Work descriptions (part 1 of 2) - Check joint boots - arrow
Contents
1. Select menu item Settings Page 34 63 Work descriptions part 1 of 2 GRAPHIC NOT AVAILABLE Press button A once in windshield wiper lever Menu Settings is brought up 3 Bringing up menu Comfort Select menu item Comfort using rocker switch B GRAPHIC NOT AVAILABLE Menu Comfort is brought up 4 Bringing up menu Compass GRAPHIC NOT AVAILABLE Select menu item Compass using rocker switch B Menu Compass is brought up The following indications are shown in the Compass menu Page 35 63 Work descriptions part 1 of 2 The compass direction Zone Calibration Back 5 Calling up the menu Zone GRAPHIC NOT AVAILABLE Select menu item Zone and confirm using the A button The following indications are shown in the Compass menu a The compass direction Zone e g zone 8 for Germany zone 6 for Mexico 1 zone the option to set 1 zone higher 1 zone the option to set 1 zone lower Back Select menu item 1 zone or 1 zone using rocker switch and press button to set compass zone higher or lower shown in display 6 Exiting the menu GRAPHIC NOT AVAILABLE Select menu item Back using rocker switch B Press button A Menu item Compass is exited and the last displayed menu is brought up Page 36 63 Work descriptions part 1 of 2 Compass calibrating 1 Bringing2. If battery clamp on positive terminal is not seated securely First disconnect battery clamp 1 from battery negative terminal Tighten battery clamp 2 on battery positive terminal to 9 Nm Reconnect battery clamp 1 on battery negative terminal and also tighten to 9 Nm If the battery clamp on negative terminal is not seated securely Tighten battery clamp 1 on battery negative terminal to 9 Nm Reinstall cover Work descriptions part 1 of 2 Page 11 63 Note Once the battery is reconnected Repair Manual Electrical Equipment Repair Group 27 Battery checking Battery Checking Repair Manual Electrical Equipment Repair Group 27 Battery Tires checking condition tire wear pattern tire pressure tread depth Checking tire condition 01 4 Tire condition checking Checking tire wear pattern 01 4 Tire wear pattern checking Tread depth including spare wheel Checking 01 4 Tread depth including spare wheel Checking General notes 01 4 General notes Checking tire pressure correcting if necessary Jetta 2006 P 01 4 Checking tire pressure correcting if necessary Jetta 2006 Checking tire pressure correcting if necessary Jetta 2005 gt gt 01 4 Checking tire pressure correcting if necessary Jetta 2005 Special tools testers and auxiliary items required Work descriptions part 1 of 2
3. Disconnect connector 1 from mass air flow sensor and lay aside Disengage both mounting clips arrows A Disengage engine cover arrows 3 first then arrows 4 and lift Installing Work descriptions part 1 of 2 Page 59 63 Installation is performed in the reverse order of removal Removing and installing engine cover 2 5 L fuel injection engine Special tools testers and auxiliary items required VAS 5024 A Spring Type Clip Pliers VAS5024A VAS5024A Removing Remove bolts of air intake apparatus arrows A Release mass air flow MAF sensor clamps arrow B using Spring Type Clip Pliers VAS5024A VAS5024A and push clamps back Disconnect intake air hose 1 from mass air flow MAF sensor 2 Work descriptions part 1 of 2 Page 60 63 Disconnect connector arrow C from mass air flow MAF sensor and lay aside Carefully pull engine cover at mounting points arrows A out of locking mechanism Slightly raise engine cover at front Carefully pull engine cover at mounting points arrows B out of locking mechanism Carefully remove engine cover upward movement arrows Note Make sure mass air flow MAF sensor is not damaged when removing engine cover Installing Position engine cover on rear mounting points arrows B then on front mounting points arrows A Carefully press on mounting points by ha
4. VAS 5216 Tire inflation device VAS 5216 Tire condition checking Warning If damage is found it must be checked whether a new tire must be installed Tests during delivery inspection Check tires tread and side walls for damage and remove foreign objects for example nails and glass splinters if necessary Tests during inspection service Check tires tread and side walls for damage and remove foreign objects for example nails and glass splinters if necessary Check tires for scuffing one sided wear porous side walls cuts and fractures Tire wear pattern checking The wear pattern of the front wheels can be used to assess whether a check of the toe and camber is necessary a Feathering on tread indicates incorrect toe setting One sided tread wear is mainly attributed to incorrect camber When wear of this nature is noticed determine cause by performing alignment checks repair measure Tread depth including spare wheel Checking Page 12 63 Work descriptions part 1 of 2 Page 13 63 Check tire tread depth Minimum depth 1 6 mm Note a This figure may vary for individual countries according to legislation x The minimum tread depth is reached when the tires have worn down level with the 1 6 mm high tread wear indicators arrows positioned at intervals around the tire f the tread depth is approaching the legal minimum permissible depth the customer must be infor
