Volkswagen Polo-Mk4 Workshop Manual (Polo Mk4)

Factory Workshop Manual
Make
Volkswagen
Model
Polo-mk4
Engine and year
Polo Mk4
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This manual was submitted by

Anonymous
Date
1st January 2018
Volkswagen Polo-mk4 Workshop Manual (Polo Mk4)
Volkswagen Workshop Manuals > Brake systems > Technical data > Technical data > Correspondence of PR numbers for
the brake > Example of a vehicle identification tag
Volkswagen Workshop Manuals > Brake systems > Technical data > Technical data > Brake technical data > Front wheel
brake FS II
brake FS III
brake C54-FN 3
Volkswagen Workshop Manuals > Brake systems > Technical data > Technical data > Brake technical data > Rear wheel
disc brake
drum brake without ABS
drum brake with ABS
Volkswagen Workshop Manuals > Brake systems > ABS, ADR, TCS, EDL, ESP > General information on the antilock
braking system (ABS) > ABS MK 60
braking system (ABS) > ABS Bosch 5.7
braking system (ABS) > Bosch 8.0 as of Year/Model 2005
Volkswagen Workshop Manuals > Brake systems > ABS, ADR, TCS, EDL, ESP > Electrical/electronic components and
installing locations > ABS MK 60 (ABS, ABS/EDS/ASR)
installing locations > ABS Bosch 5.7 (ABS/EDS/ASR/ESP)
installing locations > ABS Bosch 8.0 (ABS, ABS/ASR)
installing locations > ABS Bosch 8.0 (ABS/EDS/ASR/ESP)
Volkswagen Workshop Manuals > Brake systems > ABS, ADR, TCS, EDL, ESP > Fault indication via control lamps
Volkswagen Workshop Manuals > Brake systems > ABS, ADR, TCS, EDL, ESP > Hydraulic unit, servo brake/brake cylinder
- assembly overview > ABS MK 60 > Connect the brake pipes and the brake cylinder pipes to the hydraulic unit
- assembly overview > ABS MK 60 > Command unit and hydraulic unit - remove and install
- assembly overview > ABS Bosch 5.7 > Connect the brake pipes and the brake cylinder pipes to the hydraulic unit
- assembly overview > ABS Bosch 5.7 > Command unit for hydraulic unit - remove and install
- assembly overview > ABS Bosch 5.7 > Remove the hydraulic unit command device
- assembly overview > ABS Bosch 5.7 > Install the command device to the hydraulic unit
- assembly overview > ABS Bosch 5.7 > Brake pressure sensor 1 G201
- assembly overview > ABS Bosch 8.0 > Connect the brake pipes and the brake cylinder pipes to the hydraulic unit
- assembly overview > ABS Bosch 8.0 > Command unit for hydraulic unit - remove and install
Volkswagen Workshop Manuals > Brake systems > ABS, ADR, TCS, EDL, ESP > ABS system components on the front
and rear axles - remove and install > Remove and install the front axle ABS system components
and rear axles - remove and install > Remove and install the front axle ABS system components > Front axle speed sensor
- remove and install
and rear axles - remove and install > Remove and install the front axle ABS system components > MK 60 front speed
sensor cables - remove and install
and rear axles - remove and install > Remove and install the front axle ABS system components > Bosch 5.7 front speed
and rear axles - remove and install > Remove and install the front axle ABS system components > Bosch 8.0 front speed
and rear axles - remove and install > ABS system components on rear axle (vehicles with drum brakes) - remove and install
> Speed sensor on rear axle (drum brake) - remove and install
and rear axles - remove and install > ABS system components on rear axle (vehicles with drum brakes) - remove and install
> Rear speed sensor cables - remove and install
and rear axles - remove and install > ABS system components on rear axle (vehicles with disc brakes) - remove and install
> Speed sensor on rear axle - remove and install
and rear axles - remove and install > ABS system components on rear axle (vehicles with disc brakes) - remove and install
> Rear speed sensor cables - remove and install
Volkswagen Workshop Manuals > Brake systems > Brake, brake mechanics > Front wheel brake - repair > Repair front
brakes, FS II disc brake cylinder
Volkswagen Workshop Manuals > Brake systems > Brake, brake mechanics > Front wheel brake - repair > Brake pads, FS
II brake caliper - remove and install
II brake caliper - remove and install > Remove
II brake caliper - remove and install > Install
Volkswagen Workshop Manuals > Brake systems > Brake, brake mechanics > Front wheel brake - repair > FS II brake
caliper - remove and install
Volkswagen Workshop Manuals > Brake systems > Brake, brake mechanics > Front wheel brake - repair > FS II brake
caliper - remove and install > Install
III disc brake cylinder - remove and install
III disc brake cylinder - remove and install > Remove
III disc brake cylinder - remove and install > Install
Volkswagen Workshop Manuals > Brake systems > Brake, brake mechanics > Front wheel brake - repair > FS III brake
Volkswagen Workshop Manuals > Brake systems > Brake, brake mechanics > Front wheel brake - repair > Remove and
install brake pads, C 54-ll disc brake cylinder
install brake pads, C 54-ll disc brake cylinder > Remove
install brake pads, C 54-ll disc brake cylinder > Install
Volkswagen Workshop Manuals > Brake systems > Brake, brake mechanics > Front wheel brake - repair > C 54 II brake
Volkswagen Workshop Manuals > Brake systems > Brake, brake mechanics > Front wheel brake - repair > Brake disc with
visual check - check > ?Vehicles with light-alloy wheel
Volkswagen Workshop Manuals > Brake systems > Brake, brake mechanics > Rear wheel drum brake - repair > Rear
wheel brake - remove and install
Volkswagen Workshop Manuals > Brake systems > Brake, brake mechanics > Rear wheel drum brake - repair > Reposition
the brake
Volkswagen Workshop Manuals > Brake systems > Brake, brake mechanics > Rear wheel drum brake - repair > Brake
drum - repair
shoes - remove and install
shoes - remove and install > Remove
shoes - remove and install > Install
Volkswagen Workshop Manuals > Brake systems > Brake, brake mechanics > Rear wheel disc brake - repair
Volkswagen Workshop Manuals > Brake systems > Brake, brake mechanics > Rear wheel disc brake - repair > Brake pads
- remove and install
Volkswagen Workshop Manuals > Brake systems > Brake, brake mechanics > Rear wheel disc brake - repair > Brake pads
- remove and install > Remove
Volkswagen Workshop Manuals > Brake systems > Brake, brake mechanics > Rear wheel disc brake - repair > Brake
Volkswagen Workshop Manuals > Brake systems > Brake, brake mechanics > Handbrake - assembly overview
Volkswagen Workshop Manuals > Brake systems > Brake, brake mechanics > Handbrake - assembly overview >
Handbrake cable (drum brake) - remove and install > Remove
Handbrake cable (drum brake) - remove and install > Install
Handbrake cable (disc brake) - remove and install > Remove
Handbrake cable (disc brake) - remove and install > Install
Volkswagen Workshop Manuals > Brake systems > Brake, brake mechanics > Brake pedal - assembly overview > Servo
brake pedal - separate
Volkswagen Workshop Manuals > Brake systems > Brake, brake mechanics > Brake pedal - assembly overview > Servo
brake pedal - separate > Fasten the brake pedal to the servo brake.
Volkswagen Workshop Manuals > Brake systems > Brake, brake mechanics > Brake pedal - assembly overview > Pedal
set - remove and install > Remove
Volkswagen Workshop Manuals > Brake systems > Brake, brake mechanics > Brake pedal - assembly overview > Brake
pedal - remove and install > Remove
Volkswagen Workshop Manuals > Brake systems > Brake, brake mechanics > Brake pedal - assembly overview > Brake
pedal - remove and install > Install
Volkswagen Workshop Manuals > Brake systems > Brakes, hydraulics, regulator, servo > Front brake caliper, FS II brake
caliper - repair
caliper - repair > Front brake caliper plunger - remove and install
caliper - repair > Front brake caliper plunger - remove and install > Remove
caliper - repair > Front brake caliper plunger - remove and install > Install
Volkswagen Workshop Manuals > Brake systems > Brakes, hydraulics, regulator, servo > Front brake caliper, C54-ll brake
caliper - repair
caliper - repair > Front brake caliper plunger - remove and install
caliper - repair > Front brake caliper plunger - remove and install > Remove
caliper - repair > Front brake caliper plunger - remove and install > Install
Volkswagen Workshop Manuals > Brake systems > Brakes, hydraulics, regulator, servo > Rear brake caliper - repair >
Plunger for rear brake caliper - remove and install
Plunger for rear brake caliper - remove and install > Remove
Plunger for rear brake caliper - remove and install > Install
Plunger for rear brake caliper - remove and install > Bleed the brake caliper in advance
Tightness check
Volkswagen Workshop Manuals > Brake systems > Brakes, hydraulics, regulator, servo > Braking power adjustment -
assembly overview
Volkswagen Workshop Manuals > Brake systems > Brakes, hydraulics, regulator, servo > Bleed the brake system > Bleed
the brake system with the filling and bleeding equipment
Volkswagen Workshop Manuals > Brake systems > Brakes, hydraulics, regulator, servo > Bleed the brake system > Brake
system, only vehicles with ABS/EDS/ASR - bleed when the reservoir has been emptied
Volkswagen Workshop Manuals > Brake systems > Brakes, hydraulics, regulator, servo > Assembly overview: Brake
cylinder/servo brake > Servo brake vacuum pump (diesel vehicles) - remove and install > Vacuum pump for 4-cylinders
diesel engines and with distribution injector pump
cylinder/servo brake > Servo brake vacuum pump (diesel vehicles) - remove and install > Vacuum pump for 3-cylinder
diesel engines
cylinder/servo brake > Servo brake vacuum pump (diesel vehicles) - remove and install > Vacuum pump for 4-cylinder
diesel engines with injector pump unit
cylinder/servo brake > Inspect the check valve
Volkswagen Workshop Manuals > Brake systems > Brakes, hydraulics, regulator, servo > Brake cylinder - remove and
install > Vehicles with ABS
Volkswagen Workshop Manuals > Brake systems > Brakes, hydraulics, regulator, servo > Brake cylinder - remove and
install > Vehicles with ABS > Install
Volkswagen Workshop Manuals > Brake systems > Brakes, hydraulics, regulator, servo > Servo brake - remove and install
> Remove
> Install
Volkswagen Workshop Manuals > Running gear, axles, steering > Front suspension, drive shafts > Front suspension -
repair > Raise the front axle under unloaded conditions
Volkswagen Workshop Manuals > Running gear, axles, steering > Front suspension, drive shafts > I - Auxiliary frame
(sub-frame) , anti-roll bar, wishbones - repair > Swivel guide - check
(sub-frame) , anti-roll bar, wishbones - repair > Swivel guide - remove and install
(sub-frame) , anti-roll bar, wishbones - repair > Swivel guide - remove and install > Removal
(sub-frame) , anti-roll bar, wishbones - repair > Swivel guides - installation position
(sub-frame) , anti-roll bar, wishbones - repair > Wishbone (transversal) - remove and install
(sub-frame) , anti-roll bar, wishbones - repair > Auxiliary frame console - remove and install > Removal
(sub-frame) , anti-roll bar, wishbones - repair > Rubber support bearing for the console - replace
(sub-frame) , anti-roll bar, wishbones - repair > Rubber support bearing for the console - replace > Remove the rubber
support bearing - (versions 1 and 2)
(sub-frame) , anti-roll bar, wishbones - repair > Auxiliary frame (sub-frame) - remove and install
(sub-frame) , anti-roll bar, wishbones - repair > Auxiliary frame (sub-frame) - remove and install > Removal
(sub-frame) , anti-roll bar, wishbones - repair > Auxiliary frame (sub-frame) - position
(sub-frame) , anti-roll bar, wishbones - repair > Auxiliary frame (sub-frame) - position > Removal
(sub-frame) , anti-roll bar, wishbones - repair > Sway bar - remove and install
(sub-frame) , anti-roll bar, wishbones - repair > Sway bar - remove and install > Removal
Volkswagen Workshop Manuals > Running gear, axles, steering > Front suspension, drive shafts > II - Wheel roller bearings
- repair > Wheel roller bearing for vehicles without ABS - remove and install
- repair > Wheel roller bearing for vehicles without ABS - remove and install > Remove the wheel roller bearing hub
- repair > Wheel roller bearing for vehicles without ABS - remove and install > Installation
- repair > Front wheel hub with wheel bearing for 13" running gear - remove and install
- repair > Front wheel hub with wheel bearing for 13" running gear - remove and install > Hub with wheel bearing - remove
- repair > Front wheel hub with wheel bearing for 13" running gear - remove and install > Wheel hub with wheel bearing -
install
- repair > Front wheel hub with wheel roller bearing for 14" and 15" running gears - remove and install
- repair > Front wheel hub with wheel roller bearing for 14" and 15" running gears - remove and install > Hub with wheel
bearing - remove
- repair > Front wheel hub with wheel roller bearing for 14" and 15" running gears - remove and install > Wheel hub with
wheel bearing - install
Volkswagen Workshop Manuals > Running gear, axles, steering > Front suspension, drive shafts > III - Front suspension
column - repair > Vehicle identification tag
column - repair > Suspension column - remove and install
column - repair > Front suspension spring - repair
column - repair > Front suspension spring - repair > Coil spring - install
Volkswagen Workshop Manuals > Running gear, axles, steering > Front suspension, drive shafts > Constant velocity drive
semi-shaft - remove and install > Fastening nut (dodecagonal) of the drive semi-shaft - loosen and tighten
Volkswagen Workshop Manuals > Running gear, axles, steering > Front suspension, drive shafts > IV - Constant velocity
drive semi-shaft - repair > Articulated shaft with constant velocity joint - general overview of assembly
Volkswagen Workshop Manuals > Running gear, axles, steering > Front suspension, drive shafts > IV - Constant velocity
drive semi-shaft - repair > Constant velocity drive semi-shaft - repair .
Volkswagen Workshop Manuals > Running gear, axles, steering > Rear suspension, drive shaft > Rear suspension -
repairing > Lift the rear axle in the unloaded position
repairing > Rear axle - remove and install
repairing > Rear axle - remove and install > Removal
repairing > Metal-rubber bearing - remove and install
repairing > Metal-rubber bearing - remove and install > Removal
repairing > Metal-rubber bearing - remove and install > Installation
repairing > Spring - remove and install
repairing > Spring - remove and install > Removal
repairing > Spring - remove and install > Installation
repairing > Shock absorbers - assembly overview
repairing > Shock absorber - remove and install
repairing > Shock absorber - remove and install > Removal
repairing > Shock absorber - remove and install > Installation
Volkswagen Workshop Manuals > Running gear, axles, steering > Rear suspension, drive shaft > Wheel bearings for drum
brakes - repair > Wheel roller bearings (drum brakes) - assembly overview
brakes - repair > Wheel roller bearing/wheel hub set in vehicles with brake drums - remove and install
brakes - repair > Wheel roller bearing/wheel hub set in vehicles with brake drums - remove and install > Removal
Volkswagen Workshop Manuals > Running gear, axles, steering > Wheels, tyres. axle align > Vehicle alignment >
Preparation for measurement
Volkswagen Workshop Manuals > Running gear, axles, steering > Wheels, tyres. axle align > Vehicle alignment > Vehicle
identification tag
Volkswagen Workshop Manuals > Running gear, axles, steering > Wheels, tyres. axle align > Vehicle alignment > Left and
right-hand steering - check
Volkswagen Workshop Manuals > Running gear, axles, steering > Steering > Steering wheel > Horn buttonH - remove and
install
Volkswagen Workshop Manuals > Running gear, axles, steering > Steering > Steering wheel > Steering wheel - general
assembly overview
Volkswagen Workshop Manuals > Running gear, axles, steering > Steering > Steering wheel > Steering wheel - remove
and install
Volkswagen Workshop Manuals > Running gear, axles, steering > Steering > Steering wheel > Steering wheel - remove
and install > Removal
Volkswagen Workshop Manuals > Running gear, axles, steering > Steering > Fixed steering column - repair > Fixed
steering wheel support and column - assembly overview
Volkswagen Workshop Manuals > Running gear, axles, steering > Steering > Fixed steering column - repair > Fixed
steering column - remove and install
Volkswagen Workshop Manuals > Running gear, axles, steering > Steering > Adjustable steering column - repair >
Adjustable steering wheel support and column - assembly overview
Volkswagen Workshop Manuals > Running gear, axles, steering > Steering > Adjustable steering column - repair >
Adjustable steering column - remove and install
Volkswagen Workshop Manuals > Running gear, axles, steering > Steering > Adjustable steering column - repair > Steering
column - check
Volkswagen Workshop Manuals > Running gear, axles, steering > Steering > Power steering box - repair > Power steering
box - remove and install
box - disassemble and assemble > Steering linkage bar - remove and install
box - disassemble and assemble > Folding bellows - assembly
box - disassemble and assemble > Correspondence of steering yoke terminals
box - disassemble and assemble > Central rack position - determine
Volkswagen Workshop Manuals > Running gear, axles, steering > Steering > Hydraulic pump, compensation reservoir,
hydraulic pipes (power steering) > Hydraulic pump with hydraulic tubes - assembly overview > Compensation reservoir -
assembly overview
hydraulic pipes (power steering) > Hydraulic pump with hydraulic tubes - assembly overview > Pressure tubes and fastening
the flexible aspiration tube on vehicles with air-conditioning
hydraulic pipes (power steering) > Hydraulic pump with hydraulic tubes - assembly overview > Pressure tubes and fastening
the flexible aspiration tube on vehicles without air-conditioning
hydraulic pipes (power steering) > Hydraulic pump installed on the lower part - assembly overview
hydraulic pipes (power steering) > Hydraulic pump installed on the lower part - remove and install > Removal
hydraulic pipes (power steering) > Hydraulic pump installed on the lower part - remove and install > Installation
hydraulic pipes (power steering) > Hydraulic pump installed on the upper part - assembly overview
hydraulic pipes (power steering) > Hydraulic pump installed on the upper part - remove and install > Removal
hydraulic pipes (power steering) > Hydraulic pump installed on the upper part - remove and install > Installation
hydraulic pipes (power steering) > Hydraulic pump operating pressure - check
hydraulic pipes (power steering) > Hydraulic pump operating pressure - check > Vehicles with hydraulic pump installed on
the lower part
hydraulic pipes (power steering) > Hydraulic pump operating pressure - check > Vehicles with hydraulic pump installed on
the upper part
hydraulic pipes (power steering) > Hydraulic pump operating pressure - check > Control equipment for power steeringVAG
1402 - connect
Volkswagen Workshop Manuals > Running gear, axles, steering > Steering > Electrohydraulic steering - repair >
Electrohydraulic steering box - remove and install
Electrohydraulic steering boxG250 - remove and install
Electrohydraulic steering boxG250 - remove and install > Removal
Electrohydraulic steering boxG250 - remove and install > Installation
Electrohydraulic steering box (JTEKT) - disassemble and assemble
Electrohydraulic steering box (TRW) - disassemble and assemble
Volkswagen Workshop Manuals > Running gear, axles, steering > Steering > Electrohydraulic steering - repair > Steering
bar - remove and install
Volkswagen Workshop Manuals > Running gear, axles, steering > Steering > Electrohydraulic steering - repair > Left
steering bar length - check and adjust
Volkswagen Workshop Manuals > Running gear, axles, steering > Steering > Electrohydraulic steering - repair > Left
steering bar length - check and adjust > Check
Correspondence of the steering yoke terminals
Volkswagen Workshop Manuals > Running gear, axles, steering > Steering > Electrohydraulic steering - repair > Central
rack position - determine
Volkswagen Workshop Manuals > Running gear, axles, steering > Steering > Motor/pump set (Electrohydraulic steering) -
repair > Motor/pump set; (TRW manufacturer) - assembly overview
repair > Motor/pump set - remove and install
repair > Motor/pump set - remove and install > Removal
repair > Motor/pump set pressure (JTEKT / TRW) - check
repair > Electrohydraulic steering oil level - check
Volkswagen Workshop Manuals > Wheels, rim and tyre specifications > Technical data > General notes on rims and tyres
(vehicles and passengers) > General Remarks > Wheel specifications
Volkswagen Workshop Manuals > Wheels, rim and tyre specifications > Technical data > Curiosities about rims and tires
(passenger vehicles) > Wear/tyre mileage > Unilateral wear
(passenger vehicles) > Wear/tyre mileage > Diagonal abrasion
(passenger vehicles) > Rolling noises coming from the tyres > Wear occurrence in the shape of saw
(passenger vehicles) > Rolling noises coming from the tyres > Blockage points
(passenger vehicles) > The vehicle deviates to one side > Conicity
(passenger vehicles) > Damages on the tyres > Structure of a radial tyre
(passenger vehicles) > Damages on the tyres > Damages caused by crashes
(passenger vehicles) > Damages on the tyres > Damages due to cut.
