Volkswagen Polo 2018-2021 Repair Manual – PDF DOWNLOAD

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Volkswagen Polo 2018-2021 Repair Manual – PDF DOWNLOAD

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Volkswagen Polo 2018-2021 Repair Manual – PDF DOWNLOAD

Language : English
Pages : 11423
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Volkswagen Polo 2018-2021 Repair Manual – PDF DOWNLOAD

BRA5R035320 Troubleshooting Mechanical Transmission 1
30 – Clutch 5
1 Complaints related to clutch and clutch control 5
1 1 Checking the clutch drive 14
34 – Controls, housing 16
1 Complaints related to the selection mechanism 16
BRA5R035520 Electrical system General information 17
27 – Starter, current supply, CCS 21
1 Battery -A- 21
1 1 Important information concerning battery -A- 21
1 2 Battery -A- types 22
1 2 1 Low maintenance batteries 22
1 2 2 »Standard« battery with colour codes 22
1 2 3 »Enhanced« battery with colour codes 22
1 2 4 Sealed battery (AGM battery) 23
1 3 Warning notes and safety norms 23
1 3 1 Risks inherent to the handling of automotive batteries 23
1 3 2 Safety symbols on the Battery -A- 24
1 3 3 Airbag system work 25
1 4 Battery -A- connection terminals 26
2 Battery -A- – check 27
2 1 Battery -A- checking sequence 27
2 1 1 Battery with colour codes – test 27
2 1 2 Sealed battery (AGM battery) – test 28
2 2 Check visually 28
2 3 Battery degassing and replacement instructions 29
2 4 Check the Battery -A- with inspection window 29
2 4 1 Check the Battery -A- with battery inspection window “3 colours” 30
2 4 2 Check the Battery -A- with battery inspection window “2 colours” 30
2 5 Checking the low-maintenance Battery — 31
2 5 1 Checking the electrolyte level 31
2 5 2 Top it up with distilled water 33
2 5 3 Verifying the density of the electrolyte 33
2 6 Current consumption – test 35
2 7 Check the charge of the Battery -A- 36
2 7 1 Battery tester with printer -VAS 5097A- 37
2 7 2 Description of the battery testing device, with printer -VAS 5097A- 38
2 7 3 Check the battery -A- charge with the battery tester with printer -VAS 5097A- 38
2 7 4 Battery tester -VAS 6161- 42
2 7 5 Description of the Battery testing device -VAS 6161- 42
2 7 6 Checking the Battery -A- charge with the Battery tester -VAS 6161- 43
2 7 7 Testing in maintenance mode 44
2 7 8 Testing in warranty mode 45
2 7 9 Testing in technical assistance mode 46
2 7 10 Printed protocol information 47
2 8 Charge acceptance test 48
2 8 1 Charge acceptance test with the -VAS 6161- 48
2 8 2 Charge acceptance test with the -VAS 5097A- 48
2 9 Check the resting current of the battery 49
2 10 Check Battery -A- charging 52
2 11 Checking the resting voltage of batteries (unused or stored vehicles) 54
3 Battery -A- – charging 56
3 1 Cautions when handling Battery -A- chargers 56
3 2 Battery charger -VAS 5095A- 58
3 2 1 Description of the Battery charger -VAS 5095A- 58
3 2 2 Charging the Battery -A- with the Battery charger -VAS 5095A- 59
3 2 3 Charging a heavily drained Battery -A- with the Battery charger -VAS 5095A- 60
3 2 4 Auxiliary operations with the Battery charger -VAS 5095A- 61
3 2 5 Trickle charge with the Battery charger -VAS 5095A- 62
3 3 Battery charger -VAS 5900- 63
3 3 1 Description of the Battery charger -VAS 5900- 63
3 3 2 Charging the Battery -A- with the Battery charger -VAS 5900- 64
3 3 3 Servicing charge with the Battery charger -VAS 5900- 66
3 3 4 Charging a completely drained battery with the Battery charger -VAS 5900- 69
3 3 5 Auxiliary operations with the Battery charger -VAS 5900- 72
3 3 6 Trickle charge operational mode with the Battery charger -VAS 5900- 74
3 4 Battery charger -VAS 5900A- 75
3 4 1 Battery charger -VAS 5900A- 75
3 4 2 Battery charger -VAS 5900A- operation modes 76
3 5 Battery charger -VAS 5903- 77
3 5 1 Description of the Battery charger -VAS 5903- 77
3 5 2 Charging the Battery -A- with the Battery charger -VAS 5903- 78
3 5 3 Servicing charge with the Battery charger -VAS 5903- 80
3 5 4 Charging a heavily drained Battery -A- with Battery charger -VAS 5903- 83
3 5 5 Auxiliary operations with the Battery charger -VAS 5903- 86
3 5 6 Trickle charge operational mode with the Battery charger -VAS 5903- 88
3 6 Battery charger -VAS 5906- 88
3 6 1 Description of the Battery charger -VAS 5906- 89
3 6 2 Operation mode of the Battery charger -VAS 5906- 90
3 7 Battery charger -VAS 5908- 91
3 7 1 Battery charger -VAS 5908- – general description 91
3 7 2 Automatic mode with the battery charger -VAS 5908- 93
3 7 3 Charging batteries with the battery charger -VAS 5908- 94
3 7 4 Support function with the Battery charger -VAS 5908- 96
3 7 5 VAS I-CHECK current consumption test with the battery charger -VAS 5908- 98
3 8 Completely flat batteries 100
3 9 Battery (Delphi) – charging procedure 101
3 9 1 Completely flat batteries 102
3 9 2 Charging a single Battery -A- or “rapid charging” 102
3 9 3 Charging several batteries or “parallel charging” 102
3 9 4 Charging several batteries – charging in series or “slow charging” 103
3 9 5 Equalization of batteries 104
4 Speed regulator (GRA) 105
4 1 Speed regulator (GRA) – activating/deactivating 105
92 – Windscreen wash/wipe system 106
1 Washer hoses – connecting and disconnecting 106
2 Washer hoses – repair 108
2 1 Repairing smooth hoses 108
2 2 Repairing wrinkled hoses 108
94 – Lights, bulbs, switches – exterior 111
1 Adhere to the safety warnings and the application of gas-discharge lamps 111
96 – Lights, bulbs, switches – interior 114
1 12-V socket 114
1 1 12-V socket – remove and install 114
1 2 Socket box light bulb -L42- – remove and install 114
2 Lighter -U1- 115
2 1 General description 115
2 2 Assembly overview 116
2 3 Lighter socket – remove and install 117
2 4 Cigarette lighter light bulb -L28- – remove and install 120
97 – Wiring 122
1 Vehicle diagnostic, testing and information system 122
1 1 Vehicle Diagnosis, Measurement and Information System – connect 122
2 Harness and connection repairs 125
2 1 General notes on repair work on the electrical system of the vehicle 125
2 2 Harness repair kits 126
2 2 1 Wiring harness repair set -VAS 1978- 126
2 2 2 Complementary set -VAS 1978/50- 126
2 2 3 Wiring harness repair set -VAS 1978A- 127
2 2 4 Terminal removal tool kit -VAS 1978/35- 128
2 3 Description of tools 128
2 3 1 Cleaving pliers -VAS 1978/1- 128
2 3 2 Disassembly tool for terminals 129
2 3 3 Assembly tool for simple cable linings 129
2 3 4 Pliers for stripping cables -VAS 1978/3- 130
2 3 5 Hot air blower -VAS 1978/14- 131
2 3 6 Crimping pliers -VAS 1978/1A- 131
2 4 Harness repair 133
2 4 1 Repairing airbag and seat belt pre-tensioning cables 133
2 4 2 Repairing CAN-Bus system cables 135
2 4 3 Replacing antenna cables 135
2 4 4 Repairs of electrical connectors 0 13 mm2/0 35 mm2/0 5 mm2 137
2 4 5 Repairs of cables with 10 mm2 or 16 mm2 with individual top connectors 143
2 4 6 Repairs of aluminium cables with 2 5 mm2, 4 mm2 or 6 mm2 with individual top connectors 149
2 4 7 Interruption in cables with a repaired section 156
2 4 8 Interruption in cables with two repaired sections 158
2 5 Fibre optic cable repairs 160
2 5 1 Fibre optic cable – prepare 161
2 5 2 Fibre optic cable of the the cable set connector – separate 168
2 6 Aerial cable repairs 169
2 6 1 Repair kit, aerial cable VAS 6720 169
2 7 Repairing connector terminals and connectors 181
2 7 1 Notes regarding repair work on connector terminal and connectors 181
2 7 2 Repairing connector terminals 181
2 7 3 Assembly of simple cable linings 183
2 7 4 Repairing connectors with the cutting/compression technique 186
2 8 Unlocking and disassembling the terminals 187
2 8 1 Note regarding the unlocking and disassembly of the connectors 187
2 8 2 Secondary locking 187
2 8 3 Primary locking 188
2 8 4 Fastening systems for round terminals 189
2 8 5 Fastening systems for flat terminals 190
2 8 6 Fastening device for special terminals 192
3 Electrical contact cleaning set -VAS 6410- 195
3 1 Use of the Electrical contact cleaning set -VAS 6410- 195
3 1 1 Maintenance of cable eyes 195
3 1 2 Maintenance of bolted joints 197
3 1 3 Clean battery terminals 199
3 1 4 Preservation 201
4 Lambda probe – replace 203
4 1 LSF lambda probe (4 poles) – replace 203
4 2 LSU lambda probe (6 poles) – replace 204
4 3 Versions of the protection tube of unit lambda probes 205
D3E804CBC09 Wheels and Tyres General information 207
00 – Technical data 211
1 General notes on rims and tyres (passenger vehicles) 211
1 1 Technical conditions for combining rims and tyres 212
1 2 Miscellaneous 212
1 2 1 Wheel bolts – Tightening torques 212
1 2 2 Wheel hole circle diameter 212
1 2 3 Wheel specifications 212
1 3 Remove the tyre from the arch 214
1 4 Install the tyre in the arch 214
1 5 Protecting the wheel centering seat against corrosion 215
2 Curiosities about rims and tyres (passenger vehicles) 217
2 1 Wear/tyre mileage 217
2 1 1 Miscellaneous 217
2 1 2 What a tyre must provide 217
2 1 3 Wear behaviour of high speed tyres 218
2 1 4 Factors that influence tyre durability 218
2 1 5 Driving style: 218
2 1 6 Tyre maintenance 219
2 1 7 Tyres with uniform wear 221
2 1 8 Measuring track depth 221
2 1 9 Unilateral wear 222
2 1 10 Wear on the outer shoulder 225
2 1 11 Wear on the centre portion of the tyre 226
2 1 12 Diagonal abrasion 227
2 2 Rolling noises coming from the tyres 227
2 2 1 General notes about rolling noises 227
2 2 2 Wear occurrence in the shape of saw 228
2 2 3 Blockage points 230
2 3 Drive instability due to rim/tyre 230
2 3 1 Causes of drive instability 230
2 3 2 Wheel balancing 231
2 3 3 Perform a test drive before performing the wheel balancing 231
2 3 4 Wheel balancing with the static balancing machine 232
2 3 5 Radial and axial deviation of concentricity of rim/tyre assembly 233
2 3 6 Inspect the radial and axial deviations of the rim/tyre assembly with the Tyre gauge -V A G 1435- 234
2 3 7 Inspect the radial and axial deviations of rim concentricity 235
2 3 8 Positioning of the tyre in relation to the rim 236
2 3 9 Tyre deformation 237
2 4 The vehicle deviates to one side 238
2 4 1 Miscellaneous 238
2 4 2 Conicity 238
2 4 3 Solution when the vehicle deviates to one side 240
2 4 4 Selective change of wheels for tyres without tread direction 241
2 4 5 Selective change of wheels for tyres with tread direction 242
2 5 Damages on the tyres 243
2 5 1 General guidelines 243
2 5 2 Structure of a radial tyre 243
2 5 3 Damages caused by crashes 244
2 5 4 Damages due to cut 246
2 5 5 Damages caused by strange bodies 246
2 5 6 Loss of air from the tyres 247
2 5 7 Air pressure 247
2 5 8 Damages to the tyres due to insufficient air pressure 248
2 5 9 Rise of temperature in tyres with insufficient air pressure 249
2 5 10 Damages to the tyres due to assembly failure (assembly damages) 250
2 6 Useful notes related to tyres and wheels 252
2 6 1 Inscriptions on the side wall of the tyre 252
2 6 2 Clarifications about tyre inscriptions 254
2 6 3 Contractions 255
2 6 4 Rubber valve 256
2 6 5 Storage of tyres 257
2 6 6 Aging of tyres 257
2 6 7 Tyre rotation 258
2 6 8 Notes related to assembly in case of replacement/assembly of wheel 259
D3E8046D49A Wheels and Tyres Guide – General Information 261
44 – Wheels, tyres, vehicle geometry 269
1 Instructions on using the guide 269
1 1 Overview 269
1 1 1 Wheels and Tyres Guide – General Information 269
1 1 2 Wheels and Tyres Guide – Vehicle-specific section 269
1 2 General information 269
1 3 Notes 270
1 4 Determining correct wheel and tyre combinations, according to NEDC with tyre package 271
1 4 1 Determining the required tyre package via PR number 271
1 4 2 Determining the required tyre package via version key in the vehicle registration certificate part 1 271
1 5 Determining correct wheel and tyre combinations according to WLTP 272
1 5 1 Vehicle registration certificate part 1 272
1 5 2 COC document, item 0 10 274
1 6 NEDC, WLTP and RDE 274
1 6 1 What are NEDC, WLTP and RDE? 274
1 6 2 What are the differences between WLTP and RDE? 274
1 6 3 Since when are WLTP and RDE valid? 274
1 7 Definition of tyre package 274
1 8 Explanations regarding world regions 275
2 Legislative and technical conditions 277
2 1 Legislative conditions 277
2 1 1 Permissible wheel and tyre combinations in Germany 277
2 1 2 Vehicles with Tyre Pressure Monitoring System 277
2 2 Technical conditions 278
2 3 Load-carrying capacity depending on vehicle speed, winter tyres 278
2 4 Vehicle registration documents since 01 10 2005 280
2 5 COC document (EEC Certificate of Conformity) 281
2 6 EU general type approval number, sales type and sales or trade designation 281
3 Wheel change 284
3 1 Fitting instructions 284
3 2 Protecting wheel centring seat against corrosion 287
3 3 Fitting wheels 287
3 4 Position of anti-theft wheel bolts for steel wheels 288
4 Fitting tyre 290
4 1 Pressing tyre off wheel rim 290
4 2 Removing tyre sealant 291
4 3 Removing tyre from wheel 291
4 3 1 Removing tyres, wheels without and with tyre pressure monitoring 291
4 3 2 Removing tyres, run-flat tyres, ultra-high-performance tyres 293
4 4 Ensuring proper assembly temperature for tyres 295
4 5 Fitting tyre 296
4 5 1 Mounting tyre, wheels without and with tyre pressure monitoring 296
4 5 2 Mounting tyre, run-flat tyres, ultra-high performance tyres 298
4 6 Matching wheel rims and tyres 300
4 7 Checking radial and lateral runout of wheels and tyres 301
4 7 1 Checking radial and lateral runout of wheels and tyres, tolerances 301
4 7 2 Checking radial and lateral runout on wheels and tyres with tyre gauge 302
4 8 Matching wheels and tyres 303
4 9 Balancing wheel 304
4 9 1 Conditions 304
4 9 2 Balancing wheel on stationary wheel balancer 304
4 9 3 Balancing wheel with finish balancer 307
4 9 4 Checking radial and lateral run-out on wheel rim 308
4 10 Tyre sealant disposal 309
5 Tyre Pressure Monitoring System 310
5 1 System description – Tyre Pressure Monitoring System 310
5 1 1 System description – Tyre Pressure Monitoring System with indirect measurement (Tyre Pressure Loss Indicator) 310
5 1 2 System description – Tyre Pressure Monitoring System with direct measurement (with tyre pressure sensor) 312
5 1 3 Button behaviour – Tyre Pressure Monitoring System with direct measurement (with tyre pressure sensor) 312
5 1 4 System description – Tyre Pressure Monitoring System, Tyre Pressure Monitoring System (TPMS) with autolocation 313
5 2 Overview of fitting locations – Tyre Pressure Monitoring System 314
5 2 1 Overview of fitting locations – Tyre Pressure Monitoring System (TPMS) with autolocation 314
5 2 2 Overview of fitting locations – Tyre Pressure Monitoring System, Trigger 315
5 2 3 Overview of fitting locations – Tyre Pressure Monitoring System, Autolocation 317
5 3 Assembly overview – tyre pressure sensor 318
5 3 1 Assembly overview – tyre pressure sensor, tyre pressure sensor with valve 318
5 3 2 Assembly overview – tyre pressure sensor, tyre pressure sensor without valve, version 1 320
5 3 3 Assembly overview – tyre pressure sensor, tyre pressure sensor without valve, version 2 322
5 4 Removing and installing tyre pressure sensor -G222-/-G223-/-G224-/-G225- 323
5 4 1 Removing and installing tyre pressure sensor, tyre pressure sensor with valve 323
5 4 2 Removing and installing tyre pressure sensor, tyre pressure sensor without valve, version 1 (customer service version) 324
5 4 3 Removing and installing tyre pressure sensor, tyre pressure sensor without valve, version 1 (production version) 326
5 4 4 Removing and installing tyre pressure sensor -G222-/-G223-/-G224-/-G225-, version 2 329
5 5 Removing and installing Tyre Pressure Monitoring System control unit -J502- 331
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 332
5 5 2 Removing and installing tyre Tyre Pressure Monitoring System control unit, Passat 2011, Passat Estate 2011 334
5 5 3 Removing and installing Tyre Pressure Monitoring System control unit, CC 2010, CC 2012, Passat CC 2009 334
5 5 4 Removing and installing Tyre Pressure Monitoring System control unit, Phaeton 2003 334
5 5 5 Removing and installing Tyre Pressure Monitoring System control unit -J502-, Touran 2016 334
5 5 6 Removing and installing Tyre Pressure Monitoring System control unit -J502-, Tiguan 2008 335
5 5 7 Removing and installing Tyre Pressure Monitoring System control unit -J502-, Tiguan 2016, Tiguan 2017 (BW2), Tiguan 2021 336
5 5 8 Removing and installing Tyre Pressure Monitoring System control unit, up to model year 2014, Touareg 2010 337
5 5 9 Removing and installing Tyre Pressure Monitoring System control unit, as of model year 2015, Touareg 2015 338
5 5 10 Removing and installing Tyre Pressure Monitoring System control unit, Touareg 2018 339
5 5 11 Removing and installing bracket for Tyre Pressure Monitoring System control unit, Touareg 2015 340
5 6 Removing and installing tyre pressure monitor sender unit in wheel housing 340
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 340
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 341
5 6 3 Removing and installing sender unit for Tyre Pressure Monitoring System in wheel housing, Phaeton 2003 342
6 Wheel bolts 343
6 1 Wheel bolts, versions 343
6 2 Wheel bolts, anti-theft wheel bolt 345
6 3 Wheel bolts, adapter sets for anti-theft wheel bolts 345
7 Information on tyres 348
7 1 Identification markings on the tyre sidewall 348
7 2 Tyre dimension 350
7 3 Load rating code/load index (LI) 350
7 4 Speed rating code 351
7 5 EU tyre label 351
7 5 1 EU tyre label, summary 351
7 5 2 EU tyre label, objectives 352
7 5 3 EU tyre label, categories 353
7 6 Structure of a radial belted tyre 357
7 6 1 Cross section of a radial belted tyre 357
7 6 2 Run-flat tyres, structure and identification of a SST tyre 358
7 6 3 Run-flat tyres, seal inside technology 360
7 7 Run-flat tyre, SST (Self Supporting Tyre) 363
7 7 1 Run-flat tyres – general information 363
7 7 2 Run-flat tyres, retrofitting/requirements when using run-flat tyres 364
7 7 3 Run-flat tyres, repair work 364
7 8 Tyre storage 364
7 9 Reinforced and Extra Load (XL) tyres 365
7 10 M+S tyres 366
7 11 Winter tyres with speed symbol V 368
7 12 All-season tyres 369
7 13 Optimised rolling resistance tyres 370
7 14 Tyre ageing 370
7 15 Tyres with flange protection 372
7 16 Tyre sizes for vehicles with all-wheel drive 372
7 17 Increase in temperature due to insufficient tyre pressure 372
8 Tyre sealant 374
8 1 Models with breakdown set 374
8 2 Storage life 374
8 3 Disposal 374
9 Information about wheels (rims) 375
9 1 Structure of wheel (rim) 375
9 2 Identification 376
9 3 Composite wheels 377
9 4 Care and maintenance of alloy wheel rims 377
9 5 Restoring alloy wheels 377
9 6 Removing and installing hub cover for alloy wheels with open threaded connection 378
9 7 Renewing trim elements 379
9 7 1 Renewing trim elements, bonded trim elements 379
9 7 2 Renewing trim elements, bolted trim elements 383
9 8 Removing and installing valve 384
9 8 1 Removing and installing valve, description of the valve 384
9 8 2 Removing and installing valve, rubber valve 385
9 8 3 Removing and installing valve, metal valve 386
10 Handling problems 388
10 1 Rolling noise 388
10 1 1 General notes on tyre noise 388
10 1 2 Flat spots (from locking wheels) 389
10 2 Vehicle pulls to one side 390
10 2 1 General information 390
10 2 2 Conicity 390
10 2 3 Remedies when vehicle pulls to one side 392
10 2 4 Strategic rotation of wheels for non-directional tyres 393
10 2 5 Strategic rotation of wheels having unidirectional tyres 394
10 3 Vibration 395
10 3 1 Vibration, causes for vibration 395
10 3 2 Vibration, conducting a road test before balancing wheels 395
10 3 3 Vibration, vibration control system 395
10 4 Eliminating flat spots caused by storage or handling 396
11 Evaluating tyres 398
11 1 Flat spots caused by storage or handling 398
11 2 Undulations 398
11 3 Saw-tooth wear 399
11 4 Flat spots caused by hard braking 399
11 5 Swellings in the tyre sidewall 399
11 6 Cuts 401
11 7 Damage caused by foreign bodies 401
11 8 Stripped profile 402
11 9 Tyre damage due to insufficient tyre pressure 402
11 10 Checking tyres 403
11 11 Damage caused when fitting 404
12 Tyre wear 406
12 1 Factors influencing the service life of tyres 406
12 2 Saw-tooth wear 407
12 3 Wear behaviour of high-speed tyres 408
12 4 Measuring tread depth 408
12 5 One-sided wear 409
12 6 Outer shoulder wear 411
12 7 Diagonal washout 412
12 8 Wear in middle of tyre 413
12 9 Permissible deviation in tread depth 413
13 Overview of components 414
13 1 Assembly overview – wheel 414
14 Snow chains 417
14 1 Assembly and use of snow chains 417
15 Regular and temporary spare wheels, recommended temporary spare tyres 418
15 1 Spare wheel with yellow sticker 418
15 2 Temporary spare wheels and recommended temporary spare tyres 419
15 2 1 Atlas 2017 419
15 2 2 Golf 2013, e-Golf 2014 419
15 2 3 Golf 2017, e-Golf 2017 419
15 2 4 Golf SV 2015 419
15 2 5 Golf Variant 2014 420
15 2 6 Golf Variant 2017 420
15 2 7 Golf 2018 (AU2/BX6) 420
15 2 8 Jetta 2018 420
15 2 9 Taos 2021 421
D3E80452DD3 Body Repair General Information 422
00 – Technical data 426
1 Safety indications 426
1 1 Components removal 426
1 2 Battery, work with weld 426
1 3 Electronic control units 426
1 3 1 Procedures with electronic control units after bodywork repairs 426
1 4 Paint, glasses, stuffing, linings 427
1 5 Fuel tank or fuel line 427
1 6 Air conditioning system 427
1 6 1 Solution: 427
1 7 Airbag System – Safety measures to work 428
1 8 Airbag triggers after an accident – which should be replaced 429
1 8 1 Accident with Airbag triggering 429
1 8 2 Accident without airbag triggering 429
1 9 Verification of safety belts 429
1 9 1 Check the belt braid 430
1 9 2 Check the automatic retractor (locking effect) 431
1 9 3 Visual inspection of the belt latch 431
1 9 4 Check the operation of the belt latch 431
1 9 5 Check the belt guides and the latch tab 432
1 9 6 Check the fastening parts and fastening points 432
1 10 Safety measures for belt tensioner 432
1 11 Vehicles works with belt tensioner 433
1 12 Repair, alignment and/or bodywork works in vehicles with Airbag 433
1 13 Removal of the front seats with side airbag 434
2 Basic instructions 435
2 1 Accident vehicles diagnosis 435
2 2 Body supply condition and individual parts for painting 435
2 3 Alignment 435
2 4 Cuts for removal 435
2 5 Body partial parts 435
2 6 Original joint 436
2 7 Body galvanized parts 436
2 8 Removing the residues 436
2 9 New parts 436
3 Symbols explanation 437
3 1 Symbols explanation to welding works 437
3 2 Symbols explanation to work process 437
3 2 6 Application of anti-corrosion fluid 439
3 2 8 Sealing 439
4 Tooling to the body repair 440
4 1 Hole plier -VAG 1329- 440
4 2 Fluid pulveriser -VAG 1379- or -EQ 7608- 440
4 3 Hot air blower -VAG 1416- 440
4 4 Adjustable straps -VAG 1438- 440
4 5 Pneumatic saw -VAG 1523A- or -EQ 7415- 441
4 6 Pneumatic hammer -VAG 1577- 441
4 7 Welding points remover -VAG 1731- 441
4 8 Adhesives Pneumatic Applicator for glass bonded -VAG 1761/1- or -EQ 7434- 441
4 9 Pneumatic adhesive applicator -VAG 2005- 442
5 Glued joints of the body 443
5 1 Removal procedure: 443
5 1 1 Bonding process: 443
5 2 Bonding types 444
5 3 Partial replacement repair solution 444
5 3 1 RP spot welding and bonding 444
5 3 2 Welding SG and paste (if unable to welding spot) 444
5 3 3 Gases aspiration from welding 444
5 3 4 Preparations 445
5 3 5 Finishing works 445
6 Corrosion protection measures 446
6 1 Materials for corrosion protection prior to welding 446
6 1 1 Zinc-based conductive paint 446
6 2 Corrosion protection and special warranty against corrosion perforation 446
7 Indications to residue disposal 448
7 1 Residue elimination 448
7 2 Support covers damper – unusable for disposal 448
7 3 Airbag 449
7 3 1 Disposal as waste 449
8 Repair of steel plates 450
8 1 Plate body of high strength 450
8 2 Parts of the galvanized body 450
8 2 1 Preparation 450
8 2 2 Cutting process 450
8 2 3 Joining techniques 451
8 3 Welding work on galvanized plates 451
8 3 1 MIG Welding of galvanized plates 451
8 3 2 Bore welding of galvanized plates 451
8 3 3 Posting test 452
8 4 Repair body shop where there is no paint damage (Paintless dent repair) 452
D4B802DF404 Air conditioning with refrigerant R134a 453
00 – Technical data 457
1 General information on air conditioning 457
1 1 Basics of air conditioning 457
1 1 1 Physical principles: 457
1 1 2 Heat is always transferred from a warmer material to a cooler one 458
1 1 3 Pressure and boiling point 458
1 2 Vapour pressure table for R134a refrigerant gas 459
1 3 R134a refrigerant gas 460
1 3 1 Data on the physical properties of R134a refrigerant gas 460
1 3 2 Critical point 460
1 3 3 Environmental aspects related to R134a refrigerant gas 461
1 4 Properties of R134a refrigerant gas 461
1 4 1 Trade name and designations 461
1 4 2 Colour 461
1 4 3 Vapour pressure 461
1 4 4 Physical characteristics of R134a 462
1 4 5 Reaction with metals 462
1 4 6 Critical temperature / Critical pressure 462
1 4 7 Water content 462
1 4 8 Combustion 462
1 4 9 Filling factor 462
1 4 10 Leak detection 463
1 5 Refrigeration system oil 463
1 5 1 Characteristics of refrigeration system oil 463
1 6 Comfort 464
1 7 Environmental aspects 464
1 8 Air conditioning effects 464
1 9 Safety at work 465
1 9 1 Product characteristics 465
1 9 2 Handling refrigerant gas 465
1 9 3 Wear protective goggles 466
1 9 4 Use protective gloves and apron 466
1 9 5 Refrigerant gas should never come into contact with skin 466
1 9 6 Never inhale refrigerant gas vapours 466
1 9 7 Smoking is strictly prohibited 466
1 9 8 Soldering work in refrigeration systems 466
1 9 9 Active smell 466
1 9 10 First Aid 467
1 9 11 Handling of pressurized tanks 467
1 9 12 Do not heat above 50 °C 467
1 9 13 Monitor the heating process 467
1 9 14 Close empty containers 467
1 9 15 Safety measures related to handling refrigerant gas suction and filling equipment 468
1 9 16 Safety measures related to the works to be performed in vehicles with air conditioning and the handling of R134a refrigerant gas 468
2 General remarks on the refrigerant gas loop 470
2 1 Refrigerant gas loop components 470
2 1 1 Distribution of refrigerant gas loop components and their influence on the high and low pressure areas 470
2 1 2 Air conditioning compressor with magnetic coupling: 470
2 1 3 Air conditioning compressor without magnetic coupling 471
2 1 4 Condenser 472
2 1 5 Evaporator 472
2 1 6 Collection tank 473
2 1 7 Butterfly (restrictor) 474
2 1 8 Liquid tank 474
2 1 9 Expansion valve 476
2 1 10 O-ring seals 476
2 1 11 Rigid tubes and flexible tubes in the refrigerant gas loop 477
2 1 12 Overpressure valve 477
2 2 Refrigerant gas loop components 478
2 2 1 Refrigerant gas loop with expansion valve and evaporator 478
2 2 2 Refrigerant circuit with butterfly (restrictor) and collection tank 478
2 3 Quick coupling connections in the refrigerant gas loop 479
2 3 1 Suction and filling valve with Schrader valve 479
2 3 2 Suction and filling valve, high pressure section 480
2 3 3 Evacuating and charging valve, low pressure section 480
2 4 Switches and sensors for the refrigerant circuit and their connections 480
2 4 1 High pressure switch for air conditioning system -F23- 481
2 4 2 High pressure switch for magnetic clutch -F118- 481
2 4 3 Low pressure switch for air conditioning system -F73- 481
2 4 4 Valve connections for switch in the refrigerant gas loop 482
2 4 5 Air conditioning system pressure switch -F129- 482
2 4 6 High pressure sender -G65- 483
2 4 7 Refrigerant pressure and temperature sender -G395- 483
2 4 8 Magnetic valve for liquid refrigerant circulation -N43- 484
2 4 9 Air conditioner compressor regulating valve -N280- 484
2 5 Electrical components not assembled in the refrigerant gas loop 485
2 5 1 Control and regulating unit for air conditioning system -J127- 485
2 5 2 Radiator fan control unit -J293- 485
2 5 3 Temperature switch for evaporator -E33- 486
2 5 4 Air outlet temperature sensor for the evaporator -G263- or Evaporator temperature sensor -G308- 487
2 6 Pressures and temperatures in the refrigerant gas loop 487
2 7 Refrigerant circuit with expansion valve 487
2 8 Refrigerant circuit with butterfly (restrictor) and collection tank 489
2 9 Checking and measuring work with a pressure gauge 491
2 9 1 Pressure gauges may be used to carry out the following checking and measuring work: 491
2 10 Notes on doing repair work on the refrigerant gas loop 492
3 Legislation and standards 493
3 1 Legislation and standards 493
3 2 Regulations on recycling and disposal 496
3 3 Disposal of cooling agent and cooling machine oils 496
4 Using the climate control recovery, recycling, refilling, and cleaning equipment 497
4 1 Important notes for using the Climate control recovery, recycling and refill set or EQ 7098 -VAS 6008- 497
4 2 Connect the Climate control recovery, recycling and refill set or EQ 7098 -VAS 6008- 498
4 3 Empty the refrigerant gas loop with the Climate control recovery, recycling and refill set or EQ 7098 -VAS 6008- 499
4 3 1 Sucking out the refrigerant gas 499
4 3 2 Remove the air from the refrigerant gas loop 500
4 4 Fill the refrigerant gas loop with the Climate control recovery, recycling and refill set or EQ 7098 -VAS 6008- 500
4 4 1 Filling refrigerant gas 500
4 4 2 Activating the air conditioning after filling up the loop 501
4 5 Introduce refrigerant gas into the tank of the Climate control recovery, recycling and refill set or EQ 7098 -VAS 6008- 501
4 6 Emptying the tank of the Climate control recovery, recycling and refill set or EQ 7098 -VAS 6008- 502
5 Checking pressure values in the refrigerant gas loop 503
5 1 Checking pressure values 504
5 2 Verification for vehicles with butterfly (throttle) and collection tank (air conditioning compressor with internal adjustment device) 506
5 2 1 Nominal values 506
5 3 Verification for vehicles with expansion valve and liquid loop / dryer (air conditioning compressor with internal adjustment device) 509
5 3 1 Nominal values 509
5 4 Verification for vehicles with expansion valve, liquid tank / dryer and Adjustment valve for the air conditioning compressor -N280- (with air conditioning compressor with external adjustment device) 513
5 4 1 Nominal values 513
5 5 Verification for vehicles with butterfly (throttle), collection tank and regulating valve for the air conditioning compressor -N280- (with air conditioning compressor with external adjustment device) 522
5 5 1 Nominal values 523
6 Detecting leaks in the refrigerant gas loop 528
6 1 Detecting leaks in the refrigerant gas loop with the R134a air conditioning leak detector or EQ 7051 -VAG 1796- 529
6 2 Detecting leaks in the refrigerant gas loop by pressurizing the system 529
6 3 Detection of leaks in the refrigerant gas loop with the air conditioning recovery, recycling, recharging and cleaning set 530
7 Cleaning the refrigerant gas loop 533
7 1 Venting the refrigerant gas loop 533
7 2 Washing the refrigerant gas loop with R134a refrigerant gas (clean) 535
8 Problems 541
8 1 Possible problems in the refrigerant circuit 541
8 1 1 Checking conditions 541
8 1 2 Possible problems 541
9 Replacing components 543
9 1 Leaking or damaged components (except the compressor, collection tank and liquid tank) 543
9 1 1 A completely empty refrigerant circuit 543
9 1 2 The loop still contains refrigerant gas 544
9 2 Replace the air conditioning compressor 544
9 2 1 Without any need to vent the refrigerant circuit with compressed air and nitrogen (for example, in case of external damage caused by an accident) 544
9 2 2 Leakage or internal damage (such as noises or lack of power) 545
9 3 Replace the liquid/collection tank and the butterfly (restrictor) 545
9 3 1 After cleaning the refrigerant circuit or in case of impurities 545
9 3 2 No need to clean, no leaks and no penetration of humidity and impurities in the refrigerant circuit 546
10 Test equipment and tools 547
10 1 List of test equipment, tools, and material 547
10 2 Test equipment, tools, and material 547
D4B804D7AF4 3 cylinder direct injection engine (1 0 l engine 4V EA 211 turbocharger) 550
00 – Technical data 556
1 Safety information 556
1 1 Safety regulations for working on fuel supply 556
1 2 Safety measures when working on vehicles with a start/stop system 556
1 3 Safety precautions when using testers and measuring instruments during a road test 557
1 4 Safety precautions when working on the cooling system 557
1 5 Safety precautions when working on ignition system 557
1 6 Safety precautions when working on exhaust system 558
2 Marking 559
2 1 Engine number/engine data 559
3 Repair instructions 567
3 1 Rules for cleanliness 567
3 2 General information 567
3 3 General repair instructions 568
3 4 Foreign objects in engine 568
3 5 Contact corrosion 568
3 6 Routing and attachment of lines 569
3 7 Fitting radiator and condensers 569
3 8 Checking vacuum system 569
10 – Removing and installing engine 570
1 Removing and installing motor 570
1 1 Removing motor 570
1 1 1 Removing engine, Polo 2014 ►, Polo Saloon IN 2016 ►, Polo KH IN 2015 ► 570
1 1 2 Removing engine, Golf, Golf Estate, SV, Touran 583
1 1 3 Removing engine, up! 598
1 1 4 Removing engine, Polo 2018, T-Cross 608
1 1 5 Removing engine, T-Roc, T-Roc Cabrio 618
1 2 Separating engine and gearbox 627
1 2 1 Separating engine and gearbox, vehicles with manual gearbox, Golf, Golf Estate, Golf SV, Polo 2014 ►, Polo 2018 ►, T-Roc, T-Cross, Touran, T-Roc Cabrio, Polo Saloon IN 2016 ►, Polo KH IN 2015 ► 627
1 2 2 Separating engine and gearbox, vehicles with dual clutch gearbox, Golf, Golf Estate, Golf SV, Polo 2014 ►, Polo 2018 ►, T-Roc, T-Cross, Touran, T-Roc Cabrio, Polo Saloon IN 2016 ►, Polo KH IN 2015 ► 629
1 2 3 Separating engine and gearbox, up! 631
1 3 Securing engine on engine and gearbox support 633
1 4 Installing engine 635
1 4 1 Removing engine, Golf, Golf Estate, Golf SV, Polo 2014 ►, Touran, Polo Saloon IN 2016 ►, Polo KH IN 2015 ► 635
1 4 2 Installing engine, up! 639
1 4 3 Installing engine, Polo 2018 ►, T-Cross 643
1 4 4 Installing engine, T-Roc, T-Roc Cabrio 645
2 Assembly mountings 648
2 1 Assembly overview – assembly mountings 648
2 1 1 Assembly overview – assembly mountings, Polo 2014 ►, Polo Saloon IN 2016 ►, Polo KH IN 2015 ► 648
2 1 2 Assembly overview – assembly mountings, Golf, Golf Estate, Golf SV, Touran 650
2 1 3 Assembly overview – assembly mountings, up! 652
2 1 4 Assembly overview – assembly mountings, Polo 2018 ►, T-Roc, T-Cross, T-Roc Cabrio 655
2 2 Removing and installing engine mounting 658
2 2 1 Removing and installing engine mountings, Polo 2014 ►, Polo Saloon IN 2016 ►, Polo KH IN 2015 ► 658
2 2 2 Removing and installing engine mounting, Golf, Golf Estate, Golf SV, Polo 2018 ►, T-Roc, T-Cross, Touran, T-Roc Cabrio 660
2 2 3 Removing and installing engine mounting, up! 661
2 3 Removing and installing gearbox mountings 662
2 3 1 Removing and installing gearbox mountings, manual gearbox, Polo 2014 ►, Polo Saloon IN 2016 ►, Polo KH IN 2015 ► 662
2 3 2 Removing and installing gearbox mounting, manual gearbox, Golf, Golf Estate, Golf SV, Polo 2018 ►, T-Roc, T-Cross, Touran, T-Roc Cabrio 663
2 3 3 Removing and installing gearbox mountings, up! 666
2 4 Removing and installing pendulum support 667
2 4 1 Removing and installing pendulum support, Polo 2014 ►, Polo Saloon IN 2016 ►, Polo KH IN 2015 ► 667
2 4 2 Removing and installing pendulum support, Golf, Golf Estate, Golf SV, Polo 2018 ►, T-Roc, T-Cross, Touran, T-Roc Cabrio 668
2 4 3 Removing and installing pendulum support, up! 669
2 5 Supporting engine in installation position 670
2 5 1 Support engine in its installation position, Polo 2014 ►, Polo Saloon IN 2016 ►, Polo KH IN 2015 ► 670
2 5 2 Supporting engine in installation position, Golf, Golf Estate, Golf SV 672
2 5 3 Supporting up! engine in installation position, on right of camshaft housing 677
2 5 4 Supporting engine in installation position, up!, on camshaft housing (left-side) 681
2 5 5 Supporting engine in installation position, Polo 2018 ▶, manual gearbox 685
2 5 6 Supporting engine in installation position, Polo 2018 ►, dual clutch gearbox 687
2 5 7 Supporting engine in installation position, T-Roc, T-Roc Cabrio 691
2 5 8 Supporting engine in installation position, T-Cross 694
2 5 9 Supporting engine in installation position, Touran 696
2 6 Adjusting assembly mountings 704
2 6 1 Adjusting assembly mountings, Golf, Golf Estate, Golf SV, Polo 2018 ►, T-Roc, T-Cross, Touran, T-Roc Cabrio 704
2 6 2 Adjusting assembly mountings, up! 706
2 7 Checking adjustment of assembly mountings (engine and gearbox mountings) 707
2 7 1 Checking adjustment of assembly mountings, Golf, Golf Estate, Golf SV, Polo 2018 ►, T-Roc, T-Cross, Touran, T-Roc Cabrio 707
2 7 2 Checking assembly mounting settings, up! 708
13 – Crankshaft group 709
1 Cylinder block (pulley end) 709
1 1 Assembly overview – poly V-belt drive 709
1 1 1 Assembly overview – poly V-belt drive, vehicles without air conditioner compressor 709
1 1 2 Assembly overview – poly V-belt drive, vehicles with air conditioner compressor 711
1 2 Removing and installing poly-V belt 713
1 2 1 Removing and installing poly V-belt, vehicles without air conditioner compressor 713
1 2 2 Removing and installing poly V-belt, vehicles with air conditioner compressor 715
1 3 Removing and installing tensioner for poly V-belt 717
1 3 1 Removing and installing tensioner for poly V-belt, vehicles without air conditioner compressor 717
1 3 2 Removing and installing tensioner for poly V-belt, vehicles with air conditioner compressor 717
1 4 Removing and installing vibration damper 718
1 5 Removing and installing engine support 722
1 6 Renewing crankshaft oil seal – belt pulley end 726
2 Cylinder block, gearbox end 729
2 1 Assembly overview – cylinder block, gearbox end 729
2 2 Removing and installing flywheel 731
2 3 Removing and installing sealing flange on gearbox side 733
3 Crankshaft 744
3 1 Crankshaft dimensions 744
3 2 Renewing needle bearing in crankshaft 744
4 Pistons and conrods 747
4 1 Assembly overview – pistons and conrods 747
4 2 Removing and installing pistons 750
4 3 Checking pistons and cylinder bores 751
4 4 Separating new conrod 753
4 5 Checking radial clearance of conrods 754
4 6 Removing and installing oil spray jets 754
4 7 Setting piston to TDC position 756
15 – Cylinder head, valve gear 760
1 Cylinder head 760
1 1 Assembly overview – cylinder head 760
1 2 Assembly overview – camshaft housing 762
1 3 Removing and installing cylinder head 765
1 4 Removing and installing camshaft housing 768
1 5 Checking compression 773
2 Toothed belt drive 776
2 1 Assembly overview – toothed belt cover 776
2 2 Assembly overview – toothed belt 776
2 3 Removing and installing toothed belt 778
2 4 Preassembling and installing test tool -VAS 611 007- 785
2 4 1 Preassembling test tool -VAS 611 007- 785
2 4 2 Installing test tool -VAS 611 007- 788
2 4 3 Teaching-in test tool -VAS 611 007- electronically and performing basic setting 791
2 5 Checking valve timing 793
2 6 Adjusting valve timing 796
2 7 Removing toothed belt from camshaft 807
3 Valve gear 815
3 1 Assembly overview – valve gear 815
3 2 Measuring axial play of camshaft 817
3 3 Removing and installing camshaft oil seal 818
3 3 1 Removing and installing camshaft oil seal, inlet camshaft 818
3 3 2 Removing and installing camshaft oil seal, exhaust camshaft, pulley end 820
3 3 3 Removing and installing camshaft oil seal, exhaust camshaft, gearbox end 822
3 4 Removing and installing camshaft adjuster 825
3 4 1 Removing and installing camshaft adjuster for inlet camshaft 825
3 4 2 Removing and installing camshaft adjuster for exhaust camshaft 831
3 5 Removing and installing camshaft control valve 1 -N205- 837
3 6 Removing and installing exhaust camshaft control valve 1 -N318- 838
3 7 Removing and installing valve stem seals 839
3 7 1 Removing and installing valve stem seals (cylinder head installed) 839
3 7 2 Removing and installing valve stem seals (cylinder head removed) 846
4 Inlet and exhaust valves 852
4 1 Checking valve guides 852
4 2 Checking valves 853
4 3 Valve dimensions 853
17 – Lubrication 854
1 Sump, oil pump 854
1 1 Assembly overview – sump/oil pump 854
1 2 Engine oil: 858
1 3 Removing and installing sump 858
1 4 Removing and installing oil pump 863
1 5 Removing and installing oil level and oil temperature sender -G266- 865
2 Engine oil cooler 867
2 1 Assembly overview – engine oil cooler 867
2 2 Removing and installing engine oil cooler 868
3 Crankcase ventilation 869
3 1 Assembly overview – crankcase breather system 869
3 2 Removing and installing oil separator 870
4 Oil filter, oil pressure switch 874
4 1 Assembly overview – oil filter/oil pressure switch 874
4 2 Removing and installing oil pressure sender -G10- 875
4 3 Checking oil pressure and oil pressure switch 876
4 4 Removing and installing oil filter housing 876
4 5 Removing and installing oil pressure regulating valve -N428- 878
19 – Cooling 880
1 Cooling system/coolant 880
1 1 Connection diagram – coolant hoses 880
1 2 Checking cooling system for leaks 881
1 3 Draining and adding coolant 886
1 3 1 Draining and adding coolant, Polo 2014 ►, Polo Saloon IN 2016 ►, Polo KH IN 2015 ► 886
1 3 2 Draining and filling coolant, Golf 2013, Golf 2017, Golf Estate 2014, Golf Estate 2017, Golf SV 2015, Polo 2018 ►, T-Roc, T-Cross, Touran, T-Roc Cabrio 895
1 3 3 Draining and adding coolant, up! 905
2 Coolant pump, regulation of cooling system 914
2 1 Assembly overview – coolant pump, thermostat 914
2 2 Assembly overview – electric coolant pump 917
2 3 Assembly overview – coolant temperature sender 918
2 3 1 Assembly overview – coolant temperature sender, Polo 2014 ►, up!, Polo Saloon IN 2016 ►, Polo KH IN 2015 ► 918
2 3 2 Assembly overview – coolant temperature sender, Golf, Golf Estate, Golf SV, Polo 2018 ►, T-Roc, T-Cross, Touran, T-Roc Cabrio 918
2 4 Removing and installing electric coolant pump 919
2 5 Removing and installing coolant pump 922
2 6 Removing and installing thermostat 926
2 6 1 Removing and installing thermostat for main coolant circuit (radiator) 926
2 6 2 Removing and installing thermostat for cylinder block coolant circuit 929
2 7 Removing and installing toothed belt pulley for coolant pump 930
2 8 Removing and installing coolant temperature sender -G62- 932
2 9 Removing and installing radiator outlet coolant temperature sender -G83- 935
2 9 1 Removing and installing radiator outlet coolant temperature sender -G83-, Polo 2014 ►, Polo Saloon IN 2016 ►, Polo KH IN 2015 ► 935
2 9 2 Removing and installing radiator outlet coolant temperature sender -G83-, Golf, Golf Estate, Golf SV, Polo 2018 ►, T-Roc, T-Cross, Touran, T-Roc Cabrio 936
2 9 3 Removing and installing radiator outlet coolant temperature sender -G83-, up! 938
3 Coolant pipes 940
3 1 Assembly overview – coolant pipes 940
3 2 Removing and installing coolant pipes 940
4 Radiator, radiator fan 943
4 1 Assembly overview – radiator/radiator fan 943
4 1 1 Assembly overview – radiator/radiator fan, Polo 2014 ►, Polo Saloon IN 2016 ►, Polo KH IN 2015 ► 943
4 1 2 Assembly overview – radiator/radiator fan, Golf, Golf Estate, Golf SV, Touran 945
4 1 3 Assembly overview – radiator/radiator fan, up! 947
4 1 4 Assembly overview – radiator/radiator fan, Polo 2018 ►, T-Cross 950
4 1 5 Assembly overview – radiator/radiator fan, T-Roc, T-Roc Cabrio 952
4 2 Assembly overview – radiator cowl and radiator fan 953
4 2 1 Assembly overview – radiator cowl and radiator fan, Polo 2014 ►, Polo Saloon IN 2016 ►, Polo KH IN 2015 ► 953
4 2 2 Assembly overview – radiator cowl and radiator fan, Golf, Golf Estate, Golf SV, Polo 2018 ►, T-Roc, T-Cross, Touran, T-Roc Cabrio 953
4 2 3 Assembly overview – radiator cowl and radiator fan, up! 954
4 3 Assembly overview – radiator blind 955
4 3 1 Assembly overview – radiator blind 955
4 3 2 Assembly overview – components of radiator blind 957
4 4 Removing and installing radiator 958
4 4 1 Removing and installing radiator, Polo 2014 ►, Polo Saloon IN 2016 ►, Polo KH IN 2015 ► 958
4 4 2 Removing and installing radiator, Golf, Golf Estate, Golf SV, Touran 962
4 4 3 Removing and installing radiator, up! 963
4 4 4 Removing and installing radiator, Polo 2018 ► 969
4 4 5 Removing and installing radiator, T-Roc, T-Roc Cabrio 975
4 4 6 Removing and installing radiator, T-Cross 978
4 5 Removing and installing water radiator for charge air cooling circuit 983
4 5 1 Removing and installing water radiator for charge air cooling circuit, Golf, Golf Estate, Golf SV, Touran 983
4 5 2 Removing and installing water radiator for charge air cooling circuit, up!, T-Roc, T-Roc Cabrio 988
4 6 Removing and installing radiator cowl 989
4 6 1 Removing and installing radiator cowl, Polo 2014 ►, Polo Saloon IN 2016 ►, Polo KH IN 2015 ► 989
4 6 2 Removing and installing radiator cowl, Golf, Golf Estate, Golf SV, Touran 991
4 6 3 Removing and installing radiator cowl, up! 992
4 6 4 Removing and installing radiator cowl, Polo 2018 ►, T-Cross 993
4 6 5 Removing and installing radiator cowl, T-Roc, T-Roc Cabrio 995
4 7 Removing and installing radiator fan -V7- 996
4 7 1 Removing and installing radiator fan -V7-, Polo 2014 ►, Polo Saloon IN 2016 ►, Polo KH IN 2015 ► 996
4 7 2 Removing and installing radiator fan -V7-, Golf, Golf Estate, Golf SV, Polo 2018 ►, T-Roc, T-Cross, Touran, T-Roc Cabrio 997
4 7 3 Removing and installing radiator fan -V7-, up! 997
4 8 Removing and installing radiator blind 998
4 9 Removing and installing radiator blind control motor -V544- 1000
21 – Turbocharging/supercharging 1006
1 Turbocharger 1006
1 1 Assembly overview – turbocharger 1006
1 2 Removing and installing turbocharger 1009
1 3 Removing and installing charge pressure positioner -V465- 1016
1 4 Removing and installing connection for turbocharger 1018
1 4 1 Removing and installing connection for turbocharger 1018
1 4 2 Removing and installing turbocharger connection, Polo 2014 ►, Polo Saloon IN 2016 ►, Polo KH IN 2015 ► 1020
2 Charge air system 1023
2 1 Assembly overview – charge air system 1023
2 2 Removing and installing charge air cooler 1025
2 2 1 Removing and installing charge air cooler, Polo, Golf, Golf Estate, Golf SV, T-Roc, T-Cross, Touran, T-Roc Cabrio 1025
2 2 2 Removing and installing charge air cooler, up! 1027
2 3 Removing and installing charge pressure sender -GX26- 1029
2 4 Checking charge air system for leaks 1030
2 5 Removing and installing air pipe 1032
24 – Mixture preparation – injection 1035
1 Injection system 1035
1 1 Overview of fitting locations – injection system 1035
1 1 1 Overview of fitting locations – engine compartment, Polo 2014 ►, Polo Saloon IN 2016 ►, Polo KH IN 2015 ► 1035
1 1 2 Overview of fitting locations – engine compartment, Golf, Golf Estate, Golf SV, Polo 2018 ►, T-Roc, T-Cross, Touran, T-Roc Cabrio 1038
1 1 3 Overview of fitting locations – engine compartment, up! 1041
1 1 4 Overview of fitting locations on engine (from above) 1043
1 1 5 Overview of fitting locations – engine from above, with particulate filter 1043
1 1 6 Overview of fitting locations – engine, rear 1045
1 1 7 Overview of fitting locations – engine, front 1046
2 Injectors 1048
2 1 Assembly overview – fuel rail with injectors 1048
2 2 Removing and installing fuel rail 1051
2 3 Removing and installing injectors 1052
2 3 1 Removing and installing injectors, version 1 1052
2 3 2 Removing and installing injectors, version 2 1059
2 4 Cleaning injectors 1067
3 Air filter 1069
3 1 Assembly overview – air filter housing 1069
3 1 1 Assembly overview – air filter housing, Polo 2014 ►, Polo Saloon IN 2016 ►, Polo KH IN 2015 ► 1069
3 1 2 Assembly overview – air filter housing, Golf, Golf Estate, Golf SV, T-Roc, Touran, T-Roc Cabrio 1070
3 1 3 Assembly overview – air filter housing, up! 1072
3 1 4 Assembly overview – air filter housing, Polo 2018 1073
3 1 5 Assembly overview – air filter housing, T-Cross 1075
3 2 Removing and installing air filter housing 1077
3 2 1 Removing and installing air filter housing, Golf, Golf Estate, Golf SV, Polo 2014 ►, Polo 2018 ►, T-Roc, T-Cross, Touran, T-Roc Cabrio, Polo Saloon IN 2016 ►, Polo KH IN 2015 ► 1077
3 2 2 Removing and installing air filter housing, up! 1078
3 3 Removing air duct on lock carrier 1080
3 3 1 Removing air duct on lock carrier, Golf, Golf Estate, Golf SV, Touran 1080
3 3 2 Removing air duct on lock carrier, Polo 2018 1081
3 3 3 Removing air duct on lock carrier, T-Roc, T-Roc Cabrio 1081
3 3 4 Removing air duct on lock carrier, T-Cross 1082
4 Intake manifold 1083
4 1 Assembly overview – intake manifold 1083
4 2 Removing and installing intake manifold 1085
4 2 1 Removing and installing intake manifold, Golf, Golf Estate, Golf SV, Polo 2014 ►, Polo 2018 ►, T-Roc, T-Cross, Touran, T-Roc Cabrio, Polo Saloon IN 2016 ►, Polo KH IN 2015 ► 1085
4 2 2 Removing and installing intake manifold, up! 1089
4 3 Removing and installing throttle valve module -GX3- 1092
4 4 Cleaning throttle valve module -GX3- 1094
5 Senders and sensors 1096
5 1 Assembly overview – actuator for structure-borne sound -R214- and control unit for structure-borne sound -J869- 1096
5 2 Removing and installing fuel pressure sender -G247- 1098
5 2 1 Removing and installing fuel pressure sender -G247-, Golf, Golf Estate, Golf SV, Polo 2014, Polo 2018, Touran, T-Roc, T-Cross, T-Roc Cabrio 1098
5 2 2 Removing and installing fuel pressure sender -G247-, up! 1099
5 3 Checking fuel pressure sender -G247- 1100
5 4 Removing and installing intake manifold sender -GX9- 1103
5 5 Removing and installing exhaust gas pressure sensor 1 -G450- 1103
6 Engine control unit 1106
6 1 Assembly overview – engine control unit 1106
6 1 1 Assembly overview – engine control unit, Polo 2014 ►, Polo Saloon IN 2016 ►, Polo KH IN 2015 ► 1106
6 1 2 Assembly overview – engine control unit, up! 1107
6 1 3 Assembly overview – engine control unit, Polo 2018 ►, T-Roc, T-Cross, Touran, T-Roc Cabrio 1107
6 2 Removing and installing engine control unit -J623- 1109
6 2 1 Removing and installing engine control unit -J623-, Polo 2014 ►, Polo Saloon IN 2016 ►, Polo KH IN 2015 ► 1109
6 2 2 Removing and installing engine control unit -J623-, up! 1110
6 2 3 Removing and installing engine control unit -J623- with protective housing, Golf, Golf Estate, Golf SV, Polo 2018 ►, T-Roc, T-Cross, Touran, T-Roc Cabrio 1112
6 2 4 Removing and installing engine control unit -J623- with metal locking plate, Golf, Golf Estate, Golf SV 1115
6 2 5 Removing engine control unit -J623- from protective housing, Golf, Golf Estate, Golf SV 1118
7 High-pressure pump 1120
7 1 Assembly overview – high-pressure pump 1120
7 2 Removing and installing high-pressure pump 1121
7 3 Removing and installing high-pressure pipe 1123
8 Lambda probe 1125
8 1 Assembly overview – Lambda probe 1125
8 2 Removing and installing Lambda probe 1126
26 – Exhaust system 1129
1 Exhaust pipes and silencers 1129
1 1 Assembly overview – silencers 1129
1 1 1 Assembly overview – silencers, Polo 2014 ►, Polo Saloon IN 2016 ►, Polo KH IN 2015 ► 1129
