Volkswagen Eos 2006 Repair Manual – PDF DOWNLOAD

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Volkswagen Eos 2006 Repair Manual – PDF DOWNLOAD

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Volkswagen Eos 2006 Repair Manual – PDF DOWNLOAD 

Language : English
Pages : 11068
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Volkswagen Eos 2006 Repair Manual – PDF DOWNLOAD 

D4B80796BA2 Wheels and Tyres Guide General Information 1
44 – Wheels, tyres, vehicle geometry 5
1 Instructions on using the guide 5
1 1 Overview 5
1 1 1 Wheels and Tyres Guide – General Information 5
1 1 2 Wheels and Tyres Guide – Vehicle-specific Section 5
1 2 General information 5
1 3 Notes 6
1 4 Explanations regarding world regions 7
1 5 Definition of tyre package 7
1 6 Procedure for determining the required tyre package 8
1 6 1 Determining the required tyre package via PR number 8
1 6 2 Determining the required tyre package via version key in the vehicle registration certificate part 1 8
1 7 Vehicle registration certificate part 1 9
2 Legislative and technical conditions 11
2 1 Legislative conditions 11
2 1 1 Permissible wheel and tyre combinations in Germany 11
2 1 2 Vehicles with Tyre Pressure Monitoring System 11
2 2 Technical conditions 12
2 3 Load-carrying capacity depending on vehicle speed, winter tyres 12
2 4 Vehicle registration documents since 1 10 2005 14
2 5 COC document (EEC Certificate of Conformity) 15
2 6 EU general type approval number, sales type and sales or trade designation 15
3 Wheel change 17
3 1 Fitting instructions 17
3 2 Protecting wheel centring seat against corrosion 20
3 3 Fitting wheels 21
3 4 Position of anti-theft wheel bolts for steel wheels 21
4 Fitting tyre 22
4 1 Pressing tyre off wheel rim 22
4 2 Removing tyre sealant 22
4 3 Removing tyre from wheel 23
4 3 1 Removing tyres, wheels without and with tyre pressure monitoring 23
4 3 2 Removing tyres, run-flat tyres, ultra-high-performance tyres 24
4 4 Ensuring proper assembly temperature for tyres 26
4 5 Mounting tyre 27
4 5 1 Mounting tyre, wheels without and with tyre pressure monitoring 27
4 5 2 Mounting tyre, run-flat tyres, ultra-high performance tyres 29
4 6 Matching wheel rims and tyres 32
4 7 Checking radial and lateral runout of wheels and tyres 33
4 7 1 Checking radial and lateral runout of wheels and tyres, tolerances 33
4 7 2 Checking radial and lateral runout on wheels and tyres with tyre gauge 33
4 8 Matching wheels and tyres 34
4 9 Balancing wheel 35
4 9 1 Conditions 35
4 9 2 Balancing wheel on stationary wheel balancer 36
4 9 3 Balancing wheel with finish balancer 39
4 9 4 Checking radial and lateral run-out on wheel rim 40
4 10 Tyre sealant disposal 41
5 Tyre pressure monitoring system 42
5 1 System description – tyre pressure monitoring system 42
5 1 1 System description – tyre pressure monitoring system with indirect measurement (Tyre Pressure Loss Indicator) 42
5 1 2 System description – tyre pressure monitoring system with direct measurement (Tyre Pressure Monitoring System) 43
5 1 3 System description – tyre pressure monitoring system, tyre pressure monitoring system (TPMS) with autolocation 44
5 2 Overview of fitting locations – tyre pressure monitor system 44
5 2 1 Overview of fitting locations – Tyre Pressure Monitoring System (TPMS) with autolocation 44
5 3 Assembly overview – tyre pressure sensor 46
5 3 1 Assembly overview – tyre pressure sensor, tyre pressure sensor with valve 46
5 3 2 Assembly overview – tyre pressure sensor, tyre pressure sensor without valve, version 1 47
5 3 3 Assembly overview – tyre pressure sensor, tyre pressure sensor without valve, version 2 48
5 4 Removing and installing tyre pressure sensor -G222-/-G223-/-G224-/-G225- 49
5 4 1 Removing and installing tyre pressure sensor, tyre pressure sensor with valve 49
5 4 2 Removing and installing tyre pressure sensor, tyre pressure sensor without valve, version 1 (customer service version) 50
5 4 3 Removing and installing tyre pressure sensor, tyre pressure sensor without valve, version 1 (production version) 51
5 4 4 Removing and installing tyre pressure sensor -G222-/-G223-/-G224-/-G225-, version 2 53
5 5 Removing and installing tyre pressure monitor control unit -J502- 56
5 5 1 Removing and installing Tyre Pressure Monitoring System control unit -J502-, Arteon 2018, Passat 2015, Passat Estate 2015 56
5 5 2 Removing and installing tyre pressure monitoring system control unit -J502-, Touran 57
6 Wheel bolts 59
6 1 Wheel bolts, versions 59
6 2 Wheel bolts, anti-theft wheel bolt 60
6 3 Wheel bolts, adapter sets for anti-theft wheel bolts 60
7 Information on tyres 63
7 1 Identification markings on the tyre sidewall 63
7 2 Tyre dimension 65
7 3 Load rating code/load index (LI) 65
7 4 Speed rating code 66
7 5 EU tyre label 66
7 5 1 EU tyre label, summary 66
7 5 2 EU tyre label, objectives 67
7 5 3 EU tyre label, categories 68
7 6 Structure of a radial belted tyre 71
7 6 1 Cross section of a radial belted tyre 71
7 6 2 Run-flat tyres, structure and identification of a SST tyre 72
7 6 3 Run-flat tyres, seal inside technology 73
7 7 Run-flat tyre, SST (Self Supporting Tyre) 75
7 7 1 Run-flat tyres – general information 75
7 7 2 Run-flat tyres, retrofitting/requirements when using run-flat tyres 76
7 7 3 Run-flat tyres, repair work 77
7 8 Tyre storage 77
7 9 Reinforced and Extra Load (XL) tyres 77
7 10 Winter tyres 78
7 11 Winter tyres with speed symbol V 80
7 12 Rolling resistance optimised tyres 81
7 13 Tyre ageing 81
7 14 Tyres with flange protection 83
7 15 Tyre sizes for vehicles with four-wheel drive 83
7 16 Increase in temperature due to insufficient tyre pressure 84
8 Tyre sealant 85
8 1 Models with breakdown set 85
8 2 Storage life 85
8 3 Waste disposal 85
9 Information on wheel rims 86
9 1 Structure of wheel rim 86
9 2 Identification 87
9 3 Composite wheels 87
9 4 Care and maintenance of alloy wheel rims 87
9 5 Restoring alloy wheels 88
9 6 Removing and installing hub cover for alloy wheels with open threaded connection 88
9 7 Renewing trim elements 89
9 7 1 Renewing trim elements, bonded trim elements 89
9 7 2 Renewing trim elements, bolted trim elements 93
9 8 Removing and installing valve 95
9 8 1 Removing and installing valve, description of the valve 95
9 8 2 Removing and installing valve, rubber valve 95
9 8 3 Removing and installing valve, metal valve 96
10 Handling problems 98
10 1 Rolling noise 98
10 1 1 General notes on tyre noise 98
10 1 2 Flat spots (from locking wheels) 99
10 2 Vehicle pulls to one side 100
10 2 1 General information 100
10 2 2 Conicity 100
10 2 3 Remedies when vehicle pulls to one side 101
10 2 4 Strategic rotation of wheels for non-directional tyres 102
10 2 5 Strategic rotation of wheels having unidirectional tyres 103
10 3 Vibration 104
10 3 1 Vibration, causes for vibration 104
10 3 2 Vibration, conducting a road test before balancing wheels 104
10 3 3 Vibration, vibration control system 105
10 4 Eliminating flat spots caused by storage or handling 105
11 Evaluating tyres 107
11 1 Flat spots caused by storage or handling 107
11 2 Undulations 107
11 3 Saw-tooth wear 108
11 4 Flat spots caused by hard braking 108
11 5 Swellings in the tyre sidewall 108
11 6 Cuts 110
11 7 Damage caused by foreign bodies 110
11 8 Stripped profile 110
11 9 Tyre damage due to insufficient tyre pressure 111
11 10 Checking tyres 111
11 11 Damage caused when fitting 112
12 Tyre wear 114
12 1 Factors influencing the service life of tyres 114
12 2 Saw-tooth wear 115
12 3 Wear behaviour of high-speed tyres 115
12 4 Measuring tread depth 116
12 5 One-sided wear 116
12 6 Outer shoulder wear 119
12 7 Diagonal washout 120
12 8 Wear in middle of tyre 120
12 9 Permissible deviation in tread depth 121
13 Exploded view of components 122
13 1 Assembly overview – wheel 122
14 Snow chains 124
14 1 Assembly and use of snow chains 124
15 Regular and temporary spare wheels, recommended temporary spare tyres 125
15 1 Spare wheel with yellow sticker 125
15 2 Temporary spare wheels and recommended temporary spare tyres 126
15 2 1 Arteon 2018 126
15 2 2 Atlas 2017 126
15 2 3 Golf 2013, e-Golf 2014 126
15 2 4 Golf 2017, e-Golf 2017 126
15 2 5 Golf SV 2015 127
15 2 6 Golf Estate 2014 127
15 2 7 Golf Estate 2017 127
15 2 8 Passat 2015, Passat Estate 2015 127
15 2 9 Polo 2018 128
15 2 10 Tiguan 2016 128
00053148720 Wheels and Tyres Guide Standard 129
44 – Wheels, tyres, vehicle geometry 137
1 General notes on wheels and tyres (passenger cars) 137
2 Legislative and technical conditions for converting wheel and tyre combinations 139
2 1 Legislative conditions for converting wheel and tyre combinations 139
2 2 Technical conditions for converting wheel and tyre combinations 139
2 3 Additional wheel housing extensions (flaps) 140
2 4 „Series 80“ tyres 140
3 Documents and codes/designations 141
3 1 New vehicle registration documents since 01 10 2005 141
3 2 COC document (EEC Certificate of Conformity) 142
3 3 EU general type approval number, sales type and sales or trade designation 142
4 Useful information regarding tyres 144
4 1 Identification markings on the tyre sidewall 144
4 2 Explanation of tyre markings 145
4 3 Speed ratings for tyres 146
4 4 Undulations 147
4 5 Tyre storage 148
4 6 Tyre ageing 148
4 7 Tyre sizes for vehicles with four-wheel drive 150
4 8 Winter tyres 150
4 9 Winter tyres with speed symbol „V“ 151
4 10 Extra Load (XL) V winter tyres 152
4 11 Maximum speeds for V and Extra Load (XL) winter tyres 152
4 12 Reinforced and Extra Load (XL) tyres 153
4 13 Snow chains 153
5 Tyre wear/ mileage for passenger car tyres 155
5 1 General 155
5 2 Requirements to be met by tyres 155
5 3 Wear behaviour of high-speed tyres 156
5 4 Factors influencing the service life of a tyre 156
5 5 Driving style 156
5 6 Tyre maintenance 157
5 7 Evenly worn tyres 158
5 8 Measuring tread depth 159
5 9 One-sided wear 159
5 10 Outer shoulder wear 162
5 11 Wear in middle of tyre 162
5 12 Diagonal washout 164
6 Tyre noise 165
6 1 General notes on tyre noise 165
6 2 Saw-tooth wear 165
6 3 Flat spots (from locking wheels) 166
7 Vehicle pulls to one side 168
7 1 General 168
7 2 Conicity 168
7 3 Remedies when vehicle pulls to one side 169
7 4 Strategic rotation of wheels for non-directional tyres 170
7 5 Strategic rotation of wheels having unidirectional tyres 171
8 Tyre damage 173
8 1 General information 173
8 2 Construction of a radial belted tyre 174
8 3 Impact damage 174
8 4 Cuts 176
8 5 Damage caused by foreign bodies 176
8 6 Loss of air from tyre 176
8 7 Tyre pressure 176
8 8 Tyre damage due to insufficient tyre pressure 177
8 9 Rising tyre temperature caused by insufficient inflation pressure 178
8 10 Tyre damage due to fitting error (fitting damage) 179
9 Tyres with run-flat properties 181
9 1 General 181
9 2 Design and identification 182
9 3 Retrofitting/requirements when using run-flat tyres 182
9 4 Repairs 183
10 Rolling resistance optimised tyres 184
11 Facts about disc-type wheels (passenger cars) 185
11 1 Design of disc-type wheel 185
11 2 Data on wheel rims 185
11 3 Wheel rims – pitch circle diameter 186
11 4 Split rim composite wheels 186
11 5 Alloy wheels with exchangeable trim elements 186
11 6 Alloy wheels with exchangeable trim elements (Zaragoza) 187
11 6 1 Tools 187
11 6 2 Materials 188
11 6 3 Installing trim element 188
11 6 4 Removing trim element 190
11 7 Care and maintenance of alloy wheel rims 191
11 8 Restoring alloy wheels 191
11 9 The valve 193
12 Notes on use of temporary spare wheels 194
13 Fox from model year 2006 195
13 1 Fox, type 5Z model year 2006 to model year 2012 195
13 2 Wheel allocation for Fox, type 5Z model year 2006 to model year 2012 196
13 2 1 5 J x 14 197
13 2 2 6 J x 14 197
13 2 3 6 J x 15 199
14 up! from model year 2012 202
14 1 Advance information about up! Model year 2012 202
15 Polo from model year 2010 203
15 1 Polo, type 6R model year 2010 to model year 2012 203
15 2 Wheel allocation for Polo, type 6R model year 2010 to model year 2012 205
15 2 1 5 J x 14 205
15 2 2 6 J x 15 offset 38 206
15 2 3 6 J x 15 offset 40 206
15 2 4 7 J x 16 207
15 2 5 7 J x 17 208
16 Polo BlueMotion from model year 2010 209
16 1 Polo BlueMotion, type 6R model year 2010 to model year 2012 209
16 2 Wheel allocation for Polo BlueMotion, type 6R model year 2010 to model year 2012 210
16 2 1 51/2 J x 15 210
16 2 2 6 J x 15 offset 38 211
16 2 3 6 J x 15 offset 40 211
17 CrossPolo from model year 2011 213
17 1 CrossPolo, type 6R model year 2011 to model year 2012 213
17 2 Wheel allocation CrossPolo, type 6R model year 2011 to model year 2012 215
17 2 1 5 J x 14 215
17 2 2 6 J x 15 offset 38 216
17 2 3 6 J x 15 offset 40 216
17 2 4 7 J x 16 217
17 2 5 7 J x 17 218
17 2 6 71/2 J x 17 219
18 Polo GTI from model year 2011 220
18 1 Polo GTI, type 6R model year 2011 to model year 2012 220
18 2 Wheel allocation Polo GTI, type 6R model year 2011 to model year 2012 221
18 2 1 6 J x 15 offset 38 221
18 2 2 6 J x 15 offset 40 221
18 2 3 7 J x 16 222
18 2 4 7 J x 17 223
19 Golf from model year 2009 224
19 1 Golf, Golf 4Motion, sales type 5K model year 2009 to model year 2012 224
19 2 Wheel allocation for Golf, Golf 4Motion, sales type 5K model year 2009 to model year 2012 228
19 2 1 6 J x 15 228
19 2 2 61/2 J x 15 229
19 2 3 6 J x 16 230
19 2 4 61/2 J x 16 231
19 2 5 6 J x 17 236
19 2 6 7 J x 17 237
19 2 7 71/2 J x 17 240
19 2 8 71/2 J x 18 242
20 Golf BlueMotion from model year 2009 246
20 1 Golf BlueMotion, sales type 5K model year 2009 to model year 2012 246
20 2 Wheel allocation for Golf BlueMotion, sales type 5K model year 2009 to model year 2012 248
20 2 1 6 J x 15 248
20 2 2 61/2 J x 15 249
20 2 3 61/2 J x 16 250
21 Golf GTD from model year 2010 256
21 1 Golf GTD, sales type 5K, model year 2010 to model year 2012 256
21 2 Wheel allocation for Golf GTD, type 5K model year 2010 to model year 2012 258
21 2 1 6 J x 16 258
21 2 2 61/2 J x 16 258
21 2 3 6 J x 17 263
21 2 4 7 J x 17 264
21 2 5 71/2 J x 17 267
21 2 6 71/2 J x 18 269
22 Golf GTI from model year 2010 273
22 1 Golf GTI, sales type 5K, model year 2010 to model year 2012 273
22 2 Wheel allocation for Golf GTI, type 5K model year 2010 to model year 2012 275
22 2 1 6 J x 16 275
22 2 2 61/2 J x 16 276
22 2 3 6 J x 17 281
22 2 4 7 J x 17 281
22 2 5 71/2 J x 17 285
22 2 6 71/2 J x 18 286
22 2 7 71/2 J x 19 289
23 Golf R from model year 2010 291
23 1 Golf R, sales type 5K model year 2010 291
23 2 Golf R, sales type 5K model year 2011 to model year 2012 292
23 3 Wheel allocation for Golf R, type 5K model year 2010 to model year 2012 293
23 3 1 6 J x 17 294
23 3 2 7 J x 17 294
23 3 3 71/2 J x 17 294
23 3 4 71/2 J x 18 296
23 3 5 8 J x 19 299
24 CrossGolf from model year 2011 301
24 1 CrossGolf, sales type 521 model year 2011 to model year 2012 301
24 2 Wheel allocation CrossGolf, sales type 521 model year 2011 to model year 2012 304
24 2 1 6 J x 15 304
24 2 2 61/2 J x 15 305
24 2 3 6 J x 16 306
24 2 4 61/2 J x 16 307
24 2 5 6 J x 17 312
24 2 6 7 J x 17 offset 47 313
24 2 7 7 J x 17 offset 54 313
24 2 8 71/2 J x 17 317
25 Golf Cabriolet from model year 2012 318
25 1 Golf Cabriolet, sales type 517 from model year 2012 318
25 2 Wheel allocation Golf Cabriolet, sales type 517 from model year 2012 320
25 2 1 6 J x 15 320
25 2 2 61/2 J x 15 321
25 2 3 6 J x 16 322
25 2 4 61/2 J x 16 323
25 2 5 6 J x 17 328
25 2 6 7 J x 17 329
25 2 7 71/2 J x 17 332
25 2 8 71/2 J x 18 334
26 Golf Plus from model year 2009 338
26 1 Golf Plus, sales type 521 model year 2009 to model year 2011 338
26 2 Golf Plus, sales type 521 model year 2012 343
26 3 Wheel allocation for Golf Plus, sales type 521 model year 2009 to model year 2012 347
26 3 1 6 J x 15 347
26 3 2 61/2 J x 15 348
26 3 3 6 J x 16 349
26 3 4 61/2 J x 16 349
26 3 5 6 J x 17 354
26 3 6 7 J x 17 355
26 3 7 71/2 J x 17 358
26 3 8 71/2 J x 18 360
27 Golf Plus BlueMotion from model year 2010 364
27 1 Golf Plus BlueMotion, sales type 521, model year 2010 to model year 2012 364
27 2 Wheel allocation for Golf Plus BlueMotion, sales type 521, model year 2010 to model year 2012 366
27 2 1 6 J x 15 366
27 2 2 61/2 J x 15 367
27 2 3 6 J x 16 368
27 2 4 61/2 J x 16 369
28 Golf Variant from model year 2010 375
28 1 Golf Variant, Golf Variant 4Motion, sales type AJ5 model year 2010 to model year 2012 375
28 2 Wheel allocation for Golf Variant, Golf Variant 4Motion, sales type AJ5 model year 2010 to model year 2012 381
28 2 1 6 J x 15 381
28 2 2 61/2 J x 15 382
28 2 3 6 J x 16 383
28 2 4 61/2 J x 16 384
28 2 5 6 J x 17 389
28 2 6 7 J x 17 390
28 2 7 71/2 J x 17 393
28 2 8 71/2 J x 18 395
29 Golf Variant BlueMotion from model year 2010 399
29 1 Golf Variant BlueMotion, sales type AJ5, model year 2010 to model year 2012 399
29 2 Wheel allocation for Golf Variant BlueMotion, sales type AJ5, model year 2010 to model year 2012 400
29 2 1 6 J x 15 400
29 2 2 61/2 J x 15 401
29 2 3 6 J x 16 402
29 2 4 61/2 J x 16 403
30 Jetta from model year 2011 409
30 1 Jetta, sales type 162 model year 2011 to model year 2012 409
30 2 Wheel allocation Jetta, sales type 162 model year 2011 412
30 2 1 6 J x 15 412
30 2 2 61/2 J x 15 413
30 2 3 6 J x 16 414
30 2 4 61/2 J x 16 415
30 2 5 7 J x 17 420
30 2 6 71/2 J x 17 424
30 2 7 71/2 J x 18 425
31 Jetta from model year 2011 (NAR) 429
31 1 Jetta, sales type 162 from model year 2011 (NAR) 429
31 2 Wheel allocation for Jetta, sales type 162 from model year 2011 (NAR) 431
31 2 1 6 J x 15 431
31 2 2 61/2 J x 15 431
31 2 3 6 J x 16 433
31 2 4 61/2 J x 16 433
31 2 5 7 J x 17 438
31 2 6 71/2 J x 17 442
31 2 7 71/2 J x 18 443
32 Beetle from model year 2012 447
32 1 Beetle, sales type 5C1, from model year 2012 447
32 2 Beetle, sales type 5C1, from model year 2012 448
32 2 1 61/2 J x 16 449
32 2 2 7 J x 17 449
32 2 3 8 J x 18 451
32 2 4 8 J x 19 452
33 Scirocco from model year 2009 453
33 1 Scirocco, sales type 137, model year 2009 to model year 2011 453
33 2 Scirocco, sales type 137 model year 2012 456
33 3 Wheel allocation for Scirocco, sales type 137 model year 2009 to model year 2012 458
33 3 1 61/2 J x 16 458
33 3 2 61/2 J x 17 458
33 3 3 7 J x 17 459
33 3 4 8 J x 17 459
33 3 5 8 J x 18 461
33 3 6 8 J x 19 462
34 Scirocco R from model year 2010 464
34 1 Scirocco R, sales type 137, model year 2010 to model year 2011 464
34 2 Scirocco R, sales type 137 model year 2012 465
34 3 Wheel allocation for Scirocco R, sales type 137, model year 2010 to model year 2012 466
34 3 1 61/2 J x 17 467
34 3 2 7 J x 17 467
34 3 3 8 J x 17 467
34 3 4 8 J x 18 469
34 3 5 8 J x 19 471
35 Touran from model year 2003 472
35 1 Touran, type 1T model year 2003 to model year 2006 472
35 2 Touran, type 1T model year 2007 to model year 2010 475
35 3 Touran, type 1T and type 1t model year 2011 to model year 2012 480
35 4 Wheel allocation Touran, type 1T and type 1t model year 2003 to model year 2012 485
35 4 1 6 J x 15 485
35 4 2 61/2 J x 15 486
35 4 3 6 J x 16 487
35 4 4 61/2 J x 16 487
35 4 5 6 J x 17 493
35 4 6 7 J x 17 493
35 4 7 71/2 J x 18 494
36 CrossTouran from model year 2008 495
36 1 CrossTouran, type 1T model year 2008 to model year 2009 495
36 2 CrossTouran, type 1T and type 1t model year 2010 to model year 2012 498
36 3 Wheel allocation CrossTouran, type 1T and type 1t model year 2008 to model year 2012 502
36 3 1 6 J x 15 502
36 3 2 6 J x 16 503
36 3 3 61/2 J x 17 503
36 3 4 8 J x 17 504
37 Touran BlueMotion from model year 2009 505
37 1 Touran BlueMotion, type 1T and type 1t model year 2009 to model year 2012 505
37 2 Wheel allocation Touran BlueMotion, type 1T and type 1t model year 2009 to model year 2012 507
37 2 1 6 J x 15 507
37 2 2 61/2 J x 15 508
37 2 3 6 J x 16 509
37 2 4 61/2 J x 16 509
38 Tiguan from model year 2008 515
38 1 Tiguan, type 5N model year 2008 to model year 2011 515
38 2 Tiguan, type 5N, model year 2012 516
38 3 Wheel allocation for Tiguan, type 5N model year 2008 to model year 2012 518
38 3 1 6 1/2 J x 16 518
38 3 2 61/2 J x 17 520
38 3 3 7 J x 17 520
38 3 4 7 J x 18 521
38 3 5 9 J x 19 522
39 Eos from model year 2006 523
39 1 Eos, type 1F from model year 2006 523
39 2 Eos, type 1F model year 2007 to model year 2012 524
39 3 Wheel allocation for Eos, type 1F model year 2006 to model year 2012 527
39 3 1 61/2 J x 16 527
39 3 2 7 J x 16 528
39 3 3 6 J x 17 530
39 3 4 71/2 J x 17 531
39 3 5 8 J x 18 534
40 Passat saloon from model year 2011 537
40 1 Passat saloon, sales type 362 model year 2011 to model year 2012 537
40 2 Wheel allocation Passat saloon, sales type 362 model year 2011 to model year 2012 542
40 2 1 61/2 J x 16 543
40 2 2 7 J x 16 543
40 2 3 6 J x 17 544
40 2 4 61/2 J x 17 545
40 2 5 71/2 J x 17 545
40 2 6 8 J x 18 546
41 Passat Variant from model year 2011 548
41 1 Passat estate, sales type 365 model year 2011 to model year 2012 548
41 2 Wheel allocation Passat estate, sales type 365 model year 2011 to model year 2012 553
41 2 1 61/2 J x 16 553
41 2 2 7 J x 16 554
41 2 3 6 J x 17 555
41 2 4 61/2 J x 17 555
41 2 5 71/2 J x 17 556
41 2 6 8 J x 18 557
42 Passat CC from model year 2009, CC from model year 2010 559
42 1 Passat CC, sales type 357 model year 2009 559
42 2 Passat CC, CC, sales type 357 model year 2010 to model year 2012 561
42 3 Wheel allocation Passat CC, CC, sales type 357 model year 2009 to model year 2012 562
42 3 1 61/2 J x 17 562
42 3 2 8 J x 17 563
42 3 3 8 J x 18 564
42 3 4 8 J x 19 566
43 Phaeton from model year 2003 567
43 1 Phaeton, type 3D, model year 2003 to model year 2009 – short and long wheelbase 567
43 2 Phaeton, type 3D and type 3d, model year 2010 to model year 2012 – short and long wheelbase 570
43 3 Wheel allocation for Phaeton, type 3D and type 3d, model year 2003 to model year 2012 – short and long wheelbase 572
43 3 1 71/2 J x 16 572
43 3 2 71/2 J x 17 572
43 3 3 71/2 J x 18 574
43 3 4 81/2 J x 18 574
43 3 5 81/2 J x 19 offset 38 576
43 3 6 81/2 J x 19 offset 45 577
43 3 7 9 J x 19 offset 35 577
43 3 8 9 J x 19 offset 40 578
43 3 9 9 J x 20 578
44 Sharan from model year 2011 580
44 1 Sharan, Sharan 4Motion, type 7N model year 2011 to model year 2012 580
44 2 Wheel allocation Sharan, Sharan 4Motion, type 7N model year 2011 to model year 2012 582
44 2 1 6 1/2 J x 16 582
44 2 2 7 J x 17 583
44 2 3 71/2 J x 18 583
45 Touareg from model year 2010 585
45 1 Touareg, type 7P and type 7p, model year 2010 to model year 2012 585
45 2 Wheel allocation for Touareg, type 7P and type 7p, model year 2010 to model year 2012 587
45 2 1 71/2 J x 17 587
45 2 2 8 J x 18 588
45 2 3 81/2 J x 19 589
45 2 4 9 J x 20 589
45 2 5 91/2 J x 21 590
46 Touareg hybrid from model year 2011 592
46 1 Touareg hybrid, type 7PH and type 7pH, model year 2011 to model year 2012 592
46 2 Wheel allocation Touareg hybrid, type 7PH and type 7pH, model year 2011 to model year 2012 593
46 2 1 8 J x 18 593
46 2 2 81/2 J x 19 594
47 Breakdown set for VW Vehicles 596
48 Temporary spare tyres and wheels for VW vehicles 597
49 Recommended summer tyres 598
49 1 Summer tyres for Fox from model year 2006 598
49 2 Summer tyres for Polo from model year 2010 598
49 3 Summer tyres for Polo BlueMotion from model year 2010 599
49 4 Summer tyres for CrossPolo from model year 2011 600
49 5 Summer tyres for Polo GTI from model year 2011 600
49 6 Summer tyres for Golf from model year 2009 601
49 7 Summer tyres for Golf BlueMotion from model year 2009 602
49 8 Summer tyres for Golf GTD from model year 2009 603
49 9 Summer tyres for Golf GTI from model year 2009 603
49 10 Summer tyres for Golf R from model year 2010 604
49 11 Summer tyres for CrossGolf from model year 2011 605
49 12 Summer tyres Golf Cabriolet from model year 2012 606
49 13 Summer tyres for Golf Plus from model year 2009 607
49 14 Summer tyres for Golf Plus BlueMotion from model year 2010 608
49 15 Summer tyres for Golf Variant from model year 2010 609
49 16 Summer tyres for Golf Variant BlueMotion from model year 2010 610
49 17 Summer tyres for Jetta from model year 2011 611
49 18 Summer tyres for Beetle from model year 2012 613
49 19 Summer tyres for Scirocco from model year 2009 613
49 20 Summer tyres for Scirocco R from model year 2010 613
49 21 Summer tyres for Touran from model year 2003 614
49 22 Summer tyres for Touran BlueMotion from model year 2009 614
49 23 Summer tyres for CrossTouran from model year 2008 615
49 24 Summer tyres for Tiguan from model year 2008 615
49 25 Summer tyres for Eos from model year 2006 616
49 26 Summer tyres for Passat saloon from model year 2011 616
49 27 Summer tyres for Passat Variant from model year 2011 617
49 28 Summer tyres Passat CC from model year 2009, CC from model year 2010 618
49 29 Summer tyres for Sharan from model year 2011 618
49 30 Summer tyres for Phaeton from model year 2003 618
49 31 Summer tyres for Touareg from model year 2010 619
49 32 Summer tyres for Touareg hybrid from model year 2011 619
50 Recommended all-season tyres 620
50 1 All-season tyres for Polo from model year 2010 620
50 2 All-season tyres for Polo BlueMotion from model year 2010 620
50 3 All-season tyres for CrossPolo from model year 2011 620
50 4 All-season tyres for Polo GTI from model year 2011 621
50 5 All-season tyres for Golf from model year 2009 621
50 6 All-season tyres for CrossGolf from model year 2011 621
50 7 All-weather tyres Golf Cabriolet from model year 2012 622
50 8 All-season tyres for Golf Plus from model year 2009 622
50 9 All-season tyres for Golf Variant from model year 2010 623
50 10 All-season tyres for Jetta from model year 2011 623
50 11 All-season tyres for Jetta from model year 2011 (NAR) 623
50 12 All-season tyres for Touran from model year 2003 624
50 13 All-season tyres for Beetle from model year 2012 624
50 14 All-season tyres for Tiguan from model year 2008 624
50 15 All-season tyres for Eos from model year 2006 624
50 16 All-season tyres for Passat saloon from model year 2011 625
50 17 All-season tyres for Passat Variant from model year 2011 625
50 18 All-season tyres Passat CC from model year 2009, CC from model year 2010 625
50 19 All-season tyres for Sharan from model year 2011 626
50 20 All-season tyres for Phaeton from model year 2003 626
50 21 All-season tyres for Touareg from model year 2010 626
50 22 All-season tyres Touareg hybrid from model year 2010 626
51 Recommended winter tyres 628
51 1 Winter tyres for Fox from model year 2006 628
51 2 Winter tyres for Polo from model year 2010 628
51 3 Winter tyres for Polo BlueMotion from model year 2010 629
51 4 Winter tyres for CrossPolo from model year 2011 629
51 5 Winter tyres for Polo GTI from model year 2011 629
51 6 Winter tyres for Golf from model year 2009 629
51 7 Winter tyres for Golf BlueMotion from model year 2009 630
51 8 Winter tyres for Golf GTD from model year 2009 630
51 9 Winter tyres for Golf GTI from model year 2009 630
51 10 Winter tyres for Golf R from model year 2010 630
51 11 Winter tyres for CrossGolf from model year 20011 631
51 12 Winter tyres Golf Cabriolet from model year 2012 631
51 13 Winter tyres for Golf Plus from model year 2009 631
51 14 Winter tyres for Golf Plus BlueMotion from model year 2010 632
51 15 Winter tyres for Golf Variant from model year 2010 632
51 16 Winter tyres for Golf Variant BlueMotion from model year 2010 632
51 17 Winter tyres for Jetta from model year 2011 633
51 18 Winter tyres for Beetle from model year 2012 633
51 19 Winter tyres for Scirocco from model year 2009 633
51 20 Winter tyres for Scirocco R from model year 2010 633
51 21 Winter tyres for Touran from model year 2003 634
51 22 Winter tyres for Touran BlueMotion from model year 2009 634
51 23 Winter tyres for CrossTouran from model year 2008 634
51 24 Winter tyres for Tiguan from model year 2008 635
51 25 Winter tyres for Eos from model year 2006 635
51 26 Winter tyres for Passat saloon from model year 2011 635
51 27 Winter tyres for Passat Variant from model year 2011 635
51 28 Winter tyres Passat CC from model year 2009, CC from model year 2010 636
51 29 Winter tyres for Sharan from model year 2011 636
51 30 Winter tyres for Phaeton from model year 2003 636
51 31 Winter tyres for Touareg from model year 2010 636
51 32 Winter tyres Touareg hybrid from model year 2010 637
00059101120 4 cylinder diesel engine (2 0 l engine 2 valve) 638
00 – Technical data 644
1 Technical data 644
1 1 Engine number 644
1 2 Engine data 644
10 – Removing and installing engine 645
1 Removing and installing engine 645
1 1 Removing engine 645
1 2 Securing engine to assembly stand 650
1 3 Notes on installing 651
1 4 Assembly mountings 654
13 – Crankshaft group 655
1 Dismantling and assembling engine 655
1 1 Assembly overview – toothed belt drive 655
1 2 Assembly overview – poly V-belt drive 657
1 3 Removing and installing poly V-belt 657
1 4 Assembly overview – crankcase 659
2 Removing and installing sealing flange and flywheel 662
2 1 Assembly overview – sealing flange and flywheel 662
2 2 Renewing crankshaft oil seal – pulley end 663
2 3 Removing and installing sealing flange – pulley end 665
2 4 Renewing crankshaft sealing flange – flywheel end 667
2 4 1 Pressing out sealing flange with sender wheel 668
2 4 2 Pressing in sealing flange with sender wheel 669
2 4 3 A – Assembling seal with sender wheel on assembly tool -T10134- 669
2 4 4 B – Attaching assembling tool -T10134- with sealing flange on crankshaft flange 671
2 4 5 C – Bolting assembly tool -T10134- onto crankshaft flange 672
2 4 6 D – Pressing sender wheel onto crankshaft flange using assembly tool -T10134- 673
2 4 7 E – Checking sender wheel installation position on crankshaft 673
2 4 8 F – Re-pressing sender wheel 674
2 4 9 Removing and installing engine speed sender -G28- 674
3 Crankshaft 676
3 1 Assembly overview – crankshaft 676
3 2 Crankshaft dimensions 677
3 3 Pulling needle bearing out of and driving into crankshaft 677
4 Pistons and conrods 679
4 1 Assembly overview – pistons and conrods 679
4 2 Separating new conrods 680
4 2 1 Separating new conrod 680
4 3 Checking piston projection at TDC 681
4 4 Piston and cylinder dimensions 682
4 5 Piston rings, cylinder bore and piston installation position 682
15 – Cylinder head, valve gear 685
1 Cylinder head 685
1 1 Assembly overview – cylinder head 685
1 2 Removing and installing cylinder head cover 688
1 3 Removing, installing and tensioning toothed belt 689
1 4 Removing and installing cylinder head 696
1 4 1 Removing 698
1 4 2 Installing 699
1 5 Checking compression 700
2 Repairing valve gear 702
2 1 Assembly overview – valve gear 702
2 2 Checking valve guides 704
2 3 Renewing valve stem seals 705
2 3 1 Removing 706
2 3 2 Installing 707
2 4 Removing and installing camshaft 707
2 4 1 Removing 708
2 4 2 Installing 710
2 5 Removing and installing camshaft oil seal 711
2 5 1 Removing 712
2 5 2 Installing 713
17 – Lubrication 714
1 Engine oil 714
1 1 Oil capacities 714
1 2 Engine oil specifications 714
1 3 Checking engine oil level 714
2 Parts of lubrication system 715
2 1 Assembly overview – oil pump, sump 715
2 2 Removing and installing oil sump 716
3 Oil filter bracket, oil pressure and oil cooler 719
3 1 Assembly overview – oil filter bracket and oil cooler 719
3 2 Checking oil pressure and oil pressure switch 720
19 – Cooling 722
1 Parts of cooling system 722
1 1 Parts of cooling system, body side 722
1 2 Parts of cooling system – engine side 724
1 3 Coolant hose schematic diagram 726
1 4 Draining and filling coolant 727
1 4 1 Draining 727
1 4 2 Filling 728
1 5 Removing and installing fan mounting with fans 731
1 6 Removing and installing radiator 732
1 7 Removing and installing coolant pump 734
1 8 Removing and installing thermostat 735
1 9 Checking cooling system for leaks 737
1 9 1 Check pressure relief valve in cap 739
1 10 Checking oil cooler for leaks 739
20 – Fuel supply system 742
1 Safety precautions when working on fuel supply system 742
2 Rules for cleanliness 743
3 Fuel tank 744
3 1 Assembly overview – fuel tank 744
3 2 Emptying fuel tank 746
3 2 1 Emptying fuel tank if it is more than 3/4 full 747
3 2 2 Emptying fuel tank if it is less than 3/4 full 747
3 3 Removing and installing fuel tank 748
3 3 1 Removing 749
3 3 2 Installing 750
3 4 Removing and installing fuel delivery unit 750
3 4 1 Removing 751
3 4 2 Installing 751
3 5 Removing and installing fuel gauge sender -G- 752
3 6 Checking fuel pump 752
4 Repairing fuel supply system 755
4 1 Assembly overview – fuel filter 755
4 1 1 Fuel filter upper part 756
4 2 Removing and installing fuel cooler 756
4 3 Checking tandem pump 757
4 3 1 Checking delivery pressure 757
4 3 2 Checking for internal leaks 759
4 4 Removing and installing tandem pump 761
4 5 Assembly overview – accelerator mechanism 764
4 5 1 Removing and installing accelerator module 764
21 – Turbocharging/supercharging 766
1 Charge air system with turbocharger 766
1 1 Safety precautions 766
1 2 Rules for cleanliness 766
1 3 Assembly of hose connections 767
1 3 1 Installing hose connections with plug-in connectors 767
1 3 2 Installing hose connections with spring band ring 768
1 4 Assembly overview – turbocharger 768
1 5 Removing and installing turbocharger 770
1 6 Assembly overview – charge air cooling 771
1 7 Checking charge air system for leaks 772
23 – Mixture preparation – injection 775
1 Repairing diesel direct injection system 775
1 1 Safety precautions 775
1 2 Rules for cleanliness 776
1 3 Assembly overview – unit injector 776
1 4 Removing and installing O-rings for unit injector 777
1 5 Removing and installing unit injector 778
1 5 1 Removing 779
1 5 2 Installing 780
1 6 Assembly overview – intake manifold with intake manifold flap 781
1 7 Assembly overview – air filter 783
2 Engine control unit 784
2 1 Reading and erasing engine control unit fault memory 784
2 2 Adapting functions and components 785
2 3 Removing and installing anti-theft engine control unit 786
2 3 1 Removing 787
2 3 2 Installing 788
2 4 Removing and installing engine control unit 789
26 – Exhaust system 790
1 Parts of the exhaust system 790
1 1 Assembly overview – front exhaust pipe with particulate filter 790
1 2 Assembly overview – silencers with mountings 792
1 3 Aligning exhaust system free of stress 793
2 Exhaust gas recirculation system 794
2 1 Assembly overview – exhaust gas recirculation 794
2 2 Assembly overview – exhaust gas recirculation cooler 795
2 3 Vacuum hose schematic diagram 796
28 – Glow plug system 797
1 Checking glow plug system 797
1 1 Characteristics of ceramic glow plugs 797
1 2 Removing, installing and checking ceramic glow pin plugs 797
D3E803B83BB Fuel supply system Petrol engines 800
00 – Technical data 804
1 Engine data 804
2 Safety precautions 805
2 1 Safety precautions when working on fuel supply system 805
2 2 Safety precautions for when using test and measuring equipment during a road test 806
3 General repair notes 807
3 1 Rules for cleanliness 807
20 – Fuel supply system 808
1 Fuel tank 808
1 1 Assembly overview – fuel tank 808
1 2 Removing and installing fuel tank 809
1 3 Emptying fuel tank 812
1 3 1 Emptying fuel tank when fuel pump is intact 812
1 3 2 Emptying fuel tank if it is more than 3/4 full 815
1 3 3 Emptying fuel tank if it is less than 3/4 full 817
2 Fuel delivery unit, fuel gauge sender 819
2 1 Assembly overview – fuel delivery unit and fuel gauge sender 819
2 2 Removing and installing fuel delivery unit, fuel gauge sender 821
2 3 Removing and installing fuel gauge sender 824
3 Detaching plug-in connectors 826
4 Fuel filter 830
4 1 Assembly overview – fuel filter 830
4 2 Removing and installing fuel filter 830
5 Activated charcoal filter system 832
5 1 Assembly overview – activated charcoal filter system 832
5 2 Checking fuel tank breather 832
6 Accelerator mechanism 835
6 1 Assembly overview – accelerator module 835
6 2 Removing and installing accelerator module 835
7 Fuel pump 837
7 1 Checking fuel pump 837
7 1 1 Checking function and voltage supply 837
7 1 2 Checking fuel pressure 840
7 1 3 Checking holding pressure 845
7 1 4 Checking fuel delivery rate 850
7 1 5 Checking current draw 858
D3E803ECAD4 Fuel supply system Diesel engines 861
00 – Technical data 865
1 Identification 865
1 1 Engine number, engine data 865
2 Safety instructions 866
2 1 Safety precautions when working on fuel supply system 866
2 2 Safety precautions during road tests in which testing and measuring equipment is used 867
2 3 Safety precautions when working on vehicles with a start/stop system 868
3 General notes 869
3 1 Cleanliness specifications for working on the auxiliary heater and fuel system 869
20 – Fuel supply system 870
1 Procedure when filling with incorrect fuel 870
1 1 Step 1 (Engine was started with incorrect fuel) 870
1 2 Step 2 (Engine was not started with incorrect fuel) 871
1 3 Step 3 (There are metal particles in fuel delivery unit and fuel tank) 872
1 4 Step 4 (There are no metal particles in fuel delivery unit and fuel tank) 873
1 5 Step 5 (There are metal particles in high-pressure pump) 873
1 6 Step 6 (There are no metal particles in high-pressure pump) 874
2 Fuel tank 875
2 1 Assembly overview – fuel tank 875
2 2 Removing and installing fuel tank 877
2 3 Emptying fuel tank 880
2 3 1 Emptying fuel tank when fuel pump is intact 880
2 3 2 Emptying fuel tank if it is more than 3/4 full 882
2 3 3 Emptying fuel tank if it is less than 3/4 full 883
3 Fuel delivery unit, fuel gauge sender 886
3 1 Removing and installing fuel delivery unit, fuel gauge sender 886
3 2 Removing and installing fuel gauge sender 888
4 Detaching push-on connectors 890
5 Fuel filter 894
5 1 Assembly overview – fuel filter 894
5 1 1 Assembly overview – fuel filter 894
5 1 2 Assembly overview – upper part of fuel filter 895
5 2 Removing and installing fuel filter 895
5 2 1 Removing and installing upper part of fuel filter 895
5 2 2 Removing and installing fuel filter 898
6 Accelerator mechanism 899
6 1 Assembly overview – accelerator module 899
6 2 Removing and installing accelerator module 899
7 Fuel pump 903
7 1 Checking fuel pump 903
7 1 1 Checking delivery pressure of fuel system pressurisation pump -G6- 903
7 1 2 Checking fuel delivery rate of fuel system pressurisation pump -G6- 904
7 1 3 Checking current consumption of fuel system pressurisation pump -G6- 907
7 1 4 Checking voltage supply of fuel system pressurisation pump -G6- 908
7 1 5 Checking the fuel pump -V393- or fuel pump 2 -V277- (Inline EKP) CBAB 909
7 1 6 Checking the fuel pump -V393- or fuel pump 2 -V277- (Inline EKP) CFFA, CFFB 911
7 2 Removing and installing fuel pump 913
7 2 1 Removing and installing supplementary fuel pump -V393- or fuel pump 2 -V277- (inline electronic fuel pump) 913
D3E8046D49A Wheels and Tyres Guide – General Information 916
44 – Wheels, tyres, vehicle geometry 924
1 Instructions on using the guide 924
1 1 Overview 924
1 1 1 Wheels and Tyres Guide – General Information 924
1 1 2 Wheels and Tyres Guide – Vehicle-specific section 924
1 2 General information 924
1 3 Notes 925
1 4 Determining correct wheel and tyre combinations, according to NEDC with tyre package 926
1 4 1 Determining the required tyre package via PR number 926
1 4 2 Determining the required tyre package via version key in the vehicle registration certificate part 1 926
1 5 Determining correct wheel and tyre combinations according to WLTP 927
1 5 1 Vehicle registration certificate part 1 927
1 5 2 COC document, item 0 10 929
1 6 NEDC, WLTP and RDE 929
1 6 1 What are NEDC, WLTP and RDE? 929
1 6 2 What are the differences between WLTP and RDE? 929
1 6 3 Since when are WLTP and RDE valid? 929
1 7 Definition of tyre package 929
1 8 Explanations regarding world regions 930
2 Legislative and technical conditions 932
2 1 Legislative conditions 932
2 1 1 Permissible wheel and tyre combinations in Germany 932
2 1 2 Vehicles with Tyre Pressure Monitoring System 932
2 2 Technical conditions 933
2 3 Load-carrying capacity depending on vehicle speed, winter tyres 933
2 4 Vehicle registration documents since 01 10 2005 935
2 5 COC document (EEC Certificate of Conformity) 936
2 6 EU general type approval number, sales type and sales or trade designation 936
3 Wheel change 939
3 1 Fitting instructions 939
3 2 Protecting wheel centring seat against corrosion 942
3 3 Fitting wheels 942
3 4 Position of anti-theft wheel bolts for steel wheels 943
4 Fitting tyre 945
4 1 Pressing tyre off wheel rim 945
4 2 Removing tyre sealant 946
4 3 Removing tyre from wheel 946
4 3 1 Removing tyres, wheels without and with tyre pressure monitoring 946
4 3 2 Removing tyres, run-flat tyres, ultra-high-performance tyres 948
4 4 Ensuring proper assembly temperature for tyres 950
4 5 Fitting tyre 951
4 5 1 Mounting tyre, wheels without and with tyre pressure monitoring 951
4 5 2 Mounting tyre, run-flat tyres, ultra-high performance tyres 953
4 6 Matching wheel rims and tyres 955
4 7 Checking radial and lateral runout of wheels and tyres 956
4 7 1 Checking radial and lateral runout of wheels and tyres, tolerances 956
4 7 2 Checking radial and lateral runout on wheels and tyres with tyre gauge 957
4 8 Matching wheels and tyres 958
4 9 Balancing wheel 959
4 9 1 Conditions 959
4 9 2 Balancing wheel on stationary wheel balancer 959
4 9 3 Balancing wheel with finish balancer 962
4 9 4 Checking radial and lateral run-out on wheel rim 963
4 10 Tyre sealant disposal 964
5 Tyre Pressure Monitoring System 965
5 1 System description – Tyre Pressure Monitoring System 965
5 1 1 System description – Tyre Pressure Monitoring System with indirect measurement (Tyre Pressure Loss Indicator) 965
5 1 2 System description – Tyre Pressure Monitoring System with direct measurement (with tyre pressure sensor) 967
5 1 3 Button behaviour – Tyre Pressure Monitoring System with direct measurement (with tyre pressure sensor) 967
5 1 4 System description – Tyre Pressure Monitoring System, Tyre Pressure Monitoring System (TPMS) with autolocation 968
5 2 Overview of fitting locations – Tyre Pressure Monitoring System 969
5 2 1 Overview of fitting locations – Tyre Pressure Monitoring System (TPMS) with autolocation 969
5 2 2 Overview of fitting locations – Tyre Pressure Monitoring System, Trigger 970
5 2 3 Overview of fitting locations – Tyre Pressure Monitoring System, Autolocation 972
5 3 Assembly overview – tyre pressure sensor 973
5 3 1 Assembly overview – tyre pressure sensor, tyre pressure sensor with valve 973
5 3 2 Assembly overview – tyre pressure sensor, tyre pressure sensor without valve, version 1 975
5 3 3 Assembly overview – tyre pressure sensor, tyre pressure sensor without valve, version 2 977
5 4 Removing and installing tyre pressure sensor -G222-/-G223-/-G224-/-G225- 978
5 4 1 Removing and installing tyre pressure sensor, tyre pressure sensor with valve 978
5 4 2 Removing and installing tyre pressure sensor, tyre pressure sensor without valve, version 1 (customer service version) 979
5 4 3 Removing and installing tyre pressure sensor, tyre pressure sensor without valve, version 1 (production version) 981
5 4 4 Removing and installing tyre pressure sensor -G222-/-G223-/-G224-/-G225-, version 2 984
5 5 Removing and installing Tyre Pressure Monitoring System control unit -J502- 986
5 5 1 Removing and installing Tyre Pressure Monitoring System control unit -J502-, Arteon 2018, Arteon 2021, Arteon Shooting Brake 2021, Passat 2015, Passat Estate 2015, Passat 2019, Passat Estate 2019 987
5 5 2 Removing and installing tyre Tyre Pressure Monitoring System control unit, Passat 2011, Passat Estate 2011 989
5 5 3 Removing and installing Tyre Pressure Monitoring System control unit, CC 2010, CC 2012, Passat CC 2009 989
5 5 4 Removing and installing Tyre Pressure Monitoring System control unit, Phaeton 2003 989
5 5 5 Removing and installing Tyre Pressure Monitoring System control unit -J502-, Touran 2016 989
5 5 6 Removing and installing Tyre Pressure Monitoring System control unit -J502-, Tiguan 2008 990
5 5 7 Removing and installing Tyre Pressure Monitoring System control unit -J502-, Tiguan 2016, Tiguan 2017 (BW2), Tiguan 2021 991
5 5 8 Removing and installing Tyre Pressure Monitoring System control unit, up to model year 2014, Touareg 2010 992
5 5 9 Removing and installing Tyre Pressure Monitoring System control unit, as of model year 2015, Touareg 2015 993
5 5 10 Removing and installing Tyre Pressure Monitoring System control unit, Touareg 2018 994
5 5 11 Removing and installing bracket for Tyre Pressure Monitoring System control unit, Touareg 2015 995
5 6 Removing and installing tyre pressure monitor sender unit in wheel housing 995
5 6 1 Removing and installing sender unit for Tyre Pressure Monitoring System in front left/front right wheel housing -G431/G432-, Touareg 2010, Touareg 2015 995