(passenger vehicles) > Damages on the tyres > Damages to the tyres due to insufficient air pressure
(passenger vehicles) > Damages on the tyres > Rise of temperature in tyres with insufficient air pressure
(passenger vehicles) > Useful notes related to tyres and wheels > Inscriptions on the side wall of the tyre
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Body front > Front panel > Tools > Special tools,
workshop equipment, test and measurement devices, as well as auxiliary means necessary
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Body front > Front panel > Front panel (? 2006) -
Assembly overview
work position
remove and install > Install
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Body front > Front panel > Front panel (2007 ?) -
assembly overview
work position
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Body front > Wing > Wing - remove and install >
Remove
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Body front > Wing > Wing - remove and install >
Install
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Body front > Wing > Cover - remove and install >
Remove
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Body front > Wing > Wing dimensions (? 2006) -
vehicles
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Body front > Wing > Wing dimensions (2007 ?) -
vehicles
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Body front > Lower noise insulation in the engine
compartment > Lower noise insulation in the engine compartment (petrol / Totalflex engine) - assembly overview
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Body front > Lower noise insulation in the engine
compartment > Lower noise insulation in the engine compartment (diesel engine) - assembly overview
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Body front > Engine compartment partition panel
> Tools
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Bonnet >
Tools
Bonnet - remove and install > Remove
Bonnet - remove and install > Install
Front bonnet supporting rod (2007 ?) - remove and install > Remove
Bonnet - adjust
Front bonnet latch operating cable - remove and install > Assembly overview
Front bonnet latch operating cable - remove and install > Remove
Operating lever - remove and install > Remove
Operating lever - remove and install > Install
Front bonnet latch - Assembly overview
Front bonnet latch - remove and install > Remove
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Rear door -
Hatch > Tools > Special tools, workshop equipment, test and measurement devices and auxiliary devices necessary
Hatch > Assembly overview
Hatch > Rear door lock - remove and install > Vehicles without central locking
Hatch > Rear door lock - remove and install > Vehicles with central locking
Hatch > Rear door latch cylinder - assembly overview
Hatch > Rear door latch cylinder - disassemble and assemble > Disassemble
Hatch > Rear door lock cylinder (central locking) - assembly overview
Sedan
Sedan > Rear door - Assembly overview
Sedan > Cylinder housing of the lock with symbol (without central locking) - remove and install
Sedan > Rear door lock (without central locking) - remove and install
Sedan > Rear door lock (with central locking) - remove and install
Sedan > Cylinder housing of the lock with symbol (with central locking) - remove and install
Sedan > Rear door latch activation handle - assembly overview
Sedan > Rear door latch activation handle (without central locking) - remove and install
Sedan > Rear door latch activation handle (with central locking) - remove and install
Sedan > Rear door latch cylinder - assembly overview
Sedan > Rear door latch cylinder - disassemble and assemble > Disassemble
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Fuel
reservoir nozzle compartment and lid set > Fuel reservoir nozzle compartment and lid set (hatch) - remove and install
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Bonnet, flaps, cab, central locking > Fuel
reservoir nozzle compartment and lid set > Fuel reservoir nozzle compartment and lid set (sedan) - remove and install
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Front door, central locking > Front door > Tools
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Front door, central locking > Front door > Door -
remove and install
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Front door, central locking > Front door > Front
door lock operating cable - remove and install > Remove
door lock operating cable - remove and install > Install
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Front door, central locking > Front door >
External door handle and lock - assembly overview
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Front door, central locking > Front door > Latch
cylinder - remove and install > Remove
External door handle - remove and install > Remove
External door handle - remove and install > Install
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Front door, central locking > Front door > Lock -
remove and install > Remove
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Front door, central locking > Front door > Lock -
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Front door, central locking > Front door > Lock
button (locking rod) - remove and install > Remove
door packings - assembly overview
Internal front door packing - remove and install > Remove
External front door packing - remove and install
External front door packing - remove and install > Remove
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Front door, central locking > Central locking >
Central locking - assembly overview
Central locking (sedan) - assembly overview
Convenience system command - remove and install
Key battery with remote command via radio (articulated) - remove and install
Key battery with remote command via radio (articulated) - remove and install > Remove
Key battery with remote command via radio (articulated) - remove and install > Install
Key - synchronize
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Rear door,sliding door,wing doors,central locking
> Rear door > Tools
> Rear door > Rear passenger door lock operating cable - remove and install > Remove
> Rear door > Rear passenger door lock operating cable - remove and install > Install
> Rear door > External door handle and lock - assembly overview
> Rear door > External door handle - remove and install > Install
> Rear door > Door latch - remove and install > Install
> Rear door > Rear door packings - assembly overview
> Rear door > Internal rear door packing - remove and install > Remove
> Rear door > External rear door packing - remove and install
> Rear door > External rear door packing - remove and install > Remove
> Rear door > External rear door packing - remove and install > Install
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Sliding roof > Sliding / tilting sunroof > Operation
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Sliding roof > Sliding / tilting sunroof > Sliding /
tilting roof with glass pane - assembly overview
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Sliding roof > Sliding / tilting sunroof > Sliding /
tilting sunroof glass pane - remove and install > Removal
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Sliding roof > Sliding / tilting sunroof > Glass
pane for sliding / tilting sunroof - height adjustment
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Sliding roof > Sliding / tilting sunroof > Cover
packing - adjust
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Sliding roof > Sliding / tilting sunroof > Cover
packing - replace
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Sliding roof > Sliding / tilting sunroof > Air
deflector - remove
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Sliding roof > Sliding / tilting sunroof > Sun
protective coating - remove and install > Removal
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Sliding roof > Sliding / tilting sunroof > Sun
protective coating - remove and install > Installation
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Sliding roof > Sliding / tilting sunroof > Sunroof
sliding adjustment E139 - remove
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Sliding roof > Sliding / tilting sunroof > Draining
hoses - clean > Front water draining hoses
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Sliding roof > Sliding / tilting sunroof > Draining
hoses - clean > Rear water draining hoses
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Bumper > Front bumper > Tools
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Bumper > Front bumper > Front protector (?
06.06) - assembly overview
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Bumper > Front bumper > Front protector (?
2006) - remove and install
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Bumper > Front bumper > Protector support (?
2006) - assembly overview
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Bumper > Front bumper > Front protector (2007
?) - assembly overview
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Bumper > Front bumper > Front protector (2007
?) - remove and install > Remove
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Bumper > Front bumper > Front protector
additional components (2007 ?)
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Bumper > Front bumper > Front protector
support (2007 ?) - assembly overview
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Bumper > Front bumper > Front bumper spoiler -
Blue Motion - remove and install
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Bumper > Rear bumper - hatch > Tools
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Bumper > Rear bumper - hatch > Rear protector
- assembly overview
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Bumper > Rear bumper - hatch > Rear protector
- remove and install > Remove
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Bumper > Rear bumper - hatch > Protector
support - assembly overview
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Bumper > Rear bumper - hatch > Rear bumper
spoiler - Blue Motion - remove and install
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Bumper > Rear bumper - sedan > Tools
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Bumper > Rear bumper - sedan > Rear bumper
protector (sedan) - assembly overview
protector (sedan) - remove and install > Remove
(sedan) - assembly overview
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Glazing/window mechanism > Glued glasses >
Tools
Windscreen - Assembly overview
Lower windscreen covering - remove and install
Lower windscreen covering - remove and install > Remove
Lower windscreen covering - remove and install > Install
Side glass (hatch) - assembly overview
Undamaged side glass (hatch) - remove
Rear door glass (undamaged) - remove
Undamaged rear door glass - remove
Prepare the new glass without encapsulation for glass assembly > Dimensions for the adhesive cord and primer on the
upper glass edge
Prepare the new glass without encapsulation for glass assembly > Dimensions for the adhesive cord and primer on the
lower glass edge
Prepare the new glass without encapsulation for glass assembly > Dimensions for the adhesive cord and primer on the side
glass edge
Rear window (sedan) - assembly overview
Undamaged rear window (Sedan) - remove
New rear window (sedan) - prepare a new glass for assembly
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Glazing/window mechanism > Door windows >
Tools
Front door window - assembly overview
Front door window - adjust
Front subframe - remove and install > Remove
Front subframe - remove and install > Install
Front and rear door window drive crank - remove and install > Remove
Rear door window - assembly overview
Rear door window - install
Rear subframe - remove and install > Remove
Rear subframe - remove and install > Install
Power window drive mechanism motor - remove and install > Remove
Power window drive mechanism motor - remove and install > Install
Power window drive mechanism motor - remove and install > Assemble the subframe with the power window drive
mechanism
Rear door window (sedan) - assembly overview
Fixed rear door window (sedan) - remove
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Exterior equipment > Wheel case protector >
Front wheel case protector - remove and install
Rear wheel case protector - remove and install
Spoiler on the wheel housing front protector - remove and install > Remove
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Exterior equipment > External rear-view mirror >
Tools
External rear-view mirror (with electric command ? 2006) - assembly overview
External rear-view mirror (with manual command ? 2006) - assembly overview
External rear-view mirror (2007 ?) - assembly overview
Mirror glass (2007 ?) - remove and install > Remove
Mirror cover (2007 ?) - remove and install > Remove
Cover with direction indicator (2007 ?) - remove and install > Remove
External rear-view mirror (2007 ?) - remove and install > Remove
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Exterior equipment > Front grille > Front grille (?
2006) - assembly overview
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Exterior equipment > Front grille > Front grille (?
2006) - remove and install > Remove
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Exterior equipment > Front grille > Front grille
(2007 ?) - assembly overview
(2007 ?) - remove and install > Remove
(2007 ?) - remove and install > Install
(2007 ?, GT) - assembly overview
(2007 ?, GT) - remove and install > Remove
(2007 ?, GT) - remove and install > Install
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Exterior equipment > Front grille > Front grille -
Blue Motion - assembly overview
Blue Motion - remove and install > Remove
Blue Motion - remove and install > Install
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Exterior equipment > Trims > Door trims -
remove and install
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Exterior equipment > Trims > Rear lid trim
(Hatch, 2010?) - replace
(Hatch, 2010?) - replace > Install
(Sedan, 2010?) - replace
(Sedan, 2010?) - replace > Install
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Exterior equipment > Trims > External
longitudinal member lining (front door - GT) - replace
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Exterior equipment > Trims > Measures to
position the inscriptions on the rear door
position the inscriptions on the rear door > Inscriptions on rear door ? 2006
position the inscriptions on the rear door > Rear door inscriptions 2007 ?
