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Edition 09.2018
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2018 Volkswagen AG, Wolfsburg D4B807D9862

Fox 2004 ➤ , Gol 1995 ➤ , Gol 1999 ➤ , Gol 2009 ➤ , Golf 1999 ➤ , Ko ...
Chemicals Manual - Edition 09.2018
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00 - Technical data . . . . . . . . . . . . . . . . . . a.ut.h . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ee.or.a . 1
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1 Introduction . . . . . . . . . . . . . . . . . . . . s. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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2 List of Suppliers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
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2.1 3M do Brasil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
erm
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2.2 Alba Adesivos Ind. Com. Ltda. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
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2.3 Brascola Ltda. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
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2.4 Castrol Brasil Ltda. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
spec
2.5 Cia Brasileira de Petróleo Ipiranga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
t to the co
2.6 Chevron Brasil S/A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.7 Colauto - Adesivos e Massas Ltda . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.8 Cremer S.A. Prod. Têxteis e Cirúrgicos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
rrectne
2.9 Dow Corning do Brasil Ltda. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.10 Dow Automotive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ss o
2.11 Du Pont S/A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
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2.12 Elf Lubrificantes do Brasil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
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2.13 Esso Brasileira de Petróleo Ltda. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
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2.14 Formiquímica Com. e Repres. de Produtos Químicos Ltda . . . . . . . . . . . . . . . . . . . . . . . . 2

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2.15 Gratec System Indústria de Produtos Químicos Ltda. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
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2.16 Henkel do Brasil Ltda. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

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2.17 Klüber Lubrification Lubrificantes Especiais Ltda. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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2.18 Loctite Brasil Ltda. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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2.19 Lumobrás Imp. Com. Ind. Ltda. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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2.20 ExxonMobil do Brasil Ind. Com. Ltda. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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2.21 Motul Synthetic Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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2.22 Nippondenso Compressores Ltda. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.23 Pentosin do Brasil Ltda. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.24 Petrobras Distr. S/A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.25 Promax Prod. Máximos S/A Indústria e Comércio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.26 Repsol - YPF S.A. Divisão Lubrificantes Brasil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.27 Quaker Chemical Industria e Comércio Ltda . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.28 Shell Brasil S/A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.29 Sika S/A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.30 Solplás - Ind. de Plásticos Ltda. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.31 Solvay Química . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.32 Three Bond do Brasil Ind. e Com. Ltda. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.33 Total Lubrificantes Brasil Ltda. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.34 Tutela Lubrificantes S/A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.35 Valvoline Lubrificantes Internacionais Ltda. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 List of authorized products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 Assembly Adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 Resin adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 Polyurethane-based sealing adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.4 Adhesive for sealing gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.5 Adhesive for packings and linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.6 Polyurethane adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.7 Body adhesive (Polyurethane) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.8 Resin adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.9 Sealing adhesives for engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.10 High-resistance locking adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.11 Low viscosity lock adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.12 Locking adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.13 Locking adhesive for mechanical seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.14 Metal-glass adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Contents i
3.15 Sealing adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3.16 2-component adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.17 Universal adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.18 Additives for coolants - G11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.19 Additives for coolants - G13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.20 Activating agent for pre-laminated glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.21 Silicone rubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.22 Filling and acoustic isolation foam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.23 Polyurethane adhesive tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.24 Cotton tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.25 Self-adhesive PVC tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.26 Transferable adhesive tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.27 Sealing tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.28 Double-sided adhesive tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.29 Double-sided acrylic foam adhesive tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.30 Medium density double-sided adhesive tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.31 Hydraulic brake fluid (DOT 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.32 Automatic transmission fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.33 Refrigerant gas - R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.34 Multi-purpose grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.35 Semi-fluid grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.36 Multi-purpose grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.37 Lubrication paste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.38 Lubricating grease ........................................................
AG. Volkswagen
9
3.39 Complexogrease agen . . . . . . . . . .A.G. d.o.es. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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3.40 Graphite d by grease . . . . . . . . . . . . . . . . . g. u.a.r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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3.41 uGrease
tho for front wheel cylinder support guideeepin or ................................ 9
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3.42 ss Grease for gearbox side seals . . . . . . . . . . . . . c. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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3.43 Grease for electrical contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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3.44 Polyurea grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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3.45 High temperature grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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3.46 Temperature resistant grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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3.47 Lubricating grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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3.48 Silicone based grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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3.49 Windscreen adhesive set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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3.50 Lithium-based lubricant paste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.51 Adhesive paste and grey sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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3.52 Adhesive material for glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.53 Silicone paste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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3.54 Mouldable paste for caulking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.55 Lubricating paste for high temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
nform
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3.56 Lubricating paste for constant velocity joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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3.57 Sealing compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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3.59 Sealing paste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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3.63 Nyogel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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3.64 Engine lubrication oil for Petrol, Ethanol engines- VW 501 01 . . . . . . . . . . . . . . . . . . . . . . 11
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3.65 Engine lubrication oil for Petrol, Ethanol, Totalflex engines- VW 502 00 . . . . . . . . . . . . . . 12
3.66 Engine oil lubricant for Diesel engines - VW 505 00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.68 Engine lubricant oil for Petrol and Totalflex engines - VW 508 88 . . . . . . . . . . . . . . . . . . . . 12
3.70 Lubricating oil for manual gearbox and steering box - SAE 90, MIL-L-2105B, API-GL5 . . 13
ii Contents
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3.71 Lubricatingtho oil for
r manual gearbox - SAE 80, MIL-L-2105,e o API-GL4
.................. 13
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3.72 Lubricating
ss oil for
manual gearbox - SAE 75W90 . . . . . a.c . . . . . . .
................... 14
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3.73 Oil for manual gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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3.74 Lubricating oil for manual gearbox - SAE 75W90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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3.75 Lubricating oil for manual gearbox - SAE 75W90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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3.76 Lubricating oil for manual gearbox - SAE 75W90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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3.77 Lubricating oil for power steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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3.78 Lubricating oil for automatic gearbox and power steering . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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3.79 Lubricating oil for the automatic gearbox differential - SAE 75W90 . . . . . . . . . . . . . . . . . . 14
t to the co
3.80 VW ATF oil for power steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.81 VW ATF oil for power steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
rrectness of i
3.82 Oil for gear selection mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.83 Oil for air conditioning compressor - R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
l purpos
3.84 White lubricating grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3.85 Moly grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
nform
ercia
3.86 Molybdenum bisulphate lubricating grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

m
at
3.87 Copper grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
om
ion
3.88 Silicon grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
c
in t
or
his
e
3.89 High temperature paste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

at
do
riv
3.90 Primer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
p
cum
for
3.91 Glass primer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
en
ng
t.
yi Co
3.92 Adhesive remover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
t. Cop py
rig 16
3.93 Silicone remover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
gh ht
pyri by
Vo
o
3.94 Corrosive paste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
c by lksw
cted agen
Prote
3.95 Silicone sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
AG.
3.96 Cleaning solution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.97 Engine leak detection spray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.98 Cylinder lubricating spray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.99 Silicone adhesive for sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.100 Mixing tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.101 Liquid sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.102 Silicone sealant for engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.103 Sealant for exhaust connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4 Work Instructions for Handling Chemicals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.1 General considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5 Application guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.1 Application guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6 Repair Group 10 - Cylinders, cylinder block, support, protector . . . . . . . . . . . . . . . . . . . . . . 31
6.1 Cylinder base gasket - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.2 Engine housing - seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.3 Engine housing plugs - fasten . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.4 Cylinder block plugs - fasten . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7 Repair Group 13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
7.1 Crankshaft needle bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
7.2 Needle bearing of the fastening hollow screw for the flywheel . . . . . . . . . . . . . . . . . . . . . . 36
7.3 Flywheel fastening screw - lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
8 Repair Group 15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
8.1 Intermediate shaft seal - lubricate for assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
8.2 Camshaft valve bearing cover (1st and 5th) - Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
8.3 Cylinder head sealing gasket - glue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
8.4 Lower rear threaded pins fastening the cylinder head - rear threaded pin (crankshaft) / lower
front threaded pins (flywheel) - Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8.5 Cylinder head cover - seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Contents iii
9 Repair Group 17 - Lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

9.1 Engine crankcase - Fill / top up oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
9.2 Junction between crankcase gaskets and crankshaft front and rear flange gasket - seal . . 46
9.3 Engine crankcase - seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
10 Repair Group 19 - Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
10.1 G11 cooling system - fill / adjust additive proportion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
10.2 G13 cooling system - fill / adjust additive proportion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
11 Repair Group 20 - Supply system - tank, fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
11.1 Accelerator pedal shaft - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
11.2 Accelerator pedal fastening - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
11.3 Accelerator cable and cable end - accelerator pedal fastening - lubricate . . . . . . . . . . . . . . 52
12 Repair Group 26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
12.1 Exhaust connection - seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
13 Repair Group - 28 - Ignition system, pre-ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . 54
13.1 Ignition coils with final power stage - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
14 Repair Group 30 - Clutch - control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
14.1 Clutch pedal bung - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
14.2 Clutch control cable - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
14.3 Clutch fork, contact with bearing - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
14.4 Clutch fork bungs - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
14.5 Wing nut for clutch control cable adjustmentAG- .lubricate Volkswagen . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
14.6 Sealing ring for the de-clutch bearing sw agen - lubricate forAG
guide does
assembly .................. 60
k not
y Vol g
14.7 Clutch cable - lubricate . . . i.se.d.b . . . . . . . . . . . . . . . . . . . . . . . . . . .ua. ra. n. . . . . . . . . . . . . . . . . 61
r te
14.8 Clutch fork and clutch actuating ut
ho lever - lubricate . . . . . . . . . . . . . . . . . e.or. . . . . . . . . . . . . . 62
a a
14.9 Clutch pedal fastening -sslubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . c. . . . . . . . . . . . . 63
ce
le
14.10 Clutch actuating lever - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

un
pt
an
d
14.11 Input shaft splines - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

itte
y li
erm
ab
14.12 Clutch pedal / clutch pedal bung - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
ility
ot p
14.13 Pedal support - seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

wit
is n
14.14 Clutch fork contact with the hydraulically activated cylinder of the gearbox clutch - h re
ole,
lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
spec
14.15 Fastening flange for clutch slave cylinder - seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

t to the co
15 Repair Group - 34 - Drive, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

15.1 Linkage rod, front/rear section - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
rrectne
15.2 Gear lever bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

15.3 Manual gearbox - Fill / top up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
ss
15.4 Manual gearbox - Fill / top up level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

o
cial p
15.5 Manual Gearbox - fill / top up level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

inform
mer
15.6 Manual gearbox - Fill / top up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

atio
15.7 Manual Gearbox - fill / top up level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

om
n
c
15.8 Plastic sleeves for the linkage rod coupling system / linkage rod / supports (on the gearbox)
i
or
n thi
e
- lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
t
sd
iva
15.9 Gear lever guide plate - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

pr
cum
r
fo
15.10 Rubber shim for the clutch compartment cover - glue . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

en
ng
t.
yi Co
15.11 Clutch compartment cover - seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
t. Cop py
rig 80
15.12 Linkage rod bellows for the gear lever assembly - fasten / seal . . . . . . . . . . . . . . . . . . . . . . 81
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pyri by
Vo
o
15.13 Junction of cases and differential cover housing (transfer box / differential) - seal . . . . . . 82
c by lksw
cted agen
Prote
15.14 Gear lever handle - fasten . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
AG.
15.15 Fastening screw for the rear support of the gearbox cushion - seal . . . . . . . . . . . . . . . . . . 84
15.16 Gearbox cushion - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
15.17 Gear selection mechanism - fill up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
15.18 Electric connectors of the gear selection mechanism - apply Nyogel . . . . . . . . . . . . . . . . 87
16 Repair Group 35 - Gears and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
16.1 Input shaft splines - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
16.2 Securing bolt of the 5th gear / synchronizing hub assembly - lock . . . . . . . . . . . . . . . . . . 89
iv Contents
17 Repair Group - 37 - Drive, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

