2009 2013 VW Passat

2009-2013 VOLKSWAGEN PASSAT
SERVICE AND REPAIR MANUAL

2009 Volkswagen Passat Komfort
ENGINE 2.0 Liter - Cooling System - Engine Code(s): CBFA & CCTA
ENGINE
2.0 Liter - Cooling System - Engine Code(s): CBFA & CCTA
19 COOLING SYSTEM
GENERAL INFORMATION
COOLANT SYSTEM
WARNING: The coolant system is under pressure when the engine is warm.
Risk of scalding due to hot steam and hot coolant.
Reduce pressure by covering the coolant expansion tank cap with a cloth
and open carefully.
NOTE: Secure all hose connections with hose clamps appropriate for the model.
The arrows on the coolant pipes and the ends of the coolant hoses must align
when installing.
DRAINING AND FILLING
Special tools and workshop equipment required
 Adapter -V.A.G 1274/8-

 Drip Tray for -VAS 6100- -VAS 6208-
 Hose Clip Pliers -V.A.G 1921-
 Cooling System Charge Unit -VAS 6096-
 Refractometer -T10007-
Draining
and open carefully.
-- Open the coolant expansion tank cap.
-- Remove the noise insulation. Refer to Description and Operation .

Passat, CC, GTI and Eos
-- Loosen the clamps -items 1 and 2- , remove the charge air hose and seal the charge air cooler with a clean
cloth.
Fig. 1: Identifying Charge Air Hose And Clamps

Courtesy of VOLKSWAGEN UNITED STATES, INC.
NOTE: Collect leaking coolant in a clean container for disposal or reuse.
Fig. 2: Identifying ECT Electrical Connector

-- Place the drip tray fro -VAS 6100- -VAS 6208- under the engine.
-- Remove the lower coolant hose -1- from the radiator and allow the coolant to drain.
-- Remove the lower coolant hose from the after-run coolant pump -V51- -arrow- and allow the coolant to drain.
Fig. 3: Identifying Coolant Hose After-Run Coolant Pump V51

Tiguan
Fig. 4: Identifying After-Run Coolant Pump V51 Bracket Bolt -2-

-- Remove the after-run coolant pump bracket bolt -2-.
NOTE: The after-run coolant pump stays in the installed position.
-- Remove the coolant hose -1-.
Fig. 5: Identifying Coolant Hoses

-- Remove the lower coolant hose from the after-run coolant pump -arrow- and allow the coolant to drain.

Filling
NOTE: The water portion of the coolant influences the effectiveness of the coolant.
Volkswagen has decided to define the water quality used in the cooling system
based on the different mixtures, countries and regional requirements. For this
reason, we recommend using distilled water for older models when adding
coolant or filling the coolant for the first time. On newer models (from MY 10),
distilled water is required.
CAUTION: Only use distilled water for mixing with G12 plus-plus. Using distilled
water provides optimum corrosion protection.
NOTE: Only use coolant additive G12 plus-plus that conforms to TL -VW 774 G-.
Coolant additives with the note "conforming to TL -VW 774 G-" prevent frost
and corrosion damage, scaling and also raise boiling point of coolant. The
cooling system must be filled with coolant additive year round.
Because of its high boiling point, the coolant improves engine reliability under
heavy loads, particularly in countries with tropical climates.
Protection against frost must be assured down to approximately -25 °C (-13 °F)
(in arctic climatic countries down to approximately -35 °C (-31°F)).
The coolant concentration must not be reduced by adding water even in warmer
seasons and in warmer countries. The coolant additive portion must be at least
40%.
If for climatic reasons a greater frost protection is required, the amount of

coolant additive can be increased, but only up to 60% (frost protection to about
-40 °C (-40 °F), as otherwise frost protection is reduced again and cooling
effectiveness is also reduced.
The refractometer -T10007- is recommended for determining freeze protection

density.
If the radiator, heater core, cylinder head or cylinder head gasket is replaced, do
not reuse the old coolant.
Recommended Mixture Ratios
Frost Protection to Anti-Freeze G 12 Plus-Plus (1) Distilled Water (1)

-25 °C (-13 °F) -35 °C (-31 °F) 40% 50% 3.2 liters 4.0 liters 4.8 liters 4.0 liters
(1) The amount of coolant may vary depending on vehicle equipment.
-- Connect the lower coolant hose -1- to the radiator.

-- Install the charge air hose.
-- Connect the coolant hose to the after-run coolant pump -arrow-.


-- Install the noise insulation. Refer to Description and Operation .
Filling with the Cooling System Charge Unit -VAS 6096-
-- Install the adapter -V.A.G 1274/8- onto the expansion tank.
-- Fill the coolant circuit using the cooling system charge unit -VAS 6096-. Refer to the Operating instructions
for the cooling system filler unit -VAS 6096-.
Filling without the Cooling System Charge Unit -VAS 6096-
-- Slowly fill the coolant up to the upper mark in the hatched area on the expansion tank.
Fig. 9: Identifying Expansion Tank

-- Install the expansion tank cap.
-- Start the engine and maintain an engine speed of about 2000 RPM for approximately 3 minutes.
-- Allow the engine to run until the coolant fan -V7- starts running.
and open carefully.
-- Check the coolant level and add coolant if necessary. When the engine is at operating temperature, the
coolant must be at the top mark. When the engine is cold, the coolant must be in the center of the hatched area.
DESCRIPTION AND OPERATION
COOLANT HOSE CONNECTION DIAGRAM
Vehicles with a Manual Transmission

Fig. 10: Identifying Coolant Hose Connection Diagram - With Manual Transmission
1. Radiator
2. After-Run Coolant Pump -V51-
3. Coolant Pump
4. Coolant Thermostat
5. Oil Cooler
6. Cylinder Head and Cylinder Block
7. Turbocharger
8. Coolant Expansion Tank
 With the cap.

 Pressure relief valve in cap, checking. Refer to COOLING SYSTEM, CHECKING FOR
LEAKS.
9. to the Auxiliary Heater
 Not available in the US/Canadian market.
10. from the Auxiliary Heater

11. Heater Core

12. Coolant Connection
Vehicles with a Automatic Transmission

Fig. 11: Identifying Coolant Hose Connection Diagram - Vehicles With DSG Transmission
1. Radiator
2. After-Run Coolant Pump -V51-
4. Coolant Pump
5. Oil Cooler
6. Cylinder Head and Cylinder Block
7. Turbocharger
8. Coolant Expansion Tank
 With the cap.

 Pressure relief valve in cap, checking. Refer to COOLING SYSTEM, CHECKING FOR
LEAKS.
9. to the Auxiliary Heater
10. from the Auxiliary Heater

11. Heater Core

12. Transmission Oil Cooler
13. Coolant Connection
14. Thermostat for the Transmission Oil Cooler
 On some vehicles, the thermostat is located on the outflow side of the transmission oil cooler.
COOLANT PUMP AND THERMOSTAT OVERVIEW

Fig. 12: Identifying Assembly Overview: Coolant Pump And Thermostat

1. Bolt
9 Nm
 Tightening sequence, refer to Fig. 13.
2. O-rings
 Always replace.
3. Connection
4. Retaining Clip
 Only with the inserted version.
 Make sure it is tight.

5. Bolt
 4 Nm
 Only with the threaded version.
6. Retaining Plate
 Only with the threaded version.
7. Engine Coolant Temperature Sensor -G62-

 Removing and installing, refer to Engine Coolant Temperature Sensor -G62-.
8. O-ring
 Always replace.
9. Coolant Pump
 Removing and installing, refer to COOLANT PUMP.
 On a new coolant pump, remove the protective cap.
10. Gasket
 Always replace.
11. Centering Pin

 Quantity: 2
12. Toothed Belt

 For the coolant pump.
 Removing and installing, refer to COOLANT PUMP TOOTHED BELT.
13. Toothed Belt Guard

14. Bolt
 9 Nm
15. Bolt
 10 Nm + an additional 90° (1/4) turn.
 Always replace.
 Has left hand threads.
16. Drive Gear for the Toothed Belt

 Installed position: The collar on the drive gear faces the transmission.
17. Shaft Seal

 Removing and installing, refer to COOLANT PUMP DRIVESHAFT SEAL.
18. Balance Shaft

 The coolant thermostat can be checked in "Guided Fault Finding" under "Function and Component
Selection".
 Removing and installing, refer to COOLANT THERMOSTAT.
20. Centering Pin

21. O-ring
 Always replace.
22. Connecting Piece

23. Bolt
 9 Nm
Fig. 13: Identifying Coolant Pump Tightening Sequence

-- Tighten the bolts in sequence -1 through 5- to 9 Nm.
COOLANT PIPES OVERVIEW

Fig. 14: Identifying Coolant Pipes Assembly Overview

1. Front Coolant Pipes

 Removing and installing, refer to FRONT COOLANT PIPES.
2. Coolant Hose
 From the turbocharger.
3. Coolant Hose
 To the coolant expansion tank.
4. Bolt
 3.5 Nm
5. O-ring
 Always replace.
6. Coolant Hose
 To the heater core.
7. Small Coolant Pipe

 Removing and installing, refer to SMALL COOLANT PIPE.
8. Bolts
 9 Nm
9. Coolant Hose
10. Bolt
 5 Nm
11. Coolant Hose

 From the after-run coolant pump -V51-.
12. Coolant Hose

 To the after-run coolant pump.
After-Run Coolant Pump -V51- Overview

Fig. 15: Identifying Assembly Overview: After-Run Coolant Pump

1. Bracket
2. Bolt
 40 Nm
3. Coolant Hose
4. Coolant Hose
5. After-Run Coolant Pump
6. Bracket
7. Bolt
 8 Nm
RADIATOR, FAN SHROUD AND FANS OVERVIEW
Fig. 16: Identifying Radiator And Coolant Fan Assembly Overview

1. Coolant Fan -V7-

 Removing and installing, refer to COOLANT FAN AND COOLANT FAN 2.
2. Nut
 10 Nm
3. Fan Shroud
4. Lower Coolant Hose

 To the connection for coolant thermostat.
5. Retaining Clip
6. Engine Coolant Temperature Sensor on Radiator Outlet -G83-
7. O-ring
 Replace if damaged.
8. Upper Coolant Hose

 From the coolant pump.
9. O-ring
10. Bolt
 5 Nm
 To the charge air cooler.
11. Radiator
 Removing and installing, refer to RADIATOR.
 After replacing, replace the entire amount of coolant.
 Engine code CBFA: With the radiator identification sensor -G611-. Refer to Fig. 17.
12. Nut
 10 Nm
13. Bolt
 5 Nm
 To the radiator.
14. Coolant Fan 2 -V177-

 Removing and installing, refer to COOLANT FAN AND COOLANT FAN 2.
Fig. 17: Identifying Radiator Identification Sensor G611 - Engine Code CBFA
The -arrow- indicates the direction of travel
-A- Radiator
-B- Radiator identification sensor.
NOTE: The radiator identification sensor can only be replaced with the radiator.
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Component Fastener Size Nm

After Run Coolant Pump Bracket to Bracket Bolt - 8
After Run Coolant Pump Bracket to Upper Oil
- 40
Pan Bolt
Connecting Piece to Coolant Pump Bolt - 9
Coolant Expansion Tank Bolt - 5
Coolant Fan to Fan Shroud Nut - 10
Engine Coolant Temperature Sensor Retaining
- 4
Plate to Coolant Pump Bolt
Fan Shroud to Radiator Bolt - 5
Front Coolant Pipe Bolt - 3.5
Radiator to Charge Air Pipe Bolt (3) - 5
Small Coolant Pipe Bolt - 9
Toothed Belt Drive Gear to Balance Shaft Bolt 1, 2 - 10 + 90°

Toothed Belt Guard to Coolant Pump Bolt - 9
(1) Always replace
(2) Has left hand threads
(3) Eos, GTI, Passat and CC only
Coolant Pump Bolt Tightening Sequence and Specification

DIAGNOSIS AND TESTING
COOLING SYSTEM, CHECKING FOR LEAKS
 Cooling System Tester -V.A.G 1274 B-

Test Conditions
 The engine is at operating temperature

Test Sequence
and open carefully.
-- Open the cap on the coolant expansion tank.
-- Install the adapter -V.A.G 1274/8- on the coolant expansion tank.
-- Clamp the connecting piece -V.A.G 1274 B/1- in the adapter -V.A.G 1274/8-.
-- Connect the connector piece -V.A.G 1274 B/1- to the cooling system tester -V.A.G 1274 B- using the
connecting hose.
Fig. 19: Identifying Cooling System Tester V.A.G 1274 Connected To Coolant Reservoir
-- Generate a positive pressure of approximately 1.0 bar using the tester hand pump.
CAUTION: Risk of scalding. Reduce the pressure before disconnecting the cooling
system tester -V.A.G 1274 B- from the connecting hose or connector piece
-V.A.G 1274 B/1-. To do this, press the pressure release valve on the
cooling system tester -V.A.G 1274 B- until the pressure gauge displays
>>0<<.
If the pressure drops:
-- Look for leaks and correct.
Checking the pressure relief valve in the cap
-- Install the cap to the adapter -V.A.G 1274/9-.
-- Clamp the connecting piece -V.A.G 1274 B/1- in the adapter -V.A.G 1274/9-.
-- Connect the connector piece -V.A.G 1274 B/1- to the cooling system tester -V.A.G 1274 B- using the
connecting hose.
Fig. 20: Identifying Connector Piece -V.A.G 1274 B/1-, Connecting Hose And Cooling System Tester -
V.A.G 1274 B-
-- Actuate the hand pump.
 The pressure release valve must open at 1.4 to 1.6 bar.

REMOVAL AND INSTALLATION
COOLANT PUMP
Removing
-- Remove the small coolant pipe. Refer to SMALL COOLANT PIPE.
-- Disconnect the electrical connector -1- from the throttle valve control module -J338-.
Fig. 21: Identifying Throttle Valve Control Module Electrical Connector And Bolts
-- Remove the bolts -arrows- and remove the throttle valve control module.
-- Remove the coolant pump toothed belt. Refer to COOLANT PUMP TOOTHED BELT.
-- Remove the nut -1- , bolt -2- and intake manifold support.
Fig. 22: Identifying Intake Manifold Bracket Mounting Nut And Bolt
-- Remove the bonded rubber bushing for the intake manifold support from the intake manifold.
-- Remove the engine coolant temperature sensor -G62-. Refer to one of the following:
Inserted version, refer to Engine Coolant Temperature (ECT) Sensor with a Clip.
Threaded version, refer to ECT Sensor with a Retaining Plate.
-- Remove the bolts -1 through 5-.


-- Remove the coolant pump from the centering pin and the engine oil cooler.
Installing
NOTE: Replace the gaskets and O-rings.
-- Lubricate the O-rings -4- with coolant.
Fig. 24: Identifying Accessory Assembly Bracket, Coolant Pump Housing, Connection And O-Rings
-- Make sure both centering pins are installed in the cylinder block.
-- Install the connecting piece -2- into the engine oil cooler -1-.
-- First, slide the coolant pump -3- onto the connecting piece and then onto the centering pins in the cylinder
block.
-- Using a mirror, check if the coolant pump is seated correctly on the centering pins.
-- Tighten the bolts in sequence -1 through 5-.

NOTE: If a new coolant pump was installed, then the protective cap -arrow- must be
removed.
The rest of the installation follows the reverse of the removal procedure.
COOLANT PUMP TOOTHED BELT
 Insert Tool 12 mm -T10360-

 Torque Wrench (5-50 Nm) -V.A.G 1331-
Removing
-- Remove the small coolant pipe. Refer to SMALL COOLANT PIPE.
-- Lay aside the coolant hose -2- and electrical wiring harness -1-.
Fig. 26: Identifying Electrical Wiring Harness, Coolant Hose And Bolt
-- Remove the bolt -arrow- and remove the bracket.
-- Remove the coolant hoses -1 and 2- and lay them aside.

-- Remove the intake manifold runner control valve -N316- -2- and lay it to the side.
Fig. 29: Identifying Intake Manifold Runner Control (IMRC) Valve N316
-- Free up the wiring harness, pull it upward and secure it with cable ties.
-- Remove the bolts -arrows- and remove the toothed belt guard.
Fig. 30: Identifying Toothed Belt Cover And Bolts

CAUTION: The drive gear bolt has a left thread.
-- Loosen the bolt -1- for the coolant pump drive gear clockwise using the torque wrench (5-50 Nm) -V.A.G
1331- and insert tool 12 mm -T10360-. Counter hold the vibration damper using a 24 mm socket when doing
this.
Fig. 31: Identifying Coolant Pump Drive Gear Bolt And Torque Wrench V.A.G
-- Remove the bolt. Remove the drive gear -1- and toothed belt -2-.
Installing
Install in reverse order of removal. Note the following:
-- Replace the drive gear bolt.
-- Replace the seals and O-rings.
Drive gear installed position: The collar on the drive gear faces the transmission.
Tightening specifications, refer to COOLANT PUMP AND THERMOSTAT OVERVIEW.
COOLANT PUMP DRIVESHAFT SEAL
 Thrust Piece -T10353-
Procedure
-- Remove the coolant pump toothed belt. Refer to COOLANT PUMP TOOTHED BELT.
-- Firmly press a screwdriver -1- into the seal surface -2- -arrow B-.
Fig. 32: Identifying Pry Out Seal Using A Screwdriver

-- Pry out the seal -arrow A-.
-- Clean the running and sealing surface.
-- Lubricate the sealing surface of the balance shaft -2- with transmission fluid.
Fig. 33: Identifying Balance Shaft And Sealing Surface

-- Push the seal -1- onto the balance shaft.
 "Luftseite" ("Outside") -arrow- must be readable from the outside.
-- Mount the thrust piece -T10353- on the seal -1- and press it into the cylinder block until seated using the bolt
-2-; when doing this, do not bend the seal.
Fig. 34: Identifying Thrust Piece T10353, Seal And Bolt

-- Install the coolant pump toothed belt. Refer to COOLANT PUMP TOOTHED BELT.
The rest of the installation follows the reverse of the removal procedure.
COOLANT THERMOSTAT
 Hex Ball Socket -T10058-
Removing
-- Drain the coolant. Refer to DRAINING AND FILLING.
-- Remove the cover for the air guide, disengage the side clips -arrows- to do so.
Fig. 35: Identifying Air Duct Cover Slide Clips

-- Unclip the lower air guide, disengage the clips -arrows- to do so.
Fig. 36: Identifying Lower Air Guide Clips

-- Remove both the lower air guide and the air guide hose.
Vehicles with a Noise Generator
Continuation for all Vehicles

Fig. 37: Identifying Air Guide Hose Bolts, Air Guide Pipe Hose Clamps & Electrical Harness Connector
-- Loosen the hose clamp -2-.
-- Remove the bolt -4-.
-- Disconnect the electrical connector -arrow-.
-- Remove the bolt -1- and remove the charge air pipe downward.
-- Lay aside the coolant hose -2- and electrical wiring harness -1-.
Fig. 38: Identifying Electrical Wiring Harness, Coolant Hose And Bolt
-- Remove the bolt -arrow- and remove the bracket.
NOTE: The after-run coolant pump -V51- stays in the installed position.
-- Remove the coolant hoses -1 and 2- and lay them aside.

-- Loosen the nut -2- , remove the bolt -1- and move the support for the intake manifold to the right.
Fig. 41: Identifying Intake Manifold Support, Nut And Bolt

-- Remove the oil separator. Refer to OIL SEPARATOR .

-- Remove the bolts -arrows- and remove the connecting piece. For the right bolt, the hex ball socket -T10058-
is useful.
Fig. 42: Identifying Coolant Thermostat Housing Bolts

-- Remove the coolant thermostat.
Installing
 Tightening specifications, refer to COOLANT PUMP AND THERMOSTAT OVERVIEW.
NOTE: Replace the seals and O-rings.
-- Clean the O-ring sealing surface.
-- Lubricate the O-ring with coolant additive.
-- Install the thermostat -4- into the coolant pump housing -5- and move it slightly forward -arrow-.
Fig. 43: Identifying Thermostat, Housing And Components

-- Carefully install the connecting piece -3- ; while doing so, insert the centering pin -2- into the guide -1-.
Engine Coolant Temperature Sensor -G62-
Requirements
 The engine is cold.
Removing
-- Remove the cover for the air guide; disengage the side clips -arrows- to do so.



cloth.

-- Disconnect the electrical connector -1- from the throttle valve control module -J338-.
-- Remove the intake manifold support; to do so, remove the nut -2- and bolt -1-.
Fig. 50: Identifying Intake Manifold Support, Nut And Bolt

Engine Coolant Temperature (ECT) Sensor with a Clip

Fig. 51: Identifying Engine Coolant Temperature Sensor G62 Electrical Connector
-- Disconnect the electrical connector -1- from the ECT sensor.
-- Remove the clip, to do so, press the latches -arrow-.
-- Remove the ECT sensor.
NOTE: Install the new ECT sensor with an O-ring as quickly as possible to prevent
coolant from leaking out.
ECT Sensor with a Retaining Plate

Fig. 52: Identifying ECT Sensor And Retaining Plate

-- Disconnect the electrical connector -2- from the ECT sensor.
-- Remove the bolts -arrows- and remove the retaining plate -1-.
-- Remove the ECT sensor.
NOTE: Install the new ECT sensor with an O-ring as quickly as possible to prevent
coolant from leaking out.
Installing
 Replace the O-ring.

 Check the coolant level.
FRONT COOLANT PIPES
 Hose Clip Pliers -VAS 6362-

Removing
and open carefully.
-- Remove the cover for the air guide, disengage the side clips -arrows- to do so.


Fig. 55: Identifying Latch, Fuel Lines And Bolts

-- Open the latch -1- , unclip the fuel lines -2- and loosen the bolts -3-. Remove the charge air pipe.
Vehicles with a Evaporative Emission (EVAP) Canister in the Engine Compartment

-- Disconnect the vent line -1- , unlock the canister -A- and remove it -B-. Move the canister to the side.
Fig. 56: Identifying Vent Line, Canister And Canister Catch


-- Disconnect the electrical connectors -arrow- and free up the electrical wire.
cloth.

-- Place the drip tray for -VAS 6100- -VAS 6208- under the engine.
-- Remove the coolant hoses from the after-run coolant pump -V51- -arrows-.
-- Remove the bolts -1 and 2- and remove the front coolant pipes from the coolant hoses -arrows-.
Fig. 61: Identifying Front Coolant Pipes, Coolant Hoses And Bolts
Installing
 Tightening specifications, refer to COOLANT PIPES OVERVIEW.
Installation is performed in the reverse order of removal, noting the following:
NOTE: Always replace gaskets and seals.
Secure all hose connections with hose clamps appropriate for the model.
-- Install the charge air pipe.
SMALL COOLANT PIPE
Removing
-- Remove the air filter housing. Refer to AIR FILTER HOUSING .

-- Remove the bolts -arrows- and remove the electrical connectors -1 through 3- from the bracket.
Fig. 63: Identifying Electrical Connectors And Bolts

-- Free up the wiring harness on the small coolant pipe -arrow-.
Fig. 64: Identifying Coolant Hoses, Bolts And Coolant Pipe

-- Remove the bolts -2 and 3-.
-- Disconnect the small coolant pipe from the coolant pump and from the coolant hoses -1 and 4-.
Installing
 Tightening specifications, refer to COOLANT PIPES OVERVIEW.
NOTE: Secure all hose connections with hose clamps appropriate for the model.
-- Install the charge air pipe.
After-Run Coolant Pump -V51-
 Hose Clamps up to 25 mm Dia. -3094-

Removing
and open carefully.
-- Disconnect the electrical connector -1- from the after-run coolant pump.
-- Clamp off the hoses using the hose clamps up to 25 mm dia. -3094- and disconnect the hoses -arrows-.
-- Remove the coolant hoses from the after-run coolant pump.
-- Remove the bolt -2- and the after-run coolant pump.
Installing
 Tightening specifications, refer to After-Run Coolant Pump -V51- Overview.
-- Check the coolant level.
FAN SHROUD
Removing
-- Remove the cover for the air duct, disengage the side clips -arrows- to do so.

-- Unclip the lower air duct, disengage the clips -arrows- to do so.

-- Remove the bolts -1- from the top.

Fig. 68: Identifying Fan Shroud Bolts And Electrical Connector

NOTE: The left bolt is under the coolant connector.
Tiguan
Fig. 69: Identifying Bracket

-- Remove the bracket -1- by removing the bolts -arrows-.

Fig. 70: Identifying Fan Shroud Bolts And Electrical Connector

-- Disconnect the connector -2-.
-- Remove the bolts -3- and remove the fan shroud downward.
Installing
 Install the fan shroud from below.

 Tightening specifications, refer to RADIATOR, FAN SHROUD AND FANS OVERVIEW.
COOLANT FAN AND COOLANT FAN 2
Removing
-- Remove the fan shroud. Refer to FAN SHROUD.

Fig. 71: Identifying Coolant Fan Connector And Bolts

-- Free up the electrical wires.
-- Remove the nuts -arrows- and remove the coolant fan(s).
Installing
Installation is performed in reverse order.
RADIATOR
Removing
-- Remove the fan shroud. Refer to FAN SHROUD.
-- Remove the upper coolant hose -arrow- from the radiator.

Fig. 72: Identifying Radiator Upper Coolant Hose

-- Detach the air duct bolts -arrows- from the lock carrier and remove the air duct.
Fig. 73: Identifying Air Guide Screws And Air Guide

-- Remove the bolts -1 and 2- and remove the radiator upward.

Fig. 74: Identifying Radiator And Bolts

Installing
SPECIAL TOOLS

 Cooling System Tester -V.A.G 1274 B-
Fig. 75: Identifying Cooling System Tester V.A.G 1274 B

Fig. 76: Identifying Adapter V.A.G 1274/9

 Insert Tool 12mm -T10360-

Fig. 77: Identifying Insert Tool 12mm T10360

Fig. 78: Identifying Thrust Piece T10353

 Hex Ball Socket -T10058-

Fig. 79: Identifying Hex Ball Socket T10058

Fig. 80: Identifying Clamp Pliers VAS 6362

 Hose Clamps up to 25 mm Dia.-3094-

Fig. 81: Identifying 3094 Hose Clamps

Fig. 82: Identifying Additional Special Tools


 Cooling System Charge Unit -VAS 6096-
 Refractometer -T10007-
ENGINE 2.0 Liter - Crankshaft, Cylinder Block - Engine Code(s): CBFA & CCTA
ENGINE
2.0 Liter - Crankshaft, Cylinder Block - Engine Code(s): CBFA & CCTA
13 CRANKSHAFT, CYLINDER BLOCK

GENERAL INFORMATION
CRANKSHAFT BEARING SHELL, ALLOCATING
The bearing shells are allocated to the cylinder block with the correct thickness by the factory. Colored dots
serve to identify the bearing thicknesses.
The code letters on the lower contact surface or on the top of the cylinder block identify which bearing shell and
where it must be installed in the cylinder block (upper bearing shell).
The code letters on the crankshaft identify which bearing shell and where they must be installed in the bearing
cap (lower bearing shell).
The first letter is for bearing cap one, the second for bearing cap two, etc.
Cylinder Block
Fig. 1: Locating Cylinder Block Identification On Top (Transmission Side) Of Cylinder Block
The cylinder block identification may be located either on the oil pan sealing surface or on the top (transmission
side) of the cylinder block.
The identification on the cylinder block is for the upper bearing shell.
Fig. 2: Locating Identification On Cylinder Block

-- Note the letter and then match it to the color identification in the table.
Crankshaft
Fig. 3: Locating Identification On Crankshaft

The identification on the crankshaft is for the lower bearing shell.
-- Note the letter and then match it to the color identification in the table.
S = Black
R = Red
G = Yellow
B = Blue
W = White
NEW CONNECTING ROD, SEPARATING
New connecting rods may not be separated at the location where they should be. If the connecting rod bearing
cap cannot be removed by hand, proceed as follows:
-- Mark which cylinder the connecting rod belongs to.

-- Lightly clamp the connecting rod in a vise equipped with aluminum protective jaw pads.
Fig. 4: Identifying Connecting Rod Clamped In Vise Equipped With Aluminum Protective Pads
NOTE: Only clamp the connecting rod lightly to avoid damaging it.
Clamp the connecting rod below the dotted line.
-- Loosen both bolts -arrows- about five turns.
-- Carefully tap against the connecting rod bearing cap in the direction of the -arrow- with a plastic mallet until
the cap is loose.
Fig. 5: Identifying Connecting Rod Bearing Cap

RIBBED BELT OVERVIEW

Fig. 6: Identifying Ribbed Belt Drive Assembly Overview

1. Vibration Damper
 With the pulley for the ribbed belt.
 Removing and installing, refer to VIBRATION DAMPER.
2. O-ring
 Always replace.
3. Bolt
 Always replace.
Use the counter hold tool -T10355- to loosen and tighten.


4. Ribbed Belt
 Check for wear.
 Do not kink.
CAUTION: Risk of destroying due to a reversed running direction on a

used ribbed belt.
 Before removing the ribbed belt, marking the running

direction with chalk or a felt tip pen for reinstallation later.
 Removing and installing, refer to RIBBED BELT.

 When installing, make sure it is seated correctly on the pulleys.
5. Belt Tensioner
 To release tension on the ribbed belt, rotate using a box end wrench.
 Secure using locking pin -T10060 A-.
 Belt tensioner installed position. Refer to Fig. 7.
 Removing and installing, refer to one of the following:
 Passat and CC, refer to RIBBED BELT TENSIONER.
6. Accessory Bracket
 With the oil pressure switch -F1-, oil filter and oil cooler.
 Removing and installing, refer to ACCESSORY BRACKET.
 Oil cooler removing and installing, refer to OIL COOLER .
7. Bolt
 10 Nm
8. Generator
 Removing and installing, refer to Removal and Installation .
9. Bolt
 23 Nm
10. Bolt
11. Air Conditioning (A/C) Compressor

 Do not remove or disconnect the refrigerant lines.
12. Bolt
 25 Nm
13. Alignment Sleeve

 For the A/C compressor.
Fig. 7: Identifying Tensioning Device For Ribbed Belt

1. Belt tensioner
2. Support
3. Accessory bracket
4. Centering sleeve
5. Bolt
Fig. 8: Identifying Accessory Assembly Bracket Tightening Sequence

-- Position the accessory bracket and install the bolt -4- first, then install the bolts -1, 2, 3 and 5-.
-- Tighten the bolts in 3 passes in sequence -1 through 5- as follows:
-- Tighten the bolts by hand. -- Tighten the bolts to 20 Nm. -- Tighten the bolts an additional 90° (1/4)
turn.
SEALING FLANGE AND DUAL MASS FLYWHEEL/DRIVE PLATE OVERVIEW

Fig. 9: Identifying Sealing Flange And Dual Mass Flywheel Assembly Overview
1. Cylinder Block
 Crankshaft overview, refer to CRANKSHAFT OVERVIEW.
 Piston and connecting rod overview, refer to PISTONS AND CONNECTING ROD
OVERVIEW.
2. Alignment Pin
 Not installed.
3. Sealing Flange, Transmission Side

 With the seal.
 Only replaced as a complete unit.

 Removing and installing, refer to SEALING FLANGE, TRANSMISSION SIDE.
4. Bolt
5. Intermediate Plate
 Must be located on the alignment sleeves.
 Do not damage or bend when doing assembly work.
 Is hooked in at the sealing flange, refer to Fig. 11.
6. Bolt
 Always replace.
 For the dual mass flywheel/drive plate.
7. Dual Mass Flywheel/Drive Plate

 Dual mass flywheel removing and installing. Refer to DUAL MASS FLYWHEEL.
 Drive plate removing and installing. Refer to DRIVE PLATE.
 Drive plate installed position: the flange faces the engine.
 Only possible to install in one position - Bores are offset.
8. Alignment Pin
 Not installed.
Fig. 10: Identifying Sealing Flange Tightening Sequence

-- Tighten the bolts in sequence -1 through 8- as shown:

-- 1. Install the bolts and tighten them by hand.
-- 2. Tighten the bolts to 9 Nm.
Fig. 11: Identifying Intermediate Plate Alignment Bushings

-- Hook in the intermediate plate at the sealing flange and push it onto the alignment sleeves -arrows-.
CRANKSHAFT OVERVIEW
NOTE: Secure the engine to the assembly stand using the engine and transmission
holder -VAS 6095- when performing repair work. Refer to ENGINE, SECURING
TO Engine and Transmission Holder VAS 6095 .
Fig. 12: Identifying Assembly Overview: Crankshaft

1. Cylinder Block
 If the cylinder block is being replaced, then the bearing shells must be allocated again. Refer to
CRANKSHAFT BEARING SHELL, ALLOCATING.
2. Bearing Shell, for the Cylinder Block
 With a lubricating groove.
 Do not interchange used bearing shells (mark them).
 Crankshaft bearing shell, allocating. Refer to CRANKSHAFT BEARING SHELL,

ALLOCATING.
3. Crankshaft
 After removal, place it in such a way it does not rest on the sensor wheel -item 8- and damage it
 If the crankshaft is being replaced, then the bearing shells must be allocated to the bearing cap.
Refer to CRANKSHAFT BEARING SHELL, ALLOCATING.
 Axial clearance measuring, refer to CRANKSHAFT AXIAL PLAY, MEASURING.
 Radial clearance measuring, refer to CRANKSHAFT RADIAL PLAY, MEASURING.
 Do not rotate the crankshaft when measuring the radial play.
 Crankshaft dimensions, refer to CRANKSHAFT DIMENSIONS.
 Removing and installing, refer to SENSOR WHEEL.
4. Bearing Shell
 Without a lubricating groove.
 Crankshaft bearing shell, allocating. Refer to CRANKSHAFT BEARING SHELL,

ALLOCATING.
5. Bolt
 Always replace.
 Observe the tightening sequence, refer to Fig. 13.
6. Bearing Cap
 Bearing cap 1: Belt pulley side.
 Retaining tabs on the bearing shells and cylinder block/bearing caps must align above one another.
7. Screw
 Always replace.
 Replace the sensor wheel every time the bolts are loosened. Refer to SENSOR WHEEL.
8. Sensor Wheel
 For the engine speed sensor -G28-.
 Only possible to install in one position - Bores are offset.
 Replace the sensor wheel every time the bolts -item 7- are loosened.
 Removing and installing, refer to SENSOR WHEEL.
9. Thrust washers
 For bearing 3.
10. Bolt
 Always replace.

Fig. 13: Identifying Crankshaft Bearing Cap, Installing

-- Tighten the crankshaft bearing cap bolts in sequence -1 through 5- :
1. Tighten the bolts -1 through 10- and the -arrows- by hand.

2. Tighten the bolts -1 through 10- to 65 Nm.
3. Tighten the bolts -1 through 10- an additional 90° (1/4) turn using a ratchet.
4. Tighten the bolts -arrows- to 20 Nm.
5. Tighten the bolts -arrows- an additional 90° (1/4) turn using a ratchet.
PISTONS AND CONNECTING ROD OVERVIEW

Fig. 14: Identifying Assembly Overview: Pistons And Connecting Rod

1. Connecting Rod Bolt

 M8 bolt: 30 Nm + an additional 90° (1/4) turn.
 Always replace.
 Lubricate the threads and contact surface.
 Use an old bolt to measure the radial play.
 Do not tighten the additional 90° (1/4) turn further when measuring the radial play.
2. Connecting Rod Bearing Cap

Note the installed position.


 Due to the separation procedure (cracking) for the connecting rod, the cap only fits in one position
and only on the correct connecting rod.
 Mark the affiliation to the cylinder -A-.
 Installed position: Marks -B- point to the belt pulley side.
3. Bearing Shells
 Installed location, refer to Fig. 19.
 Axial play:
New: 0.10 to 0.35 mm
Wear limit: 0.40 mm.
 Measure the radial clearance using Plastigage R :
New: 0.02 to 0.06 mm
Wear limit: 0.09 mm
 Do not rotate the crankshaft when checking the radial clearance.

4. Pressure Relief Valve
 27 Nm
 Opening pressure 1.6 to 1.9 bar.
5. Oil Spray Jet

 For piston cooling.
6. Circlip
7. Piston Pin
 If the piston is difficult to move, heat it to 60 °C (140 °F).
 Remove and install using the pilot drift -VW 222 A-.
8. Piston
 Checking, refer to PISTON, CHECKING.
 Mark the installed position and cylinder allocation.
 The arrow on the piston face points toward the belt pulley side.
 Install using a piston ring compressor.
 Piston and cylinder dimensions. Refer to PISTON AND CYLINDER DIMENSIONS.
 Cylinder bore checking. Refer to CYLINDER BORE, CHECKING.
9. Compression Rings
 Offset gaps by 120°.
 Use piston ring pliers for removing and installing.

 "TOP" mark must face up toward piston crown.

 Checking ring gap. Refer to Fig. 15.
 Checking piston ring groove clearance. Refer to Fig. 16.
10. Oil Scraping Ring

 2 piece
 Install the upper steel ring so the gap is offset by 120° to the neighboring compression ring.
 Offset all oil scraping ring component gaps to each other.
 Checking ring gap. Refer to Fig. 15.
 The side clearance cannot be measured.
11. Connecting Rod

 Only replace as a set.
 Mark the affiliation to the cylinder -A-.
 Installed position: Marks -B- point to the belt pulley side.
Fig. 15: Identifying Piston Ring Gap

-- Push the ring squarely from above, down to approximately 15 mm from the bottom end of the cylinder. To do
this, use a piston without rings.
Piston Ring Dimensions in mm New Wear limit

Compression ring 0.20... 0.40 0.8
Oil scraping ring 0.25... 0.50 0.8
Fig. 16: Identifying Piston Ring Gap

-- Clean the ring grooves of the piston before checking.
Piston Ring Dimensions in mm New Wear limit

1. Compression ring 0.06... 0.09 0.20
2. Compression ring 0.03... 0.06 0.15
Oil scraping rings cannot be measured
PISTON, CHECKING
 Micrometer 75-100 mm -VAS 6071-
-- Measure the pistons approximately 10 mm from the bottom edge and at points offset by 90° to the piston pin
axis.
Fig. 17: Identifying Checking Piston

 Deviation from nominal dimension: Max. 0.04 mm
CYLINDER BORE, CHECKING
 Cylinder Gauge -VAS 6078-
CAUTION: Do not bore, hone, grind or rework the cylinder bores with workshop tools.
Reworking damages the surface of the cylinder bore.
-- Measure diagonally at 3 positions transversely -A- and longitudinally -B-.

Fig. 18: Identifying Measurements

 Deviation from nominal dimension: Max. 0.08 mm
NOTE: Measurement of the cylinder bore may not be performed when the cylinder
block is installed on the engine and transmission holder -VAS 6095-, false
measurements are possible.
Fig. 19: Identifying Installed Position Of Bearing Shell

-- Place the bearing shell centrally into the connecting rod and connecting rod bearing cap.
Dimension -a- must be the same on the left and right sides.
SPECIFICATIONS
CRANKSHAFT DIMENSIONS
(Dimensions are in mm)
Reconditioning Dimension (1) Crankshaft Bearing Pin Diameter Connecting

Rod
Bearing
Pin
Diameter
Basic dimension 58.00 47.80
(1) The preparation of worn crankshafts is not provided.
PISTON AND CYLINDER DIMENSIONS
CAUTION: Do not bore, hone, grind or rework the cylinder bores with shop tools.
Reworking damages the surface of the cylinder bore.
Piston Diameter Cylinder Bore Diameter

Basic dimension mm 82.465(1) 82.51

(1) Dimensions are without graphite coating (0.02 mm thick). The graphite coating wears off.

Air Conditioning Compressor to Accessory Bracket
- 25
Bolt
Connecting Rod Bearing Cap to Connecting Rod Bolt (1)
M8 30 + 90°
M9 45 + 90°
Dual Mass Flywheel/Drive Plate to Crankshaft Bolt (1) - 60 + 90°
Generator to Accessory Bracket Bolt - 23
Pressure Relief Valve - 27
Ribbed Belt Tensioner to Accessory Bracket Bolt - 10
Sensor Wheel to Crankshaft Screw (1) - 10 + 90°
Vibration Damper to Crankshaft Bolt (1) - 150 + 90°
(1) Always replace
Accessory Bracket Bolt Tightening Sequence and Specification


-- 1st pass, tighten the bolts by hand.
-- 2nd pass, tighten the bolts to 20 Nm.
-- 3rd pass, tighten the bolts an additional 90° (1/4) turn.
Sealing Flange Bolt Tightening Sequence and Specification


-- Tighten the bolts in sequence -1 through 8- as follows:
-- 1. Tighten the bolts by hand.
Crankshaft Bearing Cap Bolt Tightening Sequence and Specification

Fig. 22: Identifying Crankshaft Bearing Cap, Installing

-- Tighten the crankshaft bearing cap bolts -1 through 10- and -arrows- in sequence as follows:
1. Tighten the bolts -1 through 10- and - arrows- by hand.

2. Tighten the bolts -1 through 10- to 65 Nm.
3. Tighten the bolts -1 through 10- an additional 90° (1/4) turn using a ratchet.
4. Tighten the bolts -arrows- to 20 Nm.
5. Tighten the bolts -arrows- an additional 90° (1/4) turn using a ratchet.
CRANKSHAFT AXIAL PLAY, MEASURING
 Dial Gauge Holder -VW 387-

 Dial Gauge 0-10 mm -VAS 6079-
Procedure
Fig. 23: Identifying Dial Indicator Attached Together With VW387 Dial Gauge Holder To Cylinder
Block
-- Install the dial gauge 0-10 mm -VAS 6079- together with the dial gauge holder -VW 387- to the cylinder
block and set the indicator against the crankshaft counterweight.
-- Press the crankshaft by hand against the gauge and set the gauge to "0".
-- Press the crankshaft off the gauge and read the value.
Axial Clearance
 New: 0.07 to 0.23 mm.

 Wear limit: 0.30 mm.
CRANKSHAFT RADIAL PLAY, MEASURING
 Plastigage R
Procedure
NOTE: Do not interchange used bearing shells.
Bearing shells that are worn down to the nickel layer must be replaced.
-- Remove the main bearing cap and clean the bearing cap and journal.
-- Place the Plastigage R over the entire width of the journal or into the bearing shell.
 The Plastigage R must rest in the center of the bearing shell.
-- Position the main bearing cap and tighten the bolts to 60 Nm. Do not rotate the crankshaft when doing so.
-- Remove the main bearing cap again.
-- Compare the width of the Plastigage R with the measuring scale.
Radial Clearance
 New: 0.017 to 0.037 mm.

 Wear limit: 0.15 mm.
RIBBED BELT
Removing
CAUTION: Risk of destroying due to a reversed running direction of a used ribbed

belt.
 Before removing the ribbed belt, mark the running direction with
chalk or a felt tip pen for reinstallation later.
-- Remove the right charge air hose -arrows-.

Fig. 24: Identifying Right Charge Air Guide Hose

-- To release the tension on the ribbed belt, rotate the tensioner in the -direction of the arrow- from underneath.
Fig. 25: Identifying Wrench And Locking Pin -T10060 A-

-- Secure the tensioner using the locking pin -T10060 A-.
-- Remove the ribbed belt.
Installing
NOTE: Before installing the ribbed belt, the generator and Air Conditioning (A/C)
compressor must be securely installed.
-- First, mount the ribbed belt on the vibration damper, then on the A/C compressor and generator.
Fig. 26: Identifying Ribbed Belt Routing

-- Rotate the tensioner using a box end wrench and remove the locking pin -T10060 A-.

-- Release the tensioner.
-- Check whether the ribbed belt is routed correctly.
-- Start the engine and check whether the ribbed belt runs correctly.
RIBBED BELT TENSIONER
 Engine Support Bridge 10-222 A

 Bracket for Engine 10-222 A/1 (Passat only)
 Bracket with Spindle and Hook 10-222 A/10 (Qty: 2)
 Shackle 10-222 A/12
 Engine Support Feet 10-222 A/8 (CC only)
 Locking Pin -T10060 A-
Removing
-- Remove the front part of the right wheel housing liner. Refer to Removal and Installation .
-- First, remove the bolt -1- , then the bolts -2 and 3- and then remove the pendulum support.
Fig. 28: Identifying Support Bracket, Pendulum And Bolts

-- Install the engine support bridge 10-222 A using the following special tools:
Passat
Fig. 30: Identifying Engine Support Bridge -10-222 A- And Special Tools
 Bracket for engine 10-222 A/1 (Qty: 2)

 Bracket with spindle and hook 10-222 A/10
CC
 Engine support feet 10-222 A/8 (Qty: 2)

 Shackle 10-222 A/12
NOTE: Do not place the engine support feet 10-222 A/8 on the fender panels. The
panels will be damaged.
The shackle 10-222 A/12 is needed to make sure the engine is lifted in the
installed position and not tipped.
-- Support the engine with the spindle.

-- Remove the engine mount to engine mount bracket bolts -arrows-.
Fig. 32: Identifying Engine Mount To Engine Mount Bracket Bolts

-- Lower the engine approximately 55 mm.
-- Remove the ribbed belt. Refer to RIBBED BELT.
-- Free up the wiring harness -arrow-.
Fig. 33: Identifying Ribbed Belt Tensioner Bolt And Locating Electrical Wiring Harness
-- Remove the bolt -1- and remove the belt tensioner from the accessory bracket.
Installing
Fig. 34: Identifying Tensioning Device For Ribbed Belt

 Tightening specifications, refer to RIBBED BELT OVERVIEW.
-- Insert the belt tensioner -1- into the accessory bracket -3- and tighten the bolt -5-.
 Note the support -2- installed position: insert the support in the hole on the accessory bracket.
 Note the centering sleeve -4-.
-- Adjust the engine mount. Refer to ENGINE AND TRANSMISSION MOUNT, ADJUSTING .
ACCESSORY BRACKET
Removing
-- Drain the coolant. Refer to DRAINING AND FILLING .
-- Remove the generator. Refer to Removal and Installation .
-- Disconnect the connector -1- from the A/C compressor regulator valve -N280-.
Fig. 35: Identifying A/C Compressor Bolts And Solenoid Clutch Electrical Connector
WARNING: Refrigerant can cause serious personal injury.
 Do not open the Air Conditioning (A/C) refrigerant circuit.
-- Remove the A/C compressor bolts -arrows-.
CAUTION: Risk of damaging refrigerant lines and hoses.
 Do not stretch, kink or bend refrigerant lines and hoses.
-- Secure the A/C compressor with the refrigerant lines attached to the longitudinal member.
-- Remove the oil dipstick guide tube bolt -arrow-.


-- Remove the bolts -1 through 5- and remove the accessory bracket from the coolant pump housing.
Installing
NOTE: Replace the bolts which have been tightened to a torque angle.
Replace the O-rings and seals.
-- Lubricate the O-rings -4- with coolant.

Fig. 37: Identifying Accessory Assembly Bracket, Coolant Pump Housing, Connection And O-Rings
-- Install the connection -2- into the coolant pump housing -3-.
-- Slide the accessory bracket -1- onto the connection -2-.
-- Position the accessory bracket and install the bolt -4- first, then the bolts -1, 2, 3 and 5-.

-- Tighten the bolts by hand. -- Tighten the bolts to 20 Nm. -- Tighten the bolts an additional 90° (1/4)
turn.
The rest of the installation is basically a reverse of the removal procedure, when doing this, note the following:

 Install the A/C compressor. Refer to Removal and Installation .
 Install the generator. Refer to Removal and Installation .
VIBRATION DAMPER

 Counter Hold Tool -T10355-
Removing
-- Remove the front part of the right wheel housing liner and/or the front right wheel housing liner. Refer to
Removal and Installation .
Fig. 39: Identifying Air Guide Pipe And Bolts

-- Remove the bolts -arrows-.
-- Lift the clamps -1 and 2- and remove the charge air pipe.
-- Rotate the vibration damper to the Top Dead Center (TDC) position -arrow- using the counter hold tool -
T10355-.
Fig. 40: Identifying Vibration Damper Rotated Into "OT" Position Using Counter Hold Tool T10355
 The notch on the vibration damper must line up with the arrow mark on the lower timing chain cover.
-- Remove the vibration damper bolt using the counter hold tool -T10355-.
CAUTION: The engine could be destroyed.
 In order not to change the valve timing, the crankshaft must NOT be
moved out of the TDC position when the vibration damper is
removed.
-- Remove the vibration damper.
-- If the vibration damper is not immediately reinstalled, install the bolt and the sleeve -T10368-.
Fig. 41: Identifying Vibration Damper Bolt And Thrust Piece T10368
Installing
Fig. 42: Identifying O-Ring And Tooth Contour


NOTE: Replace the vibration damper bolt.
Replace the O-ring -1-.
-- Lubricate the sealing lip with engine oil.
-- Install the vibration damper, when doing this, pay attention to the tooth contour -arrow-.
DUAL MASS FLYWHEEL
 Flywheel Retainer -3067-
Removing
-- Remove the transmission. Refer to one of the following:
 [For transmission(s) 02Q] Removing .

 REMOVAL AND INSTALLATION .
CAUTION: To prevent damage to the dual mass flywheel when removing, the bolts -B-
must not be loosened using an air-powered or impact wrench. Only
loosening the bolts by hand is permitted.
-- Rotate the dual mass flywheel -A- so that the bolts -B- are centered with the holes -arrows-.
Fig. 43: Identifying Dual-Mass Flywheel & Bolts

-- When removing the bolts -B-, make sure the bolt head does not come into contact with the dual mass
flywheel -arrows- or the flywheel could be damaged when turning the bolt.
-- Install the flywheel retainer -3067- to the hole in the cylinder block -B-.
Fig. 44: Identifying Retainer -3067- Inserted In Hole On Cylinder Block

-- Remove the dual mass flywheel.
Installing
 Tightening specification, see -item 6- in the SEALING FLANGE AND DUAL MASS
FLYWHEEL/DRIVE PLATE OVERVIEW.
-- Install using new bolts.
-- Install the flywheel retainer -3067- to the hole in the cylinder block -A-.
Fig. 45: Identifying Retainer -3067- Inserted In Hole On Cylinder Block

DRIVE PLATE
 Flywheel Lock Adapter -VW 558-

 Depth Gauge
 M8 x 40 Bolt and M8 Nut
-- Remove the transmission. Refer to [For engine(s) CCTA] Removing .
Preparing the Flywheel Lock Adapter -VW 558-
-- Install a M8 x 40 bolt -A- with a M8 nut to the flywheel lock adapter -VW 558-.
Fig. 46: Identifying Flywheel Lock Adapter -VW 558- And Bolt
Loosening and Tightening
-- Install the flywheel lock adapter -VW 558- to the cylinder block and drive plate as illustrated.
Fig. 47: Identifying Flywheel Lock Adapter -VW 558- Installed To Cylinder Block And Drive Plate
Installed location of the flywheel lock adapter -VW 558-: -A- to loosen, -B- to tighten.
Installing
Fig. 48: Identifying Shim -A- And Bolts

-- First, position the drive plate without the shim -A-.
-- Install the used bolts -3- and tighten them to 30 Nm.
-- Calculate the dimension between the drive plate and cylinder block in three locations.
Fig. 49: Identifying Dimension Between Drive Plate And Cylinder Block
NOTE: This is measured through the hole in the drive plate to the machined surface of
the cylinder block. When measuring on the intermediate plate, take the
thickness of the plate into consideration.
 Specified value measured without the intermediate plate: 19.5 to 21.1 mm

 Specified value measured with the intermediate plate: 18.8 to 20.4 mm
If the specified value is reached, replace all the bolts and tighten them.
If the specified value is not obtained:
Fig. 50: Identifying Shim -A- And Bolts

-- Remove the drive plate again and use the shim -A-. Tighten the bolts -3- again to 30 Nm.
-- Repeat the measurement. If the specified value is reached, replace all bolts and tighten them.
 Tightening specification, see -item 6- in the SEALING FLANGE AND DUAL MASS
FLYWHEEL/DRIVE PLATE OVERVIEW.
SEALING FLANGE, TRANSMISSION SIDE
 Guide Sleeve -T20097-

 Hand Drill with Plastic Brush Attachment
 Protective Eyewear
 Silicone Sealant -D 174 003 A2-
Requirements
 The transmission is removed.

 The dual mass flywheel is removed. Refer to DUAL MASS FLYWHEEL, or the drive plate is removed.
Refer to DRIVE PLATE.
Removing
-- Unhook the intermediate plate at the sealing flange and at the alignment sleeves -arrows-.

-- Remove the bolts -1 through 8-


-- Remove the sealing flange.
Installing
NOTE: Note the expiration date of the silicone sealant.
The sealing flange must be installed within 5 minutes after application of the
silicone sealant.
The sealant bead may not be thicker than specified, otherwise the excess
sealant could enter the oil pan and clog the oil intake pipe.
After installing the sealing flange, the sealant must dry for approximately 30
minutes. Only after then may the engine oil be added.
-- Remove any sealant residue on the cylinder block using a flat blade scraper.
WARNING: Wear safety glasses.
-- Remove any remaining sealant on the sealing flange using, for example, a rotating plastic brush.
Fig. 53: Identifying Rotating Plastic Brush To Remove Sealant Residue From Sealing Flange, Cylinder
Block And Upper Part Of Oil Pan
-- Clean the sealing surfaces, they must be free of oil and grease.
-- Cut the sealant tube nozzle at the front mark (nozzle diameter: approximately 2 mm).
Fig. 54: Identifying Scissors To Cut Tube Nozzle At Front Marking (Nozzle Diameter Approx. 3 Mm)
-- Apply the silicone sealant to the clean sealing surface on the sealing flange as illustrated.
Fig. 55: Identifying Silicone Sealant Applied On Cover Sealing Surface

 Thickness of sealant bead: 2 to 3 mm
-- Position the guide sleeve -T20097- on the crankshaft.
Fig. 56: Identifying Guide Sleeve On Crankshaft

-- Slide the sealing flange onto the crankshaft using the guide sleeve -T20097-.
-- Tighten the bolts in the sequence -1 through 8- shown:


-- 1. Install the bolts and tighten them by hand.
The rest of the installation is performed in the reverse order of removal.
SENSOR WHEEL
-- Remove the engine.
-- Remove the sealing flange. Refer to SEALING FLANGE, TRANSMISSION SIDE.
-- Remove the upper oil pan. Refer to UPPER OIL PAN .
-- Remove the balance shaft timing chain. Refer to BALANCE SHAFT TIMING CHAIN .
-- Remove the connecting rod bearing caps.
-- Remove the crankshaft bearing caps.
-- Remove the crankshaft with the sensor wheel.
-- Always replace the sensor wheel -2- any time the screws are loosened -1-.
Fig. 58: Identifying Attachment Points, Countersunk Screws, Crankshaft & Sensor Wheel
NOTE: After tightening for the second time, the points where the head of the screw
make contact with the sensor wheel become so deformed that the screw heads
at the crankshaft -3- -arrows- and the sensor wheel lies >>loosely<< under the
screws.
The sensor wheel can only be installed in one position. The holes are offset.
 Tightening specifications, refer to CRANKSHAFT OVERVIEW.
CRANKSHAFT NEEDLE BEARINGS
 Counter Support, for example, Kukko Support 22/1

 Internal Puller, for example, Kukko Extractor 14.5-18.5 mm 21/2
 Drift -VW 207 C-
Removing
Fig. 59: Identifying Kukko Support 22/1 -A-

-- Using a standard puller, for example, Kukko extractor 14.5-18.5 mm 21/2 and a counter support, for example,
Kukko support 22/1 -A- , remove the needle bearings.
Installing
Fig. 60: Identifying Drift -VW 207 C- To Drive In Needle Bearing

-- Drive in the needle bearings using the drift -VW 207 C-.
Installed depth dimension is 2 mm -a-
Fig. 61: Identifying Installation Depth Dimension

SPECIAL TOOLS
 Guide Sleeve -T20097-

 Micrometer 75-100 mm -VAS 6071-
 Cylinder Gauge -VAS 6078-
Fig. 62: Identifying Dial Gauge Holder VW 387

Fig. 63: Identifying Dial Gauge VAS 6079


Fig. 64: Identifying Locking Pin T10060 A

Fig. 65: Identifying Counter Hold Tool -T10355-

 Flywheel Retainer -3067-

Fig. 66: Identifying 3067 Counter-Hold Tool

 Flywheel Lock Adapter -VW 558-
Fig. 67: Identifying Counterhold VW 558

 Kukko Support 22/1

Fig. 68: Identifying Kukko Support 22/1

 Kukko Extractor 14.5-18.5 mm 21/2
Fig. 69: Identifying Kukko Extractor 14.5-18.5 mm 21/2

 Drift -VW 207 C-

Fig. 70: Identifying Drift -VW 207 C-

Fig. 71: Identifying Engine Support Bridge And Special Tools


 Bracket with Spindle and Hook 10-222 A/10
 Shackle 10-222 A/12
ENGINE 2.0 Liter - Cylinder Head, Valvetrain - Engine Code(s): CBFA & CCTA
ENGINE
2.0 Liter - Cylinder Head, Valvetrain - Engine Code(s): CBFA & CCTA
15 CYLINDER HEAD, VALVETRAIN

CYLINDER HEAD OVERVIEW
NOTE: Replace the cylinder head bolts.
Always replace self-locking nuts, bolts which have been tightened to a torque
angle, as well as gaskets and O-rings.
The plastic protectors installed to protect the open valves must only be
removed immediately before installing the cylinder head.
When replacing the cylinder head or cylinder head gasket, the coolant must be
completely replaced.
Fig. 1: Identifying Assembly Overview: Cylinder Head

1. Cylinder Head Gasket

 Always replace.
 Note the installed position: Part number faces the cylinder head.
2. Bolt
 25 Nm
3. Transport Strap
4. Bolt
5. Cylinder Head
 Removing and installing, refer to CYLINDER HEAD.
 Checking for distortion, refer to Fig. 5.
6. Bolt
 Always replace.
 Observe the sequence for loosening, refer to Fig. 3.
 Observe the sequence for tightening, refer to Fig. 4.
7. O-ring
 Always replace.
 Lubricate with engine oil.
8. Ball Stud
 5 Nm
 With a ball head for the engine cover.
9. Cap
 With a seal.
10. O-ring
 Always replace.
11. Sealing Plug

12. Bracket
13. Bolt
 9 Nm
14. Heat Shield

15. Bolt
 20 Nm
16. Bolt
 20 Nm
17. to the Intake Hose/Turbocharger

18. Ventilation Pipe
19. O-ring
 No replacement part.
20. Gasket
21. Engine Cover

22. Bolt
23. Crankcase Ventilation


24. to the Intake Manifold
25. Gasket
26. Gasket
27. Vacuum Pump

 Removing and installing, refer to VACUUM PUMP.
28. Bolt
 9 Nm
29. Bolt
 9 Nm
 For engine code CBFA only.
30. Secondary Air Injection Solenoid Valve -N112-

31. Gasket
 Always replace.
32. Mounting Plate

33. Bolt
 9 Nm
34. Connecting Piece

35. O-ring
 Always replace.
 Lubricate with coolant.
36. Bolt
 25 Nm
37. Transport Strap

38. Bolt
 9 Nm
39. Camshaft Position Sensor -G40-

40. Partition Plate
Fig. 2: Identifying Crankcase Ventilation - Tightening Sequence

-- Tighten the crankcase ventilation bolts -1 to 10- in sequence to 11 Nm.
Fig. 3: Identifying Cylinder Head - Loosening Sequence

-- Loosen the cylinder head bolts in sequence -1 through 5-.

Fig. 4: Identifying Cylinder Head - Tightening Sequence

-- Tighten the cylinder head bolts in sequence -1 through 5-.
-- Tighten the bolts to 40 Nm using a torque wrench.
-- Tighten the bolts an additional 90° (1/4) turn using a ratchet.
-- Tighten the bolts an additional 90° (1/4) turn using a ratchet.
-- Tighten the bolts -arrows- to 8 Nm.
-- Tighten the bolts -arrows- an additional 90° (1/4) turn using a ratchet.
Fig. 5: Identifying Check For Distortion On Cylinder Head Straight Edge 500 mm -VAS 6075- And
Feeler Gauges
-- Check the cylinder head at several locations for distortion using a straight edge 500 mm -VAS 6075- and a
feeler gauge.
 Max. permissible distortion: 0.05 mm
VALVETRAIN OVERVIEW
NOTE: The cylinder head and the cylinder head cover must be replaced together.
After installing the camshafts, the engine may not be started for approximately
30 minutes. The hydraulic lash adjusters must seat themselves (otherwise the
valves will crash into the pistons).
After working on the valvetrain and lifters, carefully rotate the crankshaft by
hand at least 2 full revolutions before starting to be sure that valves do not
strike the pistons.
Always replace gaskets and seals.

Fig. 6: Identifying Assembly Overview: Valvetrain

1. Exhaust Valve
 Do not grind, only hand lapping is permitted.
 Valve dimensions, refer to Fig. 8.
 Checking valve guides, refer to VALVE GUIDE, CHECKING.
2. Cylinder Head
3. Valve Guide
 Checking, refer to VALVE GUIDE, CHECKING.
4. Valve Stem Seal

5. Valve Spring
6. Valve Spring Plate
7. Valve Retainers
8. Roller Rocker Arm with Hydraulic Lash Adjuster
 Do not interchange.
 Lubricate the contact surfaces.
9. Exhaust Camshaft
 Check the radial clearance using Plastigage R (roller rocker arm removed).
 Radial play on bearing diameter - 24 mm: 0.024 to 0.066 mm.
 Run out:
Max. 0.04 mm.
10. Cylinder Head Cover

 With integrated camshaft bearings.
 Clean the sealing surface, reworking is not permitted.
 Remove the old sealant residue.
11. Bolt
 Always replace.
12. O-ring
 Always replace.
13. Sealing Plug

14. Intake Camshaft
 Check the radial clearance using Plastigage R (roller rocker arm removed).
 Run out:
Max. 0.04 mm.
15. Cap
Always replace.
 Removing: With the cylinder head cover installed, pierce through one side of the cover with an awl
and pry it out.
 Installing: Without sealant, press in 1 to 2 mm using the thrust piece -3334-.
16. Intake Valve

 Do not grind, only hand lapping is permitted.
 Valve dimensions, refer to Fig. 8.

 Checking the valve guides, refer to VALVE GUIDE, CHECKING.
Fig. 7: Identifying Cylinder Head Cover - Tightening Sequence

-- Replace the bolts.
-- Hand tighten the bolts in several passes in sequence -1 through 6-.
-- Tighten the bolts in sequence -1 through 6- to 8 Nm using a torque wrench.
-- Tighten the bolts an additional 90° (1/4) turn using a ratchet in sequence -1 through 6-.
NOTE: Ensure the cylinder head cover is not tilted.

Fig. 8: Identifying Valve Dimensions

NOTE: Intake and exhaust valves must not be refaced by grinding. Only hand lapping
is permitted.
Dimension Intake Valve Exhaust Valve

diameter a mm 33.85 0.10 28.0 0.1
diameter b mm 5.98 0.007 5.955 0.007
c mm 103.97 101.87
a ° 45 45
TIMING CHAIN COVERS OVERVIEW

Fig. 9: Identifying Assembly Overview: Timing Chain Covers

1. O-ring
 Always replace.
 Lubricate before installing.
2. Oil Dipstick Guide Tube

3. Bolt
 9 Nm
4. Bolt
 9 Nm
5. Camshaft Adjustment Valve 1 -N205-

 Removing and installing, refer to CAMSHAFT ADJUSTMENT VALVE 1 -N205-.
6. Seal
7. Bolt
 Tightening sequence, refer to UPPER TIMING CHAIN COVER.
8. Upper Timing Chain Cover

 Removing and installing, refer to UPPER TIMING CHAIN COVER.
9. Gasket
10. O-ring
 Always replace.
11. Alignment Sleeve

 For centering the cover.
12. Lower Timing Chain Cover

 Passat and CC, refer to LOWER TIMING CHAIN COVER.
13. Bolt
 Always replace.
 Observe the tightening sequence Fig. 11.
14. Shaft Seal

 For the vibration damper.
 Removing and installing, refer to VIBRATION DAMPER SHAFT SEAL.
15. Sealing Plug

 Always replace.
Fig. 10: Identifying Upper Timing Chain Cover - Tightening Sequence

-- Tighten the bolts in 2 passes in sequence -1 through 5- :
1. Tighten the bolts by hand

2. Tighten the bolts to 9 Nm
Fig. 11: Identifying Lower Timing Chain Cover Bolts


2. Tighten the bolts an additional 45° (1/8) turn
CAMSHAFT TIMING CHAIN OVERVIEW

Fig. 12: Identifying Assembly Overview: Camshaft Timing Chain

1. Bolt
 9 Nm
2. Chain Tensioner
 Is under tension.
 Disconnect the locking pin -T40011- before removing.
3. Timing Chain Tensioning Rail

4. Guide Pin
 20 Nm
5. Bolt
 9 Nm
6. Control Valve
 35 Nm
 Left hand threads.
 Remove using the assembly toolT10352.
7. Bolt
 Always replace.
8. Washer
9. Bearing Bracket
10. Camshaft Timing Chain Guide Rail
11. Camshaft Housing
12. Camshaft Timing Chain
 Before removing, mark the direction of rotation with paint.
 Removing and installing, refer to CAMSHAFT TIMING CHAIN.
13. Camshaft Timing Chain Guide Rail

14. Guide Pin
 20 Nm
15. Sprocket
 On the crankshaft.
 Installed position, refer to Fig. 13.

Fig. 13: Identifying Chain Sprocket Crankshaft - Installation Position

 Both surfaces -arrows- must line up across from each other.
BALANCE SHAFT TIMING CHAIN OVERVIEW
Fig. 14: Identifying Assembly Overview: Balance Shaft Timing Chain

1. Bolt
9 Nm

2. Balance Shaft
 Replace after removing.

 Exhaust side.
 Lubricate the bearing with engine oil.
 Removing, refer to EXHAUST CAMSHAFT BALANCE SHAFT.
3. Pipe for the Balance Shaft

4. Chain Tensioner
 65 Nm
 Install using liquid locking fluid.
5. Cylinder Block
6. Balance Shaft
 Replace after removing.
 Intake side.
 Lubricate the bearing with engine oil.
 Removing, refer to INTAKE CAMSHAFT BALANCE SHAFT.
7. O-ring
8. Bearing Pin
9. Intermediate Shaft Sprocket

 For the balance shaft.
 The intermediate shaft sprocket must be replaced if the bolt is loosened.
10. Bolt
 9 Nm
11. Washer
12. Bolt
 The intermediate shaft sprocket must be replaced if the bolt is loosened.
13. Guide Rail

 For the timing chain.
14. Guide Pin

 20 Nm
15. Tensioning Rail

 For the timing chain.
16. Guide Pin

 20 Nm
17. Timing Chain

 Removing and installing, refer to BALANCE SHAFT TIMING CHAIN.
18. Sprocket
19. Guide Rail

 For the balance shaft timing chain.
20. Guide Pin

 20 Nm
Fig. 15: Identifying Pipe For Balance Shaft - Installation Position

 The pin from the balance shaft pipe must fit into the groove -arrow-
Fig. 16: Identifying Bearing Pins - Installation Position

 Replace and lubricate the O-ring -1-

 The pin -arrow- for the bearing pin must engage in the hole in the cylinder block.
 Lubricate the bearing pin.
Fig. 17: Identifying Intermediate Shaft Sprocket

CAUTION: Always replace the intermediate shaft sprocket. Otherwise the backlash
will not adjust itself and it could result in engine damage. The new
intermediate shaft sprocket has an anti-friction coating that wears off after
a short period of use, which automatically adjusts the backlash.
-- Tighten the bolt as follows:
-- Tighten the bolt to 10 Nm using a torque wrench.
-- Turn the chain sprocket.
The chain sprocket may not have any play; if so, loosen and tighten again.
-- Tighten the bolt to 30 Nm using a torque wrench.
-- Tighten the bolt an additional 90° (1/4) turn using a ratchet.
SPECIFICATIONS

Balance Shaft to Cylinder Block Bolt - 9
Balance Shaft Timing Chain Guide Rail to Cylinder Block
- 20
Guide Pin
Balance Shaft Timing Chain, Chain Tensioner to Cylinder
- 65
Block (2)
Balance Shaft Timing Chain Tensioning Rail to Cylinder
- 20
Block Guide Pin
Ball Stud to Cylinder Head Cover - 5
Bearing Bracket to Cylinder Head Bolt - 9
Bearing Bracket to Exhaust Camshaft Bolt (1)
M6 8 + 90°
M8 20 + 90°
Camshaft Adjustment Valve 1 to Upper Timing Chain
- 9
Cover Bolt
Camshaft Position Sensor to Cylinder Block Bolt - 9
Camshaft Timing Chain, Chain Tensioner to Cylinder
- 9
Block Bolt
Camshaft Timing Chain Guide Rail to Cylinder Block
- 20
Guide Pin
Camshaft Timing Chain Tensioning Rail to Cylinder
- 20
Block Guide Pin
Control Valve to Intake Camshaft (4) - 35
Heat Shield to Bracket Bolt - 9

Heat Shield to Cylinder Head Bolt - 20
Mounting Plate/Connecting Piece to Cylinder Head Bolt - 9
Oil Dipstick Guide Tube/Camshaft Adjustment Valve 1 to
- 9
Upper Timing Chain Cover Bolt
Oil Dipstick Guide Tube to Cylinder Head Bolt - 9
Secondary Air Injection Solenoid Valve to Cylinder Head
- 9
Bolt (3)
Transport Strap to Cylinder Head Bolt - 25
Vacuum Pump to Cylinder Head Bolt - 9
(1) Always replace
(2) Install with locking compound.
(3) Engine code CBFA only
(4) Left hand threads
Crankcase Ventilation Bolt Tightening Sequence and Specification
Fig. 18: Identifying Crankcase Ventilation - Tightening Sequence

-- Tighten the crankcase ventilation bolts in sequence -1 through 10- to 11 Nm.
Cylinder Head Cover Bolt Tightening Sequence and Specification

Fig. 19: Identifying Cylinder Head Cover - Tightening Sequence

-- Replace the bolts.
 Hand tighten the bolts in several passes in sequence -1 through 6-.

 Tighten the bolts in sequence -1 through 6- to 8 Nm.
 Tighten the bolts in sequence -1 through 6- an additional 90° (1/4) turn.
Cylinder Head Bolt Tightening Sequence and Specification

-- Tighten the cylinder head bolts in sequence -1 through 5-.
 Tighten the bolts to 40 Nm.

 Tighten the bolts an additional 90° (1/4) turn.
 Tighten the bolts an additional 90° (1/4) turn.
 Tighten the bolts -arrows- to 8 Nm.
 Tighten the bolts -arrows- an additional 90° (1/4) turn.
Upper Timing Chain Cover Bolt Tightening Sequence and Specification


Lower Timing Chain Cover Bolt Tightening Sequence and Specification



Intermediate Shaft Sprocket Bolt Tightening Sequence and Specification


WARNING: Always replace the intermediate shaft sprocket. Otherwise the backlash
intermediate shaft sprocket has an anti-friction coating that wears off
after a short period of use, which automatically adjusts the backlash.
-- Tighten the bolt to 10 Nm.
-- Turn the chain sprocket.
The chain sprocket may not have any play; if so, loosen and tighten again.
-- Tighten the bolt to 30 Nm.
-- Tighten the bolt an additional 90° (1/4) turn.
VALVE TIMING, CHECKING
-- Remove the upper timing chain cover. Refer to UPPER TIMING CHAIN COVER.
-- Disconnect the right charge air hose at the coupling.
-- Rotate the vibration damper, from underneath, in engine rotation direction to Top Dead Center (TDC) -arrow-
NOTE: Use a ratchet with a 24 mm socket to rotate the vibration damper. Rotate the
crankshaft first to TDC and then again approximately 45° in the opposite
direction of the engine rotation. Next, rotate the crankshaft in engine rotation
direction to TDC.
If the arrow mark on the lower timing chain cover is no longer visible, set the
engine to TDC using the dial gauge -VAS 6079-, refer to SETTING THE ENGINE
TO TDC USING THE DIAL GAUGE -VAS 6079-.
 The notch on the vibration damper must line up with the arrow mark on the lower timing chain cover (use
a inspection mirror, if necessary).
 The marks -1- on the camshafts must point upward.
-- Measure the distance from the outer edge -A- to the mark -B- on the intake camshaft.
Fig. 25: Identifying Measurement Points From Outer Edge -A- To Mark -B-
 Specified value: 61 to 64 mm.
-- Once the specified value is reached, measure the distance between the mark on the intake camshaft -B- and
the mark on the exhaust camshaft -C-.
Fig. 26: Identifying Measurement Points From Mark On Intake Camshaft -B- To Mark On Exhaust
Camshaft -C-
 Specified value: 124 to 126 mm

NOTE: If one tooth has an offset, there will be a deviation of approximately 6 mm from
the specified value. Install the timing chain once again if there is an offset.
SETTING THE ENGINE TO TDC USING THE DIAL GAUGE -VAS 6079-

 Adapter for the Dial Gauge -T10170- or -T10170 A-
-- Rotate the crankshaft from above using a 24 mm socket on the vibration damper in engine rotation direction
until the marks -arrows- are on top.
Fig. 27: Identifying Mark Points On Intake And Exhaust Camshafts

-- Remove the spark plug from cylinder 1.
-- Install the adapter for the dial gauge -T10170/A- all the way into the spark plug threads.
Fig. 28: Identifying Dial Gauge -VAS 6079- With Extending Piece -T10170A/1-
-- Insert the dial gauge 0-10 mm -VAS 6079- with the extending piece -T10170A/1- all the way and secure it
with the locking nut -arrow-.
-- Rotate the crankshaft slowly in engine rotation direction to the maximum dial reading. When the maximum
dial reading is reached (Bottom Dead Center (BDC) of the gauge) the piston is at Top Dead Center (TDC).
NOTE: Rotate the crankshaft first to TDC and then again approximately 45° in the
opposite direction of engine rotation. Next rotate the crankshaft in engine
rotation direction to TDC.
COMPRESSION TEST
 Spark Plug Removal Tool -3122 B-

 Ignition Coil Puller -T40039-
 Compression Tester -V.A.G 1763-
Requirements
NOTE: Follow all safety precautions. Refer to SAFETY PRECAUTIONS .
The engine oil temperature is a minimum of 30 °C (86 °F).
The battery voltage is at least 12.7 volts.

Procedure
-- Remove the engine cover. Refer to ENGINE COVER.
-- Disconnect the electrical connectors -arrows- from the ignition coils.
Fig. 29: Identifying Direction To Disconnect Ignition Coils Connectors

-- Remove the ignition coils using the ignition coil puller -T40039-.
Fig. 30: Identifying Ignition Coil Puller T40039 To Remove Ignition Coils
-- Remove the spark plugs, using the spark plug removal tool -3122 B-.
-- Check the compression using the compression tester -V.A.G 1763- and the adapter -V.A.G 1763/6-.
NOTE: Using the tester, refer to the operating instructions.
-- Operate the starter until the tester no longer indicates that the pressure is increasing.
Compression Pressure
New Bar Positive Pressure Wear Limit Bar Positive Difference Between Cylinders
Pressure Bar Positive Pressure
11.0... 14.0 7.0 Max. 3.0
-- Install the sparks plugs. Tightening specification, refer to IGNITION SYSTEM COMPONENT
OVERVIEW .
-- Install the ignition coils with power output stage. Refer to IGNITION COILS WITH POWER OUTPUT
STAGES .
NOTE: By disconnecting the ignition coil connectors, Diagnostic Trouble Codes

(DTCs) are stored to memory. After the test, check the fault memory and erase,
if necessary.
-- Read the Engine Control Module (ECM) DTC memory. Refer to the vehicle diagnostic tester.
CAMSHAFT AXIAL CLEARANCE, CHECKING

Test Sequence
Fig. 31: Identifying Dial Gauge VAS 6079 Secured To Cylinder Head With Universal Dial Gauge Holder
VW 387
-- Perform the measurement with the cylinder head cover removed.
-- Place the camshaft to be checked in the cylinder head.
-- Secure the dial gauge 0-10 mm -VAS 6079- to the cylinder head using the dial gauge holder -VW 387-.
-- Press the camshaft against dial gauge by hand.
-- Set the dial gauge to "0".
-- Press the camshaft off the dial gauge and read the value:
 Axial clearance: 0.05 to 0.17 mm.
VALVE GUIDE, CHECKING

Test Sequence
-- Insert the valve into the guide. The valve stem tip must be flush with the guide. Due to the slight difference in
stem dimensions, ensure that only an intake valve is used in the intake guide and an exhaust valve in the exhaust
guide.
Fig. 32: Identifying Dial Gauge Holder VW 387 To Determine Valve Rock (Wear limit)
-- Determine the tip clearance.
Wear Limit
Intake Valve Guide Exhaust Valve Guide

0.80 mm 0.80 mm
NOTE: If the wear limit is exceeded, measure again using new valves. If the wear limit
is still exceeded, replace the cylinder head.
If the valve is to be replaced as part of a repair, use a new valve for the
calculation.
ENGINE COVER
Removing
-- Pull the engine cover at its attachment points -arrows- upward.

Fig. 33: Identifying Engine Cover Attachment Points

Installing
-- Make sure the rubber insulators fit correctly into the mounts when installing.
Fig. 34: Identifying Correct Installation Of Rubber Insulators

-- Carefully press the engine cover onto the ball studs.
-- To prevent damage, do not hit the engine cover with a fist or tools.
VACUUM PUMP
Removing
-- Remove the high pressure pump. Refer to HIGH PRESSURE PUMP .
-- Remove the ground wire -3- and bolt -4-.

Fig. 35: Identifying Vacuum Line -1-, Ground Wire -3- And Bolt -4-
-- Remove the vacuum hose -1- from the vacuum pump.
Fig. 36: Identifying Vacuum Pump, Ground Cable, Electrical Connector And Coolant Hoses
-- Remove the bolts -arrows- and remove the vacuum pump.

Fig. 37: Identifying Vacuum Pump Bolts

NOTE: Do not disassemble the vacuum pump.
Installing
 Tightening specifications, refer to CYLINDER HEAD OVERVIEW.
Installation is the reverse of removal, noting the following:
-- Clean the sealing surfaces.
-- Install the seal on the vacuum pump, install the 2 bolts and then mount it to the cylinder head.
CAMSHAFT ADJUSTMENT VALVE 1 -N205-

Fig. 38: Identifying Camshaft Adjustment Valve And Bolts

-- Disconnect the connector from the camshaft adjustment valve 1 -1-.
-- Remove the bolts -arrows- and then the camshaft adjustment valve 1.
Installing
 Tightening specifications, refer to TIMING CHAIN COVERS OVERVIEW.
-- Lubricate the seal and the O-ring with engine oil.
CAMSHAFTS

 Assembly Tool -T10352-
 Locking Pin -T40011-
 Sealant -D 154 103 A1-
NOTE: The sealing surfaces of the cylinder head cover and the upper cylinder head
must not be reworked.
The camshaft bearings are integrated in the cylinder head or cylinder head
cover. The tension must be released from the camshaft timing chain before
removing the cylinder head cover.
If the cylinder head cover was removed, the sealing cap must be replaced.
During installation, cable ties must be installed in the same location.
Removing
-- Remove the vacuum pump. Refer to VACUUM PUMP.
-- Remove the front part of the right wheel housing liner and/or the right front wheel housing liner. Refer to

-- Disconnect the connector from the camshaft adjustment valve 1 -N205- -1-.

CAUTION: The control valve has left hand threads.
-- Remove the control valve in the -direction of the arrow- using the assembly tool T10352.
Fig. 41: Identifying Assembly Tool T10352 To Remove Control Valve

-- Remove the bolts -arrows- and remove the bearing bracket.
Fig. 42: Identifying Bearing Bracket Bolts

T10355-.
 The notch on the vibration damper must line up with the arrow mark -arrow- on the lower timing chain
cover.
-- Carefully mark the position of the drive chain to the sprockets -A arrows- with a waterproof marker. Also
mark the position of the drive chain to the guide rail -B arrows-. These marks are necessary for reinstallation.
Fig. 44: Identifying Position Marks: Drive Chain To Sprockets -A- And Drive Chain To Guide Rail -B-
-- Remove the plug -arrow-.
Fig. 45: Locating Plug

The locking wedge in the chain tensioner must be lifted in order to release the tension from the chain tensioner.
Grind the end of the locking pin -T40011- down to a point. A screwdriver with a head approximately 1.5 mm
wide can also be used.
CAUTION: There is a risk of damaging the chain tensioner. Proceed very carefully.
-- Lift the chain tensioner locking wedge by inserting a scribe or a suitable screwdriver into the hole in the chain
tensioner in the -direction of arrow 1-.
Fig. 46: Identifying Chain Tensioner Locking Wedge, Screwdriver, Crankshaft And Securing Pin T40011
-- In order to tension the chain tensioner, rotate the crankshaft opposite the engine rotation direction -2- and
secure it using a locking pin -T40011-.
NOTE: The intake camshaft switches in the engine rotation direction.
-- Remove the guide pin -1- and guide the tensioning rail -2- downward.
Fig. 47: Identifying Guide Tensioning Rail, Upper Guide Rai And Bolt
-- Remove the upper guide rail -3- by unlocking the latch located in the center with a screwdriver and pushing
the guide rail forward.
NOTE: When the lower timing chain cover is installed, the loose chain on the
crankshaft cannot jump off.
-- Remove the camshaft timing chain from the sprockets.
CAUTION: Danger of damaging the valves, piston head and lower timing chain cover.
 Make certain that the timing chain remains tensioned when turning
the crankshaft by hand.
 Panels are installed on the lower timing chain cover to prevent the
chain from falling down. The panels can bend if the crankshaft is
rotated when the chain is loose.
-- Disconnect the connectors from the ignition coils and free up the wiring harness.
-- Disconnect the hose for the crankcase ventilation -1-.
Fig. 49: Identifying Crankcase Ventilation, Tightening Sequence

-- Remove the charge air pipe bolt -arrow-.

Fig. 50: Identifying Charge Air Pipe Bolt -Arrow- And Hose Clamp -2-
-- Loosen the hose clamp -2- and remove the charge air pipe together with the crankcase ventilation.
Fig. 51: Identifying Camshaft Position Sensor G40 Electrical Connector And Lines
-- Disconnect the vacuum line -1- and free up the wire.
-- Disconnect the connector -2- from the camshaft position sensor -G40-.
-- Remove the cylinder head cover bolts in sequence -1 through 6-.

Fig. 52: Identifying Cylinder Head Cover Loosening

-- Remove the cylinder head cover.
-- Remove the camshafts.
-- Prevent dirt and adhesive residue from entering the cylinder head.
Installing
 Tightening specifications, refer to VALVETRAIN OVERVIEW.
NOTE: The sealing surfaces must be completely free of oil and grease.
The pistons must not be positioned at TDC.
Make sure that all roller rocker arms make contact correctly on the valve stem
ends.
Note the expiration date of the silicone sealant.
The cover must be installed within 5 minutes after application of the silicone
sealant.
-- Remove any sealant residue on the cylinder head using a flat blade scraper.

NOTE: Prevent dirt and adhesive residue from entering the cylinder head.
-- Remove any sealant from the groove in the cylinder head cover as well as from any sealing surface using, for
example, a rotating plastic brush.
-- Lubricate the running surfaces of both camshafts.
-- Place the camshaft into the cylinder head, the recesses -arrows- must be perpendicular to each other.
Fig. 55: Identifying Camshaft Recesses

-- Replace the cylinder head cover bolts.
-- Apply the silicone sealant -D 154 103 A1- on the clean sealing surface of the cylinder head cover as shown -
arrows-.
Fig. 56: Identifying Cylinder Head Cover Sealing Surface

 Thickness of sealant bead: 2 to 3 mm.
NOTE: The cylinder head cover must be installed within 5 minutes after application of
the silicone sealant.
The sealant bead may not be thicker than specified, otherwise excess sealant
could enter the oil pan and clog the oil intake pipe.
Note the expiration date of the sealant.
-- Tighten the bolts in several passes in the tightening sequence, refer to Fig. 7.
NOTE: Make sure the cylinder head cover is not tilted.
Instal the cap -1- without sealant using the thrust piece -T10174-.
Fig. 57: Identifying Thrust Piece T10174 To Drive In Cap

Dimension -a- : 1 to 2 mm
 Make certain that the timing chain remains tensioned when turning
the crankshaft by hand.
-- Rotate the vibration damper to the TDC position -arrow- using the counter hold tool -T10355-.
cover.
-- Mount the timing chain on the intake camshaft. The marks must align.
Fig. 59: Identifying Drive Chain/Chain Sprocket Markings And Turning Intake Camshaft Using Wrench
-- Rotate the intake camshaft in the -direction of the arrow- with a wrench until the timing chain is taut. Hold
the intake camshaft secure in this position.
-- Mount the timing chain on the exhaust camshaft: The marks on the drive chain and sprocket -A arrows- and
the drive chain and guide rail -B arrows- must line up with each other.
-- Install the upper guide rail -3-.
-- Move the tensioning rail -2- up and tighten the guide pin -1-.
NOTE: If the marks on the drive chain and guide rail -B arrows- do not align even
though the engine is at TDC, the drive chain has skipped on the crankshaft
sprocket. Check the valve timing. Refer to VALVE TIMING, CHECKING. If the
timing does not agree, the camshaft timing chain must be positioned again.
Refer to CAMSHAFT TIMING CHAIN.
Fig. 62: Identifying Position Marks: Drive Chain To Sprockets -A- And Drive
Chain To Guide Rail -B-
The rest of the installation is basically a reverse of the removal sequence.
VALVE STEM SEALS
(With the cylinder head installed)
 Spark Plug Removal Tool -3122 B-

 Valve Seal Removal Tool -3364-
 Valve Stem Seal Driver -3365-
 Adapter -T40012-
 Valve Cotters Asm/Disasm Device -VAS 5161-
 Guide Plate for FSI Engine -VAS 5161/19B-
Removing
-- Remove the camshafts. Refer to CAMSHAFTS.
-- Remove the roller rocker arms and place them on a clean surface. Make sure that they are not interchanged.
-- Using the spark plug removal tool -3122 B-, remove spark plugs.
-- Secure the guide plate for FSI engine -VAS 5161/19B- to the cylinder head as shown using the knurled
thumb screws -VAS 5161/12-.
Fig. 63: Identifying FSI Engine VAS 5161/19B Guide Plate Tightened On Cylinder Head Using Knurled
Bolts VAS 5161/12
-- Adjust the piston of the respective cylinder to the Bottom Dead Center (BDC) position.
-- Install the adapter -T40012- into the spark plug hole and connect compressed air of at least 6 bar positive
pressure.
Fig. 64: Identifying Drift VAS 5161/3 And Plastic Mallet To Loosen Stuck Valve Keepers
-- Using the punch -VAS 5161/3- and a plastic mallet, tap on any stuck valve retainers in order to loosen them.
Intake Side
Fig. 65: Identifying Installation Of Engaging Device VAS 5161/6 With Installation Forks VAS 5161/5 Into
Guide Plate VAS 5161/19
-- Install the retainer -VAS 5161/6- using the guide forks M6/M8 with threaded stud -VAS 5161/5- into the
center threads in the guide plate for FSI engine -VAS 5161/19B-.
-- Install the assembly cartridge -VAS 5161/8- into the guide plate -VAS 5161/19B-.
-- Install the pressure fork with lever for assembly cartridge -VAS 5161/2- onto the retainer -VAS 5161/6-.
Exhaust Side
Fig. 66: Identifying Pressure Forks VAS 5161/2 Engaged

-- Install the retainer -VAS 5161/6- using the guide forks M6/M8 with threaded stud -VAS 5161/5- into the
outer threads in the guide plate for FSI engine -VAS 5161/19B-.
-- Press down the assembly cartridge -VAS 5161/8-. At the same time, turn the knurled knob on the assembly
cartridge -VAS 5161/8- clockwise until the points engage in the valve retainers.
-- Lightly move the knurled knob back and forth, this causes the valve retainers to be pressed apart and captured
in the assembly cartridge.
-- Release the pressure fork with lever for assembly cartridge -VAS 5161/2-.
-- Take out the assembly cartridge -VAS 5161/8-.
-- Remove the valve stem seal using the valve seal removal tool -3364-.
Fig. 67: Identifying Valve Seal Removal Tool 3364

-- If the valve seal removal tool -3364- cannot be used due to restricted clearance, drive the roll pin -arrow- out
with a drift and remove the impact attachment.
Fig. 68: Identifying Valve Seal Removal Tool 3364

-- Place the lower part of the valve seal removal tool -3364- onto the valve stem seal.
Fig. 69: Identifying Placement Of Lower Part Of Valve Seal Removal Tool 3364 On To Valve Stem Oil
Seal
-- Insert a drift -1- into the bore in the lower part of the removal tool.
-- Using the drift -1- as a lever, pull out the valve stem seal in the -direction of the arrow-.
Installing
Fig. 70: Identifying Plastic Sleeve, New Valve Stem Oil Seals & Valve Stem Seal Driver 3365
-- Place a plastic sleeve -A- on the valve stem to prevent damage to the new valve stem seal -B-.
-- Lubricate the sealing lip of the valve stem seal -B- , insert it into the valve stem seal driver -3365- and
carefully slide it onto the valve guide.
-- Remove the plastic sleeve -A-.
-- Install the valve spring, spring plate and valve spring retainers.
Fig. 71: Identifying Installation Of Engaging Device VAS 5161/6 With Installation Forks VAS 5161/5 Into
Guide Plate VAS 5161/19

-- Install the special tools as shown.
Fig. 72: Identifying Pressure Forks VAS 5161/2 Engaged

-- Install the special tools as shown.
NOTE: If the valve retainers were removed from the assembly cartridge, they must be
inserted into the valve insertion device -VAS 5161/18- next.
Fig. 73: Identifying Installation Cartridge VAS 5161/8

Press the assembly cartridge -VAS 5161/8- onto the insertion device from above
and capture the valve retainers.
-- Press down the assembly cartridge -VAS 5161/8- with the pressure fork with lever for assembly cartridge -
VAS 5161/2- and turn the knurled knob on the assembly cartridge back and forth while pulling it upward at the
same time.
-- Release the pressure fork with lever for assembly cartridge -VAS 5161/2- with the knurled knob pulled.
-- Remove the special tools.
CYLINDER HEAD
 Engine Sling -2024 A-

 Engine Support -T10014-
 Shop Crane - Load Cap = 700-1200KG -VAS 6100-
 Engine Bung Set -VAS 6122-
 Polydrive Bit and Drive Socket -T10070-
Removing
NOTE: During installation, cable ties must be installed in the same location.

-- Disconnect the electrical connector -arrow- and free up the electrical wire.
WARNING: Risk of scalding due to hot steam and hot coolant.
The coolant system is under pressure when the engine is warm.
and open carefully.
-- Remove the front exhaust pipe with catalytic converter. Refer to FRONT EXHAUST PIPE WITH
CATALYTIC CONVERTERS .
-- Remove the right front wheel.
-- Remove the right front wheel housing liner. Refer to Removal and Installation .
-- Loosen the clamps -items 1 and 2- and remove the charge air hose.



-- Disconnect the connectors -1 and 2- and free up the wire -arrows-.
Fig. 78: Identifying Turbocharger Electrical Connectors

Vehicles with All Wheel Drive (AWD)

Fig. 79: Identifying, Tool -3247-, Bolts -1- And Heat Shield -A-
-- Remove the right drive axle heat shield bolts -1- using the hex ball socket -3247- and remove the shield -A-.
Fig. 80: Identifying Turbocharger Support And Bolts

-- Remove the bolts -1 and 2- and remove the turbocharger support.
-- Remove the banjo bolt -2- and move the coolant line to the side.
Fig. 81: Identifying Oil Return Line, Coolant Line And Oil Supply Line Fasteners
Vehicles with Front Wheel Drive (FWD)
-- Remove the bolts -1- for the oil return line.
Vehicles with AWD
-- Remove the oil return line bolts from the crankcase.
-- Remove the bolt -3- for the oil supply line.
-- On vehicles with a noise generator: Remove the charge air pipe from the noise generator.
-- Disconnect the connector from the camshaft adjustment valve 1 -N205- -1-.

-- Disconnect the connectors from the ignition coils and free up the wiring harness.
-- Disconnect the hose for the crankcase ventilation - 1 -.

Fig. 84: Identifying Crankcase Ventilation, Tightening Sequence

-- Loosen the hose clamp -2- and remove the charge air pipe together with the crankcase ventilation.
WARNING: The fuel supply line is under pressure. Always wear protective eyewear
and protective clothing to prevent injuries and fuel from coming in
contact with your skin. Wrap a cloth around the connection before
removing a fuel hose. Remove the hose connection carefully to release
the pressure.
-- Disconnect the lines - 1 through 3- from the fuel transfer.
Fig. 86: Identifying Breather Line, Vacuum Line & Fuel Supply Line
Vent line -1-
Vacuum line -2-
Fuel supply line -3-
-- Disconnect the coolant line -arrow- from to the coolant expansion tank.
Fig. 87: Identifying Coolant Line To Coolant Expansion Tank

-- Remove the coolant hoses -arrows- from the coolant pipe.
-- Disconnect the ground wire -3- and remove the bolt -4-.
-- Disconnect the vacuum hoses -arrows-.

Fig. 89: Identifying Vacuum Hoses

-- Loosen the bolts -1 though 4- and remove the heat shield together with the coolant pipe.
Fig. 90: Identifying Heat Shield Bolts

-- Disconnect the oil supply line from the turbocharger -4-.
NOTE: Remove the bolt -2- from the heat shield using a 6 mm -A- hex socket. The hex
socket must be at least 5 cm -B- long. A socket that tapers to 6 mm at the tip is
too wide.
Fig. 91: Identifying 6mm Hex Socket -A-, 5cm Long -B-
-- Disconnect the electrical connector -2- from the fuel pressure regulator valve -N276-.
Fig. 92: Identifying High Pressure Fuel Pump And Fuel Pressure Regulator Valve Electrical Harness
Connector
Engine Code CBFA

Fig. 93: Identifying Secondary Air Injection (Air) Solenoid Valve N112 Connector And Hose
-- Disconnect the connector -A- and hose -B- from the secondary air injection solenoid valve -N112-.
-- Loosen the coolant pipe, remove the bolts -arrows-.
Fig. 94: Identifying Coolant Pipe And Bolts

-- Disconnect the coolant hose from the side connection on the cylinder head.
-- Disconnect the electrical connectors -1 through 4-.
Fig. 95: Identifying EVAP Filter Vacuum Hose, Electrical Connectors And Electrical Cable
-- Free up the wire -5-.
-- Disconnect the vacuum hose -6- leading to the canister.
GTI

-- Disconnect the vent line -1- , unlock the canister -A- and remove it -B-.
Fig. 97: Identifying Vacuum Line And Electrical Connectors

-- Disconnect the electrical connectors -1 - and pull the connectors out of the retainer.
-- Disconnect the electrical connectors -2 through 4-.
-- Disconnect the coolant line from the intake manifold, when doing this, remove the bolts -arrows-.
Fig. 98: Identifying Intake Manifold Coolant Line Bolts

-- Remove the intake manifold bracket by removing the nut -1- and bolt -2-.
-- Remove the oil filter.
-- Disconnect the coolant hoses -arrows- and move them to the side.



-- Remove the control valve in the -direction of the arrow- using the assembly tool -T10352-.


T10355-.
cover.
-- Carefully mark the position of the drive chain to the sprockets -A arrows- with a waterproof marker. Also
mark the position of the drive chain to the guide rail -B arrows-. These marks are necessary for reinstallation.
-- Remove the plug -arrow-.
Fig. 106: Locating Plug

Sand the end of the locking pin -T40011- down to a point. A screwdriver with a head approximately 1.5 mm
-- Insert a screwdriver in the hole on the chain tensioner in the -direction of arrow 1- and lift the locking wedge
in the chain tensioner.
Fig. 107: Identifying Chain Tensioner Locking Wedge, Screwdriver, Crankshaft And Securing Pin
T40011
-- In order to tension the chain tensioner, rotate the crankshaft opposite the engine rotation direction in the -
direction of arrow 2- and secure it using a locking pin -T40011-.
-- Remove the guide pin -1- and guide the tensioning rail -2- downward.
-- Remove the upper guide rail -3- by unlocking the latch located in the center with a screwdriver and pushing
the guide rail forward.
-- Remove the camshaft timing chain from the sprockets.
 If the camshaft timing chain was removed from the cylinder head,
then the crankshaft may not be turned further.
-- Turn the sealing plugs -arrows- counterclockwise 90° in the -direction of the arrow- and remove them.
Fig. 109: Identifying Ball Head And Sealing Plug

-- Remove the ball studs -1 and 2-
-- Remove the cap.
Fig. 110: Identifying Cylinder Head - Loosening Sequence

-- Remove the cylinder head bolts in sequence -1 through 5- using the polydrive bit and drive socket -T10070-
until 2 are left.
NOTE: To remove the cylinder head bolts, rotate the camshaft with a wrench if
necessary.
Make sure all wires and hoses are disconnected!
Pay attention to the tensioning and guide rails when lifting the cylinder head.
-- Install the engine support -T10014- with each of the two small and large washers as illustrated.
Fig. 111: Identifying Engine Support -T10014-, Washers, Bolt And Engine Sling -2024 A-
-1- M8 washer, small.
-2- M8 washer, large. The outer diameter of the washer must be larger than the hole in the bracket.
-3- M8 x 30 bolt.
-- Install the engine sling -2024 A- to the engine support -T10014- and to the left front lifting eye on the
cylinder head.
-- Secure the engine sling -2024 A- with the shop crane and gently lift the cylinder head.
Fig. 112: Identifying Installation Of Engine Sling -2024 A- And Engine Support -T10014-
-- Remove the last two cylinder head bolts.
CAUTION:  Carefully lift the cylinder head until the guide rail for the camshaft
timing chain is free.
 The tension and guide rails must not be damaged.
-- Lay the cylinder head on a soft surface, such as foam.
Installing
 Tightening specifications, refer to CYLINDER HEAD OVERVIEW.
CAUTION: The sealing surfaces could be damaged.
 Carefully remove the sealant from the cylinder head and cylinder
block.
 Make sure that no long scrapes or scratches result.
Risk of damaging the cylinder block.
 There must be no oil or coolant in the blind holes for the cylinder
head bolts in the cylinder block.
Risk of cylinder head gasket leaking.
 Carefully remove all grinding and sanding residue.

 Only unpack new cylinder head gasket immediately prior to

installation.
 To prevent the cylinder head gasket silicone layer and recessed area
from being damaged, always handle the gasket extremely carefully.
Risk of damaging open valves.
 If a replacement cylinder head is installed, only remove the plastic

base right before the cylinder head is installed to protect open
valves.
Risk of damaging valves and piston heads after working on the valvetrain.
 To ensure valves do not strike pistons when starting, carefully rotate

engine at least 2 full revolutions.
NOTE: Replace the bolts which have been tightened to a torque angle.
Replace O-rings, seals and self-locking nuts.
Note the different sealant for the cylinder head sealing surfaces and bolts.
When installing a replacement cylinder head, rotate the camshaft to TDC and
mark the new sprockets exactly the same as on the old sprockets (note the
factory colored mark on the sprockets).
When installing a replacement cylinder head, all of the contact surfaces

between the hydraulic lash adjusters, roller rocker arms and cam running
surfaces on the camshaft must be lubricated before installing the cylinder head
cover.
The engine oil and coolant must be changed if the cylinder head or cylinder
head gasket are replaced.
-- Support the cylinder head with the shop crane and position it above the cylinder block.
Fig. 113: Identifying Installation Of Engine Sling -2024 A- And Engine Support -T10014-
CAUTION:  Carefully lower the cylinder head.

 The tensioning and guide rails must not be damaged.
 Pay attention to the alignment pins -arrows- in the cylinder block.
Fig. 114: Identifying Cylinder Block Centering Pins

 Observe the cylinder head gasket location, identification: The part number must be visible from the intake
side.
CAUTION: When rotating the crankshaft, make sure the timing chain cannot damage
any other components.
-- In the event the crankshaft has been rotated in the meantime: Set the piston for cylinder 1 to TDC and rotate
the crankshaft back again slightly.
-- Set the cylinder head in place.
-- Install the cylinder head bolts and tighten them by hand.
NOTE: In order to be able to tighten the cylinder head bolts, the intake camshaft must
be turned with a wrench.
There is no requirement to tighten the cylinder head bolts after repairs.
-- Cylinder head bolt tightening sequence, refer to Fig. 4.
CAUTION: When rotating the crankshaft, make sure the timing chain cannot damage
any other components.
-- Rotate the vibration damper to the TDC position -arrow- using the counter hold tool -T10355-.
cover.
-- Mount the timing chain on the intake camshaft. The marks must align.
Fig. 116: Identifying Drive Chain/Chain Sprocket Markings And Turning Intake Camshaft Using
Wrench
-- Turn the intake camshaft in the -direction of the arrow- with a wrench until the timing chain is >>taut<<.
Hold the intake camshaft secure in this position.
-- Mount the timing chain on the exhaust camshaft: the marks on the drive chain and sprockets -arrows A- and
the drive chain and guide rail -arrows B- must align.
-- Install the upper guide rail -3-.
-- Move the tensioning rail -2- up and tighten the guide pin -1-.
NOTE: If the marks on the drive chain and guide rail -B arrows- do not align even
though the engine is at TDC, the drive chain has skipped on the crankshaft
sprocket. Check the valve timing. Refer to VALVE TIMING, CHECKING. If the
timing does not agree, the camshaft timing chain must be positioned again.
Refer to CAMSHAFT TIMING CHAIN.
Fig. 119: Identifying Position Marks: Drive Chain To Sprockets -A- And Drive
Chain To Guide Rail -B-
The rest of the installation is performed in reverse order of removal, noting the following:
-- Change the engine oil
-- Replace the coolant. Refer to DRAINING AND FILLING .
UPPER TIMING CHAIN COVER

 Open End Spanner Insert AF 10 -V.A.G 1783/1-
Removing
-- On vehicles with a noise generator: Open the locking mechanism -1-, unclip the fuel lines -2- and loosen the
bolt -3- for the canister. Move the charge air pipe aside.

Vehicles with the EVAP Canister in the Engine Compartment
-- Disconnect the vent line -1- , unlock the canister -A- and remove it -B-. Move the canister to the side.

-- Press the coolant hoses to the side and secure them with a cable tie.
-- Remove the bolts -arrows- and remove the oil dipstick guide tube from the timing chain cover.
Fig. 122: Identifying Oil Dipstick Guide Tube And Bolts

-- Remove the camshaft adjustment valve 1 -N205-.
-- Remove the bolts -1 through 5- and remove the upper timing chain cover.

Installing
-- Lubricate the seal and the O-ring with engine oil.
-- Tighten the bolts -1 through 5- by hand in sequence.

-- Tighten the bolt to 9 Nm using the torque wrench (5-60 Nm) -V.A.G 1783- and the open end spanner insert
AF 10 -V.A.G 1783/1-.
LOWER TIMING CHAIN COVER

 Bits -T10099-
 Shackle 10-222 A/12
Removing
-- Remove the front part of the right wheel housing liner. Refer to Removal and Installation .
-- Drain the engine oil.

CAUTION: Risk of destroying due to a reversed running direction on a used ribbed

belt.
 Before removing the ribbed belt, marking the running direction with
-- Loosen the clamps -arrows- and remove the right charge air hose.
Fig. 126: Identifying Right Charge Air Guide Hose -Arrows-

-- To release the tension on the ribbed belt, rotate the tensioner in the -direction of arrow- from underneath.

-- Remove the ribbed belt from the vibration damper.
T10355-.
cover.
CAUTION: The engine could be destroyed.
 In order not to change the valve timing, the crankshaft must not be
moved out of the TDC position when the vibration damper bolt is
removed.
-- Remove the vibration damper bolt using the counter hold tool -T10355-.
-- Remove the vibration damper.
CAUTION: To avoid damaging the splines, only use the thrust piece -T10368- to
install the vibration damper bolt.
-- Install the vibration damper bolt and the thrust piece -T10368- again.
-- Hold the engine in its installed position.
Passat
 Bracket for engine 10-222 A/1

 Shackle 10-222 A/12
CC
 Engine support feet 10-222 A/8

 Shackle 10-222 A/12
The shackle 10-222 A/12 is needed to make sure the engine is lifted in the
installed position and not tilted.
-- Support the engine with the spindle.


-- Remove the engine mount. Refer to ENGINE AND TRANSMISSION MOUNT OVERVIEW .
-- Lift the engine approximately 50 mm and loosen the upper bolt for the engine mount bracket.
-- Now, lower the engine approximately 100 mm.
-- Free up the wiring harness -arrow-.

Fig. 133: Identifying Ribbed Belt Tensioner Bolt And Locating Electrical Wiring Harness
-- Remove the bolt -1- and remove the ribbed belt tensioner from the accessory bracket.
-- Remove the lower bolts for the engine mount bracket using the bits -T10099-.
-- Remove the engine mount bracket and the bolts.
-- Remove the bolts -arrows- and remove the oil dipstick guide tube from the timing chain cover.
Fig. 134: Identifying Oil Dipstick Guide Tube And Bolts

-- Remove the wastegate bypass regulator valve -N75- from the turbocharger -arrows-.
Fig. 135: Identifying Turbocharger And Supports

-- Remove the turbocharger support -1-.


CAUTION: The lower timing chain cover could be damaged. To avoid deformation, do
not hold between the bolting points.
-- Pry off the lower timing chain cover; when doing this, begin at -1 and 2-.
Fig. 137: Identifying Lower Timing Chain Cover And Bolt Removal Start Sequence
Installing

 Sealant: silicone sealant -D 174 003 A2-
The cover must be installed within 5 minutes after application of the silicone
sealant.
Replace the bolts which have been tightened to a torque angle.
Replace O-rings, seals and self-locking nuts.
-- Remove any sealant residue on the cylinder block using a flat blade scraper.
-- Cover both sides of the seal with tape to prevent contamination.
-- Use a rotating plastic brush to remove any remaining sealant on the cover.
-- Install the cover using the old bolts and tighten them to 8 Nm.
-- Check between the cover and housing using a feel gauge; the gap must not exceed 0.2 mm.
NOTE: If the gap exceeds 0.2 mm, replace the cover.
It is not possible to measure between the cover the upper oil pan, however
check the sealing surface for evenness.
-- Make sure both alignment sleeves -arrows- for centering the cover are present.
Fig. 139: Identifying Centering Cover Alignment Bushings

-- Apply the silicone sealant -D 174 003 A2- on the clean sealing surface of the cover as shown in the
illustration.
Fig. 141: Identifying Silicone Sealant Application Area For Cover Sealing Surface
NOTE: The cover must be installed within 5 minutes after application of silicone
sealant.
-- Install the cover immediately and all the bolts.
TIGHTEN THE BOLTS -1 THROUGH 15- IN TWO PASSES AND IN THE FOLLOWING SEQUENCE:


NOTE: After installing the cover, allow the sealant to dry for approximately 30 minutes.
Only after then may the engine oil be added.
-- Fill the engine oil.
-- Check the oil level.
VIBRATION DAMPER SHAFT SEAL

 Pulling Hook -T20143/2-
Removing
-- Remove the vibration damper. Refer to VIBRATION DAMPER .
-- Install the thrust piece -T10368-.
-- Remove the shaft seal using the pulling hook -T20143/2-.
Installing
 Tightening specifications, refer to RIBBED BELT OVERVIEW .
-- Clean the running and sealing surface.
-- Remove the thrust piece -T10368-.
-- Pull the seal -arrow- in all the way using the thrust piece -T10354- and the vibration damper bolt.

NOTE: Replace the vibration damper bolt
Replace the O-ring
CAMSHAFT TIMING CHAIN

Removing
T10355-.
cover.
-- Remove the lower timing chain cover, refer to one of the following:
-- Remove the control valve in the -direction of the arrow- using the assembly tool -T10352-.


-- Press the oil pump chain tensioner in the -direction of the arrow- and secure it using the locking pin -T40011-
.
Fig. 148: Identifying Oil Pump Chain Tensioner And Locking Pin T40011
-- Remove the oil pump chain tensioner guide pin -1-.
-- Remove the oil pump chain tensioner.
Sand the end of the locking pin -T40011- down to a point. A screwdriver with a head approximately 1.5 mm
-- Lift the chain tensioner locking wedge in the -direction of arrow 1- , press the timing chain tensioning rail in
the -direction of arrow 2- and secure it using the locking pin -T40011-.
Fig. 149: Identifying Directions: (Lift) Chain Tensioner Locking Wedge And (Press) Timing Chain
Tensioning Rail
-- Remove the timing chain tensioning rail guide pin -2- and tensioning rail.
Fig. 150: Identifying Camshaft Timing Chain Tensioner Bolts, Camshaft Timing Chain Guide Rail And
Guide Pins
-- Remove the timing chain guide rail guide pins -1- and guide rail.
-- Remove the timing chain.
Installing
 Tightening specifications, refer to CAMSHAFT TIMING CHAIN OVERVIEW.

 The chain tensioner for the tensioning rail is installed and secured with the locking pin -T40011-.
 The sprocket for the crankshaft is secured using the thrust piece -T10368-.
NOTE: The following procedure must be performed in one step. A second technician is
needed.
The painted links on the timing chain must be positioned on the marks on the
sprockets.
Hold the wrench tight until the tensioning rail and guide rail are installed.
-- Position the crankshaft to TDC, as shown in the illustration. It is in TDC when the marks on the balance
shafts are aligned with the balance shaft bolts.
NOTE: The marks must match up with the painted chain links each 16th turn.
Fig. 151: Identifying Timing Chain Markings

-- Mount the timing chain on the exhaust camshaft. Align the colored chain links with the marks.
Fig. 152: Identifying Intake Camshaft Turned Using Wrench

-- Mount the timing chain on the crankshaft. Align the colored chain link with the mark.
-- Rotate the intake camshaft using the wrench in the -direction of the arrow- and mount the timing chain.
Continue to hold the camshaft with the wrench.
-- Install the timing chain tensioning rail and tighten the guide pin -2-.
Guide Pins
-- Install the timing chain guide rail and tighten the guide pins -1-.
-- Install the bearing bracket and tighten the bolts -arrows- hand tight.

-- Remove the locking pin -T40011- from the chain tensioner.
-- Tighten the bolts -arrows- to specification, refer to CAMSHAFT TIMING CHAIN OVERVIEW.
BALANCE SHAFT TIMING CHAIN
Removing
-- Remove the lower timing chain cover, refer to one of the following:
-- Remove the camshaft timing chain. Refer to CAMSHAFT TIMING CHAIN.
-- Remove the camshaft timing chain guide rail guide pins -1-.
Guide Pins
-- Remove the camshaft timing chain tensioner bolts -3- and tensioner.
-- Remove the balance shaft chain tensioner -1-.

Fig. 156: Identifying Balance Shaft Timing Chain, Tensioning Rail And Guide Rails
-- Remove the tensioning rail guide pin -2- and rail.
-- Remove the guide rail guide pins -3- and rail.
-- Remove the guide rail guide pins -4- and rail.
-- Remove the balance shaft timing chain.
Installing
 Tightening specifications, refer to BALANCE SHAFT TIMING CHAIN OVERVIEW.
-- Rotate the intermediate shaft sprocket/balance shaft to the mark -arrow-.


NOTE: Due to the ratio, the mark aligns only every 7th turn.
-- Mount the timing chain; the painted links of the timing chain must be positioned on the marks on the
sprockets.

-- Install the timing chain tensioning rail and tighten the guide pin -2-.
Fig. 159: Identifying Balance Shaft Timing Chain, Tensioning Rail And Guide Rails
-- Insert the timing chain tensioner -1- using locking compound.
-- Check this adjustment one more time.

-- Check the marks on the intermediate shaft sprocket/balance shaft -arrow-.

NOTE: The marks on the intermediate shaft sprocket/balance shaft are shown with the
chain removed.
INTAKE CAMSHAFT BALANCE SHAFT
 Puller -T10394-
 Puller -T10055-
NOTE: Always replace the balance shaft after removing it.
Removing
-- Remove the toothed belt from the coolant pump. Refer to COOLANT PUMP TOOTHED BELT .
-- Remove the lower timing chain cover. Refer to one of the following:
-- Remove the balance shaft timing chain. Refer to BALANCE SHAFT TIMING CHAIN.
-- Remove the intermediate sprocket bolt -1-.

-- Remove the bolt -2- for the intake camshaft balance shaft and remove the balance shaft.
Fig. 163: Identifying Intake Camshaft Balance Shaft

If the balance shaft cannot be removed by hand, use the puller -T10394-.
-- Install the half shell -T10394/1- from the puller -T10394- and turn it upward in the -direction of the arrow-.
Fig. 164: Identifying Half Shell -T10394/1-

-- Install the puller -T10394- and push the sliding sleeve in the -direction of the arrow-.
Fig. 165: Identifying Installation Of Puller Pieces -T10394- And -T10394/1-

-- Install the puller -T10055- into the puller -T10394- and remove the balance shaft in the -direction of the
arrow-.
Fig. 166: Identifying Installation And Operation Of Puller -T10055-

Installing
NOTE: Because of the small clearance between the balance shaft and the cylinder
block, the balance shaft may need to be cooled in order to install it. Check if the
balance shaft can be installed into the cylinder block without forcing it in. If it
cannot, the balance shaft must be cooled before installing it.
-- Place the new balance shaft in a freezer for 30 minutes or spray it with commercially available cooling spray.
-- Lubricate the balance shaft bearing with engine oil.
-- Install the intake camshaft balance shaft and tighten the bolt -2-.

-- Replace the O-ring -1- and lubricate it with engine oil.

Fig. 168: Identifying Bearing Pins, Installation Position

-- Lubricate the bearing pin with engine oil and install it; the pin -arrow- must engage in the hole in the cylinder
block.
CAUTION: Always replace the intermediate shaft sprocket. Otherwise the backlash
intermediate shaft sprocket has an anti-friction coating that wears off after
a short period of use, which automatically adjusts the backlash.
-- Mark the tooth face on the intermediate sprocket -arrows-.

Fig. 169: Identifying Tooth Face On Intermediate Shaft Sprocket Marked With Paint
-- Install the intermediate sprocket; the mark on the balance shaft must be between the marks on the tooth faces.
-- Tighten the sprocket bolt -1- , refer to Fig. 17.

-- Check the marks on the intermediate shaft sprocket/balance shaft -arrow-.

NOTE: Due to the ratio, the marks align only every 7th turn.
-- Install the balance shaft timing chain. Refer to Installing.
The rest of the installation is basically a reverse of the removal sequence; when doing this, note the following:
-- Replace the coolant pump drive seal. Refer to COOLANT PUMP DRIVESHAFT SEAL .
EXHAUST CAMSHAFT BALANCE SHAFT
 Puller -T10394-
 Puller -T10055-
NOTE: Always replace the balance shaft after removing it.
Removing
-- Remove the lower timing chain cover. Refer to one of the following:
-- Remove the balance shaft timing chain. Refer to BALANCE SHAFT TIMING CHAIN.
-- Remove the bolt -1- and the balance shaft.


If the balance shaft cannot be removed by hand, use the puller -T10394-.
-- Install the half shell -T10394/1- from the puller -T10394-.
Fig. 172: Identifying Half Shell -T10394/1-

-- Install the puller -T10394- and push the sliding sleeve in the -direction of the arrow-.
Fig. 173: Identifying Installation Of Puller Pieces -T10394- And -T10394/1-

-- Install the puller -T10055- into the puller -T10394- and remove the balance shaft.
Fig. 174: Identifying Installation And Operation Of Puller -T10055-

Installing
NOTE: Because of the small clearance between the balance shaft and cylinder block,
the balance shaft may need to be cooled in order to install it. Check if the
balance shaft can be installed into the cylinder block without forcing it in. If it
cannot, the balance shaft must be cooled before installing it.
-- Check the installed position of the pipe for the balance shaft -arrow-.
Fig. 175: Identifying Pipe For Balance Shaft - Installation Position

The pin -arrow- must engage in the groove.
NOTE: Press the pipe together slightly to position it in the installed position.
Press the pipe into the crankcase and bend both halves one time to the inside.
-- Place the new balance shaft in a freezer for 30 minutes or spray it with commercially available cooling spray.
-- Lubricate the balance shaft bearing with engine oil.
-- Install the exhaust camshaft balance shaft.
-- Before tightening the bolt -1- make sure the balance shaft lies level with the crankshaft.

NOTE: If the balance shaft is not level, then the pipe for the balance shaft must be
installed again.
-- Install the balance shaft timing chain. Refer to Installing.
SPECIAL TOOLS
 Open End Spanner Insert AF 10 -V.A.G 1783/1-

 Compression Tester -V.A.G 1763-
 Spark Plug Removal -Tool 3122 B-
 Valve Seal Removal -Tool 3364-
 Valve Stem Seal Driver -3365-
 Adapter -T40012-
 Valve Cotters Asm/Disasm Device -VAS 5161-
 Guide Plate for FSI Engine -VAS 5161/19B-

 Polydrive Bit and Drive Socket -T10070-
 Bits -T10099-
 Shackle 10-222 A/12
Fig. 177: Identifying Dial Gauge Holder VW 387


Fig. 178: Identifying Dial Gauge VAS 6079

Fig. 179: Identifying Torque Wrench V.A.G 1783


Fig. 180: Identifying Engine Support Feet 10-222 A/8


 Pulling Hook -T20143/2-

Fig. 182: Identifying Extractor Hook T20143

 Puller -T10394-
Fig. 183: Identifying Puller T10055

 Puller -T10055-
Fig. 184: Identifying Puller T10055 With Adapter T10055/3

 Adapter for the Dial Gauge -T10170- or -T10170 A-
Fig. 185: Identifying Dial Gauge Adapter -T10170- or -T10170 A-

Fig. 186: Identifying Thrust Piece -T10174-, Torque Wrench -V.A.G 1331- And Special Tools

ENGINE 2.0 Liter - Engine Assembly - Engine Code(s): CBFA & CCTA
ENGINE
2.0 Liter - Engine Assembly - Engine Code(s): CBFA & CCTA
10 ENGINE ASSEMBLY
ENGINE AND TRANSMISSION MOUNT OVERVIEW
Fig. 1: Identifying Assembly Overview: Engine And Transmission Mount

1. Bolt
 Tightening specifications, refer to one of the following:
 GTI, Eos, Passat and CC with a Direct Shift Gearbox (DSG R), refer to TRANSMISSION
TO ENGINE TIGHTENING SPECIFICATIONS .
 GTI, Eos, Passat and CC with a manual transmission, refer to TRANSMISSION
TIGHTENING SPECIFICATIONS .
 Passat and CC with a automatic transmission, refer to TRANSMISSION, INSTALLING .
 Transmission mount bracket to transmission.

2. Bolt
 Tightening specification. Refer to SUBFRAME, LOWERING .
 Pendulum support to transmission.
3. Engine Mount Bracket

4. Bolt
 Always replace.
 Engine mount bracket to engine.
5. Engine Mount
6. Bolt
 Always replace.
 Engine mount to body.
7. Support
8. Bolt
 Always replace.
 Support to engine mount.
9. Bolt
 Always replace.
 Support to body.
10. Bolt
 Always replace.
 Engine mount to body.
11. Bolt
 Always replace.
12. Pendulum Support

13. Bolt
 Always replace.
 Pendulum support to subframe.
 First, install the pendulum support to transmission bolt, then install the pendulum support to
subframe bolt.
14. Bolt
 Always replace.
 Transmission mount to transmission mount bracket.
15. Bolt
 Always replace.
 Transmission mount to body
16. Transmission Mount

 The illustration shows the DSG R version.
17. Bolt
 Tightening specifications, refer to one of the following:
 GTI, Eos, Passat and CC with a DSG R , refer to TRANSMISSION TIGHTENING

SPECIFICATIONS .
 GTI, Eos, Passat and CC with a manual transmission, refer to TRANSMISSION
TIGHTENING SPECIFICATIONS .
 Passat and CC with a automatic transmission, refer to TRANSMISSION, INSTALLING .
 Transmission mount bracket to transmission.
18. Transmission Mount Bracket
ENGINE AND TRANSMISSION MOUNT, ADJUSTING
NOTE: If the engine mount will only be adjusted, a bracket with spindle and hook 10-
222 A/10 on the engine side is enough. It is not necessary to remove the air
filter housing, battery and battery tray.

 Bracket for Engine 10-222 A/1
 Bracket with Spindle and Hook 10-222 A/10 (Qty: 2)
 Shackle 10-222 A/12
 Engine Support Feet 10-222 A/8
Procedure
-- Remove the engine cover. Refer to ENGINE COVER .
CAUTION: Danger of causing damage to electrical components when disconnecting

the battery.
 Complete the steps for disconnecting the battery.
-- With the ignition turned off, disconnect the ground cable -arrow- from the battery.
Fig. 2: Identifying Battery And Ground Cable

-- Remove the battery. Refer to Removal and Installation .
-- Remove the battery tray bolts -arrows- and tray.

Fig. 3: Identifying Battery Holder Bolts

-- Install the engine support bridge 10-222 A using the following special tools as illustrated.
Passat
Fig. 4: Identifying Engine Support Bridge 10-222 A

 Bracket for engine 10-222 A/1 (Qty: 2)

 Bracket with spindle and hook 10-222 A/10 (Qty: 2)
 Shackle 10-222 A/12
CC
Fig. 5: Identifying Engine Support Feet, Bracket And Shackle

 Engine support feet 10-222 A/8 (Qty: 2)

 Bracket with spindle and hook 10-222 A/10 (Qty: 2)
 Shackle 10-222 A/12
The shackle 10-222 A/12 is needed to make sure the engine is lifted in its
installed position and not tilted.
-- Support the engine and transmission but do not lift them.
-- Replace the engine mount to engine mount bracket bolts -arrows- one after the other, if this was not already
performed when the engine was installed and tighten the bolts by hand.


-- Replace the transmission mount to transmission mount bracket bolts -arrows- one after the other, if this was
not already performed when the engine was installed and tighten the bolts by hand.

Fig. 8: Identifying Bolts For Subframe Mount At Transmission

-- Replace the transmission mount bracket to transmission mount bolts -arrows- one after the other, if this was
not already performed when the engine was installed and tighten the bolts by hand.
-- Loosen the engine and transmission mount bolts approximately 2 turns.
-- Adjust the engine and transmission mounts and tighten the bolts hand tight.
 There must be a distance of at least 10 mm -a- between the engine mount bracket -2- and the right
longitudinal member.
Fig. 9: Identifying Casting Edge On Engine Support Location

 The casting edge on the engine mount bracket -2- must be parallel to the engine mount support arm -1-.
Fig. 10: Identifying Parallel Edges On Support Arm And Transmission Mount
 On the transmission side, the edges of the transmission mount support arm -1- and the transmission
mount -2- must be parallel.
 Dimension -x- is the same size on both sides of the mount.
Fig. 11: Identifying Dimension -x- Between Edges Of Transmission Mount Support Arm -A- And
Transmission Mount -B-
 On the transmission side, the edges of the transmission mount support arm -A- and transmission mount -
B- must be parallel.
 Dimension -x- is the same size on both sides of the mount.
-- Tighten the engine and transmission mount bolts to specifications. Refer to ENGINE AND
TRANSMISSION MOUNT OVERVIEW.
Further installation is performed in the reverse order.
SPECIFICATIONS

Bolts and Nuts
M6 10
M7 15
M8 25
M10 40
M12 60
- 40 + 90°
Engine Mount to Body Bolt (1)

Engine Mount Bracket to Engine Bolt (1) - 40 + 180°
Engine Mount to Engine Mount Bracket Bolt (1) - 60 + 90°
Pendulum Support to Subframe Bolt 1,2 - 100 + 90°
Support to Body Bolt (1) - 20 + 90°
Support to Engine Mount Bolt (1) - 20 + 90°
Transmission Mount to Body Bolt (1) - 40 + 90°
Transmission Mount to Transmission Mount
- 60 + 90°
Bracket Bolt 1
(1) Always replace
(2) First, install the pendulum support to the transmission bolts then, the pendulum support to subframe
bolt.
ENGINE MOUNT ADJUSTMENT, CHECKING
There must be a distance of at least 10 mm -a- between the engine mount bracket -2- and the right longitudinal
member.
Fig. 12: Identifying Casting Edge On Engine Support Location

The casting edge on the engine mount bracket -2- must be parallel to the engine mount support arm -1-.
-- If the conditions are not met, adjust the engine mount. Refer to one of the following:
 Passat and CC, refer to ENGINE AND TRANSMISSION MOUNT, ADJUSTING.
ENGINE, REMOVING
 Pry Lever-Rmv Outside Mirror -80-200-

 Engine-/Gearbox Jack -V.A.G 1383 A-
 Step Ladder -VAS 5085-
NOTE: To perform this procedure, the ground cable must be disconnected from the
battery. If a coded radio is installed, obtain the anti-theft code beforehand.
The engine is removed downward with the transmission.
All cable ties which are opened or cut off when removing the engine, must be
replaced in the same position when installing the engine.
CAUTION: When doing any repair work, especially in the engine compartment, pay
attention to the following due to clearance issues:
 Route all lines and wires in their original locations.

 Ensure sufficient clearance to all moving or hot components.
-- Check the Diagnostic Trouble Code (DTC) memories of all control modules. Refer to the vehicle diagnostic
tester.
-- Disconnect the battery ground cable with the ignition turned off. Refer to Removal and Installation .
-- Remove the battery, the battery tray bolts -arrows- and tray.

-- Remove the wiper arms. Refer to WIPER ARMS .
-- Remove the plenum chamber cover. Refer to one of the following:
 GTI (2008 through 2009), Eos, and Passat. Refer to Description and Operation .
GTI and Eos
-- Remove the plenum chamber bulkhead. Refer to Description and Operation .
-- Disconnect the engine wiring harness connector from the Engine Control Module (ECM). Refer to one of the
following:
Passat and CC
-- Disconnect the engine wiring harness connector from the ECM. Refer to Engine Control Module -J623- .
Tiguan
Fig. 14: Identifying Pass-Through For Engine Wiring Harness

-- Release the pass-through for the engine wiring harness -arrow- and pull off upward.
-- Remove the E-box cover by sliding both latches in the -direction of the arrows-.
Fig. 15: Identifying E-Box Cover And Latches

-- Remove the nuts and the cable for the generator -A- and the cable for the battery -B- from the fuse holder.
Fig. 16: Identifying Generator Cable -A- And Battery Cable -B-
-- Remove the bolt and the ground cable -arrow- from the longitudinal member.
Fig. 17: Identifying Ground (GND) Cable On Longitudinal Member

-- Open the wire guide locking mechanisms -arrows- on the longitudinal member.
Fig. 18: Identifying Locking Mechanisms Of Cable Guide On Longitudinal Member

-- Free up the electrical connector -1- and disconnect it.
Fig. 19: Identifying Electrical Connector -1- And Wiring Guide Bracket -2-
-- Open the underlying wiring guide bracket -2-.
-- Remove the ECM wiring harness out of the wiring router and lay it on the engine.
-- Remove the shift mechanism from the transmission. Refer to REMO VAL AND INSTALLATION .
-- Pinch off the hose from the master cylinder using the hose clamps up to 25 mm dia. -3094-.
Fig. 20: Identifying Use Of Hose Clamps 3094 On Supply Hose To Master Cylinder
-- Pull out the clip -arrow- for the line up to the stop.
Fig. 21: Identifying Clip

-- Pull the line out of the breather/slave cylinder and seal it off.
CAUTION: Do not press the clutch pedal.
-- Remove the selector lever cable from the transmission. Refer to SELECTOR LEVER CABLE .
Vehicles with a Direct Shift Gearbox (DSG R)
-- Remove the selector lever cable from the transmission. Refer to SHIFT MECHANISM .
Tiguan, with a Automatic Transmission
-- Remove the transmission oil cooler lines from the transmission. Refer to REMOVING .
Fig. 22: Identifying Protective Boot Cable Tie, Electrical Connector And Ground Cable
-- Remove the upper bolts -upper arrows- from the fan shroud.
Fig. 23: Identifying Harness Connector And Fan Mount Mounting Bolts
-- Disconnect the electrical connector -arrow- and free up the electrical wire.
and open carefully.
-- Remove the front part of the wheel housing liner or the entire front wheel housing liner. Refer to Description
and Operation .
-- Remove the charge air hoses -arrows-.
Fig. 25: Identifying Charge Air Hoses

-- Disconnect the electrical connector -1- and remove the lower bolts -lower arrows- for the fan shroud.
Fig. 26: Identifying Harness Connector And Fan Mount Mounting Bolts
-- Remove the fan shroud downward.
-- Disconnect the electrical connector -2- for the engine coolant temperature sensor on radiator outlet -G83-.

NOTE: Collect the leaking coolant in a clean container for disposal or reuse.
-- Remove the coolant hoses -1 and 2-.

the pressure.
-- Disconnect the lines from the fuel transfer.
Vent line -1-
Vacuum line -2-
Fuel supply line -3-
GTI, Eos, Passat and CC

Fig. 31: Identifying Radiator Upper Coolant

-- Remove the upper coolant hose -arrow- from the radiator.
Tiguan
-- Remove the right coolant hose from the radiator and disconnect the left coolant hose from the radiator.
Fig. 32: Identifying Heat Exchanger Coolant Hoses

-- Disconnect the coolant hoses leading to the heater core -arrows-, to do this slightly pull the securing clip.
-- From above, remove the nuts -arrows- for the front exhaust pipe to the turbocharger.
Fig. 33: Identifying Front Exhaust Pipe/Turbocharger Nuts

-- Disconnect the vacuum hoses -arrows-.
Fig. 34: Identifying Vacuum Hoses


Fig. 35: Identifying Drive Axle Heat Shield Bolts And Shield
-- Remove the right drive axle heat shield bolts -arrows- and shield.
-- Remove the drive axles. Refer to Removal and Installation .
CAUTION: Risk of destroying due to a reversed running direction on a used ribbed

belt.
 Before removing the ribbed belt, mark the running direction with
-- To release the tension on the ribbed belt, rotate the belt tensioner in the -direction of the arrow- from
underneath.

-- Remove the ribbed belt.
-- Disconnect the connector -1- from the A/C compressor regulator valve -N280-.
Fig. 37: Identifying A/C Compressor Bolts And Solenoid Clutch Electrical Connector
WARNING: Refrigerant can cause serious personal injury.

 Do not open the Air Conditioning (A/C) refrigerant circuit.
-- Remove the A/C compressor bolts -arrows-.
CAUTION: Risk of damaging refrigerant lines and hoses.
 Do not stretch, kink or bend the refrigerant lines and hoses.
-- Secure the compressor, with the refrigerant lines attached, to the longitudinal member.
GTI and Eos
-- Remove the generator -C-. Refer to Removal and Installation .
NOTE: The after-run coolant pump -V51- stays in the installed position.
-- First, remove the bolt -1- then the bolts -2 and 3- and then remove the pendulum support.
Fig. 39: Identifying Support Bracket, Pendulum And Bolts

-- Disconnect all remaining necessary electrical connectors from the engine and transmission and set them
aside.
-- Disconnect all coolant, vacuum and intake hose connections from the engine.
-- Install the engine support -T10359- -1- to the engine and guide it into the mount.
Fig. 40: Identifying Engine Support With Additional Supports

-- Set the support -3- in order to prevent the engine from tilting out of the engine support -T10359-.
-- Secure the engine support -T10359- -1- to the cylinder block using the bolt -3-. Tighten to approximately 20
Nm.
Fig. 41: Identifying Engine Support And Threaded Hole Location

NOTE: The threaded hole for the bolt -1- serves to secure the after-run coolant pump -
V51-.
-- Install the engine-/gearbox jack -V.A.G 1383 A- to the engine support -T10359-.
-- Slightly lift the engine and transmission.
NOTE: Use the step ladder -VAS 5085- to remove the engine and transmission mount
bolts.


-- Remove the transmission mount to transmission mount bracket bolts -arrows-.

NOTE: Verify that all hose and wire connections between the engine, transmission and
body have been disconnected.
To prevent damage, carefully guide the engine and transmission when lowering.
Vehicles with a DSG R
 Pay attention to the selector lever cable.
-- Pull the engine and transmission as far as possible to the left and slowly lower it.
Secure the engine to the engine and transmission holder -VAS 6095- when working on it. Refer to ENGINE,
SECURING TO Engine and Transmission Holder VAS 6095.
ENGINE AND TRANSMISSION, SEPARATING AND ASSEMBLING
 Shackle 10-222 A/12

 Multipoint Socket -T10035- (vehicles with a automatic transmission)
 Insert Tool 18 mm -T10179- (vehicles with a automatic transmission)
 Socket SW15V/175 (vehicles with a automatic transmission)
Separate the Transmission from the Engine
Requirement
 The engine and transmission is removed and installed on the engine support -T10359-.
-- Remove the starter. Refer to Removal and Installation .
Vehicles with a Automatic Transmission or a Direct Shift Gearbox (DSG R)
-- If present, disconnect the coolant hoses from the transmission oil cooler and seal the openings.
-- Remove the bevel box. Refer to DRIVESHAFT, THROUGH CALENDAR WEEK 26.07 .
Continuation for all Vehicles:
-- Disconnect and free up all electrical connections from the transmission to the engine.
-- Install the shop crane to the transmission using the shackles 10-222 A/12 but do not lift it.
Fig. 44: Identifying Converter Secured From Falling Out Using A Wire
-- Remove the upper bolts connecting the engine to the transmission.
Vehicles with a Manual Transmission or DSG R
-- Before removing the last bolt, support the transmission with the shop crane.
-- Remove the lower bolts connecting the engine to the transmission.
-- Separate the transmission from the engine; when doing this, guide the transmission.
Remove the bolts using the insert tool 18 mm -T10179-. When tightening, observe the lower tightening
specification. Refer to FASTENER TIGHTENING SPECIFICATIONS .
The multipoint socket -T10035- makes the assembling easier.
-- For safety, first install a bolt which is easily accessible.

-- Begin with both lower bolts.
The hole for removing the torque converter nuts is located on the back side of the engine and is covered with a
rubber cap.
-- Remove this cap.
-- Remove the six torque converter nuts -arrow- using the socket SW15V/175.
Fig. 45: Locating Converter Nuts

NOTE: Carefully rotate the engine further.
When installing, be especially mindful of the engine while guiding the

transmission to the engine. The starter ring gear can be held steady from the
outside using a screwdriver. When installing, the stud bolts are located in the
holes on the drive plate.
-- Before removing the last bolt, support the transmission with the shop crane.
-- Now, remove the last bolt.
-- Separate the transmission from the engine; when doing this, guide the transmission.
NOTE: Pay attention to the torque converter. It must be removed together with the
transmission.
-- During transport, secure the torque converter from falling out, for example, with a wire -A-.
Fig. 46: Identifying Converter Secured From Falling Out Using A Wire
Assembly
Assembly is performed in reverse order of removal; pay attention to the tightening specifications in the relevant
repair information under.
ENGINE, SECURING TO Engine and Transmission Holder VAS 6095

 Engine and Transmission Holder -VAS 6095-
Requirement
 The engine and transmission is removed and installed on the engine support -T10359-.
-- Separate the transmission from the engine. Refer to ENGINE AND TRANSMISSION, SEPARATING
AND ASSEMBLING.
-- Install the engine sling -2024 A- as illustrated and lift the engine using the shop crane - load cap = 700-
1200KG -VAS 6100- from the engine-/gearbox jack -V.A.G 1383 A-.
Fig. 47: Identifying Engine Lifted

CAUTION: Use securing pins on the hooks and pins to prevent damaging the engine.
-- Secure the engine to the engine and transmission holder -VAS 6095-.
ENGINE, INSTALLING
CAUTION: When doing any repair work, especially in the engine compartment, pay
attention to the following due to clearance issues:
 Route all lines and wires in their original locations.

 Ensure sufficient clearance to all moving or hot components.
-- Insert new alignment sleeves in the cylinder block for centering the engine and transmission.
-- Engage the intermediate plate at the sealing flange and slide it onto the alignment sleeves -arrows-.

-- Grease the input shaft splines lightly with grease for clutch plate splines -G 000 100-.
-- Inspect and install the clutch and clutch mechanism. Refer to REMOVAL AND INSTALLATION .
Vehicles with a Direct Shift Gearbox (DSG R)
-- Replace the crankshaft needle bearings. Refer to CRANKSHAFT NEEDLE BEARINGS .
-- Install the selector lever cable. Adjust after installing. Refer to SHIFT AND SELECTOR CABLES,
INSTALLED POSITION .
-- When installing the engine and transmission make sure there is enough clearance to the subframe and
radiator. Adjust the engine and transmission mounts. Refer to one of the following:
 Passat and CC, refer to ENGINE AND TRANSMISSION MOUNT, ADJUSTING.
NOTE: For the engine and transmission mount tightening specifications, refer to
SPECIFICATIONS.
Secure electrical connections and routing. .
-- Connect the vehicle diagnostic tester.
-- Check all Diagnostic Trouble Code (DTC) memories and erase all DTC entries which may have occurred
during the assembly.
-- Perform a test drive.
-- Then, perform the vehicle system test and repair any occurring malfunctions.
NOTE: If the DTC memory was erased, the readiness code must be generated again,
refer to "Guided Fault Finding" in the vehicle diagnostic tester.
Tightening Specifications
Bolted Connections Tightening Specifications

Bolts and Nuts M6 10 Nm
M7 15 Nm
M8 25 Nm
M10 40 Nm
M12 60 Nm
SPECIAL TOOLS

 Multipoint Socket -T10035-
 Insert Tool 18 mm -T10179-
 Socket SW15 V/175
 Engine and Transmission Holder -VAS 6095-
Fig. 49: Identifying Engine Support -T10359-


 Bracket for Engine 10-222 A/1
 Bracket with Spindle and Hook 10-222 A/10
 Shackle 10-222 A/12
 Engine Support Feet 10-222 A/8
Fig. 51: Identifying Engine Sling And Additional Shop Tools

 Pry Lever-Rmv Outside Mirror -80-200-

 Engine-/Gearbox Jack -V.A.G 1383 A-
 Step Ladder -VAS 5085-
ENGINE 2.0 Liter - Exhaust System, Emission Controls - Engine Code(s): CBFA & CCTA
ENGINE
2.0 Liter - Exhaust System, Emission Controls - Engine Code(s): CBFA & CCTA
26 EXHAUST SYSTEM, EMISSION CONTROLS

EXHAUST SYSTEM OVERVIEWS
NOTE: The coupling element in the front exhaust pipe must not be bent more than 10°,
otherwise it may be damaged.
Replace gaskets and self-locking nuts.
After exhaust system repairs, make sure the exhaust system is not under stress
and is far enough from the body. If necessary, loosen the clamping sleeve and
align the muffler and exhaust pipe so that there is adequate distance to the
body and that the weight is evenly distributed among the suspended mounts.
The exhaust manifold and turbocharger are one component, removing and
installing. Refer to TURBOCHARGER .
ENGINE CODE CCTA

Fig. 1: Identifying Assembly Overview: Exhaust System, Engine Code CCTA

1. Bolt
 25 Nm
2. Suspended Mount
3. Gasket
 Always replace.
4. Nut
 40 Nm
Lubricate the studs for the exhaust manifold with hot bolt paste -G 052 112 A3-.

5. Heated Oxygen Sensor -G39-

 55 Nm
 Bank 1, sensor 1
 Threads of new oxygen sensors are coated with hot bolt paste -G 052 112 A3-.
 When reusing the old oxygen sensor, grease only the threads with hot bolt paste; the paste must not
get into the slots of the oxygen sensor body.
6. Front Exhaust Pipe with Catalytic Converter
CAUTION: Danger of causing damage to the coupling element.
 Do not bend the coupling element more than 10°.

 Do not stretch the coupling element.
 Do not damage the wire mesh on the coupling element.
 Protect the catalytic converter from shocks and impact stress.

 Removing and installing, refer to FRONT EXHAUST PIPE WITH CATALYTIC
CONVERTERS.
 Installing the exhaust system free of stress. Refer to EXHAUST SYSTEM, INSTALLING.
7. Oxygen Sensor after Three Way Catalytic Converter -G130-

 55 Nm
 Threads of new oxygen sensors is coated with hot bolt paste -G 052 112 A3-.
8. Retaining Loop
9. Suspended Mount
10. Rear Muffler

 Original equipment as one unit with the center muffler. For repairs, replace each separately.
 Separating the exhaust system. Refer to CENTER AND REAR MUFFLER, SEPARATING.
11. Nut
 Tighten the nuts evenly. Tightening torque and installed position, refer to CLAMPING SLEEVE
INSTALLED POSITION AND TIGHTENING TORQUE.
12. Rear Clamping Sleeve
 For individual replacement of the center and rear mufflers.
13. Center Muffler

 Original equipment as one unit with the rear muffler. For repairs, replace each separately.
 Separating the exhaust system. Refer to CENTER AND REAR MUFFLER, SEPARATING.
14. Nut
15. Front Clamping Sleeve
16. Suspended Mount
 For the center muffler.
ENGINE CODE CBFA

Fig. 2: Identifying Assembly Overview: Exhaust System, Engine Code CBFA

1. Bolt
 25 Nm
2. Suspended Mount
3. Gasket
 Always replace.
4. Nut
 40 Nm
Lubricate the stud bolts on the exhaust manifold with hot bolt paste -G 052 112 A3-.

5. Heated Oxygen Sensor -G39-

 55 Nm
 Threads of the new oxygen sensors are coated with hot bolt paste -G 052 112 A3-.
6. Front Exhaust Pipe with Catalytic Converter
CAUTION: Danger of causing damage to the coupling element.
 Do not bend the coupling element more than 10°.

 Do not stretch the coupling element.
 Do not damage the wire mesh on the coupling element.
 Protect the catalytic converter from shocks and impact stress.

 Removing and installing, refer to FRONT EXHAUST PIPE WITH CATALYTIC
CONVERTERS.
 Install the exhaust system free of stress. Refer to EXHAUST SYSTEM, INSTALLING.
7. Heated Oxygen Sensor 2 -G108-

 55 Nm
8. Oxygen Sensor after Three Way Catalytic Converter -G130-
 55 Nm
 When reusing the previous oxygen sensor, grease only the threads with hot bolt paste; the paste
must not get into the slots of the oxygen sensor body.
9. Retaining Loop
10. Suspended Mount

11. Rear Muffler

 Original equipment as one unit with the center muffler. For repairs, replace each separately.
 Separating the exhaust system, refer to CENTER AND REAR MUFFLER, SEPARATING.
12. Nut
13. Rear Clamping Sleeve
 For individual replacement of the center and rear mufflers.
14. Center Muffler
 Original equipment as one unit with the rear muffler. For repairs, replace each separately.
 Separating the exhaust system, refer to CENTER AND REAR MUFFLER, SEPARATING.
15. Nut
16. Front Clamping Sleeve
17. Suspended Mount
 For the center muffler.
SECONDARY AIR INJECTION SYSTEM OVERVIEW

Fig. 3: Identifying Secondary Air Injection System Assembly Overview

1. Gasket
 Always replace.
2. Secondary Air Injection Solenoid Valve -N112-

 Removing and installing, refer to Secondary Air Injection Solenoid Valve -N112-.
3. Bolt
 9 Nm
4. Secondary Air Injection Sensor 1 -G609-

5. Seal
6.to Air Filter

7.Secondary Air Pipe
8.Routing Aid for the Air Filter Drain Line
9.Nut
 9 Nm
10. Secondary Air Injection Pump Motor Bracket

11. Nut
 25 Nm
12. Secondary Air Pump Motor -V101-

 Removing and installing, refer to Secondary Air Injection Pump Motor -V101-.
SPECIFICATIONS

Clamping Sleeve Nut
-- Individual Clamp - 25
-- Continuous Clamp - 35
Front Exhaust Pipe with Catalytic Converter to Exhaust - 40
Manifold/Turbocharger Nut 1, 4
Oxygen Sensor - 55
Suspended Mount Bracket Bolt (2) - 20
Secondary Air Injection Pump Motor Bracket to Underbody Nut - 25
(3)
Secondary Air Injection Pump Motor to Bracket Nut (3) - 9

Secondary Air Injection Solenoid Valve Bolt (3) - 9
Suspended Mount to Subframe Bolt - 25
Suspended Mount to Underbody Bolt - 25
Tunnel Bridge to Underbody Bolt - 25
(1) Always replace
(2) Tiguan
(3) Engine code CBFA only
(4) Lubricate the stud bolts on the exhaust manifold/turbocharger with hot bolt paste -G 052 112 A3-
EXHAUST SYSTEM, CHECKING FOR LEAKS

-- Start the engine and let it run at idle.
-- Seal the end of the exhaust pipe temporarily, for example, with a cloth.
-- Have a second technician listen at the connections between the cylinder head/exhaust manifold and exhaust
manifold/front exhaust pipe for leaks.
-- Repair any detected leaks.
Engine Code CBFA only
EXHAUST SYSTEM COMPONENTS
CENTER AND REAR MUFFLER, SEPARATING
NOTE: A separating point has been provided in the connecting pipe for removing,
installing and individual replacement of the center or rear muffler.
The separating point is marked by a depression around the circumference of

the exhaust pipe.
 Body Repair Saw -V.A.G 1523 A-
or
 Chain Pipe Cutter -VAS 6254-
WARNING: To prevent injuries from metal shavings, wear protective goggles and
protective clothing.
-- Cut the exhaust pipe at a right angle at the separation point -arrow- , for example, using the body repair saw -
V.A.G 1523 A-.
Fig. 4: Identifying Exhaust Pipe Separation Point

-- Position the clamping sleeve at the side marks when installing.
-- When installing the double clamp, ensure that the bolt end does not project over the lower edge of double
clamp.
Fig. 5: Identifying Clamping Sleeve Orientation

-- Align the exhaust system so that the distance -a- is equal on the right and left sides.
Fig. 6: Identifying Alignment Of Exhaust System

Tightening specification:
Clamping sleeve with 2 individual clamps, 25 Nm.
Clamping sleeve with a continuous clamp, 35 Nm.
EXHAUST SYSTEM, INSTALLING
 Align the exhaust system when cold.
-- Loosen the nuts -3 and 4- on the front clamping sleeve -1-.

Fig. 7: Identifying Front Clamping Sleeve Connections

-- Align the front clamping sleeve -1- to the mark -A- on the front exhaust pipe -2- (-arrow- faces in the
direction of travel).
 Dimension -a- = Fig. 17.

 The connections must be on the right and must not project beyond the lower edge of the clamping sleeve.
-- Hand tighten the front nut -3- on clamping sleeve.
-- Push the exhaust system far enough forward so that the pretension at the retaining loop at the rear muffler
dimension -a- = 15 to 17 mm.
Fig. 8: Identifying Pre-Tension Dimension Of Retaining Loop At Rear Muffler

-- In this position, evenly tighten the nuts -3 and 4- on the clamping sleeves. Tightening specifications, refer to
Fig. 17.

FRONT EXHAUST PIPE WITH CATALYTIC CONVERTERS
Removing

Fig. 10: Identifying Heated Oxygen Sensor (HO2S) G39 Harness Connector
-- Disconnect heated oxygen sensor -G39- harness connector -arrow- and free up the wire.
Fig. 11: Identifying Front Exhaust Pipe/Turbocharger Nuts

-- From above, remove the nuts -arrows- on the front exhaust pipe to turbocharger.
-- Remove the nuts accessible from below for the front exhaust pipe to turbocharger.
-- Remove the nuts -arrows- and slightly pull the vehicle floor cover downward.
Fig. 12: Identifying Right Vehicle Floor Cover Nuts

Engine Code CCTA
Fig. 13: Identifying Right Side Of The Vehicle Floor Electrical Connector
-- Disconnect the electrical connector -arrow- on the right side of the underbody.
-- Remove the electrical connector out of the bracket and free up the electrical wire to the oxygen sensor.
Engine Code CBFA
Fig. 14: Identifying 4-Pin Electrical Harness Connector From Oxygen Sensor (O2S) And Three Way
Catalytic Converter (TWC) G130
-- Unclip the wires -arrows- , remove the bracket -2- and disconnect the connectors -1 and 3-.
Fig. 15: Identifying Exhaust System Bracket

-- Remove the suspended mount bolts -arrows-.
-- Remove the tunnel bridge nuts -arrows- and tunnel bridge from the vehicle floor.
Fig. 16: Identifying Vehicle Floor Front Cross Member

CAUTION: Danger of causing damage to the coupling elements.
 Do not bend the coupling element in front exhaust pipe more than
10°.
-- Loosen the clamping sleeve -1- and push it rearward.
-- Remove the front exhaust pipe with catalytic converter.
Installing
 Lubricate the turbocharger stud bolts with hot bolt paste -G 052 112 A3-.
 Replace gaskets and self-locking nuts.
 Install the exhaust system free of stress. Refer to EXHAUST SYSTEM, INSTALLING.
Component Nm
Tunnel bridge to body 25
CLAMPING SLEEVE INSTALLED POSITION AND TIGHTENING TORQUE
NOTE: Gradual introduction of clamping sleeves with a continuous clamp.
Fig. 17: Identifying Tightening Torque And Installed Dimension Of Clamping Sleeve
Clamping sleeve -A- with 2 individual clamps.
Tightening specification: 25 Nm
Installation dimension -a- 5 mm (only for the front clamping sleeve)
Clamping sleeve -B- with continuous clamp.
Installation dimension -a- 8.5 mm (only for the front clamping sleeve)

1 - Clamping sleeve
2 - Front exhaust pipe
a - Installed dimension
A - Mark
Fig. 19: Identifying Installed Position Double Clamps In Direction Of Travel

-- Install the clamping sleeve so that the bolt end -arrow- does not project beyond the lower edge of the
clamping sleeve.
 Threaded connection points toward the right.
Fig. 20: Identifying Installed Position Double Clamps In Direction Of Travel

-- Install the clamping sleeve so that bolt end -arrow- does not project beyond the lower edge of the clamping
sleeve.
 Threaded connection points to the rear
Secondary Air Injection Pump Motor -V101-
Removing
-- Remove the left front wheel housing liner. Refer to Removal and Installation .
-- Loosen the pipes -1-, loosen the bolts -2-, disconnect the electrical connector -3- and remove the Secondary
Air Injection (AIR) pump motor.
Fig. 21: Identifying Secondary Air Injection Pump Motor And Mounting Bolts
Installing
Secondary Air Injection Solenoid Valve -N112-
Removing
-- Remove the battery, battery tray bolts -arrows- and tray.


-- Disconnect the connector -A- and pipe -B- from the Secondary Air Injection (AIR) solenoid valve.
Fig. 23: Identifying Secondary Air Injection (Air) Solenoid Valve N112 Connector And Hose
-- Loosen the coolant pipe; remove the bolts -arrows-.
Fig. 24: Identifying Coolant Pipe And Bolts

-- Remove the bolts -arrows- and remove the AIR solenoid valve.
Fig. 25: Identifying Secondary Air Injection (Air) Solenoid Valve N112 And Bolts
Installing
-- Replace the gaskets.
SPECIAL TOOLS
 Body Repair Saw -V.A.G 1523 A-
Fig. 26: Identifying Body Repair Saw V.A.G 1523A

 Chain Pipe Cutter -VAS 6254-

Fig. 27: Identifying Chain Pipe Cutter VAS 6254

ENGINE 2.0 Liter - Fuel Supply - Engine Code(s): CBFA & CCTA
ENGINE
2.0 Liter - Fuel Supply - Engine Code(s): CBFA & CCTA
20 FUEL SUPPLY
GENERAL INFORMATION
SAFETY PRECAUTIONS
WARNING: The fuel pressure in the high pressure pipe can be up to 120 bar. Follow
the safety precautions when releasing the high side pressure.
 Releasing the high side pressure. Refer to HIGH SIDE FUEL

PRESSURE, RELEASING.
 The fuel supply line is under pressure. Always wear protective
eyewear and protective clothing to prevent injuries and fuel from
coming in contact with your skin. Wrap a cloth around the
connection before removing a fuel hose. Remove the hose
connection carefully to release the pressure.
For safety reasons, interrupt the current to the fuel pump before opening
the fuel system. Otherwise the fuel pump will activate when the drivers
door is opened. Use one of the following ways to interrupt the current:
 Battery, disconnecting
or
 Remove the fuel pump control module -J538- fuse
or
 Disconnect the connector from the fuel delivery unit flange or the
fuel pump control module
To reduce the risk of personal injury and/or damage to the fuel injection and ignition system, always observe
the following:
 Do not touch or disconnect the ignition coils with power output stages when the engine is running or
turning at starting speed.
 The ignition must be turned off before connecting or disconnecting injection and ignition system wiring
or tester cables.
Always observe the following when removing and installing the fuel delivery unit or the fuel pump from a full
or partially filled fuel tank.
 Before starting work, place the extracting hose from an exhaust extractor that is turned on near the fuel
tank opening. This will extract the fuel vapors. If no exhaust extraction system is available, a radial fan
(as long as motor is not in air flow) with a displacement greater than 15 m3 /h can be used.
 Prevent fuel from contacting skin. Wear fuel resistant gloves.
If special testing equipment is required during road test, note the following:
 Testing and measuring instruments must be secured on the rear seat and operated by a second person
from that location.
 If the vehicle is involved in a collision while testing and measuring equipment is operated from the front
passenger seat, the person sitting in that seat could be seriously injured when the airbag deploys.
HIGH SIDE FUEL PRESSURE, RELEASING
WARNING: The fuel injection system is separated into a high pressure side, where
the pressure is a maximum of approximately 120 bar and a low pressure
side, where the pressure is approximately 6 bar.
Before opening the high pressure side, for example, to remove the fuel
pressure sensor -G247-, the fuel pressure must be reduced to a residual
pressure of approximately 6 bar. The procedure for this is as follows:
-- Disconnect the connector -1- from the fuel pressure regulator valve -N276- using the assembly tool -T10118-.
Fig. 1: Identifying Connector To Fuel Pressure Regulator Valve

-- Allow the engine to idle approximately 10 seconds.
NOTE: When the fuel pressure regulator valve connector is disconnected during idle,
the pressure in the high pressure side decreases to approximately 6 bar.
After the high side pressure has been decreased, the high side must be opened,
otherwise the pressure increases again due to the warming of the fuel.
-- Turn off the ignition.
WARNING: The fuel lines are pressurized. Always wear protective eyewear and
protective clothing to prevent injuries and fuel from coming in contact
with your skin. Before opening the high pressure side, place a cloth
around the connection.
-- Place a clean cloth around the connection point and open carefully in order to release the residual pressure of
approximately 6 bar. Leaking fuel must be absorbed.
-- To complete the procedure, check the Engine Control Module (ECM) Diagnostic Trouble Code (DTC)
memory and erase all DTC entries which may have been caused by disconnecting the connector.
NOTE: If the DTC memory was erased, the readiness code must be generated again.
Refer to "Guided Fault Finding" in the vehicle diagnostic tester.
CLEAN WORKING CONDITIONS
When working on the fuel supply/injection system, pay careful attention to the following "5 rules" :
 Thoroughly clean all connections and the surrounding areas before disconnecting.
 Place parts that have been removed on a clean surface and cover them using lint free cloths.
 Carefully cover or seal opened components, if repairs are not performed immediately.
 Only install clean components: Only unpack replacement parts immediately prior to installation. Do not
use parts that have been stored loose (for example, in a tool box, etc.).
 When the system is open: Avoid working with compressed air if possible. Do not move the vehicle unless
absolutely necessary.
FUEL TANK, DRAINING
 Fuel Extracting Device -VAS 5190-

 Wrench -T10202-
-- Read the safety precautions before beginning work. Refer to SAFETY PRECAUTIONS.
WITH THE FUEL DELIVERY UNIT INSTALLED
 Fuel Extracting Adapter -VAS 5190/3-

 Test Instrument Adapter/DSO (5-pin) -VAS 5565-
 Remote Control -V.A.G 1348/3A-
WARNING:  The fuel supply line is under pressure. Always wear protective
eyewear and protective clothing to prevent injuries and fuel from
coming in contact with your skin. Wrap a cloth around the
connection before removing a fuel hose. Remove the hose
connection carefully to release the pressure.
 Connect the fuel extracting device -VAS 5190- ground strap to the
vehicle ground strap.
-- Disconnect the supply line (metal coupling) -arrow- and collect the leaking fuel with a cloth.
Fig. 2: Identifying Supply Line

NOTE: Press in the securing ring to disengage the fuel line.
-- Connect the fuel extracting device -VAS 5190- with the fuel extracting adapter -VAS 5190/3- to the fuel
supply line.
Fig. 3: Identifying Fuel Extracting Device VAS 5190 And Fuel Extracting Adapter VAS 5190/3
Connected To Fuel Supply Line
-- Remove the rear seat bench. Refer to Removal and Installation .
-- Remove the cover -1- with the fuel pump control module -J538- -2- from the fuel delivery unit.
Fig. 4: Identifying Cover With Fuel Pump Control Module J538

-- Disconnect the connector -A- from the fuel delivery unit.
Fig. 5: Identifying Fuel Line & Harness Connector

-- Install the test instrument adapter/DSO (5-pin) -VAS 5565- between the connectors on the cover and the fuel
delivery unit.
Fig. 6: Identifying Test Instrument Adapter/DSO (5-Pin) VAS 5565, Connectors On Cover And Fuel
Delivery Unit
-- Connect the remote control -V.A.G 1348/3A- to the test instrument adapter/DSO (5-pin) -VAS 5565- and
battery positive (+).
NOTE: This step allows the fuel pump to run when the engine is not running.
-- Remove the cap from the fuel filler tube.
-- Operate the remote control -V.A.G 1348/3A- and the shut off lever on the fuel extracting device -VAS 5190-
until the fuel tank is empty.
CAUTION: Do not run the fuel pump dry.
WITH THE FUEL TANK MORE THAN 3/4 FULL
CAUTION: Secure the fuel extracting device -VAS 5190- ground strap to a bare area
on the chassis.
-- Using insulating tape, apply a mark on the suction hose -arrow- at a length of 990 mm -a- from the end of the
hose.
Fig. 7: Identifying Cone Piece Pulled From Shaft Piece Of Fuel Siphoning Device VAS 5190
-- Remove the cap from the fuel filler tube.
-- Slide the suction hose into the fuel tank until the mark -arrow- applied earlier meets the fuel filler tube.
NOTE: The shaft piece -1- is not used.
A flap is located in the fuel tank on the lower end of the filler neck. It must not
be damaged by the suction hose. Therefore, slide in the hose only up to the
mark applied earlier.
-- Drain the fuel tank as much as possible via the fuel filler tube.
-- Carefully pull out the suction hose.
NOTE: When no more fuel can be extracted, the tank is emptied only enough for the
fuel delivery unit to be removed without danger. The tank may be removed while
containing the remaining fuel.
To drain the fuel tank completely, refer to WITH THE FUEL TANK LESS THAN
3/4 FULL.
WITH THE FUEL TANK LESS THAN 3/4 FULL

the pressure.
-- Disconnect the connector -1- and the fuel line -2- from the fuel delivery unit -3-.
Fig. 9: Identifying Connector -1-, Fuel Line -2- And Fuel Delivery Unit -3-
-- Remove the lock ring using the wrench -T10202-.
Fig. 10: Identifying Removal Of Locking Ring Using Wrench T10202

-- Lift the fuel delivery unit.
-- Insert the fuel extracting device -VAS 5190- suction hose as far as possible into the fuel tank and extract the
fuel.
If the fuel only needed to drained, then reinstall the fuel delivery unit. Refer to FUEL DELIVERY UNIT.
ACCELERATOR PEDAL MODULE OVERVIEW
Fig. 11: Identifying Assembly Overview: Accelerator Pedal Module

1. Connector
 Black, 6 pin
2. Accelerator Pedal Position Sensor -G79- with Accelerator Pedal Position Sensor 2 -G185-
 Not adjustable.
 The sensor transmits the driver control to the Engine Control Module (ECM).
 -A- Openings for the release tool -T10238-.
 Removing and installing, refer to ACCELERATOR PEDAL MODULE.
3. Bolt
 10 Nm
4. Cap
FUEL TANK AND ATTACHMENTS OVERVIEW

Fig. 12: Identifying Assembly Overview: Fuel Tank With Attachments

1. Fuel Line
 Make sure it is secure.
2. Cap
3. Bolt
4. Fuel Filler Door Unit

 With a rubber seal.
5. Vent Line
 Clipped to the fuel tank.
6. Vacuum Line
 Clipped to the fuel tank.
7. Ground Connection
 To the protective plate for the fuel filler tube.
8. Ground Connection
 Check for good contact to the body.
9. Clamp
10. Fuel Tank
 Draining, refer to FUEL TANK, DRAINING.
 Removing and installing, refer to FUEL TANK.
 Support using the engine-/gearbox jack -V.A.G 1383 A- when removing.
11. Securing Straps

12. Heat Shield
13. Retainer
14. Bolt
 25 Nm
 Always replace
 To secure the fuel tank straps, only bolts with loose washers may be used. If other bolts are used,
the straps could twist when the bolts are tightened. Bolt allocation.
15. Seal
 Always replace
 To install, place into the fuel tank opening dry.
 Lubricate with fuel only when installing the flange.
16. Fuel Delivery Unit

 Removing and installing, refer to FUEL DELIVERY UNIT.
 Checking the fuel pump. Refer to FUEL PUMP, CHECKING.
 Fuel level sensor -G- removing and installing. Refer to Fuel Level Sensor -G-.
 Clean the strainer if contaminated.

17. Rivets
18. Protective Plate
 For the fuel filler tube.
19. Suction Jet Pump

20. Flange with Fuel Filter
 With a pressure relief valve, 6.2 bar.
 Removing and installing, refer to FUEL DELIVERY UNIT.
21. Lock Ring

 110 Nm
 Use the wrench -T10202- for removal and installation.
EVAP SYSTEM COMPONENT OVERVIEWS
NOTE: Some vehicles have an additional filter installed on the Evaporative Emission
(EVAP) canister.
NOTE: Hose connections are secured with either spring-type or clamp-type clips.
Hose clip pliers -VAS 6340- or hose clip pliers -VAS 6362- are recommended for
installing space saving clamps.
The connectors for the fuel, vacuum and ventilation lines are color coded. There is either a colored dot on the
connector or the release button is the corresponding color.
Connector Colored Mark on the Connector

Fuel supply Black
Fuel return Blue
Ventilation White, Beige
Vacuum Green
WITH A SINGLE AIR FILTER

Fig. 13: Identifying Assembly Overview: EVAP Canister System, Single Air Filter
1. Bolts
2. Leak Detection Pump -V144-
3. Vacuum Line
4. Clamp
5. Connecting Hose
 Evaporative Emission (EVAP) canister to leak detection pump.

6. Vacuum Hose
7. Connecting Hose
 Air filter to leak detection pump
8. Air Filter Housing

9. Nut
 10 Nm
10. EVAP Canister

 Component location: inside the right rear wheel housing.
 Remove the nuts and pull the EVAP canister downward.
11. Vent Line

 To the EVAP canister purge regulator valve 1 -N80-.
 Clipped onto the fuel tank.
12. Vent Line

 From the fuel tank.
WITH DUAL AIR FILTERS

Fig. 14: Identifying Assembly Overview: EVAP Canister System, Dual Air Filters

2. Vacuum Line
3. Vacuum Hose
4. Connecting Hose
5. Clamp
6. Vent Line
 From the fuel tank.
7. Clip
 Air filter to leak detection pump.

9. Bolt
11. Auxiliary Filter
12. Nut
 10 Nm
13. Vent Line

 To the EVAP canister purge regulator valve 1 -N80-.
 Clipped onto the fuel tank.
14. Connecting Hose

15. Evaporative Emission (EVAP) Canister
 Component location: inside the right rear wheel housing.
 Remove the nuts and pull the EVAP canister downward.
16. Bolts
SPECIFICATIONS

Accelerator Pedal Position Sensor with
- 10
Accelerator Pedal Position Sensor 2 to Body Bolt
Air Filter Housing to Leak Detection Pump
- 2
Bracket Bolt 2
Air Filter Housing to Leak Detection Pump
- 3
Bracket Bolt (3)
Evaporative Emission Canister Bolt (3) - 8
Evaporative Emission Canister Nut (4) - 10
Fuel Filler Tube to Body Bolt (2) - 11
Fuel Filler Tube to Body Bolt (3) - 10
Fuel Filler Tube to Body Bolt 1, 5 - 8 + 90°
Fuel Pump Control Module Bracket to Fuel Tank
- 3.5
Nut (5)
Fuel Tank to Chassis (2) M6 10
Fuel Tank/Heat Shield to Underbody Bolt 1, 5 - 25
Fuel Tank Securing Strap to Underbody Bolt (1) - 25
Leak Detection Pump to Leak Detection Pump
- 2
Bracket Bolt 3
Leak Detection Pump Bracket to Body Nut 2, 3 - 6

Lock Ring to Fuel Tank - 110
Mounting Plate to Leak Detection Pump Bolt (2) - 3
Mounting Plate to Leak Detection Pump Bracket
- 8
Bolt (2)
(1) Always replace
(2) Eos only
(3) GTI only
(4) Passat, CC and Tiguan only
(5) Tiguan only
FUEL PUMP, CHECKING
NOTE: When replacing the fuel delivery unit, check the fuel tank for visible
contamination and clean as necessary.
 Pressure Tester -VAS 6550-

 Multi-meter -V.A.G 1715-
 Wrench -T10202-
 Measuring Container, Minimum 3 Liters
FUNCTION AND VOLTAGE SUPPLY, CHECKING
 The battery voltage is at least 11.5 volts.

 The fuel pump fuse in the fuse panel is OK. Refer to the relevant Wiring Diagram.
 The fuel pump control module -J538- is OK
NOTE: Fuel pump function is checked via output Diagnostic Test Mode (DTM).
-- Connect the vehicle diagnostic tester as follows:

Fig. 15: Identifying Evaporative Emissions Tester Connected To Vehicle

-- Connect the diagnostic cable -2- connector to the Data Link Connector (DLC) in the driver's footwell.
-- Turn on the ignition.
-- Press the buttons for Vehicle Self-Diagnosis , Engine electronics and Output Diagnostic Test Mode
(DTM) one after another on the display.
-- Press the right arrow button --> on the display until the output Diagnostic Test Mode (DTM) for the fuel
pump electronics is reached.
The fuel pump must now accelerate slowly up to maximum RPM.
NOTE: The fuel pump runs quietly.
If the Fuel Pump Does Not Start
-- Disconnect the connector from the fuel pump control module.

Fig. 16: Identifying Fuel Pump (FP) Control Module J538 Connector
-- Check the voltage supply between terminals -1 and 6- using the multi-meter -V.A.G 1715-.
Fig. 17: Identifying Fuel Pump (FP) Control Module J538 Electrical Harness Connector Terminals 1 And
6
 Specified value: approximately battery voltage
Voltage Supply is not OK

Diagram.
Voltage Supply is OK
-- Remove the cover -1- and fuel pump control module -2- from the fuel delivery unit.
-- First, pull on the connector -A- without pressing the retainer to make sure it is connected securely. If the
connector was not connected correctly, check the fuel pump function again.

-- Disconnect the connector.
-- Check the contacts on the connector and the fuel delivery unit for damage.
the pressure.
-- Disconnect the fuel line -B- from the flange.



-- Check whether the electrical wires between the flange and the fuel pump are connected.
If No Open Circuits are Found
-- Replace the fuel delivery unit, the fuel pump is faulty. Refer to FUEL DELIVERY UNIT.
FUEL PRESSURE, CHECKING
Test Conditions
 The fuel pump function must be checked. Refer to FUNCTION AND VOLTAGE SUPPLY,
CHECKING.
Test Sequence
NOTE: The output Diagnostic Test Mode (DTM) checks the fuel pressure.
Read the safety precautions before beginning work. Refer to SAFETY PRECAUTIONS.
-- Observe the rules for cleanliness. Refer to CLEAN WORKING CONDITIONS.
the pressure.

-- Connect the pressure tester -VAS 6550- to the fuel supply line using the hoses -VAS 6550/1- and -VAS
6550/2-.
Fig. 23: Identifying Pressure Tester VAS 6550 To Fuel Supply Line And Adapters VAS 6550/1 & VAS
6550/2
-- Make sure the drain is closed and the shut-off levers are open.
-- Activate the fuel pump with output DTM to build fuel pressure.
-- Check the fuel pressure on the pressure tester.
 Specified value: 4.0 to 7.0 bar
If the fuel pressure is OK, check the residual pressure. Refer to RESIDUAL PRESSURE, CHECKING.
If the Specification is Exceeded
-- The pressure relief valve in the flange is malfunctioning, replace the flange with fuel filter.
If the Specification is Not Obtained
-- Check the fuel lines for possible restrictions (kinks) or blockages.
If no malfunction can be found:
-- Replace the flange with the fuel filter and pressure relief valve.
-- Repeat the test.
If the specification is again not obtained:
RESIDUAL PRESSURE, CHECKING
Test Conditions
 The fuel pressure is OK and the pressure tester -VAS 6550- is connected. Checking the fuel pressure,
refer to FUEL PRESSURE, CHECKING.
Fig. 24: Identifying Pressure Tester VAS 6550 To Fuel Supply Line And Adapters VAS 6550/1 &
VAS 6550/2
Test Sequence
-- Activate the fuel pump with output Diagnostic Test Mode (DTM) to build fuel pressure.
-- Check the fuel pressure on the pressure tester.
 Specified value: 4.0 to 7.0 bar
-- End the On Board Diagnostic (OBD) and turn off the ignition.
-- Watch the pressure decrease on the pressure tester. After 10 minutes the pressure must not drop below a 3.0
bar decrease.
If the pressure drops further:
-- Activate the fuel pump with output DTM to build fuel pressure.
-- Close the shut-off lever -B- on the pressure tester as soon as the pressure accumulates. The lever is
perpendicular to the direction of flow.
Fig. 25: Identifying Shutoff Levers

If the Pressure No Longer Drops Now
NOTE: Check for the leak on the engine side. Repeat the residual pressure check.
Close the shut-off lever -A- this time to determine if there actually is a leak on
the engine side.
-- Check the fuel pipe to the high pressure pump for leaks.
-- Replace the high pressure pump. Refer to HIGH PRESSURE PUMP .
If the Pressure Drops Again
Check for the leak on the fuel tank side. Proceed as follows:
-- Check the fuel line to the flange for leaks.
If no malfunctions are found with the fuel line:
The pressure relief valve in the flange or pressure retention valve in the fuel pump leaks.
-- Replace the flange with the fuel filter and repeat the pressure retention test. If the leak is still present, replace
the fuel delivery unit.
FUEL DELIVERY RATE, CHECKING

Test Conditions
 Fuel level inside the fuel tank is above reserve.
Test Sequence
-- Remove the cover -1- and fuel pump control module -J538- -2- from the fuel delivery unit.
connector was not connected correctly, it could cause a fault.

delivery unit.
Fig. 28: Identifying Test Instrument Adapter/DSO (5-Pin) VAS 5565, Connectors On Cover And Fuel
Delivery Unit
-- Connect the remote control -V.A.G 1348/3A- to the test instrument adapter/DSO (5-pin) -VAS 5565- and to
battery positive (+).
NOTE: This step allows the fuel pump to run when the engine is not running.
the pressure.

-- Connect the pressure tester -VAS 6550- to the fuel supply line using the hose -VAS 6550/2-. Hold the other
hose -VAS 6550/1- in a measuring container.
Fig. 30: Identifying Pressure Tester VAS 6550 And Fuel Supply Line Using Hose VAS 6550/2
-- Make sure the drain is closed and the shut-off levers are open.
WARNING: Danger of spraying when opening the shut-off lever, wear protective
goggles and protective clothing to prevent injuries and contact with skin.
Hold container in front of the free connection of the pressure measuring
device.
-- Operate the remote control -V.A.G 1348/3A-. Slowly close the shut-off lever -arrow- until the pressure tester
shows 4 bar. From this point on do not move the position of the shut-off lever.
-- Empty the measuring container.
-- The fuel delivery rate of the fuel pump is dependent on battery voltage. So, connect the multi-meter -V.A.G
1715- to wires -1 and 5- of the test instrument adapter/DSO (5-pin) -VAS 5565-.
Fig. 31: Identifying Multi-Meter V.A.G 1715 & Wires -1 And 5- Of Adapter VAS 5565
-- Operate the remote control for 60 seconds and simultaneously measure the voltage of the fuel pump.
-- Compare the quantity of fuel delivered with the specification.

Fig. 32: Identifying Graph Of Voltage Versus Delivery Rate

*) Minimum delivery rate cm3 / 60s
**) Voltage of the fuel pump with the engine idling and the pump is on.
Example:
During the test, a voltage of 10.5 volts is measured. This results in a minimum delivery quantity of
approximately 1200 cm 3 /60 s.
If the Specification is Not Obtained
-- Check the fuel line for possible restrictions (kinks) or clogging.
-- Remove the cap from the fuel filler neck and repeat the test. If the fuel delivery quantity is now reached,
check the fuel tank ventilation.
If the Specification is Again Not Obtained
-- Remove the fuel delivery unit and check the fuel strainer for contamination.
-- If there is no malfunction here as well, replace the flange with fuel filter.
-- Repeat the test.
If the specification is again not obtained:

Delivery rate has been obtained, but malfunctions are still suspected in fuel supply (for example,
intermittent loss of fuel supply):
-- Check the fuel pump current draw. Refer to CURRENT DRAW, CHECKING.
CURRENT DRAW, CHECKING
-- First, pull on the connector -A- without pressing the retainer to make sure it connected securely. If the

delivery unit.
Fig. 35: Identifying Current Clamp Connected To Red Wire Of Test Instrument Adapter/DSO (5-Pin)
VAS 5565
-- Connect the current clamp -A- to the red wire of the test instrument adapter/DSO (5-pin) -VAS 5565- with
the word "current clamp" on it.
-- Start the engine and run at idle speed.
-- Measure the current draw of the fuel pump.
 Specified value: Max. 10 amps.
NOTE: The fuel pump starting current may be higher than the specified value briefly
when starting the engine.
If the malfunction in the fuel system only occurs sporadically, the test can also
be performed during a road test. A second person is needed to do this.
If the current draw is exceeded:
FUEL SYSTEM, CHECKING FOR LEAKS
 Evaporative Emission Tester -KLI 9210-

 Adapter for Evaporative Emission Tester KLI 9210/55-1
 Vehicle Diagnostic Tester
 Hose Clamps Up to 25 mm Dia. -3094-
The connectors for the fuel, vacuum and ventilation lines are color coded. There is either a colored dot on the
connector or the release button is the corresponding color.
Connector Colored Mark on the Connector

Fuel supply Black
Fuel return Blue
Ventilation White, Beige
Vacuum Green
Test Conditions
 A leak was detected by the leak detection pump -V144-.

 Guided fault finding was performed using the vehicle diagnostic tester.
Evaporative Emissions Tester -KLI 9210- Preparation

NOTE: Depending on the version, the appearance of the evaporative emissions tester -
KLI 9210- may vary.
-- Check the evaporative emissions tester -KLI 9210- to determine whether there is enough fluid in the smoke
generator.
-- Set the valve -D- to "Hold".
Fig. 36: Identifying Evaporative Emission (EVAP) Canister Purge Regulator Components
-- Open the nitrogen bottle -H-.
-- Connect the measuring hose -G- to the self-test connection -B-.
-- Set the valve -D- to "Test".
-- Using the pressure reducer -J- , adjust the pressure to 10 in. H2O (25 mbar).

-- The pressure must now be maintained a minimum of 2 minutes. If the pressure is not maintained, check the
tester.
Fuel System, Checking for Leaks
-- Connect the adapter for evaporative emission tester -KLI 9210/55-1 to the ventilation line -A- as shown.
(color identification: white)
Fig. 37: Identifying Adapter For Evaporative Emission Tester KLI 9210/55-1 Connected To Ventilation
Line
-- Connect the measuring hose -G- from the evaporative emissions tester -KLI 9210- to the adapter for
evaporative emission tester -KLI 9210/55-1.
Fig. 38: Identifying Measuring Hose From Evaporative Emissions Tester KLI 9210 Connected To
Adapter Hose KLI 9210/55-1
-- Connect the vehicle diagnostic tester to the vehicle.
Fig. 39: Identifying Evaporative Emissions Tester Connected To Vehicle

-- Start the engine and run at idle speed.

-- Select Guided Functions on the vehicle diagnostic tester.
-- Select "Check tank ventilation system for leaks" guided function.
-- Activate the test.
-- While the test runs, observe the pressure gauge on the evaporative emissions tester -KLI 9210-.
 The leak detection pump must pump the fuel system pressure up to at least 7 in. H2O (18 mbar).
If the minimum pressure is not reached, but the pressure reached does not decrease:
-- Turn the ignition off and perform a pressure retention test, refer to PRESSURE RETENTION TEST. If no
decrease in pressure is observed: Check the leak detection pump vacuum supply. Refer to LEAK
DETECTION PUMP, CHECKING VACUUM SUPPLY.
If the minimum pressure is not reached and the pressure reached decreases immediately:
-- Clamp off the hose to the EVAP canister purge regulator valve 1 -N80- using a hose clamp up to 25 mm dia. -
3094- -arrow-.
Fig. 40: Identifying Hose To EVAP Canister Purge Regulator Valve 1 -N80- And Clamp
-- Repeat the test. If the minimum pressure is not reached: Replace the EVAP canister purge regulator valve 1.
If the minimum pressure is not reached again and the pressure reached decreases immediately:
-- There is a leak in the fuel system. Perform the "fuel system leak test". Refer to FUEL SYSTEM LEAK
TEST.
If the minimum pressure is reached, turn the ignition off.
The valve in the leak detection pump is now closed and the pressure is maintained.
-- Observe the pressure gauge:
If the pressure does not decrease, perform a pressure retention test to locate any possible pinhole leaks. Refer to
PRESSURE RETENTION TEST.
If the pressure decreased, clamp off the hose to the EVAP canister purge regulator valve 1 using a hose clamp
up to 25 mm dia. -3094- -arrow-.
-- If pressure now no longer falls, replace the EVAP canister purge regulator valve 1.
If the pressure still decreases, perform the "fuel system leak test". Refer to FUEL SYSTEM LEAK TEST.
PRESSURE RETENTION TEST
-- Set the valve -D- to "Test". Increase the present pressure to 10 in. H2O (25 mbar).
-- Observe the pressure gauge -C- and flow meter -E-. The fuel system is filled if the flow quantity decreases
and the pressure increases to 10 in. H2O (25 mbar).
NOTE: Depending on the level in the fuel tank, this procedure may take up to 3
minutes.
-- After the pressure has stabilized, set the valve -D- to "Hold".
 After 5 minutes the pressure must not drop below 8 in. H2O (20 mbar).
If the pressure is not maintained for 5 minutes, the leak should be localized as follows:
-- First, check the EVAP canister purge regulator valve 1 for leaks. Clamp off the hose to the EVAP canister
purge regulator valve 1 using a hose clamp up to 25 mm dia. -3094- -arrow-.
-- Repeat the pressure test by resetting the valve -D- to "Test".

-- If the pressure now no longer falls, replace the EVAP canister purge regulator valve 1.
If the pressure still decreases, perform the "fuel system leak test". Refer to FUEL SYSTEM LEAK TEST.
After completing the work, perform the "Check tank ventilation system for leaks" guided function using the
vehicle diagnostic tester.
FUEL SYSTEM LEAK TEST
Test Conditions
 The "Fuel System, Checking for Leaks" procedure was performed. If not, refer to FUEL SYSTEM,
CHECKING FOR LEAKS.
 The evaporative emissions tester -KLI 9210- with the adapter for evaporative emission tester KLI
9210/55-1 is connected to the vehicle
Fig. 45: Identifying Measuring Hose From Evaporative Emissions Tester KLI 9210 Connected To
Adapter Hose KLI 9210/55-1
-- Connect the evaporative emissions tester -KLI 9210- to the vehicles battery.
-- Remove the rear right wheel housing liner.
-- Clamp off the hose between the leak detection pump -V144- and the air filter using a hose clamp up to 25 mm
dia. -3094- -arrow-.
Fig. 46: Identifying Hose Clamp -3094- And Hose Between Leak Detection Pump (LDP) V144
-- Set the valve -D- to "Test".

 After 5 minutes the pressure must not drop below 8 in. H2O (20 mbar).
-- If the pressure no longer decreases, replace the leak detection pump.
If the pressure is not maintained for a minimum of 5 minutes or if no pressure is built up, localize the
leak as follows:
-- Fill the fuel system with smoke by setting the valve -D- to "Test".
-- While the fuel system is being filled, press the smoke generator button -I- for approximately one minute.
The fuel system is now under pressure and filled with smoke.
-- Check all the fuel system lines and hoses for escaping smoke. Also check the fuel tank sealing cap.
NOTE: Illuminate components and hoses with a strong flood light, the smoke will be
more visible.
To check for leaks at accessible locations, also use a ultrasonic measuring

device or commercially available leak detection spray.
Depending on how long the fault finding lasts, the smoke generator button may
need to be pressed again. This ensures there is enough smoke present in the
fuel system.
To check the fuel pump and fuel filter flange, the assembly openings in the
vehicle interior must be opened.
-- Replace the leaking hoses or components.
After completing the work, perform the "Check tank ventilation system for leaks" guided function using the
EVAP SYSTEM FUNCTION OVERVIEW

Fig. 48: Identifying Function Overview: EVAP Canister System

1. Evaporative Emission (EVAP) Canister

2. Adapter for Evaporative Emission Tester -KLI 9210/55-1 Installed Location
 Used with the fuel system leak test.
3. EVAP Canister Purge Regulator Valve 1 -N80-

4. Vent Line
 to the throttle valve control module -J338-.
5. Solenoid Valve
 For the leak detection pump.
 To the intake manifold.

 For the leak detection pump.

9. Fuel Tank
10. Cap
LEAK DETECTION PUMP, CHECKING VACUUM SUPPLY
 Turbocharger Tester -V.A.G 1397A-

 T-piece -251 201 346-
 6 mm Diameter Hose
NOTE: Leak detection pump -V144- installed location: In the right rear wheel housing
under the wheel housing liner.
-- Remove the right rear wheel and wheel housing liner.
-- Disconnect the vacuum line -1- from the leak detection pump.
Fig. 49: Identifying Turbocharger Tester V.A.G 1397A With T-Piece And 6 mm Dia. Hose
-- Connect the turbocharger tester -V.A.G 1397A- with the T-piece and 6 mm diameter hose between the
vacuum line -1- and the leak detection pump -2-.
-- Turn on measuring range I (absolute pressure measurement).
-- Connect the vehicle diagnostic tester and start the engine.
-- Select Guided Functions on the vehicle diagnostic tester.
-- Select the "Check tank ventilation system for leaks" guided function.
-- Activate the test.
-- While the test is running, observe the display on the turbocharger tester -V.A.G 1397A-.
 The pressure must pulsate and must not rise above 0.700 bar (absolute pressure) during the test.
-- If the pressure rises above 0.700 bar during the test, the vacuum supply is too low. Check the vacuum line to
the intake manifold for kinks or blockages.
ACCELERATOR PEDAL MODULE
 Release Tool -T10238-
Removing
-- Remove the steering column cover retainers -arrows- and cover.
Fig. 50: Identifying Steering Column Cover

-- Pry out the cap -3- with a screwdriver.
Fig. 51: Identifying Accelerator Pedal Module, Connectors & Bolt

-- Disconnect the connector -1- -arrow- from the accelerator pedal module.
-- Slide the release tool -T10238- as shown, into the openings designated for it until it stops and remove the
accelerator pedal module.
Fig. 52: Installing Release Tool T10238

Installing
-- Connect the connector -1- to the accelerator pedal module -4-. Lock the connector -arrow-.
Fig. 53: Identifying Accelerator Pedal Module, Connectors & Bolt

-- Press the accelerator pedal module onto the retaining pins -5-.
-- Insert the centering pin -6- into the hole on vehicle floor.
-- Secure the accelerator pedal module with the bolt -2- and install the cap -3-.
-- Reinstall the steering column cover and retainers -arrows-.

Fig. 54: Identifying Steering Column Cover

Component Nm
Accelerator
pedal
10
module to
body
FUEL SYSTEM COMPONENTS
NOTE: Fuel hoses at the engine may only be secured with spring type clamps
appropriate for the model type.
Spring type clip pliers -VAS 6499- or hose clip pliers -VAS 6362- are
recommended for installing spring clamps.
FUEL DELIVERY UNIT
 Wrench -T10202-
CAUTION: Requirement:
 The fuel tank may be a maximum of 3/4 full. This ensures the fuel
level is below the fuel delivery unit flange.
Removing
NOTE: When replacing the fuel delivery unit, check the fuel tank for visible
contamination and clean if necessary.
Read the safety precautions before beginning work. Refer to SAFETY

PRECAUTIONS.
Observe the rules for cleanliness. Refer to CLEAN WORKING CONDITIONS.
Fuel tank and attachments overview. Refer to FUEL TANK AND ATTACHMENTS
OVERVIEW.
-- Drain the fuel tank using the fuel extracting device -VAS 5190-, if necessary. Refer to FUEL TANK,
DRAINING.

the pressure.
-- Disconnect the fuel line -B- from the flange.



-- Lift the flange.
-- Disconnect the coupling -A- and remove the suction jet pump -B-. To do so, press the tabs -arrows- together.
Fig. 59: Identifying Coupling And Suction Jet Pump

NOTE: Press in the button to disengage the coupling -A-.
-- Pull the seal and fuel delivery unit out of the fuel tank opening.
NOTE: If the delivery unit is to be replaced, then drain the old delivery unit before
disposal.
Follow disposal regulations.
INSTALLING
CAUTION: Do not bend the fuel level sensor -G- float arm when installing.
-- Insert the delivery unit without the suction jet pump into the fuel tank.
-- Now, install the suction jet pump -B- and connect the coupling -A-. Pull on the coupling to make sure it is
securely fastened.
Fig. 60: Identifying Coupling And Suction Jet Pump

-- Install the flange onto the delivery unit.
Fig. 61: Identifying Installation Of Flange On To Delivery Unit

NOTE: Make sure the hoses are fastened correctly.
-- Now, pull the seal -A- over the flange and insert it into the fuel tank opening.
Fig. 62: Identifying Sealing Ring Pulled Over Flange

-- Lubricate the seal lightly with fuel and press the flange into the fuel tank.
-- Note the installed position: The mark -A- points in the opposite direction of travel.
Fig. 63: Identifying Mark Points Installed In Opposite Direction Of Travel

-- Install the lock ring using the wrench -T10202-. Tightening specification, see -item 21- in the FUEL TANK
AND ATTACHMENTS OVERVIEW.
Further installation is performed in reverse order. When doing this note the following:
 The -arrow- on the cover must point in the direction of travel.
Fig. 64: Identifying Mark To Indicate Direction Of Travel

 Route the fuel lines free of kinks.

 Pull on the line connections to make sure they are securely fastened.
Fuel Level Sensor -G-
NOTE: Read the safety precautions before beginning work. Refer to SAFETY
PRECAUTIONS.
OVERVIEW.
Removing
-- Remove the fuel delivery unit. Refer to FUEL DELIVERY UNIT.
-- Pull the fuel level sensor slightly to the side and simultaneously upward.
Fig. 65: Pulling Fuel Level Sensor G Slightly To Side And Simultaneously Upward
-- If the sensor cannot be released this way, then press the retaining tabs -arrows- to the side slightly.
Fig. 66: Identifying Retaining Tabs

-- Note the color of the wires for installation later.
-- Disengage the wires -1 through 3- and disconnect them. Bend the retaining hooks on the wires back.
Fig. 67: Identifying Fuel Level Sensor Electrical Wires

Installing
-- Connect the wires -1 through 3-. Note the color coding.
Fig. 68: Identifying Fuel Level Sensor Electrical Wires

-- Pull on the connectors to make sure they are securely fastened.

-- Install the fuel level sensor in the guides on the fuel delivery unit and push it down until it engages.
-- Install the fuel delivery unit. Refer to INSTALLING.
FUEL TANK
Removing
NOTE: The rear subframe must be lowered to remove the fuel tank.
Read the safety precautions before beginning work. Refer to SAFETY

PRECAUTIONS.
OVERVIEW.
-- Drain the fuel tank using the fuel extracting device -VAS 5190-, if necessary. Refer to FUEL TANK,
DRAINING.
-- Disconnect the 5 pin connector -arrow- from the flange.
Fig. 70: Identifying Flange 5-Pin Harness Connector

-- Remove the right rear wheel.
-- Remove the right rear wheel housing liner. Refer to Removal and Installation .
Fig. 71: Identifying EVAP Canister Vent Lines And Vacuum Line
-- Disconnect the vent and vacuum lines -arrows- from the Evaporative Emission (EVAP) canister.
Fig. 72: Identifying Vent And Vacuum Lines

-- Unclip the electrical wire -arrows- from the filler tube.
-- Remove the tank flap unit screw and remove the unit. Refer to Removal and Installation .
-- Remove the fuel filler tube bolts -arrows-.
Fig. 73: Identifying Fuel Filler Tube Bolts

the pressure.
-- Disconnect the ventilation line (white) -1- and the fuel line (black) -2- at the connecting point.
Fig. 74: Identifying Ventilation Line (White) -1- And Fuel Line (Black) -2-
-- Lower the rear subframe. Refer to Removal and Installation .
NOTE: Make sure there is sufficient clearance for the brake lines and electrical wires
when lowering the rear subframe.
Have a second technician help when disconnecting and lowering the fuel tank.
-- Hold the fuel tank and remove the bolts from the straps -arrows-.
Fig. 75: Identifying Tension Strap Bolts

-- Remove the straps.
-- Lower the fuel tank slowly with a second technician and guide it out between the rear subframe and the
vehicle body.
Installing
-- With a second technician assisting, guide the fuel filler neck between the rear subframe and chassis.
-- Hold the fuel tank in its installed position and install the new strap bolts -arrows-.
Fig. 76: Identifying Tension Strap Bolts

NOTE: To secure the fuel tank straps, only bolts with loose washers may be used. If
other bolts are used, the straps could twist when the bolts are tightened.
-- Secure the rear subframe to the chassis again. Refer to Removal and Installation .
Further installation is performed in reverse order. When doing this note the following:
 Make sure the vent and fuel lines are not kinked.
 Pull on the line connections to make sure they are securely fastened.
 Check the fuel tank/body ground connection on the filler tube.
Component Tightening Specifications

Straps to
vehicle body
 Use new
bolts.
 To secure
the fuel
tank
straps,
only bolts
with
loose 25 Nm
washers
may be
used.
This
prevents
the straps
from
twisting
when
tightening
the bolts.
Filler tube to
8 Nm + 90°
body
Subframe to Refer to FASTENER TIGHTENING SPECIFICATIONS .

vehicle body
 Use new
bolts.
Wheel
Refer to TIGHTENING SPECIFICATION FOR MOUNTING WHEELS .
installation
SPECIAL TOOLS
 Fuel Extracting Adapter -VAS 5190/3-

 Evaporative Emission Tester -KLI 9210-
 Adapter for Evaporative Emission Tester KLI 9210/55-1
Fig. 77: Identifying Assembly Tool T10118

 Fuel Extracting Device -VAS 5190-

Fig. 78: Identifying Fuel Siphoning Unit VAS 5190

 Hose Clamps Up to 25 mm Dia. -3094-
Fig. 79: Identifying 3094 Hose Clamps

 Turbocharger Tester -V.A.G 1397A-

Fig. 80: Identifying Turbocharger Tester V.A.G 1397 A

 Release Tool -T10238-
Fig. 81: Identifying Release Tool T10238


Fig. 82: Identifying Torque Wrench (5 To 50 Nm) VAG 1331

Fig. 83: Identifying Pressure Tester -VAS 6550-, Multi-Meter -V.A.G 1715- And Special Tools
 Pressure Tester -VAS 6550-

 Multi-Meter -V.A.G 1715-
 Wrench -T10202-
ENGINE PERFORMANCE 2.0 Liter - Generic Scan Tool - Engine Code(s): CCTA
ENGINE PERFORMANCE
2.0 Liter - Generic Scan Tool - Engine Code(s): CCTA
ST GENERIC SCAN TOOL

GENERAL INFORMATION
Included in the contents of this Generic Scan Tool (GST) information is a summary table of the vehicle specific
OBD II Emission Related DTCs. The DTC table contains DTC Malfunction Criteria, Threshold Values,
Secondary Parameters, Enabling Conditions, Monitoring Time Length, Frequency of Checks, and MIL
Illumination information which can be used to accurately monitor and diagnose emissions related faults and
perform functions required to run Modes 01 through 09 with a hand held scan tool. For a further description of
specific monitor information, an OBD strategy document is referenced throughout this information.
This information also contains the step by step procedures to accurately diagnose and repair a component or
system once a DTC has been set. References to repair procedures and wiring diagrams can be found within the
diagnostic test procedures.
SAFETY PRECAUTIONS
WARNING: Failure to follow these instructions may result in personal injury or

possible death.
When performing the drive cycle operation, pay strict attention to driving
conditions and observe and obey all posted speed limits.
Test equipment must always be secured to the rear seat and operated by
a second person. If test and measuring equipment is operated from the
passenger seat, the person seated could be injured in the event of an
accident involving deployment of the passenger-side airbag.
The fuel system is under pressure! Before opening the fuel system, place
rags around the connection area. Then release pressure by carefully
loosening the connection.
The engine section of the fuel system, after the high pressure pump, is
under extremely high pressure! When working on engine or fuel injection
system, fuel pressure must be relieved to residual pressure before
opening high pressure components. Refer to the Service Information for
the proper procedure.
If the battery has not been disconnected, the fuel pump fuse must be
removed before opening the fuel supply system as the fuel pump may be
activated by the driver's door contact switch.
Testing of the EVAP and ORVR systems can result in the escape of
explosive fuel vapor. Do not smoke while testing the EVAP system, and
make sure the area you are working in is well ventilated.
Observe the following for all procedures, especially in the engine

compartment due to lack of room:
 Route lines of all types (e.g. for fuel, hydraulic, EVAP canister
system, coolant and refrigerant, brake fluid, vacuum) and electrical
wiring so that the original path is followed.
 Watch for sufficient clearance to all moving or hot components.
 Do not touch or disconnect the Ignition Coils, ignition wires,
connecting parts or adapter cables when the ignition is on or the
engine is running or turning at starting RPM.
 Only disconnect and reconnect wires for injection and ignition
system, including test leads, when the ignition is turned off.
When removing and installing components from full or partially full fuel
tanks, observe the following:
 The fuel tank must only be partially full. How much fuel can remain
in the fuel tank may be read in the respective work description.
Empty the fuel tank if necessary.
 Before starting work, switch on the exhaust extraction system and
place an extraction hose close to the installation opening of the fuel
tank to extract escaping fuel fumes. If no exhaust extraction system
is available, a radial fan (as long as motor is not in air flow) with a
displacement greater than 15 m3 /h can be used.
 Prevent fuel from contacting the skin. Wear fuel-resistant gloves!
When servicing the engine control module (ECM), it may be necessary to

use a heat gun. The heat gun, shear bolts, and parts of the protective
housing will become extremely hot. Use extreme caution when working
with or handling these parts to avoid personal injury.
Observe operating instructions when working with a heat gun. To prevent

damage (burning) to the wiring and harness connections, insulation and
the electronic components, perform outlined work steps exactly!
The cooling system is under pressure. To avoid scalding, use caution

when opening the cooling system and servicing cooling system
components!
CAUTION: The battery must only be disconnected and connected with the ignition
switched off. Otherwise, the engine control module (ECM) can be
damaged.
The use of nails, paper clips, or another unauthorized materials to back-

probe electrical harness connectors is strictly prohibited and may cause
damage to the electrical harness connectors, terminal ends or to a
component. Use only the manufacturers test lead kit or an equivalent
aftermarket test lead kit for back-probing all electrical harness connectors.
Do not use sealants containing silicone. Particles of silicone drawn into

the engine, will not be burnt in the engine and will damage the oxygen
sensors.
Secure all hose connections with the correct hose clips (the same as
original equipment).
If engine is to be cranked without starting, for example as part of a

compression test, remove the fuses for the voltage supply of Ignition Coils
and the fuel injector.
An electrostatic charge can lead to functional problems of electrical

components of the engine, transmission and selector lever mechanism.
Touch a grounded object, e.g. a water pipe or a hoist, before working on
electrical components.
Do not make direct contact with electrical harness connector terminals.
Use only gold-plated terminals when servicing any component with gold-
plated electrical harness connector terminals.
CLEAN WORKING CONDITIONS
Even minor contaminations can lead to malfunctions in the fuel injection system. When working on the fuel
supply/injection system, pay careful attention to the following rules of cleanliness:
 Thoroughly clean all connections and the surrounding area before disconnecting.
 Place removed parts on a clean surface and cover. Use lint-free cloths.
 Carefully cover over opened components or seal, if repairs are not performed immediately.
 When the system is open, do not work with compressed air. Do not move vehicle unless absolutely
necessary.
 Install clean components: Remove replacement parts immediately prior to installation. Do not use parts
that have been stored unpacked (e.g. in tool boxes etc.).
 Separated electrical connectors: Protect from dirt and moisture. Make sure connections are dry when
reconnecting.
ON BOARD DIAGNOSTIC SYSTEMS

California OBD-II applies to all gasoline engine vehicles up to 14,000 lbs. Gross Vehicle Weight Rating
(GVWR) starting in the 1996 MY and all diesel engine vehicles up to 14,000 lbs. GVWR starting in the 1997
MY.
Several states in the northeastern United States have chosen to adopt the California emission regulations starting
in the 1998 MY and are known as "Green States".
Green States receive California-certified vehicles for passenger cars and light trucks up to 6,000 lbs. GVWR.
Starting in the 2004 MY, Federal vehicle over 8,500 lbs. will start phasing in OBD-II.
Starting in 2004 MY, gasoline-fueled medium duty passenger vehicles are required to have OBD-II. Federal
OBD-II applies to all gasoline engine vehicles up to 8,500 lbs. GVWR starting in the 1996 MY and all diesel
engine vehicles up to 8,500 lbs. GVWR starting in the 1997 MY.
OBD-II system implementation and operation is described in the remainder of this document.
MALFUNCTION INDICATOR LAMP ILLUMINATION
If the engine control module (ECM) recognizes a malfunction that leads to increased emission values, it
indicates them by illuminating the malfunction indicator lamp (MIL) which is located in the instrument cluster.
The ECM switches on the MIL after the ignition is switched on. Shortly after the engine is started, the MIL goes
out if the ECM does not detect a malfunction that increases the emission values.
If the ECM recognizes a malfunction that leads to increased emissions during the operation of the engine, the
ECM switches on the MIL and an entry is stored in the DTC memory of the ECM.
CONTROLLER AREA NETWORK DATA LINK
The engine control module (ECM) communicates with data bus capable control modules via a CAN Data Link.
The data bus capable control modules are connected via data bus wires, which are twisted together (CAN high
and CAN low), and exchange information with the ECM. Missing or implausible information on the data bus is
recognized and stored as a malfunction based on specific DTC criteria.
The malfunction indicator lamp (MIL) is illuminated as a result of a CAN message sent by the ECM. The MIL
can be turned on, turned off, or blink, depending on the message received.
ELECTRONIC POWER CONTROL WARNING LAMP
The engine control module (ECM) monitors electronic power control (EPC) components when the ignition is
switched on.
If a malfunction is recognized in the EPC system, the ECM switches on the EPC warning lamp, which is
located in the instrument cluster, and an entry is stored in the DTC memory of the ECM.

NOTE: All manufacturers special tools as well as common tools may contain a
manufacturer specific part number. These tools may be substituted with an
equivalent aftermarket tool or are available for purchase through the
manufacturer.
Manufacturers special tools as well as common tools that contain a

manufacturer specific part number may be referenced in the test procedure
illustrations showing the tool use or installation. If the manufacturer specific
tool is not being used, an equivalent aftermarket tool may be installed in the
same manner as the manufacturers special tool.
FUEL SUPPLY SYSTEM
For all fuel supply system component locations, removal/installation procedures and torque specifications, refer
to the service information.
EVAPORATIVE EMISSION SYSTEM
The evaporative emission system has been designed to minimize the release of hydrocarbons from the fuel
system into the atmosphere. The evaporative system components all work together with the ECM to prevent
fuel vapor from escaping and route it to the intake manifold to be burned during normal combustion.
The leak detection system checks the integrity of the evaporative emission system by pressurizing system.
 When leak detection is activated, a pump pressurizes the evaporative system.

 During the leak diagnosis, the system is monitored for a specific time period. If the pressure does not drop
a specific amount during the time period, the system is considered to be sealed.
 If the pressure drops greater than a specified amount during a specific time period, the system is
pressurized once more. The engine control module measures the time until the pressure drops again. The
control module uses the measured value to determine the size of the leak.
Leak diagnosis is activated automatically shortly following every engine start. If a malfunction is determined,
an entry is made to the DTC memory. The Malfunction Indicator Lamp in the instrument cluster is illuminated
if the malfunction is recognized for two subsequent starts.
For all evaporative system component locations, hose routing, removal/installation procedures and torque
specifications, refer to the service information.
ELECTRONIC ENGINE POWER CONTROL
For EPC, the throttle valve is not operated by a cable from the accelerator pedal. There is no mechanical
connection between the accelerator pedal and the throttle valve.
The position of the accelerator pedal is communicated to engine control module (ECM) by the throttle position
sensor/accelerator pedal position sensor 2 (variable resistances; stored in one housing) that are connected with
the accelerator pedal.
The accelerator pedal position (driver's intention) is a main input unit for the ECM.
Operation of the throttle valve occurs via an electric motor, the throttle drive for in the throttle valve control
module. This is true across the entire engine speed and engine load spectrum.
The throttle valve is operated by the EPC according to specifications of engine control module (ECM).
With engine off and ignition switched on, the ECM controls the throttle drive according to specifications of
throttle position sensor/accelerator pedal position sensor 2. This means, if the accelerator pedal is pressed half
way, the throttle drive opens the throttle valve to the same degree; i.e. throttle valve is then opened
approximately half way.
With engine running under load, ECM can open or close the throttle valve independently of the throttle position
sensor/accelerator pedal position sensor 2.
This means, for example, that the throttle valve could be fully opened even though the accelerator pedal has
only been pressed half way. This has the advantage of preventing torque losses at the throttle valve.
In addition, it results in a significant reduction in emissions and fuel consumption under certain load conditions.
It would be incorrect to think that EPC consists of only one or two components. EPC is much more of a system
containing all components that contribute to recognizing, controlling and monitoring the position of the throttle
valve.
FUEL INJECTION SYSTEM
For all fuel injection system component locations, removal/installation procedures and torque specifications,
refer to the service information.
ENGINE CONTROL MODULE
The ECM regulates fuel injection, throttle valve control module, oxygen sensor regulation, ignition, knock
control, evaporative emission purge valve, engine speed limitation through the fuel injectors or the power
supply relay, as well as OBD functions.
EXHAUST SYSTEM COMPONENTS
For all exhaust system, emission control component locations, removal/installation procedures and torque
IGNITION SYSTEM
For all ignition and glow plug system component locations, removal/installation procedures and torque
AUTOMATIC TRANSMISSION
The transmission control module receives information from transmission related components and uses this
information to control shifting and operation of the transmission.
For all automatic transmission component locations, removal/installation procedures and torque specifications,
refer to the service information.
PRELIMINARY CHECK
Prior to component diagnosis, a preliminary check must be performed.
-- Connect the scan tool.
-- Switch the ignition on.
-- Using the scan tool, check for any stored or related DTCs.
If other DTCs are stored:
-- Repair these DTCs first before performing the following procedure.
If no other DTCs are stored:
-- Using the scan tool, erase the DTC memory. Refer to DIAGNOSTIC MODE 04 - ERASE DTC
MEMORY.
-- Perform a road test to attempt to duplicate the customers complaint.
If the DTC returns:
-- Perform the diagnostic procedure.
If the DTC does not return:
-- The fault is intermittent or a sporadic condition may exist.
-- Check the suspected component, electrical harness and electrical harness connectors for damage, corrosion,
loose or broken terminals.
-- If necessary, repair the faulty wiring connection.
-- Perform a road test to verify the repair.
If the DTC returns:
-- Perform the diagnostic procedure.

If the DTC does not return:
The fault may have been the result of a loose electrical connection.
-- Generate readiness code. Refer to READINESS CODE.
READINESS CODE
Readiness code description
Diagnostics are performed at regular intervals during normal vehicle operation. After repairing an emissions
related system, a readiness code is generated by road testing the vehicle.
If a malfunction is recognized during the drive cycle, it will be stored in the DTC memory.
The OBD drive cycle operation will be monitored with a hand held diagnostic tool. Consult the manufacturer's
instruction information for correct tool operation.
The readiness code is erased every time the DTC memory is erased or any time the battery is disconnected. If
the DTC memory has been erased or the battery is disconnected, a new readiness code must be generated.
Only erase the DTC memory if a DTC has been stored.
General recommendations
Most monitors will complete easier and quicker using a "steady-foot" and "smooth" acceleration during the
drive cycle operation, cruise, and acceleration modes.
Operating conditions
For the EVAP monitor test, the coolant temperature and the ambient air temperature must be between 10°C and
35°C with a difference between them no greater than 4°C. The ambient air temperature must not change more
than 4° C during the drive cycle procedure (e.g. when driving out of a heated workshop in the winter).
Test requirements
 Erase the DTC memory.

 Coolant temperature must be between 80°C and 110°C.
 The intake air temperature must be between 10°C and 35°C.
 Battery voltage must be a minimum of 12.5 volts.
 Fuel tank level 1/4 to 3/4 full.
Drive Cycle Procedure

-- Switch the ignition on and start the vehicle.
-- Idle the vehicle for 2-3 minutes. This executes the O2 heater, misfire, secondary air injection, fuel trim, and
purge system monitors.
-- Drive the vehicle at 45-55 mph for a continuous 7 minute period - avoid stopping. This executes the
evaporative, O2 sensor, fuel trim, and misfire monitors.
-- Accelerate the vehicle to an engine speed of 5000 RPM; lift off the throttle until the engine speed is around
1200 RPM. This executes the fuel cut off.
-- Accelerate the vehicle smoothly to 60-65 mph, cruise constantly for 5 min, this executes the catalyst; O2
sensor, misfire, fuel trim, and purge system monitors.
-- Decelerate and idle the vehicle again for 3 minutes. This executes the misfire, secondary sir injection, fuel
trim, and purge system monitors.
-- Check the status of the readiness code.
NOTE: Depending on the scan tool used. The readiness code status may be displayed
as complete, passed or OK.
-- If any engine monitor fails the drive cycle test. Repeat the drive cycle test until all engine monitors have
successfully run through and passed.
NOTE: When repeating the drive cycle operation for a failed evaporative or thermostat
monitor, allow the engine to cool until the coolant temperature and the ambient
air temperature are be between 10°C and 35°C with a difference no greater than
4°C and repeat the drive cycle operation.
If the drive cycle operation fails again.
-- Check the DTC memory for stored DTCs.
Repair the vehicle if necessary.
-- Repeat the drive cycle operation until all engine monitors have successfully run through and passed.
-- Remove the scan tool and switch the ignition off.
DIAGNOSTIC MODES 01 - 09
The information provided in Modes 01 through 09 displays the various levels of emission related data that may
be monitored, as well as the ability to retrieve and read stored DTC trouble codes, erase stored DTC trouble
codes, generate readiness codes, and select the various PIDs and Test-IDs used within the modes to monitor the
engine, and emission related component parameters.
NOTE: Depending on scan tool and protocol used, the information in diagnostic mode
01 may be referred to by different names such as Test-ID (TID), Hex-ID,
Component-ID (CID), or On-Board Diagnostic Monitor Identifier (OBDMID).
DIAGNOSTIC MODE 01 - READ CURRENT SYSTEM DATA
Diagnostic Mode 01 makes it possible to access current emissions-related measured values and diagnostic data.
The original measured values (no replacement values), input and output data and system status information are
displayed using Diagnostic Mode 1.
Test requirement
 Coolant temperature at least 80°C.
Procedure
-- Start the engine and run at idle.
-- Select "Diagnostic Mode 1: Obtain data.".
-- From the following table, select the desired the "PID" that is to be monitored, e.g. "PID $05 Coolant
temperature".
The current values of the component or system that is being monitored will be displayed on the scan tool screen.
PID Component or System

$01: Monitoring status since erasing DTC memory
$03: Condition of fuel system
$04: Calculated load value
$05: Coolant temperature
$06: Short term air fuel ratio
$07: Long term air fuel ratio
$0C: Engine RPM
$0D: Vehicle speed
$0E: Ignition timing advance for #1 cylinder
$0F: Intake air temperature
$10: Air flow rate from mass air flow sensor
$11: Absolute throttle position
$13: Oxygen Sensor Bank 1 Sensor 1
$15: Oxygen Sensor Bank 1 Sensor 2
$1F: Time since engine start
$21: Distance driven with MIL ON
$23: Fuel rail pressure

$2E: Commanded EVAP purge
$30: Warm up counts after MIL erased
$31: Distance driven after erasing DTC memory
$33: Barometric pressure
$34: Heater current Bank 1 Sensor 1
$3C: Catalyst temperature Bank 1 Sensor 1
$3E: Catalyst temperature Bank 1 Sensor 2
$41: Monitor status current drive cycle
$42: Control module voltage
$43: Absolute load value
$44: Specified value of oxygen sensor signal
$45: Relative throttle valve position
$46: Ambient temperature
$47: Throttle valve position 2 absolute
$49: Accelerator pedal position 1 absolute
$4A: Accelerator pedal position 2 absolute
$4C: Specified throttle valve position
$56: Offset oxygen sensor regulation after catalytic convertor
-- Switch the ignition off.
DIAGNOSTIC MODE 02 - READ OPERATING CONDITIONS
When an emissions-related fault (pending DTC, visible in mode 07) is first detected, operating conditions are
stored. Mode 02 makes it possible to access this freeze frame data as soon as this fault is shown in mode 03.
Each control module only shows freeze frame data for one fault via mode 02. Therefore, there are two priority
levels. If there is a malfunction with higher priority, the freeze frame data is overwritten.
-- Fault with higher priority: Misfire malfunction or fuel trim malfunction.
-- Fault with normal priority: All other emissions-related faults.
NOTE: Depending on scan tool and protocol used, the information in diagnostic mode
02 may be referred to by different names such as Test-ID (TID), Hex-ID,
Component-ID (CID), or On-Board Diagnostic Monitor Identifier (OBDMID).
Procedure

NOTE: If the engine does not start, crank the engine using starter for at least 5
seconds, do not switch the ignition off afterward.
-- Select "Diagnostic Mode 2: Obtain operating conditions.".
-- From the following table, select the desired the "PID" , e.g. "PID $05 Coolant temperature" that is to be
monitored.
The current values of the component or system that is being monitored will be displayed on the scan tool screen.
PID Component or System

$02: DTC which triggered Freeze Frame data
$03: Fuel system status
$04: Calculated load value
$05: Coolant temperature
$06: Short term air fuel ratio
$07: Long term air fuel ratio
$0C: Engine RPM
$0D: Vehicle speed
$0E: Ignition timing advance for # 1 cylinder
$0F: Intake air temperature
$10: Air flow rate from mass air flow sensor
$1F: Time since engine start
$23: Fuel rail pressure
$2E: Commanded EVAP purge
$33: Barometric pressure
$42: Control module voltage
$43: Absolute load value
$44: Commanded equivalence ratio
$45: Relative throttle valve position
$46: Ambient temperature
$49: Accelerator pedal position 1 absolute
$4A: Accelerator pedal position 2 absolute
$4C: Specified throttle valve position
$56: Offset oxygen sensor regulation after catalytic convertor
DIAGNOSTIC MODE 03 - READ DTC MEMORY

Diagnostic Mode 03 makes it possible to read emissions-related faults (confirmed DTCs: faults which have
activated the MIL) in the ECM and in the TCM.
When the ECM recognizes an emission related fault it turns on the malfunction indicator lamp. If an electronic
throttle malfunction is recognized, the ECM turns on the electronic power control warning lamp. Both are
located in the instrument cluster.
The DTCs are sorted by SAE code with the DTC tables consisting of a 5 digit alpha numeric value.
NOTE: Depending on scan tool and protocol used, diagnostic mode 03 and the
information provided may be referred to by a different name.
The following tables provide a breakdown and explanation of the DTC code.
P-Codes
Component group
DTC for the
P x x x x
drivetrain
Norm-Code
Trouble
codes
defined by
P 0 x x x SAE with
specified
malfunction
texts
Additional
emission
relevant
P 1 x x x DTCs
provided by
the
manufacturer
DTCs
defined by
SAE with
P 2 x x x
specified
texts, from
MY 2000
Additional
emission
P 3 x x x relevant
DTCs
provided by
the
manufacturer
from MY
2000
Component group
Repair group
Fuel and air
mixture and
P x 0 x x additional
emission
regulations
Fuel and air
P x 1 x x
ratios
Fuel and air
P x 2 x x
ratios
Ignition
P x 3 x x
system
Additional
P x 4 x x exhaust
system
Speed and
P x 5 x x
idle control
Control
module and
P x 6 x x
output
signals
P x 7 x x Transmission
P x 8 x x Transmission
Control
modules,
P x 9 x x input and
output
signals
U-Codes
Component group
DTC for
U x x x x network
(CAN bus)
Norm-Code
Trouble
codes
defined by
SAE with
specified
U 0 x x x
malfunction
texts
Procedure
-- Switch the ignition to the ON position.
-- Select Diagnostic Mode 03: Interrogating fault memory.
-- The stored DTC or DTCs will be displayed on the scan tool screen.
The following table is an example of the DTC information that may be displayed on the scan tool screen:
Indication example Explanation

SAE
P0444 Diagnostic
Trouble Code
Malfunctioning
wiring path or
Evaporative emission canister purge regulator valve
malfunctioning
component
Malfunction
Circuit open
type as next
-- Refer to the DTC tables for the diagnostic repair procedures.
DIAGNOSTIC MODE 04 - ERASE DTC MEMORY
Diagnostic Mode 04 makes it possible to erase the DTC memory and to reset all emissions-related diagnostic
data. In that way, all faults in the DTC memory in the ECM and TCM are erased. The adaptation values may
also be reset.
Emissions-related diagnostic data includes (as applicable):
 - MIL Status
 - Number of DTCs
 - Readiness bits
 - Confirmed DTCs
 - Pending DTCs
 - DTC that belongs to freeze frame

 - Freeze frame data
 - Test results of specific diagnostic functions
 - Distance driven with "MIL ON"
 - Number of warm-up cycles after erasing the DTC memory
 - Distance driven after erasing the DTC memory
 - Misfire counter
NOTE: Depending on scan tool and protocol used, diagnostic mode 04 and the
Procedure
-- Select Diagnostic Mode 03: Interrogating fault memory.
-- Then select Mode 4: Reset/delete diagnostic data.
The scan tool will display: Diagnostic data are being erased.
DIAGNOSTIC MODE 06 - READ TEST RESULTS FOR SPECIFIC DIAGNOSTIC FUNCTIONS
Diagnostic Mode 06 makes it possible to retrieve test results for special components and systems which are
continuously or not continuously monitored. If the diagnosis of a system is complete, the diagnostic result and
the corresponding thresholds are saved and displayed in mode 06. This data remains saved (even with the
ignition off) until either new diagnostic results become available or the DTC memory is erased.
The min & max values for each individual test in Mode 06 represent the minimum & maximum operating
values for a properly operating system. This data is provided to the individual aftermarket scan tool companies
for development of their scan tool. Depending on the scan tool being used, the min & max values shown may
vary, or be rounded up or down to the nearest decimal point depending on the aftermarket scan tool company's
development process. e.g.:
Minimum Value
GST manual documentation 0.3499
Aftermarket scan tool display 0.35
NOTE: Depending on the scan tool and protocol used, the information displayed in
diagnostic mode 06 may be referred to by different names such as Test-ID (TID),
Hex-ID, Component-ID (CID), or On-Board Diagnostic Monitor Identifier

(OBDMID).
Test requirements
 Exhaust system must be properly sealed between the catalytic converter and the cylinder heads.
 No DTCs stored in the DTC memory.
 Coolant temperature at least 80°C.
Work procedure
-- Start the engine and let run at idle speed.
-- Select Mode 6: Check test the results of components that are not continuously monitored.
Select the desired Test-ID.
The current minimum and maximum values will be displayed on the scan tool screen.
The following table is a numerical list of all "Test-IDs" that may be selected.
Monitor-ID (Hex-ID) Component or System

$01: Monitor-ID $01: Oxygen Sensor Monitor Oxygen Sensor Monitor Bank 1 - Sensor 1
Bank 1 - Sensor 1
$02: Monitor-ID $02: Oxygen Sensor Monitor Oxygen Sensor Monitor Bank 1 - Sensor 2
Bank 1- Sensor 2
$21: Monitor-ID $21: Catalytic Converter Catalytic Converter Monitoring
Monitoring
$35: Monitor-ID $35: Camshaft Adjustment/I Camshaft Adjustment/VVT Bank 1
VVT Bank 1
$3A: MONITOR-ID $3A: FUEL TANK Fuel Tank EVAP System Integrity/Leak Test (0.90")
EVAP SYSTEM INTEGRITY/LEAK TEST
(0.90")
$3B: Monitor-ID $3B: Fuel Tank EVAP Fuel Tank EVAP System Integrity/Leak Test (0.40/1.0
System Integrity/Leak Test (0.40/1.0mm) mm)
$3C: Monitor-ID $3C: Fuel Tank EVAP Fuel Tank EVAP System Integrity/Leak Test (0.20/0.5
System Integrity/Leak Test (0.20/0.5mm) mm)
$3D: Monitor-ID $3D: EVAP Valve Function EVAP Valve Function Check
Check
$41: Monitor-ID $41: Oxygen Sensor Heater Oxygen Sensor Heater Monitor Bank 1 - Sensor 1
Monitor Bank 1 - Sensor 1
$42: Monitor-ID $42: Oxygen Sensor Heater Oxygen Sensor Heater Monitor Bank 1 - Sensor 2
Monitor Bank 1 - Sensor 2

$A2: Monitor-ID $A2: Mis-Fire Cylinder 1 Mis-Fire Cylinder 1 Data
Data
Data
Data
Data
Monitor-ID $01: Oxygen Sensor Monitor Bank 1 - Sensor 1
-- Select "Mode 6: Check test the results of components that are not continuously monitored".
Select "Monitor-ID $01".
-- Select the desired "Test-ID".
-- Check specified values at idle.
Component Additional
Test-ID DTC Min. Max.
or System Information
Refer to
Response DTC P0133
$83 P0133 0.15 V 1.99 V
Check. in the DTC
TABLES.
Refer to
DTC
Response
$84 P2195/P2196 -0.060 V 0.060 V P2195/P2196
Check.
in the DTC
TABLES
O2 sensor
Refer to
signal
DTC P0133
$89 P0133 dynamic 0.200 1.999
in the DTC
Bank 1
TABLES.
Sensor 1
-- If any of components or systems fail to meet the specified values. Refer to DIAGNOSTIC MODE 03 -
READ DTC MEMORY to check for stored DTC's or the corresponding diagnostic repair procedure.
-- Switch the ignition OFF.

Monitor-ID $02: Oxygen Sensor Monitor Bank 1- Sensor 2
Select "Monitor-ID $02".
Refer to
Deceleration DTC P0139
test - O2 or DTC
$05 P0139/P013A 0.0 Sec. 1.20 Sec.
transient P013A in
time. the DTC
TABLES.
O2 sensor
minimum Refer to
voltage DTC P2271
$8A: P2271 0.000 V 0.150 V
Bank 1 in the DTC
Sensor 2 TABLES.
(2012>)
Output Refer to
Voltage rich DTC P2271
$81 P2271 0.0 V 0.7026 V
during in the DTC
decel. TABLES
Output Refer to
Voltage lean DTC P2270
$82 P2270 0.630 V 1.0795 V
during in the DTC
accel. TABLES
Deceleration Refer to
test DTC P2271
$86 P2271 0.0 Sec. 8.0 Sec.
response in the DTC
time. TABLES

Monitor-ID $21: Catalytic Converter Monitoring
Select "Monitor-ID 21".
Catalytic Refer to
converter DTC P0420
$84 P0420 0.999 19.988
monitoring in the DTC
bank 1. TABLES.
Monitor-ID $35: Camshaft Adjustment/I VVT Bank 1
VVT Refer to
specified DTC P0011
$80 P0011 -32 to 25.50° KW -27.50 to 28° KW
position not in the DTC
reached. TABLES
VVT
Refer to
specified
DTC P000A
$81 P000A position is -32 to 25.50° KW -27.50 to 28° KW
in the DTC
reached too
TABLES
slow.
Monitor-ID $3A: Fuel Tank EVAP System Integrity/Leak Test (0.90")
Select "Monitor-ID 3A".
Refer to
Tank leak
DTC P0455
$81 P0455 test: Large 0.950 Sec. 65.535 Sec.
in the DTC
leak.
TABLES.
Monitor-ID $3B: Fuel Tank EVAP System Integrity/Leak Test (0.40/1.0mm)
Select "Monitor-ID 3B".

Refer to
Fuel Tank
DTC P0442
$81 P0442 Leak Test: 1.550 to 1.750 Sec. 65.535 Sec.
in the DTC
Small leak.
TABLES
Fuel Tank Refer to
Leak Test: DTC P0442
$86: P0442 900 Pa 8191.75 Pa
Small leak in the DTC
(2012>) TABLES
Monitor-ID $3C: Fuel Tank EVAP System Integrity/Leak Test (0.20/0.5mm)
Select "Monitor-ID 3C".
Tank leak Refer to
test: Pinhole DTC P0456
$81 P0456 4.50 to 6.00 Sec. 65.535 Sec.
leak (0.5 in the DTC
mm). TABLES.
Fuel Tank
$82 Pass only 12.0 g 6553.5 g ---
Leak Test.
Fuel Tank
$84: P0456 Leak Test, 0.000 0.170 Refer to
very small DTC P0456
leak in the DTC
(2012>) TABLES.
Monitor-ID $3D: EVAP Valve Function Check
Select "Monitor-ID 3D".
Purge flow Refer to
monitor DTC P0441
$8C: P0441 0.000 mA 14.000 mA
valve open. in the DTC
(2012>) TABLES.
Purge flow
Refer to
monitor
DTC P0441
$8D: P0441 valve 0.000 mA 36.300 mA
in the DTC
closed.
TABLES.
(2012>)
Tank vent
valve check
from %
DTEV:
Refer to
Active test
DTC P0441
$80 P0441 Air balance .300 1.999
in the DTC
at idle OK,
TABLES.
(Normal
operation
and short
test 70).
Tank vent
valve check
from %
DTEV:
Active test,
Oxygen
sensor
regulator
deviating in
lean
$82 -- 0.07 10 --
direction
(can only
test OK),
(Normal
operation
and short
test 70).
Tank vent
valve check
from %
DTEV:
Active test,
Oxygen
sensor
regulator
$82 Pass only deviation in -9.994 to 0.080 -0.080 to 9.994 --
rich
direction
(can only
test OK),
(Normal
operation
and short
test 70).
Monitor-ID $41: Oxygen Sensor Heater Monitor Bank 1 - Sensor 1

Oxygen
sensor
heating in
front of
catalytic Refer to
converter, DTC P0135
$85 P0135 714.9 °C 1199.9 °C
diagnosis, in the DTC
Bank 1 TABLES.
Sensor 1
Ceramic
temperature
monitoring.
Monitor-ID $42: Oxygen Sensor Heater Monitor Bank 1 - Sensor 2
Oxygen
sensor
$81 P0141 heating 0.00 Ohms 0.792 to 4.560 k Ohms
between
catalytic Refer to
converter, DTC P0141
diagnosis, in the DTC

Bank 1 TABLES.
Sensor 2
internal
resistance
test.
Monitor-ID $A2: Mis-Fire Cylinder 1 Data
Select "Monitor-ID A2".
Test-ID DTC Min./Max. Values
Misfire
cylinder 1, Refer to
Average DTC P0301
$0B P0301 0 - 65535 (counts)
value over in the DTC
10 Driving TABLES.
Cycles.
Misfire
Refer to
cylinder 1,
DTC P0301
$0C P0301 in this 0 - 65535 (counts)
in the DTC
Driving
TABLES.
Cycle.

-- Select "Mode 6 Check test the results of components that are not continuously monitored".
Select "Monitor-ID A3:".
Misfire
Average DTC P0302
$0B P0302 0 - 65535 (counts)
10 Driving TABLES.
Cycles.
Misfire
Refer to
cylinder 2,
DTC P0302
$0C P0302 in this 0 - 65535 (counts)
in the DTC
Driving
TABLES.
Cycle.
Test-ID DTC Component Min./Max. Values Additional

Misfire
Average DTC P0303
$0B P0303 0 - 65535 (counts)
10 Driving TABLES.
Cycles.
Misfire
Refer to
cylinder 3,
DTC P0303
$0C P0303 in this 0 - 65535 (counts)
in the DTC
Driving
TABLES.
Cycle.
Misfire
Average DTC P0304
$0B P0304 0 - 65535 (counts)
10 Driving TABLES.
Cycles.
Misfire
Refer to
cylinder 4,
DTC P0304
$0C P0304 in this 0 - 65535 (counts)
in the DTC
Driving
TABLES.
Cycle.
-- If any of the components or systems fail to meet the specified values, refer to DIAGNOSTIC MODE 03 -
READ DTC MEMORY to check for stored DTCs or the corresponding diagnostic repair procedure.
DIAGNOSTIC MODE 07 - READ FAULTS DETECTED DURING THE CURRENT OR LAST DRIVING CYCLE
Mode 07 makes it possible to check emissions-related faults which appeared during the current or last driving
cycle (pending DTCs).
A pending DTC is saved the first time a fault is detected (output via Mode 07).
-- If the fault is detected again by the end of the following driving cycle, a confirmed DTC is entered (output via
Mode 03) and the MIL is activated.
-- If this malfunction is not detected again by the end of the following driving cycle, the corresponding pending
code will be deleted at the end of the driving cycle.
NOTE: Depending on scan tool and protocol used, some of the information provided
may be referred to by a different name.
Procedure
NOTE: If the engine does not start, crank the engine using starter for at least 5
seconds. Do not switch the ignition off afterward.
-- Select Mode 7: Check test results of components that are continuously monitored.
The number of pending DTCs or 0 malfunctions detected will be displayed on the scan tool screen.
-- Refer to the DTC tables for the diagnostic repair procedures.
DIAGNOSTIC MODE 08 - REQUEST CONTROL OF ON-BOARD SYSTEM, TEST OR COMPONENT
Diagnostic Mode 08 is used to control the operation of an on-board system, test or component. A Mode 8
service can be used to turn on-board system ON or OFF, or to cycle an on-board system, test or component on
or off for a specific period of time. The service can also be used to request system status or to report test results.
Test requirements

 Intake Air Temperature (IAT) maximum 60 °C.
 Coolant temperature 80 -110 °C.
 Throttle valve angle 12.0 - 16.0%.
 NOT supported for 2012 MY
Function test
NOTE: If the accelerator pedal is depressed during the test, the test will be aborted.
-- Start the engine and run at idle for at least 15 minutes.
-- Select "Mode 8: Tank Leak Test".
-- Select "Test-ID 01: Tank Leak Test".
-- Check the specified value of the tank leak test at idle.
-- The following will be displayed on the scan tool screen:
Tank leak
Specified value
test
 Test
function
active
 Test
function
is being
Test OK
initiated,
please
wait
 Test off
 Test
aborted
If the specified result is obtained:
System OK.
If the specified result is Not obtained:

-- Repeat the tank leak test, switch the ignition off and start the engine again and let run for 15 minutes at idle.
If the specified result is again Not obtained:
-- A leak may be present. Refer to EVAP SYSTEM, CHECKING FOR LEAKS.
DIAGNOSTIC MODE 09 - READ VEHICLE INFORMATION
Diagnostic Mode 09 makes it possible to access vehicle-specific information from the ECM and the TCM
(where applicable).
NOTE: Depending on scan tool and protocol used, Diagnostic Mode 09 and the
Test requirement
Procedure
-- Select Mode 09: Vehicle information.
-- Select the desired Test-ID.
-- The information requested will be displayed on the scan tool screen.
The following table is a numerical list of all Test-IDs that may be selected.
Test-ID Diagnostic text

02: Vehicle identification number e.g.
 A different 17 digit number will be displayed for each vehicle
04: Calibration identification e.g.

 Engine Control Module (ECM) --
Transmission Control Module (TCM) --

06: CVN (check sum) e.g.

 EC5AE460 the check sum is different for every control module version
 000D105
08: In Use Performance Tracking

0A: ECU's acronym and text name
Diagnostic
Service Mode:
text
Request
emission
related
DTC with
$0A: Permanent
status.
Supported
for MY
2012>
DTC TABLES
Malfunction Secondary Monitoring Frequen

Diagnostic Criteria and Parameters with Time checks, M
DTC Error Message Procedure Threshold Value Enable Conditions Length Illum.
P000A Intake Camshaft -- Check the Signal change <  Time after
14 Sec.  2 D
* Position Slow Camshaft 1.9 - 4.2 CRK engine start >
Response Adjustment Valve 1 - °/sec. 3 to 10 Sec.
N205-. Refer to
 Frequency 4
CAMSHAFT
ADJUSTMENT times
VALVE 1,  Frequency at
CHECKING. cold start 2

times
P0010 Intake Camshaft -- Check the Signal voltage, >  Camshaft
0.5 Sec.  2D
* Position Actuator Camshaft 4.70 - 5.40 V valve off
Circuit Open Adjustment Valve 1 -
 Engine speed
N205-. Refer to
CAMSHAFT > 80 RPM
ADJUSTMENT
VALVE 1,
CHECKING.
P0011 Intake Camshaft -- Check the Adjustment  Time after 30 Sec.  2D
* Position Timing - Camshaft angle> 6.8 - 8 engine start >
Over-Advanced Adjustment Valve 1 - CRK° 3 - 10 Sec.
N205-. Refer to
CAMSHAFT  Oil
ADJUSTMENT temperature -
VALVE 1, 48 to 143.30°
CHECKING. C
 Frequency 4
times
 Frequency
cold 2 times
P0016 Crankshaft Position -- Check the  Permissible
2 Sec.  2D
* vs. Camshaft Camshaft deviation <
Position Correlation Adjustment Valve 1 - 11 rev
N205-. Refer to
CAMSHAFT OR
ADJUSTMENT
VALVE 1,  Permissible
---
CHECKING.-- deviation >
Check the Engine 11 rev
Speed Sensor -G28-.
Refer to ENGINE
SPEED SENSOR,
CHECKING
P025A Fuel Pump Module -- Check the Fuel Signal voltage >  Engine speed, 0.5 Sec.  2D
Control Circuit Pump -G6-. Refer to 4.4 - 5.6 V > 80 RPM
Open FUEL PUMP
ELECTRICAL,  Battery
TESTING. voltage, 9.04-
16 V
P025C Fuel Pump Module -- Check the Fuel Signal voltage <  Engine speed, 0.5 Sec.  2D
Control Circuit Pump -G6-. Refer to 2.15 - 3.25 V > 80 RPM
Low FUEL PUMP
16 V
P025D Fuel Pump Module -- Check the Fuel Signal current >  Engine speed, 0.5 Sec.  2D
Control Circuit Pump -G6-. Refer to 1.1 A > 80 RPM
High FUEL PUMP
16 V
P0030 HO2S Heater -- Check the Oxygen Heater voltage  Time after 0.5 Sec.  2D
* Control Circuit Sensor (O2S) Heater 4.70 to 5.40 V engine start >
Bank 1 Sensor 1 -Z19-. Refer to 5 Sec.
OXYGEN SENSOR
HEATER BEFORE  Heater
CATALYTIC commanded
CONVERTER, off
CHECKING.
P0031 HO2S Heater -- Check the Oxygen Heater voltage 0  Time after 0.5 Sec.  2D
* Control Circuit Sensor (O2S) Heater to 3.26 V engine start >
Low Bank 1 Sensor -Z19-. Refer to 5 Sec.
1 OXYGEN SENSOR  Heater

HEATER BEFORE commanded
CATALYTIC off
CONVERTER,
CHECKING.
P0032 HO2S Heater -- Check the Oxygen Heater current >  Time after 0.5 Sec.  2D
* Control Circuit Sensor (O2S) Heater 5.50 A engine start >
High Bank 1 Sensor -Z19-. Refer to 5 Sec.
1 OXYGEN SENSOR
HEATER BEFORE  Heater
CATALYTIC commanded
CONVERTER, off
CHECKING.
P0036 HO2S Heater -- Check the Oxygen Heater voltage  Time after 0.5 Sec.  2D
* Control Circuit Sensor (O2S) Behind 2.34 to 3.59 V engine start >
Bank 1 Sensor 2 Three Way Catalytic 5 Sec.
Converter (TWC) -
G130-. Refer to  Heater,
OXYGEN SENSOR Commanded
HEATER BEHIND off
THREE WAY
CATALYTIC
CONVERTER,
CHECKING.
P0037 HO2S Heater -- Check the Oxygen Heater voltage <  Time after 0.5 Sec.  2D
* Control Circuit Sensor (O2S) Behind 2.34 V engine start >
Low Bank 1 Sensor Three Way Catalytic 5 Sec.
2 Converter (TWC) -
G130-. Refer to  Heater,
OXYGEN SENSOR Commanded
HEATER BEHIND off
THREE WAY
CATALYTIC
CONVERTER,
CHECKING.
P0038 HO2S Heater -- Check the Oxygen Heater voltage >  Time after 0.5 Sec.  2D
Control Circuit Sensor (O2S) Heater 3.59 V engine start >
High Bank 1 Sensor -Z29-. Refer to 5 Sec.
2 OXYGEN SENSOR
HEATER BEHIND  Heater,
THREE WAY Commanded
CATALYTIC on
CONVERTER,
CHECKING.
P0068 MAF vs Throttle -- Check the Mass Plausibility with  Fuel system 139.4 Sec.  2D
* Position Correlation Air Flow (MAF) fuel system monitor
Sensor -G70-. Refer
to MAF SENSOR,  Load running

CHECKING. calculation  Lambda
< -22% control closed
loop
Plausibility with
fuel system
 Load
calculation
> 22%
P0070 Ambient Air -- Check the Ambient air CAN active 1 Sec.  2D
* Temperature Sensor Ambient temperature < -
Circuit Temperature Sensor - 50°C
G17-. Refer to
AMBIENT AIR
TEMPERATURE
SENSOR,
CHECKING
P0071 Ambient Air -- Check the  Difference
0 Sec.  2D
* Temperature Sensor Ambient in value  Engine off
Performance Temperature Sensor - between time > 6
G17-. Refer to ECT and hours
AMBIENT AIR AAT at
TEMPERATURE  ECT at engine
engine start
SENSOR, start < = 40 to
(depending
CHECKING 25°C
on engine
off time) >
25 - 40°K minus
and  IAT @ engine

start
 Difference
 ECT @
in value
between engine start <
AAT and 0.75°C
IAT at
engine start minus
(depending
on engine  ECT @ time
off time) > after engine
25 - 40°K start 60 Sec.
 AAT at
engine start
<= 5.2°C
minus
 AAT at
condition, veh
speed > 25
mph for > 10
sec.
 Intake air
temp @
engine start <
5.2
P0072 Ambient Air -- Check the Ambient air 1 Sec.  2D
* Temperature Sensor Ambient temperature > 87 °
Circuit Low Temperature Sensor - C
G17-. Refer to
CAN active
AMBIENT AIR
TEMPERATURE
SENSOR,
CHECKING
P0087 Fuel Rail/System -- Check the Fuel  Fuel trim  Engine speed 5 Sec.  2D
* Pressure - Too Low Pressure Sensor - activity 0.90 > 800 RPM
G247-. Refer to - 1.15
FUEL PRESSURE  EVAP purge
 Output adaptation <
SENSOR,
CHECKING. value rail 22
pressure  Lambda
controller > control closed
2 MPa loop
 Difference
between
target and
actual
pressure > -
16.4
P0100 Mass Air Flow -- Check the Mass MAF sensor 0.5 Sec.  2D
* Circuit Fault Air Flow (MAF) signal 0 µs
Sensor -G70-. Refer ---
to MAF SENSOR,
CHECKING.
P0101 Mass Air Flow -- Check the Mass Mass air flow vs.  Time after 2 Sec.  2D
* Circuit Performance Air Flow (MAF) engine start,
Sensor -G70-. Refer  Upper 150 camshaft
to MAF SENSOR, threshold revolutions
CHECKING. model <
 Throttle
12%
position <
 Lower 99.6%
threshold
 Engine speed
model <
12% 1320 - 5000

 Load RPM
calculation  ECT > 60°C
> 21%  IAT < 90°C
 Fuel system  Mass air flow
< -19% 0 - 450 kg/h
 Engine load
20 - 100%
 Lambda
control closed
loop
 EVAP purge
valve closed
 No low fuel
signal
P0102 Mass Air Flow -- Check the Mass MAF sensor 0.5 Sec.  2D
* Circuit Low Input Air Flow (MAF) signal < 66 µs
Sensor -G70-. Refer ---
to MAF SENSOR,
CHECKING.
P0103 Mass Air Flow -- Check the Mass MAF sensor Battery voltage > 8 0.5 Sec.  2D
* Circuit High Input Air Flow (MAF) signal > 4500 µs V
Sensor -G70-. Refer
to MAF SENSOR,
CHECKING.
P0106 Manifold Absolute -- Check the Charge  Difference  Engine speed
2 Sec.  2D
Pressure/Barometric Air Pressure of boost < 1000 RPM
Pressure Circuit Sensor/MAP Sensor pressure  Throttle
Performance -G31/G71-. Refer to signal vs
CHARGE AIR position <
altitude 11.50%
PRESSURE sensor
SENSOR/MAP signal > 230
SENSOR, hPa
CHECKING. If
there is no fault OR
found with the
Charge Air Pressure  Difference
sensor or wiring, of boost
check for any related pressure
TSB's. The Altitude signal vs
sensor is located altitude
within the ECM and sensor
will require signal < -
replacement of the 130 hPa
ECM if the reading is
more than 10% out

of range of actual
Barometric pressure
readings. Refer to the
Repair Information
for ECM
replacement.
P0111 Intake Air -- Check the IAT  Difference  Engine off
0 Sec.  On
* Temperature Sensor sensor -G42-. Refer in value time > 6
Circuit Performance to IAT SENSOR,  2D
IAT - ECT hours
CHECKING. @ engine  ECT @
start engine start
(depending <= 40 - 25 °C
on engine
off time) > minus
25 - 40 °K
 Difference  AAT @
in value engine start
IAT - AAT
@ engine  ECT @
start < 25 - engine start <
40 °K 1.5 °C
(depending
on engine minus
off time)
 ECT @ time
after engine
start 60 Sec.
 AAT @
engine start <
5.2 °C
minus
 AAT @
condition veh
speed > 25
mph for time
> 30 Sec.
 IAT @ engine
start < 5.2 °C
minus
 IAT @
condition veh
speed > 25
mph for time
> 30 Sec.
P0112 Intake Air -- Check the IAT IAT > 141.0 °C 2 Sec.  2D
* Temperature Sensor sensor -G42-. Refer
---
Circuit Low Input to IAT SENSOR,
CHECKING.
P0113 Intake Air -- Check the IAT IAT < -46 °C 2 Sec.  2D
* Temperature Sensor sensor -G42-. Refer
---
Circuit High Input to IAT SENSOR,
CHECKING.
P0116 Engine Coolant -- Check the Engine  No change  ECT @ start 115 Sec.  2D
* Temperature Sensor Coolant Temperature on signal < 109.6 -
1 Circuit (ECT) Sensor -G62-. 1.5 °K 140.30 °C
Performance Refer to ENGINE (stuck hi) or
COOLANT or 50.30 - 88.4 °
TEMPERATURE C (stuck low)
SENSOR 1 OR 2  Signal in  V
CHECKING. range 88.5 -
109.5 °C Temp 2:
with no
change on Substitute
signal 1.5 ° ECT > -48.00
K °C
 Mass air flow
40 - 120 kg/h
Driving conditions
 Veh speed 40
- 120 km/h
 Mass air flow
12 - 36 and
36 - 152 kg/h
 Time required
> 40.0 Sec.
P0117 Engine Coolant -- Check the Engine ECT >140 °C 2 Sec.  2D
* Temperature Sensor Coolant Temperature
1 Circuit Low Input (ECT) Sensor -G62-.
Refer to ENGINE ---
COOLANT
TEMPERATURE
SENSOR 1 OR 2
CHECKING.
P0118 Engine Coolant -- Check the Engine ECT < -40 °C 2 Sec.  2D
* Temperature Sensor Coolant Temperature
1 Circuit High Input (ECT) Sensor -G62-.
Refer to ENGINE
---
COOLANT
TEMPERATURE
SENSOR 1 OR 2
CHECKING.
P0121 Pedal Position -- Check the  TPS 1 -  Engine speed 0.28 Sec.  2D
* Sensor A Circuit Accelerator Pedal TPS 2 > > 480 RPM
Performance Position Sensor 1 - 6.30%
G79- /Accelerator
 Actual TPS
Pedal Position
Sensor 2 -G185-. 1 calculated
Refer to value > TPS
ACCELERATOR 2 calculated
PEDAL POSITION value
SENSOR  TPS 1 calc.
1/ACCELERATOR value >

PEDAL POSITION 9.00%
SENSOR 2,
CHECKING.
P0122 Pedal Position -- Check the Signal voltage < 0.14 Sec.  2D
* Sensor A Circuit Accelerator Pedal 0.20 V
Low Input Position Sensor 1 -
G79- /Accelerator
Pedal Position
Sensor 2 -G185-.
Refer to
---
ACCELERATOR
PEDAL POSITION
SENSOR
1/ACCELERATOR
PEDAL POSITION
SENSOR 2,
CHECKING.
P0123 Pedal Position -- Check the Signal voltage > 0.14 Sec.  2D
* Sensor A Circuit Accelerator Pedal 4.81 V
High Input Position Sensor 1 -
G79- /Accelerator
Pedal Position
Sensor 2 -G185-. ---
Refer to
ACCELERATOR
PEDAL POSITION
SENSOR
1/ACCELERATOR
PEDAL POSITION
SENSOR 2,
CHECKING.
P013A O2 Sensor Slow -- Check the Oxygen EWMA filtered  Time of fuel 10 Sec.
* Response - Rich to Sensor (O2S) Behind max differential cutoff <= 90
Lean Bank 1 Sensor Three Way Catalytic transient time at Sec.
2 Converter (TWC) - fuel cutoff >= 0.5
G130-. Refer to Sec. for 3 function  Exhaust temp
OXYGEN SENSOR checks at sensor >=
BEHIND THREE 385°C
WAY
CATALYTIC
CONVERTER,
CHECKING.
P0130 O2 Sensor Circuit -- Check the Heated  O2S  Modeled 12 Sec.  2D
* Bank 1 Sensor 1 Oxygen Sensor ceramic exhaust temp
(HO2S) -G39-. Refer temp. < > 300°C
to OXYGEN 640°C
SENSOR BEFORE  Fuel cutoff
CATALYTIC not active
CONVERTER,
CHECKING
P0131 O2 Sensor Circuit, -- Check the Heated  VM < 1.75
10 Sec.  2D
* Bank 1 - Sensor 1 Oxygen Sensor V
Low Voltage (HO2S) -G39-. Refer
 UN < 1.50
to OXYGEN
V ---
SENSOR BEFORE
CATALYTIC  IA or IP >
CONVERTER, 0.30 V
CHECKING
P0132 O2 Sensor Circuit, -- Check the Heated  VM > 3.25
10 Sec.  2D
* Bank 1 - Sensor 1 Oxygen Sensor V
High Voltage (HO2S) -G39-. Refer
 UN > 4.40
to OXYGEN
V ---
SENSOR BEFORE
CATALYTIC  IA or IP >
CONVERTER, 7.0 V
CHECKING
P0133 O2 Circuit Slow -- Check the Heated Signal dynamic  Engine speed,  400  2D
* Response Bank 1 Oxygen Sensor slope check 1320 - 4000 Sec.
Sensor 1 (HO2S) -G39-. Refer RPM
to OXYGEN  O2S signal
SENSOR BEFORE  Engine load, Oscillation
front vs.
CATALYTIC 35 - 100.01% and delay
modeled check
CONVERTER, O2S signal  Delta engine
CHECKING load < 6%
ratio < 0.40  Actual  200

and > 0.01 lambda, 0.85- Sec.
 Cycles 1.15
completed >  Lambda
40 control,
Closed loop
Oscillation check
 EVAP purge
flow < 18-
 Lambda
amplitude  Determination
signal > of max and
20% min slope
ratios 0.01 - 4
 Cycles > 8
 O2S hexagon
 Time
modeled temp
lambda >
< 569.99 °C
lambda
amplitude  O2S ceramic
400 m sec. temp > 715 °
C
Delay check  Determination
of
 Delay measurement
modeled window, 500
lambda m sec.
signal
minus Oscillation and
measured delay check
signal > 460
m sec.  Lambda
 Cycles > 12 control,

Closed loop
 Engine load
20 - 80%
 Engine speed
1340 - 3500
RPM
 Delta engine
load < 3%
 Actual
lambda 0.75 -
1.25
P0135 O2 Heater Circuit -- Check the Oxygen  Heater duty  Heater  15 -  2D
Bank 1 Sensor 1 Sensor (O2S) Heater cycle, control, 55
-G39-. Refer to >100% Active Sec.
OXYGEN SENSOR
HEATER BEFORE  O2S  Modeled

CATALYTIC ceramic exhaust gas
CONVERTER, temperature, temp, >
CHECKING. < 715 °C 299.99 °C
 Time after  ECT at start >
O2S heater -9.80 °C
on 40 Sec.  Engine
 Difference shutoff time >
between 300 Sec.
measured  Time after
calibration engine start >
resistance in 15 Sec.
ECM and
set value >  Engine speed,
45 ohm idle
P0136 O2 Circuit Bank 1 -- Check the Oxygen  Delta  Modeled
6 Sec.  2D
Sensor 2 Sensor (O2S) Behind voltage one exhaust gas
Three Way Catalytic step at temp. 200.006
Converter (TWC) - heater - 800.006 °C
G130-. Refer to switching > for 60 Sec.
OXYGEN SENSOR 2.0020 V
BEHIND THREE
 Number of
WAY
CATALYTIC checks 10
CONVERTER,
CHECKING.
P0137 O2 Circuit Low -- Check the Oxygen Cold condition  ECT at engine
Cold cond.  2D
* Voltage Bank 1 Sensor (O2S) Behind off, > 60 °C
Sensor 2 Three Way Catalytic  Signal  5.1
 ECT < 39.8 °
Converter (TWC) - voltage, < Sec.
G130-. Refer to C
0.06 V for >
OXYGEN SENSOR 3 Sec.  Modeled Warm
BEHIND THREE exhaust gas cond.
WAY Warm condition temp. 200.006
CATALYTIC - 800.006 °C  40
CONVERTER,  Signal
for 60 Sec. Sec.
CHECKING. voltage <
0.01 V Warm condition
 Reaction at
 1st lambda
closed loop
control loop
enrichment
not at max
- no
value
reaction
 Modeled
exhaust gas
temp. 200.006
- 800.006 °C
for 60 Sec.
P0138 O2 Circuit High -- Check the Oxygen Signal voltage  Modeled 5.1 Sec.  2D
* Voltage Bank 1 Sensor (O2S) Behind 1.08 V for > 5 exhaust gas
Sensor 2 Three Way Catalytic Sec. temp. 200.006
Converter (TWC) - - 800.006 °C
G130-. Refer to for 60 Sec.
OXYGEN SENSOR
BEHIND THREE
WAY
CATALYTIC
CONVERTER,
CHECKING.
P0139 O2 Circuit Slow -- Check the Oxygen  EWMA  Rich voltage 0.1 Sec.  2D
Response Bank 1 Sensor (O2S) Behind filtered enable > =
Sensor 2 Three Way Catalytic transient 547.9 mV
Converter (TWC) - time at fuel  Lean voltage
G130-. Refer to cutoff > 0.4
OXYGEN SENSOR < = 201.2 mV
Sec.
BEHIND THREE  Fuel cutoff
WAY active
 In voltage
CATALYTIC range of  O2S rear
CONVERTER, 201.2 - ready
CHECKING. 401.4 mV  Modeled
 Number of exhaust gas

checks, 3 temp > 400 °
C
 Front O2
sensor lambda
signal > 2.00
V
P0140 O2 Circuit No -- Check the Oxygen Signal voltage Signal voltage 30 Sec.  2D
* Activity Detected Sensor (O2S) Behind
Bank 1 Sensor 2 Three Way Catalytic  Signal  Modeled
Converter (TWC) - voltage 0.40 exhaust gas
G130-. Refer to - 0.60 V temp. 800° C
OXYGEN SENSOR for > 60 Sec.
BEHIND THREE Internal resistance
WAY Internal resist.
CATALYTIC  > 40000
CONVERTER, ohm  Modeled
CHECKING. exhaust gas
temp. 600° C
for > 60 Sec.
 O2S rear
ready
P0141 O2 Heater Circuit -- Check the Oxygen Heater resistance,  Heater 15 Sec.  2D
Bank 1 Sensor 2 Sensor (O2S) Heater 1404 - 13650 commanded
-G465-. Refer to Ohm on
OXYGEN SENSOR
 Modeled
HEATER BEHIND
THREE WAY exhaust gas
CATALYTIC temp, 250 -
CONVERTER, 650.01 °C
CHECKING.  Engine
shutoff time >
300 Sec.
 Fuel cutoff
not active
P0169 Incorrect Fuel Check for  Fuel Engine speed > 0.52 to 2.08  2D
* Composition contaminated fuel or quantity 1200 RPM Sec.
possible high incorrect
concentration of
 Fuel
alcohol in fuel
(above 15%). If any correction
O2 sensor codes are factor
also set, refer to incorrect
those codes first.  Internal
check failed
P0171 System Too Lean -- Check the intake At idle At idle  10  2D
Bank 1 system for leaks Sec.
(unmetered air).--  Adaptive  Engine speed,
Check the vacuum value > 560 - 1200
lines for leaks-- 5.02% RPM
Check the fuel  Engine load,
pressure -- . Refer to At part load 9 - 45%
FUEL PRESSURE
TEST-- Check the  Mass air flow
 Adaptive
Fuel Pressure Sensor 5-23 kg/h
value >
-G247-. Refer to 21%  ECT > 63 °C
FUEL PRESSURE  IAT < 90° C
SENSOR,
 Part load
CHECKING--
adaptation
Check the fuel
ready
injectors -N30, N31,
N32, N33, -. Refer to  Lambda
FUEL control,
INJECTORS, Closed loop
CHECKING. --  EVAP purge
Check the Heated valve, Closed
Oxygen Sensor  No low fuel
(HO2S) -G465-. signal
Refer to OXYGEN
SENSOR BEFORE At part load

CATALYTIC
CONVERTER,  Throttle
CHECKING. position <
99.6%
 Engine speed
1320 - 5000
RPM
 Engine load
20 - 100%
 Mass air flow
27 - 450 kg/h
 ECT > 63 °C
 IAT < 90 °C
 Lambda
control closed
loop
 EVAP purge
valve closed
 No low fuel
signal
P0172 System Too Rich -- Check the fuel At idle At idle  10  2D
Bank 1 pressure --. Refer to Sec.
FUEL PRESSURE  Adaptive  Engine speed,
TEST-- Check the value < - 560 - 1200
Fuel Pressure Sensor 5.02% RPM
-G247-. Refer to  Engine load,
FUEL PRESSURE At part load 9 - 45%
SENSOR,
CHECKING--  Mass air flow
 Adaptive
Check the fuel 5-23 kg/h
value < -
injectors -N30, N31, 21%  ECT > 63 °C
N32, N33, -. Refer to  IAT < 90° C
FUEL
 Part load
INJECTORS,
adaptation
CHECKING.--
ready
Check the Heated
Oxygen Sensor  Lambda
(HO2S) -G465-. control,
Refer to OXYGEN Closed loop
SENSOR BEFORE  EVAP purge
CATALYTIC valve, Closed
CONVERTER,  No low fuel
CHECKING. -- signal
Check the
Evaporative At part load

Emission (EVAP)
Canister Purge  Throttle
Regulator Valve - position <
N80-. Refer to 99.6%
EVAPORATIVE  Engine speed
EMISSION 1320 - 5000
CANISTER RPM
PURGE
REGULATOR  Engine load
VALVE, 20 - 100%
CHECKING.  Mass air flow
27 - 450 kg/h
 ECT > 63 °C
 IAT < 90 °C
 Lambda
control closed
loop
 EVAP purge
valve closed
 No low fuel
signal
P0190 Fuel Rail Pressure -- Check the Fuel Signal voltage > 0.5 Sec.  2D
* Sensor Circuit Pressure Sensor - 4.8 V
G247-. Refer to
---
FUEL PRESSURE
SENSOR,
CHECKING
P0191 Fuel Rail Pressure -- Check the Fuel Actual pressure > Time after 3 Sec.  2D
Sensor Circuit Pressure Sensor - 20.6 MPa engine start >
Performance G247-. Refer to 0 Sec.
FUEL PRESSURE
SENSOR,  Engine speed
CHECKING > 90 RPM
P0192 Fuel Rail Pressure -- Check the Fuel Signal voltage < 0.5 Sec.  2D
* Sensor Circuit Low Pressure Sensor - 0.2 V
G247-. Refer to
---
FUEL PRESSURE
SENSOR,
CHECKING
P0201 Injector Circuit -- Check the fuel  Low side  Engine speed, 0.5 Sec.  2D
* Open Cylinder 1 injectors -N30-. signal > 80 RPM
Refer to FUEL current <
INJECTORS,  Injection
2.1 A valve
CHECKING.
 Internal switched on
logic failure
2.1 A valve
CHECKING.
logic failure
2.1 A valve
CHECKING.
logic failure
2.1 A valve
CHECKING.
logic failure
P0221 Pedal Position -- Check the  TPS 1 -  Engine speed 0.28 Sec.  2D
* Sensor Circuit Accelerator Pedal TPS 2 > > 480 RPM
Performance Position Sensor 1 - 6.30%
G79- /Accelerator
 Actual TPS
Pedal Position
Sensor 2 -G185-. 2 calculated
Refer to value > TPS
ACCELERATOR 1 calculated
PEDAL POSITION value
SENSOR  TPS 2 -
1/ACCELERATOR calc. value

PEDAL POSITION > 9.00%
SENSOR 2,
CHECKING.
P0222 Pedal Position -- Check the Signal voltage < 0.14 Sec.  2D
* Sensor Circuit Low Accelerator Pedal 0.20 V
Input Position Sensor 1 -
G79- /Accelerator
Pedal Position
Sensor 2 -G185-.
Refer to ---
ACCELERATOR
PEDAL POSITION
SENSOR
1/ACCELERATOR
PEDAL POSITION
SENSOR 2,
CHECKING.
P0223 Pedal Position -- Check the Signal voltage > 0.14 Sec.  2D
* Sensor Circuit High Accelerator Pedal 4.81 V
Input Position Sensor 1 -
G79- /Accelerator
Pedal Position
Sensor 2 -G185-.
Refer to
---
ACCELERATOR
PEDAL POSITION
SENSOR
1/ACCELERATOR
PEDAL POSITION
SENSOR 2,
CHECKING.
P0234 Turbocharger -- Check the Charge Difference of set Altitude < 2700 m 1.2 Sec.  2D
* Overboost Air Pressure sensor - value boost
Condition G31-. Refer to pressure vs
CHARGE AIR altitude sensor
PRESSURE signal > 200 -
SENSOR/MAP 1275 hPa
SENSOR,
CHECKING--
Check the Wastegate
Bypass Regulator
Valve -N75-. Refer
to WASTEGATE
BYPASS
REGULATOR
VALVE,
CHECKING. --
Check the
Turbocharger
Recirculating Valve -
N249-. Refer to
TURBOCHARGER
RECIRCULATING
VALVE,
CHECKING
NOTE:
Check the Altitude
sensor reading and
make sure it is
correct for the
location (if unsure
of the elevation
compare to a
vehicle with no
faults). If the
reading is off by
10% or more, the
Altitude sensor is
part of the ECM
circuit board and
will require ECM
replacement.
P0236 Turbocharger Boost -- Check the Charge Difference of  Engine speed 2 Sec.  2D
* Sensor Circuit Air Pressure sensor - boost pressure < 1000 RPM
Performance G31-. Refer to signal vs altitude
 Throttle
CHARGE AIR sensor signal >
PRESSURE 230 or < -130 hPa position <
SENSOR/MAP 6.81%
SENSOR,
CHECKING
NOTE:
Check the Altitude
sensor reading and
make sure it is
correct for the
location (if unsure
of the elevation
compare to a
vehicle with no
faults). If the
reading is off by
10% or more, the
Altitude sensor is
part of the ECM
circuit board and
will require ECM
replacement.
P0237 Turbocharger Boost -- Check the Charge Signal voltage < 0.5 Sec.  2D
* Sensor Circuit Low Air Pressure sensor - 0.2 V
G31-. Refer to
CHARGE AIR
---
PRESSURE
SENSOR/MAP
SENSOR,
CHECKING
P0238 Turbocharger Boost -- Check the Charge Signal voltage > 0.5 Sec.  2D
* Sensor Circuit High Air Pressure sensor - 4.88 V
G31-. Refer to ---
CHARGE AIR
PRESSURE
SENSOR/MAP
SENSOR,
CHECKING
P0243 Turbocharger -- Check the Signal voltage >  Charge 0.5 Sec.  2D
* Wastegate Solenoid Wastegate Bypass 5.6 - 4.4 V (boost)
Circuit Performance Regulator Valve - pressure
N75- . Refer to control valve,
WASTEGATE commanded
BYPASS off
REGULATOR
VALVE,  Engine speed
CHECKING. > 80 RPM
P0245 Turbocharger -- Check the Signal voltage <  Charge 0.5 Sec.  2D
* Wastegate Solenoid Wastegate Bypass 3.25 - 2.15 V (boost)
Low Regulator Valve - pressure
N75-. Refer to control valve,
WASTEGATE commanded
BYPASS off
REGULATOR
VALVE,  Engine speed,
CHECKING. > 80 RPM
P0246 Turbocharger -- Check the Signal current >  Charge 0.5 Sec.  2D
Wastegate Solenoid Wastegate Bypass 2.2 A (boost)
High Regulator Valve - pressure
N75-. Refer to control valve,
WASTEGATE commanded
BYPASS off
REGULATOR
VALVE,  Engine speed,
CHECKING. > 80 RPM
P025A Fuel Pump Module -- Check the Fuel Signal voltage 0.5 Sec.  2D
* Control Circuit Pump Module -J538- 4.40 - 5.60 V
Open . Refer to FUEL Engine speed > 80
PUMP RPM
ELECTRICAL,
TESTING
P025C Fuel Pump Module -- Check the Fuel Signal voltage 0.5 Sec.  2D
* Control Circuit Pump Module -J538- 2.15 - 3.25 V
Low . Refer to FUEL Engine speed > 80
PUMP RPM
ELECTRICAL,
TESTING
P025D Fuel Pump Module -- Check the Fuel Signal current > 0.5 Sec.  2D
* Control Circuit Pump Module -J538- 1.10 A
High . Refer to FUEL
Engine speed > 80
PUMP RPM
ELECTRICAL,
TESTING
P0261 Cylinder 1 Injector -- Check the fuel Signal current <  Injection 0.5 Sec.  2D
* Circuit Low injectors -N30-. 2.1 A valve,
Refer to FUEL Commanded Actual T
INJECTORS, on calculate
CHECKING. > TPS 1
 Engine speed,
> 80 RPM calculate
 High side
signal current,
> 4.20 A
P0262 Cylinder 1 Injector -- Check the fuel Signal current >  Injection 0.5 Sec.  2D
* Circuit High injectors -N30-. 14.70 A valve,
Refer to FUEL Commanded
INJECTORS, on
CHECKING.
 Engine speed,
> 80 RPM
INJECTORS, on
CHECKING.
 Engine speed,
> 80 RPM
 High side
signal current,
> 4.20 A
INJECTORS, on
CHECKING.
 Engine speed,
> 80 RPM
INJECTORS, on
CHECKING.
 Engine speed,
> 80 RPM
 High side
signal current,
> 4.20 A
P0268 Cylinder 3 Injector -- Check the fuel Signal current > 0.5 Sec.
* Circuit High injectors -N32-. 14.70 A  Injection  2D

Refer to FUEL valve,
INJECTORS, Commanded
CHECKING. on
 Engine speed,
> 80 RPM
P0270 Cylinder 4 Injector -- Check the fuel Low side signal  Injection 0.5 Sec.  2D
* Circuit Low injectors -N33-. current < 2.1 A valve,
INJECTORS, on
CHECKING.
 Engine speed,
> 80 RPM
 High side
signal current,
> 4.20 A
INJECTORS, on
CHECKING.
 Engine speed,
> 80 RPM
P0299 Turbocharger -- Check the charge Difference of set  Engine speed 6 Sec.  2D
* Underboost air system for proper boost pressure vs > 2200 - 2800
seal. Refer to the actual boost RPM
Repair Information. - pressure value >
- Check the Charge 150 hPa  Altitude <
Air Pressure sensor - 2700 m
G31-. Refer to  Difference of
CHARGE AIR set value
PRESSURE boost pressure
SENSOR/MAP vs basic boost
SENSOR, pressure value
CHECKING > 250 hPa
 Boost
pressure
control active
 Turbo charger
bypass valve
closed
Secondary
Malfunction Monitoring Frequency of
Diagnostic Parameters with
DTC Error Message Criteria and Time checks, MIL
Procedure Enable
Threshold Value Length Illum
Conditions
-- Check the
Spark plugs.--
Check the
intake system
for leaks.--
Check the
Fuel Pressure.
Refer to  Active
FUEL after
PRESSURE engine start
TEST --  Engine
Check fuel speed 440 -
 Emission
injectors - 6800 RPM
threshold 1st
N30, N31, IAT > -48°
interval 
N32, N33, -. C  1000
Misfire Rate
Refer to Rev.  2 DCY
P0300 Random Misfire (MR), > 3%  ECT > -
FUEL
* Detected  Catalyst 10.5°C
INJECTORS,  200  Immediate
CHECKING damage  Not in fuel Rev.
-- Check the misfire rate cutoff
Ignition Coils (MR), > 2% mode
with Power - 15%  Rough
Output Stage - road not
N70, N127, detected
N291, N292-.
 No internal
Refer to
CAN fault
IGNITION
COILS
WITH
POWER
OUTPUT
STAGE,
CHECKING.
 Time from
start, 0
Sec.
 IAT, >-48°
-- Check the C
Spark plugs. --
Check the  Time after
intake system engine
for leaks. -- start, Idle -
Check fuel 150 RPM
injectors -  Engine
N30, N31, torque,
N32, N33, -.  Emission >5.47-
Refer to threshold 1st 23.4%
FUEL interval  Camshaft

INJECTORS, Misfire Rate revolutions
CHECKING- (MR), > 3% 1
- Check the  Catalyst
Ignition Coils  Engine
damage speed
with Power misfire rate
Output Stage - range, 480-
(MR), > 2% 6800 RPM
N70, N127, - 15%
N291, N292-.  Fuel  1000
P0301 Cylinder 1 Misfire Refer to cutoff, Not Rev.  2 DCY
* Detected IGNITION active
COILS  ECT at  200  Immed.
WITH start, > -9° Rev.
POWER C
OUTPUT  If ECT at
STAGE, start < -99°
CHECKING. C wait
until actual
ECT >18°
C
 Time from
start, 0
Sec.
 IAT, > -
-- Check the 48° C
Spark plugs.--
for leaks.-- start, Idle -
 Emission 150 RPM
Check fuel threshold 1st
interval
N30, N31, torque, >  1000
Misfire Rate
5.47- Rev. 2 DCY
P0302 Cylinder 2 Misfire N32, N33, -. (MR), > 3% 
Refer to 23.4%
* Detected  Catalyst
FUEL  Camshaft  200  Immed.
INJECTORS, damage Rev.
revolutions
CHECKING- misfire rate
1
- Check the (MR), > 2%
- 15%  Engine
Ignition Coils speed
with Power range, 480-
Output Stage - 6800 RPM
N70, N127,
N291, N292-.  Fuel
Refer to cutoff, Not
IGNITION active
COILS  ECT at
WITH start, > -9°
POWER C
CHECKING. C wait
until actual
ECT > 18°
C
 Time from
start, 0
Sec.
-- Check the  IAT, > -
Spark plugs.-- 48° C
Check fuel 150 RPM
N30, N31, torque, >
N32, N33, -. 5.47-
 Emission
Refer to 23.4%
threshold 1st
FUEL
interval  Camshaft
INJECTORS,  1000
Misfire Rate revolutions
CHECKING- Rev.  2 DCY
P0303 Cylinder 3 Misfire (MR), > 3% 1
- Check the
* Detected  Catalyst Engine
Ignition Coils   200  Immed.
with Power damage speed Rev.
Output Stage - misfire rate range, 480-
N70, N127, (MR), > 2% 6800 RPM
N291, N292-. - 15%  Fuel
Refer to cutoff, Not
IGNITION active
COILS
 ECT at
WITH
start, > -9°
POWER
C
OUTPUT
STAGE,  If ECT at
CHECKING. start < -99°
C wait
until actual
ECT > 18°
C
 Time from
start, 0
Sec.
-- Check the  IAT, > -
Spark plugs.-- 48°C

Check fuel 150 RPM
injectors -
N30, N31,  Engine
N32, N33, -. torque, >
Refer to 5.47-
FUEL 23.4%
INJECTORS,  Emission  Camshaft
CHECKING- threshold 1st revolutions
- Check the interval 1
Ignition Coils Misfire Rate  1000
 Engine
P0304 Cylinder 4 Misfire with Power (MR), > 3% Rev.  2 DCY
speed
* Detected Output Stage -  Catalyst range 480-
N70, N127,  200  Immed.
damage 6800 RPM
N291, N292-. Rev.
misfire rate  Fuel cutoff
Refer to (MR), > 2% Not active
IGNITION - 15%
COILS  ECT at
WITH start > -9°
POWER C
CHECKING. C wait
until actual
ECT > 18°
C
-- Check the  Comparison
Engine Speed of counted
(RPM) Sensor teeth vs
Engine Speed
P0321 -G28-. Refer reference =
Input Circuit --- 0.5 Sec.  2 DCY
* to ENGINE incorrect
Performance
SPEED  Monitoring
SENSOR, reference
CHECKING. gap failure
-- Check the
Engine Speed
 Camshaft
(RPM) Sensor
Engine Speed signal > 3
P0322 -G28-. Refer
Input Circuit No  Engine --- 0.5 Sec.  2 DCY
* to ENGINE
Signal speed, no
SPEED
SENSOR, signal
CHECKING.
 Signal fault
counter
(combustion)
> 24
-- Check the
Knock
or
Sensors -G61,
P0324 Knock Control Engine speed 0
G66-. Refer to 0.5 Sec.  2 DCY
* System Error  Signal fault RPM
KNOCK
SENSOR 1, counter
CHECKING. (measuring
window) >
2.00
 Engine
speed, >
1000 RPM
 Lower
-- Check the threshold < - or for signal
70 V range check
Knock
Sensors -G61, ECT >
P0327 Knock Sensor 1 
G66-. Refer to or for signal range 40.5°C 2.5 Sec.  2 DCY
* Circuit Low Input check
KNOCK
SENSOR 1,  Engine
 Lower load >
CHECKING.
threshold < 0 22.734 -
- 2.1582 V 55.172%
 Engine
speed >
2000 RPM
 Engine
speed, >
1000 RPM
 Upper
or for signal
-- Check the threshold > range check
Knock 1.00 V
Sensors -G61,  ECT >
P0328 Knock Sensor 1
G66-. Refer to or for signal range 40.5°C 0.5 Sec.  2 DCY
* Circuit High Input
KNOCK check
 Engine
SENSOR 1,
CHECKING. load >
 > 29.0674 -
22.734 -
114.9023 V
55.172%
 Engine
speed >
2000 RPM
 Engine
speed
sensor, No
DTC
 Phase
sensor, No
DTC
 Cam
adaptation,
Active
 Engine
-- Check the Cam adaption speed
Camshaft values out of range sensor, No
Position DTC
(CMP) Sensor  > 20 °KW  Phase
Camshaft Position -G40-. Refer  < -20 °KW sensor, No
P0340 2 Sec.  2 DCY
Sensor Circuit to  Difference DTC
CAMSHAFT of adapted  Camshaft
POSITION and actual adjustment,
SENSOR, values > 9 ° No DTC
CHECKING. KW  Engine
start,
Completed
 Cam
adaptation,
Completed
 Camshaft
in ref pos.
for > 2 sec.
-- Check the
Camshaft
Position
(CMP) Sensor
Camshaft Position  Signal
P0341 -G40-. Refer
Sensor Circuit pattern --- 0.5 Sec.  2 DCY
* to
Performance incorrect
CAMSHAFT
POSITION
SENSOR,
CHECKING.
-- Check the
Camshaft
Position  Signal
Camshaft Position (CMP) Sensor
P0342 voltage low
Sensor Circuit -G40-. Refer --- 0.5 Sec.  2 DCY
*  Crankshaft
Low Input to
CAMSHAFT signals = 8
POSITION
SENSOR,
CHECKING.
-- Check the
Camshaft
Position
(CMP) Sensor  Signal
Camshaft Position
P0343 -G40-. Refer voltage high
Sensor Circuit --- 0.5 Sec.  2 DCY
* to  Crankshaft
High Input
CAMSHAFT signals = 8
POSITION
SENSOR,
CHECKING.
-- Check the
Ignition Coils
with Power
Output Stage -
 Signal
N70-. Refer to
Ignition Coil A current -0.25  Engine
P0351 IGNITION
Primary/Secondary to -2.0 mA speed > 0.5 Sec.  2 DCY
* COILS
Circuit  Internal 680 RPM
WITH
POWER check failed
OUTPUT
STAGE,
CHECKING.
-- Check the
Ignition Coils
with Power
Output Stage -
 Signal
N127-. Refer
Ignition Coil B current -0.25  Engine
P0352 to IGNITION
* COILS
WITH
POWER check failed
OUTPUT
STAGE,
CHECKING.
-- Check the
Ignition Coils
with Power
Output Stage -
 Signal
N291-. Refer
Ignition Coil C current -0.25  Engine
P0353 to IGNITION
* COILS
WITH
POWER check failed
OUTPUT
STAGE,
CHECKING.
-- Check the
Ignition Coils
with Power
Output Stage -
 Signal
N292-. Refer
Ignition Coil D current -0.25  Engine
P0354 to IGNITION
* COILS
WITH
POWER check failed
OUTPUT
STAGE,
CHECKING.
Secondary
Malfunction Monitoring Frequency of
Error Diagnostic Parameters with
DTC Criteria and Time checks, MIL
Message Procedure Enable
Threshold Value Length Illum
Conditions
Front:
 Time after
engine start
> 0 Sec.
 Delta
exhaust
mass flow <
27.1 kg/h
 Exhaust gas
mass flow,
lower range
25.0 - 80.0
kg/h
 Exhaust gas
mass flow
upper range
60.0 - 160.0
kg/h
 Modeled
exhaust gas
temp, lower
range 490 -
660°C
 Modeled
Front: exhaust gas
-- Check the temp, upper
Three Way  Oxygen range 640 -
Catalytic storage 780°C

Converter (TWC). capacity
 Engine
Refer to THREE (OSC) vs
WAY OSC of speed 1200 -
CATALYTIC borderline - 3520 RPM
CONVERTER, catalyst <  Number of
TWC 0.40 checks, 4

CHECKING. --  Front  O2S
Check the Heated catalyst< front/rear,
Oxygen Sensor 1.30 ready/no
(HO2S) -G39- . faults
 Main
Refer to
catalyst <  SAS, not
OXYGEN
1.20 active
SENSOR
BEFORE  No misfire
CATALYTIC Main:
CONVERTER, Main:
 Oxygen
CHECKING--
Check the storage  Time after
Oxygen Sensor capacity engine start

(O2S) Behind (OSC) vs > 80 Sec.
Three Way OSC of
 Delta
Catalyst borderline
System Catalytic exhaust
Converter (TWC) catalyst <  Once/DCY
P0420 Efficiency mass flow < 50 Sec.
-G130-. Refer to 0.40
Below 30 kg/h  2 DCY
OXYGEN  Front
Threshold  Exhaust gas
SENSOR catalyst<.90
mass flow,
BEHIND  While value lower range
THREE WAY for front 25.0 - 80.0
CATALYTIC catalyst < kg/h
CONVERTER, 2.00
 Exhaust gas
CHECKING.
mass flow
upper range
60.0 - 160.0
kg/h
 Modeled
exhaust gas
temp, lower
range 435 -
660°C
 Modeled
exhaust gas
temp, upper
range 530 -
740°C
 Engine
speed 1200 -
- 3520 RPM
 Number of
checks, 4
 O2S
front/rear,
ready/no
faults
 SAS, not
active
 No misfire
 EVAP
purge flow
-- Check the integral 25 -
Evaporative 120 g
Emission (EVAP)  Integrated
Canister Purge air mass 5.5
Regulator Valve - - 6.5 kg
N80-. Refer to  Engine
EVAPORATIVE speed = idle
EMISSION  Deviation <
Evaporative 0.07%  Engine
CANISTER
Emission lambda speed
P0441 PURGE  Once/DCY
System controller deviation 80 25 Sec.
* REGULATOR  2 DCY
Incorrect and 35% RPM
VALVE,
Purge Flow idle  ECT > 65.3°
CHECKING.--
Check the Leak controller C or
Detection Pump substitute
(LDP) -V144-. 80.3°C
Refer to LEAK  IAT > 3.8°C
DETECTION  Altitude <
PUMP, 2700 m
CHECKING.
 Lambda
control,
closed loop
 Time after
engine start
5 - 65530
Sec.
 ECT 3.8 -
120°C
-- Check the  ECT at start
EVAP System, 3.8 - 50.3°C
for Leaks. Refer  Engine off
to EVAP time >

SYSTEM, 21600 Sec.
CHECKING  Ambient air
FOR LEAKS-- temp 3.8 -
Check the 59.3°C
Evaporative
Emission (EVAP)  Ambient air
Canister Purge temp drop
Regulator Valve - after start <
N80-. Refer to 7.5°K
EVAPORATIVE  Intake
manifold
Evaporative EMISSION vac. > -2560
Emission CANISTER hPa
System PURGE Time for pressure
P0442 REGULATOR drop < 1.55 - 1.75  Altitude < 180 Sec.
Leak  2 DCY
* once/DCY
Detected VALVE, Sec. 2700 m
(Small CHECKING.--  Veh. speed
Leak) Check the Leak >= 0
Detection Pump
(LDP) -V144-.  Veh speed
Refer to LEAK once > 40
DETECTION km/h
PUMP,  Any drive
CHECKING. gear
 Restart temp
diff. > 0 °K
 Purge valve
closed
 LDP active
-- Check the
Evaporative
Emission (EVAP)
Evaporative
Canister Purge  EVAP
Emission
Regulator Valve - purge valve
System
N80-. Refer to Commanded
P0444 Purge Signal voltage >
EVAPORATIVE Off 0.5 Sec.  2 DCY
* Control 4.70 - 5.40 V
EMISSION  Engine
Valve
CANISTER speed > 80
Circuit
PURGE RPM
Open
REGULATOR
VALVE,
CHECKING.
 Time after
engine start
5 - 65530
Sec.
 ECT 3.8 -
120°C
 ECT at start
3.8 - 50.3°C
-- Check the
 Engine off
EVAP System,
time >
for Leaks. Refer
21600 Sec.
to EVAP
SYSTEM,  Ambient air
CHECKING temp 3.8 -
FOR LEAKS-- 59.3°C
Check the  Ambient air
Evaporative temp drop
Emission (EVAP) after start <
Evaporative
Canister Purge 12.5°K
Emission
Regulator Valve - Intake
System 
N80-. Refer to manifold
Leak Time for pressure
P0455 EVAPORATIVE vac. > -2560 120 Sec.  2 DCY
Detected drop < 0.95 Sec.
EMISSION hPa
(gross
CANISTER
leak/no  Altitude <
PURGE
flow) 2700 m
REGULATOR
VALVE,  Veh. speed
CHECKING.-- >= 0
Check the Leak  Veh speed
Detection Pump once > 40
(LDP) -V144-. km/h
Refer to LEAK
 Any drive
DETECTION
gear
PUMP,
CHECKING.  Restart temp
diff. > 0 °K
 Purge valve
closed
 LDP active
 Time after
engine start
5 - 1000
Sec.
 ECT 3.8 -
120°C
 ECT at start
-- Check the 3.8 - 50.3°C
EVAP System,  Engine off
for Leaks. Refer time >
to EVAP 21600 Sec.