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Exterior equipment > Trims > Lower longitudinal
member trim (Blue Motion) - assembly overview
member trim (Blue Motion) - remove and install
member trim (Blue Motion) - remove and install > Remove
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Exterior equipment > Spoiler - Hatch > Rear
spoiler (? 07.08)
spoiler (? 07.08) > Spoiler - assembly overview
spoiler (? 07.08) > Spoiler - install
spoiler (? 07.08) > Installation instructions
spoiler (08.08 ?) - assembly overview > Assembly overview
spoiler ( 08.08 ? ) - remove
spoiler ( 08.08 ? ) - install
spoiler (Blue Motion)
spoiler (Blue Motion) > Assembly overview
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Exterior equipment > Rear spoiler - Sedan >
Rear spoiler (? 07.07) - remove and install
Rear spoiler (? 07.07) - remove and install > Remove
Rear spoiler (08.07 ?) - remove and install
Rear spoiler (08.07 ?) - remove and install > Remove
Volkswagen Workshop Manuals > Body > General body repairs, exterior > Exterior equipment > Exclusive components for
Blue Motion version > Blue Motion - assembly overview
Volkswagen Workshop Manuals > Body > General body repairs, interior > Interior equipment > Internal rearview mirror >
Internal rear-view mirror with automatic anti-glare
Internal rear-view mirror (without rain sensor) - remove and install
Internal rear-view mirror (with rain sensor) - remove and install > Assembly overview
Internal rear-view mirror (with rain sensor) - remove and install > Removal
Mirror fastening support (with rain sensor) - install
Volkswagen Workshop Manuals > Body > General body repairs, interior > Interior equipment > Object compartment, covers
and lids > Centre console (upper) > Assembly overview
and lids > Centre console (upper) > Installation
and lids > Centre console (lower) > Assembly overview
and lids > Centre console (lower) > Removal
and lids > Centre console (lower) > Installation
and lids > Handle of the emergency brake lever - remove and install
and lids > Objects holder
and lids > Objects holder > Assembly overview
and lids > Objects holder > Tray (upper with cover) - remove and install
and lids > Objects holder > Tray (upper without cover) - remove and install
and lids > Objects holder > Cover - remove and install
and lids > Objects holder > Tray (passenger's side) - remove and install
and lids > Objects holder > Tray (driver's side) - remove and install
and lids > Objects holder > Tray (centre) - remove and install
and lids > Glove compartment > Glove compartment - assembly overview
and lids > Glove compartment > Removal
and lids > Glove compartment > Installation
and lids > Central frame of the instrument panel - remove and install
and lids > Central frame of the instrument panel - remove and install > Removal
and lids > Central frame of the instrument panel - remove and install > Installation
and lids > Fastening hook (Sedan) - general assembly overview
and lids > Sun visor
and lids > Sun visor > Assembly overview
and lids > Sun visor > Installation
and lids > Centre sun visor - remove and install
Volkswagen Workshop Manuals > Body > General body repairs, interior > Interior equipment > Door sill's trims
Volkswagen Workshop Manuals > Body > General body repairs, interior > Interior equipment > Door sill's trims > Assembly
overview
Volkswagen Workshop Manuals > Body > General body repairs, interior > Passenger protection > Safety belts - checking >
Belt - checking
Volkswagen Workshop Manuals > Body > General body repairs, interior > Passenger protection > safety belts > safety belt
with pre-tensioner > Assembly overview
with pre-tensioner > Remove and install
with pre-tensioner > Removal
with pre-tensioner > Installation
Volkswagen Workshop Manuals > Body > General body repairs, interior > Passenger protection > safety belts > Safety belt
without pre-tensioner > Assembly overview
Volkswagen Workshop Manuals > Body > General body repairs, interior > Passenger protection > safety belts > Safety belt
without pre-tensioner > Installation
Volkswagen Workshop Manuals > Body > General body repairs, interior > Passenger protection > safety belts > Height
adjuster - remove and install > Assembly overview
adjuster - remove and install > Removal
adjuster - remove and install > Installation
Volkswagen Workshop Manuals > Body > General body repairs, interior > Passenger protection > safety belts > Lower
fastening point of the front safety belt - remove and install > Removal
Volkswagen Workshop Manuals > Body > General body repairs, interior > Passenger protection > safety belts > Fastening
of the front belt - removal and installation > Removal
Volkswagen Workshop Manuals > Body > General body repairs, interior > Passenger protection > safety belts > Fastening
of the front belt - removal and installation > Installation
Volkswagen Workshop Manuals > Body > General body repairs, interior > Passenger protection > Rear safety belts > Rear
safety belts (Hatch) - remove and install
Volkswagen Workshop Manuals > Body > General body repairs, interior > Passenger protection > Rear safety belts >
Assembly overview
Assembly overview > Removal
Assembly overview > Installation
safety belts (Sedan) - remove and install
safety belts (Sedan) - remove and install > Assembly overview
safety belts (Sedan) - remove and install > Removal
safety belts (Sedan) - remove and install > Installation
Volkswagen Workshop Manuals > Body > General body repairs, interior > Passenger protection > Rear safety belts > Lower
fastening point of the rear belt - removal and installation > Removal
Volkswagen Workshop Manuals > Body > General body repairs, interior > Passenger protection > Rear safety belts > Lower
fastening point of the rear belt - removal and installation > Installation
Central lap belt and double latch - remove and install
Central lap belt and double latch - remove and install > Removal
Central lap belt and double latch - remove and install > Installation
Volkswagen Workshop Manuals > Body > General body repairs, interior > Passenger protection > Airbag > Installation
locations - assembly overview
Volkswagen Workshop Manuals > Body > General body repairs, interior > Passenger protection > Airbag > Trigger 1 for
front passenger's airbagN131- remove and install
Volkswagen Workshop Manuals > Body > General body repairs, interior > Passenger protection > Airbag > Control unit for
the airbagJ234 - removal and installation
Volkswagen Workshop Manuals > Body > General body repairs, interior > Passenger protection > Airbag > Control unit for
the airbagJ234 - removal and installation > Removal
Volkswagen Workshop Manuals > Body > General body repairs, interior > Passenger protection > Airbag > Components -
adapting/verifying
Volkswagen Workshop Manuals > Body > General body repairs, interior > Passenger protection > Airbag > Components -
adapting/verifying > Work sequence
Volkswagen Workshop Manuals > Body > General body repairs, interior > Trim, noise insulation > Instrument panel > Tools
Volkswagen Workshop Manuals > Body > General body repairs, interior > Trim, noise insulation > Instrument panel > Cross
support/Instruments panel - removal and installation
Volkswagen Workshop Manuals > Body > General body repairs, interior > Trim, noise insulation > Instrument panel > Cross
support/Instruments panel - removal and installation > Removal
Volkswagen Workshop Manuals > Body > General body repairs, interior > Trim, noise insulation > Instrument panel >
Steering column covering - remove and install
Volkswagen Workshop Manuals > Body > General body repairs, interior > Trim, noise insulation > Door lining > Driver's side
front door lining - remove and install
Volkswagen Workshop Manuals > Body > General body repairs, interior > Trim, noise insulation > Door lining > Driver's side
front door lining - remove and install > Removal
Volkswagen Workshop Manuals > Body > General body repairs, interior > Trim, noise insulation > Door lining > Front
passenger's side door lining - remove and install
Volkswagen Workshop Manuals > Body > General body repairs, interior > Trim, noise insulation > Door lining > Front
passenger's side door lining - remove and install > Removal
Volkswagen Workshop Manuals > Body > General body repairs, interior > Trim, noise insulation > Door lining > Rear door
lining (Hatch) - remove and install
lining (Hatch) - remove and install > Removal
lining (Sedan) - remove and install
lining (Sedan) - remove and install > Removal
Volkswagen Workshop Manuals > Body > General body repairs, interior > Trim, noise insulation > Lining of columns and
sides > Upper pillar A lining - remove and install > Removal
sides > Lower A pillar lining (right side) - remove and install
sides > Lower A pillar lining (left side) - remove and install
sides > B-pillar lining - assembly overview
sides > Lower B pillar lining - remove and install > Removal
sides > Upper B pillar lining - remove and install > Removal
sides > C pillar upper lining (Hatch) - remove and install > Removal
sides > Upper pillar C lining (Sedan) - remove and install > Removal
sides > Lower C pillar lining (Hatch) - remove and install
sides > Lower C pillar lining (Hatch) - remove and install > Removal
sides > C pillar lower lining (Sedan) - remove and install
sides > C pillar lower lining (Sedan) - remove and install > Remove
Volkswagen Workshop Manuals > Body > General body repairs, interior > Trim, noise insulation > Linings of the luggage
compartment > Luggage compartment cover side lining - assembly overview
compartment > Luggage compartment cover side lining - remove and install
compartment > Luggage compartment cover side lining - remove and install > Removal
compartment > Luggage compartment cover side lining - remove and install > Installation
Volkswagen Workshop Manuals > Body > General body repairs, interior > Trim, noise insulation > Roof lining
Volkswagen Workshop Manuals > Body > General body repairs, interior > Trim, noise insulation > Roof lining > Pre-molded
roof lining (Hatch) - Assembly overview
roof lining (Hatch) - sun visor - Assembly overview
roof lining (Hatch) - sun visor - Assembly overview > Removal
roof lining (Sedan) - remove and install
Volkswagen Workshop Manuals > Body > General body repairs, interior > Trim, noise insulation > Noise insulation > Tools
Volkswagen Workshop Manuals > Body > General body repairs, interior > Trim, noise insulation > Noise insulation >
Assembly overview
Volkswagen Workshop Manuals > Body > General body repairs, interior > Trim, noise insulation > Noise insulation > Floor
lining - remove and install > Removal
Volkswagen Workshop Manuals > Body > General body repairs, interior > Seat frames > Front seats > Tools
Volkswagen Workshop Manuals > Body > General body repairs, interior > Seat frames > Front seats > Lower front seat
cushion cover (without height adjustment)
cushion cover (without height adjustment) > Assembly overview
cushion cover (without height adjustment) > Removal
cushion cover (without height adjustment) > Installation
cushion cover (with height adjustment)
cushion cover (with height adjustment) > Assembly overview
cushion cover (with height adjustment) > Removal
cushion cover (with height adjustment) > Installation
Volkswagen Workshop Manuals > Body > General body repairs, interior > Seat frames > Front seats > Fire extinguisher
support - removal and installation > Removal
Volkswagen Workshop Manuals > Body > General body repairs, interior > Seat frames > Front seats > Fire extinguisher
support - removal and installation > Installation
Volkswagen Workshop Manuals > Body > General body repairs, interior > Seat frames > Front seats > Front seat head rest
- assembly overview
Volkswagen Workshop Manuals > Body > General body repairs, interior > Seat frames > Front seats > Front seat backing -
removal and installation
removal and installation > Assembly overview
removal and installation > Removal
removal and installation > Installation
Volkswagen Workshop Manuals > Body > General body repairs, interior > Seat frames > Front seats > Height adjustment
mechanism - remove and install
mechanism - remove and install > Removal
mechanism - remove and install > Installation
Volkswagen Workshop Manuals > Body > General body repairs, interior > Seat frames > Front seats > Tray under the front
seat - remove and install
seat - remove and install > Assembly overview
seat - remove and install > Removal
seat - remove and install > Installation
Volkswagen Workshop Manuals > Body > General body repairs, interior > Seat frames > Rear seats > Rear seat back (split)
- remove and install > Removal
Volkswagen Workshop Manuals > Body > General body repairs, interior > Seat frames > Rear seats > Rear seat back (split)
- remove and install > Installation
Volkswagen Workshop Manuals > Body > General body repairs, interior > Seat frames > Rear seats > (Bench) back seat
backrest - remove and install
backrest - remove and install > Removal
backrest - remove and install > Installation
Volkswagen Workshop Manuals > Body > General body repairs, interior > Seat frames > Rear seats > Rear seat head rest -
removal and installation > Removal
Volkswagen Workshop Manuals > Body > General body repairs, interior > Seat frames > Rear seats > Rear seat backrest
release button - assembly overview
Volkswagen Workshop Manuals > Body > General body repairs, interior > Seat frames > Rear seats > Rear seat rest
unlocking button - removal and installation > Removal
Volkswagen Workshop Manuals > Body > General body repairs, interior > Seat padding, covers > Linings, stuffing of front
seats > Front seat cushion linings and fillings - assembly overview
seats > Front seat cushion linings and fillings - remove and install
seats > Front seat cushion linings and fillings - remove and install > Removal
seats > Lining and stuffing of the front backing - assembly overview
seats > Front seat backing lining and stuffing - removal and installation
seats > Front seat backing lining and stuffing - removal and installation > Removal
Volkswagen Workshop Manuals > Body > General body repairs, interior > Seat padding, covers > Linings and stuffing of
front seats > Rear seat cushion lining and filling (bench) - remove and install
front seats > Lining and stuffing of the back seat (one-piece) backing - assembly overview
front seats > Lining and stuffing of the back seat (one-piece) backing - removal and installation
front seats > Lining and stuffing of the back seat (one-piece) backing - removal and installation > Removal
front seats > Lining and stuffing of the back seat (two-piece) backing - assembly overview
front seats > Lining and stuffing of the back seat (two-piece) backing - removal and installation
front seats > Lining and stuffing of the back seat (two-piece) backing - removal and installation > Removal
Volkswagen Workshop Manuals > Body > Chemicals Manual > Technical data > Work Instructions for Handling Chemicals
> General considerations > Solvent Handling
Volkswagen Workshop Manuals > Body > Chemicals Manual > Technical data > Repair Group 10 - Cylinders, engine block,
support, protector > Cylinder base gasket - lubricate
support, protector > Engine housing - seal
support, protector > Engine housing plugs - fasten
support, protector > Engine block plugs - fasten
Volkswagen Workshop Manuals > Body > Chemicals Manual > Technical data > Repair Group 13 - Crankshaft, pistons >
Crankshaft needle bearing
Needle bearing of the fastening hollow screw for the flywheel
Flywheel fastening screw - lock
Volkswagen Workshop Manuals > Body > Chemicals Manual > Technical data > Repair Group 15 - Cylinder head, valve
control mechanism > Intermediate shaft seal - lubricate for assembly
control mechanism > Camshaft valve bearing cover (1st and 5th) - Seal
control mechanism > Cylinder head sealing gasket - glue
control mechanism > Lower rear studs fastening the head - rear stud (crankshaft) / lower front studs (flywheel) - Seal
control mechanism > Cylinder head cover - seal
Volkswagen Workshop Manuals > Body > Chemicals Manual > Technical data > Repair Group 17 - Lubrication system >
Engine crankcase - Fill / top up oil level
Junction between crankcase gaskets and crankshaft front and rear flange gasket - seal
Engine crankcase - seal
Volkswagen Workshop Manuals > Body > Chemicals Manual > Technical data > Repair Group 19 - Cooling system > G 11
cooling system - fill / adjust additive proportion.
Volkswagen Workshop Manuals > Body > Chemicals Manual > Technical data > Repair Group 19 - Cooling system > G 12
cooling system - fill / adjust additive proportion.
Volkswagen Workshop Manuals > Body > Chemicals Manual > Technical data > Repair Group 20 - Supply system - tank,
fuel pump > Fuel tank - add additive
fuel pump > Accelerator pedal shaft - lubricate
fuel pump > Accelerator pedal fastening - lubricate
fuel pump > Accelerator cable and cable end - accelerator pedal fastening - lubricate
Volkswagen Workshop Manuals > Body > Chemicals Manual > Technical data > Repair Group 26 - Exhaust system >
Exhaust connection - seal
Volkswagen Workshop Manuals > Body > Chemicals Manual > Technical data > Repair Group 30 - Clutch - control system
> Clutch pedal bung - lubricate
> Clutch control cable - lubricate
> Clutch fork, contact with bearing - lubricate
> Clutch fork bungs - lubricate
> Butterfly nut for clutch control cable adjustment - lubricate
> Sealing ring for the de-clutch bearing guide - lubricate for assembly
> Clutch cable - lubricate
> Clutch fork and clutch operating lever - lubricate
> Clutch pedal fastening - lubricate
> Clutch operating cable - lubricate
> Primary shaft splines - lubricate
> Clutch pedal / clutch pedal bung - lubricate
> Pedal support - seal
> Clutch fork contact with the hydraulically activated cylinder of the transmission clutch - lubricate
> Fastening flange for the hydraulically activated slave cylinder of the clutch - seal
Volkswagen Workshop Manuals > Body > Chemicals Manual > Technical data > Repair Group - 34 - Drive, housing >
Linkage rod, front/rear section - lubricate
Gearshift lever bearing
Manual transmission - Fill / top up level
Plastic bungs for the linkage rod coupling system / linkage rod / supports (on the transmission) - lubricate
Gearshift lever guide plate - lubricate
Rubber shim for the clutch compartment cover - glue
Clutch compartment cover - seal
Linkage rod bellows for the gearshift lever assembly - fasten / seal
Junction of cases and differential cover housing (gearbox / differential) - seal
Gearshift lever handle - fasten
Fastening screw for the rear support of the transmission cushion - seal
Transmission cushion - lubricate
Volkswagen Workshop Manuals > Body > Chemicals Manual > Technical data > Repair Group - 34 - Drive, housing > Gear
selection mechanism - fill up
Electric connectors of the gear selection mechanism - apply nyogel
Volkswagen Workshop Manuals > Body > Chemicals Manual > Technical data > Repair Group 35 - Gears and shafts >
Primary shaft splines - lubricate
Volkswagen Workshop Manuals > Body > Chemicals Manual > Technical data > Repair Group 35 - Gears and shafts >
Fastening screw for the 5th gear synchronizer / clutch assembly - lock
Planetary gear box (automatic transmission) - Fill / top up oil level
Volkswagen Workshop Manuals > Body > Chemicals Manual > Technical data > Repair Group - 39 - Transmission shafts,
differential > Transmission side seals - lubricate
differential > Planetary and satellite gears - lubricate for assembly
differential > Automatic transmission differential - top up oil level
differential > Differential cover with transmission case - seal
Volkswagen Workshop Manuals > Body > Chemicals Manual > Technical data > Repair Group - 40 - Front suspension >
Constant-velocity joint spline - lubricate
Inner and outer constant-velocity joint - lubricate
Front wheel bearing housing - lubricate
Axle end - lubricate
Axle end - lubricate > Front wheel hub seal - lubricate
Axle end - lubricate > King pin bearing - lubricate
Axle end - lubricate > Front axle body - lubricate
Axle end - lubricate > Suspension arms - lubricate
Axle end - lubricate > Front wheel bearing - lubricate
Axle end - lubricate > Passage hole for the speedometer cable in the wheel hub protector - seal
Volkswagen Workshop Manuals > Body > Chemicals Manual > Technical data > Repair Group - 42 - Rear suspension >
Inner and outer constant-velocity joint - lubricate
Shaft end splines - lubricate
Rear torsion bar - lubricate
Rear wheel hub - lubricate
Rear wheel hub seal - lubricate
Rear wheel bearing - lubricate
Volkswagen Workshop Manuals > Body > Chemicals Manual > Technical data > Repair Group - 46 - Brakes - Mechanical
systems > Rear wheel brake shoe ends - lubricate
systems > Emergency brake cable terminal - lubricate
systems > Brake pedal safety pin - lubricate
systems > Fastening pin for the operating rod of the master cylinder plunger - lubricate
systems > Fastening pin of the parking brake lever - lubricate
systems > Emergency brake ratchet - lubricate
Volkswagen Workshop Manuals > Body > Chemicals Manual > Technical data > Repair Group - 47 - Brakes - Servo brake
hydraulic system > Brake system - fill / top up
hydraulic system > Guide pin for the support of the front disc brake cylinder (manufactured by Varga) - lubricate
hydraulic system > Fastening screw for the front disc brake cylinder housing - lock
Volkswagen Workshop Manuals > Body > Chemicals Manual > Technical data > Repair Group - 48 - Steering > Oil tank for
the power steering system - Fill / top up oil level
Volkswagen Workshop Manuals > Body > Chemicals Manual > Technical data > Repair Group - 48 - Steering > Steering
box - Fill / top up level
Volkswagen Workshop Manuals > Body > Chemicals Manual > Technical data > Repair Group - 48 - Steering > Steering
box mechanism - lubricate
Volkswagen Workshop Manuals > Body > Chemicals Manual > Technical data > Repair Group - 48 - Steering > Adapter
(sleeve) for the upper steering shaft - lock
Volkswagen Workshop Manuals > Body > Chemicals Manual > Technical data > Repair Group - 53 - Body - Rear section >
Bucket sealing membrane - glue
Volkswagen Workshop Manuals > Body > Chemicals Manual > Technical data > Repair Group - 53 - Body - Rear section >
Rear side panel - protect the paint
Volkswagen Workshop Manuals > Body > Chemicals Manual > Technical data > Repair Group - 55 - Covers > Bucket
protective cover longitudinal member - glue the finishing
Volkswagen Workshop Manuals > Body > Chemicals Manual > Technical data > Repair Group - 55 - Covers > Lower latch
of the hood - lubricate
Volkswagen Workshop Manuals > Body > Chemicals Manual > Technical data > Repair Group - 55 - Covers > Shock
absorber eyelet for the rear cover - lubricate
Volkswagen Workshop Manuals > Body > Chemicals Manual > Technical data > Repair Group - 57 - Front doors /
components / central lock > Front door lock - lubricate
components / central lock > Lock drive rod - lubricate
components / central lock > Noise insulation for lock operating rod - glue
components / central lock > Internal door finishing - glue
Volkswagen Workshop Manuals > Body > Chemicals Manual > Technical data > Repair Group - 58 - Rear doors /
components > Rear door lock - lubricate
Volkswagen Workshop Manuals > Body > Chemicals Manual > Technical data > Repair Group - 58 - Rear doors /
components > Side door lock - lubricate
Volkswagen Workshop Manuals > Body > Chemicals Manual > Technical data > Repair Group - 64 - Windscreens,
windows, window mechanism > Door window activation mechanism - lubricate
windows, window mechanism > Vent window latch - lubricate
windows, window mechanism > Front door glass support - lubricate
windows, window mechanism > Front door window activation mechanism - lubricate
windows, window mechanism > Window crank fastening screw - lock
windows, window mechanism > Windscreen, side window glass and rear window glass - glue
windows, window mechanism > Windscreen, side window glass and rear window glass - seal
windows, window mechanism > Glass - engrave chassis number
windows, window mechanism > Front and rear door window guide groove - glue
windows, window mechanism > Vent window - seal
Volkswagen Workshop Manuals > Body > Chemicals Manual > Technical data > Repair Group - 66 - External equipment >
Roof rack fastening screws - lock
Volkswagen Workshop Manuals > Body > Chemicals Manual > Technical data > Repair Group - 68 - Internal equipment >
Internal rearview mirror support - fasten
Volkswagen Workshop Manuals > Body > Chemicals Manual > Technical data > Repair Group - 70 - Lining/insulation >
Door noise insulation - glue
Noise insulation on rear side panel - glue
Roof noise insulation - glue
Door sealing membrane - glue
Volkswagen Workshop Manuals > Body > Chemicals Manual > Technical data > Repair Group - 72 - Seat framework >
Front seat central sliding guide - lubricate
Volkswagen Workshop Manuals > Body > Chemicals Manual > Technical data > Repair Group - 72 - Seat framework >
Front seat side sliding guide - lubricate
Volkswagen Workshop Manuals > Body > Chemicals Manual > Technical data > Repair Group - 87 - Air conditioning > Air
conditioning system - refill with gas
conditioning system - refill with oil
conditioning pressure switch - seal
Volkswagen Workshop Manuals > Body > Chemicals Manual > Technical data > Repair Group - 92 - Windscreen, rear
window and headlight wiper and washer > Windscreen wiper operating rod - lubricate
Volkswagen Workshop Manuals > Body > Chemicals Manual > Technical data > Repair Group - 92 - Windscreen, rear
window and headlight wiper and washer > Windscreen/rear window washer water tank - fill
Volkswagen Workshop Manuals > Body > Chemicals Manual > Technical data > Repair Group - 94 - Switches, lights, and
external bulbs > Contact blade for the indicator lights switch
Volkswagen Workshop Manuals > Body > Chemicals Manual > Technical data > Repair Group - 97 - Cables and electrical
harnesses > Gaskets for the plastic covers that cover the electric harnesses - seal
Volkswagen Workshop Manuals > Body > Painting Manual > Technical data > Special colors > Special colors > Fox
Blackfox 2012
Crossfox
Crossfox 2012 ?
