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Volkswagen Polo Mk4 Workshop Repair Manual Compilation
$29.95 Original price was: $29.95.$18.95Current price is: $18.95.
Comprehensive workshop service and repair manual compilation for the Volkswagen Polo Mk4. Features factory technical data, brake mechanics, ABS/ESP hydraulic systems, front and rear suspension overhaul, electrohydraulic steering, engine mechanical servicing, body repairs, and complete vehicle electrical procedures.
SKU: VW-POLO-MK4-WMR-HD
Category: Automotive Repair Manuals
Tags: Volkswagen Polo Mk4 repair compilation, Volkswagen Polo Mk4 workshop manual, Volkswagen Polo Mk4 workshop repair manual, VW Polo Mk4 service manual
Vendor: Welder Service Docs
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Description
Factory Service Information: Volkswagen Polo Mk4 Workshop Repair Manual Compilation
The Volkswagen Polo Mk4 Workshop Repair Manual Compilation is an authoritative technical reference designed for automotive technicians, mechanics, and dedicated Volkswagen owners undertaking maintenance, troubleshooting, and complete mechanical overhauls. This comprehensive manual compiles essential workshop repair groups covering the Mk4 Polo platform (Typ 9N / A04), including Hatchback, Sedan, GT, and Blue Motion variants across petrol, SDI, and TDI unit injector powertrains.
File Details
- Manual Type: Factory Workshop Repair Manual Compilation
- Brand: Volkswagen
- Model: Polo Mk4 (Typ 9N / 9N1 / A04 Platform)
- Language: English
- Page Count: 1579 pages
- File Format: Adobe PDF
- Vehicle Identification Reference: Example VIN wvwzzz 9N z 2D000134, Model Code 9N1 314 (Polo A04 SDI Highline 47kW 5G ASY FVU)
- Manual Release Date: 1st January 2018
Chapters Covered
- Brake Systems: Technical Data, PR Code Correspondence (1KB, 1LQ, 3FE), Front Disc Brakes (FS II, FS III, C54-FN 3), Rear Disc Brakes, Rear Drum Brakes (ABS and non-ABS)
- ABS, ADR, TCS, EDL, ESP Systems: ABS MK 60, Bosch 5.7, and Bosch 8.0 Hydraulic Units, Electrical/Electronic Component Locations, Control Lamp Indications, Brake Pipe Connections, Speed Sensors (G201, Front/Rear Axle Sensors, Wiring Harness Repairs with VAS 1978)
- Brake Mechanics & Hydraulics: Caliper Overhaul, Plunger Replacement, Brake Shoe/Drum Servicing, Handbrake Cable Adjustments, Brake Pedal and Servo Decoupling (Tool T10006 A), Bleeding Procedures with VAS 5234, Master Cylinder and Servo Brake Booster R&I
- Running Gear, Axles & Steering: Subframe (Auxiliary Frame) Console Bushings (Tools 3062, 3253, 3346, T10037, T40023), Wishbones, Swivel Guide Ball Joints (Tool 3287 A), Anti-Roll Sway Bars, Wheel Roller Bearings (13″, 14″, 15″ Running Gear), Front Struts and Coil Springs, Constant Velocity Drive Shafts
- Rear Suspension: Rear Axle Beam Removal/Installation, Metal-Rubber Bearings, Coil Springs, Shock Absorbers, Drum Brake Wheel Hub Bearings
- Steering Assemblies: Steering Column (Fixed and Adjustable), Rack Disassembly and Centering, Mechanical and Electrohydraulic Power Steering (TRW and JTEKT Systems, G250 Steering Sensor, Motor/Pump Set Pressure Checks)
- Body Repairs (Exterior & Interior): Front Panel Alignment, Wings, Bonnet Latch Mechanism, Hatch and Sedan Boot Lids, Door Lock Cables, Glazing and Adhesive Primer Dimensions, Sunroof Mechanisms, Bumpers, Blue Motion Spoilers and Trims, Instrument Panel Cross Members, Airbag Units (N131, J234), Seat Belts, and Upholstery Stripping
- Chemicals & Workshop Consumables Manual: Factory Lubricants, Threadlockers, Adhesives, Cavity Sealants, and Chemical Application Groups
- Painting & General Body Reconditioning: Paintwork Procedures on Zinc-Coated Steel and Plastics, Spot-Welding Symbols, Body Repair Tooling (V.A.G 1329, V.A.G 1523A, V.A.G 1731)
- Engine Mechanical & Engine Management: 4-Cylinder Injection (including 16V Roller RockerBBZ/BBY/BKY, 1.0L, 1.6L, 2.0L), 1.9L SDI Distributor Injection (ASY), and 1.9L TDI Unit Injector (ATD), Timing Belt Replacement, Cylinder Head Overhaul, Oil Pumps, Cooling Circuits, Fuel Delivery, and ECU Adaptation
- Vehicle Electrics: Battery Versions 1–5, Starter Motor Overhaul (Bosch and Valeo), Alternator Servicing and Voltage Regulators, Instrument Clusters (K), Wiper Mechanisms, and Rain/Light Sensors (G213, G397)
This technical compendium equips workshop personnel with systematic assembly overviews, precise disassembly procedures, and essential diagnostic workflows. By providing factory component illustrations alongside dedicated test sequences, the manual eliminates guesswork when carrying out critical running gear adjustments, braking system overhauls, or powertrain component replacements.
Complete PDF Bookmark Tree
Complete Bookmarks
The complete bookmarks in the “Volkswagen Polo Mk4 Workshop Repair Manual Compilation” are as follows:
+Brake systemsp. 1
+Technical datap. 1
+Correspondence of PR numbers for the brakep. 1
Example of a vehicle identification tagp. 1
+Brake technical datap. 2
Front wheel brake FS IIp. 2
Front wheel brake FS IIIp. 3
Front wheel brake C54-FN 3p. 4
Rear wheel disc brakep. 5
Rear wheel drum brake without ABSp. 6
Rear wheel drum brake with ABSp. 7
+General notes on rims and tyres (vehicles and passengers)p. 187
+General Remarksp. 187
Wheel specificationsp. 187
+Curiosities about rims and tires (passenger vehicles)p. 188
+Wear/tyre mileagep. 188
Unilateral wearp. 188
Diagonal abrasionp. 189
+Rolling noises coming from the tyresp. 190
Wear occurrence in the shape of sawp. 190
Blockage pointsp. 191
+The vehicle deviates to one sidep. 192
Conicityp. 192
+Damages on the tyresp. 193
Structure of a radial tyrep. 193
Damages caused by crashesp. 194
Damages due to cut.p. 195
Damages to the tyres due to insufficient air pressurep. 196
Rise of temperature in tyres with insufficient air pressurep. 197
+Useful notes related to tyres and wheelsp. 198
Inscriptions on the side wall of the tyrep. 198
+Work Instructions for Handling Chemicalsp. 530
+General considerationsp. 530
Solvent Handlingp. 530
+Repair Group 10 – Cylinders, engine block, support, protectorp. 531
Cylinder base gasket – lubricatep. 531
Engine housing – sealp. 532
Engine housing plugs – fastenp. 533
Engine block plugs – fastenp. 534
+Repair Group 13 – Crankshaft, pistonsp. 535
Crankshaft needle bearingp. 535
Needle bearing of the fastening hollow screw for the flywheelp. 536
Flywheel fastening screw – lockp. 537
+Repair Group 15 – Cylinder head, valve control mechanismp. 538
Intermediate shaft seal – lubricate for assemblyp. 538
Camshaft valve bearing cover (1st and 5th) – Sealp. 539
Cylinder head sealing gasket – gluep. 540
Lower rear studs fastening the head – rear stud (crankshaft) / lower front studs (flywheel) – Sealp. 541
Cylinder head cover – sealp. 542
+Repair Group 17 – Lubrication systemp. 543
Engine crankcase – Fill / top up oil levelp. 543
Junction between crankcase gaskets and crankshaft front and rear flange gasket – sealp. 544
Engine crankcase – sealp. 545
+Repair Group 19 – Cooling systemp. 546
G 11 cooling system – fill / adjust additive proportion.p. 546
G 12 cooling system – fill / adjust additive proportion.p. 547
+Repair Group 20 – Supply system – tank, fuel pumpp. 548
Fuel tank – add additivep. 548
Accelerator pedal shaft – lubricatep. 549
Accelerator pedal fastening – lubricatep. 550
Accelerator cable and cable end – accelerator pedal fastening – lubricatep. 551
+Repair Group 26 – Exhaust systemp. 552
Exhaust connection – sealp. 552
+Repair Group 30 – Clutch – control systemp. 553
Clutch pedal bung – lubricatep. 553
Clutch control cable – lubricatep. 554
Clutch fork, contact with bearing – lubricatep. 555
Clutch fork bungs – lubricatep. 556
Butterfly nut for clutch control cable adjustment – lubricatep. 557
Sealing ring for the de-clutch bearing guide – lubricate for assemblyp. 558
Clutch cable – lubricatep. 559
Clutch fork and clutch operating lever – lubricatep. 560
Clutch pedal fastening – lubricatep. 561
Clutch operating cable – lubricatep. 562
Primary shaft splines – lubricatep. 563
Clutch pedal / clutch pedal bung – lubricatep. 564
Pedal support – sealp. 565
Clutch fork contact with the hydraulically activated cylinder of the transmission clutch – lubricatep. 566
Fastening flange for the hydraulically activated slave cylinder of the clutch – sealp. 567
+Repair Group – 34 – Drive, housingp. 568
Linkage rod, front/rear section – lubricatep. 568
Gearshift lever bearingp. 569
Manual transmission – Fill / top up levelp. 570
Plastic bungs for the linkage rod coupling system / linkage rod / supports (on the transmission) – lubricatep. 571
Gearshift lever guide plate – lubricatep. 572
Rubber shim for the clutch compartment cover – gluep. 573
Clutch compartment cover – sealp. 574
Linkage rod bellows for the gearshift lever assembly – fasten / sealp. 575
Junction of cases and differential cover housing (gearbox / differential) – sealp. 576
Gearshift lever handle – fastenp. 577
Fastening screw for the rear support of the transmission cushion – sealp. 578
Transmission cushion – lubricatep. 579
Gear selection mechanism – fill upp. 580
Electric connectors of the gear selection mechanism – apply nyogelp. 581
+Repair Group 35 – Gears and shaftsp. 582
Primary shaft splines – lubricatep. 582
Fastening screw for the 5th gear synchronizer / clutch assembly – lockp. 583
+Repair Group – 37 – Drive, housingp. 584
Planetary gear box (automatic transmission) – Fill / top up oil levelp. 584
+Repair Group – 39 – Transmission shafts, differentialp. 585
Transmission side seals – lubricatep. 585
Planetary and satellite gears – lubricate for assemblyp. 586
Automatic transmission differential – top up oil levelp. 587
Differential cover with transmission case – sealp. 588
+Repair Group – 40 – Front suspensionp. 589
Constant-velocity joint spline – lubricatep. 589
Inner and outer constant-velocity joint – lubricatep. 590
Front wheel bearing housing – lubricatep. 591
Axle end – lubricatep. 592
+Axle end – lubricatep. 593
Front wheel hub seal – lubricatep. 593
King pin bearing – lubricatep. 594
Front axle body – lubricatep. 595
Suspension arms – lubricatep. 596
Front wheel bearing – lubricatep. 597
Passage hole for the speedometer cable in the wheel hub protector – sealp. 598
+Repair Group – 42 – Rear suspensionp. 599
Inner and outer constant-velocity joint – lubricatep. 599
Shaft end splines – lubricatep. 600
Rear torsion bar – lubricatep. 601
Rear wheel hub – lubricatep. 602
Rear wheel hub seal – lubricatep. 603
Rear wheel bearing – lubricatep. 604
+Repair Group – 46 – Brakes – Mechanical systemsp. 605
Rear wheel brake shoe ends – lubricatep. 605
Emergency brake cable terminal – lubricatep. 606
Brake pedal safety pin – lubricatep. 607
Fastening pin for the operating rod of the master cylinder plunger – lubricatep. 608
Fastening pin of the parking brake lever – lubricatep. 609
Emergency brake ratchet – lubricatep. 610
+Repair Group – 47 – Brakes – Servo brake hydraulic systemp. 611
Brake system – fill / top upp. 611
Guide pin for the support of the front disc brake cylinder (manufactured by Varga) – lubricatep. 612
Fastening screw for the front disc brake cylinder housing – lockp. 613
+Repair Group – 48 – Steeringp. 614
Oil tank for the power steering system – Fill / top up oil levelp. 614
Steering box – Fill / top up levelp. 615
Steering box mechanism – lubricatep. 616
Adapter (sleeve) for the upper steering shaft – lockp. 617
+Repair Group – 53 – Body – Rear sectionp. 618
Bucket sealing membrane – gluep. 618
Rear side panel – protect the paintp. 619
+Repair Group – 55 – Coversp. 620
Bucket protective cover longitudinal member – glue the finishingp. 620
Lower latch of the hood – lubricatep. 621
Shock absorber eyelet for the rear cover – lubricatep. 622
+Repair Group – 57 – Front doors / components / central lockp. 623
Front door lock – lubricatep. 623
Lock drive rod – lubricatep. 624
Noise insulation for lock operating rod – gluep. 625
Internal door finishing – gluep. 626
+Repair Group – 58 – Rear doors / componentsp. 627
Rear door lock – lubricatep. 627
Side door lock – lubricatep. 628
+Repair Group – 64 – Windscreens, windows, window mechanismp. 629
Door window activation mechanism – lubricatep. 629
Vent window latch – lubricatep. 630
Front door glass support – lubricatep. 631
Front door window activation mechanism – lubricatep. 632
Window crank fastening screw – lockp. 633
Windscreen, side window glass and rear window glass – gluep. 634
Windscreen, side window glass and rear window glass – sealp. 635
Glass – engrave chassis numberp. 636
Front and rear door window guide groove – gluep. 637
Vent window – sealp. 638
+Repair Group – 66 – External equipmentp. 639
Roof rack fastening screws – lockp. 639
+Repair Group – 68 – Internal equipmentp. 640
Internal rearview mirror support – fastenp. 640
+Repair Group – 70 – Lining/insulationp. 641
Door noise insulation – gluep. 641
Noise insulation on rear side panel – gluep. 642
Roof noise insulation – gluep. 643
Door sealing membrane – gluep. 644
+Repair Group – 72 – Seat frameworkp. 645
Front seat central sliding guide – lubricatep. 645
Front seat side sliding guide – lubricatep. 646
+Repair Group – 87 – Air conditioningp. 647
Air conditioning system – refill with gasp. 647
Air conditioning system – refill with oilp. 648
Air conditioning pressure switch – sealp. 649
+Repair Group – 92 – Windscreen, rear window and headlight wiper and washerp. 650
Windscreen wiper operating rod – lubricatep. 650
