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Volkswagen Polo Mk5 Workshop Manual PDF – Full Service & Repair Guide
$39.95 Original price was: $39.95.$23.95Current price is: $23.95.
Complete 1,702-page Volkswagen Polo Mk5 workshop manual PDF covering brakes, suspension, engine, gearbox, body, electrics and HVAC for Polo, BlueMotion, Cross Polo and GTI variants.
SKU: VW-POLO-MK5-HD-001
Category: Automotive Workshop Manuals
Tags: Polo Mk5 service and repair guide, Volkswagen Polo Mk5 PDF download, Volkswagen Polo Mk5 workshop manual, VW Polo Mk5 repair manual PDF
Vendor: Suspension Manuals
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Description
Volkswagen Polo Mk5 Workshop Manual PDF – Full Service & Repair Guide
This Volkswagen Polo Mk5 workshop manual is a 1,702-page PDF reference compilation covering the full range of service, repair, overhaul and diagnostic procedures for the Polo Mk5 platform and its variants. From Bosch 8.2 ABS hydraulics to timing chain replacement, from suspension geometry to infotainment wiring, this is a genuinely deep technical library for anyone maintaining, repairing or rebuilding a Polo Mk5.
File Details
- Manual type: Workshop Manual / Service Reference Compilation
- Brand: Volkswagen
- Model: Polo Mk5
- Language: English
- Page count: 1,702
- File format: PDF
- Compilation date: 1st January 2018
Chapters Covered
- Brake systems — ABS, ADR, TCS, EDL, ESP; hydraulic unit, brake servo and brake master cylinder; Bosch 8.2 ABS left-hand drive; front brakes FS III and FN 3; rear brakes (drum and disc); handbrake lever and cables; brake pedal (LHD and RHD); brake caliper pistons; bleeding the brake system; brake servo non-return valve
- Running gear, axles and steering — front suspension and drive shafts; subframe, anti-roll bar and suspension links; swivel joints; wheel bearings; drive shaft with VL90 or VL100 constant velocity joints; rear suspension; wheel hub with wheel bearing (drum and disc brakes); wheel alignment; wheels and tyres; tyre wear diagnosis; run-flat tyre identification; alloy wheels with exchangeable trim elements
- Body repairs, exterior — plenum chamber cover, noise insulation, underbody cladding, bulkhead and tunnel cross-piece; bonnet, flaps, cab and central locking; rear lid; tank flap unit; front door and central locking; door components; rear door; sliding roof and panorama tilting sunroof; front and rear bumper covers for Polo, Blue Motion, Cross Polo and GTI; glazing and window mechanisms; front and rear door windows; exterior equipment including wheel housing liners, exterior mirrors, radiator grille, mouldings, trims, roof railing and roof edge spoiler
- Body repairs, interior — interior mirror; compartments, covers and trims; passenger protection (seat belts, airbag, crash sensors); dash panel, door and side trims, pillar trims, rear lid trim, luggage compartment trims and roof trims; seat frames; seat padding and covers
- Vehicle electrics — electrical system and starter-current supply; battery removal and installation; starter motors for manual gearbox MQ200 and MQ250, DSG DQ200-7F and automatic AQ250-6F; alternator and voltage regulator; start/stop system; dash panel insert; windscreen wipe/wash system; rear window wiper/wash; headlight washer system; H4 and H7 headlights; gas discharge headlights; fog lights; daytime running lights; tail lights; number plate lights; additional brake light; steering column switch; ignition/starter switch; parking aid; interior lights and switches; anti-theft system; onboard supply control unit J519; trailer detector control unit J345; infotainment including RCD 210, RCD 310, RCD 510, RNS 310, multimedia system control unit, loudspeaker systems, telephone system, aerial systems and multifunction steering wheel; battery testing and charging; wiring harness and connector repairs; fibre optic cables
- Power transmission — 5-speed manual gearbox 02T; 5-speed manual gearbox 02R; 6-speed manual gearbox 02U; 6-speed automatic gearbox 09G; 7-speed dual clutch gearbox 0AM; clutch and control; selector mechanisms; gearbox mechanics, operation, construction and differential; final drive; differential; input and output shafts; reverse shaft; flange shaft oil seals
- Power unit — 4-cylinder injection engine with timing chain; 4-cylinder injection engine with toothed belt drive; 4-cylinder 1.4L direct injection engine with turbocharger and supercharger; 4-cylinder 1.6L common rail diesel; 3-cylinder injection engine (4-valve); 3-cylinder injection engine (2-valve); 4-cylinder 1.2L direct injection turbocharged engine; 4-cylinder 1.6L BiFuel; 4-cylinder 1.4L BiFuel; fuel supply systems for petrol and diesel; engine lubrication; engine cooling; exhaust systems; ignition systems; glow plug systems; turbocharger and supercharger; mixture preparation and electronic injection
- Heating, ventilation and air conditioning — heating system repair; heater unit; air conditioner; Climatic and Climatronic systems; refrigerant circuit R134a; air conditioning compressor; refrigerant lines and components
Complete PDF Bookmark Tree
Complete Bookmarks
The complete bookmarks in the “Volkswagen Polo Mk5 Workshop Manual PDF – Full Service & Repair Guide” are as follows:
+Brake systemsp. 1
+Technical datap. 1
+Technical data for brakesp. 1
+Front brakesp. 1
Front brakes FSIIIp. 1
Front brakes FN 3 (15)p. 2
+Rear brakesp. 3
Rear brake (drum brake)p. 3
Rear brakes (38" brake disc)p. 4
+Technical prerequisitesp. 171
+Trailer socketp. 171
13-pin trailer socketp. 171
+Gearbox identificationp. 629
Location on gearboxp. 629
Location on gearboxp. 689
Gearbox codesp. 760
Location on gearboxp. 857
Overview – power transmissionp. 630
+General repair notesp. 631
Seals and sealing ringsp. 631
Locking devicesp. 632
Synchro-ringsp. 633
Seals and sealing ringsp. 691
Locking devicesp. 692
Synchro-ringsp. 693
Toolsp. 757
Electrical componentsp. 758
Guided fault finding, vehicle self-diagnosis and testingp. 759
Toolsp. 797
Gearboxp. 798
Seals and sealing ringsp. 859
Locking devicesp. 860
Synchro-ringsp. 861
Testing vacuum systemp. 1108
Overview – power transmissionp. 690
Gearbox identificationp. 794
Overview – power transmissionp. 795
Capacitiesp. 796
Overview – power transmissionp. 858
Engine numberp. 917
Engine number, engine datap. 1040
+Safety precautionsp. 1041
Safety precautions when working on ignition systemp. 1041
Engine numberp. 1106
Engine number, engine datap. 1107
Engine numberp. 1285
Engine numberp. 1333
Engine numberp. 1434
+General notes on air conditioning systemsp. 1683
+Basics of air conditioningp. 1683
Physical basics:p. 1683
Pressure and boiling pointp. 1684
+General information on refrigerant circuitp. 1685
+Refrigerant circuit componentsp. 1685
Condenserp. 1685
Evaporatorp. 1686
Expansion valvep. 1687
High-pressure safety valvep. 1688
+Switch and sender in refrigerant circuit and related connectionsp. 1689
High-pressure switch for air conditioning systemF23p. 1689
High-pressure switch for magnetic clutchF118p. 1690
Low-pressure switch for air conditioning systemF73p. 1691
High-pressure senderG65p. 1692
+Electrical components not installed in refrigerant circuitp. 1693
Control and regulating unit for air conditioning systemJ127p. 1693
Evaporator output temperature senderG263 or evaporator temperature sensorG308p. 1694
Refrigerant circuit with expansion valvep. 1695
Refrigerant circuit with restrictor and reservoirp. 1696
Test and measurement work that can be performed using a pressure gaugep. 1697
+Working with the air conditioner service stationp. 1698
Important notes for working with the air conditioner service stationp. 1698
+Clearing refrigerant circuit of contaminantsp. 1699
+Purging (cleaning) refrigerant circuit with refrigerant R134ap. 1699
Adapters for setting up purging circuitsp. 1699
+Checking pressures on vehiclesp. 1700
+Checking systems with a restrictor and collector (with internally regulated air conditioner compressor)p. 1700
Specifications:p. 1700
+Checking systems with an expansion valve and reservoir (with internally regulated air conditioner compressor)p. 1701
Specifications:p. 1701
+ABS, ADR, TCS, EDL, ESPp. 5
+General notes for anti-lock brake system (ABS)p. 5
Bosch 8.2p. 5
+Electrical/electronic components and locationsp. 6
Bosch 8.2 ABSp. 6
Bosch 8.2i ABS/EDL/TCS/ESPp. 7
Fault display via warning lampsp. 8
+Assembly overview – hydraulic unit, brake servo/brake master cylinderp. 9
Bosch 8.2 ABS, left-hand drivep. 9
+Bosch 8.2 ABS, left-hand drivep. 10
Connecting brake lines from brake master cylinder to hydraulic unitp. 10
Removing control unit and hydraulic unitp. 11
Bosch 8.2 ABS, right-hand drivep. 12
+Bosch 8.2 ABS, right-hand drivep. 13
Connecting brake lines from brake master cylinder to ABS hydraulic unitN55p. 13
Removing ABS control unitJ104 and ABS hydraulic unitN55p. 14
Bosch 8.2i ABS/EDS/ASR/ESP, left-hand drivep. 15
+Bosch 8.2i ABS/EDS/ASR/ESP, left-hand drivep. 16
Connecting brake lines from brake master cylinder to hydraulic unitp. 16
Removing control unit and hydraulic unitp. 17
Bosch 8.2i ABS/EDS/ASR/ESP, right-hand drivep. 18
+Bosch 8.2i ABS/EDS/ASR/ESP, right-hand drivep. 19
Connecting brake lines from brake master cylinder to ABS hydraulic unitN55p. 19
Removing ABS control unitJ104 and ABS hydraulic unitN55p. 20
+Removing and installing parts of ABS system on front and rear axlep. 21
Removing and installing parts of ABS system on front axlep. 21
+Removing and installing parts of ABS system on front axlep. 22
Removing and installing speed sensor on front axlep. 22
Removing and installing parts of anti-lock brake system on rear axle (drum brakes)p. 23
+Removing and installing parts of anti-lock brake system on rear axle (drum brakes)p. 24
Removing and installing speed sensor on rear axle (drum brakes)p. 24
Removing and installing parts of anti-lock brake system on rear axle (disc brakes)p. 25
+Removing and installing parts of anti-lock brake system on rear axle (disc brakes)p. 26
Removing and installing speed sensor on rear axlep. 26
+Brake, brake mechanicsp. 27
+Repairing front brakesp. 27
Removing and installing brake pads, brake caliper FS IIIp. 27
+Removing and installing brake pads, brake caliper FS IIIp. 28
Installingp. 28
Removing and installing brake caliper FS IIIp. 29
+Removing and installing brake caliper FS IIIp. 30
Installingp. 30
Removingp. 62
Installingp. 63
Removing and installing brake pads, brake caliper FN 3p. 31
+Removing and installing brake pads, brake caliper FN 3p. 32
Removingp. 32
Installingp. 33
Removing and installing brake caliper FN 3p. 34
Repairing rear brakes (drum brakes)p. 35
+Repairing rear brakes (drum brakes)p. 36
Resetting brakep. 36
Repairing rear brakesp. 37
+Repairing rear brakesp. 38
Checking wheel brake cylinder for leaksp. 38
Removing and installing brake shoesp. 39
+Removing and installing brake shoesp. 40
Removingp. 40
Installingp. 41
+Repairing rear brakes (disc brakes)p. 42
Removing and installing brake pads/liningsp. 42
+Removing and installing brake pads/liningsp. 43
Removingp. 43
Installingp. 44
Assembly overview – handbrake leverp. 45
+Assembly overview – handbrake leverp. 46
+Removing and installing handbrake cable (drum brakes)p. 46
Removingp. 46
Installingp. 47
Adjusting handbrakep. 48
+Removing and installing handbrake cable (disc brakes)p. 49
Removingp. 49
Installingp. 50
+Assembly overview – brake pedalp. 51
+Assembly overview – brake pedal, left-hand drivep. 51
Separating brake pedal from brake servop. 51
Clipping brake pedal to brake servop. 52
Removing pedal clusterp. 53
Removing brake pedalp. 54
Installing brake pedalp. 55
+Assembly overview – brake pedal, right-hand drivep. 56
Separating brake pedal from brake servop. 56
Clipping brake pedal to brake servop. 57
Removing pedal clusterp. 58
Removing brake pedalp. 59
+Brakes, hydraulics, regulator, servop. 60
+Repairing front brake calipersp. 60
Repairing FSIII brake calipersp. 60
Removing and installing brake caliper FS IIIp. 61
Repairing FN3 brake calipersp. 64
Removing and installing brake caliper piston FN 3p. 65
+Removing and installing brake caliper piston FN 3p. 66
Removingp. 66
Installingp. 67
Repairing rear brake calipersp. 68
+Repairing rear brake calipersp. 69
Removing and installing rear brake caliper pistonp. 69
+Removing and installing rear brake caliper pistonp. 70
Removingp. 70
Installingp. 71
Pre-bleeding brake caliperp. 72
Pressurised leak testp. 73
+Bleeding brake systemp. 74
Bleeding brake system using brake filling and bleeding unitVAS 5234 or V.A.G1869p. 74
+Assembly overview – brake servo/brake master cylinderp. 75
Assembly overview – brake servo/brake master cylinder (left-hand drive vehicle)p. 75
Assembly overview – brake servo/brake master cylinder (right-hand drive vehicle)p. 76
+Vacuum pump for brake servo (vehicles with diesel engine)p. 77
Exhauster pump for 4-cylinder diesel enginesp. 77
Checking non-return valvep. 78
+Vacuum pump for brakesV192p. 79
Assembly overview – vacuum pump for brakesV192p. 79
Removingp. 80
Removing and installing brake light switchF, left-hand drivep. 81
Removing and installing brake light switchF, right-hand drivep. 82
+Removing and installing brake master cylinderp. 83
Removing and installing brake master cylinder, left-hand drivep. 83
+Removing and installing brake master cylinder, left-hand drivep. 84
Removingp. 84
Removing and installing brake master cylinder, right-hand drive vehiclep. 85
+Removing and installing brake master cylinder, right-hand drive vehiclep. 86
Removingp. 86
+Removing and installing brake servop. 87
Removing and installing brake servo, left-hand drivep. 87
+Removing and installing brake servo, left-hand drivep. 88
Removingp. 88
Removing and installing brake servo, right-hand drive vehiclep. 89