5 6 2 Removing and installing sender unit for Tyre Pressure Monitoring System in rear left/rear right wheel housing -G433/G434-, Touareg 2010, Touareg 2015 996
5 6 3 Removing and installing sender unit for Tyre Pressure Monitoring System in wheel housing, Phaeton 2003 997
6 Wheel bolts 998
6 1 Wheel bolts, versions 998
6 2 Wheel bolts, anti-theft wheel bolt 1000
6 3 Wheel bolts, adapter sets for anti-theft wheel bolts 1000
7 Information on tyres 1003
7 1 Identification markings on the tyre sidewall 1003
7 2 Tyre dimension 1005
7 3 Load rating code/load index (LI) 1005
7 4 Speed rating code 1006
7 5 EU tyre label 1006
7 5 1 EU tyre label, summary 1006
7 5 2 EU tyre label, objectives 1007
7 5 3 EU tyre label, categories 1008
7 6 Structure of a radial belted tyre 1012
7 6 1 Cross section of a radial belted tyre 1012
7 6 2 Run-flat tyres, structure and identification of a SST tyre 1013
7 6 3 Run-flat tyres, seal inside technology 1015
7 7 Run-flat tyre, SST (Self Supporting Tyre) 1018
7 7 1 Run-flat tyres – general information 1018
7 7 2 Run-flat tyres, retrofitting/requirements when using run-flat tyres 1019
7 7 3 Run-flat tyres, repair work 1019
7 8 Tyre storage 1019
7 9 Reinforced and Extra Load (XL) tyres 1020
7 10 M+S tyres 1021
7 11 Winter tyres with speed symbol V 1023
7 12 All-season tyres 1024
7 13 Optimised rolling resistance tyres 1025
7 14 Tyre ageing 1025
7 15 Tyres with flange protection 1027
7 16 Tyre sizes for vehicles with all-wheel drive 1027
7 17 Increase in temperature due to insufficient tyre pressure 1027
8 Tyre sealant 1029
8 1 Models with breakdown set 1029
8 2 Storage life 1029
8 3 Disposal 1029
9 Information about wheels (rims) 1030
9 1 Structure of wheel (rim) 1030
9 2 Identification 1031
9 3 Composite wheels 1032
9 4 Care and maintenance of alloy wheel rims 1032
9 5 Restoring alloy wheels 1032
9 6 Removing and installing hub cover for alloy wheels with open threaded connection 1033
9 7 Renewing trim elements 1034
9 7 1 Renewing trim elements, bonded trim elements 1034
9 7 2 Renewing trim elements, bolted trim elements 1038
9 8 Removing and installing valve 1039
9 8 1 Removing and installing valve, description of the valve 1039
9 8 2 Removing and installing valve, rubber valve 1040
9 8 3 Removing and installing valve, metal valve 1041
10 Handling problems 1043
10 1 Rolling noise 1043
10 1 1 General notes on tyre noise 1043
10 1 2 Flat spots (from locking wheels) 1044
10 2 Vehicle pulls to one side 1045
10 2 1 General information 1045
10 2 2 Conicity 1045
10 2 3 Remedies when vehicle pulls to one side 1047
10 2 4 Strategic rotation of wheels for non-directional tyres 1048
10 2 5 Strategic rotation of wheels having unidirectional tyres 1049
10 3 Vibration 1050
10 3 1 Vibration, causes for vibration 1050
10 3 2 Vibration, conducting a road test before balancing wheels 1050
10 3 3 Vibration, vibration control system 1050
10 4 Eliminating flat spots caused by storage or handling 1051
11 Evaluating tyres 1053
11 1 Flat spots caused by storage or handling 1053
11 2 Undulations 1053
11 3 Saw-tooth wear 1054
11 4 Flat spots caused by hard braking 1054
11 5 Swellings in the tyre sidewall 1054
11 6 Cuts 1056
11 7 Damage caused by foreign bodies 1056
11 8 Stripped profile 1057
11 9 Tyre damage due to insufficient tyre pressure 1057
11 10 Checking tyres 1058
11 11 Damage caused when fitting 1059
12 Tyre wear 1061
12 1 Factors influencing the service life of tyres 1061
12 2 Saw-tooth wear 1062
12 3 Wear behaviour of high-speed tyres 1063
12 4 Measuring tread depth 1063
12 5 One-sided wear 1064
12 6 Outer shoulder wear 1066
12 7 Diagonal washout 1067
12 8 Wear in middle of tyre 1068
12 9 Permissible deviation in tread depth 1068
13 Overview of components 1069
13 1 Assembly overview – wheel 1069
14 Snow chains 1072
14 1 Assembly and use of snow chains 1072
15 Regular and temporary spare wheels, recommended temporary spare tyres 1073
15 1 Spare wheel with yellow sticker 1073
15 2 Temporary spare wheels and recommended temporary spare tyres 1074
15 2 1 Atlas 2017 1074
15 2 2 Golf 2013, e-Golf 2014 1074
15 2 3 Golf 2017, e-Golf 2017 1074
15 2 4 Golf SV 2015 1074
15 2 5 Golf Variant 2014 1075
15 2 6 Golf Variant 2017 1075
15 2 7 Golf 2018 (AU2/BX6) 1075
15 2 8 Jetta 2018 1075
15 2 9 Taos 2021 1076
D3E80213DD8 Running gear axles steering 1077
00 – Technical data 1085
1 Checklist for evaluating running gear of accident vehicles 1085
2 General information 1087
40 – Front suspension 1088
1 Appraisal of accident vehicles 1088
2 Servicing front suspension 1089
2 1 Overview – front axle 1089
2 2 Raising wheel bearing to unladen position 1090
3 Subframe, anti-roll bar, suspension links 1093
3 1 Assembly overview: subframe, anti-roll bar, suspension links 1093
3 2 Assembly overview: front left vehicle level sender -G78- 1097
3 3 Removing and installing front left vehicle level sender -G78- 1098
3 4 Repairing thread in longitudinal member 1099
3 5 Fixing position of subframe and brackets 1099
3 6 Lowering subframe 1101
3 7 Removing and installing subframe without steering rack 1105
3 8 Removing and installing subframe with steering rack 1107
3 9 Repairing subframe 1113
3 10 Checking swivel joint 1121
3 11 Removing and installing swivel joint 1122
3 12 Removing and installing suspension link with mounting bracket 1126
3 13 Removing and installing suspension link with mounting bracket (left side for vehicles with DSG or automatic gearboxes) 1129
3 14 Removing and installing suspension link with mounting bracket (right side for vehicles with 6-cylinder engines) 1134
3 15 Renewing bonded rubber bush for suspension link 1138
3 16 Renewing mounting bracket with suspension link bush 1140
3 17 Removing and installing anti-roll bar 1141
4 Assembly overview: wheel bearing 1147
4 1 Removing and installing wheel bearing unit 1149
4 2 Removing and installing wheel bearing housing 1151
5 Assembly overview: suspension strut 1157
5 1 Removing and installing suspension strut 1158
5 2 Repairing suspension strut 1165
6 Removing and installing drive shafts 1168
6 1 Loosening and tightening drive shaft hexagon bolt 1168
6 2 Loosening and tightening twelve-point head bolt, with ribbing, securing drive shaft 1169
6 3 Loosening and tightening twelve-point head bolt, without ribbing, securing drive shaft 1170
6 4 Removing and installing drive shaft with constant velocity joint 1172
6 5 Removing and installing left drive shaft with (push-on) constant velocity slip joint 1175
6 6 Removing and installing right drive shaft with (push-on) constant velocity slip joint 1180
6 7 Removing and installing drive shafts with triple roller joint AAR2600i 1186
6 8 Removing and installing drive shafts with triple roller joint AAR3300i 1190
7 Repairing drive shaft – overview of drive shafts 1195
7 1 Heat shields for drive shafts 1197
8 Assembly overview: drive shaft with VL100 constant velocity joint 1198
8 1 Dismantling and assembling drive shaft with VL100 constant velocity joint 1200
8 2 Checking outer constant velocity joint 1204
8 3 Checking inner constant velocity joint 1205
9 Assembly overview: drive shaft with VL107 constant velocity joint (bolt-on) 1208
9 1 Dismantling and assembling drive shaft with VL107 constant velocity joint 1210
10 Assembly overview: drive shaft with VL107 constant velocity slip joint (push-on) 1215
10 1 Dismantling and assembling drive shaft with VL107 (push-on) constant velocity slip joint 1216
10 2 Checking outer constant velocity joint 1219
11 Assembly overview: drive shaft with triple roller joint AAR2600i 1221
11 1 Dismantling and assembling drive shaft with triple roller joint AAR2600i 1223
12 Assembly overview: drive shaft with triple roller joint AAR3300i 1228
12 1 Dismantling and assembling drive shaft with triple roller joint AAR3300i 1230
42 – Rear suspension 1235
1 Appraisal of accident vehicles 1235
2 Repairing rear suspension (front-wheel drive) 1236
2 1 Overview – rear axle 1236
2 2 Rear axle in unladen position 1237
3 Assembly overview: subframe, transverse link, track rod (front-wheel drive) 1240
3 1 Fixing position of subframe 1242
3 2 Lowering rear axle 1243
3 3 Removing and installing rear axle 1245
3 4 Vehicle level sender for vehicles with automatic headlight range control 1249
3 5 Removing and installing rear left vehicle level sender -G76- 1250
3 6 Removing and installing upper transverse link 1251
3 7 Removing and installing lower transverse link 1252
3 8 Removing and installing track rod 1254
4 Assembly overview: wheel bearing housing, trailing arm (front-wheel drive) 1257
4 1 Removing and installing wheel bearing housing 1258
4 2 Renewing bonded rubber bush for wheel bearing housing 1262
4 3 Removing and installing wheel bearing/wheel hub unit 1264
4 4 Removing and installing trailing arm with mounting bracket 1267
4 5 Repairing trailing arm 1271
5 Assembly overview: shock absorber, coil spring (front-wheel drive) 1274
5 1 Removing and installing coil spring 1274
5 2 Removing and installing shock absorbers 1276
5 3 Repairing shock absorber 1278
6 Assembly overview: anti-roll bar (front-wheel drive) 1280
6 1 Removing and installing anti-roll bar 1280
7 Removing and installing radius rods 1283
7 1 Removing radius rods 1283
7 2 Installing radius rods 1283
43 – Self-levelling suspension 1284
1 Appraisal of accident vehicles 1284
2 Components of adaptive chassis control DCC and fitting locations 1285
2 1 Shock absorber damping adjustment button -E387- 1286
2 2 Removing and installing front left body acceleration sender -G341- 1286
2 3 Removing and installing front right body acceleration sender -G342- 1287
2 4 Renewing bracket for front left/right body acceleration sender -G341/G342- 1288
2 5 Assembly overview: front left/right vehicle level sender -G78/G289- for adaptive chassis control DCC 1290
2 6 Removing and installing front left/right vehicle level sender -G78/G289- 1291
2 7 Assembly overview: rear left vehicle level sender -G76- for adaptive chassis control DCC, front-wheel drive 1292
2 8 Removing and installing rear left vehicle level sender -G76- for adaptive chassis control DCC, front-wheel drive 1293
2 9 Removing and installing electronically controlled damping control unit -J250- 1294
2 10 Basic setting of adaptive chassis control DCC 1295
2 11 Cable routing left front axle 1295
2 12 Cable routing right front axle 1297
2 13 Cable routing rear axle 1298
3 Assembly overview: suspension strut for adaptive chassis control DCC 1299
3 1 Removing and installing suspension strut for adaptive chassis control DCC 1301
4 Assembly overview: shock absorber for adaptive chassis control DCC (front-wheel drive) 1308
4 1 Removing and installing rear body acceleration sender -G343- (front-wheel drive) 1309
4 2 Removing and installing shock absorber for adaptive chassis control DCC (front-wheel drive) 1310
4 3 Repairing shock absorber for adaptive chassis control DCC (front-wheel drive) 1312
44 – Wheels, tyres, vehicle geometry 1315
1 Appraisal of accident vehicles 1315
2 Specified torques for wheel bolts 1316
3 Fitting wheel and tyre 1317
3 1 General information 1317
3 2 Fittings instructions 1317
4 Removing and fitting tyres (wheels with tyre pressure monitoring) 1319
4 1 Notes on safety and conditions for removing and fitting tyres (wheels with tyre pressure monitoring system) 1319
4 2 Wheel change 1319
4 3 Pressing tyre off wheel rim 1320
4 4 Removing tyre from wheel 1321
4 5 Fitting tyre to wheel rim 1321
5 Removing and fitting tyres with run-flat properties to wheel rims 1323
5 1 Safety notes 1323
5 2 Pressing tyre off wheel rim 1323
5 3 Removing tyre from wheel 1324
5 4 Fitting tyre to wheel rim 1325
6 Self-sealing tyres “ContiSeal” 1328
6 1 Explanations about ContiSeal tyres 1328
6 2 Handling ContiSeal tyres 1329
7 Tyre pressure monitor display 1330
7 1 System fault in the ABS system 1330
7 2 Performing basic setting 1331
8 Tyre pressure monitoring system (TPMS) 1332
8 1 Button behaviour 1332
8 2 Assembly overview: tyre pressure sensor 1333
8 3 Removing and installing tyre pressure sensor 1334
9 Vehicle alignment check 1336
9 1 General information 1336
9 2 Prerequisites for testing 1338
9 3 Test preparations 1338
9 4 Wheel alignment specifications 1339
9 5 Overview – wheel alignment procedure 1341
9 6 Correcting front axle camber 1342
9 7 Adjusting camber on rear axle 1344
9 8 Adjusting toe at rear axle 1345
9 9 Adjusting front axle toe 1346
9 10 Basic setting of steering angle sensor -G85- 1347
9 11 Vehicle data sticker 1347
10 Wheels, tyres 1348
10 1 Models with breakdown set 1348
10 2 Tyre sealant 1348
10 3 Removing a tyre 1348
10 4 Fitting a new tyre 1349
10 5 Tyre sealant disposal 1349
10 6 Alloy wheels with metal valves 1349
11 Instructions for changing or fitting wheels 1351
11 1 Fitting wheels 1352
12 Protecting wheel centring seat against corrosion 1353
13 Vibration due to wheels/tyres – causes and rectification 1354
13 1 Causes of rough running 1354
13 2 Balancing wheels 1354
13 3 Conducting a road test before balancing wheels 1354
13 4 Balancing wheels on stationary wheel balancing machine 1355
13 5 Vibration control system -VAS 6230 A- 1358
13 6 Finish balancer 1358
13 7 Radial and lateral runout of wheels and tyres 1359
13 8 Checking radial and lateral runout on wheels and tyres with tyre gauge -V A G 1435- 1359
13 9 Checking radial and lateral run-out on wheel rim 1360
13 10 Matching 1361
13 11 Flat spots caused by storage or handling 1362
48 – Steering 1364
1 Appraisal of accident vehicles 1364
2 General repair instructions 1365
2 1 Steering rack 1365
2 2 Gaskets and seals 1365
2 3 Nuts and bolts 1365
2 4 Electrical components 1366
2 5 Guided Fault Finding, vehicle self-diagnosis and Test Instruments 1366
3 Steering wheel 1367
3 1 Removing and installing steering wheel 1367
4 Steering columns up to model year 2008 1370
4 1 Assembly overview: steering column 1370
4 2 Removing and installing steering column 1370
4 3 Basic setting for steering angle sensor G85 steering angle sender must be checked after the following repair work: 1376
4 4 Handling and transporting steering column 1376
4 5 Checking steering column for damage 1378
4 6 Removing and installing mounting bracket 1378
4 7 Removing and installing strut 1380
5 Steering columns from model year 2009 1382
5 1 Assembly overview: steering column, left-hand drive 1382
5 2 Removing and installing steering column, left-hand drive vehicle 1382
5 3 Assembly overview: steering column, right-hand drive 1389
5 4 Removing and installing steering column, right-hand drive vehicle 1390
5 5 Handling and transporting steering column 1395
5 6 Checking steering column for damage 1396
6 Electromechanical steering rack up to model year 2008 1398
6 1 Assembly overview – electromechanical steering rack, left-hand drive vehicle (2nd generation) up to model year 2008 1398
6 2 Assembly overview – electromechanical steering rack, right-hand drive vehicle (2nd generation) up to model year 2008 1400
6 3 Removing and installing steering rack, left-hand drive vehicle (2nd generation) up to model year 2008 1402
6 4 Removing and installing steering rack, right-hand drive vehicle (2nd generation) up to model year 2008 1409
7 Electromechanical steering rack from model year 2009 1419
7 1 Assembly overview – electromechanical steering rack, left-hand drive vehicle (3rd generation) from model year 2009 1419
7 2 Assembly overview – electromechanical steering rack, right-hand drive vehicle (3rd generation) from model year 2009 1421
7 3 Removing and installing steering rack, left-hand drive vehicle (3rd generation) from model year 2009 1422
7 4 Removing and installing steering rack, 3rd generation, RHD vehicles, as of model year 2009 1428
8 Differentiating between 2nd and 3rd generation steering racks 1437
9 Repairing electromechanical 2nd and 3rd generation steering racks 1438
9 1 Assembly overview: electromechanical steering rack 1438
9 2 Removing and installing bellows 1439
9 3 Removing and installing track rod 1441
D3E80251958 4 cylinder common rail engine (2 0 l EA189 Gen II) 1444
00 – Technical data 1450
1 Identification 1450
1 1 Engine number/engine data 1450
1 1 1 Engine number 1450
1 1 2 Engine data 1450
2 Safety information 1452
2 1 Safety regulations for working on fuel supply 1452
2 2 Safety precautions when using testers and measuring instruments during a road test 1452
2 3 Safety measures when working on vehicles with a start/stop system 1453
2 4 Safety precautions when working on the cooling system 1453
2 5 Safety precautions when working on the SCR system 1453
2 6 Safety precautions when working on exhaust system 1454
3 Repair instructions 1456
3 1 Rules for cleanliness 1456
3 1 1 When working on fuel supply/injection system 1456
3 1 2 When working on turbocharger 1456
3 2 Foreign bodies in engine 1457
3 3 Checking vacuum system 1457
10 – Removing and installing engine 1458
1 Removing and installing engine 1458
1 1 Removing engine 1458
1 1 1 Removing engine, Golf, Golf Plus, Touran, Scirocco and Tiguan 1458
1 1 2 Removing engine, Passat, Eos and CC 1467
1 2 Separating engine and gearbox 1482
1 2 1 Separating engine from gearbox 1482
1 2 2 Separating engine from dual clutch gearbox 1485
1 3 Securing engine on engine and gearbox support 1487
1 4 Installing engine 1488
1 4 1 Notes on installing 1488
2 Assembly mountings 1492
2 1 Assembly overview – assembly mountings 1492
2 1 1 Assembly overview – assembly mounting for Golf, Golf Plus, Touran, Passat, Eos, Scirocco and CC 1492
2 1 2 Assembly overview – assembly mountings, Tiguan 1493
2 2 Supporting engine in installation position 1494
2 2 1 Supporting engine in installation position, Golf and Scirocco 1494
2 2 2 Supporting engine in installation position, Tiguan 1497
2 2 3 Supporting engine in installation position, Golf Plus 1499
2 2 4 Supporting engine in installation position, Touran 1502
2 2 5 Supporting engine in installation position, Passat, Eos and CC 1505
2 3 Adjusting assembly mountings 1509
2 3 1 Adjusting assembly mounting, Golf and Scirocco 1509
2 3 2 Adjusting assembly mountings, Tiguan 1511
2 3 3 Adjusting assembly mounting, Golf Plus 1513
2 3 4 Adjusting assembly mountings, Touran 1515
2 3 5 Adjusting assembly mounting, Passat, Eos and CC 1517
3 Engine cover panel 1519
3 1 Removing and installing engine cover 1519
13 – Crankshaft group 1521
1 Cylinder block, pulley end 1521
1 1 Assembly overview – poly V-belt drive 1521
1 1 1 Assembly overview – poly V-belt drive with tensioning element and air conditioner compressor 1521
1 1 2 Assembly overview – poly V-belt drive with tensioning roller and air conditioner compressor 1522
1 1 3 Assembly overview – poly V-belt drive 1524
1 2 Removing and installing poly-V belt 1525
1 2 1 Removing and installing poly V-belt with tensioning element and air conditioner compressor 1525
1 2 2 Removing and installing poly V-belt with tensioning roller and air conditioner compressor 1527
1 2 3 Removing and installing poly V-belt without air conditioner compressor 1529
1 3 Removing and installing poly V-belt tensioner 1530
1 3 1 Removing and installing poly V-belt tensioner 1530
1 4 Removing and installing bracket for ancillaries 1531
1 5 Removing and installing engine bracket 1533
1 5 1 Removing and installing engine bracket, Golf and Scirocco 1533
1 5 2 Removing and installing engine bracket, Tiguan 1536
1 5 3 Removing and installing engine bracket, Golf Plus 1539
1 5 4 Removing and installing engine bracket, Touran 1542
1 5 5 Removing and installing engine bracket, Passat, Eos and CC 1546
1 6 Assembly overview – cylinder block, pulley end 1549
1 6 1 Assembly overview – cylinder block, pulley end 1549
1 6 2 Assembly overview – crankcase 1551
1 7 Renewing crankshaft oil seal (pulley end) 1553
1 8 Removing and installing sealing flange, pulley end 1554
2 Cylinder block, gearbox end 1558
2 1 Assembly overview – cylinder block, gearbox end 1558
2 2 Removing and installing flywheel 1559
2 3 Removing and installing sealing flange on gearbox side 1561
2 3 1 Pressing out sealing flange with sender wheel 1561
2 3 2 Pressing in sealing flange with sender wheel 1562
3 Crankshaft 1571
3 1 Assembly overview – crankshaft 1571
3 2 Renewing needle bearing in crankshaft 1572
3 3 Crankshaft dimensions 1574
4 Pistons and conrods 1575
4 1 Assembly overview – pistons and conrods 1575
4 1 1 Assembly overview – pistons and conrods 1575
4 1 2 Piston and cylinder dimensions 1579
4 1 3 Bearing shells – installation position 1579
4 1 4 Piston and cylinder dimensions 1580
4 2 Separating new conrod 1580
4 3 Measuring piston projection at TDC 1581
4 3 1 Cylinder head gasket identification 1583
4 4 Checking radial clearance of conrods 1583
15 – Cylinder head, valve gear 1584
1 Cylinder head 1584
1 1 Assembly overview – cylinder head 1584
1 2 Removing and installing cylinder head 1588
1 3 Removing and installing cylinder head cover 1599
1 3 1 Removing and installing cylinder head cover 1599
1 3 2 Renewing seals for injectors 1602
1 4 Assembly overview – cylinder head cover 1603
1 5 Removing and installing vacuum pump 1605
1 6 Checking compression 1606
2 Toothed belt drive 1608
2 1 Assembly overview – toothed belt 1608
2 2 Removing and installing toothed belt 1610
2 2 1 Removing and installing toothed belt, tensioning roller A 1612
2 2 2 Removing and installing toothed belt, tensioning roller B 1621
3 Valve gear 1632
3 1 Assembly overview – valve gear 1632
3 2 Measuring axial play of camshaft 1634
3 3 Measuring radial clearance of camshaft 1635
3 4 Removing and installing camshaft 1636
3 5 Removing and installing camshaft oil seal 1644
3 5 1 Vehicles with »old« seal 1644
3 5 2 Vehicles with »new« seal 1646
3 6 Checking hydraulic compensation elements 1648
3 7 Removing and installing valve stem oil seals 1649
3 7 1 Renewing valve stem seals with cylinder head installed 1649
3 7 2 Renewing valve stem seals with cylinder head removed 1653
4 Inlet and exhaust valves 1657
4 1 Valve dimensions 1657
4 2 Reworking valve seats 1657
4 3 Checking valve guides 1657
4 4 Checking valves 1659
17 – Lubrication 1660
1 Sump, oil pump 1660
1 1 Assembly overview – sump/oil pump 1660
1 1 1 Assembly overview – sump/oil pump, engine codes CFFA, CFFB, CFGB, CFGC, CFFD, CLLA, CLJA 1660
1 1 2 Assembly overview – sump/oil pump, engine codes CFHB, CFHC, CFHF, CFJA, CFJB, CLCA 1663
1 2 Removing and installing sump 1666
1 3 Removing and installing oil pump 1671
1 3 1 Removing and installing oil pump, engine codes CFFA, CFFB, CFGB, CFGC, CFFD, CLLA, CLJA 1671
1 3 2 Removing and installing oil pump, engine codes CFHB, CFHC, CFHF, CFJA, CFJB, CLCA 1673
1 4 Removing and installing oil level and oil temperature sender 1674
1 5 Engine oil 1675
1 5 1 Oil capacities 1675
1 5 2 Checking engine oil level 1675
2 Engine oil cooler 1676
2 1 Assembly overview – engine oil cooler 1676
2 2 Removing and installing engine oil cooler 1677
3 Oil filter, oil pressure switch 1681
3 1 Assembly overview – oil filter housing, oil pressure switch 1681
3 2 Removing and installing oil pressure switch 1682
3 3 Checking oil pressure 1683
3 4 Checking oil pressure and oil pressure switch 1684
3 5 Removing and installing oil filter housing 1685
4 Balance shaft module 1690
4 1 Assembly overview – balance shaft module 1690
4 2 Removing and installing balance shaft module 1693
4 2 1 Removing balancer shaft module 1693
4 2 2 Installing a new balancer shaft module 1695
4 2 3 Installing a previously used balancer shaft module again 1699
19 – Cooling 1703
1 Cooling system/coolant 1703
1 1 Coolant hose connection diagram 1703
1 2 Draining and filling cooling system 1704
1 2 1 Draining 1705
1 2 2 Filling 1708
1 3 Checking cooling system for leaks 1710
2 Coolant pump, regulation of cooling system 1715
2 1 Assembly overview –coolant pump, thermostat 1715
2 2 Removing and installing coolant pump 1715
2 3 Removing and installing 4/2-way valve with thermostat 1717
2 4 Removing and installing coolant temperature sender 1722
2 4 1 Removing and installing coolant temperature sender -G62- 1722
2 4 2 Removing and installing radiator outlet coolant temperature sender -G83- 1724
3 Coolant pipes 1726
3 1 Assembly overview – coolant pipes 1726
3 2 Removing and installing coolant pipes 1728
3 2 1 Removing and installing front coolant pipe 1728
3 2 2 Removing and installing upper front coolant pipe 1733
3 2 3 Removing and installing left coolant pipe 1734
3 2 4 Removing and installing right coolant pipe 1737
4 Radiator, radiator fan 1740
4 1 Assembly overview – radiator/radiator fan 1740
4 2 Removing and installing radiator 1740
4 3 Removing and installing radiator cowl with radiator fans 1742
21 – Turbocharging/supercharging 1744
1 Turbocharger 1744
1 1 Assembly overview – turbocharger 1744
1 2 Removing and installing turbocharger 1746
1 3 Renewing vacuum unit for turbocharger 1751
2 Charge air system 1758
2 1 Assembly overview – charge air system 1758
2 2 Assembly overview – hose connections for charge air system 1759
2 3 Removing and installing charge air cooler 1760
2 4 Removing and installing charge pressure sender 1762
2 5 Checking charge air system for leaks 1762
23 – Mixture preparation – injection 1766
1 Injection system 1766
1 1 Schematic overview – fuel system 1766
1 2 Filling/bleeding fuel system 1768
1 3 Checking fuel system for leaks 1769
2 Vacuum system 1770
2 1 Assembly overview – vacuum system 1770
2 2 Checking vacuum system 1770
2 2 1 Checking supply line, vacuum reservoir and non-return valve 1771
2 2 2 Checking control line to turbocharger 1772
2 2 3 Checking control line to vacuum unit for exhaust gas recirculation cooler changeover function 1773
3 Injectors/high-pressure reservoir (rail) 1775
3 1 Assembly overview – injectors 1775
3 2 Adapting correction values for injectors 1778
3 3 Checking open injectors 1779
3 4 Checking return flow rate of injectors with engine running 1781
3 5 Checking return flow rate of injectors at starter speed 1784
3 6 Removing and installing injectors 1786
3 7 Removing and installing high-pressure lines 1790
3 8 Removing and installing fuel rail 1792
4 Intake manifold 1796
4 1 Assembly overview – intake manifold 1796
4 2 Removing and installing intake manifold 1797
4 3 Removing and installing throttle valve module 1801
5 Air filter 1804
5 1 Assembly overview – air filter housing 1804
5 2 Removing and installing air filter housing 1806
6 Senders and sensors 1808
6 1 Checking fuel pressure regulating valve 1808
6 2 Removing and installing fuel pressure regulating valve 1809
6 3 Removing and installing fuel pressure sender 1811
6 4 Removing and installing fuel temperature sender -G81- 1814
6 5 Removing and installing differential pressure sensor 1815
6 6 Removing and installing air mass meter 1816
7 High-pressure pump 1818
7 1 Assembly overview – high-pressure pump 1818
7 2 Removing and installing high-pressure pump 1820
8 Lambda probe 1824
8 1 Removing and installing lambda probe 1824
9 Engine/motor control unit 1826
9 1 Removing and installing engine control unit 1826
9 1 1 Removing and installing engine control unit -J623-, Golf, Scirocco 1826
9 1 2 Removing and installing engine control unit -J623-, Golf Plus, Touran 1828
9 1 3 Adapting functions and components, Eos 1829
9 1 4 Removing and installing engine control unit -J623-, Tiguan 1829
9 1 5 Removing and installing engine control unit -J623-, Eos 1831
9 1 6 Removing and installing engine control unit -J623-, Passat and CC up to 10 2010 1832
9 1 7 Removing and installing engine control unit -J623-, CC from 11 2010 1834
9 2 Removing and installing engine control unit with protective housing 1836
9 2 1 Removing and installing engine control unit -J623- with protective housing, Golf, Scirocco 1836
9 2 2 Removing and installing engine control unit -J623- with protective housing, Golf Plus, Touran 1839
9 2 3 Removing and installing engine control unit -J623- with protective housing, Tiguan 1842
9 2 4 Removing and installing engine control unit -J623- with protective housing, Eos 1844
9 2 5 Removing and installing engine control unit -J623- with protective housing, Passat and CC up to 10 2010 1847
9 2 6 Removing and installing engine control unit -J623- with protective housing, CC from 11 2010 1849
26 – Exhaust system 1853
1 Exhaust pipes and silencers 1853
1 1 Assembly overview – silencers 1853
1 1 1 Assembly overview – silencers, Tiguan 1853
1 1 2 Assembly overview – silencers, vehicles with front-wheel drive, Golf, Golf Plus, Eos, Scirocco 1854
1 1 3 Assembly overview – silencer, vehicles with four-wheel drive, Golf 1855
1 1 4 Assembly overview – silencers; vehicles with SCR system 1856
1 1 5 Assembly overview – silencers, vehicles with front-wheel drive, Passat and CC with engine codes CFFA, CFFB, CFGB, CFGC 1857
1 1 6 Assembly overview – silencers, vehicles with front-wheel drive, Passat and CC with engine code CLLA 1858
1 1 7 Assembly overview – silencers, vehicles with four-wheel drive, Passat and CC with engine code CFGB, CFGC 1859
1 1 8 Assembly overview – silencers, Touran 1860
1 1 9 Assembly overview – silencers, vehicles with four-wheel drive, Passat and CC with engine codes CFFA, CFFB 1861
1 2 Aligning exhaust system free of stress 1862
1 3 Installation position of clamp 1863
2 Emission control 1865
2 1 Assembly overview – emission control 1865
2 1 1 Assembly overview – front exhaust pipe with particulate filter 1865
2 1 2 Assembly overview – front exhaust pipe with catalytic converter, engine codes CLCA, CLLA, CLJA 1868
2 2 Removing and installing particulate filter 1869
2 3 Removing and installing catalytic converter 1878
2 3 1 Removing and installing front exhaust pipe with catalytic converter, engine codes CLCA, CLLA, CLJA 1878
3 SCR system (selective catalytic reduction) 1884
3 1 Assembly overview – reducing agent tank 1884
3 2 Draining reducing agent tank 1885
3 3 Removing and installing reducing agent tank 1889
3 4 Assembly overview – reducing agent supply line 1892
3 5 Removing and installing reducing agent supply line 1893
3 6 Removing and installing injector for reducing agent 1896
3 7 Assembly overview – delivery module for reducing agent 1897
3 8 Removing and installing heater element (reservoir) 1899
4 Exhaust gas temperature regulation 1904
4 1 Assembly overview – exhaust gas temperature regulation 1904
4 2 Removing and installing exhaust gas temperature sender 1906
4 2 1 Removing and installing exhaust gas temperature sender 1 -G235- 1906
4 2 2 Removing and installing exhaust gas temperature sender 3 -G495- 1908
4 2 3 Removing and installing exhaust gas temperature sender 4 -G648- 1910
5 Exhaust gas recirculation 1912
5 1 Assembly overview – exhaust gas recirculation 1912
5 2 Removing and installing exhaust gas recirculation cooler 1914
5 3 Checking exhaust gas recirculation cooler change-over 1917
5 4 Checking exhaust gas recirculation cooler for leaks 1918
5 5 Cleaning exhaust gas recirculation system 1923
5 5 1 Initiating cleaning of exhaust gas recirculation system 1923
5 5 2 Cleaning connecting pipes and pipe union 1929
28 – Glow plug system 1931
1 Glow plug system 1931
1 1 Removing and installing glow plug 1931
1 2 Removing and installing automatic glow period control unit 1933
1 3 Removing and installing Hall sender 1934
1 4 Removing and installing engine speed sender 1936
D3E80460006 Wheels and Tyres Guide 1939
44 – Wheels, tyres, vehicle geometry 1943
1 Wheel and tyre combinations 1943
1 1 General 1943
1 2 Explanations regarding world regions 1944
1 3 Eos – from model year 2006 (type 1F) 1945
2 Wheel allocation 1953
2 1 61/2 J x 16 1953
2 2 7 J x 16 1954
2 3 6 J x 17 1956
2 4 71/2 J x 17 1956
2 5 8 J x 18 1960
3 Recommended summer tyres, worldwide except North America and China 1963
4 Recommended all-season tyres 1964
4 1 Recommended all-season tyres, worldwide except North America and China 1964
4 2 Recommended all-season tyres, North America 1964
5 Recommended winter tyres, worldwide except North America and China 1965
6 Recommended temporary spare tyres and wheels 1966
D4B805CB339 Manual for Troubleshooting and Diagnosing Noises 1968
00 – Technical data 1974
1 Introduction 1974
2 Acoustic considerations during vehicle development 1975
2 1 Vibration insulation film 1975
2 2 Insulation 1976
3 General procedure for identifying noises 1978
3 1 General procedure 1978
3 2 Identifying a noise 1978
3 2 1 Localising origin of noise 1978
3 2 2 Identifying the type of noise 1979
3 2 3 Identifying the point in time when the noise occurs 1979
3 2 4 Identifying the noise by definition or designation 1979
3 3 Aid for localising noise by means of audio recordings (frequencies) 1979
3 3 1 Preparing an audio CD with downloaded files 1980
3 3 2 List of audio tracks 1980
3 3 3 Conditions for testing 1980
3 3 4 Conditions for performing the audio test 1981
3 4 Checklist 1981
4 Volkswagen equipment for localising noises 1985
4 1 Ultrasonic tester -VAG 1842- 1985
4 1 1 Design of the ultrasonic tester -VAG 1842- 1985
4 1 2 Example of procedure for identifying noises using ultrasound 1985
4 2 Borescope -VAS 6748A- 1989
4 2 1 Design of the borescope -VAS 6748A- 1989
4 2 2 Procedure for identifying noises using the borescope 1990
5 Attachments 1991
5 1 Checklist 1991
5 2 Designations for noises 1993
D4B807A09E7 6 speed dual clutch gearbox 02E 1994
00 – Technical data 2000
1 General repair instructions 2000
1 1 Tools 2000
1 2 Gearbox 2000
1 3 Overview 2000
1 4 Seals 2001
1 5 ⇒ DSG® oil 2002
1 6 Oil filter change – »Yes or no?« 2002
1 7 Oil drain and inspection plug -A- 2002
1 8 Nuts and bolts 2003
1 9 Electrical components 2003
2 Fault finding 2004
2 1 General notes on fault finding 2004
2 2 Useful information about the “behaviour of the control unit in the event of a gearbox fault” 2004
2 3 Special notes on fault finding 2005
3 Identification of gearbox 2007
3 1 Reading gearbox code letters 2007
4 Code – engine allocation 2009
4 1 Golf Plus 2009 ► 2009
4 2 Golf Plus 2005 ► 2009
4 3 Golf 2009 ► 2010
4 4 Scirocco 2009 ► 2010
4 5 Golf 2004 ► 2010
4 6 Touran 2003 ► 2011
4 7 Passat 2006 ► 2012
4 8 Eos 2006 ► 2012
4 9 Passat CC 2009 ►; CC 2010 ► 2013
4 10 Sharan 2011 ► 2013
5 Capacity 2014
30 – Clutch 2015
1 Clutch 2015
1 1 Assembly overview – dual clutch 2015
1 2 Removing and installing clutch end cover 2017
1 3 Removing dual clutch 2023
1 4 Installing dual clutch 2024
34 – Controls, housing 2030
1 Electrical and electronic components and their locations ⇒ DSG® 2030
1 1 Removing and installing mechatronic unit for dual clutch gearbox -J743- (gearbox installed) 2030
1 2 Removing and installing mechatronic unit for dual clutch gearbox -J743- (gearbox removed) 2039
1 3 Removing and installing gearbox input speed sender -G182- and oil temperature sender in multi-plate clutch -G509- 2046
2 Removing and installing gear oil cooler 2047
3 Removing and installing oil pump 2050
4 Renewing selector shaft lever oil seal with gearbox removed 2054
5 Emergency release of selector lever 2056
6 Removing and installing selector lever handle 2057
6 1 Moving push-button in the handle to installation position 2059
6 1 1 Handle with push-button on side 2059
6 1 2 Handle with front push-button 2059
7 Selector mechanism up to 02 2009 2061
7 1 Overview of selector mechanism up to 02 2009 2061
7 2 Removing and installing selector lever cable up to 02 2009 2062
7 3 Checking selector lever cable 2069
7 4 Adjusting selector lever cable 2069
8 Checking selector mechanism 2071
8 1 Selector lever in “P” position and ignition switched on 2071
8 2 Selector lever in “N” position and ignition switched on 2071
8 3 Selector lever in position “Tiptronic” 2071
8 4 Ignition and light switched on 2071
8 5 Selector lever position indicator 2071
9 Selector mechanism from 03 2009 onwards 2072
9 1 Overview of selector mechanism in vehicles from 03 2009 onwards 2072
9 2 Removing and installing selector mechanism, from 03 2009 2073
9 2 1 Removing and installing selector mechanism with selector housing 2073
9 2 2 Removing and installing selector mechanism without selector housing 2075
10 Removing and installing gearbox 2077
10 1 Removing gearbox, Passat CC 2009 ►, CC 2010 ► with 2 0 l petrol engine 2077
10 2 Removing gearbox, Golf 2009 ►, Golf Plus 2009 ► with 2 0 l petrol engine 2086
10 3 Removing gearbox, Golf Plus 2005 ► with 1 4 l petrol engine 2095
10 4 Removing gearbox, Passat CC 2009 ►, CC 2010 ► diesel engine 2102
10 5 Removing gearbox, Passat CC 2009 ►, CC 2010 ► with diesel engine, all-wheel drive 2112
10 6 Removing gearbox, Golf Plus 2009 ► with 2 0 l diesel engine 2121
10 7 Removing gearbox, Golf 2009 ► 2 0 l diesel engine 2129
10 8 Removing gearbox, Passat CC 2009 ►, CC 2010 ► with 3 6 l – V6 engine (all-wheel drive) 2136
10 9 Removing gearbox, Golf 2004 ▸ with 1 9 l and 2 0 l diesel engine 2143
10 10 Removing gearbox, Golf 2004 ► with 125 kW – 2 0 l diesel engine 2150
10 11 Removing gearbox, Eos 2006 ►, with 3 2 and 3 6 l – V6 engine 2156
10 12 Removing gearbox, Golf 2004 ► with 1 4 l petrol engine 2163
10 13 Removing gearbox, Golf 2004 ► with 2 0 l petrol engine 2170
10 14 Removing gearbox, Golf 2004 ►, with 3 2 l – V6 engine (R32 all-wheel drive) 2175
10 15 Removing gearbox, Golf Plus 2005 ► with 1 9 l and 2 0 l diesel engine, with 2 0 l petrol engine 2184
10 16 Removing gearbox, Eos 2006 ► with 2 0 l petrol engine 2191
10 17 Removing gearbox, Eos 2005 ► with 2 0 l diesel engine 2198
10 18 Removing gearbox, Touran 2003 ► 2205
10 19 Removing gearbox, Passat 2006 ► with 2 0 l diesel engine 2213
10 20 Removing gearbox, Passat 2006 ► with 2 0 l petrol engine 2221
10 21 Removing gearbox, Passat 2006 ► with 3 6 l – V6 engine (all-wheel drive) 2226
10 22 Removing gearbox, Scirocco 2009 ► with 2 0 l diesel engine 2232
10 23 Removing gearbox, Scirocco 2009 ► with 2 0 l petrol engine 2241
10 24 Removing gearbox, Sharan 2011 ► with 2 0 l diesel engine 2250
10 25 Removing gearbox, Sharan 2011 ► with 1 8 l and 2 0 l petrol engine 2258
10 26 Removing gearbox, Sharan 2011 ► with 1 4 l petrol engine 2267
10 27 Install gearbox 2274
11 Torque settings »gearbox to engine« 2276
11 1 Torque settings (⇒ ELSA) 2276
11 1 1 Torque settings and note on engine mountings 2277
11 1 2 Torque settings and note on engine mountings 2278
11 1 3 Torque settings and note on engine mountings 2279
11 1 4 Torque settings and note on engine mountings 2281
11 1 5 Torque settings and note on engine mountings 2282
11 1 6 Torque settings and note on engine mountings 2283
12 Transporting gearbox and securing to assembly stand 2284
13 Removing and installing bevel box, Golf 2004 ► and Passat 2006 ► 2285
14 Removing and installing bevel box, Passat CC 2009 ►, CC 2010 ► with diesel engine 2290
14 1 Specified torques 2296
15 Removing and installing bevel box, Passat CC 2009 ►, CC 2010 ► with 3 6 l V6 engine 2298
16 Oil and oil filter 2302
16 1 Oil filter: renewing 2302
16 2 Checking oil level and topping up 2303
16 3 Draining and filling oil 2306
35 – Gears, shafts 2310
1 Currently, no repairs can be made to gears and shafts 2310
39 – Final drive – differential 2311
1 Overview – seals 2311
1 1 Renewing seals for right flange shaft or stub shaft – front-wheel drive 2312
2 Renewing oil seal for left flange shaft – front and all-wheel drive 2314
2 1 Renewing oil seal for right flange shaft – all-wheel drive 2315
2 2 Dismantling and assembling flange shaft 2317
3 Renewing oil seal for propshaft drive flange at bevel box 2319
4 Assembly overview – Flange shafts and seals on bevel box 2325
4 1 Renewing seal on gearbox between bevel box and gearbox 2326
4 2 Removing and installing right flange shaft 2327
4 3 Renewing seal for right flange shaft on outside of bevel box 2329
4 4 Renewing needle bearing (polygon bearing) for right output shaft drive flange 2330
4 5 Renewing seal on bevel box between gearbox and bevel box 2332
5 Checking and topping up gear oil in bevel box 2334
5 1 Checking gear oil in bevel box 2334
5 2 Topping up gear oil in bevel box 2335
D4B807E3B5B Body Repairs General Body Repairs 2338
1 Safety instructions 2342
1 1 Part removal 2342
1 2 Battery and welding operation 2342
1 3 Electronic control unit 2342
1 3 1 Processing of the electronic control unit after repair dueto a traffic accident 2342
1 4 Paint, glass, soft pad and trim 2343
1 5 Fuel tank or fuel delivery pipeline 2343
1 6 Air conditioner 2343
1 6 1 Remedial measures: 2343
1 7 Airbag System 2344
1 8 Check the seat belts 2344
1 8 1 Belt body 2345
1 8 2 Automatic retractor (locking function) 2345
1 8 3 Visual inspection of the seat belt buckle 2346
1 8 4 Seat belt buckle function 2346
1 8 5 Seat belt guide member and tongue 2347
1 8 6 Fixing piece and fixing point 2347
1 9 Safety specifications for the seat belt tensioner 2347
1 10 Body repair on a vehicle equipped with the seat belt tensioners 2348
1 10 1 The following vehicles have been equipped with: 2348
1 11 Perform cutting off, correcting and/or leveling on a vehicleequipped with airbags 2349
1 12 Remove the front seats with a side airbag 2349
2 Basic instruction 2350
2 1 Diagnosis of the accident vehicle 2350
2 2 Condition of the body and/or the parts for delivery to thepainting workshop 2350
2 3 Correction 2350
2 4 Cutting 2350
2 5 Body-cut part and part section 2350
2 6 Original connection 2351
2 7 Galvanized body parts 2351
2 8 Remove the rest part 2351
2 9 New parts 2351
2 10 Parts 2351
2 11 Molded foam plastic pads 2352
3 Symbolic interpretation 2353
3 1 Symbolic interpretation for welding 2353
3 2 Symbolic interpretation for the operation method 2353
3 2 1 Grinding 2354
3 2 2 Thinning 2354
3 2 3 Punching 2354
3 2 4 Drilling 2355
3 2 5 Polishing 2355
3 2 6 Cavity corrosion protection 2355
3 2 7 Bonding 2356
3 2 8 Precise sealing 2356
4 Body repair tools 2357
4 1 Flaring tool -V A G 1317- 2357
4 2 Punching pliers -V A G 1329- 2357
4 3 Basic equipment -V A G 1366/3- 2357
4 4 Bottom protection layer spray gun -V A G 1379- 2358
4 5 Electric blower -V A G 1416- 2358
4 6 Door tensioner -V A G 1438- 2358
4 7 Body equipment component -V A G 1439- 2359
4 8 Pneumatic cutting knife -V A G 1523 A- 2359
4 9 Air chisel -V A G 1577- 2359
4 10 Edge closing iron block -V A G 1585- 2360
4 11 Welding fume ventilator -V A G 1586- 2360
4 12 Welding spot releasing device -V A G 1731- 2360
4 13 Pneumatic spray gun -V A G 1761/1- 2361
4 14 Pneumatic punching and thinning pliers -VAS 1996- 2361
4 15 Pneumatic adhesive spray gun -V A G 2005- 2361
4 16 Door hinge correction tool 2362
4 17 Hose kit 5023 for the inert gas protection welding 2362
4 18 Angle grinder -VAS 5174- 2362
4 19 Angle grinder -VAS 5175- 2363
4 20 Wire brush -VAS 5182- 2363
5 Body bonding 2364
5 1 Transporter 1991 → 2364
5 1 1 Separation process: 2364
5 1 2 Bonding process: 2364
5 2 Bonding types 2364
5 2 1 Bonding-strong 2364
5 2 2 Bonding-spot welding 2365
5 3 Repair method for replacing the parts 2365
5 3 1 Spot welding and bonding 2365
5 3 2 Plug welding and bonding (if spot welding is impossible) 2365
5 3 3 Welding fume ventilator 2366
5 3 4 Preparations 2366
5 3 5 Trimming 2366
6 Corrosion protection measures 2367
6 1 Corrosion protection 2367
7 Waste disposal instructions 2368
7 1 Waste disposal 2368
7 2 Air pressure tappet exhaust 2368
7 3 Airbag 2369
7 3 1 Waste disposal 2369
8 Contact corrosion protection 2370
8 1 Connection of aluminum alloy/magnesium alloy with steel 2370
9 Steel plate repair 2371
9 1 High-strength body plate 2371
9 2 Galvanized body parts 2371
9 2 1 Preparations 2371
9 2 2 Part cutting 2372
9 2 3 Connection process 2372
9 3 Welding on the galvanized body steel plate 2372
9 3 1 Inert gas protection plug welding SG of the galvanized steelplate 2372
9 3 2 Resistance pressure spot welding RP of the galvanized steelplate 2373
9 3 3 Welding transformer 2373
9 3 4 Welding clamp 2373
9 4 Tearing test 2373
10 Aluminum repair 2374
10 1 Painting 2374
10 2 Surface treatment 2374
10 3 Leveling 2375
10 4 Temperature control for heating 2375
11 Plastic repair method 2376
11 1 Material 2376
11 2 Repairing the pit 2377
11 3 Repairing the scratch 2378
11 4 Repair the crack 2380
11 5 Repairing the small hole (the diameter is more than 30 mm) 2381
11 6 Plastic repair (glass fibre material) 2382
11 7 Repair process 2383
11 7 1 Repairing the breakage position 2383
11 7 2 Repairing the surface damage 2385
12 Glass repair 2386
12 1 Repairing the windshield 2386
12 1 1 Premises 2386
12 1 2 Required special tools, operating equipment, testing instrumentsand auxiliary tools 2387
12 1 3 Repair description 2388
D4B802605A6 General information Paint passenger vehicles 2392