5. 13 F 25 C Checking freeze protection and adding coolant additive if necessary Special tools testers and auxiliary items required WO00 0689 a Refractometer T10007 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 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 Work descriptions part 1 of 2 Page 41 63 The scale 1 of the Refractometer T10007 is designed for coolant additives G 12 G12 Plus and G11 Scale 2 refers only to coolant additive G 13 previously L80 Note The freeze protection must be ensured to approximately 13 F 25 C f for climatic reasons greater freeze protection is required the amount of G 12 Plus can be increased but only up to 60 freeze protection to about 40 F 40 C otherwise freeze protection and cooling effectiveness will be reduced If freeze protection is insufficient drain off required quantity shown in freeze protection table and add coolant additive G 12 Plus Note Observe waste disposal regulations 13 25 o Check coolant additive concentration after test drive again Work descriptions part 1 of 2 Page 42 63 Checking coolant level and adding coolant
6. part 1 of 2 Page 57 63 Tighten upper air filter housing with bolts arrows to 9 Nm Engine and components in engine compartment from above and below performing visual check for leaks and damages Perform visual check as follows Check engine and components in engine compartment for leaks and damages Check hoses pipes and connections of Fuel system Cooling and heating system and brake system for leaks abrasions porosity and brittleness Note a Ensure that all malfunctions detected are rectified within repair measures f fluid losses are greater than can be reasonably expected determine cause and repair repair measure Upper engine cover removing and installing Caution Make sure engine cover is not hit by fist or tool when installed i e when engaging at mounting points there is the danger of damage Removing and installing engine cover 2 0 L TFSI direct fuel injection engine 01 4 Removing and installing engine cover 2 0 L TFSI direct fuel injection engine Removing and installing engine cover 2 5 L fuel injection engine 01 4 Removing and installing engine cover 2 5 L fuel injection engine Removing and installing engine cover 1 9 L pump injector diesel engine 01 4 1 9 L pump injector diesel engine Work descriptions part 1 of 2 Page 58 63 Removing and installing engine cover 2 0 L TFSI direct fuel injection engine Removing
7. 2 Page 39 63 Select menu item Calibrating and confirm using A button The following indication is shown in the Compass menu a Drive a full circle GRAPHIC NOT AVAILABLE Press A button Drive full circle at a speed of less than 10 mph 20 Km h CAL is shown at the top in display next to the arrow for direction After completing the calibration display CAL will be replaced by the actual direction e g N for North Cooling system check coolant level and freeze protection Note All engines are filled with coolant additive G 12 Plus according to TL VW 774 F purple color 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 freeze 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 Work descriptions part 1 of 2 Page 40 63 least 40 freeze protection to 13 F 25 C and should not exceed 60 freeze protection to 40 F 40 C Otherwise the freeze protection will be reduced and the cooling efficiency will be worsened The freeze protection must be ensured to approximately
8. QG2 Channels 42 49 are not available and are replaced with channels 50 51 Furthormore when coding QGO0 QG2 channels 43 44 and 49 are deactivated End Adaptation EE ais E Indicated on display Press the Go to button arrow on display Indicated on display Work descriptions part 1 of 2 Page 6 63 Press exit button arrow on display Turn off ignition and disconnect diagnostic connection Service interval display recoding at first oil change service for USA and Canada Connect diagnostic tester Switch ignition on Touch button field on screen ON BOARD DIAGNOSTICS OBD 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 Work descriptions part 1 of 2 Page 7 63 a 17 Instrument cluster ARROW a 10 Adaptation Select channel 49 Enter 372 Select channel 42 Perform adaptation according to instructions of ON BOARD DIAGNOSTICS OBD Note For vehicles in USA and Canadian markets the following applies a Cha