+Removing and installing brake servo, right-hand drive vehiclep. 90
Removingp. 90
+Repairing brake linesp. 91
Assembly overview – flanging toolp. 91
Work instructionsp. 92
+Running gear, axles, steeringp. 93
+Front suspension, drive shaftsp. 93
+Repairing front wheel suspensionp. 93
Raising wheel suspension to unladen positionp. 93
+Subframe, anti-roll bar, suspension linksp. 94
Fixing position of subframep. 94
Removing and installing subframep. 95
Checking swivel jointp. 96
Removing and installing swivel jointp. 97
Installation position of swivel jointsp. 98
Removing and installing suspension linkp. 99
Renewing front bonded rubber bush for suspension linkp. 100
Renewing rear bonded rubber bush for suspension linkp. 101
Removing and installing anti-roll barp. 102
Removing and installing rubber bush for anti-roll barp. 103
Assembly overview – wheel bearingsp. 104
+Assembly overview – wheel bearingsp. 105
Pulling out and pulling in wheel hub with wheel bearingp. 105
Removing and installing wheel bearing housingp. 106
Assembly overview – suspension strutp. 107
+Assembly overview – suspension strutp. 108
Removing and installing suspension strutp. 108
Repairing front suspension strutp. 109
+Removing and installing drive shaftsp. 110
Removing and installing drive shaft with constant velocity jointp. 110
Removing and installing drive shaft with triple roller joint AAR 2000 (bolted-on)p. 111
Repairing drive shafts – overview of drive shaftsp. 112
+Repairing drive shafts – overview of drive shaftsp. 113
Heat shields for drive shaftsp. 113
Assembly overview – drive shaft with VL90 or VL100 constant velocity jointp. 114
+Assembly overview – drive shaft with VL90 or VL100 constant velocity jointp. 115
Dismantling and assembling drive shaft with VL90 or VL100 constant velocity jointp. 115
Checking outer constant velocity jointp. 116
Checking inner constant velocity jointp. 117
Assembly overview – drive shaft with VL107 constant velocity jointp. 118
+Assembly overview – drive shaft with VL107 constant velocity jointp. 119
Dismantling and assembling drive shaft with VL107 constant velocity jointp. 119
Assembly overview – drive shaft with triple roller joint AAR 2000/108p. 120
+Assembly overview – drive shaft with triple roller joint AAR 2000/108p. 121
Dismantling and assembling drive shaft with triple roller joint AAR 2000/108p. 121
+Rear suspension, drive shaftp. 122
+Repairing rear axlep. 122
Overview – rear axlep. 122
Rear axle in unladen positionp. 123
+Assembly overview – axle body, drum brakep. 124
Removing and installing rear axlep. 124
Removing and installing bonded rubber bushp. 125
Removing and installing coil springp. 126
+Assembly overview – rear left vehicle level sender G76 , front-wheel drivep. 127
Removing and installing rear left vehicle level sender G76p. 127
Assembly overview – shock absorberp. 128
+Assembly overview – shock absorberp. 129
Removing and installing shock absorbersp. 129
Assembly overview – wheel bearings, drum brakep. 130
+Assembly overview – wheel bearings, drum brakep. 131
Removing and installing wheel hub with wheel bearing, vehicles with drum brakesp. 131
Assembly overview – wheel bearings, disc brakep. 132
+Assembly overview – wheel bearings, disc brakep. 133
Removing and installing wheel hub with wheel bearing, vehicles with disc brakesp. 133
+Wheels, tyres. axle alignp. 134
Tyre pressure monitor displayp. 134
Wheel alignmentp. 135
+Wheel alignmentp. 136
Test preparationsp. 136
Wheel alignment specificationsp. 137
Transverse vehicle inclination "zero positionp. 138
Overview – wheel alignment procedurep. 139
Adjusting front axle toep. 140
Checking left and right-hand wheel lockp. 141
Vehicle data stickerp. 142
+Wheels, tyresp. 143
Models with breakdown setp. 143
Tyre sealantp. 144
Fitting a new tyrep. 145
+Rough running due to wheels/tyres – causes and rectificationp. 146
Vibration control system VAS 6230p. 146
Recommended temporary spare tyres and wheelsp. 170
+Legislative and technical conditions for converting wheel and tyre combinationsp. 172
Additional wheel housing extensions (flaps)p. 172
+Useful information regarding tyresp. 173
Identification markings on the tyre sidewallp. 173
+Tyre wear/ mileage for passenger car tyresp. 174
One-sided wearp. 174
Diagonal washoutp. 175
+Tyre noisep. 176
Saw-tooth wearp. 176
Flat spots (from locking wheels)p. 177
+Vehicle pulls to one sidep. 178
Conicityp. 178
+Tyre damagep. 179
Construction of a radial belted tyrep. 179
Impact damagep. 180
Cutsp. 181
Tyre damage due to insufficient tyre inflation pressurep. 182
Rising tyre temperature caused by insufficient tyre inflation pressurep. 183
+Tyres with run-flat propertiesp. 184
Design and identificationp. 184
+Facts about wheels (passenger cars)p. 185
Wheel structurep. 185
Alloy wheels with exchangeable trim elementsp. 186
+Alloy wheels with exchangeable trim elements (Zaragoza)p. 187
Toolsp. 187
Installing trim elementp. 188
+Steeringp. 147
+General repair instructionsp. 147
Nuts and boltsp. 147
Electrical componentsp. 148
Guided fault finding, vehicle self-diagnosis and test instrumentsp. 149
+Steering columnp. 150
Removing and installing steering wheelp. 150
Removing and installing steering column, left-hand drive vehiclep. 151
Removing and installing steering column, right-hand drive vehiclep. 152
+Electro-hydraulic power steeringp. 153
Assembly overview for electro-hydraulic power steering, left-hand drive vehiclep. 153
Removing and installing power steering box, left-hand drive vehiclep. 154
Removing and installing power steering sensor G250 , left-hand drive vehiclep. 155
Assembly overview for electro-hydraulic power steering, right-hand drive vehiclep. 156
Removing and installing power steering box, right-hand drive vehiclep. 157
Removing and installing power steering sensor G250 , right-hand drive vehiclep. 158
+Repairing power steering boxp. 159
Assembly overview – power steering box, left-hand drive vehiclep. 159
Assembly overview – power steering box, right-hand drive vehiclep. 160
Removing and installing track rodp. 161
Checking and adjusting left track rod lengthp. 162
Allocation of track rod ball jointsp. 163
Determining centre position of steering rackp. 164
Adjusting steering boxp. 165
+Motor/pump unitp. 166
Assembly overview – motor/pump unitp. 166
Removing and installing motor/pump unitp. 167
Checking delivery pressure of motor/pump unitp. 168
+Bleeding steering system, checking for leaks and checking fluid levelp. 169
Checking hydraulic fluid level of power steeringp. 169
Wheels and Tyres Guidep. 170
Guide for using trailersp. 171
Wheels and Tyres Guide – General Informationp. 172
+Bodyp. 189
+General body repairs, exteriorp. 189
+Body frontp. 189
+Lock carrierp. 189
Toolsp. 189
+Lock carrier – attachmentsp. 190
Assembly overviewp. 190
+Service positionp. 191
Moving to service positionp. 191
Moving from service positionp. 192
+Removing and installing lock carrier with attachmentsp. 193
Installingp. 193
+Pressure hose with push-on couplingp. 194
Releasing push-on couplingp. 194
+Wingp. 195
Toolsp. 195
+Front wingp. 196
Removingp. 196
+Plenum chamber bulkheadp. 197
Toolsp. 197
Assembly overview – plenum chamber bulkheadp. 198
+Plenum chamber coverp. 199
Assembly overviewp. 199
Removingp. 200
+Noise insulationp. 201
Toolsp. 201
+Underbody claddingp. 202
Toolsp. 202
+Bulkheadp. 203
Toolsp. 203
+Tunnel cross-piecep. 204
Toolsp. 204
Assembly overview – tunnel cross-piecep. 205
+Bonnet, flaps, cab, central lockingp. 206
+Bonnetp. 206
Toolsp. 206
Assembly overview – bonnetp. 207
+Removing and installing bonnetp. 208
Installingp. 208
+Removing and installing bonnet hingep. 209
Removingp. 209
Installingp. 210
+Removing and installing insulationp. 211
Removingp. 211
Installingp. 212
Removing and installing support rodp. 213
Assembly overview – bonnet lock and release componentsp. 214
+Removing and installing lid lock – LHD vehiclep. 215
Removingp. 215
Installingp. 216
Separating Bowden cablep. 217
Removing and installing striker pinp. 218
+Removing and installing release leverp. 219
Assembly overviewp. 219
Removing and installingp. 220
+Adjusting bonnetp. 221
Adjusting bonnet lockp. 221
Adjusting striker pinp. 222
+Rear lidp. 223
Toolsp. 223
Assembly overview – rear lidp. 224
+Removing and installing rear lidp. 225
Installingp. 225
Assembly overview – gas strutp. 226
Assembly overview – rear lid hingep. 227
+Removing and installing rear lid hingep. 228
Removingp. 228
Installingp. 229
Removing and installing striker pinp. 230
Removing and installing stop bufferp. 231
+Removing and installing lid lockp. 232
Removingp. 232
Installingp. 233
+Removing and installing release elementp. 234
Removingp. 234
Installingp. 235
+Removing and installing rear lid sealp. 236
Removingp. 236
Installingp. 237
+Tank flap unitp. 238
Toolsp. 238
+Removing and installing tank flap unitp. 239
Removingp. 239
Installingp. 240
+Removing and installing actuatorp. 241
Removingp. 241
Installingp. 242
+Front door, central lockingp. 243
+Front doorp. 243
Toolsp. 243
+Removing and installing doorp. 244
Removingp. 244
Installingp. 245
Removingp. 274
Installingp. 275
+Door alignmentp. 246
Adjusting striker pinp. 246
Toolsp. 276
Adjusting striker pinp. 277
+Door componentsp. 247
Toolsp. 247
Assembly overview – front door (2-door model)p. 248
Assembly overview – front door (4-door model)p. 249
+Removing and installing cover (2-door model)p. 250
Removingp. 250
Installingp. 251
+Removing and installing cover (4-door model)p. 252
Removingp. 252
Installingp. 253
Removing and installing door retaining strapp. 254
Removing and installing striker pinp. 255
+Removing and installing lock cylinder cover capp. 256
Installingp. 256
+Removing and installing lock cylinderp. 257
Installingp. 257
+Removing and installing cover cap (without lock cylinder)p. 258
Toolsp. 258
Installingp. 259
+Removing and installing door handlep. 260
Removingp. 260
Installingp. 261
Installingp. 285
+Removing and installing door lockp. 262
Removingp. 262
Installingp. 263
Removingp. 286
Installingp. 287
+Removing and installing bearing bracketp. 264
Removingp. 264
Installingp. 265
Removingp. 288
Installingp. 289
+Removing and installing window slot outer seal (4-door model)p. 266
Installingp. 266
Assembly overview – insulation (2-door model)p. 267
Assembly overview – insulation (4-door model)p. 268
Toolsp. 278
Assembly overview – rear doorp. 279
Removing and installing coverp. 280
Removing and installing door retaining strapp. 281
Removing and installing striker pinp. 282
+Removing and installing cover capp. 283
Toolsp. 283
Installingp. 284
+Removing and installing trimp. 290
Removingp. 290
Installingp. 291
Removingp. 382
Removing and installing window slot inner sealp. 292
Assembly overview – insulationp. 293
+Central lockingp. 269
Fitting location overview – central locking componentsp. 269
Assembly overview – battery for folding key with remote controlp. 270
+Removing and installing battery for folding key with remote controlp. 271
Removingp. 271
Installingp. 272
+Rear door,sliding door,wing doors,central lockingp. 273
+Rear doorp. 273
Toolsp. 273
+Sliding roofp. 294
+Panorama tilting sunroofp. 294
Toolsp. 294
Functionp. 295
Assembly overview – panorama tilting sunroofp. 296
Removing glass panel for panorama tilting sunroofp. 297
Removing glass panel when drive is defectivep. 298
Adjusting glass panel (height adjustment)p. 299
Removing and installing glass panel sealp. 300
Removing and installing coverp. 301
Removing and installing panorama tilting sunroof switchp. 302
+Removing and installing wind deflectorp. 303
Removingp. 303
Installingp. 304
Removing and installing interior sealp. 305
+Sun blindp. 306
Assembly overviewp. 306
Removing sun blindp. 307
Installing sun blindp. 308
Removing and installing pulling ribp. 309
Installing pulling ribp. 310
+Removing and installing guide railsp. 311
Installingp. 311
+Cleaning water drain hosesp. 312
Toolsp. 312
Assembly overviewp. 313
+Assembly frame and hiderp. 314
Toolsp. 314
+Removing and installing assembly framep. 315
Removing assembly framep. 315
+Bumperp. 316
+Front bumper coverp. 316
Toolsp. 316
+Front bumper carrier and lateral guidesp. 317
Assembly overviewp. 317
Assembly overviewp. 318
Removingp. 319
Installingp. 320
Front bumper cover attachmentsp. 321
+Front bumper cover, Polop. 318
+Front bumper cover, Polo Blue Motionp. 322
Assembly overview – front bumper cover, Polo Blue Motionp. 322
Removing front bumper cover, Polo Blue Motionp. 323
Installing front bumper cover, Polo Blue Motionp. 324
Front bumper cover with attachments, Polo Blue Motionp. 325
+Front bumper cover, Cross Polop. 326
Assembly overview – front bumper cover, Cross Polop. 326
Removing front bumper cover, Cross Polop. 327
Installing front bumper cover, Cross Polop. 328
Front bumper cover with attachments, Cross Polop. 329
+Front bumper cover, Polo GTIp. 330
Assembly overview – front bumper cover, Polo GTIp. 330
Removing front bumper cover, Polo GTIp. 331
Installing front bumper cover, Polo GTIp. 332
Attachments for front bumper cover, Polo GTIp. 333
+Rear bumper coverp. 334
Toolsp. 334
+Installing bracket for parking aid systemp. 335
Toolsp. 335
Rear bumper carrier and subassembliesp. 336
Assembly overviewp. 337
Removingp. 338
Installingp. 339
+Rear bumper cover, Polop. 337
+Rear bumper cover, Polo Blue Motionp. 340
Assembly overview – rear bumper cover, Polo Blue Motionp. 340
Removing rear bumper cover, Polo Blue Motionp. 341
Installing rear bumper cover, Polo Blue Motionp. 342
Rear bumper cover with attachments, Polo Blue Motionp. 343
+Rear bumper cover, Cross Polop. 344
Assembly overview – rear bumper cover, Cross Polop. 344
Removing rear bumper cover, Cross Polop. 345
Installing rear bumper cover, Cross Polop. 346
Rear bumper cover, Cross Polo, attachmentsp. 347