17.1 Planetary gear box (automatic gearbox) - fill / top up oil level . . . . . . . . . . . . . . . . . . . . . . 90
18 Repair Group - 39 - Gearbox shafts, differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
18.1 Gearbox side seals - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
18.2 Planetary and satellite gears - lubricate for assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
18.3 Automatic gearbox differential - top up oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
18.4 Differential cover with gearbox AGhousing
. Volkswag-ensealAG do . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
agen es
ksw
19 Repair Group - 40by-VFront suspension . . . . . . . .no.t .gu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ol 97
ara
19.1 Constant velocity ed
oris joint spline - lubricate . . . . . . . . . . . .nt.ee. . . . . . . . . . . . . . . . . . . . . . . . . . . 97
th
19.2 Inner and souter
au constant velocity joint - lubricate . . . . . . .o.r a.c . . . . . . . . . . . . . . . . . . . . . . . 98
s
19.3 Front wheel bearing mounting - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
ce
le
un
pt
19.4 Axle end - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
an
d
itte
y li
20 Repair Group - 42 - Rear suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
rm
ab
pe
ility
20.1 Inner and outer constant velocity joint - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
ot
wit
, is n
20.2 Shaft end splines - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
h re
hole
20.3 Rear torsion bar - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
spec
20.4 Rear wheel hub - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
es, in part or in w
t to the co
20.5 Rear wheel hub seal - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
20.6 Rear wheel bearing - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
rrectness of i
21 Repair Group - 46 - Brakes - Mechanical systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
21.1 Rear wheel brake shoe ends - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
l purpos
21.2 Handbrake cable terminal - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

21.3 Brake pedal safety pin - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
nform
ercia
21.4 Securing pin for the operating rod of the master cylinder plunger - lubricate . . . . . . . . . . . . 116
m
a
21.5 Securing pin of the handbrake lever - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
com
tion in
21.6 Handbrake ratchet - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
r
te o
thi
22 Repair Group - 47 - Brakes - Brake servo hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . 119

s
iva
do
r
22.1 Brake system - fill / top up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

rp
cum
fo
en
22.2 Guide pin for the support of the front disc brake cylinder (manufactured by Varga) -
ng
t.
yi Co
lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ht. Cop py
rig 120
22.3 Fastening screw for the front disc brake cylinder housing - lock . . . . . . . . . . . . . . . . . . . . 121
rig ht
py by
co Vo
23 Repair Group - 48 - Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
by lksw
cted agen
Prote AG.
23.1 Power steering oil reservoir - Fill / top up oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
23.2 Oil reservoir for the power steering system - fill / top up oil level . . . . . . . . . . . . . . . . . . . . 123
23.3 Steering box - Fill / top up level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
23.4 Steering box mechanism - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
23.5 Adapter (sleeve) for the upper steering shaft - lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
24 Repair Group - 53 - Body - Rear section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
24.1 Bucket sealing membrane - glue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
24.2 Rear side panel - protect the paint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
25 Repair Group - 55 - Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
25.1 Bucket protective cover longitudinal member - glue the finishing . . . . . . . . . . . . . . . . . . . . 129
25.2 Lower latch of the bonnet - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
25.3 Damper eyelet for the rear cover - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
26 Repair Group - 57 - Front doors / components / central lock . . . . . . . . . . . . . . . . . . . . . . . . 132
26.1 Front door lock - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
26.2 Lock drive rod - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
26.3 Noise insulation for lock operating rod - glue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
26.4 Inner door seal - glue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
27 Repair Group - 58 - Rear doors / components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
27.1 Rear door lock - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
27.2 Side door lock - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Contents v
28 Repair Group - 64 - Windscreens, windows, window mechanism . . . . . . . . . . . . . . . . . . . . 138

28.1 Door window activation mechanism - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
28.2 Vent window latch - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
28.3 Front door window support - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
28.4 Front door window activation mechanism - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
28.5 Window crank fastening screw - lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
28.6 Windscreen, side window glass and rear window glass - glue . . . . . . . . . . . . . . . . . . . . . . 143
olkswagen AG
AG. Vglass
28.7 Windscreen, side ksw
window
agen and rear
doeswindow glass - seal . . . . . . . . . . . . . . . . . . . . . . 144
ol no
28.8 Glass - engrave
db
y V chassis number . . . . . . . .t .gu.a.r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
e a
28.9 Front tand
ho
ris rear door window guide groove - glue n.tee. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
or
146
28.10 Vent au
ss window - seal . . . . . . . . . . . . . . . . . . . . . . . . . . .c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
a
ce
e
29 Repair Group - 66 - External equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

nl
pt
du
an
29.1 Roof rack fastening screws - lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
itte
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erm
ab
30 Repair Group - 68 - Internal equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
ility
ot p
30.1 Interior rearview mirror support - fasten . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
wit
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h re
31 Repair Group - 70 - Lining/insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
hole
spec
31.1 Door noise insulation - glue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
es, in part or in w
t to the co
31.2 Noise insulation on rear side panel - glue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
31.3 Roof noise insulation - glue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
31.4 Door sealing membrane - glue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
rrectness of i
32 Repair Group - 72 - Seat framework . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
l purpos
32.1 Front seat central sliding guide - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

32.2 Front seat side sliding guide - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . nf
155
ercia
33 Repair Group - 87 - Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

orm
m
33.1 Air conditioning system - refill with gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

atio
om
33.2 Air conditioning system - refill with oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

n in
or c
thi
33.3 Air conditioning pressure switch - seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

te
sd
iva
34 Repair Group - 92 - Windscreen, rear window and headlight wiper and washer . . . . . . . . 159
r
rp
cu
o
m
f
34.1 Windscreen wiper operating rod - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

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35 Repair Group - 94 - Switches, lights, and external bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . 160
C py
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35.1 Contact blade for turn signal switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
yri
160
p by
o Vo
by c lksw
36 Repair Group - 97 - Cables and electrical harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . .
cted
161
agen
Prote AG.
36.1 Gaskets for the plastic covers that cover the electric harnesses - seal . . . . . . . . . . . . . . . . 161
vi Contents
00 – Technical data
1 Introduction
(VRL012260; Edition 09.2018)
• The information in this manual also cover that mentioned in
the ⇒ Electronic Replacement Parts Catalogue “ETKA” .
• Some products are sold directly by the supplier, and so con‐
tacts are directed to them.
WARNING
The information contained herein is a reference for the import‐

er, since some of the products cited in this Manual may not
exist on the market.
AG. Volkswagen AG d
agen oes
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1. Introduction 1
2 List of Suppliers
2.1 3M do Brasil
http://www.3m.com.br
2.2 Alba Adesivos Ind. Com. Ltda.

http://www.albaadesivos.com.br/
2.3 Brascola Ltda.

http://www.brascola.com.br/
2.4 Castrol Brasil Ltda.

www.castrol.com/pt_br/brazil.html
2.5 Cia Brasileira de Petróleo Ipiranga

http://www.ipiranga.com.br
2.6 Chevron Brasil S/A

https://www.chevron.com.br
2.7 Colauto - Adesivos e Massas Ltda

http://bra.sika.com/
2.8 Cremer S.A. Prod. Têxteis e Cirúrgicos

http://www.cremer.com.br
2.9 Dow Corning do Brasil Ltda.

http://www.dowcorning.com/pt_BR AG. Volkswagen AG d
agen oes
lksw not
2.10 Dow Automotive System
o
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ris nte
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http://www.dow.com/brasil/ aut ra
c
ss
2.11 Du Pont S/A
ce
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nl
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http://www.dupont.com.br
erm
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2.12 Elf Lubrificantes do Brasil

wit
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http://www.elf.com
spec
es, in part or in w
2.13 Esso Brasileira de Petróleo Ltda.

t to the co
http://www.exxonmobil.com.br
rrectness of i
2.14 Formiquímica Com. e Repres. de Pro‐

l purpos
dutos Químicos Ltda

http://formiquimica.com.br
nf
ercia
orm
2.15 Gratec System Indústria de Produtos

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Químicos Ltda.
n in
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gratec@uol.com.br
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2.16 Henkel do Brasil Ltda.

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http://www.henkel.com.br/index.htm ht. rig
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2
Prote AG.
Rep. gr.00 - Technical data
2.17 Klüber Lubrification Lubrificantes Espe‐

ciais Ltda.
http://www.klueber.com/br/pt/homepage/
2.18 Loctite Brasil Ltda.

http://www.loctite.com
2.19 Lumobrás Imp. Com. Ind. Ltda.

http://www.lumobras.com.br
2.20 ExxonMobil do Brasil Ind. Com. Ltda.

http://www.exxonmobil.com.br
2.21 Motul Synthetic Lubricants

https://www.motul.com/br/pt-br
2.22 Nippondenso Compressores Ltda.

http://www.denso.com.br/
2.23 Pentosin do Brasil Ltda.

AG. Volkswagen AG d
http://www.pentosin.net/
lksw
agen oes
not
o
yV gu
db
2.24 Petrobras Distr. S/A
ara
e nte
ris
tho eo
au ra
http://www.petrobras.com.br
ss c
ce
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un
pt
2.25 Promax Prod. Máximos S/A Indústria e

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Comércio
erm
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http://www.promax.com.br
wit
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ole,
2.26 Repsol - YPF S.A. Divisão Lubrificantes

spec
Brasil
t to the co
http://www.ypf.com/brasil/Paginas/Home.aspx
rrectne
2.27 Quaker Chemical Industria e Comércio

Ltda
ss o
cial p
http://br.quakerchem.com/
inform
mer
2.28 Shell Brasil S/A

atio
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http://www.shell.com/bra.html
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or
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2.29 Sika S/A

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pr
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http://bra.sika.com/
t.
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2.30 Solplás - Ind. de Plásticos Ltda.
ht. rig
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http://www.solplas.com.br cted agen
Prote AG.
2.31 Solvay Química

http://www.solvay.com/
2.32 Three Bond do Brasil Ind. e Com. Ltda.

http://www.threebond.com.br
2. List of Suppliers 3
2.33 Total Lubrificantes Brasil Ltda.

http://www.totalbr.com.br/
2.34 Tutela Lubrificantes S/A

http://www.tutela.com.br/
2.35 Valvoline Lubrificantes Internacionais

Ltda.
http://www.valvoline.com.br/
AG. Volkswagen AG d
agen oes
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V gu
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aut ra
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Prote AG.
4 Rep. gr.00 - Technical data

3 List of authorized products
WARNING
Observe the information in Chapter “Work Instructions for Han‐

dling Chemicals” ⇒ page 18
3.1 Assembly Adhesive

Trade Name Packaging Supplier
D 190 MKD A3 310 ml VOLKSWAGEN
3.2 Resin adhesive

DA 001 730 A2 2 Kg VOLKSWAGEN
3.3 Polyurethane-based sealing adhesive

Sikaflex 221 - white 310 ml cartridges SIKA
3.4 Adhesive for sealing gaskets

Trade Name Packaging Supplier AG. Volkswagen AG d
agen oes
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BRASCOVED 85 ML TUBES BRASCOLAby V ol not
gu
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CA-149 V rise
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ADHESIVE FOR 85 ML TUBES BRASCOLA
s aut ra
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DIESEL ENGINE s
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GASKETS
un
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3.5 Adhesive for packings and linings
rm
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D 002 100 175 g VOLKSWAGEN
spec
es, in part or in w
t to the co
3.6 Polyurethane adhesive
rrectness of i
D 180 KD2 A1 50 ml VOLKSWAGEN

l purpos
3.7 Body adhesive (Polyurethane)

nform
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D 180 003 M2 240 ml VOLKSWAGEN

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3.8 Resin adhesive

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DA 001 730 A2 37 ML VOLKSWAGEN
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3.9 Sealing adhesives for engines
co lksw
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Prote AG.