SYSTEM,  Ambient air
CHECKING temp 3.8 -
FOR LEAKS-- 59.3°C
Check the
Evaporative  Ambient air
Emission (EVAP) temp drop
Canister Purge after start <
Regulator Valve - 4.5°K
N80-. Refer to  Intake
EVAPORATIVE manifold
EMISSION vac. > -2560
CANISTER hPa
Evaporative PURGE  Intake
Emission REGULATOR manifold
System VALVE,  Time for vac. > -2560 180 Sec.
P0456 pressure
Leak CHECKING. -- hPa  2 DCY
* drop, < 4.5 once/DCY
Detected Check the Leak  Altitude <
(very small Detection Pump - 6.0 Sec.
2700 m
leak) (LDP) -V144-.
Refer to LEAK  Veh. speed
DETECTION >= 0
PUMP,  Veh speed
CHECKING. once > 40
km/h
 Any drive
gear
 Restart temp
diff. > 0 K
 Purge valve
closed
 LDP active
-- Check the
Check the
Evaporative
Evaporative Emission (EVAP)
 EVAP
Emission Canister Purge
purge valve,
System Regulator Valve -
Commanded
P0458 Purge N80-. Refer to Signal voltage
off 0.5 Sec.  2 DCY
* Control EVAPORATIVE 0.00 - 3.25 V
Valve EMISSION  Engine
Circuit CANISTER speed > 80
Low PURGE RPM
REGULATOR
VALVE,
CHECKING.
-- Check the
Check the
Evaporative
Evaporative Emission (EVAP)
 EVAP
Emission Canister Purge
purge valve,
System Regulator Valve -
Commanded
P0459 Purge N80-. Refer to Signal current >
On 0.5 Sec.  2 DCY
* Control EVAPORATIVE 2.20 A
Valve EMISSION  Engine
Circuit CANISTER speed > 80
High PURGE RPM
REGULATOR
VALVE,
CHECKING.
Malfunction Secondary
Monitoring Frequency
Diagnostic Criteria and Parameters with
DTC Error Message Time of checks,
Procedure Threshold Enable
Length MIL Illum
Value Conditions
Out of range low:
 Time after
engine start
> 0 Sec.
 Driver
torque
demand -
none
-- Check the  Veh speed 0
Throttle Valve km/h
Control Module
Cold Start Idle Air -J338-. Refer to  Altitude <
P050A 2700 m  2
Control System THROTTLE 4.0 Sec.
* Out of range DCY
Performance VALVE  IAT > -48.0
low:
CONTROL °C
MODULE,  Catalyst
 Engine
CHECKING. heating
speed
deviation active
< -80  Man. trans
RPM engine load
< 40 - 75%
Out of range
high: Out of range high:
 Engine  Time after

speed engine start
deviation > 0 Sec.

> 80 RPM  Driver
torque
demand -
none
 Veh speed 0
km/h
 Altitude <
2700 m
 IAT > -
48.0°C
 Catalyst
heating
active
 Time during
catalyst
heating > 10
This code will Sec.
set due to poor Difference  Commanded
fuel quality or between spark retard
fuel that has commanded during
P050B Cold Start Ignition  2
aged. Drain the spark timing and catalyst 8 Sec.
* Timing Performance DCY
fuel from the actual spark heating <
vehicle and timing > 20 to 70%
replace with 50%  Catalyst
fresh gasoline. heating
active.
 Idle speed
active.
 Engine
torque >
-- Check vehicle 150 Nm
speed signal.
P0501 Vehicle Speed Sensor VSS signal < 4  Engine  2
Refer to SPEED 5 Sec.
* Range/Performance km/h speed > DCY
SIGNAL,
CHECKING. 2500 RPM
 VSS no
fault
-- Check vehicle
speed signal.
Vehicle Speed Sensor Vehicle speed >  2
P0503 Refer to SPEED --- 0.5 Sec.
Intermittent/Erratic/High 290 km/h DCY
SIGNAL,
CHECKING.
 Driver
torque
demand -
none.
 Vehicle
speed 0
MPH
 Altitude <
-- Check the 2700 m
Throttle Valve  IAT, > -
Control Module 48.0°C
Idle Air Control System -J338-. Refer to Idle speed  ECT, > -
P0506  2
RPM Lower Than THROTTLE Deviation > 80 10.5°C 4 Sec.
* DCY
Expected VALVE RPM  Time after
CONTROL engine start
MODULE, > 0 Sec.
CHECKING.
 External
torque
request not
demanded
 Manual
trans engine
load < 15 -
40%
 Driver
torque
demand -
none.
-- Check the  Vehicle
Throttle Valve speed 0
Control Module MPH
Idle Air Control System -J338-. Refer to Idle speed
P0507  Altitude <  2
RPM Higher Than THROTTLE Deviation < -80 8 Sec.
* 2700 m DCY
Expected VALVE RPM
CONTROL  IAT, > -
MODULE, 48.0°C
CHECKING.  ECT, > -
10.5°C
 Time after
engine start
> 0 Sec.
Incorrect oil
viscosity can set
the code. See if  Time after
oil change was engine start
recently >= 15 Sec.

performed  Engine
(possibly using speed >= 0
wrong viscosity  Difference RPM
oil). -- Check the between
Cold Start Camshaft Camshaft  Modeled oil
P052A target temp >= - 5 Sec.
Position Timing Over- Adjustment  2
* position 13°C
Advanced Valve 1 -N205-. DCY
vs actual
Refer to  Catalyst
position:
CAMSHAFT > 6 °CRK heating
ADJUSTMENT active
VALVE 1,
CHECKING.
 Time after
 Difference engine start
between 3 Sec.
-- Check the target  Fuel cutoff
Fuel Pressure. pressure not active
P053F Cold Start Fuel Pressure vs actual  2
Refer to FUEL  Time after
3 Sec.
* Performance pressure: DCY
PRESSURE fuel cutoff >
TEST > 1.50
MPa OR 3 Sec.
< -1.50  Catalyst
MPa heating
active
Monitoring Frequency of
DTC Error Message Time checks, MIL
Length Illum
Value Conditions
-- Replace the
Engine
Control
P0606 ECM Processor Module ECM internal Key on or engine  2 DCY
* Fault (ECM) -J623- check failure running  2 Sec.
. Refer to the  Continuous
Repair
Information.
-- Replace the
Internal Engine
Control Control
P062B Module Fuel Module Internal logic Engine speed >
1.1 Sec.  2 DCY
* Injector (ECM) -J623- failure 80 RPM
Control . Refer to the
Performance Repair
Information.
 Time to
close to
reference
point >
0.56 Sec.
and  Ignition on
-- Check the  Engine
Throttle  Reference speed 0
Valve Control point RPM
Module - 2.88%  IAT > 5.25°
Throttle
J338-. Refer  Time to C
P0638 Actuator
to close  Vehicle 5 Sec.  2 DCY
* Control
THROTTLE below speed 0
Performance
VALVE reference km/h
CONTROL point, +
MODULE,  ECT > 5.3 °
2.49%, >
CHECKING. C
0.56 Sec.
 IAT > 5.3 °
 Duty
C
cycle >
80%
 ECM
power
stage no
failure
Check for any
sensor voltage
faults, and
diagnose any
sensor voltage
codes first. If
Sensor
none are set:-- Signal voltage
P0641 Reference
Replace the deviation > +/- --- 0.5 Sec.  2 DCY
* Voltage A
Engine 0.3 V
Circuit
Control
Module
(ECM) -J623-
. Refer to the
Repair
Information.
Check for any
sensor voltage
faults, and
diagnose any
sensor voltage
codes first. If
none are set:--

Replace the
Engine
Sensor
Control Signal voltage
P0651 Reference
Module deviation > +/- --- 0.5 Sec.  2 DCY
* Voltage B
(ECM) -J623- 0.3 V
Circuit
. Refer to the
Repair
Information.
Check for any
actuator
voltage faults,
and diagnose
any actuator
voltage codes
first. If none
 Relay,
are set:--
commanded
Actuator Check the
P0657 Signal voltage, off
Supply Voltage Engine 0.5 Sec.  2 DCY
* > 4.4 - 5.6 V  Engine
A Circuit Open Control
Module speed > 80
(ECM) Power RPM
Supply Relay
-J271- . Refer
to
VOLTAGE
SUPPLY,
CHECKING.
Check for any
actuator
voltage faults,
and diagnose
any actuator
voltage codes
first. If none
 Relay,
are set:--
commanded
Actuator Check the
P0658 Signal voltage, off
Supply Voltage Engine 0.5 Sec.  2 DCY
* < 2.15 - 3.25 V  Engine
A Circuit Low Control
Module speed > 80
(ECM) Power RPM
Supply Relay
-J271- . Refer
to
VOLTAGE
SUPPLY,
CHECKING.
Check for any

actuator
voltage faults,
and diagnose
any actuator  Relay,
voltage codes commanded
first. If none on
are set:--  Engine
Actuator Check the speed > 80
P0659 Signal current >
Supply Voltage Engine RPM 0.5 Sec.  2 DCY
* 1.1 A
A Circuit High Control  Battery
Module voltage test
(ECM) Power counter,
Supply Relay 9.04-16 V >
-J271- . Refer 3
to
VOLTAGE
SUPPLY,
CHECKING.
Check for any
sensor voltage
faults, and
diagnose any
sensor voltage
codes first. If
Sensor
none are set:-- Signal voltage
P0697 Reference
Replace the deviation > +/- --- 0.5 Sec.  2 DCY
* Voltage C
Engine 0.3 V
Circuit Open
Control
Module
(ECM) -J623-
. Refer to the
Repair
Information.
Frequency
Diagnostic Criteria and Parameters Monitoring
DTC Error Message of checks,
Procedure Threshold with Enable Time Length
MIL Illum
Value Conditions
-- Check the  Pressure  Engine

Fuel Pressure control speed >
Sensor -G247-. activity > 600
Refer to FUEL 2.50 MPa RPM
PRESSURE  Fuel trim  EVAP
SENSOR, activity < purge
Fuel Rail Pressure CHECKING.- 0.80 adaption
Sensor - Check the  Difference < 22.0

Inappropriately Low Fuel Pressure between  Lambda
Regulator actual control
Valve -N276-. pressure closed
P12A1 Refer to FUEL  2
vs target loop 5 Sec.
* PRESSURE DCY
pressure -  Fuel
REGULATOR 16.38 to
VALVE, cutoff
16.38 not
CHECKING. MPa active
-- Check the  Pressure  Engine
Fuel Pressure control speed >
Sensor -G247-. activity < 600
Refer to FUEL -0.05 MPa RPM
PRESSURE  Fuel trim  EVAP
SENSOR, activity > purge
CHECKING.- 1.65 adaption
Fuel Rail Pressure
P12A2 - Check the Difference < 22.0  2
Sensor  5 Sec.
* Fuel Pressure between  Lambda DCY
Inappropriately High
Regulator target control
Valve -N276-. pressure closed
Refer to FUEL and actual loop
PRESSURE pressure -  Fuel
REGULATOR 16.38 to
VALVE, cutoff
16.38 not
CHECKING. MPa active
 Engine
speed >
600
 Fuel trim RPM
-- Check the activity.90
 EVAP
Fuel Pressure to 1.15
purge
Regulator  Pressure adaption
Fuel Rail Pump Valve -N276-. control
P12A4 < 22.0  2
Control Valve Stuck Refer to FUEL activity < 5 Sec.
*  Lambda DCY
Closed PRESSURE -6 MPa
REGULATOR control
 System closed
VALVE, Deviation
CHECKING. loop
< 16.38
 Fuel
MPa
cutoff
not
active
Check for
related TSB's.
If none apply;
check the
power and
ground inputs
to the ECM
BEFORE
replacing ECM.
Lack of ignition  Key on
off power after
supply will ECM
cause the timer after run
to stop. Refer to Difference time
the Wiring between engine active
P150A Engine Off Timer Diagrams for off time and  Key on  2
6.0 Sec.
* Performance power and ECM after run during DCY
ground time < -12 Sec. ECM
locations to the or > 12 Sec. after run
ECM. If power time
and grounds are active
present at the  CAN
ECM; -- active
Replace the
Engine Control
Module (ECM)
-J623-. Refer to
the Repair
Information.
Information
code only.
Crash Fuel Shut-Off After vehicle is  2
P1609 Airbag activated --- 0 Sec.
Was Deployed properly DCY
repaired, erase
code.
Frequency
Diagnostic Criteria and Parameters with Monitoring
DTC Error Message of checks,
Procedure Threshold Enable Time Length
MIL Illum
Value Conditions
-- Check the
Intake Manifold  Tumble
Runner Control flap
Intake Manifold (IMRC) Valve -  Signal commanded
P2008 N316-. Refer to voltage  2
Runner Control off 0.5 Sec.
* INTAKE 4.70 - DCY
Circuit Open  Engine
MANIFOLD 5.40 V
RUNNER speed > 80
CONTROL RPM
VALVE,
CHECKING.
-- Check the
Intake Manifold
Runner Control  Tumble
(IMRC) Valve - flap
 Signal
Intake Manifold N316-. Refer to commanded
P2009 voltage  2
Runner Control INTAKE off 0.5 Sec.
* 0.0 to DCY
Circuit Low MANIFOLD  Engine
RUNNER 3.25 V
speed > 80
CONTROL RPM
VALVE,
CHECKING.
-- Check the
Intake Manifold
Runner Control  Tumble
(IMRC) Valve - flap
Intake Manifold N316-. Refer to  Signal commanded
P2010  2
Runner Control INTAKE current > on 0.5 Sec.
* DCY
Circuit High MANIFOLD 2.20 A  Engine
RUNNER speed > 80
CONTROL RPM
VALVE,
CHECKING.
-- Check the
Intake Manifold
Runner Position
Sensor -G336-.
Intake Manifold Refer to
P2014 Signal voltage  2
Runner Position INTAKE --- 0.3 Sec.
* > 4.75 V DCY
Sensor Circuit MANIFOLD
RUNNER
POSITION
SENSOR,
CHECKING.
-- Check the
Intake Manifold
 Deviation
Runner Position
Sensor -G336-. runner
Intake Manifold flap
Refer to
P2015 Runner Position target Flap commanded  2
INTAKE 1.5 Sec.
* Sensor Circuit position on DCY
MANIFOLD
Performance vs actual
RUNNER
POSITION position
SENSOR, > 25%
CHECKING.
-- Check the
Intake Manifold
Runner Position
Sensor -G336-.
Refer to
Intake Manifold
INTAKE
P2016 Runner Position Signal voltage  2
MANIFOLD --- 0.3 Sec.
* Sensor Circuit < 0.25 V DCY
RUNNER
Low
POSITION
SENSOR,
CHECKING.
-- Check the
Camshaft
Adjustment  Camshaft
A Camshaft
Valve 1 -N205-. valve off
P2088 Position Actuator Signal voltage,  2
Refer to  Engine 0.5 Sec.
* Control Circuit < 0.0 - 3.25 V DCY
CAMSHAFT speed > 80
Low
POSITION RPM
SENSOR,
CHECKING.
-- Check the
Camshaft
Adjustment  Camshaft
A Camshaft
Valve 1 -N205-. valve on
P2089 Position Actuator Signal current  2
Refer to  Engine 0.5 Sec.
* Control Circuit > 2.2 A DCY
CAMSHAFT speed > 80
High
POSITION RPM
SENSOR,
CHECKING.
 Modeled
exhaust gas
temp 400 to
880°C
 Exhaust gas
mass flow
20 to 180
Post Catalyst Fuel Check for Deviation kg/h
P2096 2
Trim System Too exhaust leaks lambda control Exhaust 400 Sec. 
* ahead of the  DCY
Lean < -0.04 mass air
catalyst. --
Check Heated integral
Oxygen Sensor >.28 to 5 kg
(HO2S) -G130-  Lambda
behind Three control in
Way Catalytic closed loop,
Converter not at min
(TWC). Refer to or max
OXYGEN limit
SENSOR  O2S front

BEHIND ready, no
THREE WAY DTC
CATALYTIC
CONVERTER,  O2S rear
CHECKING ready, no
DTC
 O2 heaters
active
 Not in fuel
cutoff, SAI
off
 Catalyst
heating not
active
 Modeled
exhaust gas
temp 400 to
880 °C
 Exhaust gas
mass flow
20 to 180
kg/h
-- Check Heated
Oxygen Sensor  Exhaust
(HO2S) -G130- mass air
behind Three integral
Way Catalytic >.28 to 5 kg
Converter  Lambda
Post Catalyst Fuel Integral part of
P2097 (TWC). Refer to control in  2
Trim System Too lambda control 400 Sec.
* OXYGEN closed loop, DCY
Rich > 0.04
SENSOR not at min
BEHIND or max
THREE WAY limit
CATALYTIC  O2S front
CONVERTER, ready, no
CHECKING DTC
 O2S rear
ready, no
DTC
 O2 heaters
active
 Not in fuel
cutoff, SAI
off
 Catalyst
heating not
active
Secondary
Malfunction Monitoring Frequency
Error Diagnostic Parameters with
DTC Criteria and Time of checks,
Message Procedure Enable
Threshold Value Length MIL Illum
Conditions
 Duty cycle
> 80%
-- Check the Throttle  Deviation
Valve Control throttle
Throttle Module -J338-. value
Actuator Refer to angles vs.
P2101  2
Control THROTTLE calculated --- 5 Sec.
* DCY
Motor Circuit VALVE value 4 -
Performance CONTROL 50%
MODULE,  ECM
CHECKING. power
stage no
failure
-- Check the Throttle
Throttle Valve Control
Duty cycle > 80%
Actuator Module -J338-.
or deviation
Control Refer to
P2106 Internal check throttle value  2
System THROTTLE 0.2 Sec.
* failed angles vs. DCY
Forced VALVE
calculated value >
Limited CONTROL
4 - 50%
Power MODULE,
CHECKING.
-- Check the
Accelerator Pedal
Position Sensor 1 -
G79- /Accelerator
Pedal Position
Pedal
Sensor 2 -G185-.
Position
P2122 Refer to Signal voltage <  2
Sensor D --- 0.2 Sec.
* ACCELERATOR 0.61 V DCY
Circuit Low
PEDAL POSITION
Input
SENSOR
1/ACCELERATOR
PEDAL POSITION
SENSOR 2,
CHECKING.
-- Check the
Accelerator Pedal
Position Sensor 1 -
G79- /Accelerator
Pedal Position
Pedal Sensor 2 -G185-.
Position Refer to
P2123 Signal voltage >  2
Sensor D ACCELERATOR --- 0.2 Sec.
* 4.79 V DCY
Circuit High PEDAL POSITION
Input SENSOR
1/ACCELERATOR
PEDAL POSITION
SENSOR 2,
CHECKING.
-- Check the
Accelerator Pedal
Position Sensor 1 -
G79- /Accelerator
Pedal Position
Pedal
Sensor 2 -G185-.
Position
P2127 Refer to Signal voltage <  2
Sensor E --- 0.2 Sec.
Circuit Low
PEDAL POSITION
Input
SENSOR
1/ACCELERATOR
PEDAL POSITION
SENSOR 2,
CHECKING.
-- Check the
Accelerator Pedal
Position Sensor 1 -
G79- /Accelerator
Pedal Position
Pedal
Sensor 2 -G185-.
Position
P2128 Refer to Signal voltage >  2
Sensor E --- 0.2 Sec.
Circuit High
PEDAL POSITION
Input
SENSOR
1/ACCELERATOR
PEDAL POSITION
SENSOR 2,
CHECKING.
-- Check the
Accelerator Pedal
Position Sensor 1 -
G79- /Accelerator  Signal  Signal
Pedal Position voltage: voltage
Pedal Sensor 2 -G185-. Difference sensor 1 >
Position Refer to between 445.0 mv

Sensor D/E ACCELERATOR signal  Signal
Voltage PEDAL POSITION APP1 and voltage
P2138 Correlation SENSOR APP2 > sensor 2 >  2
0.26 Sec.
* 1/ACCELERATOR 0.17 - 0.70 445.0 mv DCY
PEDAL POSITION V
SENSOR 2,
CHECKING.
 Injection
valve,
commanded
 Signal on
-- Check the Fuel current, <
2.6 A  Engine
Fuel Injector injectors -N30, N31, speed >80
P2146 A Supply N32, N33-. Refer to RPM  2
or 0.5 Sec.
* Voltage FUEL DCY
Circuit Open INJECTORS, or
CHECKING.  Signal
current >
14.90 A  Low side
signal
current
>2.70 A
 Injection
valve,
commanded
 Signal on
-- Check the Fuel current, <
2.6 A  Engine
Fuel Injector injectors -N30, N31, speed >80
P2149 B Supply N32, N33-. Refer to RPM  2
or 0.5 Sec.
* Voltage FUEL DCY
Circuit Open INJECTORS, or
CHECKING.  Signal
current >
14.70 A  Low side
signal
current
>2.70 A
-- Check the Fuel
Pressure --. Refer to
FUEL PRESSURE
TEST If the fuel
pressure is out of
range: -- Check the
Fuel Pressure
Regulator Valve -  Number of
N276-. Refer to injections
FUEL PRESSURE after engine
REGULATOR start > 1200

VALVE,  Engine
CHECKING.-- speed 1200
Check the Fuel to 6000
Injectors -N30, N31, RPM
N32, N33-. Refer to
FUEL  Engine load
INJECTORS, 20 to 130%
P2177 System Too CHECKING.-- Adaptive value >  ECT > 63 °C  2
10 Sec.
* Lean Off Idle Check the Heated 28%  IAT < 90 °C DCY
Oxygen Sensor  O2 in closed
Before Catalytic loop
Converter -G39-.
Refer to OXYGEN
SENSOR BEFORE
CATALYTIC
CONVERTER,
CHECKING.
-- Check the Fuel

FUEL PRESSURE
TEST If the fuel
pressure is out of
range: -- Check the
Fuel Pressure
Regulator Valve -  Number of
N276-. Refer to injections
FUEL PRESSURE after engine
REGULATOR start > 1200
VALVE,  Engine
CHECKING. -- speed 1200
P2178 System Too Check the Fuel Adaptive value < to 6000  2
RPM 10 Sec.
* Rich Off Idle Injectors -N30, N31, -21% DCY
N32, N33, -. Refer to  Engine load
FUEL 20 to 130%
INJECTORS,  ECT > 63 °C
CHECKING.--
Check the Heated  IAT < 90 °C
Oxygen Sensor  O2 in closed
Before Catalytic loop
Converter -G39- .
Refer to OXYGEN
SENSOR BEFORE
CATALYTIC
CONVERTER,
CHECKING. --
Check the
Evaporative
Emission (EVAP)
Canister Purge
Regulator Valve -
N80-. Refer to
EVAPORATIVE
EMISSION
CANISTER
PURGE
REGULATOR
VALVE,
CHECKING.
 Begin of air
mass
integration
when engine
temp > 30 °
C
 ECT at start,
- 6.7 - 64.5 °
C
-- Check Engine
Coolant Temperature  Ambient air
(ECT) Sensor -G62-. temp -6.7 °C
Refer to ENGINE  Fuel cutoff
COOLANT not active
TEMPERATURE Cooling system and engine
SENSOR 1 OR 2 temperature too load 0 -
Cooling
P2181 CHECKING-- low after a 400%  2
System 1000 Sec.
* Check the Coolant sufficient mass  Delta DCY
Performance
Pump -V50- Refer to air flow integral ambient
the Repair 74 - 84 °C pressure <
Information.-- Check 1.5 kPa
the Coolant
Thermostat. Refer to  Integrated
the Repair air mass
Information. depending
on engine
temp at start
and ambient
air
temperature
3.2 - 23.8
kg/h
 Accumulated
fuel cutoff <
40 - 250 Sec.
At time of fault
decision
 Average
mass air
flow 20 -
154 kg/h
 Average veh.
speed 33.4 -
120 km/h
-- Check the Engine
Coolant Temperature
Engine
(ECT) Sensor -G83-.
Coolant
P2184 Refer to ENGINE ECT outlet > 141  2
Temperature --- 2 Sec.
* COOLANT °C DCY
Sensor 2
TEMPERATURE
Circuit Low
SENSOR 1 OR 2
CHECKING.
-- Check the Engine
Coolant Temperature
Engine
(ECT) Sensor -G83-.
Coolant
P2185 Refer to ENGINE ECT outlet < -43  2
Temperature --- 2 Sec.
* COOLANT °C DCY
Sensor 2
TEMPERATURE
Circuit High
SENSOR 1 OR 2
CHECKING.
-- Check the intake

system for leaks.--
Check the vacuum
lines for leaks--
Check the Fuel
FUEL PRESSURE
TEST If the fuel
Fuel System pressure is out of
P2187 Adaptation value  2
Too Lean At range: -- Check the  Number of 10 Sec.
* Fuel Pressure > 5.02% DCY
Idle injections
Regulator Valve - after engine
N276-. Refer to start > 1200
FUEL PRESSURE  Engine
REGULATOR speed 520 to
VALVE, 1240 RPM
CHECKING.--
Check the Fuel  Engine load
Injectors -N30, N31, 17 to 45%
N32, N33, -. Refer to  ECT > 63 °C
FUEL  IAT < 90 °C

INJECTORS,
CHECKING.--  O2 in closed
Check the Heated loop
Oxygen Sensor
Before Catalytic
Converter -G39-.
Refer to OXYGEN
SENSOR BEFORE
CATALYTIC
CONVERTER,
CHECKING.
-- Check the Fuel

FUEL PRESSURE
TEST If the fuel
pressure is out of
range: -- Check the
Fuel Pressure
Regulator Valve -
N276-. Refer to
FUEL PRESSURE
REGULATOR  Number of
VALVE, injections
CHECKING.-- after engine
Check the Fuel start > 1200
Injectors -N30, N31,  Engine
N32, N33, -. Refer to speed 520 to
Fuel System FUEL
P2188 Adaptation value 1240 RPM 10 Sec.  2
Too Rich At INJECTORS,
* < -5.02% DCY
Idle CHECKING.--  Engine load
Check the Heated 17 to 45%
Oxygen Sensor  ECT > 63 °C
Before Catalytic  IAT < 90 °C
Converter -G39-.
 O2 in closed
Refer to OXYGEN
loop
SENSOR BEFORE
CATALYTIC
CONVERTER,
CHECKING. --
Check the
Evaporative
Emission (EVAP)
Canister Purge
Regulator Valve -
N80-. Refer to
EVAPORATIVE
EMISSION
CANISTER
PURGE
REGULATOR
VALVE,
CHECKING.
 Modeled
exhaust gas
temp 450 -
850 °C
 Delta engine
load < 35%
 Exh. gas
mass flow 14
- 300 kg/h
 Exhaust
mass air
integral 0.28
-- Check the Heated - 5.0kg
Oxygen Sensor  Lambda
O2 Sensor  Delta
(HO2S) -G39-. Refer control, 2nd
Signal lambda of
P2195 to OXYGEN lambda 2
Biased/Stuck 2nd lambda 400 Sec.
* SENSOR BEFORE control, DCY
Lean Bank 1, control
CATALYTIC closed loop
Sensor 1 loop > 0.06
CONVERTER,  O2S front,
CHECKING rear and
heaters ready
- no fault
 Fuel cutoff,
catalyst
heating, SAI
- not active
 1st lambda
control loop
not at min or
max
 2nd lambda
control loop
active
 Modeled
exhaust gas
temp 450 -
850 °C
 Delta engine
load < 35%
 Exh. gas
mass flow 14
- 300 kg/h
 Exhaust
mass air
integral 0.28
- 5.0kg
 Lambda
-- Check the Heated control, 2nd
Oxygen Sensor  Delta lambda
O2 Sensor control,
(HO2S) -G39-. Refer lambda of
Signal closed loop
P2196 to OXYGEN 2nd lambda 2
Biased/Stuck 400 Sec.
* SENSOR BEFORE control  O2S front, DCY
Rich - Bank
CATALYTIC loop < - rear and
1, Sensor 1
CONVERTER, 0.06 heaters ready
CHECKING - no fault
 Fuel cutoff,
catalyst
heating, SAI
- not active
 1st lambda
control loop
not at min or
max
 2nd lambda
control loop
active
 Engine
-- Check the Heated speed, <
Oxygen Sensor 2700 RPM
O2 Sensor (HO2S) -G39-. Refer  Engine load
Bank 1 to OXYGEN < 60%
Sensor 1 SENSOR BEFORE  Heater duty
Signal CATALYTIC Delta O2S signal cycle, 20 - 15 Sec. 2
P2231 CONVERTER,
Circuit front > 190 uA 80% DCY
Shorted to CHECKING--
Heater Check the Heated  Modeled
Circuit Oxygen Sensor exhaust gas
(HO2S) -G39-. Refer temp < 800.1
to OXYGEN °C
SENSOR HEATER  lambda 0.95
BEFORE - 1.05
CATALYTIC  Heater
CONVERTER, control,
CHECKING. closed loop,
no fault
 O2S ceramic
temp, 715°C
 O2S signal
front 1.493  Lambda
- 1.507 V control,
Closed loop
OR  Mass air
integral 0.8
-- Check the Heated  O2S signal kg
O2 Sensor Oxygen Sensor front <  Lambda set
Positive (HO2S) -G39-. Refer 1.7002 V value 0.97 -
Current to OXYGEN  Fuel cutoff 1.03
P2237 1.5 Sec. to  2
Control SENSOR HEATER < 3 sec.  Electrical
* 5 Sec. DCY
Circuit Open BEFORE adjustment,
Bank 1, CATALYTIC OR Not active
Sensor 1 CONVERTER,
CHECKING.  Heater
 O2S signal control
front 1.50 - active
1.51 V
 EVAP purge
 Delta valve ready,
lambda no fault
controller >
0.10  Lambda
modulation
> 0.02
 O2S signal
front < 0.30
-- Check the Heated V and
O2 Sensor Oxygen Sensor Internal
Reference (HO2S) -G39-. Refer resistance >
P2243 Voltage to OXYGEN 1000 Ohm  Heater
3 Sec.  2
* Circuit Open SENSOR BEFORE control
 O2S signal DCY
Bank 1, CATALYTIC active
front > 3.25
Sensor 1 CONVERTER, V and
CHECKING Internal
resistance >
1000 Ohm
-- Check the Heated  Modeled

O2 Sensor Oxygen Sensor exhaust gas
Negative (HO2S) -G39-. Refer Front O2S signal temp < 700 °
Current to OXYGEN 1.47 to 1.53 V C
Control SENSOR HEATER and internal  No fuel

Circuit Open BEFORE resistance > 1000 cutoff > 2
P2251 Bank 1 CATALYTIC ohms Sec.  2
25 Sec.
* Sensor 1 CONVERTER,
 Heater DCY
CHECKING.
control
active
 Mass air
flow 25 to
-- Check the Heated 150 kg/h
Oxygen Sensor  O2S signal  Modeled
(HO2S) -G130-. rear < 0.63 exhaust gas
O2 Sensor
Refer to OXYGEN - 0.64 V temp. > 350
P2270 Signal Stuck  2
SENSOR BEHIND  Enrichment °C 115 Sec.
* Lean Bank 1 DCY
THREE WAY after stuck  O2S rear
Sensor 2
CATALYTIC lean readiness >
CONVERTER, 27.90% 30 Sec.
CHECKING
 2nd lambda
control in
closed loop.
 Mass air
flow 25 to
-- Check the Heated 150 kg/h
Oxygen Sensor  O2S signal  Modeled
(HO2S) -G130-. rear > 0.63 exhaust gas
O2 Sensor
Refer to OXYGEN - 0.64 V temp. > 350
P2271 Signal Stuck  2
SENSOR BEHIND  Enleanment °C 115 Sec.
* Rich Bank 1 DCY
THREE WAY after stuck  O2S rear
Sensor 2
CATALYTIC rich readiness >
CONVERTER, 14.99% 30 Sec.
CHECKING
 2nd lambda
control in
closed loop.
 Time after
engine start
> 60 Sec.
 Engine load
< 40%
 Mass air
flow <
6553.50 kg/h
Check for air leaks  ECT > 49.50
between MAF and °C
throttle body, oil fill  IAT < 99.80
cap not seated or oil °C

dipstick not seated in  Lambda
tube. Also any control value
engine gaskets that >.95
can cause additional
air to enter the  Lambda set
crankcase can set value.95 -
this fault. If a 1.05
vacuum leak or  Threshold  Veh speed <
Intake Air crankcase seal is at to detect a 1 km/h
P2279 23 Sec.  2
System Leak cause, the idle may defective
 Lambda DCY
be rough or unstable. system >
control
1.33 - 1.60
active
 Engine
speed - idle
 Altitude <
2700 m
 O2S front -
no fault
 Difference
-- Check the Fuel between
Pressure Regulator target
Valve -N276-. Refer pressure vs
Fuel Pressure actual  Time after
P2293 to FUEL  2
Regulator 2 pressure: > engine start 3.5 Sec.
* PRESSURE DCY
Performance 1.50 MPa 10 Sec.
REGULATOR
VALVE,  OR
CHECKING.  < -1.50
MPa
-- Check the Fuel  Signal
voltage  Fuel control
Pressure Regulator
1.40 - 3.20 valve,
Fuel Pressure Valve -N276-. Refer
V Commanded
P2294 Regulator 2 to FUEL  2
Off 1 Sec.
* Control PRESSURE  OR DCY
Circuit REGULATOR  Fuel pump,
 Signal Commanded
VALVE, pattern
CHECKING. On
incorrect
-- Check the Fuel

Fuel Pressure Pressure Regulator  Fuel control
P2295 Regulator 2 Valve -N276-. Refer Signal voltage valve,  2
to FUEL 1 Sec.
* Control 1.40 - 3.20 V Commanded DCY
Circuit Low PRESSURE Off
REGULATOR
VALVE,
CHECKING.
-- Check the Fuel
Pressure Regulator
Fuel Pressure Valve -N276-. Refer  Fuel control
P2296 Regulator 2 to FUEL Signal voltage > valve,  2
1 Sec.
* Control PRESSURE 3.20 V Commanded DCY
Circuit High REGULATOR On
VALVE,
CHECKING.
Malfunction
Secondary
Criteria Frequency
Diagnostic Parameters Monitoring Time
DTC Error Message and of checks,
Procedure with Enable Length
Threshold MIL Illum
Conditions
Value
-- Check the
Ignition Coils
with Power
Output Stage
-N70-. Refer
 Engine
to Signal
P2300 Ignition Coil A Primary speed  2
IGNITION current > 0.5 Sec.
* Control Circuit Low > 680 DCY
COILS 24.0 mA
WITH RPM
POWER
OUTPUT
STAGE,
CHECKING.
-- Check the
Ignition Coils
with Power
Output Stage
-N70-. Refer
 Engine
to Signal
P2301 Ignition Coil A Primary speed  2
IGNITION current > 5.1 0.5 Sec.
* Control Circuit High > 680 DCY
COILS - 7.0 mA
WITH RPM
POWER
OUTPUT
STAGE,
CHECKING.
-- Check the
Ignition Coils
with Power
Output Stage
-N127-. Refer  Engine
to speed
IGNITION > 680
COILS RPM
Signal
P2303 Ignition Coil B Primary WITH  2
current > 0.5 Sec.
* Control Circuit Low POWER DCY
24.0 mA
OUTPUT
STAGE,
CHECKING.
-- Check the
Ignition Coils
with Power
Output Stage
-N127-. Refer
to Signal  Engine
P2304 Ignition Coil B Primary speed  2
IGNITION current > 5.1 0.5 Sec.
COILS - 7.0 mA
WITH RPM
POWER
OUTPUT
STAGE,
CHECKING.
-- Check the
Ignition Coils
with Power
Output Stage
-N291-. Refer
P2306 Ignition Coil C Primary speed  2
COILS 24.0 mA
WITH RPM
POWER
OUTPUT
STAGE,
CHECKING.
-- Check the
Ignition Coils
with Power
Output Stage
-N291-. Refer
P2307 Ignition Coil C Primary speed  2
IGNITION voltage > 5.1 0.5 Sec.
COILS - 7.0 mA
WITH RPM
POWER
OUTPUT
STAGE,
CHECKING.
-- Check the
Ignition Coils
with Power
Output Stage
-N292-. Refer
P2309 Ignition Coil D Primary speed  2
COILS 24.0 mA
WITH RPM
POWER
OUTPUT
STAGE,
CHECKING.
-- Check the
Ignition Coils
with Power
Output Stage
-N292-. Refer
P2310 Ignition Coil D Primary speed  2
IGNITION voltage > 5.1 0.5 Sec.
COILS - 7.0 mA
WITH RPM
POWER
OUTPUT
STAGE,
CHECKING.
Monitoring Frequency of
DTC Error Message Time checks, MIL
Length Illum
Value Conditions
-- Check the
Leak Detection  LDP
Evaporative
Pump (LDP) - Commanded
Emission System Signal
P2400 V144-. Refer to off
Leak Detection voltage > 4.7 0.5 Sec.  2 DCY
* LEAK  Engine
Pump Control - 5.4 V
DETECTION speed, 80
Circuit/Open
PUMP, RPM
CHECKING.
-- Check the  LDP

Evaporative
Leak Detection Commanded
Emission System Signal
P2401 Pump (LDP) - Off
Leak Detection voltage > 0.5 Sec.  2 DCY
* V144-. Refer to  Engine
Pump Control 2.74 - 3.26 V
LEAK speed, 80
Circuit Low
DETECTION RPM
PUMP,
CHECKING.
Signal
-- Check the current > 1.1
Leak Detection A or (for
Evaporative
Pump (LDP) - 2012) signal
Emission System  LDP
P2402 V144-. Refer to voltage at
Leak Detection Commanded 0.5 Sec.  2 DCY
* LEAK LDP current
Pump Control On
DETECTION measuring
Circuit High
PUMP, resistor >
CHECKING. 4.00 to 1.80
V
 Time after
engine start
5.0 - 65530
 ECT 3.8 -
120 °C
 ECT at start
3.8 - 50.3 °
C
 Engine off
time >
21600
 Altitude <
-- Check the 2700 m
Leak Detection  Integrated
Evaporative
Pump (LDP) - purge flow
Emission System Low signal
V144-. Refer to 12.1 g  Once/DCY
P2403 Leak Detection voltage >.5 0 Sec.
LEAK  Restart temp  2 DCY
Pump Sense Sec.
DETECTION diff > 0 °K
Circuit/Open
PUMP,
CHECKING.  Veh speed
>= 0 km/h
 Veh speed
once > 40
km/h
 Any drive
gear
 EVAP
purge valve
ready, no
faults
 LDP
commanded
off
 Time after
engine start
5.0 - 65530
 ECT 3.8 -
120 °C
 ECT at start
3.8 - 50.3 °
C
 Engine off
time >
21600
 Ambient air
temp 3.8 -
59.3 °C
-- Check the  Altitude <
Leak Detection 2700 m
Evaporative  High
Pump (LDP) -
Emission System signal  Integrated
V144-. Refer to  Once/DCY
P2404 Leak Detection voltage purge flow 35 Sec.
LEAK  2 DCY
Pump Sense > 30.4 12.1 g
DETECTION
Range/Performance Sec. Restart temp
PUMP, 
CHECKING. diff > 0 °K

 Veh speed
>= 0 km/h
 Veh speed
once > 40
km/h
 Any drive
gear
 EVAP
purge valve
ready, no
faults
 LDP
commanded
off
Threshold 1
 Lambda set
 Signal value 1
voltage  Fuel cut off,
3.1 - Not active
-- Check the 4.81 V  Heater
Heated Oxygen  O2S control,
Sensor (HO2S) signal closed loop
-G39-. Refer to 2.5 -  SAI not

OXYGEN 3.2 V active
SENSOR
BEFORE  O2S
Threshold 2
CATALYTIC ceramic
O2 Sensor Exhaust CONVERTER, temp > 715
P2414  Signal
Sample Error Bank CHECKING. °C 15 Sec.  2 DCY
* voltage
1, Sensor 1 2.5 V  If low fuel
signal then
 O2S
wait > 600
signal
Sec.
2.5 -
3.1 V
 ECT at
startup >= 4
°C
 Difference
between
ECT and
IAT at
startup <=
15 Kelvin
 AAT < 35
EVAP pump and > 4 °C
current  Altitude <=
Evaporative
difference 2700 m
Emission System
P2450 between  Time since 13.5 Sec.
Switching Valve  2 DCY
* reference engine start
Performance/Stuck
measurement >= 600 Sec.
Open
to idle <= 3
mA  Engine off
time >= 5
Sec.
 Vehicle
speed 0
km/h
 Within
ECM keep
alive time
after
ignition off
< 900 Sec.
 Modeled
exhaust
temp < 700
-- Check the °C
Heated Oxygen  O2S

Sensor (HO2S) ceramic
-G39-. Refer to temp, 715 °
OXYGEN C
O2 Sensor SENSOR  O2S  Fuel cut off,
P2626 Pumping Current BEFORE signal Active 1.5 Sec.  2 DCY
* Trim Circuit/Open CATALYTIC front >
Bank 1 Sensor 1 CONVERTER, 4.81 V  Heater
CHECKING. control
closed loop
 No low fuel
signal
Criteria Parameters Monitoring Frequency
Diagnostic
DTC Error Message and with Time of checks,
Procedure
Threshold Enable Length MIL Illum
Value Conditions
-- Check the
Engine Coolant
Temperature
(ECT) Sensor -
G62-. Refer to Difference
ENGINE between
Reference
P3081 Engine Temperature Too COOLANT ECT and  2
temperature 4 Sec.
* Low TEMPERATURE modeled DCY
< 60 °C
SENSOR 1 OR 2 ECT > 9.80
CHECKING.-- °K
Check for a stuck
open thermostat.
Refer to the Repair
Information.
Secondary
Malfunction Monitoring Frequency
Diagnostic Parameters with
DTC Error Message Criteria and Time of checks,
Procedure Enable
Threshold Value Length MIL Illum
Conditions
-- Check the CAN-  Time after

Bus terminal ignition on
High Speed 500 mSec.
resistance. Refer to
U0001 CAN  2
CAN-BUS Bus Off failure  Battery 250 mSec.
* Communication DCY
TERMINAL voltage <
Bus
RESISTANCE, 9.5 V
CHECKING.  Battery
voltage >
16 V
 Time after
-- Check the CAN- ignition on
High Speed Bus terminal 500 mSec.
CAN resistance. Refer to  Battery
U0002 Global Time Out  2
Communication CAN-BUS voltage < 450 mSec.
* failure DCY
Bus TERMINAL 9.5 V
Performance RESISTANCE,  Battery
CHECKING. voltage >
16 V
-- Check the CAN-
Bus Direct Shift
Gearbox (DSG)
Mechatronic -
J743- to Engine  Time after
Control Module ignition on
(ECM) - J623-.  Time Out
500 mSec.
Lost Refer to CAN- failure. No  Battery
U0101  2
Communication BUS TERMINAL message voltage < 500 mSec.
* DCY
with TCM RESISTANCE, received by 9.5 V
DIRECT SHIFT ECM  Battery
GEARBOX voltage >
MECHATRONIC 16 V
TO ENGINE
CONTROL
MODULE,
CHECKING.
Check to see if any
other modules have
set a loss of
communication
with the ABS
module fault. If  Time after
other modules can ignition on
Lost 500 mSec.
communicate with
Communication CAN
ABS and ECM  Battery
U0121 With Anti-Lock communication  2
cannot, the ECM voltage < 500 mSec.
* Brake System with ABS Time DCY
may be at fault. If 9.5 V
(ABS) Control Out.
other modules have  Battery
Module
set an ABS voltage >
communication 16 V
error, refer to the
service information
for the ABS
communication
diagnosis.
-- Check the CAN-

Bus terminal
Lost CAN
resistance. Refer to
U0146 Communication communication  2
CAN-BUS --- 0.5 Sec.
* With Gateway with gateway DCY
TERMINAL
A Time Out
RESISTANCE,
CHECKING.
Lost -- Check the CAN-
Communication Bus terminal
With resistance. Refer to Time after
U0155 CAN messages  2
Instrument CAN-BUS ignition on = 500 2000 mSec.
* not received. DCY
Panel Cluster TERMINAL mSec.
(IPC) Control RESISTANCE,
Module CHECKING.
Check for any
applicable TSB's.
Check the ECM
software version to
make sure it is
correct for the  Time after
vehicle. Reflash ignition on
Software module if incorrect 500 mSec.
Incompatibility or update is AT vehicle. ECM  Battery
U0302 2
with available. If ECM coded as MT voltage < 100 mSec.
* DCY
Transmission and TCM software vehicle 9.5 V
Control Module is correct:--  Battery
Replace the Direct voltage >
Shift Gearbox 16 V
(DSG)
Mechatronic -
J743-. Refer to the
Repair
Information.
Check for correct
software in TCM
and reflash if  Time after
necessary. Check ignition on
the CAN bus. 500 mSec.
Invalid Data Refer to CAN- Transmission Data  Battery
U0402 2
Received From BUS TERMINAL Length Code voltage < 300 mSec.

* RESISTANCE, incorrect DCY
TCM 9.5 V
DIRECT SHIFT
 Battery
GEARBOX
MECHATRONIC voltage >
TO ENGINE 16 V
CONTROL
MODULE,
CHECKING
 Speed
sensor  Time after
-- Check the CAN- initialization ignition on
Bus terminal failed 500 mSec.
CAN
resistance. Refer to  Speed  Battery
U0415 Communication 480 - 1980  2
CAN-BUS sensor low voltage < mSec.
* With ABS DCY
TERMINAL voltage 9.5 V
Error
RESISTANCE, error failed  Battery
CHECKING.  Speed voltage >
sensor error 16 V
failed
 Status
ambient
temperature
-- Check the CAN- from
Invalid Data Bus terminal instrument
Ambient
Received From resistance. Refer to cluster no
temperature value  2
U0422 Body Control CAN-BUS fault 2.0 Sec.
initialization DCY
Module TERMINAL  Electrical
failure.
(Cluster) RESISTANCE, check
CHECKING. ambient
temperature
sensor no
fault
If an AAT sensor
code is set,
Implausible
Invalid Data diagnose that code
Ambient Air
Received From before proceeding. Time after
U0423 Temperature  2
Instrument If no code is set ignition on = 500 3000 mSec.
* Sensor value DCY
Panel Cluster replace the IPC mSec.
message received
Control Module module. Refer to
from IPC
the Repair
Information.
-- Check the CAN-
Bus terminal
Lost resistance. Refer to
CAN message  2
U0447 Communication CAN-BUS --- 0.5 Sec.
incorrect DCY
With Gateway TERMINAL
RESISTANCE,
CHECKING.
DIAGNOSTIC PROCEDURES
FUEL PUMP ELECTRICAL, TESTING

 Multimeter.
 Electrical connector test lead set.
Test conditions
Fig. 1: Identifying Fuse Holder In Instrument Panel (Rabbit/GTI, Eos)

 Battery voltage 12.5 V.

 Fuse -27- in Fuse Panel C is OK.
 Fuel filter OK.
 Ignition switched OFF.
Test procedure
-- Perform a preliminary check to verify the customers complaint. Refer to PRELIMINARY CHECK
Start diagnosis
-- Remove rear seat bench. Refer to the Repair Information.
-- Remove the Fuel Pump Control Module from the retaining clips on the floor sealing cover.
Fig. 2: Fuel Pump Control Module, Retaining Clips & Floor Sealing Cover
-- Disconnect the electrical harness connector -arrow- from the Fuel Pump Control Module.
Fig. 3: Identifying Fuel Pump (FP) Control Module J538 Connector

-- Connect the multimeter ground lead to terminal -6- of the Fuel Pump Control Module harness connector.
-- Connect the multimeter positive lead to terminal -1- of the Fuel Pump Control Module harness connector.
Fig. 4: Checking Fuel Pump (FP) Control Module J538 Electrical Harness Connector Terminals 1 To 6
For Voltage
-- Turn the Ignition key to the ON position.
-- The meter should read within 1 volt of battery voltage.
-- If voltage is below specification, locate wiring fault in ground or power circuit. Refer to wiring diagram for
location.
-- If voltage is OK, connect multimeter positive lead to terminal -3- of the Fuel Pump Control Module harness
connector. The ground lead remains on terminal -6-
-- Crank the engine and note voltage displayed on multimeter during crank. Voltage should be within 2.5 volts
of battery voltage.
-- If voltage is below specification, locate wiring fault in the power circuit. Refer to appropriate SYSTEM
WIRING DIAGRAMS information for location.
-- If voltage is OK, connect multimeter positive lead to terminal -2- of the Fuel Pump Control Module harness
connector. The ground lead remains on terminal -6-
-- Crank the engine and note voltage displayed on multimeter during crank. Voltage should be 3.2 volts (+/-.4)
-- If voltage is below specification, check circuit from Fuel Pump Control Module to ECM for open, short or
high resistance and repair as necessary. If no circuit fault is found, replace ECM.
-- If voltage is OK, reconnect the wiring harness to the Fuel Pump control Module.
-- Turn the Ignition switch OFF.
Test procedure for Fuel Pump
-- Remove the floor sealing cover to access the Fuel Delivery Unit (fuel pump).
-- Disconnect the harness connector from the Fuel Delivery Unit.
Fig. 5: Identifying Fuel Delivery Unit Connector

-- Connect the multimeter positive lead to terminal -1- of the Fuel Delivery Unit harness connector.
-- Connect the multimeter ground lead to terminal -5- of the Fuel Delivery Unit harness connector.
-- Crank the engine and note voltage displayed on multimeter during crank. Voltage should be within 2.5 volts
of battery voltage.
-- If voltage is below specification, replace the Fuel Pump Control Module.
-- If voltage is within specification, replace the Fuel Delivery Unit (Fuel Pump). Refer to the Repair
Information.
Final procedures
After the repair work, the following work steps must be performed in the following sequence:
1. Check the DTC memory. Refer to DIAGNOSTIC MODE 03 - READ DTC MEMORY.
2. If necessary, erase the DTC memory. Refer to DIAGNOSTIC MODE 04 - ERASE DTC MEMORY.
3. If the DTC memory was erased, generate readiness code. Refer to READINESS CODE.
FUEL PRESSURE TEST
 Multimeter.
 Fuel line adapter set V.A.G. 1318/17A. These tools may be substituted with an equivalent aftermarket
tool and are also available for rental or purchase through Volkswagen.
 In line Fuel pressure gauge with shutoff valve. (high pressure).
Test conditions
 Battery voltage 12.5 V

 Function and voltage supply for the Fuel Pump is OK.
 Fuel tank at least 1 /4 filled.
Test procedure
WARNING: Fuel system is under pressure! Before opening the system, place rags
around the connection area. Then release the pressure by carefully
Start diagnosis
-- Disconnect fuel supply line -3- at the supply location and catch any fuel coming out with a shop towel
NOTE: Pull circlip upward to unlock fuel line
-- Install a fuel pressure gauge with appropriate adapters.
-- Open shut off valve on fuel gauge.
-- Switch ignition on and off repeatedly until fuel pressure stops increasing pressure.
-- Read fuel pressure on the gauge.
 Specified value: 3.5 to 6 bar
If specification is exceeded:
-- Check return line between fuel filter and fuel pump for kinks or blockage.
If no malfunction in fuel return line is found:
-- Pressure relief valve in fuel filter is malfunctioning.
-- Replace the fuel filter. Refer to the Repair Information.
If reading was below the specification:

-- Open shut off valve on gauge and start the engine. Allow to idle.
-- Slowly close the pressure gauge shut off and note the fuel pressure.
 Pressure must increase to 6 bar.
When 6 bar is reached: Open shut off tap immediately!
If pressure has increased during test:
-- Fuel pump is OK. Pressure relief valve in fuel filter is malfunctioning.
If pressure did not increase:
-- Fuel pump is faulty
-- Replace the fuel pump. Refer to the Repair Information.
Final procedures
FUEL PUMP DELIVERY QUANTITY, CHECKING
 Switched remote control (jumper).

 Multimeter.
 Electrical connector test lead set.
 Fuel pressure test set.
 Measuring container, fuel-resistant.
Test conditions
 Battery voltage 12.5 V

 Fuel filter OK
 Fuel tank at least 1 /4 filled.

 Fuel pressure regulator OK.
 Ignition switched off.
Test procedure
Start diagnosis
-- Remove the fuel filler cap from fuel filler tube.
-- Remove rear seat bench. Refer to the Repair Information.
-- Remove the floor sealing cover -1-.
Fig. 7: Fuel Pump Control Module, Retaining Clips & Floor Sealing Cover
-- Disconnect the electrical harness connector -arrow- from the fuel delivery unit.
Fig. 8: Identifying Fuel Delivery Unit Connector

-- Connect a switched remote control (jumper) to terminal -1- of the fuel delivery unit and to vehicle Battery
(+).
-- Connect a jumper wire from terminal -5- of the fuel delivery unit to vehicle Ground.
Fig. 9: A Jumper Cable From A Electrical Connector Test Lead Set Connected To Terminal Of The Fuel
Delivery Unit And To Vehicle Ground
WARNING: Fuel system is under pressure! Before opening the system, place rags
around the connection area. Then release the pressure by carefully
-- Disconnect the fuel return line -arrow- by pressing release buttons.
Fig. 10: Fuel Return Line

-- Connect a fuel line from the fuel pressure test set to the disconnected fuel return line and hold it in the
measuring container.
Fig. 11: Connecting Fuel Line From High Pressure Fuel Gauge To Disconnected Fuel Return Line And
Hold It In Measuring Container
-- Press the switch on the remote control (jumper) and operate the fuel pump for 15 seconds.
-- Compare quantity of fuel delivered with minimum delivery rate in the diagram (cm3 /30 sec.).
Fig. 12: Fuel Quantity Graph

NOTE: Voltage at the fuel pump with engine stopped and fuel pump running is approx.
2 volts less than battery voltage.
If minimum delivery quantity is not obtained, the following malfunctions may be present:
 Fuel lines pinched.

 Fuel filter plugged.
 Fuel pump faulty.
-- If necessary, repair any pinched or plugged lines.
If the filter is restricted;
If the fuel pump is faulty;
-- Replace the fuel pump. Refer to the Repair Information.
Assembly is performed in reverse order of removal. Note the following:
-- Install the rear seat bench. Refer to the Repair Information.

Final procedures
FUEL PRESSURE SENSOR, CHECKING
 Multimeter.
 Wiring diagram.
Test requirements
 The Fuel Pump (FP) Control Module -J538- OK.

 The Engine Control Module (ECM) - J623- fuses OK.
 The fuel filter OK.
 The battery voltage at least 12.5 V.
 All electrical consumers switched off (radiator fan must NOT run during test).
 A/C switched off.
 The fuel tank at least 1 /4 filled.
 The ignition switched OFF.
Test procedure
Start diagnosis
-- Remove the engine cover with air filter. Refer to the Repair Information.
Checking voltage
-- Disconnect the Fuel Pressure Sensor -G247- electrical harness connector.
-- Switch the ignition ON.
-- Using a multimeter, check the Fuel Pressure Sensor -G247- electrical harness connector -1- terminals for
voltage.
Fig. 13: Fuel Pressure Sensor Electrical Harness Connector

Fuel
Pressure
Sensor -
G247-
Specified value:
electrical
harness
connector
terminals:
1 to
Battery
Battery voltage
Positive
(+)
2 to
5V
Ground
3 to
5V
Ground
If the specified value was obtained:
-- Replace the Fuel Pressure Sensor -G247-: Refer to the Repair Information.
If the specified value was Not obtained:
Checking wiring connections

-- Remove the Engine Control Module (ECM) -J623-. Refer to the Repair Information.
-- Using a multimeter, check the Fuel Pressure Sensor -G247- harness connector terminals to the Engine
Control Module (ECM) -J623- harness connector for an open circuit according to the chart below.
Fuel Pressure Sensor -G247- electrical harness Engine Control Module (ECM) -J623- electrical
connector terminals: connector T60 terminals:
1 13
2 40
3 29
Specified value: 1.5 ohms Max.
-- Check the wiring for an open, high resistance or short to ground.
-- Check the electrical harness connector for damage, corrosion, loose or broken terminals.
-- Replace the Engine Control Module (ECM) -J623-. Refer to the Repair Information.
-- Install the engine cover with air filter. Refer to the Repair Information.
Final procedures
FUEL PRESSURE REGULATOR VALVE, CHECKING
 Multimeter.
 Wiring diagram.
Test requirements
 The Fuel Pump (FP) Control Module -J538- OK.


 The fuel filter OK.
Test procedure
Start diagnosis
Checking resistance
-- Disconnect the Fuel Pressure Regulator Valve -N276- electrical harness connector -2- from the Fuel High
Pressure Pump -- assembly -1-.
Fig. 14: Fuel High Pressure Pump & Fuel Pressure Regulator Valve Electrical Harness Connector
-- Using a multimeter, check the Fuel Pressure Regulator Valve -N276- terminals 1 to 2 for resistance.
Fig. 15: Checking Fuel Pressure Regulator Valve N276 Terminals 1 To 2 For Resistance
Specified value: 0.4 to 1.2 ohms (at approx. 20° C)
-- Replace the Fuel Pressure Regulator Valve -N276-: Refer to the Repair Information.
Checking voltage
Switch the ignition ON.
-- Using a multimeter, check the Fuel Pressure Regulator Valve -N276- electrical connector terminal 1 to
Ground for voltage.
Fig. 16: 2-Pin Electrical Connector & Terminals

Specified value: Battery voltage.
Switch the ignition OFF.
-- Check the wiring from the Fuel Pressure Regulator Valve -N276- electrical connector terminal 1 to the
Engine Component Power Supply Relay -J757- (for < 2011) or Fuel Pump Relay -J49- (for 2012 and later)
terminal 5 (relay pin 87) for a short circuit to Ground, high resistance or an open circuit.
-- If necessary, repair the wiring connection.
-- If a short was found, replace fuse also.
Checking wiring
-- Using a multimeter, check the Fuel Pressure Regulator Valve -N276- electrical harness connector terminals to
the Engine Control Module (ECM) -J623- electrical harness connector terminals for an open circuit according
to the chart below.

Fuel Pressure Regulator Valve -N276- Engine Control Module (ECM) -J623- electrical
electrical harness connector terminal: connector T60 terminal:
2 19
Final procedures
EVAP SYSTEM, CHECKING FOR LEAKS
 Smoke tester.
 EVAP and Fuel Supply System Vacuum hose and line routing diagram.
NOTE: Secure all hose connections using hose clamps appropriate for the model type.
Replace seals and gaskets when performing repair work.
Leak checking
-- Using a Smoke tester, check the Evaporative Emission (EVAP) canister system for leaks.
NOTE: Always follow the manufacturers directions for the proper installation and
operation of the smoke tester being used.
If a leak is detected:
-- Check the fuel filler cap seal for damage and for proper installation. Replace if necessary.
-- Check all hose connections of the fuel supply system and replace or repair any leaking lines.
-- Check all hose connections of the EVAP system and replace or repair any leaking lines.
-- Check that the seal under the locking flange is properly tightened on the fuel tank.
-- Repair or replace any damaged component.
If no leaks are found in the EVAP or Fuel Supply System:
-- Erase the DTC memory if a DTC was set. Refer to DIAGNOSTIC MODE 04 - ERASE DTC MEMORY.
-- Perform a road test to verify repair.
If a DTC was set and does not return:
Erase the DTC. Generate readiness code. Refer to READINESS CODE.
If the DTC does return and no leaks are found in the EVAP and Fuel Supply System:
-- Check the DTC memory for any DTC codes pertaining to the EVAP and Fuel Supply Systems. If a DTC is
- READ DTC MEMORY.
EVAPORATIVE EMISSION CANISTER SYSTEM, CHECKING FOR PROPER SEAL
NOTE: Secure all hose connections using hose clamps appropriate for the model type .
Replace seals and gaskets when performing repair work.
Test procedure
Start diagnosis
-- Start the engine and let run at idle for at least 15 minutes.
-- Select "Diagnostic mode 8: Tank leak test".
-- Select the "Test-ID 01: Tank leak test" and check the specified value at idle.
Specified value: test OK
NOTE: If the accelerator pedal is depressed during the test, the test will be aborted.
To repeat the tank leak-tightness test, switch the ignition off, start the engine
again, and let it run at idle.
Checking fuel supply and tank ventilation systems for leaks
-- Ensure the fuel filler cap is properly installed on the fuel tank.
-- Check the fuel filler cap seal for damage. Replace if necessary.
-- Visually check all hose connections of the fuel supply system and replace any leaking lines.
 Check the line from the EVAP canister to the EVAP Canister Purge Regulator Valve -N80-.
 Check the lines from the EVAP canister to the Leak Detection Pump (LDP) -V144-.
 Check the line from the fuel tank to the EVAP canister (below cover for EVAP canister).
 Check the lines for the tank ventilation (beneath right rear wheel housing liner).
 Check the fuel lines to the engine.
 Remove the rear seat bench. Refer to the Repair Information.
 Remove the floor cover seal.
 Inspect the seal under the Fuel Delivery Unit (fuel pump) locking flange for proper sealing. Also check
the fuel line connections.
NOTE: Leaks at the lines and components of the fuel tank ventilation system can
sometimes be located using a non flammable, environmentally compliant leak
detection spray. Initiate the leak diagnosis several times in sequence to build
up pressure in the system. At leaking areas, bubbles will form.
-- Repeat the function test.
If a leak is detected:
-- Perform a visual inspection on the fuel system components and tank ventilation system.
 Fuel tank.
 EVAP canister.
 Leak Detection Pump (LDP) -V144-.
 EVAP Canister Purge Regulator Valve -N80-.
NOTE: Due to the form or function of the components, leaking areas may not always be
localized by spraying on the leak detection spray. It may be necessary to clamp
off the relevant component using Hose Clamps Up To 25 mm Dia. and initiate
the tank leak detection diagnostic. If the leak is no longer indicated, the
component that was clamped off is faulty. If clamped off directly at the leak
detection pump and a leak is still indicated, the leak detection pump itself is
leaking.
Final procedures
EVAPORATIVE EMISSION CANISTER PURGE REGULATOR VALVE, CHECKING

 Multimeter.
 Wiring diagram.
Test requirements
 The EVAP Canister Purge Regulator Valve -N80- fuse OK.

NOTE: Voltage for the EVAP Canister Purge Regulator Valve -N80- is supplied via the
Engine Component Power Supply Relay -J757-.
Test procedure
Start diagnosis
-- Disconnect the EVAP Canister Purge Regulator Valve -N80- electrical harness connector -1-.
Fig. 18: Identifying Evaporative Emission (EVAP) Canister Purge Regulator Valve N80 Electrical
Harness Connector
Checking internal resistance

-- Using a multimeter, check the EVAP Canister Purge Regulator Valve -N80- terminals 1 and 2 for resistance.
Fig. 19: Checking Camshaft Adjustment Valve 1 N205 For Resistance

Specified value: 30.0 to 39.0 ohms.
-- Replace the EVAP Canister Purge Regulator Valve -N80-.
Checking voltage supply
-- Using a multimeter, check the electrical harness connector terminal 1 to 2 for voltage.
Fig. 20: 2-Pin Electrical Harness Connector & Terminals

-- Turn ignition switch ON.
Specified value: 10.6 volts +/- 2 volts.
-- Leave the multimeter positive lead on terminal 1 and connect the multimeter negative lead to engine ground.
-- Ignition switch ON.
-- Turn ignition switch OFF.
-- Check the wire from the EVAP Canister Purge Regulator Valve -N80- electrical harness connector terminal 1
to fuse for an open or high resistance. Refer to the appropriate SYSTEM WIRING DIAGRAMS information.
Check Ground activation

-- Using a multimeter, check the EVAP Canister Purge Regulator Valve -N80- electrical connector terminal 2 to
the Engine Control Module (ECM) -J623- electrical connector T60 terminal 35 for an open circuit.

Specified value: 1.5 ohms max.
-- Check the wiring for a short to voltage, high resistance or an open circuit.
Final procedures
LEAK DETECTION PUMP, CHECKING
 Multimeter.
 Wiring diagram.
Test requirements
 The Leak Detection Pump (LDP) -V144- fuse 15 in fuse panel B is OK.
Test procedure
Start diagnosis
-- Remove the right rear wheel housing liner. Refer to the Repair Information.
-- Disconnect the Leak Detection Pump (LDP) -V144- electrical harness connector -2-.
Fig. 22: Disconnecting Leak Detection Pump (LDP) V144 Electrical Harness Connector

-- Using a multimeter, check the Leak Detection Pump (LDP) -V144- for resistance as follows:
Fig. 23: Checking Leak Detection Pump (LDP) V144 For Resistance
Leak Detection Pump (LDP) -V144- electrical connector

Specified values:
terminals:
-1- to -3- 640 to 720 ohms
-2- to -3- 15 to 17 ohms
If the specified values were Not obtained:
-- Replace the Leak Detection Pump (LDP) --V144--. Refer to the Repair Information.
If the specified values were obtained:
NOTE: The voltage for the Leak Detection Pump (LDP) --V144-- is supplied via fuse 15
in fuse panel B.
-- Check the Leak Detection Pump (LDP) --V144-- for voltage.
-- Using a multimeter, check the Leak Detection Pump (LDP) --V144-- electrical harness connector terminal 3
for voltage. Connect the negative multimeter lead to engine ground.

-- Turn the ignition switch ON.
-- Remove fuse 16 in Fuse Panel B. Using a multimeter, check the Leak Detection Pump (LDP) --V144-- wiring
from terminal 3 to fuse 16.
-- Check the wiring for high resistance, short to ground or an open circuit.
Checking wiring
-- Using a multimeter, check the Leak Detection Pump (LDP) --V144-- electrical connector terminals to Engine
Control Module (ECM) -J623- electrical connector terminals for an open circuit or high resistance.
Leak Detection Pump (LDP) --V144-- electrical Engine Control Module (ECM) -J623- electrical
harness connector terminal: connector T94 terminal:
1 44
2 49
-- Check the wiring for high resistance or an open circuit.
If no malfunction is found in wiring:
Assembly is performed in the reverse order of the removal, note the following:
-- Install the right rear wheel housing liner. Refer to the Repair Information.
Final procedures
ACCELERATOR PEDAL POSITION SENSOR 1/ACCELERATOR PEDAL POSITION SENSOR 2, CHECKING
 Multimeter.
 Wiring diagram
Test requirement

 Battery voltage at least 12.5 volts.
 All electrical consumers such as, lights and rear window defroster, switched off.
 Vehicles with automatic transmission, shift selector lever into position "P" or "N".
 Ground connections between engine/transmission/chassis OK.
NOTE: Use only gold-plated terminals when servicing the electrical harness connector
terminals in Accelerator Pedal Position Sensor 1 -G79- /Accelerator Pedal
Position Sensor 2 -G185-.
Test procedure
Start diagnosis
-- Remove the drivers side storage compartment. Refer to the Repair Information.
-- Disconnect the Accelerator Pedal Position Sensor 1 -G79-/Accelerator Pedal Position Sensor 2 -G185- 6 pin
electrical harness connector -2-.
Fig. 25: Component Location Throttle Position (TP) Sensor G79/Accelerator Pedal Position Sensor 2
G185
Checking voltage supply and wiring
-- Using a multimeter, check the following wiring connections for voltage.


Accelerator Pedal Position Sensor 1 -G79-/Accelerator Pedal

Specified value:
Position Sensor 2 -G185- electrical harness connector terminals:
1 to Ground near 5 V
1 to 5 near 5 V
2 to Ground near 5 V
2 to 3 near 5 V
If the manufacturers test box is being used, perform the following step.
-- Install the test box.
If the manufacturers test box is not being used, perform the following step.
-- Using a multimeter, check the Accelerator Pedal Position Sensor 1 -G79-/Accelerator Pedal Position Sensor 2
-G185- electrical harness connector terminals to the Engine Control Module (ECM) -J623- electrical connector
T94 for an open circuit.
Accelerator Pedal Position Sensor 1 -G79-/Accelerator

Pedal Position Sensor 2 -G185- electrical harness Engine Control Module (ECM) -J623-
connector terminals: electrical connector T94 terminals:
1 81
2 82
3 35
4 83
5 11
6 61
-- Check the wiring for high resistance, a short circuit to each other, Battery (+) or Ground.
If no malfunction is detected in the wiring and if the voltage supply was OK:
-- Replace the Accelerator Pedal Position Sensor 1 -G79-/Accelerator Pedal Position Sensor 2 -G185-. Refer to
the Repair Information.
If no malfunction is detected in the wiring and if the voltage supply was Not OK:
-- Replace the Engine Control Module (ECM) -J623- . Refer to the Repair Information.
-- Install the drivers side storage compartment. Refer to the Repair Information.
Final procedures
THROTTLE VALVE CONTROL MODULE, CHECKING
NOTE: Use only gold-plated terminals when servicing terminals in harness connector
of Mass Air Flow (MAF) Sensor -J338-.
 Multimeter.
Test requirements

 Throttle valve must not be damaged or dirty.
 Coolant Temperature at least 80°C.
Function
Throttle valve operation occurs by an electric motor called the Throttle Drive for Electronic Power Control
(EPC) -G186- located within the Throttle Valve Control Module - J338-. It is operated by the Engine Control
Module (ECM) -J623- with input from the Accelerator Pedal Position Sensor 1 -G79- /Accelerator Pedal
Position Sensor 2 -G185-.
The Throttle Valve Control Module -J338- is made up of the following components:
 Throttle Drive for Electronic Power Control (EPC) -G186-

 Throttle Drive Angle Sensor 1 for Electronic Power Control (EPC) -G187-
 Throttle Drive Angle Sensor 2 for Electronic Power Control (EPC) -G188-
The Throttle Valve Control Module -J338- cannot be serviced separately and must be serviced as a unit.
Test procedure
Start diagnosis
-- Switch ignition ON.
-- Using the scan tool, check the throttle valve position (absolute) at idle stop:
Diagnostic
Specified value
text
Throttle
valve
(absolute)
 Idle 3.0 to 25.0%
stop
-- Slowly depress the accelerator pedal to Wide Open Throttle (WOT) stop while observing the percentage
display. The percentage display must increase uniformly.
-- Using the scan tool, check the throttle valve position (absolute) at Wide Open Throttle (WOT) stop:
Diagnostic
Specified value
text
Throttle valve
position
(absolute)
 Wide
Open
Throttle 84.0 to 97.0%
(WOT)
stop
-- Switch ignition OFF.
-- Remove the Throttle Valve Control Module -J338 - far enough so that the electrical connector terminals are
reached.
-- Disconnect the Throttle Valve Control Module -J338- electrical harness connector -arrow-.
Fig. 27: Identifying Throttle Valve Control Module J338 Electrical Harness Connector
Checking resistance
-- Using a multimeter, check the Throttle Valve Control Module -J338- terminals 3 to 5 for resistance.
Fig. 28: Checking Throttle Drive (For Electronic Power Control (EPC)) G186 At Throttle Valve Control
Module J338 Terminals 3 To 5 For Resistance
Specified value: 1.0 to 5.0 ohms (at 20°C)
-- Replace the Throttle Valve Control Module - J338-. Refer to the Repair Information.
-- Check the voltage supply of the Throttle Valve Control Module -J338- to the Engine Control Module (ECM)
-J623-.
Checking voltage supply and wiring
-- Using a multimeter, check the Throttle Valve Control Module -J338- electrical harness connector terminals 2
to 6 for voltage.
Fig. 29: Checking Connector Terminals 2 To 6 For Voltage

Specified value: at least 4.5 V
Checking wiring
-- Using a multimeter, check the Throttle Valve Control Module -J338- electrical harness connector terminals to
the Engine Control Module (ECM) -J623- electrical harness connector T60 terminals for a short to ground or an
open circuit according to the chart below.
Fig. 30: Identifying Throttle Valve Control Module J338 Electrical Harness Connector Terminals
Throttle Valve Control Module -J338- electrical Engine Control Module (ECM) -J623- electrical
harness connector terminals: connector T60 terminals:
1 41
2 12
3 17
4 24
5 16
6 44
If no malfunction is detected in the wiring and if the voltage supply was Not OK:
Final procedures
TURBOCHARGER RECIRCULATING VALVE, CHECKING
 Multimeter.
 Wiring diagram.
Test requirements
Fig. 31: Fuses On E-Box In Engine Compartment, Left Side


 On vehicles with automatic transmission, selector lever in position "P" or "N".
Test procedure
Start diagnosis
-- Lift the vehicle on a hoist to access the turbocharger recirculating valve connector.
-- Disconnect the Turbocharger Recirculating Valve -N249- electrical harness connector -2-.
Fig. 32: Disconnecting Turbocharger Recirculating Valve N249 Electrical Harness Connector
-- Using a multimeter, check the Turbocharger Recirculating Valve -N249- terminals 1 to 2 for resistance.

Specified value: 13.6 ohms +/- 5 ohms
-- Replace the Turbocharger Recirculating Valve -N249-. Refer to the Repair Information.
Checking Voltage supply
-- Turn the ignition switch On.
-- Using a multimeter, check the Turbocharger Recirculating Valve -N249- electrical harness connector terminal
1 to engine ground.

-- Check the wiring from the turbocharger recirculating valve connector to fuse SB 23 for an open, short to
ground or high resistance.
-- Check the Turbocharger Recirculating Valve -N249- electrical harness connector terminal 2 to engine
ground.

Specified value: Near 3.55 V.
-- Replace the Turbocharger Recirculating Valve -N249- Refer to the Repair Information.
Checking wiring
-- Using a multimeter, check the Turbocharger Recirculating Valve -N249- electrical harness connector terminal
to Engine Control Module (ECM) -J623- electrical harness connector T60 terminal for resistance. Refer to the
chart below.

Turbocharger Recirculating Valve -N249- Engine Control Module (ECM) -J623- electrical
2 50
-- Check the wiring for an open, short or high resistance.
If no malfunction is detected in the wiring and battery voltage was present:
Final procedures
WASTEGATE BYPASS REGULATOR VALVE, CHECKING
 Multimeter.
 Wiring diagram.
Test requirements


Test procedure
Start diagnosis
-- Disconnect the Wastegate Bypass Regulator Valve -N75- electrical harness connector -1-.
Fig. 38: Disconnecting Turbocharger Recirculating Valve N249 Electrical Harness Connector
-- Using a multimeter, check the Wastegate Bypass Regulator Valve -N75- terminals 1 to 2 for resistance.

Specified value: 20 to 30 ohms (at approx. 20°C)
-- Replace the Wastegate Bypass Regulator Valve -N75-. Refer to the Repair Information.
Checking Voltage supply

Wastegate Bypass Regulator Valve -N75- electrical

Measure to:
harness connector terminal:
1 Engine Ground
-- Start the engine.
-- Using a multimeter, check the Wastegate Bypass Regulator Valve -N75- electrical harness connector terminal
1 to engine ground.
Specified value: battery voltage.
-- Check the wiring for a short circuit to ground, high resistance or an open circuit.
-- Check fuse for open and replace if blown. Refer to the appropriate SYSTEM WIRING DIAGRAMS
information.
-- Remove the Engine Control Module (ECM) -J623- .
-- Using a multimeter, check the Wastegate Bypass Regulator Valve -N75- electrical harness connector terminal
to the Engine Control Module (ECM) -J623- electrical harness connector terminal for an open circuit.

Wastegate Bypass Regulator Valve -N75- Engine Control Module (ECM) -J623- electrical
2 3
-- Check the wiring for an open or high resistance.

Final procedures
CHARGE AIR PRESSURE SENSOR/MAP SENSOR, CHECKING
of Charge Air Pressure Sensor/MAP Sensor -G31/G71-.
 Multimeter.
 Wiring diagram.
Test requirements

Test procedure
Start diagnosis
-- Remove the engine cover. Refer to the Repair Information.
Test sequence
-- Disconnect the Charge Air Pressure Sensor/MAP Sensor -G31/G71- electrical harness connector -arrow-.
Fig. 42: Identifying Charge Air Pressure Sensor G31 Electrical Harness Connector
-- Using a multimeter, check the Charge Air Pressure Sensor/MAP Sensor -G31/G71- electrical harness
connector terminals 1 to 3 for voltage.

Specified value: min. 4.5 V
Checking wiring
-- Using a multimeter, check the Charge Air Pressure Sensor/MAP Sensor -G31/G71- electrical harness
connector terminals to the Engine Control Module (ECM) -J623- electrical harness connector terminals for an
open circuit according to wiring diagram.
Charge Air Pressure Sensor/MAP Sensor -

G31/G71- electrical harness connector Engine Control Module (ECM) -J623- electrical
terminals: connector T60 terminals:
1 13
2 Empty cavity
3 27
4 39
If no malfunction is detected in the wiring and the voltage supply was OK:
-- Replace the Charge Air Pressure Sensor/MAP Sensor -G31/G71-. Refer to the Repair Information.
If no malfunction is detected in the wiring and the voltage supply was Not OK:
-- Install the engine cover. Refer to the Repair Information.
Final procedures
OXYGEN SENSOR BEFORE CATALYTIC CONVERTER, CHECKING
NOTE: Use only gold-plated terminals when servicing terminals in the electrical
harness connector of the Heated Oxygen Sensor (HO2S) -G39- .
 Multimeter.
 Wiring diagram.
Test requirements
 The Heated Oxygen Sensor (HO2S) -G39- fuse OK.

 The Oxygen Sensor (O2S) Heater -G39- before catalytic converter OK.
 Exhaust system between catalytic converter and cylinder head properly sealed.
 Coolant Temperature at least 80 °C.
Test procedure
Start diagnosis
-- Connect scan tool.
-- Select "Diagnostic mode 6: Check test results of components that are not continuously monitored".
-- Select "Monitor ID 01: Oxygen sensor monitoring before catalytic converter".
-- Select "Test ID 131 ($89 for later models): Dynamic test".
-- Check the specified values at idle.
Refer to Mode 6 table: Monitor-ID $01: Oxygen Sensor Monitor Bank 1 - Sensor 1 for values.
-- Switch the ignition OFF. Fault is not active at this time. Check for poor connections, loose terminals and
harness check.
Checking primary voltage
-- Disconnect the Heated Oxygen Sensor (HO2S) -G39- electrical harness connector -1-.
Fig. 45: Identifying Heated Oxygen Sensor (HO2S) G39 Electrical Harness Connector
-- Using a multimeter, check the Heated Oxygen Sensor (HO2S) -G39- electrical harness connector -1-
terminals 1 to 2 for voltage.
Fig. 46: Identifying 6-Pin Electrical Harness Connector & Terminals

Specified value: 0.400 to 0.500 Volts

-- Turn the ignition switch OFF.
-- Replace the Heated Oxygen Sensor (HO2S) -G39-. Refer to the Repair Information.
Checking wiring
-- Using a multimeter, check the Heated Oxygen Sensor (HO2S) -G39- electrical harness connector terminals to
the Engine Control Module (ECM) -J623- electrical harness connector T94 terminals for an open circuit.

Heated Oxygen Sensor (HO2S) -G39- electrical Engine Control Module (ECM) -J623- electrical
1 78
2 79
5 56
6 57

Final procedures
OXYGEN SENSOR HEATER BEFORE CATALYTIC CONVERTER, CHECKING
NOTE: When servicing terminals in harness connector of Heated Oxygen Sensor

(HO2S) -G39- , use only gold-plated terminals.
 Multimeter.
 Wiring diagram.
Test requirements
 The Heated Oxygen Sensor (HO2S) -G39- fuse 24 in Fuse Panel B is OK.
Test procedure
Start diagnosis
-- Disconnect the Heated Oxygen Sensor (HO2S) -G39- electrical harness connector -1-.
-- Using a multimeter, check the Heated Oxygen Sensor (HO2S) -G39- terminals 3 and 4 for correct resistance.
Specified value: 2.5 to 10.0 ohms (at approx. 20°C)
-- Replace the Heated Oxygen Sensor (HO2S) -G39-. Refer to the Repair Information.
-- Turn the ignition switch ON
-- Using a multimeter, check the Heated Oxygen Sensor (HO2S) -G39- electrical harness connector terminal 4
to engine ground for voltage.
-- Turn the ignition switch OFF
-- Check the wiring for an open, high resistance or short to Ground and replace fuse 24 in Fuse Panel B if
necessary.
Checking Ground activation
-- Using a multimeter, check the Heated Oxygen Sensor (HO2S) -G39- electrical harness connector terminal to
the Engine Control Module (ECM) -J623- electrical harness connector terminal for an open circuit.

harness connector terminal: connector T94 terminal:
3 73
-- Check the wiring for an open, short circuit to each other, Battery (+) or Ground.
If no malfunction is detected in the wiring and the voltage supply was OK:
Final procedures
OXYGEN SENSOR BEHIND THREE WAY CATALYTIC CONVERTER, CHECKING
NOTE: Vehicle must be raised before the electrical connector for the Oxygen Sensor
(O2S) Behind Three Way Catalytic Converter (TWC) -G130- is accessible.
When servicing terminals 3 and 4 in the electrical harness connector of the

Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130-, use
only gold-plated terminals.
 Multimeter.
 Wiring diagram.
Test requirements
 The Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- fuse Ok.

 Oxygen Sensor (O2S) 1 (behind Three Way Catalytic Converter (TWC) Heater - G130- OK. Refer to the
Repair Information.
 Vehicles with automatic transmission, selector lever in position "P" or "N".
 Ground) connections between engine/transmission/chassis OK.

 Exhaust system between catalytic converter and cylinder head properly sealed.
 Ignition switched OFF
Test procedure
Start diagnosis
-- Connect scan tool.
-- Select "Diagnostic mode 6: Check test results of components that are not continuously monitored".
-- Select "Monitor ID 02: Oxygen sensor monitoring behind catalytic converter".
-- Select following Test-IDs.
-- Check the minimum voltage at idle.
Refer to Mode 6 table: Monitor-ID $02: Oxygen Sensor Monitor Bank 1- Sensor 2 for minimum voltage
values.
-- Switch ignition OFF. Fault is not active at this time. Check for poor connections, loose terminals and harness
check.
-- Remove the right vehicle floor cover -arrows-.

Fig. 50: Identifying Right Vehicle Floor Cover

Checking primary voltage
-- Disconnect the brown Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- electrical
harness connector -arrow-.
Fig. 51: Disconnecting Connector For Oxygen Sensor (O2S) Behind Three Way Catalytic Converter
(TWC) G130

-- Using a multimeter, check the Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130-
electrical harness connector terminals 3 to 4 for voltage.
Fig. 52: Checking Component Terminals 3 To 4 For Voltage

Specified value: 0.400 to 0.500 Volts
-- Replace the Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) - G130-. Refer to the
Repair Information.
Checking wiring
-- Using a multimeter, check the Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) - G130-
electrical harness connector terminals to the Engine Control Module (ECM) -J623- electrical harness connector
terminals for an open circuit according to the wiring diagram.

For 2008 - 2010 Passat:
3 34
4 62
For 2010 > CC:
3 33
4 84
-- Install the right vehicle floor cover -arrows-.

Final procedures
OXYGEN SENSOR HEATER BEHIND THREE WAY CATALYTIC CONVERTER, CHECKING
NOTE: Vehicle must be raised before electrical harness connector for the Oxygen
Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- is accessible.
When servicing terminals in harness connector of Oxygen Sensor (O2S) Behind

Three Way Catalytic Converter (TWC) -G130- , use only gold-plated terminals.
 Multimeter.
 Wiring diagram.
Test requirements
 The Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- fuse 21 in Fuse Panel
B is OK.


Test procedure
Start diagnosis
-- Remove the right vehicle floor cover -arrows-.


-- Disconnect the Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- electrical
harness connector -arrow-.
Fig. 57: Disconnecting Connector For Oxygen Sensor (O2S) Behind Three Way Catalytic Converter
(TWC) G130
electrical harness connector terminals 1 to 2 for resistance.
Fig. 58: Identifying Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130 Electrical
Harness Connector Terminals
-- Replace the Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) - G130-. Refer to the
Repair Information.
-- Using a multimeter, check the Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) - G130-
electrical harness connector terminal 1 to engine ground.
-- Check the wiring for an open, high resistance or short to Ground and replace fuse 24 in Fuse Panel B if
necessary.
Checking Ground activation
electrical harness connector terminal to the Engine Control Module (ECM) -J623- electrical harness connector
terminal for an open circuit according to the chart below.
For 2008 - 2010 Passat:
Oxygen Sensor Behind Three Way Catalytic

Converter (TWC) -G130- electrical harness Engine Control Module (ECM) -J623- electrical
2 29
For 2010 > CC:
Engine
Control
Module
(ECM) -
Oxygen Sensor Behind Three Way Catalytic Converter (TWC) -G130- electrical harness
J623-
connector terminals:
electrical
connector
T94
terminals:
2 54
-- Check the wiring for an open or high resistance.
-- Install the right vehicle floor cover.
Final procedures
MAF SENSOR, CHECKING
of Mass Air Flow (MAF) Sensor -G70-.
 Multimeter.
 Wiring diagram.
Test requirements
 The Mass Air Flow (MAF) Sensor -G70- fuse 1 in Fuse Panel C is OK.
Test procedure
Start diagnosis
-- Start engine and let it run at idle.
-- Using the scan tool, Check the air flow quantity of the Mass Air Flow (MAF) Sensor -G70- at idle:
Diagnostic
text Specified value

Air flow
quantity at
Mass Air
Flow (MAF)
sensor
 Engine
warmed
up, 2.00 to 5.00 g/sec
running
at idle
If specified value is obtained, but DTC memory has a DTC concerning Mass Air Flow (MAF) Sensor -G70-:
-- Disconnect the Mass Air Flow (MAF) Sensor -G70- electrical harness connector -1-.
Fig. 59: Identifying Mass Air Flow (MAF) Sensor G70 Electrical Harness Connector

-- Using a multimeter, check the Mass Air Flow (MAF) Sensor -G70- electrical harness connector terminal 3 to
engine Ground.

-- Remove the fuse 1 in Fuse Panel C. Check the Mass Air Flow (MAF) Sensor -G70- electrical harness
connector terminal 3 to Fuse 1 in Fuse Panel C for an open circuit, high resistance or short to ground.
-- Repair the circuit as necessary. Refer to the appropriate SYSTEM WIRING DIAGRAMS information.
-- Turn the ignition switch On.
-- Using a multimeter, check the Mass Air Flow (MAF) Sensor -G70- electrical harness connector terminal 1 to
engine Ground.

Specified value: Near 4.90 V.
Checking electrical circuit
-- Remove the Engine Control Module (ECM) -J623-. Refer to the Repair information.
-- Using a multimeter, check the Mass Air Flow (MAF) Sensor -G70- electrical harness connector terminals to
the Engine Control Module (ECM) -J623- electrical harness connector terminals for an open circuit. Refer to
the appropriate SYSTEM WIRING DIAGRAMS information.

For 2008 - 2010 Passat:
Engine
Control
Module
(ECM) -
Mass Air Flow (MAF) Sensor -G70- electrical harness connector terminals: J623-
electrical
connector
T94
terminals:
1 23
2 65
fuse SC-
3
10
4 12
5 60
For 2010 > CC:
Engine
Control
Mass Air Flow (MAF) Sensor -G70- electrical harness connector terminals: Module
(ECM) -
J623-
electrical
connector
T94
terminals:
1 23
2 65
fuse SC-
3
10
If no malfunction is detected in the wiring and the terminal 1 voltage supply was OK:
-- Replace Mass Air Flow (MAF) Sensor -G70-. Refer to the Repair Information.
If no malfunction is detected in the wiring and the terminal 1 voltage supply was Not OK:
Final procedures
ENGINE COOLANT TEMPERATURE SENSOR 1 OR 2 CHECKING
WARNING:  Cooling system is under pressure.

 Danger of scalding when opening!
harness connector of Engine Coolant Temperature (ECT) Sensor -G62-.

 Multimeter.
 Jumper wire.
 Wiring diagram.
Test requirements


 Engine cold.
Test procedure
Start diagnosis

-- Using the scan tool, check the coolant temperature:
Diagnostic
Specified value
text
Coolant
Approx. coolant temperature
temperature
If indication remains at approx. - 40.0°C:
-- Continue test according to the following table:
Indicated Cause Test

TESTING IF DISPLAY IS
approx. - 40.0°C Open circuit or short circuit to (B+)
APPROX. - 40.0°C
TESTING IF DISPLAY
approx. 140.0°C Short circuit to Ground
APPROX. 140.0°C
The temperature value must increase uniformly in increments of 1.0°C.
If the engine shows problems in certain temperature ranges and if the temperature does not climb uniformly, the
temperature signal is intermittent.
-- Replace the Engine Coolant Temperature (ECT) Sensor --. Refer to the Repair Information.
-- Disconnect the Engine Coolant Temperature (ECT) Sensor -- electrical harness connector -1-.
Fig. 64: Engine Coolant Temperature (ECT) Sensor Electrical Harness Connector
-- Using a multimeter, check the Engine Coolant Temperature (ECT) Sensor -- terminals 1 to 2 for resistance.

Use the chart below for the specified values:
Specified values:
ECT Temperature vs Resistance

Temp (C) min. value ohms max. value ohms
- 40 36816 43714
- 35 28840 33978
- 25 17680 20530
- 15 10940 12534
-5 6897 7804
0 5535 6226
5 4443 4970
15 2923 3235
25 1978 2167
35 1369 1486
45 965 1039
55 692 738
65 503 533
75 372 392
85 279 292
95 213 223
105 164 172
115 127 134
125 99 106
135 78 84
Testing if display is approx. - 40.0°C
-- Using a jumper wire, connect the Engine Coolant Temperature (ECT) Sensor -- electrical harness connector
terminals 1 to 2.
-- Check the value indicated on the scan tool display.

If the value jumps to approx. 140.0°C

If indication remains at approx. - 40.0°C:
Checking wiring
-- Using a multimeter, check the Engine Coolant Temperature (ECT) Sensor -- electrical harness connector
terminals to the Engine Control Module (ECM) -J623- electrical harness connector T60 terminals for an open
circuit or a short to voltage, refer to the chart below.

Engine Coolant Temperature (ECT) Sensor - G62- Engine Control Module (ECM) -J623-
electrical harness connector terminals: electrical connector T60 terminals:
1 57
2 14
Engine Coolant Temperature (ECT) Sensor - G83- Engine Control Module (ECM) -J623-
1 36
2 12
Specified values: 1.5 ohms Max. and 0 volts with key on and ECM disconnected.
-- Check the wiring for an open or short circuit to Battery (+).
-- Using a multimeter, check terminal 2 of the ECT sensor to engine ground.
Specified value: 1.5 ohms Max
-- Check the wiring for an open circuit or high resistance.
Testing if display approx. 140.0°C

If indication jumps to approx. - 40.0°C:
If the value remains at approx. 140.0°C
Checking wiring
-- Remove the Engine Control Module (ECM) -J623- and disconnect the ECM connectors. Refer to the Repair
Information.
-- Disconnect the ECT harness connector at the sensor.
-- Using a multimeter, check the signal circuit of the Engine Coolant Temperature (ECT) Sensor -- electrical
harness connector terminal 1 to engine ground.

Specified value: OL or no continuity.
-- Check the wiring for a short circuit to Ground.
Final procedures
IAT SENSOR, CHECKING
harness connector of the IAT sensor -G42- .
 Multimeter.
 Wiring diagram.
Test procedure
Start diagnosis
-- Engine MUST be at room temperature.
-- Using the scan tool, check the intake air temperature:
Diagnostic
Specified value
text
Intake Air
Temperature approx. ambient air temperature
(IAT)
-- Fault may be intermittent. Check for proper connection, damaged wiring or loose terminals.
-- Disconnect the IAT sensor -G42- electrical harness connector.
-- Using a multimeter, check the IAT sensor - G42- terminals 1 to 2 for resistance.
Specified values:
IAT Temperature vs Resistance

- 40 31811 37560
- 35 22941 26863
- 25 12415 14289
- 15 6958 7880
-5 4036 4495
0 3120 3442
5 2422 2655
15 1519 1623
25 968 1031
35 629 676
45 419 455
55 286 314
65 195 217
75 136 155
-- Replace the IAT sensor - G42-. Refer to the Repair Information.
If the specified values are obtained, continue the test according to the following table:
Indicated reading Cause Test

TESTING IF DISPLAY
approx. - 40°C to -46°C Open circuit or short circuit to (B+)
APPROX. - 40°C TO - 46°C:
TESTING IF DISPLAY
approx. 140°C Short circuit to Ground
APPROX. 140°C:
Testing if display approx. - 40°C to - 46°C:
-- Disconnect the IAT sensor - G42- electrical harness connector.


-- Using a jumper wire, connect the IAT sensor - G42- electrical harness connector terminals 1 to 2.
If indication jumps to approx. 140°C:
If indication remains at approx. - 40°C or - 46°C:
Checking wiring
-- Disconnect the ECM harness.
-- Using a multimeter, check the IAT sensor - G42- electrical harness connector terminal 1 to the Engine
Control Module (ECM) -J623- electrical harness connector T60 terminal 42 for an open circuit or a short to
voltage, refer to the wiring diagram.

Specified values: Circuit continuity; 1.5 ohms max; Circuit voltage = 0 volts when disconnected from ECM
(with ignition on).
-- Check the wiring for an open, high resistance or short circuit to Battery (+)
-- Using a multimeter, check terminal 2 of the IAT sensor to engine ground.
Specified value: 1.5 ohms Max
-- Check the wiring for an open circuit or high resistance.
If no malfunction is detected in the ground circuit:

Testing if display approx. 140°C:
-- Disconnect the IAT sensor - G42- electrical harness connector.
If indication jumps to approx. - 40°C or - 46°C:
If the indication remains at approx. 140° C
-- Disconnect the ECM harness.
-- Using a multimeter, check the IAT sensor - G42- electrical harness connector terminal 1 to engine ground.

Specified value: OL or no continuity.

-- Check the wiring for a short circuit to Ground.
If no malfunction is detected in the wiring and the sensor resistance was OK:
Final procedures
AMBIENT AIR TEMPERATURE SENSOR, CHECKING
 Multimeter.
 Wiring diagram.
Test procedure
Start diagnosis
-- Engine MUST be at room temperature.
-- Using the scan tool, check the ambient air temperature:
Diagnostic
Specified value
text
Ambient Air
Temperature
approx. ambient air temperature
(AAT)
Sensor
-- Fault may be intermittent. Check for proper connection, damaged wiring or loose terminals.
NOTE: The reading may default to 419°F if the circuit is open or shorted to ground. The
display on the cluster will show 3 dashes.
-- Disconnect the Ambient Air Temperature Sensor -G17- electrical harness connector.
-- Using a multimeter, check the Ambient Air Temperature Sensor -G17- terminals 1 to 2 for resistance.
Specified values:
AAT Temperature vs Resistance

- 40 31811 37560
- 35 22941 26863
- 25 12415 14289
- 15 6958 7880
-5 4036 4495
0 3120 3442
5 2422 2655
15 1519 1623
25 968 1031
35 629 676
45 419 455
55 286 314
65 195 217
75 136 155
-- Replace the Ambient Air Temperature Sensor -G17-. Refer to the Repair Information.
If the specified values are obtained, continue the test according to the following table:
Checking wiring
-- Connect a multimeter to terminals 1 and 2 of the Ambient Air Temperature Sensor -G17- electrical harness
connector.
Specified value: near 5.02 V
-- Remove the Instrument Cluster. Refer to the Repair Information.
-- Disconnect the Instrument Cluster harness.
-- Using a multimeter, check the Ambient Air Temperature Sensor -G17- electrical harness connector terminals
1 and 2 to the Instrument Cluster electrical harness connector for an open circuit or a short, refer to the
appropriate SYSTEM WIRING DIAGRAMS information.
For 2008 - 2010 Passat:
Instrument
Cluster -
J285-
Ambient Air Temperature Sensor -G17- electrical harness connector terminals: electrical
connector
T36
terminals:
1 33
2 36
For 2010 > CC:
Instrument
Cluster -
J285-
Ambient Air Temperature Sensor -G17- electrical harness connector terminals: electrical
connector
T32
terminals:
1 20
2 19

-- Check the wiring for an open, high resistance or short circuit to Battery (+) or ground.
Replace the Instrument Cluster. Refer to the Repair Information.
Final procedures
ENGINE SPEED SENSOR, CHECKING
harness connector of the Engine Speed (RPM) Sensor -G28-.
 Multimeter.
 Wiring diagram.
Test requirements

Function
The Engine Speed (RPM) Sensor -G28- detects RPM and reference marks. Without an engine speed signal, the
engine may not start. If the engine speed signal fails while the engine is running, the engine may stall.
Test procedure
Start diagnosis
-- Start the engine and allow it to idle.
-- Using the scan tool, check the engine speed:
Diagnostic
Specified value
text
Engine
revolutions
Idle speed
per minute
(RPM)
-- Disconnect the Engine Speed (RPM) Sensor -G28- electrical harness connector.
-- Using a multimeter, check the Engine Speed (RPM) Sensor -G28- terminals 1 to 2 for resistance.
Specified value: 650 to 1100 ohms
-- Replace the Engine Speed (RPM) Sensor -G28-. Refer to the Repair Information.
Checking wiring
-- Using a multimeter, check the Engine Speed (RPM) Sensor -G28- electrical harness connector terminals to
the Engine Control Module (ECM) -J623- electrical harness connector terminals for an open circuit.
Engine
Speed
(RPM)
Sensor -
G28- Engine Control Module (ECM) -J623- electrical harness T60 connector terminals:
electrical
harness
connector
terminals:
1 51
2 36
-- Check the wiring for an open circuit, high resistance or a short circuit to Battery (+).
-- Remove the Engine Speed (RPM) Sensor -G28- and check the sensor wheel for proper seating, damage and
run out Refer to the Repair Information.
If the sensor wheel is OK:

Final procedures
FUEL INJECTORS, CHECKING
The following test procedure is used to diagnose all fuel injectors.
 Multimeter
 Diode test lamp
 Wiring diagram
Test requirements
 The Fuel Injectors -N30, N31, N32, N33- fuses OK.

 The Engine Speed (RPM) Sensor -G28- is OK.

-- Observe safety precautions.
-- Observe rules for cleanliness.
Test procedure
Start diagnosis
-- Remove the engine cover with air filter.
-- Disconnect the Fuel Injector -- electrical harness connectors from Fuel Injectors -N30, N31, N32, N33- -
arrows-.
Fig. 76: Fuel Injector Electrical Harness Connectors

-- Using a multimeter, check the Fuel Injector -- electrical terminals 1 to 2 for resistance.
Fig. 77: Checking Fuel Injector Electrical Terminals 1 To 2 For Resistance

-- Replace the Fuel Injector --. Refer to the Repair Information.
Checking activation and wiring
-- Connect a Diode test lamp to the electrical harness connector terminals 1 and 2 of the Fuel Injector -- to be
tested.
Fig. 78: Checking Fuel Injector Electrical Connector For Voltage

-- Operate the starter and test the activation of the Fuel Injector -- .
LED should flicker.
If LED does not flicker:
-- Remove the Engine Control Module (ECM) -J623- . Refer to the Repair information.
-- Using a multimeter, check the Fuel Injector -- electrical harness connector terminals to the Engine Control
Module (ECM) -J623- electrical harness connector T60 terminals for an open circuit.
Fuel Injector -- Engine Control Module

Component: electrical harness (ECM) -J623- electrical
1 31
Cylinder 1 Fuel Injector -N30-
2 33
1 47
2 49
1 32
2 34
1 46
2 48
Final procedures
INTAKE MANIFOLD RUNNER CONTROL VALVE, CHECKING
 Multimeter.
 Wiring diagram.
Test requirements
 The IMRC valve fuse is OK. Refer to Wiring Diagrams for location.
 The parking brake engaged.
 The selector lever of automatic transmission in position "P" or "N".
Test procedure
-- Perform a preliminary check to verify the customers complaint. Refer to PRELIMINARY CHECK.
Start diagnosis
-- Disconnect the Intake Manifold Runner Control (IMRC) Valve -N316- electrical harness connector.
-- Using a multimeter, check the Intake Manifold Runner Control (IMRC) Valve -N316- terminals 1 to 2 for
resistance.

Specified value: 26 (+/- 10) ohms.
-- Replace the Intake Manifold Runner Control (IMRC) Valve -N316- .
Checking voltage
Switch the ignition ON.
-- Using a multimeter, check the Intake Manifold Runner Control (IMRC) Valve -N316- electrical harness
connector terminal 1 to ground for voltage.

-- Check the wiring from the Intake Manifold Runner Control (IMRC) Valve -N316- electrical harness
connector terminal 1 to fuse Panel B. Refer to Wiring Diagrams for correct fuse number.
Checking wiring
-- Using a multimeter, check the Intake Manifold Runner Control (IMRC) Valve -N316- electrical harness
connector terminal to the Engine Control Module (ECM) -J623- electrical harness connector terminal for
resistance.
Intake
Manifold
Runner
Control
(IMRC)
Valve -
N316-
electrical Engine Control Module (ECM) -J623- electrical harness T60 connector:
harness
connector
terminal:
2 20
-- Check the wiring for a open circuit.
If no malfunction is detected in the wiring, the resistance check and voltage supply were OK:
-- Replace the Engine Control Module (ECM) -J623-. Refer to the appropriate service information.
Final procedures
INTAKE MANIFOLD RUNNER POSITION SENSOR, CHECKING
 Multimeter.
 Wiring diagram.
Test requirements



Test procedure
Start diagnosis
-- Disconnect the Intake Manifold Runner Position Sensor -G336- electrical harness connector.
-- Using a multimeter, check the Intake Manifold Runner Position Sensor -G336- electrical harness connector
terminal 1 to ground for voltage.
Specified value: near 5 V

-- Using a multimeter, connect the black lead to terminal 3 and the red lead to Battery positive.
-- Using a multimeter, check the Intake Manifold Runner Position Sensor -G336- electrical terminals 2 to 3 for
resistance.
Specified value: 7-25 ohms (at approx. 20°C)
-- Using a multimeter, check the Intake Manifold Runner Position Sensor -G336- electrical terminals 1 to 3 for
resistance.
Specified value: 204 - 284 ohms (at approx. 20°C)
-- Replace the Intake Manifold Runner Position Sensor -G336-. Refer to appropriate service information.
Checking wiring
-- Using a multimeter, check the Intake Flap Motor - V157- /Intake Manifold Runner Position Sensor - G336-
electrical harness connector terminals to the Engine Control Module (ECM) -J623- electrical harness connector
T60 terminals for an open circuit.
Intake
Manifold
Runner Engine Control Module (ECM) -J623- electrical connector T60 terminals:
Position
Sensor -
G336-
electrical
harness
connector
terminals:
1 27
2 59
3 13
If no malfunction is detected in the wiring:
Final procedures
VOLTAGE SUPPLY, CHECKING
 Multimeter.
 Wiring diagram.
Test requirements



 Vehicles with automatic transmission, selector lever in position "P" or "N".
Test procedure
Start diagnosis
-- Remove the Engine Control Module (ECM) Power Supply Relay -J271-.
Checking voltage
-- Using a multimeter, check the Power Supply Relay socket 3 (relay terminal 30) to Ground.
-- Check the wiring connections from the Battery to the Engine Control Module (ECM) Power Supply Relay -
J271- socket 3 for an open, high resistance or a short circuit.
-- Check the wiring connections for damage, corrosion, loose or broken terminals.
-- Using a multimeter, check the Engine Control Module (ECM) Power Supply Relay -- socket 2, (relay
terminal 85) to Ground.
-- Remove Fuse 13 in Fuse Panel B and check resistance of circuit between fuse and relay terminal socket 2
(relay terminal 85).
Specified value: 1.5 ohm or less.
-- If fuse is blown, locate short to ground in circuit, refer to the appropriate SYSTEM WIRING DIAGRAMS
information.
-- Repair as necessary.
Checking activation
-- Remove the Engine Control Module (ECM) Power Supply Relay -J271-.
-- Using a diode test lamp (12 V) connected to Battery positive, check the Engine Control Module (ECM)
Power Supply Relay -- socket 1 (relay terminal 86) while cranking the engine.
The test lamp should be ON.
If the test lamp was ON:
-- Replace the Engine Control Module (ECM) Power Supply Relay -J271-: Refer to the Repair information.
If the test lamp was not ON:
-- Using a multimeter, check the Engine Control Module (ECM) Power Supply Relay -- socket 1 (relay terminal
86), to the Engine Control Module (ECM) -J623- electrical harness connector T94 terminal 69 for resistance.
-- Check the wiring connection for an open circuit, high resistance or short circuit to Battery (+).
-- Check the wiring connection for damage, corrosion, loose or broken terminals.
If no malfunction is found in the wiring and ground was not present from the ECM during crank:
Final procedures
SPEED SIGNAL, CHECKING
The following procedure requires a test drive. Observe all safety precautions. Refer to SAFETY
PRECAUTIONS.
 Multimeter.
 Wiring diagram.
Test requirements
 The Speedometer -G21- OK.

 The Engine Control Module (ECM) -J623- fuses OK.


Test procedure
Start diagnosis
-- Perform a road test with a vehicle speed greater than 5 Km/h.
-- Using the scan tool, Check the vehicle speed in the ECM:
Diagnostic text Specified value

Vehicle Speed Approx. Vehicle Speed
-- Compare the vehicle speed on the scan tool to the Speedometer -G21-.
Specified value: a difference of no greater than 10%.
If the specified value was not obtained or no speed was displayed:

-- Some models have a transmission speed sensor input to the TCM while other models get the signal on the
CAN bus from the ABS module. Check the ABS module for wheel speed sensor fault codes, and if present
repair the fault. Refer to Wiring Diagrams to determine if vehicle is equipped with a VSS or is ABS driven.
Final procedures
THREE WAY CATALYTIC CONVERTER, TWC CHECKING
Test requirements

 Oxygen Sensors OK.
 No leaks or damage to exhaust system.
Function test
-- Perform the function test in Diagnostic Mode 06. Refer to DIAGNOSTIC MODE 06 - READ TEST
RESULTS FOR SPECIFIC DIAGNOSTIC FUNCTIONS.
If the specified values are exceeded:
-- Check the exhaust system for leaks.
-- If necessary, repair the leak in the exhaust system.
-- Erase the DTC memory. Refer to DIAGNOSTIC MODE 04 - ERASE DTC MEMORY.
-- Perform a road test to verify Repair.
If the DTC does Not return:
If no leaks are found in the exhaust system:
-- Replace the catalytic converter with front exhaust pipe. Refer to the Repair Information.
Final procedures
CAMSHAFT POSITION SENSOR, CHECKING
of Camshaft Position (CMP) Sensor -G40-.
 Multimeter.
 Wiring diagram.
Test requirements


Test procedure
Start diagnosis
-- Disconnect the Camshaft Position Sensor electrical harness connector -2-.
Fig. 85: Camshaft Position Sensor Electrical Harness Connector

-- Using a multimeter, Check the Camshaft Position (CMP) Sensor -G40- electrical harness connector terminals
1 to 3 for voltage.
Specified value: near 5.0 V
Checking wiring
-- Using a multimeter, Check the Camshaft Position (CMP) Sensor -G40- electrical harness connector to the
Engine Control Module (ECM) electrical harness connector T60 for an open circuit.
Fig. 86: 3-Pin Electrical Harness Connector

Camshaft
Position
(CMP)
Sensor -
G40- Engine Control Module (ECM) electrical harness connector T60 terminals:
electrical
harness
connector
terminals:
1 29
2 53
3 8
-- Check the wiring connection for an open circuit, short circuit to Battery (+) or Ground.

If no malfunction is found in the wiring and voltage supply was OK:
-- Replace the Camshaft Position (CMP) Sensor -G40-. Refer to the Repair Information.
If no malfunction is found in the wiring and voltage supply was Not OK:
Final procedures
1. Check the DTC memory DIAGNOSTIC MODE 03 - READ DTC MEMORY.

2. If necessary, erase the DTC memory DIAGNOSTIC MODE 04 - ERASE DTC MEMORY.
3. If the DTC memory was erased, generate readiness code READINESS CODE.
CAMSHAFT ADJUSTMENT VALVE 1, CHECKING
 Multimeter.
 Wiring diagram.
Test requirements
 The Camshaft Adjustment Valve 1 -N205- fuse OK.

 Engine Control Module (ECM) Power Supply Relay -J271- OK.

Test procedure
Start diagnosis
-- Disconnect Camshaft Adjustment Valve 1 -N205- electrical harness connector -1-.
Fig. 88: Identifying Camshaft Adjustment Valve 1 Connector, Wiring Harness & Bolts
-- Using a multimeter, check the Camshaft Adjustment Valve 1 -N205- for resistance.

-- Replace the Camshaft Adjustment Valve 1 -N205-. Refer to the Repair Information.
Checking voltage
-- Using a multimeter, Check the Camshaft Adjustment Valve 1 -N205- electrical harness connector terminal 1
to engine ground for voltage.
-- Check the wiring connection for an open circuit, high resistance or short circuit to Ground.

Checking wiring
-- Remove the Engine Control Module (ECM) -J623- . Refer to the Repair Information.
-- Using a multimeter, Check the Camshaft Adjustment Valve 1 -N205- electrical harness connector terminal to
the Engine Control Module (ECM) electrical harness connector terminal for an open or high resistance.

Camshaft
Adjustment
Valve 1 -
N205-
Engine Control Module (ECM) electrical harness connector T60 terminal:
electrical
harness
connector
terminal:
2 5
Final procedures
KNOCK SENSOR 1, CHECKING
The following procedure is used to diagnose all Knock Sensors -- .
 Multimeter.
 Wiring diagram.
Test requirements
 The mounting bolt of Knock Sensor (KS) 1 -G61- tightened to 20 Nm.



Test procedure
Start diagnosis
NOTE: Before disconnecting the Knock Sensor electrical harness connectors, mark the
component location.
-- Disconnect the green Knock Sensor (KS) 1 -G61- electrical harness connector -1- electrical harness
connector.
Fig. 92: Identifying Engine Speed (RPM) Sensor G28 Electrical Harness Connector

-- Using a multimeter, check the Knock Sensor terminals 1 to 2 for an internal short.
Fig. 93: Identifying Engine Speed (RPM) Sensor G28 Terminals

Specified value: infinity (Infinity) or OL.
-- Replace the faulty Knock Sensor (KS) 1 -G61-. Refer to the Repair Information.
Checking wiring
-- Using a multimeter, Check the Knock Sensor electrical harness connector to the Engine Control Module
(ECM) J623 electrical harness connector T60 for an open circuit.
Fig. 94: Identifying 3-Pin Connector

Knock Sensor (KS) 1 -G61- electrical harness Engine Control Module (ECM) electrical harness
1 25
2 10
3 8
-- Check the wiring connection for an open circuit, high resistance or short circuit to Battery (+) or Ground.
If no malfunction is found in the wiring and the sensor resistance was OK:
-- Replace the Engine Control Module (ECM) -J623- . Refer to the Repair Information.
Final procedures
IGNITION COILS WITH POWER OUTPUT STAGE, CHECKING
The following procedure is used to diagnose all Ignition Coil with Power Output Stage --.
 Multimeter.
 Diode test lamp.
 Wiring diagram.
Test requirements
 The Ignition Coil with Power Output Stage - N70, N127, N291, N292- fuses OK.

 The Engine Control Module (ECM) Power Supply Relay -J271- OK.
 The Engine Speed (RPM) Sensor -G28- OK.
 The Camshaft Position (CMP) Sensor -G40- OK.

Test procedure
Start diagnosis
-- Remove the Ignition Coils with Power Output Stage -N70, N127, N291, N292- electrical harness screws -1-.
Fig. 96: Removing Ignition Coils Electrical Harness Screws

-- Disconnect the Ignition Coil with Power Output Stage -N70, N127, N291, N292- electrical harness
connectors -arrows- from the Ignition Coil with Power Output Stage -N70, N127, N291, N292-.
Fig. 97: Disconnect Connectors Of Ignition Coils

-- Using a multimeter, check the Ignition Coil electrical harness connector terminals 1 to 4 for voltage.


-- Remove fuse 10 in Fuse Panel B. Check the Ignition Coil electrical harness connector terminal 1 to fuse 10 in
Fuse Panel B for a short to ground or an open circuit.
-- Check the wiring connection for an open circuit or a short circuit to Ground.
Checking activation
WARNING: Do not touch the Ignition Coils -- connecting parts or adapter cables
during the following test.
-- Using a Diode test lamp, check the Ignition Coil -- electrical harness connector terminals 2 to 3 for voltage.

-- Operate the starter.
The LED should flicker.
If the LED flickers and the voltage was OK:
-- Replace the faulty Ignition Coil with Power Output Stage -N70, N127, N291, N292-. Refer to the Repair
Information.
If the LED does not flicker:
Checking wiring
-- Using a multimeter, Check the Ignition Coil electrical harness connector to the Engine Control Module
(ECM) J623 electrical harness connector T60 for an open circuit.

Ignition
Coils
with
Power
Output
Stage -
N70,
N127,
N291,
292-
electrical Engine Control Module (ECM) electrical harness connector T60 terminal:
harness
connector
terminal:
(N70) 3 7
(N127) 3 21
(N291) 3 22
(N292) 3 6
-- Connect the Ignition Coils with Power Output Stage -N70, N127, N291, N292- electrical harness connectors -
arrows- to the Ignition Coils with Power Output Stage -N70, N127, N291, N292-.
Fig. 101: Connecting Connectors To Ignition Coils

-- Install the Ignition Coils with Power Output Stage -N70, N127, N291, N292- electrical harness screws -1-.
Fig. 102: Removing Ignition Coils Electrical Harness Screws

Final procedures
SELECTOR LEVER VOLTAGE SUPPLY, CHECKING
 Multimeter.
 Wiring diagram.
Test requirements
 The Direct Shift Gearbox (DSG) Mechatronic -J743- fuses OK.



 Selector lever in "P".
Test procedure
Start diagnosis
-- Remove the selector mechanism, far enough to gain access to the Selector Lever -E313- electrical harness
connector -A-. Refer to the Repair Information.
-- Disconnect the Selector Lever -E313- electrical harness connector -A-.

Fig. 104: Disconnecting Selector Lever E313 Electrical Harness Connector

Checking voltage supply, terminal 30
-- Using a multimeter, check the Selector Lever -E313- electrical harness connector terminals 10 to 1 for
voltage.
-- Using a multimeter, check the Selector Lever -E313- electrical harness connector terminals 9 to 1 for voltage.
If the wiring and voltage were OK:
-- Replace the Selector Lever -E313-. Refer to the Repair Information.
Final procedures
VOLTAGE SUPPLY OF DIRECT SHIFT GEARBOX MECHATRONIC, CHECKING
 Multimeter.
 Wiring diagram.
Test requirements

 The Power Supply Relay (terminal 15) - J329- OK.

 Selector lever in "P" or "N".
Test procedure
Start diagnosis
-- Disconnect the Direct Shift Gearbox (DSG) Mechatronic -J743- electrical harness connector -1- by rotating
counterclockwise.
Fig. 106: Disconnecting Direct Shift Gearbox (DSG) Mechatronic J743 Electrical Harness Connector By
Rotating Counterclockwise
-- Using a multimeter, check the Direct Shift Gearbox (DSG) Mechatronic -J743- electrical harness connector
terminals for voltage.
Direct Shift Gearbox (DSG) Mechatronic -J743- electrical harness connector terminals
11 to 16
11 to 19
Voltage supply, terminal 15
terminals for voltage.
Direct Shift Gearbox (DSG) Mechatronic -J743- electrical harness connector terminals
18 to 16
18 to 19
-- Replace Direct Shift Gearbox (DSG) Mechatronic -J743-. Refer to the Repair Information.
Final procedures
CAN-BUS TERMINAL RESISTANCE, CHECKING
 Multimeter.
 Wiring diagram.
Test requirement
 A CAN-Bus malfunction was recognized.



Function
The Engine Control Module (ECM) -J623- communicates with other CAN-Bus capable control modules.
The control modules are connected by two data Bus wires which are twisted together (CAN High and CAN
Low), and exchange information (messages). Missing information on the CAN-Bus is recognized as a
malfunction by the Engine Control Module (ECM) -J623- and the other control modules connected to the CAN-
Bus.
Trouble-free operation of the CAN-Bus requires that it have a terminal resistance. This central terminal
resistance is located in the Engine Control Module (ECM) -J623- .
Test procedure
Start diagnosis
-- Disconnect the Data Bus On Board Diagnostic Interface -J533- electrical harness connector.
NOTE: The Engine Control Module (ECM) -J623- must remain connected for the
following step.
-- Using a multimeter, check the Data Bus On Board Diagnostic Interface -J533- electrical harness connector
terminals 6 to 16 for resistance.
If no malfunction is found in the wiring and the specified value was Not obtained
Checking wiring
-- Using a multimeter, check the Data Bus On Board Diagnostic Interface -J533- electrical harness connector to
the Engine Control Module (ECM) -J623- electrical harness connector T94 for resistance.
Data Bus
On Board
Diagnostic
Interface -
J533-
electrical
connector Engine Control Module (ECM) -J623- electrical connector T94 terminals:
T20
terminals:
6 (Can-
67
Bus Low)
16 (Can-
68
Bus High)
If no malfunction is found in the wiring:
-- Replace the Data Bus On Board Diagnostic Interface -J533- .
Final procedures
CAN-BUS TERMINAL RESISTANCE, DIRECT SHIFT GEARBOX MECHATRONIC TO ENGINE CONTROL MODULE,
CHECKING
 Multimeter.
 Wiring diagram.
Test requirement
 A CAN-Bus malfunction was recognized.

 The Engine Control Module (ECM) - J623- Direct Shift Gearbox (DSG) Mechatronic -J743- fuses OK.


Function
The Engine Control Module (ECM) -J623- communicates with other CAN-Bus capable control modules.
The control modules are connected by two Data Bus wires which are twisted together (CAN High and CAN
Low), and exchange information (messages). Missing information on the CAN-Bus is recognized as a
malfunction by the Engine Control Module (ECM) -J623- and the other control modules connected to the CAN-
Bus.
Trouble-free operation of the CAN-Bus requires that it have a terminal resistance. This central terminal
resistance is located in the Engine Control Module (ECM) -J623-.
NOTE: The Direct Shift Gearbox (DSG) Mechatronic -J743- aside from including
actuating solenoids also contains what is referred to as the TCM.
Test procedure
Start diagnosis
-- Disconnect the Direct Shift Gearbox (DSG) Mechatronic -J743- electrical harness connector.
NOTE: The Engine Control Module (ECM) -J623- must remain connected for the
following step.
terminals 10 to 15 for resistance.
If the specified value was obtained and the TCM messages were not received:
-- Check the TCM power and grounds at the module. Refer to the appropriate SYSTEM WIRING DIAGRAMS
information. If power or ground is lost, the TCM will not communicate. Correct any power or ground fault
before replacement of any component.
If TCM power and grounds are present:
-- Replace the Direct Shift Gearbox (DSG) Mechatronic -J743-. Refer to the Repair Information.
Checking wiring
-- Using a multimeter, check the Direct Shift Gearbox (DSG) Mechatronic -J743- electrical harness connector to
the Engine Control Module (ECM) -J623- electrical harness connector T94 for resistance.
Direct Shift Gearbox (DSG) Mechatronic -J743- Engine Control Module (ECM) -J623-
15 (Can-Bus Low) 67
10 (Can-Bus High) 68
-- Check the wiring connection for high resistance, an open circuit, short circuit to Battery (+) or Ground.

If no malfunction is found in the wiring and the 60 - 72 ohm resistance was Not obtained:
Final procedures
ENGINE 2.0 Liter - Ignition/Glow Plug System - Engine Code(s): CBFA & CCTA
ENGINE
2.0 Liter - Ignition/Glow Plug System - Engine Code(s): CBFA & CCTA
28 IGNITION/GLOW PLUG SYSTEM

GENERAL INFORMATION
SAFETY PRECAUTIONS
To reduce the risk of personal injury and/or damage to the fuel injection and ignition system, always observe
the following:
 Do not touch or disconnect the ignition coils with power output stages when the engine is running or
turning at starting speed.
 Only disconnect and reconnect wires for the injection and ignition system, including test leads, when the
ignition is turned off.
 If the engine is to be cranked at starting speed without starting, disconnect the connectors from the
ignition coils and fuel injectors. After performing work, check and erase the Diagnostic Trouble Code
(DTC) memory.
 Cleaning the engine should only be performed with the ignition turned off.
 The battery must only be disconnected and connected with the ignition is turned off, since the Engine
Control Module (ECM) can otherwise be damaged.
If special testing equipment is required during a road test, note the following:
 Testing and measuring instruments must be secured on the rear seat and operated by a second person
from that location.
If the vehicle is involved in a collision while testing and measuring equipment is operated from the front
passenger seat, the person sitting in that seat could be seriously injured when the airbag deploys.
IGNITION SYSTEM
 The ignition must be turned off when disconnecting the battery. Obtain the radio code for radios with a
anti-theft code before disconnecting the battery.
 Observe the required safety precautions after connecting the battery. Refer to Removal and Installation .
 For trouble-free operation of the electrical components a voltage of at least 11.5 bolts is necessary.
 To complete the procedure, check the Engine Control Module (ECM) Diagnostic Trouble Code (DTC)
memory and erase any DTCs that may have been stored when testing and making the repairs. If the DTC
memory was erased, the readiness code must be generated again, refer to "Guided Fault Finding" in the
 If the engine only starts briefly and then shuts off again after troubleshooting, repairs or checking of the
components, it may be that the immobilizer is blocking the ECM. The control module may have to be
adapted then. Refer to "Guided Functions" in the vehicle diagnostic tester.
IGNITION SYSTEM COMPONENT OVERVIEW
Fig. 1: Identifying Assembly Overview: Ignition System Component

1. Knock Sensor 1 -G61-

 On the front of the cylinder head under the intake manifold.
 Removing and installing, refer to Knock Sensor 1 -G61-.
 Contacts are gold plated.
2. Bolt
 20 Nm
 Tightening specification, affects the function of the knock sensor.
3. Ignition Coil with Power Output Stage -(N70, N127, N291, N292)-
 Removing and installing, refer to IGNITION COILS WITH POWER OUTPUT STAGES.
4. Spark Plug
 25 Nm
 Type and electrode gap, refer to TEST DATA AND SPARK PLUGS.
 Remove and install using the spark plug removal tool -3122 B-.
5. O-ring
 Always replace.
6. Engine Speed Sensor -G28-

 On the front, lower, left of the cylinder block, next to the oil separator, refer to Fig. 2.
 Removing and installing, refer to Engine Speed Sensor -G28-.
7. Bolt
 10 Nm
8. Camshaft Position Sensor -G40-

 In the front of the cylinder head cover.
 Contacts are gold plated.
Fig. 2: Identifying Engine Speed (RPM) Sensor G28 Connector -1-

SPECIFICATIONS
TEST DATA AND SPARK PLUGS

Engine Codes CBFA and CCTA

Ignition sequence 1-3-4-2
Spark plugs
VW/Audi 101 905 631 H
Electrode gap 1.0 to 1.1 mm
Tightening specifications 25 Nm
Change intervals Refer to Maintenance Intervals

Camshaft Position Sensor Bolt - 10
Engine Speed Sensor Bolt - 10
Knock Sensor Bolt - 20
Spark Plug - 25
IGNITION COILS WITH POWER OUTPUT STAGES
Removing
NOTE: Follow all safety precautions. Refer to SAFETY PRECAUTIONS.
Ignition system component overview. Refer to IGNITION SYSTEM COMPONENT

OVERVIEW.
To pull off spark plugs, place the ignition coil puller -T40039- on the topmost
thick rib -arrow- of the ignition coil with power output stage.
Fig. 3: Identifying Placement Of Ignition Coil Puller T40039 On Top Most Thick
Rib Of Ignition Coils
Lower ribs may be damaged if they are used.
-- Pull all the ignition coils out approximately 30 mm from the spark plug holes using the ignition coil puller -
T40039-.
Fig. 4: Identifying Ignition Coil Puller T40039

-- Release the connector -arrows- and disconnect all connectors from the ignition coils at the same time.
Fig. 5: Identifying Direction To Disconnect Ignition Coils Connectors

Installing
-- Insert all ignition coils loosely into the spark plug shafts.
-- Align the ignition coils with the connectors -arrows- and connect them all at the same time.
Fig. 6: Identifying Connectors To Ignition Coils

-- Press the ignition coils evenly onto the spark plugs by hand.
Knock Sensor 1 -G61-
Removing
-- Remove the electrical connector -2- from the knock sensor 1.
Fig. 7: Identifying Electrical Connector -2- To Knock Sensor 1

-- Remove the coolant pump. Refer to COOLANT PUMP .
NOTE: The knock sensor 1 is located below the intake manifold behind the coolant
pump.
-- Remove the knock sensor 1.
Installing
-- Installation is performed in reverse order.
 Tightening specifications, refer to IGNITION SYSTEM COMPONENT OVERVIEW.
Engine Speed Sensor -G28-
Removing
-- Remove the engine cover.
-- Open the air guide pipe hose clamp -2-.

-- Disconnect the electrical harness connector -arrow-.
-- Remove the bolts -1 and 4- and remove the charge air pipe downward from the throttle valve control module -
J338-.
-- Remove the charge air hose -1- from the charge air cooler and remove the charge air pipe downward.

-- Disconnect the electrical connector -1- from engine speed sensor.
-- Remove the engine speed sensor bolt.
Installing
 Tightening specification, see -item 6- in the IGNITION SYSTEM COMPONENT OVERVIEW.
SPECIAL TOOLS

Fig. 11: Identifying Extractor T40039

Edition 12052011 FB
ENGINE 2.0 Liter - Lubrication - Engine Code(s): CBFA & CCTA
ENGINE
2.0 Liter - Lubrication - Engine Code(s): CBFA & CCTA
17 LUBRICATION
GENERAL INFORMATION
ENGINE OIL
Oil System Capacity
For the correct engine oil and capacity, refer to the Fluid Capacity Tables.
Changing the oil, refer to the Maintenance Procedures.
Checking the Oil Level
NOTE: The oil level must not exceed the MAX mark - danger of damaging the catalytic
converter.
Test Conditions
 The engine oil temperature is a minimum of 60 °C (140 °F).

 The vehicle is on level ground.
 After turning off the engine, wait a few minutes to allow the oil to flow back into the oil pan.
Test Sequence
-- Pull out the oil dipstick, wipe it off with a clean cloth and reinsert it all the way into the guide tube.
-- Pull out the dipstick again and check the oil level.
Range of marks on the dipstick:

Fig. 1: Identifying Dipstick Markings

a - Oil must not be added.
b - Oil may be topped off.
c - Oil must be added.
NOTE: The oil level must not exceed the MAX. mark -arrow 1- and must not fall short of
the MIN. mark -arrow 2-.
OIL PAN AND OIL PUMP OVERVIEW
NOTE: If large quantities of metal particles or abraded material are detected during
engine repairs, it may mean the crankshaft or rod bearings are damaged. To
prevent further damage, perform the following steps after the repair:
Carefully clean the oil passages.
Replace the oil injection jets.
Replace the oil cooler.
Replace the oil filter.
The oil level must not exceed the MAX. mark - danger of damaging the catalytic
Fig. 2: Identifying Oil Pan And Oil Pump Assembly Overview

1. Oil Level Thermal Sensor -G266-

2. Gasket
 Always replace.
3. Bolt
 Always replace.

4. Lower Oil Pan

 Removing and installing, refer to LOWER OIL PAN.
5. Bolt
 9 Nm
6. Oil Baffle
 Always replace.
7. Bolt
 M6 bolt - 9 Nm.
 M8 bolt - 20 Nm.
8. Oil Pump
 Removing and installing, refer to OIL PUMP.
9. Centering Sleeve
10. Chain Tensioner
11. Guide Pin
 9 Nm
12. Bolt
 9 Nm
13. Oil Pressure Regulation Valve -N428-

14. O-ring
 Always replace.
15. Oil Pump Drive Chain

 Mark the direction of rotation before removing.
16. Gasket
 Always replace.
17. Oil Separator

 Removing and installing, refer to OIL SEPARATOR.
18. Bolt
19. Upper Oil Pan

 Removing and installing, refer to UPPER OIL PAN.
20. Bolt
 9 Nm
21. Bolt
 Always replace.

22. Oil Intake Pipe
 Clean the strainer if contaminated.
23. O-ring
 Always replace.
24. O-ring
 Always replace.
25. O-ring
 Always replace.
26. Non-Return Valve

27. Oil Drain Plug
 30 Nm
28. Nut
 9 Nm
Fig. 3: Identifying Oil Pan, Lower Part Tightening Sequence

-- Tighten the bolts -1 through 20- in 3 passes as follows:

Fig. 4: Identifying Upper Part Of Oil Pan Tightening Sequence


Fig. 5: Identifying Oil Separator Tightening Sequence

OIL FILTER, OIL COOLER AND OIL PRESSURE SWITCH OVERVIEW
Fig. 6: Identifying Oil Filter And Oil Cooler Assembly Overview

1. Accessory Bracket
 Removing and installing, refer to ACCESSORY BRACKET .
2. Oil Pressure Switch -F1-

 20 Nm
 1.4 bar - black

 Checking, refer to OIL PRESSURE AND SWITCH, CHECKING.

 Remove using the socket 24 mm and jointed extension -T40175-.
3. Gasket
 Always replace.
4. O-ring
 Always replace.
5. O-ring
 Always replace.
6. Valve Unit
7. Oil Filter Element
 22 Nm
 Remove and install using the oil filter wrench -3417-.
8. Bolt
 15 Nm
9. Connection
10. Seal
 Always replace.
11. Oil Cooler

 See the note in OIL PAN AND OIL PUMP OVERVIEW.
 Ensure sufficient clearance to surrounding components.
 Coolant hose connection diagram. Refer to COOLANT HOSE CONNECTION DIAGRAM .
 Removing and installing, refer to OIL COOLER.
12. Gasket
 Always replace.
13. Bolt

SPECIFICATIONS

Oil Baffle to Upper Oil Pan Bolt - 9
Oil Cooler to Accessory Bracket Bolt - 15
Oil Drain Plug to Lower Oil Pan - 30
Oil Filter Element to Accessory Bracket - 22
Oil Intake Pipe to Oil Pump Bolt - 9
Oil Pressure Switch to Accessory Bracket - 20
Oil Pump Drive Chain Tensioner Guide Pin to
- 9
Cylinder Block Bolt
Oil Pump to Upper Oil Pan Bolt
M6 9
M8 20
Lower Oil Pan Bolt Tightening Sequence and Specification

1. Tighten the bolts hand tight

Upper Oil Pan Bolt Tightening Sequence and Specification


1. Tighten the bolts hand tight

Oil Separator Bolt Tightening Sequence and Specification

OIL PRESSURE AND SWITCH, CHECKING
 Oil Pressure Gauge -V.A.G 1342-

 Voltage Tester -V.A.G 1527 B-
 Connector Test Set -V.A.G 1594 C-
 Socket 24 mm and Jointed Extension -T40175-
Requirements
 The engine oil level OK

 The engine oil temperature at least 80 °C (176 °F) (coolant fan must start up once).
NOTE: Function test and servicing the optical and acoustic oil pressure indicator, refer
to wiring diagrams, vehicle diagnostic tester "Function and Component
Selection".
Test Sequence
 Tightening specification, see -item 2- in the OIL FILTER, OIL COOLER AND OIL PRESSURE
SWITCH OVERVIEW.
-- Remove the oil pressure switch -F1- and install it into the oil pressure gauge.
Fig. 11: Identifying Diode Test Lamp V.A.G 1527 B, Auxiliary Cables -V.A.G 1594 A-, Battery Positive
(+) And Oil Pressure Switch
-- Thread the oil pressure gauge into the oil filter bracket in place of the oil pressure switch.
-- Connect the brown wire on the tester to the ground (-).
-- Connect the voltage tester -V.A.G 1527 B- using adapter cables from the connector test set -V.A.G 1594 C-
to battery positive (B+) and the oil pressure switch. The Light Emitting Diode (LED) must not light up.
-- If the LED lights up, replace the oil pressure switch.
If the LED does not light up:
-- Start the engine and increase the engine speed: The LED must illuminate at 1.2 to 1.6 bar. Replace the oil
pressure switch if it does not.
-- Increase the engine speed further. At 2000 RPM and an oil temperature of 80 °C (176 °F), the oil pressure
must be between 2.7 and 4.5 bar.
At higher engine speeds the oil pressure must not exceed 7.0 bar
If the specification is not obtained:
-- Check the screen in the oil intake pipe for contamination.
NOTE: Also, mechanical damage, for example, bearing damage can also be the cause
of too low oil pressure.
-- Replace the oil pump. Refer to OIL PUMP.
If the specification is exceeded:
-- Check the oil passages.
OIL SEPARATOR
Removing
-- Remove the bolts -1 through 9- and remove the oil separator.

CAUTION: Risk of contaminating the lubricating system.
 Seal the opening with a clean cloth.
Installing
NOTE: Always replace gaskets and seals.


LOWER OIL PAN
 Used Oil Collecting and Extracting Device -V.A.G 1782-

 Hand Drill with Plastic Brush Attachment
Removing
-- Drain the engine oil.
NOTE: Observe disposal regulations.


-- Remove the oil pan, if necessary loosen by applying light strikes from a rubber mallet.
Installing
 Tightening specifications, refer to OIL PAN AND OIL PUMP OVERVIEW.
The oil pan must be installed within 5 minutes after application of the silicone
sealant.
-- Remove the sealant residue from the upper oil pan with a flat scraper.
WARNING: Risk of eye injury.
 Wear protective eyewear.
-- Remove any remaining sealant from the lower oil pan using, for example, a rotating plastic brush.
Fig. 15: Identifying Removal Of Residual Sealant On Oil Pan E.G. With Rotating Plastic Brush
-- Apply the silicone sealant -D 174 003 A2- to the clean sealing surfaces of the lower oil pan as shown in the
illustration.
Fig. 17: Identifying Lower Section Of Oil Pan Sealing Surfaces

NOTE: The oil pan must be installed within 5 minutes after application of the silicone
sealant.
-- Immediately install the lower oil pan and tighten the bolts -1 through 20- in three passes as follows:


NOTE: After installing the oil pan, allow the sealant to dry for approximately 30
minutes. Only after then may the engine oil be added.
-- Fill the engine oil, refer to ENGINE OIL.
OIL PUMP
Removing
-- Remove the lower oil pan. Refer to LOWER OIL PAN.
-- Remove the oil baffle bolts -arrows- and baffle.

Fig. 19: Identifying Oil Baffle Bolts And Baffle

NOTE: The following procedure must be performed in one step. A second technician is
needed.
Fig. 20: Identifying Oil Pump Bolts

-- Pull back the chain tensioner using the assembly tool -T10118- and have a second technician remove the oil
pump.
Fig. 21: Identifying Chain Tensioner And Assembly Tool T10118

Installing
Fig. 22: Identifying Chain Tensioner And Assembly Tool T10118

-- Pull the chain tensioner back using the assembly tool -T10118- and route the drive chain on the oil pump.
The rest of the installation is performed in reverse order of removal, noting the following:
Tightening specifications, refer to OIL PAN AND OIL PUMP OVERVIEW.
-- Check the strainer in the oil intake pipe and the oil passages in the upper oil pan for contamination before
installing the oil pump.
-- Make sure both alignment sleeves for centering the oil pump are installed.
-- Replace the oil baffle.
NOTE: There are plastic ribs on the oil baffle that permanently deform when tightening.
The plastic ribs ensure the oil baffle is not loosen and does not rattle. Because
of this, always replace the oil baffle.
UPPER OIL PAN
 Testing Tool for Brake Wear -VW 136-

Removing
-- Remove the transmission, refer to the following:
 [For engine(s) CCTA] Removing .

 REMOVING .
 [For transmission(s) 02Q] REMOVING .
-- Remove the oil pump. Refer to OIL PUMP.
-- Remove the sealing flange. Refer to SEALING FLANGE, TRANSMISSION SIDE .
-- Remove the right front wheel housing liner. Refer to Removal and Installation .


-- Remove the bolt -1-
-- Disconnect the wiring bracket mount next to the after-run coolant pump -V51- from the upper oil pan.
Fig. 25: Identifying Bolts

CAUTION: Risk of injury. When removing the upper oil pan, the chain tensioner
spring for the oil pump will jump from the upper oil pan to the lower timing
chain cover. When removing the upper oil pan, do not reach between the
section and the lower timing chain cover.
-- Remove the bolts -1 through 14- and pry off the upper oil pan.

CAUTION: First, pry the upper oil pan off on the transmission side. When prying off,
be careful not to bend the timing chain cover.
Installing
 Tightening specifications, refer to OIL PAN AND OIL PUMP OVERVIEW.
The upper oil pan must be installed within 5 minutes after application of the
silicone sealant.
-- Using the assembly tool -T10118-, pull the spring in the oil pump drive chain tensioner in the -direction of
the arrow-.
Fig. 27: Identifying Assembly Tool -T10118- And Testing Tool For Brake Wear -VW 136-
-- Secure the spring by inserting the testing tool for brake wear -VW 136- into the hole in the guide rail as
illustrated.
-- Remove any sealant residue from the cylinder block with a flat scraper.
WARNING: Risk of eye injury.
 Wear protective eyewear.

-- Remove the remaining sealant on the upper oil pan and lower timing chain cover, for example with a rotating
plastic brush.
NOTE: See if the timing chain cover is deformed. Then mount the upper oil pan without
any sealant and check the gap between the cover and the upper oil pan. If
deformation is found and the cover cannot be aligned, replace the cover after
installing the upper oil pan.
-- Make sure the oil passages in the upper oil pan and in the cylinder crankcase are clean.
-- Apply the silicone sealant -D 174 003 A2- to the clean sealing surface of the upper oil pan as shown -arrows-.
Fig. 30: Identifying Silicone Sealant -D 174 003 A2- And Sealing Surface Of Upper Oil Pan
 Thickness of sealant bead: 2 to 3 mm
NOTE: The upper oil pan must be installed within 5 minutes after application of the
silicone sealant.
 On the transmission side, the upper oil pan and the crankcase must align.
-- Immediately install the upper oil pan and tighten the bolts -1 through 14- in three passes as follows:


-- Install the bolts -arrows-. Tightening specification, refer to Fig. 32.

Fig. 32: Identifying Outer Oil Pan Bolts

Fig. 33: Identifying Bolts

-- Remove the testing tool for brake wear -VW 136- from the guide rail -arrow-. The spring now returns to the
installed position.
Fig. 34: Identifying Testing Tool For Brake Wear -VW 136- And Guide Rail
OIL COOLER
Removing
and open carefully.
-- Remove the accessory bracket. Refer to ACCESSORY BRACKET .
-- Remove the bolts -4 and 5- and remove the oil cooler -3- together with the seal -2-.
Fig. 35: Identifying Oil Cooler, Bolts And Seal

Installing
 Tightening specifications, refer to OIL FILTER, OIL COOLER AND OIL PRESSURE SWITCH
OVERVIEW.
NOTE: Always replace the gaskets and seals.
-- Install the oil cooler -3- with a new seal -2-.

Fig. 36: Identifying Oil Cooler, Bolts And Seal

SPECIAL TOOLS
 Used Oil Collecting and Extracting Device -V.A.G 1782-
Fig. 37: Identifying Oil Extractor V.A.G 1782


Fig. 38: Identifying Drip Tray For Shop Crane VAS 6208
Fig. 39: Identifying Oil Pressure Gauge, Voltage Tester And Connector Test Set
 Oil Pressure Gauge -V.A.G 1342-

 Voltage Tester -V.A.G 1527 B-
 Connector Test Set -V.A.G 1594 C-
 Socket 24 mm and Jointed Extension -T40175-
Fig. 40: Identifying Testing Tool for Brake Wear, Assembly Tool And Torque Wrench
 Testing Tool for Brake Wear -VW 136-

ENGINE 2.0 Liter - Multiport Fuel Injection - Engine Code(s): CBFA & CCTA
ENGINE
2.0 Liter - Multiport Fuel Injection - Engine Code(s): CBFA & CCTA
24 MULTIPORT FUEL INJECTION

GENERAL INFORMATION
ON BOARD DIAGNOSTICS
 The Engine Control Module (ECM) is equipped with On Board Diagnostics (OBD). Before repairs such
as fault finding, check the Diagnostic Trouble Code (DTC) memory first. Also the vacuum hoses and
connections must be checked (unmetered air).
 Fuel hoses in the engine compartment must only be secured with spring type clamps. The use of clamp or
screw type clamps is not permissible.
 For the electric components to work properly, a voltage of at least 11.5 volts is required.
 Do not use sealants containing silicone. Particles of silicone drawn into the engine, will not be burnt in
the engine and may damage the oxygen sensors.
 The vehicle has a crash fuel shut off. It reduces the risk of fire in a collision because the fuel pump relay
switches the fuel pump off.
 This setup also makes it easier to start the engine. When the drivers side door is opened, the fuel pump is
activated for 2 seconds so that pressure builds in the fuel system, observe the safety measures. Refer to
SAFETY PRECAUTIONS .
COMPONENT LOCATION OVERVIEW
Components A through E are not shown in the exploded view illustration.

Fig. 1: Identifying Assembly Overview: Multi-Port Fuel Injection Component Locations

1. 1 - Camshaft Adjustment Valve 1 -N205-

 Removing and installing, refer to Camshaft Adjustment Valve 1 -N205- .
2. 2 - Wastegate Bypass Regulator Valve -N75-

 Installed directly on the turbocharger, refer to Fig. 10.
3. 3 - Turbocharger Recirculation Valve -N249-

 Installed directly on the turbocharger, refer to Fig. 10.
4. 4 - Ignition Coils with Power Output Stages

 Removing and installing, refer to IGNITION COILS WITH POWER OUTPUT STAGES .
 Ignition coil 1 with power output stage -N70-.

 The ignition coils must be pulled out of the cylinder head using the ignition coil puller -T40039-.
5. 5 - Engine Control Module -J623-

 Passat and CC, refer to ENGINE CONTROL MODULE -J623-.
6. 6 - High Pressure Pump With Fuel Pressure Regulator Valve -N276-

 Component location: See the Fig. 2.
 Removing and installing, refer to HIGH PRESSURE PUMP.
 Overview, refer to HIGH PRESSURE PUMP WITH FUEL PRESSURE REGULATOR

VALVE -N276- OVERVIEW.
7. 7 - Fuel Pressure Regulator Valve -N276-
 Component location: see Fig. 2.
8. 8 - Engine Coolant Temperature Sensor on Radiator Outlet -G83-

 Passat, CC, GTI and Eos: inside the lower radiator connection. Refer to RADIATOR, FAN
SHROUD AND FANS OVERVIEW .
9. 9 - Vacuum Diaphragm for the Channel Separating Plate
10. 10 - Intake Manifold Runner Control Valve -N316-

11. 11 - Engine Speed Sensor -G28-

 Installed location: left lower front, refer to Fig. 5.
12. 12 - Charge Air Pressure Sensor -G31-

13. 13 - Electrical Connector for the Knock Sensor 1

 Installed location beneath the intake manifold, refer to Fig. 7.
 Knock sensor 1 tightening specification: 20 Nm.
14. 14 - Electrical Connector for the Camshaft Position Sensor 2

15. 15 - 8 Pin Harness Connector for the Fuel Injectors

16. 16 - Throttle Valve Control Module -J338-

 With the Electronic Power Control (EPC) throttle drive -G186-, EPC throttle drive angle sensor 1 -
G187- and EPC throttle drive angle sensor 2 -G188-.
 After replacing the throttle valve control module, it must be readapted to the Engine Control
Module (ECM). Refer to the vehicle diagnostic tester.
17. 17 - EVAP Canister Purge Regulator Valve 1 -N80-

18. 18 - Intake Air Temperature Sensor -G42-
 Bolted to the intake manifold at the front. Refer to INTAKE MANIFOLD OVERVIEW.
19. 19 - Knock Sensor 1 -G61-

 Tightening specification: 20 Nm.
 On the front of the cylinder block under the intake manifold.
20. 20 - Engine Coolant Temperature Sensor -G62-

 In the coolant pump housing, refer to Fig. 8.
21. 21 - Camshaft Position Sensor -G40-

 Bolted on the front of the cylinder head cover. Refer to Fig. 6.
22. 22 - Fuel Pressure Sensor -G247-

 On the fuel rail, refer to FUEL RAIL OVERVIEW.
23. 23 - Intake Manifold Runner Position Sensor -G336-

 On the right side of the intake manifold.
 To remove and install, remove the intake manifold. Refer to INTAKE MANIFOLD WITH
FUEL RAIL.
24. 24 - Oil Pressure Switch -F1-
 Inside the accessory bracket, refer to OIL FILTER, OIL COOLER AND OIL PRESSURE
SWITCH OVERVIEW .
25. A - Data Link Connector (DLC)
 In the driver side footwell.
26. B - Mass Airflow Sensor -G70- and Intake Air Temperature Sensor 2 -G299-
 Removing and installing, refer to MASS AIRFLOW SENSOR -G70-.
27. C - Accelerator Pedal Position Sensor -G79- and Accelerator Pedal Position Sensor 2 -G185-
 On the accelerator pedal (both sensors are stored in one housing).
 If the accelerator pedal module or ECM is replaced in vehicles with a automatic transmissions, the
kick down function must be adapted.
 Removing and installing, refer to ACCELERATOR PEDAL MODULE .
28. D - Coolant Fan Control Module -J293-

 The coolant fan control module is integrated in the coolant fan -V7-.
29. E - Fuel Injector

 In the fuel rail
 Removing and installing, refer to FUEL INJECTORS.
 Cylinder 1 fuel injector -N30-.

Fig. 2: Identifying High Pressure Fuel Pump And Bolts

1 - Fuel pressure regulator valve
2 - High pressure pump
Fig. 3: Identifying Intake Manifold Runner Control (IMRC) Valve N316

1 - Vacuum diaphragm for the channel separating plate

2 - Intake manifold runner control valve
Fig. 4: Identifying Mass Air Flow (MAF) Sensor G70 Electrical Connector
1 - MAF sensor and intake air temperature sensor 2

1 - Engine speed sensor

Fig. 6: Identifying Camshaft Position Sensor G40 Electrical Connector

1 - CMP sensor

1 - from the Camshaft Position (CKP) sensor
2 - from the knock sensor 1

3 - 8 pin harness connector for fuel injectors
Fig. 8: Identifying Engine Coolant Temperature (ECT) Sensor Electrical Harness Connector
1 - Engine coolant temperature sensor
NOTE: Under the intake manifold (the intake manifold is not shown in the illustration).
Fig. 9: Identifying Charge Air Pressure Sensor G31

1 - Charge air pressure sensor
Fig. 10: Identifying Turbo Charger Components

1 - Turbocharger, removing and installing. Refer to TURBOCHARGER .
2 - Tighten the wastegate bypass regulator valve to 3 Nm.
3 - Tighten the turbocharger recirculation valve to 7 Nm (observe the installed position, next illustration)
Fig. 11: Identifying Installation Position Of Turbocharger Recirculating Valve N249

THROTTLE VALVE CONTROL MODULE, CLEANING
 Acetone
NOTE: Observe the rules for cleanliness. Refer to CLEAN WORKING CONDITIONS .
The throttle valve connections must not be damaged when cleaning.
Procedure
-- Remove the throttle valve control module. Refer to THROTTLE VALVE CONTROL MODULE -J338-.
-- Open the throttle valve by hand and hold it in the open position with a suitable object -arrow-.
Fig. 12: Identifying Throttle Valve Held Open With Suitable Object
WARNING: Acetone is easily flammable. Observe accident prevention measures and

safety information when working with easily flammable fluids. Do not
used compressed air when cleaning the throttle valve. Always wear
protective eyewear and protective clothing to prevent injuries and fuel
from coming in contact with your skin.
-- Clean the throttle valve, especially in the areas where the throttle valve closes -arrows- , with standard
acetone and a brush.
Fig. 13: Identifying Throttle Valve Connections

-- Wipe the throttle valve with a lint free cloth.
-- Allow the acetone to dry completely and reinstall the cleaned throttle valve control module.
-- Adapt the Engine Control Module (ECM) to the throttle valve control module. Refer to "Guided Functions"
in the vehicle diagnostic tester.
FUEL INJECTOR, CLEANING
 Ultrasonic Cleaning Unit -VAS 6418-

 Injection Module Mounting Plate -VAS 6418/1-
 Cleaning Fluid -VAS 6418/2-
Cleaning
-- Remove the fuel injectors. Refer to FUEL INJECTORS.
NOTE: Follow the safety precautions and the instructions for the ultrasonic device.
-- The ultrasonic device must be filled with cleaning fluid -VAS 6418/2-.
NOTE: Fill the ultrasonic device up to the upper edge of the holes with cleaner (see the
magnified area of the illustration).
Fig. 14: Identifying Filling Ultrasonic Device Up To Upper Edge Of Holes With
Cleaner
-- Insert the fuel injector -1- all the way into the injector module mounting plate -VAS 6418/1- -2-.
-- Dip the fuel injectors with the injector module mounting plate -VAS 6418/1- into the cleaning device.
Fig. 15: Identifying Fuel Injectors, Bracket, Ultrasonic Device Button, Temperature Adjust Knob And
Cleaning Time Set Knob
-- Adjust the temperature to 50° using the knob -4-.
-- Set a cleaning time of 30 minutes using the knob -5-.
-- Switch the ultrasonic device on with the button -3-.
NOTE: The time begins counting down once the cleaning temperature reaches 50°.
-- Replace the Teflon seal after cleaning each fuel injector. Refer to FUEL INJECTOR TEFLON SEAL.
-- Then, install the fuel injectors. Refer to FUEL INJECTORS.
AIR FILTER HOUSING OVERVIEW

Fig. 16: Identifying Assembly Overview: Air Filter

1. Spring Type Clamp

2. Connecting Pipe
 To the turbocharger.
 Check the connecting pipe for dirt and leaves.
3. Mass Airflow Sensor -G70-

 Removing and installing, refer to MASS AIRFLOW SENSOR -G70-.
4. Bolt
 1.5 Nm
 For the upper air filter housing.

5. Bolt
 1.5 Nm
 For the upper air filter housing.
6. Upper Air Filter Housing

 Clean any salt, dirt and leaves from the upper air filter housing.
7. Air Filter Element

 Always use an original air filter element.
 Removing and installing, refer to AIR FILTER ELEMENT.
 Note the change intervals, refer to Maintenance Intervals.
8. Bolt
 8 Nm
 For the lower air filter housing.
9. Snow Screen
 Not installed on all vehicles.
10. Lower Air Filter Housing

 Clean the lower air filter housing of any salt, dirt and leaves.
11. Water Drain Hose Connection

 Clean the connection.
12. Water Drain Hose

 Clean the water drain hose.
13. Shutter Valve

14. Intake Air Guide
 To the lock carrier.
 Clean dirt and leaves from the intake air guide.
INTAKE MANIFOLD OVERVIEW

Fig. 17: Identifying Assembly Overview: Intake Manifold

1. Bolt
 5 Nm
2. Intake Air Temperature Sensor -G42-
 With a check valve, a single component.
 To remove and install, remove the intake manifold.
4. Intake Manifold
 Removing and installing, refer to INTAKE MANIFOLD WITH FUEL RAIL.
5. Vacuum Diaphragm for the Channel Separating Plate

6. Bolts
 M6 threads = 8 Nm + 90° (1/4) additional turn.
 M8 thread = 20 Nm.
 Always replace.
7. Connection for the Fuel Line from the Fuel Tank

8. Fuel Pressure Regulator Valve -N276-
9. High Pressure Pump
 With the fuel pressure regulator valve.
 Make sure the dirt does not enter the fuel system when installing the high pressure pump.
 The fuel system must be pressureless to install the high pressure pump, releasing the fuel pressure,
refer to HIGH SIDE FUEL PRESSURE, RELEASING .
 Install the fuel line to the fuel rail free from tension.

10. Cam Follower
 Remains inserted in the cylinder head after removing the high pressure pump, is removable.
11. Connection, High Pressure Fuel Line

 Tightening specification, refer to HIGH PRESSURE PUMP WITH FUEL PRESSURE
REGULATOR VALVE -N276- OVERVIEW.
12. Fuel Line to the Fuel Rail
 18 Nm
 Do not install the fuel line with tension.
13. Intake Manifold Runner Control Valve -N316-

14. Fuel Injector
 Replace the O-rings.
 Note the correct installed position.

 With the EVAP canister purge regulator valve 1 as one unit.
16. Intake Manifold Support

17. Bolt
 23 Nm
18. Nut
 10 Nm
19. Bolts
 5 Nm
 Quantity: 4
20. Throttle Valve Control Module -J338-, Electronic Power Control (EPC) Throttle Drive -G186-
 EPC throttle drive angle sensor 1 -G187- and EPC throttle drive angle sensor 2 -G188-.
 After replacing the throttle valve control module, it must be readapted to the engine control module
-J623-. Refer to "Guided Functions" in the vehicle diagnostic tester.
 Removing and installing, refer to THROTTLE VALVE CONTROL MODULE -J338-.
 Cleaning, refer to THROTTLE VALVE CONTROL MODULE, CLEANING.
21. Seal
 Always replace.
 The rim of the seal must fit into the groove provided for it inside the intake manifold.
FUEL RAIL OVERVIEW

Fig. 18: Identifying Assembly Overview: Fuel Rail

1. Fuel Injector
 With the combustion chamber seal (Teflon seal), always replace.
 Replace the O-rings.
 Note the correct installed position.
2. Support Ring
3. Fuel Rail
 Removing and installing, refer to FUEL RAIL, SEPARATING FROM THE INTAKE
MANIFOLD.
 An electrical fuel pump located in the fuel tank supplies fuel to the high pressure pump at a
pressure of approximately 6 bar.
 Make sure dirt does not enter the fuel system when installing the high pressure pump.
 The fuel system must be pressureless to install the high pressure pump, releasing the fuel pressure,
refer to HIGH SIDE FUEL PRESSURE, RELEASING .
 Do not install fuel lines with tension.
 Removing and installing, refer to HIGH PRESSURE PUMP.

5. Cam Follower
6. Fuel Pressure Regulator Valve -N276-
7. Bolts
 M6 thread = 8 Nm + 90° (1/4) additional turn.
 M8 thread = 20 Nm.
 Always replace.
8. Connection, Fuel Supply Line

 22 Nm
 Always replace.
9. Fuel Supply Line Union Nut

 18 Nm
10. Channel Separating Plates

11. Gasket
 Always replace.
12. Intake Manifold

 Removing and installing, refer to INTAKE MANIFOLD WITH FUEL RAIL.
13. Vacuum Diaphragm for the Channel Separating Plate

 Checking, refer to VARIABLE INTAKE MANIFOLD, CHECKING.
14. Throttle Valve Control Module -J338-, Electronic Power Control (EPC) Throttle Drive -G186-
 EPC throttle drive angle sensor 1 -G187- and EPC throttle drive angle sensor 2 -G188-.
 After replacing the throttle valve control module, it must be readapted to the engine control module
-J623-. Refer to "Guided Functions" in the vehicle diagnostic tester.
15. Bolt
 Tighten to 3 Nm, and then tighten to 9 Nm.
16. Intake Manifold Runner Position Sensor -G336-

 To remove and install, remove the intake manifold. Refer to INTAKE MANIFOLD WITH
FUEL RAIL.
17. Fuel Pressure Sensor -G247-
 27 Nm
 Lubricate the threads with clean engine oil.
 Checking, refer to FUEL PRESSURE SENSOR -G247-, CHECKING.
 Removing and installing, refer to FUEL PRESSURE SENSOR -G247-.
Additional Tightening Specifications
Additional tightening specifications can be found at the end of the FUEL RAIL, SEPARATING FROM THE
INTAKE MANIFOLD.
HIGH PRESSURE PUMP WITH FUEL PRESSURE REGULATOR VALVE -N276- OVERVIEW
NOTE: Note the different versions of the connection for the fuel high pressure line.
Fig. 19: Identifying Assembly Overview: High Pressure Pump With Fuel Pressure Regulator Valve -
N276-
1. O-ring
 Always replace.
2. Cam Follower
 Remains inserted in the cylinder head after removing the high pressure pump, is removable.
3. Connection for the High Pressure Fuel Line (with inner threads)
 40 Nm
 Always replace.
 Counter-hold the connection when loosening the union nut.

4. Connection for the High Pressure Fuel Line (with outer threads)
 Replace
 25 Nm
 Counter-hold the connection when loosening the union nut.
5. High Pressure Fuel Line Union Nut

 18 Nm
6. Fuel Supply Line from the Fuel Tank

7. Bolts
 Always replace
 M6 threads = 8 Nm + an additional 90° (1/4) turn.
 M8 threads = 20 Nm.

 Make sure dirt does not enter the fuel system when installing the high pressure pump.
 The fuel system must be without pressure to install the high pressure pump, releasing the high side
fuel pressure. Refer to HIGH SIDE FUEL PRESSURE, RELEASING .
 Install the fuel line to the fuel rail free from tension.
SPECIFICATIONS
TECHNICAL DATA
Engine Codes CCTA, CBFA

Idle check
Idle speed(1) RPM 640... 800
Engine speed (RPM) RPM approximately 6500
limitation
(1) If the Engine Control Module (ECM) voltage supply drops below 12 volts, the idle speed is increased
in stages up to 990 RPM. Idle speed is not adjustable.

Adapter VAS 6394/2 to Fuel Rail - 27
Engine Control Module Bracket Bolt (3) - 7
Engine Control Module Mounting Frame to Bracket Nut (3) - 6
Fuel Pressure Sensor to Pressure Sensor Tester VAS 6394/1 - 27
Fuel Pressure Sensor to Fuel Rail (2) - 27
Fuel Supply Line Union Nut to High Pressure Pump - 18
Fuel Supply Line Union Nut to Fuel Rail - 18
Fuel Supply Line Connection to Fuel Rail (1) - 22

High Pressure Fuel Line Connection to High Pressure Pump (1)
-- with Inner Threads - 40
-- with Outer Threads - 25
High Pressure Pump to Cylinder Head Bolt (1)
M6 8 + 90°
M8 20
Intake Air Temperature Sensor to Intake Manifold Bolt - 5
Intake Manifold to Cylinder Head Bolt
-- First pass, tighten to - 3
-- Final pass, tighten to - 9
Intake Manifold Support to Cylinder Block Bolt - 23
Intake Manifold Support to Intake Manifold Nut - 10
Knock Sensor Bolt - 20
Lower Air Filter Housing to Body Bolt - 8
Throttle Valve Control Module to Intake Manifold Bolt - 5
Upper Air Filter Housing to Lower Air Filter Housing Bolt - 1.5
(1) Always replace
(2) Coat the threads with clean engine oil
(3) Passat, CC and Tiguan
FUEL PRESSURE SENSOR -G247-, CHECKING

 Vehicle Diagnostic Tester, for example, -VAS 5051 B-
 Pressure Sensor Tester -VAS 6394-
 Double Hexagon Socket, 1/2 inch, 27 mm -VAS 5301/7-
Procedure
-- Remove the fuel pressure sensor. Refer to FUEL PRESSURE SENSOR -G247-.
Tightening specification: 27 Nm.
Fig. 20: Identifying Adapter VAS 6394/2

-- Remove the locking bolt -2- and install the fuel pressure sensor in the pressure sensor tester -VAS 6394/1-.
Tightening specification: 27 Nm.
Fig. 21: Identifying Locking Bolt, Pressure Sensor Tester And Fuel Pressure Sensor
-- Connect the pressure sensor tester -VAS 6394/1- pressure line to the adapter -VAS 6394/2-.
-- Connect the fuel pressure sensor and then its connector to the test instrument adapter/DSO (3-pin) -VAS
5570-.
Fig. 22: Identifying Pressure Sensor Tester VAS 6394/1, Adapter VAS 6394/2 And Test Instrument
Adapter/DSO (3-Pin) VAS 5570
-- Switch the pressure sensor tester -VAS 6394/1- on by pressing the button -A- briefly.
Fig. 23: Identifying Pressure Sensor Tester VAS 6394/1 Switches

NOTE: Holding the button -A- for 2 seconds switches on the illumination for 20
seconds.
If the pressure sensor tester -VAS 6394/1- does not display 0 bar, set it back to
zero, refer to the operating instructions.
-- Connect the vehicle diagnostic tester to the diagnostic connector.
-- Press the following buttons on the vehicle diagnostic tester screen one after another.
OBD
OBD -->
01 - engine electronics -->
011 - measured values -->
-- Select measured values block 1 4 0 and confirm with Q .
Display field 3 shows the fuel pressure actual value as measured by the fuel pressure sensor.
-- Compare the pressure displayed by the pressure sensor tester -VAS 6394/1- with the actual value displayed
on the vehicle diagnostic tester.
 The pressures may have a maximum difference of 5 bar.
-- If the difference is greater than 5 bar, replace the fuel pressure sensor.
WARNING: The pressure sensor tester -VAS 6394- is under high fuel pressure.
Disconnect the connector from the fuel pressure sensor when the engine
is running. This reduces the pressure to approximately 6 bar. Turn off the
ignition. Place a cloth around the fuel pressure sensor, then carefully
loosen the fuel pressure sensor to release the remaining pressure.
-- Repeat the test with the new fuel pressure sensor and compare both measured values.
If the measured value do not match again:
-- Perform a wiring test, refer to vehicle diagnostic tester.
VARIABLE INTAKE MANIFOLD, CHECKING

Only perform the test if there is a loss of torque. That means engine acceleration is reduced.
 Hand Vacuum Pump -VAS 6213-
Test Conditions
 The intake manifold runner control valve -N316- was tested using the vehicle diagnostic tester.
If the intake manifold runner control valve is OK, perform the following:
-- Remove the engine cover carefully.
-- Start the engine and let run at idle.
-- Have a 2nd person increase the engine speed abruptly (press the accelerator pedal). Observe the variable
intake manifold vacuum actuator.
 The actuator must activate -arrow-.
Fig. 24: Identifying Vacuum Hose, Intake Manifold Runner Control Valve N316 And Actuator
If the change over does not function as specified:
-- Check the vacuum system for leaks.
-- Check whether the change over mechanism moves easily. Do this by actuating the linkage by hand.
-- Check whether the vacuum lines are correctly connected.
-- Check that vacuum hoses are not porous.
-- Remove the adjusting element vacuum hose -1- for the intake manifold runner control valve from the valve -
2-.
Fig. 25: Identifying Vacuum Hose, Intake Manifold Runner Control Valve N316 And Actuator
-- Set the sliding ring -1- on the hand vacuum pump -VAS 6213- to the -A- position for "vacuum".
Fig. 26: Identifying Slide Ring Set To "Pressure" Position On Hand Vacuum Pump VAS 6213
-- Connect the hand vacuum pump -VAS 6213- to the intake manifold runner control valve actuator.
Fig. 27: Identifying Hand Vacuum Pump VAS 6213 And Intake Manifold Runner Control Valve N316
Actuator
-- Operate the hand vacuum pump -VAS 6213- several times.
The vacuum actuator must move -arrows-.
-- Replace the vacuum actuator if it does not move.
AIR FILTER HOUSING
Removing
-- Remove the cover for the air guide; disengage the side clips -arrows- to do so.


Engine Code CBFA

-- Disconnect the hose leading from the secondary air injection pump motor -V101- to the air filter housing.
Fig. 30: Locating Bolt

-- Loosen the bolt -arrow A- and pull the air filter housing upward out of the bracket.
-- Remove the air filter housing together with the Mass Airflow (MAF) sensor and connecting pipe.
Installing
AIR FILTER ELEMENT
Removing
Engine Code CBFA
-- Disconnect the hose from the secondary air injection pump motor -V101- to the air filter housing.

Fig. 31: Identifying Upper Section Of Air Filter Housing Screws

-- Remove the bolts -arrows- from the upper air filter housing.
-- Lift the upper air filter housing and remove the air filter element.
Installing
Tightening specifications, refer to AIR FILTER HOUSING OVERVIEW.
NOTE: Always use an original equipment air filter element.
Hose connections and charge air system hoses must be free of oil and grease
before installing. When installing, do not use any lubricants containing silicone.
The air filter housing must be clean.
Secure all hose connections using hose clamps appropriate for the model type.
Note the following when blowing out the air filter housing with pressurized air:
To prevent malfunctions, cover the critical air flow components such as the
MAF sensor, air intake tubes, etc. with a clean cloth.
Observe disposal regulations.
-- Check the MAF sensor and intake hose (intake air side) for salt residue, dirt, and leaves.
-- Check the intake air guide from the air duct for dirt.
-- Remove the snow screen -1- and clean it.
Fig. 32: Identifying Snow Screen

NOTE: The snow screen is not installed in all vehicles.
-- Clean the water drain -arrow- and the lower air filter housing.
Fig. 33: Identifying Lower Air Filter Housing Section Water Drain
-- Make sure that air filter is properly centered when placed in the mounting of the lower air filter housing.
-- Set the upper air filter housing onto the lower air filter housing, without using much force. When doing this,
make sure that the upper air filter housing is not placed crooked onto the air filter element. Check the sealing lip
on the air filter element.
Further installation is performed in reverse order.
MASS AIRFLOW SENSOR -G70-
-- Disconnect the electrical connector -1- from Mass Airflow (MAF) sensor.
Fig. 34: Identifying Mass Air Flow (MAF) Sensor G70 Electrical Connector
-- Remove both bolts from the MAF sensor and carefully remove the MAF sensor from the air filter housing
guide.
Installing
For problem free operation of the MAF sensor it is very important to observe the following notes and
procedures.
NOTE: If the air filter element is very dirty or soaked, dirt particles or moisture may
have contaminated the MAF sensor and may be causing false MAF values. This
results in a reduction of power, since a lower injection quantity is calculated.
Always use an original equipment air filter element.

Use a lubricant (silicone free) for installing the intake hose.
Secure all hose connections using hose clamps appropriate for the model type.
-- Check the MAF sensor and intake hose (intake air side) for salt residue, dirt, and leaves.
-- Check the intake channels up to the air filter for dirt. If any contaminants are discovered, clean the upper air
filter housing and lower air filter housing of salt residue, dirt and leaves. Wash or vacuum if necessary. Air
filter, removing and installing AIR FILTER ELEMENT.
Further installation is performed in reverse order.
INTAKE MANIFOLD WITH FUEL RAIL
If the intake manifold is replaced, the intake manifold runner position sensor -G336- must be adapted to the
engine control module -J623- using the vehicle diagnostic tester.
 Socket TORX T30 -T10347-

 Oil Filter Wrench -3417-
NOTE: Follow all safety precautions. Refer to SAFETY PRECAUTIONS .
Observe the rules for cleanliness. Refer to CLEAN WORKING CONDITIONS .
To access the fuel injectors, the intake manifold and the fuel rail with intake
manifold runner control valve must be removed.
The combustion chamber seal (Teflon) and the O-ring must always be replaced.
Intake manifold overview. Refer to INTAKE MANIFOLD OVERVIEW.
Fuel rail overview. Refer to FUEL RAIL OVERVIEW
WARNING: The fuel system is under pressure! Before opening high pressure
components of the fuel injection system, the pressure must be reduced to
residual pressure.
 Releasing pressure in the high pressure side. Refer to HIGH SIDE

FUEL PRESSURE, RELEASING .
Removing

-- Clean the contact surface from the intake manifold to the cylinder head.
-- Remove the air filter housing. Refer to AIR FILTER HOUSING.
-- Remove the fan shroud. Refer to FAN SHROUD .
-- Disconnect the vacuum line -arrow- from the Evaporative Emission (EVAP) canister.
Fig. 36: Identifying Intake Air Temperature Sensor -1- And Throttle Valve Control Module -2-
-- Disconnect the following electrical connectors:
 Intake air temperature sensor -G42- -1-

 Throttle valve control module -J338- -2-
 EVAP canister purge regulator valve 1 -N80-
 Camshaft position sensor -G40-
-- Disconnect the vacuum line -1- at the separating point -2- and remove the crankcase ventilation hose -3-.
Fig. 37: Identifying Vacuum Line, Separating Point And Crankcase Ventilation Hose
-- Remove the bolts -arrows- for the fuel supply line and lay the line to the side.
Fig. 38: Locating Fuel Supply Line Bolts

NOTE: The fuel system must have no pressure.
-- Open the fuel line union nut -lower arrow-.
Fig. 39: Identifying Spring Clamp And High Pressure Fuel Line Union Nut
-- Disconnect the vacuum line -arrow- from the intake manifold runner control valve -N316-.
Fig. 40: Identifying Intake Manifold Runner Control Valve N316 Vacuum Line
-- Remove the bolts -arrows- for the coolant line from the intake manifold.

-- Disconnect the electrical connector -1- from the fuel pressure sensor -G247-.
Fig. 42: Identifying Fuel Pressure Sensor Electrical Harness Connector


-- Loosen the clamps -items 1 and 2- and remove the charge air pipe.

-- Disconnect the connectors -1 though 3- and remove the bracket from the intake manifold.

-- Remove the throttle valve control module bolts -arrows-.
-- Remove the intake manifold support by removing the nut -1- and bolt -2-.
-- Remove the oil filter. Refer to OIL FILTER, OIL COOLER AND OIL PRESSURE SWITCH
OVERVIEW .
-- Loosen the wiring bracket -arrows-.
Fig. 49: Locating Wiring Bracket Bolts

-- Loosen the wire -arrow- from the intake manifold.

Fig. 50: Identifying Intake Manifold Wire

-- Remove the nuts -A- and loosen the bolts -arrows- from the intake manifold using the socket TORX T30 -
T10347-.
Fig. 51: Identifying Nuts And Bolts To Intake Manifold

-- Carefully pull the intake manifold and fuel rail away from the cylinder head just a little.
-- Disconnect the electrical connector -arrow- from the intake manifold runner position sensor and remove the
intake manifold.
Fig. 52: Identifying Electrical Connector To Intake Manifold Runner Position Sensor
-- Cover the intake passages with a clean cloth.
NOTE: The fuel injectors could remain stuck in the fuel rail.
-- Disconnect the fuel rail from the intake manifold. Refer to FUEL RAIL, SEPARATING FROM THE
INTAKE MANIFOLD.
Installing
 The fuel injectors sit in the cylinder head. Fuel injector installing. Refer to FUEL INJECTORS.
-- Mount the intake manifold onto the cylinder head on the stud bolts (lower left and right).
NOTE: Make sure the fuel injectors are installed correctly and pay attention to the
wiring bracket when mounting the intake manifold (under the intake manifold).
 When installing the intake manifold, the manifold must be pulled out slightly and the fuel injectors will
stick in the fuel rail. Pull the fuel injectors out of the fuel rail and insert them in the cylinder head again.
The rest of the installation follows the reverse of the removal procedures. When doing this note the following:
-- When attaching the wiring bracket onto the intake manifold, make sure it clips into both latches.
Fig. 53: Locating Wiring Bracket Bolts

Tightening specifications, intake manifold overview. Refer to INTAKE MANIFOLD OVERVIEW.
For tightening specifications, refer to fuel rail overview. Refer to FUEL RAIL OVERVIEW.
FUEL RAIL, SEPARATING FROM THE INTAKE MANIFOLD
NOTE: Intake manifold must be removed, intake manifold removing. Refer to INTAKE
MANIFOLD WITH FUEL RAIL.
-- Remove the EVAP canister purge regulator valve 1 -N80- -arrow- from the bracket.
Fig. 54: Locating EVAP Canister Purge Regulator Valve -Arrow-, Check Valve -1- And Fuel Line -2-
-- Loosen the check-valve -1- and the fuel line -2-.
-- Open the hose clamp -1-.
Fig. 55: Identifying Hose Clamp & Bolts

-- Loosen both bolts -arrows- from the fuel rail.
-- Remove the fuel rail from the intake manifold.

Installing
-- Tighten the fuel line.
-- Further installation is performed in reverse order.
-- Connect the electrical connector.
-- Install the intake manifold. Refer to INTAKE MANIFOLD WITH FUEL RAIL.
Adapter for the fuel line to the fuel rail 25 Nm
Fuel line (union nut) to fuel rail adapter 18 Nm
FUEL INJECTORS
 Tool Set -T10133-
NOTE: The puller -T10133/2- was changed. It is now called the puller -T10133/2A-. If the
new tool is not available, the old one can be modified.
Puller -T10133/2- has been changed to Puller -T10133/2A-
 Round File Approximately 6 mm
-- File the semicircle as shown in the illustration. The semicircle allows the tool to slide farther onto the fuel
injector, thus providing the tool with a larger contact surface.
Fig. 56: Identifying Semi-Circle To File

-- Mark the modified tool with an "A" at the end of the tool number.
Fig. 57: Identifying Fuel Injector (Old Version)

1 - Combustion chamber seal ring (Teflon seal), replace, the ring must not be greased or handled with any other
lubricants when installing.
2 - The support ring is being replaced by an intermediate ring. See fuel injector (new version).
3 - Fuel injector
4 - Spacer ring, replace if damaged
5 - O-ring (replace, lubricate lightly with clean engine oil when installing)
6 - Support ring (via this support ring, fuel rail utilizes the force to hold the fuel injector in place in the cylinder
head).
Fig. 58: Identifying Fuel Injector (New Version)

1 - Intermediate ring, replacing
2 - Support
3 - Combustion chamber seal (Teflon seal), replace, the ring must not be greased or handled with any other
lubricants when installing.
4 - Fuel injector
5 - Spacer ring, replace if damaged
6 - O-ring (replace, coat lightly with clean engine oil when installing)
7 - Support ring (via this support ring, fuel rail utilizes the force to hold the fuel injector in place in the cylinder
head).
-
-- Remove the intake manifold with the fuel rail. Refer to INTAKE MANIFOLD WITH FUEL RAIL.
NOTE: Remove the fuel injectors if they remain attached in the fuel rail.
-- Cover the intake passages with a clean cloth.
-- Remove the support element -A- downward and disconnect the connector -arrows- from the fuel injectors.
Fig. 59: Identifying Fuel Injectors And Electrical Harness Connectors

-- Position the puller -T10133/2A- in the groove on the fuel injector.

Fig. 60: Identifying Position Of Puller T10133/2A In Groove On Fuel Injector & Trim Removal Wedge
T10133/16
-- Mount the removal tool -T10133/16-, turn the bolt -1- and remove the fuel injector.
NOTE: Pay attention to the intermediate rings.
The Teflon seal must always be replaced before installing the fuel injector.
Refer to FUEL INJECTOR TEFLON SEAL.
Installing
NOTE: The Teflon seal for the fuel injector may not be oiled or greased.
Possibly an opened intake valve hinders the cleaning. In this case, the engine
must be rotated further by hand using a wrench on the crankshaft.
-- Thoroughly clean the bores for the fuel injectors in the cylinder head using a nylon brush -T10133/4-.
Fig. 61: Identifying Nylon Brush T10133/4 To Clean Bores In High Pressure Fuel Injectors In Cylinder
Head
-- Teflon seal removing and installing. Refer to FUEL INJECTOR TEFLON SEAL.
-- Assemble the fuel injector with the parts from the repair kit.
-- Press the fuel injector by hand into the cylinder head (free of oil and grease) as far as the stop. Make sure the
fuel injectors are positioned -arrow- correctly inside the cylinder head.
Fig. 62: Identifying Fuel Injector And Correct Position Inside Cylinder Head
NOTE: If it is difficult to install the fuel injector by hand use the puller -T10133/2A- -2-
with the hammer -T10133/3-.
Fig. 63: Identifying Installation Hammer T10133/3 To Puller T10133/2

-- Install the support ring onto the fuel injector.
-- Lightly coat the O-rings for the fuel injector with clean engine oil before installing
-- Install the intake manifold with the fuel rail. Refer to INTAKE MANIFOLD WITH FUEL RAIL.
FUEL INJECTOR TEFLON SEAL
NOTE: The Teflon seal must not be lubricated.
-- Carefully remove the old Teflon seal with the appropriate tool (for example, cut the seal open with a razor
blade, spread it outward with a small screwdriver and remove it forward). When doing this, be sure not to
damage the groove and the rib in the groove base.
-- Thoroughly clean the fuel injector in the area of the seal -arrow-. Remove any deposits (coking) using a brass
brush.
Fig. 64: Identifying Area Of Fuel Injector's Sealing Ring To Clean

-- Clean the seal groove.
-- Insert a new seal onto the assembly cone -T10133/5-. Slide the seal as far as it will go onto the assembly cone
-T10133/5- using the assembly sleeve -T10133/6-.
Fig. 65: Identifying New Sealing Ring And Assembly Cone T10133/5
-- Rotate the assembly sleeve -T10133/6- and slide the seal onto the assembly cone -T10133/5- up to the end.
Fig. 66: Identifying Sealing Ring On Assembly Cone T10133/5 Slided Up To End
-- Place the assembly cone -T10133/5- onto the fuel injector and slide the seal onto the fuel injector using the
assembly sleeve -T10133/6-.
Fig. 67: Identifying Sealing Ring Slided On To Fuel Injector Using Assembly Sleeve T10133/6
-- Remove the assembly cone -T10133/5- and slide the seal into the groove using the assembly sleeve -
T10133/6-.
-- Press the calibrating sleeve -T10133/7- using a gentle turning motion (approximately 180°) onto the fuel
injector until it stops.
Fig. 68: Identifying Calibrating Sleeve T10133/7 Pressed On To Fuel Injector Until It Stops
-- Pull off the calibrating -T10133/7- again using a turning motion in the opposite direction.
-- Now, press the calibrating sleeve -T10133/8- using a gentle turning motion (approximately 180°) onto the
fuel injector until it stops.
Fig. 69: Identifying Calibrating Sleeve T10133/8 Pressed On To Fuel Injector Until It Stops
-- Pull off the calibrating sleeve -T10133/8- again using a turning motion in the opposite direction.
-- Replace the O-ring and support washer on the fuel injector.
FUEL PRESSURE SENSOR -G247-

Removing
WARNING: The fuel system is under pressure. Before opening high pressure
residual pressure.


-- Remove the upper bracket -arrow- from the generator -C-.
Fig. 70: Identifying Upper Bracket -Arrow- To Generator

-- Loosen the coolant pipe -arrows- from the intake manifold.

-- Disconnect the connector from the fuel pressure sensor using the assembly tool -T10118-.
Fig. 72: Identifying Fuel Pressure Sensor Electrical Harness Connector

-- Remove the fuel pressure sensor using the double hexagon socket, 1/2 inch, 27 mm -VAS 5301/7-.
-- Collect leaking fuel with a cloth.
Installing
Coat the fuel pressure sensor sealing point with clean engine oil.
-- Tightening specifications, refer to FUEL RAIL OVERVIEW.
THROTTLE VALVE CONTROL MODULE -J338-
Removing
GTI and Eos

-- Disconnect electrical connector -arrow-.
-- Loosen the clamps -items 1 and 2- and remove the charge air pipe.

-- Disconnect the electrical connector -1- from the throttle valve control module.
Installing
Tightening specifications, refer to INTAKE MANIFOLD OVERVIEW.
-- Clean the O-ring sealing surface.
-- Replace the seal; when doing so, make sure the position indicator on the seal is in the correct position.
-- Adapt the Engine Control Module (ECM) to the throttle valve control module using "Guided Functions" in
the vehicle diagnostic tester, if a new throttle valve control module was installed.
HIGH PRESSURE PUMP
WARNING: The fuel system is under pressure. Before opening high pressure
residual pressure.

NOTE: The high pressure pump can only be removed and installed when the engine is
cold.
When installing the high pressure pump, make sure that no dirt enters the fuel
system.
Catch leaking fuel with a cloth.
Always replace the O-ring and the connection.
Always install the high pressure fuel lines so that they are free of tension.
Removing
-- Disconnect the electrical connector -2- from the fuel pressure regulator valve -N276-.
Fig. 77: Identifying High Pressure Fuel Pump & Fuel Pressure Regulator Valve Electrical Harness
Connector
-- Open both fuel lines -arrows-.

Fig. 78: Identifying Fuel Line And Clamp

-- Remove the 2 bolts -arrows-.
Fig. 79: Identifying High Pressure Fuel Pump And Bolts

-- Carefully pull the high pressure fuel pump out. The cam follower may stay in the cylinder head.
Installing
NOTE: To insert the high pressure pump, the cam follower must be at its lowest point.
If the same or a used high pressure pump is installed, replace the fuel supply
line connections (high pressure side). Refer to the high pressure pump
overview, refer to HIGH PRESSURE PUMP WITH FUEL PRESSURE REGULATOR
 Tightening specifications, refer to HIGH PRESSURE PUMP WITH FUEL PRESSURE

REGULATOR VALVE -N276- OVERVIEW.
-- Replace the O-ring for the high pressure pump.
-- Insert the cam follower in the vacuum pump after checking the follower for damage.
-- Rotate the crankshaft until the cam follower is at the lowest point.
-- Install the high pressure pump into the vacuum pump.
-- Tighten the bolts by hand.
-- Replace the connections on the high pressure pump.
-- Tighten the bolts crosswise with the required torque.
-- Tighten the fuel supply line union nut by hand, align it so there is no tension and then tighten it.
-- Connect the electrical connector -2- to the fuel pressure regulator valve.
Fig. 80: Identifying High Pressure Fuel Pump & Fuel Pressure Regulator Valve Electrical Harness
Connector
-- If the fuse was pulled, insert it again.
NOTE: Check the fuel system for leaks.
ENGINE CONTROL MODULE -J623-
WITHOUT ANTI-THEFT IMMOBILIZER
NOTE: Engine Control Module (ECM) secured with anti-theft immobilizer, removing and
installing. Refer to WITH ANTI-THEFT IMMOBILIZER.
-- If the ECM will be replaced, connect the vehicle diagnostic tester and perform the "Replacing Engine Control
Module" guided function.
Removing
-- Remove the windshield wiper arms. Refer to WIPER ARMS .
-- Remove the right plenum chamber cover. Refer to "Flush Bonded Windows" in Removal and Installation .
-- Disconnect the connector -1- from the windshield defogger control module -J505-.
Fig. 81: Identifying Placement Of Mounting Frame With Engine Control Module (ECM) On To Bracket
-- Slide the connector latches -2- on the ECM outward and remove both connectors.
-- Unscrew the bolts -3-.
-- Remove the mounting frame with the ECM from the plenum chamber.
-- Press the release latches -1- outward and slide the ECM -2- in the -direction of the arrow-.
Fig. 82: Identifying Release Catches Pressed Outward And Slide Engine Control Module (ECM) From
Mounting Frame
Installing
-- Slide the ECM -1- in the -direction of the arrow- into the mounting frame.
Fig. 83: Identifying Engine Control Module (ECM) And Mounting Frame
-- Place the mounting frame with the ECM onto the bracket -4-. Tightening specification for the bracket nuts -4-
: 6 Nm.
Fig. 84: Identifying Placement Of Mounting Frame With Engine Control Module (ECM) On To Bracket
-- Tighten the bolts -3- to 7 Nm.
-- Connect the connector to the ECM and slide the latches -2- inward.
-- Connect the connector -1- to the windshield defogger control module.
-- Install the right plenum chamber cover. Refer to "Flush Bonded Windows" in Removal and Installation .
-- Install the windshield wiper arms. Refer to WIPER ARMS .
WITH ANTI-THEFT IMMOBILIZER
 Locking Pliers
-- If the Engine Control Module (ECM) will be replaced, connect the vehicle diagnostic tester and perform the
"Replacing Engine Control Module" guided function.
Removing
-- Remove the windshield wiper arms. Refer to WIPER ARMS .
-- Remove the plenum chamber cover. Refer to "Flush Bonded Windows" in Removal and Installation .
-- Remove the bolts -1-.
Fig. 85: Identifying Bolts And Engine Control Module

-- Remove the ECM cover, if applicable.

-- Cover the plenum chamber with a clean cloth so that it does not get scratched.
-- Raise the ECM with retaining mounting slightly.
-- Release the ECM -arrows- and pull it out slightly.
-- Bend the raised ends -1- of the locking bracket outward.
Fig. 86: Identifying Raised Ends & Shear Bolts

-- Remove the shear bolts -2- with locking pliers and remove the locking bracket.
-- Slide the connector latches -1- on the ECM outward and remove both connectors.
Fig. 87: Identifying Connector Release Catches

-- Remove the ECM.
Installing
-- Slide the ECM -1- in the -direction of the arrow- into the mounting frame until it engages.
Fig. 88: Identifying Engine Control Module (ECM) And Mounting Frame
-- Tighten the mounting frame.

-- Connect the connector to the ECM and slide the latches -1- inward.
Fig. 89: Identifying Connector Release Catches

-- Take a new locking bracket and tighten the new shear bolts evenly until the bolt heads shear off.
-- Install the plenum chamber cover. Refer to "Flush Bonded Windows" in Removal and Installation .
-- Install the windshield wiper arms. Refer to WIPER ARMS .
SPECIAL TOOLS
 Ultrasonic Cleaning Unit -VAS 6418-

 Injection Module Mounting Plate -VAS 6418/1-
 Cleaning Fluid -VAS 6418/2-
 Saw Set -V.A.G 1561/14-
 Socket TORX T30 -T10347-
 Oil Filter Wrench -3417-
Fig. 91: Identifying Tool Set T10133

 Window Cutter -V.A.G 1561 A-

Fig. 92: Identifying Electric Knife V.A.G 1561 A

 Hot Air Gun from the Wiring Harness Repair Set -VAS 1978 B-
Fig. 93: Identifying Hot Air Gun From Wiring Harness Repair Kit VAS 1978
Fig. 94: Identifying Vehicle Diagnostic Tester -VAS 5051 B-, Pressure Sensor Tester -VAS 6394- And
Special Tools

 Vehicle Diagnostic Tester, for example, -VAS 5051 B-
 Pressure Sensor Tester -VAS 6394-
ENGINE 2.0 Liter - Turbocharger, Supercharger - Engine Code(s): CBFA & CCTA
ENGINE
2.0 Liter - Turbocharger, Supercharger - Engine Code(s): CBFA & CCTA
21 TURBOCHARGER, SUPERCHARGER
GENERAL INFORMATION
CHARGE AIR SYSTEM
CAUTION: The charge air pipe clamps must be tightened to 5.5 Nm. An insufficient or
excessive tightening torque can cause the charge air hose to come off the
charge air pipe while driving.
TURBOCHARGER
NOTE: Secure all hose connections using hose clamps appropriate for the model type.
before installing. On connector couplings, the seal and sealing surfaces must
only be lightly oiled. Refer to CHARGE AIR HOSE, INSTALLING.
The charge air system must be properly sealed.
Replace the self-locking nuts.
Hose clip pliers VAS 6362 or hose clip pliers -V.A.G 1921- are recommended for
installing spring clamps.
Add oil to the turbocharger through the oil supply pipe connection.
After installing the turbocharger, allow the engine to idle for approximately 1
minute without increasing the engine speed. This ensures adequate oil supply
to the turbocharger.
Observe the rules for cleanliness. Refer to CLEAN WORKING CONDITIONS .
TURBOCHARGER RECIRCULATION VALVE -N249-, INSTALLED POSITION
-- Note the installed position -arrows-.

Fig. 1: Identifying Installation Position Of Turbocharger Recirculating Valve N249

CHARGE AIR COOLER SYSTEM OVERVIEW
CAUTION: The charge air pipe clamps must be tightened to 5.5 Nm. An insufficient or
excessive tightening torque can cause the charge air hose to come off the
charge air pipe while driving.
Fig. 2: Identifying Assembly Overview: Charge Air Cooler System

1. Bolt
 5 Nm
2. Mount
 For the charge air cooler.
3. Charge Air Cooler

 Passat, CC and Eos, refer to CHARGE AIR COOLER.
4. Charge Air Pipe

 10 Nm
6. from the Turbocharger
7. Charge Air Hose
 Installing, refer to CHARGE AIR HOSE, INSTALLING.
8. to the Throttle Valve Control Module -J338-

9. Charge Air Hose
10. Bolt
 10 Nm
11. Bolt
 5 Nm
12. Charge Air Pressure Sensor -G31-

13. Charge Air Pipe
14. Charge Air Hose
 Installing, refer to CHARGE AIR HOSE, INSTALLING.
TURBOCHARGER SYSTEM OVERVIEW

Fig. 3: Identifying Turbocharger System Overview

1. Brake Booster
2. Non-Return Valve
3. Vacuum Pump
4. Mass Airflow Sensor -G70-
6. Pressure Regulator Valve
 For crankcase ventilation.
7. Intake Manifold Tuning Valve -N156-

9. Non-Return Valve
 Allocations for differing versions.
10. Charge Air Cooler

11. Throttle Valve Control Module -J338-
13. to the Evaporative Emission (EVAP) Canister
14. Intake Manifold
16. Charge Air Regulation Vacuum Diaphragm
17. Wastegate Bypass Regulator Valve -N75-
18. Turbocharger Recirculation Valve -N249-
19. Turbocharger
TURBOCHARGER COMPONENT OVERVIEW

Fig. 4: Identifying Assembly Overview: Turbocharger Component

1. I - WASTEGATE BYPASS REGULATOR VALVE -N75- AND TURBOCHARGER

RECIRCULATION VALVE -N249-
2. II - COOLANT SUPPLY AND OIL PIPES
3. III - TURBOCHARGE AND COOLANT RETURN PIPE
4. IV - VACUUM DIAPHRAGM
WASTEGATE BYPASS REGULATOR VALVE -N75- AND TURBOCHARGER RECIRCULATION VALVE -N249-
Fig. 5: Identifying Assembly Overview: Turbocharger - Part I

1. Turbocharger
 Can only be replaced with the exhaust manifold and the vacuum diaphragm.
 Removing and installing, refer to TURBOCHARGER.
2. to the Evaporative Emission (EVAP) Canister

3. Turbocharger Vacuum Diaphragm
 Checking, refer to TURBOCHARGER VACUUM DIAPHRAGM, CHECKING.
 Removing and installing, refer to TURBOCHARGER VACUUM DIAPHRAGM.
4. Hose
5. Hose
6. Bolt
 3 Nm
7. Wastegate Bypass Regulator Valve
8. Hose
9. Connection
10. Securing Clip
11. Bolt
 9 Nm
12. Seal
13. Turbocharger Recirculation Valve
 Note the installed position, refer to TURBOCHARGER RECIRCULATION VALVE -N249- ,
INSTALLED POSITION.
14. Bolt
 7 Nm
15. Seal
COOLANT SUPPLY AND OIL PIPES

Fig. 6: Identifying Assembly Overview: Turbocharger - Part II

1. Seal
 Always replace.
2. Banjo Bolt
 33 Nm
3. Oil Supply Pipe

4. Turbocharger
 Can only be replaced with the exhaust manifold and vacuum diaphragm.

5. Bolt
 9 Nm
6. Bolt
 9 Nm
7. Seal
 Always replace.
8. Banjo Bolt
 38 Nm
9. Bolt
 9 Nm
10. Banjo Bolt

 38 Nm
11. Seal
 Always replace.
12. Coolant Supply Pipe

13. O-ring
 Always replace.
14. Bolt
 9 Nm
15. Gasket
 Always replace.
16. Oil Return Pipe

17. Bolt
 9 Nm
18. Gasket
 Always replace.
TURBOCHARGE AND COOLANT RETURN PIPE

Fig. 7: Identifying Assembly Overview: Turbocharger - Part III

1. Gasket
 Always replace.
2. Nut
 Always replace.
 Lubricate the studs for the exhaust manifold with hot bolt paste.
3. Banjo Bolt
 38 Nm
4. Seal
 Always replace.
5. Coolant Return Pipe
6. Bolt
 9 Nm
7. Turbocharger
8. Bracket
9. Bolt
 30 Nm
 Lubricate the bolt with hot bolt paste.
10. Bolt
 30 Nm
 Lubricate the bolt with hot bolt paste.
11. Nut
 30 Nm
 Do not loosen, when removing the turbocharger.
 Always replace.
 Lubricate the studs for the exhaust manifold with hot bolt paste.
12. Fastening Strip
Fig. 8: Identifying Turbocharger Tightening Sequence

-- Tighten the nuts -1 through 5- in 4 passes as follows:
-- 1. Tighten the nuts to 5 Nm.
VACUUM DIAPHRAGM
NOTE: Engine codes CCTA and CBFA do not have an adjustable vacuum diaphragm.
Fig. 9: Identifying Assembly Overview: Turbocharger - Part IV

1. Turbocharger
2. Vacuum Diaphragm
 Checking, refer to TURBOCHARGER VACUUM DIAPHRAGM, CHECKING.
 Removing and installing, refer to TURBOCHARGER VACUUM DIAPHRAGM.
3. Bolt
 10 Nm
4. Nut
9 Nm

 Secure with sealing wax.
 Not available with engine codes CCTA and CBFA.
5. Securing Plate
6. Knurled Nut
SPECIFICATIONS

Bracket to Cylinder Block Bolt (2) - 30
Bracket to Turbocharger Bolt (2) - 30
Charge Air Pipe Bolt
-- GTI (4) - 8
-- Eos, Tiguan, Passat, CC and GTI (4) - 10
Charge Air Pipe Clamp - 5.5
Charge Air Pressure Sensor to Charge Air Pipe Bolt - 5
Connection to Turbocharger Bolt - 9
Coolant Return Pipe to Turbocharger Banjo Bolt - 38
Coolant Return Pipe to Turbocharger Bolt - 9
Coolant Supply Pipe to Cylinder Block Banjo Bolt - 38
Coolant Supply Pipe to Cylinder Block Bolt - 9
Coolant Supply Pipe to Turbocharger Banjo Bolt - 38
Drive Axle Heat Shield Bolt - 20
Fastening Strip to Cylinder Head Nut 1, 3 - 30
Heat Shield to Cylinder Head Bolt - 20
Mount to Charge Air Cooler Bolt - 5
Noise Generator to Bracket Bolt (5) - 8
Noise Generator Bracket to Plenum Chamber
- 8
Bulkhead Nut (5)
Oil Return Pipe to Cylinder Block Bolt - 9
Oil Return Pipe to Turbocharger Bolt - 9
Oil Supply Pipe to Cylinder Block Bolt - 9
Oil Supply Pipe to Turbocharger Banjo Bolt - 33
Oil Supply Pipe to Turbocharger Bolt - 9
Plenum Chamber Bulkhead Bolt (5) - 8

Turbocharger Recirculation Valve to Turbocharger
- 7
Bolt
Vacuum Diaphragm to Turbocharger Bolt - 10
Wastegate Bypass Regulator Valve to Turbocharger
- 3
Bolt
(1) Always replace
(2) Lubricate the bolt with hot bolt paste.
(3) Lubricate the studs of the exhaust manifold with hot bolt paste.
(4) For bolt clarification for the GTI only, see -items 5 and 14- in the
(5) GTI (2008 through 2009)
Turbocharger Nut Tightening Sequence and Specification
Fig. 10: Identifying Turbocharger Tightening Sequence

-- Tighten the nuts -1 through 5- in 4 passes as follows:
-- First pass, tighten the nuts to 5 Nm.
-- Second pass, tighten the nuts to 12 Nm.
-- Third pass, tighten the nuts to 16 Nm.
-- Final pass, tighten the nuts to 25 Nm.

CHARGE AIR SYSTEM, CHECKING FOR LEAKS
 Testing Unit for Turbocharger -V.A.G 1687-

-- Release the securing clamp -A- and disconnect the hose -B- from the charge air pipe.
Fig. 11: Identifying Locking Clip & Charge Air Hose

-- Install the adapter -V.A.G 1687/5- to the charge air hose -A- and rotate it approximately 90° -B-.
Fig. 12: Identifying Method To Connect Adapter V.A.G 1687/5 To Charge Air Hose
Prepare the testing unit for turbocharger -V.A.G 1687- as follows:
-- Turn the pressure regulator valve -2- counterclockwise until it stops.
Fig. 13: Identifying Pressurized Air Hose Connected To Testing Unit For Turbo Charger V.A.G 1687
-- Close the valves -3 and 4-.
NOTE: In order to be able to turn the pressure regulator valve -2- , the rotary knob must
be pulled upward.
-- Connect the testing unit for turbocharger -V.A.G 1687- as shown.
Fig. 14: Identifying Testing Unit Connected For Turbo Charger V.A.G 1687
-- Connect a pressurized air hose -1- (pressurized air supply) to the testing unit for turbocharger -V.A.G 1687-.
Fig. 15: Identifying Pressurized Air Hose Connected To Testing Unit For Turbo Charger V.A.G 1687
NOTE: If water is located in the viewing glass, drain it via the water drain plug -6-.
-- Open the valve -3-.
-- Set the pressure to 0.5 bar using the pressure regulator valve -2-.
CAUTION: Pressure must not exceed 0.5 bar. A pressure set too high may damage
the engine.
-- Open the valve -4- and wait until the testing circuit has filled. If necessary, continue to regulate the pressure
to 0.5 bar.
-- Check the charge air system for leaks by listening, feeling, using commercially available leak detection spray
or by using the ultrasonic measuring device -V.A.G 1842-.
NOTE: Charge air hose, installing. Refer to CHARGE AIR HOSE, INSTALLING.
A small quantity of air dissipates via the valves in the engine. A pressure
retention test is not possible for this reason.
Handling instructions of ultrasonic measuring device -V.A.G 1842-. Refer to the

relevant user's information.
Before removing the adapter, discharge pressure in the testing circuit by

pulling off the coupling from the adapter -V.A.G 1687/5-.
before installing.
TURBOCHARGER VACUUM DIAPHRAGM, CHECKING
Test Conditions
 The hose between the turbocharger, the wastegate bypass regulator valve -N75- and vacuum diaphragm
must not be kinked.
 The wastegate bypass regulator valve is OK.
Procedure
-- Connect the hand vacuum pump -VAS 6213- to the vacuum diaphragm -arrow-.
Fig. 16: Identifying Hand Vacuum Pump VAS 6213 Connected To Vacuum Diaphragm
-- Set the slide ring -1- on the hand vacuum pump -VAS 6213- to position -B- for "pressure".
CAUTION: The pressure must not exceed 750 mbar. If the pressure is exceeded, the
vacuum diaphragm can be damaged.
-- Operate the hand vacuum pump -VAS 6213- several times and observe the rods.
The linkage -A- must move approximately 300 mbar and be at approximately 700 mbar at the end position.
Fig. 18: Identifying Linkage Movement

Actuator lift is approximately 10 mm.
NOTE: If the pressure cannot be raised using the hand vacuum pump -VAS 6213- or the
pressure drops immediately, check the hand vacuum pump -VAS 6213- and
connecting hoses for leaks. If no malfunction can be found: Replace the
vacuum diaphragm. Refer to TURBOCHARGER VACUUM DIAPHRAGM.
CHARGE AIR HOSE, INSTALLING
CAUTION: The connector coupling sealing ring can be damaged if the securing clamp
is in its locked position when installing. This would result in a leak. Follow
the assembly instructions.
Removing
-- Release the connector coupling by pulling the locking clip -arrow-. Separate the hose/pipe without assistance
from tools.
Fig. 19: Identifying Connection Coupling And Securing Clip

Installing
-- When replacing the sealing ring, place it in the groove in the charge air hose. Ensure the sealing ring sits
completely in the groove all the way around and is not twisted.
-- Lubricate the sealing surfaces and sealing ring.
-- Bring the securing clamp into its released position -1-.

Fig. 20: Identifying Clip In Release And Lock Positions

-- Slide the charge air hose onto the pipe as far as the stop.
-- Bring the securing clamp into the locked position -2- and then press the charge air hose back again.
-- Check for correct seating and proper locking of the connection by pulling on the hose.
CHARGE AIR COOLER
Removing
-- Remove the bumper cover. Refer to Removal and Installation .
-- Loosen the clamps -arrows- and remove the right charge air hose.
Fig. 21: Identifying Right Charge Air Guide Hose -Arrows-

-- Remove the radiator. Refer to RADIATOR .
-- Remove the air guides from the lock carrier. Refer to Description and Operation .
-- Remove the charge air cooler bracket bolts -1-.
Fig. 22: Identifying Charge Air Cooler Mount Bolts

NOTE: The Air Conditioning (A/C) condenser bolts are difficult to access. With the help
of a second technician, lift the charge air cooler out of the lower mounts. Now
the charge air cooler can be tilted >>back and forth<< and the bolts are
accessible.
-- Remove the A/C condenser pipe bolt -arrow- on the right side of the charge air cooler.
Fig. 23: Locating Side Bolt From Condenser On Radiator

-- Remove the A/C condenser bolts -arrows- from the charge air cooler.
Fig. 24: Identifying Condenser Bolts

-- Secure the A/C condenser to the lock carrier with cable ties.
-- Remove the charge air cooler downward.
Installing
 Hose connections and charge air system hoses must be free of oil and grease before installing. On
connector couplings, the seal and sealing surfaces must only be lightly oiled. Refer to CHARGE AIR
HOSE, INSTALLING.
TURBOCHARGER
 Bits -T10099-
 Bit XZN 10 -T10154-
 Spring Type Clip Pliers -VAS 5024 A-
CAUTION: If mechanical damage is found on the turbocharger, for example, a

destroyed compression wheel, it is not enough to just replace the
turbocharger. Perform the following steps to prevent subsequent damage.
 Check the air filter housing, the air filter element and the intake hoses
for contamination.
 Check the entire charge air circuit and cooler for contamination.
If contaminants are found in the charge air circuit, the circuit must be
cleaned and the cooler replaced if necessary.
Removing
-- Remove the front part of the right wheel housing liner and/or the right front wheel housing liner. Refer to

-- Remove the engine cover.
-- Disconnect the connectors from the ignition coils and the wiring harness and lay them aside.
Fig. 25: Identifying Connectors Of Ignition Coils

-- Disconnect the coolant line -arrow- from the coolant expansion tank.
Fig. 26: Identifying Coolant Line To Coolant Expansion Tank

-- Disconnect the vacuum line -1- at the separating point -2- and free up the line.
-- Remove the coolant hoses -arrows- from the coolant pipe.
-- Disconnect the ground wire -3- and loosen the bolt -4-.
-- Loose the hose clamp -2- and lay the charge air pipe on the cylinder head.
-- Seal off the turbocharger using the engine bung set -VAS 6122-.
-- Remove the bolts -1 though 3- and remove the heat shield together with the coolant pipe.

NOTE: Remove the bolt -2- from the heat shield using a 6 mm -A- hex socket. The hex
socket must be at least 5 cm -B- long. A socket that tapers to 6 mm at the tip is
too wide.
Fig. 30: Identifying 6mm Hex Socket -A-, 5cm Long -B-
-- Remove the oil supply pipe -4- from the turbocharger.



Fig. 33: Identifying, Tool -3247-, Bolts -1- And Heat Shield -A-
-- Remove the bolts -1- and heat shield -A- from above the right drive axle.
Fig. 34: Identifying Drive Axle Heat Shield Bolts And Shield
-- Remove the right drive axle heat shield bolts -arrows- and shield.

Fig. 35: Identifying Turbocharger Electrical Connectors

-- Disconnect the connectors -1 and 2- and free up the wire -arrows-.
Fig. 36: Identifying Turbocharger Support And Bolts

-- Remove the bolts -1- using the Bit XZN 10 -T10154-.

-- Remove the banjo bolt -2- and move the coolant pipe to the side.
Fig. 37: Identifying Oil Return Line, Coolant Line And Oil Supply Line Fasteners
Vehicles with FWD
-- Remove the bolts -1- for the oil return pipe.
Vehicles with AWD
-- Remove the oil return pipe bolts from the crankcase.
-- Remove the bolt -3- for the oil supply pipe.
-- Disconnect the coolant hose -arrow- and move it to the side.

Fig. 38: Identifying Coolant Hose Clamps

-- Remove the nuts -arrows-.
Fig. 39: Identifying Turbocharger/Exhaust Manifold Upper Nuts

-- Remove the turbocharger upward.
Installing
CAUTION: If mechanical damage is found on the turbocharger, for example, a

destroyed compression wheel, it is not enough to just replace the
turbocharger. Perform the following steps to prevent subsequent damage.
 Check the air filter housing, the air filter element and the intake hoses
for contamination.
 Check the entire charge air circuit and cooler for contamination.
If contaminants are found in the charge air circuit, the circuit must be
cleaned and the cooler replaced if necessary.
 Assembly of hose connections with connection couplings. Refer to CHARGE AIR HOSE,
INSTALLING.
 Always replace seals, gaskets and self-locking nuts.
 Add oil to the turbocharger through the oil supply pipe connecting piece.
 After installing the turbocharger, let the engine idle for approximately 1 minute to ensure adequate oil
supply to the turbocharger.
 The coolant return pipe must be installed together with the turbocharger.
 Hose connections and charge air system hoses must be free of oil and grease before installing. On
connector couplings, the seal and sealing surfaces must only be lightly oiled. Refer to CHARGE AIR
HOSE, INSTALLING.
 Secure all hose connections using hose clamps appropriate for the model type.
Component Nm
Exhaust manifold/turbocharger to cylinder head (1)(2) Observe the tightening
sequence, refer to Fig. 8.
Oil supply pipe to turbocharger (M12 banjo bolt) 33
Oil return pipe to turbocharger 9
Coolant supply pipe to turbocharger (M14 banjo bolt) 38
Turbocharger bracket to cylinder block (2) 30
Turbocharger bracket to turbocharger (2) 30
Right charge air pipe to oil pan 10
Heat shield to cylinder head M8 and M12 20
(1) Replace nuts
(2) Use hot bolt paste.
TURBOCHARGER VACUUM DIAPHRAGM
Removing
-- Remove the turbocharger. Refer to TURBOCHARGER.
Fig. 40: Identifying Circlip -Arrow- From Vacuum Diaphragm Linkage

-- Remove the circlip -arrow- from the vacuum diaphragm linkage
-- Remove the vacuum diaphragm bolts -arrows- from the turbocharger.
Fig. 41: Identifying Lock Nut, Turbocharger, Vacuum Diaphragm

Installing
Component Nm
Vacuum diaphragm to turbocharger 10
SPECIAL TOOLS

 Testing Unit for Turbocharger -V.A.G 1687-
Fig. 42: Identifying Testing Unit For Turbo Charger V.A.G 1687

Fig. 43: Identifying Hand Vacuum Pump VAS 6213

Fig. 44: Identifying Torque Wrench -V.A.G 1331-, Spring Type Clip Pliers -VAS 5024 A- And Special
Tools
 Bits -T10099-
 Bit XZN 10 -T10154-
 Spring Type Clip Pliers -VAS 5024 A-
HVAC Air Conditioning
HVAC
Air Conditioning
87 AIR CONDITIONING
GENERAL INFORMATION
A/C COMPRESSOR, INSTALLATION INFORMATION
-- Start the engine only after assembling the refrigerant circuit.
-- After installing a new A/C compressor or fresh refrigerant oil has been filled into compressor (for example,
after blowing through the A/C system), turn ribbed belt pulley of A/C compressor 10 rotations by hand before
starting the engine. This prevents damage to the A/C compressor.
-- Only start the engine when the refrigerant circuit is filled.
NOTE: The A/C compressor is always driven by the ribbed belt pulley (no A/C clutch).
If the A/C compressor is blocked, the compressor shaft overload protection is

activated. The blockage is mostly recognized by deformations/bumps on the
ribbed belt pulley. In addition, the blockage can be recognized by the abraded
rubber in the area of the ribbed belt pulley.
The A/C compressor is equipped with a protected oil supply, this prevents A/C
compressor damage in the event that the system is empty. This means that
approximately 40 to 50 cm3 of refrigerant oil remains in the A/C compressor.
The engine may only be started when the refrigerant circuit is installed
correctly. For example; if the refrigerant lines are not connected to A/C
compressor, when the engine is running the A/C compressor may heat up (via
internal heat generation) so much that the A/C compressor will be damaged.
A/C Compressor Regulator Valve -N280- is not activated when the refrigerant
circuit is empty and the A/C compressor idles with the engine.
If it is necessary to start the engine with a discharged refrigerant circuit:
Refrigerant circuit must be fully assembled.
At least 1/4 of the prescribed refrigerant oil must be in the A/C compressor.
No not rev engine higher than 2000 rpm.
The engine should only run as long as is absolutely necessary, maximum 10

minutes.
NOTE: Pay attention to the following when starting the engine for the first time after
filling the refrigerant circuit:
-- Start engine with A/C compressor switched off (ECON or AC ) and wait until the idling speed stabilizes.
-- Open the instrument panel vents.
-- Select the temperature setting "Lo" on the Climatronic A/C display control head -E87-.
-- Turn on the A/C compressor (AUTO) and let the engine run for 5 minutes at idling speed.
A/C SYSTEM REPAIRING AND HANDLING REFRIGERANTS
CAUTION: Do not bend or kink A/C lines excessively.
There is a foil inside the refrigerant lines that can be destroyed.
Refrigerant lines must not be bent beyond a radius less than R = 100 mm.
NOTE: Information for repairing vehicles with air conditioning and working with
refrigerant can be found in A/C SYSTEM .
Information for special tools and equipment when repairing vehicles with air
conditioning can be found in Special Tools .
Additional Information
 Refer to relevant Wiring diagrams, Troubleshooting & Component locations.
CLIMATRONIC A/C SYSTEM WITH AUTOMATIC CONTROL
NOTE: Pressing the button AUTO will reverse all settings which deviate from the
automatic operation.
Deviations from automatic operation, refer to respective operating instructions.
Vehicles through 25 May 2007 have an ECON button. The A/C compressor is set
to almost zero delivery. Depending on the vehicle equipment level, the auxiliary
air heater heating element -Z35- or the auxiliary heater (being used as an
additional heater) is switched off. The auxiliary heating remains switched on if it
is activated manually. The specific ambient conditions or activation signals
must be present. The heating and ventilation operation continues to be
controlled electronically.
When the ECON button is off, the A/C compressor turns on. Depending on the
vehicle equipment level, the Auxiliary Air Heater Heating Element -Z35- or the
auxiliary heater (being used as an additional heater) is switched on. The
auxiliary heating remains switched on if it is activated manually. The specific
ambient conditions or activation signals must be present. The heating and
ventilation operation continues to be controlled electronically.
Vehicles from 28 May 2007 do not have an ECON button. The AC button
replaces it. The ON/OFF button is no longer there. The OFF button replaces it.
When the AC button is on, the A/C compressor turns on.
If the AC button is off, the A/C compressor does not work.
When the ON/OFF button is on, the Climatronic works.
When the ON/OFF button is off, the Climatronic does not work. There is no
heating or ventilation.
OFF button is on. Climatronic is switched off. There is no heating or ventilation.
OFF button is off. Climatronic is switched on.
ODORS IN VEHICLES WITH A/C
NOTE: Numerous procedures varying in their application and effect are available on
the market for cleaning the evaporator. Currently, Volkswagen approves using
Ultrasound A/C Cleaner -VAS 6189A- and a spray nozzle to clean the
evaporator. Should Volkswagen test and approve other methods, the
information will be published in ODOR FROM EVAPORATOR OR HEAT
EXCHANGER .
REFRIGERANT CIRCUIT REPAIRS
WARNING: There is a danger of ice-up.
Refrigerant leaks out if refrigerant circuit is not discharged.
Refrigerant must be extracted before opening the refrigerant circuit. If

refrigerant circuit is not opened within 10 minutes of extraction, pressure
may form in refrigerant circuit due to evaporation. Extract refrigerant once
more.
NOTE: Information on repairs in vehicles with a climate control system and on

handling refrigerant can be found in A/C SYSTEM .
Information on tools for repairs in vehicles with climate control system can be
found in Special Tools .
Under certain conditions, the dryer cartridge should no longer be replaced each
time the refrigerant circuit is opened. Refer to REPLACING RESERVOIR/FLUID
RESERVOIR OR DRYER CARTRIDGE, CONDITIONS .
NOTE: Flush the refrigerant circuit with R134a refrigerant under the following
conditions:
In the event of dirt or other contamination in the refrigerant circuit.
If vacuum reading is not maintained on evacuating a leak-free refrigerant circuit

(pressure build-up due to moisture in refrigerant circuit).
If refrigerant circuit has been left open for longer than normal (e.g. following an
accident).
If pressure and temperature measurements in the refrigerant circuit indicate the

likelihood of moisture
If it is not clear how much refrigerant oil is in the refrigerant circuit.
The A/C compressor had to be replaced due to internal damage (such as noise
or no output).
The flushing procedure is described in REFRIGERANT CIRCUIT AND

COMPONENTS .
Information for repairing vehicles with air conditioning and working with refrigerant can be found in A/C
SYSTEM .
Information for special tools and equipment when repairing vehicles with air conditioning can be found in
Special Tools .
AIR QUALITY SENSOR -G238-
 The air quality sensor detects pollutants in the ambient air (mostly gasoline and/or diesel fumes).
 Climatronic Control Module -J255- evaluates signal from the air quality sensor. The A/C system is
activated depending on the strength and type of heavily polluted air.
- At an outside temperature greater than approximately + 2° C the recirculating air mode is switched on when
there is only a slight increase in pollutants in the ambient air.
At an outside temperature between approximately + 2° C and -5° C, the system only switches to recirculation
mode when there is a strong increase in the level of pollutants. The A/C compressor also switches on.
At an outside temperature less than approximately -5° C, the system still only changes to recirculation mode
when there is a strong increase in the level of pollutants. However, it only switches on for approximately 15
seconds and the A/C compressor does not switch on. If the concentration decreases, the air conditioner switches
to the fresh air mode.
 "Automatic recirculating air mode" can be switched off at any time. If the function is active and a request
for "Automatic air recirculation" is present the A/C compressor is also switched on when outside
temperatures are smaller than +2° C. A/C compressor operation is not possible with temperatures lower
than approximately -5° C.
 If the vehicles has "automatic recirculating air mode" , the A/C compressor can also be manually
switched on when the temperature is approximately -5° C.
 To ensure that the A/C does not operate constantly in the recirculating air mode in areas with a
consistently higher pollution, the sensor is self learning (it adjusts its sensitivity to the environmental
conditions).
 If outside air pollution load remains high for longer period of time, the sensor starts to adapt itself to the
changing environmental condition through an adaptation program (learning program), the air recirculation
request in evenly polluted ambient air is therefore generally shorter than 12 minutes. If a succession of
peaks in the polluted air is detected, the air conditioning system can operate over a longer period of time
in recirculated air mode.
 A certain amount of time is required for repositioning of the air conditioning system doors. In the event
that a sudden increase in pollutants is encountered (for example, when driving through a diesel exhaust
cloud) gaseous pollutants can be taken in with the fresh air into the passenger compartment until the door
can be closed. For this reason, a dust and pollen filter is installed with a charcoal layer. A filter that is
saturated with pollutants is no longer effective and needs to be replaced.
 In order to avoid frequent shifting of the recirculated air/fresh air door, a slight increase of pollutants in
the ambient air will not allow for immediate shifting (the sensor does not send a request to Climatronic
Control Module -J255-). The filtering of the charcoal insert in the dust and pollen filter will be sufficient.
 In order to avoid frequent shifting of the recirculating air/fresh air door, the requirement from the sensor
for "automatic air recirculation" mode remains for at least 25 seconds (minimum duration period), even if
the pollutant concentration is so far reduced that recirculating air mode is no longer necessary.
 If the A/C compressor is shut-off (for example, in ECON mode), the maximum duration of the "automatic
recirculated air mode" is limited to approximately 15 seconds by the Climatronic Control Module to
avoid windows from fogging up.
 So that fogged windows are cleared as quickly as possible, the Climatronic Control Module does not
permit recirculated air operation during the "defrost" operating mode.
 After the ignition is switched on, the air quality sensor requires approximately 30 seconds to be
operational (warm-up time). During this time there is no requirement from the sensor to Climatronic
control module for "automatic recirculating air mode".
 The air quality sensor contains a highly sensitive electronic component which can be damaged if it comes
in direct contact with solvents, fuels or chemicals. For this reason, do not install sensors that may have
come into contact with these substances.
CLIMATIC HEATING AND A/C SYSTEM OVERVIEW
NOTE: Disconnect the battery before removing the components marked with **. Refer
to Removal and Installation .
A data plate indicates the refrigerant used and capacity.
Fig. 1: Identifying Assembly Overview: Climatic Heating And A/C System

1. Dash Panel **
2. Center Outlet Temperature Sensor -G191-
 Removing and installing, refer to CENTER OUTLET TEMPERATURE SENSOR -G191-.
3. Center Vents
 Removing and installing, refer to CENTER VENT .
4. Right Side Vent

5. Controls For Heating and A/C System, Climatic
 Passat from MY 06.
 With Fresh air/recirculating door switch -E159-.
 Also with Immediate heating button -E537- in vehicles with an auxiliary heater.
 With Rear window defogger switch -E230-.
 With Fresh air blower switch -E9-.
 On vehicles with heated seals also with Heated driver seat adjuster -E94- and Heated front
passenger seat adjuster -E95-.
 With A/C control module -J301-.
 Removing and installing, refer to HEATING AND A/C SYSTEM CONTROLS.
6. Controls For Heating and A/C System, Climatic

 Passat CC from MY 09.
 With Fresh air/recirculating door switch -E159-.
 With Rear window defogger switch -E230-.
 With Fresh air blower switch -E9-.
 On vehicles with heated seats also with Heated driver seat adjuster -E94- and Heated front
passenger seat adjuster -E95-.
 Removing and installing, refer to HEATING AND A/C SYSTEM CONTROLS.
7. Fresh/Recirculating Air Door Motor -V154-

 Check using Vehicle Diagnosis, Testing and Information System -VAS 5051B-.
 Removing and installing, refer to FRESH/RECIRCULATING AIR DOOR MOTOR -V154- .
 Replacing: perform Basic Setting using Vehicle Diagnostic, Testing and Information System -VAS
5051B-. Refer to CLIMATRONIC A/C SYSTEM, CHECKING AND ADJUSTING
COMPONENTS.
8. Air Distribution Door Motor -V428- with Air Distribution Door Motor Position Sensor -G645-
 Removing and installing .
COMPONENTS.
9. Right Footwell Vent
 Removing and installing, refer to RIGHT FOOTWELL VENT .
10. Fresh Air Blower -V2-

 Removing and installing, refer to FRESH AIR BLOWER -V2- .
11. Fresh Air Blower Series Resistor With Fuse -N24-

 Removing and installing, refer to FRESH AIR BLOWER SERIES RESISTOR WITH FUSE -N24-
.
12. Evaporator Vent Temperature Sensor -G263-
 Removing and installing, refer to EVAPORATOR VENT TEMPERATURE SENSOR -G263-.
13. Heating Unit Partition

 Removing, refer to PASSENGER COMPARTMENT HEATING OVERVIEW => Removing
Heater Partition .
14. Dust and Pollen Filter
 Removing and installing, refer to DUST AND POLLEN FILTER .
15. Cap
 Only in vehicles without air guide to vent installed in center console at rear.
16. Connection
 For air duct, rear vent.
 To remove, the center console must be removed. Refer to Removal and Installation .
17. Air Duct To Rear Vent

 Removing and installing, refer to REAR VENT AIR DUCT .
18. Rear Vent

 Removing and installing, refer to REAR VENT .
19. Rear Channel For Right Footwell

 Removing and installing, refer to REAR CHANNEL, FOOTWELL .
20. Rear Channel For Left Footwell

21. Screw
 Quantity: 8
22. Adapter For Controls

23. Auxiliary Heater Heating Element -Z35-

 Not applicable to the US or Canada
24. Left Footwell Vent

 Removing and installing, refer to LEFT FOOTWELL VENT .
25. Heat Exchanger

 Removing and installing, refer to HEAT EXCHANGER .
26. Footwell Outlet Temperature Sensor -G192-

 Removing and installing, refer to FOOTWELL OUTLET TEMPERATURE SENSOR -G192-.
27. Temperature Regulator Flap Motor -V68- with Temperature Regulator Flap Motor Position
Sensor -G92-
 Removing and installing, refer to TEMPERATURE REGULATOR DOOR MOTOR -V68-.

COMPONENTS.
28. Flexible Shaft
 Removing and installing, refer to FLEXIBLE AIR DISTRIBUTION SHAFT .
29. Heating and A/C Unit

 Removing and installing, refer to HEATING AND A/C UNIT.
 Disassembling and assembling, refer to HEATING AND A/C UNIT, CLIMATIC.
CLIMATIC HEATING AND A/C CONTROL FUNCTIONS

Fig. 2: Identifying Climatic Heating And A/C Control Functions

1. Left Seat Heater Control

2. AC Button
 Push the AC button to turn on or turn off the A/C.
 When the light in the button is on, the air conditioner compressor is switched on.
3. Rear Window Defogger Button

4. Infrared Sensor For Passenger Compartment Temperature
5. Recirculating Air Mode Button
 Press button for recirculating air function to prevent polluted air from entering interior.

7. Right Seat Heater Control
 The seat heating has 3 settings. An LED indicates which setting is selected.
 If no LED is illuminated, the seat heater is switched off.
8. Air Distribution Control

9. Blower Speed Control
 To the left: decreases the blower speed.
 To the right: increases the blower speed.
10. Temperature Setting Control

 To the left: lower the temperature.
 To the right: increases the temperature.
CLIMATIC HEATING AND A/C SYSTEM CONTROLS MULTI-PIN HARNESS CONNECTOR
 Test Box -V.A.G 1598/42-

 Adapter Cable -V.A.G 1598/47-
 Template -V.A.G 1598/47-2-
20-pin Harness Connector, T20b
Fig. 3: Identifying 5-Pin Electrical Connection T5, 16-Pin Electrical Connection, In Wiring Diagram
T16E And 20-Pin Electrical Connection T20C
3 - Center Outlet Temperature Sensor -G191-

5 - High Pressure Sensor -G65-
7 - CAN bus low
8 - CAN bus high
12 - Right seat heater (optional)
13 - Left seat heater (optional)
15 - Terminal 75 seat heater (optional)
16 - A/C Compressor Regulator Valve -N280-
18 - Center Outlet Temperature Sensor -G191-
19 - Terminal 30A
20 - Terminal 31
16-pin Harness Connector, T16j
Fig. 4: Identifying 5-Pin Electrical Connection -T5-, 16-Pin Electrical Connection, In Wiring Diagram
T16E And 20-Pin Electrical Connection -T20C-
1 - Temperature Regulator Door Motor -V68-, warm
2 - Evaporator Temperature Sensor -G308-

4 - Footwell Outlet Temperature Sensor -G192-
5 - Left Temperature Door Potentiometer/Actuator -G220-
7 - + 5 V for Left Temperature Regulator Door Motor Position Sensor -G220-
8 - Ground for the Footwell Vent Temperature Sensor -G192-, the Evaporator Temperature Sensor -G308- and
the Left Temperature Door Potentiometer/Actuator -G220-
9 - Recirculation Door Motor -V113-, open
10 - Recirculation Door Motor -V113-, close
11 - Temperature Regulator Door Motor -V68-, cold
5-pin Harness Connector T5r
Fig. 5: Identifying 5-Pin Electrical Connection -T5-, 16-Pin Electrical Connection, In Wiring Diagram
T16E And 20-Pin Electrical Connection -T20C-
1 - 3rd blower speed
2 - 2nd blower speed
3 - 1st Blower speed
4 - 4th blower speed
5 - Terminal X
CLIMATRONIC HEATING AND A/C SYSTEM OVERVIEW
NOTE: Disconnect the battery before removing the components marked with **. Refer
to Removal and Installation .
A data plate indicates the refrigerant used and capacity.
Fig. 6: Identifying Assembly Overview: Climatronic Heating And A/C System Overview
1. Dash Panel **
 Removing and Installing, refer to Removal and Installation .
2. Left Vent Temperature Sensor -G150-

 Removing and installing, refer to LEFT VENT TEMPERATURE SENSOR -G150-.
3. Sunlight Photo Sensor -G107- or Sunlight Photo Sensor 2 -G134-

 Controls temperature door and fresh air blow depending on light intensity.
 Emergency running in the event of failure: the Climatronic control module -J255- utilizes a fixed
value.
 Removing and installing, refer to SUNLIGHT PHOTO SENSOR -G107- OR SUNLIGHT
PHOTO SENSOR 2 -G134-.
4. Vents For Indirect Ventilation
5. Center Vents
 Removing and installing, refer to CENTER VENT .
6. Right Vent Temperature Sensor -G151-

 Removing and installing, refer to RIGHT VENT TEMPERATURE SENSOR -G151-.
7. Air Outlet
 Removing and installing, refer to DRIVER AND PASSENGER SIDE .
8. A/C Control Head -E87- with Climatronic Control Module -J255-

 The Climatronic Control Module and the A/C Control Head are one component that cannot be
disassembled.
 Removing and installing, refer to A/C DISPLAY CONTROL HEAD -E87- WITH
CLIMATRONIC CONTROL MODULE -J255-.
COMPONENTS.
9. A/C Control Head -E87- with Climatronic Control Module -J255-
 Passat CC from MY 09
 The Climatronic Control Module and the A/C Control Head are one component that cannot be
disassembled.
 Removing and installing, refer to A/C DISPLAY CONTROL HEAD -E87- WITH
CLIMATRONIC CONTROL MODULE -J255-.
COMPONENTS.
10. Control Motor
Passat from MY 06 through calendar week 21/07 Air Flow Flap Motor -V71-.
 Removing and installing, refer to AIR FLOW DOOR MOTOR -V71- WITH BACK
PRESSURE DOOR MOTOR POSITION SENSOR -G113-.
2006 Passat from calendar week 22/07 and Passat CC from MY 2009 Fresh Air/Recirculating
Air/Back Pressure Flap Motor -V425-.
Removing and installing, refer to AIR FLOW DOOR MOTOR -V71- WITH BACK
 Replacing: perfom Basic Setting using Vehicle Diagnostic, Testing and Information System -VAS
COMPONENTS.
11. Recirculation Door Motor -V113-
From 2006 Passat only through calendar week 21/07.
Check using Vehicle Diagnosis, Testing and Information System -VAS 5051B-.
 Removing and installing, refer to RECIRCULATION DOOR MOTOR -V113-.
 Replacing: perfom Basic Setting using Vehicle Diagnostic, Testing and Information System -VAS
COMPONENTS.
12. Right Footwell Vent
 Removing and installing, refer to RIGHT FOOTWELL VENT .
13. Fresh Air Blower -V2- with Fresh Air Blower Control Module -J126-
NOTE: The fresh air blower control module and the fresh air blower are in a single
housing together and cannot be replaced individually.
 Removing, refer to FRESH AIR BLOWER -V2- WITH FRESH AIR BLOWER CONTROL
MODULE -J126-.
14. Connector
15. Evaporator Temperature Sensor -G308- or Evaporator Vent Temperature Sensor -G263-
NOTE: One or both of the component designations will appear, depending on

software. The tasks are the same.
16. Heating Unit Partition

 Removing, refer to PASSENGER COMPARTMENT HEATING OVERVIEW => Removing
Heater Partition .

 With EVAP canister.
18. Cap
 Only in vehicles without air guide to vent installed in center console at rear.
19. Connection
 For air duct, rear vent.
 To remove, the center console must be removed. Refer to Removal and Installation .
20. Air Duct To Rear Vent

 Removing and Installing, refer to REAR VENT AIR DUCT .
21. Rear Vent

 Removing and installing, refer to REAR VENT .
22. Rear Channel For Right Footwell

23. Rear Channel For Left Footwell

24. Right Temperature Door Motor -V159-

 Removing and installing, refer to RIGHT TEMPERATURE DOOR MOTOR -V159-,

THROUGH 31 OCTOBER 2008 or RIGHT TEMPERATURE DOOR MOTOR -V159-,
FROM 03 NOVEMBER 2008.
 Replacing: perform a basic setting with Vehicle Diagnosis, Testing and Information System -VAS
5051B-, refer to CLIMATRONIC A/C SYSTEM, CHECKING AND ADJUSTING
COMPONENTS.
25. Right Footwell Vent Temperature Sensor -G262-
 Removing, refer to RIGHT FOOTWELL VENT TEMPERATURE SENSOR -G262-.

27. Left Footwell Vent

 Removing and installing, refer to LEFT FOOTWELL VENT .
28. Heat Exchanger

29. Left Footwell Vent Temperature Sensor -G261-

 Removing, refer to LEFT FOOTWELL VENT TEMPERATURE SENSOR -G261-.
30. Defroster Door Motor -V107-

 Removing and installing, refer to DEFROSTER DOOR MOTOR -V107-.

COMPONENTS.
31. Left Temperature Door Motor -V158-
 Checking: Vehicle Diagnosis, Testing and Information System -VAS 5051B-
 Removing and Installing, refer to LEFT TEMPERATURE DOOR MOTOR -V158-
COMPONENTS
32. Control Motor
Passat from MY 06 Central Air Door Motor -V70-.
Passat CC from MY 09 Front Air Distribution Door Motor -V426-.
 Removing and installing, refer to CENTRAL AIR DOOR MOTOR -V70- OR FRONT AIR
DISTRIBUTION DOOR MOTOR -V426-.
COMPONENTS.
 Removing and installing, refer to HEATING AND A/C UNIT.
 Disassembling and assembling, refer to HEATER AND A/C UNIT, CLIMATRONIC.
34. Indirect Ventilation Door Control Motor -V213-

 Removing, refer to INDIRECT VENTILATION DOOR MOTOR -V213-.
COMPONENTS.
CLIMATRONIC DISPLAY CONTROL HEAD

Fig. 7: Identifying Climatronic Display Control Head

1. Display Of Selected Interior Temperature, Left Side

2. Recirculating Air Mode Button
 Press button for recirculating air function to prevent polluted air from entering interior.
3. Button - Center Air Distribution

4. Button - Lower Air Distribution
5. Button - Upper Air Distribution
6. Display Of Selected Interior Temperature, Right Side
7. Recirculating Air Mode Or Automatic Recirculating Air Mode Button
 Vehicles through 05.07. Pressing the recirculation button again activates the automatic recirculation
function.
NOTE: Only for vehicles with an Air quality sensor -G238-.
Air quality sensor -G238- function, refer to AIR QUALITY SENSOR -

G238-.
8. Windshield Defroster Button

9. Push Button For Rear Window Defroster
10. Left Interior Temperature Knob
11. Blower Regulator
 Changed blower speed by turning.
12. DUAL Button

 For vehicles from calendar week 28 May 2007.
 If the indicator light in the button comes on, different temperatures can be set for left and right.
 When the Dual button is pressed (the indicator lamp turns off), then the temperature setting for the
driver seat will also apply to the front passenger seat.
13. Interior Temperature Sensor
14. A/C ON/OFF Button or OFF Button
 Information regarding vehicles through 05.21.07 and from 05.28.07, refer to CLIMATRONIC
A/C SYSTEM WITH AUTOMATIC CONTROL.
15. AUTO Button
 By pressing the AUTO button, Climatronic maintains the selected vehicle interior temperature
completely automatically. With this setting the vent air temperature, the blower speed and the air
distribution are controlled automatically.
16. AC Button
 Vehicle from 21 May 2007.
 Push the AC button to turn on or turn off the A/C.
 Information regarding vehicles through 05.21.07 and from 05.28.07, refer to CLIMATRONIC
A/C SYSTEM WITH AUTOMATIC CONTROL.
17. ECON Button
 Vehicles through 05.21.07:
 Push the ECON button to turn on or turn off the A/C.
18. Right Side Interior Temperature Control
CLIMATRONIC CONTROL MODULE, MULTI-PIN HARNESS CONNECTOR

 Test Box -V.A.G 1598/42-

 Template -V.A.G 1598/47-2-
20-pin Harness Connector -A-, T20c
Fig. 8: Identifying 16-Pin Electrical Connection, T16D, 16-Pin Electrical Connection, T16C And 20-Pin
Electrical Connection T20C
1 - Sunlight Photo Sensor 2 -G134- or Sunlight Photo Sensor -G107-, signal
2 - High Pressure Sensor -G65-
3 - Sunlight Photo Sensor 2 -G134- or Sunlight Photo Sensor -G107-, signal
4 - From calendar week 22/07 the Air Quality Sensor -G238- is discontinued; from November 2007 for the
North American markets.
5 - CAN bus high
6 - CAN bus low
7 - Indirect Ventilation Door Control Motor -V213-
8 - Indirect Ventilation Door Control Motor -V213-

9 - + 5V For Sunlight Photo Sensor 2 -G134- or Sunlight Photo Sensor -G107-
10 - Heated Driver Seat Temperature Sensor -G59- or Front Seat Heating Control Module -J774- (optional)
11 - Front Passenger Heated Seat Temperature Sensor -G60- or Front Seat Heating Control Module -J774-
(optional)
12 - Terminal 75 (optional)
13 - Left Vent Temperature Sensor -G150-
14 - Right Vent Temperature Sensor -G151-
15 - Indirect Ventilation Flap Motor Position Sensor -G330-
16 - Terminal 30a / without auxiliary heater terminal 15
17 - Signal ground for Sunlight Photo Sensor (3241) -G107-, Sunlight Photo Sensor 2 -G134-, Left Vent
Temperature Sensor -G150-, Right Vent Temperature Sensor -G151- and Indirect Ventilation Flap Motor -
V213-
18 - A/C Compressor Regulator Valve -N280-
19 - Terminal 31
20 - Terminal 30a/without auxiliary heater terminal 15
16-pin Harness Connector -B-, T16i

1 - + 5V for motors
2 - Left Temperature Door Potentiometer/Actuator -G220-
3 - Right Temperature Door Potentiometer/Actuator -G221-
4 - Defroster Door Motor Position Sensor -G135-
5 - Central Door Motor Position Sensor -G112-
6 - Recirculation Door Motor Position Sensor -G143-
7 - Back Pressure Door Motor Position Sensor -G113-. From 28 May 2007 Fresh Air/Recirculating Air/Back
Pressure Door Motor Position Sensor -G644-.
8 - Left Footwell Vent Temperature Sensor -G261-
9 - Right Footwell Vent Temperature Sensor -G262-
11 - From calendar week 44/07 Evaporator Temperature Sensor -G308- through calendar week 43/07
Evaporator Vent Temperature Sensor -G263-
14 - Signal Ground (GND) potentiometer
16-pin Harness Connector -C-, T16h

1 - Left Temperature Door Motor -V158-, cold
2 - Left Temperature Door Motor -V158-, warm
3 - Defroster Door Motor -V107-, closed
4 - Defroster Door Motor -V107-, open
5 - Central Air Door Motor -V70-, upper body outlet
6 - Central Air Door Motor -V70-, footwell
7 - Recirculation Door Motor -V113-
8 - Recirculation Door Motor -V113-
9 - Vehicles through 04.07 Fresh Air/Recirculating Air/Back Pressure Door Motor -V425-; from 05.07 Airflow
Door Motor -V71-, open
10 - Vehicles through 04.07 Fresh Air/Recirculating Air/Back Pressure Door Motor -V425-; from 05.07
Airflow Door Motor -V71-, closed
11 - Right temperature door motor -V159-, cold
12 - Right Temperature Door Motor -V159-, warm
15 - Fresh Air Blower Control Module -J126-
16 - Control Module For Fresh Air Blower -J126-, signal
REFRIGERANT CIRCUIT COMPONENTS OVERVIEW

more.
Fig. 11: Identifying A/C Refrigerant System Components, Replacing Overview

1. A/C Compressor
 Manufacturer Sanden, Identification PXE16
 Manufacturer Zexel, Identification DSC17E
 Manufacturer Denso, Identification 6SEU14
 Manufacturer Delphi, Identification 6CVC140
 Pay attention to notes for installing A/C compressor. Refer to A/C COMPRESSOR,
INSTALLATION INFORMATION.
 Removing and installing, refer to A/C COMPRESSOR.
2. Condenser
Removing and installing, refer to CONDENSER.

