbox 1526
6 2 Assembly overview – gearbox 1526
6 3 Assembly overview – cover for gearbox housing and 5th/6th gear 1527
6 4 Assembly overview – clutch housing 1529
6 5 Assembly overview – shafts, differential, selector mechanism 1529
6 6 Assembly overview – selector unit 1531
6 7 Assembly overview – selector forks 1531
6 8 Repairing selector forks 1532
6 9 Dismantling and assembling gearbox 1537
7 Gearbox housing, clutch housing 1558
7 1 Assembly overview – gearbox housing and clutch housing 1558
7 2 Assembly overview – gearbox housing cover 1560
7 3 Repairing gearbox housing 1561
7 4 Repairing gearbox housing cover 1562
7 5 Repairing clutch housing 1565
35 – Gears, shafts 1568
1 Input shaft 1568
1 1 Assembly overview – input shaft 1568
1 2 Dismantling and assembling input shaft 1571
1 3 Renewing input shaft seal 1582
2 Output shaft 1585
2 1 Assembly overview – output shaft 1585
2 2 Dismantling and assembling output shaft 1588
39 – Final drive – differential 1596
1 Oil seals 1596
1 1 Overview of fitting locations – oil seals 1596
2 Differential 1597
2 1 Assembly overview – differential 1597
2 2 Dismantling and assembling differential 1598
2 3 Adjusting differential 1607
D4B808CF2E6 Installed 6 speed manual gearbox 0DQ 1614
00 – Technical data 1618
1 Safety information 1618
1 1 Safety measures when working on vehicles with a start/stop system 1618
2 Identification 1619
2 1 Gearbox identification 1619
3 Repair instructions 1620
3 1 General repair instructions 1620
4 Technical data 1623
4 1 Allocation gearbox – engine 1623
4 2 Capacities 1623
5 Overview – power transmission 1624
6 Electrical components 1626
6 1 Overview of fitting locations – electrical components 1626
6 1 1 Overview of fitting locations – electrical components, manual gearbox 1626
6 1 2 Overview of fitting locations – electrical components, clutch mechanism 1626
30 – Clutch 1628
1 Clutch mechanism 1628
1 1 Overview of fitting locations – clutch mechanism 1628
1 2 Assembly overview – pedal cluster 1629
1 3 Assembly overview – clutch hydraulics 1631
1 4 Removing and installing bearing bush 1633
1 5 Checking clutch master cylinder and clutch slave cylinder 1634
1 6 Removing and installing clutch position sender -G476- 1634
1 7 Removing and installing over-centre spring 1636
1 8 Removing and installing clutch pedal 1638
1 8 1 Removing and installing clutch pedal, LHD 1638
1 8 2 Removing and installing clutch pedal, RHD 1639
1 9 Removing and installing mounting bracket 1641
1 10 Removing and installing master cylinder 1644
1 11 Removing and installing clutch slave cylinder 1645
1 12 Removing and installing lines for clutch mechanism 1648
1 13 Bleeding clutch mechanism 1651
2 Clutch 1653
34 – Controls, housing 1654
1 Selector mechanism 1654
1 1 Installation position – selector mechanism 1654
1 2 Assembly overview – gear knob and cover 1655
1 3 Assembly overview – selector mechanism 1656
1 4 Removing and installing gear knob 1658
1 5 Removing and installing selector mechanism 1660
1 6 Repairing selector mechanism 1668
1 7 Adjusting selector mechanism 1672
1 8 Checking selector mechanism 1676
2 Removing and installing gearbox 1677
2 1 Removing gearbox 1677
2 2 Installing gearbox 1687
2 3 Specified torques for gearbox 1690
3 Assembly mountings 1691
4 Gear oil 1692
4 1 Checking gear oil level 1692
5 Dismantling and assembling gearbox 1694
5 1 Assembly overview – selector unit 1694
5 2 Removing and installing selector unit with gearbox installed 1695
5 3 Repairing selector unit 1700
5 4 Renewing selector shaft seal 1701
6 Gearbox housing, clutch housing 1703
35 – Gears, shafts 1704
1 Input shaft 1704
2 Output shaft 1705
39 – Final drive – differential 1706
1 Oil seals 1706
1 1 Overview of fitting locations – oil seals 1706
1 2 Renewing left seal 1706
1 3 Renewing right seal 1709
2 Differential 1712
D4B8042C9AB 4 cylinder injection engine (1 6 l engine 4 V EA 211) 1713
00 – Technical data 1719
1 Safety information 1719
1 1 Safety regulations for working on fuel supply 1719
1 2 Safety measures when working on vehicles with a start/stop system 1719
1 3 Safety precautions for when using test instruments and measuring equipment during a road test 1720
1 4 Safety precautions when working on ignition system 1720
1 5 Safety precautions when working on exhaust system 1720
1 6 Safety precautions when working on the cooling system 1721
2 Identification 1722
2 1 Engine number/engine data 1722
3 Repair instructions 1724
3 1 Rules for cleanliness 1724
3 2 General information 1724
3 3 General repair notes 1724
3 4 Foreign bodies in engine 1725
3 5 Contact corrosion 1725
3 6 Routing and attachment of lines 1725
3 7 Fitting radiator and condensers 1725
3 8 Checking vacuum system 1725
10 – Removing and installing engine 1727
1 Removing and installing engine 1727
1 1 Removing engine 1727
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> 1727
1 1 2 Removing engine, Polo 2014>, Polo Saloon RUS 2016> 1741
1 1 3 Removing engine, Polo Saloon RUS 2020 1753
1 2 Separating engine and gearbox 1764
1 2 1 Separating engine and gearbox, vehicles with manual gearbox 1764
1 2 2 Separating engine and gearbox, vehicles with automatic gearbox 1766
1 3 Securing engine on engine and gearbox support 1768
1 4 Installing engine 1770
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> 1770
1 4 2 Installing engine, Polo 2014>, Polo Saloon RUS 2016> 1774
1 4 3 Installing engine, Polo Saloon RUS 2020> 1776
2 Assembly mountings 1781
2 1 Assembly overview – assembly mountings 1781
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> 1781
2 1 2 Assembly overview – assembly mountings, Polo 2014>, Polo Saloon RUS 2016>, manual gearbox 1783
2 1 3 Assembly overview – assembly mountings, Polo 2014>, Polo Saloon RUS 2016>, automatic gearbox 1786
2 1 4 Assembly overview – assembly mountings, Polo Saloon RUS 2020> 1789
2 2 Supporting engine in installation position 1793
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> 1793
2 2 2 Supporting engine in installation position, Polo 2014>, Polo Saloon RUS 2016> 1799
2 2 3 Supporting engine in installation position, Polo Saloon RUS 2020> 1802
2 3 Removing and installing engine mounting 1804
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> 1804
2 3 2 Removing and installing engine mounting, Polo 2014>, Polo Saloon RUS 2016> 1806
2 3 3 Removing and installing engine mounting, Polo Saloon RUS 2020> 1808
2 4 Removing and installing gearbox mounting 1809
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> 1809
2 4 2 Removing and installing gearbox mounting, Polo 2014>, Polo Saloon RUS 2016> 1811
2 4 3 Removing and installing gearbox mounting, Polo Saloon RUS 2020> 1813
2 5 Removing and installing pendulum support 1814
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> 1814
2 5 2 Removing and installing pendulum support, manual gearbox, Polo 2014>, Polo Saloon RUS 2016> 1815
2 5 3 Removing and installing pendulum support, automatic gearbox, Polo 2014>, Polo Saloon RUS 2016> 1816
2 5 4 Removing and installing pendulum support, Polo Saloon RUS 2020> 1817
2 6 Checking adjustment of assembly mountings 1818
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> 1818
2 6 2 Checking adjustment of assembly mountings, Polo 2014>, Polo Saloon RUS 2016>, Polo Saloon RUS 2020> 1819
2 7 Adjusting assembly mountings 1820
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> 1820
2 7 2 Adjusting assembly mountings, Polo Saloon RUS 2020> 1823
13 – Crankshaft group 1826
1 Cylinder block (pulley end) 1826
1 1 Assembly overview – poly V-belt drive 1826
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> 1826
1 1 2 Assembly overview – poly V-belt drive, vehicles without air conditioner compressor, Polo 2014, Polo Saloon RUS 2016>, Polo 2018>, Polo 2022> 1828
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> 1830
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> 1832
1 2 Removing and installing poly-V belt 1833
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> 1833
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> 1836
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> 1837
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> 1839
1 3 Removing and installing tensioner for poly V-belt 1840
1 3 1 Removing and installing tensioner for poly V-belt, vehicles without air conditioner compressor 1840
1 3 2 Removing and installing tensioner for poly V-belt, vehicles with air conditioner compressor 1841
1 4 Removing and installing vibration damper 1842
1 5 Removing and installing engine support 1844
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> 1844
1 5 2 Removing and installing engine support, Polo Saloon RUS 2020> 1847
1 6 Renewing crankshaft oil seal – pulley end 1851
2 Cylinder block, gearbox end 1854
2 1 Assembly overview – cylinder block, gearbox end 1854
2 1 1 Assembly overview – cylinder block, gearbox end, vehicles with manual gearbox 1854
2 1 2 Assembly overview – cylinder block, gearbox end, vehicles with automatic gearbox 1856
2 2 Removing and installing flywheel 1858
2 3 Removing and installing drive plate 1860
2 4 Removing and installing sealing flange on gearbox side 1863
3 Crankshaft 1875
3 1 Measuring axial clearance of crankshaft 1875
4 Pistons and conrods 1877
4 1 Assembly overview – pistons and conrods 1877
4 2 Removing and installing pistons 1881
4 3 Checking pistons and cylinder bores 1882
4 4 Separating new conrod 1884
4 5 Checking radial clearance of conrods 1885
4 6 Removing and installing oil spray jets 1886
4 7 Setting piston to TDC position 1887
15 – Cylinder head, valve gear 1890
1 Cylinder head 1890
1 1 Assembly overview – cylinder head 1890
1 2 Assembly overview – camshaft housing 1892
1 3 Removing and installing cylinder head 1894
1 4 Removing and installing camshaft housing 1898
1 5 Checking compression 1901
2 Toothed belt drive 1904
2 1 Assembly overview – toothed belt cover 1904
2 2 Assembly overview – toothed belt 1904
2 3 Removing and installing toothed belt guard 1906
2 3 1 Removing and installing upper toothed belt guard 1906
2 3 2 Removing and installing lower toothed belt guard 1907
2 4 Removing and installing toothed belt 1907
2 5 Preassembling and installing valve timing tool 1913
2 5 1 Preassembling valve timing tool 1913
2 5 2 Installing test tool -VAS 611 007- 1917
2 5 3 Teaching in test tool -VAS 611 007- electronically and performing basic setting 1919
2 6 Checking valve timing 1922
2 7 Adjusting valve timing 1926
2 8 Removing toothed belt from camshaft 1937
3 Valve gear 1942
3 1 Assembly overview – valve gear 1942
3 1 1 Assembly overview – valves 1942
3 2 Removing and installing camshaft adjuster 1944
3 3 Removing and installing toothed belt pulley 1949
3 4 Measuring axial play of camshaft 1954
3 5 Removing and installing camshaft oil seal 1955
3 5 1 Removing and installing camshaft oil seal, inlet camshaft, pulley end 1955
3 5 2 Removing and installing camshaft oil seal, exhaust camshaft, pulley end 1957
3 5 3 Removing and installing camshaft oil seal, exhaust camshaft, gearbox end 1959
3 6 Removing and installing camshaft control valve 1 -N205- 1961
3 7 Removing and installing valve stem oil seals 1962
3 7 1 Removing and installing valve stem seals (cylinder head installed) 1962
3 7 2 Removing and installing valve stem seals (cylinder head removed) 1967
4 Inlet and exhaust valves 1972
4 1 Checking valve guides 1972
4 2 Checking valves 1973
4 3 Valve dimensions 1973
17 – Lubrication 1974
1 Sump, oil pump 1974
1 1 Assembly overview – sump/oil pump 1974
1 2 Removing and installing lower part of sump 1977
1 3 Removing and installing oil pump 1983
1 4 Removing and installing upper part of sump 1985
1 5 Engine oil: 1990
2 Engine oil cooler 1991
2 1 Assembly overview – engine oil cooler 1991
2 2 Removing and installing engine oil cooler 1991
3 Crankcase ventilation 1993
3 1 Assembly overview – crankcase breather system 1993
3 2 Removing and installing oil separator 1994
4 Oil filter, oil pressure switch 1997
4 1 Assembly overview – oil filter/oil pressure switch 1997
4 2 Removing and installing oil pressure switch -F1- 1997
4 3 Checking oil pressure 1999
4 4 Removing and installing oil filter housing 2000
19 – Cooling 2002
1 Cooling system/coolant 2002
1 1 Connection diagram – coolant hoses 2002
1 1 1 Connection diagram – coolant hoses 2002
1 1 2 Connection diagram – coolant hoses 2004
1 2 Draining and adding coolant 2005
1 3 Checking cooling system for leaks 2014
2 Coolant pump, regulation of cooling system 2018
2 1 Assembly overview – coolant pump, thermostat 2018
2 2 Assembly overview – coolant temperature sender 2021
2 3 Removing and installing coolant pump 2022
2 4 Removing and installing toothed belt pulley for coolant pump 2026
2 5 Removing and installing thermostat 2027
2 5 1 Removing and installing thermostat for main coolant circuit (radiator) 2027
2 5 2 Removing and installing thermostat for cylinder block coolant circuit 2030
2 6 Removing and installing coolant temperature sender -G62- 2031
2 7 Removing and installing radiator outlet coolant temperature sender -G83- 2032
3 Coolant pipes 2034
3 1 Assembly overview – coolant pipes 2034
3 2 Removing and installing coolant pipes 2034
4 Radiator, radiator fan 2037
4 1 Assembly overview – radiator/radiator fan 2037
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> 2037
4 1 2 Assembly overview – radiator/radiator fan, Polo Saloon RUS 2020> 2039
4 1 3 Assembly overview – radiator/radiator fan, Golf 2020> 2040
4 2 Assembly overview – radiator cowl and radiator fan 2041
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> 2041
4 2 2 Assembly overview – radiator cowl and radiator fan, Polo Saloon RUS 2020> 2042
4 3 Removing and installing radiator 2043
4 3 1 Removing and installing radiator, Polo 2014>, Polo Saloon RUS 2016> 2043
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> 2046
4 3 3 Removing and installing radiator, Polo Saloon RUS 2020> 2053
4 4 Removing and installing radiator cowl 2056
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> 2056
4 4 2 Removing and installing radiator cowl, Polo Saloon RUS 2020> 2057
4 5 Removing and installing radiator fan -V7- 2058
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> 2059
4 5 2 Removing and installing radiator fan -V7-, Polo Saloon RUS 2020> 2059
24 – Mixture preparation – injection 2062
1 Injection system 2062
1 1 Overview of fitting locations – injection system 2062
1 2 Assembly overview – fuel system 2068
2 Injectors 2071
2 1 Assembly overview – fuel rail with injectors 2071
2 2 Removing and installing fuel rail 2071
2 3 Removing and installing injectors 2074
2 4 Checking injectors 2075
2 5 Cleaning injectors 2079
3 Air filter 2081
3 1 Assembly overview – air filter housing 2081
3 2 Removing and installing air filter housing 2083
4 Intake manifold 2086
4 1 Assembly overview – intake manifold 2086
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> 2086
4 1 2 Assembly overview – intake manifold Polo Saloon RUS 2020>, Taigun 2022>, Virtus 2022> 2088
4 2 Removing and installing intake manifold 2090
4 3 Removing and installing throttle valve module -GX3- 2093
4 4 Cleaning throttle valve module -GX3- 2093
5 Senders and sensors 2095
5 1 Removing and installing intake manifold sender -GX9- 2095
6 Engine/motor control unit 2096
6 1 Removing and installing engine control unit -J623- 2096
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> 2096
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> 2099
6 1 3 Removing and installing engine control unit -J623-, engine control unit with protective housing, Polo 2014>, Polo Saloon RUS 2016> 2103
6 1 4 Removing and installing engine control unit -J623-, without protective housing, Polo 2014> Polo Saloon RUS 2016> 2105
6 1 5 Removing and installing engine control unit -J623- without protective housing, Polo Saloon RUS 2020> 2106
7 Lambda probe 2108
7 1 Assembly overview – Lambda probe 2108
7 2 Removing and installing lambda probe 2109
7 2 1 Removing and installing lambda probe 1 before catalytic converter -GX10-/lambda probe 1 after catalytic converter -GX7- 2109
26 – Exhaust system 2112
1 Exhaust pipes and silencers 2112
1 1 Assembly overview – silencers 2112
1 1 1 Assembly overview – silencers, Golf 2013>, Golf SV 2015>, Golf 2017>, Golf 2020> 2112
1 1 2 Assembly overview – silencers, Golf Estate 2014> 2115
1 1 3 Assembly overview – silencers, Polo 2014>, Polo Saloon RUS 2016>, Polo 2018>, Polo 2022> 2118
1 1 4 Assembly overview – silencer, Polo Saloon RUS 2020>, Taigun 2022>, Virtus 2022> 2120
1 2 Separating exhaust pipes from silencers 2122
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> 2122
1 2 2 Separating exhaust pipes from silencers, Golf Estate 2014, Polo 2018, Polo 2022> 2123
1 3 Removing and installing silencer 2124
1 3 1 Removing and installing front silencer, Golf 2013>, Golf Estate 2014>, Golf SV 2015>, Golf 2017>, Golf 2020> 2124
1 3 2 Removing and installing rear silencer, Golf 2013>, Golf 2017>, Golf SV 2015>, Golf 2020> 2125
1 3 3 Removing and installing rear silencer, Golf Estate 2014 2127
1 3 4 Removing and installing silencers, Polo 2014>, Polo Saloon 2016>, Polo 2018>, Polo 2022> 2128
1 3 5 Removing and installing silencer, Polo Saloon RUS 2020>, Taigun 2022>, Virtus 2022> 2130
1 4 Aligning exhaust system free of stress 2131
1 4 1 Aligning exhaust system free of stress 2131
1 4 2 Align end exhaust pipes 2131
1 5 Checking exhaust system for leaks 2132
2 Emission control 2133
2 1 Assembly overview – emission control 2133
2 1 1 Assembly overview – emission control, Golf 2013>, Golf 2017>, Golf SV 2015>, Golf Estate 2014, Golf 2020>, Taigun 2022>, Virtus 2022> 2133
2 1 2 Assembly overview – emission control, Polo 2014>, Polo Saloon RUS 2016>, Polo 2018>, Polo 2022>, Polo Saloon RUS 2020> 2135
2 2 Removing and installing catalytic converter 2137
28 – Ignition system 2141
1 Ignition system 2141
1 1 Assembly overview – ignition system 2141
1 2 Removing and installing ignition coils with output stage 2143
1 3 Removing and installing knock sensor 1 -G61- 2145
1 4 Removing and installing Hall sender 2147
1 5 Removing and installing engine speed sender -G28- 2147
D4B8076AE27 Vehicle specific paint information 2150
54 – Vehicle-specific paint information 2154
1 Explanation of symbols 2154
1 1 Sanding 2154
1 2 Seam sealing 2154
1 3 Cavity sealing 2157
2 Areas of body exposed to stone chipping 2158
2 1 Areas of body exposed to stone chipping – general overview 2158
3 Masked sectors 2159
3 1 Masking areas, front of body 2159
3 2 Masking areas, rear of body 2160
4 Seam sealing 2163
4 1 Seam seals, front body 2163
4 2 Seam seals, centre body 2168
4 3 Seam seals, rear body 2170
5 Underseal 2174
5 1 Underseal, body – overview with differing layer thickness 2174
5 2 Underseal, protected areas 2175
6 Cavity sealing 2179
6 1 Cavity sealing, body – overview 2179
6 2 Cavity sealing, rear body 2180
6 3 Cavity sealing, doors 2180
D4B8076AE94 Brake system 2182
00 – Technical data 2186
1 Safety and repair instructions 2186
1 1 Safety information 2186
1 2 Repair instructions 2186
2 Brake test 2187
2 1 General notes 2187
2 2 Checking vehicles with front-wheel drive 2187
3 Electrical components 2188
3 1 Access to diagnoses 2188
4 Technical data 2190
4 1 Technical data for brakes 2190
4 1 1 Brake master cylinder and brake servo 2190
4 1 2 Front brakes 2190
4 1 3 Rear brakes 2191
45 – Anti-lock brake system 2193
1 Safety and repair instructions 2193
1 1 Safety information 2193
1 2 Repair instructions 2193
2 Overview of fitting locations 2194
2 1 Overview of fitting locations – ABS/ESP 2194
3 Control unit and hydraulic unit 2196
3 1 Assembly overview – control unit and hydraulic unit 2196
3 1 1 Assembly overview – control unit and hydraulic unit, right-hand drive vehicles 2196
3 1 2 Assembly overview – control unit and hydraulic unit, left-hand drive vehicles 2198
3 2 Removing and installing ABS control unit [J104]/ABS hydraulic unit [N55] 2201
3 2 1 Removing and installing ABS control unit [J104]/ABS hydraulic unit [N55], left-hand drive vehicles 2201
3 2 2 Removing and installing ABS control unit [J104]/ABS hydraulic unit [N55], right-hand drive vehicles 2206
3 3 Separating control unit from and connecting to hydraulic unit 2210
4 Sensors 2213
4 1 Assembly overview – speed sensor on front axle 2213
4 2 Assembly overview – speed sensor on rear axle, disc brake 2213
4 2 1 Assembly overview – speed sensors on rear axle 2213
4 3 Assembly overview – speed sensor on rear axle, drum brake 2214
4 3 1 Assembly overview – speed sensors on rear axle 2214
4 4 Removing and installing speed sensor on front axle [G45]/[G47] 2215
4 5 Removing and installing speed sensor on rear axle [G44]/[G46] 2216
4 6 Checking ABS sensor ring 2217
46 – Brakes – mechanism 2219
1 Safety and repair instructions 2219
1 1 Safety information 2219
1 2 Repair instructions 2219
2 Front brake 2220
2 1 Assembly overview – front brake, without brake carrier 2220
2 1 1 Assembly overview – front brake 2220
2 2 Assembly overview – front brake, with brake carrier 2222
2 2 1 Assembly overview – front brake 2222
2 3 Removing and installing brake pads, without brake carrier 2224
2 3 1 Removing and installing brake pads 2224
2 4 Removing and installing brake pads, with brake carrier 2228
2 4 1 Removing and installing brake pads, pad retainer 2228
2 5 Removing and installing brake caliper, without brake carrier 2232
2 5 1 Removing and installing brake caliper 2232
2 6 Removing and installing brake caliper, with brake carrier 2236
2 6 1 Removing and installing brake caliper 2236
2 7 Removing and installing brake carrier 2238
2 8 Removing and installing brake disc 2239
2 9 Removing and installing brake splash plate 2240
3 Rear brake 2241
3 1 Assembly overview – rear brake, disc brake 2241
3 2 Assembly overview – rear brake, drum brake 2243
3 3 Assembly overview – brake shoes 2244
3 4 Removing and installing brake caliper 2245
3 5 Removing and installing brake carrier 2250
3 6 Removing and installing brake disc 2251
3 7 Removing and installing brake shoes 2251
3 8 Resetting drum brakes 2259
3 9 Removing and installing brake splash plate 2260
3 10 Removing and installing brake drum 2261
3 11 Removing and installing brake backplate 2261
3 12 Removing and installing brake pads 2262
4 Parking brake 2269
4 1 Assembly overview – handbrake 2269
4 2 Removing and installing handbrake lever 2270
4 3 Adjusting handbrake, disc brakes 2271
4 3 1 Adjusting handbrake 2271
4 4 Adjusting handbrake, drum brakes 2272
4 4 1 Adjusting handbrake 2272
4 5 Removing and installing rear brake cable, disc brake 2273
4 5 1 Removing and installing rear brake cable 2273
4 6 Removing and installing rear brake cable, drum brakes 2275
4 6 1 Removing and installing rear brake cable 2275
4 7 Removing and installing parking brake pressure switch [F234] 2277
5 Brake pedal 2278
5 1 Assembly overview – brake pedal 2278
5 1 1 Assembly overview – brake pedal, left-hand drive vehicles 2278
5 1 2 Assembly overview – brake pedal, right-hand drive vehicles 2279
5 2 Removing and installing mounting bracket 2280
5 2 1 Removing and installing mounting bracket, left-hand drive vehicles 2280
5 2 2 Removing and installing mounting bracket, right-hand drive vehicles 2281
5 3 Separating brake pedal from and joining to brake servo 2282
5 4 Removing and installing brake pedal 2284
5 4 1 Removing and installing brake pedal, left-hand drive vehicles 2284
5 4 2 Removing and installing brake pedal, right-hand drive vehicles 2285
5 5 Removing and installing mounting of brake pedal on push rod 2286
47 – Brakes – hydraulics 2287
1 Safety and repair instructions 2287
1 1 Safety information 2287
1 2 Repair instructions 2287
2 Front brake caliper 2288
2 1 Assembly overview – front brake brake caliper, without brake carrier 2288
2 1 1 Assembly overview – front brake caliper 2288
2 2 Assembly overview – front brake caliper, with brake carrier 2289
2 2 1 Assembly overview – front brake caliper 2289
2 3 Removing and installing brake caliper piston 2289
3 Rear brake caliper 2292
3 1 Assembly overview – rear brake caliper 2292
3 2 Removing and installing brake caliper piston 2292
4 Brake servo and brake master cylinder 2296
4 1 Assembly overview – brake servo/brake master cylinder 2296
4 1 1 Assembly overview – brake servo/brake master cylinder, left-hand drive vehicles 2296
4 1 2 Assembly overview – brake servo/brake master cylinder, right-hand drive vehicles 2298
4 2 Removing and installing brake servo, right-hand drive vehicles with petrol engine 2300
4 2 1 Removing and installing brake servo 2300
4 3 Removing and installing brake servo, right-hand drive vehicles with diesel engine 2303
4 3 1 Removing and installing brake servo 2303
4 4 Removing and installing brake servo, left-hand drive vehicles 2306
4 4 1 Removing and installing brake servo 2306
4 5 Removing and installing brake master cylinder 2308
4 5 1 Removing and installing brake master cylinder, left-hand drive vehicles 2308
4 5 2 Removing and installing brake master cylinder, right-hand drive vehicles 2312
4 6 Removing and installing brake fluid level warning contact [F34] 2317
4 7 Removing and installing brake light switch 2317
4 7 1 Removing and installing brake light switch, left-hand drive vehicles 2317
4 7 2 Removing and installing brake light switch, right-hand drive 2319
5 Vacuum system 2321
5 1 Assembly overview – vacuum pump 2321
5 1 1 Assembly overview – vacuum pump, 2 0 l petrol engine 2321
5 1 2 Assembly overview – vacuum pump, 1 0 l petrol engine 2321
5 1 3 Assembly overview – vacuum pump, 1 4 l and 1 5 l evo 1 petrol engine 2322
5 2 Checking non-return valve 2323
5 3 Removing and installing vacuum sender 2324
5 4 Removing and installing vacuum pump 2325
5 4 1 Removing and installing vacuum pump, 2 0 l petrol engine 2325
5 4 2 Removing and installing vacuum pump, 1 0 l petrol engine 2325
5 4 3 Removing and installing vacuum pump, vehicles with 1 4 l and 1 5 l evo 1 petrol engine 2327
5 4 4 Removing and installing vacuum pump, vehicles with oil pump and integrated vacuum pump 2329
5 5 Checking vacuum system 2329
6 Hydraulic system 2333
6 1 Leak test 2333
6 2 Checking wheel brake cylinder for leaks 2333
6 3 Changing brake fluid 2334
6 4 Bleeding hydraulic system 2334
6 5 Removing and installing wheel brake cylinder 2335
D4B8076AF14 General body repairs exterior 2338
00 – Technical data 2344
1 Safety information 2344
1 1 Safety measures when working on vehicles with a start/stop system 2344
1 2 General information 2344
1 2 1 General information for use of adhesives 2344
1 3 Repair information 2345
1 3 1 Pipe/wire routing and attachment 2345
1 3 2 Bonding surfaces for self-adhesive components 2345