Windscreen/rear window washer water tank – fillp. 651
+Repair Group – 94 – Switches, lights, and external bulbsp. 652
Contact blade for the indicator lights switchp. 652
+Repair Group – 97 – Cables and electrical harnessesp. 653
Gaskets for the plastic covers that cover the electric harnesses – sealp. 653
+Special colorsp. 654
Fox Blackfox 2012p. 654
Fox Crossfoxp. 655
Fox Crossfox 2012 ?p. 656
Fox Extremep. 657
Fox Silverfox 2012p. 658
Gol Rallyep. 659
Vintage Golp. 660
Golf GTp. 661
Golf Silver Editionp. 662
Silver series Kombip. 663
Parati Track and Field (Generation IV)p. 664
Parati Surfp. 665
Parati Titanp. 666
Saveiro Crossover (generation III)p. 667
Saveiro Crossover (generation IV)p. 668
Saveiro Titanp. 669
Saveiro Surfp. 670
Saveiro Trooper 2010 ?p. 671
Saveiro Cross 2010 ?p. 672
+Repaintingp. 673
Paint repair on steel plates and zinc-coated steel platesp. 673
+Paint repair on plastic partsp. 674
Repainting of plastic components that require special carep. 674
Spray guns and their usep. 675
+Body sealingp. 676
Santana and Quantump. 676
Gol 1995 ?p. 677
Gol 1999 ? and Parati 1999 ? – 5X and 5Wp. 678
Saveiro 2000 ? – 5X and 5Wp. 679
Gol , Voyage 2009 ? and Saveiro 2010 ?p. 680
Fox and Spacefoxp. 681
Polop. 682
Golfp. 683
+Application of anti-corrosion fluidp. 684
Equipmentp. 684
+Safety indicationsp. 685
+Checking the seat beltsp. 685
Check the belt strapp. 685
+Explanation of symbolsp. 686
Explanation of symbols for welding worksp. 686
+Explanation of symbols for working processesp. 687
Lowerp. 687
Perforatep. 688
Drillp. 689
Application of anti-corrosion fluidp. 690
Gluingp. 691
Sealingp. 692
+Tools for body repairp. 693
Drilling pliersVAG 1329p. 693
Fluid spray VAG 1379 or EQ 7608p. 694
Hot air blowerVAG 1416p. 695
Adjustable cordsVAG 1438p. 696
Pneumatic Saw VAG 1523A or EQ 7415p. 697
Pneumatic hammerVAG 1577p. 698
Spot weld removerVAG 1731p. 699
Pneumatic glued window adhesive applicatorVAG 1761/1 or EQ 7434p. 700
Pneumatic adhesive applicatorVAG 2005p. 701
Glued parts of the bodyp. 702
+Glued parts of the bodyp. 703
+Types of bondingp. 703
Resistance bonded jointsp. 703
Joints bonded with spot weldsp. 704
Engine numberp. 705
Engine numberp. 762
Engine numberp. 843
Engine numberp. 906
Engine numberp. 967
+Identification of gearboxp. 1327
Location of identification data in the gearboxp. 1327
+Filling quantitiesp. 1328
Planetary gear and axle shaft commandp. 1328
+General indications for repairp. 1329
Gaskets, retainers and oilp. 1329
Fastenersp. 1330
Screws, nutsp. 1331
Internal discsp. 1332
Clutchesp. 1333
Brakesp. 1334
Assisted troubleshooting for damages, vehicle self-diagnosis and measurement modulep. 1335
+Transmission identificationp. 1374
Location on transmissionp. 1374
+Transmission assembly schemep. 1375
Nomenclaturep. 1375
Gear ratiosp. 1376
+General repair instructionsp. 1377
Gaskets and retainersp. 1377
Gaskets, sealing ringsp. 1525
Locking devicesp. 1526
+General information on air conditioningp. 1500
+Basics of air conditioningp. 1500
Physical principles:p. 1500
Pressure and boiling pointp. 1501
+General remarks on the refrigerant gas loopp. 1502
+Refrigerant gas loop componentsp. 1502
Condenserp. 1502
Evaporatorp. 1503
Expansion valvep. 1504
Overpressure valvep. 1505
+Quick coupling connections in the refrigerant gas loopp. 1506
Suction and filling valve with Schrader valvep. 1506
Suction and filling valve, high pressure sectionp. 1507
Suction and filling valve, low pressure sectionp. 1508
+Switches and sensors for the refrigerant gas loop and their connectionsp. 1509
Air conditioning high pressure switch F23p. 1509
High pressure switch for magnetic coupling F118p. 1510
Air conditioning low pressure switch F73p. 1511
High pressure sensor G65p. 1512
Magnetic valve for refrigerant fluid circulation N43p. 1513
+Electrical components not assembled in the refrigerant gas loopp. 1514
Air conditioning adjustment and control unit J127p. 1514
Air outlet temperature sensor for the evaporator G263 or Evaporator temperature sensor G308p. 1515
Refrigerant gas loop with expansion valvep. 1516
Refrigerant gas loop with butterfly (throttle) and collection tankp. 1517
Checking and measuring work with a pressure gaugep. 1518
+Checking pressure values in the refrigerant gas loopp. 1519
+Verification for vehicles with butterfly (throttle) and collection tank (air conditioning compressor with internal adjustment dep. 1519
Nominal valuesp. 1519
+Verification for vehicles with expansion valve and liquid loop / dryer (air conditioning compressor with internal adjustment devp. 1520
Nominal valuesp. 1520
+Detecting leaks in the refrigerant gas loopp. 1521
Detection of leaks in the refrigerant gas loop with the air conditioning recovery, recycling, recharging and cleaning setp. 1521
+Cleaning the refrigerant gas loopp. 1522
Washing the refrigerant gas loop with R134a refrigerant gas (clean)p. 1522
Gearbox identificationp. 1523
Gearbox layoutp. 1524
+ABS, ADR, TCS, EDL, ESPp. 8
+General information on the antilock braking system (ABS)p. 8
ABS MK 60p. 8
ABS Bosch 5.7p. 9
Bosch 8.0 as of Year/Model 2005p. 10
+Electrical/electronic components and installing locationsp. 11
ABS MK 60 (ABS, ABS/EDS/ASR)p. 11
ABS Bosch 5.7 (ABS/EDS/ASR/ESP)p. 12
ABS Bosch 8.0 (ABS, ABS/ASR)p. 13
ABS Bosch 8.0 (ABS/EDS/ASR/ESP)p. 14
Fault indication via control lampsp. 15
+Hydraulic unit, servo brake/brake cylinder – assembly overviewp. 16
+ABS MK 60p. 16
Connect the brake pipes and the brake cylinder pipes to the hydraulic unitp. 16
Command unit and hydraulic unit – remove and installp. 17
+ABS Bosch 5.7p. 18
Connect the brake pipes and the brake cylinder pipes to the hydraulic unitp. 18
Command unit for hydraulic unit – remove and installp. 19
Remove the hydraulic unit command devicep. 20
Install the command device to the hydraulic unitp. 21
Brake pressure sensor 1 G201p. 22
+ABS Bosch 8.0p. 23
Connect the brake pipes and the brake cylinder pipes to the hydraulic unitp. 23
Command unit for hydraulic unit – remove and installp. 24
+ABS system components on the front and rear axles – remove and installp. 25
Remove and install the front axle ABS system componentsp. 25
+Remove and install the front axle ABS system componentsp. 26
Front axle speed sensor – remove and installp. 26
MK 60 front speed sensor cables – remove and installp. 27
Bosch 5.7 front speed sensor cables – remove and installp. 28
Bosch 8.0 front speed sensor cables – remove and installp. 29
+ABS system components on rear axle (vehicles with drum brakes) – remove and installp. 30
Speed sensor on rear axle (drum brake) – remove and installp. 30
Rear speed sensor cables – remove and installp. 31
+ABS system components on rear axle (vehicles with disc brakes) – remove and installp. 32
Speed sensor on rear axle – remove and installp. 32
Rear speed sensor cables – remove and installp. 33
+Brake, brake mechanicsp. 34
+Front wheel brake – repairp. 34
Repair front brakes, FS II disc brake cylinderp. 34
Brake pads, FS II brake caliper – remove and installp. 35
+Brake pads, FS II brake caliper – remove and installp. 36
Removep. 36
Installp. 37
FS II brake caliper – remove and installp. 38
+FS II brake caliper – remove and installp. 39
Installp. 39
Brake pads, FS III disc brake cylinder – remove and installp. 40
+Brake pads, FS III disc brake cylinder – remove and installp. 41
Removep. 41
Installp. 42
FS III brake caliper – remove and installp. 43
Remove and install brake pads, C 54-ll disc brake cylinderp. 44
+Remove and install brake pads, C 54-ll disc brake cylinderp. 45
Removep. 45
Installp. 46
C 54 II brake caliper – remove and installp. 47
+Brake disc with visual check – checkp. 48
?Vehicles with light-alloy wheelp. 48
+Rear wheel drum brake – repairp. 49
Rear wheel brake – remove and installp. 49
Reposition the brakep. 50
Brake drum – repairp. 51
Brake shoes – remove and installp. 52
+Brake shoes – remove and installp. 53
Removep. 53
Installp. 54
Rear wheel disc brake – repairp. 55
+Rear wheel disc brake – repairp. 56
Brake pads – remove and installp. 56
+Brake pads – remove and installp. 57
Removep. 57
Brake caliper – remove and installp. 58
Handbrake – assembly overviewp. 59
+Handbrake – assembly overviewp. 60
+Handbrake cable (drum brake) – remove and installp. 60
Removep. 60
Installp. 61
+Handbrake cable (disc brake) – remove and installp. 62
Removep. 62
Installp. 63
+Brake pedal – assembly overviewp. 64
Servo brake pedal – separatep. 64
+Servo brake pedal – separatep. 65
Fasten the brake pedal to the servo brake.p. 65
+Pedal set – remove and installp. 66
Removep. 66
+Brake pedal – remove and installp. 67
Removep. 67
Installp. 68
+Brakes, hydraulics, regulator, servop. 69
Front brake caliper, FS II brake caliper – repairp. 69
+Front brake caliper, FS II brake caliper – repairp. 70
Front brake caliper plunger – remove and installp. 70
+Front brake caliper plunger – remove and installp. 71
Removep. 71
Installp. 72
Removep. 75
Installp. 76
Front brake caliper, C54-ll brake caliper – repairp. 73
+Front brake caliper, C54-ll brake caliper – repairp. 74
Front brake caliper plunger – remove and installp. 74
+Rear brake caliper – repairp. 77
Plunger for rear brake caliper – remove and installp. 77
+Plunger for rear brake caliper – remove and installp. 78
Removep. 78
Installp. 79
Bleed the brake caliper in advancep. 80
Tightness checkp. 81
Braking power adjustment – assembly overviewp. 82
+Bleed the brake systemp. 83
Bleed the brake system with the filling and bleeding equipmentp. 83
Brake system, only vehicles with ABS/EDS/ASR – bleed when the reservoir has been emptiedp. 84
+Assembly overview: Brake cylinder/servo brakep. 85
+Servo brake vacuum pump (diesel vehicles) – remove and installp. 85
Vacuum pump for 4-cylinders diesel engines and with distribution injector pumpp. 85
Vacuum pump for 3-cylinder diesel enginesp. 86
Vacuum pump for 4-cylinder diesel engines with injector pump unitp. 87
Inspect the check valvep. 88
+Brake cylinder – remove and installp. 89
Vehicles with ABSp. 89
+Vehicles with ABSp. 90
Installp. 90
Servo brake – remove and installp. 91
+Servo brake – remove and installp. 92
Removep. 92
Installp. 93
+Running gear, axles, steeringp. 94
+Front suspension, drive shaftsp. 94
+Front suspension – repairp. 94
Raise the front axle under unloaded conditionsp. 94
+I – Auxiliary frame (sub-frame) , anti-roll bar, wishbones – repairp. 95
Swivel guide – checkp. 95
Swivel guide – remove and installp. 96
+Swivel guide – remove and installp. 97
Removalp. 97
Swivel guides – installation positionp. 98
Wishbone (transversal) – remove and installp. 99
+Auxiliary frame console – remove and installp. 100
Removalp. 100
Rubber support bearing for the console – replacep. 101
+Rubber support bearing for the console – replacep. 102
Remove the rubber support bearing – (versions 1 and 2)p. 102
Auxiliary frame (sub-frame) – remove and installp. 103
+Auxiliary frame (sub-frame) – remove and installp. 104
Removalp. 104
Auxiliary frame (sub-frame) – positionp. 105
+Auxiliary frame (sub-frame) – positionp. 106
Removalp. 106
Sway bar – remove and installp. 107
+Sway bar – remove and installp. 108
Removalp. 108
+II – Wheel roller bearings – repairp. 109
Wheel roller bearing for vehicles without ABS – remove and installp. 109
+Wheel roller bearing for vehicles without ABS – remove and installp. 110
Remove the wheel roller bearing hubp. 110
Installationp. 111
Front wheel hub with wheel bearing for 13" running gear – remove and installp. 112
+Front wheel hub with wheel bearing for 13" running gear – remove and installp. 113
Hub with wheel bearing – removep. 113
Wheel hub with wheel bearing – installp. 114
Front wheel hub with wheel roller bearing for 14" and 15" running gears – remove and installp. 115
+Front wheel hub with wheel roller bearing for 14" and 15" running gears – remove and installp. 116
Hub with wheel bearing – removep. 116
Wheel hub with wheel bearing – installp. 117
+III – Front suspension column – repairp. 118
Vehicle identification tagp. 118
Suspension column – remove and installp. 119
Front suspension spring – repairp. 120
+Front suspension spring – repairp. 121
Coil spring – installp. 121
+Constant velocity drive semi-shaft – remove and installp. 122
Fastening nut (dodecagonal) of the drive semi-shaft – loosen and tightenp. 122
+IV – Constant velocity drive semi-shaft – repairp. 123
Articulated shaft with constant velocity joint – general overview of assemblyp. 123
Constant velocity drive semi-shaft – repair .p. 124
+Rear suspension, drive shaftp. 125
+Rear suspension – repairingp. 125
Lift the rear axle in the unloaded positionp. 125
Rear axle – remove and installp. 126
+Rear axle – remove and installp. 127
Removalp. 127
Metal-rubber bearing – remove and installp. 128
+Metal-rubber bearing – remove and installp. 129
Removalp. 129
Installationp. 130
Spring – remove and installp. 131
+Spring – remove and installp. 132
Removalp. 132
Installationp. 133
Shock absorbers – assembly overviewp. 134
Shock absorber – remove and installp. 135
+Shock absorber – remove and installp. 136
Removalp. 136
Installationp. 137
+Wheel bearings for drum brakes – repairp. 138
Wheel roller bearings (drum brakes) – assembly overviewp. 138
Wheel roller bearing/wheel hub set in vehicles with brake drums – remove and installp. 139
+Wheel roller bearing/wheel hub set in vehicles with brake drums – remove and installp. 140
Removalp. 140
+Wheels, tyres. axle alignp. 141
+Vehicle alignmentp. 141