3. Fluid Reservoir With Dryer Cartridge
NOTE: Under certain conditions, the dryer cartridge should no longer be replaced
each time the refrigerant circuit is opened. Refer to REPLACING
RESERVOIR/FLUID RESERVOIR OR DRYER CARTRIDGE, CONDITIONS .
The fluid reservoir with dryer cartridge is mounted on the right or left side
on the condenser depending on the engine type.
 Removing and installing, refer to Passat FLUID RESERVOIR DRYER CARTRIDGE or Passat
CC .
4. High Pressure Sensor -G65-
 Removing, refer to HIGH PRESSURE SENSOR -G65-.
5. Bracket
6. Evacuating and Charging Valve
 High pressure side.
 Environmentally hazardous draining of refrigerant is an offense punishable by law.
 Removing, refer to EVACUATING AND CHARGING VALVE, LOW AND HIGH

PRESSURE SIDES.
 Capacities, refer to SPECIFICATIONS.
7. Retainer
8. Evacuating and Charging Valve
 Low pressure side.
 Environmentally hazardous draining of refrigerant is an offense punishable by law.
 Removing, refer to EVACUATING AND CHARGING VALVE, LOW AND HIGH

PRESSURE SIDES.
 Capacities, refer to SPECIFICATIONS.
9. Expansion Valve
 Removal and function, refer to EXPANSION VALVE.
10. Hex Head Nut

 20 Nm
11. Bracket
SPECIFICATIONS
REFRIGERANT R134A, CAPACITIES
A/C Compressor Manufacturer Total Capacity

PXE16 Sanden 600 + 25 gram
DSC17E Zexel 600 + 25 gram
6SEU14C, 7SEU16C, 7SEU17C Denso 600 + 25 gram

6CVC140 Delphi 600 + 25 gram
REFRIGERANT OIL CAPACITIES
The special refrigerant oil (for use with refrigerant circuits R134a only) is no longer obtainable on the
refrigerant/machine oil market.
Refrigerant oil can be obtained using following part number for:

PXE16- Sanden G 052 154 A2
DSC17E- Zexel G 052 200 A2
6SEU14C, 7SEU16C, 7SEU17C - Denso G 052 300 A2
6CVC140- Delphi G 052 154 A2 / G 052 300 A2
Type Total Capacity

PXE16- Sanden 110 cm3 10 cm3
DSC17E- Zexel 120 cm3 +15 cm3
7SEU17C- Denso 140 cm3 10 cm3
6CVC140- Delphi 110 cm3 10 cm3
This quantity of refrigerant oil is in a replacement compressor and equates to the total capacity.
Important Information
Refrigerant oil attracts moisture. Close any opened containers immediately after use to prevent moisture from
entering.
Refrigerant oil, because of its chemical properties, must not be disposed of with engine oils or transmission oils.
Oil Distribution
The oil, which is located in the sump of the A/C compressor before initially switching on the air conditioner
system, is distributed through the refrigerant circuit as follows:
 A/C compressor approximately 50%

 Condenser approximately 10%
 Suction hose approximately 10%
 Evaporator approximately 20%
 Fluid reservoir approximately 10%
CLIMATIC AND CLIMATRONIC COMPONENTS, FASTENER TIGHTENING SPECIFICATIONS

Component Nm
Climatic/Climatronic Heating and A/C System Controls 1.5
Heating and A/C Unit to I/P Assembly Carrier
Cable Bracket Bolts 4
Climatic/Climatronic Bracket Bolts 9 +/- 1.3
Door Motors
Fresh Air/Recirculating Air/Back Pressure Door Motor 1.4
left temperature door motor 1.4
indirect ventilation door motor 3.5
Refrigerant Line Bracket to Body, Nuts 20
REFRIGERANT SYSTEM, FASTENER TIGHTENING SPECIFICATIONS

A/C Refrigerant Line to A/C Compressor, Bolts 22 +/- 1
2.0L Engine
A/C Compressor Sub-Assembly Bracket to Engine, Bolts M10 x 45 40
A/C Compressor to A/C Compressor Sub-Assembly Bracket, M8 x 100 25
Bolts
3.6L Engine
A/C Compressor Sub-Assembly Bracket to Engine, Bolts 25
A/C Compressor to A/C Compressor Sub-Assembly Bracket, M8 x 100 25
Bolts
Ribbed Belt Pulley, Zexel
Overload Protection to A/C Compressor, Bolt 20
Overload Protection to Ribbed Belt Pulley, Bolts 5
Ribbed Belt Pulley, Sanden
Overload Protection to A/C Compressor, Bolt 25
Overload Protection to Ribbed Belt Pulley, Bolts 4.5
Condenser to Radiator, Bolts 5 +/- 0.5
Dryer Cartridge Cover, Cap 1.2 +/- 0.3
Evacuating and Charging Valve Insert 2 +/- 0.2
Expansion Valve Heat Shield, Bolt 2.5
Expansion Valve Heat Shield, Nut 4.5
Expansion Valve to Heating and A/C Unit, Bolts 5
High Pressure Sensor 8 +/- 1
Refrigerant Lines to Expansion Valve, Bolts 10 +/- 1
Refrigerant Lines to Condenser 12 +/- 1
3.6L Sub-assembly Bracket Tightening Sequence

Fig. 12: Identifying 3.6L Sub-assembly Bracket Tightening Sequence

NOTE: Bolts -1- and -2- are fitting bolts.
-- Tighten the bolts hand-tight in the following sequence: 1 through 5.
-- Tighten the bolts to 25 Nm in the following sequence: 1 through 5.
A/C COMPRESSOR PRESSURE RELIEVE VALVE, CHECKING
Check valve drains coolant when engine is running and pressure in

coolant circuit is too high.
Turn engine off.

 Function: protects refrigerant circuit against excessive pressure.
Checking Pressure Relief Valve On A/C Compressor (Sanden)
Fig. 13: Identifying Pressure Relief Valve On A/C Compressor (Sanden)

 The pressure relief valve -arrow- has operated when refrigerant oil is found in the close vicinity.
 In this case, vehicle must be taken to an authorized Volkswagen workshop.
A/C Compressor Pressure Relief Valve

 The pressure relief valve -arrow- has operated when refrigerant oil is found in the close vicinity.
 In this case, vehicle must be taken to an authorized Volkswagen workshop.
CLIMATIC FLEXIBLE SHAFT, CHECKING
Flexible shaft for adjusting unit of air distribution doors:
-- Let fresh air blower run on highest speed. If air flows out of defroster vents in the "Defrost" position and no
air flows out of footwell vents, installation of flexible shaft is correct. If this is not the case, remove flexible
shaft from adapter. Place controls for heating and A/C system, Climatic onto adapter and rotate rotary knob for
air distribution 1 /2 rotation (180°). Then re-connect flexible shaft. Repeat test
Fig. 15: Identifying Release Of Retaining Tab

CLIMATRONIC A/C SYSTEM, CHECKING AND ADJUSTING COMPONENTS
 Vehicle Diagnosis, Testing and Information System -VAS 5051B-
In -VAS 5051B-, select "Guided Functions".
After all control modules have been interrogated:
-- Select "Climatronic"
-- Select functions - Climatronic control module
 Climatronic control module initialization

 Climatronic control module memory
 Climatronic control module basic setting
 Climatronic control module measured values
 Climatronic control module control diagnosis
 Climatronic control module adaptation
 Climatronic control module coding online
 Climatronic control module compressor shut off criterion
 Climatronic control module, checking cooling output
 Climatronic control module A/C compressor first break-in
 Climatronic control module, checking temperature sensor
CONDENSATION WATER DRAIN HOSE, CHECKING
-- Remove the footwell trim on the right side. Refer to Removal and Installation .
-- Fold back the carpet near the condensation water hose just far enough until the condensation water drain is
visible.
Fig. 16: Identifying Condensation Water Hose At Heating And A/C Unit - Condensation Water Hose,
Checking
NOTE: The condensation water hose -1- must be able to be connected to connection of
heating and A/C unit without pre-tension.
Condensation water hose must sit securely on connection for condensation

water hose on heating and A/C unit.
A/C COMPRESSOR
 Torque Wrench -V.A.G 1331- (5 to 50 Nm)

 Robinair A/C Service Unit -ROB 134APF-
NOTE: Flush the refrigerant circuit with R134a refrigerant under the following
conditions:
In the event of dirt or other contamination in the refrigerant circuit.
If vacuum reading is not maintained on evacuating a leak-free refrigerant circuit

(pressure build-up due to moisture in refrigerant circuit).
If refrigerant circuit has been left open for longer than normal (for example,
following an accident).
If pressure and temperature measurements in the refrigerant circuit indicate the

likelihood of moisture
In the event of doubt about the amount of refrigerant oil in the circuit.
The A/C compressor had to be replaced on account of internal damage (such as

noise or no output).
The procedure for flushing with R134a refrigerant is described in REFRIGERANT CIRCUIT, FLUSHING
WITH REFRIGERANT R134A .
Information for repairing vehicles with air conditioning and working with refrigerant can be found in A/C
SYSTEM, REPAIR INFORMATION .
Information for special tools and equipment when repairing vehicles with air conditioning can be found in
Special Tools .
Removal


more.
-- Extract refrigerant using, for example, -ROB 134APF-, only then open the refrigerant circuit. See notes, refer
to REFRIGERANT CIRCUIT COMPONENTS OVERVIEW.
-- Remove noise insulation beneath engine. Refer to Description and Operation .
-- Remove the ribbed belt. Refer to RIBBED BELT .
-- Disconnect the connector from the A/C compressor regulator valve -N280-.
-- Remove the bolts (22 Nm +/- 1 Nm) -1- from the A/C compressor and then disconnect the refrigerant pipes
from the A/C compressor.
-- Remove the hex bolts (25 Nm) -2- and the A/C compressor.
Fig. 17: Identifying A/C Compressor Remove/Install Components

Installation
NOTE: Make sure alignment bushings -3- are seated correctly.
Pay attention to notes for installing A/C compressor, refer to A/C

COMPRESSOR, INSTALLATION INFORMATION.
-- Install in reverse order of removal.
A/C COMPRESSOR SUB-ASSEMBLY BRACKET

 Torque wrench -V.A.G 1331- / (5 to 50 Nm)
NOTE: The A/C compressor sub-assembly bracket and ancillary parts can be removed
and installed without opening the refrigerant circuit.
Removing the ribbed belt, refer to RIBBED BELT .
Fig. 18: Identifying A/C Compressor And Bracket - 2.0L 4-Cylinder TFSI Engine Remove/Install
Components
1. M10x45 Hex Collar Bolt

 Fitting hole
 2.0L Turbo FSI engine: 40 Nm



5. A/C Compressor
 Removing and installing, refer to A/C COMPRESSOR.
6. Hex Bolts M8 X 100

 25 Nm
 Quantity: 3

 Fitting hole

9. Dowel Sleeves
 Quantity: 2
 Make sure they fit correctly between the auxiliary component bracket and the A/C compressor.
10. A/C Compressor Sub-Assembly Bracket
Number on the sub-assembly bracket -06F 903 143 E/F-.
Removal
-- Remove generator. Refer to Removal and Installation .
-- Loosen A/C compressor, unscrew hex-bolts -6-. Remove A/C compressor from auxiliary component
bracket and secure to body with appropriate material (for example, welding wire), see "Securing A/C
compressor to body" below.
-- Remove the bolts -1- through -4- and -7- and -8- and the auxiliary component bracket -10- from the
cylinder block.
Installation
 Always observe tightening torque of mounting bolts:

-- Tighten hex collar bolt item -1- (fitting hole), -7- (fitting hole), -4-, -8-, -3- and -2- in succession.
Securing A/C compressor to body
Fig. 19: Identifying A/C Compressor, Securing To Body

If A/C compressor is removed and refrigerant circuit not opened, A/C compressor must be secure to body using
appropriate material, a welding wire for example.
Ensure refrigerant hoses remain on A/C compressor without tension for this.
NOTE: When installing the belt ensure it is correctly seated in the ribbed belt pulley.
Last, install ribbed belt over ribbed belt pulley of A/C compressor.
A/C COMPRESSOR SUB-ASSEMBLY BRACKET
 Torque wrench -V.A.G 1331- (or 5-50 Nm equivalent)
NOTE: The bracket for A/C compressor and ancillary parts can be removed and
installed without opening the refrigerant circuit.
Removing the ribbed belt, refer to [For transmission(s) 09M] Removal and
Installation
Position of ribbed V-belt, refer to "Ribbed Belt Routing" below.

Fig. 20: Identifying A/C Compressor Sub-Assembly

1. Ribbed Belt
 Removing and installing, refer to [For transmission(s) 09M] Removal and Installation .
2. Ribbed Belt Pulley - Coolant Pump

3. Tensioning Roller
4. Sub-Assembly Bracket For Generator and A/C Compressor
 Number on the sub-assembly bracket -038 903 143 AF-.
Removal
-- Loosen A/C compressor, unscrew hex-bolts -9-. Remove A/C compressor from auxiliary component
bracket and secure to body with appropriate material (for example, welding wire), refer to Securing A/C
Compressor to Body.
-- Remove the screws from the sub-assembly bracket.
Follow the tightening sequence when installing, refer to Sub-assembly Bracket Tightening Sequence.
5. Fitting Bolt
 25 Nm
6. Generator
7. Dowel Sleeves
 Quantity: 2
 Make sure they fit correctly between the auxiliary component bracket and the A/C compressor.
8. A/C Compressor
 Removing and Installing, refer to A/C COMPRESSOR.
9. Hex Bolts M8 X 100

 25 Nm
 Quantity: 3
10. Fitting Bolt

 25 Nm
SECURING A/C COMPRESSOR TO BODY
Fig. 21: Identifying A/C Compressor, Securing To Body

If A/C compressor is removed and refrigerant circuit not opened, A/C compressor must be secure to body using
appropriate material, a welding wire for example.
Ensure refrigerant hoses remain on A/C compressor without tension for this.
NOTE: When installing the belt ensure it is correctly seated in the ribbed belt pulley.
Last, install ribbed belt over ribbed belt pulley of A/C compressor.
SUB-ASSEMBLY BRACKET TIGHTENING SEQUENCE
Fig. 22: Identifying Sub-assembly Bracket Tightening Sequence

NOTE: Bolts -1- and -2- are fitting bolts.
-- Tighten the bolts hand-tight in the following sequence: 1 through 5.
-- Tighten the bolts to 25 Nm in the following sequence: 1 through 5.

RIBBED BELT ROUTING
Fig. 23: Identifying Ribbed Belt Routing, 3.2L Fuel Injection Engine -- Vehicles With A/C system
1 - Tensioning roller
2 - Ribbed belt pulley - generator
3 - Idler rollers
4 - Ribbed belt
5 - Ribbed belt pulley - A/C compressor
6 - Ribbed belt pulley - crankshaft
7 - Ribbed belt pulley - coolant pump
A/C COMPRESSOR RIBBED BELT, ZEXEL

Fig. 24: Identifying Ribbed Belt Pulley - Zexel Remove/Install Components

1. A/C Compressor
 Zexel
 Clean the flange before mounting the ribbed belt pulley.
2. Ribbed Belt Pulley

 Removing, refer to Remove the Ribbed Belt Pulley.
 To loosen and tighten bolt, hold ribbed belt pulley firmly in place using a standard band wrench
(with webbing).
3. Circlip
 Replace
Install on the proper side, the side with beveled insertion edge faces away from A/C compressor
(install flat side facing compressor).
4. Overload Protection
 Bolted with to the ribbed belt pulley.
 Keeps the ribbed belt pulley from turning when the A/C compressor gets blocked.
 To loosen and tighten bolts, hold ribbed belt pulley firmly in place using a standard band wrench
(with webbing).
5. Hex Bolt
 Replace
 To loosen and tighten bolt, hold ribbed belt pulley firmly in place using a standard band wrench
(with webbing).
 Clean the thread on the A/C compressor shaft of old locking compound before installing.
 Install the bolt with Locking compound -D 000 600 A2-.
 20 Nm
6. Hex Socket Head Bolt

 5 Nm
 Quantity: 3
REMOVING RIBBED BELT PULLEY
NOTE: It is not necessary to remove the A/C compressor when replacing the ribbed
belt pulley.
To loosen and tighten bolts, hold ribbed belt pulley firmly in place using a
standard band wrench (with webbing).
-- Removing ribbed belt, refer to RIBBED BELT .

Fig. 25: Identifying Ribbed Belt Pulley Bolts

-- Remove the locking ring -1-.
Fig. 26: Identifying Circlip & Ribbed Belt Pulley

-- Remove the ribbed belt pulley -2- from the A/C compressor.
INSTALLATION
Install in reverse order, paying attention to the following:
 Clean the thread on the A/C compressor shaft of old locking compound before installing.
 Clean the A/C compressor flange before mounting the ribbed belt pulley.
 Install the circlip on the proper side, the side with beveled insertion edge faces away from A/C
compressor (install flat side facing compressor).
 Replace the hex bolt -5-, refer to item 5.
A/C COMPRESSOR RIBBED BELT, SANDEN
NOTE: It is not necessary to remove the A/C compressor when replacing the ribbed
belt pulley.
To loosen and tighten bolts, hold ribbed belt pulley firmly in place using a
standard band wrench (with webbing).
Removing ribbed belt, refer to RIBBED BELT .

Fig. 27: Identifying Ribbed Belt Pulley - Sanden Remove/Install Components

1. Hex Head Nut

 Replace
 To loosen and tighten hex nuts, hold ribbed belt pulley firmly in place using a standard band
wrench (with webbing).
 Install the hex nuts with Locking compound -D 000 600 A2-.
 25 Nm
2. Screw
 To loosen and tighten hex nuts, hold ribbed belt pulley firmly in place using a standard band
wrench (with webbing).
 Quantity: 3
 4.5 Nm
3. Overload Protection
 Bolted with to the ribbed belt pulley.
 Keeps the ribbed belt pulley from turning when the A/C compressor gets blocked.
 To loosen and tighten bolts, hold ribbed belt pulley firmly in place using a standard band wrench
(with webbing).
4. Washer
5. Circlip
 Replace
 Install on proper side, beveled insertion edge -A- faces away from A/C compressor (install flat side
facing the A/C compressor).
6. Ribbed Belt Pulley
 Clean A/C compressor flange before sliding on pulley.
7. A/C Compressor
 Sanden
 Clean the flange before mounting the ribbed belt pulley.
CLIMATIC COMPONENTS
HEATING AND A/C SYSTEM CONTROLS
Removal
NOTE: The controls consist of two separable housings on the Passat from MY 06.
Before removing controls, bring rotary buttons into the following position:
Heater control to cold
Blower to 0
Air flow direction to footwell
Removal on the Passat from MY 06, on the Passat CC from MY 09 and on the CC from MY 10 is identical.
-- Remove the trim from the center of the instrument panel. Refer to Removal and Installation .
-- Remove the screws (1.5 Nm) -2- (4.2 x 45 mm) and -3- (4.2 x 16 mm) and remove the heating and ventilation
controls -1-.
Fig. 28: Identifying Bolts And Center Console Controls

-- Release the connector -A- by pulling it in direction of arrow -1-.
Fig. 29: Identifying Heating And Ventilation Controls Electrical Connection Retainers
-- Press connector release -B- toward the connector -arrow 2- and disconnect the connector -C-.
-- Disconnect the connector -D-.
Installation
Installation is performed in reverse order of removal, make sure when doing so that the rotary buttons have the
same position as when removing.
FLEXIBLE SHAFT
NOTE: The flexible shaft is installed only in Passat, from MY 06
Removal
-- Remove the glove compartment. Refer to Removal and Installation .
-- Move the flexible shaft in to the following position:
-- Turn the air distribution control -1- until the locking mechanism on the shaft -2- is visible in the step-up
gearing -3-.
Fig. 30: Identifying Distribution Rotary Switch, Shaft Locking Mechanism And Step-Up Gearing
-- Remove controls for heating and A/C system, Climatic, refer to HEATING AND A/C SYSTEM
CONTROLS.
-- Reach into center console and release retaining tab -1- by pressing -in direction of arrow-.
Fig. 31: Identifying Release Of Retaining Tab

-- Pull flexible shaft out of adapter -2-.
NOTE: When installing flexible shaft, adapter and rotary switches on controls for hot
air and fresh air must have a specific position to each other, otherwise it will
malfunction. Refer to CLIMATIC FLEXIBLE SHAFT, CHECKING.
Installation
Install in reverse order of removal.
TEMPERATURE REGULATOR DOOR MOTOR -V68-
Removal
-- Remove the left footwell vent. Refer to LEFT FOOTWELL VENT .
-- Remove footwell trim on the left side. Refer to Removal and Installation .
-- Remove the Data bus on board diagnostic interface -J533-. Refer to DATA BUS ON BOARD
DIAGNOSTIC INTERFACE J533 .
Fig. 32: Identifying Bracket And Bolts

-- Remove the bolts -3- (9 +/- 1.3 Nm).
NOTE: Do not remove the bolts -1-.
Do not remove the bracket -2-.
-- Push the bracket toward the brake pedal -arrow- and then tie it there with a cable tie.

-- Mark the connector -C- for the motor (danger of confusing it with other connectors that may look the same).
Fig. 34: Identifying Temperature Regulator Flap Motor V68, Connector, Cover And Securing Bolts
-- Disconnect the connector -C- from the Temperature regulator door motor -V68-.
-- Remove the cover -A-.
-- Remove securing bolts -D- and remove Temperature regulator door motor -B-.
-- Disconnect the lever -E- from the connecting rod -F-.
Installation
Installation is carried out in the reverse order while noting the following:
-- Install the wiring harness so that it cannot come in contact with any moving parts (for example, the lever on
the motor).
NOTE: Make sure door works correctly after installing the Temperature regulator door
motor.
-- Check using -VAS 5051B-.
-- Replacing: perform Basic Setting using -VAS 5051B-. Refer to CLIMATRONIC A/C SYSTEM,
CHECKING AND ADJUSTING COMPONENTS.
FRESH/RECIRCULATING AIR DOOR MOTOR -V154-

Removal
-- Remove the Fresh/recirculating air door motor -V154-. Refer to FRESH/RECIRCULATING AIR DOOR
MOTOR -V154-
CENTER OUTLET TEMPERATURE SENSOR -G191-
Removal
-- Remove the instrument cluster. Refer to Removal and Installation .
-- Disconnect the connector -2- on the center outlet temperature sensor -1-.
Fig. 35: Identifying Left Vent Temperature Sensor G150, Removing

-- Rotate center outlet temperature sensor -1- 90° and remove from instrument panel.
Installation
FOOTWELL OUTLET TEMPERATURE SENSOR -G192-
Removal
-- Disconnect connector at Footwell Outlet Temperature Sensor -1-.

Fig. 36: Identifying Connector At Footwell Outlet Temperature Sensor G192

-- Rotate Footwell Outlet Temperature Sensor 90° and remove from housing.
Installation
CLIMATRONIC COMPONENTS
A/C DISPLAY CONTROL HEAD -E87- WITH CLIMATRONIC CONTROL MODULE -J255-
NOTE: The Climatronic Control Module -J255- and the Front A/C display control head -
E87- are one component that cannot be disassembled.
As of 09 November 2009, reset the "A/C compressor, first break-in" using the -
VAS 5051B- under "Guided Functions" if the Front A/C display control head
control head was replaced by the Climatronic control module -J255-. Refer to
CLIMATRONIC A/C SYSTEM, CHECKING AND ADJUSTING COMPONENTS.
Removal on the Passat from MY 06, on the Passat CC from MY 09 and on the CC from MY 10 is identical.
-- Remove the trim from the center of the instrument panel. Refer to Removal and Installation .
-- Remove the screws (1.5 Nm) -2- and the Front A/C display control head with the Climatronic control module
-1- from the instrument panel.
Fig. 37: Identifying A/C Control Head E87, Climatronic Control Module J255 And Instrument Panel
-- Disconnect the connectors from the Front A/C display control head.
Installation
If the Front A/C display control head and the Climatronic control module were replaced, then the "A/C
compressor first breaking-in" must be reset. Refer to CLIMATRONIC A/C SYSTEM, CHECKING AND
ADJUSTING COMPONENTS using the -VAS 5051B- "Guided Functions". Then "replace the Climatronic
control module".
AIR QUALITY SENSOR -G238-
NOTE: The air quality sensor was discontinued from November 2007 for the American
markets.
The air quality sensor is installed at the right front on the intake air grille in the
plenum chamber.
The air quality sensor contains a highly sensitive electronic component which
can be damaged if it comes in direct contact with solvents, fuels or chemicals.
Do not install a sensor that has been kept, for example, in a tool box.
Do not store removed sensors in areas where they can come into contact with
solvents, fuels and certain chemical compositions (fluids or vapors).
Removal
-- Remove the plenum chamber cover. Refer to Description and Operation (Flush Bonded Windows).
-- Remove the cover over the air grille.
-- Disconnect the connector from the air quality sensor.
Fig. 38: Identifying Air Quality Sensor

-- Remove the air quality sensor -1- from the bracket on the air grille.
Installation
EVAPORATOR VENT TEMPERATURE SENSOR -G263-
Removal
-- Remove the footwell trim on the right side. Refer to Removal and Installation .
-- Disconnect the connector -2- from the evaporator vent temperature sensor -1-.
Fig. 39: Identifying Evaporator Vent Temperature Sensor G263 , Removing

-- Turn the evaporator vent temperature sensor -1- 90° and remove it from the housing.
Installation
FRESH AIR BLOWER -V2- WITH FRESH AIR BLOWER CONTROL MODULE -J126-
Removal
The fresh air blower and fresh air blower control module are accessible from the passenger footwell.
NOTE: The fresh air blower control module and the fresh air blower are in a single
housing together and cannot be replaced individually.
-- Remove the partition from the heater, refer to PASSENGER COMPARTMENT HEATING OVERVIEW =>
Removing Heater Partition .
-- Disconnect the connector from the fresh air blower with fresh air blower control module -1-.
Fig. 40: Identifying Harness Connector From Fresh Air Blower V2 AndFresh Air Blower Control
Module J126
-- Disengage locking mechanism -2- and then turn and remove the fresh air blower and the fresh air blower
control module -in the direction of arrow-.
Installation
LEFT FOOTWELL VENT TEMPERATURE SENSOR -G261-
Removal
-- Disconnect the -1- left footwell vent temperature sensor connector.

Fig. 41: Identifying Connector To Footwell Outlet Temperature Sensor G192

-- Turn the left footwell vent temperature sensor -2- 90° and remove it from the housing.
Installation
LEFT VENT TEMPERATURE SENSOR -G150-
Removal
-- Remove the instrument cluster. Refer to Removal and Installation .
-- Disconnect the -2- on the left vent temperature sensor connector.

Fig. 42: Identifying Left Vent Temperature Sensor G150 , Removing

-- Rotate left vent temperature sensor -1- 90° and remove from instrument panel.
Installation
OUTSIDE AIR TEMPERATURE SENSOR -G17-
Removal
-- Unclip the outside air temperature sensor -1- and disconnect the connector.
Fig. 43: Identifying Outside Air Temperature Sensor G17

Installation
RIGHT FOOTWELL VENT TEMPERATURE SENSOR -G262-
Removal
-- Remove the Comfort system central control module -J393-. Refer to COMFORT SYSTEM CENTRAL
CONTROL MODULE J393 .
-- Remove the right footwell vent. Refer to RIGHT FOOTWELL VENT .
-- Disconnect the -1- right footwell vent temperature sensor connector.

Fig. 44: Identifying Right Footwell Vent Temperature Sensor G262 , Removing
-- Turn the right footwell vent temperature sensor -2- 90° and remove it from the housing.
Installation
RIGHT VENT TEMPERATURE SENSOR -G151-
Removal
-- Disconnect the -1- right vent temperature sensor connector.

Fig. 45: Identifying Right Vent Temperature Sensor G151 , Removing

-- Turn the right vent temperature sensor -2- 90° and remove it from the air guide channel.
Installation
SUNLIGHT PHOTO SENSOR -G107- OR SUNLIGHT PHOTO SENSOR 2 -G134-
 Trim Removal Wedge -3409-
Removal
-- Mark dimensions "a and b" on the instrument panel with tape.
Fig. 46: Identifying Marking Dimensions "a And b" On Instrument Panel
a = 115 mm
b = 15 mm
CAUTION: The indirect ventilation trim could get damaged.
The trim is mounted by a screw under the photo sensor.
Lift the trim maximum 15 mm.
-- Using the -3409- unclip the right and left trim at the markings and remove them from the instrument panel.
-- Insert a screwdriver -3- with a long blade toward the photosensor -2-.
-- Use a block of wood -1- underneath.

Fig. 47: Identifying Wood Block, Screwdriver And Sunlight Photo Sensor G107
-- Press the screwdriver -in direction of arrow- and unclip the photo sensor.
-- Disconnect the connector from the Sunlight photo sensor.
Installation
-- Connect the connector to the photosensor and then install the photosensor in the instrument panel.
-- Perform remaining installation operations in reverse order of removal.
CLIMATRONIC DOOR MOTORS
CENTRAL AIR DOOR MOTOR -V70- OR FRONT AIR DISTRIBUTION DOOR MOTOR -V426-
Removal
-- Turn off all electric consumers.
-- Switch off the ignition.
-- Remove the key.
-- Remove the instrument panel. Refer to Removal and Installation .

Fig. 48: Identifying Central Air Flap Motor V70 , Removing And Installing
-- Disconnect the connector from the motor.
-- Remove the screw -1- and remove the control motor.
Installation
NOTE: Check the function of the door after installing central air door motor or the front
air distribution door motor.
Perform Basic Setting using -VAS 5051B-. Refer to CLIMATRONIC A/C SYSTEM,
AIR FLOW DOOR MOTOR -V71- WITH BACK PRESSURE DOOR MOTOR POSITION SENSOR -G113-
NOTE: The air flow door motor and the back pressure door motor position sensor is
installed only in the 2006 Passat through calendar week 21/07.
In vehicles from calendar week 22/07, the fresh air/recirculating air/back

pressure door motor -V425- performs the function of the fresh air/recirculating
air/back pressure door motor position sensor -G644-.
Air Flow Door Motor can only be removed without difficulty in "fresh air mode
stop" and installed only in this position. If motor remains standing in a different
position and can no longer be moved electrically into "fresh air mode stop"
position, it can only be pulled off and removed with difficulty.
Position of fresh/recirculating air door must not be changed.
Removal
-- Remove the key.
-- If necessary, turn on the ignition, select "Defrost" on Front A/C display control head -E87- (control motor is
always set to "fresh air mode" position in this operating mode) and wait until control motor has reached its
"fresh air mode" end position.
Fig. 49: Identifying Bracket, Bracket Guide, Intake Housing Mount & Catches
-- Open the retainers -D- and -E- and remove the bracket -A-.
-- Remove the Recirculation door motor -V113-. Refer to RECIRCULATION DOOR MOTOR -V113-.
-- Mark the connector for the Air recirculation door motor (to prevent confusing it with the connector for the
Airflow door motor -V71-).
Fig. 50: Identifying Actuator Motor From Intake Housing

-- Remove the motor -A- from the air intake shroud.
NOTE: Connection between control motor toothed gears and air flow door is designed
so that control motor can be removed without difficulty only in the "fresh air
mode" position.
If motor is found in a different position and can no longer be moved, motor

cannot be simply pulled off, rather it must be loosened first with great force
from mounting points -B- , ensure that toothed gear -C- is not damaged when
doing this.
Installation
NOTE: Motor as replacement part is delivered in the "fresh air mode" position, only
when toothed gear -A- contacts stop -B- can it then be connected onto toothed
gear of fresh/recirculating air door. If a motor was removed in a different
position or activated in the removed state, it cannot be installed.
If toothed gear -A- of motor does not stand at stop -B- "fresh air mode" ,
proceed as follows:
-- Connect the motor to the vehicle wiring harness.
-- Switch on the ignition.

Fig. 51: Identifying Toothed Gear & Stop

-- Wait until toothed gear -A- of motor reaches stop -B- "fresh air mode".
Fig. 52: Identifying Actuator Motor From Intake Housing

-- Before installing control motor, check bearing of air flow door in intake housing and of toothed gear -C- (the
back pressure door is open, "fresh air mode").
-- Connect the Airflow door motor -V71- to the vehicle wiring harness (pay attention to the correct connector
order).
Fig. 53: Identifying Fresh/Recirculating Air Door Brought In To "Fresh Air Mode" Position
-- Reach into intake opening for recirculating air mode and move the fresh/recirculating air door -A- into the
"fresh air mode" position (intake opening for recirculating air mode is closed).
Fig. 54: Identifying Actuator Motor Harness Connector & Fresh/Recirculating Air Door Motor V154
-- Insert the motor -B- into mounts -C- in opposite direction of arrow and onto toothed gear -D-.
Fig. 55: Identifying Motor Inserted Into Mounts And Onto Toothed Gear
NOTE: So that toothed gear on motor -A- can be slid on toothed gear of air flow door,
short tooth -C- of motor toothed gear must align with short tooth interval -D- of
toothed gear on shaft of air flow door -B-.
-- After installing the control motor, install the toothed gear -1- onto the back pressure door shaft again.
Fig. 56: Identifying Toothed Gear Pressed Again On To Shaft Of Air Flow Flap
-- Install the Recirculation door motor -V113-. Refer to RECIRCULATION DOOR MOTOR -V113-.
the motor).
-- Install the bracket -A-. Make sure the guide on the bracket -B- fits correctly into the mount on the air intake
shroud -C- and the bracket locks into both retainers -D- and -E-.
NOTE: Position of Air Flow door motor -V71- and of Recirculation door motor -V113-
(and corresponding doors) is no longer visible with glove compartment
installed, therefore it is advisable to check its function before installing glove
compartment.
If both toothed gears (on the Air flow door motor and the air flow door)
assembled in the incorrect position, air flow door will not reach its two end
positions or the control motor does not run cleanly without hitching.
-- Install the removed parts in the opposite order.
NOTE: Check the function of the air flow door after installing the Air flow door motor.
-- Check using -VAS 5051B-.
Perform Basic Setting using -VAS 5051B-. Refer to CLIMATRONIC A/C SYSTEM, CHECKING AND
ADJUSTING COMPONENTS.
DEFROSTER DOOR MOTOR -V107-

Removal
-- Remove the key.
-- Remove the bolts -1- and -3- (9 +/- 1.3 Nm).

-- Remove the bracket -2-.
Fig. 59: Identifying Defroster Flap Motor V107 Remove/Install Components

-- Disconnect the connector -C- from the Defroster door motor -V107-.
-- Remove securing bolts -A- and remove Defroster door motor -B-.
-- Disconnect the lever -E- from the connecting rod -D-.
Installation
NOTE: After installing, function of defroster door must be checked.
RECIRCULATION DOOR MOTOR -V113-
Removal

-- Remove the key.
NOTE: The Recirculation door motor and the Right rear child safety lock motor -G143-
are installed only in the 2006 Passat through calendar week 21/07.
In vehicles from calendar week 22/07, the Fesh air/recirculating air/back

pressure door motor -V425- performs the function of the Fresh air/recirculating
air/back pressure door motor position sensor -G644-.
-- Mark the connector -A- if necessary (this prevents confusion if several connectors are disconnected at the
same time).
Fig. 60: Identifying Actuator Motor Harness Connectors

-- Disconnect connector -A-.
-- Open the retainers -C- and -D- and remove the bracket -B- (toward the rear).
Fig. 61: Identifying Catches, Bracket, Intake Housing & Actuator Motor
-- Remove the motor -A- from the air intake shroud.
Installation
-- Check shaft of recirculation door -C- before installing control motor -A-.
Fig. 62: Identifying Catches, Bracket, Intake Housing & Actuator Motor
-- Hold the shaft -C- so that the motor connecting element -D- can be installed.
-- Insert control motor with connecting element -D- into shaft -C- and mounts at intake housing -B-.
-- Install the bracket -A-. Make sure the guide on the bracket -B- fits correctly into the mount on the air intake
shroud -C- and the bracket locks into both retainers -D- and -E-.
-- Install the removed parts in the opposite order.
NOTE: After installing, function of recirculation door must be checked.
FRESH AIR/RECIRCULATING AIR/BACK PRESSURE DOOR MOTOR -V425- WITH MOTOR POSITION SENSOR -G644-
Removal
-- Remove the key.
NOTE: The Fresh Air/Recirculating Air/Back Pressure Door Motor and Fresh
Air/Recirculating Air/Back Pressure Flap Motor Position Sensor -G644- are

installed in vehicles from calendar week 22/07.
It controls the air flow door and the fresh air/recirculating air/back pressure flap
sensor.
-- Remove the bolts -1- (1.4 Nm).
-- Turn the fresh air/recirculating air/back pressure door motor -2- approximately 15° in -direction of arrow- and
then pull it off the air intake housing.
Fig. 64: Identifying Bolts And Fresh Air/Recirculating Air/Back Pressure Door Motor
-- Disconnect the connector -1- from the fresh air/recirculating air/back pressure door motor.
Fig. 65: Identifying Connector

NOTE: Position of air flow door must not be changed.
Installation
Install in reverse order, paying attention to the following:
The fresh air/recirculating air/back pressure door motor fits in only one position on the curved washer.
Fig. 66: Identifying Placement Of Fresh Air/Recirculating Air/Back Pressure Door Motor
NOTE: After installing, check the function of the back pressure and recirculation door.
FRESH AIR/RECIRCULATING AIR/BACK PRESSURE DOOR ADJUSTER
Removal
-- Remove the key.
-- Fresh air/recirculating air/back pressure door motor -V425- with Fresh air/recirculating air/back pressure door
motor position sensor -G644-, refer to AIR FLOW DOOR MOTOR -V71- WITH BACK PRESSURE
DOOR MOTOR POSITION SENSOR -G113-.
-- Open the retainers -arrows- on the adjusting lever -1-.
Fig. 67: Identifying Curved Washer And Adjusting Lever

-- Remove the adjusting lever from the curved washer.

-- Remove the curved washer -2- from the air intake housing.
Installation
NOTE: When installing the curved washer, make sure the guide pin for the adjusting
lever for the air flow door seats in the groove.
-- Install the curved washer -1- on the air intake housing.
Fig. 68: Identifying Curved Washer

NOTE: Make sure the guide pin for the recirculation air door adjusting lever is seated in
the curved washer groove.
-- Mount and latch the recirculation air door adjusting lever.
LEFT TEMPERATURE DOOR MOTOR -V158-
Removal

-- Remove footwell trim on the left side. Refer to Removal and Installation .

-- Remove the bolts -3- (9 +/- 1.3 Nm).
NOTE: Do not remove the bolts -1-.
Do not remove the bracket -2-.
-- Push the bracket -1- toward the brake pedal -arrow- and then tie it there with a cable tie.

Fig. 71: Identifying Temperature Regulator Flap Motor V68, Connector, Cover And Securing Bolts
-- Disconnect the connector -C- from the left temperature door motor.
-- Remove the cover -A-.
-- Remove bolts -D- (1.4 Nm) and remove left temperature door motor -B-.
-- Disconnect the lever -E- from the connecting rod -F-.
Installation
the motor).
NOTE: After installing the left temperature door motor, check the recirculating air door
function.
Perform Basic Setting using VAS 5051B. Refer to CLIMATRONIC A/C SYSTEM,
RIGHT TEMPERATURE DOOR MOTOR -V159-, THROUGH 31 OCTOBER 2008
Removal
-- Remove the key.
-- Remove the Headlamp range/cornering lamp control module -J745-. Refer to Removal and Installation .
-- Remove the right support -1- from the subframe.

Fig. 72: Identifying Right Support And Bolts

-- Disconnect the connector from the right temperature door motor.
Fig. 73: Identifying Right Temperature Flap Motor V159 Remove/Install Components
-- Remove the screws -1- and the right temperature door motor.
-- Unhook brace -2- from right temperature door motor.
Installation
NOTE: After installing the right temperature door motor, recirculating air door must be
checked for function.
RIGHT TEMPERATURE DOOR MOTOR -V159-, FROM 03 NOVEMBER 2008
 5.5 mm Open-End Wrench -T10396-

Removal
-- Remove the key.
-- Remove the Headlamp range/cornering lamp control module -J745-. Refer to Removal and Installation .
-- Disconnect the connector from the right temperature door motor.
-- Remove the bolts -1- with the -T10396-.

Fig. 74: Identifying Right Temperature Flap Motor V159 Remove/Install Components
-- Remove the right temperature door motor.
-- Unhook brace -2- from right temperature door motor.
Installation
NOTE: After installing the right temperature door motor, recirculating air door must be
checked for function.
INDIRECT VENTILATION DOOR MOTOR -V213-
Removal
-- Remove the key.

-- Disconnect the connector from the indirect ventilation door motor -3-.
-- Remove the bolts (3.5 Nm) -1-.
Fig. 75: Identifying Bolts, Defroster Intermediate Piece And Indirect Ventilation Intermediate Piece
-- Remove the defroster intermediate piece -3- and the indirect ventilation intermediate piece -2- from the
heating and A/C unit.
Fig. 76: Identifying Screws And Indirect Ventilation Door Motor

-- Remove the screws -2-.
-- Disconnect the indirect ventilation door motor -1- from the indirect ventilation intermediate piece.
Installation
NOTE: Check the function of the indirect ventilation door motor.
CONDENSER
NOTE: Depending on the type of engine, the refrigerant line connections are mounted
on the right or left side of the condenser.
Refrigerant must be extracted before hand using, for example -ROB 134APF-.
The previously used A/C Service Station can still be used. Refer to V.A.G
workshop equipment information.
To prevent the entry of dampness all components of the refrigerant circuit

which have been opened must be sealed with suitable plugs.
Removal

more.
-- Extract refrigerant using, for example -ROB 134APF-.
NOTE: Environmentally hazardous draining of refrigerant is an offense punishable by

law.
-- Remove bumper. Refer to Removal and Installation .
-- Move the lock carrier into the service position. Refer to Description and Operation .
-- Remove the bolts -1- (12 +/- 1 Nm).

Fig. 77: Identifying Bolts, Refrigerant Lines, Sealing Rings And Connection
-- Remove the refrigerant lines -2- from the connection -4- on the condenser.
-- Seal off the line connections.
NOTE: Replace the sealing rings -3-.
Fig. 78: Identifying Assembly Overview: Condenser System And Components

1. Protective Grate
 Position protective grate from below on the 3rd rib.

2. Clip
 Quantity: 8
3. Condenser
 Mounted to the radiator with 4 screws -8-.
4. Sealing Strips
 Before assembly, attach side sealing strips to outer edge of condenser.
5. Diagram For The Mounting Clips

6. Radiator
7. Dryer Cartridge In Fluid Reservoir
NOTE: Under certain conditions, the dryer cartridge should no longer be replaced
each time the refrigerant circuit is opened. Refer to REPLACING
RESERVOIR/FLUID RESERVOIR OR DRYER CARTRIDGE, CONDITIONS
(Component Replacement).
The fluid reservoir with dryer cartridge is mounted on the right or left side
on the condenser depending on the engine type.
Removing and installing, refer to Passat FLUID RESERVOIR DRYER CARTRIDGE or Passat

CC
8. Screws
 Quantity: 4
 5 +/- 0.5 Nm
Installation
-- See notes, refer to A/C COMPRESSOR, INSTALLATION INFORMATION.
EVACUATING AND CHARGING VALVE, LOW AND HIGH PRESSURE SIDES
 Torque Wrench -V.A.G 1783-

 Ratchet Insert 1/4 -VAS 6234-
 Adapter Set With Service Connection -T10364-

Refrigerant and refrigerant oil will leak out if the refrigerant circuit has not
been evacuated.
Refrigerant must be extracted before opening the refrigerant circuit. If the

refrigerant circuit is not opened within 10 minutes after extracting it,
pressure may build up in the circuit again. Extract refrigerant once more.
NOTE: Environmentally hazardous draining of refrigerant is an offense punishable by

law.
To prevent the entry of dampness, all components of the refrigerant circuit

-- Remove the cap -3-.
-- Evacuate the refrigerant circuit using, for example, -ROB 134APF- (or succeeding model), then replace the
valve -2-.
Fig. 79: Identifying Valve Mount, Valve Insert, Cap And Adapter
-- Remove the valve insert -2- (2 +/- 0.2 Nm) from the valve mount -1- using the adapter -4- taken from the -
T10364-. Hold the valve mount with a suitable tool.
EVAPORATOR
Removal
-- Remove the heating and A/C unit. Refer to HEATING AND A/C UNIT.
-- Disassemble the heater and A/C unit. Refer to, vehicles with Climatronic HEATER AND A/C UNIT,
CLIMATRONIC, vehicles with Climatic HEATING AND A/C UNIT, CLIMATIC.
-- Disassemble the evaporator housing. Refer to EVAPORATOR HOUSING.
Fig. 80: Identifying Evaporator Remove/Install Components

-- Remove the evaporator -A- from the evaporator housing lower section.
NOTE: Before inserting the evaporator, check condensation water drain and clean
drain if necessary.
Before inserting evaporator, clean evaporator housing and the evaporator if

necessary.
-- When inserting evaporator -A- into lower section of evaporator housing and when assembling both housing
halves, make sure the seal -F- is not damaged.
-- Check seal -F- (it must be glued all around) before inserting evaporator.
Fig. 81: Identifying Evaporator Remove/Install Components

-- Mount the bracket -C- and seal/insulation -B- on the evaporator connecting pipes -D- and -E-.
-- Insert evaporator -A- into lower section of evaporator housing as shown in the illustration.
NOTE: After assembling both housing halves, check seal / insulation -B- for correct
seating at pass-through for both refrigerant lines -D- and -E-.
Check seating of bracket -C- on both refrigerant lines -D- and -E- for correct
seating.
If heat protection insulation -B- is missing or not installed correctly, it can

cause reduced performance of the A/C system (change of adjusted control
characteristics of expansion valve due to radiant heat).
Installation
EXPANSION VALVE
NOTE: Refrigerant must be extracted before hand using, for example -ROB 134APF-.
The previously used service stations can still be used. Refer to V.A.G workshop
equipment information.
To prevent the entry of dampness all components of the refrigerant circuit

Function
The expansion valve atomizes the streaming refrigerant and controls the flow quantity so that the vapor is
gaseous only at the evaporator outlet, depending on the heat transmission.
Only for vehicles with a heat shield in front of the expansion valve
-- Remove the nut -1- (4.5 Nm) and bolt -4- (2.5 Nm).
Fig. 82: Identifying Nuts, Bolts, Clips And Heat Shield

-- Remove the clip -2- and the heat shield -3-.
All vehicles
Fig. 83: Identifying Expansion Valve Remove/Install Components

1. Screws
 10 +/- 1 Nm
 Quantity: 2
2. Refrigerant Lines On Expansion Valve

3. O-ring
 13.7 mm; 2.5 mm
4. Expansion Valve
 Removing
-- Extract refrigerant using, for example, -ROB 134APF-.
-- Remove the bolts -1- and the refrigerant pipes -2- from the expansion valve.
-- Remove the bolts -8- and the expansion valve.
5. O-ring
 14 mm; 1.82 mm
 Coat with refrigerant oil when installing.
6. O-ring
 10.8 mm; 1.82 mm
 Coat with refrigerant oil when installing.
7. O-ring
 9.5 mm; 2.5 mm
8. Cylindrical Combination Bolt

 5 Nm
FLUID RESERVOIR DRYER CARTRIDGE

 Locking ring pliers (commercially available)
NOTE: Under certain conditions, the dryer cartridge should no longer be replaced each
time the refrigerant circuit is opened. Refer to REPLACING RESERVOIR/FLUID
RESERVOIR OR DRYER CARTRIDGE, CONDITIONS (Component Replacement).
The fluid reservoir with dryer cartridge is mounted on the right or left side on
the condenser depending on the engine type.
-- Move the lock carrier into the service position. Refer to Description and Operation .
-- Unscrew mounting bolts for cooler -arrows-.

Fig. 84: Identifying Mounting Bolts For Cooler

-- Carefully push the radiator toward the engine until the cover bolt -arrow- is accessible.
Fig. 85: Identifying Cooler Cover Bolt



more.
-- Extract refrigerant using, for example -ROB 134APF-, only then open the refrigerant circuit. See notes, refer
to REFRIGERANT CIRCUIT COMPONENTS OVERVIEW.
-- Remove the cap 1.2 Nm 0.3 Nm. The illustration shows a Passat from MY 06.
-- Install a cylinder bolt (M5) into the thread in the cap.
-- Push the cap downward and remove the circlip.
-- Using pliers on the cylinder bolt -2- pull the cap -1- straight out in the direction of arrow.
Fig. 86: Identifying Sealing Cap Pulled Out Straight

-- Using needle-nose pliers pull the dryer cartridge -1- in the direction of arrow.
Fig. 87: Identifying Pulled Out Dryer Cartridge

Installation
Tightening specification, cap on fluid reservoir: 1.2 Nm 0.3 Nm
HEATING AND A/C UNIT

 Drip Tray For Shop Crane -VAS 6208-
 Hose Clamps Up To Diameter 40 mm -VAS 3093-
 Compressed Air Gun, commercially available
Removing
NOTE: To improve accessibility, additional components, such as the engine cover

must be removed (depending on engine version). Refer to ENGINE COVER .
-- Extract refrigerant using, for example -ROB 134APF-, only then open the refrigerant circuit. See notes, refer
to REFRIGERANT CIRCUIT REPAIRS.
-- Remove the rear channels from the right and left footwells. Refer to REAR CHANNEL, FOOTWELL .
-- Place -VAS 6208- under the engine.
Only for vehicles with a heat shield in front of the expansion valve
-- Remove the nut -1- (4.5 Nm) and bolt -4- (2.5 Nm).
Fig. 88: Identifying Nuts, Bolts, Clips And Heat Shield

-- Remove the clip -2- and the heat shield -3-.
All vehicles
Fig. 89: Identifying Coolant Hoses At Heater Core

-- Mark the coolant hoses -1- to prevent interchanging them.
WARNING: Contact with hot engine coolant can cause severe scalding.
Coolant temperature can be above 100 °C with a warm engine. The

cooling system is under pressure.
If necessary, reduce pressure and temperature before repairs.
-- Clamp the coolant hoses -1- using the -VAS 3093- and remove the coolant hoses from the heat exchanger.
-- Connect a section of hose -A- to the upper connection.
Fig. 90: Identifying Section Of Hose, Suitable Container And Lower Connection
-- Hold a container -B- under the lower connection -C-.
-- Using a compressed air gun, carefully blow residual coolant out of heater core at heater core connection.
Fig. 91: Identifying Refrigerant Lines, Bolts And Expansion Valve

Refrigerant may leak out if refrigerant circuit is not discharged.
Refrigerant must be extracted before opening the refrigerant circuit.
-- From inside the engine compartment, remove the bolts (10 +/- 1 Nm), -1- from the refrigerant pipes -2-.
-- Remove the refrigerant pipes from the expansion valve -3-.
NOTE: Seal the open connections.
To seal off all open connections on expansion valve, sealing caps from a
replacement expansion valve can be used (preventing dirt and moisture from
entering the system).
-- Cover the carpet inside the passenger compartment with waterproof foil and water absorbing paper.
NOTE: When removing the bolts, make note of the lengths and location.
Fig. 92: Identifying Heating And A/C Unit Remove/Install Components

1. Screw
 4 Nm
2. Screws
 Quantity: 2
 4 Nm
3. Cable Bracket
Removal
-- Remove the condensation water hose from the heater and air conditioner. Refer to CONDENSATION
WATER DRAIN HOSE, CHECKING.
-- Disconnect the connectors from the heater and air conditioner.
NOTE: All cable ties opened or cut during removal must be reinstalled at the
same locations during installation.
-- Remove the bolts -9- and -5-.
-- Remove the supports -7- and -8-.
-- Remove the bolts -10- and -12- and bracket -11-.
-- Remove the bolts -1- and -2- from the cable bracket -3-.
NOTE: To be able to reach the bolt -1-, heating and A/C unit on driver side must
be pulled out slightly from facing wall.
When removing the heater and A/C unit, make sure the two coolant pipes
on the heater core do not get caught and bent or damaged on plenum
chamber or noise insulation pan.
Observe wiring harness, individual electrical wiring connections may get

damaged when pulling on harness.
-- Remove heating and A/C unit.
Installation
NOTE: The assistance of a second technician is necessary to install the heating

and A/C unit.
-- When installing the heater and A/C unit, have the second technician guide the coolant pipes to heater
core through the seal (from engine compartment), refer to Seal for Heating and A/C Unit / Engine
Compartment.
-- Fill with coolant. Refer to DRAINING AND FILLING .
5. Bracket
6. Subframe
7. Right Support
8. Left Support
9. Screws
 9 +/- 1.3 Nm
10. Screws
 9 +/- 1.3 Nm
 Quantity: 2
11. Bracket
12. Screws
 9 +/- 1.3 Nm
 Quantity: 2
SEAL FOR HEATING AND A/C UNIT / ENGINE COMPARTMENT
Fig. 93: Identifying Seal for Heating and A/C Unit / Engine Compartment
NOTE: Note installation position of seal -A- during assembly.
HIGH PRESSURE SENSOR -G65-
Removal
Fig. 94: Identifying High Pressure Sensor G65

NOTE: For the purpose of a better illustration, the right headlamp is removed.
-- Disconnect the connector from the high pressure sensor -1-.
-- Remove the high pressure sensor -2- (8 +/- 1 Nm) from the refrigerant line connection.
NOTE: Replace the O-ring.
High Pressure Sensor -2- may also be installed on a different side in the vicinity
of the condenser, depending on the engine version.
Installation
DISASSEMBLY AND ASSEMBLY
HEATING AND A/C UNIT, CLIMATIC

Fig. 95: Identifying Heating And A/C Unit, Climatic

1. Temperature Regulator Door Motor -V68-

 Removing and installing, refer to TEMPERATURE REGULATOR DOOR MOTOR -V68-.
2. Bracket
3. Screws
 Bolts must be unscrewed to separate air distributor and evaporator housing.
4. Cover
5. Fresh/Recirculating Air Door Motor -V154-
 Removing and installing, refer to FRESH/RECIRCULATING AIR DOOR MOTOR -V154- .
 With air recirculation door.

7. Upper Section Of Evaporator Housing
 Disassembling and assembling evaporator housing, refer to EVAPORATOR HOUSING.
8. Lower Section Of Evaporator Housing

9. Evaporator
 Removing and installing, refer to EVAPORATOR.

11. Connection For Glove Compartment Cooling

12. Coolant Hose For Glove Compartment Cooling
13. Fresh Air Blower Series Resistor With Fuse -N24-
 Removing and installing, refer to FRESH AIR BLOWER SERIES RESISTOR WITH FUSE -N24-
.
14. Fresh Air Blower -V2-
 Removing and installing, refer to FRESH AIR BLOWER -V2- .
15. Dust And Pollen Filter

16. Cover
 For dust and pollen filter.
17. Heat Exchanger

18. Heater Core Trim

20. Junction Box

21. Air Distribution Door Motor -V428- with Air Distribution Door Motor Position Sensor -G645-
 Removing and installing .
COMPONENTS.
HEATER AND A/C UNIT, CLIMATRONIC

Fig. 96: Identifying Heating And A/C Unit, Assembly Overview

1. Control Motor
Passat from MY 06 Central air door motor -V70-.
Passat CC from MY 09 and CC from MY 10 front air distribution door motor -V426-.
 Removing and installing, refer to CENTRAL AIR DOOR MOTOR -V70- OR FRONT AIR
DISTRIBUTION DOOR MOTOR -V426-.
 Replacing: perform a basic setting with Vehicle Diagnosis, Testing and Information SystemVAS
5051B. Refer to CLIMATRONIC A/C SYSTEM, CHECKING AND ADJUSTING

COMPONENTS.
2. Left Temperature Door Motor -V158-
 Removing and installing, refer to LEFT TEMPERATURE DOOR MOTOR -V158-.
3. Defroster Door Motor -V107-

 Removing and installing, refer to DEFROSTER DOOR MOTOR -V107-.
4. Indirect Ventilation Door Control Motor -V213-

 Removing and installing, refer to INDIRECT VENTILATION DOOR MOTOR -V213-.
5. Intermediate Piece For Indirect Ventilation

6. Bracket
7. Screws
 Bolts must be unscrewed to separate air distributor and evaporator housing.
8. Cover
9. Recirculation Door Motor -V113-
Passat from MY 06 through calendar week 21/07.
Beginning 05.28.07, the Recirculation Door Motor -V113- is deleted.


 Removing and installing, refer to RECIRCULATION DOOR MOTOR -V113-.
10. Control Motor
Passat from MY 06 through calendar week 21/07 Air flow flap motor -V71-.
 Removing and installing, refer to AIR FLOW DOOR MOTOR -V71- WITH BACK
2006 Passat from calendar week 22/07 and Passat CC from MY 2009 Fresh air/recirculating
air/back pressure flap motor -V425-.
Removing and installing, refer to AIR FLOW DOOR MOTOR -V71- WITH BACK

COMPONENTS.
11. Housing For Air Entry
 With fresh air and recirculation door.
 With air flow door (Climatronic).

13. Evaporator


16. Connection For Glove Compartment Cooling

17. Fresh Air Blower -V2- with Fresh Air Blower Control Module -J126-
 Cannot be replaced separately.
 The Fresh air blower control module -J126- and theFresh air blower -V2- are a single unit.
 Removing, refer to FRESH AIR BLOWER -V2- WITH FRESH AIR BLOWER CONTROL
MODULE -J126-.
 With EVAP canister.
19. Cover
 For dust and pollen filter.
20. Coolant Hose For Glove Compartment Cooling

21. Heat Exchanger
22. Heater Core Trim

24. Right Temperature Door Motor -V159-

 Removing and installing, refer to RIGHT TEMPERATURE DOOR MOTOR -V159-,
THROUGH 31 OCTOBER 2008.
25. Junction Box
EVAPORATOR HOUSING
-- Remove the evaporator housing from the heater and A/C unit. Refer to HEATING AND A/C UNIT.
-- Disconnect the connectors from the heater and A/C unit.

Fig. 97: Identifying Evaporator Housing, Assembly Overview


2. Evaporator
 Check insulation, it must be completely present.
3. Clip
5. Screw
6. Seal / Insulation
Removing and installing, refer to EVAPORATOR.


7. Bracket
SPECIAL TOOLS
Information for special tools and equipment when repairing vehicles with air conditioning can be found in Refer
to Special Tools .
Fig. 98: Identifying 3409 Wedge

 Torque wrench -V.A.G 1331- (5 to 50 Nm)


 Torque wrench -V.A.G 1783- (2... 10 Nm) for Adapter Set With Service Connections -T10364-
 for example A/C Service Station -VAS 6007A- (or succeeding model)
 Ratchet Insert 1/4 -VAS 6234- for Adapter Set With Service Connections -T10364-
 Adapter Set With Service Connection -T10364-
Fig. 100: Identifying Torque Wrench VAG 1783, A/C Service Station VAS 6007A, Ratchet Insert
VAS 6234 And Adapter Set T10364
 Test Box -V.A.G 1598/42-

Fig. 101: Identifying V.A.G 1598/42 Test Box


 Template -V.A.G 1598/47-2-
 5.5 mm Open-End Wrench -T10396-
Fig. 102: Identifying 5.5 mm Open-End Wrench T10396

 Hose Clamps Up To Diameter 40 mm -VAS 3093-

Fig. 103: Identifying Hose Clamps 3093

Fig. 104: Identifying Vehicle Diagnosis, Testing And Information System VAS 5051B
 Drip Tray For Shop Crane -VAS 6208-

Fig. 105: Identifying Drip Tray For Shop Crane VAS 6208
Edition 10282010
Brakes Antilock Brake System
Brakes
Antilock Brake System
45 ANTILOCK BRAKE SYSTEM

GENERAL INFORMATION
ABS GENERAL INFORMATION
The ABS brake system is divided diagonally (two circuits). The vacuum brake servo unit boosts the brakes
pneumatically.
Models with ABS do not have a mechanical brake pressure regulator. A specially coordinated software program
in the control module determines brake pressure allocation at the rear axle.
NOTE: ABS malfunctions do not affect the brake system and the booster. Conventional
brake system stays operative even without ABS. A change in braking behavior
should be checked. When the ABS indicator lamp is on, the rear wheels may
lock prematurely during braking!
ABS Layout
Fig. 1: Identifying Hydraulic Unit And Control Module And Brake Booster
1 - Hydraulic unit and control module
2 - Brake booster
The control module and hydraulic unit form one component. Separation is not possible. The hydraulic pump
must also not be separated from the hydraulic unit.
ABS REPAIR INFORMATION
 Before carrying out repair work on the anti-lock braking system, as well as the control module coding,
determine the cause of the malfunction using "guided fault finding".
"Guided fault finding" is performed with On Board Diagnosis, using the Vehicle Diagnostic Tester.
 Turn off the ignition and disconnect the battery ground cable.
 Carry out before welding with an electric welding tool.
 When working with brake fluid, observe relevant safety precautions and notes. Refer to BRAKE
SYSTEM, BLEEDING .
 After finishing any work that required opening the brake system, bleed the brake system using the Brake
Charger/Bleeder Unit VAS 5234 or V.A.G 1869. Refer to BRAKE SYSTEM, BLEEDING .
 During final road test, carry out at least one ABS controlled braking operation (appropriate pulsations
must be felt at brake pedal).
 Absolute cleanliness is required when working on the anti-lock brake system. Do not use any products
which contain mineral oil, such as oils, greases etc.
 Thoroughly clean all unions and the adjacent areas before loosening. Do not use aggressive cleaning
agents such as brake cleaner, fuel, thinners or similar chemicals.
 Place parts that have been removed on a clean surface and cover.
 After disconnecting control module/hydraulic unit, use transport protection for valve domes.
 Carefully cover or seal open components, if repairs are not carried out immediately. (Sealing plugs, use
repair kit 1 H0 698 311 A)
 Only use lint-free cloths.
 Only unpack replacement parts immediately prior to installation.
 Only use parts in their original packaging.
 Do not work with compressed air and do not move vehicle while the system is open.
 When painting, electronic control module can be exposed to a maximum temperature of. 95°C (203°F)
only briefly, and to a maximum of 85°C (185°F) for longer periods (approximately 2 hours). Make sure
that brake fluid does not enter harness connectors.
VAS 5051, CONNECTING AND SELECTION FUNCTIONS
 Vehicle diagnostic, test and information system VAS 5051

 Diagnostic cableVAS 5051/1 or VAS 5051/3
WARNING:  During a test drive, the testing and measuring equipment must
always be secured on the back seat.
 These devices may be operated only by a passenger during a test
drive.
-- Connect VAS 5051/1 or VAS 5051/3 to diagnostic connection.
-- Switch on VAS 5051 -arrow-.
Fig. 2: Identifying Volkswagen Tester VAS 5051, On Switch

The tester is operational when it displays a picture of a car.
-- Switch on ignition.
-- Touch Guided Fault Finding .
-- Select in succession:
 Brand
 Type
 Model year
 Version
 Engine Code
-- Confirm data entered.

Wait until VAS 5051 has checked all control modules in vehicle.
-- Press GO TO and select "function/component selection".
-- Select "suspension" on the display.
-- Select "brake system" on the display.
-- Select "01-On Board Diagnostic (OBD) capable system..." indicated on display.
Either:
-- Select on display "Anti-lock brake system...".
Or:
-- Select "electromechanical parking brake" on the display.
-- Select "function" indicated on display.
Now, all possible functions of the antilock brake system installed in the vehicle will be displayed.
-- Select desired function on display.
ELECTRICAL AND ELECTRONIC COMPONENTS AND COMPONENT LOCATIONS
ABS/EDL/ASR/ESP, TRW
Fig. 3: Identifying Electrical/Electronic Components And Installation Locations -- ABS TRW

(ABS/EDS/ASR/ESP)
1. ABS Control Module (w/EDL) -J104-

 Component location: At hydraulic unit on right side of engine compartment.
 Do not disconnect connector before successfully completing On Board Diagnostic (OBD). Switch
ignition off before separating connector.
 Must not be separated from the ABS Hydraulic Unit.
 Removing and installing, refer to CONTROL MODULE AND HYDRAULIC UNIT.
2. ABS Hydraulic Unit -N55-

 Component location: In engine compartment, right.
The hydraulic unit consists of the components:
 Brake pressure sensor -G201-

 ABS Hydraulic Pump -V64-
 Valve block (contains inlet and outlet valves)
 The ABS hydraulic pump and valve block must not be separated from one another
 Must not be separated from the ABS Control Module.
3. Brake Pad Wear Indicator Lamp -K32-

 Component location: In the instrument cluster.
 Function, refer to LEVEL CONTROL SYSTEM INDICATOR LAMPS.
4. ABS Warning Lamp -K47-

5. ASR/ESP Control Lamp -K155-

6. Brake System Warning Lamp -K118-

7. Brake Light Switch -F-

 Component location: On brake master cylinder.
 Removing and installing, refer to BRAKE LAMP SWITCH .
8. ASR/ESP Button -E256-

 Component location: In center console
9. ESP Sensor Unit -G419- and Electromechanical Parking Brake Control Module -J540-
 Component location: Beneath center console
 Combined Transverse Acceleration Sensor -G200-, Rotation Rate Sensor -G202- and Longitudinal
Acceleration Sensor -G251-
 Installed together in one housing with the Electromechanical Parking Brake Control Module -J540-
.
 Removing and installing, refer to ESP SENSOR UNIT.
10. Diagnostic Connection

 Component location: Driver side footwell cover.
11. Steering Angle Sensor -G85-

 Component location: On steering column between steering wheel and steering column switch.
 Removing and installing, refer to STEERING ANGLE SENSOR.
12. Wheel Bearing Housing

13. Right Front ABS Wheel Speed Sensor -G45-/Left Front ABS Wheel Speed Sensor -G47-
 Removing and installing, refer to FRONT AXLE ABS COMPONENTS OVERVIEW.
14. Wheel Hub with Wheel Bearing

 The ABS sensor ring is installed in the wheel bearing.
15. Right/Left Rear ABS Wheel Speed Sensor -G44-/-G46-

 Removing and installing (FWD), refer to REAR AXLE ABS COMPONENTS OVERVIEW,
FWD.
 Removing and installing (AWD), refer to REAR AXLE ABS COMPONENTS OVERVIEW,
AWD.
Front wheel drive shown.
Front wheel drive shown.
LEVEL CONTROL SYSTEM INDICATOR LAMPS
Warning Lamps
Fig. 4: Locating Warning Lamps

Item Designation
1 ASR/ESP Control Lamp -K155-
2 Brake Pad Wear Indicator Lamp -K32-

3 ABS Warning Lamp -K47-
4 Brake System Warning Lamp -K118-
Brake Pad Wear Indicator Lamp -K32-
 If Brake Pad Wear Indicator Lamp -2- does not switch off 3 seconds after the ignition is switched on or if
it lights up when vehicle is driven, it could be caused by the following malfunctions:
-a- brake pads may be worn.
Check front and rear axle brake pads/linings. Replace worn brake pads/linings.
-b- There is a wiring malfunction. Refer to the appropriate SYSTEM WIRING DIAGRAM Information.
ABS Warning Lamp -K47-
 If ABS Warning Lamp -3- does not go out after the ignition is switched on and the test sequence is
complete, it could be caused by the following errors:
-a- Voltage supply is under 10 volts.
-b- there is an ABS malfunction.
WARNING: The ABS system shuts off if there is malfunction -b- in the system,
however the standard brake system remains fully functional.
-c- There was a periodic wheel speed sensor malfunction since the last vehicle start.
In this case the ABS Warning Lamp will go out after the engine is restarted and the vehicle speed exceeds 20
km/h.
-d- The connection from instrument cluster to ABS Control Module -J104- is interrupted. Refer to the
-e- The instrument cluster is faulty.
ABS Warning Lamp -K47- and Brake System Warning Lamp -K118-
 If ABS Warning Lamp -3- goes out but rake System Warning Lamp -4- lights up, the malfunctions causes
may be:
-a- Parking brake is engaged.
-b- Brake fluid level is too low (warning lamp blinks).

Three warning tones are audible after switching on the ignition.
-c- There is a malfunction in the wiring to Brake System Warning Lamp -K118-. Refer to the appropriate
SYSTEM WIRING DIAGRAMS information.
 If the ABS warning light -3- and the brake system warning lamp -4- both light up, the ABS system is
faulty. A change in braking behavior should be checked.
WARNING: After ABS Warning Lamp and Brake System Warning Lamp light up, rear
wheels may lock prematurely when braking.
ASR/ESP Control Lamp -K155-
 If the ASR/ESP Control Lamp -1- does not turn off after the ignition is switched on and the test sequence
is completed, the malfunction may be:
There is a malfunction present which only affects the ASR/ESP. The ABS/EDL and EBD safety systems are
still completely functional, check DTC memory.
-a- Short circuit to B+ in ASR/ESP Button -E256-.
-b- A malfunction in the actuation of ASR/ESP Control Lamp. Refer to the appropriate SYSTEM WIRING
DIAGRAMS information.
-c- ASR/ESP system was switched off by ASR/ESP Button.
NOTE: If ASR/ESP Control Lamp flashes while driving, the ASR or ESP systems are
regulating the system.
 If the ASR/ESP Control Lamp -1- did not light up during self-test, the following malfunction is present:
-a- the ASR/ESP control lamp is faulty, perform an electrical test.
ABS CONTROL MODULE AND HYDRAULIC UNIT ASSEMBLY OVERVIEW
ABS/EDL/ASR/ESP, TRW
Fig. 5: Identifying Assembly Overview: Hydraulic Unit, ABS TRW (ABS/EDS/ASR/ESP)

1. ABS Control Module (w/EDL) -J104-
It is not possible to separate the control module and hydraulic unit.
Removing and installing, refer to CONTROL MODULE AND HYDRAULIC UNIT.

2. ABS Hydraulic Unit -N55-
It is not possible to separate the control module and hydraulic unit.

3. Brake Line
 To right front brake caliper.
 Identification: 5.25 mm diameter and tube fitting with M10 x 1 thread
 Marked on hydraulic unit with "VR".
4. Brake Line
 To left rear brake caliper.
 Identification: 5.25 mm diameter and tube fitting with shorter thread M12 x 1
 Marked on hydraulic unit with "HL".
5. Brake Line
 To right rear brake caliper.
 Identification: 5.25 mm diameter and tube fitting with M10 x 1 thread
 Marked on hydraulic unit with "HR".
6. Brake Line
 To left front brake caliper.
 Identification: 5.25 mm diameter and tube fitting with shorter thread M12 x 1
 Marked on hydraulic unit with "VL".
7. Brake Line
 Master brake cylinder/primary piston circuit to hydraulic control unit.
 Identification: 8.5 mm or 6 mm diameter and tube fitting with longer thread M12 x 1
 Marked on hydraulic unit with "HZ1".
8. Brake Line
 Master brake cylinder/secondary piston circuit to hydraulic unit.
 Identification: 8.5 mm or 6 mm and tube fitting with longer thread M12 x 1
 Marked on hydraulic unit with "HZ2".
9. Heat Shield
Allocation.
10. Bolt
 12 Nm
11. Brake Booster
 On vehicles with a hydraulic brake booster, a vacuum sensor is installed. Refer to the BRAKE
BOOSTER VACUUM SENSOR.
 Removing and installing, refer to BRAKE BOOSTER .
12. Bracket
13. Nut
 20 Nm
14. Rubber Insulation

15. Bolt
10 Nm

16. Bracket
BRAKE LINES FROM TANDEM BRAKE MASTER CYLINDER, CONNECTING TO HYDRAULIC UNIT
On Tandem Master Brake Cylinder
Fig. 6: Identifying Connection Of Brake Lines From Dual Brake Master Cylinder To Hydraulic Unit --
On Tandem Main Brake Cylinder
A - Primary piston circuit of master brake cylinder to hydraulic unit
- Identification: 8.5 mm or 6 mm and tube fitting with thread M12 x 1
B - Secondary piston circuit of master brake cylinder to hydraulic unit
- Identification: 8.5 mm or 6 mm and tube fitting with thread M12 x 1
1 - Hydraulic unit to front left brake caliper
3 - Hydraulic control unit to rear left brake caliper
4 - Hydraulic control unit to rear right brake caliper
On Hydraulic Unit
Fig. 7: Identifying Connection Of Brake Lines From Dual Master Brake Cylinder To Hydraulic Unit --
On Hydraulic Unit
1 - Hydraulic unit to front left brake caliper
- Identification: 5.25 mm diameter and tube fitting with shorter thread M12 x 1
2 - Hydraulic control unit to rear right brake caliper
- Identification: 5.25 mm diameter and tube fitting with M10 x 1 thread
3 - Hydraulic control unit to rear left brake caliper
- Identification: 5.25 mm diameter and tube fitting with shorter thread M12 x 1
4 - Hydraulic unit to right front brake caliper
- Identification: 5.25 mm diameter and tube fitting with M10 x 1 thread
5 - Hydraulic unit to primary piston circuit of master brake cylinder
- Identification: 8.5 mm or 6 mm and tube fitting with longer thread M12 x 1
6 - Hydraulic unit to master cylinder secondary piston circuit
- Identification: 8.5 mm or 6 mm and tube fitting with longer thread M12 x 1
FRONT AXLE ABS COMPONENTS OVERVIEW

Fig. 8: Identifying Components Overview: ABS System Components On Front Axle

1. ABS Wheel Speed Sensor

 Before inserting sensor, clean inner surface of bore hole and coat with hot bolt paste G 052 112 A3.
 Removing and installing, refer to FRONT ABS WHEEL SPEED SENSOR.
2. Bolt
 8 Nm

4. Drive Axle
REAR AXLE ABS COMPONENTS OVERVIEW, FWD
Fig. 9: Identifying Components Overview: ABS System Components On Rear Axle (Front Wheel Drive)

 Removing and installing, refer to REAR ABS WHEEL SPEED SENSOR, FWD.
2. Bolt
 8 Nm

REAR AXLE ABS COMPONENTS OVERVIEW, AWD
Fig. 10: Exploded View Of ABS System Components On Rear Axle (All Wheel Drive)

 Removing and installing, refer to REAR ABS WHEEL SPEED SENSOR, AWD.
2. Bolt
 8 Nm

SPECIFICATIONS

ABS Hydraulic Unit Bracket Nut - 20
ABS Hydraulic Unit to Bracket Bolt - 10
ABS Wheel Speed Sensor Bolt - 8
Brake Line
- to Brake Calipers - 14
- to Master Cylinder, 8.5 mm Diameter - 17
- to Master Cylinder, 6 mm Diameter - 14
ESP Sensor Unit Nut - 9
Heat Shield to ABS Hydraulic Unit Bolt - 12
CONTROL MODULE AND HYDRAULIC UNIT
 Torque wrench V.A.G 1331

 Brake pedal actuator V.A.G 1869/2
 Hose clamps, up to 25 mm 3094

Fig. 11: Identifying Sealing Plug Repair Set, Part No. 1H0 698 311 A
1 - Transport protection for valve domes (foam)
2 - Sealing plug M 10
3 - Sealing plug M 12
Removing
NOTE: Component location: The control module is bolted to the hydraulic unit and is
located at right in the engine compartment.
WARNING: Do not bend the brake lines near the hydraulic unit.
-- Read and note the present control module coding.
-- If the vehicle has a coded radio, get the radio code from the customer before beginning.
-- Disconnect battery. Refer to [For engine(s) BPY,BLV,CCTA,CBFA] Removal and Installation .
-- Remove engine cover.
6-Cylinder Gasoline Engine
-- Disconnect knock sensor and vacuum hose valve connectors at rear of intake manifold. Unclip wiring harness
from retainers on coolant pipe and lay it aside.
-- Remove vacuum hoses on rear of intake manifold, remove from retainers and set aside completely.
-- Loosen right rear coolant pipe from left and rear of engine.
-- Disconnect both coolant hoses on reservoir with 3094.
-- Now remove both coolant hoses on reservoir and then set them as far aside as possible with coolant pipe.
All Vehicles
-- On vehicles with heat shield, remove heat shield.
-- Press the red securing clip in -direction of arrow- toward the rear.
Fig. 12: Identifying Direction Of Pressing Red Securing Clip Toward Rear
-- Release and remove connector from control module in -direction of arrow-.

Fig. 13: Identifying Direction To Remove Connector From Control Module

-- Insert V.A.G 1869/2.
-- Attach bleeder hose of bleeder bottles to left-front and left-rear brake caliper bleeder valves and open bleeder
valves.
-- Operate brake pedal using V.A.G 1869/2 at least 60 mm.
-- Close left front and left rear bleeder valves.
-- Do not remove V.A.G 1869/2.
-- Place sufficient lint-free cloths under the control module and hydraulic unit.
NOTE: Make sure that brake fluid does not come in contact with the terminals.
-- First, mark both brake lines from master cylinder and remove from the hydraulic unit.
-- Plug the brake lines and threaded holes immediately with sealing plugs from the repair kit Part No. 1H0 698
311 A.
-- Mark, unfasten and plug the remaining brake lines (brake calipers).
All Vehicles
-- Lift the hydraulic unit with control module up and out of the dampers -arrow-.
Fig. 14: Identifying Hydraulic Unit And Control Module Removed From Dampers
Installing
NOTE: Do not remove sealing plugs at new hydraulic unit until the corresponding
brake line is about to be installed.
If the sealing plugs are removed too early, brake fluid can escape and unit may
not be sufficiently filled or adequately bled.
When installing the hydraulic unit, make sure the damper rubber is not pushed
out of the console.
Fastening sequence of brake lines:

Fig. 15: Identifying Connection Of Brake Lines From Dual Master Brake Cylinder To Hydraulic Unit --
On Hydraulic Unit
-- Remove V.A.G 1869/2.
-- Bleed the brake system. Refer to BRAKE SYSTEM, BLEEDING .
-- Enter radio code.
-- Code the ABS control module -J104- with the Vehicle Diagnostic Tester in "Guided Fault Finding".
A Steering Angle Sensor -G85-, Transverse Acceleration Sensor -G200-, Longitudinal Acceleration Sensor -
G251- and Brake Pressure Sensor 1 -G201- basic setting must be done.
Hydraulic unit hex bolt to bracket 10 Nm
Brake lines with the ABS unit:
Brake lines 1 through 4 (brake calipers) 14 Nm
Brake lines 5 and 6 (brake master cylinder)
Diameter 8.5 mm 17 Nm
Diameter 6 mm 14 Nm
FRONT ABS WHEEL SPEED SENSOR
Removing
-- Raise the vehicle.

-- Separate speed sensor and speed sensor wiring connector -1-.
Fig. 16: Identifying ABS Speed Sensor On Front Axle

-- Remove bolt -2- from wheel bearing housing.
-- Remove ABS speed sensor from wheel bearing housing.
Installing
-- Before inserting speed sensor, clean hole inner surface and coat speed sensor all-round with hot bolt paste G
052 112 A3.
-- Insert the speed sensor into the hole in the wheel bearing housing and tighten the bolt to 8 Nm.
-- Connect speed sensor to speed sensor wiring.
REAR ABS WHEEL SPEED SENSOR, FWD
Removing

Fig. 17: Identifying ABS Speed Sensor On Rear Axle

Installing
052 112 A3.
REAR ABS WHEEL SPEED SENSOR, AWD
Removing

Fig. 18: Identifying Speed Sensor Wiring Connector And Bolt On Rear Axle
Installing
052 112 A3.
ESP SENSOR UNIT
NOTE: The Transverse Acceleration Sensor -G200-, the Rotation Rate Sensor -G202-
and the Longitudinal Acceleration Sensor -G251- are installed in one housing,
together with the Electromechanical Parking Brake Control Module -J540- under
the center console.
After replacing the ESP sensor unit -G419- with the electromechanical parking brake control module, the ABS
control module -J104- must be coded and a basic setting of the "Brake system" (Electromechanical Parking
Brake) must be performed.
WARNING: Excessive shaking (for example, dropping, impact) may damage the ESP
sensor unit. ESP sensor unit must then no longer be used.
Removing
-- Remove the center console. Refer to Removal and Installation .
-- Disconnect connector -1- from ESP sensor unit.
Fig. 19: Identifying ESP Sensor Unit Connector And Nuts

-- Remove the three nuts -arrows-.
-- Remove ESP sensor unit.
Installing
When installing ESP sensor unit, be sure it is properly seated on the bracket and is free of tension.
NOTE: Never force ESP sensor unit into position using nuts.
-- Tighten the nuts to 9 Nm.
-- Code the ABS control module with the Vehicle Diagnostic Tester in "Guided Fault Finding".
A Steering Angle Sensor -G85-, Transverse Acceleration Sensor -G200-, Brake Pressure Sensor 1 -G201- and
Longitudinal Acceleration Sensor -G251- basic setting must be done.
-- Perform basic setting for "Brake system" (Electromechanical Parking Brake).

VAS 5051, connecting and selecting functions VAS 5051, CONNECTING AND SELECTION
FUNCTIONS.
STEERING ANGLE SENSOR
NOTE: The steering angle sensor -G85- is installed between steering wheel and
steering column switch.
Removing and Installing:
Refer to [For engine(s) BPY,BLV,CCTA,CBFA] Removal and Installation
-- Afterwards, basic setting of steering angle sensor must be performed.
VAS 5051, connecting and selecting functions, refer to VAS 5051, CONNECTING AND SELECTION
FUNCTIONS.
BRAKE BOOSTER VACUUM SENSOR
Removing
-- Remove battery. Refer to [For engine(s) BPY,BLV,CCTA,CBFA] Removal and Installation .
NOTE: On vehicles with 6-cylinder gasoline engine, battery is in luggage compartment,

accordingly only air filter housing must be removed.
-- Remove the battery carrier.
-- Disconnect harness connector -1- from brake booster vacuum sensor -G483- -2-.
Fig. 20: Identifying Brake Booster Vacuum Sensor G483 Harness Connector
-- Insert a screwdriver between stop and one end of securing ring into groove of sealing ring.
-- Press the circlip -1- just far enough out of the groove so that the brake booster vacuum sensor -2- can be
pulled out of the brake booster.
Fig. 21: Identifying Brake Booster Vacuum Sensor G483 And Securing Ring
Installing
SPECIAL TOOLS
 Vehicle diagnostic, test and information system VAS 5051

 Hose clamps, up to 25 mm 3094
 Diagnostic cable VAS 5051/1 or VAS 5051/3
Fig. 22: Identifying Special Tool - VAS 5051

Fig. 23: Identifying Special Tools - Brakes, Servicing


Electrical System Battery, Starter, Generator, Cruise Control - General Information
Electrical System
Battery, Starter, Generator, Cruise Control - General Information
27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL

GENERAL INFORMATION
ABSORBENT GLASS MAT (AGM) BATTERY
WARNING: Risk of injury. Follow all Warnings and Safety Precautions. Refer to
BATTERY SAFETY PRECAUTIONS.
CAUTION: Do not remove any of the labels on the battery and do not add distilled
water. Only perform a visual inspection. Note the information on battery
testing DIAGNOSIS AND TESTING.
Maintenance-free battery with specific electrolyte without a visual indicator.
Lead-acid battery, where the electrolyte is fixed in an absorbent glass mat (AGM). The battery is closed and
equipped with breather valves.
AGM is the English abbreviation for Absorbent Glass Mat.
These batteries do not have a visual indicator because the electrolyte level is predetermined. AGM is on the
battery to identify it.
NOTE: Always replace an AGM battery with another AGM battery.
BATTERY CHARGING
WARNING: Batteries that have light yellow visual indicator do not have to be tested
or charged. Jump starting must not be used!
There is a risk of explosion during testing, charging or jump starting.
These batteries must be replaced.
BATTERY
CAUTION: In order to prevent damage to the battery or vehicle, observe battery type
descriptions and notes. Refer to GENERAL INFORMATION.
To guarantee a long service life, the battery must be checked, serviced and maintained according to the
guidelines in this information.
In addition to supplying the power to start the engine, the battery acts as a power reserve for the entire vehicle
electrical system.
BATTERY WITH VISUAL INDICATOR
This is a maintenance-free battery with liquid electrolyte (wet battery).
WARNING: Do not check or charge batteries that have a visual indicator that is bright
yellow. Jump starting must not be used!
This battery has a color visual indicator. The visual indicator shows the state of charge and the battery acid
level. Visual indicator, checking, refer to BATTERY WITH VISUAL INDICATOR, CHECKING.
BATTERY WITH VISUAL INDICATOR, ENHANCED
This is a maintenance-free battery with liquid electrolyte (wet battery).

The battery is installed in certain Stop/Start vehicles due to special requirements. "EFB" is written on the
battery cover to identify this battery. "EFB" stands for >>enhanced flooded battery<< (enhanced wet battery).
An "EFB" battery may only be replaced with another "EFB" battery.
An "EFB" battery has a visual indicator for checking the battery electrolyte level.
Visual indicator, checking, refer to BATTERY WITH VISUAL INDICATOR, CHECKING.
NOTE: "EFB" batteries are being installed in smaller gasoline engines with the
Stop/Start system and a manual transmission as of May 2001.
BATTERY SAFETY PRECAUTIONS
Recognizing and Preventing Risks
Batteries present risks. These risks are prevented when the warnings on the battery label, owners manual and in
this Repair Information are observed.
WARNING:  Personnel instructed in protection, such as a trainee or apprentice,

may only perform work on vehicle batteries under supervision of
technical personnel such as a master automotive mechanic or a
master automotive electrician.
 Acid has strong corrosive properties. If batteries are handled
inappropriately, there is a risk that personal injury may result from
exposure to harmful electrolyte influences. Therefore, suitable
remedies for acid damage must be kept readily available. Suitable
remedy is a soap solution.
 If electrolyte drips out from the battery, skin can be burned by acid
and the vehicle may be affected by acid erosion and corrosion. It is a
possibility that safety-related vehicle components can be damaged.
 When charging and when testing after charging, explosive gas is
present. In extreme cases, if battery is handled inappropriately, the
emitted gases may cause the battery to explode.
 Batteries whose visual indicators are bright yellow must be
replaced. They may not be tested or charged and jump starting may
not be used. There is a risk of explosion during testing, charging or
jump starting.
 Generating sparks by sanding, welding, separating work and open
flame, for example smoking in vicinity of the battery, is prohibited.
Producing sparks through electrostatic discharge must also be
avoided. Always touch the vehicle body before touching the battery.
 Only perform battery procedures in suitable and well-ventilated

rooms.
BATTERY POST/TERMINAL
CAUTION: In order to prevent damage to the battery terminals and battery posts,
observe the following:
 Never use force to attach the battery terminals by hand.

 Do not apply grease to battery posts.
 The battery terminal clamps should be mounted so that the battery
terminal sits flush with the clamp or protrudes out of it.
 After tightening the battery terminal clamps to the specified torque,
the threaded connections must not be tightened again.
BATTERY SAFETY LABEL
Battery Safety Designation
Fig. 1: Identifying Details Of Battery Safety Label

1. - When working in the area of the battery, fire, sparks, open light and smoking are prohibited. Avoid sparks
when working with cables and electrical devices, and from electrostatic discharge. Avoid short circuits. For this
reason, tools should not be rested on the battery.
2. - Eye protection must be worn when working on the battery.
3. - Always keep electrolyte and batteries out of reach of children.
4. - Disposal: Old batteries require special disposal. They may only be disposed of at a suitable collection
facility and only in consideration of legal regulations.
5. - Do not dispose of old batteries in household waste.
6. - When handling batteries, there is a risk of explosion. Battery charging produces a highly explosive gas
mixture.
7. - Always observe notes on battery in ELSA "Electrical Equipment - General Information" and in the owner's
manual.
8. - Battery acid can cause severe burns! Battery acid is severely corrosive, therefore protective gloves and eye
wear must be worn when working on the battery. The battery must not be tipped, because acid may spill from
the ventilation openings.
INSPECTING
CAUTION:  An improperly secured battery can lead to damage.

 Excessive vibration due to an improperly secured battery will reduce
the battery service life, and the battery hold-down bracket could
damage the battery housing and lead to electrolyte leakage.
 Check battery for secure fitting, if necessary tighten mounting bolt to
specified tightening specification.
Prior to performing any measurements or tests, perform a visual check of the battery condition, battery
terminals and secure mounting of battery.
By performing visual inspection, it can be determined
 If the battery case is damaged. Acid can leak out if the case is damaged. Battery acid that has leaked out
can cause sever damage to the vehicle. Acid that has leaked onto any part of the vehicle should be
immediately treated with acid neutralizer or soap solution.
 If the battery terminals (battery wiring connections) are damaged. If the battery terminals are damaged,
contact with battery terminals clamps cannot be guaranteed. When connecting the battery pole shoes,
keep in mind that the tightening specification from the Electrical Equipment repair information for the
corresponding vehicle is used. If the battery post clamps are not correctly installed and secured, the
wiring may burn. Substantial malfunctions to the electrical system are a consequence. Safe operation of
the vehicle can no longer be guaranteed.
SEVERELY DISCHARGED BATTERIES
WARNING: Batteries that have light yellow visual indicator do not have to be tested
CAUTION:  Severely discharged batteries freeze earlier.

 Batteries that have frozen must no longer be used.
For a battery to be indicated as "severely discharged" , the resting voltage must be less than 11.6 V.
NOTE: Severely discharged batteries in vehicles must be replaced prior to delivery.

Pre-existing damage cannot be ruled out.
Batteries which have not been used in driving operation for a long time, for
example in stored vehicles, discharge themselves.
In severely discharged batteries, the electrolyte consists almost completely of

water, because the acid portion has been greatly reduced.
Exhaustively discharged batteries become sulfated, i.e. all the plate surfaces of
such batteries become hardened.
The sulfating process may be largely reversed if a severely discharged battery

is recharged immediately.
If the battery is not recharged, the plates will continue to harden, and the ability
to accept a charge will diminish. This results in reduction of battery
performance.
-- Check no load voltage. Refer to DIAGNOSIS AND TESTING.
CRUISE CONTROL SYSTEM

General Description
Cruise Control System functions are controlled by the Engine Control Module (ECM).
-- Cruise Control System can be activated / deactivated. Refer to CRUISE CONTROL SYSTEM,
ACTIVATING AND DEACTIVATING.
DTC Recognition and Display
Malfunctions in relation to Cruise Control System (CCS) are sent via the Engine Control Module (ECM).
Use the Vehicle diagnostic tester in the "Guided Fault Finding" mode for fault finding.
BATTERY TESTER VAS 6161
Fig. 2: Identifying Battery Tester VAS 6161 With Printer

1 - Integrated printer
2 - Operating lever for the paper tray
3 - Paper slot
4 - LCD screen with main menu
5 - ON/OFF switch
7 - Slot for the memory card
8 - Infrared temperature sensor
9 - PC file transmitter
When using VAS 6161 it is not necessary to disconnect or remove the battery.
The VAS 6161 no longer is loading the battery. It is working according to the principle of dynamic
conductivity.
All battery types are stored in the tester.
The data can be stored on a SD memory card.
The VAS 6161 can be updated using an interface or an SD memory card, so that all battery data from
Volkswagen is current.
The integrated temperature sensor increases the quality of the measurements.
An optional 2D scanner is available to carry over the data from the battery 2D code.
NOTE: Read the Operating Instructions that come with the VAS 6161.
BATTERY CHARGER VAS 5903
The -VAS 5903- is designed to charge all 12 Volt batteries in the VW group.
Battery Charger VAS 5903

Fig. 3: Identifying Battery Charger VAS 5903

Fig. 4: Identifying Control Panel For Battery Charger VAS 5903

Control Panel Overview
1 - Display
2 - Adjustment button "Up" ?
3 - Adjustment button "Down" ?
4 - START / STOP
5 - INFO
MIDTRONICS BATTERY TESTER MCR340V
WARNING: Risk of injury.
Read and follow the Safety Precautions when working with batteries.
Refer to BATTERY SAFETY PRECAUTIONS.
Dispose of electrolyte (sulfuric acid/water mixture) safely. Electrolyte

must be taken to approved locations that accept it. Follow local disposal
ordinances.
Do not check gas batteries. Danger of explosion.

WARNING: Batteries that have a light yellow visual indicator do not have to be tested
NOTE: To prevent damaging the battery or the vehicle, pay attention to the battery type
and notes. Refer to GENERAL INFORMATION.
Only Volkswagen approved battery testers may be used to test batteries in Volkswagen vehicles. Use the
MCR340V battery tester in the USA and Canada.
Read the Safety Precautions, setup and operating instructions that come with the MCR340V battery tester.
For more information refer to Self Study Program No. Vehicle Batteries.
The following charging and analysis procedures applied to all batteries, all battery installed locations (engine
compartment or luggage compartment) and all battery purposes (for the starter or for the second/comfort
battery).
Always follow the Safety Precautions, the instructions for setting up the battery tester, the display menu/display
buttons, LEDs and the procedures in the MCR340V Operating Instructions.
NOTE: Always read all information, notes and instructions for testing batteries.
MIDTRONICS BATTERY CHARGER INC 940
Keep open flame or sparks away from the batteries and do not smoke.
The battery charger must be switched off whenever connecting or

disconnect the cable.
Do not remove the plugs while charging.
Overcharging sulfated batteries can cause an explosion.
Precision tools may not be kept in areas where batteries are charged.
Chemical reactions can lead to corrosion.
Only Volkswagen approved battery chargers may be used to charge batteries in Volkswagen vehicles. The INC
940 battery charger is used in the USA and Canada.
The INC 940 battery charger combines battery charging with checking the state of charge and testing the
battery.
The following charging and analysis procedures applied to all batteries, all battery installed locations (engine
compartment or luggage compartment) and all battery use purposes (for the starter or for the second/comfort
battery).
Always follow the Safety Precautions, the instructions for setting up the battery charger, the display
menu/display buttons, LEDs and the procedures in the INC 940 Operating Instructions.
Carefully read the INC 940 Operating Instructions.
For more information refer to Self Study Program No. Vehicle Batteries.
ABSORBENT GLASS MAT (AGM) BATTERY, CHECKING
Perform battery checks in the following sequence
-- Visual inspection. Refer to INSPECTING.
NOTE: Battery tester VAS 6161 is used for Warranty testing.
-- Battery, load testing using
-- Battery Tester VAS 6161 refer to BATTERY TESTER VAS 6161.
-- Midtronics MCR340V, refer to MIDTRONICS BATTERY TESTER MCR340V.
-- Depending on the result of the battery test, perform a current draw test. Refer to CURRENT DRAW TEST.
BATTERY WITH VISUAL INDICATOR, CHECKING
Perform battery checks in the following sequence
-- Visual inspection. Refer to INSPECTING.
-- Check the visual indicator, refer to VISUAL INDICATOR, 3-COLOR, CHECKING or VISUAL
INDICATOR, 2-COLOR, CHECKING.
NOTE: Battery tester VAS 6161 is used for Warranty testing.
-- Battery, load testing using
-- Battery Tester VAS 6161, refer to BATTERY TESTER VAS 6161.
-- Midtronics MCR340V, refer to MIDTRONICS BATTERY TESTER MCR340V.
-- Depending on the result of the battery test, perform a current draw test. Refer to CURRENT DRAW TEST.
BATTERY CHARGER VAS 5903
BATTERY, CHARGING
 Battery Charger VAS 5903 -VAS 5903-

NOTE: The battery temperature must be at least 10 °C (50° F).
-- Turn off the ignition and all electrical consumers.
-- Plug in the electrical system connector of the charger. The last selected operation mode is shown on the
display. Refer to BATTERY CHARGER VAS 5903.
-- Select battery type using INFO .
Fig. 5: Identifying Charging Unit Displays - Standard Charge (Wet Batteries Or AGM Batteries)
The symbol -1- for "standard charge of wet batteries" or the symbol -2- for "standard charge of Gel/Absorbant
Glass Mat (AGM) batteries" is indicated in the display.
-- Set the capacity (Ah) of the battery to be charged with the corresponding button "Up" ? or "Down" ? .
-- Clamp the red charging clamp "+" to the positive battery terminal.
NOTE: In the case of vehicles with a start/stop function and an installed battery
monitoring control module J367, the black charge terminal - must be connected
to the body ground. The start/stop system will malfunction if it is connected to
the negative terminal on the battery.
-- Connect the black charging clamp "-" to the negative battery terminal.
The charger recognizes the nominal voltage of the connected battery (6V, 12V, or 24V) and begins the charging
process automatically.
At a charge condition of approximately 80 - 85%, charging unit begins the "Final-charging". The fourth bar is
indicated on the display -1-. The battery is ready for operation.
Fig. 6: Identifying Charging Unit Display, Charge Condition Approx. 80 - 85 %

With a charge status of 100 %, all bars are indicated on the display.
Fig. 7: Identifying Charging Unit Display, Charge Condition 100 %

NOTE: With the battery type "standard charge" , parallel operation of consumers
during the charging process is possible. The charging time is lengthened by
this.
Depending on battery type, the charger switches over to sustain charging after
approximately 1-7 hours. To achieve a 100% charge status, the battery should
remain connected to the charger for that long.
Possible Malfunctions and How They Are Handled
1. Displayed Voltage Does Not Match The Nominal Voltage
-- Hold the appropriate button "Up" ? or "Down" ? until the charging process begins.
2. Displayed Battery Voltage Does Not Match Rated Voltage - Charging Process Has Already Begun
-- Press START / STOP twice.
3. The Charger Does Not Recognize A Battery, When The Battery Voltage Is Less Than 2 Volts
The display remains unchanged.
The selected battery type and Ampere hours (Ah) are displayed.
End Battery Charging Process
-- Press START / STOP .
-- Remove the black charging clamp "-" of the charger from the negative battery terminal.
-- Remove the red charging clamp "+" of the charger from the positive battery terminal.
-- Pull out the electrical system connector of the charger.
REFRESH CHARGING
 Battery Charger 5903
CAUTION: "Refresh charging" is not permitted for VW vehicles, because voltage

surges can damage the on-board electronics.
If "Refresh charging" is still used, the battery must always be separated

from the vehicle electrical system.
CAUTION: During the charging process, always set the operation mode
corresponding with the battery. Refer to Operation instructions for VAS
5903!
Refresh charging is suitable for:
 Wet batteries, which can be filled with distilled water.
Do not use Refresh charging on maintenance-free wet batteries.
"Refresh charging (Refr)" is only used on batteries that are possibly defective (for example sulfation). Thereby
the battery is charged to the maximum specific gravity of electrolyte and the plates are reactivated (removal of
sulfation layer).
NOTE: The battery temperature must be at least 10 °C (50° F).

Fig. 8: Identifying Battery Charger Displays - Standard Charge (Wet Batteries Or AGM Batteries)
The symbol -1- for "refresh - charging wet batteries" or the symbol -2- for "refresh - charging of Gel/Absorbant
The charger recognizes the nominal voltage of the connected battery (6 Volt, 12 Volt, or 24 Volt) and begins
the charging process automatically.
At a charge condition of approximately 80 - 85% of the battery voltage, charging unit begins the "Final-
charging". The fourth bar is indicated on the display -1-. The battery is ready for operation.
Fig. 9: Identifying Charging Unit Display, Charge Condition Approx. 80 - 85 %

NOTE: The "Refresh charging" process is dependent on the degree of sulfation of the
battery.
Possible Malfunctions and How They Are Handled
1. Displayed Voltage Does Not Match The Nominal Voltage
2. Displayed Battery Voltage Does Not Match Rated Voltage - Charging Process Has Already Begun
-- Press START / STOP twice.
3. The Charger Does Not Recognize A Battery, When The Battery Voltage Is Less Than 2 Volts
The display remains unchanged.
The set operating mode and Ampere-hours (Ah) are displayed.
End Battery Charging Process
SEVERELY DISCHARGED BATTERY
CAUTION:  The polarity protection of the charger clamps is not active in the
operation mode "charging severely discharged batteries/Support
mode". Connect the charger clamps to the battery terminals correctly
according to polarity!
 During the charging process, always set the operation mode
corresponding with the battery. Refer to Operation instructions for
VAS 5903!
 The severely discharged battery is not recognized by the charger.
Refer to SEVERELY DISCHARGED BATTERIES.
 Do not touch START / STOP when battery cables are incorrectly
connected! The charger can be damaged.
It is not possible for the VAS 5903 to automatically recognize batteries with voltage under 2 Volts.
NOTE: Observe the notes regarding SEVERELY DISCHARGED BATTERIES.
Severely discharged batteries in vehicles must be replaced prior to delivery.

Pre-existing damage cannot be ruled out.
The battery temperature must be at least 10 °C (50° F).
Fig. 10: Identifying Setting Corresponding Operating Mode To Battery Type

The symbol -1- for "service charge of wet batteries" or the symbol -2- for "service charge of Gel/Absorbant
-- Press START / STOP for approximately 5 seconds. The menu selection "Charging severely discharged
batteries/Support mode" is activated.
-- Press corresponding button "Up" ? or "Down" ? , to set respective battery voltage (6 V, 12 V or 24 V).
NOTE: If no button is touched within 5 seconds, the charger will return to the main
menu (operation mode selection).
-- Confirm the selected battery voltage by pressing START / STOP .
Then the inquiry about the correct polarity of the charger clamps is made.
-- Verify that the charger clamps are connected to the correct polarity.
-- Confirm that the charger clamps are connected to the correct polarity by pressing START / STOP .
The charger begins charging the severely discharged battery.
End battery charging process
SUPPORT MODE
General Information
The support mode provides the vehicle electrical system with voltage with the battery is removed or
disconnected.
For more information, refer to VAS 5903 Operating Instructions.
The support mode is used for the following situations:
 Vehicle electrical system support mode with the battery not installed
 Maintaining the voltage when the battery is being replaced
 Testing without the battery

CAUTION:  The polarity protection of the charger clamps is not active in the
operation mode "charging severely discharged batteries/Support
mode". Connect the charger clamps to the battery terminals correctly
according to polarity!
 It can result in sparks due to short circuit.
 This constitutes an explosion risk.
 Make sure the charger clamps are secure.
 Do not touch START / STOP when battery cables are incorrectly
connected! The charger can be damaged.
-- Remove the battery.
CAUTION: Whenever the battery is removed, be careful to prevent contact between

the connected charge clamp on the positive terminal and the body ground.
Likewise prevent contact between the battery terminals.
-- Connect the red charging clamp "+" to the vehicle positive terminal.
-- Connect the black charging clamp "+" to the vehicle negative terminal.
-- Press START / STOP for approximately 5 seconds. The menu selection "Charging severely discharged
batteries/Support mode" is activated.
-- Press corresponding button "Up" ? or "Down" ? , to set respective battery voltage (6 V, 12 V or 24 V).
NOTE: If no button is touched within 5 seconds, the charger will return to the main
menu (operation mode selection).
-- Confirm the selected battery voltage by pressing START / STOP .
Then the inquiry about the correct polarity of the charger clamps is made.
-- Verify that the charger clamps are connected to the correct polarity.
-- Confirm that the charger clamps are connected to the correct polarity by pressing START / STOP .
The battery charger starts the battery support mode.
End the battery support mode
-- Remove the black charging clamp "-" of the charger from the negative battery terminal of the vehicle.
-- Remove the red charging clamp "+" of the charger from the positive battery terminal of the vehicle.
MAINTENANCE CHARGING
NOTE: If battery is discharged by an electrical consumer during charge retention, the

VAS 5903 automatically supplies the corresponding charge.
Charge retention can be performed without time restrictions.
The battery can be used constantly.
Observe the maintenance notes of the battery manufacturer.
If the battery is fully charged, the VAS 5903 begins to sustain the charge.
-- Proceed as when charging the battery. Refer to BATTERY, CHARGING.
With a charge status of 100%, all bars are indicated on the display.
Fig. 11: Identifying Charging Unit Display, Charge Condition 100 %

BATTERY TESTER VAS 6161
BATTERY TEST
 Battery Tester VAS 6161
Procedure
-- Battery with visual indicator, checking color display, refer to BATTERY WITH VISUAL INDICATOR,
CHECKING.
-- Switch on the unit.

-- Clamp the red clamp "+" of the tester to the positive terminal.
-- Clamp the black clamp "-" on the tester to the negative terminal.
NOTE: Make sure the test clamps make good contact!
-- Select the following:
 Warranty testing batteries within the warranty time, refer to WARRANTY TEST, PERFORMING.
 Maintenance test (only on new vehicles before becoming inventory), refer to MAINTENANCE TEST,
PERFORMING.
 Service test for batteries no longer under warranty and replacement batteries, refer to SERVICE TEST,
PERFORMING.
NOTE: The test is over after approximately 10 seconds.
The results of the test are output through the printer.
It is not necessary to let the tester cool down before performing the next
measurement.
WARRANTY TEST, PERFORMING
-- Select "Warranty Test".
-- Select "inside the vehicle" or "outside of the vehicle".
-- Select "at the battery pole" or "at the battery jump start terminal".
-- Scan in the battery 2D code or manually select battery type and current strength.
-- Measure the temperature. Hold the temperature sensor approximately 5 cm above the battery pole until the
temperature is stable.
-- Start the test.
-- Print out the test report if necessary.

MAINTENANCE TEST, PERFORMING
-- Select "Maintenance Test".
-- Connect the scanner.
NOTE: If there is no scanner, manually enter the VIN on the printed test results.
-- Scan the VIN.
-- Scan in the battery 2D code or manually select the type and manufacturer in the menu.
-- Measure the temperature. Hold the temperature sensor approximately 5 cm above the terminal connection
until the temperature is stable.
-- Start the test.
SERVICE TEST, PERFORMING
-- Select "Service Test".
-- Select the type of battery: "standard" , "AGM" , "2*6V" or "Gel".
-- Select the "CCA" , "JIS" , "DIN" , "SAE" , "IEC" or "EN".
-- Select battery value.

-- Measure the temperature. Hold the temperature sensor approximately 5 cm above the battery pole until the
temperature is stable.
-- Start the test.
EXPLANATION OF TEST RESULTS
Fig. 12: Identifying Details Of Printed Test Results

1. Type of test.
2. Battery test result.
3. Measured voltage
4. Measured cold start value.
5. Cold start nominal value set on the tester
6. Measured battery temperature
7. Batter installed location
8. Location of the battery terminal set on the tester

9. Selected battery.
NOTE: The printed test results are required for warranty claims.
EVALUATING TEST RESULTS
Evaluating the battery test results for the Warranty and Service Tests
Battery Test Result Measure

Battery good No measure on the battery
Battery good - recharge Battery, charging, refer to BATTERY CHARGER
VAS 5903 or MIDTRONICS BATTERY
CHARGER INC 940. If necessary, search for the
cause of the discharging.
Perform a current draw test Perform a current draw test, refer to CURRENT
DRAW TEST. Charge the battery completely, refer
to BATTERY CHARGER VAS 5903 or
and test again.
Replace the battery Disconnect the battery and test again. "Replace the
battery" can result because the cable contact is weak.
Battery cell faulty - replace Replace the battery
Check the connection Connect the cable directly to the battery and not to
the battery jump start terminal.
Evaluating the battery test results for the Maintenance test
Battery Test Result Measure

Battery good No measure
Charge the battery immediately Charge the battery completely, refer to BATTERY
CHARGER VAS 5903 or MIDTRONICS
BATTERY CHARGER INC 940.
Mark as defective Mark as defective.
Check the tester connection Disconnect the battery and test again. The result
"check the tester connection" can occur because the
cable contact is weak.
Check the connection Connect the cable directly to the battery and not to
the battery jump start terminal.
Noises Wait until the measured value appears in the display.
CRUISE CONTROL SYSTEM, ACTIVATING AND DEACTIVATING
-- Connect the Vehicle Diagnostic Tester. Refer to VEHICLE DIAGNOSIS, TESTING AND
INFORMATION SYSTEMS .
-- On the vehicle diagnostic tester, select "Guided Fault Finding".
-- Using the "Go To" button, select "Functions/Component selection" and the following menu options in
sequence:
 Powertrain
 Engine code
 01 - On Board Diagnostic (OBD) capable systems
 Engine management system or Diesel Direct Injection & Glow Plug System
 Functions
 Cruise Control System, Activating and Deactivating
CURRENT DRAW TEST
NOTE: Make sure the correct charging mode is set on the charger so the current draw
test is not inaccurate.
VAS 5903, refer to BATTERY CHARGER VAS 5903.
In order to receive an indication as quickly as possible of the battery condition of discharged batteries, a
conclusion can be made during the charging process using the current draw as to whether the battery should be
replaced or charged completely.
NOTE: In the case of the battery tester VAS 6161, the current draw test must always be
conducted when the test result "conduct current draw test" appears in the
display.
Always perform a current draw test when
 The test result from the VAS 5903 shows the following:
1 - Starting power sufficient

2 - Starting power insufficient
3 - Starting power very insufficient
4 - not able to test - charge the battery and test again
- and in cases in which the unit does not switch on (no LED, no print-out)
or
 The test result from the VAS 6161 shows the following:
1 - Perform a current draw test
Depending on the results of the test EVALUATING TEST RESULTS, additional test steps or activities for a
clear evaluation of the battery condition must be made.
By checking a battery's current draw capacity during the charging procedure, it can be determined in a short
time whether a partially discharged or severely discharged battery SEVERELY DISCHARGED
BATTERIES can become operable again by further charging.
Test Prerequisites
 The battery temperature must be minimum greater than or equal to 50° F (10 °C) when charging.
 The charger must be able to deliver at least 30 A charging current, such as the VAS 5903.
 When charging using the Battery Charger VAS 5903 indicates the current draw on the device.
-- Connect the battery to the battery charger and start the charging process.
-- Measure the battery charge current after five minutes.
Test Result
When current draw is greater than 10% of nominal capacity Ah (for example 6.1 A at 61 Ah battery), fully
charge the battery and retest.
NOTE: On the Eos with two 6V AGM batteries, the charge current must only be greater
than 5% of the battery nominal capacity in Ampere. As an example for the Eos:
the 50 Ah battery must have a charge current greater than 2.5 A after charging
for five minutes.
-- Charge the battery completely when the charge current is greater than 10% of the nominal capacity (note
exception for Eos in the note above).
-- After resting the battery for two hours, perform a battery test. Refer to BATTERY TEST.
If the charge current is less than 10% of the nominal capacity (two 6 Volt batteries in the Eos 5%) five minutes
after starting the test (that is, for a 50 Ah battery less than 5A), then replace the battery. Fill out the battery
check sheet for warranty and goodwill cases.
BATTERY CHARGING
Requirements
INC 940 output - setup performed (unit number, date / time). Refer to INC 940 Operating Instructions.
-- General Information, checking, refer to MIDTRONICS BATTERY CHARGER INC 940.
-- Open the hood or open the cover if the battery is installed somewhere else.
-- Visually inspect the battery. Refer to INSPECTING.
-- Determine if it is a "standard" battery (wet battery) or an "AGM" battery.
-- Close all the vehicle doors.
NOTE: Battery temperature must be at least 50° F (10 °C).
Refer to the INC 940 Operating Instructions for more information.
Procedure
-- Turn off all electrical consumers.
-- Switch off ignition and remove ignition key.
-- Clamp the red charging clamp "+" of the charger to the positive battery terminal.
-- Connect the black charging clamp "-" of the charger to the negative battery terminal.
-- Connect the INC 940 battery charger to a grounded outlet.
-- Switch the "ON/OFF" switch on the INC 940 battery charger to "ON".
-- Select the charge mode "automatic" or "manual".
-- Select the test: "inside the vehicle" or "outside of the vehicle".
-- Determine if it is a "standard" battery or an "AGM" battery.
-- Select the type of test: "Warranty" or "other". Note any other additional details (depending on the type of
test).
NOTE: Refer to the INC 940 Operating Instructions for more information.
If necessary, go through all the menu points when performing a "Warranty" test.
Refer to Warranty Service Circulars.
The INC 940 battery charger checks the battery and starts the charging process. The display then shows one of
three results with the exact charging time.
Result: Measure:
Batter good The battery can be used again.
Charging is required  The test shows a low state of charge.
 The charging process begins and the exact
duration for the charging will be displayed
 The cold start performance and the remaining
charging time are displayed and updated
regularly.
Replace the battery Battery faulty. The charging process is interrupted.
Replace the battery.
NOTE: If other malfunction messages or text displays, other than ones already
mentioned, appear in the display on the INC 940 battery charger, then refer to
TROUBLESHOOTING.
WARNING: If the battery starts to vent gas heavily, stop the charging process. Press
the "Stop" button on the front side.
After the charging and testing process is completed, the INC 940 battery charger will display "battery good" or
"replace the battery" as well as the total charging time.
Depending on the individual circumstance (Warranty Claim, Repair Order, Evaluation and File), there are three
possible messages:
 Produce a test code (possible only after automatic charging and testing).
 Print last test result (for Warranty)
 Display the last test result.
NOTE: Refer to the INC 940 Operating Instructions for more information.
TROUBLESHOOTING
Sometimes the display shows the malfunction or the messages based on the condition.
The following is a list of the most frequent displayed messages together with suggested solutions.
NOTE: Refer to the INC 940 Operating Instructions for messages not listed here.
Display Message Measure

Check the connection -- Make sure the battery charger terminals are
attached securely to the battery terminals. -- Make
sure the battery pole is tightened to the tightening
specification and is not corroded.
Terminals connected? Tester safety function. -- Connect the terminals to
the battery before charging.
System noises -- Switch off all electrical consumers. -- Wait until
all electrical consumers, which are monitored by the
vehicle electrical system control module, are
switched off. -- Remove the key. -- Disconnect any
doubtful or standard production electrical equipment
Wait a few minutes and repeat the charging process. Refer to BATTERY CHARGING.
MIDTRONICS BATTERY TESTER MCR340V
BATTERY TEST
Requirements
WARNING: Read and follow the Safety Precautions when working with batteries.
Refer to BATTERY SAFETY PRECAUTIONS.
Batteries that have a light yellow visual indicator do not have to be tested
-- Read the General Description. Refer to MIDTRONICS BATTERY TESTER MCR340V.
-- Visually check the battery. Refer to INSPECTING.
-- Open the hood or open the cover if the battery is installed somewhere else.
-- Determine if it is a "Standard" battery or an "AGM" battery.
-- Remove the covers on the battery positive and negative terminals.
-- Use a fender protector or some type of cover before using any equipment inside the engine compartment or
inside the passenger compartment.
-- Close all the doors.
NOTE: Battery temperature must be at least 50° F (10 °C).
Refer to the INC 940 Operating Instructions for more information.
Procedure
-- Check the visual indicator. Refer to BATTERY WITH VISUAL INDICATOR, CHECKING.
-- Switch on the unit.
-- Clamp the red clamp "+" of the tester to the positive terminal.
-- Clamp the black clamp "-" on the tester to the negative terminal.
NOTE: Make sure the test clamps make good contact!
-- Select "inside the vehicle" or "outside of the vehicle".

-- Select "Warranty Test".
NOTE: In case the test results are needed to process a warranty claim, use the print
feature on the Midtronics MCR340 battery tester.
-- Determine if it is a "Standard" battery or an "AGM" battery.
-- Enter the battery DIN value taken from the battery label. If the label does not state a DIN value, then enter the
SAE value.
-- Enter the DIN value into the tester and then perform the battery test. Refer to MCR340V Operating
Instructions.
-- If using an SAE value, go into the menu under "other" and change "DIN" to "SAE". Refer to MCR340V
Operating Instructions.
NOTE: Always use the DIN value on the battery label. Otherwise the test result will be
incorrect.
EVALUATING TEST RESULTS
Battery test result
Battery test result Measure

Battery good None
Good - charge Charge battery using MIDTRONICS BATTERY
CHARGER INC 940.
Use In charge Charge battery using MIDTRONICS BATTERY
CHARGER INC 940.
Replace the battery Replace the battery. Refer to [For engine(s)
BPY,BLV,CCTA,CBFA] Removal and
Installation .
Battery cell defective Replace the battery. Refer to [For engine(s)
BPY,BLV,CCTA,CBFA] Removal and
Installation .
TROUBLESHOOTING
Sometimes the display shows the malfunction or the messages based on the condition.
The following is a list of the most frequent displayed messages together with suggested solutions.
NOTE: Refer to the MCR340V Operating Instructions for messages not listed here.
Display Message Measure

No display -- Make sure the battery tester terminals are attached

securely to the battery terminals. -- Make sure the
battery pole is tightened to the tightening
specification and is not corroded. -- Charge battery
using MIDTRONICS BATTERY CHARGER
INC 940.
System noises -- Switch off all electrical consumers. -- Wait until
all electrical consumers, which are monitored by the
vehicle electrical system control module, are
switched off. -- Remove the key. -- Disconnect any
doubtful or standard production electrical equipment
Wait a few minutes and then perform the test again. Refer to BATTERY TEST.
NOTE: If the test was performed at the battery jump start terminal and the message still
does not go away, then perform the test directly on the battery.
VISUAL INDICATOR, 3-COLOR, CHECKING
Visual Indicator General Information
Applies to all original equipment batteries with index "1J0" , "7N0" and "3B0" and to all replacement batteries,
part number 191 915 105 AB, and beginning with index "000 915 105 AX".
The visual indicator shows the electrolyte level and the battery state of charge.
To obtain an accurate reading, gently tap the charge indicator with a screwdriver handle or rock vehicle slightly.
By doing this, the air bubbles that occur normally during battery charging (even during vehicle operation) that
adversely affect charge indicator reading will be displaced. The visual indicator will be more accurate.
NOTE: Air bubbles can especially form under visual indicator when a battery is
charged, including when charged while driving. This will cause an incorrect
color display.
The display is valid for only that one battery cell in which the visual indicator is
located. An exact assessment of the battery condition is only possible by
performing a battery load test. Refer to MIDTRONICS BATTERY TESTER
MCR340V or BATTERY TESTER VAS 6161.
The visual indicator may be located on different locations on the battery.
There are three possible color indications:
 >>Green<< : Battery is sufficiently charged.

 >>Black<< : Insufficiently charged, less than 65% or discharged.
 >>Colorless or light yellow<< , battery must be replaced.
VISUAL INDICATOR, 2-COLOR, CHECKING
Visual indicator General Information
The general introduction of the 2-color display began as a running change in 2009. The color green for the state
of charge was discontinued on the 2-color.
The visual indicator shows the battery acid level.
It is no longer possible to read the battery state of charge using the visual indicator. It is necessary to perform a
battery test. Refer to BATTERY TESTER VAS 6161 or MIDTRONICS BATTERY TESTER MCR340V
To obtain an accurate reading, gently tap the charge indicator with a screwdriver handle or rock vehicle slightly.
By doing this, the air bubbles that occur normally during battery charging (even during vehicle operation) that
adversely affect charge indicator reading will be displaced. Thereby, the color indicator of the visual indicator is
more accurate.
NOTE: Air bubbles can especially form under visual indicator when a battery is
charged, including when charged while driving. This will cause an incorrect
color display.
The display is valid for only that one battery cell in which the visual indicator is
located. An exact assessment of battery condition should always be confirmed

by performing battery charge test using BATTERY TESTER VAS 6161 or
MIDTRONICS BATTERY TESTER MCR340V.
The visual indicator may be located on different locations on the battery.
Two color displays are possible
 Black, the electrolyte level is OK

 Bright yellow, the electrolyte level is too low. The battery must be replaced.
SPECIAL TOOLS
Fig. 13: Identifying Battery Charger VAS 5903

 Battery Tester VAS 6161

Fig. 14: Identifying Battery Tester VAS 6161

Electrical System Battery, Starter, Generator, Cruise Control
Electrical System
Battery, Starter, Generator, Cruise Control
27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL

GENERAL INFORMATION
ADAPTIVE CRUISE CONTROL
NOTE: Additional information:
Refer to Owner's information.
Refer to the appropriate SYSTEM WIRING DIAGRAMS information.
General Description:
Automatic Distance Regulation (ADR) is a driver assistance system which expands the Cruise Control System
(CCS). By reducing engine torque and any braking intervention, an ADR-vehicle maintains an adjustable
following distance to the vehicle driving ahead of it. Status of ADR system is influenced by the Adaptive Cruise
Control Button -E357- on steering column, accelerator and brake pedals, selector lever as well as interventions
of other assistance systems within the vehicle.
DTC Recognition and Display:
Distance Regulation Control Module -J428- is equipped with On Board Diagnostics (OBD) which assists
troubleshooting.
The "Guided Fault Finding" function is to be used for troubleshooting of one of the systems described in
CRUISE CONTROL SYSTEM .
The distance regulation control module must be adapted prior to first use and/or after replacement, refer to
AUTOMATIC DISTANCE REGULATION, INITIALIZING.
CRUISE CONTROL SYSTEM
Cruise Control System functions are controlled by the Engine Control Module (ECM).
Cruise Control Switch -E45- is a structural component of Steering Column Combination Switch -E595- and
cannot be replaced by itself.
-- Removing and installing Steering Column Combination Switch (with Cruise Control Switch), refer to
STEERING COLUMN COMBINATION SWITCH -E595- , THROUGH 10.09 .
-- Cruise Control System can be activated/deactivated. Refer to CRUISE CONTROL SYSTEM,

ACTIVATING AND DEACTIVATING .
Malfunctions in relation to Cruise Control System (CCS) are sent via the Engine Control Module (ECM).
The "Guided Fault Finding" function is to be used for troubleshooting of one of the systems described in
CRUISE CONTROL SYSTEM .
BATTERY WARNINGS AND CAUTIONS
WARNING: Risk of injury. Observe warning notes and safety precautions! Refer to
BATTERY SAFETY LABEL !
CAUTION: In order to prevent damage to the battery or vehicle, observe battery type
descriptions and notes. Refer to General Information .
BATTERY, GENERAL INFORMATION
All instructions and information on this topic can be found in the repair information General Information .
BATTERY, DISCONNECTING AND CONNECTING
WARNING: Risk of injury. Observe warning notes and safety precautions. Refer to
BATTERY SAFETY PRECAUTIONS !
The following vehicle battery combinations are installed, depending on vehicle equipment and engine version:
Engine: Engine Compartment Luggage Compartment
Battery
 Battery,
disconnecting and
connecting, refer to
BATTERY IN
All gasoline engines (except 3.6L V6 engine) ENGINE
COMPARTMENT,
DISCONNECTING
AND
CONNECTING.
 Battery, removing
and installing, refer
to BATTERY IN
ENGINE
COMPARTMENT.
Battery
 Battery,
disconnecting and
connecting, refer to
BATTERY IN
LUGGAGE
COMPARTMENT,
DISCONNECTING
AND
CONNECTING.
 Battery, removing
3.6L V6 gasoline engines
and installing, refer
to BATTERY IN
LUGGAGE
COMPARTMENT.
 Pyrotechnic battery
isolator, refer to
PYROTECHNIC
BATTERY
ISOLATOR
COMPONENT
LOCATION
OVERVIEW.
BATTERY POST/TERMINAL
All instructions and information on this topic can be found in the repair information BATTERY
POST/TERMINAL .
BATTERY, TESTING
All instructions and information on this topic can be found in the repair information DIAGNOSIS AND
TESTING .
BATTERY, CHARGING
All instructions and information on this topic can be found in the repair information BATTERY CHARGING .
B+ CABLE MOUNT ON GENERATOR
CAUTION: If the B+ wire is not tightened to the specification, the following may
occur:
 Battery will not be completely charged.

 The complete electrical/electronics systems may fail (disabled
vehicle).
 Fire hazard due to arcing.
 Damage to electronic components and control modules caused by
excessive voltage.
-- The tightening torque for the B+ wire nut -arrow- can be found in FASTENER TIGHTENING
SPECIFICATIONS, GENERATOR, ALL VEHICLES.
Fig. 1: Identifying Terminal B+ Nut

PYROTECHNIC BATTERY ISOLATOR SAFETY PRECAUTIONS
WARNING:  Vehicles with battery in luggage compartment are equipped with a

battery isolator to increase crash safety. In the event of a collision,
the airbag control module triggers a separation, which disrupts the
power supply wiring to the starter. The battery cut-off takes place
pyrotechnically through a very small explosive charge. To prevent
accidentally triggering a separation when working on the battery or
battery cut-off, you must first disconnect negative battery terminal,
refer to BATTERY, DISCONNECTING AND CONNECTING.
 Observe notes for disposal of battery isolator units, refer to
PYROTECHNIC BATTERY ISOLATOR DISPOSAL.
WARNING:  Testing, assembly, and repairs may only be performed by trained

personnel.
 Battery Ground (GND) strap must be disconnected before
performing any work on the battery isolation system.
 Technician(s) must discharge themselves electrostatically before
touching the battery isolator. This is accomplished by, for example,
touching grounded metal such as water pipes, heating pipes or
metal carriers.
 Always install battery isolator units in the vehicle as soon as they
are removed from the packaging
 If installation work is interrupted, IMMEDIATELY return the battery
isolator unit to its original packaging.
 Battery isolator units must never be left out unattended.
 DO NOT install battery isolator units that have fallen onto a hard
surface, or which have signs of damage.
 Storage and transport are subject to laws for explosive substances.
PYROTECHNIC BATTERY ISOLATOR DISPOSAL
WARNING:  Battery isolator units that have not deployed must be returned in
original packaging for proper recycling/disposal in accordance with
national legislation! Please direct questions to your distributor or
your importer!
 Battery isolator units that have ignited can be disposed of as
industrial waste.
ADAPTIVE CRUISE CONTROL OVERVIEW

Fig. 2: Locating Adaptive Cruise Control Button E357 And Distance Regulation Control Module J428
1. 1 - Adaptive Cruise Control Button -E357-
The adaptive cruise control button is integrated in the cruise control switch on the steering column.
Cruise Control Switch on Steering Column, Removing and Installing, refer to ADAPTIVE CRUISE
CONTROL BUTTON -E357-.
2. 2 - Distance Regulation Control Module -J428-
Distance Regulation Control Module must not be disassembled further and contains the following
 Distance Regulation Control Module -J428-

 Adaptive Cruise Control Sensor -G550-
 Distance Regulation Sensor Heater -Z47-
Distance Regulation Control Module, removing and installing, refer to DISTANCE REGULATION
CONTROL MODULE -J428-.
GENERATOR OVERVIEW (BPY, CCTA & CBFA ENGINES)
Fig. 3: Identifying Assembly Overview: Generator (GEN) - 2.0L TFSI Engine

1. Collar Bolts
 M8 x 45
 23 Nm
2. Collar Bolts
 M8 x 90
 23 Nm
3. Accessories Bracket
 For generator and A/C compressor.
 Tightening sequence, refer to FASTENER TIGHTEN SPECIFICATIONS, GENERATOR.
4. Collar Bolts
 M10 x 45
 45 Nm
5. Protective Cap
6. Hex Head Collar Nut
 M8
7. Phillips Head Screw

 M5 x 21
 4.5 Nm
8. Flat Hex Nut

 M8
9. Washer
 M5
10. Phillips Head Screws

 M4 x 19
 2 Nm

 M4 x 13
 2 Nm
12. Voltage Regulator

 Removing and installing, refer to VOLTAGE REGULATOR, BOSCH or VOLTAGE
REGULATOR, VALEO
13. Generator
 Removing and installing, refer to GENERATOR.
14. Ribbed Belt

 Checking, refer to RIBBED BELT, CHECKING.
15. Ribbed Belt Tensioner
GENERATOR OVERVIEW (BLV ENGINES)

Fig. 4: Identifying Assembly Overview: Generator (GEN) - 3.6L FSI Engine

1. Internal Multi-Point Bolt

 For tensioning element. Refer to item 2.
 M10 x 85
 50 Nm
2. Ribbed Belt Tensioner

3. Collar Bolts
 For generator. Refer to item 17.
 M8 x 90
4. Accessories Bracket
 For generator and A/C compressor.
 Tightening sequence, refer to FASTENER TIGHTEN SPECIFICATIONS, GENERATOR.
5. Socket-Head Bolt
 For accessories bracket. Refer to item 4.
 M8 x 50
 23 Nm
6. Socket Head Fitting Bolts

 For accessories bracket. Refer to item 4.
 M8 x 28
 23 Nm
7. Hex Socket Head Collar Bolts

 For bracket. Refer to item 8.
 M6 x 16
 8 Nm
8. Bracket
 For Recirculation Pump -V55-.
9. Protective Cap
10. Hex Head Collar Nut
 M8

 M5 x 21
 4.5 Nm
12. Flat Hex Nut

 M8
13. Washer
 M5
14. Phillips Head Screws

 M4 x 19
 2 Nm

 M4 x 13
 2 Nm
16. Voltage Regulator

 Removing and installing, refer to VOLTAGE REGULATOR, BOSCH or VOLTAGE
REGULATOR, VALEO.
17. Generator
 Removing and installing, refer to GENERATOR.

18. Ribbed Belt
 Checking, refer to RIBBED BELT, CHECKING.
19. O-Ring
 For idler roller. Refer to item 22.
20. Dust Cap

21. Collar Bolts

 M10x36
 40 Nm
22. Idler Pulley

 With grooved ball bearing.
23. Dust Cap

JUMP START POINT WITH SUPPRESSOR COMPONENT LOCATION OVERVIEW
Vehicles with battery in luggage compartment have an additional outside starter point in the engine
compartment, left side. This consists of Terminal 30 Wire Junction -TV2- and Suppressor -C24-.
Fig. 5: Identifying Outside Starter Point With Suppressor C24

1 - Suppressor -C24-
2 - External starting point
3 - Mounting nut (collar nut) for terminal 30 wire to starter and to threaded connection (30) on E-box.
4 - Mounting nut (collar nut) for terminal 30 wire from Battery Interrupt Igniter -N253- in luggage
compartment, right side
5 - Terminal 30 wire from Battery Interrupt Igniter in luggage compartment, right side
6 - Terminal 30 wire to starter and to threaded connection (30) on E-box.
7 - Harness connector for Suppressor
8 - Bolt
PYROTECHNIC BATTERY ISOLATOR COMPONENT LOCATION OVERVIEW
Depending on equipment, the pyrotechnic battery isolator is installed in conjunction with starter battery in
luggage compartment and is integrated into the main fuse box. Main fuse box is located in the luggage
compartment, left side above the battery.
Fig. 6: Locating Installed Pyrotechnic Battery Isolator

1 - Harness connector on pyrotechnic battery isolator
2 - Mounting nut (collar nut) for B+ wire and pyrotechnic battery isolator in main fuse box
3 - B+ wire
4 - Pyrotechnic battery isolator
5 - Mounting nut (self-locking) for pyrotechnic battery isolator in main fuse box
NOTE: In the event the battery isolator has deployed, pyrotechnic battery isolator must
be replaced.
RIBBED BELT ROUTING (BPY,CCTA & CBFA ENGINES)
Vehicles Without A/C System:
Fig. 7: Identifying Ribbed Belt Routing, 2.0 L FSI Turbo Engine - Vehicles Without A/C System
1. Tension roller
2. Belt pulley - generator
3. Ribbed belt
4. Belt pulley - crankshaft
Vehicles With A/C System:

Fig. 8: Identifying Ribbed Belt - 2.0L TFSI Engine, Routing

1. Tension roller
2. Belt pulley - generator
3. Ribbed belt pulley - A/C compressor
4. Ribbed belt
5. Belt pulley - crankshaft
RIBBED BELT ROUTING (BLV ENGINES)
Fig. 9: Identifying Ribbed Belt - 3.6L FSI Engine, Routing

1. Tension roller
2. Ribbed belt pulley - generator
3. Idler pulley
4. Ribbed belt pulley - A/C compressor
5. Idler pulley
6. Ribbed belt pulley - crankshaft
7. Ribbed belt pulley - coolant pump
8. Ribbed belt
SPECIFICATIONS
FASTENER TIGHTEN SPECIFICATIONS, BATTERY IN ENGINE COMPARTMENT
Tightening
Component Fastener Size
Specifications
Additional
Terminal
M6 6 Nm
On Battery
Terminal
Air Filter
Housing To 10 Nm
Body
Battery
Terminal
M6 6 Nm
To Battery
Pole
Mounting
Bolt For
M8 x 35 20 Nm
Retaining
Bracket
FASTENER TIGHTEN SPECIFICATIONS, BATTERY IN LUGGAGE COMPARTMENT
Tightening
Specifications
Battery
Terminal
M6 6 Nm
To Battery
Pole
Mounting
Bolt For M8 x 35 20 Nm
Retaining
Bracket
FASTENER TIGHTEN SPECIFICATIONS, MAIN FUSE BOX
Tightening
Specifications
B+ Wire
The Nut To
M8 15 Nm
Main Fuse
Box
Duo-Bolt
For
Mounting
Main Fuse
9 Nm
Box To
Main Fuse
Box
Bracket
Lower The
Nut, Self-
Locking,
For
Pyrotechnic M8 15 Nm
Battery
Isolator To
Main Fuse
Box
Mounting
Nut To
M6 9 Nm
Securing
Clamp
FASTENER TIGHTEN SPECIFICATIONS, EXTERNAL STARTING POINT
Tightening
Specifications
Outside
Starter
Point With
M6 9 Nm
Suppressor
-C24- To
Body
Wires To
Terminal 30 M8 15 Nm
Wire
Junction -
Tv2-
FASTENER TIGHTENING SPECIFICATIONS, GENERATOR, ALL VEHICLES
Tightening
Specifications
B+ Lead At
M8 15 Nm
Generator
Protective
Cap To
M5 4.5 Nm
Generator
(Bosch)
Ribbed Belt
Pulley
Without
M10 65 Nm
Freewheel
To
Generator
Ribbed Belt
Pulley With
Freewheel M10 80 Nm
To
Generator
Voltage
Regulator
To
M4 2 Nm
Generator
(Bosch,
Valeo)
Wire
Retainer To M5 3.2 Nm
Generator
FASTENER TIGHTEN SPECIFICATIONS, GENERATOR (BPY,CCTA & CBFA ENGINES)
CAUTION: Always follow the tightening sequence to prevent damaging the cylinder
block and the auxiliary component bracket.
Tightening
Specifications
A/C
Compressor
To M8 x 100 23 Nm
Accessories
Bracket
Accessories
Bracket On
The M10 x 45 40 Nm
Cylinder
Block
Generator
To The
M8 x 90 23 Nm
Accessories
Bracket
Tensioner
To The
Auxiliary M8 x 90 23 Nm
Component
Bracket
FASTENER TIGHTEN SPECIFICATIONS, AUXILIARY COMPONENT BRACKET, VEHICLES WITH A/C

(BPY,CCTA & CBFA ENGINES)
Fig. 10: Identifying Compact Bracket Tightening Sequence, 2.0L FSI Turbo Engine
Procedure
-- Position the accessories bracket on the cylinder block.
NOTE: Insert all bolts before tightening to the specification.

-- Tighten the bolts on the auxiliary component bracket in the following sequence:
A - Cylinder collar bolt, M10 x 45, 40 Nm, alignment bore
B - Cylinder collar bolt, M10 x 45, 40 Nm
C - Cylinder collar bolt, M10 x 45, 40 Nm
D - Cylinder collar bolt, M10 x 45, 40 Nm
E - Cylinder collar bolt, M10 x 45, 40 Nm
F - Cylinder collar bolt, M10 x 45, 40 Nm
FASTENER TIGHTEN SPECIFICATIONS, GENERATOR (BLV ENGINES)
Tightening
Specifications
A/C
Compressor
To M8 x 90 23 Nm
Accessories
Bracket
Accessories
Bracket On
The M8 23 Nm
Cylinder
Block
Generator
To The
M8 x 90 23 Nm
Accessories
Bracket
Tensioner
To The
Auxiliary M10 x 85 50 Nm
Component
Bracket
FASTENER TIGHTEN SPECIFICATIONS, AUXILIARY COMPONENT BRACKET, VEHICLES WITH A/C (BLV
ENGINES)
Fig. 11: Identifying Bracket Tightening Sequence, Vehicles With A/C System
Procedure
-- Position the accessories bracket on the cylinder block.
NOTE: Insert all bolts before tightening to the specification.
-- Tighten the bolts on the auxiliary component bracket in the following sequence:
A - Socket head fitting bolt, M8 x 28, 23 Nm, alignment bore
B - Socket head fitting bolt, M8 x 28, 23 Nm, alignment bore
C - Multipoint socket bolt, M8 x 50, 23 Nm
D - Multipoint socket bolt, M8 x 50, 23 Nm
E - Multipoint socket bolt, M8 x 50, 23 Nm
FASTENER TIGHTEN SPECIFICATIONS, STARTER
Tightening
Specifications
Air Filter M6 10 Nm
Housing To
Body
GND Wire
To
Automatic M8 15 Nm
Transmission
Housing
Ground
(GND) Wire
To Starter M8 15 Nm
Mounting
Bolt
Positive
Wire To
Starter M8 15 Nm
Solenoid
Switch
Starter To M12 80 Nm
Transmission M10 40 Nm
Wire
Retainer To
Starter M8 15 Nm
Mounting
Bolt
Wire
Retainer To
Starter
Mounting
Bolt,
Vehicles
M8 23 Nm
With 3.6 L
FSI Engine
and
Automatic
Transmission
Only
ADAPTIVE CRUISE CONTROL SENSOR -G550- , CALIBRATING
Adaptive Cruise Control Sensor in Distance Regulation Control Module -J428- is to be calibrated:
 Whenever the adaptive cruise control sensor is removed, installed or replaced,

 Every removal and installation, and replacement of assembly carrier,
 If there is a suspicion of forceful impact on these two parts, an accident during driving or similar.
Adaptive Cruise Control Sensor, calibrating, refer to ADAPTIVE CRUISE CONTROL, CALIBRATION
WITHOUT PRIOR VEHICLE ALIGNMENT .
AUTOMATIC DISTANCE REGULATION, INITIALIZING
 Vehicle Diagnosis, Testing and Information System VAS5051B
NOTE: Adaptation of the Distance Regulation Control Module -J428- is only necessary
prior to initial use and in the event of unit replacement.
-- Connect the VAS5051B. .
-- On the VAS5051B, select "Guided Fault Finding".
sequence:
 Chassis
 Distance regulation
 Functions
 Adaptation after replacing control module
GENERATOR, CHECKING
sequence:
 Body
 Electrical Equipment
 27 - Starter, power supply
 Electrical Components
 Generator (GEN) -C-
RIBBED BELT, CHECKING

CAUTION: If defects are discovered, the ribbed belt must be replaced immediately.
Thereby, failures and malfunctions can be prevented.
-- Turn over engine at vibration damper/belt pulley using a socket wrench.
-- Check the ribbed belt for:
 Cracks in the underside (surface cracks, fragmenting, cross-section breaks)

 Layer separation (outer layer, tension cords)
 Wear-through on the underside
 Fraying of tension cords
 Edge wear (material wear, frayed edges, hardened edges -glazed edges-, surface cracks)
 Oil and grease traces
STARTER, CHECKING
sequence:
 Body
 27 - Starter, power supply
 Starter -B-
ADAPTIVE CRUISE CONTROL BUTTON -E357-
The adaptive cruise control button is integrated in the cruise control switch on the steering column.
Cruise Control Switch on Steering Column, removing and installing, refer to STEERING COLUMN
SWITCH, THROUGH 10.09 .
BATTERY IN ENGINE COMPARTMENT, DISCONNECTING AND CONNECTING

 Torque Wrench V.A.G 1331
CAUTION: Observe notes for threaded connections of battery terminals, refer to

BATTERY POST/TERMINAL.
NOTE: To disconnect battery, anti-theft alarm system must be deactivated. Refer to

ANTI-THEFT ALARM SYSTEM, ACTIVATING AND DEACTIVATING .
By removing the battery negative terminal clamp (current disruption), safe work
on the electrical system is guaranteed. Disconnecting the battery positive (B+)
terminal must only be performed as required to remove battery from vehicle,
and must only be carried out after the negative (-) terminal is disconnected.
However, observe notes for connecting battery in any case.
Disconnecting
-- Switch ignition and all electrical consumers off and disengage the key or ignition switch in position 0
(ignition off).
-- Open locking mechanism -arrow- and remove the cover on the battery case.
Fig. 12: Identifying Battery Box Cover Locking Mechanism

-- First, disconnect the battery terminal clamp of ground wire -1- from the battery negative terminal.
-- Then, remove the battery terminal clamp of positive wire -2- from the battery positive terminal.
Fig. 13: Identifying Battery Positive And Ground Connections

Connecting

NOTE: After connecting the battery and turning the ignition on, the ASR/ESP Indicator
Lamp -K155- and electromechanical power steering indicator lamp come on and
stay on. The indicator lamps go out automatically when vehicle is driven a
distance straight ahead at 15 to 20 km/h. This activates Steering Angle Sensor -
G85-.
-- Connect the positive wire battery terminal clamp -2- to the battery positive terminal and tighten the mounting
bolt to the specification shown in FASTENER TIGHTEN SPECIFICATIONS, BATTERY IN ENGINE
COMPARTMENT.
-- Attach the ground cable -1- to the battery negative terminal and tighten the bolt to the tightening
specification. Refer to FASTENER TIGHTEN SPECIFICATIONS, BATTERY IN ENGINE
COMPARTMENT.
Fig. 14: Identifying Battery Positive And Ground Connections

-- Perform the work procedures in the table.
Work Steps Required After Reconnecting Battery
Work steps Completed?

Turn on ignition using key or ignition/starter switch and then turn it off again.
Read the DTC memory using Guided Fault Finding with the Vehicle Diagnosis, Testing and
Information System VAS5051B.
Clock: Check clock time setting, set anew if necessary.
Electrical window regulators: -- Open and close windows to each end stop respectively.--
With window closed, then pull switch until relay switches audibly.-- Check comfort
switching of power window. While comfort switching is operated, window must close
without holding the switch.
Check function: all electrical consumers.
If necessary, the table can be printed out.
BATTERY IN LUGGAGE COMPARTMENT, DISCONNECTING AND CONNECTING
WARNING: Risk of injury. Observe warning notes and safety precautions! Refer to
The battery is installed in luggage compartment on left side in vehicles with a 3.6L V6 gasoline engine.
NOTE: To disconnect battery, anti-theft alarm system must be deactivated. Refer to

ANTI-THEFT ALARM SYSTEM, ACTIVATING AND DEACTIVATING .
By removing the battery negative terminal clamp (current disruption), safe work
on the electrical system is guaranteed. Disconnecting the battery positive (B+)
terminal must only be performed as required to remove battery from vehicle,
and must only be carried out after the negative (-) terminal is disconnected.
However, observe notes for connecting battery in any case.
Disconnecting
(ignition off).
Passat Sedan
-- Open locking mechanisms -arrows- and remove trim.
Fig. 15: Identifying Direction To Open Locking Mechanisms

-- Disengage retaining lug -arrow- and remove storage compartment.

Fig. 16: Locating Retaining Lug In Storage Compartment

Passat Wagon
-- Disengage locking mechanism -1- and remove trim -2- and storage compartment -3-.
Fig. 17: Identifying Sequence To Disengage Locking Mechanism To Remove Trim And Storage
Compartment
All Vehicles
-- First, disconnect the battery terminal clamp of ground wire -1- from the battery negative terminal.
Fig. 18: Identifying Battery Ground Wire And Pole Cover

-- Open pole cover -arrow- of battery positive pole.
-- Then, remove the battery terminal clamp of positive wire -2- from the battery positive terminal.
Connecting

NOTE: After connecting the battery and turning the ignition on, the ASR/ESP Indicator
Lamp -K155- and electromechanical power steering indicator lamp come on and
stay on. The indicator lamps go out automatically when vehicle is driven a
distance straight ahead at 15 to 20 km/h. This activates Steering Angle Sensor -
G85-.
-- Connect the positive wire battery terminal clamp -2- to the battery positive terminal and tighten the mounting
bolt to the specification.
NOTE: Turn positive cable/terminal in driving direction.
-- Attach the ground cable -1- to the battery negative terminal and tighten the bolt to the tightening
specification. Refer to FASTENER TIGHTEN SPECIFICATIONS, BATTERY IN LUGGAGE
COMPARTMENT.
-- Close pole cover -arrow-.
Fig. 19: Identifying Battery Ground Wire And Pole Cover

-- Perform the work procedures in the table.
Work Steps Required After Reconnecting Battery
Work Steps Completed?

-- Turn on ignition using key or ignition/starter switch and then turn it off again.
Read the DTC memory using Guided Fault Finding with the Vehicle Diagnosis, Testing and
Information System VAS5051B.
Clock: Check clock time setting, set anew if necessary.
Electrical window regulators:-- Open and close windows to each end stop respectively.--
With window closed, then pull switch until relay switches audibly.-- Check comfort
switching of power window. While comfort switching is operated, window must close
without holding the switch.
Check function: all electrical consumers.
If necessary, the table can be printed out.
BATTERY IN ENGINE COMPARTMENT
WARNING: Risk of injury. Observe warning notes and safety precautions, refer to
Removing:
-- Disconnect battery, refer to BATTERY IN ENGINE COMPARTMENT, DISCONNECTING AND

CONNECTING.
-- Remove the battery housing panel in direction of arrow.
Fig. 20: Identifying Direction To Pull Out Battery Box Panel

-- Remove mounting screws -1- and remove retaining bracket -2-.

Fig. 21: Identifying Mounting Screws And Retaining Bracket

-- Fold handles -arrows- upward (if present) and take out battery.
Fig. 22: Identifying Battery Handles Folded Upward

Installing:
CAUTION: If battery is not secured properly, the following risks are possible:
 Shortened battery service life due to vibration damage (explosion

hazard).
 The plates within the battery can be damaged.
 Damage to battery casing caused by bracket (possible electrolyte
leakage, high subsequent costs).
 Reduced collision safety.
Install in reverse order of removal, noting the following:
-- Tighten all threaded connections to the specification shown in FASTENER TIGHTEN

SPECIFICATIONS, BATTERY IN ENGINE COMPARTMENT.
-- After installing, verify battery is properly seated.
-- Reconnect battery, refer to BATTERY IN ENGINE COMPARTMENT, DISCONNECTING AND

CONNECTING.
BATTERY IN LUGGAGE COMPARTMENT
WARNING: Risk of injury. Observe warning notes and safety precautions. Refer to
Removing:
-- Disconnect battery, refer to BATTERY IN LUGGAGE COMPARTMENT, DISCONNECTING AND

CONNECTING.
-- Disconnect central gas vent hose -arrow- from top cover.

Fig. 23: Identifying Central Gas Vent Hose

-- Remove mounting screws -1- and remove retaining bracket -2-.
Fig. 24: Identifying Secondary Battery Mounting Screws And Retaining Bracket
-- Fold handles -arrows- upward and take out battery.

Fig. 25: Identifying Secondary Battery Handles

Installing:
CAUTION: If battery is not secured properly, the following risks are possible:
 Shortened battery service life due to vibration damage (explosion

hazard).
 The plates within the battery can be damaged.
 Damage to battery casing caused by bracket (possible electrolyte
leakage, high subsequent costs).
 Reduced collision safety.

SPECIFICATIONS, BATTERY IN LUGGAGE COMPARTMENT.
-- After installing, verify battery is properly seated.
-- Reconnect battery, refer to BATTERY IN LUGGAGE COMPARTMENT, DISCONNECTING AND

CONNECTING.
NOTE: For batteries with central venting system hose, make sure the hose is not
kinked while installing. Only in this way can the battery be vented freely.
Make sure that central gas venting hose -1- is inserted into rubber grommet -2-.
Fig. 26: Identifying Central Gas Venting Hose And Rubber Grommet
For batteries without hose for central venting system, make sure the opening
on the upper cover side of battery is not clogged.
DISTANCE REGULATION CONTROL MODULE -J428-
Distance Regulation Control Module is mounted on front of vehicle, behind VW-logo in the radiator protective
grille.
Distance Regulation Control Module must not be disassembled further and contains the following components:
 Adaptive Cruise Control Sensor -G550-

 Distance Regulation Sensor Heater -Z47-
Removing:
(ignition off).
-- Remove radiator protective grille. Refer to Removal and Installation .
-- Unclip Distance Regulation Control Module -1- from the three mounts -2-.
Fig. 27: Identifying Distance Regulation Control Module J428 And Retainers
-- Swivel Distance Regulation Control Module -1- forward, paying attention to lengths of connected wires.
-- Disengage and disconnect harness connector -2- and remove Distance Regulation Control Module from
vehicle.
Fig. 28: Identifying Distance Regulation Control Module J428 And Electrical Connection
Installing:
Adaptive Cruise Control Sensor -G550- in Distance Regulation Control Module is to be adjusted:
 Whenever the adaptive cruise control sensor is removed, installed or replaced,

 Every removal and installation, and replacement of assembly carrier,
 If there is a suspicion of forceful impact on these two parts, an accident during driving or similar.
Adjusting Adaptive Cruise Control Sensor, refer to ADAPTIVE CRUISE CONTROL SENSOR -G550-,
CALIBRATING.
-- The Distance Regulation Control Module must be adapted prior to first use and/or after replacement. Refer to
AUTOMATIC DISTANCE REGULATION, INITIALIZING.
JUMP START POINT WITH SUPPRESSOR
Removing:
(ignition off).

CONNECTING.
NOTE: Air filter housing is removed for reasons of clarity. It is not required when doing
repairs.
-- Disengage retaining clip -arrow A- and open cover -1- over positive pole pick-up.
Fig. 29: Identifying Direction To Disengage Retaining Clip And Cover Over Positive Pole Pick-Up
-- Disengage cover -2- over electrical wires in -direction of arrow B-.
-- Remove the nuts -5- and -6- on positive wires.

Fig. 30: Identifying Outside Starter Point With Suppressor C24 Remove/Install Components
-- Disconnect electrical harness connector -1- at suppressor -4-.
-- Remove screw -3- and remove positive terminal trip -2- with suppression filter from bracket.
Installing:
Install in reverse order.
-- Tighten all threaded connections to specified torque shown in FASTENER TIGHTEN

SPECIFICATIONS, EXTERNAL STARTING POINT.

CONNECTING.
GENERATOR (BLV ENGINES)

 Mandrel T10060 A
Removing:

CONNECTING.
-- Remove noise insulation. Refer to Removal and Installation .

-- Remove right front section of wheel housing liner. Refer to Removal and Installation .
CAUTION: Before removing ribbed belt, mark the top side and direction of travel.
When installing, pay attention to correct running direction and installation
position. If the belt is installed in the opposite running direction or is
positioned incorrectly, the belt will fail!
-- Mark running direction of ribbed belt.
-- Release tension on ribbed belt by swinging tensioning element using a 16 mm open-end wrench in direction
of -arrow-.
Fig. 31: Identifying Direction To Release Tension On Ribbed Belt With Tensioning Element
-- Secure tensioning element -2- using T10060 A -1-.

Fig. 32: Identifying Tensioner Locked Using Mandrel T10060 A

-- Remove ribbed belt.
Remove A/C compressor and secure it to body with suitable item (e.g. wire). Refer to Removal and
Installation .
-- Remove the nut -arrow- for wire bracket.

Fig. 33: Identifying Harness Retainer Nut

-- Unlock the terminal 61 connector -2- and then disconnect the connector.
Fig. 34: Identifying Terminal 61 Electrical Connection, Cap And Retainer

-- Remove the cap -1-.
-- Open clip on plug -3- and disengage wire from plug.
-- Remove the nut -1- of B+ wire -2- from generator and set aside B+ wire.
Fig. 35: Identifying Positive Cable And Nut

-- Remove mounting bolt -1- of tensioning roller -2- and remove tensioning roller.
Fig. 36: Identifying Tensioner Roller And Bolt

-- Remove mounting bolts for generator -arrows-.

Fig. 37: Identifying Generator And Bolts

-- Remove the generator.
Installing:
CAUTION:  When installing an already used ribbed belt, note direction of travel
marked when it was removed!
 Before installing the ribbed belt, make sure all drive accessories
(generator, air conditioner compressor) are secured in place.
 When installing the ribbed belt, make sure it is properly seated in the
belt pulley!


-- Drive threaded sleeves -A- out of generator housing approximately 4 mm in -direction of arrow-.
Fig. 38: Identifying Threaded Sleeves And Generator Housing

-- Screw wire retainer -arrow- firmly to rear side of generator in 9 o'clock position.
Fig. 39: Identifying Harness Retainer Screwed To Rear Side Of Generator


SPECIFICATIONS, GENERATOR.

CONNECTING.
-- Start the engine and verify that the belt is running properly.
-- Turn off the engine.
GENERATOR (BPY, CCTA & CBFA ENGINES)

 Mandrel T10060 A
Removing:

CONNECTING.
-- Remove screws -arrows-.
Fig. 40: Locating Screw

-- Open the clips -1- and remove the hose -2- from the air filter housing.
Fig. 41: Identifying Starter Electrical Connection, Hose And Clips

-- Disconnect electrical connection -3-.
-- Pull off engine cover upward -arrows-.
Fig. 42: Identifying Direction To Remove Engine Cover

CAUTION: Before removing ribbed belt, mark the top side and direction of travel.
When installing, pay attention to correct running direction and installation
position. If the belt is installed in the opposite running direction or is
positioned incorrectly, the belt will fail!
-- Mark running direction of ribbed belt.
-- Release tension on ribbed belt by swinging tensioning element using a 16 mm open-end wrench in direction
of -arrow-.
Fig. 43: Identifying Method To Relieve Tension On Poly V-Belt

-- Lock tensioner using T10060 A.

Fig. 44: Identifying Lock Tensioner With Locking Pin T10060 A

-- Remove ribbed belt.
-- Loosen bolts of coolant pipe -arrows-.

Fig. 45: Identifying Coolant Pipe Mountings

NOTE: The coolant pipe can remain installed. It must be loosened in order to remove
generator.
-- Remove generator screws -arrows-.
Fig. 46: Identifying Generator Mounting Bolts

-- Disconnect the DF wire connector -1- and remove the cap -2-.
Fig. 47: Identifying DF Wire Electrical Connection And Generator Protective Cap
-- Remove the B+ lead -arrow- from the generator.
Fig. 48: Identifying Generator B+ Wire

-- Remove the wire retainer -arrow- from generator.
Fig. 49: Identifying Generator Harness Retainer

-- Remove generator from vehicle.
Installing:
CAUTION:  When installing an already used ribbed belt, note direction of travel
marked when it was removed!
 Before installing the ribbed belt, make sure all drive accessories
(generator, air conditioner compressor) are secured in place.
 When installing the ribbed belt, make sure it is properly seated in the
belt pulley!

-- Drive threaded sleeves -A- out of generator housing approximately 4 mm in -direction of arrow-.
Fig. 50: Identifying Threaded Sleeves And Generator Housing

-- Screw wire retainer -arrow- firmly to rear side of generator in 9 o'clock position.
Fig. 51: Identifying Harness Retainer Screwed To Rear Side Of Generator


SPECIFICATIONS, GENERATOR.
-- Reconnect battery, refer to BATTERY IN ENGINE COMPARTMENT, DISCONNECTING AND

CONNECTING.
-- Start the engine and verify that the belt is running properly.
PYROTECHNIC BATTERY CUT-OUT
WARNING:  Observe safety precautions when working on battery isolation

system, refer to PYROTECHNIC BATTERY ISOLATOR SAFETY
PRECAUTIONS.
 Observe notes for disposal of battery isolator units, refer to
PYROTECHNIC BATTERY ISOLATOR DISPOSAL.
Removing:
(ignition off).
Passat Sedan
-- Open locking mechanisms -arrows- and remove flap.
Fig. 52: Identifying Direction To Open Locking Mechanisms

-- Disengage retaining lug -arrow- and remove storage compartment.
Fig. 53: Locating Retaining Lug In Storage Compartment

Passat Wagon
-- Disengage locking mechanism -1- and remove trim -2- and storage compartment -3-.
Fig. 54: Identifying Sequence To Disengage Locking Mechanism To Remove Trim And Storage
Compartment
All Vehicles

CONNECTING.
-- Open locks of main fuse box -1- by rotating 90° counterclockwise and fold open cover downward.
Fig. 55: Identifying Main Fuse Box Locks

-- Remove the collar nut -1- and remove B+ wire -2- from connection thread.
Fig. 56: Identifying Battery Positive Cable, Terminal Nut And Battery Isolator
-- Remove the self-locking nut -4- and remove pyrotechnic battery isolator -3- from connection threads, paying
attention to the connected wire lengths.
-- Pull the button -3- in direction of arrow and unlock the connector -1-.
Fig. 57: Identifying Electrical Connection, Isolator And Lock

-- Disconnect harness connector -1- in direction of arrow and remove pyrotechnic battery isolator -2- from
vehicle.
NOTE: While doing this, observe safety precautions when working on pyrotechnic
battery isolation system, refer to PYROTECHNIC BATTERY ISOLATOR SAFETY
PRECAUTIONS.
Installing:
NOTE: When connecting harness connector to pyrotechnic battery isolator, make sure
that connector lock engages audibly.
-- Tighten all threaded connections to specified torque, refer to FASTENER TIGHTEN SPECIFICATIONS,
BATTERY IN LUGGAGE COMPARTMENT.

CONNECTING.
RIBBED BELT PULLEY WITHOUT FREEWHEEL
 Socket VAS 3310

Removing:
-- Remove generator, refer to GENERATOR (2.0L) or GENERATOR (3.6L).
-- Tighten the generator in a vise at the mounting point.
-- Use the VAS 3310 to remove the ribbed belt pulley nut from the generator shaft.
Fig. 58: Identifying Removal Of Overrunning Clutch Pulley Nut From Generator Shaft With Socket
Insert VAS 3310
Installing:
-- Tighten all threaded connections to the specification shown in FASTENER TIGHTENING

RIBBED BELT PULLEY WITH FREEWHEEL, BOSCH
 Multi-point adapter VAS 3400

Removing:
-- Tighten the generator in a vise at the mounting points.
-- Remove protective cap from ribbed belt pulley with freewheel.
-- Insert VAS 3400 into ribbed belt pulley with freewheel of generator using open end wrench 17 mm.
-- Insert a multi-point socket insert M10 -1- in generator shaft.

Fig. 59: Identifying Multi-Point Socket Insert M10 Inserted In Generator Shaft
-- Loosen the threaded connection by rotating clockwise, while counter holding with the box-end wrench.
-- Hold ribbed belt pulley with freewheel in place by hand and turn at generator driveshaft until ribbed belt
pulley with freewheel can be removed.
Installing:
-- Next, screw ribbed belt pulley with freewheel onto generator driveshaft by hand until it reaches stop.
V.A.G 1332 must be rearranged for installing ribbed belt pulley with freewheel as follows:
-- Disengage socket -1- and pull it off handle part -2-.

Fig. 60: Identifying Torque Wrench Socket Drive Grip

-- Turn around handle part -2- of torque wrench 180° and insert socket again.
-- Set turning direction of torque wrench to left at socket.
-- Insert a multi-point socket insert M10 -1- in generator shaft.

Fig. 61: Identifying Multi-Point Socket Insert M10 Insert In Generator Shaft
-- Counter hold VAS 3400 using 17 mm open end wrench.
-- Tighten ribbed belt pulley with freewheel by turning generator driveshaft toward left using V.A.G 1332.

RIBBED BELT PULLEY WITH FREEWHEEL, VALEO
 Multi-point adapter VAS 3400

 TORX screwdriver insert V.A.G 1603/1
Removing:
-- Tighten the generator in a vise at the mounting points.
-- Remove protective cap from ribbed belt pulley with freewheel.
-- Insert VAS 3400 into ribbed belt pulley with freewheel of generator using open end wrench 17 mm.
-- Insert V.A.G 1603/1 into generator shaft.
Fig. 62: Identifying TORX Screwdriver Insert VAG 1603/1 Inserted Into Generator Shaft
-- Loosen the threaded connection by rotating clockwise, while counter holding with the box-end wrench.
-- Hold ribbed belt pulley with freewheel in place by hand and turn at generator driveshaft until ribbed belt
pulley with freewheel can be removed.
Installing:

-- Next, screw ribbed belt pulley with freewheel onto generator driveshaft by hand until it reaches stop.
V.A.G 1332 must be rearranged for installing ribbed belt pulley with freewheel as follows:
-- Disengage socket -1- and pull it off handle part -2-.
Fig. 63: Identifying Torque Wrench Socket Drive Grip

-- Turn around handle part -2- of torque wrench 180° and insert socket again.
-- Set turning direction of torque wrench to left at socket.
-- Insert V.A.G 1603/1 into generator shaft.

Fig. 64: Identifying TORX Screwdriver Insert VAG 1603/1 Inserted Into Generator Shaft
-- Counter hold VAS 3400 using 17 mm open end wrench.
-- Tighten ribbed belt pulley with freewheel by turning generator driveshaft toward left using V.A.G 1332.

STARTER

Removing:

CONNECTING.
-- Remove the complete air filter housing. Refer to [For transmission(s) 09M] Removal and Installation .
-- Unlock the terminal 50 connector -2- and then disconnect the connector.
Fig. 65: Locating Solenoid Terminal 50 And Sliding Protective Cap Downward From Solenoid
-- Slide the cap off the solenoid switch -1- in -direction of arrow-.
-- Remove the nut -2- and set aside the positive wire -1-.
Fig. 66: Locating Mounting Nut And Positive Wire

-- Open clip on plug -2- and disengage wire -1- from plug.
Fig. 67: Identifying Harness, Retainer And Bolt

-- Remove the nut -3-.
-- Open clip on plug -1- and disengage wire -2- from plug -1-.
Fig. 68: Identifying Harness And Retainer

-- Remove the nuts -2- and remove bracket -1- upward.
Fig. 69: Identifying Bracket And Nut

-- Remove the lower mounting bolt for starter -arrow-.
Fig. 70: Identifying Lower Starter Bolt

-- Release the connector -arrow- and pull the connector off.

Fig. 71: Identifying Starter Electrical Connection

-- Remove the nut -arrow- and set aside wires -1-.
Fig. 72: Locating Nut And Harness

-- Remove the upper mounting bolt for starter -arrow-.

Fig. 73: Identifying Upper Starter Bolt

-- Remove starter upward and out of vehicle.
Installing:

SPECIFICATIONS, STARTER.
STARTER, AUTOMATIC TRANSMISSION

Removing:

CONNECTING.


-- Disconnect hose -1- after the clips -2- have been opened.



-- Remove the nut -1- from upper mounting bolt of starter.
Fig. 77: Identifying Upper Starter Bolt Nut And Harness Retainer
-- Remove wire retainer -2-.
-- Remove upper mounting bolt for starter -arrow-.

Fig. 78: Identifying Starter Upper Mounting Bolt

-- Slide protective cap in -direction of arrow- downward from magnetic switch.
Fig. 79: Identifying Direction To Slide Protective Cap Downward From Magnetic Switch
-- Remove positive wire -1- and disconnect harness connector of terminal 50 -2-.
Fig. 80: Identifying Positive Wire And Harness Connector Of Terminal 50

-- Remove noise insulation, refer to Removal and Installation .
NOTE: All hose connections for charge air system are secured by spring-type clamps
or by connector couplings. The following must be observed with connector
couplings:
Fig. 81: Identifying Hose Connection And Locking Clip

Release connection by pulling locking clip -arrow-.

Disconnect hose/pipe without tools.
-- Open screw-type clamp -1- and disconnect connector coupling -2-.
-- Remove hose from vehicle.
Fig. 82: Identifying Screw Clamp And Connection

-- Remove the nut -1- from lower mounting bolt of starter.
Fig. 83: Identifying Lower Starter Bolt Nut And Harness Retainer
-- Remove lower mounting bolt for starter -arrow-.

-- Remove the starter downward and out from the vehicle.
Installing:
NOTE: All hose connections for charge air system are secured by spring-type clamps
or by connector couplings. The following must be observed with connector
couplings:
Fig. 85: Locating Retaining Tabs

Connect hose/pipe without tools.
Make sure retaining tabs lock securely -arrow-.

STARTER, MANUAL TRANSMISSION

Removing:

CONNECTING.


-- Disconnect hose -1- after the clips -2- have been opened.



-- Slide protective cap in -direction of arrow- downward from magnetic switch.
Fig. 89: Identifying Direction To Slide Protective Cap Downward From Magnetic Switch
-- Remove positive wire -1- and disconnect harness connector of terminal 50 -2-.
Fig. 90: Identifying Positive Wire And Harness Connector Of Terminal 50

-- Remove Ground (GND) wire from starter mounting bolt -arrow-.
Fig. 91: Identifying Ground Wire At Starter Bolt

-- Remove mounting bolt for starter -arrow-.

Fig. 92: Identifying Starter Mounting Bolt

-- Remove the nut -1- from lower mounting bolt of starter.
Fig. 93: Identifying Harness Retainer And Lower Starter Bolt

-- Remove mounting bolt for starter -arrow-.


-- Remove the starter downward and out from the vehicle.
Installing:

VOLTAGE REGULATOR, BOSCH
 Torque screwdriver V.A.G 1624
Removing:
-- Remove mounting bolt and nuts -arrows- and remove protective cap from generator.
Fig. 95: Identifying Generator Fasteners

-- Remove mounting bolts for voltage regulator -arrows-.
Fig. 96: Identifying Mounting Bolts Of Voltage Regulator

-- Take voltage regulator out of generator.
Installing:


VOLTAGE REGULATOR, VALEO
 Torque Wrench V.A.G 1783/
Removing:
-- Remove clamping rings -arrows- and remove protective cap from generator.
Fig. 97: Identifying Generator Clamping Rings And Protective Cap

-- Remove mounting bolts for voltage regulator -arrows-.

Fig. 98: Identifying Voltage Regulator Screws

-- Take voltage regulator out of generator.
Installing:
-- Release retaining tabs -arrows- and pull protective cap from voltage regulator.
Fig. 99: Identifying Sequence To Remove Voltage Regulator Cap

-- Push carbon brushes into voltage regulator housing and insert voltage regulator into generator.

-- Slide protective cap into guide rails -arrows- until it engages audibly.
Fig. 100: Identifying Protective Cap And Guide Rails

SPECIAL TOOLS
Socket VAS 3310

Fig. 101: Identifying 3310 Socket

Fig. 102: Identifying Special Tools - Ribbed Belt Pulley With Freewheel, Removing And Installing -
MFR: Valeo
Mandrel T10060 A
Fig. 103: Identifying Locking Pin T10060 A

Torque Wrench V.A.G 1331

Torque screwdriver V.A.G 1624

Fig. 105: Identifying Torque Screwdriver VAG 1624 (Or Locally Available Equivalent)
Torque Wrench V.A.G 1783/

Vehicle Diagnosis, Testing and Information System VAS5051B

Accessories and Body, Cab Body Collision Repair
Accessories and Body, Cab
Body Collision Repair
00 - TECHNICAL DATA
TECHNICAL DATA
Vehicle Identification Number (VIN)
Fig. 1: Locating Vehicle Identification Number

The vehicle identification number (chassis number) - arrow - is located at the right (in driving direction) on the
fender mount (upper longitudinal member for wheel housing).
NOTE:  If this component needs to be replaced due to damaged, call in an

assessor before performing service work.
Type plate
Fig. 2: Locating Type Plate

Type plate - arrow - is applied to outer B-pillar at left in direction of travel and is visible once the left front
door has been opened.
Vehicle data sticker
Fig. 3: Locating Vehicle Data Sticker

Vehicle data plate - arrow - is secured in spare wheel well on right side in direction of travel.
SAFETY PRECAUTIONS
Safety precautions
CAUTION: Before starting any separation work, repairs or bulge corrections, always
follow safety precautions.
MOLDED FOAM PARTS
Molded foam parts
Diverse body hollow areas are equipped with molded foam parts in this vehicle.
The transfer of driving noises into the passenger compartment are reduced by molded foam parts.
Exact positions of molded foam parts are depicted at the beginning of the respective repair descriptions.
ZINC-COATED BODY PARTS
Zinc-coated body parts
Working with zinc-coated body plates Sheet steel repairs, zinc-coated body parts.
Construction
Vehicle construction is predominantly manufactured from zinc-coated steel plates of varying stiffness.
The following sheet metal pieces - hatched area - are not zinc-coated.
Fig. 4: Zinc-Coated Body Parts

 - 1 - Parts of rear shelf

 - 2 - B-pillar reinforcement
 - 3 - B-pillar impact reinforcement (only NAR)
 - 4 - Parts of front roof frame
 - 5 - Front and rear roof cross members

 - 6 - Roof reinforcement
 - 7 - Parts of C-pillar
NOTE:  The outer side panel depicted and the roof center piece serve only as
orientation.
Platform
NOTE:  The platform of the vehicle is completely constructed of galvanized sheet

steel of various strengths and is therefore not handled any further here.
STRENGTHENED BODY PLATE
Strengthened body plate
NOTE:  Body plates with high stiffness are predominantly installed on this vehicle.
 Only the following plate parts which are not depicted here are still
manufactured from normal body plates
 Roof center piece
 Sunroof frame (only vehicles with sunroof)
 Floor panel
 Outer side panel (sidewall frame)
 Front mounting plate (bulkhead)
In the following chapters "construction" and "platform" , only the following sheet metal pieces manufactured
from strengthened or highest-strength body plates or special qualities are depicted for a better overview.
General information apply to all work on higher-strength body plates Sheet steel repairs, higher-strength body
plates.
Construction
The following areas are manufactured from higher-strength body plates

Fig. 5: Identifying Strengthened Body Plate

1 - Parts of rear wall carrier
2 - Side panel connecting piece, sealing channel reinforcement and rear lock carrier
3 - Inner B-pillar reinforcement, sidemember reinforcements, A-pillar reinforcement, inside lower A-pillar and
parts of roof frame
4 - B-pillar crash reinforcement (only NAR)
5 - Front roof cross member with end plate and rear roof cross member
6 - Roof reinforcement
NOTE:  The outer side panel depicted and the roof center piece serve only as
orientation.
Platform
Front platform
Fig. 6: Identifying Strengthened Body Plate - Front Platform

1 - Inner sill panel
2 - Front floor cross member with left and right connecting plate
3 - Reinforcement for center tunnel with front carrier piece at floor
4 - Diverse front platform parts (e.g. cover plate longitudinal member, partition plate longitudinal member,
towing eye mount with mounting bracket etc.)
NOTE:  The front longitudinal member and floor panel - 5 - are only shown to
provide orientation.
Rear platform
Fig. 7: Identifying Strengthened Body Plate - Rear Platform

1 - Rear partition plate longitudinal member, cover plate longitudinal member

2 - Rear longitudinal member with connecting plates
3 - Suspension strut mounting
4 - Floor cross member with connecting plates
5 - Cross member for spare wheel well with connecting plates
LASER WELDS
Laser welds
On this vehicle, roof and body are partially welded by laser.
In laser welding, a high energy light beam is directed onto the weld point via optical lenses or fiber optics.
During the welding operation the top panel is melted through and the bottom panel melted on the surface in this
way a weld is formed with and also without any filler material.
During repairs (except roof repairs), laser weld seams are replaced by SG plug weld seams or RP spot weld
seams.
BODY PANEL GAPS
Body panel gaps
Fig. 8: Adjusting Gauge 3371

NOTE:  Use adjustment gauge VAS 3371 to adjust or check.
Body, front
Fig. 9: Body, Front Panel Gaps (1 Of 3)



Body, rear
Fig. 12: Body, Rear Panel Gaps (1 Of 2)

Fig. 13: Body, Rear Panel Gaps (2 Of 2)

Body rear, wagon

Fig. 14: Body, Rear Panel Gaps - Wagon (1 Of 2)

Fig. 15: Body, Rear Panel Gaps - Wagon (2 Of 2)

BODY PANEL DIMENSIONS
Body panel dimensions
NOTE:  Body dimensions serve only as reference. Alignment bracket set is

standard. Bolts, plugs, trim and attachments must be removed before the
measuring procedure.
 Use the telescope measuring rod VAS 5159 or the telescope measuring
rod VAS 5160 to determine body dimensions.
Body, front
Dimension - a - - 990 mm
Fig. 16: Body, Front Panel Dimensions (1 Of 4)

Dimension - a - -670 mm

Dimension - a - -1,573 mm


Body, center
Fig. 20: Body, Center Panel Dimensions (1 Of 7)

Dimension - b - - 880 mm


Dimension - b - -888 mm
dimension - a - - 1,471 mm

NOTE:  This dimension is the same in the sedan and wagon.



Body center, wagon
Dimension between B-pillars --> Fig. 22
NOTE:  This dimension is the same in the sedan and wagon.
Fig. 27: Body, Center Panel Dimensions - Wagon (1 Of 2)

Fig. 28: Body, Center Panel Dimensions - Wagon (2 Of 2)

Body, rear
Fig. 29: Body, Rear Panel Dimensions (1 Of 2)

Fig. 30: Body, Rear Panel Dimensions (2 Of 2)

Body rear, wagon
Fig. 31: Body, Rear Panel Dimensions - Wagon (1 Of 2)

Fig. 32: Body, Rear Panel Dimensions - Wagon (2 Of 2)

Floor assembly, front
Fig. 33: Floor Assembly, Front Dimensions (1 Of 2)

Fig. 34: Floor Assembly, Front Dimensions (2 Of 2)

Floor assembly, center
Fig. 35: Floor Assembly, Center Dimensions

NOTE:  The dimension - a - is measured on the underbody at the level of the left
and right B-pillars.
Floor assembly, rear
Fig. 36: Floor Assembly, Rear Dimensions (1 Of 2)

Dimension - b - -1,327 mm
Fig. 37: Floor Assembly, Rear Dimensions (2 Of 2)

ALIGNMENT BRACKET SET
Overview
Special tools, testers and auxiliary items required
 Alignment bracket set VAS 6325
Assembly of complete alignment bracket set VAS 6325

Fig. 38: Alignment Bracket Set

 Refer to assembly plan supplied with alignment bracket set for detailed information on the assembly.
PORTAL GAUGE
Overview
 Alignment bracket set VAS 6325

 Portal gauge VAS 5007/22
Front door opening

Assembly of portal gauge VAS 5007/22 , front door opening
Fig. 39: Portal Gauge - Front Door Opening

 Refer to assembly plan supplied with gantry gauge for detailed information on the assembly.
Rear door opening
Assembly of portal gauge VAS 5007/22 , rear door opening

Fig. 40: Portal Gauge - Rear Door Opening

 Refer to assembly plan supplied with gantry gauge for detailed information on the assembly.
50 - BODY, FRONT
RIGHT CONSOLE, REPLACING
Right console, replacing
CAUTION: Observe safety precautions!
Cautions
NOTE:  The following spot welders (inverter) are recommended to carry out spot
welding procedures properly.
 Spot welder (Inverter) VAS 6237

 Spot welder (Inverter) VAS 6237 L
 Accessory kit for spot welder VAS 6238/1

Removing
Fig. 41: Right Console - Original Connection

 Separate the original connection.
Fig. 42: Right Console Residual Material

 Remove residual material.
Installing
Welding
Replacement part
 Engine console, right

 Align and affix the new part with help from the alignment bracket set.
Fig. 43: Right Console Welding Areas

 Weld in console, Straight-line spot weld seam.
LEFT CONSOLE, REPLACING
Left console, replacing
Cautions

Fig. 44: Left Console Replacing Section

Removing
Fig. 45: Left Console Original Connection


Fig. 46: Left Console Rear Of Original Connection

 Separate the original connection at rear.
Fig. 47: Left Console Residual Material

Installing
New part preparation
Replacement part
 Left engine console
 Drill holes for gas-shielded arc plug weld seam.
Welding
 Align and affix the new part with help from the alignment bracket set.
Fig. 48: Left Console Welding Areas

 Weld in engine console, Gas-shielded arc plug weld seam and straight-line spot weld seam.
RETAINING BRACKET, REPLACING - FOR SUBFRAME
Retaining bracket, replacing - for subframe
Cautions
NOTE:  In the example, replacement of retaining bracket for subframe is described

for left front retaining bracket on this vehicle. Work procedure must be
transferred to the other 3 retaining brackets accordingly as necessary.
Removing
Fig. 49: Retaining Bracket Original Connection


Fig. 50: Retaining Bracket Residual Material

Installing
Replacement part
 Front retaining bracket for subframe (replacement part designation retaining bracket mounting frame)
Fig. 51: Retaining Bracket Drilling Areas

 Drill holes for SG plug weld seam, 7 mm.
Welding
 Install new part with vehicle standing on the alignment bracket set and affix it in place.
Fig. 52: Retaining Bracket Welding Areas

 Weld in new part Gas-shielded arc plug weld seam.
BUMPER BRACKET, REPLACING
Bumper bracket, replacing
Cautions
Fig. 53: Bumper Bracket

1 - Bumper bracket
2 - Longitudinal member with cover plate
Removing
Fig. 54: Bumper Bracket Original Connection


Fig. 55: Bumper Bracket Residual Material

Installing
Welding
Replacement part
 Front bumper bracket
 Align and secure new part with vehicle standing on wheels or alignment bracket set.
Fig. 56: Bumper Bracket Welding Areas

 Weld in bumper bracket, gas-shielded arc continuous weld seam.
LONGMEMBER FOR UPPER WHEELHOUSING, REPLACING
Longmember for upper wheelhousing, replacing
Includes Upper outer longitudinal member and upper inner longitudinal member
NOTE:  The chassis number is located on the longitudinal member for upper right
wheel housing. If this component needs to be replaced due to damaged,
call in an assessor before performing service work.
Cautions


Fig. 57: Longmember For Upper Wheelhousing

1 - Separating cut (partial replacement)
2 - Glued area
NOTE:  The opening to the front plenum chamber (not shown in illustration) is
also glued.
A partial replacement can also be performed with the indicated separating cut - 1 -.
Dimension - a - = 170 mm
Removing
Fig. 58: Longmember For Upper Wheelhousing Original Connection

 Loosen the original connection between the upper outer longitudinal member - 1 - and the upper inner
longitudinal member (not visible).
 Loosen original connection to A-pillar - 2 -.

Fig. 59: Longmember For Upper Wheelhousing Drilling And Sanding Areas
 Loosen the original connection between the upper inner longitudinal member - 1 - and the front wheel
housing - 2 -.
Fig. 60: Longmember For Upper Wheelhousing Residual Material

Installing
Replacement part
 Upper inner longitudinal member

 Upper outer longitudinal member
 1K assembly adhesive D 190 MKD A3
Fig. 61: Longmember For Upper Wheelhousing Drilling Areas

 Drill holes in upper inner longitudinal member for gas-shielded arc plug weld seam 7 mm.
 Align and affix the upper inner longitudinal member with help from the alignment bracket set.
 Check the fit with the upper outer longitudinal member.
Welding
Fig. 62: Longmember For Upper Wheelhousing Welding Areas (1 Of 2)

 Weld in upper inner longitudinal member, Straight-line spot weld seam and gas-shielded arc continuous
weld seam (staggered).
Fig. 63: Longmember For Upper Wheelhousing Gluing Areas

 In the glued area, apply one-part assembly adhesive D 190 MKD A3 .

 Align the upper outer longitudinal member to the upper inner longitudinal member and check the fit to
bordering components.
Fig. 64: Longmember For Upper Wheelhousing Welding Areas (2 Of 2)

 Weld the upper outer longitudinal member - 1 - to the upper inner longitudinal member, Gas-shielded arc
plug weld seam and straight-line spot weld seam.
 Reproduce remainder of joint to A-pillar - 2 - , Gas-shielded arc plug weld seam.
FRONT WHEELHOUSING, REPLACEMENT
Front wheelhousing, replacement
Includes Suspension strut mounting

Cautions


Fig. 65: Front Wheelhousing

1 - Wheelhousing with
2 - Front longitudinal member
3 - Longitudinal member cover plate
Removing
 Longitudinal member for upper wheelhousing already removed
Fig. 66: Front Wheelhousing Original Connections

 Original joint to front longitudinal member cover plate, loosen from wheel housing side to inside and to
plenum chamber.
Fig. 67: Front Wheelhousing Remaining Joint To Plenum Chamber

 Loosen remaining joint to plenum chamber.

Fig. 68: Front Wheelhousing Residual Material

Installing
Preparing new parts
 Wheel housing
 Suspension strut mounting
 Suspension strut mounting reinforcement
Fig. 69: Front Wheelhousing Drilling Areas - Gas-Shielded Arc Plug Weld Seam In Suspension Strut
Mounting Reinforcement
 Drill holes for gas-shielded arc plug weld seam in suspension strut mounting reinforcement, 8 mm.
Fig. 70: Front Wheelhousing Drilling Areas - Gas-Shielded Arc Plug Weld Seam In Suspension Strut
Mounting
 Drill holes for gas-shielded arc plug weld seam in suspension strut mounting, 8 mm.
Fig. 71: Front Wheelhousing Drilling Areas - Gas-Shielded Arc Plug Weld Seam In Wheel Housing
 Drill holes for gas-shielded arc plug weld seam in wheel housing, 8 mm.
NOTE:  Drill holes in two rows in area - 1 -.

 Distance of holes to each other, approx. 30 mm.
Fig. 72: Parts Positioned And Secured With Help Of Alignment Bracket Mountings
 Position and secure new parts with help of alignment bracket mountings - item 13 - , - item 15 - , - item
16 - and - item 17 - from alignment bracket set VAS 6325 and adjacent components.
Welding
Fig. 73: Suspension Strut Mounting With Reinforcement Weld Areas

 Weld suspension strut mounting - 1 - with reinforcement - 2 - , gas-shielded arc plug weld.
Fig. 74: Suspension Strut Drilling Areas

 Drill holes - 1 - ( 10 mm) for bolting suspension strut and also secure suspension strut mounting with
reinforcement to alignment bracket mounting - 2 - with screws.
Fig. 75: Wheel Housing With Suspension Strut Mounting Welding Areas
 Weld in wheel housing with suspension strut mounting, SG plug weld seam and RP spot weld seam.
Fig. 76: Joint Between Wheel Housing And Plenum Chamber Welding Areas
 Restore joint between wheel housing and plenum chamber, SG plug weld seam.
Fig. 77: Remaining Joint To Plenum Chamber Welding Areas

 Restore remaining joint to plenum chamber, SG plug weld.
Fig. 78: Original Joint Between Suspension Strut Mounting And Suspension Strut Mounting
Reinforcement Welding Areas
 Restore original joint between suspension strut mounting - 1 - and suspension strut mounting
reinforcement - 2 - , RP spot weld seam.
Fig. 79: Holes For Suspension Strut Mounting Cover Cap Measurement
 Enlarge holes for suspension strut mounting cover cap.
NOTE:  Item 17 for alignment bracket set VAS 6325 can be used to check
dimension - a - , --> Alignment bracket set.
 Install upper wheelhousing longmember --> Installing

FRONT LONGMEMBER, REPLACEMENT
Front longmember, replacement
Cautions

 Spot welder (Inverter) VAS 6237L

Fig. 80: Front Longmember Separating Cuts

1 - Separating cut (cover plate)
2 - Separating cut (longitudinal member)
Removing
Fig. 81: Front Longmember Original Connection


Fig. 82: Separating Cut On Longitudinal Member

 Perform separating cut on longitudinal member as shown.
 Perform separating cut on longitudinal member cover plate as shown.

Fig. 83: Separating Cut On Longitudinal Member Cover Plate

Fig. 84: Front Longmember Residual Material

Installing
Replacement part
 Longitudinal member (ZSB)

Fig. 85: Front Longmember Drilling Areas

 Transfer separating cuts onto new part and cut to shape.
Welding
 Check fit with neighboring components.
Fig. 86: Front Longmember Welding Areas

 Butt weld longitudinal member separating cut all around Gas-shielded arc continuous weld seam.
 Weld cover plate separating cut Gas-shielded arc continuous weld seam and straight-line spot weld seam.
 Reproduce remainder of joint, SG plug weld seam and RP spot weld seam.
Fig. 87: Separating Cut On Cover Plate Welding Area

 Butt weld separating cut on cover plate Gas-shielded arc continuous weld seam.
FRONT LONGITUDINAL MEMBER, REPLACING -PARTIAL SECTION-
Front longitudinal member, replacing -partial section-
Cautions


Fig. 88: Front Longitudinal Member Partial Section

1 - Cover plate
2 - Longitudinal member
3 - Laser weld seam
Removing
Fig. 89: Front Longitudinal Member Partial Section Separating Cuts

NOTE:  Separating cut - 1 - from cover plate and separating cut - 2 - from
longitudinal member are arranged with an offset.
Fig. 90: Identifying 50 mm Before And Behind Laser Weld Seam

NOTE:  50 mm before and behind laser weld seam - 1 - (shaded area) must not be
separated nor welded.
 Mark and perform separating cut - 1 - on cover plate as shown.
Fig. 91: Front Longitudinal Member Partial Section Original Connection


 Remove cover plate.
Fig. 92: Front Longitudinal Member Partial Section Separating Cut

 Mark congruent separating cut - 3 - on longitudinal member - 1 - and reinforcement - 2 - as shown and
perform.
Fig. 93: Front Longitudinal Member Partial Section Remaining Pieces

 Remove remaining pieces and rest of reinforcement - hatched area -.
Installing
Replacement part
 Longitudinal member (sub-part)

 Cover plate for longitudinal member
 Longitudinal member reinforcement (Replacement part designation partition plate)
Fig. 94: Front Longitudinal Member Partial Section Separating Cuts

 Transfer separating cuts to longitudinal member and cover plate and cut.
Welding
Fig. 95: Front Longitudinal Member Partial Section Separating Cut Welding Areas
 Weld longmember separating cut along circumference, SG continuous seam.
Fig. 96: Front Longitudinal Member Partial Section Welding Areas (1 Of 2)

 Weld in longitudinal member reinforcement, SG plug weld seam and RP spot weld seam.
 Weld cover plate separating cut, SG continuous seam.
 Weld in cover plate, RP spot weld seam.
Fig. 97: Front Longitudinal Member Partial Section Welding Areas (2 Of 2)

NOTE:  Distance of welding points - a - approx. 35-40 mm.
THREAD FOR MOUNTING OF SUBFRAME (SUSPENSION SUBFRAME), REPAIRING
Thread for mounting of subframe (suspension subframe), repairing
Cautions
NOTE:  In the example, thread repair on this vehicle is described for left front
retaining bracket for subframe and is to be employed at the other 3
retaining brackets accordingly as necessary.
 Thread repair kit VAS 6058

 Drill machine VAS 6267
Fig. 98: Threaded Plat

1 - Threaded plate (welded into subframe retaining bracket)
NOTE:  The threaded plate is not a replacement part and may only be repaired
once if damaged!
 If damaged once again, the retaining bracket must be replaced. Replace
retaining bracket --> Retaining bracket, replacing - for subframe.
2 - Helicoil thread insert
Contents of thread repair set

Fig. 99: Contents Of Thread Repair Set

1 - Spiral drill 12.5 mm
2 - Tap M 12 x 1.5
3 - Installing spindle
4 - Thread insert M 12 x 1.5 x 24 ( VAS 6058/1 )
5 - Peg breaker with magnetic tips
Thread, repairing
Drilling thread
Fig. 100: Drilling Out The Threads With The Spiral Drill.
 Drill out the threads with the spiral drill.

 Do not angle the drill.
Fig. 101: Drill Held By A Second Person Using An Additional Handle

 For drilling and grinding, use drill VAS 6267.

NOTE:  While drilling, drill must be held by a second person using an additional
handle.
Cutting thread
Fig. 102: Cutting Thread

 Cut the threads with the thread tap.

 Clean threaded bushing (blow with pressurized air).
Inserting thread insert

Fig. 103: Thread Insert Screwed On To Installing Spindle Until Drive Peg Makes Contact On Drive Tab
Of Installing Spindle
 Screw thread insert - 3 - on to installing spindle until drive peg - 2 - makes contact on drive tab - 1 - of
installing spindle.
Fig. 104: Identifying Threaded Insert And Threaded Plate

 Screw the threaded insert into the threaded plate until the threaded insert is seated flush with the outer
edge of the threaded plate (check visually).

 Then screw the threaded insert in by a 1 4 turn.
NOTE:  Thread insert must be able to be turned easily.
 Unscrew the installation spindle.
Fig. 105: Breaking Off Thread Insert Driver Tang Using Tang Breaker
 Break off the driver tang of the threaded insert using the tang breaker - 1 -.
 Install subframe (suspension subframe) (tightening torques) --> FRONT SUSPENSION .
51 - BODY, CENTER
ROOF, REPLACEMENT
Roof, replacement
Cautions


Fig. 106: Identifying Special Tools -- Roof, Replacement


 Compressed air gun V.A.G 1761/1

 Cartridge heater V.A.G 1939 A
 Double cartridge gun VAS 5237
Removing
Fig. 107: Roof And Laser Weld Seam

1 - Roof
2 - Laser weld seam
 Loosen original joint to front and rear window cut-out.

 Roughly cut out center of roof.
Fig. 108: Sunroof Reinforcement Cutting Areas

NOTE:  Before separating roof on vehicles with slide tilt sunroof, the sunroof
reinforcement - 1 - must first be separated from the roof frame - 2 - , and
after welding in roof, it must be welded in again.
 On vehicles without slide tilt sunroof, the reinforcement (roof stiffener) is
not to be separated as well.
Fig. 109: Roof Remaining Material And Side Connections

NOTE:  When removing remaining material - 1 - on roof, make sure that side
connections - 2 - (side panels or sidewall frames) are not damaged.
 Do not use separating- or roughing blades.
 Remove the adhesive and sealant remnants on the front and rear roof cross members, as well as on the
roof reinforcements of vehicles without slide tilt sunroof.
 Repair paint damage on front and rear roof cross members and (for vehicles without sunroof) on roof
reinforcement using 1K gray primer LLS MAX 001 .
Installing
Replacement part
 Roof
 1K assembly adhesive D 190 MKD A3 (3 cartridges)
 2K-body adhesive D 180 KD3 A2 (2 cartridge sets)
 Adhesive sealant AKD 476 KD5 05
 1K gray primer LLS MAX 001

 Felt 533 867 910 B
NOTE:  In order to guarantee problem-free and long lasting roof repair, the
following work procedure must always be followed.
 Adhesion area must not be coated with primer before adhering the roof.
 Roughen the adhesion surface on the vehicle with a fine sandpaper (360 granulation).<
Fig. 110: Roof Adhesion Area

 Sand adhesion area - 1 - at left and right on roof down to bare metal.
This ensures that 2K body adhesive D 180 KD3 A2 can achieve a good bond with the adhesion area.
Fig. 111: Felt Pieces Place Onto Roof Frame At Left And Right
 Place approx. 6 -10 felt pieces - 1 - as necessary onto roof frame at left and right.
 Place roof on roof frame and verify placement to side parts and side wall frames (visual inspection).
NOTE:  Verify placement of the roof to the rear hatch and the windshield.
Fig. 112: Tension Straps Installed Across And Over Roof

 Install two tension straps (commercially available) across and over roof.
 Align strap according to marking - arrows - for installation of front and rear roof base carrier in door
cutouts.
Adjusting roof depth dimension

Fig. 113: Adjusting Roof Depth

 By tightening and loosening tensioning belts, dimension - a - can be aligned, so that roof deeper across
from side wall frames.
Dimension - a - = 4.5+1.5 mm
NOTE:  To prevent damage to roof and sidewall frame, tension straps must not be
tightened too firmly.
Fig. 114: Drill Between Roof And Tensioning Strap

 Use a drill ( 4.5 mm) to verify the dimension - a -.
The drill - 4 - must be able to be pushed lightly between roof - 2 - and tensioning strap - 1 -.
 If necessary, replace felt pieces - 3 - in order to achieve even roof alignment.

 Remove roof again.
 Clean adhesion area on roof and on vehicle using silicone remover LSE 020 100 A3 .
Adhering roof
NOTE:  Adhesive materials must be applied very quickly.

 Always observe processing time (time on pot).
 Use compressed air gun or electric cartridge pistol to apply the adhesive
materials.
Fig. 115: Front Roof Crossmember, Roof Reinforcement And Rear Roof Crossmember
 Using compressed air gun V.A.G 1761/1 , first apply 1K assembly adhesive D190 MKD A3 onto front
roof crossmember - 3 - , roof reinforcement - 2 - and rear roof crossmember - 1 - in area of adhesive
applied during production.
Fig. 116: roof frame adhesive application area

 Apply 1K assembly adhesive D190 MKD A3 - A - in area of roof frame using compressed air gun V.A.G
1761/1.
Fig. 117: Inner Side Of Roof Parallel To Roof Flange At Left And Right Sides Adhesive Area
 Apply 1K assembly adhesive D190 MKD A3 - A - onto inner side of roof parallel to roof flange at left and
right sides using compressed air gun V.A.G 1761/1.
Fig. 118: Cutting Off Section From Nozzle For The Corresponding Bead Geometry
 Cut off approx. 2 mm from nozzle - B - for the corresponding bead geometry.
NOTE:  Processing time (time on pot) for 2K body adhesive D 180 KD3 A2 is
approx. 30 min.
 Cut off the first level of mixer - D - to obtain the corresponding bead
diameter.
 Carefully press pistol without mixer until adhesive extrudes evenly out of
both chambers of cartridge union.
 Then screw mixer onto cartridge union.
 Apply the first 100 mm of adhesive onto a piece of cardboard and only
then begin the application on the vehicle.
 An assistant is required for the following work steps.
 Now fill area - C - with 2K body adhesive D 180 KD3 A2 using double cartridge pistol VAS 5237.
Fig. 119: Roof Flange

 Coat roof flanges using 2K body adhesive D 180 KD3 A2 - 1 - immediately install and align roof.
 Secure roof to front window cut-out and rear lid cut-out using locking pliers and in center region using
tension straps.
 Immediately remove adhesive flowing out at roof edges using a towel saturated with silicone remover
LSE 020 100 A3 .
 Check depth - a - for roof.
NOTE:  After adhering, vehicle must stand on a level surface at room temperature
(at least 15 ° C) for 8 to 10 hours so the adhesive components can cure
(curing time).
 Only after "curing time" has elapsed can further work be performed on the
vehicle.
Welding
Fig. 120: Roof To Front Window Cutout Welding Area

 Weld roof to front window cutout, RP spot weld seam.
Fig. 121: Roof To Rear Window Cutout Welding Area

 Weld roof to rear window cutout, RP spot weld seam.

 Prime left and right roof frames from inside with primer ALN 002 003 04 .
Fig. 122: Sunroof Reinforcement Welding Area

NOTE:  On vehicles with slide tilt sunroof, the left and right sunroof reinforcement
- 1 - must be welded to the roof frame - 2 - Gas-shielded arc continuous
Fig. 123: Identifying Fine-Sealing Of Adhesive Seam

 Perform a fine-sealing of adhesive seam - 1 - from above with adhesive sealant AKD 476 KD5 05 .
 After painting, preserve hollow roof spaces - arrow - with cavity sealing AKR 321 M15 4 .
ROOF, REPLACING - WAGON
Roof, replacing - wagon

Cautions


Fig. 124: Identifying Special Tools -- Roof, Replacement


 Cartridge heater V.A.G 1939 A
Fig. 125: Adjusting Gauge 3371

 Adjusting gauge VAS 3371
Removing
Fig. 126: Wagon Roof

1 - Laser weld seam
2 - Roof
 Separate original joint to front windshield and rear lid cut-out.

 Remove bonded connections to front and rear roof cross members and roof reinforcements (only vehicles
without sunroof).
 Roughly cut out roof.
Fig. 127: Sunroof Reinforcement Cutting Areas

NOTE:  Before separating roof on vehicles with slide tilt sunroof, the sunroof
reinforcement - 1 - must first be separated from the roof frame - 2 - , and
after welding in roof, it must be welded in again.
 On vehicles without slide tilt sunroof, the reinforcement (roof stiffener) is
not to be separated as well.
Fig. 128: Wagon Roof Residual Material

NOTE:  When removing remaining material - 1 - on roof, make sure that side
connections - 2 - (side panels or sidewall frames) are not damaged.
 Do not use separating- or roughing blades.
 Remove the adhesive and sealant remnants on the front and rear roof cross members, as well as on the
roof reinforcements of vehicles without slide tilt sunroof.
 Repair paint damage on front and rear roof cross members and (for vehicles without sunroof) on roof
reinforcement using 1K gray primer LLS MAX 001 .
Installing
Replacement part
 Roof
 1K assembly adhesive D 190 MKD A3 (3 cartridges)
 2K-body adhesive D 180 KD3 A2 (2 cartridge sets)
 Adhesive sealant AKD 476 KD5 05
 1K gray primer LLS MAX 001

 Felt 533 867 910 B
NOTE:  In order to guarantee problem-free and long lasting roof repair, the
following work procedure must always be followed.
 Adhesion area must not be coated with primer before adhering the roof.
 Roughen the adhesion surface on the vehicle with a fine sandpaper (360 granulation).<
Fig. 129: Piercing Part At Transition To Rear Lid Cut-Out

 Pierce new part at transition to rear lid cut-out.

Fig. 130: Left And Right Roof Sand Adhesion Area

 Sand adhesion area - 1 - at left and right on roof down to bare metal.
This ensures that 2K body adhesive D 180 KD3 A2 can achieve a good bond with the adhesion area.
Fig. 131: Felt Pieces Placed Onto Roof Frame At Left And Right
 Place approx. 6 -10 felt pieces - 1 - as necessary onto roof frame at left and right.
 Place roof on roof frame and verify placement to side parts and side wall frames (visual inspection).
 Verify placement of the roof to the rear hatch and the windshield.
Fig. 132: Identifying Door Cut-Outs And Side Window

 Tighten three tensioning straps (commercially available) across roof in area of door cut-outs and side
window - arrows -.
NOTE:  On vehicles with side windows installed, rear strap must be guided around
the entire vehicle.
 To prevent damage to roof frame and sidewall frame, tension straps must
not be tightened too firmly.
 The tension straps prevent roof from lifting off the roof frame and sliding
during the adhesive procedure.
Adjusting roof depth dimension

Fig. 133: Adjusting Roof Depth Dimension

 Check roof alignment to side panels and to sidewall frame.
Dimension - a - = 3.5 + 1.0 mm
NOTE:  Measurement - a - must not fall short.

 Use adjustment gauge VAS 3371 to check measurement - a -.
 You can determine dimension - a - by adding or removing felt pieces so
that the roof rests lower than the side wall frames.
 Remove roof again.

 Clean adhesion area on roof and on vehicle using silicone remover LSE 020 100 A3 .
Adhering roof
NOTE:  Adhesive materials must be applied very quickly.

 Always observe processing time (time on pot).
 Use compressed air gun or electric cartridge pistol to apply the adhesive
materials.
Fig. 134: Identifying Roof Adhesive Application Areas - Front Crossmember, Reinforcement And Rear
Crossmember
 Using compressed air gun V.A.G 1761/1 , first apply 1K assembly adhesive D190 MKD A3 onto front
roof crossmember - 3 - , roof reinforcement - 2 - and rear roof crossmember - 1 - in area of adhesive
applied during production.
Fig. 135: Identifying Roof Adhesive Application Areas - Roof Frame

 Apply 1K assembly adhesive D190 MKD A3 - A - in area of roof frame using compressed air gun V.A.G
1761/1.
Fig. 136: Identifying Roof Adhesive Application Areas - Inner Side Of Roof Parallel To Roof Flange
 Apply 1K assembly adhesive D190 MKD A3 - A - onto inner side of roof parallel to roof flange at left and
right sides using compressed air gun V.A.G 1761/1.
Fig. 137: Cutting Off Section From Nozzle For The Corresponding Bead Geometry
 Cut off approx. 2 mm from nozzle - B - for the corresponding bead geometry.
NOTE:  Processing time (time on pot) for 2K body adhesive D 180 KD3 A2 is
approx. 30 min.
 Cut off the first level of mixer - D - to obtain the corresponding bead
diameter.
 Carefully press pistol without mixer until adhesive extrudes evenly out of
both chambers of cartridge union.
 Then screw mixer onto cartridge union.
 Apply the first 100 mm of adhesive onto a piece of cardboard and only
then begin the application on the vehicle.
 An assistant is required for the following work steps.
Fig. 138: Filling Area Using Adhesive

 Now fill area - C - with 2K body adhesive D 180 KD3 A2 using double cartridge pistol VAS 5237.
Fig. 139: Roof Flanges Adhesive Coating Area

 Coat roof flanges using 2K body adhesive D 180 KD3 A2 - 1 - immediately install and align roof center
piece.
 Secure roof to front window cut-out and rear lid cut-out using locking pliers and in center region using
tension straps.
 Immediately remove adhesive flowing out at roof edges using a towel saturated with silicone remover
LSE 020 100 A3 .
 Check depth dimension - a - for center roof section.
NOTE:  After adhering, vehicle must stand on a level surface at room temperature
(at least 15 ° C) for 8 to 10 hours so the adhesive components can cure
(curing time).
 Only after "curing time" has elapsed can further work be performed on the
vehicle.
Welding
Fig. 140: Roof To Front Window Cutout Welding Area

 Weld roof to front window cutout, RP spot weld seam.
Fig. 141: Roof In Rear Lid Cut-Out Welding Area

 Weld roof in rear lid cut-out, SG plug weld seam.
NOTE:  To avoid heat damage to roof when welding to rear lit cut-out, use a heat
shield.
 Prime left and right roof frames from inside with primer ALN 002 003 04 .
Fig. 142: Sunroof Reinforcement Welding Area

NOTE:  On vehicles with slide tilt sunroof, the left and right sunroof reinforcement
- 1 - must be welded to the roof frame - 2 - Gas-shielded arc continuous
Fig. 143: Fine-Sealing Of Adhesive Seam

 Perform a fine-sealing of adhesive seam - 1 - from above with adhesive sealant AKD 476 KD5 05 .
 After painting, preserve hollow roof spaces - arrow - with cavity sealing AKR 321 M15 4 .
ROOF SIDE MEMBER, REPLACING
Roof side member, replacing

If welding or cutting with spark-producing devices tools or when plating in

foamed areas where gases are produced that are harmful to humans and
the environment, these procedures are to be omitted in each case.
Safety precautions


Fig. 144: Roof Side Member

1 - Structure foam
2 - Molded foam parts
Removing
Fig. 145: Roof Side Member Separating Cuts

 Place separating cuts as shown.
Dimension - b - = 120 mm
Dimension - c - = 90 mm.
 Separate original joint in door cut-outs.

Fig. 146: Roof Side Member Separating Cuts - Partial Replacement (1 Of 2)

According to degree of damage, a partial replacement can be performed with separating cuts - 1 - and - 2 -.
NOTE:  When performing separating cuts - 1 - and - 2 - note - hatched - area that
must not be welded.
Fig. 147: Roof Side Member Separating Cuts - Partial Replacement (2 Of 2)

 Place separating cuts as shown.
 Perform separating cut - 1 - parallel to roof.
 Separate original joint in front window cut-out.

Fig. 148: Roof Side Member Residual Material


 Completely remove adhesive remains and grind bonding surfaces down to bare metal.
Installing
Replacement part
 Side frame
 Repair kit for roof sidemember foam filling D 506 110 A2 (a set for front and rear)
 2K-body adhesive D 180 KD3 A2
 Internally threaded pop rivet
 Transfer separating cuts onto new part and cut to shape. Allow for 10 mm of excess material in roof area.
 Place new part in roof area.
Fig. 149: Inside In Area Of Foam Filling Pieces Fabric Adhesive Tape Application Area
 Apply fabric adhesive tape from Roof sidemember foam filling repair kit D 506 110 A2 to large area of
inside in area of foam filling pieces - hatched area -.
NOTE:  Structure foam should not bond with outer panel of roof sidemember.
Changing the volume of the structure foam could result in ripples in the
roof sidemember.
 The fabric adhesive tape is a component of the roof sidemember foam
filling repair kit.
Molded foam parts
Observe repair notes.
Molded foam parts Elementary Notes, molded foam parts
Welding
Fig. 150: Door Cut-Outs Adhesive Application Area

 Apply 2K body adhesive D 180 KD3 A2 to door cut-outs and front window cut-out.
NOTE:  New part must be installed within 30 minutes, otherwise bonding

properties of adhesive will be impaired.
 Use a heat shield to avoid damage to the roof paint when welding the roof
side member.
 Fit in roof side member and secure.

 Check fit with attachments.
Fig. 151: Roof Sidemember And Front Window Cut-Out Welding Areas
 Weld roof sidemember to front window cut-out, RP spot weld seam.
 Weld separating cuts, SG stepped seam.

Fig. 152: Roof Sidemember And Door Cut-Outs Welding Areas

 Weld roof sidemember into door cut-outs, RP spot weld seam.
Roof sidemember, filing with foam
Replacement part
 Roof sidemember foam filling repair kit D 506 110 A2

Structure foam, applying
 Warm structure foam cartridges for 20 minutes in an approx. 60 ° C water bath.
Fig. 153: Identifying Tools Used For Applying Front Structure Foam
1 - 2K structure foam cartridges
 Lock open.
2 - Static mixer
 Only cut off first stage on tip.
3 - Extension hose
4 - Fabric adhesive tape
NOTE:  Bonded in replacement part so that structure foam cannot bond with outer
panel.
5 - Adapter
NOTE:  Extension hose - 3 - and adapter - 5 - are not needed for applying structure
foam in the VW Passat 2006 -->.
6 - Union nut
 Screw onto 2K structure foam cartridge - 1 - with static mixer - 2 -.
Fig. 154: Roof Sidemember Static Mixer Application Area

 Using the compressed air gun V.A.G 1761/1 via the static mixer, apply structure foam in roof
sidemember - arrow - through the pop rivet openings for securing roof base carrier in front and rear door
cut-outs.
 Then seal opening with pop rivet nut - arrow -.
FRONT ROOF CROSSMEMBER, REPLACEMENT
Front roof crossmember, replacement
Cautions


Fig. 155: Left And Right Roof Frame And Front Roof Cross Member
1 - Left and right roof frame
2 - Front roof cross member
Removing
 Roof already cut out

Fig. 156: Front Roof Crossmember Original Connection


Fig. 157: Front Roof Crossmember Remaining Material

 Remove remaining material on crossover to left and right roof frames.
Installing
Welding
Replacement part
 Front roof cross member
 Align the new part and fix it in place.

 Check gap dimensions with roof and front windshield.
NOTE:  To weld the new part to the left and right roof frame, use the available
slots.
Fig. 158: Front Roof Crossmember Welding Areas

 Weld in front roof crossmember Straight-line spot weld seam and gas-shielded arc plug weld seam.
 Install roof --> Installing.
ROOF REINFORCEMENT, REPLACING (VEHICLES WITHOUT SLIDE TILT SUNROOF)
Roof reinforcement, replacing (vehicles without slide tilt sunroof)
Cautions
Fig. 159: Left And Right Roof Frame And Roof Reinforcement
2 - Roof reinforcement
Removing

Fig. 160: Roof Reinforcement Original Connection


Fig. 161: Roof Reinforcement Remaining Material

 Remove remaining material on left and right roof frames.
Installing
Welding
Replacement part
 Roof reinforcement
 Align and secure roof reinforcement.

 Check fit with roof.
Fig. 162: Roof Reinforcement Welding Areas

 Weld roof reinforcement to left and right roof frames, Gas-shielded arc continuous weld seam.
REAR ROOF CROSSMEMBER, REPLACEMENT
Rear roof crossmember, replacement
Cautions


Fig. 163: Rear Roof Crossmember And Left And Right Roof Frame

2 - Rear roof cross member
Removing
Fig. 164: Rear Roof Crossmember Original Connection


Fig. 165: Rear Roof Crossmember Remaining Material

 Remove remaining material on crossover to left and right roof frames.
Installing
Welding
Replacement part
 Rear roof cross member

 Check fit to roof and rear windshield.
NOTE:  To weld the new part to the left and right roof frame, use the available
slots.
Fig. 166: Rear Roof Crossmember Welding Areas

 Weld in new part, Gas-shielded arc continuous weld seam and straight-line spot weld seam.
REAR ROOF CROSSMEMBER, REPLACING - WAGON
Rear roof crossmember, replacing - wagon
Includes Rear roof crossmember reinforcement
Cautions


Fig. 167: Wagon Rear Roof Crossmember And Glued Area

1 - Rear roof cross member
2 - Glued area
Removing
NOTE:  Roof crossmember and reinforcement are cut out together.

Fig. 168: Wagon Rear Roof Crossmember, Roof Crossmember Reinforcement And D-Pillars
 Separate original joint at left and right between inner D-pillars - 2 - , rear roof crossmember - 1 - and roof
crossmember reinforcement - 3 -.
Fig. 169: Wagon Rear Roof Crossmember Remaining Pieces

 Remove remaining pieces at transition points to left and right D-pillars.

Installing
Replacement part
 Rear roof crossmember (wagon)

 Rear roof crossmember reinforcement (wagon)
Fig. 170: Wagon Rear Roof Crossmember Drilling Areas

 Drill holes for SG plug weld seam in rear roof crossmember - 1 -.
Welding
Fig. 171: Rear Roof Crossmember Reinforcement Secured

 Fit in and secure rear roof crossmember reinforcement.
NOTE:  Note dimension - a -.

 Dimension - a - must be maintained to ensure proper fit of roof.
Dimension - a - - 560+1 mm
 Fitting with rear roof crossmember, check roof and rear lid.
Fig. 172: Crossmember Reinforcement Weld Areas

 Weld in roof crossmember reinforcement, SG plug weld seam.

Fig. 173: Rear Roof Crossmember Adhesive Application Areas

 Apply 2K body adhesive D 180 KD3 A2 - in increments - in areas shown.

 Install rear roof crossmember with vehicle standing on its wheels or on the alignment bracket set and
affix it in place.
 Check fit to roof and rear lid.

 Weld rear roof crossmember with reinforcement and D-pillars, RP spot weld seam and SG plug weld
seam.
Fig. 174: Rear Roof Crossmember Welding Areas

 Installing roof (wagon), --> Installing
A-PILLAR, REPLACEMENT
A-pillar, replacement

Cautions


Fig. 175: A-Pillar Separating Cuts - Partial Replacement

1 - Upper separating cut
It is possible to perform a partial replacement of the A-pillar without damaging the upper outer longitudinal
member for wheel housing, using the separating cut - 2 -.
3 - Separating cut for sill panel
NOTE:  If A-pillar reinforcement must also be replaced, separating cut must be

performed 430 mm from front edge of sill panel.
4 - Glued area
5 - Molded foam part
NOTE:  Foam residue must be removed as much as possible before sanding work.
Removing
NOTE:  Upper outer longitudinal member for wheel housing is already separated --
> Removing.
 Only use body repair saw V.A.G 1523 to perform separating cuts.
Fig. 176: A-Pillar Separating Cuts

 Make separating cut - 1 - and - 3 - according to degree of damage.
NOTE:  Do not damage internal reinforcements. If the reinforcement is damaged

by the separating cut - 1 - , it must be completely replaced. A partial
replacement is not permissible, due to strength reasons crash safety.

Fig. 177: A-Pillar Original Connection

 Separate the original connection at the windshield cut-out.
Fig. 178: A-Pillar Residual Material


Installing
Replacement part
 A-pillar (sub-part)
 Molded foam part
Fig. 179: Transferring Separating Cut Onto New A-Pillar

 Transfer separating cut onto new part and cut to shape.

 Pierce the transition of the new part to the wheel housing.
Molded foam parts
Welding
 Place backing plate behind at separating cuts.

Fig. 180: A-Pillar Adhesive Application Areas

 Apply 2K body adhesive D 180 KD3 A2 in areas - 1 - and - 2 - of adhesive applied during production.

 Fit new part to vehicle standing on its wheels or on alignment bracket set and secure.
Fig. 181: A-Pillar Separating Cuts Welding Areas

 Reproduce original joint in door cut-outs, Straight-line spot weld seam.

 Weld in A-pillar at inner side member, Gas-shielded arc plug weld seam.
Fig. 182: A-Pillar Welding Areas

 Weld A-pillar together with A-pillar reinforcement, Gas-shielded arc plug weld seam.
 Weld in A-pillar at windshield cut-out, Straight-line spot weld seam.
A-PILLAR REINFORCEMENT, REPLACING
A-pillar reinforcement, replacing

Cautions


Fig. 183: A-Pillar Reinforcement Glued Area And Vehicle Lift Point Reinforcement
1 - Glued area
2 - Vehicle lift point reinforcement
NOTE:  Must be replaced together
Removing
 Upper outer longitudinal member for wheel housing is already removed --> Removing.
 A-pillar already removed --> Removing.
Fig. 184: Separating Original A-Pillar Reinforcement Joint

 Separate original joint of A-pillar reinforcement.

Fig. 185: A-Pillar Reinforcement Residual Material

Installing
Replacement part
 A-pillar reinforcement
 Vehicle lift point reinforcement
Fig. 186: A-Pillar Reinforcement Drilling Areas

 Drill holes in A-pillar reinforcement - 1 - for gas-shielded arc plug weld seam, 7 mm.
 Drill holes in vehicle lift point reinforcement - 2 - for gas-shielded arc plug weld seam, 10 mm.
Molded foam parts
Welding
Fig. 187: A-Pillar Reinforcement Adhesive Application Areas

 Apply 2K body adhesive D 180 KD3 A2 in area of door cutout and in area of hinge mounts.

 Install new part with vehicle standing on its wheels or on the alignment bracket set and affix it in place.
 Check fit to A-pillar.
Fig. 188: A-Pillar Reinforcement Welding Areas

 Weld in A-pillar reinforcement, SG plug weld seam and RP spot weld seam.
Fig. 189: A-Pillar Reinforcement At Front Window Welding Areas

 Weld in A-pillar reinforcement at front window cut-out Gas-shielded arc continuous weld seam and
straight-line spot weld seam.
Fig. 190: Vehicle Lift Point Reinforcement Welding Areas

 Weld in vehicle lift point reinforcement, Gas-shielded arc plug weld seam.
 Install upper longitudinal member for wheel housing --> Installing.
 Install A-pillar --> Installing.
B-PILLAR, REPLACING
B-pillar, replacing

Cautions


Removing
Fig. 191: B-Pillar Glued Area And Molded Foam Part

2 - Glued area
NOTE:  If B-pillar reinforcement must be replaced, it must be cut out outside of

 Do not damage original connection to roof center piece.

 Do not damage internal reinforcements. If the reinforcement is damaged
by the separating cuts, it must be completely replaced. A partial
replacement is not permissible, due to strength reasons crash safety.
 Foam residue must be removed as much as possible before sanding work.
 Only use body repair saw V.A.G 1523 to perform separating cuts.
 Observe replacement panel separating cut.
Fig. 192: B-Pillar Separating Cuts

 Perform separating cut - 1 - as shown, do not damage internal reinforcements.
It is possible to perform a partial replacement of the B-pillar without damaging the side member, using the
separating cut - 2 -.
 Make separating cut - 3 - according to degree of damage.

 Perform separating cut - 4 - as shown.
 Separate original joint to B-pillar reinforcement
NOTE:  B-pillar reinforcement must not be damaged when separating spot welds
(laser welds).
 If B-pillar reinforcement is damaged it must be replaced.
 B-pillar reinforcement must not be re-welding for safety reasons crash
safety !
Fig. 193: B-Pillar Original Joint And Sill Panel Reinforcement

 Separate original joint to sill panel reinforcement.

Fig. 194: B-Pillar Residual Material


Installing
Replacement part
 Side panel sub-part

 Butyl sealing cord AKD 497 010 04 R10

Fig. 195: B-Pillar Piercing Areas

 Pierce new part, 7 mm.
Marking of area in which welding must not be performed
 On B-pillar, mark outside of area in which welding must not be performed for reasons of safety crash
safety
NOTE:  It is important to maintain the indicated dimensions.

Fig. 196: B-Pillar Marking Dimensions

 Dimension - a - = 50 mm
 Dimension - b - = 160 mm
 Dimension - c - = 25 mm.
Molded foam parts
Welding

Fig. 197: B-Pillar Adhesive Application Area

 Line area - 1 - with butyl sealing cord AKD 497 010 04 R10 .
 Apply 2K body adhesive D 180 KD3 A2 in area - 2 - and - 3 -.

 Check fit with accessories.
Fig. 198: B-Pillar Welding Areas

 Weld in B-pillar, SG stepped seam and RP spot weld seam.
NOTE:  The welding procedure in area - 1 - (gas-shielded arc stitch weld seam) is
only applicable if the B-pillar reinforcement must also be replaced.
 Pay attention to area - 2 - in which welding must not be performed.
Fig. 199: B-Pillar Reinforcement Welding Areas

 Reproduce remainder of joint to side member reinforcement, Gas-shielded arc plug weld seam.
INNER B-PILLAR, REPLACING
Inner B-pillar, replacing
Cautions


Fig. 200: Inner B-Pillar Glued Area

1 - Glued area
NOTE:  The adhesion area - 1 - is separated before the inner B-pillar is separated,
and is restored after the inner B-pillar is welded in.
2 - Inner B-pillar
Removing
 B-pillar already removed

 B-pillar reinforcement already removed
Fig. 201: Inner B-Pillar Original Connection


Fig. 202: Inner B-Pillar Residual Material

Installing
Welding
Replacement part
 Inner B-pillar
 2K-body adhesive D180 KD3 A2
 Using the B-pillar reinforcement and the outer B-pillar, align and affix the new part with vehicle standing
on its wheels or on the alignment bracket set.
 Check fit with accessories.
Fig. 203: Inner B-Pillar Welding Areas

 Weld in new part, Gas-shielded arc continuous weld seam and straight-line spot weld seam.
Fig. 204: Inner B-Pillar Adhesive Application Area

 After completing the weld procedures in - hatched area - apply 2K body adhesive D180 KD3 A2
between roof frame reinforcement - 1 - and inner B-pillar - 2 -.
 Install B-pillar reinforcement --> Installing.
 Install B-pillar --> Installing.
B-PILLAR REINFORCEMENT, REPLACING
B-pillar reinforcement, replacing
Includes Front sidemember reinforcement (partial section) and rear sidemember reinforcement (partial section)

Cautions


Fig. 205: B-Pillar Reinforcement Separating Cuts

1 - Roof joint separating cut
2 - Glued area
3 - Rear sidemember reinforcement separating cut
4 - Front sidemember reinforcement separating cut
NOTE:
 Reinforcements for B-pillar, front sidemember and rear sidemember may

not be separated places - 1, 3 and 4 - indicated.
 For reasons of safety crash safety , it is not permitted to separate and weld
at a point other than the ones indicated.
Removing
 Outer B-pillar already cut out

 Side member already separated
Fig. 206: B-Pillar Reinforcement Separating Cuts In Roof

 Perform separating cut - 1 - in roof joint as shown.

 To do this, a section of outer roof frame must be cut out and replaced as shown when cutting out the outer
B-pillar.
 Do not damage internal roof frame reinforcement - 2 -.
NOTE:  If the roof frame reinforcement is damaged, it must be replaced.
 Drill out spot welds on roof joint as shown.

 Perform separating cuts - 3 and 4 - at front and rear sidemember reinforcements.
Fig. 207: B-Pillar Reinforcement Remainder Joint

 Separate remainder of joint.

Fig. 208: B-Pillar Reinforcement Interior Original Joint

NOTE:  Separate original joint from vehicle interior in area - 2 -.

 If inner B-pillar - 4 - is damaged too severely when doing this, it must be
replaced. Inner B-pillar, replacing --> Inner B-pillar, replacing.
 Separate original joint from outside in areas - 1 and 3 -.
Fig. 209: B-Pillar Reinforcement Residual Material

Installing
Replacement part
 B-pillar reinforcement
 Front sill panel reinforcement
 Front sidemember reinforcement partition plate
 Rear sill panel reinforcement

 2K-body adhesive D180 KD3 A2
NOTE:  B-pillar reinforcement is the same in the sedan and wagon.

 There is only a difference between vehicles for North America "NAR" and
vehicles for the rest of the world "RDW".
Fig. 210: Transfer B-Pillar Reinforcement Separating Cut

 Transfer separating cut to B-pillar reinforcement and cut off - hatched area -.
Fig. 211: Transferring B-Pillar Front and Rear Sidememember Reinforcement Cuts
 Transfer separating cuts to front and rear sidemember reinforcements and cut off - hatched area -.
NOTE:  On B-pillar reinforcement, mark area in which welding must not be

performed for reasons of safety crash safety
 Measure out area and mark.
Marking of areas in which welding must not be performed
NOTE:  For reasons of safety crash safety , areas marked in the following
illustrations must not be welded when welding in B-pillar reinforcement.
 It is important to maintain the indicated dimensions.
 Before welding in outer B-pillar, dimensions of area in which welding must
not be performed must be transferred onto outer B-pillar.
Fig. 212: B-Pillar Reinforcement Welding Markings

 Marking areas in which welding must not be performed.
 Dimension - a - = 50 mm
 Dimension - b - = 160 mm
 Dimension - c - = 25 mm.
 Fit B-pillar reinforcement with front and rear sidemember reinforcements with vehicle resting on wheels
or on alignment bracket set.
Fig. 213: B-Pillar Reinforcement Spot Welding Areas

 Secure front and rear sidemember reinforcements - 1 and 2 - with one small SG spot weld each at upper
and lower center - hatched area - to B-pillar reinforcement - 3 - and remove B-pillar reinforcement with
sidemember reinforcements again.
Fig. 214: Side Member Reinforcement Partition Plate And Front Sidemember Reinforcement
 Fit side member reinforcement partition plate - 2 - into front sidemember reinforcement - 1 -.
NOTE:  Holes - 3 - must align.
 Weld front sidemember reinforcement - 1 - and sidemember reinforcement partition panel - 2 - with B-
pillar reinforcement - 4 - , RP spot weld seam.
Fig. 215: Rear Sidemember Reinforcement (With Partition Panel) And B-Pillar Reinforcement Welding
Areas
 Weld rear sidemember reinforcement (with partition panel) - 1 - and B-pillar reinforcement - 2 - from
inside, SG plug weld seam.
NOTE:  Use slots available in replacement part for welding.
Molded foam parts
Welding
Fig. 216: B-Pillar Reinforcement Adhesive Application Areas

 Apply 2K body adhesive D180 KD3 A2 in marked area - shaded -.
 Fit B-pillar reinforcement with front and rear sidemember reinforcements and secure with help of outer
B-pillar and outer sidemember while is resting on wheels or alignment bracket set.

Fig. 217: B-Pillar Reinforcement Welding Areas

 Weld separating cut of B-pillar reinforcement, SG continuous seam.
 Re-create original joint to inner sidemember, RP spot weld seam.

Fig. 218: Remainder B-Pillar Reinforcement Joint Welding Areas

 Reproduce remainder of joint, RP spot weld seam.
NOTE:  Pay attention to area - 1 - in which welding must not be performed.
 Install outer B-pillar --> Installing.

 Install sill panel --> Installing.
SILL PANEL, REMOVING
Sill panel, removing


Cautions


Fig. 219: Sill Panel Molded Foam Parts And Glued Area
1 - Molded foam parts
2 - Glued area
Removing
NOTE:  Only use body repair saw V.A.G 1523 to perform separating cuts.
 Foam residue must be removed as much as possible before sanding work.
Fig. 220: Sill Panel Separating Cuts

 Observe replacement panel separating cut at separating cut - 1 -.
 Sand through the outer edge at the wheel well.

 Perform separating cut - 2 - and - 3 - as shown.
NOTE:  The specified dimensions - a - and - b - must be strictly maintained.

Fig. 221: Sill Panel Residual Material

 Separate original joint to side member reinforcement.

 Clean flanged area on wheelhousing (it must be free of dust and grease).
Installing
Replacement part
 Sill panel (sub-part)

 Butyl sealing cord AKD 497 010 04 R10

Fig. 222: Sill Panel Piercing Locations

 Pierce new part, 7 mm.
Marking of areas in which welding must not be performed
NOTE:  On sill panel, mark outside of area in which welding must not be
performed for reasons of safety crash safety.
 It is important to maintain the indicated dimensions.
Fig. 223: Sill Panel Areas Which Are Not Welded

 Mark areas in which welding must not be performed.
Molded foam parts
Welding
Fig. 224: Sill Panel Adhesive Application Areas

 Line area - 1 - with butyl sealing cord AKD 497 010 04 R10 .
 Apply 2K body adhesive D 180 KD3 A2 in area - 2 - and - 3 -. 2 beads each of 3.5 mm.

Fig. 225: Sill Panel To Side Panel Welding Areas

 Weld separating cut of A-pillar and B-pillar, Gas-shielded arc stitch weld seam.
 Weld separating cut of sill panel to side panel, SG stepped seam.
NOTE:  Pay attention to area - 1 - in which welding must not be performed.
 Reproduce original joint, RP spot weld seam.

Fig. 226: Remainder of Sill Panel Joint Welding Areas

 Reproduce remainder of joint to sill panel reinforcement, SG stepped seam.

 Flange wheelhousing.
 Wipe off escaping adhesive and seal wheelhousing.
REINFORCEMENT FOR FRONT SILL PANEL, REPLACING
Reinforcement for front sill panel, replacing
Cautions


Fig. 227: Reinforcement For Front Sill Panel Sections

1 - Front sidemember reinforcement
2 - B-pillar reinforcement
3 - Remainder of front sidemember reinforcement (remains stationary)
4 - Separating cut
5 - Glued area
6 - A-pillar reinforcement
Removing
 Sill panel already removed
Fig. 228: Reinforcement For Front Sill Panel Separating Cuts

 Separate original joint to A-pillar - 2 - as well as to inner side member.

Fig. 229: Reinforcement For Front Sill Panel Separating Residual Material
Installing
Replacement part
 Front sill panel reinforcement
 Transfer separating cut to new part and cut off - hatched area -.
Fig. 230: Reinforcement For Front Sill Panel Separating Drilling Areas
 As shown, drill holes for gas-shielded arc plug weld seam, 8 mm.
NOTE:  It is important to maintain the indicated dimensions.
Welding
Fig. 231: Reinforcement For Front Sill Panel Separating Adhesive Application Areas
 Apply 2K adhesive D 180 KD3 A27:00 15:45 in areas marked.

 Check fit with sidemember.
Fig. 232: Reinforcement For Front Sill Panel Separating Welding Areas
 Weld in front side member reinforcement, Gas-shielded arc plug weld seam and straight-line spot weld
seam.
 Weld the separating cut, Gas-shielded arc continuous weld seam.

 In areas - 1 - , SG plug weld seam (3x)
NOTE:  Length of seams - 1 - 20 mm, distance between seams 20 mm
REINFORCEMENT FOR REAR SILL PANEL, REPLACING

Cautions


Fig. 233: Reinforcement For Rear Sill Panel Sections

1 - Remainder of rear longitudinal member reinforcement (remains stationary)
2 - Separating cut
3 - Wheel housing liner
4 - Rear longitudinal member reinforcement
5 - Glued area
6 - B-pillar reinforcement
Removing
 Sill panel already removed
Fig. 234: Reinforcement For Rear Sill Panel Separating Cuts

 Separate original joint to inner sill panel and to outer wheelhousing liner.

Fig. 235: Reinforcement For Rear Sill Panel Residual Material


Installing
Welding
Replacement part
 Rear sill panel reinforcement

 2K adhesive D 180 KD3 A2
Fig. 236: Reinforcement For Rear Sill Panel Adhesive Application Areas
 Apply adhesive in area shown.

Fig. 237: Reinforcement For Rear Sill Panel Welding Areas

 Weld in rear sill panel reinforcement, SG continuous weld seam and RP spot weld seam.
53 - BODY, REAR
CROSS PANEL, REPLACING
Cross panel, replacing
Includes Inner crossmember, left and right brackets for exhaust system and left and right connecting plates for
tail light mounts.
Cautions


NOTE:  The rear cross plate can be replaced without removing the lock carrier.
Fig. 238: Cross Panel

Removing
Fig. 239: Cross Panel Separating Cuts

 Separate original joint on outside.

Fig. 240: Original Connection Of Inner Crossmember And Left And Right Brackets For Exhaust System
 Separate original connection of inner crossmember and left and right brackets for exhaust system.
Fig. 241: Cross Panel Residual Material

Installing
Replacement part
 Cross panel
 Crossmember for rear cross panel
 Left bracket for exhaust system
 Right bracket for exhaust system
 Left connecting plate for tail light mount

 Right connecting plate for tail light mount
Fig. 242: Cross Panel Drilling Locations

1 - Connecting plate for tail light mount
2 - Cross panel
3 - Crossmember for rear cross panel
4 - Bracket for exhaust system
Welding
 Align and secure new parts with vehicle standing on wheels or alignment bracket set.

 Check closing function of lid.
Fig. 243: Cross Panel Welding Areas

 Weld in new parts, Straight-line spot weld seam and gas-shielded arc plug weld seam.
Fig. 244: Exhaust System Bracket And Rear Cross Panel Crossmember Welding Areas
 Weld in exhaust system bracket - 1 - and rear cross panel crossmember - 2 - , SG plug weld seam and RP
spot weld seam.
NOTE:  The installation of the spare wheel well may only be performed after the
paint work has been completed.
 Install spare wheel well --> Installing.
REAR CROSS PANEL, REPLACING - WAGON
Rear cross panel, replacing - wagon
Includes Inner crossmember, left and right exhaust system bracket and lock carrier
Cautions


Fig. 245: Wagon Rear Cross Panel Separating Cuts

1 - Rear cross panel with lock carrier, inner crossmember and left and right exhaust system bracket
NOTE:  Rear cross panel - 1 - is cut out in one piece.
2 - Glued area
Removing
 Spare wheel well already removed

Fig. 246: Separating Wagon Rear Cross Panel Joints

 Separate original joint on outside.

Fig. 247: Piece Of The Original Joint For Mounting Left And Right Tail Lights
NOTE:  For better removal of old rear cross panel or installation of new, it is
suggested to also loosen a piece of the original joint for mounting left and
right tail lights - shaded - and to pull tail light mounting out slightly.
Fig. 248: Separating Wagon Rear Cross Panel Inner Joints

 Separate original joint on inside.

Fig. 249: Separating Remaining Joint To Rear Longitudinal Members From Below
 Separate remaining joint to rear longitudinal members from below.
Fig. 250: Wagon Rear Cross Panel Residual Material

Installing
Replacement part
 Rear cross panel, wagon

 Lock carrier, wagon
 Crossmember for rear cross panel
 Left bracket for exhaust system
 Right bracket for exhaust system

Fig. 251: Wagon Rear Cross Panel Drilling Areas

1 - Cross panel
2 - Lock carrier
3 - Crossmember for rear cross panel
4 - Left and right exhaust system bracket
Welding
 Align and secure new parts with vehicle standing on wheels or alignment bracket set.
NOTE:  Observe installation sequence
1. Lock carrier
2. Cross panel
3. Crossmember for rear cross panel
4. Left and right exhaust system bracket

 Check rear lid closing function.
Fig. 252: Lock Carrier Welding Areas

 Weld in lock carrier - 1 - , SG continuous weld seam.

 Weld outer rear cross panel - 2 - , RP spot weld seam and SG plug weld seam.
Fig. 253: Rear Cross Panel Crossmember With Lock Carrier And Rear Cross Panel Welding Areas
 Weld rear cross panel crossmember - 3 - with lock carrier - 1 - and rear cross panel - 2 - , RP spot weld.
NOTE:  In area - 4 - , rear cross panel crossmember, rear cross panel and lock
carrier are welded together.
Fig. 254: Interior Exhaust System Bracket Welding Areas

 Weld in left and right interior exhaust system bracket - 1 - , SG plug weld seam and RP spot weld.
Fig. 255: Remaining Joint To Tail Light Mounting And Left And Right Sealing Channel Welding Areas
 Restore remaining joint to tail light mounting - 1 - and left and right sealing channel - 2 - , SG plug weld
seam.
NOTE:  Use holes resulting from cutting out old rear cross panel to weld new rear
cross panel.
paint work has been completed.
LOCK CARRIER, REPLACING
Lock carrier, replacing
Cautions


Removing
Fig. 256: Lock Carrier Separating Cuts


Fig. 257: Lock Carrier Residual Material

Installing
Welding
Replacement part
 Lock carrier
 Check closing function of lid.
Fig. 258: Lock Carrier Welding Areas

 Weld in lock carrier, Gas-shielded arc plug weld seam and straight-line spot weld seam.
MOUNT FOR TAIL LAMP ASSEMBLY, REPLACING
Mount for tail lamp assembly, replacing
Includes Connecting plate for tail light mount
Cautions


Removing
Fig. 259: Tail Lamp Assembly Mount Separating Cuts

Fig. 260: Tail Lamp Assembly Mount Residual Material


Installing
Replacement part
 Mount for tail lamp assembly

 Connecting plate for tail light mount
Fig. 261: Tail Lamp Assembly Mount Drilling Locations

Welding
 Apply two-part body adhesive D 180 KD3 A2 onto the factory-applied adhesive area.


Fig. 262: Tail Lamp Assembly Mount Welding Areas

 Weld in new parts, Gas-shielded arc plug weld seam and straight-line spot weld seam.
TAIL LIGHT MOUNT, REPLACING - WAGON
Tail light mount, replacing - wagon
Includes Tail lamp connecting piece
Cautions


Fig. 263: Wagon Tail Light Mount Sections

1 - Tail lamp connecting piece
2 - Mount for tail lamp assembly
Removing
 Side panel already removed
Fig. 264: Wagon Tail Light Mount Cutting Sections


Fig. 265: Wagon Tail Light Mount Residual Material

Installing
Replacement part
 Tail lamp mount, wagon

 Tail lamp connecting piece
Fig. 266: Wagon Tail Light Mount Drilling Locations

 Drill holes for SG plug weld seam in tail lamp mount - 2 - , 7 mm.
Welding
Fig. 267: Tail Lamp Connecting Piece And Tail Lamp Mount Welding Areas
 Fit tail lamp connecting piece - 1 - to tail lamp mount - 2 - and weld, RP spot weld.
 Fit tail lamp mount with tail lamp connecting piece and secure.
 Check fit with other components.
Fig. 268: Wagon Tail Light Mount Welding Areas

 Weld in new parts, Gas-shielded arc plug weld seam and straight-line spot weld seam.
 Wagon side panel, installing --> Installing.
C-PILLAR REINFORCEMENT, REPLACING - WAGON
C-pillar reinforcement, replacing - wagon
Includes Striker mount

Cautions


Fig. 269: Wagon C-Pillar Reinforcement Sections

2 - C-pillar reinforcement
3 - Glued area
4 - Striker mount
Removing
 Separated bonded connection - 3 - between striker mount - 4 - , C-pillar reinforcement - 1 - and wheel
housing liner - 2 -.
Fig. 270: Wagon C-Pillar Reinforcement Separating Sections

 Separate original joint between striker mount and rear door cut-out.
NOTE:  Bonded joint - 3 - is re-created after welding in side panel.
 Perform separating cut as shown.
Fig. 271: Wagon C-Pillar Reinforcement Original Connection


Fig. 272: Wagon C-Pillar Reinforcement Residual Material


Installing
Preparing new parts
Replacement part
 C-pillar reinforcement
 Transfer separating cut to new part and cut new part.
Molded foam parts
Molded foam part Elementary Notes, molded foam parts
Welding
 Fit and secure C-pillar reinforcement and striker mount with vehicle resting on wheels or alignment
bracket set.
 Check fit with side panel.
Fig. 273: Wagon C-Pillar Reinforcement RP Spot Weld Areas

 Weld in C-pillar reinforcement, RP spot weld.

Fig. 274: Wagon C-Pillar Reinforcement Straight-Line Spot Weld Seam

 Weld in striker mount, straight-line spot weld seam.
NOTE:  Bonded joint - 1 - is re-created after welding in side panel.
 Wagon side panel, installing --> Installing.
D-PILLAR REINFORCEMENT, REPLACING -PARTIAL SECTION-
D-pillar reinforcement, replacing -partial section-
Includes Tail lamp sealing channel and connecting plate mount
Cautions



Fig. 275: D-Pillar Reinforcement Sections

1 - Sealing channel
2 - Tail lamp connecting plate mount
3 - D-pillar reinforcement
Removing

 Tail lamp mount already cut out
Fig. 276: D-Pillar Reinforcement Cutting Marks

 Mark and perform separating cut as shown.

Fig. 277: D-Pillar Reinforcement Residual Material

Installing
Replacement part
 D-pillar reinforcement
 Sealing channel
 Reverse light connecting plate mount
 Transfer separating cut to new part and cut new part.
Welding
 Check fit with sealing channel, tail lamp mount and side panel.
 Weld the separating cut, Gas-shielded arc continuous weld seam.
Fig. 278: D-Pillar Reinforcement RP Spot Weld Areas

 Weld in D-pillar reinforcement, RP spot weld.
Fig. 279: Sealing Channel And Tail Lamp Connecting Plate Mount
NOTE:  Sealing channel - 1 - and tail lamp connecting plate mount - 2 - are
reinstalled when installing side panel or installing tail lamp mount.
 Tail lamp mount, installing --> Installing.

 Install side panel --> Installing.
INNER D-PILLAR, REPLACING
Inner D-pillar, replacing
Cautions


Fig. 280: Inner D-Pillar Sections

1 - Inner side panel
2 - Inner D-pillar
3 - Rear longitudinal member
Removing

 Tail lamp mount already removed
 D-pillar reinforcement already removed
 Rear cross panel with lock carrier already removed
Fig. 281: Inner D-Pillar Cutting Sections

 Separate original joint to inner side panel - 1 - and rear longitudinal member - 2 -.
Fig. 282: Inner D-Pillar Residual Material

Installing
Welding
Replacement part
 Inner D-pillar (Replacement part designation Sealing channel reinforcement)
Fig. 283: Inner D-Pillar Welding Areas

 Weld new part with side member and inner side panel, RP spot weld seam and SG continuous weld seam.
 Install D-pillar reinforcement --> Installing.
 Tail lamp mount, installing --> Installing.
 Rear cross panel with lock carrier, installing --> Installing.
REAR LONGITUDINAL MEMBER, REPLACING -PARTIAL SECTION-
Rear longitudinal member, replacing -partial section-
Includes Floor panel, cover plate for longitudinal member and bumper mount
Cautions


Fig. 284: Rear Longitudinal Member Sections

1 - Connecting plate
2 - Rear longitudinal member
3 - Bumper mount
4 - Floor panel
NOTE:  When replacing the longitudinal member - 2 - with the bumper mount - 3 - ,
it is suggested that the floor panel - 4 - and the connecting plate - 1 - ,
depending on extent of damage, be replaced as well.
Removing
 Cross panel already cut out

 Lock carrier already removed
 Inner crossmember already removed
 Spare wheel well (plastic part) already removed
Fig. 285: Joint From Floor Panel And Connecting Plate

 Loosen original joint from floor panel - 2 - and from connecting plate - 1 - and remove panels.
Fig. 286: Rear Longitudinal Member Cutting Line

 Lay out and perform the separating cuts on longitudinal member - 2 - and on cover plate for longitudinal
member - 1 -.
Dimension - a - approx. 50 mm
Fig. 287: Rear Longitudinal Member Residual Material

Installing
Replacement part
 Rear longitudinal member

 Cover plate for longitudinal member
 Bumper mount (not shown)
 Floor panel (not shown)
 Connecting plate (not shown)
 Transfer the separating cuts onto the new parts and cut to shape.
Fig. 288: Rear Longitudinal Member Drilling Areas

 Drill holes into the new parts for welding in the bumper mount, 10 mm.
Welding
 Using the rear cross panel, align and affix new parts with vehicle standing on its wheels or on the
alignment bracket set.
Fig. 289: Longitudinal Member And Cover Plate Straight-Line Spot Welding Seam
 Weld together longitudinal member and cover plate, Straight-line spot weld seam.
Fig. 290: Longitudinal Member And Cover Plate Welding Area

 Weld in longitudinal member with cover plate all around Gas-shielded arc continuous weld seam.
Fig. 291: Bumper Mount Welding Areas

 Weld in bumper mount Gas-shielded arc plug weld seam.
Fig. 292: Connecting Plate And Floor Panel Welding Areas

 Weld in connecting plate and floor panel, Straight-line spot weld seam and gas-shielded arc plug weld
seam.
 Restore original joint of floor panel - 2 - and connecting plate - 1 - to side panel.
 Install rear cross panel --> Installing.
paint work has been completed
SIDE PANEL, REPLACING -PARTIAL SECTION-
Side panel, replacing -partial section-

Cautions


Fig. 293: Side Panel Sections


2 - Glued area
Removing
Fig. 294: Side Panel Cutting Locations

 Perform separating cut - 1 - only on outer plate, do not damage internal reinforcements.

 At the wheel well, sand through the outer edge
Fig. 295: Side Panel Original Connection

 Grind laser brazed seam.

Fig. 296: Side Panel Residual Material

NOTE:  Completely remove remainder of laser brazed seam and sand weld area
down to bare metal.
Installing
Replacement part
 Side panel sub-part

 Transfer separating cuts to new parts and cut.

Fig. 297: Side Panel Drilling Areas

 Drill holes in side panel for gas-shielded arc plug weld seam, 7 mm.
Molded foam parts
Welding

 Apply 2K body adhesive D 180 KD3 A2 in the adhesion area of the wheel housing. 2 beads each of 3.5
mm.

 For the right side panel, butyl sealing cord must be applied in area of fuel
filler neck before welding on.
Fig. 298: Side Panel Welding Areas

 Weld in side panel, Straight-line spot weld seam and gas-shielded arc plug weld seam.

Fig. 299: Side Panel Original Joint Welding Areas

 Weld original joint in rear windshield cut-out, Straight-line spot weld seam.
 Weld remaining joint, Gas-shielded arc plug weld seam.

NOTE:  The optical characteristics of laser brazed seam which no longer exists
due to repairs must be reproduced using adhesive sealant AKD 476 KD5
05 .
SIDE PANEL, REPLACING -PARTIAL SECTION- WAGON


Cautions


Fig. 300: Wagon Side Panel Sections

A partial side panel replacement is possible with separating cut - 2 - , depending on extent of damage.
3 - Bonded area
Removing
Fig. 301: Wagon Side Panel Separating Cuts

 Perform separating cuts - 1 - and - 3 - as shown, do not damage internal reinforcements.

 At the wheel well, sand through the outer edge
Fig. 302: Laser Brazed Seams Grinding Areas

 Grind out laser brazed seams - 1 - in rear lid cut-out.
 Separate original joint to tail lamp mount.

Fig. 303: Wagon Side Panel Residual Material

NOTE:  Completely remove remainder of laser brazed seam and sand weld area
down to bare metal.
Installing
Replacement part
 Side panel sub-part, wagon

 Molded foam parts
Fig. 304: Wagon Side Panel Separating Cuts Transferred Onto New Part
 Drill holes in side panel for gas-shielded arc plug weld seam, 7 mm.
Molded foam parts
Welding
 Place backing plate behind separating cuts on wheel well and D-pillar.
Fig. 305: Wagon Side Panel Adhesive Application Areas

 Apply 2K body adhesive D 180 KD3 A2 to adhesive areas. 2 beads each of 3.5 mm.

 For the right side panel, butyl sealing cord must be applied in area of fuel
filler neck before welding on.
Fig. 306: Wagon Side Panel Welding Areas

 Weld in side panel, Straight-line spot weld seam and gas-shielded arc plug weld seam.
Fig. 307: Joint In Rear Lid Cut-Out And Tail Lamp Mount
 Re-create remaining joint in rear lid cut-out and tail lamp mount.
NOTE:  The optical characteristics of laser brazed seams in rear lid cut-out which
no longer exists due to repairs must be reproduced using adhesive
sealant AKD 476 KD5 05 .
OUTER WHEELHOUSING LINER, REPLACING
Outer wheelhousing liner, replacing

Cautions


Fig. 308: Outer Wheelhousing Liner Glued Area

1 - Glued area
Removing

Fig. 309: Original Joint Between Outer Wheel Housing Liner And Inner Wheel Housing Liner
 Separate original joint between outer wheel housing liner - 1 - and inner wheel housing liner - 2 -.
Fig. 310: Original Joint To C-Pillar Reinforcement And The Bonded Joint To Latch Mount
Reinforcement
 Separate original joint to C-pillar reinforcement - 1 - and the bonded joint to latch mount reinforcement -
2 -.
NOTE:  The bonded joint to latch mount reinforcement - 2 - is to be restored just

before the alignment of the side panel.
 Loosen original connection to rear side member reinforcement - 3 -.
Fig. 311: Outer Wheelhousing Liner Residual Material


Installing
Welding
Replacement part
 Outer wheel housing liner - 1 -

Fig. 312: Outer Wheel Housing Liner And Reinforcement Part

 Reinforcement part - 2 -
Fig. 313: Outer Wheel Housing Liner Adhesive Application Areas

 In the adhesion area, apply 2K body adhesive D 180 KD3 A2 . 2 beads, each 3.5 mm diameter.

Fig. 314: Outer Wheel Housing Liner And Reinforcement Piece With Inner Wheel Housing Liner And
Rear Cross Panel Welding Areas
 Weld outer wheel housing liner - 1 - and reinforcement piece - 2 - with inner wheel housing liner - 4 - and
rear cross panel - 3 - , RP spot weld.
Fig. 315: Wheel Housing Liner To C-Pillar Reinforcement And Side Member Reinforcement Welding
Areas
 Weld outer wheel housing liner - 2 - to C-pillar reinforcement - 1 - and side member reinforcement - 3 -
Gas-shielded arc plug weld seam.
NOTE:  The bonded joint to latch mount reinforcement - 4 - is to be restored just

before the installation of the side panel.
OUTER WHEEL HOUSING LINER, REPLACING - WAGON
Outer wheel housing liner, replacing - wagon

Cautions


Fig. 316: Wagon Outer Wheel Housing Liner Sections

1 - Wheel housing liner
2 - Glued area
3 - Striker mount (must be removed and replaced if necessary)
4 - C-pillar reinforcement
Removing

Fig. 317: Bonded Joint Between Striker Mount And Wheel Housing Liner
 Separate bonded joint - hatched area - between striker mount - 3 - and wheel housing liner - 2 -.
 Separate original joint to inner C-pillar - 1 -.
Fig. 318: Original Joint To C-Pillar Reinforcement And Inner Wheel Housing Liner
 Separate original joint to C-pillar reinforcement - 1 - and to inner wheel housing liner - 2 -.
Fig. 319: Joint To Rear Sidemember Reinforcement And To Rear Connecting Plate
 Separate remaining joint to rear sidemember reinforcement - 1 - and to rear connecting plate - 2 -.
Fig. 320: Wagon Outer Wheel Housing Liner Residual Material


Installing
Welding
Replacement part
 Outer wheel housing liner - 1 -
Fig. 321: Outer Wheel Housing Liner And Reinforcement Plate

 Reinforcement plate - 2 -
Fig. 322: Wagon Outer Wheel Housing Liner Adhesive Application Area
 In the adhesion area, apply 2K body adhesive D 180 KD3 A2 . 2 beads, each 3.5 mm diameter.

Fig. 323: Reinforcement Plate With Wheel Housing Liner Welding Areas
 Weld reinforcement plate with wheel housing liner, RP spot weld.

Fig. 324: Wagon Outer Wheel Housing Liner Welding Areas (1 Of 2)

 Weld outer wheel housing liner - 2 - with C-pillar reinforcement - 1 - and inner wheel housing liner - 3 - ,
RP spot weld seam and SG plug weld seam.
Fig. 325: Wagon Outer Wheel Housing Liner Welding Areas (2 Of 2)

 Re-create original joint between rear sidemember reinforcement - 2 - and outer wheel housing liner - 1 - ,
RP spot weld seam.
 Re-create original joint between outer wheel housing liner - 1 - and rear connecting plate - 3 - , RP spot
weld seam.
Fig. 326: Striker Mount Straight-Line Spot Welding Seam

 Weld in striker mount, straight-line spot weld seam.
NOTE:  Bonded joint - hatched area - between striker mount - 1 - and wheel
housing liner - 2 - is recreated when fitting and welding in side panel.
SPARE WHEEL WELL, REPLACEMENT
Spare wheel well, replacement
Cautions
Fig. 327: Spare Wheel Well Sections

1 - Spare wheel well (bonded)
2 - Rear left or right longitudinal member
3 - Floor panel
NOTE:  Procedure is same with sedan and wagon.
Removing
Fig. 328: Spare Wheel Well Separating Line

 Roughly cut out spare wheel well on edge - separating line - with body repair saw V.A.G 1523/A.
 Allow adhesive flange - 1 - to remain.

Fig. 329: Spare Wheel Well Remaining Materials

 Remove remainder of spare wheel well (adhesive flange - 1 - ) with electric cutter V.A.G 1561/A and an
appropriate cutting blade, e.g. cutting blade, bent at right angle (25 mm) V.A.G 1561/4 or cutting blade,
bent at right angle V.A.G 1561/10.
Installing
Replacement part
 Spare wheel well (for front or all wheel drive)

 2C- window adhesive DA 004 600 A2
 Glass and paint primer D 009 200 02
 Applicator D 009 500 25
Fig. 330: Spare Wheel Well Adhesive Application Areas (1 Of 3)

NOTE:  The adhesive bead on the circumference of the replacement part - 1 - must
be cut back to a remainder of approx. 1 mm.
 To ensure proper bonding, bonding bead on replacement part may only be
cut back immediately prior to bonding.
Bonding in
NOTE:  Before bonding spare wheel sell, re-establish paint structure .

Prime spare wheel well adhesive surfaces - shaded - on body side with glasspaint primer D 009 200 02 .
Observe drying time of approx. 10 minutes.

 Then apply 2K window adhesive DA 004 600 A2 - A - to primed sheet metal flange - 1 -.
 Insert new part, align and place spare wheel in well for weight
NOTE:  Drying time for 2K window adhesive DA 004 600 A2 in 4 hours.

Accessories & Equipment Body Front
Accessories & Equipment
Body Front
50 BODY FRONT
LOCK CARRIER
LOCK CARRIER ASSEMBLY OVERVIEW
Fig. 1: Lock Carrier Service Position - Assembly Overview

1. Lock carrier with attachments

 Removing and Installing, refer to LOCK CARRIER WITH ATTACHMENTS
2. Bolt
 Left and right
 Tightening specification: 8 Nm
3. Bolt
 Left and right
4. Rubber stop
 Left and right
 Secured with bolt -3-.
5. Bolt
 4 pieces per side
LOCK CARRIER AIR VENTS ASSEMBLY OVERVIEW
NOTE: Depending on model version, slight deviations for the air vents must be
considered.
Fig. 2: Air Conducting Parts On Lock Carrier, Assembly Overview

1. Lock carrier
2. Upper air vent
 Engaged in lock carrier.
3. Left air vent

4. Right air vent

SERVICE POSITION, SETTING

Fig. 3: Lock Carrier Service Position - Assembly Overview

-- Remove front bumper cover. Refer to FRONT BUMPER COVER .
-- In vehicles with charge air cooler, disconnect pressure hoses, refer to PRESSURE HOSES.
-- Remove the bolts -5- at left and right longitudinal member.
-- Install guide rod T 10093 on left and right longitudinal members.
-- Remove bolts -2- and -3- with stop buffer -4- at left and right on top of lock carrier -1-.
SERVICE POSITION, RESETTING
-- Align the lock carrier and its attachments on the longitudinal members and between the fenders.
NOTE: Make sure the charge air cooler pressure hoses are attached securely. Refer to
PRESSURE HOSES.
Hoses and lines must not be pinched.
-- Align the adaptive cruise control sensor -G550- if the vehicle has a distance regulation sensor, refer to
Vehicle diagnosis, testing and information system VAS 5051.
FENDER
FRONT FENDER ASSEMBLY OVERVIEW
NOTE: The illustration shows a left fender. The right fender is identical.
Fig. 4: Front Fender Assembly Overview

1. Fender
 Removing and Installing, refer to FENDER.
2. Bolt
 1 piece, at the A-pillar
 Quantity: 2, on sill panel
 1 piece, on wheel housing
 Quantity: 2, on fender brace
 Quantity: 4, at fender connecting piece

3. Foam piece
 Inserted between the fender and upper longitudinal member
4. Zinc spacer
 AKL 381 035 50
5. Fender brace
 Removing and Installing, refer to FENDER BRACE.
6. Fender end plate

7. Bolt
8. Expanding nut
NOISE INSULATION
NOISE INSULATION ASSEMBLY OVERVIEW, LONG VERSION
NOTE: Slight changes may have to be made to removal and installation procedures,
depending upon engine installed in vehicle.
The screws -3- are micro-encapsulated and must be replaced after loosening.
Fig. 5: Noise Insulation (Long Version) - Assembly Overview

1. Noise Insulation
 -Arrow- points in direction of travel.
 Removing:
-- Remove screws -2- and -3-.
-- Pull the noise insulation toward the rear out of the lock carrier mounts.
2. Bolt
 Quantity 9
3. Bolt
 The screws are micro-encapsulated.
 Always replace bolts after loosening.
 Quantity: 3
NOISE INSULATION ASSEMBLY OVERVIEW, SHORT VERSION
NOTE: Slight changes may have to be made to removal and installation procedures,
depending upon engine installed in vehicle.
Fig. 6: Noise Insulation (Short Version) - Assembly Overview

1. Noise insulation
 -Arrow- points in direction of travel.
 Removing:
-- Pull the noise insulation toward the rear out of the lock carrier mounts.
2. Bolt
 Quantity 9
UNDERBODY TRIM
UNDERBODY TRIM ASSEMBLY OVERVIEW
NOTE: The illustration shows the left side. The right side is identical except for the rear
underbody trim panel.
Fig. 7: Underbody Trim - Assembly Overview

1. Rear underbody cover

 Only installed on the left side.
 Removing:
2. Bolt
 Quantity: 5
3. Hex nut
 Quantity: 8
4. Underbody cover
 Removing:
-- Remove the hex nuts -3-.
5. Bolt
 Quantity: 2
6. Cover
 Removing:
BULKHEAD
MATERIALS
 1K window
DH 009 100 03 (1)(2)
adhesive
 Activator D 181 801 A1 (3)
 Glass
primer/paint D 009 200 02 (3)
primer
 Cleaning
D 009 401 04 (3)
solution
 Primer D 009 500 25 (3)
applicator
(1) Warm with the heater cartridge V.A.G 1939 according to manufacturer's instructions.
(2) Note the minimum curing time. Refer to MINIMUM CURING TIME .
(3) The materials are stored in the box D 004 700.
BULKHEAD ASSEMBLY OVERVIEW
NOTE: The bulkhead -1- is bolted and also bonded in with PUR adhesive sealing
material -3-.
Fig. 8: Cross Panel, Assembly Overview

1. Bulkhead
 Removing:
-- After unscrewing of bolts -2-, cut through adhesive bead using workshop tools.
2. Bolt
 Quantity: 10
3. PUR adhesive sealant

 DH 009 100 03
 Bead diameter: width = 8 mm, height = 10 mm
 Minimum curing time, refer to MINIMUM CURING TIME .
TUNNEL BRIDGE
TUNNEL BRIDGE ASSEMBLY OVERVIEW
NOTE: The -arrow- points to the direction of travel.
Fig. 9: Tunnel Bridge Assembly Overview

1. Front tunnel bridge

 Removing:
-- Remove the hex-bolts -4-.
2. Rear tunnel bridge

 Removing:
-- Remove the hex nuts -3-.
3. Hex nut
 Quantity: 4
4. Hex head bolt

 Quantity: 4
LOCK CARRIER
LOCK CARRIER WITH ATTACHMENTS
Removing
NOTE: The lock carrier is a safety-relevant component and for this reason it may not be
serviced.
If damaged, replace the lock carrier.

Fig. 10: Lock Carrier With Attachments, Removing And Installing

-- Move the lock carrier and its attachments into the service position -1-. Refer to SERVICE POSITION,
SETTING.
-- Disconnect the electrical harness connectors present.
-- When disconnect the connector from the driver front airbag crash sensor -G283- proceed as described in
-- Drain the coolant and remove the coolant line. Refer to DRAINING AND FILLING (for engine: BLV),
DRAINING AND FILLING (for engine: BPY), and DRAINING AND FILLING (for engines: CCTA &
CBFA). .
-- Remove the condenser refrigerant pipes. Refer to [For engine(s) BPY,BLV,CCTA,CBFA] Removal and
Installation .
-- Be sure to perform the work procedures if the vehicle has adaptive cruise control (ACC). Refer to Removal
and Installation .
-- With a second technician, remove guide rod T 10093 on longitudinal member on left and right sides and lift
out lock carrier.
WARNING: Do not start the engine whenever the A/C system or coolant lines are
disconnected.
NOTE: Do not hang the condenser and hydraulic oil cooler by the lines.
Do not kink the condenser and hydraulic lines.
Installation
 Make sure that all plug- and hose connections are corrected installed when re-assembling.
-- Align the lock carrier on the longitudinal members and between the fenders.
-- Align the adaptive cruise control sensor -G550- if the vehicle has a distance regulation sensor. .
PRESSURE HOSES
Removing the pressure hose
Perform the following:
-- Open the clamp -1- in -direction of arrow a-.

Fig. 11: Opening Clamp & Removing Pressure Hose From Coupling
-- Remove the pressure hose -2- from the coupling -3- in -direction of arrow b-.
Installing the pressure hose
 Make sure the clip -2- is in the upper position.
Fig. 12: Attaching Pressure Hose Into Coupling

-- Attach the pressure hose -3- into the coupling -1- in -direction of arrow-.
-- Push the clip -2- through it all the way down.
NOTE: If the clip cannot be pushed all the way through, this mean the pressure hose is
not completely attached to the coupling.
Install the pressure hose again and lock the clip.
 Pull on the coupling to make sure it is secure.
Pressure Hose with Threaded Connection and Clamp
Removing and pressure hose
-- Loosen the screw on the clamp -A-.
Fig. 13: Pressure Hose And Clamp

-- Remove the pressure hose and clamp -A- from the threaded connection.
Installing the pressure hose
-- Push the pressure hose and clamp -A- all the way onto the threaded connection.
Fig. 14: Pressure Hose And Clamp

-- Tighten the screw on the clamp -A-.
CAUTION: Tighten the screw on the clamp -A- according to the specification Fig. 15.
The pressure hose could slip off the threaded connection while the vehicle
is being driven if the clamp is not tightened enough or even if it is
overtightened.
Fig. 15: Clamp Tightening Specifications

1. Clamp -a- = 13 mm wide: 5.5 Nm

2. Clamp -b- = 9 mm wide: 3 Nm
FENDER
FENDER
NOTE: Removing and installing the left fender is described here. Removing and
installing the right fender is identical.
Removing
Fig. 16: Fender Remove/Install Components

-- Remove front bumper cover. Refer to FRONT BUMPER COVER .
-- Remove the wheel housing liners. Refer to FRONT WHEEL HOUSING LINER .
-- Remove the screws -6- and pull the fender end plate -5- out of the wheel housing.
-- Pull out foam piece -3- between fender and longitudinal member.
-- Carefully remove fender -1-.
Installation
Fig. 17: Front Fender Assembly Overview

-- Insert "spacer AKL 381 035 50" between the fender and the sill panel.
-- Pay attention to the parallel alignment and gap dimensions.
FENDER BRACE
NOTE: Removing and installing the left fender brace is described here. Removing and
installing the right fender brace is identical.
Removing
 Fender is removed.
-- Remove screws -2- and remove fender brace -1-.
Fig. 18: Fender Brace Remove/Install Components

Installation
-- Assemble the fender brace -1-.