Extreme
Silverfox 2012
Volkswagen Workshop Manuals > Body > Painting Manual > Technical data > Special colors > Special colors > Gol Rallye
Volkswagen Workshop Manuals > Body > Painting Manual > Technical data > Special colors > Special colors > Vintage Gol
Volkswagen Workshop Manuals > Body > Painting Manual > Technical data > Special colors > Special colors > Golf GT
Volkswagen Workshop Manuals > Body > Painting Manual > Technical data > Special colors > Special colors > Golf Silver
Edition
Volkswagen Workshop Manuals > Body > Painting Manual > Technical data > Special colors > Special colors > Silver
series Kombi
Volkswagen Workshop Manuals > Body > Painting Manual > Technical data > Special colors > Special colors > Parati Track
and Field (Generation IV)
Volkswagen Workshop Manuals > Body > Painting Manual > Technical data > Special colors > Special colors > Parati Surf
Volkswagen Workshop Manuals > Body > Painting Manual > Technical data > Special colors > Special colors > Parati Titan
Volkswagen Workshop Manuals > Body > Painting Manual > Technical data > Special colors > Special colors > Saveiro
Crossover (generation III)
Crossover (generation IV)
Titan
Surf
Trooper 2010 ?
Cross 2010 ?
Volkswagen Workshop Manuals > Body > Painting Manual > Technical data > Repainting > Paint repair on steel plates and
zinc-coated steel plates
Volkswagen Workshop Manuals > Body > Painting Manual > Technical data > Repainting > Paint repair on plastic parts >
Repainting of plastic components that require special care
Volkswagen Workshop Manuals > Body > Painting Manual > Technical data > Repainting > Spray guns and their use
Volkswagen Workshop Manuals > Body > Painting Manual > Technical data > Body sealing > Santana and Quantum
Volkswagen Workshop Manuals > Body > Painting Manual > Technical data > Body sealing > Gol 1995 ?
Volkswagen Workshop Manuals > Body > Painting Manual > Technical data > Body sealing > Gol 1999 ? and Parati 1999 ?
- 5X and 5W
Volkswagen Workshop Manuals > Body > Painting Manual > Technical data > Body sealing > Saveiro 2000 ? - 5X and 5W
Volkswagen Workshop Manuals > Body > Painting Manual > Technical data > Body sealing > Gol , Voyage 2009 ? and
Saveiro 2010 ?
Volkswagen Workshop Manuals > Body > Painting Manual > Technical data > Body sealing > Fox and Spacefox
Volkswagen Workshop Manuals > Body > Painting Manual > Technical data > Body sealing > Polo
Volkswagen Workshop Manuals > Body > Painting Manual > Technical data > Body sealing > Golf
Volkswagen Workshop Manuals > Body > Painting Manual > Technical data > Application of anti-corrosion fluid >
Equipment
Volkswagen Workshop Manuals > Body > Body Repair - General Information > Technical data > Safety indications >
Checking the seat belts > Check the belt strap
Volkswagen Workshop Manuals > Body > Body Repair - General Information > Technical data > Explanation of symbols >
Explanation of symbols for welding works
Explanation of symbols for working processes > Lower
Explanation of symbols for working processes > Perforate
Explanation of symbols for working processes > Drill
Explanation of symbols for working processes > Application of anti-corrosion fluid
Explanation of symbols for working processes > Gluing
Explanation of symbols for working processes > Sealing
Volkswagen Workshop Manuals > Body > Body Repair - General Information > Technical data > Tools for body repair >
Drilling pliersVAG 1329
Fluid spray VAG 1379 or EQ 7608
Volkswagen Workshop Manuals > Body > Body Repair - General Information > Technical data > Tools for body repair > Hot
air blowerVAG 1416
Adjustable cordsVAG 1438
Pneumatic Saw VAG 1523A or EQ 7415
Pneumatic hammerVAG 1577
Spot weld removerVAG 1731
Pneumatic glued window adhesive applicatorVAG 1761/1 or EQ 7434
Pneumatic adhesive applicatorVAG 2005
Volkswagen Workshop Manuals > Body > Body Repair - General Information > Technical data > Glued parts of the body
Volkswagen Workshop Manuals > Body > Body Repair - General Information > Technical data > Glued parts of the body >
Types of bonding > Resistance bonded joints
Volkswagen Workshop Manuals > Body > Body Repair - General Information > Technical data > Glued parts of the body >
Types of bonding > Joints bonded with spot welds
Volkswagen Workshop Manuals > Engine > 4-cylinder injection engine > Technical data > Technical data > Engine number
Volkswagen Workshop Manuals > Engine > 4-cylinder injection engine > Engine assy,cylinder block,crankcase > Removing
and installing engine
Volkswagen Workshop Manuals > Engine > 4-cylinder injection engine > Enginecrankshaft group, pistons > Dismantling
and assembling engine > Part I: Assembly overview - belt drive
and assembling engine > Part II: Assembly overview - cylinder block
Volkswagen Workshop Manuals > Engine > 4-cylinder injection engine > Enginecrankshaft group, pistons > Removing and
installing sealing flanges and flywheel or drive plate > Assembly overview
installing sealing flanges and flywheel or drive plate > Renewing crankshaft oil seal - pulley end
installing sealing flanges and flywheel or drive plate > Removing and installing drive plate
installing sealing flanges and flywheel or drive plate > Renewing crankshaft sealing flange - flywheel end
installing sealing flanges and flywheel or drive plate > Renewing crankshaft sealing flange - flywheel end > A-Assembling
sealing flange with sender wheel on assembly appliance T10017
installing sealing flanges and flywheel or drive plate > Renewing crankshaft sealing flange - flywheel end > B-Assembling
appliance T10017 with sealing flange on crankshaft flange
installing sealing flanges and flywheel or drive plate > Renewing crankshaft sealing flange - flywheel end > E - Checking
sender wheel installation position on crankshaft
installing sealing flanges and flywheel or drive plate > Renewing crankshaft sealing flange - flywheel end > F - Re-pressing
sender wheel
and assembling pistons and conrods > Assembly overview
Volkswagen Workshop Manuals > Engine > 4-cylinder injection engine > Engine cylinder head, valve gear > Cylinder head
> Assembly overview
> Checking valve timing
> Removing, installing and tensioning toothed belt
> Removing, installing and tensioning toothed belt > Removing
> Checking semi-automatic toothed belt tensioning roller
> Removing and installing camshaft housing
> Removing and installing cylinder head
> Checking compression
Volkswagen Workshop Manuals > Engine > 4-cylinder injection engine > Engine cylinder head, valve gear > Repairing valve
gear > Assembly overview
gear > Reworking valve seats > Reworking inlet valve seat
gear > Renewing camshaft oil seal
gear > Checking valve guides
gear > Renewing valve stem seals
Volkswagen Workshop Manuals > Engine > 4-cylinder injection engine > Engine lubrication > Removing and installing parts
of lubrication system > Assembly overview
of lubrication system > Removing and installing oil sump
of lubrication system > Removing and installing oil pump
of lubrication system > Checking oil pressure and oil pressure switch
Volkswagen Workshop Manuals > Engine > 4-cylinder injection engine > Engine cooling > Dismantling and assembling
parts of cooling system > Assembly overview - parts of cooling system - body side
parts of cooling system > Assembly overview - parts of cooling system - engine side
parts of cooling system > Coolant hose schematic diagram
parts of cooling system > Draining and filling coolant
parts of cooling system > Removing and installing radiator
parts of cooling system > Removing and installing coolant pump
Volkswagen Workshop Manuals > Engine > 4-cylinder injection engine > Fuel supply, gas operation > Removing and
installing parts of fuel supply system > Assembly overview - fuel tank with attachments
installing parts of fuel supply system > Removing and installing fuel delivery unit
installing parts of fuel supply system > Removing and installing fuel gauge sender
installing parts of fuel supply system > Removing and installing fuel tank
installing parts of fuel supply system > Checking fuel pump
installing parts of fuel supply system > Bleeding fuel system
Volkswagen Workshop Manuals > Engine > 4-cylinder injection engine > Fuel supply, gas operation > Checking electronic
power control (EPC) > Assembly overview
Volkswagen Workshop Manuals > Engine > 4-cylinder injection engine > Fuel supply, gas operation > Active charcoal filter
system > Assembly overview - parts of active charcoal filter system
Volkswagen Workshop Manuals > Engine > 4-cylinder injection engine > Fuel supply, gas operation > Active charcoal filter
system > Checking fuel tank breather
Volkswagen Workshop Manuals > Engine > 4-cylinder injection engine > Mixture preparation system, electronic inj.,Gas >
Repairing injection system > Assembly overview - parts of injection system
Repairing injection system > Assembly overview - intake manifold
Repairing injection system > Assembly overview - fuel rail with injectors
Repairing injection system > Assembly overview - air cleaner
Checking components > Checking injectors
Checking components > Checking fuel pressure regulator and holding pressure > Checking fuel pressure regulator
Engine control unit > Adapting components
Volkswagen Workshop Manuals > Engine > 4-cylinder injection engine > Exhaust system > Removing and installing parts of
exhaust system > Assembly overview - exhaust system with attachments
Volkswagen Workshop Manuals > Engine > 4-cylinder injection engine > Exhaust system > Removing and installing parts of
exhaust system > Assembly overview - silencer with mountings
Volkswagen Workshop Manuals > Engine > 4-cylinder injection engine > Exhaust system > Exhaust gas recirculation
system > Assembly overview
Volkswagen Workshop Manuals > Engine > 4-cylinder injection engine > Ignition system, glow plug system > Repairing
ignition system > Assembly overview - parts of ignition system
Volkswagen Workshop Manuals > Engine > 4-cylinder injection engine > Ignition system, glow plug system > Repairing
ignition system > Safety precautions
Volkswagen Workshop Manuals > Engine > 4 - Cyl. injection engine (4-valve, rolling rockers) > Technical data > Technical
data > Engine number
Volkswagen Workshop Manuals > Engine > 4 - Cyl. injection engine (4-valve, rolling rockers) > Engine assy,cylinder
block,crankcase > Engine - remove and install
Volkswagen Workshop Manuals > Engine > 4 - Cyl. injection engine (4-valve, rolling rockers) > Engine assy,cylinder
block,crankcase > Engine - remove and install > Engine - fix on assembly anvil > Operation sequence
Volkswagen Workshop Manuals > Engine > 4 - Cyl. injection engine (4-valve, rolling rockers) > Enginecrankshaft group,
pistons > Engine - disassemble and assemble > Poly-V belt - remove and install > Removal
pistons > Engine - disassemble and assemble > Poly-V belt - remove and install > Poly-V belt trajectory.