9. and corrosion Warning Malfunctions found must be rectified repair measure Brake pads front and rear checking thickness Special tools testers and auxiliary items required V A G 1332 Torque Wrench 40 200Nm VAG1332 a Electric hand flashlight and mirror Perform the following work procedure The adapter to loosen tighten the anti theft wheel bolts is located in the vehicle tool kit 01 5 Break down set checking Front disc brake pads For better judgement of remaining pad thickness remove the front wheel on the drivers side Pull off wheel bolt caps if necessary 01 5 Wheel securing bolts tightening to correct torque setting Mark position of wheel in relation to brake disc Unbolt wheel securing bolts and remove wheel Work descriptions part 1 of 2 Page 25 63 Measure inner and outer pad thickness a Pad thickness without backing plate Wear limit 2 mm With a pad thickness of 2 mm without backing plate the brake pads have reached their wear limit and must be replaced repair measure 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 disc for wear Repair Manual Brake System Repair Group 46 Front brakes servicing Install wheel to marked position Tighten wheel securing bolts in diagonal sequ
10. approx 1 liter Fit cover caps to brake caliper bleed screws Move filler lever on Brake Charger Bleeder Unit VAS5234 or brake filling and bleeding tool V A G 1869 to position B see user manual Work descriptions part 1 of 2 Page 21 63 Take filler hose off adapter Unscrew adapter from brake fluid reservoir Check brake fluid level and correct if necessary Install brake fluid reservoir cap 1 Remove brake pedal actuator Check pedal pressure and brake pedal free play Free play Max of pedal travel Brake fluid level checking Note the following Brake fluid level is dependent on brake pad wear Use only new brake fluid with part number B 000 750 M corresponds to US standard FMVSS 116 DOT 4 Warning NEVER bring brake fluid into contact with fluids containing mineral oil oil gasoline cleaning fluids 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 meaning that it absorbs moisture from the surrounding air and must therefore always be stored in air tight Work descriptions part 1 of 2 Page 22 63 containers Rinse off any spilled brake fluid using plenty of water Observe disposal regulations Brake fluid level during delivery inspection For the delivery inspection the fluid level must li
11. filter element 1 from lower air filter housing 2 If necessary clean air filter housing using compressed air Installing Insert air filter element 1 into lower air filter housing 2 Note Work descriptions part 1 of 2 Page 53 63 Make sure sealing surfaces of air filter housing are seated properly Note For securing upper air filter housing to lower air filter housing as well as intake tube self tapping bolts are used in series production If these bolts are loosened or tightened using an electric screwdriver the thread in the upper air filter housing may be damaged For this reason an electric screwdriver must only be used if the following requirements are met Screwdriver maximum speed must not exceed 200 RPM Tightening torque of 2 Nm max must be adjustable Hook lower air filter 1 into retaining tabs arrows of upper air filter 2 and swing in direction of arrow then press on lightly Work descriptions part 1 of 2 Page 54 63 Checking surface alignment of the housing halves 1 and 2 rear part Both housing halves must contact flush arrows Checking surface alignment of housing halves 1 and 2 front part Both housing halves must contact flush arrows Tighten bolts arrows to a maximum of 2 Nm Note Alternately tighten bolts evenly in order to ensure both housing halves do not cant Insta
12. if necessary Check coolant level in expansion tank with engine cold Delivery inspection Coolant level above the MIN marking arrow Inspection service Coolant level above the MIN marking arrow If coolant is too low add required amount according to mixture ratio Note Determine cause of fluid loss which cannot be attributed to normal use and rectify repair measure Mixture ratio Freeze protection to Coolant additive G 12 Plus Water TL VW 774 F approx 40 approx 60 approx 50 approx 50 approx 60 approx 40 Coolant additive G 12 Plus conforming to TL VW 774 F prevents freeze and corrosion damage scaling and raises the boiling point For these reasons the cooling system must be filled with radiator freeze and corrosion protection fluid all year round Work descriptions part 1 of 2 Page 43 63 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 Fuel filter replacing Note There are two different fuel filter systems System 1 has a bleeder connection 1 work procedures 01 4 Replacing fuel filter Fuel filter system with bleeder connection NO1 10288 a System 2 h
13. lifted briefly the window will automatically raise fully Switch off ignition Vehicle system test performing Connect diagnostic tester 01 3 Diagnostic tester connecting Switch on ignition Select mode Guided Fault Finding on display Perform vehicle identification via tester Program now automatically performs a vehicle system test and checks all possible control modules installed in this model Press button gt All malfunctions are listed Note At this point it is useful to switch to operating mode Guided Functions in order to perform further work using VAS 5051 VAS 5052 and to avoid a second vehicle identification via tester To do So press Operating Mode button and menu item Guided Functions Work descriptions part 1 of 2 Page 29 63 Further work procedures can be taken from the corresponding work descriptions To return to operating mode Guided Fault Finding press Operating Mode button then press Guided Fault Finding Caution The vehicle must always be passed on to the customer with DTC memory erased Static malfunction If there are one or more static malfunctions stored in DTC memory it is recommended to repair these malfunctions via Guided Fault Finding upon approval by the customer Sporadic malfunction If there are only sporadic malfunctions or notes stored and the customer does not complain about problems regarding an electronic vehicle system erase DTC