1 3 3 Secured threaded connections 2346
50 – Body – front 2347
1 Lock carrier 2347
1 1 Assembly overview – lock carrier 2347
1 1 1 Assembly overview – lock carrier to model year 2021 2347
1 1 2 Assembly overview – lock carrier as of model year 2022 2349
1 2 Removing and installing lock carrier 2351
1 2 1 Removing and installing lock carrier 2351
1 2 2 Removing and installing assembly frame to model year 2021 2353
1 2 3 Removing and installing assembly frame as of model year 2022 2354
1 3 Moving to and back from service position 2356
2 Wings 2360
2 1 Assembly overview – wing 2360
2 2 Removing and installing wing 2360
3 Bulkhead 2365
3 1 Assembly overview – bulkhead 2365
3 2 Assembly overview – plenum chamber cover 2365
3 3 Removing and installing bulkhead 2366
3 4 Removing and installing plenum chamber cover 2367
55 – Bonnet, rear lid 2371
1 Bonnet 2371
1 1 Assembly overview – bonnet 2371
1 2 Assembly overview – Bowden cable 2372
1 3 Removing and installing bonnet 2373
1 4 Adjusting bonnet 2376
1 5 Removing and installing bonnet lock 2383
1 5 1 Removing and installing left bonnet lock 2383
1 5 2 Removing and installing right bonnet lock 2385
1 6 Removing and installing bonnet lock operating lever 2388
1 6 1 Removing and installing bonnet lock operating lever 2388
1 6 2 Removing and installing release lever on lock carrier 2389
1 7 Removing and installing striker pin 2391
1 8 Removing and installing hinge 2392
1 9 Removing and installing insulation 2396
1 10 Removing and installing bonnet stay 2397
1 11 Removing and installing Bowden cable 2399
1 11 1 Removing and installing Bowden cable to mounting bracket 2399
1 11 2 Removing and installing Bowden cable from right bonnet lock to release lever 2401
1 11 3 Removing and installing Bowden cable from left bonnet lock to release lever 2403
1 11 4 Removing and installing Bowden cable coupling with Bowden cables 2405
2 Rear lid 2407
2 1 Assembly overview – rear lid 2407
2 2 Removing and installing rear lid 2409
2 2 1 Removing and installing rear lid to model year 2021 2409
2 2 2 Removing and installing rear lid as of model year 2022 2412
2 3 Adjusting rear lid 2415
2 4 Removing and installing rear lid lock 2421
2 5 Removing and installing operating mechanism 2423
2 5 1 Removing and installing handle, without reversing camera 2423
2 5 2 Removing and installing handle, with reversing camera 2426
2 6 Removing and installing hinge 2428
2 7 Removing and installing striker pin 2431
2 8 Removing and installing rear lid seal 2432
2 9 Removing and installing gas strut 2434
2 10 Preparing gas strut for disposal 2436
3 Tank flap unit 2437
3 1 Assembly overview – tank flap unit 2437
3 2 Removing and installing tank flap unit 2437
3 3 Removing and installing fuel tank flap 2440
57 – Front doors, door components, central locking 2442
1 Door 2442
1 1 Assembly overview – door 2442
1 2 Removing and installing inner door seal 2445
1 3 Removing and installing outer door seal 2447
1 3 1 Removing and installing door outer seal, 4-door model 2447
1 3 2 Removing and installing door outer seal, 2-door model 2448
1 4 Removing and installing door 2449
1 5 Adjusting door 2452
1 6 Adjusting striker pin 2454
1 7 Removing and installing door arrester 2456
2 Door components 2459
2 1 Assembly overview – door components 2459
2 2 Assembly overview – window regulator 2461
2 3 Assembly overview – door handle and door lock 2461
2 4 Removing and installing window regulator motor 2462
2 5 Removing and installing window regulator 2465
2 6 Removing and installing inner door cover 2468
2 7 Removing and installing striker pin 2470
2 8 Removing and installing cap on door handle 2472
2 8 1 Removing and installing cap for door handle, for lock cylinder 2472
2 8 2 Removing and installing cap for door handle, without lock cylinder 2474
2 9 Removing and installing lock cylinder 2478
2 10 Removing and installing door handle 2481
2 11 Removing and installing mounting bracket 2483
2 12 Removing and installing door lock 2485
2 13 Removing and installing window channel 2490
2 14 Removing and installing outer window slot seal 2493
2 15 Removing and installing window slot inner seal 2495
3 Central locking 2496
3 1 Overview of fitting locations – central locking system 2496
3 2 Removing and installing ignition key battery 2498
3 3 Removing and installing cap on ignition key 2500
3 4 Removing and installing tank filler flap locking motor -V155- 2501
58 – Rear doors, door components 2503
1 Door 2503
1 1 Assembly overview – door 2503
1 2 Removing and installing door 2506
1 3 Adjusting door 2509
1 4 Adjusting striker pin 2511
1 5 Removing and installing door arrester 2513
1 6 Removing and installing inner door seal 2515
1 7 Removing and installing outer door seal 2517
2 Door components 2519
2 1 Assembly overview – door components 2519
2 2 Assembly overview – window regulator 2521
2 3 Assembly overview – door handle and door lock 2521
2 4 Removing and installing window regulator motor 2522
2 5 Removing and installing window regulator 2525
2 6 Removing and installing window crank 2528
2 7 Removing and installing inner door cover 2531
2 8 Removing and installing striker pin 2533
2 9 Removing and installing cap on door handle 2535
2 10 Removing and installing door handle 2539
2 11 Removing and installing mounting bracket 2541
2 12 Removing and installing door lock 2544
2 13 Removing and installing window channel 2548
2 14 Removing and installing outer window slot seal 2551
2 15 Removing and installing window slot inner seal 2552
60 – Sunroof 2554
1 Sliding sunroof 2554
1 1 Assembly overview – sliding sunroof 2554
1 2 Assembly overview – sunroof seals 2556
1 3 Assembly overview – sun blind 2556
1 4 Removing and installing glass panel 2557
1 5 Adjusting sunroof panel 2560
1 6 Removing and installing front trim for sliding sunroof 2562
1 7 Removing and installing wind deflector 2563
1 8 Removing and installing sunroof roller blind 2566
1 9 Removing and installing sliding sunroof frame 2573
1 10 Removing and installing -J245-sliding sunroof adjustment control unit 2582
1 11 Removing and installing sunroof motor -V1- 2584
1 12 Manual operation 2587
1 13 Removing and installing slotted guide 2588
1 14 Removing and installing sliding sunroof seals 2592
1 14 1 Installation instructions for bonded seals 2592
1 14 2 Removing and installing sunroof frame outer seal 2593
1 14 3 Removing and installing sunroof frame inner seal 2594
1 14 4 Removing and installing additional sunroof frame seal 2595
1 14 5 Removing and installing glass panel seal 2597
1 14 6 Removing and installing front trim seal 2597
1 15 Programming sliding sunroof adjustment control unit -J245- 2599
63 – Bumpers 2600
1 Bumper, front 2600
1 1 Assembly overview – bumper cover 2600
1 1 1 Assembly overview – bumper cover, up to model year 2021 2600
1 1 2 Assembly overview – bumper cover as of model year 2022 2602
1 1 3 Assembly overview – bumper cover, add-on parts, GTI, R-Line, up to model year 2021 2604
1 1 4 Assembly overview – bumper cover, add-on parts, GTI, R-Line, as of model year 2022 2605
1 2 Assembly overview – bumper carrier 2607
1 2 1 Assembly overview – bumper carrier up to model year 2021 2607
1 2 2 Assembly overview – bumper carrier from model year 2022 onwards 2608
1 3 Removing and installing bumper cover 2610
1 3 1 Removing and installing bumper cover, up to model year 2021 2610
1 3 2 Removing and installing bumper cover, as of model year 2022 2613
1 4 Installing holder for parking aid sender 2616
1 5 Installing holder for park assist steering sender 2621
2 Bumper, rear 2625
2 1 Assembly overview – bumper cover 2625
2 1 1 Assembly overview – bumper cover, up to model year 2021 2625
2 1 2 Assembly overview – bumper cover as of model year 2022 2626
2 1 3 Assembly overview – bumper cover, add-on parts, GTI, R-Line, up to model year 2021 2627
2 1 4 Assembly overview – bumper cover, add-on parts, GTI, R-Line, as of model year 2022 2628
2 2 Assembly overview – bumper carrier 2629
2 3 Removing and installing bumper cover 2630
2 4 Removing and installing bumper carrier 2633
2 5 Installing holder for parking aid sender 2635
2 6 Installing holder for park assist steering sender 2640
2 7 Removing and installing forced ventilation for passenger compartment 2643
2 8 Checking forced ventilation for passenger compartment 2645
64 – Glazing 2646
1 Repair notes 2646
1 1 Minimum drying times for bonded windows 2646
1 2 Window repair 2646
1 3 Installation instructions for bonded windows 2647
1 3 1 Fitting instructions 2647
1 3 2 Materials 2648
1 4 Preparing old undamaged windows for installing 2649
1 5 Preparing new windows for installing 2650
1 6 Preparing body flange for installing 2653
1 7 Cleaning off excess adhesive 2654
2 Windscreen 2656
2 1 Assembly overview – windscreen 2656
2 2 Removing and installing windscreen 2657
2 2 1 Removing and installing windscreen 2657
2 2 2 Removing broken windscreen 2664
3 Rear windscreen 2665
3 1 Assembly overview – rear window 2665
3 2 Removing and installing rear window 2666
3 2 1 Removing and installing rear window 2666
3 2 2 Removing broken rear window 2669
4 Side window 2671
4 1 Assembly overview – rear side windows 2671
4 2 Removing and installing rear side window 2672
4 2 1 Removing and installing rear side window 2672
4 2 2 Removing broken rear side window 2675
5 Door windows 2676
5 1 Assembly overview – front door window 2676
5 2 Assembly overview – rear door window 2676
5 3 Removing and installing front door window 2677
5 4 Removing and installing rear door window 2681
66 – Exterior equipment 2685
1 Radiator grille and front trim 2685
1 1 Assembly overview – radiator grille 2685
1 1 1 Assembly overview – radiator grille up to model year 2021 2685
1 1 2 Assembly overview – radiator grille as of model year 2022 2686
1 2 Removing and installing radiator grille 2686
1 2 1 Removing and installing radiator grille, up to model year 2021 2686
1 2 2 Removing and installing radiator grille, as of model year 2022 2688
2 Spoiler 2691
2 1 Assembly overview – spoiler 2691
2 2 Removing and installing spoiler 2691
3 Mouldings, trims, extensions 2699
3 1 Assembly overview – side member trim 2699
3 2 Removing and installing A-pillar trim 2700
3 3 Removing and installing B-pillar trim on door 2701
3 3 1 Removing and installing B-pillar trim on front door 2701
3 3 2 Removing and installing B-pillar trim on rear door 2703
3 4 Removing and installing C-pillar trim on door 2704
3 5 Removing and installing step moulding 2706
3 6 Removing and installing side member trim 2708
4 Noise insulation 2713
4 1 Assembly overview – noise insulation 2713
4 1 1 Assembly overview – short noise insulation, 06/2017 ► 07/2020 2713
4 1 2 Assembly overview – short noise insulation, 07/2020 ► 2713
4 1 3 Assembly overview – long noise insulation, 06/2017 ► 07/2020 2714
4 1 4 Assembly overview – long noise insulation, 07/2020 ► 2715
5 Underbody cladding 2717
5 1 Assembly overview – underbody cladding 2717
5 1 1 Assembly overview – underbody cladding, petrol/diesel 2717
5 1 2 Assembly overview – skid plate, 06/2017 ► 07/2020 2718
5 1 3 Assembly overview – skid plate, 07/2020 ► 2718
5 2 Removing and installing underbody cladding 2719
5 3 Removing and installing underbody cladding, centre 2721
5 3 1 Removing and installing centre underbody cladding 2721
5 3 2 Removing and installing short centre underbody cladding 2722
5 4 Removing and installing rear underbody cladding 2723
5 4 1 Removing and installing rear underbody cladding – petrol/diesel 2723
6 Trim film and protective film 2725
6 1 Renewing decorative film 2725
6 1 1 Fitting instructions 2725
6 1 2 Decorative film dimensions 2726
6 1 3 Renewing decorative film 2726
7 Exterior mirror 2729
7 1 Assembly overview – exterior mirror 2729
7 2 Removing and installing exterior mirror 2731
7 2 1 Removing and installing exterior mirror, electric adjustment 2731
7 2 2 Removing and installing exterior mirror, manual adjustment 2733
7 3 Removing and installing mirror glass 2736
7 4 Removing and installing mirror adjustment unit 2738
7 5 Removing and installing mirror cover 2740
7 6 Removing and installing mirror frame 2741
8 Wheel housing liner 2743
8 1 Assembly overview – front wheel housing liner 2743
8 2 Assembly overview – rear wheel housing liner 2744
8 3 Removing and installing front wheel housing liner 2744
8 4 Removing and installing rear wheel housing liner 2746
9 Lettering and badges 2748
9 1 Dimensions – lettering and badges on rear 2748
9 1 1 Dimensions – lettering on rear 06/2017 ► 07/2020 2748
9 1 2 Dimensions – lettering on rear, model year 2021 2749
9 1 3 Dimensions – lettering on rear, as of model year 2022 2751
9 1 4 Dimensions – GTI lettering on rear 06/2017 ► 07/2020 2752
9 1 5 Dimensions – GTI lettering on rear 07/2020 ► 2754
9 2 Dimensions – lettering and badges on sides 2756
9 2 1 Dimensions – lettering on wing, GTI, R-Line 2756
9 2 2 Dimensions – badge on B-pillar 2757
9 3 Renewing lettering and badges on sides 2759
9 4 Removing and installing lettering and badges for radiator grille 2761
9 4 1 Removing and installing emblem on radiator grille 2761
9 4 2 Removing and installing model designation, GTI 2762
9 4 3 Removing and installing model designation, R-Line 2763
9 5 Renewing lettering and badges at rear 2764
10 Special add-on parts 2766
10 1 Assembly overview – special add-on parts 2766
11 Towing bracket 2767
11 1 Assembly overview – towing bracket 2767
11 2 Removing and installing towing bracket 2769
12 Heat shields 2772
12 1 Overview of fitting locations – heat shields 2772
12 2 Removing and installing front heat shield 2772
12 3 Removing and installing centre heat shield 2773
12 4 Removing and installing rear heat shield 2774
D4B8076AF62 Wheels and Tyres Guide 2777
44 – Wheels, tyres, vehicle geometry 2781
1 General information 2781
2 Version key (D2) 2782
2 1 Version key (D2) type approval number (K): e1*2007/46*1783*00 2782
2 2 Version key (D2) type approval number (K): e1*2007/46*1783*01 to e1*2007/46*1783*02 2783
2 3 Version key (D2) type approval number (K): e1*2007/46*1783*03 to e1*2007/46*1783*06 2783
2 4 Version key (D2) type approval number (K): e1*2007/46*1783*07 to e1*2007/46*1783*08 2784
2 5 Version key (D2) type approval number (K): e1*2007/46*1783*09 2785
2 6 Version key (D2) from type approval number (K): e1*2007/46*1783*10 2786
2 7 Version key (D2) from type approval number (K): e1*2007/46*1783*11 2786
2 8 Version key (D2) from type approval no (K): e1*2007/46*1783*12 to e1*2007/46*1783*14 2787
2 9 Version key (D2) from type approval number (K): e1*2007/46*1783*15 2788
2 10 Version key (D2) from type approval no (K): e1*2007/46*1783*16 to e1*2007/46*1783*20 2788
2 11 Version key (D2) from type approval number (K): e1*2007/46*1783*21 2789
2 12 Version key (D2) from type approval number (K): e1*2007/46*1783*22 2790
2 13 Version key (D2) from type approval number (K): e1*2007/46*1783*23 2791
2 14 Version key (D2) as of type approval no (K): e1*2007/46*1783*24 and e1*2007/46*1783*25 2792
2 15 Version key (D2) from type approval number (K): e1*2007/46*1783*26 2793
2 16 Version key (D2) from type approval number (K): e1*2007/46*1783*27 2793
2 17 Version key (D2) as of type approval no (K): e1*2007/46*1783*28 and e1*2007/46*1783*29 2794
2 18 Version key (D2) as of type approval no (K): e1*2007/46*1783*30 and e1*2007/46*1783*31 2795
2 19 Version key (D2) from type approval no (K): e1*2007/46*1783*32 to e1*2007/46*1783*36 2796
3 Wheels, tyres 2798
3 1 Tightening torque for wheel bolts 2798
4 Wheel and tyre combinations according to NEDC (based on tyre package) 2799
4 1 Type approval number (K): e1*2007/46*1783*00 2799
4 2 Type approval number (K): e1*2007/46*1783*01 2799
4 3 Type Approval No (K): e1e1*2007/46*1783*02 to 1*2007/46*1783*06 2801
4 4 Type approval number (K): e1*2007/46*1783*07 2802
4 5 Type approval number (K): e1*2007/46*1783*08 2804
4 6 Changing to other wheel and tyre combinations 2805
5 Wheel and tyre combinations according to WLTP (without tyre package) 2807
5 1 Type approval number (K): e1*2007/46*1783*07 2807
5 2 Type approval no (K): e1*2007/46*1783*08 to e1*2007/46*1783*09 2809
5 3 Type approval number (K): e1*2007/46*1783*10 2810
5 4 Type approval number (K): e1*2007/46*1783*11 2811
5 5 Type approval no (K): e1*2007/46*1783*12 to e1*2007/46*1783*14 2813
5 6 Type approval number (K): e1*2007/46*1783*15 2814
5 7 Type approval no (K): e1*2007/46*1783*16 to e1*2007/46*1783*20 2816
5 8 Type approval number (K): e1*2007/46*1783*21 2818
5 9 Type approval number (K): e1*2007/46*1783*22 2820
5 10 Type approval number (K): e1*2007/46*1783*23 2821
5 11 Type approval number (K): e1*2007/46*1783*24 and e1*2007/46*1783*25 2823
5 12 Type approval number (K): e1*2007/46*1783*26 2824
5 13 Type approval number (K): e1*2007/46*1783*27 2826
5 14 Type approval number (K): e1*2007/46*1783*28 and e1*2007/46*1783*29 2828
5 15 Type approval number (K): e1*2007/46*1783*30 2829
5 16 Type approval no (K): e1*2007/46*1783*31 to e1*2007/46*1783*35 2830
5 17 Type approval number (K): e1*2007/46*1783*36 2831
5 18 Temporary spare wheel 2832
5 18 1 Temporary spare wheel, Polo 2018 2832
5 18 2 Temporary spare wheel, Polo 2022 2833
6 Wheel assignment 2834
6 1 5 J x 14 offset 38 2834
6 2 5 5 J x 15 offset 40 2834
6 3 6 J x 16 offset 45 2838
6 4 6 5 J x 16 offset 47 2838
6 5 7 J x 17 offset 51 2840
6 6 7 5 J x 17 offset 51 2842
6 7 7 5 J x 18 offset 51 2843
7 Recommended summer tyres 2844
7 1 Recommended summer tyres, worldwide except North America, China, Japan, South Korea, Singapore 2844
7 2 Recommended summer tyres, Japan, Singapore, South Korea 2845
8 Recommended all-season tyres 2846
8 1 Recommended all-season tyres, European Union 2846
9 Recommended winter tyres 2847
9 1 Recommended winter tyres, European Union 2847
D4B8076D155 Heating air conditioning system 2848
00 – Technical data 2852
1 Safety information 2852
1 1 Safety precautions when working on air conditioning systems 2852
1 2 Safety measures when working on vehicles with a start/stop system 2852
1 3 Safety precautions when using testers and measuring instruments during a road test 2853
1 4 Safety precautions when working on the cooling system 2853
1 5 Safety precautions when handling refrigerants 2853
1 6 Safety precautions when working on SCR system 2854
2 General information 2856
2 1 Type plates 2856
2 1 1 Type plates, refrigerant R134a 2856
2 1 2 Type plates, refrigerant R1234yf 2857
3 Repair instructions 2859
3 1 General repair instructions 2859
3 2 Fitting radiator and condensers 2859
3 3 Working on refrigerant circuit 2859
3 4 Refrigerant circuit seals 2860
4 Technical data 2862
4 1 Refrigerant capacity 2862
4 1 1 Capacities for refrigerant R134a 2862
4 1 2 Capacities for refrigerant R1234yf 2862
4 2 Refrigerant oil capacities 2862
4 2 1 Refrigerant oil capacities, refrigerant R134a 2862
4 2 2 Refrigerant oil capacities, refrigerant R1234yf 2863
4 3 Oil distribution 2863
80 – Heating 2864
1 Heater 2864
1 1 Removing and installing fresh air blower series resistor with overheating fuse -N24- 2864
2 Operating and display unit 2865
2 1 Overview of operating and display unit 2865
2 2 Removing and installing operating and display unit 2865
87 – Air conditioning system 2867
1 Overview of fitting locations – air conditioning system 2867
1 1 Overview of fitting locations – components not located in passenger compartment 2867
1 2 Overview of fitting locations – components located in front section of passenger compartment 2869
1 2 1 Overview of fitting locations – components inside of front passenger compartment, left-hand drive vehicles 2869
1 2 2 Overview of fitting locations – components inside of front passenger compartment, right-hand drive vehicles 2871
2 Refrigerant circuit 2872
2 1 System overview – refrigerant circuit 2872
2 2 Assembly overview – condenser 2874
2 3 Removing and installing refrigerant circuit pressure sender -G805- 2876
2 4 Removing and installing expansion valve 2877
2 5 Removing and installing condenser 2881
2 6 Removing and installing desiccant bag or cartridge 2885
2 6 1 Removing and installing desiccant bag or cartridge, Denso condenser 2885
2 6 2 Removing and installing desiccant bag or cartridge, Mahle condenser 2888
2 6 3 Removing and installing desiccant bag or cartridge, Modine condenser 2894
2 7 Removing and installing evacuating and charging valves on low and high-pressure side 2898
2 8 Commissioning air conditioning system after filling refrigerant circuit 2900
2 9 Removing and installing refrigerant line from condenser to air conditioner compressor 2901
2 10 Removing and installing refrigerant line from air conditioner compressor to evaporator 2903
2 11 Removing and installing refrigerant line from air conditioner compressor to evaporator 2907
3 Air conditioner compressor 2911
3 1 Assembly overview – drive unit of air conditioner compressor 2911
3 1 1 Assembly overview – drive unit of air conditioner compressor 2911
3 1 2 Assembly overview – drive unit of air conditioner compressor with air conditioning system magnetic clutch -N25- 2913
3 2 Assembly overview – pulley 2915
3 2 1 Assembly overview – pulley, Denso air conditioner compressor 2915
3 2 2 Assembly overview – belt pulley, Sanden air conditioner compressor 2915
3 2 3 Assembly overview – belt pulley, air conditioner compressor with air conditioning system magnetic clutch -N25- 2917
3 3 Removing air conditioning compressor from and installing on bracket 2919
3 4 Removing and installing air conditioner compressor 2921
3 5 Checking high-pressure safety valve on air conditioner compressor 2926
3 6 Removing and installing pulley 2927
3 6 1 Removing and installing Denso belt pulley 2927
3 6 2 Removing and installing Sanden belt pulley 2929
3 6 3 Removing and installing belt pulley, air conditioner compressor with air conditioning system magnetic clutch -N25- 2929
4 Control motors 2933
4 1 Overview of fitting locations – control motors at front 2933
4 1 1 Overview of fitting locations – control motors at front, air conditioning system with electric/manual controls, left-hand drive vehicles 2933
4 1 2 Overview of fitting locations – control motors at front, air conditioning system with electric/manual controls, right-hand drive vehicles 2934
4 1 3 Overview of fitting locations – front Climatronic control motors, left-hand drive vehicles 2935
4 1 4 Overview of fitting locations – front Climatronic control motors, right-hand drive vehicles 2936
4 2 Removing and installing defroster flap -VX47- 2938
4 2 1 Removing and installing defroster flap -VX47-, left-hand drive vehicles 2938
4 2 2 Removing and installing defroster flap -VX47-, right-hand drive vehicles 2939
4 3 Removing and installing front left temperature flap -VX34- 2940
4 3 1 Removing and installing front left temperature flap -VX34-, left-hand drive vehicles 2940
4 3 2 Removing and installing front left temperature flap -VX34-, right-hand drive vehicles 2941
4 4 Removing and installing front right temperature flap -VX35- 2943
4 4 1 Removing and installing front right temperature flap -VX35-, left-hand drive vehicles 2943
4 4 2 Removing and installing front right temperature flap -VX35-, right-hand drive vehicles 2944
4 5 Removing and installing fresh air and air recirculation flap -VX96- 2945
4 5 1 Removing and installing fresh air and air recirculation flap -VX96-, left-hand drive vehicles 2945
4 5 2 Removing and installing fresh air and air recirculation flap -VX96-, right-hand drive vehicles 2946
4 6 Removing and installing air distribution flap -VX33- 2948
4 7 Removing and installing fresh air and air recirculation flap control motor -V154- 2949
4 8 Removing and installing air distribution flap adjustment unit 2951
4 8 1 Removing and installing air distribution flap adjustment unit, left-hand drive vehicles 2951
4 8 2 Removing and installing air distribution flap adjustment unit, right-hand drive vehicles 2952
4 9 Removing and installing temperature flap actuator 2952
4 9 1 Removing and installing temperature flap actuator, left-hand drive vehicles 2952
4 9 2 Removing and installing temperature flap actuator, right-hand drive vehicles 2953
5 Front heater and air conditioning unit 2955
5 1 Assembly overview – heater and air conditioning unit 2955
5 2 Assembly overview – evaporator housing 2957
5 2 1 Assembly overview – evaporator housing, left-hand drive vehicles 2957
5 2 2 Assembly overview – evaporator housing, right-hand drive vehicles 2958
5 3 Removing and installing evaporator 2959
5 4 Checking auxiliary air heater element -Z35- 2960
5 5 Removing and installing auxiliary air heater element -Z35- 2961
5 6 Removing and installing heater and air conditioning unit 2962
5 7 Removing and installing holder for heater and air conditioning unit 2968
5 8 Dismantling and assembling heater and air conditioning unit 2968
5 9 Removing and installing air distribution housing 2969
5 10 Removing and installing dust and pollen filter 2970
5 11 Removing and installing fresh air blower -V2- 2972
5 12 Removing and installing fresh air blower control unit -J126- 2972
5 13 Removing and installing heat exchanger 2973
5 13 1 Removing and installing Valeo heat exchanger 2973
5 13 2 Removing and installing Mahle heat exchanger 2978
5 14 Removing and installing coolant pipes on heat exchanger 2983
5 14 1 Removing and installing coolant pipes at heat exchanger (Valeo) 2983
5 14 2 Removing and installing coolant pipes on heat exchanger, Mahle 2984
5 15 Removing and installing evaporator temperature sensor -G308- 2986
5 15 1 Removing and installing evaporator temperature sensor -G308-, Mahle 2986
5 15 2 Removing and installing evaporator temperature sensor -G308-, Valeo 2986
5 16 Removing and installing flexible shafts 2987
5 16 1 Removing and installing flexible shaft of air distribution flap actuator, left-hand drive vehicles 2987
5 16 2 Removing and installing flexible shaft of temperature flap actuator, left-hand drive vehicles 2988
5 16 3 Removing and installing flexible shaft of air distribution flap actuator, right-hand drive vehicles 2989
5 16 4 Removing and installing flexible shaft of temperature flap actuator, right-hand drive vehicles 2989
5 17 Removing and installing condensation drain 2990
5 18 Checking condensation drain 2992
5 19 Removing and installing fresh air blower series resistor with overheating fuse -N24- 2993
6 Air duct 2994
6 1 Assembly overview – air duct and air distribution in passenger compartment 2994
6 1 1 Assembly overview – air duct and air distribution in passenger compartment, left-hand drive vehicle 2994
6 1 2 Assembly overview – air duct and air distribution in passenger compartment, right-hand drive vehicles 2996