Preparation for measurementp. 141
Vehicle identification tagp. 142
Left and right-hand steering – checkp. 143
+Steeringp. 144
+Steering wheelp. 144
Horn buttonH – remove and installp. 144
Steering wheel – general assembly overviewp. 145
Steering wheel – remove and installp. 146
+Steering wheel – remove and installp. 147
Removalp. 147
+Fixed steering column – repairp. 148
Fixed steering wheel support and column – assembly overviewp. 148
Fixed steering column – remove and installp. 149
+Adjustable steering column – repairp. 150
Adjustable steering wheel support and column – assembly overviewp. 150
Adjustable steering column – remove and installp. 151
Steering column – checkp. 152
+Power steering box – repairp. 153
Power steering box – remove and installp. 153
+Power steering box – disassemble and assemblep. 154
Steering linkage bar – remove and installp. 154
Folding bellows – assemblyp. 155
Correspondence of steering yoke terminalsp. 156
Central rack position – determinep. 157
+Hydraulic pump, compensation reservoir, hydraulic pipes (power steering)p. 158
+Hydraulic pump with hydraulic tubes – assembly overviewp. 158
Compensation reservoir – assembly overviewp. 158
Pressure tubes and fastening the flexible aspiration tube on vehicles with air-conditioningp. 159
Pressure tubes and fastening the flexible aspiration tube on vehicles without air-conditioningp. 160
Hydraulic pump installed on the lower part – assembly overviewp. 161
+Hydraulic pump installed on the lower part – remove and installp. 162
Removalp. 162
Installationp. 163
Hydraulic pump installed on the upper part – assembly overviewp. 164
+Hydraulic pump installed on the upper part – remove and installp. 165
Removalp. 165
Installationp. 166
Hydraulic pump operating pressure – checkp. 167
+Hydraulic pump operating pressure – checkp. 168
Vehicles with hydraulic pump installed on the lower partp. 168
Vehicles with hydraulic pump installed on the upper partp. 169
Control equipment for power steeringVAG 1402 – connectp. 170
+Electrohydraulic steering – repairp. 171
Electrohydraulic steering box – remove and installp. 171
Electrohydraulic steering boxG250 – remove and installp. 172
+Electrohydraulic steering boxG250 – remove and installp. 173
Removalp. 173
Installationp. 174
Electrohydraulic steering box (JTEKT) – disassemble and assemblep. 175
Electrohydraulic steering box (TRW) – disassemble and assemblep. 176
Steering bar – remove and installp. 177
Left steering bar length – check and adjustp. 178
+Left steering bar length – check and adjustp. 179
Checkp. 179
Correspondence of the steering yoke terminalsp. 180
Central rack position – determinep. 181
+Motor/pump set (Electrohydraulic steering) – repairp. 182
Motor/pump set; (TRW manufacturer) – assembly overviewp. 182
Motor/pump set – remove and installp. 183
+Motor/pump set – remove and installp. 184
Removalp. 184
Motor/pump set pressure (JTEKT / TRW) – checkp. 185
Electrohydraulic steering oil level – checkp. 186
Wheels, rim and tyre specificationsp. 187
+Bodyp. 199
+General body repairs, exteriorp. 199
+Body frontp. 199
+Front panelp. 199
+Toolsp. 199
Special tools, workshop equipment, test and measurement devices, as well as auxiliary means necessaryp. 199
Special tools, workshop equipment, test and measurement devices and auxiliary devices necessaryp. 225
Front panel (? 2006) – Assembly overviewp. 200
Front panel (? 2006) – work positionp. 201
+Front panel (? 2006) – remove and installp. 202
Installp. 202
Front panel (2007 ?) – assembly overviewp. 203
Front panel (2007 ?) – work positionp. 204
+Front panel (2007 ?) – remove and installp. 205
Installp. 205
+Wingp. 206
+Wing – remove and installp. 206
Removep. 206
Installp. 207
+Cover – remove and installp. 208
Removep. 208
Wing dimensions (? 2006) – vehiclesp. 209
Wing dimensions (2007 ?) – vehiclesp. 210
+Lower noise insulation in the engine compartmentp. 211
Lower noise insulation in the engine compartment (petrol / Totalflex engine) – assembly overviewp. 211
Lower noise insulation in the engine compartment (diesel engine) – assembly overviewp. 212
+Engine compartment partition panelp. 213
Toolsp. 213
+Bonnet, flaps, cab, central lockingp. 214
+Bonnetp. 214
Toolsp. 214
+Bonnet – remove and installp. 215
Removep. 215
Installp. 216
+Front bonnet supporting rod (2007 ?) – remove and installp. 217
Removep. 217
Bonnet – adjustp. 218
+Front bonnet latch operating cable – remove and installp. 219
Assembly overviewp. 219
Removep. 220
+Operating lever – remove and installp. 221
Removep. 221
Installp. 222
Front bonnet latch – Assembly overviewp. 223
+Front bonnet latch – remove and installp. 224
Removep. 224
+Rear door – Hatchp. 225
Assembly overviewp. 226
+Rear door lock – remove and installp. 227
Vehicles without central lockingp. 227
Vehicles with central lockingp. 228
Rear door latch cylinder – assembly overviewp. 229
+Rear door latch cylinder – disassemble and assemblep. 230
Disassemblep. 230
Disassemblep. 242
Rear door lock cylinder (central locking) – assembly overviewp. 231
Rear door – Sedanp. 232
+Rear door – Sedanp. 233
Rear door – Assembly overviewp. 233
Cylinder housing of the lock with symbol (without central locking) – remove and installp. 234
Rear door lock (without central locking) – remove and installp. 235
Rear door lock (with central locking) – remove and installp. 236
Cylinder housing of the lock with symbol (with central locking) – remove and installp. 237
Rear door latch activation handle – assembly overviewp. 238
Rear door latch activation handle (without central locking) – remove and installp. 239
Rear door latch activation handle (with central locking) – remove and installp. 240
Rear door latch cylinder – assembly overviewp. 241
+Fuel reservoir nozzle compartment and lid setp. 243
Fuel reservoir nozzle compartment and lid set (hatch) – remove and installp. 243
Fuel reservoir nozzle compartment and lid set (sedan) – remove and installp. 244
+Front door, central lockingp. 245
+Front doorp. 245
Toolsp. 245
Door – remove and installp. 246
+Front door lock operating cable – remove and installp. 247
Removep. 247
Installp. 248
External door handle and lock – assembly overviewp. 249
+Latch cylinder – remove and installp. 250
Removep. 250
+External door handle – remove and installp. 251
Removep. 251
Installp. 252
Installp. 271
+Lock – remove and installp. 253
Removep. 253
Installp. 254
+Lock button (locking rod) – remove and installp. 255
Removep. 255
Front door packings – assembly overviewp. 256
+Internal front door packing – remove and installp. 257
Removep. 257
External front door packing – remove and installp. 258
+External front door packing – remove and installp. 259
Removep. 259
+Central lockingp. 260
Central locking – assembly overviewp. 260
Central locking (sedan) – assembly overviewp. 261
Convenience system command – remove and installp. 262
Key battery with remote command via radio (articulated) – remove and installp. 263
+Key battery with remote command via radio (articulated) – remove and installp. 264
Removep. 264
Installp. 265
Key – synchronizep. 266
+Rear door,sliding door,wing doors,central lockingp. 267
+Rear doorp. 267
Toolsp. 267
+Rear passenger door lock operating cable – remove and installp. 268
Removep. 268
Installp. 269
External door handle and lock – assembly overviewp. 270
+Door latch – remove and installp. 272
Installp. 272
Rear door packings – assembly overviewp. 273
+Internal rear door packing – remove and installp. 274
Removep. 274
External rear door packing – remove and installp. 275
+External rear door packing – remove and installp. 276
Removep. 276
Installp. 277
+Sliding roofp. 278
+Sliding / tilting sunroofp. 278
Operationp. 278
Sliding / tilting roof with glass pane – assembly overviewp. 279
+Sliding / tilting sunroof glass pane – remove and installp. 280
Removalp. 280
Glass pane for sliding / tilting sunroof – height adjustmentp. 281
Cover packing – adjustp. 282
Cover packing – replacep. 283
Air deflector – removep. 284
+Sun protective coating – remove and installp. 285
Removalp. 285
Installationp. 286
Sunroof sliding adjustment E139 – removep. 287
+Draining hoses – cleanp. 288
Front water draining hosesp. 288
Rear water draining hosesp. 289
+Bumperp. 290
+Front bumperp. 290
Toolsp. 290
Front protector (? 06.06) – assembly overviewp. 291
Front protector (? 2006) – remove and installp. 292
Protector support (? 2006) – assembly overviewp. 293
Front protector (2007 ?) – assembly overviewp. 294
+Front protector (2007 ?) – remove and installp. 295
Removep. 295
Front protector additional components (2007 ?)p. 296
Front protector support (2007 ?) – assembly overviewp. 297
Front bumper spoiler – Blue Motion – remove and installp. 298
+Rear bumper – hatchp. 299
Toolsp. 299
Rear protector – assembly overviewp. 300
+Rear protector – remove and installp. 301
Removep. 301
Protector support – assembly overviewp. 302
Rear bumper spoiler – Blue Motion – remove and installp. 303
+Rear bumper – sedanp. 304
Toolsp. 304
Rear bumper protector (sedan) – assembly overviewp. 305
+Rear bumper protector (sedan) – remove and installp. 306
Removep. 306
Rear bumper (sedan) – assembly overviewp. 307
+Glazing/window mechanismp. 308
+Glued glassesp. 308
Toolsp. 308
Windscreen – Assembly overviewp. 309
Lower windscreen covering – remove and installp. 310
+Lower windscreen covering – remove and installp. 311
Removep. 311
Installp. 312
Side glass (hatch) – assembly overviewp. 313
Undamaged side glass (hatch) – removep. 314
Rear door glass (undamaged) – removep. 315
Undamaged rear door glass – removep. 316
+Prepare the new glass without encapsulation for glass assemblyp. 317
Dimensions for the adhesive cord and primer on the upper glass edgep. 317
Dimensions for the adhesive cord and primer on the lower glass edgep. 318
Dimensions for the adhesive cord and primer on the side glass edgep. 319
Rear window (sedan) – assembly overviewp. 320
Undamaged rear window (Sedan) – removep. 321
New rear window (sedan) – prepare a new glass for assemblyp. 322
+Door windowsp. 323
Toolsp. 323
Front door window – assembly overviewp. 324
Front door window – adjustp. 325
+Front subframe – remove and installp. 326
Removep. 326
Installp. 327
+Front and rear door window drive crank – remove and installp. 328
Removep. 328
Rear door window – assembly overviewp. 329
Rear door window – installp. 330
+Rear subframe – remove and installp. 331
Removep. 331
Installp. 332
+Power window drive mechanism motor – remove and installp. 333
Removep. 333
Installp. 334
Assemble the subframe with the power window drive mechanismp. 335
Rear door window (sedan) – assembly overviewp. 336
Fixed rear door window (sedan) – removep. 337
+Exterior equipmentp. 338
+Wheel case protectorp. 338
Front wheel case protector – remove and installp. 338
Rear wheel case protector – remove and installp. 339
+Spoiler on the wheel housing front protector – remove and installp. 340
Removep. 340
+External rear-view mirrorp. 341
Toolsp. 341
External rear-view mirror (with electric command ? 2006) – assembly overviewp. 342
External rear-view mirror (with manual command ? 2006) – assembly overviewp. 343
External rear-view mirror (2007 ?) – assembly overviewp. 344
+Mirror glass (2007 ?) – remove and installp. 345
Removep. 345
+Mirror cover (2007 ?) – remove and installp. 346
Removep. 346
+Cover with direction indicator (2007 ?) – remove and installp. 347
Removep. 347
+External rear-view mirror (2007 ?) – remove and installp. 348
Removep. 348
+Front grillep. 349
Front grille (? 2006) – assembly overviewp. 349
+Front grille (? 2006) – remove and installp. 350
Removep. 350
Front grille (2007 ?) – assembly overviewp. 351
+Front grille (2007 ?) – remove and installp. 352
Removep. 352
Installp. 353
Front grille (2007 ?, GT) – assembly overviewp. 354
+Front grille (2007 ?, GT) – remove and installp. 355
Removep. 355
Installp. 356
Front grille – Blue Motion – assembly overviewp. 357
+Front grille – Blue Motion – remove and installp. 358
Removep. 358
Installp. 359
+Trimsp. 360
Door trims – remove and installp. 360
Rear lid trim (Hatch, 2010?) – replacep. 361
+Rear lid trim (Hatch, 2010?) – replacep. 362
Installp. 362
Rear lid trim (Sedan, 2010?) – replacep. 363
+Rear lid trim (Sedan, 2010?) – replacep. 364
Installp. 364
External longitudinal member lining (front door – GT) – replacep. 365
Measures to position the inscriptions on the rear doorp. 366
+Measures to position the inscriptions on the rear doorp. 367
Inscriptions on rear door ? 2006p. 367
Rear door inscriptions 2007 ?p. 368
Lower longitudinal member trim (Blue Motion) – assembly overviewp. 369
Lower longitudinal member trim (Blue Motion) – remove and installp. 370
+Lower longitudinal member trim (Blue Motion) – remove and installp. 371
Removep. 371
+Spoiler – Hatchp. 372
Rear spoiler (? 07.08)p. 372
+Rear spoiler (? 07.08)p. 373
Spoiler – assembly overviewp. 373
Spoiler – installp. 374
Installation instructionsp. 375
+Rear spoiler (08.08 ?) – assembly overviewp. 376
Assembly overviewp. 376
Rear spoiler ( 08.08 ? ) – removep. 377
Rear spoiler ( 08.08 ? ) – installp. 378
Rear spoiler (Blue Motion)p. 379
+Rear spoiler (Blue Motion)p. 380
Assembly overviewp. 380
+Rear spoiler – Sedanp. 381
Rear spoiler (? 07.07) – remove and installp. 381
+Rear spoiler (? 07.07) – remove and installp. 382
Removep. 382
Rear spoiler (08.07 ?) – remove and installp. 383
+Rear spoiler (08.07 ?) – remove and installp. 384
Removep. 384
+Exclusive components for Blue Motion versionp. 385