+Rear bumper cover, Polo GTIp. 348
Assembly overview – rear bumper cover, Polo GTIp. 348
Removing rear bumper cover, Polo GTIp. 349
Installing rear bumper cover, Polo GTIp. 350
Attachments for rear bumper cover, Polo GTIp. 351
+Glazing/window mechanismp. 352
+Flush bonded windowsp. 352
Assembly overview – windscreenp. 352
Removing windscreenp. 353
Assembly overview – rear windowp. 354
Assembly overview – side window (2-door model)p. 355
Assembly overview – side window (4-door model)p. 356
Removing undamaged side window (4-door model)p. 357
+Front door windowp. 358
Toolsp. 358
Assembly overview – front door windowp. 359
+Removing and installing window regulator motorp. 360
Removingp. 360
Removingp. 367
+Installing and removing window regulatorsp. 361
Installingp. 361
Removingp. 370
Installingp. 371
+Removing and installing window channelp. 362
Removing window channelp. 362
Installingp. 363
Removing window channelp. 372
Installingp. 373
+Rear door windowp. 364
Toolsp. 364
Assembly overview – rear door windowp. 365
+Removing and installing door windowp. 366
Removing door windowp. 366
Removing and installing manual drivep. 368
Removing and installing window crankp. 369
+Exterior equipmentp. 374
+Wheel housing linerp. 374
Toolsp. 374
+Front wheel housing linerp. 375
Removingp. 375
+Rear wheel housing linerp. 376
Removingp. 376
Installingp. 377
+Exterior mirrorp. 378
Toolsp. 378
+Removing and installing mirror glassp. 379
Removingp. 379
+Removing and installing adjustment unit with motorp. 380
Removingp. 380
+Removing and installing mirror housingp. 381
Removingp. 381
+Removing and installing exterior mirror (manual operation)p. 383
Removingp. 383
Installingp. 384
+Removing and installing exterior mirror (electric operation)p. 385
Removingp. 385
Installingp. 386
+Radiator grillep. 387
Toolsp. 387
+Removing and installing radiator grillep. 388
Installingp. 388
+Removing and installing emblemp. 389
Removingp. 389
Installingp. 390
+Removing and installing emblem on Polo Blue Motionp. 391
Removingp. 391
Installingp. 392
Assembly overview – radiator grille, Polo GTIp. 393
+Mouldings and trimsp. 394
Toolsp. 394
+B-pillar trimp. 395
Assembly overviewp. 395
Installingp. 396
+Wing trim panelp. 397
Removing and installing wing trim panelp. 397
+Water deflector, Polo Blue Motionp. 398
Assembly overview – water deflectorp. 398
Installing water deflector stripp. 399
+Removing and installing roof railingp. 400
Toolsp. 400
+Roof railingp. 401
Assembly overview – roof railingp. 401
+Roof edge spoilerp. 402
Toolsp. 402
+Roof edge spoiler, Polo Blue Motionp. 403
Assembly overview – roof edge spoiler, Polo Blue Motionp. 403
Removing middle piece of roof edge spoiler, Polo Blue Motionp. 404
+Roof spoiler, Polo GTIp. 405
Assembly overview – roof spoiler, Polo GTIp. 405
+Equipment-dependent attachmentsp. 406
Toolsp. 406
+Side member extension, Polo Blue Motionp. 407
Assembly overview – side member extensionp. 407
Installing side member extensionp. 408
Removing retaining stripp. 409
Installing retaining stripp. 410
Assembly overview – Cross Polo attachmentsp. 411
+Side member extension, Cross Polop. 412
Assembly overview – side member extensionp. 412
Removing side member extensionp. 413
Installing side member extensionp. 414
+Front wheel arch trim, Cross Polop. 415
Removing front wheel arch trimp. 415
Installing front wheel arch trimp. 416
+Rear wheel arch trim, Cross Polop. 417
Removing rear wheel arch trimp. 417
Installing rear wheel arch trimp. 418
+Front door cover, Cross Polop. 419
Removing front door coverp. 419
Installing front door coverp. 420
+Rear door cover, Cross Polop. 421
Removing rear door coverp. 421
Installing rear door coverp. 422
+Wheel arch trim, rear door, Cross Polop. 423
Removing and installing wheel arch trim of rear doorp. 423
Assembly overview – attachments, Polo GTIp. 424
+Side member extension, Polo GTIp. 425
Assembly overview – side member extensionp. 425
Removing side member extensionp. 426
Installing side member extensionp. 427
+Letteringp. 428
Toolsp. 428
Rear lettering dimensions, Polo Blue Motionp. 429
+Scuff protection filmp. 430
+Renewing scuff protection film, Polo GTIp. 430
Toolsp. 430
+General body repairs, interiorp. 431
+Interior equipmentp. 431
+Interior mirrorp. 431
+Toolsp. 431
Required special tools, workshop equipment, test and measuring devices and auxiliary itemsp. 431
Required special tools, workshop equipment, test and measuring devices and auxiliary itemsp. 434
Required special tools, workshop equipment, test and measuring devices and auxiliary itemsp. 448
Required special tools, workshop equipment, test and measuring devices and auxiliary itemsp. 452
Required special tools, workshop equipment, test and measuring devices and auxiliary itemsp. 454
Required special tools, workshop equipment, test and measuring devices and auxiliary itemsp. 455
Required special tools, workshop equipment, test and measuring devices and auxiliary itemsp. 458
Required special tools, workshop equipment, test and measuring devices and auxiliary itemsp. 459
Required special tools, workshop equipment, test and measuring devices and auxiliary itemsp. 461
Required special tools, workshop equipment, test and measuring devices and auxiliary itemsp. 463
Required special tools, workshop equipment, test and measuring devices and auxiliary itemsp. 466
Required special tools, workshop equipment, test and measuring devices and auxiliary itemsp. 468
+Removing and installing interior mirror with rain and light sensorG397p. 432
Removingp. 432
+Removing and installing interior mirrorp. 433
Removingp. 433
+Compartments, covers and trimsp. 434
Removing and installing centre console with armrestp. 435
Removing and installing support (vehicles with arm rest)p. 436
Removing and installing rear cup holder (vehicles with arm rest)p. 437
Removing and installingp. 438
Removing and installing hand brake cover capp. 439
Removing and installing cover for centre consolep. 440
Removing and installing dash panel middle trimsp. 441
Removing and installing centre dash panel compartmentp. 442
Removing and installing centre dash panel storage compartmentp. 443
Removing and installing dash panel end trimsp. 444
Removing and installing glove compartmentp. 445
Removing and installing fuse box coverp. 446
Removing and installing steering column trimp. 447
+Passenger protectionp. 448
+Seat beltsp. 448
Removing and installing centre rear seat beltsp. 449
Removing and installing rear double belt bucklep. 450
+Inspecting seat beltsp. 451
+Points to checkp. 451
Checking belt webbingp. 451
+Airbagp. 452
Adapting componentsp. 453
Crash sensorsp. 454
+Trim, noise insulationp. 455
+dash panelp. 455
Removing and installing dash panelp. 456
Removing and installing dash panel cross memberp. 457
Door and side trimsp. 458
+Pillar trimsp. 459
Removing and installing lower A-pillar trim (passenger side)p. 460
+Rear lid trimp. 461
Removing and installing rear lid trimp. 462
+Luggage compartment trimsp. 463
Removing and installing lock carrier coverp. 464
Removing and installing luggage compartment floor coveringp. 465
+Roof trimsp. 466
Removing and installing moulded headliner (4-door models)p. 467
+Seat framesp. 468
Front seatsp. 468
+Rear seatsp. 469
Toolsp. 469
+Seat padding, coversp. 470
+Front seat covers and paddingp. 470
Toolsp. 470
+Rear seat covers and paddingp. 471
Toolsp. 471
Removing and installing bench seat (split) cover and paddingp. 472
Removing and installing bench seat (continuous) cover and paddingp. 473
+Vehicle electricsp. 474
+Electrical systemp. 474
+Starter-current supply-CCp. 474
+Disconnecting and reconnecting batteryp. 474
+Assembly overview, vehicles with starter battery in engine compartmentp. 474
Assembly overview, 1.2 l, 44kW MPI enginep. 474
Assembly overview, 1.2l, 51kW MPI enginep. 475
Assembly overview, 1.4l MPI 63kW and 1.2l TSI 66/77kW enginesp. 476
Assembly overview, 1.6l TDI enginep. 477
Assembly overview – 1.2l TDI BlueMotionp. 478
+Assembly overview, vehicles with starter battery in luggage compartmentp. 479
Assembly overviewp. 479
+Removing and installing batteryp. 480
Removing and installing battery, vehicles with starter battery in engine compartmentp. 480
Removing and installing battery, vehicles with starter battery in luggage compartmentp. 481
+Starter, vehicles with manual gearboxp. 482
+Starter, vehicles with manual gearbox MQ200p. 482
Assembly overviewp. 482
Removing and installing starter, vehicles with manual gearbox MQ200p. 483
+Starter, vehicles with manual gearbox MQ250p. 484
Assembly overviewp. 484
Removing and installing starter, vehicles with manual gearbox MQ250p. 485
+Starter, vehicles with dual clutch gearbox (DSG)p. 486
+Starter, vehicles with 1.6l TDI engine and dual clutch gearbox (DSG) DQ200-7Fp. 486
Assembly overviewp. 486
Removing and installing starter, vehicles with 1.6l TDI engine and dual clutch gearbox (DSG) DQ200-7Fp. 487
+Starter, vehicles with 1.4 l, 132kW TSI engine and dual clutch gearbox (DSG) DQ200-7Fp. 488
Assembly overviewp. 488
Removing and installing starter, vehicles with 1.4l, 132kW TSI engine with dual clutch gearbox (DSG) DQ200-7Fp. 489
+Starter, vehicles with automatic gearboxp. 490
+Starter, vehicles with automatic gearbox AQ250-6Fp. 490
Assembly overviewp. 490
Vehicles with 6-speed automatic gearbox 09Gp. 491
+Alternatorp. 492
+Alternator, 1.2l, 51kW MPI enginep. 492
Assembly overviewp. 492
Removing and installing alternator, 1.2l, 51kW MPI enginep. 493
+Alternator, 1.4l, 63kW MPI enginep. 494
Assembly overviewp. 494
+Alternator, 1.2 l, 66kW/77kW TSI enginep. 495
Assembly overviewp. 495
+Alternator, 1.4 l, 132kW TSI enginep. 496
Assembly overviewp. 496
+Alternator 1.2l TDIp. 497
Assembly overviewp. 497
+Alternator, 1.6 l TDI enginep. 498
Assembly overviewp. 498
+Removing and installing poly V-belt pulley on alternatorp. 499
Removing and installing poly V-belt pulley without freewheelp. 499
Removing and installing poly V-belt pulley with freewheel, manufacturer: Boschp. 500
Removing and installing poly V-belt pulley with freewheel, manufacturer: Valeop. 501
+Voltage regulator for alternatorp. 502
Removing and installing voltage regulator, manufacturer: Boschp. 502
Removing and installing voltage regulator, manufacturer: Valeop. 503
+Start/stop systemp. 504
Voltage stabiliserJ532p. 504
+Batteryp. 606
+Warning notices and safety regulationsp. 606
Safety markings on batteryp. 606
+Checking batteryp. 607
+Battery tester with printerVAS 5097 Ap. 607
Description of battery tester with printerVAS 5097 Ap. 607
+Battery tester with printerVAS 6161p. 608
Description of battery tester with printerVAS 6161p. 608
+Charging batteryp. 609
+Battery chargerVAS 5095 Ap. 609
Description of battery chargerVAS 5095 Ap. 609
+Battery chargerVAS 5900p. 610
Description of battery chargerVAS 5900p. 610
+Battery chargerVAS 5903p. 611
Description of battery chargerVAS 5903p. 611
+Solar panelVAS 6102Ap. 612
Charging battery in maintenance mode with solar panelVAS 6102Ap. 612
+Instruments, GCIp. 505
+Dash panel insertp. 505
Renewing dash panel insertp. 505
+Windscreen wipe/wash systemp. 506
+Windscreen wiper systemp. 506
Assembly overview – windscreen wiper systemp. 506
Removing and installing wiper blade of joint-free wiperp. 507
+Windscreen washer systemp. 508
Assembly overview – windscreen washer systemp. 508
Removing and installing windscreen washer system spray jetsp. 509
Assembly overview of washer fluid reservoirp. 510
+Rear window wiper systemp. 511
Assembly overview – rear window wiper systemp. 511
Removing and installing wiper armp. 512
Removing and installing rear window wiper motorV12p. 513
Adjusting rear window wiper park positionp. 514
+Rear window washer systemp. 515
Assembly overview – rear window washer systemp. 515
Renewing spray jetp. 516
+Headlight washer systemp. 517
Assembly overview – headlight washer systemp. 517
+Washer fluid line hose couplingsp. 613
Windscreen and rear window washer systemp. 613
Headlight washer systemp. 614
+Hose repairp. 615
Repairing smooth pipep. 615
Distinguishing features of jointless wiper bladesp. 616
+Lights, lamps, switches outsidep. 518
+H4 headlightsp. 518
Assembly overview – headlights with halogen bulb H4p. 518
+H7 headlightsp. 519
Assembly overview – headlights with halogen bulb H7p. 519
+Headlights with gas discharge bulbsp. 520
Assembly overviewp. 520
+Headlight starter for gas discharge bulbp. 521
Removing and installing headlight starter for gas discharge bulbp. 521
+Headlight range control unitJ431p. 522
Removing and installing headlight range control unitJ431p. 522
+Fog lightsp. 523
Assembly overview – fog lightsp. 523
+Fog light Polo Cross (Polo Dune)p. 524
Assembly overview – fog lightsp. 524
+Daytime running lightsp. 525
Removing and installing daytime running light bulb in fog lightp. 525
+Tail lightp. 526
Assembly overview – tail lightp. 526
Removing and installing tail light bulb carrierp. 527
+Number plate lightp. 528
+Bolted number plate lightXp. 528
Removing and installing bolted number plate lightp. 528
Removing and installing number plate light bulbp. 529
+Clipped Number plate lightXp. 530
Removing and installing clipped number plate lightp. 530
Removing and installing clipped number plate light bulbp. 531
+Additional brake lightp. 532
+Additional brake light bulbM25p. 532
Removing and installing high-level brake light bulbM25, Polo, Polo Crossp. 532
Removing and installing high-level brake light bulbM25, Polo GTI, Polo Blue Motionp. 533
+Steering column switchp. 534
Removing and installing steering column switchp. 534
Removing and installing airbag coil connector and return ring with slip ringF138p. 535
+Ignition/starter switch and lock cylinderp. 536
+Ignition/starter switchDp. 536