pistons > Engine - disassemble and assemble > Poly-V belt - remove and install > Vehicles without air conditioning
compressor
pistons > Crank shaft rear flange - remove and install > Crank shaft seal pulley side - replace
pistons > Crank shaft rear flange - remove and install > Crank shaft seal pulley side - replace > Removal
pistons > Crank shaft rear flange - remove and install > Crank shaft seal pulley side - replace > Installation
pistons > Crank shaft rear flange - remove and install > Crank shaft rear flange, driving wheel side - replace
pistons > Crank shaft rear flange - remove and install > Crank shaft rear flange, driving wheel side - replace > Operation
sequence
pistons > Crank shaft rear flange - remove and install > Crank shaft rear flange, driving wheel side - replace > A-Install
flange with rotor on Assembly tool T10017
pistons > Crank shaft rear flange - remove and install > Crank shaft rear flange, driving wheel side - replace > E-Check
assembly position of crank shaft rotor
pistons > Crank shaft rear flange - remove and install > Crank shaft rear flange, driving wheel side - replace > F- retighten
driving wheel
pistons > Crank shaft - remove and install > Identification of engine bearing caps > Marks of bearing cover caps
pistons > Crank shaft - remove and install > Identification of engine bearing caps > Marks of engine block bearing caps
Volkswagen Workshop Manuals > Engine > 4 - Cyl. injection engine (4-valve, rolling rockers) > Engine cylinder head, valve
gear > Head - disassemble and assemble > Distribution times - check
gear > Head - disassemble and assemble > Tension pulley of indented belt - check
gear > Head - disassemble and assemble > Tension pulley of indented belt - check > Tension pulley of main indented belt -
check
gear > Head - disassemble and assemble > Tension pulley of indented belt - check > Indented belt tension pulley of valves
command shaft - check
gear > Head - disassemble and assemble > Indented belt - remove and install, adjust
gear > Head - disassemble and assemble > Indented belt - remove and install, adjust > Removal
gear > Head - disassemble and assemble > Indented belt - remove and install, adjust > Operation sequence
gear > Head - disassemble and assemble > Head cover - remove and install
gear > Head - disassemble and assemble > Head cover - remove and install > Operation sequence
gear > Head - disassemble and assemble > Head cover - remove and install > Installation
gear > Head - disassemble and assemble > Head - remove and install
gear > Head - disassemble and assemble > Head - remove and install > Remove head
gear > Head - disassemble and assemble > Head - remove and install > Install head
gear > Head - disassemble and assemble > Compression - check
gear > Head - disassemble and assemble > Compression - check > Operation sequence
gear > Head - disassemble and assemble > Valve command - repair
gear > Head - disassemble and assemble > Valve seats - grind > Intake valve seat: grind
gear > Head - disassemble and assemble > Valve seats - grind > Exhaust valve seat: grind
gear > Head - disassemble and assemble > Valve seats - grind > Valve command shaft seals - replace
gear > Head - disassemble and assemble > Valve seats - grind > Valve guides - check
gear > Head - disassemble and assemble > Valve seats - grind > Checking process
gear > Head - disassemble and assemble > Valve stem seal - replace
gear > Head - disassemble and assemble > Valve stem seal - replace > Removal
gear > Head - disassemble and assemble > Valve stem seal - replace > Installation
Volkswagen Workshop Manuals > Engine > 4 - Cyl. injection engine (4-valve, rolling rockers) > Engine lubrication >
Lubrication system components - remove and install > Oil carter - remove and install
Lubrication system components - remove and install > Oil pump - remove and install
Lubrication system components - remove and install > Oil pump - remove and install > Removal
Lubrication system components - remove and install > Oil pump - remove and install > Installation
Lubrication system components - remove and install > Oil pump - remove and install > Operation sequence
Lubrication system components - remove and install > Oil pressure and oil pressure switch - check
Lubrication system components - remove and install > Oil pressure and oil pressure switch - check > Test sequence
Volkswagen Workshop Manuals > Engine > 4 - Cyl. injection engine (4-valve, rolling rockers) > Engine cooling > Cooling
system components - remove and install > Cooling system components, body side
system components - remove and install > Cooling system components on engine side
system components - remove and install > Cooling system components on engine side > Water pump side
system components - remove and install > Cooling fluid hose connection diagram
system components - remove and install > Cooling fluid - drain and fill
system components - remove and install > Cooling fluid - drain and fill > Without cooling fluid filling equipment VAS6096
system components - remove and install > Radiator - remove and install
system components - remove and install > Water pump - remove and install
system components - remove and install > Water pump - remove and install > Removal
Volkswagen Workshop Manuals > Engine > 4 - Cyl. injection engine (4-valve, rolling rockers) > Fuel supply, gas operation >
Fuel supply system components - remove and install > Fuel container with accessory parts and fuel filter - remove and
install
Fuel supply system components - remove and install > Oil pump - remove and install
Fuel supply system components - remove and install > Fuel level sensor - remove and install > Removal
Fuel supply system components - remove and install > Fuel container - remove and install
Fuel supply system components - remove and install > Fuel pump - check
Engine power electronic regulation (E-gas electronic throttle) - check
Activated charcoal filter system. > Activated charcoal filter system components - repair
Activated charcoal filter system. > Fuel container ventilation - checking
Activated charcoal filter system. > Fuel container ventilation - checking > Test sequence
Volkswagen Workshop Manuals > Engine > 4 - Cyl. injection engine (4-valve, rolling rockers) > Mixture preparation system,
electronic inj.,Gas > Injection system - repair > Injection components - remove and install
electronic inj.,Gas > Injection system - repair > Intake collector - remove and install
electronic inj.,Gas > Injection system - repair > Injector-equipped fuel distributor - remove and install
electronic inj.,Gas > Injection system - repair > Air filter - remove and install
electronic inj.,Gas > Injection components - check > Injectors - check
electronic inj.,Gas > Injection components - check > Injectors - check > Checking process
electronic inj.,Gas > Injection components - check > Fuel pressure regulator and retaining pressure - check
electronic inj.,Gas > Engine command unit > Engine command unit - remove and install > Removal
electronic inj.,Gas > Engine command unit > Injection components - adapt
electronic inj.,Gas > Engine command unit > Injection components - adapt > Operation sequence
electronic inj.,Gas > Engine command unit > Fault memory of engine command unit - consult and delete
electronic inj.,Gas > Engine command unit > Fault memory of engine command unit - consult and delete > Operation
sequence
Volkswagen Workshop Manuals > Engine > 4 - Cyl. injection engine (4-valve, rolling rockers) > Exhaust system > Removal
and installation of exhaust system parts > Exhaust collector, front tube with catalyst and installation parts
Volkswagen Workshop Manuals > Engine > 4 - Cyl. injection engine (4-valve, rolling rockers) > Exhaust system > Removal
and installation of exhaust system parts > Muffler with supports
Volkswagen Workshop Manuals > Engine > 4 - Cyl. injection engine (4-valve, rolling rockers) > Ignition system, glow plug
system > Ignition system - repair > Ignition system components - remove and install
Volkswagen Workshop Manuals > Engine > 4 - Cyl. injection engine (4-valve, rolling rockers) > Ignition system, glow plug
system > Ignition system - repair > Safety measures
Volkswagen Workshop Manuals > Engine > 4 - Cyl. diesel engine (with distributor injection pump) > Technical data >
Technical data > Engine number
Volkswagen Workshop Manuals > Engine > 4 - Cyl. diesel engine (with distributor injection pump) > Engine assy,cylinder
Volkswagen Workshop Manuals > Engine > 4 - Cyl. diesel engine (with distributor injection pump) > Engine assy,cylinder
block,crankcase > Engine - remove and install > Notes refering to removal > Continuation for all vehicles
Volkswagen Workshop Manuals > Engine > 4 - Cyl. diesel engine (with distributor injection pump) > Enginecrankshaft
group, pistons > Engine - disassemble and assemble > Poly-V pulley - remove and install
group, pistons > Engine - disassemble and assemble > Poly-V pulley - remove and install > Vehicles without air conditioning
compressor
group, pistons > Engine - disassemble and assemble > Poly-V pulley - remove and install > Vehicles with air conditioning
compressor
group, pistons > Engine - disassemble and assemble > Semi-automatic tension pulley of indented belt - check > Checking
sequence
group, pistons > Crankshaft seal and engine steering wheel - remove and install > Crankshaft seal (pulley side) - replace
group, pistons > Crankshaft seal and engine steering wheel - remove and install > Crankshaft seal (pulley side) - replace >
Removal
group, pistons > Crankshaft seal and engine steering wheel - remove and install > Crankshaft front flange - remove and
install
group, pistons > Crankshaft seal and engine steering wheel - remove and install > Crankshaft front flange - remove and
install > Removal
group, pistons > Crank shaft - remove and install
group, pistons > Pistons and rods - disassemble and assemble
group, pistons > Pistons and rods - disassemble and assemble > Piston position on upper part - check
group, pistons > Pistons and rods - disassemble and assemble > Piston position on upper part - check > Checking
sequence
Volkswagen Workshop Manuals > Engine > 4 - Cyl. diesel engine (with distributor injection pump) > Engine cylinder head,
valve gear > Head - disassemble and assemble > Indented belt - remove and install, adjust
valve gear > Head - disassemble and assemble > Indented belt - remove and install, adjust > Removal
valve gear > Head - disassemble and assemble > Head - remove and install
valve gear > Head - disassemble and assemble > Compression - check
valve gear > Head - disassemble and assemble > Compression - check > Checking sequence
valve gear > Valve mechanism - repair > Valves - grind seats > Grind intake valve seats
valve gear > Valve mechanism - repair > Valves - grind seats > Grind exhaust system valves seats
valve gear > Valve mechanism - repair > Valve guides - check
valve gear > Valve mechanism - repair > Valve guides - check > Checking sequence
valve gear > Valve mechanism - repair > Valve stem seals - replace
valve gear > Valve mechanism - repair > Valve stem seals - replace > Installation
valve gear > Valve mechanism - repair > Valve command shaft - remove and install
Volkswagen Workshop Manuals > Engine > 4 - Cyl. diesel engine (with distributor injection pump) > Engine lubrication >
Lubrication systems components - remove and install > Carter - remove and install
Lubrication systems components - remove and install > Oil pressure switch and oil pressure - check
Lubrication systems components - remove and install > Oil pressure switch and oil pressure - check > Checking sequence
Volkswagen Workshop Manuals > Engine > 4 - Cyl. diesel engine (with distributor injection pump) > Engine cooling >
Cooling system components - remove and install > Body cooling system components
Cooling system components - remove and install > Engine cooling system components
Cooling system components - remove and install > Connection scheme for cooling fluid hoses
Cooling system components - remove and install > Cooling fluid - drain and refill
Cooling system components - remove and install > Water pump - remove and install
Cooling system components - remove and install > Radiator - remove and install
Cooling system components - remove and install > Radiator - remove and install > Removal
Cooling system components - remove and install > Thermostat valve - remove and install
Volkswagen Workshop Manuals > Engine > 4 - Cyl. diesel engine (with distributor injection pump) > Fuel supply, gas
operation > Fuel supply system components - remove and install > Fuel tank with accessories - remove and install
operation > Fuel supply system components - remove and install > Fuel filter - repair
operation > Fuel supply system components - remove and install > Fuel tank - remove and install
operation > Fuel supply system components - remove and install > Fuel pump - remove and install
operation > Fuel supply system components - remove and install > Fuel level meter - remove and install > Removal
operation > Fuel supply system components - remove and install > Throttle starting system - repair
Volkswagen Workshop Manuals > Engine > 4 - Cyl. diesel engine (with distributor injection pump) > Fuel preparation
system Diesel injection > Direct injection system-Diesel - repair > Injection pump - repair
system Diesel injection > Direct injection system-Diesel - repair > Intake tube - remove and install
system Diesel injection > Direct injection system-Diesel - repair > Injection pump - remove and install
system Diesel injection > Direct injection system-Diesel - repair > Injection pump - remove and install > Installation
system Diesel injection > Direct injection system-Diesel - repair > Injectors - remove and install
system Diesel injection > Direct injection system-Diesel - repair > Injectors - check
system Diesel injection > Direct injection system-Diesel - repair > Sealing ring on injection regulator cover - replace
system Diesel injection > Engine command unit > Engine command unit - remove and install > Removal
system Diesel injection > Engine command unit > Engine command unit fault memory - check and erase
system Diesel injection > Engine command unit > Engine command unit fault memory - check and erase > Operation
sequence
system Diesel injection > Engine command unit > Functions and components - adjust
Volkswagen Workshop Manuals > Engine > 4 - Cyl. diesel engine (with distributor injection pump) > Exhaust system >
Exhaust system parts - remove and install > Exhaust system - remove and install
Exhaust system parts - remove and install > Exhaust system - remove and install > Operations sequence
Exhaust gas return system > Exhaust return system components - remove and install
Exhaust gas return system > Vacuum hose connections
Exhaust gas return system > Check exhaust gas return valve
Exhaust gas return system > Check exhaust gas return valve > Checking sequence
Volkswagen Workshop Manuals > Engine > 4 - Cyl. diesel engine (with distributor injection pump) > Ignition system, glow
plug system > Pre-heating system - check > Spark plugs - check
Volkswagen Workshop Manuals > Engine > 4 - Cyl. diesel engine (with distributor injection pump) > Ignition system, glow
plug system > Pre-heating system - check > Spark plugs - check > Checking sequence
Volkswagen Workshop Manuals > Engine > 4 - Cyl. diesel engine (with unit injectors) > Technical data > Technical data >
Engine number
Volkswagen Workshop Manuals > Engine > 4 - Cyl. diesel engine (with unit injectors) > Engine assy,cylinder
Volkswagen Workshop Manuals > Engine > 4 - Cyl. diesel engine (with unit injectors) > Engine assy,cylinder
block,crankcase > Engine - remove and install > Aggregated insulation bearings > Torques:
Volkswagen Workshop Manuals > Engine > 4 - Cyl. diesel engine (with unit injectors) > Enginecrankshaft group, pistons >
Engine - disassemble and assemble > Poly-V belt - remove and install
Engine - disassemble and assemble > Poly-V belt - remove and install > Vehicles without climatization
Engine - disassemble and assemble > Poly-V belt - remove and install > Vehicles with climatization
Crankshaft and engine wheel sealing - remove and install > Crankshaft sealing, pulley side - replace
Crankshaft and engine wheel sealing - remove and install > Seal flange on pulley side - assemble and disassemble
Crankshaft - remove and install
Pistons and rods - disasemble and assemble
Pistons and rods - disasemble and assemble > Piston position on upper part - check
Volkswagen Workshop Manuals > Engine > 4 - Cyl. diesel engine (with unit injectors) > Engine cylinder head, valve gear >
Head - disassembly and assembly > Head cover - remove and install
Head - disassembly and assembly > Head cover - remove and install > Removal
Head - disassembly and assembly > Indented belt - remove and install, adjust
Head - disassembly and assembly > Head - remove and install
Head - disassembly and assembly > Compression - checking
Valve command unit - repair > Valves - check guides
Valve command unit - repair > Valves - check guides > Checking sequence
Valve command unit - repair > Valve stem seals - replace
Valve command unit - repair > Valve stem seals - replace > Installation
Valve command unit - repair > Valve command shaft - remove and install
Valve command unit - repair > Valve command shaft - remove and install > Remove
Valve command unit - repair > Valve command shaft seal - remove and install
Volkswagen Workshop Manuals > Engine > 4 - Cyl. diesel engine (with unit injectors) > Engine lubrication > Lubrication
system components - remove and install > Carter - remove and install
system components - remove and install > Oil pressure and oil pressure switch - check
system components - remove and install > Oil pressure and oil pressure switch - check > Checking sequence
Volkswagen Workshop Manuals > Engine > 4 - Cyl. diesel engine (with unit injectors) > Engine cooling > Cooling system
components - remove and install > Cooling system components on the body
components - remove and install > Engine cooling system components
components - remove and install > Connector system of cooling hoses > Engine ATD identification letter
components - remove and install > Cooling fluid - drain and supply
components - remove and install > Radiator - remove and install
components - remove and install > Water pump - remove and install
components - remove and install > Thermostat valve - remove and install
Volkswagen Workshop Manuals > Engine > 4 - Cyl. diesel engine (with unit injectors) > Fuel supply, gas operation > Supply
system components - remove and install > Fuel container with accessories - remove and install
system components - remove and install > Fuel filter - repair
system components - remove and install > Fuel radiator - remove and install
system components - remove and install > Fuel container - remove and install
system components - remove and install > Fuel pump - remove and install
system components - remove and install > Fuel level meter - remove and install > Removal
system components - remove and install > Fuel pump - check
system components - remove and install > Fuel pump - check > Check operation and tension supply
system components - remove and install > Throttle starting system - repair
system components - remove and install > Tandem pump - check
system components - remove and install > Tandem pump - check > Operation sequence
system components - remove and install > Tandem pump - remove and install
system components - remove and install > Tandem pump - remove and install > Removal
Volkswagen Workshop Manuals > Engine > 4 - Cyl. diesel engine (with unit injectors) > Exhaust turbocharger, G-charger >
Over-supply system with turbo-compressor > Safety measures > ATD engine identification letter
Volkswagen Workshop Manuals > Engine > 4 - Cyl. diesel engine (with unit injectors) > Fuel preparation system Diesel
injection > Diesel direct injection system - repair > Admission air tube butterfly - repair > Engine ATD identification letter
injection > Diesel direct injection system - repair > Pump unit-injector - repair
injection > Diesel direct injection system - repair > Sealing ringsfor pump unit-injector - remove and install
injection > Diesel direct injection system - repair > Pump-injector unit - remove and install
injection > Diesel direct injection system - repair > Pump-injector unit - remove and install > Removal
injection > Engine control unit > Engine control unit fault memory - check and erase
injection > Engine control unit > Engine control unit fault memory - check and erase > Operation sequence
injection > Engine control unit > Functions and components - adapt
injection > Engine control unit - remove and install
Volkswagen Workshop Manuals > Engine > 4 - Cyl. diesel engine (with unit injectors) > Exhaust system > Exhaust system
components - remove and install > Exhaust system - alignment > Condition
Volkswagen Workshop Manuals > Engine > 4 - Cyl. diesel engine (with unit injectors) > Exhaust system > Exhaust gas
return system > Exhaust gas return system components - remove and install > Engine ATD identification letter
Volkswagen Workshop Manuals > Engine > 4 - Cyl. diesel engine (with unit injectors) > Ignition system, glow plug system >
Pre-heating installation - check
Pre-heating installation - check > Glower plugs - check
Pre-heating installation - check > Glower plugs - check > Checking sequence
Volkswagen Workshop Manuals > Engine > 4 - Cyl. injection engine > Technical data > Technical data > Engine number
Volkswagen Workshop Manuals > Engine > 4 - Cyl. injection engine > Engine assy,cylinder block,crankcase > Engine -
remove and install
Volkswagen Workshop Manuals > Engine > 4 - Cyl. injection engine > Engine assy,cylinder block,crankcase > Engine -
remove and install > Engine - fasten on the assembly stand
Volkswagen Workshop Manuals > Engine > 4 - Cyl. injection engine > Enginecrankshaft group, pistons > Engine -
disassemble and assemble > Poly-V belt - remove and install > Removal
Volkswagen Workshop Manuals > Engine > 4 - Cyl. injection engine > Enginecrankshaft group, pistons > Engine -
disassemble and assemble > Poly-V belt - remove and install > Poly-V belt travel
Volkswagen Workshop Manuals > Engine > 4 - Cyl. injection engine > Enginecrankshaft group, pistons > Engine - assembly
and disassembly > Seal lid - replace > Removal
and disassembly > Seal lid - replace > Installation
and disassembly > Poly-V belt - remove and install > Removal
and disassembly > Poly-V belt - remove and install > Poly-V belt routing.
and disassembly > Poly-V belt - remove and install > Vehicles without air conditioner compressor and with hydraulic power
steering pump.
and disassembly > Poly-V belt - remove and install > Elastic Poly-V belt routing
Volkswagen Workshop Manuals > Engine > 4 - Cyl. injection engine > Enginecrankshaft group, pistons > Crankshaft and
flywheel flanges - remove and install > Crankshaft seal (pulley side) - replace
flywheel flanges - remove and install > Crankshaft seal (pulley side) - replace > Removal
flywheel flanges - remove and install > Crankshaft flange (pulley side) - remove and install
flywheel flanges - remove and install > Crankshaft flange (pulley side) - remove and install > Removal
Volkswagen Workshop Manuals > Engine > 4 - Cyl. injection engine > Engine cylinder head, valve gear > Engine cylinder
head - remove and install > Timing belt - remove and install, adjust
head - remove and install > Timing belt - remove and install, adjust > Removal
head - remove and install > Timing belt semi-automatic tensioning pulley - check
head - remove and install > Timing belt semi-automatic tensioning pulley - check > Prerequisite
head - remove and install > Engine cylinder head - remove and install
head - remove and install > Compression - check
head - remove and install > Compression - check > Operation sequence
Volkswagen Workshop Manuals > Engine > 4 - Cyl. injection engine > Engine cylinder head, valve gear > Cylinder head -
assembly and disassembly > Toothed belt semi-automatic tensioning roller - check
assembly and disassembly > Toothed belt - remove and install, adjust
assembly and disassembly > Toothed belt - remove and install, adjust > Removal
assembly and disassembly > Toothed belt - remove and install, adjust > Tensioner without adjustment
assembly and disassembly > Cylinder head - remove and install
assembly and disassembly > Compression - check
assembly and disassembly > Compression - check > Operation sequence
Volkswagen Workshop Manuals > Engine > 4 - Cyl. injection engine > Engine cylinder head, valve gear > Valve control
mechanism - repair > Valve seats - rework > Grind intake valve seats
mechanism - repair > Valve seats - rework > Grind exhaust valve seat
mechanism - repair > Camshaft seal - replace
mechanism - repair > Camshaft seal - replace > Removal
mechanism - repair > Camshaft - remove and install
mechanism - repair > Valve guides - check
mechanism - repair > Valve guides - check > Checking sequence
mechanism - repair > Valve stem seals - replace
mechanism - repair > Valve stem seals - replace > Installation
Volkswagen Workshop Manuals > Engine > 4 - Cyl. injection engine > Engine cylinder head, valve gear > Camshaft
mechanism - repair > Camshaft - check axial clearance
mechanism - repair > Valve seat - trim > Grind inlet valve seat
mechanism - repair > Valve seat - trim > Grind exhaust valve seat
mechanism - repair > Camshaft seal - replace
mechanism - repair > Camshaft seal - replace > Removal
mechanism - repair > Camshaft seal - replace > Installation
mechanism - repair > Camshaft and cylinder head cover - remove and install
mechanism - repair > Valve guides - check
mechanism - repair > Valve guides - check > Test sequence
mechanism - repair > Valve stem sealant - replace
mechanism - repair > Valve stem sealant - replace > Installation
Volkswagen Workshop Manuals > Engine > 4 - Cyl. injection engine > Engine lubrication > Lubrication system components
- remove and install > Crankcase - remove and install
- remove and install > Crankcase - remove and install > Oil crankcase (upper part)
- remove and install > Crankcase - remove and install > Oil pan
- remove and install > Oil pump - remove and install
- remove and install > Oil pump - remove and install > Removal
- remove and install > Oil pressure and Oil pressure switch F1 - check
- remove and install > Oil pressure and Oil pressure switch F1 - check > Checking sequence
Volkswagen Workshop Manuals > Engine > 4 - Cyl. injection engine > Engine cooling > Cooling system components -
remove and install > Cooling system hose connection diagram
remove and install > Cooling system - drain and fill
remove and install > Cooling system - drain and fill > Operation sequence
remove and install > Cooling system - drain and fill > Without the Cooling system supply unit VAS 6096
remove and install > Radiator - remove and install
remove and install > Water pump - remove and install
remove and install > Water pump - remove and install > Installation
remove and install > Thermostatic valve of the cooling system - remove nd install
Volkswagen Workshop Manuals > Engine > 4 - Cyl. injection engine > Fuel supply, gas operation > Supply system
components - remove and install > Fuel tank with assembly parts and fuel filter - remove and install
components - remove and install > Cold start system components - remove and install
components - remove and install > Cold start system components - remove and install > Part I
components - remove and install > Cold start system components - remove and install > Part II
components - remove and install > Cold start system components - remove and install > Part III
components - remove and install > Fuel pump (pre-supply pump) G6 - remove and install
components - remove and install > Fuel level indicator sensor G - remove and install > Removal
components - remove and install > Fuel reservoir - remove and install
components - remove and install > Fuel pump (pre-supply pump) G6 - check
Volkswagen Workshop Manuals > Engine > 4 - Cyl. injection engine > Fuel supply, gas operation > Fuel supply system
components - remove and install > Fuel tank components with accessories and fuel filter - remove and install
components - remove and install > Cold start system components - remove and install
components - remove and install > Cold start system components - remove and install > Part I
components - remove and install > Cold start system components - remove and install > Part II
components - remove and install > Cold start system components - remove and install > Part III
components - remove and install > Cold start system components
components - remove and install > Fuel pump (pre-supply pump)G6 - remove and install
components - remove and install > Fuel gauge sensorG - remove and install > Removal
components - remove and install > Fuel tank - remove and install
components - remove and install > Fuel pump (pre-supply pump)G6 - check
Volkswagen Workshop Manuals > Engine > 4 - Cyl. injection engine > Fuel supply, gas operation > Engine power electronic
adjustment (E-Gas electronic accelerator) components - repair .