1 1 2 Assembly overview – silencer, Golf, Golf SV, T-Roc, Touran, T-Roc Cabrio 1130
1 1 3 Assembly overview silencers, Golf Estate 1133
1 1 4 Assembly overview – silencers, up! 1136
1 1 5 Assembly overview – silencers, Polo 2018 ►, T-Cross 1137
1 2 Separating exhaust pipes from silencers 1138
1 2 1 Separating exhaust pipes from silencers, Golf, Golf Estate, Golf SV, Polo 2014 ►, Polo 2018 ►, T-Roc, T-Cross, Touran, T-Roc Cabrio, Polo Saloon IN 2016 ►, Polo KH IN 2015 ► 1138
1 2 2 Separating exhaust pipes/silencers, up! 1140
1 3 Removing and installing silencer 1142
1 3 1 Removing and installing front silencer, Polo 2014 ►, Polo Saloon IN 2016 ►, Polo KH IN 2015 ► 1142
1 3 2 Removing and installing front silencer, Golf, Golf Estate, Golf SV, T-Roc, Touran, T-Roc Cabrio 1144
1 3 3 Removing and installing front silencer, Polo 2018 ►, T-Cross 1145
1 3 4 Removing and installing rear silencer, Polo 2014 ►, Polo Saloon IN 2016 ►, Polo KH IN 2015 ► 1146
1 3 5 Removing and installing rear silencer, Golf, Golf Estate, Golf SV, T-Roc, Touran, T-Roc Cabrio 1149
1 3 6 Removing and installing rear silencer, Polo 2018 ►, T-Cross 1151
1 3 7 Removing and installing silencer, up! 1152
1 3 8 Align end exhaust pipes 1154
1 4 Aligning exhaust system free of stress 1154
1 5 Checking exhaust system for leaks 1155
1 6 Installation position of clamp 1155
1 6 1 Installation position of clamp, Golf, Golf Estate, Golf SV, Polo 2014 ►, Polo 2018 ►, T-Roc, T-Cross, Touran, T-Roc Cabrio, Polo Saloon IN 2016 ►, Polo KH IN 2015 ► 1155
1 6 2 Installation position of clamp, up! 1157
2 Emission control 1159
2 1 Assembly overview – emission control 1159
2 1 1 Assembly overview – emission control, Polo 2014 ►, up!, Polo Saloon IN 2016 ►, Polo KH IN 2015 ► 1159
2 1 2 Assembly overview – emission control, Golf, Golf Estate, Golf SV, Polo 2018 ►, T-Roc, T-Cross, T-Roc Cabrio 1161
2 1 3 Assembly overview – emission control with petrol particulate filter, Golf, Golf Estate, Golf SV, Polo 2018 ►, T-Roc, T-Cross, Touran, T-Roc Cabrio 1164
2 2 Removing and installing catalytic converter 1167
2 3 Removing and installing particulate filter 1171
28 – Ignition system 1172
1 Ignition system 1172
1 1 Assembly overview – ignition system 1172
1 2 Removing and installing ignition coils with output stage 1174
1 3 Removing and installing knock sensor 1 -G61- 1177
1 4 Removing and installing Hall sender 1179
1 5 Removing and installing engine speed sender -G28- 1180
1 5 1 Removing and installing engine speed sender -G28-, Golf, Golf Estate, Golf SV, Polo 2014 ►, up!, T-Roc, Touran, T-Roc Cabrio 1180
1 5 2 Removing and installing engine speed sender -G28-, Polo 2018 ►, T-Cross 1182
D4B805CB339 Manual for Troubleshooting and Diagnosing Noises 1185
00 – Technical data 1191
1 Introduction 1191
2 Acoustic considerations during vehicle development 1192
2 1 Vibration insulation film 1192
2 2 Insulation 1193
3 General procedure for identifying noises 1195
3 1 General procedure 1195
3 2 Identifying a noise 1195
3 2 1 Localising origin of noise 1195
3 2 2 Identifying the type of noise 1196
3 2 3 Identifying the point in time when the noise occurs 1196
3 2 4 Identifying the noise by definition or designation 1196
3 3 Aid for localising noise by means of audio recordings (frequencies) 1196
3 3 1 Preparing an audio CD with downloaded files 1197
3 3 2 List of audio tracks 1197
3 3 3 Conditions for testing 1197
3 3 4 Conditions for performing the audio test 1198
3 4 Checklist 1198
4 Volkswagen equipment for localising noises 1202
4 1 Ultrasonic tester -VAG 1842- 1202
4 1 1 Design of the ultrasonic tester -VAG 1842- 1202
4 1 2 Example of procedure for identifying noises using ultrasound 1202
4 2 Borescope -VAS 6748A- 1206
4 2 1 Design of the borescope -VAS 6748A- 1206
4 2 2 Procedure for identifying noises using the borescope 1207
5 Attachments 1208
5 1 Checklist 1208
5 2 Designations for noises 1210
D4B806AE0FE Removed 6 speed manual gearbox 0AJ 1211
00 – Technical data 1215
1 Safety information 1215
2 Identification 1216
3 Technical data 1217
3 1 Capacities 1217
4 Overview – power transmission 1218
5 Electrical components 1220
6 Repair notes 1221
6 1 General repair instructions 1221
30 – Clutch 1225
1 Clutch mechanism 1225
1 1 Assembly overview – clutch release mechanism 1225
1 2 Repairing clutch release mechanism 1227
2 Clutch 1229
2 1 Assembly overview – clutch 1229
2 1 1 Assembly overview – clutch in conjunction with Sachs dual-mass flywheel 1229
2 1 2 Assembly overview – clutch in conjunction with LuK dual-mass flywheel 1230
2 1 3 Assembly overview – clutch with simple flywheel 1230
2 2 Removing and installing clutch 1231
2 2 1 Removing and installing clutch in conjunction with Sachs dual-mass flywheel 1231
2 2 2 Removing and installing clutch in conjunction with LuK dual-mass flywheel 1236
2 2 3 Removing and installing clutch in connection with simple flywheel 1241
34 – Controls, housing 1247
1 Selector mechanism 1247
2 Removing and installing gearbox 1248
3 Gearbox transport 1249
4 Gear oil 1251
5 Securing to engine and gearbox support 1252
6 Dismantling and assembling gearbox 1254
6 1 Overview – gearbox 1254
6 2 Assembly overview – gearbox 1254
6 3 Assembly overview – gearbox housing cover 1255
6 4 Assembly overview – clutch housing 1257
6 5 Assembly overview – shafts, differential, selector mechanism 1258
6 6 Assembly overview – selector forks 1260
6 7 Repairing selector forks 1261
6 8 Dismantling and assembling gearbox 1266
6 8 1 Dismantling gearbox 1266
6 8 2 Assembling gearbox 1278
7 Gearbox housing, clutch housing 1288
7 1 Assembly overview – gearbox housing and clutch housing 1288
7 2 Assembly overview – gearbox housing cover 1290
7 3 Repairing gearbox housing 1291
7 4 Repairing gearbox housing cover 1292
35 – Gears, shafts 1296
1 Input shaft 1296
1 1 Assembly overview – input shaft 1296
1 2 Dismantling and assembling input shaft 1299
1 3 Renewing input shaft seal 1312
2 Output shaft 1315
2 1 Assembly overview – output shaft 1315
2 2 Dismantling and assembling output shaft 1318
39 – Final drive – differential 1326
1 Oil seals 1326
1 1 Overview of fitting locations – oil seals 1326
2 Differential 1327
2 1 Assembly overview – differential 1327
2 2 Dismantling and assembling differential 1329
2 3 Adjusting differential 1335
D4B806B8524 6 speed manual gearbox 02Q 0BB and 0FB removed 1341
00 – Technical data 1345
1 Safety information 1345
2 Identification 1346
3 Technical data 1347
3 1 Allocation gearbox – engine 1347
3 2 Capacities 1347
4 Overview – power transmission 1348
4 1 Overview – power transmission – front-wheel drive 1348
4 2 Overview – power transmission – all-wheel drive 1349
5 Electrical components 1352
6 Repair notes 1353
6 1 General repair instructions 1353
30 – Clutch 1357
1 Clutch mechanism 1357
1 1 Assembly overview – clutch release mechanism 1357
1 2 Removing and installing clutch slave cylinder together with release bearing 1359
1 3 Repairing clutch release mechanism 1361
2 Clutch 1363
2 1 Assembly overview – clutch 1363
2 1 1 Assembly overview – clutch in conjunction with Sachs dual-mass flywheel 1363
2 1 2 Assembly overview – clutch in conjunction with LuK dual-mass flywheel 1364
2 1 3 Assembly overview – clutch with simple flywheel 1365
2 2 Removing and installing clutch 1366
2 2 1 Removing and installing clutch in conjunction with Sachs dual-mass flywheel 1366
2 2 2 Removing and installing clutch in conjunction with LuK dual-mass flywheel 1373
2 2 3 Removing and installing clutch in connection with simple flywheel 1379
34 – Controls, housing 1384
1 Selector mechanism 1384
2 Removing and installing gearbox 1385
3 Bevel box 1386
3 1 Distinguishing between different types of bevel boxes 1386
3 2 Removing bevel box 1386
3 3 Installing bevel box 1386
4 Front differential lock 1387
5 Transporting gearbox 1388
5 1 Transporting manual gearbox 1388
5 2 Transporting front differential lock 1389
6 Gear oil 1390
7 Securing to engine and gearbox support 1391
7 1 Installing manual gearbox to engine and gearbox support 1391
7 2 Installing bevel box or front differential lock to engine and gearbox support 1392
8 Dismantling and assembling gearbox 1394
8 1 Schematic overview – gearbox 1394
8 1 1 Schematic overview – gearbox, front-wheel drive 1394
8 1 2 Schematic overview – front differential lock 1395
8 1 3 Schematic overview – gearbox, all-wheel drive 1396
8 2 Assembly overview – gearbox 1397
8 2 1 Assembly overview – gearbox with front-wheel drive 1397
8 2 2 Assembly overview – gearbox with four-wheel drive, gearbox with front-wheel drive and front differential lock 1398
8 3 Assembly overview – gearbox housing and selector mechanism 1399
8 4 Assembly overview – shafts, differential, selector mechanism 1402
8 4 1 Assembly overview – shafts, differential, selector mechanism, front-wheel drive 1402
8 4 2 Assembly overview – shafts, differential, gear selector, all-wheel drive and front-wheel drive with front differential lock 1404
8 5 Assembly overview – selector forks 1406
8 6 Dismantling and assembling gearbox 1407
8 6 1 Dismantling gearbox 1407
8 6 2 Assembling gearbox 1420
9 Gearbox housing, clutch housing 1432
9 1 Assembly overview – gearbox housing 1432
9 2 Assembly overview – clutch housing 1434
9 3 Repairing gearbox housing 1436
9 4 Repairing clutch housing 1446
35 – Gears, shafts 1449
1 Input shaft 1449
1 1 Assembly overview – input shaft 1449
1 2 Dismantling and assembling input shaft 1450
1 3 Renewing input shaft seal 1456
2 Output shaft 1458
2 1 Assembly overview – output shaft 1458
2 1 1 Assembly overview – output shaft for 1st to 4th gears 1458
2 1 2 Assembly overview – output shaft for 5th, 6th and reverse gears 1463
2 2 Dismantling and assembling output shaft 1465
2 2 1 Dismantling and assembling output shaft for 1st to 4th gears 1465
2 2 2 Dismantling and assembling output shaft for 5th, 6th and reverse gears 1482
2 3 Adjusting output shaft 1494
2 3 1 Adjusting output shaft for 1st to 4th gears 1494
2 3 2 Adjusting output shaft for 5th, 6th and reverse gears 1500
39 – Final drive – differential 1506
1 Seals 1506
1 1 Overview of fitting locations – oil seals 1506
2 Differential 1509
2 1 Assembly overview – differential 1509
2 1 1 Assembly overview – differential, front-wheel drive 1509
2 1 2 Assembly overview – differential, four-wheel drive and front-wheel drive with front differential lock 1511
2 2 Dismantling and assembling differential 1514
2 2 1 Dismantling and assembling differential, front-wheel drive 1514
2 2 2 Dismantling and assembling differential, four-wheel drive, front-wheel drive with front differential lock 1521
2 3 Adjusting differential 1530
3 Adjustment overview 1535
4 Components of bevel box 1536
4 1 Assembly overview – components of bevel box 1536
4 1 1 Assembly overview – components of bevel box, “0AV” 1536
4 1 2 Assembly overview – components of bevel box, “0CN” 1539
4 2 Renewing bevel box seals 1541
4 2 1 Renewing seal between gearbox and bevel box with bevel box removed 1542
4 2 2 Renewing output flange oil seal, bevel box “0AV” (bevel box removed) 1543
4 2 3 Renewing output flange oil seal, bevel box “0CN” (bevel box removed) 1558
4 3 Renewing output flange and redetermining thickness of shim 1569
5 Components of front differential lock 1571
5 1 Assembly overview – components of front differential lock 1571
5 2 Checking function 1573
5 3 Renewing seals for front differential lock 1573
5 3 1 Renewing seal between front differential lock and manual gearbox on front differential lock 1573
5 3 2 Renewing oil seal for right flange shaft within front differential lock 1575
5 4 Renewing ball bearing for flange shaft 1579
6 Gear oil 1584
7 Oil for front differential lock 1585
D4B806C0E6D Removed 5 speed manual gearbox 0A4 1586
00 – Technical data 1590
1 Safety information 1590
2 Identification 1591
3 Technical data 1592
3 1 Allocation gearbox – engine 1592
3 2 Capacities 1592
4 Overview – power transmission 1593
5 Electrical components 1595
6 Repair instructions 1596
6 1 General repair instructions 1596
30 – Clutch 1600
1 Clutch mechanism 1600
1 1 Assembly overview – clutch release mechanism 1600
1 2 Repairing clutch release mechanism 1602
2 Clutch 1603
2 1 Assembly overview – clutch 1603
2 1 1 Assembly overview – clutch in conjunction with Sachs dual-mass flywheel 1603
2 1 2 Assembly overview – clutch in conjunction with LuK dual-mass flywheel 1604
2 1 3 Assembly overview – clutch with simple flywheel 1604
2 2 Removing and installing clutch 1605
2 2 1 Removing and installing clutch in conjunction with Sachs dual-mass flywheel 1605
2 2 2 Removing and installing clutch in conjunction with LuK dual-mass flywheel 1610
2 2 3 Removing and installing clutch in connection with simple flywheel 1614
34 – Controls, housing 1620
1 Selector mechanism 1620
2 Removing and installing gearbox 1621
3 Transporting gearbox 1622
4 Gear oil 1623
5 Securing to engine and gearbox support 1624
6 Dismantling and assembling gearbox 1626
6 1 Schematic overview – gearbox 1626
6 2 Assembly overview – gearbox 1627
6 3 Assembly overview – cover for gearbox housing and 5th gear 1628
6 4 Assembly overview – gearbox housing and selector mechanism 1630
6 5 Assembly overview – selector unit 1632
6 6 Assembly overview – shafts, differential, selector mechanism 1632
6 7 Assembly overview – selector forks 1633
6 8 Repairing selector forks 1634
6 9 Removing cover for gearbox housing and 5th gear 1638
6 10 Dismantling and assembling gearbox 1645
6 11 Installing cover for gearbox housing and 5th gear 1659
7 Gearbox housing, clutch housing 1664
7 1 Assembly overview – gearbox housing and clutch housing 1664
7 2 Repairing gearbox housing 1667
7 2 1 Identifying output shaft bearing in gearbox housing 1667
7 2 2 Removing and installing roller bearing without retaining ring 1668
7 2 3 Removing and installing roller bearing with retaining ring 1670
7 3 Repairing clutch housing 1673
35 – Gears, shafts 1675
1 Input shaft 1675
1 1 Assembly overview – input shaft 1675
1 2 Dismantling and assembling input shaft 1677
1 3 Adjusting input shaft 1684
1 4 Renewing input shaft seal 1689
2 Output shaft 1691
2 1 Assembly overview – output shaft 1691
2 2 Dismantling and assembling output shaft 1694
2 3 Adjusting output shaft 1708
3 Reverse shaft 1713
3 1 Assembly overview – reverse shaft 1713
3 2 Dismantling and assembling reverse shaft 1713
39 – Final drive – differential 1717
1 Oil seals 1717
1 1 Overview of fitting locations – oil seals 1717
2 Differential 1718
2 1 Assembly overview – differential 1718
2 2 Dismantling and assembling differential 1720
2 3 Adjusting differential 1726
3 Adjustment overview 1730
D4B806DBAE8 Removed 5 speed manual gearbox 0AF 1731
00 – Technical data 1735
1 Safety information 1735
2 Identification 1736
3 Technical data 1737
3 1 Allocation gearbox – engine 1737
3 2 Capacities 1737
4 Overview – power transmission 1738
5 Electrical components 1740
6 Repair instructions 1741
6 1 General repair instructions 1741
30 – Clutch 1745
1 Clutch mechanism 1745
1 1 Assembly overview – clutch release mechanism 1745
1 2 Repairing clutch release mechanism 1747
2 Clutch 1749
2 1 Assembly overview – clutch 1749
2 1 1 Assembly overview – clutch in conjunction with Sachs dual-mass flywheel 1749
2 1 2 Assembly overview – clutch in conjunction with LuK dual-mass flywheel 1750
2 1 3 Assembly overview – clutch with simple flywheel 1750
2 2 Removing and installing clutch 1751
2 2 1 Removing and installing clutch in conjunction with Sachs dual-mass flywheel 1751
2 2 2 Removing and installing clutch in conjunction with LuK dual-mass flywheel 1756
2 2 3 Removing and installing clutch in connection with simple flywheel 1761
34 – Controls, housing 1767
1 Selector mechanism 1767
2 Removing and installing gearbox 1768
3 Gearbox transport 1769
4 Gear oil 1770
5 Securing to engine and gearbox support 1771
6 Dismantling and assembling gearbox 1773
6 1 Schematic overview – gearbox 1773
6 2 Assembly overview – gearbox 1773
6 3 Assembly overview – gearbox housing cover 1774
6 4 Assembly overview – clutch housing 1776
6 5 Assembly overview – shafts, differential, selector mechanism 1776
6 6 Assembly overview – selector forks 1778
6 7 Repairing selector forks 1779
6 8 Dismantling and assembling gearbox 1784
6 8 1 Dismantling gearbox 1784
6 8 2 Assembling gearbox 1790
7 Gearbox housing, clutch housing 1797
7 1 Assembly overview – gearbox housing and clutch housing 1797
7 2 Repairing gearbox housing 1799
7 3 Repairing clutch housing 1800
35 – Gears, shafts 1803
1 Input shaft 1803
1 1 Assembly overview – input shaft 1803
1 2 Dismantling and assembling input shaft 1805
1 3 Renewing input shaft seal 1819
2 Output shaft 1822
2 1 Assembly overview – output shaft 1822
2 2 Dismantling and assembling output shaft 1825
39 – Final drive – differential 1833
1 Oil seals 1833
1 1 Overview of fitting locations – oil seals 1833
2 Differential 1834
2 1 Assembly overview – differential 1834
2 2 Dismantling and assembling differential 1836
2 3 Adjusting differential 1844
D4B807A6D24 Installed 6 speed manual gearbox 0AJ 1850
00 – Technical data 1854
1 Safety information 1854
1 1 Safety measures when working on vehicles with a start/stop system 1854
2 Identification 1855
2 1 Gearbox identification 1855
3 Technical data 1856
3 1 Allocation gearbox – engine 1856
3 2 Capacities 1856
4 Overview – power transmission 1857
5 Electrical components 1859
5 1 Overview of fitting locations – electrical components 1859
5 1 1 Overview of fitting locations – electrical components, manual gearbox 1859
5 1 2 Overview of fitting locations – electrical components, clutch mechanism 1859
6 Repair instructions 1861
6 1 General repair instructions 1861
30 – Clutch 1864
1 Clutch mechanism 1864
1 1 Overview of fitting locations – clutch mechanism 1864
1 2 Assembly overview – pedal cluster 1865
1 3 Assembly overview – clutch hydraulics 1867
1 4 Removing and installing bearing bush 1869
1 5 Checking clutch master cylinder and clutch slave cylinder 1870
1 6 Removing and installing clutch position sender -G476- 1871
1 7 Removing and installing over-centre spring 1873
1 8 Removing and installing clutch pedal 1875
1 8 1 Removing and installing clutch pedal, LHD 1875
1 8 2 Removing and installing clutch pedal, RHD 1876
1 9 Removing and installing mounting bracket 1878
1 10 Removing and installing master cylinder 1881
1 11 Removing and installing clutch slave cylinder 1882
1 12 Removing and installing lines for clutch mechanism 1885
1 13 Bleeding clutch mechanism 1887
2 Clutch 1890
34 – Controls, housing 1891
1 Selector mechanism 1891
1 1 Installation position – selector mechanism 1891
1 2 Assembly overview – gear knob and cover 1892
1 3 Assembly overview – selector mechanism 1893
1 4 Removing and installing gear knob 1895
1 5 Removing and installing selector mechanism 1897
1 6 Repairing selector mechanism 1905
1 7 Adjusting selector mechanism 1909
1 8 Checking selector mechanism 1913
2 Removing and installing gearbox 1914
2 1 Specified torques for gearbox 1914
2 1 1 Specified torques for gearbox in vehicles with 1 0 l petrol engine 1914
2 2 Removing gearbox 1914
2 2 1 Removing gearbox, vehicles with 1 0 l petrol engine 1914
2 3 Installing gearbox 1923
2 3 1 Installing gearbox, vehicles with 1 0 l petrol engine 1923
3 Assembly mountings 1930
3 1 Assembly overview – assembly mountings 1930
4 Gear oil 1933
4 1 Checking gear oil level 1933
5 Dismantling and assembling gearbox 1935
5 1 Assembly overview – selector unit 1935
5 2 Removing and installing selector unit with gearbox installed 1936
5 2 1 Removing and installing selector unit with gearbox installed 1936
5 2 2 Repairing selector unit 1941
5 2 3 Renewing selector shaft seal 1942
6 Gearbox housing, clutch housing 1943
35 – Gears, shafts 1944
1 Input shaft 1944
2 Output shaft 1945
39 – Final drive – differential 1946
1 Oil seals 1946
1 1 Overview of fitting locations – oil seals 1946
1 2 Renewing left seal 1946
1 2 1 Renewing oil seal for left flange shaft 1946
1 3 Renewing right seal 1949
1 3 1 Renewing oil seal for right flange shaft 1949
2 Differential 1954
D4B807A82ED Installed 5 speed manual gearbox 0A4 1955
00 – Technical data 1959
1 Safety information 1959
1 1 Safety measures when working on vehicles with a start/stop system 1959
2 Identification 1960
2 1 Gearbox identification 1960
3 Technical data 1961
3 1 Allocation gearbox – engine 1961
3 2 Capacities 1961
4 Overview – power transmission 1962
5 Electrical components 1964
5 1 Overview of fitting locations – electrical components 1964
5 1 1 Overview of fitting locations – electrical components, manual gearbox 1964
5 1 2 Overview of fitting locations – electrical components, clutch mechanism 1964
6 Repair instructions 1965
6 1 General repair instructions 1965
30 – Clutch 1967
1 Clutch mechanism 1967
1 1 Overview of fitting locations – clutch mechanism 1967
1 2 Assembly overview – pedal cluster 1969
1 3 Assembly overview – clutch hydraulics 1970
1 4 Removing and installing bearing bush 1972
1 5 Checking clutch master cylinder and clutch slave cylinder 1973
1 6 Removing and installing clutch position sender -G476- 1974
1 7 Removing and installing over-centre spring 1975
1 8 Removing and installing clutch pedal 1977
1 8 1 Removing and installing clutch pedal, LHD 1977
1 8 2 Removing and installing clutch pedal, RHD 1978
1 9 Removing and installing mounting bracket 1979
1 10 Removing and installing master cylinder 1981
1 11 Removing and installing clutch slave cylinder 1982
1 12 Removing and installing lines for clutch mechanism 1984
1 13 Bleeding clutch mechanism 1986
2 Clutch 1988
34 – Controls, housing 1989
1 Selector mechanism 1989
1 1 Installation position – selector mechanism 1989
1 2 Assembly overview – gear knob and cover 1990
1 3 Assembly overview – selector mechanism 1991
1 4 Removing and installing gear knob 1992
1 5 Removing and installing selector mechanism 1994
1 6 Repairing selector mechanism 2001
1 7 Adjusting selector mechanism 2003
1 8 Checking selector mechanism 2006
2 Removing and installing gearbox 2007
2 1 Removing gearbox 2007
2 2 Installing gearbox 2014
2 3 Specified torques for gearbox 2017
3 Assembly mountings 2018
3 1 Assembly overview – assembly mountings 2018
4 Gear oil 2020
4 1 Checking gear oil level 2020
4 2 Draining and filling gear oil 2020
5 Dismantling and assembling gearbox 2023
5 1 Assembly overview – selector unit 2023
5 2 Removing and installing selector unit with gearbox installed 2024
5 3 Repairing selector unit 2026
5 4 Renewing selector shaft seal 2027
6 Gearbox housing, clutch housing 2029
35 – Gears, shafts 2030
1 Input shaft 2030
2 Output shaft 2031
3 Reverse shaft 2032
39 – Final drive – differential 2033
1 Oil seals 2033
1 1 Overview of fitting locations – seals 2033
1 2 Renewing left seal 2034
1 2 1 Renewing oil seal for left flange shaft 2034
1 3 Renewing right oil seal 2036
1 3 1 Renewing oil seal for right flange shaft 2036
2 Differential 2040
D4B807B934F Fuel supply system diesel engines 2041
00 – Technical data 2045
1 Safety information 2045
1 1 Safety precautions when working on the fuel supply system 2045
1 2 Safety measures when working on vehicles with a start/stop system 2046
1 3 Safety precautions when using testers and measuring instruments during a road test 2046
2 Identification 2047
2 1 Engine number/engine data 2047
3 General information 2048
3 1 Rules for cleanliness when working on auxiliary heater and fuel system 2048
4 Repair instructions 2049
4 1 Rules for cleanliness 2049
4 2 Foreign bodies in engine 2049
4 3 Contact corrosion 2049
4 4 Routing and attachment of lines 2050
4 5 Fitting radiators and condensers 2050
20 – Fuel supply system 2051
1 Procedure in event of misfuelling 2051
1 1 Procedure in event of misfuelling 2051
1 1 1 Step 1, engine was started with incorrect fuel 2051
1 1 2 Step 2, engine was not started with incorrect fuel 2053
1 1 3 Step 3, there are metal particles in fuel delivery unit and fuel tank 2055
1 1 4 Step 4, there are no metal particles in fuel delivery unit or fuel tank 2056
1 1 5 Step 5, there are metal particles in high-pressure pump 2058
1 1 6 Step 6, there are no metal particles in high-pressure pump 2058
2 Fuel 2059
2 1 Assembly overview – fuel tank 2059
2 2 Draining fuel tank 2060
2 2 1 Emptying fuel tank when fuel pump is intact 2060
2 2 2 Emptying fuel tank if it is more than 3/4 full 2061
2 2 3 Emptying fuel tank less than 3/4 full, vehicles with front-wheel drive 2063
2 3 Removing and installing fuel tanks 2066
3 Fuel delivery unit, fuel gauge sender 2074
3 1 Assembly overview – fuel delivery unit/fuel gauge sender 2074
3 2 Removing and installing fuel delivery unit, fuel gauge sender 2077
3 3 Removing and installing fuel gauge sender -G- 2081
3 4 Removing and installing assembly opening cover 2082
4 Plug-in connectors 2084
4 1 Disconnecting plug-in connectors 2084
5 Fuel filter 2090
5 1 Assembly overview – fuel filter 2090
5 1 1 Assembly overview – fuel filter, version 1 2090
5 1 2 Assembly overview – fuel filter, version 2 2091
5 1 3 Assembly overview – fuel filter, vehicles with water separator sender -G63- 2092
5 2 Removing and installing fuel filter 2094
6 Accelerator mechanism 2098
6 1 Assembly overview – accelerator pedal module 2098
6 2 Removing and installing accelerator pedal module -GX2- 2098
7 Fuel pump 2100
7 1 Checking fuel system pressurisation pump -G6- 2100
7 1 1 Checking fuel pressure 2100
7 1 2 Checking fuel delivery rate 2107
7 2 Removing and installing fuel pump control unit -J538- 2115
8 Senders and sensors 2117
8 1 Removing and installing water separator sender -G63- 2117
9 Fuel lines 2118
9 1 Removing and installing fuel line for auxiliary/supplementary heater 2118
9 2 Removing and installing fuel lines 2120
9 3 Fuel hoses in the engine compartment 2126
D4B807C13D1 Installed 5 speed manual gearbox 0AF 2128
00 – Technical data 2132
1 Safety information 2132
1 1 Safety measures when working on vehicles with a start/stop system 2132
2 Identification 2133
2 1 Gearbox identification 2133
3 Repair instructions 2134
3 1 General repair instructions 2134
4 Technical data 2137
4 1 Allocation gearbox – engine 2137
4 2 Capacities 2137
5 Overview – power transmission 2138
6 Electrical components 2140
6 1 Overview of fitting locations – electrical components 2140
6 1 1 Overview of fitting locations – electrical components, manual gearbox 2140
6 1 2 Overview of fitting locations – electrical components, clutch mechanism 2141
30 – Clutch 2142
1 Clutch mechanism 2142
1 1 Overview of fitting locations – clutch mechanism 2142
1 2 Assembly overview – pedal cluster 2143
1 3 Assembly overview – clutch hydraulics 2145
1 4 Removing and installing bearing bush 2147
1 5 Removing and installing clutch position sender -G476- 2148
1 6 Removing and installing over-centre spring 2150
1 7 Removing and installing clutch pedal 2152
1 7 1 Removing and installing clutch pedal, LHD 2152
1 7 2 Removing and installing clutch pedal, RHD 2153
1 8 Removing and installing mounting bracket 2155
1 9 Checking clutch master cylinder and clutch slave cylinder 2158
1 10 Removing and installing master cylinder 2159
1 11 Removing and installing clutch slave cylinder 2160
1 12 Removing and installing lines for clutch mechanism 2163
1 13 Bleeding clutch mechanism 2166
2 Clutch 2168
34 – Controls, housing 2169
1 Selector mechanism 2169
1 1 Installation position – selector mechanism 2169
1 2 Assembly overview – gear knob and cover 2170
1 3 Assembly overview – selector mechanism 2171
1 4 Removing and installing gear knob 2173
1 5 Removing and installing selector mechanism 2175
1 6 Repairing selector mechanism 2178
1 7 Adjusting selector mechanism 2183
1 8 Checking selector mechanism 2186
2 Removing and installing gearbox 2188
2 1 Removing gearbox 2188
2 2 Installing gearbox 2197
2 3 Specified torques for gearbox 2200
3 Assembly mountings 2202
3 1 Assembly overview – assembly mountings 2202
4 Gearbox transport 2205
5 Gear oil 2206
5 1 Checking gear oil level 2206
5 2 Draining and filling gear oil 2207
6 Dismantling and assembling gearbox 2209
6 1 Assembly overview – selector unit 2209
6 2 Removing and installing selector unit with gearbox installed 2210
6 3 Repairing selector unit 2214
6 4 Renewing selector shaft seal 2216
7 Gearbox housing, clutch housing 2217
35 – Gears, shafts 2218
1 Input shaft 2218
2 Output shaft 2219
39 – Final drive – differential 2220
1 Oil seals 2220
1 1 Overview of fitting locations – oil seals 2220
1 2 Renewing left seal 2220
1 2 1 Renewing oil seal for left flange shaft 2220
1 3 Renewing right seal 2223
1 3 1 Renewing right oil seal (for right flange shaft) 2223
2 Differential 2227
D4B807DC77D Chemicals Manual 2228
00 – Technical data 2234
1 — Change history — 2234
2 Introduction 2236
3 List of Suppliers 2237
3 1 3M do Brasil 2237
3 2 Brascola Ltda 2237
3 3 Castrol Brasil Ltda 2237
3 4 Cia Brasileira de Petróleo Ipiranga 2237
3 5 Chemours 2237
3 6 Chevron Brasil S/A 2237
3 7 Cremer S A Prod Têxteis e Cirúrgicos 2237
3 8 Dow Corning do Brasil Ltda 2237
3 9 Elf Lubrificantes do Brasil 2237
3 10 ExxonMobil 2237
3 11 Henkel do Brasil Ltda 2237
3 12 Klüber Lubrification Lubrificantes Especiais Ltda 2237
3 13 Loctite Brasil Ltda 2237
3 14 Lumobrás Imp Com Ind Ltda 2237
3 15 Motul Synthetic Lubricants 2237
3 16 Ocean Indústria Química 2237
3 17 Pentosin do Brasil Ltda 2238
3 18 Petrobras Distr S/A 2238
3 19 Shell Brasil S/A 2238
3 20 Sika S/A 2238
3 21 Solplás – Ind de Plásticos Ltda 2238
3 22 Solvay Química 2238
3 23 Three Bond do Brasil Ind e Com Ltda 2238
3 24 Total Lubrificantes Brasil Ltda 2238
3 25 Tutela Lubrificantes S/A 2238
3 26 Valvoline Lubrificantes Internacionais Ltda 2238
4 Work Instructions for Handling Chemicals 2239
4 1 Handling of Solvents 2239
4 2 Work instruction – Flammable material handling 2241
4 3 Handling used engine oil 2242
4 4 General guidelines on the storage of chemicals 2243
5 List of authorized products 2244
5 1 Polyurethane-based sealing adhesive 2244
5 2 High-resistance locking adhesive 2244
5 3 Low viscosity lock adhesive 2244
5 4 Sealing adhesive 2244
5 5 Self-adhesive PVC tape 2244
5 6 Double-sided adhesive tape 2244
5 7 Refrigerant gas – R134a 2245
5 8 Underbody coating 2245
5 9 Lubricating engine oil as per VW 502 00 and VW 505 00 standards 2245
5 10 Lubricating engine oil as per VW 507 00 standard 2245
5 11 Lubricating engine oil as per VW 508 88 and VW 509 99 standards 2246
5 12 Lubricating oil for manual gearbox and steering rack – SAE 90, MIL-L-2105B, API – GL5 2246
5 13 Lubricating oil for manual gearbox – SAE 80, MIL-L-2105, API – GL4 2246
5 14 Tire assembly paste 2246
5 15 Biodegradable degreasing product 2246
5 16 Grease remover spray 2247
6 List of fractionated products 2248
6 1 -000 096 319 D- Polishing material (chromium and aluminium) 2248
6 2 -032 198 561- Additional seal 2248
6 3 -AMV 188 001 02- Adhesive silicone 2249
6 4 -AMV 188 200 03- Sealing paste 2249
6 5 -AMV 189 300- Activating agent 2250
6 6 -AMV 189 400- Sealing compound 2250
6 7 Liquid sealant -D 000 600 A2- 2250
6 8 -D 001 210 M2- Universal adhesive 2251
6 9 -D 002 000 A2-Adhesive remover 2251
6 10 -D 004 660 M2- Adhesive set 2251
6 11 -D 007 000 A2- Spray silicone 2252
6 12 -D 009 200 02- Glass primer 2252
6 13 -D 009 401 04- Cleaning solution 2253
6 14 -D 009 500 25- Applicator 2253
6 15 Liquid sealant -D 154 000 A1- 2254
6 16 Liquid sealant -D 154 100 A1- 2254
6 17 -D 154 102 A1- Sealing compound 2254
6 18 -D 154 103 A1- Adhesive silicone 2255
6 19 -D 169 300 M1- Window adhesive 2255
6 20 -D 169 300 M2- Window adhesive 2255
6 21 -D 172 090 A2- Adhesive 2256
6 22 -D 174 003 M2- Silicone sealant 2256
6 23 -D 176 404 A3- Adhesive silicone 2257
6 24 -D 176 204 R2- Adhesive silicone 2257
6 25 -D 176 404 M2- Adhesive silicone 2257
6 26 -D 176 501 A1- Adhesive silicone 2257
6 27 -D 180 KU1 A1- 2-component adhesive for plastic 2258
6 28 -D 180 KU2 A1- 2-component adhesive for plastic 2258
6 29 -D 181 220 A1- Activating agent 2259
6 30 -D 181 655 A1- Activating agent 2259
6 31 -D 181 802 M1- Glass primer 2259
6 32 Liquid sealant -D 185 400 A2- 2260
6 33 Liquid sealant -D 185 400 A3- 2260
6 34 Liquid sealant -D 185 410 A2- 2260
6 35 -D 185 520 A2- Sealing compound 2260
6 36 -D 190 MKD A3- Assembly adhesive 2261
6 37 Liquid sealant -D 192 100 A2- 2261
6 38 -D 195 850 A1- Cleaning solution 2261
6 39 -D 316 D38 A2- Protective wax 2262
6 40 -D 322 000 A2- Wachs-spray 2262
6 41 -D 322 100 M2- Wachs-spray 2262
6 42 -D 330 KD2 A1- Cavity spray 2263
6 43 -D 366 PR1 A1- Plastic primer 2263
6 44 -D 454 300 A2- Sealing compound 2263
6 45 -D 469 101 A3- Gluing and sealing compound 2264
6 46 -D 822 150 A1- Plastic surfacer 2264
6 47 -G 000 100- Coupling teeth lubricant compound 2264
6 48 -G 000 115 A2- Spray lubricant 2265
6 49 -G 000 150- Consistent lubricating paste 2265
6 50 -G 000 405 A2- Silicone paste 2265
6 51 -G 000 450 02- Lubrication paste 2266
6 52 -G 000 650- Consistent lubricating paste 2267
6 53 -G 052 109 A2- Assembly paste 2267
6 54 -G 052 112 A3- High temperature paste 2267
6 55 -G 052 128 A1- Thrust ring sealing grease 2268
6 56 -G 052 133 A2- Lubricating paste for high temperatures 2268
6 57 -G 052 135 A1- Lubricating oil 2268
6 58 -G 052 142 A2- Polyurethane lubricating compound 2269
6 59 -G 052 150 A2- Lithium lubricating paste 2269
6 60 -G 052 168 A1- Steering box lubricant 2270
6 61 -G 052 172 A1- Special lubricant 2270
6 62 -G 052 172 M2- Special lubricant 2270
6 63 -G 052 181 A4- Lubricating paste for constant velocity joints 2271
6 64 -G 052 528 A2- Lubricating paste for constant velocity joints 2271
6 65 -G 052 565 A1- Silicone paste 2271
6 66 -G 052 723 A2- Moly paste 2272
6 67 -G 052 735 A2- Multi-purpose grease 2272
6 68 -G 052 738 A2- Lubricating paste for constant velocity joints 2272
6 69 -G 052 738 A3- Thrust ring sealing grease 2273
6 70 -G 052 745 A3- Lubricating paste for low temperature 2273
6 71 -G 052 751 A1- Molybdenum pasta 2273
6 72 -G 052 778 A2- Spray lubricant 2274
6 73 -G 052 817 A1- Contact grease 2274
6 74 -G 055 128 A1- Thrust ring sealing grease 2274
6 75 -G 060 567 A2- Special lubricant 2275
6 76 -G 060 735 A2- Multi-purpose grease 2275
6 77 -G 060 751 A2- Consistent lubricating paste 2275
6 78 -G 065 567 A2- Cleaning solution 2276
6 79 -G 070 528 R2- Lubricating paste for constant velocity joints 2276
6 80 -G 294 421 A1- Lubricating oil for assembly 2276
D4B807E3B5B Body Repairs General Body Repairs 2277
1 Safety instructions 2281
1 1 Part removal 2281
1 2 Battery and welding operation 2281
1 3 Electronic control unit 2281
1 3 1 Processing of the electronic control unit after repair dueto a traffic accident 2281
1 4 Paint, glass, soft pad and trim 2282
1 5 Fuel tank or fuel delivery pipeline 2282
1 6 Air conditioner 2282
1 6 1 Remedial measures: 2282
1 7 Airbag System 2283
1 8 Check the seat belts 2283
1 8 1 Belt body 2284
1 8 2 Automatic retractor (locking function) 2284
1 8 3 Visual inspection of the seat belt buckle 2285
1 8 4 Seat belt buckle function 2285
1 8 5 Seat belt guide member and tongue 2286
1 8 6 Fixing piece and fixing point 2286
1 9 Safety specifications for the seat belt tensioner 2286
1 10 Body repair on a vehicle equipped with the seat belt tensioners 2287
1 10 1 The following vehicles have been equipped with: 2287
1 11 Perform cutting off, correcting and/or leveling on a vehicleequipped with airbags 2288
1 12 Remove the front seats with a side airbag 2288
2 Basic instruction 2289
2 1 Diagnosis of the accident vehicle 2289
2 2 Condition of the body and/or the parts for delivery to thepainting workshop 2289
2 3 Correction 2289
2 4 Cutting 2289
2 5 Body-cut part and part section 2289
2 6 Original connection 2290
2 7 Galvanized body parts 2290
2 8 Remove the rest part 2290
2 9 New parts 2290
2 10 Parts 2290
2 11 Molded foam plastic pads 2291
3 Symbolic interpretation 2292
3 1 Symbolic interpretation for welding 2292
3 2 Symbolic interpretation for the operation method 2292
3 2 1 Grinding 2293
3 2 2 Thinning 2293
3 2 3 Punching 2293
3 2 4 Drilling 2294
3 2 5 Polishing 2294
3 2 6 Cavity corrosion protection 2294
3 2 7 Bonding 2295
3 2 8 Precise sealing 2295
4 Body repair tools 2296
4 1 Flaring tool -V A G 1317- 2296
4 2 Punching pliers -V A G 1329- 2296
4 3 Basic equipment -V A G 1366/3- 2296
4 4 Bottom protection layer spray gun -V A G 1379- 2297
4 5 Electric blower -V A G 1416- 2297
4 6 Door tensioner -V A G 1438- 2297
4 7 Body equipment component -V A G 1439- 2298
4 8 Pneumatic cutting knife -V A G 1523 A- 2298
4 9 Air chisel -V A G 1577- 2298
4 10 Edge closing iron block -V A G 1585- 2299
4 11 Welding fume ventilator -V A G 1586- 2299
4 12 Welding spot releasing device -V A G 1731- 2299
4 13 Pneumatic spray gun -V A G 1761/1- 2300
4 14 Pneumatic punching and thinning pliers -VAS 1996- 2300
4 15 Pneumatic adhesive spray gun -V A G 2005- 2300
4 16 Door hinge correction tool 2301
4 17 Hose kit 5023 for the inert gas protection welding 2301
4 18 Angle grinder -VAS 5174- 2301
4 19 Angle grinder -VAS 5175- 2302
4 20 Wire brush -VAS 5182- 2302
5 Body bonding 2303
5 1 Transporter 1991 → 2303
5 1 1 Separation process: 2303
5 1 2 Bonding process: 2303
5 2 Bonding types 2303
5 2 1 Bonding-strong 2303
5 2 2 Bonding-spot welding 2304
5 3 Repair method for replacing the parts 2304
5 3 1 Spot welding and bonding 2304
5 3 2 Plug welding and bonding (if spot welding is impossible) 2304
5 3 3 Welding fume ventilator 2305
5 3 4 Preparations 2305
5 3 5 Trimming 2305
6 Corrosion protection measures 2306
6 1 Corrosion protection 2306
7 Waste disposal instructions 2307
7 1 Waste disposal 2307
7 2 Air pressure tappet exhaust 2307
7 3 Airbag 2308
7 3 1 Waste disposal 2308
8 Contact corrosion protection 2309
8 1 Connection of aluminum alloy/magnesium alloy with steel 2309
9 Steel plate repair 2310
9 1 High-strength body plate 2310
9 2 Galvanized body parts 2310
9 2 1 Preparations 2310
9 2 2 Part cutting 2311
9 2 3 Connection process 2311
9 3 Welding on the galvanized body steel plate 2311
9 3 1 Inert gas protection plug welding SG of the galvanized steelplate 2311
9 3 2 Resistance pressure spot welding RP of the galvanized steelplate 2312
9 3 3 Welding transformer 2312
9 3 4 Welding clamp 2312
9 4 Tearing test 2312
10 Aluminum repair 2313
10 1 Painting 2313
10 2 Surface treatment 2313
10 3 Leveling 2314
10 4 Temperature control for heating 2314
11 Plastic repair method 2315
11 1 Material 2315
11 2 Repairing the pit 2316
11 3 Repairing the scratch 2317
11 4 Repair the crack 2319
11 5 Repairing the small hole (the diameter is more than 30 mm) 2320
11 6 Plastic repair (glass fibre material) 2321
11 7 Repair process 2322
11 7 1 Repairing the breakage position 2322
11 7 2 Repairing the surface damage 2324
12 Glass repair 2325
12 1 Repairing the windshield 2325
12 1 1 Premises 2325
12 1 2 Required special tools, operating equipment, testing instrumentsand auxiliary tools 2326
12 1 3 Repair description 2327
D4B808A76D0 Wheels and Tyres Specifications 2331
44 – Wheels, tyres, vehicle geometry 2335
1 Wheels/tyres – combinations – BZ1/BZ2/BZ3 family► 2335
1 1 Miscellaneous 2335
1 2 Explanations on country regions 2335
1 3 Features of the rims 2336
1 3 1 51/2J 2337
1 3 2 6J x 16 2338
1 3 3 61/2J x 17 2339
1 3 4 61/2J x 17 2340
1 3 5 6J x 16 2340
2 Recommended temporary spare tyres and wheels 2342
D4B808A76EF 6 Speed automatic gearbox 09G 2343
00 – Technical data 2347
1 Guidelines to automatic transmissions 2347
1 1 Diagnostic start suggestions 2347
2 General repair instructions 2348
2 1 General instructions 2348
2 2 Safety measures 2348
2 3 Safety measures for work on vehicles with Start-Stop system 2349
2 4 Safety measures while towing the vehicle 2349
2 5 Cleaning rules 2349
2 6 Gearbox 2349
2 7 Torque converter 2350
2 8 ATF 2350
2 9 Guided Fault Finding, vehicle self-diagnosis and measuring techniques 2351
2 10 Safety measures for test drives with testing and measuring devices 2351
2 11 Automatic gearbox control unit -J217- 2352
2 12 Vehicle control units 2352
2 13 Electrical components 2353
2 14 Sealing rings, gaskets and retainer seals 2353
2 15 Bolts and nuts 2354
3 Identification 2355
3 1 Gearbox identification 2355
3 2 Torque converter identification 2355
4 Technical data 2356
4 1 Assignment gearbox – engine 2356
4 2 Filling volumes 2356
5 Electrical components 2357
5 1 Electric components – fitting locations overview 2357
32 – Torque converter 2361
1 Torque converter 2361
1 1 Torque converter – assembly overview 2361
1 2 Torque converter – remove and install 2362
1 3 Torque converter – empty 2363
1 4 Torque converter – check 2363
1 5 Torque converter retainer – replace 2363
37 – Controls, housing 2365
1 ATF circuit 2365
1 1 ATF circuit – installation overview – 2365
1 2 ATF radiator – remove and install 2365
2 ATF 2368
2 1 ATF – level check 2368
2 2 ATF – drain and level check 2371
3 Gearbox – remove and install 2375
3 1 Gearbox – remove 2375
3 2 Gearbox – installation 2389
3 3 Gearbox – specified torques table 2391
4 Gearbox – transport 2392
5 Transmission – fasten to support 2393
6 Gear selector mechanism 2395
6 1 Gear selector mechanism – assembly overview 2395
6 2 Gear selector mechanism – check 2397
6 3 Emergency unlock from position P 2398
6 4 Gear selection mechanism – remove and install 2399
6 4 1 Gear selection mechanism with cable – remove and install 2399
6 4 2 Gear selection mechanism without cable – remove and install 2401
6 5 Gear selector lever handle – remove and install 2404
6 6 Handle lock button – put in installation position 2406
6 7 Selector cable – remove and install 2408
6 8 Selector cable – check and adjust 2411
6 9 Multifunction switch – F125- – remove and install 2413
6 10 Multifunction switch -F125- – adjust 2415
6 11 Selector lever retainer seal – replace 2416
38 – Gears, control 2418
1 ATF System 2418
1 1 Gearbox oil pan – remove and install 2418
1 2 ATF filter (strainer) – remove and install 2419
2 Valve body 2421
2 1 Valve body – assembly overview 2421
2 2 Valve body – remove and install 2424
2 3 Installation of wires, connectors, and fasteners in the valve body 2431
2 4 Wire harness of the solenoid valves and sensors – remove and install 2433
2 4 1 Wire harness of the solenoid valves (14-pin connector) – remove and install 2433
2 4 2 Wire harness of the sensor (8-pin connector) – remove and install 2434
2 5 Gearbox input speed sensor -G182- – remove and install 2434
2 6 Gearbox output speed sensor -G195- – remove and install 2435
39 – Final drive – differential 2436
1 Retainer seals 2436
1 1 Retainer seals – assembly overview 2436
1 2 Left drive flange retainer seal – renew 2436
1 3 Right drive flange retainer – replace 2439
2 Gearbox control 2442
2 1 Gearbox control unit – remove and install 2442
D4B808A76F1 5 Speed manual gearbox 0AF 2443
00 – Technical data 2447
1 — Change history — 2447
2 Identification 2448
2 1 Gearbox identification 2448
3 Technical Data 2450
3 1 Correspondence (gearbox / engine) 2450
3 2 Supply capacity (gearbox oil) 2450
3 3 Gear ratio calculation “i” 2450
4 Transmission assembly scheme 2451
5 Electrical components 2453
5 1 Electrical components – assembly overview 2453
5 1 1 Electrical components, mechanical gearbox – assembly overview 2453
5 1 2 Electrical components, clutch drive – overview of fitting locations 2453
6 General repair instructions 2455
30 – Clutch 2460
1 Clutch control 2460
1 1 Clutch drive system – assembly locations overview 2460
1 2 Clutch drive pedal – assembly overview 2461
1 3 Hydraulic clutch system – assembly overview 2463
1 4 Clutch release mechanism – assembly overview 2465
1 5 Support shell – remove and install 2466
1 6 Clutch position sender -G476- – remove and install 2467
1 7 Pedal return spring – remove and install 2469
1 8 Clutch drive pedal – remove and install 2471
1 9 Clutch drive pedal support – remove and install 2472
1 10 Clutch transmitter cylinder – remove and install 2475
1 11 Clutch slave cylinder – remove and install 2476
1 12 Clutch drive system line – remove and install 2479
1 13 Hydraulic clutch mechanism – bleed 2481
1 14 Clutch release mechanism – repair 2483
2 Clutch 2485
2 1 Clutch – assembly overview 2485
2 2 Clutch – remove and install 2486
34 – Controls, housing 2491
1 Gearshift mechanism 2491
1 1 Gearshift mechanism – installation position 2491
1 2 Gear lever – assembly overview 2492
1 3 Handle and boot on the gear lever – assembly overview 2494
1 4 Gear knob – remove and install 2495
1 5 Gearshift mechanism – remove and install 2497
1 6 Gearshift mechanism – repair 2501
1 7 Gearshift mechanism – adjust 2505
1 8 Gearshift mechanism – check operation 2508
1 9 Gearshift lever and mechanism – remove and install 2509
1 10 Selector cables – remove and install 2514
1 11 Selector rod – replace seal 2516
1 12 Selector rod and the selector mechanism cover – assembly overview 2518
1 13 Selector rod and selector mechanism cover – remove and install with the gearbox installed 2519
2 Gearbox – remove and install 2525
2 1 Gearbox – remove 2525
2 2 Gearbox – installation 2536
2 3 Gearbox torques 2541
3 Auxiliary frame 2542
3 1 Assembly mountings – assembly overview 2542
3 1 1 Assembly mountings – assembly overview 2542
4 Gearbox – transport 2545
4 1 Gearbox – transport 2545
5 Gearbox oil 2547
5 1 Gearbox oil – check level 2547
6 Transmission – fasten to support 2549
6 1 Transmission – fasten to support 2549
7 Gearbox – disassemble and assemble 2551
7 1 Gearbox – schematic overview 2551
7 2 gearbox – assembly overview 2551
7 3 Transmission housing cover and 5th gear – assembly overview 2552
7 4 Gearbox housing Cover and 5th gear – remove and install (gearbox installed) 2554
7 5 Clutch housing – assembly overview 2556
7 6 Input shaft, output shaft, differential, selection mechanism and selector forks 2556
7 7 Input shaft, output shaft, differential, selection mechanism and selector forks – remove and install 2558
8 Gearbox and clutch housings 2571
8 1 Transmission housing and transmission housing – assembly overview 2571
8 2 Gearbox housing – repair 2573
8 3 Clutch housing – repair 2574
9 Selector forks 2578
9 1 Selector forks – assembly overview 2578
9 2 Selector forks – repair 2578
35 – Gears, shafts 2583
1 Input shaft 2583
1 1 Input shaft – general overview of assembly 2583
1 2 Input shaft – remove and install 2585
1 3 Input shaft – replace seal 2598
2 Output shaft 2601
2 1 Output shaft – general overview of assembly 2601
2 2 Output shaft- remove and install 2603
39 – Final drive – differential 2611
1 Retainer seals 2611
1 1 Seals – assembly overview 2611
1 2 Seal (left-hand side) – replace 2611
1 2 1 Seal (left-hand side) – replace 2611
1 3 Seal (right-hand side) – replace 2614
1 3 1 Seal (right-hand side) – replace 2614
2 Differential 2617
2 1 Differential – general overview of assembly 2617
2 2 Differential – remove and install 2619
2 3 Adjust the differential 2627
D4B808A77B0 General body repairs interior 2633
00 – Technical data 2641
1 — Change history — 2641
2 Safety indications 2642
2 1 Safety measures for work in vehicles with Start-Stop system 2642
2 2 Safety measures for activities with pyrotechnical components 2643
2 3 Storage, transport and disposal of airbags, belt tensioners and battery separation units (pyrotechnical components) 2644
2 4 Additional safety instructions for the side airbag 2645
2 5 Additional safety instructions for the curtain airbag 2645
2 6 Safety instructions for collision sensors (pressure sensors) of the front side airbag 2646
2 7 Additional safety instructions for works in the seat-occupied recognition system to deactivate the front passenger’s airbag – country-specific version 2646
2 8 Replacing pyrotechnical, electrical, and mechanical components of the restraint system after accidents 2647
2 9 Airbag fastening parts after an accident – check 2649
2 10 Accident without airbag triggering 2650
2 11 Seat belts – check 2650
2 12 Seat belt webbing – check 2650
2 13 Automatic belt retractor (blocking effect) – check 2652
2 14 Visual inspection of the belt latch 2652
2 15 Check belt latch operation 2652
2 16 Belt guides and tabs – check 2653
2 17 Fastening parts and fastening points after an accident – check 2653
2 18 Child seat restraint system for additional child seats (not for the driver seat belt), country-specific version – check 2653
2 19 Child seat anchor after an accident – check 2654
2 20 Internal rearview mirror with automatic anti-glare – safety instructions 2654
3 Repair instructions 2655
3 1 Contact corrosion 2655
3 2 Cable routing and fastening 2655
68 – Interior equipment 2656
1 Storage compartment/covers 2656
1 1 Storage compartment/covers – assembly overview 2656
1 2 Dash panel cover on the driver side – Assembly overview 2657
1 3 Steering column lining – assembly overview 2658
1 4 Glove box – assembly overview 2659
1 5 Storage compartment and reading light on the passenger side and/or reading light on the driver side – assembly overview 2660
1 6 Upper steering column lining – remove and install 2661
1 7 Lower steering column lower lining – remove and install 2662
1 8 Glove box – remove and install 2664
1 9 Glove box lid – remove and install 2665
1 10 Glove compartment lid – service position 2666
1 11 Dash panel cover on the driver side – remove and install 2667
1 12 Headliner storage compartment – remove and install 2668
2 Equipment 2670
2 1 Sun visor – assembly overview 2670
2 2 Sun visor – remove and install 2671
2 3 Sun visor centre mount bearing – remove and install 2673
2 4 Roof grab handle – remove and install 2674
3 Centre console 2677
3 1 Centre console – assembly overview 2677
3 1 1 Centre console without armrest – assembly overview 2677
3 1 2 Centre console with armrest – assembly overview 2679
3 2 Rear centre console lining – remove and install 2681
3 2 1 Rear centre console lining, without front armrest – remove and install 2681
3 2 2 Rear centre console lining, with front armrest – remove and install 2682
3 2 3 Rear centre console lining with vent, with front centre armrest – remove and install 2683
3 3 Front centre console lining in the footwell area – remove and install 2683
3 4 Centre console – remove and install 2685
3 5 Centre console bracket – remove and install 2689
4 Front centre armrest 2691
4 1 Front centre armrest – assembly overview 2691
4 2 Front centre armrest – remove and install 2691
5 Interior mirror 2694
5 1 Interior mirror – assembly overview 2694
5 1 1 Internal rearview mirror with manual anti-glare, without rain sensor and sunlight penetration photosensor -G397- – assembly overview 2694
5 1 2 Internal rearview mirror with automatic anti-glare, with rain sensor and sunlight penetration photosensor -G397- – assembly overview 2694
5 2 Interior mirror – remove and install 2695
5 2 1 Internal rearview mirror with manual anti-glare, without rain sensor and sunlight penetration photosensor -G397- – remove and install 2695
5 2 2 Internal rearview mirror with automatic anti-glare, with rain sensor and sunlight penetration photosensor -G397- – remove and install 2696