Pin assignment at ignition/starter switchD up to 10/2009p. 536
Removing and installing ignition/starter switchD from 11/2009 onwardsp. 537
+Parking aidp. 538
Assembly overviewp. 538
+Parking aid control unitJ446p. 539
Removing and installing parking aid control unitJ446p. 539
+Parking aid warning buzzer H15p. 540
Removing and installing parking aid warning buzzerH15p. 540
+Lights, lamps, switches inside, anti-theft systemp. 541
+Lights and switches in engine compartmentp. 541
Removing and installing bonnet contact switchF266p. 541
+Lights and switches in dash panelp. 542
Removing and installing light switchE1p. 542
Removing and installing petrol or gas fuel selection switchE395p. 543
+Removing and installing petrol or gas fuel selection switchE395p. 544
Removing and installing petrol or gas fuel selection switchE395 (vehicles ? 01.2011)p. 544
Removing and installing petrol or gas fuel selection switchE395 (vehicles 01.2011?)p. 545
Removing and installing tyre pressure monitor display buttonE492p. 546
+Removing and installing left footwell lightW9 and right footwell lightW10p. 547
Renewing footwell light bulbp. 547
+Lights and switches in doorsp. 548
Removing and installing switch module for mirror adjustment on driver sidep. 548
Driver side interior locking warning lampK174 and central locking deadlock function warning lamp on front passenger sideK204p. 549
+Anti-theft alarm (ATA)p. 550
+Alarm hornH12p. 550
Removing and installing alarm hornH12p. 550
+Wiringp. 551
+Control unitsp. 551
+Onboard supply control unitJ519p. 551
Removing and installing onboard supply control unitJ519p. 551
+Trailer detector control unitJ345p. 552
Removing and installing trailer detector control unitJ345p. 552
+Wiring harness and connector repairsp. 617
+Wiring harness repair setp. 617
Upgrade kitVAS 1978/50p. 617
Release tool setVAS 1978/35p. 618
+Tool descriptionsp. 619
Special pliers with insertp. 619
Assembly tools for single wire sealsp. 620
Wire strippersVAS 1978/3p. 621
Crimping pliersVAS 1978/1Ap. 622
+Repairs to wiring harnessesp. 623
Repairs to CAN bus wiringp. 623
Wiring open circuit with one repair positionp. 624
Wiring open circuit with two repair positionsp. 625
+Fibre optic cables (FOC)p. 626
Preparing fibre optic cablep. 626
+Repairs to contact housings and connectorsp. 627
Repairs to contacts in contact housingsp. 627
+Releasing and dismantling contact housingsp. 628
Secondary locking elementp. 628
+Communicationp. 553
+Infotainmentp. 553
+Radio units and radio navigation systems in generalp. 553
+Removing and installing radio units and radio navigation systemsp. 553
Required special tools, testers, measuring instruments and auxiliary itemsp. 553
Removing:p. 554
+Adapting radio componentsp. 555
Required special tools, workshop equipment, testers, measuring instruments and auxiliary itemsp. 555
+Adapting radio navigation system componentsp. 556
Required special tools, workshop equipment, testers, measuring instruments and auxiliary itemsp. 556
+Radio system "RCD 210"p. 557
Overview of radio system "RCD 210"p. 557
Overview of connectors on radio "RCD 210"p. 558
+Overview of connectors on radio "RCD 210"p. 559
Multi-pin connector 1, 8-pin, loudspeaker outputsp. 559
Multi-pin connector 2, 8-pin, voltage supply, CAN busp. 560
Multi-pin connector 3, 12-pin, telephone signal input, telephone mutep. 561
Multi-pin connector 4, 12-pin, AUX audio input, CD changer control and CD audio input signalp. 562
+Radio system "RCD 310"p. 563
Overview of radio system "RCD 310"p. 563
Overview of connectors on radio "RCD 310"p. 564
+Overview of connectors on radio "RCD 310"p. 565
Multi-pin connector 1, 8-pin, loudspeaker outputsp. 565
Multi-pin connector 2, 8-pin, voltage supply, CAN bus, telephone mute switchp. 566
Multi-pin connector 3, 12-pin, AUX audio output, telephone signal inputp. 567
Multi-pin connector 4, 12-pin, AUX audio input, CD changer control and CD audio input signalsp. 568
+Radio system "RCD 510"p. 569
Overview of radio system "RCD 510"p. 569
Activating/deactivating transport lock for CD changer in "RCD 510"p. 570
Overview of connectors on radio "RCD 510"p. 571
+Overview of connectors on radio "RCD 510"p. 572
Multi-pin connector 1, 8-pin, loudspeaker outputsp. 572
Multi-pin connector 2, 8-pin, voltage supply, CAN bus, telephone mute switchp. 573
Multi-pin connector 3, 12-pin, AUX audio output, telephone signal inputp. 574
Multi-pin connector 4, 12-pin, AUX audio input, CD changer control and CD audio input signalsp. 575
Multi-pin connector 5, audio and video, 26-pinp. 576
+Radio navigation system "RNS 310"p. 577
Overview of radio navigation system "RNS 310"p. 577
Overview of connectors on radio navigation system "RNS 310"p. 578
+Overview of connectors on radio navigation system "RNS 310"p. 579
Multi-pin connector 1, 8-pin, for loudspeaker outputsp. 579
Multi-pin connector 2, 8-pin, for voltage supply wires and CAN busp. 580
Multi-pin connector 3, 12-pin, for telephone signalsp. 581
Multi-pin connector 4, 12-pin, for CD changer control and CD audio input signalsp. 582
Connectors 5, 6 and 7, aerial connectionsp. 583
+Multimedia system control unitp. 584
Overview of "multimedia system control unit"p. 584
+Removing and installing multimedia control unitp. 585
Removing:p. 585
Installing:p. 586
+Loudspeaker systemsp. 587
Overview of loudspeaker systemp. 587
+Removing and installing front bass loudspeakersp. 588
Removing:p. 588
+Removing and installing rear bass loudspeakersp. 589
Removing:p. 589
+Removing and installing front treble loudspeakersp. 590
Removing:p. 590
+Telephone systemp. 591
+Preparation for mobile telephone "UTP with audio streaming"p. 591
Overview of telephone system / telephone preparationp. 591
Removing and installing telephone transmitter and receiver unitp. 592
+Removing and installing telephone bracketp. 593
Removing:p. 593
+Aerial systemsp. 594
+Overview of aerial systemsp. 594
Aerial preparation for single AM/FM aerialp. 594
Aerial preparation for single AM/FM/FM2 aerial with diversity functionp. 595
Aerial system for vehicles with radio system "RCD 210"p. 596
Aerial system for vehicles with radio system "RCD 310"p. 597
Aerial system for vehicles with radio system "RCD 510"p. 598
Aerial system for vehicles with radio navigation system "RNS 310"p. 599
Removing and installing aerial modulesp. 600
+Removing and installing roof aerialp. 601
Removing:p. 601
+Multifunction steering wheelp. 602
+Removing and installing steering wheel operating unitp. 602
Removing:p. 602
+Removing and installing multifunction steering wheel control unitp. 603
Removing:p. 603
+Adapting multifunction steering wheel componentsp. 604
Required special tools, workshop equipment, testers, measuring instruments and auxiliary itemsp. 604
+Notes on operating mobile telephones and two-way radiosp. 605
Overview of battery, transmitter and receiver unit, fuse and wiring harnessp. 605
Electrical System, General Informationp. 606
+Power transmissionp. 629
+5-speed manual gearbox 02Tp. 629
+Clutch, controlp. 634
+Repairing clutch mechanismp. 634
Assembly overview – pedal cluster, Polo 2010 ?p. 634
Distinguishing between clutch pedal switchesF36p. 635
+Removing and installing clutch pedal switchF36 with round housingp. 636
Installing clutch pedal switchp. 636
Installing clutch pedal switchp. 696
Removing and installing mounting bracket with master cylinder, Polo 2010 ?p. 637
+Removing and installing mounting bracket with master cylinder, Polo 2010 ?p. 638
Removingp. 638
Removingp. 698
+Removing and installing clutch pedal with over-centre spring, Polo 2010 ? LHDp. 639
Removingp. 639
Installingp. 640
Removingp. 699
Installingp. 700
+Removing and installing clutch pedal with extension spring, Polo 2010 ? LHDp. 641
Removingp. 641
Installingp. 642
Removingp. 701
Installingp. 702
+Removing and installing clutch pedal, Polo 2010 ? RHDp. 643
Removingp. 643
Installingp. 644
Removingp. 703
Installingp. 704
Assembly overview – hydraulics (LHD)p. 645
Assembly overview – hydraulics (RHD)p. 646
Removing and installing master cylinder, Polo 2010 ?p. 647
+Removing and installing master cylinder, Polo 2010 ?p. 648
Removingp. 648
Installingp. 649
Removingp. 708
Installingp. 709
Removing and installing slave cylinderp. 650
+Removing and installing slave cylinderp. 651
Installingp. 651
Installingp. 711
Installingp. 879
Bleeding clutch systemp. 652
Assembly overview – pedal cluster, Polo 2010 ?p. 694
Distinguishing between clutch pedal switchesF36p. 695
Removing and installing mounting bracket with master cylinder, Polo 2010 ?p. 697
Assembly overview – hydraulics (LHD)p. 705
Assembly overview – hydraulics (RHD)p. 706
Removing and installing master cylinder, Polo 2010 ?p. 707
Removing and installing slave cylinderp. 710
Bleeding clutch systemp. 712
Assembly overview – pedal clusterp. 862
+Removing, installing and adjusting clutch pedal switchF36p. 863
Removing clutch pedal switchp. 863
Installing clutch pedal switchp. 864
Removing and installing mounting bracket with master cylinderp. 865
+Removing and installing mounting bracket with master cylinderp. 866
Removingp. 866
+Removing and installing clutch pedal with over-centre spring, LHDp. 867
Removingp. 867
Installingp. 868
+Removing and installing clutch pedal with extension spring, LHDp. 869
Removingp. 869
Installingp. 870
+Removing and installing clutch pedal, RHDp. 871
Removingp. 871
Installingp. 872
Assembly overview – hydraulics (LHD)p. 873
Assembly overview – hydraulics (RHD)p. 874
Removing and installing master cylinderp. 875
+Removing and installing master cylinderp. 876
Removingp. 876
Installingp. 877
Removing and installing slave cylinderp. 878
Bleeding clutch systemp. 880
Repairing clutch release mechanismp. 653
Repairing clutchp. 654
Repairing clutch release mechanismp. 713
Repairing clutchp. 714
+Removing and installing dual clutch, gearboxes made up to 05.2011p. 799
Removing dual clutchp. 799
Installing dual clutchp. 800
+Removing and installing dual clutch, gearboxes made from 06..2011 onwardsp. 801
Removing dual clutchp. 801
Installing dual clutchp. 802
Removing and installing oil seals at clutch endp. 803
Repairing clutch release mechanismp. 881
Repairing clutchp. 882
+Gearbox mechanics,operation, construction,diff.p. 655
+Repairing selector mechanismp. 655
Installation position of selector mechanismp. 655
Assembly overview – selector lever knob and cover, Polo 2010 ?p. 656
Removing and installing gear knob and cover, Polo 2010 ?p. 657
Repairing gear lever and selector housing (from 06.06)p. 658
+Removing and installing selector mechanismp. 659
Removingp. 659
Removingp. 719
Removingp. 887
Installingp. 888
Adjusting selector mechanismp. 660
Installation position of selector mechanismp. 715
Assembly overview – selector lever knob and cover, Polo 2010 ?p. 716
Removing and installing gear knob and cover, Polo 2010 ?p. 717
Repairing gear lever and selector housing (from 06.06)p. 718
Adjusting selector mechanismp. 720
Installation position of selector mechanismp. 883
Assembly overview – gear knob and coverp. 884
Removing and installing gear knob and coverp. 885
Repairing gear lever and selector housingp. 886
Adjusting selector mechanismp. 889
Removing and installing gearbox, Polo 2010 ?p. 661
+Removing and installing gearbox, Polo 2010 ?p. 662
Removing gearboxp. 662
+Installing gearboxp. 663
Specified torquesp. 663
Specified torquesp. 724
Removing gearboxp. 722
Installing gearboxp. 723
Transporting gearboxp. 664
Checking gear oilp. 665
+Dismantling and assembling gearboxp. 666
Overview – gearboxp. 666
Assembly overviewp. 667
Assembly overview – removing and installing cover for gearbox housing and 5th gearp. 668
Assembly overview – removing and installing clutch housingp. 669
Assembly overview – removing and installing input shaft, output shaft, differential, selector mechanism and selector forksp. 670
Dismantling and assembling procedurep. 671
+Dismantling and assembling procedurep. 672
Modifying gearbox support3221p. 672
Dismantlingp. 673
Modifying gearbox support3221p. 900
Dismantlingp. 901
Overview – gearboxp. 727
Assembly overviewp. 728
Assembly overview – removing and installing cover for gearbox housing and 5th gearp. 729
Assembly overview – removing and installing gearbox housing and selector mechanismp. 730
Assembly overview – removing and installing input shaft, output shaft, differential and selector forksp. 731
+Assembly sequence – removing and installing cover for gearbox housing and 5th gearp. 732
Removingp. 732
Assembly sequence – Dismantling and assembling gearbox completelyp. 733
+Assembly sequence – Dismantling and assembling gearbox completelyp. 734
Removingp. 734
Installing 5th gearp. 735
Overview – gearboxp. 894
Assembly overviewp. 895
Assembly overview – removing and installing cover for gearbox housing and 5th and 6th gearp. 896
Assembly overview – removing and installing clutch housingp. 897
Assembly overview – removing and installing input shaft, output shaft, differential, selector mechanism and selector forksp. 898
Dismantling and assembling procedurep. 899
Repairing gearbox housing and clutch housingp. 674
Repairing selector unitp. 675
Dismantling and assembling selector forksp. 676
Removing and installing gearbox, Polo 2010 ?p. 721
Transporting gearboxp. 725
Checking gear oilp. 726
Repairing gearbox housing and clutch housingp. 736
Dismantling and assembling selector mechanism on gearbox side (selector shaft can be removed from selector mechanism cover)p. 737
Dismantling and assembling selector mechanism on gearbox side (selector shaft cannot be removed from selector mechanism cover)p. 738
Dismantling and assembling selector forksp. 739
Renewing gear oilp. 804
Selector mechanism in vehicles up to 02.2009p. 805
Emergency release of selector leverp. 806
Removing and installing selector lever handlep. 807