6 2 Removing and installing driver side footwell vents 2998
6 2 1 Removing and installing driver side footwell vents, left-hand drive vehicles 2998
6 2 2 Removing and installing driver side footwell vents, right-hand drive vehicles 2999
6 3 Removing and installing front passenger side footwell vents 3000
6 3 1 Removing and installing front passenger side footwell vents, left-hand drive vehicles 3000
6 3 2 Removing and installing front passenger side footwell vents, right-hand drive vehicles 3000
6 4 Removing and installing rear footwell vent 3001
6 5 Removing and installing fresh air intake 3002
6 6 Removing and installing cover for fresh air intake 3003
6 7 Removing and installing air intake duct 3003
6 8 Removing and installing air duct for defroster vent 3004
6 9 Removing and installing air duct for centre vent 3005
7 Operating and display unit 3006
7 1 Overview of operating and display unit 3006
7 1 1 Overview of operating and display unit, air conditioning system with electric/manual controls 3006
7 1 2 Overview – operating and display unit, Climatronic up to week 34/2021 3007
7 1 3 Overview of operating and display unit, Climatronic, as of week 34/2021 3009
7 2 Removing and installing operating and display unit 3011
7 2 1 Removing and installing operating and display unit, air conditioning system with electric/manual controls 3011
7 2 2 Removing and installing operating and display unit, Climatronic 3011
8 Other controlling and regulating components 3013
8 1 Removing and installing sunlight penetration photosensor -G107- 3013
8 2 Removing and installing ambient temperature sensor -G17- 3013
8 3 Removing and installing humidity sender for air conditioning system -G260- 3014
8 4 Removing and installing left vent temperature sender -G150- 3014
8 4 1 Removing and installing left vent temperature sender -G150-, LHD vehicles 3014
8 4 2 Removing and installing left vent temperature sender -G150-, RHD vehicles 3015
8 5 Removing and installing right vent temperature sender -G151- 3016
8 5 1 Removing and installing right vent temperature sender -G151-, LHD vehicles 3016
8 5 2 Removing and installing right vent temperature sender -G151-, RHD vehicles 3017
8 6 Removing and installing footwell vent temperature sender -G192- 3018
D4B8076D157 Fuel supply system petrol engines 3019
00 – Technical data 3023
1 Safety information 3023
1 1 Safety regulations for working on fuel supply 3023
1 2 Safety precautions when using testers and measuring instruments during a road test 3023
1 3 Safety measures when working on vehicles with a start/stop system 3024
2 Identification 3025
2 1 Engine number/engine data 3025
3 General information 3026
3 1 Rules for cleanliness when working on auxiliary heater and fuel system 3026
4 Repair notes 3027
4 1 Routing and attachment of lines 3027
4 2 General repair instructions 3027
20 – Fuel supply system 3028
1 Fuel 3028
1 1 Assembly overview – fuel tank 3028
1 1 1 Renewing seal for cap 3030
1 2 Removing and installing fuel tank 3030
1 3 Emptying fuel tank 3037
1 3 1 Emptying fuel tank when fuel pump is intact 3037
1 3 2 Emptying fuel tank if it is more than 3/4 full 3040
1 3 3 Emptying fuel tank if it is less than 3/4 full 3042
2 Fuel delivery unit, fuel gauge sender 3046
2 1 Assembly overview – fuel delivery unit/fuel gauge sender 3046
2 2 Removing and installing fuel delivery unit, fuel gauge sender 3048
2 3 Removing and installing fuel gauge sender -G- 3053
2 4 Removing and installing assembly opening cover 3054
3 Plug-in connectors 3055
3 1 Separating plug-in connectors 3055
4 Fuel filter 3062
5 Activated charcoal filter system 3063
5 1 Connection diagram – activated charcoal filter system 3063
5 1 1 Connection diagram – activated charcoal filter system, engine compartment, vehicles with 1 5 l engine from model year 2020 3063
5 1 2 Connection diagram – activated charcoal filter system, engine compartment, vehicles with 1 0 l TSI engine from model year 2020 3064
5 1 3 Connection diagram – activated charcoal filter system, engine compartment, vehicles with 1 0 l MPI engine from model year 2020 3066
5 1 4 Connection diagram – activated charcoal filter system, rear 3067
5 2 Assembly overview – activated charcoal filter system 3068
5 3 Removing and installing activated charcoal filter 3070
5 4 Checking fuel tank breather 3071
6 Accelerator pedal 3080
6 1 Assembly overview – accelerator module 3080
6 2 Removing and installing accelerator pedal module -GX2- 3080
7 Fuel supply 3082
7 1 Checking fuel system pressurisation pump -G6-, EA888evo 3082
7 2 Checking fuel system pressurisation pump -G6- 3089
7 2 1 Checking fuel pressure in engine compartment 3089
7 2 2 Measuring pressure at fuel delivery unit -GX1- 3092
7 2 3 Checking fuel delivery rate of fuel system pressurisation pump -G6- in engine compartment 3094
7 2 4 Measuring fuel delivery rate at fuel delivery unit -GX1- 3097
7 2 5 Connecting test instrument adapter for voltage measurement at fuel delivery unit 3099
7 2 6 Connecting remote control 3101
7 3 Removing and installing fuel pump control unit -J538- 3103
8 Fuel lines 3105
8 1 Removing and installing fuel line for auxiliary/supplementary heater 3105
8 2 Removing and installing fuel lines 3107
D4B8076DBAF Body Repairs 3113
00 – Technical data 3121
1 Basic instructions 3121
1 1 Original joint 3121
1 2 Used joining techniques 3121
2 Vehicle identification data 3123
2 1 Vehicle identification number 3123
2 2 Identification plate 3124
2 3 Vehicle data sticker 3125
3 Safety information 3127
4 Gas vehicles 3128
5 Moulded foam inserts 3129
6 Galvanized body parts, high- and higher-strength and hot-formed body panels 3131
7 Laser welding 3134
8 Gaps 3135
8 1 Body – front 3135
8 2 Body, centre 3136
8 3 Body – rear 3139
9 Body dimensions 3142
9 1 Body – front 3142
9 1 1 Body dimensions for front end 3142
9 1 2 Diagonals for windscreen aperture and vehicle front end 3143
9 2 Body, centre 3144
9 2 1 Body dimensions for door apertures 3144
9 2 2 Body dimensions between pillars 3145
9 3 Body – rear 3148
9 3 1 Body dimension for rear lid aperture 3148
9 4 Body dimension for floor panel 3150
9 4 1 Floor panel, front 3150
9 4 2 Floor panel, centre 3151
9 4 3 Floor panel, rear 3152
10 Straightening bracket set 3154
10 1 Setup overview of complete body 3154
11 Portal gauge 3156
11 1 Setup overview of complete body 3156
50 – Body – front 3158
1 Overview of parts 3158
2 Renewing right bracket 3159
2 1 Tools 3160
2 2 Removing 3160
2 3 Installing 3161
2 3 1 Preparing new part 3161
2 3 2 Welding in 3163
3 Repairing threads for securing subframe 3165
3 1 Contents of thread repair kit 3166
3 2 Repairing threads 3167
3 2 1 Drilling threads 3167
3 2 2 Cutting thread 3168
3 2 3 Inserting thread insert 3169
4 Renewing mounting bracket for subframe 3171
4 1 Tools 3172
4 2 Removing 3172
4 3 Installing 3173
4 3 1 Preparing new part 3173
4 3 2 Welding in 3175
5 Renewing front longitudinal member cross panel 3177
5 1 Tools 3178
5 2 Removing 3178
5 3 Installing 3179
5 3 1 Preparing new part 3179
5 3 2 Welding in 3180
6 Renewing upper wheel housing longitudinal member 3182
6 1 Tools 3183
6 2 Removing 3183
6 3 Installing 3185
6 3 1 Preparing new part 3185
6 3 2 Welding in 3187
7 Renewing upper wheel housing longitudinal member – part section 3189
7 1 Tools 3190
7 2 Removing 3190
7 3 Installing 3192
7 3 1 Preparing new part 3192
7 3 2 Welding in 3194
8 Renewing hinge reinforcement for bonnet 3196
8 1 Tools 3197
8 2 Removing 3197
8 3 Installing 3198
8 3 1 Preparing new part 3198
8 3 2 Welding in 3199
9 Renewing upper inner wheel housing longitudinal member 3201
9 1 Tools 3202
9 2 Removing 3202
9 3 Installing 3204
9 3 1 Preparing new part 3204
9 3 2 Welding in 3206
10 Renewing upper inner wheel housing longitudinal member – part section 3208
10 1 Tools 3209
10 2 Removing 3209
10 3 Installing 3211
10 3 1 Preparing new part 3211
10 3 2 Welding in 3213
11 Renewing front wheel housing 3215
11 1 Tools 3216
11 2 Removing 3216
11 3 Installing 3218
11 3 1 Preparing new part 3218
11 3 2 Welding in 3220
12 Renewing front wheel housing (part section) 3224
12 1 Tools 3225
12 2 Removing 3225
12 3 Installing 3226
12 3 1 Preparing new part 3226
12 3 2 Welding in 3227
13 Renewing front longitudinal member 3229
13 1 Tools 3230
13 2 Removing 3230
13 3 Installing 3233
13 3 1 Preparing new part 3233
13 3 2 Welding in 3236
14 Renewing front longitudinal member (left part section) 3239
14 1 Tools 3240
14 2 Removing 3240
14 3 Installing 3241
14 3 1 Preparing new part 3241
14 3 2 Welding in 3243
15 Renewing front longitudinal member (right part section) 3245
15 1 Tools 3246
15 2 Removing 3246
15 3 Installing 3247
15 3 1 Preparing new part 3248
15 3 2 Welding in 3249
16 Renewing studs 3251
51 – Body – centre 3253
1 Overview of parts 3253
2 Renewing roof – vehicles without tilting sunroof 3254
2 1 Tools 3255
2 2 Removing 3255
2 3 Installing 3260
2 3 1 Preparing new part 3260
2 3 2 Bonding roof 3263
2 3 3 Adjusting roof depth 3267
2 3 4 Welding in 3268
3 Renewing roof – vehicles with tilting sunroof 3272
3 1 Tools 3273
3 2 Removing 3273
3 3 Installing 3277
3 3 1 Preparing new part 3277
3 3 2 Bonding roof 3279
3 3 3 Adjusting roof depth 3284
3 3 4 Welding in 3285
4 Renewing front cross member for roof 3288
4 1 Tools 3289
4 2 Removing 3289
4 3 Installing 3290
4 3 1 Preparing new part 3290
4 3 2 Welding in 3291
5 Renewing rear roof cross member 3293
5 1 Tools 3294
5 2 Removing 3294
5 3 Installing 3295
5 3 1 Preparing new part 3295
5 3 2 Welding in 3297
6 Renewing roof side member 3299
6 1 Tools 3300
6 2 Removing 3301
6 3 Installing 3304
6 3 1 Preparing new part 3304
6 3 2 Welding in 3307
7 Renewing A-pillar 3310
7 1 Tools 3311
7 2 Moulded foam inserts 3312
7 3 Removing 3312
7 4 Installing 3313
7 4 1 Preparing new part 3313
7 4 2 Welding in 3315
8 Renewing upper A-pillar reinforcement (part section repair) 3318
8 1 Tools 3319
8 2 Moulded foam inserts 3319
8 3 Removing 3319
8 4 Installing 3322
8 4 1 Preparing new parts 3322
8 4 2 Welding in 3326
9 Renewing A-pillar reinforcement 3331
9 1 Tools 3332
9 2 Moulded foam inserts 3332
9 3 Removing 3332
9 4 Installing 3333
9 4 1 Preparing new part 3333
9 4 2 Welding in 3335
10 Renewing B-pillar 3338
10 1 Tools 3340
10 2 Identification plate 3340
10 3 Moulded foam inserts 3341
10 4 Removing 3341
10 5 Installing 3343
10 5 1 Preparing new part 3343
10 5 2 Welding in 3345
11 Renewing B-pillar reinforcement 3348
11 1 Tools 3349
11 2 Identification plate 3349
11 3 Moulded foam inserts 3350
11 4 Removing 3350
11 5 Installing 3352
11 5 1 Preparing new part 3352
11 5 2 Welding in 3354
12 Renewing outer side member 3357
12 1 Tools 3358
12 2 Identification plate 3358
12 3 Moulded foam inserts 3359
12 4 Removing 3359
12 5 Installing 3361
12 5 1 Preparing new part 3361
12 5 2 Welding in 3363
13 Renewing side member reinforcement 3366
13 1 Tools 3367
13 2 Moulded foam inserts 3367
13 3 Removing 3367
13 4 Installing 3369
13 4 1 Preparing new part 3369
13 4 2 Welding in 3371
14 Renewing inner mounting for seat inner cross member 3374
14 1 Tools 3375
14 2 Removing 3375
14 3 Installing 3376
14 3 1 Preparing new part 3376
14 3 2 Welding in 3377
15 Renewing seat cross member 3379
15 1 Tools 3380
15 2 Removing 3380
15 3 Installing 3381
15 3 1 Preparing new part 3381
15 3 2 Welding in 3382
16 Renewing outer mounting for seat outer cross member 3384
16 1 Tools 3385
16 2 Removing 3385
16 3 Installing 3387
16 3 1 Preparing new part 3387
16 3 2 Welding in 3389
53 – Body – rear 3393
1 Overview of parts 3393
2 Renewing rear cross panel 3394
2 1 Tools 3395
2 2 Removing 3395
2 3 Installing 3397
2 3 1 Preparing new part 3397
2 3 2 Welding in 3399
3 Renewing rear cross member 3401
3 1 Tools 3402
3 2 Removing 3402
3 3 Installing 3403
3 3 1 Preparing new part 3403
3 3 2 Welding in 3405
4 Renewing tail light mounting 3408
4 1 Tools 3409
4 2 Removing 3409
4 3 Installing 3410
4 3 1 Preparing new part 3410
4 3 2 Welding in 3411
5 Renewing luggage compartment floor 3413
5 1 Tools 3414
5 2 Moulded foam inserts 3414
5 3 Removing 3414
5 4 Installing 3415
5 4 1 Preparing new part 3415
5 4 2 Welding in 3417
6 Renewing luggage compartment floor (natural gas vehicles) 3420
6 1 Tools 3421
6 2 Moulded foam inserts 3421
6 3 Removing 3421
6 4 Installing 3422
6 4 1 Preparing new part 3422
6 4 2 Welding in 3424
7 Renewing left floor panel 3426
7 1 Tools 3427
7 2 Removing 3427
7 3 Installing 3428
7 3 1 Preparing new part 3428
7 3 2 Welding in 3429
8 Renewing rear longitudinal member cross panel 3431
8 1 Tools 3432
8 2 Removing 3432
8 3 Installing 3433
8 3 1 Preparing new part 3433
8 3 2 Welding in 3434
9 Renewing rear longitudinal member (part section) 3436
9 1 Tools 3437
9 2 Removing 3437
9 3 Installing 3438
9 3 1 Preparing new part 3438
9 3 2 Welding in 3439
10 Renewing rear longitudinal member (part section – second parting cut) 3441
10 1 Tools 3442
10 2 Moulded foam inserts 3442
10 3 Removing 3442
10 4 Installing 3444
10 4 1 Preparing new part 3444
10 4 2 Welding in 3447
11 Permitted parting cuts on side panel 3454
12 Renewing side panel (part section) 3455
12 1 Tools 3456
12 2 Moulded foam inserts 3457
12 3 Removing 3457
12 4 Installing 3459
12 4 1 Preparing new part 3459
12 4 2 Welding in 3461
13 Renewing outer wheel housing liner 3464
13 1 Tools 3465
13 2 Moulded foam inserts 3465
13 3 Removing 3465
13 4 Installing 3466
13 4 1 Preparing new part 3466
13 4 2 Welding in 3468
14 Renewing lock reinforcement 3471
14 1 Tools 3472
14 2 Removing 3472
14 3 Installing 3474
14 3 1 Preparing new part 3474
14 3 2 Welding in 3476
D4B8076F6D5 General body repairs interior 3479
00 – Technical data 3487
1 Safety information 3487
1 1 Safety precautions when working on vehicles with a start/stop system 3487
1 2 Safety measures when working with pyrotechnic components 3488
1 3 Storage, transportation and disposal of airbag, belt tensioner and battery isolator units (pyrotechnic components) 3489
1 4 Additional safety regulations for side airbag 3489
1 5 Additional safety instructions for curtain airbag 3490
1 6 Safety regulations for crash sensors (pressure sensors) for front side airbags 3490
1 7 Additional safety instructions for repair work on seat occupied recognition for front passenger airbag deactivation – country-specific 3491
1 8 Measures for seat occupied recognition for front passenger airbag deactivation following an accident – country-specific 3491
1 9 Renewing pyrotechnic, electrical and mechanical components of the restraint system after an accident 3491
1 10 Checking airbag securing parts after an accident 3493
1 11 Accident without airbag triggering 3493
1 12 Checking seat belts 3493
1 13 Check belt webbing 3493
1 14 Checking inertia reel (locking mechanism) 3495
1 15 Visually checking belt buckle 3495
1 16 Check operation of belt buckle 3495
1 17 Checking belt relays, and buckle tongues 3496
1 18 Checking securing parts and anchorage points after an accident 3496
1 19 Checking seat belt restraint function for holding additional child seats (not for driver’s seat belt) – country-specific 3497
1 20 Checking child seat anchors after an accident 3497
2 Repair notes 3498
2 1 Rules for cleanliness 3498
2 2 General repair instructions 3498
2 3 Contact corrosion 3498
2 4 Nuts and bolts 3499
2 5 Electrical components 3499
2 6 Routing and attachment of lines 3499
68 – Interior equipment 3501
1 Compartments/covers 3501
1 1 Overview of fitting locations – compartments/covers 3501
1 2 Assembly overview – dash panel cover on driver side 3502
1 3 Assembly overview – steering column trim 3503
1 4 Assembly overview – glove compartment 3504
1 5 Assembly overview – storage compartment in headliner 3505
1 6 Removing and installing upper steering column trim 3506
1 7 Removing and installing lower steering column trim 3507
1 8 Removing and installing glove compartment 3508
1 9 Removing and installing glove compartment cover 3509
1 10 Service position for glove compartment cover 3510
1 11 Removing and installing restrictor for glove compartment cover 3511
1 12 Removing and installing dash panel cover on driver side 3512
1 13 Removing and installing headliner storage compartment 3513
1 14 Removing and installing handbrake lever trim 3514
1 15 Removing and installing service wallet holder 3516
2 Equipment 3518
2 1 Assembly overview – sun visors 3518
2 2 Removing and installing sun visor 3519
2 3 Removing and installing sun visor centre mount 3521
3 Centre console 3523
3 1 Assembly overview – centre console 3523
3 1 1 Assembly overview – centre console without armrest 3523
3 1 2 Assembly overview – centre console with armrest 3525
3 2 Removing and installing rear centre console trim 3527
3 2 1 Removing and installing rear centre console trim without armrest 3527
3 2 2 Removing and installing rear centre console trim with armrest 3528
3 3 Removing and installing centre console trim in front footwell 3528
3 4 Removing and installing centre console 3529
3 5 Removing and installing centre console bracket 3533
4 Front centre armrest 3535
4 1 Assembly overview – front centre armrest 3535
4 2 Removing and installing front centre armrest 3535
5 Interior mirror 3538
5 1 Assembly overview – interior mirror 3538
5 1 1 Assembly overview – manually operated anti-dazzle interior mirror 3538
5 1 2 Assembly overview – automatic anti-dazzle interior mirror, with rain and light sensor -G397- 3538
5 1 3 Assembly overview – interior mirror with front camera for driver assist systems -R242- 3539
5 2 Removing and installing interior mirror 3541
5 2 1 Removing and installing manually operated anti-dazzle interior mirror 3541
5 2 2 Removing and installing automatic anti-dazzle interior mirror with rain and light sensor -G397- 3541
5 2 3 Removing and installing interior mirror with front camera for driver assist systems -R242- 3543
5 3 Bonding retaining plate for interior mirror 3546
69 – Passenger protection 3549
1 Seat belts 3549
1 1 Overview of fitting locations – seat belts and anchorage points 3549
1 1 1 Overview of fitting locations – seat belts and anchorage points, Polo 2018► 3549
1 1 2 Overview of fitting locations – seat belts and anchorage points, Polo 2022► 3551
1 2 Assembly overview – front three-point seat belt 3553
1 2 1 Assembly overview – front three-point seat belt, Polo 2018► 3553
1 2 2 Assembly overview – front three-point seat belt, Polo 2022► 3555
1 3 Assembly overview – rear outer three-point seat belt 3557
1 4 Assembly overview – rear centre three-point seat belt 3557
1 5 Assembly overview – front belt buckle 3558
1 5 1 Assembly overview – front belt buckle, Polo 2018► 3558
1 5 2 Assembly overview – front belt buckle, Polo 2022► 3559
1 6 Assembly overview – rear belt buckle 3560
1 7 Removing and installing front three-point seat belt 3562
1 7 1 Removing and installing front three-point seat belt, Polo 2018► 3562
1 7 2 Removing and installing front three-point seat belt, Polo 2022► 3564
1 8 Removing and installing belt height adjuster 3567
1 9 Removing and installing front belt guide 3568
1 10 Removing and installing rear three-point seat belt 3569
1 10 1 Removing and installing rear outer three-point seat belt with belt tensioner 3569
1 10 2 Removing and installing rear outer three-point seat belt without belt tensioner 3571
1 10 3 Removing and installing rear centre three-point seat belt 3572
1 11 Removing and installing rear belt guide 3573
1 12 Removing and installing front belt end fitting 3574
1 12 1 Removing and installing front belt end fitting, Polo 2018► 3574
1 12 2 Removing and installing front belt end fitting, Polo 2022► 3574
1 13 Removing and installing rear outer belt end fitting 3575
1 14 Removing and installing front belt buckle 3576
1 15 Removing and installing rear belt buckle 3577
2 Child seat anchors 3579
2 1 Assembly overview – rear child seat anchors 3579
2 2 Removing and installing rear child seat anchors 3579
2 2 1 Removing and installing rear child seat anchor guide, rear seat 3579
2 2 2 Removing and installing upper child seat anchor cover in rear seat backrest 3580
3 Airbag system 3582
3 1 Overview of fitting locations – airbag system 3582
3 1 1 Overview of fitting locations – airbag system, Polo 2018► 3582
3 1 2 Overview of fitting locations – airbag system, Polo 2022► 3584
4 Airbag control unit 3587
4 1 Assembly overview – airbag control unit 3587
4 2 Removing and installing airbag control unit -J234- 3587
5 Battery isolator igniter 3590
5 1 Assembly overview – battery isolator igniter 3590
5 2 Removing and installing battery isolator igniter 3590
6 Front airbag 3594
6 1 Assembly overview – front airbag, driver side 3594
6 1 1 Assembly overview – front airbag, driver side, Polo 2018► 3594
6 1 2 Assembly overview – front airbag, driver side, Polo 2022► 3596
6 2 Removing and installing airbag unit with igniter 3597
6 2 1 Removing and installing airbag unit with igniter, Polo 2018► 3597
6 2 2 Removing and installing airbag unit with igniter, Polo 2022► 3599
6 3 Renewing connector on airbag 3601
7 Front passenger airbag 3604
7 1 Assembly overview – front passenger airbag 3604
7 1 1 Assembly overview – front passenger airbag, Polo 2018► 3604
7 1 2 Assembly overview – front passenger airbag, Polo 2022► 3604
7 2 Removing and installing front passenger airbag unit with igniter 3605
7 2 1 Removing and installing front passenger airbag unit with igniter, Polo 2018► 3605
7 2 2 Removing and installing front passenger airbag unit with igniter, Polo 2022► 3607
7 3 Removing and installing key-operated switch to deactivate airbag on front passenger side 3609
8 Side airbags 3611
8 1 Assembly overview – front side airbag 3611
8 1 1 Assembly overview – front side airbag, outer side 3611
8 1 2 Assembly overview – front side airbag, inner side 3611
8 2 Removing and installing front side airbag with igniter 3612
8 2 1 Removing and installing front side airbag with igniter (outer side) 3612
8 2 2 Removing and installing front side airbag with igniter (inner side) 3614
9 Curtain airbags 3616
9 1 Assembly overview – curtain airbag 3616
9 2 Removing and installing curtain airbag with igniter 3616
10 Airbag crash sensors 3620
10 1 Overview of fitting locations – airbag crash sensors 3620
10 2 Removing and installing front airbag crash sensor 3621
10 3 Removing and installing front side airbag crash sensor -G179-/-G180- 3623
10 4 Removing and installing rear side airbag crash sensor -G256-/-G257- 3625
11 Seat occupied recognition 3628
11 1 Removing and installing seat occupied recognition 3628
11 1 1 Removing and installing front seat occupied sensor -G128-, Polo 2018► 3628
11 1 2 Removing and installing front seat occupied sensor -G128-, Polo 2022► 3629
11 1 3 Removing and installing rear seat occupied sensor -G177-/-G178-, Polo 2022► 3629
11 1 4 Removing and installing rear centre seat occupied sensor -G1010-, Polo 2022► 3630
12 Pedestrian protection 3631
12 1 Assembly overview – pedestrian protection 3631
12 2 Removing and installing crash sensor for pedestrian protection system -G570-/-G571- 3633
12 3 Removing and installing trigger for pedestrian protection -G598-/-G599- 3635
12 4 Remove and installing front pressure hose sensor for pedestrian protection -G579- 3636
70 – Trim, insulation 3639
1 Front door trims 3639
1 1 Assembly overview – front door trim 3639
1 2 Removing and installing front door trim 3641
1 3 Removing and installing button trim 3645
1 4 Removing and installing mirror cover trim 3646
1 5 Removing and installing interior door handle 3647
2 Rear door trims 3650
2 1 Assembly overview – rear door trim 3650
2 2 Removing and installing rear door trim 3650
3 Dash panel 3654
3 1 Assembly overview – dash panel 3654
3 2 Removing and installing dash panel end cover 3656
3 3 Removing and installing dash panel trim 3657
3 4 Removing and installing dash panel insert trim 3658
3 5 Removing and installing radio/navigation system mounting frame 3659
3 6 Removing and installing dash panel 3661
3 7 Removing and installing outer dash panel vents 3665
3 7 1 Removing and installing outer dash panel vents, driver side 3665
3 7 2 Removing and installing outer dash panel vents, front passenger side 3666
3 8 Removing and installing centre vent 3667
3 9 Removing and installing side defroster vent 3668
4 Central tube for dash panel 3669
4 1 Assembly overview – central tube for dash panel 3669
4 2 Removing and installing dash panel cross member 3669
4 3 Removing and installing crash bar 3675
5 Interior trims 3677
5 1 Overview of fitting locations – interior trims 3677
5 2 Assembly overview – sill panel moulding 3678
5 3 Assembly overview – A-pillar trim 3679
5 3 1 Assembly overview – top A-pillar trim 3679
5 3 2 Assembly overview – bottom A-pillar trim 3680
5 4 Assembly overview – B-pillar trim 3681
5 5 Assembly overview – C-pillar trim 3682
5 6 Assembly overview – wheel housing trim 3683
5 7 Assembly overview – foot rest and floor covering 3684
5 7 1 Assembly overview – foot rest and floor covering, left-hand drive vehicle 3684
5 7 2 Assembly overview – foot rest and floor covering, right-hand drive vehicle 3685
5 8 Removing and installing sill panel moulding 3686
5 9 Removing and installing A-pillar trim 3689
5 9 1 Removing and installing top A-pillar trim 3689
5 9 2 Removing and installing bottom A-pillar trim on driver side 3691
5 9 3 Removing and installing bottom A-pillar trim on front passenger side 3692
5 10 Removing and installing A-pillar gap cover 3693
5 11 Removing and installing B-pillar trim 3694
5 11 1 Removing and installing top B-pillar trim 3694
5 11 2 Removing and installing bottom B-pillar trim 3696
5 12 Removing and installing C-pillar trim 3697
5 13 Removing and installing wheel housing trims 3699
5 14 Removing and installing foot rest 3700
5 14 1 Removing and installing foot rest, left-hand drive vehicle 3700
5 14 2 Removing and installing foot rest, RHD vehicles 3701
5 15 Removing and installing floor covering 3702
6 Luggage compartment trims 3704
6 1 Overview of fitting locations – luggage compartment trims 3704
6 2 Assembly overview – luggage compartment side trim 3705
6 3 Assembly overview – luggage compartment floor 3706
6 4 Assembly overview – lower rear lid trim 3707
6 4 1 Assembly overview – lower rear lid trim, Polo 2018► 3707
6 4 2 Assembly overview – lower rear lid trim, Polo 2022► 3708
6 5 Removing and installing lower rear lid trim 3709
6 5 1 Removing and installing lower rear lid trim, Polo 2018► 3709
6 5 2 Removing and installing lower rear lid trim, Polo 2022► 3711
6 6 Removing and installing rear shelf support 3712
6 7 Removing and installing luggage compartment side trim 3713
6 8 Removing and installing lock carrier trim 3715
6 9 Removing and installing support for luggage compartment floor covering 3716