00 – Technical data 2398
1 Safety information 2398
1 1 Safety precautions when painting natural gas-powered vehicles 2398
1 2 Safety precautions when painting electric drive vehicles 2399
2 General information 2400
2 1 Paintwork structure of a factory finish 2400
2 2 Paint structure of service department finish 2403
2 2 1 Paintwork structure, base coat 2403
2 2 2 Paintwork structure, metallic effect 2406
2 3 Fundamental approach to dealing with areas sanded through to the substrate (bare metal surface) 2408
2 4 Reduced paint structure in engine compartment and inside of bonnet 2408
2 5 Instructions for work on underbody and stone chip protection 2408
2 6 Work instruction for window flange area 2410
2 7 Pre-treatment of bonded surfaces when renewing laser-welded roofs 2412
2 8 Corrosion protection measures for wing surface in contact with wheel housing liner 2416
2 9 Notes on treating corroded fold areas 2417
2 10 Corrosion protection for body components, add-on components and welded components 2419
2 11 Painting parking aid sensor 2420
2 12 ACC – Adaptive Cruise Control 2422
2 13 Instructions for painting bumper cover in area of lane change assist control unit 2422
3 Genuine products 2424
3 1 Paint products in customer service 2424
3 2 General application instructions for repair and painting systems 2425
3 2 1 Aqua Premium – application instructions for water-based products 2425
3 2 2 Setting gloss level of HS clear coats and HS top coats with matting additive 2428
3 2 3 Setting gloss level of 2-pack HS clear coats with 2-pack clear coat, matt 2438
3 2 4 Repair paintwork system for matt-finished vehicles 2440
3 2 5 Paintwork system for plastic components 2445
3 2 6 Aqua Premium system, blending system for 2-stage colours 2453
3 2 7 Aqua Premium system, blending system for 3-stage colours 2462
3 2 8 Aqua Premium system, product preparation for processing 2469
3 2 9 Aquaplus design and multi-colour painting 2476
3 2 10 Processing instructions for paint with limited hiding power 2481
3 3 Filler 2481
3 3 1 2-pack steel filler set 2481
3 3 2 2-pack fine filler 2485
3 3 3 2-pack fine filler, flexible 2489
3 3 4 2-pack spray filler 2492
3 3 5 2-pack IR premium filler 2498
3 3 6 2-pack epoxy resin filler 2503
3 4 Priming metal 2507
3 4 1 1-pack anti-corrosion wash primer 2507
3 4 2 1-pack wash primer 2512
3 4 3 2-pack wash primer 2517
3 5 Priming plastic materials 2523
3 5 1 Adhesion promoter (transparent) 2523
3 6 Surfacer 2527
3 6 1 2-pack HS Vario surfacer 2527
3 6 2 2-pack HS premium surfacer 2537
3 6 3 2-pack HS Performance surfacer 2546
3 6 4 2-pack primer surfacer for plastics 2555
3 6 5 2-pack HS wet-on-wet surfacer 2561
3 6 6 2-pack base filler, professional 2571
3 7 Top coats 2588
3 7 1 2-pack HS top coat 2588
3 7 2 Aquaplus system, uni (solid-colour) and metallic colours 2597
3 7 3 Aquaplus system (pearlescent and heliochrome) 2605
3 7 4 Aquaplus blending system 2613
3 7 5 Aqua Premium system 2619
3 7 6 Aqua Premium blending system 2632
3 7 7 Aqua Premium system (painting rims) 2639
3 8 Clear coats 2648
3 8 1 2-pack HS clear coat 2648
3 8 2 2-pack MS matt clear coat 2655
3 8 3 2-pack HS Vario clear coat 2661
3 8 4 2-pack HS optimum clear coat 2669
3 8 5 2-pack HS optimum plus clear coat 2675
3 8 6 2-pack HS brilliant clear coat 2680
3 8 7 2-pack HS brilliant plus clear coat 2685
3 8 8 2-pack HS Performance clear coat 2691
3 8 9 Blender 2697
3 9 Hardener 2702
3 9 1 2-pack HS hardener 2702
3 9 2 2-pack VHS hardeners and 2-pack VHS Performance hardeners 2706
3 9 3 Hardener for 2-pack primer surfacer 2710
3 9 4 Aqua Premium hardener 2710
3 10 Thinners 2711
3 10 1 2-pack thinner 2711
3 10 2 HS spot thinner 2714
3 10 3 Demineralised water 2716
3 11 Anti-corrosion materials 2717
3 11 1 Anti-corrosion wax 2717
3 11 2 Cavity sealant 2718
3 11 3 Anti-corrosion wax (in aerosol can) 2721
3 12 Underseal 2722
3 12 1 Permanent underseal -D 314 D36 M2-, grey 2722
3 12 2 Permanent underseal -D 314 D37 M2-, black 2725
3 12 3 Permanent underseal -D 314 D38 M2-, light 2728
3 12 4 Underseal -D 314 D39 A3-, black 2731
3 13 Stone deflector 2733
3 13 1 Stone chip guard -AKR 311 KD1 05- 2733
3 13 2 Stone chip guard -AKR 311 KD1 10- 2735
3 14 Wax-based underseal 2742
3 14 1 Wax-based underseal -D 316 D38 A2- 2742
3 14 2 Wax-based underseal -D 316 000 A1- 2744
3 14 3 Spray wax -D 322 100 M2- 2746
3 15 Sealing materials 2747
3 15 1 Polyurethane adhesive sealant (bonding compound) 2747
3 15 2 Sprayable sealant 2750
3 15 3 Adhesive sealant 2753
3 16 Cleaning agents 2755
3 16 1 Silicone remover 2755
3 16 2 Cleaner for plastics 2757
3 16 3 Cleaner for plastics, anti-static 2758
3 16 4 Industrial dirt remover 2758
3 17 SprayMax system 2760
3 17 1 1-pack anti-corrosion primer 2760
3 17 2 1-pack test paint 2764
3 17 3 1-pack clear coat 2767
3 17 4 1-pack wash primer 2770
3 17 5 1-pack Fill Clean spray can -LLS MAX 099-/1-pack Fill Clean spray can -LLS MAX 100- – Aquaplus system 2775
3 17 6 1-pack fill clean spray can -LLS MAX 112-, Aqua Premium system 2782
3 17 7 2-pack surfacer 2790
3 17 8 2-pack HS Performance surfacer 2797
3 17 9 2-pack clear coat 2805
3 17 10 2-pack epoxy primer surfacer 2810
3 17 11 2-pack wash primer 2816
3 17 12 Silicone remover -LLS MAX 007- 2822
3 17 13 Slow-drying silicone remover -LLS MAX 008- 2824
3 17 14 Blender 2827
3 17 15 Adhesion promoter 2829
3 18 Additional materials 2833
3 18 1 Matting additive -ALN 775 106- 2833
3 18 2 Matting additive -LVM 769 810 A2- 2840
3 18 3 Texture additive 2843
3 18 4 Blending additive for Aquaplus 2849
3 18 5 Additive for Aqua Premium 2850
4 Workshop equipment 2851
4 1 Tools 2851
4 1 1 Spray can filling device -VAS 6425- 2851
4 1 2 Paint thickness tester -VAS 6272- 2852
4 1 3 Paint thickness tester -VAS 6197- 2853
4 1 4 Paint thickness tester -VAS 5278- 2853
4 1 5 Stone chip tester -VAS 5102A- 2854
4 1 6 Pneumatic brush grinder set -VAS 6446- 2855
4 1 7 Brush grinder set -VAS 6776- 2855
4 1 8 Suction feed spray-gun -V A G 1538- 2857
4 1 9 Infrared heater -VAS 6873- 2858
4 1 10 Stand -VAS 6873/1- 2858
4 1 11 Infrared heater -VAS 6874- 2859
4 1 12 Infrared heater -VAS 6875- 2860
4 1 13 Infrared heater -VAS 6876- 2860
4 1 14 Infrared heater -VAS 6877- 2861
4 1 15 Infrared heater -VAS 6878- 2862
4 1 16 Infrared heater -VAS 6879- 2863
4 2 Tack cloths 2863
4 2 1 Tack cloth -VAS 6177- 2863
4 2 2 Buffing cloth, white -VAS 6176- 2864
D4B8027068B Air conditioning systems with refrigerant R134a General information 2865
00 – Technical data 2871
1 Safety information 2871
1 1 Safety precautions when working on air conditioning systems 2871
1 2 Safety precautions when working on high-voltage system 2872
1 3 Safety precautions when working in the vicinity of high-voltage components 2872
1 4 Safety precautions when tow-starting or towing 2873
2 Repair instructions 2874
2 1 Rules for cleanliness when working on high-voltage system 2874
3 General information on air conditioning 2875
3 1 Other reference material 2875
3 2 Basics of air conditioning technology 2875
3 2 1 Physical principles: 2875
3 2 2 Heat always flows from a warmer to a colder substance 2876
3 2 3 Pressure and boiling point 2876
3 3 Vapour pressure table for refrigerant R134a 2877
3 4 Refrigerant R134a 2878
3 4 1 Physical data of refrigerant R134a 2878
3 4 2 Critical point 2878
3 4 3 Environmental aspects of refrigerant R134a 2879
3 5 Properties of refrigerant R134a 2879
3 5 1 Trade names and designations 2879
3 5 2 Colour 2879
3 5 3 Vapour pressure 2879
3 5 4 Physical properties of R134a 2880
3 5 5 Effects on metal 2880
3 5 6 Critical temperature and critical pressure 2880
3 5 7 Union 2880
3 5 8 Charge factor 2880
3 5 9 Detecting leaks 2880
3 6 Refrigerant oil 2881
3 6 1 Properties of refrigerant oil 2881
3 7 Comfort 2882
3 7 1 Environmental aspects 2882
3 8 How air conditioning works 2883
3 9 General work safety 2883
3 9 1 Product characteristics 2883
3 9 2 Handling refrigerants 2884
3 9 3 Wear safety goggles 2884
3 9 4 Wear protective gloves and apron 2884
3 9 5 Do not allow liquid refrigerant to come in contact with the skin 2884
3 9 6 Do not breath in refrigerant vapour 2884
3 9 7 Absolutely NO SMOKING 2884
3 9 8 Welding and soldering on refrigeration systems 2884
3 9 9 Pungent smell 2885
3 9 10 First aid 2885
3 9 11 Handling pressure vessels 2885
3 9 12 Do not heat up above 50°C 2885
3 9 13 Do not expose to uncontrolled heat 2885
3 9 14 Seal empty tanks/containers 2885
3 9 15 Safety instructions for using extraction and charging equipment 2886
3 10 Safety measures when working on vehicles with air conditioning and when working with refrigerant R134a 2886
3 11 Basics for working on refrigerant circuit 2887
3 11 1 O-ring 2888
3 11 2 Before operating the air conditioning system after recharging with refrigerant 2889
4 General information on refrigerant circuit 2890
4 1 Components of refrigerant circuit 2890
4 1 1 Distribution of the refrigerant circuit components and their influence on the high-pressure and low-pressure sides 2890
4 1 2 Air conditioning system compressor with magnetic clutch: 2890
4 1 3 Air conditioner compressor without magnetic clutch 2891
4 1 4 Air conditioner compressor without magnetic clutch, with elastic drive coupling 2892
4 1 5 Electrical air conditioner compressor for high-voltage system 2893
4 1 6 Condenser 2894
4 1 7 evaporator 2894
4 1 8 Reservoir 2895
4 1 9 Restrictor 2895
4 1 10 Receiver 2896
4 1 11 Expansion valve 2897
4 1 12 O-ring 2898
4 1 13 Pipes and hoses of refrigerant circuit 2898
4 1 14 High-pressure safety valve 2898
4 2 Design of refrigerant circuit 2901
4 2 1 Refrigerant circuit with expansion valve and evaporator 2901
4 2 2 Refrigerant circuit with restrictor and reservoir 2901
4 3 Evacuation and charging valves for quick-release couplings of air conditioner service station on refrigerant circuit 2902
4 3 1 Evacuation and charging valve with Schrader valve 2902
4 3 2 Extraction and charging valve, high-pressure side 2903
4 3 3 Extraction and charging valve, low-pressure side 2904
4 4 Switches and senders in refrigerant circuit and related connections 2904
4 4 1 High-pressure switch for air conditioning system -F23- 2904
4 4 2 High-pressure switch for magnetic clutch -F118- 2905
4 4 3 Low-pressure switch for air conditioning system -F73- 2905
4 4 4 Connections with valve for switches in refrigerant circuit 2906
4 4 5 Air conditioning system pressure switch -F129- 2906
4 4 6 High-pressure sender -G65- 2907
4 4 7 Refrigerant pressure and temperature sender -G395- 2908
4 4 8 Air conditioner compressor regulating valve -N280- 2908
4 5 Electrical components not installed in refrigerant circuit 2909
4 5 1 Control and regulating unit for air conditioning system -J127- 2909
4 5 2 Radiator fan control unit -J293- 2909
4 5 3 Radiator fan control unit -J293- 2910
4 5 4 Temperature switch for evaporator -E33- 2911
4 5 5 Evaporator output temperature sender -G263- or evaporator temperature sensor -G308- 2911
4 6 Pressures and temperatures in refrigerant circuit 2912
4 7 Refrigerant circuit with expansion valve 2912
4 8 Refrigerant circuit with restrictor and reservoir 2914
4 9 Test and measurement work that can be performed using a pressure gauge 2916
4 9 1 Pressure gauges enable the following test and measurement work 2916
4 10 Air conditioner service and recycling equipment 2917
4 10 1 Classification of extraction and charging devices in groups 2917
4 10 2 Charging devices that do not require a permit 2917
4 11 Notes to repairs on refrigerant circuit 2918
5 Laws and regulations 2919
5 1 Laws and regulations 2919
5 2 Recycling and refuse law 2924
5 2 1 Disposal of refrigerant and refrigerant machine oil 2924
5 3 Converting R12 refrigerant circuits to R134a refrigerant circuits and servicing them (retrofitting) 2925
5 4 Maintaining records on refrigerant 2925
6 Refrigerant circuit 2926
6 1 Important repair notes on air conditioning 2926
6 2 Converting refrigerant circuits from R12 refrigerant to R134a 2926
7 Working with the air conditioner service station 2927
7 1 Important instructions for working with the air conditioner service station 2927
7 2 Connecting a air conditioner service station for measuring and testing 2928
7 3 Drain the refrigerant circuit using the air conditioner service station 2929
7 4 Evacuating refrigerant circuit using air conditioner service station 2929
7 5 Filling refrigerant circuit with air conditioner service station 2931
7 6 Bringing air conditioning system into service after charging 2932
7 7 Charging the container in the air conditioning service station with refrigerant 2932
7 8 Emptying air conditioner service station 2933
8 Detecting leaks in refrigerant circuit 2934
8 1 Leak detection in refrigerant circuit using compressed air or nitrogen 2935
8 2 Searching for leaks in refrigerant circuits using leak detector -V A G 1796- 2936
8 3 Detecting leaks in refrigerant circuit using leak detecting system -VAS 6196- or leak detecting system -VAS 6201- or a later model 2937
9 Clearing refrigerant circuit of contaminants 2945
9 1 Vehicles with high-voltage system (hybrid vehicles) 2945
9 2 Blowing through refrigerant circuit with compressed air and nitrogen 2946
9 2 1 Flushing refrigerant circuit 2948
9 3 Flushing refrigerant circuit with refrigerant R134a 2948
9 3 1 Principle circuit diagrams for various purging circuits 2956
9 3 2 Purging electrical air conditioner compressor 2962
9 3 3 Adapters for setting up flushing circuits 2966
10 Clearing refrigerant circuit of contaminants, commercial vehicles 2980
10 1 Vehicles with high-voltage system 2980
10 2 Flushing refrigerant circuit with refrigerant R134a 2981
10 3 Adapters for setting up flushing circuits 2981
10 4 Procedure for setting up and flushing refrigerant circuit, Amarok 2023 ► 2985
10 5 Procedure for setting up and flushing refrigerant circuit, Amarok 2010 ► 2985
10 5 1 Connection diagram for flushing circuit 2985
10 5 2 Procedure for setting up and flushing refrigerant circuit 2986
10 6 Procedure for setting up and flushing refrigerant circuit, Caddy 2004 ► 2991
10 6 1 Connection diagram for flushing circuit 2991
10 6 2 Procedure for setting up and flushing refrigerant circuit 2992
10 7 Procedure for setting up and flushing refrigerant circuit, Crafter ►2017 2998
10 7 1 Connection diagram for flushing circuit, vehicles with one evaporator 2998
10 7 2 Connection diagram for flushing circuit, vehicles with second evaporator 2999
10 7 3 Procedure for setting up and flushing refrigerant circuit, vehicles with one evaporator 3000
10 7 4 Procedure for setting up and flushing refrigerant circuit, vehicles with second evaporator 3007
10 8 Procedure for setting up and flushing refrigerant circuit, Crafter 2017 ► or MAN TGE ►, Crafter Grand California ► 3015
10 8 1 Connection diagram for flushing circuit, vehicles with one evaporator 3016
10 8 2 Connection diagram for flushing circuit, vehicles with second evaporator 3017
10 8 3 Procedure for setting up and flushing refrigerant circuit, vehicles with one evaporator 3018
10 8 4 Procedure for setting up and flushing refrigerant circuit, vehicles with second evaporator 3023
10 9 Procedure for setting up and flushing refrigerant circuit, Transporter 2016 ►, Transporter 2020 ► 3032
10 9 1 Connection diagram for flushing circuit, vehicles with one evaporator 3032
10 9 2 Connection diagram for flushing circuit, vehicles with second evaporator 3033
10 9 3 Procedure for setting up and flushing refrigerant circuit, vehicles with one evaporator 3034
10 9 4 Procedure for setting up and flushing refrigerant circuit, vehicles with second evaporator 3039
11 Complaints 3048
11 1 Possible complaints about refrigerant circuit 3048
11 1 1 Conditions for testing: 3048
11 1 2 Possible complaints 3048
11 2 Odours from heater and air conditioning unit 3049
11 2 1 Does the odour emanate from the evaporator or heat exchanger? 3049
11 2 2 Ultrasonic air conditioner cleaning unit -VAS 6189A- 3050
11 2 3 Spraying the evaporator with the suction feed spray-gun -V A G 1538- and spray lance 3051
12 Connecting the air conditioning service station 3052
12 1 For vehicles that have connections on both low-pressure and high-pressure sides of refrigerant circuit 3052
12 1 1 Connecting a air conditioner service station for measuring and testing 3052
13 Checking pressures on vehicles 3053
13 1 Checking pressures in the refrigerant circuit (using a air conditioning service station) 3053
13 1 1 Conditions for testing 3053
13 1 2 Checking pressures 3054
13 1 3 Continuation of checking pressures 3056
13 2 Checking systems with a restrictor and collector (with internally regulated air conditioner compressor) 3057
13 2 1 Specifications: 3057
13 3 Checking systems with an expansion valve and reservoir (with internally regulated air conditioner compressor) 3061
13 3 1 Specifications: 3061
13 4 Checking systems with an expansion valve and reservoir (without regulated air conditioner compressor) 3066
13 4 1 Conditions for testing 3066
13 4 2 Check 3066
13 4 3 Specified values 3066
13 5 Checking systems with a restrictor and reservoir and air conditioner compressor regulating valve -N280- (with externally regulated air conditioner compressor) 3067
13 5 1 Specifications: 3067
13 6 Checking systems with an expansion valve, receiver and air conditioner compressor regulating valve -N280- (with externally regulated air conditioner compressor) 3072
13 6 1 Specifications: 3072
13 7 With expansion valve, receiver and electrical air conditioner compressor 3083
14 Renewing components 3084
14 1 In the event of leaking or damaged components (apart from the air conditioner compressor, receiver or reservoir) 3085
14 1 1 If the refrigerant circuit was completely empty 3085
14 1 2 If there is still refrigerant in the refrigerant circuit 3087
14 2 Renew the air conditioner compressor 3087
14 2 1 Without needing to flush refrigerant circuit of contaminants (cleaning), e g in cases of external damage after an accident 3087
14 2 2 Leaks or internal damage (e g noises or lack of power) 3089
14 3 Replace receiver or reservoir and restrictor 3089
14 3 1 After flushing contaminants from refrigerant circuit, e g due to moisture intrusion (because refrigerant circuit was open for a longer period of time) or due to soiling 3089
14 3 2 Without needing to flush contaminants from refrigerant circuit (e g damage in an accident); no refrigerant has escaped and no moisture or dirt has entered refrigerant circuit 3091
15 Testing equipment and tools 3092
15 1 List of test equipment, tools and materials 3092
15 1 1 Tools and materials available from regional sales centre or importer 3092
15 1 2 Tools and materials commercially available 3093
15 1 3 Tools and materials available from regional sales centre or importer 3094
15 1 4 Tools and materials commercially available 3100
K0058895220 7 speed dual clutch gearbox 0AM 3103
00 – Technical data 3109
1 Identification of gearbox 3109
2 Overview – power transmission 3110
3 Code, engine allocation 3111
3 1 Polo 2010 ► 3111
3 2 Touran 2003 ► 3111
3 3 Golf 2004 ► 3111
3 4 Passat CC 2009 ►; CC 2010 ► 3112
3 5 Passat 2006 ► 3112
3 6 Golf 2009 ► 3112
3 7 Golf Plus 2009 ► 3112
3 8 Golf Plus 2005 ►, Cross Golf 3113
3 9 Scirocco 2009 ► 3113
4 Capacities 3114
5 General repair instructions 3115
5 1 Tools 3115
5 2 Gearbox 3115
5 3 Anti-friction bearings 3117
5 4 Oil 3117
5 5 Working with tester 3117
5 5 1 Adapting installation information 3118
5 5 2 Reading measured values for mandatory reporting 3118
5 5 3 Initiating basic adjustment 3118
30 – Clutch 3119
1 Removing and installing dual clutch, gearboxes made up to 05 2011 3119
1 1 Assembly overview – dual clutch, gearboxes made up to 05 2011 3119
1 2 Removing dual clutch, gearboxes made up to 05 2011 3121
1 3 Adjusting position of engagement bearings for clutches “K 1” and “K 2”, gearboxes made up to 05 2011 3125
1 4 Installing dual clutch, gearboxes made as of 05 2011 3138
2 Removing and installing dual clutch, gearboxes made from 06 2011 onwards 3145
2 1 Assembly overview – dual clutch, gearboxes made as of 06 2011 3145
2 2 Removing dual clutch, gearboxes made as of 06 2011 3147
2 3 Adjusting position of engagement bearings for clutches “K 1” and “K 2”, gearboxes made as of 06 2011 3151
2 4 Installing dual clutch, gearbox date from 06 2011 3164
3 Removing and installing oil seals at clutch end 3171
34 – Controls, housing 3174
1 Emergency release of selector lever 3174
2 Removing and installing selector lever handle 3175
2 1 Moving push-button in the handle to installation position 3177
2 1 1 Handle with push-button on side 3177
2 1 2 Handle with front push-button 3177
3 Selector mechanism in vehicles up to 02 2009 3180
3 1 Overview of selector mechanism up to 02 2009 3180
3 2 Removing and installing selector lever cable up to 02 2009 3181
4 Selector mechanism from 03 2009 onwards 3188
4 1 Overview of selector mechanism in vehicles from 03 2009 onwards 3188
4 2 Removing and installing selector mechanism 3189
4 2 1 Removing and installing selector mechanism with selector housing 3189
4 2 2 Removing and installing selector mechanism without selector housing 3191
5 Checking selector mechanism 3193
5 1 Selector lever in “P” position and ignition switched on 3193
5 2 Selector lever in “N” position and ignition switched on 3193
5 3 Selector lever in position “Tiptronic” 3193
5 4 Ignition and light switched on 3193
5 5 Selector lever position indicator 3193
5 6 Checking and adjusting selector lever cable 3193
6 Safety note on mechatronic unit for dual clutch gearbox -J743- 3197
7 Overview – mechatronic unit 3198
8 Removing mechatronic unit for dual clutch gearbox -J743-; gearbox is installed 3200
9 Moving mechatronic unit for dual clutch gearbox -J743- into »removal position« by hand 3212
10 Installing mechatronic unit for dual clutch gearbox -J743- 3214
11 View on selector forks; mechatronic unit is removed 3222
12 Renewing clutch actuator 3223
13 Renewing control unit for mechatronic unit for dual clutch gearbox -J743- 3229
14 Removing and installing gearbox 3234
14 1 Notes on different vehicles, different gearboxes 3234
14 2 Removing gearbox, Golf 2009 ► and Golf Plus 2009 ►, 1 2 l – 63 and 77 kW petrol engine 3236
14 3 Removing gearbox, Golf 2009 ►, 1 8 l – 118 kW petrol engine 3244
14 4 Removing gearbox, Polo 2010 ►, 1 2 l – 63 and 77 kW petrol engine 3250
14 5 Removing gearbox, Polo 2010 ►, 1 4 l – 63 kW petrol engine 3255
14 6 Removing gearbox, Polo 2010 ►, 1 4 l – 103 kW petrol engine 3262
14 7 Removing gearbox, Polo 2010 ►, 1 6 l – 66 kW diesel engine 3266
14 8 Removing gearbox, Polo 2010 ►, 1 4 l – 132 kW petrol engine 3273
14 9 Removing gearbox with flange shafts; Touran 1 4 l – 103, 110 and 125 kW petrol engine (and 110 kW Eco-Fuel) 3279
14 10 Removing gearbox, Touran 1 6 l – 77 kW TDI engine 3285
14 11 Removing gearbox, Touran 1 9 l – 77 kW TDI engine 3291
14 12 Removing gearbox, Passat 2006 ► 1 4 l – 110 kW Eco-Fuel engine 3297
14 13 Removing gearbox, Passat 1 4 l – 90 and 110 kW petrol engine 3303
14 14 Removing gearbox, Passat 1 8 l – 90 and 118 kW petrol engine 3308
14 15 Removing gearbox, Golf Plus 2009 ►, 1 4 l – 90 kW and 118 kW petrol engine 3313
14 16 Removing gearbox, Golf Plus 2009 ►, 1 6 l – 75 kW petrol engine 3320
14 17 Removing gearbox, Scirocco 2009 ►, 1 4 l – 118 kW TSI engine 3327
14 18 Removing gearbox, Golf 2009 ►, 1 6 l – 75 kW petrol engine 3334
14 19 Removing gearbox, Golf 2009 ►, 1 4 l – 90 or 118 kW petrol engine 3340
14 20 Removing gearbox, Golf 2004 ►, Golf Plus 2005 ► and Cross Golf 1 4 l – 90, 118 kW TSI engine 3347
14 21 Removing gearbox, Golf Plus 2009, 1 6 l – 77 kW diesel engine 3354
14 22 Removing gearbox, Golf 2009 1 6 l and 1 9 l – 77 kW diesel engine 3361
14 23 Removing gearbox, Golf 2004 and Golf Plus 2005 1 9 l – 77 kW TDI engine 3367
14 24 Removing gearbox, Passat CC 2009 ►, CC 2010 ►, Passat 2011 ► 1 4 l – 90, 110, 118 kW petrol engine and 1 4 l – 110 kW Eco-Fuel engine 3373
14 25 Removing gearbox, Passat CC 2009►, CC 2010►, 1 8 l – 90 and 118 kW petrol engine 3380
14 26 Removing gearbox, Golf Cabriolet 2012 ►, 1 4 l – 90 or 118 kW petrol engine 3386
14 27 Install gearbox 3392
14 28 Torque settings »Gearbox to engine« and notes on assembly mounting 3395
14 28 1 1 8 – 118 kW engine 3397
14 28 2 1 4 l – 63 kW petrol engine 3398
14 28 3 1 4 l – 103 kW petrol engine 3399
14 28 4 1 2 l and 1 4 l and 1 6 l engine 3400
14 28 5 1 6 l – 77 kW diesel engine 3401
14 28 6 1 9 l – 77 kW diesel engine and 1 6 l – 66 kW diesel engine 3402
15 Transporting gearbox and securing to assembly stand 3403
16 Gear oil 3405
16 1 Draining and filling gear oil 3405
16 2 Draining and filling hydraulic fluid for mechatronic unit 3407
35 – Gears, shafts 3411
1 Notes on gearbox disassembly 3411
1 1 Overview: gearbox disassembly 3411
2 Dismantling gearbox 3413
3 Assembling gearbox 3420
4 Dismantling and assembling gearbox housing 3431
5 Dismantling and assembling clutch housing 3435
6 Dismantling and assembling outer input shaft 3439
7 Dismantling and assembling inner input shaft 3441
8 Dismantling and assembling output shaft 1 – overview 3444
8 1 Dismantling output shaft 1 partially 3445
8 2 Dismantling output shaft 1 completely 3447
8 3 Assembling output shaft 1 3449
8 4 Dismantling and assembling locking collars and synchro-hubs of output shaft 1 3454
9 Dismantling and assembling output shaft 2 – overview 3455
9 1 Dismantling output shaft 2 3456
9 2 Assembling output shaft 2 3458
9 3 Dismantling and assembling locking collars and synchro-hubs of output shaft 2 3462
10 Dismantling and assembling output shaft 3 – overview 3463
10 1 Dismantling output shaft 3 3463
10 2 Assembling output shaft 3 3465
10 3 Dismantling and assembling locking collar and synchro-hub of output shaft 3 3467
11 Notes on gearbox adjustment 3468
11 1 Calculating shims for clutch housing 3469
12 Calculating shims for gearbox housing 3482
13 Parking lock 3502
13 1 Removing and installing cover for parking lock 3502
13 2 Removing and installing parking lock 3503
39 – Final drive – front differential 3505
1 Oil seals 3505
1 1 Renewing oil seal for right stub shaft 3505
1 2 Renewing oil seal for left stub shaft 3506
1 3 Renewing seal for right flange shaft 3508
1 4 Renewing oil seal for left flange shaft 3510
K0058895320 4 cyl injection engine (1 8 and 2 0 l engine chain drive) 3514
00 – Technical data 3522
1 Engine number 3522
2 Engine data 3523
10 – Removing and installing engine 3525
1 Removing and installing engine 3525
1 1 Removing engine 3526
1 2 Separating gearbox from engine and assembling 3540
1 3 Securing engine to assembly stand 3543
1 4 Installing engine 3544
2 Assembly mountings 3547
2 1 Assembly overview – assembly mountings (Golf, Eos, Passat, CC, Scirocco) 3547
2 2 Assembly overview – assembly mountings (Tiguan) 3549
2 3 Checking adjustment of assembly mountings 3551
2 4 Adjusting assembly mountings (Passat 2006 ▶, CC) 3551
2 5 Adjusting assembly mountings (Golf, Eos, Scirocco) 3556
2 6 Adjusting assembly mounting (Tiguan) 3561
13 – Crankshaft group 3566
1 Cylinder block (pulley end) 3566
1 1 Assembly overview – poly V-belt drive 3566
1 2 Removing and installing poly-V belt 3569
1 3 Removing and installing tensioner for poly V-belt (Passat 2006 ▶, CC) 3570
1 4 Removing and installing tensioner for poly V-belt (Golf, Eos, Scirocco) 3575
1 5 Removing and installing tensioner for poly V-belt (Tiguan) 3580
1 6 Removing and installing bracket for ancillaries 3584
1 7 Removing and installing vibration damper 3586
1 8 Renewing oil seal for vibration damper 3594
2 Cylinder block, gearbox end 3597
2 1 Assembly overview – sealing flange on gearbox side and dual-mass flywheel/drive plate 3597
2 2 Removing and installing dual-mass flywheel 3598
2 3 Removing and installing drive plate 3600
2 4 Removing and installing sealing flange on gearbox side 3602
2 4 1 Removing and installing sealing flange on gearbox side, version A sealing lip faces outwards 3603
2 4 2 Removing and installing sealing flange on gearbox side, version B sealing lip faces engine 3606
3 Crankshaft 3611
3 1 Assembly overview – crankshaft 3611
3 1 1 Removing and installing sender wheel 3613
3 1 2 Allocation of crankshaft bearing shells (classification) 3614
3 2 Pulling needle bearing out of and driving into crankshaft 3616
3 3 Crankshaft dimensions 3618
3 4 Measuring axial clearance of crankshaft 3618
3 5 Measuring radial clearance of crankshaft 3619
4 Pistons and conrods 3621
4 1 Assembly overview – pistons and conrods 3621
4 2 Removing and installing pistons 3625
4 3 Checking pistons and cylinder bores 3627
4 4 Separating new conrod 3629
4 5 Checking radial clearance of conrods 3630
15 – Cylinder head, valve gear 3631
1 Chain drive 3631
1 1 Assembly overview – timing chain covers 3631
1 2 Removing and installing camshaft control valve 1 -N205- 3634
1 3 Removing and installing upper timing chain cover 3634
1 4 Removing and installing lower timing chain cover (Passat, CC) 3637
1 5 Removing and installing lower timing chain cover (Golf, Eos, Scirocco) 3645
1 6 Removing and installing bottom timing chain cover (Tiguan) 3654
1 7 Camshaft timing chain – exploded view 3662
1 8 Removing and installing camshaft timing chain 3664
1 9 Assembly overview – drive chain for balance shaft 3681
1 10 Removing and installing drive chain for balance shaft 3684
1 11 Removing and installing inlet side balance shaft 3684
1 12 Removing and installing exhaust side balance shaft 3689
1 13 Checking valve timing 3692
2 Cylinder head 3695
2 1 Assembly overview – cylinder head 3695
2 2 Renewing oil non-return valve in cylinder head 3699
2 3 Removing and installing engine cover 3700
2 4 Removing and installing cylinder head 3701
2 4 1 Removing and installing cylinder head 3702
2 4 2 Removing and installing cylinder head and camshaft timing chain 3732
2 5 Checking compression 3748
2 6 Removing and installing vacuum pump 3750
3 Valve gear 3752
3 1 Assembly overview – valve gear 3752
3 2 Removing and installing camshaft 3755
3 3 Checking axial clearance of camshafts 3776
3 4 Renewing valve stem seals 3777
3 4 1 Removing and installing valve stem seals (cylinder head installed) 3777
3 4 2 Removing and installing valve stem seals (cylinder head removed) 3782
3 5 Checking valve guides 3788
17 – Lubrication 3790
1 Sump and oil pump 3790
1 1 Assembly overview – sump, oil pump 3790
1 2 Removing and installing coarse oil separator 3793
1 3 Removing and installing lower part of sump 3794
1 4 Removing and installing oil pump 3797
1 5 Removing and installing upper part of sump 3800
1 6 Removing and installing oil pressure control valve -N428- (engine codes CCZA, CCZB, CCZC, CCZD, CDAA, CDAB) 3805
2 Engine oil: 3807
3 Oil filter, engine oil cooler and oil pressure switch (engine codes CAWA, CAWB, CBFA, CCTA, CCTB, BZB, CGYA) 3809
3 1 Assembly overview – oil filter, engine oil cooler and oil pressure switch -F1- 3809
3 2 Removing and installing engine oil cooler 3810
3 3 Checking oil pressure and oil pressure switch 3812
4 Oil filter, engine oil cooler and oil pressure switch (engine codes CCZA, CCZB, CCZC, CCZD, CDAA, CDAB) 3815
4 1 Assembly overview – oil filter, engine oil cooler 3815
4 2 Removing and installing engine oil cooler 3817
4 3 Removing and installing oil pressure switch -F1- 3818
4 4 Removing and installing oil pressure switch for reduced oil pressure -F378- 3820
4 5 Checking oil pressure and oil pressure switch 3821
19 – Cooling 3826
1 Cooling system 3826
1 1 Coolant hose connection diagram 3826
1 2 Draining and adding coolant 3828
1 3 Checking cooling system for leaks 3836
2 Coolant pump, thermostat, coolant pipes 3840
2 1 Assembly overview – coolant pump, thermostat 3840
2 2 Removing and installing coolant pump with thermostat housing 3843
2 3 Detaching coolant pump from thermostat housing/attaching coolant pump to thermostat housing 3846
2 4 Removing and installing toothed belt for coolant pump 3849
2 5 Renewing oil seal for coolant pump drive 3852
2 6 Removing and installing thermostat 3854
2 7 Removing and installing coolant temperature sender -G62- 3857
2 8 Assembly overview – coolant pipes 3860
2 9 Removing and installing front coolant pipes 3861
2 10 Removing and installing small coolant pipe 3865
2 11 Continued coolant circulation pump -V51- – exploded view 3866
2 12 Removing and installing continued coolant circulation pump -V51- 3867
3 Radiator and radiator fans 3869
3 1 Assembly overview – radiator, fan cowl and radiator fan (Passat, CC, Golf, Eos, Scirocco) 3869
3 2 Installing radiator identification sensor -G611-, engine code CBFA 3870
3 3 Assembly overview – radiator, radiator cowl and radiator fan (Tiguan) 3871
3 4 Removing and installing radiator cowl 3873
3 5 Removing and installing radiator fan -V7- and radiator fan 2 -V177- 3875
3 6 Removing and installing radiator (Passat, CC, Golf, Eos, Scirocco) 3875
3 7 Removing and installing radiator (Tiguan) 3876
20 – Fuel supply system 3879
1 Safety precautions 3879
1 1 Safety regulations for working on fuel supply 3879
2 Rules for cleanliness 3881
3 Fuel tank (Passat, CC) 3882
3 1 Assembly overview – fuel tank (engine codes BZB, CAWA, CAWB, CGYA, CCZA, CCZB, CDAA, CDAB) 3882
3 2 Assembly overview – fuel tank (engine codes CBFA, CCTA, CCTB) 3884
3 3 Emptying fuel tank 3886
3 3 1 Emptying fuel tank when fuel pump is intact 3886
3 3 2 Emptying fuel tank if it is more than 3/4 full 3889
3 3 3 Emptying fuel tank if it is less than 3/4 full 3890
3 4 Removing and installing fuel tank 3891
3 4 1 Removing fuel tank 3891
3 4 2 Installing fuel tank 3895
4 Fuel tank (Golf, Scirocco) 3897
4 1 Assembly overview – fuel tank (engine codes BZB, CAWA, CAWB, CGYA, CCZA, CCZB, CDAA) 3897
4 2 Assembly overview – fuel tank (engine codes CBFA, CCTA, CCTB) 3899
4 3 Draining fuel tank (engine codes BZB, CAWA, CAWB, CGYA, CCZA, CCZB, CDAA) 3902
4 3 1 Emptying fuel tank when fuel pump is intact 3903
4 3 2 Emptying fuel tank if it is more than 3/4 full 3905
4 3 3 Emptying fuel tank if it is less than 3/4 full 3907
4 4 Emptying fuel tank (engine codes CBFA, CCTA, CCTB) 3909
4 5 Removing and installing fuel tank 3911
5 Fuel tank (Tiguan) 3915
5 1 Assembly overview – fuel tank 3915
5 2 Emptying fuel tank 3918
5 2 1 Emptying fuel tank when fuel pump is intact 3918
5 2 2 Emptying fuel tank if it is more than 3/4 full 3920
5 2 3 Emptying fuel tank if it is less than 3/4 full 3921
5 3 Removing and installing fuel tank 3922
6 Fuel tank (Eos) 3928
6 1 Assembly overview – fuel tank (engine codes CAWA, CAWB, CCZA, CCZB) 3928
6 2 Assembly overview – fuel tank (engine codes CBFA, CCTA, CCTB) 3931
6 3 Emptying fuel tank 3934
6 3 1 Emptying fuel tank when fuel pump is intact 3934
6 3 2 Emptying fuel tank if it is more than 3/4 full 3937
6 3 3 Emptying fuel tank if it is less than 3/4 full 3938
6 4 Removing and installing fuel tank 3940
6 4 1 Removing 3940
6 4 2 Installing fuel tank 3943
7 Repairing fuel supply (Passat, CC) 3944
7 1 Removing and installing fuel delivery unit 3944
7 2 Removing and installing fuel gauge sender -G- 3949
7 3 Checking fuel pump 3950
7 3 1 Checking function and voltage supply 3952
7 3 2 Checking fuel pressure 3955
7 3 3 Checking fuel pressure when the engine is running (engine codes CCZA, CCZB, CDAA, CDAB) 3957
7 3 4 Checking holding pressure 3960
7 3 5 Checking fuel delivery rate (engine codes CAWA, CAWB, CBFA, CCTA, CCTB, CGYA, BZB) 3961
7 3 6 Checking fuel delivery rate (engine codes CCZA, CCZB, CDAA, CDAB) 3966
7 3 7 Checking current consumption 3970
8 Repairing fuel supply system (Golf, Eos, Scirocco) 3972
8 1 Removing and installing fuel delivery unit 3972
8 2 Removing and installing fuel gauge sender -G- 3976
8 3 Checking fuel pump -G6- 3977
8 3 1 Checking function and voltage supply 3979
8 3 2 Checking fuel pressure 3982
8 3 3 Checking fuel pressure when the engine is running (engine codes CCZA, CCZB, CDAA, CDAB) 3985
8 3 4 Checking holding pressure 3987
8 3 5 Checking fuel delivery rate (engine codes CAWA, CAWB, CBFA, CCTA, CCTB, BZB, CGYA) 3990
8 3 6 Checking fuel delivery rate (engine codes CCZA, CCZB, CDAA, CDAB) 3997
8 3 7 Checking current consumption 4001
9 Repairing fuel supply (Tiguan) 4003
9 1 Removing and installing fuel delivery unit 4003
9 2 Removing and installing fuel gauge sender G 4008
9 3 Removing and installing suction-jet pump, fuel filter and pressure limitation valve 4009
9 4 Removing and installing fuel gauge sender 2 -G169- 4012
9 5 Removing and installing fuel pump control unit -J538- 4013
9 6 Checking fuel pump 4016
9 6 1 Checking function and voltage supply 4017
9 6 2 Checking fuel pressure 4019
9 6 3 Checking fuel pressure when the engine is running and vehicle is in gear (engine codes CCZA, CCZB, CCZC, CCZD) 4020
9 6 4 Checking holding pressure 4023
9 6 5 Checking fuel delivery rate (engine codes CAWA, CAWB, CCTA, CCTB) 4025
9 6 6 Checking fuel delivery rate (engine codes CCZA, CCZB, CCZC, CCZD) 4029
9 6 7 Checking current consumption 4033
10 Electronic power control (EPC) 4035
10 1 Assembly overview – accelerator module 4035
10 2 Removing and installing accelerator pedal module 4035
11 Activated charcoal filter system (Passat, CC, Tiguan) 4039
11 1 Assembly overview – activated charcoal filter system (engine codes BZB, CAWA, CAWB, CGYA, CCZA, CCZB, CCZC, CCZD, CDAA, CDAB) 4039
11 2 Assembly overview – activated charcoal filter system (engine codes CBFA, CCTA, CCTB) 4040
11 2 1 Assembly overview – activated charcoal filter system 4041
11 2 2 Assembly overview – activated charcoal filter system (vehicles with additional filter) 4041
11 3 Checking fuel tank breather (engine codes BZB, CAWA, CAWB, CGYA, CCZA, CCZB, CCZC, CCZD, CDAA, CDAB) 4042
11 4 Check fuel system for leaks (engine codes CBFA, CCTA, CCTB) 4044
11 4 1 Leak detection in fuel system 4049
11 4 2 Schematic overview of activated charcoal filter system 4051
11 4 3 Checking vacuum supply of fuel system diagnostic pump -V144- 4052
12 Activated charcoal filter system (Golf, Eos, Scirocco with engine codes CAWA, CAWB, BZB, CGYA, CCZA, CCZB, CDAA) 4054
12 1 Assembly overview – activated charcoal filter system 4054
12 2 Checking fuel tank breather 4055
13 Activated charcoal filter system (Golf, Eos with engine code CBFA, CCTA, CCTB) 4058
13 1 Overview of activated charcoal filter system 4058
13 2 Assembly overview – activated charcoal filter system (Golf) 4060
13 3 Assembly overview – activated charcoal filter system (Eos) 4061
13 4 Removing and installing activated charcoal filter 4062
13 5 Removing and installing fuel system diagnostic pump -V144- (Golf) 4064
13 6 Removing and installing fuel system diagnostic pump -V144- (Eos) 4065
13 7 Checking fuel system for leaks 4066
13 7 1 Leak detection in fuel system 4071
13 7 2 Schematic overview of activated charcoal filter system 4073
13 7 3 Checking vacuum supply of fuel system diagnostic pump -V144- 4074
21 – Turbocharging/supercharging 4077
1 Turbocharger 4077
1 1 Assembly overview – turbocharger 4077
1 1 1 Part I (engine codes BZB, CGYA, CDAA, CDAB) 4078
1 1 2 Part I (engine codes CAWA, CAWB, CBFA, CCTA, CCTB, CCZA, CCZB, CCZC, CCZD) 4079
1 1 3 Part II 4080
1 1 4 Part III 4081
1 1 5 Part IV 4083
1 1 6 Installation location of turbocharger air recirculation valve -N249- 4084
1 2 Fitting hose connections with plug-in connectors 4085
1 3 Removing and installing turbocharger 4086
1 4 Checking vacuum unit for turbocharger 4093
1 5 Adjusting turbocharger vacuum unit (engine codes BZB, CGYA, CDAA, CDAB) 4095
1 6 Removing and installing vacuum unit for turbocharger 4099
2 Charge air system 4101
2 1 Assembly overview – charge air cooling (Passat, CC, Tiguan, Eos) 4101
2 2 Assembly overview – charge air cooler (Golf, Scirocco) 4102
2 3 Assembly overview – sound generator (Golf, Scirocco) 4104
2 4 Actuator for structure-borne sound -R214- and control unit for structure-borne sound -J869- 4104
2 4 1 Assembly overview – actuator for structure-borne sound -R214- and control unit for structure-borne sound -J869- (left-hand drive vehicles) 4105
2 4 2 Assembly overview – actuator for structure-borne sound -R214- and control unit for structure-borne sound -J869- (right-hand drive vehicles) 4105
2 5 Turbocharging – overview 4106
2 6 Removing and installing charge air cooler (Golf, Eos) 4107
2 7 Removing and installing charge air cooler (Passat, CC, Scirocco) 4110
2 8 Removing and installing charge air cooler, Tiguan 4111
2 9 Removing and installing charge air duct to sound generator (Golf, Scirocco) 4112
2 10 Checking charge air system for leaks 4114
24 – Mixture preparation – injection 4117
1 Safety precautions and rules for cleanliness 4117
1 1 General information on self-diagnosis 4117
2 Injection system 4118
2 1 Technical data 4118
2 2 Overview of fitting locations 4118
2 3 Assembly overview – air filter 4124
2 4 Removing and installing air filter housing 4126
2 5 Removing and installing air filter element 4127
2 6 Removing and installing air mass meter -G70- 4128
2 7 Assembly overview – intake manifold 4129
2 8 Assembly overview – fuel rail 4131
2 9 Removing and installing intake manifold with fuel rail 4133
2 9 1 Removing and installing fuel rail 4141
2 10 Removing and installing injectors 4142
2 11 Renewing Teflon seal on injector 4146
2 12 Cleaning injectors 4149
2 13 Removing and installing fuel pressure sender -G247- 4150
2 14 Removing and installing throttle valve module -J338- 4152
2 15 Cleaning throttle valve module -J338- 4153
2 16 Assembly overview – high-pressure pump with fuel pressure regulating valve -N276- 4155
2 17 Removing and installing high-pressure pump 4157
3 Checking components 4160
3 1 Checking fuel pressure sender -G247- 4160
3 2 Checking intake manifold change-over 4163
4 Engine control unit -J623- (Passat, CC up to 11/10) 4166
4 1 Removing and installing engine control unit 4166
4 2 Removing and installing engine control unit with protective housing 4167
5 Engine control unit -J623- (Golf, Eos to 11/08) 4170
5 1 Removing and installing engine control unit 4170
5 2 Removing and installing engine control unit with protective housing 4170
6 Engine control unit -J623- (Golf, Eos, Scirocco from 11/08; CC from 11/10) 4175
6 1 Removing and installing engine control unit 4175
6 2 Removing and installing engine control unit with protective housing 4177
7 Engine control unit -J623- (Tiguan) 4181
7 1 Removing and installing engine control unit 4181
7 2 Removing and installing engine control unit with protective housing 4182
8 Engine control unit -J623- (Scirocco to 11/08) 4185
8 1 Removing and installing engine control unit 4185
8 2 Removing and installing engine control unit with protective housing 4186
26 – Exhaust system 4189
1 Exhaust system (Passat, CC) 4189
1 1 Assembly overview – exhaust system (engine codes BZB, CAWA, CAWB, CGYA) 4189
1 2 Assembly overview – exhaust system (engine codes CCTA, CCTB, CCZA, CDAA, CDAB) 4191
1 3 Assembly overview – exhaust system (engine code CBFA) 4193
1 4 Separating centre and rear silencers 4195
1 5 Aligning exhaust system free of stress 4197
1 6 Installation position and specified torque of clamp 4198
1 7 Removing and installing catalytic converters with front exhaust pipe 4200
1 8 Checking exhaust system for leaks 4203
2 Exhaust system (Golf, Eos, Scirocco) 4204
2 1 Assembly overview – exhaust system (engine code CAWB) 4204
2 2 Assembly overview – exhaust system (Golf 2004 ►, Eos, Scirocco, engine codes CCTA, CCZA, CCZB) 4206
2 3 Assembly overview – exhaust system (engine code CBFA) 4208
2 4 Assembly overview – exhaust system (Golf 2009►, engine codes CCZA, CCZB) 4210
2 5 Assembly overview – exhaust system (Golf 2009 ►, engine codes CCTA, CDAA) 4212
2 6 Separating centre and rear silencers 4214
2 7 Aligning exhaust system free of stress 4216
2 8 Installation position and specified torque of clamp 4217
2 9 Removing and installing catalytic converters with front exhaust pipe 4218
2 10 Checking exhaust system for leaks 4221
3 Exhaust system (Tiguan) 4222
3 1 Assembly overview – exhaust system (engine codes CCTA, CCTB, CCZA, CCZB, CCZC, CCZD) 4222
3 2 Assembly overview – exhaust system (engine codes CAWB, CCZA) 4224
3 3 Separating centre and rear silencers 4226
3 4 Aligning exhaust system free of stress 4227
3 5 Removing and installing catalytic converters with front exhaust pipe 4229
3 6 Installation position and specified torque of clamp 4234
3 7 Checking exhaust system for leaks 4235
4 Secondary air system – engine code CBFA 4236
4 1 Assembly overview – secondary air system 4236