+Removing and installing selector lever handlep. 808
+Moving pushbutton to installation position in the handlep. 808
Handle with pushbutton on sidep. 808
Handle with front pushbuttonp. 809
+Selector mechanism from 03.2009 onwardsp. 810
Overview of selector mechanism in vehicles from 03.2009 onwardsp. 810
Safety note on mechatronic unit for dual clutch gearboxJ743p. 811
Overview – mechatronic unitp. 812
Moving mechatronic unit for dual clutch gearboxJ743 into removal position by handp. 813
Installing mechatronic unit for dual clutch gearboxJ743p. 814
View on selector forks; mechatronic unit is removedp. 815
+"Removing and installing gearbox" (erWin overview)p. 816
Notes on different vehicles, different gearboxesp. 816
Removing gearbox; Polo 2010 ?, 1.2 l – 63 and 77kW petrol enginep. 817
Removing gearbox; Polo 2010 ?, 1.4 l – 63kW petrol enginep. 818
Removing gearbox; Polo 2010 ?, 1.6l – 66kW diesel enginep. 819
Removing gearbox; Polo 2010 ?, 1.4 l – 132kW petrol enginep. 820
Installing gearboxp. 821
Torque settings Gearbox to engine and notes on assembly mountingp. 822
+Torque settings Gearbox to engine and notes on assembly mountingp. 823
1.8 – 118kW enginep. 823
1.4 l – 63kW petrol enginep. 824
1.2l and 1.4l and 1.6l enginep. 825
1.6 l – 77kW diesel enginep. 826
1.9l – 77kW – diesel engine and 1.6l – 66kW diesel enginep. 827
Transporting gearbox and securing to assembly standp. 828
Removing and installing gearboxp. 890
+Removing and installing gearboxp. 891
Removing gearboxp. 891
Specified torquesp. 892
Checking gear oilp. 893
Repairing gearbox housing and clutch housingp. 902
Repairing gearbox housing coverp. 903
Repairing selector unitp. 904
Dismantling and assembling selector forksp. 905
+Gearbox,mechanics,gears,shafts,internal operationp. 677
Dismantling and assembling input shaftp. 677
Dismantling and assembling output shaftp. 678
+Input shaftp. 740
Dismantling and assembling input shaftp. 740
Adjusting input shaftp. 741
Dismantling and assembling input shaftp. 906
+Output shaftp. 742
Dismantling and assembling output shaftp. 742
Adjusting output shaftp. 743
Dismantling and assembling output shaftp. 907
+Reverse shaftp. 744
Dismantling and assembling reverse shaftp. 744
Notes on gearbox disassemblyp. 829
+Notes on gearbox disassemblyp. 830
Overview: gearbox disassemblyp. 830
Dismantling gearboxp. 831
Assembling gearboxp. 832
Dismantling and assembling gearbox housingp. 833
Dismantling and assembling clutch housingp. 834
Dismantling and assembling outer input shaftp. 835
Dismantling and assembling inner input shaftp. 836
Dismantling and assembling output shaft 1 – overviewp. 837
+Dismantling and assembling output shaft 1 – overviewp. 838
Dismantling output shaft 1 partiallyp. 838
Dismantling output shaft 1 completelyp. 839
Assembling output shaft 1p. 840
Dismantling and assembling locking collars and synchro-hubs of output shaft 1p. 841
Dismantling and assembling output shaft 2 – overviewp. 842
+Dismantling and assembling output shaft 2 – overviewp. 843
Dismantling output shaft 2p. 843
Assembling output shaft 2p. 844
Dismantling and assembling locking collars and synchro-hubs of output shaft 2p. 845
Dismantling and assembling output shaft 3 – overviewp. 846
+Dismantling and assembling output shaft 3 – overviewp. 847
Dismantling output shaft 3p. 847
Assembling output shaft 3p. 848
Dismantling and assembling locking collar and synchro-hub of output shaft 3p. 849
Notes on gearbox adjustmentp. 850
+Notes on gearbox adjustmentp. 851
Calculating shims for clutch housingp. 851
Calculating shims for gearbox housingp. 852
Removing and installing parking lockp. 853
+Final drive, differential, differential lockp. 679
+Renewing flange shaft oil seals with gearbox installedp. 679
Renewing oil seal for left flange shaftp. 679
+Renewing oil seal for left flange shaftp. 680
Removingp. 680
Installingp. 681
Removingp. 746
Installingp. 747
Removingp. 909
Installingp. 910
Renewing seal for right flange shaftp. 682
+Renewing seal for right flange shaftp. 683
Removingp. 683
Installingp. 684
Removingp. 912
Installingp. 913
Renewing oil seal for left flange shaftp. 745
Distinguishing seals for right flange shaftp. 748
Renewing seal (two-part seal and sleeve for right flange shaft)p. 749
+Renewing seal (two-part seal and sleeve for right flange shaft)p. 750
Removingp. 750
Installingp. 751
Renewing seal and sleeve together (one-piece seal and sleeve for right flange shaft)p. 752
+Renewing seal and sleeve together (one-piece seal and sleeve for right flange shaft)p. 753
Removingp. 753
Installingp. 754
Renewing oil seal for left flange shaftp. 908
Renewing seal for right flange shaftp. 911
+Differentialp. 685
Dismantling and assembling differentialp. 685
+Dismantling and assembling differentialp. 686
One-piece thrust bearing and tapered roller bearing for differential modified from gearbox date 06052p. 686
Adjusting differentialp. 687
+Adjusting differentialp. 688
Determining shim S2p. 688
Determining shim S2p. 916
Dismantling and assembling differentialp. 755
Adjusting differentialp. 756
Dismantling and assembling differentialp. 914
Adjusting differentialp. 915
Renewing oil seals for flange shaftsp. 791
+Renewing oil seals for flange shaftsp. 792
Renewing oil seal for left flange shaftp. 792
Renewing seal for right flange shaftp. 793
Oil sealsp. 854
+Oil sealsp. 855
Renewing seal for right flange shaftp. 855
Renewing oil seal for left flange shaftp. 856
5-speed manual gearbox 02Rp. 689
+6-speed automatic gearbox 09Gp. 757
+Torque converterp. 761
Draining torque converterp. 761
Removing and installing torque converter oil sealp. 762
+Automatic gearbox, control, assembly, housingp. 763
Electrical and electronic components and their locationsp. 763
+Multifunction switchF125p. 764
Removing multifunction switchF125p. 764
Installing multifunction switchF125p. 765
Adjusting multifunction switchF125p. 766
Emergency release of selector leverp. 767
Removing and installing selector lever handlep. 768
+Selector mechanismp. 769
Assembly overview – selector mechanismp. 769
Adjusting selector lever cablep. 770
Removing and installing gearbox; 1.6 l – 77 kW enginep. 771
+Removing and installing gearbox; 1.6 l – 77 kW enginep. 772
Specified torquesp. 772
Transporting gearboxp. 773
Checking ATF level and topping upp. 774
+Checking ATF level and topping upp. 775
Checking ATF levelp. 775
Draining and filling ATFp. 776
+ATF coolerp. 777
Assembly overview – ATF coolerp. 777
+Automatic gearbox, gears, controlp. 778
Renewing oil seal for selector shaftp. 778
Removing and installing ATF panp. 779
+Removing and installing ATF panp. 780
Installingp. 780
+Removing and installing ATF strainerp. 781
Removingp. 781
Installingp. 782
+Removing and installing valve bodyp. 783
Overview – valve chestp. 783
Removing valve bodyp. 784
Installing valve bodyp. 785
Wire routing, connectors, connections and retainer on valve bodyp. 786
Specified torquesp. 787
+Removing and installing wiring harness for solenoid valves and sendersp. 788
Removingp. 788
Removing and installing gearbox input speed senderG182p. 789
Removing and installing gearbox output speed senderG195p. 790
7-speed dual clutch gearbox 0AMp. 794
6-speed manual gearbox 02Up. 857
+Power unitp. 917
+4-cyl. injection engine with timing chainp. 917
+Engine assy,cylinder block,crankcasep. 918
Removing and installing enginep. 918
Removing and installing enginep. 981
+Removing and installing enginep. 1109
Removing enginep. 1109
Separating engine from gearboxp. 1110
Securing engine on engine and gearbox supportp. 1111
Assembly mountingsp. 1112
Setting up support bracketp. 1113
+Assembly mountingsp. 1114
Installing support bracket (Polo)p. 1114
Removing and installing enginep. 1286
Removing and installing enginep. 1334
Assembly mountingsp. 1433
Removing and installing enginep. 1436
Removing and installing enginep. 1519
+Enginecrankshaft group, pistonsp. 919
+Dismantling and assembling enginep. 919
Part I Assembly overview – belt drivep. 919
Part II: Assembly overview – chain drive systemp. 920
+Removing and installing poly V-beltp. 921
Poly V-belt routingp. 921
Assembly overview – poly V-belt drive without air conditioning compressorp. 1124
Assembly overview – poly V-belt drive with tensioning element and air conditioner compressorp. 1125
Removing and installing poly V-belt with tensioning elementp. 1126
Removing and installing tensioning element for poly V-beltp. 1127
Poly V-belt routingp. 1439
Removing and installing valve timing housingp. 922
Assembly overview – part I, belt drivep. 982
Removing and installing vibration damperp. 1136
Assembly overview – toothed belt drivep. 1137
Removing and installing engine bracketp. 1138
Assembly overview – belt drivep. 1287
Removing and installing valve timing housingp. 1288
Assembly overview – belt drivep. 1335
Removing and installing valve timing housingp. 1336
Assembly overview – part I, belt drivep. 1437
Part II: Assembly overview – chain drive systemp. 1438
Removing and installing valve timing housingp. 1440
Assembly overview – part I, belt drivep. 1520
Assembly overview – part II, cylinder blockp. 1521
+Cylinder block, sealing flangep. 923
Assembly overviewp. 923
Renewing crankshaft oil seal – belt pulley endp. 924
Poly V-belt pulley securing bolt tightening procedurep. 925
+Renewing crankshaft sealing flange – flywheel end ( assembly tool T10134 )p. 926
A – Assembling sealing flange with sender wheel on assembly appliance T10134p. 926
B – Attaching assembling tool T10134 with sealing flange to crankshaft flangep. 927
E – Checking sender wheel installation position on crankshaftp. 928
F – Re-pressing sender wheelp. 929
+Renewing crankshaft sealing flange – flywheel end ( assembly tool T10017 )p. 930
A-Assembling sealing flange with sender wheel on assembly appliance T10017p. 930
B-Assembling appliance T10017 with sealing flange on crankshaft flangep. 931
E – Checking sender wheel installation position on crankshaftp. 932
F – Pressing sender wheelp. 933
Assembly overviewp. 983
Pulling needle bearing out of and driving into crankshaftp. 984
Renewing crankshaft oil seal – belt pulley endp. 985
Removing and installing drive platep. 986
+Renewing crankshaft sealing flange – flywheel end (assembly toolT10134)p. 987
A – Assembling seal with sender wheel on assembly toolT10134p. 987
B – Attaching assembling toolT10134 with sealing flange on crankshaft flangep. 988
E – Checking sender wheel installation position on crankshaftp. 989
F – Re-pressing sender wheelp. 990
A – Assembling seal with sender wheel on assembly toolT10134p. 1525
B – Attaching assembling toolT10134 with sealing flange on crankshaft flangep. 1526
E – Checking sender wheel installation position on crankshaftp. 1527
F – Re-pressing sender wheelp. 1528
+Renewing crankshaft sealing flange – flywheel end (assembly toolT10017)p. 991
A-Assembling sealing flange with sender wheel on assembly appliance T10017p. 991
B-Assembling appliance T10017 with sealing flange on crankshaft flangep. 992
E – Checking sender wheel installation position on crankshaftp. 993
F – Re-pressing sender wheelp. 994
A-Assembling sealing flange with sender wheel on assembly appliance T10017p. 1529
B – Attaching assembling toolT10017 with sealing flange on crankshaft flangep. 1530
E – Checking sender wheel installation position on crankshaftp. 1531
F – Re-pressing sender wheelp. 1532
Assembly overviewp. 1441
Removing and installing engine speed senderG28p. 1442
Renewing crankshaft oil seal – pulley endp. 1443
Removing and installing crankshaft pulleyp. 1444
Renewing crankshaft sealing flange – flywheel endp. 1445
Assembly overviewp. 1522
Renewing crankshaft oil seal – belt pulley endp. 1523
Removing and installing drive platep. 1524
+Pistons and conrodsp. 934
Assembly overviewp. 934
Checking pistonp. 935
Assembly overviewp. 995
Checking pistonp. 1054
Checking piston and cylinder borep. 1390
Assembly overviewp. 1451
Checking pistonp. 1452
Assembly overviewp. 1533
+Cylinder block (pulley end)p. 1042
Assembly overview – poly V-belt drivep. 1042
Assembly overview – cylinder block, belt pulley endp. 1043
+Removing and installing poly V-belt (Golf Plus, Eos, Scirocco, Golf, Touran, Polo, Sharan, Passat, Passat CC, Golf Cabriolet)p. 1044
Poly V-belt routingp. 1044
Renewing crankshaft oil seal – pulley endp. 1045
Removing and installing crankshaft pulleyp. 1046
Assembly overview – poly V-belt drive without air conditioning compressorp. 1115
Assembly overview – poly V-belt drive (vehicles with idler roller and air conditioner compressor)p. 1116
Assembly overview – poly V-belt drive (vehicles with tensioning element and air conditioner compressor)p. 1117
Removing and installing poly V-belt (vehicles with idler roller)p. 1118
Removing and installing poly V-belt (vehicles with tensioning element)p. 1119
+Removing and installing tensioner for poly V-beltp. 1120
Removing and installing poly V-belt tensioning elementp. 1120
Removing and installing vibration damperp. 1121
Renewing crankshaft oil seal – belt pulley endp. 1122
Removing and installing sealing flange – pulley endp. 1123
Assembly overview – poly V-belt drivep. 1380
Renewing crankshaft oil seal – belt pulley endp. 1381
Removing and installing crankshaft pulleyp. 1382
+Cylinder block, gearbox endp. 1047
Removing and installing sealing flange on gearbox sidep. 1047
+Removing and installing sealing flange on gearbox sidep. 1048
A – Assembling seal with sender wheel on assembly toolT10134p. 1048
B – Attaching assembling toolT10134 with sealing flange on crankshaft flangep. 1049
E – Checking sender wheel installation position on crankshaftp. 1050
F – Re-pressing sender wheelp. 1051
Pressing out sealing flange with sender wheelp. 1131
a) Securing seal with sender wheel on assembly toolT10134p. 1132
