Description of work Lubricating the servo
Contents
1. The battery under the front left seat is equipped with a battery isolation system Observe safety precautions when working on the battery isolation system Repair Manual Electrical Equipment Repair Group 27 Disconnect battery Ground GND wire 1 from battery Ground GND terminal Battery under front left seat Connecting Special tools testers and auxiliary items required Description of work V A G 1331 Torque wrench 5 50 Nm V A G 1331 Tighten securing bolt of battery positive terminal clamp to 9 Nm Only after securing positive terminal clamp 2 connect negative wire 1 terminal clamp to negative terminal on battery Tighten securing bolt of battery negative terminal clamp to 9 Nm Reinstall cover Page 10 105 Description of work Page 11 105 Replace seat frame mounting bolts arrows and tighten them to a torque of 45 Nm Note Once the battery is reconnected Repair Manual Electrical Equipment Repair Group 27 If the battery clamp on negative terminal is not seated securely V A G 1331 Battery under front left seat Tightening battery terminal on negative terminal Special tools testers and auxiliary items required Torque wrench 5 50 Nm V A G 1331 Description of work z 4 T 1 n N27 0368 J 139 Tighten ground connection 1 on battery to 9 Nm Reinstall cover Replace seat frame mounting b2. Compress the securing ring B at the front line and disconnect line A from air filter housing Remove air filter housing part upward Note Description of work Page 53 105 Observe installation position of air filter gt ANNE an Remove air filter element A Clean air cleaner housing if necessary using compressed air and install new air filter element Installing Insert air filter element Note a Make sure sealing surfaces on air filter housing are correctly positioned Make sure that no cables or lines are pinched Secure air filter housing again using fasteners 1 Bolt on throttle valve control module 2 again and tighten to 3 Nm Connect connector 3 Description of work NO1 10038 Reconnect line arrow Then press locking ring 1 on line flange 3 so that it engages audibly Re connect line A until it engages Install engine cover Engine oil level check Note the following After stopping engine wait at least 3 minutes to allow oil to flow back into oil pan Remove dipstick and wipe with clean rag Replace dipstick and push down to stop Note Observe waste disposal regulations Pull out dipstick again and read oil level Page 54 105 Description of work Page 55 105 If the dipstick appears as illustrated A Oil must not be topped off B Oil can be topped off This will ca
3. NO1 10080 Clean sealing surfaces at cap and at oil filter housing Install oil filter 5 Installing Install cap 3 with new O ring 4 and tighten to 25 Nm Install new sealing ring 2 for oil drain plug 1 and tighten to 10 Nm Oil filter replacing 10 cyl diesel engine Remove engine cover gt 01 4 Upper engine cover removing and installing Removing Note Observe waste disposal regulations Oil new O rings before installation Cover engine with a cloth Description of work Page 59 105 Unscrew oil filter housing cap from filter housing using tool T10192 Clean sealing surfaces at cap and at oil filter housing Install oil filter 3 Installing Install cap 1 with new O rings 2 and 4 and tighten to 25 Nm Oil filter replacing 6 cyl gasoline engine Note Observe waste disposal regulations a Oil new O rings before installation Avoid engine oil drips on components in engine compartment Perform the following work procedure Description of work Page 60 105 Unscrew oil drain plug 1 of screw cap and drain oil Loosen filter lower part 2 on hexagon 1 oron circumference and remove Clean sealing surfaces at cap and at oil filter housing Installing CEEA Replace the filter element 4 and the seal 3 Install cap 2 with new O ring and tighten to 25 Nm Install
4. Work procedure changing brake fluid Special tools testers and auxiliary items required VAS 5234 Description of work Page 25 105 Brake charger bleeder unit VAS 5234 Release securing bolts 1 and 2 and remove cover upward Remove cap from brake fluid reservoir 1 Extract as much brake fluid as possible using suction hose from brake charger bleeder unit VAS 5234 or from V A G 1869 or using a suction bottle with built in strainer Note After extracting observe that no further brake fluid runs into the reservoir the brake fluid level in the reservoir must align with the lower edge of the strainer Warning Do not reuse used extracted brake fluid Brake pedal depressor Install V A G 1869 2 between drivers seat and brake pedal and apply tension Screw adapter onto brake fluid reservoir Connect filler hose of VAS 5234 or V A G 1869 to Description of work Page 26 105 adapter Pull cover caps off bleeder screws of brake calipers Connect bleeder hose of collector bottle to rear bleeder screw open bleeder screw and allow the corresponding quantity to drain out see table below Close bleeder screw Note Use a Suitable bleed hose It must seat tightly on bleed screw so that no air can enter brake system Bleed rear right first Repeat work sequence on other side of vehicle at rear Note Front brake calipers with two valves first connect the in
5. a Part numbers are for reference only Always check Description of work Page 93 105 with your Parts Department for the latest part number information Underbody protection perform visual check for damage During visual check observe floor pan wheel housings and sills Note a Malfunctions found must be rectified repair measure This inhibits corrosion and rusting through Setting time language and units on instrument cluster display a Time The time can be set here and can be switched between the 12 and 24 hour display Language The language of the instrument cluster display can be set here Units The units for temperature consumption and pressure can be set here Instrument panel cluster Highline one color display The menu can be operated using either the control elements in the windshield wiper stalk or the control elements in the multi function steering wheel 1 Operating with windshield wiper stalk NO1 10240 Press selector B longer than 2 seconds until the main menu is displayed Description of work Page 94 105 Press the top or bottom selector until the menu selection COMFORT SETUP is displayed inverted The main menu Comfort setup has the following functions e g Light Speed warning Time Comfort Language Units Reset Press the button A enough times until the appropriate menu is selected Using the button and selector all
6. Page 64 105 Description of work Engine and components in engine compartment from above and below visual check for leaks and damage Perform visual check as follows Check engine and components in engine compartment for leaks and damage Check hoses lines and connections of Fuel system Cooling and heating system a Oil circuit Air conditioning Intake system and brake system for leaks abrasions porosity and brittleness Caution Ensure that all malfunctions detected are rectified within repair measures If fluid losses are greater than can be reasonably expected determine cause and repair repair measure Break down kit tire mobility kit checking Break down set is located in spare wheel well arrow Break down set contains a tire inflation cylinder with Page 65 105 Description of work Page 66 105 sealant next to the compressor Note a The tire sealant in the bottle has a limited shelf life Therefore on the bottle the expiration date arrow is displayed N44 0138 In this example the expiration date 05 2003 has passed and the bottle must then be replaced Verify the expiration date Replace tire sealant if expiration date has been reached Caution Tire sealant must not be older than 4 years If the bottle was opened e g if a tire went flat is must be replaced Note Residual tire sealant or full bottles which have expired must
7. Repair Manual 5 0 Liter V10 2V TDI PD Engine Mechanical Fuel Injection Glow Plug Engine Code s BKW BWF Repair Group 26 Electric windows check positioning Warning After disconnecting and connecting the battery in luggage compartment and or under front left seat the excess force limitation of electric windows does not function This can cause serious injuries if e g fingers are caught in the window Note After disconnecting and connecting the vehicle battery in luggage compartment and or under front left seat the automatic opening and closing features for the electric windows do not function Therefore the electric windows must be positioned again immediately before a new vehicle is delivered The vehicle battery must not be disconnected after the electric windows have been positioned Description of work Page 30 105 Perform the following work sequence to position the electric windows Note The following work sequence is for the front left window The positioning for the remaining windows is performed in the same manner using the respective switch in the drivers door Close all doors and windows completely Switch ignition on Open front left side window fully by pressing and holding the button in the drivers door Close the front left side window fully by lifting and holding the button in the drivers door then release button Lift button again for 1 second Now when the button