THREE BOND 1102 900 ML TINS THREE BOND
A
3. List of authorized products 5

3.10 High-resistance locking adhesive

LOCTITE 601 50g and 250g LOCTITE
TUBES
THREE BOND 1329 10, 50 and 250 g THREE BOND
TUBES
3.11 Low viscosity lock adhesive

LOCTITE 649 50g and 250g LOCTITE
TUBES
THREE BOND 1305 10, 50 and 250 g THREE BOND
TUBES
3.12 Locking adhesive

D 000 600 A2 18 ml VOLKSWAGEN
3.13 Locking adhesive for lkmechanical

swa
gen AG seals does n
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Vo ot g
by ua
Trade Name Packagingorised Supplier ran
tee
th or
THREE BOND 1386 250 ML
ss
auTUBES THREE BOND ac
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3.14 Metal-glass adhesive
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D 000 703 A1 0.01 oz VOLKSWAGEN

hole
spec
es, in part or in w
3.15 Sealing adhesive

t to the co

rrectness of i
LOCTITE 573 50 AND 250 ML LOCTITE

TUBES
l purpos
3.16 2-component adhesive

nform
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THREE BOND 3941 50 ML TUBES THREE BOND

n
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(BLUE)
his
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THREE BOND 3942 50 ML TUBES THREE BOND

p
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(RED)
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3.17 Universal adhesive C py
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Prote AG.
D 001 200 M2 420 g VOLKSWAGEN
D 001 210 M2 420 g VOLKSWAGEN
3.18 Additives for coolants - G11

G 052 774 A3 1 litre VOLKSWAGEN

3.19 Additives for coolants - G13

G 013 A8J M1 1.5 litre VOLKSWAGEN
3.20 Activating agent for pre-laminated glass

3.21 Silicone rubber

FLEXITE BLACK 85 g TUBES ALBA
BRASCOVED SI-40 85 g TUBES BRASCOLA
- BLACK
SILASTIC 732 RTV 85 g TUBES DOW CORNING
- BLACK
3.22 Filling and acoustic isolation foam

D 506 KD1 A3 200 ml VOLKSWAGEN
G. Volkswage
3.23 Polyurethane
olks
wage adhesive tape
nA n AG d
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Trade Name rise Packaging Supplier nte
tho eo
MKR 106 260 au ra
ss 95 21 MM X 50 M VOLKSWAGEN c
ROLLS
ce
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nl
pt
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3.24 Cotton tape

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TESABAND IM‐ 19 MM X 50 M CREMER

hole
spec
PERMEÁVEL 4651 ROLLS

es, in part or in w
(waterproof)
t to the co
3.25 Self-adhesive PVC tape

rrectness of i

l purpos
FITA 470 30 M X 19 MM 3M
ROLLS
nf
ercia
or
3.26 Transferable adhesive tape

m
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Y-0598 33 M X 16 MM 3M
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ROLLS
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3.27 Sealing tape Cop py
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BRASCOVED 2015 BOX CONTAINING BRASCOLA
L 10 TO 20 KG (with
tapes)

3.28 Double-sided adhesive tape

Trade Name Packaging Supplier agen
AG. Volkswagen AG d
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V 2808 6.0 MM X 61 M INDACO d by V gu
ara
ROLLS orise nte
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Y-427 6.3 MM X 10 M 3 M ss au ra
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ROLLS
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3.29 Double-sided acrylic foam adhesive
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Y-4205 5 MM X 10 M 3M
es, in part or in w
t to the co
ROLLS
3.30 Medium density double-sided adhesive
rrectness of i
tape
l purpos
nf
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Y-4210 (SENSOR) 30 X 48 MM UNITS 3 M
orm
325 /953 931 1 30 X 48 MM UNITS VOLKSWAGEN
m
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Y-4210 (GOL GTI 10 X 80 MM UNITS 3 M

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ROOF SPOILER)
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3.31 Hydraulic brake fluid (DOT 4)
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Trade Name Packaging Supplier t. Cop py
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B 000 750 M1 0.25 litre VOLKSWAGEN yri
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3.32 Automatic transmission fluid
Prote AG.

3.33 Refrigerant gas - R134a

SUVA® 134A 750 g DU PONT
SOLKANE® 134A SOLVAY QUÍMICA
3.34 Multi-purpose grease

G 052 735 A2 120 g VOLKSWAGEN
3.35 Semi-fluid grease

3.36 Multi-purpose grease

LITHOLINE EP 2 IPIRANGA
CASTROL GRAXA CASTROL
EPL 2


EXXON BEACON ESSO
EP-2
LUBRAX - GMA-2 PETROBRÁS
MULTIFAK PREMI‐ CHEVRON BRASIL
UM EP2
3.37 Lubrication paste

G 000 450 02 90 g VOLKSWAGEN
AG. Volkswagen AG d
agen oes
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3.38 Lubricating grease Vo gu
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VARILUB 745 BR 1 KG KLÜBER
ce
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3.39 Complex grease
erm
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MOBILPLEX 47 MOBIL
spec
es, in part or in w
3.40 Graphite grease
t to the co
rrectness of i
ISAGRAFITE IPIRANGA
l purpos
KLÜBER ST 25/300 KLÜBER

G-8
nform
ercia
PROFASA HD G-1 WAL

m
at
3.41 Grease for front wheel cylinder support
om
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do
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for
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SYNTHESO GLK 1 KLÜBER
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3.42 Grease for gearbox side seals
ht
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Prote AG.
GRAXA VARILUB KLÜBER
AH 70-222 BR
3.43 Grease for electrical contacts

UNIMOLY AC MET‐ KLÜBER
ALLIC
MOLYKOTE HSC LUMOBRÁS
3.44 Polyurea grease

3.45 High temperature grease



3.46 Temperature resistant grease

G 000 650 100 g VOLKSWAGEN
3.47 Lubricating grease

G 000 100 80 g VOLKSWAGEN
3.48 Silicone based grease

UNISILKON GLK 1 Kg KLÜBER
112 BR
3.49 Windscreen adhesive set

D 004 660 M2 Comp. A - 207 ml VOLKSWAGEN
gen AG
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does
and Comp. B - 193 Volkswa not
ml ed
by gu
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3.50 Lithium-based lubricant paste ss
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Trade Name Packaging Supplier pt

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3.51 Adhesive paste and grey sealant

wit
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spec

es, in part or in w
t to the co
D 511 500 A2 290 ML VOLKSWAGEN
3.52 Adhesive material for glass

rrectness of i

l purpos

nform
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3.53 Silicone paste

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tion in

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3.54 Mouldable paste for caulking

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BRASCOVED 1051 BOX WITH 20 KG BRASCOLA
by c lksw
cted agen
(20 1-KG BAGS)
Prote AG.
191 BOX WITH 20 KG HENKEL

(20 1-KG BAGS)
3.55 Lubricating paste for high temperatures


3.56 Lubricating paste for constant velocity

joints
3.57 Sealing compound

D 154 103 A1 100 g VOLKSWAGEN

VEDANTE 245/78 85 ML TUBES HENKEL
SQV - 337 85 ML TUBES BRASCOLA
3.59 Sealing paste

AMV 188 200 03 100 g TUBES VOLKSWAGEN

D 454 300 A2 125 g TUBES VOLKSWAGEN
AG. Volkswagen AG d
3.61 Volksw
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Trade Name horis
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7X0 898,539
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AMV 188 001 02 - 100 g TUBES VOLKSWAGEN

h re
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spec
gines)
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D 154 103 A1 - (EA 100 g TUBES VOLKSWAGEN

111 - 8V engines)
D 188 003 A1 - (EA 100 g TUBES VOLKSWAGEN
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111 - 16V engines)

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3.63 Nyogel
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G 052 817 A1 10-g SACHET VOLKSWAGEN

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3.64 Engine lubrication oil for Petrol, Ethanol

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Correspondence ⇒ Electronic Parts Catalogue “ETKA”
Co
Cop py
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Trade Name Packaging
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Supplier
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CASTROL 1 litre G 052 167 A1 VOLKSWA‐
cted agen
Prote AG.
MAGNATEC 200 litres G 052 167 M1 GEN
EXCLUSIVE
(SAE 10W40)

3.65 Engine lubrication oil for Petrol, Ethanol,

Totalflex engines- VW 502 00
Trade Name Packaging Supplier agen
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MAXI PER‐ 1 litre G 052 167 R2 VOLKSWA‐ byV gu
ara
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FORMANCE GEN horis nte
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VW 502 00 aut ra
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CASTROL 1 litre G 052 167 A4
ce
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MAGNATEC 200 litres G 052 167 M3
an
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ab
NAL MF (SAE
pe
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5W40)
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wit
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EDGE PRO‐ hole
spec
FESSIONAL
es, in part or in w
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A3 (SAE
0W30)
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3.66 Engine oil lubricant for Diesel engines -
VW 505 00
l purpos
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m
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MAXI PER‐ 1 litre G 052 167 R2 VOLKSWA‐
n in
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FORMANCE GEN
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(SAE 5W40)
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EDGE PRO‐ Cop py
FESSIONAL
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rig ht
by
A3 (SAE copy Vo
by lksw
0W30) cted agen
Prote AG.
EXCLUSIVE
(SAE 10W40)
PROFESSIO‐
NAL MF (SAE
5W40)

VW 507 00
CASTROL 1 litre G 052 195 R2 VOLKSWA‐
EDGE PRO‐ GEN
FESSIONAL
LONGLIFE III
(SAE 5W30)
3.68 Engine lubricant oil for Petrol and Total‐

flex engines - VW 508 88


FORMANCE GEN
VW 508 88
(SAE 5W40)
200 litres G 052 553 R6
CASTROL 1 litre G 052 553 R2
MAGNATEC wagen AG. Volkswagen AG d
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PROFESSIO‐ y Volks not
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NAL 508 88 rised b ara
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(SAE 5W40)
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VW 509 99
ab
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FORMANCE GEN
VW 508 88
rrectne
(SAE 5W40)
200 litres G 052 553 R6
ss
CASTROL 1 litre G 052 553 R2 o
cial p
f
MAGNATEC
inform
PROFESSIO‐
mer
NAL 508 88
atio
m
(SAE 5W40)
o
n
c
i
or
200 litres G 052 167 M3

thi
te
sd
iva
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3.70 Lubricating oil for manual gearbox and

p
cum
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fo
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steering box - SAE 90, MIL-L-2105B,

t.
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op py
API-GL5
t. C rig
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pyri by
Vo
o
by c lksw
Trade Name cted
Packaging Supplier
agen
Prote AG.
CASTROL MAX‐ CASTROL

TRON 90
ESSO GEAR OIL ESSO
GX
IPIRGEROL SP 90 IPIRANGA
MOBILUBE HD 90 MOBIL
LUBRAX TRM 5 PETROBRÁS
SHELL SPIRAX A SHELL
90
MULTIGEAR EP 90 TEXACO
3.71 Lubricating oil for manual gearbox - SAE

80, MIL-L-2105, API-GL4
IPIRGEROL EP 80 IPIRANGA
CASTROL UNI‐ CASTROL
TRON 80 W
ESSO GEAR OIL ESSO
GP 80 W
MOBILUBE GX 80 MOBIL
W