Fig. 19: Fender Brace Remove/Install Components

-- Tightening specification for the bolts -2-: 7.5 Nm
-- Align the fender brace and fender with the hood and bumper cover.
SPECIAL TOOLS

Fig. 21: Identifying Special Tools -- Cross Panel


 Cartridge heater V.A.G 1939
 Cartridge gun V.A.G 1628
Fig. 22: Identifying Special Tools -- Lock Carrier

 Guide rod T 10093

Accessories & Equipment Bumpers
Bumpers
63 BUMPERS
FRONT BUMPER COVER
FRONT BUMPER COVER, SERVICING
NOTE: Before replacing the bumper cover, see if it is possible to repair the damage.
FRONT BUMPER COVER ASSEMBLY OVERVIEW
NOTE: Depending on model version, there are small differences in the front bumper
covers.
Fig. 1: Front Bumper Cover - Assembly Overview

1. Front Bumper Cover

 PP/EPDM material
 Removing and Installing, refer to FRONT BUMPER COVER.
2. Hex nut
3. Bolt
 Left and right
4. Bolt
 Quantity: 7
5. Bolt
 Quantity: 6
FRONT BUMPER COVER ASSEMBLY OVERVIEW, R36
Fig. 2: Front Bumper Cover Assembly Overview, R36


2. Bolt
 Quantity: 7
3. Bolt
 Quantity: 6
4. Hex nut
5. Bolt
 Left and right
 Pointing upward
FRONT BUMPER COVER ATTACHMENTS
NOTE: Depending on model version, slight deviations for attachments must be

considered.
Fig. 3: Front Bumper Cover Attachments


2. Center protective molding

 Left and right
 Locked to bumper cover -1-.
 Protective molding can be carefully released from locking mechanisms using a plastic wedge from
outside and removed.
3. Protective strip
 Left and right

 Turn Signal, Locked, Removing and Installing, refer to [For engine(s) BPY,BLV,CCTA,CBFA]
Removal and Installation
4. Bolt
5. Cover
 Left and right
 Remove the bolt -6-.
 The cover can be carefully released from locking mechanisms using a plastic wedge from outside
and removed.
6. Bolt
7. Spoiler
 Material PC/ABS
 Remove only when bumper cover -1- has been removed.
8. Decorative trim strip

 Remove only when center vent grille -9- has been removed.
9. Center vent grille

10. Bolt
11. Guide piece

 Left and right
 Remove the bolt -10- and remove from bumper cover -1-.
FRONT BUMPER COVER ATTACHMENTS, R36

considered.
Fig. 4: Front Bumper Cover Attachments, R36


2. Center protective molding

 Left and right
 Locked to bumper cover -1-.
 Protective molding can be carefully released from locking mechanisms using a plastic wedge from
3. Protective strip
 Left and right

 Turn Signal, Locked, Removing and Installing, refer to [For engine(s) BPY,BLV,CCTA,CBFA]
4. Bolt
5. Air grille
 Left and right
 Remove the bolts -6-.
 The air guide grille can be carefully released from locking mechanisms using a plastic wedge from
6. Bolt
 Quantity: 2
7. Bolt
8. Guide piece
 Left and right
 Remove the bolt -7- and remove from bumper cover -1-.
FRONT BUMPER COVER SUBSTRUCTURE

Fig. 5: Front Bumper Cover Lower Assembly Components

1. Guide trim
 Left and right
2. Bolt
3. Expanding nut
4. Intermediate piece
5. Left guide profile

6. Bolt
 Tightening specification: 3.5 Nm
7. Right guide profile
FRONT BUMPER COVER ASSEMBLY OVERVIEW
Fig. 6: Front Bumper Cover, Assembly Overview

1. Front bumper carrier

2. Bolt
 Left and right
3. Bolt
 Quantity: 6
4. Bolt
5. Hex nut
 Left and right
6. Cross member
 Pedestrian protection, not applicable in all countries.
 Is screwed to bumper carrier.
7. Foam piece
 Self-adhesive
FRONT BUMPER CARRIER ASSEMBLY OVERVIEW

Fig. 7: Front Bumper Carrier (USA), Assembly Overview


2. Bolt
 Left and right
3. Bolt
 Quantity: 6
4. Bolt
5. Foam piece
 Self-adhesive
FRONT BUMPER CARRIER ASSEMBLY OVERVIEW, R36
Fig. 8: Front Bumper Carrier Assembly Overview, R36

1. Cross member
 Pedestrian protection, attached to the bumper carrier -5-
2. Right bracket
3. Left bracket
4. Hex nut
 Left and right, qty: 2
REAR BUMPER COVER - SEDAN
REAR BUMPER COVER, SERVICING
NOTE: If rear bumper cover is damaged, determine whether it is possible to repair the
plastic before replacing.
REAR BUMPER COVER ASSEMBLY OVERVIEW
covers.
Fig. 9: Rear Bumper Cover, Assembly Overview

1. Rear Bumper Cover

 Removing and Installing, refer to REAR BUMPER COVER - SEDAN.
2. Bolt
 Quantity: 6
3. Expanding rivet
 Left and right

 Bolted to the wheel housing liner
5. Bolt
Rear Bumper Cover, R36
Fig. 10: Rear Bumper Cover, R36


2. Bolt
 Quantity: 4
3. Catches
 Left and right
4. Quick release screw

 Quantity: 2
 For the trailer hitch cover -5-
5. Trailer hitch cover

 For trailer hitch with removable ball head.
6. Expanding rivet
 Left and right
7. Bolt
8. Bolt
REAR BUMPER COVER ATTACHMENTS

considered.
Fig. 11: Rear Bumper Cover Attachments


2. Towing eyelet cap

 Engaged in rear bumper cover -1-.
3. Right trim molding

 To be removed only with rear bumper cover removed.

 Removing, refer to [For engine(s) BPY,BLV,CCTA,CBFA] Removal and Installation

5. Spoiler
 Material PC/ABS
6. Left trim molding

 Engaged in rear bumper cover.

considered.
Fig. 12: Rear Bumper Cover Assembly, R36


2. Right rear reflector

 Bolted in the rear bumper cover -1- from the inside.



5. License plate light
 Removing, refer to [For engine(s) BPY,BLV,CCTA,CBFA] Removal and Installation
6. Spoiler
 Material PC/ABS


 Quantity: 2

 Engaged in rear bumper cover.
10. Left rear reflector

 Attached inside the rear bumper cover
REAR BUMPER COVER LOWER COMPONENTS

Fig. 13: Rear Bumper Cover Lower Assembly Components

1. Securing strip
2. Screws
 Quantity: 2
3. Hex nut
 Quantity: 4
4. Guide trim
5. Screws
6. Expanding nut
7. Expanding nut
 Quantity: 2
REAR BUMPER CARRIER ASSEMBLY OVERVIEW
Rear Bumper Carrier, USA

Fig. 14: Rear Bumper Carrier (USA), Assembly Overview

1. Rear bumper carrier

2. Bolt
 Quantity 3 left
 Quantity: 4 on right
 Tightening specification: 20 Nm + 1 /4 (90°) additional turn

Always replace
3. Foam piece
 Self-adhesive
Rear bumper carrier
Fig. 15: Rear Bumper Carrier, Assembly Overview


2. Bolt
 Quantity 3 left
 Always replace
TRAILER HITCH, ASSEMBLY OVERVIEW
NOTE: The tightening specifications only apply to factory-installed trailer hitches.
If a different trailer hitch is installed, ask the manufacturer for the tightening
specifications.
For more information regarding the electrical system, refer to the appropriate
Fig. 16: Trailer Hitch, Assembly Overview

1. Trailer Hitch
 Rear bumper cover, removing, refer to REAR BUMPER COVER - SEDAN.
 Trailer hitch with removable ball head -2- is depicted.
2. Ball head
 Removable ball head is stored in foldable luggage compartment floor.
3. Bolt
 Tightening specification: 50 Nm + 120°

NOTE: Perform the additional turn for the bolts alternating in 2 steps (1st
step: 90°; 2nd step: 30°)
WARNING: Bolts -3- must always be replaced after loosening.
4. Bolt
 Sealing threaded connections
 2 for each side
WARNING: Bolts -4- are sealing threaded connections and seal the interior
from exhaust gases and must be installed in any case.
REAR BUMPER COVER - WAGON
REAR BUMPER COVER, SERVICING
NOTE: If rear bumper cover is damaged, determine whether it is possible to repair the
plastic before replacing.
REAR BUMPER COVER ASSEMBLY OVERVIEW
covers.
Fig. 17: Rear Bumper Cover, Assembly Overview


 Removing and Installing, refer to REAR BUMPER COVER - WAGON.

 For the trailer hitch cover.

4. Bolt
5. Catches
 Left and right
6. Expanding rivet
 Left and right
7. Bolt
8. Bolt
9. Rivet
 For head shields, different number of right and left depending on version of exhaust system.



2. Bolt
 Quantity: 4
3. Catches
 Left and right
 Quantity: 2

6. Rivet
 For head shields, different number of right and left depending on version of exhaust system.
7. Expanding rivet
 Left and right
8. Bolt
9. Bolt
REAR BUMPER COVER ATTACHMENTS

considered.
Fig. 19: Rear Bumper Cover Attachments



3. Spoiler
 Material PC/ABS



 Quantity: 2
 For the trailer hitch cover.



considered.


2. Right rear reflector


4. Spoiler



 Quantity: 2
7. Left rear reflector



REAR BUMPER COVER LOWER COMPONENTS

Fig. 21: Rear Bumper Cover Lower Assembly Components

1. Securing strip
2. Screws
 Quantity: 2
3. Hex nut
 Quantity: 4
4. Guide trim
5. Screws
6. Expanding nut
7. Expanding nut
 Quantity: 2
REAR BUMPER CARRIER ASSEMBLY OVERVIEW
Rear Bumper Carrier, USA

Fig. 22: Rear Bumper Carrier (USA), Assembly Overview


2. Bolt
 Quantity: 3 left

Always replace
3. Foam piece
 Secured to bumper carrier with double-sided adhesive tape.
Rear bumper carrier

Fig. 23: Rear Bumper Carrier, Assembly Overview


2. Bolt
 Quantity 3 left

Always replace
3. Foam piece
 Not on all models
 Attached to the bumper carrier with two-sided tape
TRAILER HITCH ASSEMBLY OVERVIEW
NOTE: The tightening specifications only apply to factory-installed trailer hitches.
If a different trailer hitch is installed, ask the manufacturer for the tightening
specifications.
For more information regarding the electrical system, refer to the SYSTEM
WIRING DIAGRAM information.
Fig. 24: Trailer Hitch Assembly Overview

1. Trailer Hitch
 Trailer hitch with removable ball head -2- is depicted.
2. Ball head
 Removable ball head is stored in foldable luggage compartment floor.
3. Foam piece
 Not on all models .
 Attached to the bumper carrier with two-sided tape
4. Bolt
 Tightening specification: 50 Nm + 120°
NOTE: Perform the additional turn for the bolts alternating in 2 steps (1st
step: 90°; 2nd step: 30°)
WARNING: Bolts -3- must always be replaced after loosening.
5. Bolt
 Sealing threaded connections
 Quantity: 2 for each side
WARNING: Bolts -4- are sealing threaded connections and seal the interior
from exhaust gases and must be installed in any case.
FRONT BUMPER COVER
FRONT BUMPER COVER
NOTE: Slight changes may have to be made to removal and installation procedures of
front bumper cover, depending upon equipment installed in vehicle.
Removing
Fig. 25: Front Bumper Cover Remove/Install Components

-- Remove left and right front wheel housing liners. Refer to FRONT WHEEL HOUSING LINER .
-- Remove bolts -2- from above out of lock carrier.
-- Remove bolts -1- from below.
-- Remove screws -3- (pointing upward) at left and right.
-- Remove hex nuts -4- at left and right fenders on inside.

-- With a second mechanic, pull bumper cover parallel out of mounts of fender.
For more information regarding the parking aid, refer to [For engine(s) BPY,BLV,CCTA,CBFA] Removal
and Installation .
For more information regarding the parallel parking assistance, refer to [For engine(s)
BPY,BLV,CCTA,CBFA] Removal and Installation .
-- Disconnect the hose coupling for the windshield washer fluid hoses. Refer to [For engine(s)
BPY,BLV,CCTA,CBFA] WINDSHIELD AND REAR WINDOW WASHER SYSTEM . .
Installing
NOTE: When installing front bumper cover, make sure it is guided on parallel on
fender.
REAR BUMPER COVER - SEDAN
REAR BUMPER COVER
rear bumper cover, depending upon equipment installed in vehicle.
Removing
Fig. 26: Rear Bumper Cover And Bolts

-- Remove the side panel tail lamps. Refer to [For engine(s) BPY,BLV,CCTA,CBFA] Removal and
Installation .
-- Remove screws -3- in area of left and right wheel housing liner.
-- Pry out expanding rivet -4- in area of left and right wheel housing liners using a screwdriver.
-- From below, unscrew bolts -2- and disengage locking mechanism -arrows- (if equipped) on left and right
sides.
-- Remove left and right bolts -5- under tail light assemblies.
A second mechanic is required for the rest of the removal procedure.
-- Pull rear bumper cover parallel out of guide profiles in side panel.
-- Disconnect the connectors from the rear parking aid sensors (Sedan). Refer to [For engine(s)
Installing
REAR BUMPER COVER - WAGON
REAR BUMPER COVER
rear bumper cover, depending upon equipment installed in vehicle.
Removing
Fig. 27: Rear Bumper Cover And Bolts

-- Remove the side panel tail lamps. Refer to [For engine(s) BPY,BLV,CCTA,CBFA] Removal and
Installation .
-- Remove screws -5- in area of left and right wheel housing liner.
-- Pry out expanding rivet -6- in area of left and right wheel housing liners using a screwdriver.
-- Remove screws -3 and 8- from below and loosen left and right catches -2-.
-- Remove left and right rivets -4- , depending on exhaust system version.
-- Remove left and right bolts -7- under tail light assemblies.
-- Pull rear bumper cover -1- parallel -arrow a- out of side trims in guide panel.
-- Disconnect the connectors from the rear parking aid sensors (Wagon). Refer to [For engine(s)
Installing
SPECIAL TOOLS



CABIN AIR FILTER Volkswagen - Passat
CABIN AIR FILTER
Volkswagen - Passat
REMOVAL & INSTALLATION
NOTE: Manufacturer's terminology for this filter is dust and pollen filter.
CABIN AIR FILTER
Removal & Installation
1. Dust and pollen filter is located in passenger side footwell. Release cover (3) in direction of arrow. See
Fig. 1. Remove dust and pollen filter downward out of heating unit.
Fig. 1: Removing Dust & Pollen Filter

CABIN AIR FILTER Volkswagen - Passat
2. Installation is performed in the reverse order of removal. Note installation position of dust and pollen
filter element. See Fig. 2.
Fig. 2: Installation Position Of Dust & Pollen Filter

Accessories & Equipment Communication
Communication
91 COMMUNICATION
GENERAL INFORMATION
ANTENNA SYSTEM
NOTE: Before troubleshooting or servicing, the technicians must be familiar with the
function and operation of the radio system.
Refer to the Owner's Manual.
When the battery is reconnected, check any affected system or component

(radio, clock, comfort electrical connection etc.) according to the repair
information and/or the Owner's Manual.
Antenna system is installed in the rear window.
It consists of several antenna modules and antenna wiring in rear window.
Positive and negative side frequency filters are also installed.
One roof antenna for receiving satellite radio is installed.
An antenna system with diversity function is installed with the following radios or radio/navigation
systems
 RNS (Radio Navigation System) MFD 2 with DVD drive

 Radio Premium Sound System (Premium 7)
 RCD 510 (Premium 8)
 RNS 510
NOTE: The antenna system with diversity function serves to improve and optimize the
reception quality in the vehicle.
The diversity function is installed directly in these radio or radio/navigation

units. The vehicle does have an additional antenna selection control module.
The unit analyses the terrestrial antenna signals coming in and the better
antenna signal is then used.
An antenna system without diversity function is installed with the following radios or radio/navigation
systems
 Radio Sound System (RCD 210 Entry Radio)
Antenna module installation location:
Fig. 1: Antenna Modules, Removing And Installing

1-
AM/FM radio reception antenna module, removing and installing antenna module, refer to RADIO
RECEPTION ANTENNA MODULE.
2-
Navigation antenna module, removing and installing antenna module, refer to NAVIGATION ANTENNA
MODULE.
3-
Telephone antenna module, removing and installing antenna module, refer to TELEPHONE ANTENNA
MODULE.
CELLULAR TELEPHONE, TWO-WAY RADIOS, NOTES
Cellular Phones and Portable Two-Way Radios with Separate External Antenna
 Radio-based remotes (such as for garage door openers) and wireless peripherals (such as keyboard or PC
mouse) may only be used in vehicle when transmission output of device has a maximum of 100 mW.
 Please follow exactly the operating instructions and installation instructions of the manufacturer of
mobile telephones, radio-based devices, and antennas.
 The devices' optimal range will only be reached with an exterior antenna.
 When telephone and two-way radio systems are installed properly there is no danger to safety system
such as ABS or airbag. A prerequisite is however that there has been no intervention in their installations.
Parallel wiring to such systems must be avoided.
 Excessively high electromagnetic fields can arise if mobile telephones and radio devices, with or without
an incorrectly installed exterior antenna, are used.
In such a case, damage to health and interference with vehicle electronics cannot be ruled out.
Radios/Telephones with a Transmitted Output Above 10 Watts, Prerequisites
 The transmitting power at the antenna base (see manufacturer's data) may not exceed the applicable
maximum values.
 You may not use antenna locations other than those shown in the table.
Transmitting power and antenna location table:
Passat Wagon, refer to .
Passat Sedan, refer to TRANSMITTED OUTPUT, ANTENNA INSTALLATION LOCATIONS, FROM

MY 06.
Performing Repairs
Before starting repair work, batteries must be disconnected! Refer to [For engine(s) BPY,BLV,CCTA,CBFA]
Use valid current flow diagram. Refer to the appropriate SYSTEM WIRING DIAGRAMS.
To remove and install trims, refer to Removal and Installation .
Observe manufacturers operating and installation instructions for cellular telephones, two-way radios and
antennas.
Secure wiring harnesses to cable ties. Wrap connectors with foam to avoid rattling noises.
Transmitted Output , Possible Installation Locations
Volkswagen permits the installation and operation of radio units if the transmitted power on point of the
antenna base, listed in table, is not exceeded. For prescribed antenna locations see table.
The limits set forth in VDE 0848 Part 2 (maximum permissible field intensity to protect persons) must be
maintained even, if necessary, through reduction of transmission output.
Voltage Supply
When retrofitting transmitter/receiver unit in the vehicle, the battery is used to connect the positive and negative
wire.
The wiring harness must be manufactured additionally:
 Voltage supply positive via red wire, 2.5 mm2 cross section.
 Voltage supply negative via brown wire, 2.5 mm2 cross section.
The positive wire must have a fuse which must be located very close to the battery. Therefore a fuse panel must
be secured next to the battery. Both wires must be encased in an insulating hose.
Make suitable connections at battery end.
On unit end proceed as per Owner's manual.
The additional wiring harness must be routed separately from vehicle wiring, the distance apart must be at least
10 cm.
NOTE: For some telephone systems and radio communication units an additional
terminal 15 (ignition) is necessary. Then, a black wire connection of 1.5 mm2
cross section must be connected from transmitter/receiver unit to terminal 15a.
When installing, make sure wiring connections are not routed parallel to
standard wiring.
Antenna and Wiring
A shielded wire must be used between transmitter/receiver unit and antenna. Shielding must be grounded to unit
and antenna.
At the same time, make sure ground connection of antenna base wire to vehicle body is correct and continuous.
The transmitting system must only be used when shielded to avoid interference in antenna wiring. To ensure the
system it is tuned and operating correctly it is recommended that an output/performance check is carried out.
Other Auxiliary Installations
The installation of further electronic equipment like business equipment (such as TV, FAX) or household
equipment (such as electrical cool box) is only permitted if these appliances are marked with a CE or e-sign
(Europe only).
Voltage supply must also be routed via separate wiring set and secured by fuse.
COMMUNICATION SYSTEMS
The communication systems in the Passat are basically comprised of:
 The radio or radio/navigation system

 The telephone system
 The antenna system
 Speaker systems
 The USB connection,
 The iPod connection
 Control module for multimedia
 External audio source connection
 CD Changer
 Sound System Amplifier
Some equipment can be obtained only as options, also not all systems are installed in every vehicle.
NOTE: Before troubleshooting or servicing, technicians must be familiar with all

communications system functions and operating specifics.
Refer to the Owner's Manuals.
When performing service work or fault-finding, use the Vehicle Diagnosis and
Service System VAS 5052 in the function "Guided Fault Finding" or Diagnostic
Operation System VAS 5051. Refer to the appropriate SYSTEM WIRING
Troubleshooting
All communication systems have On Board Diagnostic (OBD) capabilities.
When performing Fault Finding, use Diagnostic Operation System VAS 5051 or Vehicle Diagnosis and Service
System VAS 5052 in the function "Guided Fault Finding".
DIGITAL SATELLITE RADIO TUNER
Depending on the vehicle radio or radio navigation system used, the reception can be expanded for satellite
radio programs via equipment with a digital satellite radio tuner.
function and operation of the radio unit/radio navigation system and of digital
satellite radio tuner.
Refer to the Owner's Manuals.
When performing service work or fault-finding, use the Vehicle Diagnosis and Service System VAS 5052 in the
function "Guided Fault Finding" or Diagnostic Operation System VAS 5051. Refer to the appropriate SYSTEM
WIRING DIAGRAMS information.
When the battery is reconnected, check any affected system or component (radio, clock, comfort electrical
connection etc.) according to the repair information and/or the Owner's Manual.
A satellite reception antenna is installed on the rear of the roof for satellite radio tuner operation.
For the sedan, digital satellite radio tuner is installed in luggage compartment behind right side wall trim.
Troubleshooting
The digital satellite radio tuner is equipped with On Board Diagnostic (OBD) capabilities
EXTERNAL AUDIO SOURCE CONNECTION
NOTE: Refer to the Owner's Manual.

The Passat has a 3.5 mm stereo jack located in the center armrest storage compartment -arrow- for connecting
external audio sources.
Fig. 2: 3.5 mm Stereo Jack

It functions with the Volkswagen radio and radio/navigation systems, and is possible only when "AUX" has
been selected on the radio.
Audio signals (generally the headphone output signals) from MP3 players and CD and cassette players can be
played in the radio or radio navigation system at the external audio source connection with the appropriate
wiring connection. They can then be played through the vehicle speakers.
For more information, see the radio or radio/navigation system in the Owner's manual.
INTERFERENCE SUPPRESSION MEASURES
All standard and optional electrical consumers in the vehicle are shielded.
This includes all sensors, actuators and all electrical motors in the vehicle, as well as controllers in control
modules that could cause high-frequency interference.
To suppress interference, all electrical parts such as, condensers, coils, and diodes are integrated with the
electrical components.
Interference suppression components are also built into the connection housings of electrical consumers.
The grounding cables that used to be employed for shielding purposes are no longer used because interference
suppression is now done as near as possible to the source of the interference.
iPOD MOUNT
NOTE: In case of complaints, it is necessary to know the function and operation of the
iPOD and radio/radio navigation system.

As special equipment, a mount for the iPOD from Apple can be ordered through VW.
Different versions of the iPOD are available from Apple. The mount in the vehicle is designed for the following
units:
 The classic iPOD, 3rd and 4th generation

 iPOD mini
 iPOD Photo
When the iPOD is inserted in the mount, the contents of the iPOD can be displayed and selected via the
radio/radio navigation system display. Power is supplied to the iPOD via the mount.
All iPOD audio data can be shown in the radio system but photos cannot be shown in the radio navigation
system display and now background information for the files (ID3 tags) is shown. The radio or radio navigation
system display simply shows the number of the file (track xx).
The files are preprocessed by the iPOD and then sent to the radio or radio navigation system.
Troubleshooting
The v mount is not equipped with On Board Diagnostics (OBD).
Procedure for troubleshooting, refer to IPOD MOUNT, TROUBLESHOOTING.
MULTIFUNCTION STEERING WHEEL
The Multifunction steering wheel makes it possible to control some functions of the Communications System
and the cruise control from the steering wheel.
Fig. 3: Identifying Multi-Function Steering Wheel Controls

The Multifunction Steering Wheel is made up of the following components:
 The Control unit in the steering wheel with two button arrays with integrated electronics, left and right on
the steering wheel.
 Control unit for Multifunction Steering Wheel.
NOTE: Before troubleshooting or servicing, technicians must be familiar with the

functions and operation specifics of the Multifunction Steering Wheel. Always
read the Owner's manual and review specific Communication system functions.
Troubleshooting
The control unit of the multifunction steering wheel communicates with the Steering Column Electronic
Systems Control Module J527. Data commands are processed there once more for further communication with
subsequent control modules (radio system, multifunction display "MFA" and telephone system).
Multifunction Steering Wheel has On Board Diagnostic (OBD) capabilities.
MULTIMEDIA SYSTEM CONTROL MODULE -J650-
Analog audio (via the AUX-In input) and digital audio (via the USB or iPod input) can be played on the radio
or radio navigation system via the multimedia system control module. Devices connected to the USB and iPod
connection can also be controlled through the radio or radio navigation system. ID3 TAGs and titles are also
displayed on the radio or radio navigation system display.
NOTE: Since the capability to display the ID3 tags and titles on the radio or
radio/navigation system display depends on the quality of the audio files being
use, always refer to the radio or radio/navigation system Owner's manual along
with the MP3 player or iPod owner's manual.
The multimedia system control module provides an audio input (Aux-In), a USB input and an iPod connection
(supply, signal and audio-in) as an interface. A specific adapter cable is used to connect the mobile device to the
USB or iPod interface on the multimedia system control module. There is an integrated storage space for the
mobile device in the multimedia system control module. It can also charge the device via the USB or iPod
connection.
NOTE: The multimedia system control module can also be installed separately if there
is no 1DIN slot in the vehicle. The customer can access the universal interface
(mitsumi socket) with a mitsumi-mitsumi extension. The mitsumi socket must
be integrated in the vehicle interior to do this. The mitsumi mitsumi extension
wires must not be longer than 1500 mm.
PREMIUM 7 RADIO
Fig. 4: Identifying "Premium Sound System" Radio System For USA And Canada Vehicles
function and operation of the radio unit.
Anti-theft coding is equipped with protection code number, deactivating

electronic anti-theft system, refer to PREMIUM SOUND SYSTEM (PREMIUM 7)
RADIO ELECTRONIC ANTI-THEFT SYSTEM.
When performing service work or fault-finding, use Diagnostic Operation

System VAS 5051 or Vehicle Diagnosis and Service System VAS 5052, Guided
Fault Finding. Refer to appropriate SYSTEM WIRING information.

The Premium 7 radio consists of radio, 6-disc CD changer integrated in radio and speaker systems in doors.
A Dynaudio Authentic Fidelity sound system is available as optional equipment.
In conjunction with the Dynaudio Authentic Fidelity sound system, the speakers are designed as a 3-way system
at the front and a 2-way system in the rear.
In conjunction with the Dynaudio Authentic Fidelity sound system, speakers are connected directly to the sound
system amplifier and the radio speaker outputs are used for the amplifier input.
The Premium 7 has the following speakers:
 There is one bass speaker, one mid-range speaker and one treble speaker each in the front doors.
 There is one bass speaker and one treble speaker each in the back doors.
For expanding functions, there are connection options for a sound system amplifier, a signal input for satellite
radio, a telephone muting and a signal input for telephone LF-signal.
The 6-disc CD changer integrated in the radio can also play back CDs in MP 3, CD-R and CD-RW formats as
well as normal audio CDs.
NOTE: Mixed CDs (CDs that contain computer data and also music) cannot be played.
In the sedan, the antenna installed is a window antenna and is located in the rear windshield. The antenna
system version has the diversity function.
For the wagon, the antenna installed is a window antenna and is located in the rear side windows. The antenna
Depending on the vehicle equipment level, the Wagon may have only one roof antenna for both the telephone
and satellite radio systems.
RCD 210 (ENTRY RADIO) RADIO
Fig. 5: Identifying "Sound System" Radio System For USA And Canada Vehicles

electronic anti-theft system, refer to RCD 210 (ENTRY RADIO) RADIO
ELECTRONIC ANTI-THEFT SYSTEM.

System VAS 5051 or Vehicle Diagnosis and Service System VAS 5052 in the
function "Guided Fault Finding". Refer to appropriate SYSTEM WIRING
information.

The RCD 210 radio consists of the radio and the speaker systems in the doors.
The radio is equipped with an end stage with 4x20 watt output performance.
Speakers are designed as 2-way system at front and rear.
The CD drive integrated in the radio can play back CDs in MP3, CD-R and CD-RW formats.
In the sedan, the antenna installed is a window antenna and is located in the rear windshield.
For the wagon, the antenna installed is a window antenna and is located in the left rear side window.
Depending on the vehicle equipment level, the Wagon may have only one roof antenna for the telephone.
RCD 510 (PREMIUM 8) RADIO
RCD 510
Fig. 6: RCD 510 (Premium 8) Radio

function and operation of the radio unit.
Anti-theft coding is equipped with protection code number. Refer to RCD 510
(PREMIUM 8) RADIO ELECTRONIC ANTI-THEFT SYSTEM

System VAS 5051 or Vehicle Diagnosis and Service System VAS 5052, Guided
Fault Finding. Refer to the appropriate SYSTEM WIRING information.

The CD changer in the RCD 510 has a transportation safeguard that must be
deactivated when a new unit is installed. The transport protection must also be
activated before shipping in units that have been removed from the vehicle. To
do this, the RCD 510 must still be connected to the voltage supply. CD changer
transportation safeguard in RCD 510, activating and deactivating, refer to RCD
510 (PREMIUM 8) RADIO TRANSPORT PROTECTION,
ACTIVATING/DEACTIVATING.
The RCD 510 radio unit has the following features, among others:
 6.5 inch multicolor display with touch screen

 4 speaker channels with 20 watts each

 Integrated 6-disc CD changer
 Connector position for using SD memory cards for audio playback
 Control for an external 6-CD changer
 Telephone control (hands free)
 Externally connectable sound amplifier
 iPod connection (USB), optional
The RCD 510 radio consists of the radio and the front and rear speakers.
The CD drive, which is integrated inside the radio, can play the following CD formats:
 CD-R
 CD-RW
 MP3
 wma
and navigation systems. On USA and Canada vehicles, this antenna is also used to receive satellite radio.
RCD 510 (PREMIUM 8) RADIO TRANSPORT PROTECTION, ACTIVATING/DEACTIVATING
The transportation safeguard must be activated before shipping a RCD 510 unit or deactivated when installing a
new unit. This takes place electronically over the unit's buttons. After activating the transportation safeguard,
the CD changer mechanism is brought into transportation position.
Activating transportation safeguard
Unit condition: ON, the wiring connections must be connected to the RCD 510.
-- Press and hold buttons marked with -arrows- simultaneously for 5 seconds.
Fig. 7: Activating/Deactivating Transportation Safeguard

The following will appear in the radio display: "CDC transportation safeguard activated".
Now the transportation safeguard is activated.
Deactivating transportation safeguard
Unit condition: ON, the wiring connections must be connected to the RCD 510.
-- Press and hold buttons marked with -arrows- simultaneously for 5 seconds.
Fig. 8: Activating/Deactivating Transportation Safeguard

The following will appear in the radio display: CDC transportation safeguard activated.
The "deactivating" button also appears.
-- Press the "deactivating" button.
Now the transportation safeguard is deactivated.
RNS 510 NAVIGATION RADIO
Fig. 9: RNS 510

The Radio Navigation System RNS 510 combines the functions of a navigation system with those of a high-
value RDS vehicle radio.
The following described the main functions:
 A RDS radio receiver part

 A 6.5-inch color liquid crystal display
 A navigation system with GPS satellite receiver
 Integrated antenna diversity
 Integrated DAB tuner for digital radio reception
 A DVD player for navigation, video and audio
 An SD memory card slot
 Memory for traffic conditions (Travel Information Memory - TIM)

 Corridor function
 Playback formats MP3 and WMA
The RNS 510 radio navigation system has four speaker outputs.
Two optional broadband speakers installed in the rear.
The RNS 510 can be expanded to include the following components:
 CD Changer
 Multifunction steering wheel
 TV tuner
 Amplifier
 Universal Cellular Telephone Preparation (UHV low)
 Universal Cellular Telephone Preparation Premium (BAP)
 Rear Seat Entertainment
and navigation systems.
Troubleshooting
The radio navigation system is equipped with On Board Diagnostic (OBD).
RNS MFD 2 DVD NAVIGATION RADIO

Fig. 10: Radio - Navigation System

NOTE: Replacement part number for radio navigation system is located on a sticker on
the radio navigation system housing.
If radio navigation system is replaced, always activate anti-theft coding, refer to

RNS MFD 2 DVD ELECTRONIC ANTI-THEFT SYSTEM. Give the new code
number to the customer.
If the anti-theft code is not known, you can retrieve it via the known systems.
You need the identification number of the radio navigation system for retrieval.
It is on a sticker attached to the side of the radio. The identification number is
also stamped in the material in the side of the radio navigation system.
If a radio navigation system from one vehicle is to be installed in another

vehicle, then always make sure that radio navigation systems of both vehicles
have the same replacement part number. Otherwise navigation system will
malfunction since the setting of the rotation angle sensor in radio navigation
system does not match the vehicle.
function and operation of the radio navigation system.
For more information, refer to the Owner's Manual and Self Study Program, No.
199; Radio/Navigation System.

electronic anti-theft system, refer to RNS MFD 2 DVD ELECTRONIC ANTI-THEFT
SYSTEM.

function "Guided Fault Finding". Refer to the appropriate SYSTEM WIRING
information.
For proper function of the navigation system, rotation angle sensor in unit must
be set corresponding to installation position of unit in the vehicle. Therefore,
always note the replacement part number when replacing the unit. An incorrect
installation causes malfunctions in the navigation system.

By the use of magnetically adhered antennae on vehicle roof, there is the

hazard that the compass module will malfunction due to magnetic influence and
remaining magnetization of the vehicle roof. For complaints of inaccurate or
faulty direction displays on the compass module, ask the customer whether a
magnetically adhered antenna is being used before starting repair work.
The RNS MFD 2 DVD radio navigation system unifies the functions of a navigation system with those of a
high-value RDS vehicle radio.
In the radio navigation system double DIN housing, there are:
 A RDS radio receiver part

 A 6.5 inch color liquid crystal display in 16:9 format
 A navigation system with GPS satellite receiver and
 A DVD drive for the navigation system
Installed.
The RNS MFD 2 DVD is available as a version which operates the speakers via 4 unit-internal speaker outputs
or as a version with an additional sound system amplifier. The speakers are then connected directly to the sound
system amplifier and the radio navigation system speaker outputs are used for the amplifier input.
NOTE: Playback of audio CDs is only possible with a separate CD-changer.
In conjunction with a RNS MFD 2 DVD a CD-changer is also always installed in

the glove compartment.
For expanded functions, there are connection options for a CD changer, TV tuner, digital satellite radio tuner,
telephone systems and amplifier.
In the sedan, antennae for radio/navigation system installed are a window antenna and are located in the rear
windshield. The antenna system version has the diversity function.
For the wagon, the radio reception antenna installed is a window antenna and is located in the rear side
windows. The antenna system version has the diversity function.
For wagon, a roof antenna is installed for navigation.
SOUND SYSTEM AMPLIFIER
function and operation of the radio and radio navigation system.

function "Guided Fault Finding". Refer to appropriate SYSTEM WIRING
information.

Two amplifier versions are available:
 8-channel amplifier as Volkswagen sound system as well as sound system Monsoon for USA and Canada
or
 10-channel amplifier as Dynaudio Authentic Fidelity sound system.
Sound system amplifiers serve to expand the sound of the radio or radio navigation system.
The activation of signal inputs to amplifier occurs via radio unit or radio navigation system speaker outputs.
Amplifier is installed under front left seat.
Remove and install amplifier, refer to SOUND SYSTEM AMPLIFIER.
Troubleshooting
Amplifier is equipped with On Board Diagnostic (OBD) capabilities
SPEAKER SYSTEMS
NOTE: With Volkswagen sound system as well as sound system Monsoon for USA and
Canada vehicles or sound system Dynaudio Authentic Fidelity: The speaker
system consists of a 3-way system with a bass speaker, midrange speaker and
treble speaker each in front left and right doors. Bass and midrange speakers in
front doors are included in one unit. In vehicle rear, a 2-way system with one
bass speaker and one treble speaker is installed in each door.
Without sound system: In connection with all radios, front speaker system
consists of a 2-way system with one bass speaker and one treble speaker each
in front left and right doors. In vehicle rear, a 2-way system with one bass
speaker and one treble speaker is installed in each door. In vehicles without
sound system, midrange tones are played back over the treble and bass
speakers
All speakers are passive speakers.
TELEPHONE SYSTEM
The telephone system in the Passat is available in two versions. As a complete telephone system and a
telephone preparation.
The telephone system or telephone preparation is only available in conjunction with a radio unit or radio
navigation system.
It is possible to retrofit telephones (cell phones) in a vehicle with telephone preparation.
In vehicles with the universal telephone preparation with telephone base plate on the instrument cluster, the
Telephone Operating Electronics Control Module (interface box) is already installed at the factory.
Two versions of telephone preparation are available:
 As universal telephone preparation with telephone base plate on instrument cluster (not available in US or
Canada).
 As Premium universal telephone preparation with Bluetooth technology with optional telephone base
plate in center armrest.
Troubleshooting
Telephone systems are equipped with On Board Diagnostic (OBD) capabilities.
USB DRIVE AND MP3 PLAYER, USB CONNECTOR
Component location of USB connection -arrow- in glove compartment

Fig. 11: Component Location Of USB Connection In Glove Compartment

function and operation of the USB connection and radio/radio-navigation
system.
Additional information, refer to the Owner's Manual, radio or RNS unit and USB
connection.

For the Passat, a USB connection for connecting USB data storage media (USB drive or MP3 player) may be
ordered individually from VW as special equipment.
The USB storage medium is connected to USB connection, the contents of the USB storage medium can be
displayed and selected on radio/radio-navigation system display. Voltage supply of the USB storage medium is
provided via the USB connection in the vehicle.
Important Information
NOTE: Never remove the storage medium as long as the USB connection has been
selected as the source (CD). It may destroy the storage medium.
Do not insert a MP3 player directly into the USB connection as this may damage
the connection. Always use a USB extension cable instead.
Do not connect any other units than USB sticks or MP3 players to the interface.
It is not possible to operate hard drives, USB hubs etc. via the interface.
The maximum power input of the USB storage medium must not exceed 2.5
Watts (500 mA/5 V).
Never insert metal objects into the USB connection. They may cause a short
circuit and damage the unit.
If storage medium is not detected by the interface within 15 seconds, remove

storage medium and reinsert into USB connection.
Some MP3 players must be activated by a button to establish a USB

connection. Consult the MP3 player operating instructions for further
information.
The permissible temperature range of USB sticks and MP3 players is limited
and often lies between 0° degrees Celsius and 40° Celsius. For this reason,
inform the customer that the storage medium must not be left in the vehicle for
extended periods.
Troubleshooting
The USB connection is not capable of On Board Diagnostics (OBD).
Procedure for troubleshooting, refer to USB CONNECTOR, TROUBLESHOOTING.
Supported Music Data Formats
Only music data in the following data formats can be played back:
 MP3 (MPEG1 Layer 3 from 32 to 320 kbps)

 wma (from 8 to 192 kbps)
 wav (16 kHz sampling frequency with 16 bit encoding, stereo)
 ogg vorbis (to q10, 48kHz, Stereo)
DMR music formats are not supported!
Supported Storage Media
Trouble-free function is assured only when the memory sticks, MP3 players and radios authorized by
Volkswagen are used. The use of memory drives or MP3 players from other manufacturers may not be
guaranteed. However, the storage medium is to have one of the two USB certificates as a minimum
requirement, see diagram.
Fig. 12: Identifying USB Certificates

The following storage media are supported:
Authorized MP3 players:
 Manufacturer Cebop, model Run XL, storage capacity 1024 MB, connection via USB-A
 Manufacturer Maxfield, model MaxRobot, storage capacity 512 MB, connection via USB-A
 Manufacturer Philips, model SA 177, storage capacity 512 MB, connection via USB-A
 Manufacturer Grundig, model MP 500, storage capacity 256 MB, connection via USB-A
 Manufacturer Mambox, model Color, storage capacity 256 MB, connection via USB-A
 Manufacturer Trekstor, model Music Stick 100, storage capacity 256 MB, connection via USB-A
 Manufacturer Trekstor, model 21617, i-Beat, storage capacity 512 MB, connection via Mini-USB
 Manufacturer Time, model DPA-20 FL+, storage capacity 128 MB, connection via USB
 Manufacturer Time, Model DPA-20 FL+, storage Capacity 128 MB, connection via Mini-USB
 Manufacturer Apple, Model iPod Shuffle Gen. 1, storage capacity 1 GB, connection via USB-A
 Manufacturer Creative, Model Movo V, storage capacity 512 MB, connection via USB-A
 Manufacturer Optix, Model Tiamat, storage capacity 2 GB, connection via Mini-USB
 Manufacturer Teac, Model MP 111, storage capacity 512 MB, connection via USB-A
 Manufacturer Thomson, Model Lyra PDP 2356K, storage capacity 256 MB, connection via USB-A
 Manufacturer Trekstor, Model I Beat Classico, storage Capacity 512 MB, connection through a special
manufacturer solution
Authorized memory drives:

Manufacturer Blue Pearl, model Cn Memory, storage capacity 64 MB, connection via USB-A
Manufacturer Buffalo, model Firestix, storage capacity 2 GB, connection via USB-A
Manufacturer Lexar Media, model Jump Drive, storage capacity 128 MB, connection via USB-A
Manufacturer LG, model Mirror USB Drive, storage capacity 128 MB, connection via USB-A
Manufacturer Silver Pearl, model Micro X, storage capacity 1024 MB, connection via USB-A
Manufacturer Pretec, model I-Disk Tiny 2.0, storage capacity 128 MB, connection via USB-A
Manufacturer Buffalo, Model RUF-2-R2G-S Firestix, storage capacity 2 GB, connection via USB-A
Manufacturer CnMemory, Model Blue Pearl, storage capacity 64 MB, connection via USB-A
Manufacturer Intenso, Model USB-Drive, storage capacity 2 GB, connection via USB-A
Manufacturer Media Markt, Model Vario Colour, storage capacity 2 GB, connection via USB-A
Manufacturer Trekstor, Model USB-Stick LE, storage capacity 256 MB, connection via USB-A
Authorized radios:
Problem-free function is only guaranteed when a factory-installed Volkswagen RCD series radio or a
Volkswagen RNS series navigation system is installed. Problem-free function is not assured by the use of radios
from other manufacturers.
AMPLIFIER MULTI-PIN CONNECTOR ASSIGNMENTS
24-Pin Connector A
Fig. 13: 24-Pin Electrical Connection A & 23-Pin Electrical Connection B

1 - Left rear treble speaker, positive
2 - Right rear bass speaker, negative
3 - Right rear bass speaker, positive
4 - Left rear bass speaker, positive
5 - Right rear treble speaker, negative
6 - Right rear treble speaker, positive
7 - Left rear treble speaker, negative
8 - Left front bass speaker, negative
9 - Left front bass speaker, positive
10 - Left rear bass speaker, negative
11 - Right front mid-range speaker, negative
12 - Right front mid-range speaker, positive
13 - Not assigned
14 - Left rear audio signal input, negative

15 - Left rear audio signal input, positive
16 - Not assigned
17 - Right rear audio signal input, negative
18 - Right rear audio signal input, positive
19 - Control in (optional)
20 - Left front audio signal input, negative
21 - Left front audio signal input, positive
22 - Not assigned
23 - Right front audio signal input, negative
24 - Right front audio signal input, positive
23-Pin Connector B
Fig. 14: 24-Pin Electrical Connection A & 23-Pin Electrical Connection B

1 - CAN, low
2 - Left front mid-range speaker, negative
3 - Left front mid-range speaker, positive

4 - CAN, high
5 - Not assigned
6 - Left front treble speaker, negative
7 - Not assigned
8 - Not assigned
9 - Left front treble speaker, positive
10 - Not assigned
11 - Right front bass speaker, positive
12 - Right front bass speaker, negative
13 - Not assigned
14 - Not assigned
15 - Right front treble speaker, positive
16 - Voltage supply, negative
17 - Not assigned
18 - Right front treble speaker, negative
20 - Voltage supply, positive
ANTENNA SYSTEM OVERVIEWS

Fig. 15: RCD 510 (Premium 8) Radio

1. Radio
 RCD 510
2. Antenna Wires From The Radio To The Antenna Module On The Rear Window
3. Radio, Telephone, Navigation System Antenna (GPS) -R52-
 Here, Antenna Module for AM/FM radio reception and optional DAB.
 Installed behind rear window.
 Removing and installing, refer to ANTENNA MODULES.
4. FM Frequency Filter (In Positive Wire) -R179-

 Its function is to prevent antenna signals from shorting to Ground (GND).

5. Rear Window Antenna 1 -R130-
6. FM Frequency Filter (In Negative Wire) -R178-
 Installed in wiring harness.

 Here, antenna module for telephone.
8. Antenna Wire From The Telephone Antenna Module For The Telephone System
9. Antenna Wire From The Radio To The Radio Reception Antenna Module, Here Optional For Digital
Radio Reception
10. Cellular Telephone -R54-
RADIO/NAVIGATION SYSTEMS RNS 510

Fig. 16: Radio/Navigation Systems RNS 510

1. Radio/Navigation Display Control Module -J503- (Radio Navigation System)

 Radio/navigation system RNS 510.
 Here, Antenna Module for AM/FM radio reception and optional DAB.




 Here, antenna module for navigation.
10. Antenna Wire From The Radio To The Radio Reception Antenna Module, Here Optional For Digital
Radio Reception
12. Antenna Wire From The Navigation Antenna Module To The Radio/Navigation System
RCD 210 (ENTRY RADIO) SOUND SYSTEM RADIO

Fig. 17: RCD 210 (Entry Radio) Sound System Radio

1. Radio
 Here, Antenna Module for AM/FM radio reception.


 Installed in wiring harness
 Its function is to prevent antenna signals from shorting to Ground (GND)

PREMIUM SOUND SYSTEM (PREMIUM 7) RADIO

Fig. 18: Premium Sound System (Premium 7) Radio

1. Satellite Tuner Antenna -R172-

 Roof antenna, removing and installing, refer to ROOF ANTENNA.
2. Digital Satellite Radio Tuner -R190-

 Digital satellite radio tuner, removing and installing, refer to DIGITAL SATELLITE RADIO
TUNER.
3. Radio



8. FM Frequency Filter (in negative wire) -R178-

 Installed behind rear window
12. Wire Connection From The Radio To The Digital Satellite Radio Tuner
 The wire connection between the digital satellite radio tuner and the radio/navigation system is not
an antenna wire connection but rather an audio signal wire.
13. Antenna Wires From The Digital Satellite Radio Tuner To The Roof Antenna
RADIO/NAVIGATION SYSTEM RNS MFD 2 WITH DVD PLAYER

Fig. 19: Radio/Navigation System RNS MFD 2 With DVD Player


 Roof antenna, removing and installing, refer to ROOF ANTENNA.

 Digital satellite radio tuner, removing and installing, refer to DIGITAL SATELLITE RADIO
TUNER.
3. Wire Connection From The Radio To The Digital Satellite Radio Tuner
 The wire connection between the digital satellite radio tuner and the radio/navigation system is not
an antenna wire connection but rather an audio signal wire.
4. Radio/Navigation Display Control Module -J503- (Radio Navigation System)
5. Antenna Wires From The Radio/Navigation System To The Antenna Module On The Rear Window


9. FM Frequency Filter (in negative wire) -R178-

 Here, antenna module for navigation.

14. Antenna Wire From The Navigation Antenna Module To The Radio/Navigation System
15. Antenna Wires From The Digital Satellite Radio Tuner To The Roof Antenna
BATTERY, TRANSMITTER AND RECEIVER UNIT, FUSE AND WIRING HARNESS, OVERVIEW
Fig. 20: Battery, Transmitter/Receiver Unit - Fuse And Wiring Harness, Overview
1. 1 - Positive Connection
 Red wire with suitable connection.
2. 2 - To Terminal 15a
 Connection to terminal 15a. Refer to the appropriate SYSTEM WIRING information.
 Ensure wire is protected by fuse.
 Fuse maximum 15 amps.
3. 3 - Antenna Ground
 Ensure correct ground connection to body.
4. 4 - Transmitting/Receiving Antenna
 Installation locations, refer to SPECIFICATIONS.
5. 5 - Shielded Antenna Wire

 Wire with coaxial connector.
6. 6 - Telephone Or Two-Way Radio Transmitter/Receiver Unit

7. 7 - Wiring Harness
 Voltage supply positive via red wire, 2.5 mm2 cross section.
 Voltage supply negative via brown wire, 2.5 mm2 cross section.
 If necessary, wire to terminal 15a via black wire 1.5 mm 2 cross section.
8. 8 - Fuse Holder
 Install next to battery.
9. 9 - To Starter
10. 10 - Battery
 Installation location in engine compartment.
11. 11 - Negative Wire

12. 12 - Body Ground
EXTERNAL AUDIO SOURCE CONNECTOR ASSIGNMENTS
Fig. 21: Aux - In Socket, Pin Assignment

1 - Left audio signal input, positive
2 - shared audio signal ground

3 - Right audio signal input, positive
iPOD MOUNT OVERVIEW
Fig. 22: "ipod" Cradle, Overview

1. iPOD
Classic version of iPOD, 3rd and 4th generation

 Mini version of iPOD or
 Photo version of iPOD
2. Adapter
 To adapt mount to different iPOD sizes.

 Mount adapter, removing and installing, refer to IPOD MOUNT ADAPTER.
3. iPOD Mount
 Mount is integrated in storage compartment under center armrest.
 iPOD mount, removing and installing, refer to IPOD MOUNT.
4. iPOD Mount System Electronics

 Electronics are not accessible, can only be replaced with entire mount.
 Connector overview IPOD MOUNT CONNECTOR OVERVIEW.
5. Left and Right Vehicle Speakers

 Depending on radio version
6. Radio or Radio/Navigation Display Control Module -J503-
iPOD MOUNT CONNECTOR OVERVIEW
Fig. 23: "ipod" Cradle, Multi-Pin Connector Assignments

1. DATA (Data exchange between iPOD and radio)

2. DATA-CLOCK (internal test protocol for monitoring data flow)
3. Voltage supply, terminal 31, negative
4. Radio control data (analog CD changer)
5. Not assigned
6. Voltage supply, positive
7. Audio signal output, right, positive
8. Control wire from radio, positive (analog CD changer)
9. Audio signal output, negative

10. Audio signal output, left, positive
11. Not assigned
12. Not assigned
MULTI MEDIA CONTROL MODULE -J650- OVERVIEW
Fig. 24: Multi Media Control Module -J650- Overview

1. Radio and Radio/Navigation System Speaker System

2. Radio or Radio/Navigation System
3. Multifunction Steering Wheel

4. CAN Bus
5. LF line
 The audio signal from the unit connected to the AUX IN socket runs through this wire and into the
multi media control module.
6. - External Audio Source Connection -R199-
 For additional information regarding the external audio source connection, refer to EXTERNAL
AUDIO SOURCE CONNECTION.
7. Input Unites For Connecting The Multi Media Control Module
 MP3-Player
 Memory sticks
 iPod player
 Connection to the multi media control module via the USB port
8. Wire Connection To The Multi Media Control Unit

 In the form of specific adapter cables depending on the unit to be connected.
9. Multimedia System Control Module -J650-

 Removing and installing, refer to MULTIMEDIA SYSTEM CONTROL MODULE -J650-.
10. Positive and Negative Voltage Supply Connection For The Multi Media Control Module
11. LF line
 The audio signal of the unit connected to the "AUX IN" socket runs from the multi media control
module into the AUX input of the radio or radio/navigation system.
PREMIUM SOUND SYSTEM (PREMIUM 7) RADIO
RADIO SYSTEM OVERVIEW

Fig. 25: Radio System - "Premium Sound System" And "Dynaudio Sound System" , Component
Overview
1. CD Changer -R41-
 Located inside the glove compartment.
 Removing and installing, refer to CD CHANGER.
2. Radio
 Premium 7 "Premium Sound System" with integrated 6-disc CD changer.
 Removing and installing, refer to RADIO.
3. Right Front Treble Speaker -R22- and Left Front Treble Speaker -R20-
 Installed in triangle window of left and right front doors.
 For more information regarding the different speaker systems refer to SPEAKER SYSTEMS.
 Optional as additional equipment.
 On rear of roof.
 For wagon, also for navigation and telephone as an optional.
 For additional notes, refer to ANTENNA SYSTEM OVERVIEWS.

 Installed in luggage compartment, left side.
 For additional notes, refer to DIGITAL SATELLITE RADIO TUNER.
6. Window Antenna
 In sedan, installed in rear windshield, for radio, navigation and telephone.
 For wagon, installed in rear side windows, for radio reception only.
7. Right Rear Bass Speaker -R17- and Left Rear Bass Speaker -R15-
 Installed in door trim of left and right rear doors.
 For more information regarding the different speaker systems, refer to SPEAKER SYSTEMS.
8. Right Rear Treble Speaker -R16- and Left Rear Treble Speaker -R14-
9. Digital Sound System Control Module -R12-

 Installed under the left front seat.
 For additional notes, refer to SOUND SYSTEM AMPLIFIER
10. Right Front Bass Speaker -R23- and Left Front Bass Speaker -R21- , Right Front Midrange Speaker -
R104- and Left Front Midrange Speaker -R103-
 Installed in door trim of left and right front doors.
 Midrange speakers are only installed in conjunction with sound system.
 Midrange and bass speakers are installed as one unit.
 Without sound system, only bass speakers are installed here, mid-range tones are played back over
bass and treble speakers.
RADIO CONNECTOR OVERVIEW

Fig. 26: Identifying Multi-Pin Electrical Connection Assignments

1. 8-Pin Multi-Pin Harness Connector 1, Speaker Outputs

 For the correct contact assignment, refer to 8-PIN MULTI-PIN HARNESS CONNECTOR 1,
SPEAKER OUTPUTS.
2. 8-Pin Connector 2, Voltage Supply, CAN-Bus, Telephone Muting
 For the correct contact assignment, refer to 8-PIN CONNECTOR 2, VOLTAGE SUPPLY,
CAN-BUS, TELEPHONE MUTING.
3. 12-Pin Connector 3, Telephone Signal Input
 For the correct contact assignment, refer to 12-PIN CONNECTOR 3, TELEPHONE SIGNAL
INPUT.
4. 12-Pin Connector 4, Digital Satellite Radio Tuner

 For the correct contact assignment, refer to 12-PIN CONNECTOR 4, DIGITAL SATELLITE
RADIO TUNER.
5. Harness Connector 5, Antenna Connection For AM/FM Radio Reception
 Beige connector color.
 Sedan: Antenna wire to antenna in the rear window connection.
 Wagon: Connection for antenna wire to antenna in rear side windows.
 For the correct contact assignment, refer to ANTENNA CONNECTORS 5 AND 6.
6. Harness Connector 6, Antenna Connection For AM/FM Radio Reception

 Transparent connector color.
8-PIN MULTI-PIN HARNESS CONNECTOR 1, SPEAKER OUTPUTS
Fig. 27: 12-Pin Multi-Pin Electrical Connection 3, Telephone Signal Input (Where Applicable)
NOTE: In conjunction with sound system amplifier, audio signals of radio are utilized
as input signal for sound system amplifier.
1 - Right rear speaker, positive
2 - Right front speaker, positive
3 - Left front speaker, positive

4 - Left rear speaker, positive
5 - Right rear speaker, negative
6 - Right front speaker, negative
7 - Left front speaker, negative
8 - Left rear speaker, negative
8-PIN CONNECTOR 2, VOLTAGE SUPPLY, CAN-BUS, TELEPHONE MUTING
9 - CAN-Bus, positive
10 - CAN-Bus, negative
11 - Telephone mute switch
12 - Negative connection, terminal 31
13 - Radio on, control wire positive
14 - Alarm contact
15 - Positive connection, terminal 30
16 - Anti-theft system control signal, SAFE

12-PIN CONNECTOR 3, TELEPHONE SIGNAL INPUT
NOTE: This harness connector is only assigned when the corresponding special
equipment for telephone system is installed.
1-5 - Not assigned
6 - Telephone LF-signal input, negative
7-11 - Not assigned
12 - Telephone LF-signal input, positive
12-PIN CONNECTOR 4, DIGITAL SATELLITE RADIO TUNER

This harness connector is only assigned when the corresponding special equipment for digital satellite radio
tuner is installed.
1 - Digital satellite radio tuner, input, audio signal left
2 - Not assigned
3 - Digital satellite radio tuner, input, audio signals negative
4 - Not assigned
5 - Digital satellite radio tuner input, continuous positive
6 - Not assigned
7 - Digital satellite radio tuner, input, audio signal right
8 - Not assigned
9 - Not assigned
10 - Not assigned
11 - Not assigned
12 - Not assigned
ANTENNA CONNECTORS 5 AND 6
Fig. 31: Connectors 5 And 6, Antenna Connections

NOTE: The radio is equipped with an antenna diversity function for AM/FM radio
reception. Both antenna connections are signal inputs. In radio, it is
continuously analyzed via which of the two connected window antennae
receives the better reception signal. It then switches to the antenna with the
better reception signal. This is not audible to the customer.
1 - Transparent color connection for antenna input signal for terrestrial radio reception
2 - Beige color connection for antenna input signal for terrestrial radio reception
SOUND SYSTEM OVERVIEW

Fig. 32: Sound System Overview

1. CD Changer -R41-
 6-disc CD changer
 For more information regarding the CD changer, refer to CD CHANGER.
 Optional installation of CD changer or multimedia system control module J650. Both systems are
not available together because they both use the same installation location.
 For additional information, refer to MULTIMEDIA SYSTEM CONTROL MODULE -J650-.

 Optional installation of CD changer or multimedia system control module. Both systems are not
available together because they both use the same installation location.
3. Radio
 Overview of radio connectors, refer to RADIO CONNECTIONS OVERVIEW.
 Transport protection device of CD changer in RCD 510, activating/deactivating, refer to RCD 510
(PREMIUM 8) RADIO TRANSPORT PROTECTION, ACTIVATING/DEACTIVATING.
 Electronic Anti-Theft System, refer to RCD 510 (PREMIUM 8) RADIO ELECTRONIC ANTI-
THEFT SYSTEM.
 Mid-range tones are played back over treble and bass speakers.
 For more information regarding the different speaker systems refer to SPEAKER SYSTEMS.
5. Window Antenna
 Installed in rear window in sedan, for radio, navigation and telephone.
 Antenna for digital radio reception, DAB, also optional.
 Depending on the vehicle equipment level, the Wagon may have only one roof antenna for both the
telephone and navigation systems.
 For more information regarding the different antenna systems, refer to ANTENNA SYSTEM
OVERVIEWS.
 Mid-range tones are played back over treble and bass speakers.
8. External Audio Source Connection -R199-

 Located inside the storage compartment under the center armrest.
 For more information regarding the external audio source connection, refer to EXTERNAL
 For more information regarding the amplifier, refer to SOUND SYSTEM AMPLIFIER.
10. Right Front Bass Speaker -R23- and Left Front Bass Speaker -R21-
RADIO CONNECTIONS OVERVIEW
Fig. 33: Radio Connections Overview

1. Antenna Connection
 Input connector for the DAB antenna, optional
or
 Input connector for SDARS antenna, USA and Canada.

2. 8-Pin Connector A, Speaker Output
 Terminal assignment, refer to 8-PIN CONNECTOR 1, SPEAKER OUTPUT.
3. 8-Pin Connector D, Voltage Supply, CAN-Bus, Telephone Muting

 Terminal assignment, refer to 8-PIN CONNECTOR 2, VOLTAGE SUPPLY, CAN-BUS,
TELEPHONE MUTING.
4. 12-Pin Connector C, AUX Audio Output, Telephone Signal Input
 Terminal assignment, refer to 12-PIN CONNECTOR 3, AUX AUDIO OUTPUT,
TELEPHONE SIGNAL INPUT.
5. 12-Pin Connector B, AUX Audio Input, CD Changer Control and CD Audio Input Signals
 Terminal assignment, refer to 12-PIN CONNECTOR 4, AUX AUDIO INPUT, CD CHANGER
CONTROL AND CD AUDIO INPUT SIGNALS.
6. 26-Pin Connector 5, Audio and Video
 Terminal assignment, refer to 26-PIN CONNECTOR 5, AUDIO AND VIDEO.
 AM/FM antenna input connection.
 FM 2 antenna input connection.
8-PIN CONNECTOR 1, SPEAKER OUTPUT

9 - Can High
10 - Can Low
11 - Supply voltage supply, connected, positive
13 - CAN Bus display, negative
14 - CAN Bus display, positive

12-PIN CONNECTOR 3, AUX AUDIO OUTPUT, TELEPHONE SIGNAL INPUT
1 - Microphone input, negative
2 - AUX output, audio, positive, right
3 - AUX output, audio, negative
4 - Microphone output, negative
5 - Telephone LF-signal input, left, negative
6 - Telephone LF-signal input, right, negative
7 - Microphone input, positive
8 - AUX output, audio, positive, left
9 - Microphone output, positive
10 - Telephone mute
11 - Telephone LF-signal input, left, positive
12 - Telephone LF-signal input, right, positive
12-PIN CONNECTOR 4, AUX AUDIO INPUT, CD CHANGER CONTROL AND CD AUDIO INPUT SIGNALS
1 - AUX input, audio, positive, left
2 - AUX input, audio, negative
3 - CD changer, audio, negative
4 - CD changer, voltage supply, positive
5 - Not assigned
6 - CD changer, DATA OUT Bus
7 - AUX input, audio, positive, right
8 - CD changer, left port audio, positive
9 - CD changer, right port audio, positive
10 - CD Changer, control signal
11 - CD changer, DATA IN Bus
12 - CD changer, CLOCK Bus
26-PIN CONNECTOR 5, AUDIO AND VIDEO

Fig. 38: 26-Pin Connector 5, Audio And Video

1 - Reserved for protocol debug RX
2 - Reserved for protocol debug TX
3 - Not assigned
4 - Not assigned
5 - Video output LF, right
6 - Video signal output, shielding mass
7 - Video signal output, synchronization vertical and horizontal
8 - Video signal output, green
9 - Not assigned
10 - Right video signal input LF
11 - Video signal input, shielding mass
12 - Video signal input, synchronization vertical and horizontal
13 - Video signal input, green
14 - Not assigned
15 - Not assigned
16 - Not assigned
17 - Video signal input LF, negative
18 - Video signal output, LF, left
19 - Video signal output, RGBS, negative
20 - Video signal output, blue
21 - Video signal output, red
23 - Left video signal input LF
24 - Video signals input, RGBS, negative
25 - Video signal input, blue
26 - Video signal input, red
RCD 210 (ENTRY RADIO) RADIO

Fig. 39: Radio System - "Sound System" , Component Overview

1. Radio
3. Window Antenna
 For wagon, installed in left rear side window, for radio reception only.
 Depending on the vehicle equipment level, the Wagon may have only one roof antenna for the
telephone.

6. Right Front Bass Speaker -R23- and Left Front Bass Speaker -R21-
.RADIO CONNECTOR OVERVIEW

Fig. 40: Multi-Pin Connector Assignments

1. 8-Pin Multi-Pin Harness Connector 1, Speaker Outputs

 For the correct contact assignment, refer to 8-PIN MULTI-PIN HARNESS CONNECTOR 1,
SPEAKER OUTPUTS.
2. 8-Pin Connector 2, Voltage Supply, CAN-Bus, Telephone Muting
 For the correct contact assignment, refer to 8-PIN CONNECTOR 2, VOLTAGE SUPPLY,
CAN-BUS, TELEPHONE MUTING.
3. 12-Pin Connector 3, Telephone Signal Input

 For the correct contact assignment, refer to 12-PIN CONNECTOR 3, TELEPHONE SIGNAL
INPUT.
4. Multi-Pin Harness Connector 4
 Not assigned
5. Harness Connector 5, Antenna Connection

 Wagon: Connection for antenna wire to antenna in left rear side window.
8-PIN MULTI-PIN HARNESS CONNECTOR 1, SPEAKER OUTPUTS

9 - CAN-Bus, positive
10 - CAN-Bus, negative
11 - Telephone mute switch
13 - Radio on, control wire
14 - Alarm contact
12-PIN CONNECTOR 3, TELEPHONE SIGNAL INPUT

1-5 - Not assigned
6 - Telephone LF-signal input, negative
7-11 - Not assigned
12 - Telephone LF-signal input, positive
RNS MFD 2 DVD NAVIGATION RADIO

Fig. 44: Radio - Navigation System (DVD), Component Overview

1. CD Changer -R41-
 6 disc CD changer
2. Radio/Navigation Display Control Module -J503- (RNS MFD 2 DVD)

 Connector overview, refer to CD CHANGER.
 Located on the roof at the back of the vehicle.
 Integrated antenna for the navigation and optional telephone.
OVERVIEWS.
 Installed under rear shelf in luggage compartment.
 Additional notes, refer to DIGITAL SATELLITE RADIO TUNER.
6. Window Antenna
OVERVIEWS.

 Additional information, refer to SOUND SYSTEM AMPLIFIER.
10. Right Front Midrange Speaker -R104- and Left Front Midrange Speaker -R103- , Right Front Bass
Speaker -R23- and Left Front Bass Speaker -R21-
SYSTEM CONNECTORS OVERVIEW

Fig. 45: Identifying Multi-Pin Electrical Connection Assignments

1. 1 - 18-Pin Connector 1
 For the correct contact assignment, refer to 18-PIN CONNECTOR 1, VIDEO AND LF INPUT.
2. 2 - Connector 2
 Connection for navigation system antenna
 For the correct contact assignment, refer to CONNECTOR 2.
 For the correct contact assignment, refer to 8-PIN CONNECTOR 3, SPEAKER OUTPUTS.
 For the correct contact assignment, refer to 8-PIN CONNECTOR 4, VOLTAGE SUPPLY
WIRES AND CAN-BUS.
 For the correct contact assignment, refer to 12-PIN CONNECTOR 5, TELEPHONE SIGNALS
AND PRE-AMPLIFIER OUTPUT SIGNALS.
 For the correct contact assignment, refer to 12-PIN CONNECTOR 6, CD CHANGER
CONTROL AND AUDIO INPUT SIGNALS, DIGITAL SATELLITE RADIO TUNER.
7. 7 - Connector 7
 Antenna connection,
8. 8 - Connector 8
 Antenna connection.
18-PIN CONNECTOR 1, VIDEO AND LF INPUT
Fig. 46: 18-Pin Multi-Pin Harness Connector 1, For Video And LF-Input
equipment for TV tuner is installed.
1 - Not assigned
2 - Audio signal, negative
3 - Audio signal, negative
4 - Shielding, negative
5 - Video signal, negative
6 - Video switching signal
10 - Not assigned
11 - Left audio signal, input, positive
12 - Right audio signal, input, positive
13 - Shielding, negative
14 - Synchronization of vertical and horizontal picture signals
15 - 50 Hertz/60 Hertz
16 - Signal input for picture signal blue
17 - Signal input for picture signal green
18 - Signal input for picture signal red
CONNECTOR 2
Fig. 47: Blue Colored Connection For Antenna Input Signal "Navigation"
1 - Blue colored connection for antenna input signal navigation.
8-PIN CONNECTOR 3, SPEAKER OUTPUTS
Fig. 48: 12-Pin And 8-pin Multi-Pin Harness Connector Terminals 3, 4, 5 And 6
NOTE: If the radio navigation system in the vehicle is also equipped with an amplifier,
these speaker outputs are used as amplifier input signals.
8-PIN CONNECTOR 4, VOLTAGE SUPPLY WIRES AND CAN-BUS
9 - CAN-Bus high
10 - CAN-Bus low
11 - Radio muting (during telephone use)
12 - Voltage supply, negative, terminal 31
13 - Connector for ignition key-controlled switching on and off (S contact)

14 - Alarm system terminal (optional)
15 - Voltage supply, positive, terminal 30
12-PIN CONNECTOR 5, TELEPHONE SIGNALS AND PRE-AMPLIFIER OUTPUT SIGNALS
1 - Not assigned
2 - Not assigned
3 - Line Out, left
4 - Not assigned
5 - Navigation language, driving directions, positive
6 - Telephone audio input signal, TEL, negative
7 - Not assigned
8 - Line Out, negative

9 - Line Out, right
10 - Not assigned
11 - Navigation language, driving directions, negative
12 - Telephone audio input signal, TEL, positive
12-PIN CONNECTOR 6, CD CHANGER CONTROL AND AUDIO INPUT SIGNALS, DIGITAL SATELLITE RADIO TUNER
This harness connector is then only assigned for special equipment digital satellite radio tuner when a digital
satellite radio tuner is installed. CD changer is installed standard.
1 - Digital satellite radio tuner input, audio left
2 - CD changer, left and right port, audio Ground (GND)
3 - Digital satellite radio tuner input, audio Ground (GND)
4 - CD changer, voltage supply, positive, terminal 30
5 - Digital satellite radio tuner input continuous positive, terminal 30
6 - CD changer, DATA OUT (data exchange for CD changer control from radio navigation system to CD
changer)
7 - Digital satellite radio tuner input, audio right

8 - CD changer, left port audio, CD/L
9 - CD changer, right port audio, CD/R
10 - CD Changer, control signal
11 - CD changer, DATA IN (data exchange for CD changer control from CD changer to radio navigation
system)
12 - CD changer, CLOCK (internal test protocol for monitoring data flow)
ANTENNA CONNECTORS 7 AND 8
Fig. 52: Connectors 5 And 6, Antenna Connections

NOTE: Radio navigation system is equipped with an antenna diversity function for
terrestrial radio reception. Both antenna connections are signal inputs. In radio
navigation system, it is continuously analyzed via which of the two connected
window antennae receives the better reception signal. It then switches to the
antenna with the better reception signal. This is not audible to the customer.
1 - Transparent color connection for antenna input signal for terrestrial radio reception
2 - Beige color connection for antenna input signal for terrestrial radio reception
RNS 510

Fig. 53: Radio System Overview

1. Radio and Navigation Display Control Module -J503- (RNS 510)

 Connector overview, refer to RADIO CONNECTORS OVERVIEW.
3. Window Antenna
 Installed in rear window in sedan, for radio, navigation and telephone.
 Depending on the vehicle equipment level, the Wagon may have only one roof antenna for both the
telephone and navigation systems.
OVERVIEWS.
4. External Audio Source Connection -R199-
 Located inside the storage compartment under the center armrest.
 For more information regarding the external audio source connection, refer to EXTERNAL

 Additional information, refer to SOUND SYSTEM AMPLIFIER.
8. Right Front Midrange Speaker -R104- and Left Front Midrange Speaker -R103- , Right Front Bass
Speaker -R23- and Left Front Bass Speaker -R21-

 For additional information, refer to MULTIMEDIA SYSTEM CONTROL MODULE -J650-.
 Optional installation of CD changer or multimedia system control module. Both systems are not
available together because they both use the same installation location.
10. CD Changer -R41-
 6-disc CD changer
RADIO CONNECTORS OVERVIEW

Fig. 54: Radio Connectors Overview

1. 8-Pin Multi-Pin Connector 1

 Terminal assignment, refer to 8-PIN CONNECTOR 1, SPEAKER OUTPUTS.

 Terminal assignment, refer to 8-PIN CONNECTOR 2, VOLTAGE SUPPLY WIRES AND
CAN BUS.
 Terminal assignment, refer to 12-PIN CONNECTOR 3, TELEPHONE AND MICROPHONE
SIGNALS.
Terminal assignment, refer to 12-PIN CONNECTOR 4, CD CHANGER CONTROL AND

AUDIO INPUT SIGNALS.
 Terminal assignment, refer to 26-PIN CONNECTOR 5, AUDIO AND VIDEO.
6. Connectors 6, Antenna
 Terminal assignment, refer to CONNECTORS 6, ANTENNA.
8-PIN CONNECTOR 1, SPEAKER OUTPUTS
Fig. 55: 8-Pin Connector 1, Speaker Outputs

NOTE: When using an amplifier, the same terminal assignment for Line-In are used for
the amplifier. The radio is factory programmed from Output Stage Power 26dB
to Output Stage Line Out 12dB.
8-PIN CONNECTOR 2, VOLTAGE SUPPLY WIRES AND CAN BUS
Fig. 56: 8-Pin Connector 2, Voltage Supply Wires And CAN BUS
9 - CAN-Bus high
10 - CAN-Bus low
11 - Display voltage supply, positive, optional only on the Low radio version
12 - Voltage supply, negative, terminal 31
13 - Display HS CAN-Bus low, optional only on the Low radio version, not for Midline
14 - Display HS CAN-Bus high, optional only on the Low radio version, not for Midline
15 - Voltage supply, positive, terminal 30
16 - Control signal, anti-theft protection, SAFE, positive
12-PIN CONNECTOR 3, TELEPHONE AND MICROPHONE SIGNALS

Fig. 57: 12-Pin Connector 3, Telephone And Microphone Signals

1 - Microphone input, negative
2 - AUX output, audio, right
3 - AUX output, common signal ground
4 - Microphone output, negative
5 - Left telephone audio input signal, negative
6 - Right telephone audio input signal, negative
7 - Microphone input, positive
8 - AUX output, audio, left
9 - Microphone output, positive
10 - Telephone mute (radio mute)
11 - Left telephone audio input signal, positive
12 - Right telephone audio input signal, positive
12-PIN CONNECTOR 4, CD CHANGER CONTROL AND AUDIO INPUT SIGNALS

Fig. 58: 12-Pin Connector 4, CD Changer Control And Audio Input Signals
1 - Left input AUX signals
2 - AUX signal ground
3 - CD changer, audio signal ground
4 - CD changer, voltage supply, positive, terminal 30, contact continuous power handling greater than 1A,
short-term peak power handling 5A
5 - Not assigned
6 - CD changer, DATA OUT (data exchange for CD changer control from radio navigation system to CD
changer)
7 - Right input AUX signals
8 - CD changer, left port audio, CD/LA
9 - CD changer, right port audio, CD/R
10 - CD changer, control wire, switched positive
11 - CD changer, DATA IN (data exchange for CD changer control from CD changer to radio navigation
system)
12 - CD changer, CLOCK (internal test protocol for monitoring data flow)

26-PIN CONNECTOR 5, AUDIO AND VIDEO
Fig. 59: 26-Pin Connector 5, Audio And Video

1 - reserved for protocol debug RX
2 - reserved for protocol debug TX
3 - Not assigned
5 - Not assigned
6 - internal universal cellular telephone preparation, handy detect
7 - internal universal cellular telephone preparation, cradle and description of key functions
8 - internal universal cellular telephone preparation, cradle, antenna diagnosis
10 - Right video signal input LF
11 - Video signal input, shielding mass
12 - Video signal input, synchronization vertical and horizontal
13 - Video signal input, green

14 - Not assigned
15 - Not assigned
16 - Not assigned
17 - Not assigned
18 - Not assigned
19 - internal universal cellular telephone preparation, cradle, negative
20 - internal universal cellular telephone preparation, switched terminal 30
21 - Not assigned
23 - Left video signal input LF
25 - Video signal input, blue
26 - Video signal input, red
CONNECTORS 6, ANTENNA
Fig. 60: Connectors 6, Antenna

1 - Terminal connector antenna radio reception AM and FM2, Double Fakra, no coding, impedance 50 Ohm,
color cream white
2 - Terminal connector antenna radio reception FM1, Double Fakra, coding B, impedance 50 Ohm, color cream
white
3 - Terminal connector antenna navigation, Fakra, coding C, impedance 50 Ohm, color signal blue
TELEPHONE PREPARATION, PREMIUM WITH BLUETOOTH OVERVIEW
Fig. 61: Telephone Preparation, Premium With Bluetooth Overview

1. Instrument Cluster
2. Multifunction Steering Wheel

 For more information regarding the multifunction steering wheel, refer to MULTIFUNCTION
STEERING WHEEL.
3. Steering Column Electronic Systems Control Module -J527-
4. Telephone Antenna -R65-
 In sedan, installed in rear window.
 Roof antenna on wagon.
OVERVIEWS.
5. Cellular Telephone Preparation Control Head -E508-
 Installed in instrument panel above radio or radio/navigation system.
 Removing and installing, refer to BLUETOOTH CELLULAR TELEPHONE PREPARATION

CONTROL HEAD.
6. Voltage Supply For Telephone Transceiver, Positive
7. Voltage Supply For Telephone Transceiver, Negative
8. Telephone Transceiver -R36-
 Installed below front right seat.
 Removing and installing, refer to BLUETOOTH TELEPHONE TRANSCEIVER.
9. Emergency Call Button -E276-

 Installed in front interior light in roof console.
 Removing and installing, refer to EMERGENCY CALL BUTTON.
10. Notebook, Laptop

 Not obtained with vehicle.
 Send and receive data via telephone transceiver.
 Additional information, refer to the Owner's Manual.
11. Headset
 Not obtained with vehicle
 Makes private telephone calling possible in vehicle, passengers cannot listen in
 Additional information, refer to the Owner's Manual.

 Available as an option.
13. Telephone Baseplate -R126-

 Available as an option.
 Installed in center armrest.
 Functions as charging station for cellular telephone.
14. Telephone Microphone -R38-

 For hands-free operation of telephone system.
 Installed in front interior light in roof console.

Removing and installing, refer to TELEPHONE MICROPHONE.


15. Radio or Radio/Navigation Display Control Module -J503-

16. Speaker System
USB CONNECTOR OVERVIEW
Fig. 62: Multi-Pin Connector Assignments

1. Data In, (here output)

2. Data clock
3. Voltage supply, terminal 31
4. Data Out, (here input)
5. Not assigned
6. Voltage supply, terminal 30
7. Audio signal LF right, positive
8. Control wire, positive, switched from radio
9. LF audio signal, negative
10. Left LF audio signal, positive
11. Not assigned
12. Not assigned
SPECIFICATIONS
TRANSMITTED OUTPUT, ANTENNA INSTALLATION LOCATIONS, FROM MY 06

NOTE: It is legally forbidden to install antennas on bumpers. This protects pedestrians.
Prescribed antenna
Designation Pmax/Watt
installation locations
All locations on the roof All
Shortwave < 54 MHZ 100 (PEAK)(1) outside locations on the
vehicle
All locations on vehicle
4 m-Band 20 (eff.)(2) exterior
Front fender Rear fender
Center of the luggage
2 m-Band 20 (eff.)
compartment All locations
on the roof
Front center of roof Center
2 m-Band 50 (eff.)
of roof Rear center of roof
Center of roof Front center
70 cm 50 (eff.) of roof Rear center of roof
Center of rear lid
23 cm 20 (eff.)
exterior
TETRA/TETRAPOL 25 (eff.)
exterior
all locations on vehicle
D-net GSM 900 20 (Peak)
exterior
E-net GSM 1800 GSM 1900 All locations on vehicle
10 (Peak)
UMTS exterior
(1) PEAK = max. carrier power (Peak Envelope Power)
(2) eff. = effective transmission output
NOTE: Deviations from these guidelines (location of antenna, frequency, output) are
only permitted in special isolated cases after a single-case test carried out by
the EMV center of VW AG in Wolfsburg.
EMV = Electromagnetic Compatibility.
iPOD MOUNT, TROUBLESHOOTING
 Diagnostic Operation System VAS 5051 or Vehicle Diagnosis and Service System VAS 5052
 Diagnostic adapter cable VAS 5051/5a or VAS 5051/6a or VAS 5052/3
 Select "Test Instruments" in Diagnostic Operation System VAS 5051 or Vehicle Diagnosis and Service
System VAS 5052.
Procedure for Troubleshooting
The iPOD mount is not equipped with On Board Diagnostics (OBD).
If signal transmission to radio/radio-navigation system is not functioning, then the voltage supply at harness
connector can be checked.
Test Prerequisites
 First make certain that the iPOD itself is not the source of the problem. Refer to the owner's manual.
 First, perform a RESET on the iPOD. Refer to the Owner's manual.
 Make sure fuse is OK.
 Check radio/radio-navigation system is free of malfunctions via On Board Diagnostic (OBD).
Proceed as follows
-- Remove iPOD mount. Refer to IPOD MOUNT.
-- Disconnect mount connector under storage compartment.
-- Using VAS 5051 or VAS 5052, measure the following voltages at harness connector on wiring harness side.
 At 12-pin harness connector T12, at voltage supply terminal 6, positive, with radio switched on.
 At 12-pin harness connector T12, at voltage supply terminal 8, positive, control wire, with radio switched
on.
 At 12-pin harness connector T12, at terminal 3 voltage supply terminal 31, negative
If the voltage values specified cannot be measured, then repair wire connections according to wiring diagram.
If a fault cannot be found, replace iPOD mount.
MULTIFUNCTION STEERING WHEEL, ADAPTING COMPONENTS
Components, Multi-Function Steering Wheel, Adapting
Select "Guided Functions" or "Guided Fault Finding" in VAS 5051 or VAS 5052.
After all control modules have been checked:
-- Press the "Go to" button.
-- Select "Functions/Component selection".
-- Select "Body".
-- Select "Electrical equipment".
-- Select "01 - Systems capable of self-diagnosis".
-- Select "Steering Column Electronics".
-- Select "Code Control Unit Function".
RADIO COMPONENTS, ADAPTING
 Diagnostic Operation System VAS 5051B or Vehicle Diagnosis and Service System VAS 5052
-- Select "Body".
-- Select "radio system".
-- Select "Radio functions".
RADIO NAVIGATION SYSTEM COMPONENTS, ADAPTING
-- Select "Body".
-- Select "Radio navigation system".
-- Select "Functions".
-- Select "Code radio" or "Code navigation system".
PREMIUM SOUND SYSTEM (PREMIUM 7) RADIO ELECTRONIC ANTI-THEFT SYSTEM
Premium 7 Radio "Premium Sound System" is equipped with an electronic Comfort anti-theft system which
operates in conjunction with the instrument cluster.
After disconnecting the radio power supply, the radio is ready for use again once the power supply is connected.
The anti-theft code does not need to be entered again. The requirement is that the first activation of the
electronic anti-theft system follows and that the radio is reconnected in the same vehicle.
Electronic Anti-Theft System, Deactivating
Reactivating a locked radio is only possible by entering correct code number for electronic anti-theft system.
NOTE: Code number for electronic anti-theft system is listed along with radio serial
number on radio card. Refer to operating instructions.
For reasons of safety, radio card should not be stored in the vehicle. Obtain the
code number from the customer, if necessary.
If a radio is replaced, code number of replacement unit must also be used.
Inform the customer that the code number has changed.
-- Obtain unit code number.

-- Switch on radio.
"SAFE" automatically appears and then "1000". No operating of buttons is required for this.
-- Using station buttons -1- to -4-, enter code number affixed to radio card. First digit of code number is entered
with button 1, second with button 2, etc.
-- Then press the Stations button located beneath "OK" on the display (normally it is the last station button) and
hold it firmly until anti-theft coding is activated. This is indicated by a short signal sound.
If the code number has been entered correctly into radio, a radio frequency appears on the display.
NOTE: If the anti-theft code has been entered incorrectly, it can be corrected
immediately in another attempt. If anti-theft code is entered incorrectly twice,
then the radio unit is locked for an hour. Then leave the radio unit and the
ignition switched on. After one hour, then the procedure for deactivating the
electronic anti-theft system can be repeated. Keep in mind: Always two
attempts to input code, after that the radio unit is locked for one hour.
RCD 510 (PREMIUM 8) RADIO ELECTRONIC ANTI-THEFT SYSTEM
 Vehicle Diagnosis, Testing and Information System VAS 5051 or Vehicle Diagnosis and Service System
VAS 5052
Radio unit is equipped with an electronic Comfort anti-theft system which operates in conjunction with the
instrument cluster.
After disconnecting the power supply, the radio can be used again after connecting the power supply. The anti-
theft code does not need to be entered again. The requirement is that the first activation of the electronic anti-
theft system follows and that the radio is reconnected in the same vehicle.
The anti-theft code is transmitted via the vehicle diagnosis, testing and information system VAS 5051 or the
vehicle diagnosis and service system VAS 5052. The radio card and the label on the radio that were used in the
past are no longer used.
NOTE: To access the anti-theft code the Guided Fault-Finding VAS 5051 or the Guided
Fault-Finding VAS 5052 "online" must be connected (network connection) and
the user must provide a valid program user id to retrieve a radio code.
Anti-Theft System, Deactivating the Anti-Theft Code
Accessing the code for the electronic anti-theft system using the VAS tester
-- Press button "Jump".
-- Select "Function/Component Selection".
-- Select "Body".
-- Select "Electrical Systems".
-- Select "01 self-diagnosis-enabled systems".
-- Select "radio or radio navigation system"
-- Select "Functions"
-- Select and start "radio code inquiry".
An authorization to the system will be requested: Then the operating data, the VIN and the Radio/RNS unit
serial number will be automatically read out.
NOTE: When installing new radio/radio-navigation unit, or a unit which has not be
adapted to the vehicle, it can happen that tester will not be able to read the
serial number of the radio/radio-navigation unit. In this case, enter the serial
number manually. The serial number can be found on a sticker on the unit and
is also stamped into the side of the unit.
Then the radio code will be displayed in the tester.
The radio or radio navigation system anti-theft code must now be entered manually.
-- Switch on radio.
An input mask with a 10-key key pad, a correction button and an input button appear.
-- Enter the correct radio code using the key pad on the input mask.
-- Confirm by pressing the input button.
Unit is enabled and ready for operation.
Using the correction button to change an incorrect number.

NOTE: If the wrong code number was entered when overriding the electronic lock, first
"SAFE" blinks in the display and "1000" appears again. You can now repeat the
entire procedure one more time. The number of tries is shown in the display. If
you enter the wrong code number again, the unit is locked for about one hour,
that is, it cannot be operated. This lock is indicated by the word "SAFE"
appearing continuously in the display. After one hour has elapsed in which the
unit and the ignition must be switched on, the number of attempts disappears
and the electronic lock can be deactivated again as described above. The cycle
two tries, locked for one hour still applies.
RCD 210 (ENTRY RADIO) RADIO ELECTRONIC ANTI-THEFT SYSTEM
RCD 210 Radio "Sound System" is equipped with an electronic Comfort anti-theft system which operates in
conjunction with the instrument cluster.
After disconnecting the radio power supply, the radio is ready for use again once the power supply is connected.
The anti-theft code does not need to be entered again. The requirement is that the first activation of the
electronic anti-theft system follows and that the radio is reconnected in the same vehicle.
Reactivating a locked radio is only possible by entering correct code number for electronic anti-theft system.
If a radio is replaced, code number of replacement unit must also be used.
-- Switch on radio.
"SAFE" automatically appears and then "1000". No operating of buttons is required for this.
-- Using station buttons -1- to -4-, enter code number affixed to radio card. First digit of code number is entered
with button 1, second with button 2, etc.
-- Then press the arrow button, which is located above the FAD button and hold it firmly until the anti-theft
coding is activated. This is indicated by a short signal sound.
If the code number has been entered correctly into radio, a radio frequency appears on the display.
then the radio unit is locked for an hour. Then leave the radio unit and the
ignition switched on. After one hour, then the procedure for deactivating the
electronic anti-theft system can be repeated. Keep in mind: Always two
attempts to input code, after that the radio unit is locked for one hour.
RNS 510 ELECTRONIC ANTI-THEFT SYSTEM
 Vehicle Diagnosis, Testing and Information System VAS 5051 or Vehicle Diagnosis and Service System
VAS 5052
RNS 510 radio navigation system is equipped with an electronic Comfort anti-theft system which operates in
conjunction with the instrument cluster.
After disconnecting the power supply, the radio navigation system is ready to be used again once the power
supply is connected. The anti-theft code does not need to be entered again. The requirement is that the first
activation of the electronic anti-theft system follows and that the radio navigation system is reconnected in the
same vehicle.
Reactivating a locked radio navigation system is only possible by entering correct code number for electronic
anti-theft system.
The anti-theft code is accessed by Guided Fault-Finding VAS 5051 or the Guided Fault-Finding VAS 5052; the
Radio Card and the sticker on the radio have been discontinued.
NOTE: To access the anti-theft code the Guided Fault-Finding VAS 5051 or the Guided
Fault-Finding VAS 5052 online must be connected (network connection) and the
user must provide a valid program user id to retrieve a radio code.
-- Press button "Jump".
-- Select "Function/Component Selection".
-- Select "Body".
-- Select "Electrical Systems".

-- Select "01 self-diagnosis-enabled systems".
-- Select "Radio navigation system"
-- Select and start "radio code inquiry".
An authorization to the system will be requested: Then the operating data, the VIN and the Radio/RNS unit
serial number will be automatically read out.
NOTE: When installing new radio/radio-navigation unit, or a unit which has not be
adapted to the vehicle, it can happen that tester will not be able to read the
serial number of the radio/radio-navigation unit. In this case, enter the serial
number manually. The serial number can be found on a sticker on the unit and
is also stamped into the side of the unit.
Then the radio code will be displayed in the tester.
The radio navigation system anti-theft code must not be entered manually.
-- Enter the radio code appearing in the display in the RNS 510 number block and confirm it.
then the radio navigation system is locked for an hour. Leave radio navigation
system and ignition switched on. The remaining running time appears in the
radio navigation system display. After one hour, the procedure for deactivating
the electronic anti-theft system can be repeated. Remember that you always
have two attempts to enter the code. After that, the radio navigation system will
be locked up for one hour.
RNS MFD 2 DVD ELECTRONIC ANTI-THEFT SYSTEM
Radio navigation system RNS MFD 2 DVD is equipped with an electronic Comfort anti-theft system which
operates in conjunction with the instrument cluster.
After disconnecting the power supply, the radio navigation system is ready to be used again once the power
supply is connected. The anti-theft code does not need to be entered again. The requirement is that the first
activation of the electronic anti-theft system follows and that the radio navigation system is reconnected in the
same vehicle.
Reactivating a locked radio navigation system is only possible by entering correct code number for electronic
anti-theft system.
If a radio navigation system is replaced, code number from replacement unit

must be used.
-- Switch on radio navigation system.
Word "SAFE" and number row "0000" appear in display.
-- Enter code number listed on radio card by selecting and confirming characters in succession on letter and
number selection screen with right rotary/push knob.
NOTE: With the entry of the first character, the number row "0000" is overwritten.
-- When anti-theft code has been entered, confirm with button located next to word "OK" on display.
immediately in two subsequent attempts. If anti-theft code is entered incorrectly
three times, then the radio navigation system is locked for an hour. Then leave
the radio navigation system and the ignition switched on. After one hour, then
the procedure for deactivating the electronic anti-theft system can be repeated.
Keep in mind: Always three attempts to input code, after that the radio
navigation system is locked for one hour.
USB CONNECTOR, TROUBLESHOOTING
 Select "Test Instruments" in Diagnostic Operation System VAS 5051 or Vehicle Diagnosis and Service
System VAS 5052.
Procedure for Troubleshooting
The USB connection is not capable of On Board Diagnostics (OBD).
If signal transmission to radio/radio-navigation system is not functioning, then the voltage supply at harness
connector can be checked.
Test Prerequisites
 Beforehand, make sure that USB stick or MP3 player itself does not factor as a malfunction source. Refer
to the Owner's Manual.
 Check that the fuse is OK.
 Check radio/radio-navigation system is free of malfunctions via On Board Diagnostic (OBD).
Proceed as follows
-- Remove storage compartment with USB connection installed. Refer to USB CONNECTOR.
-- Using VAS 5051 or VAS 5052, measure the following voltages at harness connector on wiring harness side.
 At 12-pin harness connector T12, at voltage supply terminal 6, positive, with radio switched on.
 At 12-pin harness connector T12, at voltage supply terminal 8, positive, control wire, with radio switched
on.
 At 12-pin harness connector T12, at terminal 3 voltage supply terminal 31, negative
If the voltage values specified cannot be measured, then repair wire connections according to wiring diagram.
If no faults can be detected, replace storage compartment with USB connection.
ANTENNA MODULES
RADIO RECEPTION ANTENNA MODULE
Removal
-- Remove rear headliner connector trim at rear window. Refer to Removal and Installation .
-- Disengage connectors -1, 2 and 3- and remove them.

Fig. 63: Disengage Antenna Module - Radio Reception Harness Connectors

-- Release retaining clips -arrows- on both sides.
Fig. 64: Releasing Retaining Clips

-- Carefully remove antenna module.
Installation
NOTE: Terminals on antenna module -arrows- must not be bent and must be
metallically clean so that reception problems do not result.
Fig. 65: Identifying Terminals On Antenna Module

The same applies to contact surfaces on rear window.
NAVIGATION ANTENNA MODULE
Removal
-- Release and disconnect electrical connection -2-.

Fig. 66: Disengaging Antenna Module - Navigation

-- Release retaining clips -arrows- on both sides.
Fig. 67: Releasing Retaining Clips

Installation

TELEPHONE ANTENNA MODULE
Removal
-- Release and disconnect electrical connection -1-.
Fig. 68: Disengaging Antenna Module - Navigation

-- Remove retaining clips -arrows-.

Installation
ANTENNA WIRES
Refer to ANTENNA WIRES, REPLACEMENT .
CD CHANGER
 Radio Removal Tool 3316.
Radio removal tool 3316 is made up of two identical parts
NOTE: If CD changer plays back commercially available CDs but not CDs burned by
customer, there is no malfunction in CD changer. Replacing the CD changer for
this reason is not permitted.
Mixed CDs (CDs that contain computer data and also music) cannot be played.
8 cm CDs (mini-discs) cannot be played.
When retrofitting CD changer, radio functions must always be coded again.
There are two sets of installation instructions for removing and installing the
CD changer. Note the VIN range given.
For the following VINs, refer to CD Changer Procedure 1.
 Passat sedan, produced in Mosel, to VIN WVWZZZ3CZ6P049455

 Passat sedan, produced in Emden, to VIN WVWZZZ3CZ6E065994
 Passat wagon, produced in Emden, to VIN WVWZZZ3CZ6E065994
For the following VINs, refer to CD Changer Procedure 2.
 Passat sedan, produced in Mosel, from VIN WVWZZZ3CZ6P049456

 Passat sedan, produced in Emden, from VIN WVWZZZ3CZ6E065995
 Passat wagon, produced in Emden, from VIN WVWZZZ3CZ6E065995
NOTE: The CD changer is built into the glove compartment.
Do the following before starting the procedure:
-- Turn off the ignition and all electric consumers and remove the key.
-- Open glove compartment lid.
Removal
-- Pull at tab -A- and CD changer lowers.
Fig. 70: Identifying Pull On Tab & CD Changer Slots

-- If necessary, remove CDs remaining in CD changer. Refer to the Owner's Manual.
-- Slide 3316 into slots designed for them on CD changer at left and right -arrows- until they engage audibly.
Fig. 71: Identifying Pull On Tab & CD Changer Slots

-- Pull out CD-changer using radio removal tools -arrows-.
Fig. 72: Pulling Out CD-Changer Using Radio Release Tools

-- Disengage harness connector at points designated with -arrows- and disconnect it.
Fig. 73: Disengaging Harness Connector At Points

-- Press on retaining clamp -arrow- and pull out radio removal tools from removed unit.
Fig. 74: Pressing On Retaining Clamp

Installation
CD Changer Procedure 2
NOTE: The CD changer is built into the glove compartment.
-- If necessary, remove CDs remaining in CD changer. Refer to the Owner's Manual.
Removal
-- Remove glove compartment with installed CD changer from instrument panel.
-- Disconnect connector -A- on glove compartment and remove cable tie -arrow-.
Fig. 75: Disconnecting Harness Connector On Glove Compartment And Removing Cable Tie
-- Pull at tab -A- and CD changer lowers.

Fig. 76: Identifying CD Changer Pull Tab

-- Slide 3316 into slots designed for them on CD changer at left and right -arrows- until they engage audibly.
Fig. 77: Identifying CD Changer Pull Tab

-- Remove CD changer from glove compartment -arrows- using release tools.

Fig. 78: Pull Out CD-Changer From Glove Compartment

-- Press on retaining clamp -arrow- and pull out radio removal tools from removed unit.
Fig. 79: Pressing On Retaining Clamp

Installation
-- Unclip wiring connection connector housing at CD changer.
-- Slide CD changer into glove compartment installation frame and thread wiring connection through opening in
glove compartment and upward.
-- Now slide CD changer farther in until it engages audibly.
-- Secure connector -A- at top of glove compartment with a cable tie -arrow- , ensure it does not cause any
rattling noises. Cut off extra cable tie length.
Fig. 80: Disconnecting Harness Connector On Glove Compartment And Removing Cable Tie
-- Reconnect connectors.
-- Reinstall glove compartment.
DIGITAL SATELLITE RADIO TUNER

Fig. 81: Component Location Of Digital Satellite Radio Tuner In Luggage Compartment Behind Right
Side Wall Trim
Removal
-- Unclip cover -A-.
Fig. 82: Unclipping Cover

-- Press clips -arrows- with pliers and remove digital satellite radio tuner from locking mechanism on bracket.
Fig. 83: Disengaging Digital Satellite Radio Tuner From Locking Mechanism Of Retainer
-- Disconnect connectors -A and B- to digital satellite radio tuner.
Fig. 84: Disconnecting Digital Satellite Radio Tuner Harness Connectors

-- Remove digital satellite radio tuner.

Installation
Installation is performed in the reverse order of removal.
-- When installing, slide digital satellite radio tuner under securing strip -arrow- on bracket.
Fig. 85: Sliding Digital Satellite Radio Tuner Under Mounting Strip
EXTERNAL AUDIO SOURCE CONNECTION -R199-
 Trim Removal Wedge 3409
Removal
-- Remove the center console extension. Refer to Removal and Installation .
-- Press the socket clips -arrows- of external audio source connection using 3409 and remove the socket.
Fig. 86: External Audio Source Connection Socket Clips

-- Disconnect electrical connection -arrow-.
Fig. 87: External Audio Source Connection

Installation
IPOD MOUNT ADAPTER

In order to adapt the mount for different iPOD sizes, there is an adapter that can be inserted in the mount.
Installation
For operation of classic iPOD and iPOD Photo, proceed as follows
The small adapter is needed to compensate for the different thickness of the classic iPOD and the iPOD Photo.
-- Insert adapter -A- in -direction of arrow- into mount -B- to stop.
Fig. 88: Inserting Adapter Into Adapter To Stop

NOTE: The adapter -A- is available in various thicknesses. To find out which one is
needed for a unit, refer to the Owner's manual.
To Operate iPOD mini, Proceed as Follows
-- Insert adapter in -direction of arrow- into mount to stop.

Fig. 89: Inserting Adapter Into Cradle To Stop

Removal
Removal is performed in the reverse order of installation.
IPOD MOUNT
Removal
-- Grasp inside storage compartment and remove it in -direction of arrow-.

Fig. 90: Removing Storage Compartment From Console

-- Disconnect mount connector under storage compartment.
Installation
-- Connect harness connector.
-- First insert storage compartment at -A- in center console and then press it in direction -B- until it engages in
center console.
Fig. 91: Installing Storage Compartment Into Console

MULTIFUNCTION CONTROL BUTTONS ON STEERING WHEEL
Removal and installation is identical for right and left button block.
Removal
-- Remove driver's side airbag unit.
-- Remove the driver side airbag unit. Refer to Removal and Installation .
-- Disconnect connector -1-.

Fig. 92: Identifying Button Block Harness Connector And Fastener

-- Remove screw -arrow-.
Fig. 93: Identifying Button Block Harness Connector And Fastener

-- Remove button block.
Installation

MULTIFUNCTION STEERING WHEEL CONTROL MODULE
Removal
-- Remove driver's side airbag unit.
-- Remove the driver side airbag unit. Refer to Removal and Installation .
-- Disconnect both harness connectors at control module.
-- Using a suitable screwdriver, carefully pry out control module -arrow-.
Fig. 94: Removing Steering Wheel Control Module

Installation
-- Code control module for steering column electronics, refer to MULTIFUNCTION STEERING WHEEL,
ADAPTING COMPONENTS.
MULTIMEDIA SYSTEM CONTROL MODULE -J650-
 Radio Removal Tool T10057
Removal
The multi media system control module is installed in the glove compartment.
-- Insert the T10057 into the provided openings -arrows- until it locks into place.
Fig. 95: Inserting T10057 Into Provided Openings

-- Press the tools in direction -A- and pull the control module in direction -B-.
Fig. 96: Pressing Tools And Pulling Control Module

-- Release the connector -arrow- and pull the connector -A- off the control module.
Fig. 97: Multimedia System Control Module Connector

Installation
RADIO
NOTE: Use the information for the individual unit when removing and installing.
 Radio system RCD 510, refer to RCD 510 (PREMIUM 8) RADIO.

 Radio system RCD 210 "Sound System" , refer to RCD 210 (ENTRY RADIO) RADIO.
 Radio system Premium 7 "Premium Sound System" , refer to PREMIUM 7 RADIO.
 Radio/navigation system RNS MFD 2, refer to RNS MFD 2 DVD NAVIGATION RADIO.
 Radio Navigation System RNS 510, refer to RNS 510 NAVIGATION RADIO.
Removal
-- If necessary, remove CDs remaining in unit. Refer to the Owner's Manual.
Now, perform the following work procedure:
-- Using 3409, carefully pry out cover of center console in area of -arrows- and remove cover.
Fig. 98: Removing Center Console Cover

-- Disengage connector at center console cover -arrows- and remove.
Fig. 99: Disengaging Connector At Center Console Cover

-- Remove bolts -arrows- on radio navigation system.

Fig. 100: Removing/Installing Bolts On Radio Navigation System

-- Pull radio navigation system out of installation compartment far enough until harness connectors on rear side
of radio navigation system are accessible.
-- Press together the connector lock in direction of -arrows-.
Fig. 101: Identifying Electrical Connection Lock

-- Then swing mounting bracket out in direction of -arrow- and disconnect harness connector.
Fig. 102: Rotating Mounting Bracket Up And Disconnecting Electrical Connection

-- Disengage harness connectors -arrows- from antenna connections and disconnect them.
Fig. 103: Disengaging Antenna Cable Electrical Connection Lock

Installation
-- Insert connectors to radio navigation system and engage them.
-- Slide radio navigation system straight into instrument panel.

NOTE: While sliding in the radio navigation unit, under no circumstances press on the
display or control buttons since the radio may be damaged by doing this.
-- Secure radio navigation system with 4 bolts -arrows-.
Fig. 104: Removing/Installing Bolts On Radio Navigation System

-- Reinstall cover for center console.
-- If necessary, deactivate the anti-theft coding:
 Radio system RCD 510, refer to RCD 510 (PREMIUM 8) RADIO ELECTRONIC ANTI-THEFT
SYSTEM.
 Radio system RCD 210 "Sound System" , refer to RCD 210 (ENTRY RADIO) RADIO
ELECTRONIC ANTI-THEFT SYSTEM.
 Radio system Premium 7 "Premium Sound System" , refer to PREMIUM SOUND SYSTEM
(PREMIUM 7) RADIO ELECTRONIC ANTI-THEFT SYSTEM.
 Radio/navigation system RNS MFD 2, refer to RNS MFD 2 DVD ELECTRONIC ANTI-THEFT
SYSTEM.
 Radio Navigation System RNS 510, refer to RNS 510 ELECTRONIC ANTI-THEFT SYSTEM.
-- Check radio navigation unit coding and code it again if necessary.
Radio navigation unit coding, refer to RADIO COMPONENTS, ADAPTING.
Coding the radio/navigation unit, refer to RADIO NAVIGATION SYSTEM COMPONENTS, ADAPTING.
Troubleshooting
The radio navigation system is equipped with On Board Diagnostic (OBD).
ROOF ANTENNA
Removal
Sedan
-- Remove roof end strip and both C-pillar trim pieces. Refer to Removal and Installation
-- Remove both rear grab handles under roof.
-- Carefully lower molded headliner slightly in rear area.
-- Remove nut -2-.
Fig. 105: Removing/Installing Harness Connectors In Antenna Wires & Removing Nut
-- Disengage harness connectors in antenna wires, disconnect them and remove antenna.
Wagon
-- Remove roof end strip and both D-pillar trim panels. Refer to Removal and Installation .
-- Carefully lower molded headliner slightly in rear area.

-- Remove nut -arrow-.
Fig. 106: Removing Nut

-- Loosen connectors -A and B- at plastic bracket.
Fig. 107: Releasing Harness Connectors From Plastic Retainer

-- Disengage harness connectors in antenna wires, disconnect them and remove antenna.
Installation
NOTE: When inserting antenna, ensure gasket is properly seated. Both guide
protrusions of gasket must be seated in the appropriate holes -arrows- in
antenna base.
Fig. 108: Installing Roof Antenna And Seal

When inserting the antenna, make sure antenna wires -1- are routed correctly
through the wire pass-through in the nut -2-.
Fig. 109: Removing/Installing Harness Connectors In Antenna Wires &

Removing Nut
SOUND SYSTEM AMPLIFIER
View of removed amplifier:
Fig. 110: View Of Amplifier

Removal
Amplifier is installed under front left seat.
-- Move seat into uppermost and rearmost position.
-- Unclip cover in -direction of arrow- at bottom of seat.

Fig. 111: Unclipping Cover On Seat At Bottom

-- Remove screws -arrows- on amplifier.
Fig. 112: Removing Bolts On Amplifier

-- Pull out the amplifier just far enough until the connectors are accessible.
-- Disengage connectors at amplifier -arrows- and remove them.

Fig. 113: Identifying Electrical Connections At Amplifier

-- Remove amplifier.
Installation
-- Make sure that the amplifier is slid correctly into notch on bracket -arrows- when installing.
Fig. 114: Installing Amplifier R12

Remaining installation in reverse order of removal.

SPEAKERS
FRONT BASS AND TREBLE SPEAKER
NOTE: Removal and installation of left or right side speakers is identical.
Removal
The door trim panel must be removed first in order to remove a speaker. Refer to Removal and Installation .
-- Release locking mechanism of harness connector -A- and disconnect it.
Fig. 115: Identifying Front Bass And Midrange Loudspeakers Rivets

-- Using a suitable drill, drill out rivets -arrows- and remove speaker.
Fig. 116: Identifying Front Bass And Midrange Loudspeakers Rivets

NOTE: To prevent corrosion, ensure that all metal particles from drilling are removed
from inside the door.
If paint on door frame is damaged during drilling, touch-up immediately.
Installation
-- When installing, secure new speaker with special pop rivets (note replacement part number!).
Further installation is in the reverse sequence to removal.
REAR BASS SPEAKER
NOTE: Removal and installation of left or right side speakers is identical.
Removal
In order to replace speaker, door trim must first be removed. Refer to Removal and Installation .
-- Release locking mechanism of harness connector -A- and disconnect it.

Fig. 117: Identifying Rear Bass Loudspeakers Rivets

-- Using a suitable drill, drill out rivets -arrows- and remove speaker.
Fig. 118: Identifying Rear Bass Loudspeakers Rivets

NOTE: To prevent corrosion, ensure that all metal particles from drilling are removed
from inside the door.
If paint on door frame is damaged during drilling, touch-up immediately.

Installation
-- When installing, secure new speaker with special pop rivets (note replacement part number!).
FRONT TREBLE SPEAKER
NOTE: Treble speaker is installed in mirror triangle at each front door.
Removal and installation of left or right side speakers is identical.
Removal
The door trim panel must be removed first in order to remove a speaker. Refer to Removal and Installation .
-- Disconnect harness connector in wire to speaker -arrows-.
Fig. 119: Disconnecting Electrical Connection

-- Unclip trim together with speaker -arrows-.

Fig. 120: Unclipping Trim Together With Loudspeaker

-- If plastic clip -arrow- remains on trim after removing, then remove it and insert it in door at the installation
location designed for it.
Fig. 121: Identifying Plastic Clip

Otherwise trim of mirror triangle can no longer be installed correctly.
Speaker can only be replaced in conjunction with trim of mirror triangle.

Installation
REAR TREBLE SPEAKER
NOTE: Treble speakers are secured from behind to inside door handle trim.
Speaker trim must always be replaced when replacing treble speaker.
Removal and installation of left or right side speakers is identical.
Removal
The door trim panel must be removed first in order to replace a speaker. Refer to Removal and Installation .
-- Release locking mechanism of harness connector at speaker and disconnect it.
-- Remove screw -A-.
Fig. 122: Unclipping Handle For Interior Door Mechanism

-- Unclip door handle interior mechanism -arrows-.

Fig. 123: Unclipping Handle For Interior Door Mechanism

-- Press trim releases -arrows- and remove trim together with speaker from door handle interior mechanism.
Fig. 124: Identifying Locking Mechanisms Of Panel

If speaker is to be replaced, you must also replace speaker trim.
Installation
-- Place speaker on 3 speaker trim plastic clips.

-- Weld 3 speaker trim plastic clips with a soldering iron.
TELEPHONE COMPONENTS
BLUETOOTH TELEPHONE TRANSCEIVER
Removal
Radio/Navigation Display Control Module is installed under right front seat.
-- Move front right seat to most rearward and highest position.
-- Unclip cover under seat in -direction of arrow-.
Fig. 125: Under Seat Cover

-- Remove 3 bolts -arrows-.

Fig. 126: Bluetooth Telephone Transceiver Bolts

-- Disengage harness connector of antenna wire -arrow- and disconnect it. Press locking mechanism -A- and
fold over the bracket in direction -B-. Disconnect the connector.
Fig. 127: Antenna

-- Remove control module.
Installation
BLUETOOTH CELLULAR TELEPHONE PREPARATION CONTROL HEAD
Cellular Telephone Preparation Control Head is installed above radio or radio/navigation system.
Removal
-- Remove the storage compartments in the center of the instrument panel. Refer to Removal and Installation .
-- Press locking mechanism -arrow- in housing of storage compartments.
Fig. 128: Locking Mechanism

-- Pull control head in -direction of arrow- out of housing.

Fig. 129: Pulling Control Head In Out Of Housing

-- Disconnect harness connector -A- and guide it out of housing.
Fig. 130: Housing Harness Connector

Installation
Make sure routing of wire connection to control head is trouble-free inside housing of storage compartments.

EMERGENCY CALL BUTTON
Removal
-- Unclip cover on interior light -arrows-.
Fig. 131: Interior Light Cover Clips

-- Fold up cover in -direction of arrow-.

Fig. 132: Folding Up Cover

-- Remove both screws -arrows-.
Fig. 133: Emergency Call Button Screws

-- Press the three retaining hooks -arrows- and remove emergency call button.
Fig. 134: Emergency Call Button Retaining Hooks

-- Disconnect harness connector in wire to emergency call button.
Installation
TELEPHONE MICROPHONE
Microphone for hands-free telephone system is installed in front interior light -arrow-.
Fig. 135: Locating Telephone Microphone

Removal
Do the following before starting the procedure
-- Unclip cover on interior light -arrows-.
Fig. 136: Interior Light Cover

-- Remove both screws -arrows-.

Fig. 137: Telephone Microphone Screws

-- Press three catches -arrows- and remove microphone.
Fig. 138: Microphone Catches

-- Disconnect harness connector in microphone wiring.
Installation

USB CONNECTOR
 Radio Removal Tool 3316
Radio Removal Tool 3316 is made up of two identical parts.
The storage compartment with USB connection is installed in the glove compartment.
Removal
-- Remove storage media and their wire connections from the USB connection as necessary.
-- Remove glove compartment with USB connection installed from instrument panel.
-- Disconnect harness connector -A- on glove compartment and remove cable ties -arrows-.
Fig. 139: Disconnecting Harness Connector On Glove Compartment And Removing Cable Ties
-- Pull on the tab in glove compartment and storage compartment with installed USB connection is lowered.
-- Slide 3316 into slots designed for them on storage compartment with USB connection -arrows- at left and
right until they engage audibly.
Fig. 140: Identifying Radio Release Slots

For the sake of clarity, the storage compartment is depicted in the removed state for the following work step.
-- Push extracting tools apart in -direction of arrow- so that the locking mechanism disengages easily. Then pull
the complete insert out of glove compartment with extracting tools pressed.
Fig. 141: Disengaging Locking Mechanism

-- Guide disconnected wire connection through the glove compartment.
-- Push the spring on the removed insert in -direction of arrow- and while doing so pull extracting tool out in -
direction of arrow A-.
Fig. 142: Pushing Spring On Removed Insert And Pulling Extracting Tool Out In
Installation
-- Slide storage compartment into installation frame of glove compartment and when doing this guide wire
connection upward through opening in glove compartment.
-- Now slide storage compartment in further until it engages audibly.
-- Secure harness connector -A- at top on glove compartment with two cable ties -arrows- , make sure no
flapping noises can occur. Cut off excess lengths of cable ties.
Fig. 143: Disconnecting Harness Connector On Glove Compartment And Removing Cable Ties
-- Reconnect connectors.
-- Reinstall glove compartment.
SPECIAL TOOLS
 Radio Removal Tool 3316. 3316 is made up of two identical parts
Fig. 144: Radio Release Tool 3316

Fig. 145: 3409 Wedge

 Radio Removal Tool T10057
Fig. 146: Radio Removal Tool T10057

 Diagnostic Operation System VAS 5051B or Vehicle Diagnosis and Service System VAS 5052

GENERAL INFORMATION Diagnostic Connector (DLC) Locations
GENERAL INFORMATION
Diagnostic Connector (DLC) Locations
DOMESTIC CARS
CHRYSLER GROUP LLC
NOTE: This table provides a quick reference for self-diagnostic connector locations,
when available from manufacturer, that ARE NOT located at the lower left side
of the dash, as mandated in 1996 by the Federal government.
CHRYSLER GROUP LLC - DOMESTIC CARS

Application Connector Location
Acclaim
1989-90 Under Left Side Of Dash
1991-92 On Left Front Fender Panel, Near
Shock Tower
1993-94 Near Battery
1995 Behind Left Side Of Dash, Near Fuse
Block
Aries, Caravelle, Dynasty, E Class, Executive Sedan, LeBaron Sedan, New Yorker, Reliant, Town &
Country, 400 & 600
1984-85 On Left Fender Apron, Behind Battery
(2.2L Only)
1986-87 On Front Of Right Shock Tower (2.2L
& 2.5L Only)
1988-89 On Left Fenderwell
1990 Under Left Side Of Dash
Shock Tower
1993 (Except New Yorker) Near Battery
1993 (New Yorker) On Left Fender Panel Near PCM
Under Center Of Dash, Near Center
Avenger (1995-00) Console
Breeze, Cirrus & Stratus (1995) Left Of Steering Column, On BCM
Charger, Horizon, Omni, Rampage, Scamp & Turismo
1985-89
2.2L Carbureted On Left Fender Apron
2.2L Turbo On Front Of Right Shock Tower
Concorde, Intrepid, LHS, New Yorker, Vision & 300M
1993-95 Behind Left Side Of Dash
1996-97 Under Left Side Of Dash, Near Center
Console
Daytona
1984-87 On Front Of Right Shock Tower
Shock Tower
1993 On Left Front Inner Fender Or Under
Steering Column
Dynasty
1991-93 On Left Fender Panel, Near
SBEC/PCM
Fifth Avenue
1991-93 On Left Fender Panel Near SBEC/PCM
Horizon & Omni (1989-90) Under Left Side Of Dash
Imperial
1981-83 CCC Connector Left Of Air Cleaner
1991-93 On Left Fender Panel Near SBEC/PCM
LeBaron Coupe & Convertible
1985-87 On Right Front Shock Tower
Shock Tower
1993 On Left Front Inner Fender Or Under
Steering Column
1994 Near Battery
Block
Lancer
Laser
1990-94 Above Left Kick Panel, Near Fuse
Block
1995 Under Left Side Of Dash, Near Center
Console
Monaco & Premier
1990 On Right Front Fender Panel
1991-92 On Left Fender Panel, Next To SBEC
Under Headlight Switch, Under Left Side
Neon (1995) Of Dash

Shadow
1988 On Left Fenderwell
1989 Under Dash, To Right Of Steering
Column
1990 On Left Fender Front Panel, Near
SBEC
Shock Tower
Spirit & Sundance
Shock Tower
Block
Talon
1990-94 Above Left Kick Panel, Near Fuse
Block
1995-98 Under Left Side Of Dash, Near Center
Console
FORD MOTOR CO.
FORD MOTOR CO. - DOMESTIC CARS

Bobcat & Pinto On Center Of Right Fender Apron
Capri
1980-85 On Center Of Left Front Fender Apron
1986 On Left Rear Corner Of Engine
Compartment
Continental
1984-89 On Right Rear Corner Of Engine
Compartment
1990-91 On Right Rear Corner Of Firewall, On
Electronic Assembly Cover
1992 On Right Fender Apron

1993-94 VIP Connectors (2) On Right Rear Of
Engine Compartment, On PCM Cover
Contour & Mystique
Compartment
Cougar & Thunderbird
1982-90 On Left Fender Apron
1991 On Rear Of Right Front Fender Panel
1992 Front Of Right Shock Tower
1993 2 Connectors In Right Rear Corner Of
Engine Compartment
1994 On Right Side Of Engine Compartment
& Below Glove Box
1995
3.8L On Right Side Of Engine
Compartment & Below Glove Box
4.6L Behind Right Side Of Dash, Below
Glove Box
1996 Lower Right Side Of Dash, Below
Glove Box
Crown Victoria, Grand Marquis & Lincoln Town Car
1983 & 1987 On Right Fender Apron
1985-86 & 1988-90 On Left Fender Apron
1992 On Left Front Fender Panel
1993-94 On Top Of Left Front Wheelwell
Escort, EXP, Lynx & Tracer
1985-90 On Right Fender Apron Near Firewall
1991 On Left Rear Of Engine Compartment
1992 On Right Rear Of Engine
Compartment, Near Cowl
1993-95 On Left Side Of Firewall
LTD & Marquis
1983 On Left Fender Apron
1984-86 On Left Rear Corner Of Engine
Compartment
Mark VII
Compartment
1988-90 Front Of Right Fender Apron
1991 On Right Side Of Engine
Compartment, Near Thermactor
Solenoids
Mark VIII
1993-96 On Top Of Left Wheelwell
Mustang
1980-85 On Center Of Left Front Fender Apron
Compartment
1992 On Left Shock Tower, Near Ignition
Coil
1993 2 Connectors On Right Front Strut
Tower
1994-95 Behind Right Front Strut Tower &
Right Of Steering Column
Probe
Compartment
1993 DLC - Behind Left Side Of Dash; STI
Connector - On Left Inner Fender Panel
1994-95 On Left Front Inner Fender Panel
Sable & Taurus
1986-87 (3.0L Only) Near Alternator
1988-90
2.5L On Engine Harness Near PCV Hose
3.0L On Right Rear Corner Of Engine
Compartment
1991 On Right Rear Corner Of Engine
Compartment, On ECA Cover
1992 On Right Rear Corner Of Engine
Compartment, Below MAP Sensor
1993-95 Right Rear Of Engine Compartment
Tempo & Topaz
Compartment
1993-94 In Engine Compartment, On Left Strut
Tower
GENERAL MOTORS
GENERAL MOTORS - DOMESTIC CARS


Allante Enter Diagnostic Mode By Pressing
OFF & WARM Buttons On Instrument
Panel
Bonneville (1980-81) ECU Connector On Upper Right Kick
Panel
Brougham (1987-92) Bottom Center Of Instrument Panel
Camaro & Firebird (1980) Diagnostic Ground Lead Connector On
Right Shroud Above ECM
Caprice Classic
1980-81 ECU Connector On Upper Right
Kick Panel
1982-88 Under Center Of Instrument Panel
Catalina ECU Connector On Upper Right Kick
Panel
Cavalier (1982-88) On Side Of Fuse Block
Cimarron On Side Of Fuse Block
Century Under Left Of Dash Ashtray
Corvette (1980-83) In Center Console, Under Ashtray
Custom Cruiser
1980-81 ECU Connector On Upper Right
Kick Panel
1982-88 Under Center Of Instrument Panel
DeVille (1981-88) Enter Diagnostic Mode By Pressing
OFF & WARMER Buttons On
Instrument Panel
Delta 88 ECU Connector On Upper Right Kick
Panel
Eldorado (1981-88) Enter Diagnostic Mode By Pressing
Instrument Panel
Electra (1980-81) ECU Connector On Upper Right Kick
Panel
Estate Wagon ECU Connector On Upper Right Kick
Panel
Fiero Under Ashtray Or Cigar Lighter Panel
Within Center Console
Firenza On Side Of Fuse Block
Fleetwood (1981-88) Enter Diagnostic Mode By Pressing
Instrument Panel
Fleetwood Brougham On Bottom Center Of Dash, Near
Ashtray
Impala (1982-88) Under Center Of Instrument Panel

LeMans ECM Connector On Right Kick Panel
Or Under Left Side Of Dash
LeSabre (1980-81) ECU Connector On Upper Right Kick
Panel
LeSabre Wagon (1982-88) Under Center Of Instrument Panel
Monza Under Right Side Of Dash
Ninety-Eight (1980-81) ECU Connector On Upper Right Kick
Pane
Nova Behind Right Strut Tower
Parisienne Under Center Of Instrument Panel
Reatta
1988-92 (MFI) Enter Diagnostic Mode By Pressing
OFF & WARM Buttons On
Instrument Panel
1991-93 Above Parking Brake Pedal
Riviera
1980-85 (Carbureted) Under Left Or Center Of Dash
Instrument Panel
Safari Under Center Of Instrument Panel
Seville (1981-88) Enter Diagnostic Mode By Pressing
Instrument Panel
Skyhawk Under Right Side Of Dash
Starfire Under Right Side Of Dash
Sunbird On Side Of Fuse Block, Under Right
Side Of Dash
Toronado
1980-85 (Carbureted) Under Left Or Center Of Dash
Instrument Panel
Trofeo
Instrument Panel
1991-93 Above Parking Brake Pedal
2000 On Side Of Fuse Block
DOMESTIC LIGHT TRUCKS & VANS

CHRYSLER GROUP LLC
CHRYSLER GROUP LLC - DOMESTIC LIGHT TRUCKS & VANS

Caravan, Grand Caravan, Grand Voyager, Mini Ram Van, Town & Country, & Voyager
1984-92 On Left Side Fender Apron
1993 On Left Fender Front Fender Panel, Near
SBEC
1994-95 On Wiring Harness, On Center Of
Firewall
Dakota
1987-88 On Right Side Fender Apron
1989 On Left Side Of Firewall
1990-92 On Right Side Of Firewall
Compartment
Jeep
Cherokee (1992-95) On Left Front Fender Apron, Behind Air
Cleaner
Comanche On Left Front Fender Apron, Behind Air
Cleaner
Grand Cherokee & Wagoneer
1993-95
PCM On Right Rear Of Engine
Compartment, Near PCM
TCM Behind Left Side Of Instrument
Panel
Wrangler (1992-95) On Left Side Of Firewall, Near PCM
Pickup & Ramcharger
1991-93 On Left Front Fender Panel, Next To
SBEC/PCM
1995 Pickup On Right Side Of Firewall
Ram Wagon & Van
1991-95 On Center Of Firewall, Near SBEC/PCM
FORD MOTOR CO.

FORD MOTOR CO. - DOMESTIC LIGHT TRUCKS & VANS

Aerostar
1986-90 On Left Front Fender
1991 Near Starter Relay
1992 On Left Front Inner Fender Panel
Bronco
1982-85
6-Cylinder On Left Front Fender
V8 On Right Inner Fender Panel
1986-87 On Right Front Fender, Near Starter
Relay
1993-95 2 Connectors In Left Rear Of Engine
Compartment, On Bracket
1996- Below Glove Box
Bronco II
1983-85 On Right Front Inner Fender Panel
(2.3L Only)
1986-90 On Right Front Fender Apron
Excursion Behind Center Of Dash
Explorer & Mountaineer (1991-94) On Right Rear Of Engine Compartment,
Near A/C-Heater Blower
Pickup
1982-85
6-Cylinder On Left Front Fender
V8 On Right Inner Fender Panel
1986-87 On Right Front Fender, Near Starter
Relay
1993-95 2 Connectors In Left Rear Of Engine
Compartment, On Bracket
1996- Below Center Of Instrument Panel
Pickup (F250 Heavy Duty & F350) Under Right Side Of Dash
Ranger
1983-85 On Right Front Inner Fender Panel
(2.3L Only)

1991 Behind Engine Compartment
Fuse/Relay Block
1992 On Left Front Inner Fender Panel
1993-95 On Rear Of Engine Compartment
Fuse/Relay Block
Van
1986-92 On Right Fender Apron
1993-95 On Left Front Corner Of Engine
Compartment
1996
5.8L (49 State, Over 8600 GVW) & 7.5L (Except On Left Front Corner Of Engine
Calif.) Compartment
All Others Under Left Side Of Dash
1997-98
Diesel Under Left Side Of Dash
All Others Left Front Corner Of Engine
Compartment
Villager (1993) On Left Side Of Engine Compartment,
Below Coolant Reservoir
GENERAL MOTORS
GENERAL MOTORS - DOMESTIC LIGHT TRUCKS & VANS

Astro & Safari Van (1986-87) Under Left Corner Of Cowl
"S" & "T" Series Blazer, Bravada, Envoy, Jimmy, Pickup & Sonoma
1982-85
1.9L Under Left Side Of Dash, Behind
ECM
2.0L & 2.8L Under Ashtray
2.5L Under Left Side Of Dash
1986-87 Under Ashtray
Van ("G" Series) (1982-87) Under Driver's Seat
IMPORTED CARS & TRUCKS

ACURA
ACURA - IMPORTED CARS & TRUCKS

Integra
1991-93 Behind Right Kick Panel
1994-97 Behind Glove Compartment
1998-02 Behind Right Side Of Center
Console
Legend
1991-93 Under Right Side Of Dash, Above
PGM-FI ECU/PCM
NSX (1997-01) Under Glove Compartment
SLX Behind Lower Left Corner Of Dash,
Behind Cover
Vigor
1992-93 Under Right Side Of Dash, Near
Center Console
1994 Behind Glove Compartment
2.2CL & 2.3CL In Front Of Shift Lever, Behind Ashtray
2.5TL In Front Of Shift Lever, Behind Ashtray
3.0CL In Front Of Shift Lever, Behind Ashtray
3.2TL & 3.5RL In Front Of Shift Lever, Behind Ashtray
AUDI
AUDI - IMPORTED CARS & TRUCKS

A4
1996 Next To Rear Ashtray
1997-01 (1.8L Turbo) Behind Cover, Under Left Side Of
Steering Column
1997-99 (2.8L V6) Under Cover, Next To Rear Ashtray
1997- Under Left Side Of Dash, Behind
Cover
A6
1995 Under Ashtray, In Front Storage
Compartment Of Center Console
1996-97 Under Cover, Next To Parking
Brake Handle
Cabriolet
1994-96 In Fuse/Relay Block, On Left Side
Of Dash
1997-98 Under Ashtray, At Rear Of Center
Console
Coupe GT, 4000S & 4000S Quattro In Fuse Socket, On Fuel Pump Relay
80 In Fuse Socket, On Fuel Pump Relay
90
1988-92 In Fuse Socket, On Fuel Pump Relay
1993 In Main Fuse/Relay Block, On
Plenum Tray
1994-95 In Fuse/Relay Block, On Left Side
Of Dash
100
1992-94 In Auxiliary Relay Station No. 1, On
Left Rear Of Engine Compartment
5000CS Quattro, 5000CS Turbo & 5000S In Fuse Socket, On Fuel Pump Relay
BENTLEY
BENTLEY - IMPORTED CARS & TRUCKS

1996-00
All Models In Glove Compartment
2001-04
Arnage Below Left Side Of Dash
2001-
Azure Convertible In Glove Compartment
Continental In Glove Compartment
BMW
BMW - IMPORTED CARS & TRUCKS

Z3 Behind Cover, On Right Side Of Center
Console
Z4 & Z8 Under Left Side Of Dash, Left Of Steering
Column, Behind Cover
318 & 325
1991 On Bracket, Above Thermostat Housing
1992-95 On Right Rear Of Engine Compartment
1996 Under Left Side Of Dash, Behind Panel
Labeled OBD
330 Behind Cover, Under Left Side of Dash
Above Hood & Trunk Releases
524t On Top Rear Of Engine
525i & 535i
1990-91 (Black 20-Pin Connector) Left Rear Corner Of Engine Compartment
1992-95 Outside Of Engine Compartment
Fuse/Relay Block
528e On Intake Manifold Bracket, Behind
Thermostat Housing
635CSi On Bracket, Next To Fuse/Relay Block
735i
1986-87 On Bracket, On Top Of Engine
1988-92 On Right Side Of Engine Compartment,
On Shock Tower
740 & 750 Under Left Side Of Dash, Behind Panel
Labeled OBD
740i & 740iL (1993-01) Behind Cover On Lower Left Corner Of A/C
Control Panel
745Li In Left Side Kickpanel, Behind Cover
Labeled OBD
750iL Behind Cover On Lower Left Corner Of A/C
Control Panel
DAIHATSU
DAIHATSU - IMPORTED CARS & TRUCKS

Charade At Upper Section Of Transmission
Rocky On Right Front Fender Panel
CHRYSLER GROUP LLC
CHRYSLER GROUP LLC - IMPORTED CARS & TRUCKS

Colt & Summit
1986-87 Above Inside Of Glove
Compartment
Compartment
1989-98 Under Left Side Of Dash, Near
Fuse/Relay Block
Colt Vista
Hood Release Handle
1990-96 Under Right Side Of Dash
Conquest & Starion Behind Glove Compartment
Expo Under Left Side Of Dash, Near
Fuse/Relay Block
Medallion On Left Side Of Firewall
Pickup Under Left Side Of Dash, Near
Fuse/Relay Block
Ram-50 Under Left Side Of Dash, Near
Fuse/Relay Block
Sigma In Glove Compartment
Stealth
1991-98 Under Left Side Of Dash, On
Fuse/Relay Block
1999 Under Left Side Of Dash, Left Of
Center Console
Summit Wagon Under Right Side Of Dash
Vista Wagon Under Right Side Of Dash
FERRARI
FERRARI - IMPORTED CARS & TRUCKS

All Models
1996- Behind Left Side Of Dash
FORD MOTOR CO.
FORD MOTOR CO. - IMPORTED CARS & TRUCKS

Aspire
Compartment
Capri
1991 Behind Right Side Of Dash, Behind
Glove Compartment
1992
1.3L On Left Rear Corner Of Engine
Compartment
Compartment
Compartment
Festiva
1992-93
1.3L On Left Rear Corner Of Engine
Compartment
Compartment
Merkur XR4Ti On Right Front Fender Apron, Near
Battery
Scorpio On Right Rear Corner Of Engine
Compartment
Tracer On Left Rear Corner Of Engine
Compartment
GENERAL MOTORS
GENERAL MOTORS & GEO - IMPORTED CARS & TRUCKS

LeMans Behind Right Kick Panel, Above ECM
Metro
1989-95 Under Left Side Of Dash, Near Fuse
Block
1996 Under Right Side Of Dash, Near
Center Console
Prizm & Prizm LSi
1989-95 On Left Front Strut Tower
Spectrum Under Right Side Of Dash, Above A/C-
Heater Blower Motor
Sprint On Left Front Shock Tower, Near
Battery
Storm
1990-91 Behind Right Side Of Dash, Above
A/C-Heater Blower Motor
Tracker
Block
1996 In Engine Compartment, Near MAP
Sensor
1997- Under Left Side Of Dash
HONDA
HONDA - IMPORTED CARS & TRUCKS

Accord
1990-95 Behind Right Side Of Dash, Above
Kick Panel
1996-97 Behind Ashtray In Center Console
Civic (1992-95) Behind Right Side Of Dash, Near
PGM-FI ECM
Civic Del Sol
1992-95 Behind Right Side Of Dash, Near
PGM-FI ECM
1996-97 Under Removable Cover On Right
Side Of Center Console
CR-V Behind Passenger Side Of Center
Console
Element
2003-11 Above Gas Pedal, Below Fuse
Block
Insight (2010-11) Below Left-of-Center Of Dash
Odyssey
1995 Behind Right Side Of Dash, Above
Kick Panel
1996-98 Behind Passenger Side Of Center
Console
Passport (1995) Behind Left Kick Panel
Prelude
1992-95 Behind Center Console
1996 Under Beverage Holder In Center
Console
1997-02 Under Removable Cover On Right
Side Of Center Console
S2000 Behind Right Side Of Center Console
HYUNDAI
HYUNDAI - IMPORTED CARS & TRUCKS

Accent (1995) In Coin Box
Sonata
1989 Under Left Side Of Dash, In Fuse
Block
1990
W/Passive Seat Belt Restraints In Fuse Block
W/O Passive Seat Belt Restraints On Lower Left Of Steering Column
INFINITI
INFINITI - IMPORTED CARS & TRUCKS

In ECCS Control Unit, Behind Center
G20 (1993-95) Console
I30 (1995) Beside Fuse Box
J30
1994-95 In ECM, Behind Right Kick Panel
M30 Under Left Side Of Dash, Near Fuse
Block
Q45
Block
1994-95 In ECM, Behind Right Kick Panel
ISUZU
ISUZU - IMPORTED CARS & TRUCKS

Amigo & Pickup
1990-95 Behind Left Kick Panel, Near ECM
1998-00 Lower Left Corner Of Dash, Behind
Small Cover
Hombre Under Lower Left Side Of Dash, Behind
Cover
Impulse
1986-89 Under Left Side Of Dash, Above ECU
1993-95 Behind Left Kick Panel, Near ECM
I-Mark Behind Right Side Of Dash, Above A/C-
Heater Blower Motor
Oasis Behind Right Side Of Center Console
Rodeo
1991-95 Behind Left Kick Panel
1996- Lower Left Side Of Dash, Behind
Small Cover
Stylus Behind Right Kick Panel
Trooper & Trooper II
1987-91 Under Center Console
1992
DOHC Behind Center Of Dash, Right Of
Steering Column
SOHC Under Left Side Of Dash
1993-95 Under Left Side Of Dash, Right Of
Steering Column
1996-02 Lower Left Side Of Dash, Behind
Small Cover
VehiCROSS Under Left Side Of Dash
JAGUAR
JAGUAR - IMPORTED CARS & TRUCKS

XJR (1995-97) Near Center Console
XJS
1992 On Left Rear Trunk Wheel Arch,
Behind Trim Panel
1993-94 Under Battery Tray, On Right Front
Of Luggage Compartment
1995-96 Near Center Console
XJ6
1992 On Left Rear Of Engine
Compartment
1993-94 Under Battery Tray, On Right Front
Of Luggage Compartment
Center Console
XJ12 Near Center Console
KIA
KIA - IMPORTED CARS & TRUCKS

Sephia
1994 On Center Of Firewall
1995 & 1996
1.6L Under Center Of Dash, Mounted On
Floorboard
2.0L Under Right Side Of Dash, Near
Kick Panel
Sportage
1994 On Center Of Firewall
1995 & 1996
1.6L Under Center Of Dash, Mounted On
Floorboard
2.0L Under Right Side Of Dash, Near
Kick Panel
LAND ROVER
LAND ROVER - IMPORTED CARS & TRUCKS

Defender 90 Behind Fuse Cover, In Center Of Console
Range Rover Under Right Side Of Dash, In Footwell
LEXUS
LEXUS - IMPORTED CARS & TRUCKS

ES Series
1990-91
DLC Near Left Shock Tower
Total Diagnostic Communication Link Connector Under Left Side Of Dash

1992-94
DLC No. 1 On Bracket, Behind Right Front
Strut Tower
DLC No. 2 & 3 Under Left Side Of Dash
1995-97 In Fuse Box At Lower Left Of Dash
GS Series
1990-95
DLC No. 1 On Bracket, On Top Of Engine
DLC No. 2 Under Left Side Of Dash
LS Series
1990-94
DLC No. 1 On Bracket, On Top Of Engine
DLC No. 2 Under Left Side Of Dash
SC Series
1992-95
DLC No. 1 On Bracket, Behind Right Front
Strut Tower
DLC No. 2 & 3 Under Left Side Of Dash
MAZDA
MAZDA - IMPORTED CARS & TRUCKS

B-Series
1989-93
Engine Control Check Connector (Black 6-Pin) Near Windshield Washer Motor
Trouble Codes Connector (Green 1-Pin) Near Black 6-Pin Connector (Engine
Control)
1994-95 On Right Front Fender Panel
Miata (1990-95) On Left Rear Of Engine Compartment,
Near Master Cylinder
MPV (1989-95)
Engine Control Unit (Green 6-Pin & 1-Pin Connectors) On Left Side Of Engine Compartment,
Near Inner Fender Panel

MX-3 Mounted On Bracket, On Left Front Strut
Tower
MX-6 & 626
1988 Behind Left Front Shock Tower
1989 On Left Front Corner Of Engine
Compartment
1990-91 At ECU Connector Terminal
Compartment
1993 On Side Of Fuse/Relay Block, Near
Battery
1994-95 On Left Front Fender Apron
Navajo
Compartment
1994-95 On Right Front Fender Panel
Protege
1987-89 On Passenger's Footwell (Left Foot
Area)
1990-95 On Left Side Of Firewall, Near Wiper
Motor
RX7
1986-88 (3 Check Connectors) At Left & Right Corners Of Engine
Compartment
1989-91 (Green 6-Pin Connector) Behind Ignition Coil
1993-95 On Bracket, On Left Front Strut Tower
323
1986-88 Front Left Of Engine Compartment,
Near Ignition Coil
1989 (Green 6-Pin & Green 1-Pin Connectors) On Left Side Of Firewall
1990-95 On Left Side Of Firewall, Near Wiper
Motor
929
1989 Near Air Cleaner
1990-91 (Green 6-Pin Connector) In Left Front Corner Of Engine
Compartment
1992-93 Mounted On Air Cleaner Housing
MERCEDES-BENZ
MERCEDES-BENZ - IMPORTED CARS & TRUCKS

C-Class (1994) On Right Rear Of Engine Compartment
E-Class
1994-97 On Right Rear Of Engine
Compartment
G-Class Under Left Side Of Dash, Behind Cover
ML-Class Under Left Side Of Dash, Behind Cover
S-Class
140 Platform (1994-99) On Right Rear Of Engine
Compartment
190 Series
1986-87 On Left Rear Of Engine Compartment
1988-93
All Models In Engine Compartment, On Left
Front Fender
California (OBD) On Right Side Of Firewall, Near
Battery
1994 On Right Rear Of Engine
Compartment
260E
1987 On Left Front Fender Apron, Next To
Ignition Control Module
1988-89
Front Fender
Battery
300 Series
1986-87 On Left Front Fender Apron, Next To
Ignition Control Module
1988-92
Front Fender
Battery
1993
Except 300E Left Fender Apron
300E Right Rear Corner Of Engine
Compartment
1994-95 (All Models) On Right Rear Of Engine
Compartment
400 & 500 Series
1993
12-Pin Connector On Rear Of Left Front Inner Fender
Panel
38-Pin (Impulse Readout) In Module Box, On Right Rear Of
Engine Compartment
Compartment
420SEL & 560 Series (Except 2.2L)
1986-89
Front Fender
Battery
1990-91 In Engine Compartment, On Left Front
Fender
560 Series (2.2L) On Lower Left Side Of Engine Connector
MITSUBISHI
MITSUBISHI - IMPORTED CARS & TRUCKS

Diamante (1992-98) Under Left Side Of Dash, Near
Fuse/Relay Block
Expo Under Left Side Of Dash, Near
Fuse/Relay Block
Montero
1986-88 Left Rear Corner Of Engine
Compartment
Pickup Under Left Side Of Dash, Near
Fuse/Relay Block
Raider
Compartment
3000GT
1991-98 Under Left Side Of Dash, On
Fuse/Relay Block
1999 Under Left Side Of Dash, Left Of
Center Console
NISSAN
NISSAN - IMPORTED CARS & TRUCKS

Altima
1993-94 On Driver-Side Of Center Console,
Above Accelerator Pedal
1995-96 Below Fuse Box
Maxima
1995-96 Below Fuse Box
NX & Sentra Under Left Side Of Dash, Near Fuse
Block
Pulsar NX
1986 Above Right Side Of Dash, Below
Wiper Motor
1987 Above Steering Column
Quest (1993-95)
CONSULT Tester Connector On Driver-Side Of Center Console,
Above Accelerator Pedal
Self-Test Connector Located Near Starter
Stanza Below Center Of Dash, Near Center
Console
Van On Right Side Of Engine Compartment,
Behind Fuel Filter
200SX (1995-96) Below Fuse Box
240SX
1991-94 Under Left Side Of Dash, Below
Fuse Block
1995-96 In Glove Box
300ZX (1990) Near Parking Brake
PEUGEOT
PEUGEOT - IMPORTED CARS & TRUCKS

505 Series On Lower Left Side Of Engine Connector
PORSCHE
PORSCHE - IMPORTED CARS & TRUCKS

911 Series
1992-95 In Passenger's Footwell
1996 Left Side Of Center Console
928S Top Front Of Engine
944 Series On Left Side Of Engine Compartment
RENAULT
RENAULT - IMPORTED CARS & TRUCKS

Sportwagon
Engine Diagnostic On Center Of Firewall
Fuel Injection Diagnostic Right Rear Of Engine Compartment,
Behind Airflow Meter
ROLLS-ROYCE
ROLLS-ROYCE - IMPORTED CARS & TRUCKS

All Models
1996-00 In Glove Compartment
2001- Under Left Side Of Dash
SAAB
SAAB - IMPORTED CARS & TRUCKS

900 Series
1986-90 In Front Of Fuse/Relay Panel
1991-93 Under Back Seat, On Right Side
1994
Convertible Under Rear Seat
Hatchback Under Steering Column
All Others Under Right Front Seat
9000 Series
1990 On Left Side Of Engine Compartment
1991-92 Under Passenger's Seat
1993 On Left Of Firewall
1994-95 Under Right Front Seat
SUBARU
SUBARU - IMPORTED CARS & TRUCKS

Brat, Coupe, Hatchback, Sedan & Wagon
1987
Read Memory Connector Under Left Side Of Dash, Next To
MFI/SMFI Control Unit
Test Mode Connector
MFI On Left Side Of Dash, Next To MFI
Control Unit
Sequential MFI On Left Side Of Firewall
1988-89 On Left Side Of Dash, Next To ECU
Forester Under Left Side of Dash, Behind Cover

Justy
1987-88
Read Memory Connector (Factory) On Right Front Fender, Near Strut
Tower
Test Mode Connector On Driver-Side Kick Panel Or ECU
1989-95
Read Memory Connector (Factory) Under Left Side Of Dash
Test Mode Connector On Driver-Side Kick Panel Or ECU
Legacy
1990-94
Check Connector (Black Connector) Behind Right Side Of Steering
Column, Near Heater Case
Diagnostic Connector (Black 4-Pin Connector) Behind Right Side Of Steering
Read Memory Connector (Black Connector) Behind Knee Panel, Right Of Steering
Column
Select Monitor Connector (Yellow Connector) Behind Right Side Of Steering
Test Mode Connector (Green Connector) Behind Knee Panel, Right Of Steering
Column
1995- Under Left Side Of Dash, Behind Cover
Loyale
1990-91
MFI (5-Pin Connector) In Front Of ECU
SMFI (Yellow 9-Pin & Black 13-Pin Connectors) Near Brake Booster
1992-95
Diagnostic Check Connector Behind Brake Booster
(Yellow 9-Pin & Black 13-Pin Connectors)
Diagnostic Read-Memory Connector Behind Left Front Strut Tower
(2-Single Wire Connectors)
Outback & Outback Sport Under Center Of Dash
SVX
1997 Right Of Steering Column, On Center
Console
SUZUKI
SUZUKI - IMPORTED CARS & TRUCKS

Esteem (1995) Near Battery
Samurai
1986-90 Under Right Side Of Dash, Behind
Glove Compartment
1991-92 On Right Side Of Firewall
1993-95 Under Left Side Of Dash, In Fuse
Block
Sidekick & X90
Block
1992-93
ALDL Connector Under Left Side Of Dash
Engine Connector Under Left Side Of Dash, Near
Fuse Block
1994-96 In Engine Compartment, Near
Battery
Swift
Block
1992
ALDL Connector Under Left Side Of Dash
Diagnostic Test Terminal In Fuse Block
Block
TOYOTA
TOYOTA - IMPORTED CARS & TRUCKS

Camry
1983-90 Next To Brake Master Cylinder
1991 Near Left Front Shock Tower
1992-95
4-Cylinder Near Wiper Motor
V6 Under Left Side Of Dash
Celica
1983-84 Next To Battery

1985-95 Behind Left Front Shock Tower
Celica Supra Rear Of Battery, Near Relay Panel (2-Pin
Connector)
Corolla
Front Wheel Drive
1987 Side Of Left Front Shock Tower (2-
Pin Connector)
1988-94 Behind Left Front Shock Tower
Rear Wheel Drive
1985-86 Side Of Right Front Shock Tower
(2-Pin Connector)
1987 Right Rear Corner Of Engine
Compartment
Cressida
1988-93
Check Connector On Left Front Shock Tower
Total Diagnostic Communication Link Connector Under Left Side Of Dash
Land Cruiser (1988-94) Near Wiper Motor
MR2
1986-90 Near Airflow Meter
Compartment, Near MAP Sensor
Paseo (1992-95) On Side Of Engine Compartment
Fuse/Relay Block No. 2, Near Battery
Pickup
1984-86 Near Ignition Coil, Near Master
Cylinder (2-Pin Connector)
1987-90 Right Front Inner Fender Panel, Near
Relay Block
1992-94 On Side Of Engine Compartment
Previa
1992-93 Under Front Of Driver's Seat
1994
Except Supercharged Under Center Console, Near Parking
Brake Lever
Supercharged Under Cover, On Top Center Of
Instrument Panel
1995-97 On Top Center Of Instrument Panel
RAV4 Under Dash, Near Center Console
Starlet
1981-82 On Instrument Panel Fuse Block, On

Top Of Dash
1983-84 Right Rear Of Engine Compartment
Supra
1986-90 Rear Of Battery, Near Relay Panel
1991-92 On Left Front Shock Tower
1993-94
DLC No. 1 On Right Side Of Firewall
DLC No. 2 Under Left Side Of Dash, Near Kick
Panel
Tacoma & T100
1993 On Side Of Engine Compartment
1994-95
Except OBD-II DLC On Side Of Engine Compartment
Fuse/Relay Block No. 2, Near
Battery
OBD-II DLC Under Left Side Of Dash
Tercel
1987-90 In Engine Compartment, Next To
Master Cylinder
1995-98 Near Steering Column
Van Near Airflow Meter
4Runner
1985-86 Near Ignition Coil, Next To Master
Cylinder (2-Pin Connector)
VOLKSWAGEN
VOLKSWAGEN - IMPORTED CARS & TRUCKS

Cabrio
1996 In Center Console, Below
Tachometer
1997-02 On Center Dash, Behind Panel Near
Ashtray
Corrado Under Center Console Trim Plate
Fox Under Center Console, Near Shift Lever
Golf
1993 On Center Of Dash, Below A/C-
Heater Control Knobs
1994 Under Center Console
1998-03 In Center Console
Golf III 2.0L
1995-96 Below A/C-Heater Control Panel
1997-98 On Center Dash, Behind Panel
Adjacent To Ashtray
GTI
GTI 2.8L On Center Dash, Behind Panel Adjacent
To Ashtray
Jetta
Jetta III 2.0L
1995-96 Below A/C-Heater Control Panel
1997-98 On Center Dash, Behind Panel
Adjacent To Ashtray
Jetta/Jetta III 2.8L On Center Dash, Behind Panel Adjacent
To Ashtray
New Beetle Lower Part of Dash, In Front Of Shift
Lever
Passat
1992-94 Under Center Console, Forward Of
Shift Lever
1995-97 On Center Dash, Behind Panel Near
Ashtray
Toureg
2004-2007 In the cover of the drivers side
footwell, to right of engine hood
release lever
VOLVO
VOLVO - IMPORTED CARS & TRUCKS

C30 Under Left Center Of Dash
C70 Behind Cover, Below Parking Brake
Lever
S40 Under Left Center Of Dash
S70 Behind Cover, Below Parking Brake
Lever
S90 Behind Cover, Below Parking Brake
Lever
V40 Under Left Center Of Dash
V70 (1997-00) Behind Cover Below Parking Brake Lever
V90 Behind Cover, Below Parking Brake
Lever
240
Compartment
1993 Behind Left Front Strut Tower
740 & 760
1986-92
Ignition System On Left Front Fender Apron
Fuel Injection (1990-92 Only) Left Rear Corner Of Engine
Compartment
780 On Left Front Fender, Behind Air Cleaner
Housing
850
1993 On Center Console, Forward Of Shift
Lever & Near ECM
1994-95
Non-Turbo On Right Front Strut Tower
Turbo Behind Cover, Forward Of Shift
Lever
1996-97 Behind Cover, Forward Of Shift Lever
940
1991-93
Ignition System On Left Front Fender Apron
Fuel Injection Left Rear Corner Of Engine
Compartment
1994-95 Behind Left Front Strut Tower
960
1996 In Center Console, To Right Of
Parking Brake Lever
1997 Behind Cover, Forward Of Shift Lever
DTC INDEX DTC Index - (CCTA Engine)
DTC INDEX
DTC Index - (CCTA Engine)
DIAGNOSTIC TROUBLE CODES (DTC) INDEX

DTC INDEX - (CCTA ENGINE)
SAE VAG Code Description Corrective Action
Code Code
P000A * - Intake Camshaft Position Slow Response -- Check the Camshaft Adjustment
Valve 1 -N205-. Refer to CAMSHAFT
ADJUSTMENT VALVE 1,
CHECKING .
P0010 * - Intake Camshaft Position Actuator -- Check the Camshaft Adjustment
Circuit Open Valve 1 -N205-. Refer to CAMSHAFT
ADJUSTMENT VALVE 1,
CHECKING .
P0011 * - Intake Camshaft Position Timing - Over- -- Check the Camshaft Adjustment
Advanced Valve 1 -N205-. Refer to CAMSHAFT
ADJUSTMENT VALVE 1,
CHECKING .
P0016 * - Crankshaft Position vs. Camshaft -- Check the Camshaft Adjustment
Position Correlation Valve 1 -N205-. Refer to CAMSHAFT
ADJUSTMENT VALVE 1,
CHECKING
.-- Check the Engine Speed Sensor -
G28-. Refer to ENGINE SPEED
SENSOR, CHECKING
P025A - Fuel Pump Module Control Circuit Open -- Check the Fuel Pump -G6-. Refer to
FUEL PUMP ELECTRICAL,
TESTING .
P025C - Fuel Pump Module Control Circuit Low -- Check the Fuel Pump -G6-. Refer to
TESTING .
P025D - Fuel Pump Module Control Circuit High -- Check the Fuel Pump -G6-. Refer to
TESTING .
P0030 * - HO2S Heater Control Circuit Bank 1 -- Check the Oxygen Sensor (O2S)
Sensor 1 Heater -Z19-. Refer to OXYGEN
SENSOR HEATER BEFORE
CATALYTIC CONVERTER,
CHECKING .
P0031 * - HO2S Heater Control Circuit Low Bank -- Check the Oxygen Sensor (O2S)
1 Sensor 1 Heater -Z19-. Refer to OXYGEN
CHECKING .
P0032 * - HO2S Heater Control Circuit High Bank -- Check the Oxygen Sensor (O2S)
CHECKING .
P0036 * - HO2S Heater Control Circuit Bank 1 -- Check the Oxygen Sensor (O2S)
Sensor 2 Behind Three Way Catalytic Converter
(TWC) -G130- . Refer to OXYGEN
SENSOR HEATER BEHIND THREE
WAY CATALYTIC CONVERTER,
CHECKING .
P0037 * - HO2S Heater Control Circuit Low Bank -- Check the Oxygen Sensor (O2S)
1 Sensor 2 Behind Three Way Catalytic Converter
CHECKING .
P0038 16422 HO2S Heater Control Circuit High Bank -- Check the Oxygen Sensor (O2S)
CHECKING .
P0068 * - MAF vs Throttle Position Correlation -- Check the Mass Air Flow (MAF)
Sensor -G70-. Refer to MAF SENSOR,
CHECKING .
P0070 * - Ambient Air Temperature Sensor Circuit -- Check the Ambient Temperature
Sensor -G17-. Refer to AMBIENT AIR
TEMPERATURE SENSOR,
CHECKING
P0071 * - Ambient Air Temperature Sensor -- Check the Ambient Temperature
Performance Sensor -G17-. Refer to AMBIENT AIR
TEMPERATURE SENSOR,
CHECKING
P0072 * - Ambient Air Temperature Sensor Circuit -- Check the Ambient Temperature
Low Sensor -G17-. Refer to AMBIENT AIR
TEMPERATURE SENSOR,
CHECKING
P0087 * - Fuel Rail/System Pressure - Too Low -- Check the Fuel Pressure Sensor -
G247-. Refer to FUEL PRESSURE
SENSOR, CHECKING .
P0100 * - Mass Air Flow Circuit Fault -- Check the Mass Air Flow (MAF)
CHECKING .
P0101 * - Mass Air Flow Circuit Performance -- Check the Mass Air Flow (MAF)

CHECKING .
P0102 * - Mass Air Flow Circuit Low Input -- Check the Mass Air Flow (MAF)
CHECKING .
P0103 * - Mass Air Flow Circuit High Input -- Check the Mass Air Flow (MAF)
CHECKING .
P0106 16490 Manifold Absolute Pressure/Barometric -- Check the Charge Air Pressure
Pressure Circuit Performance Sensor/MAP Sensor -G31/G71-. Refer
to CHARGE AIR PRESSURE
SENSOR/MAP SENSOR,
CHECKING . If there is no fault found
with the Charge Air Pressure sensor or
wiring, check for any related TSB's. The
Altitude sensor is located within the
ECM and will require replacement of the
ECM if the reading is more than 10%
out of range of actual Barometric
pressure readings. Refer to the Repair
Information for ECM replacement.
P0111 * - Intake Air Temperature Sensor Circuit -- Check the IAT sensor -G42-. Refer to
Performance IAT SENSOR, CHECKING .
Low Input IAT SENSOR, CHECKING .
High Input IAT SENSOR, CHECKING .
P0116 * - Engine Coolant Temperature Sensor 1 -- Check the Engine Coolant
Circuit Performance Temperature (ECT) Sensor -G62-. Refer
to ENGINE COOLANT
TEMPERATURE SENSOR 1 OR 2
CHECKING .
Circuit Low Input Temperature (ECT) Sensor -G62-. Refer
to ENGINE COOLANT
CHECKING .
Circuit High Input Temperature (ECT) Sensor -G62-. Refer
to ENGINE COOLANT
CHECKING .
P0121 * - Pedal Position Sensor A Circuit -- Check the Accelerator Pedal Position
Performance Sensor 1 -G79-/Accelerator Pedal
Position Sensor 2 -G185-. Refer to
ACCELERATOR PEDAL
POSITION SENSOR
1/ACCELERATOR PEDAL
POSITION SENSOR 2, CHECKING .
P0122 * - Pedal Position Sensor A Circuit Low -- Check the Accelerator Pedal Position
Input Sensor 1 -G79-/Accelerator Pedal
ACCELERATOR PEDAL
POSITION SENSOR
1/ACCELERATOR PEDAL
P0123 * - Pedal Position Sensor A Circuit High -- Check the Accelerator Pedal Position
ACCELERATOR PEDAL
POSITION SENSOR
1/ACCELERATOR PEDAL
P013A * - O2 Sensor Slow Response - Rich to Lean -- Check the Oxygen Sensor (O2S)
Bank 1 Sensor 2 Behind Three Way Catalytic Converter
(TWC) -G130-. Refer to OXYGEN
SENSOR BEHIND THREE WAY
CHECKING .
P0130 * - O2 Sensor Circuit Bank 1 Sensor 1 -- Check the Heated Oxygen Sensor
(HO2S) -G39-. Refer to OXYGEN
SENSOR BEFORE CATALYTIC
CONVERTER, CHECKING
P0131 * - O2 Sensor Circuit, Bank 1 - Sensor 1 -- Check the Heated Oxygen Sensor
Low Voltage (HO2S) -G39-. Refer to OXYGEN
CONVERTER, CHECKING
P0132 * - O2 Sensor Circuit, Bank 1 - Sensor 1 -- Check the Heated Oxygen Sensor
High Voltage (HO2S) -G39-. Refer to OXYGEN
CONVERTER, CHECKING
P0133 * - O2 Circuit Slow Response Bank 1 Sensor -- Check the Heated Oxygen Sensor
1 (HO2S) -G39-. Refer to OXYGEN
CONVERTER, CHECKING
P0135 16519 O2 Heater Circuit Bank 1 Sensor 1 -- Check the Oxygen Sensor (O2S)
Heater -G39-. Refer to OXYGEN
CHECKING .
P0136 16520 O2 Circuit Bank 1 Sensor 2 -- Check the Oxygen Sensor (O2S)
Behind Three Way Catalytic Converter

CHECKING .
P0137 * - O2 Circuit Low Voltage Bank 1 Sensor 2 -- Check the Oxygen Sensor (O2S)
CHECKING .
P0138 * - O2 Circuit High Voltage Bank 1 Sensor 2 -- Check the Oxygen Sensor (O2S)
CHECKING .
P0139 16523 O2 Circuit Slow Response Bank 1 Sensor -- Check the Oxygen Sensor (O2S)
2 Behind Three Way Catalytic Converter
CHECKING .
P0140 * - O2 Circuit No Activity Detected Bank 1 -- Check the Oxygen Sensor (O2S)
Sensor 2 Behind Three Way Catalytic Converter
CHECKING .
P0141 16525 O2 Heater Circuit Bank 1 Sensor 2 -- Check the Oxygen Sensor (O2S)
Heater -G465-. Refer to OXYGEN
CHECKING .
P0169 * - Incorrect Fuel Composition Check for contaminated fuel or possible
high concentration of alcohol in fuel
(above 15%). If any O2 sensor codes are
also set, refer to those codes first.
P0171 16555 System Too Lean Bank 1 -- Check the intake system for leaks
(unmetered air).
-- Check the vacuum lines for leaks
-- Check the fuel pressure --. Refer to
FUEL PRESSURE TEST
- Check the Fuel Pressure Sensor -G247-
. Refer to FUEL PRESSURE
SENSOR, CHECKING
--- Check the fuel injectors -N30, N31,
N32, N33, -. Refer to FUEL

INJECTORS, CHECKING .
-- Check the Heated Oxygen Sensor
CONVERTER, CHECKING .
P0172 16556 System Too Rich Bank 1 -- Check the fuel pressure --. Refer to
FUEL PRESSURE TEST
-- Check the Fuel Pressure Sensor -
SENSOR, CHECKING
-- Check the fuel injectors -N30, N31,
-- Check the Evaporative Emission
(EVAP) Canister Purge Regulator Valve
-N80-. Refer to EVAPORATIVE
EMISSION CANISTER PURGE
REGULATOR VALVE,
CHECKING .
P0190 * - Fuel Rail Pressure Sensor Circuit -- Check the Fuel Pressure Sensor -
SENSOR, CHECKING
P0191 16575 Fuel Rail Pressure Sensor Circuit -- Check the Fuel Pressure Sensor -
Performance G247-. Refer to FUEL PRESSURE
SENSOR, CHECKING
P0192 * - Fuel Rail Pressure Sensor Circuit Low -- Check the Fuel Pressure Sensor -
SENSOR, CHECKING
P0201 * - Injector Circuit Open Cylinder 1 -- Check the fuel injectors -N30-. Refer
to FUEL INJECTORS, CHECKING .
P0221 * - Pedal Position Sensor Circuit -- Check the Accelerator Pedal Position
Performance Sensor 1 -G79-/Accelerator Pedal
ACCELERATOR PEDAL
POSITION SENSOR
1/ACCELERATOR PEDAL
P0222 * - Pedal Position Sensor Circuit Low Input -- Check the Accelerator Pedal Position
Sensor 1 -G79-Accelerator Pedal
ACCELERATOR PEDAL
POSITION SENSOR
1/ACCELERATOR PEDAL
P0223 * - Pedal Position Sensor Circuit High Input -- Check the Accelerator Pedal Position
Sensor 1 -G79-/Accelerator Pedal
ACCELERATOR PEDAL
POSITION SENSOR
1/ACCELERATOR PEDAL
P0234 * - Turbocharger Overboost Condition -- Check the Charge Air Pressure sensor
-G31-. Refer to CHARGE AIR
PRESSURE SENSOR/MAP
SENSOR, CHECKING
-- Check the Wastegate Bypass
Regulator Valve -N75-. Refer to
WASTEGATE BYPASS
REGULATOR VALVE,
CHECKING .
-- Check the Turbocharger Recirculating
Valve -N249-. Refer to
TURBOCHARGER
RECIRCULATING VALVE,
CHECKING NOTE: Check the
Altitude sensor reading and make sure it
is correct for the location (if unsure of
the elevation compare to a vehicle with
no faults). If the reading is off by 10% or
more, the Altitude sensor is part of the
ECM circuit board and will require ECM
replacement.
P0236 * - Turbocharger Boost Sensor Circuit -- Check the Charge Air Pressure sensor
Performance -G31-. Refer to CHARGE AIR
PRESSURE SENSOR/MAP
SENSOR, CHECKING NOTE: Check
the Altitude sensor reading and make
sure it is correct for the location (if
unsure of the elevation compare to a
vehicle with no faults). If the reading is
off by 10% or more, the Altitude sensor
is part of the ECM circuit board and will
require ECM replacement.

P0237 * - Turbocharger Boost Sensor Circuit Low -- Check the Charge Air Pressure sensor
PRESSURE SENSOR/MAP
SENSOR, CHECKING
P0238 * - Turbocharger Boost Sensor Circuit High -- Check the Charge Air Pressure sensor
PRESSURE SENSOR/MAP
SENSOR, CHECKING
P0243 * - Turbocharger Wastegate Solenoid Circuit -- Check the Wastegate Bypass
Performance Regulator Valve -N75-. Refer to
WASTEGATE BYPASS
REGULATOR VALVE,
CHECKING .
P0245 * - Turbocharger Wastegate Solenoid Low -- Check the Wastegate Bypass
WASTEGATE BYPASS
REGULATOR VALVE,
CHECKING .
P0246 16630 Turbocharger Wastegate Solenoid High -- Check the Wastegate Bypass
WASTEGATE BYPASS
REGULATOR VALVE,
CHECKING .
P025A * - Fuel Pump Module Control Circuit Open -- Check the Fuel Pump Module -J538-.
Refer to FUEL PUMP ELECTRICAL,
TESTING
P025C * - Fuel Pump Module Control Circuit Low -- Check the Fuel Pump Module -J538-.
TESTING
P025D * - Fuel Pump Module Control Circuit High -- Check the Fuel Pump Module -J538-.
TESTING
P0261 * - Cylinder 1 Injector Circuit Low -- Check the fuel injectors -N30-. Refer
P0262 * - Cylinder 1 Injector Circuit High -- Check the fuel injectors -N30-. Refer
P0299 * - Turbocharger Underboost -- Check the charge air system for proper
seal. Refer to the Repair Information.
-- Check the Charge Air Pressure sensor
PRESSURE SENSOR/MAP
SENSOR, CHECKING
P0300 * - Random Misfire Detected -- Check the Spark plugs.
-- Check the intake system for leaks.
-- Check the Fuel Pressure. Refer to
FUEL PRESSURE TEST
- Check fuel injectors -N30, N31, N32,
N33, -. Refer to FUEL INJECTORS,
CHECKING
--- Check the Ignition Coils with Power
Output Stage -N70, N127, N291, N292-.
Refer to IGNITION COILS WITH
POWER OUTPUT STAGE,
CHECKING .
P0301 * - Cylinder 1 Misfire Detected -- Check the Spark plugs.
-- Check fuel injectors -N30, N31, N32,
N33, -. Refer to FUEL INJECTORS,
CHECKING
-- Check the Ignition Coils with Power
POWER OUTPUT STAGE,
CHECKING .
P0302 * - Cylinder 2 Misfire Detected -- Check the Spark plugs.-- Check fuel
injectors -N30, N31, N32, N33, -. Refer
to FUEL INJECTORS, CHECKING
Output Stage -N70, N127, N291, N292-
. Refer to IGNITION COILS WITH
POWER OUTPUT STAGE,
CHECKING .
N33, - . Refer to FUEL INJECTORS,
CHECKING

POWER OUTPUT STAGE,
CHECKING .
N33, - . Refer to FUEL INJECTORS,
CHECKING
POWER OUTPUT STAGE,
CHECKING .
P0321 * - Engine Speed Input Circuit Performance -- Check the Engine Speed (RPM)
Sensor -G28-. Refer to ENGINE
SPEED SENSOR, CHECKING .
P0322 * - Engine Speed Input Circuit No Signal -- Check the Engine Speed (RPM)
Sensor -G28. Refer to ENGINE SPEED
SENSOR, CHECKING .
P0324 * - Knock Control System Error -- Check theKnock Sensors -G61, G66-.
Refer to KNOCK SENSOR 1,
CHECKING .
P0327 * - Knock Sensor 1 Circuit Low Input -- Check theKnock Sensors -G61, G66- .
CHECKING .
P0328 * - Knock Sensor 1 Circuit High Input -- Check theKnock Sensors -G61, G66- .
CHECKING .
P0340 16724 Camshaft Position Sensor Circuit -- Check the Camshaft Position (CMP)
Sensor -G40-. Refer to CAMSHAFT
POSITION SENSOR, CHECKING .
P0341 * - Camshaft Position Sensor Circuit -- Check the Camshaft Position (CMP)
Performance Sensor -G40-. Refer to CAMSHAFT
P0342 * - Camshaft Position Sensor Circuit Low -- Check the Camshaft Position (CMP)
Input Sensor -G40- . Refer to CAMSHAFT
P0343 * - Camshaft Position Sensor Circuit High -- Check the Camshaft Position (CMP)
Input Sensor -G40- . Refer to CAMSHAFT
P0351 * - Ignition Coil A Primary/Secondary -- Check the Ignition Coils with Power
Circuit Output Stage -N70- . Refer to
IGNITION COILS WITH POWER
OUTPUT STAGE, CHECKING .
P0352 * - Ignition Coil B Primary/Secondary -- Check the Ignition Coils with Power
Circuit Output Stage -N127-. Refer to
P0353 * - Ignition Coil C Primary/Secondary -- Check the Ignition Coils with Power
P0354 * - Ignition Coil D Primary/Secondary -- Check the Ignition Coils with Power
P0420 16804 Catalyst System Efficiency Below -- Check the Three Way Catalytic
Threshold Converter (TWC). Refer to THREE
TWC CHECKING .
CONVERTER, CHECKING
-- Check the Oxygen Sensor (O2S)
CHECKING .
P0441 * - Evaporative Emission System Incorrect -- Check the Evaporative Emission
Purge Flow (EVAP) Canister Purge Regulator Valve
REGULATOR VALVE,
CHECKING .
-- Check the Leak Detection Pump
(LDP) -V144-. Refer to LEAK
DETECTION PUMP, CHECKING .
P0442 * - Evaporative Emission System Leak -- Check the EVAP System, for Leaks.
Detected (Small Leak) Refer to EVAP SYSTEM,
CHECKING FOR LEAKS
REGULATOR VALVE,
CHECKING .
P0444 * - Evaporative Emission System Purge -- Check the Evaporative Emission

Control Valve Circuit Open (EVAP) Canister Purge Regulator Valve
-N80- . Refer to EVAPORATIVE
REGULATOR VALVE,
CHECKING .
P0455 16839 Evaporative Emission System Leak -- Check the EVAP System, for Leaks.
Detected (gross leak/no flow) Refer to EVAP SYSTEM,
CHECKING FOR LEAKS
REGULATOR VALVE,
CHECKING .
P0456 * - Evaporative Emission System Leak -- Check the EVAP System, for Leaks.
Detected (very small leak) Refer to EVAP SYSTEM,
CHECKING FOR LEAKS
REGULATOR VALVE,
CHECKING .
P0458 * - Evaporative Emission System Purge -- Check the Check the Evaporative
Control Valve Circuit Low Emission (EVAP) Canister Purge
EVAPORATIVE EMISSION
CANISTER PURGE REGULATOR
VALVE, CHECKING .
P0459 * - Evaporative Emission System Purge -- Check the Check the Evaporative
Control Valve Circuit High Emission (EVAP) Canister Purge
EVAPORATIVE EMISSION
CANISTER PURGE REGULATOR
VALVE, CHECKING .
P050A * - Cold Start Idle Air Control System -- Check the Throttle Valve Control
Performance Module -J338-. Refer to THROTTLE
VALVE CONTROL MODULE,
CHECKING .
P050B * - Cold Start Ignition Timing Performance This code will set due to poor fuel
quality or fuel that has aged. Drain the
fuel from the vehicle and replace with
fresh gasoline.
P0501 * - Vehicle Speed Sensor -- Check vehicle speed signal. Refer to
Range/Performance SPEED SIGNAL, CHECKING .
P0503 16887 Vehicle Speed Sensor -- Check vehicle speed signal. Refer to
Intermittent/Erratic/High SPEED SIGNAL, CHECKING .
P0506 * - Idle Air Control System RPM Lower -- Check the Throttle Valve Control
Than Expected Module -J338-. Refer to THROTTLE
CHECKING .
P0507 * - Idle Air Control System RPM Higher -- Check the Throttle Valve Control
Than Expected Module -J338-. Refer to THROTTLE
CHECKING .
P052A * - Cold Start Camshaft Position Timing Incorrect oil viscosity can set the code.
Over-Advanced See if oil change was recently performed
(possibly using wrong viscosity oil).
-- Check the Camshaft Adjustment
Valve 1 -N205- . Refer to CAMSHAFT
ADJUSTMENT VALVE 1,
CHECKING .
P053F * - Cold Start Fuel Pressure Performance -- Check the Fuel Pressure. Refer to
FUEL PRESSURE TEST
P0606 * - ECM Processor Fault -- Replace the Engine Control Module
(ECM) -J623-. Refer to the Repair
Information.
P062B * - Internal Control Module Fuel Injector -- Replace the Engine Control Module
Control Performance (ECM) -J623-. Refer to the Repair
Information.
P0638 * - Throttle Actuator Control Performance -- Check the Throttle Valve Control
Module -J338-. Refer to THROTTLE
CHECKING .
P0641 * - Sensor Reference Voltage A Circuit Check for any sensor voltage faults, and
diagnose any sensor voltage codes first.
If none are set:
-- Replace the Engine Control Module
Information.
P0651 * - Sensor Reference Voltage B Circuit Check for any sensor voltage faults, and
If none are set:
Information.
P0657 * - Actuator Supply Voltage A Circuit Open Check for any actuator voltage faults,
and diagnose any actuator voltage codes
first. If none are set:
-- Check the Engine Control Module
(ECM) Power Supply Relay -J271- .
Refer to VOLTAGE SUPPLY,
CHECKING .
P0658 * - Actuator Supply Voltage A Circuit Low Check for any actuator voltage faults,
(ECM) Power Supply Relay -J271-.
CHECKING .
P0659 * - Actuator Supply Voltage A Circuit High Check for any actuator voltage faults,
(ECM) Power Supply Relay -J271-.
CHECKING .
P0697 * - Sensor Reference Voltage C Circuit Open Check for any sensor voltage faults, and
If none are set:
Information.
P12A1 * - Fuel Rail Pressure Sensor Inappropriately -- Check the Fuel Pressure Sensor -
Low G247-. Refer to FUEL PRESSURE
SENSOR, CHECKING .
-- Check the Fuel Pressure Regulator
Valve -N276-. Refer to FUEL
PRESSURE REGULATOR VALVE,
CHECKING .
P12A2 * - Fuel Rail Pressure Sensor Inappropriately -- Check the Fuel Pressure Sensor -
High G247-. Refer to FUEL PRESSURE
SENSOR, CHECKING .
CHECKING .
P12A4 * - Fuel Rail Pump Control Valve Stuck -- Check the Fuel Pressure Regulator
Closed Valve -N276-. Refer to FUEL
CHECKING .
P150A * - Engine Off Timer Performance Check for related TSB's. If none apply;
check the power and ground inputs to
the ECM BEFORE replacing ECM.
Lack of ignition off power supply will
cause the timer to stop. Refer to the
Wiring Diagrams for power and ground
locations to the ECM. If power and
grounds are present at the ECM
Information.
P1609 18017 Crash Fuel Shut-Off Was Deployed Information code only. After vehicle is
properly repaired, erase code.
P2008 * - Intake Manifold Runner Control Circuit -- Check the Intake Manifold Runner
Open Control (IMRC) Valve -N316-. Refer to
INTAKE MANIFOLD RUNNER
CONTROL VALVE, CHECKING .
Low Control (IMRC) Valve -N316-. Refer to
High Control (IMRC) Valve -N316-. Refer to
P2014 * - Intake Manifold Runner Position Sensor -- Check the Intake Manifold Runner
Circuit Position Sensor -G336-. Refer to
Circuit Performance Position Sensor -G336-. Refer to
Circuit Low Position Sensor -G336-. Refer to
P2088 * - A Camshaft Position Actuator Control -- Check the Camshaft Adjustment
Circuit Low Valve 1 -N205-. Refer to CAMSHAFT
P2089 * - A Camshaft Position Actuator Control -- Check the Camshaft Adjustment
Circuit High Valve 1 -N205-. Refer to CAMSHAFT
P2096 * - Post Catalyst Fuel Trim System Too Check for exhaust leaks ahead of the
Lean catalyst. -- Check Heated Oxygen Sensor
(HO2S) -G130- behind Three Way
Catalytic Converter (TWC). Refer to

OXYGEN SENSOR BEHIND
THREE WAY CATALYTIC
CONVERTER, CHECKING
P2097 * - Post Catalyst Fuel Trim System Too Rich -- Check Heated Oxygen Sensor (HO2S)
-G130- behind Three Way Catalytic
Converter (TWC). Refer to OXYGEN
CHECKING
P2101 * - Throttle Actuator Control Motor Circuit -- Check the Throttle Valve Control
Performance Module -J338-. Refer to THROTTLE
CHECKING .
P2106 * - Throttle Actuator Control System Forced -- Check the Throttle Valve Control
Limited Power Module -J338-. Refer to THROTTLE
CHECKING .
P2122 * - Pedal Position Sensor D Circuit Low -- Check the Accelerator Pedal Position
ACCELERATOR PEDAL
POSITION SENSOR
1/ACCELERATOR PEDAL
P2123 * - Pedal Position Sensor D Circuit High -- Check the Accelerator Pedal Position
Input Sensor 1 -G79- /Accelerator Pedal
ACCELERATOR PEDAL
POSITION SENSOR
1/ACCELERATOR PEDAL
P2127 * - Pedal Position Sensor E Circuit Low -- Check the Accelerator Pedal Position
Input Sensor 1 -G79- /Accelerator Pedal
ACCELERATOR PEDAL
POSITION SENSOR
1/ACCELERATOR PEDAL
P2128 * - Pedal Position Sensor E Circuit High -- Check the Accelerator Pedal Position
ACCELERATOR PEDAL
POSITION SENSOR
1/ACCELERATOR PEDAL
P2138 * - Pedal Position Sensor D/E Voltage -- Check the Accelerator Pedal Position
Correlation Sensor 1 -G79-/Accelerator Pedal
ACCELERATOR PEDAL
POSITION SENSOR
1/ACCELERATOR PEDAL
P2146 * - Fuel Injector A Supply Voltage Circuit -- Check the Fuel injectors -N30, N31,
Open N32, N33-. Refer to FUEL
P2149 * - Fuel Injector B Supply Voltage Circuit -- Check the Fuel injectors -N30, N31,
Open N32, N33-. Refer to FUEL
P2177 * - System Too Lean Off Idle -- Check the Fuel Pressure --. Refer to
FUEL PRESSURE TEST If the fuel
pressure is out of range:
- Check the Fuel Pressure Regulator
CHECKING .
--- Check the Fuel Injectors -N30, N31,
Before Catalytic Converter -G39-. Refer
to OXYGEN SENSOR BEFORE
CHECKING .
P2178 * - System Too Rich Off Idle -- Check the Fuel Pressure -- . Refer to
FUEL PRESSURE TEST
If the fuel pressure is out of range: --
Check the Fuel Pressure Regulator
CHECKING .
-- Check the Fuel Injectors -N30, N31,
CHECKING .
-N80- . Refer to EVAPORATIVE
REGULATOR VALVE,
CHECKING .
P2181 * - Cooling System Performance -- Check Engine Coolant Temperature
(ECT) Sensor -G62-. Refer to ENGINE
COOLANT TEMPERATURE
SENSOR 1 OR 2 CHECKING
-- Check the Coolant Pump -V50-. Refer
to the Repair Information.
-- Check the Coolant Thermostat. Refer
to the Repair Information.
Circuit Low Temperature (ECT) Sensor -G83-. Refer
to ENGINE COOLANT
CHECKING .
Circuit High Temperature (ECT) Sensor -G83-. Refer
to ENGINE COOLANT
CHECKING .
P2187 * - Fuel System Too Lean At Idle -- Check the intake system for leaks. -
-- Check the vacuum lines for leaks
-- Check the Fuel Pressure --. Refer to
CHECKING .
- Check the Heated Oxygen Sensor
CHECKING .
P2188 * - Fuel System Too Rich At Idle -- Check the Fuel Pressure --. Refer to
CHECKING .

CHECKING .
REGULATOR VALVE,
CHECKING .
P2195 * - O2 Sensor Signal Biased/Stuck Lean -- Check the Heated Oxygen Sensor
Bank 1, Sensor 1 (HO2S) -G39-. Refer to OXYGEN
CONVERTER, CHECKING
P2196 * - O2 Sensor Signal Biased/Stuck Rich - -- Check the Heated Oxygen Sensor
Bank 1, Sensor 1 (HO2S) -G39-. Refer to OXYGEN
CONVERTER, CHECKING
P2231 18663 O2 Sensor Bank 1 Sensor 1 Signal -- Check the Heated Oxygen Sensor
Circuit Shorted to Heater Circuit (HO2S) -G39-. Refer to OXYGEN
CONVERTER, CHECKING
CHECKING .
P2237 * - O2 Sensor Positive Current Control -- Check the Heated Oxygen Sensor
Circuit Open Bank 1, Sensor 1 (HO2S) -G39-. Refer to OXYGEN
CHECKING .
P2243 * - O2 Sensor Reference Voltage Circuit -- Check the Heated Oxygen Sensor
Open Bank 1, Sensor 1 (HO2S) -G39-. Refer to OXYGEN
CONVERTER, CHECKING
P2251 * - O2 Sensor Negative Current Control -- Check the Heated Oxygen Sensor
Circuit Open Bank 1 Sensor 1 (HO2S) -G39-. Refer to OXYGEN
CHECKING .
P2270 * - O2 Sensor Signal Stuck Lean Bank 1 -- Check the Heated Oxygen Sensor
Sensor 2 (HO2S) -G130-. Refer to OXYGEN
CHECKING
P2271 * - O2 Sensor Signal Stuck Rich Bank 1 -- Check the Heated Oxygen Sensor
CHECKING
P2279 18711 Intake Air System Leak Check for air leaks between MAF and
throttle body, oil fill cap not seated or oil
dipstick not seated in tube. Also any
engine gaskets that can cause additional
air to enter the crankcase can set this
fault. If a vacuum leak or crankcase seal
is at cause, the idle may be rough or
unstable.
P2293 * - Fuel Pressure Regulator 2 Performance -- Check the Fuel Pressure Regulator
CHECKING .
P2294 * - Fuel Pressure Regulator 2 Control Circuit -- Check the Fuel Pressure Regulator
CHECKING .
Low Valve -N276-. Refer to FUEL
CHECKING .
High Valve -N276-. Refer to FUEL
CHECKING .
P2300 * - Ignition Coil A Primary Control Circuit -- Check the Ignition Coils with Power
Low Output Stage -N70-. Refer to
P2301 * - Ignition Coil A Primary Control Circuit -- Check the Ignition Coils with Power
High Output Stage -N70-. Refer to
P2303 * - Ignition Coil B Primary Control Circuit -- Check the Ignition Coils with Power
P2304 * - Ignition Coil B Primary Control Circuit -- Check the Ignition Coils with Power
P2306 * - Ignition Coil C Primary Control Circuit -- Check the Ignition Coils with Power
P2307 * - Ignition Coil C Primary Control Circuit -- Check the Ignition Coils with Power
P2309 * - Ignition Coil D Primary Control Circuit -- Check the Ignition Coils with Power
P2310 * - Ignition Coil D Primary Control Circuit -- Check the Ignition Coils with Power
P2400 * - Evaporative Emission System Leak -- Check the Leak Detection Pump
Detection Pump Control Circuit/Open (LDP) -V144-. Refer to LEAK
Detection Pump Control Circuit Low (LDP) -V144-. Refer to LEAK
Detection Pump Control Circuit High (LDP) -V144-. Refer to LEAK
P2403 18835 Evaporative Emission System Leak -- Check the Leak Detection Pump
Detection Pump Sense Circuit/Open (LDP) -V144-. Refer to LEAK
P2404 18836 Evaporative Emission System Leak -- Check the Leak Detection Pump
Detection Pump Sense (LDP) -V144-. Refer to LEAK
Range/Performance DETECTION PUMP, CHECKING .
P2414 * - O2 Sensor Exhaust Sample Error Bank 1, -- Check the Heated Oxygen Sensor
P2450 * - Evaporative Emission System Switching
Valve Performance/Stuck Open
P2626 * - O2 Sensor Pumping Current Trim -- Check the Heated Oxygen Sensor
Circuit/Open Bank 1 Sensor 1 (HO2S) -G39-. Refer to OXYGEN
P3081 * - Engine Temperature Too Low -- Check the Engine Coolant
Temperature (ECT) Sensor -G62-. Refer
to ENGINE COOLANT
CHECKING .
-- Check for a stuck open thermostat.
Refer to the Repair Information.
U0001 * - High Speed CAN Communication Bus -- Check the CAN-Bus terminal
resistance. Refer to CAN-BUS
TERMINAL RESISTANCE,
CHECKING .
U0002 * - High Speed CAN Communication Bus -- Check the CAN-Bus terminal
Performance resistance. Refer to CAN-BUS
CHECKING .
U0101 * - Lost Communication with TCM -- Check the CAN-Bus Direct Shift
Gearbox (DSG) Mechatronic -J743- to
Engine Control Module (ECM) - J623-.
Refer to CAN-BUS TERMINAL
RESISTANCE, DIRECT SHIFT
GEARBOX MECHATRONIC TO
ENGINE CONTROL MODULE,
CHECKING .
U0121 * - Lost Communication With Anti-Lock Check to see if any other modules have
Brake System (ABS) Control Module set a loss of communication with the
ABS module fault. If other modules can
communicate with ABS and ECM
cannot, the ECM may be at fault. If other
modules have set an ABS
communication error, refer to the
Service Information for the ABS
communication diagnosis.
U0146 * - Lost Communication With Gateway A -- Check the CAN-Bus terminal
CHECKING .
U0155 * - Lost Communication With Instrument -- Check the CAN-Bus terminal
Panel Cluster (IPC) Control Module resistance. Refer to CAN-BUS
CHECKING .
U0302 * - Software Incompatibility with Check for any applicable TSB's. Check
Transmission Control Module the ECM software version to make sure
it is correct for the vehicle. Reflash
module if incorrect or update is
available. If ECM and TCM software is
correct:-- Replace the Direct Shift
Gearbox (DSG) Mechatronic -J743-.
Refer to the Repair Information.
U0402 * - Invalid Data Received From TCM Check for correct software in TCM and
reflash if necessary. Check the CAN bus.
Refer to CAN-BUS TERMINAL

RESISTANCE, DIRECT SHIFT
GEARBOX MECHATRONIC TO
ENGINE CONTROL MODULE,
CHECKING
U0415 * - CAN Communication With ABS Error -- Check the CAN-Bus terminal
CHECKING .
U0422 - Invalid Data Received From Body -- Check the CAN-Bus terminal
Control Module (Cluster) resistance. Refer to CAN-BUS
CHECKING .
U0423 * - Invalid Data Received From Instrument If an AAT sensor code is set, diagnose
Panel Cluster Control Module that code before proceeding. If no code
is set replace the IPC module. Refer to
the Repair Information.
U0447 - Lost Communication With Gateway -- Check the CAN-Bus terminal
CHECKING .
2009 VOLKSWAGEN Passat
2009 VOLKSWAGEN
Passat
BUZZERS, RELAYS & TIMERS

BUZZERS, RELAYS & TIMERS LOCATION
Component Location
Alarm Horn Relay (D) On relay carrier no. 2. See Fig. 106.
Auxiliary Engine Coolant (EC) Pump Relay (2) On relay carrier no. 1. See Fig. 108.
Auxiliary Heater Operation Relay (1) On relay carrier no. 1. See Fig. 108.
On vehicle electrical system control module relay
Dual Horn Relay (B6)
carrier. See Fig. 107.
Dual Washer Pump Relay No. 1 (B7)
Dual Washer Pump Relay No. 2 (B8)
Fresh Air Fan Relay (3) On relay carrier no. 1. See Fig. 108.
Fuel Pump (FP) Relay (4) On relay carrier no. 1. See Fig. 108.
Headlight Washer Relay (6) On relay carrier no. 1. See Fig. 108.
Load Reduction Relay (B9)
Motronic Engine Control Module (ECM) Power In engine compartment electronics box (low). See
Supply Relay (A2) Fig. 109.
Motronic Engine Control Module (ECM) Power In engine compartment electronics box (high). See
Supply Relay 2 (A3) Fig. 110.
Parking Aid Warning Buzzer (Front) Behind left kick panel.
Parking Aid Warning Buzzer (Rear) Left rear of trunk.
Power Supply Relay No. 2 (Terminal 30) (B4)
Power Supply Relay (Terminal 15) (B1)
Power Supply Relay (Terminal 50) (7) On relay carrier no. 1. See Fig. 108.
Powertrain CAN-Bus Low Cut-Off Relay (A) On relay carrier no. 2. See Fig. 106.
Rear Window Defogger Relay (B5)
In engine compartment electronics box (high). See
Recirculation Pump Relay (A2)
Fig. 110.
In engine compartment electronics box (low). See
Secondary Air Injection Relay (A1)
Fig. 109.
Second Battery Charge Relay (C) On relay carrier no. 2. See Fig. 106.
In plenum chamber, near engine control module.
Windshield Heater Relay
See Fig. 105.
CIRCUIT PROTECTION DEVICES

CIRCUIT PROTECTION DEVICES LOCATION
Component Location
Engine Compartment Electronics Box (High) Left side of engine compartment. See Fig. 110.
Engine Compartment Electronics Box (Low) Left side of engine compartment. See Fig. 109.
Fuse Panel A Left side of engine compartment. See Fig. 37.
Fuse Panel B Left side of engine compartment. See Fig. 38.
Fuse Panel C At left end of dash. See Fig. 39.
Fuse Panel D At right end of dash. See Fig. 40.
Relay Carrier No. 1 Under left side of dash. See Fig. 108.
Relay Carrier No. 2 Under left side of dash. See Fig. 106.
Relay Carrier (Vehicle Electrical System Control
Behind left side of dash. See Fig. 107.
Module)
CONTROL UNITS
CONTROL UNITS LOCATION
Component Location
ABS Control Module Right rear of engine compartment. See Fig. 7.
Mounted on floor in front of center console. See
Airbag Control Module
Fig. 9.
Comfort System Central Control Module Behind right side of dash. See Fig. 15.
Door Control Module (Driver's Side) In driver's door. See Fig. 19.
Door Control Module (Front Passenger's) (4) In front passenger's door. See Fig. 113.
Door Control Module (Left Rear) In left rear door. See Fig. 74.
Door Control Module (Right Rear) In right rear door. See Fig. 91.
Electro-Mechanical Parking Brake Control Module Under center console. See Fig. 22.
Electronic Steering Column Lock Control Module Under left side of dash. See Fig. 23.
Engine Control Module In center of plenum. See Fig. 24.
Fresh Air Blower Control Module (12) On fresh air blower motor. See Fig. 112.
Fuel Pump Control Module Under right rear seat. See Fig. 36.
Heated Seat Control Module (Driver's) On driver's seat frame. See Fig. 20.
Parking Aid Control Module Right side of trunk.
Power Steering Control Module Integral with steering gear assembly. See Fig. 82.
Radar Interior Monitoring Control Module 1 (6) In roof console. See Fig. 113.
Radiator Fan Control Unit Integrated into radiator fan assembly.
Rear Lid Control Module Left rear of roof. See Fig. 121.
Rear Lid Control Module 2 Right rear of roof. See Fig. 122.
Seat Occupied Recognition Control Module Under front passenger's seat. See Fig. 92.
Steering Column Electronic Systems Control On steering column. See Fig. 95.
Module
Throttle Valve Control Module On left side of engine. See Fig. 97.
Transmission Control Module (TCM) In left front wheelwell. See Fig. 120.
Vehicle Electrical System Control Module Behind left side of dash. See Fig. 100.
Wiper Motor Control Module In left side of plenum. See Fig. 104.
MOTORS
MOTORS LOCATION
Component Location
Air Flow Flap Motor (9) Behind right side of dash. See Fig. 112.
Central Air Flap Motor (30) Behind center of dash. See Fig. 112.
Closing Assist Motor (Rear Lid) At rear lid latch assembly. See Fig. 118.
Defroster Flap Motor (28) Behind left side of dash. See Fig. 112.
Door Central Locking Lock Unit (Driver's) (11) Rear of driver's door. See Fig. 113.
Door Central Locking Lock Unit (Front Passenger's)
Rear of front passenger's door. See Fig. 113.
(5)
Door Central Locking Lock Unit (Left Rear) (9) Rear of left rear door. See Fig. 113.
Door Central Locking Lock Unit (Right Rear) (7) Rear of right rear door. See Fig. 113.
Fresh Air Blower (12) Under right side of dash. See Fig. 112.
Indirect Ventilation Flap Motor (32) Behind left side of dash. See Fig. 112.
Intake Flap Motor Left rear of engine. See Fig. 68.
Intake Manifold Runner Position Sensor/Intake Flap
Left rear of engine. See Fig. 69.
Motor
Leak Detection Pump In right rear wheelwell. See Fig. 130.
Left Temperature Flap Motor (29) Behind left side of dash. See Fig. 112.
Motor (Rear Lid Control Module) Integral to rear lid control module. See Fig. 121.
Motor (Rear Lid Control Module 2) Integral to rear lid control module 2. See Fig. 122.
Parking Brake Motor (Left) On left rear brake caliper. See Fig. 72.
Parking Brake Motor (Right) On right rear brake caliper. See Fig. 89.
Rear Lid Lock Unit Bottom center of rear lid door. See Fig. 117.
Rear Lid Opening Motor In rear lid lock assembly. See Fig. 124.
Recirculation Flap Motor (10) Behind right side of dash. See Fig. 112.
Recirculation Pump On lower left side of engine. See Fig. 87.
Right Temperature Flap Motor (22) Behind center of dash. See Fig. 112.
Starter On left side of engine. See Fig. 94.
Integral to wiper motor control module. See Fig.
Windshield Wiper Motor
104.
SENDING UNITS & SENSORS

SENDING UNITS & SENSORS LOCATION

Component Location
ABS Wheel Speed Sensor (Left Front) On left front wheel bearing housing. See Fig. 71.
ABS Wheel Speed Sensor (Left Rear) On left rear wheel bearing assembly. See Fig. 73.
ABS Wheel Speed Sensor (Right Front) On right front wheel bearing housing. See Fig. 88.
ABS Wheel Speed Sensor (Right Rear) On right rear wheel bearing assembly. See Fig. 90.
Accelerator Pedal Position Sender 2/Throttle
Above accelerator pedal. See Fig. 8.
Position Sensor
Air Mass Meter On air intake duct.
Brake Booster Sensor On brake booster assembly. See Fig. 129.
Camshaft Position (CMP) Sensor (2.0L) On front of cylinder head. See Fig. 13.
Charge Air Pressure Sensor Lower front of engine compartment. See Fig. 14.
Coolant Temperature Sender (2.0L) (20) In coolant pump housing. See Fig. 116.
Engine Coolant Level Sensor Integral with coolant reservoir. See Fig. 25.
Engine Coolant Temperature (ECT) Sensor On lower rear of engine. See Fig. 26.
Engine Coolant Temperature (ECT) Sensor (On
Integral with radiator hose. See Fig. 27.
Radiator)
Engine Speed (RPM) Sensor (3.6L) (25) Left rear of engine. See Fig. 115.
Engine Speed Sender (2.0L) (11) Left rear of engine. See Fig. 116.
Evaporator Vent Temperature Sensor Above right front center console. See Fig. 29.
Front Airbag Crash Sensor (Driver's) Left front of engine compartment. See Fig. 18.
Front Airbag Crash Sensor (Passenger's) Right front of engine compartment. See Fig. 32.
Front Parking Aid Sensors (4) Behind front bumper.
Fuel Pressure Sensor At front of engine. See Fig. 35.
Heated Oxygen Sensor (HO2S) (2.0L) Integral with exhaust manifold. See Fig. 60.
Heated Oxygen Sensor (HO2S) 2 (3.6L) (3) Integral with left exhaust manifold. See Fig. 111.
Heated Oxygen Sensor (HO2S) (3.6L) (2) Integral with right exhaust manifold. See Fig. 111.
High Pressure Sensor Right front of engine compartment. See Fig. 61.
Intake Air Temperature (IAT) Sensor Left side of engine. See Fig. 67.
Intake Manifold Runner Position Sensor/Intake Flap
At left rear of engine. See Fig. 69.
Motor
Interior Monitoring Sensors (6) In roof console. See Fig. 113.
Knock Sensor (KS) 1 (3.6L) (8) Between cylinders 1 & 3. See Fig. 115.
Knock Sensor (KS) 2 (3.6L) (30) Between cylinders 4 & 6. See Fig. 115.
Knock Sensor 1 (2.0L) (19) Below intake manifold. See Fig. 116.
Left Footwell Vent Temperature Sensor Above accelerator pedal. See Fig. 70.
Left Vent Temperature Sensor (4) At left vent. See Fig. 112.
Level Control Sensor (Left Rear, Right Rear
Under left rear of vehicle. See Fig. 131.
Similar)
Low Fuel Pressure Sensor At rear of engine. See Fig. 76.
Front of engine compartment. See Fig. 78.
Mass Air Flow Sensor/Intake Air Temperature
Sensor
Oil Level Thermal Sensor (2.0L) Bottom of engine oil pan. See Fig. 119.
Oil Level Thermal Sensor (3.6L) (22) Bottom of engine oil pan. See Fig. 115.
Outside Air Temperature Sensor Left side of grill. See Fig. 80.
Oxygen Sensor (Behind TWC) (2.0L) Behind catalytic converter. See Fig. 81.
Oxygen Sensor (O2S) (Behind TWC) 2 (3.6L) (6) Behind left catalytic converter. See Fig. 111.
Oxygen Sensor (O2S) (Behind TWC) (3.6L) (8) Behind right catalytic converter. See Fig. 111.
Radiator Outlet Coolant Temperature Sender (8) In lower radiator connection. See Fig. 116.
Rear Parking Aid Sensors (4) Behind rear bumper.
Rear Side Airbag Crash Sensor (Driver's Side) On left "C" pillar. See Fig. 85.
Rear Side Airbag Crash Sensor (Passenger's Side) On right "C" pillar. See Fig. 86.
Right Footwell Vent Temperature Sensor (23) Under right side of dash. See Fig. 112.
Right Vent Temperature Sensor (6) At right vent. See Fig. 112.
Steering Angle Sensor (2) On steering column. See Fig. 132.
Sunlight Photo Sensor (2) Under top center of dash. See Fig. 112.
Throttle Position (TP) Sensor Left front footwell. See Fig. 96.
Tire Pressure Monitoring Sensor (Left Front) In Left front wheel assembly. See Fig. 126.
Tire Pressure Monitoring Sensor (Left Rear) In left rear wheel assembly. See Fig. 128.
Tire Pressure Monitoring Sensor (Right Front) In right front wheel assembly. See Fig. 125.
Tire Pressure Monitoring Sensor (Right Rear) In right rear wheel assembly. See Fig. 127.
Vehicle Inclination Sensor (6) In roof console. See Fig. 113.
Vent Temperature Sensor (Left) Behind instrument cluster. See Fig. 75.
Windshield Washer Fluid Level Sensor In windshield washer fluid reservoir. See Fig. 103.
SOLENOIDS & SOLENOID VALVES

SOLENOIDS & SOLENOID VALVES LOCATION
Component Location
Camshaft Adjustment Valve No. 1 On rear of cylinder head. See Fig. 12.
Charge Pressure Control Solenoid Valve (2) On turbocharger. See Fig. 116.
Evaporative Emission (EVAP) Canister Purge
On left side of engine. See Fig. 28.
Regulator Valve
Fuel Injectors (2.0L) (4) Top of engine.
Fuel Pressure Regulator Valve At rear of engine. See Fig. 34.
Inlet Camshaft Control Valve 1 (1) Front of cylinder head. See Fig. 116.
Intake Manifold Flap Air Flow Control Valve (10) On intake manifold. See Fig. 116.
Shift Lock Solenoid On shifter assembly. See Fig. 93.
Turbocharger Air Recirculation Valve (3) On turbocharger. See Fig. 116.
Wastegate Bypass Regulator Valve Right side of engine compartment. See Fig. 123.
SWITCHES
SWITCHES LOCATION
Component Location
In brake fluid master cylinder fluid reservoir. See
Brake Fluid Level Warning Switch
Fig. 11.
Deactivate Vehicle Inclination Sensor Button (10) Behind left "B" pillar trim. See Fig. 113.
Door Contact Switch (Driver's) (11) Rear of driver's door. See Fig. 113.
Door Contact Switch (Front Passenger's) (5) Rear of front passenger's door. See Fig. 113.
Door Contact Switch (Left Rear) (9) Rear of left rear door. See Fig. 113.
Door Contact Switch (Right Rear) (7) Rear of right rear door. See Fig. 113.
Front Hood Switch (1) Integral to hood lock assembly. See Fig. 113.
Interior Monitoring Deactivation Switch (10) Behind left "B" pillar trim. See Fig. 113.
Luggage Compartment Light Switch In rear tailgate lock assembly. See Fig. 117.
Main Battery Switch Left side of luggage compartment. See Fig. 114.
Multi-Function Transmission Range (TR) Switch On top of transmission. See Fig. 79.
Oil Pressure Switch (24) On oil filter assembly. See Fig. 116.
Rear Lid Closing Assist Lock Stop Switch At rear lid latch assembly. See Fig. 118.
Rear Lid Opening Assist Unlock Stop Switch At rear lid latch assembly. See Fig. 118.
Trunk Lock/Alarm/Central Locking Switch In rear tailgate lock assembly. See Fig. 117.
MISCELLANEOUS
MISCELLANEOUS LOCATION
Component Location
A/C Compressor Regulator Valve On A/C compressor. See Fig. 6.
Alarm Horn (2) In right front wheelwell. See Fig. 113.
Amplifier On floor in front of driver's seat. See Fig. 10.
Central Locking & Anti-Theft Alarm System
In "A" pillar. See Fig. 113.
Antenna (14)
Data Bus On Board Diagnostic Interface Under left side of dash. See Fig. 16.
Diagnostic Connector In driver's footwell.
Digital Satellite Radio Tuner Right side of trunk. See Fig. 17.
Front Passenger Airbag Igniter 1 Behind glove compartment. See Fig. 30.
Front Passenger Airbag Igniter 2 Behind glove compartment. See Fig. 31.
High Tone Horn Left front wheel housing. See Fig. 62.
Ignition Coil 1 With Power Output Stage On top front of engine. See Fig. 63.
Ignition Coil 2 With Power Output Stage On top of engine. See Fig. 64.
Ignition Coil 3 With Power Output Stage On top of engine. See Fig. 65.
Ignition Coil 4 With Power Output Stage On top rear of engine. See Fig. 66.
Intake Manifold Flap Potentiometer (23) In intake manifold. See Fig. 116.
Low Tone Horn In right wheel housing. See Fig. 77.
Safety Belt Tensioner Igniter (Left Rear) On left "C" pillar. See Fig. 83.
Safety Belt Tensioner Igniter (Right Rear) On right "C" pillar. See Fig. 84.
Safety Belt Tensioner Igniter 1 (Driver's) Lower left "B" pillar. See Fig. 21.
Safety Belt Tensioner Igniter 1 (Passenger's) Lower right "B" pillar. See Fig. 33.
Turbocharger Recirculation Valve On turbo assembly. See Fig. 99.
Voltage Regulator On rear of generator. See Fig. 101.
Wastegate Bypass Regulator Valve On turbo assembly. See Fig. 102.
CONNECTORS
CONNECTORS LOCATION
Component Location
T4i Below cooling fan. See Fig. 3.
T5b Behind right side of dash. See Fig. 4.
T8aa Above transmission oil pan. See Fig. 5.
T10f Behind glove compartment. See Fig. 1.
T14f Above transmission oil pan. See Fig. 2.
GROUNDS
GROUNDS LOCATION
Component Location
G12 Left side of engine compartment. See Fig. 133.
G13 Right rear of engine compartment. See Fig. 43.
G42 On steering column. See Fig. 42.
G50 Left side of trunk. See Fig. 44.
G51 Right side of trunk. See Fig. 45.
G77 On lower left "B" pillar. See Fig. 49.
G78 On lower right "B" pillar. See Fig. 51.
G610 Right front of center console. See Fig. 41.
G638 On right "A" pillar. See Fig. 50.
G639 On left "A" pillar. See Fig. 47.
G646 In right side of plenum. See Fig. 58.
G647 In left side of plenum. See Fig. 59.
G652 (Transmission/Engine) Below transmission cooler. See Fig. 98.
G671 Left front of engine compartment. See Fig. 55.
G676 Left side of luggage compartment. See Fig. 134.
G684 Near left side of driver's seat. See Fig. 48.
G685 Right front of engine compartment. See Fig. 56.
G687 On center console. See Fig. 52.
G688 Under center console. See Fig. 57.

G689 Center front of roof. See Fig. 46.
COMPONENT LOCATION GRAPHICS
NOTE: Figures may show multiple component locations. Refer to appropriate table for
proper figure references.
Fig. 1: Behind Glove Compartment

Fig. 2: Above Transmission Oil Pan

Fig. 3: Below Cooling Fan

Fig. 4: Behind Right Side Of Dash

Fig. 5: Above Transmission Oil Pan

Fig. 6: A/C Compressor

Fig. 7: Right Rear Of Engine Compartment

Fig. 8: Left Front Footwell

Fig. 9: Under Center Of Dash


Fig. 11: Left Rear Of Engine Compartment

Fig. 12: Rear Of Engine

Fig. 13: Front Of Engine (2.0L)

Fig. 14: Front Of Engine Compartment

Fig. 15: Behind Right Side Of Dash

Fig. 16: Under Left Side Of Dash

Fig. 17: Right Side Of Trunk

Fig. 18: Left Front Of Engine Compartment

Fig. 19: Left Front Door

Fig. 20: Under Driver's Seat

Fig. 21: Lower Left "B" Pillar

Fig. 22: Center Console

Fig. 23: Lower Left Side Of Dash

Fig. 24: Center Of Plenum

Fig. 25: Right Side Of Engine Compartment


Fig. 27: Lower Front Of Engine Compartment


Fig. 29: Under Right Side Of Dash

Fig. 30: Right Side Of Dash

Fig. 31: Right Side Of Dash

Fig. 32: Right Front Of Engine Compartment

Fig. 33: Right "B" Pillar

Fig. 34: Rear Of Engine (2.0L)


Fig. 36: Right Rear Seat

Fig. 37: Left Side Of Engine Compartment


Fig. 39: Left End Of Dash

Fig. 40: Right End Of Dash

Fig. 41: Under Center Of Dash



Fig. 44: Left Side Of Trunk

Fig. 45: Right Side Of Trunk

Fig. 46: Front Of Roof

Fig. 47: Left "A" Pillar

Fig. 48: Left Side Of Driver's Seat

Fig. 49: Left "B" Pillar

Fig. 50: Right "A" Pillar

Fig. 51: Right "B" Pillar







Fig. 58: Right Side Of Plenum

Fig. 59: Left Side Of Plenum

Fig. 60: Rear Of Engine Compartment (2.0L)


Fig. 62: Left Front Wheel Housing

Fig. 63: Top Of Engine (2.0L)





Fig. 68: Left Rear Of Engine

Fig. 69: Left Rear Of Engine


Fig. 71: Left Front Wheel

Fig. 72: Left Rear Wheel

Fig. 73: Left Rear Wheel

Fig. 74: Left Rear Door

Fig. 75: Left Side Of Dash


Fig. 77: Right Front Wheel Housing


Fig. 79: Top Of Transmission

Fig. 80: Front Of Vehicle

Fig. 81: Under Center Of Vehicle (2.0L)

Fig. 82: Under Front Of Vehicle

Fig. 83: Left "C" Pillar

Fig. 84: Right "C" Pillar

Fig. 85: Left "C" Pillar

Fig. 86: Right "C" Pillar

Fig. 87: Lower Front Of Engine Compartment

Fig. 88: Right Front Wheel

Fig. 89: Right Rear Wheel Housing

Fig. 90: Right Rear Wheel Housing

Fig. 91: Right Rear Door

Fig. 92: Right Front Seat


Fig. 94: Left Side Of Engine

Fig. 95: Steering Column





Fig. 100: Left Side Of Dash



Fig. 103: Right Front Wheel Housing

Fig. 104: Left Side Of Plenum

Fig. 105: Plenum Chamber

Fig. 106: Relay Carrier No. 2

Fig. 107: Vehicle Electrical System Control Module Relay Carrier

Fig. 108: Relay Carrier No. 1

Fig. 109: Engine Compartment Electronics Box (Low)

Fig. 110: Engine Compartment Electronics Box (High)

Fig. 111: Exhaust System (3.6L)

Fig. 112: Behind Dash

Fig. 113: Vehicle Overview (Anti-Theft System)

Fig. 114: Left Side Of Luggage Compartment (Wagon)

Fig. 115: Engine (3.6L)

Fig. 116: Engine (2.0L)

Fig. 117: Rear Lid (Wagon)

Fig. 118: Center Rear Of Cargo Area (Wagon)

Fig. 119: Bottom Of Engine Oil Pan (2.0L)

Fig. 120: Left Front Wheelwell

Fig. 121: Left Rear Of Roof (Wagon)

Fig. 122: Right Rear Of Roof (Wagon)

Fig. 123: Engine Compartment (2.0L)

Fig. 124: Rear Lid (Wagon)

Fig. 125: Right Front Wheel Assembly

Fig. 126: Left Front Wheel Assembly

Fig. 127: Right Rear Wheel Assembly

Fig. 128: Left Rear Wheel Assembly

Fig. 129: Left Rear Of Engine Compartment

Fig. 130: Fuel Lines (Overview)

Fig. 131: Under Left Rear Of Vehicle

Fig. 132: Steering Wheel Assembly


Fig. 134: Luggage Compartment

2009 ENGINE PERFORMANCE Emission Applications - Volkswagen Passat
2009 ENGINE PERFORMANCE
Emission Applications - Volkswagen Passat
EMISSION APPLICATIONS
PASSAT
Engine & Fuel System (1) Emission Control Systems & Devices
2009
2.0L (121") 4-Cyl. PCV, EVAP, TWC, FR, SPK, (2) HO2S, CEC, MIL,
Turbo SFI EVAP-CPRV, EVAP-LDP, EVAP-VC
(1) For quick reference, major emission control systems and devices are listed in bold type; components
and other related devices are listed in light type.
(2) Equipped with 2.
ABBREVIATIONS
CEC
Computerized Engine Controls
EVAP
Fuel Evaporative System
EVAP-CKV
EVAP Check Valve
EVAP-CPRV
EVAP Canister Purge Regulator Valve
EVAP-LDP
EVAP Leak Detection Pump
EVAP-VC
EVAP Vapor Canister
FR
Fill Pipe Restrictor

2009 ENGINE PERFORMANCE Emission Applications - Volkswagen Passat
HO2S
Heated Oxygen Sensor
MIL
Malfunction Indicator Light
PCV
Positive Crankcase Ventilation
SFI
Sequential Multiport Fuel Injection
SPK
Spark Controls
SPK-CC
SPK Computer Controlled
TWC
Three-Way Catalytic Converter

GENERAL INFORMATION Emission Control Abbreviations
GENERAL INFORMATION
Emission Control Abbreviations
"A"
A/C
Air Conditioning
A/C-ISUS
A/C Idle Speed-Up Solenoid
AAI
Air Assist Injector
ACL
Air Cleaner (Thermostatic Air Cleaner)
ACL-AD
ACL Air Diverter
ACL-BMS
ACL Bimetallic Sensor
ACL-CKV
ACL Check Valve
ACL-DV
ACL Delay Valve
ACL-PVS
ACL Ported Vacuum Switch
ACL-RDV
ACL Reverse Delay Valve

ACL-RDVS
ACL Reverse Delay Valve (Single)
ACL-TCV
ACL Thermal Control Valve
ACL-TS
ACL Temperature Sensor
ACL-TSOV
ACL Temperature Sensor Override Valve
ACL-TVS
ACL Thermal Vacuum Switch
ACL-TVV
ACL Thermal Vacuum Valve
ACL-VCDV
ACL Vacuum Control Delay Valve
ACL-VCV
ACL Vacuum Control Valve
ACL-VM
ACL Vacuum Motor
ACL-WP
ACL Wax Pellet Type Motor
ADS
Anti-Dieseling Solenoid
AFS
Air/Fuel Ratio Sensor
AIH
Air Intake Heaters
AIH-TS
AIH Temperature Sensor
AIS
Air Injection System
AIS-ACV
AIS Air Control Valve
AIS-AMV
AIS Air Management Valve
AIS-ASS
AIS Air Switching Solenoid
AIS-ASV
AIS Air Switching Valve
AIS-BPV
AIS By-Pass Valve
AIS-CKV
AIS Check Valve
AIS-CV
AIS Combination Valve
AIS-DV
AIS Diverter Valve

AIS-PAF
AIS Pulse Air Feeder
AIS-PM
AIS Pump Motor
AIS-PV
AIS Pneumatic Valve
AIS-RV
AIS Relief Valve
AIS-SOL
AIS Solenoid
AIS-SV
AIS Solenoid Valve
AIS-VCV
AIS Vacuum Control Valve
AIS-VSV
AIS Vacuum Switching Valve
AIS-VT
AIS Vacuum Tank
AIS-VCV
AIS Vacuum Control Valve
AIS-VSV
AIS Vacuum Switching Valve
ALVW
Adjusted Loaded Vehicle Weight
AP
Air Pump Injection System
AP-ACV
AP Air Control Valve
AP-AMV
AP Air Management Valve
AP-ASRV
AP Air Switching Relief Valve
AP-ASS
AP Air Switching Solenoid
AP-ASV
AP Air Switching Valve
AP-BPV
AP By-Pass Valve
AP-CKV
AP Check Valve
AP-CS
AP Control Solenoid
AP-DCTO
AP Dual Coolant Temperature Override
AP-DLY
AP Delay Valve
AP-DV
AP Diverter Valve
AP-EADV
AP Electric Air Control Diverter Valve
AP-EAMR
AP Electric Air Management Relay
AP-EAMS
AP Electric Air Management Solenoid
AP-EAP
AP Electric Air Pump
AP-EC
AP Electromagnetic Clutch
AP-ERLY
AP Electric Air Pump Relay
AP-RDV
AP Reed Valve
AP-RV
AP Relief Valve
AP-SOV
AP Shut-Off Valve
AP-SV
AP Solenoid Valve
AP-SWV
AP Switchover Valve
AP-TV
AP Transmitting Valve
AP-VCS
AP Vacuum Control Solenoid
AP-VCV
AP Vacuum Control Valve
AP-VSV
AP Vacuum Switching Valve
A/T
Automatic Transmission
ATCV
Air Temperature Control Valve
"B"
BP/EGR
Backpressure EGR System
BP/EGR-BPS
BP/EGR Backpressure Sensor
BP/EGR-BPT
BP/EGR Backpressure Transducer
BP/EGR-BPV
BP/EGR Backpressure Valve
BP/EGR-BS
BP/EGR Bleed Solenoid
BP/EGR-BVSV
BP/EGR Bimetallic Vacuum Switching Valve
BP/EGR-C
BP/EGR Controller
BP/EGR-CLR
BP/EGR Cooler
BP/EGR-CS
BP/EGR Control Solenoid
BP/EGR-CTO
BP/EGR Coolant Temperature Override
BP/EGR-CV
BP/EGR Control Valve
BP/EGR-DCTO
BP/EGR Dual Coolant Temperature Override
BP/EGR-DS
BP/EGR Diagnostic Solenoid
BP/EGR-DSOL
BP/EGR Duty Solenoid
BP/EGR-DTVSW
BP/EGR Distributor Thermal Vacuum Switch
BP/EGR-DV
BP/EGR Delay Valve

BP/EGR-EET
BP/EGR Electric Transducer
BP/EGR-EPV
BP/EGR External Pressure Valve
BP/EGR-FDV
BP/EGR Forward Delay Valve
BP/EGR-LC
BP/EGR Load Control Valve
BP/EGR-PS
BP/EGR Position Sensor
BP/EGR-PVS
BP/EGR Ported Vacuum Switch
BP/EGR-RES
BP/EGR Reservoir
BP/EGR-RST
BP/EGR Restrictor
BP/EGR-SOL
BP/EGR Solenoid
BP/EGR-TCTVS
BP/EGR Torque Converter Thermal Vacuum Switch
BP/EGR-TCV
BP/EGR Thermal Control Valve
BP/EGR-TCVLV
BP/EGR Temperature Control Valve
BP/EGR-TS
BP/EGR Temperature Sensor
BP/EGR-TVS
BP/EGR Thermal Vacuum Switch
BP/EGR-TVV
BP/EGR Thermal Vacuum Valve
BP/EGR-VCV
BP/EGR Vacuum Control Valve
BP/EGR-VM
BP/EGR Vacuum Modulator
BP/EGR-VRV
BP/EGR Vacuum Regulator Valve
BP/EGR-VS
BP/EGR Vacuum Switch
BP/EGR-VSOL
BP/EGR Vent Solenoid
BP/EGR-VSV
BP/EGR Vacuum Switching Valve
"C"
C-4
Computer Controlled Catalytic Converter
CAC
Charge Air Cooler
CAS
Clean Air System
CB
Crankcase Breather
CBPS
Coasting By-Pass System
CBVC
Crankcase Breather Vapor Canister
CCIEV
Coolant Controlled Idle Enrichment Valve
CCS
Controlled Combustion System
CCV
Closed Crankcase Ventilation
CD-REGVLV
Crankcase Depression Regulator Valve
CDRV
Crankcase Depression Relief Valve
CEAB
Cold Engine Air Bleed
CEAB-TVS
CEAB Thermal Vacuum Switch

CEAB-TVV
CEAB Thermal Vacuum Valve
CEC
Computerized Engine Controls
CESS
Cold Engine Sensor Switch
CETS
Cold Engine Temperature Switch
CFI
Continuous Fuel Injection
CMH
Cold Mixture Heater
CNG
Compressed Natural Gas
CO
Carbon Monoxide
CO2
Carbon Dioxide
CPI
Central Port Injection
CRV
Coasting Richer Valve
CSI
Central Sequential Injection
CTAVS
Cold Temperature Activated Vacuum System
CTOX
Continous Trap Oxidizer
"D"
DCLV
Deceleration Valve
DCS
Deceleration Control System
DDI
Direct Diesel Injection
DFI
Direct Diesel Injection
DI
Direct Injection
DKV
Deceleration Kick Valve
DMCV
Deceleration Mixture Control Valve
DMS
Dual Manifold System
DOHC
Dual Overhead Cam
DPF
Diesel Particulate Filter
DPFE
Differential Pressure Feedback EGR Valve
DPFEGR
Differential Pressure Feedback EGR Valve
DTM
Deceleration Throttle Modulator
"E"
EAIR
Electric Air Injection System
EAIR-DV
EAIR Diverter Valve
ECM
Electronic Control Module
ECU
Electronic Control Unit
EDC
Electronic Diesel Control
EDS
Electronic Diesel System
EEC
Electronic Engine Control
EFE
Early Fuel Evaporation
EFE-CKV
EFE Check Valve
EFE-CV
EFE Control Valve
EFE-DTVS
EFE Delay Thermal Vacuum Switch
EFE-HTR
EFE Heater
EFE-HCV
EFE Heat Control Valve
EFE-OTS
EFE Oil Temperature Switch
EFE-PTC
EFE Positive Temperature Coefficient (Intake Heater Grid)
EFE-PVS
EFE Ported Vacuum Switch
EFE-SOL
EFE Solenoid
EFE-TVS
EFE Thermal Vacuum Switch

EFE-TVV
EFE Thermal Vacuum Valve
EFE-VSV
EFE Vacuum Switching Valve
EFI
Electronic Fuel Injection
EFI-MA
EFI Mass Airflow Sensor
EFI-MAF
EFI Mass Airflow Sensor
EGR
Exhaust Gas Recirculation System
EGR-BCS
EGR Boost Check Solenoid
EGR-BPBV
EGR By-Pass Backpressure Valve
EGR-BPT
EGR Backpressure Transducer
EGR-BPV
EGR By-Pass Valve
EGR-BS
EGR Bleed Solenoid
EGR-BSSV
EGR Boost Sensor Solenoid Valve
EGR-BVSV
EGR Bimetallic Vacuum Switching Valve
EGR-C
EGR Controller
EGR-CC
EGR Coolant Controlled
EGR-CLR
EGR Cooler
EGR-VSOL
EGR Vacuum Solenoid
EGR-CKV
EGR Check Valve
EGR-CS
EGR Control Solenoid
EGR-CSOL
EGR Cut-Off Solenoid
EGR-CSV
EGR-CTO
EGR Coolant Temperature Override
EGR-CTS
EGR Charge Temperature Sensor

EGR-CTSW
EGR Charge Temperature Switch
EGR-CTTS
EGR Coolant Temperature Thermoswitch
EGR-CV
EGR Control Valve
EGR-CVCV
EGR Constant Vacuum Control Valve
EGR-CVS
EGR Control Vent Solenoid
EGR-DC
EGR Digital Control
EGR-DCTO
EGR Dual Coolant Temperature Override
EGR-DPFE
Differential Pressure Feedback EGR Sensor
EGR-DPFS
EGR Differential Pressure Feedback Sensor
EGR-DS
EGR Diagnostic Solenoid
EGR-DSOL
EGR Duty Solenoid
EGR-DTVS
EGR Delay Thermal Vacuum Switch
EGR-DTVSW
EGR Distributor Thermal Vacuum Switch
EGR-DV
EGR Delay Valve
EGR-EPRS
EGR Exhaust Pressure Regulator Solenoid
EGR-EPRV
EGR Exhaust Pressure Regulator Valve
EGR-EPV
EGR External Pressure Valve
EGR/EVAP-CSV
EGR/EVAP Control Solenoid Valve
EGR-EVR
EGR Vacuum Regulator
EGR-EVRV
EGR Electronic Vacuum Regulator Valve
EGR-FDV
EGR Forward Delay Valve
EGR-FJS
EGR Floor Jet System
EGR-FPS
EGR Feedback Pressure Sensor

EGR-LCV
EGR Load Control Valve
EGR-MAP
EGR Manifold Absolute Pressure Sensor
EGR-PFE
EGR-PFE Sensor
EGR-PS
EGR Position Sensor
EGR-PSW
EGR Pulse Switch
EGR-PVS
EGR Ported Vacuum Switch
EGR-REG
EGR Regulator
EGR-RES
EGR Reservoir
EGR-RST
EGR Restrictor
EGR-SC
EGR Signal Converter
EGR-SEC
EGR, Secondary
EGR-SEN
EGR Sensor
EGR-SOL
EGR Solenoid
EGR-SU
EGR Switchover Valve
EGR-SUB
Sub-EGR Valve
EGR-T
EGR Temperature Sensor
EGR-TC
EGR Transmission Controlled
EGR-TCTVS
EGR Torque Converter Thermal Vacuum Switch
EGR-TCV
EGR Thermal Control Valve
EGR-TCVLV
EGR Temperature Control Valve
EGR-TRANS
EGR Transducer
EGR-TS
EGR Temperature Sensor
EGR-TSW
EGR Temperature Switch

EGR-TVD
EGR Throttle Valve Diaphragm
EGR-TVS
EGR Thermal Vacuum Switch
EGR-TVSOL
EGR Throttle Valve Solenoid
EGR-TVV
EGR Thermal Vacuum Valve
EGR-VA
EGR Vacuum Amplifier
EGR-VCV
EGR Vacuum Control Valve
EGR-VM
EGR Vacuum Modulator
EGR-VR
EGR Vacuum Regulator
EGR-VRS
EGR Vacuum Regulator Solenoid
EGR-VRSV
EGR Vacuum Regulator Solenoid Valve
EGR-VRV
EGR Vacuum Regulator Valve
EGR-VS
EGR Vacuum Switch
EGR-VSDV
EGR Vacuum Switch Dump Valve
EGR-VSEN
EGR Vacuum Sensor
EGR-VSOL
EGR Vent Solenoid
EGR-VSS
EGR Vacuum Switching Solenoid
EGR-VSV
EGR Vacuum Switching Valve
EGR-VVCS
EGR Venturi Vacuum Control System
EGRC
EGRC-BPT
EGR Control Backpressure Transducer
EGRC-SV
EGR Control Solenoid Valve
EHOC
Electronically Heated Oxidation Catalyst
EHTWC
Electronically Heated Three-Way Catalyst

EI
Electronic Ignition System
EIS
Electronic Ignition System
ELB
Electronic Lean Burn
EPR
Exhaust Pressure Regulator
EPR-SOL
EPR Solenoid
ESA
Electronic Spark Advance
EVAP
Fuel Evaporative System
EVAP-AAC
EVAP Auxiliary Air Control
EVAP-BPSV
EVAP By-Pass Solenoid Valve
EVAP-BVSV
EVAP Bimetallic Vacuum Switching Valve
EVAP-CAV
EVAP Canister Air Valve
EVAP-CCV
EVAP Control Canister Close Valve
EVAP-CCVSV
EVAP Control Canister Vent Shut Valve
EVAP-CCVVSV
EVAP Closed Canister Valve Vacuum Switching Valve
EVAP-CDCV
EVAP Canister Drain Cut Valve
EVAP-CKV
EVAP Check Valve
EVAP-CPCS
EVAP Canister Purge Control Solenoid
EVAP-CPCV
EVAP Canister Purge Control Valve
EVAP-CPRV
EVAP Canister Purge Regulator Valve
EVAP-CPSV
EVAP Canister Vent Shut Valve
EVAP-CPT
EVAP Canister Purge Timer
EVAP-CPTVS
EVAP Canister Purge Thermal Vacuum Switch
EVAP-CPV
EVAP Canister Vent Valve

EVAP-CPVCSV
EVAP Canister Purge Volume Control
EVAP-CPVDV
EVAP Canister Purge Vacuum Delay Valve
EVAP-CS
EVAP Control Solenoid
EVAP-CSPS
EVAP Control System Pressure Sensor
EVAP-CST
EVAP Canister Surge Tank
EVAP-CVCS
EVAP Canister Vent Control Solenoid
EVAP-CVCV
EVAP Canister Vent Control Valve
EVAP-CVS
EVAP Canister Vent Solenoid
EVAP-CVSV
EVAP Carburetor Vent Switching Valve
EVAP-CVV
EVAP Canister Vent Valve
EVAP-DCTO
EVAP Dual Coolant Temperature Override
EVAP-DPS
EVAP Differential Pressure Sensor
EVAP-EV
EVAP Emission Valve
EVAP-FBVV
EVAP Fuel Bowl Vent Valve
EVAP-FBVS
EVAP Fuel Bowl Vent Solenoid
EVAP-FLS
EVAP Fuel Level Sensor
EVAP-FOLV
EVAP Fuel Overflow Limiter Valve
EVAP-FS
EVAP Flow Switch
EVAP-FSV
EVAP Flow Switchover Valve<
EVAP-FTPCSV
EVAP Fuel Tank Pressure Control Solenoid Valve
EVAP-FTPS
EVAP Fuel Tank Pressure Sensor
EVAP-FTS
EVAP Fuel Temperature Sensor
EVAP-FVCV
EVAP Fuel Vapor Control Valve

EVAP-FVS
EVAP Fuel Vapor Separator
EVAP-FVV
EVAP Fuel Vent Valve
EVAP-IVS
EVAP Inner Vent Solenoid
EVAP-LDP
EVAP Leak Detection Pump
EVAP-LDPAF
EVAP Leak Detection Pump Air Filter
EVAP-LDPF
EVAP Leak Detection Pump Filter
EVAP-LDPVV
EVAP Leak Detection Pump Vent Valve
EVAP-LSEP
EVAP Liquid Separator
EVAP-NVLD
EVAP Natural Vacuum Leak Detection
EVAP-ORVR
Evaporative On-Board Refueling Vapor Recovery System
EVAP-ORVRFTVRV
EVAP-ORVR Fuel Tank Vapor Recirculation
EVAP-OVCV
EVAP Outer Vent Control Valve
EVAP-OWV
EVAP One-Way Valve
EVAP-PCSV
EVAP Purge Cut-Off Solenoid Valve
EVAP-PFS
EVAP Purge Flow Sensor
EVAP-PFSVVSV
EVAP Purge Flow Switching Valve Vacuum Switching Valve
EVAP-PRRV
EVAP Pressure Relief Rollover Valve
EVAP-PSVVSV
EVAP Pressure Switching Valve Vacuum Switching Valve
EVAP-PSOL
EVAP Purge Solenoid
EVAP-PSSV
EVAP Pressure Switching Solenoid
EVAP-PSVVSV
EVAP Pressure Switching Valve Vacuum Switching Valve
EVAP-PV
EVAP Purge (Frequency) Valve
EVAP-PVS
EVAP Ported Vacuum Switch

EVAP-RV
EVAP Rollover Valve
EVAP-RV/FTPS
EVAP Rollover Valve/Fuel Tank
EVAP-RVSV
EVAP Rollover Vapor Separator Valve
EVAP-SNR
EVAP Canister Sensor
EVAP-SOV
EVAP Shutoff Valve
EVAP-SSV
EVAP Shut-Off Solenoid Valve
EVAP-SV
EVAP Solenoid Valve
EVAP-TS
EVAP Temperature Switch
EVAP-TPBPV
EVAP Tank Pressure By-Pass Valve
EVAP-TPCS
EVAP Tank Pressure Control Solenoid
EVAP-TPCV
EVAP Tank Pressure Control Valve
EVAP-TRWV
EVAP Tree-Way Valve
EVAP-TV
EVAP Thermal Valve
EVAP-TVS
EVAP Thermal Vacuum Switch
EVAP-TWV
EVAP Two-Way Valve
EVAP-VC
EVAP Vapor Canister
EVAP-VCAT
EVAP Vapor Canister Air Tank
EVAP-VCF
EVAP Vapor Canister Filter
EVAP-VCTV
EVAP Vacuum Control Valve
EVAP-VCV
EVAP Vacuum Canister Valve
EVAP-VCVS
EVAP Vapor Canister Vent Solenoid
EVAP-VM
EVAP Vacuum Motor
EVAP-VPS
EVAP Vapor Pressure Sensor

EVAP-VPSVSV
EVAP Vapor Pressure Sensor Vacuum Switching Valve
EVAP-VS
EVAP Vacuum Sensor
EVAP-VSOL
EVAP Ventilation Solenoid
EVAP-VSOL/LDP
EVAP Ventilation Solenoid/Leak Detection Pump
EVAP-VST
EVAP Vacuum Surge Tank
EVAP-VSV
EVAP Vacuum Switching Valve
EVAP-VV
EVAP Ventilation Valve
EVRS
EGR Vacuum Regulator Solenoid
"F"
FBC
Feedback Carburetor
FCOV
Fuel Change Over Valve
FF
Flex Fuel
FF-CKV
Fuel Fill Check Valve
FF-FCV
Fuel Tank Fuel Cut-Off Valve
FF-FLVV
Fuel Tank Fill Limit Vent Valve
FGOV
Fuel Gravity/Overflow Valve
FGVV
Fuel Gravity Vent Valve
FI
Fuel Injected
FICD
Fast Idle Control Device
FISR
Fast Idle Solenoid Relay
FLV
Fill Limit Valve
FLVV
Fill Limiting Vent Valve
FP-CKV
Fill Pipe Check Valve
FP-RV
Fill Pipe Rollover Valve
FR
Fill Pipe Restrictor
FT-FLVV
Fuel Tank Fill Limit Vent Valve
FT-GVV
Fuel Tank Grade Vent Valve
FT-OPRV
Fuel Tank Over Pressure Vent Valve
FT-PCV
Fuel Tank Pressure Control Valve
FT-VCV
Fuel Tank Vapor Control Valve
FT-VRV
Fuel Tank Vapor Recirculation Valve
FTCV
Fuel Tank Check Valve
FTDPS
Fuel Tank Differential Pressure Sensor
FTEV
Fuel Tank EVAP Valve
FTPS
Fuel Tank Pressure Sensor

FTT
Fuel Tank Temperature Sensor
FTTS
Fuel Tank Temperature Sensor
FTVPRV
Fuel Tank Ventilation Pressure Retention Valve
FTVV
Fuel Tank Vent Valve
FVV
Fuel Vapor Valve
"G"
GVWR
Gross Vehicle Weight Rating
"H"
HAC
High Altitude Compensator
HAFS
Heated Air Fuel Ratio Sensor
HAI
Hot Air Intake
HAS
High Altitude System
HC
Hydrocarbons
HCAC-VSV
Hydrocarbon Absorber Catalyst Vacuum Switching Valve
HDC
Heavy Duty Cooling
HDC-CTO
HDC Coolant Temperature Override
HFM-SFI
Hot Film Engine Management SFI
HIC
Hot Idle Compensator
HIM
Heated Intake Manifold
HO
High Output
HO2S
Heated Oxygen Sensor
HP
High Performance
HP
Horsepower
HPCA
Housing Pressure Cold Advance

HSC
High Swirl Combustion
"I"
IAC
Idle Air Control Valve
IACV-SW
IACV Switch
ICOM
Idle Compensator
IDI
Indirect Diesel Injection
IES
Idle Enrichment System
IMCO
Improved Combustion System
"K"
KS
Knock Sensor
"L"
LH-SFI
Hot Wire Sequential Multiport Fuel Injection
LVFD
Liquid/Vapor Fuel Discriminator

LVW
Loaded Vehicle Weight
"M"
MD-TICS
Timing & Injection rate Control System
ME-SFI
Motor Electronics Sequential Fuel Injection
MFI
Multiport Fuel Injection
MFI-MAF
MFI Mass Airflow Sensor
MFLS
Main Fuel Level Sensor
MI
Mechanical Fuel Injection
MIL
Malfunction Indicator Light
M/T
Manual Transmission
"N"
NAC
Nitrogen Oxides (NOx) Adsorbing Catalyst
NLV
Non-Linear Valve
NOS
NOx Sensor
NOx
NOx Emission Control
NOxC
Nitrogen Oxide Catalyst
NOxS
Nitrogen Oxide Sensor
NSC
Nitrogen Oxides (NOx) Storage Catalyst
"O"
OBD
On-Board Diagnostic System
PBD (F)/(P)
Full/Partial On-Board Diagnostic
OC
Oxidation Catalytic Converter
OHC
Overhead Cam
ORVR
On-Board Refueling Vapor Recovery
ORVR-COV
ORVR Cut-Off Valve
ORVR-CV
ORVR Control Valve
ORVR-FMV
ORVR Flow Management Valve
ORVR-FTVCV
ORVR Fuel Tank Vapor Control Valve
ORVR-FTVRV
ORVR Fuel Tank Vapor Recirculation Valve
ORVR-LV
ORVR Leveling Valve
ORVR-OCKV
ORVR Overfill Check Valve
ORVR-RCV
ORVR Refueling Control Valve
ORVR-VCV
ORVR Vapor Cut Valve
ORVR-VRV
ORVR Vapor Recirculating Valve
ORVR-VSV
ORVR Vent Shut Valve
ORVR-VV
ORVR Vent Valve

OVCV
Outer Vent Control Valve
O2S
Oxygen Sensor
"P"
PAIR
Pulsed Secondary Air Injection
PAIR-ABV
PAIR Anti-Backfire Valve
PAIR-ACOV
PAIR Air Cut-Off Valve
PAIR-ACS
PAIR Air Control Solenoid
PAIR-ACV
PAIR Air Control Valve
PAIR-AIV
PAIR Air Injection Valve
PAIR-ASCS
PAIR Air Suction Control Solenoid
PAIR-ASOV
PAIR Air Shutoff Valve
PAIR-ASS
PAIR Air Switching Solenoid

PAIR-ASV
PAIR Air Switching Valve
PAIR-ASVL
PAIR Air Suction Valve
PAIR-AVCS
PAIR Air Valve Control Solenoid
PAIR-CSV
PAIR Control Solenoid Valve
PAIR-CKV
PAIR Check Valve
PAIR-DV
PAIR Diverter Valve
PAIR-PAF
PAIR Pulse Air Feeder
PAIR-PAV
PAIR Pulse Air Valve
PAIR-RES
PAIR Resonator
PAIR-RV
PAIR Reed Valve
PAIR-SCSV
PAIR Swirl Control Solenoid Valve
PAIR-SCV
PAIR Swirl Control Valve
PAIR-SOL
PAIR Solenoid
PAIR-VSV
PAIR Vacuum Switching Valve
PCM
Powertrain Control Module
PCV
Positive Crankcase Ventilation
PCV-DOV
PCV Dual Orifice Valve
PCV-HCB
PCV Heated Crankcase Breather
PCV-HE
PCV Heating Element
PCV-PRV
PCV Pressure Regulator Valve
PCV-SOL
PCV Solenoid
PEVR
Power Enrichment Vacuum Regulator
PPM
Parts Per Million

PTOX
Periodic Trap Oxidizer
PURCV
Purge Crankcase Ventilation
PVCS
Ported Valve Control System
PVCS-A
PVCS Actuator
PVCS-CS
PVCS Control Solenoid
PVLCS
Power Valve Control System
"R"
ROV
Rollover Valve
"S"
SAI-SV
Secondary Air Injection Shutoff Valve
SC
Supercharged or Super Charger
SC MFI
Supercharged Multiport Fuel Injection
SCR
Selective Catalytic Reduction
SCSV
Swirl Control Solenoid Valve
SCV
Swirl Control Valve
SCV-A
SCV Actuator
SFI
Sequential Multiport Fuel Injection
SFI-MAF
SFI Mass Airflow Sensor
SFLS
Sub-Fuel Level Sensor
SOHC
Single Overhead Cam
SPK
Spark Controls
SPK-AVM
SPK Advance Vacuum Modulator
SPK-BVSV
SPK Bimetal Vacuum Switching Valve
SPK-CC
SPK Computer Controlled

SPK-CKV
SPK Check Valve
SPK-CSSA
SPK Cold Start Spark Advance System
SPK-CSSH
SPK Cold Start Spark Hold System
SPK-CTO
SPK Coolant Temperature Override
SPK-DAVS
SPK Distributor Vacuum Advance Solenoid
SPK-DCKV
SPK Distributor Check Valve
SPK-DCTO
SPK Dual Coolant Temperature Override
SPK-DDD
SPK Dual Diaphragm Distributor
SPK-DMV
SPK Distributor Modulator Valve
SPK-DPD
SPK Dual Point Distributor
SPK-DPVS
SPK Distributor Ported Vacuum Switch
SPK-DRCV
SPK Distributor Retard Control Valve
SPK-DRS
SPK Distributor Retard Solenoid
SPK-DSVMV
SPK Distributor Spark Vacuum Modulator Valve
SPK-DTVS
SPK Distributor Thermal Vacuum Switch
SPK-DTVV
SPK Distributor Thermal Vacuum Valve
SPK-DV
SPK Delay Valve
SPK-DVA
SPK Distributor Vacuum Advance
SPK-DVAS
SPK Distributor Vacuum Advance Solenoid
SPK-DVCS
SPK Distributor Vacuum Control Solenoid
SPK-DVCSW
SPK Distributor Vacuum Controlled Switch
SPK-DVCV
SPK Distributor Vacuum Control Valve
SPK-DVDV
SPK Distributor Vacuum Delay Valve

SPK-DVRS
SPK Distributor Vacuum Retard Switch
SPK-DVRV
SPK Distributor Vacuum Regulating Valve
SPK-DVVV
SPK Distributor Vacuum Vent Valve
SPK-EAVS
SPK Electronically Actuated Vacuum Switch
SPK-EDM
SPK Electronic Distributor Modulator
SPK-EI
SPK Electronic Ignition
SPK-ESA
SPK Electronic Spark Advance
SPK-ESC
SPK Electronic Spark Control (Retard)
SPK-ESS
SPK Electronic Spark Selection
SPK-EST
SPK Electronic Spark Timing
SPK-FDV
SPK Forward Delay Valve
SPK-HPCA
SPK Housing Pressure Cold Advance
SPK-ITCS
SPK Ignition Timing Control System
SPK-ITVS
SPK Ignition Timing Vacuum Switch
SPK-NLVR
SPK Non-Linear Vacuum Regulator
SPK-OSAC
SPK Orifice Spark Advance Control
SPK-PVA
SPK Ported Vacuum Advance
SPK-PVS
SPK Ported Vacuum Switch
SPK-RDO
SPK Retard Delay Orifice
SPK-RDV
SPK Reverse Delay Valve
SPK-RDVD
SPK Reverse Delay Valve (Dual)
SPK-RDVLV
SPK Retard Delay Valve
SPK-RDVS
SPK Reverse Delay Valve (Single)

SPK-RETS
SPK Retard Switch
SPK-SC
SPK Speed Controlled
SPK-SOL
SPK Solenoid
SPK-SRRV
SPK Spark Relay Regulator Valve
SPK-TAVIA
SPK Temperature Activated Vacuum Ignition Advance
SPK-TCS
SPK Transmission Controlled Spark
SPK-TCSYS
SPK Timing Control System
SPK-TIDC
SPK Thermostatic Ignition Distributor Control
SPK-TV
SPK Thermal Valve
SPK-TVS
SPK Thermal Vacuum Switch
SPK-VACTO
SPK Vacuum Advance Coolant Temperature Override
SPK-VAS
SPK Vacuum Advance Solenoid
SPK-VAV
SPK Vacuum Advance Valve
SPK-VR
SPK Vacuum Retard
SPK-VRSW
SPK Vacuum Retard Switch
SPK-VSV
SPK Vacuum Switching Valve
SPK-VTCS
SPK Vacuum Timing Control System
SPL
Smoke Puff Limiter
SRI
Service Reminder Indicator
SSCA
Stepped Speed Control Actuator
SSCS
Stepped Speed Control Solenoid
STS
Service Throttle Soon Light
STVS
Secondary Throttle Valve System

SUB-O2S
Sub-Oxygen Sensor
SUB-TWC
Sub Three-Way Catalytic Converter
"T"
TAA
Turbo Air-To-Air
TAA
Throttle Actuator Assembly
TAB
Thermactor Air By-Pass
TAD
Thermactor Air Diverter
TBI
Throttle Body Injection
TBPCS
Throttle By-Pass Control System
TC
Turbo Charger
TCC
Torque Converter Clutch
TCCL
Torque Converter Control

TCD
Throttle Closing Dashpot
TC-DV
TC Delay Valve
TC-TVC
TC Thermal Vacuum Switch
TC-VS
TC Vacuum Switch
TD
Thermactor Diverter
TFT
Tank Fuel Temperature Sensor
TICV
Thermal Ignition Control Valve
TIV
Thermal Idle Valve
TK
Throttle Kicker
TLUC
Transmission Lock-Up Converter
TLUC-TVS
TLUC Thermal Vacuum Switch
TLUC-VS
TLUC Vacuum Switch
TM
Throttle Modulator
TOS
Throttle Opener System
TP
Throttle Positioner
TPI
Tuned Port Fuel Injection
TPV
Throttle Poppet Valve
TR
Thermal Reactor
TRC
Throttle Return Control
TRCS
Throttle Return Control Solenoid
TRCTL
Throttle Return Control Throttle Lever Actuator
TRSCV
Throttle Return Solenoid Control Valve
TRTVV
Temperature Regulator Thermal Vacuum Valve

TRVV
Transmission Vacuum Valve
TSOL
Throttle Solenoid
TVISD
Throttle Vacuum Idle Speed Diaphragm
TVM
Transmission Vacuum Modulator
TWC
Three-Way Catalytic Converter
TWC+OC
Three-Way + Oxidation Catalytic Converter
"V"
VA
Vacuum Advance Unit
VAC-AMP
Vacuum Amplifier
VA-CTO
VA Coolant Temperature Override
VCV
Vacuum Cut Valve
VCV-BV
VCV By-Pass Valve

VLFR
Vent Line Flow Restrictor/Anti-Trickle Fill Valve
"W"
WU
Warm-Up Catalyst
WU-OC
Warm-Up Oxidation Converter
WU-TWC
Warm-Up Three-Way Catalytic Converter

Accessories & Equipment Exterior Equipment
Exterior Equipment
66 EXTERIOR EQUIPMENT
WHEEL HOUSING LINER
FRONT WHEEL HOUSING LINER ASSEMBLY OVERVIEW
The front wheel housing liner may differ slightly depending on the model.
Front wheel housing liner consists of front and rear parts.

Fig. 1: Identifying Front Wheel Housing Liner, Assembly Overview

1. Rear part of wheel housing liner

 Material - PP/EPDM
 Removing and Installing, refer to REAR WHEEL HOUSING LINER.
2. Expanding nut
 Quantity: 4
3. Bolt
 Quantity: 5
 Removing and Installing, refer to FRONT WHEEL HOUSING LINER.
5. Bolt
 Quantity 10
REAR WHEEL HOUSING LINER ASSEMBLY OVERVIEW
The rear wheel housing liner may differ slightly depending on the model.
Fig. 2: Identifying Rear Wheel Housing Liner, Assembly Overview

1. Wheel housing liner

 Removing and Installing, refer to WHEEL HOUSING LINER.
2. Bolt
 Quantity 12
3. Expanding nut
 Gas-tight
 Quantity: 3
WARNING:  Check the gas-tight expanding nuts for damage and

replace if necessary.
 The expanding nuts seal off the passenger compartment
from exhaust gas and must always be replaced if they are
damaged.
4. Spring nut
 Quantity: 4
REAR WHEEL HOUSING LINER ASSEMBLY OVERVIEW, R36
Fig. 3: Identifying Rear Wheel Housing Liner Assembly Overview, R36

1. Wheel housing liner

 Removing and Installing, refer to WHEEL HOUSING LINER.
2. Bolt
 Quantity: 12
3. Expanding nut
 Gas-tight
WARNING:  Check the gas-tight expanding nuts for damage and

replace if necessary.
 The expanding nuts seal off the passenger compartment
from exhaust gas and must always be replaced if they are
damaged.
4. Spring nut
 Quantity: 4
5. Underbody protection
 Seal any exposed areas on the body with long life underbody protection D 003 500.
 1 to 1.5 mm thick
EXTERIOR MIRROR ASSEMBLY OVERVIEW
Fig. 4: Identifying Exterior Rear View Mirror, Assembly Overview

1. Mirror base plate

2. Bolt
 Quantity: 3
3. Assembly piece
4. Bolt
 Quantity: 2
5. Bolt
 Quantity: 2
6. Turn signal
 Removing and Installing, refer to TURN SIGNALS.
7. Trim
 Removing and Installing, refer to TRIM.
8. Mirror glass
 Removing and Installing, refer to MIRROR GLASS.
9. Mirror housing
 Material - ABS
 Removing and Installing, refer to MIRROR HOUSING.
RADIATOR GRILLE
RADIATOR GRILLE ASSEMBLY OVERVIEW

Fig. 5: Identifying Radiator Grille, Assembly Overview

1. Radiator grille
 Material - ASA
 Removing, refer to RADIATOR GRILLE.
 For some markets, there is the radiator grille with no license plate holder, refer to LICENSE
PLATE HOLDER ASSEMBLY OVERVIEW
2. Bolt
 Quantity: 6
3. Bolt
 Quantity: 2
4. Bolt
 Quantity: 2
5. Emblem
 Can be removed only when radiator grille is removed.
 Removing and Installing, refer to EMBLEM.
 Removing and installing in vehicles with adaptive cruise control, refer to EMBLEMS ON
VEHICLES WITH ADAPTIVE CRUISE CONTROL
RADIATOR GRILLE ASSEMBLY OVERVIEW, R36

Fig. 6: Identifying Radiator Grille Assembly Overview, R36

1. Radiator Grille, R36

 Material - ASA
 Removing, refer to RADIATOR GRILLE, R36
 For some markets, there is the radiator grille with no license plate holder, refer to LICENSE
PLATE HOLDER ASSEMBLY OVERVIEW
2. Bolt
 Quantity: 2
3. Bolt
 Quantity: 6
4. Emblem
 Removing and Installing, refer to EMBLEM.
5. License plate holder

 Removing and Installing, LICENSE PLATE HOLDER.
6. Bolt
 Quantity: 2
7. R36 name plate

 Attached to the radiator grille -1- from the outside
 Can be removed only when radiator grille is removed
LICENSE PLATE HOLDER ASSEMBLY OVERVIEW
NOTE: For some markets, radiator grille is supplied without license plate holder.
Fig. 7: Identifying License Plate Holder - Assembly Overview

1. License plate holder

2. Clip
 Quantity: 4
3. Radiator grille
 Without license plate holder
ROOF RAIL
ROOF RAIL ASSEMBLY OVERVIEW
Fig. 8: Identifying Roof Rail - Assembly Overview

1. Roof Rail
2. Roof
3. Hex nut
 Consists of upper and lower conical washers.

5. Rear angle bracket
 Various angle brackets are installed and they must not be interchanged.
6. Lower tolerance compensation

 Consists of upper and lower washers as well as bracket.
7. Bolt
 Quantity: 2 per bracket
8. Center angle bracket

9. Front angle bracket

ROOF RAIL ANGLE BRACKET ASSEMBLY OVERVIEW
NOTE: The illustration shows the middle bracket, the front and rear brackets are
treated in the same way.
The brackets must not be interchanged.
The various conical washers must not be interchanged.

Fig. 9: Identifying Roof Rail Angle Bracket - Assembly Overview

1. Angle bracket
 There are different angle brackets for front, center and rear.
2. Bolt
 Quantity: 2 per angle bracket
3. Upper conical washer

 In lower tolerance compensation
4. Lower conical washer

5. Bracket for lower tolerance compensation

6. Hex nut
 For securing roof rail.
7. Lower conical washer

 In upper tolerance compensation
8. Upper conical washer

 In upper tolerance compensation
9. Seal
10. Roof Rail
MOLDINGS AND TRIM
DRIP RAIL ASSEMBLY OVERVIEW
NOTE: The illustration shows a right door hinge. The left door hinge is identical.
Fig. 10: Identifying Drip Rail Remove/Install Components

1. Drip rail
 Removing and Installing, refer to DRIP RAIL.
2. Retaining strip
 Remove and install only when the windshield is removed.
3. Pop rivet
 Quantity: 5 on the A-pillar
FRONT AND REAR DOOR COVER ASSEMBLY OVERVIEW, FROM 06.07

Fig. 11: Identifying Front And Rear Door Cover Assembly Overview, From 06.07
1. Front door cover

 Pay attention to the installation instructions for bonded covers, refer to FRONT AND REAR
DOOR COVER BONDED COVERS INSTALLATION INSTRUCTIONS, FROM 06.07.
 Removing, refer to FRONT AND REAR DOOR COVER, FROM 06.07
2. Rear door cover

 Pay attention to the installation instructions for bonded covers, refer to FRONT AND REAR
DOOR COVER BONDED COVERS INSTALLATION INSTRUCTIONS, FROM 06.07.
 Removing, refer to FRONT AND REAR DOOR COVER, FROM 06.07
3. Bolt
 Quantity: two per door cover

4. Securing pin
5. Adhesive tape
 Component of the cover
6. Protective film
 Covers the adhesive tape
FRONT AND REAR DOOR COVER BONDED COVERS INSTALLATION INSTRUCTIONS, FROM 06.07
NOTE: Warm the cover with a hot air gun V.A.G 1416 before removing.
Only use adhesive remover D 002 000 10.
Make sure the adhesive surfaces are free of dust and grease.
Attach the name plates, foils or emblem immediately after cleaning them.
Peel off the protective film just before installation.
Temperature approx. 70°F (21°C).
ROCKER PANEL EXTENSION ASSEMBLY OVERVIEW
NOTE: The description applies to the left side. It can also be applied to the right side.
The rocker panel extension and sill panel trim may differ slightly depending on
the model.
Fig. 12: Identifying Sill Trim - Assembly Overview

1. Front rocker panel extension

2. Rear rocker panel extension
3. Sill panel cover
4. Bolt
 Quantity: 3
5. Expanding nut
 Quantity: 3
 Quantity: 12
7. Rivet
 Quantity: 5
8. Bolt
Quantity: 2
9. Grommet
 Quantity: 12
10. Expanding nut

 Quantity: 2
REAR LID TRIM MOLDING ASSEMBLY OVERVIEW, WAGON, THOROUGH 10.10

Fig. 13: Identifying Rear Lid Trim Molding, Wagon - Assembly Overview

 Clipped and glued
 Removing:
-- Lightly warm trim molding with hot air gun V.A.G 1416 and remove from grommets and
adhesive tape.
 Installing:
-- Adhesive surfaces must be cleaned with adhesive remove D 002 000 10 before assembling trim
molding.
-- Remove any adhesive residue with adhesive remover VAS 6349.
-- Center trim molding in grommets and push down forcefully.
2. Grommet
 Quantity: 4
3. Mounting hole
4. Rear lid, wagon
WHEEL COVER TRIM ASSEMBLY OVERVIEW, THROUGH 01.08
NOTE: Front and rear wheel trim is necessary on vehicles with 18 inch rim/tire
combination.
The wheel covers may differ slightly depending on the model.

Fig. 14: Identifying Wheel Trim - Assembly Overview

1. Front wheel trim

 Self-adhesive
 Removing:
-- Lightly warm wheel trim with hot air gun V.A.G 1416 and carefully remove.
 Installing:
-- Push on the surface just cleaned with adhesive remover D 002 000 10.
2. Protective film
 Must be removed before adhering.
3. Adhesive tape
 Component of wheel trim.
4. Front fender
5. Distance dimension
 Dimension -a- is 190 mm.

7. Rear wheel trim
 Self-adhesive
 Removing:
-- Lightly warm wheel trim with hot air gun V.A.G 1416 and carefully remove.
 Installing:
WHEEL COVER TRIM ASSEMBLY OVERVIEW, FROM 02.08
NOTE: Front and rear wheel trim is necessary on vehicles with 18 inch rim/tire
combination.
Fig. 15: Identifying Wheel Cover Trim Assembly Overview, From 02.08
1. Front wheel cover trim

 Self-adhesive
 Removing:
-- Warm the wheel cover trim with a hot air gun V.A.G 1416 and carefully remove it.
 Installing:
2. Protective film
 Must be removed before adhering.
3. Adhesive tape
 Is component of the wheel cover trim
4. Front fender
5. Distance dimension
 Dimension -a- is 190 mm.

7. Rear wheel cover trim
 Self-adhesive, attached to the wheel housing liner by a screw
 Removing:
-- Warm the wheel cover trim with a hot air gun V.A.G 1416 and carefully remove it.
 Installing:
-- Push on the surface just cleaned with adhesive remover D 002 000 10 and attach it.
8. Bolt
FRONT AND REAR DOOR COVER ASSEMBLY OVERVIEW FROM 05.07
Fig. 16: Identifying Cover For Front And Rear Door, Assembly Overview
1. Front door cover

 Removing, refer to FRONT AND REAR DOOR COVER, FROM 05.07 or FRONT AND
REAR DOOR COVER, FROM 06.07.
2. Rear door cover
 Removing, refer to FRONT AND REAR DOOR COVER, FROM 05.07 or FRONT AND
REAR DOOR COVER, FROM 06.07.
3. Bolt
 Quantity: two per door cover

COVER STRIP ASSEMBLY INFORMATION
NOTE: Depending on the model >>R Line<< and >>Exclusive<<.
The covers cannot be removed without damaging them.
The assembly procedure describes the left cover strip. The procedure for the
right cover strip is the same.
 Warm the cover strip with a hot air blower V.A.G 1416 before removing it.
 If removing the cover strip, only use the adhesive remover D 002 000 10 to remove the adhesive residue.
 Remove any adhesive residue left by the tape using adhesive remover VAS 6349.
 Make sure the adhesive surfaces are free of dust and grease.
 Apply the cover strip immediately after cleaning.
 Only remove the protective film right before assembly.
 Temperature approx. 70°F (21°C).
 The covers cannot be removed without damaging them.
BODY SIDE MOLDING ASSEMBLY OVERVIEW
Fig. 17: Identifying Side Protective Moldings - Assembly Overview

1. Side protective molding, front door

 Self-adhesive
 Removing, refer to BODY SIDE MOLDING.
 The left and right body side moldings have different hole patterns.
2. Side protective molding, side panel

 Self-adhesive
 The left and right body side moldings have different hole patterns.
SPECIFICATIONS
NAME PLATES
ASSEMBLY INFORMATION
 Warm the name plate with a hot air blower V.A.G 1416.
 If removing the name plate, only use the adhesive remover D 002 000 10 to remove the adhesive residue.
 Remove any adhesive residue left by the tape using adhesive remover VAS 6349.
 Apply the name plates immediately after cleaning them.
 It is not possible to remove the name plate without breaking it.
REAR NAME PLATE, SEDAN
NOTE: Always follow the procedure when installing a name plate. Refer to ASSEMBLY
INFORMATION.
Fig. 18: Identifying Rear Name Plate, Sedan

1. Dimension -a- = 18 mm
 From lower edge of tail lamp up to name plate.
2. Dimension -b- = 30 mm
 From the outer edge of the rear lid to the name plate.
3. Dimension -c- = 8 mm
 From the lower edge of the name plate to the upper edge of the lower name plate.
REAR NAME PLATE, WAGON

NOTE: Always follow the procedure when installing a name plate. Refer to ASSEMBLY
INFORMATION.
Fig. 19: Identifying Rear Name Plate, Wagon

 From the lower edge of the name plate up to the upper edge of the lower name plate.
REAR NAME PLATES, R36
Name plates for the Sedan
Fig. 20: Identifying Rear Name Plates For Sedan, R36

Name plates for the Wagon

Fig. 21: Identifying Rear Name Plates For Wagon, R36

 From the outer recess on the rear lid to name plate.
DIMENSION, FENDER NAME PLATE, R-LINE
NOTE: The dimensions for the R-line fender name plate are for the left side. It can also
be applied to the right side.
Dimension -b- and dimension -c- specify the inclination of the name plate. The
name plate is installed parallel to the lower edge of the fender.
Fig. 22: Identifying Dimension, Fender Name Plate, R-Line

 From the lower edge of the fender to the corner of the name plate

 From the lower rear edge of the fender to the -dimension a-.

 From the lower front edge of the fender to the corner of the name plate
DIMENSIONS, FENDER NAME PLATE >>Exclusive<<
Right side of the vehicle
Fig. 23: Identifying Dimensions, Fender Name Plate >>Exclusive<< (Right Side Of Vehicle)
1. Fender
2. Name plate
 Assembly Information, refer to NAME PLATES.
 Distance -dimension A- = 50 mm, from the name plate to the upper edge of the fender
 Distance -dimension B- = 40 mm, from the name plate to the outer edge of the fender
Left side of the vehicle
Fig. 24: Identifying Dimensions, Fender Name Plate >>Exclusive<< (Left Side Of Vehicle)
1. Fender
2. Name plate
 Assembly Information, refer to NAME PLATES.
 Distance -dimension A- = 50 mm, from the name plate to the upper edge of the fender
 Distance -dimension B- = 40 mm, from the name plate to the outer edge of the fender

WHEEL HOUSING LINER
FRONT WHEEL HOUSING LINER
NOTE: Removing and installing is described only for the left front wheel housing liner.
Removing and installing right front wheel housing liner is derived accordingly
from this.
Slight changes may have to be made to removal and installation procedures of

front wheel housing liner, depending upon equipment installed in vehicle.
Removing
Rear part of wheel housing liner
-- Remove the wheel. Refer to Removal and Installation .
-- Remove rear part of wheel housing liner -1-.
Front part of wheel housing liner
-- Remove front part of wheel housing liner -4-.
Installing
REAR WHEEL HOUSING LINER
NOTE: The following describes removing and installing the left rear wheel housing
liner. Removing and installing the right rear wheel housing liner is identical.
Removing and installing the R36 rear wheel housing liner is identical.
Slight changes may have to be made to removal and installation procedures of

rear wheel housing liner, depending upon equipment installed in vehicle.
Removing
Fig. 26: Identifying Rear Wheel Housing Liner, Assembly Overview

-- Remove the wheel. Refer to Removal and Installation .
-- Pull off wheel housing liner -1-.
Installing

MIRROR GLASS
NOTE: The following describes removing and installing the left mirror glass only.
Removing and installing the right mirror glass is identical.
WARNING: Wear protective eyewear and gloves when working.
Removing
-- Protect housing edge -1- from paint damage, for example, cover using fabric-reinforced adhesive tape.
Fig. 27: Identifying Mirror Glass, Removing And Installing

-- Press the bottom of the mirror glass -2- into the mirror housing -1-.
-- Press off mirror glass -2- using pry lever 80-200 from bracket -5- and housing -1- -arrow 6-.
-- Swing mirror glass -2- to the side -arrow 4- and disconnect the installed connector terminals -3- for electric
dimming function and mirror heater from rear side of mirror glass -2-.
Installing
-- Insert connector terminals for mirror heater to mirror glass.
-- Press mirror glass at center onto holder in housing.
-- The mirror glass will engage with a click.
 Then perform a function test.
MIRROR HOUSING
NOTE: The following describes removing and installing the left mirror housing.
Removing and installing the right mirror housing is identical.
Removing
-- Remove the mirror glass.
-- Fold the exterior rearview mirror forward for easier installation.
Inner retaining hook -2- is not to be reached from front.
Fig. 28: Identifying Retaining Tabs -2-

-- Slide trim removal wedge 3409 between mirror housing and turn signal. This disengages the retaining hooks -
2-.
-- Pull mirror housing at the front slightly off the mirror base plate.
-- Then, remove the mirror housing -1- from the mirror base plate.
Installing
-- Position the mirror housing -1- on the mirror base plate and press down until the catches -2- engage audibly.
Fig. 29: Identifying Retaining Tabs -2-

-- Re-install mirror glass.
TRIM
NOTE: Removing and installing is described only for the left trim. Removing and
installing right trim is derived accordingly from this.
Removing
-- Remove the mirror glass.
-- Remove mirror housing, refer to MIRROR HOUSING.
-- Release retaining tabs -2- from mirror carrier using a screwdriver.