8. danger of damage could occur Middle engine compartment cover for 10 cyl diesel engine Removing Page 62 105 Description of work Page 63 105 Remove oil dipstick 2 Unclip cover 1 from catches arrows and remove upward Installing Set engine cover 1 onto fastening points arrows and press it on until it engages Do not forget oil dipstick 2 Caution Make sure to not strike the engine cover with a fist or a tool when installing the engine cover and engaging the fastening points there is the risk of damage Lower engine cover noise insulation tray removing and installing Note On some vehicle equipment versions the engine compartment is equipped with an additional underbody impact guard from below Underbody protection removing and installing Repair Manual Body Exterior Repair Group 50 Front noise insulation cover Note Description of work n the illustration the fittings on the left hand side of the noise insulation is located in front The fittings on the right hand side are similar For removing the noise insulation cover screws must be removed Remove screws 1 and 2 Noise insulation front and rear NO1 10088 Remove bolts A First remove noise insulation 3 Remove screws B Remove the rear noise insulation 2 out of the spring latches 1 Tighten bolts to torque of 8 Nm
9. 105 VAS 6096 5 ral Cooling system charge unit VAS 6096 V A G 1274 8 W00 0703 Adapter V A G 1274 8 Note All engines are filled with coolant additive G 12 Plus conforming to TL VW 774 F color purple G 12 Plus can be mixed with the previous coolant additives G 11 and G 12 red Ensure that the system is replenished only with G12 Plus due to its positive properties G 12 Plus is suitable as a filled for life filling for cast iron and all aluminum engines and gives optimum protection against frost corrosion damage scaling and over heating G 12 Plus increases the boiling point to 275 F 135 C and ensures for a better heat dissipation The coolant portion of the mixture must amount to at least 40 freeze protection to 13 F 25 C and should not exceed 60 freeze protection to 40 Description of work Page 42 105 F 40 C Otherwise the freeze protection will be reduced and the cooling efficiency will be worsened Freeze protection must be guaranteed to approx 13 F approx 31 F 35 C in countries with an arctic climate Checking freeze protection and adding coolant additive if necessary Special tools testers and auxiliary items required a Refractometer T10007 Check freeze protection Note Read the bright dark boundary to obtain an accurate reading for the following tests Place a drop of water on the glass to improve the readability
10. 5 51 3 5 51 195 75 18 3 5 51 3 5 51 3 5 51 3 5 51 Brake pads front and rear checking thickness Special tools testers and auxiliary items required Description of work a Pliers 3314 V A G 1332 Torque wrench 40 200 Nm V A G 1332 a Electric flashlight and mirror Note The adapter to loosen tighten the anti theft wheel bolts is located with the vehicle tool kit Front disc brake pads For better judgment of remaining pad thickness remove the front wheel on the drivers side Remove wheel bolt caps using Pliers 3314 if necessary Page 20 105 Description of work Page 21 105 NO2 1091 Mark position of wheel in relation to brake disc Unbolt wheel securing bolts and remove wheel Measure inner and outer pad thickness a Pad thickness not including backing plate Wear limit 2 mm With pad thickness not including backing plate of 2 mm the brake pads have reached their wear limit and must be replaced repair procedure Inform customer Note a When replacing brake pads it is absolutely necessary to check brake discs for wear Checking and if necessary replacing brake discs is a repair measure Check brake discs for wear Repair Manual Brake System Repair Group 46 Install wheel to marked position Tighten wheel securing bolts using diagonal sequence to following tightening torque Tightening torque 160 Nm Place adapter with vehicle tool kit after
11. Note To make it easier to find break away point 2 cover and uncover left half of headlight as viewed when looking forward a few times Then check low beam again After correct adjustment of low beams the center point of the main beam must lie on the center mark 3 a For the previous test screens with 15 setting line adjust for new test screen To avoid incorrect settings ignore 15 setting line Description of work Fog lights Check whether the upper light dark border touches the setting line horizontally over the complete test screen width Other additional lights Auxiliary light systems must be checked and adjusted according to the guidelines valid for them Headlamps with HID lamps without cornering light system adjusting Headlamp range control performing basic setting Connect diagnostic tester 01 3 Diagnostic testing unit connecting Switch ignition on Select Guided Functions Perform vehicle identification Select vehicle system Automatic headlamp range control Mark Perform basic setting and confirm with gt Now the number of malfunctions is read out and if there are 0 malfunctions Complete can be selected Observe displayed notes and confirm by selecting Complete Switch low beams on and confirm with Complete Now adjust headlamps as follows Left headlamp Page 75 105 Description of work Left headlam
12. Te Y EEE Remove air filter element A Clean air cleaner housing if necessary using compressed air and install new air filter element Installing Insert air filter element A Note a Make sure sealing surfaces on air filter housing are correctly positioned Make sure that no cables or lines are pinched Description of work Page 50 105 Perform the following work procedure wi S Ka TK NO1 10038 Then press locking ring 1 on line flange 3 so that it engages audibly Description of work Install intake hose Install intake hose securing pins as follows Insert securing pins so that the mark on the pin 1 and the mark on the air cleaner housing 2 align Install engine cover Air filter element removing and installing 6 and 8 cyl gasoline engines Removing Remove engine cover 01 4 Upper engine cover removing and installing Open clamps 1 Disconnect connector 3 of throttle valve control module Remove bolts 2 of throttle valve control module Page 51 105 Description of work Page 52 105 Disconnect line connections at air filter housing arrow as follows NO1 10038 On the rear line press off locking ring 1 usinga screwdriver C from line flange 3 Press securing sleeve 2 in direction of arrow and at the same time disconnect line A from line B
13. is pressed briefly the window will lower fully and when the button is lifted briefly the window will raise fully Vehicles with Rear View Camera System check license plate Note In vehicles with Rear View Camera System it is not permitted to install an additional license plate holder or an additional license plate base For additional information see Repair Manual Electrical Equipment Repair Group 94 Vehicle system test perform Connect diagnostic tester 01 3 Diagnostic testing unit connecting Switch ignition on Select operating mode Guided Fault Finding on the display Then perform vehicle identification on tester Program now performs a vehicle system test automatically Description of work Page 31 105 and checks for all possible control modules for this vehicle type Press Continue gt button Now all DTCs will be listed Note At this point it makes sense to switch into operating mode Guided Functions in order to perform further work using VAS 5051 and to prevent a second vehicle identification on the tester To do so press operating mode button and then Guided Functions Refer to the corresponding work descriptions for the continued sequence norder to return to Guided Fault Finding press the operating mode button and then Guided Fault Finding Caution In any case the vehicle must be returned to the customer with DTC memory erased Static malfunct