4 2 Removing and installing secondary air pump motor -V101- 4236
4 3 Removing and installing secondary air inlet valve -N112- 4237
28 – Ignition system 4239
1 Repairing ignition system 4239
1 1 General notes on ignition system 4239
1 2 Safety precautions 4239
1 3 Assembly overview – ignition system 4240
1 4 Removing and installing ignition coils with output stage 4240
1 5 Removing and installing knock sensor 1 -G61- 4242
1 6 Removing and installing engine speed sender -G28- 4243
1 7 Test data, spark plugs 4244
K0058970420 6 speed manual gearbox 0AJ 4245
00 – Technical data 4251
1 Safety precautions 4251
1 1 Safety precautions for vehicles with a start-stop system 4251
2 Identification 4252
2 1 Gearbox identification 4252
3 Identification codes, assembly allocation, ratios and capacities 4253
3 1 Identification codes, assembly allocation, gear ratios and capacities, Golf 2004 ► 4253
3 2 Identification codes, assembly allocation, gear ratios and capacities, Golf 2009 ► 4253
3 3 Identification codes, assembly allocation, ratios and capacities, Golf Plus 2005 ► 4255
3 4 Identification codes, assembly allocation, ratios and capacities, Golf Plus 2009 ► 4255
3 5 Identification codes, assembly allocation and capacities, Passat 2006 ► 4256
3 6 Identification code, assembly allocation, transmission ratios and capacities, Passat 2011 ► 4257
3 7 Identification codes, assembly allocation and capacities, Eos 2006 ► 4258
3 8 Identification codes, assembly allocation, ratios and capacities, Scirocco 2009 ► 4260
3 9 Identification codes, assembly allocation, ratios and capacities, Touran 2003 ► 4262
3 10 Calculation of gear ratios 4263
4 Overview – power transmission 4265
5 General repair instructions 4267
30 – Clutch 4270
1 Clutch mechanism 4270
1 1 Overview – clutch actuation 4270
1 2 Assembly overview, pedal cluster with clutch pedal switch -F36-, only Touran up to 05 03 4272
1 3 Only Touran up to 05 03 – removing and installing clutch pedal switch -F36- 4273
1 4 Assembly overview, pedal cluster with clutch position sender -G476- – Touran from 06 03, Passat, Eos, Scirocco, Golf, and Golf Plus 4274
1 5 Removing and installing over-centre spring 4277
1 5 1 Removing and installing over-centre spring – Golf 2004 ► 4277
1 5 2 Removing and installing over-centre spring – Golf 2009 ► left-hand drive and Scirocco 4281
1 5 3 Removing and installing over-centre spring – Golf 2009 ► right-hand drive 4286
1 5 4 Removing and installing over-centre spring, Golf Plus 4290
1 5 5 Removing and installing over-centre spring, Passat, Eos 4295
1 5 6 Removing and installing over-centre spring with mounting bracket removed (Touran up to 05 03) 4296
1 5 7 Removing and installing over-centre spring with mounting bracket installed (Touran from 06 03) 4298
1 6 Removing and installing clutch pedal 4301
1 6 1 Removing and installing clutch pedal – Golf 2004 ► 4301
1 6 2 Removing and installing clutch pedal, Golf 2009 ► left-hand drive and Scirocco 4306
1 6 3 Removing and installing clutch pedal – Golf 2009 ► right-hand drive 4312
1 6 4 Removing and installing clutch pedal, Golf Plus 4316
1 6 5 Removing and installing clutch pedal, Passat, Eos 4322
1 6 6 Removing and installing clutch pedal, Touran from 06 03 4324
1 7 Removing and installing mounting bracket 4328
1 7 1 Removing and installing mounting bracket, Golf 2004 ► 4328
1 7 2 Removing and installing mounting bracket – Golf 2009 ► left-hand drive and Scirocco 4333
1 7 4 Removing and installing mounting bracket, Golf Plus left-hand drive 4343
1 7 5 Removing and installing mounting bracket, Passat 4349
1 7 6 Removing and installing mounting bracket, Eos 4353
1 7 7 Removing and installing mounting bracket (all Tourans) 4356
1 8 Removing and installing master cylinder 4364
1 8 1 Removing and installing master cylinder, Passat, Eos, Scirocco, Golf and Golf Plus 4364
1 8 2 Removing and installing master cylinder – Touran with clutch pedal switch -F36- (up to 05 03) 4366
1 8 3 Removing and installing master cylinder – Touran with clutch position sender -G476- (from 06 03) 4368
1 9 Removing and installing clutch position sender -G476- 4370
1 10 Assembly overview – hydraulics (LHD) 4372
1 11 Assembly overview – hydraulics (RHD) 4374
1 12 Removing and installing slave cylinder 4375
1 13 Bleeding clutch system 4377
2 Clutch release mechanism 4379
2 1 Assembly overview – clutch release mechanism 4379
2 2 Repairing clutch release mechanism 4380
3 Clutch 4382
3 1 Assembly overview – clutch 4382
3 2 Removing and installing clutch 4384
34 – Controls, housing 4388
1 Selector mechanism 4388
1 1 Installation position of selector mechanism 4388
1 2 Overview – selector mechanism 4389
1 3 Assembly overview – gear knob and cover 4389
1 4 Removing and installing gear knob with gaiter and noise insulation 4391
1 4 1 Removing and installing gear knob with gaiter and noise insulation, Golf, Eos and Scirocco 4391
1 4 2 Removing and installing gear knob with gaiter and noise insulation, Golf Plus 4392
1 4 3 Removing and installing gear knob with gaiter, Passat 4394
1 4 4 Removing and installing gear knob with gaiter, Touran 4395
1 5 Assembly overview – Gear lever and selector housing 4397
1 5 1 Assembly overview – selector lever and selector housing (up to 10 06) 4397
1 5 2 Assembly overview – selector lever and selector housing (from 11 06) 4400
1 6 Dismantling and assembling selector mechanism (from 11 06) 4401
1 6 1 Attaching base plate 4405
1 7 Assembly overview – Selector cables 4406
1 7 1 Assembly overview – selector cables (cable support bracket and metal relay lever ) 4406
1 7 2 Assembly overview – selector cables (cable support bracket and plastic relay lever) 4409
1 8 Removing and installing selector mechanism 4414
1 8 1 Specified torques 4418
1 9 Adjusting selector mechanism 4418
1 9 1 Checking selector mechanism 4420
2 Removing and installing gearbox 4421
2 1 Removing and installing gearbox, Touran (except vehicles with 1 2 l engine) 4421
2 1 1 Removing gearbox 4423
2 1 2 Installing gearbox 4428
2 1 3 Specified torques 4434
2 2 Removing and installing gearbox, Touran (only vehicles with 1 2 l engine) 4435
2 2 1 Removing gearbox 4439
2 2 2 Installing gearbox 4445
2 2 3 Specified torques 4450
2 3 Removing and installing gearbox, Golf 2004 ► 4451
2 3 1 Removing gearbox 4453
2 3 2 Installing gearbox 4458
2 3 3 Specified torques 4464
2 4 Removing and installing gearbox, Golf 2009 ► with 1 2 l engine 4465
2 4 1 Removing gearbox 4469
2 4 2 Installing gearbox 4474
2 4 3 Specified torques 4480
2 5 Removing and installing gearbox, Golf 2009 ► with 1 4 l engine and Passat 2011 ► 4481
2 5 1 Removing gearbox 4485
2 5 2 Installing gearbox 4492
2 5 3 Specified torques 4498
2 6 Removing and installing gearbox, Golf Plus with 1 2 l engine 4499
2 6 1 Removing gearbox 4501
2 6 2 Installing gearbox 4507
2 6 3 Specified torques 4512
2 7 Removing and installing gearbox, Golf Plus with 1 4 l engine 4513
2 7 1 Removing gearbox 4516
2 7 2 Installing gearbox 4522
2 7 3 Specified torques 4528
2 8 Removing and installing gearbox, Passat 2006 ► and Eos 4529
2 8 1 Removing gearbox 4530
2 8 2 Installing gearbox 4534
2 8 3 Specified torques 4540
2 9 Removing and installing gearbox – Scirocco 4541
2 9 1 Removing gearbox 4544
2 9 2 Installing gearbox 4551
2 9 3 Specified torques 4556
3 Transporting gearbox 4557
4 Securing to engine and gearbox support 4558
5 Gear oil 4560
5 1 Checking gear oil level 4560
5 2 Fill with gear oil 4561
6 Dismantling and assembling gearbox 4563
6 1 Overview – gearbox 4563
6 2 Overview – dismantling and assembling gearbox 4564
6 3 Assembly overview – Removing and installing cover for gearbox housing and 5th and 6th gears 4565
6 4 Assembly overview – removing and installing clutch housing 4567
6 5 Assembly overview – removing and installing input shaft, output shaft, differential, selector mechanism and selector forks 4568
6 6 Dismantling and assembling gearbox 4569
6 6 1 Dismantling gearbox 4573
6 6 2 Assembling gearbox 4578
7 Gearbox housing and clutch housing 4585
7 1 Assembly overview – gearbox housing and clutch housing 4585
8 Gearbox housing cover 4588
8 1 Assembly overview – gearbox housing cover 4588
8 2 Repairing gearbox housing cover 4589
9 Selector unit 4591
9 1 Assembly overview – selector unit 4591
9 2 Repairing selector unit 4592
10 Selector forks 4594
10 1 Assembly overview – selector forks 4594
10 2 Repairing selector forks 4595
35 – Gears, shafts 4599
1 Input shaft 4599
1 1 Assembly overview – input shaft 4599
1 2 Dismantling and assembling input shaft 4602
1 3 Renewing input shaft seal 4610
2 Output shaft 4612
2 1 Assembly overview – output shaft 4612
2 2 Dismantling and assembling output shaft 4615
39 – Final drive – differential 4621
1 Oil seals 4621
1 1 Renewing left flange shaft oil seal with gearbox installed 4621
1 2 Renewing right flange shaft oil seal with gearbox installed 4622
2 Differential 4626
2 1 Assembly overview – differential 4626
2 2 Dismantling and assembling differential 4628
2 3 Adjusting differential 4632
K0058970520 Brake systems 4636
00 – Technical data 4642
1 Brake allocation via PR No 4642
1 1 Front brakes, Golf 4642
1 2 Front brakes, Eos 4643
1 3 Rear brakes, front-wheel drive Golf 4643
1 4 Rear brakes, four-wheel drive Golf 4644
1 5 Rear brakes, Eos 4644
2 Technical data for brakes 4645
2 1 Brake master cylinder and brake servo 4645
2 2 Front brakes 4645
2 3 Rear brakes (disc brakes) 4647
3 Brake test 4650
3 1 General 4650
3 2 Test for vehicles with front-wheel drive 4650
3 3 Test for vehicles with four-wheel drive via a Haldex coupling 4650
3 3 1 The brake test should be performed on a single-axle roller dynamometer with contra-rotating rollers for four-wheel drive vehicles 4650
3 3 2 If no test rig is available for four-wheel drive vehicles, the brake test can also be carried out on a standard single-axle roller dynamometer as follows: 4650
45 – Anti-lock brake system 4652
1 General notes on anti-lock brake system 4652
2 Notes for repair work on anti-lock brake system 4653
3 Connecting -VAS 5051- and selecting functions 4654
4 Electrical/electronic components and locations 4656
4 1 ABS Mark 70 (ABS/TCS) 4656
4 2 ABS Mark 60 (ABS/EDL/TCS/ESP) up to week 22/2008 4658
4 3 ABS Mark 60 (ABS/EDL/TCS/ESP) from week 22/2008 4660
5 Fault display via warning lamps 4663
6 Assembly overview – hydraulic unit, brake servo/brake master cylinder 4665
6 1 ABS Mark 70 (ABS/TCS) 4665
6 1 1 Connecting brake lines from brake master cylinder to hydraulic unit 4666
6 1 2 Removing control unit and hydraulic unit 4667
6 1 3 Unscrewing control unit from hydraulic unit 4669
6 1 4 Installing new control unit 4670
6 1 5 Installing control unit and hydraulic unit 4671
6 2 ABS Mark 60 (ABS/EDL/TCS/ESP) up to week 22/2008 4671
6 2 1 Connecting brake lines from brake master cylinder to hydraulic unit 4673
6 2 2 Removing control unit and hydraulic unit 4674
6 2 3 Unscrewing control unit from hydraulic unit 4677
6 2 4 Installing new control unit 4678
6 2 5 Installing control unit and hydraulic unit 4679
6 3 ABS Mark 60 (ABS/EDL/TCS/ESP) from week 22/2008 4679
6 3 1 Connecting brake lines from brake master cylinder to hydraulic unit 4681
6 3 2 Removing control unit and hydraulic unit 4682
6 3 3 Unscrewing control unit from hydraulic unit 4684
6 3 4 Installing new control unit 4685
6 3 5 Installing control unit and hydraulic unit 4685
7 Removing and installing parts of ABS system on front and rear axle 4687
7 1 Removing and installing parts of ABS system on front axle 4687
7 1 1 Removing and installing speed sensor on front axle 4687
7 2 Removing and installing parts of anti-lock brake system on rear axle (front-wheel drive) 4688
7 2 1 Removing and installing speed sensor on rear axle 4689
7 3 Removing and installing parts of anti-lock brake system on rear axle (four-wheel drive) 4689
7 3 1 Removing and installing speed sensor on rear axle 4690
8 Removing and installing parts of ESP system 4691
8 1 Removing and installing ESP sensor unit -G419- 4691
8 2 Removing and installing steering angle sender -G85- 4692
8 3 Removing and installing brake servo vacuum sender -G483- 4692
46 – Brakes – mechanism 4694
1 Repairing front brakes 4694
1 1 Repairing front brakes, FS III brake caliper 4694
1 2 Removing and installing brake pads/linings 4695
1 2 1 Removing 4696
1 2 2 Installing 4697
1 3 Removing and installing brake caliper 4698
1 3 1 Removing 4699
1 3 2 Installing 4699
1 4 Repairing front brakes, FN 3 brake caliper 4700
1 5 Removing and installing brake pads/linings 4703
1 5 1 Removing 4704
1 5 2 Installing 4705
1 6 Removing and installing brake caliper 4706
1 6 1 Removing 4706
1 6 2 Installing 4707
1 7 Repairing front brake, FNR-G brake caliper 4708
1 8 Removing and installing brake pads/linings 4709
1 8 1 Removing 4710
1 8 2 Installing 4711
1 9 Removing and installing brake caliper 4712
1 9 1 Removing 4713
1 9 2 Installing 4713
2 Repairing rear brakes 4715
2 1 Repairing rear brake CI 38 4715
2 2 Removing and installing brake pads/linings 4716
2 2 1 Removing 4717
2 2 2 Installing 4717
2 3 Removing and installing brake caliper 4718
2 3 1 Removing 4719
2 3 2 Installing 4719
2 4 Repairing rear brake CII 38 4720
2 5 Removing and installing brake pads/linings 4722
2 5 1 Removing 4722
2 5 2 Installing 4723
2 6 Removing and installing brake caliper 4724
2 6 1 Removing 4725
2 6 2 Installing 4725
2 7 Repairing rear brake CII 41 4726
2 8 Removing and installing brake pads/linings 4728
2 8 1 Removing 4729
2 8 2 Installing 4730
2 9 Removing and installing brake caliper 4731
2 9 1 Removing 4731
2 9 2 Installing 4732
2 10 Assembly overview – Bosch rear wheel brake 4732
2 11 Removing and installing brake pads, Bosch 4734
2 12 Removing and installing brake caliper, Bosch 4736
2 13 Adjusting handbrake 4738
3 Assembly overview – handbrake lever 4740
3 1 Removing and installing handbrake cable up to model year 2007 4740
3 1 1 Removing 4740
3 1 2 Installing 4742
3 2 Removing and installing handbrake cable from model year 2008 4743
3 2 1 Removing 4743
3 2 2 Installing 4744
4 Assembly overview – brake pedal 4746
4 1 Separating brake pedal from brake servo 4746
4 1 1 Clipping brake pedal to brake servo 4747
4 2 Removing and installing brake light switch – F- from week 45 of 2005 4747
4 2 1 Brake light switch, old version 4748
4 2 2 Brake light switch, new version 4749
47 – Brakes – hydraulics 4750
1 Repairing front brake caliper 4750
1 1 Assembly overview – brake caliper FS III 4750
1 2 Removing and installing piston for brake caliper FS III 4750
1 2 1 Removing 4751
1 2 2 Installing 4751
1 3 Assembly overview – brake caliper FN 3 4752
1 4 Removing and installing piston for brake caliper FN 3 4753
1 4 1 Removing 4754
1 4 2 Installing 4755
1 5 Assembly overview – brake caliper FNR-G 4756
1 6 Removing and installing piston for FNR-G brake caliper 4757
1 6 1 Removing 4758
1 6 2 Installing 4758
2 Repairing rear brake caliper 4760
2 1 Assembly overview – brake calipers CI 38 and CII 38 4760
2 2 Assembly overview – brake caliper CII 41 4761
2 3 Removing and installing brake caliper piston 4762
2 4 Assembly overview – Bosch brake caliper 4764
2 5 Removing and installing brake caliper piston, Bosch 4765
2 6 Pre-bleeding brake caliper 4767
3 Pressurised leak test 4768
3 1 Test prerequisites: 4768
4 Bleeding brake system 4769
4 1 Bleeding brake system using brake filling and bleeding equipment -VAS 5234- or -V A G 1869- 4769
4 1 1 Pre-bleeding: 4770
4 1 2 Bleeding (normal): 4770
4 1 3 Subsequent bleeding 4771
4 2 Changing brake fluid 4771
5 Brake servo and brake master cylinder 4772
5 1 Assembly overview: brake servo/brake master cylinder (left-hand drive vehicle) 4772
5 2 Assembly overview: brake servo/brake master cylinder (right-hand drive vehicle) 4773
5 3 Overview – vacuum pump for brake servo (diesel vehicles) 4775
5 4 Checking brake servo vacuum system 4776
5 4 1 Connecting vacuum gauge for brake servo -VAS 6721- 4776
5 4 2 Checking vacuum generation 4777
5 4 3 Checking for leaks 4778
5 5 Checking non-return valve 4780
5 6 Removing and installing brake servo pressure sensor -G294- 4780
5 7 Vacuum pump for brakes -V192- 4780
5 7 1 Removing 4781
5 7 2 Installing 4781
5 8 Removing and installing brake light switch -F- as of week 45/05 4781
6 Removing and installing brake master cylinder 4782
6 1 Removing 4782
6 2 Installing 4783
7 Removing and installing brake servo 4784
7 1 Removing 4784
7 2 Installing 4786
8 Brake lines 4787
8 1 Separating point on underbody 4787
8 2 Repairing brake lines 4787
8 2 1 Assembly overview – flanging tool 4789
8 2 2 Work instructions 4789
K0058990320 6 speed manual gearbox 02S 4792
00 – Technical data 4798
1 Identification 4798
1 1 Gearbox identification 4798
2 Identification codes, assembly allocation, ratios and capacities 4799
2 1 Identification codes, assembly allocation, ratios and capacities, Golf 2004 ► 4799
2 2 Identification codes, assembly allocation, ratios and capacities, Golf 2009 ► 4802
2 3 Identification codes, assembly allocation, ratios and capacities, Golf Plus 2005 ► 4803
2 4 Identification codes, assembly allocation, ratios and capacities, Golf Plus 2009 ► 4805
2 5 Identification codes, assembly allocation and capacities, Passat 2006 ► 4806
2 6 Identification code, assembly allocation, transmission ratios and capacities, Passat 2011 ► 4807
2 7 Identification codes, assembly allocation, gear ratios and capacities, Passat CC 2009 ► 4808
2 8 Identification codes, assembly allocation, gear ratios and capacities, CC 2010 ► 4809
2 9 Identification codes, assembly allocation and capacities, Eos 2006 ► 4810
2 10 Identification codes, assembly allocation, ratios and capacities, Scirocco 2009 ► 4810
2 11 Calculating overall gear ratio “i” 4811
3 Overview – power transmission 4812
4 General repair instructions 4814
5 Safety precautions 4817
5 1 Safety precautions for vehicles with a start-stop system 4817
30 – Clutch 4818
1 Clutch operation 4818
1 1 Overview – clutch actuation 4818
1 2 Assembly overview – pedal cluster 4820
1 3 Removing and installing over-centre spring 4822
1 3 1 Removing and installing over-centre spring – Golf 2004 ► 4822
1 3 2 Removing and installing over-centre spring – Golf 2009 ► left-hand drive and Scirocco 4826
1 3 3 Removing and installing over-centre spring – Golf 2009 ► right-hand drive 4831
1 3 4 Removing and installing over-centre spring, Golf Plus 4835
1 3 5 Removing and installing over-centre spring, Passat, Passat CC, CC and Eos 4840
1 4 Removing and installing clutch pedal 4842
1 4 1 Removing and installing clutch pedal, Golf 2004 ►, Golf 2009 ►, Golf Plus and Scirocco 4842
1 4 2 Removing and installing clutch pedal, Passat, Passat CC, CC and Eos 4843
1 5 Removing and installing mounting bracket 4845
1 5 1 Removing and installing mounting bracket, Golf 2004 ► 4845
1 5 2 Removing and installing mounting bracket – Golf 2009 ► left-hand drive and Scirocco 4850
1 5 4 Removing and installing mounting bracket, Golf Plus left-hand drive 4861
1 5 5 Removing and installing mounting bracket, Passat, Passat CC and CC 4866
1 5 6 Removing and installing mounting bracket, Eos 4870
1 6 Removing and installing master cylinder 4874
1 7 Removing and installing clutch position sender -G476- 4876
1 8 Assembly overview – hydraulics (LHD) 4879
1 9 Assembly overview – hydraulics (RHD) 4881
1 10 Removing and installing slave cylinder 4882
1 11 Bleeding clutch system 4884
2 Clutch release mechanism 4886
2 1 Assembly overview – clutch release mechanism 4886
2 2 Repairing clutch release mechanism 4887
3 Clutch 4888
3 1 Clutch in connection with dual mass flywheel 4888
3 1 1 Identifying make of clutch, vehicles with 1 9 l – 66 kW turbo diesel engine and vehicles with 1 9 l – 77 kW turbo diesel engine 4888
3 1 2 Assembly overview – “Sachs” clutch 4890
3 1 3 Removing and installing “Sachs” clutch 4891
3 1 4 Assembly overview – “LuK” clutch 4893
3 1 5 Removing and installing “LuK” clutch 4894
3 2 Clutch in connection with simple flywheel 4896
3 2 1 Assembly overview – clutch in connection with simple flywheel 4896
3 2 2 Removing and installing clutch in connection with simple flywheel 4898
34 – Controls, housing 4900
1 Selector mechanism 4900
1 1 Installation position of selector mechanism 4900
1 2 Overview – selector mechanism 4901
1 3 Assembly overview – gear knob and cover 4901
1 4 Removing and installing gear knob with gaiter and noise insulation 4903
1 4 1 Removing and installing gear knob with gaiter and noise insulation, Golf, Eos and Scirocco 4903
1 4 2 Removing and installing gear knob with gaiter and noise insulation, Golf Plus 4904
1 4 3 Removing and installing gear knob with gaiter and noise insulation, Passat, Passat CC and CC 4906
1 5 Assembly overview – Gear lever and selector housing 4908
1 5 1 Assembly overview – selector lever and selector housing (up to 10 06) 4908
1 5 2 Assembly overview – selector lever and selector housing (from 11 06) 4910
1 6 Dismantling and assembling selector mechanism (from 11 06) 4911
1 6 1 Attaching base plate 4915
1 7 Assembly overview – Selector cables 4916
1 7 1 Assembly overview – selector cables (cable support bracket and metal relay lever ) 4916
1 7 2 Assembly overview – selector cables (cable support bracket and plastic relay lever) 4919
1 8 Removing and installing selector mechanism 4924
1 9 Adjusting selector mechanism 4928
1 9 1 Checking selector mechanism 4931
2 Removing and installing gearbox 4932
2 1 Removing and installing gearbox, Golf 2004 ► 4932
2 1 1 Removing gearbox 4934
2 1 2 Install gearbox 4940
2 1 3 Specified torques 4945
2 2 Removing and installing gearbox, Golf 2009 ► with 1 4 l engine 4946
2 2 1 Removing gearbox 4949
2 2 2 Install gearbox 4956
2 2 3 Specified torques 4962
2 3 Removing and installing gearbox, Golf 2009 ► with 1 8 l engine 4963
2 3 1 Removing gearbox 4966
2 3 2 Install gearbox 4972
2 3 3 Specified torques 4980
2 4 Removing and installing gearbox, Golf Plus 2005 ► 4981
2 4 1 Removing gearbox 4983
2 4 2 Install gearbox 4989
2 4 3 Specified torques 4995
2 5 Removing and installing gearbox, Golf Plus 2009 ► 4996
2 5 1 Removing gearbox 4999
2 5 2 Install gearbox 5006
2 5 3 Specified torques 5012
2 6 Removing and installing gearbox, Passat 2006 ► 5013
2 6 1 Removing gearbox 5015
2 6 2 Install gearbox 5020
2 6 3 Specified torques 5027
2 7 Removing and installing gearbox, Passat 2011 ► with turbo diesel engine 5028
2 7 1 Removing gearbox 5031
2 7 2 Install gearbox 5036
2 7 3 Specified torques 5042
2 8 Removing and installing gearbox, Passat 2011 ► with 1 4 l petrol engine and CC with 1 4 l petrol engine 5043
2 8 1 Removing gearbox 5046
2 8 2 Install gearbox 5052
2 8 3 Specified torques 5059
2 9 Removing and installing gearbox, Passat 2011 ► with 1 8 l petrol engine, Passat CC and CC with 1 8 l petrol engine 5060
2 9 1 Removing gearbox 5063
2 9 2 Install gearbox 5069
2 9 3 Specified torques 5076
2 10 Removing and installing gearbox, Eos 5077
2 10 1 Removing gearbox 5079
2 10 2 Install gearbox 5084
2 10 3 Specified torques 5090
2 11 Removing and installing gearbox – Scirocco 5091
2 11 1 Removing gearbox 5093
2 11 2 Install gearbox 5101
2 11 3 Specified torques 5107
3 Transporting gearbox 5109
4 Assembly overview – assembly mountings 5110
5 Gear oil 5112
5 1 Checking and topping up gear oil 5112
5 1 1 Preparing 5112
5 1 2 Drain gear oil 5113
5 1 3 Fill with gear oil 5114
6 Dismantling and assembling gearbox 5115
6 1 Overview – gearbox 5115
6 2 Overview – dismantling and assembling gearbox 5116
6 3 Assembly overview – removing and installing cover for gearbox housing and 5th and 6th gears 5117
6 4 Assembly overview – removing and installing gearbox housing and selector mechanism 5120
6 5 Assembly overview – removing and installing input shaft, output shaft, differential and selector forks 5121
6 6 Assembly sequence – Removing and installing cover for gearbox housing and 5th and 6th gear 5122
6 6 1 Removing 5124
6 6 2 Installing 5128
6 7 Assembly sequence – Dismantling and assembling gearbox completely 5128
6 7 1 Removing 5131
6 7 2 Installing 5137
7 Gearbox housing and clutch housing 5149
7 1 Assembly overview – gearbox housing and clutch housing 5149
7 2 Repairing gearbox housing and clutch housing 5151
7 2 1 Identifying output shaft bearing in gearbox housing 5155
7 2 2 Removing and installing roller bearing without retaining ring 5155
7 2 3 Removing and installing roller bearing with retaining ring 5156
8 Gearbox housing cover 5160
8 1 Assembly overview – gearbox housing cover 5160
8 2 Repairing gearbox housing cover 5161
9 Selector unit 5164
9 1 Assembly overview – selector unit 5164
9 2 Repairing selector unit 5166
10 Selector forks 5168
10 1 Assembly overview – selector forks in connection with reverse synchromeshed gear -arrow- 5168
10 2 Assembly overview – selector forks in connection with reverse gear locking collar -arrow- 5169
10 3 Repairing selector forks 5171
35 – Gears, shafts 5175
1 Input shaft 5175
1 1 Assembly overview – input shaft 5175
1 2 Dismantling and assembling input shaft 5177
1 3 Adjusting input shaft 5183
1 4 Renewing input shaft seal 5188
2 Output shaft 5190
2 1 Assembly overview – output shaft 5190
2 2 Dismantling and assembling output shaft 5193
2 3 Adjusting output shaft 5203
3 Reverse shaft 5208
3 1 Assembly overview – reverse shaft with reverse synchromeshed gear -arrow- 5208
3 2 Assembly overview – reverse shaft with reverse gear locking collar -arrow- 5209
3 3 Dismantling and assembling reverse shaft 5211
39 – Final drive – differential 5214
1 Oil seals 5214
1 1 Renewing left flange shaft oil seal with gearbox installed 5214
1 1 1 Removing 5215
1 1 2 Installing 5216
1 1 3 Specified torque 5216
1 2 Distinguishing seals for right flange shaft 5216
1 3 Renewing right seal with manual gearbox installed (two-part seal for flange shaft and sleeve) 5216
1 3 1 Removing 5217
1 3 2 Installing 5219
1 3 3 Specified torque 5219
1 4 Renewing right seal and sleeve together with manual gearbox installed (one-piece seal and sleeve for flange shaft) 5219
1 4 1 Removing 5221
1 4 2 Installing 5222
1 4 3 Specified torque 5222
2 Adjustment overview 5223
3 Differential 5224
3 1 Assembly overview – differential 5224
3 2 Dismantling and assembling differential 5226
3 3 Adjusting differential 5231
K0058990820 4 cylinder direct injection engine (1 4 l and 1 6 l engines 4 V EA 111 FSI) 5235
00 – Technical data 5241
1 Technical data 5241
1 1 Engine number 5241
1 2 Engine data 5241
10 – Removing and installing engine 5242
1 Removing and installing engine (Golf, Golf Plus) 5242
1 1 Removing engine 5243
1 2 Securing engine to assembly stand 5248
1 3 Installing engine 5248
1 4 Specified torques 5249
1 5 Assembly mountings 5250
1 6 Additional information and assembly work for vehicles with air conditioner 5251
2 Removing and installing engine (Touran) 5252
2 1 Removing engine 5253
2 2 Securing engine to assembly stand 5256
2 3 Installing engine 5256
2 4 Specified torques 5258
2 5 Assembly mountings 5259
2 6 Additional information and assembly work for vehicles with air conditioner 5260
3 Removing and installing engine (Passat) 5261
3 1 Removing engine 5262
3 2 Securing engine to assembly stand 5266
3 3 Installing engine 5266
3 4 Specified torques 5267
3 5 Assembly mountings 5268
3 6 Notes on repairs to air conditioning system 5268
4 Removing and installing engine (Eos) 5270
4 1 Removing engine 5271
4 2 Securing engine to assembly stand 5275
4 3 Installing engine 5275
4 4 Assembly mountings 5278
13 – Crankshaft group 5280
1 Dismantling and assembling engine 5280
1 1 Assembly overview – parts l and ll 5280
1 2 Assembly overview – part I, belt drive 5282
1 3 Assembly overview – part II, cylinder block 5283
1 4 Removing and installing poly-V belt 5285
1 4 1 Poly V-belt routing 5286
1 5 Removing and installing valve timing housing (timing case) 5286
1 5 1 Removing 5287
1 5 2 Installing 5289
1 6 Removing and installing valve timing housing (Touran) 5290
1 6 1 Removing 5291
1 6 2 Installing 5293
2 Sealing flange and flywheel or drive plate 5295
2 1 Assembly overview 5296
2 2 Removing and installing engine speed sender -G28- 5297
2 3 Renewing crankshaft oil seal – belt pulley end 5298
2 4 Poly V-belt pulley securing bolt tightening procedure 5301
2 5 Characteristics of the sealing flange and the assembly device -T10017- and -T10134- 5303
2 6 Renewing crankshaft sealing flange – flywheel end (assembly tool -T10134-) 5304
2 6 1 Pressing sealing flange with sender wheel off crankshaft 5305
2 6 2 Pressing sealing flange with sender wheel onto crankshaft 5306
2 6 3 A – Assemble seal with sender wheel on assembly tool -T10134- 5307
2 6 4 B – Fitting assembly tool -T10134- with sealing flange to crankshaft flange 5309
2 6 5 C – Screwing assembly tool -T10134- on crankshaft flange 5310
2 6 6 D – Pressing sender wheel onto crankshaft flange using assembly tool -T10134- 5310
2 6 7 E – Checking sender wheel installation position on crankshaft 5310
2 6 8 f) Re-pressing sender wheel 5311
2 7 Renewing crankshaft sealing flange – flywheel end (assembly tool -T10017-) 5312
2 7 1 Pressing out sealing flange with sender wheel 5313
2 7 2 Pressing in sealing flange with sender wheel 5314
2 7 3 A – Fitting sealing flange with sender wheel on assembly tool -T10017- 5315
2 7 4 B – Fitting assembly tool -T10017- with sealing flange to crankshaft flange 5317
2 7 5 C – Screwing assembly tool -T10017- on crankshaft flange 5318
2 7 6 D – Pressing sender wheel onto crankshaft flange using assembly tool -T10017- 5318
2 7 7 E – Checking sender wheel installation position on crankshaft 5318
2 7 8 f) Re-pressing sender wheel 5320
2 8 Renewing crankshaft sealing flange at flywheel end (Eos) 5320
2 8 1 Pressing sealing flange with sender wheel off crankshaft 5321
2 8 2 Pressing sealing flange with sender wheel onto crankshaft 5322
2 8 3 A – Assemble seal with sender wheel on assembly tool -T10134- 5323
2 8 4 B – Fitting assembly tool -T10134- with sealing flange to crankshaft flange 5325
2 8 5 C – Screwing assembly tool -T10134- on crankshaft flange 5326
2 8 6 D – Pressing sender wheel onto crankshaft flange using assembly tool -T10134- 5326
2 8 7 E – Checking sender wheel installation position on crankshaft 5326
2 8 8 f) Re-pressing sender wheel 5327
2 9 Crankshaft dimensions 5328
3 Dismantling and assembling pistons and conrods 5329
3 1 Assembly overview 5329
3 2 Checking piston 5331
3 2 1 Checking cylinder bores 5332
3 3 Piston and cylinder dimensions 5332
15 – Cylinder head, valve gear 5333
1 Cylinder head 5333
1 1 Assembly overview 5333
1 2 Checking valve timing 5336
1 3 Adjusting valve timing 5337
1 4 Removing and installing timing chain and chain drive for oil pump (engine codes BAG, BLP, BLF) 5342
1 5 Removing and installing timing chain and chain drive for oil pump (engine codes BKG, BLN) 5349
1 6 Removing and installing camshaft housing 5356
1 6 1 Removing 5358
1 6 2 Installing 5359
1 7 Removing and installing cylinder head 5361
1 8 Checking compression 5364
2 Repairing valve gear 5367
2 1 Assembly overview 5367
2 2 Checking camshaft axial clearance 5369
2 3 Reworking valve seats 5369
2 4 Checking valve guides 5371
2 5 Renewing valve stem seals 5371
17 – Lubrication 5374
1 Removing and installing parts of lubrication system 5374
1 1 Engine oil: 5374
1 2 Assembly overview 5374
1 3 Removing and installing sump 5377
1 4 Removing and installing oil pump 5378
1 5 Checking oil pressure and oil pressure switch 5380
19 – Cooling 5383
1 Removing and installing parts of cooling system 5383
1 1 Assembly overview – parts of cooling system, body side, radiator with two fans (Golf, Golf Plus) 5384
1 2 Assembly overview – parts of cooling system, body side, radiator with one fan (Golf, Golf Plus) 5385
1 3 Assembly overview – part of cooling system, body side, radiator with two fans (Touran) 5387
1 4 Assembly overview – parts of cooling system, body side, radiator with two fans (Touran) 5388
1 5 Assembly overview – parts of cooling system, body side, radiator with two fans (Passat, Eos) 5390
1 6 Assembly overview – parts of cooling system, body side, radiator with one fan (Passat, Eos) 5391
1 7 Assembly overview – parts of cooling system, engine side 5392
1 8 Coolant hose connection diagram 5395
1 9 Draining and adding coolant 5395
1 10 Removing and installing radiator fan -V7- and radiator fan 2 -V177- 5399
1 11 Removing and installing radiator 5400
1 12 Removing and installing coolant pump 5402
1 13 Checking cooling system for leaks 5403
20 – Fuel supply system 5406
1 Safety precautions 5406
1 1 Safety regulations for working on fuel supply 5406
1 2 Releasing pressure in high-pressure area 5406
2 Rules for cleanliness 5408
3 Fuel tank (Golf, Golf Plus) 5409
3 1 Fuel tank – assembly overview (Golf, Golf Plus) 5409
3 2 Emptying fuel tank 5410
3 2 1 Emptying fuel tank if it is more than 3/4 full 5411
3 2 2 Emptying fuel tank if it is less than 3/4 full 5412
3 3 Removing and installing fuel tank 5413
4 Fuel tank (Touran) 5416
4 1 Assembly overview – fuel tank 5416
4 2 Emptying fuel tank 5418
4 2 1 Emptying fuel tank if it is more than 3/4 full 5419
4 2 2 Emptying fuel tank if it is less than 3/4 full 5420
4 3 Removing and installing fuel tank 5420
5 Fuel tank (Passat) 5423
5 1 Assembly overview – fuel tank 5423
5 2 Emptying fuel tank 5424
5 2 1 Emptying fuel tank if it is more than 3/4 full 5425
5 2 2 Emptying fuel tank if it is less than 3/4 full 5425
5 3 Removing and installing fuel tank 5426
5 3 1 Removing fuel tank 5427
5 3 2 Installing fuel tank 5429
6 Fuel tank (Eos) 5430
6 1 Assembly overview – fuel tank 5430
6 2 Emptying fuel tank 5432
6 2 1 Emptying fuel tank if it is more than 3/4 full 5432
6 2 2 Emptying fuel tank if it is less than 3/4 full 5433
6 3 Removing and installing fuel tank 5434
6 3 1 Removing 5434
6 3 2 Installing 5436
7 Repairing fuel supply system (Golf, Golf Plus, Eos) 5437
7 1 Removing and installing fuel delivery unit 5437
7 2 Removing and installing fuel gauge sender G 5440
7 3 Crash fuel shut-off 5442
7 4 Checking fuel pump 5442
7 4 1 Checking function and voltage supply 5443
7 4 2 Checking fuel pressure 5446
7 4 3 Checking holding pressure 5447
7 4 4 Checking fuel delivery rate 5449
7 4 5 Checking current consumption 5452
8 Repairing fuel supply (Touran) 5454
8 1 Removing and installing fuel delivery unit 5454
8 2 Removing and installing fuel gauge sender -G- 5456
8 3 Crash fuel shut-off 5458
8 4 Checking fuel pump 5458
8 4 1 Checking function and voltage supply 5459
8 4 2 Checking fuel pressure 5462
8 4 3 Checking holding pressure 5464
8 4 4 Checking fuel delivery rate 5465
8 4 5 Checking current consumption 5468
9 Repairing fuel supply (Passat) 5470
9 1 Removing and installing fuel delivery unit 5470
9 2 Removing and installing fuel gauge sender -G- 5473
9 3 Checking fuel pump 5474
9 3 1 Checking function and voltage supply 5475
9 3 2 Checking fuel pressure 5477
9 3 3 Checking holding pressure 5479
9 3 4 Checking fuel delivery rate 5479
9 3 5 Checking current consumption 5482
10 Electronic power control; EPC (Golf, Golf Plus, Passat, Eos) 5484
10 1 Assembly overview – accelerator module 5484
10 2 Removing and installing accelerator pedal module 5484
11 Electronic power control; EPC (Touran) 5487
11 1 Assembly overview – accelerator module 5487
11 2 Removing and installing accelerator pedal module 5487
12 Activated charcoal filter system (Golf, Golf Plus, Eos) 5489
12 1 Assembly overview – activated charcoal filter system 5489
12 2 Checking fuel tank breather 5489
13 Activated charcoal filter system (Touran) 5492
13 1 Checking fuel tank breather 5492
14 Activated charcoal filter system (Passat) 5494
14 1 Assembly overview – activated charcoal filter system 5494
14 2 Checking fuel tank breather 5494
24 – Mixture preparation – injection 5496
1 Injection system 5496
1 1 General notes on injection 5496
1 2 Technical data 5497
1 3 Assembly overview – air filter 5497
1 4 Removing and installing air filter 5498
1 5 Assembly overview – intake manifold (engine codes BAG, BKG) 5499
1 6 Assembly overview – intake manifold (engine codes BLF, BLN, BLP) 5502
1 7 Assembly overview – fuel rail with injectors 5504
1 8 Cleaning throttle valve module -J338- 5505
1 9 Removing and installing high-pressure pump (engine codes BAG, BKG) 5505
1 10 Removing and installing high-pressure pump (engine codes BLF, BLN, BLP) 5507
1 11 Removing and installing injectors 5511
1 11 1 Removing 5512
1 11 2 Installing 5514
2 Checking components 5516
2 1 Checking function of intake manifold flap 5516
2 2 Checking vacuum reservoir in intake manifold for leaks 5516
2 3 Checking intake air preheating 5517
3 Engine control unit -J623- (Golf, Eos) 5518
3 1 Removing and installing engine (motor) control unit -J623- 5518
3 2 Removing and installing engine (motor) control unit -J623- with protective housing 5519
4 Engine control unit -J623- (Golf Plus, Touran) 5522
4 1 Removing and installing engine (motor) control unit -J623- 5522
4 2 Removing and installing engine (motor) control unit -J623- with protective housing 5523
5 Engine control unit -J623- (Passat) 5526
5 1 Removing and installing engine (motor) control unit -J623- 5526
5 2 Removing and installing engine control unit -J623- with locking plate 5527
5 3 Removing and installing engine control unit -J623- with locking clip 5530
26 – Exhaust system 5532
1 Parts of exhaust system (Golf, Golf Plus, Touran) 5532
1 1 Assembly overview – catalytic converters and attachments, engine codes BAG, BKG 5532
1 2 Assembly overview – catalytic converters and attachments, engine codes BLN, BLP, BLF 5534
1 3 Assembly overview – silencers with mountings 5536
2 Parts of exhaust system (Passat) 5537
2 1 Assembly overview – catalytic converters and attachments 5537
2 2 Assembly overview – silencers with mountings 5538
3 Parts of exhaust system (Eos) 5540
3 1 Assembly overview – catalytic converters and attachments 5540
3 2 Assembly overview – silencers with mountings 5542
3 3 Separating centre and rear silencers 5542
4 Exhaust gas recirculation system 5544
4 1 Assembly overview – exhaust gas recirculation system 5544
4 2 Removing and installing exhaust gas recirculation valve N18 5545
28 – Ignition system 5547
1 Repairing ignition system 5547
1 1 General notes on ignition system 5547
1 2 Safety precautions 5547
1 3 Assembly overview – ignition system 5547
1 4 Removing and installing ignition coils with output stage 5548
1 5 Test data, spark plugs 5550
K0058992820 4 cylinder injection engine (2 0 l engine turbocharger) 5551
00 – Technical data 5557
1 Engine number 5557
2 Engine data 5558
10 – Removing and installing engine 5559
1 Removing and installing engine 5559
1 1 Removing engine 5560
1 2 Securing engine to assembly stand 5565
1 3 Installing engine 5567
1 4 Assembly mountings 5569
13 – Crankshaft group 5571
1 Dismantling and assembling engine 5571
1 1 Assembly overview 5571
1 1 1 Part I 5573
1 1 2 Part II, vehicles without split toothed belt guard 5574
1 1 3 Part III, vehicles with split toothed belt guard 5576
1 1 4 Part IV 5578
1 2 Removing and installing poly-V belt 5578
2 Sealing flange and flywheel or drive plate 5581
2 1 Assembly overview – sealing flange 5581
2 2 Renewing crankshaft oil seal (belt pulley end) 5582
2 3 Removing and installing sealing flange (belt pulley end) 5584
2 4 Removing and installing crankshaft sealing flange (flywheel end) 5587
2 5 Removing and installing flywheel 5588
2 6 Removing and installing drive plate 5589
3 Crankshaft 5591
3 1 Assembly overview – crankshaft 5591
3 1 1 Removing and installing sender wheel 5593
3 2 Pulling needle bearing out of and driving into crankshaft 5593
3 3 Crankshaft dimensions 5595
3 4 Identification of crankshaft upper bearing 5595
4 Pistons and conrods 5596
4 1 Assembly overview – pistons and conrods 5596
4 1 1 Bearing shells – installation position 5597
4 2 Separating new conrod 5597
4 3 Removing and installing pistons 5598
4 4 Checking pistons and cylinder bores 5599
15 – Cylinder head, valve gear 5602
1 Cylinder head 5602
1 1 Assembly overview – cylinder head 5602
1 2 Removing and installing cylinder head cover 5604
1 3 Removing and installing cylinder head 5606
1 3 1 Removing cylinder head 5607
1 3 2 Installing cylinder head 5610
1 4 Removing and installing toothed belt, vehicles without split toothed belt guard 5611
1 4 1 Removing toothed belt 5612
1 4 2 Installing toothed belt 5619
1 5 Removing and installing toothed belt, vehicles with split toothed belt guard 5622
1 5 1 Removing toothed belt 5623
1 5 2 Installing toothed belt 5629
1 6 Checking compression 5632
2 Valve gear 5635
2 1 Assembly overview – valve gear 5635
2 2 Valve dimensions 5637
2 3 Checking valve guides 5637
2 4 Renewing valve stem seals 5638
2 4 1 Removing valve stem oil seals 5639
2 4 2 Installing valve stem seals 5641
2 5 Renewing exhaust camshaft seal 5642
2 6 Removing and installing camshaft adjuster 5645
2 7 Removing and installing camshaft control valve 1 -N205- 5648
2 8 Removing and installing camshafts 5650
17 – Lubrication 5654
1 Parts of lubrication system 5654
1 1 Engine oil: 5654
1 2 Assembly overview – parts of lubrication system 5654
1 2 1 Part 1 5656
1 2 2 Part 2 5657
1 2 3 Part 3 Oil filter bracket 5658
1 3 Drain oiling filter housing 5659
1 4 Removing and installing sump 5660
1 5 Removing and installing oil pump with balance shaft gear assembly 5663
1 5 1 Removing oil pump with balance shaft gear assembly 5663
1 5 2 Removing and installing oil pump with balance shaft gear assembly 5665
1 5 3 Preloading chain tensioner 5667
1 6 Removing and installing oil filter bracket 5667
1 7 Removing and installing oil pressure switch -F1- 5668
1 8 Checking oil pressure and oil pressure switch (single pin oil pressure switch) 5669
1 9 Checking oil pressure and oil pressure switch (2-pin oil pressure switch) 5671
19 – Cooling 5674
1 Parts of cooling system 5674
1 1 Assembly overview – parts of cooling system, engine side 5674
1 2 Assembly overview – coolant circulation pump -V50- (vehicles with bypass thermostat) 5676
1 3 Assembly overview – coolant circulation pump -V50- (vehicles with no bypass thermostat) 5677
1 4 Assembly overview – parts of cooling system, body side 5678
1 5 Coolant hose schematic diagram (vehicles to 06 2005) 5679
1 6 Coolant hose schematic diagram (vehicles from 06 2005) 5680
1 7 Bypass thermostat 5681
1 8 Draining and adding coolant 5682
1 8 1 Draining coolant 5682
1 8 2 Filling with coolant 5683
1 9 Removing and installing coolant pump 5685
1 10 Removing and installing coolant pipes 5687
1 11 Removing and installing coolant thermostat housing with thermostat 5689
1 12 Removing and installing radiator fan -V7- and radiator fan 2 -V177- 5690
1 13 Removing and installing radiator, Golf and Eos 5690
1 14 Removing and installing radiator, Passat 5692
1 15 Checking cooling system for leaks 5693
20 – Fuel supply system 5696
1 Safety precautions 5696
1 1 Safety regulations for working on fuel supply 5696
1 2 Releasing fuel pressure in high-pressure section 5697
2 Rules for cleanliness 5699
3 Fuel tank, Golf 5700
3 1 Assembly overview – fuel tank (engine code BPY) 5700
3 2 Assembly overview – fuel tank (engine codes AXX, BWA) 5702
3 3 Emptying fuel tank 5703
3 3 1 Emptying fuel tank when fuel pump is intact 5704
3 3 2 Emptying fuel tank if it is more than 3/4 full 5706
3 3 3 Emptying fuel tank if it is less than 3/4 full 5707
3 4 Removing and installing fuel tank 5708
3 4 1 Removing 5708
3 4 2 Installing 5710
4 Fuel tank, Eos 5711
4 1 Assembly overview – fuel tank (engine code BWA) 5711
4 2 Assembly overview – fuel tank (engine code BPY) 5713
4 3 Emptying fuel tank 5715
4 3 1 Emptying fuel tank when fuel pump is intact 5715
4 3 2 Emptying fuel tank if it is more than 3/4 full 5717
4 3 3 Emptying fuel tank if it is less than 3/4 full 5718
4 4 Removing and installing fuel tank 5719
4 4 1 Removing 5719
4 4 2 Installing fuel tank 5721
5 Fuel tank, Passat 5723
5 1 Assembly overview – fuel tank (engine code BPY) 5723
5 2 Assembly overview – fuel tank (engine codes AXX, BWA) 5725
5 3 Emptying fuel tank 5726
5 3 1 Emptying fuel tank when fuel pump is intact 5726
5 3 2 Emptying fuel tank if it is more than 3/4 full 5728
5 3 3 Emptying fuel tank if it is less than 3/4 full 5729
5 4 Removing and installing fuel tank 5730
5 4 1 Removing fuel tank 5730
5 4 2 Installing fuel tank 5733
6 Repairing fuel supply system, Golf, Eos 5735
6 1 Removing and installing fuel delivery unit 5735
6 2 Removing and installing fuel gauge sender -G- 5738
6 3 Checking fuel pump -G6- 5739