69 – Passenger protection 2700
1 Seat belts 2700
1 1 Seat belt and fastening points – assembly overview and locations 2700
1 2 Front three-point seat belt – assembly overview 2702
1 3 Rear exterior three-point seat belt – assembly overview 2704
1 4 Rear centre three-point seat belt – assembly overview 2704
1 5 Front belt latch – assembly overview 2705
1 6 Rear belt latch – assembly overview 2706
1 7 Front three-point seat belt – remove and install 2707
1 8 Belt height adjuster – remove and install 2711
1 9 Front seat belt guide – remove and install 2712
1 10 Rear three-point seat belt – remove and install 2713
1 10 1 Rear exterior three-point seat belt – remove and install 2713
1 10 2 Rear centre three-point seat belt – remove and install 2714
1 11 Rear seat belt guide – remove and install 2716
1 12 Front belt fitting – remove and install 2716
1 13 Rear exterior seat belt fitting – remove and install 2717
1 14 Front belt latch – remove and install 2718
1 15 Rear seat belt latch – remove and install 2719
2 Child seat fittings 2722
2 1 Rear child seat fastening points — assembly overview 2722
2 2 Rear child seat anchors – remove and install 2722
2 2 1 Rear child seat anchor guide, rear seat – remove and install 2722
2 2 2 Child seat anchor cover in the rear backrest – remove and install 2723
3 Airbag system 2725
3 1 Airbag system – assembly overview 2725
4 Airbag control unit 2727
4 1 Airbag control unit – assembly overview 2727
4 2 Airbag control unit -J234- 2727
5 Driver-side airbag 2731
5 1 Driver-side airbag – assembly overview 2731
5 2 Airbag unit with igniter – remove and install 2733
5 3 Airbag connector – replace 2737
6 Passenger-side airbag 2740
6 1 Passenger-side airbag – assembly overview 2740
6 2 Passenger-side airbag unit with igniter – remove and install 2740
6 3 Passenger airbag deactivation key switch – remove and install 2744
7 Side airbags 2746
7 1 Front side airbag – assembly overview 2746
7 2 Front side airbag unit with igniter – remove and install 2746
8 Airbag collision sensors 2749
8 1 Airbag collision sensors – assembly overview 2749
8 2 Front airbag collision sensor -G190- – remove and install 2749
8 3 Front side airbag collision sensor -G179-/-G180- – remove and install 2753
9 Seat belt use recognition sensor 2756
9 1 Passenger seat-occupied sensor -G128- – remove and install 2756
70 – Trim, insulation 2757
1 Front door lining 2757
1 1 Front door lining – assembly overview 2757
1 2 Front door lining – remove and install 2759
1 3 Mirror cover lining – remove and install 2763
1 4 Interior door handle – remove and install 2764
2 Rear door lining 2767
2 1 Rear door lining – assembly overview 2767
2 2 Rear door lining – remove and install 2767
3 Dash panel 2772
3 1 dash panel – assembly overview 2772
3 2 Dashboard side cover – remove and install 2774
3 3 Dash panel cover – remove and install 2775
3 4 Dash panel unit gap cover – remove and install 2775
3 5 Radio/navigation system assembly frame – remove and install 2777
3 6 Dash panel – remove and install 2778
3 7 Outer dash panel vents – remove and install 2782
3 7 1 Outer dash panel vents, driver side – remove and install 2782
3 7 2 Outer dash panel vents, passenger side – remove and install 2783
3 8 Centre vent – remove and install 2784
3 9 Heating side vent – remove and install 2785
4 Dash panel cross member 2787
4 1 Dash panel cross member – assembly overview 2787
4 2 Dash panel cross member – remove and install 2787
4 3 Impact bar – remove and install 2793
5 Internal lining 2795
5 1 Internal lining (Polo) – assembly overview 2795
5 2 Internal lining (Virtus) – assembly overview 2796
5 3 Sill panel trim lining – assembly overview 2797
5 4 A-pillar lining – assembly overview 2798
5 4 1 Upper A-pillar trim – assembly overview 2798
5 4 2 A-pillar gap lining – assembly overview 2799
5 5 B-pillar lining (model 1) – assembly overview 2800
5 6 B-pillar lining (model 2) – assembly overview 2801
5 7 C-pillar lining (Polo) – assembly overview 2802
5 8 Steering housing lining – assembly overview 2803
5 9 Footwell and foot rest lining – assembly overview 2804
5 9 1 Footwell and foot rest lining – assembly overview 2804
5 10 Sill panel trim lining – remove and install 2805
5 11 A-pillar lining – remove and install 2808
5 11 1 A-pillar upper lining – remove and install 2808
5 11 2 A-pillar lower lining, driver side – remove and install 2810
5 11 3 A-pillar lower lining, passenger side – remove and install 2811
5 12 A-pillar gap lining – remove and install 2812
5 13 B-pillar lining – remove and install 2814
5 13 1 B-pillar upper lining (model 1) – remove and install 2814
5 13 2 B-pillar upper lining (model 2) – remove and install 2816
5 13 3 B-pillar lower lining – remove and install 2818
5 14 C-pillar lining (Polo) – remove and install 2820
5 15 C-pillar lining (Virtus) – remove and install 2821
5 16 Luggage compartment lining (Virtus) – remove and install 2823
5 17 Wheel housing trim – remove and install 2824
5 18 Foot rest – remove and install 2826
5 18 1 Foot rest – remove and install 2826
5 19 Floor lining – remove and install 2826
6 Luggage compartment lining 2829
6 1 Luggage compartment lining (Polo) – assembly overview 2829
6 2 Luggage compartment lining (Virtus) – assembly overview 2830
6 3 Luggage compartment lining – temporary spare wheel (Polo) – assembly overview 2831
6 4 Boot lid lower lining (Virtus) – assembly overview 2832
6 5 Boot lid lower lining (Polo) – assembly overview 2833
6 6 Boot lid lower lining (Polo) – remove and install 2834
6 7 Boot lid lower lining (Virtus) – remove and install 2835
6 8 Luggage compartment cover support (Polo) – remove and install 2836
6 9 Luggage compartment side lining – remove and install 2838
6 10 Luggage compartment side trim (Virtus) – remove and install 2840
6 11 Rear panel lining (Polo) – remove and install 2842
6 12 Rear panel lining (Virtus) – remove and install 2844
6 13 Luggage compartment floor cover (Virtus) – remove and install 2845
6 14 Luggage compartment lining support (Polo) – remove and install 2846
6 15 Luggage compartment lining support (Virtus) – remove and install 2847
7 Moulded headliner 2849
7 1 Moulded headliner – assembly overview 2849
7 2 Moulded headliner (Polo) – remove and install 2849
7 3 Moulded headliner (Virtus) – remove and install 2852
7 4 Body roof reinforcement – remove and install 2857
72 – Seat frames 2861
1 Front seat – assembly overview 2861
1 1 Seat versions – assembly overview 2861
2 Front seat 2862
2 1 Electrical and electronic components – assembly overview 2862
2 2 Front seat – assembly overview 2863
2 3 Front backrest – assembly overview 2864
2 4 Front backrest (GTS) – assembly overview 2865
2 5 Head restraint – assembly overview 2866
2 6 Seat frame – assembly overview 2867
2 7 Seat height adjustment – assembly overview 2868
2 8 Front seat – remove and install 2869
2 9 Airbag adapter – connect and disconnect 2872
2 10 Seat height adjustment lever – remove and install 2873
2 11 Seat height adjuster – remove and install 2875
2 12 Backrest adjustment lever – remove and install 2876
2 13 Front backrest – remove and install 2877
2 14 Front backrest (GTS) – remove and install 2879
2 14 1 Front seat backrest with no entry function – remove and install 2879
2 14 2 Front seat backrest with entry function – remove and install 2880
2 15 Head restraint – remove and install 2882
2 16 Head restraint guide – remove and install 2883
2 17 Seat frame – remove and install 2883
2 18 Seat lining – remove and install 2885
2 18 1 Side seat lining, tunnel side – remove and install 2885
2 18 2 Seat lining, stone guard side, with height adjustment – remove and install 2886
2 19 Install the front seat in the seat repair bracket 2887
3 Rear seats 2889
3 1 Individual seats — assembly overview 2889
3 2 Backrest locking – general assembly overview 2890
3 3 Head restraint and head restraint guide – assembly overview 2890
3 4 Rear backrest – assembly overview 2891
3 4 1 Rear backrest, split – assembly overview 2891
3 4 2 Rear backrest, not split – assembly overview 2892
3 5 Back seat seating – remove and install 2893
3 6 Head restraint – remove and install 2896
3 7 Head restraint guide – remove and install 2897
3 8 Back seat backrest – remove and install 2899
3 9 Locking mechanism lining – remove and install 2901
3 10 Rear backrest catch – remove and install 2902
3 11 Internal support pin – remove and install 2904
74 – Seat – padding, covers 2905
1 Front seat padding and lining 2905
1 1 Seat frame padding and lining – assembly overview 2905
1 2 Backrest padding and lining – assembly overview 2906
1 3 Backrest padding and lining (GTS) – assembly overview 2906
1 4 Seat frame lining and padding – remove and install 2907
1 5 Backrest lining and padding – remove and install 2909
1 6 Backrest lining and padding (GTS) – remove and install 2911
1 7 Seat frame lining and padding – separate 2915
1 8 Backrest lining and padding – separate 2918
2 Rear seat lining and padding 2921
2 1 Seat lining and padding – assembly overview 2921
2 1 1 Rear seat padding and cover – assembly overview 2921
2 1 2 Rear backrest lining and padding – assembly overview 2921
2 2 Rear seat lining and padding – remove and install 2923
2 2 1 Seat lining and padding – remove and install 2923
2 2 2 Rear backrest lining and padding – remove and install 2923
2 3 Seat lining and padding – separate 2926
2 3 1 Seat lining and padding – separate 2926
2 3 2 Rear backrest lining and padding – separate 2927
D4B808A758C Body Repairs 2929
00 – Technical data 2935
1 Basic information 2935
2 Vehicle identification data 2936
2 1 Vehicle identification number (VIN) – localization 2936
2 2 Vehicle Identification number – corrosion protection 2936
2 3 Destructive labels (Brazil only) – VIS 2937
2 4 Destructive labels (Brazil only) – VIS – replacement 2937
3 Foam part/support 2938
4 Galvanized body parts, high and very high strength and hot pre shaped body panels 2939
5 Laser welding 2941
6 Body clearance dimensions 2942
6 1 Front body section 2942
6 2 Body – centre section (Polo) 2944
6 3 Body – centre section (Virtus) 2946
6 4 Rear body section 2948
7 Body dimensions 2953
7 1 Front body section 2953
7 2 Body – centre section (Polo) 2955
7 3 Body – centre section (Virtus) 2959
7 4 Body – rear section (Polo) 2963
7 5 Body – rear section (Virtus) 2965
7 6 Body – lower front section 2967
7 7 Body – lower centre section 2968
7 8 Body – lower rear section (Polo) 2969
7 9 Body – lower rear section (Virtus) 2970
50 – Body – front 2972
1 Engine bracket (right side) – replace 2972
1 1 Tools 2972
1 2 Remove 2973
1 3 Install 2973
1 3 1 Prepare the new part 2973
1 3 2 Weld 2974
2 Auxiliary frame support thread – repair 2975
2 1 M12x1 5 Heli-coil thread repair set -VAS 6058- 2976
2 2 Thread repair 2977
2 2 1 Perforating thread 2977
2 2 2 Cutting the thread 2978
2 2 3 Install the insert 2979
3 Front bumper support – replace 2981
3 1 Tools 2981
3 2 Remove 2982
3 3 Install 2982
3 3 1 Prepare the new part 2982
3 3 2 Weld 2983
4 Bonnet hinge support – replace 2985
4 1 Tools 2985
4 2 Remove 2986
4 3 Install 2986
4 3 1 Prepare the new part 2986
4 3 2 Weld 2987
5 Studs – replace 2989
51 – Body – centre 2991
1 Roof – replace 2991
1 1 Roof (Polo) – replace 2991
1 1 1 Tools 2992
1 1 2 Remove 2992
1 1 3 Install 2995
1 1 4 Prepare the new part 2995
1 1 5 Roof depth gauge – adjust 2997
1 1 6 Roof bonding 2998
1 1 7 Weld 3003
1 2 Roof (Virtus) – replace 3004
1 2 1 Tools 3005
1 2 2 Remove 3006
1 2 3 Install 3008
1 2 4 Prepare the new part 3008
1 2 5 Roof depth gauge – adjust 3009
1 2 6 Roof bonding 3010
1 2 7 Weld 3016
2 Front roof cross member – replace 3017
2 1 Tools 3018
2 2 Remove 3018
2 3 Install 3019
2 3 1 Prepare the new part 3019
2 3 2 Weld 3020
3 Rear roof cross member – replace 3022
3 1 Tools 3023
3 2 Remove 3023
3 3 Install 3024
3 3 1 Prepare the new part 3024
3 3 2 Weld 3025
4 Side cuts that are permitted 3028
4 1 Side cuts that are permitted (Polo) 3028
4 2 Side cuts that are permitted (Virtus) 3028
5 External side panel – upper section – replace 3030
5 1 External side panel – upper section (Polo) – replace 3030
5 1 1 Tools 3031
5 1 2 Remove 3031
5 1 3 Install 3035
5 1 4 Prepare the new part 3035
5 1 5 Weld 3037
5 2 Outer side panel (upper section) (Virtus) – replace 3040
5 2 1 Tools 3042
5 2 2 Remove 3042
5 2 3 Install 3043
5 2 4 Prepare the new part 3043
5 2 5 Weld 3044
6 Pillar A – replace 3047
6 1 Tools 3049
6 2 Remove 3049
6 3 Install 3051
6 3 1 Prepare the new part 3052
6 3 2 Weld 3053
7 A-pillar reinforcement (internal) – replace 3055
7 1 Tools 3056
7 2 Remove 3056
7 3 Install 3057
7 3 1 Prepare the new part 3057
7 3 2 Weld 3059
8 B-pillar – replace 3061
8 1 Tools 3063
8 2 Foam part/support 3063
8 3 Remove 3063
8 4 Install 3065
8 4 1 Prepare the new part 3065
8 4 2 Weld 3066
9 B-pillar reinforcement – replace 3069
9 1 Tools 3070
9 2 Foam part/support 3070
9 3 Remove 3070
9 4 Install 3072
9 4 1 Prepare the new part 3072
9 4 2 Weld 3073
10 Lower longitudinal member (external section) – replace 3076
10 1 Tools 3077
10 2 Foam part/support 3078
10 3 Remove 3078
10 4 Install 3080
10 4 1 Prepare the new part 3080
10 4 2 Weld 3081
53 – Body – rear 3083
1 Back panel – replace 3083
1 1 Back panel (Polo) – replace 3083
1 1 1 Tools 3084
1 1 2 Remove 3084
1 1 3 Install 3087
1 1 4 Prepare the new part 3087
1 1 5 Weld 3088
1 2 Back panel (Virtus) – replace 3091
1 2 1 Tools 3092
1 2 2 Remove 3092
1 2 3 Install 3093
1 2 4 Prepare the new part 3093
1 2 5 Weld 3094
2 Rear cross member – replace 3097
2 1 Rear cross member (Polo) – replace 3097
2 1 1 Tools 3098
2 1 2 Remove 3098
2 1 3 Install 3099
2 1 4 Prepare the new part 3099
2 1 5 Weld 3101
2 2 Rear cross member (Virtus) – replace 3103
2 2 1 Tools 3104
2 2 2 Remove 3104
2 2 3 Install 3105
2 2 4 Prepare the new part 3105
2 2 5 Weld 3106
3 Tail light cluster housing – replace 3109
3 1 Tail light cluster housing (Polo) – replace 3109
3 1 1 Tools 3110
3 1 2 Remove 3110
3 1 3 Install 3112
3 1 4 Prepare the new part 3112
3 1 5 Weld 3113
3 2 Tail light cluster housing (Virtus) – replace 3115
3 2 1 Tools 3115
3 2 2 Remove 3116
3 2 3 Install 3117
3 2 4 Prepare the new part 3117
3 2 5 Weld 3118
4 Luggage compartment floor – replace 3120
4 1 Luggage compartment floor (Polo) – replace 3120
4 1 1 Tools 3121
4 1 2 Foam part/support 3121
4 1 3 Remove 3121
4 1 4 Install 3123
4 1 5 Prepare the new part 3123
4 1 6 Weld 3125
4 2 Luggage compartment floor (Virtus) – replace 3126
4 2 1 Tools 3127
4 2 2 Foam part/support 3127
4 2 3 Remove 3127
4 2 4 Install 3129
4 2 5 Prepare the new part 3129
4 2 6 Weld 3131
5 Rear bumper support – replace 3133
5 1 Tools 3134
5 2 Remove 3134
5 3 Install 3135
5 3 1 Prepare the new part 3135
5 3 2 Weld 3136
6 Front longitudinal member (partial part) – replace 3138
6 1 Rear longitudinal member (partial part) (Polo) – replace 3138
6 1 1 Tools 3139
6 1 2 Remove 3139
6 1 3 Install 3141
6 1 4 Prepare the new part 3141
6 1 5 Weld 3142
6 2 Rear longitudinal member (Virtus) – replace 3144
6 2 1 Tools 3145
6 2 2 Remove 3145
6 2 3 Install 3146
6 2 4 Prepare the new part 3146
6 2 5 Weld 3147
7 Rear longitudinal member (second cut partial part) – replace 3149
7 1 Tools 3150
7 2 Foam part/support 3150
7 3 Remove 3150
7 4 Install 3153
7 4 1 Prepare the new part 3153
7 4 2 Weld 3156
8 Rear side panel (partial part) – replace 3162
8 1 Rear side panel (partial part) (Polo) – replace 3162
8 1 1 Tools 3163
8 1 2 Foam part/support 3164
8 1 3 Remove 3164
8 1 4 Install 3166
8 1 5 Prepare the new part 3166
8 1 6 Weld 3167
8 2 Rear side panel (partial part) (Virtus) – replace 3171
8 2 1 Tools 3172
8 2 2 Foam part/support 3173
8 2 3 Remove 3173
8 2 4 Install 3175
8 2 5 Prepare the new part 3175
8 2 6 Weld 3176
9 Wheel housing – replace 3180
9 1 Wheel housing (Polo) – replace 3180
9 1 1 Tools 3181
9 1 2 Foam part/support 3181
9 1 3 Remove 3181
9 1 4 Install 3183
9 1 5 Prepare the new part 3183
9 1 6 Weld 3184
9 2 Wheel housing (Virtus) – replace 3188
9 2 1 Tools 3189
9 2 2 Foam part/support 3189
9 2 3 Remove 3189
9 2 4 Install 3191
9 2 5 Prepare the new part 3191
9 2 6 Weld 3192
10 Wheel housing reinforcement – replace 3196
10 1 Tools 3197
10 2 Remove 3197
10 3 Install 3199
10 3 1 Prepare the new part 3199
10 3 2 Weld 3200
D4B808A769B 3 Cyl injection engine (1 0 l) 3203
00 – Technical data 3209
1 — Change history — 3209
2 Safety instructions 3210
2 1 Safety measures regarding work on the fuel supply 3210
2 2 Safety measures in test drives using testing and measurement devices 3211
2 3 Safety measures when working on the cooling system 3212
2 4 Safety measures when working on the ignition system 3212
3 Identification 3214
3 1 Engine number/engine characteristics 3214
4 Repair instructions 3216
4 1 Cleanliness rules 3216
4 2 General instructions 3216
4 3 General repair instructions 3217
4 4 Foreign bodies on the engine 3217
4 5 Contact corrosion 3217
4 6 Connection installation and fastening 3218
4 7 Radiator and capacitor installation 3218
4 8 Check the vacuum system 3218
10 – Removing and installing engine 3219
1 Engine – remove and install 3219
1 1 Engine – removal 3219
1 2 Engine – separate gearbox 3230
1 3 Engine – secure to engine and gearbox support 3232
1 4 Engine – installation 3234
1 5 Engine – remove and install, summarized instructions 3237
2 Power-drive unit supports 3240
2 1 Power unit brackets – assembly overview 3240
2 2 Power unit bracket (engine side) – remove and install 3243
2 3 Drive-train mounting (gearbox side) – remove and install 3244
2 4 Pendulum support (torque limiter) – remove and install 3247
2 5 Support the engine in assembly position 3248
2 6 Drive train mountings – adjust 3250
2 7 Drive train mounting adjustment – check 3252
13 – Crankshaft group 3253
1 Cylinder block (pulley side) 3253
1 1 Poly-V belt mechanism – assembly overview 3253
1 2 Cylinder block (pulley side) – assembly overview 3255
1 3 Poly-V belt – remove and install 3258
1 3 1 Poly-V belt (vehicles with air conditioner compressor) – remove and install 3258
1 4 Poly-V belt tensioner – remove and install 3260
1 4 1 Poly-V belt tensioner (vehicles with air conditioner compressor) – remove and install 3260
1 5 Engine console – remove and install 3261
1 6 Crankshaft pulley (vibration damper) – remove and install 3265
1 7 Crankshaft seal (pulley side) – replace 3268
2 Cylinder block (gearbox side) 3271
2 1 Cylinder block (gearbox side) – assembly overview 3271
2 2 Flywheel – remove and install 3272
2 3 Crankshaft flange (flywheel side) – replace 3274
2 3 1 Crankshaft flange with Engine speed sensor – G28- rotor – remove 3275
2 3 2 Flange with Engine speed sensor – G28- rotor – install 3277
2 3 3 Flange with Engine speed sensor – G28- rotor in the Fitter – T10134- or Fitter – T10017K- – install 3278
2 3 4 Fitter -T10134- or Fitter – T10017K- with the crankshaft flange – install 3280
2 3 5 Fitter – T10134- or Fitter – T10017K- in the crankshaft flange – screw 3282
2 3 6 Engine speed sensor -G28- rotor with the Fitter – T10134- or Fitter – T10017K- in the crankshaft flange – install 3282
2 3 7 Installation position of the Engine speed sensor -G28- rotor on the crankshaft – check 3283
2 3 8 Engine speed sensor -G28- rotor – further compression 3284
3 Crankshaft 3286
3 1 Crankshaft – dimensions 3286
4 Pistons and conrods – remove and install 3287
4 1 Pistons and conrods – assembly overview 3287
4 2 Pistons – remove and install 3290
4 3 Pistons, rings, and cylinders – check 3291
4 3 1 Cylinders (inner diameter) – check 3293
4 3 2 Pistons and cylinders – dimensions 3294
4 4 Conrod and cap (new part) – separate 3294
4 5 Conrod radial clearance – check 3294
4 6 Oil spray jet and valve – remove and install 3295
15 – Cylinder head, valve gear 3297
1 Engine cylinder head 3297
1 1 Engine cylinder head – assembly overview 3297
1 2 Cylinder head – remove and install 3300
1 3 Cylinder head – remove and install, summarized instructions 3308
1 4 Cylinder head cover with exhaust and inlet camshafts – remove and install 3309
1 5 Cylinder compression – check 3313
2 Toothed belt drive 3316
2 1 Toothed belt – remove and install 3316
2 2 Valve timing – check 3320
2 3 Remove the camshaft toothed belt 3324
3 Camshaft mechanism 3337
3 1 Camshaft mechanism – assembly overview 3337
3 2 Crankshaft – check axial clearance 3339
3 3 Camshaft gasket (pulley side) – replace 3340
3 3 1 Inlet camshaft gasket – replace 3340
3 3 2 Exhaust camshaft seal on the toothed belt sprocket side – replace 3342
3 3 3 Exhaust camshaft seal on the gearbox side 3345
3 4 Inlet camshaft regulator – remove and install 3347
3 5 Exhaust camshaft sprocket – remove and install 3352
3 6 Camshaft adjustment valve 1 -N205- – remove and install 3356
3 7 Valve stem sealant – replace 3357
3 7 1 Valve stem sealant – replace (cylinder head installed) 3357
3 7 2 Valve stem sealant – replace (cylinder head removed) 3362
4 Inlet and exhaust valves 3368
4 1 Valve guides – check 3368
4 2 Valves – check 3369
4 3 Valve dimensions 3369
17 – Lubrication 3370
1 Crankcase/oil pump 3370
1 1 Crankcase/oil pump – assembly overview 3370
1 2 Engine oil 3375
1 3 Lower sump – remove and install 3376
1 4 Upper crankcase – remove and install 3378
1 5 Oil pump – remove and install 3382
2 Engine crankcase ventilation 3385
2 1 Engine crankcase ventilation – assembly overview 3385
2 2 Crankcase ventilation device – remove and install 3386
3 Oil filter/Oil pressure switch – F1- 3389
3 1 Oil pressure switch 0 3 0 6 bar -F1- – remove and install 3389
3 2 Oil pressure and Oil pressure switch -F1- – check 3390
3 3 Oil filter – remove and install 3393
19 – Cooling 3395
1 Cooling system/coolant 3395
1 1 Hose connection diagram for cooling system 3395
1 2 Cooling system – check air-tightness 3395
1 3 Coolant tank flap – check safety valve 3398
1 4 Cooling system – drainage and replenishment 3400
1 4 1 Drain 3402
1 4 2 Replenishing 3403
2 Water pump/coolant adjustment 3407
2 1 Water pump/thermostatic valves – assembly overview 3407
2 2 Thermostat valve – assembly overview 3410
2 3 Water pump – remove and install 3413
2 4 Thermostats – remove and install 3418
2 4 1 Thermostat valve (small circuit) – remove and install 3418
2 4 2 Thermostat valve (large circuit) – remove and install 3421
2 5 Water pump toothed belt – remove and install 3424
2 6 Water pump sprocket – remove and install 3425
2 7 Coolant temperature sensor -G62- – remove and install 3427
3 Cooling system pipes 3430
3 1 Coolant system line – assembly overview 3430
3 2 Cooling system line – remove and install 3430
4 Radiator/Radiator fan 3432
4 1 Radiator/Radiator fan – assembly overview 3432
4 2 Fan cowl and radiator fan – assembly overview 3433
4 3 Radiator – remove and install 3434
4 4 Fan housing – remove and install 3440
4 5 Radiator fan -V7- – remove and install 3442
20 – Fuel supply system 3443
1 Fuel tank 3443
1 1 Fuel tank – assembly overview 3443
1 1 1 Fuel tank – assembly overview 3443
1 2 Fuel tank – remove and install 3445
1 2 1 Fuel tank – remove and install 3445
1 3 Fuel tank – drain 3453
1 3 1 Fuel tank with intact fuel pump – drain 3453
1 3 2 Fuel tank with more than 3/4 of fuel – drain 3458
1 3 3 Fuel tank with less than 3/4 of fuel – drain 3460
2 Fuel supply unit/Fuel level sensor 3464
2 1 Fuel pump (pre-supply pump) -G6-/Fuel gauge sensor -G- – assembly overview 3464
2 2 Fuel pump (pre-supply pump) -G6-/Fuel gauge sensor -G- – remove and install 3466
2 3 Fuel gauge sensor -G- – remove and install 3471
2 4 Installation opening cover – remove and install 3472
3 Plug-in connectors 3474
3 1 Plug-in connectors – disconnect 3474
4 Fuel filter 3480
4 1 Fuel filter – remove and install 3480
5 Activated charcoal system 3482
5 1 Wiring diagram – Activated carbon filter system 3482
5 1 1 Wiring diagram – Activated charcoal tank system in the engine compartment, vehicles from the year of manufacture 2022 3482
5 1 2 Rear activated charcoal tank system wiring diagram 3482
5 2 Activated charcoal tank system – assembly overview 3483
5 3 Activated charcoal tank – remove and install 3485
5 4 Fuel tank ventilation – check 3486
6 Accelerator activation 3495
6 1 Accelerator pedal module – assembly overview 3495
6 2 Accelerator pedal module -GX2- – remove and install 3495
7 Fuel system pressurisation pump -G6- 3497
7 1 Fuel system pressurisation pump -G6- – check 3497
7 1 1 Fuel pump operation and power supply – check 3497
7 1 2 Fuel pressure – check 3500
7 1 3 Holding pressure – check 3504
7 1 4 Fuel supply system output – check 3510
8 Fuel lines 3520
8 1 Fuel lines – remove and install 3520
24 – Mixture preparation – injection 3525
1 Injection system 3525
1 1 Injection system – assembly overview 3525
1 2 Combustion system – assembly overview 3528
2 Injection valves 3531
2 1 Fuel rail with injection valves – assembly overview 3531
2 2 Injection valves – remove and install 3533
2 3 Injection valves – check 3535
3 Air cleaner 3542
3 1 Air filter – assembly overview 3542
3 2 Air filter – remove and install 3543
4 Intake manifold 3545
4 1 Intake manifold – assembly overview 3545
4 2 Intake manifold – remove and install 3547
4 3 Throttle butterfly valve control unit -J338- – remove and install 3550
4 4 Throttle valve control unit -J338- – clean 3552
5 Transmitters and sensors 3554
5 1 Intake manifold pressure sensor – G71- with Air intake temperature sensor – G42- – remove and install 3554
6 Engine control unit -J623- 3556
6 1 Engine control unit -J623- – assembly overview 3556
6 2 Engine control unit -J623- – remove and install 3556
6 2 1 Engine control unit -J623-, ◄ MY 2022 – remove and install 3556
6 2 2 Engine control unit -J623- , MY 2023 ►- remove and install 3558
7 Lambda probe 3562
7 1 Lambda probe – assembly overview 3562
7 2 Lambda Probe -G39- – remove and install 3563
7 3 Lambda Probe after the catalytic converter -G130- – remove and install 3564
26 – Exhaust system 3567
1 Silencer/exhaust pipes 3567
1 1 Silencer – assembly overview 3567
1 2 Silencer/exhaust pipes – detach 3568
1 3 Centre silencer with rear silencer – remove and install 3570
1 4 Centre silencer – remove and install 3574
1 5 Rear silencer – remove and install 3576
1 6 Exhaust system – tension free alignment 3577
1 7 Exhaust system – check tightness 3578
1 8 Pipe clamp installation position 3579
2 Exhaust system 3581
2 1 Emission control – assembly overview 3581
2 2 Catalytic converter – remove and install 3584
28 – Ignition system 3588
1 Ignition system 3588
1 1 Ignition system – assembly overview 3588
1 2 Ignition coils with final power stage – assembly overview 3590
1 3 Spark plugs -Q- – technical data 3591
1 4 Ignition coil with final power stage – remove and install 3591
1 5 Knock sensor 1 -G61- – remove and install 3595
1 6 Hall Sensor -G40- – remove and install 3596
1 7 Engine speed sensor -G28- – remove and install 3597
1 8 Heater control unit -J65- – remove and install 3599
D4B808A771F Heating air conditioning 3601
00 – Technical data 3605
1 Safety indications 3605
1 1 Safety measures for working with air conditioning system 3605
1 2 Safety provisions for work to be carried out on vehicles with the Start-Stop system 3605
1 3 Safety precautions during a test drive with measuring and testing equipment 3606
1 4 Safety measures when working on refrigeration system 3606
1 5 Safety measures for handling coolants 3606
1 6 Safety measures when working on SCR system 3607
2 General guidelines 3609
2 1 Model plates 3609
2 1 1 Model plates; Coolant R134a 3609
3 Repair instructions 3611
3 1 General repair instructions 3611
3 2 Installation of radiators and condensers 3611
3 3 Work on the coolant circuit 3611
3 4 Gaskets for the coolant circuit 3612
4 Technical data 3613
4 1 Coolant filling quantities 3613
4 1 1 Filling capacity – R134a coolant 3613
4 2 Oil filling quantities for refrigerating machines 3613
4 2 1 Oil filling quantities for refrigerating machines for R134a coolant 3613
4 3 Oil distribution 3613
80 – Heating 3615
1 — Change history — 3615
2 Heating 3616
3 Command unit and display 3617
3 1 Air conditioning command unit and display, manual electrical adjustment – assembly overview 3617
3 2 Air conditioning control unit and display, manual electrical adjustment – remove and install 3618
87 – Air conditioning system 3619
1 — Change history — 3619
2 Air-conditioning system – assembly location overview 3620
2 1 External passenger compartment components – assembly location overview 3620
2 1 1 External passenger compartment components (Polo) – assembly location overview 3620
2 1 2 External passenger compartment components (Virtus) – assembly location overview 3621
2 2 Front passenger compartment components – assembly location overview 3622
3 Coolant gas loop 3624
3 1 Refrigerant circuit – assembly overview 3624
3 2 Condenser – assembly overview 3625
3 3 Pressure sensor for coolant circulation -G805- – remove and install 3627
3 4 Expansion valve – remove and install 3628
3 5 Condenser – remove and install 3630
3 6 Dryer filter – remove and install 3633
3 6 1 Dryer filter (Denso) – remove and install 3633
3 6 2 Dryer filter (Mahle) – remove and install 3636
3 7 Evacuating and charging valve, low and high pressure side – remove and install 3640
3 8 Air conditioning system hoses – remove and install 3642
3 8 1 Condenser compressor hose – remove and install 3642
3 8 2 Air conditioning system high pressure hose – remove and install 3643
3 8 3 Air conditioning system low pressure hose – remove and install 3646
4 Air conditioner compressor 3648
4 1 Air conditioner compressor – assembly overview 3648
4 2 Capacitor pulley – assembly overview 3648
4 2 1 Capacitor pulley (Delphi) – assembly overview 3648
4 3 Air conditioning compressor – remove and install 3650
5 Control motors 3654
5 1 Front control motors – overview of fitting locations 3654
5 1 1 Front control motors, electromanual air conditioning system – overview of fitting locations 3654
5 1 2 Front control motors, Climatronic – overview of fitting locations 3655
5 2 Valve control motor for defrosting -V107- – remove and install 3656
5 3 Control motor on the air distributor cover, front -V426- – remove and install 3658
5 4 Control motor for fresh air valve and recirculation valve -V154- – remove and install 3659
5 5 Temperature adjustment valve control motor, left -V158– Remove and install 3661
5 6 Temperature adjustment valve control motor, right -V159– Remove and install 3662
5 7 Control motor for pressure non-return valve for natural air and air circulation -V425- – remove and install 3664
5 8 Control motor on the air distributor cover – remove and install 3665
5 9 Control motor on the air distributor cover – remove and install 3666
6 Plenum chamber (air conditioning) 3668
6 1 Plenum chamber (air conditioning) components – assembly overview 3668
6 2 Evaporator housing – assembly overview 3670
6 3 Evaporator – remove and install 3670
6 4 Plenum chamber (air conditioning) – remove and install 3671
6 5 Evaporator housing – disassemble and assemble 3676
6 6 Dust and pollen filter – remove and install 3676
6 7 Fresh air fan -V2- – remove and install 3678
6 8 Natural air fan control unit -J126- – remove and install 3679
6 9 Heat exchanger – remove and install 3680
6 9 1 Heat exchanger (Valeo) – remove and install 3680
6 9 2 Heat exchanger (Mahle) – remove and install 3682
6 10 Coolant pipes in the heat exchanger – remove and install 3686
6 10 1 Refrigerant line in the heat exchanger (Valeo) – remove and install 3686
6 10 2 Refrigerant line in the heat exchanger (Mahle) – remove and install 3686
6 11 Evaporator temperature sensor -G308- – remove and install 3688
6 11 1 Evaporator temperature sensor -G308-, Mahle – remove and install 3688
6 11 2 Evaporator temperature sensor -G308-, Valeo – remove and install 3688
6 12 Plenum chamber drain – remove and install 3689
6 13 Air box bleeder connection – check 3692
6 14 Fresh air blower pre-resistance with overheating cut-out -N24- – remove and install 3692
7 Air duct system 3694
7 1 Air distribution and duct in the passenger compartment – assembly overview 3694
7 2 Footwell flap (front right) – remove and install 3696
7 3 Footwell flap (front left) – remove and install 3697
7 4 Rear centre console vent air duct – remove and install 3698
7 5 Exhaust valve – remove and install 3698
7 5 1 Exhaust valve (Polo) – remove and install 3698
7 5 2 Exhaust valve (Virtus) – remove and install 3699
7 6 Exhaust valve – check 3700
7 7 Fresh air intake nozzle grille – remove and install 3701
7 8 Fresh air intake nozzle – remove and install 3702
7 9 Fresh air intake duct – remove and install 3702
7 10 Defogger air duct – remove and install 3703
7 11 Central vent air duct – remove and install 3703
8 Air conditioning display and control unit 3704
8 1 Air conditioning display and control unit – assembly overview 3704
8 1 1 Air conditioning command unit and display, manual electrical adjustment – assembly overview 3704
8 1 2 Air conditioning display and control unit, Climatronic – assembly overview 3705
8 2 Air conditioning display and control unit – remove and install 3707
8 2 1 Air conditioning control unit and display, manual electrical adjustment – remove and install 3707
8 2 2 Air conditioning display and control unit, Climatronic – remove and install 3708
9 Other command and adjustment components 3709
9 1 Sun irradiation photosensor -G107- – remove and install 3709
9 2 External temperature sensor -G17- – remove and install 3710
9 3 Air conditioning humidity sensor -G260- – remove and install 3710
9 4 Air outlet temperature sensor for the left vent -G150– Remove and install 3711
9 5 Air outlet temperature sensor for the right vent -G151– Remove and install 3711
9 6 Feet area air outlet temperature sensor -G192- – remove and install 3712
10 R134a refrigerant filling capacity 3714
D4B808A773C Communication 3715
00 – Technical data 3719
1 — Change history — 3719
2 Repair instructions 3720
2 1 General repair instructions 3720
2 2 Installation and securing of pipelines and cables 3720
2 3 Notes on CAN-Bus cable repair work 3720
91 – Communication 3721
1 Infotainment 3721
1 1 Infotainment – architecture 3721
1 1 1 Infotainment system, Media Plus (R240G) – architecture 3721
1 1 2 Infotainment system, Media Plus (R340G) – architecture 3721
1 1 3 Infotainment system, Composition Touch 2 – structure 3722
1 1 4 Infotainment system, Discover Media – architecture 3723
1 1 5 Infotainment, Mib Regio – architecture 3724
1 2 Infotainment system – overview of fitting locations 3724
1 3 Infotainment system display – remove and install 3725
1 4 Control unit 1 for information electronics -J794- – remove and install 3727
1 5 Infotainment system, Mib Regio – remove and install 3728
2 Radio system 3730
2 1 Sound system – assembly overview 3730
2 2 Amplifier -R12- – remove and install 3731
2 3 Amplifier -R12- support bracket – remove and install 3732
2 4 Front treble loudspeaker -R20 / R22- – remove and install 3733
2 5 Rear loudspeaker -R4 / R5– remove and install 3733
2 6 Front bass loudspeaker -R2 / R3- – remove and install 3735
2 7 Subwoofer -R211- – remove and install 3736
2 8 Subwoofer -R211- support bracket – remove and install 3737
3 Aerial systems 3741
3 1 Aerial systems – architecture 3741
3 2 Aerial systems – overview of fitting locations 3741
3 3 Rear window aerial 1 -R130- – remove and install 3742
3 4 Roof aerial -RX5- – remove and install 3743
4 Radio 3745
4 1 Radio – architecture 3745
4 1 1 Media Plus (R240G) radio – installation 3745
4 1 2 Composition Touch (R340G) radio – installation 3745
4 1 3 Radio, Composition Touch 2 – assembly 3745
4 1 4 Discover Media radio – installation 3745
4 1 5 Radio, Mib Regio – assembly 3746
4 2 Radio – remove and install 3746
4 2 1 Media Plus and Composition Touch radio – remove and install 3746
4 2 2 Discover Media radio – remove and install 3747
4 2 3 Radio , Mib Regio- remove and install 3747
5 Phone system 3748
5 1 Provision for mobile telephone 3748
5 1 1 Provision for Mobile telephone -R54-, Bluetooth hands-free system 3748
5 2 Telephone system – overview of fitting locations 3748
5 3 Telephone microphone -R38- – remove e install 3749
5 3 1 Telephone microphone -R38- vehicles without interior rear lights -WX2- – remove and install 3749
5 3 2 Telephone microphone -R38- vehicles withinterior rear lights -WX2- – remove and install 3750
5 4 Connecting base for USB charging socket 1 -U37- – remove and install 3751
6 Navigation system 3753
6 1 Navigation system – architecture 3753
6 2 Navigation system – fitting location overview 3753
6 3 Navigation system control unit – remove and install 3754
7 Rear view camera system 3755
7 1 Rear view camera – architecture 3755
7 2 Rear view camera system – assembly overview 3755
7 2 1 Rear view camera system (Polo) – assembly overview 3755
7 2 2 Rear view camera system (Virtus) – assembly overview 3756
7 3 Reversing camera -R189- – remove and install 3757
7 3 1 Reversing camera -R189- (Polo) – remove and install 3757
7 3 2 Reversing camera -R189- (Virtus) – remove and install 3758
8 Multifunction steering wheel 3760
8 1 Multifunction steering wheel – architecture 3760
8 2 Multifunction steering wheel – general assembly overview 3760
8 2 1 Multifunction steering wheel, ◄ 2022 – assembly overview 3760
8 2 2 Multifunction steering wheel, ► 2023 – assembly overview 3761
8 3 Multifunction steering wheel buttons -J453 / E441- – remove and install 3762
8 3 1 Multifunction steering wheel buttons -J453 / E441-, ◄ 2022- remove and install 3762
8 3 2 Multifunction steering wheel buttons -J453 / E441-, ►2023- remove and install 3766
8 4 Tiptronic switch on the steering wheel-E479/ E480- – remove and install 3769
9 Port for external multimedia devices 3771
9 1 USB 1 port -U41- USB port in the front centre console – remove and install 3771
9 2 USB 2 port -U42- in the front center console storage compartment – remove and install 3772
9 3 USB 2 charging port -U38- in the rear centre console – remove and install 3773
9 3 1 USB 2 charging port -U38- in the rear centre console ◄ 2022- remove and install 3773
9 3 2 USB 2 charging port -U38- in the rear centre console ► 2023- remove and install 3774
D4B808A777A Electrical system 3776
00 – Technical data 3784
1 — Change history — 3784
2 Safety instructions 3785
2 1 Safety and application warnings for LED headlights 3785
2 2 Safety measures for work on vehicles with Start-Stop system 3785
2 3 Safety precautions during a test drive with measuring and testing equipment 3785
3 Repair instructions 3786
3 1 Cleanliness rules 3786
3 2 General Notes 3786
3 3 Contact corrosion 3786
3 4 Installation and securing of pipelines and cables 3786
4 Battery 3788
4 1 Battery – general guidelines 3788
4 2 Battery Types 3788
27 – Starter, current supply, CCS 3789
1 Battery 3789
1 1 Battery A – assembly overview 3789
1 2 Battery A – remove and install 3790
1 3 Battery A – disconnect and connect 3793
1 3 1 Battery A – disconnect and connect, vehicles with Start-Stop Start-Stop system 3793
1 3 2 Battery A – disconnect and connect, vehicles without Start-Stop system 3795
1 4 Battery Console A – remove and install 3796
1 5 Battery – check 3797
1 6 Battery – charging 3798
1 7 Earth cable with Battery control unit -J367- – remove and install 3798
1 8 Adapt the Battery control unit -J367- 3799
2 Alternator 3800
2 1 Generator (Alternator c) – assembly overview 3800
2 2 Generator (Alternator c) – remove and install 3801
2 2 1 Generator (Alternator c) 1 4 TSI engine – remove and install 3801
2 2 2 Generator (Alternator c) 1 0 TSI engine – remove and install 3803
2 2 3 Generator (Alternator c) 1 0 MPI and 1 6 MSI engine – remove and install 3805
2 3 Alternator – check 3807
2 4 Poly-V belt pulley – remove and install 3807
2 4 1 Poly-V belt pulley with no free spin – remove and install 3807
2 4 2 Poly-V belt pulley with free spin (Bosch) – remove and install 3809
2 4 3 Poly-V belt pulley with free spin (Valeo) – remove and install 3811
2 4 4 Decoupling pulley with free spin – remove and install 3813
2 5 Voltage regulator – remove and install 3817
2 5 1 Voltage regulator -C1- (Bosch) – remove and install 3817
2 5 2 Voltage regulator -C1- (Valeo) – remove and install 3818
3 Starter 3820
3 1 Starter – assembly overview 3820
3 1 1 Starter (vehicles with manual gearbox) – assembly overview 3820
3 1 2 Starter (vehicles with automatic gearbox) – assembly overview 3820
3 2 Starter – remove and install 3821
3 2 1 Starter (vehicles with manual gearbox) – remove and install 3821
3 2 2 Starter (vehicles with automatic gearbox) – remove and install 3823
3 3 Starter – check 3825
4 Start-Stop system 3826
4 1 Start-Stop system, general description 3826
90 – Gauges, instruments 3827
1 Instrument cluster 3827
1 1 Instrument cluster KX2 – assembly overview 3827
1 2 Instrument cluster -KX2- – remove and install 3827
1 2 1 Analog Instrument cluster -KX2- – remove and install 3827
1 2 2 Digital cockpit -KX2- – remove and install 3829
2 Horn 3832
2 1 Horn – assembly overview 3832
2 2 Treble tone horn -H2- and Bass tone horn -H7- – remove and install 3832
92 – Windscreen wash/wipe system 3834
1 Wiper system 3834
1 1 Wiper system – assembly overview 3834
1 2 Place the wiper system in service position 3836
1 3 Window wiper blade – remove and install 3836
1 4 Wiper arm – remove and install 3837
1 5 Wiper arms – adjust resting position 3839
1 6 Wiper motor -V- – remove and install 3841
1 7 Rain and light sensor -G397- – remove and install 3843
1 8 Rain and light sensor -G397- – repair 3846
2 Windscreen washer system 3849
2 1 Windscreen washer system – assembly overview 3849
2 2 Washer water reservoir filler neck – remove and install 3850
2 3 Washer water reservoir – remove and install 3850
2 4 Windscreen and rear window washer pump -V59– remove and install 3852
2 5 Spray jets – remove and install 3853
2 5 1 Spray jets ◄ 2022 – remove and install 3853
2 5 2 Spray jets ► 2023 – remove and install 3854
2 6 Spray nozzles – adjust 3855
3 Rear window wiper system 3856
3 1 Rear window wiper system – assembly overview 3856
3 2 Rear wiper blade – remove and install 3857
3 3 Rear window wiper arm – remove and install 3857
3 4 Rear window wiper arm – adjust 3858
3 5 Rear window wiper motor -V12– remove and install 3859
4 Rear window washer system 3861
4 1 Rear window washer system – assembly overview 3861
4 2 Washer jet – remove and install 3861
4 3 Washer jet – adjust 3862
5 Washer water lines 3863
5 1 Repair the washer water lines 3863
94 – Lights, bulbs, switches – exterior 3864
1 Headlights 3864
1 1 Headlights – assembly overview 3864
1 1 1 Twin halogen headlights ◄ 2022 – assembly overview 3864
1 1 2 LED Headlights GTS version ◄ 2022 – assembly overview 3866
1 1 3 LED Headlights , Polo ► 2023 – assembly overview 3868
1 1 4 Headlight housing repair kit, Polo ► 2023 – assembly overview 3869
1 1 5 LED Headlights , Virtus ► 2023 – assembly overview 3870
1 1 6 Daytime running lights – assembly overview 3871
1 2 Headlight – remove and install 3872
1 2 1 Headlight ◄ 2022 – remove and install 3872
1 2 2 Headlight, Polo ►2023 – remove and install 3875
1 2 3 Headlight, Virtus ►2023 – remove and install 3876
1 3 Headlights – adjust 3880
1 4 Headlights – correct the alignment position 3880
1 4 1 Headlights ◄ 2022- correct the alignment position 3880
1 4 2 Headlights, Polo ► 2023 – correct the alignment position 3881
1 4 3 Headlights, Virtus ► 2023 – correct the alignment position 3882
1 5 Side light bulb -M1-/-M3- – remove and install 3884
1 6 Front turn signal bulb -M5-/-M7- – remove and install 3886
1 7 Headlight housing repair set – install 3887
1 7 1 Headlight housing repair set ◄ 2022 – install 3887
1 7 2 Headlight housing repair set , Polo ► 2023 – install 3888
1 8 Headlight beam range control motor -V48-/-V49- – remove and install 3889
1 8 1 Headlight beam range control motor -V48-/-V49- ◄ 2022- remove and install, LED Headlights 3889
1 8 2 Headlight beam range control motor -V48-/-V49- , Polo ► 2023- remove and install, LED Headlights 3891
1 9 Dipped beam headlight bulb -M29-/-M31- – remove and install 3892
1 10 Main beam headlight bulb -M30-/-M32– remove and install 3894
1 11 Daytime running light – remove and Install 3895
1 12 Static cornering light bulb -L148-/-L149- – remove and install 3896
1 13 LED Headlight output module 1 -A27- / -A31- – remove and install 3896
1 14 Daytime running light LED module -L176-/-L177- – remove and install 3897
1 14 1 Daytime running light LED module -L176-/-L177-, Virtus ► 2023 – remove and install 3897
2 Fog lights 3900
2 1 Fog lights – assembly overview 3900
2 1 1 Fog lights ◄ 2022 – assembly overview 3900
2 1 2 Fog lights, Virtus ► 2023 – assembly overview 3900
2 2 Fog lights – remove and install 3901
2 2 1 Fog lights ◄ 2022- remove and install 3901
2 2 2 Fog lights, Virtus ►2023 – remove and install 3901
2 3 Fog light bulb -L22-/-L23- – remove and install 3903
2 4 Fog lights – adjust 3903
3 Turn signal in the exterior mirror housing 3904
3 1 Turn signal in the exterior mirror housing – general assembly overview 3904
3 2 Turn signal in the exterior mirror – remove and install 3906
4 Tail lights 3907
4 1 Tail lights – assembly overview 3907
4 1 1 Tail light cluster (Polo) – assembly overview 3907
4 1 2 Tail light cluster Virtus ◄ 2022 – assembly overview 3909
4 2 Tail light lamp support – remove and install 3909
4 2 1 Tail light bulb support (Polo) – remove and install 3909
4 2 2 Tail light bulb support (Virtus) – remove and install 3910
4 3 Tail light – remove and install 3911
4 3 1 Tail light, Polo ◄ 2022 – remove and install 3911
4 3 2 Tail light, Polo ► 2023 – remove and install 3912
4 3 3 Tail light cluster (Virtus) – remove and install 3913
4 4 Centre tail light “rear lid” (Virtus) – remove and install 3914
4 5 Tail light cluster – installation position – correct 3915
4 6 Tail light bulb -M2-/-M4- – remove and install 3916
4 6 1 Tail light bulb -M2 / M4-(Polo) without LED tail light clusters – remove and install 3916
4 6 2 Tail light bulb -M2 / M4-(Polo GTS), with LED tail light clusters – remove and install 3917
4 6 3 Tail light bulb -M2-/-M4- (Virtus) – remove and install 3917
4 7 Rear brake light bulb – remove and install 3918
4 7 1 Brake light bulb and tail light bulb -M9/M10-(Polo) without LED tail light clusters – remove and install 3918
4 7 2 Brake light bulb and tail light bulb -M21/M22-(Polo GTS), with LED tail light clusters – remove and install 3919
4 7 3 Rear brake light bulb -M9-/-M10- (Virtus) – remove and install 3919
4 8 Reverse gear light bulb -M16-/-M17- – remove and install 3920
4 8 1 Reverse gear light bulb -M16-/-M17- (Polo) – remove and install 3920
4 8 2 Reverse gear light bulb -M16-/-M17- (Virtus) – remove and install 3921
4 9 Rear turn signal bulb -M6-/-M8- – remove and install 3922
4 9 1 Rear turn signal bulb -M6-/-M8- (Polo) – remove and install 3922
4 9 2 Rear turn signal bulb -M6-/-M8- (Virtus) – remove and install 3923
5 Auxiliary brake light 3925
5 1 Auxiliary brake light – assembly overview 3925
5 1 1 Additional brake light (Polo) – assembly overview 3925
5 1 2 Additional brake light (Virtus) – assembly overview 3925
5 2 Auxiliary brake light – remove and install 3926
5 2 1 Additional brake light (Polo) – remove and install 3926
5 2 2 Auxiliary brake light (Virtus) – remove and install 3928
6 License plate light 3930
6 1 Number plate light – remove and install 3930
6 2 Number plate light -X4-/-X5- – remove and install 3931
7 Access and departure authorization 3932
7 1 Access and departure authorization system – overview of fitting locations 3932
7 2 Keyless access authorization system (Kessy) – overview of fitting locations 3933
7 3 Interface for entry and start system -J965- – remove and install 3934
7 4 Front door handle contact sensor -G605 / G606- – remove and install 3936
7 5 Interior aerial 1 for entry and start system -R138- – remove and install 3936
7 6 Interior aerial 2 for entry and start system -R139- – remove and install 3937
7 7 Aerial for authorization for access and starting switch, left hand side -R200– remove and install 3938
7 8 Aerial for authorization for access and starting switch, right hand side -R201– remove and install 3938
7 9 Rear bumper aerial for entry and start system -R136- – remove and install 3938
8 Steering column switch module 3940
8 1 Steering column switch module – assembly overview 3940
8 1 1 Steering column switch module, mechanical ignition lock – assembly overview 3940
8 1 2 Steering column switch module, electronic ignition lock (Kessy) – assembly overview 3941
8 2 Lock cylinder – remove and install 3942
8 3 Ignition key withdrawal lock solenoid -N376- – remove and install 3945
8 4 Ignition/starter switch – remove and install 3945
8 5 Steering column switch module (Kostal) – remove and install 3947
8 6 Steering column electronics control unit -J527- – remove and install 3949
8 7 Turn signal switch -E2- (Kostal) – remove and install 3951
8 8 Cruise control system switch -E45- – remove and install 3953
8 9 Window wiper timer switch -E22- – remove and install 3953
8 10 Steering lock set – remove and install 3953
9 Auxiliary parking system 3957
9 1 Auxiliary parking system – assembly general view 3957
9 1 1 Rear auxiliary parking system, Polo ◄ 2022 – assembly overview 3957
9 1 2 Rear auxiliary parking system, Virtus ◄ 2022 – assembly overview 3958
9 1 3 Auxiliary parking system, Polo ► 2023 – assembly overview 3959
9 2 Parking aid control unit -J446- – remove and install 3960
9 3 Warning buzzer for front parking aid -H22– remove and install 3961
9 4 Warning buzzer for rear parking aid -H15– remove and install 3962
9 5 Front parking aid sensor – remove and install 3962
9 6 Rear parking aid sensor – remove and install 3963
10 Automatic headlight range control 3965
10 1 Automatic headlight range control – assembly overview 3965
10 2 Main beam headlight range control unit – remove and install 3965
96 – Lights, bulbs, switches – interior 3967
1 Lights 3967
1 1 Centre console lights – assembly overview 3967
1 2 Luggage compartment lights – overview of fitting locations 3968
1 2 1 Luggage compartment lights (Polo) – overview of fitting locations 3968
1 2 2 Luggage compartment lights (Virtus) – overview of fitting locations 3969
1 3 Headliner lights – overview of fitting locations 3970
1 3 1 Headliner lights – vehicles without Rear interior lights -WX2- – assembly overview 3970
1 3 2 Headliner lights – vehicles with Rear interior lights -WX2- – assembly overview 3971
1 4 “SAFE” central locking system indicator lamp -K133- – remove and install 3972
1 5 Selector lever position display -Y26- – remove and install 3973
1 6 Boot light -W3- – remove and install 3973
1 7 Bulb of the Luggage compartment light -W3- – remove and install 3974
1 8 Passenger illuminated vanity mirror -W49-/-W50- – remove and install 3975
1 9 Front interior light -WX1– replace bulb 3976
1 9 1 Front interior light -WX1-, vehicles without Rear interior light -WX2- – renew the bulb 3976