14. nozzles are preset Small height adjustments Description of work Page 86 105 can be made If both spray fields are not at same height adjust spray direction upward or downward as follows Adjust spray jet on adjuster 1 by hand upward or downward Headlamp washer nozzle adjusting Special tools testers and auxiliary items required Adjustment device 3019A Adjustment device T10167 Description of work Page 87 105 fe ES Spray jet adjustment for left headlight right headlight is identical but reversed Check nozzle adjustment a 100 mm b 75 mm C 230 mm d 50 mm If necessary adjust spray jets as follows Switch on headlamps and operate windshield wiper washer system long enough until spray nozzles for headlight cleaning system are driven out Hold spray nozzle arrow firmly and pull out up to stop and align to the respective spray points using adjustment tool T10167 Adjustment of spray nozzles rear windshield wipe wash system Note a Spray nozzle of rear windshield wipe wash system is acomponent of auxiliary brake light and cannot be Description of work Page 88 105 adjusted f spray nozzle sprays unevenly or does not spray the wiper area replace the auxiliary brake light with spray nozzle Removing and installing auxiliary brake light Repair Manual Electrical Equipment Repair Group 94 Service interval display
15. of the bright dark boundary The bright dark boundary can be clearly recognized on the WATERLINE Check the concentration of the coolant additive using refractometer T10007 operating instructions Description of work Page 43 105 NO2 0625 The scale 1 of the refractometer T10007 refers to the coolant additives G 12 G 12 Plus and G 11 Scale 2 refers only to coolant additive G 13 previously L80 If freeze protection ratio is too low drain listed amount and replace it with coolant additive G 12 Plus conforming to TL VW 774 F Freeze protection table Freeze protection to C Specified value 6 cyl engine 6 cyl engine 1 1 Models with 2 heat exchangers Freeze protection to C Difference amount in liters Actual Specified 8 cyl 8 cyl engine 10 cyl 10 cyl engine Description of work Page 44 105 value value engine 1 engine 1 1 1 I j 1 N Fo Fh Fv Fw neEntinrnrn I Nn 1 I l WEN Fw Fv ou Bou BoE Eo L o E E EE te Lise oe eee Ee v Ees Ri I I I KP de Jo STaATa Models with 2 heat exchangers Mixture ratio Coolant additive G 12 Plus approx 40 approx 60 Note Observe waste disposal regulations Check coolant additive concentration after test drive again Checking coolant level and adding coolant if necessary Description of work Unscrew cap 1 from expansion tank a Delivery inspecti
16. of the other instrument cluster menus can be operated 2 Operating with multi function steering wheel Touch press button 1 or button 3 to change menus and use thumb wheel 2 to make a selection turn Press button 1 or button 3 until the menu selection COMFORT SETUP is displayed inverted The main menu Comfort setup has the following functions e g Light Speed warning Time Comfort Language Units Reset Turn the thumb wheel 2 until the desired menu selection is displayed Press the thumb wheel The selected menu is displayed For example set clock via multi function steering wheel Switch ignition on Description of work Page 95 105 Press button 1 to activate menu selection in instrument panel cluster display mh Select the menu option Clock with the thumb wheel 2 When the menu item Clock is selected in display 1 confirm the menu setting by pressing the thumb wheel Set the time using the thumb wheel as well as the 12 24 hour clock mode settings Note a f the clock is found in the tachometer the clock can be set using the adjustment knob below the tachometer Instrument panel cluster premium color display Note n the color display outside temperature time and mileage are continually displayed Operating with multi function steering wheel Description of work Page 96 105 Touch
17. of the same type and tread pattern must be used Otherwise the center differential may be damaged Tire condition checking At the delivery inspection Check tire tread and side walls for damage if necessary remove any foreign material such as nails or screws Warning If damage is discovered the tire must be examined to determine whether a new one must be installed Inspection Service Check tire tread and side walls for damage if necessary remove any foreign material such as nails or screws Check tires for scuffing one sided wear porous side walls cuts and fractures Warning The customer must be informed of malfunctions found Checking tire wear pattern Note a The wear pattern of the front wheels can be used to assess whether a check of the track and camber is necessary Causes Feathered edges of the treads may indicate faulty toe adjustment One sided tread wear is mainly attributed to incorrect camber Description of work Page 18 105 When wear of this nature is noticed determine cause by performing alignment checks repair measure Depth of tire tread checking including spare wheel Check tire tread depth Minimum depth 1 6 mm Note a This value may vary for individual countries due to different legislative regulations The minimum tread depth is reached when the tires have worn down level with the 1 6 mm high tread wear indicators positioned at intervals aroun
18. oil drain plug 1 with new seal and tighten to 10 Nm Filling engine oil For appropriate oil specifications please refer to Additional information Fluid Capacity Charts for appropriate Model and Year General notes Note Observe waste disposal regulations After topping off with oil wait at least 3 minutes then Description of work Page 61 105 check oil level Pull out oil dipstick and wipe with clean rag Replace dipstick and push down to stop Pull out dipstick again and read oil level If the dipstick appears as illustrated A Oil must not be topped off B Oil can be topped off This will cause the oil level to be in area A C Oil must be topped off It is sufficient when oil level is in area B grooved field If oil level is above area A the catalytic converter can be damaged When oil level is below marking C top off with oil to marking A Upper engine cover removing and installing Side engine compartment cover Remove right engine cover as follows Description of work 2 r WO Pry off cover 2 Remove engine cover from catches arrows and remove it upward Middle engine compartment cover for 6 cyl gasoline engine Unclip engine compartment covers 1 and 2 and remove upward and off Caution To install engine cover or to engage at mounting points be sure not to strike the engine cover with a fist or tool
19. 0 minutes Power assisted steering checking fluid level Fluid when cold Page 69 105 Description of work Page 70 105 NO2 1108 AY With engine not running move front wheels in straight ahead position Remove reservoir cap arrow with dipstick Clean dipstick with clean cloth Screw cap on hand tight and remove again Caution Screw cap fully in to get an accurate fluid level reading Check fluid level Fluid level must be in area of MIN mark up to 2 mm above or below mark Note f fluid level is above specified range fluid must be extracted off f the fluid level is below the specified level check the hydraulic system for leaks repair measure It is not enough to simply top off with fluid fno leaks are detected top off with hydraulic fluid G 002 000 Description of work Page 71 105 a Part numbers are for reference only Always check with your Parts Department for the latest part number information Screw in cap hand tight Warm fluid at approx 122 F 50 C With engine not running move front wheels in straight ahead position au Hep OA NOAA A A NO2 1106 Unscrew reservoir cap arrow with fitted dipstick Clean dipstick with clean cloth Screw cap on hand tight and remove again Caution Screw cap fully in to get an accurate fluid level reading Check fluid level Check fluid level It must be between MIN
20. Manual Body Interior Repair Group 68 Description of work Remove screws 1 and take out filter element 2 downward Note Observe installed position of filter element Observe waste disposal regulations Installing Insert new filter Re install cover Ribbed belt checking condition Perform the following work procedure Check ribbed belt 1 for Sub surface cracks cracks core ruptures cross sectional breaks Layer separation top layer cord strands Page 33 105 Description of work Page 34 105 Base break up Fraying of cord strands Flank wear material wear frayed flanks flank brittleness glassy flanks surface cracks Traces of oil and grease Note Replace the belt if any damage is found This will avoid possible break downs or operating problems The replacement of a ribbed belt is a repair measure Fuel filter drain water Fuel filter draining water 10 cyl diesel engines Special tools testers and auxiliary items required VAS 5226 a Suction pump VAS 5226 Description of work Page 35 105 Insert hose of suction pump VAS 5226 with a suitable adapter into the hole for water extraction arrow Extract about 100 ml of diesel fuel using the suction pump VAS 5226 Replace the seal of the water extraction plug Tighten water extraction plug to 3 Nm Fuel filter replacing diesel engine Replace