14. memory Press button gt once again to access the test plan End Guided Fault Finding via button Go To and then press End Once again all DTC memories are checked The window displayed now shows all sporadic malfunctions were erased The diagnostic report will be sent online or stored in tester Note a f the tester is not connected to the network the diagnostic report will be stored and sent as soon as the tester is connected to the network Stored reports older than 40 days will be erased automatically The vehicle system test is completed CV joint boots visual check Perform the following work procedure Work descriptions part 1 of 2 Page 30 63 Check outer and inner CV joint boots arrows for leaks and damage Ribbed belt checking condition Perform the following work procedure Crank engine at harmonic balancer belt pulley using a socket wrench SSS SS me SO gt f NO2 0878 bh No2 0878 Check ribbed belt 1 for Sub surface cracks cracks core ruptures cross sectional breaks Layer separation top layer cord strands Base break up Fraying of cord strands a Flank wear material wear frayed flanks flank brittleness glassy flanks surface cracks Work descriptions part 1 of 2 Page 31 63 Traces of oil and grease Note tis essential to replace ribbed belt if malfunctions are found This will avoid possib
15. remove any dirt or water residue from lower part of fuel filter Note Observe disposal regulations Installing Install new replacement filter in lower fuel filter es 0O NO1 10297 Insert new seal 1 into groove of upper fuel filter arrows Attach upper fuel filter with gasket onto lower fuel filter and screw in bolts approx 1 turn Work descriptions part 1 of 2 Page 49 63 Bolt upper fuel filter to lower fuel filter NO1 10288 Tighten bolts according to sequence shown in illustration Tighten bolts to tightening torque of 5 Nm Tightening sequence avoids canting of the upper fuel filter thus preventing damages to the gasket Water separator draining Note There are two different fuel filter systems System 1 has a bleeder connection 1 work procedures 01 4 Draining fuel filter Fuel filter system with bleeder connection Work descriptions part 1 of 2 Page 50 63 NO1 10288 a System 2 has no bleeder connection work procedures and does not require draining Note a Make sure that diesel does not come in contact with the coolant hoses Clean hoses immediately if necessary Observe disposal regulations Draining fuel filter Fuel filter system with bleeder connection Special tools testers and auxiliary items required VAS 5226 a Suction Pump VAS5226 Note a Make sure that diesel does not come in contact with t
16. Work descriptions part 1 of 2 Page 1 63 BY Work descriptions part 1 of 2 Ball joints visual check Check joint boots arrow of ball joints for leaks and damage Service interval display reset Service Reminder Indicator must for Vehicle release inspection Every service Adapt Connect diagnostic tester 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 Work descriptions part 1 of 2 Model year a Engine Code Confirm vehicle identification Select in succession a Instrument cluster ARROW Resetting Service Reminder Indicator SRI Perform adaptation according to instructions of GUIDED FUNCTIONS End Adaptation Indicated on display Press the Go to button arrow on display Page 2 63 Work descriptions part 1 of 2 Page 3 63 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 i
17. a 4 2 2 4 2 4 225 40 R 18 92 Y XL 2 4 4 2 205 55 R 1691 W Spare wheel collapsible spare wheel o Diesel engine Displacement Performance sr eS TY TC CN Spare wheel callable pare whee _ __ Brake fluid changing Warning NEVER bring brake fluid into contact with fluids containing mineral oil oil gasoline cleaning fluids 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 Work descriptions part 1 of 2 Page 17 63 Brake fluid is hygroscopic meaning that it absorbs moisture from the surrounding air and must therefore always be stored in air tight containers Rinse off any spilled brake fluid using plenty of water Observe disposal regulations Special tools testers and auxiliary items required VAS 5234 Brake Charger Bleeder Unit VAS5234 or V A G 1869 a brake charger bleeding unit V A G 1869 Upgrade kit and extraction unit V A G 1869 4 Work descriptions part 1 of 2 Page 18 63 V A G 1869 2 a Brake Pedal Actuator VAG1869 2 AK 5 j XV PAL A Extract as much brake fluid as possible using intake hose from Brake Charger Bleeder Unit VAS5234 Note Work descriptions part 1 of 2 Page 19 63 a The strainer in the brake fluid reservoir must not be removed Warning Extracted brake fluid must not be reus