Fox 2004 ➤ , Gol 1995 ➤ , Gol ge1999
n AG. V➤
olks, wGol
agen2009
AG do ➤ , Golf 1999 ➤ , Ko ...
swa es n
Chemicals Manual - Edition
y Volk 09.2018 ot g
u b ara
ed nte
oris e
au
th Supplier or
ac
ss
LUBRAX TRM-4 PETROBRÁS
ce
e
nl
pt
du
SHELL SPIRAX G SHELL
an
itte
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80 W
erm
ab
ility
UNIVERSAL EP TEXACO
ot p
wit
, is n
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hole
spec
75W90
es, in part or in w
t to the co
G 052 157 A2 0.5 litre VOLKSWAGEN
rrectness of i
l purpos
3.73 Oil for manual gearbox

nf
ercia
orm
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n in
c

or
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75W90
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op py
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rig by
copy Vo

by lksw
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Prote AG.
75W90

75W90
3.77 Lubricating oil for power steering

G 004 000 M2 1 litre VOLKSWAGEN
3.78 Lubricating oil for automatic gearbox

and power steering
325 029 901 1 20 litre VOLKSWAGEN
3.79 Lubricating oil for the automatic gearbox

differential - SAE 75W90
G 052 145 S2 1 litre VOLKSWAGEN

3.80 VW ATF oil for power steering

3.81 VW ATF oil for power steering

3.82 Oil for gear selection mechanism

olkswagen AG
en AG. V
olks
wag Supplierdoes not
yV gu
G 052 512 S1 db a
rise1 litre VOLKSWAGEN rante
tho eo
au ra
3.83 Oilss for air conditioning compressor - c
ce
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R134a
un
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an
d
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ab
ility
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G 052 154 A2 250 ml VOLKSWAGEN
wit
is n
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3.84 White lubricating grease
spec
t to the co
rrectne
3.85 Moly grease ss o
cial p
f inform
G 052 723 A2 50 ml VOLKSWAGEN

mer
atio
m
3.86 Molybdenum bisulphate lubricating

o
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c
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grease
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sd
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UNIMOLY R 55/10 KLÜBER
Cop py
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MOLYKOTE G LUMOBRÁS
ht
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Vo
o
PASTE by c lksw
cted agen
Prote AG.
3.87 Copper grease

MOLIKOTE (r) LUMOBRÁS
CU-7439 PLUS
3.88 Silicon grease

3.89 High temperature paste


Chemicals Manual - Edition 09.2018 gen AG
. Volkswagen AG
d wa oes
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3.90 Primer
b ara
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ris
tho eo
au ra
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un
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an
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ab
3.91 Glass primer
pe
ility
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wit
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spec
D 009 200 02 10 ML es, in part or in w
VOLKSWAGEN
t to the co
3.92 Adhesive remover
rrectness of i
D 002 000 A2 1 litre VOLKSWAGEN
l purpos
3.93 Silicone remover
nform
ercia

m
a
com
tion in
LVM 020 100 A5 2.5 litres VOLKSWAGEN
r
te o
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s
iva
3.94 Corrosive paste
do
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fo
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g

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t.
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Cop py
GRATECRIL ACTI‐ 125 g TUBES GRATEC SISTEM
t. rig
gh ht
yri
VATED TLB 1012
p by
co Vo
by lksw
cted agen
Prote AG.
3.95 Silicone sealant
D 174 003 M2 80 ML VOLKSWAGEN
3.96 Cleaning solution

D 009 401 04 250 ML VOLKSWAGEN
3.97 Engine leak detection spray

G 001 800 A1 200 ML VOLKSWAGEN
3.98 Cylinder lubricating spray

G 052 778 A2 50 ML VOLKSWAGEN
3.99 Silicone adhesive for sealing

3.100 Mixing tube

D 001 001 50 ml VOLKSWAGEN

3.101 Liquid sealant

3.102 Silicone sealant for engines

D 176 404 M2 80 ML TUBES VOLKSWAGEN
3.103 Sealant for exhaust connections

TMX 386 3.6-LITER CANS SOLPLÁS
UV-93 3.6-LITER CANS BRASCOLA
AIR DRYING SEAL‐ 3.6-LITER CANS HENKEL
ANT
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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or eo
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aut ra
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un
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an
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wit
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spec
t to the co
rrectness o
cial p
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mer
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c
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fo
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t.
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Cop py
t. rig
gh ht
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Vo
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by c lksw
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Prote AG.

4 Work Instructions for Handling

Chemicals
4.1 General considerations
4.1.1 Solvent Handling

♦ Description of the Material
Solvents and their mixtures, e.g., hydrocarbons, halogens, alco‐
hols, esters, ketones are liquid organic substances. This Safety
Information applies to all solvents and water-free cleaning prod‐
ucts, and hardeners, primers, separators, and all preparations
used as well for this purpose.
Solvents can be classified as follows:
A - Irritant
B - Noxious
C - Toxic
D - Easily flammable
AG. Volkswagen AG d
agen oes
olksw not
byV gu
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aut ra
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nl
pt
du
an
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ab
ility
ot p
wit
, is n
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spec
es, in part or in w
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rrectness of i
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nf
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or c
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♦ Applications
t
sd
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painting, cleaning and maintenance of parts.

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♦ Storage
Co
Cop py
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rig ht
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18
co Vo
by lksw
cted
Rep. gr.00 - Technical data
agen
Prote AG.
Solvents must be stored in closed, identified safety containers.

Storing solvents in beverage bottles is strictly prohibited. Keep
only a volume sufficient to carry out the work in one shift in the
workplace. Volumes exceeding the daily requirement must be
stored in well ventilated, explosion-proof rooms.
♦ Work
Work with solvents requires the use of exhaust fans or environ‐
ments with good ventilation. Greater quantities of easily flamma‐
ble or flammable materials must be handled only in explosion-
proof locations. To prevent spontaneous combustion, solvents
must not come into contact with highly corrosive substances (e.g.
chromic acid, organic peroxides, etc.).
Thus, the following should be observed:
1 - prevent contact with hot surfaces, alkalis, such as caustic so‐
da, burnt lime or light metal chips.
2 - prevent contact with hot surfaces, alkalis, such as caustic so‐
da, burnt lime or light metal chips.
3 - protect the material against sunlight.
4 - do not use open flames, such as welding torches.
In case of prolonged use or storage, mixtures of halogen and
flammable solvents, such as cold cleaning products, classified as
less flammable, may become flammable solutions, due to evap‐
oration of the halogen component.
♦ Maintenance in confined spaces
Solvent vapours are heavier than air. Thus, they concentrate in
wells and tanks. Accordingly, before starting work in these places,
. Volkswagen AG
an "authorization for confined space" must be requested.
swa
gen AG does
k not
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♦ Operational failures d by ara
e nte
ris
utho
Spilt solvent must be collected using appropriate absorption prod‐
eo
ra
a c
ucts. The products should be stored inssclosed containers with ce
le
material identification and information on the content for future

un
pt
an
disposal.
d
itte
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erm
ab
♦ Protection against fire
ility
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When handling solvents, open flames, exposed lighting and

is n
h re
smoking are prohibited. For fire extinguishers, use CO2 and dry
ole,
spec
chemical powder.
t to the co
♦ Health protection, hygiene at work

1- When inhaled, most solvents have a narcotic effect and re‐
duce ethanol tolerance. Some solvents, even in small con‐
rrectne
centrations, are noxious.

s
2- In case of severe intoxication, remove the person to an out‐

s o
side or a well-ventilated location, until an ambulance arrives.

cial p
f inform
3- Work uniforms heavily-stained with solvent should be

mer
changed and thoroughly cleaned.

atio
om
n
c
4- Workers who have handled solvents and later complain

i
or
n thi
e
about health problems should consult a doctor immediately.

t
sd
va
The doctor must be informed about the solvents handled by

i
o
pr
cum
r
the worker.
fo
en
ng
t.
yi Co
5- Solvents have a degreasing effect on the skin. Using sol‐ . Cop py
vents to clean the skin is prohibited. Should contact with the
t rig
gh ht
yri by
skin be inevitable, treat the skin beforehand with protective cop Vo
by lksw
cream. cted agen
Prote AG.
6- In workplaces where solvents are used, eating, drinking and

storing food, especially close to chemicals, are prohibited.
4. Work Instructions for Handling Chemicals 19

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
Fox 2004 ➤ , Gol 1995 ➤ , Gol 1999au➤
t , Gol 2009 ➤ , Golf 1999 ➤ , Ko ... ra
c
s
s
ce
e
nl
pt
du
an
itte
7- Smoking while handling solvents is prohibited, since there
y li
erm
ab
is risk of fire or formation of products that cause toxic reac‐
ility
ot p
tions in atmospheres with high hydrocarbon and halogen
wit
contents.
, is n
h re
hole
♦ Personal protective equipment
spec
es, in part or in w
In compliance with Standard 6 (NR-6) Ordinance 3214 of the
t to the co
Ministry of Labour, handling of solvents requires the use of per‐
sonal protective equipment, such as the following:
rrectness of i
1 - gloves l purpos
2 - safety goggles
3 - protective clothing
nform
ercia
♦ Environmental protection, waste treatment

m
at
om
io
Solvents must not be disposed of in the sewer network. These
n
c
in t
or
products must be collected into proper containers, which must be
his
te
closed and identified, for future disposal or recycling.

a
do
priv
cum
or
4.1.2 Work instruction - Flammable material

f
en
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handling Cop py
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Flammable liquids are liquids, liquid mixtures or liquids with solid
op Vo
by c lksw
particles in solution or suspension (including substances classi‐
cted agen
Prote AG.
fied in a different way, based on their hazardous characteristics)
producing flammable vapours at temperatures up to 60.5 °C, in
open vessel tests.
Flammable materials may be solid, liquid or gaseous. As they re‐
lease oxygen, these materials burn and, under certain circum‐
stances, may ignite explosively. Flammable materials cause
irritations, corrosion, and noxious and toxic reactions.
In accordance with legislation, flammable materials are classified
as follows:
♦ Extremely flammable: Liquid substances or mixtures, which
flash point (temperature at which the substance may catch
fire) is below 0 °C and boiling point is below 35 °C;
♦ Easily flammable:
substances or mixtures that may warm and ignite in the air at room
temperature, without interference from any energy source;
substances or solid mixtures that may easily ignite after a brief
contact with an ignition source and that keep burning after the
source is removed;
For liquid substances, the flash point is lower than 21 °C. In con‐
tact with water or humid air, extremely flammable gases are
released in dangerous volumes;
♦ Flammable: substances or liquid mixtures, the flash point of
which is equal to or higher than 21 °C and lower than or equal
to 55 °C.
Handling these materials requires that the following be observed:
1- In work and storage places, wood is not to be used for floors,
desks or racks. The floor must be kept clean.
2- Eating, drinking, smoking, and storing food or cigarettes are
prohibited at the workplace and areas close to it.
3- The required personal protective equipment, such as safety
goggles, gloves, and, where applicable, aprons and rubber
boots, must be used.
4- Wet or excessively dirty clothing must be promptly changed.
This clothing must not be dried. Work clothes - even those
slightly dirty - must be sorted and marked with the following

warning before being sent to laundry: “CLOTHES CONTA‐

MINATED WITH FLAMMABLE MATERIAL”. These clothes
must be washed in water. gen AG
. Volkswagen AG
d wa oes
olks not
5- Contaminated or wet personal clothes mustdalso
by be washed
V gu
ara
in water at home. orise nte
eo
h
ut ra
6- Flammable materials must not come ss into contact with or‐
a c
ganic substances, such as oil, grease, and solvent, since
ce
le
un
pt
there is risk of fire.
an
d
itte
y li
erm
7- While handling flammable materials, prevent spillage and
ab
ility
dust. In case of leaks, spilt products must not be adsorbed
ot p
wit
by sawdust or disposed of in trash cans. is n
h re
ole,
8- Solid flammable materials must be swept or wet with ab‐
spec
sorption products. These materials must be collected into
t to the co
proper containers and sent for disposal with identification of
their content.
9- Should flammable materials come into contact with the skin
rrectne
or eyes, wash them promptly with plenty of water (for at least
15 minutes). Then, consult a doctor. Inform about the prod‐
s
uct affecting the person.
s o
cial p
f in
4.1.3 Handling used engine oil
form
mer
atio
♦ Description of the material
om
n
c
i
or
n
Oils for four-cylinder engines comprise basically superior hydro‐
thi
te
sd
carbons with additives. At temperatures that can reach over
iva
o
r
450ºC at the bottom of the piston, oxidation and other chemical

p
cum
r
fo
reactions take place. In these processes reactive products are
en
ng
t.
yi
formed, such as "polycyclic aromatic hydrocarbons".
Co
Cop py
t. rig
gh
♦ Applications
ht
pyri by
Vo
o
by c lksw
Used engine oil is produced mostly in engine test workshops after
cted agen
Prote AG.
long-running operational tests. It is also produced during oil
change, for example, at a customer service centre, and from ve‐
hicles undergoing durability tests. For sealing quality control,
these engine oils are submitted to thermal load.
♦ Storage
Used engine oil must be collected and temporarily stored into
metal containers with locks and the following warning:
“Caution. Used engine oil” Prevent contact with skin
♦ Work
Production-scale work at recovery facilities, unproductive appli‐
cation in used oil coagulation.
♦ Maintenance
When carrying out maintenance work, observe the following
items: Operational failures - Leaks, Protection against fire, and
Health protection, hygiene at work.
♦ Operational failures - Leaks
Should absorption of spilt oil be required, the spilt product must
be stored in closed containers for future disposal.
♦ Protection against fire
Engine oils are not classified as flammable materials, since their
flash points are above 100 ºC. To prevent spontaneous ignition,
fire or explosion, cloths or other absorbent materials impregnated
with oil must be stored in non-flammable containers with a cover.
♦ Health protection and hygiene at work
4. Work Instructions for Handling Chemicals 21