21. The space A between the wiper rubber and bottom edge of windshield must be 9 mm The distance B between wiper blade and lower edge of windshield must be 12 mm Adjust park position by moving wiper arm if necessary Torque wiper arm 32 Nm Page 81 105 Description of work Windshield passengers side Check the park position The space A between the wiper rubber and bottom edge of windshield must be 12 mm The distance B between wiper blade and lower edge of windshield must be 44 mm Adjust park position by moving wiper arm if necessary Torque wiper arm 32 Nm Rear window Check the park position N92 0315 The distance a between wiper blade and lower edge of windshield must be 55 mm measured from lower edge of glass If necessary adjust the park position by relocating the wiper arm Torque wiper arm 12 Nm Windshield wash wipe system and headlight wash system check for function and damage top off fluid if necessary Checking freeze protection concentration of fluid adding Page 82 105 Description of work Page 83 105 fluid 01 4 Checking freeze protection concentration of fluid adding fluid Windshield wash wipe system and headlight wash system Check jet setting adjust jets if necessary 01 4 Windshield wash wipe system and headlight wash system checking nozzle setting adjusting nozzles if necessary Checking freeze protection concentra
22. Volkswagen Touareg Maintenance Description of work Page 1 105 69 Description of work Turbocharger lubricate servo motor linkage Lubricating the servo motor linkage applies to 1 The Turbocharger TC 1 Servo Motor V280 for cylinder bank 1 right engine side 2 The Turbocharger TC 2 Servo Motor V281 for cylinder bank 2 left engine side Remove engine cover Lower noise insulation 01 4 Lower engine cover noise insulation tray removing and installing 1 Lubricating linkage Turbocharger TC 1 Servo Motor V280 right engine side Installed location Wheel housing front right above the steering boot between the front longitudinal member and engine block arrow A Lubricate the pivot of the servo motor shaft and linkage arrows A and B by hand Only use Hot Bolt Paste G 052 112 A3 Description of work Page 2 105 Note a Part numbers are for reference only Always check with your Parts Department for the latest part number information 2 Lubricate linkage Turbocharger TC 2 Servo Motor V281 left engine side AS not 10309 Installed location Front left between the steering and housing of front final drive above the coolant hoses arrow A Lubricate the pivot of the servo motor shaft and linkage arrows A and B by hand Only use Hot Bolt Paste G 052 112 A3 Note a Part numbers are for reference only Always check with your Parts D
23. ad wear check Work procedure brake fluid level depending on brake pad wear check 7 P _ _ ce OT TEANAS VY AANA AAAA TNN OOnHOOR AAYA 1 AVENA VANNA Release securing bolts 1 and 2 and remove cover Description of work upward Note the following Brake fluid level at delivery inspection At time of delivery inspection brake fluid level must be at MAX mark 1 Note a To prevent the brake fluid from overflowing from the reservoir the level must not be over the MAX mark 1 Brake fluid level at Inspection Service The fluid level must always be judged in conjunction with brake pad wear When vehicle is in use the fluid level tends to drop slightly due to brake pad wear and automatic adjustment Recommended brake fluid level when brake pad wear limit has almost been reached At MIN marking and slightly above 2 TOPPING OFF NOT NECESSARY Page 28 105 Description of work Page 29 105 Recommended brake fluid level if brake pads are new or are far from the brake pad wear limit Between MIN and MAX Marking Warning If fluid level is below MIN marking 2 brake system must be checked before brake fluid is added repair measure Diesel particle filter replacing For installed position of the Diesel particle filter see underside of the vehicle Diesel particle filter removing and installing
24. adjustment Turn the adjustment screw for height adjustment 1 until the correct setting is achieved Note Also check whether both headlamps work evenly when operating the headlight range adjuster Adjustment screws for right headlight are arranged symmetrically Adjusting fog lights and other auxiliary lights Fog lights in headlamps Note The adjustment of fog lights is performed automatically when adjusting headlamps Left fog lamp in bumper Adjusting screw on right fog light is arranged symmetrically Description of work Release cover caps 1 from locking devices in direction of arrow Perform adjustment 1 Height adjustment Turn height adjustment screw 1 with hex socket head wrench until the correct setting is achieved Lateral adjustment is not possible Other auxiliary lights Auxiliary light systems must be checked and adjusted according to the guidelines valid for them Sunroof checking function cleaning and lubricating guide rails Page 80 105 Description of work Perform the following work procedure Check function of sunroof Clean guide rails and lubricate with Grease G 000450 02 Note a Part numbers are for reference only Always check with your Parts Department for the latest part number information Windshield wiper blades check park position adjust if necessary Windshield drivers side Check the park position y
25. and MAX markings Note Description of work Page 72 105 f the fluid level is above the MAX mark siphon fluid off If the fluid level is below the MIN mark check the hydraulic system for leaks repair procedure It is not enough to simply top off with oil If no leaks are detected top off with hydraulic fluid G 002 000 a Part numbers are for reference only Always check with your Parts Department for the latest part number information Screw in cap hand tight Headlight adjustment check Test requirements 01 4 Test requirements Check headlight adjustment 01 4 Headlamp adjustment checking with new test screen without 15 adjustment line Headlamps with halogen lamps adjusting 01 4 Headlamps with halogen lamps adjusting Headlamps with gas discharge lamps without cornering light system adjusting 01 4 Headlamps with HID lamps without cornering light system adjusting Headlamps with gas discharge lamps with cornering light system adjusting 01 4 Headlamps with HID lamps and cornering light system adjusting Fog lights and other auxiliary headlamps adjusting 01 4 Adjusting fog lights and other auxiliary lights Test requirements Test and adjustment requirements Tire pressure OK Lenses must not be damaged or dirty a Reflectors and bulbs OK Move vehicle back and forth for 1 meter 3 to 4 feet or bounce front and rear of vehicle s
26. be disposed of a Old tire sealant or remainder of it must not be mixed with other fluids and must be disposed of Perform test drive To what extent the following can be checked is dependent upon the vehicle equipment and local conditions urban country Description of work Page 67 105 The following should be checked by means of a road test Engine Output misfiring idling speed acceleration Gear selection Ease of operation shift lever position Automatic transmission Selector lever position shift lock ignition key interlock shift behavior display in instrument cluster Foot brake Function free travel and effectiveness pulling to one side juddering squeal Parking brake At most after 5 7 notches for effective parking on the street 2 3 notches of free travel on operating lever before start of braking ABS function When braking with activated ABS the brake pedal must pulse noticeably Steering Function steering free play steering wheel centralized when wheels are in straight ahead position Sunroof Function Radio Radio Navigation system Function Reception GALA interference A C system Function Vehicle Moving off line when traveling straight ahead level road Imbalance Wheels drive shafts prop shafts Wheel bearings Noises Engine Hot starting behavior Wheel securing bolts tighten to correct torque setting Special tools testers and auxiliary item
27. bleeding In order to ensure engine starts immediately after changing fuel filter fuel system must be bled with diagnostic tester Connect diagnostic tester 01 3 Diagnostic testing unit connecting Switch ignition on Select Guided Functions Perform vehicle identification Select OBD Capable Systems Diesel direct fuel injection and glow plug system Functions Bleed Fuel System Page 38 105 Description of work Page 39 105 Follow the instructions on the diagnostic tester After bleeding exit Guided Functions with Go to button Compass in the roof module adjust compass zones The compass indicates the direction vehicle is facing For a correct reading the correct compass zone must be adjusted Adjust compass settings Determine your geographical location on the zone map Ay Ea i ALS x NO1 10182 Description of work With ignition switched on press button 3 Select with the function keys 2 in the display 1 the symbol N and confirm OK Select the function keys 2 the selected zone between 1 and 15 and confirm OK in order to adjust the compass zone The selected zone is stored the compass reading appears in the display Cooling system freeze protection and coolant level checking Special tools testers and auxiliary items required a Refractometer T10007 Page 40 105 Description of work Page 41