1 9 2 Front interior light -WX1-/-W65-/-W66-, vehicles with Rear interior light -WX2- – renew the bulb 3977
1 10 Internal rear light -WX2– replace bulb 3979
1 11 Rear reading light bulb -W11-/-W12- – remove and install 3980
2 Control elements 3981
2 1 Dash panel control elements – assembly overview 3981
2 2 Front door control elements – assembly overview 3982
2 3 Rear door control elements – assembly overview 3983
2 4 Centre console switch module – assembly overview 3984
2 5 Boot lid contact switch – assembly overview 3985
2 6 Control elements in the headliner – assembly overview 3986
2 7 Light switch -EX1- – remove and install 3987
2 8 Headlight beam range adjustment control -E102- – remove and install 3988
2 9 ASR and Electronic Stabilisation Programme (ESP) switch -E256- – remove and install 3989
2 10 Parking aid button -E266- – remove and install 3989
2 11 Driving profile selection button -E735- – remove and install 3990
2 12 Rear cap unlocking switch -E165– remove and install 3990
2 13 Passenger airbag off control light -K145- – remove and install 3990
2 14 Centre console switch module – remove and install 3991
2 15 Warning light switch -EX3- – removal and install 3992
2 16 Exterior mirror adjustment -EX11- – remove and install 3992
2 17 Driver door window control unit -EX36- – remove and install 3993
2 18 Front window control switch, passenger side -EX27- – remove and install 3994
2 19 Driver side interior locking button for central locking system -E308- – remove and install 3994
2 20 Door contact switch -F2/F3- – remove and install 3995
2 21 Rear door power window control switch -EX28-/-EX29- – remove and install 3995
2 22 Rear door contact switch -F10 / F11– remove and install 3996
2 23 Starter button -E378- – remove and install 3996
2 24 Boot lid contact switch – remove and install 3997
2 25 Vanity mirror contact switch -F298-/-F299- – remove and Install 3997
2 26 Front interior light -WX1– remove and install 3997
2 26 1 Front interior light -WX1-, vehicles without Rear interior light -WX2- – remove and install 3997
2 26 2 Front interior light -WX1-, vehicles with Rear interior light -WX2- – remove and install 3999
2 27 Internal rear light -WX2– remove and install 4000
3 Anti-theft alarm system 4003
3 1 Interior monitoring – assembly overview 4003
3 2 Alarm system horn -H8- – remove and install 4003
3 3 Anti-theft alarm sensor -G578- – remove and install 4004
4 Immobilizer 4006
4 1 Immobilizer control unit – remove and install 4006
4 2 Immobilizer reading coil – remove and install 4006
4 2 1 Immobilizer reading coil, mechanical ignition lock – remove and install 4006
4 2 2 Immobilizer reading coil, electronic ignition lock (Kessy) – remove and install 4006
5 Lighter, socket 4008
5 1 Lighter -U1- – remove and install 4008
5 2 Electric socket -U- – remove and install 4008
5 3 Rear cigarette lighter illumination bulb -L32– remove and install 4008
97 – Wiring 4009
1 Relay carrier, fuse holder, electronic boxes 4009
1 1 Relay carrier, fuse carrier, E-box – overview of fitting locations 4009
1 1 1 Relay carrier, fuse holder in the engine compartment – assembly overview 4009
1 1 2 Relay carrier, fuse carrier in the dash panel / column A – Assembly overview 4010
1 2 Fuse holder A -SA- – assembly overview 4011
1 3 E-Box – remove and install 4012
1 4 Relay carrier and fuse holder of E-box – remove and install 4014
1 5 Relay carrier and fuse carrier behind the driver side dash panel – remove and install 4016
1 6 Fuse carrier A -SA- – remove and install 4019
2 Control units 4022
2 1 Control units – assembly overview 4022
2 2 Control unit for the on-board electrical system -J519- – remove and install 4023
2 3 Data bus diagnostics interface -J533- – remove and install 4024
2 4 Support of the On-board supply control unit -J519- – remove and install 4025
2 5 Support of the Parking aid control unit -J446- – remove and install 4025
3 Connector connections 4027
3 1 Wiring harnesses and connections – repair 4027
3 1 1 Wiring harnesses and electrical connections – repair 4027
3 1 2 Connection sockets and electrical connectors – repair 4027
4 Connector housings – unlock and disassemble 4028
5 Aerial cables – repair 4029
6 Fibre optic cables 4030
7 Vehicle diagnostic, testing and information system 4031
D4B808A7709 Running gear axles steering 4032
00 – Technical data 4038
1 — Change history — 4038
2 Safety indications 4039
2 1 Safety measures when working on vehicles with Start-Stop system 4039
2 2 Safety measures for work in the auxiliary frame 4039
3 Repair instructions 4040
3 1 Shock absorbers – leaks 4040
3 2 Shock absorbers – noises 4040
3 3 Shock absorbers – test 4041
3 4 Steering box 4041
3 5 Seals, seal rings 4042
3 6 Screws, nuts 4042
3 7 Electric components 4042
3 8 Raise the axle of the unloaded vehicle with coil spring 4043
3 8 1 Raise the front axle (wheel bearing housing) of the unloaded vehicle with coil spring 4043
3 8 2 Raise the rear axle (wheel bearing housing) of the unloaded vehicle with coil spring 4045
4 Assessment of crashed vehicles 4049
4 1 Crashed vehicles – running gear assessment checklist 4049
5 Disposal of gas struts 4051
5 1 Disposal of front gas struts 4051
5 1 1 Disposal of front gas struts (conventional shock absorbers) 4051
5 1 2 Disposal of front gas struts (DCC shock absorbers) 4052
5 2 Disposal of rear gas struts 4052
5 2 1 Disposal of rear gas struts (conventional shock absorbers) 4052
5 2 2 Disposal of rear gas struts (DCC shock absorbers) 4053
40 – Front suspension 4055
1 Front axle 4055
1 1 Front axle – general assembly overview 4055
2 Auxiliary frame 4058
2 1 Auxiliary frame – general assembly overview 4058
2 2 Auxiliary frame without steering rack – remove and install 4058
2 3 Auxiliary frame with steering rack – remove and install 4061
2 4 Auxiliary frame – position 4066
2 5 Auxiliary frame – Lower 4070
3 Anti-roll bar 4075
3 1 Anti-roll bar – general assembly overview 4075
3 2 Anti-roll bar – remove and install 4076
3 3 Coupling rod – remove and install 4079
4 Suspension strut, upper wishbone 4081
4 1 Suspension strut, upper wishbone – Assembly overview 4081
4 2 Suspension strut – remove and install 4082
4 3 Suspension strut – repair 4092
5 Lower wishbone, swivel joint 4096
5 1 Lower wishbone, swivel joint – Assembly overview 4096
5 2 Lower wishbone – remove and install 4097
5 3 Check the drive shaft 4100
5 4 Swivel guide – remove and install 4100
5 5 Lower front metal/rubber bearings of the wishbone – replace 4104
5 5 1 Lower front metal/rubber bearings of the wishbone – replace 4104
5 5 2 Rear bonded rubber bush of the lower wishbone – replace, ∅ 60 mm 4107
6 Wheel roller bearing 4112
6 1 Wheel bearing – general overview of assembly 4112
6 2 Wheel bearing case – remove and install 4113
6 3 Hub and wheel bearing – remove and install 4119
7 Drive shaft 4128
7 1 Drive shaft – assembly overview 4128
7 1 1 Drive shaft with triple roller joint – assembly overview (Model 1 0 MPI 1 0/1 4 TSI / 1 6 MSI) 4128
7 1 2 Drive shaft with constant velocity joint – remove and install (Model 1 6 MSi Manual) 4130
7 2 Drive shaft – remove and install 4132
7 2 1 Articulating shaft with tripod joint – remove and install (Model 1 4 MPI / 1 0 TSI Manual) 4132
7 2 2 Drive shaft with constant velocity joint – remove and install (Model 1 6 MSI Manual) 4140
7 2 3 Drive shaft with triple roller joint – remove and install (Model 1 0/1 4 TSI Automatic / 1 6 MSI Automatic) 4145
7 3 Joint – remove and install 4150
7 4 Drive shaft heat shield – remove and install 4155
7 5 Drive shaft – assemble and disassemble 4155
7 5 1 Drive shaft with constant velocity joint – assemble and disassemble (Model 1 0 MPI / 1 0/1 4 TSI Automatic/ 1 6 MSI Automatic) 4155
7 5 2 Drive shaft with constant velocity joint – remove and install (Model 1 6 MSI) 4162
7 6 External constant velocity joint – check 4169
7 7 Internal constant velocity joint – check (Only for model 1 6 MSI Manual) 4171
42 – Rear suspension 4174
1 Rear axle 4174
1 1 Rear axle – overview 4174
1 2 Rear axle – remove and install 4175
2 Axle beam 4181
2 1 Axle beam – assembly overview 4181
2 1 1 Axle beam, mounting bracket – assembly overview 4181
2 2 Axle beam – replace the bonded rubber bush 4181
3 Suspension strut/shock absorber, spring 4191
3 1 Suspension strut/shock absorber, spring – assembly overview 4191
3 1 1 Suspension strut/shock absorber, spring – assembly overview 4191
3 1 2 Shock absorber – assembly overview 4192
3 2 Shock absorber – remove and install 4192
3 3 Shock absorber – repair 4194
3 3 1 Shock absorber – repair 4194
3 4 Spring – remove and install 4196
4 Wheel roller bearing 4199
4 1 Wheel bearing – general overview of assembly 4199
4 1 1 Wheel bearing – general overview of assembly (drum brake) 4199
4 1 2 Wheel bearing – assembly overview (drum brake) 4199
4 2 Wheel hub/wheel bearing unit – remove and install 4200
4 2 1 Wheel hub/wheel bearing unit – remove and install (drum brake) 4200
4 2 2 Wheel hub/wheel bearing unit – remove and install (disc brake) 4204
43 – Self-levelling suspension 4208
1 Vehicle level sender 4208
1 1 Rear vehicle level sender – assembly overview 4208
1 2 Rear vehicle level sender -G76- – remove and install 4208
44 – Wheels, tyres, vehicle geometry 4211
1 Tyre monitoring system 4211
1 1 Tyre Pressure Monitoring System – system description 4211
2 Axle geometry check 4213
2 1 Axle geometry check instructions 4213
2 2 Preliminary testing conditions 4214
2 3 Preparation for alignment 4214
2 3 1 Preparation for alignment, axle geometry alignment without assist systems 4214
2 3 2 Preparation for alignment, axle geometry measurement with assist systems 4216
2 4 Nominal vehicle geometry alignment values 4216
2 5 Place the vehicle in initial position to check geometry 4218
2 6 Axle alignment work procedure 4218
2 7 Axle geometry measurement requirement 4220
2 8 Vehicle data tag 4220
2 9 Adjust front axle camber angle 4221
2 10 Adjust the rear axle camber angle 4222
2 11 Adjust the rear axle toe-out 4222
2 12 Adjust front axle toe-out angle 4222
2 13 Check the maximum steering angle 4224
3 Tightening torques of wheel bolts 4225
48 – Steering 4226
1 Steering wheel 4226
1 1 Steering wheel – assembly overview 4226
1 2 Steering wheel – remove and install 4226
2 Steering column 4229
2 1 Steering column – assembly overview 4229
2 2 Steering column – remove and install 4231
2 3 Handling and transporting the steering column 4240
2 4 Intermediate steering column axle – remove and install 4243
3 Steering rack 4245
3 1 Steering rack – general overview of assembly 4245
3 1 1 Steering rack – general overview of assembly 4245
3 1 2 Steering rack, track rods – assembly overview 4246
3 2 Steering rack – remove and install 4248
3 3 Track rod – remove and install 4254
3 4 Track rod ball joint – remove and install 4258
4 Sensors 4261
4 1 Steering angle sensor -G85- 4261
D4B808A7775 3 Cyl injection engine (1 0 l turbocharger) 4262
00 – Technical data 4270
1 — Change history — 4270
2 Safety instructions 4271
2 1 Safety measures regarding work on the fuel supply 4271
2 2 Safety measures when working on vehicles with Start-Stop system 4272
2 3 Safety measures in test drives using testing and measurement devices 4272
2 4 Safety measures when working on the ignition system 4273
2 5 Safety measures when working on the exhaust system 4273
2 6 Safety measures when working on the cooling system 4274
3 Identification 4275
3 1 Engine number/engine characteristics 4275
4 Repair instructions 4277
4 1 Cleanliness rules 4277
4 2 General instructions 4277
4 3 General repair instructions 4278
4 4 Foreign bodies on the engine 4278
4 5 Contact corrosion 4278
4 6 Connection installation and fastening 4279
4 7 Radiator and capacitor installation 4279
4 8 Check the vacuum system 4279
10 – Removing and installing engine 4280
1 Engine – remove and install 4280
1 1 Engine – removal 4280
1 2 Engine – separate gearbox 4293
1 2 1 Engine – separate manual gearbox 4293
1 2 2 Engine – separate automatic gearbox 4294
1 3 Engine – secure to engine and gearbox support 4297
1 4 Engine – installation 4299
1 5 Engine – remove and install, summarized instructions 4302
2 Power-drive unit supports 4306
2 1 Power unit brackets – assembly overview 4306
2 2 Power unit bracket (engine side) – remove and install 4309
2 3 Drive-train mounting (gearbox side) – remove and install 4310
2 4 Pendulum support (torque limiter) – remove and install 4312
2 5 Support the engine in assembly position 4314
2 5 1 Support the engine in assembly position; Polo, Virtus 4314
2 5 2 Support engine in installation position; T-Cross, Nivus 4318
2 6 Drive train mountings – adjust 4323
2 7 Drive train mounting adjustment – check 4325
13 – Crankshaft group 4327
1 Cylinder block (pulley side) 4327
1 1 Poly-V belt mechanism – assembly overview 4327
1 2 Poly-V belt – remove and install 4329
1 3 Poly-V belt tensioner – remove and install 4330
1 4 Crankshaft pulley (vibration damper) – remove and install 4331
1 5 Engine console – remove and install 4335
1 6 Crankshaft seal (pulley side) – replace 4340
2 Cylinder block (gearbox side) 4344
2 1 Cylinder block (gearbox side) – assembly overview 4344
2 1 1 Cylinder block (gearbox side), vehicles with manual gearbox – assembly overview 4344
2 1 2 Cylinder block (gearbox side), vehicles with automatic gearbox – assembly overview 4346
2 2 Flywheel – remove and install 4348
2 3 Clutch Disk – removal and installation 4350
2 4 Crankshaft flange (flywheel side) – replace 4352
2 4 1 Crankshaft flange with Engine speed sensor – G28- rotor – remove 4354
2 4 2 Flange with Engine speed sensor – G28- rotor – install 4356
2 4 3 Flange with Engine speed sensor – G28- rotor in the Fitter – T10134- or Fitter – T10017K- – install 4357
2 4 4 Fitter -T10134- or Fitter – T10017K- with the crankshaft flange – install 4359
2 4 5 Fitter – T10134- or Fitter – T10017K- in the crankshaft flange – screw 4361
2 4 6 Engine speed sensor -G28- rotor with the Fitter – T10134- or Fitter – T10017K- in the crankshaft flange – install 4361
2 4 7 Installation position of the Engine speed sensor -G28- rotor on the crankshaft – check 4362
2 4 8 Engine speed sensor -G28- rotor – further compression 4363
3 Crankshaft 4365
3 1 Crankshaft – dimensions 4365
4 Pistons and conrods – remove and install 4366
4 1 Pistons and conrods – assembly overview 4366
4 2 Pistons – remove and install 4369
4 3 Pistons, rings, and cylinders – check 4370
4 3 1 Cylinders (inner diameter) – check 4372
4 3 2 Pistons and cylinders – dimensions 4373
4 4 Conrod and cap (new part) – separate 4373
4 5 Conrod radial clearance – check 4373
4 6 Oil spray jet and valve – remove and install 4374
15 – Cylinder head, valve gear 4376
1 Engine cylinder head 4376
1 1 Engine cylinder head – assembly overview 4376
1 2 Cylinder head cover with exhaust and inlet camshafts – assembly overview 4378
1 3 Cylinder head – remove and install 4381
1 4 Cylinder head – remove and install, summarized instructions 4385
1 5 Cylinder head cover with exhaust and inlet camshafts – remove and install 4387
1 6 Cylinder compression – check 4393
2 Toothed belt drive 4396
2 1 Console, upper and lower cover of the toothed belt – assembly overview 4396
2 2 Toothed belt – assembly overview 4396
2 3 Toothed belt – remove and install 4398
2 4 Valve timing – check 4402
2 5 Valve timing – adjust 4408
2 6 Camshaft toothed belt – remove 4416
3 Camshaft mechanism 4422
3 1 Camshaft mechanism – assembly overview 4422
3 2 Crankshaft – check axial clearance 4424
3 3 Camshaft gasket (pulley side) – replace 4425
3 3 1 Inlet camshaft gasket – replace 4425
3 3 2 Exhaust camshaft seal on the toothed belt sprocket side – replace 4427
3 3 3 Exhaust camshaft seal on the gearbox side 4430
3 4 Inlet and exhaust camshaft regulators – remove and install 4432
3 4 1 Inlet camshaft regulator – remove and install 4432
3 4 2 Exhaust camshaft regulator – remove and install 4437
3 5 Camshaft adjustment valve 1 -N205- and Exhaust camshaft adjustment valve 1 -N318- – remove and install 4443
3 6 Valve stem sealant – replace 4444
3 6 1 Valve stem sealant – replace (cylinder head installed) 4444
3 6 2 Valve stem sealant (cylinder head removed) – replace 4451
4 Inlet and exhaust valves 4457
4 1 Valve guides – check 4457
4 2 Valves – check 4458
4 3 Valve dimensions 4458
17 – Lubrication 4459
1 Crankcase/oil pump 4459
1 1 Crankcase/oil pump – assembly overview 4459
1 2 Lower sump – remove and install 4464
1 3 Upper crankcase – remove and install 4466
1 4 Oil pump – remove and install 4470
1 5 Engine oil 4472
2 Engine oil cooler 4474
2 1 Engine oil cooler – assembly overview 4474
2 2 Engine oil cooler – remove and install 4474
3 Engine crankcase ventilation 4476
3 1 Engine crankcase ventilation – assembly overview 4476
3 2 Crankcase ventilation device – remove and install 4477
4 Oil filter/Oil pressure switch -F378- 4482
4 1 Oil filter/Oil pressure switch -F378- – assembly overview 4482
4 2 Oil filter – remove and install 4482
4 3 Oil pressure switch -F378- – remove and install 4483
4 4 Oil pressure and Oil pressure switch -F378- – check 4485
19 – Cooling 4488
1 Cooling system/coolant 4488
1 1 Hose connection diagram for cooling system 4488
1 1 1 Hose connection diagram for cooling system, vehicles with manual gearbox 4488
1 1 2 Hose connection diagram for cooling system, vehicles with automatic gearbox 4489
1 2 Cooling system – check air-tightness 4490
1 3 Coolant tank flap – check safety valve 4493
1 4 Cooling system – drainage and replenishment 4495
1 4 1 Drain 4497
1 4 2 Replenishing 4499
2 Water pump/coolant adjustment 4504
2 1 Water pump/thermostatic valves – assembly overview 4504
2 2 Air intake cooling pump -V188- – assembly overview 4507
2 3 Coolant temperature sensor – assembly overview 4508
2 4 Air intake cooling pump -V188- – remove and install 4509
2 5 Water pump – remove and install 4511
2 6 Thermostats – remove and install 4516
2 6 1 Thermostat valve (large circuit) – remove and install 4516
2 6 2 Thermostat valve (small circuit) – remove and install 4519
2 7 Water pump toothed belt – remove and install 4522
2 8 Water pump sprocket – remove and install 4525
2 9 Coolant temperature sensor -G62- – remove and install 4526
2 10 Coolant temperature sensor on the radiator outlet -G83- – remove and install 4528
3 Cooling system pipes 4530
3 1 Coolant system line – assembly overview 4530
3 2 Cooling system line – remove and install 4530
4 Radiator/Radiator fan 4533
4 1 Radiator – assembly overview 4533
4 2 Fan cowl and radiator fan – assembly overview 4535
4 3 Radiator – remove and install 4536
4 4 Fan housing – remove and install 4538
4 5 Radiator fan -V7- – remove and install 4539
4 6 Charge air cooling system radiator – remove and install 4540
20 – Fuel supply system 4544
1 Fuel tank 4544
1 1 Fuel tank – assembly overview 4544
1 1 1 Fuel tank – assembly overview 4544
1 2 Fuel tank – remove and install 4546
1 2 1 Fuel tank – remove and install 4546
1 3 Fuel tank – drain 4554
1 3 1 Fuel tank with intact fuel pump – drain 4554
1 3 2 Fuel tank with more than 3/4 of fuel – drain 4559
1 3 3 Fuel tank with less than 3/4 of fuel – drain 4561
2 Fuel supply unit/Fuel level sensor 4564
2 1 Fuel pump (pre-supply pump) -G6-/Fuel gauge sensor -G- – assembly overview 4564
2 2 Fuel pump (pre-supply pump) -G6-/Fuel gauge sensor -G- – remove and install 4566
2 3 Fuel gauge sensor -G- – remove and install 4572
2 4 Installation opening cover – remove and install 4572
3 Plug-in connectors 4574
3 1 Plug-in connectors – disconnect 4574
4 Fuel filter 4580
4 1 Fuel filter – remove and install 4580
5 Activated charcoal system 4582
5 1 Wiring diagram – Activated carbon filter system 4582
5 1 1 Wiring diagram – Activated charcoal tank system in the engine compartment, vehicles from the year of manufacture 2022 4582
5 1 2 Rear activated charcoal tank system wiring diagram 4583
5 2 Activated charcoal tank system – assembly overview 4584
5 3 Activated charcoal tank – remove and install 4586
5 4 Fuel tank ventilation – check 4587
6 Accelerator activation 4596
6 1 Accelerator pedal module – assembly overview 4596
6 2 Accelerator pedal module -GX2- – remove and install 4596
7 Fuel system pressurisation pump -G6- 4598
7 1 Fuel system pressurisation pump -G6- – check 4598
7 1 1 Fuel pump operation and power supply – check 4598
7 1 2 Fuel pressure – check 4602
7 1 3 Holding pressure, totalflex motors – check 4606
7 1 4 Holding pressure, petrol engines – check 4612
7 1 5 Flow of the fuel supply system, totalflex engines – check 4616
7 1 6 Fuel system flow, petrol engines – check 4625
7 2 Fuel pump control unit -J538- – remove and install 4632
8 Fuel lines 4634
8 1 Fuel lines – remove and install 4634
21 – Turbocharging/supercharging 4639
1 Exhaust gas turbocharger 4639
1 1 Exhaust gas turbocharger – Assembly overview 4639
1 2 Exhaust gas turbocharger – remove and install 4643
1 3 Exhaust gas turbocharger – remove and install, summarized instructions 4648
1 4 Load pressure control -V465- – remove and install 4649
1 5 Turbocharger nozzle – remove and install 4650
1 5 1 Turbocharger connection nozzle, vehicles up to the year of manufacture 2021 – remove and install 4650
1 5 2 Turbocharger connection nozzle, vehicles from the year of manufacture 2022 – remove and install 4653
2 Supercharging air system 4656
2 1 Supercharging air system – Assembly overview 4656
2 2 Air duct – remove and install 4659
2 2 1 Air conductor, vehicles up to the year of manufacture 2021 – remove and install 4659
2 2 2 Air conductor, vehicles from the year of manufacture 2022 – remove and install 4660
2 3 Supercharging air intercooler – remove and install 4661
2 4 Load pressure sensor -GX26- – remove and install 4663
2 5 Charge air system – check air-tightness 4664
24 – Mixture preparation – injection 4667
1 Injection system 4667
1 1 Injection system – assembly overview 4667
1 2 Fuel system – relieve pressure 4673
2 Air cleaner 4675
2 1 Air filter – assembly overview 4675
2 2 Air filter – remove and install 4677
2 3 Front panel air filter lead – remove and install 4679
3 Intake manifold 4681
3 1 Intake manifold – assembly overview 4681
3 2 Intake manifold – remove and install 4683
3 3 Throttle butterfly valve control unit -GX3- – remove and install 4687
3 4 Throttle valve control unit -GX3- – clean 4688
4 Injection valves 4690
4 1 Fuel rail with injection valves – assembly overview 4690
4 2 Fuel distributor – removal and installation 4692
4 3 Injection valves – remove and install 4693
4 4 Injectors – remove and install, summarized instructions 4700
4 5 Injection valves – clean 4702
5 Transmitters and sensors 4704
5 1 Intake manifold sensor -GX9- – remove and install 4704
5 2 Fuel pressure sensor -G247- – remove and install 4705
5 3 Fuel pressure sensor -G247- – check 4706
5 4 Fuel composition sensor -G446- – remove and install 4709
6 High pressure pump 4711
6 1 High pressure pump – assembly overview 4711
6 2 High pressure pump – remove and install 4713
6 3 High pressure line – remove and install 4715
7 Lambda probe 4718
7 1 Lambda probe – assembly overview 4718
7 2 Lambda probe 1 before the catalytic converter -GX10-/Lambda probe 1 after the catalytic converter -GX7- – remove and install 4719
8 Engine control unit -J623- 4722
8 1 Engine control unit -J623- – assembly overview 4722
8 2 Engine control unit -J623- – remove and install 4722
8 2 1 Engine control unit -J623-, ◄ MY 2022 – remove and install 4722
8 2 2 Engine control unit -J623- , MY 2023 ►- remove and install 4724
26 – Exhaust system 4728
1 Silencer/exhaust pipes 4728
1 1 Silencer – assembly overview 4728
1 2 Silencer/exhaust pipes – detach 4729
1 3 Centre silencer with rear silencer – remove and install 4731
1 4 Centre silencer – remove and install 4735
1 5 Rear silencer – remove and install 4737
1 6 Exhaust system – tension free alignment 4738
1 7 Exhaust system – check tightness 4739
1 8 Pipe clamp installation position 4739
2 Exhaust system 4741
2 1 Emission control – assembly overview 4741
2 2 Catalytic converter – remove and install 4744
28 – Ignition system 4748
1 Ignition system 4748
1 1 Ignition system – assembly overview 4748
1 2 Ignition coils with final power stage – assembly overview 4750
1 3 Spark plugs -Q- – technical data 4751
1 4 Ignition coil with final power stage – remove and install 4751
1 5 Knock sensor 1 -G61- – remove and install 4754
1 6 Hall Sensor -G40- – remove and install 4756
1 7 Engine speed sensor -G28- – remove and install 4757
D4B8026F7C6 Painting Manual 4760
00 – Technical data 4764
1 Introduction 4764
2 Safety at the working area 4765
2 1 Product handling 4765
2 2 Wear individual protection equipment (IPE) 4765
2 3 Important safety items in the repainting workshop 4766
2 3 1 Fire extinguishers 4766
2 3 2 Ventilation 4767
2 4 Storage of chemicals 4767
2 4 1 Grounding 4767
2 4 2 Electrical Installations 4767
2 4 3 Location of the painting section 4767
2 5 Environment and disposal of paints 4767
2 5 1 Residues 4767
2 5 2 Paint leftovers 4768
2 5 3 Disposal of grout and empty packages 4768
2 5 4 Filters, cloths and papers 4768
2 5 5 Disposal of cans and drums 4768
2 5 6 Rain waters, sewage and earth 4768
2 5 7 Risk of chemicals 4768
3 Colours 4770
3 1 1995 line – Imported vehicles 4770
3 1 1 Solid colours 4770
3 1 2 Metallic colours 4770
3 1 3 Pearly colours 4771
3 2 1995 line – Domestically manufactured vehicles 4771
3 2 1 Solid colours 4771
3 2 2 Metallic colours 4771
3 2 3 Pearly colours 4771
3 3 1996 line – Imported vehicles 4772
3 3 1 Solid colours 4772
3 3 2 Metallic colours 4772
3 3 3 Pearly colours 4773
3 4 1996 line – Domestically manufactured vehicles 4773
3 4 1 Solid colours 4773
3 4 2 Metallic colours 4773
3 4 3 Pearly colours 4774
3 5 1997 line – Imported vehicles 4774
3 5 1 Solid colours 4774
3 5 2 Metallic colours 4774
3 5 3 Pearly colours 4775
3 6 1997 line – Domestically manufactured vehicles 4775
3 6 1 Solid colours 4775
3 6 2 Metallic colours 4776
3 6 3 Pearly colours 4776
3 7 1998 line – Imported vehicles 4776
3 7 1 Solid colours 4776
3 7 2 Metallic colours 4777
3 7 3 Pearly colours 4778
3 8 1998 line – Domestically manufactured vehicles 4779
3 8 1 Solid colours 4779
3 8 2 Metallic colours 4779
3 8 3 Pearly colours 4780
3 9 1999 line – Imported vehicles 4780
3 9 1 Solid colours 4780
3 9 2 Metallic colours 4781
3 9 3 Pearly colours 4782
3 10 1999 line – Domestically manufactured vehicles 4783
3 10 1 Solid colours 4783
3 10 2 Metallic colours 4783
3 10 3 Pearly colours 4784
3 11 2000 line – Imported vehicles 4784
3 11 1 Solid colours 4784
3 11 2 Metallic colours 4785
3 11 3 Pearly colours 4786
3 12 2000 line – Domestically manufactured vehicles 4786
3 12 1 Solid colours 4786
3 12 2 Metallic colours 4787
3 12 3 Pearly colours 4787
3 13 2001 line – Imported vehicles 4788
3 13 1 Solid colours 4788
3 13 2 Metallic colours 4788
3 13 3 Pearly colours 4789
3 14 2001 line – Domestically manufactured vehicles 4789
3 14 1 Solid colours 4789
3 14 2 Metallic colours 4790
3 14 3 Pearly colours 4791
3 15 2002 line – Imported vehicles 4791
3 15 1 Solid colours 4791
3 15 2 Metallic colours 4792
3 15 3 Pearly colours 4793
3 16 2002 line – Domestically manufactured vehicles 4794
3 16 1 Solid colours 4794
3 16 2 Metallic colours 4794
3 16 3 Pearly colours 4795
3 17 2003 line – Imported vehicles 4796
3 17 1 Solid colours 4796
3 17 2 Metallic colours 4796
3 17 3 Pearly colours 4796
3 18 2003 line – Domestically manufactured vehicles 4797
3 18 1 Solid colours 4797
3 18 2 Metallic colours 4798
3 18 3 Pearly colours 4798
3 19 2004 line – Imported vehicles 4799
3 19 1 Solid colours 4799
3 19 2 Metallic colours 4799
3 19 3 Pearly colours 4799
3 20 2004 line – Domestically manufactured vehicles 4800
3 20 1 Solid colours 4800
3 20 2 Metallic colours 4800
3 20 3 Pearly colours 4801
3 21 2005 line – Imported vehicles 4801
3 21 1 Solid colours 4801
3 21 2 Metallic colours 4802
3 21 3 Pearly colours 4802
3 22 2005 line – Domestically manufactured vehicles 4803
3 22 1 Solid colours 4803
3 22 2 Metallic colours 4804
3 22 3 Pearly colours 4804
3 23 2006 line – Imported vehicles 4805
3 23 1 Solid colours 4805
3 23 2 Metallic colours 4805
3 23 3 Pearly colours 4807
3 24 2006 line – Domestically manufactured vehicles 4807
3 24 1 Solid colours 4807
3 24 2 Metallic colours 4808
3 24 3 Pearly colours 4809
3 25 2007 line – Imported vehicles 4809
3 25 1 Solid colours 4809
3 25 2 Metallic colours 4810
3 25 3 Pearly colours 4812
3 26 2007 line – Domestically manufactured vehicles 4812
3 26 1 Solid colours 4812
3 26 2 Metallic colours 4813
3 26 3 Pearly colours 4813
3 27 2008 line – Imported vehicles 4814
3 27 1 Solid colours 4814
3 27 2 Metallic colours 4814
3 27 3 Pearly colours 4815
3 28 2008 line – Domestically manufactured vehicles 4816
3 28 1 Solid colours 4816
3 28 2 Metallic colours 4816
3 28 3 Pearly colours 4817
3 29 2009 line – Imported vehicles 4817
3 29 1 Solid colours 4817
3 29 2 Metallic colours 4819
3 29 3 Pearly colours 4821
3 30 2009 line – Domestically manufactured vehicles 4823
3 30 1 Solid colours 4823
3 30 2 Metallic colours 4824
3 30 3 Pearly colours 4826
3 31 2010 line – Imported vehicles 4826
3 31 1 Solid colours 4826
3 31 2 Metallic colours 4827
3 31 3 Pearly colours 4830
3 32 2010 line – Domestically manufactured vehicles 4831
3 32 1 Solid colours 4831
3 32 2 Metallic colours 4832
3 32 3 Pearly colours 4833
3 33 2011 line – Imported vehicles 4834
3 33 1 Solid colours 4834
3 33 2 Metallic colours 4835
3 33 3 Pearly colours 4839
3 34 2011 line – Domestically manufactured vehicles 4839
3 34 1 Solid colours 4839
3 34 2 Metallic colours 4840
3 34 3 Pearly colours 4842
3 35 2012 line – Imported vehicles 4842
3 35 1 Solid colours 4842
3 35 2 Metallic colours 4843
3 35 3 Pearly colours 4846
3 36 2012 line – Domestically manufactured vehicles 4846
3 36 1 Solid colours 4846
3 36 2 Metallic colours 4847
3 36 3 Pearly colours 4849
3 37 2013 line – Imported vehicles 4849
3 37 1 Solid colours 4849
3 37 2 Metallic colours 4850
3 37 3 Pearly colours 4853
3 38 2013 line – Domestically manufactured vehicles 4853
3 38 1 Solid colours 4853
3 38 2 Metallic colours 4855
3 38 3 Pearly colours 4856
3 39 2014 line – Imported vehicles 4856
3 39 1 Solid colours 4856
3 39 2 Metallic colours 4857
3 39 3 Pearly colours 4858
3 40 2014 line – Domestically manufactured vehicles 4859
3 40 1 Solid colours 4859
3 40 2 Metallic colours 4860
3 40 3 Pearly colours 4861
3 41 2015 line – Imported vehicles 4862
3 41 1 Solid colours 4862
3 41 2 Metallic colours 4863
3 41 3 Pearly colours 4866
3 42 2015 line – Domestically manufactured vehicles 4866
3 42 1 Solid colours 4866
3 42 2 Metallic colours 4867
3 42 3 Pearly colours 4869
3 42 4 Special colours 4869
3 43 2016 line – Imported vehicles 4869
3 43 1 Solid colours 4869
3 43 2 Metallic colours 4870
3 43 3 Pearly colours 4872
3 44 2016 line – Domestically manufactured vehicles 4873
3 44 1 Solid colours 4873
3 44 2 Metallic colours 4874
3 44 3 Pearly colours 4876
3 44 4 Special colours 4876
3 45 2017 line – Domestically manufactured vehicles 4877
3 45 1 Solid colours 4877
3 45 2 Metallic colours 4877
3 45 3 Pearly colours 4879
3 45 4 Special colours 4879
3 46 2017 line – Imported vehicles 4880
3 46 1 Solid colours 4880
3 46 2 Metallic colours 4880
3 46 3 Pearly colours 4883
3 47 2018 line – Domestically manufactured vehicles 4883
3 47 1 Solid colours 4883
3 47 2 Metallic colours 4884
3 47 3 Pearly colours 4886
3 47 4 Special colours 4886
3 48 2018 line – Imported vehicles 4887
3 48 1 Metallic colours 4887
3 48 2 Pearly colours 4888
3 49 2019 line – Domestically manufactured vehicles 4888
3 49 1 Solid colours 4888
3 49 2 Metallic colours 4889
3 49 3 Pearly colours 4891
3 50 2019 line – Imported vehicles 4891
3 50 1 Solid colours 4891
3 50 2 Metallic colours 4891
3 50 3 Pearly colours 4893
3 51 2020 line – Domestically manufactured vehicles 4893
3 51 1 Solid colours 4893
3 51 2 Metallic colours 4894
3 52 2020 line – Imported vehicles 4896
3 52 1 Solid colours 4896
3 52 2 Metallic colours 4896
3 52 3 Pearly colours 4898
3 53 2021 line – Domestically manufactured vehicles 4898
3 53 1 Solid colours 4898
3 53 2 Metallic colours 4899
3 54 2021 line – Imported vehicles 4900
3 54 1 Solid colours 4900
3 54 2 Metallic colours 4901
3 54 3 Pearly colours 4901
4 Special colours 4903
4 1 Special colours 4903
4 1 1 Fox Blackfox 2012 4903
4 1 2 Crossfox 4903
4 1 3 Crossfox 2012 ► 4904
4 1 4 Fox Extreme 4905
4 1 5 Fox Silverfox 2012 4906
4 1 6 Gol – Special fleet painting 4907
4 1 7 Gol Rallye (5W) 4908
4 1 8 Gol Vintage (5U) 4909
4 1 9 Golf GT 4911
4 1 10 Golf Silver Edition 4912
4 1 11 Golf Black Edition 2011 4913
4 1 12 Silver series Kombi 4913
4 1 13 Parati Track and Field (Generation IV) 4914
4 1 14 Parati Surf 4915
4 1 15 Parati Titan 4916
4 1 16 Saveiro Crossover (generation III) 4917
4 1 17 Saveiro Crossover (generation IV) 4918
4 1 18 Saveiro Titan 4919
4 1 19 Saveiro Surf 4920
4 1 20 Saveiro Trooper 2010 ► 4921
4 1 21 Saveiro Cross 2010 ► 4922
4 1 22 Saveiro basic 2013 ► 4923
4 1 23 Kombi Last Edition 2013 4924
4 1 24 Fox Pepper 2015 ► 4925
4 1 25 up! TSI 2016 ► 4926
4 1 26 speed up! TSI 2016 ► 4927
4 1 27 CrossFox — Urban White 2017 ► 4928
4 1 28 CrossFox — Camou Red 2018 4929
4 1 29 Up – Connect 2018 4930
4 1 30 Up – Pepper 2018 4931
4 1 31 Saveiro – Pepper 2018 4932
4 1 32 Polo Beats 4934
4 1 33 T-Cross Highline 4934
4 1 34 NIVUS – HERO 4935
5 Paints 4937
5 1 Basic composition of paints 4937
5 2 Types of paints 4937
6 Complements 4939
6 1 Thinners / Solvents / Diluents 4939
6 1 1 Basic composition 4939
6 1 2 Types of thinners 4939
6 2 Rust neutralizers 4939
6 3 Sealing and protection of the lower part of the vehicle 4939
6 4 Sanding control 4940
6 5 Primers 4940
6 5 1 PU Primer 4940
6 6 Polyester paste 4940
6 6 1 Body repair paste 4940
6 6 2 Polyurethane-based sealing adhesive (thread) 4940
6 6 3 Polyester Paste 4941
6 7 Abrasives 4941
6 7 1 Polishers 4941
7 Repainting 4942
7 1 Paint Repair 4942
7 1 1 General information 4942
7 2 Paint repair on steel plates and zinc-coated steel plates 4942
7 2 1 Solid paint – solid colours 4943
7 2 2 Double-layer paint (solid, metallic and pearly colours) 4944
7 2 3 Water-based double-layer paint (smooth, metallic and pearly colours) 4946
7 3 Paint repair on plastic parts 4948
7 3 1 Repainting of plastic components that require special care 4950
7 4 Spray guns and their use 4951
7 5 Paint dryers by irradiation 4955
7 6 Dryers based on air insufflation (water-based painting) 4956
8 Body sealing 4957
8 1 Materials 4957
8 1 1 Polyurethane-based sealing adhesive 4957
8 1 2 Body repair paste 4957
8 1 3 Paste for load bed protection 4958
8 2 Santana and Quantum 4958
8 3 Gol 1995 ► 4968
8 4 Gol 1999 ► and Parati 1999 ► – 5X and 5W 4977
8 5 Saveiro 2000 ► – 5X and 5W 4991
8 6 Gol, Voyage 2009 ► and Saveiro 2010 ► 4995
8 7 Fox and Spacefox 5030
8 8 Polo 5063
8 9 Golf 5096
9 Application of anti-corrosion fluid 5114
9 1 Anti-corrosive fluid 5114
9 2 Equipment 5114
9 3 Gol , Parati and Saveiro – 5X and 5W 5114
9 4 New Gol , Voyage 2009 ► Saveiro 2010 ► 5122
9 5 Fox and Spacefox 5135
9 6 Polo 5147
D4B8040D52F 3 cylinder injection engine (1 0 l engine 4 V EA 211) 5158
00 – Technical data 5164
1 Safety information 5164
1 1 Safety regulations for working on fuel supply 5164
1 2 Safety measures when working on vehicles with a start/stop system 5164
1 3 Safety precautions when using testers and measuring instruments during a road test 5165
1 4 Safety precautions when working on the cooling system 5165
1 5 Safety precautions when working on ignition system 5165
2 Identification 5166
2 1 Engine number/engine data 5166
3 Repair instructions 5167
3 1 Rules for cleanliness 5167
3 2 General information 5167
3 3 General repair instructions 5167
3 4 Foreign objects in engine 5168
3 5 Contact corrosion 5168
3 6 Routing and attachment of lines 5168
3 7 Fitting radiator and condensers 5168
3 8 Checking vacuum system 5168
10 – Removing and installing engine 5170
1 Removing and installing engine 5170
1 1 Removing engine 5170
1 1 1 Removing engine, Polo 2014, Ameo 5170
1 1 2 Removing engine, Polo 2018 5177
1 2 Separating engine and gearbox 5187
1 3 Securing engine on engine and gearbox support 5188
1 4 Installing engine 5190
1 4 1 Installing engine, Polo 2014, Ameo 5190
1 4 2 Installing engine, Polo 2018 5191
2 Assembly mountings 5195
2 1 Assembly overview – assembly mountings 5195
2 1 1 Assembly overview – assembly mountings, Polo 2014, Ameo 5195
2 1 2 Assembly overview – assembly mountings, Polo 2018 5197
2 2 Removing and installing engine mounting 5199
2 2 1 Removing and installing engine mounting, Polo 2014, Ameo 5199
2 2 2 Removing and installing engine mounting, Polo 2018 5200
2 3 Removing and installing gearbox mounting 5202
2 3 1 Removing and installing gearbox mounting, Polo 2014, Ameo 5202
2 3 2 Removing and installing gearbox mounting, Polo 2018 5203
2 4 Removing and installing pendulum support 5206
2 4 1 Removing and installing pendulum support, Polo 2014, Ameo 5206
2 4 2 Removing and installing pendulum support, Polo 2018 5207
2 5 Supporting engine in installation position 5208
2 5 1 Supporting engine in installation position, Polo 2014, Ameo 5208
2 5 2 Supporting engine in installation position, Polo 2018 5210
2 6 Adjusting assembly mountings 5212
2 7 Checking adjustment of assembly mountings (engine and gearbox mountings) 5213
13 – Crankshaft group 5214
1 Cylinder block (pulley end) 5214
1 1 Assembly overview – poly V-belt drive 5214
1 1 1 Assembly overview – poly V-belt drive, vehicles without air conditioner compressor 5214
1 1 2 Assembly overview – poly V-belt drive, Polo 2014, Ameo, vehicles with air conditioner compressor 5216
1 1 3 Assembly overview – poly V-belt drive, Polo 2018, vehicles with air conditioner compressor 5217
1 2 Assembly overview – cylinder block (pulley end) 5218
1 3 Removing and installing poly-V belt 5220
1 3 1 Removing and installing poly V-belt, Polo 2014, Ameo, vehicles with air conditioner compressor 5220
1 3 2 Removing and installing poly V-belt, Polo 2018, vehicles with air conditioner compressor 5222
1 3 3 Removing and installing poly V-belt, Polo 2014, Ameo, vehicles without air conditioner compressor 5223
1 3 4 Removing and installing poly V-belt, Polo 2018, vehicles without air conditioner compressor 5224
1 4 Removing and installing tensioner for poly V-belt 5225
1 4 1 Removing and installing tensioner for poly V-belt, vehicles without air conditioner compressor 5225
1 4 2 Removing and installing tensioner for poly V-belt, vehicles with air conditioner compressor 5227
1 5 Removing and installing engine support 5228
1 6 Renewing crankshaft oil seal – belt pulley end 5230
2 Cylinder block, gearbox end 5233
2 1 Assembly overview – cylinder block, gearbox end 5233
2 2 Removing and installing flywheel 5234
2 3 Removing and installing sealing flange on gearbox side 5235
3 Crankshaft 5243
3 1 Crankshaft dimensions 5243
4 Pistons and conrods 5244
4 1 Assembly overview – pistons and conrods 5244
4 2 Checking pistons and cylinder bores 5245
4 3 Separating new conrod 5247
4 4 Removing and installing oil spray jets 5248
4 5 Setting piston to TDC position 5249
15 – Cylinder head, valve gear 5251
1 Cylinder head 5251
1 1 Assembly overview – cylinder head 5251
1 2 Removing and installing cylinder head 5254
1 3 Removing and installing camshaft housing 5260
1 4 Checking compression 5263
2 Toothed belt drive 5267
2 1 Assembly overview – toothed belt cover 5267
2 2 Assembly overview – toothed belt 5268
2 3 Removing and installing toothed belt guard 5269
2 3 1 Removing and installing upper toothed belt guard 5269
2 3 2 Removing and installing lower toothed belt guard 5269
2 4 Removing and installing toothed belt 5270
2 5 Preassembling and installing valve timing tool 5277
2 5 1 Preassembling valve timing tool 5277
2 5 2 Installing test tool -VAS 611 007- 5280
2 5 3 Teaching in test tool -VAS 611 007- electronically and performing basic setting 5282
2 6 Checking valve timing 5284
2 7 Adjusting valve timing 5287
2 8 Removing toothed belt from camshaft 5296
3 Valve gear 5301
3 1 Assembly overview – valve gear 5301
3 2 Measuring axial play of camshaft 5302
3 3 Removing and installing camshaft oil seal 5303
3 3 1 Removing and installing camshaft oil seal, pulley end 5303
3 3 2 Removing and installing camshaft oil seal, gearbox end 5305
3 4 Removing and installing camshaft adjuster 5307
3 5 Removing and installing toothed belt pulley 5312
3 6 Removing and installing valve stem seals 5315
3 6 1 Removing and installing valve stem seals (cylinder head installed) 5315
3 6 2 Removing and installing valve stem seals (cylinder head removed) 5319
4 Inlet and exhaust valves 5323
4 1 Checking valve guides 5323
17 – Lubrication 5324
1 Sump, oil pump 5324
1 1 Assembly overview – sump/oil pump 5324
1 2 Engine oil: 5327
1 3 Removing and installing sump 5328
1 4 Removing and installing oil pump 5331
1 5 Removing and installing oil level and oil temperature sender -G266- 5333
2 Crankcase ventilation 5334
2 1 Assembly overview – crankcase breather system 5334
2 2 Removing and installing oil separator 5335
3 Oil filter, oil pressure switch 5338
3 1 Removing and installing oil pressure switch -F1- 5338
3 2 Checking oil pressure and oil pressure switch 5339
3 3 Removing and installing oil filter housing 5340
19 – Cooling 5342
1 Cooling system/coolant 5342
1 1 Connection diagram – coolant hoses 5342
1 1 1 Connection diagram – coolant hoses, Polo 2014, Ameo 5342
1 1 2 Connection diagram – coolant hoses, Polo 2018 5343
1 2 Checking cooling system for leaks 5343
1 3 Draining and adding coolant 5346
1 3 1 Draining coolant, Polo 2014, Ameo 5346
1 3 2 Filling coolant, Polo 2014, Ameo 5348
1 3 3 Draining and filling coolant, Polo 2018 5353
2 Coolant pump, regulation of cooling system 5360
2 1 Assembly overview – coolant pump 5360
2 2 Assembly overview – thermostat 5362
2 3 Removing and installing coolant pump 5364
2 4 Removing and installing thermostat 5368
2 4 1 Removing and installing thermostat (small circuit) 5368
2 4 2 Removing and installing thermostat (extended circuit) 5371
2 5 Removing and installing toothed belt for coolant pump 5374
2 6 Removing and installing toothed belt pulley for coolant pump 5377
2 7 Removing and installing coolant temperature sender -G62- 5378
3 Coolant pipes 5380
3 1 Assembly overview – coolant pipes 5380
3 1 1 Assembly overview – coolant pipes, Polo 2014, Ameo 5380
3 1 2 Assembly overview – coolant pipes, Polo 2018 5381
3 2 Removing and installing coolant pipes 5381
4 Radiator, radiator fan 5383
4 1 Assembly overview – radiator/radiator fan 5383
4 1 1 Assembly overview – radiator/radiator fan, Polo 2014, Ameo 5383
4 1 2 Assembly overview – radiator/radiator fan, Polo 2018 5385
4 2 Assembly overview – radiator cowl and radiator fan 5386
4 2 1 Assembly overview – radiator cowl and radiator fan, Polo 2014, Ameo 5386
4 2 2 Assembly overview – radiator cowl and radiator fan, Polo 2018 5387
4 3 Removing and installing radiator 5388
4 3 1 Removing and installing radiator, Polo 2014, Ameo 5388
4 3 2 Removing and installing radiator, Polo 2018 5391
4 4 Removing and installing radiator cowl with radiator fan 5396
4 4 1 Removing and installing radiator cowl with radiator fan, Polo 2014, Ameo 5396
4 4 2 Removing and installing radiator cowl with radiator fan, Polo 2018 5397
4 5 Removing and installing radiator fan -V7- 5398
4 5 1 Removing and installing radiator fan -V7-, Polo 2014, Ameo 5398
4 5 2 Removing and installing radiator fan -V7-, Polo 2018 5399
24 – Mixture preparation – injection 5400
1 Injection system 5400
1 1 Overview of fitting locations – injection system 5400
1 1 1 Overview of fitting locations – injection system, Polo 2014, Ameo 5400
1 1 2 Overview of fitting locations – injection system, Polo 2018 5403
1 2 Assembly overview – fuel system 5407
2 Injectors 5409
2 1 Assembly overview – fuel rail with injectors 5409
2 2 Removing and installing injectors 5409
2 3 Checking injectors 5411
2 4 Cleaning injectors 5416
3 Air filter 5418
3 1 Assembly overview – air filter housing 5418
3 1 1 Assembly overview – air filter housing, Polo 2014 5418
3 1 2 Assembly overview – air filter housing, Polo 2018, Ameo 5419
3 2 Removing and installing air filter housing 5421
3 2 1 Removing and installing air filter housing, Polo 2014 5421
3 2 2 Removing and installing air filter housing, Polo 2018, Ameo 5422
4 Intake manifold 5423
4 1 Assembly overview – intake manifold 5423
4 2 Removing and installing intake manifold 5424
4 3 Removing and installing throttle valve module -GX3- 5426
4 4 Cleaning throttle valve module -GX3- 5428
5 Senders and sensors 5429
5 1 Removing and installing intake manifold sender -GX9- 5429
6 Engine control unit 5431
6 1 Assembly overview – engine control unit 5431
6 2 Removing and installing engine (motor) control unit -J623- 5432
6 2 1 Removing and installing engine/motor control unit -J623-, Polo 2014, Ameo 5432
6 2 2 Removing and installing engine control unit -J623-, Polo 2018 5433
6 3 Removing and installing engine (motor) control unit -J623- with protective housing 5434
6 3 1 Removing and installing engine/motor control unit -J623- with protective housing, Polo 2014, Ameo 5434
6 3 2 Removing and installing engine control unit -J623- with protective housing, Polo 2018 5435
7 Lambda probe 5439
7 1 Assembly overview – Lambda probe 5439
7 2 Removing and installing Lambda probe 5440
7 2 1 Removing and installing lambda probe 1 before catalytic converter -GX10-, Polo 2014, Ameo 5440
7 2 2 Removing and installing lambda probe 1 after catalytic converter -GX7-, Polo 2014, Ameo 5442
7 2 3 Removing and installing lambda probe 1 before catalytic converter -GX10-, Polo 2018 5443
7 2 4 Removing and installing lambda probe 1 after catalytic converter -GX7-, Polo 2018 5445
26 – Exhaust system 5447
1 Exhaust pipes and silencers 5447
1 1 Assembly overview – silencers 5447
1 1 1 Assembly overview – silencers, Polo 2014, Ameo 5447
1 1 2 Assembly overview – silencer, Polo 2018 5449
1 2 Separating exhaust pipes from silencers 5450
1 3 Removing and installing silencer 5451
1 3 1 Removing and installing front silencer 5451
1 3 2 Removing and installing rear silencer 5452
1 4 Aligning exhaust system free of stress 5454
1 5 Checking exhaust system for leaks 5454
1 6 Installation position of clamp 5455
1 6 1 Installation position of clamp, Polo 2014, Ameo 5455
1 6 2 Installation position of clamp, Polo 2018 5456
2 Emission control 5457
2 1 Assembly overview – emission control 5457
2 1 1 Assembly overview – emission control, Polo 2014, Ameo 5457
2 1 2 Assembly overview – emission control, Polo 2018 5459
2 2 Removing and installing catalytic converter 5460
2 2 1 Removing and installing catalytic converter, Polo 2014, Ameo 5460
2 2 2 Removing and installing catalytic converter, Polo 2018 5463
28 – Ignition system 5466
1 Ignition system 5466
1 1 Assembly overview – ignition system 5466
1 2 Removing and installing ignition coils with output stage 5468
1 3 Removing and installing knock sensor 1 -G61- 5470
1 4 Removing and installing Hall sender -G40- 5471
1 5 Removing and installing engine speed sender -G28- 5472
1 5 1 Removing and installing engine speed sender -G28-, Polo 2014, Ameo 5472
1 5 2 Removing and installing engine speed sender -G28-, Polo 2018 5475
D4B8042C9AB 4 cylinder injection engine (1 6 l engine 4 V EA 211) 5478
00 – Technical data 5484
1 Safety information 5484
1 1 Safety regulations for working on fuel supply 5484
1 2 Safety measures when working on vehicles with a start/stop system 5484
1 3 Safety precautions for when using test instruments and measuring equipment during a road test 5485
1 4 Safety precautions when working on ignition system 5485
1 5 Safety precautions when working on exhaust system 5485
1 6 Safety precautions when working on the cooling system 5486
2 Identification 5487
2 1 Engine number/engine data 5487
3 Repair instructions 5489
3 1 Rules for cleanliness 5489
3 2 General information 5489
3 3 General repair notes 5489
3 4 Foreign bodies in engine 5490
3 5 Contact corrosion 5490
3 6 Routing and attachment of lines 5490
3 7 Fitting radiator and condensers 5490
3 8 Checking vacuum system 5490
10 – Removing and installing engine 5492
1 Removing and installing engine 5492
1 1 Removing engine 5492
1 1 1 Removing engine, Golf 2013>, Golf SV 2015>, Golf Estate 2014>, Golf 2017>, Polo 2018>, Polo 2022>, Golf 2020>, Taigun 2022>, Virtus 2022> 5492
1 1 2 Removing engine, Polo 2014>, Polo Saloon RUS 2016> 5506
1 1 3 Removing engine, Polo Saloon RUS 2020 5518
1 2 Separating engine and gearbox 5529
1 2 1 Separating engine and gearbox, vehicles with manual gearbox 5529
1 2 2 Separating engine and gearbox, vehicles with automatic gearbox 5531
1 3 Securing engine on engine and gearbox support 5533
1 4 Installing engine 5535
1 4 1 Installing engine, Golf 2013>, Golf SV 2015>, Golf Estate 2014>, Golf 2017>, Polo 2018>, Polo 2022>, Golf 2020>, Taigun 2022>, Virtus 2022> 5535
1 4 2 Installing engine, Polo 2014>, Polo Saloon RUS 2016> 5539
1 4 3 Installing engine, Polo Saloon RUS 2020> 5541
2 Assembly mountings 5546
2 1 Assembly overview – assembly mountings 5546
2 1 1 Assembly overview – assembly mountings, Golf 2013>, Golf Estate 2014>, Golf SV 2015>, Polo 2018>, Polo 2022>, Golf 2017>, Golf 2020>, Taigun 2022>, Virtus 2022> 5546
2 1 2 Assembly overview – assembly mountings, Polo 2014>, Polo Saloon RUS 2016>, manual gearbox 5548
2 1 3 Assembly overview – assembly mountings, Polo 2014>, Polo Saloon RUS 2016>, automatic gearbox 5551
2 1 4 Assembly overview – assembly mountings, Polo Saloon RUS 2020> 5554
2 2 Supporting engine in installation position 5558
2 2 1 Supporting engine in installation position, Golf 2013>, Golf Estate 2014>, Golf SV 2015>, Golf 2017>, Polo 2018>, Polo 2022>, Golf 2020>, Virtus 2022> 5558
2 2 2 Supporting engine in installation position, Polo 2014>, Polo Saloon RUS 2016> 5564
2 2 3 Supporting engine in installation position, Polo Saloon RUS 2020> 5567
2 3 Removing and installing engine mounting 5569
2 3 1 Removing and installing engine mounting, Golf 2013>, Golf Estate 2014>, Golf SV 2015>, Golf 2017>, Polo 2018>, Polo 2022>, Golf 2020>, Taigun 2022>, Virtus 2022> 5569
2 3 2 Removing and installing engine mounting, Polo 2014>, Polo Saloon RUS 2016> 5571
2 3 3 Removing and installing engine mounting, Polo Saloon RUS 2020> 5573
2 4 Removing and installing gearbox mounting 5574
2 4 1 Removing and installing gearbox mounting, Golf 2013>, Golf Estate 2014>, Golf SV 2015>, Golf 2017>, Polo 2018>, Polo 2022>, Golf 2020>, Taigun 2022>, Virtus 2022> 5574
2 4 2 Removing and installing gearbox mounting, Polo 2014>, Polo Saloon RUS 2016> 5576
2 4 3 Removing and installing gearbox mounting, Polo Saloon RUS 2020> 5578
2 5 Removing and installing pendulum support 5579
2 5 1 Removing and installing pendulum support, Golf 2013>, Golf Estate 2014>, Golf SV 2015>, Golf 2017>, Polo 2018>, Polo 2022>, Golf 2020>, Taigun 2022>, Virtus 2022> 5579
2 5 2 Removing and installing pendulum support, manual gearbox, Polo 2014>, Polo Saloon RUS 2016> 5580