b) Securing assembling toolT10134 with sealing flange on crankshaft flangep. 1133
E – Checking sender wheel installation position on crankshaftp. 1134
F – Re-pressing sender wheelp. 1135
Assembly overview – cylinder block, gearbox endp. 1128
Assembly overview – removing and installing flywheel (vehicles with single flywheel)p. 1129
Removing and installing sealing flange on gearbox sidep. 1130
Removing and installing crankshaft sealing flange on gearbox sidep. 1383
+Removing and installing crankshaft sealing flange on gearbox sidep. 1384
Mounting seal with sender wheel on assembly toolT10134p. 1384
Mounting assembly toolT10134 with sealing flange on crankshaft flangep. 1385
Checking sender wheel installation position on crankshaftp. 1386
Re-pressing sender wheelp. 1387
Removing and installing ancillary bracket (top)p. 1388
+Crankshaftp. 1052
Assembly overview – crankshaftp. 1052
Pulling needle bearing out of and driving into crankshaftp. 1053
Assembly overview – crankshaftp. 1148
+Assembly overview – crankshaftp. 1149
Measuring axial clearance of crankshaftp. 1149
Pulling needle bearing out of and driving into crankshaftp. 1389
Assembly overviewp. 1450
+Removing and installing sealing flange and flywheelp. 1139
Renewing crankshaft sealing flange – flywheel endp. 1139
+Renewing crankshaft sealing flange – flywheel endp. 1140
Pressing out sealing flange with sender wheelp. 1140
a) Securing seal with sender wheel on assembly toolT10134p. 1141
b) Securing assembling toolT10134 with sealing flange on crankshaft flangep. 1142
E – Checking sender wheel installation position on crankshaftp. 1143
F – Re-pressing sender wheelp. 1144
A – Assembling seal with sender wheel on assembly toolT10134p. 1446
B – Attaching assembling toolT10134 with sealing flange on crankshaft flangep. 1447
E – Checking sender wheel installation position on crankshaftp. 1448
F – Re-pressing sender wheelp. 1449
Renewing crankshaft oil seal – pulley endp. 1145
Removing and installing sealing flange – pulley endp. 1146
Removing and installing engine speed senderG28p. 1147
+Cylinder block, sealsp. 1289
Assembly overviewp. 1289
Renewing crankshaft oil seal – belt pulley endp. 1290
Renewing crankshaft oil seal – flywheel endp. 1291
Assembly overviewp. 1337
Renewing crankshaft oil seal – belt pulley endp. 1338
Renewing crankshaft oil seal – flywheel endp. 1339
+Engine cylinder head, valve gearp. 936
+Cylinder headp. 936
Assembly overviewp. 936
Checking valve timingp. 937
Adjusting valve timingp. 938
Removing and installing timing chain and chain drive for oil pumpp. 939
Removing and installing camshaft housingp. 940
Removing and installing cylinder headp. 941
Checking compressionp. 942
Checking valve timingp. 996
Removing, installing and tensioning toothed beltp. 997
+Removing, installing and tensioning toothed beltp. 998
Removingp. 998
Removingp. 1537
Checking semi-automatic toothed belt tensionerp. 999
Removing and installing camshaft housingp. 1000
Removing and installing cylinder headp. 1001
Checking compressionp. 1002
Assembly overview – cylinder headp. 1055
Removing and installing camshaft housingp. 1056
Removing and installing cylinder headp. 1057
+Removing and installing cylinder headp. 1058
Removingp. 1058
Removingp. 1154
Checking compressionp. 1059
Removing and installing cylinder head coverp. 1150
Removing and installing injector seal in cylinder head coverp. 1151
Removing, installing and tensioning toothed beltsp. 1152
Removing and installing cylinder headp. 1153
Checking compressionp. 1155
Assembly overviewp. 1292
Removing and installing cylinder headp. 1293
Removing and installing camshaft housingp. 1294
Checking valve timingp. 1295
Removing and installing timing chain and drive chain for oil pumpp. 1296
Checking compressionp. 1297
Assembly overviewp. 1340
Removing and installing cylinder headp. 1341
Checking valve timingp. 1342
Removing and installing timing chain and drive chain for oil pumpp. 1343
Adjusting valve timingp. 1344
Checking compressionp. 1345
Assembly overview – cylinder headp. 1391
+Removing and installing cylinder head cover and camshaftp. 1392
Removing and installing camshaftp. 1392
Removing and installing cylinder headp. 1393
Checking compressionp. 1394
Assembly overview – cylinder headp. 1453
Checking valve timingp. 1454
Adjusting valve timingp. 1455
Removing and installing timing chain and chain drive for oil pumpp. 1456
Removing and installing camshaft housingp. 1458
+Removing and installing camshaft housingp. 1459
Installingp. 1459
Removing and installing cylinder headp. 1460
Checking compressionp. 1461
Assembly overviewp. 1534
Checking valve timingp. 1535
Removing, installing and tensioning toothed beltp. 1536
Checking semi-automatic toothed belt tensionerp. 1538
Removing and installing camshaft housingp. 1539
Removing and installing cylinder headp. 1540
Checking compressionp. 1541
+Valve gearp. 943
Assembly overviewp. 943
Checking camshaft axial clearancep. 944
Checking valve guidesp. 945
Renewing valve stem sealsp. 946
Assembly overviewp. 1003
+Reworking valve seatsp. 1004
Reworking inlet valve seatp. 1004
Reworking exhaust valve seatp. 1005
Reworking inlet valve seatp. 1543
Reworking exhaust valve seatp. 1544
Renewing camshaft oil sealsp. 1006
Checking valve guidesp. 1007
Renewing valve stem sealsp. 1008
Assembly overview – valve gearp. 1060
Measuring axial clearance of camshaftp. 1061
Checking valve guidesp. 1062
Removing and installing valve stem sealsp. 1063
+Removing and installing valve stem sealsp. 1064
Removingp. 1064
Installingp. 1065
Assembly overview – valve gearp. 1156
Measuring axial clearance of camshaftp. 1157
+Valvesp. 1158
Checking valve guidesp. 1158
Renewing valve stem seals with cylinder head installedp. 1159
Renewing valve stem seals with cylinder head removedp. 1160
Removing and installing camshaftsp. 1161
+Removing and installing camshaftsp. 1162
Removingp. 1162
Removing and installing camshaft oil sealp. 1163
Assembly overviewp. 1298
Checking camshaft axial clearancep. 1299
Checking valve guidesp. 1300
Renewing valve stem sealsp. 1301
Checking camshaft axial clearancep. 1346
Checking valve guidesp. 1347
Renewing valve stem sealsp. 1348
Assembly overview – valve gearp. 1395
Measuring axial play of camshaftp. 1396
+Inlet and exhaust valvesp. 1397
Checking valve guidesp. 1397
Renewing valve stem sealsp. 1398
Assembly overviewp. 1462
Checking camshaft axial clearancep. 1463
Checking valve guidesp. 1464
Renewing valve stem sealsp. 1465
Assembly overviewp. 1542
Renewing camshaft oil sealsp. 1545
Checking valve guidesp. 1546
Renewing valve stem sealsp. 1547
+Cover for timing chainp. 1066
Removing and installing valve timing housing (Eos, Golf Plus, Scirocco, Golf, Polo, Sharan, Golf Cabriolet)p. 1066
+Removing and installing valve timing housing (Eos, Golf Plus, Scirocco, Golf, Polo, Sharan, Golf Cabriolet)p. 1067
Removingp. 1067
+Chain drivep. 1068
Checking valve timingp. 1068
Adjusting valve timingp. 1069
Removing and installing timing chain and chain drive for oil pumpp. 1070
Assembly overview – timing chainp. 1399
Checking valve timingp. 1400
+Removing and installing timing chain and chain drive for oil pumpp. 1401
Removing timing chainp. 1401
Removing and installing chain drive for oil pumpp. 1402
Installing timing chainp. 1403
Removingp. 1457
+Toothed belt drivep. 1164
Assembly overview – toothed belt drive (Polo)p. 1164
Removing, installing and tensioning toothed beltp. 1165
+Engine lubricationp. 947
+Parts of lubrication systemp. 947
Assembly overviewp. 947
Removing and installing sumpp. 948
Removing and installing oil pumpp. 949
Checking oil pressure and oil pressure switchp. 950
Assembly overviewp. 1009
Removing and installing oil sumpp. 1010
Removing and installing oil pumpp. 1011
Checking oil pressure and oil pressure switchp. 1012
Assembly overview – oil pump, sumpp. 1170
Removing and installing oil sumpp. 1171
Removing and installing oil pumpp. 1172
Assembly overviewp. 1302
Assembly overview – oil filterp. 1303
Removing and installing oil sumpp. 1304
Checking oil pressure and oil pressure switchp. 1305
Assembly overviewp. 1349
Assembly overview – oil filterp. 1350
Removing and installing oil sumpp. 1351
Checking oil pressure and oil pressure switchp. 1352
Assembly overviewp. 1466
Removing and installing oil sumpp. 1467
Removing and installing oil pumpp. 1468
Checking oil pressure and oil pressure switchp. 1469
Assembly overviewp. 1548
Removing and installing oil sumpp. 1549
Removing and installing oil pumpp. 1550
Checking oil pressure and oil pressure switchp. 1551
+Sump, oil pumpp. 1071
Assembly overview – sump, oil pumpp. 1071
Removing and installing oil sumpp. 1072
Assembly overview – sump / oil pumpp. 1166
Removing and installing oil sumpp. 1167
Removing and installing oil pumpp. 1168
Removing and installing oil level and oil temperature senderG 266p. 1169
Assembly overview – sump, oil pumpp. 1404
Removing and installing oil sumpp. 1405
Removing and installing oil pumpp. 1406
+Oil filter, oil pressure switchp. 1073
Checking oil pressure and oil pressure switchp. 1073
Removing and installing oil filter bracket with engine oil coolerp. 1175
+Checking oil pressure and oil pressure switchp. 1176
Checking oil pressurep. 1176
Checking oil pressure switchp. 1177
Checking oil pressurep. 1183
Removing and installing oil pressure switchF1p. 1178
Checking oil pressure and oil pressure switchp. 1407
+Engine oil coolerp. 1173
Removing and installing engine oil coolerp. 1173
Checking engine oil cooler for leaksp. 1174
Removing and installing engine oil coolerp. 1408
+Oil filter bracket, oil pressure, engine oil cooler and oil supply linep. 1179
Removing and installing oil filter bracket with engine oil coolerp. 1179
Removing and installing engine oil coolerp. 1180
Checking engine oil cooler for leaksp. 1181
Checking oil pressure and oil pressure switchp. 1182
Removing and installing oil pressure switchF1p. 1184
+Oil circuitp. 1185
Assembly overview – parts of oil supply line and oil return line (turbocharger support)p. 1185
+Oil supply line and turbocharger supportp. 1186
Assembly overview – oil supply line and turbocharger supportp. 1186
Removing and installing oil supply line and turbocharger supportp. 1187
+Engine coolingp. 951
+Parts of cooling systemp. 951
Assembly overview – parts of cooling system, body sidep. 951
Assembly overview – parts of cooling system, engine sidep. 952
Coolant hose schematic diagramp. 953
Draining and filling coolantp. 954
Removing and installing radiatorp. 955
Removing and installing coolant pumpp. 956
Assembly overview – parts of cooling system, body sidep. 1013
Assembly overview – parts of cooling system, engine sidep. 1014
Coolant hose schematic diagramp. 1015
Draining and filling coolantp. 1016
Removing and installing radiatorp. 1017
Removing and installing coolant pumpp. 1018
Assembly overview – parts of cooling system, body sidep. 1306
Assembly overview – parts of cooling system, engine sidep. 1307
Coolant hose schematic diagramp. 1308
Draining and filling coolantp. 1309
Removing and installing radiatorp. 1310
Removing and installing coolant pumpp. 1311
Assembly overview – parts of cooling system, body sidep. 1353
Assembly overview – parts of cooling system, engine sidep. 1354
Coolant hose schematic diagramp. 1355
Draining and filling coolantp. 1356
Removing and installing radiatorp. 1357
Removing and installing coolant pumpp. 1358
Assembly overview – parts of cooling system, body sidep. 1470
Assembly overview – parts of cooling system, engine sidep. 1471
Coolant hose schematic diagramp. 1472
Draining and filling coolantp. 1473
Checking cooling system for leaksp. 1474
Removing and installing cowling with radiator fanV7p. 1475
Removing and installing radiator fanV7p. 1476
Removing and installing radiatorp. 1477
Removing and installing coolant pumpp. 1478
Assembly overview – parts of cooling system, body sidep. 1552
+Assembly overview – parts of cooling system, engine sidep. 1553
Parts of cooling system – coolant controller sidep. 1553
Parts of cooling system – coolant pump sidep. 1554
Coolant hose schematic diagramp. 1555
Draining and filling coolantp. 1556
Removing and installing radiatorp. 1557
Removing and installing coolant pumpp. 1558
+Cooling system, coolantp. 1074
Coolant hose schematic diagram (Golf Plus, Eos, Scirocco, Golf, Touran, Polo, Golf Cabriolet)p. 1074
Draining and filling with coolant (Polo)p. 1075
Checking cooling system for leaks (Polo, Touran, Golf Plus, Eos, Tiguan, Scirocco, Golf, Golf Cabriolet)p. 1076
+Coolant hose schematic diagramp. 1199
Coolant hose schematic diagram (vehicles with auxiliary heater, Polo)p. 1199
Coolant hose schematic diagram (vehicles with 4/2 way valve, Polo)p. 1200
Checking cooling system for leaksp. 1201
+Cooling system – fitting locationsp. 1202
Assembly overview – parts of cooling system, engine side (Polo)p. 1202
Coolant hose schematic diagramp. 1409
Checking cooling system for leaksp. 1410
+Coolant pump, regulation of cooling systemp. 1077
Assembly overview – thermostatp. 1077
Removing and installing coolant pump belt pulley (Polo, Touran, Golf Plus, Eos, Tiguan, Scirocco, Golf, Golf Cabriolet)p. 1078
Removing and installing coolant circulation pumpV50 (Polo, Touran, Golf Plus, Eos, Tiguan, Scirocco, Golf, Golf Cabriolet)p. 1079
Assembly overview – coolant pump and 4/2-way valve with thermostat (Polo, Golf, Passat, Touran)p. 1205
Removing and installing coolant pumpp. 1206
+Electric coolant pumpp. 1207
Removing and installing coolant circulation pump 2V178 (Polo)p. 1207
Assembly overview – thermostatp. 1411
Removing and installing coolant circulation pumpV50p. 1412
+Radiator, radiator fanp. 1080
Assembly overview – radiator, radiator fan (Polo)p. 1080
Removing and installing radiator fanV7 and radiator fan 2V177 (Polo)p. 1081