7 Roof trims 3718
7 1 Assembly overview – moulded headliner 3718
7 2 Removing and installing moulded headliner 3718
7 3 Installing roof reinforcement to body 3722
72 – Seat frames 3726
1 Overview of seat variants 3726
1 1 Overview of fitting locations – seat variants 3726
2 Front seats 3727
2 1 Overview of fitting locations – electrical and electronic components 3727
2 2 Assembly overview – front seat 3728
2 3 Assembly overview – front backrest 3729
2 4 Assembly overview – head restraint 3731
2 5 Assembly overview – seat pan 3732
2 6 Assembly overview – seat height adjustment 3734
2 7 Removing and installing front seat 3734
2 8 Connecting and disconnecting airbag adapter 3737
2 9 Removing and installing seat height adjustment handle 3738
2 10 Removing and installing seat height adjuster 3740
2 11 Removing and installing lumbar support adjuster 3741
2 11 1 Removing and installing lumbar support adjustment lever 3741
2 11 2 Removing and installing manual lumbar support 3742
2 12 Removing and installing backrest adjuster 3743
2 13 Removing and installing front backrest 3744
2 14 Removing and installing head restraint 3746
2 15 Removing and installing head restraint guide 3746
2 16 Removing and installing bracket for seat trim 3747
2 17 Dismantling and assembling seat pan 3748
2 18 Removing and installing seat trim 3749
2 18 1 Removing and installing seat trim, tunnel side 3749
2 18 2 Removing and installing seat trim, sill side, with seat height adjustment 3749
2 18 3 Removing and installing seat trim, sill side, without seat height adjustment 3750
2 19 Securing front seat to seat repair stand 3751
3 Rear seats 3753
3 1 Assembly overview – bench seat/individual seats 3753
3 2 Assembly overview – locking mechanism 3754
3 3 Assembly overview – head restraint and head restraint guide 3754
3 4 Assembly overview – rear seat backrest 3755
3 4 1 Assembly overview – rear backrest, split folding 3755
3 4 2 Assembly overview – rear backrest, one piece 3756
3 5 Removing and installing bench seat/individual seats 3757
3 6 Removing and installing head restraint 3760
3 7 Removing and installing head restraint guide 3761
3 8 Removing and installing rear seat backrest 3763
3 9 Removing and installing trim for locking mechanism 3765
3 10 Removing and installing locking mechanism for rear seat backrest 3766
3 11 Removing and installing inner pivot pin 3767
3 12 Removing and installing back panel trim 3767
74 – Seat – padding, covers 3769
1 Front seat covers and padding 3769
1 1 Assembly overview – seat pan cover and padding 3769
1 2 Assembly overview – backrest cover and padding 3770
1 3 Assembly overview – seat heating element 3771
1 4 Assembly overview – backrest heating element 3772
1 5 Removing and installing seat pan cover and padding 3773
1 6 Removing and installing backrest cover and padding 3774
1 7 Separating seat pan cover from seat pan padding 3777
1 8 Separating backrest cover from backrest padding 3779
1 9 Removing and installing seat heating element -Z6-/-Z8- 3781
1 10 Removing and installing backrest heating element -Z7-/-Z9- 3782
2 Rear seat covers and padding 3784
2 1 Assembly overview – cover and padding 3784
2 1 1 Assembly overview – cover and padding of bench seat, Polo 2018► 3784
2 1 2 Assembly overview – cover and padding of bench seat, Polo 2022► 3784
2 1 3 Assembly overview – backrest cover and padding 3785
2 2 Removing and installing covers and padding 3787
2 2 1 Removing and installing cover and padding for bench seat 3787
2 2 2 Removing and installing backrest cover and padding 3787
2 3 Separating cover and padding 3790
2 3 1 Separating rear bench seat cover and padding 3790
2 3 2 Separating backrest cover from backrest padding 3791
D4B80609EAF Air conditioning systems with refrigerant R1234yf – General information 3792
00 – Technical data 3798
1 Safety information 3798
1 1 Safety precautions when working on air conditioning systems 3798
1 2 Safety precautions when handling refrigerants 3799
1 3 Safety measures when working on vehicles with a start/stop system 3799
1 4 Safety precautions when using air conditioner service stations 3799
1 5 Safety measures for working on vehicles with high-voltage system 3800
1 6 Safety precautions when working in the vicinity of high-voltage components 3801
1 7 Safety precautions when working on pressure vessels 3801
2 Laws and regulations 3802
2 1 Legal regulations and standards 3802
2 2 Charging refrigerant circuit with different refrigerants 3803
2 3 Occupational health and safety 3804
3 Repair notes 3805
3 1 Rules for cleanliness 3805
3 2 Refrigerant circuit seals 3805
3 3 Refrigerant and refrigerant oil 3806
3 3 1 Important repair notes for refrigerant and refrigerant oil 3806
3 3 2 Refrigerant oil 3807
3 4 Handling pressure vessels 3808
3 5 Handling refrigerants 3809
4 Identification 3811
4 1 Notice for refrigerant circuit 3811
5 Technical data 3812
5 1 Refrigerant capacity 3812
5 2 Refrigerant oil capacities 3812
5 3 Safety data sheets 3812
6 Basic technical and physical properties 3813
6 1 Basics of air conditioning technology 3813
6 1 1 Physical properties of air conditioning system 3813
6 1 2 Pressure and boiling point of refrigerant 3814
6 1 3 Vapour pressure table for refrigerant 3815
6 2 Physical properties 3817
6 2 1 Refrigerant R1234yf 3817
6 2 2 Potential risks with refrigerant R1234yf 3817
6 2 3 Physical and chemical properties of refrigerant R1234yf 3818
6 2 4 Critical point 3818
6 2 5 Environmental aspects of refrigerant R1234yf 3819
6 2 6 Trade names and designations of refrigerant R1234yf 3819
6 2 7 Colour and odour of R1234yf refrigerant 3820
6 2 8 Vapour pressure of R1234yf refrigerant 3820
6 2 9 Physical properties of R1234yf refrigerant 3820
6 2 10 How R1234yf refrigerant reacts to metals and plastics 3820
6 2 11 Critical temperature / critical pressure of R1234yf refrigerant 3821
6 2 12 Water content of R1234yf refrigerant 3821
6 2 13 Flammability / decomposition of R1234yf refrigerant 3821
6 2 14 Charge factor of refrigerant R1234yf 3821
6 2 15 Evidence of leaks in a refrigerant circuit with R1234yf refrigerant 3822
6 2 16 Analysis of refrigerant R1234yf 3822
6 2 17 Returning contaminated R1234yf refrigerant for analysis, processing or disposal 3823
6 3 Product characteristics 3824
6 4 Function and role of air conditioning system 3824
6 4 1 Principle of operation 3824
6 4 2 Comfort 3825
6 4 3 Environmental aspects 3825
6 5 Other reference material 3826
87 – Air conditioning system 3827
1 Refrigerant circuit 3827
1 1 System overview – refrigerant circuit 3827
1 1 1 System overview – refrigerant circuit with expansion valve and receiver 3827
1 1 2 System overview – refrigerant circuit with restrictor and reservoir 3829
1 1 3 System overview – refrigerant circuit with electrically driven air conditioner compressor (with and without battery cooling module) 3830
1 2 General description – components of refrigerant circuit 3833
1 2 1 Layout and function of refrigerant circuit 3833
1 2 2 Mechanical air conditioner compressor 3834
1 2 3 Electrical air conditioner compressor for hybrid vehicles 3837
1 2 4 Condenser 3840
1 2 5 evaporator 3841
1 2 6 Reservoir 3843
1 2 7 Heat exchanger for heat pump mode 3843
1 2 8 Liquid receiver 3844
1 2 9 Restrictor 3844
1 2 10 Receiver 3846
1 2 11 Expansion valve (with and without shut-off valve) 3848
1 2 12 Refrigerant shut-off valves 3850
1 2 13 Refrigerant line with internal heat exchanger 3852
1 2 14 Quick release couplings of refrigerant lines 3853
1 2 15 Seals 3854
1 2 16 Pipes and hoses in refrigerant circuit 3855
1 2 17 High-pressure safety valve 3855
1 2 18 Non-return valves 3857
1 2 19 Quick-release coupling connections in refrigerant circuit 3858
1 2 20 Connections with valve for switches in refrigerant circuit 3862
1 2 21 Pressure senders and switches in refrigerant circuit 3863
1 2 22 Refrigerant pressure and temperature sender 3864
1 2 23 Air conditioner compressor regulating valve -N280- 3867
1 2 24 Refrigerant temperature sender 3868
1 3 Possible complaints 3869
1 3 1 Prerequisites for investigating a complaint 3869
1 3 2 Possible complaints 3869
1 3 3 Odours from heater and air conditioning unit 3871
1 4 Investigating leaks 3873
1 4 1 General information about investigating leaks in the refrigerant circuit 3873
1 4 2 Searching for leaks in refrigerant circuits using an electronic leak detector 3874
1 4 3 Searching for leaks with UV leak detection system 3875
1 4 4 Detecting leaks in a vacuum test using air conditioner service station, or in a pressure test 3881
1 4 5 Detecting leaks in a pressure test (with nitrogen or compressed air) 3882
1 5 Renewing components 3884
1 5 1 General information about renewing components 3884
1 5 2 Renewing leaking or damaged components of empty refrigerant circuit (apart from air conditioner compressor and receiver) 3885
1 5 3 Renewing leaking or damaged components of charged refrigerant circuit (apart from air conditioner compressor and receiver) 3887
1 5 4 Renewing air conditioner compressor with no need to clean refrigerant circuit 3888
1 5 5 Renewing air conditioner compressor due to leaks or internal damage 3891
1 5 6 Renewing desiccant cartridge / receiver after cleaning refrigerant circuit 3892
1 5 7 Renewing receiver with no need to clean refrigerant circuit 3894
1 5 8 Renewing desiccant cartridge / desiccant bag with no need to clean refrigerant circuit 3895
1 6 Cleaning refrigerant circuit 3896
1 6 1 General information about cleaning refrigerant circuit 3896
1 6 2 Preparations for cleaning refrigerant circuit (flushing with R1234yf refrigerant) 3898
1 6 3 Refrigerant circuit cleaning procedure 3902
1 6 4 Principle circuit diagrams for cleaning (flushing circuits) – refrigerant circuit with expansion valve and receiver 3902
1 6 5 Principle circuit diagrams for cleaning (flushing circuits) – refrigerant circuit with restrictor and receiver (without high-voltage system) 3907
1 6 6 Adapters for setting up flushing circuits 3910
1 6 7 General information about blowing through with compressed air or nitrogen 3923
1 6 8 Blowing through refrigerant circuit with compressed air or nitrogen 3927
1 7 Checking pressures with pressure gauge 3928
1 7 1 Display on pressure gauges 3928
1 7 2 Pressure gauges enable the following test and measurement work 3929
2 Working with air conditioner service station 3932
2 1 Working with air conditioner service station 3933
2 2 Connecting air conditioner service station to refrigerant circuit 3935
2 3 Performing gas analysis of refrigerant 3938
2 4 Purging refrigerant circuit 3941
2 5 Evacuating refrigerant circuit 3944
2 6 Charging refrigerant circuit 3950
2 7 Bringing air conditioning system into service after charging 3953
2 8 Switching off air conditioner service station and separating from refrigerant circuit 3955
2 9 Charging refrigerant in reservoir 3957
2 10 Emptying air conditioner service station 3958
2 11 Cleaning electrical air conditioning compressor 3958
2 12 Cleaning refrigerant circuit 3961
2 13 Filling contaminated refrigerant in a recycling cylinder for analysis, processing or disposal 3964
2 13 1 Filling contaminated refrigerant into recycling cylinder using extraction unit -VAS 581 011- 3964
2 13 2 Filling contaminated refrigerant into recycling cylinder using extraction unit -VAS 581 007- 3965
2 14 Checking pressures 3969
2 14 1 General information on checking pressures in the refrigerant circuit 3969
2 14 2 Pressures and temperatures in refrigerant circuit 3971
2 14 3 Checking pressures in the refrigerant circuit with the ignition switched off 3975
2 14 4 Checking pressures with air conditioning system switched on – vehicles with mechanical air conditioning compressor 3982
2 14 5 Checking pressures with air conditioning system switched on – vehicles with electrical air conditioning compressor 4004
3 Testing equipment and tools 4057
3 1 Tools and materials available from distribution centre or importer 4057
3 2 Tools and materials available commercially 4057
D4B80609EEB 4 cyl direct injection engine (2 0 l 4 V EA 888 gen III BZ turbocharger chain drive) 4059
00 – Technical data 4067
1 Safety information 4067
1 1 Safety regulations for working on fuel supply 4067
1 2 Safety measures when working on vehicles with start/stop system 4067
1 3 Safety precautions when using testers and measuring instruments during a road test 4068
1 4 Safety precautions when working on ignition system 4068
1 5 Safety precautions when working on the cooling system 4068
1 6 Safety precautions when working on exhaust system 4069
2 Identification 4070
2 1 Engine number/engine data 4070
3 Repair notes 4072
3 1 Rules for cleanliness 4072
3 2 Foreign objects in engine 4072
3 3 Contact corrosion 4072
3 4 Routing and attachment of lines 4072
3 5 Fitting radiator and condensers 4073
3 6 Checking vacuum system 4073
10 – Removing and installing engine 4074
1 Removing and installing engine 4074
1 1 Removing engine 4074
1 2 Separating engine and gearbox 4090
1 2 1 Separating engine and gearbox, vehicles with manual gearbox 4090
1 2 2 Separating engine and gearbox, vehicles with 7-speed dual clutch gearbox 4093
1 2 3 Separating engine and gearbox, vehicles with 6-speed dual clutch gearbox 4097
1 3 Securing engine on engine and gearbox support 4100
1 4 Installing engine 4103
2 Assembly mountings 4107
2 1 Assembly overview – assembly mountings 4107
2 2 Removing and installing engine mounting 4109
2 3 Removing and installing gearbox mounting 4110
2 4 Removing and installing pendulum support 4112
2 4 1 Removing and installing pendulum support, Tiguan, Arteon, T-Roc, Passat 4112
2 4 2 Removing and installing pendulum support, Polo 4113
2 5 Supporting engine in installation position 4114
2 5 1 Supporting engine in installation position, Tiguan 4114
2 5 2 Supporting engine in installation position, Arteon 4118
2 5 3 Supporting engine in installation position, Passat 4121
2 5 4 Supporting engine in installation position, T-Roc 4126
2 5 5 Supporting engine in installation position, Polo 4131
2 6 Checking adjustment of assembly mountings 4135
2 7 Adjusting assembly mountings 4135
3 Engine cover panel 4138
3 1 Removing and installing engine cover 4138
13 – Crankshaft group 4139
1 Cylinder block (pulley end) 4139
1 1 Assembly overview – cylinder block (pulley end) 4139
1 2 Removing and installing poly-V belt 4142
1 3 Removing and installing tensioner for poly V-belt 4143
1 4 Removing and installing vibration damper 4144
1 5 Renewing seal for vibration damper 4151
1 6 Removing and installing bracket for ancillaries 4154
1 7 Removing and installing engine support 4156
2 Cylinder block, gearbox end 4159
2 1 Assembly overview – cylinder block, gearbox end 4159
2 2 Removing and installing flywheel 4160
2 3 Removing and installing sealing flange on gearbox side 4162
3 Crankshaft 4167
3 1 Assembly overview – crankshaft 4167
3 2 Crankshaft dimensions 4170
3 3 Allocation of main bearing shells 4170
3 4 Renewing needle bearing in crankshaft 4172
3 5 Measuring axial clearance of crankshaft 4174
3 6 Measuring radial clearance of crankshaft 4175
3 7 Removing and installing sender wheel 4176
4 Balancer shaft 4178
4 1 Assembly overview – balance shaft 4178
4 2 Removing and installing balance shaft 4180
4 2 1 Removing and installing inlet side balance shaft 4180
4 2 2 Removing and installing exhaust side balance shaft 4183
4 2 3 Renewing oil seal for balance shaft (inlet side) 4185
5 Pistons and conrods 4187
5 1 Assembly overview – pistons and conrods 4187
5 2 Removing and installing pistons 4191
5 3 Checking pistons and cylinder bores 4193
5 4 Separating new conrod 4195
5 5 Checking radial clearance of conrods 4195
5 6 Removing and installing oil spray jets 4196
15 – Cylinder head, valve gear 4198
1 Cylinder head 4198
1 1 Assembly overview – cylinder head 4198
1 2 Removing and installing cylinder head 4201
1 3 Assembly overview – vacuum pump 4207
1 4 Removing and installing vacuum pump 4208
1 5 Checking compression 4210
2 Cover for timing chain 4213
2 1 Assembly overview – cover for timing chain 4213
2 2 Removing and installing timing chain cover 4216
2 2 1 Removing and installing upper timing chain cover 4216
2 2 2 Removing and installing timing chain cover (bottom) 4218
3 Chain drive 4223
3 1 Assembly overview – camshaft timing chains 4223
3 2 Assembly overview – drive chain for balance shaft 4226
3 3 Removing and installing camshaft timing chain 4228
3 4 Removing and installing drive chain for balance shaft 4241
3 5 Checking timing chain 4244
4 Valve gear 4246
4 1 Assembly overview – valve gear 4246
4 2 Removing and installing camshaft 4250
4 3 Removing and installing actuators for camshaft adjustment 4261
4 4 Removing and installing camshaft control valve 1 -N205- 4263
4 5 Removing and installing exhaust camshaft control valve 1 -N318- 4263
4 6 Removing and installing valve stem oil seals 4264
4 6 1 Removing and installing valve stem seals (cylinder head installed) 4264
4 6 2 Removing and installing valve stem seals (cylinder head removed) 4269
5 Inlet and exhaust valves 4275
5 1 Checking valve guides 4275
5 2 Checking valves 4276
5 3 Valve dimensions 4276
17 – Lubrication 4277
1 Sump, oil pump 4277
1 1 Assembly overview – sump/oil pump 4277
1 2 Engine oil: 4280
1 3 Removing and installing lower part of sump 4280
1 3 1 Removing and installing bottom section of sump, plastic sump 4280
1 3 2 Removing and installing bottom section of sump, sheet-metal sump 4282
1 4 Removing and installing upper part of sump 4286
1 5 Removing and installing oil pump 4292
1 6 Removing and installing oil level and oil temperature sender -G266- 4295
2 Engine oil cooler 4297
2 1 Assembly overview – engine oil cooler 4297
2 2 Removing and installing engine oil cooler 4297
3 Crankcase ventilation 4300
3 1 Assembly overview – crankcase breather system 4300
3 2 Removing and installing oil separator 4301
4 Oil filter, oil pressure switch 4303
4 1 Assembly overview – oil filter 4303
4 2 Assembly overview – oil pressure switches/oil pressure control 4303
4 3 Removing and installing piston cooling jet control valve -N522- 4305
4 4 Removing and installing oil pressure switch 4306
4 4 1 Removing and installing oil pressure switch -F1- 4306
4 4 2 Removing and installing oil pressure switch for reduced oil pressure -F378- 4307
4 4 3 Removing and installing stage 3 oil pressure switch -F447- 4308
4 5 Checking oil pressure 4310
4 5 1 Checking engine oil pressure 4310
4 5 2 Checking oil pressure and oil spray jets 4312
4 6 Removing and installing oil pressure regulating valve -N428- 4314
19 – Cooling 4316
1 Cooling system/coolant 4316
1 1 Connection diagram – coolant hoses 4316
1 1 1 Vehicles with manual gearbox 4316
1 1 2 Vehicles with dual clutch gearbox 4317
1 2 Checking cooling system for leaks 4318
1 3 Draining and adding coolant 4322
1 4 Flushing cooling system 4330
1 4 1 Flushing cooling system 4330
1 4 2 Flushing cooling system, quick reference guide 4352
2 Coolant pump, regulation of cooling system 4354
2 1 Assembly overview – coolant pump, thermostat 4354
2 2 Assembly overview – electric coolant pump 4356
2 3 Assembly overview – coolant temperature sender 4359
2 4 Removing and installing electric coolant pump 4360
2 4 1 Removing and installing auxiliary pump for heating -V488- 4360
2 5 Removing and installing coolant pump 4363
2 6 Removing and installing toothed belt for coolant pump 4366
2 7 Removing and installing coolant valves 4367
2 7 1 Removing and installing coolant shut-off valve -N82- 4367
2 7 2 Removing and installing coolant valve for gearbox -N488-, vehicles with 6-speed dual clutch gearbox 4369
2 7 3 Removing and installing coolant valve for gearbox -N488-, vehicles with 7-speed dual clutch gearbox 4371
2 8 Removing and installing actuator for engine temperature regulation -N493- 4372
2 9 Removing and installing coolant temperature sender -G62- 4375
2 10 Removing and installing radiator outlet coolant temperature sender -G83- 4376
3 Coolant pipes 4378
3 1 Assembly overview – coolant pipes 4378
3 2 Removing and installing coolant pipes 4378
3 2 1 Removing and installing front coolant pipe 4378
3 3 Removing and installing upper coolant pipes 4380
4 Radiator, radiator fan 4382
4 1 Assembly overview – radiator 4382
4 1 1 Assembly overview – radiator, Tiguan, Arteon, T-Roc, Passat 4382
4 1 2 Assembly overview – radiator, Polo 4384
4 2 Assembly overview – radiator cowl and radiator fan 4386
4 2 1 Assembly overview – radiator cowl and radiator fan, twin fan 4386
4 2 2 Assembly overview – radiator cowl and radiator fan, single fan 4387
4 3 Removing and installing radiator 4388
4 3 1 Removing and installing radiator, Tiguan, Arteon, T-Roc, Passat 4388
4 3 2 Removing and installing radiator, Polo 4390
4 4 Removing and installing radiator cowl 4395
4 4 1 Removing and installing radiator cowl, twin fan 4395
4 4 2 Removing and installing radiator cowl, single fan 4397
4 4 3 Removing and installing radiator cowl, Polo 4398
4 5 Removing and installing radiator fan 4401
4 5 1 Removing and installing radiator fan, twin fan 4401
4 5 2 Removing and installing radiator fan, single fan 4402
21 – Turbocharging/supercharging 4404
1 Turbocharger 4404
1 1 Assembly overview – turbocharger 4404
1 2 Removing and installing turbocharger 4408
2 Charge air system 4414
2 1 Assembly overview – charge air system 4414
2 1 1 Assembly overview – charge air system, Tiguan, Arteon, T-Roc, Passat 4414
2 1 2 Assembly overview – charge air system, Polo 4415
2 2 Assembly overview – charge-air hose connections 4417
2 3 Removing and installing charge air cooler 4417
2 3 1 Removing and installing charge air cooler, Tiguan, Arteon, T-Roc, Passat 4417
2 3 2 Removing and installing charge air cooler, Polo 4421
2 4 Removing and installing charge pressure sender -G31- 4422
2 5 Checking charge air system for leaks 4423
2 6 Removing and installing air intake pipe between turbocharger and charge air cooler 4425
24 – Mixture preparation – injection 4427
1 Injection system 4427
1 1 Overview of fitting locations – injection system 4427
2 Injectors 4439
2 1 Assembly overview – fuel rail with injectors 4439
2 1 1 Assembly overview – fuel rail with injectors, direct injection 4439
2 1 2 Assembly overview – fuel rail with injectors, indirect injection 4440
2 2 Removing and installing fuel rail 4441
2 3 Removing and installing injectors 4442
2 3 1 Removing and installing injectors, direct injection 4442
2 3 2 Removing and installing injectors, indirect injection 4447
2 4 Renewing seals on injectors 4449
2 5 Cleaning injectors 4452
3 Air filter 4454
3 1 Assembly overview – air filter housing 4454
3 1 1 Assembly overview – air filter housing, Tiguan, Arteon, T-Roc, Passat 4454
3 1 2 Assembly overview – air filter housing, Polo 4456
3 2 Removing and installing air filter housing 4457
3 3 Removing and installing air guide on lock carrier 4459
3 3 1 Removing air duct on lock carrier, Tiguan, Arteon, Passat 4459
3 3 2 Removing air guide on lock carrier, T-Roc 4460
3 3 3 Removing air guide on lock carrier, Polo 4461
4 Intake manifold 4462
4 1 Assembly overview – intake manifold 4462
4 2 Removing and installing intake manifold 4464
4 3 Removing and installing throttle valve module -GX3- 4469
4 4 Cleaning throttle valve module -GX3- 4472
4 5 Checking intake manifold change-over 4473
5 Senders and sensors 4475
5 1 Removing and installing fuel pressure sender -G247- 4475
5 2 Checking fuel pressure sender -G247- 4478
5 3 Removing and installing fuel pressure sender for low-pressure -G410- 4480
5 4 Removing and installing intake manifold sender -GX9- 4481
5 5 Removing and installing air mass meter -G70- 4482
5 6 Assembly overview – actuator for structure-borne sound and control unit for structure-borne sound, Polo 4484
5 7 Removing and installing pressure differential sender for particulate filter -G1037- 4486
6 Engine/motor control unit 4488
6 1 Removing and installing engine control unit -J623- 4488
6 2 Removing and installing engine (motor) control unit -J623- with protective housing 4489
7 High-pressure pump 4493
7 1 Assembly overview – high-pressure pump 4493
7 2 Removing and installing high-pressure pump 4495
7 3 Removing and installing high-pressure pipe 4498
8 Lambda probe 4502
8 1 Assembly overview – Lambda probe 4502
8 2 Removing and installing lambda probe 4503
8 2 1 Removing and installing Lambda probe 1 before catalytic converter -GX10- 4503
8 2 2 Removing and installing Lambda probe 1 after catalytic converter -GX7- 4505
26 – Exhaust system 4507
1 Exhaust pipes and silencers 4507
1 1 Assembly overview – silencers 4507
1 1 1 Assembly overview – silencers, Tiguan 4507
1 1 2 Assembly overview – silencer, Arteon, Passat 4508
1 1 3 Assembly overview – silencers, Polo 4509
1 1 4 Assembly overview – silencers, T-Roc 4511
1 2 Removing and installing silencer 4512
1 2 1 Removing and installing silencer, Tiguan 4512
1 2 2 Removing and installing silencer, Arteon, Passat 4514
1 2 3 Removing and installing front silencer, Polo 4515
1 2 4 Removing and installing rear silencer, Polo 4516
1 2 5 Removing and installing silencers, T-Roc 4517
1 3 Separating exhaust pipes from silencers 4519
1 3 1 Separating exhaust pipes/silencers, Arteon, Passat 4519
1 3 2 Separating exhaust pipes/silencers, Polo 4522
1 3 3 Separating exhaust pipes/silencers, T-Roc 4523
1 4 Aligning exhaust system free of stress 4525
1 5 Checking exhaust system for leaks 4525
2 Emission control 4526
2 1 Assembly overview – emission control 4526
2 1 1 Assembly overview – exhaust gas treatment, Tiguan 4526
2 1 2 Assembly overview – emission control, Arteon, Polo, T-Roc, Passat 4530
2 1 3 Assembly overview – emission control, vehicles with particulate filter and front-wheel drive 4531
2 1 4 Assembly overview – emission control, vehicles with particulate filter and all-wheel drive 4533
2 1 5 Catalytic converter – specified torque and tightening sequence 4535
2 2 Assembly overview – bracket and pipes for pressure differential sender for particulate filter -G1037- 4536
2 3 Removing and installing catalytic converter 4537
2 3 1 Removing and installing catalytic converter, vehicles without particulate filter and front-wheel drive 4537
2 3 2 Removing and installing catalytic converter, vehicles without particulate filter and all-wheel drive 4541
2 3 3 Removing and installing catalytic converter, vehicles with particulate filter and front-wheel drive 4548
2 3 4 Removing and installing catalytic converter, vehicles with particulate filter and all-wheel drive 4552
2 4 Removing and installing holder of pressure differential sender for particulate filter -G1037- 4557
3 Exhaust gas temperature regulation 4558