2 5 3 Removing and installing pendulum support, automatic gearbox, Polo 2014>, Polo Saloon RUS 2016> 5581
2 5 4 Removing and installing pendulum support, Polo Saloon RUS 2020> 5582
2 6 Checking adjustment of assembly mountings 5583
2 6 1 Checking adjustment of assembly mountings, Golf 2013>, Golf Estate 2014>, Golf SV 2015>, Golf 2017>, Polo 2018>, Polo 2022>, Golf 2020>, Virtus 2022> 5583
2 6 2 Checking adjustment of assembly mountings, Polo 2014>, Polo Saloon RUS 2016>, Polo Saloon RUS 2020> 5584
2 7 Adjusting assembly mountings 5585
2 7 1 Adjusting assembly mountings, Golf 2013>, Golf Estate 2014>, Golf SV 2015>, Golf 2017>, Polo 2018>, Polo 2022>, Golf 2020>, Taigun 2022>, Virtus 2022> 5585
2 7 2 Adjusting assembly mountings, Polo Saloon RUS 2020> 5588
13 – Crankshaft group 5591
1 Cylinder block (pulley end) 5591
1 1 Assembly overview – poly V-belt drive 5591
1 1 1 Assembly overview – poly V-belt drive, vehicles without air conditioner compressor, Golf 2013>, Golf Estate 2014>, Golf SV 2015>, Golf 2017>, Polo Saloon RUS 2020>, Golf 2020> 5591
1 1 2 Assembly overview – poly V-belt drive, vehicles without air conditioner compressor, Polo 2014, Polo Saloon RUS 2016>, Polo 2018>, Polo 2022> 5593
1 1 3 Assembly overview – poly V-belt drive, vehicles with air conditioner compressor, Golf 2013>, Golf Estate 2014>, Golf SV 2015>, Golf 2017>, Golf 2020>, Taigun 2022> 5595
1 1 4 Assembly overview – poly V-belt drive, vehicles with air conditioner compressor, Polo 2014>, Polo Saloon RUS 2016>, Polo 2018>, Polo 2022>, Polo Saloon RUS 2020>, Virtus 2022> 5597
1 2 Removing and installing poly-V belt 5598
1 2 1 Removing and installing poly-V belt, vehicles without air conditioner compressor, Golf 2013>, Golf Estate 2014>, Golf SV 2015>, Golf 2017>, Polo Saloon RUS 2020>, Golf 2020> 5598
1 2 2 Removing and installing poly V-belt, vehicles without air conditioner compressor, Polo 2014> Polo Saloon RUS 2016>, Polo 2018>, Polo 2022>, Polo Saloon RUS 2020> 5601
1 2 3 Removing and installing poly-V belt, vehicles with air conditioner compressor, Golf 2013>, Golf Estate 2014>, Golf SV 2015>, Golf 2017>, Golf 2020>, Taigun 2022> 5602
1 2 4 Removing and installing poly V-belt, vehicles with air conditioner compressor, Polo 2014> Polo Saloon RUS 2016>, Polo 2018>, Polo 2022>, Polo Saloon RUS 2020>, Virtus 2022> 5604
1 3 Removing and installing tensioner for poly V-belt 5605
1 3 1 Removing and installing tensioner for poly V-belt, vehicles without air conditioner compressor 5605
1 3 2 Removing and installing tensioner for poly V-belt, vehicles with air conditioner compressor 5606
1 4 Removing and installing vibration damper 5607
1 5 Removing and installing engine support 5609
1 5 1 Removing and installing engine support, Golf 2013>, Golf 2017>, Golf SV 2015>, Golf Estate 2014>, Polo 2014>, Polo 2018>, Polo 2022>, Polo Saloon RUS 2016>, Golf 2020>, Taigun 2022>, Virtus 2022> 5609
1 5 2 Removing and installing engine support, Polo Saloon RUS 2020> 5612
1 6 Renewing crankshaft oil seal – pulley end 5616
2 Cylinder block, gearbox end 5619
2 1 Assembly overview – cylinder block, gearbox end 5619
2 1 1 Assembly overview – cylinder block, gearbox end, vehicles with manual gearbox 5619
2 1 2 Assembly overview – cylinder block, gearbox end, vehicles with automatic gearbox 5621
2 2 Removing and installing flywheel 5623
2 3 Removing and installing drive plate 5625
2 4 Removing and installing sealing flange on gearbox side 5628
3 Crankshaft 5640
3 1 Measuring axial clearance of crankshaft 5640
4 Pistons and conrods 5642
4 1 Assembly overview – pistons and conrods 5642
4 2 Removing and installing pistons 5646
4 3 Checking pistons and cylinder bores 5647
4 4 Separating new conrod 5649
4 5 Checking radial clearance of conrods 5650
4 6 Removing and installing oil spray jets 5651
4 7 Setting piston to TDC position 5652
15 – Cylinder head, valve gear 5655
1 Cylinder head 5655
1 1 Assembly overview – cylinder head 5655
1 2 Assembly overview – camshaft housing 5657
1 3 Removing and installing cylinder head 5659
1 4 Removing and installing camshaft housing 5663
1 5 Checking compression 5666
2 Toothed belt drive 5669
2 1 Assembly overview – toothed belt cover 5669
2 2 Assembly overview – toothed belt 5669
2 3 Removing and installing toothed belt guard 5671
2 3 1 Removing and installing upper toothed belt guard 5671
2 3 2 Removing and installing lower toothed belt guard 5672
2 4 Removing and installing toothed belt 5672
2 5 Preassembling and installing valve timing tool 5678
2 5 1 Preassembling valve timing tool 5678
2 5 2 Installing test tool -VAS 611 007- 5682
2 5 3 Teaching in test tool -VAS 611 007- electronically and performing basic setting 5684
2 6 Checking valve timing 5687
2 7 Adjusting valve timing 5691
2 8 Removing toothed belt from camshaft 5702
3 Valve gear 5707
3 1 Assembly overview – valve gear 5707
3 1 1 Assembly overview – valves 5707
3 2 Removing and installing camshaft adjuster 5709
3 3 Removing and installing toothed belt pulley 5714
3 4 Measuring axial play of camshaft 5719
3 5 Removing and installing camshaft oil seal 5720
3 5 1 Removing and installing camshaft oil seal, inlet camshaft, pulley end 5720
3 5 2 Removing and installing camshaft oil seal, exhaust camshaft, pulley end 5722
3 5 3 Removing and installing camshaft oil seal, exhaust camshaft, gearbox end 5724
3 6 Removing and installing camshaft control valve 1 -N205- 5726
3 7 Removing and installing valve stem oil seals 5727
3 7 1 Removing and installing valve stem seals (cylinder head installed) 5727
3 7 2 Removing and installing valve stem seals (cylinder head removed) 5732
4 Inlet and exhaust valves 5737
4 1 Checking valve guides 5737
4 2 Checking valves 5738
4 3 Valve dimensions 5738
17 – Lubrication 5739
1 Sump, oil pump 5739
1 1 Assembly overview – sump/oil pump 5739
1 2 Removing and installing lower part of sump 5742
1 3 Removing and installing oil pump 5748
1 4 Removing and installing upper part of sump 5750
1 5 Engine oil: 5755
2 Engine oil cooler 5756
2 1 Assembly overview – engine oil cooler 5756
2 2 Removing and installing engine oil cooler 5756
3 Crankcase ventilation 5758
3 1 Assembly overview – crankcase breather system 5758
3 2 Removing and installing oil separator 5759
4 Oil filter, oil pressure switch 5762
4 1 Assembly overview – oil filter/oil pressure switch 5762
4 2 Removing and installing oil pressure switch -F1- 5762
4 3 Checking oil pressure 5764
4 4 Removing and installing oil filter housing 5765
19 – Cooling 5767
1 Cooling system/coolant 5767
1 1 Connection diagram – coolant hoses 5767
1 1 1 Connection diagram – coolant hoses 5767
1 1 2 Connection diagram – coolant hoses 5769
1 2 Draining and adding coolant 5770
1 3 Checking cooling system for leaks 5779
2 Coolant pump, regulation of cooling system 5783
2 1 Assembly overview – coolant pump, thermostat 5783
2 2 Assembly overview – coolant temperature sender 5786
2 3 Removing and installing coolant pump 5787
2 4 Removing and installing toothed belt pulley for coolant pump 5791
2 5 Removing and installing thermostat 5792
2 5 1 Removing and installing thermostat for main coolant circuit (radiator) 5792
2 5 2 Removing and installing thermostat for cylinder block coolant circuit 5795
2 6 Removing and installing coolant temperature sender -G62- 5796
2 7 Removing and installing radiator outlet coolant temperature sender -G83- 5797
3 Coolant pipes 5799
3 1 Assembly overview – coolant pipes 5799
3 2 Removing and installing coolant pipes 5799
4 Radiator, radiator fan 5802
4 1 Assembly overview – radiator/radiator fan 5802
4 1 1 Assembly overview – radiator/radiator fan Golf 2013>, Golf 2017>, Golf SV 2015>, Golf Estate 2014>, Polo 2014>, Polo 2018>, Polo 2022>, Polo Saloon RUS 2016>, Taigun 2022>, Virtus 2022> 5802
4 1 2 Assembly overview – radiator/radiator fan, Polo Saloon RUS 2020> 5804
4 1 3 Assembly overview – radiator/radiator fan, Golf 2020> 5805
4 2 Assembly overview – radiator cowl and radiator fan 5806
4 2 1 Assembly overview – radiator cowl and radiator fan, Golf 2013>, Golf 2017>, Golf SV 2015>, Golf Estate 2014>, Polo 2014>, Polo 2018>, Polo 2022>, Polo Saloon RUS 2016>, Golf 2020>, Taigun 2022>, Virtus 2022> 5806
4 2 2 Assembly overview – radiator cowl and radiator fan, Polo Saloon RUS 2020> 5807
4 3 Removing and installing radiator 5808
4 3 1 Removing and installing radiator, Polo 2014>, Polo Saloon RUS 2016> 5808
4 3 2 Removing and installing radiator, Golf 2013>, Golf Estate 2014>, Golf SV 2015>, Golf 2017>, Polo 2018>, Polo 2022>, Golf 2020>, Taigun 2022>, Virtus 2022> 5811
4 3 3 Removing and installing radiator, Polo Saloon RUS 2020> 5818
4 4 Removing and installing radiator cowl 5821
4 4 1 Removing and installing radiator cowl, Golf 2013>, Golf 2017>, Golf SV 2015>, Golf Estate 2014>, Polo 2014>, Polo 2018>, Polo 2022>, Polo Saloon RUS 2016>, Golf 2020>, Taigun 2022>, Virtus 2022> 5821
4 4 2 Removing and installing radiator cowl, Polo Saloon RUS 2020> 5822
4 5 Removing and installing radiator fan -V7- 5823
4 5 1 Removing and installing radiator fan -V7-, Golf 2013>, Golf 2017>, Golf SV 2015>, Golf Estate 2014>, Polo 2014>, Polo 2018>, Polo 2022>, Polo Saloon RUS 2016>, Golf 2020>, Taigun 2022>, Virtus 2022> 5824
4 5 2 Removing and installing radiator fan -V7-, Polo Saloon RUS 2020> 5824
24 – Mixture preparation – injection 5827
1 Injection system 5827
1 1 Overview of fitting locations – injection system 5827
1 2 Assembly overview – fuel system 5833
2 Injectors 5836
2 1 Assembly overview – fuel rail with injectors 5836
2 2 Removing and installing fuel rail 5836
2 3 Removing and installing injectors 5839
2 4 Checking injectors 5840
2 5 Cleaning injectors 5844
3 Air filter 5846
3 1 Assembly overview – air filter housing 5846
3 2 Removing and installing air filter housing 5848
4 Intake manifold 5851
4 1 Assembly overview – intake manifold 5851
4 1 1 Assembly overview – intake manifold, Golf 2013>, Golf 2017>, Golf SV 2015>, Golf Estate 2014>, Polo 2014>, Polo 2018>, Polo 2022>, Polo Saloon RUS 2016>, Golf 2020> 5851
4 1 2 Assembly overview – intake manifold Polo Saloon RUS 2020>, Taigun 2022>, Virtus 2022> 5853
4 2 Removing and installing intake manifold 5855
4 3 Removing and installing throttle valve module -GX3- 5858
4 4 Cleaning throttle valve module -GX3- 5858
5 Senders and sensors 5860
5 1 Removing and installing intake manifold sender -GX9- 5860
6 Engine/motor control unit 5861
6 1 Removing and installing engine control unit -J623- 5861
6 1 1 Removing and installing engine control unit -J623-, engine control unit with metal locking plate, Golf 2013>, Golf Estate 2014>, Golf SV 2015>, Golf 2017>; 2018>, Polo 2018>, Polo 2022>, Golf 2020>, Virtus 2022> 5861
6 1 2 Removing and installing engine control unit -J623-, engine control unit with protective housing, Golf 2013>, Golf Estate 2014>, Golf SV 2015>, Golf 2017>, Polo 2018>, Polo 2022>, Taigun 2022> 5864
6 1 3 Removing and installing engine control unit -J623-, engine control unit with protective housing, Polo 2014>, Polo Saloon RUS 2016> 5868
6 1 4 Removing and installing engine control unit -J623-, without protective housing, Polo 2014> Polo Saloon RUS 2016> 5870
6 1 5 Removing and installing engine control unit -J623- without protective housing, Polo Saloon RUS 2020> 5871
7 Lambda probe 5873
7 1 Assembly overview – Lambda probe 5873
7 2 Removing and installing lambda probe 5874
7 2 1 Removing and installing lambda probe 1 before catalytic converter -GX10-/lambda probe 1 after catalytic converter -GX7- 5874
26 – Exhaust system 5877
1 Exhaust pipes and silencers 5877
1 1 Assembly overview – silencers 5877
1 1 1 Assembly overview – silencers, Golf 2013>, Golf SV 2015>, Golf 2017>, Golf 2020> 5877
1 1 2 Assembly overview – silencers, Golf Estate 2014> 5880
1 1 3 Assembly overview – silencers, Polo 2014>, Polo Saloon RUS 2016>, Polo 2018>, Polo 2022> 5883
1 1 4 Assembly overview – silencer, Polo Saloon RUS 2020>, Taigun 2022>, Virtus 2022> 5885
1 2 Separating exhaust pipes from silencers 5887
1 2 1 Separating exhaust pipes from silencers, Polo 2014>, Polo Saloon RUS 2016>, Golf 2013>, Golf SV 2015>, Golf 2017, Polo Saloon RUS 2020>, Golf 2020>, Taigun 2022>, Virtus 2022> 5887
1 2 2 Separating exhaust pipes from silencers, Golf Estate 2014, Polo 2018, Polo 2022> 5888
1 3 Removing and installing silencer 5889
1 3 1 Removing and installing front silencer, Golf 2013>, Golf Estate 2014>, Golf SV 2015>, Golf 2017>, Golf 2020> 5889
1 3 2 Removing and installing rear silencer, Golf 2013>, Golf 2017>, Golf SV 2015>, Golf 2020> 5890
1 3 3 Removing and installing rear silencer, Golf Estate 2014 5892
1 3 4 Removing and installing silencers, Polo 2014>, Polo Saloon 2016>, Polo 2018>, Polo 2022> 5893
1 3 5 Removing and installing silencer, Polo Saloon RUS 2020>, Taigun 2022>, Virtus 2022> 5895
1 4 Aligning exhaust system free of stress 5896
1 4 1 Aligning exhaust system free of stress 5896
1 4 2 Align end exhaust pipes 5896
1 5 Checking exhaust system for leaks 5897
2 Emission control 5898
2 1 Assembly overview – emission control 5898
2 1 1 Assembly overview – emission control, Golf 2013>, Golf 2017>, Golf SV 2015>, Golf Estate 2014, Golf 2020>, Taigun 2022>, Virtus 2022> 5898
2 1 2 Assembly overview – emission control, Polo 2014>, Polo Saloon RUS 2016>, Polo 2018>, Polo 2022>, Polo Saloon RUS 2020> 5900
2 2 Removing and installing catalytic converter 5902
28 – Ignition system 5906
1 Ignition system 5906
1 1 Assembly overview – ignition system 5906
1 2 Removing and installing ignition coils with output stage 5908
1 3 Removing and installing knock sensor 1 -G61- 5910
1 4 Removing and installing Hall sender 5912
1 5 Removing and installing engine speed sender -G28- 5912
D4B8071B7F9 4 cylinder direct injection engine (1 5 l engine 4V EA 211 turbocharger) 5915
00 – Technical data 5921
1 Safety information 5921
1 1 Safety regulations for working on fuel supply 5921
1 2 Safety measures when working on vehicles with a start/stop system 5921
1 3 Safety precautions when using testers and measuring instruments during a road test 5922
1 4 Safety precautions when working on the cooling system 5922
1 5 Safety precautions when working on ignition system 5922
2 Identification 5923
2 1 Engine number/engine data 5923
3 Repair instructions 5927
3 1 Rules for cleanliness 5927
3 2 General information 5927
3 3 General repair instructions 5928
3 4 Foreign objects in engine 5928
3 5 Contact corrosion 5928
3 6 Routing and attachment of lines 5928
3 7 Fitting radiator and condensers 5928
3 8 Checking vacuum system 5928
10 – Removing and installing engine 5930
1 Removing and installing engine 5930
1 1 Removing engine 5930
1 2 Separating engine and gearbox 5940
1 3 Securing engine on engine and gearbox support 5943
1 4 Installing engine 5944
2 Assembly mountings 5949
2 1 Assembly overview – assembly mountings 5949
2 1 1 Assembly overview – assembly mountings (without belt-driven starter-alternator) 5949
2 1 2 Assembly overview – assembly mountings (without belt-driven starter-alternator) 5952
2 1 3 Assembly overview – assembly mountings (without belt-driven starter-alternator) 5955
2 1 4 Assembly overview – assembly mountings (with belt-driven starter-alternator) 5958
2 2 Removing and installing engine mounting 5961
2 3 Removing and installing gearbox mounting 5962
2 4 Removing and installing pendulum support 5964
2 5 Supporting engine in installation position 5965
2 5 1 Supporting engine in installation position, Golf, Golf Estate and Golf SV 5965
2 5 2 Supporting engine in installation position, Arteon, Passat, Passat Estate, Arteon Shooting Brake 5972
2 5 3 Supporting engine in installation position, T-Roc and T-Roc Cabriolet 5978
2 5 4 Supporting engine in installation position, Touran and Tiguan 5985
2 5 5 Supporting engine in installation position, Polo 5990
2 5 6 Supporting engine in installation position, T-Cross 5994
2 6 Adjusting assembly mountings 5998
2 7 Checking adjustment of assembly mountings 6000
3 Engine cover panel 6002
3 1 Removing and installing engine cover 6002
13 – Crankshaft group 6003
1 Cylinder block (pulley end) 6003
1 1 Assembly overview – poly V-belt drive 6003
1 1 1 Assembly overview – poly V-belt drive, vehicles without air conditioner compressor 6003
1 1 2 Assembly overview – poly V-belt drive, vehicles with air conditioner compressor 6005
1 1 3 Assembly overview – poly V-belt drive, vehicles with air conditioner compressor and starter-alternator 6007
1 2 Removing and installing poly-V belt 6009
1 2 1 Removing and installing poly V-belt, vehicles without air conditioner compressor 6009
1 2 2 Removing and installing poly V-belt, vehicles with air conditioner compressor 6011
1 2 3 Removing and installing poly V-belt, vehicles with air conditioner compressor and starter-alternator 6013
1 3 Removing and installing tensioner for poly V-belt 6014
1 3 1 Removing and installing tensioner for poly V-belt, vehicles without air conditioner compressor 6014
1 3 2 Removing and installing tensioner for poly V-belt, vehicles with air conditioner compressor 6015
1 3 3 Removing and installing poly V-belt tensioner, vehicles with air conditioner compressor and starter-alternator 6016
1 4 Removing and installing vibration damper 6016
1 5 Removing and installing engine support 6019
1 6 Renewing crankshaft oil seal – belt pulley end 6021
2 Cylinder block, gearbox end 6025
2 1 Assembly overview – cylinder block, gearbox end 6025
2 2 Removing and installing flywheel 6028
2 2 1 Removing and installing flywheel 6028
2 2 2 Preloading teeth in flywheel – vehicles with dual clutch gearbox 6030
2 3 Removing and installing sealing flange on gearbox side 6030
3 Crankshaft 6043
3 1 Renewing needle bearing in crankshaft 6043
3 2 Crankshaft dimensions 6045
3 3 Measuring axial clearance of crankshaft 6045
4 Pistons and conrods 6047
4 1 Assembly overview – pistons and conrods 6047
4 2 Removing and installing pistons 6049
4 3 Checking pistons and cylinder bores 6051
4 4 Separating new conrod 6053
4 5 Checking radial clearance of conrods 6053
4 6 Removing and installing oil spray jets 6054
4 7 Setting piston to TDC position 6055
15 – Cylinder head, valve gear 6058
1 Cylinder head 6058
1 1 Assembly overview – cylinder head 6058
1 2 Assembly overview – camshaft housing 6060
1 3 Removing and installing cylinder head 6063
1 4 Removing and installing camshaft housing 6067
1 5 Checking compression 6073
2 Toothed belt drive 6076
2 1 Assembly overview – toothed belt cover 6076
2 2 Assembly overview – toothed belt 6077
2 3 Assembly overview – valve timing tool 6080
2 4 Removing and installing toothed belt guard 6080
2 4 1 Removing and installing upper toothed belt guard 6080
2 4 2 Removing and installing lower toothed belt guard 6081
2 5 Removing and installing toothed belt 6081
2 6 Preassembling and installing valve timing tool 6088
2 6 1 Preassembling valve timing tool 6088
2 6 2 Installing test tool -VAS 611 007- 6091
2 6 3 Teaching in test tool -VAS 611 007- electronically and performing basic setting 6095
2 7 Checking valve timing 6098
2 8 Adjusting valve timing 6101
2 9 Removing toothed belt from camshaft 6112
3 Valve gear 6117
3 1 Assembly overview – valve gear 6117
3 2 Removing and installing camshaft oil seal 6120
3 2 1 Removing and installing camshaft oil seal for holder of inlet camshaft control valve 1 -N727- 6120
3 2 2 Removing and installing camshaft oil seal for inlet camshaft, belt pulley end 6123
3 2 3 Removing and installing exhaust camshaft oil seal, pulley end 6127
3 2 4 Removing and installing exhaust camshaft oil seal, gearbox end 6129
3 3 Removing and installing camshaft adjuster 6132
3 3 1 Removing and installing camshaft adjuster, inlet side 6132
3 3 2 Removing and installing camshaft adjuster, exhaust side 6138
3 4 Removing and installing cam actuators 6144
3 5 Removing and installing inlet camshaft control valve 1 -N727- 6146
3 6 Removing and installing exhaust camshaft control valve 1 -N318- 6147
3 7 Removing and installing valve stem seals 6148
3 7 1 Removing and installing valve stem seals (cylinder head installed) 6148
3 7 2 Removing and installing valve stem seals (cylinder head removed) 6156
3 8 Removing and installing holder for oil seal 6163
4 Inlet and exhaust valves 6167
4 1 Checking valve guides 6167
4 2 Checking valves 6168
4 3 Valve dimensions 6168
17 – Lubrication 6169
1 Sump, oil pump 6169
1 1 Assembly overview – sump/oil pump 6169
1 2 Engine oil: 6174
1 3 Removing and installing sump 6174
1 4 Removing and installing oil pump 6179
1 5 Removing and installing oil level and oil temperature sender -G266- 6182
2 Engine oil cooler 6183
2 1 Assembly overview – engine oil cooler 6183
2 2 Removing and installing engine oil cooler 6183
3 Crankcase ventilation 6185
3 1 Assembly overview – crankcase breather system 6185
3 2 Removing and installing oil separator 6187
3 2 1 Removing and installing lower oil separator 6187
3 2 2 Removing and installing upper oil separator 6189
4 Oil filter, oil pressure switch 6191
4 1 Assembly overview – oil pressure switches/oil pressure control 6191
4 2 Removing and installing oil pressure sender -G10- 6191
4 3 Checking oil pressure and oil pressure switch 6193
4 4 Removing and installing oil filter housing 6193
4 5 Removing and installing oil pressure regulating valve -N428- 6194
19 – Cooling 6196
1 Cooling system/coolant 6196
1 1 Connection diagram – coolant hoses 6196
1 2 Checking cooling system for leaks 6198
1 3 Draining and adding coolant 6202
1 4 Flushing cooling system 6210
2 Coolant pump, regulation of cooling system 6225
2 1 Assembly overview – coolant pump, thermostat 6225
2 2 Assembly overview – electric coolant pump 6227
2 3 Assembly overview – coolant temperature sender 6227
2 4 Removing and installing electric coolant pump 6228
2 5 Removing and installing coolant pump 6231
2 6 Removing and installing toothed belt pulley for coolant pump 6236
2 7 Removing and installing coolant temperature sender -G62- 6240
2 8 Removing and installing radiator outlet coolant temperature sender -G83- 6242
2 9 Removing and installing engine outlet coolant temperature sender -G82- 6244
2 10 Removing and installing engine temperature regulation module -GX33- 6246
2 11 Checking coolant pump 6250
3 Coolant pipes 6256
3 1 Assembly overview – coolant pipes 6256
3 2 Removing and installing coolant pipes 6258
3 2 1 Removing and installing lower left coolant pipe 6258
3 2 2 Removing and installing upper left coolant pipe 6260
3 2 3 Removing and installing upper front coolant pipe 6263
3 2 4 Removing and installing lower front coolant pipe 6265
4 Radiator, radiator fan 6267
4 1 Assembly overview – radiator/radiator fan 6267
4 2 Assembly overview – radiator cowl and radiator fan 6269
4 2 1 Assembly overview – radiator cowl with one radiator fan 6269
4 2 2 Assembly overview – radiator cowl with 2 radiator fans 6270
4 3 Assembly overview – radiator blind 6271
4 3 1 Assembly overview – radiator blind 6271
4 3 2 Assembly overview – components of radiator blind 6273
4 4 Removing and installing radiator 6274
4 5 Removing and installing water radiator for charge air cooling circuit 6277
4 6 Removing and installing radiator cowl 6282
4 7 Removing and installing radiator fan 6283
4 7 1 Removing and installing radiator fan, vehicles with one radiator fan 6283
4 7 2 Removing and installing radiator fan, vehicles with two radiator fans 6284
4 8 Removing and installing radiator blind 6285
4 9 Removing and installing radiator blind control motor -V544- 6287
21 – Turbocharging/supercharging 6293
1 Turbocharger 6293
1 1 Assembly overview – turbocharger 6293
1 1 1 Assembly overview – turbocharger, wastegate turbocharger 6293
1 1 2 Assembly overview – turbocharger (variable turbocharger geometry) 6295
1 1 3 Assembly overview – lines on turbocharger 6297
1 2 Removing and installing turbocharger 6299
1 3 Removing and installing connection for turbocharger 6304
1 4 Removing and installing charge pressure control module -GX34- 6306
1 4 1 Removing and installing charge pressure control module -GX34-, wastegate turbocharger 6306
1 4 2 Removing and installing charge pressure control module -GX34-, variable turbocharger geometry 6309
2 Charge air system 6311
2 1 Assembly overview – charge air system 6311
2 2 Removing and installing charge air cooler 6314
2 3 Removing and installing charge pressure sender -GX26- 6317
2 4 Checking charge air system for leaks 6318
2 5 Removing and installing air pipe 6322
2 5 1 Removing and installing air intake pipe between charge air cooler and turbocharger 6322
2 5 2 Removing and installing air intake pipe between charge air cooler and intake manifold 6325
2 6 Checking charge air cooler for leaks 6329
24 – Mixture preparation – injection 6335
1 Injection system 6335
1 1 Overview of fitting locations – injection system 6335
2 Air filter 6345
2 1 Assembly overview – air filter housing 6345
2 2 Removing and installing air filter housing 6347
2 3 Removing and installing air guide on lock carrier 6349
2 3 1 Removing and installing air guide on lock carrier, Golf, Golf Estate, Golf SV, Tiguan, Touran; Arteon, Passat, Passat Estate, Arteon Shooting Brake 6349
2 3 2 Removing air duct on lock carrier, T-Roc and T-Roc Cabriolet 6351
2 3 3 Removing and installing air guide on lock carrier, Polo and T-Cross 6352
3 Intake manifold 6353
3 1 Assembly overview – intake manifold 6353
3 2 Removing and installing intake manifold 6356
3 3 Removing and installing throttle valve module -GX3- 6362
3 4 Cleaning throttle valve module -GX3- 6364
4 Injectors 6366
4 1 Assembly overview – fuel rail with injectors 6366
4 2 Removing and installing fuel rail 6368
4 3 Removing and installing injectors 6369
4 4 Cleaning injectors 6377
5 Senders and sensors 6379
5 1 Removing and installing intake manifold sender -GX9- 6379
5 2 Removing and installing fuel pressure sender -G247- 6380
5 3 Checking fuel pressure sender -G247- 6382
5 3 1 Checking fuel pressure sender -G247-, using pressure sensor tester -VAS 6394- and vehicle diagnostic tester 6382
5 3 2 Checking fuel pressure sender -G247-, using vehicle diagnostic tester 6384
5 4 Removing and installing exhaust gas pressure sensor 1 -G450- 6386
5 5 Removing and installing air mass measurement module -GX35- 6387
6 High-pressure pump 6389
6 1 Assembly overview – high-pressure pump 6389
6 2 Removing and installing high-pressure pump 6390
6 3 Removing and installing high-pressure pipe 6392
7 Lambda probe 6394
7 1 Assembly overview – Lambda probe 6394
7 2 Removing and installing Lambda probe 6395
8 Engine control unit 6397
8 1 Removing and installing engine control unit -J623- 6397
8 1 1 Removing and installing engine control unit -J623- 6397
8 1 2 Removing and installing engine control unit -J623- (with metal locking plate) 6398
8 1 3 Removing and installing engine control unit -J623- (with protective housing) 6401
26 – Exhaust system 6405
1 Exhaust pipes and silencers 6405
1 1 Assembly overview – silencers 6405
1 1 1 –Assembly overview – silencers, Golf, Golf Estate, Golf SV and T-Roc Cabriolet 6405
1 1 2 Assembly overview – silencer, Arteon, Passat; Passat Estate, Arteon Shooting Brake 6407
1 1 3 Assembly overview – silencers, T-Roc with all-wheel drive 6409
1 1 4 Assembly overview – silencers, T-Roc with front-wheel drive 6411
1 1 5 Assembly overview – silencers, Touran 6413
1 1 6 Assembly overview – silencers, Tiguan 6415
1 1 7 Assembly overview – silencers, Polo, T-Cross 6417
1 1 8 Assembly overview silencers, Golf Estate 6419
1 2 Removing and installing silencer 6421
1 2 1 Removing and installing silencer, Golf, Golf Estate, Golf SV and T-Roc Cabriolet 6421
1 2 2 Removing and installing silencer, Arteon Passat, Passat Estate, Arteon Shooting Brake 6423
1 2 3 Removing and installing silencers, T-Roc with all-wheel drive 6425
1 2 4 Removing and installing silencers, T-Roc with front-wheel drive 6426
1 2 5 Removing and installing silencer, Touran 6428
1 2 6 Removing and installing silencer, Tiguan 6430
1 2 7 Removing and installing silencer, Polo, T-Cross 6433
1 2 8 Removing and installing silencer, Golf Estate 6435
1 3 Separating exhaust pipes from silencers 6436
1 4 Aligning exhaust system free of stress 6438
1 5 Checking exhaust system for leaks 6438
1 6 Installation position of clamp 6439
1 7 Assembly overview – front exhaust pipe 6440
1 7 1 Assembly overview – mounting for front exhaust pipe 6440
1 8 Removing and installing bracket for front exhaust pipe 6441
2 Emission control 6443
2 1 Assembly overview – emission control 6443
2 2 Removing and installing catalytic converter 6446
2 3 Removing and installing particulate filter 6451
2 4 Removing and installing exhaust flap control unit -J883- 6452
28 – Ignition system 6453
1 Ignition system 6453
1 1 Assembly overview – ignition system 6453
1 2 Removing and installing ignition coils with output stage 6455
1 3 Removing and installing knock sensor 1 -G61- 6459
1 4 Removing and installing engine speed sender -G28- 6460
1 5 Removing and installing inlet camshaft position sender -G1002- 6462
1 6 Removing and installing exhaust camshaft position sender -G1003- 6463
D4B8076AE27 Vehicle specific paint information 6465
54 – Vehicle-specific paint information 6469
1 Explanation of symbols 6469
1 1 Sanding 6469
1 2 Seam sealing 6469
1 3 Cavity sealing 6472
2 Areas of body exposed to stone chipping 6473
2 1 Areas of body exposed to stone chipping – general overview 6473
3 Masked sectors 6474
3 1 Masking areas, front of body 6474
3 2 Masking areas, rear of body 6475
4 Seam sealing 6478
4 1 Seam seals, front body 6478
4 2 Seam seals, centre body 6483
4 3 Seam seals, rear body 6485
5 Underseal 6489
5 1 Underseal, body – overview with differing layer thickness 6489
5 2 Underseal, protected areas 6490
6 Cavity sealing 6494
6 1 Cavity sealing, body – overview 6494
6 2 Cavity sealing, rear body 6495
6 3 Cavity sealing, doors 6495
D4B8076AE94 Brake system 6497
00 – Technical data 6501
1 Safety and repair instructions 6501
1 1 Safety information 6501
1 2 Repair instructions 6501
2 Brake test 6502
2 1 General notes 6502
2 2 Checking vehicles with front-wheel drive 6502
3 Electrical components 6503
3 1 Access to diagnoses 6503
4 Technical data 6505
4 1 Technical data for brakes 6505
4 1 1 Brake master cylinder and brake servo 6505
4 1 2 Front brakes 6505
4 1 3 Rear brakes 6506
45 – Anti-lock brake system 6508
1 Safety and repair instructions 6508
1 1 Safety information 6508
1 2 Repair instructions 6508
2 Overview of fitting locations 6509
2 1 Overview of fitting locations – ABS/ESP 6509
3 Control unit and hydraulic unit 6511
3 1 Assembly overview – control unit and hydraulic unit 6511
3 1 1 Assembly overview – control unit and hydraulic unit, right-hand drive vehicles 6511
3 1 2 Assembly overview – control unit and hydraulic unit, left-hand drive vehicles 6513
3 2 Removing and installing ABS control unit [J104]/ABS hydraulic unit [N55] 6516
3 2 1 Removing and installing ABS control unit [J104]/ABS hydraulic unit [N55], left-hand drive vehicles 6516
3 2 2 Removing and installing ABS control unit [J104]/ABS hydraulic unit [N55], right-hand drive vehicles 6521
3 3 Separating control unit from and connecting to hydraulic unit 6525
4 Sensors 6528
4 1 Assembly overview – speed sensor on front axle 6528
4 2 Assembly overview – speed sensor on rear axle, disc brake 6528
4 2 1 Assembly overview – speed sensors on rear axle 6528
4 3 Assembly overview – speed sensor on rear axle, drum brake 6529
4 3 1 Assembly overview – speed sensors on rear axle 6529
4 4 Removing and installing speed sensor on front axle [G45]/[G47] 6530
4 5 Removing and installing speed sensor on rear axle [G44]/[G46] 6531
4 6 Checking ABS sensor ring 6532
46 – Brakes – mechanism 6534
1 Safety and repair instructions 6534
1 1 Safety information 6534
1 2 Repair instructions 6534
2 Front brake 6535
2 1 Assembly overview – front brake, without brake carrier 6535
2 1 1 Assembly overview – front brake 6535
2 2 Assembly overview – front brake, with brake carrier 6537
2 2 1 Assembly overview – front brake 6537
2 3 Removing and installing brake pads, without brake carrier 6539
2 3 1 Removing and installing brake pads 6539
2 4 Removing and installing brake pads, with brake carrier 6543
2 4 1 Removing and installing brake pads, pad retainer 6543
2 5 Removing and installing brake caliper, without brake carrier 6547
2 5 1 Removing and installing brake caliper 6547
2 6 Removing and installing brake caliper, with brake carrier 6551
2 6 1 Removing and installing brake caliper 6551
2 7 Removing and installing brake carrier 6553
2 8 Removing and installing brake disc 6554
2 9 Removing and installing brake splash plate 6555
3 Rear brake 6556
3 1 Assembly overview – rear brake, disc brake 6556
3 2 Assembly overview – rear brake, drum brake 6558
3 3 Assembly overview – brake shoes 6559
3 4 Removing and installing brake caliper 6560
3 5 Removing and installing brake carrier 6565
3 6 Removing and installing brake disc 6566
3 7 Removing and installing brake shoes 6566
3 8 Resetting drum brakes 6574
3 9 Removing and installing brake splash plate 6575
3 10 Removing and installing brake drum 6576
3 11 Removing and installing brake backplate 6576
3 12 Removing and installing brake pads 6577
4 Parking brake 6584
4 1 Assembly overview – handbrake 6584
4 2 Removing and installing handbrake lever 6585
4 3 Adjusting handbrake, disc brakes 6586
4 3 1 Adjusting handbrake 6586
4 4 Adjusting handbrake, drum brakes 6587
4 4 1 Adjusting handbrake 6587
4 5 Removing and installing rear brake cable, disc brake 6588
4 5 1 Removing and installing rear brake cable 6588
4 6 Removing and installing rear brake cable, drum brakes 6590
4 6 1 Removing and installing rear brake cable 6590
4 7 Removing and installing parking brake pressure switch [F234] 6592
5 Brake pedal 6593
5 1 Assembly overview – brake pedal 6593
5 1 1 Assembly overview – brake pedal, left-hand drive vehicles 6593
5 1 2 Assembly overview – brake pedal, right-hand drive vehicles 6594
5 2 Removing and installing mounting bracket 6595
5 2 1 Removing and installing mounting bracket, left-hand drive vehicles 6595
5 2 2 Removing and installing mounting bracket, right-hand drive vehicles 6596
5 3 Separating brake pedal from and joining to brake servo 6597
5 4 Removing and installing brake pedal 6599
5 4 1 Removing and installing brake pedal, left-hand drive vehicles 6599
5 4 2 Removing and installing brake pedal, right-hand drive vehicles 6600
5 5 Removing and installing mounting of brake pedal on push rod 6601
47 – Brakes – hydraulics 6602
1 Safety and repair instructions 6602
1 1 Safety information 6602
1 2 Repair instructions 6602
2 Front brake caliper 6603
2 1 Assembly overview – front brake brake caliper, without brake carrier 6603
2 1 1 Assembly overview – front brake caliper 6603
2 2 Assembly overview – front brake caliper, with brake carrier 6604
2 2 1 Assembly overview – front brake caliper 6604
2 3 Removing and installing brake caliper piston 6604
3 Rear brake caliper 6607
3 1 Assembly overview – rear brake caliper 6607
3 2 Removing and installing brake caliper piston 6607
4 Brake servo and brake master cylinder 6611
4 1 Assembly overview – brake servo/brake master cylinder 6611
4 1 1 Assembly overview – brake servo/brake master cylinder, left-hand drive vehicles 6611
4 1 2 Assembly overview – brake servo/brake master cylinder, right-hand drive vehicles 6613
4 2 Removing and installing brake servo, right-hand drive vehicles with petrol engine 6615
4 2 1 Removing and installing brake servo 6615
4 3 Removing and installing brake servo, right-hand drive vehicles with diesel engine 6618
4 3 1 Removing and installing brake servo 6618
4 4 Removing and installing brake servo, left-hand drive vehicles 6621
4 4 1 Removing and installing brake servo 6621
4 5 Removing and installing brake master cylinder 6623
4 5 1 Removing and installing brake master cylinder, left-hand drive vehicles 6623
4 5 2 Removing and installing brake master cylinder, right-hand drive vehicles 6627
4 6 Removing and installing brake fluid level warning contact [F34] 6632
4 7 Removing and installing brake light switch 6632
4 7 1 Removing and installing brake light switch, left-hand drive vehicles 6632
4 7 2 Removing and installing brake light switch, right-hand drive 6634
5 Vacuum system 6636
5 1 Assembly overview – vacuum pump 6636
5 1 1 Assembly overview – vacuum pump, 2 0 l petrol engine 6636
5 1 2 Assembly overview – vacuum pump, 1 0 l petrol engine 6636
5 1 3 Assembly overview – vacuum pump, 1 4 l and 1 5 l evo 1 petrol engine 6637
5 2 Checking non-return valve 6638
5 3 Removing and installing vacuum sender 6639
5 4 Removing and installing vacuum pump 6640
5 4 1 Removing and installing vacuum pump, 2 0 l petrol engine 6640
5 4 2 Removing and installing vacuum pump, 1 0 l petrol engine 6640
5 4 3 Removing and installing vacuum pump, vehicles with 1 4 l and 1 5 l evo 1 petrol engine 6642
5 4 4 Removing and installing vacuum pump, vehicles with oil pump and integrated vacuum pump 6644
5 5 Checking vacuum system 6644
6 Hydraulic system 6648
6 1 Leak test 6648
6 2 Checking wheel brake cylinder for leaks 6648
6 3 Changing brake fluid 6649
6 4 Bleeding hydraulic system 6649
6 5 Removing and installing wheel brake cylinder 6650
D4B8076AF14 General body repairs exterior 6653
00 – Technical data 6659
1 Safety information 6659
1 1 Safety measures when working on vehicles with a start/stop system 6659
1 2 General information 6659
1 2 1 General information for use of adhesives 6659
1 3 Repair information 6660
1 3 1 Pipe/wire routing and attachment 6660
1 3 2 Bonding surfaces for self-adhesive components 6660
1 3 3 Secured threaded connections 6661
50 – Body – front 6662
1 Lock carrier 6662
1 1 Assembly overview – lock carrier 6662
1 1 1 Assembly overview – lock carrier to model year 2021 6662
1 1 2 Assembly overview – lock carrier as of model year 2022 6664
1 2 Removing and installing lock carrier 6666
1 2 1 Removing and installing lock carrier 6666
1 2 2 Removing and installing assembly frame to model year 2021 6668
1 2 3 Removing and installing assembly frame as of model year 2022 6669
1 3 Moving to and back from service position 6671
2 Wings 6675
2 1 Assembly overview – wing 6675
2 2 Removing and installing wing 6675
3 Bulkhead 6680
3 1 Assembly overview – bulkhead 6680
3 2 Assembly overview – plenum chamber cover 6680
3 3 Removing and installing bulkhead 6681
3 4 Removing and installing plenum chamber cover 6682
55 – Bonnet, rear lid 6686
1 Bonnet 6686
1 1 Assembly overview – bonnet 6686
1 2 Assembly overview – Bowden cable 6687
1 3 Removing and installing bonnet 6688
1 4 Adjusting bonnet 6691
1 5 Removing and installing bonnet lock 6698
1 5 1 Removing and installing left bonnet lock 6698
1 5 2 Removing and installing right bonnet lock 6700
1 6 Removing and installing bonnet lock operating lever 6703
1 6 1 Removing and installing bonnet lock operating lever 6703
1 6 2 Removing and installing release lever on lock carrier 6704
1 7 Removing and installing striker pin 6706
1 8 Removing and installing hinge 6707
1 9 Removing and installing insulation 6711
1 10 Removing and installing bonnet stay 6712
1 11 Removing and installing Bowden cable 6714
1 11 1 Removing and installing Bowden cable to mounting bracket 6714
1 11 2 Removing and installing Bowden cable from right bonnet lock to release lever 6716
1 11 3 Removing and installing Bowden cable from left bonnet lock to release lever 6718
1 11 4 Removing and installing Bowden cable coupling with Bowden cables 6720
2 Rear lid 6722
2 1 Assembly overview – rear lid 6722
2 2 Removing and installing rear lid 6724
2 2 1 Removing and installing rear lid to model year 2021 6724
2 2 2 Removing and installing rear lid as of model year 2022 6727
2 3 Adjusting rear lid 6730
2 4 Removing and installing rear lid lock 6736
2 5 Removing and installing operating mechanism 6738
2 5 1 Removing and installing handle, without reversing camera 6738
2 5 2 Removing and installing handle, with reversing camera 6741
2 6 Removing and installing hinge 6743
2 7 Removing and installing striker pin 6746
2 8 Removing and installing rear lid seal 6747
2 9 Removing and installing gas strut 6749
2 10 Preparing gas strut for disposal 6751
3 Tank flap unit 6752
3 1 Assembly overview – tank flap unit 6752
3 2 Removing and installing tank flap unit 6752
3 3 Removing and installing fuel tank flap 6755
57 – Front doors, door components, central locking 6757
1 Door 6757
1 1 Assembly overview – door 6757
1 2 Removing and installing inner door seal 6760
1 3 Removing and installing outer door seal 6762
1 3 1 Removing and installing door outer seal, 4-door model 6762
1 3 2 Removing and installing door outer seal, 2-door model 6763
1 4 Removing and installing door 6764
1 5 Adjusting door 6767
1 6 Adjusting striker pin 6769
1 7 Removing and installing door arrester 6771
2 Door components 6774
2 1 Assembly overview – door components 6774
2 2 Assembly overview – window regulator 6776
2 3 Assembly overview – door handle and door lock 6776
2 4 Removing and installing window regulator motor 6777
2 5 Removing and installing window regulator 6780
2 6 Removing and installing inner door cover 6783
2 7 Removing and installing striker pin 6785
2 8 Removing and installing cap on door handle 6787
2 8 1 Removing and installing cap for door handle, for lock cylinder 6787
2 8 2 Removing and installing cap for door handle, without lock cylinder 6789
2 9 Removing and installing lock cylinder 6793
2 10 Removing and installing door handle 6796
2 11 Removing and installing mounting bracket 6798
2 12 Removing and installing door lock 6800
2 13 Removing and installing window channel 6805
2 14 Removing and installing outer window slot seal 6808
2 15 Removing and installing window slot inner seal 6810
3 Central locking 6811
3 1 Overview of fitting locations – central locking system 6811
3 2 Removing and installing ignition key battery 6813
3 3 Removing and installing cap on ignition key 6815
3 4 Removing and installing tank filler flap locking motor -V155- 6816
58 – Rear doors, door components 6818
1 Door 6818
1 1 Assembly overview – door 6818
1 2 Removing and installing door 6821
1 3 Adjusting door 6824
1 4 Adjusting striker pin 6826
1 5 Removing and installing door arrester 6828
1 6 Removing and installing inner door seal 6830
1 7 Removing and installing outer door seal 6832
2 Door components 6834
2 1 Assembly overview – door components 6834
2 2 Assembly overview – window regulator 6836
2 3 Assembly overview – door handle and door lock 6836
2 4 Removing and installing window regulator motor 6837
2 5 Removing and installing window regulator 6840
2 6 Removing and installing window crank 6843
2 7 Removing and installing inner door cover 6846
2 8 Removing and installing striker pin 6848
2 9 Removing and installing cap on door handle 6850
2 10 Removing and installing door handle 6854
2 11 Removing and installing mounting bracket 6856
2 12 Removing and installing door lock 6859
2 13 Removing and installing window channel 6863
2 14 Removing and installing outer window slot seal 6866
2 15 Removing and installing window slot inner seal 6867
60 – Sunroof 6869
1 Sliding sunroof 6869
1 1 Assembly overview – sliding sunroof 6869
1 2 Assembly overview – sunroof seals 6871
1 3 Assembly overview – sun blind 6871
1 4 Removing and installing glass panel 6872
1 5 Adjusting sunroof panel 6875
1 6 Removing and installing front trim for sliding sunroof 6877
1 7 Removing and installing wind deflector 6878
1 8 Removing and installing sunroof roller blind 6881
1 9 Removing and installing sliding sunroof frame 6888
1 10 Removing and installing -J245-sliding sunroof adjustment control unit 6897
1 11 Removing and installing sunroof motor -V1- 6899
1 12 Manual operation 6902
1 13 Removing and installing slotted guide 6903
1 14 Removing and installing sliding sunroof seals 6907
1 14 1 Installation instructions for bonded seals 6907
1 14 2 Removing and installing sunroof frame outer seal 6908
1 14 3 Removing and installing sunroof frame inner seal 6909
1 14 4 Removing and installing additional sunroof frame seal 6910
1 14 5 Removing and installing glass panel seal 6912
1 14 6 Removing and installing front trim seal 6912
1 15 Programming sliding sunroof adjustment control unit -J245- 6914
63 – Bumpers 6915
1 Bumper, front 6915
1 1 Assembly overview – bumper cover 6915
1 1 1 Assembly overview – bumper cover, up to model year 2021 6915
1 1 2 Assembly overview – bumper cover as of model year 2022 6917
1 1 3 Assembly overview – bumper cover, add-on parts, GTI, R-Line, up to model year 2021 6919
1 1 4 Assembly overview – bumper cover, add-on parts, GTI, R-Line, as of model year 2022 6920
1 2 Assembly overview – bumper carrier 6922
1 2 1 Assembly overview – bumper carrier up to model year 2021 6922
1 2 2 Assembly overview – bumper carrier from model year 2022 onwards 6923
1 3 Removing and installing bumper cover 6925
1 3 1 Removing and installing bumper cover, up to model year 2021 6925
1 3 2 Removing and installing bumper cover, as of model year 2022 6928
1 4 Installing holder for parking aid sender 6931
1 5 Installing holder for park assist steering sender 6936
2 Bumper, rear 6940
2 1 Assembly overview – bumper cover 6940
2 1 1 Assembly overview – bumper cover, up to model year 2021 6940
2 1 2 Assembly overview – bumper cover as of model year 2022 6941
2 1 3 Assembly overview – bumper cover, add-on parts, GTI, R-Line, up to model year 2021 6942
2 1 4 Assembly overview – bumper cover, add-on parts, GTI, R-Line, as of model year 2022 6943
2 2 Assembly overview – bumper carrier 6944
2 3 Removing and installing bumper cover 6945
2 4 Removing and installing bumper carrier 6948
2 5 Installing holder for parking aid sender 6950
2 6 Installing holder for park assist steering sender 6955
2 7 Removing and installing forced ventilation for passenger compartment 6958
2 8 Checking forced ventilation for passenger compartment 6960
64 – Glazing 6961
1 Repair notes 6961
1 1 Minimum drying times for bonded windows 6961
1 2 Window repair 6961
1 3 Installation instructions for bonded windows 6962
1 3 1 Fitting instructions 6962
1 3 2 Materials 6963
1 4 Preparing old undamaged windows for installing 6964
1 5 Preparing new windows for installing 6965
1 6 Preparing body flange for installing 6968
1 7 Cleaning off excess adhesive 6969
2 Windscreen 6971
2 1 Assembly overview – windscreen 6971
2 2 Removing and installing windscreen 6972
2 2 1 Removing and installing windscreen 6972
2 2 2 Removing broken windscreen 6979
3 Rear windscreen 6980
3 1 Assembly overview – rear window 6980
3 2 Removing and installing rear window 6981
3 2 1 Removing and installing rear window 6981
3 2 2 Removing broken rear window 6984
4 Side window 6986
4 1 Assembly overview – rear side windows 6986
4 2 Removing and installing rear side window 6987
4 2 1 Removing and installing rear side window 6987
4 2 2 Removing broken rear side window 6990
5 Door windows 6991
5 1 Assembly overview – front door window 6991
5 2 Assembly overview – rear door window 6991
5 3 Removing and installing front door window 6992
5 4 Removing and installing rear door window 6996
66 – Exterior equipment 7000
1 Radiator grille and front trim 7000
1 1 Assembly overview – radiator grille 7000
1 1 1 Assembly overview – radiator grille up to model year 2021 7000
1 1 2 Assembly overview – radiator grille as of model year 2022 7001
1 2 Removing and installing radiator grille 7001
1 2 1 Removing and installing radiator grille, up to model year 2021 7001
1 2 2 Removing and installing radiator grille, as of model year 2022 7003
2 Spoiler 7006
2 1 Assembly overview – spoiler 7006
2 2 Removing and installing spoiler 7006
3 Mouldings, trims, extensions 7014
3 1 Assembly overview – side member trim 7014
3 2 Removing and installing A-pillar trim 7015
3 3 Removing and installing B-pillar trim on door 7016
3 3 1 Removing and installing B-pillar trim on front door 7016
3 3 2 Removing and installing B-pillar trim on rear door 7018
3 4 Removing and installing C-pillar trim on door 7019
3 5 Removing and installing step moulding 7021
3 6 Removing and installing side member trim 7023
4 Noise insulation 7028
4 1 Assembly overview – noise insulation 7028
4 1 1 Assembly overview – short noise insulation, 06/2017 ► 07/2020 7028
4 1 2 Assembly overview – short noise insulation, 07/2020 ► 7028
4 1 3 Assembly overview – long noise insulation, 06/2017 ► 07/2020 7029
4 1 4 Assembly overview – long noise insulation, 07/2020 ► 7030
5 Underbody cladding 7032
5 1 Assembly overview – underbody cladding 7032
5 1 1 Assembly overview – underbody cladding, petrol/diesel 7032
5 1 2 Assembly overview – skid plate, 06/2017 ► 07/2020 7033
5 1 3 Assembly overview – skid plate, 07/2020 ► 7033
5 2 Removing and installing underbody cladding 7034
5 3 Removing and installing underbody cladding, centre 7036
5 3 1 Removing and installing centre underbody cladding 7036
5 3 2 Removing and installing short centre underbody cladding 7037
5 4 Removing and installing rear underbody cladding 7038
5 4 1 Removing and installing rear underbody cladding – petrol/diesel 7038
6 Trim film and protective film 7040
6 1 Renewing decorative film 7040
6 1 1 Fitting instructions 7040
6 1 2 Decorative film dimensions 7041
6 1 3 Renewing decorative film 7041
7 Exterior mirror 7044
7 1 Assembly overview – exterior mirror 7044
7 2 Removing and installing exterior mirror 7046
7 2 1 Removing and installing exterior mirror, electric adjustment 7046
7 2 2 Removing and installing exterior mirror, manual adjustment 7048
7 3 Removing and installing mirror glass 7051
7 4 Removing and installing mirror adjustment unit 7053
7 5 Removing and installing mirror cover 7055
7 6 Removing and installing mirror frame 7056
8 Wheel housing liner 7058
8 1 Assembly overview – front wheel housing liner 7058
8 2 Assembly overview – rear wheel housing liner 7059
8 3 Removing and installing front wheel housing liner 7059
8 4 Removing and installing rear wheel housing liner 7061
9 Lettering and badges 7063
9 1 Dimensions – lettering and badges on rear 7063
9 1 1 Dimensions – lettering on rear 06/2017 ► 07/2020 7063
9 1 2 Dimensions – lettering on rear, model year 2021 7064
9 1 3 Dimensions – lettering on rear, as of model year 2022 7066
9 1 4 Dimensions – GTI lettering on rear 06/2017 ► 07/2020 7067
9 1 5 Dimensions – GTI lettering on rear 07/2020 ► 7069
9 2 Dimensions – lettering and badges on sides 7071
9 2 1 Dimensions – lettering on wing, GTI, R-Line 7071
9 2 2 Dimensions – badge on B-pillar 7072
9 3 Renewing lettering and badges on sides 7074
9 4 Removing and installing lettering and badges for radiator grille 7076
9 4 1 Removing and installing emblem on radiator grille 7076
9 4 2 Removing and installing model designation, GTI 7077
9 4 3 Removing and installing model designation, R-Line 7078
9 5 Renewing lettering and badges at rear 7079
10 Special add-on parts 7081