18. as no bleeder connection work procedures 01 4 Replacing fuel filter Fuel filter system without bleeder connection Work descriptions part 1 of 2 Note Make sure that diesel does not come in contact with the coolant hoses Clean hoses immediately if necessary Observe disposal regulations Replacing fuel filter Fuel filter system with bleeder connection 01 4 Replacing fuel filter Fuel filter system with bleeder connection Replacing fuel filter Fuel filter system without bleeder connection 01 4 Replacing fuel filter Fuel filter system without bleeder connection Replacing fuel filter Fuel filter system with bleeder connection Special tools testers and auxiliary items required VAS 5226 a Suction Pump VAS5226 Note a Make sure that diesel does not come in contact with the coolant hoses Clean hoses immediately if necessary Observe disposal regulations Perform the following work procedure Page 44 63 Work descriptions part 1 of 2 Page 45 63 Remove screw plug for water extraction 1 Connect hose of Suction Pump VAS5226 to adapter Extract approx 100 ml diesel fuel using Suction Pump VAS5226 Replace screw plug seal of water extraction Tighten screw plug of water extraction to 3 Nm NO1 10141 Loosen all bolts arrows of upper fuel filter in diagonal sequence approx 1 5 to 2 turns Remove bolts completely an
19. d remove upper fuel filter NO1 10026 Work descriptions part 1 of 2 Page 46 63 Remove replacement filter 1 and seal 2 from lower fuel filter 4 Replace seal 3 Note Observe disposal regulations Install new replacement filter in lower fuel filter NO1 10144 Attach new seal 1 onto upper fuel filter Place upper fuel filter with seal onto lower fuel filter Bolt upper fuel filter to lower fuel filter Tighten bolts according to sequence shown in illustration Tighten bolts to tightening torque of 5 Nm Tightening sequence avoids canting of the upper fuel filter Work descriptions part 1 of 2 thus preventing damages to the seal Replacing fuel filter Fuel filter system without bleeder connection Remove engine cover 01 4 Upper engine cover removing and installing Removing Note a Make sure that diesel does not come in contact with the coolant hoses Clean hoses immediately if necessary Observe disposal regulations Perform the following work procedure NO1 10288 Loosen all bolts arrows of upper fuel filter in diagonal sequence approx 1 5 to 2 turns Remove bolts completely and remove upper fuel filter Page 47 63 Work descriptions part 1 of 2 Page 48 63 NO1 10289 Remove old gasket 2 from upper fuel filter 1 Remove replacement filter 3 from lower fuel filter Caution If necessary
20. e at the MAX marking 1 Note a The MAX marking 1 must not be exceeded this will ensure that the brake fluid will not overflow the reservoir Brake fluid level during 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 pads are almost at wear limit Work descriptions part 1 of 2 Page 23 63 At MIN marking or just above 2 NO FILL UP IS NECESSARY Recommended brake fluid level when brake pads are new or well above 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 Brake system performing visual check for leaks and damages Check the following components for leaks and damages Master brake cylinder Brake booster with Anti lock Brake System ABS Hydraulic unit Brake pressure regulator and a Brake calipers Ensure that brake hoses are not twisted Ensure that brake hoses do not touch any vehicle components when steering is at full lock Check brake hoses are not porous or brittle Check brake hoses and pipes for chafing Work descriptions part 1 of 2 Page 24 63 Check brake connections and methods of securing for correct seating leaks
21. ed Install adapter 1 on brake fluid reservoir Connect filler hose to adapter Observe Operating instructions for Brake Charger Bleeder Unit VAS5234 or operating instructions for V A G 1869 Install Brake Pedal Actuator VAG1869 2 between drivers seat and brake pedal and tension Connect filler hose of Brake Charger Bleeder Unit VAS5234 or brake filling and bleeding tool V A G 1869 to adapter Remove both wheels from rear axle in order to access bleeder screws Pull cover caps off bleeder screws of brake calipers NO1 10056 Connect collector bottle bleeder hose 1 to right rear Work descriptions part 1 of 2 Page 20 63 bleeder screw Open bleeder screw and let the corresponding amount of brake fluid see table flow out Close bleeder screw Note Use appropriate bleeder hose It must fit tightly on the bleeder screw so that no air gets into the brake system Repeat work procedure on left side of vehicle at rear Connect collector bottle bleeder hose 1 to a right front bleeder screw open bleeder screw and allow the corresponding quantity to flow out see table Close bleeder screw Repeat work procedure on left side of vehicle at front Table Sequence quantity of brake fluid Sequence Brake fluid quantity which must flow out of wheel brake cylinders or brake wheel brake calipers cylinder brake calipers Right front 0 25 Liter Total quantity