3 1 Assembly overview – exhaust gas temperature regulation 4558
3 2 Removing and installing parts of exhaust gas temperature regulation 4559
3 2 1 Removing and installing exhaust gas temperature sender, vehicles with front-wheel drive 4559
3 2 2 Removing and installing exhaust gas temperature sender, vehicles with all-wheel drive 4561
28 – Ignition system 4564
1 Ignition system 4564
1 1 Assembly overview – ignition system 4564
1 2 Removing and installing ignition coils with output stage 4566
1 3 Removing and installing knock sensor 1 -G61- 4568
1 4 Removing and installing Hall sender 4569
1 4 1 Removing and installing Hall sender -G40- 4569
1 4 2 Removing and installing Hall sender 3 -G300- 4570
1 5 Removing and installing engine speed sender -G28- 4570
D4B80768BC5 Running gear axles steering 4573
00 – Technical data 4579
1 Safety and repair instructions 4579
1 1 Safety information 4579
1 2 Repair instructions 4579
2 Electrical components 4580
2 1 Access to diagnoses 4580
40 – Front suspension 4582
1 Safety and repair instructions 4582
1 1 Safety information 4582
1 2 Repair instructions 4582
2 Subframe 4583
2 1 Assembly overview – subframe 4583
2 2 Removing and installing subframe without steering rack 4583
2 2 1 Removing and installing subframe without steering rack 4583
2 3 Removing and installing subframe with steering rack 4585
2 3 1 Removing and installing subframe with steering rack 4585
2 4 Repairing thread in longitudinal member 4585
2 5 Fixing subframe in position 4585
2 6 Lowering subframe 4587
2 7 Preparing foot pump 4589
3 Suspension strut, upper suspension link 4591
3 1 Assembly overview – suspension strut, upper suspension links, Polo 2018, Polo 2022, T-Cross 2019, Taigo 2022, Taigun 2022 4591
3 1 1 Assembly overview – suspension strut, upper suspension links 4591
3 2 Assembly overview – suspension strut, upper suspension link, Virtus 2022 4592
3 2 1 Assembly overview – suspension strut, upper suspension links 4592
3 3 Removing and installing suspension strut, Polo 2018, Polo 2022, T-Cross 2019, Taigo 2022, Taigun 2022 4594
3 3 1 Removing and installing suspension strut 4594
3 4 Removing and installing suspension strut, Virtus 2022 4599
3 4 1 Removing and installing suspension strut 4599
3 5 Removing and installing spring 4603
4 Lower suspension link, swivel joint 4609
4 1 Assembly overview – lower suspension link, swivel joint 4609
4 2 Removing and installing lower suspension link 4611
4 3 Checking swivel joint 4611
4 4 Removing and installing swivel joint 4612
4 5 Renewing bonded rubber bush for lower suspension link 4614
4 5 1 Renewing front bonded rubber bush for lower suspension link 4614
4 5 2 Renewing rear bonded rubber bush for lower suspension link 4616
4 6 Removing and installing stone deflector for suspension link 4620
5 Wheel bearing 4621
5 1 Assembly overview – wheel bearing assembly 4621
5 2 Removing and installing wheel bearing housing 4621
5 3 Removing and installing wheel bearing unit 4625
6 Drive shaft 4631
6 1 Overview – drive shaft 4631
6 2 Assembly overview – drive shaft, inner triple roller joint 4631
6 2 1 Assembly overview – drive shaft 4631
6 3 Assembly overview – drive shaft, constant velocity joint VL100 4633
6 3 1 Assembly overview – drive shaft 4633
6 4 Assembly overview – drive shaft, constant velocity joint VL107 4635
6 4 1 Assembly overview – drive shaft 4635
6 5 Removing and installing drive shaft 4637
6 6 Loosening and tightening threaded connections of drive shaft 4640
6 7 Tensioning clamp for boot 4643
6 8 Pressing out drive shaft of wheel bearing housing 4644
6 9 Removing and installing drive shaft heat shield 4645
6 10 Dismantling and assembling drive shaft, outer constant velocity joint 4646
6 10 1 Dismantling and assembling drive shaft 4646
6 11 Dismantling and assembling drive shaft, inner constant velocity joint VL100 4648
6 11 1 Dismantling and assembling drive shaft 4648
6 12 Dismantling and assembling drive shaft, inner constant velocity joint VL107 4652
6 12 1 Dismantling and assembling drive shaft 4652
6 13 Dismantling and assembling drive shaft, inner triple roller joint AAR2600i 4655
6 13 1 Dismantling and assembling drive shaft 4655
6 14 Dismantling and assembling drive shaft, inner triple roller joint with joint body TS1800 4659
6 14 1 Dismantling and assembling drive shaft 4659
6 15 Checking outer constant velocity joint 4662
6 16 Removing and installing deflector ring 4663
6 17 Checking inner constant velocity joint 4665
7 Anti-roll bar 4668
7 1 Assembly overview – anti-roll bar 4668
7 2 Removing and installing anti-roll bar 4668
7 3 Removing and installing coupling rod 4669
42 – Rear suspension 4671
1 Safety and repair instructions 4671
1 1 Safety information 4671
1 2 Repair instructions 4671
2 Rear axle 4672
2 1 Removing and installing rear axle 4672
2 2 Securing vehicle to support arms of lifting platform 4674
3 Axle beam 4676
3 1 Assembly overview – axle beam 4676
3 2 Assembly overview – attachments for torsion beam axle 4676
3 3 Renewing bonded rubber bush for axle beam 4677
3 4 Removing and installing outer trim of torsion beam axle 4681
3 5 Removing and installing centre cladding of torsion beam axle 4682
4 Suspension strut, shock absorber, spring 4684
4 1 Assembly overview – suspension strut, shock absorber, spring 4684
4 2 Assembly overview – shock absorber, adaptive chassis control 4684
4 2 1 Assembly overview – shock absorber 4684
4 3 Assembly overview – shock absorber, standard running gear 4685
4 3 1 Assembly overview – shock absorber 4685
4 4 Removing and installing shock absorber 4686
4 5 Removing and installing spring 4687
4 6 Renewing shock absorber, standard suspension 4689
4 6 1 Renewing shock absorber 4689
4 7 Renewing shock absorber, adaptive chassis control DCC 4692
4 7 1 Renewing shock absorber 4692
5 Wheel bearing assembly, trailing arm 4697
5 1 Assembly overview – wheel bearings, drum brake 4697
5 1 1 Assembly overview – wheel bearing assembly 4697
5 2 Assembly overview – wheel bearings, disc brake 4697
5 2 1 Assembly overview – wheel bearing assembly 4697
5 3 Removing and installing wheel bearing unit, drum brake 4698
5 3 1 Removing and installing wheel bearing unit 4698
5 4 Removing and installing wheel bearing unit, disc brake 4700
5 4 1 Removing and installing wheel bearing unit 4700
43 – Self-levelling suspension 4702
1 Safety and repair instructions 4702
1 1 Safety information 4702
1 2 Repair instructions 4702
2 Electronic damping control 4703
2 1 Overview of fitting locations – electronically controlled damping 4703
2 2 Removing and installing electronically controlled damping control unit [J250] 4704
3 Vehicle level sender 4705
3 1 Assembly overview – rear vehicle level senders 4705
3 2 Removing and installing rear vehicle level senders [G77] 4705
44 – Wheels, tyres, vehicle geometry 4708
1 Wheel alignment 4708
1 1 Notes on wheel alignment 4708
1 2 Conditions for testing 4708
1 3 Preparations for measurement 4708
1 4 Setting vehicle to initial position for wheel alignment 4709
1 5 Necessity of wheel alignment 4709
1 6 Adjusting camber at front wheels 4710
1 7 Adjusting camber at rear axle, torsion beam axle 4711
1 7 1 Adjusting camber on rear axle 4711
1 8 Adjusting toe at rear axle, torsion beam axle 4711
1 8 1 Adjusting toe at rear axle 4711
1 9 Adjusting front axle toe 4711
1 10 Checking full steering lock 4712
1 11 Specifications for wheel alignment Polo 2018 (AW1), Polo 2022 (AE1), Virtus 2022 (D22) 4713
1 11 1 Specifications for wheel alignment 4713
1 12 Specifications for wheel alignment T-Cross 2019 (C11), Taigun 2022 (CW1) 4715
1 12 1 Specifications for wheel alignment 4715
1 13 Specifications for wheel alignment Taigo 2022 (CS1) 4717
1 13 1 Specifications for wheel alignment 4717
2 Wheels, tyres 4721
2 1 Removing wheel 4721
2 2 Installing wheel 4721
48 – Steering 4723
1 Safety and repair instructions 4723
1 1 Safety information 4723
1 2 Repair instructions 4723
2 Steering wheel 4724
2 1 Assembly overview – steering wheel 4724
2 2 Removing and installing steering wheel 4724
3 Steering column 4726
3 1 Assembly overview – steering column, integrated power steering control unit [J500] 4726
3 1 1 Assembly overview – steering column 4726
3 2 Assembly overview – steering column, power steering control unit [J500], separate 4727
3 2 1 Assembly overview – steering column 4727
3 3 Removing and installing steering column 4729
3 4 Removing and installing intermediate steering shaft 4730
3 5 Removing and installing control unit for electronic steering column lock [J764] 4731
3 6 Removing and installing power steering control unit [J500] 4733
4 Steering rack 4736
4 1 Assembly overview – steering rack 4736
4 2 Assembly overview – track rods 4736
4 3 Removing and installing steering rack 4737
4 4 Removing and installing bellows 4739
4 5 Removing and installing track rod 4741
4 6 Removing and installing track rod ball joint 4742
4 7 Repairing steering rack 4743
D4B80769F80 Removed 5 speed manual gearbox 0DF and 0D0 4745
00 – Technical data 4749
1 Safety information 4749
2 Identification 4750
3 Technical data 4751
3 1 Allocation gearbox – engine 4751
3 2 Capacities 4751
4 Overview – power transmission 4752
5 Electrical components 4753
6 Repair notes 4754
6 1 General repair instructions 4754
30 – Clutch 4758
1 Clutch mechanism 4758
1 1 Assembly overview – clutch release mechanism 4758
1 2 Repairing clutch release mechanism 4760
2 Clutch 4762
2 1 Assembly overview – clutch 4762
2 1 1 Assembly overview – clutch in conjunction with Sachs dual-mass flywheel 4762
2 1 2 Assembly overview – clutch in conjunction with LuK dual-mass flywheel 4763
2 1 3 Assembly overview – clutch with simple flywheel 4763
2 2 Removing and installing clutch 4764
2 2 1 Removing and installing clutch in conjunction with Sachs dual-mass flywheel 4764
2 2 2 Removing and installing clutch in conjunction with LuK dual-mass flywheel 4769
2 2 3 Removing and installing clutch in connection with simple flywheel 4773
34 – Controls, housing 4779
1 Selector mechanism 4779
2 Removing and installing gearbox 4780
3 Gearbox transport 4781
4 Gear oil 4783
5 Securing to engine and gearbox support 4784
6 Dismantling and assembling gearbox 4785
6 1 Schematic overview – gearbox 4785
6 2 Assembly overview – gearbox 4785
6 3 Assembly overview – gearbox housing cover 4786
6 4 Assembly overview – clutch housing 4787
6 5 Assembly overview – shafts, differential, selector mechanism 4788
6 6 Assembly overview – selector forks 4790
6 7 Repairing selector forks 4791
6 8 Dismantling and assembling gearbox 4796
7 Gearbox housing, clutch housing 4809
7 1 Assembly overview – gearbox housing and clutch housing 4809
7 1 1 Assembly overview – gearbox housing and clutch housing 4809
7 2 Repairing clutch housing 4811
35 – Gears, shafts 4815
1 Input shaft 4815
1 1 Assembly overview – input shaft 4815
1 2 Dismantling and assembling input shaft 4817
1 3 Renewing input shaft seal 4831
2 Output shaft 4834
2 1 Assembly overview – output shaft 4834
2 2 Dismantling and assembling output shaft 4837
39 – Final drive – differential 4845
1 Oil seals 4845
2 Differential 4846
2 1 Assembly overview – differential 4846
2 1 1 Assembly overview – differential 4846
2 2 Dismantling and assembling differential 4847
2 3 Adjusting differential 4858
D4B80866E2F 3 cyl injection engine (1 0 l engine 4V EA 211 EVO) 4866
00 – Technical data 4872
1 Safety information 4872
1 1 Safety regulations for working on fuel supply 4872
1 2 Safety measures when working on vehicles with a start/stop system 4872
1 3 Safety precautions when using testers and measuring instruments during a road test 4873
1 4 Safety precautions when working on the cooling system 4873
1 5 Safety precautions when working on ignition system 4873
2 Identification 4874
2 1 Engine number/engine data 4874
3 Repair instructions 4876
3 1 Rules for cleanliness 4876
3 2 General information 4876
3 3 General repair instructions 4876
3 4 Foreign bodies in engine 4877
3 5 Contact corrosion 4877
3 6 Routing and attachment of lines 4877
3 7 Fitting radiator and condensers 4877
3 8 Checking vacuum system 4878
10 – Removing and installing engine 4879
1 Removing and installing engine 4879
1 1 Removing engine 4879
1 1 1 Removing engine, Polo 4879
1 1 2 Removing engine, up! 2020 4891
1 2 Separating engine and gearbox 4901
1 3 Securing engine on engine and gearbox support 4902
1 4 Installing engine 4905
2 Assembly mountings 4909
2 1 Assembly overview – assembly mountings 4909
2 1 1 Assembly overview – assembly mountings, Polo 4909
2 1 2 Assembly overview – assembly mountings, up! 2020 4912
2 2 Removing and installing engine mounting 4915
2 2 1 Removing and installing engine mounting, Polo 4915
2 2 2 Removing and installing engine mounting, up! 2020 4916
2 3 Removing and installing gearbox mounting 4917
2 3 1 Removing and installing gearbox mountings, Polo 4917
2 3 2 Removing and installing gearbox mountings, up! 2020 4919
2 4 Removing and installing pendulum support 4920
2 4 1 Removing and installing pendulum support, Polo 4920
2 4 2 Removing and installing pendulum support, up! 2020 4921
2 5 Supporting engine in installation position 4922
2 5 1 Supporting engine in installation position, Polo 4922
2 5 2 Supporting engine in installation position, up! 2020 on right of camshaft housing 4923
2 5 3 Supporting engine in installation position, up! 2020 on left of camshaft housing 4926
2 6 Adjusting assembly mountings 4930
2 6 1 Adjusting assembly mountings, Polo 4930
2 6 2 Adjusting assembly mountings, up! 2020 4931
2 7 Checking adjustment of assembly mountings 4932
2 7 1 Checking assembly mounting settings, Polo 4932
2 7 2 Checking assembly mounting settings, up! 2020 4933
13 – Crankshaft group 4934
1 Cylinder block (pulley end) 4934
1 1 Assembly overview – poly V-belt drive 4934
1 1 1 Assembly overview – poly V-belt drive, vehicles without air conditioner compressor 4934
1 1 2 Assembly overview – poly V-belt drive, vehicles with air conditioner compressor 4936
1 2 Removing and installing poly-V belt 4938
1 2 1 Removing and installing poly V-belt, vehicles with air conditioner compressor 4938
1 2 2 Removing and installing poly V-belt, vehicles without air conditioner compressor 4940
1 3 Removing and installing tensioner for poly V-belt 4942
1 3 1 Removing and installing tensioner for poly V-belt, vehicles without air conditioner compressor 4942
1 3 2 Removing and installing tensioner for poly V-belt, vehicles with air conditioner compressor 4943
1 4 Removing and installing vibration damper 4943
1 5 Removing and installing engine support 4947
1 6 Renewing crankshaft oil seal – pulley end 4949
1 7 Removing and installing sealing flange on pulley end 4952
2 Cylinder block, gearbox end 4956
2 1 Assembly overview – cylinder block, gearbox end 4956
2 2 Removing and installing flywheel 4957
2 3 Removing and installing sealing flange on gearbox side 4959
3 Crankshaft 4970
3 1 Crankshaft dimensions 4970
4 Pistons and conrods 4971
4 1 Assembly overview – pistons and conrods 4971
4 2 Checking pistons and cylinder bores 4973
4 3 Separating new conrod 4976
4 4 Removing and installing oil spray jets 4976
4 5 Setting piston to TDC position 4978
15 – Cylinder head, valve gear 4981
1 Cylinder head 4981
1 1 Assembly overview – cylinder head 4981
1 2 Removing and installing cylinder head 4984
1 3 Removing and installing camshaft housing 4990
1 4 Checking compression 4995
2 Toothed belt drive 4998
2 1 Assembly overview – toothed belt cover 4998
2 2 Assembly overview – toothed belt 4999
2 3 Removing and installing toothed belt guard 5002
2 3 1 Removing and installing upper toothed belt guard 5002
2 3 2 Removing and installing lower toothed belt guard 5003
2 4 Removing and installing toothed belt 5003
2 5 Preassembling and installing valve timing tool 5013
2 5 1 Preassembling valve timing tool 5013
2 5 2 Installing test tool -VAS 611 007- 5016
2 5 3 Teaching in test tool -VAS 611 007- electronically and performing basic setting 5019
2 6 Checking valve timing 5021
2 7 Adjusting valve timing 5024
2 8 Removing toothed belt from camshaft 5035
3 Valve gear 5043
3 1 Assembly overview – valve gear 5043
3 2 Removing and installing camshaft oil seal 5046
3 2 1 Removing and installing camshaft oil seal for holder of camshaft control valve 1 -N727- 5046
3 2 2 Removing and installing camshaft oil seal for inlet camshaft, belt pulley end 5049
3 2 3 Removing and installing exhaust camshaft oil seal, pulley end 5052
3 2 4 Removing and installing camshaft oil seal, gearbox end 5055
3 3 Removing and installing camshaft adjuster 5057
3 3 1 Removing and installing camshaft adjuster for inlet camshaft 5057
3 3 2 Removing and installing camshaft adjuster for exhaust camshaft 5062
3 4 Removing and installing camshaft control valve 1 -N727- 5067
3 5 Removing and installing exhaust camshaft control valve 1 -N318- 5068
3 6 Removing and installing valve stem oil seals 5068
3 6 1 Removing and installing valve stem seals (cylinder head installed) 5068
3 6 2 Removing and installing valve stem seals (cylinder head removed) 5073
3 7 Removing and installing holder for oil seal 5078
4 Inlet and exhaust valves 5082
4 1 Checking valve guides 5082
17 – Lubrication 5084
1 Sump, oil pump 5084
1 1 Assembly overview – sump/oil pump 5084
1 2 Engine oil: 5090
1 3 Removing and installing oil sump 5091
1 4 Removing and installing oil pump 5095
1 4 1 Removing and installing oil pump, without tandem pump 5095
1 4 2 Removing and installing oil pump, with tandem pump 5097
1 5 Removing and installing oil level and oil temperature sender -G266- 5099
2 Crankcase ventilation 5100
2 1 Assembly overview – crankcase breather system 5100
2 2 Removing and installing oil separator 5101
3 Oil filter, oil pressure switch 5102
3 1 Assembly overview – oil pressure switches/oil pressure control 5102
3 2 Removing and installing oil pressure sender -G10- 5103
3 3 Checking oil pressure and oil pressure switch 5104
3 4 Removing and installing oil filter housing 5104
3 5 Removing and installing oil pressure regulating valve -N428- 5105
19 – Cooling 5107
1 Cooling system/coolant 5107
1 1 Connection diagram – coolant hoses 5107
1 2 Checking cooling system for leaks 5107
1 3 Draining and adding coolant 5111
1 3 1 Draining and adding coolant, Polo 5111
1 3 2 Draining and adding coolant, up! 2020 5120
2 Coolant pump, regulation of cooling system 5128
2 1 Assembly overview – coolant pump, thermostat 5128
2 2 Assembly overview – coolant temperature sender 5130
2 3 Removing and installing coolant pump 5130
2 4 Removing and installing toothed belt pulley for coolant pump 5135
2 5 Removing and installing coolant temperature sender -G62- 5137
2 6 Removing and installing engine outlet coolant temperature sender -G82- 5139
2 7 Removing and installing engine temperature regulation module -GX33- 5142
2 8 Checking coolant pump 5145
3 Coolant pipes 5151
3 1 Assembly overview – coolant pipes 5151
3 2 Removing and installing coolant pipes 5152
4 Radiator, radiator fan 5153
4 1 Assembly overview – radiator/radiator fan 5153
4 1 1 Assembly overview – radiator/radiator fan, Polo 5153
4 1 2 Assembly overview – radiator/radiator fan, up! 5154
4 2 Assembly overview – radiator cowl and radiator fan 5156
4 3 Removing and installing radiator 5157
4 3 1 Removing and installing radiator, Polo 5157
4 3 2 Removing and installing radiator, up! 2020 5162
4 4 Removing and installing radiator cowl with radiator fan 5167
4 4 1 Removing and installing radiator cowl with radiator fan, Polo 2018 5167
4 4 2 Removing and installing radiator cowl with radiator fan, up! 2020 5169
4 5 Removing and installing radiator fan -VX57- 5171
24 – Mixture preparation – injection 5172
1 Injection system 5172
1 1 Overview of fitting locations – injection system 5172
2 Injectors 5176
2 1 Assembly overview – fuel rail with injectors 5176
2 2 Removing and installing injectors 5177
2 2 1 Removing and installing injectors, with one fuel tank breather valve 5177
2 2 2 Removing and installing injectors, with two fuel tank breather valves 5179
2 3 Checking injectors 5181
3 Air filter 5187
3 1 Assembly overview – air filter housing 5187
3 1 1 Assembly overview – air filter housing, Polo 5187
3 1 2 Assembly overview – air filter housing, up! 2020 5189
3 2 Removing and installing air filter housing 5190
3 2 1 Removing and installing air filter housing, Polo 5190
3 2 2 Removing and installing air filter housing, up! 2020 5191
3 3 Removing and installing resonator for intake air 5192
3 4 Removing air duct on lock carrier 5192
4 Intake manifold 5193
4 1 Assembly overview – intake manifold 5193
4 2 Removing and installing intake manifold 5195
4 2 1 Removing and installing intake manifold, with one fuel tank breather valve 5195
4 2 2 Removing and installing intake manifold, with two fuel tank breather valves 5196
4 3 Removing and installing throttle valve module -GX3- 5198
4 4 Cleaning throttle valve module -GX3- 5200
5 Senders and sensors 5202
5 1 Removing and installing intake manifold sender -GX9- 5202
5 2 Removing and installing fuel pressure sender for low-pressure 5203
6 Engine/motor control unit 5204
6 1 Assembly overview – engine/motor control unit 5204
6 2 Removing and installing engine control unit -J623- 5204
6 2 1 Removing and installing engine control unit -J623-, Polo 5204
6 2 2 Removing and installing engine control unit -J623-, up! 5206
6 3 Removing and installing engine (motor) control unit -J623- with protective housing 5207
7 Lambda probe 5212
7 1 Assembly overview – Lambda probe 5212
7 2 Removing and installing lambda probe 5213
7 2 1 Removing and installing Lambda probe 1 before catalytic converter -GX10- 5213
7 2 2 Removing and installing Lambda probe 1 after catalytic converter -GX7-, Polo 5214
7 2 3 Removing and installing Lambda probe 1 after catalytic converter -GX7-, up! 2020 5216
26 – Exhaust system 5218
1 Exhaust pipes and silencers 5218
1 1 Assembly overview – silencers 5218
1 1 1 Assembly overview – silencers, Polo 5218
1 1 2 Assembly overview – silencers, up! 2020 5219
1 2 Separating exhaust pipes from silencers 5220
1 3 Removing and installing silencer 5222
1 3 1 Removing and installing front silencer, Polo 5222
1 3 2 Removing and installing rear silencer, Polo 5224
1 3 3 Removing and installing silencer, up! 2020 5225
1 4 Aligning exhaust system free of stress 5227
1 5 Checking exhaust system for leaks 5227
1 6 Installation position of clamp 5228
1 6 1 Installation position of clamp, Polo 5228
1 6 2 Installation position of clamp, up! 2020 5229
2 Emission control 5232
2 1 Assembly overview – emission control 5232
2 2 Removing and installing catalytic converter 5235
28 – Ignition system 5239
1 Ignition system 5239
1 1 Assembly overview – ignition system 5239
1 2 Removing and installing ignition coils with output stage 5241
1 3 Removing and installing knock sensor 1 -G61- 5244
1 4 Removing and installing engine speed sender -G28- 5244
1 4 1 Removing and installing engine speed sender -G28-, Polo 5244
1 4 2 Removing and installing engine speed sender -G28-, up! 2020 5246
1 5 Removing and installing inlet camshaft position sender -G1002- 5249
1 6 Removing and installing exhaust camshaft position sender -G1003- 5250
D4B802791F3 6 speed dual clutch gearbox 0D9 5251
00 – Technical data 5255
1 Safety information 5255
1 1 General safety provisions 5255
1 2 Safety measures when working on vehicles with a start/stop system 5255
1 3 Safety precautions when using testers and measuring instruments during a road test 5256
2 Identification 5257
2 1 Gearbox identification 5257
2 1 1 Identification on gearbox 5257
2 1 2 Reading gearbox code letters 5257
3 Repair notes 5260
3 1 General repair instructions 5260
3 1 1 General information 5260
3 2 Gaskets, seals 5261
3 3 Nuts and bolts 5261
4 Technical data 5263
4 1 Capacities 5263
4 1 1 Capacities – dual clutch gearbox 5263
4 1 2 Capacities, front differential lock 5263
4 1 3 Bevel box 5263
5 Electrical components 5264
5 1 Overview of fitting locations – electrical components 5264
5 1 1 Overview of fitting locations – gearbox control 5264
5 1 2 Overview of fitting locations – electrical components, front differential lock 5264
30 – Clutch 5266
1 Clutch 5266
1 1 Assembly overview – dual clutch 5266
1 2 Removing and installing clutch end cover 5268
1 3 Removing dual clutch 5273
1 4 Installing dual clutch 5274
34 – Controls, housing 5283
1 Mechatronic unit 5283
1 1 Assembly overview – mechatronic unit 5283
1 1 1 Renewing securing clip on vehicle connector 5286
1 2 Removing and installing oil pan 5288
1 3 Removing and installing mechatronic unit for dual clutch gearbox -J743- 5296
1 3 1 Removing and installing mechatronic unit for dual clutch gearbox -J743-, gearbox installed 5296
1 3 2 Removing and installing mechatronic unit for dual clutch gearbox -J743-, gearbox removed 5310
2 Bevel box 5318
2 1 Assembly overview – bevel box 5318
2 2 Removing bevel box 5319
2 3 Installing bevel box 5326
3 Selector mechanism 5330
3 1 Assembly overview – selector mechanism 5330
3 1 1 Assembly overview – selector mechanism, manufacturer ZF 5330
3 1 2 Assembly overview – selector mechanism, manufacturer ECS 5331
3 2 Manual release from position P 5333
3 2 1 Emergency release from P position, manufacturer ZF 5333
3 2 2 Emergency release from P position, manufacturer ECS 5335
3 3 Removing and installing selector lever handle 5337
3 3 1 Removing and installing selector lever handle, Golf 2013 ►, Golf Estate 2014 ►, Golf 2017 ►, Golf Estate 2017 ►, T-Roc, T-Roc Cabriolet 5337
3 3 2 Removing and installing selector lever handle, Passat 2015 ►, Passat estate 2015 ►, Arteon 2018 ►, Passat estate 2019 ► 5341
3 3 3 Removing and installing selector lever handle, Polo 2018 ►, Golf SV 2015 ►, Golf SV 2018 ► 5345
3 3 4 Removing and installing selector lever handle, Touran 2016 ► 5348
3 3 5 Removing and installing selector lever handle, Tiguan 2016 ► 5352
3 4 Bringing interlock button in handle into installation position 5356
3 5 Removing and installing selector mechanism 5358
3 5 1 Removing and installing selector mechanism with selector lever cable 5358
3 5 2 Removing and installing selector mechanism without selector lever cable, manufacturer ZF 5361
3 5 3 Removing and installing selector mechanism without selector lever cable, manufacturer ECS 5364
3 6 Adjusting selector mechanism 5367
3 7 Removing and installing gear selector cable 5373
3 7 1 Removing and installing selector lever cable, manufacturer ZF 5373
3 7 2 Removing and installing selector lever cable, manufacturer ECS 5376
3 8 Checking selector mechanism 5379
3 9 Checking and adjusting selector lever cable 5380
3 10 Renewing selector shaft seal 5382