Prolonged or repetitive contact with any type of engine oil results

in skin degreasing. Skin drying, irritation or inflammation may oc‐
cur. In addition, used engine oils contain hazardous substances
classified as "polycyclic aromatic hydrocarbons". The following
work hygiene precautions should be observed:
1- Before handling used engine oils, apply appropriate skin
protection.
2- Preferentially, use warm water and soap to remove engine
oil from skin.
3- Solvents, cold cleaners, thinners, diesel oil should not be
used for cleaning skin contaminated with engine oil.
♦ Personal protection equipment
The following equipment should be used:
- Safety goggles
- Gloves
- Aprons
♦ Environmental protection, waste treatment
Used oils are classified as liquids hazardous to water. Do not dis‐
pose of used oil in the sewer system or the soil.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
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orm
m
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n in
or c
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sd
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Cop py
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by lksw
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Prote AG.

5 Application guide
5.1 Application guide

Repair group - 10 - Cylinders, Cylinder block, Support, Protector
DESCRIPTION / PROCE‐ APPLICATION
DURE
G. Volkswagen AG d
Cylinder base gasketlk-swlubri‐
agen
A
1.6-litre, air-cooled
oes engine
not
cate by Vo ⇒ page 31 gu
ara
ed
Air-cooled engine
thoris housing - 1.6-litre, air-cooled engine nte
eo
seal s au ⇒ page 32 ra
c
s
Cylinder block plugs - fasten Water-cooled engines
ce
le
un
pt
⇒ page 34
an
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Cylinder block plugs - seal 1.6-litre engine ⇒ page 33
erm
ab
ility
ot p
Repair group - 13 - Crankshaft group
wit
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spec
DURE
t to the co
Needle bearing of the fasten‐ Air-cooled engines ⇒ page 36
ing hollow screw for the fly‐
wheel - lubricate
rrectne
Crankshaft needle bearing - Engines - 1.6 , 1.8 and 2.0 L EA
lubricate 827 , 2.0 L 16 V , 1.0 , 1.4 and ss
1.6 L - EA 111 , 1.0 16 V - EA
o
cial p
111 , 1.8 and 2.0 L - EA 113

inform
⇒ page 35
mer
atio
Flywheel fastening screw - Air-cooled engines ⇒ page 37

om
lock
n
c
i
or
n thi
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Repair group - 15 - Cylinders, Cylinder block, Support, Protector

sd
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DURE
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Cop py
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Intermediate shaft seal - lu‐ gh
Engines - 1.6, 1.8 and 2.0 L EA
ht
yri by
bricate for assembly 827 ⇒ page 38
op Vo
by c lksw
cted agen
Camshaft valve bearing cov‐ Engines - 1.0-litre - EA 111
Prote AG.
er (1st and 5th) - Seal (Tasse) ⇒ page 39

Cylinder head sealing gasket Air-cooled engines ⇒ page 40
- glue
Lower rear threaded pins fas‐ Air-cooled engines ⇒ page 41
tening the cylinder head - rear
threaded pin (crankshaft) /
lower front threaded pins (fly‐
wheel) - Seal
Cylinder head cover - seal Engines - 1.0 L - EA 111 , 1.0 16
V - EA 111 ⇒ page 44
Cylinder head cover - seal 8V engine RSH - ⇒ page 43
Cylinder head cover - seal 8 V Tasse Engine - ⇒ page 42
Repair group - 17 - Lubrication system
DURE
Engine crankcase - Fill / top Engines - all ⇒ page 45
up oil level
Engine crankcase - Fill / top 2.4 L Engine - Caravelle and Eu‐
up oil level rovan ⇒ page 45
5. Application guide 23
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Engine crankcase - Fill / top 2.0-litre engine - Amarok ot
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up oil level ⇒ page 45
h re
hole
spec
Engine crankcase - seal Engines - 1.6 , 1.8 and 2.0 L EA
es, in part or in w
827 , 1.0 , 1.4 and 1.6 L - EA 111 ,
t to the co
1.0 16 V - EA 111 , ⇒ page 47
Junction between crankcase Engines - 1.6, 1.8 and 2.0 L EA
gaskets and crankshaft front 827 - UNF, UPQ, UDH, UQG -
rrectness of i
and rear flange gasket - seal 2.0L 16 V ⇒ page 46
l purpos
Repair group - 19 - Cooling system
nform
ercia

DURE
m
a
com
tio
G11 cooling system - fill / ad‐ Engines - all until 05/01/2000
n in
r
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just additive proportion ⇒ page 48
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G13 cooling system - fill / ad‐ Engines - all from 05/02/2000
r
rp
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just additive proportion ⇒ page 49
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Repair group - 20 - Fuel tank, fuel pump Cop py
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DURE cted agen
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Accelerator pedal shaft - lu‐ All (except Kombi and E-gas ve‐
bricate hicles) ⇒ page 50
Accelerator pedal fastening - Kombi ⇒ page 51
lubricate
Accelerator cable and cable Kombi ⇒ page 52
end - accelerator pedal fas‐
tening - lubricate
Repair group - 26 - Exhaust system
DURE
Exhaust connection - seal All ⇒ page 53
Repair group - 28 - Ignition system, pre-ignition system
DURE
Ignition coils with final power All ⇒ page 54
stage - lubricate
Repair group - 30 - Clutch - control system
DURE
Clutch pedal bung - lubricate Gol GTI 16 V and Parati GTI 16
V ⇒ page 55
Clutch control cable - lubri‐ Gol, Parati, Saveiro and Santana
cate ⇒ page 56
Clutch fork, contact with bear‐ Gearboxes (013) ⇒ page 57
ing - lubricate
Clutch fork bungs - lubricate Gearboxes (013) ⇒ page 58
Wing nut for clutch control ca‐ Gearbox (081) ⇒ page 59
ble adjustment - lubricate
Sealing ring for the clutch Gearboxes (02T) ⇒ page 60
bearing guide - lubricate for
assembly
Clutch cable - lubricate Kombi ⇒ page 61


DURE
Clutch fork and clutch actuat‐ Gearbox (081) ⇒ page 62
ing lever - lubricate
Clutch pedal fastening - lubri‐ Kombi ⇒ page 63
cate
Clutch actuating lever - lubri‐ Gearbox (081) ⇒ page 64
cate
Input shaft splines - lubricate Gearboxes (013) 1.0, 1.6 , 1.8
and 2.0 L ⇒ page 65
Clutch pedal / clutch pedal All (except Kombi) ⇒ page 66
bung
Pedal support - seal Gol , Parati, and Saveiro - 98 ►
⇒ page 67
Clutch fork contact with the Gearbox - CNX ⇒ page 68
hydraulically activated cylin‐
der of the gearbox clutch -
lubricate
Fastening flange for clutch agenGearbox
AG. Volksw-aCNX
gen AG⇒ page 69
does
slave cylinder - seal y Volksw not
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Repair group - t34 ris
ho - Drive, housing tee
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DESCRIPTION / PROCE‐ APPLICATION ce
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DURE
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Linkage rod, front/rear sec‐ Kombi ⇒ page 70
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tion - lubricate
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Gear lever bearing - lubricate All (except Kombi) ⇒ page 71

, is n
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Manual gearbox - Fill / top up Gearbox - CNX ⇒ page 72

hole
spec
Manual gearbox - Fill / top up Gearboxes (013) 1.0, 1.6 , 1.8

es, in part or in w
t to the co
level and 2.0 L ⇒ page 73

Manual gearbox - Fill / top up Gearbox (02T - MQ250)
level ⇒ page 74
rrectness of i
Manual gearbox - Fill / top up Gearbox (02T - MQ200)

l purpos
⇒ page 75
Manual gearbox - Fill / top up Gearbox (081) Kombi
⇒ page 76
nf
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Plastic sleeves for the linkage Gol, Parati, Saveiro and Santana
m
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rod coupling system / linkage ⇒ page 77

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rod / supports (on the gear‐

or
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Co
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compartment cover - glue ⇒ page 79
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seal ⇒ page 80
agen
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Linkage rod bellows for the Gol, Parati, Saveiro and Santana
gear lever assembly - fasten / ⇒ page 81
seal
Housing junction (transfer Gearbox - CNX ⇒ page 82
box / differential) and differ‐
ential cover housing - seal
Gear lever handle - fasten Gol, Parati, Saveiro and Santana
⇒ page 83
Gearbox cushion - lubricate Polo and Fox manual gearbox
⇒ page 85
Fastening screw for the rear Gearboxes (013) 1.0, 1.6 , 1.8
support of the gearbox cush‐ and 2.0 L ⇒ page 84
ion - seal

DURE
Gear selection mechanism - Automated gearboxes (SQ200)
fill up ⇒ page 86
Electric connectors of the Automated gearboxes (SQ200)
gear selection mechanism - ⇒ page 87
apply nyogel
Repair group - 35 - Gears and shafts
DURE
Input shaft splines - lubricate Gearbox - 081 ⇒ page 88
Securing bolt of the 5th gear / Gearboxes (013) 1.0, 1.6 , 1.8
synchronizing hub assembly and 2.0 L ⇒ page 89
- lock
Repair group - 37 - Drive, housing
DURE
Planetary gear box (automat‐ Gearbox - 01M ⇒ page 90
ic gearbox) - Fill / top up oil
level
Planetary gear box (automat‐ Gearbox - 09A ⇒ page 91
level
Planetary gear box (automat‐ Gearbox - 09G ⇒ page 92
level
Repair group - 39 - Gearbox shafts, differential
DESCRIPTION / PROCE‐ APPLICATION n AG. Volkswagen AG do
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Gearbox side seals - lubricate Gearboxes th (013 and 081)
o tee
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⇒ page
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Planetary and satellite gears Gearbox (081) ⇒ page 94
ce
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- lubricate for assembly

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Automatic gearbox differen‐ Gearbox (01M) ⇒ page 95

erm
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tial - top up oil level

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Differential cover with gear‐ Gearboxes (013) 1.0, 1.6 , 1.8

h re
box housing - seal and 2.0 L ⇒ page 96

hole
spec
es, in part or in w
Repair group - 40 - Front suspension

t to the co

DURE
rrectness of i
Constant velocity joint spline Gol, Parati, Saveiro and Santana

l purpos
- lubricate ⇒ page 97
Inner and outer constant ve‐ Gol, Parati, Saveiro and Santana
nf
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locity joint - lubricate ⇒ page 98

orm
Front wheel bearing mount‐ Gol, Parati, Saveiro and Santana

m
atio
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ing - lubricate ⇒ page 99

o
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Axle end - lubricate Kombi ⇒ page 100

thi
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King pin bearing - lubricate Kombi ⇒ page 102

iv
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Front axle beam - lubricate Kombi ⇒ page 103

f
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Suspension arms - lubricate Kombi ⇒ page 104
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DURE
Passage hole for the speed‐ Kombi ⇒ page 106
ometer cable in the wheel hub
protector - seal
olkswagen AG
en AG. V
Repair group - 42 - Rear osuspension
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DESCRIPTION / oPROCE‐
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APPLICATION nte
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DURE au
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Inner and outer constant ve‐ Kombi ⇒ page 98
ce
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locity joint - lubricate
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Shaft end splines - lubricate Kombi ⇒ page 108
erm
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Rear torsion bar - lubricate Kombi ⇒ page 109
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Rear wheel hub - lubricate Kombi ⇒ page 110
h re
hole
Rear wheel hub seal - lubri‐ Kombi ⇒ page 111
spec
cate
es, in part or in w
t to the co
Rear wheel bearing - lubri‐ Kombi ⇒ page 112
cate
rrectness of i
Repair group - 46 - Brakes - Mechanical systems
l purpos