Fig. 30: Identifying Trim -1- And Retaining Tabs -2-

-- Remove trim -1- in -direction of arrow-.
Installing
TURN SIGNALS
NOTE: The following describes removing and installing the left turn signal. Removing
and installing the right turn signal is identical.
LEDs with a long service life are installed in the side turn signals instead of
standard bulbs.
It is not necessary to replace the LED. The entire turn signal must be replaced if
damaged.
Removing
-- Remove the mirror glass, refer to MIRROR GLASS.
-- Remove mirror housing, refer to MIRROR HOUSING.
-- Remove trim, refer to TRIM.

-- Remove screws -4- and remove assembly piece -B- downward.
Fig. 31: Identifying Trim -1-, Screws -2-, Turn Signal -3- And Screws -4-
-- Disconnect harness connector -5- from turn signal -3-.
-- Remove screws -2- and remove turn signal -3- from assembly piece -1-.
Installing
EXTERIOR REARVIEW MIRROR
NOTE: The following describes removing and installing the left exterior mirror.
Removing and installing the right exterior mirror is identical.
Removing
-- Remove the front door trim panel on the driver side. Refer to Removal and Installation .
-- Remove the cable bracket -2- and disconnect the connector -1- for the exterior rearview mirror.
Fig. 32: Identifying Cable Bracket And Harness Connector For Rearview Mirror
Fig. 33: Identifying Side Mirror And Bolts

-- Remove exterior mirror -1- and guide the wire -3- through opening in door.
Installing

-- Tightening specification: screw -2- for the exterior mirror -1- 8 Nm
Fig. 34: Identifying Side Mirror And Bolts

 A function test must be performed before door trim is installed.
RADIATOR GRILLE
RADIATOR GRILLE
Removing

-- Remove bolts -2, 3 and 4-.
-- Remove radiator grille -1- upward out of bumper cover.
-- Disconnect the connectors from all electric components.
Installing

-- Connect harness connectors of installed electrical components.
-- Insert radiator grille -1- into bumper cover.
-- Install bolts -2, 3 and 4-.
RADIATOR GRILLE, R36
Removing

-- Remove the front bumper cover. Refer to FRONT BUMPER COVER .
-- Remove screws -2 and 6-.
-- Loosen the catches from the radiator grille on the inside of the bumper cover.
-- Remove the radiator grille forward from the bumper cover.
-- Disconnect the connectors from the front parking aid sensor. Refer to [For engine(s)
Installing

-- Connect the connectors for the front parking aid sensor. Refer to [For engine(s) BPY,BLV,CCTA,CBFA]
-- Insert radiator grille -1- into bumper cover.
-- Push the radiator grille -1- into the bumper cover until it audibly engages.
-- Install the screws -2 and 6-.

EMBLEM
Removing
-- Remove radiator grille:
Refer to RADIATOR GRILLE, R36
-- Remove the honeycomb grille (if equipped) from the back of the radiator grille.
-- Disengage the hooks -arrows- on the back of the emblem -2-.
Fig. 39: Identifying Removal Of VW Emblem

-- Twist emblem -2- slightly in -direction of arrow- and pull emblem forward out of radiator grille -1-.
Installing
-- Guide emblem -2- with retaining hooks into cutouts in radiator grille -1-.
Fig. 40: Identifying Installation Of VW Emblem

-- Twist emblem -2- slightly in the -direction of the arrow- until emblem -2- engages with radiator grille -1-.
-- Install the honeycomb grille (if equipped) from the back of the radiator grille.
-- Install the radiator grille:
EMBLEMS ON VEHICLES WITH ADAPTIVE CRUISE CONTROL
Removing
NOTE: Not all model versions have the ring -3-.

Fig. 41: Identifying Removal Of Emblems From Vehicles With Adaptive Cruise
Control
-- Remove radiator grille:
Refer to RADIATOR GRILLE, R36
-- Engage the upper hooks on the back of the emblem -4-.
-- Remove emblem -4- with lower catches -arrow a- from retaining ring -3- or radiator grille -1-.
-- To remove retaining ring -3- , both catches -arrow b- in radiator grille -1- must be released.
Installing
NOTE: Read the information regarding the adaptive cruise control sensor -G550- -2-
before installing the emblem. Refer to [For engine(s) BPY,BLV,CCTA,CBFA]
Vehicles with a ring
-- Press retaining ring -3- into radiator grille -1- until both retaining hooks engage -arrow b-.
Fig. 42: Identifying Installation Of Emblems From Vehicles With Adaptive Cruise Control
Procedure for all vehicles
-- Place emblem -4- with lower retaining hooks -arrow b- in the recesses in retaining ring -3- or the
corresponding recesses in radiator grille -1-.
-- Press emblem -2- with the upper retaining hooks into retaining ring -3- or radiator grille -1- until the retaining
hooks engage.
-- Install the radiator grille:
LICENSE PLATE HOLDER
Removing
Fig. 43: Identifying License Plate Holder - Assembly Overview

-- Remove clips -2- and remove license plate holder -1- from radiator grille -3-.
Installing
Fig. 44: Identifying Installation Of License Plate Holder

With holes present
-- Place license plate holder -1- on radiator grille -3- and press in clips -2-.
With no holes present
NOTE: On vehicles with front parking assist, -depth dimension a- of 12 mm must be

maintained when boring holes.
The parking assist wiring harness -3- is routed at the height of the upper bore
hole on the bumper carrier -5-.
-- Center license plate holder -1- to radiator grille -3-.
-- Set drill machine depth stop to dimension -a- of 12 mm and drill holes.
-- Place license plate holder -1- on radiator grille -3- and press in clips -2-.
ROOF RAIL
ROOF RAIL
Removing
-- Remove the headliner. Refer to Removal and Installation .
To remove roof rail upper hex nut -4- , it is first necessary to remove grab handle mounting frame -1-.
Fig. 45: Identifying Mounting Frame And Screws

-- Remove screws -2- and remove mounting frame -1-.
Then you can reach the roof rail hex nut -4-.
Fig. 46: Identifying Roof Rail Threaded Screws And Hex Nuts
-- Turn hex nut -2- downward from roof rail threaded screws -1-.
-- Guide roof rail -1- with threaded screws upward over angle bracket -3- and out and remove roof rail from
roof.
Installing
Fig. 47: Identifying Installation Of Roof Molding

 All angle brackets -4- are installed. Refer to ROOF RAIL ANGLE BRACKET.
-- Place roof rail -1- on roof -2-. Do this beginning with front threaded screws -5-.
-- Tighten the nut -3- to 23 Nm.
-- Mount the frame -1- and tighten the bolts -2- to 5 Nm.
Fig. 48: Identifying Mounting Frame And Screws

-- Install the headliner. Refer to Removal and Installation .
ROOF RAIL ANGLE BRACKET
Removing
NOTE: If angle bracket is to be re-installed, make sure conical washers remain in

tolerance compensations in their places.
The various conical washers must not be interchanged.
-- Roof the roof railing -5-.

Fig. 49: Identifying Roof Rail Angle Bracket Components

-- Remove angle bracket -1- together with tolerance compensations -3 and 4-.
If angle bracket is to be reinstalled, secure tolerance compensations with commercially available adhesive tape.
Installing
NOTE: The various conical washers in tolerance compensations -4 and 5- must not be
interchanged.
If you have secure the tolerance compensations with adhesive tape, remove tape before installation.
-- Make sure individual conical washers are seated properly in tolerance compensations -4 and 5-.
Fig. 50: Identifying Installation Of Angle Bracket

-- First place roof rail -6- on roof, then guide angle bracket -1- over threaded screws until conical washers are
centered in tolerance compensations -4 and 5-.
-- Remove the hex head nut -2- until angle bracket comes in contact with roof.
-- Tighten bolts -3- , tightening specification: 20 Nm.
-- Tighten the nut -2- to 23 Nm.
-- If dents appear around the base of the roof rail, readjust angle bracket.
New angle bracket, installing
-- Insert new angle bracket -1- until securing cap -4- engages in roof.
Fig. 51: Identifying Installation Of New Angle Bracket

-- Remove securing pin -3- downward and securing cap -4- upward.
-- If dents appear around the base of the roof rail, readjust angle bracket.
MOLDINGS AND TRIM
BODY SIDE MOLDING
Removing
Warm the cover with a hot air gun V.A.G 1416 before removing.

-- Warm the body side moldings -1- and -2- with a hot air gun V.A.G 1416 and remove them.
Installing
Only remove the protective film right before assembly. Processing temperature
workshop temperature.
Stand time after installing body side moldings is approximately 4 hours at an

ambient temperature of approx. 70° F (21° C).
Only use adhesive remover D 002 000 10.
Make sure the adhesive surfaces are free of dust and grease.
Install the body side molding immediately after cleaning the surfaces.
Peel off the protective film just before installation.
Temperature approx. 70°F (21°C).

-- Remove any adhesive residue with adhesive remover VAS 6349.
-- Clean the adhesive surface with adhesive remover D 002 000 10 right before bonding the outer door seal.
 The adhesive surface must be free of dust, grease and adhesive residue.
-- Peel the protective film off the body side moldings -1- and -2- just before installing them.
-- Secure the body side moldings -1- and -2- in centering hole.
-- Install the body side moldings -1- and -2- on the vehicle and press on them.
FRONT AND REAR DOOR COVER, FROM 05.07
Removing
NOTE: Removal and installation are described only for the left front and rear door
cover. The removal and installation of the right front and rear door cover are
derived accordingly from this.
Fig. 54: Identifying Removal Of Cover For Front And Rear Door
Front door cover
-- Remove the bolts -3- on inside of door.
-- Pull front door cover -1- in -direction of arrow- out of key holes.
-- Remove front door cover -1- downward.
Rear door cover

-- Pull rear door cover -2- in -direction of arrow- out of key holes.
-- Remove rear door cover -2- downward.
Installing
Fig. 55: Identifying Cover For Front And Rear Door, Assembly Overview
Front door cover
-- Coat door contact area and door rabbet in application area of front door cover -1- with lubricant.
-- Pull front door cover -1- in -direction of arrow- out of key holes. Tighten the screws -3- from inside the door.
Rear door cover
-- Coat door contact area and door rabbet in application area of rear door cover -2- with lubricant.
-- Engage rear door cover -2- under door rabbet and swivel rear door cover -2- upward on to door.
-- Pull rear door cover -2- in -direction of arrow- out of key holes. Tighten the screws -3- from inside the door.
DRIP RAIL
NOTE: Removal and installation are described only for the left drip rail. The removal
and installation of the right drip rail are derived accordingly from this.
Removing
Fig. 56: Identifying Drip Rail Components

-- Lift drip rail -1- from retaining strip -2- starting from top.
Installing
Fig. 57: Identifying Drip Rail Components

-- Place drip rail -1- on to retaining strip.
-- Install drip rail -1- from bottom to top, guiding the lip of drip rail -1- behind windshield when doing this.
-- Guide the edged lip at top end of drip rail -1- between windshield and roof.
FRONT AND REAR DOOR COVER, FROM 06.07
Removing
NOTE: Removal and installation are described only for the left front and rear door
cover. The removal and installation of the right front and rear door cover are
derived accordingly from this.
The covers cannot be removed without destroying them.
Front door cover

-- Remove the cover -1- from the front door -1-.
Rear door cover
-- Remove the cover -2- from the rear door -2-.
Installing
-- Peel the protective film -6- from the adhesive tape -5-.
-- Mount the cover -1- and the securing pins -4- on the door.
-- Press the cover on the door.
-- Tighten the screws -3- , tightening specification: 1.5 Nm.
Rear door cover
-- Peel the protective film -6- from the adhesive tape -5-.
-- Mount the cover -2- and the securing pins -4- on the door.
-- Press the cover on the door.
-- Tighten the screws -3- , tightening specification: 1.5 Nm.
COVER STRIP
NOTE: Depending on the model >>R Line<< and >>Exclusive<<.
The covers cannot be removed without damaging them.
The assembly procedure describes the left cover strip. The procedure for the
right cover strip is the same.
Fig. 60: Identifying Cover Strip Assembly

Removing
Perform the following steps:
-- Warm the cover strip -1- with the hot air gun V.A.G 1416 and remove it from the sill panel.
Installing
Follow the installation instructions. Refer to COVER STRIP.

-- Bond the cover strip -1- to the sill panel according to -dimension a-.
Distance from the cover strip -1- to the sill panel strip -3- = 20 mm
SPECIAL ATTACHMENTS
SAFETY PRECAUTIONS
NOTE: The following special attachments have been developed to match the technical
requirements of that specific model.
Always use Original Parts whenever replacing a special attachment.
If special attachments are missing, then the vehicle cannot be driven in public
traffic.
MATERIALS
 2K window adhesive DA 004 600 A2

 1K window adhesive DH 009 100
 Mixer with cone shaped nozzle D 002 001
 Glass/paint primer D 900 200 02
 Plastic primer D 009 600
 Cleaning solution D 009 401 04
 Primer applicator D 009 500 25
 Adhesive remover D 002 000 10
 Plastic cleaner D 195 850 A1
 Silicone remover LSE 020 100 A3
 Cutting cord 357 853 999 A
NOTE: Follow the manufacturer instructions supplied with the package.
Use a double cartridge pistol VAS 5237 when working with 2K adhesive.
Warm the 1K adhesive with a cartridge heater V.A.G 1939A according to the manufacturer instructions.
The 110 ml cartridge is only for sealing and/or when a 400 ml double cartridge is not sufficient.
SPECIAL ATTACHMENTS, PASSAT R36
Optional Equipment, Volkswagen Individual

NOTE: The assembly overview shows only the left side. The installation overview for
the right side is identical.
It is not possible to remove the any special attachments glued on without

destroying them.
Fig. 61: Identifying Special Attachments, Passat R36


 Removing and Installing, refer to FRONT BUMPER COVER .
2. Rear spoiler

4. Rear wheel trim
 Removing and Installing, refer to WHEEL COVER TRIM ASSEMBLY OVERVIEW,
THROUGH 01.08 or WHEEL COVER TRIM ASSEMBLY OVERVIEW, FROM 02.08.
5. Rear wheel housing extension
 Material PU-R-RIM
 Removing and Installing, refer to REAR WHEEL HOUSING EXTENSION.
6. Rear scuff protective film

 Replacing, refer to SCUFF GUARD FOIL.
7. Extended sill panel

 Removing and Installing, refer to ROCKER PANEL EXTENSION ASSEMBLY OVERVIEW.
8. Front scuff protective film

9. Front wheel housing extension
 Removing and Installing, refer to FRONT WHEEL HOUSING EXTENSION.
10. Front wheel trim

 Removing and Installing, refer to WHEEL COVER TRIM ASSEMBLY OVERVIEW,
THROUGH 01.08 or WHEEL COVER TRIM ASSEMBLY OVERVIEW, FROM 02.08.
FRONT WHEEL HOUSING EXTENSION
NOTE: The front wheel housing extension cannot be removed without destroying it.
Removal and installation is described only for the left-hand side. Removing and
installing on the right side is identical.
Removing
Fig. 62: Identifying Front Wheel Housing Extension

-- Warm the front wheel housing extension -1- with a hot air gun V.A.G 1416.
-- Lift one corner -arrow- of the front wheel housing extension -1- using the trim removal wedge 3409.
-- Grab the corner and pull the front wheel housing extension -1- off the fender.
Installing
Fig. 63: Identifying Protective Film On Front Wheel Housing Extension

-- Follow the cleaning instructions. Refer to CLEANING INSTRUCTIONS.
-- Follow the installation instructions. Refer to INSTALLATION INFORMATION.
-- Prepare the body for the adhesive. Refer to PREPARING BODYWORK FOR ADHESIVE.
-- Prepare the body for the special attachments.
-- Peel the protective film -2- off the front wheel housing extension -1-.
REAR WHEEL HOUSING EXTENSION
NOTE: The rear wheel housing extension cannot be removed without destroying it.
Removal and installation is described only for the left-hand side. Removing and
installing on the right side is identical.
Removing
Fig. 64: Identifying Rear Wheel Housing Extension

-- Warm the rear wheel housing extension -1- with a hot air gun V.A.G 1416.
-- Lift one corner -arrow- of the rear wheel housing extension -1- using the trim removal wedge 3409.
-- Grab the corner and pull the rear wheel housing extension -1- off the side panel.
Installing
Fig. 65: Identifying Protective Film Rear Wheel Housing Extension


-- Peel the protective film -2- off the rear wheel housing trim -1-.
-- Press the rear wheel housing extension -1- onto the side panel -3-.
ROCKER PANEL EXTENSION ASSEMBLY OVERVIEW
Fig. 66: Identifying Rocker Panel Extension Assembly Overview

1. Front rocker panel extension

2. Front cover
 For vehicle jack clearance
3. Rear panel
 For vehicle jack clearance
4. Rear rocker panel extension

5. Expanding nut
 Quantity: 3
6. Bolt
 Quantity: 3
7. Sill panel cover

8. Clip
 Quantity: 12
9. Rivet
 Quantity: 5
10. Grommet
 Quantity: 12
11. Bolt
 Quantity: 2
12. Expanding nut

 Quantity: 2
SPOILER ON EDGE OF ROOF ASSEMBLY OVERVIEW, WAGON

Fig. 67: Identifying Spoiler On Edge Of Roof Assembly Overview, Wagon

1. Roof edge spoiler

 Removing, refer to SPOILER ON EDGE OF ROOF, WAGON.
2. PUR adhesive bead

 Outside adhesive surface
 Adhesive bead: 6 mm +/- 1 mm
3. Double sided adhesive tape


 Adhesive bead: 10 mm +/- 1 mm
5. Connector
 High-Mounted Brake Lamp, Removing and Installing. Refer to [For engine(s)
6. Retaining strip
 Remove the roof edge spoiler. Refer to SPOILER ON EDGE OF ROOF, WAGON
 Cut off from the rear lid with cutting wire 357 853 999 A and pull handle V.A.G 1351/1
7. Clips
 Quantity: 3
 Clipped into the retaining strip -6-
8. Primer surface
 For adhesive bead on roof edge spoiler
 Transfer the primer surface position from the roof edge spoiler
 Prepare the rear lid.
SPOILER ON EDGE OF ROOF, WAGON
Removing
NOTE: It is not possible to remove the roof spoiler without breaking it.
WARNING: Before beginning the work, clean and seal off all surrounding part.
When disassembling roof edge spoiler, a cutting cable must not be used
because of the danger of damaging painted surfaces.
Fig. 68: Identifying Spoiler Assembly On Edge Of Roof, Wagon

-- Insert the cutting wire 357 853 999 A -5- between the rear lid -1- and roof edge spoiler -2-.
-- Cut through the adhesive tape -6- and the adhesive bead -7- in a "sawing motion" with both pull handles
V.A.G 1351/1 -4- on one side.
-- Repeat the same cutting on the other side.
-- Cut the adhesive bed -3- (on the flat surface) between the rear lid -1- and the roof edge spoiler -2- with the
electric cutter V.A.G 1561 A -8- and cutting blade V.A.G 1561/10.
Fig. 69: Identifying Removal Of Hooks Between Rear Lid And Roof Edge Spoiler With Trim Removal
Wedge 3409
-- Unhook the 5 hooks -3- between the rear lid -1- and the roof edge spoiler -2- in -direction of arrow- using the
trim removal wedge 3409
NOTE: A clear clicking sound should be heard while doing this.
The hooks should be removed starting from the corner of the spoiler -2- working toward the center -dimension
a- = 85 mm, -dimension b- = 220 mm (left and right) and -dimension c- = 475 mm.
-- Remove the roof spoiler -2- from the rear lid -1- and disconnect the connector from the high-mounted brake
lamp. Refer to [For engine(s) BPY,BLV,CCTA,CBFA] Removal and Installation .
Installing
Fig. 70: Identifying Installation Of Spoiler On Edge Of Roof, Wagon

 The brake lamp inside the roof spoiler is installed. Refer to [For engine(s) BPY,BLV,CCTA,CBFA]
 Make sure the brake lamp in the spoiler on the edge of the roof is working correctly.
 The surfaces of roof edge spoiler -1- and rear lid -3- are primed.
-- Apply a bead of adhesive -4- (2K adhesive DA 004 600 A2) on the primed surface -1- of the spoiler using a
dual cartridge pistol VAS 5237 -5-.
-- Peel off the protective film from the two-sided adhesive tape -6- on the left and right sides.
-- Connect the connector to the high-mounted brake lamp. Refer to [For engine(s) BPY,BLV,CCTA,CBFA]
-- Install the spoiler -1- , slightly tilted, into the brake lamp opening with the help of a second technician.
-- Push the spoiler -1- , tilted, all the way in.
-- Make sure all three clips -7- engage.
NOTE: Check it for correct seating and for any extra adhesive.
Make sure the high-mounted brake lamp is working correctly.
SPOILER ASSEMBLY OVERVIEW, SEDAN

Fig. 71: Identifying Spoiler Assembly Overview, Sedan

1. Spoiler
 Removing, refer to SPOILER, SEDAN.
2. Primer surface
 For the bead of adhesive on the spoiler
 Transfer the position of the primer surface from the spoiler
 Prepare the rear lid.

 1K window adhesive DH 009 100 03
 Preparing the spoiler, refer to SPOILER, SEDAN.
SPOILER, SEDAN
Removing
NOTE: It is not possible to remove the rear lid spoiler without breaking it.
WARNING: Before beginning the work, clean and seal off all surrounding part.
Do not use a cutting wire to remove the spoiler. It could damage the paint.
Fig. 72: Identifying Removal Of Spoiler, Sedan

-- Insert the cutting wire 357 853 999 A -5- between the rear lid -1- and spoiler -2-.
-- Cut through the adhesive -3- in a "sawing motion" with both pull handles V.A.G 1351/1 -4-.
Installing
Fig. 73: Identifying Installation Of Spoiler, Sedan


 The surfaces on the spoiler -3- and rear lid -2- are primed.
-- Apply a bead of adhesive -6- (1K adhesive DH 009 100 03) on the primed surface -1- of the spoiler using a
cartridge pistol V.A.G 1628 -5-.
 Use a commercially available cartridge gun -4- to apply the adhesive -6-.
-- With a second technician, place the spoiler -1- on the rear lid.
-- Align the spoiler to the specified dimension with a second technician.
 -a- = approximately 410 mm left and right

 -b- = approximately 4 mm left and right
 Make sure the spoiler sits flush on the rear lid.
-- Secure the spoiler to the rear lid with four strips of tape.
The spoiler can exert reset force.
NOTE: Check it for correct seating and for any extra adhesive.
ASSEMBLY INFORMATION
NOTE: The special attachments are attached at the factory with two-sided adhesive
tape and 2K windshield adhesive.
The manufacturer has already primed the special attachments and delivers
them with two-sided adhesive tape.
When painting the spoiler, be careful not get any paint or paint spray on the
two-sided adhesive tape.
CAUTION: Wear protective gloves and eyewear when removing the special
attachments.
Never use cutting wire to remove any special attachments.
The temperature of the room, working space and vehicle must be the same, between 65° and 86°F (18°C and
maximum 30°C).
Remove any remaining adhesive with adhesive remover VAS 6349.
Always use a clean, lint-free towel.
Clean the outer panel with adhesive remover D 002 000 10 just before installing the special attachments. Then
remove dirt, grease, wax or other contaminants with plastic cleaner D 195 850 A1.
Only remove the protective film right before assembly.
Before washing and protecting the vehicle, the wheel covers must be adhered for at least 4 hours.
PREPARING COMPONENTS FOR ADHESION

-- Remove any adhesive still on the two-sided adhesive tape with adhesive strip remover VAS 6349.
-- Clean the adhesive surface with adhesive remover D 002 000 10 right before bonding the attachments.
 The bonding surfaces must be free of dust and grease and there must be no left-over adhesive on them.
-- Now apply plastic primer D 009 600 uniformly in one stroke using applicator D 009 500 25.
 Drying time is approximately 10 minutes

 Bodywork must be prepared for adhesion.
-- Apply a thin and even coat of 2K adhesive DA 004 600 A2 on the primed surfaces with a double cartridge
gun VAS 5237.
NEW ATTACHMENT, PREPARING FOR BONDING
WARNING: Clean the adhesive surfaces before applying the primer.
For 2K windshield adhesive DA 004 600 A2
-- Prepare the adhesive surface with plastic primer D 009 600.
-- Apply the 2K adhesive DA 004 600 A2 on the marked locations on the attachment with a double cartridge
pistol VAS 5237.
PREPARING BODYWORK FOR ADHESIVE
-- Remove any adhesive still on the two-sided adhesive tape with adhesive strip remover VAS 6349.
-- The PUR adhesive points are cut down to approximately 2 to 3 mm without damaging the paint.
-- It is not necessary to clean the cutting surface.
NOTE: The remaining material serves as a base for the new adhesive sealant being
applied.
-- Make sure the surrounding parts are clean. Refer to CLEANING INSTRUCTIONS.
-- Immediately mount the new special attachments with the adhesive points on the specified positions.
If bodywork is being worked on or is partially replaced, it must be cleaned and primed again after painting the
corresponding area.
WARNING: Exception: If the bonding is going to be performed longer than one day
after cutting back the adhesive bead, then remaining material must be
activated with the activator D 181 801 A1.
Apply the activator evenly and in one wiping motion using the applicator
D 009 500 25.
Do not let the activator come in contact with the paint because this will
damage the paint.
Drying time is approximately 10 minutes
INSTALLATION INFORMATION
Always use a clean, lint-free towel.
Peel off the protective film just before installing.
Room and object temperature must be at least +65°F (+ 18°C).
The points on the outer panel that are going to be primed must be clean.
-- Remove adhesive residue using adhesive removal solution D 002 000 10.
 Drying time is approximately 10 minutes.
-- Apply the adhesive material on the primed locations on the extension with a double cartridge pistol VAS
5237.
WARNING: Components must be installed within 10 minutes, otherwise bonding

MINIMUM CURING TIME
Minimum hardening time for newly mounted special attachments is two hours.
Minimum curing time is the time from applying the components up to vehicle use.
Wait two hours after bonding with two-sided adhesive tape before performing other work on the vehicle.
During the time, the vehicle must be standing on an even surface and the temperature in the room must be 18°C.
WARNING: The vehicle is operationally ready only after the minimum curing time has
elapsed.
ADHESIVE SEALANT, REMOVING FROM WINDOW

-- Using adhesive remover D 002 000 10 is recommended. Always follow the safety precautions when using
adhesive remover.
-- Clean the painted surface with a dry cloth and remove any dirt with adhesive remover D 002 000 10.
CLEANING INSTRUCTIONS
-- Clean the outer panel from dirt, grease, wax and other contaminants just before installing the special
attachments first with adhesive remover D 002 000 10 and then with plastic cleaner D 195 850 A1.
 Always use a clean, lint-free towel.
SCUFF GUARD FOIL
 If removing the scuff guard, only use the adhesive remover D 002 000 10 to remove the adhesive residue.
 Apply the scuff guard immediately after cleaning.
Scuff guard foil, replacing
NOTE: Replacement of scuff guard is described for the left side. It can also be applied
to the right side.
Fig. 75: Identifying Scuff Guard Foil, Replacement

Removing
-- Heat the front scuff guard film -1- and the rear scuff guard film -2- using a hot air gun V.A.G 1416 and peel
the film off the sill.
Installing
-- Remove the protective film -3-.
NOTE: Pay attention to the markings -arrows- for positioning on the rocker panel.
-- Position the front scuff protection film -1- or the rear scuff protection film -2- and apply it evenly using a
plastic blade wrapped in a soft paper towel.
SPECIAL TOOLS
Fig. 76: Identifying Special Tools -- Flush Bonded Windows (1 Of 2)



 Hot air gun V.A.G 1416
 Adhesive strip remover VAS 6349
 Trim removal wedge 3409
 Cutting tools for glass V.A.G 1351


 Electric cutter V.A.G 1561 A

 Blade, offset V.A.G 1561/2
 Adjustment gauge 3371
Fig. 78: Identifying Cartridge Gun V.A.G 1628

Electrical System Exterior Lights, Switches
Electrical System
Exterior Lights, Switches
94 EXTERIOR LIGHTS, SWITCHES

GENERAL INFORMATION
HID HEADLAMPS, USAGE AND SAFETY PRECAUTIONS
 Gloves
-- Note the following if working with HID headlamps:
 Notes on hazardous high voltage/currents, refer to Notes On Hazardous High Voltage/Currents.

 Notes on pressure, temperature and radiation/electric arc, refer to Notes On Pressure, Temperature and
Radiation/Glare.
 Assembly notes for HID lamps, refer to Assembly Notes On HID Lamps.
 Disposal regulations for HID lamps, refer to Disposal Regulations For HID Lamps.
WARNING: Always make sure to disconnect the battery ground cable before
performing work on parts of the headlamp with a gas discharge lamp
marked with yellow high voltage symbols.
Then switch low beams on and back off. This removes any possible
residual voltage.
The gas-discharge lamp control module should not be operated without

the gas-discharge lamp.
Due to the high voltage (over 28000 V when igniting the lamp), the gas-
discharge lamp should only be operated inside the headlamp housing.
WARNING:  Never replace bulbs if you are not familiar with the procedures,
safety precautions and tools.
Notes On Hazardous High Voltage/Currents
WARNING: Light system control modules, connectors or components in the bulb

socket area conduct dangerous high voltage.
Control module and igniter operation is only permitted with lamp.
WARNING:  Turn off the ignition and all electric consumers and remove the key.
 Make sure all components have zero potential when working on
headlamp system, even residual voltage after switching off
headlamps must be discharged.
 Residual voltages are discharged by switching low beam on and off
again after ignition key was removed.
 Make sure lamps cannot be switched on when working on headlamp
system.
Notes On Pressure, Temperature and Radiation/Glare
WARNING:  Lamp must only be operated in headlamp housing (protection

against contact because of hot lamp, absorption of ultraviolet
radiation, avoiding danger of glare, explosion protection).
 Glass cones of bulbs can become very hot - danger of burns!
 Avoid looking directly into light beam, since UV radiation of the HID
lamp is approximately 2.5 times higher than that of standard
Halogen lamps.
 Avoid looking into light beam (danger of glare); vision can be
impaired for a longer period of time.
WARNING:  Avoid contact with burst glass cone.

 H7 bulbs and HID bulbs (Xenon/Bi-Xenon) are under pressure and
can burst when replaced - danger of injury!
 When removing and installing HID bulbs, always wear safety glasses
and gloves.
Assembly Notes On HID Lamps
CAUTION:  Before replacing a bulb, the corresponding consumer must always

be switched off.
 Turn off the ignition and all electric consumers and remove the key.
 Do not touch glass cone of bulb with bare fingers, use clean cloth
gloves. The remaining fingerprint would evaporate due to the heat of
the operated bulb and condense on the reflector which would impair
headlamp luminosity.
 A bulb must only be replaced with one of the same version. Bulb
identification can be found on bulb socket or glass cone.
 Harness connectors must engage correctly when installed and must
be checked for proper connection.
Disposal Regulations For HID Lamps
WARNING:  HID lamps must be disposed of as hazardous waste, never dispose

of HID lamps via domestic waste.
 HID lamps contain metallic mercury (Hg) and traces of thallium, they
must not be destroyed.
 These components must be returned for proper recycling in
accordance with national legislation.
 Dispose of only in the designated containers at the responsible
collection point.
Electrical System
Exterior Lights, Switches
94 EXTERIOR LIGHTS, SWITCHES

GENERAL INFORMATION
ACCESS/START AUTHORIZATION
CAUTION: When disconnecting and connecting the battery, always perform the work
procedure as described in BATTERY, DISCONNECTING AND
CONNECTING .
Refer to Owner's Manual.
Access/start authorization is equipped with On Board Diagnostic (OBD) which assists troubleshooting.
All malfunctions relating to the access/start authorization system are output via the Comfort System Central
Control Module -J393-.
The "Guided Fault Finding" function is to be used for troubleshooting of one of the systems described as in
COMFORT SYSTEM CENTRAL CONTROL MODULE -J393- .
AUXILIARY BRAKE LIGHTS
NOTE: Auxiliary brake light function can be checked via output Diagnostic Test Mode
(DTM) of Vehicle Electrical System Control Module -J519-.
Vehicle Electrical System Control Module -J519- is equipped with On Board Diagnostics (OBD) which assists
in troubleshooting.
VEHICLE ELECTRICAL SYSTEM CONTROL MODULE -J519-, CODING .
NOTE: Individual LEDs (Light Emitting Diodes) in auxiliary brake lights are combined
into groups of up to four LEDs and are supplied with power as a group.
When one LED group fails, the intact LEDs are given a higher load, by which
failure of other LED groups can be assumed in the near future.
If more than four individual LEDs in auxiliary brake light have failed, the
auxiliary brake light must be replaced (repair measure).
COMFORT SYSTEM CENTRAL CONTROL MODULE J393
The comfort system central control module is located behind the glove compartment.
All access/start authorization functions are actuated via the comfort system central control module. Refer to
It is necessary to adapt the Access/Start Authorization after replacing the comfort system central control
module.
NOTE: If the comfort system central control module is to be replaced, the work
procedure COMFORT SYSTEM CENTRAL CONTROL MODULE J393, REPLACE
AND CODING to read out the codes stored in the module must always be
performed.
After replacing comfort system central control module, other functions of

Comfort System Central Control Module such as Anti-theft Immobilizer, Anti-
theft Alarm System, access and start authorization, tire pressure monitoring
and central locking system key must also be adapted, depending on vehicle
equipment.
In this case, start by adapting the Anti-theft Immobilizer, refer to ANTI-THEFT

IMMOBILIZER CONTROL MODULE -J362-, ADAPTING and then the other
equipment-dependent functions of access and start authorization in any order.
Access and start authorization, removing and installing, refer to COMFORT SYSTEM CENTRAL
ELECTRONIC IGNITION SWITCH -D9-
The ignition/starter lock of the Passat 2006 is now called the Electronic Ignition Switch.
All malfunctions in conjunction with the Electronic Ignition Switch are output via the Comfort System Central
The Electronic Ignition Switch is a single construction unit and can only be replaced completely.
Depending on equipment, the Electronic Ignition Switch contains the following components:
 Anti-Theft Immobilizer Reading Module -D1-

 Push Button Illumination -L76-

 Ignition Switch Key Lock Solenoid -N376- (vehicles with automatic transmission only)
-- Electronic Ignition Switch, removing and installing, refer to ELECTRONIC IGNITION SWITCH -D9- .
EMERGENCY STARTING FOR FAULTY COMMUNICATION BETWEEN ID SENSOR AND CONTROL

MODULE
In the event that communication between ID sensor in ignition/starter switch button and Comfort System
Central Control Module -J393- is faulty (e.g. ignition/starter switch button battery discharged), engine can be
started via remote control ignition key.
-- Remove the ignition/starter switch button from the electronic ignition lock.
-- To do this, release catch -1- by pulling slide -arrow- on bottom side back and pulling start button -2- out of
electronic ignition lock.
Fig. 1: Identifying Release Catch -1- And Ignition/Starter Switch Button -2-
-- Insert remote control ignition key into electronic ignition lock.
The ID sensor in ignition key is identified via a transponder in the electronic ignition lock and the steering is
unlocked and start authorization is achieved.
Start process occurs in the same way as with the ignition/starter switch button.
NOTE: If ignition/starter switch button is reinserted into electronic ignition lock, make
sure that locking latch -1- faces upward. Otherwise, the locking latch does not
lock in the ignition lock.
EXTERIOR REAR VIEW MIRROR TURN SIGNAL AND ENTRY LAMP BULBS
NOTE: Lamp for mirror flasher and access lamp in exterior mirror can be checked via
output Diagnostic Test Mode (DTM) of Driver Door Control Module -J386- and
Front Passenger Door Control Module -J387-.
Refer to the appropriate SYSTEM WIRING DIAGRAMS Wiring Diagram.
Driver's Door Control Module and Front Passenger's Door Control Module are equipped with On Board
Diagnostics (OBD) which assists troubleshooting.
DRIVER DOOR CONTROL MODULE -J386-, OUTPUT DIAGNOSTIC TEST MODE .
The turn signal bulbs (side turn signal lamp) are installed in the exterior mirror housings.
In addition, there is one entry lamp each in exterior mirror housing which illuminates the dark entry area around
opened driver and front passenger door.
Fig. 2: Identifying Turn Signals And Entry Lamps In Exterior Mirrors Components
1 - Driver Exterior Mirror Turn Signal Lamp -L131- and Front Passenger Exterior Mirror Turn Signal Lamp -
2 - Driver Entry Lamp In Exterior Rearview Mirror -W52- and Front Passenger Entry Lamp In Exterior
Rearview Mirror -W53-
FOG LAMPS
NOTE: Fog lamp function can be checked via output Diagnostic Test Mode (DTM) of
Vehicle Electrical System Control Module -J519- .
Vehicle Electrical System Control Module is equipped with On Board Diagnostics (OBD) which assists in
troubleshooting.
VEHICLE ELECTRICAL SYSTEM CONTROL MODULE -J519- OUTPUT DIAGNOSTIC TEST
MODE .
FRONT PARKING AID AND PARALLEL PARKING ASSISTANCE SENSORS
The front parking aid sensor and parallel parking assistance sensors are installed in the front bumper. Both of
the parallel parking assistance sensors sit sideways in the outer locations in the bumper cover and are used with
the parking aid sensors for measuring during the parking process.
NOTE: If a new front bumper cover or a new radiator grille is installed, then the sensor
holders in the bumper cover or radiator grille must be glued in while observing
the established process steps. Refer to SENSOR BRACKET FOR PARKING AID
AND PARALLEL PARKING ASSISTANCE, BONDING.
FRONT TURN SIGNAL LAMPS
NOTE: Function of front turn signals can be checked via output Diagnostic Test Mode
troubleshooting.
MODE .
HEADLAMPS
NOTE: Before working on headlamps, always switch off headlamps and move ignition
key or ignition/starter switch to position 0 (preliminary engaged position).
Familiarity with the function and operation of the lighting system is essential in
the event of customer complaints.
Additional information:
Headlamps from two different manufacturer's are installed in the vehicle:
 Hella
 Valeo
Assembly and disassembly of headlamps and their attachments is identical up to removing and installing
positioning motors.
Vehicle electrical system is equipped with OBD which assists Fault Finding the headlamps.
MODE .
HEADLAMP MOUNTING TABS, SERVICING
If one or more headlamp mounting tabs are damaged or broken off, they can be replaced by installing the repair
set. It is not necessary to replace the entire headlamp.
Fig. 3: Identifying Headlamp Mounting Tabs

1. Outer top mounting tab

2. Inner top mounting tab
3. Side mounting tab
4. Lower mounting tab
NOTE:  Check whether there is no further damage on the headlamp that makes
installation of the repair set superfluous.
 There are two different repair sets, one for the left and one for the right
headlamp.
 The same repair set is used for both manufacturers (Hella and Valeo).
 Each repair set contains the corresponding top, side and lower headlamp
retaining lugs, four mounting bolts and two banjo fittings.
 The following illustrations depict replacement of mounting tabs at right
headlamp.
 Replacement of securing lugs on left headlamp and on right headlamp are
performed analogously.
-- Outer top mounting tab, repairing, refer to OUTER TOP MOUNTING TAB, REPAIRING.
-- Inner top mounting tab, repairing, refer to INNER TOP MOUNTING TAB, REPAIRING.
-- Side mounting tab, repairing, refer to SIDE MOUNTING TAB, REPAIRING.
-- Lower mounting tab, repairing, refer to LOWER MOUNTING TAB, REPAIRING.
HID HEADLAMPS
HEADLAMPS WITH CORNERING LAMP
NOTE:  Before working on HID headlamps and cornering lamps, always switch off
headlamps and bring ignition key or ignition/starter switch into position 0
(preliminary engaged position).
 Automatic Headlamp Range Control and cornering light in HID headlamps
have On Board Diagnostics (OBD).
 Familiarity with the function and operation of the lighting system is
essential in the event of customer complaints.
 Additional information:

Main headlamps with gas-discharge lamps and cornering lamps (AFS = Adaptive Front lighting System) have
Bi-Xenon function.
Gas discharge lamps generate only the low beam headlamp in standard Xenon headlamps. Bi-Xenon allows one
gas-discharge lamp to generate low beam and high beam headlamp. For this purpose, an electro-mechanical
adjuster (Left Low Beam Reflector Motor -V294- and Right Low Beam Reflector Motor -V295-) opens the
dimmed region of low beam headlamp when high beam function is operated and a high beam light emission
results.
For this reason, the high beam is also adjusted automatically with the low beam on Bi-Xenon headlamps.
HID headlamps with cornering lights do not have auxiliary high beams.
The cornering light system has the following functions:
 Swiveling low beam and high beam (dynamic cornering lamp) from vehicles speeds above 10 km/h and
steering wheel angle.
 Cornering lamp (static cornering lamp) at sharp curves (curve radius < 500 m) or on turning-off and
vehicles speeds below 50 km/h.
Automatic headlamp range control, cornering lamps and vehicle electrical system control are equipped with On
Board Diagnostic (OBD) which assists troubleshooting of main headlamps with HID lamps and cornering
lamps.
MODE .
NOTE: The indicator light amp failure lights up in instrument cluster when headlamp
range control or Adaptive Front lighting System (AFS) system malfunctions.
See item 21 ("Lamp Failure Control Lamp") under: INSTRUMENT CLUSTER
INDICATOR LAMPS .
DYNAMIC CORNERING LAMP MOTOR
Left Dynamic Cornering Light Motor -V318- and Right Dynamic Cornering Light Motor -V319- are located
inside the headlamp and must not be removed.
If a failure occurs, the entire headlamp must be replaced. Refer to HEADLAMPS.
SWIVEL MODULE POSITION SENSOR
Left Swivel Module Position Sensor -G474- and Right Swivel Module Position Sensor -G475- are located
inside the headlamp and cannot be replaced or adjusted separately.
LOW BEAM REFLECTOR MOTOR
Gas discharge lamps generate only the low beam headlamp in standard Xenon headlamps. Bi-Xenon allows one
gas-discharge lamp to generate low beam and high beam headlamp. For this purpose, an electro-mechanical
adjuster (Left Low Beam Reflector Motor -V294- and Right Low Beam Reflector Motor -V295-) opens the
dimmed region of low beam headlamp when high beam function is operated and a high beam light emission
results.
IGNITION/STARTER SWITCH
As of the Passat 2006, the electric ignition starter lock is installed in a modified shape and function and is now
called the Electronic Ignition Switch -D9-, refer to ELECTRONIC IGNITION SWITCH -D9- .
The Electronic Ignition Switch is a single construction unit and can only be replaced completely.
The Electronic Ignition Switch contains the following components:
 Access/Start Authorization Switch -E415-

 Ignition Switch Key Lock Solenoid -N376-
LICENSE PLATE LAMP
NOTE: License plate light function can be checked via output Diagnostic Test Mode
troubleshooting.
MODE .
LOCK CYLINDER
The Electronic Ignition Switch is no longer installed in an assembly with the lock cylinder. The Steering
Column Lock Actuator -N360- inside the Electronic Steering Column Lock Control Module -J764- assumes the
function of the steering column lock. Refer to ELECTRONIC STEERING COLUMN LOCK CONTROL
MODULE -J764- .
On vehicles with keyless entry, the steering lock is activated by pulling the start button out of ignition lock
position S and into position Ignition off - steering locked. The ignition/starter switch can remain in the ignition
switch in position Ignition off - steering locked. Refer to Owner's Manual.
PARALLEL PARKING ASSISTANCE CONTROL MODULE -J791-
The parallel parking assistance control module is located inside the footwell on the driver side above the fuse
box. The parallel parking assistance control module also controls the parking aid functions on vehicles with
front parking aid or PLA.
PARKING AID CONTROL MODULE -J446- CONNECTOR ASSIGNMENTS
The connector assignment for the parking aid control module can be found in the wiring diagram. Refer to the
REAR PARKING AID WARNING BUZZER H15, VEHICLES WITH PARALLEL PARKING ASSISTANCE
On vehicles with front parking aid or parallel parking assistance, the Parallel Parking Assistance Control
Module -J791- controls the parking aid functions. Because of this, the rear parking aid warning buzzer
adaptations are performed with the parallel parking assistance control module on vehicles with parallel parking
assistance or front parking aid.
REARVIEW CAMERA SYSTEM
function and operation of the rear system.
For additional information, refer to Operating instructions.
When performing service work or fault-finding, use Vehicle Diagnosis, Testing

and Information System VAS 5051B or Vehicle Diagnosis and Service System
VAS 5052 in the function "Guided Fault Finding". Refer to the appropriate
When the battery is connected, check the all the vehicle accessories (radio,
clock, electronic conveniences, etc.) according to the repair information and/or
the Owner's Manual.
The rear system assists the driver during back-up driving by providing the driver with an image of the traffic
situation behind the vehicle via the monitor of the radio or radio navigation system. The system is optional
equipment.
The system switches itself on by selecting the reverse gear, even when the radio or radio/navigation system is
switched off.
The rear view camera system consists of the following components:
 Rear View Camera -R189-

 Rear View Camera System Control Module -J772-
 Radio/Navigation Display Control Module -J503-
 and steering wheel with Steering Angle Sensor -G85-.
NOTE: It is not permitted to install an auxiliary license plate holder for vehicles with
rear view camera system because it would impair the function of the rear view
camera system. License plate lights may also be impaired.
Rear view camera system is equipped with On Board Diagnostic (OBD).
When performing Fault Finding, use Vehicle Diagnosis, Testing and Information System VAS 5051B or
Vehicle Diagnosis and Service System VAS 5052 in the function "Guided Fault Finding".
STEERING COLUMN SWITCH
STEERING COLUMN SWITCH, THROUGH 10.09
CAUTION: When disconnecting and connecting battery, the procedure must be

followed as described in BATTERY, DISCONNECTING AND CONNECTING .
NOTE: After installing a new Steering Column Electronic Systems Control Module -
J527-, it must be coded, refer to STEERING COLUMN ELECTRONIC SYSTEMS
CONTROL MODULE J527, CODING, THROUGH 10.09.
If malfunctions occur at steering column switch, coding of Steering Column

Electronic Systems Control Module must be checked using Output Diagnostic
Test Mode (DTM), refer to STEERING COLUMN ELECTRONIC SYSTEMS
CONTROL MODULE J527 OUTPUT DIAGNOSTIC TEST MODE, THROUGH 10.09.

Steering Column Electronic Systems Control Module is equipped with On Board Diagnostics (OBD) which
assists troubleshooting.
STEERING COLUMN ELECTRONIC SYSTEMS CONTROL MODULE J527 OUTPUT
DIAGNOSTIC TEST MODE, THROUGH 10.09. .
STEERING COLUMN COMBINATION SWITCH -E595-, THROUGH 10.09
Depending on equipment, the Steering Column Combination Switch consists of the following components and
cannot be disassembled further in the event of repairs:
 Turn Signal Switch -E2-

 Headlamp Dimmer/Flasher Switch -E4-
 Cruise Control Switch -E45-
 Windshield Wiper Switch -E-
 Rear Window Wiper Switch -E34-
 Windshield Wiper/Washer Switch -E22-
 Windshield Wiper Intermittent Regulator -E38-
 Windshield and Headlamp Washer Pump Switch -E44-
STEERING COLUMN SWITCH, FROM 11.09
CAUTION: The removal and installation of individual steering column switch

components must be done in a specified sequence, refer to STEERING
COLUMN SWITCH COMPONENTS, REMOVAL AND INSTALLATION
SEQUENCE, FROM 11.09.
There are two versions of the steering column combination switch components, the steering column electronics
control module and the steering column switch base carrier depending on the manufacturer (Valeo or Kostal). In
order to determine which version is installed, check the mounting for the steering column electronics control
module on the steering column combination switch.
 Valeo: 3 bolts
 Kostal: 1 screw at the bottom and 2 clips at the top.
NOTE: After installing a new Steering Column Electronics Control Module -J527-, it
must be coded, refer to STEERING COLUMN ELECTRONIC SYSTEMS
CONTROL MODULE J527, CODING, FROM 11.09.
Steering Column Electronic Systems Control Module is equipped with On Board Diagnostics (OBD) which
assists troubleshooting.
For troubleshooting, use Vehicle Diagnostic, Testing and Information System VAS 5051B in operating mode
"Guided Fault Finding".
Base Carrier For Steering Column Switches
Removing and installing the steering column switch base carrier differs between the two manufacturers.
 Steering Column Switch Base Carrier, Valeo, removing and installing, refer to STEERING COLUMN
SWITCH BASE CARRIER, VALEO, FROM 11.09.
 Steering Column Switch Base Carrier, Kostal, removing and installing, refer to STEERING COLUMN
SWITCH BASE CARRIER, KOSTAL, FROM 11.09.
STEERING COLUMN ELECTRONIC SYSTEMS CONTROL MODULE -J527-, FROM 11.09
The Steering Column Electronic Systems Control Module -J527- includes the following components and cannot
be disassembled:
 Airbag Spiral Spring/Return Spring With Slip Ring -F138-

 Steering Angle Sensor -G85-
NOTE: Remove the transportation safeguard before installing a new steering column
electronic systems control module.
After installing a new steering column electronic systems control module, it

must be coded, refer to STEERING COLUMN ELECTRONIC SYSTEMS
CONTROL MODULE J527, CODING, FROM 11.09.
If steering column switch malfunctions occur, the coding of the steering column
electronic systems control module must be checked, refer to STEERING
COLUMN ELECTRONIC SYSTEMS CONTROL MODULE J527, CODING, FROM
11.09.
The procedure for removing and installing the steering column electronic systems control module differs
between the two manufacturers.
 Steering Column Electronic Systems Control Module, Valeo, removing and installing, refer to
STEERING COLUMN ELECTRONIC SYSTEMS CONTROL MODULE J527, VALEO, FROM
11.09.
 Steering Column Electronic Systems Control Module, Kostal, removing and installing, refer to
STEERING COLUMN ELECTRONIC SYSTEMS CONTROL MODULE J527, KOSTAL, FROM

11.09.
STEERING COLUMN COMBINATION SWITCH -E595-, FROM 11.09
Depending on equipment, the Steering Column Combination Switch consists of the following components and
cannot be disassembled:
 Turn Signal Switch -E2-

 Windshield Wiper Switch -E-
 Cruise Control Switch -E45-
Removing and installing the steering column combination switch differs between the two manufacturers.
 Steering Column Combination Switch, Valeo, removing and installing, refer to STEERING COLUMN
COMBINATION SWITCH E595, VALEO, FROM 11.09.
 Steering Column Combination Switch, Kostal, removing and installing, refer to STEERING COLUMN
COMBINATION SWITCH, KOSTAL E595, FROM 11.09.
TAIL LAMPS
NOTE: Tail lamp function can be checked via output Diagnostic Test Mode (DTM) of
Vehicle Electrical System Control Module -J519-.
troubleshooting.
MODE .
Tail lamp assemblies cannot be disassembled up to the right back-up light and left rear fog light. The right back-
up light and left rear fog light are generated by one light bulb, which cannot be replaced individually. The
remaining lights are generated by LEDs (Light Emitting Diodes). Malfunctioning diodes cannot be replaced.
NOTE: Individual LEDs (Light Emitting Diodes) in LED tail lamp assemblies (tail, turn
signal, brake and backup lamps) are combined in groups of up to four LEDs
each and are supplied with power as a group.
LED tail lamp assemblies are constructed in such a way that when one LED
group fails as a function (e.g. brake lamp), the requirements of ECE regulations
(Economic Commission for Europe) are still met.
If another LED group fails functionally, these legal requirements are no longer
met.
When one LED group fails, the function of the intact LEDs are given a higher
load, by which failure of other LED groups can be assumed in the near future.
If more than four individual LEDs fail functionally in the LED tail lamp assembly,
the entire tail lamp assembly must be replaced (repair measure).
Tail Lamps
For vehicles with USA and Canada equipment, removal and installation of tail lamps in side panel and in rear
lid as described in the same way. With this equipment, a backup light is also installed in place of fog light in the
left rear lid tail amp.
 Tail lamp assembly in side panel (Sedan), refer to TAIL LAMPS IN SIDE PANEL OVERVIEW.
 Rear Lid Tail Lamp Assembly, Sedan, refer to REAR LID TAIL LAMPS OVERVIEW.
 Side panel tail lamp assembly, Wagon, refer to .
 Tail lamp assembly in rear lid (Wagon), refer to .
ACCESS/START AUTHORIZATION
The KESSY system (Keyless Entry Start Stop System) regulates keyless opening, locking and vehicle start-up.
Opening:
The ID sensor in ignition key must be located within reception range of lock location (approximately 1.5
meters). Grasping the door handle activates the proximity sensor on the inside of the door handle, ID sensor in
ignition key is triggered and the door is unlocked immediately upon valid identification. Pulling door handle
opens the vehicle.
Starting:
The ID sensor in ignition key must be located in the vehicle interior. When sliding in the start button to the
second engaged position of electronic ignition switch, the ID sensor in ignition key is triggered and steering is
unlocked and start authorization is achieved upon valid identification.
It is only possible to start engine with ignition/starter switch in electronic ignition switch when a valid ID sensor
is located in the vehicle interior.
Locking:
The ID sensor in ignition key must be located within reception range of lock location (approximately 1.5
meters). Touching the lock sensor on the outside of the door handle activates the lock sensor, the ID sensor in
ignition key is triggered and the vehicle locks upon valid identification.
Ignition key:
The ignition key is designed without a key bit since the vehicle is started for the first time with a sliding motion
and not a rotary motion. On vehicles with KESSY equipment, switch procedures in ignition lock are performed
by a ignition/starter switch button. This ignition/starter switch button remains in the ignition lock and functions
only in conjunction with a valid ID sensor in the remote control ignition key. Switch-on of the various terminal
voltages (terminal S, terminal 15) and the start procedure are performed by a sliding motion of the
ignition/starter switch button in the Electronic Ignition Switch -D9-. The following switch positions are possible
via sliding motions of the ignition/starter switch button:
 P0 - Off (preliminary engaged position)

 P1 - S-terminal on
 P2 - terminal 15 on
 P3 - terminal 15 drive (in this position, ignition key springs back automatically after the start procedure)
All access/start authorization functions are actuated via the Comfort System Central Control Module -J393-,
refer to COMFORT SYSTEM CENTRAL CONTROL MODULE -J393- .
ACCESS/START AUTHORIZATION ANTENNAS AND SENSORS OVERVIEW
The illustration depicts component locations in the Passat Sedan. In the Passat Wagon, the component locations
of the individual components are identical. Component 4 is discontinued in the wagon.
Fig. 4: Identifying Assembly Overview: Antenna And Sensors For Access/Start Authorization
1. Comfort System Central Control Module -J393-

 Component location: behind glove compartment on front passenger's side.
 Removing and installing, refer to COMFORT SYSTEM CENTRAL CONTROL MODULE

J393 .
 Replacing/coding Comfort System Central Control Module -J393-, refer to COMFORT SYSTEM
CENTRAL CONTROL MODULE J393, REPLACE AND CODING .
2. Passenger's Side Outside Door Handle
The following components are integrated in passenger's side outside door handle:
 Front Passenger's Outside Door Handle Touch Sensor -G416-

 Right Access/Start Authorization Antenna -R135-
Removing and installing passenger-side outside door handle, refer to PASSENGER OUTSIDE DOOR
HANDLE.
 Checking Right Access/Start Authorization Antenna -R135-, refer to FRONT PASSENGER

ACCESS/START AUTHORIZATION ANTENNA -R135-, CHECKING.
3. Right Rear Outside Door Handle
The following components are integrated in right rear outside door handle:
 Proximity sensor
 Locking sensor
 Removing and installing right rear outside door handle, refer to RIGHT REAR OUTSIDE DOOR
HANDLE.
 Checking Right Rear Outside Door handle Touch Sensor -G418-, refer to RIGHT REAR
OUTSIDE DOOR HANDLE TOUCH SENSOR -G418-, CHECKING.
4. Interior Access/Start Authorization Antenna 3 -R154-
NOTE: The Interior Access/Start Authorization Antenna 3 is installed in the Passat

Sedan only and has been discontinued in the wagon.
 Sedan location: Below rear shelf.

 Removing and installing, refer to INTERIOR ACCESS/START AUTHORIZATION
ANTENNA 3 R154.
 Checking Interior Access/Start Authorization Antenna 3 -R154-, refer to INTERIOR
ACCESS/START AUTHORIZATION ANTENNA 3 -R154-, CHECKING.
5. Access/Start Authorization Antenna In Rear Bumper -R136-
 Component location: behind rear bumper cover.
 Removing and installing, refer to REAR BUMPER ACCESS/START AUTHORIZATION

ANTENNA R136.
 Checking Access/Start Authorization Antenna (in rear bumper) -R136-, refer to ACCESS/START
AUTHORIZATION ANTENNA IN REAR BUMPER -R136-, CHECKING.
6. Luggage Compartment Access/Start Authorization Antenna -R137-
 Component location: in luggage compartment, center, in front of spare wheel well.
 Removing and installing, refer to LUGGAGE COMPARTMENT ACCESS/START

AUTHORIZATION ANTENNA R137.
 Checking Luggage Compartment Access/Start Authorization Antenna -R137-, refer to LUGGAGE
COMPARTMENT ACCESS/START AUTHORIZATION ANTENNA -R137-, CHECKING.
7. Rear Left Outer Door Handle
The following components are integrated in left rear outside door handle:
 Proximity sensor
 Locking sensor
 Removing and installing left rear outside door handle, refer to LEFT REAR OUTSIDE DOOR
HANDLE.
 Checking Left Rear Outside Door Handle Touch Sensor -G417-, refer to LEFT REAR OUTSIDE
DOOR HANDLE TOUCH SENSOR -G417-, CHECKING.
8. Driver's Side Outside Door Handle
The following components are integrated in driver's side outside door handle:
 Driver Outside Door Handle Touch Sensor -G415-

 Left access/start authorization antenna -R134-
 Removing and installing driver-side outside door handle, refer to DRIVER OUTSIDE DOOR
HANDLE.
 Checking Driver Outside Door Handle Touch Sensor -G415-, refer to DRIVER OUTSIDE
DOOR HANDLE TOUCH SENSOR -G415-, CHECKING.
 Checking Left Access/Start Authorization Antenna -R134-, refer to DRIVER ACCESS/START
AUTHORIZATION ANTENNA -R134-, CHECKING.
 Component location: on center tunnel at rear, in front of rear seat bench heel panel.
 Removing and installing, refer to ACCESS/START AUTHORIZATION ANTENNA 2 IN

VEHICLE INTERIOR R139.
 Component location: on center tunnel, between front seats.
 Removing and installing, refer to INTERIOR ACCESS/START AUTHORIZATION

ANTENNA 1 R138.
FOG LAMPS OVERVIEW

Fig. 5: Identifying Component Overview: Fog Lamps

1. 1 - Front Bumper
2. 2 - Bleeder Hose
3. 3 - Left Front Fog Lamp -L22- and Right Front Fog Lamp -L23-
 Bulb H11 12V, 55W.
 Removing and installing, refer to FOG LAMP BULBS.
 Checking, refer to FOG LAMPS, CHECKING.
4. 4 - Fog Lamp Housing

 Removing and installing, refer to FOG LAMP.
6. 6 - Screws
 Tightening specification, refer to FASTENER TIGHTENING SPECIFICATIONS, FOG
LAMPS.
HEADLAMPS OVERVIEW
NOTE: In the exploded view illustration, the adjusting motors of the two headlamp
manufacturers are depicted, since the removal and installation of them differ.
Fig. 6: Identifying Assembly Overview: Headlamps

1. Left Headlamp Beam Adjustment Motor -V48- and Right Headlamp Beam Adjustment Motor -V49-
 Headlamp manufacturer: Hella.

 Removing and installing, refer to HELLA HEADLAMP RANGE CONTROL POSITIONING
MOTOR.
2. Clamping Ring
 Headlamp manufacturer: Valeo.
 Removing and installing, refer to VALEO HEADLAMP RANGE CONTROL POSITIONING

MOTOR.
4. Clamping Ring
5. Body Cross Section
6. Cap
7. Left High Beam Headlamp -M30- and Right High Beam Headlamp -M32-
 Bulb H7 12V, 55 W
 Replacing, headlamp manufacturer: Hella, refer to HELLA HIGH BEAM BULB.
8. Screws
 2 Nm
9. Screws
 8 Nm
10. Adjustment Bushings

 Correcting installation position of headlamp, refer to HEADLAMPS, CORRECTING
INSTALLATION POSITION.
11. Headlamp
 Removing and installing, refer to HEADLAMPS.

 Servicing headlamp securing straps, refer to HEADLAMP MOUNTING TABS, SERVICING.
12. Left Parking Lamp -M1- and Right Parking Lamp -M3-
 USA and Canada equipment: Bulb 12V, WY 5 W.
 Replacing, headlamp manufacturer: Hella, refer to HELLA PARKING LAMP BULB.
 Replacing, headlamp manufacturer: Valeo, refer to VALEO PARKING LAMP BULB.
13. Cap
14. Left Low Beam Headlamp -M29- and Right Low Beam Headlamp -M31-
 Bulb H7 12V, 55 W.
 Replacing, headlamp manufacturer: Hella, refer to HELLA LOW BEAM BULB.
 Replacing, headlamp manufacturer: Valeo, refer to VALEO LOW BEAM BULB.
15. Cap
HID HEADLAMPS WITH CORNERING LAMP OVERVIEW

NOTE: After performing work which can affect headlamp adjustment, check headlamp
adjustment and adjust headlamps if necessary. Refer to the relevant
Maintenance Interval under 03 MAINTENANCE, DIAGNOSIS .
Fig. 7: Identifying Assembly Overview: Main Headlamps With HID Lamps And Cornering Lamps
1. Cap
2. Left Cornering Lamp -L148- or Right Cornering Lamp -L149-
 Bulb H7 12V, 55 W.
 Replacing, refer to HID CORNERING LAMP BULB.
 Checking, refer to HEADLAMP RANGE/CORNERING LAMP CONTROL MODULE -J745-

OUTPUT DIAGNOSTIC TEST MODE.

3. Left Parking Lamp -M1- and Right Parking Lamp -M3-
 Lamp 12V, BLUE W 5 W.
 Replacing, refer to HID PARKING LAMP BULB.
 Checking, refer to VEHICLE ELECTRICAL SYSTEM CONTROL MODULE -J519-

OUTPUT DIAGNOSTIC TEST MODE .
4. Screws
 2 Nm
5. Headlamp
 Removing and installing, refer to HEADLAMPS

 Perform a basic setting. Refer to the relevant Maintenance Interval under 03 MAINTENANCE,
DIAGNOSIS .
6. Screws
 8 Nm
7. Adjustment Bushings
8. Clamping Ring
9. Screws
10. Left High-intensity Gas Discharge Lamp Control Module -J343- and Right High-intensity Gas Discharge
Lamp Control Module -J344-
 Removing and installing, refer to HID HEADLAMP CONTROL MODULE.
11. Wire For Gas-Discharge Lamp

12. High intensity gas discharge lamp -L13- and High intensity discharge lamp -L14- (Bi-Xenon)
 Type D1S, 35 W.
 Replacing, refer to HID BULB.
 Checking, refer to VEHICLE ELECTRICAL SYSTEM CONTROL MODULE -J519-

 Removing and installing, refer to HID HEADLAMP RANGE CONTROL POSITIONING
MOTOR.
 Checking, refer to HEADLAMP RANGE/CORNERING LAMP CONTROL MODULE -J745-
14. Cap
15. Gasket
16. Left Headlamp Power Output Stage -J667- or Right Headlamp Power Output Stage -J668-
 Removing and installing, refer to HID HEADLAMP POWER OUTPUT STAGES.
NOTE: After installing a new headlamp power output stage, Headlamp

Range/Cornering Lamp Control Module -J745- must be coded, refer
to HEADLAMP RANGE/CORNERING LAMP CONTROL MODULE -
J745-, CODING and then basic headlamp setting performed. Refer to
the relevant Maintenance Interval under 03 MAINTENANCE,
DIAGNOSIS .
17. Screws
18. Body Cross Section
19. Headlamp Range/Cornering Lamp Control Module -J745-
 Removing and installing, refer to HID HEADLAMP RANGE/CORNERING LAMP
CONTROL MODULE -J745-.
 Coding, refer to HEADLAMP RANGE/CORNERING LAMP CONTROL MODULE -J745-,
CODING.
 Output Diagnostic Test Mode (DTM), refer to HEADLAMP RANGE/CORNERING LAMP
CONTROL MODULE -J745- OUTPUT DIAGNOSTIC TEST MODE.
 Adapting, refer to HEADLAMP RANGE/CORNERING LAMP CONTROL MODULE,
ADAPTING.
NOTE: If Headlamp Range/Cornering Lamp Control Module -J745- is coded,

headlamp basic setting must then be performed. Refer to the relevant
Maintenance Interval under 03 MAINTENANCE, DIAGNOSIS .
HID LEVEL CONTROL SYSTEM SENSOR
A vehicle level sensor is located at the front axle (Left Front Level Control System Sensor -G78-) and (Left
Rear Level Control System Sensor -G76-) is located at rear axle.
The vehicle level sensors are a component of automatic headlamp range control.
Level control system sensors transmit vehicle inclination in the form of a Pulse-Width Modulated (PWM)
signal to the Headlamp Range/Cornering Lamp Control Module -J745-.
In order to generate this PWM signal, voltage is supplied from the left rear level control system sensor via two
positive wires and one ground wire. Voltage is supplied to the left front level control system sensor via one
positive wire and two ground wires.
Removing and Installing Level Control System Sensor:
Removing and installing Left Front Level Control System Sensor, refer to Removal and Installation .
Removing and installing Left Rear Level Control System Sensor, refer to Removal and Installation .
NOTE: If the Vehicle Level Sensors are replaced, basic setting of headlamps must be
performed. Refer to the relevant Maintenance Interval under 03 MAINTENANCE,

DIAGNOSIS . .
PARKING AID
In the Passat, an 8-channel parking aid system is installed with 4 ultrasonic sensors (parking aid sensors) in rear
bumper and 4 ultrasonic sensors in front bumper and radiator protective grille.
The parking aid system monitors the vehicle periphery via ultrasonic sensors in the front and rear bumpers. The
acoustic distance indicator sounds via two warning buzzers in the passenger compartment.
Should a trailer be used (that is compatible with the factory-installed trailer wiring), the rear parking aid sensors
are disabled. The front sensors remain active.
The 8-channel parking aid system consists of:
 Parking Aid Control Module -J446-

 Left Front Parking Aid Sensor -G255-
 Left Front Center Parking Aid Sensor -G254-
 Right Front Center Parking Aid Sensor -G253-
 Right Front Parking Aid Sensor -G252-
 Left Rear Parking Aid Sensor -G203-
 Left Rear Center Parking Aid Sensor -G204-
 Right Rear Center Parking Aid Sensor -G205-
 Right Rear Parking Aid Sensor -G206-
 Front Parking Aid Warning Buzzer -H22-
 Rear Parking Aid Warning Buzzer -H15-
 Parking Aid Button -E266-
 Parking Aid Switch Illumination -L117-
Function:
After switching on the ignition, a system self test (that lasts less that a second) is performed. The control
module is now permanently operating, distance acquisition is activated.
When the parking aid system is ready, a short signal is sounded and the function light lights up. If a malfunction
is detected in the system, a constant signal sounds for 5 seconds and the function lamp for parking aid system
blinks.
During the distance measurement, the pauses between chime impulses get shorter as the gap between vehicles
gets smaller. At proximity of less than 30 cm, a continuous tone is heard. Exception: Driving along a wall = no
warning.
Parking Aid Control Module -J446- is equipped with On Board Diagnostics (OBD) which assists
troubleshooting.
PARKING AID CONTROL MODULE -J446- OUTPUT DIAGNOSTIC TEST MODE.
Perform output Diagnostic Test Mode (DTM) to test the parking aid system, refer to PARKING AID
CONTROL MODULE -J446- OUTPUT DIAGNOSTIC TEST MODE.
PARKING AID OVERVIEW

Fig. 8: Identifying Assembly Overview: Parking Aid System

1. Parking Aid Sensor In Rear Bumper Cover

 Left Rear Parking Aid Sensor -G203- in rear bumper cover
 Left Rear Center Parking Aid Sensor -G204- in rear bumper cover
 Right Rear Center Parking Aid Sensor -G205- in rear bumper cover
 Right Rear Parking Aid Sensor -G206- in rear bumper cover
 Removing and installing (Sedan), refer to REAR PARKING AID SENSORS.
 Removing and installing (Wagon), refer to .
 Bonding the sensor bracket in the event of repairs, refer to SENSOR BRACKET FOR
PARKING AID AND PARALLEL PARKING ASSISTANCE, BONDING.
2. Rear Parking Aid Warning Buzzer -H15-

 Removing and installing (Sedan), refer to REAR PARKING AID WARNING BUZZER -H15-.
 Removing and installing (Wagon), refer to .
 Checking, refer to PARKING AID CONTROL MODULE -J446- OUTPUT DIAGNOSTIC

TEST MODE.
3. Parking Aid Button -E266-
 In center console next to gear selector lever.
 Removing and installing, refer to PARKING AID BUTTON -E266-.
4. Front Parking Aid Warning Buzzer -H22-

 Removing and installing, refer to FRONT PARKING AID WARNING BUZZER H22 WITH
PARKING AID.
 Checking, refer to PARKING AID CONTROL MODULE -J446- OUTPUT DIAGNOSTIC
TEST MODE.
5. Parking Aid Sensor In Front Bumper Cover And Radiator Protective Grille
 Left Front Center Parking Aid Sensor -G254- (in radiator protective grille)
 Right Front Center Parking Aid Sensor -G253- (in radiator protective grille)
 Removing and installing, refer to FRONT PARKING AID SENSORS.
 Bonding the sensor bracket in the event of repairs, refer to SENSOR BRACKET FOR
6. Parking Aid Control Module -J446-
 Behind the right side trim panel inside the luggage compartment, from 04.2008.
 Driver side above the fuse box, from 05.2008.
 Removing and installing, refer to PARKING AID AND PARALLEL PARKING ASSISTANCE
CONTROL MODULE J446, THROUGH 05.08.
 Output Diagnostic Test Mode (DTM), refer to PARKING AID CONTROL MODULE -J446-
PARALLEL PARKING ASSISTANCE
WARNING:  The driver is responsible for parking the vehicle.

 The parallel parking assistance does not replace the attention of the
driver.
 The sensors have dead zones, whereby it cannot recognize people
or other objects.
 Pay special attention for small children or animals, because the
sensors do not recognize these in every case.
NOTE: Familiarity with the function and operation of the parallel parking assistance is
essential when addressing complaints.
For additional information, refer to Operating instructions.
The parallel parking assistance assists the driver when backing up to parallel park in a spot on the driver or
passenger side. When parallel parking assistance is activated and the vehicle is moving forward less than 35
km/h, ultrasonic sensors scan for a suitable parking space. When a suitable parking space is found, the parallel
parking assistance directs the driver to drive past the space until the vehicle will be able to parallel park in one
movement. When reverse gear is engaged, the parallel parking assistance controls the EPS (electronic power
steering = electro-mechanical power steering) which steers the vehicle along a calculated route into the parking
space. During this time, the drive still controls the accelerator, clutch and brake pedals and determines the
vehicle parking speed. During the parking process, the parallel parking assistance sensors and the parking
distance sensors are used.
The parking process with the parallel parking assistance will be interrupted under the following conditions:
 The Parallel Parking Assistance Button -E581- switches off the parallel parking assistance.
 The ignition is switched off
 The parking speed is too high (> 7 km/h)
 The driver grabs the steering wheel during the parking process
 The vehicle is shifted out of reverse gear
 The time limit for the vehicle standing still is exceeded (approximately 30 seconds)
 The ESP is switched off or on
 The ASR is switched on
 The vehicle is towing a trailer
 The front parking aid is switched on
 The sensor recognize a condition, which would cause damage to the vehicle
 System malfunction
The parallel parking assistance system consists of:
 Parallel Parking Assistance Control Module -J791-

 Parallel Parking Assistance Button -E581-
 Left Front Parallel Parking Assistance Sensor (vehicle - left side) -G568-
 Right Front Parallel Parking Assistance Sensor -G569-

The parallel parking assistance system is equipped with On Board Diagnostic (OBD) capabilities which assists
in troubleshooting.
Use the Vehicle Diagnosis, Testing and Information System VAS5051B in the "Guided Fault Finding" mode
for fault finding.
Perform a Output Diagnostic Test to check the entire parallel parking assistance system.
PARALLEL PARKING ASSISTANCE OVERVIEW
Fig. 9: Identifying Parallel Parking Assistance Overview

1. Left Front Parallel Parking Assistance Sensor -G568-

 In front bumper cover.

 Removing and installing, refer to FRONT PARKING AID AND PARALLEL PARKING
ASSISTANCE SENSORS.
 Checking, refer to FRONT PARKING AID AND PARALLEL PARKING ASSISTANCE
SENSORS, CHECKING.
 Replace the sensor and the sensor holder during repair work, refer to SENSOR BRACKET FOR
2. Left Front Parking Aid Sensor -G255-
ASSISTANCE SENSORS.
SENSORS, CHECKING.
3. Left Front Center Parking Aid Sensor -G254-
 In the radiator grille.
ASSISTANCE SENSORS.
SENSORS, CHECKING.
4. Right Front Center Parking Aid Sensor -G253-
 In the radiator grille.
ASSISTANCE SENSORS.
SENSORS, CHECKING.
5. Right Front Parking Aid Sensor -G252-
ASSISTANCE SENSORS.
SENSORS, CHECKING
6. Right Front Parallel Parking Assistance Sensor -G569-

ASSISTANCE SENSORS.
SENSORS, CHECKING.
7. Front Parking Aid Warning Buzzer -H22-
 Inside the driver footwell, behind the relay carrier on the left side of the instrument panel.
 Removing and installing, refer to FRONT PARKING AID WARNING BUZZER H22 WITH
PARALLEL PARKING ASSISTANCE.
 Adapting the volume, refer to FRONT PARKING AID WARNING BUZZER VOLUME,
ADAPTING.
 Adapting the tone, refer to FRONT PARKING AID WARNING BUZZER TONE,
ADAPTING.
8. Front Parking Aid Button -E266-
 In the center console storage compartment in front of the selector lever.
 Removing and installing, refer to SWITCHES IN CENTER CONSOLE .
9. Parallel Parking Assistance Button -E581-

 In the center console storage compartment in front of the selector lever.
 Removing and installing, refer to PARALLEL PARKING ASSISTANCE BUTTON E581.
 Checking, refer to PARALLEL PARKING ASSISTANCE BUTTON, CHECKING.
10. Parallel Parking Assistance Control Module -J791-

 Driver footwell above the fuse box.
 Removing and installing, refer to PARKING AID AND PARALLEL PARKING ASSISTANCE
CONTROL MODULE J446, FROM 05.08.
 Coding, refer to PARALLEL PARKING ASSISTANCE CONTROL MODULE, CODING.
 Tightening specification mounting screws: 5 Nm.
REAR VIEW CAMERA SYSTEM OVERVIEW

Fig. 10: Identifying Rear View Camera System Overview

1. Radio/Navigation Display Control Module -J503-

 Component location: in center console, front.
2. Rear View Camera System Control Module -J772-

 Component location: in the luggage compartment behind the right trim panel.
 Removing and installing, refer to REARVIEW CAMERA SYSTEM CONTROL MODULE.
 Rear View Camera Control Module, Coding, refer to REARVIEW CAMERA CONTROL
MODULE, CODING.
3. Rear View Camera -R189-
 Component location: in the rear lid handle.

 Removing and installing, refer to REAR VIEW CAMERA, REMOVING FROM HANDLE.
 Tightening specification for the nuts: 6 Nm.
 Rear View Camera System, Calibrating, refer to REAR VIEW CAMERA SYSTEM,
CALIBRATING.
4. Steering Angle Sensor -G85-
 Component location: in the steering column switch trim, behind the steering wheel.
 Removing and installing, refer to STEERING ANGLE SENSOR SEGMENT SENSOR,

THROUGH 10.09.
STEERING COLUMN SWITCH OVERVIEW, THROUGH 10.09

Fig. 11: Identifying Assembly Overview: Steering Column Switch

1. 1 - Steering Column Combination Switch -E595-

 The individual switches of the Steering Column Combination Switch are combined into one unit
and cannot be disassembled further.
 Checking via output Diagnostic Test Mode (DTM), refer to STEERING COLUMN
ELECTRONIC SYSTEMS CONTROL MODULE J527 OUTPUT DIAGNOSTIC TEST
MODE, THROUGH 10.09.
2. 2 - Windshield Wiper Switch
 Structural component of Steering Column Combination Switch -E595-, refer to STEERING
COLUMN COMBINATION SWITCH -E595-, THROUGH 10.09.
3. 3 - Airbag Spiral Spring/Return Spring With Slip Ring -F138-
 Removing and installing, refer to AIRBAG SPIRAL SPRING/RETURN SPRING WITH SLIP
RING F138, THROUGH 10.09.
4. 4 - Segment Sensor For Steering Angle Sensor
 Removing and installing, refer to STEERING ANGLE SENSOR SEGMENT SENSOR,
THROUGH 10.09.
5. 5 - Cruise Control Switch -E45-
6. 6 - Steering Column Electronic Systems Control Module -J527-
 Removing and installing, refer to STEERING COLUMN ELECTRONIC SYSTEMS
CONTROL MODULE J527, THROUGH 10.09.
 Coding, refer to STEERING COLUMN ELECTRONIC SYSTEMS CONTROL MODULE
J527, CODING, THROUGH 10.09.
 Output Diagnostic Test Mode (DTM), refer to STEERING COLUMN ELECTRONIC
SYSTEMS CONTROL MODULE J527 OUTPUT DIAGNOSTIC TEST MODE, THROUGH
10.09.
7. 7 - Mounting Bolt (T7)
8. 8 - Turn Signal Switch -E2-
STEERING COLUMN SWITCH OVERVIEW, FROM 11.09
NOTE: There are different versions of the Steering Column Electronic Systems Control
Module -J527-, the Steering Column Combination Switch -E595- and the
steering column switch base carrier depending on the manufacturer (Valeo or
Kostal). The Valeo version is shown in the illustration.
Fig. 12: Identifying Steering Column Switch Overview, From 11.09

1. 1 - Steering Column Electronic Systems Control Module -J527-

 Pay attention to the removing/installing sequence. Refer to STEERING COLUMN SWITCH
COMPONENTS, REMOVAL AND INSTALLATION SEQUENCE, FROM 11.09.
 Removing and Installing, Valeo, refer to STEERING COLUMN ELECTRONIC SYSTEMS

CONTROL MODULE J527, VALEO, FROM 11.09.
 Removing and Installing, Kostal, refer to STEERING COLUMN ELECTRONIC SYSTEMS
CONTROL MODULE J527, KOSTAL, FROM 11.09.
 Coding, refer to STEERING COLUMN ELECTRONIC SYSTEMS CONTROL MODULE
J527, CODING, FROM 11.09.
2. 2 - Steering Column Combination Switch -E595-
 Pay attention to the removing/installing sequence. Refer to STEERING COLUMN SWITCH
COMPONENTS, REMOVAL AND INSTALLATION SEQUENCE, FROM 11.09.
 Removing and Installing, Valeo, refer to STEERING COLUMN COMBINATION SWITCH
E595, VALEO, FROM 11.09.
 Removing and Installing, Kostal, refer to STEERING COLUMN COMBINATION SWITCH,
KOSTAL E595, FROM 11.09.
3. 3 - Screws
TAIL LAMPS IN SIDE PANEL OVERVIEW

Fig. 13: Identifying Assembly Overview: Tail lamp Assembly In Side Panel
1. 1 - Threaded Pin At Tail Lamp In Side Panel

2. 2 - Nuts
 Tightening specification, refer to FASTENER TIGHTENING SPECIFICATIONS, TAIL
LAMP ASSEMBLY IN SIDE PANEL.
3. 3 - Tail lamps in side panel
 Removing and installing, refer to TAIL LAMPS IN SIDE PANEL.
 Checking, refer to TAIL LAMP ASSEMBLY IN SIDE PANEL, CHECKING.
4. 4 - Connector For Tail Lamp Assembly In Side Panel

REAR LID TAIL LAMPS OVERVIEW
Fig. 14: Identifying Assembly Overview: Taillight Assembly In Luggage Compartment Lid
1. 1 - Threaded Pin On Tail Lamp Assembly Housing

2. 2 - Nuts
 Tightening specification, refer to FASTENER TIGHTENING SPECIFICATIONS, TAIL
LAMP ASSEMBLY IN REAR LID.
3. 3 - Connector For Tail Lamp Assembly In Rear Lid
4. 4 - Bulb Holder
 Removing and installing, refer to REAR LID TAIL LAMP BULB HOLDER.
5. 5 - Left Rear Fog Light -L46- and Right Back-Up Lamp -M17-
 12V, P 21 W.
 Checking, refer to TAIL LAMP ASSEMBLY IN REAR LID, CHECKING.
6. 6 - Tail Lamp Housing

 Removing and installing, refer to REAR LID TAIL LAMPS.
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS, HEADLAMPS

Left Lower Headlamp 8 Nm
Right Lower Headlamp 8 Nm
Top Headlamp 2 Nm
FASTENER TIGHTENING SPECIFICATIONS, FOG LAMPS

Fog Lamp Screws 1.5 Nm
FASTENER TIGHTENING SPECIFICATIONS, TAIL LAMP ASSEMBLY IN SIDE PANEL

Hex Head Collar Nut 3 Nm
FASTENER TIGHTENING SPECIFICATIONS, TAIL LAMP ASSEMBLY IN REAR LID

Hex Head Collar Nut 3 Nm
FASTENER TIGHTENING SPECIFICATIONS, STEERING COLUMN SWITCH ASSEMBLY

Torx Bolts For Steering Column Switch Unit To
10 Nm
Steering Column
HEADLAMPS, CORRECTING INSTALLATION POSITION

NOTE: Illustrations depict left headlamp.
Correcting the installation position of the left headlamp and the right headlamp
is performed analogously.
When checking installation position of headlamp, determine that headlamp has no uneven gap dimensions to
body, otherwise installation position must be corrected.
(ignition off).
-- Remove radiator grille. Refer to Removal and Installation .
-- Remove front bumper cover. Refer to Removal and Installation .
-- Loosen mounting bolts -arrows- at top of headlamp.
Fig. 15: Identifying Headlamp Mounting Bolts

-- Loosen mounting bolt -arrows- at bottom of headlamp.

Fig. 16: Identifying Headlamp Bottom Mounting Bolts

-- Adapt surface alignment to body by screwing in or screwing out adjustment bushing -arrow- at lower left of
headlamp or at lower right of headlamp.
Fig. 17: Identifying Adjustment Bushing At Lower Left Of Headlamp

-- Tighten all threaded connections to specified torques, refer to FASTENER TIGHTENING

SPECIFICATIONS, HEADLAMPS.
-- Check and if necessary correct installation position of headlamp again for uniform gap dimension.
-- Install front bumper cover. Refer to Removal and Installation .
-- Install radiator grille. Refer to Removal and Installation .
-- Check headlamp for function.
NOTE: If a headlamp is removed or adapted to the body, it must always be adjusted

after installing or after adapting.
-- Check headlamp adjustment and adjust headlamp if necessary. Refer to the relevant Maintenance Interval
under 03 MAINTENANCE, DIAGNOSIS .
HEADLAMP, ADJUSTING
Adjust the headlamp. Refer to the relevant Maintenance Interval under 03 MAINTENANCE, DIAGNOSIS .
HID HEADLAMPS
HEADLAMP, ADJUSTING
-- Adjusting headlamp with gas-discharge lamps. Refer to the relevant Maintenance Interval under 03
MAINTENANCE, DIAGNOSIS .
HEADLAMP POWER OUTPUT STAGES, CODING
NOTE: Be careful not to mix up the old headlamp housing through part index 3C0 941
753 K or 754 with the power output stage 7L6 941 329 A.
Be careful not to mix up the new headlamp housing from part index 3C0 941 753
K or 754 K with power output stage 7L6 941 329 or 330.
Interchanging the parts during installation will result in an incorrect diagnosis

when performing Fault Finding.
NOTE: After installing a new headlamp power output stage, Headlamp

Range/Cornering Lamp Control Module -J745- must be coded and then basic
headlamp setting performed.
-- Code Headlamp Range/Cornering Lamp Control Module, refer to HEADLAMP RANGE/CORNERING

LAMP CONTROL MODULE -J745-, CODING.
-- Perform basic setting of headlamps. Refer to the relevant Maintenance Interval under 03 MAINTENANCE,
DIAGNOSIS . .
HEADLAMP RANGE/CORNERING LAMP CONTROL MODULE -J745-, CODING

 Vehicle Diagnosis, Testing and Information System VAS 5051B
-- Connect the VAS 5051B.
-- On the VAS 5051B, select "Guided Fault Finding".
sequence:
 Body
 01 - OBD capable systems
 Automatic headlamp range control cornering light
 Automatic headlamp range control functions
 AFS light control module, coding
NOTE: If Headlamp Range/Cornering Lamp Control Module is coded, basic setting of

headlamps must be performed after coding. Refer to the relevant Maintenance
Interval under 03 MAINTENANCE, DIAGNOSIS .
HEADLAMP RANGE/CORNERING LAMP CONTROL MODULE -J745- OUTPUT DIAGNOSTIC TEST MODE
The following components and functions can be checked via output Diagnostic Test Mode (DTM) of Comfort
System Central Control Module -J393-:
 Left Headlamp Beam Adjustment Motor -V48- and Right Headlamp Beam Adjustment Motor -V49-
 Left Dynamic Cornering Light Motor -V318- or Right Dynamic Cornering Light Motor -V319-
 Left Cornering Lamp -L148- or Right Cornering Lamp -L149-
 Headlamp range control lamp in instrument cluster
 AFS (Adaptive Front lighting System) lamp in instrument cluster
NOTE: The indicator light "lamp failure" lights up in instrument cluster when headlamp
range control and AFS (Adaptive Front lighting System) system malfunctions
INSTRUMENT CLUSTER INDICATOR LAMPS => List Item:Lamp Failure Control
Lamp .

sequence:
 Body
 Automatic headlamp range control cornering light
 Automatic headlamp range control functions
 AFS Output Diagnostic Test Mode (DTM)
HEADLAMP RANGE/CORNERING LAMP CONTROL MODULE, ADAPTING
The Adapting control module for cornering light and automatic headlamp range control function was not
changed yet at the time this was edited.
DYNAMIC CORNERING LAMP MOTOR, CHECKING
Left Dynamic Cornering Light Motor -V318- and Right Dynamic Cornering Light Motor -V319- can be
checked using Headlamp Range/Cornering Lamp Control Module -J745- Output Diagnostic Test Mode (DTM),
refer to HEADLAMP RANGE/CORNERING LAMP CONTROL MODULE -J745- OUTPUT
DIAGNOSTIC TEST MODE.
LOW BEAM REFLECTOR MOTOR, CHECKING
Left Low Beam Reflector Motor -V294- and Right Low Beam Reflector Motor -V295- can be checked via
output Diagnostic Test Mode (DTM) of Vehicle Electrical System Control Module -J519-. Refer to VEHICLE
ELECTRICAL SYSTEM CONTROL MODULE -J519- OUTPUT DIAGNOSTIC TEST MODE .
HEADLAMP RANGE CONTROL POSITIONING MOTOR, CHECKING
Left Headlamp Beam Adjustment Motor -V48- and Right Headlamp Beam Adjustment Motor -V49- can be
checked using Headlamp Range/Cornering Lamp Control Module -J745- Output Diagnostic Test Mode (DTM).
Refer to HEADLAMP RANGE/CORNERING LAMP CONTROL MODULE -J745- OUTPUT
FOG LAMPS, CHECKING
Fog lights (Left Front Fog Lamp -L22- and Right Front Fog Lamp -L23-) can be checked via output Diagnostic
Test Mode (DTM) of Vehicle Electrical System Control Module -J519-. Refer to VEHICLE ELECTRICAL
SYSTEM CONTROL MODULE -J519- OUTPUT DIAGNOSTIC TEST MODE .
FOG LAMPS, ADJUSTING
Adjusting fog lamps. Refer to the relevant Maintenance Interval under 03 MAINTENANCE, DIAGNOSIS . .
FRONT TURN SIGNALS, CHECKING
The front turn signals (Left Front Turn Signal Lamp -M5- and Right Front Turn Signal Lamp -M7-) can be
checked via output Diagnostic Test Mode (DTM) of Vehicle Electrical System Control Module -J519-. Refer to
MODE .
MIRROR TURN SIGNAL LAMP, CHECKING
Driver Exterior Mirror Turn Signal Lamp -L131- can be checked via output Diagnostic Test Mode (DTM) of
Driver Door Control Module -J386-. Refer to DRIVER DOOR CONTROL MODULE -J386-, OUTPUT
DIAGNOSTIC TEST MODE .
Front Passenger Exterior Mirror Turn Signal Lamp -L132- can be checked via output Diagnostic Test Mode
(DTM) of Front Passenger Door Control Module -J387-. Refer to FRONT PASSENGER DOOR CONTROL
MODULE -J387-, OUTPUT DIAGNOSTIC TEST MODE .
ENTRY LIGHT IN OUTSIDE MIRROR, CHECKING
Driver Entry Lamp In Exterior Rearview Mirror -W52- can be checked via output Diagnostic Test Mode
(DTM) of Driver Door Control Module -J386-. Refer to DRIVER DOOR CONTROL MODULE -J386-,
Front Passenger Entry Lamp In Exterior Rearview Mirror -W53- can be checked via output Diagnostic Test
Mode (DTM) of Front Passenger Door Control Module -J387-. Refer to FRONT PASSENGER DOOR
CONTROL MODULE -J387-, OUTPUT DIAGNOSTIC TEST MODE .
TAIL LAMP ASSEMBLY IN REAR LID, CHECKING
Tail lamp in rear lid (Left Rear Fog Lamp -L46- and Right Back-Up Lamp -M17-) can be checked via output
Diagnostic Test Mode (DTM) of Vehicle Electrical System Control Module -J519-. Refer to VEHICLE
TAIL LAMP ASSEMBLY IN SIDE PANEL, CHECKING
Left Tail lamp -M4-, Right Tail lamp -M2-, Left Brake Lamp -M9-, Right Brake Lamp -M10-, Left Rear Turn
Signal Lamp -M6-, Right Rear Turn Signal Lamp -M8- function can be checked via output Diagnostic Test
Mode (DTM) of Vehicle Electrical System Control Module -J519-. Refer to VEHICLE ELECTRICAL
SYSTEM CONTROL MODULE -J519- OUTPUT DIAGNOSTIC TEST MODE .
LICENSE PLATE LAMP, CHECKING
License Plate Lamp can be checked via output Diagnostic Test Mode (DTM) of Vehicle Electrical System
Control Module -J519-. Refer to VEHICLE ELECTRICAL SYSTEM CONTROL MODULE -J519-
HIGH-MOUNT BRAKE LAMP -M25-, CHECKING

High-mount Brake Lamp can be checked via output Diagnostic Test Mode (DTM) of Vehicle Electrical System
Control Module -J519-. Refer to VEHICLE ELECTRICAL SYSTEM CONTROL MODULE -J519-
STEERING COLUMN ELECTRONIC SYSTEMS CONTROL MODULE J527, CODING, THROUGH 10.09
sequence:
 Body
 Steering wheel electronics
 Functions of steering wheel electronics
 Code Control Module for steering wheel electronics
STEERING COLUMN ELECTRONIC SYSTEMS CONTROL MODULE J527, CODING, FROM 11.09
sequence:
 Body
 Code Control Module for steering wheel electronics
STEERING COLUMN ELECTRONIC SYSTEMS CONTROL MODULE J527 OUTPUT DIAGNOSTIC TEST
MODE, THROUGH 10.09
sequence:
 Body
 Output Diagnostic Test Mode (DTM) of steering wheel electronics
STEERING COLUMN COMBINATION SWITCH -E595-, CHECKING, THROUGH 10.09
NOTE: If the steering column combination switch malfunctions, check the Steering
Column Electronic Systems Control Module -J527- coding using an output
diagnostic test. Refer to STEERING COLUMN ELECTRONIC SYSTEMS
CONTROL MODULE J527 OUTPUT DIAGNOSTIC TEST MODE, THROUGH 10.09.
PARKING AIDS
PARKING AID CONTROL MODULE -J446- OUTPUT DIAGNOSTIC TEST MODE
The following components can be checked via output Diagnostic Test Mode (DTM):

 Rear Parking Aid Warning Buzzer -H15-
 Parking Aid Indicator Lamp -K136-

sequence:
 Body
 Body repair procedures
 Parking Aid
 Parking assistance functions
 Parking Aid System Output Diagnostic Test Mode (DTM)
PARKING AID CONTROL MODULE -J446-, CODING
Via coding, the Parking Aid Control Module can be specifically adjusted to the demands of the vehicle at hand.
sequence:
 Body
 Parking Aid
 Parking assistance functions
 Coding parking aid system
PARALLEL PARKING ASSISTANCE CONTROL MODULE, CODING

sequence:
 Body
 Parallel Parking Assistance
 Parallel parking assistance functions
 Code the parallel parking assistance.
FRONT PARKING AID AND PARALLEL PARKING ASSISTANCE SENSORS, CHECKING
sequence:
 Body
 Parking assistance sensor, parallel parking assistance sensor
PARALLEL PARKING ASSISTANCE BUTTON, CHECKING

sequence:
 Body
 Parallel Parking Assistance Button
FRONT PARKING AID WARNING BUZZER VOLUME, ADAPTING
sequence:
 Body
 Front Parking Aid Warning Buzzer Volume, Adapting
FRONT PARKING AID WARNING BUZZER TONE, ADAPTING

sequence:
 Body
 Adapt the front parking aid warning buzzer tone.
REAR PARKING AID WARNING BUZZER VOLUME, ADAPTING
sequence:
 Body
 Rear Parking Aid Warning Buzzer Volume, Adapting
REAR PARKING AID WARNING BUZZER TONE, ADAPTING

sequence:
 Body
 Rear Parking Aid Warning Buzzer Tone, Adapting
REARVIEW CAMERA CONTROL MODULE, CODING
sequence:
 Body
 Electrical system
 01 - On Board Diagnostic capable system
 Rearview Camera System
 Functions rear view camera
 Control module, coding
REAR VIEW CAMERA PRELIMINARY CALIBRATION WORK
Vehicle must stand on a firm and level surface to perform the calibration. No persons may be in the vehicle
interior during the measurement. Vehicle must not be moved during the measurement, opening and closing of
vehicle doors is to be avoided.
Connect the VAS 5051B.

-- Bring the Steering Angle Sensor -G85- into 0-position (wheels straight ahead).
Overview Of The Assembled Measuring Device:
Fig. 18: Identifying Assembled Measuring Device Overview

1. Wheel Center Sensor VAS 6350/1

2. Wheel Center Sensor VAS 6350/1
3. Right-Side Angle Bracket For Mounting Measuring Unit For Distance Measurement
4. Line Laser VAS 6350/3
 Switching on and off, refer to operating instructions.
5. Plastic Foot
 Total of three on the under side of measuring device.
 Adjustable, for aligning horizontal position of measuring device.
6. Spacing Laser VAS 6350/2

 Notes on operation, refer to operating instructions.
7. Fluid Level On Measuring Device

 For checking horizontal position of measuring device.
8. Left-Side Angle Bracket For Mounting Measuring Unit For Distance Measurement
9. Calibration Tool For Lane Changing Assist VAS 6350/4
 Distance between the angled brackets on the calibration device (See items 3 or 8) and the paddles
on the rear wheel center wheel mounts: 1.2 m - 1.7 m -dimension A-.
-- Install the three wheel bolt adapters in the holes "112" for the wheel center sensors.
-- Mount the paddles on both wheel pick-ups and secure them with the lock nuts.
-- Mount the wheel pick-ups on the wheel bolts on the rear wheels. When doing this, the wheel pick-ups are
positioned by the O-rings in the adapters and held in place.
Fig. 19: Identifying Wheel Pick-Ups On Wheel Mounting Bolts At Rear Wheels
NOTE: Attach the wheel pick-ups onto wheels so that any installed anti-theft wheel
mounting bolts are not connected to the wheel bolt adapters.
-- Adjust paddle with aid of locking nuts so that they move freely just above the floor.
Make sure the paddles move easily.
-- Position the calibration device VAS 6350/4 behind the vehicle with a distance of 1.2 m to 1.7 m between the
angled brackets on the calibration device and the paddles at the rear wheel center wheel mounts as shown in the
overview illustration -dimension A-. See item 9.
-- Bring calibration tool for lane changing assist VAS 6350/4 to a horizontal position. To do so, twist plastic
feet under calibration device so that air bubble in spirit level is located exactly in the center of the indicator -
arrow-.
Fig. 20: Identifying Center Of The Indicator

-- Switch on the laser on the calibration device -1- and align the entire calibration device so that laser beam -2-
strikes the rear of the vehicle centered above the VW emblem.
Fig. 21: Identifying Calibration Device & Laser Beam

-- Switch on the Distance Laser VAS 6350/2 for distance measurement with the ON button. The following
display appears and laser switches itself on:
Fig. 22: Identifying Laser Display

-- Hold distance laser for distance measurement -2- flush into angle bracket on one side of calibration device as
shown in the illustration, distance laser must make contact firmly on angle bracket when doing this.
Fig. 23: Ensuring Laser Beam From Distance Laser VAS 6350/2 Hits Lower, Enlarged Part Of Paddle
-- Make sure that the laser beam from the distance laser for distance measurement contacts the paddle -1- at the
lower, enlarged part.
Fig. 24: Ensuring Laser Beam From Distance Laser VAS 6350/2 Hits Lower, Enlarged Part Of Paddle
If this is not the case, paddles must be corrected accordingly via clamping screws on the wheel pick-ups.
-- Hold the distance laser for distance measurement firmly by the hand in the angle bracket on the measuring
device while the laser beam can be seen on the paddle. Now press the ON button briefly for the distance
measurement. When doing this, the following display appears on screen:
Fig. 25: Identifying Display Readout

The distance measurement is specified on the display in "meters".
-- Note the value read off.
-- Repeat measuring procedure in the same manner for the other rear wheel on the other side of the calibration
device.
The distance value must be the same on both sides. If the value is not identical, align the calibration device only
as long until the values on both sides are identical.
When aligning the calibration device, make sure the distance laser beam still strikes the center above the VW
logo and indicator of fluid-level remains centered. If necessary, make further corrections accordingly.
The dimension for distance that was measured must be entered during calibration into the VAS 5051B or
Diagnostic Operation System VAS 5052 in millimeters.
Rear view camera system, calibrating, refer to REAR VIEW CAMERA SYSTEM, CALIBRATING.
REAR VIEW CAMERA SYSTEM, CALIBRATING
 Calibration Tool For Lane Changing Assist VAS 6350

 Vehicle Diagnostic, Testing and Information System VAS 5051B
After performing service work on the vehicle, it may be necessary to calibrate the rear view camera system
anew. In detail, this is the case after:
 Removing and installing rear view camera

 Replacing the control module for rear view camera system
 After repair work performed on rear lid following an accident
 After an axle alignment
 After performing a repair at front or rear axle
Extensive preparatory work must be completed before the appropriate calibrating procedure can be performed
using VAS 5051B or Vehicle Diagnosis And Service Information System VAS 5052. This is described in the
following.
NOTE: Observe the points regarding the preparation for calibrating. Refer to REAR
VIEW CAMERA PRELIMINARY CALIBRATION WORK.
-- In VAS 5051B, select operating mode "Guided Fault Finding".
sequence:
 Body
 Electrical system
 01 - On Board Diagnostic capable system
 Rearview Camera System
 Functions rear view camera
 Perform a rear view camber calibration
From here, you will be directed by the VAS 5051B or the Vehicle Diagnosis and Service Information System
VAS 5052 during the calibrating procedure.
ANTENNAE AND SENSORS FOR ACCESS/START AUTHORIZATION, CHECKING
The following access/start authorization antennas and sensors can be checked with the Vehicle Diagnosis,
Testing and Information System VAS 5051B.
 Driver Access/Start Authorization Antenna -R134-, refer to DRIVER ACCESS/START

AUTHORIZATION ANTENNA -R134-, CHECKING
 Front Passenger Access/Start Authorization Antenna -R135-, refer to FRONT PASSENGER
ACCESS/START AUTHORIZATION ANTENNA -R135-, CHECKING
 Access/Start Authorization Antenna (in rear bumper) -R136-, refer to ACCESS/START
AUTHORIZATION ANTENNA IN REAR BUMPER -R136-, CHECKING
 Luggage Compartment Access/Start Authorization Antenna -R137- , refer to LUGGAGE

COMPARTMENT ACCESS/START AUTHORIZATION ANTENNA -R137-, CHECKING
 Interior Access/Start Authorization Antenna 1 -R138- , refer to INTERIOR ACCESS/START
AUTHORIZATION ANTENNA 1 -R138-, CHECKING
 Interior Access/Start Authorization Antenna 2 -R139-, refer to INTERIOR ACCESS/START
 Interior Access/Start Authorization Antenna 3 -R154-, refer to INTERIOR ACCESS/START
 Driver Outside Door Handle Touch Sensor -G415-, refer to DRIVER OUTSIDE DOOR HANDLE
TOUCH SENSOR -G415-, CHECKING
 Front Passenger's Outside Door Handle Touch Sensor -G416-, refer to FRONT PASSENGER
OUTSIDE DOOR HANDLE TOUCH SENSOR -G416-, CHECKING
 Left Rear Outside Door Handle Touch Sensor -G417-, refer to LEFT REAR OUTSIDE DOOR
HANDLE TOUCH SENSOR -G417-, CHECKING
 Right Rear Outside Door handle Touch Sensor -G418-, refer to RIGHT REAR OUTSIDE DOOR
HANDLE TOUCH SENSOR -G418-, CHECKING
DRIVER ACCESS/START AUTHORIZATION ANTENNA -R134-, CHECKING
sequence:
 Body
 Comfort system
 Electrical components - access/start authorization
 R134 - Driver's Access/Start Authorization Antenna
FRONT PASSENGER ACCESS/START AUTHORIZATION ANTENNA -R135-, CHECKING

sequence:
 Body
 Comfort system
 R135 - Front Passenger's Access/Start Authorization Antenna
ACCESS/START AUTHORIZATION ANTENNA IN REAR BUMPER -R136-, CHECKING
sequence:
 Body
 Comfort system
 R136 - Access/Start Authorization Antenna (in rear bumper)
LUGGAGE COMPARTMENT ACCESS/START AUTHORIZATION ANTENNA -R137-, CHECKING
sequence:
 Body
 Comfort system
 R137 - Luggage Compartment Access/Start Authorization Antenna
INTERIOR ACCESS/START AUTHORIZATION ANTENNA 1 -R138-, CHECKING
sequence:
 Body
 Comfort system
 R138 - Interior Access/Start Authorization Antenna 1
sequence:
 Body
 Comfort system
sequence:
 Body
 Comfort system
DRIVER OUTSIDE DOOR HANDLE TOUCH SENSOR -G415-, CHECKING
sequence:
 Body
 Comfort system
 G415 - Driver's Outside Door Handle Touch Sensor
FRONT PASSENGER OUTSIDE DOOR HANDLE TOUCH SENSOR -G416-, CHECKING
sequence:
 Body
 Comfort system
 G416 - Front Passenger's Outside Door Handle Touch Sensor
LEFT REAR OUTSIDE DOOR HANDLE TOUCH SENSOR -G417-, CHECKING
sequence:
 Body
 Comfort system
 G417 - Left Rear Outside Door Handle Touch Sensor
RIGHT REAR OUTSIDE DOOR HANDLE TOUCH SENSOR -G418-, CHECKING

sequence:
 Body
 Comfort system
 G418 - Right Rear Outside Door handle Touch Sensor
ACKNOWLEDGMENT FOR UNLOCKING VIA ACCESS/START AUTHORIZATION
sequence:
 Body
 Comfort system
 Functions of central control module for comfort system
 Adapting acknowledgment for unlocking via access/start authorization
ADAPTING ACKNOWLEDGMENT FOR LOCKING VIA ACCESS/START AUTHORIZATION

sequence:
 Body
 Comfort system
 Functions of central control module for comfort system
 Adapting acknowledgment for locking via access/start authorization
ACCESS/START AUTHORIZATION ANTENNAS AND SENSORS
DRIVER OUTSIDE DOOR HANDLE
The following components are integrated in driver's side outside door handle:
 Driver Outside Door Handle Touch Sensor -G415-

 Left Access/Start Authorization Antenna -R134-
NOTE: The complete outer door handle must always be replaced if malfunctioning.
No coding, basic setting or adaptation is necessary when outside door handle

is replaced. Erase the DTC memory in "Guided Fault Finding" with the Vehicle
Diagnosis, Testing and Information System VAS5051B. Refer to DRIVER
ACCESS/START AUTHORIZATION ANTENNA -R134-, CHECKING or DRIVER
OUTSIDE DOOR HANDLE TOUCH SENSOR -G415-, CHECKING.
Removing:
(ignition off).
-- Remove left front outside door handle. Refer to Description and Operation .
Installing:
PASSENGER OUTSIDE DOOR HANDLE
The following components are integrated in passenger's side outside door handle:
 Front Passenger's Outside Door Handle Touch Sensor -G416-


is replaced. Erase the entry in the DTC memory in "Guided Fault Finding" with
the Vehicle Diagnosis, Testing and Information System VAS5051B. Refer to
FRONT PASSENGER ACCESS/START AUTHORIZATION ANTENNA -R135-,
CHECKING or FRONT PASSENGER OUTSIDE DOOR HANDLE TOUCH SENSOR
-G416-, CHECKING.
Removing:
(ignition off).
-- Remove right front outside door handle Description and Operation .
Installing:
LEFT REAR OUTSIDE DOOR HANDLE
The following components are integrated in left rear outside door handle:
 Left Access/Start Authorization Antenna -R134-

DRIVER ACCESS/START AUTHORIZATION ANTENNA -R134-, CHECKING.
Removing:
(ignition off).
-- Remove left rear outside door handle Description and Operation .
Installing:

RIGHT REAR OUTSIDE DOOR HANDLE
The following components are integrated in right rear outside door handle:

FRONT PASSENGER ACCESS/START AUTHORIZATION ANTENNA -R135-,
CHECKING.
Removing:
(ignition off).
-- Remove right rear outside door handle Description and Operation .
Installing:
REAR BUMPER ACCESS/START AUTHORIZATION ANTENNA R136
Component location of Access/Start Authorization Antenna In Rear Bumper is behind the rear bumper cover.
NOTE: No coding, basic setting or adaptation is necessary if Access/Start

Authorization Antenna In Rear Bumper is replaced. Erase the entry in the DTC
memory in "Guided Fault Finding" with the Vehicle Diagnosis, Testing and
Information System VAS5051B. Refer to ACCESS/START AUTHORIZATION
ANTENNA IN REAR BUMPER -R136- , CHECKING.
Removing:
(ignition off).
-- Remove rear bumper cover. Refer to Removal and Installation .
-- Disengage Access/Start Authorization Antenna In Rear Bumper -1- from lower section of bumper, paying
attention to lengths of connected wires.
Fig. 26: Identifying Access/Start Authorization Antenna (In Rear Bumper) R136 And Harness Connector
-- Disengage and disconnect harness connector -2- and remove Access/Start Authorization Antenna In Rear
Bumper -1- from vehicle.
Installing:
-- Connect harness connector -2- to the Access/Start Authorization Antenna In Rear Bumper -1- until it
engages.
Fig. 27: Identifying Access/Start Authorization Antenna (In Rear Bumper) R136 And Harness Connector
-- Insert Access/Start Authorization Antenna In Rear Bumper -1- first into mount in bumper base and then press
it into its end position until it engages.
INTERIOR ACCESS/START AUTHORIZATION ANTENNA 1 R138
Component location of Interior Access/Start Authorization Antenna 1 is beneath center console at front,
between front seats.
NOTE: No coding, basic setting or adaptation is necessary if Interior Access/Start

Authorization Antenna 1 is replaced. Erase the entry in the DTC memory in
"Guided Fault Finding" with the Vehicle Diagnosis, Testing and Information
System VAS5051B, refer to INTERIOR ACCESS/START AUTHORIZATION
ANTENNA 1 -R138-, CHECKING.
Removing:
NOTE: The alignment and exact position of the antennas are crucial for their function.
Before removing antennas in interior, mark their exact location and alignment
and secure them in this exact position and alignment during installation. The
thickness of the adhesive pad layer on antennas is an integral part of their
function. If an antenna's bond loosens, re-adhere it with commercially-available
adhesive. In this case, a new antenna must be installed with a new adhesive
pad. If this is not done, the KESSY system will malfunction.
(ignition off).
-- Remove center console. Refer to Removal and Installation .
NOTE: For reasons of clarity, vehicle floor carpet is not depicted in the illustration.
Fig. 28: Identifying Interior Access/Start Authorization Antenna 1 R138 And

Harness Connector
-- Disengage and disconnect harness connector -2- and remove adhesive of Interior Access/Start Authorization
Antenna 1 -1-.
-- Remove Interior Access/Start Authorization Antenna 1 -1- from vehicle.
Installing:
-- Insert harness connector -2- into Interior Access/Start Authorization Antenna 1 -1- until it engages.
-- Bond the Interior Access/Start Authorization Antenna 1 onto center console in the position and alignment
marked during removal.
ACCESS/START AUTHORIZATION ANTENNA 2 IN VEHICLE INTERIOR R139
Component location of Interior Access/Start Authorization Antenna 2 is on center console at rear, in front of
rear seat bench heel panel.

ANTENNA 2 -R139- , CHECKING.
(ignition off).
-- Remove rear seats. Refer to Removal and Installation .
-- Remove rear entry trim strips far enough so that vehicle carpet can be folded forward enough to gain access
to Interior Access/Start Authorization Antenna 2. Refer to Removal and Installation .
NOTE: The vehicle carpet and foam piece are not shown in illustration.
Fig. 29: Identifying Interior Access/Start Authorization Antenna 2 R139 And

Harness Connector
-- Disengage and disconnect harness connector -2- and remove adhesive of Interior Access/Start Authorization
Antenna 2 -1-.
-- Remove Interior Access/Start Authorization Antenna 2 -1- from vehicle.
Installing:
-- Insert harness connector -3- into Interior Access/Start Authorization Antenna 2 -2- until it engages.
Fig. 30: Identifying Interior Access/Start Authorization Antenna 2 R139, Harness Connector And Foam
Piece
-- Push Interior Access/Start Authorization Antenna 2 into foam piece -1-.
-- Align foam piece -1- together with antenna at wiring -2- on center console.
Fig. 31: Identifying Antenna At Wiring Aligned With Foam Pieces

-- Bond Interior Access/Start Authorization Antenna 2 onto center tunnel.
INTERIOR ACCESS/START AUTHORIZATION ANTENNA 3 R154
Component location of Interior Access/Start Authorization Antenna 3 is beneath rear shelf, in vicinity of rear
window roller shade.

ANTENNA 3 -R154- , CHECKING.
Removing:
No further information was available at time of publication.
LUGGAGE COMPARTMENT ACCESS/START AUTHORIZATION ANTENNA R137
Component location of Luggage Compartment Access/Start Authorization Antenna is in luggage compartment,

at center in front of spare wheel well.
NOTE: No coding, basic setting or adaptation is necessary if Luggage Compartment

Access/Start Authorization Antenna is replaced. Erase the entry in the DTC
memory in "Guided Fault Finding" with the Vehicle Diagnosis, Testing and
Information System VAS5051B, refer to LUGGAGE COMPARTMENT
ACCESS/START AUTHORIZATION ANTENNA -R137-, CHECKING.
Removing:
(ignition off).
-- Remove luggage compartment floor. Refer to Removal and Installation .
-- Disengage and disconnect harness connector -2- and remove adhesive of Luggage Compartment Access/Start
Authorization Antenna -1-.
Fig. 32: Identifying Luggage Compartment Access/Start Authorization Antenna R137 And Harness
Connector
-- Remove Luggage Compartment Access/Start Authorization Antenna -1- from vehicle.
Installing:
Fig. 33: Identifying Luggage Compartment Access/Start Authorization Antenna R137 And Harness
Connector
-- Before bonding, align antenna at both markings -arrows- on edge of spare wheel well.
-- Bond on the Luggage Compartment Access/Start Authorization Antenna within these markings so that lower
edge of antenna housing lies 4-5 mm above upper edge of spare wheel well edge.
-- Electronic ignition switch, removing and installing. Refer to ELECTRONIC IGNITION SWITCH -D9-
EXTERIOR MIRROR ENTRY LAMPS
Driver Entry Lamp In Exterior Rearview Mirror -W52- as well as Front Passenger Entry Lamp In Exterior
Rearview Mirror -W53- is installed in housing of left and right exterior mirror.
NOTE: Exterior mirror must not be disassembled to remove and install entry lamps
Removing and installing driver's side lamp and passenger's side lamp is
performed in the same manner on both sides and is only described for one side.
Removing:
(ignition off).
NOTE: During removal and installation, leave ignition key with remote control inside
the vehicle to prevent the doors from locking and possibly activating the
Coming Home/Leaving Home functions on its own.
-- Fold exterior mirror -1- in direction of arrow toward front.

Fig. 34: Identifying Folding Exterior Mirror Toward Front

-- Remove bolt -1-.
Fig. 35: Identifying Entry Lamp Bolt

-- Unclip entry light in direction of arrow from exterior mirror and pull it out while paying attention to lengths
of connected wires.
Fig. 36: Identifying Entry Light Unclipped From Exterior Mirror

-- Pull socket -2- in direction of arrow out of housing -1- of entry light.
Fig. 37: Identifying Direction To Pull Socket Out Of Housing Of Entry Light
Bulb, Replacing:
-- Pull plug-in socket lamp -1- in direction of arrow out of socket -2-.
Fig. 38: Identifying Direction To Pull Plug-In Socket Lamp Out Of Socket
Plug-in socket lamp: 12V, 6 W.
Installing:
NOTE: After installation, perform a function test of the exterior mirror.
EXTERIOR REARVIEW MIRROR TURN SIGNAL BULBS
Driver Exterior Rearview Mirror Turn Signal Bulb -L131- as well as Front Passenger Exterior Rearview Mirror
Turn Signal Bulb -L132- is installed in housing of left and right exterior mirror.
NOTE: In case of damage, the entire Driver Exterior Rearview Mirror Turn Signal Bulb
or the entire Front Passenger Exterior Rearview Mirror Turn Signal Bulb must
be replaced.
Removing:
(ignition off).
-- Remove the Driver Exterior Rearview Mirror Turn Signal Bulb or the Front Passenger Exterior Rearview
Mirror Turn Signal Bulb. Refer to Removal and Installation .
Installing:
-- Install Driver Exterior Rearview Mirror Turn Signal Bulb or Front Passenger Exterior Rearview Mirror Turn
Signal Bulb. Refer to Removal and Installation .
FOG LAMP
NOTE: Illustrations depict removal and installation of left fog lamp. Removal of right
fog lamp is performed in the same way.
Removing:
(ignition off).
-- Remove the mounting bolt -1- and unclip cover -2- at top -arrow- from bumper cover.
Fig. 39: Locating Mounting Bolt And Bumper Cover


Fig. 40: Identifying Fog Lamp Housing Screws

-- Pull fog lamp housing out of bumper while paying attention to the lengths of the connected wires.
-- Disengage and disconnect harness connector -arrow-.
Fig. 41: Identifying Fog Lamp Harness Connector

Installing:

-- Tighten the screws to the tightening specification. Refer to FASTENER TIGHTENING

SPECIFICATIONS, FOG LAMPS.
-- After completing assembly work, check function of fog lamp.
-- Check fog lamp adjustment and adjust if necessary. Refer to the relevant Maintenance Interval under 03
MAINTENANCE, DIAGNOSIS .
FOG LAMP BULBS
NOTE: The illustration shows the procedure for removing and installing the left fog
lamp.
Removing:
-- Remove fog lamp, refer to FOG LAMP.
-- Rotate lamp socket with fog light -1- in direction of arrow and remove it from fog light housing.
Fig. 42: Identifying Direction To Rotate/Remove Lamp Socket With Fog Light
The lamp for fog light is joined firmly to lamp socket and cannot be replaced separately.
Fog lamp bulb: H11 12V, 55 W.
Installing:

-- After completing assembly work, check function of headlamp.
-- Check fog light adjustment, refer to FOG LAMPS, CHECKING and adjust if necessary, refer to FOG
LAMPS, ADJUSTING.
FRONT TURN SIGNALS
NOTE: Illustrations depict removal and installation of left turn signal. Removal of right
turn signal is performed symmetrically in the same way.
Removing:
(ignition off).
-- Remove the mounting bolt -1- and unclip cover -2- at locking mechanism -arrow- from bumper cover.
Fig. 43: Locating Mounting Bolt And Bumper Cover

-- Remove mounting bolt -arrow- on underside of turn signal.

Fig. 44: Identifying Turn Signal Underside Mounting Bolt

-- Pull turn signal -1- out of bumper cover while paying attention to the lengths of the connected wires.
-- Disengage and disconnect harness connector -1- and remove turn signal -2- together with the clipped-on
protective strip.
Fig. 45: Identifying Turn Signal And Harness Connector

-- Using a suitable screwdriver, release locks -arrows- and remove clipped-on protective strip -2- from turn
signal -1-.
Fig. 46: Identifying Turn Signal, Locks And Clipped-On Protective Strip
Installing:
NOTE: When installing protective strip onto turn signal housing, make sure that all
retaining lugs engage correctly.
FRONT TURN SIGNAL BULBS
NOTE: The illustration depicts removal and installation of left turn signal.
Removing:
-- Remove front turn signal, refer to FRONT TURN SIGNALS.
-- Rotate lamp socket -1- in -direction of arrow- and remove it from turn signal housing -2-.
Fig. 47: Identifying Lamp Socket Rotated And Removed From Turn Signal Housing
-- Pull turn signal light bulb out of lamp socket.
Front turn signal bulb: 12V 21W.
Installing:
NOTE: Do not touch the glass of the light bulb, when installing. Your fingers will leave
traces of grease on the glass which, when the light is switched on, will
evaporate and cloud the glass.
HIGH-MOUNT BRAKE LAMP BULB -M25-
 Wedge T10039/1
 Torque Screwdriver V.A.G 1624
High-mount Brake Lamp Bulb is located at upper edge of rear window beneath molded headliner end strip.
NOTE: The high-mounted brake lamp contains LEDs.
The high-mounted brake lamp cannot be disassembled.
If damaged, the entire high-mounted brake lamp must be replaced.

Removing:
Fig. 48: Identifying High-Mount Brake Light M25, Headliner End Strip And Harness Connector
(ignition off).
-- Unclip headliner end strip -4- downward.
-- Carefully push high-mounted brake lamp -3- out of its retainer -1- in direction or arrow.
-- Disengage and disconnect harness connector -2-.
-- Remove high-mounted brake lamp from vehicle.
Installing:
Install in reverse order.
HEADLAMPS
HEADLAMPS
NOTE: It is not necessary to disconnect battery.

Illustrations depict removal and installation of left headlamp.
Replacement of left headlamp and right headlamp is performed analogously.
If one headlamp is removed, it must always be adjusted after installation. Refer

to the relevant Maintenance Interval under 03 MAINTENANCE, DIAGNOSIS .
Should an HID headlamp be removed, perform basic setting after installation.

Refer to the relevant Maintenance Interval under 03 MAINTENANCE,
DIAGNOSIS .
Removing
(ignition off).
-- Release and disconnect electrical connection -arrow-.
Fig. 49: Locating Electrical Connection

-- Remove radiator grille. Refer to Removal and Installation .

-- Remove mounting bolts -arrows- and remove guide profile -1-.
Fig. 50: Identifying Guide Profile And Bolts

-- Remove the mounting bolts -arrows- at top of headlamp.
Fig. 51: Identifying Headlamp Mounting Bolts

-- Remove the mounting bolts -arrows- at bottom of headlamp.

Fig. 52: Identifying Headlamp Bottom Mounting Bolts

-- Remove headlamp from body cutout.
Installing
-- Tighten all screws to their tightening specification. Refer to FASTENER TIGHTENING

SPECIFICATIONS, HEADLAMPS.
-- Check installation position of headlamp for uniform gap dimensions.
If headlamp has an uneven gap dimension to the body, installation position must be corrected, refer to
HEADLAMPS, CORRECTING INSTALLATION POSITION.
NOTE: If one headlamp is removed, it must always be adjusted after installation.
HELLA LOW BEAM BULB
NOTE: Left Low Beam Headlamp -M29- and Right Low Beam Headlamp -M31- can be
checked via output Diagnostic Test Mode (DTM) of Vehicle Electrical System
Removing:
(ignition off).
In order to remove the low beam bulb, it may be necessary to remove some
components in order to gain access.
Refer to the following tables as to which components are to be removed

depending on engine version, in order to replace the low beam headlamp.
Right
Replacing
Vehicles with Gasoline Engine Low
Left Low
Beam
Beam
Headlamp
Headlamp
Displacement Engine code Engine: -M31-,
-M29-
replacing
BLR 110 kW -1) (1) -1) (1)
BLX 110 kW -1) (1) -1) (1)
2.0L BVY 110 kW -1) (1) -1) (1)
AXX 147 kW -1) (1) -1) (1)
BPY 147 kW -1) (1) -1) (1)
3.6L BLV 206 kW -1) (1) -1) (1)
(1) No additional work required.
NOTE: Replacing the low beam headlamp bulb in a right headlamp is shown in the
following illustrations.
Replacing a left low beam headlamp bulb and a right low beam headlamp bulb
is identical.
-- Pull off cover cap -1-.

Fig. 53: Identifying Headlamp Back Cover

-- Remove the lamp socket with Low Beam Headlamp -1- in -direction of arrow- and take it out of headlamp as
far as wire lengths permit.
Fig. 54: Identifying Direction To Unscrew Lamp Socket And Low Beam Headlamp
-- Pull low beam headlamp bulb -2- out of lamp socket -1- in -direction of arrow-.
Fig. 55: Identifying Direction To Pull Low Beam Headlamp Bulb Out Of Lamp Socket
Installing:
NOTE: When installing cap, ensure proper seating. It is destroyed by entry of water
into headlamp.
Do not touch the glass of the light bulb, when installing. Your fingers will leave
-- Insert low beam headlamp bulb into lamp socket so that peg -1- of low beam headlamp bulb lies on the guide
-2- of lamp socket.
Fig. 56: Identifying Low Beam Headlamp Bulb, Lamp Peg And Lamp Socket Guide
-- Insert lamp socket with low beam headlamp bulb -1- into headlamp and rotate lamp socket with low beam
headlamp bulb in -direction of arrow-.
Fig. 57: Identifying Direction To Rotate Lamp Socket And Low Beam Headlamp Bulb
-- Reinstall cover cap.

HELLA HIGH BEAM BULB
NOTE: Left High Beam Headlamp -M30- and Right High Beam Headlamp -M32- can be
Removing:
(ignition off).
In order to be able to replace high beam headlamp, it is sometimes necessary to

remove neighboring components at the corresponding headlamp.
Refer to the following tables to determine additional component removal as

required, depending on engine.
Vehicles with Gasoline Engine

Engine Replacing Left High Beam Replacing Right High Beam
Displacement Engine:
code Headlamp -M30- Headlamp -M32-
2.0L BLR 110 kW -1) (1) -1) (1)
BLX 110 kW -1) (1) -1) (1)
BVY 110 kW -1) (1) -1) (1)
AXX 147 kW -1) (1) -1) (1)
BPY 147 kW -1) (1) -1) (1)
3.6L BLV 206 kW -1) (1) -1) (1)
NOTE: Replacing the high beam headlamp bulb in a right headlamp is shown in the
Replacing a left high beam headlamp bulb and a right high beam headlamp bulb
is identical.

Fig. 58: Identifying Headlamp Cover Cap

-- Remove the lamp socket with high beam headlamp -1- in -direction of arrow- and take it out of headlamp as
far as wire lengths permit.
Fig. 59: Identifying Direction To Unscrew Lamp Socket And High Beam Headlamp
-- Pull high beam headlamp bulb -2- out of lamp socket -1- in -direction of arrow-.
Fig. 60: Identifying Direction To Pull Low Beam Headlamp Bulb Out Of Lamp Socket
Installing:
into headlamp.
-- Insert high beam headlamp bulb into lamp socket so that peg -1- of high beam headlamp bulb lies on the
guide -2- of lamp socket.
Fig. 61: Identifying Low Beam Headlamp Bulb, Lamp Peg And Lamp Socket Guide
-- Insert lamp socket with high beam headlamp bulb -1- into headlamp and rotate lamp socket with high beam
headlamp bulb in -direction of arrow-.
Fig. 62: Identifying Direction To Turn High Beam Bulb To Secure In Headlamp Housing
-- Reinstall cover cap.

HELLA PARKING LAMP BULB
NOTE: Left Parking Lamp -M1- and Right Parking Lamp -M3- can be checked via output
Diagnostic Test Mode (DTM) of Vehicle Electrical System Control Module -J519-.
Removing:
(ignition off).
In order to remove the parking lamp bulb, it may be necessary to remove some


Engine Replacing Left Parking Lamp - Replacing Right Parking Lamp -
code M1- M3-
2.0L BLR 110 kW -1) (1) -1) (1)
BLX 110 kW -1) (1) -1) (1)
BVY 110 kW -1) (1) -1) (1)
AXX 147 kW -1) (1) -1) (1)
BPY 147 kW -1) (1) -1) (1)
3.6.0L BLV 206 kW -1) (1) -1) (1)
NOTE: Replacing the parking lamp bulb in a right headlamp is shown in the following
illustrations.
Replacing a left parking lamp bulb and a right parking lamp bulb is identical.

Fig. 63: Identifying Parking Lamp Cover Cap

-- Pull the lamp socket -1- with parking lamp out of reflector as far as the wire lengths permit.
Fig. 64: Locating Lamp Socket With Parking Lamp

-- Remove parking lamp -2- from lamp socket -1- in -direction of arrow-.
Fig. 65: Identifying Parking Light And Lamp Socket

Installing:
into headlamp.
VALEO LOW BEAM BULB
NOTE: Left Low Beam Headlamp -M29- and Right Low Beam Headlamp -M31- can be
Removing:
(ignition off).
In order to remove the low beam bulb, it may be necessary to remove some
Refer to the following tables as to which components are to be removed

depending on engine version, in order to replace the low beam headlamp.

Engine Replacing Left Low Beam Right Low Beam Headlamp -
code Headlamp -M29- M31-, replacing
2.0L BLR 110 kW -1) (1) -1) (1)
BLX 110 kW -1) (1) -1) (1)
BVY 110 kW -1) (1) -1) (1)
AXX 147 kW -1) (1) -1) (1)
BPY 147 kW -1) (1) -1) (1)
3.6.0L BLV 206 kW -1) (1) -1) (1)
NOTE: Replacing the low beam headlamp bulb in a right headlamp is shown in the
Replacing a left low beam headlamp bulb and a right low beam headlamp bulb
is identical.

Fig. 66: Identifying Low Beam Headlamp Cover Cap

NOTE: Low beam headlamp bulb -2- is clipped into the reflector -1-.
Fig. 67: Identifying Low Beam Headlamp Bulb -2-, Connector -3- And Reflector -
1-
When removing low beam headlamp bulb -2- , the connector -3- is not
disconnected first.
-- Push the connector and the bulb socket in -direction of arrow- until the bulb comes loose.
-- Pull low beam headlamp by the connector -3- out of the reflector.
-- Guide the low beam headlamp with the connector connected out of the headlamp housing.
-- Pull low beam headlamp -2- from the connector -1-.
Fig. 68: Identifying Direction To Pull Low Beam Headlamp From Harness Connector
Installing:
into headlamp.
-- Guide low beam headlamp into headlamp housing.
-- Push low beam headlamp into reflector to its installation position as depicted in the illustration.
Fig. 69: Identifying Low Beam Headlamp Pushed To Its Installation Position In Reflector
NOTE: Low beam headlamp must engage audibly.
-- Connect the connector -1- to the low beam headlamp bulb -2-.
Fig. 70: Identifying Bulb And Socket/Connection

VALEO HIGH BEAM BULB
NOTE: Left High Beam Headlamp -M30- and Right High Beam Headlamp -M32- can be
Removing:
(ignition off).
In order to be able to replace high beam headlamp, it is sometimes necessary to

remove neighboring components at the corresponding headlamp.


Engine Replacing Left High Beam Replacing Right High Beam
code Headlamp -M30- Headlamp -M32-
2.0L BLR 110 kW -1) (1) -1) (1)
BLX 110 kW -1) (1) -1) (1)
BVY 110 kW -1) (1) -1) (1)
AXX 147 kW -1) (1) -1) (1)
BPY 147 kW -1) (1) -1) (1)
3.6.0L BLV 206 kW -1) (1) -1) (1)
NOTE: Replacing the high beam headlamp bulb in a right headlamp is shown in the
Replacing a left high beam headlamp bulb and a right high beam headlamp bulb
is identical.

Fig. 71: Identifying Upper Starter Mounting Bolt Nut And Wire Retainer
NOTE: High beam headlamp bulb -2- is clipped into the reflector -1-.
Fig. 72: Identifying Direction To Push Harness Connector

When removing high beam headlamp bulb -2- , the connector -3- is not
disconnected first.
-- Push the connector and the bulb socket in -direction of arrow- until the bulb comes loose.
-- Pull the high beam headlamp bulb at the connector -3- out of the reflector.
-- Guide the high beam headlamp bulb with the connector connected out of the headlamp housing.
-- Pull the high beam headlamp bulb -2- off the connector -1-.
Installing:
into headlamp.
-- Guide high beam headlamp into headlamp housing.
-- Push high beam headlamp into reflector to its installation position as depicted in the illustration.
Fig. 74: Identifying High Beam Headlamp Pushed To Its Installation Position In Reflector
NOTE: High beam headlamp must engage audibly.
-- Connect the connector -2- to the high beam headlamp bulb -1-.
Fig. 75: Identifying Socket/Connection And Bulb

under 03 MAINTENANCE, DIAGNOSIS . .
VALEO PARKING LAMP BULB
NOTE: Left Parking Lamp -M1- and Right Parking Lamp -M3- can be checked via output
Diagnostic Test Mode (DTM) of Vehicle Electrical System Control Module -J519-.
Removing:
(ignition off).
In order to remove the parking lamp bulb, it may be necessary to remove some


Engine Replacing Left Parking Lamp - Replacing Right Parking Lamp -
code M1- M3-
2.0L BLR 110 kW -1) (1) -1) (1)
BLX 110 kW -1) (1) -1) (1)
BVY 110 kW -1) (1) -1) (1)
AXX 147 kW -1) (1) -1) (1)
BPY 147 kW -1) (1) -1) (1)
3.6.0L BLV 206 kW -1) (1) -1) (1)
NOTE: Replacing the parking lamp bulb in a right headlamp is shown in the following
illustrations.

Fig. 76: Identifying Parking Lamp Cover Cap

-- Pull the lamp socket -1- with parking lamp out of reflector as far as the wire lengths permit.
Fig. 77: Locating Lamp Socket

Fig. 78: Identifying Parking Light And Lamp Socket

Installing:
into headlamp.
HELLA HEADLAMP RANGE CONTROL POSITIONING MOTOR
NOTE: The following illustrations depict replacement of headlamp beam adjusting

motor at right headlamp.
Replacement of Left Headlamp Beam Adjustment Motor and of Right Headlamp

Beam Adjustment Motor is performed analogously.
Removing:
Fig. 79: Identifying Headlamp Back Cover

-- Rotate headlamp beam adjustment motor -1- in -direction of arrow- and remove it.
Fig. 80: Identifying Direction To Rotate And Remove Headlamp Beam Adjustment Motor
-- Disconnect the connector -2- on the headlamp range control positioning motor -1-.
Fig. 81: Locating Electrical Connection At Motor

Installing:
-- Carefully insert ball head of headlamp beam adjustment motor -1- into ball head guide -arrow-, pull reflector
toward rear while doing this.
Fig. 82: Identifying Ball Head Of Headlamp Beam Adjustment Motor, Ball Head Guide And Reflector
-- Now place adjustment motor into mount and rotate it approximately 30° clockwise until it engages.
into headlamp.
VALEO HEADLAMP RANGE CONTROL POSITIONING MOTOR
NOTE: The following illustrations depict replacement of headlamp beam adjustment

motor at left headlamp.
Replacement of headlamp beam adjustment motor at right headlamp is

performed analogously.
Removing:
-- Remove headlamp, refer to HEADLAMPS.
Fig. 83: Identifying Headlamp Housing, Cover Cap And Mounting Bolt
-- Remove mounting bolt -2- and remove housing -1- completely.
-- Pull out toothed gear -1- upward out of its installation opening.
Fig. 84: Identifying Toothed Gear

NOTE: When removing toothed gear, make sure that the small O-ring does not get lost.
Fig. 85: Identifying Direction To Remove Headlamp Beam Adjustment Motor

-- Disengage headlamp beam adjustment motor -1- by rotating in -direction of arrow B-.
-- Carefully push ball head of headlamp beam adjustment motor -arrow A- toward rear out of its guide.
-- Remove headlamp beam adjustment motor -1- upward out of its mount.
Installing:
-- Guide the headlamp beam adjustment motor -1- in the disengaged position completely into its mount.
Fig. 86: Identifying Headlamp Beam Adjustment Motor

-- Engage headlamp beam adjustment motor -1- by rotating in -direction of arrow B- until it stops.
Fig. 87: Identifying Headlamp Beam Adjustment Motor

-- First, carefully push ball head of headlamp beam adjustment motor -arrow A- toward rear.
-- Then, carefully pull ball head of headlamp beam adjustment motor in -direction of arrow- into mount -1-.
Fig. 88: Identifying Ball Head Of Headlamp Beam Adjustment Motor And Mount
NOTE: While doing this, pull reflector toward rear slightly to assist guiding the ball
head into the mount.
-- Reconnect connector -2- to headlamp beam adjustment motor.
-- Insert toothed gear -1- into its installation opening.

Fig. 89: Identifying Toothed Gear

-- Install housing -1- with mounting bolt -2- and put on the cover cap -3-.
Fig. 90: Identifying Headlamp Housing, Cover Cap And Mounting Bolt
into headlamp.
OUTER TOP MOUNTING TAB, REPAIRING

(ignition off).
-- Remove the remains of the headlamp mounting tab -1- as depicted.
Fig. 91: Identifying Remains Of Headlamp Mounting Tab

-- Insert the new mounting tab -2- into the mount -3- on the headlamp and secure the securing lug with
mounting bolt -1-.
Fig. 92: Identifying New Mounting Tab Inserted Into Mount On Headlamp And Secured Tab With
Mounting Bolt
-- Install headlamp, refer to HEADLAMPS.
INNER TOP MOUNTING TAB, REPAIRING
(ignition off).
-- Remove the remains of the headlamp mounting tab as depicted.

Fig. 93: Identifying Remains Of The Headlamp Mounting Tab

-- Insert the new mounting tab -2- into the mount -3- on the headlamp and secure the securing lug with
mounting bolt -1-.
Fig. 94: Identifying New Mounting Tab Inserted Into Mount On Headlamp And Secure Tab With
Mounting Bolt

SIDE MOUNTING TAB, REPAIRING
(ignition off).
Fig. 95: Identifying Headlamp Mounting Remains

-- Insert new mounting tab -2- into the mount -1- on the headlamp and secure the securing lug with mounting
bolt -3-.
Fig. 96: Identifying New Mounting Tab Inserted Into Mount On Headlamp And Secure The Tab With
Mounting Bolt
-- Install banjo fitting -1- in mounting tab -2-.
Fig. 97: Identifying Banjo Fitting And Mounting Tab


LOWER MOUNTING TAB, REPAIRING
(ignition off).
Fig. 98: Identifying Headlamp Mounting Remains

-- Insert new mounting tab -2- in mount -3- on the headlamp and secure the mounting tab with mounting bolt -
1-.
Fig. 99: Identifying New Mounting Tab Inserted Into Mount On Headlamp And Secured Tab With
Mounting Bolt
-- Install the banjo fitting -2- in the mounting tab -1-.
Fig. 100: Identifying Banjo Fitting And Mounting Tab


HID BULB
NOTE: Function of Left High Intensity Gas Discharge (HID) Lamp -L13- and Right High
Intensity Gas Discharge (HID) Lamp -L14- can be checked using Vehicle
Electrical System Control Module -J519- Output Diagnostic Test Mode (DTM).
Refer to VEHICLE ELECTRICAL SYSTEM CONTROL MODULE -J519- OUTPUT
Illustrations depict replacement of gas-discharge headlamp at right headlamp.
Replacement of Left High Intensity Gas Discharge (HID) Lamp and Right High
Intensity Gas Discharge (HID) Lamp is identical.
Removing:
WARNING:  There are pressures from 7 bar (cold) to 100 bar (hot) in the glass
portion of the HID bulb. The hot glass of the bulb can reach
temperatures of up to 700 degrees Celsius.
 The glass can explode and there is a danger of burning.
 When removing and installing HID bulbs, always wear safety glasses
and gloves.
(ignition off).
-- Press wire bracket -1- to the side in -direction of arrow-.

Fig. 101: Identifying Wire Bracket Pressed To The Side

-- Pull off cap -1- with headlamp power output stage -2- in -direction of arrow- from headlamp as far as wire
lengths permit.
Fig. 102: Identifying Cap Pulled Off With Headlamp Power Output Stage From Headlamp As Far As
Wire Lengths Permit
NOTE: Headlamp power output stage -2- must not be removed from cap -1-.
-- Disengage the harness connectors -arrows- and disconnect the connectors.

Fig. 103: Identifying Headlight Harness Connectors

-- Disconnect the connector -1- from the HID headlamp bulb -2-.
Fig. 104: Identifying HID Lamp And Harness Connector

-- Open the wire clip -1-.

Fig. 105: Identifying Wire Clamp And Gas-Discharge Lamp

-- Carefully pull HID bulb -2- out of socket.
Installing:
NOTE: Do not touch the glass of the HID bulb when installing. Your fingers will leave
traces of grease on the glass which will evaporate and cloud the glass when the
bulb is switched on.
Do not subject the HID bulb glass to any mechanical stress. Glass cone is
extremely sensitive and is also under high pressure.
Avoid looking directly into the light beam, since the UV-rays given off by the
gas-discharge lamp are approximately 2.5 times stronger than those of a
halogen bulb.
Make sure seal has proper seating when installing bracket with headlamp power
output stage. It is destroyed by entry of water into headlamp.
If a headlamp with automatic vertical headlamp aim control is removed, basic

setting of headlamps must always be performed after installation. Refer to the
relevant Maintenance Interval under 03 MAINTENANCE, DIAGNOSIS .
-- Insert new HID lamp so that retaining tabs lie in cut-outs in reflector.

HID PARKING LAMP BULB
NOTE: Function of Left Parking Lamp -M1- and Right Parking Lamp -M3- can be
checked using Output Diagnostic Test Mode (DTM) of Vehicle Electrical System
Control Module -J519- VEHICLE ELECTRICAL SYSTEM CONTROL MODULE -
J519- OUTPUT DIAGNOSTIC TEST MODE .
Replacing the parking lamp bulb in a right headlamp is shown in the following
illustrations.
Removing:
(ignition off).
-- Press wire brackets -1- and -2- to the side in -direction of arrow-.
Fig. 106: Identifying Wire Brackets Pressed To Side And Cover Cap Removed From Headlamp
-- Pull the grip piece -1- with parking lamp out of reflector as far as the wire lengths permit.
Fig. 107: Locating Grip Piece

Fig. 108: Identifying Parking Light Removed From Lamp Socket

Installing:

NOTE: When installing cover cap, check gasket for proper fitting. It is destroyed by
entry of water into headlamp.
HID CORNERING LAMP BULB
NOTE: Left Cornering Lamp -L148- and Right Cornering Lamp -L149- can be checked
using Headlamp Range/Cornering Lamp Control Module -J745- Output
Diagnostic Test Mode (DTM) HEADLAMP RANGE/CORNERING LAMP CONTROL
MODULE -J745- OUTPUT DIAGNOSTIC TEST MODE.
Replacing the cornering lamp bulb in a right headlamp is shown in the following
illustrations.
Replacing a left cornering lamp bulb and a right cornering lamp bulb is
identical.
Removing:
(ignition off).
-- Press wire brackets -1- and -2- to the side in -direction of arrow-.
Fig. 109: Identifying Wire Brackets Pressed To Side And Cover Cap Removed From Headlamp
-- Remove cover cap -3- from headlamp.
NOTE: The cornering light bulb -1- is clipped into the reflector -2-.
Fig. 110: Identifying Cornering Lamp, Reflector And Harness Connector

When removing cornering light bulb, connector -3- is not disconnected.
-- Press connector and the bulb socket in -direction of arrow- until bulb comes loose.
-- Pull cornering lamp out of reflector by grasping on the harness connector -3-.
-- Guide the cornering lamp bulb out of the headlamp housing with the connector still connected.
-- Remove the cornering lamp bulb -2- from the connector -1-.
Installing:
-- Guide cornering lamp into headlamp housing.
-- Push cornering lamp -1- into reflector to its installation position as depicted in the illustration.
Fig. 112: Identifying Cornering Lamp

NOTE: Cornering light bulb must engage audibly.
When installing cover cap, check gasket for proper fitting. It is destroyed by
-- Connect the cornering light bulb connector.
HID HEADLAMP RANGE CONTROL POSITIONING MOTOR
NOTE: The following illustrations depict replacement of headlamp beam adjusting

motor at right headlamp.
Replacement of Left Headlamp Beam Adjustment Motor and of Right Headlamp

Beam Adjustment Motor is identical.
Removing:
(ignition off).
-- Remove headlamp HEADLAMPS.
-- Press wire bracket -1- to the side in -direction of arrow-.
Fig. 113: Identifying Wire Bracket Pressed To The Side

-- Pull off cap -1- with headlamp power output stage -2- in -direction of arrow- from headlamp as far as wire
lengths permit.
Fig. 114: Identifying Cap Pulled Off With Headlamp Power Output Stage From Headlamp As Far As
Wire Lengths Permit

NOTE: Headlamp power output stage -2- must not be removed from cap -1-.
Fig. 115: Identifying Headlight Harness Connectors

-- Carefully pry adjustment screw -1- in -direction of arrow- out of headlamp housing.
Fig. 116: Identifying Adjustment Screw Pried Out Of Headlamp Housing

-- Disconnect the connector -2- on the headlamp range control positioning motor -1-.
Fig. 117: Identifying Connector -2- And Headlamp Range Control Positioning Motor -1
-- Rotate headlamp beam adjustment motor -1- in -direction of arrow- and remove it.
Installing:
-- Carefully insert ball head of headlamp beam adjustment motor -1- into ball head guide -2- , pull reflector
toward rear while doing this.
Fig. 118: Identifying Ball Head Of Headlamp Beam Adjustment Motor, Ball Head Guide And Reflector
-- Now place adjustment motor into mount and rotate it approximately 30° clockwise until it engages.
NOTE: When installing cover cap, check gasket for proper fitting. It is destroyed by
If a headlamp with automatic vertical headlamp aim control is removed, basic

setting of headlamps must always be performed after installation. Refer to the
relevant Maintenance Interval under 03 MAINTENANCE, DIAGNOSIS .
HID HEADLAMP POWER OUTPUT STAGES
NOTE: Illustrations depict replacement of headlamp power output stage at right

headlamp.
Replacement of Left Headlamp Power Output Stage -J667- and of Right

Headlamp Power Output Stage -J668- is identical.
NOTE: Be careful not to mix up the old headlamp housing through part index 3C0 941
753 K or 754 with the power output stage 7L6 941 329 A.
Be careful not to mix up the new headlamp housing from part index 3C0 941 753
K or 754 K with power output stage 7L6 941 329 or 330.
Interchanging the parts during installation will result in an incorrect diagnosis

when performing Fault Finding
Removing:
(ignition off).
-- Remove mounting bolts -arrows- of headlamp power output stage -1-.
Fig. 119: Identifying Mounting Bolts And Headlamp Power Output Stage

Fig. 120: Identifying Harness Connectors

-- Detach headlamp power output stage from headlamp.
Installing:
NOTE: When installing covers and headlamp power output stage, ensure seals are
seated correctly. It is destroyed by entry of water into headlamp.
After installing a new headlamp power output stage, Headlamp

Range/Cornering Lamp Control Module -J745- must be coded. Refer to
HEADLAMP RANGE/CORNERING LAMP CONTROL MODULE -J745-, CODING
and then basic headlamp setting. Refer to the relevant Maintenance Interval
HID HEADLAMP CONTROL MODULE
NOTE: Left High-intensity Gas Discharge Lamp Control Module -J343- and Right High-
intensity Gas Discharge Lamp Control Module -J344- is not capable of On Board
Diagnostic (OBD).
Illustrations depict replacement of High-intensity Gas Discharge Lamp Control

Module at right headlamp.
Replacement of Left High-intensity Gas Discharge Lamp Control Module and of

Right High-intensity Gas Discharge Lamp Control Module is identical.
Removing:
(ignition off).
-- Remove mounting bolts -arrows- and pull High-intensity Gas Discharge Lamp Control Module -1- as far
from headlamp as wire lengths allow.
Fig. 121: Identifying High-Intensity Gas Discharge Lamp Control Module And Bolts
-- Release the tab -arrow A- on the connector -1- and remove connector -1-.
Fig. 122: Identifying Retaining Bracket And Harness Connector

-- Release retainer -3- on connector -2- in -direction of arrow B- and remove connector -2-.
Installing:
CAUTION: Make sure seals have proper seating when installing High-intensity Gas
Discharge Lamp Control Module. It is destroyed by entry of water into

headlamp.
HID HEADLAMP RANGE/CORNERING LAMP CONTROL MODULE -J745-
-- Unlock the connector in -direction of arrow- and disconnect the connector -1- from the headlamp
range/cornering lamp control module -2-.
Fig. 123: Identifying Connector And Headlamp Range/Cornering Lamp Control Module J745
-- Remove the mounting bolts -arrows- and remove headlamp range/cornering lamp control module -1-.
Fig. 124: Locating Mounting Bolts And Headlamp Range/Cornering Lamp Control Module J745
Installing:
NOTE: After installing a new Headlamp Range/Cornering Lamp Control Module,

module must be coded, refer to HEADLAMP RANGE/CORNERING LAMP
CONTROL MODULE -J745-, CODING and then headlamp basic setting must be
performed. Refer to the relevant Maintenance Interval under 03 MAINTENANCE,
DIAGNOSIS .
HID LOW BEAM REFLECTOR MOTOR
Left Low Beam Reflector Motor -V294- and Right Low Beam Reflector Motor -V295- are located inside the
headlamp and cannot be replaced or adjusted separately.
LICENSE PLATE LAMP ATTACHED BY SCREWS
Removing:
(ignition off).
-- Remove mounting bolts -1- from License Plate Lamp -2-.
Fig. 125: Identifying License Plate Light And Bolts

-- Using a suitable screwdriver, carefully pry License Plate Lamp out of bumper cover at recess -arrow-.
Fig. 126: Identifying License Plate Light Harness Connector

-- Pry diffusion lens -1- out of license plate light housing -2- in direction of arrow using a suitable screwdriver.
Fig. 127: Identifying Diffusion Lens Pried Out Of License Plate Light Housing
NOTE: When prying out the diffusion lenses, make sure that the gasket between
diffusion lens and license plate light housing is not damaged.
License Plate Lamp: tubular bulb 12V, 5 W.
Installing:
When assembling license plate light, make sure that diffusion lens gasket has proper fit.
LICENSE PLATE LAMP ATTACHED BY CLIPS
Removing:
-- Switch off ignition, switch off all electrical consumers and remove ignition key.
-- Press the license plate lamp tab -arrow- and remove the lamp from the bumper cover.
Fig. 128: Identifying License Plate Lamp Tab And Bumper Cover
Fig. 129: Identifying Harness Connector

Installing:
NOTE: Install the license plate lamp into the bumper cover so that the connector faces
the left side of the vehicle.
-- Check the license plate lamp function.
BULB, LICENSE PLATE LAMP ATTACHED BY CLIPS
Removing:
-- Remove the license plate lamp. Refer to LICENSE PLATE LAMP ATTACHED BY CLIPS.
-- Turn the bulb socket in -direction of arrow- and pull it out of the license plate lamp.
Fig. 130: Identifying Bulb Socket

Bulb: 12V W5W.
Installing:
PARKING AIDS
FRONT PARKING AID SENSORS
Removal and installation of parking aid sensors in bumper and radiator protective grille is performed in the
same way.
Removing:
(ignition off).
-- Remove radiator protective grille. Refer to Description and Operation .
-- Remove front turn signal. Refer to FRONT TURN SIGNALS.
Fig. 131: Identifying Parking Aid Sensor, Retaining Lugs And Harness Connector
-- Press both retaining lugs -2- on sensor bracket outward and pull parking aid sensor -1- toward rear out of
sensor bracket.
NOTE: When removing sensor, make sure that the sensor de-coupling ring (black
silicone ring) does not remain in the sensor bracket.
Installing:
NOTE: When inserting sensor into sensor bracket, make sure that de-coupling ring
(black silicone ring) has proper fit on the sensor head.
Both sensor bracket retaining clips must engage audibly when installing
sensor.
REAR PARKING AID SENSORS
Removing:
(ignition off).
-- Remove rear bumper cover. Refer to Removal and Installation .
Removal of the rear parking aid sensors is performed in the same way as for the front parking aid sensors, refer
to FRONT PARKING AID SENSORS.
Installing:
NOTE: When inserting sensor into sensor bracket, make sure that de-coupling ring
(black silicone ring) has proper fit on the sensor head.
Both sensor bracket retaining clips must engage audibly when installing
sensor.
PARKING AID AND PARALLEL PARKING ASSISTANCE CONTROL MODULE J446, THROUGH 05.08
Parking Aid Control Module is located behind side panel trim in luggage compartment, right side.
Removing:
(ignition off).
-- Open cover of right side wall trim in luggage compartment.
NOTE: For clearer illustration, component location of Parking Aid Control Module is
depicted with the side trim panel removed.
-- Disengage and disconnect harness connectors -2-.

Fig. 132: Identifying Parking Aid Control Module J446 And Harness Connector
-- On both sides of Parking Aid Control Module depress locking tabs -arrows- and pull Parking Aid Control
Module -1- out of retainers.
Installing:
PARKING AID AND PARALLEL PARKING ASSISTANCE CONTROL MODULE J446, FROM 05.08
The parking aid control module is located above the fuse box on the driver side -arrow-.
Fig. 133: Identifying Parking Aid Control Module

-- Switch off the ignition and all electrical consumers and remove the key or move the ignition/starter switch to
the 0 position.
-- Remove the trim inside the footwell. Refer to Removal and Installation .
-- Disconnect the connectors.
-- Remove the control module from the retainer.
NOTE: The control module is shown in the illustration with the instrument panel
partially disassembled.
-- Loosen the expanding rivets, disconnect the connectors and remove the control module.
Installing:
FRONT PARKING AID WARNING BUZZER H22 WITH PARKING AID
The front parking aid warning buzzer is located under instrument panel in left footwell and is secured to the
relay carrier console.
Removing:
(ignition off).
-- Remove the cover under the instrument panel in the driver footwell. Refer to Removal and Installation .
-- Loosen both expanding rivets -arrows-.

Fig. 134: Identifying Front Parking Aid Warning Buzzer H22, Electrical Connection And Rivets
-- Disengage and disconnect harness connector -1- and remove front parking aid warning buzzer -2- from
vehicle.
Installing:
NOTE: If a new front parking aid warning buzzer is installed, it is not necessary to
perform coding, basic setting or adaptation.
FRONT PARKING AID WARNING BUZZER H22 WITH PARALLEL PARKING ASSISTANCE
The front parking aid warning buzzer is located in the footwell on the driver side behind the left instrument
panel relay carrier.
Removing:
-- Remove the left instrument panel relay carrier. Refer to FRONT PARKING AID WARNING BUZZER
H22 WITH PARKING AID.
-- Remove both rivet pins -arrows- and remove the front parking aid warning buzzer -1- while being careful of
connected lines.
Fig. 135: Identifying Rivet Pins And Front Parking Aid Warning Buzzer
-- Release and disconnect electrical connection -arrow- and remove front parking aid warning buzzer -H22- -1-
from vehicle.
Fig. 136: Identifying Front Parking Aid Warning Buzzer -H22- And Electrical Connection
Installing:

Rear Parking Aid Warning Buzzer is located below rear shelf at right.
Removing:
(ignition off).
-- Remove parcel shelf. Refer to Removal and Installation .
Fig. 137: Identifying Rear Parking Aid Warning Buzzer H15, Harness Connector And Rivets
-- Remove the expanding rivets -arrows- and remove rear parking aid warning buzzer -1- from the vehicle.
Installing:
NOTE: If a new rear parking aid warning buzzer is installed, it is not necessary to
perform coding, basic setting or adaptation.
PARKING AID BUTTON -E266-
The Parking Aid Button is located in center console next to gear selector lever.
-- Parking Aid Button, removing and installing, refer to SWITCHES IN CENTER CONSOLE .
FRONT PARKING AID AND PARALLEL PARKING ASSISTANCE SENSORS

The following 6 sensors are located in front bumper cover:
 Left Front Parallel Parking Assistance Sensor -G568-

 Right Front Parallel Parking Assistance Sensor -G569-
NOTE: Removing and installing the Front Parking Aid Sensor -- and the Parallel
Parking Assistance Sensor -- is performed in the same manner and the
following is described for one sensor.
Removing:
CAUTION: Always follow the sensor removal sequence.
Otherwise, the sensor may be damaged. Hairline cracks which lead to

sensor failure can develop if too much force is used on the sensor.
Remove the sensor from the bracket and then disconnect the sensor
connectors.
-- Release the retaining tabs -arrows- on the sensor bracket and remove the sensor -1- from the bumper cover
with the connector connected.
Fig. 138: Identifying Sensor And Retaining Tabs

NOTE: When removing the sensor, make sure that the coupling ring (black silicone
ring) remains on the sensor head and does not stick in the bracket or get lost.
Do not bend the coupling ring.
-- Unlatch and disconnect the harness connector -2- and remove the sensor -1-.
Fig. 139: Identifying Sensor And Harness Connector

Installing:
CAUTION: An incorrect or damaged coupling ring can lead to malfunctions.
Do not bend the coupling ring.
Replace damaged coupling rings and ensure the correct ring is installed.
NOTE: Since the lengths of the sensor heads of the front parking aid and the parallel
parking assistance sensors are different, the high coupling rings installed are
also different.
-- Make sure the correct coupling ring is installed on the sensor head.
Fig. 140: Identifying Coupling Ring Height Dimensions

Type of Sensor Height Dimension Coupling Ring -B-

Front Parking Aid Sensors -- 5.7 mm
Parallel Parking Assistance Sensor -- 9.05 mm
-- If necessary, replace the sensor coupling ring -1-.
NOTE: When installing the sensor, make sure the coupling ring is correctly mounted
on the sensor head and that it does not fall off or become jammed when
inserting into the sensor holder.
Both retaining clips on the sensor holder must engage audibly when installing
sensor.
-- Make sure the sensor is seated correctly in the bracket after installing. Dimension -a- for the circular gap
between the sensor head and bumper cover must be even all around on the outer side of the bumper cover.
Fig. 141: Identifying Dimension Of Decoupling Ring

PARALLEL PARKING ASSISTANCE BUTTON E581
The parallel parking assistance button is installed in the center console storage compartment in front of the
selector lever. It contains the Parallel Parking Assistance Indicator Lamp -K241- and cannot be disassembled
further.
The removing and installing of the parallel parking assistance button is performed in the same manner as for all
buttons in the center console storage compartment and is described in SWITCHES IN CENTER CONSOLE .
REAR VIEW CAMERA, REMOVING HANDLE FROM REAR LID
The rear view camera is installed in the handle button in the rear lid. To remove the rear view camera, the
handle must be removed from the rear lid first. Then the rear view camera can be removed from the handle.
Removing:
Remove the rear lid trim. Refer to Removal and Installation .
-- Open the wiring bracket for the rear view camera wiring harness in the connector area and remove both wires.
-- Release and disconnect both connectors -arrows-.
Fig. 142: Identifying Rear View Camera Wiring Harness Connectors

-- Remove both mounting nuts -arrows-.
Fig. 143: Identifying Rear View Camera Wiring Harness Mounting Nuts
Fig. 144: Identifying Rear View Camera Wiring Harness Connector

-- Remove both nuts -arrows- and the cover from the rear lid. Be careful of the connected wires.
Fig. 145: Identifying Rear Lid Cover Nuts

-- Release both side retaining tabs -arrows- and remove the handle with the rear view camera from the cover.
Fig. 146: Identifying Rear View Camera Side Retaining Tabs

Rear View Camera, removing from the rear lid handle, refer to REAR VIEW CAMERA, REMOVING
FROM HANDLE.
Installing:
-- Secure the rear view camera wires again with a cable clip to prevent rattling.
-- After installing, clean the rear view camera lens using a lint-free cloth.
-- Calibrate the system again, refer to REAR VIEW CAMERA SYSTEM, CALIBRATING.
REAR VIEW CAMERA, REMOVING FROM HANDLE
The rear view camera is installed in the handle button in the rear lid. To remove the rear view camera, the
handle must be removed from the rear lid first. Then the rear view camera can be removed from the handle.
Removing:
-- Release the retaining tabs -arrows- and remove the housing -1-.
Fig. 147: Identifying Retaining Tabs And Housing

-- Pull the rear view camera -1- out of the handle -2-.
Fig. 148: Identifying Rear View Camera And Handle

Installing:
REARVIEW CAMERA SYSTEM CONTROL MODULE

Control module is installed in luggage compartment behind right side wall trim.
The following describes the assembly procedure for the wagon. Adapt the steps as needed for the sedan.
Removing:
-- Remove the luggage compartment cover and screen separator if necessary.
-- Remove the lock carrier cover in the luggage compartment. Refer to Removal and Installation .
-- Remove both tie down eyes -arrows-.
Fig. 149: Identifying Tie Down Eyes

-- Unclip the side trim at the locations marked with -arrows-.

Fig. 150: Identifying Side Trim Clips

-- Raise the side trim from the guide near the window.
-- Carefully press the side trim in the -direction of the arrow-.
Fig. 151: Identifying Side Trim

-- Release and disconnect both connectors -1- and remove the control module -arrow- from the retainer.
Fig. 152: Identifying Control Module & Connectors

Installing:
Only if the control module has been replaced:
-- Calibrate the system again, refer to REAR VIEW CAMERA SYSTEM, CALIBRATING.
SENSOR BRACKET FOR PARKING AID AND PARALLEL PARKING ASSISTANCE, BONDING
In the event that the bumper cover is replaced, the sensor retainers must be glued into the appropriately marked
locations on the new bumper cover. Before bonding, the sensor brackets and sensors must be painted separately
in the color of the bumper cover. The following requirements must be observed when painting the sensor
brackets and the sensors in order to ensure full functionality of the parking aid system. Preparation of the
adhesive contact surface and the adhesive process are to be performed while observing the following process
steps.
PAINTING SENSOR BRACKETS AND SENSORS
Painting Sensor Brackets:
-- Remove grease from sensor brackets in the area to be painted -1- using isopropyl alcohol.
Fig. 153: Identifying Sensor Brackets And Paint Application Dimension

-- Paint sensor bracket in the area to be painted -1- in the color of the bumper cover.
NOTE: The paint application dimension -A- must not cross over 2.5 mm into inside of
sensor bracket.
Paint inside of sensor bracket only up to the specified area. If this is not
observed, it may lead to difficulty when assembling or malfunctions in the
parking aid system.
Painting Sensor:
-- Remove de-coupling ring (black silicon ring) from sensor head.
-- Remove grease from the black sensor head -1- in the area to be painted -2- with isopropyl alcohol.
Fig. 154: Identifying Black Sensor Head, Area To Paint And Paint Application Dimension
-- Paint sensor in the area to be painted -2- in the color of the bumper cover.
NOTE: Paint application dimension -B- is 3 mm (+ maximum 2 mm).
-- After the paint has dried, attach the coupling ring (black silicone ring) to the sensor head.
SENSOR BRACKET ASSIGNMENT
Sensor brackets are designed in different shapes and must be matched to the respective component location in
the bumper cover or radiator protective grille. To simplify assignment, the sensor brackets are marked on the
inside with a capital letter -arrow-. Observe the alignment of sensor connections in the respective assignment.
Fig. 155: Identifying Sensor Brackets Marked On Inside With Capital Letter
Sensor Bracket Assignment On Inside Of Front Bumper Cover and Radiator Protective Grille:
Fig. 156: Identifying Sensor Bracket Assignment On Inside Of Front Bumper Cover And Radiator
Protective Grille
Bracket letter:
A - left center (in radiator protective grille)

B - right center (in radiator protective grille)
C - right outer
D - left outer
Sensor Bracket Assignment On Inside Of Rear Bumper Cover, Sedan:
Fig. 157: Identifying Sensor Bracket Assignment On Inside Of Rear Bumper Cover (Sedan)
Bracket letter:
A - left center
B - right center
C - right outer
D - left outer
Sensor Bracket Assignment On Inside Of Rear Bumper Cover, Wagon:

Fig. 158: Identifying Sensor Bracket Assignment On Inside Of Rear Bumper Cover (Wagon)
Bracket letter:
A - left center
B - right center
C - right outer
D - left outer
BONDING SENSOR BRACKET IN BUMPER COVER
Bonding of sensor bracket into front and rear bumper cover is performed in the same way. To assist in aligning
the sensor retainers in their proper positions when bonding, sensor location punched holes with corresponding
retainer bonding adhesive surfaces are marked on the inside of the bumper cover. Before proceeding with
bonding procedure, ensure sensor retainer and bumper cover materials are between 15°C and 25°C.
-- Clean the marked adhesive surface -1- on inside of bumper thoroughly with isopropyl alcohol.
Fig. 159: Identifying Marked Bonding Area And Sensor Retainer Bonding Area
-- Apply bonding agent Scotchmount 4298 evenly on the marked adhesive surface -1-.
-- Allow bonding agent to air dry approximately 5 minutes.
-- Assign the sensor bracket to be bonded to its correct component location, refer to SENSOR BRACKET
ASSIGNMENT.
-- Pull off both protective foils from adhesive surface of sensor bracket -2- until a gray surface appears.
-- Align sensor bracket -2- with respect to marked adhesive surface -1- so that there is a uniform edge of
approximately 3 mm.
NOTE: Make sure that recesses for sensor connection in the sensor bracket face in the
correct direction as depicted in the assignment. If sensor bracket is glued in
incorrectly, connection wires for sensor are too short.
-- Press sensor bracket -2- with strong pressure into bumper cover for approximately 10 seconds.
NOTE: The contact pressure and pressing time are crucial for the adhesive durability!
BONDING SENSOR BRACKET IN RADIATOR PROTECTIVE GRILLE
When bonding the sensor bracket in radiator grille, take special care that the sensor bracket is aligned centrally
to the punch hole in the radiator protective grille, since there is no enclosing joint present on the sensor bracket
in this case. If sensor bracket is not bonded exactly in the center of the punch hole in the radiator protective
grille, the decoupling ring (black silicone ring) on the chrome sensor is under pressure after installation, causing
radiator grille materials are between 15°C and 25°C.
-- Clean the adhesive area on inside of radiator protective cover thoroughly with isopropyl alcohol.
-- Apply bonding agent Scotchmount 4298 evenly in adhesive area around punch hole.
-- Allow bonding agent to air dry approximately 5 minutes.
-- Assign the sensor bracket to be bonded to its correct component location, refer to SENSOR BRACKET
ASSIGNMENT.
-- Insert chrome-covered sensor into sensor bracket until both retaining clips engage audibly.
-- Pull off both protective foils from adhesive surface of sensor bracket until a gray surface appears.
-- Align chrome-covered sensor head exactly in center of punch hole in radiator protective grille.
NOTE: If sensor head is not aligned exactly in the center of the punch hole in the
radiator protective grille, the decoupling ring (black silicone ring) on the chrome
sensor is under pressure after installation, causing parking aid system
malfunctions.
-- Press sensor bracket with strong pressure into radiator protective grille for approximately 10 seconds.
NOTE: The contact pressure and pressing time are crucial for the adhesive durability!
STEERING COLUMN SWITCH
STEERING COLUMN SWITCH, THROUGH 10.09

Removing:
Also, if only one individual component of steering column switch is removed or replaced, it must be performed
in sequence as described in the following.
-- Disconnect battery. Refer to BATTERY, DISCONNECTING AND CONNECTING .
-- Remove steering wheel. Refer to Removal and Installation .
-- Remove steering column trim. Refer to Removal and Installation .
Remove steering column switch assembly components in the following sequence:

 Steering Column Electronic Systems Control Module -J527-. Refer to STEERING COLUMN
ELECTRONIC SYSTEMS CONTROL MODULE J527, THROUGH 10.09
 Airbag Spiral Spring/Return Spring With Slip Ring -F138-. Refer to AIRBAG SPIRAL
SPRING/RETURN SPRING WITH SLIP RING F138, THROUGH 10.09
 Segment sensor for steering angle sensor. Refer to STEERING ANGLE SENSOR SEGMENT
SENSOR, THROUGH 10.09
 Steering Column Combination Switch -E595-. Refer to STEERING COLUMN COMBINATION
SWITCH -E595-, THROUGH 10.09
Installing:
STEERING COLUMN ELECTRONIC SYSTEMS CONTROL MODULE J527, THROUGH 10.09
NOTE: After installing a new control module, it must be coded. Refer to STEERING
COLUMN ELECTRONIC SYSTEMS CONTROL MODULE J527, CODING,
THROUGH 10.09.
If malfunctions occur at steering column switch, coding of control module must

be checked. Refer to STEERING COLUMN ELECTRONIC SYSTEMS CONTROL
MODULE J527, CODING, THROUGH 10.09.
Removing:
-- Remove the bolt -2- on Steering Column Electronic Systems Control Module -1-.
Fig. 160: Identifying Steering Column Electronic Systems Control Module J527 And Bolt
-- Disengage connector -1- on right side of control module by pressing on the latching button -2- in direction of
arrow and disconnect connector -1- from steering column electronic systems control module -3-.
Fig. 161: Identifying Connector On Right Side Of Control Module And Steering Column Electronic
Systems Control Module J527 Connector
-- Disengage connectors -2- and -3- on left side of control module by pressing latching buttons -4- and
disconnect connectors -2- and -3- from steering column electronic systems control module -1-.
Fig. 162: Identifying Electrical Left Side Connection Of Control Module And Electrical Steering Column
Electronic Systems Control Module J527 Connection
-- Disengage the catches -arrows- on right side of the steering column electronic systems control module.
Fig. 163: Identifying Catches On Right Side Of Steering Column Electronic Systems Control Module
J527
-- Disengage catches -arrows- on right side of steering column electronic systems control module.
Fig. 164: Identifying Catches On Right Side Of Steering Column Electronic Systems Control Module
J527
-- Carefully pull steering column electronic systems control module downward from Steering Column
Combination Switch -E595- .
NOTE: When disconnecting, the harness connectors to Airbag Spiral Spring/Return

Spring With Slip Ring -F138- and to segment sensor for steering angle sensor
are disconnected automatically.
-- Release electrical connection -1- by pulling locking button -arrow A- and pulling connection -1- from
steering column electronic systems control module.
Fig. 165: Identifying Steering Column Electronic Systems Control Module J527, Harness Connector,
Locking Button And Securing Latch
-- Remove securing latch -3- from harness connector -2-.
-- Disengage lock -arrow B- on electrical connection -2- and disconnect from steering column electronic
systems control module.
Installing:
NOTE: Make sure that none of the pins are bent and that the connector clicks into the
place.
AIRBAG SPIRAL SPRING/RETURN SPRING WITH SLIP RING F138, THROUGH 10.09
Removing:
Remove the following components in order:
-- Remove Steering Column Electronic Systems Control Module -J527-. Refer to STEERING COLUMN
ELECTRONIC SYSTEMS CONTROL MODULE J527, THROUGH 10.09.
NOTE: When removing, the spiral spring must not be twisted out of the center position
and wheels must be in the straight ahead position.
-- Lift both retaining straps -arrows- on Airbag Spiral Spring/Return Spring With Slip Ring -1- slightly and pull
off Airbag Spiral Spring/Return Spring With Slip Ring toward rear from steering column.
Fig. 166: Identifying Airbag Spiral Spring/Return Spring With Slip Ring F138 And Retaining Straps
Installing:
NOTE: When installing spiral spring, spiral spring must be in center position and
wheels must be in the straight ahead position.
Make sure that retaining straps engage correctly.
The following depicts center position of spiral spring, which is dependent on the manufacturer:
 The color marked (black square) band -arrow- must be located in viewing window -1-.
Fig. 167: Identifying Color Marked (Black Square) Band And Viewing Window
 The color marked (yellow) roller -arrow- must be located in viewing window -1-.
Fig. 168: Identifying Color Marked (Yellow) Band And Viewing Window
STEERING ANGLE SENSOR SEGMENT SENSOR, THROUGH 10.09
Removing:

-- Remove Airbag Spiral Spring/Return Spring With Slip Ring -F138-. Refer to AIRBAG SPIRAL
SPRING/RETURN SPRING WITH SLIP RING F138, THROUGH 10.09.
-- Disengage catches -arrows- and pull off segment sensor for steering angle sensor -1- toward rear from
steering column switch unit.
Fig. 169: Identifying Steering Angle Sensor And Catches

Installing:
STEERING COLUMN COMBINATION SWITCH -E595-, THROUGH 10.09
Removing:
-- Remove Airbag Spiral Spring/Return Spring With Slip Ring -F138-. Refer to AIRBAG SPIRAL
SPRING/RETURN SPRING WITH SLIP RING F138, THROUGH 10.09.
-- Remove segment sensor for steering column sensor. Refer to STEERING ANGLE SENSOR SEGMENT
SENSOR, THROUGH 10.09.
-- Remove both bolts -arrows- on top side of Steering Column Combination Switch.
Fig. 170: Identifying Steering Column Combination Switch E595 Bolts

-- Pull off Steering Column Combination Switch toward rear from steering column.
Installing:

SPECIFICATIONS, STEERING COLUMN SWITCH ASSEMBLY.
STEERING COLUMN SWITCH COMPONENTS, REMOVAL AND INSTALLATION SEQUENCE, FROM 11.09
WARNING:  Risk of airbag deployment!

 The airbag could deploy if the airbag unit is handled incorrectly.
 Observe safety precautions when working on the airbag. Refer to
General Information .

When removing the complete steering column switches including base carrier, it is disassembled and steering
lock housing is also removed with it. New shear bolts are required for installing steering lock housing.
Also, if only one individual component of steering column switch is removed or replaced, the sequence
described in the following must always be adhered to.
Removing:
Remove steering column switch assembly components in the following sequence:
 Steering Column Electronic Systems Control Module -J527-, refer to STEERING COLUMN
ELECTRONIC SYSTEMS CONTROL MODULE -J527-, FROM 11.09.
 Steering Column Combination Switch -E595-, refer to STEERING COLUMN COMBINATION
SWITCH -E595-, FROM 11.09
 Steering column switch base carrier, refer to STEERING COLUMN SWITCH BASE CARRIER,
VALEO, FROM 11.09 or STEERING COLUMN SWITCH BASE CARRIER, KOSTAL, FROM
11.09.
Installing:
STEERING COLUMN ELECTRONIC SYSTEMS CONTROL MODULE J527, VALEO, FROM 11.09
Removing:



components must be done in the specified sequence, refer to STEERING
Fig. 171: Identifying Steering Column Electronic Systems Control Module Connectors And Mounting
Bolts
-- Disconnect the connectors -1- , -2- , -3- and -4- , depending on the vehicle equipment level.
NOTE: Do not turn the spiral spring on the steering column electronic systems control
module from its center position during removal. The front wheels must be in the
straight-ahead position.
-- Remove the 3 mounting bolts -arrows- and remove the steering column electronic systems control module
from the steering column switch.
Installing:
CAUTION: The turn signal switch lever could break when installing the control
module.
The turn signal lever must be in the 0 position when installing the spiral
spring so that it does not fall out.
-- Mount the steering column electronic systems control module on the steering column switch making sure it is
straight.
-- Install the three mounting bolts for the steering column electronic systems control module on the steering
column switch module and tighten them to 1.5 Nm.
-- Install all components in reverse order of removal.
STEERING COLUMN ELECTRONIC SYSTEMS CONTROL MODULE J527, KOSTAL, FROM 11.09
Removing:


-- Disconnect batter. Refer toy BATTERY, DISCONNECTING AND CONNECTING .

Fig. 172: Identifying Steering Column Electronic Systems Control Module Connectors, Mounting Bolt
And Catches
-- Disconnect the connectors -1- , -2- , -3- , -4- and -5- , depending on the vehicle equipment level.
-- Remove bolt -arrow B-.
NOTE: Do not turn the spiral spring on the steering column electronic systems control
module for the steering column electronics from its center position during
removal. The front wheels must be in the straight-ahead position.
-- Unlock both catches -arrows A- and remove the steering column electronics control module from the steering
column switch.
Installing:
CAUTION: The turn signal switch lever could break when installing the control
module.
The turn signal lever must be in the 0 position when installing the spiral
spring so that it does not fall out.
-- Mount the steering column electronic systems control module on the steering column switch making sure it is
straight until it latches.
-- Install the bolt for the steering column electronic systems control module on the steering column switch
module and tighten it to 1.5 Nm.
STEERING COLUMN COMBINATION SWITCH E595, VALEO, FROM 11.09

Removing:
Fig. 173: Identifying Steering Column Combination Switch Releases And Bolts
-- Unlock both releases -arrows- and remove the entire steering column combination switch from the steering
column switch base carrier.
Installing:
-- Push the steering column combination switch onto the guide on the steering column switch base carrier until
it latches.
STEERING COLUMN COMBINATION SWITCH, KOSTAL E595, FROM 11.09

Removing:
Fig. 174: Identifying teering Column Combination Switch And Bolt

-- Remove the bolt -arrow- and remove the entire steering column combination switch -1- from the steering
column switch base carrier.
Installing:
-- Slide the steering column combination switch onto the guides on the steering column switch base carrier.
-- Install the bolt -arrow-.

STEERING COLUMN SWITCH BASE CARRIER, VALEO, FROM 11.09
 Angled hand drill


CAUTION:  Before drilling out shear bolts, always ensure all components
secured to base carrier are removed beforehand.
 By drilling out, drill shavings can reach the neighboring components,
which can lead to damage and/or malfunctions!

Removing:
NOTE: The shear bolts on the -1- steering lock housing must be drilled out in order to
remove the steering column switch base carrier -2-. New shear bolts will be
needed later for installing.
Fig. 175: Identifying Shear Bolts, Steering Column Switch Base Carrier And
Steering Lock Housing
Removing:
-- Remove all components secured to the base carrier in the specified sequence, refer to STEERING
COLUMN SWITCH COMPONENTS, REMOVAL AND INSTALLATION SEQUENCE, FROM 11.09.
After components secured to base carrier have been removed, the base carrier can be removed:
-- Drill out the shear bolts -1- on the steering lock housing -3-.
Fig. 176: Identifying Shear Bolts, Steering Column Switch Base Carrier And Steering Lock Housing
NOTE: Bolts M8 -1-, core hole diameter 6.8 mm.
-- Remove the steering lock housing -3- and the steering column switch base carrier -2- from the steering
column.
-- Remove steering lock housing from base carrier for steering column switches.
Installing:
-- Install the steering lock housing -3- in the steering column switch base carrier -2-.
-- Slide the Steering Column Combination Switch -E595- onto the steering column switch base carrier until it
latches.
-- Slide the pre-assembled unit from the steering lock housing, the steering column switch base carrier and the
steering column combination switch all the way onto the steering column and align them with the threaded
holes.
-- Attach the steering lock housing -3- to the steering column with new shear bolts -1-.
-- Tighten new shear bolts -1- until bolt heads shear off.
STEERING COLUMN SWITCH BASE CARRIER, KOSTAL, FROM 11.09
 Angled hand drill


CAUTION:  Before drilling out shear bolts, always ensure all components
secured to base carrier are removed beforehand.

 By drilling out, drill shavings can reach the neighboring components,
which can lead to damage and/or malfunctions!

Removing:
NOTE: The shear bolts on the -1- steering lock housing must be drilled out in order to
remove the steering column switch base carrier -2-. New shear bolts will be
needed later for installing.
Fig. 178: Identifying Shear Bolts, Steering Column Switch Base Carrier And
Steering Lock Housing
Removing:
-- Remove all components secured to the base carrier in the specified sequence, refer to STEERING
COLUMN SWITCH COMPONENTS, REMOVAL AND INSTALLATION SEQUENCE, FROM 11.09.
After components secured to base carrier have been removed, the base carrier can be removed:
-- Drill out the shear bolts -1- on the steering lock housing -3-.
NOTE: Bolts M8 -1- , core hole diameter 6.8 mm.
-- Remove the steering lock housing -3- and the steering column switch base carrier -2- from the steering
column.
-- Remove steering lock housing from base carrier for steering column switches.
Installing:
-- Install the steering lock housing -3- in the steering column switch base carrier -2-.
-- Slide the Steering Column Combination Switch -E595- onto the steering column switch base carrier and
install the lower bolt.
-- Slide the pre-assembled unit from the steering lock housing, the steering column switch base carrier and the
steering column combination switch all the way onto the steering column and align them with the threaded
holes.
-- Attach the steering lock housing -3- to the steering column with new shear bolts -1-.
-- Tighten new shear bolts -1- until bolt heads shear off.
TAIL LAMPS
TAIL LAMPS IN SIDE PANEL
Tail lamp in side panel must not be disassembled further. It contains the following components:
 Left Tail Lamp -M4- and Right Tail Lamp -M2-

 Left Brake Lamp -M9- and Right Brake Lamp -M10-
 Left Rear Turn Signal Lamp -M6- and Right Rear Turn Signal Lamp -M8-
Removing:
NOTE: Illustrations depict removal and installation of the left side. Removal and
installation of the right side is performed the same way.
(ignition off).
-- Unclip service cover -1- out of side trim -2- in direction of arrow.
Fig. 181: Identifying Service Cover Unclipped Out Of Side Trim

-- Disengage connector -2- by pulling locking button -3- in direction of arrow and disconnect it from tail lamp.
Fig. 182: Identifying Connector, Mounting Nuts, Locking Button And Tail Lamp
-- Remove nuts -1- and remove tail lamp toward rear out of side panel.
Installing:
-- Tighten the nut -3- to the tightening specification. Refer to FASTENER TIGHTENING
SPECIFICATIONS, TAIL LAMP ASSEMBLY IN SIDE PANEL.
Fig. 183: Identifying Connector, Mounting Nuts, Locking Button And Tail Lamp
NOTE: Tail lamp connector -2- must engage audibly in side panel when connecting.
Connector is locked correctly when latching button -3- is engaged!
REAR LID TAIL LAMPS
NOTE: Illustrations depict removal and installation of the left side. Removal and
installation of the right side is performed the same way.
Removing:
(ignition off).
-- Unclip service cover -1- in -direction of arrow- from trim -2-.
Fig. 184: Identifying Service Cover Unclipped From Trim

-- Disconnect the connector -1- from the bulb holder -2-.

Fig. 185: Identifying Lamp Carrier, Connector And Mounting Nuts

-- Remove both nuts -3-.
-- Remove the tail lamp back out of the rear lid.
Installing:


-- When installing, tighten tail lamp first with the top and then with the bottom nut.
-- Tighten the nuts -3- to the tightening specification. Refer to FASTENER TIGHTENING
SPECIFICATIONS, TAIL LAMP ASSEMBLY IN REAR LID.
-- Insert connector into lamp carrier until it engages audibly.
-- Check the gap dimension to the body after installing the tail lamp assembly.
REAR LID TAIL LAMP BULB HOLDER
Removing:
(ignition off).
-- Unclip service cover -1- in -direction of arrow- from trim -2-.
Fig. 187: Identifying Service Cover Unclipped From Trim

-- Release the connector -1- and disconnect it from the bulb carrier -2-.

-- Rotate lamp carrier -1- in -direction of arrow- and remove it from tail lamp assembly housing.
Fig. 189: Identifying Direction To Rotate/Remove Lamp Carrier From Tail Lamp Assembly Housing
Left Rear Fog Lamp -L46- 12V, P 21 W.
Right Back-Up Lamp -M17- 12V, P 21 W.
Installing:
-- Insert connector into lamp carrier until it engages audibly.
SPECIAL TOOLS
Wedge T10039/1
Fig. 190: Identifying Release Lever T10039


Torque Screwdriver V.A.G 1624
Fig. 192: Identifying Torque Screwdriver VAG 1624 (Or Locally Available Equivalent)

Trim Removal Wedge VAS 3409


Vehicle Diagnostic, Testing and Information System VAS 5051B
Calibration Tool For Lane Changing Assist VAS 6350

Fig. 196: Identifying Calibration Device VAS 6350

TRANSMISSION Final Drive, Differential - 09G
TRANSMISSION
Final Drive, Differential - 09G
39 FINAL DRIVE, DIFFERENTIAL

LEFT FLANGE SHAFT SEAL
Short Description:
The seal for the flange shaft can be changed with the transmission installed.
The drive axle is completely removed.
 Puller T10055
 Thrust Piece T10176
Removing
-- Remove the left drive axle. Refer to Removal and Installation .
-- Seal off the drive axle opening in the transmission with a clean cloth -A-.
Fig. 1: Identifying Outer Metal Ring Of Drive Axle, Sealing Ring Drive Axle And Cloth In Seal Opening
-- Carefully drill a hole, 2 to 4 mm in diameter -B- into the outer metal ring -C- in the seal.
NOTE: Grease the drill bit -B- so that the shavings stick to the drill bit.
Drill only through the metal ring -C- otherwise the transmission will get
damaged.
-- Install a 4 mm screw into the drilled hole in the seal -arrow-.
Fig. 2: Identifying Installation Of Metal Bolt At Drilled Hole Of Sealing Ring

NOTE: Be careful not to install the screw too deep otherwise the bearing underneath
will get damaged.
Remove the seal using the puller T10055 and adapter T10055/2
Remove the cloth and carefully clean the transmission and the opening for the
drive axle.
Metal shavings must not get into the transmission or into the opening for the
drive axle; vacuum up any shavings if necessary.
If only the metal ring of the seal could be removed, carefully pry out the
remaining parts of the seal using screwdriver.
Installing
Install in reverse order of removal. Pay attention to the following:

-- Coat the outer circumference and sealing lips of the new seal with transmission fluid.
Installed position:
The open side of the seal faces the transmission.
-- Install the new seal all the way using the thrust piece T10176. Do not tilt the seal.
Fig. 3: Identifying Installation Of Seal Using Thrust Piece T10176

-- Install the drive axle. Refer to Removal and Installation .
-- Check the transmission fluid level and add if necessary. Refer to TRANSMISSION FLUID LEVEL,
CHECKING AND FILLING .
-- Install the noise insulation.
RIGHT FLANGE SHAFT SEAL
Short Description:
The seals for the flange shafts can be changed with transmission installed.
The drive axle remains in the vehicle and is only removed from the transmission.
-- The drive axle remains in the wheel bearing.

 Puller T10055
Removing
-- Remove the noise insulation.
-- Remove the right drive axle from the transmission. Refer to Removal and Installation .
-- Tie the drive axle as high up as possible. Be careful not to damage the paint on the drive axle.
-- Seal off the drive axle opening in the transmission with a clean cloth -A-.
Fig. 4: Identifying Outer Metal Ring Of Drive Axle, Sealing Ring Drive Axle And Cloth In Seal Opening
-- Carefully drill a hole, 2 to 4 mm in diameter -B- into the outer metal ring -C- in the seal.
NOTE: Grease the drill bit -B- so that the shavings stick to the drill bit.
Drill only through the metal ring -C- otherwise the transmission will get
damaged.
-- Install a 4 mm screw into the drilled hole in the seal -arrow-.

Fig. 5: Identifying Installation Of Metal Bolt At Drilled Hole Of Sealing Ring

NOTE: Be careful not to install the screw too deep otherwise the bearing underneath
will get damaged.
Remove the seal with the puller T10055 and adapter T10055/2
Remove the cloth and carefully clean the transmission and the opening for the
drive axle.
Metal shavings must not get into the transmission or into the opening for the
drive axle; vacuum up any shavings if necessary.
If only the metal ring of the seal could be removed, carefully pry out the
remaining seal using a screwdriver.
Installing
-- Coat the outer circumference and sealing lips of new seal with transmission fluid.
Installed position:
The open side of the seal faces the transmission.
-- Install the new seal all the way using the thrust piece T10177. Do not tilt the seal.
Fig. 6: Identifying Installation Of Seal Using Thrust Piece T10177

-- Install the drive axle. Refer to Removal and Installation .
-- Check the transmission fluid level and add if necessary. Refer to TRANSMISSION FLUID LEVEL,
-- Install the noise insulation.
SPECIAL TOOLS

 Puller T10055
Fig. 7: Identifying Puller T10055 With Adapter T10055/3


Edition 08022011
ENGINE PERFORMANCE Firing Order & Cylinder Identification - Volkswagen - All Models
ENGINE PERFORMANCE
Firing Order & Cylinder Identification - Volkswagen - All Models
FIRING ORDER & CYLINDER IDENTIFICATION
NOTE: This information is intended as a quick reference for firing order and cylinder
identification only. The information provided covers many vehicles and may
include some information that does not apply to the vehicle you have currently
selected.
4 CYLINDER ENGINE
Engine Configuation Firing Order Cylinder Identification
In-Line 4 1-3-4-2
5 CYLINDER ENGINE
In-Line 5 1-2-4-5-3
V6 ENGINE

V6 1-4-3-6-2-5
VR6 ENGINE
VR6 1-5-3-6-2-4
V8 ENGINE
V8 1-5-4-8-6-3-7-2
W8 ENGINE
W8 1-5-2-6-4-8-3-7
V10 ENGINE
V10 1-6-5-10-2-7-3-8-4-9
W12 ENGINE
W12 1-12-5-8-3-10-6-7-2-11-4-9
Accessories & Equipment Front Doors, Central Locking System
Front Doors, Central Locking System
57 FRONT DOORS, CENTRAL LOCKING SYSTEM

FRONT DOOR
FRONT DOOR ASSEMBLY OVERVIEW
Fig. 1: Identifying Front Door, Assembly Overview

1. Door
 Removing and Installing, refer to DOOR, REMOVING AND INSTALLING.
 Adjusting, refer to DOOR, ADJUSTING
2. Door handle with backing plate

 Door handle with Kessy, removing, refer to DOOR HANDLE WITH KESSY
3. Lock cylinder housing

 Removing and Installing, refer to LOCK CYLINDER HOUSING
4. Door lock
 The door lock can only be removed with the subframe.
 Removing and Installing, refer to DOOR LOCK
5. Subframe
 Removing and Installing, refer to SUBFRAME
6. Socket head bolt

 Different tightening specifications
 Tightening specification to body: 20 Nm + 1 /4 (90°) additional turn

 Tightening specification to door: 50 Nm
 Always replace bolts after removing them.
7. Door hinge
 The lower portion is attached to the upper portion of the hinge by the bolt -8-.
 Hinge is divided
8. Bolt
 This screw must be removed to remove door from hinge.
 28 Nm
9. Door hinge
 Upper portion is attached to lower portion of hinge with screw -8-.
10. Door hinge

11. Door hinge

12. Bolt
 This screw must be removed to remove door from hinge.
 28 Nm
DOOR HINGE ASSEMBLY OVERVIEW

Always replace the door hinge bolts after loosening them.
The lower hinge may be attached with bolt -8- or a nut -9-.
The tightening specification for the bolts from the door hinge to the door -2, 4
and 12- has changed.
Lubricate new hinges. Refer to "Maintenance" for the procedure. Refer to the
appropriate maintenance information.
Fig. 2: Identifying Door Hinge Assembly

1. Door
 Removing and Installing, refer to DOOR, REMOVING AND INSTALLING
 Adjusting, refer to DOOR, ADJUSTING
2. Socket head bolt

3. Door hinge
 A bolt -8- or a nut -9- attach the upper part of the hinge to the lower part.
4. Socket head bolt

5. Socket head bolt

 Tightening specification: 20 Nm + 1 /4 (90 °) additional turn
Installed from the inside of the vehicle

 Remove the lower A-pillar trim. Refer to Removal and Installation
6. Door hinge with door arrester

 A bolt -8- or a nut -9- attach the lower part of the hinge to the upper part.
7. Socket head bolt

8. Bolt
 This screw must be unscrewed to remove the door from the hinge
9. Nut

 This nut must be lowered in order to remove the door from the hinge.
10. Socket head bolt

Always replace bolts after removing them.

11. Door hinge

 Lower portion is attached to upper portion of hinge with screw -15-

Always replace bolts after removing them.
14. Door hinge

15. Bolt
 This screw must be unscrewed to remove the door from the hinge
DOOR, ADJUSTING
Fig. 3: Identifying Screws At A-Pillar For Gap Dimension Adjustment

NOTE: The vehicle must be resting on its wheels to adjust the front door.
The front door is adjusted properly when it has an even gap dimension overall
when closed, it does not rest too far in or out and the contours align.
For checking the gap dimensions, refer to the appropriate repair information.
Perform corrosion protection measures on the hinge and bolts after assembly
or adjusting work.
For correct gap dimension adjustment, screws -5, 7, 8 and 10- at A-pillar must be loosened. The A-pillar lower
trim must be removed in order to access the bolt -5-. Refer to Removal and Installation .
Other measures, such as aligning the door upward, do not work. Pressure later will cause the door to sag again.
Bolts -2, 4 and 11- must be loosened to adjust flush dimension correctly.
For this, the door adjusting wrench 3320 with the bit insert 3320/3 must be used.
Adjust the striker pin.
Striker Pin, Adjusting
NOTE: The following describes adjusting the right front door only. Adjusting the left
front door is identical.
When closing, the front door must latch completely without having to press it
and it must not have any play.
The door must not be pushed up or down when adjusting the striker pin.
The striker pin can be used to adjust:
 If the front door does not align with the rear door.
-- Loosen the bolts -2- on the B-pillar to loosen the striker pin -1-.

-- Adjust front door with striker pin -1- so that front door aligns with rear door when closed (wind noise).
-- Tighten the striker pin -2- bolts -1-.
-- Bolt -2- tightening specification: 20 Nm.
DOOR COMPONENTS
SUBFRAME ASSEMBLY OVERVIEW
Fig. 5: Identifying Subframe, Assembly Overview

1. Subframe
2. Retaining bracket
3. Cover caps for assembly opening
 Quantity: 2
4. Bolt
 Quantity: 2
5. Bolt
6. Wiring harness
 To door lock.
7. Window Regulator Motor

 Removing, refer to WINDOW REGULATOR MOTOR
8. Wiring harness
 For the exterior mirror.
9. Connector
 For door trim wiring harness.
DOOR HANDLE AND DOOR LOCK ASSEMBLY OVERVIEW
Fig. 6: Identifying Door Handle And Door Lock, Assembly Overview

1. Door lock
2. Angle bracket
 Inserted on and engaged on door lock.
 Also adopts function of the previously known cover.
3. Cable
 Allows the interior door mechanism to unlock the lock
4. Bolt
 Mounting bracket is disengaged from door by loosening this bolt.
5. Mounting bracket
 Slid into angled mounting bracket.
 Remove the lock cylinder housing, refer to LOCK CYLINDER HOUSING

 Door handle with KESSY, removing and installing, refer to DOOR HANDLE WITH KESSY
7. Cover
 For lock cylinder housing.
 Removing, refer to LOCK CYLINDER HOUSING COVER CAP

 Only one lock cylinder is located at driver side door.
9. Backing
10. Cable
 To the bracket, allows the exterior door handle to unlock the lock
11. Bolt
 For lock cylinder.
12. Bolt
 Quantity: 2
INSULATION ASSEMBLY OVERVIEW

Fig. 7: Identifying Insulation, Assembly Overview

1. Door
2. Insulation
 Self-adhesive
 Installing:
-- Cut to fit as necessary and align between the door edges.
-- Heat using a hot air gun V.A.G 1416 and press onto the outer door panel.
3. Adhesive strips
 Quantity: 4
 20 mm x 40 mm commercially available cloth reinforced adhesive tape
INNER DOOR SEAL
The inner door seals are equipped at the factory with sealant, applied to the door flange and then rolled on.
NOTE: The sealing compound will be distributed on the inside of the seal and the
flanks will be slightly bent when the seal is removed. When the seal is installed
again, it may not fit securely and it make leak.
For this reason, every completely removed seal must be replaced with a so-
called "hammer-stroke seal".
With partially removed seals, press the edges of the seal together before
installing.
CENTRAL LOCKING
CENTRAL LOCKING COMPONENT OVERVIEW

Fig. 8: Identifying Component Locations For Central Locking System

1. Coupling station
 Installed location: right A-pillar
 To disconnect harness connector, release bellows at pillar, refer to DOOR, REMOVING AND
INSTALLING
2. Comfort System Central Control Module -J393-
 Installed location: under the instrument panel on the front passenger side
 Removing, refer to Removal and Installation
3. Front passenger door control module -J387-

 Integrated in the front passenger window regulator motor -V148-

4. Front passenger side door lock
 Door lock is secured to subframe.
 Electrical central locking system is integrated in door lock.
 Removing, refer to DOOR LOCK
5. Coupling station
 Installed location: right B-pillar
 To disconnect harness connector, release bellows at pillar, refer to DOOR
6. Right Rear Door Control Module -J389-

 Integrated inside the right rear window regulator motor -V27-
7. Right rear door lock

8. Motor for fuel tank lid unlock -V155-

 Installed location: behind the luggage compartment trim panel on the right side
 Removing, refer to ACTUATOR
9. Release button in rear lid handle -E234-

 Installed location on the Sedan: inside the emblem
 Installed location on the Wagon: on the rear lid
10. Rear lid lock

 Installed location: attached to the rear lid
11. Rear lid coupling station

 Only on the Sedan
 Installed location: behind the luggage compartment trim panel on the left side
 Removing and Installing, refer to Removal and Installation
12. Left rear door lock

13. Left Rear Door Control Module -J388-

 Integrated inside the left rear window regulator motor -V26-.
14. Coupling station

 Installed location: left B-pillar
 To disconnect harness connector, release bellows at pillar, refer to DOOR
15. Left front door lock


16. Driver door control module -J386-

 Integrated inside the driver window regulator motor -V147-.
17. Central window regulator switch in driver door

 Installed location: inside the door trim panel
 Window Regulator Central Switch, Removing and Installing, refer to illustrations in SHIFT
ELEMENT, DRIVER SIDE
18. Coupling station
 Installed location: left A-pillar
 To disconnect harness connector, release bellows at pillar, refer to DOOR, REMOVING AND
INSTALLING
19. Hood switch -F266-
 Removing and Installing, refer to [For engine(s) BPY,BLV,CCTA,CBFA] FRONT HOOD
SWITCH F266 .
 Installed location: on the latch
 Removing and installing lid lock, refer to HOOD LATCH
20. Alarm Horn -H12-

 Installed location: under the right fender
 Removing, refer to [For engine(s) BPY,BLV,CCTA,CBFA] ALARM HORN H12 .
REMOTE CONTROL KEYS, ADAPTING
Adaptation of keys to remote control is performed using Vehicle Diagnosis, Testing and Information System
VAS 5051B.
-- In Vehicle Diagnosis, Testing and Information System VAS 5051B, select "Guided Fault Finding".
-- Using the Go to button, select "Function/Component selection" and the following menu items one after the
other:
 Body
 Body - repair work
 46 - Comfort System
 46 - Functions - Comfort System central control module
 J393 - adapt key with remote control
REMOTE CONTROL KEYS, ADAPTING TO IMMOBILIZER

Use the Vehicle Diagnosis, Testing and Information System VAS 5051B to adapt the keys to the anti-theft
immobilizer.
-- In Vehicle Diagnosis, Testing and Information System VAS 5051B, select "Guided Fault Finding".
-- Using the Go to button, select "Function/Component selection" and the following menu items one after the
other:
 Body
 25 - Anti-theft immobilizer 4D
 25 - Functions
 Adapt the key
FRONT DOOR
DOOR, REMOVING AND INSTALLING
NOTE: The following describes removing and installing the right door only. Removing
and installing the left door is identical.
Lubricate new hinges. Refer to the Appropriate Maintenance Information.
Removing
Fig. 9: Identifying Removal Of Door Hinge Assembly And Bolts

-- Press on the catch -arrow a- and remove the boot -2- from the A-pillar.
-- Swing locking lever -3- downward -arrow b- and disconnect electrical harness connector -4- from connector
station.
-- Remove the bolt -1- from the upper hinge.
-- Remove the bolt -6- or nut -5- from the lower hinge.
-- Lift door upward -arrow c- out of hinges.

Installing
NOTE: The tightening specifications for the bolt -6- and nut -5- are different for the
lower hinge.
-- Tightening specification: screws -1 and 5- 28 Nm.
-- Tightening specification: nut -5- 14 Nm.
-- Pay attention to the gap dimensions for the front door. Refer to the appropriate repair information.
DOOR COMPONENTS
SUBFRAME
NOTE: Removing and installing the right subframe is described here. Removing and
installing the left subframe is identical.
Bolts -3- have a left-hand thread.
The window regulator, door lock and speaker are secured to the subframe.
The door lock can only be removed with the subframe.
The subframe can be removed only if the door window is detached at the clamping screws on the window
regulator.
If it is not possible to drive down the door window by the electrical window regulator, first the exact cause of
malfunction must be determined.
Check the DTC memory for the Comfort System, refer to the appropriate information: Vehicle diagnosis,
testing and information system VAS 5051.
If electrical malfunction is present, repair this malfunction first.
If there is an electrical malfunction due to window regulator motor, it can be unscrewed from subframe and
door window can be slid by hand into the necessary work position.
Removing
Fig. 10: Identifying Door Window Remove/Install Components

-- Remove the front door trim panel. Refer to Removal and Installation .
-- Remove the door handle. Refer to DOOR HANDLE or door handle with KESSY. Refer to DOOR
HANDLE WITH KESSY.
-- Pry out cover caps -2-.
-- Lower the door window until the screws -3- are accessible.
-- Loosen the screws -3- (do not remove them, left-hand thread) tightening specification: 8 Nm and open the
-- Raise the door window and secure it, for example, with adhesive tape.
-- Disengage retainers of protective sleeve -arrow a- and pull off protective sleeve.
-- Open lock of harness connector -1- of A-pillar by swiveling downward -arrow b- and disconnect harness
connector.
-- Disconnect the exterior rearview mirror connector -arrow- on the window regulator motor -4-.
Fig. 11: Identifying Removal Of Door Window Components

-- Remove the wiring harness for the exterior mirror -8-.

-- Guide wire for A-pillar into door and disengage wire holder -7-.
-- Remove bolt -2- for mounting bracket.
-- Remove bolts -3- for door lock.
-- Remove the screws -4-, -6- and -arrows-.
Fig. 12: Identifying Subframe Remove/Install Components

-- Slide subframe -1- contacting door upward -arrow a- and pull lower area of subframe from door -arrows b-.
Lower section of window regulator must be guided out of door along with it.
-- Pull subframe downward at an angle -arrow c- toward hinge pillar out of door. First, upper section of window
regulator must be guided out of door, then the door lock -2-.
-- When pulling out subframe -1-, guide out wiring harness -3- accordingly.
Installing
Fig. 13: Identifying Installation Of Subframe Components

-- Insert subframe upward -arrow a- at an angle into door.
-- Guide door lock -2- and wiring harness -3- in door to the corresponding component locations.
-- Engage cable bracket -4- in door mounting hole.
NOTE: If cable bracket is not engaged in door mounting hole, wiring harness may be
damaged and therefore all electrical components in door may fail.
-- Place subframe on to door.
Fig. 14: Identifying Removal Of Door Window Components

-- Center the subframe -1- in door cutout with the centering pins -5-.
-- Install all bolts -arrows-. Tighten screw -6- first and then screw -4-.
-- Tighten the remaining bolts -arrow- in any desired sequence.
-- Bolt tightening specification -arrows, 4 and 6-: 8 Nm.
-- Secure the door window.
-- Tighten the door lock screws -4-, tightening specification: 20 Nm
-- Continue by performing the steps used in removal in reverse order.
LOCK CYLINDER HOUSING COVER CAP
Removing
NOTE: When removing cover cap of lock cylinder housing, emergency key must not be
turned and do not use prying motions with emergency key.
-- Remove emergency key from remote control key.
-- Press emergency key -3- lightly -arrow a- into hole on underside of cover cap for lock cylinder housing.
-- Pull off cover cap for lock cylinder -1-, together with emergency key, lightly at underside from door -arrow
b-.
-- Slide cover cap upward -arrow c- from lock cylinder housing.

Fig. 15: Identifying Removal Of Lock Cylinder Housing Cover Cap

Installing
-- Place cover cap for lock cylinder housing -2- lightly at an angle from above -arrow a- on to lock cylinder
housing.
-- Press cover cap of lock cylinder housing -2- on to door -arrow b- until cover cap engages with lock cylinder
housing.
Fig. 16: Identifying Installing Lock Cylinder Housing Cover Cap

LOCK CYLINDER HOUSING
NOTE: Only the driver door still has a lock cylinder.
Removing and installing the lock cylinder housing is described. Removing and
installing the left lock cylinder is identical.
Removing
 Cover cap for lock cylinder housing has been removed.
Only for lock cylinder housing with lock cylinder at driver's door
-- Pry off cover from securing bolt -1-.
-- Remove the securing bolt -1- for lock cylinder housing with lock cylinder -2-.
Fig. 17: Identifying Bolt And Lock Cylinder

For all lock cylinder housings
-- Pry out cover cap -4- in front of bolt -3-.
-- Pull out door handle -1- in -direction of arrow- until it stops and unscrew bolt -3- far enough until lock
cylinder housing -2- can be pulled out.
-- Remove lock cylinder housing -2- at right angle to door from door handle mounting bracket.
Fig. 18: Identifying Removal Of Lock Cylinder Housing

NOTE: Door handle remains standing in pulled-out position. Do not attempt to press
door handle in, otherwise retaining tab on mounting bracket breaks off and a
removed door handle can no longer be installed.
Installing
In pulled-out position -arrow-, door handle must stand off from door.
-- Insert lock cylinder housing -3- at right angle into mounting bracket.
-- Screw bolt -3- into mounting bracket.
Door handle -1- swings automatically on to door.

Fig. 19: Identifying Installation Of Lock Cylinder Housing

NOTE: During installation, lock cylinder housing must be pressed onto the outer door
panel.
 Then, always perform a function test with door opened.
DOOR HANDLE
NOTE: Removing and installing the right door handle is described here. Removing and
installing the left door handle is identical.
Door handle remains standing in pulled-out position. Do not attempt to press

Removing
-- Remove lock cylinder housing. Refer to LOCK CYLINDER HOUSING.
-- Pull door handle -2- slightly toward rear -arrow a- out of mount of mounting bracket.
-- Swivel door handle around in -direction of arrow b-.
-- Remove door handle at right angle -arrow c- from mounting bracket -1-.
Fig. 20: Identifying Removal Of Door Handle

Installing
-- Insert door handle -1- at right angle -arrow a- into mounting bracket -2-.
-- Swivel door handle -1- into door -arrow b-.
-- Slide door handle slightly toward front -arrow c- into mount in mounting bracket.
Fig. 21: Identifying Installation Of Door Handle

removed door handle can no longer be installed. Door handle contacts on door
after installing lock cylinder housing.
Install the lock cylinder housing.
DOOR HANDLE WITH KESSY

Removing
-- Remove lock cylinder housing. Refer to LOCK CYLINDER HOUSING.
Fig. 22: Identifying Dismantling Of Door Handle

-- Swing door handle down in -direction of arrow b-, the KESSY connector is carried along in the mounting
bracket.
-- If door handle is at a right angle to the door, KESSY connector is in a "park position".
-- Pull door handle -1- at a right angle -arrow- out of mounting bracket -1-, the KESSY connector -2- loosens at
the same time.
Fig. 23: Identifying Removal Of Door Handle And Kessy Connector

Installing
-- Insert door handle -1- in mounting bracket at a right angle -arrow- and in KESSY connector -2- locking tab.
Fig. 24: Identifying Installation Of Door Handle And Kessy Connector

Fig. 25: Identifying Reinstallation Of Door Handle

Install the lock cylinder housing.
Function Test, Performing
-- Remove remote control key from ignition lock and from vehicle.
-- Lock vehicle via button on door handle.
-- Lock vehicle again via button on door handle.

-- Erase the DTC memory. Refer to the appropriate diagnosis information: Vehicle diagnosis, testing and
information system VAS 5051.
 On Board Diagnostic (OBD)

 46 - comfort system central control module
 004 DTC memory contents
DOOR LOCK
NOTE: Removing and installing the door lock is described. Removing and installing the
left door lock is identical.
Removing
-- Remove the subframe -4-. Refer to SUBFRAME.
-- Rotate subframe -4- around and disconnect harness connector -2- from door lock -1-.
-- Drive out clips -5- using a mandrel.
-- Using a screwdriver, pry off door lock -1- with angled mounting bracket -6- and mounting bracket -7- from
subframe.
Fig. 26: Identifying Subframe, Mounting Bracket And Door Lock

-- Remove bearing bracket. Refer to BRACKET.
-- Remove the bracket. Refer to ANGLED BRACKET.
-- Engage retainer -5- by rotating in -direction of arrow a-.
-- Lift retainer -5- out of mount -arrow b-.
-- Swivel cable -4- 90° -arrow c- and remove the cable nipple -3- from eyelet -2-.
Fig. 27: Identifying Removal Of Angel Bracket

-- Rotate lock -1- around.
-- Remove retainer -2- from mount.
-- Swivel cable -3- in -direction of arrow b- and remove cable nipple -4- from eyelet -5-.
Fig. 28: Identifying Removal Of Nipple From Eyelet

Installing
 Then a function test must be performed because the lock will not open if the release cable is not adjusted
and secured correctly.
BRACKET
Removing
-- Press down locking mechanism -arrow a- on mounting bracket -1-.
-- Slide mounting bracket -1- in -direction of arrow b- until mounting points -6- in guide of angled mounting
bracket -5- are completely visible.
-- Remove mounting bracket from angled mounting bracket.
Fig. 29: Identifying Direction To Slide Mounting Bracket

-- Remove cable -1- out of guide in mounting bracket -2-.
-- Swivel cable -1- in -direction of arrow- and remove cable nipple -3- from eyelet.
Fig. 30: Identifying Bearing Bracket Remove/Install Components

Installing
-- Secure the cable nipple -3- of cable in eyelet and swivel cable -1- in opposite -direction of arrow- on to
mounting bracket.
Fig. 31: Identifying Bearing Bracket Remove/Install Components

-- Secure cable -1- in guide in mounting bracket -2-.

Fig. 32: Identifying Direction To Slide Mounting Bracket

-- Guide mounting points -6- of mounting bracket -1- into guides of angled mounting bracket -5-.
-- Slide the bracket into the retainer until the it engages -arrow a-.
ANGLED BRACKET
Removing
-- Disengage catches -arrows a-.
-- Pull off angled mounting bracket -1- from door lock -2- -arrow c-.
Fig. 33: Identifying Angled Mounting Bracket Remove/Install Components

Installing
-- Slide angled mounting bracket into mount of lock -arrow b-.
-- Engage angled mounting bracket -1- and door lock -2- with each other -arrows a-.
Fig. 34: Identifying Angled Mounting Bracket Remove/Install Components

INNER DOOR SEAL
NOTE: The following describes removal and installation of the left inner door seal only.
The procedure for the right inner door seal is derived accordingly from this.
Removing
-- Pull off inner door seal from body flange.

Fig. 35: Identifying Inner Door Seal Remove/Install Components

Installing
-- Align inner door seal with vulcanized point -arrow- at the height of the lower hinge.
-- Start installation of inner door seal in upper radius of door cutout.

Fig. 36: Identifying Inner Door Seal Remove/Install Components

OUTER DOOR SEAL
NOTE: The following describes removing and installing the right outer door seal only.
Removing and installing the left outer door seal is identical.
Remove protective film just prior to assembly. The processing temperature is

approximately 68 °F (20 °C).
Removing
-- Pull off outer door seal from door.
Fig. 37: Identifying Outer Door Seal Remove/Install Components

Installing
-- Remove any adhesive residue with the adhesive strip remover VAS 6349 radial disc.
-- Thoroughly clean the adhesive surface with adhesive remover D 002 000 10 right before installing the outer
door seal.
-- Vulcanized point -arrow- on the outer door seal is located in center area of door entry sill.
-- Remove the protective film and apply the seal to the door. Do not stretch the outer door seal excessively so
that the seal is not too long at the end.
Fig. 38: Identifying Outer Door Seal Remove/Install Components

-- Press the entire adhesive surface of the seal -3- firmly onto the door all around -1- using the roller 3356.
-- This way, the seal is pressed to the side -arrow a- so that the roller 3356 comes into direct contact with the
seal contact surface.
used.
-- If the seal has become too long, cut it back to the correct length and press the area with the joint on well.
-- If small areas of the seal -3- loosen again, press them back on with the roller 3356.
Fig. 39: Identifying Seal, Door And Application Roller 3356

NOTE: To ensure that the outer door seal does not loosen or slide again, do not close
the door for 2 hours.
CENTRAL LOCKING
BATTERY FOR REMOTE CONTROL KEY
Fig. 40: Identifying Remote Control Key, Assembly Overview

1. Emergency key
2. Remote control key - upper section
3. Battery
4. Remote control key - cover cap
5. Remote control key with variable code transponder - lower section
Removing
Press side button -2- on remote control key -3- and remove emergency key -4-.
Fig. 41: Identifying Direction To Pull Off Remote Control Key Cover Cap
-- Pull off cover cap -1- forcefully in direction of -arrow- of side button -2- for remote control key -3-.
-- Unlock the catches on the remote key upper section -2-.
Fig. 42: Identifying Upper Section Of Remote Control Key And Trim Removal Wedge 3409
-- Using trim removal wedge 3409 -3-, lift off upper section of remote control key -arrow-.
-- Lift battery -3- slightly using a screwdriver -2-.
Fig. 43: Identifying Removal Of Battery From Retainer

-- Remove battery -3- in -direction of arrow- from retainer -4-.
Installing
NOTE: Before installing the battery, one of the buttons must be pushed.
The radio remote container is reset and only recognize a new battery.
Keep the correct polarity and position when installing the batteries.
Fig. 44: Identifying Installation Of Battery Into Retainer

-- Guide battery -2-, with positive pole facing up, at an angle -arrow- into retainer -3- of remote control key -1-
(positive pole is marked in housing).
-- Battery engages in remote control key by applying light pressure.
-- Now engage upper section of remote control key with remote control key (do not damage seal).
-- Then slide cover on to remote control key. And guide emergency key into remote control key.
SPECIAL TOOLS

 Socket 3410
 Application roller for door insulation foil 3356
 Hot air gun V.A.G 1416
 Adhesive remover VAS 6349
 Door adjusting wrench 3320
 Joint for 3320 3320/1
 Box wrench 3320/2
Fig. 45: Identifying Door Adjusting Wrench 3320, Joint For 3320 3320/1, Box Wrench 3320/2 And
Box Wrench 3320/3

Socket T10054
Fig. 47: Identifying Socket T10054

Adjustment gauge 3371
Fig. 48: Identifying Adjusting Gauge 3371

Fig. 49: Identifying Special Tools -- Door Components

Suspension Front Suspension
Suspension
Front Suspension
40 FRONT SUSPENSION
GENERAL INFORMATION
LONGITUDINAL MEMBER THREADS, SERVICING
Servicing weld nut threads in side rail is possible under certain circumstances.
FRONT SUSPENSION OVERVIEW

Fig. 1: Front Axle, Overview

1. I -
Refer to SUBFRAME, STABILIZER BAR AND CONTROL ARMS ASSEMBLY OVERVIEW.
2. II -
Refer to WHEEL BEARING ASSEMBLY OVERVIEW.
3. III -
4. III -
Adaptive chassis DCC suspension strut, refer to FRONT SUSPENSION STRUT ASSEMBLY
OVERVIEW .
Drive axles, removing and installing, refer to:
 DRIVE AXLE WITH CV JOINT

 DRIVE AXLE WITH TRIPLE ROLLER JOINT AAR2600I AND AAR3300I MOUNTED
 DRIVE AXLE WITH TRIPOD JOINT AAR3300I MOUNTED
WHEEL BEARING, LIFTING TO CURB WEIGHT POSITION
 Engine/transmission jack V.A.G 1383 A

 Tensioning strap T10038
 Wheel hub support T10149
NOTE: All bolts at suspension parts with bonded rubber bushings must always be
tightened in curb weight position (unloaded condition).
Bonded rubber bushings can only be turned to a limited extent.
Parts with bonded rubber bushings must therefore be brought into a position that corresponds to the position in
driving mode before being tightened (curb weight position).
Otherwise, the bonded rubber bushing will be stressed resulting in a shortened service life.
By raising appropriate suspension using V.A.G 1383 A and T10149, this position can be simulated on the hoist.
WARNING: Before appropriate suspension is raised, vehicle must be strapped on

both sides to lift arms of hoist using T10038.
If a vehicle is not secured, there is danger that the vehicle could slip off
the lift!
-- Turn wheel hub far enough until one of the holes for wheel bolts is on top.
-- Install T10149 with wheel bolt on wheel hub.
Tightening of the respective bolts/nuts must then only occur after dimension -a- between the wheel hub center
and the lower edge of wheel housing has been attained.
Fig. 2: Identifying Dimension Between Wheel Hub Center And Lower Edge Of Wheel Housing
Dimension -a- is dependent on standing height of installed suspension:
Chassis (1) Standing Height -a- in mm

Basic suspension (G02/G07/G11/G12/G15) 383 +/- 10 mm
Basic suspension with Nivomat (G02/G07/G15) 383 +/- 10 mm
Basic chassis with adaptive chassis DCC (G41) 373 +/- 10 mm
Heavy duty suspension (G04/G09) 403 +/- 10 mm
Comfort heavy duty suspension (G05/G10/G16) 393 +/- 10 mm
Sport suspension except 18" wheels (G/G08) 368 +/- 10 mm
Sport suspension with 18" wheels (G23/G28) 368 +/- 10 mm
Basic suspension with adaptive chassis DCC and 18" wheels (G41) 373 +/- 10 mm
Blue Motion (G37/G38) 368 +/- 10 mm
R36 (G36) 358 +/- 10 mm
R36 with adaptive chassis DCC (G46) 358 +/- 10 mm
(1) The suspension that the vehicle is equipped with is indicated on the vehicle data plate. Suspension is
represented by PR number. To determine which PR number represents which suspension, refer to
WHEEL ALIGNMENT SPECIFIED VALUES .
-- Using V.A.G 1383 A, lift wheel bearing housing until dimension -a- is reached.
WARNING:  Do not lift or lower vehicle with V.A.G 1383 A below vehicle.
 Do not leave V.A.G 1383 A below vehicle any longer than necessary.
-- Tighten respective bolts/nuts.

-- Lower wheel bearing housing.
-- Remove V.A.G 1383 A under vehicle.
-- Remove T10149.
SUBFRAME, SECURING
 Locating pins T10096

Installing T10096
To secure the subframe with the brackets, T10096 must be installed in positions -1- , -8- , -9- and -16- , one
after the other.
Fig. 3: Identifying Locating Pins T10096 Positions

NOTE: T10096 may only be tightened to a maximum of 20 Nm, since otherwise the
threads of the locating bolts will be damaged.
Fig. 4: Locating Control Arm Bolts And T10096

Securing Mounting Bracket
-- Replace the bolts of the mounting bracket one after the other on both sides using T10096 and tighten them to
20 Nm.
Fig. 5: Locating Subframe

Subframe, Securing
-- Replace the front bolts of the subframe one after the other using T10096 and tighten to 20 Nm.
Position of front axle is now secured.
Continue with removing stabilizer.
Remove steering gear, through MY 2008. Refer to V.A.G 1383 A under subframe" under: STEERING GEAR,
THROUGH MY 2008 .
Remove steering gear, from MY 2009. Refer to V.A.G 1383 A under subframe" under:STEERING GEAR,
FROM MY 2009 .
Continue removing the subframe without the steering gear.
Continue removing the subframe with the steering gear.
Removing T10096
Removal is performed in the reverse order of installation. Make sure that the T10096 are replaced one after the
other with new bolts.
Tightening Specifications, Subframe to Body
Bolt Tightening Specification

M12 x 1.5
x 90
70 Nm + 90° turn
 Use
new
bolts.
M12 x 1.5
x 100
70 Nm + 90° turn
 Use
new
bolts.
M12 x 1.5
x 110
70 Nm + 90° turn
 Use
new
bolts.
SUBFRAME, LOWERING

Removing
-- Turn the steering wheel to the straight-ahead position and remove the ignition key so that the electric steering
wheel lock releases.
-- Remove the nuts -arrows- and remove foot well trim -1-.
Fig. 6: Identifying Footwell Trim And Nuts

-- Remove the bolt -1- and remove the universal joint -2- from the steering gear.
Fig. 7: Identifying Universal Joint

-- Remove the lower noise insulation. Refer to Description and Operation .
Vehicles with Auxiliary Heater
-- Remove bolts -arrows A- from heat shield.

Fig. 8: Heat Shield And Subframe Bracket Bolts

-- Remove bracket -2- from subframe.
-- Remove bolt -arrow B- and slide exhaust pipe of auxiliary heater -1- upward.
Continuation for All Vehicles
-- Remove exhaust system bracket from subframe -arrows-.

Fig. 9: Identifying Exhaust System Bracket From Subframe Bolts

-- Remove pendulum support from transmission, unscrew bolts -13- to do so.

Fig. 10: Identifying pendulum support bolts

-- Remove the coupling rods from the stabilizer bar.
-- Subframe, securing, refer to SUBFRAME, SECURING.
-- Place the V.A.G 1383 A under the subframe.

Fig. 11: Engine/Transmission Jack V.A.G 1383 A Placed Below Subframe

-- Place for example a block of wood -1- between V.A.G 1383 A and subframe.
-- Remove the bolts -9- and -10- and lower the subframe maximum 10 cm.
Fig. 12: Identifying Subframe Bolts

NOTE: Be careful not to overstretch the electrical wire for the steering.
Installing
-- Install the lower noise insulation. Refer to Description and Operation .
NOTE: Make sure that the ball joint boot is not damaged or twisted.
Component Tightening Specification

Stabilizer bar to
connecting link
 Use new
nut.
 Counterhold
at joint pin 65 Nm
inner multi-
point fitting.
Universal joint to
steering gear
20 Nm + 90° turn
Use a new
bolt.
Exhaust system bracket to the subframe, refer to FRONT EXHAUST PIPE WITH CATALYTIC
CONVERTER .

M12 x 1.5
x 90
70 Nm + 90° turn
 Use
new
bolts.
M12 x 1.5
x 100
70 Nm + 90° turn
 Use
new
bolts.
M12 x 1.5
x 110
70 Nm + 90° turn
 Use
new
bolts.
Tightening Specifications, Pendulum Support to the Transmission
CAUTION: From MY 2008, Heli-Coil inserts are installed in the threads for the
pendulum support threaded connection in the 02Q manual transmissions.
Differences, refer to TRANSMISSION .
On these and all other transmissions, use strength class 10.9 bolts.
If, in the 02Q manual transmissions, there is not Heli-Coil insert, then use
8.8 strength class bolts and the appropriate tightening specification.

M10 x 35
strength
class 8.8:
40 Nm + 90° turn
 Use
a
new
bolt.
M10 x 35
strength
class 10.9:
50 Nm + 90° turn
 Use
a
new
bolt.
M10 x 75
strength
class 8.8:
40 Nm + 90° turn
 Use
a
new
bolt.
M10 x 75
strength
class 10.9:
50 Nm + 90° turn
Use
a
new
bolt.
M12 x 1.5
x 85
 Use 60 Nm + 90° turn

a
new
bolt.
SUBFRAME, STABILIZER BAR AND CONTROL ARMS ASSEMBLY OVERVIEW
CAUTION:  Welding and straightening work on supporting or wheel carrying

components of suspension is not permitted.
 Always replace self-locking nuts.

 Always replace corroded bolts/nuts.
Fig. 13: Assembly Overview: Subframe, Stabilizer Bar, Control Arm

1. Nut
 65 Nm
 Counterhold at socket head of joint bolt when tightening.
 Self-locking.
 Always replace if removed.
2. Stabilizer Bar
 Various versions.
 Removing and installing, refer to STABILIZER BAR.
3. Coupling Rod
 Linking stabilizer to suspension strut.
4. Nut
 65 Nm
 Counterhold at socket head of joint bolt when tightening.
 Self-locking.
5. Mounting Bracket
 Locating, refer to Fig. 4.
 With bonded rubber bushing.
6. Bolt
 M10 x 70
 50 Nm + 90° turn
7. Bolt
 M12 x 1.5 x 100
 70 Nm + 90° turn
8. Bolt
 M6 x 16
 9 Nm
9. Left Front Level Control System Sensor -G78-

 Removing and installing, refer to FRONT LEFT LEVEL CONTROL SYSTEM SENSOR.
 Can be checked in Guided Fault Finding using the Vehicle Diagnostic Tester.
10. Control Arm

 Replace with ball joint if damaged.
 Removing and installing, refer to CONTROL ARM WITH MOUNTING BRACKET.
 Replacing bushing, refer to CONTROL ARM BONDED RUBBER BUSHING.
 it is possible there are different control arm versions (steel, sheet steel, aluminum).
NOTE: Do not install control arms made of different versions or made of

different materials on the right and left sides.
11. Nut
 M12 x 1.5
 20 Nm + 90° turn
 Self-locking
12. Ball Joint

 Checking, refer to BALL JOINT, CHECKING.
 Removing and installing, refer to BALL JOINT.
 Replace with control arm if damaged.
13. Nut
 Cast steel control arm: 60 Nm
 Steel and aluminum control arms: 100 Nm
 Self-locking
14. Nut
 9 Nm
15. Bolt
 M12 x 1.5 x 100: 70 Nm + 90° turn
 M12 x 1.5 x 110: 70 Nm + 90° turn
16. Bolt
 M8 x 55
 20 Nm + 90° turn
17. Bolt
 M12 x 1.5 x 110
 70 Nm + 90° turn
 Tighten only in curb weight position. Refer to WHEEL BEARING, LIFTING TO CURB
WEIGHT POSITION.
18. Bolt
 M14 x 1.5 x 70
 100 Nm + 90° turn
 Only tighten when pendulum support is bolted to transmission.
19. Lower Bonded Rubber Bushing for Pendulum Support

 Ejecting and pressing in. Refer to SUBFRAME BONDED RUBBER BUSHING.
 Various versions. Refer to Fig. 14
20. Pendulum Support

 Bolt first to transmission, then to subframe.

21. Bolt
Always pay attention the bolt size and strength class. There are different tightening specifications.
 M10 x 75 strength class 8.8: 40 Nm + 90° turn

CAUTION: From MY 2008, Heli-Coil inserts are installed in the threads for
the pendulum support threaded connection in the 02Q manual
transmissions. Differences, refer to TRANSMISSION .
On these and all other transmissions, use strength class 10.9

bolts.
If, in the 02Q manual transmissions, there is not Heli-Coil insert,

then use 8.8 strength class bolts and the appropriate tightening
specification.
 M12 x 1.5 x 85: 60 Nm + 90° turn

22. Bolt
Pay attention to the bolt strength class. There are different tightening specifications.

CAUTION: From MY 2008, Heli-Coil inserts are installed in the threads for
the pendulum support threaded connection in the 02Q manual
transmissions. Differences, refer to TRANSMISSION .
On these and all other transmissions, use strength class 10.9

bolts.
If, in the 02Q manual transmissions, there is not Heli-Coil insert,

then use 8.8 strength class bolts and the appropriate tightening
specification.

23. Shield
24. Bolt
 6 Nm
25. Bolt
 M12 x 1.5 x 90
 70 Nm + 90° turn
26. Subframe
 Locating, refer to SUBFRAME, SECURING.
 Lowering, refer to SUBFRAME, LOWERING.
 Removing and installing without steering gear, refer to SUBFRAME WITHOUT STEERING
GEAR.
 Removing and installing with steering gear, refer to SUBFRAME WITH STEERING GEAR.
27. Upper Bonded Rubber Bushing for Pendulum Support

 Ejecting and pressing in, refer to SUBFRAME BONDED RUBBER BUSHING.
 Various versions. Refer to Fig. 14
Fig. 14: Identifying the Pendulum Support Bonded Rubber Bushing

NOTE: There are two different versions of the pendulum support bonded rubber
bushing: the T version -I- and the V version -II-.
I-
The corners on the inner core -1- face toward the opening for the pendulum support -arrow- (T version).
II -
The corners on the inner core -2- face away from the opening for the pendulum support -arrow- (V version).
LEFT FRONT LEVEL CONTROL SYSTEM SENSOR ASSEMBLY OVERVIEW
NOTE: Assembly Overview: front left and right level control system sensors -
G78/G289- for the adaptive chassis DCC, refer to FRONT LEVEL CONTROL
SYSTEM SENSOR ASSEMBLY OVERVIEW .
A replacement front left level control system sensor comes complete with the
coupling rod and the upper and lower retaining plate.
Replace with subframe installed.

Fig. 15: Identifying Subframe Component Locations

1. Subframe
2. Bolt
 M6 x 16
 9 Nm
3. Left Front Level Control System Sensor -G78- and Right Front Level Control Sensor -G289-
 Complete with components.
 Lever -arrow- must point toward vehicle exterior.
 Removing and Installing, refer to FRONT LEFT LEVEL CONTROL SYSTEM SENSOR.
"Guided Fault Finding" function.

4. Control Arm
5. Nut
 9 Nm
 Self-locking.
WHEEL BEARING ASSEMBLY OVERVIEW
Fig. 16: Wheel Bearings, Assembly Overview

1. Suspension Strut
2. Bolt
 Bolt point must face in direction of travel.
3. Left Front ABS Wheel Speed Sensor -G47- /Right Front ABS Wheel Speed Sensor -G45-
 Before inserting wheel speed sensor, clean inner surface of bore hole and coat with securing grease
G 000 650.
4. Bolt
 M6 x 16
 8 Nm
5. Tie Rod End

 Sensor ring for ABS is installed in wheel hub.
7. Nut
 M12 x 1.5
 Tighten to 100 Nm, then loosen by 180° and tighten to 100 Nm again.
 Self-locking
8. Internally Vented Brake Disc

9. Bolt
 Hex head bolt: 200 Nm + 180° additional turn
 Bolt, Loosening and Tightening, refer to DRIVE AXLE HEX BOLT CONNECTION,
LOOSENING AND TIGHTENING.
WARNING:  There are 2 types of twelve-point bolts, with and without

ribs. Distinguishing characteristic, refer to Fig. 17
 When installing a twelve-point bolt, always check what
type of twelve-point bolt is to be used.
 Use the correct tightening specification for the specific
bolt.
 The tightening specification for a twelve-point bolt with
ribs is 70 Nm + 90° turn. For loosening and tightening
specifications, refer to DRIVE AXLE TWELVE-POINT BOLT
WITH RIBS, LOOSENING AND TIGHTENING.
 The tightening specification for a twelve-point bolt without

10. Bolt
 Tightening specification, refer to Description and Operation .
11. Bolt
 M6 x 12
 12 Nm
12. Cover Plate

 Removing and installing, refer to WHEEL BEARING HOUSING.
 With bolted brake carrier.
 If a wheel bearing housing is replaced, vehicle must then be aligned. Refer to WHEEL
ALIGNMENT .
14. Bolt
 M12 x 1.5 x 45
 70 Nm + 90° turn
15. Drive Axle

 Removing and installing, refer to DRIVE AXLE WITH CV JOINT.
16. Nut
 M12 x 1.5 x 80
 70 Nm + 90° turn
 Self-locking

Fig. 17: Differences Between a Twelve-Point Bolt with Ribs and a Twelve-Point Bolt without Ribs
The contact surfaces -arrow A- and -arrow B- are different on the two-point bolts.
I-
Twelve-point bolt with ribs -arrow A-
II -
Twelve-point bolt without ribs -arrow B-
SUSPENSION STRUT ASSEMBLY OVERVIEW
NOTE: Assembly overview for adaptive chassis DCC, refer to FRONT SUSPENSION
STRUT ASSEMBLY OVERVIEW .
CAUTION:  Shock absorber 3C0.413.031.AE has been replaced by shock

absorber 3C0.413.031.AL as a running change. Shock absorber
3C0.413.031.AE is not longer available as a replacement part.
 It is not possible to interchange shock absorbers 3C0.413.031.AE and
3C0.413.031.AL.
 Late in production shock absorber 3C0.413.031.AL was replaced by
shock absorber 3C0.413.031.AT. Shock absorber 3C0.413.031.AL is
not longer available as a replacement part.
 If shock absorber 3C0.413.031.AL or shock absorber 3C0.413.031.AE
is to be replaced by a shock absorber 3C0.413.031.AT then is must be
replace as a pair. The right and left shock absorber must be replaced.
 It is not possible to interchange shock absorber 3C0.413.031.AL or
shock absorber 3C0.413.031.AE with shock absorber 3C0.413.031.AT.
Fig. 18: Suspension, Assembly Overview

1. Shock Absorber
 Individually replaceable.
Note the following before beginning the work!

CAUTION: Shock absorber 3C0.413.031.AE has been replaced by shock

absorber 3C0.413.031.AL as a running change. Shock absorber
3C0.413.031.AE is not longer available as a replacement part.
2. Buffer Stop
3. Protective Sleeve
4. Coil Spring
 Removing and installing, refer to SUSPENSION STRUT.
 Note color code.
Spring allocation via PR No.
These numbers can be found on vehicle data plate.
 Surface of spring coil may not be damaged.

5. Axial Groove Ball Bearing
6. Suspension Strut Bearing
 Note installed position. Refer to SUSPENSION STRUT
7. Nut
 M14 x 1.5
 60 Nm
 Self-locking
8. Suspension Strut Dome

9. Bolt
 M8 x 26
 15 Nm + 90° turn
DRIVE AXLE HEX BOLT CONNECTION, LOOSENING AND TIGHTENING
 Angle wrench V.A.G 1756
The wheel bearing must not be under a load while the drive axle threaded connection on the wheel side is loose.
If the bearings are loaded by the vehicle's own weight the wheel bearing will be damaged. This reduces the
service life of the wheel bearings. Therefore, observe the following:
 Procedure for loosening hex bolt.

Vehicles without a drive axle must not be moved, otherwise the wheel bearing will be damaged. If vehicle must
be moved, observe the following:
-- Install an outer joint in place of the drive axle.
-- Tighten outer joint to 120 Nm.
Loosening
-- With vehicle still standing on its wheels, loosen hex bolt a maximum of 90°, otherwise wheel bearing will be
damaged.
-- Raise vehicle enough that wheels hang freely.
-- Operate brake (second mechanic required).
-- Remove hex bolt -arrow-.
Fig. 19: Wheel Hex Bolt

Tightening
-- Replace hex bolt.
NOTE: Wheels must not yet touch the ground to tighten the drive axle, wheel bearing
may otherwise be damaged.

-- Tighten hex bolt to 200 Nm.
-- Lower the vehicle onto its wheels.
-- Turn bolt an additional 180°.
DRIVE AXLE TWELVE-POINT BOLT WITH RIBS, LOOSENING AND TIGHTENING
 Socket XZN 24 T10361

Differences Between a Twelve-Point Bolt with Ribs and a Twelve-Point Bolt without Ribs
I-
II -
CAUTION: The wheel bearing must not be under a load while the drive axle threaded
connection on the wheel side is loose.
If the wheel bearings are under the load of the vehicle's own weight, the
wheel bearing will be damaged. This reduces the service life of the wheel
bearings.
The drive axle bolt may be loosened maximum 90° when the vehicle is
standing on its wheels.
Vehicles without a drive axle must not be moved, otherwise the wheel
bearing will be damaged. If a vehicle must be moved, be sure to note the
following:
 Install an outer joint in place of the drive axle.

 Tighten the outer joint to 120 Nm.
Loosening
-- With vehicle still resting on wheels, loosen 12-point bolt with T10361 maximum 90°, otherwise, wheel
bearing will be damaged.
-- Remove 12-point bolt -arrow-.

Fastening
-- Replace 12-point bolt.
-- Tighten 12-point bolt to 70 Nm.
-- Tighten 12-point bolt an additional 90°.
DRIVE AXLE TWELVE-POINT BOLT WITHOUT RIBS, LOOSENING AND TIGHTENING
 Socket XZN 24T10361

I-
II -
bearings.
following:

Loosening
-- With vehicle still resting on wheels, loosen 12-point bolt with T10361 maximum 90°, otherwise, wheel


Tightening
DRIVE AXLE OVERVIEW

Fig. 24: Drive Shafts, Overview

1. I -
Drive axle with CV joint VL100, refer to DRIVE AXLE ASSEMBLY OVERVIEW, WITH CV
JOINT VL100.
2. II -
Drive axle with CV joint VL 107, refer to DRIVE AXLE ASSEMBLY OVERVIEW, WITH CV
JOINT VL 107.
Drive axle with tripod joint AAR2600i, refer to DRIVE AXLE ASSEMBLY OVERVIEW, WITH
TRIPOD JOINT AAR2600I.
4. IV -
Drive axle with tripod joint AAR3300i, refer to DRIVE AXLE ASSEMBLY OVERVIEW, WITH
TRIPLE ROLLER JOINT AAR3300I.
5. IV -
Drive axle with tripod joint AAR3300i for automatic transmission 09M, 6-speed, AWD, refer to DRIVE
AXLE ASSEMBLY OVERVIEW, WITH TRIPLE ROLLER JOINT AAR3300I, 09M
AUTOMATIC TRANSMISSION, 6-SPEED, AWD.
Difference of Drive Axles in Installed Condition
VL100 VL107 AAR2600i AAR3300i

Diameter of inner joint in mm 100 107 - -
Cover between inner joint and flange shaft - X - -
Inner joint inserted into transmission (automatic transmission only) - - X X
Inner joint placed on transmission (only automatic transmission
- - - X
with AWD)
Inner joint with flange shaft bolted to transmission (manual or
X X - X
direct clutch transmission only)
DRIVE AXLE HEAT SHIELDS
Fig. 25: Drive Axle Heat Shield -- Front Wheel Drive


Hex bolt -1- 25 Nm
Fig. 26: FWD 09M Automatic Transmission


Bolts -1- 40 Nm
Fig. 27: Drive Axle Heat Shield -- All Wheel Drive


20 Nm
Nuts -1-
 Pre-tighten all nuts to 10 Nm.
DRIVE AXLE ASSEMBLY OVERVIEW, WITH CV JOINT VL100
Fig. 28: Drive Axle With CV Joint Vl100, Assembly Overview

1. Outer CV Joint
 Replace only as complete unit.
 Removing, refer to Removing the Outer CV Joint.

 Installing: Drive onto shaft until impact using plastic hammer.

 Checking, refer to OUTER CV JOINT, CHECKING.
2. Bolt
 Hex head bolt: 200 Nm + 180° additional turn.
 Bolt, loosening and tightening, refer to DRIVE AXLE HEX BOLT CONNECTION,

bolt.

3. Right Drive Axle
4. Clamp
 Tensioning, refer to Fig. 146
5. Protective Boot
 Check for tears and scuffing.
 Material: Hytrel (Polyelastomer).
6. Clamp
7. Dished Washer
 Installed position, refer to Fig. 141
8. Thrust Washer
9. Securing Ring
 Insert in shaft groove.

10. CV Boot
 Material: Hytrel (Polyelastomer)
 Without ventilation bore.
 Drive off CV joint using drift.
 Before mounting onto CV joint, coat sealing surface using D 454 300 A2.
11. Clamp
12. Left Drive Axle

13. Backing Plate
14. Bolt
 First tighten to 10 Nm in a diagonal sequence, then tighten to tightening specification in a diagonal
sequence.
M8 bolt: 40 Nm
M10 bolt: 70 Nm
 Always replace bolts after disassembly.

15. Securing Ring
 Remove and install using VW 161 A.
16. Gasket
 Bonding surface on CV joint must be free of grease and oil!
17. Inner CV Joint

 Pressing off, refer to Fig. 142
 Pressing on, refer to Fig. 144
 Checking, refer to INNER CV JOINT, CHECKING.
18. Dished Washer

Fig. 29: Differences Between A Twelve-Point Bolt With Ribs And A Twelve-Point Bolt Without Ribs
Differences between a twelve-point bolt with ribs and a twelve-point bolt without ribs
I-
II -
DRIVE AXLE ASSEMBLY OVERVIEW, WITH CV JOINT VL 107

Fig. 30: Drive Axle Constant Velocity (CV) Joint Vl107, Assembly Overview
1. Outer CV Joint
 Removing the Outer CV, refer to DRIVE AXLE WITH CV JOINT VL107
2. Bolt
 Hex head bolt: 200 Nm + 180° turn


bolt.

3. Securing Ring
4. Spacer
5. Dished Washer
6. Clamp
7. Protective Boot
8. Clamp
9. Driveshaft
10. Clamp
11. CV Boot

12. Clamp
13. Backing plate

14. Cover
 Carefully drive off using a drift.
 Adhesive surface must be free of oil and grease.
15. Inner CV Joint

 Pressing on, refer to Fig. 151
16. Gasket
17. Securing Ring

 Remove and install using snap ring pliers VW 161 A.
18. Cover
19. Bolt
sequence.
M8 bolt: 40 Nm
M10 bolt: 70 Nm

Fig. 31: Differences Between A Twelve-Point Bolt With Ribs And A Twelve-Point Bolt Without Ribs
I-
II -
DRIVE AXLE ASSEMBLY OVERVIEW, WITH TRIPOD JOINT AAR2600I

Fig. 32: Drive Axle With Triple Roller Joint AAR2600i, Assembly Overview
1. Outer CV Joint
 Replace only as complete unit,
 Installing: Drive onto shaft using plastic hammer until expanded securing ring contracts.
2. Bolt


bolt.

3. Right Drive Axle
4. Left Drive Axle
5. Clamp
6. CV Boot
7. Clamp
8. Dished Washer
9. Spacer
10. Securing Ring

11. Clamp
 Tension using hose clamp pliers V.A.G 1275.


13. Clamp
14. Securing Ring

15. Joint Piece

16. Securing Ring
 insert in groove on shaft using circlip pliers VW 161 A.
17. Triple Roller Star with Rollers
The chamfer -arrow- points to drive axle splines.
I-
II -
DRIVE AXLE ASSEMBLY OVERVIEW, WITH TRIPLE ROLLER JOINT AAR3300I
Fig. 34: Drive Axle With Triple-Roller Joint AAR3300I, Assembly Overview
1. Outer CV Joint
 Installing: Drive onto shaft using plastic hammer until expanded securing ring contracts.

2. Bolt
 Bolt, loosening and tightening, refer to DRIVE AXLE HEX BOLT CONNECTION,

bolt.

3. Securing Ring
4. Spacer
5. Dished washer
6. Clamp
7. CV Boot
8. Clamp
9. Drive Axle

11. Protective Joint Boot for Triple Roller Joint

12. Clamp
13. Triple Roller Star with Rollers
14. Securing Ring

15. Joint Piece

 For automatic transmission.
16. Securing Ring

17. Bolt
sequence.
M10 bolt: 70 Nm
18. Joint Piece

I-
II -
DRIVE AXLE ASSEMBLY OVERVIEW, WITH TRIPLE ROLLER JOINT AAR3300I, 09M AUTOMATIC
TRANSMISSION, 6-SPEED, AWD
Fig. 36: Identifying Drive Axle Assembly Component Locations

1. Outer CV Joint
 Installing: Drive onto shaft using plastic hammer until compressed circlip seats.
2. Bolt


bolt.

3. Securing Ring
4. Clamp
 Tensioning Fig. 145
5. CV boot
 Material: Hytre (Polyelastomere).
6. Clamp
7. Drive Axle
8. Clamp
9. Protective Joint Boot for Triple Roller Joint

10. Clamp

12. Securing Ring

13. Adapter
14. Joint Piece
I-
II -
SPECIFICATIONS

ABS Wheel Speed Sensor to Wheel Bearing Housing Bolt M6 x 16 8
Ball Joint to Control Arm Nut (1)

- Cast Steel Control Arm - 60
- Steel and Aluminum Control Arms - 100
Ball Joint to Wheel Bearing Housing Nut (1) M12 x 1.5 20 + 90° turn
Control Arm to Subframe Bolt 1, 2 M12 x 1.5 x 110 70 + 90° turn
Control Arm Mounting Bracket to Body Bolt (1) M12 x 1.5 x 100 70 + 90° turn
Control Arm Mounting Bracket to Subframe Bolt (1) M10 x 70 50 + 90° turn
Coupling Rod to Stabilizer Bar Nut (1) - 65
Coupling Rod to Strut Nut (1) - 65
Cover Plate to Wheel Bearing Housing Bolt M6 x 12 12
CV Joint Boot Clamp - 25
Drive Axle Heat Shield to Transmission
- FWD Bolt - 25
- FWD 09M Automatic Transmission Bolt - 40
- AWD Nut (4) - 20
Drive Axle to Transmission Bolt 1, 5 M8 40
M10 70
Drive Axle to Wheel Hub Bolt (1)
- Hex Head Bolt - 200 + 180° turn
- Twelve-Point Bolt with Ribs - 70 + 90° turn
- Twelve-Point Bolt without Ribs - 200 + 180° turn
Front Level Control System Sensor to Control Arm Nut (1) - 9
Front Level Control System Sensor to Subframe Bolt M6 x 16 9
Pendulum Support to Subframe Bolt M14 x 1.5 x 70 100 + 90° turn
Pendulum Support to Transmission Bolt (1)
- Strength Class 8.8 M10 x 35 40 + 90° turn
- M12 x 1.5 x 85 60 + 90° turn
Shield to Subframe Bolt - 6
Stabilizer Bar to Subframe Bolt M8 x 55 20 + 90° turn
Strut to Body Bolt (1) M8 x 26 15 + 90° turn
Strut to Strut Bearing Nut (1) M14 x 1.5 60
Strut to Wheel Bearing Housing Nut (1) M12 x 1.5 x 80 70 + 90° turn
Subframe to Body Bolt (1) - 70 + 90° turn
Tie Rod End to Wheel Bearing Housing Nut 1, 3 M12 x 1.5 100
Wheel Hub to Wheel Bearing Housing Bolt (1) M12 x 1.5 x 45 70 + 90° turn
(1) Always replace after removal.
(2) Tighten only in curb weight position. Refer to WHEEL BEARING, LIFTING TO CURB
WEIGHT POSITION.
(3) Pre-tighten to 100 Nm, then loosen by 180° and tighten to 100 Nm again.
(4) Pre-tighten all nuts to 10 Nm.
(5) Pre-tighten to 10 Nm in a diagonal sequence, then tighten to tightening specification in a diagonal

sequence.
BALL JOINT, CHECKING
Axial Play, Checking
-- Pull control arm firmly downward in -direction of arrow - and press back up again.
Fig. 38: Checking Ball Joint Axial Play

Radial Clearance, Checking
-- Press wheel firmly in and out at bottom in -direction of arrow-.

Fig. 39: Checking Ball Joint Radial Play

NOTE: There should not be any noticeable or visible "play" in either of the two checks.
Observe lower ball joint while performing checks.
Make allowance for any wheel bearing play or "play" in strut mounting at top.
Check rubber boot for damage, replace lower ball joint, if necessary.
OUTER CV JOINT, CHECKING

Fig. 40: Ball Hub And Ball Cage Swiveled

It is necessary to disassemble the joint whenever replacing the grease or if the ball surfaces show wear or
damage.
Removing
-- Mark position of ball hub to ball cage and to housing before disassembling, using electro-writer or
grindstone.
-- Swing ball hub and ball cage.
-- Remove balls in sequence.
-- Turn cage, until two rectangular windows -arrow- contact joint body.
Fig. 41: Two Rectangular Windows Aligned With The Joint Housing
-- Lift out cage with hub.
-- Swing segment of hub into rectangular window of cage.

Fig. 42: Tilting Hub Out Of Cage

-- Fold hub out from cage.
6 balls for each joint belong to a tolerance group. Check stub axle, hub, cage and balls for small depressions
(pitting build-up) and chafing. Excessive circumferential backlash in joint makes itself noticed via tip-in shock,
in such cases joint should be replaced. Flattening and running marks of balls are no reason to replace joint.
Installing
-- Press in half of the total grease amount (40 grams) into joint body.
-- Insert cage with hub into joint body.
-- Press in opposing balls in sequence, during this, previous position of ball hub to ball cage and to joint body
must be established again.
-- Install new circlip into the hub.
-- Distribute remaining grease in cover.
INNER CV JOINT, CHECKING

Removing
The joint must be disassembled to replace dirty grease or for checking the balls and ball tracks for wear and
damage.
Fig. 43: Pressing Out Ball Joint Housing

-- Press out ball joint housing in direction of arrow.
-- Press balls out of cage.
NOTE: Ball hub and joint piece are paired. Do not interchange.
-- Flip out ball hub from ball cage via running path of ball -arrows-.
Fig. 44: Tilting Ball Hub Out Of Ball Cage Over Ball Track
-- Check joint piece, ball hub, ball cage and balls for small broken off depressions (pitting build-up) and
chafing.
Excessive circumferential backlash in joint makes itself noticed via tip-in shock. Joint must be replaced in such
cases. Flattening and running marks of balls are no reason to replace joint.
Installing
-- Insert ball hub into ball cage via two chamfers. The installation position is at random. Press balls into cage.
Fig. 45: Inserting Ball Hub Over Both Chamfers Into Ball Cage
Ball hub has 2 different distances between ball tracks, a larger and a smaller.
-- Insert hub with cage and balls upright into joint piece, a smaller space -b- must face toward open side of joint
piece when doing this.
Fig. 46: Identifying Wide Space On Joint Housing Aligned With The Narrow Space On The Hub
-- Also note chamfer on inner diameter of ball hub, it must be visible after swiveling in.
-- Swing in ball hub; to do so, swing out hub far enough out of cage -arrows- (as depicted in illustration).
Fig. 47: Ball Hub Installed With Hub Able To Be Swivelled Out Of The Cage
-- Swing in hub with balls by pressing forcefully onto cage -arrow-.

Fig. 48: Pressing Cage Firmly Until Hub Is In Position

CV Joint, Checking for Function
CV joint is properly assembled, if ball hub can be slid back and forth by hand over whole compensation length.
FRONT LEFT LEVEL CONTROL SYSTEM SENSOR
Removing
NOTE: In order to be able to remove the left front level control system sensor -G78- the
steering wheel must be turned all the way to the right; this assures that there is
enough clearance between the control arm and the stabilizer bar.

Fig. 49: Identifying Front Left Level Control Bolt And Sensor
-- Remove the bolt and the nut.
-- Remove level control system sensor.
Installing
NOTE: The level control system sensor lever must point toward vehicle exterior.
The thread on the vehicle level sensor must be installed into the front hole in
the control arm. The tab on the vehicle level sensor retainer must lock into the
rear hole in order to assure a correct installation position.
-- Perform a basic setting on the headlamps using the Vehicle Diagnostic Tester in "Guided Fault Finding"
function.

Bolt to
9 Nm
subframe
Nut
9 Nm
 Use
new
nut
SUBFRAME WITHOUT STEERING GEAR

Removing
NOTE: Subframe is removed together with control arms.
-- Remove wheels.
-- Remove the nuts -arrows- on left and right side of vehicle.
Fig. 50: Control Arm To Ball Joint Nuts

-- Remove the control arm from the ball joint.
-- Remove bracket for exhaust system from the subframe.
-- Remove bolts -arrows- from heat shield.

Fig. 51: Locating Heat Shield Bolts



-- Remove heat shield from subframe.
-- Remove coupling rod from stabilizer bar.


-- Subframe, locating, refer to SUBFRAME, SECURING.
-- Now remove the bolts for:
 Steering gear -3- and -6-

 Stabilizer -11- and -14-
 Subframe -4- and -5-.
-- Lower the subframe using the V.A.G 1383 A.
-- Remove cable guide from subframe -arrow-.

Fig. 54: Cable Guide At Subframe

-- Secure steering gear to body.
Installing
Installation is performed in the reverse sequence.
-- Install wheels, tightening specification, refer to TIGHTENING SPECIFICATION FOR MOUNTING

WHEELS .
-- Install noise insulation and tighten. Refer to Description and Operation .

Stabilizer bar to
subframe
20 Nm + 90° turn
 Use new
bolts.
Stabilizer bar to
connecting link
 Use new 65 Nm
nut.
 Counterhold
at joint pin
inner multi-
point fitting.
Shield to
subframe
6 Nm
 M6 bolt is
self-
tapping.
Steering gear to
subframe
50 Nm + 90° turn
 Use new
bolts.
Ball joint to steel
control arm
60 Nm
 Use new
nuts.
Ball joint to sheet
steel or aluminum
control arm
100 Nm
Use new
nuts.
CONVERTER .

M12 x 1.5
x 90
70 Nm + 90° turn
 Use
new
bolts.
M12 x 1.5
x 100
70 Nm + 90° turn
 Use
new
bolts.
M12 x 1.5 70 Nm + 90° turn

x 110
 Use
new
bolts.

M10 x 35
strength
class 8.8:
40 Nm + 90° turn
 Use
a
new
bolt.
M10 x 35
strength
class 10.9:
50 Nm + 90° turn
 Use
a
new
bolt.
M10 x 75
strength
class 8.8:
40 Nm + 90° turn
 Use
a
new
bolt.
M10 x 75
strength
class 10.9: 50 Nm + 90° turn
 Use
a
new
bolt.
M12 x 1.5
x 85

a
new
bolt.
SUBFRAME WITH STEERING GEAR
 Ball joint puller 3287 A

Removing
Vehicles with the Battery in the Engine Compartment
-- Remove the battery and the battery tray. Refer to [For engine(s) BPY,BLV,CCTA,CBFA] Removal and
Installation .
-- Disconnect the wire -1- from the E-box.
Fig. 55: Locating Wire In E-Box

-- Disconnect the ground wire -2-.
Fig. 56: Identifying Ground Cable And Connector

-- Disconnect the harness connector -3-.
-- Guide the wiring harness out of all the brackets on the longitudinal so it can be removed together with the
steering gear.
Fig. 57: Identifying Wiring Harness And Brackets On Longmember



-- Remove the front wheels.


-- Disconnect the connector from the oil level thermal sensor -G266- and disconnect the wire on the subframe.
-- Remove coupling rods from stabilizer.

Fig. 61: Identifying Lower Control Arm And Bolts

-- Loosen nut of track rod ball joint, but do not unscrew yet.
NOTE: To protect thread, screw nut on pin a few turns.
-- Press off tie rod end from wheel bearing housing with 3287A and then remove nut.
Fig. 62: Pressing Off Tie Rod End From Wheel Bearing Housing With Ball Joint Puller 3287A


-- Secure the subframe with consoles. Refer to SUBFRAME, SECURING


-- Place a block of wood -1- , for example, between V.A.G 1383 A and the subframe.
-- Loosen screws -4 and 5- and lower subframe with brackets slightly. Observe electrical wires when doing this.

-- Lower the VAG 1383 A and guide the steering gear wiring harness back.
-- Secure the subframe on the V.A.G 1383 A with the accompanying strap.
Fig. 66: Subframe Secured On Engine/Transmission Jack V.A.G 1383 A With Accompanying Strap
Installing
Installation is performed in the reverse sequence.
-- Install the battery tray and the battery. Refer to [For engine(s) BPY,BLV,CCTA,CBFA] Removal and
Installation .
-- Install noise insulation and tighten. Refer to Description and Operation .

Stabilizer bar to
connecting link
Use new
nut. 65 Nm
 Counterhold
at joint pin
inner multi-
point fitting.
Tie rod end to
wheel bearing
housing
Tighten to 100 Nm, then loosen by 180° and tighten to 100 Nm again
 Use new
nut.
Ball joint to steel

control arm
60 Nm
 Use new
nuts.
Ball joint to sheet
steel or aluminum
control arm
100 Nm
 Use new
nuts.
Universal joint to
steering gear
20 Nm + 90° turn
Use a new
bolt.
CONVERTER .

M12 x 1.5
x 90
70 Nm + 90° turn
 Use
new
bolts.
M12 x 1.5
x 100
70 Nm + 90° turn
 Use
new
bolts.
M12 x 1.5
x 110
70 Nm + 90° turn
 Use
new
bolts.

M10 x 35
strength
class 8.8:
40 Nm + 90° turn
 Use
a
new
bolt.
M10 x 35
strength
class 10.9:
50 Nm + 90° turn
 Use
a
new
bolt.
M10 x 75
strength
class 8.8:
40 Nm + 90° turn
 Use
a
new
bolt.
M10 x 75
strength
class 10.9:
50 Nm + 90° turn
 Use
a
new
bolt.
M12 x 1.5
x 85
60 Nm + 90° turn
 Use
a
new
bolt.
SUBFRAME BONDED RUBBER BUSHING
 Installation device 3372

 Thrust plate VW 401
 Punch VW 407
 Thrust piece VW 432
 Assembly tool T10214
 Assembly Tool T10267 with adapter T10267/1A
 Tube from assembly tool T10244/3
Pressing Out the Bonded Rubber Bushing
-- Remove subframe. Refer to SUBFRAME WITHOUT STEERING GEAR.
-- Install T10267 -4- on subframe. Secure safety bolts using securing pins.
Fig. 67: Assembly Tool T10267 Attached To Subframe

1. VW 407
2. Thrust piece 3372/1
3. VW 401
4. T10267
5. T10244/3
-- Press out both bonded rubber bushings at the same time as depicted in the illustration.
NOTE: Flat side of 3372/1 must face insert -A- of T10267, otherwise insert may be
damaged.
T10244/3 has a larger and a smaller inner diameter. Subframe must contact
larger inner diameter of T10244/3.
Pressing In the Bonded Rubber Bushing

Fig. 68: Both Bonded Rubber Bushings Bolted Onto Original Bolt
-- Insert bolted bonded rubber bushings, with bolt head downward, into large diameter of tube T10214/2.
Fig. 69: Bolted Bonded Rubber Bushings Placed Into Larger Diameter Of Tube T10214/2 With Bolt
Head Facing Downward
1. VW 432
2. Thrust piece T10214/3 without bolts
3. Bonded rubber mount
4. Tube T10214/2
5. Tube T10214/1
6. VW 401
-- Press bonded rubber bushing -1- in until dimension -a- has been obtained.
Fig. 70: Bonded Rubber Bushing Pressed In

Dimension -a- = 2 - 3 mm.
NOTE: There are two different versions of the pendulum support bonded rubber
bushing: the T version -I- and the V version -II-.
Fig. 71: Identifying the Pendulum Support Bonded Rubber Bushing

I-
The corners on the inner core -1- face toward the opening for the pendulum support -arrow- (T version).
II -
The corners on the inner core -2- face away from the opening for the pendulum support -arrow- (V version).
T Version of the Bonded Rubber Bushing

Fig. 72: View Of Inner Core Pendulum Support Opening

-- Align T10214/2 on subframe with pressed in bonded rubber bushings.
NOTE: The corners on the inner core of the bonded rubber bushing -arrows- must face
toward the T10244 -1-.
The corners on the inner core of the bonded rubber bushing -arrows- must lie
parallel with the edge of the T10244 -1-.
Distance -a- must be identical at left and right to guarantee parallelism.
V Version of the Bonded Rubber Bushing

Fig. 73: View Of Bonded Rubber Bushing

-- Align T10214/2 on subframe with pressed in bonded rubber bushings.
NOTE: The corners on the inner core of the bonded rubber bushing -arrows- must face
away from the T10244 -1-.
The corners on the inner core of the bonded rubber bushing -arrows- must lie
parallel with the edge of the T10244 -1-.
Distance -a- must be identical at left and right to guarantee parallelism.
Procedure for Both Versions
-- Subframe makes contact on smaller inner diameter of T10244/3.