4 Removing and installing gearbox 5385
4 1 Removing gearbox 5385
4 1 1 Removing gearbox, Golf 2013 ►, Golf Estate 2014 ►, Golf 2017 ►, Golf Estate 2017 ►, vehicles with diesel engine 5385
4 1 2 Removing gearbox, Golf SV 2015 ►, Golf SV 2018 ►, T-Roc, T-Roc Cabriolet, vehicles with diesel engine 5393
4 1 3 Removing gearbox, Golf 2013 ►, Golf 2017 ►, vehicles with petrol engine 5402
4 1 4 Removing gearbox, Golf Estate 2014 ►, Golf Estate 2017 ►, vehicles with diesel engine, all-wheel drive 5410
4 1 5 Removing gearbox, Golf Estate 2014 ►, Golf Estate 2017 ►, vehicles with petrol engine, all-wheel drive 5421
4 1 6 Removing gearbox, Passat 2015 ►, Passat Variant 2015 ►, Arteon 2018 ►, vehicles with diesel engine, front-wheel drive, radiator version “1” or “3” 5429
4 1 7 Removing gearbox, Passat 2015 ►, Passat Variant 2015 ►, Arteon 2018 ►, vehicles with diesel engine, front-wheel drive, radiator version “2” 5437
4 1 8 Removing gearbox, Passat 2015 ►, vehicles with diesel engine, all-wheel drive 5447
4 1 9 Removing gearbox, Passat 2015 ►, Passat estate 2015 ►, Passat 2019 ►, vehicles with petrol engine 5458
4 1 10 Removing gearbox, Passat 2015 ►, Passat estate 2015 ►, Passat estate 2019 ►, vehicles with petrol engine, all-wheel drive 5466
4 1 11 Removing gearbox, Touran 2016 ►, vehicles with diesel engine 5476
4 1 12 Removing gearbox, Tiguan 2016 ►, vehicles with 1 4 l petrol engine 5483
4 1 13 Removing gearbox, Polo 2018 ►, Polo 2022 ►, vehicles with 2 0 l petrol engine 5495
4 2 Gearbox transport 5505
4 3 Installing gearbox 5506
4 4 Specified torques for gearbox 5512
5 Assembly mountings 5515
5 1 Assembly overview – assembly mountings 5515
6 Dismantling and assembling gearbox 5519
6 1 Assembly overview – gearbox 5519
7 Securing to engine and gearbox support 5523
7 1 Secure gearbox on engine and gearbox support 5523
7 2 Secure front differential lock to engine and gearbox support 5524
8 Gear oil circuit 5526
8 1 Removing and installing gear oil cooler 5526
8 2 Removing and installing cover for gear oil pump 5529
8 3 Removing and installing gear oil pump 5531
8 4 Removing and installing gear oil filter 5533
9 Gear oil 5536
9 1 Checking gear oil level 5536
9 2 Draining and filling gear oil 5539
10 Front differential lock 5543
10 1 Assembly overview – front differential lock 5543
10 2 Removing front differential lock 5543
10 2 1 Transporting front differential lock 5547
10 3 Installing front differential lock 5547
10 4 Removing and installing differential lock control unit -J647- 5549
35 – Gears, shafts 5551
1 Currently, no repairs can be made to gears and shafts 5551
39 – Final drive – differential 5552
1 Gear oil 5552
1 1 Checking gear oil level 5552
1 1 1 Checking gear oil in bevel box 5552
1 1 2 Filling gear oil in bevel box 5552
2 Oil for front differential lock 5556
2 1 Checking oil level for front differential lock 5556
2 2 Draining and filling oil for front differential lock 5557
3 Oil seals 5561
3 1 Overview of fitting locations – oil seals 5561
3 2 Renewing left seal 5563
3 3 Renewing right seal 5567
3 3 1 Renewing right oil seal, front wheel drive 5567
3 3 2 Renewing outer seal on right of bevel box 5572
3 3 3 Renewing right seal on gearbox, between front differential lock and gearbox or between bevel box and gearbox 5573
3 3 4 Renewing seal on bevel box between bevel box and gearbox 5575
3 3 5 Renewing oil seal for propshaft drive flange at bevel box 5576
4 Components of front differential lock 5584
4 1 Assembly overview – components of front differential lock 5584
4 2 Checking function 5586
4 3 Removing and installing pump for front differential lock -V181- 5586
4 4 Removing and installing coupling for front differential lock 5588
4 5 Renewing seal for front differential lock 5588
4 5 1 Renewing outer seal on right of front differential lock 5588
4 5 2 Renewing seal between front differential lock and gearbox on front differential lock 5592
4 5 3 Renewing seal for right flange shaft in front differential lock 5594
4 6 Renewing ball bearing for flange shaft 5596
5 Bevel box 5600
5 1 Assembly overview – bevel box 5600
5 2 Removing and installing right flange shaft 5602
5 3 Dismantling and assembling bevel box 5605
5 3 1 Renewing needle bearing (polygon bearing) for right flange shaft 5605
5 3 2 Renewing output flange and redetermining thickness of shim, bevel box removed 5607
D4B802791F6 7 speed dual clutch gearbox 0CW 5620
00 – Technical data 5624
1 Safety information 5624
1 1 General safety provisions 5624
1 2 Safety measures when working on vehicles with a start/stop system 5624
1 3 Safety precautions when using testers and measuring instruments during a road test 5625
1 4 Safety precautions when tow-starting or towing 5625
2 Identification 5626
2 1 Gearbox identification 5626
3 Repair notes 5627
3 1 General information 5627
3 2 General repair instructions 5628
3 3 Gaskets, seals 5629
3 4 Nuts and bolts 5629
4 Technical data 5631
4 1 Capacities 5631
5 Overview – power transmission 5633
5 1 Overview – power transmission – front-wheel drive 5633
30 – Clutch 5634
1 Clutch mechanism 5634
1 1 Assembly overview – clutch engagement mechanism 5634
1 2 Removing and installing clutch engagement mechanism 5636
1 3 Adjusting clutch engagement mechanism 5640
2 Clutch 5656
2 1 Assembly overview – dual clutch 5656
2 2 Removing dual clutch 5658
2 3 Installing dual clutch 5663
2 4 Renewing input shaft seal 5669
2 5 Renewing oil seal for inner input shaft 5671
34 – Controls, housing 5674
1 Mechatronic unit 5674
1 1 Assembly overview – mechatronic unit 5674
1 2 Removing and installing mechatronic unit 5676
1 3 Moving mechatronic unit for dual clutch gearbox -J743- into removal position by hand 5693
1 4 Renewing clutch actuator piston 5695
1 5 Renewing control unit for mechatronic unit for dual clutch gearbox -J743- 5701
2 Selector mechanism 5707
2 1 Assembly overview – selector mechanism 5707
2 1 1 Assembly overview – selector mechanism, manufacturer ZF 5707
2 1 2 Assembly overview – selector mechanism, manufacturer ECS 5709
2 2 Manual release from position P 5711
2 2 1 Manual release mechanism from position P, Golf 2013 ►, Golf Estate 2014 ►, Golf 2017 ►, Golf Estate 2017 ► 5711
2 2 2 Manual release from position P, Polo 2014 ► 5712
2 2 3 Emergency release from position P, Golf SV 2015 ►, Golf SV 2018 ► 5713
2 2 4 Manual release mechanism from position P, Passat 2015 ►, Passat Estate 2015 ►, Passat 2019 ►, Passat Estate 2019 ► 5714
2 2 5 Manual release from position P, Touran 2016 ► 5715
2 2 6 Manual release from position P, Polo, Taigo, Virtbus 5716
2 2 7 Emergency release from position P, T-Roc, T-Roc Cabriolet 5717
2 3 Removing and installing selector lever handle 5718
2 3 1 Removing and installing selector lever handle, Golf 2013 ►, Golf Estate 2014 ►, Golf 2017 ►, Golf Estate 2017 ► 5718
2 3 2 Removing and installing selector lever handle, Passat 2015 ►, Passat Estate 2015 ►, Passat 2019 ►, Passat Estate 2019 ► 5721
2 3 3 Removing and installing selector lever handle, Polo, Taigo, Virtbus, Golf SV 2015 ►, Golf SV 2018 ► 5725
2 3 4 Removing and installing selector lever handle, Touran 2016 ► 5728
2 3 5 Removing and installing selector lever handle, T-Roc 2018 ►, T-Roc Cabriolet 2020 ► 5731
2 4 Bringing interlock button in handle into installation position 5734
2 5 Removing and installing selector mechanism 5737
2 5 1 Removing and installing selector mechanism with selector lever cable 5737
2 5 2 Removing and installing selector mechanism without selector lever cable, manufacturer ZF 5740
2 5 3 Removing and installing selector mechanism without selector lever cable, manufacturer ECS 5743
2 6 Adjusting selector mechanism 5746
2 7 Removing and installing gear selector cable 5751
2 7 1 Removing and installing selector lever cable, manufacturer ZF 5751
2 7 2 Removing and installing selector lever cable, manufacturer ECS 5755
2 8 Checking selector mechanism 5757
2 9 Checking and adjusting selector lever cable 5759
2 10 Renewing selector shaft seal 5761
3 Removing and installing gearbox 5762
3 1 Removing gearbox 5762
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 5762
3 1 2 Removing gearbox, Golf 2013 ►, Golf Estate 2014 ►, Golf 2017 ►, Golf Estate 2017 ►, vehicles with diesel engine 5769
3 1 3 Removing gearbox, Golf SV 2015 ►, Golf SV 2018 ►, vehicles with diesel engine 5775
3 1 4 Removing gearbox, Polo 2014 ►, vehicles with 1 0 l, 1 2 l and 1 4 l petrol engine 5782
3 1 5 Removing gearbox, Polo 2014 ►, vehicles with diesel engine 5790
3 1 6 Removing gearbox, Passat 2015 ►, Passat Estate 2015 ►, Passat 2019 ►, Passat Estate 2019 ►, vehicles with diesel engine 5797
3 1 7 Removing gearbox, Polo 2014 ►, vehicles with 1 8 l petrol engine 5803
3 1 8 Removing gearbox, Passat 2015 ►, Passat estate 2015 ►, Passat 2019 ►, vehicles with 1 4 l petrol engine 5810
3 1 9 Removing gearbox, Passat 2015 ►, Passat Estate 2015 ►, vehicles with 1 8 l petrol engine 5816
3 1 10 Removing gearbox, Touran 2016 ►, vehicles with 1 4 l petrol engine 5823
3 1 11 Removing gearbox, Touran 2016 ►, vehicles with diesel engine 5829
3 1 12 Removing gearbox, Touran 2016 ►, vehicles with 1 8 l petrol engine 5836
3 1 13 Removing gearbox, Golf 2017 ►, Golf Estate 2017 ►, Golf SV 2018 ►, vehicles with 1 5 l petrol engine 5842
3 1 14 Removing gearbox, Polo, vehicles with 1 0 l petrol engine 5849
3 1 15 Removing gearbox, T-Roc, T-Roc Cabriolet, vehicles with 1 5 l petrol engine 5857
3 1 16 Removing gearbox, Polo 2018 ►, vehicles with diesel engine 5864
3 1 17 Removing gearbox, Passat 2015 ►, Passat estate 2015 ►, Passat 2019 ►, Passat estate 2019 ►, vehicles with 1 5 l petrol engine 5870
3 1 18 Removing gearbox, Touran 2016 ►, vehicles with 1 5 l petrol engine 5876
3 1 19 Removing gearbox, Polo 2018 ►, Polo 2022 ►, Virtbus, Taigo vehicles with 1 5 l petrol engine 5883
3 2 Installing gearbox 5889
3 3 Specified torques for gearbox 5895
4 Assembly mountings 5897
4 1 Assembly overview – assembly mountings 5897
4 1 1 Assembly overview – assembly mountings, Golf, Golf Estate, Golf SV, Passat, Passat Estate, Touran, T-Roc, T-Roc Cabriolet, Polo, Virtbus, Taigo 5897
4 1 2 Assembly overview – assembly mountings, Polo 2014 ► 5899
5 Gearbox transport 5901
6 Securing to engine and gearbox support 5903
7 Gear oil 5906
7 1 Draining and filling gear oil 5906
7 2 Draining and filling hydraulic fluid for mechatronic unit 5909
35 – Gears, shafts 5913
1 Parking lock 5913
1 1 Removing and installing cover for parking lock 5913
1 2 Removing and installing parking lock 5914
39 – Final drive – differential 5916
1 Oil seals 5916
1 1 Overview of fitting locations – oil seals 5916
1 2 Renewing left seal 5916
1 3 Renewing right seal 5920
1 3 1 Renewing right oil seal, gearboxes with flange shaft 5920
1 3 2 Renewing right oil seal, gearboxes with stub shaft 5925
D4B806742B7 Gas drive General information 5928
00 – Technical data 5932
1 Safety information 5932
1 1 Safety precautions when working on natural gas system 5932
2 General information 5933
2 1 Other reference material 5933
3 Safety briefing/employee qualification 5934
3 1 Safety briefing/employee qualification 5934
4 Receiving vehicles for repair 5936
4 1 Procedure for taking receipt of vehicles 5936
5 Laws and regulations 5937
5 1 Rules and regulations 5937
5 2 Workplace requirements 5937
6 Basic technical and physical principles 5938
6 1 Physical properties 5938
6 1 1 Physical data of dried natural gas 5938
7 Repair instructions 5939
7 1 Rules for cleanliness 5939
8 Checking natural gas system 5940
8 1 Test requirements for gas systems 5940
8 1 1 Testing with self-diagnosis 5940
8 2 Checking natural gas system for leaks 5940
8 3 Searching for leaks in gas system using gas leak detector 5940
8 4 Searching for leaks in gas system using leak detector spray 5942
20 – Fuel supply system 5943
1 Fuel 5943
1 1 Handling natural gas fuel tanks 5943
1 2 Storing natural gas fuel tanks 5943
1 3 Damage assessment catalogue for natural gas fuel tanks 5945
1 3 1 Damage assessment of steel fuel tanks 5945
1 3 2 Damage assessment of carbon fibre fuel tank (composition fibre reinforced fuel tank) 5945
1 4 Discharging natural gas fuel tanks 5948
1 5 Rendering natural gas fuel tanks inert 5960
1 5 1 With water: 5960
1 5 2 With nitrogen: 5960
1 6 Disposing of natural gas fuel tanks 5961
1 7 Determining residual pressure in natural gas fuel tank 5961
1 7 1 Checking and converting adapter for back-pressure test on natural gas tank 5961
1 7 2 Checking (self test) cooling system tester 5963
1 7 3 Determining residual pressure in natural gas fuel tank 5969
1 8 Reducing fuel pressure in high-pressure section 5974
1 8 1 Reducing fuel pressure in high-pressure section 5974
2 Senders and sensors 5977
2 1 Gas rail temperature and pressure sensor -GX21- 5977
2 2 High-pressure valve for gas mode -N372- 5977
2 3 Gas rail sensor -G401- (low-pressure side) 5978
2 4 Tank pressure sensor -G400- 5978
24 – Mixture preparation – injection 5979
1 Mixture preparation – injection 5979
1 1 Distinguishing between pressure sections of natural gas supply system 5979
1 1 1 High-pressure section 5979
1 1 2 Low-pressure section 5981
1 2 High-pressure injectors N30 – N33 5982
D4B807678A4 5 speed manual gearboxes 0DF and 0D0 installed 5984
00 – Technical data 5988
1 Safety information 5988
1 1 Safety measures when working on vehicles with a start/stop system 5988
2 Identification 5989
2 1 Gearbox identification 5989
3 Technical data 5990
3 1 Allocation gearbox – engine 5990
3 2 Capacities 5990
4 Overview – power transmission 5991
5 Electrical components 5993
5 1 Overview of fitting locations – electrical components 5993
5 1 1 Overview of fitting locations – electrical components, manual gearbox 5993
5 1 2 Overview of fitting locations – electrical components, clutch mechanism 5994
6 Repair notes 5995
6 1 General repair instructions 5995
30 – Clutch 5998
1 Clutch mechanism 5998
1 1 Overview of fitting locations – clutch mechanism 5998
1 2 Assembly overview – pedal cluster 5999
1 3 Assembly overview – clutch hydraulics 6001
1 4 Removing and installing bearing bush 6003
1 5 Checking clutch master cylinder and clutch slave cylinder 6004
1 6 Removing and installing clutch position sender -G476- 6005
1 7 Removing and installing over-centre spring 6007
1 8 Removing and installing clutch pedal 6009
1 8 1 Removing and installing clutch pedal, LHD 6009
1 8 2 Removing and installing clutch pedal, RHD 6010
1 9 Removing and installing mounting bracket 6012
1 10 Removing and installing master cylinder 6015
1 11 Removing and installing clutch slave cylinder 6016
1 12 Removing and installing lines for clutch mechanism 6019
1 13 Bleeding clutch mechanism 6022
2 Clutch 6024
34 – Controls, housing 6025
1 Selector mechanism 6025
1 1 Installation position – selector mechanism 6025
1 2 Assembly overview – gear knob and cover 6026
1 3 Assembly overview – selector mechanism 6026
1 4 Removing and installing gear knob 6028
1 5 Removing and installing selector mechanism 6030
1 6 Repairing selector mechanism 6033
1 7 Adjusting selector mechanism 6037
1 8 Checking selector mechanism 6040
2 Removing and installing gearbox 6042
2 1 Specified torques for gearbox 6042
2 2 Removing gearbox 6042
2 3 Installing gearbox 6051
3 Gearbox transport 6055
4 Assembly mountings 6056
4 1 Assembly overview – assembly mountings 6056
5 Gear oil 6059
5 1 Checking gear oil level 6059
5 2 Draining and filling gear oil 6060
6 Dismantling and assembling gearbox 6062
6 1 Assembly overview – selector unit 6062
6 2 Removing and installing selector unit with gearbox installed 6063
6 2 1 Removing and installing selector unit with gearbox installed 6063
6 2 2 Repairing selector unit 6066
6 2 3 Renewing selector shaft seal 6067
7 Gearbox housing, clutch housing 6069
35 – Gears, shafts 6070
1 Input shaft 6070
2 Output shaft 6071
39 – Final drive – differential 6072
1 Oil seals 6072
1 1 Overview of fitting locations – oil seals 6072
1 2 Renewing left seal 6072
1 2 1 Renewing seal for left drive shaft 6072
1 3 Renewing right seal 6075
1 3 1 Renewing seal for right drive shaft 6075
2 Differential 6078
D4B807926CA 3 cylinder injection engine (1 0 l natural gas 4 V EA 211 turbocharger) 6079
00 – Technical data 6085
1 Safety information 6085
1 1 Safety regulations for working on fuel supply 6085
1 2 Safety precautions when working on vehicles with a gas system 6085
1 3 Safety measures when working on vehicles with start/stop system 6087
1 4 Safety precautions when using testing and measuring instruments during a road test 6087
1 5 Safety precautions when working on the cooling system 6088
1 6 Safety precautions when working on ignition system 6088
2 Identification 6089
2 1 Engine number/engine data 6089
3 Repair notes 6091
3 1 Rules for cleanliness 6091
3 2 General information 6091
3 3 General repair instructions 6091
3 3 1 General notes on injection 6091
3 3 2 General notes on ignition system 6092
3 3 3 General notes on charge air system 6092
3 4 Foreign objects in engine 6093
3 5 Contact corrosion 6093
3 6 Routing and attachment of lines 6093
3 7 Fitting radiators and condensers 6093
3 8 Checking vacuum system 6093
10 – Removing and installing engine 6095
1 Removing and installing engine 6095
1 1 Removing engine 6095
1 2 Separating engine and gearbox 6106
1 3 Securing engine on engine and gearbox support 6108
1 4 Installing engine 6109
2 Assembly mountings 6115
2 1 Assembly overview – assembly mountings 6115
2 2 Removing and installing engine mounting 6118
2 3 Removing and installing gearbox mounting 6120
2 4 Removing and installing pendulum support 6122
2 5 Checking adjustment of assembly mountings 6123
2 6 Adjusting assembly mountings 6124
2 7 Supporting engine in installation position 6127
13 – Crankshaft group 6129
1 Cylinder block (pulley end) 6129
1 1 Assembly overview – poly V-belt drive 6129
1 1 1 Assembly overview – poly V-belt drive, vehicles without air conditioner compressor 6129
1 1 2 Assembly overview – poly V-belt drive, vehicles with air conditioner compressor 6131
1 2 Removing and installing poly-V belt 6133
1 2 1 Removing and installing poly V-belt, vehicles without air conditioner compressor 6133
1 2 2 Removing and installing poly V-belt, vehicles with air conditioner compressor 6135
1 3 Removing and installing tensioner for poly V-belt 6137
1 3 1 Removing and installing tensioner for poly V-belt, vehicles without air conditioner compressor 6137
1 3 2 Removing and installing tensioner for poly V-belt, vehicles with air conditioner compressor 6137
1 4 Removing and installing vibration damper 6138
1 5 Removing and installing engine support 6141
1 6 Renewing crankshaft oil seal – belt pulley end 6145
2 Cylinder block, gearbox end 6148
2 1 Assembly overview – cylinder block, gearbox end 6148
2 2 Removing and installing flywheel 6149
2 3 Removing and installing sealing flange on gearbox side 6150
3 Crankshaft 6162
3 1 Crankshaft dimensions 6162
3 2 Measuring axial clearance of crankshaft 6162
4 Pistons and conrods 6164
4 1 Assembly overview – pistons and conrods 6164
4 2 Removing and installing pistons 6167
4 3 Checking pistons and cylinder bores 6168
4 4 Separating new conrod 6170
4 5 Checking radial clearance of conrods 6171
4 6 Removing and installing oil spray jets 6171
4 7 Setting piston to TDC position 6172
15 – Cylinder head, valve gear 6176
1 Cylinder head 6176
1 1 Assembly overview – cylinder head 6176
1 2 Assembly overview – camshaft housing 6178
1 3 Removing and installing cylinder head 6180
1 4 Removing and installing camshaft housing 6186
1 5 Checking compression 6190
2 Toothed belt drive 6193
2 1 Assembly overview – toothed belt cover 6193
2 2 Assembly overview – toothed belt 6193
2 3 Removing and installing toothed belt guard 6195
2 3 1 Removing and installing upper toothed belt guard 6195
2 3 2 Removing and installing lower toothed belt guard 6196
2 4 Preassembling and installing test tool -VAS 611 007- 6197
2 4 1 Preassembling test tool -VAS 611 007- 6197
2 4 2 Installing test tool -VAS 611 007- 6200
2 4 3 Teaching-in test tool -VAS 611 007- electronically and performing basic setting 6203
2 5 Checking valve timing 6205
2 6 Adjusting valve timing 6208
2 7 Removing toothed belt from camshaft 6218
2 8 Removing and installing toothed belt 6225
3 Valve gear 6236
3 1 Assembly overview – valve gear 6236
3 2 Removing and installing camshaft adjuster 6238
3 2 1 Removing and installing camshaft adjuster for inlet camshaft 6238
3 2 2 Removing and installing camshaft adjuster for exhaust camshaft 6242
3 3 Measuring axial play of camshaft 6246
3 4 Removing and installing camshaft oil seal 6247
3 4 1 Removing and installing camshaft oil seal for inlet camshaft, belt pulley end 6247
3 4 2 Removing and installing exhaust camshaft oil seal, pulley end 6249
3 4 3 Removing and installing exhaust camshaft oil seal, gearbox end 6253
3 5 Removing and installing camshaft control valve 1 -N205- 6255
3 6 Removing and installing exhaust camshaft control valve 1 -N318- 6257
3 7 Removing and installing valve stem seals 6258
3 7 1 Removing and installing valve stem seals (cylinder head installed) 6258
3 7 2 Removing and installing valve stem seals (cylinder head removed) 6265
4 Inlet and exhaust valves 6270
4 1 Checking valve guides 6270
4 2 Checking valves 6271
4 3 Valve dimensions 6271
17 – Lubrication 6272
1 Sump, oil pump 6272
1 1 Assembly overview – sump/oil pump 6272
1 2 Engine oil 6276
1 3 Removing and installing sump 6276
1 4 Removing and installing oil level and oil temperature sender -G266- 6282
1 5 Removing and installing oil pump 6283
2 Engine oil cooler 6286
2 1 Assembly overview – engine oil cooler 6286
2 2 Removing and installing engine oil cooler 6286
3 Crankcase ventilation 6288
3 1 Assembly overview – crankcase breather system 6288
3 2 Removing and installing oil separator 6289
4 Oil filter, oil pressure switch 6293
4 1 Assembly overview – oil filter/oil pressure switch 6293
4 2 Removing and installing oil filter housing 6294
4 3 Removing and installing oil pressure sender -G10- 6295
4 4 Removing and installing oil pressure regulating valve -N428- 6296
4 5 Checking oil pressure 6298
19 – Cooling 6299
1 Cooling system/coolant 6299
1 1 Connection diagram – coolant hoses 6299
1 2 Draining and adding coolant 6300
1 3 Checking cooling system for leaks 6308
2 Coolant pump, regulation of cooling system 6313
2 1 Assembly overview – coolant pump, thermostat 6313
2 2 Assembly overview – electric coolant pump 6316
2 2 1 Assembly overview – charge air cooling pump -V188- 6316
2 3 Assembly overview – coolant temperature sender 6317
2 4 Removing and installing coolant pump 6318
2 5 Removing and installing toothed belt pulley for coolant pump 6323
2 6 Removing and installing thermostat 6325
2 6 1 Removing and installing thermostat for main coolant circuit (radiator) 6325
2 6 2 Removing and installing thermostat for cylinder block coolant circuit 6327
2 7 Removing and installing electric coolant pump 6329
2 7 1 Removing and installing charge air cooling pump -V188- 6329
2 8 Removing and installing coolant temperature sender -G62- 6331
2 9 Removing and installing radiator outlet coolant temperature sender -G83- 6333
3 Coolant pipes 6335
3 1 Assembly overview – coolant pipes 6335
3 2 Removing and installing coolant pipes 6335
4 Radiator, radiator fan 6338
4 1 Assembly overview – radiator/radiator fan 6338
4 2 Assembly overview – radiator cowl and radiator fan 6339
4 3 Removing and installing radiator 6340
4 4 Removing and installing radiator cowl 6345
4 5 Removing and installing radiator fan -V7- 6347
21 – Turbocharging/supercharging 6348
1 Turbocharger 6348
1 1 Assembly overview – turbocharger 6348
1 2 Removing and installing turbocharger 6351
1 3 Removing and installing charge pressure positioner -V465- 6356
1 4 Removing and installing connection for turbocharger 6358
2 Charge air system 6361
2 1 Assembly overview – charge air system 6361
2 2 Removing and installing air pipe 6363
2 3 Removing and installing charge pressure sender -GX26- 6364
2 4 Removing and installing charge air cooler 6365
2 5 Checking charge air system for leaks 6367
24 – Mixture preparation – injection 6370
1 Injection system 6370
1 1 Overview of fitting locations – injection system 6370
2 Air filter 6377
2 1 Assembly overview – air filter housing 6377
2 2 Removing and installing air filter housing 6379
3 Intake manifold 6381
3 1 Assembly overview – intake manifold 6381
3 2 Removing and installing intake manifold 6383
3 3 Removing and installing throttle valve module -GX3- 6389
3 4 Cleaning throttle valve module -GX3- 6391
4 Checking natural gas supply system for leaks 6393
4 1 Distinguishing between pressure sections of natural gas supply system 6393
4 1 1 High-pressure section 6394
4 1 2 Low-pressure section 6396
4 2 Determining pressure in gas system 6397
4 3 Determining operating mode of natural gas vehicles 6397
4 4 Activating and deactivating natural gas mode 6397
4 5 Checking gas system for leaks 6399
4 5 1 Checking gas system for leaks after working on the high-pressure section 6401
4 5 2 Checking gas system for leaks after working on the low-pressure section 6401
5 Gas pressure regulator 6404
5 1 Assembly overview – gas pressure regulator 6404
5 1 1 Assembly overview – gas pressure regulator 6404
5 1 2 Assembly overview – gas pressure regulator with add-on parts 6404
5 2 Removing and installing gas pressure regulator 6406
5 3 Removing and installing tank pressure sensor -G400- 6412
6 Gas injectors 6415
6 1 Assembly overview – gas rail 6415
6 2 Removing and installing gas rail with gas injector -N366-/-N367-/-N368- 6417
6 3 Removing and installing gas rail temperature and pressure sensor -GX21- 6420
7 Injectors 6423
7 1 Assembly overview – fuel rail with injectors 6423
7 2 Removing and installing fuel rail 6425
7 3 Removing and installing injectors 6426
7 4 Cleaning injectors 6438
8 Senders and sensors 6440
8 1 Removing and installing intake manifold sender -GX9- 6440
8 2 Removing and installing fuel pressure sender -G247- 6441
8 3 Checking fuel pressure sender -G247- 6442
8 3 1 Checking fuel pressure sender -G247-, using vehicle diagnostic tester 6442
9 High-pressure pump 6445
9 1 Assembly overview – high-pressure pump 6445
9 2 Removing and installing high-pressure pump 6446
9 3 Removing and installing high-pressure pipe 6448
10 Lambda probe 6450
10 1 Assembly overview – Lambda probe 6450
10 2 Removing and installing Lambda probe 6451
10 2 1 Removing and installing lambda probe 1 before catalytic converter -GX10-/lambda probe 1 after catalytic converter -GX7- 6451
11 Engine control unit 6453
11 1 Removing and installing engine control unit -J623- 6453