Blue Motion – assembly overviewp. 385
+General body repairs, interiorp. 386
+Interior equipmentp. 386
+Internal rearview mirrorp. 386
Internal rear-view mirror with automatic anti-glarep. 386
Internal rear-view mirror (without rain sensor) – remove and installp. 387
+Internal rear-view mirror (with rain sensor) – remove and installp. 388
Assembly overviewp. 388
Removalp. 389
Mirror fastening support (with rain sensor) – installp. 390
+Object compartment, covers and lidsp. 391
+Centre console (upper)p. 391
Assembly overviewp. 391
Installationp. 392
+Centre console (lower)p. 393
Assembly overviewp. 393
Removalp. 394
Installationp. 395
Handle of the emergency brake lever – remove and installp. 396
Objects holderp. 397
+Objects holderp. 398
Assembly overviewp. 398
Tray (upper with cover) – remove and installp. 399
Tray (upper without cover) – remove and installp. 400
Cover – remove and installp. 401
Tray (passenger's side) – remove and installp. 402
Tray (driver's side) – remove and installp. 403
Tray (centre) – remove and installp. 404
+Glove compartmentp. 405
Glove compartment – assembly overviewp. 405
Removalp. 406
Installationp. 407
Central frame of the instrument panel – remove and installp. 408
+Central frame of the instrument panel – remove and installp. 409
Removalp. 409
Installationp. 410
Fastening hook (Sedan) – general assembly overviewp. 411
Sun visorp. 412
+Sun visorp. 413
Assembly overviewp. 413
Installationp. 414
Centre sun visor – remove and installp. 415
Door sill's trimsp. 416
+Door sill's trimsp. 417
Assembly overviewp. 417
+Passenger protectionp. 418
+Safety belts – checkingp. 418
Belt – checkingp. 418
+safety beltsp. 419
+safety belt with pre-tensionerp. 419
Assembly overviewp. 419
Remove and installp. 420
Removalp. 421
Installationp. 422
+Safety belt without pre-tensionerp. 423
Assembly overviewp. 423
Installationp. 424
+Height adjuster – remove and installp. 425
Assembly overviewp. 425
Removalp. 426
Installationp. 427
+Lower fastening point of the front safety belt – remove and installp. 428
Removalp. 428
+Fastening of the front belt – removal and installationp. 429
Removalp. 429
Installationp. 430
+Rear safety beltsp. 431
Rear safety belts (Hatch) – remove and installp. 431
Assembly overviewp. 432
+Assembly overviewp. 433
Removalp. 433
Installationp. 434
Rear safety belts (Sedan) – remove and installp. 435
+Rear safety belts (Sedan) – remove and installp. 436
Assembly overviewp. 436
Removalp. 437
Installationp. 438
+Lower fastening point of the rear belt – removal and installationp. 439
Removalp. 439
Installationp. 440
Central lap belt and double latch – remove and installp. 441
+Central lap belt and double latch – remove and installp. 442
Removalp. 442
Installationp. 443
+Airbagp. 444
Installation locations – assembly overviewp. 444
Trigger 1 for front passenger's airbagN131- remove and installp. 445
Control unit for the airbagJ234 – removal and installationp. 446
+Control unit for the airbagJ234 – removal and installationp. 447
Removalp. 447
Components – adapting/verifyingp. 448
+Components – adapting/verifyingp. 449
Work sequencep. 449
+Trim, noise insulationp. 450
+Instrument panelp. 450
Toolsp. 450
Cross support/Instruments panel – removal and installationp. 451
+Cross support/Instruments panel – removal and installationp. 452
Removalp. 452
Steering column covering – remove and installp. 453
+Door liningp. 454
Driver's side front door lining – remove and installp. 454
+Driver's side front door lining – remove and installp. 455
Removalp. 455
Front passenger's side door lining – remove and installp. 456
+Front passenger's side door lining – remove and installp. 457
Removalp. 457
Rear door lining (Hatch) – remove and installp. 458
+Rear door lining (Hatch) – remove and installp. 459
Removalp. 459
Rear door lining (Sedan) – remove and installp. 460
+Rear door lining (Sedan) – remove and installp. 461
Removalp. 461
+Lining of columns and sidesp. 462
+Upper pillar A lining – remove and installp. 462
Removalp. 462
Lower A pillar lining (right side) – remove and installp. 463
Lower A pillar lining (left side) – remove and installp. 464
B-pillar lining – assembly overviewp. 465
+Lower B pillar lining – remove and installp. 466
Removalp. 466
+Upper B pillar lining – remove and installp. 467
Removalp. 467
+C pillar upper lining (Hatch) – remove and installp. 468
Removalp. 468
+Upper pillar C lining (Sedan) – remove and installp. 469
Removalp. 469
Lower C pillar lining (Hatch) – remove and installp. 470
+Lower C pillar lining (Hatch) – remove and installp. 471
Removalp. 471
C pillar lower lining (Sedan) – remove and installp. 472
+C pillar lower lining (Sedan) – remove and installp. 473
Removep. 473
+Linings of the luggage compartmentp. 474
Luggage compartment cover side lining – assembly overviewp. 474
Luggage compartment cover side lining – remove and installp. 475
+Luggage compartment cover side lining – remove and installp. 476
Removalp. 476
Installationp. 477
Roof liningp. 478
+Roof liningp. 479
Pre-molded roof lining (Hatch) – Assembly overviewp. 479
Pre-molded roof lining (Hatch) – sun visor – Assembly overviewp. 480
+Pre-molded roof lining (Hatch) – sun visor – Assembly overviewp. 481
Removalp. 481
Pre-molded roof lining (Sedan) – remove and installp. 482
+Noise insulationp. 483
Toolsp. 483
Assembly overviewp. 484
+Floor lining – remove and installp. 485
Removalp. 485
+Seat framesp. 486
+Front seatsp. 486
Toolsp. 486
Lower front seat cushion cover (without height adjustment)p. 487
+Lower front seat cushion cover (without height adjustment)p. 488
Assembly overviewp. 488
Removalp. 489
Installationp. 490
Lower front seat cushion cover (with height adjustment)p. 491
+Lower front seat cushion cover (with height adjustment)p. 492
Assembly overviewp. 492
Removalp. 493
Installationp. 494
+Fire extinguisher support – removal and installationp. 495
Removalp. 495
Installationp. 496
Front seat head rest – assembly overviewp. 497
Front seat backing – removal and installationp. 498
+Front seat backing – removal and installationp. 499
Assembly overviewp. 499
Removalp. 500
Installationp. 501
Height adjustment mechanism – remove and installp. 502
+Height adjustment mechanism – remove and installp. 503
Removalp. 503
Installationp. 504
Tray under the front seat – remove and installp. 505
+Tray under the front seat – remove and installp. 506
Assembly overviewp. 506
Removalp. 507
Installationp. 508
+Rear seatsp. 509
+Rear seat back (split) – remove and installp. 509
Removalp. 509
Installationp. 510
(Bench) back seat backrest – remove and installp. 511
+(Bench) back seat backrest – remove and installp. 512
Removalp. 512
Installationp. 513
+Rear seat head rest – removal and installationp. 514
Removalp. 514
Rear seat backrest release button – assembly overviewp. 515
+Rear seat rest unlocking button – removal and installationp. 516
Removalp. 516
+Seat padding, coversp. 517
+Linings, stuffing of front seatsp. 517
Front seat cushion linings and fillings – assembly overviewp. 517
Front seat cushion linings and fillings – remove and installp. 518
+Front seat cushion linings and fillings – remove and installp. 519
Removalp. 519
Lining and stuffing of the front backing – assembly overviewp. 520
Front seat backing lining and stuffing – removal and installationp. 521
+Front seat backing lining and stuffing – removal and installationp. 522
Removalp. 522
+Linings and stuffing of front seatsp. 523
Rear seat cushion lining and filling (bench) – remove and installp. 523
Lining and stuffing of the back seat (one-piece) backing – assembly overviewp. 524
Lining and stuffing of the back seat (one-piece) backing – removal and installationp. 525
+Lining and stuffing of the back seat (one-piece) backing – removal and installationp. 526
Removalp. 526
Lining and stuffing of the back seat (two-piece) backing – assembly overviewp. 527
Lining and stuffing of the back seat (two-piece) backing – removal and installationp. 528
+Lining and stuffing of the back seat (two-piece) backing – removal and installationp. 529
Removalp. 529
Chemicals Manualp. 530
Painting Manualp. 654
Body Repair – General Informationp. 685
+Enginep. 705
+4-cylinder injection enginep. 705
+Engine assy,cylinder block,crankcasep. 706
Removing and installing enginep. 706
Engine – remove and installp. 763
+Engine – remove and installp. 764
+Engine – fix on assembly anvilp. 764
Operation sequencep. 764
+Notes refering to removalp. 845
Continuation for all vehiclesp. 845
+Aggregated insulation bearingsp. 908
Torques:p. 908
Engine – fasten on the assembly standp. 969
Engine – remove and installp. 844
Engine – remove and installp. 907
Engine – remove and installp. 968
+Enginecrankshaft group, pistonsp. 707
+Dismantling and assembling enginep. 707
Part I: Assembly overview – belt drivep. 707
Part II: Assembly overview – cylinder blockp. 708
+Removing and installing sealing flanges and flywheel or drive platep. 709
Assembly overviewp. 709
Renewing crankshaft oil seal – pulley endp. 710
Removing and installing drive platep. 711
Renewing crankshaft sealing flange – flywheel endp. 712
+Renewing crankshaft sealing flange – flywheel endp. 713
A-Assembling sealing flange with sender wheel on assembly appliance T10017p. 713
B-Assembling appliance T10017 with sealing flange on crankshaft flangep. 714
E – Checking sender wheel installation position on crankshaftp. 715
F – Re-pressing sender wheelp. 716
+Dismantling and assembling pistons and conrodsp. 717
Assembly overviewp. 717
+Engine – disassemble and assemblep. 765
+Poly-V belt – remove and installp. 765
Removalp. 765
Poly-V belt trajectory.p. 766
Vehicles without air conditioning compressorp. 767
Vehicles without climatizationp. 910
Vehicles with climatizationp. 911
Removalp. 970
Poly-V belt travelp. 971
Removalp. 974
Poly-V belt routing.p. 975
Vehicles without air conditioner compressor and with hydraulic power steering pump.p. 976
Elastic Poly-V belt routingp. 977
Poly-V pulley – remove and installp. 846
+Poly-V pulley – remove and installp. 847
Vehicles without air conditioning compressorp. 847
Vehicles with air conditioning compressorp. 848
+Semi-automatic tension pulley of indented belt – checkp. 849
Checking sequencep. 849
Poly-V belt – remove and installp. 909
+Crank shaft rear flange – remove and installp. 768
Crank shaft seal pulley side – replacep. 768
+Crank shaft seal pulley side – replacep. 769
Removalp. 769
Installationp. 770
Crank shaft rear flange, driving wheel side – replacep. 771
+Crank shaft rear flange, driving wheel side – replacep. 772
Operation sequencep. 772
A-Install flange with rotor on Assembly tool T10017p. 773
E-Check assembly position of crank shaft rotorp. 774
F- retighten driving wheelp. 775
+Crank shaft – remove and installp. 776
+Identification of engine bearing capsp. 776
Marks of bearing cover capsp. 776
Marks of engine block bearing capsp. 777
+Crankshaft seal and engine steering wheel – remove and installp. 850
Crankshaft seal (pulley side) – replacep. 850
+Crankshaft seal (pulley side) – replacep. 851
Removalp. 851
Removalp. 979
Crankshaft front flange – remove and installp. 852
+Crankshaft front flange – remove and installp. 853
Removalp. 853
Crank shaft – remove and installp. 854
Pistons and rods – disassemble and assemblep. 855
+Pistons and rods – disassemble and assemblep. 856
Piston position on upper part – checkp. 856
+Piston position on upper part – checkp. 857
Checking sequencep. 857
+Crankshaft and engine wheel sealing – remove and installp. 912
Crankshaft sealing, pulley side – replacep. 912
Seal flange on pulley side – assemble and disassemblep. 913
Crankshaft – remove and installp. 914
Pistons and rods – disasemble and assemblep. 915
+Pistons and rods – disasemble and assemblep. 916
Piston position on upper part – checkp. 916
+Engine – assembly and disassemblyp. 972
+Seal lid – replacep. 972
Removalp. 972
Installationp. 973
+Crankshaft and flywheel flanges – remove and installp. 978
Crankshaft seal (pulley side) – replacep. 978
Crankshaft flange (pulley side) – remove and installp. 980
+Crankshaft flange (pulley side) – remove and installp. 981
Removalp. 981
+Engine cylinder head, valve gearp. 718
+Cylinder headp. 718
Assembly overviewp. 718
Checking valve timingp. 719
Removing, installing and tensioning toothed beltp. 720
+Removing, installing and tensioning toothed beltp. 721
Removingp. 721
Checking semi-automatic toothed belt tensioning rollerp. 722
Removing and installing camshaft housingp. 723
Removing and installing cylinder headp. 724
Checking compressionp. 725
+Repairing valve gearp. 726
Assembly overviewp. 726
+Reworking valve seatsp. 727
Reworking inlet valve seatp. 727
Renewing camshaft oil sealp. 728
Checking valve guidesp. 729
Renewing valve stem sealsp. 730
+Head – disassemble and assemblep. 778
Distribution times – checkp. 778
Tension pulley of indented belt – checkp. 779
+Tension pulley of indented belt – checkp. 780
Tension pulley of main indented belt – checkp. 780
Indented belt tension pulley of valves command shaft – checkp. 781
Indented belt – remove and install, adjustp. 782
+Indented belt – remove and install, adjustp. 783
Removalp. 783
Operation sequencep. 784
Removalp. 859
Head cover – remove and installp. 785
+Head cover – remove and installp. 786
Operation sequencep. 786
Installationp. 787
Removalp. 918
Head – remove and installp. 788
+Head – remove and installp. 789
Remove headp. 789
Install headp. 790
Compression – checkp. 791