6 3 1 Checking function and voltage supply 5740
6 3 2 Checking fuel pressure 5743
6 3 3 Checking holding pressure 5745
6 3 4 Checking fuel delivery rate 5746
6 3 5 Checking current consumption 5750
7 Repairing fuel supply system, Passat 5752
7 1 Removing and installing fuel delivery unit 5752
7 2 Removing and installing fuel gauge sender -G- 5755
7 3 Checking fuel pump 5756
7 3 1 Checking function and voltage supply 5757
7 3 2 Checking fuel pressure 5760
7 3 3 Checking holding pressure 5761
7 3 4 Checking fuel delivery rate 5761
7 3 5 Checking current consumption 5764
8 Electronic power control (EPC) 5766
8 1 Function of EPC system 5766
8 2 Assembly overview – accelerator module 5766
8 3 Removing and installing accelerator pedal module 5767
9 Activated charcoal filter system (Golf, Eos) 5770
9 1 Assembly overview – activated charcoal filter system (engine codes AXX, BWA) 5770
9 2 Checking fuel tank breather (engine codes AXX, BWA) 5771
9 3 Schematic diagram of activated charcoal filter system (engine code BPY) 5773
9 4 Assembly overview – activated charcoal filter system (Golf with engine code BPY) 5775
9 5 Assembly overview – activated charcoal filter system (Eos with engine code BPY) 5776
9 6 Removing and installing activated charcoal filter (engine code BPY) 5777
9 7 Removing and installing fuel system diagnostic pump -V144- (Golf with engine code BPY) 5778
9 8 Removing and installing fuel system diagnostic pump -V144- (Eos with engine code BPY) 5779
9 9 Checking fuel system for leaks 5779
9 9 1 Leak detection in fuel system 5783
9 9 2 Schematic overview of activated charcoal filter system 5784
9 9 3 Checking vacuum supply of fuel system diagnostic pump -V144- 5785
10 Activated charcoal filter system (Passat) 5787
10 1 Assembly overview – activated charcoal filter system (engine codes AXX, BWA) 5787
10 2 Checking fuel tank breather (engine codes AXX, BWA) 5788
10 3 Schematic diagram of activated charcoal filter system (engine code BPY) 5789
10 4 Assembly overview – activated charcoal filter system (engine code BPY) 5791
10 5 Checking fuel system for leaks 5791
10 5 1 Leak detection in fuel system 5795
10 5 2 Schematic overview of activated charcoal filter system 5796
10 5 3 Checking vacuum supply of fuel system diagnostic pump -V144- 5797
21 – Turbocharging/supercharging 5799
1 Exhaust turbocharger 5799
1 1 Fitting hose connections with plug-in connectors 5799
1 2 Rules for cleanliness 5800
1 3 Assembly overview – turbocharger 5800
1 3 1 Part I 5800
1 3 2 Part II 5802
1 3 3 Part III 5803
1 4 Removing and installing turbocharger 5804
1 5 Checking vacuum unit for turbocharger 5812
1 6 Removing and installing vacuum unit for turbocharger 5813
1 7 Adjusting vacuum unit for turbocharger 5813
2 Charge air system 5818
2 1 Assembly overview – charge air cooling, Golf 5818
2 2 Assembly overview – sound amplifier, Golf 5819
2 3 Assembly overview – charge air cooling, Eos, Passat 5820
2 4 Removing and installing charge air cooler (Golf, Eos) 5820
2 5 Removing and installing charge air cooler, Passat 5822
2 6 Schematic diagram of turbocharging system 5823
2 7 Checking charge air system for leaks 5824
24 – Mixture preparation – injection 5827
1 Injection system 5827
1 1 General notes on injection 5827
1 2 Technical data 5828
1 3 Assembly overview – engine cover panel/air filter 5828
1 4 Removing and installing engine cover panel/air filter 5829
1 5 Removing and installing air filter element 5830
1 6 Assembly overview – intake manifold 5831
1 7 Removing and installing intake manifold 5833
1 8 Removing and installing intake manifold flap motor -V157- and intake manifold flap potentiometer -G336- 5836
1 9 Assembly overview – fuel rail (vehicles up to 05 2006) 5838
1 10 Assembly overview – fuel rail (vehicles from 05 2006) 5839
1 11 Removing and installing fuel rail 5841
1 12 Removing and installing throttle valve module -J338- 5842
1 13 Cleaning throttle valve module -J338- 5842
1 14 Assembly overview – high-pressure pump 5843
1 15 Removing and installing high-pressure pump 5845
1 16 Removing and installing fuel pressure sender -G247- 5846
1 17 Checking fuel pressure sender -G247- 5848
1 18 Removing and installing injectors 5851
1 19 Renewing Teflon seal on injector 5852
2 Checking components 5855
3 Engine control unit -J623-, Golf, Eos 5856
3 1 Removing and installing engine (motor) control unit -J623- 5856
3 2 Removing and installing anti-theft engine control unit -J623- 5856
4 Engine control unit -J623- (Passat) 5860
4 1 Removing and installing engine (motor) control unit -J623- 5860
4 2 Removing and installing anti-theft engine control unit -J623- (with locking plate) 5861
4 3 Removing and installing anti-theft engine control unit -J623- (with locking clip) 5865
26 – Exhaust system 5868
1 Removing and installing parts of exhaust system 5868
1 1 Assembly overview – exhaust system; Golf, Eos 5868
1 2 Assembly overview – exhaust system, Passat 5870
1 3 Clamps 5871
1 4 Separating centre and rear silencers, Golf, Eos 5872
1 5 Separating centre and rear silencers, Passat 5873
1 6 Removing and installing front exhaust pipe with catalytic converter 5874
1 7 Aligning exhaust system free of stress 5876
28 – Ignition system 5878
1 Repairing ignition system 5878
1 1 General notes on ignition system 5878
1 2 Safety precautions 5878
1 3 Assembly overview – ignition system 5878
1 4 Removing and installing ignition coils with output stage 5879
1 5 Test data, spark plugs 5880
K0059020320 4 cylinder injection engine (2 0 l direct injection) 5882
00 – Technical data 5888
1 Engine number 5888
2 Engine data 5889
10 – Removing and installing engine 5890
1 Removing and installing engine 5890
1 1 Removing engine 5891
1 1 1 Securing engine to assembly stand 5896
1 2 Installing engine 5898
13 – Crankshaft group 5903
1 Cylinder block attachments 5903
1 1 Assembly overview – cylinder block attachments 5903
1 1 1 Part I 5904
1 1 2 Part II, vehicles without split toothed belt guard 5905
1 1 3 Part III, vehicles with split toothed belt guard 5907
1 1 4 Part IV 5909
1 2 Removing and installing poly-V belt 5910
2 Sealing flange and flywheel or drive plate 5911
2 1 Assembly overview – sealing flange 5911
2 2 Renewing crankshaft oil seal – pulley end 5912
2 3 Removing and installing sealing flange – pulley end 5914
2 4 Removing and installing crankshaft sealing flange – flywheel end 5917
2 4 1 Removing and installing aluminium sealing flange 5918
2 4 2 Removing and installing plate sealing flange 5920
2 5 Removing and installing flywheel 5921
2 6 Removing and installing drive plate 5922
3 Crankshaft 5924
3 1 Assembly overview – crankshaft 5924
3 2 Removing and installing sender wheel 5925
3 3 Crankshaft dimensions 5925
3 4 Identification of crankshaft upper bearing 5925
4 Pistons and conrods 5927
4 1 Assembly overview – pistons and conrods 5927
4 2 Separating new conrod 5928
4 3 Bearing shells – installation position 5929
4 4 Checking pistons, piston rings and cylinder bores 5929
4 5 Piston and cylinder dimensions 5931
15 – Cylinder head, valve gear 5932
1 Cylinder head 5932
1 1 Assembly overview – cylinder head 5932
1 2 Removing and installing cylinder head cover 5934
1 3 Removing and installing cylinder head 5935
1 3 1 Removing cylinder head 5937
1 3 2 Installing cylinder head 5940
1 4 Removing and installing toothed belt, vehicles without split toothed belt guard (Passat) 5941
1 4 1 Removing toothed belt 5942
1 4 2 Installing toothed belt 5946
1 5 Removing and installing toothed belt, vehicles without split toothed belt guard (Eos) 5950
1 5 1 Removing toothed belt 5951
1 5 2 Installing toothed belt 5955
1 6 Removing and installing toothed belt, vehicles with split toothed belt guard (Passat) 5958
1 6 1 Removing toothed belt 5958
1 6 2 Installing toothed belt 5963
1 7 Removing and installing toothed belt, vehicles with split toothed belt guard (Eos) 5967
1 7 1 Removing toothed belt 5969
1 7 2 Installing toothed belt 5973
1 8 Checking compression 5976
2 Valve gear 5979
2 1 Assembly overview – valve gear 5979
2 2 Valve dimensions 5981
2 3 Checking valve guides 5981
2 4 Renewing valve stem seals 5982
2 4 1 Removing valve stem oil seals 5983
2 4 2 Installing valve stem seals 5985
2 5 Renewing exhaust camshaft seal 5986
2 6 Removing and installing camshaft adjuster 5989
2 7 Removing and installing inlet camshaft control valve 1 -N205- 5993
2 8 Removing and installing camshafts 5994
17 – Lubrication 5998
1 Parts of lubrication system 5998
1 1 Engine oil: 5998
1 2 Assembly overview – parts of lubrication system 5999
1 2 1 Part I 6000
1 2 2 Part ll, assembly overview – oil pump with balance shaft gear assembly 6002
1 2 3 Part IIl, assembly overview – oil filter bracket 6003
1 3 Drain oiling filter housing 6004
1 4 Removing and installing sump, engine codes BLX, BLY, BLR 6005
1 5 Removing and installing sump, engine codes BVX, BVY, BVZ 6007
1 6 Removing and installing oil pump with balance shaft gear assembly 6010
1 6 1 Removing oil pump with balance shaft gear assembly 6011
1 6 2 Removing and installing oil pump with balance shaft gear assembly 6012
1 6 3 Preloading chain tensioner 6015
1 7 Removing and installing oil filter bracket 6015
1 8 Checking oil pressure and oil pressure switch 6016
19 – Cooling 6019
1 Parts of cooling system 6019
1 1 Assembly overview – parts of cooling system, engine side, (engine codes BLX, BLY, BLR) 6019
1 2 Assembly overview – parts of cooling system, engine side, (engine codes BVX, BVY, BVZ) 6021
1 3 Assembly overview – parts of cooling system, body side 6022
1 4 Coolant hose schematic diagram, (engine codes BLX, BLY, BLR) 6023
1 5 Coolant hose schematic diagram, (engine codes BVX, BVY, BVZ) 6024
1 6 Draining and adding coolant 6025
1 6 1 Draining coolant 6025
1 6 2 Filling with coolant 6026
1 7 Removing and installing coolant pump 6029
1 8 Removing and installing coolant pipe 6030
1 9 Mapped cooling, (engine codes BLX, BLY, BLR) 6031
1 9 1 Assembly overview – coolant distributor housing with thermostat 6031
1 9 2 Removing and installing map-controlled engine cooling system thermostat -F265- 6032
1 9 3 Checking map-controlled engine cooling system thermostat -F265- 6034
1 10 Removing and installing coolant distributor housing with thermostat 6036
1 11 Removing and installing radiator fan -V7- and radiator fan 2 -V177- 6036
1 12 Removing and installing radiator 6038
1 13 Checking cooling system for leaks 6039
20 – Fuel supply system 6042
1 Safety precautions 6042
1 1 Safety regulations for working on fuel supply 6042
1 2 Releasing pressure in high-pressure area 6043
2 Fuel tank, vehicles with four-wheel drive (Passat) 6045
2 1 Rules for cleanliness 6045
2 2 Assembly overview – fuel tank 6045
2 3 Emptying fuel tank 6047
2 3 1 Emptying fuel tank when fuel pump is intact 6048
2 3 2 Emptying fuel tank if it is more than 1/3 full 6050
2 3 3 Emptying fuel tank if it is less than 1/3 full 6050
2 4 Removing and installing fuel tank (vehicles to 06/2007) 6053
2 4 1 Removing fuel tank 6054
2 4 2 Installing fuel tank 6057
2 5 Removing and installing fuel tank (vehicles from 06/2007) 6058
2 5 1 Removing fuel tank 6059
2 5 2 Installing fuel tank 6062
2 6 Removing and installing fuel gauge sender 2 -G169- 6063
2 7 Removing and installing suction-jet pump 6066
3 Fuel tank, vehicles with front-wheel drive (Passat) 6068
3 1 Rules for cleanliness 6068
3 2 Assembly overview – fuel tank 6068
3 3 Emptying fuel tank 6070
3 3 1 Emptying fuel tank when fuel pump is intact 6070
3 3 2 Emptying fuel tank if it is more than 3/4 full 6072
3 3 3 Emptying fuel tank if it is less than 3/4 full 6073
3 4 Removing and installing fuel tank 6074
3 4 1 Removing fuel tank 6074
3 4 2 Installing fuel tank 6077
4 Fuel tank (Eos) 6078
4 1 Rules for cleanliness 6078
4 2 Assembly overview – fuel tank 6078
4 3 Emptying fuel tank 6080
4 3 1 Emptying fuel tank when fuel pump is intact 6081
4 3 2 Emptying fuel tank if it is more than 3/4 full 6083
4 3 3 Emptying fuel tank if it is less than 3/4 full 6083
4 4 Removing and installing fuel tank 6084
4 4 1 Removing 6085
4 4 2 Installing 6086
5 Repairing fuel supply system (Passat) 6088
5 1 Rules for cleanliness 6088
5 2 Removing and installing fuel delivery unit 6088
5 2 1 Removing fuel delivery unit 6089
5 2 2 Installing fuel delivery unit 6091
5 3 Removing and installing fuel gauge sender -G- 6093
5 4 Checking fuel pump -G6- 6094
5 4 1 Checking function and voltage supply 6095
5 4 2 Checking fuel pressure 6097
5 4 3 Checking holding pressure 6098
5 4 4 Checking fuel delivery rate 6099
5 4 5 Checking current consumption 6102
6 Repairing fuel supply system (Eos) 6104
6 1 Safety regulations for working on fuel supply 6104
6 2 Rules for cleanliness 6104
6 3 Removing and installing fuel delivery unit 6105
6 3 1 Removing 6105
6 3 2 Installing 6106
6 4 Removing and installing fuel gauge sender -G- 6108
6 5 Checking fuel pump -G6- 6109
6 5 1 Checking function and voltage supply 6110
6 5 2 Checking fuel pressure 6113
6 5 3 Checking holding pressure 6115
6 5 4 Checking fuel delivery rate 6116
6 5 5 Checking current consumption 6120
7 Electronic power control (EPC) 6122
7 1 Function of EPC system 6122
7 2 Assembly overview – accelerator module 6122
7 3 Removing and installing accelerator pedal module 6123
8 Activated charcoal filter system (Passat) 6126
8 1 Function 6126
8 2 Assembly overview – activated charcoal filter system 6126
8 3 Checking fuel tank breather 6127
9 Activated charcoal filter system (Eos) 6129
9 1 Function 6129
9 2 Assembly overview – activated charcoal filter system 6129
9 3 Checking fuel tank breather 6130
24 – Mixture preparation – injection 6133
1 Injection system 6133
1 1 General notes on injection 6133
1 2 Rules for cleanliness 6134
1 3 Technical data 6134
1 4 Assembly overview – intake manifold 6134
1 4 1 Assembly overview – suction-jet pump 6137
1 5 Assembly overview – fuel rail with intake manifold flap motor -V157- – (engine codes BLR, BLX, BLY) 6138
1 6 Assembly overview – fuel rail with intake manifold flap motor -V157- – (engine codes BVX, BVY, BVZ) 6139
1 7 Assembly overview – air filter 6141
1 8 Removing and installing intake manifold 6142
1 9 Removing and installing fuel rail with intake manifold flaps 6143
1 10 Assembly overview – high-pressure pump 6145
1 11 Removing and installing high-pressure pump 6146
1 12 Removing and installing fuel pressure sender -G247- 6148
1 13 Checking fuel pressure sender -G247- 6149
1 14 Removing and installing injectors 6153
1 15 Renewing Teflon seal on injector 6155
1 16 Cleaning throttle valve module -J338- 6157
2 Checking components 6159
3 Engine control unit -J623- (Passat) 6161
3 1 Removing and installing engine (motor) control unit -J623- 6161
3 2 Removing and installing anti-theft engine control unit -J623- (with locking plate) 6162
3 2 1 Removing anti-theft engine control unit (with locking plate) 6163
3 2 2 Installing anti-theft engine control unit 6164
3 3 Removing and installing anti-theft engine control unit -J623- (with locking clip) 6165
4 Engine control unit -J623- (Eos) 6168
4 1 Removing and installing engine (motor) control unit -J623- 6168
4 2 Removing and installing anti-theft engine control unit -J623- 6168
4 2 1 Removing 6169
4 2 2 Installing 6170
26 – Exhaust system 6171
1 Parts of exhaust system 6171
1 1 Assembly overview – exhaust manifold with catalytic converter, (engine codes BLR, BLX, BVX) 6171
1 2 Assembly overview – exhaust manifold with catalytic converter, (engine code BVY) 6173
1 3 Assembly overview – exhaust manifold, (engine codes BLY, BVZ) 6174
1 4 Removing and installing exhaust manifold 6175
1 5 Assembly overview – exhaust system, engine codes BLR, BVY (Passat) 6179
1 6 Assembly overview – exhaust system, engine codes BLX, BVX (Passat) 6181
1 7 Assembly overview – exhaust system, engine codes BLY, BVZ (Passat) 6183
1 8 Assembly overview – exhaust system, engine code BVY (Eos) 6185
1 9 Assembly overview – exhaust system, engine code BVZ (Eos) 6187
1 10 Removing and installing front exhaust pipe with catalytic converter 6188
1 11 Separating centre and rear silencers 6191
1 11 1 Vehicles with front wheel drive (Passat) 6192
1 11 2 Vehicles with four wheel drive (Passat) 6193
1 11 3 Eos 6194
1 12 Aligning exhaust system free of stress 6195
1 13 Installation position and specified torque of clamp 6196
2 Exhaust gas recirculation system, (engine codes BLR, BLX, BVX and BVY) 6198
2 1 Assembly overview – exhaust gas recirculation system 6198
28 – Ignition system 6200
1 Repairing ignition system 6200
1 1 General notes on ignition system 6200
1 2 Safety precautions 6200
1 3 Assembly overview – ignition system 6200
1 4 Removing and installing ignition coils with output stage 6201
1 5 Test data, spark plugs 6202
K0059022320 4 cylinder common rail engine (2 0 l EA189) 6204
00 – Technical data 6210
1 Identification 6210
1 1 Engine number/engine data 6210
1 1 1 Engine number 6210
1 1 2 Engine data 6210
2 Safety information 6212
2 1 Safety precautions when working on fuel system 6212
2 2 Safety precautions when using testers and measuring instruments during a road test 6213
2 3 Safety measures when working on vehicles with a start/stop system 6213
2 4 Safety precautions when working on the cooling system 6213
2 5 Safety precautions when working on the SCR system 6214
2 6 Safety precautions when working on exhaust system 6214
3 Repair notes 6216
3 1 Rules for cleanliness 6216
3 2 Foreign objects in engine 6216
3 3 Checking vacuum system 6217
10 – Removing and installing engine 6218
1 Removing and installing engine 6218
1 1 Removing and installing engine 6218
1 1 1 Removing engine, Passat, Passat CC, Tiguan, Eos 6218
1 1 2 Removing engine, Golf, Golf Plus, Scirocco 6225
1 2 Securing engine on engine and gearbox support 6231
1 3 Installing engine 6232
1 3 1 Notes on installing, Passat, Passat CC, Tiguan and Eos 6232
1 3 2 Notes on installing, Golf, Golf Plus, Scirocco 6233
2 Assembly mountings 6236
2 1 Assembly overview – assembly mountings 6236
2 2 Supporting engine in installation position 6237
2 2 1 Supporting engine in installation position, Passat, Passat CC, Eos, Golf and Scirocco 6237
2 2 2 Supporting engine in installation position, Tiguan 6240
2 2 3 Supporting engine in installation position, Golf Plus 6242
2 3 Adjusting assembly mountings 6245
2 3 1 Adjusting assembly mountings, Passat, Passat CC, Eos, Golf and Scirocco 6245
2 3 2 Adjusting assembly mountings, Tiguan 6246
2 3 3 Adjusting assembly mountings, Golf Plus 6248
3 Engine cover panel 6250
3 1 Removing and installing engine cover 6250
13 – Crankshaft group 6251
1 Cylinder block (pulley end) 6251
1 1 Assembly overview – poly V-belt drive 6251
1 1 1 Assembly overview – poly V-belt drive with tensioning element and air conditioner compressor 6251
1 1 2 Assembly overview – poly V-belt drive with tensioning roller and air conditioner compressor 6253
1 1 3 Assembly overview – poly V-belt drive without air conditioner compressor 6255
1 2 Removing and installing poly-V belt 6255
1 2 1 Removing and installing poly V-belt with tensioning element and air conditioner compressor 6255
1 2 2 Removing and installing poly V-belt with tensioning roller and air conditioner compressor 6257
1 2 3 Removing and installing poly V-belt without air conditioner compressor 6258
1 3 Removing and installing tensioner for poly V-belt 6259
1 3 1 Removing and installing poly V-belt tensioner 6259
1 4 Removing and installing bracket for ancillaries 6260
1 5 Removing and installing engine bracket 6262
1 5 1 Removing and installing engine bracket, Passat, Passat CC, Eos, Golf and Scirocco 6262
1 5 2 Removing and installing engine bracket, Tiguan 6265
1 5 3 Removing and installing engine bracket, Golf Plus 6268
1 6 Assembly overview – cylinder block (pulley end) 6272
1 7 Removing and installing sealing flange on pulley end 6273
1 8 Renewing crankshaft oil seal – belt pulley end 6275
2 Cylinder block, gearbox end 6278
2 1 Assembly overview – cylinder block, gearbox end 6278
2 2 Removing and installing sealing flange on gearbox side 6279
2 2 1 Pressing out sealing flange with sender wheel 6280
2 2 2 Pressing in sealing flange with sender wheel 6281
2 2 3 A – Assembling seal with sender wheel on assembly tool -T10134- 6282
2 2 4 B – Fitting assembly tool -T10134- with sealing flange to crankshaft flange 6283
2 2 5 C – Screwing assembly tool -T10134- on crankshaft flange 6284
2 2 6 D – Pressing sender wheel onto crankshaft flange using assembly tool -T10134- 6285
2 2 7 E – Checking sender wheel installation position on crankshaft 6285
2 2 8 F – Re-pressing sender wheel 6286
3 Crankshaft 6288
3 1 Assembly overview – crankshaft 6288
3 2 Renewing needle bearing in crankshaft 6288
3 3 Crankshaft dimensions 6291
4 Pistons and conrods 6292
4 1 Assembly overview – pistons and conrods 6292
4 1 1 Assembly overview – pistons and conrods 6292
4 1 2 Piston and cylinder dimensions 6295
4 2 Measuring piston projection at TDC 6295
4 3 Separating new conrod 6296
15 – Cylinder head, valve gear 6298
1 Cylinder head 6298
1 1 Assembly overview – cylinder head 6298
1 2 Removing and installing cylinder head 6300
1 3 Assembly overview – cylinder head cover 6309
1 4 Removing and installing cylinder head cover 6310
1 5 Removing and installing vacuum pump 6313
1 6 Checking compression 6314
2 Toothed belt drive 6316
2 1 Assembly overview – toothed belt 6316
2 2 Removing and installing toothed belt 6318
3 Valve gear 6325
3 1 Assembly overview – valve gear 6325
3 2 Removing and installing camshaft oil seal 6326
3 2 1 Vehicles up to 08 09 6327
3 2 2 Vehicles from 09 09 6328
3 3 Removing and installing camshaft 6330
3 4 Removing and installing valve stem seals 6337
4 Inlet and exhaust valves 6342
4 1 Valve dimensions 6342
4 2 Reworking valve seats 6342
4 3 Checking valve guides 6342
17 – Lubrication 6343
1 Sump, oil pump 6343
1 1 Assembly overview – sump/oil pump 6343
1 1 1 Assembly overview – sump / oil pump, engine codes CBAA, CBAB, CBAC, CBBA, CBBB 6343
1 1 2 Assembly overview – sump / oil pump, engine codes CBDA, CBDC, CBDB, CJAA 6346
1 2 Removing and installing oil sump 6349
1 3 Removing and installing oil pump 6352
1 3 1 Removing and installing oil pump, engine codes CBAA, CBAB, CBAC, CBBA, CBBB 6352
1 4 Engine oil: 6353
1 4 1 Oil capacities, engine codes CBAA, CBAB, CBAC, CBBA, CBBB 6353
1 4 2 Oil capacities, engine codes CBDA, CBDB, CBDC, CJAA 6354
2 Engine oil cooler 6355
2 1 Assembly overview – engine oil cooler 6355
3 Oil filter, oil pressure switch 6357
3 1 Assembly overview – oil filter/oil pressure switch 6357
3 2 Removing and installing oil filter housing 6358
3 3 Checking oil pressure and oil pressure switch 6361
3 3 1 Checking oil pressure switch 6362
3 3 2 Checking oil pressure 6362
4 Oil circuit 6363
4 1 Removing and installing oil supply line for turbocharger 6363
5 Balancer shaft module 6365
5 1 Assembly overview – balancer shaft module 6365
5 2 Removing and installing balance shaft module 6368
5 2 1 Removing balancer shaft module 6368
5 2 2 Installing a new balancer shaft module 6369
5 2 3 Installing a previously used balancer shaft module again 6373
5 2 4 Renewing spur gear for crankshaft, engine codes CBAA, CBAB, CBAC, CBBA, CBBB 6375
19 – Cooling 6379
1 Cooling system/coolant 6379
1 1 Coolant hose connection diagram 6379
1 1 1 Coolant hose schematic diagram, vehicles with 4/2-way valve, engine codes CBAA, CBBB, CBAB, CBBA, CBDB, CBDC, CBAC, CBDA 6379
1 1 2 Coolant hose schematic diagram, vehicles without 4/2-way valve, engine codes CBAA, CBBB, CBAB, CBBA, CBDB, CBDC, CBAC, CBDA 6380
1 1 3 Coolant hose schematic diagram, engine code CJAA 6382
1 2 Checking cooling system for leaks 6383
1 2 1 Checking cooling system for leaks 6383
1 2 2 Checking oil cooler for leaks 6385
1 3 Draining and adding coolant 6387
1 3 1 Draining 6388
1 3 2 Filling 6390
1 4 Assembly overview – engine preheater 6391
1 4 1 Assembly overview – engine preheater 6391
1 4 2 Removing and installing engine preheater 6393
2 Coolant pump, regulation of cooling system 6395
2 1 Removing and installing coolant pump 6395
2 2 Removing and installing thermostat 6396
2 3 Removing and installing 4/2-way valve with thermostat 6398
3 Coolant pipes 6400
3 1 Assembly overview – coolant pipes 6400
3 1 1 Assembly overview – coolant pipes, engine side, engine codes CBAA, CBBB, CBAB, CBBA, CBDB, CBDC, CBAC, CBDA 6400
3 1 2 Assembly overview – coolant pipes, engine side, engine code CJAA 6401
3 1 3 Assembly overview – coolant pipes, gearbox side, engine code CJAA 6403
4 Radiator, radiator fan 6404
4 1 Assembly overview – radiator/radiator fan 6404
4 1 1 Assembly overview – radiator/radiator fan, engine codes CBAA, CBBB, CBAB, CBBA, CBDB, CBDC, CBAC, CBDA 6404
4 1 2 Assembly overview – radiator/radiator fan, engine code CJAA 6406
4 2 Removing and installing radiator 6407
4 3 Removing and installing radiator cowl with radiator fan 6408
21 – Turbocharging/supercharging 6409
1 Exhaust turbocharger 6409
1 1 Assembly overview – turbocharger 6409
1 1 1 Assembly overview – turbocharger, engine codes CBAA, CBBB, CBAB, CBBA, CBDB, CBDC, CBAC, CBDA 6409
1 1 2 Assembly overview – turbocharger, engine code CJAA 6411
1 2 Removing and installing turbocharger 6415
1 2 1 Removing and installing turbocharger, engine codes CBAA, CBBB, CBAB, CBBA, CBDB, CBDC, CBAC, CBDA 6415
1 2 2 Removing and installing turbocharger, engine code CJAA 6417
1 3 Renewing vacuum unit for turbocharger 6419
2 Charge air system 6427
2 1 Assembly overview – charge air system 6427
2 2 Assembly overview – charge-air hose connections 6429
2 2 1 Assembly overview – charge-air hose connections with plug-in connectors 6429
2 3 Checking charge air system for leaks 6430
23 – Mixture preparation – injection 6433
1 Injection system 6433
1 1 Schematic overview – fuel system 6433
1 2 Assembly overview – fuel system 6435
1 3 Filling/bleeding fuel system 6438
1 4 Checking fuel system for leaks 6439
2 Injectors/high-pressure accumulator (rail) 6440
2 1 Check pressure retention valve in fuel return line 6440
2 2 Removing and installing injectors 6441
2 2 1 Removing injectors 6441
2 2 2 Installing injectors 6444
2 3 Removing and installing high-pressure lines 6445
2 4 Removing and installing fuel rail 6447
3 Vacuum system 6451
3 1 Assembly overview – vacuum system 6451
3 1 1 Assembly overview – vacuum system, engine codes CBAA, CBBB, CBAB, CBBA, CBDB, CBDC, CBAC, CBDA 6451
3 1 2 Assembly overview – vacuum system, engine code CJAA 6452
3 2 Checking vacuum system 6452
3 2 1 Checking supply line, vacuum reservoir and non-return valve 6453
3 2 2 Checking control line to turbocharger 6454
3 2 3 Checking control line to vacuum unit for exhaust gas recirculation cooler changeover, engine codes CBAA, CBBB, CBAB, CBBA, CBDB, CBDC, CBAC, CBDA 6454
4 Air filter 6456
4 1 Assembly overview – air filter housing 6456
4 1 1 Assembly overview – air filter, engine codes CBAA, CBBB, CBAB, CBBA, CBDB, CBDC, CBAC, CBDA 6456
4 1 2 Assembly overview – air filter, engine code CJAA 6457
4 2 Removing and installing air filter housing 6458
4 3 Checking changeover flap for intake air preheating 6459
4 4 Removing and installing changeover flap for intake air preheating 6460
5 Intake manifold 6463
5 1 Assembly overview – intake manifold 6463
5 2 Removing and installing intake manifold 6463
6 Senders and sensors 6467
6 1 Checking fuel pressure regulating valve 6467
6 2 Removing and installing fuel pressure regulating valve -N276- 6468
6 3 Removing and installing fuel pressure sender 6470
6 4 Assembly overview – actuator for structure-borne sound and control unit for structure-borne sound 6471
6 4 1 Assembly overview – actuator for structure-borne sound -R214- and control unit for structure-borne sound -J869- (left-hand drive vehicles) 6471
6 4 2 Assembly overview – actuator for structure-borne sound -R214- and control unit for structure-borne sound -J869- (right-hand drive vehicles) 6472
7 High-pressure pump 6474
7 1 Removing and installing high-pressure pump 6474
8 Engine (motor) control unit 6478
8 1 Removing and installing engine control unit 6478
8 1 1 Removing and installing anti-theft engine control unit -J623-, Scirocco 6478
8 1 2 Removing and installing engine control unit -J623-, Scirocco 6480
8 1 3 Removing and installing anti-theft engine control unit -J623-, Passat, Passat CC and Tiguan 6481
8 1 4 Removing and installing engine control unit -J623-, Passat, Passat CC and Tiguan 6483
8 1 5 Removing and installing engine control unit, Golf Plus 6484
8 1 6 Removing and installing anti-theft engine control unit, Golf Plus 6485
8 1 7 Removing and installing engine control unit -J623-, Golf 6487
8 1 8 Removing and installing anti-theft engine control unit -J623-, Golf 6488
8 1 9 Removing and installing engine control unit, Eos 6491
8 1 10 Removing and installing anti-theft engine control unit, Eos 6492
9 Lambda probe 6496
9 1 Removing and installing lambda probe 6496
9 1 1 Removing and installing Lambda probe -G39- 6496
9 1 2 Removing and installing lambda probe after catalytic converter -G130-, engine code CJAA 6497
26 – Exhaust system 6500
1 Exhaust pipes and silencers 6500
1 1 Assembly overview – silencers 6500
1 1 1 Assembly overview – silencer, vehicles with front-wheel drive, Passat, Passat CC 6500
1 1 2 Assembly overview – silencer, vehicles with four-wheel drive, Passat, Passat CC 6502
1 1 3 Assembly overview – silencer, vehicles with SCR system, Passat, Passat CC 6503
1 1 4 Assembly overview – silencers, Tiguan 6504
1 1 5 Assembly overview – silencer, vehicles with front-wheel drive, Eos, Golf, Scirocco, Golf Plus 6505
1 1 6 Assembly overview – silencer, vehicles with four-wheel drive, Golf 6506
1 1 7 Assembly overview – silencer, engine code CJAA 6507
1 2 Separating exhaust pipes from silencers 6508
1 2 1 Separating and joining exhaust system, engine code CJAA 6508
1 2 2 Separating exhaust pipe/silencer, engine codes CBAA, CBBB, CBAB, CBBA, CBDB, CBDC, CBAC, CBDA 6509
1 3 Aligning exhaust system free of stress 6510
1 3 1 Aligning exhaust system free of stress, engine codes CBAA, CBBB, CBAB, CBBA, CBDB, CBDC, CBAC, CBDA 6510
1 3 2 Aligning exhaust system free of stress, engine code CJAA 6511
1 4 Check exhaust system for leaks 6512
1 5 Installation position of clamp 6513
2 Exhaust gas cleaning 6515
2 1 Assembly overview – emission control 6515
2 1 1 Assembly overview – front exhaust pipe with particulate filter, engine codes CBAA, CBBB, CBAB, CBBA, CBDB, CBDC, CBAC, CBDA 6515
2 1 2 Assembly overview – particulate filter with NOx storage catalytic converter, engine code CJAA 6518
2 1 3 Assembly overview – exhaust flap control unit -J883- with SCR catalytic converter 6521
2 1 5 Routing cables/lines of exhaust system components, engine code CJAA 6523
2 2 Removing and installing particulate filter 6525
2 2 1 Removing and installing particulate filter, engine codes CBAA, CBBB, CBAB, CBBA, CBDB, CBDC, CBAC, CBDA 6525
2 2 2 Removing and installing particulate filter, Tiguan with front-wheel drive 6529
2 3 Removing and installing particulate filter with NOx storage catalytic converter 6533
2 3 1 Removing particulate filter with NOx storage catalytic converter 6535
2 3 2 Installing particulate filter with NOx storage catalytic converter 6539
2 4 Removing and installing NOx storage catalytic converter 6541
3 SCR system (selective catalytic reduction) 6543
3 1 Assembly overview – tank for reducing agent 6543
3 2 Draining reducing agent tank 6544
3 3 Removing and installing reducing agent tank 6547
3 4 Assembly overview – delivery module for reducing agent 6549
3 5 Assembly overview – reducing agent delivery line 6551
3 6 Removing and installing reducing agent supply line 6552
3 7 Removing and installing injector for reducing agent 6554
3 8 Removing and installing heater element (heater cup) 6555
4 Exhaust gas recirculation 6560
4 1 Assembly overview – exhaust gas recirculation 6560
4 1 1 Assembly overview – exhaust gas recirculation system, engine codes CBAA, CBBB, CBAB, CBBA, CBDB, CBDC, CBAC, CBDA 6560
4 1 2 Assembly overview – exhaust gas recirculation system, engine code CJAA 6562
4 2 Removing and installing exhaust gas recirculation filter 6563
4 3 Removing and installing exhaust gas recirculation cooler 6565
4 4 Checking exhaust gas recirculation cooler for leaks 6569
4 5 Removing and installing temperature sensor for exhaust gas recirculation 6572
4 6 Cleaning exhaust gas recirculation system 6576
4 6 1 Initiating exhaust gas recirculation system cleaning procedure 6577
4 6 2 Cleaning exhaust gas recirculation valve -N18- and connecting pipe 6581
28 – Glow plug system 6583
1 Glow plug system 6583
1 1 Removing and installing automatic glow period control unit -J179- 6583
1 2 Removing and installing glow plug 6584
1 2 1 Removing and installing glow plugs, engine codes CBAA, CBBB, CBAB, CBBA, CBDB, CBDC, CBAC, CBDA 6584
1 2 2 Removing and installing glow plugs, engine code CJAA 6586
1 3 Removing and installing Hall sender 6591
1 3 1 Vehicles up to 12 2007 6592
1 3 2 Vehicles from 01 08 6593
1 4 Removing and installing engine speed sender 6595
K0059040220 6 cylinder injection engine (direct injection) 6597
00 – Technical data 6603
1 Engine number 6603
2 Engine data 6604
10 – Removing and installing engine 6605
1 Removing and installing engine 6605
1 1 Removing engine 6606
1 2 Securing engine on engine and gearbox support -VAS 6095- 6613
1 3 Installing engine 6614
1 4 Specified torques for assembly mounting 6616
13 – Crankshaft group 6618
1 Dismantling and assembling engine (engine code CDVA, BLV, BWS up to 01 2011) 6618
1 1 Part I 6620
1 2 Part II 6623
1 3 Removing and installing vibration damper (engine codes BWS, CDVA) 6624
1 4 Removing and installing vibration damper (engine code BLV) 6625
1 5 Removing and installing bracket for ancillaries 6627
1 6 Assembly overview – poly V-belt drive 6627
1 7 Removing and installing poly-V belt 6629
1 8 Removing and installing tensioner for poly V-belt 6630
2 Dismantling and assembling engine (engine code CNNA, BWS from 01 2011) 6632
2 1 Part I 6633
2 2 Part II 6635
2 3 Removing and installing vibration damper 6637
2 4 Removing and installing bracket for ancillaries 6637
2 5 Assembly overview – poly V-belt drive 6638
2 6 Removing and installing poly-V belt 6639
2 7 Removing and installing tensioner for poly V-belt 6640
3 Sealing flange and flywheel or drive plate 6642
3 1 Assembly overview – sealing flanges and flywheel 6642
3 2 Assembly overview – sealing flanges and drive plate 6644
3 3 Assembly overview – timing chain covers 6645
3 4 Removing and installing crankshaft seal on gearbox side 6645
3 5 Removing and installing sealing flange on gearbox side 6647
3 6 Removing and installing flywheel 6650
3 7 Removing and installing drive plate 6651
3 8 Renewing crankshaft sealing flange -vibration damper end- (engine code BLV) 6652
3 9 Renewing crankshaft sealing flange -vibration damper end- (engine code BWS, CDVA, CNNA) 6654
4 Assembly overview – crankshaft 6657
4 1 Fitting sender wheel to crankshaft 6658
4 2 Pulling needle bearing out of and driving into crankshaft 6659
4 3 Allocation of main bearing shells 6661
4 3 1 Allocation of main bearing shells, up to and including manufacturing date 23 09 12 6661
4 3 2 Allocation of main bearing shells, from manufacturing date 24 09 12 6663
5 Pistons and conrods 6666
5 1 Assembly overview – pistons and conrods 6666
5 2 Checking pistons, piston rings and cylinder bores 6667
5 2 1 Checking piston ring gap 6667
5 2 2 Checking ring-to-groove clearance 6667
5 2 3 Checking piston 6668
5 2 4 Checking cylinder bores 6668
5 2 5 Removing and installing pistons 6669
5 3 Piston and cylinder dimensions 6671
15 – Cylinder head, valve gear 6672
1 Cylinder head 6672
1 1 Assembly overview – cylinder head 6672
1 2 Removing and installing cylinder head 6675
1 3 Checking valve timing 6683
1 3 1 Checking valve timing (vehicles up to 11/2008) 6683
1 3 2 Checking valve timing (vehicles as of 11/2008) 6686
1 4 Removing and installing camshaft adjuster 6688
1 4 1 Removing and installing camshaft adjuster (vehicles to 11/2008) 6688
1 4 2 Removing and installing camshaft adjuster (vehicles from 11/2008) 6694
1 5 Removing and installing chain drive for oil pump 6700
1 5 1 Removing and installing oil pump drive chain, 1-part sprocket 6700
1 5 2 Removing and installing oil pump drive chain, 2-part sprocket 6706
1 6 Removing and installing camshaft drive timing chain 6711
1 7 Removing and installing chain drive sprocket for high-pressure pump 6714
1 8 Removing and installing cylinder head cover 6715
1 9 Assembly overview – mechanical vacuum pump 6718
1 10 Removing and installing mechanical vacuum pump 6719
1 11 Installing cover oil seals 6721
1 12 Checking compression 6722
2 Valve gear 6725
2 1 Assembly overview – valve gear 6725
2 2 Camshafts, checking axial clearance 6727
2 3 Assembly overview – valve timing housing (engine codes CDVA, BLV, BWS up to 01 2011) 6728
2 4 Assembly overview – valve timing housing (engine codes CNNA, BWS from 01 2011) 6729
2 5 Removing and installing camshaft control valves 6730
2 6 Removing and installing camshafts 6734
2 7 Camshaft identification 6741
2 8 Renewing valve stem seals 6741
2 9 Valve dimensions 6744
2 10 Checking valve guides 6744
2 11 Reworking valve seats 6745
17 – Lubrication 6747
1 Parts of lubrication system 6747
1 1 Engine oil: 6747
1 2 Assembly overview – oil sump, oil pump and oil filter bracket (engine code CDVA, BLV, BWS up to 01 2011) 6748
1 3 Assembly overview – oil sump, oil pump and oil filter bracket (engine code CNNA, BWS from 01 2011) 6750
1 4 Removing and installing oil spray jet 6751
1 5 Removing and installing sump 6752
1 6 Removing and installing oil pump 6754
1 6 1 Removing and installing oil pump, 1-part sprocket 6754
1 6 2 Removing and installing oil pump, 2-part sprocket 6759
1 7 Assembly overview – oil filter housing (engine codes CDVA, BWS up to 01 2011) 6763
1 8 Assembly overview – oil filter housing (engine codes CNNA, BWS from 01 2011) 6765
1 9 Assembly overview – oil filter housing (engine code BLV) 6766
1 10 Checking oil pressure and oil pressure switch (engine code CDVA, BLV, BWS up to 01 2011) 6768
1 11 Checking oil pressure and oil pressure switch (engine code CNNA, BWS from 01 2011) 6770
19 – Cooling 6774
1 Parts of cooling system 6774
1 1 Assembly overview – parts of cooling system, body side 6775
1 2 Assembly overview – cooling system, engine side 6776
1 3 Coolant hose connection diagram 6778
1 4 Draining and adding coolant 6779
1 5 Removing and installing fan mounting with fans 6782
1 6 Removing and installing radiator 6784
1 7 Removing and installing coolant pump 6786
1 8 Removing and installing thermostat 6789
1 9 Checking cooling system for leaks 6791
20 – Fuel supply system 6793
1 Safety precautions and rules for cleanliness 6793
1 1 Safety measures when working on fuel supply 6793
1 2 Releasing pressure in high-pressure area 6794
1 3 Rules for cleanliness 6795
2 Fuel tank (Passat CC with front-wheel drive) 6796
2 1 Assembly overview – fuel tank 6796
2 2 Emptying fuel tank 6798
2 2 1 Emptying fuel tank when fuel pump is intact 6798
2 2 2 Emptying fuel tank if it is more than 3/4 full 6800
2 2 3 Emptying fuel tank if it is less than 3/4 full 6801
2 3 Removing and installing fuel tank 6802
2 3 1 Removing fuel tank 6803
2 3 2 Installing fuel tank 6805
2 4 Removing and installing fuel gauge sender -G- 6805
3 Fuel tank (Passat CC with four-wheel drive) 6807
3 1 Assembly overview – fuel tank (engine code BWS) 6807
3 2 Assembly overview – fuel tank (engine code BLV, CNNA) 6810
3 3 Emptying fuel tank 6811
3 3 1 Emptying fuel tank when fuel pump is intact 6812
3 3 2 Emptying fuel tank if it is more than 3/4 full 6814
3 3 3 Emptying fuel tank if it is less than 3/4 full 6814
3 4 Removing and installing fuel tank 6817
3 4 1 Removing fuel tank 6817
3 4 2 Installing fuel tank 6821
3 5 Removing and installing fuel gauge sender 2 -G169- 6822
3 6 Removing and installing suction-jet pump 6825
4 Repairing fuel supply (Passat CC) 6827
4 1 Removing and installing fuel delivery unit 6827
4 1 1 Removing fuel pump unit 6828
4 1 2 Installing fuel pump unit 6830
4 2 Removing and installing fuel gauge sender -G- 6832
4 3 Checking fuel pump 6833
4 3 1 Checking function and voltage supply 6834
4 3 2 Checking fuel pressure 6837
4 3 3 Checking holding pressure 6838
4 3 4 Checking fuel delivery rate 6839
4 3 5 Checking current consumption 6842
5 Activated charcoal filter system (Passat CC with engine code BLV, CNNA) 6844
5 1 Function 6844
5 2 Assembly overview – activated charcoal filter system 6844
5 3 Checking fuel system for leaks 6845
5 3 1 Leak detection in fuel system 6849
5 3 2 Schematic overview of activated charcoal filter system 6850
5 3 3 Checking vacuum supply of fuel system diagnostic pump -V144- 6851
6 Activated charcoal filter system (Passat CC with engine code BWS) 6853
6 1 Function 6853
6 2 Assembly overview – activated charcoal filter system 6853
6 3 Checking fuel tank breather 6854
7 Fuel tank (Eos) 6856
7 1 Assembly overview – fuel tank 6856
7 2 Emptying fuel tank 6858
7 2 1 Emptying fuel tank when fuel pump is intact 6859
7 2 2 Emptying fuel tank if it is more than 3/4 full 6860
7 2 3 Emptying fuel tank if it is less than 3/4 full 6861
7 3 Removing and installing fuel tank 6862
7 3 1 Removing 6863
7 3 2 Installing fuel tank 6864
8 Repairing fuel supply (Eos) 6866
8 1 Removing and installing fuel delivery unit 6866
8 2 Removing and installing fuel gauge sender -G- 6869
8 3 Checking fuel pump -G6- 6870
8 3 1 Checking function and voltage supply 6871
8 3 2 Checking fuel pressure 6874
8 3 3 Checking holding pressure 6876
8 3 4 Checking fuel delivery rate 6877
8 3 5 Checking current consumption 6880
9 Activated charcoal filter system (Eos) 6882
9 1 Assembly overview – activated charcoal filter system 6882
9 2 Checking fuel tank breather 6882
10 Electronic power control (EPC) 6885
10 1 Assembly overview – accelerator module 6885
10 2 Removing and installing accelerator pedal module 6885
24 – Mixture preparation – injection 6888
1 Injection system 6888
1 1 General notes on the injection system 6889
1 2 Rules for cleanliness 6889
1 3 Technical data 6889
1 4 Assembly overview – intake manifold 6890
1 5 Assembly overview – fuel rail with high-pressure pump and injectors 6891
1 6 Assembly overview – air filter 6894
1 7 Checking intake air preheating 6895
1 8 Removing and installing intake manifold upper part 6895
1 9 Removing and installing lower part of intake manifold with fuel rail 6898
1 10 Removing and installing high-pressure pump 6902
1 11 Checking fuel pressure sender -G247- 6905
1 12 Removing and installing injectors 6908
1 13 Renewing seals on injectors 6912
2 Engine control unit -J623- (Passat) 6916
2 1 Removing and installing engine (motor) control unit -J623- 6916
2 2 Removing and installing anti-theft engine control unit -J623- 6917
3 Engine control unit -J623- (Eos) 6920
3 1 Removing and installing engine control unit 6920
3 2 Removing and installing anti-theft engine control unit 6921
26 – Exhaust system 6925
1 Exhaust manifold, front exhaust pipes, catalytic converters and Lambda probes (engine codes BWS, CDVA) 6925
1 1 Assembly overview – exhaust manifold, front exhaust pipe with catalytic converters and front silencers 6927
1 2 Removing and installing exhaust manifold 6928
1 3 Removing and installing Lambda probe -G39- and Lambda probe 2 -G108- 6929
1 4 Removing and installing front exhaust pipes with catalytic converters and front silencers 6931
2 Exhaust manifolds, front exhaust pipes, catalytic converters and Lambda probes (engine code CNNA, BLV) 6934
2 1 Assembly overview – exhaust manifold, front exhaust pipe with catalytic converters and front silencers 6936
2 2 Removing and installing exhaust manifold 6937
2 3 Removing and installing Lambda probe -G39- and Lambda probe 2 -G108- 6938
2 4 Removing and installing front exhaust pipes with catalytic converters and front silencers (vehicles with four-wheel drive) 6940
2 5 Removing and installing front exhaust pipes with catalytic converters and front silencers (vehicles with front-wheel drive) 6942
3 Silencers with mountings (vehicles with four-wheel drive) 6945
3 1 Assembly overview – silencers with mountings 6945
3 1 1 Separating centre and rear silencers 6946
4 Silencers with mountings (Passat CC with front-wheel drive) 6949
4 1 Assembly overview – silencers with mountings 6949
4 1 1 Separating centre and rear silencers 6950
5 Silencer with mountings (Eos) 6952