28. completing work Reinstall wheel bolt covers if necessary Rear disc brake pads Description of work Page 22 105 Illuminate area behind hole in wheel using an electric flashlight on _ N02 1090 fal im os Z Determine thickness of outer pad by checking visually Illuminate inner pad using an electric flashlight and mirror Determine thickness of inner pad by checking visually a Pad thickness inner and outer not including backing plate Wear limit 2 mm With pad thickness not including backing plate of 2 mm the brake pads have reached their wear limit and must be replaced repair procedure Inform customer Note a When replacing brake pads it is absolutely necessary to check brake discs for wear Checking and if necessary replacing brake discs is a repair measure Check brake discs for wear Repair Manual Brake System Repair Group 46 Brake system visual check for leaks and damage Check the following components for leaks and damage Brake master cylinder Description of work Page 23 105 a Hydraulic unit Brake pressure regulator and Brake calipers Check that brake hoses are not twisted Turn steering to left stop and to right stop During this operation no brake hose must touch any vehicle components Check brake hoses are not porous or brittle Check brake hoses and lines for chafing Check brake connections and methods of securing for corre
29. ct seating leaks and corrosion Warning Malfunctions found must be rectified repair measure Brake fluid changing Notes on application and safety 01 4 Notes on application and safety precaution Specification of brake fluid 01 4 Specification of brake fluid Work procedure changing brake fluid 01 4 Work procedure changing brake fluid Notes on application and safety precaution Note From model year 2006 a new brake fluid is introduced a The new brake fluid can also be used for older vehicles New brake fluid can be mixed with previous brake fluid Warning Brake fluid must never come into contact with Description of work Page 24 105 fluids containing mineral oils oil gas cleaning solutions Oils containing minerals damage seals and sleeves on brake systems Brake fluid is poisonous Due to its caustic nature it must also never be brought into contact with paint Brake fluid is hygroscopic which means that it absorbs moisture from the air Always store brake fluid in air tight containers Wash off brake fluid spillage using plenty of water Do not reuse used extracted brake fluid Observe waste disposal regulations Specification of brake fluid Permitted brake fluid specifications Brake fluid corresponding to US standard FMVSS 116 DOT 4 previous brake fluid Brake fluid corresponding to VW standard VW 501 14 new brake fluid
30. d the tire f the tread depth is approaching the legal minimum permissible depth the customer must be informed Tire pressure check if necessary correct Special tools testers and auxiliary items required VAS 5216 W00 10057 Tire filling unit VAS 5216 Note a Observe that the inflation pressure specifications refer to the air pressure of cold tires Do not reduce increased pressures on warm tires Important information about recommended winter tires can be found in Description of work Page 19 105 Repair Manual Wheels tires guide Repair Group 44 Inflation pressure specifications can be found on a sticker located on the driver door at the door jamb a Pressures are indicated in BAR and PSI Pressures apply to all factory installed mounted tire sizes Check the tire size used on the vehicle with the sizes in the table and correct tire pressure regardless of engine type Tire pressure values half load full load Tire sizes front bar rear bar front bar rear bar psi psi psi psi 235 70 R 16 2 4 34 2 5 36 2 4 34 2 9 42 235 65 R 17 2 5 36 2 6 38 2 6 38 3 0 44 255 60 R 17 2 5 36 2 6 38 2 5 36 3 0 44 235 60 R 18 2 71 39 2 7 39 2 9 42 3 2 46 255 55 R 18 2 6 38 2 9 42 2 8 39 3 1 45 255 50 R 19 2 8 39 3 0 44 3 0 44 3 4 49 275 45 R 19 2 4139 3 0 44 2 8 39 3 2 46 275 40 R 20 2 8 39 3 0 44 3 0 44 3 4 49 Spare wheel collapsible spare wheel 195 80 17 3 5 51 3 5 51 3
31. epartment for the latest part number information Ball joints visual inspection Description of work Page 3 105 Aa Ry Check joint boots arrow of upper ball joints for leaks and damage Check joint boots arrow of lower ball joints for leaks and damage Automatic transmission ATF level checking Work procedure Repair Manual 6 Spd Automatic Transmission 09D All Wheel Drive Repair Group 37 Battery disconnect relay removing The battery disconnect relay protects the battery from discharging through unnecessary electrical components while transporting from manufacturing factory to dealer The battery disconnect relay must be removed during the delivery inspection a Collect the removed battery disconnect relays and Description of work Page 4 105 send them back to the manufacturer Work procedure The battery disconnect relay is located in the footwell in front of the driver seat The battery disconnect relay is fastened to the ground connection for the battery negative terminal in front of the driver seat Note The battery under the driver seat is equipped with a battery isolation system Observe safety measures when working on battery isolation system removing and installing battery disconnect relay Repair Manual Electrical Equipment Repair Group 27 Switch off ignition and all electrical components and remove ignition key If the trim under the dri
32. everal times up and down to settle suspension Description of work Page 73 105 Vehicle and headlight adjuster must be on a level surface User manual for headlight adjuster a Vehicle and headlight adjuster must be aligned a Inclination must be set In the trim above the headlight inclination measurements are stamped in The headlamps must be adjusted according to these measurements Percentage information is based on a projection distance of 10 meters For example inclination of 1 0 converts to approx 10 cm Vehicles with gas discharge lamps with dynamic headlight range adjuster Note a On vehicles with high intensity discharge HID headlamps the basic setting must be performed with diagnostic tester before every headlamp adjustment Headlamp adjustment checking with new test screen without 15 adjustment line Special tools testers and auxiliary items required VAS 5046 Headlight adjuster VAS 5046 a Headlight adjuster VAS 5047 Headlamps Check the following Description of work Page 74 105 With the low beam switched on check whether the horizontal light dark border of the setting line 1 contacts the test surface Check whether the break away point 2 between the left horizontal part and the rising part on the right of the light dark border runs vertically through the center point 3 The bright core of the light beam must be on the right of the vertical line
33. fuel filter 10 cylinder diesel engines Note There are two different fuel filter systems n system 1 the fuel filter is located on the engine under the engine cover n system 2 the fuel filter is located to the left in the engine compartment on the strut tower Special tools testers and auxiliary items required VAS 5226 Description of work Page 36 105 a Suction pump VAS 5226 Remove engine cover 01 4 Upper engine cover removing and installing Removing Remove plug arrow from fuel filter housing water drain connector Extract diesel fuel via water drain connection located on the side of the fuel filter housing arrow using V A G 1390 and V A G 1390 1 Seal off oil plug again and tighten to 3 Nm Remove line connectors for fuel lines Remove screws arrows along with connection lines to fuel filter housing Description of work Removing fuel filter cover Remove screws arrow for fuel filter housing and remove cover Remove fuel filters 3 from cover 1 Note Observe waste disposal regulations Installing Install new fuel filters 3 and replace seal 2 Install fuel filter cover 1 Page 37 105 Description of work Install line connectors for fuel lines Note Replace sealing ring between fuel filter covers and line unions for fuel hoses Tighten bolts arrows to 8 Nm Fuel system