Fig. 74: Mounting Pressed Onto Stop And Continue Pressing Until A Force Of 20 kN Is Achieved
-- Install the bearing all the way until a 20 kN force is reached.
1. VW 407
2. Thrust piece T10214/3
3. Tube T10214/2
4. T10267
5. Tube T10214/1
-- Remove T10267 from subframe and check seating of the pressed in bonded rubber bushing.
 The outer diameter -1- of both bonded rubber bushings must project up to 2 mm beyond edge in area of
opening for pendulum support.
Fig. 75: Identifying Outer Diameter Of Both Bonded Rubber Bushings And Pendulum Support
Opening
 Cutouts of bonded rubber bushings must lie at center in opening of subframe.

 Gap -arrow- between bonded rubber bushings is permissible.
-- Install subframe. Refer to Installing.
BALL JOINT
 Ball joint puller 3287A

Removing
-- Loosen drive axle bolt to wheel hub:

 Hex head bolt. Refer to DRIVE AXLE HEX BOLT CONNECTION, LOOSENING AND
TIGHTENING.
 Twelve point bolt. Refer to DRIVE AXLE TWELVE-POINT BOLT WITH RIBS, LOOSENING
AND TIGHTENING.
-- Remove the wheel.

-- Pull the drive axle slightly off the wheel hub.
-- Pull ball joint out of control arm.
-- Bend control arm as far downward as necessary.
-- Attach 3287 A as depicted in illustration and press out ball joint.

Fig. 77: Ball Joint Puller Installed

NOTE: Place V.A.G 1383 A or something similar underneath (danger of accident if parts
fall off when ejecting ball joint).
To protect ball joint thread, leave nut on a few turns.
Installing
-- Insert ball joint into wheel bearing housing.
-- Install drive axle in wheel hub.
-- Install new self-locking nut, and counter-hold using internal Torx bit T40.
-- Tighten nuts -arrows-.


-- Install wheel and tighten. Refer to TIGHTENING SPECIFICATION FOR MOUNTING WHEELS .
-- Tighten drive axle bolt to wheel hub:
 Hex head bolt, refer to DRIVE AXLE HEX BOLT CONNECTION, LOOSENING AND
TIGHTENING.
 Twelve point bolt with ribs, refer to DRIVE AXLE TWELVE-POINT BOLT WITH RIBS,
 Twelve point bolt without ribs, refer to DRIVE AXLE TWELVE-POINT BOLT WITHOUT RIBS,
NOTE: Vehicle must not be standing on its wheels when doing this, otherwise wheel
Ball joint to
steel control
arm 60 Nm
 Use
new
nuts.
Ball joint to
sheet steel
or
aluminum
control arm 100 Nm
 Use
new
nuts.
Ball joint to
wheel
bearing
housing
20 Nm + 90° turn
 Use
new
nut.
Drive axle
to wheel
hub "hex
head bolt"
200 Nm + 180° turn
 Use a
new
bolt.
Drive axle
to wheel
hub "12-
point bolt"
70 Nm + 90° turn
 Use a
new
bolt.
CONTROL ARM WITH MOUNTING BRACKET

Removing

-- Remove the coupling rod for the left front level control system sensor -G78- from the control arm.
-- Remove nuts -arrows-.

-- Remove both the wheel bearing housing and ball joint from the control arm.
-- Secure position for mounting bracket. Refer to Fig. 4
-- Replace bolt -1- for left side, -8- for right side using T10096 and tighten locating pins to 20 Nm.

-- Now unscrew item -10- for left side of vehicle, item -15- for right side of vehicle.
-- Remove left front level control system sensor coupling rod from control arm, if present.
-- Remove bolts -1-.


-- Remove control arm with mounting bracket.
Installing
-- Insert control arm with mounting bracket into subframe.
-- Attach -10- and -15- but do not tighten.


-- Insert bolts -1- and tighten.


-- Now replace T10096 with a new bolt and tighten it.
-- Bolt control arm tightly to ball joint -arrows-.

-- Bolt control arm onto console in curb weight position -10- and -15-. Refer to WHEEL BEARING,
LIFTING TO CURB WEIGHT POSITION.

-- Install lower noise insulation. Refer to Description and Operation .

Mounting
bracket to
body
70 Nm + 180° turn
 Use new
bolts.
Mounting
bracket to
subframe
50 Nm + 90° turn
 Use new
bolts.
Ball joint to
steel control
arm
60 Nm
 Use new
nuts.
Ball joint to
sheet steel or
aluminum
control arm 100 Nm
 Use new
nuts.
Control arm to
subframe
 Use a
new
bolt. 70 Nm + 180° turn
 Tighten
bolts in
curb
weight
position.
Left front
level control
system sensor
9 Nm
-G78-
coupling rod
to control arm
LEFT CONTROL ARM WITH MOUNTING BRACKET, DSG AND AUTOMATIC TRANSMISSION

Removing
-- Remove left front wheel.

With FWD





-- Remove Left Front Level Control System Sensor -G78- coupling rod from control arm, if present.


-- Loosen bolt -15-.


-- Now remove the bolts for:
 Steering gear -3- and -6-

 Stabilizer -11- and -14-
completely.
-- Subframe, securing, refer to SUBFRAME, SECURING.


-- Remove screws -2- , -4- , and -5- and lower the subframe with the brackets as far as possible.

-- When doing this, pry alignment bushings of steering gear out of left console.
-- Remove the bolt -15- and remove control arm from console.
Installing
NOTE: Make sure alignment bushings of steering gear fit correctly in console!
-- Install the lower noise insulation. Refer to Description and Operation .

Control arm
to subframe
70 Nm + 180° turn
 Use
new
bolts.
Ball joint to
steel control
arm
60 Nm
 Use
new
nuts.
Ball joint to
sheet steel or
aluminum
control arm
100 Nm
 Use
new
nuts.
Mounting
bracket to
body
70 Nm + 180° turn
 Use
new
bolts.
Mounting
bracket to
subframe
50 Nm + 90° turn
 Use
new
bolts.
Stabilizer bar
to subframe
20 Nm + 90° turn
 Use
new
bolts.
Shield to
subframe
6 Nm
 M6
bolt is
self-
tapping
Steering gear
to subframe
50 Nm + 90° turn
Use
new
bolts.
CONVERTER .

M12 x 1.5
x 90
70 Nm + 90° turn
 Use
new
bolts.
M12 x 1.5
x 100
70 Nm + 90° turn
 Use
new
bolts.
M12 x 1.5
x 110
70 Nm + 90° turn
 Use
new
bolts.

M10 x 35
strength
class 8.8:
40 Nm + 90° turn
 Use
a
new
bolt.
M10 x 35
strength
class 10.9:
50 Nm + 90° turn
 Use
a
new
bolt.
M10 x 75
strength
class 8.8:
40 Nm + 90° turn
 Use
a
new
bolt.
M10 x 75
strength
class 10.9:
50 Nm + 90° turn
Use
a
new
bolt.
M12 x 1.5
x 85

a
new
bolt.
CONTROL ARM BONDED RUBBER BUSHING
 Tube T10219/1
 Drift T10219/2

 Punch VW 411
-- Press out bonded rubber bushings as depicted in the illustration.
Fig. 93: Pressing Out Bonded Rubber Bushings

1. VW 411
2. T10219/1
3. VW 402
Bonded rubber bushing must be installed at an angle to prevent damaging it when pressing in. Bonded rubber
bushing settles straight while pressing in.
-- Apply installation lubricant G 294 421 A1 onto outside of bonded rubber bushing.
-- Place bonded rubber bushing on at an angle (in direction of control arm), when doing this the lip -arrow- must
slip into hole as shown in the illustration.
Fig. 94: Setting Bonded Rubber Bushing In Place On An Angle (In Direction Of Control Arm)
1. T10219/2
2. T10219/1
3. VW 402
-- Press in bonded rubber bushings as far until core -1- and hole of control arm -2- are at the same height.
Fig. 95: Bonded Rubber Bushing Pressed In Until Core And Opening Of Control Arm At Same Height
-- Press back bearing slightly in control arm.
Fig. 96: Pressing Back Bearing Slightly In Control Arm

1. T10219/1
2. VW 402
Dimensions -a- and -b- must be identical.

Fig. 97: Identifying Dimensions A And B

MOUNTING BRACKET WITH CONTROL ARM BEARING
 Guide piece VW 439

 Sleeve VW 426
Pressing Off Mounting Bracket with Bearing for Control Arm
Bonded rubber bushing is available as a replacement part only with the mounting bracket.
-- Press mounting bracket with bonded rubber bushing off control arm.
NOTE: Hold control arm firmly while pressing out.

Fig. 98: Holding Control Arm While Pressing Out

1. VW 401
2. VW 439
3. VW 402
Pressing On Mounting Bracket with Bearing on Control Arm
-- Thinly coat control arm hex head with installation lubricant G 294 421 A1 (1:20).
-- Carefully press bearing onto control arm as far as stop.

Fig. 99: Pressing Bushing Onto Control Arm Up To Stop

1. VW 426
2. Mounting bracket with bonded rubber bushing
3. Control arm
4. VW 401
STABILIZER BAR

Removing
-- Remove front wheels.


-- Remove the bolt -1- and pull off universal joint -2- from steering gear.


-- Remove the nuts -arrows- on left and right side of vehicle.

-- Loosen nut of track rod ball joint on both sides, but do not unscrew yet.
-- Press off track rod ball joint from wheel bearing housing using 3287A.
Fig. 103: Pressing Off Tie Rod End From Wheel Bearing Housing Using Ball Joint Puller 3287A
-- Secure subframe with brackets. Refer to SUBFRAME, SECURING.
- Remove the stabilizer from subframe -11- and -14-



-- Loosen bolts -4- and -5- and slightly lower subframe with brackets. Observe electrical wires when doing this.

-- Slide stabilizer bar toward right, as seen in direction of travel.
-- Now, lift the stabilizer bar -1- toward the front, over the subframe -2- and down, while turning the stabilizer
bar slightly.
Fig. 107: Identifying Lift Stabilizer Toward Front, Over Console And Down From Subframe
Installing
NOTE: Coat seal on steering gear with lubricant, e.g. soft soap, before installing
steering gear.
After attaching steering gear to drive axle, make sure that seal on steering gear
is positioned to mounting plate without kinks and opening to foot well is sealed
correctly. Ingress of water and/or noises may be the result.
Make sure sealing surfaces are clean.

Ball joint to steel
control arm
60 Nm
 Use new
nuts.
Ball joint to sheet

100 Nm
steel or aluminum
control arm
 Use new
nuts.
Stabilizer bar to
connecting link
 Use new
nut. 65 Nm
 Counterhold
at joint pin
inner multi-
point fitting.
Control arm to
subframe
 Use a new
bolt. 70 Nm + 180° turn
 Tighten
bolts in curb
weight
position.
Steering gear to
subframe
50 Nm + 90° turn
 Use new
bolts.
Tie rod end to
wheel bearing
housing
Pre-tighten to 100 Nm, then loosen by 180° and tighten to 100 Nm again.
 Use new
nut.
Universal joint to
steering gear
20 Nm + 90° turn
 Use a new
bolt.

M12 x 1.5
x 90
70 Nm + 90° turn
 Use
new
bolts.
M12 x 1.5
x 100
70 Nm + 90° turn
 Use
new
bolts.
M12 x 1.5
x 110
70 Nm + 90° turn
 Use
new
bolts.

M10 x 35
strength
class 8.8:
40 Nm + 90° turn
 Use
a
new
bolt.
M10 x 35
strength
class 10.9:
50 Nm + 90° turn
 Use
a
new
bolt.
M10 x 75
strength
class 8.8:
 Use
a 40 Nm + 90° turn
new
bolt.
M10 x 75
strength
class 10.9:
50 Nm + 90° turn
Use
a
new
bolt.
M12 x 1.5
x 85

a
new
bolt.
-- After installing, perform the basic setting on the Steering Angle Sensor -G85- using the Vehicle Diagnostic
Tester.
WHEEL BEARING UNIT
Removing
TIGHTENING.
 Twelve-point bolt with ribs, refer to DRIVE AXLE TWELVE-POINT BOLT WITH RIBS,
 Twelve-point bolt without ribs, refer to DRIVE AXLE TWELVE-POINT BOLT WITHOUT RIBS,
bearings.
following:

-- Remove brake caliper with brake carrier and hang on body using wire. Refer to Removal and Installation .
-- Remove ABS wheel speed sensor. Refer to Removal and Installation .
-- Remove disc brake.
-- Press the drive axle out of the hub as far as possible (in direction of transmission).
Fig. 108: Wheel Bearing Housing Bolts

-- Remove wheel bearing unit from wheel bearing housing.
Installing
-- Install brake caliper. Refer to Removal and Installation .
TIGHTENING.
CAUTION: Vehicle must not rest on wheels when doing so.
With screw loosened, wheel bearing can be damaged by vehicle's own

weight.
I-

II -
-- Install ABS wheel speed sensor. Refer to Removal and Installation .
-- Install the wheel and tighten the wheel bolts. Refer to TIGHTENING SPECIFICATION FOR
MOUNTING WHEELS .

Drive axle
to wheel
hub "hex
head bolt"
200 Nm + 180° turn
Use a

new
bolt.
Drive axle
to wheel
hub
"twelve-
point bolt
70 Nm + 90° turn
with ribs"
Use a

new
bolt.
Drive axle
to wheel
hub
"twelve-
point bolt
without 200 Nm + 180° turn
ribs"
 Use a
new
bolt.
Wheel hub
with wheel
70 Nm + 90° turn
bearing to
wheel
bearing
housing
 Use
new
bolts.
WHEEL BEARING HOUSING
 Ball joint puller 3287A

 Spreader 3424
Removing
TIGHTENING.
bearings.
following:


-- Remove brake caliper with brake carrier and hang on body using wire. Refer to Removal and Installation .
-- Remove ABS wheel speed sensor. Refer to Removal and Installation .
-- Remove disc brake.
-- Now remove cover plate from wheel bearing housing.
-- Press off track rod ball joint from wheel bearing housing using 3287A and now unscrew nut.
-- Press the drive axle out of the hub as far as possible (in direction of transmission).
-- Remove threaded connection of wheel bearing housing/suspension strut -arrow-.

Fig. 111: Threaded Connection Of Wheel Bearing Housing/Suspension Strut

-- Insert 3424 into slot of wheel bearing housing.
Fig. 112: Spreader 3424 Inserted Into Slot Of Wheel Bearing Housing
-- Using a ratchet and the 3424, open the wheel bearing housing slot.
-- Loosen nuts -arrows-.


-- Now place V.A.G 1383 A under wheel bearing housing.
-- First press off ball joint from control arm in order to then pull off the wheel bearing housing from suspension
strut.
Installing
Installation is the reverse of removal, with special attention to the following:
TIGHTENING.
With screw loosened, wheel bearing can be damaged by vehicle's own

weight.
I-
II -
If a wheel bearing housing was replaced, vehicle must be aligned. Refer to WHEEL ALIGNMENT .
MOUNTING WHEELS .

Suspension
strut to
wheel
bearing
housing 70 Nm + 90° turn
 Use
new
nut.
Ball joint to
steel control
arm
60 Nm
 Use
new
nuts.
Ball joint to
sheet steel
or
aluminum
control arm 100 Nm
 Use
new
nuts.
Tie rod end
to wheel
bearing
housing
Tighten to 100 Nm, then loosen by 180° and tighten to 100 Nm again
 Use
new
nut.
Drive axle
to wheel
hub "hex
head bolt"
200 Nm + 180° turn
 Use a
new
bolt.
Drive axle
to wheel
hub
"twelve-
point bolt
70 Nm + 90° turn
with ribs"
 Use a
new
bolt.
Drive axle
to wheel
hub
"twelve-
point bolt
without
ribs"
200 Nm + 180° turn
 Use a
new
bolt.
SUSPENSION STRUT
NOTE: Adaptive chassis DCC suspension strut, removing and installing, refer to
FRONT SUSPENSION STRUT .
 Spreader 3424
Removing
TIGHTENING.
bearings.
following:

-- Remove the nut -arrow- of the connecting link from suspension strut.
Fig. 115: Locating Suspension Strut Coupling Hex Nut



-- Remove the drive axle outer joint from the wheel hub.
-- Secure drive axle to body using wire.
NOTE: The drive axle must not hang down, otherwise the inner joint will be damaged
by overflexing.
-- Bolt ball joint to control arm again.
-- Fasten V.A.G 1383 A using T10149 to wheel hub with a wheel bolt.
-- Disconnect threaded connection of wheel bearing housing/suspension strut -arrow-.


-- Press brake disc in direction of suspension strut by hand.
Otherwise strut tube may be canted in hole of wheel bearing housing.

-- Pull off wheel bearing housing downward from strut tube and lower using V.A.G 1383 A as far until strut
tube hangs freely.
-- Tightly tie wheel bearing housing to console/subframe using binding wire.
-- Remove V.A.G 1383 A from below wheel bearing housing.
-- Remove wiper arms. Refer to WIPER ARMS .
-- Remove plenum chamber cover.
-- Remove the hex bolts -arrows- for upper strut mount and remove suspension strut.
Fig. 120: Upper Suspension Strut Mounting Hex Bolts

Installing
-- Secure V.A.G 1383 A with T10149 to wheel hub using a wheel bolt.
-- Attach suspension strut to wheel bearing housing and secure suspension strut using socket head bolt and new
nut.
Socket head bolt tip must point in direction of travel.
-- Remove 3424.
One of two markings -arrows- on spring plate must point in direction of travel.
Fig. 122: Identifying Suspension Strut Markings

-- Remove wire on wheel bearing housing.
-- Carefully lift the wheel bearing housing using the transmission jack enough so that the suspension strut/strut
tower bolts -arrows- can be installed.
Fig. 123: Upper Suspension Strut Mounting Hex Bolts

If necessary, use ladder, e.g. step ladder VAS 5085 to install bolts.
-- Tighten hex bolts for upper strut mounting -arrows-.
-- Remove T10149.
-- Tighten threaded connection of wheel bearing housing/suspension strut -arrow-.



-- Insert drive axle into wheel hub.
-- Insert wheel bearing housing with ball joint into control arm.
-- Attach the ball joint to the control arm -arrows-.

TIGHTENING.
With bolt loosened, wheel bearing can be damaged by vehicle's own

weight.
I-
II -
-- Install plenum chamber cover.
-- Install wiper arms. Refer to WIPER ARMS .
MOUNTING WHEELS .

Suspension strut
to wheel bearing
 Use new nut

Suspension strut
to body
(suspension strut
tower) 15 Nm + 90° turn
 Use new
bolts
Ball joint to steel
control arm
60 Nm
 Use new
nuts
Ball joint to sheet
steel or aluminum
control arm
100 Nm
 Use new
nuts
Connecting link to
suspension strut
 Use new nut

65 Nm
 Counterhold
at joint pin
inner multi-
point fitting
Drive axle to
wheel hub "hex

head bolt"
200 Nm + 180° turn
 Use a new
bolt
Drive axle to
wheel hub
"twelve-point bolt
with ribs" 70 Nm + 90° turn
 Use a new
bolt
Drive axle to
wheel hub
"twelve-point bolt
without ribs" 200 Nm + 180° turn
 Use a new
bolt
DRIVE AXLE WITH CV JOINT

CAUTION: When disassembling and performing repairs on vehicle, the drive axles
must not be allowed to hang down and contact the stops in the joint by
overflexing.
Removing
TIGHTENING.
bearings.
following:

-- Disconnect drive axle from transmission axle flange.
-- Slide outer joint out of wheel hub by hand.

-- Remove the drive axle from the wheel hub.
Installing
Remove any paint residue and/or corrosion in threads/splines of outer joint.
-- Insert drive axle.
-- Insert outer joint as far as possible into wheel hub splines.

-- Install inner joint of drive axle and initially tighten bolts diagonally to 10 Nm.
-- Tighten multi-point socket head bolts to specified tightening specification in diagonal sequence.
TIGHTENING.

weight.
I-
II -
MOUNTING WHEELS .

Ball joint to steel

control arm
60 Nm
 Use new
nuts.
Ball joint to sheet
steel or aluminum
control arm
100 Nm
 Use new
nuts.
Drive axle to
wheel hub "hex
head bolt"
200 Nm + 180° turn
 Use a new
bolt.
Drive axle to
wheel hub
"twelve-point bolt
 Use a new
bolt.
Drive axle to
wheel hub
"twelve-point bolt
 Use a new
bolt.
Drive axle to
flange
shaft/transmission
"Multi-point
socket head bolt
M8" 40 Nm
 Use new  Pre-tighten to 10 Nm in diagonal sequence.

bolts.
 Use new
backing
plates.
Drive axle to
flange
shaft/transmission
"Multi-point
socket head bolt
M10"
70 Nm
 Use new
bolts.  Pre-tighten to 10 Nm in diagonal sequence.
 Use new
backing
plates.
DRIVE AXLE WITH TRIPLE ROLLER JOINT AAR2600I AND AAR3300I MOUNTED

 Wedge T10161
overflexing.
Removing
TIGHTENING.
bearings.
following:


-- Pull drive axle out from wheel hub and secure it to body.
-- Attach T10161 between transmission housing and triple roller joint.

Fig. 131: Pressing Both Drive Axles Out Of Transmission

-- Press inner joint out of transmission via a hammer blow on the T10161.
-- Remove drive axle.
Installing
-- Insert new circlip into groove of joint piece bolt.
-- Bring outer and inner splines of joint piece and transmission into engagement.
-- Grab drive axle by hand and push it into the joint up to the stop.
-- Now slide joint piece into transmission with a >>tug<<.
Slide path in joint piece can be used for this >>tug<<. When doing this, do not pull the drive axle too far out of
the joint.
NOTE: Do not use a hammer or a knocking tool under any circumstances!
-- Check drive axle for secure fitting in transmission by pulling joint piece against resistance of the securing
ring.
NOTE: For this check, do not pull on the drive axle, but rather only on the joint.


TIGHTENING.

weight.
I-
II -
MOUNTING WHEELS .

Ball joint to
steel control
arm
60 Nm
 Use
new
nuts.
Ball joint to
sheet steel
or
aluminum
control arm
 Use 100 Nm
new
nuts.
Drive axle
to wheel
hub "hex
head bolt"
200 Nm + 180° turn
 Use a
new
bolt.
Drive axle
to wheel
hub
"twelve-
point bolt
70 Nm + 90° turn
with ribs"
 Use a
new
bolt.
Drive axle
to wheel
hub
"twelve-
point bolt
without 200 Nm + 180° turn
ribs"
 Use a
new
bolt.
DRIVE AXLE WITH TRIPOD JOINT AAR3300I MOUNTED
overflexing.
Removing
TIGHTENING.
bearings.
following:

-- Disconnect drive axle from transmission axle flange.


-- Remove the drive axle from the wheel hub.
Installing
Remove any paint residue and/or corrosion in threads/splines of outer joint.
-- Insert drive axle.


-- Install inner joint of drive axle and initially tighten bolts diagonally to 10 Nm.
-- Tighten multi-point socket head bolts to specified tightening specification in diagonal sequence.
-- Install lower noise insulation. Refer to Description and Operation .
TIGHTENING.

weight.
I-
II -
MOUNTING WHEELS .

Ball joint to steel
control arm
60 Nm
Use new

nuts
Ball joint to sheet
steel or aluminum
control arm
100 Nm
 Use new
nuts
Drive axle to
wheel hub "hex
head bolt"
200 Nm + 180° turn
 Use a new
bolt
Drive axle to
wheel hub
"twelve-point bolt
 Use a new
bolt
Drive axle to
wheel hub
"twelve-point bolt
 Use a new
bolt
Drive axle to
flange
shaft/transmission
"Multi-point 40 Nm
socket head bolt
M8"  Pre-tighten to 10 Nm in diagonal sequence.
 Use new
bolts
Drive axle to
flange
shaft/transmission
"Multi-point 70 Nm
socket head bolt
M10"  Pre-tighten to 10 Nm in diagonal sequence.
 Use new
bolts
SUSPENSION STRUT

 Spring compressor V.A.G 1752/1

 Spring holder V.A.G 1752/5
 Holding fixture for suspension struts V.A.G 1752/20
 Shock absorber set T10001
 Ratchet (commercially available)
-- Remove the suspension strut. Refer to SUSPENSION STRUT.
Coil Spring, Removing
-- Tension the V.A.G 1752/20 -4- in a vice.
Fig. 137: Identifying Coil Spring Special Tools

-- Tension the suspension strut in the V.A.G 1752/20 -4-.
-- Pretension the coil spring using the V.A.G 1752/1 until the upper axial groove ball bearing is free.
1. V.A.G 1332
2. Ring spanner insert AF 21T10001/8

3. V.A.G 1752/1
4. V.A.G 1752/20
5. V.A.G 1752/4
6. Ring spanner insert AF 21T10001/5
7. Ratchet T10001/11
WARNING: First pre-load spring far enough so that tension is relieved on upper
spring plate!
-- Make sure the coil spring fits correctly inside the V.A.G 1752/4 -arrows-.
Fig. 138: View Of Correct Fit For Coil Spring

-- Remove hex nut from piston rod.
-- Remove individual components of suspension strut and coil spring with V.A.G 1752/1.
Installing Coil Spring
-- Install the coil spring on the lower spring plate using the V.A.G 1752/1.
End of spring coil must rest against stop -arrow-.

Fig. 139: Identifying Coil Spring Stop

-- Tighten new hex nut to piston rod.
-- Relieve the tension on the V.A.G 1752/1 and remove from the coil spring.
-- Suspension strut, installing, refer to SUSPENSION STRUT.
Tightening Specification

Suspension
strut mount
to damper
60 Nm
 Use
new
nut.
DRIVE AXLE WITH CV JOINT VL100

 Punch VW 408 A
 Punch VW 411
 Sleeve VW 416 B
 Thrust pad VW 447 H

 Circlip pliers VW 161 A
 CV joint boot clamp tool V.A.G 1682
 Slide hammer - complete set VW 771
 Puller T10382
Removing the Outer CV Joint
-- Secure the drive axle with protective covers in a vise clamp.
-- Fold back boot.
-- Align the T10382 so that the flat side of the plate T10382/1 faces the spindles T10382/2.
-- Attach the T10382 to the VW 771.
-- Remove the CV joint from the drive axle using the T10382 and VW 771.
Fig. 140: Identifying Outer CV Joint

1. T10382/1
2. T10382/2
Driving on Outer CV Joint

Fig. 141: Installed Location Of Spring Washer And Thrust Washer On Outer Joint
Installed Location: Spring Washer And Thrust Washer On Outer Joint
1. Dished washer
2. Thrust washer
-- Install the new circlips.
-- Slide new CV boot onto drive axle if necessary.
-- Drive it onto shaft with plastic hammer until securing ring engages.
Fig. 142: Pressing Off Inner Constant Velocity Joint

Assembling
-- Slide small clamp for joint protective boot onto shaft.
-- Slide CV boot onto shaft.

Fig. 143: Installed Location Of Spring Washer On Inner Joint

Installed Location Of Spring Washer On Inner Joint
1. Dished washer
Fig. 144: Pressing On Inner Constant Velocity Joint

Pressing On Inner CV Joint
NOTE: Chamfer on inner diameter of ball hub (splines) must face the contact shoulder
on the drive axle.
Tightening Hose Clamp On Outer Joint

Fig. 145: Attaching CV Joint Boot Clamp Tool V.A.G 1682

-- Attach V.A.G 1682 as shown in illustration. Be sure that edges of clamping pliers are seated in corners -
arrows B- of hose clamp.
-- Tension clamp by turning spindle with a torque wrench (do not tilt clamp tool).
NOTE: A stainless steel clamp must be used due to hardness of CV boot material
(compared to rubber). This clamp can only be tensioned using V.A.G 1682.
Torque specification: 25 Nm.
Use torque wrench -C- with adjustment range 5 to 50 Nm (e.g. V.A.G 1331).
Be sure thread of spindle -A- of clamp tool moves freely. Grease with MOS 2
grease if necessary.
If it does not move freely, e.g. due to dirt in thread, the required clamp tension
will not be achieved at the specified torque.
Tensioning Clamp On Small Diameter

Fig. 146: Tightening Clamp For CV Joint Boot (Inner, Small Dia.)
DRIVE AXLE WITH CV JOINT VL107

 Punch VW 408 A
 Support sleeve VW 522
 Clamp 40 - 204 A
 Puller T10382

-- Fold back boot.

1. T10382/1
2. T10382/2
Driving On Outer CV Joint
Installed Location: Spring Washer And Thrust Washer On Outer Joint

1. Dished washer
2. Thrust washer
Driving Off Cover For Inner Joint

Fig. 149: Driving Off Cover For Inner Joint

-- Remove securing ring.
-- Remove both clamps and slide joint boot toward outer joint.
-- Drive out CV joint boot with a drift.
Removing the Inner CV Joint
Fig. 150: Pressing Off Inner Constant Velocity Joint

Assembling
Pressing On Inner Constant Velocity Joint

Fig. 151: Pressing On Inner Constant Velocity Joint

-- Press on joint until stop.
-- Install lock ring.
-- Coat cover sealing surface with D 454 300 A2

Fig. 152: Cover Sealing Surface To Be Covered With D 454 300 A2

-- Apply unbroken sealant bead with 2 to 3 mm diameter in area of inner holes -arrow- to clean cover surface.
-- Align new cover with bolts -arrows- to bolt holes.
Fig. 153: New Cover Aligned With Bolts To Bolt Holes

NOTE: It must be aligned exactly because it cannot be aligned after driving on.
-- Drive cover on with a plastic hammer.

-- Wipe away any sealant leaking out.
Fig. 154: Attaching CV Joint Boot Clamp Tool V.A.G 1682

-- Attach V.A.G 1682 as shown in illustration. Be sure that edges of clamping pliers are seated in corners -
(compared to rubber). This clamp can only be tensioned using V.A.G 1682.
Use torque wrench -C- with adjustment range 5 to 50 Nm (e.g. V.A.G 1331).
Tensioning Clamp On Small Diameter
Fig. 155: Tightening Clamp For CV Joint Boot (Inner, Small Dia.)
DRIVE AXLE WITH TRIPLE ROLLER JOINT AAR2600I

 Punch VW 408 A
 Punch VW 411
 Sleeve VW 416 B
 Hose clamp pliers V.A.G 1275
 Puller T10382
-- Fold back boot.

1. T10382/1
2. T10382/2

1. Dished washer
2. Thrust washer
Disassembling
-- Open both clamps at inner joint and slide back CV boot.
-- Pull off joint piece from drive axle.

Fig. 158: Removing Circlip Using Pliers

1-
Pliers (commercially available)
-- Insert drive axle in vise.
-- Press triple roller star off drive axle.

Fig. 159: Pressing Off The Triple Roller Star From The Driveshaft
-- Pull off CV boot from shaft.
-- Clean shaft, joint and groove for oil seal.
Assembling
-- Slide joint piece onto shaft.
Mount Triple Roller Star
Conical-Type Drive Axle
The chamfer on star faces toward shaft, this is used as an assembly aid.
-- Connect triple roller star on shaft and press on up to stop.
Fig. 160: Installing Triple Roller Star Onto Shaft And Press Onto Stop
-- Make sure that pressure does not increase above 3.0 t!
-- If necessary coat drive axle splines and triple-roller star with lubricating paste G 052 142 A2.
-- Insert securing ring, be sure to fit properly.
NOTE: As of 08.2004, a different grease will be used for triple roller joints. The grease
must not be mixed with grease previously used. Therefore, triple roller joint
must be cleaned before greasing when performing service work.
-- Press 70 grams of joint grease from repair set, into triple roller joint.
-- Slide joint piece over rollers and secure.
-- Press 60 grams of joint grease, from repair set, into the reverse side of the triple roller joint.
-- Install CV boot.
Cylindrical-Type Drive Axle
Fig. 161: Pressing Triple Roller Star Axle Shaft With Cylindrical Shaft

-- Install CV boot.
-- Tension both clamps using V.A.G 1275.
DRIVE AXLE WITH TRIPLE ROLLER JOINT AAR3300I

 Punch VW 408 A
 Punch VW 411
 Sleeve VW 416 B
 Puller T10382
-- Fold back boot.

1. T10382/1
2. T10382/2
Driving on Outer CV Joint
Installed Location: Spring Washer and Thrust Washer on Outer Joint

1. Dished washer
2. Thrust washer
Disassembling
-- Open both clamps at inner joint and slide back CV boot.


1-

Assembling
The chamfer on star faces toward shaft, this is used as an assembly aid.
-- If necessary coat drive axle splines and triple roller star with lubricating paste G 052 142 A2.
-- Install CV boot.

-- Install CV boot.
-- Install clamp.
Fig. 168: Clamping Ear Of The Clamp Placed Between The Fixing Flanges From The Joint
NOTE: For a better alignment of the multi-point socket head bolts when mounting the
axle shaft, it is necessary that the clamping ear of the clamp -arrow A- is placed
between the fixing flanges from the joint -arrows B-.
-- Tension clamp using V.A.G. 1275.
Fig. 169: Tightening Clamp With Hose Clamp Pliers V.A.G 1275
-- Tension small clamp using V.A.G. 1275.
Fig. 170: Tightening Clamp With Hose Clamp Pliers V.A.G 1275
DRIVE AXLE WITH TRIPLE ROLLER JOINT AAR3300I, 09M AUTOMATIC TRANSMISSION, 6-SPEED, AWD

 Punch VW 408 A
 Punch VW 411
 Sleeve VW 416 B
 Puller T10382


1. T10382/1
2. T10382/2
Disassembling
-- Open clamping sleeve on inner joint and slide protective boot back from adapter.

1-

Assembling
NOTE: The chamfer on star faces toward shaft, this is used as an assembly aid.
-- If necessary coat drive axle splines and triple roller star with lubricating paste G 052 142 A2.
-- Install CV boot.

-- Slide protective boot onto adapter and ensure boot engages correctly in groove on adapter -arrow-.
Fig. 176: View Of Protective Boot And Adapter

-- Install clamping sleeve and clamp with V.A.G 1275 until a proper seal is guaranteed.
SPECIAL TOOLS
 Tube T10219/1
 Drift T10219/2
 Guide piece VW 439
 Support sleeve VW 522
 Clamp 40 - 204 A
Fig. 177: Locating Fixture T10096

 Socket XZN 24T10361
Fig. 178: Socket XZN 24 T10361


Fig. 179: Angle Wrench V.A.G 1756

Fig. 180: Ball Joint Puller 3287 A

 Tube from assembly tool T10244/3

Fig. 181: Assembly Tool T10244

 Sleeve VW 426
Fig. 182: Tube Trans. Drive Shaft VW 426

 Spreader 3424
Fig. 183: Spreader 3424

 Wedge T10161
Fig. 184: Wedge T10161


Fig. 185: Identifying Slide Hammer VW 771

 Puller T10382
Fig. 186: Identifying Special Tool Puller T10382

Fig. 187: Identifying Special Tools -- Front Axle To Unladen Position, Lifting

 Tensioning strap T10038
Fig. 188: Identifying Special Tools -- Subframe, Servicing

 Installation device 3372

 Punch VW 407
 Thrust piece VW 432
 Assembly Tool T10267 with adapter T10267/1A
Fig. 189: -- Identifying Special Tools - Axle Shaft Assembly (2 Of 2)


 Spring compressor V.A.G 1752/1
 Spring holder V.A.G 1752/5
 Holding fixture for suspension struts V.A.G 1752/20
Fig. 190: Identifying Special Tools - Axle Shaft Assembly (1 Of 2)


 Punch VW 408 A
 Punch VW 411
 Sleeve VW 416 B
Fig. 191: Identifying Special Tools - Axle Shaft Assembly (2 Of 2)

 Circlip pliers VW 161 A

TRANSMISSION Gears, Hydraulic Controls 09G
TRANSMISSION
Gears, Hydraulic Controls 09G
38 GEARS, HYDRAULIC CONTROLS

VALVE BODY OVERVIEW
Fig. 1: Identifying Valve Body Assembly And Components

1. Inspection Plug
 Transmission fluid level, checking and filling. Refer to TRANSMISSION FLUID LEVEL,
 Tightening specification, refer to FASTENER TIGHTENING SPECIFICATIONS.
2. Seal
 Always replace.
3. Overflow Tube
 Remove in order to drain the transmission fluid.
4. Transmission Fluid Pan

 Removing and installing, refer to TRANSMISSION FLUID PAN.
5. Bolt
 Tighten the transmission fluid pan bolts diagonally and in several steps.
6. Gasket
 With spacers (quantity: 8).
 Check before installing
 Replace a brittle, cracked or deformed gasket.
7. Magnet
 Quantity: 2; in the depressions in the pan.
 Clean before installing the pan.
8. Bolt
 For securing the valve body to the transmission.
 Quantity 12; with different lengths, refer to Fig. 20.
 Always replace the bolts.
9. Bolt
 Quantity: 3
 For securing the transmission fluid filter to the valve body.
10. Transmission Fluid Filter

 Removing and installing, refer to TRANSMISSION FLUID FILTER.
11. Valve Body

 Removing and installing, refer to VALVE BODY.
12. Bolt
13. Bolt

14. Transmission Input Speed Sensor -G182-
 Removing and installing, refer to Transmission Input Speed Sensor -G182-.
15. Bolt
16. Transmission Output Speed Sensor -G195-

 Removing and Installing, refer to Transmission Output Speed Sensor -G195-.
17. Transmission Housing

 The transmission fluid cooler is not illustrated
18. Vent Cap

19. Multifunction Transmission Range Switch -F125-
 Removing and installing, refer to Multifunction Transmission Range Switch -F125- .
 Adjusting, refer to Multifunction Transmission Range Switch -F125-, ADJUSTING .
20. Transmission Fluid Temperature Sensor -G93-

 Integrated into the wiring harness.
 Removing and installing, refer to SOLENOID VALVE AND SENSOR WIRING HARNESS.
 Wire routing, refer to WIRE ROUTING, CONNECTORS AND BRACKET ON VALVE

BODY.
21. Bolt
22. Bolt
23. Sensor Wiring Harness

 With the transmission fluid temperature sensor.
 For the transmission input speed sensor and the transmission output speed sensor.
 Always replace the seal on the connector housing.

BODY.
24. Seal
 Always replace.
25. Drain Plug

26. Selector Shaft Lever

27. Washer
28. Nut

29. Spring
30. Piston
31. Solenoid Valve Wiring Harness
 Always replace the seal on the connector housing.

BODY.
32. Bolt
WIRE ROUTING, CONNECTORS AND BRACKET ON VALVE BODY
The information regarding working on the solenoid valves is shown in illustrations.
Wiring Routing and Connectors:

Fig. 2: Identifying Wire Routing, Connectors And Bracket On Valve Body

1. 1 - Solenoid Valve 4 -N91-

 Wiring colors to the valve: green/brown.

 Wiring colors to the valve: green/gray.

 Wiring colors to the valve: yellow/purple.

 Wiring colors to the valve: red/blue
 Wiring colors to the valve: white/black.

 Wiring colors to the valve: green/blue.

 Wiring color to the valve: white.

 Wiring color to the valve: black.
9. A - Transmission Output Speed Sensor Connector

 Wiring colors to the sensor: blue/orange.
10. B - Transmission Input Speed Sensor Connector

 Wiring colors to the sensor: white/red.
Bracket for Connectors, Securing the Wires:

Fig. 3: Identifying Sensor, Lever And Bracket for Connectors

1. 1 - Transmission Output Speed Sensor Connector Bracket

2. 2 - Transmission Input Speed Sensor Connector Bracket

3. 3 - Transmission Fluid Temperature Sensor -G93-

 Wiring color for sensor: orange/orange.
4. 4 - Selector Lever
 The wires are attached here.
SPECIFICATIONS
Fig. 4: Identifying Fasteners For Valve Body Assembly With Torque Specifications
SELECTOR SHAFT SEAL

Removing
-- Remove the multifunction transmission range switch -F125-.
-- Carefully pry out the selector shaft seal with a screwdriver. Be careful not to damage the selector shaft when
doing this.
Installing
Install the new seal using the thrust piece -T10174-. Do not tilt the seal.
Fig. 5: Identifying Thrust Piece T10174 To Drive-In New Gasket

-- Adjust the multifunction transmission range switch. Refer to Multifunction Transmission Range Switch -
F125-, ADJUSTING .
TRANSMISSION FLUID PAN

 Drip Tray -V.A.G 1306-

Removing
-- Remove the noise insulation under the engine.
-- Place the drip tray -V.A.G 1306- underneath.
-- Remove the plug -A-.
-- Remove the overflow tube -C- and drain the transmission fluid.
Fig. 6: Identifying Overflow Tube, Check Plug And Sealing Ring

-- Loosen the transmission fluid pan bolts -arrows- diagonally.

Fig. 7: Locating Oil Pan Bolts

-- Remove the pan and gasket.
Installing
-- Clean the two magnets inside the recesses in the pan. Make sure that the magnets are in full contact with the
pan.
-- Check the gasket for damage and make sure all of the spacers (quantity: 8) are present.
Otherwise, replace the gasket.
-- Install the pan and gasket; when doing this be sure not to pinch any wires.
-- Make sure the pan gasket fits correctly.
-- Tighten the pan bolts -arrows- diagonally and in several steps. Tightening specifications, refer to
FASTENER TIGHTENING SPECIFICATIONS.
Fig. 8: Locating Oil Pan Bolts

-- Install the overflow tube -C-. For the correct tightening specification, refer to FASTENER TIGHTENING
SPECIFICATIONS.
Fig. 9: Identifying Overflow Tube, Check Plug And Sealing Ring

-- Fill with transmission fluid and check the level. Refer to TRANSMISSION FLUID LEVEL, CHECKING
AND FILLING .
TRANSMISSION FLUID FILTER
Removing
-- Remove the transmission fluid pan. Refer to TRANSMISSION FLUID PAN.
-- Remove the transmission fluid filter bolts -arrows-.

Fig. 10: Identifying Oil Filter Bolts

-- Remove the filter -A- from the valve body.
Installing
-- Lightly coat the seals on the filter suction collar with transmission fluid.
-- Replace the filter if the seals are loose or faulty.
-- Install the filter -A- and tighten the bolts. Refer to FASTENER TIGHTENING SPECIFICATIONS.
Fig. 11: Identifying Oil Filter Bolts

-- Install the transmission fluid pan. Refer to TRANSMISSION FLUID PAN.
-- Fill with fluid and check the level. Refer to TRANSMISSION FLUID LEVEL, CHECKING AND
FILLING .
VALVE BODY
WARNING: Do not run the engine or tow the vehicle when the pan is removed or
when there is no transmission fluid in the transmission.
 The valve body and the wiring harnesses can also be removed with the transmission installed.
 Install seals using transmission fluid. Other types of lubricants can lead to faults in the transmission
hydraulics.
 Always replace a dirty or faulty valve body.
 Only use lint free cloths
 Check the fluid level after installing the pan. Refer to TRANSMISSION FLUID LEVEL, CHECKING
AND FILLING .

 Digital Torque Wrench -V.A.G 1756-
Removing
-- Remove the transmission fluid filter. Refer to TRANSMISSION FLUID FILTER.
-- Disconnect the connector from the solenoid valves. See items 1 through 8.
To unlock the connector housing on the solenoid valves, use a flat head screwdriver with a 2.5 mm diameter
shaft.
CAUTION: If a connector or the connector housing are damaged, then the wiring
harness or solenoid valve must be replaced.
-- Disconnect the connectors. See items 9 and 10.
-- Remove the bracket for the connectors. See items 1 and 2.
-- Disconnect the transmission fluid temperature sensor -G93- and carefully remove it from the valve body. See
item: 3.
-- Bend the securing plate -arrows- on the selector lever back.
Fig. 12: Identifying Securing Plates Around Nut

-- Remove the selector lever -1- from the selector shaft.
Fig. 13: Identifying Removal Of Selector Lever On Selector Shaft

-- Hold the selector lever -1- steady with pliers -2- to prevent transferring the torque onto the multifunction
transmission range switch -F125-.
-- Make sure the valve -A- on the valve body is not damaged.
Fig. 14: Identifying Wiring Harness, Bracket, Selector Lever And Selector Shaft
The valve is very >>sensitive<<. Even minor damage can lead to a malfunction.
-- Always slide the valve into the body, secure it against falling out and never exchange it.
-- Loosen the bolts -arrows- (quantity 12).
Fig. 15: Identifying Valve Body Bolts To Be Loosened

CAUTION: If other bolts are loosened, the valve body will distort.
-- Remove the brackets -1 and 2-.


-- Disconnect the valve body and remove it.
-- When removing the valve body, pay attention to the piston -2-.
Fig. 17: Identifying Valve Body Wiring Harness And Damping Plunger
-- Remove the piston with the spring.
Installing
To make sure that the wires do not get pinched during installation:
-- Route and secure the wires -1, 3, 4 and 5- as illustrated.

The distance -a- must be maintained so that the wiring harness -5- does not touch the planetary gear and get
damaged when the vehicle is being driven.
The valve body is secured with bolts with three different lengths.
-- Sort the bolts according to length before installing the valve body.
-- Coat the piston -2- with transmission fluid and install the spring.
-- Install the valve body carefully and secure it using 2 bolts.


Bolts -
Quantity 6, M6 x 21
arrows-
Bolts -
arrows Quantity 2, M6 x 16
A-
Bolts -
arrows Quantity 4, M6 x 28
B-
-- Make sure the wires are not pinched.
-- Install the remaining bolts and the brackets -1 and 2- and tighten by hand.

-- Install the transmission fluid temperature sensor and tighten to specification. Refer to FASTENER
TIGHTENING SPECIFICATIONS.
-- Connect the connectors (quantity 8) to the solenoid valves. Refer to WIRE ROUTING, CONNECTORS
AND BRACKET ON VALVE BODY.
-- Connect the bracket for the connectors WIRE ROUTING, CONNECTORS AND BRACKET ON
VALVE BODY, tightening specifications, refer to FASTENER TIGHTENING SPECIFICATIONS.
-- Connect the connectors. See items: 9 and 10.
-- Tighten the valve body bolts working from the inside toward the outside diagonally. Tightening specification,
refer to FASTENER TIGHTENING SPECIFICATIONS.
-- Install the selector lever.
-- Tighten the nut on the selector lever -1-. For the correct tightening specification refer to FASTENER
Fig. 22: Identifying Installation Of Selector Lever On Selector Shaft

-- Hold the selector lever -1- steady with pliers -2- to prevent transferring the torque onto the multifunction
transmission range switch.
-- Bend the securing plate -arrows- on the nut up.
Fig. 23: Identifying Securing Plates Around Nuts

-- Install the transmission fluid filter. Refer to TRANSMISSION FLUID FILTER.

-- Fill the transmission fluid and check the level. Refer to TRANSMISSION FLUID LEVEL, CHECKING
AND FILLING .
-- Connect the vehicle diagnostic tester and move through the selections until "Functions-/component selection"
is displayed.
-- Press "Drive (Repair Groups 01; 10 through.26; 28 through.39)".
-- After that "6-speed automatic transmission 09G".
-- Press "01 - OBD".
-- Press "Functions".
-- Press "basic setting".
SOLENOID VALVE AND SENSOR WIRING HARNESS
Removing
-- Drain the transmission fluid. Refer to TRANSMISSION FLUID, DRAINING AND FILLING .
-- Remove the valve body. Refer to VALVE BODY.
-- Disconnect the connectors from the transmission:
-1- transmission sensor terminal
-2- connector for solenoid valves

Fig. 24: Identifying 8-Pin G68 and 14-Pin G93 Electrical Harness Connectors
-- Disconnect the connector housings from the transmission.
-- Disconnect the connector housing together with the wiring harness outward from the transmission housing.
Installing
-- Replace the seals on the connector housings.
-- Carefully guide the wiring harness from the outside into the transmission.
-- Coat the connector housing seals with transmission fluid and then press the connector housing all the way
into the transmission.
-- Connect the connector housing, tightening specification, refer to FASTENER TIGHTENING

SPECIFICATIONS.
-- Install the valve body. Refer to VALVE BODY.
Transmission Input Speed Sensor -G182-
Removing
-- Remove the transmission input speed sensor bolt -1-.

Fig. 25: Identifying Transmission Input G182 & Output G195 Speed (RPM) Sensors
-- Remove the transmission input speed sensor from the transmission.
Installing
-- Press the sensor all the way into the transmission.
-- Install the transmission input speed sensor bolt -1-. Tightening specification, refer to FASTENER
Transmission Output Speed Sensor -G195-
Removing

-- Remove the transmission output speed sensor bolt -2.
Fig. 26: Identifying Transmission Input G182 & Output G195 Speed (RPM) Sensors
-- Remove the transmission output speed sensor from the transmission.
Installing
-- Press the sensor all the way into the transmission.
-- Install the transmission output speed sensor bolt -2-. Tightening specification, refer to FASTENER
SPECIAL TOOLS


 Drip Tray -V.A.G 1306-
Fig. 28: Identifying Drip Tray V.A.G 1306




 Digital Torque Wrench -V.A.G 1756-

Fig. 31: Identifying Angle Wrench V.A.G 1756

Brakes General, Technical Data
Brakes
General, Technical Data
00 GENERAL, TECHNICAL DATA

GENERAL INFORMATION
BRAKE PR NUMBER ALLOCATION
The PR number on the vehicle data label describes which brake system is installed in the vehicle.
The vehicle data label can be found in the spare wheel well as well as in the Maintenance booklet.
 The following tables explain the PR numbers. These are important for the combination brake
caliper/brake disc and brake pad.
Front Wheel Brakes
Engine version PR number Front Wheel Brake

2.0L - 110 kW 1ZG FN3 (16")
3.6L - 206 kW (FWD)
3.6L -206 kW (AWD) 1LK / 1LM FNR-G (17")
Rear Wheel Brakes
Engine version PR number Rear Wheel Brake

2.0L - 147 kW FSI 1KU / 1KW CII 38 (16")
3.6L - 206 kW (FWD)
3.6L -206 kW (AWD) 2EA / 2EL CII 41 (17")
BRAKE TESTING
 The testing takes place on a test stand.

 During testing, manual transmission vehicles must in idle and automatic transmission vehicles must be in
>>N<<.
 Always follow the instructions provided by the test stand manufacturer.
NOTE: The brake systems do not work when the ignition is off.
With FWD, Testing
The brake test is to be performed on a one-axle roller test stand.

Do not exceed a test speed of 6 km/h (4 mph).
Volkswagen approved test stands meet these requirements.
SPECIFICATIONS
BRAKE MASTER CYLINDER AND BRAKE BOOSTER
Brake
Master
Cylinder Diameter in mm 22.22
(low
engine)
Brake
Master
Cylinder Diameter in mm 23.81
(high
engine)
Brake
Diameter in inches 11
Booster
FRONT BRAKES
Front Brakes FN 3
Fig. 1: Identifying Front Brake Calipers (FN 3) Assembly And Components

Item PR Number 1LJ / 1LH / 1ZM / 1ZG

1 Brake caliper FN3 (16")
2 Brake pad, thickness mm 14
3 Brake disc Diameter in mm 312
Brake disc, thickness mm 25
4 Brake caliper, piston Diameter in mm 54
FNR-G Front Brakes

Fig. 2: Identifying Front Brakes FNR-G Assembly And Components

Item PR Number 1LK / 1LM

1 Brake caliper FNR-G (17")
REAR BRAKES
CII 38 Rear Brakes

Fig. 3: Identifying Rear Brake CII 38 Assembly And Components

Item PR Number 1KU / 1KW

1 Brake caliper CII 38 (16")
CII 41 Rear Brakes
Fig. 4: Identifying Rear Brake CII 38 Assembly And Components

Item PR Number 2EA / 2EL

1 Brake caliper CII 41 (17")
BRAKE TESTING VIA HALDEX CLUTCH, AWD
With AWD, Testing with a Controlled Opposite-Running One-Axle Dynamometer
"Moving in opposite directions" means: The rollers on the brake test stand turn forward on the one side and
backward on the other side.
"Controlled" means: The speed of the test stand rollers must be regulated in such a way as to avoid any speed
difference during the brake test.
The transferring of a force to the rolling wheels in the roller set is prevented by the stationary wheel (outside of
the roller set) via the drive harness.
During testing, the wheel turning forward is measured, therefore two braking test are necessary on each axle.
Do not exceed a test speed of 6 km/h (4 mph).
Volkswagen approved test stands meet these requirements.
With AWD, Testing with Standard One-Axle Dynamometer
-- Drive the vehicle forward onto the rollers.
-- Turn off the engine and wait 2 seconds.
-- Perform the braking test.
-- Start the engine and wait approximately 5 seconds until there is enough vacuum.
-- Drive the vehicle forward until the rear wheel are standing on the rollers.
-- Turn off the engine and wait 2 seconds.
-- Perform the braking test for the rear brakes.
ELECTROMECHANICAL PARKING BRAKE, TESTING
FWD Vehicles
Activating TUV Mode

 The seat belt is on.

 Rear axle in the one-axle roller test stand.
 The ignition remains on.
 Auto Hold is off.
 The front wheel must not be moving.
 The rear wheel must rotate for at least 5 seconds non-stop between 2.5 and 9 km/h (1.6 and 6 mph)
Access to the TUV mode is indicated when the yellow Electric Park/Handbrake Malfunction Indicator Lamp -
K214- comes on.
NOTE: The electromechanical parking brake does not close completely the first time
the TUV mode button is pressed.
Operating the electromechanical parking brake button -E538- four times increases the tension.
Operating the electromechanical parking brake button a fifth time releases the electromechanical parking brake.
Ending TUV Mode
 Front wheels, speed greater than 0 km/h

 Rear wheels, speed less than 2.5 km/h (1.6 mph) or greater than 9 km/h (6 mph).
 Ignition off.
AWD Vehicles
Activating TUV Mode
 The seat belt is on.

 Rear axle in the one-axle roller test stand
 The engine is off and the ignition is on.
 Auto Hold is off.
 The front wheel must not be moving.
 The rear wheel must rotate for at least 5 seconds non-stop between 2.5 km/h (1.6 mph) or greater than 9
km/h (6 mph).
Access to the TUV mode is indicated when the yellow Electric Park/Handbrake Malfunction Indicator Lamp -
K214- comes on.
NOTE: The electromechanical parking brake does not close completely the first time
the TUV mode button is pressed.
Operating the electromechanical parking brake button -E538- four times increases the tension.
Operating the electromechanical parking brake button a fifth time releases the electromechanical parking brake.
Ending TUV Mode
 Front wheels, speed greater than 0 km/h

 Rear wheels, speed less than 2.5 km/h or greater than 9 km/h
 Ignition off.
HVAC General, Technical Data - HVAC
HVAC
General, Technical Data - HVAC

GENERAL INFORMATION
A/C SYSTEM
A/C SYSTEM AND REFRIGERANT R134A, SAFETY PRECAUTIONS
WARNING:  It is recommended to have an eye-flushing bottle available.

 If liquid refrigerant has come in contact with your skin and eyes,
immediately flush with cool water for 15 minutes. Afterwards instill
eye drops and consult a doctor immediately, even when the eyes are
not hurting.
 The doctor must be informed that the injury was caused by
refrigerant R134a. Should refrigerant come into contact with other
parts of the body despite compliance with safety regulations, these
must likewise be rinsed immediately for at least 15 minutes with cold
water.
 Work on refrigerant system should only be performed in ventilated
areas (workshops). Turn on the exhaust gas ventilation system
 Refrigerant must not be stored in low-lying areas such as cellars or
in their entry ways or windowsills.
 Do not attempt repair on filled air conditioning systems by soldering, brazing or welding. This applies
also for welding and soldering work on the vehicle, in the event that parts of the A/C system may heat up.
When performing paint work repairs, the temperature in the drying booth or preheating zone must not
exceed 80°C (176°F).
Reason
Exposure to heat increases the pressure in the system, which could cause the pressure relief valve to open.
Corrective action
-- Discharge refrigerant circuit using service station.
NOTE: Always replace damaged or leaking A/C system components. Do not attempt to
repair them by soldering, brazing or welding.
Refrigerant vessels (such as, charging cylinders of A/C service station) must never be subjected to excessive
heat or exposed to direct sunlight.
Corrective action
-- Vessels must never be completely filled with liquid refrigerant. Without sufficient room for expansion (gas
cushion), vessels will rupture with devastating effect in the event of an increase in temperature. Refer to
REFRIGERANT R134A CHARACTERISTICS.
Refrigerant is never to be transferred to systems or vessels in which air is present.
Corrective action
-- Evacuate systems and vessels before charging with refrigerant.
A/C SYSTEM, REPAIR INFORMATION
WARNING: When performing work on refrigerant circuit, observe all generally

applicable safety precautions and pressure vessel regulations.
CAUTION: Non-approved tools or materials such as leak sealing additives can cause
damage or malfunctions in the system.
Only use tools and materials approved by the manufacturer.
The warranty is voided if non-approved tools or materials are used.
 An A/C system made for refrigerant R12 must not be filled with refrigerant R134a without making
modifications to the refrigerant circuit. Refer to REFRIGERANT CIRCUIT, CONVERTING R12 TO
R134A AND SERVICING.
 The refrigerant oils specifically developed for R134a and R12 refrigerant circuits are never to be mixed.
 Service stations which come in contact with the refrigerant are only to be used for the intended
refrigerant.
 Components of R134a refrigerant circuits can be identified by their markings, green labels or design
(such as different threads) to prevent interchanging with components designed for refrigerant R12.
 A label indicating the refrigerant used is provided in the engine compartment on the lock carrier or in the
plenum chamber.
 Different refrigerants are never to be mixed.
NOTE: When working on the refrigerant circuit, always heed the information given in
A/C SYSTEM AND REFRIGERANT R134A, SAFETY PRECAUTIONS and
REFRIGERANT CIRCUIT, GENERAL PRECAUTIONS.
Special Tools and Accessories
The performance of proper workmanlike repairs on an air conditioning system:

 Requires the use of special tools and materials as listed in SPECIAL TOOLS.
 Requires compliance with the basic instructions for use of leak detectors. Refer to REFRIGERANT
CIRCUIT, FINDING LEAKS WITH ELECTRONIC LEAK DETECTOR VAG 1796.
 Requires expert knowledge.
NOTE: Releasing refrigerant into the environment is not permitted (punishable by law).
Refer to LAWS AND REGULATIONS.
A/C SERVICE AND RECYCLING UNITS
At this time, A/C service units for extracting, cleaning and filling refrigerant for motor vehicle A/C systems are
available from various manufacturers.
COMPONENT REPLACEMENT
CAUTION:  For instructions on how to handle refrigerant oil, refer to

Volkswagen-Service Net, Handbook, Handbook Service Germany; 15.
Environment Protection; further with Environmental Protection; 7
emission protection; refrigerant oil.
 All components of the refrigerant circuit submitted for quality observation are always to be sealed (use
original sealing caps of original part).
 To date, the original parts (compressor, reservoir, receiver, evaporator and condenser) have been filled
with nitrogen gas. This charging stops gradually or the charging pressure is so low that gas does not
escape noticeably when opening.
 On vehicles installed with a compressor with no A/C clutch, the engine is only to be started following
complete assembly of the refrigerant circuit (compressor always in operation as well). Refer to
REFRIGERANT CIRCUIT, GENERAL PRECAUTIONS.
 So that the compressor with A/C Compressor Regulator Valve -N280- (without A/C clutch) is not
damaged when the refrigerant circuit is empty, it is equipped with a secured oil supply. This means that
approximately 40 to 50 cm3 of refrigerant oil remains in the A/C compressor. Refer to REFRIGERANT
CIRCUIT, GENERAL PRECAUTIONS.
NOTE: As original parts are sometimes stored for lengthy periods and at different
locations within the spare parts organization, it is entirely possible that gas will
escape from some parts and not from others on initial opening (even in the case
of identical original part numbers). Sealing caps at original part connections are
therefore to be removed carefully and the nitrogen gas allowed to escape
slowly.
The refrigerant circuit is equipped either with a restrictor and accumulator or

with an expansion valve and receiver.
Seal open connections and pipes (to prevent absorption of moisture).
Always replace restrictor.
NOT REPLACING RESERVOIR/FLUID RESERVOIR OR DRYER BAG/CARTRIDGE, CONDITIONS
 After an accident when there is no damage on the reservoir/fluid reservoir.

 The repair was done quickly (not beyond the normal repair time) and no moisture has entered. The
vehicle is not older than 5 years.
REPLACING RESERVOIR/FLUID RESERVOIR OR DRYER CARTRIDGE, CONDITIONS
 The refrigerant circuit was opened and the vehicle is older than 5 years.
 The refrigerant circuit has been opened for an indefinite period of time (slow leak).
 The repair exceeded the normal repair time and moisture has entered.
 Always replace the reservoir or dryer cartridge after flushing with compressed air, nitrogen or refrigerant
R134a. Leave original parts in their packaging as long as possible to minimize the amount of moisture
they absorb.
 The A/C compressor has locked up.
 The reservoir/fluid reservoir is damaged (accident).
COMPRESSOR REPLACEMENT
-- After installing a new A/C compressor or fresh refrigerant oil has been filled into compressor (for example,
after blowing through the A/C system), turn ribbed belt pulley of A/C compressor 10 rotations by hand before
starting the engine. This prevents damage to the A/C compressor.
-- For 5 cylinder and 10 cylinder diesel engines, rotate A/C compressor 10 rotations by hand at overload
protection. Then install A/C compressor. This prevents damage to the A/C compressor.
-- Start the engine with the A/C turned off (A/C clutch -N25- and A/C compressor regulator valve -N280- are
not actuated).
-- Following engine idling speed stabilization, switch on A/C compressor and run it for at least 10 minutes at
idling speed with maximum cooling output.
EVAPORATOR, SPRAYING WITH PRESSURE CUP GUN AND SPRAY NOZZLE VAG 1538
Spray off the evaporator directly with Contra Sept using a spray nozzle (approximately 10 bar) Contra Sept
neutralizes microbes and bacteria directly on the evaporator.
To make it possible to access the evaporator, some prework and different spray nozzles are needed, for example
-V.A.G 1538/5-; -V.A.G 1538/6- or -V.A.G 1538/7-.
A vehicle-specific instruction booklet is included with the evaporator cleaning solution -D 600 100 A2-
For the current units and spray nozzles, refer to Service Net.
EXTRACTION AND CHARGING SYSTEM SAFETY PRECAUTIONS
 Make sure the shut-off valves are closed before connecting the charging system to the air conditioning
system.
 Make sure the process is finished before disconnecting the charging system from the A/C system. This
prevents any refrigerant from escaping into the atmosphere.
 Once the purified refrigerant from the charging system has been transferred to an external compressed-
gas cylinder, close the hand shut-off valves at the cylinder and charging system.
 Do not expose charging system to moisture or use it in a wet environment.
 Disconnect from power supply before performing service work on the charging system.
 Never use an extension cable on account of the fire hazard. If the use of an extension cable is
unavoidable, the minimum cross-section should be 2.5 mm2 .
 In case of fire, remove external cylinder.
 Entrained oil from the air conditioning system drawn by the suction unit into the measurement vessel
supplied is subsequently to be transferred to a sealed container as it contains a small quantity of
refrigerant. It must not be released into the environment.
 Following shutdown, service station is to be secured to stop it rolling away.
HANDLING PRESSURE VESSELS
 Secure vessels to prevent them falling over!
Secure upright cylinders to stop them falling over and cylinders lying flat to stop them rolling away.
 Do not throw vessels.
If dropped, the vessels could be so severely deformed that they rupture. The refrigerant evaporates immediately,
liberating considerable force. Flying fragments of cylinders can cause severe injuries.
Valves may break off if cylinders are not properly transported. To protect the valves, cylinders are only to be
transported with protective cap screwed on.
 Never store in the vicinity of radiators.
High temperatures may occur next to radiators. High temperatures are also accompanied by high pressures and
the maximum permissible vessel pressure may be exceeded.
Temperature Warning
To avoid possible risk, pressure vessel regulations specify that vessels are not to be heated to in excess of 50°C
(122°F).
Heating Warning
Do not heat with a naked flame under any circumstances. Localized overheating can cause structural changes in
the vessel material, which then reduce its ability to withstand pressure. There is also a danger of refrigerant
decomposition due to localized overheating.
Empty Containers
Empty refrigerant vessels must always be sealed to prevent the ingress of moisture. Moisture causes steel
vessels to corrode. This weakens the vessel walls. In addition, rust particles entering into refrigeration systems
from vessels will cause malfunctioning.
HANDLING REFRIGERANT
The refrigerant can then escape as a fluid or vapor.
Do not open containers, which store refrigerant.
Follow the instructions for the workplace. Refer to Volkswagen Service Net, Handbooks, Service Handbook;
Protecting the Environment. They should be displayed in the workplace.
If refrigerant vessels are opened, the contents may escape in liquid or vapor form. This process is intensified the
higher the pressure in the vessel.
The pressure level is governed by two factors:
 The type of refrigerant in the vessel. The lower the boiling point, the higher the pressure.
 The temperature level. The higher the temperature, the higher the pressure.
Protective Eyewear
Put on protective goggles. They prevent refrigerant getting into the eyes, as this could cause severe injury from
exposure to cold.
Protective Gloves and Clothing
Greases and oils dissolve readily in refrigerants. They would therefore destroy the protective layer of grease if
allowed to come into contact with the skin. Degreased skin is however sensitive to the cold and germs.
Fluid Refrigerant and Skin Precaution
The refrigerant draws heat for evaporation from the surrounding area. Even if this is the skin. This may cause
extremely low temperatures. Local frost bite may result (boiling point of R134a: -26.5°C (-15.7°F) at ambient
pressure).
Do Not Breathe In Refrigerant Vapor

NOTE: If highly concentrated refrigerant vapor escapes, it mixes with the surrounding
air and displaces the oxygen necessary for breathing.
Smoking Hazard
A burning cigarette can cause refrigerant to decompose. The resultant substances are toxic and must not be
inhaled.
Welding and Soldering on Refrigeration Systems
Before performing welding or soldering work on vehicles near the air conditioning system components, extract
the refrigerant and remove the residue by flushing with compressed air and nitrogen.
The products of refrigerant decomposition due to the effect of heat are not only toxic, but may also have a
highly corrosive effect on pipes and system components. They mainly take the form of hydrogen fluoride.
Pungent Odor
A pungent odor indicates that the products of decomposition mentioned above have already formed. Avoid
inhaling these substances under all circumstances, as otherwise the respiratory system, lungs and other organs
could be damaged.
First Aid
 Following contact with eyes or mucous membranes, immediately rinse with copious amounts of running
water and consult an eye specialist.
 Following contact with the skin, immediately remove affected clothing and rinse skin with copious
amounts of water.
 Following inhalation of highly concentrated refrigerant vapors, immediately take the affected person into
the open air. Call a doctor. Administer oxygen in the event of breathing difficulties. If the affected person
has difficulty breathing or cannot breathe, tip head back and perform mouth to mouth respiration.
REFRIGERANT R134A
Vehicle air conditioning systems make use of the vaporization and condensation process. In this case, one
works with a substance which boils easily, designated as refrigerant.
The refrigerant employed is tetrafluoroethane R134a, which boils at -26.5°C (-15.7°F) at a vapor pressure of 1
bar.
Refrigerant R134a Environmental Information
 R134a is a fluorocarbon and contains no chlorine.

 R134a has a shorter atmospheric life span than refrigerant R12.
 R134a does not damage the ozone layer. The ozone depletion potential is zero.
 The greenhouse potential of R134a (Global Warming Potential (GWP)) is approximately 1300 (the GWP
of carbon dioxide is 1).
 The global warming effect of R134a is ten times less than that of refrigerant R12.
Vehicles manufactured after 1992 have air conditioning systems that use refrigerant R134a. This refrigerant
does not contain chlorine and does not deplete the ozone layer.
Refrigerant R12 was used through 1992. Due to its chlorine atoms, this CFC has a high potential for depleting
the ozone layer as well as a tendency to increase the greenhouse effect.
Conversions are offered for existing systems filled with the ozone-depleting substance R12.
Refer to Repair Information for A/C systems with refrigerant R12. This repair information is only available in
hard copy.
For environmental protection reasons, refrigerants must not be released into the atmosphere. For laws and
regulations, refer to LAWS AND REGULATIONS.
Refrigerant R134a Physical Data
Chemical formula CH2F-CF3 or CF3-CH2F

Chemical designation Tetrafluoroethane
Boiling point at 1 bar - 26.5°C (-15.7°F)
Solidification point -101.6°C (-150.88°F)
Critical temperature 100.6°C (213°F)
Critical pressure 40.56 bar (absolute)
Critical Point
The critical point (critical temperature and critical pressure) is that above which there is no longer a boundary
between liquid and gas.
A substance above its critical point is always in the gaseous state.
At temperatures below the critical point, all types of refrigerant in pressure vessels exhibit both a liquid and a
gas phase, for example, there is a layer of gas above the liquid.
As long as there is still gas present in the container next to the fluid, pressure is dependent on ambient
temperature. Refer to REFRIGERANT R134A VAPOR PRESSURE TABLE.
NOTE: Different types of refrigerant are never to be mixed. Only the refrigerant
designated for the corresponding A/C system may be used.
REFRIGERANT R134A CHARACTERISTICS

The vapor pressure curves of R134a and other refrigerants are sometimes very similar, therefore it is not
possible to make a certain distinction solely by pressure.
With R134a, the A/C compressor is lubricated with special synthetic refrigerant oils, for example, PAG oils
(polyalkylene glycol oils).
Trade Names and Designations
Refrigerant R134a is currently available under the following trade names:
 H-FKW 134a
 SUVA 134a
 KLEA 134a
NOTE: Different trade names may be used in other countries.
Of the wide range of refrigerants available, this is the only one which may be
used for vehicles. The designations Frigen and Freon are trade names. They
also apply to refrigerants which may not be used in automotive vehicles.
Product Characteristics
Refrigerants used in motor vehicle air conditioning systems belong to the new generation of refrigerants based
on chlorine-free, partially fluorinated hydrocarbons (H-FKW, R134a).
With regard to their physical properties, these are refrigerants which have been liquefied under pressure. They
are subject to the regulations governing pressure vessels and use is only to be made of approved and
appropriately marked containers.
Compliance with specific conditions is required to ensure safe and proper use.
Color
Like water, refrigerants are colorless in both vapor and liquid form. Gas is invisible. Only the boundary layer
between gas and liquid is visible. (Liquid level in tube of charging cylinder or bubbles in sight glass).
Refrigerant R134a fluid may appear colored (milky) in a sight glass. This cloudiness is caused by partially
dissolved refrigerant oil and does not indicate a malfunction.
Vapor Pressure
In a partially filled, closed vessel, the quantity of refrigerant evaporating from the surface equals the quantity
returning to the liquid state as vapor particles condense. This state of equilibrium occurs under the influence of
pressure and is often called vapor pressure. Vapor pressure is dependent on temperature. Refer to
REFRIGERANT R134A VAPOR PRESSURE TABLE.
Affect on Metal
In its pure state, refrigerant R134a is chemically stable and does not corrode iron or aluminum.
Refrigerant impurities such as chlorine compounds however cause corrosion of certain metals and plastics. This
can lead to blockage, leaks or deposits on the A/C compressor piston.
Critical Temperature/Pressure
The refrigerant R134a remains chemically stable up to a gas pressure of 39.5 bar (corresponding to a
temperature of 101°C (213°F). Above this temperature, the refrigerant decomposes (refer to Combustibility).
Water Content
Only very small amounts of water are soluble in liquid refrigerant. On the other hand, refrigerant vapor and
water vapor mix in any ratio.
Only a small drop of water may get into the refrigerant circuit. The dryer, dryer bag or dryer cartridge contained
in the reservoir can absorb approximately 7 grams (0.25 oz.) of water. They are then saturated and cannot
absorb any more water. If water is still present in the refrigerant circuit, it flows up to the expansion valve
nozzle or restrictor and becomes ice.
The air conditioning system stops cooling.
Water destroys the air conditioner as it combines with other impurities at high pressures and temperatures to
form acids.
Combustibility
Refrigerant is non-flammable. It actually has a fire resistant or fire extinguishing effect. Refrigerant decomposes
when exposed to flames or red-hot surfaces. UV light (occurring for example during electric welding) also
causes refrigerant decomposition. The resultant decomposition products are toxic and are not to be inhaled.
However, irritation of the mucous membranes provides an adequate and timely warning.
Charge Factor
A vessel must have space for vapor as well as liquid. As the temperature rises, the liquid expands. The vapor-
filled space becomes smaller. At a certain point, there will only be liquid in the vessel. Beyond this, even a
slight increase in temperature causes great pressure to build up in the vessel as the liquid attempts to continue
expanding despite the absence of the necessary space. The forces that result are strong enough to rupture the
vessel. To prevent a vessel from being overfilled, the regulations regarding compresses gasses specify how
many kilograms of refrigerant that may be added to a vessel per liter of interior volume. Multiplying this filling
factor with the interior volume gives the permitted filling capacity. The figure for refrigerant used in vehicles is
1.15 kg/liter.
Evidence of Leaks
External damage, for example, can cause a leak in the refrigerant circuit. The small quantity of refrigerant
escaping from minor leaks can be detected for example using an electronic leak detector or by introducing a
leak detection additive into the refrigerant circuit. Electronic leak detectors are capable of registering leaks with
refrigerant losses of less than 5 g per year. Use leak detectors designed for the type of refrigerant. For example,
a leak detector for R12 refrigerant will not work with R134a because R134a refrigerant has no chlorine atoms
so the leak detector will not respond to it.
REFRIGERANT R134A VAPOR PRESSURE TABLE
The vapor pressure table for every refrigerant is published in literature for refrigeration system engineers. This
table makes it possible to determine the vapor pressure acting on the column of liquid in a vessel if the
temperature of the vessel is known.
Because each refrigerant has its own characteristic vapor pressure table, refrigerant can be identified by
measuring the pressure and temperature.
NOTE: At absolute pressure, 0 bar corresponds to absolute vacuum. Normal ambient

pressure (positive pressure) corresponds to 1 bar absolute pressure. 0
pressure corresponds to an absolute pressure of one bar on most pressure
gauges (indicated by -1 bar below 0).
Temperature in °C Pressure in Bar (Positive Pressure) of R134a

-45 -0.61
-40 -0.49
-35 -0.34
-30 -0.16
-25 0.06
-20 0.32
-15 0.63
-10 1.00
-5 1.43
0 1.92
5 2.49
10 3.13
15 3.90
20 4.70
25 5.63
30 6,70
35 7.83
40 9.10
45 10.54
50 12.11
55 13.83
60 15.72
65 17.79
70 20.05
75 22.52
80 25.21
85 28.14
90 31.34
REFRIGERANT OIL
Refrigerant oil mixes with the refrigerant (about 20 - 40%, depending on compressor type and amount of
refrigerant) and circulates constantly in the system, lubricating the moving parts.
Special synthetic refrigerant oils, for example polyalkylene glycol (PAG) oil, are used in conjunction with
R134a air conditioning systems. This is necessary as mineral oil, for example, does not mix with R134a. In
addition, the materials of the R134a air conditioning system could be corroded as a result of mixture flowing
through the refrigerant circuit under pressure at high temperatures or breakdown of the lubricating film in the
compressor. Using non-approved oils can cause the HVAC system to malfunction. Only use approved oils.
Type of oil for R134a in motor vehicles: PAG
NOTE: Do not store open containers of refrigerant oil because it attracts moisture.
Always keep oil containers sealed.
Do not use old refrigerant oil over again. Dispose of old oil. Refer to
Volkswagen-Service Net, Handbook, Handbook Service Germany; 15.
Environment Protection; further with Environmental Protection; 7 emission
protection; refrigerant oil. Ester-based oils are only intended for use in large
systems, not in passenger vehicle systems.
REFRIGERANT OIL CHARACTERISTICS
The most important properties are a high degree of solubility with refrigerant, good lubricity, absence of acid
and minimal water content. Only certain oils are permitted. For a list of approved refrigerant oils and capacities,
refer to Maintenance, Diagnosis .
PAG oils, which are appropriate for refrigerant R134a, are highly hygroscopic and do not mix with other oils.
Opened containers should therefore be closed again immediately to prevent ingress of moisture. Moisture and
acids promote aging of refrigerant oil, causing it to become dark and viscous as well as corrosive towards
metals.
NOTE: Only use oils approved for the A/C compressor in refrigerant circuits with
refrigerant R134a. For capacities, refer to Maintenance, Diagnosis .
Dispose of old oil. Refer to Volkswagen-Service Net, Handbook, Handbook

Service Germany; 15. Environment Protection; further with Environmental
Protection; 7 emission protection; refrigerant oil.
SERVICING A/C SYSTEM
The purpose of this Repair Information is to provide foremen and mechanics with the basic knowledge needed
to ensure expert working.
NOTE: Expert knowledge is achieved by one who has taken part successfully in
instructional training for example, AB160 or ST160, including trained experts.
This Repair Information also serves as instructional material.
It should also be available for presentation to the responsible supervisory agency on request.
Additional Information Sources
 Technical Service Handbook outlining action to be taken to rectify current problems.

 Repair Information for type-specific servicing work, refer to [For engine(s) BPY,BLV,CCTA,CBFA]
Air Conditioning .
 Refer to appropriate System Wiring Diagram information.
 Sections of Self Study Program number 208 are no longer up-to-date. An example of this is the statement
"The fluid reservoir is replaced each time the refrigerant circuit is opened". The following prerequisites
apply. Refer to NOT REPLACING RESERVOIR/FLUID RESERVOIR OR DRYER
BAG/CARTRIDGE, CONDITIONS.
 Video programs for in-dealership training.
 Special Tools and Workshop Equipment Information.
 Service Organization Volume 1 Additional Equipment.
 Repair information Air Conditioning with Refrigerant R12. Only hardcopies of this information are
available for vehicles through MY 1993.
 The procedure for flushing the refrigerant circuit is selected in Volkswagen Service Net; Volkswagen TV;
API Online; or Volkswagen TV Net; API/PKW under the book title Body and then the program from
June 8, 2005 Refrigerant Circuit, Flushing, Golf Plus.
ULTRASOUND A/C CLEANER -VAS 6189A-
-- The Ultrasound A/C Cleaner -VAS 6189A- is placed in the front passenger footwell and sprays Aero-Clean.
Aero-Clean neutralizes microbes and bacteria inside the heater and A/C unit.
The unit comes with Operating Instructions.

For the current units, refer to relevant information in Service Net; Workshop Equipment; ; V.A.G Workshop
Equipment ; A/C and Heater; Service Units.
LAWS AND REGULATIONS
CHARGING SYSTEMS NOT REQUIRING A PERMIT
Charging systems not requiring a permit are ones used for transferring compressed gases to mobile compressed-
gas vessels for internal use only.
Note
Some A/C service units are charging systems not requiring a permit. When working with such equipment, the
refrigerant is not transferred to mobile compressed-gas vessels, but rather into a permanently installed charging
cylinder with visible level gauge and float switch.
Recommendation
It is advisable to use a portable cylinder with visible level gauge and pressure relief valve for surplus refrigerant
for internal use.
Attention must be paid to TRG 402 (technical regulations for compressed gases) when transferring compressed
gases to other compressed-gas vessels.
EXTRACTION SYSTEM GROUP CLASSIFICATIONS
Group 3
Mobile extraction and charging systems for filling compressed-gas vessels permanently connected to the
system.
The refrigerant or refrigerant/oil mixture is transferred to compressed gas vessels which are permanently
connected to the mobile systems. In accordance with 3 Paragraph 5 No. 3 of pressure vessel regulations,
compressed-gas vessels are classified as pressure vessels in this case.
The charging systems require:
 No permit
 No expert testing as the gas is transferred to compressed-gas vessels which are classed as being pressure
vessels. (Systems used for transfer from these pressure vessels to compressed-gas vessels for supplying to
third parties do require a permit and are subject to mandatory testing).
NOTE: The A/C service and recycling units used in motor vehicle workshops are
extraction and charging systems not requiring a permit (Group "3") but which
are only to be operated by qualified personnel. Instructions for unit operation
and maintenance can be found in the relevant manufacturer's documentation.
LAWS AND REGULATIONS
NOTE: The laws and regulations listed below are applicable in Germany. Different or
additional laws and regulations may apply in other countries.
Addresses in other countries can be obtained from the relevant authorities.
The effects of climate change can be seen worldwide. Protecting the climate is one of the most important
responsibilities. However, this responsibility presents enormous challenges to all involved.
The Kyoto Protocol outlines worldwide goals regarding climate protection, among other things. In addition to
target reductions of carbon dioxide, this protocol also outlines target reductions for fluorinated greenhouse
gases such as refrigerant R134a due to their high potential of contributing to the greenhouse effect.
Numerous laws have been created for the automotive industry, for example at the European level. For example,
chemical-climate protection regulations were put into effect on August 1, 2008 in Germany in order to define
the European legislation in more detail.
 Provision (EU) no. 1005/2009

 Guideline 2006/40/EU
 Chemical-climate protection provision, recycling management and disposal regulations (for Germany)
Maintenance and repair work on the A/C system refrigerant circuit
All individuals performing maintenance and repair work on vehicle A/C systems must have completed a
training program and be competent in the work required. Other regulations may apply in addition to those of the
European Union.
The following general points apply
Operation, repair, decommissioning, take-back obligation
 When operating, repairing and decommissioning items that contain refrigerant, allowing the refrigerant to
vent into the air is prohibited.
 Keep records about the quantities used during operation and maintenance (Refrigerant Log, refer to
Volkswagen Service Net, Handbooks, Service Handbook; Protecting the Environment; Emission
Protection) so they can be presented to the authorities upon request. Other provisions may apply in
countries that are not members of the EU.
 Distributors of the substances and preparations discussed above are obligated to accept these items back
after use or to ensure they are accepted by a third party of their choosing.
 Maintenance and decommissioning of items containing refrigerant that are named in the legislation
Substances and preparations named in this legislation may only be accepted by those with the necessary
expertise and technical equipment.
Criminal offenses and infringements of the law
 Willfully or negligently venting refrigerant into the air when operating, repairing or decommissioning
items that contain refrigerant constitutes a violation of the laws and legislation described above.
Technical Regulations For Compressed Gases (TRG) 400, 401, 402
Only excerpts concerning vehicle manufacturers and workshops are listed below.
TRG 400 (General Regulations For Charging Systems)
2. Definition of terms and explanations
2. 1 Charging systems
2.1.1 Charging systems are systems for filling mobile compressed-gas vessels. The charging system includes
the premises and facilities concerned.
2. 4 Charging systems requiring a permit
Charging systems requiring a permit are ones used to transfer compressed gases to mobile compressed-gas
vessels for supplying to third parties.
5 Charging systems not requiring a permit are ones used for transferring compressed gases to mobile
compressed-gas vessels for internal use only.
TRG 401 (Installation Of Charging Systems)
Does not apply to vehicle manufacturers or workshops.
TRG 402 (Operation Of Charging Systems)
2. Employees and employee instruction
2. 1 Charging systems are only to be operated and maintained by personnel
 Who are 18 years of age and older

 Who possess the necessary technical knowledge
 Who can be relied upon to work diligently.
2. 2 Supervised work may also be performed by personnel that do not meet the requirements stipulated in item
2. 1, points 1 and 2.
2. 3 Employees are to be given instruction on the following topics before beginning work and at regular,
appropriate intervals, however at least once a year:
 Hazards specifically associated with handling compressed gases

 Safety regulations, particularly the applicable TRG
 Procedures in the event of malfunction, damage and accidents
 The use of fire-extinguishing and protective equipment
 Operation and maintenance of the charging system according to the operating instructions.
Charging (a separate TRG applies to vessels from other countries and their charging)
A compressed-gas vessel is only to be filled with the compressed gas declared on it and the quantity must
comply with the stipulated pressure, weight or volume data (refer to g15, Para. 2, pressure vessel regulations).
2. In the case of vessels approved for use with several types of compressed gas, the compressed gas with which
it is to be filled and - if the compressed gas has a tk greater than or equal to -10°C (14°F) (tk = critical
temperature) - the maximum permissible charging weight in line with TRG 104 No. 3. 3 must be marked on the
vessel prior to connection for filling.
3. Compressed-gas vessels marked with the maximum permissible charge pressure in bar at 15°C (59°F) must
be filled manometrically. If, at the time of filling, the temperature is not 15°C (59°F), the pressure
corresponding to the prevailing temperature must be established; it must be ensured that the permissible charge
pressure at 15°C (59°F) is not exceeded in the compressed- gas vessel. The charged vessels are to be checked by
way of random pressure measurements to determine possible overfilling.
4. Compressed-gas vessels on which the maximum permissible capacity is indicated by the net weight (filling
weight, permissible weight of fill) in kilograms must be filled gravimetrically. The vessels are to be weighed
during filling and subsequently subjected to a weight check on special scales to establish possible overfilling.
Scales used for this purpose must be calibrated.
5. Under certain conditions, gases with a tk greater than or equal to 70°C (158°F) may be transferred
volumetrically from compressed-gas vessels with a maximum volume of 150 l to compressed-gas vessels with a
volume of maximum 1000 ccm. The stipulations of the TRG apply to the transfer of liquefied gas to cylinders
used by workmen.
6. Vessels in vehicles for
(1) Gases with tk greater than or equal to +70°C (158°F) (refer to TRG 101 Annex 3)
(2) Industrial gas mixtures with tk greater than or equal to +70°C (158°F) (refer to TRG 102 Annex 1 Groups 3)
or
Liquefied extremely low-temperature compressed gases (refer to TRG 103) may, contrary to item 4, be filled
volumetrically if the charging system and/or the vessels is/are equipped with devices for measuring or limiting
the volume of the charge and - with the exception of motor vehicle vessels as per item 3 - for measuring the
temperature of the charge. When filling volumetrically, it must be ensured that the permissible charge weight
indicated on the vessel is not exceeded. To determine possible overfilling, the filled containers are to be
checked gravimetrically on a calibrated scale or - provided that the pressurized gases are not highly toxic -
volumetrically. Volumetric checking requires the use of appropriate equipment with completely separate
charging and checking devices.
7. Charging and check measurements are to be performed by different people. Check measurements must be
performed immediately upon completion of the filling process.
8. Overfilled vessels must be drained immediately and in a safe manner until the permissible fill is attained. The
compressed-gas fill is then to be determined again.
9. Items 4 to 7 do not apply to vessels for liquefied, extremely low-temperature compressed gases which are
neither flammable nor toxic; this does not affect the provisions of road traffic legislation.
10. When filling compressed gas vessels with liquefied gases at charging temperatures less than or equal to -20°
C (-4°F), the compressed gas vessel (if the vessel material has not been tested for temperatures less than or
equal to -20°C (-4°F) is not to be released from the charging system for transportation until the vessel wall
temperature is greater than or equal to +20°C (68°F).
Recycling and Disposal Regulations
Specifications and rules for handling and disposing of refrigerants and refrigerant oils can be found in the
chemical-climate protection provision and recycling and disposal regulations. These are valid in Germany.
Different specifications and rules may apply in other countries.
Refrigerant, Keeping Records
The environmental statistics law requires records to be kept on the use of refrigerants.
Consequently, motor vehicle workshops may well have to provide the relevant local authorities with
information on their use of refrigerant. It is therefore recommended to keep records of the quantities used during
operation and maintenance (refrigerant log) and present them to the relevant authorities upon request.
NOTE: Other provisions may apply in countries that are not members of the EU.
RECYCLING AND DISPOSAL REGULATIONS
Specifications and rules for handling and disposing of refrigerants and refrigerant oils can be found in the
chemical-climate protection provision and recycling and disposal regulations. These are valid in Germany.
Different specifications and rules may apply in other countries.
Refer to Volkswagen Service Net, Handbooks, Service Handbook; Protecting the Environment; Waste
Disposal.
Refrigerant Disposal
Refrigerants intended for disposal are to be transferred to marked recycling containers, observing the
permissible filling quantity. Refer to the chemical-climate protection provision and the recycling and disposal
regulations in Germany. Different specifications and rules may apply in other countries.
Refrigerant Oil Disposal
Used refrigerant oils from systems employing halogenated hydrocarbons are to be disposed of as waste subject
to special supervision. They are not to be mixed with other oils or substances. Proper storage and disposal must
be ensured in line with local regulations. Refer to the chemical-climate protection provision and the recycling
and disposal regulations in Germany. Different specifications and rules may apply in other countries.
REFRIGERANT CIRCUIT, CONVERTING R12 TO R134A AND SERVICING
For environmental reasons and on account of the corresponding legislation,

refrigerant R12 can no longer be manufactured or supplied. Refrigerant R134a
has been developed as a replacement for R12.
Air conditioning systems developed and designed for refrigerant R12 cannot
however simply be charged with refrigerant R134a. To ensure trouble-free
operation of the air conditioning system even after conversion, various
components of the refrigerant circuit must be replaced.
A precise description of the conversion procedure and information on the

servicing of converted refrigerant circuits can be found in Repair Information:
Air conditioner with refrigerant R12 Parts 2 and 3. This repair information is
only available in hard copy.
REFRIGERANT, KEEPING RECORDS
Keep records about the quantities used during operation and maintenance (Refrigerant Log, refer to
Volkswagen Service Net, Handbooks, Service Handbook; Protecting the Environment; Emission Protection) so
they can be presented to the authorities upon request. Other provisions may apply in countries that are not
members of the EU.
A/C SYSTEM PRINCIPLES
PHYSICAL PRINCIPLES
The four known states of water also apply to air conditioning system refrigerants.
Fig. 1: Identifying Four States Of Water

1. Gaseous (invisible)
2. Vapor
3. Fluid
4. Solid
When water is heated in a vessel (heat absorption), water vapor can be seen to rise. If the vapor is further heated
through heat absorption, the visible vapor turns into invisible gas. The process is reversible. The warmth is
extracted from gaseous water, vapor forms first, then water and then ice.
Fig. 2: Identifying Diagram Of Heat Absorption & Heat Emission

A - Heat absorption
B - Heat emission
Heat Transfer
Every substance consists of a mass of moving molecules. The fast moving molecules of a warmer substance
give off some of their energy to the cooler and thus slower molecules. As a result, the molecular motion of the
warmer substance slows down and that of the colder substance is accelerated. This process continues until the
molecules of both substances are moving at the same speed. They are then at the same temperature and no
further heat exchange takes place.
PRESSURE AND BOILING POINT
The boiling point given in tables for a liquid is always referenced to an atmospheric pressure of 1 bar. If the
pressure acting on a fluid changes, its boiling point also changes.
For example, water boils at a lower temperature the lower the pressure.
The vapor pressure curves for water and refrigerant R134a show that, at constant pressure, reducing the
temperature changes vapor to liquid (in the condenser) or that reducing the pressure causes the refrigerant to
change from liquid to vapor (evaporator).
Vapor pressure curve of water

Fig. 3: Identifying Vapor Pressure Curve Of Water Graph

A - Fluid
B - Gaseous
C - Vapor pressure curve of water
1 - Pressure acting on liquid in bar (absolute)
2 - Temperature in °C
Vapor pressure curve of refrigerant R134a

Fig. 4: Identifying Vapor Pressure Curve Of Refrigerant R134a Graph

A - Fluid
B - Gaseous
D - Vapor pressure curve of refrigerant R134a
1 - Pressure acting on liquid in bar (absolute)
2 - Temperature in °C
COMFORT
Being comfortable while driving leads to better concentration and safe driving. Air conditioning makes drivers
and passengers more comfortable when temperatures or humidity are high. While opening the windows or
sunroof or increasing the air flow can make vehicle occupants more comfortable, it also exposes them to more
noise, draughts, exhaust, pollen and dust.
A well-designed heating and air conditioning system can increase comfort by controlling the temperature,
humidity and air flow inside the vehicle. This is done both when the vehicle is moving and when it is stationary.
Air conditioning also offers these advantages:
 It cleans the air that enters the vehicle interior. The damp fins on the evaporator collect dust and pollen,
which is then removed by condensation.
 Temperatures in a mid-size vehicle (for example: after a short drive, outside temperature 30°C in the
shade and the vehicle exposed to sunlight).
With A/C system Without A/C system

Head area 23°C (73°F) 42°C (107°F)
Upper body area 24°C (75°F) 40°C (104°F)
Foot area 30°C (86°F) 35°C (95°F)
A/C SYSTEM OPERATION
The temperature in the passenger compartment depends on the amount of heat radiated through the windows
and conducted by the metal parts of the body. In hot weather it is possible to achieve a more comfortable
temperature for the passengers by pumping off some of the heat.
As heat spreads into cooler areas, the passenger compartment is equipped with a unit for generating low
temperatures. In the unit, refrigerant is constantly evaporated. The heat required for this is extracted from the air
flowing through the evaporator.
After absorbing heat, the refrigerant is pumped off through the compressor. The action of the A/C compressor
increases the heat content and temperature of the refrigerant. Its temperature is then substantially higher than
that of the surrounding air.
The warm refrigerant flows to the condenser. There, the refrigerant dissipates its heat to the surrounding air via
the condenser due to the temperature gradient between the refrigerant and the surrounding air.
The refrigerant thus acts as a heat transfer medium. As it is to be reused, the refrigerant is returned to the
evaporator.
For this reason all air conditioning systems are based on the refrigerant circulation principle. There are however
differences in the combination of aggregates.
REFRIGERANT CIRCUIT AND COMPONENTS
REFRIGERANT CIRCUIT, GENERAL PRECAUTIONS
 Follow the instructions for the workplace. Refer to Volkswagen Service Net, Handbooks, Service
Handbook; Protecting the Environment. They should be displayed in the workplace.
 Ensure absolute cleanliness when working.
 Wear work clothing, safety goggles and gloves when working with refrigerant and nitrogen.
 Turn on the exhaust gas ventilation system
 Use service station to discharge refrigerant circuit, only then open screw connections and replace
malfunctioning components.
 Use caps to seal off opened assemblies and hoses to prevent ingress of moisture and dirt.
 Make exclusive use of tools and materials intended for refrigerant R134a.
 Be sure to close the container to prevent the refrigerant from absorbing moisture from the air.
-- Flushing refrigerant circuit with compressed air and nitrogen, refer to REFRIGERANT CIRCUIT,
FLUSHING WITH COMPRESSED AIR AND NITROGEN.
-- Flush the refrigerant circuit with R134a refrigerant. Refer to REFRIGERANT CIRCUIT, FLUSHING
WITH REFRIGERANT R134A.
On vehicles with A/C compressor without magnetic clutch:
NOTE: The engine should only be started after assembling the refrigerant circuit.
If possible start engine only with a filled refrigerant circuit.
The A/C compressor is always driven by the ribbed belt pulley/torsion elastic
clutch. It does not have a magnetic clutch.
If an A/C compressor locks-up the overload protection for the A/C compressor
shaft is triggered. If no bumps are visible on the ribbed belt pulley/overload
protection, the A/C compressor may be blocked. Another indicator is abraded
rubber material in the area of the ribbed belt pulley/overload protection
The engine may only be started when the refrigerant circuit is installed
correctly. For example; if the refrigerant pipes are not connected to A/C
compressor, when the engine is running the A/C compressor may heat up (via
internal heat generation) so much that the A/C compressor will be damaged.
A/C Compressor Regulator Valve -N280- is not activated when the refrigerant
circuit is empty and the A/C compressor idles with the engine.
If it is necessary to start the engine with a discharged refrigerant circuit:
Refrigerant circuit must be fully assembled.
At least 1/4 of the prescribed refrigerant oil must be in the A/C compressor.
Do not rev engine higher than 2000 RPM.
The engine should run less than 10 minutes.
O-RING SEALS
 Only O-rings that are resistant to refrigerant R134a and refrigerant oil must be installed. Color coding of
O-rings is no longer employed. Colored and black O-rings are used.
 Ensure inner diameter on seals used is correct.
Refer to [For engine(s) BPY,BLV,CCTA,CBFA] Removal and Installation .

 The O-rings may be used one time only.

 Before installing O-rings, coat lightly with refrigerant oil (PAG oil).
NOTE: When flushing components with compressed air and nitrogen, always extract
the gas mixture escaping from the components with suitable extraction units
(workshop extraction system).
After engine all service work, screw sealing caps (with seals) onto all
connections with valve and service connections.
Before starting up A/C system. Observe vehicle specific filling capacities. Refer to Maintenance, Diagnosis .
Do not fill refrigerant, extract refrigerant present and refill the system.
REFRIGERANT CIRCUIT PIPES AND HOSES
The mixture of refrigerant oil and refrigerant R134a corrodes certain metals (for example copper) and alloys
and dissolves some hose materials. Therefore use original replacement parts only.
Pipes and hoses are joined by threaded connections or special plug connectors.
NOTE: Observe specified torque for threaded connections, use appropriate release
tools for plug connectors.
REFRIGERANT CIRCUIT PRESSURES AND TEMPERATURES
WARNING: When performing work on refrigerant circuit, observe all generally

applicable safety precautions and pressure vessel regulations.
The pressures and temperatures in the refrigerant circuit depend on the current operating conditions (such as
engine RPM, coolant fan level 1, 2 or 3, engine temperature, A/C compressor on or off) as well as on the effects
of outside influences (such as outside temperature, humidity, desired cooling output).
In vehicles with A/C compressor regulator valve -N280-, the pressure is modified on the low pressure side by
the valve.
For this reason, values indicated in the following table are valid only as reference points. They are attained at an
engine speed of 1500 to 2000 RPM and an ambient temperature of 20°C (68°F) after about 20 minutes.
The connections provided for measuring pressure for the manometer battery are located in the vehicle-specific
refrigerant circuit.
Refer to [For engine(s) BPY,BLV,CCTA,CBFA] Description and Operation .
At 20°C (68°F) with the engine not running, the pressure in the refrigerant circuit is 4.7 bar. Refer to
REFRIGERANT R134A VAPOR PRESSURE TABLE.
REFRIGERANT CIRCUIT, CONVERTING R12 TO R134A
CFC refrigerants are no longer used in the automotive industry.
Converting refrigerant circuits from R12 refrigerant to R134a refrigerant and servicing converted circuits, refer
to Repair Information Air conditioner with refrigerant R12 Parts 2 and 3. This repair information is only
available in hard copy.
REFRIGERANT CIRCUIT, FLUSHING WITH COMPRESSED AIR AND NITROGEN
WARNING:  Nitrogen can leak uncontrolled from the cylinder.

 Make exclusive use of pressure reducers for nitrogen cylinders
(maximum work pressure 15 bar).
 Use appropriate emissions extraction units to draw off gas mixture
escaping from components.
 In order to be able to force moisture and other contaminants out of refrigerant circuit, compressed air and
nitrogen (to force moisture out of refrigerant circuit) are to be used.
 For the most part, blowing through the refrigerant circuit with compressed air and nitrogen requires
significantly more work than flushing with refrigerant R134a. As flushing with refrigerant R134a cleans
the components more efficiently, always flush in case of a complaint (blowing through should only be
used for certain complaints and individual components).
Only individual components should be flushed if
 There is no possibility of flushing the refrigerant circuit with refrigerant R134a.

 Dirt or other contaminants are located in individual components of the circuit.
 Vacuum reading is not maintained on evacuating a leak-free refrigerant circuit (pressure build-up due to
moisture in refrigerant circuit).
 Refrigerant circuit has been left open for longer than normal (for example following an accident).
 Pressure and temperature measurements in the refrigerant circuit indicate the likelihood of moisture.
 Stipulated by the vehicle-specific repair information. Refer to [For engine(s) BPY,BLV,CCTA,CBFA]
Removal and Installation following replacement of certain components.
NOTE: Blowing compressed air and nitrogen through the refrigerant circuit does not
achieve the level of cleanliness as flushing with refrigerant R134a. Flushing
with refrigerant R134a loosens the refrigerant oil and the components are then
cleaner. Refer to REFRIGERANT CIRCUIT, FLUSHING WITH REFRIGERANT
R134A.
When blowing, working pressure must not exceed a maximum of 217 psi (15
bar), (also use a pressure reducer for compressed air if necessary).
-- Always flush components in direction opposite of refrigerant flow direction.
Restrictor, expansion valve, compressor, receiver and reservoir cannot be flushed with compressed air and
nitrogen.
-- Remove dryer cartridge on condensers with dryer.
-- First blow out dirt with compressed air, then remove moisture from components with nitrogen.
-- Connect adapter to connect the pressure hose to the refrigerant circuit. Refer to ADAPTER FOR
ASSEMBLING FLUSHING CIRCUIT and [For engine(s) BPY,BLV,CCTA,CBFA] Removal and
Installation .
Note the following points to prevent oil and moisture from entering the refrigerant circuit from the compressed
air system.
 The compressed air must be routed through a compressed air purifier for cleaning and drying. Use is
therefore to be made of filter and dryer for compressed air (included in scope of delivery as tool for
painting work).
 For refrigerant lines with threads or union nut at connection, make use of Adapter -V.A.G 1785/1- up to
Adapter -V.A.G 1785/8- for connection of 5/8" -18 UNF charging hoses. These adapters can be found in
VW/Audi passenger vehicle adapter chest -VAS 6338/1- and Commercial vehicle adapter chest -VAS
6338/50-.
 On refrigerant pipes without thread or union nut on the connection, use adapter from VW/Audi passenger
vehicle set adapter chest -VAS 6338/1- as well as Commercial vehicle adapter chest -VAS 6338/50- or a
standard blower pistol with rubber mouthpiece.
NOTE: Compressed air/nitrogen emerging from components is to be drawn off by way

of an appropriate system (for example workshop extraction system).
Certain contaminants cannot be removed or can only be removed insufficiently

from the refrigerant circuit with compressed air. These contaminants can only
be removed by flushing with refrigerant R134a. Refer to REFRIGERANT
CIRCUIT, FLUSHING WITH REFRIGERANT R134A.
REFRIGERANT CIRCUIT, FLUSHING
NOTE: For vehicles in which no adapters fit on to the refrigerant pipes, a blower pistol
with rubber mouthpiece is to be used to blow through individual components.
Special care must be taken not to damage the connections (crushing or
scratching).
Evaporator is to be flushed via the connection for low-pressure pipe (large

diameter) after removing expansion valve or removing restrictor.
Always flush components in direction opposite of refrigerant flow direction.
Check expansion valve and replace if dirty or corroded.
If there are dark, sticky deposits in the components that cannot be removed
with compressed air, replace these components.
Thin, light grey deposits on the insides of refrigerant pipes do not impair the
function of the components.
After flushing, always replace receiver or reservoir and restrictor. Replace dryer
cartridge or dryer on condensers with attached dryer.
REFRIGERANT CIRCUIT, FLUSHING WITH REFRIGERANT R134A
 Robinair A/C Service Unit -ROB134APF- or Rinsing device for refrigerant circuits -VAS6337/1-. The
auxiliary function "Flush refrigerant circuit" and the refrigerant circuit flushing device required for it are
present on these A/C service stations.
 VW/Audi passenger vehicle set adapter chest -VAS 6338/1-. Refer to ADAPTER FOR ASSEMBLING
FLUSHING CIRCUIT .
 Commercial vehicle set adapter chest -VAS 6338/50-. Refer to ADAPTER FOR ASSEMBLING
FLUSHING CIRCUIT .
CAUTION:  If it is suspected that chemicals were added to the refrigerant circuit

to seal leaks, do not connect the A/C service station and do not
extract the refrigerant.
 Chemicals that seal leaks in the coolant circuit form deposits that
affect the function of the A/C system and lead to failure of the A/C
system and the A/C service station.
 Inform that customer that there are substances in the A/C system
that are no approved by Volkswagen. This A/C system cannot be
drained or serviced in the workshop.
NOTE: VW does not approve the use of chemicals to seal leaks in the refrigerant
circuit.
Chemicals used to seal leaks in the refrigerant circuit often react with air and
the moisture in it. They cause deposits in the refrigerant circuit and the A/C
service station and malfunctions in valves and other components that they
come in contact with. These deposits cannot be removed completely from the
components, even by flushing.
Chemicals used to seal leaks in the refrigerant circuit usually cannot be

detected from outside. The label that should be applied to identify it is often
missing. Therefore be careful when working with if you do not know its service
history.
 Refrigerant circuit must be flushed with refrigerant R134a in order to force out contaminants (such as
abraded material from a malfunctioning A/C compressor) as well as old refrigerant oil as efficiently and
as cleanly as possible and without the need for extensive work.
NOTE: The procedure for flushing the refrigerant circuit is displayed in Volkswagen
Service Net; Volkswagen TV; API Online; or Volkswagen TV Net; API/PKW under
the book title Body and the program from June 8, 2005 Refrigerant Circuit,
Flushing, Golf Plus.
The refrigerant circuit should be flushed with refrigerant R134a if
 Dirt or other contamination is in the refrigerant circuit.

 Vacuum reading is not maintained on evacuating a leak-free refrigerant circuit (pressure build-up due to
moisture in refrigerant circuit).
 Refrigerant circuit has been left open for longer than normal (for example following an accident).
 The pressure and temperature measurements in the refrigerant circuit indicate the likelihood of moisture
in the circuit.
 In the event of doubt about the amount of refrigerant oil in the circuit. If the A/C compressor should be
reinstalled, the refrigerant should be drained from the compressor via the oil drain plug. To facilitate this,
the ribbed belt pulley or magnetic clutch plate on the A/C compressor should be rotated by hand. After
flushing, the entire quantity of refrigerant oil specified by Maintenance, Diagnosis should be added to
the refrigerant circuit (50 grams directly in the A/C compressor). Note additional oil quantity for systems
with a 2nd evaporator.
 A/C compressor had to be replaced on account of internal damage (for example noise or no output).
 Stipulated by the vehicle-specific repair information following replacement of certain components.
NOTE: If neither of the two A/C service stations listed above are available for use in the
workshop, Refrigerant Circuit Flushing Device -VAS 6336/1- or Refrigerant
Circuit Flushing Device -VAS 6337/1- (depending on the workshop A/C service
station version) (minimum 7 kg refrigerant R134a in refrigerant bottle) can also
be used to flush the refrigerant circuit. However, the flushing procedure must
then be performed manually. Refer to FLUSHING SEQUENCE PROCEDURE
(OCCURS AUTOMATICALLY ACCORDING TO A/C SERVICE STATION
PROGRAM).
In vehicles with screw-connections on refrigerant circuit, Adapter -V.A.G 1785/1-

up to Adapter -V.A.G 1785/8- from VW/Audi passenger vehicle set adapter chest
-VAS 6338/1- or Commercial vehicle set adapter chest -VAS 6338/50- may be
used. In vehicles with screw-connections on A/C compressor and on
accumulator, two of the Adapters -V.A.G 1785/8- are required.
A Charging hose -VAS 6338/31- with 5/8 -18 UNF connections and large internal
diameter can be found in the adapter chests in order to be able to bridge
components (it is commercially available).
Preparation
-- Discharge refrigerant circuit. Refer to REFRIGERANT CIRCUIT, DISCHARGING WITH SERVICE

STATION.
-- Remove A/C compressor. Refer to [For engine(s) BPY,BLV,CCTA,CBFA] Removal and Installation .
On a vehicle with restrictor and reservoir:
-- Remove restrictor (specific to vehicle) and reconnect refrigerant pipes to each other. Refer to [For engine(s)
-- Remove reservoir (specific to vehicle). Refer to [For engine(s) BPY,BLV,CCTA,CBFA] Removal and
Installation and connect refrigerant pipes to each other (to do this, use adapter and Charge hose -VAS 6338/31-
) from VW/Audi passenger vehicle set adapter chest VAS 6338/1. Refer to ADAPTER FOR ASSEMBLING
FLUSHING CIRCUIT.
NOTE: The reservoir could be flushed, but it requires too much refrigerant due to its
large volume. When this refrigerant is extracted, the reservoir ices up severely
and this prolongs the extraction process significantly.
On a vehicle with expansion valve and fluid reservoir:
-- Remove fluid reservoir. Refer to [For engine(s) BPY,BLV,CCTA,CBFA] Removal and Installation
(specific to vehicle, not required for all vehicles) and connect refrigerant pipes to each other (for this, use
adapters and Charging hose -VAS 6338/31-). Refer to ADAPTER FOR ASSEMBLING FLUSHING
CIRCUIT.
-- Remove expansion valve. Refer to [For engine(s) BPY,BLV,CCTA,CBFA] Removal and Installation
(specific to vehicle) and install the adapter for it. Refer to ADAPTER FOR ASSEMBLING FLUSHING
CIRCUIT.
NOTE: If no suitable adapter for the expansion valve is available in Adapter Set for
Refrigerant Circuits -VAS 6338/1- or Commercial Vehicle Adapter Set Chest -
VAS 6338/50-, the removed expansion valve can also be drilled open (the
expansion valve must be replaced with a new one).
CAUTION:  Make sure the sealing surfaces on the expansion valve are not
damaged when drilling open.
 Otherwise refrigerant leaks out.
NOTE: Several components are to be removed from expansion valve before drilling
open.
Fig. 5: Identifying Expansion Valve Components

Expansion valves are available in different versions. For version -A-,

components -B-, -C- and -D- must be removed. Then separate regulating
element -E- from component -D-. Then drill open expansion valve in area -F-
using a suitable drill (6 mm diameter).
For version -G-, parts -H-, -I- and -K- must be removed and then drill open area -
L- using suitable drill (6 mm diameter).
Clean the drilled open expansion valve of residue from the work (shavings).
Install parts -B-, -C- and -D- for version -A- or -H- for version -G-.
NOTE: In vehicles with two evaporators, the circuit to the second evaporator must be
disconnected from circuit of the first evaporator and must be flushed via a
separate work procedure. Refer to [For engine(s) BPY,BLV,CCTA,CBFA]

Removal and Installation and ADAPTER FOR ASSEMBLING FLUSHING
CIRCUIT.
Flushing
-- Check refrigerant quantity in the refrigerant cylinder, there must be at least 15 lb (7 kg) of refrigerant R134a.
NOTE: If necessary, switch on the heater installed on the refrigerant cylinder for 30
minutes before the first flushing procedure. This increases pressure in the
refrigerant cylinder and accelerates charging of the flushing circuit.
-- Drain the old oil container of the A/C service station.
-- Connect the supply hose (high pressure side) of A/C service station to the low pressure line leading to the
A/C compressor (line with larger diameter) using an adapter. Refer to ADAPTER FOR ASSEMBLING
FLUSHING CIRCUIT.
-- Connect return hose (low pressure- or intake side) of A/C service station to output of refrigerant circuit
flushing device.
-- Connect the input on the refrigerant circuit flushing device to the high pressure line leading to the A/C
compressor (line with smaller diameter) using an adapter. Refer to ADAPTER FOR ASSEMBLING
FLUSHING CIRCUIT.
NOTE: Components are always flushed in the opposite direction of refrigerant flow
when A/C system is in operation. Refer to FLUSHING CIRCUIT BLOCK
DIAGRAMS.
While flushing, contaminants from the refrigerant circuit enter the refrigerant
circuit flushing device and the A/C service station and are absorbed by the
filters and dryers installed there. Depending on the contaminant, these
components are to be replaced in shorter intervals in line with operating
instructions for A/C service station or refrigerant circuit flushing device.
The filter in the refrigerant circuit flushing device depends on the type and
degree of contamination in the flushed refrigerant circuit. It should be replaced
after 2 flushing cycles, at the most. If a heavily contaminated refrigerant circuit
is flushed (the refrigerant oil from the circuit is black and viscous or there are
many shavings in the refrigerant circuit), the filter should be replaced after
flushing. With a refrigerant circuit heavily contaminated in this way, it is wise to
flush the circuit again after changing the filter.
Depending on the type of contamination, dirt (old refrigerant oil and abraded
material from A/C compressor) is deposited on the viewing glass(es). Clean
viewing glass(es) after flushing and flush the refrigerant circuit once more with
one flushing procedure as a check.
Fluid refrigerant cannot be conducted with the necessary speed through the
expansion valve, restrictor and desiccant bag of certain fluid reservoirs,
therefore these components must be removed and replaced by an adapter.
Adapters for connecting A/C service station and for bridging certain
components of refrigerant circuit, refer to ADAPTER FOR ASSEMBLING
FLUSHING CIRCUIT.
-- Switch on the service station and flush the refrigerant circuit (duration for one flushing cycle with three
flushing procedures is approximately 1 to 1.5 hours for about 9 lb. (4kg) of coolant R134a).
NOTE: Perform flushing of refrigerant circuit according to operating instructions of the

A/C service station.
Depending on A/C service station version, the old oil container holds only
approximately 125 cm 3 of refrigerant oil. In the event a system with a larger
volume of refrigerant oil must be flushed, it may be necessary to empty the old
oil container after the first flushing procedure of a flushing cycle.
Observe the refrigerant which flows back from the refrigerant circuit. The
refrigerant circuit is only clean when the refrigerant flows clear and completely
colorless through the viewing glass(es) on the flushing device in the A/C
service station.
When flushing, the complete amount of refrigerant oil is washed out of the
refrigerant circuit (except for minor remains which can be disregarded).
If contamination is especially severe, it may be necessary to perform the

flushing cycle twice (two flushing cycles with three flushing operations each).
Before the second flushing cycle, the filter on the flushing device must be
replaced.
FLUSHING SEQUENCE PROCEDURE (OCCURS AUTOMATICALLY ACCORDING TO A/C SERVICE STATION

PROGRAM)
 After switching on, the flushing circuit (refrigerant circuit with connecting hoses and refrigerant circuit
flushing device) is first evacuated and the refrigerant circuit is simultaneously checked for leaks.
Depending on A/C service station version, it is possible that manually switching to advance the program
is required.
 A prescribed amount of refrigerant (for example 9lb. (4 kg)) is filled into the evacuated flushing circuit
via the high pressure side of the A/C service station (opposite the normal direction of flow during normal
A/C system operation and thus on the low pressure side of vehicle refrigerant circuit). Depending on the
version of the A/C service station, refrigerant is added until the flushing circuit is completely full. This
can be detected by refrigerant no longer flowing in after a certain period of time.

 After the prescribed quantity of refrigerant has been filled, for example. The heater for the refrigerant
circuit flushing device is switched on (only in the event the refrigerant is extracted in gaseous form from
the refrigerant circuit flushing device), depending on version of A/C service station and refrigerant circuit
flushing device.
 After the refrigerant has been extracted, the heater on the refrigerant circuit flushing device (if applicable)
switches off, the refrigerant circuit may be evacuated again (depending on the version), and the
refrigerant oil extracted from the refrigerant circuit is separated by the A/C service station after
evacuating.
 The sequence of filling refrigerant, extracting (and evacuating) is repeated twice (performed a total of
three times).
 After the third extraction, the flushing circuit is evacuated depending on the version of the A/C service
station.
-- After the flushing cycle has ended, check the viewing glass(es) on the flushing device. If they are dirty, clean
them according to the instructions for the flushing device or A/C service station. Perform one addition flushing
cycle as a check. One flushing procedure is sufficient (approximately 30 min.)
-- Check pressure in refrigerant circuit, there must be no positive pressure in the refrigerant circuit (evacuate
refrigerant circuit briefly once more if necessary).
-- Disconnect A/C service station connections from vehicle refrigerant circuit. There must be no positive
pressure in the refrigerant circuit.
-- Replace these vehicle-specific components.
 Restrictor and reservoir

 Expansion valve and fluid reservoir or dryer cartridge in fluid reservoir
-- Refer to [For engine(s) BPY,BLV,CCTA,CBFA] Description and Operation
-- Depending on the complaint, replace A/C compressor. Refer to [For engine(s) BPY,BLV,CCTA,CBFA]
Removal and Installation or drain the remaining refrigerant oil from the removed A/C compressor. Refer to
COMPONENT REPLACEMENT (replace refrigerant circuit components) and re-fill the prescribed quantity
of fresh refrigerant oil. Refer to Maintenance, Diagnosis .
NOTE: A certain prescribed quantity of refrigerant oil is in the A/C compressor original
part. On vehicles with two evaporators, a certain quantity of refrigerant oil must
also be added to the circuit if necessary. Refer to Maintenance, Diagnosis .
If the A/C compressor is not replaced, the quantity of refrigerant oil in the A/C
compressor must be topped off to the prescribed capacity (tilt the refrigerant oil
out and refill the prescribed quantity into the A/C compressor or refrigerant
circuit). Refer to COMPONENT REPLACEMENT and Maintenance, Diagnosis .
-- Completely reassemble the refrigerant circuit. Refer to [For engine(s) BPY,BLV,CCTA,CBFA] Removal
and Installation .
-- Evacuate and recharge refrigerant circuit according to specification. Refer to REFRIGERANT CIRCUIT,
DISCHARGING WITH SERVICE STATION and REFRIGERANT CIRCUIT, CHARGING WITH
SERVICE STATION.
-- Start up A/C system according to specification. Refer to [For engine(s) BPY,BLV,CCTA,CBFA] General
Information and A/C SYSTEM, OPERATING AFTER CHARGING.
REFRIGERANT CIRCUIT
ADAPTER FOR ASSEMBLING FLUSHING CIRCUIT
 The following table lists the different adapters necessary to connect the service station to the refrigerant
circuit, to flush and to bypass the removed fluid reservoir or reservoir and expansion valve (depending on
the vehicle).
 Using a charge hose with 5/8 -18 UNF connections (short version, for example Charge hose -VAS
6338/31-), connect the two adapters (contained in VW/Audi passenger vehicle set adapter chest -VAS
6338/1-) which have been installed for the removed reservoir or fluid reservoir.
 If a flushed refrigerant circuit is not to be reassembled immediately after the flushing, leave the adapters
on the connections and seal the connections on the adapters with sealing caps -VAS 6338/30- (from
VW/Audi passenger vehicle set adapter chest -VAS 6338/1-).
 Depending on the version of the A/C compressor and on the time period of production, various
connecting and sealing technologies can be found on the refrigerant circuit. Refer to [For engine(s)
BPY,BLV,CCTA,CBFA] Description and Operation .
Block or screw connections

Fig. 6: Identifying Screw & Block Connections

Screw connection -A-
Block connection -B-
Block connections with different types of seals
Fig. 7: Identifying Different Types Of Block Connections

Block connection with radially sealed connection -A- (with plastic or metal guide -B-)
-- Block connection with axial sealing connection -C-
Golf 1992; Passat 1994
Required adapters for Required adapters for

refrigerant pipes to A/C refrigerant pipes to fluid
Vehicle compressor reservoir Other
Golf from MY Adapter -VAS 6338/14- -- Remove fluid reservoir -- Replace expansion valve with
1992; Vento and bridge coolant pipes. adapter -VAS 6338/19- (or a drilled
from MY 1992; open expansion valve, for example,
Passat from  Adapter VAS 6N0 820 679 C.). -- Install a new
MY 1994 6338/28 expansion valve after flushing.
 Adapter VAS
6338/29 NOTE:
If no suitable adapter for the
-- Install a new fluid expansion valve is available in
reservoir after flushing. Adapter Set for Refrigerant
Circuits -VAS 6338/1- or
Commercial Vehicle Adapter Set
Chest -VAS 6338/50-, the
removed expansion valve can
also be drilled open (the
expansion valve must be
replaced with a new one).
Touran 2003; Golf 2004; Golf Plus 2005; Golf Plus 2009; Jetta 2005; Eos 2006; Golf Variant 2007;
Tiguan 2008; Scirocco 2009; Golf 2009; Golf Variant 2010; Jetta 2011; Golf Cabrio 2012; NMS 2012;
Beetle 2012
Required adapters Required adapters for

for refrigerant pipes refrigerant pipes to fluid
Vehicle to A/C compressor reservoir Other
Touran from 2003 ;  Low pressure
There are two versions of the -- Replace expansion
Golf from 2004 ; side adapter - reservoir: Refer to the vehicle valve with adapter -VAS
Golf Plus from VAS 6338/12- specific repair information. 6338/18- (or a drilled
2005 ; Golf Plus open expansion valve). --
 High pressure
from 2009 ; Jetta  Reservoir with an installed Install a new expansion
from 2005 ; Eos side adapter - valve after flushing.
dryer.
from 2006 ; Golf VAS 6338/3-
Variant from 2007 ; -- May be over-flushed. -- Install a NOTE:
Tiguan from 2008 ; new fluid reservoir after flushing. If no suitable adapter
Scirocco from for the expansion valve
2009 ; Golf from  Fluid container with dryer is available in Adapter
2009 ; Golf Variant bag Set for Refrigerant
from 2010 ; Jetta Circuits VAS 6338/1 or
from 2011 ; Golf Commercial Vehicle
-- Remove the dryer bag and close Adapter Set Chest -VAS
Cabrio from 2012 ; the reservoir. -- Install a new fluid 6338/50-, the removed
NMS from 2012 ; reservoir after flushing. expansion valve can

Beetle from 2012 also be drilled open (the
expansion valve must
be replaced with a new
one).
Golf 1998; Golf Wagon 1998; Vento 1999; New Beetle 1999; New Beetle Convertible 2003; Bora 1999;
Golf from MY  Low pressure side -- Remove fluid reservoir -- Replace expansion valve
1998; Golf Wagon adapter -VAS and bridge coolant pipes. -- with adapter -VAS 6338/19-
from MY 1998; 6338/7- Connect two adapters -VAS (or a drilled open expansion
Vento from MY 6338/2- and with hose - valve). -- Install a new
1999; New Beetle  High pressure VAS 6338/31-. -- Install a expansion valve after flushing.
from MY 1999; side adapter - new fluid reservoir after
New Beetle Cabrio VAS 6338/2- flushing. NOTE:
from MY 2003; If no suitable adapter for the
Bora from MY expansion valve is available
1999 in Adapter Set for
Refrigerant Circuits -VAS
6338/1- or Commercial
Vehicle Adapter Set Chest -
VAS 6338/50-, the removed
expansion valve can also be
drilled open (the expansion
valve must be replaced with
a new one).
Phaeton 2003

Vehicle compressor reservoir/reservoir Other
Phaeton from  Low pressure side adapter - -- Remove reservoir and -- Restrictor removed
MY 2003 VAS 6338/12- bridge coolant pipes. -- and refrigerant pipe
Connect two adapters -VAS reconnected. -- Install a
 High pressure side for 12 and 6338/6- and with hose -VAS new restrictor after
6 cylinder gasoline engines 6338/31-. -- Install a new flushing.
adapter -VAS 6338/2-, high reservoir after flushing.
pressure side for 10 and 6
cylinder Diesel engine
adapter -VAS 6338/3-
Passat MY 1997; Passat MY 2006; Passat CC MY 2009; CC MY 2010; Passat MY 2011

Vehicle compressor reservoir/reservoir Other
Passat from  Adapter -V.A.G -- Remove reservoir and bridge -- Restrictor removed and
MY 1997 1785/7- coolant pipes. -- Connect refrigerant line
through 09.00 Adapter -VAS 6338/9- and reconnected. -- Install a
 Adapter -V.A.G Adapter -VAG 1785/8- with new restrictor after
1785/8- Hose -VAS 6338/31-. -- Install a flushing.
 Low pressure side new reservoir after flushing.
 High pressure side
Passat from  Adapter -V.A.G -- Remove reservoir and bridge -- Restrictor removed and
MY 1997 from 1785/7- coolant pipes. -- Connect two refrigerant line
10.00 adapters -VAS 6338/10- and reconnected. -- Install a
 Adapter -V.A.G with hose -VAS 6338/31-. -- new restrictor after
1785/8- Install a new reservoir after flushing.
 Low pressure side flushing.
Passat from  Low pressure side -- Remove dryer cartridge and -- Replace expansion
MY 2006; adapter -VAS 6338/12- seal fluid reservoir. -- Install a valve with adapter -VAS
Passat CC new dryer cartridge after 6338/18- (or a drilled
from MY  High pressure side flushing. open expansion valve). --
2009; CC from adapter -VAS 6338/3- Install a new expansion
MY 2010; valve after flushing.
Passat from
MY 2011; CC NOTE:
FL If no suitable adapter
for the expansion valve
is available in Adapter
Set for Refrigerant
Circuits -VAS 6338/1- or
Commercial Vehicle
Adapter Set Chest -VAS
6338/50-, the removed
expansion valve can
also be drilled open
(the expansion valve
must be replaced with a
new one).
Touareg 2003; Touareg 2010; Touareg Hybrid 2010
NOTE: On vehicles with second evaporator (Sharan), the front and rear refrigerant
circuits must be flushed individually. Seal the front refrigerant circuit using
adapter -V.A.G 1785/1-, adapter 1785/3 and sealing caps -VAS 6338/30-.
On vehicles with second evaporator (Touareg), the front and rear refrigerant
circuits must be flushed individually. Seal the front refrigerant circuit using
sealing adapter -VAS 6338/5- and sealing adapter -VAS 6338/11-.
Required adapters for

Required adapters for refrigerant pipes to fluid
refrigerant pipes to A/C reservoir and second
Vehicle compressor evaporator. Other
Touareg from  Low pressure side
-- Remove dryer cartridge and -- Replace expansion valve
MY 2003 adapter -VAS seal fluid reservoir. -- Install a for the front with adapter -
through VIN 6338/12- new dryer cartridge after VAS 6338/17- (or a drilled
50000 flushing. open expansion valve). --
Install a new expansion
adapter -VAS valve after flushing. -- Drill
 Low pressure line for
6338/2-
second evaporator adapter - open expansion valve at
 Engine code BJN VAS 6338/3- second evaporator. --
6.0L through VIN Install a new expansion
 High pressure line for
20000 to high
second evaporator adapter - valve after flushing.
pressure side
VAS 6338/4-
adapter -VAS NOTE:
6338/3-  Sealing adapter -VAS
6338/5- for front If no suitable adapter for
the expansion valve is
refrigerant circuit. available in Adapter Set
 Sealing adapter -VAS for Refrigerant Circuits -
6338/11- for front VAS 6338/1- or
refrigerant circuit. Commercial Vehicle
Adapter Set Chest -VAS
6338/50-, the removed
expansion valve can also
be drilled open (the
Touareg from  Low pressure side -- Remove dryer cartridge and -- Replace expansion valve
MY 03, from adapter -VAS seal fluid reservoir. -- Install a for the front and rear with
VIN 50001; 6338/12- new dryer cartridge after adapter VAS 6338/17 (or a
Touareg from flushing. drilled open expansion
MY 10 and  High pressure side valve.). -- Install new
Touareg adapter VAS 6338/2 expansion valves after
 Low pressure line for
Hybrid from or adapter VAS
second evaporator adapter flushing.
MY 10 6338/3
VAS 6338/3
 High pressure line for NOTE:
second evaporator adapter If no suitable adapter for
VAS 6338/4 the expansion valve is
available in Adapter Set
 Sealing adapter VAS for Refrigerant Circuits
6338/5 for front refrigerant VAS 6338/1 or
circuit. Commercial Vehicle
 Sealing adapter VAS Adapter Set Chest VAS
6338/50, the removed
6338/11 for front
refrigerant circuit. expansion valve can also

be drilled open (the
Transporter 1991
NOTE: On vehicles with second evaporator, the front and rear refrigerant circuits must
be flushed individually. Seal the front refrigerant circuit using sealing adapter
VAS 6338/5 and sealing adapter VAS 6338/11.

Vehicle compressor reservoir and second evaporator. Other
Transporter  A/C compressor  For vehicles on which the
-- Replace expansion
from MY 1991 2D0 820 805 B and fluid reservoir is mounted valve for the front and
through 12.95 701 820 805 Q below the condenser, it may rear with adapter VAS
adapter VAS be over-flushed. 6338/55 (or a drilled
6338/54 open expansion valve.). -
 On vehicles with -- On the other versions, the fluid - Install a new expansion
valve after flushing.
auxiliary evaporator reservoir should be removed.
on the roof, the
 Adapter VAS 6338/20 for NOTE:
Adapter VAS
6338/51 and fluid reservoir. If no suitable adapter
Adapter VAS  Adapter VAS 6338/29 for
6338/52 should be fluid reservoir. Set for Refrigerant
used.  Adapter VAS 6338/26 and Circuits VAS 6338/1 or
with sealing cap -VAS Commercial Vehicle
Adapter Set Chest VAS
6338/30- to seal the front
refrigerant circuit. expansion valve can
 Adapter VAS 6338/27 and also be drilled open
with sealing cap -VAS (the expansion valve
6338/30- to seal the front must be replaced with a
new one).
 Adapter VAS 6338/57 for
refrigerant line of second
evaporator.
evaporator.
-- Install a new fluid reservoir after

flushing.
Transporter  A/C compressor  For vehicles on which the -- Replace expansion
from MY 1991 7D0 820 805 E fluid reservoir is mounted valve for the front and
from 01.96 adapter VAS below the condenser, it may rear with adapter -VAS
6338/53 be over-flushed. 6338/55- (or a drilled
 A/C compressor open expansion valve.). -
7D0 820 805 H low -- On the other versions, the fluid - Install a new expansion
pressure side reservoir should be removed. valve after flushing.
adapter VAS
6338/7  Adapter VAS 6338/20 for NOTE:
fluid reservoir. If no suitable adapter
 Adapter VAS 6338/29 for for the expansion valve
adapter VAS is available in Adapter
6338/2 fluid reservoir.
Set for Refrigerant
 On vehicles with  Adapter VAS 6338/26 and Circuits -VAS 6338/1- or
auxiliary evaporator with sealing cap -VAS Commercial Vehicle
on the roof, the 6338/30- to seal the front Adapter Set Chest -VAS
refrigerant circuit. 6338/50-, the removed
Adapter VAS
expansion valve can
6338/51 and  Adapter VAS 6338/27 and also be drilled open
Adapter VAS with sealing cap -VAS (the expansion valve
6338/52 should be 6338/30- to seal the front must be replaced with a
used. refrigerant circuit. new one).
evaporator.
evaporator.
-- Install a new fluid reservoir after

flushing.
Transporter MY 2004; LT 2 from MY 1997; Transporter MY 2010; Multivan MY 2010; California MY

2010; Caravelle MY 2010; Amarok MY 2011; Crafter MY 2006
NOTE: On vehicles with second evaporator, the front and rear refrigerant circuits must
be flushed individually. Seal the front refrigerant circuit using sealing adapter -
VAS 6338/5- and sealing adapter -VAS 6338/11-.

Vehicle compressor reservoir and second evaporator. Other
Transporter 7H  A/C compressor
-- Remove dryer cartridge and seal -- Through VIN 20000,
from MY 2004 7H0 820 805 E low fluid reservoir. -- Install a new drill out the expansion
pressure side dryer cartridge after flushing. valve. -- From VIN
adapter VAS 20001, replace the front
6338/12 high  Sealing adapter VAS 6338/5 expansion valve with an
pressure side for front refrigerant circuit. adapter VAS 6338/56 --
adapter VAS  Sealing adapter VAS Install a new expansion

6338/3 6338/11 for front refrigerant valve after flushing. --
 A/C compressor circuit. Expansion valve on
7H0 820 803 C low second evaporator,
 Low pressure line for second replace with adapter VAS
pressure side evaporator adapter VAS
adapter VAS 6338/33 -- Install a new
6338/3 expansion valve after
6338/7 high
pressure side  High pressure line for flushing.
adapter VAS second evaporator adapter
6338/2 VAS 6338/4 NOTE:
If no suitable adapter
Set for Refrigerant
Circuits VAS 6338/1 or
Commercial Vehicle
expansion valve can
new one).
Transporter 7J  A/C compressor -- Remove dryer cartridge and seal -- Through VIN 5000,
from MY 2004 7H0 820 805 E low fluid reservoir. -- Install a new drill out the expansion
pressure side dryer cartridge after flushing. valve. -- From VIN 5001,
adapter VAS replace the front
6338/12 high  Sealing adapter VAS 6338/5 expansion valve with an
pressure side for front refrigerant circuit. adapter VAS 6338/56 --
adapter VAS  Sealing adapter VAS
Install a new expansion
6338/3 6338/11 for front refrigerant valve after flushing. --
circuit. Expansion valve on
 A/C compressor second evaporator,
7H0 820 803 C low  Low pressure line for second
replace with adapter VAS
pressure side evaporator adapter VAS 6338/56 -- Install a new
adapter VAS 6338/3 expansion valve after
6338/7 high  High pressure line for flushing.
pressure side second evaporator adapter
adapter VAS VAS 6338/4 NOTE:
6338/2
 A/C compressor is available in Adapter
7H0 820 805 D low Set for Refrigerant
pressure side Circuits VAS 6338/1 or
adapter VAS Commercial Vehicle
6338/52 high Adapter Set Chest VAS
pressure side 6338/50, the removed
adapter VAS expansion valve can
6338/51

new one).
Transporter  Low pressure side -- Remove dryer cartridge and seal -- Replace expansion
from MY 2010; adapter VAS fluid reservoir. -- Install a new valve with adapter VAS
Multivan from 6338/12 dryer cartridge after flushing. -- 6338/56 (or a drilled
MY 2010; Flush the fluid container on the open expansion valve.). -
California from  High pressure side Amarok and then replace the - Install a new expansion
MY 2010; adapter VAS condenser. Reason: the dryer valve after flushing.
Caravelle from 6338/3 cartridge is not available as a
MY 2010; replacement part. NOTE:
Amarok from If no suitable adapter
MY 2011  Sealing adapter VAS 6338/5 for the expansion valve
for front refrigerant circuit. is available in Adapter
Set for Refrigerant
 Sealing adapter VAS Circuits VAS 6338/1 or
6338/11 for front refrigerant Commercial Vehicle
circuit. Adapter Set Chest VAS
 Low pressure line for second 6338/50, the removed
evaporator adapter VAS expansion valve can
6338/3 (the expansion valve
 High pressure line for must be replaced with a
second evaporator adapter new one).
VAS 6338/4
Crafter from  A/C compressor Fluid Reservoir -- May be over- -- Drill a hole for the
MY 2006 2E0 820 803 A low flushed. -- Install a new fluid expansion valve. --
pressure side reservoir after flushing. Install a new expansion
adaptor VAS valve after flushing.
6338/12 high  Sealing adapter VAS 6338/5
pressure side for front refrigerant circuit. NOTE:

adaptor VAS  Sealing adapter VAS If no suitable adapter
6338/3. 6338/11 for front refrigerant for the expansion valve
circuit. is available in Adapter
 A/C compressor Set for Refrigerant
2E0 820 805 A low  Low pressure line for second Circuits VAS 6338/1 or
pressure side evaporator adapter VAS Commercial Vehicle
adaptor VAS 6338/3 Adapter Set Chest VAS
6338/7 high 6338/50, the removed
 High pressure line for
pressure side expansion valve can
second evaporator adapter also be drilled open
adaptor VAS VAS 6338/4 (the expansion valve
6338/3. must be replaced with a
new one).
LT 2 from MY  Low pressure side -- Remove fluid reservoir and -- Replace expansion
1997 adapter VAS bridge coolant pipes. -- Connect valve with adapter VAS
6338/7 two adapters VAS 6338/29 and 6338/56 (or a drilled
with hose VAS 6338/31. -- Install open expansion valve.). -
 High pressure side a new fluid reservoir after flushing. - Install a new expansion
adapter VAS
6338/2 valve after flushing.

 Adapter VAS
6338/20 NOTE:
Set for Refrigerant
Circuits VAS 6338/1 or
Commercial Vehicle
expansion valve can
new one).
A/C COMPRESSOR WITH MAGNETIC CLUTCH
The engine drives the A/C compressor via a ribbed belt.
Fig. 8: Identifying A/C Compressor -- With Clutch

An electromagnetic clutch installed on the A/C compressor creates a frictional connection between the ribbed
belt pulley and A/C compressor crankshaft when the air conditioning system is switched on.
If the A/C compressor sticks, a fuse installed in the compressor ribbed belt pulley releases the electromagnetic
clutch and protects the ribbed belt pulley from overload.
The A/C compressor extracts the refrigerant gas from the evaporator, compresses it and relays it to the
condenser.
NOTE: The A/C compressor contains refrigerant oil, which can be mixed with
refrigerant R134a under any temperature.
The type plate lists the type of refrigerant required for the A/C compressor. A
regulator valve regulates pressure within the specified range (control
characteristics) on the low pressure side.
So that the A/C compressor does not get damaged when the refrigerant circuit
is empty, the A/C clutch is turned off and the A/C compressor regulator valve -
N280- is no longer activated (A/C compressor runs at idle with engine).
A/C COMPRESSOR WITHOUT MAGNETIC CLUTCH
The engine drives the A/C compressor via a ribbed belt.
Fig. 9: Identifying A/C Compressor -- With Clutch

Overload protection (shear) installed in the A/C compressor ribbed belt pulley releases when the compressor
stops and protects the ribbed belt pulley from being overloaded.
condenser.
On this A/C compressor, the control valve is activated from outside.
The engine should only be started if the refrigerant circuit is completely

assembled. Refer to REFRIGERANT CIRCUIT, GENERAL PRECAUTIONS.
A/C COMPRESSOR WITHOUT MAGNETIC CLUTCH WITH TORSION-ELASTIC CLUTCH
The A/C compressor is driven directly by the power steering vane pump.
Fig. 10: Identifying A/C Compressor Without Magnetic Clutch With Torsion-Elastic Clutch
On the A/C compressor driveshaft, there is an overload protection that shears off when the compressor is
blocked so that the power steering vane pump remains functional.
condenser.
On this A/C compressor, the control valve is activated from outside.

CONDENSER
The condenser conducts heat from compressed refrigerant gas to the ambient air.
This condenses the refrigerant gas to fluid.
E-COMPRESSOR FOR HYBRID VEHICLES
WARNING:  High voltage at the high voltage system in a hybrid vehicle. Health
risks to persons with life assist systems.
 It will also be necessary to work on the high voltage system when
performing the following procedures. Any work to be performed on a
vehicle with a high voltage electrical system may only be performed
by technician specifically trained to work on this system. The work
must be performed by a certified high voltage technician.
 Follow the General Warnings for working on the high voltage
electrical system Electric Drive; Repair Group 93; General Warnings
for Working on High Voltage Electrical Systems.
 Switching off the high voltage system Electric Drive, Repair Group
93, Switching off the high voltage system
WARNING: Danger of short circuit
The A/C compressor works with 288 volts at 800 to 8,600 RPM.
Do not touch the A/C compressor when starting the drive generators,
danger of short circuit.
E-A/C Compressor
Fig. 12: Identifying E-A/C Compressor

condenser.
The type plate lists the type of refrigerant required for the A/C compressor. The
RPM controls the delivery.

The A/C compressor has a relief valve.
EVAPORATOR
The fluid refrigerant evaporates in the evaporator pipe coils. The heat required for this is extracted from the air
flowing on the evaporator ribbing. The air cools off. Refrigerant evaporates and is extracted with the absorbed
heat by the A/C compressor.
Fig. 13: Identifying Evaporator

A defined amount of refrigerant is supplied to the evaporator by a restrictor or expansion valve. In systems with
expansion valve, the throughput is regulated so that only gaseous refrigerant escapes the evaporator outlet.
EVACUATING AND CHARGING VALVE WITH SCHRADER VALVE
 Torque Wrench -V.A.G 1783- (2 to 10 Nm) with 1/4" socket -VAS 6234-
Refrigerant will leak out if refrigerant circuit is not discharged.
Refrigerant must be extracted before opening refrigerant circuit. If

more.
 Only valves and connections that are resistant to refrigerant R134a and refrigerant oil must be installed.
 Always screw on sealing caps.
Refer to [For engine(s) BPY,BLV,CCTA,CBFA] Description and Operation
Fig. 14: Identifying A/C Service Connection Components

NOTE: Torque wrench -V.A.G 1783- with 1/4" socket -VAS 6234-
Use a suitable socket -T10364- to loosen the Schrader valve insert. Refer to
Socket T10364 for the high pressure/low pressure side service connection
valves in the refrigerant circuit.
A - Service connection (soldered in)
B - Schrader valve insert (2.4 +/- 0.2 Nm)
C - O-ring (belongs to the valve)
D - Sealing cap with seal
EVACUATING AND CHARGING VALVE, HIGH PRESSURE SIDE

 Torque wrench -V.A.G 1783- (2 to 10 Nm) with 1/4" socket -VAS 6234-

more.
 Different connections (outer diameter) for high pressure and low pressure side.
Fig. 15: Identifying Connection, O-Ring, Extraction/Filling Valve, And Cap

Use a suitable socket -T10364- to loosen the valve insert.
1. Socket with external and internal threads

2. O-ring: 10.8 mm; 1.8 mm identification: black or with colors
3. Valve with M12 x 1.5 mm external threads and groove for O-ring (7 +/- 1 Nm)
4. O-ring for the cap: 10.8 mm; 1.8 mm identification: black or with colors
5. Cap
EVACUATING AND CHARGING VALVE, LOW PRESSURE SIDE
 Torque wrench -V.A.G 1783- (2 to 10 Nm) with 1/4" socket -VAS 6234-

more.
 Different connections (outer diameter) for high pressure and low pressure side.

Fig. 16: Identifying Connection, O-Ring, Extraction/Filling Valve, And Cap

Use a suitable socket -T10364- to loosen the valve insert.
1. Connection with external thread and groove for O-ring

2. O-ring: 7.6 mm; 1.8 mm identification: black or with colors
3. Valve with M10 x 1.25 mm external threads and groove for O-ring (7 +/- 1 Nm)
4. O-ring for the cap: 7.6 mm; 1.8 mm identification: black or with colors
5. Cap
EXPANSION VALVE
The expansion valve atomizes the streaming refrigerant and controls the flow quantity so that the vapor is
gaseous only at the evaporator outlet, depending on the heat transmission.
Fig. 17: Identifying Expansion Valve

FLUID RESERVOIR
The receiver collects the fluid drops and then directs them in an uninterrupted stream to the expansion valve.
Moisture which has entered the refrigerant circuit during repairs will be collected by the dryer bag in the
reservoir.
Fig. 18: Identifying A/C Receiver Drier

NOTE: Replace the reservoir if refrigerant circuit has been open for a long time
(beyond the normal repair time) and moisture has penetrated inside, or if
required due to a specific complaint. Refer to COMPONENT REPLACEMENT.
Only remove sealing plugs shortly before installation.
A dryer bag in an unsealed reservoir is saturated with moisture after a short

period of time and unusable.
When installing, note arrow for direction of flow if necessary.
The new generation of reservoirs are installed directly on the condenser and contain a dryer cartridge.
Fig. 19: Identifying Positioning Of Dryer Cartridge

NOTE: Replace the dryer cartridge if refrigerant circuit has been open for a long time
Remove dryer cartridge from packaging shortly before installation.
The dryer cartridge becomes saturated with moisture and unusable after a short
time in an unsealed package.
FLUSHING CIRCUIT BLOCK DIAGRAMS
NOTE: The arrows in the following illustrations show the direction of refrigerant flow
while flushing. During flushing, refrigerant flows in the opposite direction than
during A/C system operation, therefore the high pressure side of A/C service
station is connected to A/C compressor at low pressure side of refrigerant
circuit.
These block diagrams indicate a refrigerant circuit with restrictor and reservoir
and a refrigerant circuit with expansion valve, fluid reservoir and a second
evaporator (optional equipment on certain vehicles)
Depending on the design of A/C service station, check-valves may be installed

between refrigerant circuit and A/C service station. They guarantee the correct
direction of refrigerant flow during flushing.
Refrigerant Circuit With Expansion Valve, Fluid Reservoir and Second Evaporator, refer to Refrigerant
Flushing Circuit With E-Compressor, refer to Flushing Circuit With E-Compressor.
Refrigerant Circuit with Restrictor and Reservoir
NOTE: On vehicles with restrictor and reservoir, the restrictor and reservoir are
removed. Restrictor refrigerant pipes are reassembled. Refrigerant pipes to the
removed reservoir are connected with each other via two adapters and Charge
hose -VAS 6338/31- (from VW/Audi passenger vehicle set adapter chest -VAS
6338/1-).
Fig. 20: Identifying Block Diagrams For Flushing Circuits (Type 1)

1. A/C Service Station

 With electronics and a flushing program, for example Robinair A/C Service Unit -ROB134APF-
with Air Conditioning Flush Tool -VAS6337/1A-.
 If an A/C service station without a flushing program is used, the procedure must be performed
manually (evacuate, flush 3 times with at least 4 kg refrigerant each and extract refrigerant again,
evacuate).
2. Refrigerant Hose Of A/C Service Station
 From high pressure side of A/C service station (mostly colored red) to low pressure side connection
of A/C compressor on refrigerant circuit (larger diameter).
3. Adapter To Connection For Low Pressure Side On Refrigerant Circuit
 Different versions depending on vehicle. Refer to ADAPTER FOR ASSEMBLING FLUSHING
CIRCUIT.
 From VW/Audi passenger vehicle set adapter chest -VAS 6338/1-.
4. Low Pressure Side Connection On Refrigerant Circuit

CIRCUIT.
 On refrigerant line from A/C compressor to reservoir.
5. Connection To Reservoir
CIRCUIT.
 On refrigerant line from A/C compressor to reservoir.
6. Adapter For Bridging The Removed Reservoir

CIRCUIT.
7. Refrigerant Charge Hose, refer to ADAPTER FOR ASSEMBLING FLUSHING CIRCUIT

 Charge hose -VAS 6338/31- (from VW/Audi passenger vehicle set adapter chest -VAS 6338/1-)
for example.
8. Adapter For Bridging The Removed Reservoir
CIRCUIT.
9. Connection To Reservoir
CIRCUIT.
10. Evaporator
11. Component Location Of Restrictor
 Restrictor is removed.
 Remove restrictor. Refer to [For engine(s) BPY,BLV,CCTA,CBFA] Removal and Installation .

 Bolt together again after removing restrictor. Refer to [For engine(s) BPY,BLV,CCTA,CBFA]
13. Condenser
14. High Pressure Side Connection On Refrigerant Circuit
CIRCUIT.
15. Adapter To Connection For High Pressure Side On Refrigerant Circuit
CIRCUIT.
16. Charge Hose For Refrigerant Circuit Flushing Device

 From connection to high pressure side of A/C compressor on refrigerant circuit (smaller diameter)
to input of Refrigerant Circuit Flushing Device -VAS 6336/1- or Refrigerant Circuit Flushing
Device -VAS 6337/1-.
17. Refrigerant Circuit Flushing Device
 Different versions and different construction, for example Refrigerant circuit flushing device -VAS
6336/1- or Refrigerant circuit flushing device -VAS 6337/1A-.
 With filter, viewing glass, security valve, heater, refrigerant container, etc. (depending on version).
 Depending on the construction of the A/C service station and of refrigerant circuit flushing device,
a check-valve may be installed at output of refrigerant circuit flushing device (to guarantee correct
direction of refrigerant flow during flushing).
 From low pressure side of A/C service station (mostly colored blue) to output of refrigerant circuit
flushing device.
Refrigerant Circuit With Expansion Valve, Fluid Reservoir and Second Evaporator
NOTE: This block diagram shows a refrigerant circuit with expansion valve, fluid
reservoir and second evaporator (optional equipment on certain vehicles).
On vehicles with expansion valve and fluid reservoir, the expansion valve is
removed and replaced by an adapter. Depending on vehicle, fluid reservoir is
flushed or dryer cartridge is removed. Depending on fluid reservoir version, it is
to be removed and line connections to fluid reservoir are to be connected to
each other with two adapters and a charging hose.
On a vehicle with only one evaporator, the components as of position 16 are not
installed or are not required.
Fig. 21: Identifying Block Diagrams For Flushing Circuits (Type 1)

1. A/C Service Station

 With electronics and a flushing program, for example Robinair A/C Service Unit -ROB134APF-
with Air Conditioning Flush Tool -VAS6337/1A-.
 If an A/C service station without program is used for flushing, the procedure should be performed
manually.
-- Extract the refrigerant, if necessary.
-- Set up the Refrigerant circuit flushing device -VAS 6336/1- or Refrigerant circuit flushing device
-VAS 6337/1A- between the service station and refrigerant circuit return line.
-- Evacuate refrigerant circuit for 20 minutes and then charge with 4 kg refrigerant R134a. Then
extract again and repeat the procedure 2 more times. If the refrigerant in the viewing glass(es) is not
clear after the third attempt, an additional attempt is necessary.

 From high pressure side of A/C service station (mostly colored red) to low pressure side connection
of A/C compressor on refrigerant circuit (larger diameter).
CIRCUIT.
4. Low Pressure Side Connection On Refrigerant Circuit

CIRCUIT.
5. Adapter For The Removed Expansion Valve
CIRCUIT.
6. Evaporator
7. Connection To Fluid Reservoir
CIRCUIT.
 Not present on vehicles with a dryer cartridge in fluid reservoir on condenser or a fluid reservoir
installed in the condenser. Refer to [For engine(s) BPY,BLV,CCTA,CBFA] Removal and
Installation .
8. Adapter For Bridging The Removed Fluid Reservoir
 Not required for all vehicles.

CIRCUIT.
9. Refrigerant Charge Hose, refer to ADAPTER FOR ASSEMBLING FLUSHING CIRCUIT

 Charge hose -VAS 6338/31- (from VW/Audi passenger vehicle set adapter chest -VAS 6338/1-)
for example.
10. Condenser
 If a fluid reservoir with dryer cartridge is installed on the condenser, dryer cartridge must be
removed (seal again the fluid reservoir on or in the condenser after removing). Refer to [For
engine(s) BPY,BLV,CCTA,CBFA] Removal and Installation .
 If fluid reservoir is built directly on the condenser, fluid reservoir is to be removed and replaced
only after flushing. Refer to [For engine(s) BPY,BLV,CCTA,CBFA] Removal and Installation .
11. High Pressure Side Connection On Refrigerant Circuit
CIRCUIT.
CIRCUIT.

 From connection to the high pressure side of the A/C compressor on the refrigerant circuit (smaller
diameter) to input of refrigerant circuit flushing device.
 Different versions and different construction, for example, Refrigerant circuit flushing device -VAS
6336/1- or Refrigerant circuit flushing device -VAS 6337/1-.
flushing device.
16. Adapter For Sealing Outlet To The Second Evaporator
 Only required for certain vehicles with optional equipment 2nd evaporator.
 From commercial vehicle set adapter chest -VAS 6338/50-.
17. Adapter For Sealing Outlet To The Second Evaporator

18. Low Pressure Side Connection On Refrigerant Circuit To Second Evaporator

CIRCUIT.
 Only present on certain vehicles with optional equipment 2nd evaporator.
19. High Pressure Side Connection On Refrigerant Circuit To Second Evaporator

CIRCUIT.
20. Adapter For The Removed Expansion Valve On Second Evaporator

CIRCUIT.
21. Second Evaporator

Flushing Circuit With E-Compressor
If an E-compressor is being replaced that does not have a mechanical fault (for example, a faulty circuit board),
then determine how much refrigerant is in it.
Quantity: for example 50 cm 3
A new E-compressor is filled with 150 cm 3 refrigerant oil.
-- Pour 90 cm 3 out of the new E-compressor. 10 cm 3 is extra.
NOTE: The E-compressor must be flushed to get all the refrigerant oil out.
The main wiring diagram shows the refrigerant circuit with E-compressor.
Fig. 22: Identifying Flushing Circuit With E-Compressor Diagram

1. A/C service station
NOTE: Flushing the E-compressor is performed manually.
-- Extract the refrigerant, if necessary.
-- Empty the Service Station old oil container.
NOTE: On some Service Stations, the oil is first separated in the vacuum phase
and then it goes into the old oil container.
-- Set the amount of refrigerant on the Service Station to 2 kg and the oil quantity to 0.
-- Set up the Refrigerant circuit flushing device -VAS 6336/1- or Refrigerant circuit flushing device -
VAS 6337/1A- between the service station and refrigerant circuit return line.
-- Evacuate the refrigerant circuit for 10 minutes. Then observe the vacuum display. If the vacuum
remains constant, then fill the circuit with 2 kg refrigerant R134a. Then extract again and repeat the
procedure one more time.

flushing device.
 Different versions and different construction, for example, Refrigerant circuit flushing device -VAS
6336/1- or Refrigerant circuit flushing device -VAS 6337/1-.
 From connection to high pressure side of A/C compressor on refrigerant circuit (smaller diameter)
to input of Refrigerant Circuit Flushing Device -VAS 6336/1- or Refrigerant Circuit Flushing
Device -VAS 6337/1-.
 From VW/Audi passenger vehicle set adapter chest -VAS 6338/1- adapter number -6338/3-.
6. Refrigerant Line, High Pressure Side, From The E-Compressor
-- Remove the centering pin.
7. E-compressor
8. Refrigerant Line, Low Pressure Side, To The E-Compressor
-- Remove the centering pin.

 From VW/Audi passenger vehicle set adapter chest -VAS 6338/1- adapter number -6338/6-.

 From the high pressure side of the service station (mostly red) to the connection on the low
pressure line above the engine to the E-compressor
HIGH AND LOW PRESSURE SIDES
High pressure side are the condenser, receiver and restrictor or expansion valve to separate the high and low
pressure liquid ends.
High pressure results from the restrictor or expansion valve forming a constriction and causing the refrigerant to
accumulate, thus leading to an increase in pressure and temperature.
Excess pressure results if too much refrigerant or refrigerant oil is used, the condenser is contaminated, the
radiator fan is malfunctioning, the system is blocked or if there is moisture in the refrigerant circuit (the
restrictor or expansion valve freezes).
Low pressure side are the evaporator, reservoir, evaporator temperature sensor and compressor to separate high
and low pressure gas ends.
A drop in system pressure can occur due to loss of refrigerant, restrictor or expansion valve (restriction not
given), A/C compressor malfunction or iced evaporator.
O-RING SEALS
These O-rings seal off the connection points between individual components of the refrigerant circuit.
Fig. 23: Identifying O-Ring Seals Diameters

Only O-rings that are resistant to refrigerant R134a and refrigerant oil must be installed. Make sure they are
original replacement parts.
O-ring:
 Always use only once.

 Make sure diameters -a- and -b- are correct.
 Moisten with refrigerant oil before installing.
NOTE: The color coding of refrigerant circuit o-rings with R134a has been
discontinued. Colored and black O-rings are used.
PRESSURE RELIEF VALVE
The pressure relief valve is installed on the A/C compressor or reservoir.
Fig. 24: Identifying A/C Refrigerant System Pressure Relief Valve

At a pressure of approximately 38 bar positive pressure, valve opens and closes again once pressure has
dissipated (approximately 30 bar).
Refrigerant does not escape completely.
Depending on the version, a transparent plastic disc may be installed which breaks off as soon as the valve is
activated.
RESERVOIR
The reservoir collects the vaporized and gaseous mixture coming from the evaporator to ensure the compressor
only receives gaseous refrigerant. Gaseous refrigerant is formed from the vapor.
Fig. 25: Identifying Accumulator

The refrigerant oil flowing in the circuit is not retained in the reservoir as it has an oil drilling.
Moisture which has entered the refrigerant circuit during repairs will be collected by a filter (desiccant bag) in
the reservoir.
Gaseous refrigerant is extracted with oil by the A/C compressor.

NOTE: Replace the reservoir if refrigerant circuit has been open for a long time
Remove sealing plugs -A- and -B- only immediately prior to installing.
A desiccant bag in an unsealed reservoir is saturated with moisture after a

short period of time and unusable.
When installing, note arrow for direction of flow if necessary.
RESTRICTOR
The restrictor creates a constriction. This restriction reduces the flow and creates high and low pressure sides in
the refrigerant circuit. Before the restrictor the refrigerant which is under a higher pressure is warm. After the
restrictor the refrigerant which is under a low pressure is cold. Before the restriction there is a strainer for
contaminants and after the restriction there is a strainer, to atomize the refrigerant before it reaches the
evaporator.
Fig. 26: Identifying Restrictor

NOTE: Arrow -A- on restrictor points to evaporator.
Replace after each opening of the circuit.
Note different versions.

REFRIGERANT CIRCUIT WITH EXPANSION VALVE AND EVAPORATOR
Fig. 27: Identifying A/C Refrigerant Circuit With Expansion Valve And Receiver Drier
1. Evaporator
2. Expansion Valve
3. Valve for extracting, filling and measuring
4. Reservoir with dryer bag/dryer cartridge
5. Condenser
6. A/C Compressor
NOTE: Arrows point in direction of refrigerant flow.
REFRIGERANT CIRCUIT WITH RESTRICTOR AND RESERVOIR
Arrows point in direction of refrigerant flow.
A- Low pressure side of refrigerant circuit.
B- High pressure side of refrigerant circuit

Fig. 28: Identifying Refrigerant Circuit With Restrictor & Reservoir

Aggregate State Of Pressure (Bar Positive Temperature In Degrees

Component Refrigerant Pressure) Celsius
-1- A/C compressor B-side Gas Up to 20 bar Up to + 70°C (158°F)
-2- Condenser From gas to vapor to Up to 20 bar Up to + 70°C (158°F)
fluid
-3- Restrictor From fluid to vapor B-side through 20 bar, B-side up to + 60°C (140°F),
A-side greater than 1.5 A-side warmer than -4°C (-
bar 25°F)
-4- Evaporator From vapor to gas Greater than 1.5 bar Warmer than -4°C (-25°F)
-5- Reservoir Gas
-6- A/C compressor A-side Gas
Pressures on A-side are maintained at approximately 2 bar by regulating A/C compressor also at various engine
speeds. However, this applies only within the performance range of the A/C compressor; if the performance
limits of the A/C compressor are exceeded. Refer to PRESSURES, CHECKING.
NOTE: In vehicles with A/C compressor regulator valve -N280-, the pressure is
modified on the low pressure side by the valve.
REFRIGERANT CIRCUIT WITH EXPANSION VALVE
A- Low pressure side of refrigerant circuit.
B- High pressure side of refrigerant circuit

Fig. 29: Identifying A/C Refrigerant System Pressure Diagram

Aggregate state of Pressure (bar positive Temperature in degrees

Component refrigerant pressure) Celsius
-1- Evaporator, from Vapor Approximately 1.2 bar(1) Approximately -7°C (20°F)(2)
input to output
(approximately 1.8 bar)(3) Approximately -1°C (30°F)(3)
-2- A/C compressor A- Gas Approximately 1.2 bar(1) Approximately -1°C (30°F)
side
-3- A/C compressor B- Gas Approximately 14 bar Approximately + 149°F (65°
side C)
-4- Condenser Gas, vapor, fluid Approximately 14 bar Approximately + 55°C (131°
F) at outlet
-5- Receiver Fluid Approximately 14 bar Approximately + 55°C (131°
F)
-6- Extraction and filling Fluid Approximately 14 bar Approximately + 55°C (131°
valve, B-side F)
-7- Expansion valve Fluid, released as Approximately 14 bar Approximately + 55°C (131°
vapor F), reduced to -7°C (20°F)
-8- Extraction and filling Gas Approximately 1.2 bar(1) Approximately -7°C (20°F)(2)
valve, A-side
(1) Pressure in refrigerant circuits is maintained at approximately 2 bar, regulated by A/C compressor,
even though heat transfer changes and engine speeds vary. However, this applies only within the
performance range of the A/C compressor; if the performance limits of the A/C compressor are
exceeded, the pressure increases PRESSURES, CHECKING.
(2) Within the control range of the A/C compressor, temperature in the refrigerant circuits is maintained,
regulated by A/C compressor, even though heat transfer changes and engine speeds vary. However,
this applies only within the performance range of the A/C compressor; if the performance limits of
the A/C compressor are exceeded, the temperature increases PRESSURES, CHECKING.
(3) Measured values for A/C systems with two evaporators
NOTE: A/C compressors which do not regulate their performance are switched off by
the respective control module via the A/C compressor regulator valve -N280- at
an evaporator temperature below 0°C (32°F).
In vehicles with A/C compressor regulator valve -N280-, the pressure is

modified on the low pressure side by the valve.
SWITCHES AND SENSORS ON REFRIGERANT CIRCUIT AND CONNECTIONS
A/C COMPRESSOR REGULATOR VALVE -N280-
NOTE: For switching pressures, removing and installing switches and switch
arrangement and version, see vehicle-specific refrigerant circuit.
The regulator valve is installed in the compressor. It is activated by the A/C Display Control Head -E87- or
Climatronic Control Module -J255-. Pressure on the low pressure side is influenced via the regulator valve and
thus regulates the temperature in the evaporator.
Fig. 30: Identifying A/C Compressor Regulator Valve - N280

NOTE: The A/C compressor regulator valve is a component of the A/C compressor and
cannot be replaced separately.
A/C PRESSURE SWITCH -F129-
This pressure switch has 3 functions:

Fig. 31: Identifying A/C Pressure Switch - F129

1. Switches the coolant fan to the next higher level when the pressure in the refrigerant circuit increases
(approximately 16 bar).
2. Switches off A/C system if pressure is excessive (approximately 32 bar), for example, because of insufficient
engine cooling.
3. Switches off A/C system if pressure is insufficient (approximately 2 bar), for example, loss of refrigerant.
NOTE: A/C Pressure Switch -F129- replaces the A/C Refrigerant High Pressure Switch -
F23-, A/C Refrigerant Low Pressure Switch -F73- and the A/C Refrigerant High
Pressure Switch -F118-.
A/C PRESSURE/TEMPERATURE SENSOR -G395-
The refrigerant must be extracted before the A/C Pressure/temperature

Sensor is removed. If refrigerant circuit is not opened within 10 minutes
of extraction, pressure may form in refrigerant circuit due to evaporation.

Extract refrigerant once more.
This A/C Pressure/temperature Sensor -G395- is installed instead of the High Pressure Sensor -G65- or A/C
Pressure Switch -F129-.
Fig. 32: Identifying A/C Pressure/temperature Sensor - G395

The pressure signal is always being checked, where the temperature signal is only checked at temperatures
above 32°F (0°C).
The Climatronic control module -J255- operates with this information and controls the coolant fans and
activation of the A/C compressor regulator valve -N280-.
A/C REFRIGERANT HIGH PRESSURE SWITCH -F23-
Function:
Fig. 33: Identifying A/C Refrigerant High Pressure Switch

Switches the coolant fan to the next higher level when the pressure in the refrigerant circuit increases
(approximately 16 bar).
A/C REFRIGERANT HIGH PRESSURE SWITCH -F118-
Function:
Fig. 34: Identifying A/C Refrigerant High Pressure Switch

Switches off A/C compressor when there is excessive pressure in the refrigerant circuit (approximately 32 bar).
A/C REFRIGERANT LOW PRESSURE SWITCH -F73-
Function:
Fig. 35: Identifying A/C Refrigerant Low Pressure Switch

Switches off A/C compressor when there is excessive pressure in the refrigerant circuit (approximately 2 bar).
HIGH PRESSURE SENSOR -G65-
This high pressure sensor -G65- is installed in place of an A/C pressure switch -F129-.
Fig. 36: Identifying High Pressure Sensor - G65

When a voltage is applied, the high pressure sensor generates a square wave signal or a data telegram. This
signal changes along with pressure in the system.
The downstream control modules (coolant fan control module, ECM), A/C control head -E87- or Climatronic
control module -J255-, etc.) use this signal to calculate pressure in the refrigerant circuit and to activate the
coolant fans and motor and A/C clutch -N25- or to change the A/C compressor regulator valve -N280-
activation.
REFRIGERANT CIRCUIT CONNECTIONS WITH VALVE FOR SWITCHES
Refrigerant must be extracted before removing valve -C-. If refrigerant

circuit is not opened within 10 minutes of extraction, pressure may form
in refrigerant circuit due to evaporation. Extract refrigerant once more.
 Different threads for switch on high pressure and low pressure sides.
 Only valves and O-rings that are resistant to refrigerant R134a and refrigerant oil must be installed.
Fig. 37: Identifying Service Port Components

A - Connection (soldered in)
B - O-ring
C - Valve (with O-ring)
ELECTRICAL COMPONENTS NOT ON REFRIGERANT CIRCUIT
A/C PROGRAMMER -J127-

Fig. 38: Identifying A/C Programmer - J127

This programmer switches the refrigerant flow direction through the 2nd evaporator if the temperature on the
cooling fins on the 2nd evaporator lowers to the freezing point for water (icing protection).
RADIATOR FAN CONTROL MODULE -J293-
NOTE: There are different construction styles.
This control module switches on and off the A/C clutch and therefore the A/C compressor. It switches the
coolant fan and calculates the pressure in the refrigerant circuit on vehicles with a High pressure sensor -G65-
or A/C pressure/temperature sensor -G395-.
Fig. 39: Identifying Coolant FC (Fan Control) Control Module - J293

NOTE: Available in different construction styles, some separate some installed on

radiator fan -arrows-.
This control module switches on and off the A/C clutch and therefore the A/C compressor. It switches the
coolant fan and calculates the pressure in the refrigerant circuit on vehicles with a high pressure sensor -G65- or
A/C pressure/temperature sensor -G395-.
Fig. 40: Identifying A/C Pressure/Temperature Sensor/high Pressure Sensor

A/C EVAPORATOR TEMPERATURE SWITCH -E33-
Fig. 41: Identifying A/C Evaporator Temperature Switch - E33

Function:
The A/C Evaporator Temperature Switch -E33- determines the temperature between the evaporator cooling
fans. It prevents the possibility of ice building up between the evaporator cooling fans because the current entry
to the condenser magnetic clutch is interrupted when the temperature on the cooling fins lowers to the freezing
point for humidity.
The insertion depth of the feeler tube is marked or indicated in the repair information. Refer to [For engine(s)
NOTE: Installed in VW vehicles with A/C compressor drive via ribbed belt.
EVAPORATOR VENT TEMPERATURE SENSOR -G263- OR EVAPORATOR TEMPERATURE SENSOR -G308-

Fig. 42: Identifying Evaporator Vent Temperature Sensor - G263 or Evaporator Temperature Sensor -
G308
Function:
The Evaporator Vent Temperature Sensor -G263- or Evaporator Temperature Sensor -G308- determines the
temperature behind the evaporator. This value goes to the air conditioning control module and serves as a
reference signal for regulating the A/C compressor. This prevents the evaporator from icing up.
A/C SERVICE STATION
A/C SYSTEM, OPERATING AFTER CHARGING
NOTE: If A/C compressor was removed, it must be cranked by hand at ribbed belt
pulley/freewheel approximately 10 rotations before bringing into operation for
the first time. This prevents damage in the A/C compressor due to liquid when
switching the A/C system on. If there is oil in the A/C compressor cylinder, it
will be forced out.
-- Start engine with compressor switched off (version with A/C clutch).
Fig. 43: Identifying A/C Service Station

-- Set compressor to minimum output, for example, "Econ" or A/C off mode (version with no A/C clutch with
regulating valve).
-- Wait until idle speed has stabilized.
-- Switch on compressor and operate system for at least 2 minutes at idling speed.
-- If necessary, check pressures in refrigerant circuit using A/C service station.
-- Turn engine off.
-- Screw out handwheel on quick-release coupling adapter.
-- Disconnect charging hose from refrigerant circuit.
-- Screw protective caps back on.
REFRIGERANT CIRCUIT, DISCHARGING WITH SERVICE STATION
 The refrigerant circuit is to be discharged if parts of the refrigerant circuit are to be removed, if there is
any doubt about the quantity of refrigerant in the circuit or if safety precautions so require.
 The work procedure is always to be performed as described in the operating instructions for the A/C
service station.
 The procedure described here is for the A/C service station -ROB 134APF-.
Before filling the refrigerant circuit with refrigerant, it should be evacuated (vacuum) for 45 minutes on systems
with 1 evaporator and 60 minutes on systems with 2 evaporators. Moisture is also extracted from the circuit.
Leaks may be found when evacuating the refrigerant circuit.
Evacuating
CAUTION:  Do not start the engine during the evacuation process or when there
is a vacuum in the refrigerant circuit.
 The A/C compressor could be damaged if the engine is started when
there is a vacuum in the refrigerant circuit.
 Only start the engine when the refrigerant circuit is filled.
NOTE: There is a possibility of refrigerant oil being extracted from the refrigerant
circuit together with the refrigerant. To ensure compressor lubrication, the
refrigerant oil in the circuit must be topped up with fresh oil. Refer to
Maintenance, Diagnosis .
On vehicles with an A/C compressor without a magnetic clutch (with A/C

compressor regulator valve -N280-), the engine should run < 10 minutes with
the refrigerant circuit empty and closed (the A/C compressor also runs
continuously). Engine speed must not exceed 2000 RPM.
On vehicles equipped with an A/C compressor with A/C clutch, the engine must
be started since the A/C Pressure Switch -F129- or High Pressure Sensor -G65-
(checks whether refrigerant is present in the circuit) switches off the A/C clutch
as soon as there is no refrigerant in the refrigerant circuit.
-- Check refrigerant oil quantity in refrigerant circuit if necessary. Refer to Maintenance, Diagnosis .
-- Connect service station to power supply.
-- Check quantity of refrigerant in the A/C service station.
-- Connect charging hose of A/C service station to vehicle refrigerant circuit with quick-release coupling
adapter (refer to vehicle-specific refrigerant circuit). Refer to [For engine(s) BPY,BLV,CCTA,CBFA]
Description and Operation .
-- Only tighten the handwheel on the quick-release coupling adapter just enough so the valves in the service
connections are securely open. Do not put too much pressure on the valve.
NOTE: If pressure is to be measured after charging system on vehicles with a service

connection on one side of the refrigerant circuit only, use valve adapter and
charging hose with valve opener.
-- Initiate vacuum phase on the A/C service station. The refrigerant circuit is automatically evacuated. Check
the preset evacuating time if necessary.
When the vacuum phase ends, the refrigerant circuit leak test begins. Pressure in bar and seconds are displayed.
Proceed as follows if the vacuum is not maintained:
-- Start the vacuum phase on the A/C service station again. The refrigerant circuit is automatically evacuated.
Check the preset evacuating time if necessary. Watch the vacuum indicator for an extended period of time. Only
when the vacuum is maintained can the refrigerant circuit be charged.
 If there is a leak that allowed enough air to enter during evacuation that the A/C service station cannot
generate a sufficient vacuum or that the vacuum is lost immediately after switching the A/C service
station off:
-- Determine the location of the leak in the refrigerant circuit as follows, refer to LEAK DETECTION.
REFRIGERANT CIRCUIT, CHARGING WITH SERVICE STATION
WARNING: High voltage within the high voltage system. Danger of electric shock in
the A/C compressor.
Disable high voltage system. .
service station.
 Before pouring in refrigerant, correct the quantity of refrigerant oil. [For engine(s)
 The entire refrigerant charge can be added to either the high or low pressure side.
Charging the refrigerant circuit
-- Discharging refrigerant circuit using service station. Refer to REFRIGERANT CIRCUIT,

DISCHARGING WITH SERVICE STATION.
-- Screw out handwheel at quick-release coupling adapter (to close it).
-- Allow refrigerant to flow into charging hose.
-- Tighten the handwheel on the quick-release coupling adapter without putting too much pressure on the valve
and add the specified amount of refrigerant.
-- Switch off service station.
NOTE: If A/C compressor was removed, it must be cranked by hand at ribbed belt
pulley/freewheel approximately 10 rotations before bringing into operation for

the first time. This prevents damage in the A/C compressor due to liquid when
switching the A/C system on. If there is oil in the A/C compressor cylinder, it
will be forced out.
-- Start engine with compressor switched off (version with A/C clutch).
-- Set compressor to minimum output, for example, "Econ" or A/C off mode (version with no A/C clutch with
regulating valve).
-- Wait until idle speed has stabilized.
-- Switch on compressor and operate system for at least 2 minutes at idling speed.
-- If necessary, check pressures in refrigerant circuit using A/C service station.
-- Turn engine off.
-- Screw out handwheel on quick-release coupling adapter.
-- Disconnect charging hose from refrigerant circuit.
-- Screw protective caps back on.
REFRIGERANT, TRANSFERRING TO A/C SERVICE STATION CHARGING CYLINDER
service station.
 A certain quantity of refrigerant is specified as charge for each air conditioning system. To ensure that the
correct amount of refrigerant is added and the cooling output is not reduced, the charging cylinder stands
on a scale indicating the weight.
SERVICE STATION, IMPORTANT USAGE INFORMATION

that are no approved by Volkswagen. This A/C system cannot be
NOTE: The chemical materials (stop leak additive) for sealing leaks in the refrigerant
circuit offered on the market are not approved by VW Audi AG. There are no
permanent, validity or material compatibility tests. Therefore damage or
malfunctions in the A/C system or the A/C Service Station cannot be excluded.
The stop leak additives offered on the open market have different physical and
chemical properties, which can impair the function of the A/C system and the
A/C Service Station and can even shut down the system completely.
VW does not approve the use of chemicals to seal leaks in the refrigerant
circuit.
components.

history.
Accessories offer containers used to separate out these chemicals (used to

seal leaks in the refrigerant circuit). Because VW does not approve the use of
these chemicals, there is no evidence of the effectiveness of these filters.
Note the following when operating an A/C service station
 The filters and dryers installed must be replaced at the latest on completion of the service life specified in
the relevant operating instructions.
 Only refrigerant oils that are approved for the refrigerant circuit in that vehicle may be added.
Extracted refrigerant must not be reused under the following conditions, even after cleaning in the station:
 In the case of A/C compressor damage in which the refrigerant was disintegrated due to overheating.
 In the case of dark, sticky deposits in the refrigerant circuit (these can only be found after opening the
system).
 If there is any doubt as to the composition of the refrigerant extracted from the refrigerant circuit.
The A/C service station is to be drained in all these cases, the system cleaned if necessary and the filters, dryers
and refrigerant oil replaced.
For example, within Germany, contaminated refrigerant can be returned to the supplier in recycling containers
for recycling or for environmentally safe disposal. Other or additional regulations may apply in other countries.
Commercially available service stations can be classified in 2 groups:

 A. A/C service stations which clean extracted refrigerant for reuse (extraction and recycling stations) such
as the A/C service station -ROB 134APF-.
 B. A/C service stations which transfer extracted refrigerant to recycling containers (for large-scale
recycling). These are referred to as extraction systems.
SERVICING STATION, CONNECTING FOR MEASURING AND TESTING
 Work procedure may vary depending on the type of tools selected (the tool-specific operating instructions
should therefore be followed).
NOTE: The work procedure is always to be performed as described in the operating

instructions for the A/C service station -ROB 134APF- (or subsequent models).
The charging hoses are to be connected as follows to prevent the entry of air or moisture into the refrigerant
circuit:
-- Connect service station to power supply.
-- Connect quick-release coupling adapter to charging hoses of service station (hand wheels not screwed in/hand
shut-off valve not open).
-- Switch on service station and evacuate charging hoses (only necessary if there is air in charging hoses).
-- Switch off service station.
-- Remove sealing caps from service connections or connections with valve (see vehicle-specific refrigerant
circuit).
NOTE: Connect filler hose with quick-release couplings to refrigerant circuit service
connections.
CAUTION: Never open valves on low or high-pressure side with engine running.
Otherwise, the compressor or service station could be destroyed by a
short circuit between the high and low-pressure sides of the refrigerant
circuit if the A/C system is switched on.
-- Only tighten the handwheel in the quick-release coupling just enough so the service connection is open.
Watch the pressure gauge and do not place too much pressure on the valve.
-- Start the engine and perform the planned tests and measurements.
-- Compare values determined to specified measured values. Refer to TEST PREREQUISITES.
-- Loosen the handwheel to close the quick-release coupling before disconnecting it.
SERVICE STATION, DRAINING
WARNING:  When filling recycling containers (compressed-gas vessels),

observe applicable regulations, technical rules and laws.
 Recycling containers are never to be overfilled. Overfilled containers
do not have a sufficient gas cushion to accommodate the liquid
expansion caused by the effects of heat. There is a danger of
rupture.
 To ensure safety, make exclusive use of recycling containers fitted
with a safety valve.
 Recycling containers must be weighed on calibrated scales during
the filling process. The maximum permissible capacity is 75%
(charge factor 0.75) of the charge weight indicated on the recycling
container (the possibility of refrigerant oil entering the recycling
container along with the refrigerant cannot be ruled out).
NOTE: If it is necessary to evacuate the A/C service station (for example, because
contaminated refrigerant was extracted), always replace all filters and dryers.
Only remove the filters and dryers from their air-tight packaging immediately
before installing them to prevent moisture from entering.
Refrigerant containers filled with contaminated used refrigerant are referred to

as "Recycling containers".
Always evacuate recycling cylinders before first charging with refrigerant.

Refrigerant cylinders in which there is air must not be filled with refrigerant.
Different refrigerant types must not be mixed together. Refrigerant mixtures

cannot be reprocessed but must be disposed of. If there is any doubt about the
composition of the contents of the container, the refrigerant recycling company
is to be informed accordingly.
SPECIFICATIONS

Schrader Valve Insert - 2.4 ± 0.2
Valve With M12 x 1.5 mm External Threads and Groove for - 7±1
O-ring
PRESSURE GAUGE, TESTS AND MEASUREMENTS
Indicators on pressure gauge
Fig. 44: Identifying Indicators On Pressure Gauge

1. Temperature scale for refrigerant R134a CF3-CH2F or CH2F-CF3.

2. Pressure scale
The pressure gauge may have one or more temperature scales next to the pressure scale. R134a scale values are
allocated respectively in the vapor pressure table. Since various refrigerants create different vapor pressures at
the same temperature, each temperature scale is identified for the respective refrigerant.
a- Pressure And Temperature Measurement At Refrigerant Circuit
 High pressure gauge measures pressure and temperature, which expand uniformly from outlet of A/C
compressor via the condenser up to constriction (restrictor, or expansion valve) with A/C system switched
on.
 Low pressure gauge measures pressure and temperature, which expand uniformly from constriction
(restrictor, or expansion valve) via evaporator up to input of A/C compressor with A/C system switched
on.
NOTE: The relationship between pressure and temperature indicated on the gauges
only exists in a refrigerant circuit that contains liquid or vapor, but not gas. In a
gaseous state, the temperature is approximately 10°C (50°F) to 30°C (86°F)
higher than indicated on the gauge.
b - Verification Of Refrigerant In A Closed Vessel
Refrigerant R134a is present in a closed vessel or in a refrigerant circuit when the temperature indicator on the
gauge matches the refrigerant temperature (the temperature of standing fluid is equal to the outside
temperature).
A closed vessel or a refrigerant circuit that has been switched off is empty when the temperature indicated on
the gauge is below the temperature of the refrigerant.
NOTE: The relationship between pressure and temperature indicated on the gauges no
longer applies if no liquid is present and the pressure is built up solely by gas.
LEAK DETECTION
DETECTING LEAKS

that are not approved by Volkswagen. This A/C system cannot be
NOTE: This repair information describes different methods for detecting leaks in the
refrigerant circuit. These methods have been tested and result in success when
used correctly.
If when searching for compressed air/Nitrogen or vacuum leaks none are found,
add a leak detection additive i.e UV leak detection additive, to the electric leak
detecting unit.
Minor leaks can be detected using an electronic leak detector or UV leak

detector lamp.
Many methods for detecting leaks in the refrigerant circuit are offered in the
open market. These methods do not always have optimum results. If they are
not used exactly according to specifications, they can indicate refrigerant
circuit components have leaks even when they do not. Also, refrigerant circuit
components can be damaged by some methods.
Do not repair components with leaks. Replace them with new original parts.
Do not charge a leaking refrigerant circuit with refrigerant. Evacuate the circuit
and check it for leaks before charging. Refer to REFRIGERANT CIRCUIT,
NOTE: VW does not approve the use of chemicals to seal leaks in the refrigerant
circuit.
components, even by flushing.

history.
Accessories offer containers used to separate out these chemicals (used to

seal leaks in the refrigerant circuit). Because VW does not approve the use of
these chemicals, there is no evidence of the effectiveness of these filters.
SEARCHING FOR REFRIGERANT CIRCUIT LEAKS WITH COMPRESSED AIR OR NITROGEN
NOTE: A leak can be identified if a maximum of pressure of 15 bar can be generated in

the refrigerant circuit using clean, dry compressed air or nitrogen. Refer to
REFRIGERANT CIRCUIT, FLUSHING WITH COMPRESSED AIR AND NITROGEN.
If the leak is large enough, the sound of escaping air or gas can be heard at the
location of the leak.
Use the service connection for the compressed air or nitrogen.

Fig. 45: Identifying Quick-release Coupling Adapter For Service Connections

The quick-release coupling adapter for service connections can be connected

to the air compressor using a modified filler hose -A- (for example, with 5/8" 18
UNF threads, different from the threads on the quick-release coupling adapter)
and a suitable adapter -B-. Refer to IMPROVISED TOOLS. This keeps humidity,
oil and dirt coming out of the workshop compressed air system from getting
into the A/C refrigerant circuit. Also use a combination fine-gauge filter for
compressed air systems such as those that are standard in paint shops. Install
it between the compressed air system and the filler hose -A-.
Fig. 46: Identifying Improvised Tool

A compressed gas cylinder filled with nitrogen -3- can be connected to the
closed refrigerant circuit using a pressure gauge battery with a pressure
reducer for nitrogen (maximum reduction pressure: 15 bar) -1- and a filler hose -
2- (for example, with 5/8" 18 UNF threads) connected to the service connection.
A quick-release coupling adapter must also be connected to the service
connection. Refer to IMPROVISED TOOLS.
Fig. 47: Identifying Pressure Gauge Set With Pressure Reducer For Nitrogen
(Maximum Reducing Pressure: 15 bar)
-- Slowly increase the pressure in the refrigerant circuit to a maximum of 15 bar.
WARNING:  The maximum permitted working pressure is 15 bar.

 When testing for leaks with nitrogen, always work with a pressure
reducer for nitrogen bottles.
-- Find the location of the leak by listening for the sound of venting gas. An Ultrasonic tester -V.A.G 1842- will
aid in detecting the origin of noise.
-- Use clean, dry compressed air to force the nitrogen out of the refrigerant circuit. The nitrogen must not get
into the Service bottle. Reason: gases that do not condense do not get into the Service bottle.
-- Repair the leak.
-- Evacuate and again observe the vacuum display over a period of hours. Only when the vacuum is maintained
can the refrigerant circuit be charged.
 If there is a leak that is small enough that no air or very little air vents through it and the A/C service
station can generate a sufficient vacuum: The vacuum indicator does not increase after switching the A/C
system service station or only increases slowly, indicating that air is only entering through a small leak.
-- Add 100 grams of refrigerant to the circuit, find the location of the leak using an electronic leak detector and
repair it. Refer to REFRIGERANT CIRCUIT, FINDING LEAKS WITH ELECTRONIC LEAK
DETECTOR VAG 1796 or add UV contrast dye to the refrigerant and find the location of the leak with the
leak detection system VAS 6201 and repair it. Refer to REFRIGERANT CIRCUIT, FINDING LEAKS
WITH LEAK DETECTION SYSTEM VAS 6201 OR VAS 6196.
-- Empty the refrigerant circuit, if necessary. Refer to REFRIGERANT CIRCUIT, DISCHARGING WITH
SERVICE STATION.
-- Evacuate and check the vacuum display again over several hours. Only when the vacuum is maintained can
the refrigerant circuit be charged.
REFRIGERANT CIRCUIT, FINDING LEAKS WITH ELECTRONIC LEAK DETECTOR VAG 1796
NOTE: Minor leaks can be detected using an electronic leak detector for example.
-- Evacuate the refrigerant circuit with the A/C service station. Refer to REFRIGERANT CIRCUIT,
NOTE: Be ready to evacuate a large leak should one be found. Refer to REFRIGERANT
CIRCUIT, DISCHARGING WITH SERVICE STATION.
If no leak is found during evacuation or there is a leak that is so small that the
location cannot be found, proceed as follows. Refer to SEARCHING FOR
REFRIGERANT CIRCUIT LEAKS WITH COMPRESSED AIR OR NITROGEN.
Currents of air quickly disperse refrigerant gas. Draughts must therefore be

avoided during leak detection.
If the refrigerant circuit is completely empty, fill with refrigerant to

approximately 10% of the fill capacity (R134a label or vehicle-specific Repair
Information).
Leak Detection
-- Start up leak detector in line with relevant operating instructions.
-- Always hold test probe beneath suspected leak.
Depending on the model, leak detection is indicated by an increase in clicking rate or a warning tone (refer to
operating instructions for leak detector).
Fig. 48: Identifying A/C Refrigerant System, Checking For Leaks

REFRIGERANT CIRCUIT, FINDING LEAKS WITH LEAK DETECTION SYSTEM VAS 6201 OR VAS 6196
 Leak Detection System -VAS 6196-

 Leak Detection System -VAS 6201-
NOTE: Small leaks can be detected using a UV-leak detection additive for example.
-- Evacuate the refrigerant circuit with the A/C service station. Refer to REFRIGERANT CIRCUIT,
NOTE: Be ready to evacuate a large leak should one be found. Refer to REFRIGERANT
CIRCUIT, DISCHARGING WITH SERVICE STATION.
If no leak is found during evacuation or there is a leak that is so small that the
location cannot be found, proceed as follows. Refer to SEARCHING FOR
REFRIGERANT CIRCUIT LEAKS WITH COMPRESSED AIR OR NITROGEN.
Currents of air quickly disperse refrigerant gas. Draughts must therefore be

avoided during leak detection.
If the refrigerant circuit is completely empty, fill with refrigerant to

approximately 10% of the fill capacity (R134a label or vehicle-specific Repair
Information).
Filling leak detection additive when refrigerant circuit is empty
Fig. 49: Identifying Leak Detection Cartridge

The cartridge -A- contains 15.4 ml leak detection additive (one unit -B- corresponds to 2.5 ml).
-- Assemble hand pump -VAS 6201- item -1- with cartridge item -2- -VAS 6201/2-.
Fig. 50: Identifying Assemble Hand Pump & Cartridge

-- Insert the filler tube -VAS 6201/8- in the hand pump.
-- Open hand pump service valve.
Leak detection additive is best added to empty refrigerant circuit via opened connection.
Fig. 51: Identifying Adding Leak Detection Additive To Refrigerant Circuit

-- Open an easily accessible connection point on refrigerant circuit

-- Cover area around connection point with foil or absorbent paper.
-- Hold tube upwards.
-- Tighten the toggle on the hand pump until the leak detection additive comes out of the tube.
-- Add 2.5 +/- 0.5 ml (milliliter = cm3 ) of leak detection additive to the refrigerant circuit.
NOTE: If leak detection fluid was filled already in a refrigerant circuit for an earlier
repair, note the following: only add new leak detection additive if the refrigerant
oil will be replaced. If only a portion of the refrigerant oil was replaced, only add
a proportionate amount of the leak detection additive. For example, if 100 ml of
refrigerant oil was replaced in a vehicle with 250 ml, add only 1 ml (cm3 ) of leak
detection additive.
-- Replace the O-rings on opened connection point.
-- Assemble refrigerant circuit.
-- Apply a label near the service connection stating that leak detection additive was added to the refrigerant
circuit.
-- Evacuate and recharge refrigerant circuit according to specification. Refer to REFRIGERANT CIRCUIT,
DISCHARGING WITH SERVICE STATION and REFRIGERANT CIRCUIT, CHARGING WITH
SERVICE STATION.
-- Start the A/C system.
NOTE: The A/C system must run for at least 60 minutes so the additive distributes
itself through the entire refrigerant circuit. The compressor must be running.
Depending on the size of the leak, it may become visible within that time.
-- Find the leak in the refrigerant circuit with the UV lamp -VAS 6196/4-. Refer to Detecting leaks in
refrigerant circuit using UV lamp VAS 6196/4.
Leak Detection Additive With Filled Refrigerant Circuit, Filling
NOTE: If leak detection fluid was filled already in a refrigerant circuit for an earlier
repair, note the following: only add new leak detection additive if the refrigerant
oil will be replaced. If only a portion of the refrigerant oil was replaced, only add
a proportionate amount of the leak detection additive. For example, if 100 ml of
refrigerant oil was replaced in a vehicle with 250 ml, add only 1 ml (cm3 ) of leak
detection additive.
A small quantity of leak detection additive remains in the service connection.

Carefully remove this residual amount so a leaking area is not detected

erroneously upon a later leak detection.
The cartridge -A- contains 15.4 leak detection additive (one unit -B- corresponds to 2.5 ml).
Fig. 52: Identifying Leak Detection Cartridge

-- Switch off ignition.
Fig. 53: Identifying Assemble Hand Pump & Cartridge

-- Assemble hand pump -VAS 6201- item -1- with cartridge item -2- -VAS 6201/2-.
NOTE: Make sure the hand pump hose is completely filled with leak detection additive.
-- Place the quick-release coupling on the low pressure side service connection and tighten the hand wheel to
open the service coupling. Hold the hose upward and tighten the handle of the hand pump just enough until the
leak detection additive starts to emerge from the tube.
-- Cover area around service connection on vehicle with foil or absorbent paper.
Fig. 54: Adding Leak Detection Additive To Refrigerant Circuit

-- Tighten the toggle on the hand pump to add 2.5 +/- 0.5 ml (milliliter = cm3 ) of leak detection additive to the
-- Close the service coupling and remove it from the service connection.
Fig. 55: Identifying Leak Detection Additive Label

-- Remove the rest of the leak detection additive from the service connection, for example with absorbent paper.
-- Seal service connection with sealing cap.
-- If necessary, clean area around service connection using cleaning agents.
-- Place a label next to the service connection stating that leak detection additive was added to the refrigerant
circuit.
-- Start the A/C system.
-- Find the leak in the refrigerant circuit with the UV lamp -VAS 6196/4-. Refer to Detecting leaks in
refrigerant circuit using UV lamp VAS 6196/4
Detecting leaks in refrigerant circuit using UV lamp VAS 6196/4
WARNING: Do not look into UV lamp.
Do not direct UV lamp at other people.
With leaks on evaporator, leak detection additive is possibly washed off with
condensation and flows out via evaporator drain. Since the evaporator is not
easily accessible on most vehicles, checking the evaporator drain may indicate
if the evaporator is leaking. However, it is necessary for this purpose that leak
detection additive has already been in the refrigerant circuit for a long period of
time.
Protective goggles do not only serve as eye protection but also amplify the
illumination of leak detection additive under UV light.
Depending on the accessibility of different components in the refrigerant

circuit, it may be necessary to remove some vehicle components such as the
bumper or air filter.
-- Move vehicle into a slightly darker area of the workshop (with daylight or bright lighting the effect of the UV
light is diminished).
Fig. 56: Checking For Refrigerant Leaks

-- Check the accessibility of the various components in the refrigerant circuit and remove any components in the
area that block access to the refrigerant circuit such as noise insulation and the bumper.
-- Wear protective eyewear to protect the eyes.
-- Connect the UV-lamp to a 12 volt battery (vehicle battery). Observe correct polarity of connections.
-- Switch on UV lamp and illuminate components of refrigerant circuit. Locations where refrigerant, refrigerant
oil and leak detection additive has leaked out light up under fluorescent UV light.
NOTE: The leak detection additive can remain in the refrigerant circuit.
REFRIGERANT CIRCUIT CONCERNS
NOTE: The air conditioning system is functioning correctly when the air flowing from
the instrument panel vents has a temperature of 7°C or lower.
Setting on Climatronic "LO".
Setting on air conditioning system "AC" on; "max" ; "cold".
 The A/C system OBD cannot find malfunctions with the Vehicle Diagnostic Tester in "Guided Fault
Finding". The measured value block does not show any shut-off condition for the A/C compressor (only
on vehicles with "A/C system" OBD).
Refer to [For engine(s) BPY,BLV,CCTA,CBFA] Diagnosis and Testing .
NOTE: With all complaints marked with *, refer to PRESSURES, CHECKING.
 Total cooling system failure.*

 Insufficient cooling performance at all vehicles speeds or engine speeds.*
 None or insufficient cooling after driving a few miles.* *
 A/C compressor, A/C Clutch -N25- or A/C Compressor Regulator Valve -N280- are switched off by A/C
Refrigerant Low Pressure Switch -F73-, A/C Refrigerant High Pressure Switch -F118-, A/C Pressure
Switch -F129- or by A/C Control Head -E87- or Climatronic Control Module -J255- due to excessive or
insufficient pressure. *
 None or sharp decrease in fresh-air supply after driving several miles (evaporator iced up).* *
From these, the following complaints may also occur:
The A/C compressor makes noises
-- Re-tighten compressor securing bolts and compressor bracket using a torque wrench.
-- Check routing of refrigerant lines; they must not touch other components and must not be subject to strain
(align if necessary).
Noise (refrigerant hammer) occurring immediately after switching on air conditioner and/or when
cornering or braking
-- Discharge, evacuate and charge refrigerant circuit (too much refrigerant in circuit).
NOTE: Too much refrigerant oil in the circuit could also cause this problem. This could
occur if the amount of refrigerant oil was not adjusted when replacing the A/C
compressor. If this occurs, flush the refrigerant circuit with refrigerant R134a.
Refer to REFRIGERANT CIRCUIT, FLUSHING WITH REFRIGERANT R134A.
Drain refrigerant from the A/C compressor using the oil drain plug. To facilitate
this, the ribbed belt pulley or magnetic clutch plate on the A/C compressor
should be rotated by hand. After flushing, the entire quantity of refrigerant oil
specified by Maintenance, Diagnosis should be added to the refrigerant circuit
(50 grams directly in the A/C compressor).
Water sprays out of vents (in dash panel or footwell) although air conditioning system is otherwise
functioning properly
-- Check proper routing of condensate drain; it must not be crushed or kinked.
-- Check condensation drain valve, it must not be clogged by wax or underbody sealant and must open and close
properly.
-- Check plenum chamber cover; it must not be damaged and must be properly installed (to stop water running
into evaporator).
-- Check water drains in plenum chamber; they must not be blocked (for example, by leaves).
ODOR FROM EVAPORATOR OR HEAT EXCHANGER
 Fishy smell
-- From leak at cooling system of engine or of A/C system heater core.
NOTE: If the fishy smell gets weaker when the temperature is set to cold and stronger
when it is set to warm, then check the heat exchanger for leaks.
 Smells like a burned clutch.

 Evaporation from floor mats, decorative seat covers, etc.
 Musty smell
-- Due to various contaminants, such as leaves, pine needles, etc. collecting.
NOTE: Clean the plenum chamber.
-- Due to water that cannot drain out of the plenum chamber.
NOTE: Check that the plenum chamber water is draining.

 Odor from the Heater and A/C Unit
NOTE: Odors originating in the heating and A/C unit can mainly be detected in fresh air
mode and recirculated air mode.
-- Due to too much condensation water in A/C unit.
NOTE: Check the condensation water drain. Refer to [For engine(s)

BPY,BLV,CCTA,CBFA] Diagnosis and Testing .
-- Due to an old or heavily contaminated dust and pollen filter.
NOTE: Check the dust and pollen filter. Refer to [For engine(s) BPY,BLV,CCTA,CBFA]
Description and Operation .
-- Due to deposits on evaporator fins.
NOTE: Clean the evaporator using an Ultrasound A/C Cleaner -VAS 6189A- or pressure
cup gun -V.A.G 1538- and a suitable spray nozzle. Refer to ULTRASOUND A/C
CLEANER VAS 6189A and EVAPORATOR, SPRAYING WITH PRESSURE CUP
GUN AND SPRAY NOZZLE VAG 1538.
PRESSURES, CHECKING
TEST PREREQUISITES
NOTE: Check cooling performance. The air conditioning system is functioning

correctly when the air flowing from the instrument panel vents has a
temperature of 70 C or lower.
Setting on Climatronic "LO".
Setting on air conditioning system "AC" on; "max" ; "cold".
Connections with valve and service connections for measuring and checking.
 Radiator and condenser are clean (clean if necessary)

 Thermal insulation at expansion valve OK and properly installed. Refer to [For engine(s)
 Ribbed belt is OK and properly tensioned. Ribbed belt for A/C compressor and generator are OK and
correctly tensioned. Refer to [For engine(s) BPY,BLV,CCTA,CBFA] Removal and Installation .
 All air ducts, covers and seals OK and properly installed
 Fault finding on the electrical equipment and vacuum system found no malfunction. Refer to [For engine
(s) BPY,BLV,CCTA,CBFA] Diagnosis and Testing .
 The A/C system OBD cannot find malfunctions with the Vehicle Diagnostic Tester in "Guided Fault
Finding". The measured value block does not show any shut-off condition for the A/C compressor (only
on vehicles with A/C system OBD).
 Air flow through dust and pollen filter not obstructed by dirt. Refer to [For engine(s)
 The heater and A/C unit does not draw in any secondary air at the highest fresh air blower speed.
Evaporator and heater not drawing in secondary air at maximum fresh-air blower speed. Refer to [For
engine(s) BPY,BLV,CCTA,CBFA] Description and Operation .
 The air flaps in the heater and A/C unit reach their end position. Refer to [For engine(s)
 Fresh-air intake ducts beneath hood and in passenger compartment as well as corresponding water drain
valves OK. Refer to [For engine(s) BPY,BLV,CCTA,CBFA] Diagnosis and Testing .
 Engine is warm
 Vehicle not exposed to direct sunlight
 Ambient temperature greater than 15°C (60°F).
 All instrument panel vents open
 With engine running and maximum cooling output set on air conditioning system:
Set Maximum Cooling Output
Setting on A/C Display Control Head -E87-.
-- Preselect "Auto" mode (A/C compressor on).
-- Set temperature selection "LO" for driver's and passenger's side.
Setting on heater controls:
-- A/C button and Rec- or recirculated air button pressed.
-- Temperature dial in the "Cold" position.
-- Rotary fresh-air blower control in "4" position.
 The Coolant Fan -V7- runs (the fans run) (at least in level 1).*
NOTE: For some versions, fan is switched on only once the pressure in refrigerant
circuit has exceeded a specified value.
 The Fresh Air Blower -V2- runs at maximum speed.

 Recirculated/fresh-air door set to "air recirculation mode" (within 1 minute after starting vehicle, air-flow
door is closed and recirculated air door opened).*

 Is the coolant shut-off valve closed? *
 Are the valves on the pump valve unit closed and the coolant circulation pump is not pumping?
PRESSURES, CHECKING
-- Connecting service station, refer to SERVICING STATION, CONNECTING FOR MEASURING AND
TESTING.
-- Take pressure gauge readings (two possible results).
Pressure In Refrigerant Circuit In Bar Positive

Ambient Temperature (In Degrees Celsius) Pressure
+ 15°C 3.9
+ 20°C 4.7
+ 25°C 5.6
+ 30°C 6.7
+ 35°C 7.8
+ 40°C 9.1
+ 45°C 10.5
NOTE: Temperature of refrigerant circuit components should be equal to ambient

temperature.
Pressure will deviate from values in table if individual components of refrigerant

circuit are warmer or colder.
At absolute pressure, 0 bar corresponds to absolute vacuum. Normal ambient

pressure (positive pressure) corresponds to 1 bar absolute pressure. 0
pressure corresponds to an absolute pressure of one bar on most pressure
gauges (indicated by -1 bar below 0).
On vehicles with High Pressure Sensor -G65- with which the measured pressure
is displayed in the measured value block, the measured pressure should
correspond to the values in the table.
Pressure in refrigerant circuit lower than indicated in table
Not enough refrigerant in refrigerant circuit.
-- Determine refrigerant circuit leaks. Refer to REFRIGERANT CIRCUIT, FINDING LEAKS WITH
ELECTRONIC LEAK DETECTOR VAG 1796.
-- Check pressure relief valve.
If pressure relief valve has responded:
-- Check coolant fan activation.
-- Check refrigerant lines and hoses for cross-section constrictions caused by inadequate bending radii.
-- Check refrigerant pipes and hoses for external damage.
-- If no malfunction is found, flush refrigerant circuit with compressed air and nitrogen.
Pressure in refrigerant circuit in line with table or higher
-- Set air conditioning system to maximum cooling output.
NOTE: If the low pressure switch was removed to connect the service station, bridge
the electrical connections in the corresponding connector for the pressure
measurement.
 A/C compressor is driven by the engine via A/C Clutch -N25-.

 The A/C Compressor Regulator Valve -N280- is activated by the Climatronic Control Module -J255-.
If compressor is not driven with engine running or regulating valve is not actuated
-- Determine and eliminate cause for example, by checking air conditioner DTC memory.
-- Observe test conditions.
-- Check the A/C clutch -N25- voltage supply. If it is OK, repair the A/C clutch.
-- Check activation of A/C Compressor Regulator Valve -N280-. Refer to [For engine(s)
 Check on vehicles with restrictor and reservoir (with internally regulated A/C compressor). Refer to
CHECKING WITH RESTRICTOR AND RESERVOIR WITH INTERNALLY REGULATED
A/C COMPRESSOR.
 Check on vehicles with expansion valve and reservoir (with internally regulated A/C compressor). Refer
to CHECKING WITH EXPANSION VALVE AND RESERVOIR WITH INTERNALLY
REGULATED A/C COMPRESSOR.
 On vehicles with expansion valve and reservoir (without regulated A/C compressor). Refer to
CHECKING WITH EXPANSION VALVE AND RESERVOIR WITHOUT REGULATED A/C
COMPRESSOR.
 Checking pressures for vehicles with restrictor, reservoir and A/C Compressor Regulator Valve -N280-
(externally regulated A/C compressor). Refer to CHECKING WITH RESTRICTOR, RESERVOIR
AND A/C COMPRESSOR REGULATOR VALVE N280.
CHECKING WITH RESTRICTOR AND RESERVOIR WITH INTERNALLY REGULATED A/C COMPRESSOR
NOTE: Connecting service station, refer to SERVICING STATION, CONNECTING FOR

MEASURING AND TESTING.
Observe test requirements, refer to PRESSURES, CHECKING.
-- Bring engine speed up to 2000 RPM.
-- Check the pressure gauge on the A/C service station.
NOTE: Switching pressures for refrigerant circuit switches are vehicle-specific.
Connection with valve for low-pressure switch or at evaporator is only to be

used for vehicles with no service connection on low-pressure side and
inaccessible connection at compressor or accumulator (measurement
accuracy). Only applies to certain vehicles.
Target values
High-pressure side
Increasing from initial pressure (when connecting pressure gauges) to a maximum of 20 bar.
Low-pressure side
Decreasing from initial pressure (when connecting pressure gauges) to the value in the graph.
Fig. 57: Identifying Permissible Tolerance Range Graph

A - High pressure (measured at service connection) in bar
B - Low pressure (measured at connection with valve at compressor or accumulator) in bar
C - Permissible tolerance range
D - Low pressure (measured at connection with valve for low-pressure switch or at service connection) in bar
E - Permissible tolerance range
Possible Deviation From Specification Possible Cause Of Fault Corrective Action

 High pressure remains constant or
Not enough refrigerant in -- Check for leaks and correct. --
increases only slightly (above refrigerant circuit Charge the refrigerant circuit
pressure with engine stopped),
 Low pressure quickly drops to
value in graph or below
 Required cooling output is not
attained
 High pressure normal
 Low pressure in line with value in
graph
attained
 Low pressure too low (see Fig. 57)
attained
NOTE: If no malfunction is found with this complaint, flush (clean) refrigerant circuit
with refrigerant R134a. If that is not possible in this workshop, flush the
refrigerant circuit with compressed air and remove moisture with nitrogen.
Refer to REFRIGERANT CIRCUIT, FLUSHING WITH REFRIGERANT R134A and
REFRIGERANT CIRCUIT, FLUSHING WITH COMPRESSED AIR AND NITROGEN.

 High pressure only increases
A/C compressor faulty. -- Flush (clean) refrigerant circuit.
slightly above pressure with Refer to REFRIGERANT
engine stopped CIRCUIT, FLUSHING WITH
REFRIGERANT R134A. --
 Low pressure drops only slightly
Replace A/C compressor.
attained

 High pressure increases above
Constriction or -- Run hand over refrigerant circuit
specification obstruction in refrigerant to check for differences in
circuit temperature
 If difference in temperature is
 Required cooling output is not found at one component:
attained
-- Replace hose or pipe if kinked or
constricted -- In the event of an
obstruction, flush refrigerant circuit
with compressed air and nitrogen --
Repeat test if function is not OK. --
Flush (clean) refrigerant circuit.
Refer to REFRIGERANT
CIRCUIT, FLUSHING WITH
REFRIGERANT R134A.
 High and low pressure normal at
Moisture in refrigerant -- Refrigerant Circuit, Flushing with
first After some time, circuit Compressed Air and Nitrogen --

 High pressure increases above Replace fluid reservoir. -- Repeat
specification test if function is not OK. -- Flush
(clean) refrigerant circuit. Refer to
 Low pressure quickly drops to REFRIGERANT CIRCUIT,
value in graph or below, FLUSHING WITH
 Required cooling output is no REFRIGERANT R134A. --
longer attained. Charge the refrigerant circuit --
Repeat test
 High pressure normal A/C compressor faulty. -- Flush (clean) refrigerant circuit.
 Low pressure too low (see Fig. 57) CIRCUIT, FLUSHING WITH
 The required cooling performance REFRIGERANT R134A. --
is obtained Replace A/C compressor.
NOTE: For the malfunction "high pressure normal, low pressure too low", note the
following:
This fault may cause the evaporator to ice up or the A/C Refrigerant Low
Pressure Switch -F73- to shut off the compressor although the amount of
refrigerant in the circuit is OK.

 High pressure normal or too high
To much refrigerant in -- Extract refrigerant from
the circuit. refrigerant circuit
 Low pressure too high (see Fig.
57)
 If quantity of refrigerant
 A/C compressor noise (particularly extracted roughly corresponds
after switch-on) to specified capacity:
attained -- Replace A/C compressor.
extracted is substantially
greater than specified
capacity:
-- Charge the refrigerant circuit --

Repeat test

 High and low pressure normal
To much refrigerant oil -- Discharge refrigerant circuit --
in the circuit. Flush (clean) refrigerant circuit.
attained CIRCUIT, FLUSHING WITH
REFRIGERANT R134A.
 A/C compressor noise (particularly
after switch-on)
 The required cooling performance
is obtained
NOTE: Overfilling with refrigerant oil can occur in the event, for example, the
compressor has been replaced without adjusting the quantity of refrigerant oil.
If the A/C compressor is not replaced, the refrigerant oil should be drained from
the A/C compressor via the oil drain plug. Out of the entire quantity of
refrigerant oil, 50 grams should be put in the A/C compressor and the rest in the
refrigerant circuit. Refer to Maintenance, Diagnosis
CHECKING WITH EXPANSION VALVE AND RESERVOIR WITH INTERNALLY REGULATED A/C COMPRESSOR

-- Observe manometer battery.
NOTE: Switching pressures and design of refrigerant circuit switches are vehicle-
specific.
The pressures should be measured at the service connections. The location of these connections is vehicle-
specific.
Target values
High-pressure side
Increasing from initial pressure (when connecting pressure gauges) to a maximum of 20 bar.
Low-pressure side

A - High pressure in bar
B - Low pressure in bar

 High pressure remains constant or
Not enough refrigerant in -- Extract refrigerant from
increases only slightly (above circuit or expansion valve refrigerant circuit
pressure with engine stopped), malfunctioning.
extracted roughly corresponds
to specified capacity:
attained -- Replace expansion valve --
Charge the refrigerant circuit --
Repeat test
 High pressure normal  If quantity of refrigerant
 Low pressure in line with value in extracted is substantially less
graph than specified capacity:
-- Localize leak with leak detector
attained
and eliminate -- Charge the
refrigerant circuit -- Repeat test
NOTE: If no malfunction can be found and the function of the A/C system is not correct
after repeating the test, flush (clean) refrigerant circuit with refrigerant R134a. If
that is not possible in this workshop, flush the refrigerant circuit with
compressed air and remove moisture with nitrogen. Refer to REFRIGERANT
CIRCUIT, FLUSHING WITH REFRIGERANT R134A and REFRIGERANT CIRCUIT,
FLUSHING WITH COMPRESSED AIR AND NITROGEN.

 High pressure increases above  Constriction or -- Run hand over refrigerant circuit
specification obstruction in to check for differences in
refrigerant circuit temperature
value in graph or below  Expansion valve
 Required cooling output is not malfunctioning
found at one component:
attained
constricted -- If there is an
with compressed air and nitrogen
and replace expansion valve.
 If no malfunction can be
found.
-- Flush (clean) refrigerant circuit.

Repeat test
NOTE: If the function is not correct after flushing the refrigerant circuit, the expansion
valve must be replaced.
Possible Deviation From

Specification Possible Cause Of Fault Corrective Action
 High and low pressure normal  Expansion valve -- Examine expansion valve for
at first malfunctioning dirt or corrosion; replace if
necessary -- Refrigerant Circuit,
 After some time, high pressure  Moisture in refrigerant Flushing with Compressed Air
increases above specification circuit and Nitrogen -- Replace fluid
and low pressure drops to value reservoir. -- Repeat test if function
in graph or below is not OK. -- Flush (clean)
 Required cooling output is no refrigerant circuit. Refer to
longer attained. REFRIGERANT CIRCUIT,
FLUSHING WITH
Repeat test
NOTE: Always replace reservoir in case of this malfunction.

 High pressure normal or too  To much refrigerant in -- Extract refrigerant from
high (see Fig. 57), the circuit. refrigerant circuit
 Required cooling output is not  Expansion valve or A/C
attained compressor faulty.
extracted roughly
 A/C compressor noise corresponds to specified
(particularly after switch-on) capacity:
-- Replace expansion valve --

Repeat test
greater than specified
capacity:

Repeat test
NOTE: If the function of the A/C system is not correct when the test is repeated, re-
install old expansion valve and flush refrigerant circuit with compressed air and
nitrogen. Then replace A/C compressor and reservoir.

 High pressure only increases  A/C compressor faulty. -- Flush (clean) refrigerant circuit.
slightly above pressure with Refer to REFRIGERANT
engine stopped CIRCUIT, FLUSHING WITH
 Low pressure drops only Replace A/C compressor and
slightly reservoir.
attained

 High pressure normal  Expansion valve or A/C -- Replace expansion valve --
compressor faulty Charge the refrigerant circuit --
 Low pressure too low (see Fig. Repeat test

57)
 The required cooling
performance is obtained
NOTE: If A/C system function is not OK when the test is repeated, flush (clean)
refrigerant circuit. Refer to REFRIGERANT CIRCUIT, FLUSHING WITH
REFRIGERANT R134A. Then replace A/C compressor and reservoir.
With this malfunction, evaporator may ice up although quantity of refrigerant in

circuit is OK.

 High and low pressure normal To much refrigerant oil in the -- Discharge refrigerant circuit --
circuit. Flush (clean) refrigerant circuit.
 Required cooling output is not Refer to REFRIGERANT
attained CIRCUIT, FLUSHING WITH
REFRIGERANT R134A.
 A/C compressor noise
(particularly after switch-on)
NOTE: Overfilling with refrigerant oil can occur in the event, for example, the
compressor has been replaced without adjusting the quantity of refrigerant oil.
CHECKING WITH EXPANSION VALVE AND RESERVOIR WITHOUT REGULATED A/C COMPRESSOR
Test Prerequisites
 Radiator and condenser are clean (clean if necessary).

 The ribbed belt for the A/C compressor and alternator tensioned correctly.
 All air ducts, covers and seals are OK and installed correctly.
 The doors reach their end position.
 Engine is warm.
 Evaporator and heater not drawing in secondary air (at maximum fresh-air blower speed).
With engine running and A/C system set to maximum cooling output, pay attention to the following
points:
 The fresh air blower is running.

 The coolant fan must be running or it must be switched on.
 The recirculation/fresh air door must be in the "recirculation" position.
 Ambient temperature is greater than 15 0 C.
 The A/C Evaporator Temperature Switch -E33- is installed correctly and its switch temperatures are
correct.
Checking
-- Connect pressure gauge set (A/C service station).
-- Take pressure gauge readings. There are two possible results A and B.
Pressure In Bar (Positive Pressure) In

Ambient Temperature In Degrees Celsius Refrigerant Circuit
+ 15°C 3.9
+ 20°C 4.7
+ 30°C 6.7
+ 40°C 9.1
 A- The pressure in the refrigerant circuit is lower than the pressure specified in the table. There is not
enough refrigerant in the circuit.
- Search for leak with leak detection device.
- The pressure release valve is open, check coolant fan activation according to the wiring diagram.
Check refrigerant pipes and hoses to see if they are bent too sharply (cross-section constrictions) or have
external damage. If no malfunction is found, flush refrigerant circuit.
 B - The pressure in the refrigerant circuit matches the table or is higher.
-- Set A/C system to maximum cooling output.
-- Open doors.
-- Open vents in instrument panel.

The A/C compressor is driven by the engine via the magnetic clutch using the ribbed belt.
NOTE: If the A/C compressor is not driven, check A/C Clutch -N25- voltage supply.
If the voltage supply is OK, repair the magnetic clutch.
If the A/C compressor is driven, check refrigerant circuit:
-- Observe manometer battery:
Specified Values
High-pressure side
Increasing from pressure with engine not running to a maximum of 20 bar.
Low-pressure side
Decreasing from pressure with engine not running down to 1.3 bar.
CHECKING WITH RESTRICTOR, RESERVOIR AND A/C COMPRESSOR REGULATOR VALVE N280

NOTE: Switching pressures for actuation of A/C compressor regulator valve -N280- and
radiator fan -V7- are vehicle-specific.
Target values
High-pressure side
Increasing from initial pressure (when connecting pressure gauges) to 20 bar.
Low-pressure side

A - Low pressure (measured at service connection) in bar absolute
B - Control current for A/C Compressor Regulator Valve -N280-.
NOTE: Under unfavorable conditions (very high ambient temperatures, high humidity),
pressure on high-pressure side may increase to max. 29 bar.
The control current -B- is shown in the measured value block.
The high pressure is shown in the measured value block. Refer to [For engine
Low pressure settles as a function of control current for A/C compressor

regulator valve -N280- within compressor output range in tolerance range.
Under unfavorable conditions (very high ambient temperatures, high humidity),

compressor output may not always be sufficient to attain the specified value.
The specified operating current for the regulator valve must be greater than 0.3
A in order to ensure reliable valve activation.
In the setting "maximum cooling output" control current is regulated to

approximately 0.8 A (displayed in measured value block). Refer to [For engine

pressure corresponds to 1 bar absolute pressure. 0 pressure corresponds to an
absolute pressure of one bar on most pressure gauges (indicated by -1 bar
below 0).

 High pressure remains constant  Activation of A/C -- Check activation of A/C
or increases only slightly Compressor Compressor Regulator Valve -N280-.
(above pressure with engine Regulator Valve - -- Localize leak with leak detector
stopped), N280- is faulty. and eliminate -- Charge the
refrigerant circuit
 Low pressure quickly drops to  Not enough
value in graph or below refrigerant in
 Required cooling output is not refrigerant circuit
attained
 Low pressure in line with value
in graph
attained
 Low pressure too low (see Fig.
59)
attained
 Low pressure too low (see Fig.
59)
attained
with refrigerant R134a. Refer to REFRIGERANT CIRCUIT, FLUSHING WITH
REFRIGERANT R134A. If that is not possible in this workshop, flush the
Refer to REFRIGERANT CIRCUIT, FLUSHING WITH COMPRESSED AIR AND
NITROGEN.

 High pressure only increases  Activation of A/C -- Check activation of A/C

slightly above pressure with Compressor Compressor Regulator Valve -N280-. -
engine stopped Regulator Valve - - Flush (clean) refrigerant circuit.
N280- is faulty. Refer to REFRIGERANT
 Low pressure drops only CIRCUIT, FLUSHING WITH
slightly  A/C compressor REFRIGERANT R134A. -- Replace
 Required cooling output is not faulty. A/C compressor.
attained
 High pressure increases above  Constriction or -- Run hand over refrigerant circuit to
specification obstruction in check for differences in temperature
 Low pressure drops only refrigerant circuit
slightly
attained -- Replace hose or pipe if kinked or
constricted -- In the event of an
with compressed air and nitrogen
 If no malfunction can be found:

REFRIGERANT R134A.
 High and low pressure normal  Moisture in -- Refrigerant Circuit, Flushing with
at first, after some time high refrigerant circuit Compressed Air and Nitrogen --
pressure increases above Replace reservoir. -- Repeat test if
specification function is not OK. -- Flush (clean)
refrigerant circuit. Refer to
 Low pressure quickly drops to REFRIGERANT CIRCUIT,
value in graph or below, FLUSHING WITH
 Required cooling output is no REFRIGERANT R134A. -- Charge
longer attained. the refrigerant circuit -- Repeat test
 High pressure normal  Activation of A/C -- Check activation of A/C
Compressor Compressor Regulator Valve -N280-. -
 Low pressure too low (see Fig. - Flush (clean) refrigerant circuit.
59) Regulator Valve -
N280- is faulty. Refer to REFRIGERANT
 The required cooling CIRCUIT, FLUSHING WITH
performance is obtained  A/C compressor REFRIGERANT R134A. -- Replace
faulty. A/C compressor.
NOTE: Note the following when the malfunction "high pressure normal, low pressure
too low" is detected: faulty, the evaporator can ice up or the cooling output will
not be reached.

circuit is OK.
Check measured values of Evaporator Vent Temperature Sensor -G263- or

Evaporator Temperature Sensor -G308-.
Check the A/C compressor regulator valve -N280- activation

 High pressure normal or too  To much refrigerant -- Extract refrigerant from refrigerant
high in the circuit. circuit
 Low pressure too high (see
graph)
 A/C compressor noise to specified capacity:
 Required cooling output is not -- Replace A/C compressor.
attained
extracted is substantially greater
than specified capacity:

Repeat test
 High and low pressure normal  To much refrigerant -- Discharge refrigerant circuit --
oil in the circuit. Flush (clean) refrigerant circuit. Refer
 Required cooling output is not to REFRIGERANT CIRCUIT,
attained FLUSHING WITH
REFRIGERANT R134A.
 A/C compressor noise
NOTE: Overfilling with refrigerant oil can occur if, for example, the compressor has
been replaced without adjusting the quantity of refrigerant oil.
refrigerant circuit. Refer to Maintenance, Diagnosis .
CHECKING WITH EXPANSION VALVE, RESERVOIR AND A/C COMPRESSOR REGULATOR VALVE N280

NOTE: Switching pressures for actuation of A/C compressor regulator valve -N280- and
radiator fan -V7- are vehicle-specific.
The pressure should be measured at the service connections. The location of

these connections depends on the vehicle. Refer to [For engine(s)
Target values
High-pressure side
Increasing from initial pressure (when connecting pressure gauges) to 20 bar.
Low-pressure side

A - Low pressure (measured at service connection) in bar absolute
B - Control current for A/C Compressor Regulator Valve -N280-.
NOTE: Under unfavorable conditions (very high ambient temperatures, high humidity),
pressure on high-pressure side may increase to max. 29 bar.
The control current -B- is shown in the measured value block.
The high pressure measured from the High Pressure Sensor -G65- is not shown
in the measured value block. Refer to [For engine(s) BPY,BLV,CCTA,CBFA]
Diagnosis and Testing .
Low pressure settles as a function of control current for A/C compressor

regulator valve -N280- within compressor output range in tolerance range.
Under unfavorable conditions (very high ambient temperatures, high humidity),

compressor output may not always be sufficient to attain the specified value.
The specified operating current for the regulator valve must be greater than 0.3
A in order to ensure reliable valve activation.
In the setting "maximum cooling output" control current is regulated to

approximately 0.65 A up to 0.85 A (vehicle specific, displayed in measured value
block). Refer to [For engine(s) BPY,BLV,CCTA,CBFA] Diagnosis and Testing .

pressure corresponds to 1 bar absolute pressure. 0 pressure corresponds to an
absolute pressure of one bar on most pressure gauges (indicated by -1 bar
below 0).

 High pressure remains constant  Activation of A/C -- Check activation of A/C
or increases only slightly Compressor Regulator Compressor Regulator Valve -N280-.
(above pressure with engine Valve -N280- is -- Localize leak with leak detector
stopped). faulty. and eliminate -- Charge the
refrigerant circuit
 Low pressure quickly drops to  Not enough refrigerant
value in graph or below. in refrigerant circuit
attained
 High pressure normal.
 Low pressure in line with
value in graph.
attained
 High pressure normal.  Not enough refrigerant -- Extract refrigerant from refrigerant
 Low pressure too low (see Fig. in refrigerant circuit circuit
60).
 Required cooling output is not extracted is substantially less
attained than specified capacity.
-- Localize leak with leak detector

and eliminate. -- Charge the
refrigerant circuit -- Repeat test
 Expansion valve -- Replace expansion valve -- Charge
faulty the refrigerant circuit -- Repeat test
REFRIGERANT R134A. If that is not possible in this workshop, flush the
Refer to REFRIGERANT CIRCUIT, FLUSHING WITH COMPRESSED AIR AND
NITROGEN.
Check measured values from Evaporator Vent Temperature Sensor -G263- or

Evaporator Temperature Sensor -G308- and activation of A/C Compressor
Regulator Valve -N280-. If the measured value of the High Pressure Sensor -
G65- is faulty, the evaporator can ice up or the cooling output is not reached.
If the function of the air conditioning system is not OK when the test is repeated
after replacing expansion valve, re-install old expansion valve and flush
refrigerant circuit with compressed air and nitrogen. Then replace A/C
compressor and reservoir.

circuit is OK.
If expansion valve is malfunctioning (permanently closed or does not open

sufficiently), A/C compressor regulator valve -N280- is actuated to maximum
output and low pressure drops to value in graph or below (compressor draws
off refrigerant from low-pressure side). Because refrigerant cannot flow through
the expansion valve, the correct cooling output cannot be reached. The high
pressure may not increase or may only increase slightly.

 High pressure only increases  Activation of A/C -- Check activation of A/C
slightly above pressure with Compressor Compressor Regulator Valve -N280-.
engine stopped. Regulator Valve -
 Low pressure drops only N280- is faulty.
slightly.
attained
 A/C compressor -- Extract refrigerant circuit. -- Flush
faulty. (clean) refrigerant circuit. Refer to
REFRIGERANT CIRCUIT,
FLUSHING WITH
REFRIGERANT R134A. -- Replace
A/C compressor. -- Charge the
refrigerant circuit
 High pressure increases above  Activation of A/C -- Check activation of A/C
specification. Compressor Compressor Regulator Valve -N280-.
 Low pressure quickly drops to Regulator Valve -
value in graph or below. N280- is faulty.
attained
 Constriction or -- Run hand over refrigerant circuit to
obstruction in check for differences in temperature
refrigerant circuit

constricted. -- In the event of an
with compressed air and nitrogen. --
Repeat test
 If no malfunction can be found:

REFRIGERANT R134A. -- Charge
the refrigerant circuit. -- Repeat test if
function is not OK.
 Expansion valve -- Extract refrigerant circuit. --
Replace expansion valve and receiver.
malfunctioning -- Charge the refrigerant circuit
NOTE: With this malfunction, evaporator may ice up although quantity of refrigerant in
circuit is OK.


 High and low pressure normal  Activation of A/C -- Check activation of A/C
at first, after some time high Compressor Compressor Regulator Valve -N280-.
pressure increases above Regulator Valve -
specification. N280- is faulty.
 After some time, low pressure
decreases to graph value or
lower.
 Required cooling output is no
longer attained.
 High pressure and lower  Moisture in -- Extract refrigerant circuit. --
pressure normal first, after a refrigerant circuit Refrigerant Circuit, Flushing with
long period of driving, the low Compressed Air and Nitrogen. --
pressure falls below the Replace reservoir with dryer. --
specified value (evaporator iced Evacuate refrigerant circuit for at least
up). 3 hours. -- Charge the refrigerant
circuit -- Repeat test, if function is not
OK. -- Flush (clean) refrigerant
circuit. Refer to REFRIGERANT
the refrigerant circuit. -- Repeat test
NOTE: If this complaint occurs after a long operating time or only sporadically (the low
pressure falls under the specified value and the evaporator ices up), replacing
the dryer (installed in the reservoir) is sufficient. The quantity of refrigerant oil
should be adjusted. Refrigerant circuit is then to be evacuated for at least 3
hours.
First, it is not necessary to flush the refrigerant circuit with compressed air and
nitrogen in case of this complaint because generally only a small amount of
moisture is in the system and this can be removed by a long evacuation.

circuit is OK.

 High pressure normal, low  Activation of A/C -- Check activation of A/C
pressure too low (see Fig. 60), Compressor Regulator Compressor Regulator Valve -N280-.
the necessary cooling output is Valve -N280- is
not reached. faulty.
 Expansion valve -- Extract refrigerant circuit. -- Flush
malfunctioning (clean) refrigerant circuit. Refer to
FLUSHING WITH
expansion valve and receiver. --
Charge the refrigerant circuit. --
Repeat test if function is not OK. --
Replace A/C compressor.
 A/C compressor -- Extract refrigerant circuit. -- Flush
faulty. (clean) refrigerant circuit. Refer to
FLUSHING WITH
A/C compressor. -- Charge the
refrigerant circuit. -- Repeat test
NOTE: Note the following when the malfunction "high pressure normal, low pressure
too low" is detected: faulty, the evaporator can ice up or the cooling output will
not be reached.

circuit is OK.
Check measured values from Evaporator Vent Temperature Sensor -G263- or

Evaporator Temperature Sensor -G308- and activation of A/C Compressor
Regulator Valve -N280-. If the measured value of the High Pressure Sensor -
G65- is faulty, the evaporator can ice up or the cooling output is not reached.
If the problem is with the A/C Compressor Regulator Valve -N280- (regulating
valve is not actuated but compressor operates nevertheless), refrigerant circuit
does not have to be flushed. With this malfunction, replacing the A/C
compressor is sufficient (adjust refrigerant oil quantity in new A/C compressor).


 High pressure normal or too  Activation of A/C -- Check activation of A/C
high. Compressor Regulator Compressor Regulator Valve -N280-.
Valve -N280- is -- Extract refrigerant from refrigerant
 Low pressure too high (see circuit
Fig. 60). faulty.
 A/C compressor noise  To much refrigerant in
(particularly after switch-on). the circuit.
 Required cooling output is not to specified capacity:
attained
-- Replace A/C compressor.
greater than specified capacity:
-- Charge the refrigerant circuit. --

Repeat test
 To much refrigerant -- Discharge refrigerant circuit
oil in the circuit.

the refrigerant circuit. -- Repeat test
 Expansion valve -- Discharge refrigerant circuit. --
malfunctioning Replace expansion valve and
receiver. -- Charge the refrigerant
circuit. -- Repeat test if function is
not OK. -- Replace A/C compressor.
 A/C compressor -- Discharge refrigerant circuit. --
faulty. Flush (clean) refrigerant circuit. Refer
to REFRIGERANT CIRCUIT,
FLUSHING WITH

A/C compressor.
greater than specified capacity:
-- Charge the refrigerant circuit. --

Repeat test
NOTE: If the problem is with the A/C Compressor Regulator Valve -N280- (regulating
valve is not actuated but compressor operates nevertheless), refrigerant circuit
does not have to be flushed. With this malfunction, replacing the A/C
compressor is sufficient (adjust refrigerant oil quantity in new A/C compressor).
Overfilling with refrigerant oil can occur if, for example, the compressor has


 High and low pressure normal.  Activation of A/C -- Check activation of A/C
 Required cooling output is not Compressor Regulator Compressor Regulator Valve -N280-.
Valve -N280- is -- Flush (clean) refrigerant circuit.
attained Refer to REFRIGERANT
faulty.
 To much refrigerant REFRIGERANT R134A.
oil in the circuit.
 High and low pressure normal.  To much refrigerant -- Discharge refrigerant circuit. --
oil in the circuit. Flush (clean) refrigerant circuit.
 A/C compressor noise Refer to REFRIGERANT
(particularly after switch-on). CIRCUIT, FLUSHING WITH
 The required cooling REFRIGERANT R134A. -- Charge
performance is obtained the refrigerant circuit -- Repeat test
 Expansion valve -- Replace expansion valve
malfunctioning
NOTE: Overfilling with refrigerant oil can occur if, for example, the compressor has
refrigerant oil , 50 grams should be put in the A/C compressor and the rest in
the refrigerant circuit. See Maintenance, Diagnosis .
If expansion valve is malfunctioning (permanently open), evaporator

temperature is no longer regulated such that only refrigerant in gaseous state
exits from the evaporator. Under certain usage conditions, liquid droplets may
then be drawn in by the compressor and cause noise (liquid cannot be
compressed).
WITH EXPANSION VALVE, FLUID CONTAINER AND E-COMPRESSOR FOR HYBRID VEHICLES
NOTE: The E-compressor does not have an A/C compressor regulator valve -N280-.
The E-compressor RPM does the regulating. The E-compressor has the control
electronics and G-charger, that moves the refrigerant.
A pressure check is possible only with Vehicle diagnostic tester.
COMPRESSOR, FLUSHING NOT REQUIRED
-- Discharge refrigerant circuit.
-- Remove A/C compressor.
-- Remove oil drain plug from A/C compressor.
-- To accelerate drainage of refrigerant oil, rotate compressor, for example, by way of ribbed belt pulley/clutch
plate of A/C clutch for example.
-- Pour old refrigerant oil out of A/C compressor. For information on handling refrigerant oil, refer to
Volkswagen Service Net, Handbooks, Service Handbook; Protecting the environment; Emissions Protection.
-- Remove oil drain plug from original part compressor, pour out refrigerant oil and only add a quantity of fresh
refrigerant oil equal to the amount poured out of the malfunctioning compressor.
NOTE: If, for example, 70 cm3 of refrigerant oil has been poured out of the
malfunctioning compressor and 220 cm3 out of the original part compressor (a
small quantity of refrigerant oil remains in the compressor). Fill the compressor
to be installed with 70 cm 3 of refrigerant oil (use can be made of oil poured out
of original part compressor).
Use different refrigerant oils and quantities for the various compressors. Refer
to Maintenance, Diagnosis .
If a greater quantity of refrigerant oil (more than approximately 80 cm3 ) has

been poured out of the malfunctioning compressor, the remaining refrigerant oil
can also be added to the evaporator or reservoir/receiver. Refer to [For engine
(s) BPY,BLV,CCTA,CBFA] Specifications .
-- Replace restrictor.
-- Assemble, evacuate and charge refrigerant circuit.
COMPRESSOR, REPLACING
-- Discharge refrigerant circuit
NOTE: In the case of internal damage (on A/C compressor), flush refrigerant circuit
REFRIGERANT R134A.
-- Replace fluid reservoir/dryer cartridge and expansion valve or reservoir and restrictor.
-- If a leak is present, check the expansion valve for debris or corrosion and replace if necessary.
FLUID RESERVOIR OR RESERVOIR AND RESTRICTOR, WITH CONTAMINANTS REMOVED FROM

REFRIGERANT CIRCUIT
The reservoir/fluid reservoir or dryer bag/cartridge should not be replaced under the following conditions.
 After an accident when there is no damage on the reservoir/fluid reservoir.

 The repair was done quickly (not beyond the normal repair time) and no moisture has entered. The
vehicle is not older than 5 years.
The reservoir/fluid reservoir or dryer cartridge should be replaced under the following conditions.
 The refrigerant circuit was opened and the vehicle is older than 5 years.
 The refrigerant circuit has been opened for an indefinite period of time (slow leak).
 The repair exceeded the normal repair time and moisture has entered.
 Always replace the reservoir or dryer cartridge after flushing with compressed air, nitrogen or refrigerant
R134a. Leave original parts in their packaging as long as possible to minimize the amount of moisture
they absorb.
 The A/C compressor has locked up.
 The reservoir/fluid reservoir is damaged (accident).
-- Discharge refrigerant circuit
-- Rectify cause of trouble.
-- Examine expansion valve for dirt or corrosion; replace if necessary
-- To accelerate drainage of refrigerant oil, rotate compressor, for example, by way of ribbed belt pulley/clutch
plate of A/C clutch for example.
-- Pour old refrigerant oil out of A/C compressor. For information on handling refrigerant oil, refer to
Volkswagen Service Net, Handbooks, Service Handbook; Protecting the environment; Emissions Protection.
-- Then fill compressor with quantity of fresh refrigerant oil corresponding to quantity of refrigerant oil in
original part compressor. Refer to [For engine(s) BPY,BLV,CCTA,CBFA] Specifications .
NOTE: Which refrigerant oils and quantities are used for the various compressors.
Refer to [For engine(s) BPY,BLV,CCTA,CBFA] Specifications .
To ensure compressor lubrication on start-up, at least 80 cm3 of refrigerant oil

must be poured into the compressor, the remainder can be added for example
to the new reservoir or receiver. Refer to [For engine(s) BPY,BLV,CCTA,CBFA]
Specifications .
If dirt has penetrated into the compressor with the refrigerant circuit open (for
example, after an accident), compressor is to be replaced.
-- Replace receiver or accumulator and restrictor.
LEAKING OR DAMAGED COMPONENTS EXCEPT A/C COMPRESSOR, ACCUMULATOR OR RECEIVER
Empty Refrigerant Circuit

-- Remove malfunctioning component.
NOTE: To speed up refrigerant oil drainage, turn A/C compressor by hand via ribbed
belt or magnetic clutch plate.
Pour the used refrigerator oil out of the A/C compressor. For information on
handling refrigerant oil, refer to Volkswagen Service Net, Handbooks, Service
Handbook; Protecting the Environment, Emissions Protection.
Then fill compressor with quantity of fresh refrigerant oil corresponding to

quantity of refrigerant oil in original part compressor. Refer to [For engine(s)
BPY,BLV,CCTA,CBFA] Specifications .
Use different refrigerant oils and quantities for the various compressors. Refer
to [For engine(s) BPY,BLV,CCTA,CBFA] Specifications .
To ensure compressor lubrication on start-up, at least 80 cm3 of refrigerant oil

must be poured into the compressor, the remainder can be added for example
to the new reservoir or receiver. Refer to [For engine(s) BPY,BLV,CCTA,CBFA]
Specifications .
If dirt has penetrated into the compressor with the refrigerant circuit open (for
example, after an accident), compressor is to be replaced.
Flush the refrigerant circuit with compressed air and remove moisture with
nitrogen. Refer to REFRIGERANT CIRCUIT, FLUSHING WITH COMPRESSED AIR
AND NITROGEN.
-- Replace receiver or accumulator and restrictor.
-- Assemble, evacuate and recharge refrigerant circuit.
No Refrigerant in Circuit
-- Remove malfunctioning component, flush with compressed air, collect escaping refrigerant oil.
-- The new component is to be filled with the amount of refrigerant oil flushed out (plus 20 cm3 for evaporator,
plus 10 cm3 for condenser, refrigerant pipes and refrigerant hoses) as fresh refrigerant oil fill.
REPLACING RESERVOIR, NO CONTAMINANTS, NO LOSS OF REFRIGERANT
-- Remove receiver or accumulator.
-- Remove dirt from receiver or reservoir.
-- Weigh receiver or reservoir removed.
NOTE: Add refrigerant oil to the reservoir until it is the same weight as the reservoir
that was removed.
Install new receiver or reservoir.
SPECIAL TOOLS
COMMERCIALLY AVAILABLE TOOLS AND MATERIALS
NOTE: This list outlines the testers, tools and materials required for expert refrigerant
circuit repair work.
Overview Refer to
A/C service station -ROB 134APF-, other A/C A/C Service Station -ROB 134APF- (and other
service stations . A/C service stations)
Leak Detector -V.A.G 1796- Leak Detector -V.A.G 1796-
Leak Detection System -VAS 6196- Leak Detection System -VAS 6196-
Leak Detection Additive -VAS 6196/1- Not illustrated
Leak Detection System -VAS 6201- Leak Detection System -VAS 6201-
Service station with flushing equipment -ROB Not illustrated
134APF- or Service station with flushing equipment
-VAS 6337/1A-.
 With installed program to flush refrigerant

circuit with refrigerant R134a.
Refrigerant Circuit Flushing Device -VAS 6337/1- Refrigerant Circuit Flushing Device -VAS
(flushing devices that can currently be delivered . 6337/1- made by Behr or succeeding model
 For flushing refrigerant circuit with refrigerant

R134a. To be used also with older A/C service
stations (flushing procedure must then be
performed manually) with a reservoir volume
of at least 10 kg of refrigerant R134a.
Refrigerant Circuit Flushing Device -VAS 6336/1- Refrigerant Circuit Flushing Device -VAS
(flushing devices that can currently be delivered . 6336/1- made by Waeco or succeeding model
 For flushing refrigerant circuit with refrigerant

R134a. To be used also with older A/C service
stations (flushing procedure must then be
performed manually) with a reservoir volume
of at least 10 kg of refrigerant R134a.
VW/Audi passenger vehicle set adapter chest - Not illustrated
VAS6338/1- for refrigerant circuits with refrigerant
R134a.
 For connecting the A/C service station to the

refrigerant circuit and bridging certain
components when flushing with refrigerant
R134 or compressed air and nitrogen.
Commercial vehicle set adapter chest -VAS6338/50- Not illustrated
for refrigerant circuits with refrigerant R134a.
 For connecting the A/C service station to the

refrigerant circuit and for bridging certain
components when flushing.
Ultrasound A/C Cleaner -VAS 6189A- Not illustrated
 For eliminating unpleasant odors caused by

A/C system.
Pressure-fed spray gun -V.A.G 1538- Not illustrated
 Spray nozzle -VAG 1538/5- (short)

 Spray nozzle -VAG 1538/6- (long)
 Spray nozzle -VAG 1538/7- (700 mm,
commercial vehicle)
 Cleaning solution -D 600 100 A1-
 Cleaning solution for evaporator -D 600 100
A2-
 To remove unpleasant odors from the

evaporator
Release Tools -VAS 6127- case The Release tools -VAS 6127- case consists of the
Release tool -VAS 6127/1-, Release tool -VAS
 For opening refrigerant pipes. 6127/2- and Release tool -VAS 6127/3-.
Release Tools -VAS 6127/1-3- Release tool -VAS 6127/1- Release tool -VAS
6127/2-
 For opening refrigerant pipes.
Counterhold -V.A.G 1616- Counterhold -V.A.G 1616- for clutch plate (for
Sanden A/C compressors)
 For clutch plate (A/C compressor
manufactured by Sanden).
Puller -V.A.G 1616/1- for A/C clutch (Sanden Puller -V.A.G 1616/1- (for Sanden A/C
compressors). compressors)
A/C clutch set -V.A.G 1719- (Zexel compressors). A/C Clutch Set -V.A.G 1719- (for Zexel A/C
compressors)
Adapter set for refrigerant circuit -V.A.G 1785/1-10- Adapter Set -V.A.G 1785/1-10-
R134a.
Combined fine filter unit for compressed-air system Not illustrated
(oil, dirt and water separator as used for painting
facilities).
O-ring seals. Not illustrated
Refrigerant oil. Not illustrated
Socket -T10364- for high pressure/low pressure side Socket -T10364- for the high pressure/low
service connection valves on refrigerant circuit. pressure side service connection valves in the
refrigerant circuit
Overview Refer to
Fin comb Fin Comb
Charging hoses 5/8" - 18 UNF with valve opener. Charging Hoses
Connection piece for refrigerant cylinder and seal Connection Piece For Refrigerant Cylinder and
with quick-release coupling connection or threaded Seal With Quick-Release Coupling Connection
connection 5/8" - 18 UNF. Or Threaded Connection 5/8" - 18 UNF
Valve caps 5/8"-18 UNF. Valve Caps With Spare Seals (for 5/8"-18 UNF
thread)
Pressure gauge set with pressure reducer for Pressure Gauge Set With Pressure Reducer For
nitrogen. Nitrogen (Maximum Reducing Pressure: 15 bar)
Quick-release coupling adapter for service Quick-Release Coupling Adapter For Service
connections, 2x included in scope of delivery of Connections
service station.
Open end wrench, size according to bolted joints at Not illustrated
refrigerant pipes.
Valve opener for charging hoses. Not illustrated

Connecting nipple for conical seal 5/8"-18 UNF. Not illustrated
Compressed-air gun with rubber mouthpiece. Not illustrated
Hand shut-off valve 5/8"-18 UNF. Not illustrated
Recycling container for refrigerant R134a. Not illustrated
Digital thermometer Not illustrated
Protective gloves Not illustrated
Protective glasses Not illustrated
Refrigerant R134a with cylinder (capacity as Not illustrated
required).
Nitrogen with compressed gas cylinder. Not illustrated
Band wrench (oil filter) as counterhold for ribbed Not illustrated
belt pulley.
A/C Service Station -ROB 134APF- (and other A/C service stations)
 Procedure: the operations "testing, extraction (recycling), evacuation and charging" are to be performed in
line with the relevant operating instructions.
 The filters and dryers installed are to be replaced at the latest at the end of the period of use specified in
the operating instructions and whenever the station has been drained (keep replacement filter to hand.
Available from equipment manufacturer, refer to operating instructions).
 Other A/C service stations or flushing equipment that is approved by VW but not illustrated here may
also be used.
NOTE: This A/C service station has the following known units: charging cylinder,
pressure gauge set, vacuum pump, shutoff valves and charging hoses.
One quick-release coupling each (for service connections on high and low-
pressure side) is included in the scope of delivery of this service station.
Refrigerant Circuit Flushing Device -VAS 6337/1- made by Behr or succeeding model
Fig. 61: Identifying Refrigerant Circuit Flushing Device VAS 6337/1 (Behr)
NOTE: With a filter -1- and two large cylindrical viewing glasses.
degree of contamination in the flushed refrigerant circuit, it should be changed
after 2 flushing cycles at the latest. If a heavily contaminated refrigerant circuit
flushing.
Refrigerant Circuit Flushing Device -VAS 6336/1- made by Waeco or succeeding model
Fig. 62: Identifying Filter For Refrigerant Circuit Flushing Device VAS 6336/1 (Waeco)
NOTE: With a filter -1- and one viewing glass.
degree of contamination in the flushed refrigerant circuit, it should be changed
after 2 flushing cycles at the latest. If a heavily contaminated refrigerant circuit
flushing.
Leak Detector -V.A.G 1796-

Fig. 63: Identifying A/C Refrigerant System, Checking For Leaks

Leak Detection System -VAS 6196-
Fig. 64: Identifying Leak Detection System (VAS 6196)

Leak Detection System -VAS 6201-
Fig. 65: Identifying Leak Detection System VAS 6201

1. Hand pump with low-pressure service hose, service coupling and non-return valve -VAS 6201/1-
2. Cartridge -VAS 6201/2-
3. Cleaning agent -VAS 6201/3-
4. UV leak detection lamp -VAS 6201/4-
5. UV-absorbing safety goggles -VAS 6201/6-
6. Sticker -VAS 6201/7-
7. Filler tube VAS 6201/8
8. Protective gloves -VAS 6201/9-
Release tools -VAS 6127- case consists of Release tools: -VAS 6127/1-, -VAS 6127/2- and -VAS 6127/3-.
Fig. 66: Identifying Release Tools VAS 6127 (1/2/3/4)

Release tools -VAS 6127/1- and -VAS 6127/2-
Fig. 67: Identifying Release Tool - VAS 6127/1 or VAS 6127/2

 Blue 1/2 inch

 Black 5/8 inch
 Red 3/8 inch
 White 3/4 inch
Fig. 68: Identifying Release Tool - VAS 6127/3

 Green NW 8 for the high pressure line

 Black NW 13 for the low pressure line
Counterhold -V.A.G 1616- for clutch plate (for Sanden A/C compressors)
Fig. 69: Identifying Counterhold V.A.G 1616 For Clutch Plate (For "Sanden" A/C Compressors)
Puller -V.A.G 1616/1- (for Sanden A/C compressors)

Fig. 70: Identifying Puller V.A.G 1616/1 (For "Sanden" A/C Compressors)
A/C Clutch Set -V.A.G 1719- (for Zexel A/C compressors)

Fig. 71: Identifying A/C Clutch Set V.A.G 1719 (For "Zexel" A/C Compressors)
Adapter Set -V.A.G 1785/1-10-

Fig. 72: Identifying Adapter Set V.A.G 1785/1-10

 Adapter for cleaning refrigerant circuit (flush with refrigerant R134a. Refer to REFRIGERANT
CIRCUIT, FLUSHING WITH REFRIGERANT R134A or blow through with compressed air and
nitrogen, refer to REFRIGERANT CIRCUIT, FLUSHING WITH COMPRESSED AIR AND
NITROGEN.
A - 5/8" 18 UNF thread for conical seal
B - Union nut (for connection with O-ring) with thread
 M 18x1.5 -V.A.G 1785/1-

 M 20x1.5 -V.A.G 1785/2-
 M 24x1.5 -V.A.G 1785/3-
 M 28x1.5 -V.A.G 1785/4-
A - 5/8"-18 UNF thread for conical seal
B - Threaded connection for O-ring
 M 18x1.5 -V.A.G 1785/5-

 M 20x1.5 -V.A.G 1785/6-

 M 24x1.5 -V.A.G 1785/7-
 M 28x1.5 -V.A.G 1785/8-
Fig. 73: Identifying M 28X1.5 V.A.G 1785/8

Valve Adapter
Fig. 74: Identifying Valve Adapter

A - 5/8"-18 UNF thread for conical seal
B - Internal threads with valve opener M 10x1.25 -VAG 1785/9- (for connections with valve on high pressure
side) M 12x1.5 -VAG 1785/10- (for connections on low pressure side)
NOTE: A Schrader valve is screwed into connection -A-.
A valve opener must be installed in the charging hose connection.
Socket -T10364- for high pressure/low pressure side service connection valves in refrigerant circuit
Fig. 75: Identifying Adapter Set For Evacuating And Charging Valves
Fin Comb
Fig. 76: Identifying Fin Comb

Charging Hoses
Fig. 77: Identifying Charging Hoses

5/8"-18 UNF thread
NOTE: Use differently colored charging hoses (1800 mm long).
Have valve opener and spare seals to hand.
Connection Piece For Refrigerant Cylinder and Seal With Quick-Release Coupling Connection Or Threaded Connection 5/8" -
18 UNF
Fig. 78: Identifying Connection Piece For Refrigerant Cylinder With Seal
Valve Caps With Spare Seals (for 5/8"-18 UNF thread)

Fig. 79: Identifying Valve Caps With Spare Seal

Seals can also be used for charging hoses.
Pressure Gauge Set With Pressure Reducer For Nitrogen (Maximum Reducing Pressure: 15 bar)
Fig. 80: Identifying Pressure Gauge Set With Pressure Reducer For Nitrogen (Maximum Reducing
Pressure: 15 bar)
1. Manometer battery with pressure reducer

2. Pressure hose (inner diameter 5 mm, length 2 m) with hose fittings
3. Nitrogen cylinder
4. Hose fitting
NOTE: Hose fittings for connecting on Adapter Set -V.A.G 1785- with threads 5/8" 18
UNF for service connection quick-release coupling adapter to refrigerant circuit.
Quick-Release Coupling Adapter For Service Connections
Fig. 81: Identifying Quick-release Coupling Adapter For Service Connections

 High-pressure side, nominal size 16 mm

 Low-pressure side, nominal size 13 mm
NOTE: This quick-release couplings are delivered with the service station.
IMPROVISED TOOLS
Overview Refer to
Charging hose with connection for workshop Charging hose with connection for workshop
compressed-air system compressed-air system
Charging hose with connection for workshop compressed-air system
Fig. 82: Identifying Improvised Tool

A - Charging hose 5/8" - 18 UNF** (version with large inner diameter)
B - Compressed air system connection** (operate only with filter and dryer for compressed air)
** Commercially available tools and materials.

Suspension General, Technical Data
Suspension

GENERAL INFORMATION
EVALUATING SUSPENSION OF VEHICLES INVOLVED IN ACCIDENTS
When servicing load-bearing or wheel-supporting components on accident vehicles, damages on suspension

could remain undiscovered. These undiscovered damages may lead to heavy damages in continued vehicle
operation. Therefore, on accident vehicles, the listed components must be checked in the described manner and
sequence, independent of performing a vehicle alignment. If no deviations from specified values were
determined during vehicle alignment, no deformations of the suspension are present.
Visual and Function Check of Steering System
 Visual check for deformations and cracks.

 Check for play in tie rod joints and steering gear.
 Visual inspection for faulty bellows and grease boots.
 Check electric and hydraulic lines and hoses for chafe marks, cuts and kinks.
 Check hydraulic lines, bolted connections and steering gear for leaks.
 Check steering gear and lines for proper seating.
 Check proper function through entire steering angle by turning steering wheel from stop to stop. Steering
wheel must be rotary without hitching at equal force.
Visual and Function Check of Suspension
 Observe the sequence of the following test steps:
 Check all components shown in assembly overviews for deformation, cracks and other damages.
 Replace damaged components.
 Perform vehicle alignment on wheel alignment stand approved by VOLKSWAGEN AG.
Visual and Function Check for Wheels and Tires
 Run-out and balance, checking, refer to WHEELS AND TIRES, RADIAL LATERAL RUN-OUT .
 Tires, checking for cuts and impact damage on tread and flanks, refer to TIRE DAMAGE .
 Check tire inflation pressure; inflation pressure see inflation pressure plate in tank flap.
For damage on disc wheel and/or tire, tire must be replaced. This also applies when the course of the accident
and damage on the vehicle points to possible non-visible damages.
Suspension General, Technical Data
Another determining factor is the age of the tires: Tires should not be older than 6 years.
In case of doubt, always proceed as follows:
 As soon as a safety risk cannot be ruled out, the tire(s) must be replaced.
Entire Vehicle
Also check other vehicle systems as, for example:
 Brake system including ABS.

 Exhaust system and passenger protection by visual and function check.
Test values, adjustment values and notes can be found in respective repair information for ELSA.
Checking of accident vehicles described here, refers to suspension and does not lay claim to completeness for
entire vehicle.
Electronic Vehicle Systems
Safety-related system such as: ABS/EDL, airbag, electronically regulated vehicle systems, electromechanical,
electrohydraulic steering and other driver assistance systems must be queried for fault codes that could possibly
be stored, using the Vehicle Diagnostic Tester. If faults were stored in the DTC memory for the system
mentioned, then these systems must be serviced according to the specifications in the repair information for
ELSA. After performing repairs, check the fault stored in the DTC memory of the affected system again, to
make sure that proper function can be ensured again.
WHEELS AND TIRES
Information on wheels, tires and snow chains can be found in the DESCRIPTION AND OPERATION .
TRANSMISSION General, Technical Data - Transmission 09M & 09MA
TRANSMISSION
General, Technical Data - Transmission 09M & 09MA

GENERAL INFORMATION
GENERAL REPAIR INFORMATION
Transmission
The 6 speed 09M automatic transmission has 6 hydraulically controlled forward gears. By passing the torque
converter slip, 2nd, 3rd, 4th, 5th and 6th gears become mechanically driven gears if the lockup clutch is closed.
Torque Converter
The torque converter is equipped with a slip controlled torque converter lockup clutch. The lockup clutch closes
depending on load and speed. The 2nd, 3rd, 4th, 5th and 6th gears can be mechanically driven (without slip).
SPECIAL TOOLS
A list of special tools and workshop equipment used in the repair information can be found at the beginning of
each repair procedure and at the end of each repair group.
Often times there are questions when a fastener has a low tightening specification. Use torque wrench -V.A.G
1783- to tighten these fasteners.
TRANSMISSION
 Do not run the engine and do not tow the vehicle if the transmission pan is removed or if there is no
transmission fluid inside the transmission.
 Always clean the connection points and the area around them first, and then loosen the fasteners.
 When installing the transmission, make sure the alignment sleeves are correctly installed between the
engine and transmission.
 Place removed parts on a clean surface and cover them so that they do not get dirty. Use foil, paper or a
lint free cloth.
 Only install clean components: Remove the replacement parts from their packaging just prior to installing
them.
 Carefully cover or seal unpacked components, if repairs cannot be performed immediately.
 With the transmission removed, secure the torque converter so that it cannot fall out.
Transmission, With and Without a Filling Tube

Fig. 1: Identifying Filler Tube As It Is Installed In Older Transmissions

Here is an example of a filler tube -arrow- as it was installed in older transmissions. This tube has been
removed.
You also do not need the old filler hole with the red cap because the transmission fluid is drained and filled at
the lower hole when necessary. The height of the overflow tube corresponds to the height of the fluid level.
Fig. 2: Identifying ATF Level And Temperature

To drain the fluid, the overflow tube is removed.

 After installing, check the fluid level and fill. Refer to TRANSMISSION FLUID LEVEL,
 Capacities, refer to the Fluid Capacity Tables .
AUTOMATIC TRANSMISSION FLUID
CAUTION: Be cautious when dealing with transmission fluid. Dispose of the drained
fluid properly. Bear in mind that: One drop can contaminate 1000 liters of
drinking water.
Transmission fluid does not just "lubricate" the transmission.
Imagine: The fluid also transports the finest differential abrasive particles in the filter, ensures the lubricating
film does not wear off the differential tooth flanks and at the same time, it acts as a switch valve pressure
medium to enable it to perform its functions.
It also seals the selector lever and helps clutch friction lamellae (plate) when shifting gears. It conserves and
transports warmth, minimizes noise - transmission fluid has many tasks. And it does not matter if all of this
takes place in the heat of the equator or in the cold of earth's arctic poles. Transmission fluid meets some very
high demands.
Transmission Fluid Troubleshooting Check
You have already read what transmission fluid can do. Now for something it cannot do: >>Disappear without a
trace.<<
Transmission fluid can only be missing if it has leaked from the transmission.
-- on where it has escaped from the transmission. Repair this leak first.
Transmission fluid is a permanent fill. As far as Maintenance is concerned, the transmission does not need to be
replaced.
The transmission fluid level inside the planetary gear and inside the final drive are checked and filled at the
same time. Refer to TRANSMISSION FLUID LEVEL, CHECKING AND FILLING .
Do not mix any additives with the transmission fluid, do not add other transmission fluid types.
Drained transmission fluid must not be reused again.
TRANSMISSION CONTROL MODULE WITH FUZZY LOGIC
Determining the driving situation and the driving resistance dependent shift points occurs automatically.
Advantages:
 It is shifted depending on consumption

 Maximum engine output is always available
 Individual adaptation of shift points in all driving situations
 Gear shift points are infinitely variable
CONTROL MODULES
The installed locations of all vehicle control modules and other useful information can also be found in
appropriate Wiring Diagram.
O-RINGS, GASKETS AND SEALS
 Always replace the O-rings, gaskets and seals.

 Fill the space between the sealing lips halfway with sealing grease for seal -G 052 128 A1- before
installing the radial shaft seal.
Fig. 3: Identifying Oil Seals Sealing Lips

 The open side of the seal faces the oil.

 Check the transmission fluid level after installing.
CAUTION: Be cautious when dealing with transmission fluid. Dispose of the drained
fluid properly. Bear in mind that: One drop of transmission fluid can
contaminate 1000 liters of drinking water.
BOLTS AND NUTS

Fig. 4: Identifying Nut And Bolt

 Tighten and loosen the bolts and nuts for securing covers and housings in a diagonal sequence.
 The tightening specifications stated apply to non-lubricated nuts and bolts.
 Use a wire brush to clean the threads of bolts that were installed using locking fluid. Install the bolts using
liquid locking fluid -AMV 185 100 A1-.
 Clean all threaded holes with a thread tap to remove any locking fluid residue. Otherwise the bolts could
shear the next time they are removed.
 Always replace self-locking nuts and bolts.
ELECTRICAL COMPONENTS
You have probably received a electrical shock at one time, when touching a metal item. The reason behind this
is the electrostatic charge to the human body. This charge can damage the electrical components on the
transmission and the selector mechanism.
-- Touch a grounded object, such as, a water pipe or the vehicle hoist, before working on electrical components.
Do not touch the connectors directly.
GUIDED FAULT FINDING, ON BOARD DIAGNOSTIC AND TEST INSTRUMENTS
Determine the cause of the damage using "Guided Fault Finding" before beginning any service work on the
automatic transmission.
Perform Guided Fault Finding using the vehicle diagnostic tester. Refer to VEHICLE DIAGNOSIS
TESTER, CONNECTING AND SELECTING FUNCTIONS .
Guided Functions finds the transmission fluid temperature quickly. Refer to VEHICLE DIAGNOSIS
TRANSMISSION IDENTIFICATION
Transmission code letters and date of manufacture -arrow-
Fig. 5: Identifying Location Of Transmission Codes

Example:
Identification is on an 09G transmission
Code letter -arrow 1-

Fig. 6: Identifying Code Letters, 6-Speed Automatic Transmission 09G

Automatic transmission 09G - 6-speed -arrow 2-
GGZ 06 05 02
I I I I
Identification codes Day Month Production year -2002-
The transmission code letters are also included on the vehicle data label.
BEVEL BOX IDENTIFICATION
The identification -arrow- is located under the output flange.