Volkswagen Workshop Manuals > Engine > 4 - Cyl. injection engine > Fuel supply, gas operation > Engine power electronic
adjustment (electronic throttle) - check
Volkswagen Workshop Manuals > Engine > 4 - Cyl. injection engine > Fuel supply, gas operation > Activated charcoal filter
system > Activated charcoal filter components - repair
Volkswagen Workshop Manuals > Engine > 4 - Cyl. injection engine > Fuel supply, gas operation > Activated charcoal filter
system > Fuel tank ventilation - check
Volkswagen Workshop Manuals > Engine > 4 - Cyl. injection engine > Mixture preparation system, electronic inj.,Gas >
Injection - repair > Component location - overview
Injection - repair > Injection components - remove and install
Injection - repair > Intake manifold (upper part) - disassemble and assemble
Injection - repair > Intake manifold (lower part) - disassemble and assemble
Injection - repair > Fuel distributor with injection valves - remove and install
Injection - repair > Air filter - disassemble and assemble
Injection system - repair > Component location
Injection system - repair > Injection components - remove and install
Injection system - repair > Intake manifold - remove and install
Injection system - repair > Fuel rail with injectors - remove and install
Injection system - repair > Air filter case - disassemble and assemble
Injection components - check
Injection components - check > Residual pressure and fuel pressure regulator - check
Component checks > Injection valves - check
Component checks > Residual pressure and fuel pressure regulator - check
Component checks > Residual pressure and fuel pressure regulator - check > Check fuel pressure regulator
Engine control unit J623 > Engine control unit J623 - remove and install > Removal
Engine control unit J623 > Injection components - adapt
Engine control unit J623 > Injection components - adapt > Operation sequence
Engine control unit J623 > Fault memory in the Engine control unit J623 - read and clear
Engine control unit J623 > Fault memory in the Engine control unit J623 - read and clear > Operation sequence
Volkswagen Workshop Manuals > Engine > 4 - Cyl. injection engine > Exhaust system > Exhaust system components -
remove and install
remove and install > Intake manifold, front tube with catalytic converter and assembly parts - overview
remove and install > Muffler with cushions - assembly overview
Volkswagen Workshop Manuals > Engine > 4 - Cyl. injection engine > Ignition system, glow plug system > Ignition - repair >
Safety measures
Volkswagen Workshop Manuals > Engine > 4 - Cyl. injection engine > Ignition system, glow plug system > Ignition system -
repair > Safety measures
Volkswagen Workshop Manuals > Engine > 4 - Cyl. injection engine > Ignition system, glow plug system > Ignition system -
repair > Checking heating plugs
Volkswagen Workshop Manuals > Vehicle electrics > Electrical system > Starter-current supply-CC > Battery > BatteryA -
remove and install > Remove the BatteryA (Version 1).
Volkswagen Workshop Manuals > Vehicle electrics > Electrical system > Starter-current supply-CC > Battery > BatteryA
console - remove and install > BatteryA console (version 1) - remove and install
Volkswagen Workshop Manuals > Vehicle electrics > Electrical system > Starter-current supply-CC > Battery > BatteryA
console - remove and install > BatteryA console (version 2) - remove and install
Volkswagen Workshop Manuals > Vehicle electrics > Electrical system > Starter-current supply-CC > Starter > StarterB -
remove and install
remove and install > StarterB for vehicles with 1.0l, 1.6l and 2.0l engines (ARA, BAH, BPA, CCRA, BBX, CFEA)
remove and install > StarterB for vehicles with 1.4l engines (BBZ, BBY, BKY)
remove and install > StarterB for vehicles with 1.4l engine (BAY)
remove and install > StarterB for vehicles with 1.9l engine (ASY)
(Manufacturer Valeo) - disassemble and assemble
(Manufacturer Valeo) - disassemble and assemble > Magnetic switch - remove and install
(Manufacturer Valeo) - disassemble and assemble > Armature and gearing pinion - remove and install
(Manufacturer Bosch) - disassemble and assemble
(Manufacturer Bosch) - disassemble and assemble > Magnetic switch - remove and install
(Manufacturer Bosch) - disassemble and assemble > Armature - remove and install
(Manufacturer Bosch) - disassemble and assemble > Gearing pinion (Fastened on planetary shaft) - remove and install
(Manufacturer Bosch) - disassemble and assemble > Bearing bush - remove and install
Volkswagen Workshop Manuals > Vehicle electrics > Electrical system > Starter-current supply-CC > Alternator > Generator
(Alternator)C for 1.6l (CCRA) engine - assembly overview
(Alternator)C for 1.6l (CCRA) engine - assembly overview > Generator (Alternator)C for 1.6l (CCRA) engine - remove and
install
(Alternator)C for 1.0 and 1.6l (ARA, BPA, BAH) engines - assembly overview
(Alternator)C for 1.0 and 1.6l (ARA, BPA, BAH) engines - assembly overview > Generator (Alternator)C for 1.0 and 1.6l
(ARA, BPA, BAH) engines - remove and install
(Alternator)C for 1.4 and 1.6l (BBZ, BBY, BKY, BAH) engines - assembly overview
(Alternator)C for 1.4 and 1.6l (BBZ, BBY, BKY, BAH) engines - assembly overview > Generator (Alternator)C for 1.4 and
1.6l (BBZ, BBY, BKY, BAH) engines - remove and install
(Alternator)C for 1.4l (BAY) engine - assembly overview
(Alternator)C for 1.4l (BAY) engine - assembly overview > Generator (Alternator)C for 1.4l (BAY) engine - remove and install
(Alternator)C for 1.9l (ASY) engine - assembly overview
(Alternator)C for 1.9l (ASY) engine - assembly overview > Generator (Alternator)C for 1.9l (ASY) engine - remove and install
(Alternator)C for 2.0l (BBX, CFEA) engines - assembly overview
(Alternator)C for 2.0l (BBX, CFEA) engines - assembly overview > Generator (Alternator)C for 2.0l (BBX, CFEA) engines -
remove and install
(Alternator)C - replace Poly-V belt pulley
(Alternator)C - replace Poly-V belt pulley > Removal
Volkswagen Workshop Manuals > Vehicle electrics > Electrical system > Starter-current supply-CC > Alternator > Voltage
regulatorC1 (Manufacturer Bosch) - disassemble and assemble
regulatorC1 (Manufacturer Bosch) - disassemble and assemble > Disassembly
regulatorC1 (Manufacturer Valeo) - disassemble and assemble
regulatorC1 (Manufacturer Valeo) - disassemble and assemble > Disassembly
regulatorC1 (Manufacturer Valeo) - disassemble and assemble > Assembly
Volkswagen Workshop Manuals > Vehicle electrics > Electrical system > Instruments, GCI > Combined instrument >
Locating defects and indicating faults
Combined instrumentK - remove and install > Installation
Combined instrumentK - control light symbols > Version (12/07?)
Combined instrumentK - control light symbols > Version (07/06?)
Combined instrumentK - control light symbols > Version (? 07/06)
Volkswagen Workshop Manuals > Vehicle electrics > Electrical system > Instruments, GCI > Cigarette lighter and 12V
socket > Cigarette lighterU1 and 12V socketU5 - general overview of assembly
Volkswagen Workshop Manuals > Vehicle electrics > Electrical system > Instruments, GCI > Cigarette lighter and 12V
socket > Cigarette lighterU1 and 12V socketU5 - remove and install > Installation
Volkswagen Workshop Manuals > Vehicle electrics > Electrical system > Windscreen wipe/wash system > Windscreen
wiper system > Windscreen wiper system - assembly overview
wiper system > Windscreen wiper blade - remove and install > Windscreen wiper blade
wiper system > Windscreen wiper blade - remove and install > Windscreen wiper blade - streamlined (version 1)
wiper system > Windscreen wiper blade - remove and install > Windscreen wiper blade - streamlined (version 2)
wiper system > Windscreen wiper blade and arm set - remove and install
wiper system > Windscreen wiper blade and arm set - remove and install > Installation
wiper system > Windscreen wiper mechanism - remove and install > Removal
wiper system > Windscreen wiper mechanism - remove and install > Installation
wiper system > Windscreen wiper blade resting position - adjust > Driver's side
wiper system > Windscreen wiper blade resting position - adjust > Passenger's side
wiper system > Rain sensorG213 - remove and install > Removal
wiper system > Rain sensor and sunlight penetration photosensorG397 - remove and install > Removal
washer system > Reservoir for the windscreen and rear window washer system (version 1) - remove and install
washer system > Reservoir for the windscreen and rear window washer system (version 1) - remove and install > Removal
washer system > Reservoir for the windscreen and rear window washer system (version 2) - remove and install
washer system > Reservoir for the windscreen and rear window washer system (version 2) - remove and install > Removal
washer system > Windscreen and rear window washer pumpV59 - remove and install > Removal
washer system > Windscreen washer system washer jets - replace > Removal
Volkswagen Workshop Manuals > Vehicle electrics > Electrical system > Windscreen wipe/wash system > Rear window
wiper system > Rear window wiper and washer system - assembly overview
wiper system > Rear window wiper arm - remove and install > Removal
wiper system > Rear window wiper arm - remove and install > Installation
wiper system > Rear window wiper motorV12 - remove and install > Removal
wiper system > Rear window wiper blade resting position - adjust
wiper system > Rear window wiper blade - remove and install > Rear window wiper blade (version 1)
wiper system > Rear window wiper blade - remove and install > Rear window wiper blade (version 2)
washer system > Rear window washer system - assembly overview
washer system > Rear window washer system washer jet - replace > Removal
Volkswagen Workshop Manuals > Vehicle electrics > Electrical system > Lights, lamps, switches outside > Main headlights
(?07/06) > Main headlights (?07/06) - general assembly overview
(?07/06) > Left headlight beam reach control motor V48 and/or Right headlight beam reach control motorV49 (Manufacturer
- automotiv lighti
- automotiv lighti > Removal
- automotiv lighti > Installation
- Valeo) - remove > Installation
(?07/06) > Mains headlight lamps (?07/06) - replace > Left front sidelight lampM1 and/or Right front sidelight lampM3 -
replace
(?07/06) > Mains headlight lamps (?07/06) - replace > Left low-beam headlight lampM29 and/or Right low-beam headlight
lampM31 - replace
(?07/06) > Mains headlight lamps (?07/06) - replace > Left high-beam headlight lampM30 and/or Right high-beam headlight
lampM32 - replace
(?07/06) > Mains headlight lamps (?07/06) - replace > Left front indicator light lampM5 and/or Right front indicator light
lampM7 - replace
(?07/06) > Main headlights (?07/06) - repair fastening tabs > Upper fastening tab - repair
(?07/06) > Main headlights (?07/06) - repair fastening tabs > Side fastening tab - repair
(?06/11) > Main headlights (?06/11) - general assembly overview
(?06/11) > Main headlights (?06/11) - remove and install > Installation
- Hella) - remove
- Hella) - remove > Installation
(?06/11) > Main headlights "Manufacturer: Hella" (?06/11) - replace the lamp > Left front sidelight lampM1 and/or Right front
sidelight lampM3 - replace
(?06/11) > Main headlights "Manufacturer: Hella" (?06/11) - replace the lamp > Left low-beam headlight lampM29 and/or
Right low-beam headlight lampM31 - replace
(?06/11) > Main headlights "Manufacturer: Hella" (?06/11) - replace the lamp > Left high-beam headlight lampM30 and/or
Right high-beam headlight lampM32 - replace
(?06/11) > Main headlights "Manufacturer: Hella" (?06/11) - replace the lamp > Left front indicator light lampM5 and/or Right
front indicator light lampM7 - replace
(?06/11) > Main headlights "Manufacturer: Valeo" (?06/11) - replace the lamp > Left front sidelight lampM1 and/or Right
front sidelight lampM3 - replace
(?06/11) > Main headlights "Manufacturer: Valeo" (?06/11) - replace the lamp > Left high-beam headlight lampM30 and/or
Right high-beam headlight lampM32 - replace
(?06/11) > Main headlights "Manufacturer: Valeo" (?06/11) - replace the lamp > Left front indicator light lampM5 and/or
Right front indicator light lampM7 - replace
(?06/11) > Main headlights (?06/11) - repair fastening tabs > Upper fastening tab - repair
(?06/11) > Main headlights (?06/11) - repair fastening tabs > Side fastening tab - repair
(?06/11) > Main headlights (?06/11) - repair fastening tabs > Lower fastening tab - repair
(07/11?) > Main headlights (07/11?) - general assembly overview
(07/11?) > Main headlights (07/11?) - remove and install > Installation
(07/11?) > Main headlights (07/11?) - replace lamp > Left front sidelight lampM1 and/or Right front sidelight lampM3 -
replace
(07/11?) > Main headlights (07/11?) - replace lamp > Left low-beam headlight lampM29 and/or Right low-beam headlight
lampM31 - replace
(07/11?) > Main headlights (07/11?) - replace lamp > Left high-beam headlight lampM30 and/or Right high-beam headlight
lampM32 - replace
(07/11?) > Main headlights (07/11?) - replace lamp > Left front indicator light lampM5 and/or Right front indicator light
lampM7 - replace
(07/11?) > Main headlights (07/11?) - repair fastening tabs > Upper fastening tab - repair
(07/11?) > Main headlights (07/11?) - repair fastening tabs > Side fastening tab - repair
(07/11?) > Main headlights (07/11?) - repair fastening tabs > Lower fastening tab - repair
Volkswagen Workshop Manuals > Vehicle electrics > Electrical system > Lights, lamps, switches outside > Fog lights
(?07/06) > Fog lights - remove and install > Installation
(?07/06) > Left fog light lampL22 and/or Right fog light lampL23 - replace > Removal
Volkswagen Workshop Manuals > Vehicle electrics > Electrical system > Lights, lamps, switches outside > Fog headlights
(?06/11) > Fog lights - remove and install > Installation