10 1 Assembly overview – special add-on parts 7081
11 Towing bracket 7082
11 1 Assembly overview – towing bracket 7082
11 2 Removing and installing towing bracket 7084
12 Heat shields 7087
12 1 Overview of fitting locations – heat shields 7087
12 2 Removing and installing front heat shield 7087
12 3 Removing and installing centre heat shield 7088
12 4 Removing and installing rear heat shield 7089
D4B8076AF62 Wheels and Tyres Guide 7092
44 – Wheels, tyres, vehicle geometry 7096
1 General information 7096
2 Version key (D2) 7097
2 1 Version key (D2) type approval number (K): e1*2007/46*1783*00 7097
2 2 Version key (D2) type approval number (K): e1*2007/46*1783*01 to e1*2007/46*1783*02 7098
2 3 Version key (D2) type approval number (K): e1*2007/46*1783*03 to e1*2007/46*1783*06 7098
2 4 Version key (D2) type approval number (K): e1*2007/46*1783*07 to e1*2007/46*1783*08 7099
2 5 Version key (D2) type approval number (K): e1*2007/46*1783*09 7100
2 6 Version key (D2) from type approval number (K): e1*2007/46*1783*10 7101
2 7 Version key (D2) from type approval number (K): e1*2007/46*1783*11 7101
2 8 Version key (D2) from type approval no (K): e1*2007/46*1783*12 to e1*2007/46*1783*14 7102
2 9 Version key (D2) from type approval number (K): e1*2007/46*1783*15 7103
2 10 Version key (D2) from type approval no (K): e1*2007/46*1783*16 to e1*2007/46*1783*20 7103
2 11 Version key (D2) from type approval number (K): e1*2007/46*1783*21 7104
2 12 Version key (D2) from type approval number (K): e1*2007/46*1783*22 7105
2 13 Version key (D2) from type approval number (K): e1*2007/46*1783*23 7106
2 14 Version key (D2) as of type approval no (K): e1*2007/46*1783*24 and e1*2007/46*1783*25 7107
2 15 Version key (D2) from type approval number (K): e1*2007/46*1783*26 7108
2 16 Version key (D2) from type approval number (K): e1*2007/46*1783*27 7108
2 17 Version key (D2) as of type approval no (K): e1*2007/46*1783*28 and e1*2007/46*1783*29 7109
2 18 Version key (D2) as of type approval no (K): e1*2007/46*1783*30 and e1*2007/46*1783*31 7110
2 19 Version key (D2) from type approval no (K): e1*2007/46*1783*32 to e1*2007/46*1783*36 7111
3 Wheels, tyres 7113
3 1 Tightening torque for wheel bolts 7113
4 Wheel and tyre combinations according to NEDC (based on tyre package) 7114
4 1 Type approval number (K): e1*2007/46*1783*00 7114
4 2 Type approval number (K): e1*2007/46*1783*01 7114
4 3 Type Approval No (K): e1e1*2007/46*1783*02 to 1*2007/46*1783*06 7116
4 4 Type approval number (K): e1*2007/46*1783*07 7117
4 5 Type approval number (K): e1*2007/46*1783*08 7119
4 6 Changing to other wheel and tyre combinations 7120
5 Wheel and tyre combinations according to WLTP (without tyre package) 7122
5 1 Type approval number (K): e1*2007/46*1783*07 7122
5 2 Type approval no (K): e1*2007/46*1783*08 to e1*2007/46*1783*09 7124
5 3 Type approval number (K): e1*2007/46*1783*10 7125
5 4 Type approval number (K): e1*2007/46*1783*11 7126
5 5 Type approval no (K): e1*2007/46*1783*12 to e1*2007/46*1783*14 7128
5 6 Type approval number (K): e1*2007/46*1783*15 7129
5 7 Type approval no (K): e1*2007/46*1783*16 to e1*2007/46*1783*20 7131
5 8 Type approval number (K): e1*2007/46*1783*21 7133
5 9 Type approval number (K): e1*2007/46*1783*22 7135
5 10 Type approval number (K): e1*2007/46*1783*23 7136
5 11 Type approval number (K): e1*2007/46*1783*24 and e1*2007/46*1783*25 7138
5 12 Type approval number (K): e1*2007/46*1783*26 7139
5 13 Type approval number (K): e1*2007/46*1783*27 7141
5 14 Type approval number (K): e1*2007/46*1783*28 and e1*2007/46*1783*29 7143
5 15 Type approval number (K): e1*2007/46*1783*30 7144
5 16 Type approval no (K): e1*2007/46*1783*31 to e1*2007/46*1783*35 7145
5 17 Type approval number (K): e1*2007/46*1783*36 7146
5 18 Temporary spare wheel 7147
5 18 1 Temporary spare wheel, Polo 2018 7147
5 18 2 Temporary spare wheel, Polo 2022 7148
6 Wheel assignment 7149
6 1 5 J x 14 offset 38 7149
6 2 5 5 J x 15 offset 40 7149
6 3 6 J x 16 offset 45 7153
6 4 6 5 J x 16 offset 47 7153
6 5 7 J x 17 offset 51 7155
6 6 7 5 J x 17 offset 51 7157
6 7 7 5 J x 18 offset 51 7158
7 Recommended summer tyres 7159
7 1 Recommended summer tyres, worldwide except North America, China, Japan, South Korea, Singapore 7159
7 2 Recommended summer tyres, Japan, Singapore, South Korea 7160
8 Recommended all-season tyres 7161
8 1 Recommended all-season tyres, European Union 7161
9 Recommended winter tyres 7162
9 1 Recommended winter tyres, European Union 7162
D4B8076D12A Electrical system 7163
00 – Technical data 7171
1 Safety information 7171
1 1 Safety measures when working on vehicles with a start/stop system 7171
1 2 Safety precautions when using test and measuring equipment during a road test 7171
2 Repair notes 7172
2 1 Rules for cleanliness 7172
2 2 General information 7172
2 3 Contact corrosion 7172
2 4 Routing and attachment of lines 7172
3 Battery 7174
3 1 Battery – general notes 7174
3 2 Types of battery 7174
27 – Starter, current supply, CCS 7175
1 Battery 7175
1 1 Assembly overview – battery 7175
1 1 1 Assembly overview – battery, battery in engine compartment 7175
1 1 2 Assembly overview – battery, battery in luggage compartment 7176
1 2 Removing and installing battery 7178
1 2 1 Removing and installing battery, battery in engine compartment 7178
1 2 2 Removing and installing battery, battery in luggage compartment 7181
1 3 Disconnecting and connecting battery 7184
1 3 1 Disconnecting and connecting battery, battery in engine compartment 7184
1 3 2 Disconnecting and connecting battery, battery in luggage compartment 7186
1 4 Removing and installing battery tray 7187
1 4 1 Removing and installing battery tray, battery in engine compartment 7187
1 4 2 Removing and installing battery tray, battery in luggage compartment 7189
1 5 Checking battery 7192
1 6 Charging battery 7192
1 7 Removing and installing earth wire with battery monitor control unit -J367- 7192
1 7 1 Removing and installing earth cable with battery monitor control unit -J367-, battery in engine compartment 7192
1 7 2 Removing and installing earth cable with battery monitor control unit -J367-, battery in luggage compartment 7193
1 8 Adapting battery monitor control unit -J367- 7194
2 Jump-start connection point 7195
2 1 Assembly overview – jump-start connection point 7195
2 2 Removing and installing jump-start connection 7195
3 Alternator 7199
3 1 Assembly overview – alternator 7199
3 1 1 Assembly overview – alternator with sliding bushes 7199
3 1 2 Assembly overview – alternator without sliding bushes 7200
3 2 Removing and installing alternator 7201
3 2 1 Removing and installing alternator, vehicles with 1 0 l manifold injection engine and 1 0 l TSI engine 7201
3 2 2 Removing and installing alternator, vehicles with 1 0 l TSI natural gas engine 7203
3 2 3 Removing and installing alternator, vehicles with 1 5 l TSI engine 7206
3 2 4 Removing and installing alternator, vehicles with 2 0 l TSI engine 7207
3 2 5 Removing and installing alternator, vehicles with diesel engine 7210
3 3 Checking alternator 7211
3 4 Removing and installing poly V-belt pulley 7212
3 4 1 Removing and installing poly V-belt pulley without freewheel 7212
3 4 2 Removing and installing poly V-belt pulley with freewheel, manufacturer: Bosch 7213
3 4 3 Removing and installing poly V-belt pulley with freewheel, manufacturer: Valeo 7215
3 4 4 Removing and installing decoupler pulley with freewheel 7218
3 5 Removing and installing voltage regulator 7221
3 5 1 Removing and installing voltage regulator -C1-, manufacturer: Bosch 7221
3 5 2 Removing and installing voltage regulator -C1-, Valeo 7223
4 Starter 7225
4 1 Assembly overview – starter 7225
4 1 1 Assembly overview – starter, vehicles with manual gearbox 7225
4 1 2 Assembly overview – starter, vehicles with 7-speed dual clutch gearbox 7225
4 1 3 Assembly overview – starter, vehicles with 6-speed dual clutch gearbox 7226
4 2 Removing and installing starter 7227
4 2 1 Removing and installing starter, vehicle with manual gearbox 7227
4 2 2 Removing and installing starter, vehicles with 7-speed dual clutch gearbox 7229
4 2 3 Removing and installing starter, vehicles with 6-speed dual clutch gearbox 7231
4 3 Checking starter 7233
5 Cruise control system (CCS) 7234
6 Start/stop system 7235
6 1 General description – start/stop system 7235
7 Adaptive cruise control 7236
7 1 Overview of fitting locations – adaptive cruise control 7236
7 2 Removing and installing automatic distance control unit 7236
7 3 Calibrating adaptive cruise control 7237
90 – Gauges, instruments 7238
1 Dash panel insert 7238
1 1 Assembly overview – dash panel insert 7238
1 2 Removing and installing dash panel insert -KX2- 7239
1 2 1 Removing and installing dash panel insert -KX2-, dash panel insert with analogue instruments 7239
1 2 2 Removing and installing dash panel insert -KX2-, fully digital dash panel insert 7240
2 Horn 7244
2 1 Assembly overview – horn 7244
2 2 Removing and installing treble horn -H2- and bass horn -H7- 7244
92 – Windscreen wash/wipe system 7246
1 Windscreen wiper system 7246
1 1 Assembly overview – windscreen wiper system 7246
1 2 Moving wipers to service position 7248
1 3 Removing and installing wiper blade 7248
1 4 Removing and installing wiper arms 7249
1 5 Adjusting wiper arms 7251
1 6 Removing and installing wiper motor 7253
1 7 Removing and installing rain and light sensor 7254
2 Windscreen washer system 7259
2 1 Assembly overview – windscreen washer system 7259
2 2 Removing and installing filler pipe for washer fluid reservoir 7261
2 3 Removing and installing washer fluid reservoir 7261
2 4 Removing and installing windscreen washer fluid level sender 7264
2 5 Removing and installing windscreen washer pump 7264
2 6 Removing and installing spray jets 7265
2 7 Adjusting spray jets 7266
3 Rear window wiper system 7268
3 1 Assembly overview – rear window wiper system 7268
3 2 Removing and installing wiper blade 7269
3 3 Removing and installing wiper arm 7269
3 4 Adjusting wiper arm 7271
3 5 Removing and installing rear window wiper motor -V12- 7272
4 Rear window washer system 7274
4 1 Assembly overview – rear window washer system 7274
4 2 Removing and installing washer fluid reservoir 7274
4 3 Removing and installing rear window washer pump 7275
4 4 Removing and installing spray jet 7275
4 5 Adjusting spray jet 7275
5 Washer fluid lines 7276
5 1 Repairing washer fluid lines 7276
94 – Lights, bulbs, switches – exterior 7277
1 Headlights 7277
1 1 Assembly overview – headlight 7277
1 1 1 Assembly overview – headlight, dual halogen headlight 7277
1 1 2 Assembly overview – headlight, LED headlight 7279
1 1 3 Assembly overview – daytime running lights 7281
1 2 Removing and installing headlight 7281
1 3 Adjusting headlights 7284
1 4 Adjusting headlight installation position 7284
1 5 Removing and installing front turn signal bulb -M5-/-M7- 7285
1 6 Installing repair kit for headlight housing 7285
1 7 Converting headlights from driving on right to driving on left 7287
1 7 1 Changing headlights over from driving on right to driving on left (dual halogen headlights) 7287
1 7 2 Converting headlights from driving on right to driving on left, LED headlights 7287
1 8 Converting headlights from driving on left to driving on right 7287
1 8 1 Changing headlights over from driving on left to driving on right (dual halogen headlights) 7287
1 8 2 Converting headlights from driving on left to driving on right, LED headlights 7287
1 9 Removing and installing headlight range control motor -V48-/-V49- 7288
1 9 1 Removing and installing headlight range control motor -V48-/-V49- (dual halogen headlights) 7288
1 9 2 Removing and installing headlight range control motor -V48-/-V49-, LED headlights 7289
1 10 Removing and installing headlight dipped beam bulb 7290
1 11 Removing and installing headlight main beam bulb -M30-/-M32- 7292
1 12 Removing and installing daytime running lights 7294
1 13 Removing and installing static cornering light bulb 7295
1 14 Removing and installing output module 1 for LED headlight [A27]/[A31] 7295
2 Fog lights 7297
2 1 Assembly overview – fog lights 7297
2 2 Removing and installing fog light 7297
2 3 Removing and installing fog light bulb -L22-/-L23- 7297
2 4 Adjusting fog lights 7298
3 Tail light cluster 7299
3 1 Assembly overview – tail light cluster in body 7299
3 2 Removing and installing bulb carrier 7301
3 3 Removing and installing tail light cluster 7301
3 4 Adjusting installation position of tail light 7302
3 5 Removing and installing tail light bulb -M2-/-M4- 7303
3 5 1 Removing and installing tail light cluster bulb -M2-/-M4-, vehicles without LED tail lights 7303
3 5 2 Removing and installing tail light cluster bulb -M2-/-M4-, vehicles with LED tail lights 7304
3 6 Removing and installing rear fog light bulb -L46-/-L47- 7304
3 7 Removing and installing brake and tail light bulb -M21-/-M22- 7305
3 7 1 Removing and installing tail light cluster bulb -M2-/-M4-, vehicles without LED tail lights 7305
3 7 2 Removing and installing tail light cluster bulb -M2-/-M4-, vehicles with LED tail lights 7305
3 8 Removing and installing reversing light bulb 7305
3 9 Removing and installing turn signal bulb 7306
4 High-level brake light 7307
4 1 Assembly overview – high-level brake light 7307
4 2 Removing and installing high-level brake light 7307
5 Additional exterior lights 7310
5 1 Assembly overview – lights in exterior mirror 7310
5 2 Removing and installing turn signal repeater 7312
5 3 Removing and installing number plate light -X4-/-X5- 7312
5 4 Removing and installing bulb for number plate light X4/X5 7313
6 Entry and start authorisation 7314
6 1 Overview of fitting locations – entry and start authorisation system 7314
6 2 Overview of fitting locations – keyless entry system 7315
6 3 Removing and installing entry and start authorisation control unit -J518- 7315
6 4 Removing and installing contact sensor for front exterior door handle G605/G606 7316
6 5 Removing and installing interior aerial 1 for entry and start system -R138- 7317
6 6 Removing and installing interior aerial 2 for entry and start system R139 7317
6 7 Removing and installing entry and start authorisation aerial [R200]/[R201] 7318
6 8 Removing and installing rear bumper aerial for entry and start authorisation R136 7318
7 Steering column switch module 7320
7 1 Assembly overview – steering column switch module 7320
7 1 1 Assembly overview – steering column switch module, mechanical ignition lock 7320
7 1 2 Assembly overview – steering column switch module, electronic ignition lock 7321
7 2 Removing and installing lock cylinder 7322
7 3 Removing and installing ignition key withdrawal lock solenoid -N376- 7324
7 4 Removing and installing ignition/starter switch 7325
7 5 Removing and installing steering column switch module 7326
7 5 1 Removing and installing steering column switch module, Kostal 7326
7 5 2 Removing and installing steering column switch module, Valeo 7329
7 6 Removing and installing steering column electronics control unit -J527- 7331
7 7 Removing and installing turn signal switch -E2- 7333
7 7 1 Removing and installing turn signal switch -E2-, Kostal 7333
7 7 2 Removing and installing turn signal switch -E2-, Valeo 7335
7 8 Removing and installing cruise control system switch -E45- 7336
7 9 Removing and installing intermittent wiper switch -E22- 7336
7 10 Removing and installing base for steering column combination switch 7337
7 10 1 Removing and installing base for steering column combination switch, mechanical ignition lock 7337
7 10 2 Removing and installing base for steering column combination switch, electronic ignition lock 7337
7 11 Removing and installing steering lock housing 7337
8 Parking aid 7340
8 1 Assembly overview – parking aid 7340
8 1 1 Assembly overview – parking aid, left-hand drive vehicles 7340
8 1 2 Assembly overview – parking aid, right-hand drive vehicles 7341
8 2 Removing and installing parking aid control unit -J446- 7343
8 2 1 Removing and installing parking aid control unit -J446-, left-hand drive vehicle 7343
8 2 2 Removing and installing parking aid control unit -J446-, RHD vehicle 7343
8 2 3 Removing and installing parking aid control unit -J446-/park assist steering control unit -J791- 7344
8 3 Removing and installing front parking aid warning buzzer -H22- 7345
8 3 1 Removing and installing front parking aid warning buzzer -H22-, left-hand drive vehicles 7345
8 3 2 Removing and installing front parking aid warning buzzer -H22-, right-hand drive vehicles 7345
8 4 Removing and installing rear parking aid warning buzzer -H15- 7346
8 5 Removing and installing front parking aid senders 7347
8 6 Removing and installing rear parking aid senders 7348
9 Park assist steering 7349
9 1 Assembly overview – park assist steering 7349
9 2 Removing and installing control unit 7349
9 3 Removing and installing front senders 7350
9 4 Removing and installing rear senders 7350
10 Automatic headlight range control 7352
10 1 Assembly overview – automatic headlight range control 7352
10 2 Removing and installing headlight range control unit 7352
11 Blind Spot Monitor 7354
11 1 Assembly overview – Blind Spot Monitor 7354
11 2 Removing and installing Blind Spot Monitor warning lamp in exterior mirror K303/K304 7354
11 3 Removing and installing Blind Spot Monitor control unit J1086/J1087 7355
96 – Lights, bulbs, switches – interior 7357
1 Lights 7357
1 1 Overview of fitting locations – lights in dash panel 7357
1 2 Overview of fitting locations – lights in front doors 7358
1 3 Overview of fitting locations – lights in centre console 7359
1 4 Overview of fitting locations – lights in luggage compartment 7360
1 5 Overview of fitting locations – lights in roof trim 7361
1 5 1 Overview of fitting locations – lights in roof trim, vehicles without rear interior light -WX2- 7361
1 5 2 Overview of fitting locations – lights in roof trim, vehicles with rear interior light -WX2- 7362
1 6 Removing and installing footwell light -W9-/-W10- 7363
1 7 Removing and installing bulb for front footwell light L151/L152 7364
1 8 Removing and installing Central locking SAFELOCK function warning lamp -K133- 7365
1 9 Removing and installing storage compartment illumination bulb -L120- 7366
1 10 Removing and installing door opener illumination bulb L108/L109 7366
1 11 Removing and installing bulb for background lighting in front door -L164-/-L165- 7367
1 12 Removing and installing light 1 for dashboard background lighting L292 7368
1 13 Removing and installing light for right dash panel background lighting -L230- 7368
1 14 Removing and installing light for centre dashboard background lighting -L231- 7369
1 15 Removing and installing selector lever position display -Y26- 7370
1 16 Removing and installing luggage compartment light -W3- 7370
1 17 Removing and installing bulb for luggage compartment light -W3- 7370
1 18 Removing and installing illuminated vanity mirror -W20-/-W14- 7371
1 19 Renewing front interior light bulb -W1-/-W13-/-W19- 7372
1 19 1 Renewing front interior light -W1-, vehicles without rear interior light -WX2- 7372
1 19 2 Renewing front reading light -W13-/-W19-, vehicles without rear interior light -WX2- 7373
1 19 3 Renewing bulb for interior light/reading light -W1-/-W13-/-W19-, vehicles with rear interior light -WX2- 7374
1 20 Renewing bulb for rear interior light W47/W48 7376
1 21 Removing and installing rear reading light W11/W12 7377
2 Controls 7379
2 1 Overview of fitting locations – controls in dash panel 7380
2 2 Overview of fitting locations – controls in front doors 7381
2 3 Overview of fitting locations – controls in rear doors 7381
2 4 Overview of fitting locations – controls in centre console 7382
2 5 Overview of fitting locations – controls in luggage compartment 7383
2 6 Overview of fitting locations – controls in roof trim 7384
2 6 1 Overview of fitting locations – controls in roof trim, vehicles without rear interior light -WX2- 7384
2 6 2 Overview of fitting locations – controls in roof trim, vehicles with rear interior light -WX2- 7385
2 7 Removing and installing rotary light switch -EX1- 7386
2 8 Removing and installing headlight range control regulator -E102- 7387
2 9 Removing and installing button for TCS and electronic stabilisation program E256 7388
2 10 Removing and installing parking aid button -E266- 7389
2 11 Removing and installing park assist steering button -E581- 7389
2 12 Removing and installing Start/Stop operation button -E693- 7389
2 13 Removing and installing driving mode selection button -E735- 7389
2 14 Removing and installing warning lamp for airbag deactivated on front passenger side K145 7389
2 15 Removing and installing centre console switch module 7390
2 16 Removing and installing hazard warning light switch -EX3- 7391
2 17 Removing and installing buttons for seat heating -E653-/-E654- 7391
2 18 Removing and installing exterior mirror adjuster -EX11- 7392
2 19 Removing and installing operating unit for window regulator in driver door -E512- 7392
2 20 Removing and installing window regulator switch in front passenger door -EX27- 7393
2 21 Removing and installing driver side interior locking button for central locking system -E308- 7394
2 22 Removing and installing door contact switch -F2-/-F3- 7394
2 23 Removing and installing rear window regulator button -E700-/-E705- 7394
2 24 Removing and installing rear door contact switches -F10-/-F11- 7395
2 25 Removing and installing starter button -E378- 7395
2 26 Removing and installing rear lid contact switch 7396
2 27 Removing and installing vanity mirror contact switch -F147-/-F148- 7396
2 28 Removing and installing sunroof button -E325- 7396
2 29 Removing and installing front interior light/reading light 7397
2 29 1 Removing and installing front interior light/reading light, vehicles without rear interior light -WX2- 7397
2 29 2 Removing and installing front interior light/reading light, vehicles with rear interior light -WX2- 7398
2 30 Removing and installing rear interior light/reading light 7400
3 Anti-theft alarm 7402
3 1 Assembly overview – interior monitor 7402
3 2 Removing and installing alarm horn -H12- 7402
3 3 Removing and installing anti-theft alarm sensor -G578- 7403
4 Immobiliser 7405
4 1 Removing and installing immobiliser control unit 7405
4 2 Removing and installing immobiliser reader coil 7405
4 2 1 Removing and installing immobiliser reader coil, mechanical ignition lock 7405
4 2 2 Removing and installing immobiliser reader coil, electronic ignition lock 7405
5 Towing bracket 7406
5 1 Assembly overview – socket, trailer detector control unit 7406
5 2 Removing and installing trailer socket -U10- 7406
5 3 Removing and installing trailer detector control unit -J345- 7407
6 Front camera for driver assist systems 7408
6 1 Assembly overview – front camera for assist systems 7408
6 2 Removing and installing front camera for driver assist systems -R242- 7408
6 3 Calibrating front camera for assist systems 7410
7 Cigarette lighter, socket 7419
7 1 Removing and installing cigarette lighter -U1- 7419
7 2 Removing and installing socket illumination bulb -L42- 7419
7 3 Removing and installing bulb for illuminating cigarette lighter 7419
7 4 Removing and installing 12 V socket 3 U19 7419
97 – Wiring 7420
1 Relay carriers, fuse holders, electronics boxes 7420
1 1 Overview of fitting locations – relay carriers, fuse holders, electronics boxes 7420
1 1 1 Overview of fitting locations – relay carriers, fuse carriers, electronics boxes, engine compartment 7420
1 1 2 Overview of fitting locations – relay carriers, fuse carriers, electronics boxes, A-pillar 7421
1 1 3 Assembly overview – fuse holder A -SA- 7422
1 1 4 Assembly overview – main fuse carrier 7424
1 2 Removing and installing electronics box 7424
1 3 Removing and installing relay and fuse holder in electronics box 7426
1 4 Removing and installing relay and fuse holder behind dash panel on driver side 7428
1 5 Removing and installing fuse holder A -SA- 7431
1 6 Removing and installing main fuse carrier 7433
2 Control units 7435
2 1 Overview of fitting locations – control units 7435
2 2 Removing and installing onboard supply control unit -J519- 7435
2 3 Removing and installing data bus diagnostic interface -J533- 7437
2 4 Removing and installing bracket for onboard supply control unit -J519- 7438
3 Connectors 7439
3 1 Repairing electrical wiring harnesses and plug-in connections 7439
3 1 1 Repairs to wiring harnesses and connectors 7439
3 1 2 Repairing connector housings and electrical connectors 7439
4 Releasing and dismantling connector housings 7440
5 Repairing aerial wires 7441
6 Fibre optic cables 7442
7 Vehicle diagnosis, testing and information systems 7443
D4B8076D13A Communication 7444
00 – Technical data 7448
1 Repair notes 7448
1 1 General information 7448
91 – Communication 7449
1 Infotainment system 7449
1 1 Overview of infotainment system 7449
1 1 1 Components of infotainment system, Composition Colour 7449
1 1 2 Components of Infotainment system, Composition Media, Discover Media 7450
1 2 Overview of fitting locations – Infotainment system 7451
1 3 Removing and installing infotainment system display 7453
1 4 Removing and installing control unit 1 for information electronics -J794- 7454
1 5 Removing and installing DVD/CD changer or CD changer 7455
1 6 Renewing rotary knobs for infotainment display 7456
2 Sound system 7458
2 1 Overview of fitting locations – sound system 7458
2 2 Removing and installing digital sound package control unit 7459
2 2 1 Removing and installing digital sound package control unit 7459
2 2 2 Removing and installing retainer for amplifier -R12- 7461
2 3 Removing and installing front treble loudspeakers -R20-/-R22- 7461
2 4 Removing and installing rear loudspeaker -R4-/-R5- 7461
2 5 Removing and installing front bass loudspeakers -R21-/-R23- 7463
2 6 Removing and installing subwoofer -R211- 7465
2 6 1 Removing and installing subwoofer -R211- 7465
2 6 2 Removing and installing subwoofer -R211- 7466
3 Aerial systems 7470
3 1 Components of aerial systems 7470
3 2 Overview of fitting locations – aerial systems 7470
3 3 Removing and installing aerial module 7471
3 4 Removing and installing roof aerial 7472
3 5 Removing and installing rear bumper aerial for entry and start system -R136- 7474
4 Radio 7476
4 1 Overview of radio 7476
4 1 1 Components of Composition Colour radio 7476
4 1 2 Components of Composition Media radio 7476
4 2 Removing and installing radio 7476
4 2 1 Removing and installing radio, Composition Colour 7476
4 2 2 Removing and installing radio, Composition Media 7478
5 Telephone system 7479
5 1 Preparation for mobile telephone 7479
5 1 1 Mobile telephone preparation, Bluetooth hands-free system 7479
5 1 2 Preparation for mobile telephone, Bluetooth hands-free system, Comfort 7480
5 2 Overview of fitting locations – telephone system 7480
5 3 Removing and installing telephone microphone -R38- 7482
5 3 1 Removing and installing telephone microphone -R38-, vehicles without rear interior light -WX2- 7482
5 3 2 Removing and installing telephone microphone -R38-, vehicles with rear interior light -WX2- 7482
5 4 Removing and installing two-way signal amplifier for mobile telephone/data services -J984- 7483
5 5 Removing and installing storage compartment with interface for mobile telephone -R265- 7484
6 Navigation system 7486
6 1 Overview of navigation system 7486
6 2 Overview of fitting locations – navigation system 7486
6 3 Removing and installing control unit for navigation system 7487
7 Reversing camera system 7488
7 1 Overview of reversing camera system 7488
7 2 Overview of fitting locations – reversing camera system 7488
7 3 Removing and installing reversing camera -R189- 7489
8 Multifunction steering wheel 7490
8 1 Overview of multifunction steering wheel 7490
8 2 Assembly overview – multifunction steering wheel 7490
8 3 Removing and installing multifunction buttons in steering wheel -E441-/-E440- 7491
8 4 Removing and installing Tiptronic switch in steering wheel -E439-/-E438- 7495
9 Connection for external multimedia devices 7497
9 1 Removing and installing connection for external multimedia devices 7497
9 2 Removing and installing USB hub -R293- 7498
10 Online services 7500
10 1 Overview of fitting locations – mobile online services 7500
10 2 Removing and installing emergency call module control unit and communication unit -J949- 7501
10 3 Removing and installing Telematics button module -E734- 7502
10 4 Removing and installing loudspeaker for emergency call module -R335- 7503
10 5 Renewing battery in emergency call module control unit and communication unit -J949- 7504
10 6 Renewing control unit for emergency call module and communication unit -J949- 7506
D4B8076D155 Heating air conditioning system 7507
00 – Technical data 7511
1 Safety information 7511
1 1 Safety precautions when working on air conditioning systems 7511
1 2 Safety measures when working on vehicles with a start/stop system 7511
1 3 Safety precautions when using testers and measuring instruments during a road test 7512
1 4 Safety precautions when working on the cooling system 7512
1 5 Safety precautions when handling refrigerants 7512
1 6 Safety precautions when working on SCR system 7513
2 General information 7515
2 1 Type plates 7515
2 1 1 Type plates, refrigerant R134a 7515
2 1 2 Type plates, refrigerant R1234yf 7516
3 Repair instructions 7518
3 1 General repair instructions 7518
3 2 Fitting radiator and condensers 7518
3 3 Working on refrigerant circuit 7518
3 4 Refrigerant circuit seals 7519
4 Technical data 7521
4 1 Refrigerant capacity 7521
4 1 1 Capacities for refrigerant R134a 7521
4 1 2 Capacities for refrigerant R1234yf 7521
4 2 Refrigerant oil capacities 7521
4 2 1 Refrigerant oil capacities, refrigerant R134a 7521
4 2 2 Refrigerant oil capacities, refrigerant R1234yf 7522
4 3 Oil distribution 7522
80 – Heating 7523
1 Heater 7523
1 1 Removing and installing fresh air blower series resistor with overheating fuse -N24- 7523
2 Operating and display unit 7524
2 1 Overview of operating and display unit 7524
2 2 Removing and installing operating and display unit 7524
87 – Air conditioning system 7526
1 Overview of fitting locations – air conditioning system 7526
1 1 Overview of fitting locations – components not located in passenger compartment 7526
1 2 Overview of fitting locations – components located in front section of passenger compartment 7528
1 2 1 Overview of fitting locations – components inside of front passenger compartment, left-hand drive vehicles 7528
1 2 2 Overview of fitting locations – components inside of front passenger compartment, right-hand drive vehicles 7530
2 Refrigerant circuit 7531
2 1 System overview – refrigerant circuit 7531
2 2 Assembly overview – condenser 7533
2 3 Removing and installing refrigerant circuit pressure sender -G805- 7535
2 4 Removing and installing expansion valve 7536
2 5 Removing and installing condenser 7540
2 6 Removing and installing desiccant bag or cartridge 7544
2 6 1 Removing and installing desiccant bag or cartridge, Denso condenser 7544
2 6 2 Removing and installing desiccant bag or cartridge, Mahle condenser 7547
2 6 3 Removing and installing desiccant bag or cartridge, Modine condenser 7553
2 7 Removing and installing evacuating and charging valves on low and high-pressure side 7557
2 8 Commissioning air conditioning system after filling refrigerant circuit 7559
2 9 Removing and installing refrigerant line from condenser to air conditioner compressor 7560
2 10 Removing and installing refrigerant line from air conditioner compressor to evaporator 7562
2 11 Removing and installing refrigerant line from air conditioner compressor to evaporator 7566
3 Air conditioner compressor 7570
3 1 Assembly overview – drive unit of air conditioner compressor 7570
3 1 1 Assembly overview – drive unit of air conditioner compressor 7570
3 1 2 Assembly overview – drive unit of air conditioner compressor with air conditioning system magnetic clutch -N25- 7572
3 2 Assembly overview – pulley 7574
3 2 1 Assembly overview – pulley, Denso air conditioner compressor 7574
3 2 2 Assembly overview – belt pulley, Sanden air conditioner compressor 7574
3 2 3 Assembly overview – belt pulley, air conditioner compressor with air conditioning system magnetic clutch -N25- 7576
3 3 Removing air conditioning compressor from and installing on bracket 7578
3 4 Removing and installing air conditioner compressor 7580
3 5 Checking high-pressure safety valve on air conditioner compressor 7585
3 6 Removing and installing pulley 7586
3 6 1 Removing and installing Denso belt pulley 7586
3 6 2 Removing and installing Sanden belt pulley 7588
3 6 3 Removing and installing belt pulley, air conditioner compressor with air conditioning system magnetic clutch -N25- 7588
4 Control motors 7592
4 1 Overview of fitting locations – control motors at front 7592
4 1 1 Overview of fitting locations – control motors at front, air conditioning system with electric/manual controls, left-hand drive vehicles 7592
4 1 2 Overview of fitting locations – control motors at front, air conditioning system with electric/manual controls, right-hand drive vehicles 7593
4 1 3 Overview of fitting locations – front Climatronic control motors, left-hand drive vehicles 7594
4 1 4 Overview of fitting locations – front Climatronic control motors, right-hand drive vehicles 7595
4 2 Removing and installing defroster flap -VX47- 7597
4 2 1 Removing and installing defroster flap -VX47-, left-hand drive vehicles 7597
4 2 2 Removing and installing defroster flap -VX47-, right-hand drive vehicles 7598
4 3 Removing and installing front left temperature flap -VX34- 7599
4 3 1 Removing and installing front left temperature flap -VX34-, left-hand drive vehicles 7599
4 3 2 Removing and installing front left temperature flap -VX34-, right-hand drive vehicles 7600
4 4 Removing and installing front right temperature flap -VX35- 7602
4 4 1 Removing and installing front right temperature flap -VX35-, left-hand drive vehicles 7602
4 4 2 Removing and installing front right temperature flap -VX35-, right-hand drive vehicles 7603
4 5 Removing and installing fresh air and air recirculation flap -VX96- 7604
4 5 1 Removing and installing fresh air and air recirculation flap -VX96-, left-hand drive vehicles 7604
4 5 2 Removing and installing fresh air and air recirculation flap -VX96-, right-hand drive vehicles 7605
4 6 Removing and installing air distribution flap -VX33- 7607
4 7 Removing and installing fresh air and air recirculation flap control motor -V154- 7608
4 8 Removing and installing air distribution flap adjustment unit 7610
4 8 1 Removing and installing air distribution flap adjustment unit, left-hand drive vehicles 7610
4 8 2 Removing and installing air distribution flap adjustment unit, right-hand drive vehicles 7611
4 9 Removing and installing temperature flap actuator 7611
4 9 1 Removing and installing temperature flap actuator, left-hand drive vehicles 7611
4 9 2 Removing and installing temperature flap actuator, right-hand drive vehicles 7612
5 Front heater and air conditioning unit 7614
5 1 Assembly overview – heater and air conditioning unit 7614
5 2 Assembly overview – evaporator housing 7616
5 2 1 Assembly overview – evaporator housing, left-hand drive vehicles 7616
5 2 2 Assembly overview – evaporator housing, right-hand drive vehicles 7617
5 3 Removing and installing evaporator 7618
5 4 Checking auxiliary air heater element -Z35- 7619
5 5 Removing and installing auxiliary air heater element -Z35- 7620
5 6 Removing and installing heater and air conditioning unit 7621
5 7 Removing and installing holder for heater and air conditioning unit 7627
5 8 Dismantling and assembling heater and air conditioning unit 7627
5 9 Removing and installing air distribution housing 7628
5 10 Removing and installing dust and pollen filter 7629
5 11 Removing and installing fresh air blower -V2- 7631
5 12 Removing and installing fresh air blower control unit -J126- 7631
5 13 Removing and installing heat exchanger 7632
5 13 1 Removing and installing Valeo heat exchanger 7632
5 13 2 Removing and installing Mahle heat exchanger 7637
5 14 Removing and installing coolant pipes on heat exchanger 7642
5 14 1 Removing and installing coolant pipes at heat exchanger (Valeo) 7642
5 14 2 Removing and installing coolant pipes on heat exchanger, Mahle 7643
5 15 Removing and installing evaporator temperature sensor -G308- 7645
5 15 1 Removing and installing evaporator temperature sensor -G308-, Mahle 7645
5 15 2 Removing and installing evaporator temperature sensor -G308-, Valeo 7645
5 16 Removing and installing flexible shafts 7646
5 16 1 Removing and installing flexible shaft of air distribution flap actuator, left-hand drive vehicles 7646
5 16 2 Removing and installing flexible shaft of temperature flap actuator, left-hand drive vehicles 7647
5 16 3 Removing and installing flexible shaft of air distribution flap actuator, right-hand drive vehicles 7648
5 16 4 Removing and installing flexible shaft of temperature flap actuator, right-hand drive vehicles 7648
5 17 Removing and installing condensation drain 7649
5 18 Checking condensation drain 7651
5 19 Removing and installing fresh air blower series resistor with overheating fuse -N24- 7652
6 Air duct 7653
6 1 Assembly overview – air duct and air distribution in passenger compartment 7653
6 1 1 Assembly overview – air duct and air distribution in passenger compartment, left-hand drive vehicle 7653
6 1 2 Assembly overview – air duct and air distribution in passenger compartment, right-hand drive vehicles 7655
6 2 Removing and installing driver side footwell vents 7657
6 2 1 Removing and installing driver side footwell vents, left-hand drive vehicles 7657
6 2 2 Removing and installing driver side footwell vents, right-hand drive vehicles 7658
6 3 Removing and installing front passenger side footwell vents 7659
6 3 1 Removing and installing front passenger side footwell vents, left-hand drive vehicles 7659
6 3 2 Removing and installing front passenger side footwell vents, right-hand drive vehicles 7659
6 4 Removing and installing rear footwell vent 7660
6 5 Removing and installing fresh air intake 7661
6 6 Removing and installing cover for fresh air intake 7662
6 7 Removing and installing air intake duct 7662
6 8 Removing and installing air duct for defroster vent 7663
6 9 Removing and installing air duct for centre vent 7664
7 Operating and display unit 7665
7 1 Overview of operating and display unit 7665
7 1 1 Overview of operating and display unit, air conditioning system with electric/manual controls 7665
7 1 2 Overview – operating and display unit, Climatronic up to week 34/2021 7666
7 1 3 Overview of operating and display unit, Climatronic, as of week 34/2021 7668
7 2 Removing and installing operating and display unit 7670
7 2 1 Removing and installing operating and display unit, air conditioning system with electric/manual controls 7670
7 2 2 Removing and installing operating and display unit, Climatronic 7670
8 Other controlling and regulating components 7672
8 1 Removing and installing sunlight penetration photosensor -G107- 7672
8 2 Removing and installing ambient temperature sensor -G17- 7672
8 3 Removing and installing humidity sender for air conditioning system -G260- 7673
8 4 Removing and installing left vent temperature sender -G150- 7673
8 4 1 Removing and installing left vent temperature sender -G150-, LHD vehicles 7673
8 4 2 Removing and installing left vent temperature sender -G150-, RHD vehicles 7674
8 5 Removing and installing right vent temperature sender -G151- 7675
8 5 1 Removing and installing right vent temperature sender -G151-, LHD vehicles 7675
8 5 2 Removing and installing right vent temperature sender -G151-, RHD vehicles 7676
8 6 Removing and installing footwell vent temperature sender -G192- 7677
D4B8076D157 Fuel supply system petrol engines 7678
00 – Technical data 7682
1 Safety information 7682
1 1 Safety regulations for working on fuel supply 7682
1 2 Safety precautions when using testers and measuring instruments during a road test 7682
1 3 Safety measures when working on vehicles with a start/stop system 7683
2 Identification 7684
2 1 Engine number/engine data 7684
3 General information 7685
3 1 Rules for cleanliness when working on auxiliary heater and fuel system 7685
4 Repair notes 7686
4 1 Routing and attachment of lines 7686
4 2 General repair instructions 7686
20 – Fuel supply system 7687
1 Fuel 7687
1 1 Assembly overview – fuel tank 7687
1 1 1 Renewing seal for cap 7689
1 2 Removing and installing fuel tank 7689
1 3 Emptying fuel tank 7696
1 3 1 Emptying fuel tank when fuel pump is intact 7696
1 3 2 Emptying fuel tank if it is more than 3/4 full 7699
1 3 3 Emptying fuel tank if it is less than 3/4 full 7701
2 Fuel delivery unit, fuel gauge sender 7705
2 1 Assembly overview – fuel delivery unit/fuel gauge sender 7705
2 2 Removing and installing fuel delivery unit, fuel gauge sender 7707
2 3 Removing and installing fuel gauge sender -G- 7712
2 4 Removing and installing assembly opening cover 7713
3 Plug-in connectors 7714
3 1 Separating plug-in connectors 7714
4 Fuel filter 7721
5 Activated charcoal filter system 7722
5 1 Connection diagram – activated charcoal filter system 7722
5 1 1 Connection diagram – activated charcoal filter system, engine compartment, vehicles with 1 5 l engine from model year 2020 7722
5 1 2 Connection diagram – activated charcoal filter system, engine compartment, vehicles with 1 0 l TSI engine from model year 2020 7723
5 1 3 Connection diagram – activated charcoal filter system, engine compartment, vehicles with 1 0 l MPI engine from model year 2020 7725
5 1 4 Connection diagram – activated charcoal filter system, rear 7726
5 2 Assembly overview – activated charcoal filter system 7727
5 3 Removing and installing activated charcoal filter 7729
5 4 Checking fuel tank breather 7730
6 Accelerator pedal 7739
6 1 Assembly overview – accelerator module 7739
6 2 Removing and installing accelerator pedal module -GX2- 7739
7 Fuel supply 7741
7 1 Checking fuel system pressurisation pump -G6-, EA888evo 7741
7 2 Checking fuel system pressurisation pump -G6- 7748
7 2 1 Checking fuel pressure in engine compartment 7748
7 2 2 Measuring pressure at fuel delivery unit -GX1- 7751
7 2 3 Checking fuel delivery rate of fuel system pressurisation pump -G6- in engine compartment 7753
7 2 4 Measuring fuel delivery rate at fuel delivery unit -GX1- 7756
7 2 5 Connecting test instrument adapter for voltage measurement at fuel delivery unit 7758
7 2 6 Connecting remote control 7760
7 3 Removing and installing fuel pump control unit -J538- 7762
8 Fuel lines 7764
8 1 Removing and installing fuel line for auxiliary/supplementary heater 7764
8 2 Removing and installing fuel lines 7766
D4B8076DBAF Body Repairs 7772
00 – Technical data 7780
1 Basic instructions 7780
1 1 Original joint 7780
1 2 Used joining techniques 7780
2 Vehicle identification data 7782
2 1 Vehicle identification number 7782
2 2 Identification plate 7783
2 3 Vehicle data sticker 7784
3 Safety information 7786
4 Gas vehicles 7787
5 Moulded foam inserts 7788
6 Galvanized body parts, high- and higher-strength and hot-formed body panels 7790
7 Laser welding 7793
8 Gaps 7794
8 1 Body – front 7794
8 2 Body, centre 7795
8 3 Body – rear 7798
9 Body dimensions 7801
9 1 Body – front 7801
9 1 1 Body dimensions for front end 7801
9 1 2 Diagonals for windscreen aperture and vehicle front end 7802
9 2 Body, centre 7803
9 2 1 Body dimensions for door apertures 7803
9 2 2 Body dimensions between pillars 7804
9 3 Body – rear 7807
9 3 1 Body dimension for rear lid aperture 7807
9 4 Body dimension for floor panel 7809
9 4 1 Floor panel, front 7809
9 4 2 Floor panel, centre 7810
9 4 3 Floor panel, rear 7811
10 Straightening bracket set 7813
10 1 Setup overview of complete body 7813
11 Portal gauge 7815
11 1 Setup overview of complete body 7815
50 – Body – front 7817
1 Overview of parts 7817
2 Renewing right bracket 7818
2 1 Tools 7819
2 2 Removing 7819
2 3 Installing 7820
2 3 1 Preparing new part 7820
2 3 2 Welding in 7822
3 Repairing threads for securing subframe 7824
3 1 Contents of thread repair kit 7825
3 2 Repairing threads 7826
3 2 1 Drilling threads 7826
3 2 2 Cutting thread 7827
3 2 3 Inserting thread insert 7828
4 Renewing mounting bracket for subframe 7830
4 1 Tools 7831
4 2 Removing 7831
4 3 Installing 7832
4 3 1 Preparing new part 7832
4 3 2 Welding in 7834
5 Renewing front longitudinal member cross panel 7836
5 1 Tools 7837
5 2 Removing 7837
5 3 Installing 7838
5 3 1 Preparing new part 7838
5 3 2 Welding in 7839
6 Renewing upper wheel housing longitudinal member 7841
6 1 Tools 7842
6 2 Removing 7842
6 3 Installing 7844
6 3 1 Preparing new part 7844
6 3 2 Welding in 7846
7 Renewing upper wheel housing longitudinal member – part section 7848
7 1 Tools 7849
7 2 Removing 7849
7 3 Installing 7851
7 3 1 Preparing new part 7851
7 3 2 Welding in 7853
8 Renewing hinge reinforcement for bonnet 7855
8 1 Tools 7856
8 2 Removing 7856
8 3 Installing 7857
8 3 1 Preparing new part 7857
8 3 2 Welding in 7858
9 Renewing upper inner wheel housing longitudinal member 7860
9 1 Tools 7861
9 2 Removing 7861
9 3 Installing 7863
9 3 1 Preparing new part 7863
9 3 2 Welding in 7865
10 Renewing upper inner wheel housing longitudinal member – part section 7867
10 1 Tools 7868
10 2 Removing 7868
10 3 Installing 7870
10 3 1 Preparing new part 7870
10 3 2 Welding in 7872
11 Renewing front wheel housing 7874
11 1 Tools 7875
11 2 Removing 7875
11 3 Installing 7877
11 3 1 Preparing new part 7877
11 3 2 Welding in 7879
12 Renewing front wheel housing (part section) 7883
12 1 Tools 7884
12 2 Removing 7884
12 3 Installing 7885
12 3 1 Preparing new part 7885
12 3 2 Welding in 7886
13 Renewing front longitudinal member 7888
13 1 Tools 7889
13 2 Removing 7889
13 3 Installing 7892
13 3 1 Preparing new part 7892
13 3 2 Welding in 7895
14 Renewing front longitudinal member (left part section) 7898
14 1 Tools 7899
14 2 Removing 7899
14 3 Installing 7900
14 3 1 Preparing new part 7900
14 3 2 Welding in 7902
15 Renewing front longitudinal member (right part section) 7904
15 1 Tools 7905
15 2 Removing 7905
15 3 Installing 7906
15 3 1 Preparing new part 7907
15 3 2 Welding in 7908
16 Renewing studs 7910
51 – Body – centre 7912
1 Overview of parts 7912
2 Renewing roof – vehicles without tilting sunroof 7913
2 1 Tools 7914
2 2 Removing 7914
2 3 Installing 7919
2 3 1 Preparing new part 7919
2 3 2 Bonding roof 7922
2 3 3 Adjusting roof depth 7926
2 3 4 Welding in 7927
3 Renewing roof – vehicles with tilting sunroof 7931
3 1 Tools 7932
3 2 Removing 7932
3 3 Installing 7936
3 3 1 Preparing new part 7936
3 3 2 Bonding roof 7938
3 3 3 Adjusting roof depth 7943
3 3 4 Welding in 7944
4 Renewing front cross member for roof 7947
4 1 Tools 7948
4 2 Removing 7948
4 3 Installing 7949
4 3 1 Preparing new part 7949
4 3 2 Welding in 7950
5 Renewing rear roof cross member 7952
5 1 Tools 7953
5 2 Removing 7953
5 3 Installing 7954
5 3 1 Preparing new part 7954
5 3 2 Welding in 7956
6 Renewing roof side member 7958
6 1 Tools 7959
6 2 Removing 7960
6 3 Installing 7963
6 3 1 Preparing new part 7963
6 3 2 Welding in 7966
7 Renewing A-pillar 7969
7 1 Tools 7970
7 2 Moulded foam inserts 7971
7 3 Removing 7971
7 4 Installing 7972
7 4 1 Preparing new part 7972
7 4 2 Welding in 7974
8 Renewing upper A-pillar reinforcement (part section repair) 7977
8 1 Tools 7978
8 2 Moulded foam inserts 7978
8 3 Removing 7978
8 4 Installing 7981
8 4 1 Preparing new parts 7981
8 4 2 Welding in 7985
9 Renewing A-pillar reinforcement 7990
9 1 Tools 7991
9 2 Moulded foam inserts 7991
9 3 Removing 7991
9 4 Installing 7992
9 4 1 Preparing new part 7992
9 4 2 Welding in 7994
10 Renewing B-pillar 7997
10 1 Tools 7999
10 2 Identification plate 7999
10 3 Moulded foam inserts 8000
10 4 Removing 8000
10 5 Installing 8002
10 5 1 Preparing new part 8002
10 5 2 Welding in 8004
11 Renewing B-pillar reinforcement 8007
11 1 Tools 8008
11 2 Identification plate 8008
11 3 Moulded foam inserts 8009
11 4 Removing 8009
11 5 Installing 8011
11 5 1 Preparing new part 8011
11 5 2 Welding in 8013
12 Renewing outer side member 8016
12 1 Tools 8017
12 2 Identification plate 8017
12 3 Moulded foam inserts 8018
12 4 Removing 8018
12 5 Installing 8020
12 5 1 Preparing new part 8020
12 5 2 Welding in 8022
13 Renewing side member reinforcement 8025
13 1 Tools 8026
13 2 Moulded foam inserts 8026
13 3 Removing 8026
13 4 Installing 8028
13 4 1 Preparing new part 8028
13 4 2 Welding in 8030
14 Renewing inner mounting for seat inner cross member 8033
14 1 Tools 8034
14 2 Removing 8034
14 3 Installing 8035
14 3 1 Preparing new part 8035
14 3 2 Welding in 8036
15 Renewing seat cross member 8038
15 1 Tools 8039
15 2 Removing 8039
15 3 Installing 8040
15 3 1 Preparing new part 8040
15 3 2 Welding in 8041
16 Renewing outer mounting for seat outer cross member 8043
16 1 Tools 8044
16 2 Removing 8044
16 3 Installing 8046
16 3 1 Preparing new part 8046
16 3 2 Welding in 8048
53 – Body – rear 8052
1 Overview of parts 8052
2 Renewing rear cross panel 8053
2 1 Tools 8054
2 2 Removing 8054
2 3 Installing 8056
2 3 1 Preparing new part 8056
2 3 2 Welding in 8058
3 Renewing rear cross member 8060
3 1 Tools 8061
3 2 Removing 8061
3 3 Installing 8062
3 3 1 Preparing new part 8062
3 3 2 Welding in 8064
4 Renewing tail light mounting 8067
4 1 Tools 8068
4 2 Removing 8068
4 3 Installing 8069
4 3 1 Preparing new part 8069
4 3 2 Welding in 8070
5 Renewing luggage compartment floor 8072
5 1 Tools 8073
5 2 Moulded foam inserts 8073
5 3 Removing 8073
5 4 Installing 8074
5 4 1 Preparing new part 8074
5 4 2 Welding in 8076
6 Renewing luggage compartment floor (natural gas vehicles) 8079
6 1 Tools 8080
6 2 Moulded foam inserts 8080
6 3 Removing 8080
6 4 Installing 8081
6 4 1 Preparing new part 8081
6 4 2 Welding in 8083
7 Renewing left floor panel 8085
7 1 Tools 8086
7 2 Removing 8086
7 3 Installing 8087
7 3 1 Preparing new part 8087
7 3 2 Welding in 8088
8 Renewing rear longitudinal member cross panel 8090
8 1 Tools 8091
8 2 Removing 8091
8 3 Installing 8092
8 3 1 Preparing new part 8092
8 3 2 Welding in 8093
9 Renewing rear longitudinal member (part section) 8095
9 1 Tools 8096
9 2 Removing 8096
9 3 Installing 8097
9 3 1 Preparing new part 8097
9 3 2 Welding in 8098
10 Renewing rear longitudinal member (part section – second parting cut) 8100
10 1 Tools 8101
10 2 Moulded foam inserts 8101
10 3 Removing 8101
10 4 Installing 8103
10 4 1 Preparing new part 8103
10 4 2 Welding in 8106
11 Permitted parting cuts on side panel 8113
12 Renewing side panel (part section) 8114
12 1 Tools 8115
12 2 Moulded foam inserts 8116
12 3 Removing 8116
12 4 Installing 8118
12 4 1 Preparing new part 8118
12 4 2 Welding in 8120
13 Renewing outer wheel housing liner 8123
13 1 Tools 8124
13 2 Moulded foam inserts 8124
13 3 Removing 8124
13 4 Installing 8125