22. ement Performance 2 5 L 110 kW Tire sizes half load full load front rear front rear bar kpa bar kpa bar kpa bar kpa Work descriptions part 1 of 2 Page 15 63 psi psi psi psi 195 65 R 15 2 3 230 33 2 3 230 33 2 3 230 33 2 3 230 33 205 55 R 16 2 3 230 2 3 230 33 92 3 230 33 92 3 230 33 33 225 45 R 17 2 3 230 33 2 3 230 33 92 3 230 33 92 3 230 33 2 4 2 4 2 6 3 0 225 40 R 18 92 Y XL Spare wheel collapsible spare wheel Gasoline engine Displacement Performance Tire sizes half load full load 205 55 R 1691 W 225 45 R 1791 W Y 225 40 R 18 92 Y XL Spare wheel collapsible spare wheel i g Diesel engine Displacement Performance 1 9 L 74 kW TDI Tire sizes half load full load front rear front rear bar kpa bar kpa psi bar kpa bar kpa psi psi psi 195 65 R 15 2 2 220 32 2OP 2007 29 2 4 240 34 29 7290 42 205 55 R 16 2 2 220 32 2 0 200 29 2 4 240 34 f 2 9 290 42 225 45 R 17 2 2 220 32 2 0 200 29 2 4 240 34 f 2 9 290 42 Spare wheel collapsible spare wheel Checking tire pressure correcting if necessary Jetta 2006 gt Gasoline engines Work descriptions part 1 of 2 Page 16 63 2 0 L 147 kW Topic 01 4 Diesel engines 1 9 L 77 kW TDI Topic 01 4 Gasoline engine Displacement Performance 2 0 L147 kW Tire sizes half load full load front bar front bar rear bar 225 45 R 1791 W Y 24 pa bap
23. ence tightening torque 01 5 Wheel securing bolts tightening to correct torque setting Store adapter with vehicle tool kit after completing work Reinstall wheel bolt covers if necessary Rear disc brake pads Illuminate area behind hole in wheel using an electric hand flashlight Determine thickness of outer pad by checking visually Work descriptions part 1 of 2 Page 26 63 Illuminate inner pad using an electric hand flashlight and mirror NO1 10133 Determine thickness of inner pad by checking visually a Inner and outer pad thickness without backing plate Wear limit 2 mm With a pad thickness of 2 mm without backing plate the brake pads have reached their wear limit and must be replaced repair measure 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 disc for wear Repair Manual Brake System Repair Group 46 Rear brakes servicing Climatronic setting temperature to 72 F 22 C Switch on ignition Work descriptions part 1 of 2 Page 27 63 NO1 10015 Turn switch 4 on driver side until 72 F 22 C appears in display 1 clockwise warm counter clockwise cold Turn switch 3 on passenger side until 72 F 22 C appears in display 2 clockwise warm counter c
24. he coolant hoses Clean hoses immediately if necessary Work descriptions part 1 of 2 Observe disposal regulations Perform the following work procedure NO1 10046 Remove screw plug for water extraction 1 Connect hose of Suction Pump VAS5226 to adapter Extract approx 100 ml diesel fuel using Suction Pump VAS5226 Replace screw plug seal of water extraction Tighten screw plug of water extraction to 3 Nm Air cleaner cleaning housing and replacing filter element Removing and installing air filter element 2 5 L engine 01 4 Removing and installing air filter element 2 5 L engine Removing and installing air filter element 2 0 L TFSI engine 01 4 Removing and installing air filter element 2 5 L engine Removing and installing air filter element on vehicles with diesel engine 01 4 Removing and installing air filter element on vehicles with diesel engine Removing and installing air filter element 2 5 L engine Removing Remove engine cover 01 4 Upper engine cover removing and installing Set aside engine cover with upper side on a soft surface avoid damages to housing Page 51 63 Work descriptions part 1 of 2 Page 52 63 Remove bolts arrows on underside of engine cover T F E 5 Quill TTT Cr ra lt Flip up lower air filter housing 1 in direction of arrow and remove IN yI Remove air
25. le break downs or operating problems The replacement of a ribbed belt is a repair measure Instrument cluster adapting language Note The vehicle electronics and range of equipment determine which menus will be shown in the display 1 Bringing up main menu on vehicles without multi function steering wheel Switch ignition on A vehicle pictogram will appear GRAPHIC NOT AVAILABLE Press button A once in windshield wiper lever To move back out of another menu into the main menu hold rocker switch B depressed for two seconds This procedure might have to be repeated until the main menu appears 2 Bringing up menu Settings Press upper or lower rocker switch to select menu item The selected menu item is located between both horizontal lines a triangle is located at the right Select menu item Settings Work descriptions part 1 of 2 Page 32 63 GRAPHIC NOT AVAILABLE Press button A once in windshield wiper lever Menu Settings is brought up The following indications are shown in the Settings menu Settings for time Speed warning for winter tires Units Language Auxiliary heater Light View and Comfort 3 Bringing up menu Language Select menu item Language and confirm using A button Several languages are displayed in the menu Select desired language and confirm using A button Compass adapting compass zone and calibrating c