Volkswagen Workshop Manuals > Vehicle electrics > Electrical system > Lights, lamps, switches outside > Fog headlights
(?06/11) > Left fog light lampL22 andRight fog light lampL23 - replace > Removal
(07/11?) > Fog lights - remove and install > Installation
(07/11?) > Left fog light lampL22 andRight fog light lampL23 - replace > Removal
Volkswagen Workshop Manuals > Vehicle electrics > Electrical system > Lights, lamps, switches outside > Headlights -
check adjustment
Volkswagen Workshop Manuals > Vehicle electrics > Electrical system > Lights, lamps, switches outside > Turn signal
repeater lights > Turn signal repeater lights - remove and install > Installation
Volkswagen Workshop Manuals > Vehicle electrics > Electrical system > Lights, lamps, switches outside > Taillights
(?07/06) > Tail lights (Hatch) - assembly overview
(?07/06) > Tail lights (Hatch) - assembly overview > Tail light lamp support (Hatch) - disassemble and assemble
(?07/06) > Tail lights (Sedan) - assembly overview
(?07/06) > Tail lights (Sedan) - assembly overview > Tail light lamp support (Sedan) - disassemble and assemble
(08/06?) > Tail lights (Hatch) - assembly overview
(08/06?) > Tail lights (Hatch) - assembly overview > Tail light lamp support (Hatch) - disassemble and assemble
(08/06?) > Tail lights (Sedan) - assembly overview
(08/06?) > Tail lights (Sedan) - assembly overview > Side tail light lamp support - disassemble and assemble
Volkswagen Workshop Manuals > Vehicle electrics > Electrical system > Lights, lamps, switches outside > Number plate
light > Number plate lightX (Hatch) - replace the lamp
Volkswagen Workshop Manuals > Vehicle electrics > Electrical system > Lights, lamps, switches outside > Number plate
light > Number plate light (Sedan) - remove and install
Volkswagen Workshop Manuals > Vehicle electrics > Electrical system > Lights, lamps, switches outside > Additional brake
light > Additional brake light (Hatch) > Additional brake light (version 1) - remove and install
light > Additional brake light (Hatch) > Additional brake light lamp support (version 1) - remove and install
light > Additional brake light (Hatch) > Additional brake light (version 3) - remove and install
light > Additional brake light (Sedan) > Additional brake light (Sedan) - remove and install
Volkswagen Workshop Manuals > Vehicle electrics > Electrical system > Lights, lamps, switches outside > Light switches
on the instrument panel > Light switchE1 - remove and install > Removal
on the instrument panel > Light switchE1 - remove and install > Installation
on the instrument panel > Headlight reach adjustment controlE102 and/or Instrument switch and lighting adjustmentE20 -
remove and install > Removal
Volkswagen Workshop Manuals > Vehicle electrics > Electrical system > Lights, lamps, switches outside > Switch set >
Indicator and wiper/washer switches - remove and install > Removal
Volkswagen Workshop Manuals > Vehicle electrics > Electrical system > Lights, lamps, switches outside > Switch set >
Indicator and wiper/washer switches - remove and install > Installation
Volkswagen Workshop Manuals > Vehicle electrics > Electrical system > Lights, lamps, switches outside > Ignition/starter
switch and key cylinder > Ignition switchD - remove and install > Removal
Volkswagen Workshop Manuals > Vehicle electrics > Electrical system > Lights, lamps, switches outside > Auxiliary parking
system > Auxiliary parking system - assembly general view
system > Control unit for Park Assist steeringJ446 (Hatch) - remove and install > Removal
system > Warning buzzer for rear Park Assist steeringH15 (Hatch) - remove and install > Removal
system > Control unit for Park Assist steeringJ446 (Sedan) - remove and install > Removal
system > Warning buzzer for rear Park Assist steeringH15 (Sedan) - remove and install > Removal
system > Park Assist steering sensor - remove and install > Removal
Volkswagen Workshop Manuals > Vehicle electrics > Electrical system > Lights, lamps, switches inside, anti-theft system >
Lights and internal switches > Interior monitoring deactivation switchE267 (version 2) - remove and install > Removal
Lights and switches in the engine compartment > Contact switch for bonnetF266 - remove and install > Removal
Switched on the instrument panel > Dashboard switches - remove and install
Front door lights and switches > Front and rear window drive switches - remove and install > Removal
Front door lights and switches > Right front window drive switchE41 - remove and install > Removal
Front door lights and switches > Rearview mirror adjustment switchE43 with switch for rearview mirror adjustmentE48 -
Rear door lights and switches > Power window drive switch on left rear doorE52 and/or Power window drive switch on right
rear doorE54 - remove and install > Removal
Lights and switches in luggage compartment > Luggage compartment lighting - remove and install > Removal
Lights and switches in luggage compartment > Luggage Compartment lighting fixtureW3 - replace
Roof lining lights and switches > Internal front lightW1 > Internal front lightW1 - remove and install
Roof lining lights and switches > Front internal lightW1 with reading light > Sunroof sliding adjustmentE139 - remove and
install
Roof lining lights and switches > Make-up mirror lighting - remove and install > Make-up mirror lighting lampL31 - replace
Horns > Treble tone hornH2 - remove and install > Removal
Horns > Treble tone hornH2 and Bass tone hornH7 - remove and install > Removal
Horns > Treble tone hornH2 and Bass tone hornH7 - remove and install > Installation
Immobilizer > Ignition key - adapt to immobilizer
Alarm System > Ultra-sound sensor for alarm systemG209 - remove and install
Alarm System > Ultra-sound sensor for alarm systemG209 - remove and install > On vehicles without sunroof
Alarm System > Ultra-sound sensor for alarm systemG209 - remove and install > On vehicles with sunroof
Alarm System > Alarm system hornH8 - remove and install > Removal
Alarm System > Alarm system hornH8 - remove and install > Installation
Volkswagen Workshop Manuals > Vehicle electrics > Electrical system > Wiring > Fuse holder > Instrument panel fuse
holder - remove and install > Installation
Volkswagen Workshop Manuals > Vehicle electrics > Electrical system > Wiring > Fuse box > Fuse box - remove and install
> Main fuse holder (Version 1) - remove and install
> Main fuse holder (version 2) - remove and install
> Main fuse holder (versions 3 and 4) - remove and install
> Main fuse holder (version 5) - remove and install
Volkswagen Workshop Manuals > Vehicle electrics > Electrical system > Wiring > Relay carrier > Relay carrier - remove
and install
Volkswagen Workshop Manuals > Vehicle electrics > Electrical system > Wiring > Power distributor > Power distributor -
disassemble and assemble
Volkswagen Workshop Manuals > Vehicle electrics > Electrical system > Wiring > Coupling stations and multi-pin connector
> Coupling station - A pillar
> Coupling station - B pillar
> Multi-pin connector in the fire wall > Removing and installing the multi-pin connector on the engine side (version 1)
> Multi-pin connector in the fire wall > Removing and installing the multi-pin connector on the engine side (version 2)
Volkswagen Workshop Manuals > Vehicle electrics > Electrical system > Wiring > Control units > Control unit for the
on-board electrical systemJ519 > Control unit for the on-board electrical systemJ519 - remove and install
Volkswagen Workshop Manuals > Vehicle electrics > Electrical system > Wiring > Control units > Control unit for the
on-board electrical systemJ519 > Control unit for the on-board electrical systemJ519 - replace
Volkswagen Workshop Manuals > Vehicle electrics > Electrical system > Wiring > Control units > Interactive System control
unitJ879 > Interactive system control unitJ879 - General assembly overview
Volkswagen Workshop Manuals > Vehicle electrics > Electrical system > Wiring > Control units > Control unit of lights with
windscreen wiper functionsJ917 > Control unit of lights with windscreen wiper functionsJ917 - Assembly overview
Volkswagen Workshop Manuals > Vehicle electrics > Electrical system > Wiring > Control units > Control unit of lights with
windscreen wiper functionsJ917 > Control unit of lights with windscreen wiper functionsJ917 - remove and install
Volkswagen Workshop Manuals > Vehicle electrics > Communication > Infotainment > Communication Systems >
Troubleshooting
Volkswagen Workshop Manuals > Vehicle electrics > Communication > Infotainment > Radio R > RadioR"ALPHA" ? 12/04
> RadioR"ALPHA" - Assembly overview
> RadioR"ALPHA" - remove and install
> RadioR"ALPHA" - connector pinout
Volkswagen Workshop Manuals > Vehicle electrics > Communication > Infotainment > Radio R > RadioR"BETA" ? 12/04
Volkswagen Workshop Manuals > Vehicle electrics > Communication > Infotainment > Radio R > RadioR"BETA" ? 12/04 >
RadioR"BETA" - Assembly overview
RadioR"BETA" - remove and install
RadioR"BETA" - connector pinout
Volkswagen Workshop Manuals > Vehicle electrics > Communication > Infotainment > Radio R > RadioR"GAMMA" ? 12/04
> RadioR"GAMMA" - Assembly overview
> RadioR"GAMMA" - remove and install
> RadioR"GAMMA" - connector pinout
> RadioR"BETA" and "GAMMA" - adapt
Volkswagen Workshop Manuals > Vehicle electrics > Communication > Infotainment > "CD player"R89 > "CD
player"R89"MP3" - 08/06 ?
player"R89"MP3" - 08/06 ? > "CD player"R89"MP3" - assembly overview
player"R89"MP3" - 08/06 ? > "CD player"R89"MP3" - remove and install
player"R89"MP3" - 08/06 ? > "CD player"R89"MP3" - connector pinout
player"R89"MP3" - 08/06 ? > "CD player"R89"MP3" - adapt
player"R89"Clarion MP3" - 08/06 ?
player"R89"Clarion MP3" - 08/06 ? > "CD player"R89"Clarion MP3" - assembly overview
player"R89"Clarion MP3" - 08/06 ? > "CD player"R89"Clarion MP3" - remove and install
player"R89"Clarion MP3" - 08/06 ? > "CD player"R89"Clarion MP3" - connector pinout
player"R89"RCD 200" - 08/06 ?
player"R89"RCD 200" - 08/06 ? > "CD player"R89"RCD 200" - assembly overview
player"R89"RCD 200" - 08/06 ? > "CD player"R89"RCD 200" - remove and install
player"R89"RCD 200" - 08/06 ? > "CD player"R89"RCD 200" - connector pinout
player"R89"RCD 200" - 08/06 ? > "CD player"R89"RCD 200" - adapt
Volkswagen Workshop Manuals > Vehicle electrics > Communication > Infotainment > "CD player"R89 > "CD player"R89"2
Din Clarion" - ? 12/07
Din Clarion" - ? 12/07 > "CD player"R89"2 Din Clarion" - general overview of assembly
Din Clarion" - ? 12/07 > "CD player"R89"2 Din Clarion" - remove and install
Din Clarion" - ? 12/07 > "CD player"R89"2 Din Clarion" - occupation of connectors
Volkswagen Workshop Manuals > Vehicle electrics > Communication > Infotainment > "CD player"R89 > "CD player"R89 "2
Din MID" - 02/08?
Din MID" - 02/08? > "CD player"R89"2 Din MID" - general overview of assembly
Din MID" - 02/08? > CD playerR89"2 Din MID" - remove and install
Din MID" - 02/08? > CD playerR89"2 Din MID" - connector pinout
player"R89"Concept" - 03/08 ?
player"R89"Concept" - 03/08 ? > "CD player"R89"Concept" - assembly overview
player"R89"Concept" - 03/08 ? > "CD player"R89"Concept" - remove and install
player"R89"Concept" - 03/08 ? > "CD player"R89"Concept" - connector pinout
Volkswagen Workshop Manuals > Vehicle electrics > Communication > Infotainment > Speakers > Left front treble
speakerR20 and/or Right front treble speakerR22 - replace > Removal
Volkswagen Workshop Manuals > Vehicle electrics > Communication > Infotainment > Multifunction steering wheel >
Multifunction steering wheel - general information
Multifunction steering wheel - general assembly overview
Command keys - remove and install > Removal
Volkswagen Workshop Manuals > Vehicle electrics > Communication > Infotainment > Antenna system > AntennaR11 -
remove and install
remove and install > Installation
Volkswagen Workshop Manuals > Vehicle electrics > Communication > Infotainment > Antenna system > Antenna cable -
general overview of assembly
Volkswagen Workshop Manuals > Vehicle electrics > Communication > Infotainment > Antenna system > Antenna cable -
Volkswagen Workshop Manuals > Vehicle electrics > Electrical system - General information > Starter-current supply-CC >
BatteryA > Warning notes and safety norms > Safety symbols on the BatteryA
BatteryA - check > Check BatteryA with inspection visor (magic eye)
BatteryA - check > Checking the charge of the BatteryA. > Description of the battery testing device, with printerVAS 5097A
BatteryA - charging > Battery chargerVAS 5095A > Description of the Battery chargerVAS 5095A
BatteryA - charging > Battery chargerVAS 5900 > Description of the Battery chargerVAS 5900
BatteryA - charging > Battery chargerVAS 5903 > Description of the Battery chargerVAS 5903
Volkswagen Workshop Manuals > Vehicle electrics > Electrical system - General information > Windscreen wipe/wash
system > Washer hoses - connecting and disconnecting
Volkswagen Workshop Manuals > Vehicle electrics > Electrical system - General information > Windscreen wipe/wash
system > Washer hoses - repair > Repairing smooth hoses
Volkswagen Workshop Manuals > Vehicle electrics > Electrical system - General information > Wiring > Harness and
connection repairs > Harness repair kits > Complementary setVAS 1978/50
connection repairs > Harness repair kits > Harness repair setVAS 1978A
connection repairs > Description of tools > Cleaving pliers VAS 1978/1
connection repairs > Description of tools > Assembly tool for simple cable linings
connection repairs > Description of tools > Pliers for stripping cablesVAS 1978/3
connection repairs > Harness repair > Repairing CAB-Bus system cables
connection repairs > Harness repair > Interruption in cables with a repaired section.
connection repairs > Harness repair > Interruption in cables with two repaired sections.