+Compression – checkp. 792
Operation sequencep. 792
Checking sequencep. 862
Operation sequencep. 988
Operation sequencep. 995
Valve command – repairp. 793
+Valve seats – grindp. 794
Intake valve seat: grindp. 794
Exhaust valve seat: grindp. 795
Valve command shaft seals – replacep. 796
Valve guides – checkp. 797
Checking processp. 798
Valve stem seal – replacep. 799
+Valve stem seal – replacep. 800
Removalp. 800
Installationp. 801
Indented belt – remove and install, adjustp. 858
Head – remove and installp. 860
Compression – checkp. 861
+Valve mechanism – repairp. 863
+Valves – grind seatsp. 863
Grind intake valve seatsp. 863
Grind exhaust system valves seatsp. 864
Valve guides – checkp. 865
+Valve guides – checkp. 866
Checking sequencep. 866
Checking sequencep. 1002
Test sequencep. 1013
Valve stem seals – replacep. 867
+Valve stem seals – replacep. 868
Installationp. 868
Installationp. 925
Installationp. 1004
Valve command shaft – remove and installp. 869
+Head – disassembly and assemblyp. 917
Head cover – remove and installp. 917
Indented belt – remove and install, adjustp. 919
Head – remove and installp. 920
Compression – checkingp. 921
+Valve command unit – repairp. 922
Valves – check guidesp. 922
+Valves – check guidesp. 923
Checking sequencep. 923
Valve stem seals – replacep. 924
Valve command shaft – remove and installp. 926
+Valve command shaft – remove and installp. 927
Removep. 927
Valve command shaft seal – remove and installp. 928
+Engine cylinder head – remove and installp. 982
Timing belt – remove and install, adjustp. 982
+Timing belt – remove and install, adjustp. 983
Removalp. 983
Timing belt semi-automatic tensioning pulley – checkp. 984
+Timing belt semi-automatic tensioning pulley – checkp. 985
Prerequisitep. 985
Engine cylinder head – remove and installp. 986
Compression – checkp. 987
+Cylinder head – assembly and disassemblyp. 989
Toothed belt semi-automatic tensioning roller – checkp. 989
Toothed belt – remove and install, adjustp. 990
+Toothed belt – remove and install, adjustp. 991
Removalp. 991
Tensioner without adjustmentp. 992
Cylinder head – remove and installp. 993
Compression – checkp. 994
+Valve control mechanism – repairp. 996
+Valve seats – reworkp. 996
Grind intake valve seatsp. 996
Grind exhaust valve seatp. 997
Camshaft seal – replacep. 998
+Camshaft seal – replacep. 999
Removalp. 999
Removalp. 1009
Installationp. 1010
Camshaft – remove and installp. 1000
Valve guides – checkp. 1001
Valve stem seals – replacep. 1003
+Camshaft mechanism – repairp. 1005
Camshaft – check axial clearancep. 1005
+Valve seat – trimp. 1006
Grind inlet valve seatp. 1006
Grind exhaust valve seatp. 1007
Camshaft seal – replacep. 1008
Camshaft and cylinder head cover – remove and installp. 1011
Valve guides – checkp. 1012
Valve stem sealant – replacep. 1014
+Valve stem sealant – replacep. 1015
Installationp. 1015
+Engine lubricationp. 731
+Removing and installing parts of lubrication systemp. 731
Assembly overviewp. 731
Removing and installing oil sumpp. 732
Removing and installing oil pumpp. 733
Checking oil pressure and oil pressure switchp. 734
+Lubrication system components – remove and installp. 802
Oil carter – remove and installp. 802
Oil pump – remove and installp. 803
+Oil pump – remove and installp. 804
Removalp. 804
Installationp. 805
Operation sequencep. 806
Removalp. 1020
Oil pressure and oil pressure switch – checkp. 807
+Oil pressure and oil pressure switch – checkp. 808
Test sequencep. 808
Checking sequencep. 931
Carter – remove and installp. 929
Oil pressure and oil pressure switch – checkp. 930
Crankcase – remove and installp. 1016
+Crankcase – remove and installp. 1017
Oil crankcase (upper part)p. 1017
Oil panp. 1018
Oil pump – remove and installp. 1019
Oil pressure and Oil pressure switch F1 – checkp. 1021
+Oil pressure and Oil pressure switch F1 – checkp. 1022
Checking sequencep. 1022
+Lubrication systems components – remove and installp. 870
Carter – remove and installp. 870
Oil pressure switch and oil pressure – checkp. 871
+Oil pressure switch and oil pressure – checkp. 872
Checking sequencep. 872
+Engine coolingp. 735
+Dismantling and assembling parts of cooling systemp. 735
Assembly overview – parts of cooling system – body sidep. 735
Assembly overview – parts of cooling system – engine sidep. 736
Coolant hose schematic diagramp. 737
Draining and filling coolantp. 738
Removing and installing radiatorp. 739
Removing and installing coolant pumpp. 740
+Cooling system components – remove and installp. 809
Cooling system components, body sidep. 809
Cooling system components on engine sidep. 810
+Cooling system components on engine sidep. 811
Water pump sidep. 811
Cooling fluid hose connection diagramp. 812
Cooling fluid – drain and fillp. 813
+Cooling fluid – drain and fillp. 814
Without cooling fluid filling equipment VAS6096p. 814
Radiator – remove and installp. 815
Water pump – remove and installp. 816
+Water pump – remove and installp. 817
Removalp. 817
Installationp. 1029
Body cooling system componentsp. 873
Engine cooling system componentsp. 874
Connection scheme for cooling fluid hosesp. 875
Cooling fluid – drain and refillp. 876
Water pump – remove and installp. 877
Radiator – remove and installp. 878
+Radiator – remove and installp. 879
Removalp. 879
Thermostat valve – remove and installp. 880
Cooling system components on the bodyp. 932
Engine cooling system componentsp. 933
+Connector system of cooling hosesp. 934
Engine ATD identification letterp. 934
Cooling fluid – drain and supplyp. 935
Radiator – remove and installp. 936
Water pump – remove and installp. 937
Thermostat valve – remove and installp. 938
Cooling system hose connection diagramp. 1023
Cooling system – drain and fillp. 1024
+Cooling system – drain and fillp. 1025
Operation sequencep. 1025
Without the Cooling system supply unit VAS 6096p. 1026
Radiator – remove and installp. 1027
Water pump – remove and installp. 1028
Thermostatic valve of the cooling system – remove nd installp. 1030
+Fuel supply, gas operationp. 741
+Removing and installing parts of fuel supply systemp. 741
Assembly overview – fuel tank with attachmentsp. 741
Removing and installing fuel delivery unitp. 742
Removing and installing fuel gauge senderp. 743
Removing and installing fuel tankp. 744
Checking fuel pumpp. 745
Bleeding fuel systemp. 746
+Checking electronic power control (EPC)p. 747
Assembly overviewp. 747
+Active charcoal filter systemp. 748
Assembly overview – parts of active charcoal filter systemp. 748
Checking fuel tank breatherp. 749
+Fuel supply system components – remove and installp. 818
Fuel container with accessory parts and fuel filter – remove and installp. 818
Oil pump – remove and installp. 819
+Fuel level sensor – remove and installp. 820
Removalp. 820
Fuel container – remove and installp. 821
Fuel pump – checkp. 822
Fuel tank with accessories – remove and installp. 881
Fuel filter – repairp. 882
Fuel tank – remove and installp. 883
Fuel pump – remove and installp. 884
+Fuel level meter – remove and installp. 885
Removalp. 885
Removalp. 944
Throttle starting system – repairp. 886
Fuel tank components with accessories and fuel filter – remove and installp. 1040
Cold start system components – remove and installp. 1041
Cold start system componentsp. 1045
Fuel pump (pre-supply pump)G6 – remove and installp. 1046
+Fuel gauge sensorG – remove and installp. 1047
Removalp. 1047
Fuel tank – remove and installp. 1048
Fuel pump (pre-supply pump)G6 – checkp. 1049
Engine power electronic regulation (E-gas electronic throttle) – checkp. 823
+Activated charcoal filter system.p. 824
Activated charcoal filter system components – repairp. 824
Fuel container ventilation – checkingp. 825
+Fuel container ventilation – checkingp. 826
Test sequencep. 826
+Supply system components – remove and installp. 939
Fuel container with accessories – remove and installp. 939
Fuel filter – repairp. 940
Fuel radiator – remove and installp. 941
Fuel container – remove and installp. 942
Fuel pump – remove and installp. 943
Fuel pump – checkp. 945
+Fuel pump – checkp. 946
Check operation and tension supplyp. 946
Throttle starting system – repairp. 947
Tandem pump – checkp. 948
+Tandem pump – checkp. 949
Operation sequencep. 949
Tandem pump – remove and installp. 950
+Tandem pump – remove and installp. 951
Removalp. 951
Fuel tank with assembly parts and fuel filter – remove and installp. 1031
Cold start system components – remove and installp. 1032
+Cold start system components – remove and installp. 1033
Part Ip. 1033
Part IIp. 1034
Part IIIp. 1035
Part Ip. 1042
Part IIp. 1043
Part IIIp. 1044
Fuel pump (pre-supply pump) G6 – remove and installp. 1036
+Fuel level indicator sensor G – remove and installp. 1037
Removalp. 1037
Fuel reservoir – remove and installp. 1038
Fuel pump (pre-supply pump) G6 – checkp. 1039
Engine power electronic adjustment (E-Gas electronic accelerator) components – repair .p. 1050
Engine power electronic adjustment (electronic throttle) – checkp. 1051
+Activated charcoal filter systemp. 1052
Activated charcoal filter components – repairp. 1052
Fuel tank ventilation – checkp. 1053
+Mixture preparation system, electronic inj.,Gasp. 750
+Repairing injection systemp. 750
Assembly overview – parts of injection systemp. 750
Assembly overview – intake manifoldp. 751
Assembly overview – fuel rail with injectorsp. 752
Assembly overview – air cleanerp. 753
+Checking componentsp. 754
Checking injectorsp. 754
+Checking fuel pressure regulator and holding pressurep. 755
Checking fuel pressure regulatorp. 755
+Engine control unitp. 756
Adapting componentsp. 756
Engine control unit fault memory – check and erasep. 958
+Engine control unit fault memory – check and erasep. 959
Operation sequencep. 959
Functions and components – adaptp. 960
+Injection system – repairp. 827
Injection components – remove and installp. 827
Intake collector – remove and installp. 828
Injector-equipped fuel distributor – remove and installp. 829
Air filter – remove and installp. 830
Component locationp. 1060
Injection components – remove and installp. 1061
Intake manifold – remove and installp. 1062
Fuel rail with injectors – remove and installp. 1063
Air filter case – disassemble and assemblep. 1064
+Injection components – checkp. 831
Injectors – checkp. 831
+Injectors – checkp. 832
Checking processp. 832
Fuel pressure regulator and retaining pressure – checkp. 833
Residual pressure and fuel pressure regulator – checkp. 1066
+Engine command unitp. 834
+Engine command unit – remove and installp. 834
Removalp. 834
Removalp. 894
Injection components – adaptp. 835
+Injection components – adaptp. 836
Operation sequencep. 836
Operation sequencep. 1072
Fault memory of engine command unit – consult and deletep. 837
+Fault memory of engine command unit – consult and deletep. 838
Operation sequencep. 838
Engine command unit fault memory – check and erasep. 895
+Engine command unit fault memory – check and erasep. 896
Operation sequencep. 896
Functions and components – adjustp. 897
+Injection – repairp. 1054
Component location – overviewp. 1054
Injection components – remove and installp. 1055
Intake manifold (upper part) – disassemble and assemblep. 1056
Intake manifold (lower part) – disassemble and assemblep. 1057
Fuel distributor with injection valves – remove and installp. 1058
Air filter – disassemble and assemblep. 1059
Injection components – checkp. 1065
+Component checksp. 1067
Injection valves – checkp. 1067
Residual pressure and fuel pressure regulator – checkp. 1068
+Residual pressure and fuel pressure regulator – checkp. 1069
Check fuel pressure regulatorp. 1069
+Engine control unit J623p. 1070
+Engine control unit J623 – remove and installp. 1070
Removalp. 1070
Injection components – adaptp. 1071
Fault memory in the Engine control unit J623 – read and clearp. 1073
+Fault memory in the Engine control unit J623 – read and clearp. 1074
Operation sequencep. 1074
+Exhaust systemp. 757
+Removing and installing parts of exhaust systemp. 757
Assembly overview – exhaust system with attachmentsp. 757
Assembly overview – silencer with mountingsp. 758
+Exhaust gas recirculation systemp. 759
Assembly overviewp. 759
+Removal and installation of exhaust system partsp. 839
Exhaust collector, front tube with catalyst and installation partsp. 839
Muffler with supportsp. 840
+Exhaust system parts – remove and installp. 898
Exhaust system – remove and installp. 898
+Exhaust system – remove and installp. 899
Operations sequencep. 899
+Exhaust gas return systemp. 900
Exhaust return system components – remove and installp. 900
Vacuum hose connectionsp. 901
Check exhaust gas return valvep. 902
+Check exhaust gas return valvep. 903
Checking sequencep. 903
+Exhaust gas return system components – remove and installp. 963
Engine ATD identification letterp. 963
+Exhaust system components – remove and installp. 962
+Exhaust system – alignmentp. 962
Conditionp. 962
Intake manifold, front tube with catalytic converter and assembly parts – overviewp. 1076
Muffler with cushions – assembly overviewp. 1077
Exhaust system components – remove and installp. 1075
+Ignition system, glow plug systemp. 760
+Repairing ignition systemp. 760
Assembly overview – parts of ignition systemp. 760
Safety precautionsp. 761
+Ignition system – repairp. 841
Ignition system components – remove and installp. 841
Safety measuresp. 842
Safety measuresp. 1079
Checking heating plugsp. 1080
+Pre-heating system – checkp. 904