DURE
nf
ercia
o
Rear wheel brake shoe ends Gol, Parati, Saveiro, Santana
rm
m
- lubricate and Kombi ⇒ page 113

atio
om
Handbrake cable terminal - Gol, Parati, Saveiro and Santana n in

or c
lubricate ⇒ page 114

thi
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Brake pedal safety pin - lubri‐ Gol, Parati, Saveiro and Santana
o
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cate ⇒ page 115

o
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Securing pin for the operating Kombi ⇒ page 117
Co
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Gol, Parati, Saveiro and Santana
agen
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brake lever - lubricate ⇒ page 117
Handbrake ratchet - lubricate Kombi ⇒ page 118
Repair group - 47 - Brakes - Brake servo hydraulic system
DURE
Brake system - fill / top up All ⇒ page 119
Guide pin for the support of Gol, Parati, Saveiro and Santana
the front disc brake cylinder ⇒ page 120
(manufactured by Varga) - lu‐
bricate
Fastening screw for the front Gol, Parati, Saveiro and Santana
disc brake cylinder housing - with Vargas brake system
lock ⇒ page 121
Repair group - 48 - Steering
DURE
Power steering oil reservoir - Santana, Gol, Parati, Saveiro,
Fill / top up oil level Polo and Fox. ⇒ page 122
Oil reservoir for the power Santana, Golf, Passat, Polo
steering system - Fill / top up Classic, Fox, Polo and Saveiro
oil level ⇒ page 123
Steering box - Fill / top up oil Kombi ⇒ page 124
level

DURE
Steering box mechanism - lu‐ Gol , Parati , Saveiro (Genera‐
bricate tion II , III and IV) and Santana
⇒ page 125 n AG. Volkswagen AG do
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Adapter (sleeve) for the up‐ Gol, Parati, Saveiro and y VSantana
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per steering shaft - lock ⇒ page 126 ir se
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Repair group - 53 - Body - Rear section ss
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DURE itte
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Bucket sealing membrane - Saveiro Generation II , III and IV
ility
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glue ⇒ page 127
wit
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Rear side panel - protect the Saveiro Generation II , III and IV
ole,
spec
paint ⇒ page 128
t to the co
Repair group - 55 - Covers, Protector
rrectne
DURE
Bucket protective cover lon‐ Saveiro ⇒ page 129
ss
gitudinal member - glue the
o
cial p
f
finishing
inform
Lower latch of the bonnet - lu‐ Gol, Parati, Saveiro and Santana
mer
atio
bricate ⇒ page 130
om
n
c
Damper eyelet for the rear All ⇒ page 131
i
or
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and front lid
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Tailgate buffer - lubricate Saveiro 2013 ► ⇒ page 9
pr
cum
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fo
en
ng
Repair group - 57 - Front doors / components / central lock

t.
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DURE
co Vo
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Front door lock - lubricate Gol, Parati, Saveiro and Santana
⇒ page 132
Lock drive rod - lubricate Kombi ⇒ page 133
Noise insulation for lock op‐ All (except vehicles with cable
erating rod - glue operation) ⇒ page 134
Inner door seal - glue Kombi ⇒ page 135
Repair group - 58 - Rear doors / components
DURE
Rear door lock - lubricate Gol, Parati, Saveiro and Santana
⇒ page 136
Side door lock - lubricate Kombi ⇒ page 137
Repair group - 64 - Windscreens, windows, window mechanisms
DURE
Door window activation Gol, Parati, Saveiro and Santana
mechanism - lubricate ⇒ page 138
Vent window - seal Kombi ⇒ page 147
Vent window latch - lubricate Kombi ⇒ page 139
Front door window support - Kombi ⇒ page 140
lubricate
Front door window activation Kombi ⇒ page 140
mechanism - lubricate


DURE
Window crank fastening All (fastened with screw)
screw - lock ⇒ page 141
Windscreen, side window All (except windows with finish‐
glass and rear window glass ing) ⇒ page 143
- glue
Windscreen, side window All (except glued windows)
glass and rear window glass ⇒ page 144
- seal
Glass - engrave chassis num‐ All ⇒spage AG. Volkswagen AG d
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Front and rear door window
oris Kombi ⇒ page 146
e nte
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guide groove - glue auth ra
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Repair group - 66 - External equipment

nl
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DURE
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Roof rack fastening screws - Santana, Quantum and Parati
h re
lock ⇒ page 148
hole
spec
es, in part or in w
Repair group - 68 - Internal equipment
t to the co
DURE
rrectness of i
Interior rearview mirror sup‐ Santana ⇒ page 149
l purpos
port - fasten
Repair group - 70 - Lining/insulation
nf
ercia
orm
m
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DURE
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Door noise insulation - glue All ⇒ page 150

thi
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Noise insulation on rear side All ⇒ page 151

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Roof noise insulation - glue All ⇒ page 152
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Door sealing membrane - All ⇒ page 153
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Repair group - 72 - Seat framework
DURE
Front seat central sliding Gol, Parati, Saveiro and Santana
guide - lubricate ⇒ page 154
Front seat side sliding guides Gol, Parati, Saveiro and Santana
- lubricate ⇒ page 155
Repair group - 87 - Air conditioning
DURE
Air conditioning system - refill All ⇒ page 156
with gas
Air conditioning system - refill All ⇒ page 157
with oil
Air conditioning pressure Gol, Parati, Saveiro and Santana
switch - seal ⇒ page 158
Repair group - 90 - Instrument case, indicators

DURE
Windscreen ultrasound sen‐ Santana (► 12.01), Gol and Par‐
sor - fasten ati (► 04.99)
Repair group - 92 - Windscreen, rear window and headlight wiper
and washer
DURE
Windscreen wiper operating Kombi ⇒ page 159
rod - lubricate
Repair group - 94 - Switches, lights, and external bulbs
DURE
Contact blade for turn signal All ⇒ page 160
switch - lubricate
Repair group - 97 - Cables and electric harnesses
DURE
AG. Volkswagen AG d
agen oes
Gaskets for the plastic covers
olks All ⇒ page 161
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that cover the electric
se
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6 Repair Group 10 - Cylinders, cylinder

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block, support, protector
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WARNING
spec
es, in part or in w
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Check the regulations on the disposal of each product and
packaging as per manufacturer's guidelines and current legis‐
lation at local, state and federal level.
rrectness of i
Observe the information contained in Chapter “Work Instruc‐
l purpos
tions for the Handling of Chemicals” ⇒ page 18 .
nform
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6.1 Cylinder base gasket - lubricate

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tion in
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- Air-cooled engines
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⇒ page 8
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6. Repair Group 10 - Cylinders, cylinder block, support, protector 31

6.2 Engine housing - seal
- Product used
- Sealing adhesive ⇒ page 6
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6.3 Engine housing plugs - fasten
- Product used
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sive
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6. Repair Group 10 - Cylinders, cylinder block, support, protector 33

6.4 Cylinder block plugs - fasten
- Water-cooled engines
- Product used
- Locking adhesive for me‐
chanical seal ⇒ page 6
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7 Repair Group 13 - Crankshaft group
WARNING

7.1 Crankshaft needle bearing
- All, except automatic gearbox

- Product used
⇒ page 8
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7. Repair Group 13 - Crankshaft group 35

7.2 Needle bearing of the fastening hollow screw for the flywheel
- Product used
⇒ page 8
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7.3 Flywheel fastening screw - lock
- All
- Product used
- Low viscosity lock adhesive
⇒ page 6
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7. Repair Group 13 - Crankshaft group 37

8 Repair Group 15 - Cylinder head,

valve gear
WARNING

dling Chemicals” ⇒ page 18en AG. Volkswagen AG
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8.1 Intermediate shaft seal - lubricate for assembly
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an
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velocity joints ⇒ page 11
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8.2 Camshaft valve bearing cover (1st and 5th) - Seal
- AT engines, except RSH

- Product used
- Sealing compound for en‐
gines ⇒ page 11
AG. Volkswagen AG d
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8. Repair Group 15 - Cylinder head, valve gear 39

8.3 Cylinder head sealing gasket - glue
- Product used
- Sealing gasket adhesive
⇒ page 5
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8.4 Lower rear threaded pins fastening the cylinder head - rear threaded pin
(crankshaft) / lower front threaded pins (flywheel) - Seal
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8.6 Cylinder head cover - seal ris
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9 Repair Group 17 - Lubrication system
WARNING

9.1 Engine crankcase - Fill / top up oil level
- Product used
- Engines - All up to 11/2002 ,
except Passat 2001 ►
- Multi-purpose engine lubri‐
cating, as per VW 501 01
standard ⇒ page 11
- Engines - For Passat 2001 ►
and all as of 12/2002 ►
12/2014
- Engine lubricating oil with
high lubricating capacity, as
per VW 502 00 standard
⇒ page 12
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du
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hole
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⇒ page 13
rrectness of i
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diesel particulate filter - DPF)
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⇒ page 12
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9. Repair Group 17 - Lubrication system 45

9.2 Junction between crankcase gaskets and crankshaft front and rear flange
gasket - seal
- AP engines with solid crank‐

case gasket
- Product used
- Engine sealing adhesive
⇒ page 5
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9.3 Engine crankcase - seal
- Engines without solid crank‐

case gasket
- Product used
- Silicone sealant for engine
⇒ page 17
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9. Repair Group 17 - Lubrication system 47

10 Repair Group 19 - Cooling system
WARNING
Check the regulations on the disposal of ageach

en AG.product
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10.2 G13 cooling system - fill / adjust additive proportion.
*Forvehicles manufactured as
from 05/02/2000
- Product used
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⇒ page 7
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10. Repair Group 19 - Cooling system 49

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11 Repair Group 20 - Supply system -
y li
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11.1 Accelerator pedal shaft - lubricate
atio
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n
c
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⇒ page 15
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11.2 Accelerator pedal fastening - lubricate
- Kombi
- Product used
⇒ page 8
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11. Repair Group 20 - Supply system - tank, fuel pump 51

11.3 Accelerator cable and cable end - accelerator pedal fastening - lubricate
- Kombi
- Product used
⇒ page 8
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12 Repair Group 26 - Exhaust system

AG. Volkswagen AG d
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WARNING d by V gu
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Check the regulations on the disposal of each
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spec
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- All
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ss
tions ⇒ page 17
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12. Repair Group 26 - Exhaust system 53

13 Repair Group - 28 - Ignition system,

pre-ignition system
WARNING

13.1 Ignition coils with final power stage - lubricate
- Engines with ignition coils

with final power stage
- Product used
- Silicon lubricating grease
⇒ page 15
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14 Repair Group 30 - Clutch - control
an
d
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14.1 Clutch pedal bung - lubricate
mer
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14. Repair Group 30 - Clutch - control system 55

14.2 Clutch control cable - lubricate
- Gol, Parati, Saveiro and San‐

tana
- Product used
Note
Lubrication of the cable end fitted in

the clutch lever, in the gearbox, is
only valid for 1.6, 1.8 and 2.0 L en‐
gines manufactured until 12/02/98
AG. Volkswagen AG d
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14.3 Clutch fork, contact with bearing - lubricate
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013 - 1.0 L
013 - 1.6, 1.8 and 2.0 L AG. Volkswagen AG d