11 1 1 Removing and installing engine control unit -J623- (with protective housing) 6453
26 – Exhaust system 6457
1 Exhaust pipes and silencers 6457
1 1 Assembly overview – silencers 6457
1 2 Removing and installing silencer 6458
1 3 Aligning exhaust system free of stress 6459
1 4 Checking exhaust system for leaks 6460
2 Emission control 6461
2 1 Assembly overview – emission control 6461
2 2 Removing and installing catalytic converter 6464
28 – Ignition system 6468
1 Ignition system 6468
1 1 Assembly overview – ignition system 6468
1 2 Removing and installing ignition coils with output stage 6470
1 3 Removing and installing knock sensor 1 -G61- 6473
1 4 Removing and installing Hall sender -G40- 6474
1 5 Removing and installing engine speed sender -G28- 6475
D4D808FD0C9 Safety information and repair notes 6478
00 – Technical data 6482
1 Safety information 6482
1 1 General safety information 6482
1 2 Safety precautions when working on vehicles with combustion engine 6482
1 3 Safety precautions when working on fuel system 6483
1 4 Safety precautions when working on the cooling system 6484
1 5 Safety precautions when working on air conditioning systems 6484
1 6 Safety precautions when working on vehicles with auxiliary/supplementary heater 6485
1 7 Safety measures during road test with testing and measuring instruments 6485
1 8 Safety precautions when working on passenger protection systems 6485
1 9 Safety precautions when working with chemical substances 6486
1 10 Safety precautions when working with compressed gas cylinders 6486
1 11 Safety precautions when working with batteries 6487
2 Repair notes 6488
2 1 Laws, specifications, guidelines and risk assessments 6488
2 2 Notes on how to use the workshop manual 6488
2 3 Spare parts, servicing materials and consumables 6488
2 4 Replacement parts, service fluids and consumables, vehicles with combustion engine 6490
2 5 Transport and storage 6490
2 6 Qualification 6491
2 7 Environmental protection 6491
2 8 Rules for cleanliness 6491
2 9 Identification labels 6492
2 10 Bolts and nuts 6492
2 11 Using power tools 6492
2 12 Contact corrosion 6493
2 13 Gaskets and seals 6493
2 14 Bonding surfaces 6494
2 15 Unplugging electrical connectors 6494
2 16 Routing and attachment of lines 6494
2 17 Retaining rings 6495
2 18 Working on refrigerant circuit 6495
2 19 Work on seat occupied recognition for front passenger airbag deactivation 6495
2 20 Battery 6496
2 21 Assessing accident vehicles 6496
2 21 1 Assessing accident vehicles, basic information 6496
2 21 2 Assessing accident vehicles, running gear 6497
2 21 3 Assessing accident vehicles, passenger protection systems 6497
D4D80781DD6 4 cyl direct injection engine (2 0l 4V TSI EA888evo4) 6502
00 – Technical data 6510
1 Safety information and repair notes 6510
1 1 Safety information 6510
1 2 Repair instructions 6510
2 Identification 6511
2 1 Engine identification 6511
2 2 Engine data 6511
2 2 1 Engine data DNNA 6511
2 2 2 Engine data DNND 6512
2 2 3 Engine data DNFC 6512
2 2 4 Engine data DNFE 6512
2 2 5 Engine data DNFF 6513
2 2 6 Engine data DNFG 6513
2 2 7 Engine data DSFB 6514
2 2 8 Engine data DSFE 6514
2 2 9 Engine data DSFF 6515
2 2 10 Engine data DNPA 6515
2 2 11 Engine data DRNA 6516
3 Technical data 6517
3 1 Test and adjustment values 6517
4 Electrical components 6521
4 1 Access to diagnoses 6521
10 – Removing and installing engine 6522
1 Safety information and repair notes 6522
1 1 Safety information 6522
1 2 Repair instructions 6522
2 Removing and installing engine 6523
2 1 Removing engine 6523
2 2 Separating engine and gearbox 6534
2 2 1 Separating engine and gearbox, manual gearbox 6534
2 2 2 Separating engine and gearbox, dual-clutch gearbox 6535
2 3 Securing engine on engine and gearbox support 6537
2 4 Installing engine 6540
3 Assembly mountings 6542
3 1 Assembly overview – assembly mountings 6542
3 2 Removing and installing engine mounting 6545
3 3 Removing and installing gearbox mounting 6545
3 4 Removing and installing pendulum support 6546
3 5 Supporting engine in installation position, Golf 6547
3 5 1 Supporting engine in installation position 6547
3 6 Supporting engine in installation position, Tiguan 6549
3 6 1 Supporting engine in installation position 6549
3 7 Supporting engine in installation position, Passat 6552
3 7 1 Supporting engine in installation position 6552
3 8 Supporting engine in installation position, Arteon 6555
3 8 1 Supporting engine in installation position 6555
3 9 Supporting engine in installation position, T-Roc 6558
3 9 1 Supporting engine in installation position 6558
3 10 Supporting engine in installation position, Polo 6561
3 10 1 Supporting engine in installation position 6561
3 11 Checking and adjusting assembly mountings 6563
4 Engine cover panel 6567
4 1 Removing and installing engine cover panel 6567
13 – Crankshaft group 6568
1 Safety information and repair notes 6568
1 1 Safety information 6568
1 2 Repair instructions 6568
2 Cylinder block (pulley end) 6569
2 1 Assembly overview – cylinder block (pulley end) 6569
2 2 Removing and installing poly-V belt 6571
2 3 Removing and installing tensioner for poly V-belt 6572
2 4 Removing and installing vibration damper 6573
2 5 Renewing seal for vibration damper 6579
2 6 Removing and installing bracket for ancillaries 6581
2 7 Removing and installing engine support 6583
3 Cylinder block, gearbox end 6586
3 1 Assembly overview – cylinder block, gearbox end 6586
3 2 Removing and installing flywheel 6587
3 2 1 Removing and installing flywheel 6587
3 2 2 Removing and installing intermediate plate 6590
3 2 3 Removing and installing intermediate plate 6590
3 3 Removing and installing sealing flange on gearbox side 6591
4 Crankshaft 6595
4 1 Assembly overview – crankshaft 6595
4 2 Allocation of main bearing shells 6597
4 3 Renewing needle bearing in crankshaft 6598
4 4 Measuring axial clearance of crankshaft 6600
4 5 Measuring radial clearance of crankshaft 6601
4 6 Removing and installing crankshaft 6602
4 7 Removing and installing sender wheel 6604
5 Balancer shaft 6606
5 1 Assembly overview – balance shaft 6606
5 2 Removing and installing balance shaft 6606
5 2 1 Removing and installing balance shaft, inlet side 6606
5 2 2 Removing and installing balance shaft, exhaust side 6610
5 2 3 Renewing oil seal for balance shaft (inlet side) 6611
6 Pistons and conrods 6614
6 1 Assembly overview – pistons and conrods 6614
6 2 Removing and installing pistons 6615
6 3 Removing and installing oil spray jets 6620
6 4 Checking pistons and cylinder bores 6622
6 5 Separating new conrod 6624
6 6 Checking radial clearance of conrods 6625
15 – Cylinder head, valve gear 6627
1 Safety information and repair notes 6627
1 1 Safety information 6627
1 2 Repair instructions 6627
2 Cylinder head 6628
2 1 Assembly overview – cylinder head 6628
2 2 Assembly overview – vacuum pump, 2 0 l petrol engine 6630
2 3 Removing and installing cylinder head 6631
2 4 Removing and installing vacuum pump, 2 0 l petrol engine 6638
2 5 Checking compression 6639
2 6 Checking cylinder head for distortion 6640
3 Cover for timing chain 6642
3 1 Assembly overview – cover for timing chain 6642
3 2 Removing and installing timing chain cover 6645
3 2 1 Removing and installing upper timing chain cover 6645
3 2 2 Removing lower timing chain cover 6646
4 Chain drive 6650
4 1 Assembly overview – camshaft timing chains 6650
4 2 Assembly overview – drive chain for balance shaft 6651
4 3 Removing and installing camshaft timing chain 6653
4 4 Removing and installing bearing saddle 6664
4 5 Checking timing chain 6668
4 6 Removing and installing drive chain for balance shaft 6669
5 Valve gear 6673
5 1 Assembly overview – valve gear, DNPA, DNFC, DNFF, DNFE, DNFG, DSFE, DRNA, DSFB, DSFF 6673
5 1 1 Assembly overview – valve gear 6673
5 2 Assembly overview – valve gear, DNNA, DNND 6675
5 2 1 Assembly overview – valve gear 6675
5 3 Removing and installing camshaft, DNPA, DNFC, DNFF, DNFE, DNFG, DSFE, DRNA, DSFB, DSFF 6678
5 3 1 Removing and installing camshaft 6678
5 3 2 Installing ball for sliding piece 6686
5 4 Removing and installing camshaft, DNNA, DNND 6686
5 4 1 Removing and installing camshaft 6686
5 4 2 Installing ball for sliding piece 6695
5 5 Removing and installing cam actuators 6695
5 6 Removing and installing camshaft control valves [N205]/[N318] 6696
5 7 Removing and installing valve stem oil seals 6697
5 7 1 Removing and installing valve stem seals (cylinder head installed) 6697
5 7 2 Removing and installing valve stem seals (cylinder head removed) 6704
5 8 Removing and installing control valve 6710
5 9 Checking control valve 6711
6 Inlet and exhaust valves 6712
6 1 Checking valve guides 6712
6 2 Checking valves 6712
17 – Lubrication 6713
1 Safety information and repair notes 6713
1 1 Safety information 6713
1 2 Repair instructions 6713
2 Sump, oil pump 6714
2 1 Assembly overview – sump/oil pump 6714
2 2 Engine oil: 6717
2 3 Removing and installing lower part of sump 6717
2 4 Removing and installing upper part of sump 6720
2 5 Removing and installing oil pump 6724
2 6 Removing and installing oil level and oil temperature sender [G266] 6725
3 Engine oil cooler 6727
3 1 Assembly overview – engine oil cooler 6727
3 2 Removing and installing engine oil cooler 6727
3 2 1 Removing and installing engine oil cooler 6727
3 2 2 Removing and installing mechanical switching valve 6728
4 Crankcase ventilation 6729
4 1 Assembly overview – crankcase breather system 6729
4 2 Removing and installing oil separator 6730
4 3 Removing and installing crankcase pressure sensor [G1068] 6731
5 Oil filter, oil pressure switch 6732
5 1 Assembly overview – oil filter 6732
5 2 Assembly overview – oil pressure switches/oil pressure control 6732
5 3 Removing and installing oil pressure switch [F22] 6733
5 4 Removing and installing oil pressure switch for reduced oil pressure [F378] 6734
5 5 Removing and installing stage 2 oil pressure switch [F446] 6735
5 6 Removing and installing oil pressure regulating valve [N428] 6735
5 7 Removing and installing piston cooling jet control valve [N522] 6736
5 8 Checking oil pressure 6737
5 8 1 Checking engine oil pressure 6737
5 8 2 Checking oil pressure for piston spray jets 6737
6 Oil circuit 6739
6 1 Removing and installing oil return line for turbocharger 6739
6 2 Removing and installing oil supply line 6739
19 – Cooling 6741
1 Safety information and repair notes 6741
1 1 Safety information 6741
1 2 Repair instructions 6741
2 Cooling system/coolant 6742
2 1 Connection diagram – coolant hoses 6742
2 2 Checking cooling system for leaks 6744
2 3 Checking filling quality of cooling system 6747
2 4 Removing and installing coolant expansion tank 6749
2 5 Draining coolant 6751
2 6 Filling cooling system 6752
2 7 Checking coolant level and topping up 6754
3 Coolant pump, regulation of cooling system 6756
3 1 Assembly overview – coolant pump, thermostat 6756
3 2 Assembly overview – electric coolant pump 6758
3 3 Assembly overview – coolant valves 6759
3 4 Assembly overview – coolant temperature sender 6760
3 5 Removing and installing electric coolant pump 6761
3 6 Removing and installing coolant pump 6763
3 7 Removing and installing toothed belt for coolant pump 6764
3 8 Removing and installing actuator for engine temperature regulation [N493] 6766
3 9 Removing and installing coolant temperature sender [G62] 6767
3 10 Removing and installing radiator outlet coolant temperature sender [G83] 6768
3 11 Removing and installing coolant valves 6770
4 Coolant pipes 6771
4 1 Assembly overview – coolant pipes 6771
4 2 Removing and installing coolant pipes 6772
4 2 1 Removing and installing front coolant pipe 6772
4 2 2 Removing and installing upper coolant pipe 6772
4 2 3 Removing and installing coolant pipe on radiator cowl 6773
4 2 4 Removing and installing coolant pipe on gearbox 6774
5 Radiator, radiator fan 6776
5 1 Assembly overview – radiator, Golf, Tiguan, Arteon, T-Roc, Passat 6776
5 1 1 Assembly overview – radiator 6776
5 2 Assembly overview – radiator, Polo 6776
5 2 1 Assembly overview – radiator 6776
5 3 Assembly overview – auxiliary radiator 6777
5 4 Assembly overview – radiator cowl and radiator fan 6778
5 5 Removing and installing radiator, Golf, Tiguan, Arteon, T-Roc, Passat 6779
5 5 1 Removing and installing radiator 6779
5 6 Removing and installing radiator, Polo 6782
5 6 1 Removing and installing radiator 6782
5 7 Removing and installing radiator cowl, Golf, Tiguan, Arteon, T-Roc, Passat 6784
5 7 1 Removing and installing radiator cowl 6784
5 8 Removing and installing radiator cowl, Polo 6785
5 8 1 Removing and installing radiator cowl 6785
5 9 Removing and installing radiator fan 6788
5 9 1 Removing and installing radiator fan [VX57] 6788
5 9 2 Removing and installing radiator fan 2 [V177] 6789
5 10 Removing and installing auxiliary radiator 6789
21 – Turbocharging/supercharging 6792
1 Safety information and repair notes 6792
1 1 Safety information 6792
1 2 Repair instructions 6792
2 Turbocharger 6793
2 1 Assembly overview – turbocharger, DNFC, DNFE, DNFF, DNFG, DSFB, DSFE, DSFF 6793
2 1 1 Assembly overview – turbocharger 6793
2 2 Assembly overview – turbocharger, DNPA, DNNA, DNND, DRNA 6796
2 2 1 Assembly overview – turbocharger 6796
2 3 Removing and installing turbocharger, DNFC, DNFE, DNFF, DNFG, DSFB, DSFE, DSFF 6800
2 3 1 Removing and installing turbocharger 6800
2 4 Removing and installing turbocharger, DNPA, DNNA, DNND, DRNA 6806
2 4 1 Removing and installing turbocharger 6806
2 5 Removing and installing charge pressure control module [GX34] 6811
2 6 Removing and installing sender 1 for turbocharger speed G688, DNFC, DNFE, DNFF, DNFG, DSFB, DSFE, DSFF 6813
2 6 1 Removing and installing sender 1 for turbocharger speed [G688] 6813
3 Charge air system 6814
3 1 Assembly overview – charge air system, DNFC, DNFE, DNFF, DNFG, DSFB, DSFE, DSFF 6814
3 1 1 Assembly overview – charge air system 6814
3 2 Assembly overview – charge air system, DNPA, DNNA, DNND, DRNA 6816
3 2 1 Assembly overview – charge air system 6816
3 3 Assembly overview – charge air system, Polo 6817
3 3 1 Assembly overview – charge air system 6817
3 4 Removing and installing charge air cooler, Golf, Tiguan, Arteon, T-Roc, Passat 6818
3 4 1 Removing and installing charge air cooler 6818
3 5 Removing and installing charge air cooler, Polo 6821
3 5 1 Removing and installing charge air cooler 6821
3 6 Removing and installing charge pressure sender [GX26] 6821
3 7 Checking charge air system for leaks 6822
3 8 Removing and installing air intake pipe, DNFC, DNFE, DNFF, DNFG, DSFB, DSFE, DSFF 6824
3 8 1 Removing and installing front air intake pipe 6824
3 8 2 Removing and installing left air intake pipe 6825
3 9 Removing and installing air intake pipe, DNPA, DNNA, DNND, DRNA 6827
3 9 1 Removing and installing front air intake pipe 6827
3 9 2 Removing and installing left air intake pipe 6828
3 10 Removing and installing turbocharger air recirculation valve N249, DNFC, DNFE, DNFF, DNFG, DSFB, DSFE, DSFF 6829
3 10 1 Removing and installing turbocharger air recirculation valve [N249] 6829
3 11 Removing and installing turbocharger air recirculation valve [N249], DNPA, DNNA, DNND, DRNA 6830
3 11 1 Removing and installing turbocharger air recirculation valve [N249] 6830
3 12 Charge air hose connections 6830
24 – Mixture preparation – injection 6832
1 Safety information and repair notes 6832
1 1 Safety information 6832
1 2 Repair instructions 6832
2 Injection system 6833
2 1 Overview of fitting locations – injection system 6833
2 1 1 Overview of fitting locations – front view of engine 6833
2 1 2 Overview of fitting locations – engine (view from right side) 6835
2 1 3 Overview of fitting locations – rear view of engine 6835
2 1 4 Overview of fitting locations – left of engine 6836
2 2 Overview of fitting locations – engine from above, DNNA, DNND 6837
2 2 1 Overview of fitting locations – engine from above 6837
2 3 Overview of fitting locations engine from above, DNFC, DSFF, DSFB, DSFE, DRNA, DNFG, DNFE, DNPA 6839
2 3 1 Overview of fitting locations – engine from above 6839
3 Injectors 6842
3 1 Assembly overview – fuel rail with injectors 6842
3 2 Removing and installing fuel rail 6842
3 3 Removing and installing injectors 6844
3 4 Cleaning injectors 6847
3 5 Renewing seals on injectors 6848
4 Air filter 6852
4 1 Assembly overview – air filter housing 6852
4 2 Removing and installing air filter housing 6854
4 3 Removing and installing air duct on lock carrier, Golf, Tiguan, Arteon, Passat 6855
4 3 1 Removing and installing air duct on lock carrier 6855
4 4 Removing and installing air duct on lock carrier, Polo 6857
4 4 1 Removing and installing air duct on lock carrier 6857
4 5 Removing and installing air duct on lock carrier, T-Roc 6857
4 5 1 Removing and installing air duct on lock carrier 6857
5 Intake manifold 6860
5 1 Assembly overview – intake manifold 6860
5 2 Removing and installing intake manifold 6862
5 3 Removing and installing throttle valve module [GX3] 6865
5 4 Cleaning throttle valve module [GX3] 6866
5 5 Removing and installing intake manifold flap valve [N316] 6867
5 6 Checking intake manifold change-over 6867
6 Senders and sensors 6870
6 1 Assembly overview – actuator for structure-borne sound and control unit for structure-borne sound, Polo 6870
6 1 1 Assembly overview – actuator for structure-borne sound and control unit for structure-borne sound 6870
6 2 Actuator for structure-borne sound, Golf, Tiguan, Arteon, T-Roc, Passat 6870
6 2 1 Assembly overview – actuator for structure-borne sound and control unit for structure-borne sound 6870
6 2 2 Removing and installing control unit for structure-borne sound [J869] 6871
6 2 3 Removing and installing actuator for structure-borne sound [R214] 6872
6 2 4 Removing and installing bracket of actuator and control unit for structure-borne sound 6873
6 3 Removing and installing intake manifold pressure sender [GX9] 6873
6 4 Removing and installing fuel pressure sender [G247] 6874
6 5 Checking fuel pressure sender G247 6875
6 6 Removing and installing intake manifold flap potentiometer [G336] 6876
7 Engine/motor control unit 6878
7 1 Assembly overview – engine/motor control unit 6878
7 2 Removing and installing motor control unit [J623] 6878
7 2 1 Removing and installing engine control unit without protective housing [J623] 6878
7 2 2 Removing and installing engine control unit [J623] with protective housing 6879
8 High-pressure pump 6883
8 1 Assembly overview – high-pressure pump 6883
8 2 Removing and installing high-pressure pump 6884
8 3 Removing and installing high-pressure pipe 6886
9 Lambda probe 6888
9 1 Assembly overview – Lambda probe 6888
9 2 Removing and installing lambda probe 6890
9 2 1 Removing and installing Lambda probe 1 before catalytic converter [GX10] 6890
9 2 2 Removing and installing Lambda probe 1 after catalytic converter [GX7] 6891
10 Vacuum system 6893
10 1 Connection diagram – vacuum system 6893
26 – Exhaust system 6894
1 Safety information and repair notes 6894
1 1 Safety information 6894
1 2 Repair instructions 6894
2 Exhaust pipes and silencers 6895
2 1 Assembly overview – silencer, Golf, front-wheel drive 6895
2 1 1 Assembly overview – silencers 6895
2 2 Assembly overview – silencer, Golf Estate, all-wheel drive 6896
2 2 1 Assembly overview – silencers 6896
2 3 Assembly overview – silencer, Golf Estate, front-wheel drive 6898
2 3 1 Assembly overview – silencers 6898
2 4 Assembly overview – silencers, Golf all-wheel drive, T-Roc “R” 6900
2 4 1 Assembly overview – silencers 6900
2 5 Assembly overview – silencers, Passat, Arteon 6902
2 5 1 Assembly overview – silencers 6902
2 6 Assembly overview – silencers, Tiguan 6903
2 6 1 Assembly overview – silencers 6903
2 7 Assembly overview – silencers, T-Roc 6904
2 7 1 Assembly overview – silencers 6904
2 8 Assembly overview – silencers, Polo 6905
2 8 1 Assembly overview – silencers 6905
2 9 Removing and installing centre silencer, Golf Estate 6906
2 9 1 Removing and installing centre silencer 6906
2 10 Removing and installing rear silencer, Golf Estate 6908
2 10 1 Removing and installing rear silencer 6908
2 11 Removing and installing silencer, Golf, T-Roc, Tiguan with one rear silencer 6909
2 11 1 Removing and installing silencer, vehicles with one rear silencer 6909
2 12 Removing and installing silencer, Golf, Arteon, Passat with two rear silencers 6911
2 12 1 Removing and installing silencer, vehicles with two rear silencers 6911
2 13 Removing and installing silencer, Polo 6912
2 13 1 Removing and installing front silencer 6912
2 13 2 Removing and installing rear silencer 6914
2 14 Separating exhaust pipes from silencers 6915
2 15 Aligning exhaust system free of stress 6916
2 16 Checking exhaust system for leaks 6916
2 17 Installation position of clamp 6917
3 Emission control 6919
3 1 Assembly overview – emission control, front-wheel drive 6919
3 1 1 Assembly overview – emission control 6919
3 2 Assembly overview – emission control, all wheel drive 6922
3 2 1 Assembly overview – emission control 6922
3 3 Assembly overview – bracket and pipes for pressure differential sender for particulate filter 6925
3 4 Removing and installing bracket of catalytic converter/front exhaust pipe 6926
3 5 Removing and installing catalytic converter, front-wheel drive 6928
3 5 1 Removing and installing catalytic converter 6928
3 6 Removing and installing catalytic converter, all-wheel drive 6933
3 6 1 Removing and installing catalytic converter 6933
3 7 Removing and installing exhaust flap control unit 6938
3 8 Removing and installing pressure differential sender for particulate filter [G1037] 6939
4 Exhaust gas temperature regulation 6941
4 1 Assembly overview – exhaust gas temperature regulation, front-wheel drive 6941
4 1 1 Assembly overview – exhaust gas temperature regulation 6941
4 2 Assembly overview – exhaust gas temperature regulation, all-wheel drive 6941
4 2 1 Assembly overview – exhaust gas temperature regulation 6941
4 3 Removing and installing exhaust gas temperature sender, all-wheel drive 6942
4 3 1 Removing and installing exhaust gas temperature sender 6942
4 4 Removing and installing exhaust gas temperature sender, front-wheel drive 6944
4 4 1 Removing and installing exhaust gas temperature sender 6944
5 Secondary air system 6947
5 1 Assembly overview – secondary air system 6947
5 2 Removing and installing secondary air inlet valve N112 6947
5 3 Removing and installing secondary air pump motor V101 6949
5 3 1 Removing and installing secondary air pump motor V101 6949
5 3 2 Renewing stop buffer for secondary air pump 6950
28 – Ignition system 6951
1 Safety information and repair notes 6951
1 1 Safety information 6951
1 2 Repair instructions 6951
2 Ignition system 6952
2 1 Assembly overview – ignition system 6952
2 2 Removing and installing ignition coil with output stage 6954
2 3 Removing and installing knock sensor 1 [G61] 6957
2 4 Removing and installing Hall sender 6958
2 4 1 Removing and installing Hall sender [G40] 6958
2 4 2 Removing and installing Hall sender 3 [G300] 6958
2 5 Removing and installing engine speed sender [G28] 6959
D4D80870DB8 7 speed dual clutch gearbox 0GC 6961
00 – Technical data 6965
1 Safety information 6965
1 1 General safety provisions 6965
1 2 Safety measures when working on vehicles with a start/stop system 6966
1 3 Notes on tow-starting/towing 6966
1 4 Safety precautions when using testers and measuring instruments during a road test 6966
1 5 Safety precautions when working on cooling system 6967
2 Identification 6968
2 1 Gearbox identification 6968
3 Repair instructions 6969
3 1 General notes 6969
3 2 Rules for cleanliness 6969
3 3 General repair instructions 6969
3 4 Gaskets and seals 6970
3 5 Nuts and bolts 6971
4 Technical data 6972
4 1 Capacities 6972
5 Electrical components 6973
5 1 Overview of fitting locations – electrical components 6973
30 – Clutch 6974
1 Clutch 6974
1 1 Assembly overview – dual clutch 6974
1 2 Removing and installing clutch end cover 6974
1 3 Removing dual clutch 6979
1 4 Installing dual clutch 6983
34 – Controls, housing 6992
1 Mechatronic unit 6992
1 1 Assembly overview – mechatronic unit 6992
1 2 Removing and installing sump 6993
1 3 Removing and installing mechatronic unit 6996
2 Selector mechanism 7000
2 1 Assembly overview – selector mechanism 7000
2 2 Manual release from position P 7002
2 3 Removing and installing selector lever handle 7003
2 4 Moving push-button in the handle to installation position 7006
2 5 Removing and installing selector mechanism 7008
2 6 Checking selector mechanism 7010
2 7 Checking and adjusting selector lever cable 7011
2 8 Renewing selector shaft seal 7012
3 Removing and installing gearbox 7016
3 1 Specified torques for gearbox 7016
3 2 Removing gearbox 7016
3 3 Installing gearbox 7024
4 Assembly mountings 7028
4 1 Assembly overview – assembly mountings 7028
5 Transporting gearbox 7030
6 Securing to engine and gearbox support 7032
7 Gear oil circuit 7034
7 1 Assembly overview – gear oil circuit 7034
7 2 Removing and installing gear oil cooler 7034
7 3 Removing and installing gear oil filter 7037
7 4 Removing and installing motor for auxiliary hydraulic pump 1 for gearbox oil -V475- 7039
8 Gear oil 7041
8 1 Overview of oil drain and inspection plugs 7041
8 2 Tools for gear oil change 7041
8 3 Checking gear oil level 7043
8 4 Draining and filling gear oil 7047
35 – Gears, shafts 7050
1 Currently, no repairs can be made to gears and shafts 7050
39 – Final drive – differential 7051
1 Oil seals 7051
1 1 Overview of fitting locations – oil seals 7051
1 2 Renewing left seal 7051
1 3 Renewing right seal 7054
D4D80891FDA Driver assist systems 7058
00 – Technical data 7062
1 Safety information 7062
1 1 Safety measures when working on vehicles with a start/stop system 7062
1 2 Safety precautions when using testers and measuring instruments during a road test 7062
2 Repair notes 7063
2 1 Rules for cleanliness 7063
2 2 General information 7063
2 3 Contact corrosion 7063
2 4 Line routing and attachment 7063
98 – Assist systems 7065
1 Fitting locations 7065
1 1 Overview of fitting locations – senders, sensors and control units in front section of vehicle 7065
1 2 Overview of fitting locations – senders, sensors and control units in centre section of vehicle 7066
1 3 Overview of fitting locations – senders, sensors and control units in rear section of vehicle 7067
2 Senders/sensors/control units 7070
2 1 Removing and installing front parking aid senders -G252-/-G253-/-G254-/-G255- 7070
2 2 Removing and installing rear parking aid senders -G203-/-G204-/-G205-/-G206- 7072
2 3 Removing and installing front park assist steering sender -G568-/-G569- 7074