Fig. 7: Identifying Bevel Box Identification

Example:
-Arrow A- bevel box part number
Fig. 8: Identifying Bevel Box Part Number And Code Letters

-Arrow B- bevel box code letters
-Arrow C- bevel box "0AU"

 If you do not have the code letters, use the part number for the allocation.
Additional data depends on the manufacturing.
SPECIFICATIONS
Passat
Passat CC and CC
Tiguan
CAPACITIES
The planetary transmission and final drive are checked and filled together. Refer to TRANSMISSION FLUID
LEVEL, CHECKING AND FILLING .
Capacities Planetary Gear Set and Final Drive

Initial filling Refer to the Fluid Capacity Tables
Change Permanent fill no change
Lubricant Transmission fluid is available as a replacement part.
CAPACITIES
The planetary transmission and final drive are checked and filled together. Refer to TRANSMISSION FLUID
LEVEL, CHECKING AND FILLING .
Capacities Planetary Gear Set and Final Drive Front Bevel Box
Initial
Refer to the Fluid Capacity Tables Refer to the Fluid Capacity Tables
filling
Change Permanent fill, no change Permanent fill, no change
Transmission fluid is available as a replacement Gear oil is obtainable as a replacement
Lubricant
part. part.
ENGINE AND TRANSMISSION CODE ALLOCATION
6 Speed Automatic Transmission (09M)

Transmission codes HTY, JUP and KFE
Engine 3.6L - 206 kW
ENGINE AND TRANSMISSION CODE ALLOCATION
6 Speed Automatic Transmission (09M) Code Bevel Box Code Engine

HTY HVB and JKF
JUN KCE, KUJ, KQP, LGR and LGY

3.6L - 206 kW
KFD LGY
Engine General, Technical Data
Engine

GENERAL INFORMATION
Carefulness, cleanliness and the correct tools are required for transmission repairs to be successful. The usual
basic safety precautions also, naturally apply when carrying out vehicle repairs.
A number of generally applicable instructions for individual repair procedures, which are otherwise mentioned
at various points in this repair information, are summarized here. Refer to COMPONENTS.
OIL
NOTE: The final drive and Haldex clutch have separate oil circuits.
The final drive is filled with "gear oil" and the Haldex clutch with high performance gear oil for Haldex clutch -
052 175 A1-.
Oil for the "final drive" and "Haldex clutch" is available as a replacement part.
Do not mix additives into the oil.
Do not refill drained oil.
CAUTION: Be cautious when dealing with oil. Dispose of drained oil properly. Bear in
mind that: One drop of oil can contaminate 1000 liters of drinking water.
COMPONENTS
Rear Final Drive
 When replacing the rear final drive, check the Haldex clutch oil level and the gear oil level and fill if
necessary.
 Passat, refer to CODE LETTERS, TRANSMISSION ALLOCATION AND CAPACITIES.
 Clean the contact surfaces when installing the brackets as well as any waxed components. Contact
surfaces must be free of grease and wax.
Guided Fault Finding, OBD and Test Instruments
 Before servicing the Haldex clutch, the malfunction cause must be determined as closely as possible via
the vehicle diagnostic tester in the operating modes "Guided Fault Finding" , "vehicle self-diagnosis" and
"test instruments".
O-rings, Seals and Gaskets
 O-rings, seals, and gaskets must be replaced.

 Always clean separation surfaces.
Prior to installing:
 Before installing the seal, lightly oil the outer circumference and fill the space between the sealing lips -
arrow- halfway with sealing grease for seal -G 052 128 A1-.
Fig. 1: Identifying Oil Seals Sealing Lips

 Before installing the flange shaft/driveshaft seals, lightly lubricate the outer circumference and the space
between the sealing lips with high performance gear oil for Haldex clutch -052 175 A1-.
 The open side of the seal point toward the fluid to be sealed in.
After installing:
 Check the oil level in the rear final drive, add oil if necessary. Refer to one of the following:
Passat, refer to REAR FINAL DRIVE OIL LEVEL, CHECKING OR FILLING .
 Check the oil level in the Haldex clutch, add oil if necessary. Refer to one of the following:
Passat, refer to HALDEX CLUTCH OIL LEVEL, CHECKING OR FILLING .

Fasteners
 Do not overstretch the circlips.

 Always replace damaged or stretched circlips.
 The circlips must fit completely inside the groove.
 Replace the roll pins. Installed position: The slit -A- should be in line with the line of force -arrow-.
Fig. 2: Identifying Locking Elements

Bolts and Nuts
 Always loosen or tighten bolts and nuts for covers and housings diagonally.
 Parts which are particularly sensitive to distortion must be kept straight when removing and installing;
loosen or tighten diagonally and in stages.
 The tightening specification apply to non-lubricated nuts and bolts.
 Only wax all the contact surfaces on the threaded connection bolts and nuts after installing.
Bearings
 Install needle bearings with the lettered side (thicker metal) racing the installation tool.
 Insert all the bearings in the transmission using gear oil.
 Replace all the tapered roller bearings that are on the same shaft. Use tapered roller bearings from the
same manufacturer.
 Heat the inner races to approximately 100 °C (212 °F) before installing
 Do not interchange outer and inner bearing races with those from other bearing of the same size. The
bearings are paired.
Adjusting Shims
 Measure the adjusting shims at several locations with a micrometer caliper. Tolerance variations make it
possible to find the exact shim thickness required.
 Check for burrs and damage.
 Only install perfect shims.
ORIGINAL REPLACEMENT PARTS
NOTE: Only use original replacement parts. Always pay attention to the transmission
codes when ordering.
REAR FINAL DRIVE IDENTIFICATION
NOTE: The identification -arrow- on the bottom side of the final drive identifies which
final drive is installed.
Fig. 3: Identifying Identification Code On Bottom Of Final Drive (1 Of 2)

Example: identification on an 02D final drive
-Arrow A- final drive part number

-Arrow B- final drive code letters
-Arrow C- Final drive build date
Example:
HEZ 12 01 04
I I I I
I I I I
Code letters Day Month Production year -2004-
SPECIFICATIONS
CODE LETTERS, TRANSMISSION ALLOCATION AND CAPACITIES
Rear Final Dive - 01Z

(Generation II Haldex Clutch)
Transmission type 6 Speed Automatic Transmission 09M
Identification codes JUW, FQW, KJP and LGT
Engine 3.6L - 206 kW

Final drive capacity Refer to the Fluid Capacity Tables
Haldex clutch, initial fill capacity Refer to the Fluid Capacity Tables
Haldex clutch, refill capacity
Refer to the Fluid Capacity Tables
 Also, refer to Maintenance Intervals
Driveshaft flange diameter 100 mm
Accessories & Equipment Glass, Window Regulators
Glass, Window Regulators
64 GLASS, WINDOW REGULATORS

FLUSH BONDED WINDOWS
MATERIALS
 2K window
DA 004 600 A2 (1)2) 3)
adhesive
 1K window
DH 009 100 03 (1), (2), (3), (4), (5)
adhesive
 Glass
primer/paint D 009 200 02 (1)
primer
 Cleaning
D 009 401 04 (1)
solution
 Primer
D 009 500 25 (1)
applicator
 Adhesive
D 002 000 10 (1)
remover
 Cutting 357 853 999
cord
(1) Follow the manufacturer instructions supplied in the packaging.
(2) Note the minimum curing time. Refer to MINIMUM CURING TIME.
(3) The double cartridge gun VAS 5237 must be used with this material.
(4) Warm with the heater cartridge V.A.G 1939 according to manufacturer's instructions.
(5) Small 110 ml cartridge for sealing and/or when a 400 ml double cartridge is not enough.
WINDSHIELD SERVICING
NOTE: Before replacing windshield, see if it is possible to repair the glass.

Damaged windshields can be serviced using the Glass Repair Kit VAS 6092.
The damage cannot exceed a specific size and location.
The glass repair kit includes the how to use manual.
 Glass repair kit VAS 6092
Fig. 1: Glass Repair Kit VAS 6092

WINDSHIELD ASSEMBLY OVERVIEW

Fig. 2: Windshield, Assembly Overview

1. Windshield
 Remove the windshield. Refer to WINDSHIELD, REMOVING.
 Windshield, Installing, refer to WINDSHIELD, INSTALLING.
2. Window adjuster
 443.845.631 A

 Bead diameter: width = 7 mm, height = 11 mm (including pre-coating, residual material on window
glass and window flange)
 Minimum curing time, refer to MINIMUM CURING TIME.
4. Body flange
5. Retainer
 Is a part of the windshield
6. Electrical connections
 Kapton wire for windshield heater
7. Plenum Chamber Cover

 Must only be pulled out of binding profile by hand.
 Remove plenum chamber cover, refer to PLENUM CHAMBER COVER.
8. Drip rail
9. Height dimension
 From top surface of window to upper edge of roof
 Set a constant dimension of 2.5 mm using the adjustment gauge 3371
10. Gap dimension

 From window edge to roof edge
 Set a constant dimension of 2.5 mm using the adjustment gauge 3371

 Kapton wire for Ground (GND) connection
12. Communication window

 Only with tinted glass
 There is no infrared reflecting coating in this area, it serves to fulfill function of electronic
components installed as retail accessories.
PLENUM CHAMBER COVER ASSEMBLY OVERVIEW

Fig. 3: Plenum Chamber Cover - Assembly Overview

1. Right plenum chamber cover

 Removing, refer to PLENUM CHAMBER COVER
2. Molded foam part

3. Left plenum chamber cover
 Removing, refer to PLENUM CHAMBER COVER
4. Retainer
 Part of the windshield
5. Retaining clip
REAR WINDOW ASSEMBLY OVERVIEW, SEDAN
Fig. 4: Rear Window, Sedan - Assembly Overview

1. Rear window
 Rear Window, Removing, refer to UNDAMAGED REAR WINDOW, SEDAN
 Rear Window, Installing, refer to REAR WINDOW, SEDAN, INSTALLING
2. Seal
 For the rear lid
3. Body flange
Bead diameter: width = 6.5 mm, height = 10 mm (including pre-coating, residual material on
window glass and window flange)
 Minimum curing time, refer to MINIMUM CURING TIME
5. Gap dimension
 Set a constant dimension at the top and sides of 2.5 mm using the adjustment gauge 3371
6. Height dimension at top and sides

 Top, from top surface of window to upper edge of roof
 Top: set a constant dimension of 3 mm using adjustment gauge 3371
 Side, from window edge to upper edge of side panel
 Side: set a constant dimension of 6.5 mm using adjustment gauge 3371
7. Contact for window heater
REAR WINDOW ASSEMBLY OVERVIEW, WAGON

Fig. 5: Rear Window, Wagon - Assembly Overview

1. Rear window
 Rear Window, Removing, refer to UNDAMAGED REAR WINDOW, WAGON, REMOVING
 Rear Window, Installing, refer to REAR WINDOW, WAGON, INSTALLING
2. Rear lid
3. Spacer
 Bead diameter: width = 6.5 mm, height = 10 mm (including pre-coating, residual material on
 Minimum curing time, refer to MINIMUM CURING TIME
5. Contact for window heater

6. Side panel
SIDE WINDOW ASSEMBLY OVERVIEW, WAGON
Fig. 6: Side Window, Wagon - Assembly Overview

1. Side Window
 Remove side window, refer to UNDAMAGED WAGON SIDE WINDOW, REMOVING
 Installing side window, refer to WAGON SIDE WINDOW, INSTALLING

 Component part of side window.

3. Seal
4. Side panel
 Bead diameter: width = 6.5 mm, height = 10 mm (including pre-coating, residual material on
 Minimum curing time, refer to MINIMUM CURING TIME.
6. Retaining clip
7. Clips
 Connections for various Infotainment systems
UNDAMAGED WINDOW, PREPARING FOR GLAZING
WARNING: Do not prime the adhesive surface or use a cleaning solution on it. Keep
the adhesive surface free of dirt and grease.
Do not yet treat the cut adhesive surface with the activator.
NOTE: When re-using an undamaged window, cut back remaining adhesive sealant to
1 to 2 mm shortly before re-adhering, do not damage primer and ceramic
coating.
Fig. 7: Cutting Back Remaining Adhesive Sealant

The remaining material serves as a base for the new adhesive sealant being
applied.
D 009 500 25.
damage the paint.
PREPARING NEW WINDOW WITHOUT PRE-COATING FOR GLAZING
All windows as replacement parts are not pre-coated.

NOTE: The application area for adhesive bead 3 is not pre-coated and not primed.
-- Clean window circumference to width of 20 mm all around using cleaning solution D 009 401 04.
-- Then dry the edge of the window with a lint-free cloth.
WARNING: The ceramic coating on the glass is not a glass/paint primer. It must be
primed before the application of adhesive sealing material! Use only
glass/paint primer D 009 200 02.
-- Apply primer -2- uniformly in one stroke using applicator D 009 500 25 -1-.
Fig. 8: Applying Activator Uniformly In One Stroke Using Applicator D 009 500 25
 Drying time is approximately 10 minutes
WINDOW FLANGE, PREPARING FOR GLAZING
WARNING: Do not prime the adhesive surface or use a cleaning solution on it. Keep
the adhesive surface free of dirt and grease.
Do not yet treat the cut adhesive surface with the activator.
-- Cut back remaining material on body flange using U-shape knife V.A.G 1561/3, do not remove all residue
under any circumstances.
Fig. 9: Cutting Back Remaining Material On Body Flange Using Electric Cutter V.A.G 1561 A And
Scraper V.A.G 1561/8
NOTE: The remaining material serves as a base for the new adhesive sealant being
applied. Keep the adhesive surfaces free of dirt and grease.
 If the window flange is being repair or partially replaced, the corresponding area must be clean and
primed again before painting.
D 009 500 25.
damage the paint.

NOTE: It is possible that the laser weld seam does not lie in the area of the adhesive
bead. In this case, the open weld seam must be sealed with window adhesive
before bonding the window.
-- If the laser weld seam -3- on the sheet metal flange -4- is not covered by the adhesive bead -1- , coat the weld
seam -3- with glass/paint primer D 009 200 02 -3- and fill the weld seam with window adhesive DH 009 100 03
-1-.
Fig. 10: Identifying Laser Weld Seam, Sheet Metal Flange, Adhesive Bead , Weld Seam, Glass/Paint
Primer D 009 200 02 And Window Adhesive DH 009 100 03
INSTALLATION INFORMATION
General Installation Information for All Windows
-- Apply the adhesive all around circumference at a right angle to window.

Fig. 11: Applying Adhesive Material All Around Onto Pre-Coating

WARNING: The window must be installed within 10 minutes or the adhesive will not
bond well.
Do not apply the adhesive too thick and do not press on the window glass
too hard. Since the window glass no longer has sealing lips, it is possible
to see the adhesive inside the seam.
 With help of two Suction Cups (V.A.G 1344) install window in window opening, center and press in onto
the spacing lip.
 Re-affix any stickers (for example, for airbag).
Windshield Installation Instructions

Fig. 12: Whether Height Stops, Adhesive Bead, Applied Primer And Binding Profile
 Check whether height stops -1- are present.

 The windshield does not have markings for adhesive bead -2-. Placing of adhesive bead is between
dimensions -3 and 4- : on top window edge, from height stop -1- toward the inside. On side window edge,
from inside edge of applied primer -3- toward outside. Lower window edge, from binding profile -4-
toward inside.
 For the windshield gap and height dimensions, refer to WINDSHIELD ASSEMBLY OVERVIEW.
 Secure windshield using window adjuster (443 845 631 A) -5- during the minimum curing time.
 Always install the plenum chamber cover as described under, refer to PLENUM CHAMBER COVER
ASSEMBLY OVERVIEW.
Rear Window Installation Information
Fig. 13: Markings, Sealant And Height Stops

 Check whether height stops -3- are present.

 For the rear window gap and height dimensions, refer to REAR WINDOW ASSEMBLY OVERVIEW,
SEDAN.
 Activator must not be applied onto distributing wire for window heater.
 Markings -1- are made along circumference of rear window for applying the sealant -2-.
 Secure the rear window with tape during the curing time.
 If too much adhesive was applied and it spreads onto the window defroster, remove the excess.
MINIMUM CURING TIME
WARNING: Certain requirements must be maintained when replacing a bonded

window. For example, always allow the adhesive to harden for the
minimum curing time.
The minimum curing time for 2K adhesive DA 004 600 A2 is 3 hours for all windows.
Curing time means the time from when the window is bonded to when the vehicle is put back into use. During
this time, the vehicle must stand on an even surface at room temperature (at least 60°F (15°C)).
WARNING: The vehicle is operationally ready only after the minimum curing time has
elapsed.
FRONT DOOR WINDOW
FRONT DOOR WINDOW ASSEMBLY OVERVIEW
Fig. 14: Front Door Window Assembly Overview

1. Door window
 Removing and Installing, refer to FRONT DOOR WINDOW.
2. Window guide
 Inserted on flange.
 Removing and Installing, refer to WINDOW GUIDE.
 Version with and without trim molding.

 Placed into window guide.
4. Clip
 For securing trim molding in window guide.
5. Trim
 Removing, refer to TRIM PANEL
6. Bolt
 Quantity: 2
7. Spring nut
 Quantity: 2
8. Outer window recess seal

9. Intermediate piece
 Between door and trim panel.
10. Inner window recess seal

11. Bolt
 For door lock.
 Quantity: 2
12. Insulation
 Self-adhesive
 Between the inner door panel and the door window.
13. Bolt
Left hand threaded
 Quantity: 2
14. Cover
 Quantity: 2
15. Rivet
Quantity: 3
 For securing retaining bracket.
16. Retaining bracket

 Secured by 3 rivets.
17. Subframe
 Removing and Installing, refer to Fig. 51.
 Window regulator is a component of the subframe.

 Window regulator motor is bolted to subframe from front.
18. Bolt
 Quantity: 10
19. Rivet
 Quantity: 8
 For the speaker mounting
20. Speaker
21. Clamping brackets

 Quantity: 2
22. Connector
 On the A-pillar
23. Window regulator

 Component of subframe.
REAR DOOR WINDOW, SEDAN
REAR DOOR WINDOW ASSEMBLY OVERVIEW, SEDAN
Fig. 15: Rear Door Windows Assembly Overview

1. Door window
2. Door
3. Window guide
 With fixed window.
 Removing and Installing, refer to
4. Clip

 Removing, refer to WINDOW GUIDE TRIM MOLDING
6. Spring nut
 Quantity: 2
7. Trim
 Removing, refer to TRIM PANEL
8. Bolt
 Quantity: 2
9. Fixed door glass

 Component of window guide.
 Removing and installing with window guide, refer to WINDOW GUIDE
10. Guide rail


 Removing, refer to DOOR WINDOW RECESS SEAL

13. Bolt
 For center bar.
 Quantity: 2
14. Cover
 Quantity: 2
15. Bolt
 For door lock.
 Quantity: 2

17. Spreader pin
 Door window retainer
18. Spreader plug

19. Cover
20. Speaker
21. Rivet
 Quantity: 3
22. Bolt
 Quantity: 10
23. Connector
REAR DOOR WINDOW, WAGON
REAR DOOR WINDOW ASSEMBLY OVERVIEW, WAGON
Fig. 16: Rear Door Windows Assembly Overview - Wagon

1. Door window
2. Door
3. Window guide
 Removing and Installing, refer to WINDOW GUIDE.
4. Clip
 For securing trim molding in window guide.

 Removing, refer to WINDOW GUIDE TRIM MOLDING
6. Spring nut
 Quantity: 2
7. Front trim
 Removing, refer to REAR DOOR WINDOW FRONT TRIM
8. Bolt
 Quantity: 2
9. Bolt
 Quantity: 2
10. Rear trim

 Removing, refer to REAR DOOR WINDOW REAR TRIM
11. Spring nut

 Quantity: 2

 Removing, refer to REAR DOOR WINDOW RECESS SEAL, WAGON
13. Backing
15. Guide rail

 For mounting window guide.
 Removing and Installing, refer to WINDOW GUIDE RAILS.
16. Bracket
 For mounting guide rail.
17. Bolt
 For door lock.
 Quantity: 2

19. Spreader pin
20. Spreader plug


21. Cover
22. Speaker
23. Rivet
 Quantity: 3
24. Bolt
 Quantity: 10
25. Connector
FLUSH BONDED WINDOWS
PLENUM CHAMBER COVER
Removing

-- Remove the wiper arms. Refer to WIPER ARMS
-- Pull off seal -6- on the entire length of plenum chamber cover -1 and 3-.
-- Remove the clips -5- from the plenum chamber cover and the plenum chamber bulkhead.
-- Unclip the spray nozzle hoses from the bracket on the right plenum chamber cover -1-.
CAUTION: The windshield could get damaged. Do not use a screwdriver, a wedge or
any other prying tool to pry off the plenum chamber covers -1- and -3-. The
windshield will be damaged and could crack later.
-- Pull out plenum chamber covers -1 and 3- starting at center carefully upward from binding profile -4-.
Always begin with the top plenum chamber cover.
Installing
CAUTION: The windshield could get damaged.
Using a hammer to install the plenum chamber covers -1- and -3- into the
retainer -4- on the windshield can cause the windshield to crack.

NOTE: New windshields have a insert in the binding profile. Remove the insert before
installing the plenum chamber cover.
Press the plenum chamber cover into the retainer lightly by hand. Do not strike
it or press on it with a tool.
-- Spray binding profile -4- with soap solution so that plenum chamber covers -1 and 3- can be pressed in more
easily.
-- Place plenum chamber covers -1 and 3- onto binding profile -4- and clip it into binding profile starting from
the center using light pressure. Begin with plenum chamber cover lying on bottom.
-- Attach the plenum chamber cover to the plenum chamber bulkhead with the clips -5-.
-- Install the spray nozzle hoses into the bracket on the right plenum chamber cover -1-.
-- Install the seal -6- on the plenum chamber cover.
-- Install the wiper arms. Refer to "Installing" under: WIPER ARMS
WINDSHIELD, REMOVING
-- Remove the A-pillar trim. Refer to Removal and Installation .
-- Remove all sun visors. Refer to Removal and Installation .
-- Remove the interior rearview mirror. Refer to Removal and Installation .
-- The headliner can now be lowered far enough so that windshield can be cut out without damaging headliner.
-- Remove the rain/light recognition sensor -G397- (if equipped). Refer to RAIN/LIGHT RECOGNITION
SENSOR G397 .
-- For more information regarding lane assist, refer to Removal and Installation .
-- Pull off left and right drip rails from engine hood, starting from retaining strips on A-pillar.
Fig. 19: Ground Wire On Mirror And Harness Connectors In Plenum Chamber
-- Disengage Ground (GND) wire -5- at mounting screw -6- and secure Kapton wire on to window with
adhesive tape.
-- Then disconnect harness connectors -2 and 3- in plenum chamber and unclip from holder. Kapton wires -1
and 4- must be secured to window with adhesive tape.
NOTE: Make sure that wires are not damaged when windshield is cut out. The
windshield must be replaced if the wires are damaged.
-- Push the cover for instrument panel V.A.G 1474/19 -1- in between the windshield and instrument panel.
Fig. 20: Pushing The Cover For Instrument Panel V.A.G 1474/19 In Between The Windshield And
Instrument Panel
-- Pull the cutting wire -2- with the awl V.A.G 1474/2 through the adhesive inside the passenger compartment.
-- Secure cutting cord end on the inside against pulling out using pull handle V.A.G 1351/1 -3-.
Fig. 21: Cutting Cord Inserted Into Window Flange By Aid Of Small Tube
-- Insert cutting cord -2- into window flange by aid of small tube -1-.
-- Lay cutting cord around window.
-- Make sure the cutting cord is inserted under the corners of the windshield.
-- Secure second cutting cord end onto spooling tool V.A.G 1654 A.
Fig. 22: Removing Sections Of Window

-- Set spooling tool V.A.G 1654 A to "position I".
-- Relocate spooling tool V.A.G 1654 A appropriately and cut window free.
-- While cutting free, press cutting cord against window using plastic wedge in order to have clearance from
window flange and instrument cluster.
WINDSHIELD, INSTALLING
Preparing undamaged window for glazing, refer to UNDAMAGED WINDOW, PREPARING FOR
GLAZING.
Window, New, Preparing for Glazing, refer to PREPARING NEW WINDOW WITHOUT PRE-COATING
FOR GLAZING.
Preparing window flange for glazing, refer to WINDOW FLANGE, PREPARING FOR GLAZING.
Installation notes, refer to INSTALLATION INFORMATION.
Minimum curing time, refer to MINIMUM CURING TIME.
UNDAMAGED REAR WINDOW, SEDAN
NOTE: If window will be reused, make sure the window defroster and antenna module
electrical connectors are not damaged.
Fig. 23: Removing Undamaged Rear Window (Sedan) (1 Of 2)

-- Remove the C-pillar trim and rear shelf. Refer to Removal and Installation and Removal and Installation .
-- Disconnect connections for heated rear window on right and left -5- and secure them to window with
adhesive tape.
-- Lower the headliner. Refer to Removal and Installation .
-- Lower the headliner just far enough so that it is possible to cut out the rear window without damaging the
headliner.
Installation .
-- Unclip antenna modules -1, 3 and 4- from rear window and disconnect harness connectors.
-- Antenna modules are adhered to window with double-sided adhesive tape. Carefully pry antenna modules off
window. Always replace damaged adhesive tape.
-- Insert the cutting wire into the window flange using a tube.
-- Push cutting cord through adhesive sealant into vehicle interior at lower area of rear window using awl from
separating device for bonded windows V.A.G 1474 A.
Fig. 24: Cutting Windshield Free

-- Pull the outer end of the cord in and hold it with the pull handle V.A.G 1351/1.
-- Secure the inner end of the cord to the reel device.
-- Move the reel device as needed and cut the windshield out.
-- While cutting, press the cutting cord against the window with a plastic wedge in order to have clearance from
the window flange.
DAMAGED REAR WINDOW, SEDAN
-- Protect body and interior from glass splinters.
-- Remove glass pieces from adhesive material.

-- Remove harness connectors for glass defroster and antenna.
-- Bond flange -2- all around with fabric reinforced adhesive tape.
Fig. 25: Bonding Flange With Fabric Reinforced Adhesive Tape

-- Cut through adhesive material (with glass residue) in window opening using electric cutter V.A.G 1561 A
and knife U-shape knife V.A.G 1561.
WARNING: Always wear protective goggles and leather gloves.
REAR WINDOW, SEDAN, INSTALLING
GLAZING.
FOR GLAZING.
UNDAMAGED REAR WINDOW, WAGON, REMOVING
-- Remove the window frame trim. Refer to Removal and Installation .

-- Disconnect the electrical connectors -1- for the heated rear window -arrow- and press connector tabs onto
window.
Fig. 26: Removing Connectors For Heated Rear Window And Press Connector Tabs Onto Window
-- Remove the rear window wiper motor. Refer to WINDSHIELD WIPER SYSTEM .
-- Pull cutting cord -1- through adhesive sealant into vehicle interior at lower area of rear window using awl
V.A.G 1474/2 from separating device for bonded windows V.A.G 1474 A.
Fig. 27: Pulling Cutting Cord Through Adhesive Sealant Into Vehicle Interior Using Awl V.A.G 1474/2
From Separating Device For Bonded Windows V.A.G 1474 A
-- Lay cutting cord -1- around rear window and pull other end of cord into interior.
-- Secure end of cord to grip V.A.G 1351/1 -2- to counter hold.
Fig. 28: Spooling Tool And V.A.G. 1351/1

-- Secure other end of cord to spooling tool -1-.

-- Cut window free by moving spooling tool -1- accordingly.
-- While cutting window free, push cutting cord with plastic wedge against window in order to have clearance at
window flange.
DAMAGED REAR WINDOW, WAGON, REMOVING
-- Protect body and interior from glass splinters.
-- Remove glass pieces from adhesive material.
-- Remove harness connectors for glass defroster and antenna.
-- Bond flange -2- all around with fabric reinforced adhesive tape.
Fig. 29: Bonding Flange With Fabric Reinforced Adhesive Tape

-- Cut through adhesive material (with glass residue) in window opening using electric cutter V.A.G 1561 A
and knife U-shape knife V.A.G 1561.
WARNING: Always wear protective goggles and leather gloves.
REAR WINDOW, WAGON, INSTALLING
GLAZING.
FOR GLAZING.
UNDAMAGED WAGON SIDE WINDOW, REMOVING
NOTE: The following describes removing and installing the left side window. Removing
and installing the right side window is identical.
Fig. 30: Locating Wagon Side Window Connectors And Connections

-- Loosen the top of the luggage compartment trim panel. Refer to Removal and Installation .
-- Remove the C- and D-pillar trim. Refer to Removal and Installation .
-- With corresponding vehicle equipment, remove connectors -4 and 5- from connections -2 and 3-.
-- Pull cutting cord -1- through adhesive sealant at place shown in picture into vehicle interior at lower area of
rear window using awl V.A.G 1474/2 from separating device for bonded windows V.A.G 1474 A.
Fig. 31: Pulling Cutting Cord Through Adhesive Sealant Into Vehicle Interior At Lower Area Of Rear
Window Using Awl V.A.G 1474/2
-- Insert the cutting cord -3- into the window flange behind the seal using the small tube -1-.
Fig. 32: Cutting Cord Inserted Into Window Flange Behind Seal By Aid Of Small Tube
-- Secure the end of the cord -3- to the handle V.A.G 1351/1 -2- to counterhold.
Fig. 33: Cutting Window Free By Moving Spooling Tool V.A.G 1654 A Accordingly
-- Pull other end of cutting cord into interior.
-- Secure other end of cord to spooling tool V.A.G 1654 A -4-.
-- Cut window free by moving spooling tool V.A.G 1654 A -4- accordingly.
Increased counter forces are used at the angle bracket -3- positions.
-- While cutting window free, push cutting cord with plastic wedge against window in order to have clearance at
window flange.
-- In place of spooling tool V.A.G 1654, the spooling tool V.A.G 1654 A can also be used.
Fig. 34: Cutting Window Free Using Spooling Tool V.A.G 1654 A
-- As shown in illustration, one suction cup can be removed from spooling tool V.A.G 1654. By doing this, the
roller of the spooling tool V.A.G 1654 A can be placed closer to window flange.
DAMAGED WAGON SIDE WINDOW, REMOVING
The procedure for removing a broken side window is identical to the removal of a broken rear window, refer to
DAMAGED REAR WINDOW, WAGON, REMOVING.
WAGON SIDE WINDOW, INSTALLING
GLAZING.
FOR GLAZING.

ADHESIVE SEALANT, REMOVING FROM WINDOW
-- It is recommended to use adhesive remover D 002 000 10 as a cleaning solution. Follow the safety
precautions when using it.
WARNING: When cleaning from inside the vehicle, do not press out on the window
that was just installed.
-- First clean paint surface coarsely using a dry rag. Eliminate remaining soiling using adhesive removal
solution D 002 000 10.
-- Clean the plastic trim: let the adhesive sealant harden for approximately 1 hour and then peel it off.
FRONT DOOR WINDOW
DOOR WINDOW
NOTE: The following describes removing and installing the right door window.
Removing and installing the left door window is identical.
Removing
NOTE: Bolts -3- have a left-hand thread.

Fig. 35: Door Window Remove/Install Components

-- Lower door window until clamping screws -3- of door window are accessible.
-- Loosen bolts -3- (do not remove. left-hand thread) and press clamping brackets apart.
NOTE: If this cannot be done because of a power window malfunction, remove the
window regulator motor and then slide the window down.
-- Raise the rear door window and tilt it out of the door toward the front in the -direction of the arrow-.
Fig. 36: Swivelling Window Out Of Door Toward Front

Installing
-- Install the door window -1- in -direction of arrow a- into the door. Make sure the door window sits correctly
inside the window guide.
Fig. 37: Swivelling Window Into Door

-- Without using pressure, guide the door window into clamping brackets -arrow a-.
Fig. 38: Guiding Door Window Into Clamping Brackets

-- Align door window to window frame -arrow b-.

Fig. 39: Door Window Remove/Install Components

-- Tighten clamping screws -3- (quantity: 2 left-hand thread), tightening specification: 8 Nm.
WINDOW REGULATOR MOTOR

Removing
Fig. 40: Window Regulator Motor Remove/Install Components

-- Fix window using adhesive tape so that it does not slip down.
-- Disconnect all harness connectors -3-.
-- Remove the three bolts -2-.
-- Remove window regulator motor with control module -1- from subframe.
Installing
WARNING: It is necessary to code the additional functions and pinch protection each
time a new window regulator motor (door control module) is installed.
-- Place window regulator motor on and pull door window lightly up and down so that splines are located better
between motor and cable drum.

-- Tightening specification for the window regulator motor screws -2- : 3.5 Nm
-- Code the new window regulator motor using the Vehicle Diagnosis, Testing and Information System VAS
5051 A.
-- After coding, let the window regulator work in the one-touch up/one-touch down mode and pull the switch
for 2 seconds. This way the window regulator recognizes it upper stop.
WINDOW GUIDE
NOTE: The following describes removing and installing the right window guide only.
Removing and installing the left window guide is identical.
Do not bend window recess seal when lifting off!
Window recess seal, removing
NOTE: Window recess seal must not be bent when removing.
-- Remove the exterior mirror.

Fig. 42: Removing Window Recess Seal

-- Begin at rear window guide -arrow a- and carefully lift window recess seal -1-.
-- Pull window recess seal -1- off evenly -arrows b- from door flange -2-.
Installing
NOTE: Window recess seal must not be knocked on to door flange.
-- Press window recess seal evenly onto door flange by hand.
TRIM PANEL
Removing
 The exterior mirror and the window shaft strip are removed.
-- Remove the door window. Refer to DOOR WINDOW.

Fig. 43: Removing Window Trim

-- Pull window guide -2- out of mount -arrows a-.
-- Remove bolts -1- and pull off panel -3- in direction of B-pillar -arrow b-.
Installing
-- Check spring clips -5- , seal -4- and intermediate bearings -3- for damage and completeness. Replace parts if
necessary.
Fig. 44: Installing Window Panel

-- Slide trim -1- on window frame in -direction of arrow-.
-- Guide window guide -6- into mount.
WINDOW GUIDE
Removing
 The exterior mirror, the window shaft strip and the trim have been removed.
Fig. 45: Removing Window Guide

-- Pull window guide -2- out of forward mount -2- -arrow-.
For window guides with trim molding
-- Push window guide -1- in top rear area -4- slightly aside.
-- Remove the clip -3-.
All window guides

-- Pull window guide -2- evenly -arrows b- all around from door flange, start in rear area -arrow a-.
Installing
NOTE: Slightly loosen the clamping screws on the front door window if necessary to
be able to install the window guide into the mounts.
Tightening specification for the bolts -2- : 2 Nm
NOTE: While installing window guide, make sure it is seated evenly (wind noise).
WINDOW GUIDE TRIM MOLDING
Removing
-- Remove window guide trim. Refer to TRIM PANEL.

Fig. 46: Window Guide Trim Molding Remove/Install Components

-- Push window guide in top rear area -2- slightly aside.
-- Guide trim removal wedge 3409 in carefully between trim molding -1- and window guide -2-.
Fig. 47: Sliding Trim Removal Wedge 3409 Evenly Between Trim Molding And Window Guide
-- Slide trim removal wedge 3409 evenly between trim molding -1- and window guide -2-.
Installing
-- Spray soap/water solution on to window guide.
-- Press trim molding evenly into window guide.
-- Then press window guide correctly into trim molding mount with pinch roller T 10314.
REAR DOOR WINDOW, SEDAN
DOOR WINDOW RECESS SEAL
Removing
-- Begin at rear area -arrow a- and carefully lift window recess seal -1-.

Installing
-- Press window recess seal on to door flange by applying uniform pressure from above.
TRIM PANEL
Removing
 Window recess seal is removed.

Fig. 49: Removing Front Trim

-- Pull off seal of window guide -2- from trim panel -arrow b-.
-- Remove bolts -3- and pull off panel -1- in direction of B-pillar -arrows b-.
Installing
-- Check spring clips -5- and seal -4- for damage and completeness. Replace parts if necessary.
Fig. 50: Installing Front Trim

-- Press seal of window guide -3- evenly on to flange.
DOOR WINDOW
Removing
Fig. 51: Subframe Remove/Install Components

-- Remove the rear door trim. Refer to Removal and Installation .
-- Lower the door window just far enough until the expanding pin -4- and the spreader plug -3- inside the
opening for the window regulator are accessible.
-- Install a 5 mm bolt (approximately. 70 mm long) into the spreader pin -3- and pull bolt out of spreader plug -
2-.
-- Screw a 8 mm bolt (approximately. 80 mm long) into spreader plug -2-.
NOTE: When screwing the bolt into spreader plug, do not use excessive force on the
plug otherwise it may fall inside into the door.
-- Pull the spreader plug -2- out of the window guide -1- and out of door window.
-- Pull door window -1- upward -arrow- at an angle toward vehicle exterior out of window recess and center bar
-2-.
Fig. 52: Removing Door Window

Installing
NOTE: For reasons of clarity, the subframe is not depicted in the illustration.
Spreader plug and spreader pin must always be replaced when performing
assembly work on door window.
Before inserting the spreader plug -2- and spreader pin -1- , check the window -
3- for damage.
-- Center the spreader plug -2- and insert it with the window -3- removed.
Fig. 53: Identifying Spreader Plug, Spreader Pin, Door Window & Window Regulator Guide
-- Press the expanding pin -1- flush into the spreader plug -2-.
-- Guide door window -3- into door and insert door window into slot of window regulator guide -4-.
-- Using a light pressure from above -arrow- , engage window -3- into window regulator -4-.

NOTE: Removing and installing the right window regulator motor is described here.
Removing and installing the left window regulator motor is identical.
Removing
-- Remove the rear door trim panel. Refer to Removal and Installation .

Installing
-- Tightening specification for window regulator motor screws: 3.5 Nm

5051 A.
WINDOW GUIDE
Removing
Fig. 55: Removing Window Guide (1 Of 2)

Center bar has been removed.
-- Push window guide in top rear area -4- slightly aside.
All window guides
-- Fold seal of window guide -1- from inside from window frame.
-- Using release tool T 10236, disengage retaining tab on guide pin -4- in window frame -1-.
-- Pull off window guide all around and evenly -arrows a and b- from door flange.
Fig. 56: Removing Window Guide (2 Of 2)

-- Begin this -arrow a- at fixed door window.

-- Pull window guide including fixed window out of door upward and at an angle -arrows c-.
Installing
Tightening specification for the bolts -2- : 2 Nm
WINDOW GUIDE RAILS
Removing
Do not bend window guide when removing!
The fixed window glass is part of the window guide.
-- Remove the door window.

Fig. 57: Window Guide Remove/Install Components

-- Pull window guide -4- out of center bar -1- -arrow a- and guide window guide outward.
-- Remove bolts -3- and slide guide rail -1- downward -arrow b- until top end of guide rail appears from
window frame.
-- Remove guide rail -1- in upper area of seal for fixed window and upward -arrow c- out of window recess.
Removing
-- Remove window guide trim.

Fig. 58: Removing Window Guide Trim Molding

-- Push window guide in top front area -2- slightly aside.
-- Guide trim removal wedge 3409 -3- in carefully between trim molding -1- and window guide -2-.
Fig. 59: Removing Window Guide Trim Molding Using Trim Removal Wedge 3409
Installing
-- Press trim molding evenly into window guide.
REAR DOOR WINDOW, WAGON
REAR DOOR WINDOW RECESS SEAL, WAGON
Removing
-- Begin at rear area -arrow a- and carefully lift window recess seal -1-.

Installing
-- Press window recess seal by hand onto door flange by applying uniform pressure from above.
REAR DOOR WINDOW FRONT TRIM
Removing

Fig. 61: Removing Front Trim

-- Pull off seal of window guide -2- from trim panel -arrow b-.
-- Remove bolts -3- and remove panel -1- in direction of B-pillar -c arrows-.
Installing
-- Check spring clips -5- and seal -4- for damage and completeness. Replace parts if necessary.
Fig. 62: Installing Front Trim

-- Press seal of window guide -3- evenly on to flange.
REAR DOOR WINDOW REAR TRIM
Removing
-- Pull window guide -3- out of window frame -arrows a-.

Fig. 63: Removing Rear Trim

-- Loosen window guide seal clips from door.
-- Remove screws -2- and pull off panel -1- in direction of C-pillar -b arrows-.
Installing
-- Check spring clips -5- , clips -7- seal and backing -6- for damage and completeness. Replace parts if
necessary.
Fig. 64: Installing Rear Trim

-- Guide window guide -4- into window frame -3-.
-- Press seal clips -7- evenly into door.
REAR DOOR WINDOW
Removing


 Front trim is removed.
-- Remove the rear door trim. Refer to Removal and Installation .
2-.
-- Screw a 8 mm bolt (approximately. 80 mm long) into spreader plug -3-.
-- Pull the spreader plug -3- out of the window guide -1- and out of door window.
-- Pull door window -1- upward -arrow- at an angle toward vehicle exterior out of window recess and window
frame -2-.
Fig. 66: Pulling Door Window Upward At An Angle Toward Vehicle Exterior Out Of Window Recess
And Window Frame
Installing
NOTE: For reasons of clarity, the subframe is not depicted in the illustration.
Spreader plug and spreader pin must always be replaced when performing
assembly work on door window.
Before inserting the spreader plug -2- and spreader pin -1- , check the window -
3- for damage.
-- Center the spreader plug -2- and insert it with the window -3- removed.
Fig. 67: Identifying Spreader Plug, Spreader Pin, Door Window & Window Regulator Guide
-- Press spreader pin -1- flush into spreader plug -2-.
-- Guide door window -3- into door and insert door window into slot of window regulator guide -4-.
-- Using a light pressure from above -arrow- , engage window -3- into window regulator -4-.
NOTE: Removing and installing the right window regulator motor is described here.
Removing and installing the left window regulator motor is identical.
Removing
-- Remove the rear door trim panel. Refer to Removal and Installation .

Installing
-- Tightening specification for window regulator motor screws: 3.5 Nm
5051 A.
WINDOW GUIDE
Removing
-- Push window guide -1- in upper front and rear area slightly to side.
Fig. 69: Removing Window Guide

-- Remove both clips -3-.
All window guides
-- Fold seal of window guide -1- from inside from window frame.
-- Loosen seal clips -4- from door.
-- Pull window guide in upper area evenly from door flange -arrow a-.
Installing
GUIDE RAIL BRACKET
Removing
-- Remove the rear trim. Refer to REAR DOOR WINDOW REAR TRIM.
Fig. 70: Installing Guide Rail Bracket

-- Remove guide rail -1- upward from bracket -2-.
Installing
-- Check bracket -2- for secure fit.
Fig. 71: Installing Guide Rail Bracket

-- Press guide rail -1- into bracket -2-.
-- It is further secured with installation of rear trim.
Removing
-- Remove front trim and rear trim, refer to REAR DOOR WINDOW REAR TRIM.
Fig. 72: Removing Window Guide Trim Molding

-- Push window guide -2- in upper front and rear area slightly to side.
-- Remove both clips -3-.
-- Guide trim removal wedge 3409 -3- in carefully between trim molding -1- and window guide -2-.
Fig. 73: Removing Window Guide Trim Molding Using Removal Wedge 3409
Installing

Fig. 74: Pressing trim molding using pinch roller T 10314

-- Press trim molding -1- by hand evenly -arrow- into window guide -2-.
SPECIAL TOOLS
 Glass repair kit VAS 6092

Fig. 75: Glass Repair Kit VAS 6092

Fig. 76: Identifying Special Tools -- Rear Door Windows - Sedan


 Roller T 10314
 Release tool T 10236
Fig. 77: Identifying Special Tools - Flush-Bonded Windows (1 Of 2)

 Cutting tool kit V.A.G 1474 A

 Suction lifter V.A.G 1344
 Cutting tools for glass V.A.G 1351
 Window removing kit V.A.G 1755
 Cartridge heater V.A.G 1939


Accessories & Equipment Hood, Lids
Hood, Lids
55 HOOD, LIDS
HOOD
HOOD ASSEMBLY OVERVIEW
Fig. 1: Identifying Hood - Assembly Overview

1. Hood
 Removing and Installing, refer to HOOD
 Adjusting, refer to HOOD, ADJUSTING
2. Adjusting buffer
 Left and right
 Adjusting, refer to ADJUSTING BUFFER, ADJUSTING
3. Seal
 Left and right
 Clipped into the hood
4. Gas strut
 Removing, refer to GAS STRUT
5. Hinge
 Removing and Installing, refer to HOOD HINGE
6. Noise insulation
 Removing and Installing, refer to NOISE INSULATION
GAS STRUT, VENTING
-- Clamp area -x- of the gas strut in the vise, area -x- = 50 mm.
Fig. 2: Identifying Clamping Area Of Gas Strut In Vise

WARNING: Only clamp the gas strut in area -x-. Otherwise, an accident may occur.
-- Saw into the cylindrical part of strut in the first third of the total cylinder length, determined starting from the
edge of the cover on the side with the piston rod.
NOTE: Always wear eye protection when sawing.
Cover the area of the sawn portion with a clean rag.
Dispose of the oil and rag properly.
HOOD HINGE ASSEMBLY OVERVIEW
Fig. 3: Identifying Hinge For Hood, Assembly Overview

1. Hood
 Removing and Installing, refer to HOOD
2. Hinge
 Removing and Installing, refer to HOOD HINGE
3. Screws
 Quantity 3
NOISE INSULATION ASSEMBLY OVERVIEW


1. Retaining clips
 Quantity: 10
2. Insulation
 Removing and Installing, refer to NOISE INSULATION
3. Gas strut
 Removing, refer to GAS STRUT
4. Hood
HOOD LOCKING AND UNLOCKING COMPONENTS ASSEMBLY OVERVIEW

Fig. 5: Identifying Locking And Unlocking Components Of Hood, Assembly Overview

1. Catch
 Removing:
-- Remove bolts -2- and remove catch.
 Adjusting:
-- Catch can be adjusted toward the left or right in longitudinal holes.
2. Bolt
 Quantity: 3
3. Expanding nut
 Quantity: 2
4. Mounting bracket
5. Release cable
 Clipped into mounting bracket.
6. Bolt
 Quantity: 2
7. Actuating lever
8. Release cable
 Clipped in on wheel housing and lock carrier.
9. Release coupling
10. Hood lock
RELEASE, DISCONNECTING
-- Open the hood.
-- Unclip release coupling -1- over headlight on driver side of lock carrier -2-.
-- Open release coupling -1- and remove release -3- in -direction of arrow- from release coupling.
Fig. 6: Identifying Disconnection Of Release

NOTE: When installing, make sure that the release sleeve is inserted correctly and the
coupling is locked.
 Before closing the hood, test the release lever and the release.
HOOD, ADJUSTING
NOTE: The vehicle must be standing on the ground when adjusting the hood -5-.
The left and right buffers are not meant for adjusting. Their function is to
stabilize and to cushion the hood -5-.
The hood -5- is properly adjusted when there is an overall even gap dimension
when closed, it is not too far inward or outward and contours align.
The hood -5- must latch without much force into the hood lock.
Fig. 7: Identifying Adjustment Of Hood

-- Remove catches -6-. Refer to item 1.
-- Remove the gas-filled strut -8- from the hood -5-. Refer to GAS STRUT.
-- By loosening bolts -1- and bolts -3- at left and right on lid hinge -4- (do not unscrew completely), hood -5-
can be aligned between fenders.
-- In rear area, height of hood -5- can be adjusted to fenders with adjusting screw -2- on left and right sides.
-- Make sure the gap dimensions are even. Refer to appropriate repair information: Body Repair.
-- After adjusting, apply corrosion protection to the hinge, -4- and the bolts -1- and -3-.
-- Install and adjust the hook -6- after adjusting the hood -5-.
-- Adjust the height at the front of the hood to the fenders using the hood latch -5-. Refer to HOOD LATCH,
ADJUSTING.
-- Adjust the adjusting buffer -7-. Refer to ADJUSTING BUFFER, ADJUSTING.
HOOD LATCH, ADJUSTING
-- Remove the radiator grille. Refer to RADIATOR GRILLE
Fig. 8: Identifying Adjustment Of Hood Lock

-- Remove the covers -1- (if equipped) from the hood latch bolts.
-- Loosen the bolts -1- and correct or adjust the hood gap dimensions. Refer to appropriate repair information:
Body Repair.
-- Tightening specification for the bolts -1- : 12 Nm
-- Adjust catches, refer to item: 1.
ADJUSTING BUFFER, ADJUSTING
NOTE: The following describes adjusting the left adjusting buffer. Adjusting the right
adjusting buffer is identical.
-- Loosen the clamping screw -1- far enough until it is visible inside the rubber buffer.
-- Now pull notched slider -2- out of adjusting buffer.
Fig. 9: Identifying Clamping Screw And Notched Slider

-- Set notched slider to dimension -a- = 12.5 mm.
-- Close the hood with light pressure over the center.

Fig. 10: Identifying Notched Slider Adjustment Dimension

-- Open the hood again.
-- Screw in clamping screw -1- for adjusting buffer to a depth of dimension -a- = 25 mm.
-- Check the adjustment.
Fig. 11: Identifying Clamping Screw Screwed In For Adjustment Buffer To A Depth Of Dimension
REAR LID, SEDAN

REAR LID ASSEMBLY OVERVIEW
Fig. 12: Identifying Rear Lid, Assembly Overview

1. Rear lid
 Removing and Installing, refer to REAR LID
 Adjusting, refer to REAR LID, ADJUSTING
2. Hood lock
3. Adjusting buffer
 Left and right
 Adjusting, refer to ADJUSTING BUFFER, ADJUSTING

4. Hinge
 Removing and Installing, refer to REAR LID HINGE
5. Hood catch
GAS STRUT, VENTING
-- Clamp gas-filled strut in vice area -x- = 50 mm (2 in.).
Fig. 13: Identifying Clamping Area Of Gas Strut In Vise

REAR LID HINGE ASSEMBLY OVERVIEW
Fig. 14: Identifying Hinge For Rear Lid, Assembly Overview

1. Hinge
2. Rubber stop
3. Bolt
 Quantity: 2
4. Connector
 For electrical components in rear lid, also for locking and unlocking components.
5. Gas strut
HINGE SEAL ASSEMBLY OVERVIEW
Fig. 15: Identifying Hinge Gasket, Assembly Overview

1. Hinge
2. Hinge gasket
 Removing and installing, refer to HINGE SEAL
3. Hose
 Water drain
 Is secured to side panel and on back panel.
4. Grommet
5. Valve
 For water drain hose.
REAR LID, ADJUSTING
NOTE: Vehicle must be on ground to adjust rear lid.
The rear lid latch -3- is attached directly to the rear lid -1-. There are no oblong
holes in the rear lid, therefore it is not possible to adjust the latch.
The left and right buffers -2- are not for adjusting. They stabilize the hood -1-.
The rear lid is properly adjusted when there is an overall even gap dimension
Rear lid must engage in striker pin -3- without great force.
The adjustment of the rear lid is described in multiple steps.
Use an adjustment gauge 3371 to adjust or check the gap dimensions. Refer to the appropriate repair
information: Body Repair.
Fig. 16: Identifying Adjusting Rear Lid

-- By loosening bolts -5- , rear lid -1- can be adjusted in oversized holes on hinge -4-.
-- Remove the hat shelf and adjust at the hinge bolts -4- item: 3. Refer to Removal and Installation .
-- After adjusting, apply a corrosion protectant to the hinge and bolts.
-- Adjust rear lid -1- on striker pin -3-. Refer to STRIKER PIN, ADJUSTING.
-- Adjust left and right adjusting buffers -2- ADJUSTMENT BUFFER, ADJUSTING.
STRIKER PIN, ADJUSTING

NOTE: The striker pin -2- can slide into the oversized holes by loosening screws -1-.
Adjust latch bracket -1- so that recess of rear lid lock with detent engages at
center on latch bracket -1-.
-- Remove the lock carrier cover. Refer to Removal and Installation .
-- Disengage the latch bracket -1-.
-- Move the rear lid catch -1- into the upper position and tighten the bolts -2-.
-- Close rear lid and check adjustment.
Fig. 17: Identifying Adjustment Of Latch Bracket

ADJUSTMENT BUFFER, ADJUSTING
NOTE: The following describes adjusting the right adjusting buffer. Adjusting the left
adjusting buffer is identical.
-- Loosen the clamping screw -2- far enough until it is visible inside the rubber buffer.
-- Now pull notched slider -1- out of adjusting buffer.

Fig. 18: Identifying Notched Slider And Clamping Screw

-- Set notched slider to dimension -a- = 12.5 mm.
-- Close the rear lid with light pressure over the center.
Fig. 19: Identifying Notched Slider Adjustment Dimension

-- Open tailgate again.
-- Screw in clamping screw -1- for adjusting buffer to a depth of dimension -a- = 25 mm.
-- Check the adjustment.
Fig. 20: Identifying Clamping Screw Screwed In For Adjustment Buffer To A Depth Of Dimension
RELEASE ELEMENT ASSEMBLY OVERVIEW

Fig. 21: Identifying Unlocking Element, Assembly Overview

1. Release element
 Removing and Installing, refer to RELEASE ELEMENT
2. Connector
3. Bolt
 Quantity: 3
REAR LID SEAL

The weather seal on the rear lid is equipped at the factory with a sealant, applied to body flange and then rolled
on.
For partially removed seals, seal flanks must be pressed together before
installation.
REAR LID, WAGON
REAR LID ASSEMBLY OVERVIEW

Fig. 22: Identifying Rear Lid - Assembly Overview

1. Rear lid
 Removing and installing, refer to REAR LID
 Adjusting, refer to REAR LID, ADJUSTING
2. Hood lock
 Removing and installing , refer to HOOD LATCH
3. Stop
4. Hood catch
5. Gas strut
 Venting gas, refer to GAS STRUT, VENTING

6. Hinge
 Removing, refer to REAR LID HINGE
7. Rubber stop
8. Motor in rear lid control module
9. Cover
10. Handle button
REAR LID, ADJUSTING
Fig. 23: Identifying Rear Lid Components

NOTE: Vehicle must be on ground to adjust rear lid.
The rear lid latch -2- is attached directly to the rear lid -1-. There are no oblong
holes in the rear lid, therefore it is not possible to adjust the latch.
The left and right buffers -3- are not for adjusting. They stabilize the hood -1-.
The rear lid is properly adjusted when there is an overall even gap dimension
Rear lid must engage in striker pin -4- without great force.
Fig. 24: Identifying Adjustment Of Rear Lid

The adjustment of the rear lid is described in multiple steps.
Use an adjustment gauge 3371 to adjust or check the gap dimensions. Refer to the appropriate repair
information: Body Repair.
-- By loosening bolts -6-, rear lid -1- can be adjusted in oversized holes on hinge -3-.
The cover -2- is removed from the hinge.
-- In addition, the hinge -3- can be adjusted slightly at the threaded pins -4- after loosening the nuts -5-.
-- After adjusting, apply a corrosion protectant to the hinge and bolts.
-- Adjust the rear lid -1- at the rear lid catch, refer to or at the rear lid catch with closing aid -3- , refer to REAR
LID CATCH WITH CLOSING AID MOTOR, ADJUSTING.
-- Adjust the left and right stop buffers -2-. Refer to STOP BUFFER, ADJUSTING.
STRIKER PIN, ADJUSTING
Adjust latch bracket -1- so that recess of rear lid lock with detent engages at
center on latch bracket -1-.
Fig. 25: Identifying Latch Bracket And Bolts

-- Loosen the stop buffers. Refer to STOP BUFFER, ADJUSTING.
-- Bring the hood catch -1- into the top position and tighten the bolts -4-.
REAR LID CATCH WITH CLOSING AID MOTOR, ADJUSTING
Adjust striker pin with closing aid -1- so that recess of rear lid lock with detent
engages at center on latch bracket -1-.
Fig. 26: Identifying Adjustment Of Striker Pin With Closing Aid Motor
-- Open rear lid and bring lock into "closed" position.
Striker pin moves into "closed" position.
-- Disconnect the connector -3- from the closing assist motor -V329-.
-- Loosen the stop buffers. Refer to STOP BUFFER, ADJUSTING.
-- Bring the hood catch -1- into the top position and tighten the bolts -4-.
STOP BUFFER, ADJUSTING
Fig. 27: Identifying Adjustment Of Stop Buffer

-- Tighten the stop -2- , bolt tightening specification -3- : 10 Nm.
-- Lift cover -4- from stop buffer.
-- Loosen screw -5- at stop buffer -6- slightly until stop buffer can be moved to highest position -arrow-.
-- Close rear lid to initial locking position -1- using light pressure over center.
-- Open tailgate again.
-- Tighten the bolt -5- , tightening specification: 10 Nm.
-- Press cover -4- onto stop buffer.
GAS STRUT, VENTING
-- Clamp gas-filled strut in vice area -x- = 50 mm (2 in.).
Fig. 28: Clamping Area Of Gas Strut In Vise


REAR LID CONTROL MODULE MOTOR COMPONENTS, ASSEMBLY OVERVIEW
Fig. 29: Identifying Motor In Electrically Operated Rear Lid Control Module Remove/Install
Components
1. Motor in rear lid control module

2. Nut
 Tightening specification 22 Nm
3. Seal
4. Roof Crossmember
5. Rear lid
6. Hinge
7. Angle
 The movement of the motor is transferred to the hinge
8. Bolt
9. Bolt
 Component of motor in rear lid control module
10. Bolt
11. Connector
COVER ASSEMBLY OVERVIEW

Fig. 30: Identifying Cover - Assembly Overview

1. Cover
 Removing:
-- Loosen locking tab cover in retaining strip.
 installing:
-- Place on retaining strip and engage.
2. Retaining strip
 Consists of 2 parts
 Secured with clip -3-.
3. Clip
 Quantity: 6
REAR LID SEAL
The weather seal on the rear lid is equipped at the factory with a sealant, applied to body flange and then rolled
on.
For partially removed seals, seal flanks must be pressed together before
installation.
FUEL FILLER DOOR UNIT
FUEL FILLER DOOR UNIT AND ACTUATOR ASSEMBLY OVERVIEW
NOTE: If tank flap does not open, it can be opened by hand via the actuator -7-.
The adjusting element -7- is behind the luggage compartment side trim panel.
Refer to Removal and Installation .
Fig. 31: Identifying Actuator Remove/Install Components

1. Fuel filler door unit

 Removing and Installing, refer to FUEL FILLER DOOR UNIT
2. Bolt
3. Drain hose
4. Assembly piece
 Clipped into side panel.
5. Release rod
7. Actuator
 Removing and Installing, refer to ACTUATOR
8. Mounting bolt for actuator

 Quantity: 2
HOOD
HOOD
Removing
Fig. 32: Identifying Hood Remove/Install Components

-- Remove the spray nozzles -2-. Refer to [For engine(s) BPY,BLV,CCTA,CBFA] WINDSHIELD AND
REAR WINDOW WASHER SYSTEM
-- Unclip the line -5- from the hinge -3- and hood -1-.
-- Remove the line -5- through the opening in the hood -1-.
-- Remove the caps from the bolts -4- , if equipped.
-- Loosen the left and right bolts -4- but do not remove them.
-- Remove the bolts -4- and then remove the hood -1- from the hinges -3-.
Installation
Fig. 33: Identifying Hood Remove/Install Components

Installing the hood -1- is the same as removal, but in reverse order.
NOTE: Route the hose -5- as illustrated. Be sure not to twist the hose.
-- Bolt tightening specification: -4- 22 Nm
-- Adjust hood -1-. Refer to
GAS STRUT
-- Open and support the hood.
Fig. 34: Identifying Spring Clips Of Gas-Filled Strut

-- Reach under spring clips -2- using a small screwdriver.
-- Raise the spring clips -2- just far enough so they can slide over the ball socket in direction of the -arrow-.
-- Remove gas-filled strut -1- from the ball studs -3- and -4-.
After removing gas-filled strut -1- , immediately slide back spring clips -2- again.
WARNING: Be very careful when reusing a gas-filled strut. The spring clip must not
be removed completely from the ball socket, otherwise it will get
damaged. The gas-filled strut will spring out of the mount and will damage
the vehicle and cause serious personal injury.
NOTE: Ball studs -3- and -4- are components of hood or body.
-- Releasing pressure from gas-filled strut. Refer to GAS STRUT, VENTING.
HOOD HINGE
NOTE: Removing and installing the right hinge is described. Removing and installing
the left hinge is identical.
Removing

-- Remove the hood -1-.
-- Remove plenum chamber cover. Refer to PLENUM CHAMBER COVER .
-- Unclip the wiring guide from the hinge -2- , if equipped.
-- Remove the cable cover (if equipped) from the hinge -2- , if equipped.
-- Remove screws -3- and remove hinge -2-.


Installation of hinge -2- is the same in reverse order.
-- Tightening specification for the bolts -3- : 22 Nm
-- Install the plenum chamber cover. Refer to PLENUM CHAMBER COVER .
-- Install hood -1-.
NOISE INSULATION
Removing

-- Support the hood -4-.
-- Remove the gas-filled strut -3- from the hood -4-. Refer to GAS STRUT.
-- Pry the clips -1- out of the insulation -2- using the pry lever 80-200.
-- Pull insulation -2- out of longitudinal holes.
Installation

 When installing insulation -2- , install clips -1- with the wide side facing out.
-- Slide insulation -2- with mounting tabs into longitudinal holes.
-- Engage all clips -1- in insulation -1-.
-- Press gas-filled strut -3- onto ball studs on the hood -4-.
HOOD LATCH
Removing
-- Open the hood.
Fig. 39: Identifying Hood Lock Remove/Install Components

-- Remove radiator grille. Refer to RADIATOR GRILLE .
-- Disconnecting release. Refer to RELEASE, DISCONNECTING.
-- Disconnect harness connector -5- for Front Hood Switch.
Harness connector is secured over right headlamp.
-- Remove bolts -4- (three pieces) on lock carrier -3- and remove lid lock -1- upward.
-- To unclip release -2- , press together tabs on release -arrows-.
-- The locking mechanism is released and release -2- can be removed from lid lock -1-.
NOTE: Engine Hood Contact Switch on Hood Latch, Removing and Installing, refer to
FRONT HOOD SWITCH F266 .
Installing
-- Clip release -2- into lid lock -1-.
Fig. 40: Identifying Hood Lock Remove/Install Components

-- Install lid lock -1- in lock carrier -3-.
-- Tightening specifications for bolts -4- 12 Nm.
-- Connect harness connector -5- for Front Hood Switch.
-- Install release -2-. Refer to RELEASE, DISCONNECTING.
-- Adjust the lid lock. Refer to HOOD LATCH, ADJUSTING.
OPERATING LEVER
Removing
-- Pull operating lever -1- and release hood.
Fig. 41: Identifying Insertion Of Small Screwdriver Into Gap Between Operating Lever And Clip
-- Insert a small screwdriver into the gap between the operating lever -1- and the clip -2-.
-- Remove clip -2- from operating lever -1- and pull operating lever off.
Installing
-- Slide clip -2- completely into operating lever -1-.

Fig. 42: Identifying Insertion Of Small Screwdriver Into Gap Between Operating Lever And Clip
-- Then push operating lever -1- onto mount in mounting bracket and lock the operating lever.
REAR LID, SEDAN
REAR LID
Removing
Fig. 43: Identifying Rear Lid Remove/Install Components

-- Remove the rear lid trim panel. Refer to Removal and Installation .
-- Disconnect the connectors from all electric components.
-- Loosen bolts -3- at left and right lid hinges -2- (do not unscrew completely).
-- Only now remove bolts -3-.

-- Guide the electric wires (if equipped) out through the opening under the right hinge -1-.
-- Remove the rear lid -1- from the hinges -2-.
Installing

Installing the rear lid -1- is the same as removal, but in reverse order.
-- Tighten the rear lid -1- bolts -3- to 22 Nm.

 Before the rear lid -1- is closed, perform a function test on the unlocking components.
GAS STRUT
Removing
Fig. 45: Identifying Gas-Filled Strut Remove/Install Components

-- Open and support rear lid.
-- Reach under spring clips -4 and 5- using a small screwdriver.
-- Lift spring clips -4 and 5- straight up far enough so that spring clip can be slid over ball sockets.
-- Pull off gas-filled strut from ball stud.
After removing gas-filled strut, immediately slide back spring clips -4 and 5- again.
-- Gas-filled strut, venting, refer to
Installing
Fig. 46: Identifying Gas-Filled Strut Remove/Install Components

Installing existing gas-filled strut
-- Press gas-filled strut on to rear ball pin -3-.
-- To press on the front ball pin, slide a screwdriver into assembly slot -6- in hinge -1-.
-- Now compress gas-filled strut with the blade of the screwdriver far enough until ball socket -5- can be
pressed over ball pin.
Installing new gas-filled strut
NOTE: The new gas-filled strut has an "internal" assembly lock which limits the length
the piston rod can be pulled out for the first installation.
-- Press gas-filled strut on to rear ball pin -3-.
-- Lower the rear lid far enough so that gas-filled strut can be pressed on to front ball pin -5-.
-- Open the rear lid by hand. The "internal" assembly lock breaks audibly.
Stop buffer -2- touches the body panel.
REAR LID HINGE
NOTE: This removal and installation procedure describes the left hinge. The procedure
is the same for the right hinge.
Removing
Fig. 47: Identifying Hinge For Rear Lid Remove/Install Components

-- Remove the rear shelf. Refer to Removal and Installation .
-- Remove the left luggage compartment trim panel. Refer to Removal and Installation .
-- Remove the rear lid.
-- Remove the gas-filled strut -7- from the hinge -1-. Refer to GAS STRUT.
-- Remove the seal around the hinge. Refer to HINGE SEAL ASSEMBLY OVERVIEW.
-- Remove the screws -3- and remove the hinge -1- through the openings in the rear shelf -4- and the sealing
channel -5-.
Installing
Fig. 48: Identifying Hinge For Rear Lid Remove/Install Components

Installation of hinge -1- is the same in reverse order.
-- Tightening specification of bolts -3- for hinge -1- : 22 Nm.
-- Install the rear lid.

NOTE: When closing rear lid, the sealing lip on hinge gasket must not be pulled in from
hinge pipe. Hinge must be adjusted so that hinge pipe does not grind on the
sealing lip.
HINGE SEAL
Removing

-- Remove the left luggage compartment trim panel. Refer to Removal and Installation .
-- Pull off seal -2- from sealing channel and from valve.
-- Open locking mechanism in gasket and pull off seal from hinge -1-.
-- Disengage hose -3- from mount in side panel and from grommet -4-.
-- Pull valve -5- with hose -3- out of sealing channel.
Installing

-- Slide seal -2- over hinge -1- and press seal together until it engages audibly.
NOTE: When closing rear lid, the sealing lip on hinge seal must not be pulled in from
hinge pipe. Hinge must be adjusted so that hinge pipe does not grind on the
sealing lip.
-- Press valve -5- into sealing channel.
-- Press gasket -2- into sealing channel and into valve -5-.
NOTE: Make sure that seal -2- and clips in valve -5- are properly seated.
-- Slide hose -3- into grommet -4-.
STRIKER PIN
Removing

-- Remove screws -2- and remove striker pin -1-.
Installing
-- Assemble the latch bracket -1-.


-- Adjust the striker pin. Refer to STRIKER PIN, ADJUSTING.
RELEASE ELEMENT
NOTE: If the rear lid does not open, use the emergency release inside the rear lid trim
and open it manually. Refer to the Owner's Manual.
Removing

-- Note the information and work procedures if the vehicle has a rearview camera. Refer to [For engine(s)
-- Disconnect harness connector -2- from unlocking element -1-.
-- Remove the unlocking element -1- from the rear lid.

Installing

Installation of unlocking element -1- is the same in reverse order.
 Perform a function test on the unlocking components before closing the rear lid.
REAR LID LOCK

NOTE: If the rear lid does not open, use the emergency release inside the rear lid trim
panel and open it manually. Refer to the Owner's Manual.
Removing
Fig. 55: Identifying Rear Lid Lock Remove/Install Components

NOTE: Unclip the emergency release cable -4- from the rear lid catch when removing
the rear lid trim panel.
-- Disconnect connector -2- from rear lid lock -1-.
-- Remove the hex nuts -3- and remove rear lid lock -1- from the rear lid.
Installing
-- Position the rear lid lock -1- on the rear lid and install hex nut -3-.

-- Nut tightening specifications -3- : 8 Nm.
-- Connect harness connector -2- to lid lock -1-.
 Perform a function test on the unlocking components before closing the rear lid.
REAR LID SEAL
Removing
Fig. 57: Identifying Rear Lid Seal Remove/Install Components

-- Pull the rear lid weather seal -1- off the body flange.
Installing
Fig. 58: Identifying Rear Lid Seal Remove/Install Components

-- Align rear lid seal -1- with vulcanized point -arrow- to center of left tail lamp.
-- Press the seal -1- evenly onto the body flange.
REAR LID, WAGON
REAR LID
Removing

-- Carefully lift cover -2- out of locking tabs on hinge.
-- Disconnect connectors in rear lid.
-- Loosen bellows -4- and guide electrical wires through opening and out of rear lid.

-- Remove the gas-filled strut -5-. Refer to GAS-FILLED STRUT.
-- Remove the rear lid -1- from the hinges -3-.
Installing

Installing the rear lid -1- is the same as removal, but in reverse order.
-- Guide electrical wires through opening in rear lid and secure bellows -4-.
-- Adjust rear lid and tighten screws -6- , tightening specification: 10 Nm.
-- Install the gas-filled strut -5-.
REAR LID HINGE
Removing
Fig. 61: Identifying Rear Lid Hinge Remove/Install Components

-- Remove the rear lid. Refer to REAR LID.

-- If equipped, remove the bolt -3- from the bracket -2- for the control module motor. Bracket remains in
vehicle.
-- Screw hex nut -4- in vehicle interior downward from hinge threaded screws -1- and remove hinge -1- from
outside.
Installing
Fig. 62: Identifying Rear Lid Hinge Remove/Install Components

-- Insert hinge in vehicle and install hex nuts -4- on threaded screws -1- on hinge.
-- Align hinge to rear lid.
-- Tightening specification for nuts -4- : 20 Nm.
-- Bolt -3- tightening specification: 10 Nm
HOOD LATCH
Removing

-- Loosen connector -3- on rear side of lock.
-- Remove screws -2- and remove lock -1- from rear lid.
In case of an electrical fault, rear lid can be opened at emergency release -4-. The emergency release is reached
through an opening in the rear lid trim.
Installing

-- Secure connector -3- on rear side of lock.
-- Insert lock -1- in rear lid and tighten screws -2- , tightening specification: 22 Nm.
STRIKER PIN
Removing
-- Remove screws -2- and remove latch bracket -1-.

Installing
-- Install striker pin -1- and install screws -2-.


-- Adjust the striker pin. Refer to STRIKER PIN, ADJUSTING.
STRIKER PIN WITH CLOSING AID MOTOR
Removing
-- Disconnect the connector -3- from the closing assist motor -V329- -2-.
-- Remove screws -4- and remove latch bracket -1-.

Installing
-- Install striker pin -1- and install screws -4-.
-- Connect the connector -3- to the closing assist motor -V329- -2-.
-- Adjust the striker pin. Refer to REAR LID CATCH WITH CLOSING AID MOTOR, ADJUSTING.
UNLOCK BUTTON, THROUGH VIN 3C-8E108000 / 3C-8P064070
Removing
Fig. 69: Identifying Release Button Remove/Install Components

-- Note the information and work procedures if the vehicle has a rearview camera. Refer to [For engine(s)
-- Disconnect connector -3- at grip piece connection -2-.
-- Remove hex nut -4- from grip piece threaded screws and remove grip piece -1- from rear lid.
The rear lid can be opened using the emergency release in the lock if there is an electrical malfunction. The
emergency release is reached through an opening in the rear lid trim panel.
Installing
Fig. 70: Identifying Release Button Remove/Install Components


-- Install the grip piece -1- into the rear lid and tighten the nuts -4- on the threaded pins; tightening specification:
8 Nm.
-- Secure connector -3- at grip piece connection -2-.
UNLOCK BUTTON, FROM VIN 3C-8E108001 / 3C-8P064071
Removing
Fig. 71: Identifying Removal Of Unlock Button Assembly

Vehicles with a cover -6-
-- Remove the nuts -5- from the threaded pins and remove the cover -6- from the rear lid.
Procedure for all vehicles
-- Remove the nuts -4- from the threaded pins for the button and remove the cap -3-.
-- Remove the button -1- from the rear lid.
The rear lid can be opened using the emergency release in the lock if there is an electrical malfunction. The
emergency release is reached through an opening in the rear lid trim panel.
Installing
Fig. 72: Identifying Removal Of Unlock Button Assembly

-- Make sure the license plate lamps -2- are installed correctly and connected.
-- Connect the connector -7- to the button.
-- Install the button -1- inside the rear lid and install the cap -3-.
-- Tighten the nuts -4- on the threaded pins on the button.

Vehicles with a cover -6-
-- Install the cover -6- in the rear lid and tighten the nuts -5-.
GAS-FILLED STRUT
-- Open and support rear lid.
Fig. 73: Identifying Removal Of Lifting Spring Clips From Gas-Filled Strut
-- Reach under spring clips -2- using a small screwdriver.
-- Raise the spring clips -2- just far enough so they can slide over the ball socket in direction of the -arrow-.
-- Remove gas-filled strut -1- from the ball studs -3- and -4-.
After removing gas-filled strut -1- , immediately slide back spring clips -2- again.
NOTE: Ball studs -3- and -4- are screwed into rear lid or body, tightening specification:
23 Nm.
-- Gas-filled strut, venting. Refer to GAS STRUT, VENTING
MOTOR IN ELECTRICALLY OPERATED REAR LID CONTROL MODULE
Electrically operated rear lid function
Electrically operated rear lid equipment always consists of both motors in rear lid control modules and striker
pin with closing aid.
Electrically operated rear lid is opened via the handle button on outside of rear lid, via the button in the remote
control key or via the button in the driver's door.
Electrically operated rear lid is closed via the button in the rear lid trim, or via the handle button on outside of
rear lid.
If rear lid does not open completely, there is not necessarily a malfunction. The opening height can be
programmed.
Electrically operated rear lid motors are equipped with a force limitation. If rear lid encounters an obstacle when
"opening" , opening procedure is stopped. If rear lid encounters an obstacle when "closing" , closing procedure
is stopped and rear lid re-opens slightly.
The rear lid can also be opened or closed by hand. After briefly intensified force when operating, the motors are
disengaged and operation can be carried out with normal force.
If there is an electrical malfunction, motors are not disengaged and operation must be carried out with
intensified force.
For more information, refer to the Owner's Manual.
Removing
Fig. 74: Identifying Removal Of Motor In Electrically Operated Rear Lid Control Module
 The rear lid remains closed.
-- Disconnect connector -8- at motor in rear lid control module -1-.

-- Remove the bolt -7- and then remove the motor -1- toward the center of the vehicle.
Bracket -4- is not removed.
Installing
NOTE: The rear lid must be closed in order to install the motor in the rear lid control
module.
Fig. 75: Identifying Installation Of Motor In Electrically Operated Rear Lid Control Module
-- Slide motor -1- into installation position under hex nut -2- and splines -arrow- in bracket -4-.
-- Set screw -7- on but do not tighten.
-- Align motor horizontally and free of tension.
-- Tighten the screw -7- , tightening specification: 22 Nm.
-- Tighten the nut -2- , tightening specification: 22 Nm.
-- Secure connector -8- to motor -1-.
Installation of motor in rear lid control module
-- Allow rear to completely open and close once via electric operation. This makes motor in rear lid control
module ready for operation and activates the pinch protection.
Installing a new motor in rear lid control module
NOTE: Motor in rear lid control module is delivered in "closed" condition.
-- Close the rear lid manually and then open it again but only half way up.
-- At the same time press the inner and outer buttons.
-- Release both buttons.
CAUTION: The rear lid should now move without pinch protection.
NOTE: The rear lid goes all the way up and the motor in the control module is now
adapted.
-- Then perform a function test of electric operation.
REAR LID SEAL
Removing
-- Remove rear lid seal -1- from body flange -3-.

Fig. 76: Identifying Rear Lid Gasket Remove/Install Components

Installing
Body flange -3- is taped in lower area with commercially available fabric adhesive tape -2-.
-- Align rear lid seal -1- with vulcanized point -arrow- to center of left tail lamp.
-- Press the weather seal -1- evenly onto the body flange -3-.
Fig. 77: Identifying Rear Lid Gasket Remove/Install Components

Removing
-- Remove the tank cap.
-- Fold back boot from tank filler neck.

-- Pull tank flap unit -1- with drain hose -3- toward rear out of retainers and swivel tank flap unit -1- out of side
panel.
-- Unclip assembly piece -4- from side panel and pull off assembly piece from release rod -5-.

Installing
 Assembly piece -4- is clipped in.


-- Insert drain hose -3- through opening in tank flap unit and pull drain hose through until it stops.
-- Guide drain hose into side panel.
-- Slide tank flap unit -1- with hinge side first into side panel.
-- Then swivel the fuel filler door unit completely into side panel, make sure that upper and lower catches
engage correctly in side panel.
-- Pull rubber piece over tank filler neck and tighten bolt -2-.
-- Tightening specification for screw -2- : 2 Nm.
ACTUATOR
Removing

-- Remove the luggage compartment side trim panel. Refer to Removal and Installation .
-- Disconnect the connector from the actuator -7-.
-- Loosen the bolts -8- on the adjusting element -7- but do not remove them.
-- Remove actuator -7- together with release rod -5- from seal -8-.
Installing
SPECIAL TOOLS
 Socket wrench -T 10010-
Fig. 81: Identifying Socket Wrench T 10010

or
 Socket wrench -T 10072-

Fig. 82: Identifying Socket Wrench T 10072


 Pry lever -80-200-

Fig. 84: Identifying Pry Lever 80-200

Brakes Hydraulic Components
Brakes
Hydraulic Components
47 HYDRAULIC COMPONENTS
GENERAL INFORMATION
REAR BRAKE CALIPER, PRE-BLEEDING
-- Open the bleeder valve -arrow A- and using a standard bleeder bottle, fill with brake fluid until brake fluid
with no bubbles flows from the threaded hole (brake hose connection) -arrow B-. Close the bleed valve.
Fig. 1: Identifying Bleed Valve, Standard Bleeder Bottle & Threaded Hole
Position brake caliper as shown during pre-bleed procedure.
BRAKE SYSTEM, BLEEDING
NOTE: Description covers bleeding of brake system using the brake filler and bleeder
tool VAS 5234 and V.A.G 1869.
 Brake filler/bleeder unit VAS 5234

 or
 Brake filler/bleeder unit V.A.G 1869
 Brake filler/bleeder unit suction adapter V.A.G 1869/4
WARNING: The Passat utilizes a new special brake fluid. This is indicated by the VW
standard (VW 501 14) and part number.
NOTE: Brake fluid is poisonous. Due to its caustic nature, it must also never be
brought into contact with paint.
Brake fluid is hygroscopic, meaning that it absorbs moisture from the

surrounding air, and must therefore be stored in air-tight containers.
Wash off any spilled brake fluid with plenty of water.
There must be a positive pressure of 2 bar to bleed the hydraulic unit.
Bleeding Brake System with VAS 5234 or V.A.G 1869
WARNING: Only use new brake fluid conforming to VW standard (VW 501 14).
NOTE: On vehicles with EDL, EDL/ASR or EDL/ASR/ESP, the brake system must be
pre-bled when a chamber in the brake fluid reservoir is completely empty (e.g.
brake system leaking).
-- Remove rear wheels.
Pre-Bleeding
-- Connect VAS 5234 or V.A.G 1869.
Bleeding sequence:
1 - Bleed left front and right front brake caliper together simultaneously.
2 - Bleed left rear and right rear brake caliper together simultaneously
-- With bleeder bottle hoses attached, leave bleeder valves open long enough that brake fluid exits without
bubbles.
Then hydraulic unit must be bled once more via function "Basic setting" using Vehicle Diagnostic Tester.
Initiate basic setting (to bleed the brake system):
Vehicle Diagnostic Tester, connecting and selecting functions, refer to VAS 5051, CONNECTING AND
SELECTION FUNCTIONS .
-- Then, brake system must be bled normally
Bleeding
Adhere strictly to work sequence when bleeding brake system.
-- Connect VAS 5234 or V.A.G 1869.
-- Open bleeder valves in the prescribed sequence and bleed brake caliper.
1- Front left brake caliper
2 - Right front brake caliper
3 - Left rear brake caliper
4 - Right rear brake caliper
NOTE: Use suitable bleeder hose. It must fit tightly on bleeder valve so that no air gets
into brake system.
-- With bleeder bottle hose attached, leave bleeder valve open long enough that brake fluid exits without
bubbles.
Post-Bleeding
A second mechanic is required to assist:
-- Depress brake pedal forcefully and hold.
-- Open bleeder valve at brake caliper.
-- Press brake pedal down onto stop.
-- Close bleeder valve with pedal depressed.
-- Release brake pedal slowly.
NOTE: This bleeding procedure must be performed 5 times per brake caliper.
Bleeding sequence:
1- Front left brake caliper
2 - Right front brake caliper

3 - Left rear brake caliper
4 - Right rear brake caliper
NOTE: A road test must be performed after bleeding. During this, at least one ABS
regulation must be performed!
-- Install rear wheels.
Torque specification for wheel bolts, refer to TIGHTENING SPECIFICATION FOR MOUNTING
WHEELS .
BRAKE FLUID, CHANGING
Refer to BRAKE AND CLUTCH SYSTEM, CHANGING BRAKE FLUID .
FRONT BRAKE CALIPER ASSEMBLY OVERVIEW, FN 3
NOTE: Install complete repair kit when servicing.
Only use mineral spirits to clean brake parts.
Apply thin coat of assembly paste G 052 150 A2 to brake cylinders, pistons and
seals.
Fig. 2: Exploded View Of FN 3 Front Brake Calipers

1. 1 - Dust Cap
 Install onto bleeder valve.
2. 2 - Bleeder Valve
 10 Nm
 Apply a thin coat of assembly paste G 052 150 A2 to the threads before screwing in.
3. 3 - Caps
 Insert in bushing.
4. 4 - Guide Pins
5. 5 - Bushing
 Insert in brake caliper.
6. 6 - Brake Caliper
7. 7 - Brake Carrier
 Bolt to brake caliper.
8. 8 - Retaining Spring
 Insert with both ends in holes of brake caliper.
9. 9 - Seal
 Removing and installing, refer to FRONT BRAKE CALIPER PISTON, FN 3.
10. 10 - Pistons
 Apply thin coat of assembly paste G 052 150 A2 to piston before inserting.
11. 11 - Protective Cap

 Do not damage when installing piston.
FRONT BRAKE CALIPER ASSEMBLY OVERVIEW, FNR-G
seals.
Fig. 3: Exploded View Of Brake Caliper FNR-G

1. 1 - Dust Cap
 Install onto bleeder valve.
2. 2 - Bleeder Valve
 12 Nm
3. 3 - Caps
 Insert in bushing.
4. 4 - Guide Pins
5. 5 - Bushing
 Insert in brake caliper.
6. 6 - Brake Caliper
 Must not be removed.
7. 7 - Retaining Spring
 Insert in brake pad retaining spring and press below brake carrier.
8. 8 - Brake Carrier
 Bolt to brake caliper.
9. 9 - Seal
 Removing and installing, refer to FRONT BRAKE CALIPER PISTON, FNR-G.
10. 10 - Pistons
11. 11 - Protective Cap

 Do not damage when installing piston.
REAR BRAKE CALIPER ASSEMBLY OVERVIEW
New brake calipers are filled with brake fluid and are pre-bled.
seals.
In case of repair, brake calipers must always be pre-bled before being installed
into vehicle (without brake pads). Refer to REAR BRAKE CALIPER, PRE-
BLEEDING.
Fig. 4: Exploded View Of Rear Brake Caliper

1. Brake Caliper
 Pre-bleed brake caliper after repairing. Refer to REAR BRAKE CALIPER, PRE-BLEEDING.
2. Bolt
 Self-locking
 35 Nm
 Replace
 When loosening and tightening, counter-hold at guide pin.
3. Dust Cap
4. Bleeder Valve
 10 Nm
5. Bolt
 12 Nm
6. Parking Brake Motor

7. Seal
8. Guide Pins
 Grease before pulling on protective cap.
9. Protective Cap
 Install on brake carrier and guide pin.
10. Brake Carrier with Guide Pins and Protective Cap

 Supplied as an assembled replacement part with sufficient grease on guide pins.
 If protective caps or guide pins are damaged, install repair kit. Use supplied grease packet to
lubricate guide pins.
11. Protective Cap
 Pull onto piston with outer sealing lip.
 Removing and installing, refer to REAR BRAKE CALIPER PISTON.
12. Pistons
13. Seal
14. Pressure Nut
BRAKE BOOSTER AND BRAKE MASTER CYLINDER ASSEMBLY OVERVIEW
NOTE: Use only new brake fluid. Observe information on brake fluid reservoir!
Fig. 5: Identifying Assembly Overview: Brake Booster/Master Brake Cylinder

1. Pedal Assembly
2. Nut
 Self-locking
 25 Nm
3. Gasket
 For brake booster.
4. Brake Booster
 Vehicles with FSI engine without HBV are equipped with a pressure sensor. Refer to BRAKE
BOOSTER PRESSURE SENSOR.
 On vehicles with a hydraulic brake booster, a vacuum sensor is installed. Refer to BRAKE
BOOSTER VACUUM SENSOR .
 Functional check:
-- With engine switched off, depress brake pedal firmly several times (to exhaust the vacuum in the
unit).
-- Depress and hold brake pedal with average foot pressure and start engine. If brake booster is
working properly, pedal will be felt to give noticeably under foot (booster assistance becomes
effective).
 Replace completely if there are malfunctions (check the vacuum system for the brake booster first;
refer to BRAKE BOOSTER VACUUM SYSTEM, CHECKING).
 Removing and installing, refer to BRAKE BOOSTER.
5. Seal
6. Brake Booster Vacuum Sensor -G483-
 Only on vehicles with the hydraulic brake booster.
 Removing and installing, refer to BRAKE BOOSTER VACUUM SENSOR .
7. Dual Master Brake Cylinder

 Cannot be serviced. Replace as complete unit if malfunctioning.
 Removing and installing, refer to BRAKE MASTER CYLINDER.
8. Brake Light Switch -F-

 Removing and installing, refer to BRAKE LAMP SWITCH.
9. Bolt
 5 Nm
10. Heat Shield

11. Nut
 Self-locking
 25 Nm
12. Brake Line

 8.5 mm diameter: 17 Nm
 6 mm diameter: 14 Nm
 Master brake cylinder/secondary piston circuit to hydraulic unit.
13. Brake Line

 8.5 mm diameter: 17 Nm
 6 mm diameter: 14 Nm
 Master brake cylinder/primary piston circuit to hydraulic control unit.

14. Sealing Plugs

 Moisten with brake fluid and press into brake fluid reservoir.
15. Brake Fluid Reservoir

16. Cap
17. Vacuum Hose
 With check valve and, on also vehicles with FSI engine without HBV, with Brake Booster Pressure
Sensor -G294-.
 Insert into brake booster.
 Brake booster pressure sensor, removing and installing, refer to BRAKE BOOSTER PRESSURE
SENSOR.
18. Sealing Plugs
 Connection for vacuum hose.
BRAKE BOOSTER VACUUM PUMP
Vacuum Pump for 4-Cylinder Gasoline Engine
Must not be disassembled.
Fig. 6: Identifying Vacuum Pump & Vacuum Hose

Vacuum pump -1-
Vacuum hose to brake booster -2- with check-valve
High pressure fuel pump -3-.

-- Vacuum pump, removing and installing, refer to [For engine(s) CCTA,CBFA] VACUUM PUMP or [For
engine(s) BLV] MECHANICAL VACUUM PUMP OVERVIEW .
Vacuum Pump for 6-Cylinder Gasoline Engine
Must not be disassembled.
Fig. 7: Identifying Vacuum Line And Bolts

Vacuum pump -B-.
Vacuum hose to brake booster -A- with check valve.
-- Vacuum pump, removing and installing, refer to [For engine(s) CCTA,CBFA] VACUUM PUMP and [For
engine(s) BLV] MECHANICAL VACUUM PUMP .
BRAKE LINE SEPARATING POINT, UNDERBODY
Old Connection
Fig. 8: Identifying Old Connection

1. Tube fitting: 14 Nm
2. Connection, counterhold while tightening.
New Connection
Fig. 9: Identifying New Connection

1. Tube fitting: 14 Nm
2. Ring
3. Flare F
4. Flare E, not flareable
5. Nut, counterhold when tightening
BRAKE LINES, REPAIRING
NOTE: Flare brake lines with 5 mm outer diameter using Flaring Tool VAS 6056 without
damaging coating. In this way, brake lines can be inexpensively partially
replaced in certain cases.
Work with brake line kit V.A.G. 1356 is not permitted because of the coating and
diameter of black brake lines.
Brake lines must not be bent more than 90°, otherwise they kink or deform
causes unacceptable constriction in the line.
Disconnect brake lines preferably at vehicle floor.
Position of intermediate pieces should be selected so that they cannot rub

against moving parts.
Do not lubricate spindle, clean only with mineral spirits.
 Brake line flaring appliance VAS 6056

Listing of Individual Tools

Fig. 10: Identifying Brake Line Repair Tools

1. Flaring Appliance VAS 6056/1

 The flaring tool contains flaring jaws VAS 6056/6
2. Tube Cutter VAS 6056/2

3. Brake Line Shearing Tool VAS 6056/3
 The threaded pins (in shaft and at sides) are set and must not be adjusted!
4. Self-grip Pliers with Plastic Clamping Jaws VAS 6056/4

5. Line Bending Tool VAS 6056/5
6. SW6 Angle Screwdriver
Flaring Tool Assembly Overview
Fig. 11: Identifying Assembly Overview: Flaring Tool

1. Upper Part of Flaring Tool

 Remove to change flaring jaws.
2. Hand Grip Mount

 Must be removed to reach retaining screw for upper part.
3. Retaining Screw
 For upper part of flaring tool.
4. Flaring Jaws Threaded Pins

Center and hold the flaring jaws.

 2 mm hex socket head.
5. Flaring Jaws
 Various.
Flaring Jaws Assembly Instructions
Fig. 12: Identifying Assembly Instructions: Flaring Jaws

 VAS 6056/6 (dark) for black brake lines

 VAS 6056/7 (light) for green brake lines
NOTE: The arrow on the rounded side of the flaring jaws must face toward edge of
housing and the straight side of the flaring jaws must be installed toward
spindle, otherwise flared head will not be formed correctly.
Instructions
-- Remove affected brake line at brake caliper or wheel brake cylinder and collect escaping brake fluid and
dispose of it correctly.
-- Disconnect brake line at appropriate location (straight, accessible part) with line cutter -2-.
Fig. 13: Identifying Brake Line Disconnected At Appropriate Location With Line Cutter
-- Remove piece to be exchanged.
-- Lubricate brake line surface.
-- Clamp brake line in self-grip pliers -4- so that 50 mm of the plastic clamping jaws show.
Fig. 14: Brake Line Clamped In Self-Grip Pliers

-- Clamp shearing tool -3- in a drill and place it on brake line.

-- Shear coating from brake line at a slow drill RPM and with light pressure against the line.
NOTE: The length of the sheared-off portion is determined by the stop in the shearing
tool.
-- Remove shearing tool from brake line and remove shearing remains.
-- Remove self-grip pliers and tube fitting -D- from brake line.
Fig. 15: Identifying Self-Grip Pliers, Tube Fitting And Brake Line
-- Slide brake line -B- against stop -A- in flaring tool.

Fig. 16: Sliding Brake Line Against Stop In Flaring Tool

NOTE: Brake line must contact stop when hex socket heat screws are tightened,
otherwise flared head will not be formed correctly.
-- Clamp brake line in flaring tool until it cannot be moved any more. Fold stop -A- up and tighten hex socket
head screws diagonally with angle screw driver -C-.
-- Turn spindle to stop in flaring tool.
Fig. 17: Turning Spindle To Stop In Flaring Tool

-- Turn spindle back.
-- Loosen hex socket head screws diagonally.
-- Remove brake line from flaring tool, clean and check brake line and flared head.
NOTE: Briefly rinse part of brake line remaining in vehicle.
-- Connect the VAS 5234, place the bleeder container hose on the flared head of the brake line and run the VAS
5234 briefly until some brake fluid runs through.
-- Clean the brake line with compressed air.
-- Join brake lines with connecting piece -E-.
Fig. 18: Identifying Brake Lines Joined With Connecting Piece

-- Assemble brake line.
-- Bleed the brake system. Refer to BRAKE SYSTEM, BLEEDING.
SPECIFICATIONS

Bleeder Valve to Brake Caliper
- Front FN 3 and Rear - 10
- Front FNR-G - 12
Brake Booster to Brake Pedal Assembly Nut (1) - 25
Brake Light Switch to Master Cylinder Bolt - 5
Brake Line to Master Cylinder
- 8.5 mm Diameter - 17
- 6 mm Diameter - 14
Brake Line Underbody Connection - 14
Brake Master Cylinder and Heat Shield to Brake Booster Nut (1) - 25
Guide Pin to Front Brake Carrier - 30
Parking Brake Motor to Rear Brake Caliper Bolt - 12
Rear Caliper to Brake Carrier Bolt (1) - 35
(1) Always replace after removal
PRESSURE LEAK TEST
 Brake pressure gauge 0-250 bar V.A.G 1310 A

 Adapter M 10 V.A.G 1310/6
Test Prerequisites
NOTE: Brake system (hydraulic unit, brake hoses, brake lines and brake calipers)
operating properly and free of leaks.
-- Remove the bleeder valve at one front brake caliper. Connect pressure gauge V.A.G 1310 A and bleed.
-- Apply pressure to brake pedal until the gauge indicates a pressure of 50 bar. The pressure must not drop by
more than 4 bar during the test period of 45 seconds. Replace master cylinder if pressure drops greatly.
BRAKE BOOSTER VACUUM SYSTEM, CHECKING
The following checks will be helpful when performing Fault Finding if there are complaints regarding the brake
booster or the so-called >>hard brake pedal<<.
The following components are included in the check:
 Brake booster
 Seal between the master brake cylinder and the brake booster
 Check valve
 Vacuum hoses and connectors

 Vacuum pump (if equipped)
Keep the geographical surrounding in mind when evaluating the measured results. The higher above sea level,
the lower the air pressure.
Always observe all test requirements before checking the vacuum system:
 Check all the vacuum hoses for damage (for example, tears or damaged caused by animals) and make
sure they are secure.
 Maintain clean working conditions when working on the vacuum system.
 Clean the engine compartment before starting, if necessary.
BRAKE SERVO TESTER, CONNECTING
 Brake servo tester VAS 6721

 Hand vacuum pump VAS 6213
-- Remove the vacuum hose from the brake booster.
NOTE: Pressing the brake pedal a few times beforehand makes it easier to remove the
vacuum hose.
-- Connect the VAS 6721 -see following illustrations-.

Fig. 19: Identifying Connecting VAS 6721

Item
Number Component Explanation
A Shut-off In direction toward the vacuum hose, the check valve and vacuum pump (if
valve equipped)
B Shut-off  Opening the VAS 6721 makes it easier to remove
valve
 Open to simulate an incorrect source
 Connecting the VAS 6213
C Shut-off Toward the brake booster

valve
-- Connect the VAS 6721 hose -A- too the vacuum hose and push the adapter -C- into the brake booster.
Fig. 20: Identifying VAS 6721 Hose Connected Too Vacuum Hose And Adapter Pushed Into Brake
Booster
VACUUM, CHECKING

NOTE: The average earth atmospheric air pressure at sea level (N. N.) is 1013 mbar and
it decreases dramatically at higher altitudes (approximately 100 mbar every
1000 meters higher) Local and time fluctuations will influence the vacuum.
A cold engine, the A/C switched being on and even only the engine idling can
negatively influence the vacuum.
-- Check all the vacuum hoses beforehand for damage (for example, tears or damaged caused by animals) and
make sure they are secure.
-- Connect the VAS 6721. Refer to BRAKE SERVO TESTER, CONNECTING.
-- Open the shut-off valve -A-.
-- Close the shut-off valves -B+C-.

Fig. 21: Identifying VAS 6721 Shut-Off Valves

-- Start the warm (above 60°C) engine and press the accelerator pedal one time quickly (engine RPM higher
than 2,000).
-- Read the measured value displayed.
Normally (see note) the vacuum should be between 600 and 950 mbar (depending on the engine installed).
Check the vacuum system for leaks if the measured value is not reached, even though all requirements (see
notes).
-- Create the vacuum using a VAS 6213 for comparison purposes. Refer to VACUUM, CREATING USING
HAND VACUUM PUMP.
Opening the shut-off valve -B- makes it easier to remove the hose connections and the adapter.
LEAK TEST
NOTE: The average earth atmospheric air pressure at sea level (N. N.) is 1013 mbar and
it decreases dramatically at higher altitudes (approximately 100 mbar every
1000 meters higher) Local and time fluctuations will influence the vacuum.
A cold engine, the A/C switched being on and even only the engine idling can
negatively influence the vacuum.
-- Check all the vacuum hoses beforehand for damage (for example, tears or damaged caused by animals) and
make sure they are secure
-- Connect the VAS 6721. Refer to BRAKE SERVO TESTER, CONNECTING.
-- Open the shut-off valve -A-.
-- Close the shut-off valves -B+C-.

-- Start the warm (above 60°C) engine and press the accelerator pedal one time quickly (engine RPM higher
than 2,000).
Normally (see note) the vacuum should be between 600 and 950 mbar (depending on the engine installed).
-- Open the shut-off valve -C- and evacuate the brake booster.

-- Read the measured value displayed and write it down.
The vacuum may drop 400 mbar within 12 hours.
If the drop in vacuum is greater, check the:
1. Brake booster
or in the
2. Check valve, vacuum hoses and connections and vacuum pump/intake manifold for leaks.
The vacuum will drop considerably within a few seconds if there are large leaks.
Checking the Vacuum Near the Brake Booster
-- Close the shut-off valve -A- after creating the vacuum to test the brake booster vacuum.

Vacuum Test Near the Check Valve, Vacuum Hoses and Connections and Vacuum Pump/Intake
Manifold
-- Close the shut-off valve -C- after creating the vacuum to check the VAS 6721 vacuum up to the intake
manifold or up to the vacuum pump.

Opening the shut-off valve -B- makes it easier to remove the hose connections and the adapter.
VACUUM, CREATING USING HAND VACUUM PUMP

In certain situations, the vacuum can be created using a VAS 6213 instead of using the engine or a vacuum
pump.

-- Connect the VAS 6213 to the vacuum hose on the connection -B- on the VAS 6721.
-- Open the shut-off valve -B-.
-- Create the vacuum using the VAS 6213 until a vacuum between 600 and 950 mbar on the VAS 6721 is
displayed.
-- Perform the tests.
CHECK VALVE, CHECKING

Fig. 27: Identifying Check-Valve

 The check valve -A- must allow air through in direction of arrow.
 Check-valve must remain closed for opposite direction.
Observe correct installation position!
FRONT BRAKE CALIPER PISTON, FN 3
 Disassembly wedge 3409

 Piston resetting tool T 10145
 Assembly device for protective cap T10146/6
Removing
-- Force piston from brake caliper using compressed air.
Place a wooden board into the recess of the caliper housing so it is not damaged.
Fig. 28: Identifying Brake Caliper Housing

-- Remove protective cap from brake caliper with 3409.
Fig. 29: Identifying Protective Cap Pried Off From Brake Caliper With Trim Removal Wedge 3409
-- Remove seal with 3409.

Fig. 30: Identifying Removal Of Brake Caliper Seal With Wedge 3409
When removing, make sure that surface of cylinder is not damaged.
Installing
-- The surface of the piston and seal must only be cleaned with mineral spirits and then dried.
-- Thinly coat piston and seal with assembly paste G 052 150 A2 before inserting.
-- Install sealing ring in brake caliper.
-- Insert the protective cap -A- into the T10146/6 -1-.

Fig. 31: Identifying Protective Cap And Assembly Tool T 10146/6

-- Press the protective cap with the assembly tool -1- and the piston resetting tool -2- into the brake caliper so
that it contacts the brake caliper all around.
Fig. 32: Identifying Protective Cap T10146/1 & Piston Resetting Tool T10145
Check Seating of Protective Caps
-- Protective cap must no longer be able to be pulled from brake caliper by hand.
Fig. 33: Identifying Protective Cap

-- Press the piston lightly against the protective cap and lock it into position, e.g. with the trim removal wedge -
2-.
Fig. 34: Pressing Piston Lightly Against Protective Cap And Lock It Into Position With Trim Removal
Wedge
NOTE: Do not angle piston, to avoid damaging the seal sleeve.
-- Blow the protective cap on with pressurized air (max. 3 bar) -1-. Protective cap springs onto piston.
-- Press piston into brake caliper using piston resetting tool -1-.
Fig. 35: Identifying Piston Pressed Into Brake Caliper With Piston Resetting Tool
Outer sealing lip of protective cap will then engage in piston groove.
FRONT BRAKE CALIPER PISTON, FNR-G

 Assembly device for protective cap T 10146/6
Removing
-- Force piston from brake caliper using compressed air.
Place a wooden board into the recess of the caliper housing so it is not damaged.
Fig. 36: Removing Protective Cap From Brake Caliper With Trim Removal Wedge 3409
-- Remove protective cap from brake caliper with 3409.
Fig. 37: Removing Seal With Trim Removal Wedge 3409

When removing, make sure that surface of cylinder is not damaged.
Installing
-- Install sealing ring in brake caliper.
Fig. 38: Identifying Sealing Ring Installed In Brake Caliper

-- Insert the protective cap -A- into the assembly tool T 10146/1 -1-.
Fig. 39: Identifying Protective Cap And Assembly Tool T 10146/6

-- Press the protective cap with the assembly tool -1- and the piston resetting tool -2- into the brake caliper so
that it contacts the brake caliper all around.
Fig. 40: Identifying Protective Cap Pressed Into Brake Caliper With Assembly Tool And Piston Resetting
Tool
Check Seating of Protective Caps
-- Protective cap must no longer be able to be pulled from brake caliper by hand.
-- Lightly press piston against protective cap with an extension and ratchet adapter -1- and hold it there, in that
position.
Fig. 41: Identifying Piston Pressed Against Protective Cap With An Extension And Ratchet Adapter
NOTE: Do not angle piston, to avoid damaging the seal sleeve.
-- Blow the protective cap on with pressurized air (max. 3 bar) -2-. Protective cap springs onto piston.
-- Press piston with hand into brake caliper, possibly push back slightly with piston resetting tool.
Outer sealing lip of protective cap will then engage in piston groove.
REAR BRAKE CALIPER PISTON
Removing
-- Rotate the spindle -arrow movement- using a Torx insert T45.
Fig. 42: Identifying Spindle Rotated Using A Torx Insert T45

The pressure nut presses the piston out of the brake caliper.
-- Remove the piston with the protective boot from the brake caliper.

Fig. 43: Identifying Wedge 3409 To Remove Seal

Installing
-- Insert oil seal into brake caliper.
-- Place protective cap with outer sealing lip on piston.

-- Screw the pressure nut so far onto the spindle until the dimension -a- 15 mm has been achieved.
Fig. 45: Identifying Pressure Nut Installed On Spindle Until Dimension Achieved
-- Using the 3409, insert the inner sealing lip of the protective boot into the groove -arrows- in the brake caliper.
Fig. 46: Identifying Inner Sealing Lip Of Protective Boot Inserted In Groove In Brake Caliper With Trim
Removal Wedge 3409
-- Push the piston onto the pressure nut, which is only possible in four positions.
-- Carefully press the piston into the brake caliper, moving the piston while doing this.
-- Only press the piston so far into the brake caliper until it contacts the pressure nut.
Fig. 47: Pressing Piston Into The Brake Caliper Until It Contacts Pressure Nut
-- Carefully turn the spindle clockwise until the pressure nut is at the stop.
Fig. 48: Turning Spindle

-- Make sure that the protective cap is seated against the brake caliper -arrows- all around.
Fig. 49: Identifying Protective Cap Seated Against Brake Caliper

-- Press the piston into the brake caliper by hand.
Fig. 50: Pressing Piston Into Brake Caliper By Hand

The outer sealing lip thereby slips into the groove on the piston.
BRAKE BOOSTER PRESSURE SENSOR

-- Remove engine cover.
-- Pull vacuum hose with Brake Booster Pressure Sensor -G294- out of brake booster.
-- Release the clips using pliers -1-.
Fig. 51: Identifying Brake Booster Pressure Sensor G294, Clips And Pliers
-- Carefully pry the brake booster pressure sensor -2- off.
BRAKE LAMP SWITCH
Removing
-- Remove intake hose, air filter housing (on vehicles with diesel engine and some gasoline engines) and
battery. Refer to [For engine(s) BPY,BLV,CCTA,CBFA] Removal and Installation

-- Disconnect the connector -1- from Brake Light Switch -F- .

Fig. 52: Identifying Brake Light Switch F Connector And Brake Master Cylinder Bolt
-- Remove bolt -2- from brake master cylinder.
-- Pull the brake light switch -3- upward and off from the brake master cylinder and remove it from the clip at
the bottom.
Installing
Bolt to master brake cylinder 5 Nm
BRAKE MASTER CYLINDER

Removing
battery. Refer to [For engine(s) BPY,BLV,CCTA,CBFA] Removal and Installation

-- Place sufficient lint-free cloths in the area of the engine and transmission.
-- Extract as much brake fluid as possible from the brake fluid reservoir. Use the VAS 5234 or V.A.G 1869/4.
For Vehicles with Manual Transmission
-- Disconnect the clutch slave cylinder return hose -B- and secure it out of the way or clamp it off with a
commercially available tool such as the Ha 4590 and then remove it.
Fig. 53: Identifying Clutch Master Cylinder Supply Hose, Floating Warning Indicator Sensor Connector
And Brake Like Switch F Connector
All Vehicles
-- Remove the connector -A- from the brake fluid level warning switch -F34-.
-- Pull off connector -C- from Brake Lamp Switch -F- .
-- Remove brake fluid reservoir, press the engagement straps toward outside at reservoir and simultaneously
pull brake fluid reservoir out of sealing plugs.
Fig. 54: Identifying Brake Master Cylinder, Brake Lines And Nuts
-- Disconnect the brake lines -1- at the brake master cylinder and seal the lines with sealing plugs from repair kit
part number. 1H0 698 311 A.
-- Remove the nuts -2- from master brake cylinder.
-- If present, remove heat shield.
-- Carefully take brake master cylinder out of brake booster.
-- Remove the brake lamp switch from brake master cylinder.
Installing
Observe the following points when installing:
-- When installing together the brake master cylinder and brake booster, make sure that the push rod is correctly
located in the brake master cylinder.
-- Bleed the brake system. Refer to BRAKE SYSTEM, BLEEDING.
Master brake cylinder at brake booster 25 Nm
Use new nuts!

Brake Lamp Switch to brake master cylinder 5 Nm
Brake lines to master brake cylinder
8.5 mm 17 Nm
6 mm 14 Nm
BRAKE BOOSTER
NOTE: Check the brake boost vacuum first if there are complaints regarding the brake
booster. Refer to BRAKE BOOSTER VACUUM SYSTEM, CHECKING.

 Engine support bridge 10 - 222 A
Removing
battery. Refer to [For engine(s) BPY,BLV,CCTA,CBFA] Removal and Installation .

accordingly only air filter housing with bracket must be removed.
-- Place sufficient lint-free cloths in the area of the engine and transmission.
-- Extract as much brake fluid as possible from the brake fluid reservoir. Use the VAS 5234 or V.A.G 1869/4.
-- Disconnect the clutch slave cylinder return hose -B- and secure it out of the way or clamp it off with a
commercially available tool such as the Ha 4590 and then remove it.
Fig. 55: Identifying Clutch Master Cylinder Supply Hose, Floating Warning Indicator Sensor Connector
And Brake Like Switch F Connector
All Vehicles
-- Remove the connector -A- from the brake fluid level warning switch -F34-.
-- Pull off connector -C- from Brake Lamp Switch -F-.
-- On vehicles with HBV, pull off connector from Brake Booster Vacuum Sensor -G483-.
-- Pull vacuum hose out of brake booster.
-- Remove the cables -1-, remove the bracket -2- and move it to the side. Refer to [For engine(s)
BPY,CCTA,CBFA] SHIFT AND SELECTOR CABLES, INSTALLED POSITION .
Fig. 56: Identifying Cable And Mounting Bracket

On Vehicles with Automatic Transmission 09G
On this automatic transmission, the ATF cooler is located directly in front of the brake booster, see following
illustration. Removing, refer to [For engine(s) BLV,CCTA] REMOVING and [For engine(s) BPY,CCTA]
TRANSMISSION, REMOVING .
Fig. 57: Identifying ATF Cooler Bolts

-- Mount the 10 - 222 A and support the engine/transmission. Do not lift the engine. Refer to [For engine(s)
BLV,CCTA] REMOVING and [For engine(s) BPY,CCTA] TRANSMISSION, REMOVING .
-- Remove noise insulation tray.
-- Remove the pendulum support, first -A-, then -B-.
Fig. 58: Identifying Pendulum Support And Bolts

(When installing, first tighten -B-, then -A-.) Tightening specifications, refer to Description and Operation .
-- Pry off the selector lever cable, remove it from the mounting bracket and retainer and lay it aside. Refer to
[For engine(s) BLV,CCTA] REMOVING and [For engine(s) BPY,CCTA] TRANSMISSION,
REMOVING .
-- Open the cable channel, pull the wiring harness for servotronic out, then remove the cable channel from the
console and lay it aside.
-- Remove both bolts from the transmission bracket to the vehicle.
-- Slightly lower the engine and transmission using the 10 - 222 A spindle.
-- Remove the vacuum hose -2- from the vacuum pump -1-.
Fig. 59: Identifying Vacuum Pump & Vacuum Hose

-- Remove the bracket for a wiring harness from the vacuum pump -1-.
On Vehicles with Automatic Transmission
-- Open the cable channel, pull the wiring harness for Servotronic out, then remove the cable channel from the
console and lay it aside.
-- Pry off the selector lever cable, remove it from the mounting bracket and retainer and lay it aside. Refer to
[For engine(s) BLV,CCTA] REMOVING and [For engine(s) BPY,CCTA] TRANSMISSION,
REMOVING .
-- Remove the retainer from the selector lever cable.

Fig. 60: Identifying Selector Lever Cable Retainer And Bolts

Additionally, on vehicles with 2.0L 110 kW FSI engine:
-- Remove the connecting tube for the EGR system and remove the bracket for the coolant hose on the cylinder
head.
All Vehicles
-- Disconnect the brake lines at the brake master cylinder and seal the lines with sealing plugs from repair kit
part number. 1H0 698 311 A.
and also on vehicles with 6-cylinder gasoline engine:
-- Remove the nuts for the brake master cylinder.
-- Carefully remove master brake cylinder from brake booster as well as heat shield.
-- Remove Brake Booster Vacuum Sensor -G483- . Refer to BRAKE BOOSTER VACUUM SENSOR .
All Vehicles
-- Remove footwell trim on driver side. Refer to Removal and Installation .

-- Disconnect brake pedal from brake booster. Refer to BRAKE PEDAL AND BRAKE BOOSTER,
SEPARATING AND CONNECTING .
-- Remove the nuts -1- from brake booster.

Fig. 62: Identifying Brake Booster Nuts And Mounting Bracket Nuts
-- Loosen both upper nuts -2- from the mounting bracket.
-- Carefully remove brake booster from vehicle.
-- Remove the nuts for the brake master cylinder.
-- Carefully remove the brake master cylinder from the brake booster.
Installing
Observe the following points when installing:
-- Clip the brake pedal to the brake booster; refer to BRAKE PEDAL AND BRAKE BOOSTER,
SEPARATING AND CONNECTING => Hold the push rod ball head in front of the mount and push the
brake pedal toward the brake booster until the ball head engages audibly. .
-- After installing, bleed brake system. Refer to BRAKE SYSTEM, BLEEDING
-- Bleed clutch.
Brake booster to pedal assembly/bulkhead 25 Nm
 Use new nuts!

Master brake cylinder at brake booster 25 Nm
 Use new nuts!

Brake lines to master brake cylinder
8.5 mm 17 Nm
6 mm 14 Nm
SPECIAL TOOLS
 Engine support bridge 10 - 222 A

 Adapter M 10 V.A.G 1310/6
Fig. 63: Identifying Brake Charger/Bleeder Unit VAS 5234

 Brake filler/bleeder unit V.A.G 1869

 Brake filler/bleeder unit suction adapter V.A.G 1869/4
Fig. 64: Identifying Brake Filler And Bleeder Unit V.A.G 1869
 Brake line flaring appliance VAS 6056
Fig. 65: Identifying Brake Line Flaring Appliance VAS 6056


Fig. 66: Identifying Brake Servo Tester VAS 6721


 Brake pressure gauge 0-250 bar V.A.G 1310 A

Fig. 68: Identifying Brake Pressure Gauge V.A.G 1310 A


 Piston resetting tool T10145

Fig. 70: Identifying Piston Resetting Tool T10145

 Assembly device for protective cap T10146/6
Fig. 71: Identifying Assembly Device For Protective Cap T 10146/6



Electrical System Instruments
Electrical System
Instruments
90 INSTRUMENTS
GENERAL INFORMATION
INSTRUMENT CLUSTER
NOTE: Instrument cluster component functions can be checked using On Board

Diagnostic (OBD) program function, refer to INSTRUMENT CLUSTER OUTPUT
Refer to Self Study Program, No. 339; Passat 2006.
Refer to Self Study Program, No. 340; Passat 2006 - Electrical System.
Refer to the relevant instrument cluster information under 03 MAINTENANCE, DIAGNOSIS .
The following components are integrated in the instrument cluster:
 Instrument Cluster Control Module -J285-

 Engine oil temperature display
 Tachometer
 Coolant temperature gauge
 Multifunction indicator
 Fuel gauge
 Speedometer
 Indicator lamps, refer to INSTRUMENT CLUSTER INDICATOR LAMPS.
All warning and indicator lamps are equipped with light-emitting diodes (LEDs) which cannot be serviced or
replaced separately. In the event of malfunctions, the complete instrument cluster must be replaced, refer to
INSTRUMENT CLUSTER, ADAPTATION/REPLACING.
NOTE: The Anti-theft Immobilizer Control Module -J362- is integrated into Comfort
System Central Control Module -J393-.
The instrument cluster is equipped with On Board Diagnostic (OBD) capabilities which assists with
troubleshooting.
INSTRUMENT CLUSTER OUTPUT DIAGNOSTIC TEST MODE.
SERVICE INTERVAL DISPLAY, RESETTING
-- Resetting Service Reminder Indicator (SRI). Refer to 03 MAINTENANCE, DIAGNOSIS .
INSTRUMENT CLUSTER INDICATOR LAMPS
NOTE: Assignment of warning lamps in instrument cluster is dependent on equipment,

country- and engine versions of vehicle.
Different instrument clusters are used, depending on vehicle equipment.

Therefore, the arrangement of the control lamps may deviate from the
illustration.
Fig. 1: Identifying Instrument Cluster Warning And Indicator Lamps, Overview

1. Electro-Mechanical Power Steering Indicator Lamp

2. Emissions Warning Lamp (OBD)
3. Engine Control Indicator Lamp (EPC - Electronic Power Control)
 The indicator lamp is only on gasoline vehicles.
4. Electronic Parking Brake Indicator Lamp

5. Generator Control Lamp
6. Tire Pressure Monitor Control Lamp
7. Control Lamp Of Left/Right Turn Signal Indicator (Turn Signal/Emergency Flasher System)
9. Coolant Temperature/Level Control Lamp

10. Brake Pad Wear Display Indicator Lamp
11. Opened Door Indicator Control Lamp
12. Windshield Washer Fluid Control Lamp
13. Hood/Rear Lid Open Indicator Lamp
14. Fuel Level Control Lamp
15. Engine Oil Level Control Lamp
16. Anti-Lock Brake System (ABS) Control Lamp
17. Electronic Stabilization Program (ESP) Indicator Lamp
18. Parking Brake / Brake System Warning Lamp
19. Cruise Control System (CCS) Control Lamp
20. Fog Lamp Control Lamp
21. Lamp Failure Control Lamp
22. Seat Belt Control Lamp
23. Operate Foot Brake Control Lamp
 Control lamp present only for vehicles with automatic transmission.
24. Airbag System/Belt Tensioner System Indicator Lamp

25. Rear Fog Lamp Control Lamp
26. Tank Cap Open Control Lamp
27. High Beams Control Lamp
REAR SIDE OF INSTRUMENT CLUSTER
NOTE: Do not disassemble instrument cluster. In the event of malfunctions, replace

complete instrument cluster.
Description of rear side of instrument cluster, refer to the appropriate SYSTEM WIRING DIAGRAMS
information.
INSTRUMENT CLUSTER CONNECTOR ASSIGNMENTS
NOTE: Multi-pin connector assignments depend on market, vehicle equipment and

engine versions.
Connector assignment of connectors on instrument cluster, refer to the appropriate SYSTEM WIRING
INSTRUMENT CLUSTER, ADAPTATION/REPLACING

-- Connect the VAS5051B.
sequence:
 Body
 Instrument Cluster
 Instrument cluster functions
 Instrument cluster, adaptation/replacing
INSTRUMENT CLUSTER OUTPUT DIAGNOSTIC TEST MODE
The following components and functions can be checked via output Diagnostic Test Mode (DTM) of instrument
cluster:
 Speedometer -G21-
 Tachometer -G5-
 Fuel Gauge -G1-
 Coolant Temperature Gauge -G3-
 Warning Buzzer -H3- (activation of gong in instrument cluster)
 Flasher acoustic (activation of flasher relay)
 Segment test (During segment test, all segments of display unit are activated. For this, the display will be
activated in sequence in the colors white, red, green and blue.)
 Glow Plug Indicator Lamp -K29-
 Anti-Theft Engine Disable Indicator Light -K115-
 Safety Belt Warning Lamp -K19-
 Brake and Parking Brake Indicator Lamp -K7-
 Brake Pad Wear Indicator Lamp -K32-
 Low Windshield Washer Fluid Level Indicator Lamp -K106-
 Low Fuel Level Warning Lamp -K105-
 Oil Pressure Warning Lamp -K3-

 Oil Level Indicator Lamp -K38-
 Oil Pressure Warning Buzzer -H11-
NOTE: Above system/component checks depend on market version and installed

equipment.
sequence:
 Body
 Instrument Cluster
 Instrument cluster functions
 Output Diagnostic Test Mode (DTM) of instrument cluster
INSTRUMENT CLUSTER
NOTE: Before removing instrument cluster, the work procedure INSTRUMENT

CLUSTER, ADAPTATION/REPLACING must be performed in every case to read
out data stored in the control module.
Removing:
(ignition off).
-- Remove driver's side panel. Refer to Removal and Installation .
-- Remove instrument cluster panel. Refer to Removal and Installation .
-- Remove mounting bolts -arrows- of instrument cluster -1-.

Fig. 2: Identifying Instrument Cluster And Bolts

NOTE: The fixed electrical connection to the instrument cluster is disconnected

automatically when the cluster is pulled out of the instrument panel opening.
Harness connector is installed permanently in vehicle and is disconnected
automatically when pulling out instrument cluster.
-- Pull instrument cluster -1- out of instrument panel.
Installing:
-- After installing, test the functions of the instrument cluster.

Accessories & Equipment Interior Equipment
Interior Equipment
68 INTERIOR EQUIPMENT
INTERIOR REARVIEW MIRROR WITH RAIN SENSOR RETAINING PLATE, ATTACHING
WINDSHIELD, PREPARING
NOTE: Removal of windshield is no longer necessary, as with previous repair

procedure.
At the same time, it is possible to use the old, detached mirror base.
-- All adhesive and primer residue must be removed up to ceramic coating.
-- Clean adhesion surface using D 009 401 04 cleaning solution.
-- Dry off period must be at least 10 minutes.
-- Apply glass-/paint primer D 009 200 02.
-- Drying time: minimum 10 minutes up to an hour.
PREPARING USED OR NEW MIRROR BASE
-- Use a tool to remove adhesive residue (only for detached mirror base).
-- Prepare adhesive surface by wet-sanding with fine emery paper (800-1200 grit) until water remains (does not
bead and run off) on adhesive surface.
-- Then clean using D 009 401 04 cleaning solution.
MIRROR BASE, INSTALLING
-- Apply 2C polyurethane adhesive D 180 KD2 A1 direct to prepared and cleaned mirror base adhesive surface.
-- Diameter of the bead of adhesive: approximately 2.5 to 3 mm.
-- Immediately after applying adhesive on mirror base, press onto prepared windshield.
-- Align mirror base on its designated position on ceramic coating and secure using adhesive tape.
CLEANING AND REMOVING EXCESS ADHESIVE

-- Carefully remove adhesive tape 0.5 to 1 hour after attaching mirror base.
-- Remove excess soft adhesive all around using spatula.
-- Then remove any remaining excess adhesive using a primer applicator or rag, saturated with cleaning
solution.
RAIN SENSOR AND MIRROR, INSTALLING
-- Mirror can be installed 2.5 hours after mirror base has been attached!
INTERIOR REARVIEW MIRROR
AUTOMATIC DIMMING INTERIOR REARVIEW MIRROR
The automatically dimming interior rearview mirror dims progressively when the driver is blinded from the
rear.
It consists of a mirror element and an electrical element with two photo sensors.
The electronic element registers light incidence from the front and rear through the photo sensors.
If the incident light from the rear is greater than that from the front, a current flows through the electronic
element to a conductive coating.
The applied current will change the color of the electrolytes. The higher the voltage, the darker the electrolyte.
The incident light will be reflected to a lesser degree.
When the reverse gear is engaged, the dimming function is switched off so the mirror can be used, for example,
to back out of a dark garage.
INTERIOR REARVIEW MIRROR WITH RAIN SENSOR
Removing
-- In vehicles with rain sensor, switch ignition off.
-- Remove left -1- and right cover caps -2- outward at the same time.
-- Carefully slide the interior rearview mirror -3- along the windshield and down off the mount.
-- Press the connector socket locking tabs and disconnect the wiring harness from the interior rearview mirror.
Fig. 1: Identifying Interior Rearview Mirror With Rain Sensor Remove/Install Components
Installation
-- To install, perform the steps used for removal in reverse order.
INTERIOR REARVIEW MIRROR
Removing
-- Rotate the interior rearview mirror -1- 90° counterclockwise -arrow- and remove it from the adhesive plate -
2-.
Fig. 2: Identifying Interior Mirror

Installation
INTERIOR REARVIEW MIRROR BASE PLATE WITHOUT RAIN SENSOR
Materials
 Glass/metal adhesive set "D 000 703 A1" (interior rearview mirror, standard)
Fig. 3: Identifying Tools To Install Retaining Plate For Interior Mirror

1 - Window scraper (commercially available)
2 - Blade (commercially available)
-- Remove retaining plate from mirror base.
-- Remove PUR adhesive material from retaining plate with wire brush.
-- Grind off the three spacer knobs on the adhesive surface using 360 - 400 grit sand paper on a flat surface.
-- Keep sanded surface free of dirt and grease.
-- Scrape off PUR adhesive and primer from windshield down to ceramic layer using glass scraper.
-- Clean adhesive surface with adhesive remover D 002 000 10 or cleaning solution D 009 401 04.
WARNING: Be careful not to damaged the ceramic coating because scratches are
always visible.
-- Cut nylon mesh to exact dimensions of mirror base.
NOTE: Protective gloves (rubber gloves) should be worn.
-- Spread thick layer of adhesive evenly on mirror base.
-- Lay nylon mesh on mirror base.
-- While continuing to apply adhesive with tube dab nylon mesh.
30 seconds are available from laying the nylon mesh on the adhesive to pressing on the windshield.
-- Press mirror base (without force) onto windshield and hold for 15 seconds.
-- Use a rag to remove excess adhesive.
NOTE: The interior rearview mirror can be installed after 15 minutes.
STORAGE COMPARTMENTS, COVERS AND TRIM
CENTER CONSOLE, BASIC
NOTE: To provide a better overview, the seats are not shown in the following
illustration. It is not necessary to remove the seats.
Removing
-- Remove footwell trim. Refer to FOOTWELL TRIM
-- Remove front ashtray or front compartment. Refer to FRONT ASHTRAY OR FRONT COMPARTMENT
-- Remove Infotainment trim. Refer to INFOTAINMENT TRIM
-- Remove the cover, "Climatronic/Climatic". Refer to CLIMATRONIC AND CLIMATIC COVER
Vehicles without "Climatronic/Climatic"
-- Remove heating and ventilation controls. Refer to [For engine(s) BPY,BLV,CCTA,CBFA] Removal and
Installation
"Climatic" A/C System with Manual Control
Remove the heater and A/C controls, Climatic. Refer to [For engine(s) BPY,BLV,CCTA,CBFA] Removal
and Installation
"Climatronic" A/C System with Automatic Control

-- Remove Control head and display units for A/C, Climatronic -E87- with control module for Climatronic -
J255-. Refer to [For engine(s) BPY,BLV,CCTA,CBFA] Removal and Installation
-- Remove lining mat -1- from center console.
-- Remove the two bolts -2-.
-- Remove the two nuts -3-.
NOTE: To remove the following screws -4- , the seats must be moved accordingly.
-- Raise center console in rear area.
Vehicles with an AUX-In socket in the center console
-- Remove the AUX IN socket. Refer to Removal and Installation
-- Loosen the center console from the centering tabs -5- in the center console.
Fig. 4: Identifying Center Console, Without Foldable Armrest Remove/Install Components

Installation
-- Insert center console in the two centering tabs -5- in instrument panel.
-- Install the AUX IN socket. Refer to Removal and Installation
-- Secure center console with two screws -2- (1.5 Nm).

-- Secure center console in center and side area with two bolts -4- (1.5 Nm).
-- Lay lining mat -1- in center console.
Fig. 5: Identifying Center Console, Without Foldable Armrest Remove/Install Components

Rest of installation of center console is the reverse order of removal.
CENTER CONSOLE, COMFORT
NOTE: To provide a better overview, the seats are not shown in the following
illustration. It is not necessary to remove the seats.
Removing
-- Remove the cover, "Climatronic/Climatic"; refer to CLIMATRONIC AND CLIMATIC COVER
Installation
and Installation
-- Remove rear trim. Refer to REAR TRIM
-- Remove the two nuts -2-.
NOTE: In order to remove screws -4- , -6- , -7- and -8-, seats must be moved
accordingly.
-- Remove cover cap -3- and remove screw -4-.
-- Remove cover cap -5- and remove screw -6-.
-- Raise center console in rear area.
-- Remove the AUX IN socket. Refer to Removal and Installation

-- Loosen the center console from the centering tabs -9- in the center console.
Fig. 6: Identifying Center Console, With Foldable Armrest Remove/Install Components

Installation
-- Insert center console in the two centering tabs -9- in instrument panel.
NOTE: Check whether heating and cooling channels -10- are precisely fit to the heating
and cooling channels in the center console.

-- Install the AUX IN socket. Refer to Removal and Installation
-- Secure center console with two screws -1- (1.5 Nm).
-- Bolt in center console in rear area with two nuts -2- (6 Nm).
-- Secure center console in rear left side area with bolt -4- (6 Nm) and seal opening with cover cap -3-.
-- Secure center console in rear right side area with bolt -6- (6 Nm) and seal opening with cover cap -5-.
-- Secure center console in center and side area with two bolts -7- and -8- (1.5 Nm).
Fig. 7: Identifying Center Console, With Foldable Armrest Remove/Install Components

Rest of installation of center console is the reverse order of removal.
FOOTWELL TRIM
NOTE: Removal and installation is described for the left side, it is the same on the right
side.
To provide a better illustration, the steering wheel parts of the gear selector and
driver's seat are not shown.
Removing
-- Unclip cover -1- using a small screwdriver.
-- Remove bolt -2- (1.5 Nm).
-- Remove trim from mounts in center console -arrows A, B and C-.
-- Pull trim in area of front guide -3- out of mount in footwell -4- -arrow-.
Fig. 8: Identifying Footwell Trim Remove/Install Components

Installation
FRONT ASHTRAY OR FRONT COMPARTMENT
Removing
Vehicles with automatic transmission

-- Loosen the selector lever boot off the cover. Refer to SELECTOR LEVER MANUAL RELEASE
Vehicles with manual and DSG transmission
-- Loosen the selector lever boot off the cover. Refer to SHIFT KNOB, BOOT AND NOISE INSULATION
-- Remove gear selector insulation -1- from shifter guide rail.
NOTE: To provide a better illustration, the shifter knob and boot are not shown in the
illustration.
Note -arrow- when installing insulation, it must point in direction of travel.

Fig. 9: Identifying Shift Cover Removed

All vehicles
-- Remove shifter cover -1- upward out of center console.
-- Depending on vehicle equipment, disconnect wiring harnesses -2- and -3- from cover.
Fig. 10: Identifying Wiring Harnesses And Shift Cover

NOTE: The heating or cooling mechanism is not shown in the illustration.

-- Remove ashtray insert -1- or compartment -2-.
-- Remove two screws -3- and -4- (1.5 Nm).
-- Remove ashtray -5- or storage compartment -6- from center console and disconnect wiring harness if
necessary.
Fig. 11: Identifying Ashtray And Storage Compartment Removed From Center Console And Wiring
Harness Disconnected
Installation
INFOTAINMENT TRIM
NOTE: The adjacent components are only partially shown in the illustration.
Removing
-- Remove trim from mountings in instrument panel.
-- If equipped, disconnect the wiring harness from the front passenger airbag disabled indicator lamp -K145- -1-
.
Fig. 12: Identifying Infotainment Trim

Installation
CLIMATRONIC AND CLIMATIC COVER
NOTE: Removal and installation of cover is described for vehicles equipped with
"Climatronic".
Removal and installation of cover for vehicles equipped with "Climatic" is

identical.
The adjacent components are only partially shown in the illustration.
Removing
-- Remove trim -1- from mountings in instrument panel.

Fig. 13: Identifying Climatronic/Climatic Cover

Installation
REAR TRIM
Removing
Vehicles with Converter with Socket, 12V, 230V -U13-

-- Pry trim -1- out of mounts and remove two bolts -2- (1.5 Nm).
Vehicles with a storage compartment
-- Open storage compartment -3- and remove two screws -4- (1.5 Nm).
All vehicles
-- Remove rear trim from mounts in center console.
-- Depending on vehicle equipment, disconnection wiring harnesses from rear trim -5-.
Fig. 14: Identifying Rear Trim Remove/Install Components

Installation
CENTER CONSOLE AIR DUCT
Removing
Installation
and Installation
-- Remove Comfort center console. Refer to CENTER CONSOLE, COMFORT
-- Remove two screws -1- (1.5 Nm) and remove front air duct -2- from rear air duct -3-.
Fig. 15: Identifying Center Console Air Duct Remove/Install Components

Installation
CENTER CONSOLE STORAGE COMPARTMENT, BASIS
Removing
-- Remove the cover, "Climatronic/Climatic" ; refer to CLIMATRONIC AND CLIMATIC COVER
Installation
and Installation
-- Remove center console, Basis. Refer to CENTER CONSOLE, BASIC
-- Remove six screws -1- (1.5 Nm).
-- Lower storage compartment -2- slightly in front area.
-- Slide storage compartment forward and remove it downward from center console -arrow-.
Fig. 16: Identifying Center Console Storage Compartment, Without Foldable Armrest Remove/Install
Components
Installation
CENTER CONSOLE STORAGE COMPARTMENT, COMFORT
Removing

Installation
and Installation
-- Remove center console air duct. Refer to CENTER CONSOLE AIR DUCT
-- Remove six screws -1- (1.5 Nm).
-- Lower storage compartment -2- slightly in front area.
-- Slide storage compartment forward and remove it downward from center console -arrow-.
Fig. 17: Identifying Center Console Storage Compartment, With Foldable Armrest Remove/Install
Components
Installation
CENTER CONSOLE EXTENSION, BASIS
Removing

Installation
and Installation
-- Remove the two sets of bolts -1- and -2-.
-- Remove center console extension -3- upward out of mounts in center console.
Fig. 18: Identifying Center Console Extension, Without Foldable Armrest Remove/Install Components (1
Of 2)
Installation
-- Insert center console extension from above into center console.
NOTE: When connecting the parts, ensure all guide tabs -1- and centering tabs -2- are
located in the corresponding openings.
-- Install center console extension with the two screws -3- and -4- (1.5 Nm).
Fig. 19: Identifying Center Console Extension, Without Foldable Armrest Remove/Install Components (2
Of 2)
CENTER CONSOLE EXTENSION, COMFORT
Removing

Installation
and Installation
-- Remove center console air duct. Refer to CENTER CONSOLE AIR DUCT
-- Remove Comfort center console storage compartment. Refer to CENTER CONSOLE STORAGE
COMPARTMENT, COMFORT
-- Remove center console extension -3- upward out of mounts in center console.
Fig. 20: Identifying Center Console Extension, With Foldable Armrest Remove/Install Components (1 Of
2)
Installation
Fig. 21: Identifying Center Console Extension, With Foldable Armrest Remove/Install Components (2 Of
2)
CENTER CONSOLE ARMREST

Removing
-- Remove rear trim. Refer to REAR TRIM.
-- Remove the two bolts -6- and -7- (1.5 Nm).
Vehicles with telephone preparation
-- Loosen connector -9- from armrest frame -8- and disconnect.
-- Release both retaining hooks -4- and unclip trim -3-.
-- Remove armrest -5- from frame -8- -arrow- until wiring harness -2- is accessible.
-- Thread wiring harness -2- through opening in center console armrest -1-.
All vehicles
-- Remove armrest -5- from frame -arrow-.

Fig. 22: Identifying Center Console Armrest Remove/Install Components

Installation
ARMREST STORAGE COMPARTMENT
Removing
-- Remove center console armrest. Refer to CENTER CONSOLE ARMREST.

-- Open storage compartment -1-.
-- Press retaining hooks -3- and -4- inward and remove storage compartment from mount -2- -arrows-.
Fig. 23: Identifying Armrest Storage Compartment Remove/Install Components (1 Of 2)

-- Using a small screwdriver, pry clips -1- from mount -2-.
-- Remove mount from joint -3-.

Fig. 24: Identifying Armrest Storage Compartment Remove/Install Components (2 Of 2)

Installation
UPPER PART OF ARMREST
Removing
-- Remove center console armrest. Refer to CENTER CONSOLE ARMREST.

Vehicles with telephone preparation
-- Remove armrest storage compartment (storage compartment mount must not be removed). Refer to
ARMREST STORAGE COMPARTMENT.
All vehicles
NOTE: Cover -4- is destroyed during removal and must be replaced during installation.
-- Using a small screwdriver, remove cover -4- from armrest -2- -arrows-.
-- Using trim removal wedge 3409, remove cover -4- from catches in upper part of armrest, -1- beginning at
armrest joint.
-- Swing cover -4- forward out of upper part of armrest -1-.
-- Remove bolts -3- and remove upper part of armrest.

Fig. 25: Identifying Upper Part Of Armrest Remove/Install Components

Installation
INSTRUMENT PANEL SIDE COVERS
Removing
-- Using trim removal wedge 3409, pry right side instrument panel cover -1- out of locking mechanisms.
-- Using the Trim Removal Wedge 3409, pry the left side of the instrument panel cover -2- out of the retainers.
Fig. 26: Identifying Instrument Panel Side Covers Remove/Install Components

Installation
STEERING COLUMN TRIM
Removing
NOTE: For reasons of clarity, the steering wheel is not shown in the illustration.
-- Loosen upper steering column trim -1- from mounts in lower steering column trim -2-.
-- Loosen upper steering column trim from gap cover -3-.
-- Remove the three bolts -4- (1.5 Nm).
-- Loosen lower steering column trim -2- from mounts and remove foam insert -5- , if necessary.
Fig. 27: Identifying Steering Column Trim Remove/Install Components

Installation
GLOVE COMPARTMENT
Removing
-- Remove 7 bolts -1- , -2- , and -3- (1.5 Nm).
-- Insert a small screwdriver in the opening -arrow- at lower end of glove compartment and release catch.
-- Loosen glove compartment from instrument panel.
-- In vehicles with glove compartment cooling, disconnect A/C channel from glove compartment.
-- Disconnect wiring harness from lights and contact switch.
-- In vehicles with footwell lights, disconnect wiring harness from lights.
-- In vehicles with front passenger airbag shut-off, disconnect wiring harness from key switch.
Fig. 28: Identifying Glove Compartment Remove/Install Components

Installation
GLOVE COMPARTMENT LOCK CYLINDER
Removing
-- Open the glove compartment.

NOTE: It is not possible to remove separately from lock cylinder -1- , release button -2-
must be replaced.
-- Remove screw -3- and remove release button -2- from glove compartment lid.
Fig. 29: Identifying Glove Compartment Lock Cylinder Removing/Installing Components

Installation
DRIVER SIDE FOOTWELL COVER

Removing
-- Remove the two bolts -1- (1.5 Nm).
-- Remove cover from mounts and disconnect wiring harness (if installed) from footwell lights.
-- Press the two locking mechanisms -arrows- and disconnect diagnostic connector from cover.
Fig. 30: Identifying Drivers Side Footwell Cover Remove/Install Components

CENTER INSTRUMENT PANEL TRIM
Removing
-- Pry trim -1- out of mountings using trim removal wedge 3409.
Fig. 31: Identifying Center Instrument Panel Trim Remove/Install Components

Installation
PASSENGER SIDE INSTRUMENT PANEL TRIM
Removing

-- Remove the glove compartment. Refer to GLOVE COMPARTMENT
-- Remove instrument panel center trim. Refer to CENTER INSTRUMENT PANEL TRIM
-- Remove the screw -1- (1.5 Nm), in place of a screw there may be catch. The release for the catch is on the
back side of the trim.
-- Pry trim -2- out of mounts in area around catches using Trim Removal Wedge 3409.
Fig. 32: Identifying Passengers Side Instrument Panel Trim Remove/Install Components
Installation
INSTRUMENT CLUSTER TRIM
Removing
NOTE: To provide a better illustration, the steering wheel and steering column trim are
not shown in the illustration.
Fig. 33: Identifying Instrument Cluster Trim Remove/Install Components

Installation
CENTER COMPARTMENT
Removing
NOTE: To provide a better overview, the adjacent components are only partially shown
in the illustration.
-- Remove two screws -1- and -2- (1.5 Nm).
-- Remove compartment -3- from instrument panel.

Fig. 34: Identifying Center Compartment Remove/Install Components

Installation
CENTER STORAGE COMPARTMENT UNIT
Removing

-- Remove instrument cluster trim. Refer to INSTRUMENT CLUSTER TRIM
-- Remove passenger side instrument panel trim. Refer to PASSENGER SIDE INSTRUMENT PANEL
TRIM
-- Remove center storage compartment unit -2- from instrument panel.
-- Disconnect wiring harness from warning light switch.

Fig. 35: Identifying Center Storage Compartment Unit Remove/Install Components

Installation
Installation is reverse of removal.
COVER PLATE CARRIER
Removing

TRIM
-- Remove cover plate carrier -3- from instrument panel.
-- Disconnect wiring harness from warning light switch.

Fig. 36: Identifying Cover Plate Carrier Remove/Install Components

Installation
DRIVER SIDE TRIM
Removing
-- Remove left side instrument panel cover. Refer to INSTRUMENT PANEL SIDE COVERS

-- Remove two side screws -1- (1.5 Nm).
-- Press rotary light switch in as far as stop, rotate it toward right until it stands vertically, now pull it out and
disconnect wiring harness.
-- Loosen trim from instrument panel.
-- Disconnect wiring harnesses from automatic headlamp range control and parking brake switch.
-- Disconnect wiring harness from ignition lock.

Fig. 37: Identifying Drivers Side Trim Remove/Install Components

Installation
STORAGE COMPARTMENT WITH CONSOLE IN HEADLINER
Removing
-- Remove the front interior and reading lamps. Refer to ROOF TRIM LAMPS AND SWITCHES
-- Operate the two catches -arrows- and remove storage compartment -1- from console.
-- Remove the two rear screws -2- (2 Nm).
-- Remove the two front screws -3- (2 Nm).
-- Remove console -4- from reinforcing frame in headliner -5-.
Fig. 38: Identifying Storage Compartment With Console In Headliner Remove/Install Components
Installation
STORAGE COMPARTMENT AND SEAT BENCH, PASSAT CC
Removing
-- Remove the seat bench, Passat CC. Refer to SEAT BENCH, SEDAN/PASSAT CC
-- Use the trim removal wedge 3409 to unclip the securing strip -1- from the mounts on the underside of the seat
bench.
-- Using a screwdriver, release the three side catches -arrows- on the underside of the seat bench and remove the
storage compartment.
Fig. 39: Identifying Using Trim Removal Wedge 3409 To Unclip Securing Strip From Mounts On
Underside Of Seat Bench
Installation
STANDARD SUN VISORS
NOTE: Removal and installation is described for the right side of the vehicle. Removing
and installing on the left side is identical.
Removing
-- Remove the front and rear interior and reading lamps in the headliner. Refer to ROOF TRIM LAMPS AND
SWITCHES
-- Remove storage compartment with console in headliner. Refer to STORAGE COMPARTMENT WITH
CONSOLE IN HEADLINER
-- Remove upper trim on A-pillars. Refer to UPPER A-PILLAR TRIM
-- Remove the front roof grab handles. Refer to ROOF GRAB HANDLES
-- Using a small screwdriver, open cover caps -1- and -2-.
-- Remove the bolts -3- and -4- (2 Nm).
-- Pull sun visor mount -6- out of mount.
-- Carefully pull sun visor mount -5- out of mount.
-- Hold the sun visor with one hand and lower the headliner just a little, then remove the flat wire connector
from the clip.
-- Carefully pull connector out through opening in headliner, pulling out just far enough until connector is
located closely beneath headliner.
NOTE: Do not pull harness connector further, since the excess length of wiring
harness (flat wire) is limited and there is a hazard it will shear off.
-- Disconnect connector.
Fig. 40: Identifying Standard Sun Visor Components

Installation
NOTE: When installing the sun visor, apply a felt strip (part number: 533.863.288.A)
over the connector.
From June 2007
On vehicles that were produced from June 2007, make a cut on the flat wire connector that comes out of the
opening in the roof crossmember.
How to recognize: Beginning June 2007, the sun visors shall be screwed in using threaded connector on the roof
crossmember. Visors in vehicles produced before June 2007 were mounted using metric screws.
-- Using a diagonal cutter, remove the -shaded area- from the flat wire connector -1- that is coming out of the
Fig. 41: Identifying Section Of Flat Wire Connector At Opening In Roof Crossmember
CAUTION: To prevent a possible short circuit, be careful not to damage the connector
when cutting the center vertical brace.
-- The bonded connector is horizontal, and should be inserted in the opposite direction of travel, between the
roof cross member and the headliner. The -cross-hatched surface- from the connector should be pointing
upward.
Fig. 42: Identifying Area Of The Connector That Faces Up

DOUBLE SUN VISORS
Removing
SWITCHES
-- Remove the front roof grab handles. Refer to ROOF GRAB HANDLES
-- Hold the sun visor with one hand and lower the headliner just a little, then remove the flat wire connector
from the clip.
-- Carefully pull connector out through opening in headliner, pulling out just far enough until connector is
located closely beneath headliner.
NOTE: Do not pull harness connector further, since the excess length of wiring
harness (flat wire) is limited and there is a hazard it will shear off.
-- Disconnect connector.
Fig. 43: Identifying Sun Visor, Double Remove/Install Components

Installation
over the connector.
From June 2007
On vehicles that were produced from June 2007, make a cut on the flat wire connector that comes out of the
How to recognize: Beginning June 2007, the sun visors shall be screwed in using threaded connector on the roof
crossmember. Visors in vehicles produced before June 2007 were mounted using metric screws.
upward.

SUN VISORS, PASSAT CC
Removing
-- If equipped, open the Panorama sunroof.
-- Remove the front interior and reading lights:
 (Vehicles without Panorama sunroof): ROOF TRIM LAMPS AND SWITCHES

 (Vehicles with Panorama sunroof): ROOF TRIM LAMPS AND SWITCHES
-- Remove the roof grab handles on vehicles without Panorama sunroof. Refer to ROOF GRAB HANDLES
-- Remove upper trim on A-pillars. Refer to UPPER A-PILLAR TRIM, PASSAT CC
-- Remove the upper B-pillar trim from the brackets. Refer to LOOSENING UPPER B-PILLAR TRIM
FROM MOUNTS AND SECURING, PASSAT CC .
-- Using the trim removal wedge 3409 remove the caps from the mirror -arrows-.
Fig. 46: Identifying Trim Removal Wedge 3409 To Remove Caps From Mirror
-- Disconnect the connector -1- and remove the screws -2- (1.6 Nm).
Fig. 47: Identifying Mirror Connector & Screws

-- On vehicles equipped with a Panorama sunroof, remove the clamping profile -1- from the mounting clamps -
2- -arrow- using the release tool T10236 and the trim removal wedge 3409.
NOTE: In total, the clamping profile is attached by 20 clips.

Fig. 48: Identifying Profile, Mounting Clamps, Release Tool T10236 And Trim Removal Wedge 3409
-- Pull sun visor mount -6- out of mount.
NOTE: The sun visor is now hanging on the sun visor wiring harness.
Fig. 49: Identifying Standard Sun Visor Components

-- Grab between the headliner and roof and slightly lift sun visor connector -1- and push it in direction of drive
over the brace -2-.
Fig. 50: Identifying Sun Visor Connector & Brace

-- Next, push the connector through the opening in the headliner and disconnect it.
Installation
over the connector.
Before installing, center the sheet metal nuts for the inner sun visor bracket.
-- Carefully pry the "vanity mirror light" out of the headliner using the trim removal wedge VAS 3409 or a
screwdriver.
Fig. 52: Identifying Roof Trim Light Using Trim Removal Wedge VAS 3409
upward.

-- Reach into the "vanity mirror light" opening and carefully insert the connector opposite the drive direction.
PARKING VOUCHER HOLDER
Removing
-- Remove upper driver side A-pillar trim. Refer to UPPER A-PILLAR TRIM
-- Remove bolt -1- (2 Nm).
-- Remove parking voucher holder -2- from body.

Fig. 54: Identifying Parking Voucher Holder Components

Installation
SILL PANEL TRIM
SILL PANEL TRIM
NOTE: Removing and installing on the left side of the vehicle is described here.
Removing and installing on the right side is identical.
Removing
Sedan/Passat CC and CC
-- Remove the seat bench. Refer to SEAT BENCH, SEDAN/PASSAT CC .
Wagon
-- Fold the bench seat forward.
All vehicles
-- Remove side upholstery:
 With rear side airbag: SIDE UPHOLSTERY WITH SIDE AIRBAG

 Without rear side airbags: SIDE UPHOLSTERY WITHOUT SIDE AIRBAG
-- Remove wheel housing trim. Refer to WHEEL HOUSING TRIM.
NOTE: To provide a better illustration, the front seat is not shown in the illustration.
-- Remove sill molding -2- from catches in sill in front door area.
-- Loosen sill panel trim from mounts in front area of B-pillar.
-- Remove sill panel trim from catches in door sill in rear door area.
-- Thread seat belt -3- through the slit in sill panel -2-.
Fig. 55: Identifying Sill Panel Trim Components

Installation
-- Bend sill panel trim outward in rear area of B-pillar.
-- Press sill panel trim into mounts in door sill in rear door area.
-- Place sill panel trim in corresponding mounts in front area of B-pillar.

-- Secure sill panel trim with two screws -1- (2 Nm).
-- Check whether sill panel trim is located in door seal moldings.
Fig. 56: Identifying Sill Panel Trim Components

WHEEL HOUSING TRIM
Removing
-- Remove the seat bench; refer to SEAT BENCH, SEDAN/PASSAT CC
Wagon
All vehicles
 With rear side airbag:SIDE UPHOLSTERY WITH SIDE AIRBAG

NOTE: To provide a better illustration, the rear backrest is not shown in the illustration.
-- Remove trim -1- in center area from mount in body and door seal molding -arrow A-.
-- Remove trim in lower area from mount in body -arrow B-.
-- Remove trim in upper area from clip -2- in body -arrow C-.
NOTE: To provide a better overview, the clip -2- is shown removed in the illustration.
Fig. 57: Identifying Wheel Housing Trim Components

Installation
-- Check whether sill panel strip is located in the door seal molding.
GRAB HANDLES
ROOF GRAB HANDLES

-- Swing front right grab handle away -2- and open both small cover caps with a small screwdriver.
-- Remove two screws -1- (2 Nm) and loosen grab handle from adapter plate in roof.
-- Swing rear right grab handle away -4- and open both small cover caps with a small screwdriver.
-- Remove two screws -3- (2 Nm) and loosen grab handle from adapter plate in roof.
Fig. 58: Identifying Roof Grab Handle Components

Installation
REAR SHELVES/SUN SHADES
REAR SHELF, WITHOUT SUN SHADE
Removing
-- Remove trim on C-pillars, sedan:
 Vehicles without sun shade: C-PILLAR TRIM, SEDAN, VEHICLES WITHOUT SUN SHADE

-- Remove wheel housing trim on both sides -1- from clip -2-.
-- Remove clip -2- on both sides from body.
-- Remove rear shelf upward out of mounts.
-- Remove seat belt trim -3- on both sides from rear shelf -4-.
-- Thread seat belt -5- on both sides through opening in rear shelf.
Fig. 59: Identifying Rear Shelf Components For Vehicles Without Sun Shade
Installation
NOTE: Before installation, mounting elements of rear shelf must be checked for
damage and replaced if necessary.
REAR SHELF, WITH SUN SHADE
Removing
 Vehicles with sun shade: C-PILLAR TRIM, SEDAN, VEHICLES WITH SUN SHADE
-- Remove the seat bench. Refer to SEAT BENCH, SEDAN/PASSAT CC

-- Remove wheel housing trim on both sides -1- from clip -2-.
-- Remove clip -2- on both sides from body.
-- Remove rear shelf upward out of mounts.
-- Remove seat belt trim -3- on both sides from rear shelf -4-.
-- Thread seat belt -5- on both sides through opening in rear shelf.
Fig. 60: Identifying Rear Shelf Components For Vehicles With Sun Shade
Installation
SUN SHADE, SEDAN
Removing
NOTE: Removal of sun protection shade is performed when it is in a rolled in state.

-- Remove rear shelf (vehicles with sun shade). Refer to REAR SHELF, WITH SUN SHADE
NOTE: Removal is described for the left side of the vehicle, removal on the right side is
the same.
-- Remove trim -1- from mounts in sun shade guide -2-.
-- Remove sun shade guide -2- from mounts in body.
-- Loosen sun shade guide -2- from mounts in sun shade -4-.
Fig. 61: Identifying Sun Shade Components (1 Of 2)

-- Remove two screws -1- (1.5 Nm) on each holder.
-- Remove sun shade -2- upward out of mounts.
-- On vehicles with electric sun shade, disconnect wiring harness.

Fig. 62: Identifying Sun Shade Components (2 Of 2)

Installation
REAR SHELF WITHOUT SUN SHADE, PASSAT CC

Removing

-- Remove C-pillar trim. Refer to C-PILLAR TRIM WITHOUT SUN SHADE, PASSAT CC
-- Fold up the bracket -3- , open the cap -1- , remove the screw -2- (20 Nm) and remove the securing eye -4-
from the rear shelf.
NOTE: When installing, make sure that the securing eye anti-twist mechanism is
installed in the appropriate opening in the body -arrow- !
Fig. 63: Identifying Cap, Screw, Bracket & Securing Eye

-- Guide the right and left seat belt -1- through the rear shelf -2-.
Fig. 64: Identifying Right/Left Seat Belt & Rear Shelf

-- Remove the rear shelf first upward -arrows A- and then in the drive direction -arrows B- out of the mounts.
Fig. 65: Identifying Removal Of Rear Shelf

Installation
REAR SHELF WITH SUN SHADE, PASSAT CC
Removing
 With rear side airbag:SIDE UPHOLSTERY WITH SIDE AIRBAG

-- Remove C-pillar trim. Refer to C-PILLAR TRIM, WITH SUN SHADE, PASSAT CC
-- Fold up the bracket -3- , open the cap -1- , remove the screw -2- (20 Nm) and remove the securing eye -4-
from the rear shelf.
NOTE: When installing, make sure that the securing eye anti-twist mechanism is
installed in the appropriate opening in the body -arrow- !
Fig. 66: Identifying Cap, Screw, Bracket & Securing Eye

-- Guide the right and left seat belt -1- through the rear shelf -2-.
Fig. 67: Identifying Right/Left Seat Belt & Rear Shelf

-- Remove the rear shelf -2- first upward -arrows A- and then in the drive direction -arrows B- out of the
mounts.
-- Remove the screws -1- (1.5 Nm).

Fig. 68: Identifying Removal Of Rear Shelf

-- Lift the rear shelf -1- slightly in the front and then remove it from its mounts.
-- Disconnect the wiring harness -2-.

Fig. 69: Identifying Rear Shelf & Wiring Harness

Installation
SUN SHADE, REAR DOOR TRIM
 Removal and installation is described for the sedan, it is similar on the wagon.
 Removal and installation is described for the right side of the vehicle. Removing and installing on the left
side is identical.
Removing
-- Removing rear door trim. Refer to REAR DOOR TRIM .
-- Pull the shade down slightly and remove the cover cap -1-.
Fig. 70: Identifying Sun Shade, Rear Door Trim Components

-- Remove the cover -1- from the shade -2-.
-- Remove the six upper bolts -1- (0.8 Nm).
-- Remove the six lower bolts -2- (2 Nm).
NOTE: On the wagon, the sun shade is only secured with the five lower bolts.
-- Remove the sun shade -3- from the trim.

Fig. 71: Identifying Sun Shade, Trim And Bolts

-- Insert a suitable spiral drill -arrows- into the openings on both sides of the mounting piece -1- and press the
retainers on the mounting hooks -2-.
Fig. 72: Identifying Mounting Hooks And Mounting Piece

-- Remove the mounting hooks -1- from the mounting piece -2-.
Installation
-- The height can be adjusted by moving the tabs -1- and -2- up or down before locking the hook -3-.
Fig. 73: Identifying Tabs And Hook

SCREEN SEPARATOR WALL
SCREEN SEPARATOR WALL
Removing
-- Fold the bench seat backrest forward and open the right rear door.
-- Pull screen separator wall -1- outward -arrow- out of mounts -2- in right rear backrest.
Fig. 74: Identifying Screen Separator Wall Remove/Install Components

Installation
SCREEN SEPARATOR WALL, MOUNTING COMPONENTS
Removing
-- Remove screen separator wall. Refer to SCREEN SEPARATOR WALL
-- Remove the two bolts -1- (8 Nm).
-- Remove insert -2- and mounting component -3- from right backrest.
-- Remove insert -5- and mounting component -6- from right backrest.
Fig. 75: Identifying Screen Separator Wall, Mounting Components Remove/Install Components
Installation
SPECIAL TOOLS



 Special hook 3370

Fig. 78: Identifying Front End Hook VAS 3370

Electrical System Interior Lights, Switches
Electrical System
Interior Lights, Switches
96 INTERIOR LIGHTS, SWITCHES

GENERAL INFORMATION
SOCKETS AND ILLUMINATION
CAUTION: Using force to remove cigarette lighter sockets without illumination can
result in damage to the mounting sleeve retainers.
The puller T40148 can only be used to remove cigarette lighter sockets
with illumination.
The puller is not capable of releasing the retainers on power sockets

without illumination.
Power sockets without illumination usually cannot be removed without

damage.
On some vehicle equipment levels, socket illumination is via Light Emitting Diode (LED) instead of a bulb.
These LEDs are integrated with the illumination housing and cannot be serviced or replaced separately.
Various versions of illumination housing with bulb exist. One version allows separate replacement of the
illumination bulb, and another where the bulb cannot be serviced or replaced separately. In this case, the entire
illumination housing must be replaced.
There are different versions of the power outlet and cigarette lighter outlet due to different mounting locations
and construction. The differences are primarily In the length and type of electrical connectors. On power outlets
and cigarette lighters with an electrical cable pig tail, additional work may be necessary to access the connector.
12 V SOCKET, REPLACEMENT
with illumination.


damage.
Cigarette Lighter -U1-, removing and installing, CIGARETTE LIGHTER SOCKET/12 VOLT SOCKET.
CIGARETTE LIGHTER OVERVIEW
with illumination.


damage.
Fig. 1: Identifying Cigarette Lighter Assembly Overview

1. Cigarette Lighter Receptacle With Cable Pig Tail

2. Cigarette Lighter
3. Power Outlet Receptacle
4. Cigarette Lighter Receptacle
5. Mounting Sleeve
6. Bulb W 5 12V 1.2 Watt
7. Bulb Holder

SOCKET ILLUMINATION BULB
with illumination.


damage.
The socket illumination bulb -L42- is removed in the same manner as the cigarette lighter illumination bulb -
L28-. Refer to CIGARETTE LIGHTER ILLUMINATION BULB.
CIGARETTE LIGHTER SOCKET/12 VOLT SOCKET
 Puller T40148
The following procedures apply to Left Rear Cigarette Lighter -U3-, Right Rear Cigarette Lighter -U7-, Rear
Cigarette Lighter -U9-, 12V outlet 2 -U18-, 12V outlet 3 -U19-, 12V outlet 4 -U20-, Cigarette Lighter 2 -U25-
and 12V outlet 5 -U26- with illumination.
NOTE: The procedure for removing and installing is the same for all power sockets and
is only described for the cigarette lighter socket.
The puller T 40148 can only be used to remove cigarette lighter sockets
with illumination.


damage.
Removing
-- Remove cigarette lighter insert or blank plug from receptacle.

NOTE: The illustration shows the socket removed.
CAUTION: The outlet or mounting sleeve can be damaged.
Make sure the puller is seated properly or the mounting sleeve retainers
will not release.
-- Insert puller -arrow- in receptacle so retainers -1- engage in recesses -2-.
Fig. 2: Identifying Insertion Of Puller Into Receptacle

-- Release the mounting sleeve retainers by pulling on grip piece -3- in direction of -arrow-.
Fig. 3: Identifying Release Of Mounting Sleeve Retainers

-- Pull receptacle with puller out of mounting sleeve.
CAUTION: The outlet electrical wiring can be damaged.
Pay attention to the lengths of the electrical wires when removing the
outlet.
Depending on installation location, it is recommended to use press 40148/1 -2- with knurled wheel -1-.
Fig. 4: Identifying Knurled Wheel And Press 40148/1

CAUTION: Make careful not to damage any of the surrounding components when
using the press.
-- Disconnect electrical connection.
NOTE: There are different versions of the power outlet and cigarette lighter outlet due
to different mounting locations and construction. The differences are primarily
In the length and type of electrical connectors. On power outlets and cigarette
lighters with an electrical cable pig tail, additional work may be necessary to
access the connector.
-- Release puller retainers by pressing spindle -1- in direction of -arrow B-. Then release press -2- by turning
slightly to left -arrow A-. Remove the puller from the outlet.
Fig. 5: Identifying Release Of Puller Retainers As Shown

NOTE: Make sure the puller retainers are not spread.
CAUTION: The cigarette lighter could be ejected from the socket when the heating
cycle is complete.
Inserting the puller into the socket spreads the socket retainer springs and
reduces their ability to retain the cigarette lighter insert.
After removing the socket, bend the retainer springs together carefully to
tighten them and make sure the insert remains in the socket when the
heating cycle is complete.
-- Carefully bend retainer springs together -arrows-.
Fig. 6: Identifying Bending Of Retainer Springs Together

-- Make sure the cigarette lighter insert is not ejected completely into vehicle interior on completion of glow
cycle, and remains in receptacle.
Installing
CIGARETTE LIGHTER ILLUMINATION BULB
NOTE: On some vehicle equipment levels, socket illumination is via Light Emitting
Diode (LED) instead of a bulb. These LEDs are integrated with the illumination
housing and cannot be serviced or replaced separately.
Various versions of illumination housing with bulb exist. One version allows
separate replacement of the illumination bulb, and another where the bulb
cannot be serviced or replaced separately. In this case, the entire illumination
housing must be replaced.
Removing
-- Remove the socket. Refer to CIGARETTE LIGHTER SOCKET/12 VOLT SOCKET.

-- Depress retainers -arrows- and remove mounting sleeve with bulb holder.
Fig. 7: Identifying Removal Of Mounting Sleeve With Bulb Holder

-- Unclip bulb holder from mounting sleeve.
-- Separate bulb holder sections -A- and -B-.
Fig. 8: Identifying Separation Of Bulb Holder Sections

-- Open bulb holder section -B-.

-- Remove bulb in direction of -arrow-.
Fig. 9: Identifying Removal Of Bulb From Holder

Installing
SPECIAL TOOLS
 Puller T 40148
Fig. 10: Identifying Puller T 40148

Electrical System
Interior Lights, Switches
96 INTERIOR LIGHTS, SWITCHES

GENERAL INFORMATION
ANTI-THEFT ALARM SYSTEM
Functions of anti-theft alarm system are integrated in Comfort System Central Control Module -J393-.
Anti-theft alarm system must be adapted after replacing Comfort System Central Control Module, refer to
NOTE: If Comfort System Central Control Module is to be replaced, the work procedure
COMFORT SYSTEM CENTRAL CONTROL MODULE J393, REPLACE AND
CODING to read out the codes stored in the module must always be performed.
After replacing Comfort System Central Control Module, other functions of

equipment.
In this case, start by adapting the Anti-theft Immobilizer and then the other
equipment-dependent functions of access and start authorization in any order.
Refer to ANTI-THEFT IMMOBILIZER CONTROL MODULE -J362-, ADAPTING
Anti-theft alarm system is equipped with On Board Diagnostics (OBD) which assists troubleshooting.
ANTI-THEFT IMMOBILIZER CONTROL MODULE -J362-, ADAPTING .
NOTE: After anti-theft alarm system has triggered, the alarm source, which is stored in
Comfort System Central Control Module, can be checked, refer to ANTI-THEFT
ALARM SYSTEM SOURCES, CHECKING .
After Alarm Horn -H12- has triggered, the alarm source, which is stored in
Comfort System Central Control Module, can be checked, refer to ALARM
HORN SOURCES, CHECKING .
INTERIOR MONITORING DEACTIVATION SWITCH -E267- AND VEHICLE INCLINATION SENSOR DEACTIVATION
BUTTON -E360-
-- Removing and installing Interior Monitoring Deactivation Switch and Vehicle Inclination Sensor
Deactivation Button, refer to INTERIOR MONITORING DEACTIVATION SWITCH E267 AND
VEHICLE INCLINATION DEACTIVATION SENSOR BUTTON E360.
INTERIOR MONITORING SENSOR -G273-
Radar Interior Monitoring Control Module 1 -G303-, Vehicle Inclination Sensor -G384- and Interior
Monitoring Sensor -G273- (three sensors) compose one component.
The interior monitoring sensor is comprised of three individual sensors that are wired to the radar interior
monitoring control module 1.
Interior monitoring sensors cannot be replaced separately.
RADAR INTERIOR MONITORING CONTROL MODULE 1 -G303-
NOTE: Radar Interior Monitoring Control Module 1, Vehicle Inclination Sensor -G384-
and Interior Monitoring Sensor -G273- (three sensors) compose one
component.
VEHICLE INCLINATION SENSOR -G384-
Radar Interior Monitoring Control Module 1 -G303-, Vehicle Inclination Sensor -G384- and Interior
Monitoring Sensor -G273- (three sensors) compose one component.
The Vehicle Inclination Sensor cannot be serviced or replaced separately.
CENTRAL LOCKING AND ANTI-THEFT ALARM SYSTEM ANTENNA -R47-
The Central Locking and Anti-Theft Alarm System Antenna receives radio signals of the remote control key
and relays them to the Comfort System Central Control Module -J393-.
The Central Locking and Anti-Theft Alarm System Antenna consists of an RG174 HF-cable which has
approximately 17 cm of the shielding removed (the unshielded area of the cable serves as the antenna). The
Central Locking and Anti-Theft Alarm System Antenna is integrated with the wiring harness in the left A-pillar
and cannot be serviced or replaced separately.
ALARM HORN -H12-
The Alarm Horn is located in right front wheel housing.
ANTI-THEFT IMMOBILIZER
The Passat is equipped with Anti-theft Immobilizer 4 with on-line connection. The chief integral component of
the fourth generation immobilizer is a central database, in which all anti-theft relevant data of participating
control modules is stored. It is not possible to adapt the participating control modules to the immobilizer
without an on-line connection to this data bank.
On-line system test, refer to ANTI-THEFT IMMOBILIZER ON-LINE SYSTEM TEST.
Modifications from Immobilizer 3:
 It is not possible to request the PIN of anti-theft immobilizer components via fax or earlier clearing of the
components.
 All components participating on the immobilizer must be adapted on-line.
 All vehicle keys (subsequently ordered keys as well) are already pre-coded to a specific vehicle from the
factory and can only be adapted to this vehicle.
 It is necessary to have the VIN to be able to order replacement keys.
 It is no longer possible to perform adaptation on components originating from other Konzern brands in
Volkswagen vehicles.
Immobilizer Components:
 Anti-Theft Immobilizer Control Module -J362-, refer to ANTI-THEFT IMMOBILIZER CONTROL

MODULE -J362-.
 Electronic Steering Column Lock Control Module -J764-, refer to ELECTRONIC STEERING
COLUMN LOCK CONTROL MODULE -J764-.
 Electronic Ignition Switch -D9, refer to ELECTRONIC IGNITION SWITCH -D9-.
 Engine Control Module (ECM) -J623-, refer to [For engine(s) BLV] Engine Control Module -J623- ,
[For engine(s) BPY] Engine Control Module -J623- and [For engine(s) CCTA,CBFA] Engine
Control Module -J623- .
 Ignition key, refer to IGNITION KEY.
Replacing all immobilizer components, refer to ANTI-THEFT IMMOBILIZER NEW IDENTITY WHEN
REPLACING ALL COMPONENTS.
Functions of Anti-Theft Immobilizer Control Module -J362-:
 Communicating all theft relevant data to the central data bank via the on-line connection.
 Communication of all components participating on immobilizer with each other.
 Data encryption between participating control modules.
The immobilizer is equipped with On Board Diagnostic (OBD) capabilities which aids in troubleshooting.
ANTI-THEFT IMMOBILIZER CONTROL MODULE -J362-, ADAPTING .
ANTI-THEFT IMMOBILIZER CONTROL MODULE -J362-
The Anti-theft Immobilizer Control Module is integrated into Comfort System Central Control Module -J393-.
If anti-theft control module is malfunctioning, the Comfort System Central Control Module must be replaced.
-- Comfort System Central Control Module, removing and installing, refer to COMFORT SYSTEM
CENTRAL CONTROL MODULE J393 .
NOTE: If Comfort System Central Control Module is to be replaced, the work procedure
COMFORT SYSTEM CENTRAL CONTROL MODULE J393, REPLACE AND
CODING to read out the codes stored in the module must always be performed.
After replacing Comfort System Central Control Module, other functions of

equipment.
In this case, start by adapting the Anti-theft Immobilizer, refer to ANTI-THEFT

IMMOBILIZER CONTROL MODULE -J362-, ADAPTING and then the other
equipment-dependent functions of Comfort System Central Control Module in
any order.
ANTI-THEFT IMMOBILIZER READING MODULE -D1-
Anti-Theft Immobilizer Reading Module is integrated in the electronic ignition switch and cannot be replaced
individually.
Electronic Ignition Switch -D9-, refer to ELECTRONIC IGNITION SWITCH -D9-

The following components are integrated in the electronic ignition switch (depending on equipment):

 Ignition Switch Key Lock Solenoid -N376- (vehicles with automatic transmission only)
ELECTRONIC STEERING COLUMN LOCK CONTROL MODULE -J764-
The Steering Column Lock Actuator -N360- is integrated in the Electronic Steering Column Lock Control
Module.
Authorization of steering column lock/unlock occurs via Anti-Theft Immobilizer Control Module -J362- in
Comfort System Central Control Module -J393-.
FRONT DOOR LOCK COMPONENTS
Depending on equipment level, the following components are integrated with the driver door lock:
 Driver Door Contact Switch -F2-

 Driver Door Central Locking System Switch -F59-
 Driver Door Central Locking Lock Unit -F220-
 Driver Door Central Locking System Motor -V56-
 Driver Door Central Locking (Safe) Motor -V161-
Depending on equipment level, the following components are integrated with the front passenger door
lock:
 Front Passenger Door Contact Switch -F3-

 Front Passenger Door Central Locking Lock Unit -F221-
 Front Passenger Door Central Locking System Motor -V57-
 Front Passenger Central Locking (Safe) Motor -V162-
NOTE: The components listed above cannot be replaced separately.
All components in the driver's side door lock can be checked via output
Diagnostic Test Mode (DTM) of Driver Door Control Module -J386-, refer to
DRIVER DOOR CONTROL MODULE -J386-, OUTPUT DIAGNOSTIC TEST MODE .
All components in front passenger door lock can be checked using Front
Passenger Door Control Module -J387- On Board Diagnostic (OBD) program
function FRONT PASSENGER DOOR CONTROL MODULE -J387-, OUTPUT
In the event of front door lock component malfunctions:
-- Replace the respective door lock. Refer to DOOR LOCK .
FRONT INTERIOR LAMP
The following components are integrated in the front interior light, depending on equipment:
 Front Interior Lamp Button -E326-

 Driver Reading Lamp Button -E457-
 Front Passenger Reading Lamp Button -E458-
 Front Interior Lamp -W1-
 Left Center Reading Light -W39-
 Right Center Reading Light -W40-
 Sunroof Switch -E8-
 Sunroof Switch Illumination -L65-
 Telephone Microphone -R38-
NOTE: The Front Interior Lamp Button -E326-, Driver Reading Light Button -E457- and
Front Passenger Reading Light Button -E458- cannot be replaced individually.
The entire component must always be replaced in the event of repairs.
GARAGE DOOR OPENER
The garage door opener is integrated into driver's side sun visor. Garage Door Opener Control Module -J530-,
Garage Door Opener Button 1 -E392-, Garage Door Opener Button 2 -E393-, Garage Door Opener Button 3 -
E394- and Garage Door Opener Indicator Lamp -K179- are located in one component in the sun visor.
NOTE: Garage door opener cannot be replaced separately. If malfunctioning, the entire
sun visor must be replaced.
Removing:
-- Remove sun visor on driver's side. Refer to Removal and Installation .
LOST IGNITION KEY

All vehicle keys (subsequently ordered keys as well) are already pre-coded to a specific vehicle from the factory
and can only be adapted to this vehicle. The subsequent ordering of vehicle keys must be performed via entry of
the respective Vehicle Identification Number (VIN) and then the new keys must be adapted to the Comfort
System Central Control Module -J393-.
NOTE: If complete lock set (all keys and lock cylinder) is replaced, the Electronic
Steering Column Lock Control Module -J764- must also be replaced together
with Comfort System Central Control Module -J393-.
The function must be called up before removing the lock-set or the control
modules. Refer to: ANTI-THEFT IMMOBILIZER NEW IDENTITY WHEN
REPLACING ALL COMPONENTS
Adapting ignition key to Comfort System Central Control Module -J393-, refer to IGNITION KEY,
ADAPTING.
Checking ignition key, refer to IGNITION KEY, CHECKING.
REAR DOOR LOCK COMPONENTS
Depending on equipment level, the following components are integrated with the left rear door lock:
 Left Rear Door Contact Switch -F10-

 Left Rear Central Locking Lock Unit -F222-
 Left Rear Central Locking (Safe) Motor -V163-
 Left Rear Central Locking (Lock) Motor -V214-
Depending on equipment level, the following components are integrated with the right rear door lock:
 Right Rear Door Contact Switch -F11-

 Right Rear Central Locking Lock Unit -F223-
 Right Rear Central Locking (Safe) Motor -V164-
 Right Rear Central Locking (Lock) Motor -V215-
The Left Rear Central Locking Lock Unit -F222- and Right Rear Central Locking
Lock Unit -F223- can be checked with the Comfort System Central Control
Module -J393- output diagnostic test mode, refer to COMFORT SYSTEM
CENTRAL CONTROL MODULE -J393-, OUTPUT DIAGNOSTIC TEST MODE .
In the event of rear door lock component malfunctions:
-- Replace affected door lock. Refer to Removal and Installation .

REAR LID LOCK UNIT -F256-
The following components are integrated into the Rear Lid Lock Unit:
 Luggage Compartment Light Switch -F5-

 Rear Lid Opening Motor -V254-
Rear Lid Lock Unit can be checked via output Diagnostic Test Mode (DTM) of
Comfort System Central Control Module -J393-, refer to COMFORT SYSTEM
CENTRAL CONTROL MODULE -J393-, OUTPUT DIAGNOSTIC TEST MODE .
Rear Lid Lock Unit is integrated in rear lid lock and cannot be replaced separately.
In the event the Rear Lid Lock Unit malfunctions, the complete rear lid lock must be replaced.
-- Replace rear lid lock. Refer to Removal and Installation .
REAR INTERIOR AND READING LIGHTS
The following components are integrated in the rear interior and reading lights:
 Left Rear Reading Lamp -W11-

 Right Rear Reading Lamp -W12-
 Rear Interior Lamp -W43-
NOTE: Removal and installation of all lamps is identical, refer to REAR INTERIOR AND
READING LIGHT BULBS.
Interior and reading lights as well as switches for interior and reading lights are
integrated and cannot be serviced or replaced separately. In the event of
malfunction, the entire assembly must be replaced.
SIGNAL HORN -H- ACTIVATION
Activation of signal horns occurs via the spring-bearing cover in center of steering wheel. Depending on
equipment, signal horn activation is either a structural component of steering wheel or integrated in the driver's
side airbag unit and cannot be replaced individually. If signal horn activation is malfunctioning, replace driver's
side airbag unit or steering wheel.
Removing driver's side airbag unit. Refer to Removal and Installation .
Removing the steering wheel. Refer to Removal and Installation .
VANITY MIRROR LAMPS -W20- AND -W14- WITH CONTACT SWITCHES -F147- AND -F148-
Vanity mirror lamp contact switches as well as vanity mirror lamps are integrated in the sun visor and cannot be
replaced individually.
The entire sun visor must always be replaced if the vanity mirror contact switch or lamp is malfunctioning.
-- Replace simple sun visor. Refer to Removal and Installation .
-- Replace double sun visor. Refer to Removal and Installation .
ANTI-THEFT ALARM SYSTEM OVERVIEW
NOTE: Components of Anti-Theft Alarm System are dependent on vehicle equipment.

Fig. 1: Identifying Anti-Theft Alarm System, Assembly Overview

1. Front Hood Switch -F266-

 In hood lock
 Removing and installing, refer to FRONT HOOD SWITCH F266.
2. Alarm Horn -H12-

 In right front wheel housing
 Removing and installing, refer to ALARM HORN H12.

3. Comfort system central control module -J393-
 Behind the glove compartment.
 Removing and installing, refer to COMFORT SYSTEM CENTRAL CONTROL MODULE

J393 .
4. Front Passenger Door Control Module -J387-
 In front passenger door
5. Front Passenger Door Contact Switch -F3-

 In Front Passenger Door Central Locking Lock Unit -F221-.
 Removing and installing, refer to DOOR LOCK
6. Radar Interior Monitoring Control Module 1 -G303- With Interior Monitoring Sensors and
Vehicle Inclination Sensor -G384-
 In roof console.
 Removing and installing, refer to RADAR INTERIOR MONITORING CONTROL MODULE

1 -G303-.
7. Right Rear Door Contact Switch -F11-
 In Right Rear Central Locking Lock Unit -F223-.
8. Rear Lid Lock Unit -F256-

9. Left Rear Door Contact Switch -F10-

 In Left Rear Central Locking Lock Unit -F222-.
10. Interior Monitoring Deactivation Switch -E267- and Deactivate Vehicle Inclination Sensor Button -
E360-
 In driver's side B-pillar trim.
 Removing and installing, refer to INTERIOR MONITORING DEACTIVATION SWITCH

E267 AND VEHICLE INCLINATION DEACTIVATION SENSOR BUTTON E360.
11. Driver Door Contact Switch -F2-
 In Driver Door Central Locking Lock Unit -F220-.
 Removing and installing, refer to DOOR LOCK .
12. Central Locking -SAFE- Indicator Lamp -K133-

 In front door trim.
 Removing and installing, refer to CENTRAL LOCKING -SAFE- INDICATOR LAMP K133.
13. Driver Door Control Module -J386-

 In driver door.

14. Central Locking and Anti-Theft Alarm System Antenna -R47-

 Behind the trim on the A-pillar, refer to CENTRAL LOCKING AND ANTI-THEFT ALARM
SYSTEM ANTENNA -R47-.
ANTI-THEFT ALARM SYSTEM, ACTIVATING AND DEACTIVATING
Activating Anti-Theft Alarm System:
Anti-theft alarm system is automatically switched on by locking the vehicle. Anti-theft alarm system is then
activated immediately.
NOTE: So that anti-theft alarm system does not trigger unnecessary alarms, close all
windows and doors before locking the vehicle.
Anti-theft alarm system does not activate if:
 Ignition terminal 15 is switched on.

 Immobilizer transmits an authorized key.
 Driver's door is opened.
 Door control module is not OK.
Deactivating Anti-Theft Alarm System:
 Anti-theft alarm system is deactivated when the vehicle is unlocked via the unlock button on radio-
frequency remote control, or
 If vehicle is opened with keyless access, or
 When ignition terminal 15 is switched on, or
 When immobilizer transmits an authorized key.
Unlocking Vehicle Mechanically (Emergency Opening).
-- Unlock vehicle at driver's door using emergency key.
Anti-theft alarm system remains activated, however no alarm is triggered.
-- Switch on ignition within 15 seconds.
NOTE: If the ignition is not switched on after 15 seconds the alarm is triggered.
By switching on the ignition, the electronic immobilizer recognizes a valid vehicle key and deactivates the anti-
theft alarm system.
IGNITION KEY
The ignition key is designed without a key bit since the vehicle is started for the first time with a sliding motion
and not a rotary motion. The reading coil for key identification and an emergency key is integrated in the
ignition key. The emergency key provides the means to open the driver's door mechanically if it is not possible
to open it using the remote control. The emergency key is contained within the ignition key and can be pushed
out by the side button in two stages.
Detent 1 = emergency key is completely inserted.
Stage 2 = Key ring mount can be used - emergency key remains locked
Switch-on of the various terminal voltages (terminal S, terminal 15) and the start procedure are performed by a
sliding motion of the ignition key in the Electronic Ignition Switch -D9-. The following switch positions are
possible via sliding motions of the ignition key:
 P0 - Off (preliminary engaged position)

 P1 - S-terminal on
 P3 - terminal 15 drive (in this position, ignition key springs back automatically after the start procedure)
For vehicles with Kessy equipment (Keyless Entry Start Stop System), switch procedures in ignition lock are
performed using a ignition/starter switch button. The ignition/starter switch button remains in the ignition lock
and functions only in conjunction with a valid remote control ID sensor. Additional information on the KESSY
system, refer to ACCESS/START AUTHORIZATION .
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS, ALARM HORN -H12-

Self-locking Nut 5 Nm
Shear Bolts 7 Nm
FASTENER TIGHTENING SPECIFICATIONS, HIGH TONE HORN -H2-
Tightening
Specifications
Bracket
Mounting
Bolt To M6 20 Nm
Longitudinal
Member
FASTENER TIGHTENING SPECIFICATIONS, LOW TONE HORN -H7-

Tightening
Specifications
Bracket
Mounting
Bolt To M6 20 Nm
Longitudinal
Member
ALARM DELAY WHEN OPENING DRIVER'S DOOR, ADAPTING
 Vehicle Diagnosis, Testing and Information System -VAS5051B-
This function allows the alarm delay when opening driver's door to be switched on and off.
-- Connect the -VAS5051B-.
-- On the -VAS5051B-, select "Guided Fault Finding".
sequence:
 Body
 Comfort system
 Functions - central control module for comfort system
 Alarm delay when opening driver's door, adapting
ALARM HORN -H12-, CHECKING
Alarm Horn can be checked via output Diagnostic Test Mode (DTM) of Comfort System Central Control
Module -J393-, refer to COMFORT SYSTEM CENTRAL CONTROL MODULE -J393-, OUTPUT
ANTI-THEFT IMMOBILIZER CONTROL MODULE -J362-, ADAPTING
After replacing Comfort System Central Control Module -J393-, immobilizer must be adapted.
sequence:
 Body
 Anti-Theft Immobilizer
 Anti-theft Immobilizer functions
 Adaptation when replacing immobilizer
ANTI-THEFT IMMOBILIZER NEW IDENTITY WHEN REPLACING ALL COMPONENTS
All required steps necessary for new installation of all immobilizer components are performed by this program.
sequence:
 Body
 New Identity When Replacing All Components
ANTI-THEFT IMMOBILIZER ON-LINE SYSTEM TEST
The following steps will be performed by this test program:

 System test for the on-line connection

 Test of user authorization
 Testing for the correct connection to the Volkswagen data bank
It is necessary that the tester have an on-line connection (network connection)
sequence:
 Body
 On-line system test
CENTRAL LOCKING -SAFE- INDICATOR LAMP -K133-, CHECKING
Central Locking -SAFE- Indicator Lamp can be checked via output Diagnostic Test Mode (DTM) of Driver
Door Control Module -J386-, refer to DRIVER DOOR CONTROL MODULE -J386-, OUTPUT
ELECTRONIC IGNITION SWITCH -D9-, CHECKING
sequence:
 Body
 Immobilizer electrical components
 D9 - Electronic Ignition Switch
ELECTRONIC STEERING COLUMN LOCK CONTROL MODULE -J764-, ADAPTING
 Vehicle Diagnostic Tester
-- Connect the Vehicle diagnostic tester. Refer to Procedure .
-- On the Vehicle diagnostic tester, select "Guided Fault Finding".
sequence:
 Body
 Adapt the electric steering column adjustment
ELECTRONIC STEERING COLUMN LOCK CONTROL MODULE -J764-, CHECKING
sequence:
 Body
 J764 - Electronic Steering Column Lock Control Module
FOOTWELL LAMPS, CHECKING

The footwell lights (Left Footwell Light -W9- and Right Footwell Light -W10- can be checked via output
Diagnostic Test Mode (DTM) of Vehicle Electrical System Control Module -J519-. Refer to VEHICLE
FRONT ENTRY LIGHTS -W31- AND -W32-, CHECKING
Left Front Entry Light -W31- can be checked via output Diagnostic Test Mode (DTM) of Driver Door Control
Module -J386- , refer to DRIVER DOOR CONTROL MODULE -J386-, OUTPUT DIAGNOSTIC TEST
MODE .
Right Front Entry Light -W32- can be checked via output Diagnostic Test Mode (DTM) of Front Passenger
Door Control Module -J387-, refer to FRONT PASSENGER DOOR CONTROL MODULE -J387-,
HORNS -H2- AND -H7-, CHECKING
Signal horns (High Tone Horn -H2- and Low Tone Horn -H7-) can be checked via output Diagnostic Test Mode
(DTM) of Vehicle Electrical System Control Module -J519- , refer to VEHICLE ELECTRICAL SYSTEM
CONTROL MODULE -J519- OUTPUT DIAGNOSTIC TEST MODE .
IGNITION KEY, ADAPTING
Adapting ignition key to Comfort System Central Control Module -J393-:
sequence:
 Body
 Ignition key adaptation
IGNITION KEY, CHECKING

sequence:
 Body
 Ignition Key
REAR ENTRY LIGHTS -W33- AND -W34-, CHECKING
The Left Rear Entry Lamp -W33- and Right Rear Entry Lamp -W34- can be checked using the Comfort System
Central Control Module -J393- output diagnostic test mode, refer to COMFORT SYSTEM CENTRAL
CONTROL MODULE -J393-, OUTPUT DIAGNOSTIC TEST MODE .
SIGNAL HORN H ACTIVATION, CHECKING
sequence:
 Body
 H - Signal Horn Activation

ALARM HORN H12
 Drill -VAS 5134-

 Drill bit 2.5 mm
 Drill bit 6 mm
NOTE: To remove the alarm horn, anti-theft alarm system must be deactivated, refer to
ANTI-THEFT ALARM SYSTEM, ACTIVATING AND DEACTIVATING.
Removing:
(ignition off).
-- Remove right front wheel housing liner. Refer to Removal and Installation .
-- Use -VAS 5134- with 6 mm drill bit to remove the heads from both shear bolts -arrows-.
Fig. 2: Identifying Shear Bolts

-- Disengage harness connector -1- through opening in housing -2- using a small screwdriver and remove Alarm
Horn -3- out of wheel housing.
Fig. 3: Identifying Harness Connector, Opening In Housing, Small Screwdriver And Alarm Horn H12
-- Use -VAS 5134- with 2.5 mm drill bit to remove remaining threads -arrows-. Restore threads with
appropriate thread tap.
Fig. 4: Identifying Alarm Horn H12 Treads

Installing:
NOTE: Remove all metal shavings through the drilled holes.
-- Apply the necessary corrosion protection. Refer to Appropriate Information; Body Repairs, Body Collision
Repair
-- Connect the connector to the Alarm Horn.
NOTE: For reasons of clarity, the Alarm Horn is not depicted in the following 3ions and
thus the connector is not connected.
-- Guide clip -2- for Alarm Horn into body cutout -1-.
Fig. 5: Identifying Alarm Horn H12 Guide Clip And Body Cutout
-- Secure Alarm Horn with new shear bolts.
-- Tighten shear bolts until bolt heads shear off.
-- Install right front wheel housing liner. Refer to Removal and Installation .
CENTER CONSOLE LAMPS AND SWITCHES
SWITCHES IN CENTER CONSOLE
The same procedure is used to remove and install the following components. The procedure is only described
for one component.
 Rear Window Shade Switch -E149-

 ASR/ESP Button -E256-
 Parallel Parking Assistance Button -E581-

 Tire Pressure Monitoring Display Button -E492-
 -AUTO HOLD- Button -E540-
NOTE: When removing and installing components in a visible area (switches, covers,
trim, etc.), mask off the areas at which a prying tool (3409, screwdriver) will be
positioned, using commercially available adhesive tape.
Removing:
(ignition off).
-- Carefully remove trim -1-.
Fig. 6: Identifying Switches In Center Console Trim

-- Disconnect electrical connector.
-- Disengage retaining tabs and remove switch.
Installing:
FRONT ASHTRAY LAMP AND CIGARETTE LIGHTER U1
The front ashtray light function is undertaken by the Cigarette Lighter Illumination -L28-. It is a structural
component of Cigarette Lighter and can only be removed and installed together with Cigarette Lighter.
The Cigarette Lighter is located in the front center console, next to the ashtray.
-- Cigarette Lighter removing and installing, refer to CIGARETTE LIGHTER SOCKET/12 VOLT
SOCKET .
REAR HEATED SEAT REGULATING SWITCHES -E128- AND -E129-
Removal and installation of the following components is performed for Left Rear Heated Seat Regulating
Switch -E128- and Right Rear Heated Seat Regulating Switch -E129- in the same way and is only described for
one component.
Removing:
(ignition off).
Fig. 7: Identifying Rear Center Console Lower Trim

Fig. 8: Identifying Rear Center Console Panel Mounting Bolts

-- First pull panel toward rear in -direction of arrow 1- , then upward in -direction of arrow 2- and remove panel.
Fig. 9: Identifying Removal Of Center Console Rear Panel

-- Disengage connector -1- and disconnect it.

Fig. 10: Identifying Left Rear Heated Seat Regulating Switch E128 Connector
-- Remove Left Rear Heated Seat Regulating Switch -2- from panel.
Installing:
STORAGE COMPARTMENT ILLUMINATION -L120-
Removing:
(ignition off).



-- First pull panel toward rear in -direction of arrow 1-, then upward in -direction of arrow 2- and remove panel.

-- Unclip harness connector -2- , disengage it and disconnect connector.
Fig. 14: Identifying Storage Compartment Illumination L120 And Harness Connector
-- Unclip Storage Compartment Illumination -1- and remove it with wire.
Installing:

CONVERTER WITH SOCKET 12V-230V -U13-
WARNING:  The Converter with Socket, 12V-230V housing contains chargeable

capacitors.
 There is a danger of electric shock.
 The housing of Converter with Socket 12V-230V must not be opened
under any circumstances.
No repairs may be performed on the harness connector, on the wires and the
230V outlet.
If there is a fault at harness connector, at wires, at 230V socket or in the

converter, the complete unit must always be replaced.
Removing:
(ignition off).



-- First pull panel toward rear in -direction of arrow 1-, then upward in -direction of arrow 2- and remove panel.

Fig. 18: Identifying Converter With Socket, 12V, 230V U13 Harness Connector
-- On vehicles with heated rear seats, unclip rear heated seat regulating switch from panel.
-- Disengage power outlet at retaining lugs -arrows- and disconnect it.
Fig. 19: Identifying Power Outlet Retaining Lugs


Fig. 20: Identifying Converter With Socket, 12V, 230V U13 Mounting Screws
Installing:
 Pliers -VAS 6339-
NOTE: Coding, basic setting or adaptation is not necessary if Electronic Ignition

Switch is replaced.
Removing:
(ignition off).

-- Remove driver's side panel. Refer to Removal and Installation .
-- Push cover -3- down with panel -1- to gain access to catches of panel -1-.
Fig. 21: Identifying Cover, Panel And Electronic Ignition Switch D9 Panel
-- Press catches of panel -1- outward using -VAS 6339- through the recesses -2- on both sides.
Fig. 22: Identifying Catches Of Panel Pressed Outward Using Pliers VAS 6339 Through The Recesses
-- Remove trim.

Fig. 23: Identifying Electronic Ignition Switch D9 Mounting Bolt

-- Release catches -arrow- on both sides and remove Electronic Ignition Switch -2- in -direction of arrow- from
driver's side panel -1-.
Fig. 24: Identifying Catches On Both Sides And Electronic Ignition Switch D9 From Drivers Side Panel
Installing:
NOTE: When installing, make sure electronic ignition switch locks securely in driver's
side panel.
ELECTRONIC STEERING COLUMN LOCK CONTROL MODULE -J764-
 Socket Insert -T10424-
Removing:
NOTE: The electronic steering column lock control module is secured to the steering
column with shear bolts.
The Vehicle Diagnostic Tester provides all of the information about the
remainder of the procedure.
Perform the function ELECTRONIC STEERING COLUMN LOCK CONTROL

MODULE -J764-, ADAPTING, if the electronic steering column lock control
module -J764- is replaced.
-- Remove steering column with electronic steering column lock control module. Refer to Removal and
Installation .
-- Carefully tighten the steering column in the vise -1- using protective backings and pivot the universal joint -2-
downward.
Fig. 25: Identifying Tension The Steering Column & Universal Joint
-- Remove the lower shear bolt from the electronic steering column lock control module using -T10424-.
NOTE: Remove any shavings with a brush. Otherwise, damage could result.
-- Loosen the vise and rotate the steering column 180°.
-- Tighten the vise and pivot the universal joint -2- downward.
-- Remove the lower shear bolt -arrow- from the -electronic steering column lock control module- using -
T10424-.
Fig. 26: Identifying Electronic Steering Column Lock Control Module -J764 & Universal Joint
NOTE: Remove any shavings with a brush. Otherwise, damage could result.
Rotating 180° is necessary to prevent any shavings from enter the steering
column from above when removing the shear bolt.
Installing:
-- Secure the electronic steering column lock control module -1- with new shear bolts -arrows-. Tighten the
shear bolts evenly until the heads shear off.
Fig. 27: Identifying Electronic Steering Column Lock Control Module

-- Install the steering column with the electronic steering column lock control module. Refer to Removal and
Installation .
FRONT DOOR LAMPS AND SWITCHES
CENTRAL LOCKING -SAFE- INDICATOR LAMP K133
Removing:
(ignition off).
-- Remove door trim. Refer to Removal and Installation .
-- Unclip Central Locking -SAFE- Indicator Lamp -1- from door trim by pressing retaining tabs -arrows-
together.
Fig. 28: Identifying Central Locking -SAFE- Indicator Lamp K133

-- Disconnect connector -1- from central locking -SAFE- indicator lamp -2-.
Fig. 29: Identifying Central Locking -SAFE- Indicator Lamp K133 And Harness Connector
Installing:
DRIVER INTERIOR LOCKING BUTTON -E308-
The following components are integrated in the Driver Interior Locking Button:

 Driver Interior Locking Indicator Lamp -K174-
Removing:
(ignition off).

-- Disconnect the connector -1- and remove the screw -arrow-.
Fig. 30: Identifying Drivers Interior Locking Button E308 Harness Connector And Bolt
-- Disengage retaining tabs -arrows- and remove door opener with Driver Interior Locking Button.
Fig. 31: Identifying Drivers Interior Locking Button E308 Retaining Tabs
-- Disengage retaining tabs -arrows- and remove Driver Interior Locking Button -1-.
Fig. 32: Identifying Drivers Interior Locking Button E308 Retainers

Installing:
FRONT ENTRY LAMPS -W31- AND -W32-
NOTE: Removal and installation for all entry lights is performed in the same way and is
only described for one light.
Entry lights:
 Left Front Entry Light -W31-

 Right Front Entry Light -W32-
 Left Rear Entry Light -W33-
 Right Rear Entry Light -W34-
Removal and installation for all entry lights is performed in the same way and is
only described for one light.
Removing:
(ignition off).
-- Carefully pry out lights using -3409- or a screwdriver.
Fig. 33: Identifying Lights To Pry-Out Using Trim Removal Wedge 3409
Bulb, replacing:
-- Carefully pry the diffusion lens off the housing.

Fig. 34: Identifying Prying Off Diffusion Lens

-- Carefully pull lamp -1- out of socket.
Fig. 35: Identifying Lamp Removed From Socket

-- Replace the glass base bulb (12V, 5 W).
Installing:

FRONT PASSENGER DOOR WINDOW REGULATOR SWITCH -E107-
NOTE: Power Window Switch Illumination -L53-, which cannot be replaced separately,
is integrated in Front Passenger Door Window Regulator Switch -E107-.
Removing:
(ignition off).
-- Remove the mounting bolts -arrows- and remove handle with Front Passenger Door Window Regulator
Switch.
Fig. 36: Identifying Window Regulator Switch (In RF Door) E107 And Mounting Bolts
-- Disengage retaining tabs -arrows- and remove window regulator switch -1-.
Fig. 37: Identifying Locating Window Regulator Switch (In RF Door) E107 And Retaining Tabs
Installing:
REAR LID REMOTE RELEASE BUTTON -E233-
Removing:
(ignition off).
-- Disengage retaining tabs -arrows- and remove Fuel Filler/Rear Lid Remote Unlocking Button -2- from door
trim.
Fig. 38: Identifying Fuel Filler/Rear Lid Remote Unlocking Button E463 And Retaining Tabs
Installing:
MIRROR ADJUSTMENT SWITCH -E43-
The following components are integrated in Mirror Adjustment Switch (depending on equipment):
 Mirror Selector Switch -E48-

 Outside Mirror Heating Switch -E231-
 Mirror Folding Switch -E263-
 Mirror Adjustment Switch Illumination -L78-
NOTE: When removing and installing components in visible area (switches, covers,
trim, etc.), cover by taping the areas at which a prying tool (3409, screwdriver)
will be positioned using commercially available adhesive tape.
Removing:
(ignition off).
-- Carefully pry off grip panel at retaining lugs -arrows- using -3409-.
Fig. 39: Identifying Grip Panel To Pry Off At Retaining Lugs Using Trim Removal Wedge 3409
-- Disconnect the connector -arrow-.
Fig. 40: Identifying Mirror Adjustment Switch E43 Harness Connector

-- Disengage retaining tabs -arrows- and remove Mirror Adjustment Switch -1- from grip panel.
Fig. 41: Identifying Mirror Adjustment Switch E43 Retaining Tabs

Installing:
REAR LID REMOTE LOCK KEY SWITCH -E232-
Removing:
(ignition off).

Fig. 42: Identifying Rear Lid Remote Lock Key Switch E232 And Harness Connector
-- Disengage retaining tabs -arrows- and remove Rear Lid Remote Lock Key Switch -1- from door trim.
Fig. 43: Identifying Rear Lid Remote Lock Key Switch E232 And Retaining Tabs
Installing:
SHIFT ELEMENT, DRIVER SIDE

Depending on equipment level, the following components are integrated with the driver door switch module:
 Left Front Window Regulator Switch -E40-

 Driver Left Rear Window Regulator Switch -E53-
 Driver Right Rear Window Regulator Switch -E55-
 Driver Right Front Window Regulator Switch -E81-
 Child Safety Button -E318-
Removing:
(ignition off).
-- Carefully pry off grip panel at retaining lugs -arrows- using -3409-.
Fig. 44: Identifying Grip Panel To Pry Off At Retaining Lugs Using Trim Removal Wedge 3409

Fig. 45: Identifying Drivers Door Switch Module And Harness Connector
-- Release retainers -arrows- and remove switch element -1- from grip trim.
Fig. 46: Identifying Drivers Door Switch Module And Retaining Tabs
Installing:
FRONT HOOD SWITCH F266

Removing:
(ignition off).
-- Remove hood lock. Refer to Removal and Installation .
-- Disengage harness connector -2- and disconnect it.
Fig. 47: Identifying Front Hood Switch F266 Harness Connector And Wire Retainer
-- Unclip wire retainer -1-.
-- Cut cable tie -2-.

Fig. 48: Identifying Front Hood Switch F266 Cable Tie And Retaining Lug
-- Disengage retaining lug -1- and move the Front Hood Switch in the longitudinal holes so that it can be
removed.
Installing:
HORNS
NOTE: High Tone Horn -H2- and Low Tone Horn -H7- are activated in parallel by Vehicle
Electrical System Control Module -J519-.
Removal and installation procedure for both horns is the same.
High Tone Horn -H2- is installed at left and Low Tone Horn -H7- is installed at
right, next to radiator.
Removing:

Fig. 49: Identifying Electrical Connection, Mounting Bolt And Signal Horn
-- Remove the mounting bolt -1- and remove signal horn -3- with bracket.
Installing:
-- Install in reverse order of removal, noting the following:
-- Tighten the fasteners to the specification shown in SPECIFICATIONS.
INSTRUMENT PANEL LAMPS AND SWITCHES
ELECTRO-MECHANICAL PARKING BRAKE BUTTON -E538-
 Trim Removal Wedge -VAS 3409-
The following components are integrated in the Electro-Mechanical Parking Brake Button:
 Electro-mechanical Parking Brake Indicator Lamp -K213-

 -AUTO HOLD- Indicator Lamp 2 -K238-
Removing:
(ignition off).
-- Remove side cover -1- of instrument panel, do this by inserting -3409- or a screwdriver into recess -2- and
pry off cover -1- in -direction of arrow-.
Fig. 50: Identifying Removal Of Instrument Panel Driver Side Cover

-- Push Electro-Mechanical Parking Brake Button -1- out of instrument panel from rear.
Fig. 51: Identifying Electro-Mechanical Parking Brake Button E538

Fig. 52: Identifying Electro-Mechanical Parking Brake Button E538 And Harness Connector
Installing:
EMERGENCY FLASHER SWITCH -E3-

The following component is integrated in Emergency Flasher Switch:
 Emergency Flasher Indicator Lamp -K6-
Remove the panels only in the sequence indicated.
Removing:
(ignition off).
-- Remove panel -2- using -3409-. Refer to Removal and Installation .
Fig. 53: Identifying Entertainment Console Trim


-- Remove the mounting bolts -arrows- and remove bracket -1- with Emergency Flasher Switch.
Fig. 54: Identifying Bracket With Emergency Flasher Switch E3 And Mounting Bolts
Fig. 55: Identifying Emergency Flasher Switch E3 And Harness Connector

-- Disengage retaining lugs -arrows- and remove Emergency Flasher Switch -1-.
Fig. 56: Identifying Emergency Flasher Switch E3 And Tabs

Installing:
FOOTWELL LAMPS
 Left Footwell Lamp -W9-

 Right Footwell Lamp -W10-
NOTE: The foot well lights are located in trim beneath instrument cluster.
Removing and installation is the same for all footwell lights and is described
here for only one light.
Removing:
(ignition off).
-- Carefully pry out footwell lights using -3409- or a screwdriver.
Fig. 57: Locating Footwell Lights

-- Disengage harness connector and disconnect it.
Bulb, Replacing:
-- Disengage retaining tabs -1- and remove heat shield -2- from diffusion lens of foot well light.
Fig. 58: Identifying Retaining Tabs & Heat Shield

-- Carefully pry bulb from socket.
Fig. 59: Identifying Prying Bulb From Socket

-- Replace the glass base bulb (12V, 5W).
Installing:
FRONT PASSENGER AIRBAG -DISABLED- INDICATOR LAMP K145
WARNING: Observe safety precautions when working on the airbag. Refer to General
Information .
trim, etc.), mask off the areas at which a prying tool (-3409-, screwdriver) will be
Removing:
(ignition off).
-- Carefully pry off panel -1- using -VAS 3409- at retaining lugs -arrows-.
Fig. 60: Identifying Trim To Pry Up Using Trim Removal Wedge VAS 3409 At Retainers
Fig. 61: Identifying Front Passengers Airbag Disabled Indicator Lamp K145 And Harness Connector
-- Disengage Front Passenger's Airbag Disabled Indicator Lamp -arrow- and remove it from panel.
Installing:
GLOVE COMPARTMENT LAMP -W6-
Removing:
(ignition off).
-- Carefully pry out Glove Compartment Lamp using 3409 or a screwdriver.
Fig. 62: Identifying Screwdriver To Pry-Out Glove Compartment Light W6

Bulb, replacing:
Fig. 63: Identifying Retaining Tabs & Heat Shield

-- Release the tabs -1- and remove the heat shield -2- from the diffusion lens in the glove compartment lamp.
-- Carefully pry bulb from socket.
Fig. 64: Identifying Screwdriver To Pry-Out Bulb From Socket

Installing:
GLOVE COMPARTMENT LAMP SWITCH -E26-
NOTE: The illustration shows Glove Compartment Lamp Switch -1- with instrument
panel removed. The instrument panel does not need to be removed in order to
remove and install the switch.
Fig. 65: Identifying Glove Compartment Lamp Switch E26

Glove Compartment Lamp Switch -1- can be reached through the opened glove
compartment and can be unclipped.
Removing:
(ignition off).
-- Unclip Glove Compartment Lamp Switch -1- with connected wire -arrows-.
-- Pull out Glove Compartment Lamp Switch as far as wire lengths permit and disconnect harness connector.
Installing:
LIGHT SWITCH -E1-
The following components are integrated with Light Switch:

 Fog Lamp Switch -E7-

 Rear Fog Lamp Switch -E18-
 Headlamp Switch Light -L9-
Removing:
(ignition off).
-- Turn light switch rotary knob to 0 position.
-- Push in light switch rotary handle -arrow 1- and turn it slightly toward right -arrow 2-.
Fig. 66: Identifying Operating Method For Light Switch Rotary Handle
-- Hold rotary handle in this position and pull Light Switch on rotary handle out of instrument panel -arrow 3-.
-- Disengage harness connector -arrow- and disconnect the connector from the light switch.
Fig. 67: Locating Light Switch E1 Harness Connector

Installing:
-- Connect the connector to the light switch.
NOTE: For reasons of clarity, vehicle floor carpet is not depicted in the illustration.
-- Hold light switch firmly in place and push light switch rotary hand in -1- and at the same time rotate it toward
the right -2-.
Fig. 68: Identifying Installation Method For Light Switch

-- Hold rotary knob in this position and insert light switch into instrument panel -3-.
-- Turn rotary handle to position 0, release and thus engage switch.
HEADLAMP ADJUSTER -E102- AND INSTRUMENT PANEL ILLUMINATION DIMMER SWITCH -E20-
NOTE: Headlamp Adjuster and Instrument Panel Illumination Dimmer Switch compose
one component.
Removing:
(ignition off).
-- Remove cover -2-.
Fig. 69: Identifying Headlamp Adjuster E102, Instrument Panel Illumination Dimmer Switch E20 And
Panel Cover
-- Press switch -1- out of instrument panel from rear.

Fig. 70: Identifying Headlamp Adjuster E102, Instrument Panel Illumination Dimmer Switch E20 And
Harness Connector
Installing:
INTERIOR MONITORING DEACTIVATION SWITCH E267 AND VEHICLE INCLINATION DEACTIVATION

SENSOR BUTTON E360
To remove the Interior Monitoring Deactivation Switch and Deactivate Vehicle

Inclination Sensor Button, anti-theft alarm system must be deactivated.
The Interior Monitoring Deactivation Switch and Deactivate Vehicle Inclination

Sensor Button compose one component.
Interior Monitoring Deactivation Switch and Deactivate Vehicle Inclination

Sensor Button are located in B-pillar trim on driver's side.
The following components are integrated in the Interior Monitoring Deactivation Switch:
 Interior Monitoring -Off- Indicator Lamp -K162-

 Interior Monitoring Deactivation Switch Illumination -L118-
The following components are integrated in the Deactivate Vehicle Inclination Sensor Button:
 Interior Monitoring -Off- Indicator Lamp

The Interior Monitoring -Off- Indicator Lamp and Vehicle Inclination Sensor Indicator Lamp -K188- can be
checked via output Diagnostic Test Mode (DTM) of Comfort System Central Control Module -J393-, refer to
COMFORT SYSTEM CENTRAL CONTROL MODULE -J393-, OUTPUT DIAGNOSTIC TEST
MODE .
Removing:
(ignition off).
-- Carefully pry out Interior Monitoring Deactivation Switch and Deactivate Vehicle Inclination Sensor Button
using -VAS 3409- or a screwdriver.
Fig. 71: Identifying Interior Monitoring Deactivation Switch E267, Vehicle Inclination Sensor Button
E360 And Screwdriver
-- Disengage harness connector -arrow- and disconnect it.

Fig. 72: Identifying Interior Monitoring Deactivation Switch E267 And Vehicle Inclination Sensor Button
E360 Connector
Installing:
LUGGAGE COMPARTMENT LAMP -W3-
Removing:
(ignition off).
-- Carefully pry out Luggage Compartment Lamp using -3409- or a screwdriver.

Fig. 73: Locating Luggage Compartment Light W3

Fig. 74: Identifying Luggage Compartment Light Connector

Bulb, replacing:
-- Push contact plate -1- of Luggage Compartment Light in -direction of arrow- and remove light lamp -2- out
of socket.
Fig. 75: Identifying Contact Plate & Light Lamp

-- Replace the tubular bulb (12V, 10 W).
Installing:
RADAR INTERIOR MONITORING CONTROL MODULE 1 -G303-
Removing:
(ignition off).

Fig. 76: Identifying Front Interior Light Module Trim

-- Remove screws -1-, release retainers -arrows B- and remove interior light module from headliner opening -
direction of arrow A-, considering length of available cable.
Fig. 77: Identifying Screws, Retainers And Interior Light Module From Headliner Opening
-- Disconnect the connectors -1- and -2-.
Fig. 78: Identifying Front Interior Light Module Electrical Connections

-- For vehicles with hands-free telephone equipment, unclip Telephone Microphone -R38- -arrow-.
-- Remove front interior light.
-- Remove the bolts -arrows A- , disengage retaining lugs -arrows B- and remove console from molded
headliner in -direction of arrow C-.
Fig. 79: Identifying Bolts, Retaining Lugs And Console From Molded Headliner
-- Disconnect connector -2- from Radar Interior Monitoring Control Module 1 -1-.
Fig. 80: Identifying Radar Interior Monitoring Control Module 1 G303 And Electrical Connector
-- Disengage Radar Interior Monitoring Control Module 1 -1- at retaining lug -arrow-.
-- Release retainers at interior monitoring sensors and remove from headliner along with Radar Interior
Monitoring Control Module 1.
Fig. 81: Identifying Radar Interior Monitoring Control Module 1 G303 And Retaining Lugs
REAR DOOR LAMPS AND SWITCHES
REAR WINDOW SWITCHES -E52- AND -E54-
NOTE: Removal and installation is performed at the Left Rear Power Window Switch In
Left Rear Door -E52- and Right Rear Window Switch In Right Rear Door -E54- in
the same way and is described for only one switch.
Power Window Switch Illumination -L53-, which cannot be replaced separately,

is integrated in Left Rear Power Window Switch In Left Rear Door -E52-.
Power Window Switch Illumination -L53-, which cannot be replaced separately,

is integrated in Right Rear Window Switch In Right Rear Door -E54-.
Removing:
(ignition off).

-- Remove the mounting bolts -arrows- and remove handle with window regulator switch.
Fig. 82: Identifying Handle With Window Regulator Switch Mounting Bolts
-- Disengage retaining tabs -arrows- and remove window regulator switch -1-.
Fig. 83: Identifying Rear Window Switch E52 And E54 And Retaining Tabs
Installing:

REAR ENTRY LAMPS -W33- AND -W34-
NOTE: Removal and installation for all entry lights is performed in the same way and is
only described for one light. Refer to FRONT ENTRY LAMPS -W31- AND -W32-.
ROOF TRIM LAMPS AND SWITCHES
FRONT INTERIOR LAMP -W1-
Removing:
(ignition off).
Fig. 84: Identifying Front Interior Light Module Trim

-- Remove screws -1- , release retainers -arrows B- and remove interior light module from headliner opening -
direction of arrow A- , considering length of available cable.
Fig. 85: Identifying Screws, Retainers And Interior Light Module From Headliner Opening
-- Disconnect the connectors -1- and -2-.
Fig. 86: Identifying Front Interior Light Module Electrical Connections

-- For vehicles with hands-free telephone equipment, unclip Telephone Microphone -R38- -arrow-.
-- Remove front interior light.
Installing:
FRONT INTERIOR BULB
Removing:
(ignition off).
-- Remove front interior lamp. refer to FRONT INTERIOR LAMP W1.
-- Push contact plate -1- of Front Interior Lamp -W1- in -direction of arrow- and remove soffit -2- together with
contact plate out of mount.
Fig. 87: Identifying Front Interior Light W1 Bulb

-- Replace the tubular bulb (12V, 10 W).
Installing:
FRONT MAP/READING LIGHTS -W13- AND -W19-
NOTE: Lamp replacement is performed in the same way at both map/reading lights.
Removing:
(ignition off).
-- Remove front interior lamp, refer to FRONT INTERIOR LAMP W1.
-- Turn light socket in direction of -arrow- and remove.
Fig. 88: Identifying Front Map / Reading Lights W13 And W19 Light Socket
-- Carefully remove bulb from socket.

Fig. 89: Identifying Bulb Removed From Socket

Installing :
SUNROOF SWITCH -E8-
NOTE: The Sunroof Switch Illumination Bulb -L65- is located in the Sunroof Switch.
Removing:
(ignition off).
-- Remove front interior lamp, refer to FRONT INTERIOR LAMP W1.
-- Disconnect electrical connection -arrow-.

Fig. 90: Identifying Sunroof Switch E8 Electrical Connection

-- Disengage retaining lugs -arrows- and remove Sunroof switch from panel.
Fig. 91: Identifying Sunroof Switch E8 Retaining Lugs

Installing:
REAR INTERIOR AND READING LAMPS

Removing:
-- Disengage retainers -arrows- and remove panel with diffusion lens from interior and reading lights.
Fig. 92: Identifying Rear Interior And Reading Lights Retainers

-- Disengage retaining tabs -arrows- and remove interior and reading lights from molded headliner.
Fig. 93: Identifying Rear Interior And Reading Lights Retaining Tabs
Fig. 94: Identifying Rear Interior And Reading Harness Connector

Installing:
REAR INTERIOR AND READING LIGHT BULBS

Removing:
-- Disengage retainers -arrows- and remove panel with diffusion lens from interior and reading lights.
Fig. 95: Identifying Rear Interior And Reading Lights Retainers

-- Carefully remove bulb from socket -arrows-.
Fig. 96: Identifying Rear Interior And Reading Lights Bulbs


Installing:
SPECIAL TOOLS
Trim Removal Wedge -3409-

Vehicle Diagnosis, Testing and Information System -VAS5051B-

Drill -VAS 5134-
Fig. 99: Identifying Drill VAS 5134

Pliers -VAS 6339-
Fig. 100: Identifying Pliers VAS 6339

Accessories & Equipment Interior Trim
Interior Trim
70 INTERIOR TRIM
INSTRUMENT PANEL
INSTRUMENT PANEL
Removing
Installation
and Installation
-- Remove Sunlight Photosensor 2 -G134-. Refer to [For engine(s) BPY,BLV,CCTA,CBFA] Removal and
Installation
Vehicles with a basic center console
Vehicles with a Comfort center console
-- Remove rear trim REAR TRIM

-- Remove center console, Comfort. Refer to CENTER CONSOLE, COMFORT
All vehicles
-- Remove driver side airbag unit. Refer to AIRBAG UNIT, DRIVER SIDE
-- Remove the steering wheel. Refer to Removal and Installation
-- Remove steering column trim. Refer to STEERING COLUMN TRIM
-- Remove side instrument panel covers. Refer to INSTRUMENT PANEL SIDE COVERS
-- Remove center trim on A-pillars. Refer to CENTER A-PILLAR TRIM
-- Remove driver side footwell cover. Refer to DRIVER SIDE FOOTWELL COVER
TRIM
Passat CC and CC equipped with a radio system or a radio/navigation system
-- Remove the radio and/or radio/navigation system. Refer to Removal and Installation
Sedan or Wagon equipped with a radio or radio/navigation system
Vehicles not equipped with a radio and/or radio/navigation system
-- Remove center compartment. Refer to CENTER COMPARTMENT
Vehicles with storage compartments near the warning light switch
-- Remove center storage compartment unit. Refer to CENTER STORAGE COMPARTMENT UNIT
Vehicles without storage compartments near warning light switch
-- Remove cover plate carrier. Refer to COVER PLATE CARRIER

All vehicles
-- Remove the steering column switch. Refer to [For engine(s) BPY,BLV,CCTA,CBFA] Removal and
Installation
-- Remove driver side trim. Refer to DRIVER SIDE TRIM .
-- Remove the instrument cluster [For engine(s) BPY,BLV,CCTA,CBFA] Removal and Installation
Vehicles with cell phone mount on instrument panel
-- Disconnect the wiring harnesses from the cell phone mount. Refer to Removal and Installation
All vehicles
-- Disconnect wiring harness to passenger air bag module.
-- If present, disconnect temperature gauge wiring harness from right and left vent ducts.
-- Remove screw -1- behind instrument cluster (3.5 Nm).

Fig. 1: Identifying Screw Behind Instrument Cluster

-- Remove nut -1- (3.5 Nm) on left side of instrument panel.
-- Remove the bolts -2- and -3- (3.5 Nm).

Fig. 2: Identifying Nuts And Bolts Behind Left Side Of Instrument Panel
-- Remove nut -1- (3.5 Nm) on right side of instrument panel.

Fig. 3: Identifying Nuts And Bolts Behind Right Side Of Instrument Panel
-- Remove two screws -1- (3.5 Nm) in center area of instrument panel.

Fig. 4: Identifying Nuts And Bolts Behind Center Of Instrument Panel

-- Remove instrument panel -1- from clips -2- and -3- in windshield transition area.
NOTE: To provide a better overview, clips -2- and -3- are shown removed.
When installing instrument panel, make sure that instrument panel is placed
with exact fit into clips.
Fig. 5: Identifying Instrument Panel And Clips

Installation
ASSEMBLY CARRIER
When disconnecting or removing electrical wires, make a sketch or take a photo to remember the original
installation locations.
Removing
Installation
and Installation
J255-. Refer to[For engine(s) BPY,BLV,CCTA,CBFA] Removal and Installation
-- Remove Sunlight Photosensor 2 -G134-. Refer to [For engine(s) BPY,BLV,CCTA,CBFA] Removal and
Installation
Vehicles with a basic center console
Vehicles with a Comfort center console
-- Remove center console, Comfort. Refer to CENTER CONSOLE, COMFORT
All vehicles
-- Remove driver side airbag unit. Refer to AIRBAG UNIT, DRIVER SIDE
-- Remove the steering wheel. Refer to Removal and Installation
-- Remove steering column trim. Refer to STEERING COLUMN TRIM
-- Remove side instrument panel covers. Refer to INSTRUMENT PANEL SIDE COVERS
-- Remove driver side footwell cover. Refer to DRIVER SIDE FOOTWELL COVER
TRIM
Passat CC and CC equipped with a radio system or a radio/navigation system
Sedan or Wagon equipped with a radio or radio/navigation system
Vehicles not equipped with a radio and/or radio/navigation system
-- Remove center compartment. Refer to CENTER COMPARTMENT
Vehicles with storage compartments near the warning light switch
-- Remove center storage compartment unit. Refer to CENTER STORAGE COMPARTMENT UNIT
Vehicles without storage compartments near warning light switch
-- Remove cover plate carrier. Refer to COVER PLATE CARRIER
All vehicles
-- Remove the steering column switch. Refer to [For engine(s) BPY,BLV,CCTA,CBFA] Removal and
Installation
-- Remove driver side trim. Refer to DRIVER SIDE TRIM .
-- Remove the instrument cluster. Refer to [For engine(s) BPY,BLV,CCTA,CBFA] Removal and
Installation
Vehicles with cell phone mount on instrument panel
-- Disconnect the wiring harnesses from the cell phone mount. Refer to Removal and Installation
-- Remove the instrument panel. Refer to INSTRUMENT PANEL
-- If equipped, remove the parking aid control module -J446-. Refer to [For engine(s)
BPY,BLV,CCTA,CBFA] Removal and Installation
-- If equipped, remove the parallel parking assistance control module -J791-
-- If equipped, remove the headlamp range/cornering lamp control module -J745-
-- Remove the plenum chamber bolt -1- (20 Nm).
Fig. 6: Identifying Removal Of Plenum Chamber Bolt

-- Remove the screws -1- (3.5 Nm) and disconnect the connector -2-.
Fig. 7: Identifying Removal Of Screws And Connectors

-- Remove the intermediate pieces -1- and -2- from the A/C unit.
Fig. 8: Identifying Removal Of Intermediate Pieces From A/C Unit

-- Remove the screws -1- (4 Nm) and move the fuse panel C -SC- -2- to the side.
Fig. 9: Identifying Removal Of Screws And Movement Of Fuse Panel

-- Remove the wiring harness from the assembly carrier -arrow-.
Fig. 10: Identifying Removal Of Wiring Harness From Assembly Carrier (1 Of 2)


Fig. 11: Identifying Removal Of Wiring Harness From Assembly Carrier (2 Of 2)

Fig. 12: Identifying Removal Of Bolts

-- Remove the wiring harnesses from the assembly carrier -arrows-.

Fig. 13: Identifying Removal Of Wiring Harness From Assembly Carrier

-- Remove the screws -1- (20 Nm).
Fig. 14: Identifying Removal Of Wiring Harness And Screws

-- Remove the wiring harnesses from the assembly carrier -arrows-.

Fig. 15: Identifying Removal Of Wiring Harness From Assembly Carrier

-- Remove the screws -1- , -2- and -3- (9 Nm).

Fig. 16: Identifying Removal Of Screws

NOTE: Using a scriber, mark the height and side position of the assembly carrier in the
vehicle around the nuts -1- and -2-.
-- Remove the two nuts -1- and -2- (20 Nm) on the driver side.
Fig. 17: Identifying Removal Of Nuts

NOTE: Using a scriber, mark the height and side position of the assembly carrier in the
vehicle around the nut -1-.
-- Remove the nut -1- (20 Nm) on the passenger side.
Fig. 18: Identifying Removal Of Wiring Harness From Assembly Carrier And Removal Of Nut
-- With a second technician, carefully remove the assembly carrier -1- from the vehicle.
Fig. 19: Identifying Removal Of Assembly Carrier

Installation
NOTE: Before installing the assembly carrier, line it up with the markings made before
it was removed.
DOOR TRIM, SEDAN AND WAGON
DRIVER SIDE FRONT DOOR TRIM
Removing
-- Pry upper section of grip shell -1- upward out of mounts in door trim using trim removal wedge 3409.
-- Depending on vehicle equipment, disconnect wiring harnesses from upper section of grip shell.
-- Remove three screws -2- (4.5 Nm) in area handle molding area.
-- Disengage door trim from mounts in lower area using disassembly pliers 3392.
-- Disengage door trim from mounts on the sides using disassembly pliers 3392.
-- Pull door trim vertically upward out of window shaft.
-- Disconnect door trim wiring harness from door control module.
-- Disengage the release cable -4- from the interior door mechanism -5-.
Fig. 20: Identifying Drivers Side Front Door Trim Remove/Install Components
Installation
NOTE: Before installing, inspect the securing clips for damage and replace if
necessary.
-- Press door trim securing clip inward.
PASSENGER SIDE FRONT DOOR TRIM
Removing
-- Use the trim removal wedge 3409 to pry the upper part of the grip recess -1- out of the pull handle in the door
trim panel.
-- Disconnect door trim wiring harness from door control module.
Fig. 21: Identifying Passengers Side Front Door Trim Remove/Install Components
Installation
necessary.
REAR DOOR TRIM

NOTE: Removing and installing the trim panel is described for the right rear door.
Removing and replacing the trim panel for the left rear door is done in the same
manner.
Removing
Vehicles with manual window regulators
-- Remove window crank. Refer to WINDOW CRANK
All vehicles
-- Use the trim removal wedge 3409 to pry the upper part of the grip recess -1- out of the pull handle in the door
trim panel.
-- Depending on vehicle equipment, disconnect wiring harnesses from door trim.
Fig. 22: Identifying Rear Door Trim Remove/Install Components

Installation
necessary.
SUN SHADE, REAR DOOR TRIM

Refer to SUN SHADE, REAR DOOR TRIM
WINDOW CRANK
Removing
-- Press circlip -1- back in direction of travel -arrow- and remove window crank -2- from drive mechanism -3-.
Fig. 23: Identifying Manual Window Crank Remove/Install Components

Installation
NOTE: After installation, the window crank must point forward horizontally 6° when
window is closed.
Deviation of window cranks to each other must be 6° max.
FRONT DOOR TRIM COVER
Removing
-- Remove front door trim:
 Driver side: DRIVER SIDE FRONT DOOR TRIM

 Passenger side: PASSENGER SIDE FRONT DOOR TRIM
-- Use the trim removal wedge 3409 to pry the door trim cover -1- out of its mounts in the inner door panel.
Fig. 24: Identifying Front Door Trim Cover Remove/Install Components

NOTE: For the sake of illustration, securing clips are depicted as removed in the
illustration.
-- Disconnect wiring harness from speaker in cover.
Installation
NOTE: Check the fasteners for damage and replace if necessary.
DOOR TRIMS, PASSAT CC
FRONT DOOR TRIM
Removing
-- First remove the switch mount -1- in the front using the trim removal wedge 3409, then remove the door trim.
-- Remove the wiring harnesses.
-- First remove the grip recess -2- in the front using the trim removal wedge 3409, then remove the door trim.

Fig. 25: Identifying Removal Of Switch Mount, Grip Recess, Bolts And Door Trim
Vehicles with expanding rivet
-- Remove expanding rivet -1-.

Fig. 26: Identifying Removal Of Expanding Rivet

Vehicles with a bolt
-- Remove the bolt -1- (1.7 Nm).

Fig. 27: Identifying Removal Of Bolt

All vehicles
-- Remove the screws -1- (1.7 Nm).
Fig. 28: Identifying Removal Of Screws

CAUTION: When loosening the door trim, the mounting elements could be damaged.
To prevent this, follow the specified location and sequence for the clip
connections to be loosened when removing the door trim.
-- Use the wedges T10383 to remove the door trim from the clip connectors in the -specified sequence-.
Fig. 29: Identifying Wedges T10383 To Remove Door Trim

-- On the inside of the door trim, pull off the securing tab -1-.
Fig. 30: Identifying Removal Of Securing Tab And Release

-- Remove the release out of the guide to the rear.
-- Remove the release -2- from the interior door mechanism.
Installation
necessary.
CAUTION: Before installing the door trim, make sure the release mechanisms on all
the clips are in the -1 position-.
It is not possible to install the door trim correctly if the clips are in the -2
position-.
Fig. 31: Identifying Correct Position Of Clips

REAR DOOR TRIM
Removing
-- First remove the switch mount -1- in the front using the trim removal wedge 3409, then remove the door trim.
-- Disconnect the wiring harness.
-- First remove the grip recess -2- in the front using the trim removal wedge 3409, then remove the door trim.
Fig. 32: Identifying Removal Of Switch Mount, Grip Recess, Bolts And Door Trim

Fig. 33: Identifying Removal Of Bolt

CAUTION: When loosening the door trim, the mounting elements could be damaged.
To prevent this, follow the specified location and sequence for the clip
connections to be loosened when removing the door trim.
-- Use the wedges T10383 to remove the door trim from the clip connectors in the -specified sequence-.
Fig. 34: Identifying Wedges T10383 To Remove Door Trim

-- On the inside of the door trim, pull off the securing tab -1-.
Fig. 35: Identifying Removal Of Securing Tab And Release

-- Remove the release out of the guide to the rear.
-- Remove the release -2- from the interior door mechanism.
Installation
necessary.
CAUTION: Before installing the door trim, make sure the release mechanisms on all
the clips are in the -1 position-.
It is not possible to install the door trim correctly if the clips are in the -2
position-.
Fig. 36: Identifying Correct Position Of Clips

PILLAR TRIM
UPPER A-PILLAR TRIM
Removing
-- Remove airbag emblem -1- and remove screw -2- (2 Nm).

-- Remove trim in area of mounting clip -3- inward from mounts -arrow A-.
NOTE: For the sake of illustration, securing elements -3- are depicted as removed in
the illustration.
-- Loosen trim from door seal molding -arrow B-.
-- Remove trim from front mounts in instrument cluster -arrow C-.
-- Remove trim upward out of mounts -arrow D-.
NOTE: When installing, airbag emblem -1- must be replaced.
Before installing, inspect the securing clips for damage and replace if
necessary.
Fig. 37: Identifying Upper A-Pillar Trim Remove/Install Components

Installation
UPPER A-PILLAR TRIM, PASSAT CC
Removing
NOTE: For the sake of illustration, the clamp -1- is not shown in the illustration.
-- Pull the trim near the clamp -1- out of the catch -arrow A-, then compress the clamp between the headliner
and the trim using long nose pliers and remove the trim from of the upper catch.
CAUTION: The clamp -1- may not be re-used and must be replaced prior to installing!
-- Loosen trim from door seal molding -arrow B-.
-- Remove trim from front mounts in instrument cluster -arrow C-.
-- Remove trim upward out of mounts -arrow D-.

Fig. 38: Identifying Removal Of Trim

Installation
CENTER A-PILLAR TRIM
Removing
-- Remove trim -1- from mounts in body -arrow A-.
-- Pull trim upward out of lower A-pillar trim -arrow B-.
Fig. 39: Identifying Center A-Pillar Trim Remove/Install Components

Installation
LOWER A-PILLAR TRIM

Removing
Driver side only
-- Remove the hood release lever. Refer to Removal and Installation
All vehicles
-- Pull sill panel strip out of mounts in body in lower A-pillar trim transition area.
-- Remove clip -1-.
-- Pull trim -2- inward out of mounts in body -arrow A-.
-- Remove trim from door seal piping.
-- Pull trim back out of mounts -arrow B-.
NOTE: Before installation, clip -1- must be checked for damage and replaced if
necessary.
Fig. 40: Identifying Lower A-Pillar Trim Remove/Install Components

Installation
UPPER B-PILLAR TRIM
Removing
-- Position seat as far forward as possible using fore/aft adjustment.
-- Remove airbag emblem -1-.
-- Insert a screwdriver -2- in opening and press clip downward -arrow A-.
-- Remove trim inward from B-pillar -arrow B-.
Fig. 41: Identifying Press Clip Downward Using Screwdriver

When removing headliner, the following work does not need to be done:
-- Loosen sill panel trim from mounts in area of B-pillar.
-- Remove sill panel trim from catches in door sill in front part of rear door area.
-- Remove the bolt -3- (40 Nm) and remove belt anchor -4- from body.
Fig. 42: Identifying Sill Molding, Belt Anchor And Bolts

-- Thread belt anchor from seat belt through opening in trim.

-- Slide seat belt height adjuster to the topmost position.
-- Position slide in trim in highest position.
After installation, perform the following function test on the belt height adjuster:
-- Operate height adjuster slide and position height adjuster in highest position.
-- Pull seat belt down.
-- Height adjuster must engage in highest lock position when doing so.
LOOSENING UPPER B-PILLAR TRIM FROM MOUNTS AND SECURING, PASSAT CC
Removing
-- Pull the trim around the catches -3- and -4- out of the mounts in the lower B-pillar trim.
-- Insert a small screwdriver through the opening for the emblem; unlock the clip -1- -arrow- while pressing the
trim upward and then tilt it toward the inside.
Fig. 43: Identifying Airbag Emblem And Lower B-Pillar Trim

Installation
After installation, perform the following function test on the belt height adjuster:
-- Height adjuster must engage in highest lock position when doing so!
UPPER B-PILLAR TRIM, PASSAT CC
Removing
-- Pull the trim around the catches -3- and -4- out of the mounts in the lower B-pillar trim.
-- Insert a small screwdriver through the opening for the emblem; unlock the clip -1- -arrow- while pressing the
trim upward and then tilt it toward the inside.
Fig. 44: Identifying Airbag Emblem And Lower B-Pillar Trim

-- Remove sill molding -1- from catches in sill in front door area.
Fig. 45: Identifying Sill Molding, Belt Anchor And Bolts

-- Thread belt anchor from seat belt through opening in trim.
Installation

-- Operate height adjuster slide and position height adjuster in highest position.
-- Height adjuster must engage in highest lock position when doing so!
LOWER B-PILLAR TRIM
Removing
-- Remove upper B-pillar trim (the belt anchor must not be removed form body). Refer to UPPER B-PILLAR
TRIM.
-- Remove sill panel trim from catches in door sill in front door area.
-- Remove trim on sides from door seal moldings.
-- Remove trim inward out of mounts in body -arrow-.
Driver side only
-- On vehicles equipped with interior monitoring, switch off the ignition and disconnect the wiring harness from
the interior monitoring deactivation switch -E267- -1-.
Fig. 46: Identifying Lower B-Pillar Trim Remove/Install Components

Installation
C-PILLAR TRIM, SEDAN, VEHICLES WITHOUT SUN SHADE
Removing
-- Loosen trim from door seal molding -arrow A-.
-- Pull trim inward out of mounts -arrow B-.
Fig. 47: Identifying C-Pillar Trim, Sedan, Vehicles Without Sun Shade
Installation
C-PILLAR TRIM, SEDAN, VEHICLES WITH SUN SHADE
Removing
Fig. 48: Identifying Trim Pried Out Of Mountings Using Trim Removal Wedge 3409

Fig. 49: Identifying C-Pillar Trim, Sedan, Vehicles With Sun Shade Remove/Install Components
Installation
C-PILLAR TRIM WITHOUT SUN SHADE, PASSAT CC
Removing

Installation
C-PILLAR TRIM, WITH SUN SHADE, PASSAT CC

Removing
Fig. 51: Identifying Trim Pried Out Of Mountings Using Trim Removal Wedge 3409


Installation
C-PILLAR TRIM, WAGON
Removing
-- Remove trim on right side from door seal piping.
-- Pull trim toward rear out of clips in C-pillar -arrow A-.
-- Pull trim with clip -3- inward out of mount in C-pillar -arrow B-.
NOTE: For the sake of illustration, clip -3- is depicted as removed in the illustration.
Fig. 53: Identifying C-Pillar Trim, Wagon

Installation
D-PILLAR TRIM
Removing
Vehicles with rear side-airbag:
-- Disconnect the battery. Refer to [For engine(s) BPY,BLV,CCTA,CBFA] Removal and Installation
All vehicles:
-- Remove roof end strip, wagon. Refer to ROOF END STRIP, WAGON
-- Remove lock carrier cover (wagon). Refer to LOCK CARRIER COVER, WAGON
-- Fold left bench seat and its backrest forward.
 with rear side airbag: SIDE UPHOLSTERY WITH SIDE AIRBAG

 without rear side airbags: SIDE UPHOLSTERY WITHOUT SIDE AIRBAG
-- Remove luggage compartment side trim (wagon):
 Right: RIGHT LUGGAGE COMPARTMENT SIDE TRIM, WAGON

 Left: LEFT LUGGAGE COMPARTMENT SIDE TRIM, WAGON
-- Pull trim -1- inward out of mounts in D-pillar and out of rear lid seal piping -arrow A-.
NOTE: For the sake of illustration, clip -2- is depicted as removed.
-- Pull trim forward out of the two clips -3- -arrow B-.
Fig. 54: Identifying D-Pillar Trim Remove/Install Components

Installation
REAR LID TRIM
WARNING TRIANGLE BRACKET, SEDAN
Removing
-- Open rear lid and remove warning triangle.

-- Remove screw -1- (1.5 Nm) and remove bracket -2- from mounts in rear lid.
Fig. 55: Identifying Warning Triangle Bracket Remove/Install Components

Installation
REAR LID TRIM, SEDAN
Removing
-- Remove warning triangle bracket. Refer to WARNING TRIANGLE BRACKET, SEDAN

-- Remove 4 screws -1- in grip recesses (1.5 Nm).
NOTE: In addition to the four screws, the trim is secured all around to rear lid with ten
metal clips -arrows-.
-- Pull trim up slightly and press metal clips -arrows- all around with a screwdriver out of mounts in rear lid.
-- Disengage rear lid emergency release from rear lid lock.
Fig. 56: Identifying Rear Lid Trim, Sedan Remove/Install Components

Installation
NOTE: Before installing, check metal clips for damage and replace if necessary.
REAR LID TRIM, PASSAT CC
Removing
-- Remove the emergency triangle.
-- Press the retaining tabs outward -arrows- and remove the retainer -1-.
Fig. 57: Identifying Removal Of Retainer

-- Remove the caps -1- and -3-.
-- Remove the cap -2- using the release tool T10236.

Fig. 58: Identifying Removal Of Caps

-- Unclip the trim around the area of the clips -1- (12 clips) by using the wedges T10383.

Installation
WINDOW FRAME TRIM, WAGON
Removing
-- Remove rear lid trim (wagon). Refer to REAR LID TRIM, WAGON.
-- Use the disassembly pliers 3392 to disengage the side trim -1- from the mounts for the lid.
-- Pull trim on upper edge out of mounts.

Fig. 60: Identifying Window Frame Trim, Wagon Remove/Install Components

Installation
REAR LID TRIM, WAGON
Removing
-- Remove bolts -1- and -3- (1.5 Nm) respectively on right and left sides in handle recesses.
-- Remove cover from trim and unscrew two bolts -2- (1.5 Nm).
-- Use the disassembly pliers 3392 to disengage the trim -4- from the mounts in lid.
-- Disengage trim -4- at the side from mounts in window frame trim -5-.
-- For vehicles with electric lid control, disconnect wiring harness from switch -6-.
Fig. 61: Identifying Rear Lid Trim, Wagon Remove/Install Components

WARNING TRIANGLE BRACKET, WAGON
Removing
-- Open the warning triangle bracket.
 The opening angle of the warning triangle bracket must be approx. 45° for the following removal
procedure.
-- Use the trim removal wedge 3409 to press the emergency triangle bracket -1- inward on the right side and
release it from the mounting pin.
Fig. 62: Identifying Removal Of Emergency Triangle Bracket With Wedge 3409
-- Remove warning triangle bracket -1- from the left mounting pin.
Fig. 63: Identifying Removal Of Emergency Triangle Bracket From Left Mounting Pin
Installation
-- Slide warning triangle bracket -1- at a 45° angle onto the left mounting pin.
Fig. 64: Identifying Removal Of Emergency Triangle Bracket From Right Mounting Pin
-- Then press the warning triangle bracket to the left and slide it onto the right mounting pin.
-- After assembly, perform the function test.

LUGGAGE COMPARTMENT TRIM
LOCK CARRIER COVER, SEDAN
Removing
-- Remove floor covering from vehicle.
-- Remove spare wheel from vehicle.
-- Remove vehicle tool kit mount from vehicle.
-- Remove lock carrier cover -1- upward out of lock carrier.

Fig. 65: Identifying Lock Carrier Cover, Sedan Remove/Install Components

Installation
LOCK CARRIER COVER, PASSAT CC
Removing
-- Remove the carpet.
-- Remove lock carrier cover -1- upward out of lock carrier -arrows-.
Fig. 66: Identifying Removal Of Lock Carrier Cover

Installation
LOCK CARRIER COVER, WAGON
Removing
-- Slide floor carpet forward and remove cover of vehicle tool kit mount.
NOTE: Neighboring components, for example, rear bumper are not depicted in the
following illustration.
-- Remove lock carrier cover -2- upward out of lock carrier.
Fig. 67: Identifying Lock Carrier Cover, Wagon Remove/Install Components

Installation
LUGGAGE COMPARTMENT LINER, WAGON
Removing
-- Fold the two rear elements -1- of lining forward and unscrew two bolts -2- (1.5 Nm).
-- Remove lining -3- from vehicle.
Fig. 68: Identifying Luggage Compartment Liner, Wagon Remove/Install Components

Installation
LUGGAGE COMPARTMENT SIDE TRIM, PASSAT CC
Removing
-- Remove the lock carrier cover, (Passat CC and CC). Refer to LOCK CARRIER COVER, PASSAT CC
-- Remove the two bolts -1- (6 Nm) and remove the anchor point -2-.
-- Remove the four press buttons -arrows- using the release tool T10236 and remove trim from the mounts in
the vehicle.
Fig. 69: Identifying Removal Of Bolts, Anchor Point And Trim

Installation
NOTE: Before installing, check press buttons for damage and replace if necessary.
LEFT LUGGAGE COMPARTMENT SIDE TRIM, SEDAN
Removing
-- Remove lock carrier cover (sedan). Refer to LOCK CARRIER COVER, SEDAN

-- Remove rear left backrest. Refer to LEFT REAR BACKREST
-- Remove the three bolts -3- (1.5 Nm).
-- Remove screw -4- (1.5 Nm) and remove hook -5-.
the vehicle.
Fig. 70: Identifying Left Luggage Compartment Side Trim, Sedan Remove/Install Components
Installation
RIGHT LUGGAGE COMPARTMENT SIDE TRIM, SEDAN
Removing
-- Remove lock carrier cover. Refer to LOCK CARRIER COVER, SEDAN

-- Remove rear right backrest. Refer to RIGHT REAR BACKREST
-- Remove screw -4- (1.5 Nm) and remove hook -5-.
the vehicle.
-- Disconnect wiring harness from power outlet and lights.

Fig. 71: Identifying Right Luggage Compartment Side Trim, Sedan Remove/Install Components
Installation
LEFT LUGGAGE COMPARTMENT SIDE TRIM, WAGON
Removing
All vehicles:

-- Pull wheel housing trim -1- in upper area out of mounts in body.
Fig. 72: Identifying Wheel Housing Trim And Bolt

NOTE: For the sake of illustration, wheel housing trim -1- and clip -2- are depicted as
removed.
Illustration shows left side of vehicle, disengaging wheel housing trim on left
side of vehicle is performed accordingly.
Vehicles without track system:
-- Remove two bolts -1- (6 Nm) and remove tie down -2-.
All vehicles:
-- Remove bolt -5- (4.5 Nm) and remove coat hook bracket -6-.
-- Remove the clamping pin -7- using a screwdriver with hex socket head (3 mm) and remove expanding rivet -
8-.
-- Pull trim -9- inward out of retainers in body.
-- Thread seat belt -10- through both tabs -11- of trim -9-.
-- Slide trim away toward front over bracket for backrest lock -12-.
-- Remove trim from vehicle.

Fig. 73: Identifying Left Luggage Compartment Side Trim, Wagon Remove/Install Components
Installation
RIGHT LUGGAGE COMPARTMENT SIDE TRIM, WAGON
Removing
All vehicles:
-- Fold the right bench seat and its backrest forward.

-- Pull wheel housing trim -1- in upper area out of mounts in body.
Fig. 74: Identifying Wheel Housing Trim And Bolt

NOTE: For the sake of illustration, wheel housing trim -1- and clip -2- are depicted as
removed.
Illustration shows left side of vehicle, disengaging wheel housing trim on left
side of vehicle is performed accordingly.
Vehicles without track system:
All vehicles:
-- Remove bolt -5- (4.5 Nm) and remove coat hook bracket -6-.
-- Remove the clamping pin -7- using a screwdriver with hex socket head (3 mm) and remove expanding rivet -
8-.
-- Pull trim -9- inward out of retainers in body.
-- Thread seat belt -10- through both tabs -11- of trim -9-.
-- Slide trim away toward front over bracket for backrest lock -12-.
-- Disconnect wiring harness of luggage compartment light.
-- Remove trim from vehicle.

Fig. 75: Identifying Right Luggage Compartment Side Trim, Wagon Remove/Install Components
Installation
TRACK SYSTEM, PASSAT WAGON
RETAINING TRACKS
-- Operate push-button -1- and slide tie-down -2- up to corresponding opening in respective retaining track -
arrows-.
-- Remove tie down from retaining track.
-- Operate push-button -3- and slide anchoring lug -4- up to corresponding opening in respective retaining track
-arrows-.
-- Remove anchoring lug from retaining track.
-- Remove the remaining tie downs and anchoring lugs as described.
Fig. 76: Identifying Retaining Tracks Remove/Install Components (1 Of 2)

-- Remove the five bolts -1- (9 Nm).
-- Remove right retaining track -2- from vehicle.
-- Remove the five bolts -3- (9 Nm).
-- Remove left retaining track -4- from vehicle.
Fig. 77: Identifying Retaining Tracks Remove/Install Components (2 Of 2)

Installation
TRACK SYSTEM BRACKET AND CARRIER
Removing
All vehicles:
-- Remove luggage compartment lining. Refer to LUGGAGE COMPARTMENT LINER, WAGON


-- Remove mount with vehicle tool kit and, if present, spare wheel from well in vehicle floor.
-- Remove the nuts -1- , -2- and -3-.
-- Remove carrier -4- from vehicle.

Fig. 78: Identifying Carrier And Nuts

-- Remove nut -1- (2 Nm).
-- Remove right front bracket -3- from vehicle.
-- Remove left front bracket -4- accordingly.

-- Remove right rear bracket -8- from vehicle.
-- Remove left rear bracket -9- accordingly.
-- Remove the nuts -10- and -11- (2 Nm).
-- Remove lower section of luggage compartment carpet -12- from vehicle.
Fig. 79: Identifying Track System Bracket And Carrier Remove/Install Components
Installation
ROOF TRIM
ROOF END STRIP, SEDAN
Removing
-- Pull roof end strip -1- downward out of mounts in roof cross member.
NOTE: Before installing, check securing clips for damage and replace if necessary.
Fig. 80: Identifying Roof End Strip, Sedan Remove/Install Components

ROOF END STRIP, WAGON
Removing
-- Pull roof end strip -1- downward out of mounts in roof cross member.
NOTE: Before installing, check securing clips for damage and replace if necessary.
Fig. 81: Identifying Roof End Strip, Wagon Remove/Install Components

HEADLINER, SEDAN
Removing
Vehicles with sunroof
-- Open sunroof.
All vehicles
Vehicles in which an interior rearview mirror with rain sensor is installed
-- Remove the interior rearview mirror with rain sensor. Refer to INTERIOR REARVIEW MIRROR WITH
RAIN SENSOR
All vehicles
SWITCHES
-- Remove sun visors.
 Basic: STANDARD SUN VISORS

 Double: DOUBLE SUN VISORS
-- Remove roof grab handle. Refer to ROOF GRAB HANDLES
-- Fold the front seat backrests forward.
-- Remove upper B-pillar trim. Refer to UPPER B-PILLAR TRIM
-- Remove roof end strip, sedan. Refer to ROOF END STRIP, SEDAN
-- Push the wedge T10039/1 between the frame -1- and headliner -2-.
-- Use the release lever T10039/1 to separate the frame in the -direction of the arrow- from the headliner, the
whole way around.
Fig. 82: Identifying Separation Of Frame From Headliner Using Release Lever T10039/1
All vehicles
-- In rear window transition area, remove four screws -1- (2 Nm).
-- Remove headliner from door seal moldings.
-- Lower headliner slightly and (depending on vehicle equipment) disconnect wiring harnesses from headliner.
Fig. 83: Identifying Molded Headliner And Bolts, Sedan

Installing
NOTE: The installation of the headliner is made much easier by replacing clips "part
number: 1K0 867 633" below the roof grab handle.
MOLDED HEADLINER, SEDAN
Removing
NOTE: If the headliner is being replaced, then the corresponding openings must be
created for new part 2 in vehicles equipped with an illuminated "make-up
mirror". The openings should be in the same location as the previous openings.
Use a carpet knife to cut out the openings, and, to prevent damaging the
surface of the headliner material, cut down through to the padding--depending,
of course, on the surface of the material. Reinforce the edges of the openings
with a reinforcement plate.
-- Open sunroof.
All vehicles
-- Position steering wheel in highest position.
-- Position shifter or selector lever as far back as possible.
Vehicles in which an interior rearview mirror with rain sensor is installed
-- Remove the interior rearview mirror with rain sensor. Refer to INTERIOR REARVIEW MIRROR WITH
RAIN SENSOR
All vehicles
SWITCHES

Only vehicles with a passenger's seat without height adjustment and a front center armrest with storage
box "(PR no.: 6E3)"
-- Remove passenger side front seat FRONT SEAT
All vehicles
Installation
Remove the heater and A/C controls. Refer to [For engine(s) BPY,BLV,CCTA,CBFA] Removal and
Installation
Vehicle with Basis center console
-- Remove the center console, basic. Refer to CENTER CONSOLE, BASIC
Vehicles with Comfort center console
-- Remove rear trim REAR TRIM
-- Remove the center console, comfort. Refer to CENTER CONSOLE, COMFORT
All vehicles
-- Lower the driver seat backrest. Lower the passenger seat backrest, too, if this seat is still in the vehicle.
whole way around.
All vehicles
-- In rear window transition area, remove four screws -1- (2 Nm).

-- With a second technician, remove headliner through passenger door and out of vehicle.
Fig. 85: Identifying Molded Headliner And Bolts, Sedan

Installation
MOLDED HEADLINER, WAGON

Removing
NOTE: If the headliner is being replaced, then the corresponding openings must be
created for new part 2 in vehicles equipped with an illuminated "make-up
mirror". The openings should be in the same location as the previous openings.
Use a carpet knife to cut out the openings, and, to prevent damaging the
surface of the headliner material, cut down through to the padding--depending,
of course, on the surface of the material. Reinforce the edges of the openings
with a reinforcement plate.
Vehicles with sunroof:
-- Open sunroof.
SWITCHES

-- Remove trim on C-pillars, wagon. Refer to C-PILLAR TRIM, WAGON
All vehicles:

 with rear side airbag, refer to SIDE UPHOLSTERY WITH SIDE AIRBAG
 without rear side airbags. Refer to SIDE UPHOLSTERY WITHOUT SIDE AIRBAG

-- Remove D-pillar trim panels. Refer to D-PILLAR TRIM.
Vehicles in which an interior rearview mirror with rain sensor is installed:
-- Remove the side cover caps from the interior rearview mirror. Refer to INTERIOR REARVIEW MIRROR
WITH RAIN SENSOR
whole way around.
Vehicles with screen separator wall
-- Operate locking mechanism -1- and pull off cover -2-.

-- Remove remaining panels as described.
All vehicles
-- Lower the headliner -6- and remove it from vehicle with a second mechanic through rear lid.
Fig. 87: Identifying Molded Headliner, Wagon Remove/Install Components

Installation
LOWERING HEADLINER, PASSAT CC
NOTE: When working on the side curtain airbag, the roof insulation/reinforcement or
roof antenna, remove the headliner. It is not necessary to do this when
removing the windshield.
Removing
 Vehicles without Panorama sunroof: ROOF TRIM LAMPS AND SWITCHES

 Vehicles with Panorama sunroof: ROOF TRIM LAMPS AND SWITCHES
FROM MOUNTS AND SECURING, PASSAT CC.
-- Remove visors. Refer to STANDARD SUN VISORS .
-- Remove the C-pillar trim:
 Vehicles not equipped with a sun shade: C-PILLAR TRIM WITHOUT SUN SHADE, PASSAT CC
 Vehicles equipped with a sun shade: C-PILLAR TRIM, WITH SUN SHADE, PASSAT CC
Fig. 88: Identifying Removal Of Mirror Caps

Fig. 89: Identifying Removal Of Screws And Connector

2- -arrow- using the release tool T10236 and the trim removal wedge 3409.

Fig. 90: Identifying Removal Of Clamping Profile And Mounting Clips

-- Loosen the headliner around the C-pillars toward the inside and out of the catches -arrow-.
Fig. 91: Identifying Loosening Of Headlinder

-- Pull the headliner -1- downward and out of the remaining retainers.
Fig. 92: Identifying Removal Of Headliner

Installing
HEADLINER, PASSAT CC
NOTE: If the headliner is being replaced on vehicles with a sun shade, it is necessary
to adapt the new part near the rear lid window with workshop tools.
Removing

Fig. 93: Identifying Removal Of Mirror Caps

Fig. 94: Identifying Removal Of Screws And Connector

2- -arrow- using the release toolT10236 and the trim removal wedge3409.