34. icles with 8 cyl gasoline engine Removing Unclip engine covers and remove upward Remove bracket for left engine cover 1 Unscrew bolt as well as retaining bolts for engine cover arrows Page 102 105 Description of work i NO1 10100 Press connector catches arrows in direction of arrow and disconnect connectors A from ignition coils with power output stages Note Before removing plugs note installation position of ignition coils with power output stages if necessary mark installation position of plugs Remove ignition coils with power output stages using Puller T40039 in direction of arrow Page 103 105 Description of work Page 104 105 Remove spark plugs using spark plug wrench 3122B Installing Screw in new spark plugs using spark plug wrench 3122B Note Observe torque specification Current values Repair Manual Engine Mechanical Fuel Injection Ignition Repair Group 28 Install ignition coils with power output stages while lightly turning They should noticeably engage Description of work Re connect connectors A so that they engage Re install left bracket for engine cover 1 and tighten it to 10 Nm Install engine covers Static cornering lights and automatic headlamps checking function Static cornering lights Switch ignition and low beams on Turn steering wheel out of center position o
35. in luggage compartment Connecting Special tools testers and auxiliary items required Description of work Page 15 105 V A G 1331 a Torque wrench 5 50 Nm V A G 1331 Tighten mounting bolt of battery positive terminal clamp arrow to9 Nm Only after securing positive terminal clamp fit negative terminal clamp arrow to negative terminal on battery Tighten mounting bolt of battery negative terminal clamp arrow to 9 Nm Note Once the battery is reconnected Description of work Page 16 105 Repair Manual Electrical Equipment Repair Group 27 If the battery clamp on negative terminal is not seated securely A LEE AVA EE E e NN LA yw OA Tighten ground connection 2 on battery to 9 Nm Re install battery cover Close cover in luggage compartment floor Note Once the battery is reconnected Repair Manual Electrical Equipment Repair Group 27 Batteries check Check the battery Repair Manual Electrical Equipment Repair Group 27 Check tires tire condition wear pattern inflation pressure and tread depth Note On vehicles with tire pressure monitor system TPMS the new tire pressures must be adapted Description of work Page 17 105 01 4 Storing tire pressure values Warning For reasons of safety only tires of same type and tread pattern should be installed on a vehicle On All Wheel Drive vehicle tires
36. ion If one or more static malfunctions are stored in data memory it is recommended to arrange with the customer to repair this malfunction via Guided Fault Finding Sporadic malfunctions In the event only sporadic malfunctions or notes are stored in DTC memory and the customer has made registered no complaint in conjunction with an electronic vehicle system erase DTC memory Press the Continue gt button again to enter the test plan End Guided Fault Finding via Goto button and then End All DTC memories will be checked now once more The window that now appears confirms that all sporadic faults were cleared Description of work Page 32 105 Then the diagnostic protocol is sent online or stored on the tester Note lf tester is not connected to the network diagnostic protocol is stored and the transmission follows as soon as tester is connected to the network a Protocols that have been stored and are older than four days are erased automatically Vehicle system test is completed Constant velocity CV joint boots visual inspection Perform the following work procedure Check outer and inner CV joint boots arrows for leaks and damage Note Also check the CV joint boots at the rear axle Dust and pollen filter cleaning housing and replacing filter element Removing Perform the following work procedure Remove cover under glove compartment in passenger footwell Repair
37. laced V A G 1782 Extract engine oil using old oil collecting and extracting unit V A G 1782 or Remove oil drain plug Drain engine oil Note Observe waste disposal regulations Screw in the new oil drain plug hand tight and then fasten to the specified torque Fill up with engine oil For appropriate oil specifications please refer to Additional information Fluid Capacity Charts for appropriate Model and Year Torque specifications for oil drain plug 6 cylinder gasoline engines 30 Nm Description of work Page 57 105 8 cylinder gasoline engines 50 Nm a 10 cylinder diesel engines 30 Nm Warning Torque settings must not be exceeded A torque figure that is too high may lead to leaks or even damage the oil pan Oil filter replacing Oil filter replacing 6 cyl gasoline engine 01 4 Oil filter replacing 6 cyl gasoline engine Oil filter replacing 8 cyl gasoline engine 01 4 Oil filter replacing 8 cyl gasoline engine Oil filter replacing 10 cyl diesel engine 01 4 Oil filter replacing 10 cyl diesel engine NO1 10045 Oil filter replacing 8 cyl gasoline engine Removing Note Observe waste disposal regulations Oil new O rings before installation Unscrew oil drain plug 1 of screw cap and drain oil Loosen filter lower part 2 on hexagon 1 or on circumference and remove Description of work Page 58 105
38. light is located between the low beam headlight and turn signal The headlamps for cornering light system contain 4 lamps 1 The gas discharge lamp for low beam high beam and dynamic cornering light 2 The lamp for static cornering light 3 The lamp for turn signal 4 The lamp for parking light Adjusting left main headlight Description of work Page 78 105 aff NO1 10302 Left headlamp side adjustment B Side adjustment for low beam high beam and dynamic cornering light Turn the adjustment screw for side adjustment B until the correct setting is achieved Left headlamp height adjustment Adjust adjusting screw with hex head wrench 1 A Height adjustment for low beam high beam and dynamic cornering light Turn the adjustment screw for height adjustment A until the correct setting is achieved Adjustment screws for right headlight are arranged symmetrically After adjustment confirm on tester with Complete Guided Functions can be exited with Goto End Headlamps with halogen lamps adjusting NS4 0812 Left headlamp side adjustment 1 Low beam lateral adjustment Description of work Page 79 105 2 High beam lateral adjustment Turn respective lowbeam lateral adjustment screw 1 and high beam lateral adjustment screw 2 until the correct settings are achieved N94 0813 Left headlamp height adjustment 1 Low and high beam height
39. nd hoses from freezing Vehicles with fan type spray jets must be filled with Volkswagen windshield cleanser G 052 164 as this fluid has a low viscosity at minus temperatures The complicated spray jet system could otherwise become blocked due to crystallized washer fluid and adversely affect the fan pattern of the spray jet Volkswagen windshield cleanser G 052 164 assures that the fan type spray jets remain functional even at low temperatures a Use genuine Volkswagen windshield cleanser G 052 164 in the warmer periods of the year also The Description of work Page 85 105 powerful cleanser removes wax and oil deposits from the windows Freeze protection anti freeze must be guaranteed to approx 13 F 25 C approx 31 F 35 C in countries with an arctic climate in the washer system a Part numbers are for reference only Always check with your Parts Department for the latest part number information Windshield wash wipe system and headlight wash system checking nozzle setting adjusting nozzles if necessary Note In case of an uneven spray field due to dirt in spray nozzles remove nozzle Repair Manual Electrical Equipment Repair Group 92 and flush out with water opposite to spraying direction a Subsequently blowing through in the opposite direction of the spray flow with compressed air is permitted Do not use any objects to clean the spray jets Preset washer jets The washer
40. ne turn to the right and check in right headlamp whether cornering light bulb comes on Repeat this step for left side Automatic headlamps a Condition There must be daylight when testing Turn light switch to automatic headlamps position When there is daylight headlamps must not come on Using your hand or another suitable object cover Rain and Light Recognition Sensor from outside behind front window in rearview mirror area This causes a decrease in light and both headlamps are switched on Page 105 105
41. ner bleeder valve then connect the outer valve Connect the collecting bottle bleeder hose to the front bleeder screw Open bleeder screw and let the corresponding amount of brake fluid see table below flow out Close bleeder screw Bleed front right first Repeat work sequence on other side of vehicle at front Table Sequence brake fluid quantity Sequence Clutch slave cylinder wheel brake cylinder Quantity of brake fluid that must brake caliper flow out Clutch slave cylinder bleeder valve 0 15 liter Right front 0 25 liter Total quantity approx 1 15 liter Fit cover caps to brake caliper bleed screws Move filler lever on VAS 5234 or V A G 1869 to position B see operating instructions Take filler hose off adapter Description of work Page 27 105 Unscrew adapter from brake fluid reservoir Check brake fluid level and correct if necessary Screw in cap 1 for brake fluid reservoir Re install cover Remove brake pedal depressor Check pedal pressure and brake pedal free play Free play Max of pedal travel Brake fluid level depending on brake pad wear check Notes on application and safety 01 4 Notes on application and safety precaution Specification of brake fluid 01 4 Specification of brake fluid Work procedure brake fluid level depending on brake pad wear Checking 01 4 Work procedure brake fluid level depending on brake p