2 4 Removing and installing rear park assist steering sender -G716-/-G717- 7075
2 5 Removing and installing adaptive cruise control unit -J428- 7076
2 6 Removing and installing front parking aid warning buzzer -H22- 7077
2 6 1 Removing and installing front parking aid warning buzzer -H22-, left-hand drive vehicles 7077
2 6 2 Removing and installing front parking aid warning buzzer -H22-, right-hand drive vehicles 7078
2 7 Removing and installing rear parking aid warning buzzer -H15- 7079
2 8 Removing and installing parking aid control unit -J446- 7079
2 8 1 Removing and installing parking aid control unit -J446-, left-hand drive vehicle 7079
2 8 2 Removing and installing parking aid control unit -J446-, RHD vehicle 7080
2 9 Removing and installing Blind Spot Monitor warning lamp in left exterior mirror -K303-/-K304- 7081
2 10 Removing and installing Blind Spot Monitor control unit -J1086-/-J1087- 7081
2 11 Removing and installing reversing camera -R189- 7082
2 12 Removing and installing front camera for driver assist systems -R242- 7082
3 Adaptive cruise control 7085
3 1 Components of adaptive cruise control 7085
3 2 Calibrating adaptive cruise control 7085
3 2 1 Calibration conditions 7085
3 2 2 Dynamic calibration of adaptive cruise control 7085
3 2 3 Static calibration of adaptive cruise control 7085
4 Parking aid/park assist steering/autonomous parking system 7090
4 1 Components of parking aid/park assist steering/autonomous parking system 7090
5 Blind Spot Monitor 7091
5 1 Assembly overview – Blind Spot Monitor 7091
6 Reversing camera system 7092
6 1 Overview of reversing camera system 7092
6 2 Calibrating reversing camera system 7092
6 2 1 Calibrating reversing camera -R189- 7092
7 Front camera for assist systems 7098
7 1 Components of front camera for driver assist systems 7098
7 2 Calibrating front camera for assist systems 7098
7 2 1 Calibrating front camera for assist systems, dynamic 7098
7 2 2 Calibrating front camera for assist systems, static 7099
D4D80891FF4 Electrical system 7107
00 – Technical data 7115
1 Safety information 7115
1 1 Safety measures when working on vehicles with a start/stop system 7115
1 2 Safety precautions when using testers and measuring instruments during a road test 7115
2 Repair instructions 7116
2 1 Rules for cleanliness 7116
2 2 General information 7116
2 3 Contact corrosion 7116
2 4 Routing and attachment of lines 7116
3 Battery 7118
3 1 Battery – general notes 7118
3 2 Types of battery 7118
27 – Starter, current supply, CCS 7119
1 Battery 7119
1 1 Assembly overview – battery 7119
1 1 1 Assembly overview – battery, battery in engine compartment 7119
1 1 2 Assembly overview – battery, battery in luggage compartment 7120
1 2 Removing and installing battery 7122
1 2 1 Removing and installing battery, battery in engine compartment 7122
1 2 2 Removing and installing battery, battery in luggage compartment 7124
1 3 Disconnecting and connecting battery 7127
1 3 1 Disconnecting and connecting battery, battery in engine compartment 7127
1 3 2 Disconnecting and connecting battery, battery in luggage compartment 7129
1 4 Removing and installing battery tray 7130
1 4 1 Removing and installing battery tray, battery in engine compartment 7130
1 4 2 Removing and installing battery tray, battery in luggage compartment 7131
1 5 Checking battery 7134
1 6 Charging battery 7134
1 7 Removing and installing earth wire with battery monitor control unit -J367- 7135
1 7 1 Removing and installing earth cable with battery monitor control unit -J367-, battery in engine compartment 7135
1 7 2 Removing and installing earth cable with battery monitor control unit -J367-, battery in luggage compartment 7136
1 8 Adapting battery monitor control unit -J367- 7137
2 Jump-start connection point 7138
2 1 Assembly overview – jump-start connection point 7138
2 2 Removing and installing jump-start connection 7138
3 Alternator 7142
3 1 Assembly overview – alternator 7142
3 1 1 Assembly overview – alternator with sliding bushes 7142
3 1 2 Assembly overview – alternator without sliding bushes 7142
3 2 Removing and installing alternator 7143
3 2 1 Removing and installing alternator, vehicles with 1 0 l PFI engine, 1 0 l TSI engine and 1 0 l TGI engine 7143
3 2 2 Removing and installing alternator, vehicles with 1 6 l MPI engine 7146
3 2 3 Removing and installing alternator, vehicles with 2 0 l TFSI engine 7147
3 3 Checking alternator 7149
3 4 Removing and installing poly V-belt pulley 7150
3 4 1 Removing and installing poly V-belt pulley without freewheel 7150
3 4 2 Removing and installing poly V-belt pulley with freewheel, manufacturer: Bosch 7151
3 4 3 Removing and installing poly V-belt pulley with freewheel, manufacturer: Valeo 7152
3 4 4 Removing and installing decoupler pulley with freewheel 7154
3 5 Removing and installing voltage regulator 7157
3 5 1 Removing and installing voltage regulator -C1-, manufacturer: Bosch 7157
3 5 2 Removing and installing voltage regulator -C1-, Valeo 7158
4 Starter 7160
4 1 Assembly overview – starter 7160
4 1 1 Assembly overview – starter, vehicles with manual gearbox 7160
4 1 2 Assembly overview – starter, vehicles with 7-speed dual clutch gearbox 7160
4 1 3 Assembly overview – starter, vehicles with 6-speed dual clutch gearbox 7161
4 2 Removing and installing starter 7162
4 2 1 Removing and installing starter, vehicle with manual gearbox 7162
4 2 2 Removing and installing starter, vehicles with 7-speed dual clutch gearbox 7164
4 2 3 Removing and installing starter, vehicles with 6-speed dual clutch gearbox 7165
4 3 Checking starter 7167
5 Start/stop system 7168
5 1 General description – start/stop system 7168
90 – Gauges, instruments 7169
1 Dash panel insert 7169
1 1 Assembly overview – dash panel insert 7169
1 2 Removing and installing dash panel insert -KX2- 7170
1 2 1 Removing and installing dash panel insert -KX2-, dash panel insert with analogue instruments 7170
1 2 2 Removing and installing dash panel insert -KX2-, fully digital dash panel insert 7171
2 Horn 7175
2 1 Assembly overview – horn 7175
2 2 Removing and installing treble horn -H2- and bass horn -H7- 7175
92 – Windscreen wash/wipe system 7177
1 Windscreen wiper system 7177
1 1 Assembly overview – windscreen wiper system 7177
1 2 Moving wipers to service position 7179
1 3 Removing and installing wiper blade 7179
1 4 Removing and installing wiper arms 7180
1 5 Adjusting wiper arms 7182
1 6 Removing and installing wiper motor -V- 7183
1 7 Removing and installing rain and light sensor 7185
2 Windscreen washer system 7190
2 1 Assembly overview – windscreen washer system 7190
2 2 Removing and installing filler pipe for washer fluid reservoir 7192
2 3 Removing and installing washer fluid reservoir 7192
2 4 Removing and installing windscreen washer fluid level sender 7194
2 5 Removing and installing windscreen washer pump 7195
2 6 Removing and installing spray jets 7196
2 7 Adjusting spray jets 7197
3 Rear window wiper system 7198
3 1 Assembly overview – rear window wiper system 7198
3 2 Removing and installing wiper blade 7199
3 3 Removing and installing wiper arm 7199
3 4 Adjusting wiper arm 7200
3 5 Removing and installing rear window wiper motor -V12- 7201
4 Rear window washer system 7203
4 1 Assembly overview – rear window washer system 7203
4 2 Removing and installing washer fluid reservoir 7203
4 3 Removing and installing rear window washer pump 7204
4 4 Removing and installing spray jet 7204
4 5 Adjusting spray jet 7204
5 Washer fluid lines 7206
5 1 Repairing washer fluid lines 7206
94 – Lights, bulbs, switches – exterior 7207
1 Headlights 7207
1 1 Assembly overview – headlight 7207
1 1 1 Assembly overview – headlight, ECO LED 7207
1 1 2 Assembly overview – headlight, TOP LED 7208
1 1 3 Assembly overview – repair caps, TOP LED 7210
1 1 4 Assembly overview – repair kit for headlight housing 7211
1 1 5 Assembly overview – daytime running lights 7212
1 2 Removing and installing headlight 7213
1 3 Adjusting headlights 7215
1 4 Removing and installing headlight dipped beam bulb 7215
1 5 Removing and installing headlight main beam bulb -M30-/-M32- 7217
1 6 Removing and installing LED modules for daytime running light and side light -L176-/-L177- 7219
1 7 Adjusting headlight installation position 7220
1 8 Installing repair kit for headlight housing 7221
1 9 Converting headlights from driving on right to driving on left 7223
1 10 Converting headlights from driving on left to driving on right 7223
1 11 Removing and installing headlight range control motor -V48-/-V49- 7224
1 11 1 Removing and installing headlight range control motor -V48-/-V49-, standard ECO LED headlights 7224
1 11 2 Removing and installing headlight range control motor -V48-/-V49-, TOP LED headlights 7225
1 12 Removing and installing daytime running lights 7227
1 13 Removing and installing output module 1 for LED headlights -A27-/-A31- 7227
1 14 Removing and installing light conductor for contour lighting in radiator grille, front -L362-/-L363- 7229
2 Fog lights 7230
2 1 Assembly overview – fog lights 7230
2 2 Removing and installing fog light 7230
2 3 Adjusting fog lights 7231
3 Lights in exterior mirror 7232
3 1 Assembly overview – lights in exterior mirror 7232
3 2 Removing and installing turn signal 7234
4 Tail lights 7235
4 1 Assembly overview – tail light cluster in body 7235
4 2 Assembly overview – tail light clusters in rear lid 7235
4 3 Removing and installing tail light cluster 7236
4 4 Removing and installing tail light in rear lid 7238
4 5 Adjusting installation position of tail light 7239
5 High-level brake light 7240
5 1 Assembly overview – high-level brake light 7240
5 2 Removing and installing high-level brake light 7240
6 Number plate light 7243
6 1 Removing and installing number plate light -X4-/-X5- 7243
6 2 Removing and installing bulb for number plate light -X4-/-X5- 7244
7 Entry and start authorisation system 7245
7 1 Overview of fitting locations – entry and start authorisation system 7245
7 2 Overview of fitting locations – keyless entry system 7246
7 3 Removing and installing entry and start authorisation control unit -J518- 7246
7 4 Removing and installing contact sensor for front left exterior door handle -G605-/-G606- 7248
7 5 Removing and installing interior aerial 1 for entry and start authorisation -R138- 7248
7 6 Removing and installing interior aerial 2 for entry and start system -R139- 7249
7 7 Removing and installing entry and start authorisation aerial -R200-/-R201- 7249
7 8 Removing and installing rear bumper aerial for entry and start system -R136- 7250
8 Steering column switch module 7251
8 1 Assembly overview – steering column switch module 7251
8 1 1 Assembly overview – steering column switch module, mechanical ignition lock 7251
8 1 2 Assembly overview – steering column switch module, electronic ignition lock 7252
8 2 Removing and installing lock cylinder 7253
8 3 Removing and installing ignition key withdrawal lock solenoid -N376- 7256
8 4 Removing and installing ignition/starter switch 7256
8 5 Removing and installing steering column switch module 7258
8 5 1 Removing and installing steering column switch module, Kostal 7258
8 5 2 Removing and installing steering column switch module, Valeo 7260
8 6 Removing and installing steering column electronics control unit -J527- 7262
8 7 Removing and installing turn signal switch -E2- 7264
8 7 1 Removing and installing turn signal switch -E2-, Kostal 7264
8 7 2 Removing and installing turn signal switch -E2-, Valeo 7266
8 8 Removing and installing cruise control system switch -E45- 7268
8 9 Removing and installing intermittent wiper switch -E22- 7268
8 10 Removing and installing base for steering column combination switch 7268
8 10 1 Removing and installing base for steering column combination switch, mechanical ignition lock 7268
8 10 2 Removing and installing base for steering column combination switch, electronic ignition lock 7269
8 11 Removing and installing steering lock housing 7269
9 Automatic headlight range control 7272
9 1 Assembly overview – automatic headlight range control 7272
9 2 Removing and installing headlight range control unit 7273
96 – Lights, bulbs, switches – interior 7275
1 Lights 7275
1 1 Overview of fitting locations – lights in dash panel 7275
1 2 Overview of fitting locations – lights in front doors 7276
1 3 Overview of fitting locations – lights in centre console 7277
1 4 Overview of fitting locations – lights in luggage compartment 7278
1 5 Overview of fitting locations – lights in roof trim 7279
1 5 1 Overview of fitting locations – lights in roof trim, vehicles without rear interior light -WX2- 7279
1 5 2 Overview of fitting locations – lights in roof trim, vehicles with rear interior light -WX2- 7280
1 6 Removing and installing footwell light -W9-/-W10- 7281
1 7 Removing and installing Central locking SAFELOCK function warning lamp -K133- 7282
1 8 Removing and installing storage compartment illumination bulb -L120- 7283
1 9 Removing and installing interior door handle illumination bulb -L146-/-L147- 7283
1 10 Removing and installing bulb for background lighting in front door -L164-/-L165- 7284
1 11 Removing and installing light for left dash panel background lighting -L229- 7285
1 12 Removing and installing light for right dash panel background lighting -L230- 7285
1 13 Removing and installing light for centre dashboard background lighting -L231- 7286
1 14 Removing and installing selector lever position display -Y26- 7287
1 15 Removing and installing luggage compartment light -W3- 7287
1 16 Removing and installing illuminated vanity mirror -W20-/-W14- 7287
1 17 Renewing front interior light bulb -W1-/-W13-/-W19- 7288
1 17 1 Renewing front interior light -W1-, vehicles without rear interior light -WX2- 7288
1 17 2 Renewing front reading light -W13-/-W19-, vehicles without rear interior light -WX2- 7290
1 17 3 Renewing bulb for interior light/reading light -W1-/-W13-/-W19-, vehicles with rear interior light -WX2- 7291
1 18 Renewing bulb for rear interior light -W43- 7292
1 19 Removing and installing bulb for rear reading light -W11-/-W12- 7293
2 Controls 7295
2 1 Overview of fitting locations – controls in dash panel 7296
2 2 Overview of fitting locations – controls in front doors 7298
2 3 Overview of fitting locations – controls in rear doors 7298
2 4 Overview of fitting locations – controls in centre console 7299
2 5 Overview of fitting locations – controls in luggage compartment 7300
2 6 Overview of fitting locations – controls in roof trim 7301
2 6 1 Overview of fitting locations – controls in roof trim, vehicles without rear interior light -WX2- 7301
2 6 2 Overview of fitting locations – controls in roof trim, vehicles with rear interior light -WX2- 7302
2 7 Removing and installing rotary light switch -EX1- 7304
2 8 Removing and installing headlight range control regulator -E102- 7304
2 9 Removing and installing TCS and ESP button -E256- 7306
2 10 Removing and installing parking aid button -E266- 7306
2 11 Removing and installing park assist steering button -E581- 7306
2 12 Removing and installing Start/Stop operation button -E693- 7306
2 13 Removing and installing driving mode selection button -E735- 7306
2 14 Removing and installing front passenger side airbag deactivated warning lamp -K145- 7307
2 15 Removing and installing centre console switch module 7308
2 16 Removing and installing hazard warning light switch -EX3- 7308
2 17 Removing and installing buttons for seat heating -E653-/-E654- 7309
2 18 Removing and installing exterior mirror adjuster -EX11- 7309
2 19 Removing and installing operating unit for window regulator in driver door -E512- 7310
2 20 Removing and installing window regulator switch in front passenger door -EX27- 7311
2 21 Removing and installing driver side interior locking button for central locking system -E308- 7312
2 22 Removing and installing door contact switch -F2-/-F3- 7313
2 23 Removing and installing rear window regulator switch in door -E52-/-E54- 7313
2 24 Removing and installing rear door contact switches -F10-/-F11- 7314
2 25 Removing and installing the starter button -E378- 7314
2 26 Removing and installing rear lid contact switch 7315
2 27 Removing and installing vanity mirror contact switch -F147-/-F148- 7315
2 28 Removing and installing sunroof button -E325- 7315
2 29 Removing and installing front interior light/reading light 7316
2 29 1 Removing and installing front interior light/reading light, vehicles without rear interior light -WX2- 7316
2 29 2 Removing and installing front interior light/reading light, vehicles with rear interior light -WX2- 7317
2 30 Removing and installing rear interior light/reading light 7319
3 Anti-theft alarm 7322
3 1 Assembly overview – interior monitor 7322
3 2 Removing and installing alarm horn -H12- 7322
3 3 Removing and installing anti-theft alarm sensor -G578- 7323
4 Immobiliser 7325
4 1 Removing and installing immobiliser control unit 7325
4 2 Removing and installing immobiliser reader coil 7325
4 2 1 Removing and installing immobiliser reader coil, mechanical ignition lock 7325
4 2 2 Removing and installing immobiliser reader coil, electronic ignition lock 7325
5 Towing bracket 7327
5 1 Assembly overview – socket, trailer detector control unit 7327
5 2 Trailer socket 7327
5 3 Removing and installing trailer detector control unit -J345- 7328
6 Cigarette lighter, socket 7329
6 1 Removing and installing cigarette lighter -U1- 7329
6 2 Removing and installing socket illumination bulb -L42- 7329
6 3 Removing and installing rear cigarette lighter illumination bulb -L32- 7329
6 4 Removing and installing electric socket -U- 7329
97 – Wiring 7330
1 Relay carriers, fuse holders, electronics boxes 7330
1 1 Overview of fitting locations – relay carriers, fuse holders, electronics boxes 7330
1 1 1 Overview of fitting locations – relay carriers, fuse carriers, electronics boxes, engine compartment 7330
1 1 2 Overview of fitting locations – relay carriers, fuse carriers, electronics boxes, A-pillar 7331
1 1 3 Assembly overview – fuse holder A -SA- 7332
1 1 4 Assembly overview – main fuse carrier 7334
1 2 Removing and installing electronics box 7334
1 3 Removing and installing relay and fuse holder in electronics box 7336
1 4 Removing and installing relay and fuse holder behind dash panel on driver side 7338
1 5 Removing and installing fuse holder A -SA- 7341
1 6 Removing and installing main fuse carrier 7343
2 Control units 7345
2 1 Overview of fitting locations – control units 7345
2 2 Removing and installing onboard supply control unit -J519- 7346
2 3 Removing and installing data bus diagnostic interface -J533- 7347
2 4 Removing and installing bracket for onboard supply control unit -J519- 7348
2 5 Removing and installing parking aid control unit -J446-/park assist steering control unit -J791- 7348
3 Connectors 7350
3 1 Repairing electrical wiring harnesses and plug-in connections 7350
3 1 1 Repairs to wiring harnesses and connectors 7350
3 1 2 Repairing connector housings and electrical connectors 7350
4 Releasing and dismantling connector housings 7351
5 Repairing aerial wires 7352
6 Fibre optic cables 7353
7 Vehicle diagnosis, testing and information systems 7354
D4D80892AEF Communication 7355
00 – Technical data 7359
1 Repair notes 7359
1 1 General repair instructions 7359
1 2 Line routing and attachment 7359
1 3 Notes on repair of CAN bus wiring 7359
1 4 General information 7359
91 – Communication 7361
1 Fitting locations 7361
1 1 Overview of fitting locations – components/control units in middle section of vehicle 7361
1 2 Overview of fitting locations – components/control units in rear section of vehicle 7363
2 Components/control units 7365
2 1 Removing and installing infotainment system display 7365
2 2 Removing and installing control unit 1 for information electronics -J794- 7366
2 3 Removing and installing DVD/CD changer or CD changer 7367
2 4 Renewing rotary knobs for infotainment display 7368
2 5 Removing and installing digital sound package control unit 7368
2 5 1 Removing and installing digital sound package control unit 7368
2 5 2 Removing and installing retainer for amplifier -R12- 7370
2 6 Removing and installing rear treble loudspeakers -R14-/-R16- 7370
2 7 Removing and installing front treble loudspeakers -R20-/-R22- 7370
2 8 Removing and installing rear bass loudspeakers -R15-/-R17- 7370
2 9 Removing and installing front bass loudspeakers -R21-/-R23- 7372
2 10 Removing and installing subwoofer -R211- 7373
2 11 Removing and installing subwoofer -R211- 7374
2 12 Removing and installing frequency modulation (FM) frequency filter -R178-/-R179- 7376
2 13 Removing and installing aerial module 7377
2 14 Removing and installing roof aerial 7378
2 15 Removing and installing LTE aerial [R306] 7378
2 16 Removing and installing telephone microphone -R38- 7379
2 16 1 Removing and installing telephone microphone -R38-, vehicles without rear interior light -WX2- 7379
2 16 2 Removing and installing telephone microphone -R38-, vehicles with rear interior light -WX2- 7380
2 17 Removing and installing transmission and reception stabilisation control unit -R308- 7381
2 18 Removing and installing telephone bracket -R126- 7382
2 19 Removing and installing multifunction buttons in steering wheel -E441-/-E440- 7383
2 20 Removing and installing Tiptronic switch in steering wheel -E439-/-E438- 7386
2 21 Removing and installing USB connection 1 -U41- 7387
2 22 Removing and installing USB hub -R293- 7388
2 23 Removing and installing USB charging socket 1 -U37- 7389
2 24 Removing and installing emergency call module control unit and communication unit -J949- 7390
2 25 Removing and installing operating unit for preparation for mobile telephone -E508- 7391
2 26 Removing and installing loudspeaker for emergency call module -R335- 7392
2 27 Removing and installing battery for control unit for emergency call module 7392
3 Multifunction steering wheel 7394
3 1 Assembly overview – multifunction steering wheel 7394
K0059101320 Electrical system General information 7395
27 – Starter, current supply, CCS 7401
1 Battery 7401
1 1 Fundamentals for batteries 7401
1 2 Battery load test 7401
1 2 1 Battery with »standard« colour indicator 7402
1 2 2 Battery with »enhanced« colour indicator 7402
1 2 3 Absorbent glass mat battery 7403
1 2 4 Lithium ion battery 7403
1 3 Warning notices and safety regulations 7403
1 3 1 Dangers when handling vehicle batteries 7403
1 3 2 Safety markings on battery 7404
1 3 3 Working on airbag system 7405
1 4 Battery load test 7405
2 Checking battery 7407
2 1 Checking the various types of batteries 7407
2 1 1 Checking a battery with colour indicator 7407
2 1 2 Absorbent glass mat battery 7407
2 2 Visual inspection 7408
2 3 Information about battery replacement and battery gas venting 7409
2 4 Checking colour indicator in battery cover 7410
2 4 1 Checking colour indicator, “3-colour” 7410
2 4 2 Checking colour indicator, “2-colour” 7411
2 5 Current draw test 7412
3 Charging the battery 7414
3 1 Totally discharged batteries 7414
4 Cruise control system (CCS) 7416
4 1 Activating and deactivating cruise control system (CCS) 7416
90 – Gauges, instruments 7417
92 – Windscreen wash/wipe system 7418
1 Washer fluid line hose couplings 7418
1 1 Windscreen and rear window washer system 7418
1 2 Headlight washer system 7419
2 Hose repair 7420
2 1 General description 7420
2 2 Repairing smooth pipe 7420
2 3 Repairing corrugated pipe 7420
3 Distinguishing features of jointless wiper blades 7423
94 – Lights, bulbs, switches – exterior 7424
1 Operation and safety notes for gas discharge lamps 7424
96 – Lights, bulbs, switches – interior 7427
1 12 V socket 7427
1 1 Removing and installing 12 V socket 7427
1 2 Removing and installing socket illumination bulb -L42- 7427
2 Cigarette lighter -U1- 7428
2 1 General description 7428
2 2 Assembly overview 7429
2 3 Removing and installing cigarette lighter socket 7430
2 4 Removing and installing cigarette lighter illumination bulb -L28- 7433
97 – Wiring 7435
1 Vehicle diagnostic, testing and information systems 7435
1 1 Connecting vehicle diagnostic tester 7435
1 2 Connecting vehicle diagnostic tester Golf Model Year 1998 – 2003 7437
2 Repairs to wiring harnesses and connectors 7438
2 1 General notes concerning repairs to vehicle electrical system 7438
2 2 Wiring harness repair set 7440
2 2 1 Wiring harness repair set -VAS 1978- 7440
2 2 2 Upgrade kit -VAS 1978/50- 7440
2 2 3 Wiring harness repair set -VAS 1978A- 7441
2 2 4 Release tool set -VAS 1978/35- 7441
2 3 Tool descriptions 7442
2 3 1 Special pliers with insert 7442
2 3 2 Release tools for contacts 7443
2 3 3 Assembly tools for single wire seals 7443
2 3 4 Wire stripper -VAS 1978/3- 7443
2 3 5 Hot air blower 220 V/50 Hz -VAS 1978/14- 7445
2 3 6 Crimping pliers -VAS 1978/1A- 7445
2 4 Repairing wiring harnesses 7447
2 4 1 Repairs to airbag and belt tensioner wiring 7447
2 4 2 Repairing CAN bus wiring 7449
2 4 3 Repair of Flexray wires with sheath 7450
2 4 4 Repair of Flexray wires without sheath 7451
2 4 5 Renewal of aerial wiring 7452
2 4 6 Repairing 0 13 mm2/0 35 mm2/0 5 mm2 wire 7454
2 4 7 Repair of 10 mm2 or 16 mm2 wire with single butt connector 7459
2 4 8 Repair of 2 5 mm2, 4 mm2 or 6 mm2 aluminium wire with single butt connector 7466
2 4 9 Wiring open circuit with one repair position 7472
2 4 10 Wiring open circuit with two repair positions 7475
2 5 Repairing fibre optic cables 7477
2 5 1 Preparing fibre optic cable 7478
2 5 2 Detaching fibre optic cable from cable harness connector 7485
2 6 Repair of aerial wires 7486
2 6 1 Repair set, aerial cable VAS 6720 7486
2 7 Repairs to contact housings and connectors 7498
2 7 1 Notes on repairs to contact housings and connectors 7498
2 7 2 Repairs to contacts in contact housings 7498
2 7 3 Fitting single wire seals 7500
2 7 4 Repairs to contact housings using cut-and-clamp method 7503
2 8 Releasing and dismantling contact housings 7504
2 8 1 Notes on releasing and dismantling contact housings 7504
2 8 2 Secondary locking element 7504
2 8 3 Primary locking element 7505
2 8 4 Round connector systems 7506
2 8 5 Flat connector systems 7507
2 8 6 Special connector systems 7509
3 Contact surface cleaning set -VAS 6410- 7512
3 1 Using contact surface cleaning set -VAS 6410- 7512
3 1 1 Servicing ring terminals 7512
3 1 2 Servicing screw connections 7514
3 1 3 Cleaning battery clamp and battery terminal 7516
3 1 4 Anti-corrosion treatment 7518
4 Renewing lambda probe 7520
4 1 Renewing LSF Lambda probe (4-pin) 7520
4 2 Renewing LSU Lambda probe (6-pin) 7521
4 3 Types of protective tube on universal lambda probes 7522
5 Exhaust gas temperature sensor 7524

S.V 03/02/2025