Spark plugs – checkp. 904
+Spark plugs – checkp. 905
Checking sequencep. 905
Pre-heating installation – checkp. 964
+Pre-heating installation – checkp. 965
Glower plugs – checkp. 965
+Glower plugs – checkp. 966
Checking sequencep. 966
+Ignition – repairp. 1078
Safety measuresp. 1078
4 – Cyl. injection engine (4-valve, rolling rockers)p. 762
+4 – Cyl. diesel engine (with distributor injection pump)p. 843
+Fuel preparation system Diesel injectionp. 887
+Direct injection system-Diesel – repairp. 887
Injection pump – repairp. 887
Intake tube – remove and installp. 888
Injection pump – remove and installp. 889
+Injection pump – remove and installp. 890
Installationp. 890
Injectors – remove and installp. 891
Injectors – checkp. 892
Sealing ring on injection regulator cover – replacep. 893
+Diesel direct injection system – repairp. 953
+Admission air tube butterfly – repairp. 953
Engine ATD identification letterp. 953
Pump unit-injector – repairp. 954
Sealing ringsfor pump unit-injector – remove and installp. 955
Pump-injector unit – remove and installp. 956
+Pump-injector unit – remove and installp. 957
Removalp. 957
Engine control unit – remove and installp. 961
+4 – Cyl. diesel engine (with unit injectors)p. 906
+Exhaust turbocharger, G-chargerp. 952
+Over-supply system with turbo-compressorp. 952
+Safety measuresp. 952
ATD engine identification letterp. 952
4 – Cyl. injection enginep. 967
+Vehicle electricsp. 1081
+Electrical systemp. 1081
+Starter-current supply-CCp. 1081
+Batteryp. 1081
+BatteryA – remove and installp. 1081
Remove the BatteryA (Version 1).p. 1081
Remove the BatteryA (Version 2).p. 1082
Remove the BatteryA (Version 3).p. 1083
Remove the BatteryA (Version 4).p. 1084
Remove the BatteryA (Version 5).p. 1085
+BatteryA console – remove and installp. 1086
BatteryA console (version 1) – remove and installp. 1086
BatteryA console (version 2) – remove and installp. 1087
+Starterp. 1088
StarterB – remove and installp. 1088
+StarterB – remove and installp. 1089
StarterB for vehicles with 1.0l, 1.6l and 2.0l engines (ARA, BAH, BPA, CCRA, BBX, CFEA)p. 1089
StarterB for vehicles with 1.4l engines (BBZ, BBY, BKY)p. 1090
StarterB for vehicles with 1.4l engine (BAY)p. 1091
StarterB for vehicles with 1.9l engine (ASY)p. 1092
StarterB – (Manufacturer Valeo) – disassemble and assemblep. 1093
+StarterB – (Manufacturer Valeo) – disassemble and assemblep. 1094
Magnetic switch – remove and installp. 1094
Armature and gearing pinion – remove and installp. 1095
StarterB – (Manufacturer Bosch) – disassemble and assemblep. 1096
+StarterB – (Manufacturer Bosch) – disassemble and assemblep. 1097
Magnetic switch – remove and installp. 1097
Armature – remove and installp. 1098
Gearing pinion (Fastened on planetary shaft) – remove and installp. 1099
Bearing bush – remove and installp. 1100
+Alternatorp. 1101
Generator (Alternator)C for 1.6l (CCRA) engine – assembly overviewp. 1101
+Generator (Alternator)C for 1.6l (CCRA) engine – assembly overviewp. 1102
Generator (Alternator)C for 1.6l (CCRA) engine – remove and installp. 1102
Generator (Alternator)C for 1.0 and 1.6l (ARA, BPA, BAH) engines – assembly overviewp. 1103
+Generator (Alternator)C for 1.0 and 1.6l (ARA, BPA, BAH) engines – assembly overviewp. 1104
Generator (Alternator)C for 1.0 and 1.6l (ARA, BPA, BAH) engines – remove and installp. 1104
Generator (Alternator)C for 1.4 and 1.6l (BBZ, BBY, BKY, BAH) engines – assembly overviewp. 1105
+Generator (Alternator)C for 1.4 and 1.6l (BBZ, BBY, BKY, BAH) engines – assembly overviewp. 1106
Generator (Alternator)C for 1.4 and 1.6l (BBZ, BBY, BKY, BAH) engines – remove and installp. 1106
Generator (Alternator)C for 1.4l (BAY) engine – assembly overviewp. 1107
+Generator (Alternator)C for 1.4l (BAY) engine – assembly overviewp. 1108
Generator (Alternator)C for 1.4l (BAY) engine – remove and installp. 1108
Generator (Alternator)C for 1.9l (ASY) engine – assembly overviewp. 1109
+Generator (Alternator)C for 1.9l (ASY) engine – assembly overviewp. 1110
Generator (Alternator)C for 1.9l (ASY) engine – remove and installp. 1110
Generator (Alternator)C for 2.0l (BBX, CFEA) engines – assembly overviewp. 1111
+Generator (Alternator)C for 2.0l (BBX, CFEA) engines – assembly overviewp. 1112
Generator (Alternator)C for 2.0l (BBX, CFEA) engines – remove and installp. 1112
Generator (Alternator)C – replace Poly-V belt pulleyp. 1113
+Generator (Alternator)C – replace Poly-V belt pulleyp. 1114
Removalp. 1114
Voltage regulatorC1 (Manufacturer Bosch) – disassemble and assemblep. 1115
+Voltage regulatorC1 (Manufacturer Bosch) – disassemble and assemblep. 1116
Disassemblyp. 1116
Voltage regulatorC1 (Manufacturer Valeo) – disassemble and assemblep. 1117
+Voltage regulatorC1 (Manufacturer Valeo) – disassemble and assemblep. 1118
Disassemblyp. 1118
Assemblyp. 1119
+BatteryAp. 1309
+Warning notes and safety normsp. 1309
Safety symbols on the BatteryAp. 1309
+BatteryA – checkp. 1310
Check BatteryA with inspection visor (magic eye)p. 1310
+Checking the charge of the BatteryA.p. 1311
Description of the battery testing device, with printerVAS 5097Ap. 1311
+BatteryA – chargingp. 1312
+Battery chargerVAS 5095Ap. 1312
Description of the Battery chargerVAS 5095Ap. 1312
+Battery chargerVAS 5900p. 1313
Description of the Battery chargerVAS 5900p. 1313
+Battery chargerVAS 5903p. 1314
Description of the Battery chargerVAS 5903p. 1314
+Instruments, GCIp. 1120
+Combined instrumentp. 1120
Locating defects and indicating faultsp. 1120
+Combined instrumentK – remove and installp. 1121
Installationp. 1121
+Combined instrumentK – control light symbolsp. 1122
Version (12/07?)p. 1122
Version (07/06?)p. 1123
Version (? 07/06)p. 1124
+Cigarette lighter and 12V socketp. 1125
Cigarette lighterU1 and 12V socketU5 – general overview of assemblyp. 1125
+Cigarette lighterU1 and 12V socketU5 – remove and installp. 1126
Installationp. 1126
+Windscreen wipe/wash systemp. 1127
+Windscreen wiper systemp. 1127
Windscreen wiper system – assembly overviewp. 1127
+Windscreen wiper blade – remove and installp. 1128
Windscreen wiper bladep. 1128
Windscreen wiper blade – streamlined (version 1)p. 1129
Windscreen wiper blade – streamlined (version 2)p. 1130
Windscreen wiper blade and arm set – remove and installp. 1131
+Windscreen wiper blade and arm set – remove and installp. 1132
Installationp. 1132
+Windscreen wiper mechanism – remove and installp. 1133
Removalp. 1133
Installationp. 1134
+Windscreen wiper blade resting position – adjustp. 1135
Driver's sidep. 1135
Passenger's sidep. 1136
+Rain sensorG213 – remove and installp. 1137
Removalp. 1137
+Rain sensor and sunlight penetration photosensorG397 – remove and installp. 1138
Removalp. 1138
+Windscreen washer systemp. 1139
Reservoir for the windscreen and rear window washer system (version 1) – remove and installp. 1139
+Reservoir for the windscreen and rear window washer system (version 1) – remove and installp. 1140
Removalp. 1140
Reservoir for the windscreen and rear window washer system (version 2) – remove and installp. 1141
+Reservoir for the windscreen and rear window washer system (version 2) – remove and installp. 1142
Removalp. 1142
+Windscreen and rear window washer pumpV59 – remove and installp. 1143
Removalp. 1143
+Windscreen washer system washer jets – replacep. 1144
Removalp. 1144
+Rear window wiper systemp. 1145
Rear window wiper and washer system – assembly overviewp. 1145
+Rear window wiper arm – remove and installp. 1146
Removalp. 1146
Installationp. 1147
+Rear window wiper motorV12 – remove and installp. 1148
Removalp. 1148
Rear window wiper blade resting position – adjustp. 1149
+Rear window wiper blade – remove and installp. 1150
Rear window wiper blade (version 1)p. 1150
Rear window wiper blade (version 2)p. 1151
+Rear window washer systemp. 1152
Rear window washer system – assembly overviewp. 1152
+Rear window washer system washer jet – replacep. 1153
Removalp. 1153
Washer hoses – connecting and disconnectingp. 1315
+Washer hoses – repairp. 1316
Repairing smooth hosesp. 1316
+Lights, lamps, switches outsidep. 1154
+Main headlights (?07/06)p. 1154
Main headlights (?07/06) – general assembly overviewp. 1154
Left headlight beam reach control motor V48 and/or Right headlight beam reach control motorV49 (Manufacturer – automotiv lightip. 1155
+Left headlight beam reach control motor V48 and/or Right headlight beam reach control motorV49 (Manufacturer – automotiv lightip. 1156
Removalp. 1156
Installationp. 1157
+Left headlight beam reach control motor V48 and/or Right headlight beam reach control motorV49 (Manufacturer – Valeo) – removep. 1158
Installationp. 1158
+Mains headlight lamps (?07/06) – replacep. 1159
Left front sidelight lampM1 and/or Right front sidelight lampM3 – replacep. 1159
Left low-beam headlight lampM29 and/or Right low-beam headlight lampM31 – replacep. 1160
Left high-beam headlight lampM30 and/or Right high-beam headlight lampM32 – replacep. 1161
Left front indicator light lampM5 and/or Right front indicator light lampM7 – replacep. 1162
+Main headlights (?07/06) – repair fastening tabsp. 1163
Upper fastening tab – repairp. 1163
Side fastening tab – repairp. 1164
+Main headlights (?06/11)p. 1165
Main headlights (?06/11) – general assembly overviewp. 1165
+Main headlights (?06/11) – remove and installp. 1166
Installationp. 1166
Left headlight beam reach control motor V48 and/or Right headlight beam reach control motorV49 (Manufacturer – Hella) – removep. 1167
+Left headlight beam reach control motor V48 and/or Right headlight beam reach control motorV49 (Manufacturer – Hella) – removep. 1168
Installationp. 1168
+Main headlights "Manufacturer: Hella" (?06/11) – replace the lampp. 1169
Left front sidelight lampM1 and/or Right front sidelight lampM3 – replacep. 1169
Left low-beam headlight lampM29 and/or Right low-beam headlight lampM31 – replacep. 1170
Left high-beam headlight lampM30 and/or Right high-beam headlight lampM32 – replacep. 1171
Left front indicator light lampM5 and/or Right front indicator light lampM7 – replacep. 1172
+Main headlights "Manufacturer: Valeo" (?06/11) – replace the lampp. 1173
Left front sidelight lampM1 and/or Right front sidelight lampM3 – replacep. 1173
Left high-beam headlight lampM30 and/or Right high-beam headlight lampM32 – replacep. 1174
Left front indicator light lampM5 and/or Right front indicator light lampM7 – replacep. 1175
+Main headlights (?06/11) – repair fastening tabsp. 1176
Upper fastening tab – repairp. 1176
Side fastening tab – repairp. 1177
Lower fastening tab – repairp. 1178
+Main headlights (07/11?)p. 1179
Main headlights (07/11?) – general assembly overviewp. 1179
+Main headlights (07/11?) – remove and installp. 1180
Installationp. 1180
+Main headlights (07/11?) – replace lampp. 1181
Left front sidelight lampM1 and/or Right front sidelight lampM3 – replacep. 1181
Left low-beam headlight lampM29 and/or Right low-beam headlight lampM31 – replacep. 1182
Left high-beam headlight lampM30 and/or Right high-beam headlight lampM32 – replacep. 1183
Left front indicator light lampM5 and/or Right front indicator light lampM7 – replacep. 1184
+Main headlights (07/11?) – repair fastening tabsp. 1185
Upper fastening tab – repairp. 1185
Side fastening tab – repairp. 1186
Lower fastening tab – repairp. 1187
+Fog lights (?07/06)p. 1188
+Fog lights – remove and installp. 1188
Installationp. 1188
Installationp. 1190
Installationp. 1192
+Left fog light lampL22 and/or Right fog light lampL23 – replacep. 1189
Removalp. 1189
+Fog headlights (?06/11)p. 1190
+Left fog light lampL22 andRight fog light lampL23 – replacep. 1191
Removalp. 1191
Removalp. 1193
Fog lights (07/11?)p. 1192
Headlights – check adjustmentp. 1194
+Turn signal repeater lightsp. 1195
+Turn signal repeater lights – remove and installp. 1195
Installationp. 1195
+Taillights (?07/06)p. 1196
Tail lights (Hatch) – assembly overviewp. 1196
+Tail lights (Hatch) – assembly overviewp. 1197
Tail light lamp support (Hatch) – disassemble and assemblep. 1197
Tail light lamp support (Hatch) – disassemble and assemblep. 1201
Tail lights (Sedan) – assembly overviewp. 1198
+Tail lights (Sedan) – assembly overviewp. 1199
Tail light lamp support (Sedan) – disassemble and assemblep. 1199
Side tail light lamp support – disassemble and assemblep. 1203
+Taillights (08/06?)p. 1200
Tail lights (Hatch) – assembly overviewp. 1200
Tail lights (Sedan) – assembly overviewp. 1202
+Number plate lightp. 1204
Number plate lightX (Hatch) – replace the lampp. 1204
Number plate light (Sedan) – remove and installp. 1205
+Additional brake lightp. 1206
+Additional brake light (Hatch)p. 1206
Additional brake light (version 1) – remove and installp. 1206
Additional brake light lamp support (version 1) – remove and installp. 1207
Additional brake light (version 3) – remove and installp. 1208
+Additional brake light (Sedan)p. 1209
Additional brake light (Sedan) – remove and installp. 1209
+Light switches on the instrument panelp. 1210
+Light switchE1 – remove and installp. 1210
Removalp. 1210
Installationp. 1211
+Headlight reach adjustment controlE102 and/or Instrument switch and lighting adjustmentE20 – remove and installp. 1212
Removalp. 1212
+Switch setp. 1213
+Indicator and wiper/washer switches – remove and installp. 1213
Removalp. 1213
Installationp. 1214
+Ignition/starter switch and key cylinderp. 1215
+Ignition switchD – remove and installp. 1215
Removalp. 1215
+Auxiliary parking systemp. 1216