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14.4 Clutch fork bungs - lubricate
- Gearboxes
013 - 1.0 L
013 - 1.6 L , 1.8 L and 2.0 L
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14.5 Wing nut for clutch control cable adjustment - lubricate
- Gearbox
081
- Product used
⇒ page 8
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14.6 Sealing ring for the de-clutch bearing guide - lubricate for assembly
- Gearboxes
❑ MQ 200
❑ MQ 250
- Product used
⇒ page 8
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14.7 Clutch cable - lubricate
- Kombi
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⇒ page 8
AG. Volkswagen AG d
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14.8 Clutch fork and clutch actuating lever - lubricate
- Gearbox
❑ 081
- Product used
⇒ page 8
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14.9 Clutch pedal fastening - lubricate
- Kombi
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⇒ page 8
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14.10 Clutch actuating lever - lubricate
- Gearbox - 081
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⇒ page 8
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ss
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14.11 Input shaft splines - lubricate
nl
pt
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ab
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ot p
- Gearboxes
wit
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❑ 013 - 1.0 L
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spec
es, in part or in w
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⇒ page 8
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AG. Volkswagen A
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14.12 Clutch pedal / clutch pedal bung - lubricate au ra
ss c
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nl
pt
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14.13 Pedal support - seal
- Product used
- Sealing compound
⇒ page 11
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14.14 Clutch fork contact with the hydraulically activated cylinder of the gearbox
clutch - lubricate
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14.15 Fastening flange for clutch slave cylinder - seal aut
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15 Repair Group - 34 - Drive, housing
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15. Repair Group - 34 - Drive, housing 71

15.3 Manual gearbox - Fill / top up
- Gearbox -
- Product used
- Manual gearbox oil - SAE
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15.4 Manual gearbox - Fill / top up level
- Gearboxes 013
❑ For engines: 1.0 L, 1.6
L, 1.8 L, 1.9 L and 2.0 L
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15.5 Manual Gearbox - fill / top up level
- Gearbox - MQ 250
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75W90 ⇒ page 14
♦ -G 005 100 A1- - 1 litre
♦ -G 052 512 A2- - 1 litre
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15.6 Manual gearbox - Fill / top up
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75W90 ⇒ page 14
♦ -G 052 512 A2- - 1 litre
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15.7 Manual Gearbox - fill / top up level
- Gearbox - 081 - Kombi

- Product used
- Lubricating oil for manual
gearbox and steering box -
SAE 90, MIL-L-2105B, API-
GL5 ⇒ page 13
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15.8 Plastic sleeves for the linkage rod coupling system / linkage rod / supports
(on the gearbox) - lubricate
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15.9 Gear lever guide plate - lubricate
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15.10 Rubber shim for the clutch compartment cover - glue

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Chemicals Manual - Edition 09.2018 autho eo
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15.11 Clutch compartment cover - seal
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15.12 Linkage rod bellows for the gear lever assembly - fasten / seal

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15.13 Junction of cases and differential cover housing (transfer box / differential)
- seal
- Gearbox -
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15.14 Gear lever handle - fasten

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15.15 Fastening screwssfor the rear support of the gearbox cushion - seal au ra
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15.16 Gearbox cushion - lubricate
- Mechanical gearbox
♦ For Fox and Polo
- Product used
- Silicone based grease
⇒ page 10
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15.17 Gear selection mechanism - fill up
- Gearbox - SQ 200
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- Oil for gear selection mecha‐
nism ⇒ page 15
♦ -G 052 512 S1- - 1 litre
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15.18 Electric connectors of the gear selection mechanism - apply Nyogel

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16 Repair Group 35 - Gears and shafts
WARNING

16.1 Input shaft splines - lubricate
- Gearbox -
- Product used
⇒ page 8 agen
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16.2 Securing bolt of the 5th gear / synchronizing hub assembly - lock
- Gearboxes -
❑ 013 - 1.0 L
❑ 013 - 1.6 L, 1.8 L and 2.0
L
- Product used
⇒ page 6
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16. Repair Group 35 - Gears and shafts 89

17 Repair Group - 37 - Drive, housing
WARNING

17.1 Planetary gear box (automatic gearbox) - fill / top up oil level
- Gearboxes
- Product used
- ATF oil for automatic gearbox
⇒ page 15
♦ -G 052 162 A2- - 1.0 litre
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- Gearboxes - 09G
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18 Repair Group - 39 - Gearbox shafts,

differential
WARNING

18.1 Gearbox side seals - lubricate

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18. Repair Group - 39 - Gearbox shafts, differential 93

18.2 Planetary and satellite gears - lubricate for assembly
- Gearbox
- Product used
⇒ page 8
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pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
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Prote AG.

AG. Volkswagen AG d
agen oes
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V gu
d by ara
Fox 2004 ➤ , Goloris 1995 ➤ , Gol 1999 ➤ , Gol 2009 ➤ , Golf
e nte 1999 ➤ , Ko ...
h eo
aut Chemicals Manual - Edition ra
c
09.2018
ss
ce
e
nl
18.3 Automatic gearbox differential - top up oil level
pt
du
an
itte
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erm
ab
ility
ot p
- Gearboxes - 01M
wit
, is n
h re
- Product used
hole
spec
- Automatic gearbox differen‐
es, in part or in w
t to the co
tial oil SAE 75W90 ⇒ page 14
♦ -G 052 145 S2- - 1.0 litre
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
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cum
for
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t.
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Vo
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Prote AG.
18. Repair Group - 39 - Gearbox shafts, differential 95

18.4 Differential cover with gearbox housing - seal
- Gearboxes -
012 - 2.0 16v
013 - 1.0 L
013 - 1.6 L, 1.8 L and 2.0 L
081
- Authorized product
- Sealing adhesive ⇒ page 6
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.

19 Repair Group - 40 - Front suspension
WARNING

AG. Volkswagen AG d
agen oes
olksw not
19.1 Constant velocity joint spline - lubricate
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
tana
pt
an
d
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- Product used
erm
ab
ility
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wit
is n
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spec
t to the co
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cial p
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mer
atio
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n
c
i
or
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iva
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pr
cum
r
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en
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t.
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Cop py
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Vo
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by c lksw
cted agen
Prote AG.
19. Repair Group - 40 - Front suspension 97

19.2 Inner and outer constant velocity joint - lubricate

tana
- Product used
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
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ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
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l purpos
nf
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sd
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Vo
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Prote AG.

19.3 Front wheel bearing mounting - lubricate

tana
- Product used
⇒ page 15
AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
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ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
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m
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n in
or c
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
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Prote AG.

19.4 Axle end - lubricate
- Kombi
- Product used
⇒ page 8
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
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rm
ab
pe
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
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rig ht
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by lksw
cted agen
Prote AG.

olkswagen AG
en AG. V
19.4.1 Front wheel hub seal -y Vlubricate
olks
wag does
not
gu
b ara
ed nte
oris eo
th
- Kombi au ra
c
ss
ce
e
- Product used
nl
pt
du
an
itte
y li
erm
ab
⇒ page 8
ility
ot p
wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
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mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

19.4.2 King pin bearing - lubricate
- Kombi
- Product used
⇒ page 8
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
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nf
ercia
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m
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n in
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

19.4.3 Front axle beam - lubricate
- Kombi
- Product used
⇒ page 8
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
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n in
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thi
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sd
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cu
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f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

19.4.4 Suspension arms - lubricate
- Kombi
- Product used
⇒ page 8
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

19.4.5 Front wheel bearing - lubricate
- Kombi
- Product used
⇒ page 8
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

19.4.6 Passage hole for the speedometer cable in the wheel hub protector - seal
- Kombi
- Product used
- Sealing compound - MKD
106 007 40-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
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ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

20 Repair Group - 42 - Rear suspension
WARNING

lation at local, state and federal level. agen AG. Volkswagen AG do
w es n
olks ot g
Observe the information in Chapter by “Work Instructions for Han‐
V ua
ed ran
dling Chemicals” ⇒ page 18 horis tee
t or
au ac
ss
ce
le
20.1 Inner and outer constant velocity joint - lubricate

un
pt
an
d
itte
y li
erm
ab
ility
ot p
- Kombi
wit
is n
h re
- Product used
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
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sd
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pr
cum
r
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t.
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
20. Repair Group - 42 - Rear suspension 107

20.2 Shaft end splines - lubricate
- Kombi
- Product used
⇒ page 8
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

20.3 Rear torsion bar - lubricate
- Kombi
- Product used
⇒ page 8
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
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wit
is n
h re
ole,
spec
t to the co
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cial p
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mer
atio
om
n
c
i
or
n thi
te
sd
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o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

20.4 Rear wheel hub - lubricate

lkswage es n
Vo ot g
- Gol, Parati, Saveiro and San‐ ed
by ua
ran
tana thoris tee
or
au ac
- Product used ss
ce
le
un
pt
an
d
itte
⇒ page 8
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

20.5 Rear wheel hub seal - lubricate
- Kombi
- Product used
⇒ page 8
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
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thi
te
sd
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r
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cu
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m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

20.6 Rear wheel bearing - lubricate
- Kombi
- Product used
⇒ page 8
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
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nf
ercia
orm
m
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n in
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

21 Repair Group - 46 - Brakes - Mechan‐

ical systems
WARNING

21.1 Rear wheel

wage
brake
n AG. Volkswashoe
gen AG ends - lubricate
does
ks not
Vol gu
d by ara
e nte
ris
- Gol, Parati,
tho Saveiro, Santana eo
and Kombi
ss
au ra
c
ce
e
- Product used
nl
pt
du
an
itte
y li
- Complex grease ⇒ page 9
erm
ab
ility
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wit
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h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
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n in
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thi
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sd
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t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.
21. Repair Group - 46 - Brakes - Mechanical systems 113

21.2 Handbrake cable terminal - lubricate

tana
- Product used
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
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wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
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mer
atio
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n
c
i
or
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pr
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fo
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t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.

21.3 Brake pedal safety pin - lubricate

tana
- Product used
⇒ page 15
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
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nl
pt
du
an
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wit
, is n
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hole
spec
es, in part or in w
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nf
ercia
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m
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n in
or c
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t.
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Cop py
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115
copy Vo
by lksw
cted 21. Repair Group - 46 - Brakes - Mechanical systems
agen
Prote AG.
21.4 Securing pin for the operating rod of the master cylinder plunger - lubricate
- Kombi
- Product used
⇒ page 8
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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rp
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f
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ng
t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.

21.5 Securing pin of the handbrake lever - lubricate

AG. Volkswagen AG d
agen oes
olksw not
- Gol, Parati, Saveiro and San‐ d byV gu
ara
tana orise nte
eo
h
ut ra
- Product used ss a c
ce
le
un
pt
an
d
⇒ page 8 itte
y li
rm
ab
pe
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
21. Repair Group - 46 - Brakes - Mechanical systems 117

21.6 Handbrake ratchet - lubricate
- Kombi
- Product used
⇒ page 8
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

22 Repair Group - 47 - Brakes - Brake

servo hydraulic system
WARNING

22.1 Brake system - fill / top up
- All
- Product used
- Hydraulic brake fluid (DOT 4)
⇒ page 8
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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f
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ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
22. Repair Group - 47 - Brakes - Brake servo hydraulic system 119

22.2 Guide pin for the support of the front disc brake cylinder (manufactured by
Varga) - lubricate

tana
- Product used
- Grease for front wheel cylin‐
der support guide pin
⇒ page 9
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
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hole
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es, in part or in w
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nf
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orm
m
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n in
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t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
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Prote AG.