5 1 Assembly overview – silencers with mountings 6952
5 2 Clamps 6953
5 3 Separating centre and rear silencers 6953
5 4 Aligning exhaust system free of stress 6954
28 – Ignition system 6956
1 Ignition system 6956
1 1 General notes on ignition system 6956
1 2 Assembly overview – ignition system 6956
1 3 Test data, spark plugs 6958
1 4 Removing and installing ignition coils with output stage 6958
K0059100120 4 cylinder injection engine (2 0 l engine direct injection) 6961
00 – Technical data 6967
1 Technical data 6967
1 1 Engine number 6967
1 2 Engine data 6967
10 – Removing and installing engine 6968
1 Removing and installing engine 6968
1 1 Removing engine 6968
1 1 1 Securing engine to assembly stand 6974
1 2 Installing engine 6975
13 – Crankshaft group 6979
1 Dismantling and assembling engine 6979
1 1 Assembly overview – dismantling and assembling engine 6980
1 1 1 Part I 6981
1 1 2 Part II 6982
1 1 3 Part III 6983
1 2 Removing and installing poly V-belt 6984
2 Sealing flange and flywheel 6986
2 1 Assembly overview – sealing flange 6986
2 2 Renewing crankshaft oil seal – pulley end 6987
2 2 1 Removing seal 6987
2 2 2 Installing seal 6988
2 3 Removing and installing sealing flange – pulley end 6990
2 3 1 Removing sealing flange 6990
2 3 2 Installing sealing flange 6991
2 4 Removing and installing crankshaft sealing flange – flywheel end 6992
2 5 Removing and installing flywheel 6993
3 Crankshaft 6995
3 1 Assembly overview – crankshaft 6995
3 1 1 Removing and installing sender wheel 6996
3 2 Crankshaft dimensions 6996
3 2 1 Identification of upper crankshaft bearing 6996
4 Pistons and conrods 6998
4 1 Assembly overview – pistons and conrods 6998
4 1 1 Bearing shells – installation position 6999
4 2 Checking pistons, piston rings and cylinder bores 6999
4 3 Piston and cylinder dimensions 7001
15 – Cylinder head, valve gear 7002
1 Cylinder head 7002
1 1 Assembly overview – cylinder head 7003
1 2 Removing and installing cylinder head cover 7004
1 3 Removing and installing cylinder head 7006
1 3 1 Removing cylinder head 7006
1 3 2 Installing cylinder head 7009
1 4 Removing and installing toothed belt 7010
1 4 1 Removing toothed belt 7011
1 4 2 Installing toothed belt 7015
1 5 Checking compression 7018
2 Valve gear 7020
2 1 Assembly overview – valve gear 7021
2 2 Valve dimensions 7022
2 3 Checking valve guides 7022
2 4 Renewing valve stem seals 7023
2 4 1 Removing valve stem oil seals 7024
2 4 2 Installing valve stem oil seals 7026
2 5 Renewing exhaust camshaft oil seal 7028
2 5 1 Removing seal 7028
2 5 2 Installing seal 7029
2 6 Removing and installing camshaft adjuster 7030
2 6 1 Removing camshaft adjuster 7031
2 6 2 Installing camshaft adjuster 7032
2 7 Removing and installing inlet camshaft control valve 1 -N205- 7033
2 8 Removing and installing camshafts 7034
2 8 1 Removing camshafts 7035
2 8 2 Installing camshafts 7036
17 – Lubrication 7038
1 Parts of lubrication system 7038
1 1 Engine oil 7038
1 2 Assembly overview – parts of lubrication system 7039
1 2 1 Part 1 7040
1 2 2 Part 2 7041
1 2 3 Part 3 Oil filter bracket 7042
1 3 Draining oil filter housing 7043
1 4 Removing and installing sump 7044
1 5 Removing and installing oil pump with balancer shaft gear assembly 7046
1 5 1 Removing oil pump with balancer shaft gear assembly 7047
1 5 2 Installing and adjusting oil pump with balancer shaft gear assembly 7048
1 5 3 Pretensioning chain tensioner 7050
1 6 Removing and installing oil filter bracket 7050
1 7 Checking oil pressure and oil pressure switch 7052
19 – Cooling 7054
1 Parts of cooling system 7054
1 1 Assembly overview – parts of cooling system, engine side 7055
1 2 Assembly overview – parts of cooling system, body side 7056
1 3 Coolant hose schematic diagram 7057
1 4 Draining and filling coolant 7058
1 4 1 Draining coolant 7058
1 4 2 Filling with coolant 7059
1 5 Removing and installing coolant pump 7061
1 6 Removing and installing coolant pipe 7062
1 7 Removing and installing coolant distributor housing with thermostat 7063
1 8 Removing and installing radiator fan -V7- and radiator fan 2 -V177- 7064
1 9 Removing and installing radiator 7066
1 10 Checking cooling system for leaks 7067
20 – Fuel supply system 7069
1 Safety precautions 7069
1 1 Safety precautions when working on fuel supply system 7069
1 2 Releasing pressure in high-pressure section 7069
2 Fuel tank 7071
2 1 Rules for cleanliness 7071
2 2 Assembly overview – fuel tank 7072
2 3 Emptying fuel tank 7073
2 3 1 Emptying fuel tank if it is more than 3/4 full 7074
2 3 2 Emptying fuel tank if it is less than 3/4 full 7074
2 4 Removing and installing fuel tank 7075
2 4 1 Removing 7076
2 4 2 Installing 7077
3 Repairing fuel supply system 7079
3 1 Safety precautions when working on fuel supply system 7079
3 2 Rules for cleanliness 7080
3 3 Removing and installing fuel delivery unit 7080
3 3 1 Removing 7080
3 3 2 Installing 7081
3 4 Removing and installing fuel gauge sender -G- 7082
3 5 Checking fuel pump 7083
3 5 1 Checking function and voltage supply 7084
3 5 2 Checking fuel pressure 7086
3 5 3 Checking residual pressure 7087
3 5 4 Checking delivery rate 7088
3 5 5 Checking current consumption 7090
3 6 Assembly overview – high-pressure pump 7092
3 7 Removing and installing high-pressure pump 7092
4 Electronic power control (EPC) 7095
4 1 Function of EPC system 7095
4 2 Assembly overview – accelerator pedal module 7096
4 3 Removing and installing accelerator pedal module 7096
5 Activated charcoal filter system 7098
5 1 Function 7098
5 2 Assembly overview – activated charcoal filter system 7099
5 3 Checking fuel tank breather 7099
24 – Mixture preparation – injection 7102
1 Injection system 7102
1 1 General notes on injection 7102
1 2 Safety precautions 7103
1 3 Rules for cleanliness 7103
1 4 Technical data 7104
1 5 Assembly overview – intake manifold 7105
1 5 1 Assembly overview – suction-jet pump 7106
1 6 Assembly overview – fuel rail with intake manifold flap motor -V157- 7107
1 7 Assembly overview – air filter 7108
1 8 Removing and installing intake manifold 7108
1 9 Removing and installing fuel rail with intake manifold flaps 7110
1 10 Removing and installing injectors 7112
1 11 Renewing Teflon seal on injector 7113
1 12 Cleaning throttle valve module -J338- 7116
2 Checking components 7117
2 1 Checking intake manifold change-over 7117
3 Engine control unit 7119
3 1 Removing and installing engine control unit 7119
3 2 Removing and installing anti-theft engine control unit 7119
3 2 1 Removing 7120
3 2 2 Installing 7121
26 – Exhaust system 7122
1 Parts of the exhaust system 7122
1 1 Assembly overview – exhaust manifold with catalytic converter, engine code BVY 7123
1 2 Assembly overview – exhaust system, engine code BVY 7124
1 3 Assembly overview – exhaust manifold, engine code BVZ 7126
1 4 Assembly overview – exhaust system, engine code BVZ 7127
1 5 Separating centre and rear silencers 7128
1 6 Aligning exhaust system free of stress 7129
1 7 Removing and installing front exhaust pipe with catalytic converter 7130
1 8 Removing and installing exhaust manifold 7131
1 8 1 Removing exhaust manifold 7132
1 8 2 Installing exhaust manifold 7134
2 Exhaust gas recirculation system, engine code BVY 7136
2 1 Assembly overview – exhaust gas recirculation system 7137
28 – Ignition system 7138
1 Repairing ignition system 7138
1 1 General notes on ignition system 7138
1 2 Safety precautions 7138
1 3 Assembly overview – ignition system 7139
1 4 Removing and installing ignition coils with output stage 7139
1 5 Spark plug test data 7140
K0059100220 4 cylinder injection engine (2 0 l engine turbocharger) 7142
00 – Technical data 7148
1 Technical data 7148
1 1 Engine number 7148
1 2 Engine data 7148
10 – Removing and installing engine 7149
1 Removing and installing engine 7149
1 1 Removing engine 7149
1 1 1 Securing engine to assembly stand 7156
1 2 Installing engine 7157
13 – Crankshaft group 7161
1 Dismantling and assembling engine 7161
1 1 Assembly overview 7162
1 1 1 Part I 7163
1 1 2 Part II 7164
1 1 3 Part III 7165
1 2 Removing and installing poly-V-belt 7166
2 Sealing flange and flywheel 7168
2 1 Assembly overview – sealing flange 7168
2 2 Renewing crankshaft oil seal – belt pulley end 7169
2 2 1 Removing seal 7169
2 2 2 Installing seal 7170
2 3 Removing and installing sealing flange – pulley end 7172
2 3 1 Removing sealing flange 7172
2 3 2 Installing sealing flange 7173
2 4 Removing and installing crankshaft sealing flange – flywheel end 7174
2 5 Removing and installing flywheel 7175
3 Crankshaft 7177
3 1 Assembly overview – crankshaft 7178
3 1 1 Removing and installing sender wheel 7179
3 2 Pulling needle bearing out of and driving into crankshaft 7179
3 3 Crankshaft dimensions 7180
3 3 1 Identification of upper crankshaft bearing 7181
4 Pistons and conrods 7182
4 1 Assembly overview – pistons and conrods 7182
4 1 1 Bearing shells – installation position 7183
4 2 Checking pistons, piston rings and cylinder bores 7183
4 3 Piston and cylinder dimensions 7185
15 – Cylinder head, valve gear 7186
1 Cylinder head 7186
1 1 Assembly overview – cylinder head 7187
1 2 Removing and installing cylinder head cover 7188
1 3 Removing and installing cylinder head 7190
1 3 1 Removing cylinder head 7191
1 3 2 Installing cylinder head 7194
1 4 Removing and installing toothed belt 7195
1 4 1 Removing toothed belt 7196
1 4 2 Installing toothed belt 7201
1 5 Checking compression 7204
2 Valve gear 7206
2 1 Assembly overview – valve gear 7207
2 2 Valve dimensions 7208
2 3 Checking valve guides 7208
2 4 Renewing valve stem oil seals 7209
2 4 1 Removing valve stem oil seals 7209
2 4 2 Installing valve stem oil seals 7211
2 5 Renewing exhaust camshaft oil seal 7213
2 5 1 Removing seal 7213
2 5 2 Installing seal 7214
2 6 Removing and installing camshaft adjuster 7215
2 6 1 Removing camshaft adjuster 7216
2 6 2 Installing camshaft tensioner 7217
2 7 Removing and installing inlet camshaft control valve 1 -N205- 7219
2 8 Removing and installing camshafts 7220
2 8 1 Removing camshafts 7221
2 8 2 Installing camshafts 7222
17 – Lubrication 7224
1 Parts of lubrication system 7224
1 1 Engine oil 7224
1 2 Assembly overview – parts of lubrication system 7225
1 2 1 Part 1 7226
1 2 2 Part 2 7227
1 2 3 Part 3 Oil filter bracket 7228
1 3 Draining oil filter housing 7229
1 4 Removing and installing sump 7230
1 5 Removing and installing oil pump with balancer shaft gear assembly 7232
1 5 1 Removing oil pump with balancer shaft gear assembly 7233
1 5 2 Removing and installing oil pump with balancer shaft gear assembly 7234
1 5 3 Pretensioning chain tensioner 7235
1 6 Removing and installing oil filter bracket 7236
1 7 Checking oil pressure and oil pressure switch 7237
19 – Cooling 7239
1 Parts of cooling system 7239
1 1 Assembly overview – parts of cooling system, engine side 7240
1 2 Assembly overview – coolant circulation pump -V50-, engine code BWA 7241
1 3 Assembly overview – coolant circulation pump -V50-, engine code BPY 7242
1 4 Assembly overview – parts of cooling system, body side 7243
1 5 Coolant hose schematic diagram, engine code BWA 7244
1 6 Coolant hose schematic diagram, engine code BPY 7245
1 7 Bypass thermostat 7246
1 8 Draining and filling coolant 7247
1 8 1 Draining coolant 7247
1 8 2 Filling with coolant 7248
1 9 Removing and installing coolant pump 7250
1 9 1 Removing coolant pump 7251
1 9 2 Installing coolant pump 7251
1 9 3 Removing and installing coolant pipes 7251
1 10 Removing and installing coolant thermostat housing with thermostat 7253
1 11 Removing and installing radiator fan -V7- and radiator fan 2 -V177- 7254
1 12 Removing and installing radiator 7255
1 13 Checking cooling system for leaks 7257
20 – Fuel supply system 7259
1 Safety precautions 7259
1 1 Safety precautions when working on fuel supply system and ignition system 7259
1 2 Reducing pressure in high pressure area 7260
2 Fuel tank 7262
2 1 Rules for cleanliness 7262
2 2 Assembly overview – fuel tank, engine code BPY 7263
2 3 Assembly overview – fuel tank, engine code BWA 7265
2 4 Emptying fuel tank 7266
2 4 1 Emptying fuel tank if it is more than 3/4 full 7267
2 4 2 Emptying fuel tank if it is less than 3/4 full 7268
2 5 Removing and installing fuel tank 7269
2 5 1 Removing 7269
2 5 2 Installing 7271
3 Repairing fuel supply system 7272
3 1 Safety precautions when working on fuel supply system 7272
3 2 Rules for cleanliness 7273
3 3 Removing and installing fuel delivery unit 7273
3 3 1 Removing 7273
3 3 2 Installing 7274
3 4 Removing and installing fuel gauge sender -G- 7275
3 5 Checking fuel pump 7276
3 5 1 Checking function and voltage supply 7277
3 5 2 Checking fuel pressure 7279
3 5 3 Checking residual pressure 7280
3 5 4 Checking delivery rate 7281
3 5 5 Checking current draw 7283
3 6 Assembly overview – high-pressure pump 7284
3 7 Removing and installing high-pressure pump 7285
4 Electronic power control (EPC) 7287
4 1 Function of EPC system 7287
4 2 Assembly overview – accelerator module 7288
4 3 Removing and installing accelerator module 7288
5 Activated charcoal filter system, engine code BWA 7290
5 1 Function 7290
5 2 Assembly overview – activated charcoal filter system 7291
5 3 Checking fuel tank breather 7291
6 Activated charcoal filter system, engine code BPY 7294
6 1 Schematic diagram of activated charcoal filter system 7294
6 2 Assembly overview – activated charcoal filter system 7296
6 3 Removing and installing activated charcoal filter 7296
6 4 Removing and installing fuel system diagnostic pump -V144- 7298
6 5 Checking fuel system for leaks 7299
21 – Turbocharging/supercharging 7302
1 Turbocharger 7302
1 1 Rules for cleanliness 7302
1 2 Assembly overview – turbocharger 7303
1 2 1 Part I 7304
1 2 2 Part II 7305
1 2 3 Part III 7306
1 3 Removing and installing turbocharger 7307
1 4 Checking turbocharger vacuum unit 7314
1 5 Removing and installing turbocharger vacuum unit 7315
1 6 Adjusting turbocharger vacuum unit 7316
2 Charge air system 7319
2 1 Assembly overview – charge air cooling 7319
2 2 Schematic diagram of turbocharging system 7320
2 3 Checking charge air system for leaks 7320
24 – Mixture preparation – injection 7323
1 Injection system 7323
1 1 General notes on injection 7323
1 2 Rules for cleanliness 7324
1 3 Technical data 7324
1 4 Assembly overview – intake manifold 7325
1 5 Assembly overview – fuel rail 7326
1 6 Assembly overview – air filter/engine cover 7327
1 7 Removing and dismantling air filter/engine cover 7327
1 8 Removing and installing throttle valve module -J338- 7328
1 9 Removing and installing intake manifold 7329
1 9 1 Removing and installing fuel rail 7331
1 10 Removing and installing fuel pressure sender -G247- 7332
1 11 Removing and installing injectors 7334
1 12 Renewing Teflon seal on injector 7335
2 Checking components 7338
2 1 Checking double non-return valve 7338
3 Engine control unit 7339
3 1 Removing and installing engine control unit 7339
3 2 Removing and installing anti-theft engine control unit 7339
3 2 1 Removing 7340
3 2 2 Installing 7342
26 – Exhaust system 7343
1 Removing and installing parts of exhaust system 7343
1 1 Assembly overview – exhaust system 7343
1 2 Separating middle and rear silencers 7345
1 3 Removing and installing front exhaust pipe with catalytic converter 7346
1 4 Aligning exhaust system stress free 7348
28 – Ignition system 7349
1 Repairing ignition system 7349
1 1 General notes on ignition system 7349
1 2 Assembly overview – ignition system 7350
1 3 Removing and installing ignition coils with output stage 7350
1 4 Spark plug test data 7351
K0059100320 General body repairs interior 7353
68 – Interior equipment 7359
1 Interior mirror 7359
1 1 Tools 7359
1 1 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 7359
1 2 Automatic anti-dazzle interior mirror 7359
1 3 Removing and installing interior mirror with rain sensor 7360
1 3 1 Removing 7360
1 3 2 Installing 7360
1 4 Bonding on retaining plate for interior mirror with rain sensor 7361
1 4 1 Preparing windscreen 7361
1 4 2 Preparing detached or new mirror base 7361
1 4 3 Bonding mirror base 7361
1 4 4 Cleaning and removing excessive adhesive 7361
1 4 5 Installing rain sensor and mirror 7361
1 5 Removing and installing interior mirror 7361
1 5 1 Removing 7361
1 5 2 Installing 7362
1 6 Bonding on retaining plate for interior mirror without rain sensor 7362
1 6 1 Materials: 7362
2 Compartments, covers and trims 7364
2 1 Tools 7364
2 1 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 7364
2 2 Removing and installing basic version centre console 7364
2 2 1 Removing 7364
2 3 Removing and installing centre console (Highline version) 7368
2 3 1 Removing 7368
2 3 2 Installing 7376
2 4 Removing and installing cup holder in Highline centre console 7376
2 4 1 Removing 7376
2 4 2 Installing 7377
2 5 Repairing cup holder in centre console, Highline 7377
2 5 1 Checking for possible repair 7377
2 5 2 Repairing cup holder 7379
2 5 3 Installing cup holder 7380
2 6 Removing and installing dash panel middle trim 7380
2 6 1 Removing 7380
2 6 2 Installing 7381
2 7 Removing and installing dash panel end trims 7381
2 7 1 Removing 7381
2 7 2 Installing 7382
2 8 Removing and installing steering column trim 7382
2 8 1 Removing 7382
2 8 2 Installing 7383
2 9 Removing and installing left trim panel on driver side 7383
2 9 1 Removing 7383
2 9 2 Installing 7384
2 10 Removing and installing right trim panel on driver side 7385
2 10 1 Removing 7385
2 10 2 Installing 7386
2 11 Removing and installing centre cover 7387
2 11 1 Removing 7387
2 11 2 Installing 7387
2 12 Removing and installing glove compartment 7388
2 12 1 Removing 7388
2 12 2 Installing 7389
2 13 Removing and installing glove compartment lock cylinder 7389
2 13 1 Removing 7389
2 13 2 Installing 7390
2 14 Removing and installing footwell cover on driver side 7390
2 14 1 Removing 7390
2 14 2 Installing 7391
2 15 Removing and installing dash panel decorative trims 7391
2 15 1 Removing 7391
2 15 2 Installing 7392
2 16 Removing and installing sun visor 7392
2 16 1 Removing 7392
2 16 2 Installing 7394
3 Sill panel mouldings 7395
3 1 Removing and installing sill panel mouldings 7395
3 1 1 Removing 7395
3 1 2 Installing 7396
4 Repairing windbreak 7397
4 1 Tools 7397
4 1 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 7397
4 2 Renewing broken-off bar 7397
4 2 1 Removing 7397
4 2 2 Installing 7398
4 3 Renewing locking pin 7399
4 3 1 Removing locking pin 7399
4 3 2 Installing locking pin 7399
4 4 Renewing middle joint 7400
4 4 1 Removing 7400
4 4 2 Installing 7400
69 – Passenger protection 7401
1 Seat belts 7401
1 1 Safety regulations for belt tensioners 7401
1 2 Disposal of belt tensioner units 7401
1 3 Removing and installing front seat belts 7401
1 3 1 Assembly overview 7401
1 3 2 Removing 7402
1 3 3 Installing 7403
1 4 Removing and installing front belt buckle 7403
1 4 1 Removing 7403
1 4 2 Installing 7405
1 5 Removing and installing rear seat belts 7405
1 5 1 Removing 7405
1 5 2 Installing 7406
1 6 Removing and installing rear belt buckles 7406
1 6 1 Removing 7406
1 6 2 Installing 7407
1 7 Removing and installing rear seat belt end anchors 7407
1 7 1 Removing 7407
1 7 2 Installing 7407
2 Inspecting seat belts 7408
2 1 Points to check 7408
2 1 1 Checking belt webbing 7408
2 1 2 Checking inertia reel (locking mechanism) 7409
2 1 3 Visually checking belt buckle 7410
2 1 4 Checking operation of belt buckle 7410
2 1 5 Checking belt guide fittings and latch plates 7410
2 1 6 Checking securing parts and anchorage points 7410
3 Checking child seat anchors (ISOFIX) after an accident 7411
3 1 Points to check 7411
4 Roll-over bar 7412
4 1 Safety regulations and notes for working on the roll-over bar 7412
4 2 Removing and installing headrest cover 7412
4 2 1 Removing 7412
4 2 2 Installing 7413
4 3 Removing and installing roll-over bar trim 7413
4 3 1 Removing 7413
4 3 2 Installing 7414
4 4 Removing and installing roll-over bar trim support 7414
4 4 1 Removing 7414
4 4 2 Installing 7415
4 5 Removing and installing roll-over bar 7416
4 5 1 Removing 7416
4 5 2 Installing 7417
4 6 Retracting the roll-over bar 7417
5 Airbag 7419
5 1 Tools 7419
5 1 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 7419
5 2 Overview of locations – airbag systems 7420
5 3 Safety precautions when working on airbag 7421
5 3 1 Disposal of airbag units 7422
5 3 2 Deactivating the airbag 7422
5 4 Renewing airbag units following an accident 7422
5 4 1 Accident involving triggering of airbag 7422
5 4 2 Accident not involving triggering of airbag 7423
5 5 Removing and installing airbag control unit -J234- 7423
5 5 1 Removing 7423
5 5 2 Installing 7425
5 6 Removing and installing driver airbag unit 7426
5 6 1 Removing 7426
5 6 2 Installing 7428
5 7 Removing and installing return spring with slip ring 7429
5 8 Removing and installing front passenger airbag unit 7430
5 8 1 Removing 7430
5 8 2 Installing 7431
5 9 Removing and installing side airbags on driver and front passenger sides 7434
5 9 1 Removing 7435
5 9 2 Installing 7436
5 10 Adapting components 7437
6 Seat occupied sensor, front passenger side 7438
6 1 Tools 7438
6 2 Removing and installing seat occupied sensor, front passenger side -G128- 7438
6 2 1 Removing 7438
6 2 2 Installing 7440
7 Seat occupied recognition (USA) 7443
7 1 Safety precautions for when working on seat occupied recognition 7443
7 2 Procedure after an accident when belt tensioner and/or airbag was triggered 7443
7 3 Assembly overview – seat occupied recognition (USA) 7444
7 4 Components of repair kit for seat occupied recognition 7444
7 5 Removing components of seat occupied recognition (vehicles with manually operated seats) 7445
7 6 Installing repair kit for seat occupied recognition (vehicles with manually adjusted seats) 7447
7 7 Removing components of seat occupied recognition (vehicles with electrically operated seats) 7448
7 8 Installing repair kit for seat occupied recognition (vehicles with electrically operated seats) 7451
7 9 Importers reporting obligation 7452
8 Crash sensors 7453
8 1 Removing and installing front door crash sensors 7453
8 1 1 Removing 7453
8 1 2 Installing 7453
70 – Trim, insulation 7454
1 Dash panel 7454
1 1 Tools 7454
1 1 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 7454
1 2 Removing and installing dash panel 7454
1 2 1 Removing 7454
1 2 2 Installing 7459
1 3 Removing and installing assembly carrier, left-hand drive vehicle 7459
1 3 1 Removing 7459
1 3 2 Installing 7465
2 Door and side trims 7466
2 1 Tools 7466
2 1 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 7466
2 2 Removing and installing door trim on driver side 7467
2 2 1 Removing 7467
2 2 2 Installing 7471
2 3 Removing and installing door trim on front passenger side 7472
2 3 1 Removing 7472
2 3 2 Installing 7475
2 4 Removing and installing door trim cover 7476
2 4 1 Removing 7476
2 4 2 Installing 7477
2 5 Removing and installing side trim 7477
2 5 1 Removing 7477
2 5 2 Installing 7478
3 Pillar trims 7480
3 1 Removing and installing upper trim for A-pillar 7480
3 1 1 Removing 7480
3 1 2 Installing 7481
3 2 Removing and installing middle trim for A-pillar 7481
3 2 1 Removing 7481
3 2 2 Installing 7482
3 3 Removing and installing lower trim for A-pillar 7482
3 3 1 Removing 7482
3 3 2 Installing 7483
4 Rear lid trim 7485
4 1 Tools 7485
4 1 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 7485
4 2 Removing and installing rear lid trim 7485
4 2 1 Removing 7485
4 2 2 Installing 7486
5 Load and luggage compartment trims 7488
5 1 Tools 7488
5 1 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 7488
5 2 Removing and installing lock carrier cover 7488
5 2 1 Removing 7488
5 2 2 Installing 7489
5 3 Removing and installing luggage compartment cover 7489
5 3 1 Removing 7489
5 3 2 Installing 7490
5 4 Removing and installing battery covers (6-cylinder petrol engine) 7490
5 4 1 Removing 7490
5 4 2 Installing 7491
5 5 Removing and installing luggage and load compartment right side trim 7491
5 5 1 Removing 7491
5 5 2 Installing 7492
5 6 Removing and installing luggage and load compartment left side trim 7493
5 6 1 Removing 7493
5 6 2 Installing 7494
5 7 Removing and installing main bearing cover cap 7494
5 7 1 Removing 7494
5 7 2 Installing 7495
5 8 Removing and installing back panel trim 7495
5 8 1 Removing 7495
5 8 2 Installing 7496
6 Roof cross member 7498
6 1 Removing and installing lower roof cross member trim 7498
6 1 1 Removing 7498
6 1 2 Installing 7499
6 2 Removing trim from upper corner of windscreen and installing 7499
6 2 1 Removing 7499
6 2 2 Installing 7499
72 – Seat frames 7501
1 Front seats 7501
1 1 Tools 7501
1 2 Removing and installing front seat 7502
1 2 1 Removing 7502
1 2 2 Installing 7504
1 3 Removing and installing trim on seat, on sill panel side 7506
1 3 1 Removing 7506
1 3 2 Installing 7507
1 4 Removing and installing seat drawer mounting 7507
1 4 1 Removing 7508
1 4 2 Installing 7508
1 5 Removing and installing trims of electrically adjustable seat, on sill panel side 7509
1 5 1 Removing 7509
1 5 2 Installing 7510
1 6 Removing and installing seat drawer mounting 7510
1 6 1 Removing 7510
1 6 2 Installing 7511
1 7 Removing and installing front seat bar and operating lever 7511
1 7 1 Removing 7511
1 7 2 Installing 7512
1 8 Removing and installing bar and operating lever on electrically adjustable seat 7512
1 8 1 Removing 7512
1 8 2 Installing 7513
1 9 Removing and installing trim on seat, on tunnel side 7513
1 9 1 Removing 7513
1 9 2 Installing 7515
1 10 Removing and installing front seat backrest 7515
1 10 1 Removing 7515
1 10 2 Installing 7516
1 11 Removing and installing backrest release Bowden cable 7517
1 11 1 Removing 7517
1 11 2 Installing 7518
1 12 Removing and installing manually adjustable lumbar support frame 7518
1 12 1 Removing 7519
1 12 2 Installing 7520
1 13 Removing and installing Easy Entry unit Bowden cable 7520
1 13 1 Removing 7520
1 13 2 Installing 7521
1 14 Removing and installing seat adjustment switch in the backrest 7521
1 14 1 Removing 7521
1 14 2 Installing 7522
1 15 Removing and installing electric longitudinal seat adjustment 7522
1 15 1 Removing 7522
1 15 2 Installing 7523
1 16 Removing and installing seat pan on electrically adjustable seat 7524
1 16 1 Removing 7524
1 16 2 Installing 7525
1 17 Removing and installing rake adjustment on electrically adjustable seat 7526
1 17 1 Removing 7526
1 17 2 Installing 7527
1 18 Removing and installing height adjustment on electrically adjustable seat 7527
1 18 1 Removing 7528
1 18 2 Installing 7529
1 19 Removing and installing lumbar support on electrically adjustable seat 7529
1 19 1 Removing 7529
1 19 2 Installing 7530
1 20 Removing and installing drive for (electric) backrest adjustment 7531
2 Rear seats 7532
2 1 Tools 7532
2 1 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 7532
2 2 Removing and installing rear seat 7532
2 2 1 Removing 7532
2 2 2 Installing 7533
2 3 Removing and installing backrest 7534
2 3 1 Removing 7534
2 3 2 Installing 7535
2 4 Removing and installing through-loading aperture cover 7535
2 4 1 Removing 7535
2 4 2 Installing 7536
2 5 Removing and installing through-loading aperture 7536
2 5 1 Removing 7536
2 5 2 Installing 7537
74 – Seat – padding, covers 7538
1 Front seat covers and padding 7538
1 1 Tools 7538
1 2 Removing and installing front seat cushion cover and padding 7539
1 2 1 Removing 7539
1 2 2 Installing 7541
1 3 Removing and installing front seat backrest cover and padding 7541
1 3 1 Removing 7541
1 3 2 Installing 7547
2 Rear seat covers and padding 7548
2 1 Removing and installing bench seat cover and padding 7548
2 2 Removing and installing backrest cover and padding 7548
K0059100420 General body repairs exterior 7549
50 – Body – front 7559
1 Lock carrier 7559
1 1 Tools 7559
1 1 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 7559
1 2 Assembly overview – lock carrier, service position 7560
1 3 Service position 7560
1 3 1 Moving to service position 7560
1 3 2 Moving from service position 7562
1 3 3 Releasing pressure hoses 7562
1 4 Removing and installing lock carrier with attachments 7562
1 4 1 Removing 7562
1 4 2 Installing 7564
1 5 Assembly overview – air deflectors on lock carrier 7564
2 Wings 7565
2 1 Tools 7565
2 2 Assembly overview – wing 7565
2 3 Removing and installing wing 7566
2 3 1 Removing 7567
2 3 2 Installing 7567
2 4 Removing and installing wing bracket 7568
2 4 1 Removing 7568
2 4 2 Installing 7568
3 Noise insulation 7569
3 1 Tools 7569
3 2 Noise insulation 7569
4 Underbody cover 7571
4 1 Tools 7571
4 2 Underbody trim panels 7571
5 Plenum chamber bulkhead 7573
5 1 Tools 7573
5 2 Materials 7573
5 3 Assembly overview – bulkhead 7574
6 Bulkhead of plenum chamber 7575
6 1 Tools 7575
6 2 Assembly overview – plenum chamber bulkhead 7575
7 Radius rod 7576
7 1 Tools 7576
7 2 Assembly overview – radius rod 7576
8 Tunnel cross-piece 7578
8 1 Tools 7578
8 2 Assembly overview – tunnel cross-piece 7578
55 – Bonnet, rear lid 7579
1 Bonnet 7579
1 1 Tools 7579
1 2 Assembly overview – bonnet 7579
1 3 Removing and installing bonnet 7581
1 3 1 Removing 7581
1 3 2 Installing 7582
1 4 Removing gas strut 7583
1 5 Releasing gas from gas strut 7583
1 6 Removing and installing lid hinge 7583
1 6 1 Removing 7584
1 6 2 Installing 7584
1 7 Removing and installing insulation 7585
1 7 1 Removing 7585
1 7 2 Installing 7585
1 8 Assembly overview – bonnet lock and release components 7585
1 9 Removing and installing lid lock 7587
1 9 1 Removing 7587
1 9 2 Installing 7588
1 10 Bowden cable coupling 7589
1 10 1 Unhooking Bowden cable 7589
1 10 2 Engaging Bowden cable 7589
1 11 Adjusting bonnet 7589
1 11 1 Adjusting lid lock 7591
1 11 2 Adjusting adjustment buffer 7591
1 12 Removing and installing release lever 7591
1 12 1 Removing 7591
1 12 2 Installing 7592
2 Tailgate 7593
2 1 Tools 7593
2 2 Assembly overview – rear lid 7593
2 3 Removing and installing rear lid 7594
2 3 1 Removing 7595
2 3 2 Installing 7596
2 4 Adjusting rear lid 7596
2 5 Removing gas strut 7599
2 6 Releasing gas from gas strut 7599
2 7 Assembly overview – release element 7599
2 8 Removing and installing release element 7600
2 8 1 Removing 7601
2 8 2 Installing 7601
2 9 Removing and installing lid lock 7602
2 9 1 Removing 7602
2 9 2 Installing 7602
2 10 Removing and installing striker pin with power latching motor 7603
2 10 1 Removing 7603
2 10 2 Installing 7603
2 10 3 Adjusting striker pin with power latching motor 7603
2 11 Removing and installing side striker pin 7604
2 11 1 Removing 7604
2 11 2 Installing 7604
2 11 3 Adjusting striker pin 7604
2 12 Adjusting adjustment buffer 7605
2 13 Emergency release for rear lid 7606
2 14 Rear lid seal 7606
2 14 1 Removing rear lid seal 7607
3 Tank flap unit 7609
3 1 Tools 7609
3 2 Assembly overview – tank flap unit and actuator 7609
3 3 Removing and installing tank flap unit 7611
3 3 1 Removing 7611
3 3 2 Installing 7612
3 4 Removing and installing actuator 7613
3 4 1 Removing 7613
3 4 2 Installing 7613
57 – Front doors, door components, central locking 7614
1 Rear door 7614
1 1 Tools 7614
1 2 Assembly overview – front door 7614
1 3 Assembly overview – door hinges 7616
1 4 Removing and installing door 7617
1 4 1 Removing 7618
1 4 2 Installing 7619
1 5 Adjusting door 7619
1 5 1 Adjusting striker pin 7620
2 Door components 7621
2 1 Tools 7621
2 2 Assembly overview – assembly carrier 7623
2 3 Removing and installing subframe 7623
2 3 1 Removing 7624
2 3 2 Installing 7626
2 4 Assembly overview – door handle and door lock 7627
2 5 Removing and installing housing 7628
2 5 1 Removing 7628
2 5 2 Installing 7628
2 6 Removing and installing door handle 7629
2 6 1 Removing 7629
2 6 2 Installing 7629
2 7 Removing and installing door lock 7629
2 7 1 Removing 7629
2 7 2 Installing 7630
2 8 Removing and installing mounting plate 7630
2 8 1 Removing 7631
2 8 2 Installing 7631
2 9 Inner door seal 7631
2 10 Removing and installing inner door seal 7632
2 10 1 Removing 7632
2 10 2 Installing 7632
2 11 Removing and installing outer door seal 7633
2 11 1 Removing 7633
2 11 2 Installing 7634
2 12 Assembly overview – insulation 7634
3 Central locking 7636
3 1 Tool 7636
3 2 Fitting location overview – central locking components 7636
3 3 Adapting radio remote control ignition keys to the convenience system 7637
3 4 Adapting remote control keys to immobilizer 7638
3 5 Assembly overview – battery for folding key with remote control 7638
3 6 Battery for folding key with radio remote control 7639
3 6 1 Removing 7639
3 6 2 Installing 7639
58 – Rear doors, door components 7641
60 – Sunroof 7642
1 Externally guided sliding roof with glass panel 7642
61 – Convertible roof, hardtop, canopy 7643
1 Notes for working on the CSC roof 7643
1 1 Notes for safety and working on the CSC roof 7643
1 2 Rear lid service position 7644
1 3 Opening CSC roof without electrohydraulic system 7645
1 4 Closing CSC roof without electrohydraulic system 7649
1 5 Repairing seals with Sipiol coatings 7654
1 5 1 Notes 7654
1 5 2 Damage 7655
1 5 3 Overview of coated seals 7656
1 5 4 Repair set G 052 523 A2 7656
1 5 5 Repair description 7657
2 Sequence description 7658
3 Assembly overview – CSC roof 7664
4 Glass panel 7665
4 1 Tool 7665
4 2 Assembly overview – glass panel 7665
4 3 Removing glass panel 7667
4 4 Installing glass panel 7672
4 5 Adjusting glass panel 7674
4 6 Shut lines for glass panel 7675
4 7 Removing Bowden cables for glass panel 7677
4 8 Installing Bowden cables for glass panel 7683
4 9 Removing sliding sunroof motor 7685
4 10 Installing sliding sunroof motor 7686
4 11 Glass panel seal (> 07 2007) 7687
4 12 Cleaning water drainage hoses 7688
4 13 Removing guide rail 7689
4 14 Install guide rail 7695
4 15 Adjusting guide rail 7703
5 Roof 7704
5 1 Tool 7704
5 2 Removing centre roof section 7704
5 3 Install middle section of roof 7711
5 4 Adjusting centre roof section 7716
5 5 Removing seal for centre roof section 7717
5 6 Installing seal for centre roof section 7718
5 7 Shut lines for roof centre section 7720
6 Rear window frame 7721
6 1 Tool 7721
6 2 Assembly overview – rear window frame 7721
6 3 Removing rear window frame 7722
6 4 Installing rear window frame 7726
6 5 Adjusting rear window frame 7727
6 6 Shut lines for rear window frame 7728
6 7 Assembly overview – rear window frame seal 7730
6 8 Removing and installing rear window frame seal 7731
7 Roof member 7733
7 1 Tool 7733
7 2 Removing roof side member 7734
7 3 Installing roof side member 7742
7 4 Adjusting roof side member 7748
7 5 Roof side member shut lines 7749
7 6 Removing seal for roof side member 7751
7 7 Installing seal for roof side member 7754
7 8 Removing locking device for roof side member 7757
7 9 Installing locking device for roof side member 7758
7 10 Repairing water drain on roof side member 7759
7 11 Repairing water drain point on roof side member 7763
7 12 Assembly overview – lock fitting 7765
8 CSC roof 7766
8 1 Note on sender transferral when changing roof 7766
8 2 Tools 7766
8 3 Removing CSC roof 7768
8 4 Setting CSC roof down 7774
8 5 Removing new CSC roof from transportation box 7775
8 6 Installing CSC roof 7777
8 7 Basic settings for a newly installed CSC roof 7781
9 Interior trim 7790
9 1 Tool 7790
9 2 Assembly overview – interior trim 7790
9 3 Removing sliding headliner 7792
9 4 Installing sliding headliner 7795
9 5 Removing Bowden cables for sun visor 7798
9 6 Installing Bowden cables for sliding headliner 7801
9 7 Removing tensioned headlining 7803
9 8 Installing tensioned headlining 7806
9 9 Tensioning straps for tensioned headlining 7809
9 9 1 Notes for when routing tensioning straps 7809
9 9 2 Assembly overview – tensioning straps for tensioned headliner 7810
9 9 3 Routing tensioning strap 1 7811
9 9 4 Routing tensioning straps 2 and 3 7813
9 9 5 Routing tensioning straps 4 and 5 7815
9 10 Removing bracing bow for tensioned headlining 7816
9 11 Installing bracing bow for tensioned headlining 7817
9 12 Trim for roof side member 7818
9 13 Preparing new trim for roof side member 7819
9 14 Tensioning straps for roof side member trim 7820
9 14 1 Assembly overview – tensioning straps for roof side member trim 7820
9 14 2 Routing tensioning strap 1 7821
9 14 3 Routing tensioning strap 2 7823
9 15 Lower trim for rear window frame 7824
9 16 Upper trim for rear window frame 7825
10 Roof side member flap 7826
10 1 Tool 7826
10 2 Assembly overview – trim for roof side member flap 7826
10 3 Assembly overview – roof side member flap mechanism 7827
10 4 Removing roof side member flap 7828
10 5 Installing roof side member flap 7831
10 6 Adjusting roof side member flaps 7832
11 Cover flaps 7833
11 1 Assembly overview – trim for cover flap 7833
11 2 Removing cover flaps 7834
11 3 Installing cover flaps 7835
11 4 Adjusting cover flap 7836
12 Rear shelf 7837
12 1 Assembly overview – rear shelf 7837
12 2 Removing rear shelf 7838
12 3 Installing rear shelf 7839
12 4 Installing stop buffer for rear shelf 7841
12 5 Removing and installing rear shelf protective strip 7842
12 5 1 Removing 7842
12 5 2 Installing 7843
12 6 Hinges for rear shelf with assembly frame 7844
12 7 Covers for assembly frame 7845
12 8 Repairing cables in assembly frame 7846
13 Hinge for rear shelf 7850
13 1 Assembly overview 7850
13 2 Removing 7851
13 3 Installing 7852
14 Securing bracket 7853
14 1 Assembly overview 7853
14 2 Removing 7854
14 3 Installing 7855
15 Windscreen frame seal 7856
15 1 Assembly overview – windscreen frame seal 7856
15 2 Removing windscreen frame seal 7857
15 3 Installing windscreen frame seal 7858
16 Wind deflector 7861
16 1 Assembly overview – wind deflector 7861
17 Electrical components 7862
17 1 Tool 7862
17 2 Assembly overview 7862
17 3 Front sender for position of roof side member (G556 / G557) 7864
17 4 Sender for roof side member locked (G558 / G559) 7865
17 5 Sender for rear window frame locked (G560 / G561) 7866
17 6 Sender for rear window frame open (G562) 7868
17 7 Sender roof side member flap open (G566 / G567) 7870
17 8 Sender for rear shelf locked (G563 / G564) 7871
17 9 Sender for roof stowed (G565) – vehicles > VIN 8V036221 7872
17 10 Senders for roof stowed (G565 and G672) – vehicles with VIN 8V036222 > 7873
17 11 Luggage cover contact switch (F364) 7874
17 12 Convertible roof actuation control unit (J256) 7875
17 13 Coding roof actuation control unit 7875
17 13 1 Tools 7875
17 13 2 Convertible roof actuation control unit 7876
18 Hydraulic system 7877
18 1 Notes on hydraulic system 7877
18 2 Rules for cleanliness 7877
18 3 Filling and bleeding the hydraulic system 7878
18 4 Tool 7880
18 5 Assembly overview 7880
18 6 Assembly overview – hydraulic pump 7882
18 7 Hydraulic pump connection assignment 7883
18 7 1 Connection assignment, left side 7883
18 7 2 Connection assignment, right side 7884
18 7 3 Connection assignment for right side when using lines from the genuine replacement parts system 7886
18 8 Removing hydraulic oil reservoir 7888
18 9 Removing and installing hydraulic lines on hydraulic cylinder 7889
18 10 Hydraulic cylinder in roof side member 7890
18 11 Hydraulic cylinder in securing frame 7892
18 12 Hydraulic cylinder on hinge 7894
18 13 Hydraulic cylinder in main hinge 7895
63 – Bumpers 7897
1 Front bumper cover > 12 2010 7897
1 1 Tools 7897
1 2 Repairing front bumper cover 7897
1 3 Assembly overview – front bumper cover 7897
1 4 Removing and installing front bumper cover 7898
1 4 1 Removing 7899
1 4 2 Installing 7900
1 5 Front bumper cover add-on parts 7900
1 6 Front bumper cover substructure parts 7901
1 7 Assembly overview – front bumper carrier 7902
1 8 Assembly overview – front bumper carrier (USA) 7903
2 Front bumper cover 01 2011 > 7904
2 1 Tools 7904
2 2 Repairing front bumper cover 7904
2 3 Assembly overview – front bumper cover 7904
2 4 Removing and installing front bumper cover 7905
2 4 1 Removing 7906
2 4 2 Installing 7907
2 5 Front bumper cover add-on parts 7907
2 6 Front bumper cover substructure parts 7908
2 7 Assembly overview – front bumper carrier 7909
2 8 Assembly overview – front bumper carrier (USA) 7910
2 9 Number plate carrier 7911
3 Rear bumper cover > 12 2010 7912
3 1 Tools 7912
3 2 Repairing rear bumper cover 7912
3 3 Installing brackets for parking aid system 7912
3 3 1 Tools 7912
3 3 2 Materials 7913
3 3 3 Installing brackets 7913
3 3 4 Minimum curing period 7916
3 4 Assembly overview – rear bumper cover 7917
3 5 Removing and installing rear bumper cover 7917
3 5 1 Removing 7918
3 5 2 Installing 7918
3 6 Rear bumper cover add-on parts 7919
3 7 Rear bumper cover substructure parts 7920
3 8 Assembly overview – rear bumper carrier 7921
3 9 Assembly overview – rear bumper carrier (USA) 7922
3 10 Assembly overview – towing bracket 7922
4 Rear bumper cover 01 2011 > 7924
4 1 Tools 7924
4 2 Repairing rear bumper cover 7924
4 3 Assembly overview – rear bumper cover 7924
4 4 Removing and installing rear bumper cover 7925
4 4 1 Removing 7926
4 4 2 Installing 7926
4 5 Rear bumper cover add-on parts 7927
4 6 Rear bumper cover substructure parts 7928
4 7 Assembly overview – rear bumper carrier 7929
4 8 Assembly overview – rear bumper carrier (USA) 7930
4 9 Assembly overview – towing bracket 7930
64 – Glazing 7932
1 Flush bonded windows 7932
1 1 Tools 7932
1 2 Materials 7934
1 3 Repairing windscreen 7934
1 4 Assembly overview – windscreen 7934
1 5 Plenum chamber cover 7936
1 5 1 Assembly overview – plenum chamber cover 7936
1 5 2 Removing plenum chamber cover 7937
1 5 3 Installing plenum chamber cover 7938
1 6 Removing windscreen 7939
1 7 Installing windscreen 7939
1 8 Assembly overview – rear window 7939
1 9 Removing undamaged rear window 7941
1 10 Removing broken rear window 7943
1 11 Installing rear window 7944
1 12 Preparing old undamaged window for glazing 7944
1 13 Preparing new window for glazing 7944
1 14 Preparing body flange for glazing 7945
1 14 1 Preparing body flange for rear window 7946
1 15 Fitting instructions 7947
1 15 1 Installation instructions for all windows 7947
1 15 2 Installation instructions for windscreen 7947
1 15 3 Installation instructions for rear window 7949
1 16 Minimum curing period 7949
1 17 Touching up paint damage 7950
1 18 Cleaning in the event of dirt caused by adhesive sealing material 7950
2 Door window 7951
2 1 Tools 7951
2 2 Assembly overview – door window 7952
2 3 Removing door window 7953
2 4 Installing door window 7954
2 5 Adjusting door window 7955
2 5 1 Notes for adjustment 7955
2 5 2 Adjusting door window to front window channel 7955
2 5 3 Adjusting inclination of door window to roof side member seal 7956
2 5 4 Adjusting height of door window to roof side member seal 7957
2 6 Door window adjustment dimensions 7958
2 7 Removing window regulator motor 7959
2 8 Installing window regulator motor 7960
2 9 Removing window lifters 7961
2 10 Installing window lifters 7962
2 11 Basic settings for window regulator 7963
2 12 Removing window channel and window slot seal 7963
2 13 Installing window channel and window slot seal 7965
3 Side window 7966
3 1 Tools 7966
3 2 Assembly overview – side window 7966
3 3 Removing side window with window regulator 7967
3 4 Installing side window with window regulator 7968
3 5 Removing side window 7969
3 6 Installing side window 7970
3 7 Adjusting side window 7971
3 7 1 Notes for adjustment 7971
3 7 2 Basic settings for window regulator 7971
3 7 3 Adjusting height and parallelism 7972
3 7 4 Adjusting inclination 7973
3 8 Side window adjustment dimensions 7974
3 9 Window regulator motor 7975
3 10 Assembly overview – window slot seals 7976
3 11 Assembly overview – intermediate plate 7977
66 – Exterior equipment 7978
1 Wheel housing liner 7978
1 1 Tools 7978
1 2 Assembly overview – front wheel housing liner 7978
1 3 Removing and installing front wheel housing liner 7979
1 3 1 Removing 7980
1 3 2 Installing 7980
1 4 Assembly overview – rear wheel housing liner 7981
1 5 Removing and installing rear wheel housing liner 7982
1 5 1 Removing 7982
1 5 2 Installing 7983
2 Exterior mirror > 05 2008 7984
2 1 Tools 7984
2 2 Assembly overview – exterior mirror 7985
2 3 Removing and installing mirror glass 7985
2 3 1 Removing 7986
2 3 2 Installing 7986
2 4 Removing and installing mirror housing 7986
2 4 1 Removing 7986
2 4 2 Installing 7988
2 5 Removing and installing trim 7988
2 5 1 Removing 7988
2 5 2 Installing 7988
2 6 Removing and installing turn signal repeater 7988
2 6 1 Removing 7989
2 6 2 Installing 7989
2 7 Removing and installing adjustment unit with motor 7989
2 7 1 Removing 7989
2 7 2 Installing 7990
2 8 Removing and installing entry light 7990
2 8 1 Removing 7990
2 8 2 Installing 7990