26. ll engine cover 01 4 Upper engine cover removing and installing Removing and installing air filter element 2 0 L TFSI engines Removing Remove engine cover 01 4 Upper engine cover removing and installing Set aside engine cover with upper side on a soft surface avoid damages to chrome trim Work descriptions part 1 of 2 NO1 10260 Remove lower air filter housing and remove air filter element 2 from upper air filter housing 1 Note For securing upper air filter housing to lower air filter housing as well as intake tube self tapping bolts are used in series production If these bolts are loosened or tightened using an electric screwdriver the thread in the upper air filter housing may be damaged For this reason an electric screwdriver must only be used if the following requirements are met Screwdriver maximum speed must not exceed 200 RPM Tightening torque of 3 Nm max must be adjustable Install lower air filter housing on upper air filter housing Tighten bolts arrows to a maximum of 3 Nm Work descriptions part 1 of 2 Removing and installing air filter element on vehicles with diesel engine Remove upper air filter housing and air filter element 1 Note Observe disposal regulations Clean lower air filter housing Insert new air filter element and attach upper air filter housing NO1 10049 Page 56 63 Work descriptions
27. lockwise cold Switch off ignition 6 speed Direct shift transmission 02E changing oil and filter Work procedure Repair Manual 6 Spd Direct Shift Automatic Transmission 02E Front Wheel Drive Repair Group 34 Electric window regulators checking positioning Note After disconnecting and reconnecting the battery the run up and run down function of the power window regulators will 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 Warning After disconnecting and reconnecting the battery pinch protection of the power window regulators will not function This can cause serious injuries if e g fingers are caught in the window Work descriptions part 1 of 2 Page 28 63 Perform the following work procedure to position the electric windows Note The following work sequence is for the left front window The positioning for the remaining windows is performed in the same manner using the respective switch in the drivers door Switch on ignition Close all doors and windows completely Fully close left front side window by pulling and holding switch for more than 1 second in position Close Lift switch again for 1 second Now when the switch is pressed briefly the side window will automatically lower fully and when the button is
28. med General notes Warning For reasons of safety only tires of same type and tread pattern should be fitted on a vehicle On All Wheel Drive AWD vehicles tires of the same type and tread pattern must be used Otherwise the center differential may be damaged Note Tire inflation pressure table applies to normal tires for all factory installed tire sizes The pressures listed in the table are valid for cold tires Do not reduce increased pressures on warm Work descriptions part 1 of 2 Page 14 63 tires a Tire pressures for the relevant model are on a sticker attached to the inside of fuel tank flap or on B pillar at drivers side Adjust tire pressure to load accordingly a The spare wheel is inflated to the maximum tire pressure specified for the vehicle a Observe that vehicles with tire pressure monitoring display basic setting should be performed after each change in pressure 01 5 Tire pressure monitoring display performing basic setting Winter tires Note Important information on winter tires recommended by Volkswagen can be found in ELSA Win Technical Information Wheel and Tire Guide a For winter tires tire pressure must be increased by 0 2 bar Checking tire pressure correcting if necessary Jetta 2005 gt Gasoline engines 2 5 L 110 kW Topic 01 4 2 0 L 147 kW FSI Topic 01 4 Diesel engines 1 9 L 74 kW TDI Topic 01 4 Gasoline engine Displac
29. nd until engine cover engages noticeably Work descriptions part 1 of 2 Note Make sure mass air flow MAF sensor is not damaged when engine cover is installed a The rest of the installation follows the reverse of the removal procedures 1 9 L pump injector diesel engine Removing Note a Engine cover consists of two parts 1 the outer part here shaded in illustration 2 the center part not shaded in illustration Carefully disengage engine cover in the following sequence at individual mounting points and lift Page 61 63 Work descriptions part 1 of 2 Page 62 63 Remove outer part 1 Also carefully disengage center part 2 and remove Installing Place center part 2 on mounting points and press on Place outer part 1 on mounting points arrows and press on Lower engine compartment cover noise insulation removing and installing Special tools testers and auxiliary items required Work descriptions part 1 of 2 Page 63 63 V A G 1783 a Torque Wrench 5 60 Nm VAG1783 Remove bolts arrows Remove noise insulation Note The rest of the installation follows the reverse of the removal procedures Tighten bolts to a tightening torque of 2 Nm