Removing and installing radiator fanV7 (Polo)p. 1413
+Cooling systemp. 1188
Assembly overview – parts of cooling system, body sidep. 1188
Assembly overview – cowling with radiator fanV7p. 1189
Parts of cooling system, engine sidep. 1190
Assembly overview – coolant pump and 4/2-way valve with thermostatp. 1191
Coolant hose schematic diagramp. 1192
Removing and installing cowling with radiator fanV7p. 1193
Removing and installing radiator and detaching charge air cooler from radiatorp. 1194
Removing and installing coolant circulation pump 2V178p. 1195
Removing and installing coolant pumpp. 1196
Removing and installing front coolant pipep. 1197
Removing and installing right coolant pipesp. 1198
+Draining and replenishing coolantp. 1203
Draining and filling coolantp. 1203
Checking cooling system for leaksp. 1204
+Coolant pipesp. 1208
Removing and installing front coolant pipe (Polo)p. 1208
Removing and installing right coolant pipes (Polo)p. 1209
+Fuel supply, gas operationp. 957
+Parts of fuel supply systemp. 957
Assembly overview – fuel tank with attachmentsp. 957
Removing and installing fuel delivery unitp. 958
Removing and installing fuel gauge sender Gp. 959
Removing and installing fuel tankp. 960
Assembly overview – fuel filter with attachmentsp. 961
Checking fuel pumpp. 962
Bleeding fuel systemp. 963
Assembly overview – fuel tank with attachmentsp. 1019
Removing and installing fuel delivery unitp. 1020
Removing and installing fuel gauge senderp. 1021
Removing and installing fuel tankp. 1022
Checking fuel pump (engine code CGGB)p. 1023
Bleeding fuel systemp. 1024
+Fuel tankp. 1212
Assembly overview – fuel tankp. 1212
Removing and installing fuel tankp. 1213
+Assembly overview – fuel tankp. 1587
Assembly overview – fuel tank (CFWA)p. 1587
Removing, installing and checking breather valvep. 1588
+Removing and installing fuel tankp. 1589
Removing and installing the fuel tank (CAYA, CAYB, CAYC)p. 1589
Removing and installing fuel tank (CFWA)p. 1590
Removing, installing and checking gravity valvep. 1591
Emptying fuel tankp. 1592
Assembly overview – fuel tankp. 1606
Removing and installing fuel tankp. 1607
Emptying fuel tankp. 1608
Removing and installing fuel delivery unitp. 1214
+Removing and installing fuel delivery unitp. 1215
Removingp. 1215
Assembly overview – fuel tank with attachmentsp. 1312
Removing and installing fuel delivery unitp. 1313
Removing and installing fuel gauge senderGp. 1314
Removing and installing fuel tankp. 1315
Checking fuel pumpp. 1316
Bleeding fuel systemp. 1317
Assembly overview – fuel tank with attachmentsp. 1359
Removing and installing fuel delivery unitp. 1360
Removing and installing fuel gauge senderGp. 1361
Removing and installing fuel tankp. 1362
Checking fuel pumpp. 1363
Bleeding fuel systemp. 1364
+Assembly overview – fuel tank with attachmentsp. 1479
Assembly overview – fuel tankp. 1479
Emptying fuel tankp. 1480
Removing and installing fuel delivery unitp. 1482
Removing and installing external fuel gauge senderG with two cable connectionsp. 1483
Removing and installing interior fuel gauge senderGp. 1484
Removing and installing fuel tankp. 1485
+Checking fuel pumpp. 1486
Checking function and voltage supplyp. 1486
Checking holding pressurep. 1487
Checking current drawp. 1488
Checking voltage supply of the fuel pump for delivery rateG6 (CAYA, CAYB, CAYC)p. 1605
Checking holding pressurep. 1616
Checking current drawp. 1617
Bleeding fuel systemp. 1489
+Parts of Autogas (LPG) fuel supply systemp. 1490
Assembly overview – gas tank (Autogas)p. 1490
Gas gauge senderG707p. 1491
Removing and installing gas tank valveN495p. 1492
Removing and installing fuel tank (Autogas)p. 1493
Assembly overview – gas tank (Autogas)p. 1565
Gas gauge senderG707p. 1566
Removing and installing gas tank valveN495p. 1567
Removing and installing fuel tank (Autogas)p. 1568
Assembly overview – fuel tank with attachmentsp. 1559
Removing and installing fuel delivery unitp. 1560
Removing and installing fuel gauge senderp. 1561
Removing and installing fuel tankp. 1562
Checking fuel pumpp. 1563
Bleeding fuel systemp. 1564
+Electronic power control (EPC)p. 964
Assembly overviewp. 964
Assembly overviewp. 1025
Assembly overviewp. 1320
Assembly overviewp. 1367
Assembly overviewp. 1494
Assembly overviewp. 1569
+Activated charcoal filter systemp. 965
Assembly overviewp. 965
Checking fuel tank breatherp. 966
Assembly overview – parts of activated charcoal filter systemp. 1026
Checking fuel tank breatherp. 1027
Assembly overviewp. 1318
Checking fuel tank breatherp. 1319
Assembly overviewp. 1365
Checking fuel tank breatherp. 1366
+Assembly overviewp. 1495
Assembly overview – activated charcoal filterp. 1495
+Checking fuel tank breatherp. 1496
Checking activated charcoal filterp. 1496
Assembly overview – parts of activated charcoal filter systemp. 1570
Checking fuel tank breatherp. 1571
Assembly overview – activated charcoal filter systemp. 1613
Checking fuel tank breatherp. 1614
Emptying fuel tankp. 1210
+Emptying fuel tankp. 1211
Emptying fuel tank when fuel pump is intactp. 1211
Emptying fuel tank if it is less than 3/4 fullp. 1481
Emptying fuel tank when fuel pump is intact (CAYA, CAYB, CAYC)p. 1593
Emptying fuel tank if it is less than 3/4 full (CFWA)p. 1594
Emptying fuel tank when fuel pump is intactp. 1609
+Fuel gauge sender G6p. 1216
Removing and installing fuel gauge sender G 6 in vehicles with 0.5 bar low-pressure fuel systemp. 1216
Removing and installing fuel gauge sender G6, vehicles with 6.0 bar low-pressure fuel systemp. 1217
+Repairing fuel supplyp. 1218
Assembly overview – fuel filterp. 1218
Removing and installing fuel filterp. 1219
Assembly overview – accelerator mechanismp. 1220
+Testing low-pressure fuel systems (fuel pump)p. 1221
Distinguishing features of the various low-pressure fuel systemsp. 1221
+Checking fuel pump, vehicles with 0.5 bar low-pressure fuel systemp. 1222
Checking voltage supply of fuel system pressurisation pump G6p. 1222
+Checking fuel pump, vehicles with 6.0 bar low-pressure fuel systemp. 1223
Checking delivery pressure of fuel pumpp. 1223
Checking fuel system pressurisation pump delivery ratep. 1224
Checking voltage supply of fuel system pressurisation pumpp. 1225
+Fuel delivery unit, fuel gauge senderp. 1595
Assembly overview – fuel delivery unit/fuel gauge sender (CAYA, CAYB, CAYC)p. 1595
+Removing and installing fuel delivery unit/fuel gauge senderp. 1596
Removing and installing the fuel delivery unit/fuel gauge sender (CAYA, CAYB, CAYC)p. 1596
Removing and installing fuel delivery unit/fuel gauge sender (CFWA)p. 1597
+Removing and installing fuel gauge senderp. 1598
Removing and installing fuel gaugeG sender (CAYA, CAYB, CAYC)p. 1598
Removing and installing fuel gauge senderG6 (CFWA)p. 1599
Checking fuel gaugeG sender (CAYA, CAYB, CAYC)p. 1600
Removing and installing fuel delivery unit, fuel gauge senderp. 1610
Removing and installing fuel gauge senderp. 1611
+Fuel filterp. 1601
+Assembly overview – fuel filterp. 1601
Assembly overview – fuel filter (CAYA, CAYB, CAYC)p. 1601
Assembly overview – fuel filter (CFWA)p. 1602
+Removing and installing fuel filterp. 1603
Removing and installing the fuel filter (CAYA, CAYB, CAYC)p. 1603
Assembly overview – fuel filterp. 1612
+Accelerator mechanismp. 1604
Assembly overview – accelerator modulep. 1604
Assembly overview – accelerator modulep. 1615
Fuel pumpp. 1605
+Mixture preparation system, electronic inj.,Gasp. 967
+Injection systemp. 967
Assembly overview – intake manifoldp. 967
Assembly overview – fuel rail with injectorsp. 968
Assembly overview – air filterp. 969
Removing and installing air filter housingp. 970
Assembly overview – parts of injection systemp. 1028
Assembly overview – intake manifoldp. 1029
Assembly overview – fuel rail with injectorsp. 1030
Assembly overview – air filterp. 1031
Removing and installing air filter housingp. 1032
Checking injectorsp. 1033
Assembly overview – parts of injection systemp. 1321
Assembly overview – intake manifoldp. 1322
Assembly overview – fuel rail with injectorsp. 1323
Removing and installing air filterp. 1324
Checking injectorsp. 1325
Assembly overview – parts of injection systemp. 1368
Assembly overview – intake manifoldp. 1369
Assembly overview – fuel rail with injectorsp. 1370
Removing and installing air filterp. 1371
Checking injectorsp. 1372
Check non-return valve for crankcase breatherp. 1373
Assembly overview – intake manifoldp. 1497
Assembly overview – fuel rail with injectorsp. 1498
+Fuel rail, removing and installing gas railp. 1499
Installingp. 1499
Installingp. 1575
Assembly overview – air filterp. 1500
Removing and installing air filter housingp. 1501
+Renewing filter on Autogas systemp. 1502
Renewing paper filter on vaporiserp. 1502
Removing and installing vaporiser on vehicles which can be operated with liquid gasp. 1503
Assembly overview – parts of injection systemp. 1572
Assembly overview – intake manifoldp. 1573
Assembly overview – fuel rail with injectorsp. 1574
Assembly overview – air filterp. 1576
Removing and installing air filter housingp. 1577
Checking injectorsp. 1578
Removing and installing vaporiser on vehicles which can be operated with liquid gasp. 1579
+Checking componentsp. 971
Checking injectors for leaks and quantity injectedp. 971
+Checking injectors for leaks and quantity injectedp. 972
Checking quantity injectedp. 972
Checking quantity injectedp. 1505
Checking fuel pressure regulator and holding pressurep. 973
Checking injectors for leaks and quantity injectedp. 1504
+Engine control unit J623p. 974
Removing and installing engine control unit J623p. 974
Vehicles with anti-theft secured engine control unit J623p. 975
+Engine control unitJ623p. 1034
Removing and installing anti-theft engine control unitJ623 (engine codes BUD and CGGB)p. 1034
Removing and installing engine control unitJ623 (Polo)p. 1097
Removing and installing engine control unitJ623 with protective housing (Polo)p. 1098
Removing and installing engine control unitJ623p. 1326
Vehicles with anti-theft secured engine control unitJ623p. 1327
Removing and installing engine control unitJ623p. 1374
Removing and installing anti-theft engine control unitJ623p. 1375
Removing and installing engine control unitJ623 (Polo)p. 1425
Removing and installing engine control unitJ623 with protective housing (Polo)p. 1426
Removing and installing engine control unitJ623p. 1506
Vehicles with anti-theft secured engine control unitJ623p. 1507
Removing and installing engine control unitJ623p. 1580
+Air filterp. 1089
Assembly overview – air filter (Polo)p. 1089
Removing and installing air filter housing (Polo)p. 1090
Assembly overview – air filterp. 1256
+Assembly overview – air filterp. 1257
Removing and installing air filter housingp. 1257
Assembly overview – air filter (Polo)p. 1418
Removing and installing air filter housing (Polo)p. 1419
+Intake manifoldp. 1091
Assembly overview – intake manifoldp. 1091
Assembly overview – intake manifold with attachments (vehicles with intake manifold flapV157)p. 1251
Assembly overview – intake manifold with attachments (vehicles without intake manifold flap)p. 1252
Removing and installing intake manifold (vehicles with intake manifold flapV157)p. 1253
Removing and installing intake manifold (vehicles without intake manifold flapV157)p. 1254
Removing and installing throttle valve moduleJ338p. 1255
Removing and installing intake manifoldp. 1420
Removing and installing throttle valve moduleJ338p. 1421
+Injectorsp. 1092
Assembly overview – fuel rail with injectorsp. 1092
Renewing seals on injectorsp. 1093
Renewing seals on injectorsp. 1422
+Senders and sensorsp. 1094
Actuator for structure-borne soundR214 and control unit for structure-borne soundJ869 (Polo, left-hand drive)p. 1094
Assembly overview – actuator for structure-borne soundR214 and control unit for structure-borne soundJ869 (Polo, right-hand drivp. 1095
Checking fuel pressure senderG247p. 1424
+High-pressure pumpp. 1096
Removing and installing high-pressure pumpp. 1096
Assembly overview – high-pressure pumpp. 1241
Pressure testing high-pressure pumpp. 1242
Checking return flow rate at high-pressure pumpp. 1243
Removing and installing high-pressure pumpp. 1423
+Gas mode control unitJ659p. 1508
+Removing and installing gas mode control unitJ659p. 1508
Removingp. 1508
Removingp. 1581
Removing holder for gas mode control unitJ659p. 1509
Removing holder for gas mode control unitJ659p. 1582
+Exhaust systemp. 976
+Parts of the exhaust systemp. 976
Assembly overview – catalytic converters and attachmentsp. 976
Assembly overview – silencers with mountingsp. 977
Assembly overview – front exhaust system with attachmentsp. 1035
Assembly overview – silencers with mountingsp. 1036
Assembly overview – front exhaust system with attachmentsp. 1328
Assembly overview – silencers with mountingsp. 1329
Assembly overview – front exhaust system with attachmentsp. 1376
Assembly overview – silencers with mountingsp. 1377
Assembly overview – catalytic converters and attachmentsp. 1510
Assembly overview – silencers with mountings, squarebackp. 1511
Separating front and rear silencersp. 1512
Assembly overview – front exhaust system with attachmentsp. 1583
Assembly overview – silencers with mountingsp. 1584
+Exhaust gas recirculation systemp. 1037
Assembly overviewp. 1037
Assembly overview – parts of exhaust gas recirculation systemp. 1268
Checking changeover for exhaust gas recirculation coolerp. 1269
Removing and installing exhaust gas recirculation systemp. 1270
+Exhaust pipes, silencersp. 1099
Assembly overview – silencer (Polo)p. 1099
Separating exhaust pipes/silencers (Polo)p. 1100
+Assembly overview – exhaust systemp. 1265
Assembly overview – silencer (Polo)p. 1265
Disconnect exhaust system (Polo)p. 1266