2 9 Removing and installing exterior mirror 7991
2 9 1 Removing 7991
2 9 2 Installing 7991
3 Exterior mirror 06 2008 > 7992
3 1 Tools 7992
3 2 Assembly overview – exterior mirror 7992
3 3 Removing and installing mirror glass 7993
3 3 1 Removing 7994
3 3 2 Installing 7994
3 4 Removing and installing mirror housing 7995
3 4 1 Removing 7995
3 4 2 Installing 7995
3 5 Removing and installing trim 7996
3 5 1 Removing 7996
3 5 2 Installing 7997
3 6 Removing and installing side turn signal and entry light in exterior mirror 7997
3 6 1 Removing 7997
3 6 2 Installing 7998
3 7 Removing and installing exterior mirror 7999
3 7 1 Removing 7999
3 7 2 Installing 7999
4 Radiator grille > 12 2010 8000
4 1 Assembly overview – radiator grille 8000
4 2 Removing and installing radiator grille 8001
4 2 1 Removing 8001
4 2 2 Installing 8002
4 3 Removing and installing emblem 8003
4 3 1 Removing 8003
4 3 2 Installing 8003
4 4 Assembly overview – number plate carrier 8003
4 5 Removing and installing number plate carrier 8005
4 5 1 Removing 8005
4 5 2 Installing 8006
5 Radiator grille 01 2011 > 8007
5 1 Removing radiator grille 8007
5 2 Installing radiator grille 8008
5 3 Removing and installing emblem 8009
5 3 1 Removing 8009
5 3 2 Installing 8010
6 Mouldings and trims 8011
6 1 Cover strip 8011
6 1 1 Installation instructions for cover strips 8011
6 1 2 Removing and installing cover strip 8012
6 2 Wheel arch trim 8013
7 Lettering 8015
7 1 Tools 8015
7 2 Fitting instructions 8015
7 3 Rear lettering dimensions > 12 2010 8015
7 4 Rear lettering dimensions 01 2011 > 8017
7 5 Lettering on wing 8018
7 5 1 Dimensions of wing badge »Individual« 8018
7 5 2 Dimensions for wing lettering »Exclusive« 8020
K0059100520 Heating air conditioner 8022
00 – Technical data 8026
1 Safety information 8026
1 1 Safety precautions when working on air conditioning systems 8026
1 2 Safety measures when working on vehicles with a start/stop system 8026
1 3 Safety precautions when working on the cooling system 8026
2 General information 8028
2 1 Notes concerning odours in air conditioned vehicles 8028
2 2 Notes for vehicles with start-stop system 8028
3 Repair instructions 8029
3 1 Working on refrigerant circuit 8029
3 2 Refrigerant circuit seals 8029
3 3 Notes on control motors 8030
3 3 1 Notes on control motors 8030
3 3 2 Inserting link into the shaft of a control motor 8032
3 3 3 Activating control motor using adapter cable 8034
3 3 4 Locally manufacturing an adapter cable to activate control motors 8035
4 Technical data 8036
4 1 Capacities for refrigerant R134a 8036
4 2 Refrigerant oil 8036
4 3 Oil distribution 8036
80 – Heating 8037
1 Heater 8037
1 1 Removing and installing fresh air blower -V2- 8037
1 2 Removing and installing fresh air blower series resistor with overheating fuse -N24- 8038
1 3 Removing and installing heater unit 8038
1 4 Dismantling and assembling heater unit 8042
2 Control motors 8045
3 Air duct 8046
4 Operating and display unit 8047
5 Other controlling and regulating components 8048
87 – Air conditioning system 8049
1 Overview of fitting locations – air conditioning system 8049
1 1 Overview of fitting locations – components located in front section of passenger compartment 8049
1 1 1 Overview of fitting locations – components located in front section of passenger compartment, Climatic and air conditioning system with electric/manual controls 8049
1 1 2 Overview of fitting locations – components inside of front passenger compartment, Climatronic 8052
2 Refrigerant circuit 8055
2 1 System overview – refrigerant circuit 8055
2 2 Removing and installing high-pressure sender -G65- 8056
2 3 Removing and installing expansion valve 8057
2 4 Removing and installing condenser 8060
2 5 Removing and installing receiver 8063
2 6 Removing and installing desiccant bag or cartridge 8064
2 6 1 Removing and installing desiccant bag or cartridge, Modine 8064
2 7 Removing and installing evacuating and charging valves on low and high-pressure side 8066
3 Air conditioner compressor 8068
3 1 Assembly overview – drive unit of air conditioner compressor 8068
3 2 Removing and installing air conditioner compressor 8068
3 3 Checking high-pressure safety valve on air conditioner compressor 8073
3 4 Ancillary bracket for air conditioner compressor 8074
3 4 1 Removing and installing ancillary bracket for air conditioner compressor, engine codes BKC and BMM 8074
3 4 2 Removing and installing ancillary bracket for air conditioner compressor, engine codes: AXX, BLR, BPY, BSF, BVY, BVZ, BWA, CAWB, CBFA, CCTA, CCZA and CCZB 8076
3 4 3 Removing and installing ancillary bracket for air conditioner compressor, engine codes BUB, CBRA and CDVA 8078
3 4 4 Removing and installing ancillary bracket for air conditioner compressor, engine codes BLF and CAXA 8080
3 4 5 Removing and installing ancillary bracket for air conditioner compressor, engine code CAVD 8082
3 4 6 Removing and installing ancillary bracket for air conditioner compressor, engine code CBAB 8083
4 Front heater and air conditioning unit 8086
4 1 Assembly overview – heater and air conditioning unit 8086
4 1 1 Assembly overview – heater and air conditioning unit, Climatic 8086
4 1 2 Assembly overview – heater and air conditioning unit, air conditioning system with electric/manual controls 8088
4 1 3 Assembly overview – heater and air conditioning unit, Climatronic 8090
4 2 Removing and installing heater and air conditioning unit 8091
4 3 Removing and installing evaporator 8096
4 4 Dismantling and assembling evaporator housing 8097
4 5 Removing fresh air blower -V2- with fresh air blower control unit -J126- 8098
4 6 Removing and installing evaporator output temperature sender -G263- 8099
4 7 Removing and installing evaporator temperature sensor -G308- 8100
4 8 Removing and installing dust and pollen filter 8100
4 9 Removing and installing heat exchanger 8101
4 10 Removing and installing auxiliary air heater element -Z35- 8105
4 11 Checking condensation drain 8108
4 12 Removing and installing glove box cooling 8108
5 Air duct 8110
5 1 Removing and installing fresh air intake 8110
5 2 Removing and installing air intake duct 8111
5 3 Removing vents 8112
5 3 1 Removing centre vent 8112
5 3 2 Removing and installing vent on front passenger side or driver side 8112
5 3 3 Removing and installing rear footwell air duct 8112
5 3 4 Removing and installing right footwell vent 8113
5 3 5 Removing and installing left footwell vent 8114
5 4 Checking forced ventilation for passenger compartment 8114
5 5 Removing and installing forced ventilation for passenger compartment 8114
6 Operating and display unit 8116
6 1 Overview of operating and display unit 8116
6 1 1 Overview of operating and display unit for Climatic up to week 21/08 8116
6 1 2 Overview of operating and display unit, Climatic as of week 22/08 up to week 44/10 8119
6 1 3 Overview of control and display unit, air conditioning system with electric and manual controls, as of week 45/2010 8119
6 1 4 Overview of operating and display unit, Climatronic up to week 21/08 8120
6 1 5 Overview of operating and display unit, Climatronic from week 22/08 to week 44/10 8123
6 1 6 Overview of operating and display unit, Climatronic from week 45/10 8124
6 2 Removing and installing operating and display unit 8127
6 2 1 Removing and installing operating and display unit for Climatic and air conditioning system with electric/manual controls 8127
6 2 2 Removing and installing operating and display unit, Climatronic 8128
6 3 Multi-pin connector pin assignment on back of operating and display unit 8128
6 3 1 Multi-pin connector pin assignment on back of operating and display unit, vehicles with Climatic up to week 21/08 8128
6 3 2 Multi-pin connector pin assignment on back of operating and display unit, vehicles with Climatic as of week 22/08 up to week 44/10 8129
6 3 3 Multi-pin connector pin assignment on back of operating and display unit, air conditioning system with electric/manual controls from week 45/2010 8130
6 3 4 Multi-pin connector pin assignment on back of operating and display unit, Climatronic up to week 21/08 8131
6 3 5 Multi-pin connector pin assignment on back of operating and display unit, Climatronic as of week 22/08 up to week 44/10 8132
6 3 6 Multi-pin connector pin assignment on back of operating and display unit, Climatronic from week 45/2010 8133
7 Control motors 8135
7 1 Removing and installing temperature flap control motor -V68- 8135
7 2 Removing and installing centre flap control motor -V70- 8137
7 3 Removing and installing air flow flap control motor -V71- 8138
7 4 Removing and installing defroster flap control motor -V107- 8142
7 5 Removing and installing air recirculation flap control motor -V113- 8144
7 6 Removing and installing fresh air and air recirculation flap control motor -V154- 8146
7 7 Removing and installing left temperature flap control motor -V158- 8149
7 8 Removing and installing right temperature flap control motor -V159- 8151
7 9 Removing and installing fresh air/air recirculation, air flow flap control motor -V425- 8153
7 9 1 Removing and installing fresh air/air recirculation, air flow flap control motor -V425-, left-hand drive vehicles 8153
7 9 2 Removing and installing fresh air/air recirculation, air flow flap control motor -V425-, RHD vehicles 8154
7 10 Removing and installing front air distribution flap control motor -V426- 8155
7 11 Removing and installing air distribution flap control motor -V428- 8156
7 12 Removing and installing air distribution flap actuator 8157
7 13 Removing and installing flexible shaft, vehicles up to week 21/08 8158
8 Other controlling and regulating components 8160
8 1 Removing and installing ambient temperature sensor -G17- 8160
8 2 Removing sunlight penetration photosensor -G107- or sunlight penetration photosensor 2 -G134- 8160
8 3 Principle of operation of air quality sensor -G238- 8161
8 4 Removing and installing air quality sensor -G238-, vehicles from week 22/08 8162
8 5 Removing and installing left vent temperature sender -G150- 8163
8 6 Removing and installing right vent temperature sender -G151- 8164
8 7 Removing and installing centre vent temperature sender -G191- 8164
8 8 Removing and installing footwell vent temperature sender -G192- 8164
8 9 Removing and installing left footwell vent temperature sender -G261- 8165
8 10 Removing and installing right footwell vent temperature sender -G262- 8165
K0059100720 Body Repairs 8167
00 – Technical data 8173
1 Vehicle identification data 8173
1 1 Vehicle identification number 8173
1 2 Identification plate 8173
1 3 Vehicle data sticker 8173
2 Safety instructions 8174
3 Moulded foam elements 8175
4 Galvanized body parts 8176
4 1 Body 8176
4 2 Platform 8177
5 Strengthened steel body panels 8178
5 1 Body 8179
5 2 Platform 8180
6 Laser welding 8181
7 Body panel gaps/shut lines 8182
7 1 Body – front 8182
7 2 Body – rear 8185
8 Body dimensions 8188
8 1 Body – front 8188
8 2 Body – centre 8191
8 3 Body – rear 8198
8 4 Floor group – front 8201
8 5 Floor group – centre 8203
8 6 Floor group – rear 8204
9 Alignment bracket set 8208
9 1 Overview 8208
10 Portal / convertible roof gauge 8209
10 1 Overview – portal gauge 8209
10 2 Overview – convertible roof gauge 8210
50 – Body – front 8211
1 Renewing right console 8211
1 1 Tools 8211
1 2 Removing 8212
1 3 Installing 8213
1 3 1 Welding in 8213
2 Renewing left console 8215
2 1 Tools 8215
2 2 Removing 8216
2 3 Installing 8217
2 3 1 Preparing new part 8217
2 3 2 Welding in 8217
3 Renewing retaining bracket (for subframe) 8219
3 1 Tools 8219
3 2 Removing 8220
3 3 Installing 8221
3 3 1 Preparing new part 8221
3 3 2 Welding in 8221
4 Renewing bumper bracket 8223
4 1 Tools 8223
4 2 Removing 8223
4 3 Installing 8224
4 3 1 Welding in 8224
5 Renewing upper wheel housing longitudinal member 8226
5 1 Tools 8227
5 2 Removing 8227
5 3 Installing 8229
5 3 1 Preparing new part 8229
5 3 2 Welding in 8229
6 Renewing front wheel housing 8232
6 1 Tools 8232
6 2 Removing 8233
6 3 Installing 8235
6 3 1 Preparing new parts 8235
6 3 2 Welding in 8238
7 Renewing front longitudinal member 8242
7 1 Tools 8242
7 2 Removing 8243
7 3 Installing 8245
7 3 1 Preparing new part 8245
7 3 2 Welding in 8245
7 3 3 Shortening new longitudinal member with cover plate 8247
8 Renewing front longitudinal member – partial renewal 8250
8 1 Tools 8250
8 2 Removing 8251
8 3 Installing 8253
8 3 1 Preparing new part 8253
8 3 2 Welding in 8253
8 3 3 Shortening new longitudinal member with cover plate 8254
9 Repairing threads for securing subframe (suspension subframe) 8255
9 1 Tools 8256
9 2 Contents of thread repair kit 8256
9 3 Repairing thread 8257
9 3 1 Drilling thread 8257
9 3 2 Cutting the thread 8258
9 3 3 Inserting thread insert 8258
51 – Body – centre 8260
1 Renewing windscreen frame 8260
1 1 Tools 8260
1 2 Removing 8261
1 3 Installing 8261
1 3 1 Welding in 8261
2 Renewing A-pillar 8263
2 1 Tools 8263
2 2 Removing 8264
2 3 Installing 8265
2 3 1 Preparing new part 8266
2 3 2 Moulded foam elements 8266
3 Renewing left and right upper A-pillars 8271
3 1 Tools 8271
3 2 Removing 8272
3 3 Installing 8273
3 3 1 Preparing new part 8273
3 3 2 Marking the area where no welding work may be carried out 8274
3 3 3 Welding in 8275
4 Renewing A-pillar reinforcement 8279
4 1 Tools 8279
4 2 Removing 8280
4 3 Installing 8285
4 3 1 Preparing new part 8285
4 3 2 Welding in 8287
5 Renewing B-pillar reinforcement 8293
5 1 Tools 8294
5 2 Removing 8294
5 3 Installing 8296
5 3 1 Preparing new part 8296
5 3 2 Moulded foam elements 8297
5 3 3 Welding in 8297
6 Renewing outer side member 8300
6 1 Tools 8300
6 2 Removing 8301
6 3 Installing 8302
6 3 1 Preparing new part 8302
7 Renewing side member reinforcement 8306
7 1 Tools 8306
7 2 Removing 8307
7 3 Installing 8308
7 3 1 Preparing new part 8308
7 3 2 Welding in 8309
53 – Body – rear 8311
1 Renewing rear cross panel 8311
1 1 Tools 8312
1 2 Removing 8312
1 3 Installing 8314
1 3 1 Preparing new part 8314
1 3 2 Welding in 8314
2 Renewing tail light mounting 8316
2 1 Tools 8316
2 2 Removing 8317
2 3 Installing 8319
2 3 1 Preparing new part 8319
2 3 2 Welding in 8320
3 Renewing rear longitudinal member – partial renewal 8323
3 1 Tools 8323
3 2 Removing 8324
3 3 Installing 8325
3 3 1 Preparing new part 8325
3 3 2 Welding in 8325
4 Renewing side panel 8327
4 1 Tools 8328
4 2 Removing 8328
4 3 Installing 8330
4 3 1 Preparing new part 8330
4 3 2 Moulded foam elements 8332
5 Renewing wheel housing liner 8337
5 1 Tools 8337
5 2 Removing 8338
5 3 Installing 8339
5 3 1 Moulded foam elements 8339
5 3 2 Welding in 8339
6 Renewing window lifter mounting 8344
6 1 Tools 8344
6 2 Removing 8344
6 3 Installing 8345
6 3 1 Preparing new part 8346
6 3 2 Welding in 8346
7 Renewing spare wheel well 8348
7 1 Tools 8348
7 2 Removing 8349
7 3 Installing 8352
7 3 1 Preparing new part 8352
7 3 2 Moulded foam elements 8353
7 3 3 Welding in 8353
K0059100820 Communication 8356
91 – Communication 8362
1 Communication systems 8362
1 1 Fault finding 8362
2 Radio and radio navigation systems in general 8363
2 1 Removing and installing radio and radio navigation systems 8363
2 1 2 Removing: 8363
2 1 3 Installing: 8365
2 2 Fault finding 8365
2 3 Adapting radio components 8366
2 4 Adapting radio navigation system components 8366
3 Radio system “RCD 300” 8367
3 1 General notes 8367
3 2 Overview of radio system “RCD 300” 8368
3 3 Overview of connectors on radio “RCD 300” 8369
3 4 Anti-theft coding 8370
3 4 1 Deactivating anti-theft coding 8371
4 Radio system “RCD 310” 8372
4 1 General notes 8372
4 2 Overview of radio system “RCD 310” 8372
4 3 Overview of connectors on radio “RCD 310” 8374
4 4 Anti-theft coding 8376
4 4 1 Deactivating anti-theft code of anti-theft coding 8377
5 Radio system “RCD 500” 8379
5 1 General description 8379
5 2 Overview of radio system “RCD 500” 8380
5 3 Activating/deactivating transport lock for CD changer in “RCD 500” 8381
5 4 Overview of connectors on radio “RCD 500” 8382
5 5 Anti-theft coding 8383
5 5 1 Deactivating anti-theft coding 8384
6 Radio system “RCD 510” 8385
6 1 General notes 8385
6 2 Overview of radio system “RCD 510” 8386
6 3 Activating/deactivating transport lock for CD changer in “RCD 510” 8387
6 4 Overview of connectors on radio “RCD 510” 8388
6 5 Anti-theft coding 8391
6 5 1 Deactivating anti-theft code of anti-theft coding 8393
7 Radio system “Premium Sound System”, for vehicles for USA and Canada 8395
7 1 General description 8395
7 2 Overview of radio system “Premium Sound System” 8395
7 3 Overview of connectors on radio “Premium Sound System” 8397
7 4 Anti-theft coding 8399
7 4 1 Deactivating anti-theft coding 8399
8 Radio navigation system “RNS 300” 8401
8 1 General description 8401
8 2 Overview of radio navigation system “RNS 300” 8402
8 3 Overview of connectors on radio navigation system “RNS 300” 8403
8 4 Anti-theft coding 8405
8 4 1 Deactivating anti-theft coding 8405
9 Radio navigation system “RNS 310” 8407
9 1 General notes 8407
9 2 Overview of radio navigation system “RNS 310” 8408
9 3 Overview of connectors on radio navigation system “RNS 310” 8410
9 4 Anti-theft coding 8412
9 4 1 Deactivating anti-theft coding 8414
10 Radio navigation system “RNS 315” 8416
10 1 General notes 8416
10 2 Features of radio navigation system “RNS 315” 8416
10 3 System overview of the radio navigation system “RNS 315” 8417
10 4 Overview of connectors on radio navigation system “RNS 315” 8420
10 4 4 Multi-pin connector 4, 12-pin, for CD changer control and CD audio input signals 8422
10 5 Anti-theft coding 8423
10 5 1 Deactivating anti-theft coding 8425
11 Radio navigation system “RNS MFD 2 DVD” 8427
11 1 General description 8427
11 2 Overview of “RNS MFD 2 DVD” 8428
11 3 Overview of connectors on “RNS MFD 2 DVD” 8430
11 4 Anti-theft coding 8434
11 4 1 Deactivating anti-theft coding 8434
12 Radio navigation system “RNS MFD 2 DVD”, for vehicles for USA and Canada 8435
12 1 General description 8435
12 2 Overview of radio navigation system “RNS MFD 2 DVD” 8436
12 3 Overview of connectors on radio navigation system “RNS MFD 2 DVD” 8438
12 4 Anti-theft coding 8442
12 4 1 Deactivating anti-theft coding 8442
13 Radio navigation system “RNS 510” 8444
13 1 General notes 8444
13 2 Overview of radio navigation system “RNS 510” 8444
13 3 Overview of connectors on radio navigation system “RNS 510” 8446
13 4 Anti-theft coding 8449
13 4 1 Deactivating anti-theft coding 8451
14 Sound system amplifier 8452
14 1 General description 8452
14 1 1 Fault finding 8452
14 2 Removing and installing amplifier 8452
14 2 1 Removing: 8452
14 2 2 Installing: 8453
14 3 Pin assignments on connectors of amplifier 8454
15 Satellite digital radio tuner for vehicles for USA and Canada 8456
15 1 General notes 8456
15 2 Fault finding 8456
15 3 Removing and installing satellite digital radio tuner 8456
15 3 1 Removing: 8456
15 3 2 Installing: 8457
16 Compass, for vehicles for USA and Canada 8458
16 1 General description 8458
16 2 Removing and installing magnetic field sender 8458
16 2 1 Removing: 8458
16 2 2 Installing 8459
17 CD changer 8460
17 1 Removing and installing CD changer 8460
17 1 2 Removing CD changer 8460
17 1 3 Installing: 8461
18 USB connection for USB sticks and MP3 player 8462
18 1 General notes 8462
18 1 1 Fault finding 8462
18 1 2 Supported music file formats 8462
18 1 3 Supported memory media 8463
18 1 4 General notes 8464
18 2 Removing and installing storage compartment with USB connection 8464
18 2 2 Removing: 8465
18 2 3 Installing: 8466
18 3 Overview of connectors on USB connection 8466
18 4 Fault finding procedure 8467
19 Interface for external multimedia devices -R215- 8468
19 1 General notes 8468
19 2 System overview of interface for external multimedia devices -R215- 8468
19 3 Interface for external multimedia devices -R215- 8469
19 3 1 Removing: 8470
19 3 2 Installing: 8470
20 Connection for external audio sources 8471
20 1 General notes 8471
20 2 Removing and installing connection for external audio sources -R199- 8471
20 2 1 Removing: 8471
20 2 2 Installing: 8472
20 3 Contact assignment on connection for external audio sources -R199- 8472
21 Loudspeaker systems 8473
21 1 Removing and installing front bass loudspeakers 8473
21 1 1 Removing: 8473
21 1 2 Installing: 8474
21 2 Removing and installing rear bass loudspeakers 8474
21 2 1 Removing: 8474
21 2 2 Installing: 8475
21 3 Removing and installing front treble loudspeakers 8476
21 3 1 Removing: 8476
21 3 2 Installing: 8476
21 4 Removing and installing rear treble loudspeakers 8477
21 4 1 Removing: 8477
21 4 2 Installing: 8477
21 5 Removing and installing front mid-range loudspeakers 8478
21 5 1 Removing: 8478
21 5 2 Installing: 8478
22 Telephone system 8479
22 1 General notes 8479
22 1 1 Fault finding 8479
22 2 Telephone system/universal preparation for mobile telephone 8479
22 2 1 Overview of telephone system/universal preparation for mobile telephone 8479
22 2 2 Removing and installing telephone bracket ► 06 2006 8480
22 2 4 Removing and installing telephone operating electronics control unit ► 06 2006 8482
22 2 5 Removing and installing telephone operating electronics control unit 06 2006 ► 8484
22 3 Removing and installing telephone system microphone 8484
22 3 1 Removing: 8485
22 3 2 Installing: 8485
23 Aerial systems 8486
23 1 General notes 8486
23 2 Overview of aerial system for RCD 300, 500, RNS 300, RNS MFD 8486
23 3 Overview of aerial system component locations in rear lid 8488
23 4 Overview of aerial system as block circuit diagram for vehicles for USA and Canada 8489
23 5 Overview of aerial system component locations in the rear lid for USA and Canada vehicles 8490
23 6 Overview of aerial systems RCD 310, 510, RNS 300, 310, 315, 510 8490
23 7 Removing and installing aerial amplifier 8491
23 7 1 Removing: 8491
23 7 2 Installing: 8492
23 8 Removing and installing carrier plate for aerial modules 8492
23 8 1 Removing: 8492
23 8 2 Installing: 8493
23 9 Removing and installing aerial modules 8493
23 9 1 Removing: 8493
23 9 2 Installing: 8494
23 10 Renewal of aerial wiring 8494
24 Multifunction steering wheel 8495
24 1 Multifunction steering wheel ▶ 11 2010 8495
24 1 1 General notes 8495
24 1 2 Fault finding 8495
24 1 3 Removing and installing steering wheel operating unit 8495
24 1 4 Removing and installing multifunction steering wheel control unit 8496
24 1 5 Adapting multifunction steering wheel components 8497
24 2 Multifunction steering wheel 11 2010 ▶ 8497
24 2 1 General notes 8497
24 2 2 Fault finding 8497
24 2 3 Removing and installing steering wheel operating unit 8498
24 2 4 Adapting multifunction steering wheel components 8499
25 Mobile online services 8500
25 1 General notes 8500
25 2 Overview of fitting locations – mobile online services 8500
25 3 Removing and installing emergency call module control unit and communication unit -J949- 8501
26 Notes on operating mobile telephones and two-way radios 8503
26 1 General notes 8503
26 1 1 Mobile telephones or portable two-way radios may not be used in the vehicle without a separate external aerial 8503
26 1 2 The installation and operation of two-way radios with a transmitting power above 10 watts for the radio communication services listed in the table are permitted only under the following conditions: 8503
26 2 Notes on performing repair work 8503
26 2 1 Transmitting power and possible fitting locations 8504
26 2 2 Voltage supply 8504
26 2 3 Aerial and aerial wiring 8504
26 2 4 Further additional installations 8505
26 3 Overview of battery, transmitter and receiver unit, fuse and wiring harness 8505
26 4 Transmitting power and aerial fitting locations 8506
26 4 1 Eos 2006 ► 8506
27 Suppression measures 8508
27 1 Implementation of suppression measures 8508
K0059100920 Auxiliary heater 8509
82 – Supplementary heating 8513
1 Auxiliary heater Thermo Top V 8513
1 1 Safety measures for working on vehicles with auxiliary heaters 8513
2 Notes on general repairs on vehicles with auxiliary heaters 8514
2 1 Starting conditions for auxiliary heating (preheater) 8514
2 2 Starting conditions for auxiliary heating 8514
3 Rules for cleanliness when working on the auxiliary heater and the fuel system 8515
4 Repairing auxiliary heater Thermo Top V 8516
4 1 Manufacturer’s plates for Thermo Top V 8518
4 2 Removing and installing ambient temperature sensor -G17- 8518
4 3 Removing and installing exhaust system 8519
4 4 Removing and installing remote control receiver for auxiliary coolant heater -R149- 8519
5 Removing and installing auxiliary heater Thermo Top V 8521
5 1 Components of auxiliary heater Thermo Top V 8522
5 2 Removing auxiliary heater Thermo Top V 8522
5 3 Installing auxiliary heater Thermo Top V 8526
5 4 Removing ancillaries of auxiliary heater Thermo Top V 8526
5 4 1 Removing and installing air intake silencer 8526
5 4 2 Removing and installing circulation pump -V55- 8527
5 4 3 Removing and installing silencer with bracket 8527
5 4 4 Removing and installing bracket for auxiliary heater 8528
5 4 5 Removing and installing cover 8528
5 5 Dismantling and assembling auxiliary heater Thermo Top V 8528
5 6 Inner components of auxiliary heater 8529
5 7 Removing and installing glow plug with flame monitoring -Q8- 8531
5 8 Removing and installing temperature sensor -G18- and overheating sensor -G189- 8532
5 9 Removing and installing heater coolant shut-off valve -N279- for vehicles with petrol engine 8532
6 Bleeding coolant circuit 8534
7 Connecting auxiliary heater Thermo Top V to coolant circuit 8535
7 1 Connection diagram for coolant hoses in vehicles with auxiliary heating, engine code BVY 8535
7 2 Connection diagram for coolant hoses in vehicles with auxiliary heating, engine code BLF 8536
8 Fuel supply for auxiliary heater Thermo Top V 8537
8 1 Rules for cleanliness 8537
8 2 Fuel feel to Thermo Top V 8537
8 2 1 Fuel feel to Thermo Top V 8538
8 3 Removing and installing metering pump -V54- 8539
8 3 1 Removing 8539
8 3 2 Installing 8541
8 4 Testing quantity of fuel delivered 8541
9 Regulation of auxiliary heater Thermo Top V 8544
9 1 Functional description of auxiliary heater Thermo Top V 8544
9 1 1 Preheating mode 8544
9 1 2 Auxiliary heating mode 8545
9 1 3 Switching off 8545
9 2 Remote control operation 8546
9 2 1 Switching auxiliary heater on using remote control 8546
9 2 2 Switching auxiliary heater off using remote control 8546
9 2 3 Renewing remote control batteries 8546
K0059101520 4 cylinder injection engine (1 6 l engine direct injection) 8548
00 – Technical data 8554
1 Technical data 8554
1 1 Engine number 8554
1 2 Engine data 8554
10 – Removing and installing engine 8555
1 Removing and installing engine 8555
1 1 Removing engine 8556
1 2 Securing engine to assembly stand 8560
1 3 Installing engine 8560
1 4 Assembly mountings 8563
13 – Crankshaft group 8565
1 Dismantling and assembling engine 8565
1 1 Part I Assembly overview – belt drive 8565
1 2 Part II Assembly overview – cylinder block 8567
1 3 Removing and installing poly V-belt 8569
1 4 Removing and installing valve timing housing 8570
1 4 1 Removing 8571
1 4 2 Installing 8573
2 Sealing flange and flywheel 8574
2 1 Assembly overview – sealing flange 8574
2 2 Renewing crankshaft oil seal – belt pulley end 8576
2 3 Poly V-belt pulley securing bolt tightening procedure 8577
2 4 Renewing crankshaft sealing flange – flywheel end 8580
2 4 1 Pressing sealing flange with sender wheel off crankshaft 8581
2 4 2 Pressing sealing flange with sender wheel onto crankshaft 8582
2 4 3 A – Assembling sealing flange with sender wheel on assembly appliance -T10134- 8583
2 4 4 B – Attaching assembling tool -T10134- with sealing flange to crankshaft flange 8584
2 4 5 C – Bolting assembly tool -T10134- onto crankshaft flange 8585
2 4 6 D – Pressing sender wheel onto crankshaft flange using assembly tool -T10134- 8586
2 4 7 E – Checking sender wheel installation position on crankshaft 8586
2 4 8 F – Pressing sender wheel on fully 8587
2 5 Crankshaft dimensions 8587
3 Pistons and conrods 8589
3 1 Assembly overview – Pistons and conrods 8589
3 2 Checking piston 8590
3 2 1 Checking cylinder bore 8591
3 3 Piston and cylinder dimensions 8591
15 – Cylinder head, valve gear 8592
1 Cylinder head 8592
1 1 Assembly overview – cylinder head 8592
1 2 Checking valve timing 8595
1 3 Adjusting valve timing 8596
1 4 Removing and installing timing chain and chain drive for oil pump 8600
1 5 Removing and installing camshaft housing 8607
1 5 1 Removing 8609
1 5 2 Installing 8610
1 6 Removing and installing cylinder head 8612
1 7 Checking compression 8614
2 Valve gear 8616
2 1 Assembly overview – valve gear 8616
2 2 Checking camshaft axial clearance 8618
2 3 Machining valve seats 8618
2 4 Checking valve guides 8620
2 5 Renewing valve stem seals 8620
17 – Lubrication 8623
1 Parts of lubrication system 8623
1 1 Engine oil 8623
1 2 Assembly overview – parts of lubrication system 8623
1 3 Removing and installing sump 8626
1 4 Removing and installing oil pump 8627
1 5 Checking oil pressure and oil pressure switch 8629
19 – Cooling 8632
1 Parts of cooling system 8632
1 1 Assembly overview – parts of cooling system, body side 8632
1 2 Assembly overview – parts of cooling system, engine side 8634
1 3 Coolant hose schematic diagram 8636
1 4 Draining and filling coolant 8637
1 5 Removing and installing radiator fan -V7- and radiator fan 2 -V177- 8640
1 6 Removing and installing radiator 8641
1 7 Removing and installing coolant pump 8644
1 8 Checking cooling system for leaks 8645
20 – Fuel supply system 8648
1 Safety precautions 8648
1 1 Safety precautions when working on fuel supply system 8648
1 2 Releasing fuel pressure in high-pressure section 8649
2 Fuel tank 8651
2 1 Rules for cleanliness 8651
2 2 Assembly overview – fuel tank 8651
2 3 Emptying fuel tank 8653
2 3 1 Emptying fuel tank if it is more than 3/4 full 8654
2 3 2 Emptying fuel tank if it is less than 3/4 full 8654
2 4 Removing and installing fuel tank 8655
2 4 1 Removing 8656
2 4 2 Installing 8657
3 Repairing fuel supply system 8659
3 1 Rules for cleanliness 8659
3 2 Removing and installing fuel delivery unit 8659
3 3 Removing and installing fuel gauge sender -G- 8661
3 4 Checking fuel pump 8661
3 4 1 Checking function 8663
3 4 2 Checking fuel pressure 8664
3 4 3 Checking residual pressure 8666
3 4 4 Checking delivery rate 8666
3 4 5 Checking current draw 8669
4 Electronic power control (EPC) 8670
4 1 Assembly overview – accelerator module 8670
4 2 Removing and installing accelerator pedal module 8670
5 Activated charcoal filter system 8673
5 1 Assembly overview – activated charcoal filter system 8673
5 2 Checking fuel tank breather 8673
24 – Mixture preparation – injection 8676
1 Injection system 8676
1 1 General notes on injection 8676
1 2 Technical data 8676
1 3 Assembly overview – air filter 8677
1 4 Removing and installing air filter 8677
1 5 Assembly overview – intake manifold 8679
1 6 Assembly overview – Fuel rail with injectors 8681
1 7 Removing and installing injectors 8683
1 7 1 Removing 8683
1 7 2 Installing 8685
1 8 Removing and installing high-pressure pump 8686
1 9 Cleaning throttle valve module -J338- 8690
2 Checking components 8692
2 1 Checking function of intake manifold flap 8692
2 2 Checking vacuum reservoir in intake manifold for leaks 8692
2 3 Checking intake air preheating 8693
3 Engine control unit -J623- 8694
3 1 Removing and installing engine control unit -J623- 8694
3 2 Removing and installing anti-theft engine control unit -J623- 8694
26 – Exhaust system 8698
1 Parts of exhaust system 8698
1 1 Assembly overview – catalytic converters and attachments 8698
1 2 Assembly overview – silencers with mountings 8700
1 3 Separating centre and rear silencers 8700
2 Exhaust gas recirculation system 8702
2 1 Assembly overview – exhaust gas recirculation system 8702
2 2 Removing and installing exhaust gas recirculation valve -N18- 8703
28 – Ignition system 8704
1 Ignition system 8704
1 1 General notes on ignition system 8704
1 2 Safety precautions 8704
1 3 Assembly overview – ignition system 8705
1 4 Removing and installing ignition coils with output stage 8706
1 5 Spark plug test data 8707
K0059101720 6 cylinder injection engine 8708
00 – Technical data 8714
1 Engine number 8714
2 Engine data 8715
10 – Removing and installing engine 8716
1 Removing and installing engine 8716
1 1 Removing engine 8717
1 2 Securing engine on engine and gearbox support -VAS 6095- 8723
1 3 Installing engine 8724
1 4 Specified torques for assembly mounting 8726
13 – Crankshaft group 8728
1 Dismantling and assembling engine 8728
1 1 Assembly overview – parts l and ll 8728
1 2 Assembly overview – part I: chain drive 8730
1 3 Part II: Assembly overview – crankshaft drive 8732
1 4 Removing and installing poly-V belt 8733
1 5 Removing and installing vibration damper 8735
2 Sealing flanges and flywheel 8737
2 1 Assembly overview – sealing flange 8737
2 2 Removing and installing crankshaft seal on gearbox side 8738
2 3 Renewing crankshaft sealing flange, vibration damper side 8739
2 4 Removing and installing flywheel 8741
2 5 Removing and installing drive plate 8742
3 Crankshaft 8745
3 1 Assembly overview – crankshaft 8745
3 2 Allocation of main bearing shells 8746
3 2 1 Allocation of main bearing shells, up to and including manufacturing date 23 09 12 8746
3 2 2 Allocation of main bearing shells, from manufacturing date 24 09 12 8748
3 3 Fitting sender wheel to crankshaft 8750
3 4 Pulling needle bearing out of and driving into crankshaft 8751
4 Pistons and conrods 8753
4 1 Assembly overview – pistons and conrods 8753
4 1 1 Separating new conrod 8754
4 2 Checking pistons, piston rings and cylinder bores 8755
4 3 Installing piston 8756
4 4 Piston and cylinder dimensions 8757
15 – Cylinder head, valve gear 8758
1 Cylinder head 8758
1 1 Assembly overview – cylinder head 8758
1 2 Removing and installing cylinder head 8761
1 2 1 Removing 8763
1 2 2 Installing 8767
1 2 3 Preparing cylinder head gasket for assembly 8768
1 3 Assembly overview – cover 8769
1 4 Checking valve timing 8771
1 4 1 Checking valve timing (vehicles up to 11/2008) 8771
1 4 2 Checking valve timing (vehicles as of 11/2008) 8774
1 5 Removing and installing camshaft adjuster 8777
1 5 1 Removing and installing camshaft adjuster (vehicles to 11/2008) 8777
1 5 2 Removing and installing camshaft adjuster (vehicles from 11/2008) 8784
1 6 Removing and installing camshaft timing chain and intermediate shaft drive chain 8791
1 6 1 Removing and installing camshaft timing chain and intermediate shaft drive chain (vehicles to 11/2008) 8791
1 6 2 Removing and installing camshaft timing chain and intermediate shaft drive chain (vehicles from 11/2008) 8802
1 7 Removing and installing cylinder head cover 8813
1 8 Checking compression 8814
2 Valve gear 8817
2 1 Assembly overview 8817
2 2 Removing and installing camshafts 8819
2 2 1 Removing 8820
2 3 Removing and installing camshaft control valves 8825
2 4 Valve stem seals 8829
2 4 1 Removing 8831
2 4 2 Installing 8831
2 5 Checking valve guides 8833
2 6 Reworking valve seats 8833
17 – Lubrication 8836
1 Parts of lubrication system 8836
1 1 Engine oil: 8836
1 2 Assembly overview – sump 8836
1 3 Removing and installing sump 8839
1 4 Assembly overview – oil filter bracket 8841
1 5 Removing and installing oil filter bracket 8843
1 6 Assembly overview – oil pump 8844
1 7 Checking oil pressure and oil pressure switch 8846
1 7 1 Checking oil pressure switch 8847
1 7 2 Checking oil pressure 8848
19 – Cooling 8850
1 Removing and installing parts of cooling system 8850
1 1 Assembly overview – parts of cooling system, body side 8851
1 2 Assembly overview – cooling system, engine side (vehicles with manual gearbox) 8853
1 3 Assembly overview – cooling system, engine side (vehicles with DSG®) 8854
1 4 Assembly overview – thermostat housing 8856
1 5 Coolant hose connection diagram 8858
1 6 Draining and adding coolant 8859
1 7 Removing and installing fan mounting with fans 8862
1 8 Removing and installing radiator 8863
1 9 Checking continued coolant circulation pump 8865
1 10 Removing and installing coolant pump 8866
1 11 Removing and installing thermostat housing 8869
1 12 Removing and installing thermostat 8872
1 13 Removing and installing coolant pipe 8873
1 14 Checking cooling system for leaks 8875
1 14 1 Check pressure relief valve in cap 8876
20 – Fuel supply system 8877
1 Safety measures when working on fuel supply 8877
2 Rules for cleanliness 8878
3 Fuel 8879
3 1 Assembly overview – fuel tank 8879
3 2 Assembly overview – fuel tank (vehicles for USA and Canada) 8881
3 3 Emptying fuel tank 8883
3 3 1 Emptying fuel tank when fuel pump is intact 8884
3 3 2 Emptying fuel tank if it is more than 3/4 full 8886
3 3 3 Emptying fuel tank if it is less than 3/4 full 8886
3 4 Removing and installing fuel tank 8887
4 Repairing fuel supply 8891
4 1 Removing and installing fuel delivery unit 8891
4 2 Removing and installing fuel gauge sender -G- 8894
4 3 Assembly overview – fuel filter with attachments 8896
4 4 Removing and installing fuel filter 8897
4 5 Checking fuel pump 8898
4 5 1 Checking function and voltage supply 8899
4 5 2 Checking fuel delivery rate 8900
4 5 3 Checking current consumption 8903
4 5 4 Checking non-return valve for fuel pump 8904
4 6 Bleeding fuel system 8906
5 Electronic power control (EPC) 8909
5 1 Assembly overview – accelerator module 8909
5 2 Removing and installing accelerator pedal module 8909
6 Activated charcoal filter system 8912
6 1 Assembly overview – activated charcoal filter system 8912
6 2 Checking fuel tank breather 8912
7 Activated charcoal filter system (vehicles for USA and Canada) 8915
7 1 Overview of activated charcoal filter system 8915
7 2 Assembly overview – activated charcoal filter system 8916
7 3 Removing and installing activated charcoal filter 8917
7 4 Removing and installing fuel system diagnostic pump -V144- 8919
7 5 Checking fuel system for leaks 8919
7 5 1 Leak detection in fuel system 8923
7 5 2 Schematic overview of activated charcoal filter system 8924
7 5 3 Checking vacuum supply of fuel system diagnostic pump -V144- 8925
24 – Mixture preparation – injection 8927
1 Repairing injection system 8927
1 1 General notes on the injection system 8927
1 2 Technical data 8927
1 3 Assembly overview – intake manifold 8928
1 3 1 Assembly overview – vacuum system (engine code BUB) 8930
1 3 2 Assembly overview – vacuum system (engine code CBRA) 8931
1 4 Removing and installing throttle valve module -J338- 8932
1 5 Removing and installing intake manifold 8932
1 6 Assembly overview – fuel rail 8935
1 7 Assembly overview – air filter 8936
1 8 Checking intake air preheating 8936
2 Checking components 8938
2 1 Checking vacuum unit for intake manifold flaps 8938
2 2 Checking injectors for leaks and quantity injected 8939
2 2 1 Check for leaks 8940
2 2 2 Checking quantity injected 8942
2 3 Checking fuel pressure regulator and holding pressure 8944
3 Engine control unit 8948
3 1 Removing and installing engine control unit 8948
3 2 Removing and installing anti-theft engine control unit 8948
26 – Exhaust system 8952
1 Exhaust manifold, front exhaust pipe with catalytic converters and Lambda probes 8952
1 1 Assembly overview – exhaust manifold, front exhaust pipe with catalytic converters and front silencers 8953
1 2 Removing and installing Lambda probe -G39- and Lambda probe 2 -G108- 8955
1 3 Removing and installing exhaust manifold 8956
1 4 Removing and installing front exhaust pipe with catalytic converters 8958
2 Silencer with mountings 8961
2 1 Assembly overview – silencers with mountings 8961
2 2 Clamps 8962
2 3 Separating centre and rear silencers 8962
2 4 Aligning exhaust system free of stress 8963
3 Secondary air system (engine code BUB) 8965
3 1 Function 8965
3 2 Assembly overview – secondary air system 8965
3 3 Removing and installing secondary air pump motor -V101- 8966
3 4 Checking combination valve for secondary air system 8967
3 5 Removing and installing combination valve for secondary air system 8967
4 Secondary air system (engine code CBRA) 8969
4 1 Function 8969
4 2 Assembly overview – secondary air system 8969
4 3 Checking secondary air combination valves 8971
4 4 Removing and installing left combination valve for secondary air system 8972
4 5 Removing and installing right combination valve for secondary air system 8972
28 – Ignition system 8974
1 Ignition system 8974
1 1 General notes on ignition system 8974
1 2 Safety precautions 8974
1 3 Assembly overview – parts of ignition system 8975
1 4 Removing and installing ignition coils with output stage 8976
1 5 Test data, spark plugs 8978
K0059101820 4 cyl injection engine (1 4 l engine 4V EA 111 turbocharger) 8979
00 – Technical data 8987
1 Technical data 8987
1 1 Engine number 8987
1 2 Engine data 8987
10 – Removing and installing engine 8989
1 Removing and installing engine (Golf, Golf Plus, Eos, Scirocco) 8989
1 1 Removing engine 8989
1 2 Securing engine to assembly stand 8997
1 3 Installing engine 8997
1 4 Torque settings 9000
1 5 Assembly mountings 9000
1 6 Additional information and assembly work for vehicles with air conditioner 9001
2 Removing and installing engine (Tiguan) 9002
2 1 Removing engine 9002
2 2 Securing engine to assembly stand 9011
2 3 Installing engine 9011
2 4 Torque settings 9013
2 5 Assembly mountings 9014
2 6 Additional information and assembly work for vehicles with air conditioner 9015
3 Removing and installing engine (Passat) 9016
3 1 Removing engine 9016
3 2 Securing engine to assembly stand 9027
3 3 Installing engine 9027
3 4 Torque settings 9030
3 5 Assembly mountings 9030
3 6 Additional information and assembly work for vehicles with air conditioner 9031
13 – Crankshaft group 9032
1 Dismantling and assembling engine 9032
1 1 Assembly overview – parts l and ll 9032
1 2 Assembly overview – part I, belt drive 9034
1 3 Assembly overview – part II, cylinder block 9035
1 4 Removing and installing poly-V belt 9037
1 4 1 Poly V-belt routing 9038
1 5 Removing and installing valve timing housing (Golf, Golf Plus, Eos, Scirocco) 9038
1 5 1 Removing 9040
1 5 2 Installing 9042
1 6 Removing and installing valve timing housing (Tiguan) 9043
1 7 Removing and installing valve timing housing (Passat) 9047
1 8 Removing and installing bracket for ancillaries 9052
2 Removing and installing sealing flanges and flywheel or drive plate 9054
2 1 Assembly overview 9054
2 2 Removing and installing engine speed sender -G28- 9055
2 3 Renewing crankshaft oil seal – belt pulley end 9056
2 4 Removing and installing crankshaft pulley 9058
2 5 Renewing crankshaft sealing flange – flywheel end 9061
2 5 1 Pressing sealing flange with sender wheel off crankshaft 9062
2 5 2 Pressing sealing flange with sender wheel onto crankshaft 9063
2 5 3 A – Assemble seal with sender wheel on assembly tool -T10134- 9064
2 5 4 B – Attaching assembling tool -T10134- with sealing flange on crankshaft flange 9066
2 5 5 C – Bolting assembly tool -T10134- onto crankshaft flange 9067
2 5 6 D – Pressing sender wheel onto crankshaft flange using assembly tool -T10134- 9067
2 5 8 f) Re-pressing sender wheel 9069
3 Crankshaft 9070
3 1 Assembly overview 9070
3 2 Pulling needle bearing out of and driving into crankshaft 9071
3 3 Crankshaft dimensions 9073
4 Dismantling and assembling pistons and conrods 9074
4 1 Assembly overview 9074
4 2 Checking piston 9076
4 2 1 Checking cylinder bores 9077
4 3 Separating new conrod 9077
4 4 Piston and cylinder dimensions 9077
4 5 Removing and installing pistons 9078
4 6 Removing and installing oil spray jets 9079
15 – Cylinder head, valve gear 9080
1 Cylinder head 9080
1 1 Assembly overview 9080
1 2 Checking valve timing 9083
1 3 Adjusting valve timing 9085
1 4 Checking timing chain 9094
1 5 Removing and installing timing chain and chain drive for oil pump 9100
1 6 Removing and installing camshaft housing 9108
1 6 1 Removing 9110
1 6 2 Installing 9112
1 7 Removing and installing cylinder head 9114
1 8 Checking compression 9117
2 Repairing valve gear 9120
2 1 Assembly overview 9120
2 2 Checking camshaft axial clearance 9122
2 3 Removing and installing camshaft 9122
2 4 Reworking valve seats 9123
2 5 Checking valve guides 9124
2 6 Renewing valve stem seals 9125
17 – Lubrication 9127
1 Removing and installing parts of lubrication system 9127
1 1 Engine oil, oil capacities, engine oil specification 9127
1 2 Assembly overview (► model year 2008) 9127
1 3 Assembly overview (model year 2009 ►) 9130
1 4 Removing and installing oil sump 9132
1 5 Removing and installing oil pump 9135
1 6 Checking oil pressure and oil pressure switch 9137