Auxiliary parking system – assembly general viewp. 1216
+Control unit for Park Assist steeringJ446 (Hatch) – remove and installp. 1217
Removalp. 1217
+Warning buzzer for rear Park Assist steeringH15 (Hatch) – remove and installp. 1218
Removalp. 1218
+Control unit for Park Assist steeringJ446 (Sedan) – remove and installp. 1219
Removalp. 1219
+Warning buzzer for rear Park Assist steeringH15 (Sedan) – remove and installp. 1220
Removalp. 1220
+Park Assist steering sensor – remove and installp. 1221
Removalp. 1221
+Lights, lamps, switches inside, anti-theft systemp. 1222
+Lights and internal switchesp. 1222
+Interior monitoring deactivation switchE267 (version 2) – remove and installp. 1222
Removalp. 1222
+Lights and switches in the engine compartmentp. 1223
+Contact switch for bonnetF266 – remove and installp. 1223
Removalp. 1223
+Switched on the instrument panelp. 1224
Dashboard switches – remove and installp. 1224
+Front door lights and switchesp. 1225
+Front and rear window drive switches – remove and installp. 1225
Removalp. 1225
+Right front window drive switchE41 – remove and installp. 1226
Removalp. 1226
+Rearview mirror adjustment switchE43 with switch for rearview mirror adjustmentE48 – remove and installp. 1227
Removalp. 1227
+Rear door lights and switchesp. 1228
+Power window drive switch on left rear doorE52 and/or Power window drive switch on right rear doorE54 – remove and installp. 1228
Removalp. 1228
+Lights and switches in luggage compartmentp. 1229
+Luggage compartment lighting – remove and installp. 1229
Removalp. 1229
Luggage Compartment lighting fixtureW3 – replacep. 1230
+Roof lining lights and switchesp. 1231
+Internal front lightW1p. 1231
Internal front lightW1 – remove and installp. 1231
+Front internal lightW1 with reading lightp. 1232
Sunroof sliding adjustmentE139 – remove and installp. 1232
+Make-up mirror lighting – remove and installp. 1233
Make-up mirror lighting lampL31 – replacep. 1233
+Hornsp. 1234
+Treble tone hornH2 – remove and installp. 1234
Removalp. 1234
+Treble tone hornH2 and Bass tone hornH7 – remove and installp. 1235
Removalp. 1235
Installationp. 1236
+Immobilizerp. 1237
Ignition key – adapt to immobilizerp. 1237
+Alarm Systemp. 1238
Ultra-sound sensor for alarm systemG209 – remove and installp. 1238
+Ultra-sound sensor for alarm systemG209 – remove and installp. 1239
On vehicles without sunroofp. 1239
On vehicles with sunroofp. 1240
+Alarm system hornH8 – remove and installp. 1241
Removalp. 1241
Installationp. 1242
+Wiringp. 1243
+Fuse holderp. 1243
+Instrument panel fuse holder – remove and installp. 1243
Installationp. 1243
+Fuse boxp. 1244
+Fuse box – remove and installp. 1244
Main fuse holder (Version 1) – remove and installp. 1244
Main fuse holder (version 2) – remove and installp. 1245
Main fuse holder (versions 3 and 4) – remove and installp. 1246
Main fuse holder (version 5) – remove and installp. 1247
+Relay carrierp. 1248
Relay carrier – remove and installp. 1248
+Power distributorp. 1249
Power distributor – disassemble and assemblep. 1249
Coupling stations and multi-pin connectorp. 1250
+Coupling stations and multi-pin connectorp. 1251
Coupling station – A pillarp. 1251
Coupling station – B pillarp. 1252
+Multi-pin connector in the fire wallp. 1253
Removing and installing the multi-pin connector on the engine side (version 1)p. 1253
Removing and installing the multi-pin connector on the engine side (version 2)p. 1254
+Control unitsp. 1255
+Control unit for the on-board electrical systemJ519p. 1255
Control unit for the on-board electrical systemJ519 – remove and installp. 1255
Control unit for the on-board electrical systemJ519 – replacep. 1256
+Interactive System control unitJ879p. 1257
Interactive system control unitJ879 – General assembly overviewp. 1257
+Control unit of lights with windscreen wiper functionsJ917p. 1258
Control unit of lights with windscreen wiper functionsJ917 – Assembly overviewp. 1258
Control unit of lights with windscreen wiper functionsJ917 – remove and installp. 1259
+Harness and connection repairsp. 1317
+Harness repair kitsp. 1317
Complementary setVAS 1978/50p. 1317
Harness repair setVAS 1978Ap. 1318
+Description of toolsp. 1319
Cleaving pliers VAS 1978/1p. 1319
Assembly tool for simple cable liningsp. 1320
Pliers for stripping cablesVAS 1978/3p. 1321
+Harness repairp. 1322
Repairing CAB-Bus system cablesp. 1322
Interruption in cables with a repaired section.p. 1323
Interruption in cables with two repaired sections.p. 1324
+Repairing connector terminals and connectorsp. 1325
Repairing connector terminalsp. 1325
+Unlocking and disassembling the terminalsp. 1326
Secondary lockingp. 1326
+Communicationp. 1260
+Infotainmentp. 1260
+Communication Systemsp. 1260
Troubleshootingp. 1260
+Radio Rp. 1261
RadioR"ALPHA" ? 12/04p. 1261
+RadioR"ALPHA" ? 12/04p. 1262
RadioR"ALPHA" – Assembly overviewp. 1262
RadioR"ALPHA" – remove and installp. 1263
RadioR"ALPHA" – connector pinoutp. 1264
RadioR"BETA" ? 12/04p. 1265
+RadioR"BETA" ? 12/04p. 1266
RadioR"BETA" – Assembly overviewp. 1266
RadioR"BETA" – remove and installp. 1267
RadioR"BETA" – connector pinoutp. 1268
RadioR"GAMMA" ? 12/04p. 1269
+RadioR"GAMMA" ? 12/04p. 1270
RadioR"GAMMA" – Assembly overviewp. 1270
RadioR"GAMMA" – remove and installp. 1271
RadioR"GAMMA" – connector pinoutp. 1272
RadioR"BETA" and "GAMMA" – adaptp. 1273
+"CD player"R89p. 1274
"CD player"R89"MP3" – 08/06 ?p. 1274
+"CD player"R89"MP3" – 08/06 ?p. 1275
"CD player"R89"MP3" – assembly overviewp. 1275
"CD player"R89"MP3" – remove and installp. 1276
"CD player"R89"MP3" – connector pinoutp. 1277
"CD player"R89"MP3" – adaptp. 1278
"CD player"R89"Clarion MP3" – 08/06 ?p. 1279
+"CD player"R89"Clarion MP3" – 08/06 ?p. 1280
"CD player"R89"Clarion MP3" – assembly overviewp. 1280
"CD player"R89"Clarion MP3" – remove and installp. 1281
"CD player"R89"Clarion MP3" – connector pinoutp. 1282
"CD player"R89"RCD 200" – 08/06 ?p. 1283
+"CD player"R89"RCD 200" – 08/06 ?p. 1284
"CD player"R89"RCD 200" – assembly overviewp. 1284
"CD player"R89"RCD 200" – remove and installp. 1285
"CD player"R89"RCD 200" – connector pinoutp. 1286
"CD player"R89"RCD 200" – adaptp. 1287
"CD player"R89"2 Din Clarion" – ? 12/07p. 1288
+"CD player"R89"2 Din Clarion" – ? 12/07p. 1289
"CD player"R89"2 Din Clarion" – general overview of assemblyp. 1289
"CD player"R89"2 Din Clarion" – remove and installp. 1290
"CD player"R89"2 Din Clarion" – occupation of connectorsp. 1291
"CD player"R89 "2 Din MID" – 02/08?p. 1292
+"CD player"R89 "2 Din MID" – 02/08?p. 1293
"CD player"R89"2 Din MID" – general overview of assemblyp. 1293
CD playerR89"2 Din MID" – remove and installp. 1294
CD playerR89"2 Din MID" – connector pinoutp. 1295
"CD player"R89"Concept" – 03/08 ?p. 1296
+"CD player"R89"Concept" – 03/08 ?p. 1297
"CD player"R89"Concept" – assembly overviewp. 1297
"CD player"R89"Concept" – remove and installp. 1298
"CD player"R89"Concept" – connector pinoutp. 1299
+Speakersp. 1300
+Left front treble speakerR20 and/or Right front treble speakerR22 – replacep. 1300
Removalp. 1300
+Multifunction steering wheelp. 1301
Multifunction steering wheel – general informationp. 1301
Multifunction steering wheel – general assembly overviewp. 1302
+Command keys – remove and installp. 1303
Removalp. 1303
+Antenna systemp. 1304
AntennaR11 – remove and installp. 1304
+AntennaR11 – remove and installp. 1305
Removalp. 1305
Installationp. 1306
Antenna cable – general overview of assemblyp. 1307
+Antenna cable – remove and installp. 1308
Removalp. 1308
Electrical system – General informationp. 1309
+Power transmissionp. 1327
+4 – Speed automatic gearbox 001p. 1327
+Torque converterp. 1336
Identification of the torque converterp. 1336
Distinctive letters for the torque converterp. 1337
Torque converter: emptyp. 1338
+Retainer of the torque converter: disassemble and assemblep. 1339
Special tools, workshop equipment, checking and measurement equipment, as well as auxiliary devices necessaryp. 1339
Disassemble the retainer from the torque converterp. 1340
Fit the retainer from the torque converter to the levelp. 1341
Torque converter: assemblep. 1342
+Automatic gearbox, control, assembly, housingp. 1343
+Electric and electronic components and their locationp. 1343
Components in the vehiclep. 1343
Gear componentsp. 1344
+Transmission activation mechanismp. 1345
Transmission activation mechanism: checkp. 1345
Transmission activation mechanism: disassemble and assemblep. 1346
+Electromagnet for blocking the selector lever -N110-: disassemble and assemblep. 1347
Disassemblyp. 1347
+Selector lever cable: disassemble and assemblep. 1348
Disassemblyp. 1348
Assemblyp. 1349
Selector lever: disassemble and assemblep. 1350
+Blocking cable: disassemble and assemblep. 1351
Disassemblyp. 1351
Assemblyp. 1352
Gearbox: disassemble and assemblep. 1353
+Gearbox: disassemble and assemblep. 1354
Transmission disassemblyp. 1354
ATF level: check and addp. 1355
Gearbox with command elementsp. 1356
+Automatic gearbox, gears, controlp. 1357
ATF pump: disassemble and assemblep. 1357
Idler pinion: disassemble and assemblep. 1358
1st to 3rd gear clutch -K1-: disassemble and assemblep. 1359
Reverse clutch -K2-: disassemble and assemblep. 1360
3rd and 4th gear clutch -K3-: disassemble and assemblep. 1361
Reverse brake -B1-: disassemble and assemblep. 1362
Plungers for the 2nd and 4th -B2- brake: disassemble and assemblep. 1363
Parking blocking: disassemble and assemblep. 1364
+Final drive, differential, differential lockp. 1365
Flanged axle retainers: replacep. 1365
+Flanged axle retainers: replacep. 1366
Left flanged axle: disassemble and assemblep. 1366
Right flanged axle: disassemble and assemblep. 1367
+Final group: disassemble and assemblep. 1368
Final group repair boardp. 1368
Differential: disassemble and assemblep. 1369
Drive pinion shaft: disassemble and assemblep. 1370
+Final group: adjustp. 1371
General view of the adjustment worksp. 1371
Differential: adjustp. 1372
Drive pinion shaft: adjustp. 1373
+Retainer for the propelling flange – replacep. 1424
Left propelling flange retainer – replacep. 1424
+Left propelling flange retainer – replacep. 1425
Removalp. 1425
Installationp. 1426
Right propelling flange retainer – replacep. 1427
+Right propelling flange retainer – replacep. 1428
Removalp. 1428
Installationp. 1429
+Differential – repairp. 1430
Differential – disassemble and assemblep. 1430
Differential – adjustp. 1431
Oil seals for flanged shafts – renewp. 1570
+Oil seals for flanged shafts – renewp. 1571
+Oil seal for left flanged shaft – renewp. 1571
Removep. 1571
Installp. 1572
Oil seal for right flanged shaft – renewp. 1573
+Oil seal for right flanged shaft – renewp. 1574
Removep. 1574
Installp. 1575
Differential – dismantle and assemblep. 1576
+Differential – dismantle and assemblep. 1577
Installp. 1577
Differential – adjustp. 1578
+5 – Speed manual gearbox 02Tp. 1374
+Clutch, controlp. 1378
Clutch operating mechanism – repairp. 1378
+Clutch operating mechanism – repairp. 1379
I – Command pedals – assembly overviewp. 1379
+Clutch pedal switch F36 with round case – remove and installp. 1380
Install and adjustp. 1380
Clutch pedal return spring – remove and installp. 1381
+Clutch pedal return spring – remove and installp. 1382
Removalp. 1382
Installationp. 1383
Clutch pedal support – remove and installp. 1384
+Clutch pedal support – remove and installp. 1385
Installationp. 1385
Clutch pedal – remove installp. 1386
+Clutch pedal – remove installp. 1387
Removalp. 1387
Installationp. 1388
II – Hydraulic system – assembly overviewp. 1389
Transmitting cylinder – clutch hydraulic drive – remove and installp. 1390
+Transmitting cylinder – clutch hydraulic drive – remove and installp. 1391
Installationp. 1391
Clutch hydraulic drive slave cylinder – remove and installp. 1392
Clutch system – bleedp. 1393
Clutch – repairp. 1394
Control system – servicep. 1527
+Control system – servicep. 1528
Pedal cluster – assembly overviewp. 1528
Over-centre spring – remove and installp. 1529
+Over-centre spring – remove and installp. 1530
Removep. 1530
Installp. 1531
Clutch pedal – remove and installp. 1532
+Clutch pedal – remove and installp. 1533
Removep. 1533
Installp. 1534
Hydraulic system – assembly overviewp. 1535
Master cylinder – remove and installp. 1536
+Master cylinder – remove and installp. 1537
Removep. 1537
Installp. 1538
Slave cylinder – remove and installp. 1539
+Slave cylinder – remove and installp. 1540
Removep. 1540
Installp. 1541
Clutch system – bleedp. 1542
Cutch release mechanism – servicep. 1543
Clutch – servicep. 1544
+Gearbox mechanics,operation, construction,diff.p. 1395
+Shift mechanismp. 1395
Shift mechanism – installation positionp. 1395
I – Handle and bellows on the gearshift lever – remove and installp. 1396
Handle and bellows on the gearshift lever – remove and installp. 1397
+Handle and bellows on the gearshift lever – remove and installp. 1398
Removalp. 1398
Installationp. 1399
+Handle and bellows on the gearshift lever – disassemble and assemblep. 1400
Disassemblyp. 1400
Gear selection mechanism – adjustp. 1401
+Gear selection mechanism – adjustp. 1402
Gear selection mechanism – adjustp. 1402
Gear selection mechanism – check operationp. 1403
Transmission – remove and installp. 1404
+Transmission – remove and installp. 1405
+Removalp. 1405
Transmission transportp. 1405
Installationp. 1406
+Installationp. 1407
Tightening torquesp. 1407
Transmission oil level – check and replenishp. 1408
+Transmission oil level – check and replenishp. 1409