42. olts arrows and tighten them to a torque of 45 Nm Note a Once the battery is reconnected Repair Manual Electrical Equipment Repair Group 27 Second battery in luggage compartment Check battery terminals for secure seating Perform the following work procedure Page 12 105 Description of work Page 13 105 rt ra Open luggage compartment floor cover 2 and secure with prop rod 1 Remove retaining strap anchors arrows and remove battery cover along with retaining straps Check battery terminal clamps are seated securely on the battery terminals by moving the battery positive wire 1 and the battery Ground GND wire 2 back and forth by hand Warning If the battery clamp is not seated securely on the positive terminal disconnect battery Ground GND clamp on battery negative terminal first to prevent Description of work Page 14 105 possible accidents Note The following procedure must be strictly followed f the sequence is not adhered to the pyrotechnical isolation system for the battery may trigger which may damage electrical components in the vehicle If the battery clamp on positive terminal is not seated securely f j W N27 0421 AA Disconnect battery ground GND strap arrow at negative terminal first a Then disconnect the battery positive cable arrow at battery positive terminal Second battery
43. on Coolant level at max marking a Inspection service Coolant level between min and max marking If coolant is too low add required amount according to mixture ratio Note a Small quantities of coolant can be refilled When larger quantities of coolant are needed when filling Cooling system filling equipment VAS 6096 should be used Follow operating instructions for cooling system charge unit Page 45 105 Description of work Page 46 105 VAS 6096 Note Determine cause of fluid loss which cannot be attributed to normal use and rectify repair measure a Checking coolant level and adding coolant if necessary Note Coolant additive G 12 Plus prevents frost and corrosion damage scaling and also raises boiling point of coolant For these reasons the cooling system must be filled with radiator freeze and corrosion protection fluid all year round a Especially in countries with tropical climates or when vehicle is driven under heavy load the coolant improves the engine reliability by its increased boiling point The coolant concentration must not be reduced by adding water even during the warmer season The coolant additive ratio must be at least 40 Air cleaner cleaning housing and replacing filter insert Note Vehicles with 6 cylinder engines are equipped with an air filter Vehicles with 8 10 cylinder engines have two air filters in the engine compartment Air filter elemen
44. p side adjustment 1 Low beam lateral adjustment 2 High beam lateral adjustment Turn respective lowbeam lateral adjustment screw 1 and high beam lateral adjustment screw 2 until the correct settings are achieved Left headlamp height adjustment 1 Low and high beam height adjustment Turn the adjustment screw for height adjustment 1 until the correct setting is achieved Adjustment screws for right headlight are arranged symmetrically After adjustment confirm on tester with Complete Guided Functions can be exited with Goto End Headlamps with HID lamps and cornering light system adjusting Headlamp range control performing basic setting Connect diagnostic tester 01 3 Diagnostic testing unit Page 76 105 Description of work Page 77 105 connecting Switch ignition on Select Guided Functions Perform vehicle identification Select vehicle system Automatic headlamp range control cornering light Mark Perform basic setting and confirm with gt Now the number of malfunctions is read out and if there are 0 malfunctions Complete can be selected Observe displayed notes and confirm by selecting Complete Switch low beams on and confirm with Complete Now adjust headlamps as follows Identification of headlamps with cornering light system Note An additional reflector with halogen lighting for the static cornering
45. press button 1 or button 3 to change menus and use thumb wheel 2 to make a selection turn Press button 1 or button 3 until the menu selection COMFORT SETUP is displayed inverted The main menu Comfort setup has the following functions e g Light Speed warning Time Comfort Language Units Reset Turn the thumb wheel 2 until the desired menu selection is displayed Press the thumb wheel The selected menu is displayed Toothed belt for camshaft drive replacing 8 cyl gasoline engine Perform work sequence Repair Manual Engine Mechanical Fuel Injection Ignition Repair Group 15 Spark plugs replacing Spark plugs for 6 cyl engine replacing 01 4 Vehicles with 6 cyl gasoline engine Spark plugs for 8 cyl engine replacing 01 4 Vehicles with 8 cyl gasoline engine Note Plug designation and torque specification Description of work Page 97 105 Repair Manual Engine Mechanical Fuel Injection Ignition Repair Group 28 Observe waste disposal regulations Special tools testers and auxiliary items required Spark plug wrench 3122B V A G 1331 a Torque wrench V A G 1331 710118 a W00 1148 Description of work a Removal installation tool T10118 T10095 A Puller T10095 A T40039 Puller T40039 VAS 5024 A Spring type clip pliers VAS 5024 Vehicles with 6 cyl ga
46. ption of work remove ignition key After waiting 60 seconds Remove front and side trim on front left seat frame Remove seat spindle covers Remove seat slide rail cover caps Tilt seat frame and seat to rear arrow Page 7 105 Description of work Page 8 105 HQ Vag A Falzes ya Check battery terminal clamps are seated securely on the battery terminals by moving the battery positive wire 2 and the battery Ground GND wire 1 back and forth by hand Warning If the battery clamp is not seated securely on the positive terminal disconnect battery Ground GND clamp on battery negative terminal first to prevent possible accidents Description of work Page 9 105 If the battery clamp on positive terminal is not seated securely The following procedure must be strictly followed Battery under front left seat Disconnecting Warning To increase crash safety the battery under front left seat is equipped with a battery isolator In an accident the airbag control module triggers a charge disconnecting the voltage supply wire to the starter Battery isolation is performed pyrotechnically with a very small explosive charge To avoid accidentally triggering the charge when working on the battery or the battery isolator you must absolutely first disconnect the battery Ground GND on the negative terminal of the battery Note
47. reset Service Reminder Indicator must for Vehicle release inspection Every service adapted Connect diagnostic tester 01 3 Diagnostic testing unit connecting Switch ignition on Touch button field on screen GUIDED FUNCTIONS on screen If the displays indicated in the work procedure are not indicated on display Operating instructions for Vehicle Diagnosis Testing and Information System 5051 or Vehicle Diagnosis Service Syst VAS 5052 Press gt button to confirm Select in succession a Brand a Model Model year a Engine Code Confirm vehicle identification Description of work Select in succession a Instrument cluster arrow a Resetting Service Reminder Indicator SRI Perform adaptation according to instructions of GUIDED FUNCTIONS End Adaptation Indicated on display Press the Goto button arrow on display Page 89 105 Description of work Page 90 105 Indicated on display Press exit button arrow on display Press exit button in exit menu Turn off ignition and disconnect diagnostic connection Switch ignition on After switching on the ignition service event is no longer indicated in the odometer display in the instrument panel insert Service interval display adapting Connect diagnostic tester 01 3 Diagnostic testing unit connecting Switch ignition on Touch bu