connection repairs > Repairing connector terminals and connectors > Repairing connector terminals
connection repairs > Unlocking and disassembling the terminals > Secondary locking
Volkswagen Workshop Manuals > Power transmission > 4 - Speed automatic gearbox 001 > Technical data > Identification
of gearbox > Location of identification data in the gearbox
Volkswagen Workshop Manuals > Power transmission > 4 - Speed automatic gearbox 001 > Technical data > Filling
quantities > Planetary gear and axle shaft command
Volkswagen Workshop Manuals > Power transmission > 4 - Speed automatic gearbox 001 > Technical data > General
indications for repair > Gaskets, retainers and oil
indications for repair > Fasteners
indications for repair > Screws, nuts
indications for repair > Internal discs
indications for repair > Clutches
indications for repair > Brakes
indications for repair > Assisted troubleshooting for damages, vehicle self-diagnosis and measurement module
Volkswagen Workshop Manuals > Power transmission > 4 - Speed automatic gearbox 001 > Torque converter > Torque
converter > Identification of the torque converter
converter > Distinctive letters for the torque converter
converter > Torque converter: empty
converter > Retainer of the torque converter: disassemble and assemble > Special tools, workshop equipment, checking
and measurement equipment, as well as auxiliary devices necessary
converter > Retainer of the torque converter: disassemble and assemble > Disassemble the retainer from the torque
converter
converter > Retainer of the torque converter: disassemble and assemble > Fit the retainer from the torque converter to the
level
converter > Torque converter: assemble
Volkswagen Workshop Manuals > Power transmission > 4 - Speed automatic gearbox 001 > Automatic gearbox, control,
assembly, housing > Electric and electronic components and their location > Components in the vehicle
assembly, housing > Electric and electronic components and their location > Gear components
assembly, housing > Transmission activation mechanism > Transmission activation mechanism: check
assembly, housing > Transmission activation mechanism > Transmission activation mechanism: disassemble and assemble
assembly, housing > Transmission activation mechanism > Electromagnet for blocking the selector lever -N110-:
disassemble and assemble > Disassembly
assembly, housing > Transmission activation mechanism > Selector lever cable: disassemble and assemble > Disassembly
assembly, housing > Transmission activation mechanism > Selector lever cable: disassemble and assemble > Assembly
assembly, housing > Transmission activation mechanism > Selector lever: disassemble and assemble
assembly, housing > Transmission activation mechanism > Blocking cable: disassemble and assemble > Disassembly
assembly, housing > Transmission activation mechanism > Blocking cable: disassemble and assemble > Assembly
assembly, housing > Gearbox: disassemble and assemble
assembly, housing > Gearbox: disassemble and assemble > Transmission disassembly
assembly, housing > ATF level: check and add
assembly, housing > Gearbox with command elements
Volkswagen Workshop Manuals > Power transmission > 4 - Speed automatic gearbox 001 > Automatic gearbox, gears,
control > ATF pump: disassemble and assemble
control > Idler pinion: disassemble and assemble
control > 1st to 3rd gear clutch -K1-: disassemble and assemble
control > Reverse clutch -K2-: disassemble and assemble
control > 3rd and 4th gear clutch -K3-: disassemble and assemble
control > Reverse brake -B1-: disassemble and assemble
control > Plungers for the 2nd and 4th -B2- brake: disassemble and assemble
control > Parking blocking: disassemble and assemble
Volkswagen Workshop Manuals > Power transmission > 4 - Speed automatic gearbox 001 > Final drive, differential,
differential lock > Flanged axle retainers: replace
differential lock > Flanged axle retainers: replace > Left flanged axle: disassemble and assemble
differential lock > Flanged axle retainers: replace > Right flanged axle: disassemble and assemble
differential lock > Final group: disassemble and assemble > Final group repair board
differential lock > Final group: disassemble and assemble > Differential: disassemble and assemble
differential lock > Final group: disassemble and assemble > Drive pinion shaft: disassemble and assemble
differential lock > Final group: adjust > General view of the adjustment works
differential lock > Final group: adjust > Differential: adjust
differential lock > Final group: adjust > Drive pinion shaft: adjust
Volkswagen Workshop Manuals > Power transmission > 5 - Speed manual gearbox 02T > Technical data > Transmission
identification > Location on transmission
assembly scheme > Nomenclature
assembly scheme > Gear ratios
Volkswagen Workshop Manuals > Power transmission > 5 - Speed manual gearbox 02T > Technical data > General repair
instructions > Gaskets and retainers
Volkswagen Workshop Manuals > Power transmission > 5 - Speed manual gearbox 02T > Clutch, control > Clutch
operating mechanism - repair
operating mechanism - repair > I - Command pedals - assembly overview
operating mechanism - repair > Clutch pedal switch F36 with round case - remove and install > Install and adjust
operating mechanism - repair > Clutch pedal return spring - remove and install
operating mechanism - repair > Clutch pedal return spring - remove and install > Removal
operating mechanism - repair > Clutch pedal return spring - remove and install > Installation
operating mechanism - repair > Clutch pedal support - remove and install
operating mechanism - repair > Clutch pedal support - remove and install > Installation
operating mechanism - repair > Clutch pedal - remove install
operating mechanism - repair > Clutch pedal - remove install > Removal
operating mechanism - repair > Clutch pedal - remove install > Installation
operating mechanism - repair > II - Hydraulic system - assembly overview
operating mechanism - repair > Transmitting cylinder - clutch hydraulic drive - remove and install
operating mechanism - repair > Transmitting cylinder - clutch hydraulic drive - remove and install > Installation
operating mechanism - repair > Clutch hydraulic drive slave cylinder - remove and install
operating mechanism - repair > Clutch system - bleed
Volkswagen Workshop Manuals > Power transmission > 5 - Speed manual gearbox 02T > Clutch, control > Clutch - repair
Volkswagen Workshop Manuals > Power transmission > 5 - Speed manual gearbox 02T > Gearbox mechanics,operation,
construction,diff. > Shift mechanism > Shift mechanism - installation position
construction,diff. > Shift mechanism > I - Handle and bellows on the gearshift lever - remove and install
construction,diff. > Shift mechanism > Handle and bellows on the gearshift lever - remove and install
construction,diff. > Shift mechanism > Handle and bellows on the gearshift lever - remove and install > Removal
construction,diff. > Shift mechanism > Handle and bellows on the gearshift lever - remove and install > Installation
construction,diff. > Shift mechanism > Handle and bellows on the gearshift lever - disassemble and assemble >
Disassembly
construction,diff. > Shift mechanism > Gear selection mechanism - adjust
construction,diff. > Shift mechanism > Gear selection mechanism - adjust > Gear selection mechanism - adjust
construction,diff. > Shift mechanism > Gear selection mechanism - adjust > Gear selection mechanism - check operation
construction,diff. > Transmission - remove and install
construction,diff. > Transmission - remove and install > Removal > Transmission transport
construction,diff. > Transmission - remove and install > Installation
construction,diff. > Transmission - remove and install > Installation > Tightening torques
construction,diff. > Transmission oil level - check and replenish
construction,diff. > Transmission oil level - check and replenish > Oil level - check
construction,diff. > Transmission oil level - check and replenish > Oil level - replenish
construction,diff. > Transmission - disassemble and assemble
construction,diff. > Transmission - disassemble and assemble > Transmission - assembly overview
construction,diff. > Transmission - disassemble and assemble > I - Gearbox case cover and 5th gear
construction,diff. > Transmission - disassemble and assemble > II - Clutch case
construction,diff. > Transmission - disassemble and assemble > III - Primary shaft, pinion shaft, differential, selection
mechanism and selection forks
construction,diff. > Transmission - disassemble and assemble > Primary shaft, pinion shaft, differential, selection
mechanism and selection forks - disassemble and assemble
mechanism and selection forks - disassemble and assemble > Disassembly
mechanism and selection forks - disassemble and assemble > Assembly
construction,diff. > Transmission and clutch cases - repair
construction,diff. > Gear selection mechanism - disassemble and assemble
construction,diff. > Selection forks - disassemble and assemble
Volkswagen Workshop Manuals > Power transmission > 5 - Speed manual gearbox 02T >
Gearbox,mechanics,gears,shafts,internal operation > Primary shaft - disassemble and assemble
Volkswagen Workshop Manuals > Power transmission > 5 - Speed manual gearbox 02T >
Gearbox,mechanics,gears,shafts,internal operation > Pinion shaft - disassemble and assemble
Volkswagen Workshop Manuals > Power transmission > 5 - Speed manual gearbox 02T > Final drive, differential,
differential lock > Retainer for the propelling flange - replace > Left propelling flange retainer - replace
differential lock > Retainer for the propelling flange - replace > Left propelling flange retainer - replace > Removal
differential lock > Retainer for the propelling flange - replace > Left propelling flange retainer - replace > Installation
differential lock > Retainer for the propelling flange - replace > Right propelling flange retainer - replace
differential lock > Retainer for the propelling flange - replace > Right propelling flange retainer - replace > Removal
differential lock > Retainer for the propelling flange - replace > Right propelling flange retainer - replace > Installation
differential lock > Differential - repair > Differential - disassemble and assemble
differential lock > Differential - repair > Differential - adjust
Volkswagen Workshop Manuals > Heating, ventilation, air conditioning > Heating, air conditioning > Heating > Heating -
passenger compartment components > Heat exchanger/engine compartment partition panel sealing
passenger compartment components > Natural air fanV2 > Fresh air fanV2 (version 1) - remove and install
passenger compartment components > Natural air fanV2 > Fresh air fanV2 (version 2) - remove and install
passenger compartment components > Natural air fanV2 > Natural air fanV2 - check
passenger compartment components > Fresh air fan pre-resistance with overheating fuseN24 (version 1) - remove and
install > Removal
install > Removal
install > Installation
passenger compartment components > Dust and pollen filter - remove and install > Removal
passenger compartment components > Air baffles (central) - remove and install
passenger compartment components > Footwell vent - remove and install > Feet air duct (left rear and right rear) - remove
and install
passenger compartment components > Demister nozzle - remove and install
passenger compartment components > Exhaust valve - remove and install > Exhaust valve (Hatch) - remove and install
passenger compartment components > Ventilation adjustment mechanism > Ventilation adjustment mechanism - remove
and install
passenger compartment components > Command cable - remove and install > Removal
Volkswagen Workshop Manuals > Heating, ventilation, air conditioning > Heating, air conditioning > Heating > Plenum
chamber (ventilation and heating) - remove and install > Plenum chamber (Behr) - remove and install
chamber (heating) - disassemble and assemble
chamber (heating) - disassemble and assemble > Air distribution drive mechanism (Behr box) - remove and install >
Removal
chamber (heating) - disassemble and assemble > Air distribution drive mechanism (Behr box) - remove and install >
Installation
chamber (heating) - disassemble and assemble > Temperature adjustment mechanism (Behr box) - remove and install >
Removal
chamber (heating) - disassemble and assemble > Control motor for natural air valve and recirculation valveV154 (Behr box)
- remove and install > Removal
chamber (heating) - disassemble and assemble > Auxiliary heating resistanceZ35 (Behr box) - remove and install >
Removal
chamber (heating) - disassemble and assemble > Auxiliary heating resistanceZ35 (Behr box) - remove and install >
Installation
chamber (heating) - disassemble and assemble > Additional heating resistanceZ35 > Additional heating resistanceZ35 -
check
Volkswagen Workshop Manuals > Heating, ventilation, air conditioning > Heating, air conditioning > Air conditioner >
Ventilation adjustment mechanism (heating and air conditioning). > Ventilation / air conditioning adjustment mechanism
power connectors
power connectors (Climatic)
power connectors (Climatronic)
Volkswagen Workshop Manuals > Heating, ventilation, air conditioning > Heating, air conditioning > Air conditioner > Air
conditioning with manual adjustment/Climatic > Seals of the engine compartment partition panel
conditioning with manual adjustment/Climatic > Air conditioning adjustment mechanism - remove and install > Removal
conditioning with manual adjustment/Climatic > Air conditioning adjustment mechanism - remove and install > Installation
Plenum chamber (heating and air conditioning/Climatic) - disassemble and assemble
Plenum chamber (heating and air conditioning/Climatic) - disassemble and assemble > Plenum chamber (heating and air
conditioning/Climatic) - remove and install
Plenum chamber (heating and air conditioning/Climatic) - disassemble and assemble > Control motor for temperature
adjustment valveV68 - remove and install > Removal
Plenum chamber (heating and air conditioning/Climatic) - disassemble and assemble > Evaporator (version 1) - remove and
install
install > Removal
install > Removal
conditioning with automatic adjustment, (Climatronic) > Air conditioning command and indicator unit / ClimatronicE87 with
Climatronic control unitJ255 - Functions
the Climatronic control unitJ255 - remove and install > Removal
the Climatronic control unitJ255 - remove and install > Installation
conditioning with automatic adjustment, (Climatronic) > Air outlet temperature sensor for the feet regionG192 - remove and
install > Removal
conditioning with automatic adjustment, (Climatronic) > Air outlet temperature sensor for the central baffleG191 - remove
and install > Removal
conditioning with automatic adjustment, (Climatronic) > Air outlet temperature sensor for the evaporatorG263 - remove and
install > Removal
conditioning with automatic adjustment, (Climatronic) > Sun radiation photo sensorG107 - remove and install
conditioning with automatic adjustment, (Climatronic) > Sun radiation photo sensorG107 - remove and install > Removal
conditioning with automatic adjustment, (Climatronic) > Fresh air aspiration duct temperature sensorG89 - remove and
install > Removal
Plenum chamber (heating and air conditioning/Climatronic) - disassemble and assemble
Plenum chamber (heating and air conditioning/Climatronic) - disassemble and assemble > Plenum chamber (Climatronic
heating and air conditioning) - remove and install
Plenum chamber (heating and air conditioning/Climatronic) - disassemble and assemble > Air conditioning adjustment and
control unitJ127 - remove and install > Removal
Plenum chamber (heating and air conditioning/Climatronic) - disassemble and assemble > Central valve control motorV70 -
Plenum chamber (heating and air conditioning/Climatronic) - disassemble and assemble > Central valve control motorV70 -
remove and install > Installation
Plenum chamber (heating and air conditioning/Climatronic) - disassemble and assemble > Defrosting valve control
motorV107 and Control motor for temperature adjustment valveV68 - remove and install > Removal
motorV107 and Control motor for temperature adjustment valveV68 - remove and install > Installation
motorV107 and Control motor for temperature adjustment valveV68 - remove and install > Create the adaptation cable for
the activation of the adjusting motors
Plenum chamber (heating and air conditioning/Climatronic) - disassemble and assemble > Control motor for natural air
valve and recirculation valveV154 (version 1) - remove and install > Removal
Plenum chamber (heating and air conditioning/Climatronic) - disassemble and assemble > Control motor for natural air
valve and recirculation valveV154 (version 2) - remove and install > Removal
conditioner compressor support
conditioner compressor support > Air conditioning compressor support for engines 1.0L (ARA), 1.4L (BBY, BKY) and 1.6L
(BAH) - remove and install
Refrigerant circuit - assembly overview > Air conditioning magnetic couplingN25 manufacturer Delphi (model 1) - repair >
Electromagnetic clutch for Delphi compressor (model 1) - remove and install
Refrigerant circuit - assembly overview > Electromagnetic clutch for Delphi compressor (model 2) - remove and install
Refrigerant circuit - assembly overview > Electromagnetic clutch for Delphi compressor (model 2) - remove and install >
Removal
Refrigerant circuit - assembly overview > Compressor - remove and install > Installation
Refrigerant circuit - assembly overview > Compressor - remove and install > Pressure relief valve in the compressor - check
Refrigerant circuit - assembly overview > High pressure sensorG65 - remove and install
Refrigerant circuit - assembly overview > Expansion valve - remove and install
Refrigerant circuit - assembly overview > Expansion valve - remove and install > Installation
Refrigerant circuit - assembly overview > Quick-release coupling - remove and install
Refrigerant circuit - assembly overview > Quick-release coupling - remove and install > Removing the quick-release
coupling components
Refrigerant circuit - assembly overview > Quick-release coupling - remove and install > Installing the quick-release coupling
components
Refrigerant circuit - assembly overview > Quick-release coupling - remove and install > Quick-release coupling installation
Volkswagen Workshop Manuals > Heating, ventilation, air conditioning > Air conditioning with refrigerant R134a > Technical
data > General information on air conditioning > Basics of air conditioning > Physical principles:
data > General information on air conditioning > Basics of air conditioning > Pressure and boiling point
data > General remarks on the refrigerant gas loop > Refrigerant gas loop components > Condenser
data > General remarks on the refrigerant gas loop > Refrigerant gas loop components > Evaporator
data > General remarks on the refrigerant gas loop > Refrigerant gas loop components > Expansion valve
data > General remarks on the refrigerant gas loop > Refrigerant gas loop components > Overpressure valve
data > General remarks on the refrigerant gas loop > Quick coupling connections in the refrigerant gas loop > Suction and
filling valve with Schrader valve
filling valve, high pressure section
filling valve, low pressure section
data > General remarks on the refrigerant gas loop > Switches and sensors for the refrigerant gas loop and their
connections > Air conditioning high pressure switch F23
connections > High pressure switch for magnetic coupling F118
connections > Air conditioning low pressure switch F73
connections > High pressure sensor G65
connections > Magnetic valve for refrigerant fluid circulation N43
data > General remarks on the refrigerant gas loop > Electrical components not assembled in the refrigerant gas loop > Air
conditioning adjustment and control unit J127
data > General remarks on the refrigerant gas loop > Electrical components not assembled in the refrigerant gas loop > Air
outlet temperature sensor for the evaporator G263 or Evaporator temperature sensor G308
data > General remarks on the refrigerant gas loop > Refrigerant gas loop with expansion valve
data > General remarks on the refrigerant gas loop > Refrigerant gas loop with butterfly (throttle) and collection tank
data > General remarks on the refrigerant gas loop > Checking and measuring work with a pressure gauge
data > Checking pressure values in the refrigerant gas loop > Verification for vehicles with butterfly (throttle) and collection
tank (air conditioning compressor with internal adjustment de > Nominal values
data > Checking pressure values in the refrigerant gas loop > Verification for vehicles with expansion valve and liquid loop /
dryer (air conditioning compressor with internal adjustment dev > Nominal values
data > Detecting leaks in the refrigerant gas loop > Detection of leaks in the refrigerant gas loop with the air conditioning
recovery, recycling, recharging and cleaning set
data > Cleaning the refrigerant gas loop > Washing the refrigerant gas loop with R134a refrigerant gas (clean)
Volkswagen Workshop Manuals > Clutch and gearbox > 5-speed manual gearbox 02R > Technical data > Gearbox
identification
Volkswagen Workshop Manuals > Clutch and gearbox > 5-speed manual gearbox 02R > Technical data > Gearbox layout
Volkswagen Workshop Manuals > Clutch and gearbox > 5-speed manual gearbox 02R > Technical data > General repair
instructions > Gaskets, sealing rings
Volkswagen Workshop Manuals > Clutch and gearbox > 5-speed manual gearbox 02R > Technical data > General repair
instructions > Locking devices
Volkswagen Workshop Manuals > Clutch and gearbox > 5-speed manual gearbox 02R > Clutch, control > Control system -
service
service > Pedal cluster - assembly overview
service > Over-centre spring - remove and install
service > Over-centre spring - remove and install > Remove
service > Over-centre spring - remove and install > Install
service > Clutch pedal - remove and install
service > Clutch pedal - remove and install > Remove
service > Clutch pedal - remove and install > Install
service > Hydraulic system - assembly overview
service > Master cylinder - remove and install
service > Master cylinder - remove and install > Remove
service > Master cylinder - remove and install > Install
service > Slave cylinder - remove and install
service > Slave cylinder - remove and install > Remove
service > Slave cylinder - remove and install > Install
service > Clutch system - bleed
Volkswagen Workshop Manuals > Clutch and gearbox > 5-speed manual gearbox 02R > Clutch, control > Cutch release
mechanism - service
Volkswagen Workshop Manuals > Clutch and gearbox > 5-speed manual gearbox 02R > Clutch, control > Clutch - service
Volkswagen Workshop Manuals > Clutch and gearbox > 5-speed manual gearbox 02R > Gearbox mechanics,operation,
construction,diff. > Gear selector mechanism - service > Gear selector mechanism - installation position
construction,diff. > Gear selector mechanism - service > Selector lever knob and gaiter - remove and install
construction,diff. > Gear selector mechanism - service > Flexible shafts - remove and install > Installation position of
gearbox selector lever/inversion lever
construction,diff. > Gear selector mechanism - service > Gear selector mechanism - remove and install > Remove
construction,diff. > Gear selector mechanism - service > Gear selector mechanism - adjust
construction,diff. > Gear selector mechanism - service > Gear selector mechanism - adjust > Functional check
construction,diff. > Gearbox - remove and install
construction,diff. > Gearbox - remove and install > Remove
construction,diff. > Gearbox - remove and install > Install
construction,diff. > Gearbox - remove and install > Tightening torque
construction,diff. > Gearbox oil - check
construction,diff. > Gearbox - dismantle and assemble > Assembly overview
construction,diff. > Gearbox - dismantle and assemble > Gearbox body cover and 5th gear - remove and install
construction,diff. > Gearbox - dismantle and assemble > Gearbox body and selector mechanism - remove and install
construction,diff. > Gearbox - dismantle and assemble > Input shaft, output shaft (pinion shaft), differential and selector
forks - remove and install
construction,diff. > Gearbox - dismantle and assemble > Assembly sequence
construction,diff. > Gearbox - dismantle and assemble > Assembly sequence > Dismantle
construction,diff. > Gearbox housing and clutch housing - service
construction,diff. > Gearbox selector mechanism - dismantle and assemble
construction,diff. > Selector forks - dismantle and assemble
Volkswagen Workshop Manuals > Clutch and gearbox > 5-speed manual gearbox 02R >
Gearbox,mechanics,gears,shafts,internal operation > Input shaft - dismantle and assemble
Gearbox,mechanics,gears,shafts,internal operation > Input shaft - adjust
Gearbox,mechanics,gears,shafts,internal operation > Output shaft - dismantle and assemble
Gearbox,mechanics,gears,shafts,internal operation > Output shaft - adjust
Gearbox,mechanics,gears,shafts,internal operation > Reverse shaft - dismantle and assemble
Volkswagen Workshop Manuals > Clutch and gearbox > 5-speed manual gearbox 02R > Final drive, differential, differential
lock > Oil seals for flanged shafts - renew
lock > Oil seals for flanged shafts - renew > Oil seal for left flanged shaft - renew > Remove
lock > Oil seals for flanged shafts - renew > Oil seal for left flanged shaft - renew > Install
lock > Oil seals for flanged shafts - renew > Oil seal for right flanged shaft - renew
lock > Oil seals for flanged shafts - renew > Oil seal for right flanged shaft - renew > Remove
lock > Oil seals for flanged shafts - renew > Oil seal for right flanged shaft - renew > Install
lock > Differential - dismantle and assemble
lock > Differential - dismantle and assemble > Install
lock > Differential - adjust

Volkswagen Polo-Mk4 Workshop Manual (Polo Mk4)

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