Oil level – checkp. 1409
Oil level – replenishp. 1410
Transmission – disassemble and assemblep. 1411
+Transmission – disassemble and assemblep. 1412
Transmission – assembly overviewp. 1412
I – Gearbox case cover and 5th gearp. 1413
II – Clutch casep. 1414
III – Primary shaft, pinion shaft, differential, selection mechanism and selection forksp. 1415
Primary shaft, pinion shaft, differential, selection mechanism and selection forks – disassemble and assemblep. 1416
+Primary shaft, pinion shaft, differential, selection mechanism and selection forks – disassemble and assemblep. 1417
Disassemblyp. 1417
Assemblyp. 1418
Transmission and clutch cases – repairp. 1419
Gear selection mechanism – disassemble and assemblep. 1420
Selection forks – disassemble and assemblep. 1421
+Gear selector mechanism – servicep. 1545
Gear selector mechanism – installation positionp. 1545
Selector lever knob and gaiter – remove and installp. 1546
+Flexible shafts – remove and installp. 1547
Installation position of gearbox selector lever/inversion leverp. 1547
+Gear selector mechanism – remove and installp. 1548
Removep. 1548
Gear selector mechanism – adjustp. 1549
+Gear selector mechanism – adjustp. 1550
Functional checkp. 1550
Gearbox – remove and installp. 1551
+Gearbox – remove and installp. 1552
Removep. 1552
Installp. 1553
Tightening torquep. 1554
Gearbox oil – checkp. 1555
+Gearbox – dismantle and assemblep. 1556
Assembly overviewp. 1556
Gearbox body cover and 5th gear – remove and installp. 1557
Gearbox body and selector mechanism – remove and installp. 1558
Input shaft, output shaft (pinion shaft), differential and selector forks – remove and installp. 1559
Assembly sequencep. 1560
+Assembly sequencep. 1561
Dismantlep. 1561
Gearbox housing and clutch housing – servicep. 1562
Gearbox selector mechanism – dismantle and assemblep. 1563
Selector forks – dismantle and assemblep. 1564
+Gearbox,mechanics,gears,shafts,internal operationp. 1422
Primary shaft – disassemble and assemblep. 1422
Pinion shaft – disassemble and assemblep. 1423
Input shaft – dismantle and assemblep. 1565
Input shaft – adjustp. 1566
Output shaft – dismantle and assemblep. 1567
Output shaft – adjustp. 1568
Reverse shaft – dismantle and assemblep. 1569
+Heating, ventilation, air conditioningp. 1432
+Heating, air conditioningp. 1432
+Heatingp. 1432
+Heating – passenger compartment componentsp. 1432
Heat exchanger/engine compartment partition panel sealingp. 1432
+Natural air fanV2p. 1433
Fresh air fanV2 (version 1) – remove and installp. 1433
Fresh air fanV2 (version 2) – remove and installp. 1434
Natural air fanV2 – checkp. 1435
+Fresh air fan pre-resistance with overheating fuseN24 (version 1) – remove and installp. 1436
Removalp. 1436
+Fresh air fan pre-resistance with overheating fuseN24 (version 2) – remove and installp. 1437
Removalp. 1437
Installationp. 1438
+Dust and pollen filter – remove and installp. 1439
Removalp. 1439
Air baffles (central) – remove and installp. 1440
+Footwell vent – remove and installp. 1441
Feet air duct (left rear and right rear) – remove and installp. 1441
Demister nozzle – remove and installp. 1442
+Exhaust valve – remove and installp. 1443
Exhaust valve (Hatch) – remove and installp. 1443
+Ventilation adjustment mechanismp. 1444
Ventilation adjustment mechanism – remove and installp. 1444
+Command cable – remove and installp. 1445
Removalp. 1445
+Plenum chamber (ventilation and heating) – remove and installp. 1446
Plenum chamber (Behr) – remove and installp. 1446
Plenum chamber (heating) – disassemble and assemblep. 1447
+Plenum chamber (heating) – disassemble and assemblep. 1448
+Air distribution drive mechanism (Behr box) – remove and installp. 1448
Removalp. 1448
Installationp. 1449
+Temperature adjustment mechanism (Behr box) – remove and installp. 1450
Removalp. 1450
+Control motor for natural air valve and recirculation valveV154 (Behr box) – remove and installp. 1451
Removalp. 1451
+Auxiliary heating resistanceZ35 (Behr box) – remove and installp. 1452
Removalp. 1452
Installationp. 1453
+Additional heating resistanceZ35p. 1454
Additional heating resistanceZ35 – checkp. 1454
+Air conditionerp. 1455
+Ventilation adjustment mechanism (heating and air conditioning).p. 1455
Ventilation / air conditioning adjustment mechanism power connectorsp. 1455
Ventilation / air conditioning adjustment mechanism power connectors (Climatic)p. 1456
Ventilation / air conditioning adjustment mechanism power connectors (Climatronic)p. 1457
+Air conditioning with manual adjustment/Climaticp. 1458
Seals of the engine compartment partition panelp. 1458
+Air conditioning adjustment mechanism – remove and installp. 1459
Removalp. 1459
Installationp. 1460
Plenum chamber (heating and air conditioning/Climatic) – disassemble and assemblep. 1461
+Plenum chamber (heating and air conditioning/Climatic) – disassemble and assemblep. 1462
Plenum chamber (heating and air conditioning/Climatic) – remove and installp. 1462
+Control motor for temperature adjustment valveV68 – remove and installp. 1463
Removalp. 1463
Evaporator (version 1) – remove and installp. 1464
+Evaporator (version 1) – remove and installp. 1465
Removalp. 1465
+Evaporator (version 2) – remove and installp. 1466
Removalp. 1466
+Air conditioning with automatic adjustment, (Climatronic)p. 1467
Air conditioning command and indicator unit / ClimatronicE87 with Climatronic control unitJ255 – Functionsp. 1467
+Air conditioning command and indicator unit / ClimatronicE87 with the Climatronic control unitJ255 – remove and installp. 1468
Removalp. 1468
Installationp. 1469
+Air outlet temperature sensor for the feet regionG192 – remove and installp. 1470
Removalp. 1470
+Air outlet temperature sensor for the central baffleG191 – remove and installp. 1471
Removalp. 1471
+Air outlet temperature sensor for the evaporatorG263 – remove and installp. 1472
Removalp. 1472
Sun radiation photo sensorG107 – remove and installp. 1473
+Sun radiation photo sensorG107 – remove and installp. 1474
Removalp. 1474
+Fresh air aspiration duct temperature sensorG89 – remove and installp. 1475
Removalp. 1475
Plenum chamber (heating and air conditioning/Climatronic) – disassemble and assemblep. 1476
+Plenum chamber (heating and air conditioning/Climatronic) – disassemble and assemblep. 1477
Plenum chamber (Climatronic heating and air conditioning) – remove and installp. 1477
+Air conditioning adjustment and control unitJ127 – remove and installp. 1478
Removalp. 1478
+Central valve control motorV70 – remove and installp. 1479
Removalp. 1479
Installationp. 1480
+Defrosting valve control motorV107 and Control motor for temperature adjustment valveV68 – remove and installp. 1481
Removalp. 1481
Installationp. 1482
Create the adaptation cable for the activation of the adjusting motorsp. 1483
+Control motor for natural air valve and recirculation valveV154 (version 1) – remove and installp. 1484
Removalp. 1484
+Control motor for natural air valve and recirculation valveV154 (version 2) – remove and installp. 1485
Removalp. 1485
Air conditioner compressor supportp. 1486
+Air conditioner compressor supportp. 1487
Air conditioning compressor support for engines 1.0L (ARA), 1.4L (BBY, BKY) and 1.6L (BAH) – remove and installp. 1487
+Refrigerant circuit – assembly overviewp. 1488
+Air conditioning magnetic couplingN25 manufacturer Delphi (model 1) – repairp. 1488
Electromagnetic clutch for Delphi compressor (model 1) – remove and installp. 1488
Electromagnetic clutch for Delphi compressor (model 2) – remove and installp. 1489
+Electromagnetic clutch for Delphi compressor (model 2) – remove and installp. 1490
Removalp. 1490
+Compressor – remove and installp. 1491
Installationp. 1491
Pressure relief valve in the compressor – checkp. 1492
High pressure sensorG65 – remove and installp. 1493
Expansion valve – remove and installp. 1494
+Expansion valve – remove and installp. 1495
Installationp. 1495
Quick-release coupling – remove and installp. 1496
+Quick-release coupling – remove and installp. 1497
Removing the quick-release coupling componentsp. 1497
Installing the quick-release coupling componentsp. 1498
Quick-release coupling installationp. 1499
Air conditioning with refrigerant R134ap. 1500
+Clutch and gearboxp. 1523
5-speed manual gearbox 02Rp. 1523
Braking Mechanics, Anti-Lock Systems & Hydraulic Service
The braking section of the Volkswagen Polo Mk4 Workshop Repair Manual Compilation details complete mechanical and hydraulic procedures across standard and anti-lock configurations. Technicians can identify specific brake assemblies using factory PR numbers decoded directly from the vehicle identification plate (such as 1KB for rear drum systems and 1LQ for front disc assemblies). Step-by-step instructions cover brake pad and caliper servicing for FS II, FS III, and C54-FN 3 front disc systems, as well as caliper piston overhaul utilizing specialist press tools 3409 and 3272.
Advanced hydraulic control coverage encompasses the ABS MK 60, Bosch 5.7, and post-2005 Bosch 8.0 systems with integrated ABS, EDL, ASR, and ESP functionalities. The guide provides line connection layouts between the tandem master cylinder, brake servo, and hydraulic pump block, accompanied by terminal pinouts and wiring repair instructions for wheel speed sensors using repair kit VAS 1978. Bleeding routines are fully detailed for conventional pressure flushing with VAS 5234 as well as secondary hydraulic circuit bleeding required when master cylinder reservoirs have been completely drained.
Running Gear, Suspension Struts & Electrohydraulic Steering
Chassis maintenance is thoroughly documented, focusing on front subframe console bush renewal—a notorious wear point on the Polo 9N platform. The manual illustrates the exact usage of hydraulic press tools (3062, 3253, 3346, and T40023) to extract and seat console metal-rubber bearings on the vehicle without full axle dismantling. Additional suspension repair instructions cover swivel guide ball joint inspection and removal using separator 3287 A, transversal wishbone re-bushing, coil spring replacement, and front wheel hub bearing installation across 13-inch, 14-inch, and 15-inch running gear configurations.
Steering system servicing includes both mechanical rack repairs and modern electrohydraulic power-assisted steering systems manufactured by TRW and JTEKT. Technicians have direct access to procedures for testing hydraulic pump delivery pressures using test equipment VAG 1402, checking fluid reservoirs, inspecting the steering angle sender G250, and resetting central rack positions to guarantee straight-line tracking and correct dynamic stability calibration.
Engine Mechanical, Fuel Injection & Powertrain Systems
Powertrain coverage in this Polo Mk4 workshop repair manual addresses petrol multi-point injection engines alongside rugged Volkswagen diesel units. Detailed sections outline timing belt replacement, tensioning roller adjustment, and valve timing verification for 4-cylinder 16-valve engines fitted with roller cam followers, complete with crankshaft oil seal renewal on the flywheel side using assembly appliance T10017. Lubrication and cooling circuits are fully mapped, including oil pan resealing, oil pump chain drive assembly, and water pump extraction.
For diesel applications, the documentation covers both naturally aspirated SDI engines (engine code ASY) with mechanical distributor injection pumps and turbocharged TDI engines (engine code ATD) equipped with high-pressure Unit Injectors (Pumpe-Düse). Critical procedures cover tandem fuel/vacuum pump pressure testing, unit injector seal renewal, valve lash rocker adjustments, glow plug testing, and exhaust gas recirculation (EGR) valve diagnostic sequences.
IMAGES PREVIEW
Vehicle Electrical Infrastructure & Body Repair
The electrical section guides the technician through starter motor teardown and overhaul for both Bosch and Valeo units, detailing solenoid switch replacement, armature testing, and planetary gearing inspection. Alternator diagnostics include poly-V belt pulley removal and voltage regulator replacement. Furthermore, the guide covers instrument cluster warning lamp symbology, rain and light sensor calibration (G213/G397), and wiper linkage servicing.
Bodywork procedures encompass both exterior structural panels and interior appointments. From windscreen and fixed quarter glass replacement using defined adhesive primer bead dimensions to door lock mechanism overhauls, dashboard cross-member dismantling, and airbag module servicing (N131 passenger inflator and J234 control unit), the manual ensures factory-standard fit and finish.
Professional Capability & Instant PDF Delivery
Investing in the Volkswagen Polo Mk4 Workshop Repair Manual Compilation gives you workshop-level capability to tackle intricate electrical troubleshooting, suspension rebuilds, brake overhaul, and routine engine servicing with absolute precision. Relying on correct factory procedures and specialized tool references prevents costly mechanical damage, ensures passenger safety, and preserves the roadworthiness of your Polo Mk4. Delivered as an instant high-quality digital PDF download immediately upon checkout, this manual requires no shipping waiting times and can be viewed seamlessly across desktop computers, tablets, and smartphones, or printed out for direct use in the workshop bay.
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