30. nnel 42 100 10 000 miles for USA a Channel 42 160 16 000 km for CDN a Channel 49 372 372 days for USA and CDN End Adaptation Work descriptions part 1 of 2 Ss aaj a a Indicated on display Press the Go to button arrow on display Indicated on display Press exit button arrow on display Turn off ignition and disconnect diagnostic connection Automatic transmission 09G transmission checking ATF level Perform work procedure Repair Manual 6 Spd Automatic Transmission 09G Repair Group 37 ATF level checking and topping off Battery checking battery terminals for secure seating Special tools testers and auxiliary items required Page 8 63 Work descriptions part 1 of 2 Page 9 63 V A G 1331 Torque Wrench 5 50Nm VAG1331 Note Tight fitting battery terminals guarantee proper function and a long battery service life Perform the following work procedure Release latch arrow flip up and remove cover toward front Check whether battery terminal clamps are seated securely on battery terminals by moving battery positive Work descriptions part 1 of 2 Page 10 63 wire 2 and battery Ground GND wire 1 to and fro 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
31. nstrument panel insert Service interval display recoding at delivery inspection for USA and Canada Connect diagnostic tester Switch ignition on Touch button field on screen GUIDED FAULT FINDING 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 a Brand a Model Model year Work descriptions part 1 of 2 Page 4 63 a Engine Code Confirm vehicle identification If the vehicle identification procedure was performed correctly press gt button for confirmation Select in succession o Body a Electrical Equipment 01 On Board Diagnostic OBD capable systems a Instrument cluster ARROW a Instrument cluster functions Adapt Service Interval Display Note a Check which intervals are set a Intervals must be set or recoded for first oil change service at 5 000 miles 8 000 km Perform Adaptation according to instructions from GUIDED FAULT FINDING Note for vehicles from model year 2007 Note Work descriptions part 1 of 2 Page 5 63 For vehicles in USA and Canadian markets the following applies Channel 50 50 5000 miles for USA Channel 50 80 8000 km for CDN Channel 51 372 372 days for USA and CDN When coding to QGO or
32. ompass General Information 01 4 General Information Adjusting compass zone 01 4 Compass zone adapting Calibrating compass 01 4 Compass calibrating General Information Note a Only for vehicles with Highline instrument cluster The compass indicates the direction in which the vehicle drives Work descriptions part 1 of 2 Page 33 63 To get a correct indication the correct geographical zone must be adapted Determine geographic area referring to zone map e g zone 8 for Germany zone 6 for Mexico etc Za eZ EIH IAS EN DN GRAPHIC NOT AVAILABLE Adapting compass zone and calibrating compass is Work descriptions part 1 of 2 performed using button A and rocker switch B of windshield wiper lever in main menu Button A serves to confirm menu items a Rocker switch B serves to switch menus Compass zone adapting 1 Bringing up the main menu Switch ignition on A vehicle pictogram will appear GRAPHIC NOT AVAILABLE Press button A once in windshield wiper lever To move back out of another menu into the main menu hold rocker switch B depressed for two seconds This procedure might have to be repeated until the main menu appears 2 Bringing up menu Settings Press upper or lower rocker switch to select menu item The selected menu item is located between both horizontal lines a triangle is located at the right
33. up the main menu Switch ignition on A vehicle pictogram will appear GRAPHIC NOT AVAILABLE Press button A once in windshield wiper lever To move back out of another menu into the main menu hold rocker switch B depressed for two seconds This procedure might have to be repeated until the main menu appears 2 Bringing up menu Settings Press upper or lower rocker switch to select menu item The selected menu item is located between both horizontal lines a triangle is located at the right Select menu item Settings GRAPHIC NOT AVAILABLE Press button A once in windshield wiper lever Menu Settings is brought up 3 Bringing up menu Comfort Page 37 63 Work descriptions part 1 of 2 Select menu item Comfort using rocker switch B GRAPHIC NOT AVAILABLE Menu Comfort is brought up 4 Bringing up menu Compass Select menu item Compass using rocker switch B Menu Compass is brought up The following indications are shown in the Compass menu a The direction Zone a Calibration a Back 5 Bringing up menu Calibration GRAPHIC NOT AVAILABLE Select menu item Calibrating and confirm using the A button The following indications are shown in the Compass menu To calibrate drive in a full circle a Calibrate a Back 6 Bringing up menu Calibrating Page 38 63 Work descriptions part 1 of
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