13 4 1 Preparing new part 8125
13 4 2 Welding in 8127
14 Renewing lock reinforcement 8130
14 1 Tools 8131
14 2 Removing 8131
14 3 Installing 8133
14 3 1 Preparing new part 8133
14 3 2 Welding in 8135
D4B80609EAA 4 cylinder common rail (1 6 l and 2 0 l 4 V turbocharger EA 288) 8138
00 – Technical data 8146
1 Safety information 8146
1 1 Safety precautions when working on the fuel supply system 8146
1 2 Safety measures when working on vehicles with a start/stop system 8147
1 3 Safety precautions when using testers and measuring instruments during a road test 8147
1 4 Safety precautions when working on the cooling system 8147
1 5 Safety precautions when working on the SCR system 8147
1 6 Safety precautions when working on the exhaust system 8149
2 Identification 8150
2 1 Engine number/engine data 8150
3 Repair instructions 8154
3 1 Rules for cleanliness 8154
3 2 Foreign material in engine 8154
3 3 Contact corrosion 8154
3 4 Routing and attachment of lines 8155
3 5 Installing radiators and condensers 8155
10 – Removing and installing engine 8156
1 Removing and installing engine 8156
1 1 Removing engine 8156
1 2 Separating engine and gearbox 8169
1 2 1 Separating engine and gearbox, vehicles with manual gearbox 8169
1 2 2 Separating engine and gearbox, vehicles with dual clutch gearbox 8172
1 3 Securing engine on engine and gearbox support 8175
1 4 Installing engine 8177
2 Assembly mountings 8182
2 1 Assembly overview – assembly mountings 8182
2 1 1 Assembly overview – assembly mountings, Tiguan 8182
2 1 2 Assembly overview – assembly mountings, T-Roc, Polo, T-Cross 8184
2 2 Removing and installing engine mounting 8186
2 3 Removing and installing gearbox mounting 8187
2 4 Removing and installing pendulum support 8190
2 5 Supporting engine in installation position 8192
2 5 1 Supporting engine in installation position, Tiguan 8192
2 5 2 Supporting engine in installation position, T-Roc 8197
2 5 3 Supporting engine in installation position, Polo 8199
2 5 4 Supporting engine in installation position, T-Cross 8202
2 6 Adjusting assembly mountings 8204
2 7 Checking adjustment of assembly mountings 8208
3 Engine cover panel 8209
3 1 Removing and installing engine cover 8209
13 – Crankshaft group 8210
1 Cylinder block, pulley end 8210
1 1 Assembly overview – cylinder block, pulley end 8210
1 2 Assembly overview – sealing flange, pulley end 8212
1 3 Removing and installing poly-V belt 8214
1 3 1 Removing and installing poly V-belt, vehicles with air conditioner compressor 8214
1 3 2 Removing and installing poly V-belt, vehicles without air conditioner compressor 8215
1 4 Removing and installing poly V-belt tensioner 8216
1 5 Removing and installing vibration damper 8216
1 6 Removing and installing bracket for ancillaries 8217
1 7 Removing and installing engine support 8219
1 8 Removing and installing sealing flange, pulley end 8221
1 9 Renewing caps in cylinder block, pulley end 8224
2 Cylinder block, gearbox end 8226
2 1 Assembly overview – cylinder block, gearbox end 8226
2 2 Removing and installing flywheel 8227
2 3 Removing and installing sealing flange on gearbox side 8230
2 3 1 Removing and installing sealing flange, crankshaft flange with 6 bolting points 8230
2 3 2 Removing and installing sealing flange, crankshaft flange with 8 bolting points 8240
2 4 Renewing caps in cylinder block (gearbox end) 8250
3 Crankshaft 8252
3 1 Assembly overview – crankshaft 8252
3 2 Crankshaft dimensions 8253
3 3 Measuring axial clearance of crankshaft 8254
3 4 Renewing needle bearing in crankshaft 8255
4 Pistons and conrods 8258
4 1 Assembly overview – pistons and conrods 8258
4 2 Removing and installing pistons 8263
4 3 Measuring piston projection at TDC 8264
4 4 Checking piston and cylinder bore 8266
4 5 Checking radial clearance of conrods 8268
15 – Cylinder head, valve gear 8269
1 Cylinder head 8269
1 1 Assembly overview – cylinder head 8269
1 2 Assembly overview – cylinder head cover 8273
1 3 Removing and installing cylinder head 8275
1 4 Removing and installing cylinder head cover 8285
1 5 Removing and installing injector seals 8286
1 6 Removing and installing camshaft housing 8287
1 7 Checking compression 8294
2 Toothed belt drive 8296
2 1 Assembly overview – toothed belt cover 8296
2 2 Assembly overview – toothed belt 8296
2 3 Removing and installing toothed belt guard 8298
2 3 1 Removing and installing upper toothed belt guard 8298
2 3 2 Removing and installing lower toothed belt guard 8301
2 4 Removing and installing toothed belt 8303
2 5 Removing toothed belt from camshaft 8317
3 Valve gear 8323
3 1 Assembly overview – valve gear 8323
3 2 Measuring axial play of camshaft 8327
3 3 Removing and installing camshaft oil seal 8328
3 4 Removing and installing camshaft adjuster 8330
3 4 1 Removing and installing camshaft adjuster 8330
3 4 2 Removing and installing control valve for the camshaft adjuster 8333
3 5 Removing and installing camshaft control valve 1 -N205- 8336
3 6 Checking hydraulic compensation elements 8337
3 7 Removing and installing valve stem oil seals 8338
3 7 1 Removing and installing valve stem seals (cylinder head installed) 8338
3 7 2 Removing and installing valve stem seals (cylinder head removed) 8342
4 Inlet and exhaust valves 8348
4 1 Checking valve guides 8348
4 2 Checking valves 8349
4 3 Valve dimensions 8349
17 – Lubrication 8350
1 Sump, oil pump 8350
1 1 Assembly overview – sump/oil pump 8350
1 1 1 Assembly overview – sump/oil pump 8350
1 1 2 Assembly overview – sump/oil pump, two-piece sump 8352
1 2 Engine oil 8356
1 3 Removing and installing oil sump 8357
1 4 Removing and installing lower part of sump 8361
1 5 Removing and installing upper part of sump 8365
1 6 Removing and installing oil pump 8369
1 7 Removing and installing oil level and oil temperature sender -G266- 8370
1 7 1 Removing and installing oil level and oil temperature sender -G266- 8370
1 7 2 Removing and installing oil level and oil temperature sender -G266-, vehicles with two-piece sump 8371
2 Engine oil cooler 8373
3 Oil filter, oil pressure switch 8374
3 1 Assembly overview – oil filter housing, oil pressure switch 8374
3 2 Removing and installing oil pressure switch -F1- 8376
3 3 Removing and installing oil pressure switch for reduced oil pressure -F378- 8378
3 4 Checking oil pressure 8380
3 5 Removing and installing oil filter housing 8380
3 6 Removing and installing valve for oil pressure control -N428- 8383
4 Oil circuit 8384
4 1 Removing and installing oil supply line 8384
4 2 Removing and installing oil return line for turbocharger 8385
19 – Cooling 8387
1 Cooling system/coolant 8387
1 1 Connection diagram – coolant hoses 8387
1 1 1 Connection diagram – coolant hoses 8387
1 1 2 Schematic diagram for coolant hoses, vehicles with water-cooled turbocharger 8389
1 2 Checking cooling system for leaks 8391
1 3 Draining coolant 8395
1 4 Filling with coolant 8398
1 4 1 Filling with coolant without electric vacuum pump 8398
1 4 2 Filling coolant with electric vacuum pump -VAS 6096/2- 8404
1 4 3 Checking electric vacuum pump -VAS 6096/2- 8414
1 5 Checking filling quality of cooling system 8415
1 6 Flushing cooling system 8417
1 6 1 Flushing cooling system, quick reference guide 8439
2 Coolant pump, regulation of cooling system 8441
2 1 Assembly overview – coolant pump/thermostat 8441
2 1 1 Assembly overview – coolant pump/thermostat, version 1 8441
2 1 2 Assembly overview – coolant pump/thermostat, version 2 8443
2 2 Assembly overview – electric coolant pump 8445
2 2 1 Assembly overview – charge air cooling pump -V188- and auxiliary pump for heating -V488-, version 1 8445
2 2 2 Assembly overview – charge air cooling pump -V188-, version 2 8446
2 2 3 Assembly overview – auxiliary pump for heating -V488-, version 2 8447
2 2 4 Assembly overview – charge air cooling pump -V188-, version 3 8448
2 2 5 Assembly overview – auxiliary pump for heating -V488-, version 3 8449
2 2 6 Assembly overview – charge air cooling pump -V188-, version 4 8450
2 3 Assembly overview – coolant temperature sender 8451
2 3 1 Assembly overview – coolant temperature sender -G62- 8451
2 3 2 Assembly overview – radiator outlet coolant temperature sender -G83- 8452
2 4 Removing and installing electric coolant pump 8454
2 4 1 Removing and installing charge air cooling pump -V188-, versions 1 and 2 8454
2 4 2 Removing and installing auxiliary pump for heating -V488-, version 1 8456
2 4 3 Removing and installing charge air cooling pump -V188-, version 3 8459
2 4 4 Removing and installing auxiliary pump for heating -V488-, version 2 8462
2 4 5 Removing and installing auxiliary pump for heating -V488-, version 3 8465
2 4 6 Removing and installing charge air cooling pump -V188-, version 4 8468
2 5 Removing and installing coolant pump 8472
2 6 Removing and installing thermostat 8473
2 6 1 Removing and installing thermostat, version 1 8473
2 6 2 Removing and installing thermostat, version 2 8474
2 7 Checking thermostat 8476
2 8 Removing and installing coolant valve for cylinder head -N489- 8477
2 9 Removing and installing coolant temperature sender -G62- 8477
2 10 Removing and installing radiator outlet coolant temperature sender -G83- 8479
3 Coolant pipes 8481
3 1 Assembly overview – coolant pipes 8481
3 2 Removing and installing coolant pipes 8483
3 2 1 Removing and installing coolant pipes (top front) 8483
3 2 2 Removing and installing lower front coolant pipe 8484
3 2 3 Removing and installing coolant pipe (front left) 8487
3 2 4 Removing and installing left coolant pipes 8488
3 2 5 Removing and installing rear coolant pipe 8491
3 2 6 Removing and installing rear right coolant pipe 8493
3 2 7 Rear upper left coolant pipe 8497
3 2 8 Removing and installing front coolant connection 8499
4 Radiator, radiator fan 8501
4 1 Assembly overview – radiator/radiator fan 8501
4 1 1 Assembly overview – radiator/radiator fan, Tiguan, T-Roc, version 1 8501
4 1 2 Assembly overview – radiator/radiator fan, Tiguan, T-Roc, version 2 8503
4 1 3 Assembly overview – radiator/radiator fan, Polo, T-Cross 8504
4 1 4 Plug-in connectors of coolant hoses 8505
4 1 5 Coolant hoses with pretensioned spring-type clips 8506
4 2 Assembly overview – radiator cowl and radiator fans 8507
4 2 1 Assembly overview – radiator cowl and radiator fan, vehicles with two radiator fans 8507
4 2 2 Assembly overview – radiator cowl and radiator fan, vehicles with one radiator fan 8507
4 3 Removing and installing radiator 8508
4 3 1 Removing and installing radiator, Tiguan, T-Roc 8508
4 3 2 Removing and installing radiator, Polo 8511
4 3 3 Removing and installing radiator, T-Cross 8515
4 4 Removing and installing water radiator for charge air cooling circuit 8520
4 5 Removing and installing radiator cowl 8526
4 5 1 Removing and installing radiator cowl, Tiguan, T-Roc 8526
4 5 2 Removing and installing radiator cowl, Polo 8528
4 5 3 Removing and installing radiator cowl, T-Cross 8530
4 6 Removing and installing radiator fan 8532
4 6 1 Removing and installing radiator fan -V7- 8532
4 6 2 Removing and installing radiator fan, vehicles with two fan motors 8533
21 – Turbocharging/supercharging 8535
1 Turbocharger 8535
1 1 Assembly overview – turbocharger 8535
1 1 1 Assembly overview – turbocharger, vehicles with EU5 and EU6 emission standard 8535
1 1 2 Assembly overview – turbocharger, water-cooled turbocharger, vehicles with EU5 and EU6 emission standard 8537
1 1 3 Assembly overview – turbocharger, vehicles with EU4 emission standard 8540
1 2 Removing and installing turbocharger 8543
1 2 1 Removing and installing turbocharger, vehicles with EU5 and EU6 emission standard 8543
1 2 2 Removing and installing turbocharger, water-cooled turbocharger, vehicles with EU5 and EU6 emission standard 8549
1 2 3 Removing and installing turbocharger, vehicles with EU4 emission standard 8555
1 3 Renewing vacuum unit for turbocharger 8559
1 3 1 Renewing vacuum unit for turbocharger, versions 1 and 2 8559
1 3 2 Renewing vacuum unit for turbocharger, version 3 8566
1 4 Removing and installing connection for turbocharger 8572
2 Charge air system 8574
2 1 Assembly overview – charge air system 8574
2 2 Removing and installing charge pressure sender -G31- 8577
2 3 Checking charge air system for leaks 8577
2 4 Removing and installing air intake pipe 8580
2 4 1 Removing and installing air pipe, vehicles with non-water-cooled turbocharger 8580
2 4 2 Removing and installing air pipe, vehicles with water-cooled turbocharger 8581
2 5 Checking charge air cooler for leaks 8582
23 – Mixture preparation – injection 8589
1 Injection system 8589
1 1 Schematic overview – fuel system 8589
1 1 1 Schematic overview – fuel system 8589
1 2 Overview of fitting locations – injection system 8590
1 2 1 Overview of fitting locations – engine compartment 8590
1 2 2 Overview of fitting locations on engine (from above) 8594
1 2 3 Overview of fitting locations – front view of engine 8597
1 2 4 Overview of fitting locations – rear view of engine 8597
1 2 5 Overview of fitting locations – electrical connectors 8599
1 3 Filling/bleeding fuel system 8600
1 4 Checking fuel system for leaks 8601
2 Vacuum system 8602
2 1 Connection diagram – vacuum system 8602
2 2 Checking vacuum system 8603
3 Injectors/high-pressure reservoir (rail) 8604
3 1 Assembly overview – injectors 8604
3 2 Assembly overview – fuel rail 8606
3 3 Adapting correction values for injectors 8607
3 4 Testing injectors 8608
3 5 Checking return flow rate of injectors with engine running 8609
3 5 1 Checking return flow rate of injectors while engine is running, vehicles with Bosch injection system 8609
3 5 2 Checking return flow rate of injectors while engine is running, vehicles with Delphi injection system 8612
3 6 Checking return flow rate of injectors at starter speed 8615
3 6 1 Checking return flow rate of injectors at starter speed, vehicles with Bosch injection system 8615
3 6 2 Checking return flow rate of injectors at starter speed, vehicles with Delphi injection system 8617
3 7 Checking open injectors 8619
3 8 Removing and installing injectors 8621
3 9 Removing and installing high-pressure lines 8626
3 9 1 Removing high-pressure pipe between fuel rail and high-pressure pump 8626
3 9 2 Installing high-pressure line 8627
3 10 Removing and installing fuel rail 8629
4 Air filter 8634
4 1 Assembly overview – air filter housing 8634
4 2 Removing and installing air filter housing 8636
4 3 Removing and installing air duct on lock carrier 8639
4 3 1 Removing and installing air guide on lock carrier, Tiguan 8639
4 3 2 Removing air guide on lock carrier, T-Roc 8640
4 3 3 Removing air guide on lock carrier, Polo 8641
4 3 4 Removing air duct on lock carrier, T-Cross 8641
5 Intake manifold 8643
5 1 Assembly overview – intake manifold 8643
5 2 Removing and installing intake manifold 8647
5 3 Removing and installing throttle valve module -J338- 8651
6 Senders and sensors 8654
6 1 Removing and installing fuel pressure regulating valve -N276- 8654
6 1 1 Versions of fuel pressure regulating valve -N276- 8654
6 1 2 Removing and installing fuel pressure regulating valve, version 1 8655
6 1 3 Removing and installing fuel pressure regulating valve -N276-, version 2 8659
6 2 Checking fuel pressure regulating valve -N276- 8661
6 3 Removing and installing fuel pressure sender -G247- 8663
6 4 Removing and installing air mass meter -G70-/intake air temperature sender -G42- 8664
6 5 Removing and installing pressure differential sender -G505- 8666
6 5 1 Removing and installing pressure differential sender -G505-, version 1 8666
6 5 2 Removing and installing pressure differential sender -G505-, version 2 8668
6 6 Removing and installing exhaust gas pressure sensor 1 -G450- 8670
6 7 Removing and installing NOx sender 2 -G687- 8671
6 8 Removing and installing charge air temperature sender before charge air cooler -G810- 8673
6 9 Removing and installing charge air temperature sender after charge air cooler -G811- 8673
6 10 Removing and installing fuel temperature sender -G81- 8674
6 11 Removing and installing control unit for NOx sender -GX30- 8675
6 11 1 Versions of NOx sender control unit -GX30- 8675
6 11 2 Removing and installing control unit for NOx sender -GX30-, version A 8676
6 11 3 Removing and installing control unit for NOx sender -GX30-, version B 8681
6 12 Removing and installing temperature and pressure sender for low-pressure fuel system -GX20- 8684
7 Engine/motor control unit 8686
7 1 Removing and installing motor control unit -J623- 8686
7 2 Removing and installing engine control unit -J623- (with protective housing) 8687
7 2 1 Removing and installing engine control unit -J623- (with metal locking plate) 8687
7 2 2 Removing and installing engine control unit -J623- (with protective housing) 8691
8 High-pressure pump 8694
8 1 Assembly overview – high-pressure pump 8694
8 2 Removing and installing high-pressure pump 8694
9 Lambda probe 8699
9 1 Assembly overview – lambda probe 8699
9 2 Removing and installing lambda probe 8701
9 2 1 Removing and installing Lambda probe 1 before catalytic converter -GX10- 8701
9 2 2 Removing and installing Lambda probe 1 after catalytic converter -GX7- 8702
26 – Exhaust system 8705
1 Exhaust pipes and silencers 8705
1 1 Assembly overview – silencers 8705
1 1 1 Assembly overview – silencers, Tiguan 8705
1 1 2 Assembly overview – silencers, T-Roc with torsion beam axle 8706
1 1 3 Assembly overview – silencers, T-Roc with multi-link suspension 8707
1 1 4 Assembly overview – silencers, Polo, T-Cross 8708
1 2 Assembly overview – front exhaust pipe 8709
1 2 1 Assembly overview – front exhaust pipe 8709
1 2 2 Assembly overview – front exhaust pipe, vehicles with NOx sender 2 -G687- 8711
1 3 Removing and installing front exhaust pipe 8713
1 4 Separating exhaust pipes from silencers 8715
1 5 Removing and installing silencer 8716
1 5 1 Removing and installing silencer, Tiguan 8716
1 5 2 Removing and installing silencers, T-Roc with torsion beam axle 8717
1 5 3 Removing and installing silencers, T-Roc with multi-link suspension 8719
1 5 4 Removing and installing centre exhaust pipe, T-Roc 8720
1 5 5 Removing and installing silencer, Polo, T-Cross 8721
1 6 Aligning exhaust system free of stress 8722
1 7 Checking exhaust system for leaks 8723
1 8 Installation position of clamp 8723
1 9 Aligning tailpipes 8725
1 10 Removing and installing bracket for front exhaust pipe 8725
2 Emission control 8727
2 1 Assembly overview – emission control 8727
2 1 1 Versions of emission control system 8727
2 1 2 Assembly overview – emission control, vehicles with EU5 and EU6 emission standard 8728
2 1 3 Assembly overview – emission control, vehicles with EU4 emission standard 8731
2 2 Removing and installing catalytic converter 8733
2 3 Removing and installing particulate filter 8735
2 4 Removing and installing emission control module 8735
2 5 Removing and installing exhaust flap control unit -J883- 8747
3 SCR system (selective catalytic reduction) 8749
3 1 Assembly overview – reducing agent tank 8749
3 1 1 Assembly overview – tank for reducing agent, Tiguan 8749
3 1 2 Assembly overview – reducing agent tank, T-Roc with multi-link rear suspension 8751
3 1 3 Assembly overview – reducing agent tank, T-Roc with torsion beam rear suspension 8753
3 1 4 Assembly overview – reducing agent, Polo, T-Cross 8755
3 2 Assembly overview – reducing agent supply line 8757
3 2 1 Assembly overview – reducing agent supply line, Tiguan 8757
3 2 2 Assembly overview – reducing agent supply line, T-Roc 8758
3 2 3 Assembly overview – delivery line for reducing agent, Polo, T-Cross 8759
3 3 Assembly overview – delivery module for reducing agent 8761
3 4 Assembly overview – filler tube for reducing agent tank 8761
3 5 Removing and installing reducing agent tank 8763
3 5 1 Removing and installing tank for reducing agent, Tiguan 8763
3 5 2 Removing and installing reducing agent tank, T-Roc 8766
3 5 3 Removing and installing reducing agent tank, Polo, T-Cross 8768
3 5 4 Removing and installing reducing agent tank, T-Roc with torsion beam rear suspension 8771
3 6 Removing and installing front section of reducing agent supply line 8776
3 6 1 Removing and installing front section of reducing agent supply line, Tiguan 8776
3 6 2 Removing and installing front section of reducing agent supply line, T-Roc 8784
3 6 3 Removing and installing front section of reducing agent supply line, Polo, T-Cross 8793
3 7 Removing and installing delivery module for reducing agent 8801
3 8 Removing and installing injector for reducing agent -N474- 8803
3 9 Removing and installing control unit for reducing agent heater -J891- 8807
3 9 1 Removing and installing control unit for reducing-agent heater -J891-, Tiguan 8807
3 9 2 Removing and installing control unit for reducing agent heater -J891-, T-Roc with multi-link rear suspension 8808
3 9 3 Removing and installing control unit for reducing-agent heater -J891-, Polo 8808
3 9 4 Removing and installing control unit for reducing agent heater -J891-, T-Cross 8809
3 9 5 Removing and installing control unit for reducing agent heater -J891-, T-Roc with torsion beam rear suspension 8810
3 10 Assembly overview – injector for reducing agent 8814
3 11 Draining reducing agent tank 8816
3 12 Removing and installing rear section of reducing agent supply line 8819
3 12 1 Removing and installing rear section of reducing agent supply line, Tiguan 8819
3 12 2 Removing and installing rear section of reducing agent supply line, T-Roc 8820
3 12 3 Removing and installing rear section of reducing agent supply line, Polo, T-Cross 8824
3 13 Removing and installing filler pipe for reducing agent tank 8826
3 13 1 Removing and installing filler tube for reducing agent tank, Tiguan 8826
3 13 2 Removing and installing filler pipe for reducing agent tank, T-Roc with multi-link rear suspension 8829
3 13 3 Removing and installing filler tube for reducing agent tank, T-Roc with torsion beam rear suspension 8831
3 13 4 Removing and installing filler pipe for reducing agent tank, Polo, T-Cross 8833
3 14 Disconnecting reducing agent supply line 8836
3 15 SCR – resetting learnt values 8841
4 Exhaust gas temperature regulation 8843
4 1 Assembly overview – exhaust gas temperature regulation 8843
4 1 1 Assembly overview – exhaust gas temperature regulation, vehicles with EU5 and EU6 emission standard 8843
4 1 2 Assembly overview – exhaust gas temperature regulation, vehicles with EU4 emission standard 8845
4 2 Removing and installing exhaust gas temperature sender 1 -G235- 8845
4 2 1 Removing and installing exhaust gas temperature sender 1 -G235- 8845
4 2 2 Removing and installing exhaust gas temperature sender 1 -G235-, vehicles with water-cooled turbocharger 8847
4 3 Removing and installing exhaust gas temperature sender 2 -G448- 8849
4 4 Removing and installing exhaust gas temperature sender 3 -G495- 8851
4 5 Removing and installing exhaust gas temperature sender 4 -G648- 8853
5 Exhaust gas recirculation 8855
5 1 Assembly overview – exhaust gas recirculation 8855
5 1 1 Assembly overview – exhaust gas recirculation, vehicles with EU5 and EU6 emission standard 8855
5 1 2 Assembly overview – exhaust gas recirculation, vehicles with EU4 emission standard 8857
5 1 3 Assembly overview – exhaust gas recirculation valve 1 -GX5- 8859
5 2 Removing and installing exhaust gas recirculation cooler 8860
5 2 1 Removing and installing exhaust gas recirculation cooler, vehicles with EU5 and EU6 emission standard 8860
5 2 2 Removing and installing exhaust gas recirculation cooler, vehicles with EU4 emission standard 8865
5 3 Removing and installing exhaust gas recirculation valve 1 -GX5- 8867
5 4 Removing and installing exhaust gas recirculation valve 2 -GX6- 8869
5 5 Removing and installing exhaust gas recirculation temperature sensor -G98- 8870
5 5 1 Removing and installing exhaust gas recirculation temperature sensor -G98-, vehicles with EU5 and EU6 emission standard 8870
5 5 2 Removing and installing exhaust gas recirculation temperature sensor -G98-, vehicles with EU4 emission standard 8871
5 6 Checking exhaust gas recirculation cooler for leaks 8873
28 – Glow plug system 8874
1 Glow plug system 8874
1 1 Assembly overview – glow plug system 8874
1 2 Removing and installing glow plug 8876
1 3 Removing and installing automatic glow period control unit -J179- 8879
1 4 Removing and installing Hall sender -G40- 8879
1 5 Removing and installing engine speed sender -G28- 8880
D4B80609EAF Air conditioning systems with refrigerant R1234yf – General information 8882
00 – Technical data 8888
1 Safety information 8888
1 1 Safety precautions when working on air conditioning systems 8888
1 2 Safety precautions when handling refrigerants 8889
1 3 Safety measures when working on vehicles with a start/stop system 8889
1 4 Safety precautions when using air conditioner service stations 8889
1 5 Safety measures for working on vehicles with high-voltage system 8890
1 6 Safety precautions when working in the vicinity of high-voltage components 8891
1 7 Safety precautions when working on pressure vessels 8891
2 Laws and regulations 8892
2 1 Legal regulations and standards 8892
2 2 Charging refrigerant circuit with different refrigerants 8893
2 3 Occupational health and safety 8894
3 Repair notes 8895
3 1 Rules for cleanliness 8895
3 2 Refrigerant circuit seals 8895
3 3 Refrigerant and refrigerant oil 8896
3 3 1 Important repair notes for refrigerant and refrigerant oil 8896
3 3 2 Refrigerant oil 8897
3 4 Handling pressure vessels 8898
3 5 Handling refrigerants 8899
4 Identification 8901
4 1 Notice for refrigerant circuit 8901
5 Technical data 8902
5 1 Refrigerant capacity 8902
5 2 Refrigerant oil capacities 8902
5 3 Safety data sheets 8902
6 Basic technical and physical properties 8903
6 1 Basics of air conditioning technology 8903
6 1 1 Physical properties of air conditioning system 8903
6 1 2 Pressure and boiling point of refrigerant 8904
6 1 3 Vapour pressure table for refrigerant 8905
6 2 Physical properties 8907
6 2 1 Refrigerant R1234yf 8907
6 2 2 Potential risks with refrigerant R1234yf 8907
6 2 3 Physical and chemical properties of refrigerant R1234yf 8908
6 2 4 Critical point 8908
6 2 5 Environmental aspects of refrigerant R1234yf 8909
6 2 6 Trade names and designations of refrigerant R1234yf 8909
6 2 7 Colour and odour of R1234yf refrigerant 8910
6 2 8 Vapour pressure of R1234yf refrigerant 8910
6 2 9 Physical properties of R1234yf refrigerant 8910
6 2 10 How R1234yf refrigerant reacts to metals and plastics 8910
6 2 11 Critical temperature / critical pressure of R1234yf refrigerant 8911
6 2 12 Water content of R1234yf refrigerant 8911
6 2 13 Flammability / decomposition of R1234yf refrigerant 8911
6 2 14 Charge factor of refrigerant R1234yf 8911
6 2 15 Evidence of leaks in a refrigerant circuit with R1234yf refrigerant 8912
6 2 16 Analysis of refrigerant R1234yf 8912
6 2 17 Returning contaminated R1234yf refrigerant for analysis, processing or disposal 8913
6 3 Product characteristics 8914
6 4 Function and role of air conditioning system 8914
6 4 1 Principle of operation 8914
6 4 2 Comfort 8915
6 4 3 Environmental aspects 8915
6 5 Other reference material 8916
87 – Air conditioning system 8917
1 Refrigerant circuit 8917
1 1 System overview – refrigerant circuit 8917
1 1 1 System overview – refrigerant circuit with expansion valve and receiver 8917
1 1 2 System overview – refrigerant circuit with restrictor and reservoir 8919
1 1 3 System overview – refrigerant circuit with electrically driven air conditioner compressor (with and without battery cooling module) 8920
1 2 General description – components of refrigerant circuit 8923
1 2 1 Layout and function of refrigerant circuit 8923
1 2 2 Mechanical air conditioner compressor 8924
1 2 3 Electrical air conditioner compressor for hybrid vehicles 8927
1 2 4 Condenser 8930
1 2 5 evaporator 8931
1 2 6 Reservoir 8933
1 2 7 Heat exchanger for heat pump mode 8933
1 2 8 Liquid receiver 8934
1 2 9 Restrictor 8934
1 2 10 Receiver 8936
1 2 11 Expansion valve (with and without shut-off valve) 8938
1 2 12 Refrigerant shut-off valves 8940
1 2 13 Refrigerant line with internal heat exchanger 8942
1 2 14 Quick release couplings of refrigerant lines 8943
1 2 15 Seals 8944
1 2 16 Pipes and hoses in refrigerant circuit 8945
1 2 17 High-pressure safety valve 8945
1 2 18 Non-return valves 8947
1 2 19 Quick-release coupling connections in refrigerant circuit 8948
1 2 20 Connections with valve for switches in refrigerant circuit 8952
1 2 21 Pressure senders and switches in refrigerant circuit 8953
1 2 22 Refrigerant pressure and temperature sender 8954
1 2 23 Air conditioner compressor regulating valve -N280- 8957
1 2 24 Refrigerant temperature sender 8958
1 3 Possible complaints 8959
1 3 1 Prerequisites for investigating a complaint 8959
1 3 2 Possible complaints 8959
1 3 3 Odours from heater and air conditioning unit 8961
1 4 Investigating leaks 8963
1 4 1 General information about investigating leaks in the refrigerant circuit 8963
1 4 2 Searching for leaks in refrigerant circuits using an electronic leak detector 8964
1 4 3 Searching for leaks with UV leak detection system 8965
1 4 4 Detecting leaks in a vacuum test using air conditioner service station, or in a pressure test 8971
1 4 5 Detecting leaks in a pressure test (with nitrogen or compressed air) 8972
1 5 Renewing components 8974
1 5 1 General information about renewing components 8974
1 5 2 Renewing leaking or damaged components of empty refrigerant circuit (apart from air conditioner compressor and receiver) 8975
1 5 3 Renewing leaking or damaged components of charged refrigerant circuit (apart from air conditioner compressor and receiver) 8977
1 5 4 Renewing air conditioner compressor with no need to clean refrigerant circuit 8978
1 5 5 Renewing air conditioner compressor due to leaks or internal damage 8981
1 5 6 Renewing desiccant cartridge / receiver after cleaning refrigerant circuit 8982
1 5 7 Renewing receiver with no need to clean refrigerant circuit 8984
1 5 8 Renewing desiccant cartridge / desiccant bag with no need to clean refrigerant circuit 8985
1 6 Cleaning refrigerant circuit 8986
1 6 1 General information about cleaning refrigerant circuit 8986
1 6 2 Preparations for cleaning refrigerant circuit (flushing with R1234yf refrigerant) 8988
1 6 3 Refrigerant circuit cleaning procedure 8992
1 6 4 Principle circuit diagrams for cleaning (flushing circuits) – refrigerant circuit with expansion valve and receiver 8992
1 6 5 Principle circuit diagrams for cleaning (flushing circuits) – refrigerant circuit with restrictor and receiver (without high-voltage system) 8997
1 6 6 Adapters for setting up flushing circuits 9000
1 6 7 General information about blowing through with compressed air or nitrogen 9013
1 6 8 Blowing through refrigerant circuit with compressed air or nitrogen 9017
1 7 Checking pressures with pressure gauge 9018
1 7 1 Display on pressure gauges 9018
1 7 2 Pressure gauges enable the following test and measurement work 9019
2 Working with air conditioner service station 9022
2 1 Working with air conditioner service station 9023
2 2 Connecting air conditioner service station to refrigerant circuit 9025
2 3 Performing gas analysis of refrigerant 9028
2 4 Purging refrigerant circuit 9031
2 5 Evacuating refrigerant circuit 9034
2 6 Charging refrigerant circuit 9040
2 7 Bringing air conditioning system into service after charging 9043
2 8 Switching off air conditioner service station and separating from refrigerant circuit 9045
2 9 Charging refrigerant in reservoir 9047
2 10 Emptying air conditioner service station 9048
2 11 Cleaning electrical air conditioning compressor 9048
2 12 Cleaning refrigerant circuit 9051
2 13 Filling contaminated refrigerant in a recycling cylinder for analysis, processing or disposal 9054
2 13 1 Filling contaminated refrigerant into recycling cylinder using extraction unit -VAS 581 011- 9054
2 13 2 Filling contaminated refrigerant into recycling cylinder using extraction unit -VAS 581 007- 9055
2 14 Checking pressures 9059
2 14 1 General information on checking pressures in the refrigerant circuit 9059
2 14 2 Pressures and temperatures in refrigerant circuit 9061
2 14 3 Checking pressures in the refrigerant circuit with the ignition switched off 9065
2 14 4 Checking pressures with air conditioning system switched on – vehicles with mechanical air conditioning compressor 9072
2 14 5 Checking pressures with air conditioning system switched on – vehicles with electrical air conditioning compressor 9094
3 Testing equipment and tools 9147
3 1 Tools and materials available from distribution centre or importer 9147
3 2 Tools and materials available commercially 9147
D4B80609EEB 4 cyl direct injection engine (2 0 l 4 V EA 888 gen III BZ turbocharger chain drive) 9149
00 – Technical data 9157
1 Safety information 9157
1 1 Safety regulations for working on fuel supply 9157
1 2 Safety measures when working on vehicles with start/stop system 9157
1 3 Safety precautions when using testers and measuring instruments during a road test 9158
1 4 Safety precautions when working on ignition system 9158
1 5 Safety precautions when working on the cooling system 9158
1 6 Safety precautions when working on exhaust system 9159
2 Identification 9160
2 1 Engine number/engine data 9160
3 Repair notes 9162
3 1 Rules for cleanliness 9162
3 2 Foreign objects in engine 9162
3 3 Contact corrosion 9162
3 4 Routing and attachment of lines 9162
3 5 Fitting radiator and condensers 9163
3 6 Checking vacuum system 9163
10 – Removing and installing engine 9164
1 Removing and installing engine 9164
1 1 Removing engine 9164
1 2 Separating engine and gearbox 9180
1 2 1 Separating engine and gearbox, vehicles with manual gearbox 9180
1 2 2 Separating engine and gearbox, vehicles with 7-speed dual clutch gearbox 9183
1 2 3 Separating engine and gearbox, vehicles with 6-speed dual clutch gearbox 9187
1 3 Securing engine on engine and gearbox support 9190
1 4 Installing engine 9193
2 Assembly mountings 9197
2 1 Assembly overview – assembly mountings 9197
2 2 Removing and installing engine mounting 9199
2 3 Removing and installing gearbox mounting 9200
2 4 Removing and installing pendulum support 9202
2 4 1 Removing and installing pendulum support, Tiguan, Arteon, T-Roc, Passat 9202
2 4 2 Removing and installing pendulum support, Polo 9203
2 5 Supporting engine in installation position 9204
2 5 1 Supporting engine in installation position, Tiguan 9204
2 5 2 Supporting engine in installation position, Arteon 9208
2 5 3 Supporting engine in installation position, Passat 9211
2 5 4 Supporting engine in installation position, T-Roc 9216
2 5 5 Supporting engine in installation position, Polo 9221
2 6 Checking adjustment of assembly mountings 9225
2 7 Adjusting assembly mountings 9225
3 Engine cover panel 9228
3 1 Removing and installing engine cover 9228
13 – Crankshaft group 9229
1 Cylinder block (pulley end) 9229
1 1 Assembly overview – cylinder block (pulley end) 9229
1 2 Removing and installing poly-V belt 9232
1 3 Removing and installing tensioner for poly V-belt 9233
1 4 Removing and installing vibration damper 9234
1 5 Renewing seal for vibration damper 9241
1 6 Removing and installing bracket for ancillaries 9244
1 7 Removing and installing engine support 9246
2 Cylinder block, gearbox end 9249
2 1 Assembly overview – cylinder block, gearbox end 9249
2 2 Removing and installing flywheel 9250
2 3 Removing and installing sealing flange on gearbox side 9252
3 Crankshaft 9257
3 1 Assembly overview – crankshaft 9257
3 2 Crankshaft dimensions 9260
3 3 Allocation of main bearing shells 9260
3 4 Renewing needle bearing in crankshaft 9262
3 5 Measuring axial clearance of crankshaft 9264
3 6 Measuring radial clearance of crankshaft 9265
3 7 Removing and installing sender wheel 9266
4 Balancer shaft 9268
4 1 Assembly overview – balance shaft 9268
4 2 Removing and installing balance shaft 9270
4 2 1 Removing and installing inlet side balance shaft 9270
4 2 2 Removing and installing exhaust side balance shaft 9273
4 2 3 Renewing oil seal for balance shaft (inlet side) 9275
5 Pistons and conrods 9277
5 1 Assembly overview – pistons and conrods 9277
5 2 Removing and installing pistons 9281
5 3 Checking pistons and cylinder bores 9283
5 4 Separating new conrod 9285
5 5 Checking radial clearance of conrods 9285
5 6 Removing and installing oil spray jets 9286
15 – Cylinder head, valve gear 9288
1 Cylinder head 9288
1 1 Assembly overview – cylinder head 9288
1 2 Removing and installing cylinder head 9291
1 3 Assembly overview – vacuum pump 9297
1 4 Removing and installing vacuum pump 9298
1 5 Checking compression 9300
2 Cover for timing chain 9303
2 1 Assembly overview – cover for timing chain 9303
2 2 Removing and installing timing chain cover 9306
2 2 1 Removing and installing upper timing chain cover 9306
2 2 2 Removing and installing timing chain cover (bottom) 9308
3 Chain drive 9313
3 1 Assembly overview – camshaft timing chains 9313
3 2 Assembly overview – drive chain for balance shaft 9316
3 3 Removing and installing camshaft timing chain 9318
3 4 Removing and installing drive chain for balance shaft 9331
3 5 Checking timing chain 9334
4 Valve gear 9336
4 1 Assembly overview – valve gear 9336
4 2 Removing and installing camshaft 9340
4 3 Removing and installing actuators for camshaft adjustment 9351
4 4 Removing and installing camshaft control valve 1 -N205- 9353
4 5 Removing and installing exhaust camshaft control valve 1 -N318- 9353
4 6 Removing and installing valve stem oil seals 9354
4 6 1 Removing and installing valve stem seals (cylinder head installed) 9354
4 6 2 Removing and installing valve stem seals (cylinder head removed) 9359
5 Inlet and exhaust valves 9365
5 1 Checking valve guides 9365
5 2 Checking valves 9366
5 3 Valve dimensions 9366
17 – Lubrication 9367
1 Sump, oil pump 9367
1 1 Assembly overview – sump/oil pump 9367
1 2 Engine oil: 9370
1 3 Removing and installing lower part of sump 9370
1 3 1 Removing and installing bottom section of sump, plastic sump 9370
1 3 2 Removing and installing bottom section of sump, sheet-metal sump 9372
1 4 Removing and installing upper part of sump 9376
1 5 Removing and installing oil pump 9382
1 6 Removing and installing oil level and oil temperature sender -G266- 9385
2 Engine oil cooler 9387
2 1 Assembly overview – engine oil cooler 9387
2 2 Removing and installing engine oil cooler 9387
3 Crankcase ventilation 9390
3 1 Assembly overview – crankcase breather system 9390
3 2 Removing and installing oil separator 9391
4 Oil filter, oil pressure switch 9393
4 1 Assembly overview – oil filter 9393
4 2 Assembly overview – oil pressure switches/oil pressure control 9393
4 3 Removing and installing piston cooling jet control valve -N522- 9395
4 4 Removing and installing oil pressure switch 9396
4 4 1 Removing and installing oil pressure switch -F1- 9396
4 4 2 Removing and installing oil pressure switch for reduced oil pressure -F378- 9397
4 4 3 Removing and installing stage 3 oil pressure switch -F447- 9398
4 5 Checking oil pressure 9400
4 5 1 Checking engine oil pressure 9400
4 5 2 Checking oil pressure and oil spray jets 9402
4 6 Removing and installing oil pressure regulating valve -N428- 9404
19 – Cooling 9406
1 Cooling system/coolant 9406
1 1 Connection diagram – coolant hoses 9406
1 1 1 Vehicles with manual gearbox 9406
1 1 2 Vehicles with dual clutch gearbox 9407
1 2 Checking cooling system for leaks 9408
1 3 Draining and adding coolant 9412
1 4 Flushing cooling system 9420
1 4 1 Flushing cooling system 9420
1 4 2 Flushing cooling system, quick reference guide 9442
2 Coolant pump, regulation of cooling system 9444
2 1 Assembly overview – coolant pump, thermostat 9444
2 2 Assembly overview – electric coolant pump 9446
2 3 Assembly overview – coolant temperature sender 9449
2 4 Removing and installing electric coolant pump 9450
2 4 1 Removing and installing auxiliary pump for heating -V488- 9450
2 5 Removing and installing coolant pump 9453
2 6 Removing and installing toothed belt for coolant pump 9456
2 7 Removing and installing coolant valves 9457
2 7 1 Removing and installing coolant shut-off valve -N82- 9457
2 7 2 Removing and installing coolant valve for gearbox -N488-, vehicles with 6-speed dual clutch gearbox 9459
2 7 3 Removing and installing coolant valve for gearbox -N488-, vehicles with 7-speed dual clutch gearbox 9461
2 8 Removing and installing actuator for engine temperature regulation -N493- 9462
2 9 Removing and installing coolant temperature sender -G62- 9465
2 10 Removing and installing radiator outlet coolant temperature sender -G83- 9466
3 Coolant pipes 9468
3 1 Assembly overview – coolant pipes 9468
3 2 Removing and installing coolant pipes 9468
3 2 1 Removing and installing front coolant pipe 9468
3 3 Removing and installing upper coolant pipes 9470
4 Radiator, radiator fan 9472
4 1 Assembly overview – radiator 9472
4 1 1 Assembly overview – radiator, Tiguan, Arteon, T-Roc, Passat 9472
4 1 2 Assembly overview – radiator, Polo 9474
4 2 Assembly overview – radiator cowl and radiator fan 9476
4 2 1 Assembly overview – radiator cowl and radiator fan, twin fan 9476
4 2 2 Assembly overview – radiator cowl and radiator fan, single fan 9477
4 3 Removing and installing radiator 9478
4 3 1 Removing and installing radiator, Tiguan, Arteon, T-Roc, Passat 9478
4 3 2 Removing and installing radiator, Polo 9480
4 4 Removing and installing radiator cowl 9485
4 4 1 Removing and installing radiator cowl, twin fan 9485
4 4 2 Removing and installing radiator cowl, single fan 9487
4 4 3 Removing and installing radiator cowl, Polo 9488
4 5 Removing and installing radiator fan 9491
4 5 1 Removing and installing radiator fan, twin fan 9491
4 5 2 Removing and installing radiator fan, single fan 9492
21 – Turbocharging/supercharging 9494
1 Turbocharger 9494
1 1 Assembly overview – turbocharger 9494
1 2 Removing and installing turbocharger 9498
2 Charge air system 9504
2 1 Assembly overview – charge air system 9504
2 1 1 Assembly overview – charge air system, Tiguan, Arteon, T-Roc, Passat 9504
2 1 2 Assembly overview – charge air system, Polo 9505
2 2 Assembly overview – charge-air hose connections 9507
2 3 Removing and installing charge air cooler 9507
2 3 1 Removing and installing charge air cooler, Tiguan, Arteon, T-Roc, Passat 9507
2 3 2 Removing and installing charge air cooler, Polo 9511
2 4 Removing and installing charge pressure sender -G31- 9512
2 5 Checking charge air system for leaks 9513
2 6 Removing and installing air intake pipe between turbocharger and charge air cooler 9515
24 – Mixture preparation – injection 9517
1 Injection system 9517
1 1 Overview of fitting locations – injection system 9517
2 Injectors 9529
2 1 Assembly overview – fuel rail with injectors 9529
2 1 1 Assembly overview – fuel rail with injectors, direct injection 9529
2 1 2 Assembly overview – fuel rail with injectors, indirect injection 9530
2 2 Removing and installing fuel rail 9531
2 3 Removing and installing injectors 9532
2 3 1 Removing and installing injectors, direct injection 9532
2 3 2 Removing and installing injectors, indirect injection 9537
2 4 Renewing seals on injectors 9539
2 5 Cleaning injectors 9542
3 Air filter 9544
3 1 Assembly overview – air filter housing 9544
3 1 1 Assembly overview – air filter housing, Tiguan, Arteon, T-Roc, Passat 9544
3 1 2 Assembly overview – air filter housing, Polo 9546
3 2 Removing and installing air filter housing 9547
3 3 Removing and installing air guide on lock carrier 9549
3 3 1 Removing air duct on lock carrier, Tiguan, Arteon, Passat 9549
3 3 2 Removing air guide on lock carrier, T-Roc 9550
3 3 3 Removing air guide on lock carrier, Polo 9551
4 Intake manifold 9552
4 1 Assembly overview – intake manifold 9552
4 2 Removing and installing intake manifold 9554
4 3 Removing and installing throttle valve module -GX3- 9559
4 4 Cleaning throttle valve module -GX3- 9562
4 5 Checking intake manifold change-over 9563
5 Senders and sensors 9565
5 1 Removing and installing fuel pressure sender -G247- 9565
5 2 Checking fuel pressure sender -G247- 9568
5 3 Removing and installing fuel pressure sender for low-pressure -G410- 9570
5 4 Removing and installing intake manifold sender -GX9- 9571
5 5 Removing and installing air mass meter -G70- 9572
5 6 Assembly overview – actuator for structure-borne sound and control unit for structure-borne sound, Polo 9574
5 7 Removing and installing pressure differential sender for particulate filter -G1037- 9576
6 Engine/motor control unit 9578
6 1 Removing and installing engine control unit -J623- 9578
6 2 Removing and installing engine (motor) control unit -J623- with protective housing 9579
7 High-pressure pump 9583
7 1 Assembly overview – high-pressure pump 9583
7 2 Removing and installing high-pressure pump 9585
7 3 Removing and installing high-pressure pipe 9588
8 Lambda probe 9592
8 1 Assembly overview – Lambda probe 9592
8 2 Removing and installing lambda probe 9593
8 2 1 Removing and installing Lambda probe 1 before catalytic converter -GX10- 9593
8 2 2 Removing and installing Lambda probe 1 after catalytic converter -GX7- 9595
26 – Exhaust system 9597
1 Exhaust pipes and silencers 9597
1 1 Assembly overview – silencers 9597
1 1 1 Assembly overview – silencers, Tiguan 9597
1 1 2 Assembly overview – silencer, Arteon, Passat 9598
1 1 3 Assembly overview – silencers, Polo 9599
1 1 4 Assembly overview – silencers, T-Roc 9601
1 2 Removing and installing silencer 9602
1 2 1 Removing and installing silencer, Tiguan 9602
1 2 2 Removing and installing silencer, Arteon, Passat 9604
1 2 3 Removing and installing front silencer, Polo 9605
1 2 4 Removing and installing rear silencer, Polo 9606
1 2 5 Removing and installing silencers, T-Roc 9607
1 3 Separating exhaust pipes from silencers 9609
1 3 1 Separating exhaust pipes/silencers, Arteon, Passat 9609
1 3 2 Separating exhaust pipes/silencers, Polo 9612
1 3 3 Separating exhaust pipes/silencers, T-Roc 9613
1 4 Aligning exhaust system free of stress 9615
1 5 Checking exhaust system for leaks 9615
2 Emission control 9616
2 1 Assembly overview – emission control 9616
2 1 1 Assembly overview – exhaust gas treatment, Tiguan 9616
2 1 2 Assembly overview – emission control, Arteon, Polo, T-Roc, Passat 9620
2 1 3 Assembly overview – emission control, vehicles with particulate filter and front-wheel drive 9621
2 1 4 Assembly overview – emission control, vehicles with particulate filter and all-wheel drive 9623
2 1 5 Catalytic converter – specified torque and tightening sequence 9625
2 2 Assembly overview – bracket and pipes for pressure differential sender for particulate filter -G1037- 9626
2 3 Removing and installing catalytic converter 9627
2 3 1 Removing and installing catalytic converter, vehicles without particulate filter and front-wheel drive 9627
2 3 2 Removing and installing catalytic converter, vehicles without particulate filter and all-wheel drive 9631
2 3 3 Removing and installing catalytic converter, vehicles with particulate filter and front-wheel drive 9638
2 3 4 Removing and installing catalytic converter, vehicles with particulate filter and all-wheel drive 9642
2 4 Removing and installing holder of pressure differential sender for particulate filter -G1037- 9647
3 Exhaust gas temperature regulation 9648
3 1 Assembly overview – exhaust gas temperature regulation 9648
3 2 Removing and installing parts of exhaust gas temperature regulation 9649
3 2 1 Removing and installing exhaust gas temperature sender, vehicles with front-wheel drive 9649
3 2 2 Removing and installing exhaust gas temperature sender, vehicles with all-wheel drive 9651
28 – Ignition system 9654
1 Ignition system 9654
1 1 Assembly overview – ignition system 9654
1 2 Removing and installing ignition coils with output stage 9656
1 3 Removing and installing knock sensor 1 -G61- 9658
1 4 Removing and installing Hall sender 9659
1 4 1 Removing and installing Hall sender -G40- 9659
1 4 2 Removing and installing Hall sender 3 -G300- 9660
1 5 Removing and installing engine speed sender -G28- 9660
D4B80768BC5 Running gear axles steering 9663
00 – Technical data 9669
1 Safety and repair instructions 9669
1 1 Safety information 9669
1 2 Repair instructions 9669
2 Electrical components 9670
2 1 Access to diagnoses 9670
40 – Front suspension 9672
1 Safety and repair instructions 9672
1 1 Safety information 9672
1 2 Repair instructions 9672
2 Subframe 9673
2 1 Assembly overview – subframe 9673
2 2 Removing and installing subframe without steering rack 9673
2 2 1 Removing and installing subframe without steering rack 9673
2 3 Removing and installing subframe with steering rack 9675
2 3 1 Removing and installing subframe with steering rack 9675
2 4 Repairing thread in longitudinal member 9675
2 5 Fixing subframe in position 9675
2 6 Lowering subframe 9677
2 7 Preparing foot pump 9679
3 Suspension strut, upper suspension link 9681
3 1 Assembly overview – suspension strut, upper suspension links, Polo 2018, Polo 2022, T-Cross 2019, Taigo 2022, Taigun 2022 9681
3 1 1 Assembly overview – suspension strut, upper suspension links 9681
3 2 Assembly overview – suspension strut, upper suspension link, Virtus 2022 9682
3 2 1 Assembly overview – suspension strut, upper suspension links 9682
3 3 Removing and installing suspension strut, Polo 2018, Polo 2022, T-Cross 2019, Taigo 2022, Taigun 2022 9684
3 3 1 Removing and installing suspension strut 9684
3 4 Removing and installing suspension strut, Virtus 2022 9689
3 4 1 Removing and installing suspension strut 9689
3 5 Removing and installing spring 9693
4 Lower suspension link, swivel joint 9699
4 1 Assembly overview – lower suspension link, swivel joint 9699
4 2 Removing and installing lower suspension link 9701
4 3 Checking swivel joint 9701
4 4 Removing and installing swivel joint 9702
4 5 Renewing bonded rubber bush for lower suspension link 9704
4 5 1 Renewing front bonded rubber bush for lower suspension link 9704
4 5 2 Renewing rear bonded rubber bush for lower suspension link 9706
4 6 Removing and installing stone deflector for suspension link 9710
5 Wheel bearing 9711
5 1 Assembly overview – wheel bearing assembly 9711
5 2 Removing and installing wheel bearing housing 9711
5 3 Removing and installing wheel bearing unit 9715
6 Drive shaft 9721
6 1 Overview – drive shaft 9721
6 2 Assembly overview – drive shaft, inner triple roller joint 9721
6 2 1 Assembly overview – drive shaft 9721
6 3 Assembly overview – drive shaft, constant velocity joint VL100 9723
6 3 1 Assembly overview – drive shaft 9723
6 4 Assembly overview – drive shaft, constant velocity joint VL107 9725
6 4 1 Assembly overview – drive shaft 9725
6 5 Removing and installing drive shaft 9727
6 6 Loosening and tightening threaded connections of drive shaft 9730
6 7 Tensioning clamp for boot 9733
6 8 Pressing out drive shaft of wheel bearing housing 9734
6 9 Removing and installing drive shaft heat shield 9735