+Aligning exhaust system free of stressp. 1267
Aligning exhaust system free of tension (Passat)p. 1267
Assembly overview – silencer (Polo)p. 1427
Separating exhaust pipes, silencersp. 1428
+Cleansing exhaust emissionsp. 1101
Assembly overview – exhaust gas purification system (Polo)p. 1101
Removing and installing catalytic converter (Polo)p. 1102
+Removing and installing particulate filterp. 1271
Removing and installing particulate filter with front exhaust pipe (Polo)p. 1271
Removing and installing catalytic converter with non-engine-mounted particulate filter (Polo)p. 1272
Assembly overview – exhaust gas purification system (Polo)p. 1429
Removing and installing catalytic converter (Polo)p. 1430
Removing and installing catalytic converterp. 1260
+Removing and installing catalytic converterp. 1261
Removingp. 1261
Assembly overview – silencerp. 1262
+Assembly overview – silencerp. 1263
Separating catalytic converter and silencerp. 1263
Aligning exhaust system free of stressp. 1264
+Exhaust gas temperature regulationp. 1273
Assembly overview – exhaust gas temperature regulationp. 1273
+Removing and installing parts of exhaust gas temperature regulationp. 1274
Removing and installing exhaust gas temperature sender 3G495p. 1274
Tightening exhaust gas temperature sender 3 G 495p. 1275
Removing and installing exhaust gas temperature sender 4G648p. 1276
+Removing and installing parts of exhaust gas temperature control system (Polo, right-hand drive)p. 1277
Tightening exhaust gas temperature sender 3G 495 (Polo, right-hand drive)p. 1277
Tightening exhaust gas temperature sender 4G 648 (Polo, right-hand drive)p. 1278
+Exhaust gas recirculationp. 1279
Assembly overview – exhaust gas recirculationp. 1279
Checking changeover for exhaust gas recirculation coolerp. 1280
Removing and installing exhaust gas recirculation coolerp. 1281
+Ignition system, glow plug systemp. 978
+Ignition systemp. 978
Assembly overview – ignition systemp. 978
Removing and installing ignition coils with output stagep. 979
Safety precautionsp. 980
Assembly overview – parts of ignition systemp. 1038
Safety precautionsp. 1039
Assembly overview – ignition systemp. 1103
Removing and installing ignition coils with output stagep. 1104
Removing and installing engine speed senderG28p. 1105
Assembly overview – parts of ignition systemp. 1330
Removing and installing ignition coils with output stagep. 1331
Safety precautionsp. 1332
Assembly overview – parts of ignition systemp. 1378
Safety precautionsp. 1379
Assembly overview – ignition systemp. 1431
Removing and installing engine speed senderG28p. 1432
Assembly overview – ignition systemp. 1513
Removing and installing ignition coils with output stagep. 1514
Safety precautionsp. 1515
Assembly overview – parts of ignition systemp. 1585
Safety precautionsp. 1586
Removing, installing and checking glow plugsp. 1282
+Glow plug systemp. 1283
Removing and installing glow plugsp. 1283
Removing and installing engine speed senderG 28p. 1284
4-cyl. injection engine (toothed belt drive)p. 981
+4-cylinder injection engine (1.4 l direct injection engine, turbocharger and supercharger)p. 1040
+Exhaust turbocharger, G-chargerp. 1082
+Turbochargerp. 1082
Assembly overview – turbochargerp. 1082
Removing and installing turbochargerp. 1083
Checking vacuum unit for turbochargerp. 1084
Removing and installing vacuum unit for turbochargerp. 1085
+Removing and installing turbochargerp. 1229
Removing and installing turbocharger (Polo)p. 1229
Assembly overview – turbochargerp. 1414
+Assembly overview – turbochargerp. 1415
Part Ip. 1415
Part IIp. 1416
+Superchargerp. 1086
Assembly overview – superchargerp. 1086
Removing and installing superchargerp. 1087
+Charge air systemp. 1088
Checking charge air system for leaksp. 1088
+Removing and installing charge air coolerp. 1232
Removing and installing charge air cooler (Polo)p. 1232
+Fitting charge air system hose connectionsp. 1233
Removing and installing charge air pipe hot sidep. 1233
Checking charge air system for leaksp. 1234
Removing and installing charge air cooler (intake manifold)p. 1417
+Charge air system with turbochargerp. 1226
Removing and installing turbochargerp. 1226
Removing and installing charge air coolerp. 1227
Removing and installing charge air pipe hot sidep. 1228
Checking charge air systemp. 1230
+Checking charge air systemp. 1231
Checking charge air system for leaksp. 1231
+Vacuum systemp. 1235
Testing vacuum systemp. 1235
+4-cylinder diesel engine (1.6 l engine, common rail)p. 1106
+Fuel preparation system Diesel injectionp. 1236
+Injectors, high pressure accumulatorp. 1236
Assembly overview – injectorsp. 1236
Removing and installing injectorsp. 1237
Removing and installing high-pressure accumulator (rail)p. 1238
Removing and installing high-pressure linesp. 1239
+Mixture preparation, 1.6l common railp. 1240
Assembly overview – installation position of clampp. 1240
+Removing and installing components of the diesel direct injection systemp. 1244
Removing and installing injectorsp. 1244
Removing and installing high-pressure linesp. 1245
Removing and installing high-pressure accumulatorp. 1246
+Filling/bleeding/checking the diesel direct injection systemp. 1247
+Filling/bleeding, checking high-pressure pump/fuel systemp. 1247
Pressure testing high-pressure pumpp. 1247
Checking return flow rate at high-pressure pumpp. 1248
+Lambda probep. 1249
+Assembly overview – Lambda probep. 1249
Assembly overview – Lambda probe and exhaust gas temperature senders (Polo)p. 1249
+Removing and installing Lambda probep. 1250
Removing and installing Lambda probeG39 with Lambda probe heaterZ19 (Polo)p. 1250
+Engine control unitp. 1258
Removing and installing engine control unit with no ant-theft protectionp. 1258
Removing and installing anti-theft engine control unitp. 1259
3-cylinder injection engine (4-valve)p. 1285
3-cylinder injection engine (2-valve)p. 1333
4-cylinder injection engine (1.2 l direct injection engine, turbocharger)p. 1380
3-cylinder diesel engine (1.2 l engine, common rail)p. 1433
+4-cylinder injection engine (1.6 l engine, BiFuel) Volkswagen R GmbHp. 1434
+Self diagnosis, V.A.G Inspection Servicep. 1435
Read event memoryp. 1435
+Reading fault memory for Autogas (LPG) systemp. 1516
Preparation to read fault memoryp. 1516
Read fault memoryp. 1517
Clear fault memoryp. 1518
4-cylinder injection engine (1.4 l engine, BiFuel) Volkswagen R GmbHp. 1516
Fuel supply system – Diesel enginesp. 1587
Fuel supply system – Petrol enginesp. 1606
+Heating, ventilation, air conditioning systemp. 1618
+Heating, air conditioningp. 1618
+Heatingp. 1618
+Repairing heating systemp. 1618
Passenger compartment heatingp. 1618
+Removing and installing fresh air blowerV2p. 1619
Removingp. 1619
Removingp. 1657
+Removing and installing dust and pollen filterp. 1620
Removingp. 1620
Removingp. 1658
+Removing ventsp. 1621
Removing centre ventsp. 1621
Removingp. 1622
Removing right footwell ventp. 1623
Removing left footwell ventp. 1624
Removing and installing rear air ductp. 1625
Removing left footwell ventp. 1660
Removing right footwell ventp. 1661
+Removing and installing controls for heated and fresh airp. 1626
Removingp. 1626
Removing and installing heater unitp. 1627
Dismantling and assembling heater unitp. 1628
+Dismantling and assembling heater unitp. 1629
+Removing and installing air distribution flap actuatorp. 1629
Removingp. 1629
Installingp. 1630
+Removing and installing temperature flap actuatorp. 1631
Removingp. 1631
Removingp. 1659
+Removing and installing fresh air and air recirculation flap control motorV154p. 1632
Removingp. 1632
Assembly overview – heat exchangerp. 1633
Removing and installing heat exchangerp. 1634
Removing and installing auxiliary air heater elementZ35p. 1635
+Checking auxiliary air heater elementZ35p. 1636
Checking auxiliary air heater elementZ35p. 1636
Test procedurep. 1637
+Air conditionerp. 1638
+Climatic air conditioning system with manual regulation up to week 44/10p. 1638
Pin assignment for multi-pin connectors on back of Climatic heating regulation and air-conditioning systemp. 1638
Checking water drain valvep. 1639
+Air conditioning system with manual regulation from week 45/10p. 1640
Air conditioning system with manual controls – passenger compartmentp. 1640
Function of operating and display unit for front air conditioning systemE87p. 1641
Pin assignment of multi-pin connectors for operating and display unit for front air conditioning systemE87 with air conditioningp. 1642
+Climatronic air conditioning with automatic regulationp. 1643
+Removing and installing operating and display unit for Climatronic air conditioning systemE87 with Climatronic control unitJ255p. 1643
Removingp. 1643
+Removing and installing footwell vent temperature senderG192p. 1644
Removingp. 1644
+Removing and installing evaporator output temperature senderG263p. 1645
Removingp. 1645
Removingp. 1662
+Removing and installing centre vent temperature senderG191p. 1646
Removingp. 1646
Removingp. 1663
Removing and installing sunlight penetration photosensorG107p. 1647
+Removing and installing sunlight penetration photosensorG107p. 1648
Removingp. 1648
+Removing and installing fresh air blower control unitJ126p. 1649
Removingp. 1649
Installingp. 1650
Locally manufacturing an adapter cable to activate control motorsp. 1651
+Removing and installing air flow flap control motorV71p. 1652
Removingp. 1652
Removingp. 1666
+Removing and installing central flap control motorV70p. 1653
Removingp. 1653
Installingp. 1654
Removingp. 1664
Installingp. 1665
+Removing and installing defroster flap control motorV107 and temperature flap control motorV68p. 1655
Removingp. 1655
Installingp. 1656
Removingp. 1667
Installingp. 1668
Differences in repair work for right-hand drive vehiclesp. 1657
Air conditioning system with automatic regulation "Climatronic", right-hand drive vehiclesp. 1662
Removing and installing heater and air conditioning unit, right-hand drive vehiclesp. 1669
+Removing and installing heater and air conditioning unit, right-hand drive vehiclesp. 1670
Removing and installing heater and air conditioning unitp. 1670
Dismantling and assembling heater and air conditioner unit "Climatic"p. 1671
Dismantling and assembling heater and air conditioner unit "Climatronic"p. 1672
+Repair work on refrigerant circuit which may be performed only in appropriate workshops by specially trained mechanicsp. 1673
Required special tools, facilities, testing and measuring instruments and auxiliary itemsp. 1673
Removing and installing heater and air conditioning unitp. 1674
Dismantling and assembling heater and air conditioner unit "Climatic"p. 1675
Dismantling and assembling heater and air conditioner unit "Climatronic"p. 1676
Removing evacuating and charging valve, high-pressure side and low-pressure sidep. 1677
+Removing and installing high-pressure senderG65p. 1678
Removingp. 1678
Installingp. 1679
+Removing dryer cartridgep. 1680
Installingp. 1680
+Removing and installing poly V-belt pulley or air conditioning system magnetic clutchN25p. 1681
Removing and installing poly V-belt pulley, Denso air conditioner compressorp. 1681
+Removing and installing air conditioner compressorp. 1682
Removingp. 1682
Air conditioning system with refrigerant R134ap. 1683
Across these chapters the manual delivers the kind of depth a working technician needs: assembly overviews with numbered exploded views, component removal and installation sequences, hydraulic and vacuum schematics, wiring connector pin assignments, torque specifications, service limits and adjustment values. The electrics section alone spans battery diagnosis, starter and alternator repair, headlight and taillight replacement, parking aid diagnostics, radio and navigation connector layouts, loudspeaker replacement, telephone preparation and aerial systems. The power unit chapters go from routine oil sump removal through to full cylinder head, camshaft housing, timing chain and toothed belt service across petrol, diesel, TSI and BiFuel engines. The transmission chapters cover clutch hydraulics, selector mechanism adjustment, gearbox removal and installation, and complete dismantling and reassembly of manual, automatic and dual clutch gearboxes with differential adjustment procedures. Body chapters document door removal and alignment, bumper cover replacement for every Polo Mk5 trim level, sliding roof and panorama roof service, and interior trim removal down to individual pillar trims and seat covers.
IMAGES PREVIEW
What This Manual Enables You to Do
With this Volkswagen Polo Mk5 workshop manual PDF you can carry out scheduled maintenance, diagnose ABS and ESP faults, replace brake pads and calipers on FS III and FN 3 front brakes, service drum and disc rear brakes, adjust the handbrake, bleed the brake system, overhaul front and rear suspension, renew wheel bearings, rebuild drive shafts with VL90 or VL100 CV joints, set wheel alignment, remove and install manual and automatic gearboxes, service DSG mechatronic units, replace timing chains and toothed belts, check valve timing, renew crankshaft sealing flanges, service the cooling system, repair the heating and air conditioning system, and trace electrical faults through the infotainment and body electrical networks.
Using the correct procedures and specifications matters. Torque values, tightening sequences, seal installation depths and adjustment clearances are all documented here, which helps avoid component damage, repeat failures and safety-critical mistakes on braking, steering and restraint systems. The manual is delivered as an instant PDF download — no shipping, no waiting, and it can be stored on a laptop, tablet or phone and printed page by page for use in the workshop.
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