22.3 Fastening screw for the front disc brake cylinder housing - lock

tana with Vargas brake system
- Product used
sive
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
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mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
22. Repair Group - 47 - Brakes - Brake servo hydraulic system 121

23 Repair Group - 48 - Steering
WARNING

23.1 Power steering oil reservoir - Fill / top up oil level
- Santana (1), Gol (2), Parati,

Saveiro, Polo (3) and Fox (3)
(1)Chassis
numbers up to
SP055380, and from
2P006394 onwards
(2)Except
exports to Russia n AG. Volkswagen AG do
and Kazakhstan olks
wage es n
o V t gu
by ara
(3)Without ed
hydraulichopower
ris nte
eo
steering au
t ra
c
ss
ce
e
- Product used
nl
pt
du
an
itte
y li
- Power steering oil - 325 029

erm
ab
901 1- ⇒ page 14
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
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23.2 Oil reservoir for the power steering system - fill / top up oil level
- Santana (1), Gol (2) , Golf,

Passat, Polo Classic, Fox (3),
Polo (3) and Saveiro (4)
(1)From
chassis number
SP055381, to chassis number
2P006393.
(2)
Export to Russia and Ka‐
zakhstan.
(3)With electric power steering.
(4)As
from chassis number
24000001 (made in Curitiba).
- Product used
- Power steering oil - G 004
000 M2- ⇒ page 14
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23. Repair Group - 48 - Steering 123

23.3 Steering box - Fill / top up level
- Kombi
- Product used
- Steering box oil - SAE 90,
MIL-L-2105B, API-GL5
⇒ page 13
AG. Volkswagen AG d
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23.4 Steering box mechanism - lubricate

tana
- Product used
- Semi-fluid grease ⇒ page 8
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23. Repair Group - 48 - Steering 125

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Fox 2004 ➤ , Gol 1995 ➤ , Gol 1999 ➤ , Gol 2009 ➤ ,risGolf
ed b
1999 ➤ , Ko ... ara
nte
Chemicals Manual - Edition 09.2018 autho eo
ra
ss c
ce
e
23.5 Adapter (sleeve) for the upper steering shaft - lock
nl
pt
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24 Repair Group - 53 - Body - Rear sec‐

tion
WARNING

24.1 Bucket sealing membrane - glue
- Saveiro
- Product used
- Transferable adhesive tape
⇒ page 7
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24. Repair Group - 53 - Body - Rear section 127

24.2 Rear side panel - protect the paint
- Saveiro
- Product used
- Polyurethane adhesive tape
⇒ page 7
❑ 1 - Polyurethane adhe‐
sive tape
AG. Volkswagen AG d
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25 Repair Group - 55 - Covers
WARNING

25.1 Bucket protective cover longitudinal member - glue the finishing
- Saveiro
- Product used
ing ⇒ page 5
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25. Repair Group - 55 - Covers 129

25.2 Lower latch of the bonnet - lubricate
- All (except Kombi)

- Product used
⇒ page 8
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25.3 Damper eyelet for the rear cover - lubricate
- All
- Product used
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25. Repair Group - 55 - Covers 131

26 Repair Group - 57 - Front doors /

components / central lock
WARNING

lation at local, state and federal level. wagen AG. Volkswagen AG doe
ks s no
Vol t gu
Observe the information in Chapterd b “Work Instructions for Han‐
y ara
se
dling Chemicals” ⇒ page 18 thori nte
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un
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26.1 Front door lock - lubricate
an
d
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pe
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tana
h re
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spec
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es, in part or in w
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⇒ page 8
rrectness of i
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te o
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Fox 2004 ➤ , Gol 1995 ➤ , Gol 1999lk➤
swa, Gol 2009 ➤ , Golf d1999
gen AG o
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db
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ua
ra e nte
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26.2 Lock drive rod - lubricate ss
au ra
c
ce
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un
pt
an
d
itte
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y li
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ab
pe
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ot
wit
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hole
⇒ page 8
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
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26. Repair Group - 57 - Front doors / components / central lock 133

26.3 Noise insulation for lock operating rod - glue
- All (except vehicles with cable

operation)
- Product used
ing ⇒ page 5
AG. Volkswagen AG d
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26.4 Inner door seal - glue
- Kombi
- Product used
ing ⇒ page 5
AG. Volkswagen AG d
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26. Repair Group - 57 - Front doors / components / central lock 135

27 Repair Group - 58 - Rear doors / com‐

ponents
WARNING

27.1 Rear door lock - lubricate

tana
- Product used
⇒ page 8
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wage ➤ , Gol 1999 ➤ d,oGol
n AG n AG
es n 2009 ➤ , Golf 1999 ➤ , Ko ...
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r
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27.2 Side door lock
ss - lubricate
au ac
ce
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an
d
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pe
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⇒ page 8
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27. Repair Group - 58 - Rear doors / components 137

28 Repair Group - 64 - Windscreens,

windows, window mechanism
WARNING

28.1 Door window activation mechanism - lubricate

tana
- Product used
⇒ page 8
AG. Volkswagen AG d
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28.2 Vent window latch - lubricate
- Kombi
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⇒ page 8
AG. Volkswagen AG d
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28. Repair Group - 64 - Windscreens, windows, window mechanism 139

28.3 Front door window support - lubricate
- Kombi
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⇒ page 8
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byFox
V 2004 ➤ , Gol 1995 ➤ , Golot1999
ol
gu
ara
➤ , Gol 2009 ➤ , Golf 1999 ➤ , Ko ...
d
rise nteChemicals Manual - Edition 09.2018
tho eo
s au ra
c
28.4 Front door window activation mechanism - lubricate
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
- Kombi
ility
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wit
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hole
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⇒ page 8
es, in part or in w
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rrectness of i
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Fox 2004 ➤ , Gol 1995 ➤au,thGol 1999 ➤ , Gol 2009 ➤ , Golf 1999 ➤ , Ko ... ra
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s 09.2018
ce
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28.5 Window crank fastening screw - lock
itte
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- All (fastened with screw)
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28.6 Windscreen, side window glass and rear window glass - glue
- All (except windows with

packing)
- Product used
- Glass adhesion kit
❑ Total drying time:
U-400 HVBN Adhesive: partial
3 h , total 72 h / 5500SA Pri‐
mer: 15 min
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Prote AG.
28. Repair Group - 64 - Windscreens, windows, window mechanism
28.7 Windscreen, side window glass and rear window glass - seal
- All (except glued windows)

swage es n
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olk ot g
ua
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⇒ page 11 au ac
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d by ara
ise nte
r
ut
ho Fox 2004 ➤ , Gol 1995 ➤ , Gol 1999 eo
ra ➤ , Gol 2009 ➤ , Golf 1999 ➤ , Ko ...
a
ss c Chemicals Manual - Edition 09.2018
ce
le
un
pt
an
28.8 d Glass - engrave chassis number
itte
y li
rm
ab
pe
ility
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- All
, is n
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hole
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es, in part or in w
- Corrosive paste ⇒ page 16
t to the co
❑ The destructible labels -
VIS are only supplied
rrectness of i
exclusively to the gov‐
ernmental traffic-related
l purpos
bodies (Detrans / Cire‐

trans) or Security bodies
(Police Station). On the
nform
ercia
network portal, under

m
“After sales”, “Sist.
a
com
tio
Service info.” in Circular
n in
r
no. 98/09 of 16/06/2009

te o
thi
“Engraving of the vehi‐
s
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cle identification num‐

rp
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ber (VIS) on the win‐
en
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28.9 Front and rear door window guide groove - glue

Volkswa AG. gen AG
agen does
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db ara
nte
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ing ⇒ page 5
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28.10 Vent window - seal
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⇒ page 11
❑ -7X0 989 539- lkswage es n
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29 Repair Group - 66 - External equip‐

ment
AG. Volkswagen AG d
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WARNING olksw not
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Check the regulationsauton the disposal of each product and
ho eo
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itte
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29.1 Roof rack fastening screws - lock
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t to the co
- Santana, Quantum and Par‐
ati
rrectne
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⇒ page 6
cial p
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30 Repair Group - 68 - Internal equip‐

ment
WARNING

. Volkswag
Observe the informationksw
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agChapter
en AG “Work Instructions
en AG
does for Han‐
dling Chemicals” ⇒
by page
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30.1 ss
Interior rearview mirror support - fasten
ce
e
nl
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an
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30. Repair Group - 68 - Internal equipment 149

31 Repair Group - 70 - Lining/insulation
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31. Repair Group - 70 - Lining/insulation 151

31.3 Roof noise insulation - glue
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31. Repair Group - 70 - Lining/insulation 153

32 Repair Group - 72 - Seat framework
WARNING

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32. Repair Group - 72 - Seat framework 155

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33. Repair Group - 87 - Air conditioning 157

33.3 Air conditioning pressure switch - seal

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34 Repair Group - 92 - Windscreen, rear
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34. Repair Group - 92 - Windscreen, rear window and headlight wiper and washer 159
35 Repair Group - 94 - Switches, lights,

and external bulbs
WARNING

35.1 Contact blade for turn signal switch
- All
- Grease for electrical contacts
⇒ page 9
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36 Repair Group - 97 - Cables and elec‐

trical harnesses
WARNING

36.1 Gaskets for the plastic covers that cover the electric harnesses - seal
- All
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kets
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36. Repair Group - 97 - Cables and electrical harnesses 161

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Service olksw

Gol 2009 ➤ , Golf 1999 ➤ ,

Parati 2006 ➤ , Polo 2003 ➤ ,

Polo 2007 ➤ , Polo Sedan 2003 ➤ ,

Polo Sedan 2007 ➤ , Santana 1991 ➤ ,

Saveiro 2000 ➤ , Saveiro 2006 ➤ ,

SpaceFox 2006 ➤ , Voyage 2009 ➤

Service Department. Technical Information

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Copyright © 2018 Volkswagen AG, Wolfsburg D4B807D9862

2.13 Esso Brasileira de Petróleo Ltda. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2.14 Formiquímica Com. e Repres. de Produtos Químicos Ltda . . . . . . . . . . . . . . . . . . . . . . . . 2

2.16 Henkel do Brasil Ltda. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2.17 Klüber Lubrification Lubrificantes Especiais Ltda. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

3.15 Sealing adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3.43 Grease for electrical contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.44 Polyurea grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.45 High temperature grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.46 Temperature resistant grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.47 Lubricating grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.48 Silicone based grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.49 Windscreen adhesive set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.50 Lithium-based lubricant paste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.52 Adhesive material for glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.54 Mouldable paste for caulking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.56 Lubricating paste for constant velocity joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.57 Sealing compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.58 Sealing compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.59 Sealing paste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.60 Sealing compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.61 Sealing compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.75 Lubricating oil for manual gearbox - SAE 75W90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3.76 Lubricating oil for manual gearbox - SAE 75W90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3.77 Lubricating oil for power steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3.78 Lubricating oil for automatic gearbox and power steering . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3.84 White lubricating grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3.86 Molybdenum bisulphate lubricating grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3.89 High temperature paste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3.91 Glass primer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.96 Cleaning solution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

9 Repair Group 17 - Lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

14.10 Clutch actuating lever - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

14.11 Input shaft splines - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

14.13 Pedal support - seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

14.15 Fastening flange for clutch slave cylinder - seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

15 Repair Group - 34 - Drive, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

15.2 Gear lever bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

15.4 Manual gearbox - Fill / top up level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

15.5 Manual Gearbox - fill / top up level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

15.6 Manual gearbox - Fill / top up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

15.7 Manual Gearbox - fill / top up level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

15.9 Gear lever guide plate - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

15.10 Rubber shim for the clutch compartment cover - glue . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

17 Repair Group - 37 - Drive, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

20.2 Shaft end splines - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

20.3 Rear torsion bar - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

21.2 Handbrake cable terminal - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

22 Repair Group - 47 - Brakes - Brake servo hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . 119

22.1 Brake system - fill / top up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

28 Repair Group - 64 - Windscreens, windows, window mechanism . . . . . . . . . . . . . . . . . . . . 138

29 Repair Group - 66 - External equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

30.1 Interior rearview mirror support - fasten . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

32.1 Front seat central sliding guide - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154