6 10 Dismantling and assembling drive shaft, outer constant velocity joint 9736
6 10 1 Dismantling and assembling drive shaft 9736
6 11 Dismantling and assembling drive shaft, inner constant velocity joint VL100 9738
6 11 1 Dismantling and assembling drive shaft 9738
6 12 Dismantling and assembling drive shaft, inner constant velocity joint VL107 9742
6 12 1 Dismantling and assembling drive shaft 9742
6 13 Dismantling and assembling drive shaft, inner triple roller joint AAR2600i 9745
6 13 1 Dismantling and assembling drive shaft 9745
6 14 Dismantling and assembling drive shaft, inner triple roller joint with joint body TS1800 9749
6 14 1 Dismantling and assembling drive shaft 9749
6 15 Checking outer constant velocity joint 9752
6 16 Removing and installing deflector ring 9753
6 17 Checking inner constant velocity joint 9755
7 Anti-roll bar 9758
7 1 Assembly overview – anti-roll bar 9758
7 2 Removing and installing anti-roll bar 9758
7 3 Removing and installing coupling rod 9759
42 – Rear suspension 9761
1 Safety and repair instructions 9761
1 1 Safety information 9761
1 2 Repair instructions 9761
2 Rear axle 9762
2 1 Removing and installing rear axle 9762
2 2 Securing vehicle to support arms of lifting platform 9764
3 Axle beam 9766
3 1 Assembly overview – axle beam 9766
3 2 Assembly overview – attachments for torsion beam axle 9766
3 3 Renewing bonded rubber bush for axle beam 9767
3 4 Removing and installing outer trim of torsion beam axle 9771
3 5 Removing and installing centre cladding of torsion beam axle 9772
4 Suspension strut, shock absorber, spring 9774
4 1 Assembly overview – suspension strut, shock absorber, spring 9774
4 2 Assembly overview – shock absorber, adaptive chassis control 9774
4 2 1 Assembly overview – shock absorber 9774
4 3 Assembly overview – shock absorber, standard running gear 9775
4 3 1 Assembly overview – shock absorber 9775
4 4 Removing and installing shock absorber 9776
4 5 Removing and installing spring 9777
4 6 Renewing shock absorber, standard suspension 9779
4 6 1 Renewing shock absorber 9779
4 7 Renewing shock absorber, adaptive chassis control DCC 9782
4 7 1 Renewing shock absorber 9782
5 Wheel bearing assembly, trailing arm 9787
5 1 Assembly overview – wheel bearings, drum brake 9787
5 1 1 Assembly overview – wheel bearing assembly 9787
5 2 Assembly overview – wheel bearings, disc brake 9787
5 2 1 Assembly overview – wheel bearing assembly 9787
5 3 Removing and installing wheel bearing unit, drum brake 9788
5 3 1 Removing and installing wheel bearing unit 9788
5 4 Removing and installing wheel bearing unit, disc brake 9790
5 4 1 Removing and installing wheel bearing unit 9790
43 – Self-levelling suspension 9792
1 Safety and repair instructions 9792
1 1 Safety information 9792
1 2 Repair instructions 9792
2 Electronic damping control 9793
2 1 Overview of fitting locations – electronically controlled damping 9793
2 2 Removing and installing electronically controlled damping control unit [J250] 9794
3 Vehicle level sender 9795
3 1 Assembly overview – rear vehicle level senders 9795
3 2 Removing and installing rear vehicle level senders [G77] 9795
44 – Wheels, tyres, vehicle geometry 9798
1 Wheel alignment 9798
1 1 Notes on wheel alignment 9798
1 2 Conditions for testing 9798
1 3 Preparations for measurement 9798
1 4 Setting vehicle to initial position for wheel alignment 9799
1 5 Necessity of wheel alignment 9799
1 6 Adjusting camber at front wheels 9800
1 7 Adjusting camber at rear axle, torsion beam axle 9801
1 7 1 Adjusting camber on rear axle 9801
1 8 Adjusting toe at rear axle, torsion beam axle 9801
1 8 1 Adjusting toe at rear axle 9801
1 9 Adjusting front axle toe 9801
1 10 Checking full steering lock 9802
1 11 Specifications for wheel alignment Polo 2018 (AW1), Polo 2022 (AE1), Virtus 2022 (D22) 9803
1 11 1 Specifications for wheel alignment 9803
1 12 Specifications for wheel alignment T-Cross 2019 (C11), Taigun 2022 (CW1) 9805
1 12 1 Specifications for wheel alignment 9805
1 13 Specifications for wheel alignment Taigo 2022 (CS1) 9807
1 13 1 Specifications for wheel alignment 9807
2 Wheels, tyres 9811
2 1 Removing wheel 9811
2 2 Installing wheel 9811
48 – Steering 9813
1 Safety and repair instructions 9813
1 1 Safety information 9813
1 2 Repair instructions 9813
2 Steering wheel 9814
2 1 Assembly overview – steering wheel 9814
2 2 Removing and installing steering wheel 9814
3 Steering column 9816
3 1 Assembly overview – steering column, integrated power steering control unit [J500] 9816
3 1 1 Assembly overview – steering column 9816
3 2 Assembly overview – steering column, power steering control unit [J500], separate 9817
3 2 1 Assembly overview – steering column 9817
3 3 Removing and installing steering column 9819
3 4 Removing and installing intermediate steering shaft 9820
3 5 Removing and installing control unit for electronic steering column lock [J764] 9821
3 6 Removing and installing power steering control unit [J500] 9823
4 Steering rack 9826
4 1 Assembly overview – steering rack 9826
4 2 Assembly overview – track rods 9826
4 3 Removing and installing steering rack 9827
4 4 Removing and installing bellows 9829
4 5 Removing and installing track rod 9831
4 6 Removing and installing track rod ball joint 9832
4 7 Repairing steering rack 9833
D4B80769F80 Removed 5 speed manual gearbox 0DF and 0D0 9835
00 – Technical data 9839
1 Safety information 9839
2 Identification 9840
3 Technical data 9841
3 1 Allocation gearbox – engine 9841
3 2 Capacities 9841
4 Overview – power transmission 9842
5 Electrical components 9843
6 Repair notes 9844
6 1 General repair instructions 9844
30 – Clutch 9848
1 Clutch mechanism 9848
1 1 Assembly overview – clutch release mechanism 9848
1 2 Repairing clutch release mechanism 9850
2 Clutch 9852
2 1 Assembly overview – clutch 9852
2 1 1 Assembly overview – clutch in conjunction with Sachs dual-mass flywheel 9852
2 1 2 Assembly overview – clutch in conjunction with LuK dual-mass flywheel 9853
2 1 3 Assembly overview – clutch with simple flywheel 9853
2 2 Removing and installing clutch 9854
2 2 1 Removing and installing clutch in conjunction with Sachs dual-mass flywheel 9854
2 2 2 Removing and installing clutch in conjunction with LuK dual-mass flywheel 9859
2 2 3 Removing and installing clutch in connection with simple flywheel 9863
34 – Controls, housing 9869
1 Selector mechanism 9869
2 Removing and installing gearbox 9870
3 Gearbox transport 9871
4 Gear oil 9873
5 Securing to engine and gearbox support 9874
6 Dismantling and assembling gearbox 9875
6 1 Schematic overview – gearbox 9875
6 2 Assembly overview – gearbox 9875
6 3 Assembly overview – gearbox housing cover 9876
6 4 Assembly overview – clutch housing 9877
6 5 Assembly overview – shafts, differential, selector mechanism 9878
6 6 Assembly overview – selector forks 9880
6 7 Repairing selector forks 9881
6 8 Dismantling and assembling gearbox 9886
7 Gearbox housing, clutch housing 9899
7 1 Assembly overview – gearbox housing and clutch housing 9899
7 1 1 Assembly overview – gearbox housing and clutch housing 9899
7 2 Repairing clutch housing 9901
35 – Gears, shafts 9905
1 Input shaft 9905
1 1 Assembly overview – input shaft 9905
1 2 Dismantling and assembling input shaft 9907
1 3 Renewing input shaft seal 9921
2 Output shaft 9924
2 1 Assembly overview – output shaft 9924
2 2 Dismantling and assembling output shaft 9927
39 – Final drive – differential 9935
1 Oil seals 9935
2 Differential 9936
2 1 Assembly overview – differential 9936
2 1 1 Assembly overview – differential 9936
2 2 Dismantling and assembling differential 9937
2 3 Adjusting differential 9948
D4B80796BA2 Wheels and Tyres Guide General Information 9956
44 – Wheels, tyres, vehicle geometry 9960
1 Instructions on using the guide 9960
1 1 Overview 9960
1 1 1 Wheels and Tyres Guide – General Information 9960
1 1 2 Wheels and Tyres Guide – Vehicle-specific Section 9960
1 2 General information 9960
1 3 Notes 9961
1 4 Explanations regarding world regions 9962
1 5 Definition of tyre package 9962
1 6 Procedure for determining the required tyre package 9963
1 6 1 Determining the required tyre package via PR number 9963
1 6 2 Determining the required tyre package via version key in the vehicle registration certificate part 1 9963
1 7 Vehicle registration certificate part 1 9964
2 Legislative and technical conditions 9966
2 1 Legislative conditions 9966
2 1 1 Permissible wheel and tyre combinations in Germany 9966
2 1 2 Vehicles with Tyre Pressure Monitoring System 9966
2 2 Technical conditions 9967
2 3 Load-carrying capacity depending on vehicle speed, winter tyres 9967
2 4 Vehicle registration documents since 1 10 2005 9969
2 5 COC document (EEC Certificate of Conformity) 9970
2 6 EU general type approval number, sales type and sales or trade designation 9970
3 Wheel change 9972
3 1 Fitting instructions 9972
3 2 Protecting wheel centring seat against corrosion 9975
3 3 Fitting wheels 9976
3 4 Position of anti-theft wheel bolts for steel wheels 9976
4 Fitting tyre 9977
4 1 Pressing tyre off wheel rim 9977
4 2 Removing tyre sealant 9977
4 3 Removing tyre from wheel 9978
4 3 1 Removing tyres, wheels without and with tyre pressure monitoring 9978
4 3 2 Removing tyres, run-flat tyres, ultra-high-performance tyres 9979
4 4 Ensuring proper assembly temperature for tyres 9981
4 5 Mounting tyre 9982
4 5 1 Mounting tyre, wheels without and with tyre pressure monitoring 9982
4 5 2 Mounting tyre, run-flat tyres, ultra-high performance tyres 9984
4 6 Matching wheel rims and tyres 9987
4 7 Checking radial and lateral runout of wheels and tyres 9988
4 7 1 Checking radial and lateral runout of wheels and tyres, tolerances 9988
4 7 2 Checking radial and lateral runout on wheels and tyres with tyre gauge 9988
4 8 Matching wheels and tyres 9989
4 9 Balancing wheel 9990
4 9 1 Conditions 9990
4 9 2 Balancing wheel on stationary wheel balancer 9991
4 9 3 Balancing wheel with finish balancer 9994
4 9 4 Checking radial and lateral run-out on wheel rim 9995
4 10 Tyre sealant disposal 9996
5 Tyre pressure monitoring system 9997
5 1 System description – tyre pressure monitoring system 9997
5 1 1 System description – tyre pressure monitoring system with indirect measurement (Tyre Pressure Loss Indicator) 9997
5 1 2 System description – tyre pressure monitoring system with direct measurement (Tyre Pressure Monitoring System) 9998
5 1 3 System description – tyre pressure monitoring system, tyre pressure monitoring system (TPMS) with autolocation 9999
5 2 Overview of fitting locations – tyre pressure monitor system 9999
5 2 1 Overview of fitting locations – Tyre Pressure Monitoring System (TPMS) with autolocation 9999
5 3 Assembly overview – tyre pressure sensor 10001
5 3 1 Assembly overview – tyre pressure sensor, tyre pressure sensor with valve 10001
5 3 2 Assembly overview – tyre pressure sensor, tyre pressure sensor without valve, version 1 10002
5 3 3 Assembly overview – tyre pressure sensor, tyre pressure sensor without valve, version 2 10003
5 4 Removing and installing tyre pressure sensor -G222-/-G223-/-G224-/-G225- 10004
5 4 1 Removing and installing tyre pressure sensor, tyre pressure sensor with valve 10004
5 4 2 Removing and installing tyre pressure sensor, tyre pressure sensor without valve, version 1 (customer service version) 10005
5 4 3 Removing and installing tyre pressure sensor, tyre pressure sensor without valve, version 1 (production version) 10006
5 4 4 Removing and installing tyre pressure sensor -G222-/-G223-/-G224-/-G225-, version 2 10008
5 5 Removing and installing tyre pressure monitor control unit -J502- 10011
5 5 1 Removing and installing Tyre Pressure Monitoring System control unit -J502-, Arteon 2018, Passat 2015, Passat Estate 2015 10011
5 5 2 Removing and installing tyre pressure monitoring system control unit -J502-, Touran 10012
6 Wheel bolts 10014
6 1 Wheel bolts, versions 10014
6 2 Wheel bolts, anti-theft wheel bolt 10015
6 3 Wheel bolts, adapter sets for anti-theft wheel bolts 10015
7 Information on tyres 10018
7 1 Identification markings on the tyre sidewall 10018
7 2 Tyre dimension 10020
7 3 Load rating code/load index (LI) 10020
7 4 Speed rating code 10021
7 5 EU tyre label 10021
7 5 1 EU tyre label, summary 10021
7 5 2 EU tyre label, objectives 10022
7 5 3 EU tyre label, categories 10023
7 6 Structure of a radial belted tyre 10026
7 6 1 Cross section of a radial belted tyre 10026
7 6 2 Run-flat tyres, structure and identification of a SST tyre 10027
7 6 3 Run-flat tyres, seal inside technology 10028
7 7 Run-flat tyre, SST (Self Supporting Tyre) 10030
7 7 1 Run-flat tyres – general information 10030
7 7 2 Run-flat tyres, retrofitting/requirements when using run-flat tyres 10031
7 7 3 Run-flat tyres, repair work 10032
7 8 Tyre storage 10032
7 9 Reinforced and Extra Load (XL) tyres 10032
7 10 Winter tyres 10033
7 11 Winter tyres with speed symbol V 10035
7 12 Rolling resistance optimised tyres 10036
7 13 Tyre ageing 10036
7 14 Tyres with flange protection 10038
7 15 Tyre sizes for vehicles with four-wheel drive 10038
7 16 Increase in temperature due to insufficient tyre pressure 10039
8 Tyre sealant 10040
8 1 Models with breakdown set 10040
8 2 Storage life 10040
8 3 Waste disposal 10040
9 Information on wheel rims 10041
9 1 Structure of wheel rim 10041
9 2 Identification 10042
9 3 Composite wheels 10042
9 4 Care and maintenance of alloy wheel rims 10042
9 5 Restoring alloy wheels 10043
9 6 Removing and installing hub cover for alloy wheels with open threaded connection 10043
9 7 Renewing trim elements 10044
9 7 1 Renewing trim elements, bonded trim elements 10044
9 7 2 Renewing trim elements, bolted trim elements 10048
9 8 Removing and installing valve 10050
9 8 1 Removing and installing valve, description of the valve 10050
9 8 2 Removing and installing valve, rubber valve 10050
9 8 3 Removing and installing valve, metal valve 10051
10 Handling problems 10053
10 1 Rolling noise 10053
10 1 1 General notes on tyre noise 10053
10 1 2 Flat spots (from locking wheels) 10054
10 2 Vehicle pulls to one side 10055
10 2 1 General information 10055
10 2 2 Conicity 10055
10 2 3 Remedies when vehicle pulls to one side 10056
10 2 4 Strategic rotation of wheels for non-directional tyres 10057
10 2 5 Strategic rotation of wheels having unidirectional tyres 10058
10 3 Vibration 10059
10 3 1 Vibration, causes for vibration 10059
10 3 2 Vibration, conducting a road test before balancing wheels 10059
10 3 3 Vibration, vibration control system 10060
10 4 Eliminating flat spots caused by storage or handling 10060
11 Evaluating tyres 10062
11 1 Flat spots caused by storage or handling 10062
11 2 Undulations 10062
11 3 Saw-tooth wear 10063
11 4 Flat spots caused by hard braking 10063
11 5 Swellings in the tyre sidewall 10063
11 6 Cuts 10065
11 7 Damage caused by foreign bodies 10065
11 8 Stripped profile 10065
11 9 Tyre damage due to insufficient tyre pressure 10066
11 10 Checking tyres 10066
11 11 Damage caused when fitting 10067
12 Tyre wear 10069
12 1 Factors influencing the service life of tyres 10069
12 2 Saw-tooth wear 10070
12 3 Wear behaviour of high-speed tyres 10070
12 4 Measuring tread depth 10071
12 5 One-sided wear 10071
12 6 Outer shoulder wear 10074
12 7 Diagonal washout 10075
12 8 Wear in middle of tyre 10075
12 9 Permissible deviation in tread depth 10076
13 Exploded view of components 10077
13 1 Assembly overview – wheel 10077
14 Snow chains 10079
14 1 Assembly and use of snow chains 10079
15 Regular and temporary spare wheels, recommended temporary spare tyres 10080
15 1 Spare wheel with yellow sticker 10080
15 2 Temporary spare wheels and recommended temporary spare tyres 10081
15 2 1 Arteon 2018 10081
15 2 2 Atlas 2017 10081
15 2 3 Golf 2013, e-Golf 2014 10081
15 2 4 Golf 2017, e-Golf 2017 10081
15 2 5 Golf SV 2015 10082
15 2 6 Golf Estate 2014 10082
15 2 7 Golf Estate 2017 10082
15 2 8 Passat 2015, Passat Estate 2015 10082
15 2 9 Polo 2018 10083
15 2 10 Tiguan 2016 10083
D4B80882D49 Installed 6 speed manual gearbox 02Q 10084
00 – Technical data 10088
1 Safety information 10088
1 1 Safety precautions when using testers and measuring instruments during a road test 10088
1 2 Safety precautions when working on vehicles with a start/stop system 10089
1 3 All-wheel drive – notes on performance test 10089
2 Identification 10090
3 Technical data 10092
3 1 Allocation gearbox – engine 10092
3 2 Capacities 10092
4 Overview – power transmission 10093
5 Electrical components 10095
5 1 Overview of fitting locations – electrical components, manual gearbox 10095
5 2 Overview of fitting locations – electrical components, clutch mechanism 10095
6 Repair instructions 10096
6 1 General repair instructions 10096
30 – Clutch 10099
1 Clutch mechanism 10099
1 1 Overview of fitting locations – clutch mechanism 10099
1 2 Assembly overview – pedal cluster 10100
1 3 Assembly overview – clutch hydraulics 10102
1 4 Removing and installing bearing bush 10104
1 5 Checking clutch master cylinder and clutch slave cylinder 10105
1 6 Removing and installing clutch position sender -G476- 10106
1 7 Removing and installing over-centre spring 10108
1 8 Removing and installing clutch pedal 10110
1 8 1 Removing and installing clutch pedal, LHD 10110
1 8 2 Removing and installing clutch pedal, RHD 10111
1 9 Removing and installing mounting bracket 10113
1 10 Removing and installing clutch master cylinder 10116
1 11 Removing and installing clutch slave cylinder 10116
1 12 Removing and installing bleeder 10119
1 13 Removing and installing lines for clutch mechanism 10122
1 14 Bleeding clutch mechanism 10124
2 Clutch 10126
2 1 Determining make of clutch 10126
34 – Controls, housing 10128
1 Selector mechanism 10128
1 1 Installation position – selector mechanism 10128
1 2 Assembly overview – gear knob and cover 10129
1 3 Assembly overview – selector mechanism 10130
1 4 Removing and installing gear knob 10132
1 5 Removing and installing selector mechanism 10134
1 6 Repairing selector mechanism 10139
1 7 Adjusting selector mechanism 10144
1 8 Checking selector mechanism 10148
2 Removing and installing gearbox 10149
2 1 Removing gearbox 10149
2 2 Installing gearbox 10163
2 3 Specified torques for gearbox 10167
3 Assembly mountings 10168
3 1 Assembly overview – assembly mountings 10168
4 Transporting gearbox 10171
5 Gear oil 10172
5 1 Distinguishing between different manual gearbox types when filling oil 10172
5 2 Checking gear oil level 10172
5 2 1 Checking gear oil level, gearboxes “with” oil filler plug 10172
5 2 2 Checking gear oil level, gearboxes “without” oil filler plug 10173
5 2 3 Draining an adding gear oil, manual gearbox “without” oil filler plug 10174
5 2 4 Specified torque for oil filler and oil drain plugs 10176
6 Dismantling and assembling gearbox 10177
6 1 Assembly overview – selector unit 10177
6 2 Removing and installing selector unit with gearbox installed 10178
6 3 Renewing selector shaft seal 10182
7 Gearbox housing, clutch housing 10185
35 – Gears, shafts 10186
1 Input shaft 10186
2 Output shaft 10187
39 – Final drive – differential 10188
1 Seals 10188
1 1 Overview of fitting locations – oil seals 10188
1 2 Renewing left seal 10188
1 2 1 Renewing oil seal for left flange shaft 10188
1 3 Renewing right seal 10192
1 3 1 Renewing oil seal for right flange shaft 10192
2 Differential 10196
D4B802791F3 6 speed dual clutch gearbox 0D9 10197
00 – Technical data 10201
1 Safety information 10201
1 1 General safety provisions 10201
1 2 Safety measures when working on vehicles with a start/stop system 10201
1 3 Safety precautions when using testers and measuring instruments during a road test 10202
2 Identification 10203
2 1 Gearbox identification 10203
2 1 1 Identification on gearbox 10203
2 1 2 Reading gearbox code letters 10203
3 Repair notes 10206
3 1 General repair instructions 10206
3 1 1 General information 10206
3 2 Gaskets, seals 10207
3 3 Nuts and bolts 10207
4 Technical data 10209
4 1 Capacities 10209
4 1 1 Capacities – dual clutch gearbox 10209
4 1 2 Capacities, front differential lock 10209
4 1 3 Bevel box 10209
5 Electrical components 10210
5 1 Overview of fitting locations – electrical components 10210
5 1 1 Overview of fitting locations – gearbox control 10210
5 1 2 Overview of fitting locations – electrical components, front differential lock 10210
30 – Clutch 10212
1 Clutch 10212
1 1 Assembly overview – dual clutch 10212
1 2 Removing and installing clutch end cover 10214
1 3 Removing dual clutch 10219
1 4 Installing dual clutch 10220
34 – Controls, housing 10229
1 Mechatronic unit 10229
1 1 Assembly overview – mechatronic unit 10229
1 1 1 Renewing securing clip on vehicle connector 10232
1 2 Removing and installing oil pan 10234
1 3 Removing and installing mechatronic unit for dual clutch gearbox -J743- 10242
1 3 1 Removing and installing mechatronic unit for dual clutch gearbox -J743-, gearbox installed 10242
1 3 2 Removing and installing mechatronic unit for dual clutch gearbox -J743-, gearbox removed 10256
2 Bevel box 10264
2 1 Assembly overview – bevel box 10264
2 2 Removing bevel box 10265
2 3 Installing bevel box 10272
3 Selector mechanism 10276
3 1 Assembly overview – selector mechanism 10276
3 1 1 Assembly overview – selector mechanism, manufacturer ZF 10276
3 1 2 Assembly overview – selector mechanism, manufacturer ECS 10277
3 2 Manual release from position P 10279
3 2 1 Emergency release from P position, manufacturer ZF 10279
3 2 2 Emergency release from P position, manufacturer ECS 10281
3 3 Removing and installing selector lever handle 10283
3 3 1 Removing and installing selector lever handle, Golf 2013 ►, Golf Estate 2014 ►, Golf 2017 ►, Golf Estate 2017 ►, T-Roc, T-Roc Cabriolet 10283
3 3 2 Removing and installing selector lever handle, Passat 2015 ►, Passat estate 2015 ►, Arteon 2018 ►, Passat estate 2019 ► 10287
3 3 3 Removing and installing selector lever handle, Polo 2018 ►, Golf SV 2015 ►, Golf SV 2018 ► 10291
3 3 4 Removing and installing selector lever handle, Touran 2016 ► 10294
3 3 5 Removing and installing selector lever handle, Tiguan 2016 ► 10298
3 4 Bringing interlock button in handle into installation position 10302
3 5 Removing and installing selector mechanism 10304
3 5 1 Removing and installing selector mechanism with selector lever cable 10304
3 5 2 Removing and installing selector mechanism without selector lever cable, manufacturer ZF 10307
3 5 3 Removing and installing selector mechanism without selector lever cable, manufacturer ECS 10310
3 6 Adjusting selector mechanism 10313
3 7 Removing and installing gear selector cable 10319
3 7 1 Removing and installing selector lever cable, manufacturer ZF 10319
3 7 2 Removing and installing selector lever cable, manufacturer ECS 10322
3 8 Checking selector mechanism 10325
3 9 Checking and adjusting selector lever cable 10326
3 10 Renewing selector shaft seal 10328
4 Removing and installing gearbox 10331
4 1 Removing gearbox 10331
4 1 1 Removing gearbox, Golf 2013 ►, Golf Estate 2014 ►, Golf 2017 ►, Golf Estate 2017 ►, vehicles with diesel engine 10331
4 1 2 Removing gearbox, Golf SV 2015 ►, Golf SV 2018 ►, T-Roc, T-Roc Cabriolet, vehicles with diesel engine 10339
4 1 3 Removing gearbox, Golf 2013 ►, Golf 2017 ►, vehicles with petrol engine 10348
4 1 4 Removing gearbox, Golf Estate 2014 ►, Golf Estate 2017 ►, vehicles with diesel engine, all-wheel drive 10356
4 1 5 Removing gearbox, Golf Estate 2014 ►, Golf Estate 2017 ►, vehicles with petrol engine, all-wheel drive 10367
4 1 6 Removing gearbox, Passat 2015 ►, Passat Variant 2015 ►, Arteon 2018 ►, vehicles with diesel engine, front-wheel drive, radiator version “1” or “3” 10375
4 1 7 Removing gearbox, Passat 2015 ►, Passat Variant 2015 ►, Arteon 2018 ►, vehicles with diesel engine, front-wheel drive, radiator version “2” 10383
4 1 8 Removing gearbox, Passat 2015 ►, vehicles with diesel engine, all-wheel drive 10393
4 1 9 Removing gearbox, Passat 2015 ►, Passat estate 2015 ►, Passat 2019 ►, vehicles with petrol engine 10404
4 1 10 Removing gearbox, Passat 2015 ►, Passat estate 2015 ►, Passat estate 2019 ►, vehicles with petrol engine, all-wheel drive 10412
4 1 11 Removing gearbox, Touran 2016 ►, vehicles with diesel engine 10422
4 1 12 Removing gearbox, Tiguan 2016 ►, vehicles with 1 4 l petrol engine 10429
4 1 13 Removing gearbox, Polo 2018 ►, Polo 2022 ►, vehicles with 2 0 l petrol engine 10441
4 2 Gearbox transport 10451
4 3 Installing gearbox 10452
4 4 Specified torques for gearbox 10458
5 Assembly mountings 10461
5 1 Assembly overview – assembly mountings 10461
6 Dismantling and assembling gearbox 10465
6 1 Assembly overview – gearbox 10465
7 Securing to engine and gearbox support 10469
7 1 Secure gearbox on engine and gearbox support 10469
7 2 Secure front differential lock to engine and gearbox support 10470
8 Gear oil circuit 10472
8 1 Removing and installing gear oil cooler 10472
8 2 Removing and installing cover for gear oil pump 10475
8 3 Removing and installing gear oil pump 10477
8 4 Removing and installing gear oil filter 10479
9 Gear oil 10482
9 1 Checking gear oil level 10482
9 2 Draining and filling gear oil 10485
10 Front differential lock 10489
10 1 Assembly overview – front differential lock 10489
10 2 Removing front differential lock 10489
10 2 1 Transporting front differential lock 10493
10 3 Installing front differential lock 10493
10 4 Removing and installing differential lock control unit -J647- 10495
35 – Gears, shafts 10497
1 Currently, no repairs can be made to gears and shafts 10497
39 – Final drive – differential 10498
1 Gear oil 10498
1 1 Checking gear oil level 10498
1 1 1 Checking gear oil in bevel box 10498
1 1 2 Filling gear oil in bevel box 10498
2 Oil for front differential lock 10502
2 1 Checking oil level for front differential lock 10502
2 2 Draining and filling oil for front differential lock 10503
3 Oil seals 10507
3 1 Overview of fitting locations – oil seals 10507
3 2 Renewing left seal 10509
3 3 Renewing right seal 10513
3 3 1 Renewing right oil seal, front wheel drive 10513
3 3 2 Renewing outer seal on right of bevel box 10518
3 3 3 Renewing right seal on gearbox, between front differential lock and gearbox or between bevel box and gearbox 10519
3 3 4 Renewing seal on bevel box between bevel box and gearbox 10521
3 3 5 Renewing oil seal for propshaft drive flange at bevel box 10522
4 Components of front differential lock 10530
4 1 Assembly overview – components of front differential lock 10530
4 2 Checking function 10532
4 3 Removing and installing pump for front differential lock -V181- 10532
4 4 Removing and installing coupling for front differential lock 10534
4 5 Renewing seal for front differential lock 10534
4 5 1 Renewing outer seal on right of front differential lock 10534
4 5 2 Renewing seal between front differential lock and gearbox on front differential lock 10538
4 5 3 Renewing seal for right flange shaft in front differential lock 10540
4 6 Renewing ball bearing for flange shaft 10542
5 Bevel box 10546
5 1 Assembly overview – bevel box 10546
5 2 Removing and installing right flange shaft 10548
5 3 Dismantling and assembling bevel box 10551
5 3 1 Renewing needle bearing (polygon bearing) for right flange shaft 10551
5 3 2 Renewing output flange and redetermining thickness of shim, bevel box removed 10553
D4B802791F6 7 speed dual clutch gearbox 0CW 10566
00 – Technical data 10570
1 Safety information 10570
1 1 General safety provisions 10570
1 2 Safety measures when working on vehicles with a start/stop system 10570
1 3 Safety precautions when using testers and measuring instruments during a road test 10571
1 4 Safety precautions when tow-starting or towing 10571
2 Identification 10572
2 1 Gearbox identification 10572
3 Repair notes 10573
3 1 General information 10573
3 2 General repair instructions 10574
3 3 Gaskets, seals 10575
3 4 Nuts and bolts 10575
4 Technical data 10577
4 1 Capacities 10577
5 Overview – power transmission 10579
5 1 Overview – power transmission – front-wheel drive 10579
30 – Clutch 10580
1 Clutch mechanism 10580
1 1 Assembly overview – clutch engagement mechanism 10580
1 2 Removing and installing clutch engagement mechanism 10582
1 3 Adjusting clutch engagement mechanism 10586
2 Clutch 10602
2 1 Assembly overview – dual clutch 10602
2 2 Removing dual clutch 10604
2 3 Installing dual clutch 10609
2 4 Renewing input shaft seal 10615
2 5 Renewing oil seal for inner input shaft 10617
34 – Controls, housing 10620
1 Mechatronic unit 10620
1 1 Assembly overview – mechatronic unit 10620
1 2 Removing and installing mechatronic unit 10622
1 3 Moving mechatronic unit for dual clutch gearbox -J743- into removal position by hand 10639
1 4 Renewing clutch actuator piston 10641
1 5 Renewing control unit for mechatronic unit for dual clutch gearbox -J743- 10647
2 Selector mechanism 10653
2 1 Assembly overview – selector mechanism 10653
2 1 1 Assembly overview – selector mechanism, manufacturer ZF 10653
2 1 2 Assembly overview – selector mechanism, manufacturer ECS 10655
2 2 Manual release from position P 10657
2 2 1 Manual release mechanism from position P, Golf 2013 ►, Golf Estate 2014 ►, Golf 2017 ►, Golf Estate 2017 ► 10657
2 2 2 Manual release from position P, Polo 2014 ► 10658
2 2 3 Emergency release from position P, Golf SV 2015 ►, Golf SV 2018 ► 10659
2 2 4 Manual release mechanism from position P, Passat 2015 ►, Passat Estate 2015 ►, Passat 2019 ►, Passat Estate 2019 ► 10660
2 2 5 Manual release from position P, Touran 2016 ► 10661
2 2 6 Manual release from position P, Polo, Taigo, Virtbus 10662
2 2 7 Emergency release from position P, T-Roc, T-Roc Cabriolet 10663
2 3 Removing and installing selector lever handle 10664
2 3 1 Removing and installing selector lever handle, Golf 2013 ►, Golf Estate 2014 ►, Golf 2017 ►, Golf Estate 2017 ► 10664
2 3 2 Removing and installing selector lever handle, Passat 2015 ►, Passat Estate 2015 ►, Passat 2019 ►, Passat Estate 2019 ► 10667
2 3 3 Removing and installing selector lever handle, Polo, Taigo, Virtbus, Golf SV 2015 ►, Golf SV 2018 ► 10671
2 3 4 Removing and installing selector lever handle, Touran 2016 ► 10674
2 3 5 Removing and installing selector lever handle, T-Roc 2018 ►, T-Roc Cabriolet 2020 ► 10677
2 4 Bringing interlock button in handle into installation position 10680
2 5 Removing and installing selector mechanism 10683
2 5 1 Removing and installing selector mechanism with selector lever cable 10683
2 5 2 Removing and installing selector mechanism without selector lever cable, manufacturer ZF 10686
2 5 3 Removing and installing selector mechanism without selector lever cable, manufacturer ECS 10689
2 6 Adjusting selector mechanism 10692
2 7 Removing and installing gear selector cable 10697
2 7 1 Removing and installing selector lever cable, manufacturer ZF 10697
2 7 2 Removing and installing selector lever cable, manufacturer ECS 10701
2 8 Checking selector mechanism 10703
2 9 Checking and adjusting selector lever cable 10705
2 10 Renewing selector shaft seal 10707
3 Removing and installing gearbox 10708
3 1 Removing gearbox 10708
3 1 1 Removing gearbox, Golf 2013 ►, Golf Estate 2014 ►, Golf SV 2015 ►, Golf 2017 ►, Golf Estate 2017 ►, Golf SV 2018 ►, vehicles with 1 0 l, 1 2 l and 1 4 l petrol engines and 1 4 l natural gas engine 10708
3 1 2 Removing gearbox, Golf 2013 ►, Golf Estate 2014 ►, Golf 2017 ►, Golf Estate 2017 ►, vehicles with diesel engine 10715
3 1 3 Removing gearbox, Golf SV 2015 ►, Golf SV 2018 ►, vehicles with diesel engine 10721
3 1 4 Removing gearbox, Polo 2014 ►, vehicles with 1 0 l, 1 2 l and 1 4 l petrol engine 10728
3 1 5 Removing gearbox, Polo 2014 ►, vehicles with diesel engine 10736
3 1 6 Removing gearbox, Passat 2015 ►, Passat Estate 2015 ►, Passat 2019 ►, Passat Estate 2019 ►, vehicles with diesel engine 10743
3 1 7 Removing gearbox, Polo 2014 ►, vehicles with 1 8 l petrol engine 10749
3 1 8 Removing gearbox, Passat 2015 ►, Passat estate 2015 ►, Passat 2019 ►, vehicles with 1 4 l petrol engine 10756
3 1 9 Removing gearbox, Passat 2015 ►, Passat Estate 2015 ►, vehicles with 1 8 l petrol engine 10762
3 1 10 Removing gearbox, Touran 2016 ►, vehicles with 1 4 l petrol engine 10769
3 1 11 Removing gearbox, Touran 2016 ►, vehicles with diesel engine 10775
3 1 12 Removing gearbox, Touran 2016 ►, vehicles with 1 8 l petrol engine 10782
3 1 13 Removing gearbox, Golf 2017 ►, Golf Estate 2017 ►, Golf SV 2018 ►, vehicles with 1 5 l petrol engine 10788
3 1 14 Removing gearbox, Polo, vehicles with 1 0 l petrol engine 10795
3 1 15 Removing gearbox, T-Roc, T-Roc Cabriolet, vehicles with 1 5 l petrol engine 10803
3 1 16 Removing gearbox, Polo 2018 ►, vehicles with diesel engine 10810
3 1 17 Removing gearbox, Passat 2015 ►, Passat estate 2015 ►, Passat 2019 ►, Passat estate 2019 ►, vehicles with 1 5 l petrol engine 10816
3 1 18 Removing gearbox, Touran 2016 ►, vehicles with 1 5 l petrol engine 10822
3 1 19 Removing gearbox, Polo 2018 ►, Polo 2022 ►, Virtbus, Taigo vehicles with 1 5 l petrol engine 10829
3 2 Installing gearbox 10835
3 3 Specified torques for gearbox 10841
4 Assembly mountings 10843
4 1 Assembly overview – assembly mountings 10843
4 1 1 Assembly overview – assembly mountings, Golf, Golf Estate, Golf SV, Passat, Passat Estate, Touran, T-Roc, T-Roc Cabriolet, Polo, Virtbus, Taigo 10843
4 1 2 Assembly overview – assembly mountings, Polo 2014 ► 10845
5 Gearbox transport 10847
6 Securing to engine and gearbox support 10849
7 Gear oil 10852
7 1 Draining and filling gear oil 10852
7 2 Draining and filling hydraulic fluid for mechatronic unit 10855
35 – Gears, shafts 10859
1 Parking lock 10859
1 1 Removing and installing cover for parking lock 10859
1 2 Removing and installing parking lock 10860
39 – Final drive – differential 10862
1 Oil seals 10862
1 1 Overview of fitting locations – oil seals 10862
1 2 Renewing left seal 10862
1 3 Renewing right seal 10866
1 3 1 Renewing right oil seal, gearboxes with flange shaft 10866
1 3 2 Renewing right oil seal, gearboxes with stub shaft 10871
D4B806742B7 Gas drive General information 10874
00 – Technical data 10878
1 Safety information 10878
1 1 Safety precautions when working on natural gas system 10878
2 General information 10879
2 1 Other reference material 10879
3 Safety briefing/employee qualification 10880
3 1 Safety briefing/employee qualification 10880
4 Receiving vehicles for repair 10882
4 1 Procedure for taking receipt of vehicles 10882
5 Laws and regulations 10883
5 1 Rules and regulations 10883
5 2 Workplace requirements 10883
6 Basic technical and physical principles 10884
6 1 Physical properties 10884
6 1 1 Physical data of dried natural gas 10884
7 Repair instructions 10885
7 1 Rules for cleanliness 10885
8 Checking natural gas system 10886
8 1 Test requirements for gas systems 10886
8 1 1 Testing with self-diagnosis 10886
8 2 Checking natural gas system for leaks 10886
8 3 Searching for leaks in gas system using gas leak detector 10886
8 4 Searching for leaks in gas system using leak detector spray 10888
20 – Fuel supply system 10889
1 Fuel 10889
1 1 Handling natural gas fuel tanks 10889
1 2 Storing natural gas fuel tanks 10889
1 3 Damage assessment catalogue for natural gas fuel tanks 10891
1 3 1 Damage assessment of steel fuel tanks 10891
1 3 2 Damage assessment of carbon fibre fuel tank (composition fibre reinforced fuel tank) 10891
1 4 Discharging natural gas fuel tanks 10894
1 5 Rendering natural gas fuel tanks inert 10906
1 5 1 With water: 10906
1 5 2 With nitrogen: 10906
1 6 Disposing of natural gas fuel tanks 10907
1 7 Determining residual pressure in natural gas fuel tank 10907
1 7 1 Checking and converting adapter for back-pressure test on natural gas tank 10907
1 7 2 Checking (self test) cooling system tester 10909
1 7 3 Determining residual pressure in natural gas fuel tank 10915
1 8 Reducing fuel pressure in high-pressure section 10920
1 8 1 Reducing fuel pressure in high-pressure section 10920
2 Senders and sensors 10923
2 1 Gas rail temperature and pressure sensor -GX21- 10923
2 2 High-pressure valve for gas mode -N372- 10923
2 3 Gas rail sensor -G401- (low-pressure side) 10924
2 4 Tank pressure sensor -G400- 10924
24 – Mixture preparation – injection 10925
1 Mixture preparation – injection 10925
1 1 Distinguishing between pressure sections of natural gas supply system 10925
1 1 1 High-pressure section 10925
1 1 2 Low-pressure section 10927
1 2 High-pressure injectors N30 – N33 10928
D4B807678A4 5 speed manual gearboxes 0DF and 0D0 installed 10930
00 – Technical data 10934
1 Safety information 10934
1 1 Safety measures when working on vehicles with a start/stop system 10934
2 Identification 10935
2 1 Gearbox identification 10935
3 Technical data 10936
3 1 Allocation gearbox – engine 10936
3 2 Capacities 10936
4 Overview – power transmission 10937
5 Electrical components 10939
5 1 Overview of fitting locations – electrical components 10939
5 1 1 Overview of fitting locations – electrical components, manual gearbox 10939
5 1 2 Overview of fitting locations – electrical components, clutch mechanism 10940
6 Repair notes 10941
6 1 General repair instructions 10941
30 – Clutch 10944
1 Clutch mechanism 10944
1 1 Overview of fitting locations – clutch mechanism 10944
1 2 Assembly overview – pedal cluster 10945
1 3 Assembly overview – clutch hydraulics 10947
1 4 Removing and installing bearing bush 10949
1 5 Checking clutch master cylinder and clutch slave cylinder 10950
1 6 Removing and installing clutch position sender -G476- 10951
1 7 Removing and installing over-centre spring 10953
1 8 Removing and installing clutch pedal 10955
1 8 1 Removing and installing clutch pedal, LHD 10955
1 8 2 Removing and installing clutch pedal, RHD 10956
1 9 Removing and installing mounting bracket 10958
1 10 Removing and installing master cylinder 10961
1 11 Removing and installing clutch slave cylinder 10962
1 12 Removing and installing lines for clutch mechanism 10965
1 13 Bleeding clutch mechanism 10968
2 Clutch 10970
34 – Controls, housing 10971
1 Selector mechanism 10971
1 1 Installation position – selector mechanism 10971
1 2 Assembly overview – gear knob and cover 10972
1 3 Assembly overview – selector mechanism 10972
1 4 Removing and installing gear knob 10974
1 5 Removing and installing selector mechanism 10976
1 6 Repairing selector mechanism 10979
1 7 Adjusting selector mechanism 10983
1 8 Checking selector mechanism 10986
2 Removing and installing gearbox 10988
2 1 Specified torques for gearbox 10988
2 2 Removing gearbox 10988
2 3 Installing gearbox 10997
3 Gearbox transport 11001
4 Assembly mountings 11002
4 1 Assembly overview – assembly mountings 11002
5 Gear oil 11005
5 1 Checking gear oil level 11005
5 2 Draining and filling gear oil 11006
6 Dismantling and assembling gearbox 11008
6 1 Assembly overview – selector unit 11008
6 2 Removing and installing selector unit with gearbox installed 11009
6 2 1 Removing and installing selector unit with gearbox installed 11009
6 2 2 Repairing selector unit 11012
6 2 3 Renewing selector shaft seal 11013
7 Gearbox housing, clutch housing 11015
35 – Gears, shafts 11016
1 Input shaft 11016
2 Output shaft 11017
39 – Final drive – differential 11018
1 Oil seals 11018
1 1 Overview of fitting locations – oil seals 11018
1 2 Renewing left seal 11018
1 2 1 Renewing seal for left drive shaft 11018
1 3 Renewing right seal 11021
1 3 1 Renewing seal for right drive shaft 11021
2 Differential 11024
D4B807926CA 3 cylinder injection engine (1 0 l natural gas 4 V EA 211 turbocharger) 11025
00 – Technical data 11031
1 Safety information 11031
1 1 Safety regulations for working on fuel supply 11031
1 2 Safety precautions when working on vehicles with a gas system 11031
1 3 Safety measures when working on vehicles with start/stop system 11033
1 4 Safety precautions when using testing and measuring instruments during a road test 11033
1 5 Safety precautions when working on the cooling system 11034
1 6 Safety precautions when working on ignition system 11034
2 Identification 11035
2 1 Engine number/engine data 11035
3 Repair notes 11037
3 1 Rules for cleanliness 11037
3 2 General information 11037
3 3 General repair instructions 11037
3 3 1 General notes on injection 11037
3 3 2 General notes on ignition system 11038
3 3 3 General notes on charge air system 11038
3 4 Foreign objects in engine 11039
3 5 Contact corrosion 11039
3 6 Routing and attachment of lines 11039
3 7 Fitting radiators and condensers 11039
3 8 Checking vacuum system 11039
10 – Removing and installing engine 11041
1 Removing and installing engine 11041
1 1 Removing engine 11041
1 2 Separating engine and gearbox 11052
1 3 Securing engine on engine and gearbox support 11054
1 4 Installing engine 11055
2 Assembly mountings 11061
2 1 Assembly overview – assembly mountings 11061
2 2 Removing and installing engine mounting 11064
2 3 Removing and installing gearbox mounting 11066
2 4 Removing and installing pendulum support 11068
2 5 Checking adjustment of assembly mountings 11069
2 6 Adjusting assembly mountings 11070
2 7 Supporting engine in installation position 11073
13 – Crankshaft group 11075
1 Cylinder block (pulley end) 11075
1 1 Assembly overview – poly V-belt drive 11075
1 1 1 Assembly overview – poly V-belt drive, vehicles without air conditioner compressor 11075
1 1 2 Assembly overview – poly V-belt drive, vehicles with air conditioner compressor 11077
1 2 Removing and installing poly-V belt 11079
1 2 1 Removing and installing poly V-belt, vehicles without air conditioner compressor 11079
1 2 2 Removing and installing poly V-belt, vehicles with air conditioner compressor 11081
1 3 Removing and installing tensioner for poly V-belt 11083
1 3 1 Removing and installing tensioner for poly V-belt, vehicles without air conditioner compressor 11083
1 3 2 Removing and installing tensioner for poly V-belt, vehicles with air conditioner compressor 11083
1 4 Removing and installing vibration damper 11084
1 5 Removing and installing engine support 11087
1 6 Renewing crankshaft oil seal – belt pulley end 11091
2 Cylinder block, gearbox end 11094
2 1 Assembly overview – cylinder block, gearbox end 11094
2 2 Removing and installing flywheel 11095
2 3 Removing and installing sealing flange on gearbox side 11096
3 Crankshaft 11108
3 1 Crankshaft dimensions 11108
3 2 Measuring axial clearance of crankshaft 11108
4 Pistons and conrods 11110
4 1 Assembly overview – pistons and conrods 11110
4 2 Removing and installing pistons 11113
4 3 Checking pistons and cylinder bores 11114
4 4 Separating new conrod 11116
4 5 Checking radial clearance of conrods 11117
4 6 Removing and installing oil spray jets 11117
4 7 Setting piston to TDC position 11118
15 – Cylinder head, valve gear 11122
1 Cylinder head 11122
1 1 Assembly overview – cylinder head 11122
1 2 Assembly overview – camshaft housing 11124
1 3 Removing and installing cylinder head 11126
1 4 Removing and installing camshaft housing 11132
1 5 Checking compression 11136
2 Toothed belt drive 11139
2 1 Assembly overview – toothed belt cover 11139
2 2 Assembly overview – toothed belt 11139
2 3 Removing and installing toothed belt guard 11141
2 3 1 Removing and installing upper toothed belt guard 11141
2 3 2 Removing and installing lower toothed belt guard 11142
2 4 Preassembling and installing test tool -VAS 611 007- 11143
2 4 1 Preassembling test tool -VAS 611 007- 11143
2 4 2 Installing test tool -VAS 611 007- 11146
2 4 3 Teaching-in test tool -VAS 611 007- electronically and performing basic setting 11149
2 5 Checking valve timing 11151
2 6 Adjusting valve timing 11154
2 7 Removing toothed belt from camshaft 11164
2 8 Removing and installing toothed belt 11171
3 Valve gear 11182
3 1 Assembly overview – valve gear 11182
3 2 Removing and installing camshaft adjuster 11184
3 2 1 Removing and installing camshaft adjuster for inlet camshaft 11184
3 2 2 Removing and installing camshaft adjuster for exhaust camshaft 11188
3 3 Measuring axial play of camshaft 11192
3 4 Removing and installing camshaft oil seal 11193
3 4 1 Removing and installing camshaft oil seal for inlet camshaft, belt pulley end 11193
3 4 2 Removing and installing exhaust camshaft oil seal, pulley end 11195
3 4 3 Removing and installing exhaust camshaft oil seal, gearbox end 11199
3 5 Removing and installing camshaft control valve 1 -N205- 11201
3 6 Removing and installing exhaust camshaft control valve 1 -N318- 11203
3 7 Removing and installing valve stem seals 11204
3 7 1 Removing and installing valve stem seals (cylinder head installed) 11204
3 7 2 Removing and installing valve stem seals (cylinder head removed) 11211
4 Inlet and exhaust valves 11216
4 1 Checking valve guides 11216
4 2 Checking valves 11217
4 3 Valve dimensions 11217
17 – Lubrication 11218
1 Sump, oil pump 11218
1 1 Assembly overview – sump/oil pump 11218
1 2 Engine oil 11222
1 3 Removing and installing sump 11222
1 4 Removing and installing oil level and oil temperature sender -G266- 11228
1 5 Removing and installing oil pump 11229
2 Engine oil cooler 11232
2 1 Assembly overview – engine oil cooler 11232
2 2 Removing and installing engine oil cooler 11232
3 Crankcase ventilation 11234
3 1 Assembly overview – crankcase breather system 11234
3 2 Removing and installing oil separator 11235
4 Oil filter, oil pressure switch 11239
4 1 Assembly overview – oil filter/oil pressure switch 11239
4 2 Removing and installing oil filter housing 11240
4 3 Removing and installing oil pressure sender -G10- 11241
4 4 Removing and installing oil pressure regulating valve -N428- 11242
4 5 Checking oil pressure 11244
19 – Cooling 11245
1 Cooling system/coolant 11245
1 1 Connection diagram – coolant hoses 11245
1 2 Draining and adding coolant 11246
1 3 Checking cooling system for leaks 11254
2 Coolant pump, regulation of cooling system 11259
2 1 Assembly overview – coolant pump, thermostat 11259
2 2 Assembly overview – electric coolant pump 11262
2 2 1 Assembly overview – charge air cooling pump -V188- 11262
2 3 Assembly overview – coolant temperature sender 11263
2 4 Removing and installing coolant pump 11264
2 5 Removing and installing toothed belt pulley for coolant pump 11269
2 6 Removing and installing thermostat 11271
2 6 1 Removing and installing thermostat for main coolant circuit (radiator) 11271
2 6 2 Removing and installing thermostat for cylinder block coolant circuit 11273
2 7 Removing and installing electric coolant pump 11275
2 7 1 Removing and installing charge air cooling pump -V188- 11275
2 8 Removing and installing coolant temperature sender -G62- 11277
2 9 Removing and installing radiator outlet coolant temperature sender -G83- 11279
3 Coolant pipes 11281
3 1 Assembly overview – coolant pipes 11281
3 2 Removing and installing coolant pipes 11281
4 Radiator, radiator fan 11284
4 1 Assembly overview – radiator/radiator fan 11284
4 2 Assembly overview – radiator cowl and radiator fan 11285
4 3 Removing and installing radiator 11286
4 4 Removing and installing radiator cowl 11291
4 5 Removing and installing radiator fan -V7- 11293
21 – Turbocharging/supercharging 11294
1 Turbocharger 11294
1 1 Assembly overview – turbocharger 11294
1 2 Removing and installing turbocharger 11297
1 3 Removing and installing charge pressure positioner -V465- 11302
1 4 Removing and installing connection for turbocharger 11304
2 Charge air system 11307
2 1 Assembly overview – charge air system 11307
2 2 Removing and installing air pipe 11309
2 3 Removing and installing charge pressure sender -GX26- 11310
2 4 Removing and installing charge air cooler 11311
2 5 Checking charge air system for leaks 11313
24 – Mixture preparation – injection 11316
1 Injection system 11316
1 1 Overview of fitting locations – injection system 11316
2 Air filter 11323
2 1 Assembly overview – air filter housing 11323
2 2 Removing and installing air filter housing 11325
3 Intake manifold 11327
3 1 Assembly overview – intake manifold 11327
3 2 Removing and installing intake manifold 11329
3 3 Removing and installing throttle valve module -GX3- 11335
3 4 Cleaning throttle valve module -GX3- 11337
4 Checking natural gas supply system for leaks 11339
4 1 Distinguishing between pressure sections of natural gas supply system 11339
4 1 1 High-pressure section 11340
4 1 2 Low-pressure section 11342
4 2 Determining pressure in gas system 11343
4 3 Determining operating mode of natural gas vehicles 11343
4 4 Activating and deactivating natural gas mode 11343
4 5 Checking gas system for leaks 11345
4 5 1 Checking gas system for leaks after working on the high-pressure section 11347
4 5 2 Checking gas system for leaks after working on the low-pressure section 11347
5 Gas pressure regulator 11350
5 1 Assembly overview – gas pressure regulator 11350
5 1 1 Assembly overview – gas pressure regulator 11350
5 1 2 Assembly overview – gas pressure regulator with add-on parts 11350
5 2 Removing and installing gas pressure regulator 11352
5 3 Removing and installing tank pressure sensor -G400- 11358
6 Gas injectors 11361
6 1 Assembly overview – gas rail 11361
6 2 Removing and installing gas rail with gas injector -N366-/-N367-/-N368- 11363
6 3 Removing and installing gas rail temperature and pressure sensor -GX21- 11366
7 Injectors 11369
7 1 Assembly overview – fuel rail with injectors 11369
7 2 Removing and installing fuel rail 11371
7 3 Removing and installing injectors 11372
7 4 Cleaning injectors 11384
8 Senders and sensors 11386
8 1 Removing and installing intake manifold sender -GX9- 11386
8 2 Removing and installing fuel pressure sender -G247- 11387
8 3 Checking fuel pressure sender -G247- 11388
8 3 1 Checking fuel pressure sender -G247-, using vehicle diagnostic tester 11388
9 High-pressure pump 11391
9 1 Assembly overview – high-pressure pump 11391
9 2 Removing and installing high-pressure pump 11392
9 3 Removing and installing high-pressure pipe 11394
10 Lambda probe 11396
10 1 Assembly overview – Lambda probe 11396
10 2 Removing and installing Lambda probe 11397
10 2 1 Removing and installing lambda probe 1 before catalytic converter -GX10-/lambda probe 1 after catalytic converter -GX7- 11397
11 Engine control unit 11399
11 1 Removing and installing engine control unit -J623- 11399
11 1 1 Removing and installing engine control unit -J623- (with protective housing) 11399
26 – Exhaust system 11403
1 Exhaust pipes and silencers 11403
1 1 Assembly overview – silencers 11403
1 2 Removing and installing silencer 11404
1 3 Aligning exhaust system free of stress 11405
1 4 Checking exhaust system for leaks 11406
2 Emission control 11407
2 1 Assembly overview – emission control 11407
2 2 Removing and installing catalytic converter 11410
28 – Ignition system 11414
1 Ignition system 11414
1 1 Assembly overview – ignition system 11414
1 2 Removing and installing ignition coils with output stage 11416
1 3 Removing and installing knock sensor 1 -G61- 11419
1 4 Removing and installing Hall sender -G40- 11420
1 5 Removing and installing engine speed sender -G28- 11421