48. s required V A G 1332 Description of work Torque wrench V A G 1332 T10101 a Master wheel bolt key set T10101 The adapter to loosen tighten the anti theft wheel bolts is located with the vehicle tool kit Note Be sure to tighten wheel bolts one after the other to the following specified torque Tightening torque 160 Nm Tire pressure sensors replacing Note Tire pressure sensor is located on inside of disc wheel or rim a For removal and installation of tire pressure sensor wheel and tire must be separated Work procedure removing and installing tire pressure sensor Repair Manual Suspension Wheels Steering Repair Group 44 Storing tire pressure values Correct tire pressure set 01 4 Check tires tire condition wear pattern inflation pressure and tread Page 68 105 Description of work depth a Tires must be cold Switch ignition on f f era Press button 1 to show menu selection in instrument cluster display Select menu item tire pressure using thumb wheel 2 rarer When the menu item tire pressure is selected in display 1 confirm the menu item by pressing the thumb wheel In the sub menu Tire pressure monitor turn the thumb wheel until the position Store is marked on the display 1 and save the current inflation pressure by pressing the thumb wheel Then drive vehicle continuously for approx 8 1
49. soline engine Removing Page 98 105 Description of work Page 99 105 Perform the following work procedure S Remove engine covers 1 and 2 upward Unlock connector release Insert Removal installation tool T10118 at the plug resting set arrow and carefully pull up until the plug rest releases Remove plugs 1 through 6 for ignition coils with power output stages upward Note Before removing plugs note installation position of ignition coils with power output stages if necessary Description of work Page 100 105 mark installation position of plugs The straight side of the connector must fit to the straight side of the ignition coil with power output stage arrow Push the Puller T10095 A from the straight connector side in the direction of arrow on the ignition coil with power output stage Pull the ignition coil with power output stage up perpendicularly and out Remove spark plugs using spark plug wrench 3122B Installing Description of work Page 101 105 Screw in new spark plugs using spark plug wrench 3122B Note Observe torque specification Carefully insert ignition coils with power output stages on spark plugs by hand so that the straight connector sides fit to each other arrows Install new spark plugs 1 through 6 Description of work Install engine covers 1 and 2 Veh
50. t removing and installing 10 cyl diesel engines 01 4 Air filter element removing and installing 10 cyl diesel engines Air filter element removing and installing 6 and 8 cyl gasoline engines 01 4 Air filter element removing and installing 6 and 8 cyl gasoline engines Air filter element removing and installing 10 cyl diesel engines Description of work Page 47 105 Remove engine cover 01 4 Upper engine cover removing and installing Removing Note The following describes removing and installing the left air filter element Removing and installing the right air filter element is performed in the same way Open snap fasteners 1 Remove intake hose securing pins 2 Remove intake hose securing pins Description of work Page 48 105 Turn pin far enough that marking point 1 aligns with mark on air cleaner housing 3 Pull out securing pin upward Pull off intake hose Age SHANE va WN amp P Disconnect line connection at air filter housing arrow as follows NO1 10038 Description of work Page 49 105 Press off locking ring 1 using a screwdriver C from line flange 3 Press securing sleeve 2 in direction of arrow and at the same time disconnect line A from line B Remove upper part of air filter housing upward Note Observe installation position of air filter VZ
51. tion of fluid adding fluid Checking freeze protection concentration Special tools testers and auxiliary items required a Refractometer T10007 Read the bright dark boundary to obtain an accurate reading for the following tests Place a drop of water on the glass to improve the readability of the bright dark boundary The bright dark boundary can be clearly recognized on the WATERLINE Check the concentration of the anti freeze additive using the refractometer T10007 follow the operating instructions Description of work Page 84 105 The scale 1 of the refractometer T10007 is designed specifically for genuine Volkswagen windshield cleanser G 052 164 The scale 2 is designed for commercially available windshield washer fluid as well as a mixture of commercially available windshield washer fluid and Volkswagen windshield cleanser G 052 164 Note a Part numbers are for reference only Always check with your Parts Department for the latest part number information Mixture ratio Freeze protection to Windshield cleaner Water G 052 164 17 18 C 37 38 C Filling up with fluid The windshield wash wipe system fluid reservoir must be filled up fully Use only genuine Volkswagen windshield cleanser G 052 164 all year round when topping off the windshield wash wipe system Note Genuine Volkswagen windshield cleanser G 052 164 protects the spray jets fluid reservoir a
52. tton field on screen GUIDED FUNCTIONS on screen Note Ifthe displays indicated in the work procedure are not indicated on display Operating instructions for Vehicle diagnosis testing and information system VAS 5051 or Vehicle diagnosis and service system VAS 5052 Select in succession Brand Model Model year a Engine Code Confirm vehicle identification If the vehicle identification procedure was performed correctly press gt button for confirmation Select in succession Description of work a Instrument cluster arrow Adapt service interval extension Perform adaptation according to instructions of GUIDED FUNCTIONS End Adaptation Indicated on display Press the Goto button arrow on display Indicated on display Page 91 105 Description of work Page 92 105 Press exit button arrow on display Press exit button in exit menu Turn off ignition and disconnect diagnostic connection Tie rod ends check play security and joint boots Perform the following work procedure With vehicle raised wheels hanging free check play by moving tie rods and wheels Play zero play Check mountings Check tie rod joint boots arrow for damage and proper seating Door arrester lubricate Perform the following work procedure Lubricate door arrester at points shown arrows Use lubricant G 000 150 Note
53. use the oil level to be in area A C Oil must be topped off It is sufficient when oil level is in area B grooved field If oil level is above area A the catalytic converter can be damaged When oil level is below marking C top off with oil to marking A For appropriate oil specifications please refer to Additional information Fluid Capacity Charts for appropriate Model and Year Engine oil draining or extracting changing oil filter and filling engine oil Engine oil capacities Repair Manual Engine Mechanical Fuel Injection Ignition Repair Group 17 orin Fluid Capacity Charts for appropriate Model and Year Engine oil draining or extracting 01 4 Engine oil draining or extracting Oil filter replacing 01 4 Oil filter replacing Engine oil filling 01 4 Filling engine oil It is not permitted to siphon engine oil from V8 cylinder engine Engine oil draining or extracting Caution Description of work Page 56 105 On engines with standing oil filter module oil filter should be changed before the oil change 01 4 Oil filter replacing Removing the filter element will open a valve and oil in the filter housing will flow automatically into the crankshaft housing It is not permitted to siphon engine oil from V8 cylinder engine The oil drain plug is equipped with a permanent seal therefore the oil drain plug must always be rep
54. ver seat has not yet been removed Remove trim under drivers seat in order to disconnect battery Repair Manual Electrical Equipment Repair Group 27 Disconnect the connection A from the relay cable Description of work Page 5 105 NO1 10304 Pull a foam covering A over the connection of the relay cable Secure the foam covering with adhesive tape Unfasten the ground cable 2 from the battery disconnect relay 1 Unfasten the battery disconnect relay retainer from the ground connection B Set the ground cable onto the ground connection A and fasten the ground connection to 20 Nm Note Description of work Page 6 105 Once the ground cable for the battery is reconnected Repair Manual Electrical Equipment Repair Group 27 Route the connector with relay cable to the indicated point arrows Reinstall the trim under the driver seat Observe the work steps after connecting the battery Repair Manual Electrical Equipment Repair Group 27 Perform a vehicle system test 01 4 Vehicle system test perform Battery check battery terminals for secure seating There are two different battery concepts with this vehicle Battery concepts Repair Manual Electrical Equipment Repair Group 27 Battery under front left seat Check battery terminals for secure seating Switch off ignition and all electrical components and Descri
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