19 – Cooling 9140
1 Removing and installing parts of cooling system 9140
1 1 Assembly overview – parts of cooling system, body side 9141
1 2 Assembly overview – parts of cooling system, engine side 9143
1 3 Coolant hose connection diagram 9144
1 4 Draining and adding coolant 9145
1 5 Removing and installing radiator fan -V7- and radiator fan 2 -V177- (Golf, Golf Plus, Eos, Scirocco) 9148
1 6 Removing and installing radiator fan -V7- and radiator fan 2 -V177- (Tiguan, Passat) 9149
1 7 Checking cooling system for leaks 9150
1 8 Removing and installing radiator (Golf, Golf Plus, Scirocco, Eos) 9151
1 9 Removing and installing radiator (Tiguan, Passat) 9153
1 10 Removing and installing auxiliary radiator for charge air system (Tiguan, Passat) 9155
1 11 Removing and installing coolant pump 9159
1 12 Removing and installing coolant circulation pump -V50- 9161
20 – Fuel supply system 9164
1 Safety precautions 9164
1 1 Safety regulations for working on fuel supply 9164
1 2 Releasing pressure in high-pressure area 9165
2 Separating plug-in connectors 9166
3 Fuel tank (Golf, Golf Plus, Scirocco) 9169
3 1 Assembly overview – fuel tank 9169
3 2 Emptying fuel tank 9170
3 2 1 Emptying fuel tank if it is more than 3/4 full 9171
3 2 2 Emptying fuel tank if it is less than 3/4 full 9172
3 3 Removing and installing fuel tank 9173
4 Fuel tank (Passat) 9175
4 1 Assembly overview – fuel tank 9175
4 2 Emptying fuel tank 9176
4 2 1 Emptying fuel tank if it is more than 3/4 full 9177
4 2 2 Emptying fuel tank if it is less than 3/4 full 9178
4 3 Removing and installing fuel tank 9179
4 3 1 Removing fuel tank 9179
4 3 2 Installing fuel tank 9181
5 Fuel tank (Eos) 9183
5 1 Assembly overview – fuel tank 9183
5 2 Emptying fuel tank 9185
5 2 1 Emptying fuel tank if it is more than 3/4 full 9185
5 2 2 Emptying fuel tank if it is less than 3/4 full 9186
5 3 Removing and installing fuel tank 9187
6 Fuel tank (Tiguan) 9190
6 1 Assembly overview – fuel tank (Tiguan) 9190
6 2 Draining fuel tank (Tiguan) 9192
6 2 1 Emptying fuel tank if it is more than 3/4 full 9193
6 2 2 Emptying fuel tank if it is less than 3/4 full 9194
6 3 Removing and installing fuel tank (Tiguan) 9194
7 Repairing fuel supply system (Golf, Golf Plus, Scirocco, Eos) 9199
7 1 Rules for cleanliness 9199
7 2 Crash fuel shut-off 9199
7 3 Removing and installing fuel delivery unit (Golf Plus, Golf, Scirocco, Eos) 9200
7 4 Removing and installing fuel gauge sender G 9202
7 5 Checking fuel pump 9203
7 5 1 Checking function and voltage supply 9204
7 5 2 Checking fuel pressure 9207
7 5 3 Checking holding pressure 9208
7 5 4 Checking fuel delivery rate 9210
7 5 5 Checking current consumption 9213
8 Repairing fuel supply (Passat) 9215
8 1 Rules for cleanliness 9215
8 2 Crash fuel shut-off 9215
8 3 Removing and installing fuel delivery unit 9216
8 4 Removing and installing fuel gauge sender G 9219
8 5 Checking fuel pump 9221
8 5 1 Checking function and voltage supply 9222
8 5 2 Checking fuel pressure 9224
8 5 3 Checking holding pressure 9225
8 5 4 Checking fuel delivery rate 9226
8 5 5 Checking current consumption 9228
9 Repairing fuel supply (Tiguan) 9230
9 1 Rules for cleanliness 9230
9 2 Crash fuel shut-off 9230
9 3 Removing and installing fuel delivery unit (Tiguan) 9231
9 3 1 Removing 9231
9 3 2 Installing 9233
9 4 Removing and installing fuel gauge sender -G- (Tiguan) 9233
9 5 Removing and installing suction-jet pump (Tiguan) 9234
9 5 1 Removing 9235
9 5 2 Installing 9236
9 6 Removing and installing fuel gauge sender 2 -G169- (Tiguan) 9237
9 7 Removing and installing fuel pump control unit -J538- (Tiguan) 9237
9 8 Checking fuel pump (Tiguan) 9239
9 8 1 Checking function and voltage supply 9240
9 8 2 Checking fuel pressure 9241
9 8 3 Checking holding pressure 9242
9 8 4 Checking fuel delivery rate 9243
9 8 5 Checking current consumption 9246
10 Repairing electronic power control (EPC) 9248
10 1 Assembly overview 9248
10 2 Removing and installing accelerator pedal module 9248
11 Activated charcoal filter system (Golf, Golf Plus, Eos, Scirocco) 9250
11 1 Assembly overview (Golf, Golf Plus, Eos, Scirocco) 9250
11 2 Checking fuel tank breather (Golf, Golf Plus, Eos, Scirocco) 9251
11 3 Rules for cleanliness 9251
12 Activated charcoal filter system (Passat) 9253
12 1 Assembly overview 9253
12 2 Checking fuel tank breather 9254
12 3 Rules for cleanliness 9255
13 Activated charcoal filter system (Tiguan) 9256
13 1 Assembly overview (Tiguan) 9256
13 2 Checking fuel tank breather (Tiguan) 9257
13 3 Rules for cleanliness 9258
21 – Turbocharging/supercharging 9259
1 Exhaust turbocharger 9259
1 1 Assembly overview – turbocharger 9259
1 2 Part I 9261
1 3 Part II 9262
1 4 Removing and installing turbocharger 9263
1 5 Removing and installing compressor housing and turbine housing 9268
1 6 Checking vacuum unit for turbocharger 9272
1 7 Removing and installing vacuum unit for turbocharger 9274
1 8 Adjusting vacuum unit for turbocharger 9276
2 Charge air system 9283
2 1 Assembly overview – charge air system 9283
2 2 Removing and installing intake manifold charge air cooler 9284
24 – Mixture preparation – injection 9286
1 Injection system 9286
1 1 Assembly overview – parts l and II, intake manifold 9286
1 2 Assembly overview – part I, intake manifold 9288
1 3 Assembly overview – part II, intake manifold 9289
1 4 Assembly overview – fuel rail with injectors 9290
1 5 Assembly overview – air filter 9290
1 6 Removing and installing air filter 9291
1 7 Removing and installing throttle valve module -J338- 9292
1 8 Cleaning throttle valve module -J338- 9295
1 9 Removing and installing intake manifold 9296
1 10 Assembly overview – high-pressure pump 9297
1 11 Checking fuel pressure sender -G247- 9298
1 12 Removing and installing high-pressure pump 9301
1 13 Removing and installing injectors 9305
1 14 Renewing Teflon seal and support washer on injector 9308
1 15 Safety precautions 9311
1 16 Rules for cleanliness 9313
1 17 Technical data 9313
2 Engine control unit -J623- 9314
2 1 Removing and installing engine control unit -J623- (Golf ► 2008, Eos) 9314
2 2 Removing and installing anti-theft engine control unit -J623- (Golf ► 2008, Eos ► 10 2008) 9315
2 3 Removing and installing engine control unit -J623- (Golf 2009 ►) 9317
2 4 Removing and installing anti-theft engine control unit -J623- (Golf 2009 ►, Eos 11 2008 ►, Scirocco 10 2008►, Passat 2011►) 9319
2 5 Removing and installing engine control unit -J623- (Golf Plus) 9321
2 6 Removing and installing anti-theft engine control unit -J623- (Golf Plus) 9322
2 7 Removing and installing engine control unit -J623- (Passat 2006 ►) 9325
2 8 Removing and installing anti-theft engine control unit -J623- (Passat 2006 ►) 9326
2 9 Removing and installing engine control unit -J623- (Scirocco) 9327
2 10 Removing and installing anti-theft engine control unit -J623- (Scirocco ► 09 2008) 9328
2 11 Removing and installing engine control unit -J623- (Tiguan) 9330
2 12 Removing and installing anti-theft engine control unit -J623- (Tiguan) 9331
26 – Exhaust system 9334
1 Removing and installing parts of exhaust system 9334
1 1 Assembly overview – catalytic converter and attachments 9334
1 2 Assembly overview – silencer with mountings (Golf, Golf Plus, Scirocco) 9337
1 3 Assembly overview – silencer with mountings (Passat 2006 ►) 9338
1 4 Assembly overview – silencer with mountings (Passat 2011 ►) 9339
1 5 Assembly overview – silencer with mountings (Eos) 9340
1 6 Assembly overview – silencer with mountings (Tiguan) 9341
1 7 Removing and installing centre and rear silencers (Golf, Golf Plus, Scirocco, Eos) 9341
1 8 Detaching centre and rear silencers (Passat) 9343
1 9 Detaching centre and rear silencers (Tiguan) 9345
1 10 Installation position and specified torque of clamp 9346
28 – Ignition system 9348
1 Repairing ignition system 9348
1 1 Assembly overview – ignition system 9348
1 2 Removing and installing ignition coils with output stage 9349
1 3 Safety precautions 9350
1 4 Test data, spark plugs 9351
K0059111420 4 cylinder direct injection engine (1 4 l EA 111 turbocharger supercharger) 9352
00 – Technical data 9360
1 Engine number/engine data 9360
2 Safety precautions 9364
2 1 Safety regulations for working on fuel supply 9364
2 2 Safety precautions when working on ignition system 9364
2 3 Releasing pressure in high-pressure area 9365
3 General repair instructions 9366
3 1 Rules for cleanliness 9366
10 – Removing and installing engine 9367
1 Removing and installing motor 9367
1 1 Removing engine (Golf Plus, Eos, Scirocco, Golf, Touran, Golf Cabriolet) 9367
1 2 Installing engine (Golf Plus, Eos, Scirocco, Golf, Touran, Golf Cabriolet) 9377
1 3 Removing engine (Tiguan) 9379
1 4 Installing engine (Tiguan) 9387
1 5 Removing engine (Polo) 9390
1 6 Installing engine (Polo) 9398
1 7 Removing engine (Sharan) 9399
1 8 Installing engine (Sharan) 9407
1 9 Removing engine (Passat, Passat CC) 9409
1 10 Installing engine (Passat, Passat CC) 9419
2 Assembly mountings 9423
2 1 Assembly overview – assembly mountings (Touran, Golf Plus, Eos, Scirocco, Golf, Golf Cabriolet) 9423
2 2 Assembly overview – assembly mountings (Tiguan) 9424
2 3 Assembly overview – assembly mountings (Polo) 9425
2 4 Assembly overview – assembly mountings (Sharan) 9426
2 5 Assembly overview – assembly mountings (Passat, Passat CC) 9426
13 – Crankshaft group 9428
1 Cylinder block (pulley end) 9428
1 1 Assembly overview – poly V-belt drive 9430
1 2 Assembly overview – cylinder block, belt pulley end 9432
1 3 Removing and installing poly V-belt (Golf Plus, Eos, Scirocco, Golf, Touran, Polo, Sharan, Passat, Passat CC, Golf Cabriolet) 9434
1 3 1 Poly V-belt routing 9436
1 4 Removing and installing poly V-belt (Tiguan) 9437
1 4 1 Poly V-belt routing 9438
1 5 Removing and installing bracket for ancillaries 9439
1 6 Renewing crankshaft oil seal – pulley end 9440
1 7 Removing and installing crankshaft pulley 9442
2 Cylinder block, gearbox end 9446
2 1 Assembly overview – cylinder block, gearbox end 9446
2 2 Removing and installing sealing flange on gearbox side 9448
2 2 1 Pressing sealing flange with sender wheel off crankshaft 9448
2 2 2 Pressing sealing flange with sender wheel onto crankshaft 9449
2 2 3 A – Assemble seal with sender wheel on assembly tool -T10134- 9450
2 2 4 B – Fitting assembly tool -T10134- with sealing flange to crankshaft flange 9452
2 2 5 C – Screwing assembly tool -T10134- on crankshaft flange 9453
2 2 6 D – Pressing sender wheel onto crankshaft flange using assembly tool -T10134- 9453
2 2 8 f) Re-pressing sender wheel 9455
3 Crankshaft 9456
3 1 Assembly overview – crankshaft 9456
3 2 Pulling needle bearing out of and driving into crankshaft 9457
3 3 Crankshaft dimensions 9459
4 Pistons and conrods 9460
4 1 Assembly overview – pistons and conrods 9460
4 2 Checking piston 9462
4 3 Checking cylinder bores 9463
4 4 Separating new conrod 9463
4 5 Removing and installing pistons 9463
4 6 Removing and installing oil spray jets 9464
15 – Cylinder head, valve gear 9466
1 Cylinder head 9466
1 1 Assembly overview – cylinder head 9466
1 2 Removing and installing camshaft housing 9469
1 2 1 Removing 9470
1 2 2 Installing 9472
1 3 Removing and installing cylinder head 9475
1 3 1 Removing 9475
1 3 2 Installing 9476
1 4 Checking compression 9477
2 Valve gear 9480
2 1 Assembly overview – valve gear 9480
2 2 Measuring axial clearance of camshaft 9482
2 3 Reworking valve seats 9482
2 4 Checking valve guides 9484
2 5 Removing and installing valve stem seals 9484
2 5 1 Removing 9485
2 5 2 Installing 9486
3 Cover for timing chain 9487
3 1 Removing and installing valve timing housing (Eos, Golf Plus, Scirocco, Golf, Polo, Sharan, Golf Cabriolet) 9487
3 1 1 Removing 9488
3 1 2 Installing 9490
3 2 Removing and installing valve timing housing (Touran, Tiguan) 9491
3 2 1 Removing 9494
3 2 2 Installing 9496
3 3 Removing and installing valve timing housing (Passat CC, Passat) 9497
4 Chain drive 9502
4 1 Checking valve timing 9502
4 2 Adjusting valve timing 9504
4 3 Checking timing chain 9511
4 4 Removing and installing timing chain and chain drive for oil pump 9518
17 – Lubrication 9527
1 Sump, oil pump 9527
1 1 Engine oil: 9527
1 2 Assembly overview – sump, oil pump 9527
1 3 Removing and installing sump 9530
1 4 Removing and installing oil pump 9534
2 Oil filter, oil pressure switch 9537
2 1 Checking oil pressure and oil pressure switch 9537
19 – Cooling 9539
1 Cooling system/coolant 9539
1 1 Coolant hose schematic diagram (Golf Plus, Eos, Scirocco, Golf, Touran, Polo, Golf Cabriolet) 9540
1 2 Schematic diagram for coolant hoses (Tiguan) 9541
1 3 Schematic diagram for coolant hoses (Sharan) 9542
1 4 Coolant hose schematic diagram (Passat, Passat CC) 9543
1 5 Draining and filling with coolant (Golf Plus, Eos, Scirocco, Golf, Touran, Tiguan, Golf Cabriolet) 9544
1 6 Draining and filling coolant (Polo) 9548
1 7 Draining and filling coolant (Sharan) 9552
1 8 Draining and filling coolant (Passat, Passat CC) 9557
1 9 Checking cooling system for leaks (Polo, Touran, Golf Plus, Eos, Scirocco, Golf, Golf Cabriolet) 9563
1 10 Checking cooling system for leaks (Sharan, Tiguan) 9565
1 11 Checking cooling system for leaks (Passat, Passat CC) 9567
2 Coolant pump, regulation of cooling system 9570
2 1 Assembly overview – thermostat 9570
2 2 Assembly overview – thermostat (Passat, Passat CC) 9572
2 3 Removing and installing coolant pump (Polo, Touran, Golf Plus, Eos, Tiguan, Scirocco, Golf, Golf Cabriolet) 9573
2 4 Removing and installing coolant pump belt pulley (Polo, Touran, Golf Plus, Eos, Tiguan, Scirocco, Golf, Golf Cabriolet) 9577
2 5 Removing and installing coolant circulation pump -V50- (Polo, Touran, Golf Plus, Eos, Tiguan, Scirocco, Golf, Golf Cabriolet) 9582
2 6 Removing and installing coolant pump (Sharan) 9584
2 7 Removing and installing coolant pump belt pulley (Sharan) 9589
2 8 Removing and installing coolant circulation pump -V50- (Sharan) 9593
2 9 Removing and installing coolant pump belt pulley (Passat, Passat CC) 9595
2 10 Removing and installing coolant pump (Passat, Passat CC) 9601
2 11 Removing and installing coolant circulation pump -V50- (Passat, Passat CC) 9608
2 12 Assembly overview – heater element for engine preheater -Z97- (Passat, Passat CC) 9610
2 13 Removing and installing heater element for engine preheater -Z97- (Passat, Passat CC) 9612
3 Radiator, radiator fan 9615
3 1 Assembly overview – radiator/radiator fan (Eos, Golf Plus, Scirocco, Golf, Touran, Golf Cabriolet) 9615
3 2 Assembly overview – parts of cooling system, body side (Tiguan) 9617
3 3 Assembly overview – radiator/radiator fan (Polo) 9619
3 4 Assembly overview – radiator/radiator fan (Sharan) 9620
3 5 Assembly overview – radiator/radiator fan (Passat, Passat CC) 9621
3 6 Removing and installing radiator fan -V7- and radiator fan 2 -V177- (Eos, Golf Plus, Scirocco, Golf, Touran, Golf Cabriolet) 9622
3 7 Removing and installing radiator fan -V7- and radiator fan 2 -V177- (Polo) 9623
3 8 Removing and installing radiator, radiator fan -V7- and radiator fan 2 -V177- (Sharan) 9624
3 9 Removing and installing radiator (Passat, Passat CC) 9626
3 10 Removing and installing fan cowling (Passat, Passat CC) 9629
3 11 Removing and installing radiator fan -V7- and radiator fan 2 -V177- (Passat, Passat CC) 9630
3 12 Removing and installing radiator (Golf Plus, Eos, Scirocco, Golf, Touran, Golf Cabriolet) 9631
3 13 Removing and installing radiator and radiator fan -V7- (Tiguan) 9632
3 14 Removing and installing radiator with charge air cooler (Polo) 9634
21 – Turbocharging/supercharging 9637
1 Turbocharger 9637
1 1 Assembly overview – turbocharger 9637
1 2 Removing and installing turbocharger 9641
1 3 Checking vacuum unit for turbocharger 9646
1 4 Removing and installing vacuum unit for turbocharger 9648
1 5 Adjusting vacuum unit for turbocharger 9650
2 Compressor 9656
2 1 Assembly overview – supercharger 9656
2 2 Removing and installing supercharger 9658
2 3 Removing and installing supercharger (Tiguan with four-wheel drive) 9666
2 4 Removing and installing drive unit seal for supercharger 9674
3 Charge air system 9678
3 1 Assembly overview – charge air system (Eos, Golf Plus, Golf, Touran, Scirocco, Tiguan, Sharan, Golf Cabriolet) 9679
3 2 Assembly overview – charge air system (Polo) 9680
3 3 Assembly overview – charge air system (Passat, Passat CC) 9681
3 4 Fitting hose connections with plug-in connectors 9682
3 5 Checking charge air system for leaks 9683
3 6 Removing and installing charge air cooler (Eos, Golf Plus, Golf, Golf Cabriolet, Touran) 9686
3 7 Removing and installing charge air cooler, Sharan 9688
3 8 Removing and installing charge air cooler (Scirocco) 9690
3 9 Removing and installing charge air cooler, Tiguan 9692
3 10 Removing and installing charge air cooler (Passat, Passat CC) 9694
24 – Mixture preparation – injection 9699
1 Air filter 9699
1 1 Assembly overview – air filter 9699
1 2 Assembly overview – air filter (Polo) 9700
1 3 Removing and installing air filter housing 9701
1 4 Removing and installing air filter housing (Polo) 9702
2 Intake manifold 9703
2 1 Assembly overview – intake manifold 9703
2 2 Removing and installing regulating flap control unit -J808- and throttle valve module -J338- 9708
2 3 Cleaning throttle valve module -J338- 9710
3 Injectors 9712
3 1 Assembly overview – fuel rail with injectors 9712
3 2 Removing and installing injectors 9714
3 3 Renewing seals on injectors 9717
4 Senders and sensors 9721
4 1 Checking fuel pressure sender 9721
4 2 Actuator for structure-borne sound -R214- and control unit for structure-borne sound -J869- (Polo, left-hand drive) 9724
4 3 Assembly overview – actuator for structure-borne sound -R214- and control unit for structure-borne sound -J869- (Polo, right-hand drive) 9726
5 High-pressure pump 9727
5 1 Assembly overview – high-pressure pump 9727
5 2 Removing and installing high-pressure pump 9728
6 Engine control unit -J623- 9732
6 1 Removing and installing engine control unit -J623- (Golf Plus, Touran) 9732
6 2 Removing and installing engine control unit -J623- with protective housing (Golf Plus, Touran) 9734
6 3 Removing and installing engine control unit -J623- (Eos) 9736
6 4 Removing and installing engine control unit -J623- with protective housing (Eos► 10 2008) 9737
6 5 Removing and installing engine control unit -J623- (Tiguan) 9739
6 6 Removing and installing engine control unit -J623- with protective housing (Tiguan) 9740
6 7 Removing and installing engine control unit -J623- (Scirocco) 9742
6 8 Removing and installing engine control unit -J623- with protective housing (Scirocco► 09 2008) 9743
6 9 Removing and installing engine control unit -J623- (Golf, Golf Cabriolet) 9745
6 10 Removing and installing engine control unit -J623- (Passat, Passat CC) 9746
6 11 Removing and installing engine control unit -J623- with protective housing (Golf, Eos 11 2008►, Scirocco 10 2008►, Passat, Passat CC, Golf Cabriolet) 9747
6 12 Removing and installing engine control unit -J623- (Polo) 9750
6 13 Removing and installing engine control unit -J623- with protective housing (Polo) 9751
6 14 Removing and installing engine control unit -J623- (Sharan) 9752
6 15 Removing and installing engine control unit -J623- with protective housing (Sharan) 9753
26 – Exhaust system 9755
1 Exhaust pipes and silencers 9755
1 1 Assembly overview – silencer (Golf Plus, Eos, Scirocco, Golf, Touran, Golf Cabriolet) 9756
1 2 Assembly overview – silencers (Tiguan) 9757
1 3 Assembly overview – silencers (Polo) 9758
1 4 Assembly overview – silencers (Sharan) 9759
1 5 Assembly overview – silencer (Passat, Passat CC) 9760
1 6 Removing and installing front exhaust pipe (Tiguan with four-wheel drive) 9761
1 7 Removing and installing front exhaust pipe (Golf Plus, Eos, Scirocco, Golf, Tiguan, Touran, Golf Cabriolet) 9762
1 8 Removing and installing front exhaust pipe (Sharan) 9763
1 9 Removing and installing (Passat, Passat CC) 9764
1 10 Separating exhaust pipes, silencers (Tiguan) 9766
1 11 Separating exhaust pipes/silencers (Golf Plus, Eos, Scirocco, Golf, Touran, Golf Cabriolet) 9767
1 12 Separating exhaust pipes, silencers (Polo) 9769
1 13 Separating exhaust pipes, silencers (Sharan) 9770
1 14 Separating exhaust pipes/silencers (Passat, Passat CC) 9771
1 15 Aligning exhaust system free of stress (Passat, Passat CC) 9773
1 16 Installation position of clamp 9774
2 Emission control 9775
2 1 Assembly overview – exhaust gas treatment (Golf Plus, Eos, Scirocco, Golf, Touran, Tiguan, Golf Cabriolet) 9775
2 2 Assembly overview – exhaust gas treatment (Tiguan with four-wheel drive) 9777
2 3 Assembly overview – exhaust gas treatment (Polo) 9779
2 4 Assembly overview – exhaust gas treatment (Sharan) 9780
2 5 Assembly overview – exhaust gas treatment (Passat, Passat CC) 9781
2 6 Removing and installing catalytic converter (Polo) 9783
2 7 Removing and installing (Passat, Passat CC) 9784
28 – Ignition system 9787
1 Ignition system 9787
1 1 Assembly overview – ignition system 9787
1 2 Removing and installing ignition coils with output stage 9788
1 3 Removing and installing engine speed sender -G28- 9790
1 4 Test data, spark plugs 9792
K0358990220 6 speed manual gearbox 02Q 9793
00 – Technical data 9801
1 Front-wheel drive – gearbox identification 9801
1 1 Location on gearbox 9801
1 2 Front-wheel drive – identification codes, assembly allocation and capacities, Golf 2004 ► 9802
1 3 Front-wheel drive – identification codes, assembly allocation and capacities, Golf 2009 ► 9805
1 4 Identification codes, assembly allocation, capacities, Golf Plus 2005 ► 9807
1 5 Identification codes, assembly allocation, capacities, Golf Plus 2009 ► 9808
1 6 Front-wheel drive – identification codes, assembly allocation and capacities, Passat 2006 ► 9809
1 7 Identification codes, assembly allocation, capacities, Passat CC 2009 ► 9812
1 8 Identification codes, assembly allocation and capacities, front-wheel drive CC 2010 ► 9813
1 9 Identification codes, assembly allocation, capacities, Eos 2006 ► 9815
1 10 Identification codes, assembly allocation and capacities, Scirocco 2009 ► 9817
1 11 Identification codes, assembly allocation, capacities, Touran 2003 ► 9819
2 All-wheel drive – gearbox identification 9823
2 1 Location on gearbox 9823
2 2 All-wheel drive – identification codes, assembly allocation, capacities – Golf 2005 ► 9824
2 3 All-wheel drive – identification codes, assembly allocation, capacities – Golf 2009 ► 9828
2 4 All-wheel drive – identification codes, assembly allocation, capacities – Passat 2006 ► 9829
2 5 All-wheel drive – identification codes, assembly allocation and capacities – CC 2010 ► 9830
3 Front-wheel drive – Overview power transmission 9832
4 Overview – all-wheel drive power train 9834
5 Calculating overall gear ratio “i” 9836
6 All-wheel drive – notes on performance test 9837
7 General repair instructions 9838
7 1 Contact corrosion 9838
7 2 Special tool 9838
7 3 Front-wheel drive – gearbox 9838
7 4 four-wheel drive – gearbox 9838
7 5 Gaskets, seals 9839
7 6 Sealant 9839
7 7 Locking devices 9840
7 8 Nuts and bolts 9840
7 9 Bearings 9840
7 10 Shims 9841
7 11 Synchro-rings 9841
7 12 Gear wheels 9841
7 13 Synchromeshed gears 9841
7 14 Clutch 9842
8 Safety precautions for vehicles with a start-stop system 9843
30 – Clutch 9844
1 Repairing clutch mechanism 9844
1 1 Overview 9844
1 2 Touran to 05 03 only: Assembly overview – pedal cluster with clutch pedal switch -F36- 9845
1 3 Touran as of 06 03, Golf, Golf Plus, Passat, Passat CC, CC, Eos and Scirocco: Assembly overview – pedal cluster 9847
1 4 Removing and installing over-centre spring 9850
1 4 1 Removing and installing over-centre spring – Golf 2004 ► 9850
1 4 2 Removing and installing over-centre spring – Golf 2009 ► left-hand drive and Scirocco 9855
1 4 3 Removing and installing over-centre spring – Golf 2009 ► right-hand drive 9860
1 4 4 Removing and installing over-centre spring, Golf Plus 9865
1 4 5 Removing and installing over-centre spring, Passat, Passat CC, CC, Touran to approx 05 03 and Eos 9870
1 5 Removing and installing over-centre spring with mounting bracket installed (Touran from approx 06 03) 9872
1 6 Removing and installing clutch pedal 9875
1 6 1 Removing and installing clutch pedal, Golf 2004 ►, Golf 2009 ►, Golf Plus, Touran from approx 06 03 and Scirocco 9875
1 6 2 Removing and installing clutch pedal, Passat, Passat CC, CC, Touran to approx 05 03 and Eos 9877
1 7 Removing and installing mounting bracket, Golf 2004 ► 9879
1 7 1 Removing 9880
1 7 2 Installing 9885
1 7 3 Specified torques 9887
1 8 Removing and installing mounting bracket – Golf 2009 ► left-hand drive and Scirocco 9887
1 8 1 Removing 9887
1 8 2 Installing 9892
1 8 3 Specified torques 9893
1 9 Removing and installing mounting bracket, Golf Plus left-hand drive 9893
1 9 1 Removing 9894
1 9 2 Installing 9899
1 9 3 Specified torques 9900
1 10 Removing and installing mounting bracket, Golf 2009 ► RHD and Golf Plus RHD 9900
1 10 1 Removing 9901
1 10 2 Installing 9905
1 10 3 Specified torques 9908
1 11 Removing and installing master cylinder 9908
1 11 1 Removing 9908
1 11 2 Installing 9909
1 12 Assembly overview – hydraulics (left-hand drive vehicles) 9910
1 13 Assembly overview – hydraulics (right-hand drive vehicles) 9913
1 14 Touran: Removing and installing clutch pedal switch -F36- 9915
1 14 1 Removing 9915
1 14 2 Installing 9916
1 15 Removing and installing mounting bracket (all Tourans) 9917
1 15 1 Removing 9919
1 15 2 Installing 9925
1 15 3 Specified torques 9928
1 16 Touran: removing and installing master cylinder with mounting bracket removed (to 05 03) 9928
1 16 1 Removing 9928
1 16 2 Installing 9929
1 17 Removing and installing mounting bracket, Passat, Passat CC and CC 9930
1 17 1 Removing 9931
1 17 2 Installing 9933
1 17 3 Specified torques 9934
1 18 Removing and installing mounting bracket, Eos 9934
1 18 1 Removing 9935
1 18 2 Installing 9937
1 18 3 Specified torques 9939
2 Removing and installing clutch position sender -G476- 9940
2 1 Removing 9940
2 2 Installing 9943
3 Bleeding clutch system 9945
4 Servicing clutch release mechanism 9947
4 1 Assembly overview 9947
4 2 Removing line and bleeder from and installing on slave cylinder 9948
4 3 Removing and installing slave cylinder with release bearing 9949
4 3 1 Removing 9949
4 3 2 Installing 9950
4 4 Removing and installing line for clutch mechanism 9951
4 4 1 Removing 9951
4 4 2 Installing 9953
5 Servicing clutch, in conjunction with dual-mass flywheel 9955
5 1 Identifying make of clutch, vehicles with 2 0 l – 100 kW turbo diesel engine and vehicles with 2 0 l – 103 kW turbo diesel engine 9955
5 2 Removing and installing “Sachs” clutch 9957
5 2 1 Removing 9957
5 2 2 Installing 9957
5 3 Repairing “Sachs” clutch 9960
5 4 Removing and installing “LuK” clutch 9961
5 4 1 Removing 9961
5 4 2 Installing 9961
5 5 Servicing LuK clutch 9965
6 Servicing clutch, in conjunction with one-piece flywheel 9966
34 – Controls, housing 9970
1 Repairing selector mechanism 9970
1 1 Installation position of selector mechanism 9970
1 2 Overview of selector mechanism 9971
1 3 Assembly overview – gear knob and cover 9971
1 4 Removing and installing gaiter with gear knob and noise insulation, Golf, Eos and Scirocco 9973
1 5 Removing and installing gaiter with gear knob and noise insulation, Golf Plus 9975
1 6 Removing and installing gaiter with gear knob, Touran 9977
1 7 Removing and installing gaiter with gear knob and noise insulation, Passat, Passat CC and CC 9978
1 8 Repairing gear lever and selector housing (to 10 06) 9981
1 9 Repairing gear lever and selector housing (from 11 06) 9984
1 9 1 Dismantling and assembling selector mechanism 9986
1 9 2 Installing base plate to selector housing 9991
1 10 Assembly overview – removing and installing selector cables 9992
1 11 Removing and installing selector mechanism 9998
1 11 1 Removing 9998
1 11 2 Installing 10002
1 11 3 Specified torques 10004
1 12 Adjusting selector mechanism 10004
1 13 Function 10007
2 Plastic relay lever 10008
3 Touran, identifying gearbox for removal and installation 10012
4 Touran, removing and installing gearbox to gearbox date 31 10 4 (gearbox with stub shaft on right) 10014
4 1 Removing gearbox 10014
4 2 Installing gearbox 10021
4 2 1 Specified torques 10028
5 Touran, difference between removing and installing gearbox from gearbox date 01 11 4 (gearbox with right flange shaft) 10030
6 Touran, removing and installing gearbox (to 11 06 = vehicles with small headlights, from 12 06 to 05 10 = vehicles with large headlights with curvature) 10032
6 1 Removing gearbox 10032
6 2 Installing gearbox 10043
6 2 1 Specified torques 10051
7 Touran, removing and installing gearbox (from 06 10 = vehicles with large headlights without curvature) 10053
7 1 Removing gearbox 10053
7 2 Installing gearbox 10065
7 2 1 Specified torques 10075
8 Removing and installing gearbox, Golf 2004 ► front-wheel drive 10078
8 1 Removing gearbox 10078
8 2 Installing gearbox 10090
8 2 1 Specified torques 10099
9 Removing and installing gearbox, Golf 2009 ► front-wheel drive with turbo diesel engine 10101
9 1 Removing gearbox 10101
9 2 Installing gearbox 10113
9 2 1 Specified torques 10123
10 Removing and installing gearbox, Golf 2009 ► front-wheel drive with petrol engine 10125
10 1 Removing gearbox 10125
10 2 Installing gearbox 10137
10 2 1 Specified torques 10147
11 Removing and installing gearbox, Golf 2004 ► all-wheel drive 10149
11 1 Removing and installing gearbox in vehicles with turbo diesel engine 10149
11 1 1 Removing gearbox 10149
11 1 2 Installing gearbox 10161
11 1 3 Specified torques 10170
11 2 Removing and installing gearbox, vehicles with 6-cylinder petrol engine 10173
11 2 1 Removing gearbox 10174
11 2 2 Installing gearbox 10185
11 2 3 Specified torques 10194
12 Removing and installing gearbox, Golf 2009 ► all-wheel drive 10196
12 1 Removing gearbox 10197
12 2 Installing gearbox 10210
12 2 1 Specified torques 10222
13 Removing and installing gearbox, Golf Plus 2005 ► 10225
13 1 Removing gearbox 10225
13 2 Installing gearbox 10237
13 2 1 Specified torques 10245
14 Removing and installing gearbox, Golf Plus 2009 ► 10248
14 1 Removing gearbox 10249
14 2 Installing gearbox 10262
14 2 1 Specified torques 10272
15 Removing and installing gearbox, Passat 2006 ► front-wheel drive 10275
15 1 Removing gearbox 10275
15 2 Installing gearbox 10287
15 2 1 Specified torques 10295
16 Removing and installing gearbox, Passat 2006 ► all-wheel drive 10297
16 1 Removing gearbox 10297
16 2 Installing gearbox 10309
16 2 1 Specified torques 10319
17 Removing and installing gearbox, Passat CC front-wheel drive and CC front-wheel drive, with turbo diesel engine 10322
17 1 Removing gearbox 10322
17 2 Installing gearbox 10334
17 2 1 Specified torques 10344
18 Removing and installing gearbox, Passat CC front-wheel drive and CC front-wheel drive, with petrol engine 10347
18 1 Removing gearbox 10347
18 2 Installing gearbox 10359
18 2 1 Specified torques 10369
19 Removing and installing gearbox, CC all-wheel drive 10371
19 1 Removing gearbox 10372
19 2 Installing gearbox 10385
19 2 1 Specified torques 10397
20 Removing and installing gearbox, Eos 10400
20 1 Removing gearbox 10401
20 2 Installing gearbox 10411
20 2 1 Specified torques 10419
21 Removing and installing gearbox, Scirocco with petrol engine 10421
21 1 Removing gearbox 10421
21 2 Installing gearbox 10432
21 2 1 Specified torques 10442
22 Removing and installing gearbox in Scirocco with turbo diesel engine 10444
22 1 Removing gearbox 10444
22 2 Installing gearbox 10455
22 2 1 Specified torques 10466
23 Gearbox transport 10468
23 1 Front-wheel drive – transporting gearbox 10468
23 2 All-wheel drive – transporting gearbox 10469
24 Checking gearbox oil 10471
25 Removing and installing bevel box, vehicles with 6-cylinder petrol engine and vehicles with turbo diesel engine without particulate filter 10473
25 1 Removing bevel box 10473
25 2 Installing bevel box 10480
25 2 1 Specified torques 10485
26 Removing and installing bevel box, vehicles with turbo diesel engine and particulate filter, to approx 10  09 10486
26 1 Removing bevel box 10487
26 2 Installing bevel box 10494
26 2 1 Specified torques 10497
27 Removing and installing bevel box, vehicles with turbo diesel engine and particulate filter, from approx 11  09 10499
27 1 Removing bevel box 10499
27 2 Installing bevel box 10504
27 2 1 Specified torques 10507
28 Checking or topping up gear oil in bevel box 10508
28 1 Checking gear oil in bevel box 10508
28 2 Topping up gear oil in bevel box 10510
28 2 1 Specified torque 10514
29 Dismantling and assembling gearbox 10515
29 1 Overview – gearbox, front-wheel drive, Golf 2004 ► and Touran 10515
29 2 Overview – gearbox, front-wheel drive, Golf 2009 ►, Golf Plus, Passat, Passat CC, CC, Eos and Scirocco 10515
29 3 Overview – gearbox, all-wheel drive 10516
29 4 Assembly overview – front-wheel drive 10517
29 5 Assembly overview – all-wheel drive 10519
29 6 Assembly overview – removing and installing gearbox housing and selector unit 10521
29 7 Assembly overview – front-wheel drive – removing and installing input shaft, output shafts, differential and selector rods; Touran and Golf 2004 ► 10523
29 8 Assembly overview – front-wheel drive – removing and installing input shaft, output shafts, differential and selector rods; Golf 2009 ►, Golf Plus, Passat, Passat CC, CC and Eos and Scirocco 10525
29 9 All-wheel drive – removing and installing input shaft, output shafts, differential, bevel box and selector rods 10527
29 10 Installation position of shafts and selector rods in gearbox 10529
29 11 Securing to engine and gearbox support 10529
29 12 Assembly order, gearbox »without« circlip -A- for input shaft cover made from sheet metal 10531
29 12 1 Removing 10532
29 12 2 Installing 10539
29 13 Assembly order: I = gearbox »with« circlip -A- for input shaft cover made from sheet metal; II = gearbox with input shaft cover made from plastic 10547
29 13 1 Removing 10548
29 13 2 Installing 10555
30 Repairing gearbox housing 10565
31 Front-wheel drive – servicing clutch housing 10576
32 four-wheel drive – repairing clutch housing 10580
33 Repairing selector unit 10584
33 1 Renewing selector shaft seal 10586
34 Repairing selector forks 10589
35 – Gears, shafts 10592
1 Input shaft 10592
1 1 Assembly overview – input shaft 10592
1 2 Dismantling and assembling input shaft 10594
1 2 1 Modification in area of deep groove ball bearing 10598
1 3 Renewing input shaft seal 10600
1 3 1 Procedure 10600
2 Output shaft for 1st to 4th gears 10602
2 1 Assembly overview – output shaft for 1st to 4th gears 10602
2 2 Dismantling and assembling output shaft for 1st to 4th gears 10605
2 2 1 Distinguishing 1st/2nd gear synchronisation, distinguishing 3rd gear synchronisation 10613
2 2 2 Assembling 1st to 4th gear output shaft up to gearbox date 25 10 9 10615
2 2 3 Assembling 1st to 4th gear output shaft – from gearbox date 26 10 9 up to gearbox date 24 05 0 10621
2 2 4 Assembling 1st to 4th gear output shaft – from gearbox date 25 05 0 onwards 10627
2 3 Adjusting output shaft for 1st to 4th gears 10634
2 3 1 Determining thickness of shim 10637
2 3 2 Table of shims 10638
2 3 3 Carrying out check measurement 10638
3 Output shaft for 5th and 6th gears and reverse gear 10640
3 1 Assembly overview – output shaft for 5th, 6th and reverse gears 10640
3 2 Dismantling and assembling output shaft for 5th, 6th and reverse gears 10642
3 3 Adjusting output shaft for 5th, 6th and reverse gears 10653
3 3 1 Determining thickness of shim 10656
3 3 2 Table of shims 10657
3 3 3 Carrying out check measurement 10657
39 – Final drive – differential 10659
1 Front-wheel drive – renewing seals for flange shafts or stub shaft with gearbox installed 10659
1 1 Renewing oil seal for left flange shaft 10659
1 1 1 Removing 10659
1 1 2 Installing 10660
1 2 Identifying gearbox to renew right oil seal, Golf and Touran 10661
1 3 Renewing stub shaft seal – Golf and Touran to gearbox manufacture date 31 10 4 10661
1 3 1 Removing 10662
1 3 2 Installing 10662
1 4 Renewing oil seal for right flange shaft, Golf and Touran from gearbox manufacture date 01 11 4, Golf Plus, Passat, Passat CC, CC, Eos and Scirocco 10663
1 4 1 Removing 10663
1 4 2 Installing 10664
2 All-wheel drive – renewing flange shaft oil seals with gearbox and bevel box installed 10666
2 1 Renewing oil seal for left flange shaft 10666
2 2 Renewing seal for right flange shaft 10666
2 2 1 Removing 10666
2 2 2 Installing 10667
3 Renewing seal between gearbox and bevel box, in gearbox 10669
4 Assembly overview – seals, flange shaft mount and output flange mount in bevel box 10671
5 Renewing seal between gearbox and bevel box with bevel box removed 10674
6 Renewing bevel box output flange oil seal (bevel box removed) 10676
7 Renewing output flange and redetermining thickness of shim (bevel box removed) 10687
8 Renewing polygon needle bearing and seal on right flange shaft 10688
8 1 Removing 10688
8 2 Installing 10690
9 Adjustment overview – manual gearbox 10692
10 Differential 10693
10 1 Front-wheel drive – dismantling and assembling differential 10693
10 2 All-wheel drive – dismantling and assembling differential 10701
10 3 Adjusting differential 10709
10 3 1 Determining thickness of shim 10711
K0458972220 6 speed dual clutch gearbox 02E 10713
00 – Technical data 10719
1 General repair instructions 10719
1 1 Tools 10719
1 2 Gearbox 10719
1 3 Overview 10719
1 4 Seals 10720
1 5 ⇒ DSG® oil 10721
1 6 Oil filter change – »Yes or no?« 10721
1 7 Oil drain and inspection plug -A- 10721
1 8 Nuts and bolts 10722
1 9 Electrical components 10722
2 Fault finding 10723
2 1 General notes on fault finding 10723
2 2 Useful information about the “behaviour of the control unit in the event of a gearbox fault” 10723
2 3 Special notes on fault finding 10724
3 Identification of gearbox 10726
3 1 Reading gearbox code letters 10726
4 Code – engine allocation 10728
4 1 Golf Plus 2009 ► 10728
4 2 Golf Plus 2005 ► 10728
4 3 Golf 2009 ► 10729
4 4 Scirocco 2009 ► 10729
4 5 Golf 2004 ► 10729
4 6 Touran 2003 ► 10730
4 7 Passat 2006 ► 10731
4 8 Eos 2006 ► 10731
4 9 Passat CC 2009 ►; CC 2010 ► 10732
4 10 Sharan 2011 ► 10732
5 Capacity 10733
30 – Clutch 10734
1 Clutch 10734
1 1 Assembly overview – dual clutch 10734
1 2 Removing and installing clutch end cover 10736
1 3 Removing dual clutch 10742
1 4 Installing dual clutch 10743
34 – Controls, housing 10749
1 Electrical and electronic components and their locations ⇒ DSG® 10749
1 1 Removing and installing mechatronic unit for dual clutch gearbox -J743- (gearbox installed) 10749
1 2 Removing and installing mechatronic unit for dual clutch gearbox -J743- (gearbox removed) 10758
1 3 Removing and installing gearbox input speed sender -G182- and oil temperature sender in multi-plate clutch -G509- 10765
2 Removing and installing gear oil cooler 10766
3 Removing and installing oil pump 10769
4 Renewing selector shaft lever oil seal with gearbox removed 10773
5 Emergency release of selector lever 10775
6 Removing and installing selector lever handle 10776
6 1 Moving push-button in the handle to installation position 10778
6 1 1 Handle with push-button on side 10778
6 1 2 Handle with front push-button 10778
7 Selector mechanism up to 02 2009 10780
7 1 Overview of selector mechanism up to 02 2009 10780
7 2 Removing and installing selector lever cable up to 02 2009 10781
7 3 Checking selector lever cable 10788
7 4 Adjusting selector lever cable 10788
8 Checking selector mechanism 10790
8 1 Selector lever in “P” position and ignition switched on 10790
8 2 Selector lever in “N” position and ignition switched on 10790
8 3 Selector lever in position “Tiptronic” 10790
8 4 Ignition and light switched on 10790
8 5 Selector lever position indicator 10790
9 Selector mechanism from 03 2009 onwards 10791
9 1 Overview of selector mechanism in vehicles from 03 2009 onwards 10791
9 2 Removing and installing selector mechanism, from 03 2009 10792
9 2 1 Removing and installing selector mechanism with selector housing 10792
9 2 2 Removing and installing selector mechanism without selector housing 10794
10 Removing and installing gearbox 10796
10 1 Removing gearbox, Passat CC 2009 ►, CC 2010 ► with 2 0 l petrol engine 10796
10 2 Removing gearbox, Golf 2009 ►, Golf Plus 2009 ► with 2 0 l petrol engine 10803
10 3 Removing gearbox, Golf Plus 2005 ► with 1 4 l petrol engine 10812
10 4 Removing gearbox, Passat CC 2009 ►, CC 2010 ► diesel engine 10819
10 5 Removing gearbox, Passat CC 2009 ►, CC 2010 ► with diesel engine, all-wheel drive 10829
10 6 Removing gearbox, Golf Plus 2009 ► with 2 0 l diesel engine 10838
10 7 Removing gearbox, Golf 2009 ► 2 0 l diesel engine 10846
10 8 Removing gearbox, Passat CC 2009 ►, CC 2010 ► with 3 6 l – V6 engine (all-wheel drive) 10853
10 9 Removing gearbox, Golf 2004 ▸ with 1 9 l and 2 0 l diesel engine 10860
10 10 Removing gearbox, Golf 2004 ► with 125 kW – 2 0 l diesel engine 10867
10 11 Removing gearbox, Eos 2006 ►, with 3 2 and 3 6 l – V6 engine 10873
10 12 Removing gearbox, Golf 2004 ► with 1 4 l petrol engine 10880
10 13 Removing gearbox, Golf 2004 ► with 2 0 l petrol engine 10887
10 14 Removing gearbox, Golf 2004 ►, with 3 2 l – V6 engine (R32 all-wheel drive) 10892
10 15 Removing gearbox, Golf Plus 2005 ► with 1 9 l and 2 0 l diesel engine, with 2 0 l petrol engine 10901
10 16 Removing gearbox, Eos 2006 ► with 2 0 l petrol engine 10908
10 17 Removing gearbox, Eos 2005 ► with 2 0 l diesel engine 10915
10 18 Removing gearbox, Touran 2003 ► 10922
10 19 Removing gearbox, Passat 2006 ► with 2 0 l diesel engine 10930
10 20 Removing gearbox, Passat 2006 ► with 2 0 l petrol engine 10938
10 21 Removing gearbox, Passat 2006 ► with 3 6 l – V6 engine (all-wheel drive) 10943
10 22 Removing gearbox, Scirocco 2009 ► with 2 0 l diesel engine 10949
10 23 Removing gearbox, Scirocco 2009 ► with 2 0 l petrol engine 10958
10 24 Removing gearbox, Sharan 2011 ► with 2 0 l diesel engine 10967
10 25 Removing gearbox, Sharan 2011 ► with 1 8 l and 2 0 l petrol engine 10975
10 26 Removing gearbox, Sharan 2011 ► with 1 4 l petrol engine 10984
10 27 Install gearbox 10991
11 Torque settings »gearbox to engine« 10993
11 1 Torque settings (⇒ ELSA) 10993
11 1 1 Torque settings and note on engine mountings 10994
11 1 2 Torque settings and note on engine mountings 10995
11 1 3 Torque settings and note on engine mountings 10996
11 1 4 Torque settings and note on engine mountings 10998
11 1 5 Torque settings and note on engine mountings 10999
11 1 6 Torque settings and note on engine mountings 11000
12 Transporting gearbox and securing to assembly stand 11001
13 Removing and installing bevel box, Golf 2004 ► and Passat 2006 ► 11002
14 Removing and installing bevel box, Passat CC 2009 ►, CC 2010 ► with diesel engine 11007
14 1 Specified torques 11013
15 Removing and installing bevel box, Passat CC 2009 ►, CC 2010 ► with 3 6 l V6 engine 11015
16 Oil and oil filter 11019
16 1 Oil filter: renewing 11019
16 2 Checking oil level and topping up 11020
16 3 Draining and filling oil 11023
35 – Gears, shafts 11027
1 Currently, no repairs can be made to gears and shafts 11027
39 – Final drive – differential 11028
1 Overview – seals 11028
1 1 Renewing seals for right flange shaft or stub shaft – front-wheel drive 11029
2 Renewing oil seal for left flange shaft – front and all-wheel drive 11031
2 1 Renewing oil seal for right flange shaft – all-wheel drive 11032
2 2 Dismantling and assembling flange shaft 11034
3 Renewing oil seal for propshaft drive flange at bevel box 11036
4 Assembly overview – Flange shafts and seals on bevel box 11042
4 1 Renewing seal on gearbox between bevel box and gearbox 11043
4 2 Removing and installing right flange shaft 11044
4 3 Renewing seal for right flange shaft on outside of bevel box 11046
4 4 Renewing needle bearing (polygon bearing) for right output shaft drive flange 11047
4 5 Renewing seal on bevel box between gearbox and bevel box 11049
5 Checking and topping up gear oil in bevel box 11051
5 1 Checking gear oil in bevel box 11051
5 2 Topping up gear oil in bevel box 11052
V0051206420 Fault finding Power transmission 11055
30 – Clutch 11059
1 Complaints regarding clutch and clutch mechanism 11059
1 1 Checking clutch mechanism (slave cylinder is bolted from outside on clutch housing) 11065
1 2 Checking clutch mechanism (slave cylinder is located inside clutch housing) 11066
34 – Controls, housing 11068
1 Complaints regarding the selector mechanism 11068

S.V 26/01/2025