Fig. 95: Identifying Removal Of Clamping Profile And Mounting Clips

-- Loosen the headliner around the C-pillars toward the inside and out of the catches -arrow-.
Fig. 96: Identifying Loosening Of Headlinder

-- Pull the headliner -1- downward and out of the remaining retainers.
Fig. 97: Identifying Removal Of Headliner

-- Remove the windshield. Refer to Removal and Installation
-- Remove the headliner through the windshield opening.
Installation
-- Guide the headliner through the windshield opening into the vehicle.
-- Install the windshield. Refer to Removal and Installation
ROOF INSULATION/REINFORCEMENTS, SEDAN, PASSAT CC
NOTE: An exemplary sedan without sunroof is shown in the following description.
Removing
Sedan
-- Remove the front and rear interior and reading lamps in the headliner. Refer to: ROOF TRIM LAMPS AND
SWITCHES


WITH RAIN SENSOR
-- Remove headliner, sedan. Refer to MOLDED HEADLINER, SEDAN
Passat CC and CC

-- Lower the headliner, Passat CC and CC LOWERING HEADLINER, PASSAT CC
-- Cut roof insulation/reinforcements -1- in direction of travel in strips approx. 6 cm wide -2- using a carpet
knife.
-- Pull off strips -2- from roof.
-- Cut back any remaining adhesive -3- using an electric cutter V.A.G 1561 A and a trimmer V.A.G 1561/20 -4-
.
NOTE: If paint structure was damaged while removing roof insulation/reinforcements,

paint damage must be repaired.
Fig. 98: Identifying Roof Insulation/Reinforcements Remove/Install Components

Installation
NOTE: Processing instructions of adhesive must be observed when installing roof

insulation/reinforcements.
-- Apply adhesive D 190 MKD A3 on to insulation/reinforcements using cartridge gun V.A.G 1628.
-- Dimension a = 67 +/- 2 mm
-- Dimension b = 34 +/- 5 mm
-- Dimension c = 23 +/- 5 mm
-- Transport roof insulation/reinforcements into vehicle and press on to roof over the entire surface.
Fig. 99: Identifying Adhesive Application Areas For Insulation/Reinforcements

ROOF INSULATION/REINFORCEMENTS, WAGON
NOTE: Note the sedan that does not have any adjustable sunroof in the following
example. Carry out removal and replacement for this variant (with/without
sunroof) the same as for roof noise insulation/reinforcement.
Removing
-- Open sunroof.
SWITCHES
 Basic STANDARD SUN VISORS

 Double DOUBLE SUN VISORS
All vehicles:



-- Remove D-pillar trim panels. Refer to D-PILLAR TRIM.
WITH RAIN SENSOR
All vehicles:
-- Remove headliner, wagon. Refer to MOLDED HEADLINER, WAGON
-- Cut roof insulation/reinforcements -1- in direction of travel in strips approx. 6 cm wide -2- using a carpet
knife.
-- Pull off strips -2- from roof.
-- Cut back any remaining adhesive -3- using an electric cutter V.A.G 1561 A and a trimmer V.A.G 1561/20 -4-
.
NOTE: If paint structure was damaged while removing roof insulation/reinforcements,

paint damage must be repaired.
Fig. 100: Identifying Roof Insulation/Reinforcements Remove/Install Components

Installation
NOTE: Processing instructions of adhesive must be observed when installing roof

insulation/reinforcements.
-- Apply adhesive D 190 MKD A3 on to insulation/reinforcements using cartridge gun V.A.G 1628.
-- Dimension a = 67 +/- 2 mm
-- Dimension b = 34 +/- 5 mm
-- Dimension c = 23 +/- 5 mm
-- Transport roof insulation/reinforcements into vehicle through rear lid and press on to roof over the entire
surface.
Fig. 101: Identifying Adhesive Application Areas For Insulation/Reinforcements

SPECIAL TOOLS


Fig. 103: Identifying Special Tools - Roof Trim


 Cutting blade V.A.G 1561/20
 Wedge T10039
 Trim removal wedge T10039 /1
 Removal pliers 3392
Fig. 104: Identifying Disassembly Pliers 3392

 Wedges T10383
Fig. 105: Identifying Wedges T10383



 Release tool T10236

MAINTENANCE Maintenance, Diagnosis - Fluid Capacity Tables
MAINTENANCE
Maintenance, Diagnosis - Fluid Capacity Tables
03 MAINTENANCE, DIAGNOSIS
PASSAT/PASSAT WAGON
CAUTION: All quantities are approximate. Always refer to the Repair Information
and/or the Maintenance Procedures for correct filling instructions.
Part numbers are for reference only. Always check with your parts
department for the latest information.
Component/System Capacity Part Number/Specification

2.0T Engine
Oil and Filter Change 4.6 L (4.9 qt.) VW 502 00
Coolant 7.2 L (7.6 qt.) G 012 A8G or G 012 A8F
3.6 L Engine
Oil and Filter Change 5.5 L (5.8 qt.) VW 502 00
Coolant 8.0 L (8.5 qt.) G 012 A8G or G 012 A8F
6 Speed Manual Transmission 02Q
Initial Fill 2.3 L (2.4 qt.) G 052 171 A2
6 Speed Automatic Transmission 09G
6 Speed Automatic Transmission 09M
Rear Final Drive 0.95 L (1.0 qt.) G 052 145 S2
Haldex Clutch Initial
0.85 L (0.9 qt.)
Fill G 055 175 A2
Haldex Clutch Refill 0.7 L (0.7 qt.)
Brake Fluid
- 1.2 L (1.25 qt.) B 000 750
A/C System
600 25 g (21.2 0.9
Refrigerant
oz.)
110 10 cc (3.7 0.3
PAG Oil, Sanden G 052 154 A2
fl. oz.)
120 15 cc (4.0 0.5
PAG Oil, Zexel G 052 154 A2
fl. oz.)
140 10 cc (4.7 0.3
PAG Oil, Denso G 052 300 A2
fl. oz.)
110 10 cc (3.7 0.3
MAINTENANCE Maintenance, Diagnosis - Fluid Capacity Tables
PAG Oil, Delphi fl. oz.) G 052 154 A2 G 052 300 A2

Window/Headlamp Washer System
- 2.5 L (2.6 qt.) G 052 164
MAINTENANCE Maintenance, Diagnosis - Maintenance Intervals
MAINTENANCE
Maintenance, Diagnosis - Maintenance Intervals
MY 2011 MAINTENANCE INTERVALS
MY 2011 MAINTENANCE INTERVALS (EXCEPT ROUTAN) - USA
NOTE: Service through 30,000 miles is included in the Volkswagen Carefree

Maintenance Program.
TIME DEPENDENT SERVICE
Every 1 Year
Perform visual check of airbag system.
Every 2 Years
 Dust and pollen filter: Replace (if applicable)

 Check latch for convertible roof (if applicable)
 Tire filler bottle in the tire mobility set: Check (observe expiration date)
Every 3 Years, Then Every 2 Years Regardless of Miles Driven
 Brake Fluid: Replace. First fluid replacement included under the Volkswagen Carefree Maintenance
Program (CC, Touareg, Eos, Passat, Jetta models, GTI, Golf, Tiguan, Passat CC)
Every 3 Years Regardless of Miles Driven
 Haldex Clutch: Change oil (if applicable)
 Tire Filler Bottle In The Tire Mobility Set: Replace (observe expiration date)
 Spark Plugs: Replace (2.0L MPI only)
At the 4 Year mark, if miles driven is under 10,000 miles
 AdBlue® : Change fluid (3.0L TDI only)

 Spark Plugs: Replace (all engines except 2.0L MPI and TDI)
 Air Filter Element and Snow Filter: Replace and clean housing (if applicable)
 Tire Pressure Sensors: Replace (if applicable)
SERVICE AT 10,000 MILES
NOTE: Included in the Volkswagen Carefree Maintenance Program
 AdBlue® Fluid: Check and add if necessary (3.0L TDI engine only)
 Airbag System: Perform visual inspection (Every 1 year regardless of mileage)
 Brake Pads: Check thickness and brake disc condition (front and rear)
 Engine: Change oil and replace oil filter
 Hybrid Components: Perform a visual inspection of high voltage components and the lines in the engine
compartment and the rear of the vehicle for damage
 Rear Window: Check cleaning nozzle functionality (if applicable)
 Service Interval Display: Reset
 Service Label: Enter the date of the next service on the service sticker and apply to the driver side door
pillar
 Tires: Rotate front to rear
 Windshield Washer, Headlight Cleaning System, and Wiper Blades: Check for damage and function,
Check fluid level and add if necessary
 Battery: Check (and second battery if applicable)
 Brakes: Inspect brake system and shock absorber for leaks and damage, check thickness of brake pads,
brake disc condition and check brake fluid level
 Convertible roof: Check latch: (if applicable) (Every 2 years regardless of mileage)
 Dust and Pollen Filter: Replace (if applicable)
 Fuel Filter: Replace (2.0L TDI and 3.0L TDI only)
 Tires: Check tread depth, condition, wear pattern and pressure of all tires (including spare)
 Tire mobility kit: Check and observe expiration date on the tire filler bottle (Every 2 years regardless of
mileage)
 Brake fluid: Change fluid (Touareg, Eos, Passat models, Jetta models, GTI, Golf, Tiguan, and CC) (Every
3 years regardless of mileage and every 2 years after)
pillar
 Body: Visual inspection for corrosion
 Convertible roof, CSC roof, and retractable hard top: Check for function and damage, clean and lubricate
seals (if applicable)
 Coolant level and frost protection: Check
 CV joints: Check for leaks and damage
 Door checks and mounting pins: Lubricate

 Dust and pollen filter: Replace (if applicable) (Every 2 years regardless of mileage)
 Engine and engine compartment components: Check (from above) for leaks and damage
 Engine and engine compartment components: Check (from below) for leaks and damage, check
transmission, final drive, and drive shaft boots
 Exhaust system: Check for leaks, damage and secure fittings
 Fuel filter: Replace (2.0L TDI and 3.0L TDI only)
 Headlights, daytime running lights, curve lighting, and automatic headlights: Check adjustment
 Hybrid components: Perform a visual inspection of high voltage components and the lines in the engine
 Interior lighting and glove box lights, cigarette lighter/power outlets, horn, and all warning lamps: Check
 Lighting: Front and rear lights, luggage compartment lighting, turn signals, hazard warning lights: Check
 Power steering: Check oil level
 Rear window: Check cleaning nozzle functionality (if applicable)
 Ribbed V-belt: Check condition
 Service interval display: Reset (if applicable)
 Service sticker: Enter the date of the next service on the service sticker and apply to the driver's side door
pillar
 Spark plugs: Replace (2.0L MPI only)
 Spark plugs: Replace (2.5L only)
 Sunroof and panoramic sunroof: Check, clean, and lubricate (if applicable)
 Sunroof: Open sunroof and check front water drains and clean if necessary (if applicable)
 Test drive: Check braking, kick-down, steering, electrical, heating and ventilation systems, air
conditioning, and handling
 Tie rod ends: Check for excessive play, check boots
 Tires: Check tread depth, condition, tire age, wear pattern and pressure of all tires (including spare)
mileage)
 Tire mobility kit: Replace tire filler bottle (Every 4 years regardless of mileage)
 Transmission: DSG (non automatic): Change fluid and filter
 Underbody sealant: Inspect for damage
 Windshield washers, headlight cleaning system, and wiper blades: Check for damage and function, Check
fluid level and add if necessary

pillar
 Transmission: Automatic (non DSG): Change fluid (all 2.5L, 2.0L MPI only)
 Air filter element and snow filter: Replace and clean housing (if applicable) (Every 6 years regardless of
mileage)
pillar
 Spark plugs: Replace (2.0T, 3.0L Hybrid and 3.6L only)
 Timing Belt: Check (2.0L MPI only)
mileage)
 Tire pressure sensors: Replace (Every 6 years regardless of mileage)
pillar
pillar
mileage)

pillar
pillar
mileage)
 Transmission: Automatic (non DSG): Change fluid (all 2.5L, 2.0L MPI only)

pillar
mileage)
 Diesel particulate filter: Only after 120,000 miles: Check ash loading according to manufacturer work
procedure. Replace if necessary. Note: If DPF replacement is not necessary, perform check every 10,000
miles thereafter until replacement becomes necessary. Subsequent DPF replacement interval is a
minimum of 120,000 miles, thereafter (2.0L TDI and 3.0L TDI only).

pillar
 Spark plugs: Replace (2.0T, 3.0L Hybrid and 3.6L only)
mileage)
pillar
 Timing belt: Replace (2.0L TDI only)
Edition 12022010
MY 2011 MAINTENANCE INTERVALS (EXCEPT ROUTAN) - CANADA
Every 1 Year
Every 2 Years
 Brake fluid: Replace (New Beetle)

Every 3 Years, then Every 2 years Regardless of Kilometers Driven
 Brake fluid: Replace (Touareg, Eos, Passat, Jetta models, GTI, Golf, Tiguan, Passat CC)
Every 3 Years Regardless of Kilometers Driven
 Haldex clutch: Change oil (if applicable)
 Tire filler bottle in the tire mobility set: Replace (observe expiration date)
 Spark Plugs: Replace (2.0L MPI only)
Every 4 Years if Kilometers is under 15,000 km

 Replace AdBlue® fluid (3.0L TDI only)
 Spark Plugs: Replace (all engines except 2.0L MPI and TDI)
 Air filter element and snow filter element: Replace and clean housing
 Tire pressure sensors: Replace (where applicable)
SERVICE AT 15,000 KILOMETERS
 AdBlue®. Fluid: Check fluid level and add if necessary (3.0L TDI only)
 Airbag system: Perform visual inspection (Every 1 year regardless of mileage)
 Brake pads: Check thickness and brake disc condition (front and rear)
 Headlights: Check adjustment
 Lighting: Front and rear lights, luggage compartment lighting, turn signals, hazard warning lights,
daytime running lights, curve lighting, and automatic headlights: Check
pillar
 Visual inspection of windshield. Note damage if necessary
 Windshield washer, headlight cleaning system, and wiper blades: Check for damage and function, Check

 Fuel filter: Replace (2.0L and 3.0L TDI only)
pillar
 Tire mobility kit: Check and observe date on the tire filler bottle (Every 2 years regardless of mileage)
3 years regardless of kilometers driven and every 2 years after)
pillar

 Power steering: Check oil level (if applicable)
pillar
 Transmission: Automatic (non DSG): Check fluid
pillar

mileage)
pillar
 Spark plugs: Replace (2.0T and 3.6L only)

pillar
pillar
pillar
pillar

pillar
mileage)
 Diesel particle filter: Only after 180,000 km: Check ash loading according to manufacturer work
procedure. Replace if necessary. Note: If DPF replacement is not necessary, perform check every 15,000
km thereafter until replacement becomes necessary. Subsequent DPF replacement interval is a minimum
of 180,000 km, thereafter (2.0L TDI and 3.0L TDI only).
pillar
 Spark plugs: Replace (2.0T and 3.6L only)
 Spark plugs: Replace (all engines except TDI)
pillar
 Timing belt: Replace (2.0L TDI only)
MY 2010 MAINTENANCE INTERVALS - USA


Every 1 Year
Every 2 Years

 Brake fluid: Replace. First fluid replacement included under the Volkswagen Carefree Maintenance
Program (New Beetle).
Every 3 Years, Then Every 2 Years Regardless of Miles Driven
 Brake Fluid: Replace. First fluid replacement included under the Volkswagen Carefree Maintenance
Program (CC, Touareg, Eos, Passat, Jetta models, GTI, Golf, Tiguan, Passat CC).
 Tire Filler Bottle In The Tire Mobility Set: Replace (observe expiration date)
 Spark Plugs: Replace

 Air Filter Element and Snow Filter: Replace and clean housing
 Tire Pressure Sensors: Replace (if applicable)
SERVICE AT EACH 5,000 MILES THROUGH 35,000 MILES
NOTE: Service at 10,000 miles or one year after last service, whichever occurs first.
Included in the Volkswagen Carefree Maintenance Program
pillar
 Battery: Check
 Fuel Filter: Replace (2.0L TDI only)
 Fuel Filter: Drain water (3.0L TDI only)
 Second Battery: Check (if applicable)
pillar
pillar
SERVICE AT 40,000 MILES AND EACH 5,000 MILES AFTER
 Battery: Check
 Coolant Level And Frost Protection: Check
 Convertible Roof, CSC Roof and Retractable Hard Top: Check for function and damage, clean and
lubricate seals (if applicable)
 CV Joints: Check for leaks and damage
 Door Checks and mounting pins: Lubricate
 Engine and Engine Compartment Components: Check (from above) for leaks and damage
 Engine and Engine Compartment Components: Check (from below) for leaks and damage, check
 Exhaust System: Check for leaks, damage, and secure fittings
 Fuel Filter: Replace (2.0L, and 3.0L TDI only)
 Headlamps: Check adjustment
 Interior Lighting and Glove Box Lights, Cigarette Lighter/Power Outlets, Horn, and All Warning Lamps:
Check
 Lighting: Check front and rear lights, Luggage Compartment Lighting, Turn Signals, Hazard Warning
Lights, Daytime Running Lights, Curve Lighting, and Automatic Headlights: Check
 Power Steering: Check oil level
pillar
 Spark Plugs: Replace (2.5 and 3.2L only)
 Sunroof and Panoramic Sunroof: Check, clean, and lubricate (if applicable)
 Test Drive: Check braking, kick-down, steering, electrical, heating and ventilation systems, air
 Tie Rod Ends: Check for excessive play, check boots
 Tires: Check tread depth, condition, wear pattern, and pressure of all tires (including spare)
 Transmission: Automatic: Check fluid. (3.0L TDI and 3.6L Touareg)

 Transmission: DSG: Change fluid and filter
 Underbody Sealant: Inspect for damage
 Windshield Washer, Headlight Cleaning System and Wiper Blades: Check for damage and function,
pillar
 Transmission: Automatic (non DSG): Change Fluid (2.5L Jetta models, NB, NBC and Golf)
 Battery: Check
 Fuel Filter: Replace (2.0 L TDI only)
 Fuel Filter: Drain water (3.0 L TDI only)
pillar
 Spark Plugs: Replace (2.0T, 3.6L and 4.2L only)

 Windshield Washer, Headlight Cleaning System and Wiper Blades: Check for damage and function.
pillar
 Windshield, Headlamp Washer Systems and Wiper Blades: Check for damage and function. Check fluid
level and add if necessary
 Battery: Check
 Coolant Level and Frost Protection: Check
 Door Checks and Mounting Pins: Lubricate
 Fuel Filter: Replace (2.0 L, and 3.0 L TDI only)
Check
 Lighting: Check front and rear lights, luggage compartment lighting, turn signals, hazard warning lights,
daytime running lights, curve lighting, and automatic headlamps
 Power Steering: Check Oil Level
 Rear Window: Check Cleaning Nozzle Functionality (if applicable)
 Ribbed V-belt: Check Condition
pillar
 Spark Plugs: Replace (2.5 and 3.2L only)
pillar
 Battery: Check
pillar
 Transmission: Automatic (non DSG): Change Fluid (2.5L Jetta models, NB, NBC and Golf)
pillar
 Timing Belt: Replace (if applicable, except 2.0 L TDI)
 Battery: Check
 Retractable Hard Top: and Retractable Hard Top: Check for function and damage, clean and lubricate
 Coolant Level and Frost Protection: Check
 Diesel Particulate Filter: (ONLY after 120,000 miles) Check ash loading according to manufacturer work
procedure; Replace if necessary. NOTE: If DPF replacement is not necessary, perform check every
20,000 miles thereafter until replacement becomes necessary. Subsequent DPF replacement interval is a
minimum of 120,000 miles thereafter. (2.0 L and 3.0 L TDI engine only)
 Door Checks and Mounting Pins: Lubricate
 Fuel Filter: Replace (2.0 L, and 3.0 L TDI only)
 Interior Lighting and Glove Box Lights, Cigarette Lighter/Power Outlets, Horn and All Warning Lamps:
Check
daytime running lights, curve lighting, and automatic headlights
pillar
 Spark Plugs: Replace (All engines except TDI)
 Road Test: Check braking, kick-down, steering, electrical, heating and ventilation systems, air
 Timing Belt: Replace (2.0 L TDI only)
MY 2010 MAINTENANCE INTERVALS - CANADA
Every 1 Year
Every 2 Years

Every 3 Years, then Every 2 Years Regardless of kilometers Driven
Every 4 Years Regardless of kilometers Driven
Every 6 Years

 Air filter element: Replace and clean housing
Brake Fluid Replacement
The brake fluid must be replaced every 2 years regardless of kilometers driven, and every 2 years thereafter
regardless of kilometers driven (New Beetle)
regardless of kilometers driven (Touareg, Eos, Passat, Jetta models, GTI, Golf, Tiguan, Passat CC)
SERVICE AT 15,000 KILOMETERS OR ONE YEAR FROM VEHICLE IN-SERVICE DATE
NOTE: Service at 15,000 km or one year from vehicle in-service date, whichever occurs
first.
 AdBlue® Fluid: Check and add if necessary (3.0 L TDI only)

pillar
NOTE: Service at 30,000 km or one year after last service, whichever occurs first.

 Battery: Check
pillar


pillar

 Battery: Check
transmission, final drive and drive shaft boots
 Fuel Filter: Replace (2.0 L TDI and 3.0 L TDI only)
 Interior Lighting and Glove Box Lights, Cigarette Lighter/Power Outlets, Horn, and All Warning Lamps:
Check
daytime running lights, curve lighting, and automatic headlights
 Power Steering: Check oil level (if applicable)
pillar
 Spark Plugs: Replace (2.5, 3.2, and 3.6 L only)
 Spark Plugs: Replace (2.0L gasoline engines only)
 Sunroof and Panoramic sunroof: Check, clean, and lubricate (if applicable)
 Transmission: Automatic: Check fluid

pillar
SERVICE AT 90.000 KILOMETERS

 Battery: Check

pillar
 Spark Plugs: Replace (2.0 L gasoline engine only)

pillar

 Battery: Check

 Fuel Filter: Replace (2.0 LTDI and 3.0 L TDI only)
pillar

pillar

 Battery: Check
pillar


pillar
 Timing Belt: Replace (if applicable except 2.0 L TDI)

 Battery: Check
 Diesel particulate filter: (ONLY after 180,000 km.) Check ash loading according to manufacturer work
30,000 km thereafter until replacement becomes necessary. Subsequent DPF replacement interval is a
minimum of 180,000 km thereafter. (2.0 L and 3.0 L TDI engine only)
 Fuel Filter: Replace (2.0 L and 3.0 L TDI only)
 Interior Lighting And Glove Box Lights, Cigarette Lighter/Power Outlets, Horn, And All Warning
Lamps: Check
 Power Steering: Check oil level (if applicable)

pillar
 Tie Rod Ends: Check for excessive play and check boots

TIME-DEPENDENT MAINTENANCE ITEMS
Every 1 year
Every 2 years

 Brake Fluid: Replace (New Beetle)
Every 3 years, then every 2 years regardless of miles driven
 Brake Fluid: Replace (Touareg, Eos, Passat, Jetta models, GTI, Rabbit, Tiguan, Passat CC)
Every 4 years regardless of miles driven
 Tire Filler Bottle In The Tire Mobility Set: Replace (Observe Expiration Date)

 Air Filter Element: Replace and clean housing
 Tire Pressure Sensors: Replace (where applicable)
SERVICE EVERY 5,000 MILES
 AdBlue® Fluid: Check and add fluid if necessary (3.0L TDI only)
 Brake Pads: Check thickness

 Headlamps: Check cleaning nozzle functionality (if applicable)
 Service label: Enter the date of the next service on the service label and apply to the driver's side door
pillar
 Windshield: Check cleaning nozzle functionality
 Wiper Blades: Check functionality
 Battery: Check
 Brakes: Inspect brake system for leaks and damage, check thickness of brake pads and check brake fluid
level

pillar

pillar
 Battery: Check
 Brakes: Inspect brake system for leaks and damage, check thickness of brake pads, and check brake fluid
level
 Convertible Roof: Check for function and damage, clean and lubricate (if applicable)
 Door Checks: Lubricate
 Fuel Filter: Replace (TDI engines only)
 Interior and Glove Box Lamps, Cigarette Lighter/Power Outlets, Horn, And All Warning Lamps: Check
 Retractable Hard Top: Check for function and damage (if applicable)
 Service Label: Enter the date of the next service on the service label and apply to the driver's side door
pillar
 Spark Plugs: Replace (1.9L, 2.5L and 3.2L only)
 Sunroof: Check, clean, and lubricate (if applicable)
 DSG Transmission: Change fluid and filter
 Windshield Washer system: Check function and fluid level (add if necessary), and inspect for damage
 Front Sunroof Drains (where applicable): Open Sunroof to check front water drains and clean if
necessary.
 Test drive and final check

pillar
 Transmission: Automatic: Change Fluid (2.5L Jetta models, NB, NBC, Rabbit and Golf)
 Air filter element: Replace and clean housing (if applicable)

 Battery: Check
 Brake pads: Inspect brake system for leaks and damage, check thickness of brake pads, and check brake
fluid level
pillar
 Spark Plugs: Replace (1.8L, 2.0L, 3.6L and 4.2L only)

pillar
 Battery: Check
level
 Interior and Glove Box Lamps, Cigarette Lighter/Power Outlets, Horn, and All Warning Lamps: Check
pillar
 Spark Plugs: Replace (1.9L, 2.5L and 3.2L only)

 Windshield and Headlamp Washer Systems: Check function and fluid level (add if necessary), and
inspect for damage
necessary.

pillar
 Battery: Check
level.
pillar
 Transmission: Automatic: Change Fluid (2.5L Jetta models, NB, NBC, Rabbit and Golf)

pillar
 Timing Belt: Replace (if applicable)
 Battery: Check
level
 Diesel Particle Filter: Check

 Interior and Glove Box Lamps, Cigarette Lighter/Power Outlets, Horn, and All Warning Lamps: Check
pillar
 Spark Plugs: Replace (all gasoline engines)
 Timing Belt: Replace (2.0L TDI only)
 Windshield and headlamp washer systems: Check function and fluid level (add if necessary), and inspect
for damage
necessary.
 Brake pads: Check thickness

 Diesel particle filter: Check ash content within the filter. Replace the filter if ash content is greater than 46
liters (3.0L TDI engine only).
 Headlight: Check cleaning nozzle functionality (if applicable)

 Service interval display: Reset
pillar
 Wiper blades: Check functionality
Every 1 Year
Every 2 Years

Every 3 Years, then Every 2 Years Regardless of Kilometers Driven
Every 6 Years

 Air filter element: Replace and clean housing
Brake Fluid Replacement
regardless of kilometers driven (New Beetle)
regardless of kilometers driven (Touareg, Eos, Passat, Jetta models, GTI, Golf, Tiguan, Passat CC)
SERVICE AT 15,000 KILOMETERS OR ONE YEAR FROM VEHICLE IN-SERVICE DATE
NOTE: Service at 15,000 km or one year from vehicle in-service date, whichever occurs
first.

pillar

 Battery: Check
pillar

pillar

 Battery: Check
 Fuel Filter: Replace (2.0 L TDI and 3.0 L TDI only)

pillar
 Spark Plugs: Replace (All 2.0L only)

pillar
SERVICE AT 90.000 KILOMETERS

 Battery: Check
pillar
 Spark Plugs: Replace (2.0L gasoline engine only)
 AdBlue® Fluid: Check and add if necessary (3.0L TDI only)

pillar
 AdBlue® Fluid: Check and add if necessary (3.0L TDI only)

 Battery: Check

 Fuel Filter: Replace (2.0 LTDI and 3.0 L TDI only)
pillar


pillar

 Battery: Check
pillar


pillar
 Timing Belt: Replace (if applicable except 2.0 L TDI)

 Battery: Check
 Diesel particulate filter: (ONLY after 180,000 km.) Check ash loading according to manufacturer work
30,000 km thereafter until replacement becomes necessary. Subsequent DPF replacement interval is a
minimum of 180,000 km thereafter. (2.0 L and 3.0 L TDI engine only)
 Fuel Filter: Replace (2.0 L and 3.0 L TDI only)

pillar
 Tie Rod Ends: Check for excessive play and check boots
Every 1 year
Every 2 years
 Dust and pollen filter: Replace (if applicable) (for vehicles driven less than 40,000 miles in 2 years)
 Brake fluid: Replace
necessary.
 Air filter element: Replace and clean housing (for vehicles driven less than 60,000 miles in 6 years)
 Engine Oil: Change and replace filter

 Brake System: Check for damage, leaks and fluid level
 Brake System: Check brake pad thickness
 Service Interval Display: Reset (where applicable)
 Water Separator: Drain (TDI)

 Airbag System: Visual check every 12 months regardless of mileage (kilometers)
 Windshield Wiper and Headlight Fluid: Check level; add if necessary
 Automatic Shift Lock: Check operation including park/neutral position switch
 Brake System: Check damage/leaks, fluid level
 Tires: Check tread depth and pressure; adjust if necessary.
 Wheels: Rotate
 Rear Spoiler: Lubricate (New Beetle)
 Service Interval Display: Adapt (for 10,000 mile/16,000 Km service interval only) (where applicable)
 12V Starter and Auxiliary Battery: Check (where applicable)

 Headlamps: Check and adjust if necessary
 Windshield Wiper and Headlight fluid: Check level; add if necessary
 Battery: Check
 Second battery: Check (Eos, where applicable)
 Dust and Pollen Filter: Replace (New Beetle, City Golf, City Jetta) (where applicable)
 Cooling System: Check coolant level; add if necessary
 Automatic Transmission: Check for leaks
 Manual Transmission: Check for leaks and level; add if necessary (where applicable)
 Tires/Spare: Check condition and pressure
 Wheels: Rotate
 Driveshaft: Check boots
 Engine On Board Diagnosis: Check DTC Memory; purge if necessary
 Door arresters: Lubricate
 Exterior lights: Check front and rear
 Exhaust System: Check for damage and links
 Sunroof Frame: Clean and lubricate
 CSC Roof: Check for damage and function; clean wind deflector and seals. (Eos)
 Road Test: Check kick down, braking, steering, heating and ventilation, air conditioning, power
accessories and electrical systems.
 Front Axle: Check dust seals on ball joints, tie rods; check tie rods
 Fuel Filter: Replace (TDI)
 Turbocharger: Lubricate servo motor rods (5.0L TDI)

 Wheels: Rotate

 Ribbed Belt: Check condition and tension; adjust if necessary
 Spark Plugs: Replace (2.0L engine, Canada only) (2.5L, 3.2L engines only)
 Air Cleaner: Replace filter and clean housing (New Beetle, City Golf, City Jetta)
 Wiper Blades: Check
 Brake Fluid: Replace every 2 years regardless of mileage (New Beetle, City Golf, City Jetta) (where
applicable)
 Brake Fluid: Replace every 3 years regardless of mileage (Touareg, Eos, Passat, Jetta, GTI, Rabbit)
(where applicable)
 Battery: Check
 Second Battery: Check (Eos, where applicable)
 Second Battery: Check (5.0L TDI)
 Engine: Check for leaks
 Dust and Pollen Filter: Replace (All models) (where applicable)
 Automatic Transmission: Check ATF
 Automatic Transmission Final Drive Oil: Check level and for leaks; add if necessary
 Manual Transmission: check for leaks and level; add if necessary (where applicable)
 DSG transmission: Change transmission fluid and filter (where applicable)
 Wheels: Rotate
 Exterior Lights: Check front and rear
 CSC Sunroof: Clean and lubricate guide rails. (Eos)
 Convertible Top: Check function and check roll-over protection with convertible top open (New Beetle
Convertible)
 Power Steering: check fluid level
 Underbody: Check for damage
 12V Starter and auxiliary battery: Check (where applicable)
 Interior Lights and power outlets: Check
 Air Suspension: Check for leaks and damage (Touareg)
 Haldex Clutch: Check fluid level (where applicable)
necessary.

 Wheels: Rotate

 Timing Belt: Check condition and replace if necessary (2.0L engine, Canada only)
 Spark Plugs: Replace (2.0T FSI, 3.6L FSI and 4.2L FSI engines only)
 Air Cleaner: Replace filter and clean housing (Eos, Passat, GTI, Jetta, Rabbit)
 Battery: Check
 Manual Transmission- check for leaks and level; add if necessary (where applicable)
 Wheels: Rotate
 Door Arresters: Lubricate


 Wheels: Rotate

 Air Cleaner: Replace filter element, clean housing and snow filter (Touareg)
 Brake Fluid: Replace every 2 years regardless of mileage (kilometers) (New Beetle, City Golf, City Jetta)
(where applicable)
 Brake Fluid: Replace every 3 years regardless of mileage (kilometers) (Touareg, Eos, Passat, Jetta, GTI,
Rabbit) (where applicable)
 Battery: Check
 DSG Transmission: Change transmission fluid and filter (where applicable)
 Wheels: Rotate
Convertible)
 Power Steering: Check fluid level
 Interior Lights and Power Outlets: Check
necessary.


 Wheels: Rotate

 Airbag system: Visual check every 12 months regardless of mileage (kilometers)
 Battery: Check
 Wheels: Rotate


 Timing Belt and Tensioning Roller: Replace (2.0T FSI engine)
 Wheels: Rotate

 Spark Plugs: Replace (All models)
 Air Cleaner: Replace filter element, clean housing (all models except Touareg)
 Brake System- Check brake pad thickness

(where applicable)
 Battery: Check
 Wheels: Rotate
Convertible)

 Diesel Particle Filter: Replace (5.0L TDI)
necessary.
Every 1 year
Every 2 years
 Dust and pollen filter: Replace (if applicable) (for vehicles driven less than 64,000 Km in 2 years)
Every 4 years regardless of kilometers driven
 Air filter element: Replace and clean housing (for vehicles driven less than 96,000 Km in 6 years)

 Brake System: Check for damage, leaks and fluid level


 Wheels: Rotate
 Service Interval Display: Adapt (for 10,000 mile/16,000 Km service interval only) (where applicable)

 Battery: Check
 Wheels: Rotate

 Wheels: Rotate

(where applicable)
 Battery: Check
 Wheels: Rotate
Convertible)
 Power Steering: check fluid level


 Wheels: Rotate

 Air Cleaner: Replace filter and clean housing (Eos, Passat, GTI, Jetta, Rabbit)
 Battery: Check
 Manual Transmission- check for leaks and level; add if necessary (where applicable)

 Wheels: Rotate

 Wheels: Rotate


 Air Cleaner: Replace filter element, clean housing and snow filter (Touareg)
 Brake System- Check brake pad thickness
 Brake Fluid: Replace every 2 years regardless of kilometers (New Beetle, City Golf, City Jetta) (where
applicable)
 Brake Fluid: Replace every 3 years regardless of kilometers (Touareg, Eos, Passat, Jetta, GTI, Rabbit)
(where applicable)
 Battery: Check
 Wheels: Rotate
Convertible)
 Interior Lights and Power Outlets: check

 Wheels: Rotate

 Airbag system: Visual check every 12 months regardless of mileage (kilometers)

 Battery: Check
 Wheels: Rotate

 Timing Belt and Tensioning Roller: Replace (2.0T FSI engine)
 Airbag System: Visual check every 12 months regardless of kilometers

 Wheels: Rotate

 Spark Plugs: Replace (All models)
 Air Cleaner: Replace filter element, clean housing (all models except Touareg)
(where applicable)
 Battery: Check

 Wheels: Rotate
Convertible)
 Diesel Particle Filter: Replace (5.0L TDI)
Every 1 year
Every 2 years

 Check function of convertible top and check roll-over protection with convertible top open. (if applicable)
necessary.
 Air filter element: Replace and clean housing (New Beetle only)
 Spark Plugs: Replace (for vehicles driven less than 40,000 miles in 4 years)
 Spark Plugs: Replace (2.0L TFSI, 3.6L FSI only) (for vehicles driven less than 60,000 miles in 6 years)
 Brake System: Check for leaks/damage, break pad thickness and brake fluid level
 Engine: Change engine oil and oil filter
 Service Interval Display: Reset and Adapt if necessary
 Water Separator: Drain (TDI Engines only)

 Rear Spoiler: Lubricate (New Beetle only)
 Tires: Check condition, tread depth and adjust pressure if needed (including spare)
 Wheels: Rotate front to rear
 Windshield Washer Fluid: Check level and add if needed

 Battery: Check
 Cooling System: Check coolant level and add if needed

 Dust and Pollen Filter: Replace (2.0L only)
 Drive Shafts: Check boots
 Exhaust System: Check for damage and leaks
 Front Axle: Check dust seals on ball joints and Tie Rod Ends: Check tie rods
 Fuel Filter: Replace (TDI Engines Only)
 Headlamps: Check and adjust if needed
 On-Board Diagnostic System: Check fault memory and erase if necessary
 Power Steering: Check fluid level (1.9L TDI,
 Road Test: Check kickdown, braking, steering, heating and ventilation, air conditioning, power
accessories and electrical systems
 Rear Spoiler: Lubricate (New Beetle Only)
 Transmission: Automatic: Check for leaks
 Transmission: Automatic: Check ATF and final drive (1.9L TDI only)
 Transmission: Manual: Check oil level: add if needed: Check for leaks
 Turbocharger: Lubricate Servomotor Rods (5.0L V10 TDI Only)
 V-Belt/Ribbed belt: Check and adjust if needed (1.9L TDI
 Water Separator: Drain (TDI Engines Only)
 Windshield Washer Fluid: Check level: add if needed

 Brake System: Check for leaks/damage, break pad thickness, and brake fluid level
 Air Cleaner: Replace filter and Clean Housing

 Air Suspension: Check for damage or leaks (Touareg, 4.2L FSI only)
 Battery: Check
 Battery: Check Second Battery (5.0L V10 TDI Only)
 Convertible Top: Check function and rollover protection
 Dust and Pollen Filter: Replace (1.9L TDI, 2.0L TFSI, 2.0L, 2.5L, 3.2L, 3.6L FSI, 4.2L FSI)
 Haldex Clutch: Change Fluid (where applicable), (3.6L FSI only)
 Interior/Exterior Lamps: Check function
 Power Steering: Check fluid level (2.0L, 2.0L TFSI, 2.5L, 3.2L, 3.6L FSI, 1.9L TDI)
 Retractable hard Top (CSC roof): Check function and for damage
 Spark Plugs: Replace (2.0L, 2.5L, 3.2L)
 Transmission: Automatic: Check ATF and final drive (2.0L, 2.0L TFSI. 2.5L, 3.2L, 3.6L FSI, 4.2L FSI,
1.9L TDI, 5.0L V10 TDI Only)
 Transmission: Direct Shift (DSG): Change fluid and filter (2.0L TFSI, 2.5L, 3.2L only)

 V-Belt/Ribbed belt: Check and adjust if needed (2.0L, 2.0L TFSI. 2.5L, 3.2L, 3.6L FSI, 4.2L FSI, 1.9L
TDI 5.0l V10 TDI Only)
necessary.

 Timing Belt: Check condition (2.0L only)
 Water Separator: Drain (TDI engines Only)

 Battery: Check
 Cooling System: Check coolant level: add if needed
 Dust and Pollen Filter: Replace (2.0L

 Spark Plugs: Replace (2.0L TFSI, 3.6L FSI, 4.2L FSI only)
 Timing Belt: Check condition (2.0L TFSI


 Battery: Check
 Dust and Pollen Filter: Replace (1.9L TDI, 2.0L TFSI, 2.0L, 2.5L, 3.2L, 3.6L FSI, 4.2L FSI,)
 Timing Belt: Replace (1.9L TDI, and 4.2l FSI)
 Timing Belt: Check condition (2.0L)

necessary.


 Battery: Check
 Timing Belt: Check condition (2.0L,



 Battery: Check
 Diesel Particle Filter: Replace (5.0L TDI only)

 Timing Belt: Replace (2.0L, 2.0L TFSI only)
necessary.

Every 1 year
Every 2 years

 Spark Plugs: Replace (for vehicles driven less than 64,000 Km in 4 years)
 Air filter element: Replace and clean housing (for vehicles driven less than 96,000 Km in 6 years)
 Spark Plugs: Replace (2.0L TFSI, 3.6L FSI only) (for vehicles driven less than 96,000 Km in 6 years)

 Rear Spoiler: Lubricate (New Beetle only)


 Battery: Check
 Dust and Pollen Filter: Replace (2.0L only)


 Battery: Check
 Dust and Pollen Filter: Replace (1.9L TDI, 2.0L TFSI, 2.0L, 2.5L, 3.2L, 3.6L FSI, 4.2L FSI)


 Timing Belt: Check condition (2.0L only)

 Battery: Check



 Battery: Check

 Timing Belt: Replace (1.9L TDI, and 4.2l FSI)
 Timing Belt: Check condition (2.0L)



 Battery: Check
 Timing Belt: Check condition (2.0L,



 Battery: Check

 Timing Belt: Replace (2.0L, 2.0L TFSI only)
Every 1 year
Every 2 years

(or every 20,000 miles, whichever occurs first)
necessary.
 Spark Plugs: Replace (2.0L TFSI only) (for vehicles driven less than 60,000 miles in 6 years)
 Engine: Change engine oil and oil filter (1.8L Turbo Only)

 Battery: Check (3.2L, 3.6L, 4.2L, 5.0L TDI, 6.0L W12 only)
 Tire Pressure Monitoring System Sensors: Check battery charge, replace wheel electronics and aluminum
valve if necessary (where applicable)


 Battery: Check
 Door Check Straps: Lubricate
 Dust and Pollen Filter: Replace (where applicable)
 Power Steering: Check fluid level (4.2L, 5.0L TDI, 6.0L W12 only)
 Road test: Check kickdown, braking, steering, heating and ventilation, air conditioning, power
 Transmission: Automatic: Check for leaks (1.8L Turbo, 1.9L TDI, 2.0L, 2.0L TFSI, 2.5L, 3.2L, 3.6L,
4.2L, 5.0L TDI, 6.0L W12 only)
 Transmission: Automatic: Check ATF (4.2L , 5.0L TDI only)
 Transmission: Automatic: Change ATF (6.0L W12 only)
 Transmission: Direct Shift (DSG): Check fluid (2.0L TFSI)
 Transmission: Manual: Check oil level: add if needed: Check for leaks (1.8L Turbo, 1.9L TDI, 2.0L, 2.0L
TFSI, 3.2L, 3.6L, 4.2L, 5.0L TDI only)


 Air Suspension: Check for damage or leaks (3.2L, 3.6L, 4.2L, 5.0L TDI only)
 Battery: Check
 Dust and Pollen Filter: Replace (3.6L, 5.0L TDI only)

 Haldex Clutch: Change Fluid (where applicable), (3.6L only)
 Interior/Exterior Lamps: Check function (3.2L, 3.6L, 4.2L, 5.0L TDI, 6.0L W12 only)
 Power Steering: Check fluid level (1.8L Turbo, 1.9L TDI, 2.0L, 3.6L, 4.2L only)
 Spark Plugs: Replace (all engines except 2.0L TFSI, Touareg and Phaeton V8)
4.2L, 5.0L TDI, 6.0L W12 only)
 Transmission: Automatic: Check ATF and final drive (1.8L Turbo, 1.9L TDI, 2.0L, 2.0L TFSI, 2.5L,
3.2L, 3.6L only)
 Transmission: Direct Shift (DSG): Change fluid and filter (1.9L TDI, 2.0L TFSI, 2.5L only)
 V-Belt/Ribbed belt: Check and adjust if needed

necessary.


 Battery: Check
 Diesel Particle Filter: Check soot load measurement (5.0L TDI only)

 Spark Plugs: Replace (2.0L TFSI, Touareg and Phaeton V8 4.2L, only)
 Timing Belt: Check condition (1.8L, 2.0L, 2.0L TFSI
4.2L, 5.0L TDI, 6.0L W12 only)



 Battery: Check

 Spark Plugs: Replace (all engines except 2.0L TFSI, Touareg and Phaeton V8)
 Timing Belt: Replace (1.9L TDI, Touareg and Phaeton V8 4.2L)
4.2L, 5.0L TDI, 6.0L W12 only)
3.2L, 3.6L only)
 Ribbed Belt Guide Rollers: Replace (Phaeton V8 4.2L only)
necessary.



 Battery: Check
 Diesel Particle Filter: Check (1.9L TDI only)

4.2L, 5.0L TDI, 6.0L W12 only)
Every 1 year
Every 2 years

(or every 32,000 km, whichever occurs first)
 Spark Plugs: Replace (for vehicles driven less than 64,000 km in 4 years)

 Air filter element: Replace and clean housing (for vehicles driven less than 96,000 km in 6 years)
 Spark Plugs: Replace (2.0L TFSI only) (for vehicles driven less than 96,000 km in 6 years)


 Battery: Check

4.2L, 5.0L TDI, 6.0L W12 only)



 Battery: Check

 Spark Plugs: Replace (1.8L, 2.0L, 2.5L, 3.2L except Touareg V8, Passat and Touareg 3.6L, 6.0L W12
Phaeton Only)
4.2L, 5.0L TDI, 6.0L W12 only)
3.2L, 3.6L only)


 Battery: Check
 Spark Plugs: Replace (2.0L TFSI, Touareg and Phaeton V8 4.2L, only)
 Timing Belt: Check condition (1.8L, 2.0L, 2.0L TFSI)
4.2L, 5.0L TDI, 6.0L W12 only)


 Battery: Check
 Spark Plugs: Replace (1.8L, 2.0L, 2.5L, 3.2L except Touareg V8, Passat and Touareg 3.6L, 6.0L W12
Phaeton Only)
 Timing Belt: Replace (1.9L TDI, Touareg and Phaeton V8 4.2L)
4.2L, 5.0L TDI, 6.0L W12 only)
3.2L, 3.6L only)
 Ribbed Belt Guide Rollers: Replace (Phaeton V8 4.2L only)


 Battery: Check

 Diesel Particle Filter: Check (1.9L TDI only)
4.2L, 5.0L TDI, 6.0L W12 only)
Every 1 year
Every 2 years

necessary.
 Plenum Panel: Remove cover for plenum panel to check water drains and clean if necessary. (Passat and
Passat Wagon only)
 Engine: Change engine oil and oil filter (1.8L Turbo, 2.8L Only)

 Battery: Check (2.8L VR6, 3.2L, 4.2L, 6.0L Only)


 Battery: Check
 Power Steering: Check fluid level (3.2L, 4.2L only)
 Tires: Check condition, tread depth and adjust pressure if needed (including spare
 Transmission: Automatic: Check ATF (3.2L, 4.2L, 6.0L only)
 Transmission: Manual: Check oil level: add if needed: Check for leaks (1.9L, 2.0L, 2.0L TFSI, 2.5L,
2.8L. 2.8L VR6, 3.2L, 4.0L W8, 4.2L only)

 Air Cleaner: Replace filter

 Air Suspension: Check for damage or leaks (3.2L, 6.0L only)
 Battery: Check

 Interior/Exterior Lamps: Check function (3.2L, 4.2L only)
 Spark Plugs: Replace (1.8L, 2.0L, 2.5L, 2.8L, 2.8L VR6, All 3.2L except Touareg V8, 4.0L W8 only)
 Transmission: Automatic: Change Fluid (Phaeton W12 only)
 Transmission: Automatic: Check ATF and final drive
 Transmission: Direct Shift (DSG): Change fluid and filter
2.8L. 2.8L VR6, 3.2L, 4.0L W8, 4.2L only)
necessary.
Passat Wagon only)


 Battery: Check
 Spark Plugs: Replace (2.0L TFSI, 4.2L Touareg and Phaeton V8 only)
 Timing Belt: Check condition (1.8L, 2.0L, 2.0L TFSI, 2.8L Only)
2.8L. 2.8L VR6, 3.2L, 4.0L W8, 4.2L only)



 Battery: Check
 Timing Belt: Replace (1.9L TDI, 2.0L TDI, 4.2L Touareg and Phaeton V8 Only)
2.8L. 2.8L VR6, 3.2L, 4.0L W8, 4.2L only)
necessary.
Passat Wagon only)


 Battery: Check
2.8L. 2.8L VR6, 3.2L, 4.0L W8, 4.2L only)
 Timing Belt: Replace (2.0L Only)
Every 1 year
Every 2 years

 Air filter element: Replace and clean housing (for vehicles driven less than 96,000 km in 6 years)


 Battery: Check
2.8L. 2.8L VR6, 3.2L, 4.0L W8, 4.2L only)


 Battery: Check
2.8L. 2.8L VR6, 3.2L, 4.0L W8, 4.2L only)


 Battery: Check

 Spark Plugs: Replace (2.0L TFSI, 4.2L Touareg and Phaeton V8 only)
2.8L. 2.8L VR6, 3.2L, 4.0L W8, 4.2L only)


 Battery: Check
 Timing Belt: Replace (1.9L TDI, 2.0L TDI, 4.2L Touareg and Phaeton V8 Only)

2.8L. 2.8L VR6, 3.2L, 4.0L W8, 4.2L only)


 Battery: Check

2.8L. 2.8L VR6, 3.2L, 4.0L W8, 4.2L only)
 Timing Belt: Replace (2.0L Only)

Every 1 year
Every 2 years
 Dust and pollen filter: Replace (if applicable) (for vehicles driven less than 40,000 miles) (Tourareg only)
necessary.
Passat Wagon only)
 Air filter element: Replace (for vehicles driven less than 80,000 miles in 4 years)
 Tire pressure monitoring system batteries: Replace (where applicable)

 Water Separator: Drain (1.9L TDI, 2.0L TDI and 5.0L V10 engines Only)

 Windshield Washer Fluid: Check level
 Battery: Check
 Engine: Change engine oil and oil filter (1.8T and 2.8L engine only)

 Fuel Filter: Replace (1.9L TDI, 2.0L TDI and 5.0L V10 engines Only)
 Battery: Check
 Engine: Check for Leaks
 Dust Pollen Filter: Replace
 Cooling System: Check Level, add if necessary
 Auto Transmission: Check ATF (Touareg and Phaeton Only)
 Auto Transmission: Check for leaks
 Manual Transmission: Check oil levels and leaks (All models except Touareg)
 Tires/Spare: Check Condition
 Drive Shafts: Check Boots
 On Board Diagnosis: Check DTC Memory and Purge
 Sunroof Frame: Clean and Lubricate
 Road Test
 Power Steering: Check Fluid Level (Touareg and Phaeton Only)
 Front Axle: Check Dust Seals, Ball Joints, and Tie Rods


 Battery: Check

 V-Belt/Ribbed Belt: Check
 Spark Plugs: Replace (1.8T, 2.0L, 2.8L VR6, 3.2L VR6, 2.8L)
 Haldex Clutch: Change oil (R32)
 Air Cleaner: Replace Filter
 Battery: Check
 Auto Transmission: Check ATF (All models except Touareg)
 Auto Trans/Final Drive: Check for Leaks (1.8T, 2.0L, and 2.8L Only)
 Auto Transmission: Change ATF (EuroVan Only)
 Manual Trans: Check oil levels and leaks (All models except Touareg)

 Road Test
 Power Steering: Check Fluid Level
 Interior/Exterior Lights: Check (Touareg and Phaeton Only)
 Air Suspension: Check (Touareg and Phaeton Only)
 Underbody: Check (Touareg and Phaeton Only)
 Direct Shift Trans (DSG): Change Fluid
necessary.
Passat Wagon only)

 Battery: Check


 Battery: Check
 Timing Belt: Check Condition (1.8T Only)
 Spark Plugs: Replace (4.2 Only)
 Road Test

 Battery: Check


 Timing Belt: Check Condition (1.9L TDI, 2.0L TDI, 5.0L V10, 1.8T and 2.8L engines)
 Spark Plugs: Replace (2.8L VR6, 3.2L VR6, W8, W12, 2.8L, 1.8T and 2.0L engines)
 Timing Belt: Replace (4.2L V8 engine only)
 Battery: Check
 Road Test

necessary.
Passat Wagon only)

 Battery: Check

 Battery: Check

 Timing Belt: Replace (1.9L TDI, 2.0L TDI and 5.0L V10 engines)
 Road Test
 Timing Belt: Replace (2.0L engine only)
 Timing Belt and Tensioning Roller: Replace (1.8T and 2.8L engine only)
Every 1 year
Every 2 years
 Dust and pollen filter: Replace (if applicable) (for vehicles driven less than 64,000 km) (Tourareg only)
 Air filter element: Replace (for vehicles driven less than 128,000 km in 4 years)
 Tire pressure monitoring system batteries: Replace (where applicable)


 Battery: Check

 Battery: Check

 Road Test

 Battery: Check

 Spark Plugs: Replace (1.8T, 2.0L, 2.8L VR6, 3.2L VR6, 2.8L)

 Battery: Check
 Road Test

 Battery: Check

 Battery: Check
 Timing Belt: Check Condition (1.8T Only)
 Spark Plugs: Replace (4.2 Only)
 Road Test


 Battery: Check

 Timing Belt: Check Condition (1.9L TDI, 2.0L TDI, 5.0L V10, 1.8T and 2.8L engines)
 Spark Plugs: Replace (2.8L VR6, 3.2L VR6, W8, W12, 2.8L, 1.8T and 2.0L engines)
 Timing Belt: Replace (4.2L V8 engine only)
 Battery: Check

 Road Test

 Battery: Check

 Battery: Check
 Timing Belt: Replace (1.9L TDI, 2.0L TDI and 5.0L V10 engines)
 Road Test
 Timing Belt: Replace (2.0L engine only)
 Timing Belt and Tensioning Roller: Replace (1.8T and 2.8L engine only)
Every 1 year

Every 2 years
 Brake Fluid: Replace

necessary.
Passat Wagon only)

 Water Separator: Drain (1.9L TDI engine only)

 Timing Belt: Check condition (1.9L TDI engine only)
 Airbag System: Check function/damage
 Battery: Check electrolyte level
 Engine: Change engine oil and oil filter (1.8T, 2.0L and 2.8L V6 engines only)

 Fuel Filter: Replace (1.9L TDI engine only)

 Cooling System: Check Level
 Manual Transmission: Check for Leaks, add if necessary
 Automatic Transmission: Check for Leaks
 On Board Diagnosis: Check DTC Memory
 Door Hinge: Lubricate
 Road Test


 Timing Belt: Check Condition (1.9L TDI, 1.8T, 2.0L and 2.8L V6)
 Spark Plugs: Replace (1.8T, 2.0L, VR6, 4.0L W8 and 2.8L V6)

 Road Test
 ATF and Differential Levels: Check, add if necessary
 ATF: Change ATF (Euro Van only)
necessary.
Passat Wagon only)



 Road Test


 V-Belt: Replace (1.8T and 2.0L engines only)

 Road Test
necessary.
Passat Wagon only)


 Timing Belt: Replace (1.9L TDI engine only)

 Road Test
 Timing Belt: Replace (2.0L and 2.8L V6 engine only)
 Timing Belt Tensioner: Replace (2.0L and 2.8L V6 engine only)
Every 1 year
Every 2 years




 Road Test



 Road Test



 Road Test



 V-Belt: Replace (1.8T and 2.0L engines only)
 Road Test



 Timing Belt: Replace (1.9L TDI engine only)

 Road Test
 Timing Belt: Replace (2.0L and 2.8L V6 engine only)
 Timing Belt Tensioner: Replace (2.0L and 2.8L V6 engine only)
Every 1 year
Every 2 years

necessary.
Passat Wagon only)

 Water Separator: Drain (TDI engine only)

 Timing Belt: Check condition (TDI engine only)


 Fuel Filter: Replace (TDI engine only)
 Road Test


Engine: Change engine oil and oil filter
Water Separator: Drain (TDI engine only)
Fuel Filter: Replace (TDI engine only)
V Belt/Ribbed Belt: Check
Timing Belt: Check condition (1.8T, 2.0L, 2.8L V6 and TDI engines only)
Spark Plugs: Replace
Windshield Washer Fluid: Check level
Automatic Shift Lock: Check operation including park/neutral position switch
Airbag System: Check function/damage
Brake System: Check for leaks/damage, break pad thickness, and brake fluid level
Wheels: Rotate front to rear
Battery: Check electrolyte level
Engine: Check for leaks
Dust Pollen Filter: Replace
Cooling System: Check Level
Manual Transmission: Check for Leaks, add if necessary

Automatic Transmission: Check for Leaks
Tires/Spare: Check Condition
Drive Shafts: Check Boots
On Board Diagnosis: Check DTC Memory
Door Hinge: Lubricate
Headlamps: Check and adjust if necessary
Exhaust System: Check for damage and leaks
Sunroof Frame: Clean and Lubricate
Road Test
Air Cleaner: Replace filter
Power Steering: Check fluid level
Brake Fluid: Change
ATF and Differential Fluid Levels: Check and add if necessary
ATF Fluid: Change (Euro Van only)
Front Axle: Check dust seals, ball joints and tie rods
Front Sunroof Drains (where applicable): Open Sunroof to check front water drains and clean if necessary.
Plenum Panel: Remove cover for plenum panel to check water drains and clean if necessary. (Passat and Passat
Wagon only)


 Road Test



 V Belt/Ribbed Belt: Check
 V Belt: Replace (1.8T and 2.0L engines only)
 Timing Belt: Check condition (1.8T, 2.0L, 2.8L V6 and TDI engines only)
 Timing Belt: Replace (TDI engines only)
 Timing Belt Idler: Replace (TDI engines only)

 Road Test
 Brake Fluid: Change
 ATF and Differential Fluid Levels: Check and add if necessary
 ATF Fluid: Change (Euro Van only)
 Front Axle: Check dust seals, ball joints and tie rods
necessary.
Passat Wagon only)



 Road Test
 Timing Belt and Tensioner: Replace (1.8T, 2.0L and 2.8L V6 engines only)
Every 1 year
Every 2 years



 Road Test

Engine: Change engine oil and oil filter
Water Separator: Drain (TDI engine only)
Fuel Filter: Replace (TDI engine only)
V Belt/Ribbed Belt: Check
Timing Belt: Check condition (1.8T, 2.0L, 2.8L V6 and TDI engines only)
Spark Plugs: Replace
Windshield Washer Fluid: Check level
Automatic Shift Lock: Check operation including park/neutral position switch
Airbag System: Check function/damage
Brake System: Check for leaks/damage, break pad thickness, and brake fluid level
Wheels: Rotate front to rear

Battery: Check electrolyte level
Engine: Check for leaks
Dust Pollen Filter: Replace
Cooling System: Check Level
Manual Transmission: Check for Leaks, add if necessary
Automatic Transmission: Check for Leaks
Tires/Spare: Check Condition
Drive Shafts: Check Boots
On Board Diagnosis: Check DTC Memory
Door Hinge: Lubricate
Headlamps: Check and adjust if necessary
Exhaust System: Check for damage and leaks
Sunroof Frame: Clean and Lubricate
Road Test
Air Cleaner: Replace filter
Power Steering: Check fluid level
Brake Fluid: Change
ATF and Differential Fluid Levels: Check and add if necessary
ATF Fluid: Change (Euro Van only)
Front Axle: Check dust seals, ball joints and tie rods



 Road Test


 V Belt/Ribbed Belt: Check
 V Belt: Replace (1.8T and 2.0L engines only)
 Timing Belt: Check condition (1.8T, 2.0L, 2.8L V6 and TDI engines only)
 Timing Belt: Replace (TDI engines only)
 Timing Belt Idler: Replace (TDI engines only)

 Road Test
 Brake Fluid: Change
 ATF and Differential Fluid Levels: Check and add if necessary
 ATF Fluid: Change (Euro Van only)



 Road Test
 Timing Belt and Tensioner: Replace (1.8T, 2.0L and 2.8L V6 engines only)
Every 1 year
Every 2 years
 Air Filter: Replace (every 2 years or 40,000 miles, whichever occurs first) (Cabrio, Passat, Euro Van
only)
Passat Wagon only)
Every 4 years
 Air Filter: Replace (or 40,000 miles, whichever occurs first) (Golf, Jetta, New Beetle only)


 Engine: Change engine oil and oil filter (1.8T and V6 engine only)

 Spark Plugs: Replace (2.0L Cabrio only)

 Road Test


 Timing Belt: Check condition (TDI, 1.8T, 2.0L and V6 engine only)
 Timing Belt: Replace (TDI with Automatic Transmission only)

 ATF and Differential Levels: Check
necessary.
Passat Wagon only)
 Road Test



 Timing Belt: Replace (TDI with Manual Transmission only)
 Road Test



 V Belt: Replace (1.8T engine only)
necessary.
Passat Wagon only)
 Road Test


 Road Test

 Timing Belt and Tensioner: Replace (1.8T and V6 engine only)
Every 1 year
Every 2 years
 Air Filter: Replace (or 64,000 km, whichever occurs first) (Cabrio, Passat, Euro Van only)
Every 4 years
 Air Filter: Replace (or 64,000 km, whichever occurs first) (Golf, Jetta, New Beetle only)




 Road Test


 Road Test


 Road Test



 Road Test



 Road Test
Every 1 year
Every 2 years
 Air Filter: Replace (Cabrio, Passat, Euro Van only)

necessary.
Passat Wagon only)
Every 4 years
 Air Filter: Replace (Golf, Jetta, New Beetle only)




 Road Test



necessary.
Passat Wagon only)
 Road Test



 Road Test



necessary.
Passat Wagon only)
 Road Test



 Road Test
Every 1 year
Every 2 years
 Air Filter: Replace (Cabrio, Passat, Euro Van only)

Every 4 years
 Air Filter: Replace (Golf, Jetta, New Beetle only)




 Road Test



 Road Test



 Road Test



 Road Test


 Road Test
MAINTENANCE Maintenance, Diagnosis - Maintenance Procedures
MAINTENANCE
Maintenance, Diagnosis - Maintenance Procedures
GENERAL INFORMATION
ENGINE OVERVIEW
Passat gasoline engines
Engines: Gasoline engine Gasoline engine

Displacement I 3.6 2.0
Engine code BLV BPY
Number of cylinders/valves per cylinder 6/4 4/4
Output kW at RPM 206/6200 147/5700
Torque Nm at RPM 360/2800 280/2000
Bore diameter mm 89.0 82.5
Stroke mm 95.9 92.8
Compression ratio 12.0 10.5
Motronic MED 9.1 Motronic MED 9.1
Fuel injection/Ignition
FSI TFSI
RON unleaded, minimum. 98 95
Camshaft drive Chain Timing belt
Engines: Gasoline engine

Displacement I 2.0
Engine code CCTA
Number of cylinders/valves per cylinder 4/4
Output kW at RPM 147/5100 through 6000
Torque Nm at RPM 280/1700 through 5000
Bore diameter mm 82.5
Stroke mm 92.8
Compression ratio 9.6
Motronic MED 17.5 TSI
Turbocharger
RON unleaded, minimum. 95
Camshaft drive Chain
Passat diesel engines
Passat CC through MY 2009 and CC from MY 2010 gasoline engines

Engines: Gasoline engine

Displacement I 3.6
Engine code BLV
Output kW at RPM 206/6200
Torque Nm at RPM 360/2800
Stroke mm 95.9
Fuel injection/Ignition Motronic MED 9.1 FSI
Engines: Gasoline engine Gasoline engine

Displacement I 2.0 2.0
Engine code CBFA CCTA
Number of cylinders/valves per cylinder 4/4 4/4
Output kW at RPM 147/5100 through 6000 147/5100 through 6000
Torque Nm at RPM 280/1700 through 5000 280/1700 through 5000
Bore diameter mm 82.5 82.5
Stroke mm 92.8 92.8
Compression ratio 10.3 9.6
Motronic MED 17.1 TSI Motronic MED 17.5 TSI
Turbocharger Turbocharger
RON unleaded, minimum. 95 95
Camshaft drive Chain Chain
Gasoline
Engines:
engine
Displacement L 3.6
Engine code CNNA
Output kW at RPM 206/6200
Torque Nm at RPM 360/2800
Stroke mm 95.9
Motronic
Fuel injection/Ignition MED 9.1
FSI
RON Ethanol 85 ---

SERVICE IDENTIFICATION
-- Check the vehicle data label to see which PR number the vehicle has "QG0" , "QG2" or "QG3". The PR
number determines the service intervals.
Vehicle with the following PR number
"QG0" , "QG2" or "QG3" means time and/or distance dependent service
TIME AND/OR DISTANCE DEPENDANT SERVICE
Vehicles with PR numbers "QG0/QG2/QG3" that have time- and/or distance-dependent service must be brought
in for service at specific mileage/kilometer or time intervals, which are established by Volkswagen. Under
ordinary operating conditions, this technically assures that the service will be performed when the interval is
reached.
The time and/or distance dependant service is therefore referred to as being fixed.
On vehicles,
 which were delivered without any service interval extension (WIV)

 or where the maintenance interval extension was switched off
applies to time and/or distance dependant service.
The fixed service intervals apply to all maintenance services, which include an oil change.
Vehicles with PR number "QG0"
The time or distance dependent service intervals (fixed intervals) apply to the vehicle maintenance.
This means these vehicles have a fixed Service Interval Display (SID) and the time or distance dependent
service interval apply to the vehicle maintenance. These vehicles have the following components:
 Fixed service interval display in instrument cluster

 Engine oil level sensor
 Brake pad wear display, if equipped
This means these vehicles have a fixed Service Interval Display (SID) and the time or distance dependent
service interval apply to the vehicle maintenance. These vehicles have the following components:
 Fixed service interval display in instrument cluster

 Brake pad wear display, if equipped
SERVICE INTERVAL DISPLAY
Fixed service interval display (vehicles with time or distance dependent service only, PR number,
"QG0/QG2/QG3"
Calculating the maintenance intervals:
 Time and/or distance dependant service vehicles: These service intervals are established by Volkswagen
and the vehicle must be brought in for service at specific kilometer or time intervals.
 Under ordinary operating conditions, this technically assures that the service will be performed when the
interval is reached.
SERVICE TABLES
GENERAL INFORMATION
The Volkswagen Service Tables containing the Maintenance requirements can be found in the following
information. In the past, individual Maintenance requirements were introduced in several markets. The market-
specific differences are listed in the Service tables.
NOTE: With combined distance and time measurements: whichever comes first.
In addition to interval service or inspection service or other inspection service

interval must be performed, depending on operating conditions and vehicle
equipment. Refer to SEVERE OPERATING CONDITIONS.
It is also possible that additional work, depending on what is listed in the

customer Maintenance booklet (or on the: Your Next Service label), must be
performed outside of the maintenance interval.
SERVICE TABLES
Service intervals, refer to SERVICE INTERVALS
Volkswagen approved oils, refer to VOLKSWAGEN ENGINE OIL STANDARDS
Filter change intervals, refer to FILTER CHANGE INTERVAL
Toothed belt replacement intervals, refer to TOOTHED BELT REPLACEMENT INTERVAL
Spark plug change intervals, refer to SPARK PLUG CHANGE INTERVAL

SERVICE INTERVALS
Refer to Maintenance, Diagnosis .
NOTE: With combined distance and time measurements: whichever comes first.
VOLKSWAGEN ENGINE OIL STANDARDS
CAUTION: Only engine oils authorized by VW must be used. Refer to PASSAT .
FILTER CHANGE INTERVAL
Refer to MAINTENANCE, DIAGNOSIS .
TOOTHED BELT REPLACEMENT INTERVAL
SPARK PLUG CHANGE INTERVAL
LIFTING VEHICLE ON A JACK OR WORKSHOP HOIST
SAFETY PRECAUTIONS
WARNING:  Before driving the vehicle onto a workshop hoist, make sure there is
enough clearance between any low-lying vehicle components and
the hoist.
 Before driving a vehicle onto a lifting platform it must be ensured
that the vehicle weight does not exceed the permissible lifting
capacity of the platform.
 Vehicle may only be lifted at points indicated in illustration in order
to avoid damaging vehicle floor pan and to prevent vehicle from
tipping.
 Never start engine and engage a gear with vehicle lifted so long as
even one wheel has contact with the floor. There is a risk of an
accident if this is not observed.
 If work is to be performed under vehicle it must be supported by
suitable stands.
HOIST AND JACK MOUNTING POINTS
NOTE: The Passat R36 has sill trim. To access the mounting points, you must remove
the covers over them.
Front
Fig. 1: Identifying Support Plate Placement (Front)

-- Place support plate, in area of side member marking -arrow A- , on vertical stiffener of floor plate -arrow B-.
WARNING: Make sure that side member stiffener contacts support plate of lifting
platform at center.
Rear
Fig. 2: Identifying Support Plate Placement (Rear Mounting Point)

-- Place support plate, in area of side member marking -arrow A- , on vertical stiffener of floor plate -arrow B-.
WARNING: Make sure that side member stiffener contacts support plate of lifting
platform at center.
LABELS
GENERAL INFORMATION
The label used in the German market is described here. The importer supplies the label for that market.
Fig. 3: Locating "Next Service" Or "Vehicle Data" Label (Germany)

Applying the "Next Service" label, refer to NEXT SERVICE LABEL, APPLYING
Applying the "Vehicle Data Label" in the customer Maintenance booklet, refer to DATA LABEL,
APPLYING IN CUSTOMER MAINTENANCE BOOKLET
NEXT SERVICE LABEL, APPLYING
Label through November 06 2009
Fig. 4: Locating "Next Service" Label (-11/6/2009)

-- "Your next service" decal: check off the oil change or inspection service (whichever is due next) and enter the
date/mileage.
Label from November 06 2009
Fig. 5: Locating "Next Service" Label (11/6/2009-)

-- "Your Next Service" label: Check off the oil change service or Inspection service or the legally required test,
for example, inspecting the gas system, (whichever one is due next) and enter the date and mileage (kilometers).
NOTE: A new label was introduced in 9 November 2009.
Service intervals, refer to SERVICE TABLES
-- Apply the label to the B-pillar on the driver side.
DATA LABEL, APPLYING IN CUSTOMER MAINTENANCE BOOKLET

Fig. 6: Identifying Data Label

-- Apply the bottom data label -arrow- inside the customer Maintenance booklet.
CUSTOMER MAINTENANCE BOOKLET ENTRIES
If a part is being replaced earlier than what is recommended by the manufacturer, for example, the toothed belt,
then the time period for the next change begins the time the part is replaced.
 For this reason it is very important to document inside the customer Maintenance booklet every time a
part is replaced.
 This applies also to parts that are being replaced earlier than when they are scheduled to be replaced.
NOTE: When using an "Original Replacement Part Kit" , determine if it is necessary for
technical reasons to use all the parts that come in the kit.
If it is necessary to replace more parts than what is technically required, always

inform the customer before performing the repair.
VEHICLE DIAGNOSIS TESTER, CONNECTING
 Vehicle diagnosis, testing and information system -VAS 5051 A-

Fig. 7: Identifying Diagnostic Operation System VAS 5051A

 Vehicle diagnosis, testing and information system -VAS 5051B-
 Diagnostic cable -VAS 5051/6A-

Fig. 9: Identifying Diagnostic Cable (VAS5051/6A)

 Vehicle diagnosis, testing and information system -VAS 5052-
Fig. 10: Identifying VAS 5052 Vehicle Diagnostic And Service Information System
 Diagnostic system -VAS 5053-

Fig. 11: Identifying Diagnostic system VAS 5053

 Diagnostic cable -VAS 5052/3-
Fig. 12: Identifying Diagnostic Cable VAS 5052/3 A

NOTE: Make sure the selected Vehicle diagnosis tester is only used with the
accompanying diagnostic cable.
WARNING:  During a road test you must always secure testing and measuring
equipment on the back seat.

 Drivers must NEVER operate these tools while driving.
-- Perform the following:
Fig. 13: Locating Data Link Connector (DLC)

-- Connect diagnosis cable connector to data link connector.
-- Switch on the Vehicle diagnosis tester.
Follow the instructions appearing on the screen to start the desired functions.
VIN
Component Location Engine Compartment

Fig. 14: Locating Vehicle Identification Number (VIN) In Engine Compartment

Vehicle Identification Number (VIN) is located on extension of longitudinal member -arrow-.
Meaning of Vehicle Identification Number (VIN)
WVW ZZZ 3C Z 5 8 000 234

Filler Model year Producing Serial
Manufacturer code Type Filler character
character 2005 Factory number
VEHICLE DATA LABEL
The vehicle data label -arrow- is located in rear of vehicle on the spare wheel recess. The vehicle data label is
also inside the customer Maintenance booklet.
Fig. 15: Locating Vehicle Data Label

NOTE: The vehicle data label is located inside the spare wheel well on the right side in
the Passat R36, the Passat CC through MY 2009 and the CC from MY 2010.
The label inside the luggage compartment contains the following vehicle data:
Fig. 16: Identifying Luggage Compartment Label

The label inside the customer Maintenance booklet contains the same information. The legend is under the
label.
Fig. 17: Identifying Customer Maintenance Booklet Label

SEVERE OPERATING CONDITIONS
Under severe operating conditions, it is necessary to have some work performed before the next service is due
or between specified Service Intervals.
Severe Operating Conditions
 Constant short-distance driving or stop-and-go driving in the city

 High proportion of cold starts
 Operating the vehicle in areas with extremely low temperatures for an extended period of time
 Frequently running at idle for extended periods of time (e.g. a taxi)
 Frequently driving full throttle or with a high load or a trailer
 Running with diesel fuel with high sulfur content
 Frequently operating in areas with excessive dust
ENGINE CODE AND ENGINE NUMBER
Engine code and engine number are found:
 On vehicle data label, refer to VEHICLE DATA LABEL.

 On the type plate (4-digit engine code)
 On the engine control module (4-digit engine code)
TYPE PLATE
NOTE: Vehicles for some countries do not have a type plate.
Type plate -arrow 1- can be seen after opening left front door, in lower area of B-pillar.
Fig. 18: Identifying Vehicle Information On Type Plate

The type plate contains the following vehicle information:
A - Vehicle Identification Number
B - Variable specification, such as axle load, total weight permitted, towing weight permitted
C - Type identification number
D - Engine code
GLOSSARY
These explanations apply only to "Maintenance". They are not intended to be generally applicable.
Term Description
(Anti-lock
braking system),
the ABS is a
regulation
device in the
brake system,
that prevents the
wheels from
locking up while
braking.
Thereby,
ABS
directional
stability and
steering ability
are retained.
(Automatic
Transmission
Fluid)
Automatic Transmission Fluid
Transmission oil
for automatic
transmission.
"Fill height" of
ATF level ATF in
transmission.
(Carbon
monoxide)
results by
CO incomplete
combustion of
fuels containing
carbon
Refers to a
shared high-
pressure fuel
injection line
Common Rail "CR" "Rail" , that
supplies fuel to
all cylinders of a
respective
cylinder bank.
Deutsches
Institut fµr
Normung e.V
DIN
(German
Institute for
Standards)
DS Direct shift
Direct shift
DSG
transmission
Anti-theft alarm
DWA
system
EN Euro-Norm
Abbreviation for
Replacement
ET-No.
Part Number.
Euro On Board
EOBD Diagnostic
(OBD)
Fatty Acid
FAME
Methyl Ester
(Fuel Stratified
Injection)
FSI
stratified fuel
injection
Instandhaltung
genau
IGG
genommen
(Maintenance)
Light emitting
LED
diode
(Malfunction
Indicator Light)
American
MIL
designation for
exhaust warning
light K83
Multi Point
MPI
Injection
within North
NAR (North American Region)
America
On Board
Diagnostic,
OBD monitors
OBD all components
which influence
the emission
quality
American On
Board
OBD-II
Diagnostic
(OBD)
Pump-injector -
Fuel injection
PD
unit for diesel
engines
Abbreviation for
production
control number.
They designate,
among other
things, optional
PR number
equipment,
country-specific
variations
(Particulate
matter) Soot
PM particle value of
diesel engine
emissions
Time and
distance
dependent
QG0
intervals (fixed
intervals) apply
for maintenance.
This means,
vehicles have a
fixed service
interval display
(time and
distance
dependent
maintenance
intervals) and
are equipped
with the
following
components:
QG2
 Fixed
service
interval
display in
instrument
cluster
 Engine oil
level
sensor
 Brake pad
wear
indicator
This means,
vehicles have a
fixed service
interval display
(time and
distance
dependent
maintenance
intervals) and
are equipped
with the
following
components:
QG3
 Fixed
service
interval
display in
instrument
cluster
 Brake pad
wear
indicator
Registered
R
trademark
8 digit binary
code which
indicates
whether all
emissions-
Readiness code
relevant
diagnostics were
performed by
engine
management.
(Research
Octane Number)
Measure for
RON
anti-knock
properties of
gasoline
Sulphur
RPF
particulate filter
Tire pressure
monitoring, tire
TPM, TPI
pressure
indicator
(Society of
Automotive
Engineers)
Society which
generates
designations /
guidelines as to
SAE
how legal
requirements
can be
implemented
(e.g. Norms)
The Selective
Catalytic
Reduction
(SCR)
drastically
reduces the
amount of nitric
oxide in the
exhaust gas and
uses a urea
solution to
SCR
change it into
water vapor and
nitrogen. A
special urea
solution,
AdBlue® , is
injected into the
exhaust gas
system by a
special catalytic
converter.
Normally
SD aspirated Diesel
engine
Normally
aspirated Diesel
SDI
engine with
direct injection
Intake manifold
SRE
injection
Turbo (Fuel
Stratified
TFSI Injection)
concerns the
fuel injection
From model
year 2008, the
designation
TFSI is being
discontinued
and is being
replaced by TSI.
Within the
designation TSI,
there is a
separation as
TSI-
TSI Turbocharger
and TSI-
Twincharger.
TSI
turbocharger:
charging only
with
turbocharger
TSI
twincharger:
charging with
turbocharger
and compressor
Distributor
VEP
injection pump
Ultra Low
ULEV Emission
Vehicles
Service Interval
SIE
extension
ASM Assembly
MAINTENANCE PROCEDURES
BALL JOINT AND AXLE BEARING, CHECKING
-- Check ball joint boots -arrow- for leaks and damage.

Fig. 19: Identifying Ball Joint Boots

Fig. 20: Identifying Axle Bearing: Jetta Model Year -05, Golf Wagon Model Year -07 And Golf Wagon
Model Year -10
-- Check the axle bearing -arrow- for the following damage:
 There must not be any play.

 The vulcanized rubber bushing must not have any cracks or porous spots.
ATF LEVEL, CHECKING

-- Refer to TRANSMISSION FLUID LEVEL, CHECKING AND FILLING .
BATTERY TERMINALS, CHECKING FOR SECURE FIT
 Torque Wrench -V.A.G. 1331-

NOTE: Tight battery connections assure trouble-free battery function and long service
life.
Battery in Engine Compartment
-- Operate lock -arrow-, fold up and remove cover toward front.

Fig. 22: Identifying Battery Cover Lock

-- Check battery terminal clamps are seated securely on the battery terminals by moving the battery Ground
(GND) wire -1- and the battery positive wire -2- to and fro by hand.
Fig. 23: Identifying Battery Cable Clamps

WARNING: If battery positive (B+) connection is loose, disconnect ground (GND)

cable first before attempting to remove or tighten plus connection, to
prevent personal injury.
If battery plus (B+) connection is not tight:
-- First disconnect battery clamp -1- at battery minus pole.

-- Tighten battery clamp -2- on battery positive terminal to 6 Nm.
-- Attach the battery clamp -1- on battery negative terminal and tighten to 6 Nm.
If ground connection on battery is not tight:
-- Tighten the battery clamp -1- on the battery negative terminal to 6 Nm.

-- Reinstall cover.
NOTE: After connecting the battery, Note general information, refer to INSPECTING .
Battery Inside Luggage Compartment
Remove the left storage compartment upward from the luggage compartment in the -direction of the arrow-.
Fig. 26: Identifying Direction To Remove Left Storage Compartment

-- Fold the positive terminal cover upward.
-- Move the battery negative wire -1- and positive wire -2- back and forth to see if the battery clamps are secure
on the battery terminals.
Fig. 27: Identifying Battery Negative Wire -1- And Positive Wire -2-
WARNING: If battery positive (B+) connection is loose, disconnect ground (GND)

cable first before attempting to remove or tighten plus connection, to
prevent personal injury.
If battery plus (B+) connection is not tight:
-- First clamp the battery clamp -1- to the negative terminal.

-- Fold the positive terminal cover upward and tighten the battery clamp -2- on the positive terminal to 6 Nm.
-- Close the positive terminal cover.
-- Clamp the battery clamp -1- on the negative terminal and tighten it to 6 Nm.
If ground connection on battery is not tight:
-- Tighten the battery clamp -1- on the negative terminal to 6 Nm.

-- Install the storage compartment in the luggage compartment.
NOTE: After connecting the battery note general information, refer to INSPECTING
BATTERY, CHECKING WITH BATTERY TESTER AND PRINTER -VAS 5097A- OR -VAS 6161-
Refer to BATTERY TESTER VAS 6161
TIRES, CHECKING
GENERAL INFORMATION
 Tire filling unit -VAS 5216-
Fig. 30: Identifying Tire Filling Unit VAS 5216

WARNING:  For safety reasons, all tires on the vehicle should be of the same
make and tread design.
 AWD vehicles must have tires of the same make and tread design. If
not, the center differential could get damaged.
NOTE: The tire pressures for relevant model are found on a sticker. This sticker is on
the inside of the fuel filler door or on the B-pillar.
Observe that the inflation pressure specifications on the sticker refer to the air
pressure of cold tires. Do not reduce tire pressure when the tires are warm.
Adjust tire pressure accordingly.
Spare tire receives highest tire pressure
Note that a basic setting should be performed after every change in pressure in
vehicles with tire pressure control indicator. Refer to TIRE PRESSURE
DISPLAY, PERFORMING BASIC SETTING.
Winter tires
NOTE: Important information regarding recommended winter tires can be found in the
Wheels and Tires Guide, Standard Production.
If winter tires are mounted, a label informing the customer of the speed limit
must be affixed inside the passenger compartment so that it is clearly visible.
On winter tires, the tire pressure must no longer be increased. But this is true
only when the winter tires being used are the exact same size as the standard
summer tire, and the speed index does not exceed "H". If you deviate from this,
then you must follow the tire manufacturer recommendations.
TIRES, CHECKING CONDITION
WARNING: If damage is discovered, the tire must be examined to determine whether

a new one must be installed.
Checks during Delivery Inspection
-- Check tire tread and side walls for damage, if necessary remove any foreign objects, such as nails or screws.
Checks during a Service
-- Check tire tread and side walls for damage, if necessary remove any foreign objects, such as nails or screws.
-- Check tire treads for cupping, feathering, one-sided tread wear, porous side walls, cracks, cuts, and rim
damage.
-- Check the age of the tires. It is recommended to replace the tires if they are older than 6 years. Inform the
customer.
TIRES, CHECKING WEAR PATTERN

The wear pattern of the front wheels can be used to assess whether a check of the track and camber is necessary:
 Feathered edges of the treads may indicate faulty toe adjustment.

 One-sided tread wear is mostly caused by faulty camber.
If such wear patterns are found, determine the causes by checking the wheel alignment (repair measure).
TIRES, INCLUDING SPARE WHEEL, CHECKING TREAD DEPTH
Fig. 31: Identifying Tread Depth

-- Check tread depth
Minimum tread depth: 1.6 mm
NOTE: This value may vary for individual countries due to different legislative
regulations.
The minimum tread depth is reached when the tires have worn down level with
the 1.6 mm high tread wear indicators -arrows- positioned at intervals around
the tire.
If the tread wear is close to the wear limits, inform customer and note findings
on the repair order.
BRAKE AND CLUTCH SYSTEM, CHANGING BRAKE FLUID
WARNING:  Brake fluid must never come into contact with fluids containing
mineral oils (oil, gas, cleaning solutions). Oils containing minerals

damage seals and sleeves on brake systems.
 Brake fluid is poisonous. Do not let brake fluid come in contact with
the paint.
 Brake fluid is hygroscopic, which means that it absorbs moisture
from the air. Always store brake fluid in air-tight containers.
 Wash off any spilled brake fluid with plenty of water.
 Observe waste disposal regulations.
CAUTION:  Use a "new" special brake fluid with this vehicle. This can only be
recognized by the replacement part number Brake fluid -VW 501 14B
000 750.
 Use the new brake fluid only, the previous brake fluid with
replacement part number >>B 000 700 A<< must "Not" be filled into
the Passat.
 Brake filler and bleeder unit -VAS 5234-
Fig. 32: Identifying Brake Charger/Bleeder Unit VAS 5234

 Brake bleeder socket -VAS 5519-

Fig. 33: Identifying Brake Bleeder Socket VAS 5519

 Brake bleeder tool -VAS 6564-
Fig. 34: Identifying Brake Bleeder Tool VAS 6564

-- Remove cap from brake fluid reservoir -1-.

Fig. 35: Identifying Brake Fluid Reservoir Cap -1-

-- Take the hose from the brake charger/bleeding unit -VAS 5234- and extract as much brake fluid as possible.
Fig. 36: Identifying Hose From Brake Charger/Bleeding Unit VAS 5234
NOTE: Do not remove the strainer inside the brake fluid reservoir.
WARNING: Do not use extracted brake fluid again.
-- Screw adapter -1- onto brake fluid reservoir.

Fig. 37: Identifying Screw Adapter -1-

Observe operating instructions for -VAS 5234-.
-- Set the correct pressure on the -VAS 5234-. Refer to Description and Operation
-- Connect the filler hose on the brake charger/bleeder unit -VAS 5234- to the adapter -1-.
NOTE: Use a suitable bleed hose. It must seat tightly on bleed screw so that no air can
enter brake system.
-- Remove the bleeder screw cap -1- on the left front brake caliper.
Fig. 38: Identifying Bleeder Screw Cap -1-

-- Connect collector bottle bleeder hose -1- to left front bleeder screw, open bleed screw and allow the
corresponding quantity to flow out (see table). Close bleeder screw. Tightening specification, refer to
Fig. 39: Identifying Collector Bottle Bleeder Hose -1-

-- Install the bleeder screw cap on the left front brake caliper.
Repeat work procedure on right side of vehicle at front.

-- Remove both rear wheels to access the bleed valve.
-- Remove the vent screw cap -1- on the left rear brake caliper.
Fig. 40: Identifying Vent Screw Cap -1-

-- Connect collector bottle bleeder hose -1- to left rear bleeder screw.
Fig. 41: Identifying Collector Bottle Bleeder Hose -1-

-- Open bleeder screw and let the corresponding amount of brake fluid (see table) flow out. Close bleeder screw.
Tightening specification, refer to Description and Operation
-- Install the bleeder screw cap on the left rear brake caliper.
-- Repeat work procedure on right side of vehicle at rear.
For manual transmission vehicles
Remove the air filter housing.
Procedure:
-- Refer to AIR FILTER HOUSING
-- Attach the bleeder hose to the bleeder valve -arrow- on the clutch slave cylinder -1-.
Fig. 42: Identifying Clutch Slave Cylinder -1-

-- Open valve and allow about 50 ml of brake fluid to flow out.
-- Close the valve and depress the clutch pedal rapidly 10 to 15 times.
-- Open valve again and allow about 50 ml of brake fluid to flow out.
-- Close valve, remove bleeder hose and press clutch pedal several times.
-- Install air filter housing in reverse order.
Sequence/Brake Fluid Quantity

Sequence bleed valves: Amount of brake fluid, which must flow out of the bleed
valves:
Brake caliper
Left front 0.20 liter
Right front 0.20 liter
Brake wheel cylinder/brake caliper
Left rear 0.30 liter
Right rear 0.30 liter
Clutch slave cylinder 0.10 liter
Total capacity: approximately 1.15 liter; including the amount extracted from the brake fluid reservoir
-- Move filler lever on brake charger/bleeding unit -VAS 5234- to "B" (see operating instructions).
-- Remove the filler hose from the adapter.
-- Remove the adapter from the brake fluid reservoir.
-- Check brake fluid level and fill if necessary. It must be between -1- and -2-.
Fig. 43: Identifying Brake Fluid Level Marks On Reservoir

-- Install the brake fluid reservoir cap -1-.

Fig. 44: Identifying Brake Fluid Reservoir Cap -1-

-- Perform a function test during the test drive.
-- Mount the rear wheels, if necessary. Refer to WHEEL BOLTS, TIGHTENING SPECIFICATIONS.
BRAKE FLUID LEVEL, CHECKING
Please note the following:
 Brake fluid level is dependent on pad wear.
CAUTION:  Use a "new" special brake fluid with this vehicle. This can only be
recognized by the replacement part number Brake fluid -VW 501- -
14B 000 750-.
 Use the new brake fluid only, the previous brake fluid with
replacement part number >>B 000 700 A<< must "Not" be filled into
the Passat.
WARNING:  Brake fluid must never come into contact with fluids containing
mineral oils (oil, gas, cleaning solutions). Oils containing minerals
damage seals and sleeves on brake systems.
 Brake fluid is poisonous. Do not let brake fluid come in contact with
the paint.
 Brake fluid is hygroscopic, which means that it absorbs moisture
from the air. Always store brake fluid in air-tight containers.
 Wash off any spilled brake fluid with plenty of water.
 Observe waste disposal regulations.
Brake Fluid Level at Delivery Inspection:
-- At time of Delivery Inspection, brake fluid level must be at MAX mark -1-.

NOTE: To prevent the brake fluid from overflowing from the reservoir, the level must
not be over the MAX mark -1-.
Brake Fluid Level at Inspection Service:
Brake fluid level must always be evaluated depending on brake pad wear.
During operation of the vehicle, the brakes are automatically readjusted depending on wear of the brake pads.
Because of the adjustment, brake fluid level will be slightly lower as a result.
 Recommended brake fluid level when brake pad wear limit is nearly reached:
"At the MIN mark and slightly above it" -2- , "NO TOPPING OFF REQUIRED".

 Recommended brake fluid level when brake pads are new, or pad wear limit is not nearly reached:
"Between the MIN and MAX marks".
WARNING: If brake fluid level is below MIN mark -2- , check brake system for leaks
"repair procedure" , before adding brake fluid.
BRAKE SYSTEM AND SHOCK ABSORBERS, CHECKING FOR LEAKS AND DAMAGE
Check the following components for leaks and damage:
 Brake Master Cylinder

 Brake booster (with ABS: hydraulic unit)
 Brake pressure regulator
 Brake calipers
 Shock absorber (only during Inspection)
 Make sure the dust caps are on the brake fluid bleed valves.
-- Make sure the brake hoses are not twisted.
-- Turn steering to left stop and to right stop. During this operation no brake hose must touch any vehicle
components.
-- Check brake hoses for porosity and cracks.

-- Check brake hoses for chafing.
-- Check the brake line connections for leaks and corrosion and make sure they are attached securely.
WARNING: Correct any malfunctions (repair procedure).
FRONT AND REAR BRAKE PAD THICKNESS AND BRAKE DISC CONDITION, CHECKING
FRONT DISC BRAKE PADS
 Torque wrench -V.A.G. 1332-
Fig. 47: Identifying Torque Wrench 40-200Nm Vag 1332

 Flashlight and mirror
The adapter to loosen/tighten the anti-theft wheel bolts is located in the vehicle tool kit. Refer to WHEEL
BOLTS, TIGHTENING SPECIFICATIONS.
-- To be better be able to evaluate the remaining pad thickness, use a mirror and, if necessary, remove the tire to
check the break wear indicator.
-- Pull off wheel bolt covers if necessary. Refer to WHEEL BOLTS, TIGHTENING SPECIFICATIONS.
-- Mark installation position of wheel in relation to brake rotor.
-- Remove wheel bolts and then the wheel.
-- Measure thickness of inner and outer brake pad.
Fig. 48: Identifying Pad Thickness -a- "Without" Backing Plate

a - Pad thickness "without" backing plate
Wear limit: 2 mm
With pad thickness (not including backing plate) of 2 mm, the brake pads have reached their wear limit and
must be replaced (repair procedure). Be sure to notify customer and mark findings on repair order.
NOTE: When replacing brake pads, it is absolutely necessary to check brake discs for
wear. Checking and replacing the brake pads, if necessary, is a repair measure.
-- Check brake discs for wear:
Procedure
Refer to Description and Operation
-- Install wheel in previously marked position.
-- Tighten wheel securing bolts, using diagonal sequence to tightening torque. Refer to WHEEL BOLTS,
-- Return the adapter to the vehicle tools.
-- Pull off wheel bolt covers if necessary.
REAR DISC BRAKE PADS
 Torque wrench -V.A.G. 1332-

-- Look through the opening with a flashlight and check the brake pads.
-- Check thickness of outer pad visually.

Fig. 50: Identifying Pad thickness -a- inner and outer, not including backing plate
-- With flashlight up inner brake pad and position mirror.
-- Check thickness of inner pad visually.
a - Pad thickness inner and outer, not including backing plate
Wear limit: 2 mm
With pad thickness (not including backing plate) of 2 mm, the brake pads have reached their wear limit and
must be replaced (repair procedure). Be sure to notify customer and mark findings on repair order.
NOTE: When replacing brake pads, it is absolutely necessary to check brake discs for
wear. Checking and replacing the brake pads, if necessary, is a repair measure.
-- Check brake discs for wear:
Procedure
BRAKE DISCS, CHECKING CONDITION


Check all brake discs for the following:
 Cracks
 Scoring
 Rust
 Wear on the edge of the brake disc
NOTE: Inform the customer if any damage is found on the brake disc. Replacing a
brake disc is a repair.
OIL AND FILTER, 6-SPEED DSG R 02E, REMOVING AND INSTALLING
Refer to OIL FILTER .
POWER WINDOW REGULATORS, CHECKING POSITION
NOTE: After disconnecting and reconnecting the battery, the power window one-touch
up/one-touch down feature does not work. Before delivering a new vehicle, the
window regulator must be repositioned. The vehicle battery must not be
disconnected after the electric windows have been positioned.
WARNING: After disconnecting and reconnecting the battery, pinch protection of the
power window regulators will not function. This can cause serious
injuries if e.g. fingers are caught in the window.
Perform the following to position the power windows:
NOTE: The following work sequence is for the front left window. The positioning for the
remaining windows is performed in the same manner using the respective
switch in the driver door.
-- Close all doors and windows.
-- Hold left front side-window in position "Close" by pulling and holding switch for longer than 1 second.
-- Lift button again for 1 second. Now when the button is pressed briefly the window will lower fully and when
the button is lifted briefly the window will raise fully.
DTC MEMORIES, CHECKING
Procedure
-- Connect the Vehicle Diagnosis Tester. Refer to VEHICLE DIAGNOSIS TESTER, CONNECTING
-- Select "OBD".
-- Select system "OBD".
-- Read the "Gateway device".
-- Correct any faults according to the repair procedure.
CAUTION: In every case, the vehicle must be released to the customer with the DTC
memory erased.
Static Malfunctions
If one or more static malfunctions are stored in data memory, it is recommended to arrange with the customer to
repair this malfunction via Guided Fault Finding.
Sporadic Malfunctions
In the case that only sporadic malfunctions or notes are stored in DTC memory and the customer has no
complaints in conjunction with an electronic vehicle system, erase the DTC memory.
-- Press the Continue > button again to enter the test plan.
-- Now end Guided Fault Finding via Go to button and then End.
All DTC memories will be checked now once more.
In the window now appearing, it will be confirmed that all sporadic DTCs were erased, diagnostic protocol is
sent "online" automatically.
Vehicle system test is completed.
PROTECTIVE JOINT BOOTS, INSPECTING
-- Check outer and inner CV joint boots -arrows- for leaks and damage.
Fig. 52: Identifying Inner & Outer CV Joint Boots

INNER AND OUTER BODY, CHECKING FOR CORROSION
Checking Locations
 Sunroof frame
 Inner and outer door frame

 The area around the trim strips
 Windshield roof edge
 Outer and inner A-pillar
 Hood
 Wheel housings
 Inner and outer rear lid
RIBBED BELT, CHECKING CONDITION
-- Turn engine at vibration damper/ belt pulley with socket wrench.
Check ribbed belt -1- for:
Fig. 53: Identifying Engine Accessory Drive Belt

 Sub-surface cracks (cracks, core ruptures, cross sectional breaks)

 Separation (cover layer, belt cords)
 Breaks at lower layer
 Fraying of cords
 Wear at flanks (material wear, frayed flanks, hardening or glazing of flanks, surface cracks)
 Oil or grease contamination
NOTE: Replace the belt if any damage is found. This will prevent any belt malfunctions.
Replacing the belt is a repair procedure.
COOLING SYSTEM, CHECKING FREEZE PROTECTION AND COOLANT LEVEL
GENERAL INFORMATION
NOTE: All engines from MY 2008 are filled with coolant additive G12 Plus Plus (purple
color). Due to the positive properties, fill only with G12 Plus Plus. Do not add
G12 Plus. It will cancel out the advantages provided by G12 Plus.
All engines through MY 2007 are filled with coolant additive G12 Plus in
accordance with TL -VW 774 F- (purple color). Only use G12 Plus or G12 Plus
Plus because of its advantages.
The coolant additive G12 Plus Plus protects the entire cooling system better
from corrosion and reduces the danger of the sludge and corrosion.
G 12 Plus Plus is a permanent fill for cast iron and all-aluminum engines and
gives optimum protection against freezing, corrosion damage, scaling and
overheating.
G 12 Plus Plus increases the boiling point to 275°F (135°C) and ensures better
heat dissipation.
The additional coolant portion of the mixture must amount to at least 40%
(freeze protection to -13°F (-25 °C)) and should not exceed 60% (freeze
protection to -40°F [-40°C]). Otherwise the freeze protection will be reduced and
the cooling efficiency is diminished.
The freeze protection must be guaranteed down to approximately -13°F (-25 °C).
FREEZE PROTECTION, CHECKING AND ADDING COOLANT ADDITIVE
 Refractometer -T10007 A-
Fig. 54: Identifying Refractometer T10007 A

NOTE: Read the bright/ark boundary to obtain an accurate reading for the following
tests. Place a drop of water on the glass to improve the readability of the
bright/dark boundary. The bright/dark boundary can be clearly recognized on
the "WATERLINE".
-- Check the concentration of the coolant additive using refractometer -T10007 A- (operating instructions).
The scale -1- on the refractometer applies to coolant additive G12 Plus Plus.
Fig. 55: Identifying Scales On Refractometer: Coolant Additive G12 Plus Plus -1- And Coolant Additive
G13 -2-
The scale -2- is designed only for coolant additive G13.
NOTE: The freeze protection must be guaranteed down to approximately -13°F (-25 °C).
If for climatic reasons greater freeze protection is required, the amount of G12
Plus Plus can be increased, but only up to 60% (freeze protection down to
approximately -40°F (-40°C), otherwise freeze protection and cooling
effectiveness will be reduced.
-- If freeze protection is insufficient, drain off required quantity shown in freeze protection table and add
coolant additive G12 Plus Plus.
NOTE: Follow all waste disposal regulations.
Difference
Freeze protection to
(in liters)
Specified 4-cylinder
Actual value
value engines
-25°C (-
0°C (32°F) 3.5
13°F)
-35°C (-
4.0
31°F)
-25°C (-
-5°C (23°F) 3.0
13°F)
-35°C (-
3.5
31°F)
-25°C (-
-10°C (14°F) 2.0
13°F)
-35°C (-
3.0
31°F)
-25°C (-
-15°C (5°F) 1.5
13°F)
-35°C (-
2.0
31°F)
-25°C (-
-20°C (-4°F) 1.0
13°F)
-35°C (-
1.5
31°F)
-35°C (-
-25°C (-13°F) 1.0
31°F)
-30°C (-22°F) -35°C (- 0.5
31°F)
-40°C (-
-35°C (-31°F) 0.5
40°F)
-- Check the freeze protection after the road test.
COOLANT LEVEL, CHECKING AND FILLING
-- Check the coolant level in the reservoir when the engine is cold.
 Delivery inspection: coolant level above "MIN marking" -arrow-.
Fig. 56: Identifying Inspection: Coolant Level

 Inspection service: coolant level above "MIN marking" -arrow-.
-- If coolant level is too low, fill with coolant mixture.
NOTE: Determine cause of fluid loss, which cannot be attributed to normal use and
repair.
MIXTURE RATIO
WARNING: Use distilled water for mixing. Tap water and well water do not have the
necessary quality to assure the functionality of the coolant.
Freeze protection to Coolant additive G12 Plus Plus/ TL VW Water(1)

774 G
-25°C (-13°F) approximately 40 % approximately 60 %

(1) Use only distilled water.
NOTE: Coolant additive G 12 Plus Plus conforming to TL -VW 774 F- prevents freeze
and corrosion damage, scaling, and raises the boiling point. For these reasons,
the cooling system must be filled with radiator freeze and corrosion protection
fluid all year round.
Especially in countries with tropical climates or when vehicle is driven under

heavy load, the coolant improves the engine reliability by its increased boiling
point.
The coolant concentration must not be reduced by adding water, even during
the warmer season. The coolant additive ratio must be at least 40%.
AIR FILTER, CLEANING HOUSING AND REMOVING AND INSTALLING AIR FILTER
2.0L FSI
-- Remove the 4 bolts -arrows- and remove the cover.
Fig. 57: Identifying Bolts To Cover

-- Unscrew bracket -2-.

Fig. 58: Identifying Bolt -1-, Bracket -2- And Filter Element -3-
-- Remove old filter element -3-.
-- Clean the filter housing and insert a new air filter.
-- Tighten the bolt -1- for this bracket to 2 Nm and the bolt for the cover to 1.6 +/- 0.2 Nm.
2.0L TFSI
Removing
-- Remove the engine cover. Refer to UPPER ENGINE COVER, REMOVING AND INSTALLING.
-- Place engine cover with upper side on a soft surface to prevent damage to the chrome.
-- Unscrew bolts -arrows- on lower side of engine cover.

Fig. 59: Identifying Lower Side Of Engine Cover Bolts

-- Remove lower part of air filter housing and remove air filter -2- from the upper part of air filter housing -1-.
Fig. 60: Identifying Air Filter Element & Housing

NOTE: Self-locking bolts are equipped for fastening the upper part of the air filter
housing to the lower part of air filter housing as well as the intake supports. If
these bolts are loosened of tightened using a drill motor, the threads in the
upper part of air filter housing can be damaged.
For this reason, a drill motor may only be used when the following prerequisites
are met:
Drill motor RPM: maximum 200.
The tightening torque must be adjustable.
Installing
Fig. 61: Identifying Air Filter Element & Housing

-- Clean filter housing and install new filter element -2-.
-- Mount the air filter housing lower section on the air filter housing upper section.
Fig. 62: Identifying Lower Side Of Engine Cover Bolts

-- Tighten bolts -arrows- to maximum 2.0 +/- 0.5 Nm.
-- Install engine cover. Refer to UPPER ENGINE COVER, REMOVING AND INSTALLING.
3.6L FSI
Fig. 63: Identifying Air Filter Element, 3.6L FSI Engines, Removing And Installing
-- Remove connector -2- and loosen clip -1- with spring-type clip pliers -VAS 6499-.
-- Loosen screws -arrows- and remove upper part of air filter.
-- Replace the air filter -2-.
Fig. 64: Identifying Replacing Air Filter Insert

-- Tighten screws for upper part of air filter -1- to 1.6 +/- 0.2 Nm.
-- Replace clip and insert connector until it engages.
UPPER ENGINE COVER, REMOVING AND INSTALLING
2.0L FSI
CAUTION:  To install engine cover or to engage at mounting points, be sure not

to strike the engine cover with a fist or tool, danger of damage.
The engine cover has been omitted in the current model year 2006 with engine codes BLR and BLY. The
following engine codes no longer had the cover from series introduction.
Fig. 65: Identifying Engine Cover Mounting Points

Removing
-- Unclip engine cover at mounting points -arrows- and remove upward.
Installing
Installation is the reverse of removal.
2.0L TFSI
CAUTION:  To install engine cover or to engage at mounting points, be sure not

to strike the engine cover with a fist or tool, danger of damage.
 Spring type clip pliers -VAS 6499-

Fig. 66: Identifying Spring Type Clip Pliers VAS 6499

-- Release clip -3- at air intake connections with spring-type clip pliers -VAS 6499- and slide back.
Fig. 67: Identifying Engine Cover Clip, Connector & Clamps

-- Disconnect connector -1- from Mass Air Flow (MAF) sensor, and set connector aside.
-- Open both clamps -2-.

Fig. 68: Identifying Engine Cover Clip, Connector & Clamps

-- Remove engine cover upward. Note dashed fastening points shown in illustration.
LOWER ENGINE COMPARTMENT COVER, REMOVING AND INSTALLING
Procedure
Refer to Removal and Installation
ENGINE AND ENGINE COMPARTMENT COMPONENTS, CHECKING FOR LEAKS AND DAMAGE
Perform visual check as follows:
-- Check engine and components in engine compartment for leaks and damage.
-- Check the lines, hoses and connections on the following systems for leaks, abrasions, porosity and brittleness:
 Fuel system
 Heating and ventilation system
 Lubrication system
 A/C system
 Air intake system
 Brake system
NOTE: Make sure the all malfunctions detected are rectified within repair measures.
If the fluid loss is excessive, then determine the cause and repair it.
ENGINE OIL, CHECKING LEVEL
Please note the following:
-- After stopping the engine, wait for at least 3 minutes for the oil to flow back into the oil pan.
-- Pull out oil dipstick and wipe it with clean rag. Insert the dipstick and push it all the way down.
-- Pull out dipstick again and read oil level.
NOTE: The oil level must always be in the A range at the delivery inspection.
If the dipstick appears as illustrated:
Fig. 69: Identifying Oil Levels Shown On Different Dipstick Types



A - Oil must not be topped off.
B - Add oil. This will cause the oil level to be within the -A- range.
C - Add oil. The oil level should be at least in the upper third of the measuring range -B-.
Damage to the catalytic converter can occur if the oil level is above the -A- range.
-- If the oil level goes below the -C- mark, add oil until it reaches the -A- marking. For the correct oil to use,
refer to SERVICE TABLES.
ENGINE OIL, DRAINING OR EXTRACTING, CHANGING OIL FILTER AND FILLING OIL
ENGINE OIL, DRAINING OR EXTRACTING
 Oil extractor -V.A.G. 1782-


 Used oil collection and extraction device -VAS 6622-
Fig. 72: Identifying Used Oil Collection And Extraction Device VAS 6622
 Oil absorbent towel -VAS 6204/1-
Engine Oil, Draining or Extracting

NOTE: On engines with standing oil filter module, oil filter should be changed before
the oil change. Removing the filter element will open a valve and oil in the filter
housing will flow automatically into the crankshaft housing.
If engine oil is drained and not extracted using old oil extraction unit, replace oil
drain plug. This prevents leaks.
Follow all waste disposal regulations.
-- Extract engine oil using oil collecting and extracting unit.
or
-- Remove oil drain plug
-- Let engine oil drain.
-- Install the new oil drain plug and seal hand-tight and then tighten to the tightening specification.
-- Fill the engine oil to the correct specification, refer to PASSAT .
Engine oil capacity, refer to PASSAT .
Oil drain plug tightening specifications:
 M14: 30 Nm
 M24: 50 Nm
WARNING:  Torque settings must not be exceeded

 A torque figure that is too high may lead to leaks or even damage
the oil pan.
OIL FILTER, 2.0L FSI AND TFSI, REMOVING AND INSTALLING
 Oil drain adapter -T40057-

Fig. 73: Identifying Oil Drain Adapter T40057

 Oil filter wrench -VAS 3417-
Fig. 74: Identifying Oil Filter Wrench VAS 3417


 Needle-nose pliers
Oil Filter Housing, Draining

CAUTION:  Oil filter housing must be drained before it is removed.
NOTE: When screwing in oil drain adapter -T40057-, a valve in the oil filter housing is
opened.
If oil drain adapter -T40057- is unscrewed again, the valve closes automatically
again.
-- Unscrew dust cap -arrow- from oil filter housing.
Fig. 75: Identifying Oil Filter Housing Dust Cap

-- Screw oil drain adapter -T40057- into oil filter housing and hold hose into an oil collecting pan.
Fig. 76: Identifying Oil Drain Adapter T40057 To Drain Oil Filter
-- Allow engine oil to drain.
-- Unscrew oil drain adapter -T40057- again.
The drain valve -1- should seal flush with the under side of the oil filter housing -2-.
Fig. 77: Identifying Oil Filter Housing Drain Valve

Oil Filter Insert, Removing

-- The oil filter housing can be loosened using the oil filter wrench -VAS 3417-.
-- Then unscrew by hand and remove together with oil filter insert.
-- Remove oil filter insert -2- from oil filter housing center tube -4-.
Fig. 78: Identifying Oil Filter Components

Seal, Removing
CAUTION: The oil filter housing sealing ring -3- must be replaced each time the oil
filter insert is changed -2- or every other time the oil filter housing is
loosened.
The sealing ring is equipped with a so-called "service flag" -A-.
 The sealing ring can be gripped at the "service flag" -A- with a
suitable tool and then removed from the seal groove.
pliers -3- on the "service flag" -arrow-.
Fig. 79: Identifying Oil Filter Housing Sealing Ring

Seal, Installing
-- Lubricate sealing ring -3-.


-- Lay sealing ring in oil filter housing seal groove so service flag -A- is aligned toward top.
-- Press sealing ring into seal groove and check whether ring contacts entire groove evenly by feeling above
sealing ring with finger -arrows-.
Fig. 81: Installing Oil Filter Sealing Ring

Oil Filter Insert, Installing


-- Press new oil filter insert -2- onto oil filter housing center tube -4- as far as stop.
Oil Filter Housing, Installing
-- Install oil filter housing -4- with new sealing ring -3- and new oil filter insert -2- by hand until almost on oil
filter housing stop -1-.
-- Tighten oil filter housing -2- to 25 Nm.

Fig. 83: Identifying Oil Filter Housing Drain Valve

-- Install dust cap -arrow- hand-tight in oil filter housing.
Fig. 84: Identifying Oil Filter Housing Dust Cap

OIL FILTER, 6-CYLINDER FSI, REMOVING AND INSTALLING


 Hex Ball Socket SW 36 -T10125-
Fig. 86: Identifying Hex Ball Socket SW 36 T10125

-- Open oil drain plug -6- to empty oil filter housing
-- Loosen the cap with a 36 mm socket -T10125- -4-.
-- Remove oil filter insert -2-.

Fig. 87: Identifying Oil Filter, 3.6L FSI Engine Remove/Install Components
-- Replace O-rings -1, 3, 5- and lightly lubricate rings before assembly.
-- Now insert a new oil filter insert.
-- Tighten screw cover -4- to 25 Nm.
-- Oil drain plug -6- is tightened to 10 Nm.
ENGINE OIL, FILLING
Oil specifications, refer to PASSAT .
General Information
NOTE: Make sure the cleanliness so that no oil misses the mark.
-- After filling the oil, wait 3 minutes and then check the oil level.
-- Pull out oil dipstick and wipe it with clean rag. Insert the dipstick and push it all the way down.
-- Pull out dipstick again and read oil level.
Fig. 88: Identifying Oil Levels Shown On Dipstick Types



A - Oil must not be topped off.
B - Add oil. After topping off, oil may be in range -A-.
C - Add oil. The oil level should be at least in the upper third of the measuring range -B-.
Damage to the catalytic converter can occur if the oil level is above the -A- range.
-- If the oil level goes below the -C- mark, add oil until it reaches the -A- marking. For the correct oil to use,
refer to PASSAT
TIRE REPAIR KIT, CHECKING
Fig. 90: Locating Tire Sealant In Luggage Compartment

NOTE: The tire repair kit is located in the spare wheel well.
The tire repair kit contains a tire filler bottle with tire sealant.
-- Verify the expiration date.
The expiration date is located on a sticker on the tire sealant container -arrow-.
-- Enter expiration date in maintenance table.
-- Replace tire sealant, if expiration date has been reached. (tire sealant may not be older than 4 years).
NOTE: Replace the tire sealant if it was already used once.
ROAD TEST, PERFORMING
The following checks depend on the vehicle equipment level and the available testing possibilities (city or
rural).
During the road test, check the following:
-- Engine: performance, stalling, idle, acceleration
-- Clutch: starting, pedal force, smell
-- Shifting: ease of movement, shift lever position
-- Automatic transmission: selector lever position, shift lock/ignition key interlock, shift behavior, instrument
cluster display
-- Foot and parking brake: function, free travel and effectiveness, pulling to one side, rubbing, squeaking
-- ABS function: when braking with activated ABS, the brake pedal must pulse noticeably.
-- Steering: function, steering travel, steering wheel center position when driving straight ahead.
-- Sunroof: function
-- Radio/radio-navigation system: functionality, reception, speed compensated volume, objectionable noise
-- Multi-function display: functions
-- A/C System: Check functionality At low temperatures, test the air conditioning function in the workshop.
-- Vehicle: pulling to one side while driving straight ahead (level road)
-- Imbalance: wheels, driveshafts, propshaft
-- Wheel bearing: noises
-- Engine: warm starting behavior
WHEEL BOLTS, TIGHTENING SPECIFICATIONS
 Center Hubcap, Removing, refer to CENTER HUBCAP, REMOVING

 Wheel Bolt Caps, Removing, refer to WHEEL BOLT CAPS, REMOVING
 Anti-Theft Wheel Bolts, Loosening and Tightening, refer to ANTI-THEFT WHEEL BOLTS,
LOOSENING AND TIGHTENING
 Wheel Bolts, Tightening, refer to WHEEL BOLTS, TIGHTENING
CENTER HUBCAP, REMOVING
CAUTION: On vehicles with alloy wheels, do not pry out center hubcap with
screwdriver. Rather, use special tool designed for this purpose (puller
hook in vehicle tool kit).
Extractor -1- for removing cover cap is located in vehicle tool kit.
Fig. 91: Identifying Wheel Center Cover

-- Insert removal hook into one of the holes of the center hubcap and pull in -direction of arrow-.
-- On vehicles with full covers, install full wheel cover by guiding the tire inflating valve through the designated
recess -arrow-.
Fig. 92: Identifying Cut-Out In Wheel Cover

WHEEL BOLT CAPS, REMOVING
CAUTION: On vehicles with alloy wheels, do not pry out wheel bolt cover caps with
screwdriver. Rather, use special tool designed for this purpose (puller
hook in vehicle tool kit).
NOTE: Wheel bolt cover caps must be removed before wheel bolts can be loosened.
The pulling hook for removing the cover caps is located in the vehicle tool kit.
-- Insert wire bracket through opening in cover cap.
-- Pull off cap using wire bracket.
ANTI-THEFT WHEEL BOLTS, LOOSENING AND TIGHTENING

Fig. 93: Identifying Anti-Theft Wheel Bolts

NOTE: A special adapter, located in the vehicle's tool kit, is required to loosen/tighten
anti-theft wheel bolts.
Do not use an impact wrench to loosen anti-theft wheel bolts (lockable wheel
bolts).
If there is no adapter in the vehicle for loosening/tightening the anti-theft wheel

bolts, use corresponding master wheel bolt key set.
 Master Wheel Bolt Key Set -T10101-

Fig. 94: Identifying Master Wheel Bolt Key Set T10101

 Master Wheel Bolt Key Set -T10313-
Fig. 95: Identifying Master Wheel Bolt Key Set T10313



-- Slide adapter -2- into anti-theft wheel bolt -1- until it stops.
Fig. 97: Identifying Anti-Theft Wheel Bolts

-- Slide wheel wrench on to adapter -2- until it stops.
WHEEL BOLTS, TIGHTENING
-- Tighten wheel bolts in diagonal sequence to the following tightening torque.

WARNING: Never use an impact wrench to tighten wheel bolts.
NOTE: Place the adapter and extractor back in the vehicle tool kit.
RADIO CODE, CHECKING WITH VEHICLE DIAGNOSIS TESTER
Requirement for the Vehicle Diagnostic Tester
 The Vehicle Diagnostic Tester is connected to the central data bank (Carport, Fazit) via the Central
Partner Network (CPN).
 The existing access authorization for the "GeKo" system
NOTE: The radio codes are also called security codes; they can be requested in the
central database and shown on the Vehicle Diagnostic Tester display.
To activate the radio, the codes must be entered via the radio keys, as before
RADIO NAVIGATION SYSTEM, ENTERING ANTI-THEFT CODE PIN AND
STORING STATIONS.
Procedure
-- Connect the vehicle diagnostic tester Refer to VEHICLE DIAGNOSIS TESTER, CONNECTING.
-- Touch the >>GUIDED FUNCTIONS<< button/field on the screen.
-- Press > button to confirm.
 Brand
 Type
 Model year
 Engine code
-- Confirm vehicle identification.
 "Radio system".
 "Request radio code".
-- Perform code request according to instructions from "GUIDED FUNCTIONS".
-- End code request as follows:
-- Press the >>Go to<< button -arrow- on display.
-- Press the >>End<< button on the display.
-- Press >>Exit<< button in exit menu.
-- Turn off ignition and disconnect diagnostic connection.
RADIO NAVIGATION SYSTEM, ENTERING ANTI-THEFT CODE PIN AND STORING STATIONS
The anti-theft coding electronically prohibits unauthorized individuals from starting the unit again after it has
been removed. This anti-theft code is also called the radio code of security code. Security code means that every
unit with anti-theft coding has been programmed with its own code. This security code is not active from the
factory. If a device card is available, the security code is on it. If the device card is not available, the safety code
can be requested from the central database using the vehicle diagnosis tester. Refer to RADIO CODE,
CHECKING WITH VEHICLE DIAGNOSIS TESTER.
NOTE: If an incorrect code is entered while canceling the electronic lock, the entire
process can be repeated just one time more. If an incorrect code is entered
once again, the unit will lock up for about one hour. It will not work. After an
hour, during which the unit must remain switched on, the display will go out.
The electronic lock can be cancelled as previously described. The cycle: two
attempts, an hour locked, begins again.
Procedure
TIRE PRESSURE DISPLAY, PERFORMING BASIC SETTING
Applies only to tire pressure monitoring system with PR number 7K6 (indirect measuring).
Tire pressure monitoring system with auto-location from MY 12 (direct measuring) with PR numbers 7K3 (rest
of world, direct measuring) and 7K4 (USA and Canada, direct measuring) calibrate themselves in normal
driving depending on the tire pressures filled by the driver.
A basic setting on the tire pressure monitoring system from MY 12 is no longer necessary.
NOTE: Perform the basic setting on the tire pressure monitoring system display -K220-
only "after" the tire pressures have been adjusted to the correct values.
If no pressure loss and no tire damage is detected after a tire pressure warning,
the erroneous warning can be eliminated by a basic setting.
Tire Pressure Monitoring Display Indicator Lamp -K220- compares the speed, i.e. the rolling circumference of
the individual wheels using the ABS sensors. If rolling circumference of a wheel changes, this is displayed via
tire pressure control indicator. Rolling circumference of tire may be change if:
 Tire pressure is too low.

 Tires have structural damage.
 Vehicle is loaded on one side.
 Wheels of one axle are loaded higher (e.g. when towing trailer or driving uphill and downhill).
 Snow chains are installed.
 Spare wheel is installed.
 One wheel per axle was replaced.
Tire Pressure Monitoring Display Indicator Lamp -K220- has a yellow indicator light in instrument cluster -
arrow-.
Fig. 98: Identifying Tire Pressure Monitoring Display Indicator Light

 "BLINKING LIGHT" means that no "INITIAL BASIC SETTING" was performed yet.
 "STEADY LIGHT", in conjunction with a warning tone, indicates "WARNING", a loss of pressure has
been recognized, check tire pressure, perform system basic setting.
Perform "INITIAL" Basic Setting

-- Press the ESP and SET -A- buttons in the center console together for longer than 2 seconds.
Fig. 99: Identifying ESP & SET Button

Press the ASR button if the vehicle does not have ESP.
Beginning of basic setting is confirm by a notifying tone.
On next new ignition start, warning does not appear.
Perform Basic Setting
-- Switch ignition on.
-- Press the SET -A- button in the center console for longer than 2 seconds.
Tire Pressure Monitoring Display Indicator Lamp -K220- in instrument cluster -arrow- lights up as long as
button is pressed.
Fig. 100: Identifying Tire Pressure Monitoring Display Indicator Light

Beginning of basic setting is confirm by a notifying tone.
On next new ignition start, warning does not appear.
DUST AND POLLEN FILTER, CLEANING HOUSING AND REMOVING AND INSTALLING FILTER ELEMENT
Procedure
HEADLAMPS, CHECKING AND ADJUSTING
TEST PREREQUISITES
 Head light adjusting unit -VAS 5046- or

Fig. 101: Identifying Head Light Adjusting Unit VAS 5046

 Headlamp adjuster -VAS 5047-

 Headlamp adjuster -VAS 5208A-
 Headlamp adjuster -VAS 5209A-
Test and Adjustment Requirements:
 Tire pressure must be OK.

 Lenses must not be damaged or dirty.
 Reflectors and bulbs OK.
 Vehicle must be properly loaded.
 Move vehicle back and forth for 1 meter (3 to 4 feet) or bounce front and rear of vehicle several times up
and down to settle suspension.
 Both the vehicle and the headlamp adjusting unit must be standing on flat ground --> Operating
Instructions for headlamp adjusting units -VAS 5046-, -VAS 5047-, -VAS 5208A- and -VAS 5209A-.
 Inclination must be set.
 If the vehicle is equipped with separate low beams and high beams, high beam must be adjusted extra.
Note that the adjuster must be set to 0% when adjusting the high beams.
 On vehicles with HID headlamps, the DTC memory and the Vehicle Diagnosis Tester should be queried,
erased, and the headlamp range control should be adjusted to the basic setting.
NOTE: Head lamp side adjustment is not possible on USA and Canada vehicles, and
for this reason, cannot be turned.
In the trim above the headlamp, inclination measurements are stamped in "%". The headlamps must be adjusted
according to these measurements. Percentage information is based on a projection distance of 10 meters. For
example: inclination of 1.0 % converts to approximately 10 cm.
On North America vehicles, set the inclination to 0.7%.
NOTE: For certain markets, no manual headlamp range control is offered with halogen
headlamps.
-- Check the headlamp height adjustment by setting to the maximum level and observing the light.
-- The headlamp range adjuster thumb wheel, if present, must be in 0 .
The vehicle must either have a person or 165 lbs (75 kg) of weight on the driver seat, and it must not be loaded
with any other weight.
The curb weight is the weight of the vehicle ready to be operated with filled fuel tank (at least 90% filled),
including the weight of all equipment usually carried in the car such as spare wheel, tools, car jack, fire
extinguisher, etc.
If the fuel tank is not at least 90% full, adjust the weight as follows:
-- Read fuel level from fuel gauge. Calculate additional weight needed using the following table. Place extra
weight in luggage compartment.
Tank Filling Table
Fuel level according to fuel gauge Gasoline engine additional weight in lbs (kg)
1/4 88 (40)
1/2 66 (30)
3/4 33 (15)
Full 0
1 Average natural gas tank and fuel tank.
Example:
If the tank is half full, place an additional of 66 or 33 lbs (30 or 15 kg) weight in the luggage compartment.
NOTE: For additional weight use containers filled with water. A container filled with 5
liters of water weighs approximately 11 lbs (5 kg).
Make sure the there are kg markings on the container and that it cannot be
opened.
Place a cloth on the luggage compartment floor to protect it from getting dirty.
HEAD LAMPS, CHECKING ADJUSTMENT WITH TEST SCREEN WITHOUT 15° ADJUSTMENT LINE
Headlamps
Please check the following:
-- With the dipped beam switched on check whether the horizontal light-dark border of the setting line -1-
contacts the test surface.
Fig. 102: Identifying Headlamp Adjustment Setting Line -1-, Break-Away Point -2- And Center
Point/Mark -3-
-- Check whether the break-away point -2- between the left horizontal part and the rising part on the right of the
light-dark border runs vertically through the center point -3-. The bright core of the light beam must be on the
right of the vertical line.
NOTE: To make it easier to find break-away point -2- cover and uncover left half of
headlamp (as viewed when looking forward) a few times. Then check dipped
beam again.
After correct adjustment of dipped beams the center point of the main beam
must lie on the center mark -3-.
Fog Lights
Fig. 103: Identifying Main Beam Center Mark

-- Check whether the upper light-dark border touches the setting line and runs across the complete test screen
width horizontally.
HID HEADLAMPS, ADJUSTING
Basic Setting, Performing
-- Connect the vehicle diagnostic tester. Refer to VEHICLE DIAGNOSIS TESTER, CONNECTING.

-- Press "Guided Functions ".
-- Select VIN.
-- Select 55 - Headlight Range Control.
-- Mark "Perform basic setting" and confirm with --> .
-- Observe displayed notes and confirm by selecting "complete".
Adjusting Right Headlamp
Adjustment screws for left headlamp are arranged symmetrically

Fig. 105: Identifying Adjustment Screws For Headlight

 Adjusting screw for side adjustment (sealed for the USA and Canada market) of the Bright-Dark Limit -
3-
 Adjustment screw for height adjustment of bright/dark boundary -2-
 Adjusting screw for adjusting the cornering lamp -1- (pre-adjusted at the factory, do not adjust further).
NOTE: If the adjusting screw used for setting the light curvature should be accidentally
turned, set an angle dimension of 1.1% on the adjusting unit, in order to correct
the light setting.
-- First turn adjustment screw -2- to adjust height of bright/dark boundary.
-- Then the side adjustment must be checked and correct with adjustment screw -3- if necessary.
HALOGEN HEADLAMPS, ADJUSTING
NOTE: Check whether both headlamps work evenly when operating the manual
headlamp range adjuster.
If the vehicle is equipped with separate low beams and high beams, high beam
must be adjusted extra. Note that the adjuster must be set to 0% when adjusting
the high beams.
Adjusting Right Headlamp
Adjustment screws for left headlamp are arranged symmetrically

Fig. 106: Identifying Adjustment Screws For Headlight

 Adjusting screw for side adjustment (sealed for the USA and Canada market) of the Bright-Dark Limit -
3-
 Adjustment screw height adjustment of low beam bright/dark boundary -2-.
 Adjustment screw for side adjustment of high beam bright/dark boundary -1-
-- First rotate adjustment screw for bright/dark boundary height adjustment.
-- Check the lateral adjustment and correct if necessary.
FOG LAMPS AND OTHER AUXILIARY HEADLAMPS, ADJUSTING
Right Fog Light In Bumper
Adjusting screw on left fog light is arranged symmetrically.
-- Set the angle dimension on the headlamp adjusting unit.
 Fog lamp angle dimension: "2.0%"
NOTE: Percentage information is based on a projection distance of 10 meters.
-- Turn adjustment screw -arrow A- to adjust beam width.

Fig. 107: Identifying Adjustment Screw To Adjust Beam Width

Lateral adjustment is not possible.
Other Auxiliary Headlamps
Accessory auxiliary headlamp systems must be checked and adjusted according to the guidelines valid for them.
WINDSHIELD AND HEADLAMP WASHER SYSTEMS, CHECKING FUNCTION, ADJUSTMENT AND FOR
DAMAGE
FLUID, CHECKING FREEZE PROTECTION AND FILLING
 Refractometer -T10007 A-
Fig. 108: Identifying Refractometer T10007 A

Read the bright/ark boundary to obtain an accurate reading for the following tests. Place a drop of water on the
glass to improve the readability of the bright/dark boundary. The bright/dark boundary can be clearly
recognized on the "WATERLINE".
-- Check concentration of anti-freeze additive using refractometer -T10007 A-.
The scale -4- of the refractometer is designed specifically for genuine Volkswagen Windshield Clear -G 052
164-.
Fig. 109: Identifying Scales On Refractometer: Coolant Additive G12 Plus Plus -1- And Coolant Additive
G13 -2-
Mixture Ratio
Windshield Washer fluid G 052

Freeze protection to Water
164
-2/-0.5 °F (-17/-18 °C) 1 part 3 part
-8/-10 °F (-22/-23 °C) 1 part 2 part
-35-/37 °F (-37/-38 °C) 1 part 1 part
Filling-up with fluid:
The windshield washer system fluid reservoir must be filled.
Use only windshield washer fluid concentrate -G 052 164- when filling the windshield washer fluid reservoir.
NOTE: Windshield washer fluid concentrate -G 052 164- protects the spray nozzles, the
reservoir and the hoses from freezing.
All vehicles with fan type spray jets must be filled with windshield washer fluid
concentrate -G 052 164 as this fluid has a low viscosity at minus temperatures.
The complicated spray jet system could otherwise become blocked due to
crystallized washer fluid that can affect the fan pattern of the spray jet.
Windshield washer fluid concentrate -G 052 164- assures that the fan type spray
nozzles remain functional even at low temperatures.
Fill with windshield washer fluid concentrate -G 052 164- in the warmer season
also. The powerful cleanser removes wax and oil deposits from the windows.
Freeze protection (anti-freeze) must be guaranteed to approximately -13 °F (-25 °

C) (approximately -31°F (-35 °C)) in countries with an arctic climate) in the
washer system.
WINDSHIELD WASHER SYSTEM, CHECKING AND ADJUSTING SPRAY NOZZLES
 Adjustment tool -T10127- equipped with needle -3125/ 5 A-

Fig. 110: Identifying Adjustment Tool T10127 Equipped With Needle 3125/ 5 A
 Or setting tool -T40187-
Fig. 111: Identifying Setting Tool T40187

NOTE: In cases where contamination in spray jet results in an uneven spray pattern,
remove the spray jet and rinse it with water in the opposite direction of the
spray flow. Subsequently blowing through in the opposite direction of the spray
flow with compressed air is permitted. Do not use any objects to clean the
spray jets.
Passat front windshield washer nozzle adjustment:
Fig. 112: Identifying Spray Nozzle Pattern

The washer nozzles are preset. Small height adjustments can be made.
-- If both spray fields are not at same height, adjust spray direction upward or downward as follows:
Fig. 113: Identifying Spray Nozzle & Rotating At Adjuster

1 - Cowl plate in front of front window

2 - Adjuster
3 - Fan-type nozzle
4 - Hood
-- Adjust spray nozzle -3- by rotating at adjuster -2- using a screwdriver.
 "Clockwise" deeper adjustment.

 "Counter-clockwise" higher adjustment.
Front Windshield Washer Nozzle Adjustment
-- Adjust the nozzles according to this illustration. The values for nozzles are specified in "mm".
Fig. 114: Identifying Front Windshield Washer Nozzle Patterns And Adjustment Values
-- The dimensions can be repeated for both the driver and front passenger sides.
Rear Window Washer Nozzle Adjustment:
-- Adjust the spray nozzle using socket wrench -T10127- or socket wrench -T40187- so that fluid sprays onto
upper third of rear window, as shown.
Fig. 115: Identifying Rear Window Wiper And Washer Operation

HEADLAMP WASHER SYSTEM, CHECKING SPRAY NOZZLE SETTING
CAUTION: The spray nozzles can be checked for functionality, but they cannot be
adjusted.
Nozzle setting dimensions for right headlamp (left headlamp is arranged symmetrically)
Fig. 116: Identifying Spray Directions Of Respective Nozzles

Check Spray Nozzle Setting
-- Switch on driving lights.
-- Operate the windshield washer system.
The headlamps are washed when windshield washer lever is held in "wipe position" at least 1.5 seconds.
The spray should hit the center of the headlamp lens, see -B- and -C-.
If the spray pattern differs from the specification, perform a repair.
WINDSHIELD WIPER BLADES, CHECKING PARK POSITION
WINDSHIELD WIPER PROTECTORS, REMOVING
GENERAL INFORMATION
NOTE: There are 3 types of windshield wiper protectors.
1. Wiper blade with a protective rail and two fasteners
Fig. 117: Locating Fasteners -1- And -2- On Protective Rails

 can be recognized by the protective rails with the two fasteners arrows: -1- and -2-.
2. Wiper blade with protective rail, which can be pushed on

Fig. 118: Identifying Protective Rail Pushed Onto Wiper Blade

 can be recognized in that the protective rail -arrow- is pushed onto the wiper blade
3. Transport wiper blade
Fig. 119: Identifying Transport Wiper Blade (No Wind Deflector)

 can be recognized in that it does not have a wind deflector; it must exchanged for the standard wiper
blade
-- With the engine hood closed, switch the ignition on and off briefly.
Fig. 120: Identifying Windshield Wiper Service Position

-- Within 10 seconds after switching off the ignition, move the windshield wiper lever downward to the mist
wipe position.
The wiper will move in the service position.
-- Lift the wiper off the windshield.
CAUTION: Do not hold the wiper by the wiper blade to prevent damaging it.
-- Remove the upper and lower fasteners -arrows-.

Fig. 121: Identifying Removal Of Upper And Lower Fasteners

-- Remove the protective rail off the wiper blade as illustrated.
Fig. 122: Removing Protective Rail Off Wiper Blade

-- Place the wiper arm carefully on the windshield.
-- Now move the windshield wipers back into the park position by switching the ignition on and tapping the
wiper lever. Switch the ignition off.

wipe position.
-- Pull the protective rail off the wiper blade as illustrated.

Fig. 124: Removing Protective Rail Off Wiper Blade

WIPER BLADE PROTECTOR, TYPE 3, TRANSPORT WIPER BLADE, REMOVING AND INSTALLING

wipe position.
-- Depending on the version, rotate the wiper blade with the lip upward and remove it or loosen the wiper blade
at the joint -3- by pressing the locking mechanism -1- in the retainer -2- and removing the wiper blade.
Fig. 126: Identifying Locking Mechanism -1- And Retainer -2-

-- Slide the standard wiper blade into the retainer making sure it audibly engages into the lock, or turn the wiper
blade with the lip facing downward.
SERVICE INTERVAL DISPLAY, CODING

-- Touch the "GUIDED FUNCTIONS" button/field on the screen.
NOTE: If the displays indicated in the procedure are not shown on the display. Refer to
Operating Instructions for the Vehicle Diagnosis Tester
 Brand
 Type
 Model year
 Engine code
If the vehicle identification procedure was performed correctly, press > button for confirmation.
 "Instrument cluster" -ARROW-.
Fig. 127: Identifying "Instrument Cluster" Selection On Scan Tool

 "Adapt service interval extension".
-- Perform Adaptation according to instructions from "GUIDED FUNCTIONS".
End Adaptation
Indicated on display:
Fig. 128: Identifying "Go To" Button On Scan Tool Display

-- Press the Go to button -arrow- on display.
Fig. 129: Identifying "Exit" Button On Scan Tool Display

-- Press End button -arrow- on display.

-- Press Exit button in exit menu.
SERVICE INTERVAL DISPLAY, RESETTING
GENERAL INFORMATION
For additional information regarding the service interval display refer to SERVICE INTERVAL DISPLAY
Reset the Service Interval Display using Vehicle Diagnosis Tester; refer to SERVICE INTERVAL DISPLAY,
RESETTING WITH VEHICLE DIAGNOSTIC TESTER
Reset the Service Interval Display without the Vehicle Diagnosis Tester; refer to SERVICE INTERVAL
DISPLAY, RESETTING WITHOUT VEHICLE DIAGNOSTIC TESTER
Service interval display must be reset at
 Delivery Inspection
 Oil change service and interval service at each inspection service (only for vehicles through 2004)
NOTE: The service interval display can also be reset manually. When resetting the
service interval display manually, make sure the vehicle is coded for fixed
intervals, i.e. every 10,000 miles (15,000 km) or 12 months. The adaptation
channel for the oil quality will also change when doing this.
SERVICE INTERVAL DISPLAY, RESETTING WITH VEHICLE DIAGNOSTIC TESTER
-- Touch the >>GUIDED FUNCTIONS<< button/field on the screen.
If the displays indicated in the procedure are not shown on the display. Refer to Operating Instructions for the
Vehicle Diagnosis Tester
-- Press > button to confirm.
 Brand
 Type
 Model year
 Engine code
 "Instrument cluster" -ARROW-.
Fig. 130: Identifying "Instrument Cluster" Selection On Scan Tool

 "Rest service interval display".
-- Perform Adaptation according to instructions from "GUIDED FUNCTIONS".

End Adaptation
-- Press the Go to button -arrow- on display.

After switching on the ignition, service event is no longer indicated in the odometer display in the instrument
panel insert.
NOTE: The service interval display can also be reset manually. When resetting the
service interval display manually, make sure the vehicle is coded for fixed
intervals, i.e. every 10,000 miles (15,000 km) or 12 months.
SERVICE INTERVAL DISPLAY, RESETTING WITHOUT VEHICLE DIAGNOSTIC TESTER

NOTE: When resetting the service interval display manually, make sure the vehicle is
coded for fixed intervals, i.e. every 10,000 miles (15,000 km) or 12 months.
Using Rocker Switch on Windshield Wiper Lever or Button in Multifunction Steering Wheel
Fig. 133: Identifying Rocker Switch On Windshield Wiper Lever

-- Using the rocker switch, select the "settings" menu, or
-- Using the button on the multifunction steering wheel, select the "settings" menu.
Fig. 134: Identifying Multifunction Steering Wheel Control Buttons

-- Once in the "Service" submenu, select "Reset" and then press the OK button -1- either in the windshield
wiper lever or in the multifunction steering wheel -5- to reset the service interval display.
-- Press the OK button one more to confirm.
Using Buttons in Instrument Cluster
Fig. 135: Identifying Instrument Cluster And Buttons

-- With the ignition switched off, hold the -3- button pressed.
-- Release the button -3- and briefly press the button for setting the clock -1- one time.
The Service Interval Display is now in the Reset mode.
After a brief period, the display switches back to the normal display.
SUNROOF, CHECKING FUNCTION, CLEANING AND LUBRICATING GUIDE RAILS

Fig. 136: Identifying Sunroof Guide Rails

-- Check sunroof functionality.
-- Clean guide rails -arrows- and lubricate with lithium grease -G 052 147 A2-.
SUNROOF WATER DRAINS, CHECKING AND CLEANING
 Cleaning and installing support -VAS 6620-

-- Open the sunroof.
-- Make sure the sunroof drain holes -arrows- are not blocked with dirt. Clean them if necessary.
Fig. 138: Identifying Sunroof Drain Holes -Arrows-

-- Using tap water, pour water through the sunroof drains making sure the same amount of water is coming out
of the wheel housing.
If this is happening, then the check is completed. If only a little water is coming out, or no water at all, then
perform the following:
-- Remove the plenum chamber cover. Refer to Removal and Installation
NOTE: Removing and installing the plenum chamber is charged separately.
-- Open the latches -A and B- and remove the cover -1-.
Fig. 139: Identifying Cover -1- And Latches -A & B-

-- Move the cleaning and removing tool -VAS 6620- back and forth up to the drain valves and push out any dirt.
Fig. 140: Identifying Cleaning And Removing Tool VAS 6620

-- The drains -arrows- are located on the left and right sides of the plenum chamber.
Fig. 141: Locating Drains -Arrows- On Left And Right Sides Of Plenum Chamber
-- Make sure the plenum chamber drains -arrows- are not blocked with dirt. Clean them if necessary.
Fig. 142: Identifying Plenum Chamber Drains -Arrows-

-- Using tap water, pour water through the sunroof drain holes one more time.
TIE ROD ENDS, CHECKING PLAY, SECURITY AND JOINT BOOTS

Fig. 143: Identifying Tie Rod Joint Boots

-- With vehicle raised (wheels off ground) check tie rods by moving tie rods and wheels. Play: no play
-- Check attachments
-- Check track rod joint boots -arrow- for damage and proper seating.
DOOR ARRESTER, LUBRICATING

Fig. 144: Identifying Door Arrester Lubrication Points

-- Lubricate door arrester at points shown -arrows-.
Use solid lubricant -G 000 150-.
TRANSPORT MODE, DEACTIVATING
Fig. 145: Identifying Vehicle Self-Diagnosis Button On Scan Tool Display

Select operating mode
-- Press button for >>Vehicle Self-Diagnosis<< on display.
NOTE: If the displays indicated in the procedure are not shown on the display, refer to
Operating Instructions for the Vehicle Diagnosis Tester.
Fig. 146: Identifying Grouped Services Selection On Scan Tool Display

-- Press "Grouped services" on display.
Fig. 147: Identifying Switch Off Transport Mode Selection On Scan Tool Display
-- Press "Switch off transport mode" on display.
End output
Fig. 148: Identifying "Go To" Button On Scan Tool Display

-- Press Go to button -arrow- on display.


-- Turn off ignition.
NOTE: Ignition key required to terminate the procedure. The DTC entry will not reset to
intermittent in the engine control module until this is done; the entry can be
removed during the next time it is serviced "Delete DTC Memory".
NOTE: The vehicle diagnostic tester must remain connected for other testing.
TRANSPORT PROTECTION, REMOVING LOCKING PIECES FROM FRONT AXLE STRUTS
In vehicles with sport suspension, locking pieces are installed in springs of front axle. These models can be
identified by a tag attached at the mirror -arrow-.
Fig. 150: Identification Tag Attached At Mirror

NOTE: Locking pieces should prevent vehicle from bouncing when being driven on to
an automobile transport or railroad car and thereby become damaged.
WARNING: Locking pieces must always be removed before delivering the vehicle. An
"Attention!" hanging tag is secured to interior mirror to make this point
absolutely clear.

NOTE: It is not necessary to remove the wheels.
Be careful not to damage surface of coil springs.
-- Relieve load on coil spring by raising vehicle on lifting platform.
-- Press locking piece -arrow- from coil spring.
Fig. 151: Identifying Blocking Piece On Piston Rod (2 Of 2)

UNDERBODY COMPONENTS, CHECKING FOR DAMAGE
When checking the underbody protection also check wheel wells and sill panels.
Make sure all the lines are secure in their mountings, all plugs are present and there is no damage to the
underbody.
NOTE: Correct any malfunctions (repair procedure). This can help prevent corrosion
and rust-through.
CLOCK, SETTING
Setting clock via the instrument cluster: Passat from MY 2006

Fig. 152: Identifying Clock Adjusting Buttons

-- Press the left button -1- to set the hour. Press button only briefly to advance by one hour.
-- Press the right button -2- to set the minutes. Press button only briefly to advance by one minute.
Setting clock via the instrument panel: Passat from MY 2009
Fig. 153: Identifying Hour Display Button -1- And -2-

-- Press the button -1- to activate the hour display.

-- Press the button -2- to set the correct hour.
-- Repeat the same procedures to set the minute.
Setting clock using the buttons on the multifunction steering wheel: Passat from MY 2006
Fig. 154: Identifying Multi-Function Steering Wheel Buttons

-- Press button -1- until "Settings" menu appears.
-- Then select menu item "Clock" with buttons -2- and -4-.
-- Confirm selection with button -3-.
-- If "Hour" is marked, marked menu item is located between both horizontal lines, confirm again with button -
3- and set correct hour with buttons -2- and -4-.
-- Confirm again with button -3- and change to minute setting which is done the same as when setting the hour.
-- You can leave the menu again with button -1-.
-- Turn the ignition off.
Setting the clock using the buttons on the multifunction steering wheel: CC from MY 2009
Fig. 155: Identifying Buttons On Multifunction Steering Wheel

-- Press the button -5- to activate the multifunction display.
-- Press the button -3- until you reach the "settings" menu. Press the button -5- to confirm.
-- Select "clock time".
-- Use the button -4- to change the "hour". Press the button -5- to confirm.
-- Now set the "hour" with the buttons -2- and -4-. When finished, press the button -5- to confirm.
-- Repeat the same process to set the "minutes".
-- Press the button -6- to return to the "main menu".
Setting the clock using the buttons on the windshield wiper lever
Fig. 156: Identifying Wiper Switch Button & Switch

-- Press button -2- for 2 seconds to go to main menu.
-- Select "Settings" menu with button -2- and confirm with button -1-.
-- Select "Clock" menu with button -2- and confirm with button -1-.
-- Now mark menu time "Hours" by pressing button -1- , set correct hour with button -2- and then confirm with
button -1-.
-- Do the same with menu item "Minutes".
-- You can leave the "Settings" menu using menu item "back".
-- Now select "MFD" as actual display and confirm with button -1-.
-- Turn the ignition off.
NOTE: Make sure each vehicle key is set to daylight saving time or winter time. Go to
the multifunction display, under the clock menu, to find the season settings.
CAMSHAFT DRIVE TOOTHED BELT, 2.0L FSI, TFSI AND COMMON RAIL, REMOVING AND INSTALLING
NOTE: Generally, it is not necessary to replace the belt before reaching the next
replacement interval. In particular, cracks on the back side of the belt do not
affect service life and cannot be claimed as goodwill or warranty measures.
-- Toothed Belt, Removing and Installing, refer to TOOTHED BELT, WITH A DIVIDED TOOTHED
BELT GUARD .
SPARK PLUGS, REPLACING
2.0L FSI AND 2.0L TFSI
 Spark plug wrench -3122 B-
Fig. 157: Identifying Spark Plug Wrench 3122 B



 Ignition coil puller -T40039- for 1.8L TSI; 2.0L FSI; 2.0L TFSI; 2.0L TSI engines

 Puller -T10112- for 1.6L SRE engine


 Ignition coil puller -T10094 A- for 1.4L TSI engines and 1.6L gasoline direct fuel injection engines
Fig. 161: Identifying Puller T10094 A

 Assembly tool -T10118- for 1.4L TSI engines and 1.6L gasoline direct fuel injection engines

 Ignition coil puller -T10095 A- for 6-cylinder FSI engines

Removing
Fig. 164: Identifying Ignition Coil Puller -T40039-

NOTE: To pull off spark plugs, place ignition coil puller -T40039- on topmost thick rib -
arrow- of ignition coils with power output stages.
If lower ribs are used, these can be damaged
-- Remove engine covers. Refer to UPPER ENGINE COVER, REMOVING AND INSTALLING.
Spark plugs are located under ignition coils with power output stages -2-.
Fig. 165: Identifying Ignition Coils

NOTE: Note installation position of ignition coils with power output stages.
-- Pull all ignition coils approximately 30 mm out of cylinder head in direction of arrow using ignition coil
puller -T40039-.
Fig. 166: Identifying Position And Direction To Use Ignition Coil Puller
-- Push connector in direction of ignition coils with power output stages, press catch down by hand and
disconnect connectors -arrows-.
Fig. 167: Identifying Direction To Push Connectors

-- Remove spark plugs using spark plug wrench -3122 B-.
Fig. 168: Identifying Spark Plug Wrench -3122 B-

NOTE: Spark plug identification and tightening specification, refer to IGNITION

COMPONENTS OVERVIEW

Installing
-- Install new spark plugs using spark plug wrench -3122 B-.
Fig. 169: Identifying Spark Plug Wrench -3122 B-

NOTE: Lubricate the ignition coils with spark plug grease -G 052 141 A2- whenever
installing new spark plugs.
New ignition coils are delivered already lubricated. It is not necessary to

lubricate them again.
-- Apply a thin bead of spark plug grease -G 052 141 A2- all around the sealing hose on the ignition coil -arrow-
. The bead of grease must be 1 to 2 mm thick.
Fig. 170: Identifying Application Of Thin Bead Of Lubricating Paste Around The Ignition Sealing Hose
-- Guide ignition coils with power output stages into cylinder head.
Fig. 171: Identifying Ignition Coils With Power Output Stages Guided Into Cylinder Head
-- Align ignition coils with power output stages into designated recesses of cylinder head cover.
-- Connect all connectors to ignition coils -arrows-.
-- Press ignition coils with power output stages onto spark plugs by hand until stop. They must engage audibly.
Fig. 172: Identifying Ignition Coils

-- Install engine cover.

3.6L FSI
 Spark plug wrench -3122 B-
Fig. 173: Identifying Spark Plug Wrench 3122 B


 Ignition coil puller -T40039- for 1.8L TSI; 2.0L FSI; 2.0L TFSI; 2.0L TSI engines

 Puller -T10112- for 1.6L SRE engine

 Ignition coil puller -T10094 A- for 1.4L TSI engines and 1.6L gasoline direct fuel injection engines
Fig. 177: Identifying Puller T10094 A

 Assembly tool -T10118- for 1.4L TSI engines and 1.6L gasoline direct fuel injection engines

 Ignition coil puller -T10095 A- for 6-cylinder FSI engines


-- Carefully loosen connector retainer with help of assembly tool -T10118- and remove connector.
-- Then place Puller -T10095 A- on ignition coils with power output stages and remove them.
Fig. 180: Identifying Placement Of Puller -T10095 A- On Ignition Coils

-- Remove spark plugs using spark plug wrench -3122 B-.

-- Install new spark plugs using spark plug wrench -3122 B-.
NOTE: Spark plug identification and tightening specification, refer to [For engine(s)
BPY] SPARK PLUG TECHNICAL DATA or [For engine(s) CCTA,CBFA] TEST
DATA AND SPARK PLUGS or [For engine(s) BLV] TEST DATA AND SPARK
PLUGS
NOTE: Lubricate the ignition coils with spark plug grease -G 052 141 A2- whenever
installing new spark plugs.
New ignition coils are delivered already lubricated. It is not necessary to

lubricate them again.
-- Apply a thin bead of spark plug grease -G 052 141 A2- all around the sealing hose on the ignition coil -arrow-
. The bead of grease must be 1 to 2 mm thick.
Fig. 181: Identifying Application Of Thin Bead Of Lubricating Paste Around The Ignition Sealing Hose
-- Press ignition coils with power output stages onto spark plugs.
-- Slide connector onto ignition coils with power output stages until it engages audibly.
COMPASS, ACTIVATING
To activate compass module, rear window heater must be adapted as follows:
 Activation must be performed with vehicle standing still.
-- Wait 10 seconds.
-- Switch on the rear window defroster.
-- Wait 10 seconds.
-- Switch off the rear window defroster.
STATIC CORNERING LIGHT AND AUTOMATIC HEADLAMP CONTROL, CHECKING FUNCTION
STATIC CORNERING LIGHT, CHECKING
 Vehicle parked, steering wheel in straight ahead position
NOTE: Vehicles with cornering light can be recognized by an additional reflector -

arrow- between the turn signal -1- and low beam module -3-.
Fig. 182: Identifying Additional Reflector Between The Turn Signal And Low
Beam Module
The static cornering light only functions in conjunction with the low beams.
-- Switch ignition and low beams on
-- Turn steering wheel one turn to the right out of straight position and check in right headlamp whether
cornering light bulb comes on.
-- Turn steering wheel one turn to the left out of straight position and check in left headlamp whether cornering
light bulb comes on.
Cornering light must go out when steering wheel is in straight position.
AUTOMATIC HEAD LAMP CONTROL, CHECKING
NOTE: Automatic headlamps are also called Automatic Head Lamp Control.
 Vehicle must be in daylight.
Checking in Daylight or Brightness
-- Turn the headlamp switch -4- to the automatic headlamps position -2-.
Fig. 183: Identifying Light Switch Positions

The headlamp should not come on when it is bright.
Checking at Night or in Darkness
 Ignition is switched on
 Light switch is on automatic headlamps
Rain/Light Recognition Sensor -G397- is secured to rearview mirror bracket.
Fig. 184: Locating Rain/Light Recognition Sensor -G397-

Rain/Light Recognition Sensor -G397- is located in upper center area of front windshield -arrow-.
-- Cover area where rearview mirror is secured with hand or suitable object from outside of windshield -arrow-.
The decrease in light is measured and the headlamps are switched on.
-- Turn the headlamp switch -4- to the O position -1- and then switch off the ignition.
Fig. 185: Identifying Light Switch Positions

HALDEX CLUTCH, CHANGING OIL
NOTE: On vehicles equipped with a Haldex clutch, the drain and sealing screws of both
systems get interchanged due to the integrated housing. This results in
unavoidable mistakes in maintenance and servicing, which can result in the
Haldex clutch or the axle drive failing.
The Haldex clutch and axle drive are a single unit with separate oil housings.
Fig. 186: Identifying Filler And Drain Plugs For Haldex Clutch
-1- Plug for filler hole for the Haldex oil.
-2- Drain plug for the Haldex oil.
-3- Plug for the filler hole for the axle oil.
-4- Drain plug for the axle oil.
Drain plug allocation, refer to TPI 2017008.


 Used Oil Collection and Extraction Device -V.A.G. 1782-

 Used oil collection and extraction device -VAS 6622-

Fig. 189: Identifying Used Oil Collection And Extraction Device VAS 6622
 Oil absorbent towel -VAS 6204/1-

 Charging Device F/Held 2 Coup. -VAS 6291-
Fig. 190: Identifying Charging Device F/Haldex 2 Coup. VAS 6291

Procedure:
-- Lift the vehicle with a vehicle hoist and move used oil collecting and extracting device -V.A.G. 1782- or used
oil collection and extraction device -VAS 6622- under the Haldex clutch.
-- Remove oil drain plug -A- and drain high-performance oil completely.
Fig. 191: Identifying Oil Drain Plug

-- Install a new drain plug with a new gasket. The drain plug has a permanent seal.
-- Remove oil filler plug -B-.
-- Disconnect elbow -B- from adapter -A- and completely install adapter in oil filler opening.
Fig. 192: Identifying Connecting Adapter And Elbow

-- Position elbow again and route hose over driveshaft to prevent it from hanging down.
-- After hose is routed above left rear wheel and away from vehicle, you can drain vehicle.
-- Screw oil container -A- with valve closed -arrow- onto Charging Device F/Held 2 Coup. -VAS 6291-.
Fig. 193: Installing Oil Container On Charging Device F/Haldex 2 Coup. VAS 6291
-- Open valve -arrow- and hold oil container as shown in illustration.
Oil capacity in service: 0.65 liters high performance fluid for the Haldex clutch -G 055 175-.
-- Remove the charging device for Haldex 2 clutch -VAS 6291-.
-- To check for a correct filling, remove the adapter -A- and see if any oil comes out of the oil fill hole.
-- Let any excess oil flow out until it just dripping.

Fig. 194: Identifying Connecting Adapter And Elbow

-- If oil is still not leaking, lower vehicle again and continue with filling procedure.
-- Install a new oil filler plug with a permanent seal.
Checking the specified temperature range while checking the oil level:
-- Connect the vehicle diagnostic tester. Refer to VEHICLE DIAGNOSIS TESTER, CONNECTING.

 Guided Fault Finding

 Chassis
 AWD with Haldex clutch
 Functions
 Read the measured values
Oil temperature must be between 68° and 104° F (20 and 40 °C); this can be achieved by driving until warm.
Check the oil level one more time.
-- Remove oil filler plug again -arrow-.

Fig. 196: Locating Bolt With New Seal

The oil level is correct when the oil drips out of the oil fill hole.
-- Tighten the oil filler plug again.
FINAL DRIVE, CHECKING OIL LEVEL
Refer to REAR FINAL DRIVE OIL LEVEL, CHECKING OR FILLING
MEMORY SEAT, INITIALIZING
All memories and assignments are deleted during initialization. The memory buttons can then be re-
programmed and a remote control key assigned.
-- Open the driver door.
-- Adjust backrest all the way forward as far as stop.
-- When the backrest is all the way forward, let go of switch and press it again until a tone is heard after a few
seconds.
AUTOMATIC TRANSMISSION, CHANGING ATF
-- Refer to TRANSMISSION FLUID LEVEL, CHECKING AND FILLING
NOTE: The transmission ATF must also be replaced in countries with a very hot
climate. The ATF wears down in these climate conditions. All countries affected
are listed in the table below.
Hot Climate Countries
Afghanistan Egypt Algeria

Angola Equatorial. Guinea Ethiopia
Australia Bahrain (GCC) Benin (Dahomey)
Botswana Brunei Burkina Faso (Upper Volta)
Burundi China Democratic Republic of Congo
Djibouti Dubai (AGCC) Ivory Coast
Eritrea Gabon Gambia
Ghana Guinea Guinea-Bissau
India Indonesia / (Borneo) Iraq
Iran Israel Japan
Yemen (AGCC) Jordan Cameroon
Qatar (AGCC) Kenya Congo
Kuwait (AGCC) Lesotho Lebanon
Liberia Libya Madagascar
Malawi Malaysia Mali
Morocco Mauritania Mauritius
Mexico Mozambique Namibia
Republic of Niger Nigeria Oman (AGCC)
Palestine Puerto Rico Rwanda
Zambia Saudi Arabia (AGCC) Senegal
Sierra Leone Zimbabwe Singapore
Somalia South Africa Sudan
Swaziland Syria Tanzania
Thailand Togo Chad
Tunisia Turkey Uganda
United States of America United Arab Emirates / Abu Dabi (AGCC) West Sahara
Central African Republic
TRANSPORT PROTECTION, REMOVING TIE DOWNS

Fig. 197: Identifying Short Tie Down, Long Tie Down And Towing Eye
The tie downs are used to secure vehicles during transport, for example, when being transported by truck or by
ship.
The tie downs are attached to the towing eyes.
 The tie downs must be removed from the vehicle prior to vehicle delivery and thrown away.
 Any parts, which had to be removed when the tie downs were installed, must be installed again.
-- Determine which eyes are installed on the vehicle before throwing them away.
CAUTION: Never put the tie downs with the vehicle tools.
A tie down -1- is not corrosion protected and is a welded part.
The part number for the long tie down -1- is -3C0 802 994 A-.
The part number for the short tie down -1- is -3C0 802 994-.
Contrary to a tie down, a towing eye -2- is corrosion protected and is a forged part, meaning it has no welding
seams.
The towing eye part of the vehicle tools. Do not throw it away.
NOTE: Vehicles with a factory equipped trailer hitch do not have a mount for the
towing eye.
 The air grille in the front bumper and the screws for the grille are inside the luggage compartment.
 The rear cap has a strap. The strap is there to protect the cap.
Tie Down Inside Right Front Bumper:
Fig. 198: Identifying Direction To Turn Tie Down For Removal

-- Turn the tie down to the right -arrow- and remove it.
Insert the tabs into the openings in the bumper -arrows- and then press the air grille -1- into the bumper.
Fig. 199: Identifying Insertion Of Air Grille -1-

CAUTION: Be careful not to damage the paint when installing the bumper cover.
-- Tighten the screw -arrow A- to 1.5 Nm.
Fig. 200: Locating Screw -Arrow A-

Tie Down Inside Right Rear Bumper:

Fig. 201: Identifying Direction To Turn Tie Down For Removal

NOTE: The cap has strap which limit the amount space.
-- Turn the tie down to the right -arrow- and remove it.
-- Remove the tape on the cap, if present.
-- To install the cap, first gently press on the right side -arrow- and then press on the left side.
Fig. 202: Identifying Installation Of Cap

ACTIVATING SURROUNDING AREA OBSERVATION SYSTEM (FRONT ASSIST)
Make sure the surrounding area observation system is on before delivering the vehicle to the customer. The
green indicator lamp in the instrument cluster will come on when the ignition is turned on. The surrounding area
observation system is an option. The maintenance point is identified by the PR number in the maintenance list.
Fig. 203: Identifying Activated Surrounding Area Observation System

If the system is not active, proceed as follows:
-- Select "Assistant" in the instrument cluster menu.
-- Select "Front Assist" and then confirm with "OK".
The system is now active.
Edition 12052011
GENERAL INFORMATION Volkswagen - 1983-13
GENERAL INFORMATION
Volkswagen - 1983-13
EGR MAINTENANCE LIGHT
NOTE: To determine the appropriate reset procedure, refer to EGR MAINTENANCE

LIGHT RESET INDEX. Only vehicles listed in this index have an EGR
Maintenance Light reset.
EGR MAINTENANCE LIGHT RESET INDEX

Model & Year Reset Procedure
Cabriolet
1985-87 EGR Maintenance Light Reset - Procedure 1
Fox
1987 EGR Maintenance Light Reset - Procedure 1
Golf & GTI
Jetta
Pickup
1983 EGR Maintenance Light Reset - Procedure 1
Quantum
Rabbit
Scirocco
Vanagon
EGR MAINTENANCE LIGHT RESET - PROCEDURE 1
EGR light comes on at 15,000 mile intervals as a reminder to service EGR system. After servicing EGR system,
reset mileage counter. See Mileage Counter Reset Procedure under OXYGEN SENSOR WARNING LIGHT
RESET - PROCEDURE 1.
OXYGEN SENSOR WARNING LIGHT
NOTE: To determine the appropriate reset procedure, refer to OXYGEN SENSOR

WARNING LIGHT RESET INDEX. Only vehicles listed in this index have an
Oxygen Sensor Warning Light reset.
OXYGEN SENSOR WARNING LIGHT RESET INDEX

Cabriolet
1985-87 Oxygen Sensor Warning Light Reset - Procedure 1
Fox
1987 Oxygen Sensor Warning Light Reset - Procedure 1
Golf
GTI
Jetta
Pickup
1983 Oxygen Sensor Warning Light Reset - Procedure 1
Quantum
Rabbit
Scirocco
Vanagon
OXYGEN SENSOR WARNING LIGHT RESET - PROCEDURE 1
Oxygen sensor (O2S) light comes on at 30,000 mile intervals and indicates oxygen sensor needs replacement.
After installing new sensor, reset mileage counter. See Mileage Counter Reset Procedure.
Mileage Counter Reset Procedure
1. On Rabbit and Pickup models, remove instrument panel cover plate. Reach into opening at top left corner
of speedometer and pull release arm to reset counter. See Fig. 1. Left arm resets EGR counter, right arm
resets oxygen sensor counter.
2. On Vanagon, locate mileage counter under spare tire or under driver's floorboard (in-line with
speedometer cable). Using a pointed instrument, depress reset button. Ensure light is out. On all other
models, locate mileage counter (in-line with speedometer cable). Push White reset button. See Fig. 1.
Ensure light is out.
Fig. 1: Resetting Mileage Counters (Rabbit & Pickup)

SERVICE REMINDER INDICATOR (SRI)
NOTE: Some Service Reminder Indicators (SRI) were eliminated from late production
1999 and later vehicles. Use VIN to identify early and late production vehicles.
For Golf and GTI, the 7th and 8th characters of the VIN are 1J for the late 1999
production vehicles. For Jetta, 7th and 8th characters of the VIN are 9M for the
late 1999 production vehicles. On early production vehicles, the 7th and 8th
characters of the VIN are 1H.
NOTE: To determine the appropriate reset procedure, refer to SRI RESET INDEX. Only
vehicles listed in this index have an SRI reset.
SRI RESET INDEX

Model & Year Platform Body/Sales Code Reset Procedure
Beatle
1998-10 NB 1C/1Y SRI Reset - Procedure 6
2012-13 NB 5C SRI Reset - Procedure 4
CC
2009-13 B6 357 SRI Reset - Procedure 4
Cabrio
1996-02 A3 1V SRI Reset - Procedure 1

Eos
2007-13 - 1F SRI Reset - Procedure 4
Eurovan
2000 T4 70 & 7D SRI Reset - Procedure 2
Golf/ Golf R
1993-99 A3 1H & 1W SRI Reset - Procedure 1
1998-04 A4 1J SRI Reset - Procedure 6
2004-06 A4 1J1 SRI Reset - Procedure 4
2010-12 A6 5K1 SRI Reset - Procedure 4
2013 A6 5G1 SRI Reset - Procedure 4
GTI
1995-99 A3 - SRI Reset - Procedure 1
Jetta (Sedan)
1993-99 A3 1H SRI Reset - Procedure 1
1999-05 A4 1J SRI Reset - Procedure 6
2005-10 A5 1K SRI Reset - Procedure 4
2011-13 A6 162 SRI Reset - Procedure 4
Jetta (SportWagen)
2008-09 A5 1K SRI Reset - Procedure 4
2010-13 A6 AJ SRI Reset - Procedure 4
Passat
1998-05 B5 3B SRI Reset - Procedure 7
2006-10 B6 3C SRI Reset - Procedure 4
2012-13 B7 A32 SRI Reset - Procedure 4
Rabbit
Routan
2009-13 - 7B1 SRI Reset - Procedure 5
Tiguan
2009-13 A5 5N SRI Reset - Procedure 4
Tuoareg
2010-13 PL71 7P5 SRI Reset - Procedure 3
SRI RESET - PROCEDURE 1
NOTE: This procedure applies to A3 models.

NOTE: The Service Reminder Indicator can also be reset using an OEM scan tool.
After performing the specified maintenance, reset the Service Reminder Indicator (SRI) displays according to
the following table:
SRI DISPLAYS TO RESET

Service Interval Display(s) To Reset
7500 mile (12,000 km) or OEL
6-month engine oil change
15,000 mile (24,000 km) or OEL
12-month maintenance IN01
22,500 mile (36,000 km) or OEL
30,000 mile (48,000 km) or OEL
IN02
37,500 mile (60,000 km) or OEL
45,000 mile (72,000 km) or OEL
52,500 mile (84,000 km) or OEL
60,000 mile (96,000 km) or OEL
IN02
1. Switch ignition ON.

2. Press and hold odometer reset button (arrow) located below speedometer. See Fig. 2.
Fig. 2: Identifying Odometer Reset Button

Courtesy of VOLKSWAGEN OF AMERICA, INC.
3. Switch ignition OFF and release odometer reset button.
"OEL" will now appear in SRI display
4. Press and hold lower digital clock reset button (1) or analog clock reset (2) (see Fig. 3), until five dashes
(- - - - -) appear in display.
Fig. 3: Identifying Lower Digital Clock & Analog Clock Reset Buttons
5. OEL SRI is now reset for 7500 miles (12,000 km) or 6 months, whichever comes first. Once OEL is
reset, the other displays can be reset the same way without switching the ignition on and off again.
a. Press odometer reset button to proceed to IN01 display (15,000 mile maintenance) and reset using
clock reset button.
b. If necessary, repeat procedure to reset IN02 (30,000 mile maintenance) display.
c. To escape reset mode: Switch ignition ON; when "IN01" is displayed, switch ignition OFF.
NOTE: Some 2000 EuroVan vehicles were mistakenly equipped with instrument
clusters having Service Reminder Indicator (SRI) functions (SRI is not specified
as standard equipment for the USA and Canadian markets). Vehicles so
equipped may indicate a service or maintenance interval not applicable to the

USA and Canadian markets.
NOTE: On EuroVan, only the actual display shown can be reset.
1. Turn ignition switch to OFF position.

2. Press and hold trip reset button under the speedometer.
3. Turn ignition switch to ON position and release reset button. SERVICE will appear on trip recorder
(odometer) display.
NOTE: Pressing trip recorder button again switches the display to INSP SERVICE
without resetting the OEL (or OIL) service.
4. Turn adjusting knob, located next to tachometer, to the right (clockwise). The service shown on the trip
recorder is reset and SERVICE _ _ _ will appear on display. Turn ignition switch to OFF position.
Resetting the Oil Change Interval indicator:
1. Turn ignition ON.

2. Using the CAR Infotainment button, enter the Service Function menu.
3. Reset the Oil Change Interval item.
NOTE: Do not reset the Oil Change Interval between oil changes.
NOTE: If you reset the service display yourself, the next service is displayed after 9,320
miles (15,000 km) or one year. The service interval is not determined
individually.
Using Buttons in Instrument Cluster (Basic Message Display)
1. With the ignition switched off, press and hold the 0.0 (trip reset) button (3). See Fig. 4, Fig. 5, or Fig. 6.
2. Switch ignition on. Release the 0.0 button. Press the HOUR and MINUTE button (clock reset button (1)
one time, quickly.
3. The Service Interval Display is now in the Reset mode.
4. After a brief period, the display switches back to the normal display.
5. Turn off ignition and remove key from lock. Wait at least 10 seconds.
6. Insert key and start engine. The service interval is now reset. Confirm "wrench" indicator light is not
illuminated.
Fig. 4: Identifying Instrument Cluster Buttons (Typical - All Models Except 2012 Beetle, 2004-08 Golf
Sedan, 2004 R32)
Fig. 5: Identifying Instrument Cluster Buttons (2004-08 Golf Sedan & 2004 R32)
Fig. 6: Identifying Instrument Cluster Buttons (2012 Beetle)

Using The Windshield Wiper Lever Buttons (Premium Message Display)
1. Using the rocker switch on the windshield wiper lever (2), select the "Settings" menu. See Fig. 7.
2. Once in the service submenu, select "Reset", then press the "OK" button (1). The service interval is now
reset.
Fig. 7: Identifying Windshield Wiper Lever Buttons (All Models)

Using The Buttons In Multifunction Steering Wheel
1. Press the appropriate multifunction steering wheel button continually until the "Settings" menu is
displayed (button 1 in 2004-08 Golf Sedan & 2004 R32, or button 5 in all other models). See Fig. 8 or
Fig. 9)
2. Once in the service submenu, select "Reset" and then press the "OK" button (3 in 2004-08 Golf Sedan &
2004 R32, or 5 in all other models). The service interval is now reset.
Fig. 8: Identifying Multifunction Steering Wheel Buttons (All Models Except 2004-08 Golf Sedan & 2004
R32)
Fig. 9: Identifying Multifunction Steering Wheel Buttons (2004-08 Golf Sedan & 2004 R32)
1. Turn ignition switch to the ON position, but DO NOT start the engine.
2. Slowly depress and release the accelerator pedal fully 3 times within 10 seconds.
3. Turn the ignition switch to the OFF position.
4. If the change oil indicator illuminates the next time the engine is started, repeat this procedure.
1. Turn ignition off.

2. Press and hold trip reset button under the speedometer.
3. Switch ignition on.
4. Release trip reset button. "Service" appears in the odometer display.
5. Push trip reset button again, until "Service" disappears (approx. 10 seconds).
6. Turn ignition off.
NOTE: Depending on the service performed, one or both service types must be reset:
 If "OIL service" (oil change service every 15,000 km) was performed, only
"OIL service" must be reset.
 If "INSP service" was performed (inspection service every 12 months or
one inspection service every 30,000 km) with oil change, "INSP service"
and "OIL service" must be reset.
 If "INSP service" was performed (inspection service every 12 months or
one inspection service every 30,000 km) without oil change, only "INSP
service" must be reset.
1. Turn off ignition.

2. Press and hold the odometer trip reset button, left of the speedometer.
3. Switch the ignition on. The message service OIL (for country code "D") or service OIL (remaining
countries) appears in the odometer.
4. Release the button.
NOTE: By pressing the distance button once again, the display switches to
service event INSP without resetting the service event OIL. Observe that
only the respective currently displayed service event is reset.
5. Actuate adjustment button, right of the tachometer.
NOTE: On an instrument cluster with digital clock, the adjustment button must be
turned to the right. If the instrument cluster is equipped with an analog
clock, the adjustment button must be pulled.
6. The service event indicated in the odometer is reset and (- - -) appears in the display.
7. Turn off ignition.
8. Only the respective currently displayed service event is reset. Repeat the steps to reset another service
event.
TIRE PRESSURE MONITOR SYSTEM (TPMS)
NOTE: To determine the appropriate reset procedure, refer to TPMS RESET INDEX.
Only vehicles listed in this index have a TPMS reset.
TPMS RESET INDEX

Beetle
2008-11 TPMS Reset - Procedure 4
CC
Eos
Golf/ Golf R
GTI
Jetta
Passat
Phaeton
Rabbit
Routan
R32
2004 & 2008 TPMS Reset - Procedure 2
Tiguan
Touareg
TPMS RESET - PROCEDURE 1
NOTE: Whenever a wheel is changed or replaced, or whenever vehicle has been

loaded, the TPM system needs to be reset. See Tire Pressure Monitor System
Reset.
Tire Pressure Monitor Warning Light
When the low tire pressure warning light comes on, immediately check air pressure of all tires and adjust to the
specified pressure. Reset TPM system. See Tire Pressure Monitor System Reset. If light is still on, there is a
malfunction in the TPM system. See appropriate manufacturer service information.
Under the following conditions, the system may not function properly:
 Insufficient tire pressure.

 Structural damage on tires.
 Load on vehicle on one side.
 One axle is heavily loaded (i.e., when pulling a trailer).
 When snow chains are used.
 When spare wheel is installed.
 One wheel is replaced.
 Tire pressure sensor battery is depleted (7-10 year life span).
Tire Pressure Monitor System Reset
CAUTION: DO NOT reset TPM system until all problems are fixed and tire pressure in
all tires has been adjusted. If reset procedure is done when tire pressures
are incorrect, TPM system will not work properly and may not set an alert
when a tire pressure is low or high.
NOTE: Whenever a wheel is changed or replaced, the TPM system needs to be reset.
See Basic Setting . If wheels are changed and replaced with manufacturer-
approved wheel/tire combinations (i.e., from summer to winter tires) or if tire
pressure deviates from pressures given on fuel filler flap, see After Wheel Or
Pressure Change . If vehicle is equipped with unapproved tires or tires with
pressures other than those listed on fuel filler flap (a 2nd wheel set), see Wheel
Sets With Different Pressure Specifications .
Basic Setting
1. Set the tire pressure of all wheels to specified pressure.

2. With vehicle stopped and parking brake applied, turn ignition switch to ON position.
3. Press SET button (located near gear shift) until an audio signal is heard. See Fig. 10. The signal confirms
basic setting.
Fig. 10: Locating TPM System SET Button (Typical)

After Wheel Or Pressure Change

2. With parking brake applied, allow vehicle to stand for 20 minutes (5 minutes after a recognized tire
puncture) so that control module enters learning mode.
3. Drive vehicle at 16 MPH (25 KM/H) or more. As soon as vehicle reaches this speed, tire pressure sensor
IDs are automatically recognized and read by control module.
NOTE: An acceleration data check also occurs with vehicle speed. This process
takes about 7 minutes.
Wheel Sets With Different Pressure Specifications
NOTE: If unapproved wheel/tire combinations are installed, a 2nd wheel set must be
learned. To perform this procedure, Volkswagen VAS 5051B is required.
1. Read out tire pressure sensor IDs before installation.

2. Switch TPMS to wheel set 2.
3. Enter needed specified tire pressures and sensor IDs into system.
NOTE: Whenever a wheel is changed or replaced, the TPM system needs to be reset.
See Basic Setting. If wheels are changed and replaced with manufacturer-
approved wheel/tire combinations (i.e., from summer to winter tires) or if tire
pressure deviates from pressures given on fuel filler flap, see After Wheel Or
Pressure Change. If vehicle is equipped with unapproved tires or tires with
pressures other than those listed on fuel filler flap (a 2nd wheel set), see Wheel
Sets With Different Pressure Specifications.
Basic Setting

3. Press SET button (located near gear shift) until an audio signal is heard. See Fig. 11. The signal confirms
basic setting.
Fig. 11: Locating TPM System SET Button


2. With parking brake applied, allow vehicle to stand for 20 minutes (5 minutes after a recognized tire
puncture) so that control module enters learning mode.
3. Drive vehicle at 16 MPH (25 KM/H) or more. As soon as vehicle reaches this speed, tire pressure sensor
IDs are automatically recognized and read by control module.
NOTE: An acceleration data check also occurs with vehicle speed. This process
takes about 7 minutes.


loaded, the TPM system needs to be reset.
all tires (including spare tire) has been adjusted. If reset procedure is done
when tire pressures are incorrect, TPM system will not work properly and
may not set an alert when a tire pressure is low or high.

loaded, the TPM system needs to be reset.
NOTE: In the following procedure, tires must be cold.
1. Set the tire pressure of all wheels to pressure specified on the tire information label (located on open edge
of driver's door).
3. Press appropriate button to show menu selection in instrument cluster display. See Fig. 12 and Fig. 13 .
4. Select menu item "TIRE PRESSURE" using thumbwheel (or rocker switch).
5. When menu item "TIRE PRESSURE" is selected in display, confirm menu item by pressing thumbwheel.
6. In "TIRE PRESSURE MONITOR" sub-menu, turn thumbwheel until position "STORE" is displayed.
Save current inflation pressure by pressing thumbwheel.
7. Drive vehicle continuously for approximately 8-10 minutes.
Fig. 12: Accessing Instrument Cluster Display Menus (Using Wiper/Washer Lever)
Fig. 13: Accessing Instrument Cluster Display Menus (Using Multifunction Steering Wheel
Buttons)
NOTE: Whenever a wheel is changed or replaced the TPM system needs to be reset.
See Tire Pressure Monitor System Reset.
Tire Pressure Monitor Warning Light
When the low tire pressure warning light comes on, immediately check air pressure of all tires and adjust to the
specified pressure. If light is still on, there is a malfunction in the TPM system. See appropriate manufacturer
service information.
Under the following conditions, the system may not function properly:
 Insufficient tire pressure.

 Structural damage on tires.
 Load on vehicle on one side.
 One axle is heavily loaded (i.e., when pulling a trailer).
 When snow chains are used.
 When a spare wheel without a pressure sensor is installed.

 One wheel is replaced.
 Tire pressure sensor battery is depleted (7-10 year life span).
NOTE: Whenever a wheel is changed or replaced, the TPM system needs to be reset. If
wheels are changed and replaced with manufacturer-approved wheel/tire
combinations (i.e., from summer to winter tires) or if tire pressure deviates from
pressures given on the label inside the driver's door, see After Wheel Or
Pressure Change . If vehicle is equipped with unapproved tires or tires with
pressures other than those listed on the label inside the driver's door (a 2nd
wheel set), see Wheel Sets With Different Pressure Specifications .
If wheels are changed (e.g. change from summer to winter tires), wheel electronics send data as soon as speed
of new wheels exceeds 25 km/h. Wheel electronics identification numbers are automatically recognized and
read by control module.
An acceleration data check also accurs with vehicle speed. This process takes about 7 minutes.
Tire Pressure Monitoring Control Module must first be in learning mode before it can automatically learn wheel
electronics.
Vehicle must stand for 20 minutes for this. This takes 5 minutes after a recognized tire puncture.
If the standing time is not followed, control module is not in learning mode so system recognizes a malfunction
and can only automatically learn wheel electronics after standing 20 minutes.

After the following work and/or changes and with the ignition switched on, the Tire Pressure Monitoring
Display Button must be pressed until the confirmation chime sounds:
 Tire pressure change.

 A change of one or more tires.
 After rotating tires.
After every change at wheels, the SET button (near the shift lever, or inside the glove compartment) must be
pressed, with ignition switched on and vehicle standing still, until a signal tone sounds. The signal tone
confirms the basic setting.
There are two tire pressure monitoring systems available, a base system and a premium system. The base
system does not specify how many tires are low or where they are located. The premium system does so.
The base TPM system consists of 4 tire sensors, a central receiver module, and an indicator light. The Premium
TPM system consists of 4 sensors, three wheel sensor transponders located in three of the four wheel wells, an
electronic display, and an indicator light.
Base TPM System
Once pressure in the tires raises above the Low Pressure (lamp) OFF Threshold, and the TPM module receives
a valid signal from the sensor, the indicator light will go out.
NOTE: If a system fault is detected, the indicator lamp will flash on/off for 75 seconds,
then remain on solid.
The TPM module automatically learns and stores the sensor IDs while driving "within 20 minutes continuously
above 15 mph (24 km/h)" after a sensor has been replaced. The learning sequence will initiate when the vehicle
has been stopped for more than 20 minutes.
NOTE: A new sensor ID can also be programmed directly into the WIN or TPM module
by using a RKE-TPM Analyzer in conjunction with a Scan Tool. Once the new
sensor ID has been programmed, the vehicle will need to be driven above 15
mph until the fault is no longer active (lamp extinguishes) and display is
updated (for up to 20 minutes). Using a TPM-RKE Analyzer can take up to a
minute to force a transmission from a sensor.
Premium TPM System
Once pressure in the tires raises above the Low Pressure (lamp) OFF Threshold, and the TPM module receives
a valid signal from the sensor, the indicator light will go out.
NOTE: If a system fault is detected due to a missing sensor signal, in addition to a

chime and a indicator lamp flashing, a "Check TPM System" text message will
be displayed in the instrument cluster, and the tire pressure graphic display will
have "- -" in place of the pressure value. After the flash sequence, the TPM
indicator light will remain illuminated. The system will return to normal once the
TPM module receives a valid transmission from that sensor location. If a system
fault is detected, the indicator lamp will flash on/off for 75 seconds and then
remain on solid.
The TPM module automatically learns and stores the sensor IDs while driving "within 20 minutes continuously
above 15 mph (24 km/h)" after a sensor has been replaced. The learning sequence will initiate when the vehicle
has been stopped for more than 20 minutes.
NOTE: A new sensor ID can also be programmed directly into the WIN or TPM module
by using a RKE-TPM Analyzer in conjunction with a Scan Tool. Once the new
sensor ID has been programmed, the vehicle will need to be driven above 15
mph until the fault is no longer active (lamp extinguishes) and display is
updated (for up to 20 minutes). Using a TPM-RKE Analyzer can take up to a
minute to force a transmission from a sensor.
Brakes Mechanical Components
Brakes
Mechanical Components
46 MECHANICAL COMPONENTS
FRONT BRAKES ASSEMBLY OVERVIEW, FN 3
NOTE: After replacing brake pads, depress brake pedal firmly several times with
vehicle stationary so that the brake pads are properly seated in their normal
operating position.
Use brake charger/bleeder unit VAS 5234 or extraction device V.A.G 1869/4 to
extract brake fluid from brake fluid reservoir.
Before removing brake caliper or disconnecting brake hose, brake pedal

depressor V.A.G 1869/2 must be inserted (this dissipates pressure).
Fig. 1: Exploded View Of Front Brakes (FN 3 Calipers)

1. Cover Plate
2. Bolt
 12 Nm
3. Brake Disc
 Internally vented: 312 mm diameter
 Thickness: 25 mm
 Wear limit: 22 mm
 Must always be replaced together on both sides of vehicle.

4. Bolt
 4 Nm
5. Brake Carrier
 Bolt to wheel bearing housing.
6. Retaining Spring
 Insert in both holes of brake caliper.
7. Ribbed Bolt
 200 Nm
 Clean if using again.
8. Brake Pads
 Thickness: 14 mm without backing plate
 With wear indicator (left front).
 When wear limit is reached (limit: approximately 4 mm without backing plate), the warning lamp
in the instrument cluster comes on.
 Wear limit: 2 mm without backing plate.
 Check the thickness. Refer to FRONT AND REAR BRAKE PAD THICKNESS AND BRAKE
DISC CONDITION, CHECKING
 Removing and installing, refer to FRONT BRAKE PADS, FN 3
9. Brake Caliper
 Do not unscrew brake hose when replacing brake pad.
 Removing and installing, refer to FRONT BRAKE CALIPER, FN 3.
 Servicing, refer to FRONT BRAKE CALIPER ASSEMBLY OVERVIEW, FN 3 .
10. Guide Pins

 30 Nm
11. Cap
 Remove.
12. Brake Hose with Banjo Fitting and Union Bolt

 35 Nm
13. Bolt
 8 Nm
14. Bracket
15. Retaining Clip
FRONT BRAKES ASSEMBLY OVERVIEW, FNR-G
operating position.
Use brake charger/bleeder unit VAS 5234 or extraction device V.A.G 1869/4 to

Fig. 2: Exploded View Of Front Brakes, FNR-G Brake Caliper

1. Cover Plate
2. Bolt
 12 Nm
3. Brake Disc
 Internally vented: 345 mm diameter
 Thickness: 30 mm
 Wear limit: 27 mm
 Remove brake caliper before removing.
4. Bolt
 4 Nm
5. Brake Carrier
 Bolt to wheel bearing housing.
6. Retaining Spring
 Insert in brake pad retaining spring and press below brake carrier.
7. Ribbed Bolt
 190 Nm
 Clean if using again.
8. Brake Pads
 Thickness: 14 mm without backing plate.
 With wear indicator.
 When wear limit is reached (limit: approximately 4 mm), the warning lamp lights up in instrument
cluster.
 Wear limit: 2 mm without backing plate
DISC CONDITION, CHECKING .
 Removing and installing, refer to FRONT BRAKE PADS, FNR-G.
9. Brake Caliper
 Do not bolt to brake hose/brake line when changing brake pads.
 Must not be removed.
 Removing and installing, refer to FRONT BRAKE CALIPER, FNR-G.
 Servicing, refer to FRONT BRAKE CALIPER ASSEMBLY OVERVIEW, FNR-G .
10. Guide Pins

 30 Nm
11. Cap
 Remove
12. Washer
13. Vibration Damper
Allocation.
14. Bolt
 10 Nm
15. Dust Cap
16. Bracket
17. Bolt
 15 Nm
18. Brake Line

 14 Nm
19. Brake Hose

20. Bolt
 8 Nm
21. Bracket
22. Spring Clamp
REAR BRAKES ASSEMBLY OVERVIEW
NOTE: Use brake charger/bleeder unit VAS 5234 or extraction device V.A.G 1869/4 to

Fig. 3: Exploded View Of Rear Wheel Brakes (CII 38 And CII 41)
1. Cover Plate
 Allocation.
2. Brake Disc
 16 inches: 286 mm
 17 inches: 310 mm
 Thickness 16 inches: 12 mm
 Thickness 17 inches: 22 mm
 Wear limit 16 inch: 10 mm

 Always replace pads on both sides of vehicle if worn.

 To remove, first remove brake caliper and carrier.
3. Bolt
 4 Nm
4. Bolt
 90 Nm + 90° turn
 With multipoint socket T10035.
5. Brake Carrier with Guide Pins and Protective Cap

 Supplied as an assembled replacement part with sufficient grease on guide pins.
 If protective caps or guide pins are damaged, install repair kit. Use supplied grease packet to
lubricate guide pins.
6. Anti-Rattle Spring
 Always replace when pads are replaced.
7. Brake Pads
 Thickness 11 mm without backing plate
 Removing and installing, refer to REAR BRAKE PADS.
8. Brake Pads
 Thickness: 11 mm without backing plate
 Removing and installing, refer to REAR BRAKE PADS
9. Anti-Rattle Spring
 Always replace when pads are replaced
10. Brake Caliper

 Do not unscrew brake hose when replacing brake pad.
 Removing and installing, refer to REAR BRAKE CALIPER.
 Servicing, refer to REAR BRAKE CALIPER ASSEMBLY OVERVIEW .
 Perform a basic setting after servicing or replacing.
11. Bolt
 Self-locking
 35 Nm
 Replace
12. Bracket
13. Brake Line
 14 Nm
14. Retaining Clip

15. Seal
16. Parking Brake Motor
17. Bolt
 12 Nm
18. Brake Hose

19. Bolt
 12 Nm
ELECTROMECHANICAL PARKING BRAKE COMPONENT OVERVIEW

Fig. 4: Identifying Electro-Mechanical Parking Brake, Component Overview

1. Electromechanical Parking Brake Button -E538-

 Component location: In the instrument panel, next to the light switch
2. Electromechanical Parking Brake Indicator Lamp -K213-

 Component location: In electromechanical parking brake button.
3. Electric Park/Handbrake Malfunction Indicator Lamp -K214-

4. Brake System Warning Lamp -K118-

6. -AUTO HOLD- Button -E540-

 With -AUTO HOLD- Indicator Lamp 2 -K237-
 Component location: In center console.
7. Electromechanical Parking Brake Control Module -J540- and ESP Sensor Unit -G419-
 Installed together in one housing.
 Removing and installing, refer to ELECTROMECHANICAL PARKING BRAKE CONTROL

MODULE.
8. Seal
9. Right Parking Brake Motor -V283-
 Component location: On right rear brake caliper.
 Removing and installing, refer to PARKING BRAKE MOTOR.
10. Bolt
 12 Nm
11. Left Parking Brake Motor -V282-

 Component location: On left rear brake caliper.
 Removing and installing, refer to PARKING BRAKE MOTOR.
BRAKE PEDAL ASSEMBLY OVERVIEW
WARNING: The path of the brake pedal must not be shortened via extra floor mats.
Before installing, lubricate all mounting points with grease, part no. G 000 602.
Fig. 5: Identifying Brake Pedal, Assembly Overview

1. Mounting Bracket
2. Nut
 Self-locking
 25 Nm
3. Nut
 Self-locking
 25 Nm
4. Brake Pedal
5. Cover
6. Ball Socket
7. Wheel Hub Support
 For the ball head on the brake booster push rod.
8. Bolt
9. Bushing
10. Pivot Pin
SPECIFICATIONS

Brake Disc to Wheel Hub Bolt - 4
Brake Hose with Union Bolt to Front Brake Caliper, FN3 - 35
Brake Hose Bracket Bolt - 8
Brake Line Bracket to Front Brake Caliper Bolt, FNR-G - 15
Brake Line to Front Brake Caliper, FNR-G - 14
Brake Line to Rear Brake Caliper - 14
Brake Pedal Mounting Bracket to Body Nut - 25
Brake Pedal to Mounting Bracket Nut - 25
Cover Plate to Wheel Bearing Housing Bolt - 12
Electromechanical Parking Brake Control Module Nut - 9
Front Brake Caliper Guide Pin to Brake Carrier - 30
Front Brake Carrier to Wheel Bearing Housing Bolt
- FN 3 - 200
- FNR-G - 190
Parking Brake Motor to Rear Brake Caliper Bolt - 12
Rear Brake Caliper to Brake Carrier Bolt (1) - 35
Rear Brake Carrier to Wheel Bearing Housing Bolt (1) - 90 + 90° turn
Vibration Damper to Front Brake Caliper Bolt, FNR-G - 10
FRONT BRAKE PADS, FN 3

Removing
NOTE: When removing, mark brake pads that will be used again. Install in the same
position, otherwise braking effect will be uneven!
-- Remove wheels.
-- Using screwdriver, pry off brake pad retaining spring from brake caliper -arrow- and remove.
Fig. 6: Identifying Brake Pad Retaining Spring, Brake Caliper Housing And Screwdriver
-- Separate the connector -1- for brake pad wear indicator.

Fig. 7: Identifying Brake Pad Wear Indicator Connector

-- Remove caps -arrows-.
Fig. 8: Identifying Protective Caps

-- Loosen both guide pins -arrows- and remove from brake caliper.
Fig. 9: Identifying Removal Of Brake Caliper Guide Pins

-- Remove brake caliper and secure with wire so that the weight of the brake caliper does not burden or damage
the brake hose.
-- Remove brake pad from brake caliper or from brake carrier.
Cleaning
WARNING: Do not blow brake system using compressed air, the dust produced is
harmful to health!
-- Thoroughly clean contact surfaces for brake pads at brake carrier, remove corrosion.
-- Clean brake caliper.
NOTE: Use only appropriate solvents for cleaning brake caliper.
Installing
NOTE: Before pressing piston into cylinder using piston resetting tool, brake fluid
must be extracted from brake fluid reservoir. Otherwise, especially if reservoir
has been topped off, fluid will overflow and cause damage.
-- Press piston back.

Fig. 10: Identifying Piston Pressed Back Into Cylinder

-- Install outer brake pad on brake carrier.
-- Insert inner brake pad with retaining spring in brake caliper (piston).
-- Tighten brake caliper to brake carrier using both guide pins.
Fig. 11: Identifying Installation Of Brake Caliper Guide Pins

-- Install both protective caps.

-- Install retaining spring in brake caliper.
-- Connect brake pad wear indicator connector.
-- Install wheels.
Tightening specification for wheel bolts, refer to TIGHTENING SPECIFICATION FOR MOUNTING
WHEELS .
operating position.
Check brake fluid level after replacing brake pad.
Guide pin to brake carrier 30 Nm
FRONT BRAKE CALIPER, FN 3

Removing
NOTE: Work procedure applies only for replacing or when performing subsequent
service work on brake caliper.
-- Remove wheels.
-- Using screwdriver, pry off brake pad retaining spring from brake caliper and remove.
-- Separate the connector for brake pad wear indicator.
-- Connect bleeder hose of bleeder bottle to bleeder valve of brake caliper and then open bleeder valve.
-- Insert V.A.G 1869/2.
-- Close bleeder valve and remove bleeder bottle.
-- Remove the brake hose.
-- Pull both cover caps from bushings of brake caliper.

-- Loosen both guide pins and remove from brake caliper.
-- Pull off brake caliper from brake carrier.
-- Remove brake pads from brake caliper.
Installing
 Piston is pressed back.

 Outer brake pad sits on brake carrier.
-- Screw brake hose on brake caliper.
-- Remove V.A.G 1869/2.
-- Install retaining spring in brake caliper.
-- Install wheels.
WHEELS .
NOTE: Before moving vehicle, depress brake pedal several times firmly to properly
seat brake pads in their normal operating position.
Check brake fluid level.
Brake line to brake caliper 35 Nm
FRONT BRAKE PADS, FNR-G


Removing
-- Remove wheels.
-- Pry brake caliper retaining spring out of brake pad retaining spring with screwdriver. To do this, place
screwdriver between both retaining springs -close-up-.
-- Secure brake caliper retaining spring with a cloth when doing this so that it cannot jump away.
Fig. 12: Identifying Brake Caliper Retaining Spring Pried Out Of Brake Pad Retaining Spring With
Screwdriver
-- Separate the connector -1- for brake pad wear indicator.

Fig. 13: Identifying Brake Pad Wear Indicator Connector

-- Remove caps -arrows-.
Fig. 14: Identifying Brake Pad Caps

-- Loosen both guide pins -arrows- and remove from brake caliper.
Fig. 15: Identifying Loosening Of Brake Pad Guide Pins

-- Remove brake caliper and secure with wire so that the weight of the brake caliper does not burden or damage
the brake hose.
Cleaning
harmful to health!
Installing
NOTE: Before pressing piston into cylinder using piston resetting tool, brake fluid
must be extracted from brake fluid reservoir. Otherwise, especially if reservoir
has been topped off, fluid will overflow and cause damage.
-- Press piston back.

Fig. 16: Identifying Piston Pressed Back Into Cylinder

Fig. 17: Identifying Insertion Of Inner Brake Pad With Retaining Spring In Brake Caliper
-- Set outer brake pad -2- with retaining springs into brake caliper.
Fig. 18: Identifying Outer Brake Pad, Retaining Springs And Brake Caliper
-- Place brake caliper with brake pads on brake carrier.
Fig. 19: Identifying Tightening Of Brake Pad Guide Pins

-- Insert brake caliper retaining spring in brake pad retaining spring and press under brake carrier.
-- Install wheels.
Tightening specification for wheel bolts, refer to TIGHTENING SPECIFICATION FOR MOUNTING
WHEELS .
operating position.
Check brake fluid level after replacing brake pad.
FRONT BRAKE CALIPER, FNR-G

Removing
-- Remove wheels.
-- Pry brake caliper retaining spring out of brake pad retaining spring with screwdriver. To do this, place
screwdriver between both retaining springs.
-- Secure brake caliper retaining spring with a cloth when doing this so that it cannot jump away.
-- Separate the connector for brake pad wear indicator.
-- Insert V.A.G 1869/2.
-- Remove the brake hose.

-- Pull both cover caps from bushings of brake caliper.
-- Loosen both guide pins and remove from brake caliper.
Installing
 Piston is pressed back.
-- Set outer brake pad with retaining springs into brake caliper.
-- Place brake caliper with brake pads on brake carrier.
-- Connect brake hose with brake caliper line.
-- Remove V.A.G 1869/2.
-- Insert brake caliper retaining spring in brake pad retaining spring and press under brake carrier.
-- Install wheels.
WHEELS .
NOTE: Before moving vehicle, depress brake pedal several times firmly to properly
seat brake pads in their normal operating position.
Check brake fluid level.
Brake hose to brake line 14 Nm
REAR BRAKE PADS

Removing
NOTE: Do not disconnect the connectors from the parking brake motors.
 Electromechanical parking brake not actuated.
-- Remove wheels.
The pistons on the electromechanical parking brake must be driven back using the Vehicle Diagnostic Tester.
NOTE: Before pressing piston back, draw off brake fluid from reservoir using a bleeder
bottle. Otherwise, especially if reservoir has been topped off, fluid will overflow
and cause damage.
-- Vehicle Diagnostic Tester, connecting and selecting functions VAS 5051, CONNECTING AND
-- Select the electromechanical parking brake and the function "Moving piston of parking brake motor out and
in".
-- Drive the pistons back using the Vehicle Diagnostic Tester.
-- Then, unscrew the bolts from the brake caliper, while counter-holding the guide pins.
Fig. 20: Identifying Removal Of Bolts From Brake Caliper, While Counter-Holding Guide Pins
-- Remove brake caliper downward from brake carrier.
NOTE: Resetting the piston with Vehicle Diagnostic Tester is often not sufficient but
necessary! The pressure nut in the piston is a floating mount so the piston can
only be pressed and cannot be pulled back. Only the spindle with the pressure
nut is moved back.
CAUTION: The piston must first be reset with Vehicle Diagnostic Tester.
-- Now press piston all the way back with T10145.

Fig. 21: Identifying Piston Pressed Into Brake Caliper Using Piston Resetting Tool
-- Secure the brake caliper with wire so the weight of caliper does hang from or damage the brake line.
-- Remove brake pads and anti-rattle springs -arrows-.
Fig. 22: Identifying Brake Pad Retention Plates And Brake Pads Inserted In Brake Carrier
Cleaning
harmful to health!
Installing
-- Insert brake pad retention plates -arrows- and brake pads in brake carrier.
Fig. 23: Identifying Brake Pad Retention Plates And Brake Pads Inserted In Brake Carrier
-- Make sure that the brake pads are located correctly in the anti-rattle springs -arrows-.
Fig. 24: Identifying Brake Pads Located Correctly In The Anti-Rattle Springs
-- Secure brake caliper using new self-locking bolts.
 The repair kit includes four self-locking hex bolts which must be installed in all cases.
After driving the pistons out with the Vehicle Diagnostic Tester, a basic setting of the brake system must be
performed.
-- Perform the brake system basic setting with the Vehicle Diagnostic Tester.
-- Install wheels.
Torque specification for wheel bolts. Refer to TIGHTENING SPECIFICATION FOR MOUNTING
WHEELS .
NOTE: Check brake fluid level after replacing brake pad.
Hex bolt, brake caliper to brake carrier 35 Nm
 Use new bolts!
REAR BRAKE CALIPER
 Ring spanner insert AF 21T10035


Removing
NOTE: Do not disconnect the connectors from the parking brake motors.
-- Remove wheels.
The pistons on the electromechanical parking brake must be driven back using the Vehicle Diagnostic Tester.
NOTE: Before pressing piston back, draw off brake fluid from reservoir using a bleeder
bottle. Otherwise, especially if reservoir has been topped off, fluid will overflow
and cause damage.
-- Vehicle Diagnostic Tester, connecting and selecting functions VAS 5051, CONNECTING AND
-- Select the electromechanical parking brake and the function "Moving piston of parking brake motor out and
in".
-- Drive the pistons back using the Vehicle Diagnostic Tester.
-- Remove the parking brake motor without disconnecting the connector.
-- Insert V.A.G 1869/2.
-- Remove the brake line from the brake hose and brake caliper.
-- Remove both bolts from brake caliper, counterhold on guide pin when doing this.
Installing
 Brake pads sit in retaining springs on the brake carrier.
-- Secure brake caliper on brake carrier using new self-locking bolts.

NOTE: Ring groove and contact surface of parking brake motor must be clean.
-- Install new seal.
-- Turn the spindle back slightly the with help of a TORX insert T45, until the parking brake motor can be
correctly positioned.
-- Carefully set the parking brake motor in place, paying attention to the seat of the seal.
-- Rotate the parking brake motor until the bolt hole and threads are aligned.
NOTE: Make sure that the parking brake motor is seated flush against the brake
caliper. Do not, under any circumstances, pull the parking brake motor against
the brake caliper using the bolts.
-- Set the bolts in place by hand and then tighten.
-- Screw brake line on brake caliper.
After driving the pistons out with the Vehicle Diagnostic Tester, a basic setting of the brake system must be
performed.
-- Perform the basic setting of the brake system with the Vehicle Diagnostic Tester.
-- Install wheels.
WHEELS .
NOTE: Check brake fluid level.
Hex bolt, brake caliper to brake carrier 35 Nm
 Use new bolts!

Brake line to brake caliper 14 Nm
Parking brake motor to brake caliper 12 Nm
ELECTROMECHANICAL PARKING BRAKE CONTROL MODULE
NOTE: The Electromechanical Parking Brake Control Module -J540- and the ESP
Sensor Unit -G419- are installed in one housing under the center console.
After replacing the electromechanical parking brake control module with the ESP sensor unit , the ABS control
module -J104- must be coded and a basic setting of the "Brake system" (electromechanical parking brake) must
be performed.
WARNING: Excessive shaking (for example, dropping, impact) may damage the ESP
sensor unit. ESP Sensor Unit must then no longer be used.
Removing
-- Remove the center console. Refer to Removal and Installation .
-- Remove the three nuts -arrows-.
-- Disconnect the connector -1- from electromechanical parking brake control module.
Fig. 25: Identifying ESP Sensor Unit Connector And Nuts

-- Remove electromechanical parking brake control module.
Installing
When installing electromechanical parking brake control module make sure it is correctly seated in its mounting
and is free of stress.
NOTE: Do not use the securing nuts to forcibly position the electromechanical parking
brake control module.
-- Tighten the nuts to 9 Nm.
-- Code the ABS control module with the Vehicle Diagnostic Tester in "Guided Fault Finding".
A Steering Angle Sensor -G85-, Transverse Acceleration Sensor -G200-, Brake Pressure Sensor 1 -G201- and
Longitudinal Acceleration Sensor -G251- basic setting must be done.
-- Perform basic setting for "Brake system" (Electromechanical Parking Brake).
Vehicle Diagnostic Tester, connecting and selecting functions, refer to VAS 5051, CONNECTING AND
PARKING BRAKE MOTOR
Removing
NOTE: Ignition must be switched off for at least 30 seconds before disconnecting the
connector.
-- Pull connector -1- off from parking brake motor.

Fig. 26: Identifying Parking Brake Motor Connector

-- Remove both inner bolts -arrows- on the parking brake motor.

Fig. 27: Identifying Parking Brake Motor And Torx Bolts

-- Pull off parking brake motor from brake caliper.
-- Remove the seal.
NOTE: Make sure that the ring groove of the seal and the contact surface of the
parking brake motor do not become damaged.
-- Clean the ring groove and the contact surface of the parking brake motor.
Installing
-- Lightly coat the new gasket with brake fluid and then install it.
Fig. 28: Identifying Installation Of Sealing Ring

-- Turn the spindle back slightly the with help of a TORX insert T45 -A- , until the parking brake motor can be
correctly positioned.
Fig. 29: Identifying Spindle Turned Back Slightly With Help Of Torx Insert T45
CAUTION: Do not remove the gasket when assembling the parking brake motor.
-- Carefully set the parking brake motor in place, paying attention to the seat of the seal.
-- Rotate the parking brake motor until the bolt hole and threads are aligned.
NOTE: Make sure that the parking brake motor is seated flush against the brake
caliper. Do not, under any circumstances, pull the parking brake motor against
the brake caliper using the bolts.
-- Set the bolts -arrows- in place by hand and then tighten.
Fig. 30: Identifying Parking Brake Motor And Torx Bolts

-- Install connector.
-- Perform basic setting of brake system.

-- Vehicle Diagnostic Tester, connecting and selecting functions, refer to VAS 5051, CONNECTING AND
BRAKE PEDAL AND BRAKE BOOSTER, SEPARATING AND CONNECTING
Separating
-- Remove trim on driver side. Refer to Removal and Installation .
-- First press brake pedal in direction of brake booster and hold.
Fig. 31: Identifying Separation Of Brake Pedal From Brake Booster

2 - Pressure rod
3 - Retaining lugs
-- Insert T10159 and pull in direction of driver seat. When doing this, counter-hold on brake pedal. (At this
moment the pedal must not be allowed to move backward). The mounting retaining lugs -3- will thereby be
pressed off the ball head of the push rod -2-.
The process of separating the brake pedal from the brake booster is shown with the pedal assembly removed.
-- Pull T10159 and brake pedal together toward the driver seat. (The brake pedal will thereby be pulled off the
ball head of the push rod).
Connecting
-- Hold the push rod ball head in front of the mount and push the brake pedal toward the brake booster until the
ball head engages audibly.
Fig. 32: Identifying Brake Pedal, Joining To Brake Booster

SPECIAL TOOLS


Fig. 34: Identifying Piston Resetting Tool T10145


Fig. 35: Identifying Brake Pedal Actuator V.A.G 1869/2

 Ring spanner insert AF 21 T10035
Fig. 36: Identifying Socket And Key T10035



Accessories & Equipment Passenger Protection, Airbags, Seat Belts
Passenger Protection, Airbags, Seat Belts
69 PASSENGER PROTECTION, AIRBAGS, SEAT BELTS

SEAT BELTS
AIRBAG, BELT TENSIONER AND BATTERY CUT-OUT UNITS, GENERAL SAFETY PRECAUTIONS
WARNING:  Pyrotechnic components always contain chemicals, which turn into

an expanding gas when detonated. There is also additional stored
gas available for discharge.
 This gas is contained under high pressure and is stored in a
pressurized gas container.
 An electric/mechanical igniter ignites the pyrotechnic components.
 Testing, removing, installing and repair work may only be performed
by qualified personnel.
 There is no change interval for airbag units.
 Never test with a test light, volt meter or ohm meter.
 The pyrotechnic components may be check only when they are
installed and with a Volkswagen approved vehicle diagnosis, testing
and information system.
 When working on pyrotechnic components and on the Airbag
control module, the battery ground cable must be disconnected
when the ignition is switched on. Then cover the negative pole.
 Wait for 10 seconds after disconnecting the battery.
 Connect the battery with the ignition SWITCHED ON. No one should
be sitting inside the vehicle when doing this. Exception: vehicles
with the battery inside the passenger compartment. In this case, stay
away from the airbags and the safety belts.
 Wash hands after touching ignited restraint system pyrotechnic
components.
 Pyrotechnic components may not be opened nor repaired; always
use new parts (risk of injury).
 Pyrotechnic components that have fallen onto a hard surface or
show signs of damage must not be installed in vehicle.
 Before handling pyrotechnic components of the restraint system, for
example, before disconnecting the electrical harness connector, the
relevant person must discharge static electricity. Touching
grounded metal parts, for example, touching the door striker, will
discharge the static electricity.

 Pyrotechnic components should be installed immediately upon
removal from shipping package.
 If the work must be stopped for awhile, put the pyrotechnic
component back into its shipping package.
 Do not leave the pyrotechnic component out unattended.
 Do not use any grease or cleaning solutions on pyrotechnic
components.
 Pyrotechnic components must not be exposed to temperatures over
100 °C, even for a short time.
BELT TENSIONER, SPECIAL INSTRUCTIONS
WARNING:  The open end of the belt tensioner should never be pointed at
anyone.
 Use extreme care when removing and installing belt tensioners.
Handling belt tensioner units improperly is very dangerous and
could result in serious personal injury.
 When connecting a belt tensioner, all mechanical parts, including
those in the three-point seat belt, must be secured correctly. If it is
not possible to connect the belt tensioner because of insufficient
space, the seat belt must be rolled up completely prior to
connection. In this case there is no increased safety risk, if all other
safety instructions are followed. In particular, this includes the notes
regarding the disconnection of the battery and the static discharging
of the technician prior to connection of the belt tensioner.
 Even after a crash, it is possible that the belt tensioner did ignite, but
the belt force limiter did NOT ignite. These parts shall be treated like
non-ignited parts.
AIRBAG, BELT TENSIONER AND BATTERY CUT-OUT UNITS, STORAGE, TRANSPORTING AND DISPOSAL
WARNING:  Storage must conform to national legislation.

 Transport must conform to national and international guidelines,
whereby packaging, identification and shipping documents are
controlled to the greatest detail.
 Undeployed pyrotechnic components must be disposed of in an
orderly manner, conforming to national legislation, in their original
packaging. Direct questions to Volkswagen of America.
 Only pyrotechnic components, which have been ignited completely,
may be disposed in industrial waste.
FRONT SEAT BELTS ASSEMBLY OVERVIEW

Fig. 1: Identifying Front Seat Belts Remove/Install Components

1. Bolt
 40 Nm
2. Belt anchor
3. Bolt
 40 Nm
4. B-pillar belt retractor

5. Wiring harness
6. Screws
 4.5 Nm
7. Belt guide
 Note location
8. Bolt
 40 Nm
9. Belt guide ring

10. Belt latch
 Removing, refer to FRONT SEAT BELT LATCHES
REAR OUTER SEAT BELTS WITH BELT TENSIONER ASSEMBLY OVERVIEW, SEDAN
Fig. 2: Identifying Rear Outer Seatbelts With Belt Tensioner, Sedan Remove/Install Components
1. Bolt
 40 Nm
2. Belt guide ring
3. Bolt
 40 Nm
4. Belt tensioner
5. Connector, wiring harness
6. Bolt
 40 Nm
7. Automatic belt retractor
REAR OUTER SEAT BELTS WITHOUT BELT TENSIONER ASSEMBLY OVERVIEW. SEDAN
Fig. 3: Identifying Rear Outer Seatbelts Without Belt Tensioner. Sedan Remove/Install Components
1. Bolt
 40 Nm
2. Belt anchor
3. Bolt
 40 Nm
REAR OUTER SEAT BELTS WITH BELT TENSIONER ASSEMBLY OVERVIEW, WAGON
Fig. 4: Identifying Rear Outer Seat Belts With Belt Tensioner, Wagon Remove/Install Components
1. Bolt
 40 Nm
2. Belt anchor
3. Bolt
 40 Nm
4. Belt tensioner
5. Wiring harness
6. Screws
 Quantity: 2
 8 Nm
7. Bracket
 Only for vehicles with screen separator wall
8. Screws
 Quantity: 2
 6 Nm
9. Belt guide
10. Bolt
 40 Nm
REAR OUTER SEAT BELTS WITHOUT BELT TENSIONER ASSEMBLY OVERVIEW, WAGON
Fig. 5: Identifying Rear Outer Seat Belts Without Belt Tensioner, Wagon Remove/Install Components
1. Bolt
 40 Nm
2. Belt anchor
3. Screws
 Only for vehicles with screen separator wall
 Quantity: 2
 8 Nm
4. Bracket
5. Screws
 Quantity: 2
 6 Nm
6. Belt guide
7. Bolt
SEAT BELTS, INSPECTING
GENERAL INFORMATION
WARNING: After every accident the seat belt system must be inspected
systematically. If damage is determined when inspecting the check
points, customer must be informed regarding necessity of changing belts.
Check points:
 Belt Webbing, Checking

 Retractor, Checking Locking Function
 Belt Latch, Inspecting Visually
 Belt Latch Function, Testing
 Belt Guide Rings and Locking Tongue, Checking
 Checking the mounting components and mounting points
BELT WEBBING, CHECKING
-- Pull belt completely out of retractor or lap belt adjustment tongue.
-- Inspect the belt webbing for contamination and, if necessary, wash with mild soap solution also refer to the
appropriate operating information.
 If one of the types of damage (1 or 2) shown in the following is detected on a vehicle which has been in
an accident - seat belt must be replaced completely with seat belt latch and seat belt height adjuster.
 If one kind of damage under points 1, 2, 3 and 4 is detected on a vehicle which has not been in an
accident, only the damaged seat belt needs to be replaced.
 Belt webbing cut, torn or chafed.
Fig. 6: Identifying Belt Webbing Cut, Torn Or Chafed

 Webbing loops on belt edge torn.

Fig. 7: Identifying Belt Webbing - Webbing Loops On Belt Edge Torn

 Burn marks from cigarettes or similar.

Fig. 8: Identifying Burn Marks From Cigarettes Or Similar

 One side of belt edge deformed or area of belt edge is wavy.
Fig. 9: Identifying Belt Edge Deformed On One Side And/Or Belt Edge Area Is Wavy
RETRACTOR, CHECKING LOCKING FUNCTION
The belt retractor has two locking functions.
 The first locking function is initiated by belt being jerked out of the retractor (belt extraction
acceleration).
Checking
-- Pull belt webbing out of retractor with a firm jerk.
 No locking function - replace compete seat belt with belt latch.

 If difficulties are experienced when pulling out or retracting belt, first check whether position of retractor
has been altered.
 The second locking function is initiated by change in vehicle velocity (vehicle-dependent locking
function). For this, the vehicle must be moved on a level surface.
Checking
-- Fasten seat belt.
-- Accelerate vehicle to 12 mph (20 km/h) and then perform a full braking maneuver with foot brake.
 If the locking mechanism does not lock the seat belt during the braking maneuver, the complete seat belt
with seat belt latch must be replaced.
WARNING: For safety reasons, road test should be carried out on traffic-free stretch
to ensure that other motorists/pedestrians etc. are not endangered.
BELT LATCH, INSPECTING VISUALLY
-- Inspect the seat belt latch for cracks and chipping.
 If damaged, replace the complete seat belt and the seat belt latch.
BELT LATCH FUNCTION, TESTING
Check the seat belt latch:
-- Slide the latch tongue into the belt latch until it clicks in place. Pull on the belt webbing strongly to make sure
the latch mechanism is engaged.
 If locking tongue fails to engage properly into the seat belt latch even once during at least 5 tests, replace
complete seat belt with seat belt latch.
Check release mechanism:
-- Press the seat belt latch to release the seat belt.
-- When belt is slack, locking tongue must spring out of seat belt latch on its own.
 Perform the test at least five times. If the latch tongue does not spring out even one time, replace the
entire seat belt, including the belt latch.
WARNING: Under no circumstances may grease be used to eliminate noise or

stiffness at belt buckle buttons.
BELT GUIDE RINGS AND LOCKING TONGUE, CHECKING
Plastic-coated fittings face the load (seat belt on during accident) of the belt system parallel to the small grooves
(wear created by significant usage, in contrast, is recognizable on the basis of the smooth, stripe-free abrasion).
-- Inspect for deformation, chipping and cracks in plastic.
 If scoring and/or damage is discovered, replace complete seat belt with seat belt latch.
CHECKING MOUNTING COMPONENTS AND MOUNTING POINTS
 Latch bracket deformed (stretched)

 Height adjuster not functional
 Mounting points (seat, pillar, vehicle floor) distorted or thread damaged
 If damage is discovered on these components, replace complete seat belt with seat belt latch.
 Replace anchorage points.
NOTE: In damage is discovered that is not accident-related, for example, wear, replace
the particular part which is damaged.
LATCH CHILD SEAT ANCHORS, INSPECTING AFTER AN ACCIDENT
Inspection Points
 After an accident, child seat anchors must be inspected for damage and deformation.
 Child seat anchors that are welded into the body cannot be repaired or corrected.
 Child seat anchors that are bolted to the body must be replaced if damaged or deformed.
AIRBAG
AIRBAG COMPONENT LOCATION OVERVIEW

Fig. 10: Identifying Location Overview: Airbag Components

1. Driver airbag unit

 Removing, refer to AIRBAG UNIT, DRIVER SIDE
2. Airbag indicator lamp -K75-

3. Front passenger airbag unit
 Removing, refer to PASSENGER AIRBAG UNIT
4. Front passenger side curtain airbag, sedan

 Removal, refer to (up to November 2009); refer to HEAD CURTAIN AIRBAG, SEDAN UP TO
NOVEMBER 2009
 Removal, refer to (From November 2009); refer to HEAD CURTAIN AIRBAG, SEDAN FROM
NOVEMBER 2009
5. Front passenger side airbag
 Removing, refer to FRONT SIDE AIRBAG
6. Rear passenger side airbag

 Removing, refer to REAR SIDE AIRBAG
7. Driver side curtain airbag, sedan

 Removal (up to November 2009); refer to HEAD CURTAIN AIRBAG, SEDAN UP TO
NOVEMBER 2009
 Removal (From November 2009); refer to HEAD CURTAIN AIRBAG, SEDAN FROM
NOVEMBER 2009
8. Rear driver side airbag
 Removing, refer to REAR SIDE AIRBAG
9. Front driver side airbag

 Removing, refer to FRONT SIDE AIRBAG
10. Airbag control module -J234-

 Removing, refer to AIRBAG CONTROL MODULE
11. Diagnostic connector
AIRBAG, BELT TENSIONER AND BATTERY CUT-OUT UNITS SAFETY PRECAUTIONS
WARNING:  Pyrotechnic components always contain chemicals, which turn into

an expanding gas when detonated. There is also additional stored
gas available for discharge.
 This gas is contained under high pressure and is stored in a
pressurized gas container.
 An electric/mechanical igniter ignites the pyrotechnic components.
 Testing, removing, installing and repair work may only be performed
by qualified personnel.
 There is no change interval for airbag units.
 Never test with a test light, volt meter or ohm meter.
 The pyrotechnic components may be check only when they are
installed and with a Volkswagen approved vehicle diagnosis, testing
and information system.
 When working on pyrotechnic components and on the Airbag
control module, the battery ground cable must be disconnected
when the ignition is switched on. Then cover the negative pole.
 Wait for 10 seconds after disconnecting the battery.
 Connect the battery with the ignition SWITCHED ON. No one should
be sitting inside the vehicle when doing this. Exception: vehicles
with the battery inside the passenger compartment. In this case, stay
 Wash hands after touching ignited restraint system pyrotechnic

components.
 Pyrotechnic components may not be opened nor repaired; always
use new parts (risk of injury).
 Pyrotechnic components that have fallen onto a hard surface or
show signs of damage must not be installed in vehicle.
 Before handling pyrotechnic components of the restraint system, for
example, before disconnecting the electrical harness connector, the
relevant person must discharge static electricity. Touching
grounded metal parts, for example, touching the door striker, will
discharge the static electricity.
 Pyrotechnic components should be installed immediately upon
removal from shipping package.
 If the work must be stopped for awhile, put the pyrotechnic
component back into its shipping package.
 Do not leave the pyrotechnic component out unattended.
 Do not use any grease or cleaning solutions on pyrotechnic
components.
 Pyrotechnic components must not be exposed to temperatures over
100 °C, even for a short time.
DRIVER AND PASSENGER AIRBAG ADDITION SAFETY PRECAUTIONS
WARNING:  Store driver and passenger airbag units in their uninstalled

condition so that the cushioned side faces upward.
SIDE AIRBAG MODULE ADDITION SAFETY PRECAUTIONS
WARNING:  Place any removed head curtain airbag modules back in their
transport containers or on a clean and even surface with a cloth
underneath.
 They may be folded as long as this does not damage them,
especially the protective sleeve.
 Handle head curtain airbag modules with great care when removing
and installing them to prevent causing any damage.
 As long as the gas generator is NOT attached, hold it securely when
transporting, removing, installing, etc.
 Always replace damaged pillar trim panels, never repair.
 After body repairs, inspect the body for weld splatter, deformations
and chafing areas near the head curtain airbag (compare with
opposite side if necessary).
 If a deployed head curtain airbag is replaced, the headliner, door
seals with weather stripping, curtain airbag guides, grab handle

brackets, and the A, B, C and (if equipped) D-pillar trim must be
replaced. The interior reading lights (rear), roof grab handles and the
roof end strip must be replaced if damaged.
AIRBAG, BELT TENSIONER AND BATTERY CUT-OUT UNITS, STORAGE, TRANSPORTING AND DISPOSAL
WARNING:  Storage must conform to national legislation.

 Transport must conform to national and international guidelines,
whereby packaging, identification and shipping documents are
controlled to the greatest detail.
 Undeployed pyrotechnic components must be disposed of in an
orderly manner, conforming to national legislation, in their original
packaging!
 Only pyrotechnic components, which have been ignited completely,
may be disposed in industrial waste.
PASSENGER OCCUPANT DETECTION SYSTEM FOR PASSENGER AIRBAG DEACTIVATION, PASSAT AND
PASSAT WAGON
PASSENGER OCCUPANT DETECTION SYSTEM SAFETY PRECAUTIONS
Seat occupied recognition controls automatic passenger airbag deactivation.
This equipment is only installed on vehicles released in the USA and Canada.
CAUTION:  After every repair on the passenger seat in which the seat and/or
backrest cover was "disengaged" basic setting on passenger
occupant detection system control module - J706- must be
performed. Perform the basic setting with a Vehicle Diagnosis Tester
that has "Guided Fault Finding".
 Do not bend the passenger occupant detection system mat.
 A leaking mat must be replaced (repair kit).
 Do not bend the passenger occupant detection system pressure
hose.
 Seat occupied recognition (repair kit) components must not fall on
hard surfaces.
 Seat occupied recognition components must not come in contact
with grease.
 There is the danger that the seat occupied recognition components
may be damaged by sharp objects when working on the seat. This
danger must be minimized.
 The mat, the fleece and various covers must be fitted to be free of
folds.
 When installing, ensure upholstery and cover are installed correctly.
 Replace all upholstery clips and clip connectors from cover, ensure it
is positioned correctly on seat when doing so.
 System basic setting is only possible at temperatures between 0 °
Celsius and + 40 Celsius.
 Make sure that no objects are placed on seat when performing basic
setting.
 Using a seat cover or placing a cushion on the seat will impair the
passenger occupant detection system as well as the effectiveness of
the airbag system.
 Do not install any clips near the mat for the passenger occupant
detection system. This also applies to changes to the seat wiring
harness.
AFTER AN ACCIDENT WITH BELT TENSIONER AND/OR AIRBAG DEPLOYMENT
 The passenger occupant detection system control module - J706- must be used to restore the basic setting
whenever a passenger airbag and/or seatbelt tensioner has been deployed. To restore the basic setting, use
a Vehicle Diagnosis Tester that is also able to run "Guided Fault Finding".
 If the seat rail and/or the seat pan has to be replaced because it is deformed after an accident, then the
"repair kit for the passenger occupant detection system" must be used for replacing the passenger
occupant detection system. Afterward, the passenger occupant detection system -J706- must be used to
restore the basic setting. To restore the basic setting, use a Vehicle Diagnosis Tester that is also able to
run "Guided Fault Finding".
PASSENGER OCCUPANT DETECTION SYSTEM ASSEMBLY OVERVIEW

Fig. 11: Identifying Assembly Overview: Passenger Occupant Detection System (PODS) (USA)
1. Wiring harness, seat

 No long necessary to removed due to technical update.
2. Seat frame
3. Seat Occupied Recognition Control Module -J706-
4. Seat cushion
 Must not be separated from mat for seat occupied recognition.
5. Passenger occupant detection system mat

 The pressure hose must not be disconnected from the seat occupied recognition mat.
Note installation position


7. Retaining plate
 White
 No long necessary to removed due to technical update.
PASSENGER OCCUPANT DETECTION SYSTEM REPAIR KIT COMPONENTS
If a malfunction does occur in one part of the system, then the repair kit must be used to replace it. This repair
kit is already coordinated to dovetail with the characteristics of the vehicle under repair, and includes the
following parts:
 Seat cushion with the passenger occupant detection system mat and pressure hose
 Passenger occupant detection system pressure sensor -G452-.
 Passenger occupant detection system control module -J706-.
WARNING: Never use repair set components separately.
Make sure that only parts that have been calibrated as an entire entity are
installed. These parts include the mat for passenger occupant detection
system, the passenger occupant detection system control module -J706-
and the seat cushion.
WARNING: Read and follow the instructions for usage that are included on the
packaging. Mistakes could cause the system to malfunction.
PASSENGER OCCUPANT DETECTION SYSTEM FOR PASSENGER AIRBAG DEACTIVATION, PASSAT CC
PASSIVE OCCUPANT DETECTION SYSTEM SAFETY PRECAUTIONS
Seat occupied recognition controls automatic passenger airbag deactivation.
This equipment is only installed on vehicles released in the USA and Canada.
CAUTION:  After every repair on the passenger seat in which the seat and/or
backrest cover was "disengaged" basic setting on passenger
occupant detection system control module - J706- must be
performed. Perform basic setting with a diagnostic tester that has
"Guided Fault Finding".
 Do not bend the passenger occupant detection system mat.
 A leaking mat must be replaced (repair kit).
 Do not bend the passenger occupant detection system pressure
hose.
 Seat occupied recognition (repair kit) components must not fall on
hard surfaces.
 Seat occupied recognition components must not come in contact
with grease.
 There is the danger that the seat occupied recognition components
may be damaged by sharp objects when working on the seat. This
danger must be minimized.
 The mat, the fleece and various covers must be fitted to be free of
folds.
 When installing, ensure upholstery and cover are installed correctly.
 Replace all upholstery clips and clip connectors from cover, ensure it
is positioned correctly on seat when doing so.
 System basic setting is only possible at temperatures between 0° and
+40° Celsius.
 Make sure that no objects are placed on seat when performing basic
setting.
 Use of seat covers, such as cushions or something similar, impairs
seat occupied recognition function and airbag system effectiveness.
 Do not install any clips near the mat. This also applies to changes to
the seat wiring harness.
AFTER AN ACCIDENT WITH BELT TENSIONER AND/OR AIRBAG DEPLOYMENT
 The passenger occupant detection system control module - J706- must be used to restore the basic setting
whenever a passenger airbag and/or seatbelt tensioner has been deployed. To restore the basic setting, use
a Vehicle Diagnosis Tester that is also able to run "Guided Fault Finding".
 If the seat rail and/or the seat pan has to be replaced because it is deformed after an accident, then the
"repair kit for the passenger occupant detection system" must be used for replacing the passenger
occupant detection system. Afterward, the passenger occupant detection system -J706- must be used to
restore the basic setting. To restore the basic setting, use a Vehicle Diagnosis Tester that is also able to
run "Guided Fault Finding".
SEAT OCCUPIED RECOGNITION ASSEMBLY OVERVIEW
WARNING: The passenger occupant detection system service kit is precalibrated and
must not be disconnected. The service kit consists of:
 Seat Occupied Recognition Control Module -J706-

 Passenger occupant detection system pressure sensor -G452-
 Passive Occupant Detection System Mat
 Seat cushion
WARNING: Observe safety precautions when working on seat occupied recognition.

Refer to PASSIVE OCCUPANT DETECTION SYSTEM SAFETY
PRECAUTIONS.
NOTE: The passenger occupant detection system is only installed in the front
passenger side.
Fig. 12: Identifying Assembly Overview: Passenger Occupant Detection System

1. Passenger occupant detection system pressure sensor -G452-

 Is a component with the seat occupied recognition mat
 Removing and Installing, refer to PASSIVE OCCUPANT DETECTION SYSTEM
 The connector may be disconnected for removing and installing

2. Seat pan
3. Retaining clip
4. Cushion
 For seat pan
 Do not separate from the seat occupied recognition mat -6-
5. Retaining clip
 Do not release
6. Mat
 For seat occupied recognition
 Is a component with the seat occupied recognition pressure sensor -G452-
 Do not separate from the seat pan upholstery -4-
7. Mount
 For passenger occupant detection system control module -J706-
8. Spreader pin
 For securing the mount to the seat pan
9. Electrical wiring harness

 Do not separate from the passenger occupant detection system pressure sensor -G452- and
passenger occupant detection system control module -J706-
10. Front passenger seat position sensor -G554-
 Is a component of the electrical wiring harness -9-
 Removing and Installing, refer to SEAT POSITION SENSOR
11. Seat Occupied Recognition Control Module -J706-

 Do not disconnect the electrical connector.
SEAT BELTS
FRONT SEAT BELTS
Removing
WARNING:  Read the Safety Instructions for working with airbags, belt
tensioners and battery cut-out units. Refer to AIRBAG, BELT
TENSIONER AND BATTERY CUT-OUT UNITS, GENERAL SAFETY
PRECAUTIONS.
 Pay attention especially to the instructions for belt tensioners. Refer
to BELT TENSIONER, SPECIAL INSTRUCTIONS.
-- Remove the B-pillar lower trim. Refer to LOWER B-PILLAR TRIM
NOTE: The bolt is micro-encapsulated and must be replaced every time it is loosened.
Before installing the new screw, threads on nut must be cleaned and cut again
if necessary.
-- Remove screw -3- (40 Nm) and remove automatic belt retractors -4- from B-pillar.
WARNING: Electrostatic discharges can lead to an unintended deployment of the

seatbelt. Therefore, the technician must discharge static electricity from
the body before separating the ignition and ground wiring. This is done
for example, by briefly touching the body or the door striker pin.
-- Disconnect wiring harness from belt inertia reels.
-- Remove the connector from the wiring harness -5- out of mount in body.
-- Remove bolts -6- (4.5 Nm) and belt guide -7-.
-- Remove bolt -8- (40 Nm) and remove belt relay -9- from belt height adjuster.
Fig. 13: Identifying Front Seat Belts Remove/Install Components

Installation
-- Connect the battery. Refer to [For engine(s) BPY,BLV,CCTA,CBFA] Removal and Installation
FRONT SEAT BELTS, PASSAT CC
Fig. 14: Identifying Assembly Overview: Left Front Seat Belt

1. Bolt
 40 Nm
2. Belt anchor
3. Bolt
 40 Nm
4. B-pillar belt retractor

5. Screws
 Quantity: 2
6. Belt guide
 Note location
7. Bolt
 40 Nm
8. Belt guide ring
Removing
PRECAUTIONS.
-- Remove the upper B-pillar trim from the brackets LOOSENING UPPER B-PILLAR TRIM FROM
MOUNTS AND SECURING, PASSAT CC .
-- Remove the B-pillar lower trim. Refer to LOWER B-PILLAR TRIM
-- Remove the bolt -1- (40 Nm) and remove the belt anchor -2- from body.
-- Remove screw -3- (40 Nm) and remove automatic belt retractors -4- from B-pillar.

-- Disconnect wiring harness from belt inertia reels.
-- Remove bolts -5- (4.5 Nm) and belt guide -6-.
Fig. 15: Identifying Bolts, Belt Guide, Belt Relay And Belt Height Adjuster
Installation
FRONT SEAT BELT HEIGHT ADJUSTER
Removing
NOTE: Belt anchor does not need to be removed.
-- Remove bolt -3- (20 Nm) and separate belt height adjuster -4- from mounting in carrier plate.
Fig. 16: Identifying Front Seat Belt Height Adjuster Remove/Install Components
Installation
FRONT SEAT BELT HEIGHT ADJUSTER, PASSAT CC
Removing
Fig. 17: Identifying Bolt And Belt Relay

-- Remove bolt -1- (20 Nm) and separate belt height adjuster -2- from mounting in carrier plate.
Fig. 18: Identifying Bolt And Belt Height Adjuster

Installation
FRONT SEAT BELT LATCHES
NOTE: The following describes removing and installing the seat belt latch on the left
seat. Removing and installing the right seat belt latch is identical.
Removal and installation procedure for seat belt buckles shown in illustration
applies to all seat belt buckles in vehicle.
Removing
-- Remove the front seat. Refer to FRONT SEAT
-- If present, disconnect wiring harness -1- from seat frame.
NOTE: The screw is micro-encapsulated and must be replaced every time it is

loosened.
Before new bolts are installed, the thread of the corresponding nut must be
cleaned.
-- Remove the seat belt latch -3- from the mount in the seat rail -arrow-.
Fig. 19: Identifying Front Belt Latch Remove/Install Components

Installation
REAR OUTER SEAT BELTS WITH BELT TENSIONER, SEDAN
Removing
PRECAUTIONS.
-- Remove rear backrest:
 Left: LEFT REAR BACKREST

 Right: RIGHT REAR BACKREST
 With rear side airbag, refer to SIDE UPHOLSTERY WITH SIDE AIRBAG
 Without rear side airbags, refer to SIDE UPHOLSTERY WITHOUT SIDE AIRBAG
-- Remove wheel housing trim, refer to WHEEL HOUSING TRIM .
-- Remove luggage compartment side trim (sedan):
 Left: LEFT LUGGAGE COMPARTMENT SIDE TRIM, SEDAN

 Right:RIGHT LUGGAGE COMPARTMENT SIDE TRIM, SEDAN
-- Remove rear shelf.
 Vehicles with sun shade: REAR SHELF, WITH SUN SHADE

 Vehicles without sun shade: REAR SHELF, WITHOUT SUN SHADE


-- Disconnect connector, wiring harness, -5-.
-- Remove the bolt -1- and remove seat belt guide -2- from body.
-- Remove bolt -3- and remove belt tensioner -4- from mount.
-- Remove the felt cover from belt inertia reels -7-.
-- Remove bolt -6- and remove automatic belt retractor -7- from mount.
Fig. 20: Identifying Rear Outer Seatbelts With Belt Tensioner, Sedan Remove/Install Components
Installation
REAR OUTER SEAT BELTS WITHOUT BELT TENSIONER. SEDAN
Removing
 Left: LEFT REAR BACKREST

 Right: RIGHT REAR BACKREST

-- Remove wheel housing trim. Refer to WHEEL HOUSING TRIM .
-- Remove luggage compartment side trim:
 Left: LEFT LUGGAGE COMPARTMENT SIDE TRIM, SEDAN

 Right: RIGHT LUGGAGE COMPARTMENT SIDE TRIM, SEDAN
-- Remove rear shelf. Refer to REAR SHELF, WITHOUT SUN SHADE
-- Remove the bolt -1- and remove seat belt end fitting -2- from body.
-- Remove the felt cover from belt inertia reels -4-.
Fig. 21: Identifying Rear Outer Seatbelts Without Belt Tensioner. Sedan Remove/Install Components
Installation
REAR SEAT BELTS, PASSAT CC
Removing and installing seat belts equipped with a belt tensioner is described.
Removing and installing seat belts not equipped with a belt tensioner is
identical.
Fig. 22: Identifying Assembly Overview: Rear Seat Belts

1. Bolt
40 Nm
3. Clip
 Replace if damaged
4. Bolt
 6 Nm
5. Belt guide
6. Connector with clip
 If damaged, replace the clip
7. Bolt
 40 Nm
8. Belt anchor
Removing
PRECAUTIONS.
-- On vehicles equipped with a belt tensioner, disconnect the vehicle battery [For engine(s)

-- Remove the C-pillar trim.
 with sun shade: C-PILLAR TRIM, WITH SUN SHADE, PASSAT CC

 without sun shade: C-PILLAR TRIM WITHOUT SUN SHADE, PASSAT CC
-- Remove the rear shelf:
 with sun shade: REAR SHELF WITH SUN SHADE, PASSAT CC

 without sun shade: REAR SHELF WITHOUT SUN SHADE, PASSAT CC
-- Remove the bolt -7- and remove seat belt guide -8- from body.

-- Disconnect the wiring harness and loosen the connector and clip -6-.
-- Remove the bolt -4- and then remove the seat belt guide -5-.
-- Remove the clip -3- from the body.
Fig. 23: Identifying Bolts, Seat Belt Guide, Clip And Automatic Belt Retractor
Installation
REAR OUTER SEAT BELTS WITH BELT TENSIONER, WAGON
Removing
PRECAUTIONS.
-- Fold the right or left bench seat forward.
 Left LEFT REAR BACKREST

 Right RIGHT REAR BACKREST
-- Remove roof end strip, wagon ROOF END STRIP, WAGON
-- Remove lock carrier cover (wagon) LOCK CARRIER COVER, WAGON



-- Disconnect connector, wiring harness, -5-.

-- Remove bolt -3- and remove belt tensioner -4- from mount.
-- Remove bracket -7-.
All vehicles
-- Remove belt guide -9-.
Fig. 24: Identifying Rear Outer Seat Belts With Belt Tensioner, Wagon Remove/Install Components
Installation
REAR OUTER SEAT BELTS WITHOUT BELT TENSIONER, WAGON
Removing
-- Fold the right or left bench seat forward.
 Left LEFT REAR BACKREST

 Right RIGHT REAR BACKREST
-- Remove lock carrier cover, wagon. Refer to LOCK CARRIER COVER, WAGON


-- Remove the bolt -1- and remove seat belt end fitting -2- from body.
-- Remove bracket -4-.
All vehicles
-- Remove belt guide -6-.
Fig. 25: Identifying Rear Outer Seat Belts Without Belt Tensioner, Wagon Remove/Install Components
Installation
CENTER REAR SEAT BELT
Removing
Sedan

Wagon
All vehicles
-- Remove right cover and upholstery backrest. Refer to RIGHT REAR BACKREST, COVER AND
UPHOLSTERY
-- Remove hex nut -1- (40 Nm) and remove automatic belt retractors -2- from backrest.
-- Thread seat belt -4- through slit in belt guide -3-.
-- Thread seat belt -4- and seat belt latch -5- through opening in backrest.
Fig. 26: Identifying Center Rear Seat Belt Remove/Install Components

Installation
REAR DOUBLE BELT LATCH
Removing
Sedan

Wagon
All vehicles
NOTE: To provide a better overview, backrests are not depicted in the illustration.
-- Remove screw -1- (40 Nm) and remove double latch -2- from body.
Fig. 27: Identifying Rear Double Belt Latch Remove/Install Components

Installation
REAR SEAT BELT LATCHES, PASSAT CC
Removing
-- Remove the bolt -1- and -2- (40 Nm) and then remove the seat belt latches -3- and -4- from the body.
Fig. 28: Identifying Bolts And Seat Belt Latches

Installation
AIRBAG
AIRBAG UNITS, REMOVING AND INSTALLING AFTER AN ACCIDENT
Accident with Airbag Deployment
Always replace the following components after an accident when airbag has deployed:
 All deployed airbag units.

 Support for passenger module where passenger airbag deployed.
 Return ring with slip ring, if driver side airbag deployed.
 All seat belts with deployed seat belt tensioners.

 If needed (visual inspection), the following must also be replaced: all faulty components.
Accident without Airbag Deployment
 If the airbag malfunction indicator lamp (K 75) does not indicate a malfunction, the airbag components
do not need to be replaced. Check seat belts separately.
AIRBAG CONTROL MODULE
Removing
WARNING: When working on the airbag control module, -J234- always not the safety
guidelines when working on airbags, belt tensioners and battery cut-out
units. Refer to AIRBAG, BELT TENSIONER AND BATTERY CUT-OUT
UNITS SAFETY PRECAUTIONS.
-- Grasp, from passenger side footwell out, with Hook for Front End -3370- behind catch -1- from connector -2-
.
-- Pull Hook for Front End -3370- outward and release securing mechanism from connector.
-- Swing bracket -3- back -arrow- and disconnect bracket from control module -4-.
-- Remove three nuts -arrows- (9 Nm).
-- Remove the control module from the vehicle.

Fig. 29: Identifying Hook For Front End, Catch, Connector And Bracket
Installation
WARNING: Make sure that no persons are in the vehicle.
-- If the control unit was replaced, it must be coded. Adapting components (coding). Refer to COMPONENTS,
ADAPTING
AIRBAG UNIT, DRIVER SIDE
NOTE: Removal and installation of airbag unit is described for multi-function steering
wheel.
The screwdriver mentioned in the following should be about 175 mm long and
have a blade width of 7 mm.
Removing
TENSIONER AND BATTERY CUT-OUT UNITS SAFETY
PRECAUTIONS.
 Note the special instructions for the driver and passenger airbags.
Refer to DRIVER AND PASSENGER AIRBAG ADDITION SAFETY
PRECAUTIONS.
-- Adjust steering wheel height to the highest position.
-- Adjust steering wheel depth (reach) so it is in the fully extended position.
-- Turn steering wheel into the position depicted.
-- Insert a screwdriver into hole on rear side of steering wheel until it stops (approx. 8 mm).
-- Turn the screwdriver in the direction of passenger side door -arrow- ; this unlocks the airbag unit locking
frame on the right side of the steering wheel.
-- Turn steering wheel 180° and disengage airbag unit locking mechanism on left side of steering wheel as
described.
-- Turn steering wheel back 90° into center position.
-- Remove airbag unit from steering wheel.

Fig. 30: Identifying Airbag Unit And Steering Wheel


airbag. Therefore the technician must discharge static electricity from the
body before separating the ignition and ground wiring. This is done for
example, by briefly touching the body or the door striker pin.
NOTE: This connector is only installed with multifunction steering wheel.
-- Release connector lock -in direction of arrow- and disconnect airbag connector -2-.
Fig. 31: Identifying Connector Lock And Airbag Connector

Installation
-- Check whether wiring harness -3- is routed as shown in the illustration.
-- Connect the airbag connector -2- into the connector coupling. The connector must audibly engage.
-- Insert connector -1- into connector coupling.
-- Push airbag unit into steering wheel.

Fig. 32: Identifying Connector Lock And Airbag Connector

AIRBAG UNIT, DRIVER SIDE, PASSAT CC
NOTE: The screwdriver mentioned in the following should be about 175 mm long and
have a blade width of 7 mm.
Removing
PRECAUTIONS.
PRECAUTIONS.
-- Adjust steering wheel height to the highest position.
-- Adjust steering wheel depth (reach) so it is in the fully extended position.
-- Turn steering wheel into the position depicted.
-- Insert a screwdriver into hole on rear side of steering wheel until it stops (approx. 8 mm).
-- Turn the screwdriver in the direction of passenger side door -arrow- ; this unlocks the airbag unit locking
frame on the right side of the steering wheel.
-- Turn steering wheel 180° and disengage airbag unit locking mechanism on left side of steering wheel as
described.
-- Turn steering wheel back 90° into center position.
-- Remove airbag unit from steering wheel.

Fig. 33: Identifying Screwdriver To Disassemble Steering Wheel


-- Release the connector lock and remove the airbag connector -2-.

Fig. 34: Identifying Airbag And Connector

Installation
-- Connect the airbag connector -2- into the connector coupling. The connector must audibly engage.
-- Insert connector -1- into connector coupling.
-- Push airbag unit into steering wheel.
-- Check whether airbag unit is engaged on the left and right-hand side of the steering wheel.
Fig. 35: Identifying Airbag And Connector

AIRBAG SPIRAL SPRING/RETURN SPRING WITH SLIP RING
Airbag Spiral Spring/Return Spring With Slip Ring -F138- is a construction-specific component of steering
column switches.
PASSENGER AIRBAG UNIT
Removing
PRECAUTIONS.
PRECAUTIONS.

-- Disconnect wiring harness from front passenger side airbag.
-- Remove passenger airbag from mount in instrument panel.

Fig. 36: Identifying Front Passenger Side Airbag Wiring Harness And Bolts
Installation
NOTE: Screws -1- and -2- are to be inserted with locking compound D 197 300 A1.
Tightening specification for screws is 8 Nm.

Fig. 37: Identifying Front Passenger Side Airbag Wiring Harness And Bolts
FRONT SIDE AIRBAG
Removing
WARNING: Read the Safety Instructions for working with airbags, belt tensioners and
battery cut-out units. Refer to AIRBAG, BELT TENSIONER AND BATTERY
CUT-OUT UNITS SAFETY PRECAUTIONS.
-- Mount the fixture for seat repair -VAS 6136- on the engine and transmission holder -VAS 6095-.
-- Secure the seat to the fixture for seat repair -VAS 6136-.
-- Remove the front seat belt latch. Refer to FRONT SEAT BELT LATCHES
-- Remove seat cap COVER CAP
Electric Seat
-- Remove electric seat front end trim. Refer to POWER SEAT FRONT SIDE TRIM
-- Remove electric seat trim. Refer to POWER SEAT TRIM
Partially Electric Seat
-- Remove partially electric seat trim. Refer to PARTIAL POWER SEAT TRIM
Height-Adjustable Seat
-- Remove height-adjustable seat trim. Refer to HEIGHT-ADJUSTABLE SEAT TRIM
Fixed Seat
-- Remove fixed seat trim. Refer to SEAT TRIM, WITHOUT HEIGHT ADJUSTMENT
Passenger Seat with Pass-Through
-- Remove the front seat trim. Refer to PASSENGER SEAT TRIM, WITH PASS-THROUGH .
-- Remove bracket and actuating lever, trim of partially electric/height adjustable seat. Refer to PARTIAL
POWER/HEIGHT-ADJUSTABLE SEAT TRIM BRACKET AND OPERATING LEVER
All Seats
-- Remove front seat backrest. Refer to LEFT FRONT SEAT BACKREST

-- Secure backrest on fixture for seat repair -VAS 6136-.
-- Remove headrests. Refer to HEADREST
Remove the cover and upholstery from the front seat backrest:
 all vehicles except the Trendline: FRONT BACKREST COVER AND UPHOLSTERY, EXCEPT
TRENDLINE
 Trendline: FRONT BACKREST COVER AND UPHOLSTERY, TRENDLINE
-- Separate wiring harness -1- from backrest frame.
-- Remove side airbag -3- from mounting in backrest frame.

Fig. 38: Identifying Front Side Airbag Remove/Install Components

Installation
REAR SIDE AIRBAG
Removing
Wagon
All vehicles
-- Remove side upholstery with side airbag. Refer to SIDE UPHOLSTERY WITH SIDE AIRBAG
-- Remove connector -1- from mounting plate -2- in side upholstery.
-- Remove wiring harness from mount -3-.
-- Remove circuit board -5- and open airbag case.
NOTE: For the sake of illustration, airbag case is not depicted in the illustration.
-- Remove side airbag -6- from recess in side upholstery -7-.

Fig. 39: Identifying Rear Side Airbag Remove/Install Components

Installation
HEAD CURTAIN AIRBAG, SEDAN UP TO NOVEMBER 2009
Removing
PRECAUTIONS.
 Pay attention especially to the instructions for side airbag modules.
Refer to SIDE AIRBAG MODULE ADDITION SAFETY PRECAUTIONS.
-- Remove the front and rear interior and reading lamps in the headliner. Refer to [[Editorial:Pick one xref]]
Removal and Installation [For engine(s) BPY,BLV,CCTA,CBFA] Removal and Installation
 Basic STANDARD SUN VISORS

 Double DOUBLE SUN VISORS
-- Remove roof grab handle: ROOF GRAB HANDLES
-- Remove upper B-pillar trim: UPPER B-PILLAR TRIM
-- Remove the interior rearview mirror. Refer to INTERIOR REARVIEW MIRROR WITH RAIN
SENSOR
-- Lower the headliner, Sedan. Refer to HEADLINER, SEDAN

-- Disconnect wiring harness from side curtain airbag.
-- Remove five screws -arrows- (4.5 Nm).
-- Remove side curtain airbag from mounts in body.

Fig. 40: Identifying Side Curtain Airbag, Sedan Remove/Install Components

Installation
HEAD CURTAIN AIRBAG, SEDAN FROM NOVEMBER 2009
Removing
PRECAUTIONS.

-- Remove roof end strip, sedan: ROOF END STRIP, SEDAN
-- Remove the interior rearview mirror: INTERIOR REARVIEW MIRROR WITH RAIN SENSOR
-- Lower the headliner, Sedan: HEADLINER, SEDAN


-- Disconnect harness connector -5- from the head curtain airbag.
-- Place a screwdriver (tip width 2.5 mm) in right opening -2- of clip -3-.
NOTE: The immersion depth of the screwdriver should be approx. 1 cm when the tip is
vertical.
-- Tilt the screwdriver to the right and release the right side of the clip from the body.
-- Push the trim removal wedge -3409- between the clip and body to prevent the right side of the clips from
reengaging in the body.
-- Place the screwdriver in left opening -1- of the clip.
-- Tilt the screwdriver to the left and release the clip from the body.
-- Unclip the rest of the clips -arrows- starting at the A-pillar.
-- Remove the side curtain airbag -5- from the mounts in the body.
Fig. 41: Identifying Clips, Bolts And Side Curtain Airbag

Installation
HEAD CURTAIN AIRBAG, PASSAT CC
Removing
PRECAUTIONS.
 Vehicles without Panorama sunroof: [[Editorial:Pick one xref]]Removal and Installation [For engine(s)
 Vehicles with Panorama sunroof: [[Editorial:Pick one xref]]Removal and Installation [For engine(s)
-- Lower the headliner, Passat CC. Refer to LOWERING HEADLINER, PASSAT CC

-- Using a small screwdriver, pry the connector lock out of the connector -1-.
-- Disconnect the connector from the side curtain airbag.
-- Remove the tensioning band -3- from the clips -2- and -4-.
-- Place a flat O-ring pliers in both clip openings -5- and carefully remove the clips out of the opening in the
body.
-- Remove the clamps -6- from the body.
-- Remove the remaining five clamps -arrows-, -3- from the body.
WARNING: If one of the four clips were damaged while removing, the side curtain
airbag must be replaced.
Fig. 42: Identifying Tensioning Band, Clips, Connector And Clamps

Installation
HEAD CURTAIN AIRBAG, WAGON UP TO NOVEMBER 2009
Removing
PRECAUTIONS.
-- Open sunroof.

All vehicles:

 right: RIGHT LUGGAGE COMPARTMENT SIDE TRIM, WAGON

 left: LEFT LUGGAGE COMPARTMENT SIDE TRIM, WAGON
-- Remove D-pillar trim panels. Refer to D-PILLAR TRIM .
WITH RAIN SENSOR
All vehicles:

-- Disconnect wiring harness from side curtain airbag
-- Remove five screws -arrows- (4.5 Nm).
-- Remove side curtain airbag from mounts in body.

Fig. 43: Identifying Side Curtain Airbag, Wagon Remove/Install Components

Installation
HEAD CURTAIN AIRBAG, WAGON FROM NOVEMBER 2009
Removing
PRECAUTIONS.
-- Open sunroof.

All vehicles:

 Right RIGHT LUGGAGE COMPARTMENT SIDE TRIM, WAGON

 Left LEFT LUGGAGE COMPARTMENT SIDE TRIM, WAGON
-- Remove D-pillar trim panels. Refer to D-PILLAR TRIM .
WITH RAIN SENSOR
All vehicles:

-- Disconnect harness connector -5- from the head curtain airbag.
-- Place a screwdriver (tip width 2.5 mm) in right opening -2- of clip -3-.
NOTE: The immersion depth of the screwdriver should be approx. 1 cm when the tip is
vertical.
-- Tilt the screwdriver to the right and release the right side of the clip from the body.
-- Push the trim removal wedge -3409- between the clip and body to prevent the right side of the clips from
reengaging in the body.
-- Place the screwdriver in left opening -1- of the clip.
-- Tilt the screwdriver to the left and release the clip from the body.
-- Unclip the rest of the clips -arrows- starting at the A-pillar.
Fig. 44: Identifying Clips, Bolts And Side Curtain Airbag

FRONT PASSENGER SEAT OCCUPANT SENSOR
WARNING: If the Front Passenger Seat Occupied Sensor -G128- is replaced, also the
upholstery, front seat cushion must always be replaced.
Removing
-- Remove seat cap. Refer to COVER CAP
Electric Seat
-- Remove electric seat trim bracket. Refer to POWER SEAT TRIM BRACKET

Seat without Height Adjustment
-- Remove trim of seat (without height adjuster). Refer to SEAT TRIM, WITHOUT HEIGHT
ADJUSTMENT
-- Remove bracket, trim, seat (without height adjuster). Refer to SEAT TRIM BRACKET, WITHOUT
HEIGHT ADJUSTMENT
All Seats
-- Cover and upholstery, front seat cushion, removing and installing. Refer to FRONT SEAT CUSHION
COVER AND UPHOLSTERY
NOTE: Removing the seat occupied recognitions is described for the vehicle
equipment lines trend and comfort lines. Removing the sport line equipment
line is done in similar fashion.
-- On seats with a massage- / ventilation function, remove cover -1- and loosen seat occupied sensor -2- from
upholstery -3-.
-- On seats without massage- / ventilation function, loosen seat occupied sensor -4- from upholstery -5-.
Fig. 45: Identifying Front Passengers Seat Occupied Sensor G128 Remove/Install Components
Installation
Trendline and Comfortline equipment lines
-- Position flat wire -1- of Front Passenger's Seat Occupied Sensor -G128- into corresponding recess in center of
upholstery.
-- Pull off adhesive strips -2- from Front Passenger's Seat Occupied Sensor -G128- -arrow A- on right side.
-- Adhere right sensor strip -3- of Front Passenger's Seat Occupied Sensor -G128- on to upholstery.
-- Pull off adhesive strips -4- from Front Passenger's Seat Occupied Sensor -G128- -arrow B- on left side.
-- Adhere left sensor strip -5- of the front passenger seat occupant sensor -G128- to the upholstery.
NOTE: While adhering, make sure that sensor strips are aligned so that they run
parallel to recess in upholstery.
-- Position flat wire -6- of Front Passenger's Seat Occupied Sensor -G128- into corresponding recess on left rear
edge of upholstery.
-- Pull off adhesive strip -7- from Front Passenger's Seat Occupied Sensor -G128- -arrow C- and adhere flat
wire on to upholstery in this area.
-- Position Front Passenger Seat Occupied Sensor -G128- -8- and wiring harness -9- into corresponding recesses
on rear edge of upholstery.
Fig. 46: Identifying Trendline And Comfortline Equipment Lines

-- On seats with a massage- / ventilation function, position cover -1- on upholstery, fleece -2- must be located
on lower side of cover when doing this.
Fig. 47: Identifying Upholstery Cover And Fleece Lower Side Of Cover -- Seats With A Massage-
/Ventilation Function
Sportline equipment line
-- Position flat wire -1- of Front Passenger Seat Occupied Sensor -G128- into corresponding recess of
upholstery.
-- Slide flat wire forward in direction of travel until the two tabs -2- are located in corresponding recess of
upholstery.
-- Press flat wire -3- in rear area of tabs -2- into recess of upholstery.
Fig. 48: Identifying Adhesive Strip, Tabs And Flat Wire

-- Pull off adhesive strip -1- from Front Passenger's Seat Occupied Sensor -G128- -arrow A-.
-- Adhere Front Passenger's Seat Occupied Sensor -G128- on to upholstery in this area.
-- Pull off adhesive strip -2- from Front Passenger's Seat Occupied Sensor -G128- -arrow B-.
-- Adhere Front Passenger's Seat Occupied Sensor -G128- on to upholstery in this area.
-- Position Front Passenger Seat Occupied Sensor -G128- -3- and wiring harness -4- into corresponding recesses
on rear edge of upholstery.
Fig. 49: Identifying Front Passengers Seat Occupied Sensor G128 And Wiring Harness
COMPONENTS, ADAPTING
Fig. 50: Identifying Diagnostic Operation System VAS5051A


 Diagnostic cable -VAS 5051/1- or -VAS 5051/3-
Select "Guided Fault Finding" in the Vehicle Diagnosis, Testing and Information System -VAS 5051 A-.
After all control modules have been interrogated:
-- Press "Go to" button
-- Select "Function/Component selection"
-- Select "Body"
-- "Body Repairs"
-- Select "01 - On Board Diagnostic (OBD) capable systems"
-- Select "Airbag"
-- Select "Action"
PASSENGER OCCUPANT DETECTION SYSTEM FOR PASSENGER AIRBAG DEACTIVATION, PASSAT AND
PASSAT WAGON
PASSIVE OCCUPANT DETECTION SYSTEM COMPONENTS, MANUAL SEATS, REMOVING


Refer to PASSENGER OCCUPANT DETECTION SYSTEM SAFETY
PRECAUTIONS.
NOTE: The seat cushion, mat for passenger occupant detection system, control
module and pressure sensor can only be replaced as a single unit. These
components are adapted to work together and are not allowed to be separated.
Only disconnect wiring harnesses mentioned in the following description.
-- Remove the cover from the seat area. Refer to FRONT SEAT CUSHION COVER AND UPHOLSTERY
-- Disconnect the connector from the passenger occupant detection system control module -J706-.
-- Unclip the passenger occupant detection system pressure sensor -G452- from the bracket.
-- Disconnect the connector from the passenger occupant detection system pressure sensor -G452-.
-- Unclip pressure hose -2- from retainers.
-- Remove the screws -1- (1.5 Nm) and the passenger occupant detection system control module -J706- -3-.
Fig. 51: Identifying Pressure Hose, Screws And Passenger Occupant Detection System Control Module
J706
-- Lift the seat cushion -1-. When doing this do not separate the seat cushion from the passenger occupant
detection system mat -4-.
-- Remove the clips -2- from the lower seat frame -5-. Do not remove clip -3-.
WARNING:  The seat cushion, the mat for the passenger occupant detection
system, the pressure hose, the passenger occupant detection
system pressure sensor -G452- and the passenger occupant
detection system control module -J706- are calibrated to work
together and may not be replaced by other components.
-- Remove the seat cushion and the mat for the passenger occupant detection system from the lower seat frame.
-- Guide the pressure hose and the passenger occupant detection system pressure sensor -G452- through the
opening inside the seat frame.
Fig. 52: Identifying Seat Cushion, Clips, Seat Frame And Passenger Occupant Detection System Mat
PASSIVE OCCUPANT DETECTION SYSTEM REPAIR KIT, MANUAL SEATS, INSTALLING
NOTE: When installing, make sure the seat heating wiring harness does not get caught
between the seat cushion and the passenger occupant detection system mat.
Pressure hose must be routed without kinking.
After being connected to the vehicle electrical system, verify that the replaced
components can move easily by moving the seat.
After replacing, perform a basic setting on the passenger occupant detection system using a Vehicle Diagnosis
Tester that has "Guided Fault Finding".
WARNING: Basic setting must be performed when seat is not occupied.
-- Tape the insert -2- to the lower seat frame -1- with two-sided tape -3- as illustrated.
Fig. 53: Identifying Insert Profile, Seat Frame And Double-Sided Adhesive Tape
WARNING:  Make sure that no persons are in the vehicle.
-- Connect the battery. Refer to [For engine(s) BPY,BLV,CCTA,CBFA] Removal and Installation .
PASSIVE OCCUPANT DETECTION SYSTEM COMPONENTS, POWER SEATS, REMOVING


Refer to PASSENGER OCCUPANT DETECTION SYSTEM SAFETY
PRECAUTIONS.
NOTE: The seat cushion, mat for passenger occupant detection system, control
module and pressure sensor can only be replaced as a single unit. These
components are adapted to work together and are not allowed to be separated.
Only disconnect wiring harnesses mentioned in the following description.
-- Perform the following seat adjustment:
 Seat height: highest position

 Seat tilt: highest position
-- Remove the cover from the seat area. Refer to FRONT SEAT CUSHION COVER AND UPHOLSTERY
-- Remove the screw -1- and then move the control module with bracket -2- and the wiring harness -3- to the
side.
Fig. 54: Identifying Screw, Bracket And Wiring Harness

-- Disconnect the connector from the passenger occupant detection system control module -J706-.
-- Unclip the passenger occupant detection system pressure sensor -G452- from the bracket.
-- Disconnect the connector from the passenger occupant detection system pressure sensor -G452-.
-- Unclip pressure hose -2- from retainers.
-- Remove the screws -1- (1.5 Nm) and the passenger occupant detection system control module -J706- -3-.
Fig. 55: Identifying Pressure Hose, Screws And Passenger Occupant Detection System Control Module
J706
-- Lift the seat cushion -1-. When doing this do not separate the seat cushion from the passenger occupant
detection system mat -4-.
-- Remove the clips -2- from the lower seat frame -5-. Do not remove clip -3-.
WARNING:  The seat cushion, the mat for the passenger occupant detection
system, the pressure hose, the passenger occupant detection
system pressure sensor -G452- and the passenger occupant
detection system control module -J706- are calibrated to work
together and may not be replaced by other components.
-- Remove the seat cushion and the mat for the passenger occupant detection system from the lower seat frame.
-- Guide the pressure hose and the passenger occupant detection system pressure sensor -G452- through the
opening inside the seat frame.
Fig. 56: Identifying Front Seat Cushion Upholstery And Seat Occupied Recognition Mat
PASSIVE OCCUPANT DETECTION SYSTEM REPAIR KIT, POWER SEATS, INSTALLING
NOTE: When installing, make sure the seat heating wiring harness does not get caught
between the seat cushion and the passenger occupant detection system mat.
Pressure hose must be routed without kinking.
After being connected to the vehicle electrical system, verify that the replaced
components can move easily by moving the seat.
After replacing, perform a basic setting on the passenger occupant detection system using a Vehicle Diagnosis
Tester that has "Guided Fault Finding".
WARNING: Basic setting must be performed when seat is not occupied.
-- Tape the insert -2- to the lower seat frame -1- with two-sided tape -3- as illustrated.
Fig. 57: Identifying Insertion Profile, Double-Sided Tape And Seat Frame
WARNING:  Make sure that no persons are in the vehicle.
PASSENGER OCCUPANT DETECTION SYSTEM FOR PASSENGER AIRBAG DEACTIVATION, PASSAT CC

PASSIVE OCCUPANT DETECTION SYSTEM
WARNING:  Follow the additional safety precautions for working on the

passenger airbag deactivation passenger occupant detection
system; refer to PASSIVE OCCUPANT DETECTION SYSTEM SAFETY
PRECAUTIONS.
 Before handling pyrotechnical components (for example,
disconnecting the connector), the person handling them must
"discharge static electricity". For example, by briefly touching the
door striker pin.
WARNING: The passenger occupant detection system service kit is precalibrated and
must not be disconnected. The service kit consists of:
 Seat Occupied Recognition Control Module -J706-

 Passenger occupant detection system pressure sensor -G452-
 Passive Occupant Detection System Mat
 Seat cushion
Removing
-- Move the seat height to the middle position before removing the seat.
-- Remove the passenger seat. Refer to FRONT SEAT .
-- Disconnect the battery ground cable with the ignition switched on. Refer to [For engine(s)
NOTE: On vehicles with a luggage pass-through, it is sufficient to fold the backrest

forward, it does not have to be removed.
-- Remove front backrest. Refer to LEFT FRONT SEAT BACKREST .
NOTE: Do not disconnect the connectors from the passenger occupant detection
system pressure sensor -G452- and passenger occupant detection system -
J706-.
-- Using a narrow screwdriver, carefully press the passenger occupant detection system pressure sensor -G452- -
item 3- off the bracket -arrow-.
-- Open the seat occupied recognition pressure hose guide -1- and free up the pressure hose -2-.
Fig. 58: Identifying Hose Guide, Pressure Hose And Spring

-- Release the retaining spring -1- and tilt and swivel the passenger occupant detection system control module -
J706- -2- out of the mount.
Fig. 59: Identifying Retaining Spring, Passenger Occupant Detection System Control Module, Connector
And Electrical Wiring Harness
-- Remove the electrical connector -4- from the bracket by pressing the release and removing the electrical
connector.
-- Open the retaining tab on the electrical wiring harness guide -5- -arrow- and free up the wiring harness -3-.
-- Remove the front seat cover and cushion. Refer to FRONT SEAT CUSHION COVER AND
UPHOLSTERY .
-- Carefully pry out the passenger occupant detection system mat clips -1- and -3- on the front of the seat pan
using a pry lever 80 - 200.
Fig. 60: Identifying Mat Clips, Pry Lever And Passenger Occupant Detection System Pressure Sensor
-- Remove the seat pan cover with upholstery by first guiding the passenger occupant detection system pressure
sensor -G452- through the opening in the lower seat frame.
WARNING: Risk of damage.
 Do not bend the seat occupied recognition pressure hose and mat.
-- Remove the cover and cushion, the mat for the -2- passenger occupant detection system and the passenger
occupant detection system pressure sensor -G452-.
Installation
-- Clean the threaded bolt holes for self-locking nuts, for example using a thread tap.
-- Replace all self-locking bolts.
Installation is reverse of removal, but note the following:

system. Refer to PASSIVE OCCUPANT DETECTION SYSTEM
SAFETY PRECAUTIONS.
 Before handling pyrotechnical components (for example, connecting
electrical connector), the person handling them must "discharge
static electricity". For example, by briefly touching the door striker
pin.
 Do not bend the seat occupied recognition pressure hose and mat.
NOTE: Make sure the connectors are installed all the way in and are secure.
WARNING: Connect the battery with the ignition switched on. Pyrotechnic
components could deploy after connecting the battery if they were not
repaired correctly. Individuals must not be inside the vehicle when
connecting the battery.
-- Connect the battery ground cable with the ignition turned on. Refer to [For engine(s)
When installing a new service kit and after each repair on the front passenger seat where the seat and/or the
backrest cover is >>disengaged<<, a basic setting procedure must be performed on the seat occupied
recognition control module.
-- At the end, select the "Airbag" function in "guided fault finding" using appropriate Vehicle diagnosis, testing
and information system -VAS 5051-.
 -J706 Passive occupant detection system control module basic setting
SEAT POSITION SENSOR
The seat position sensor is part of the wiring harness for the passenger occupant detection system control
module -J706-, whose connectors can be separated. To replace the seat position sensors, the seat position sensor
wires must therefore be split up and the new seat position sensor with the crimp connectors have to be
connected.
Removing

system. Refer to PASSIVE OCCUPANT DETECTION SYSTEM
SAFETY PRECAUTIONS.
 Before handling pyrotechnical components (for example,
disconnecting the connector), the person handling them must
"discharge static electricity". For example, by briefly touching the
door striker pin.
-- Remove the passenger seat. Refer to FRONT SEAT .
-- Remove screw -3- and (0.3 Nm) and seat position sensor -4- from the seat pan lower frame.
Fig. 61: Identifying Protective Hose, Clip And Screw

CAUTION: Do not damage the insulation on the individual wires.
-- Cut protective hose -2- to just in front of clip -1-.
-- Cut through both electrical wires at the places marked with -arrow A- and -arrow B- to approximately 1 /3 to
2 / of the free length.
3
Installation
WARNING:  Observe safety precautions for work on airbags. Refer to AIRBAG,

BELT TENSIONER AND BATTERY CUT-OUT UNITS SAFETY
PRECAUTIONS.
 Before handling pyrotechnical components (for example, connecting
electrical connector), the person handling them must "discharge
static electricity". For example, by briefly touching the door striker
pin.
-- Cut the electrical wires on the new seat position sensor to the same length as those on the old sensor.
 The same wire colors must have the same length.
-- Connect the electrical wires with crimp connectors -arrow A- and -arrow B-.
Fig. 62: Identifying Crimp Connectors And Hook

-- Wrap the entire length of the wiring harness from the clip to the seat position sensor with fabric-reinforced
adhesive tape.
-- Install the seat position sensor, making sure the hook -arrow C- on the sensor is inserted in the seat pan lower
frame.
Further installation is performed in reverse sequence of removal, but observe the following:
NOTE: Make sure the connectors are installed all the way in and are secure.
WARNING: Connect the battery with the ignition switched on. Pyrotechnic
components could deploy after connecting the battery if they were not
repaired correctly. Individuals must not be inside the vehicle when
connecting the battery.
-- Connect the battery ground cable with the ignition turned on. Refer to [For engine(s)
NOTE: If the airbag indicator lamp -K75- indicates a fault after installation, the DTC
memory must be checked, deleted and checked again. Refer to appropriate
information, Electrical Equipment, Removal and Installation.
CRASH SENSORS
DRIVER'S FRONT AIRBAG CRASH SENSOR

NOTE: The driver front airbag crash sensor -G283- is installed behind the front lid lock.
Removing
-- Press connector lock -1- and disconnect connector -2- from the driver front airbag crash sensor -G283- -3-.
Fig. 63: Identifying Connector Lock, Bolts, Connector And Drivers Front Airbag Crash Sensor G283
Installation
DRIVER FRONT AIRBAG CRASH SENSOR

NOTE: The driver front airbag crash sensor -G283- is located on the left side of the lock
carrier.
Removing
-- Disconnect the battery. Refer to [For engine(s) BPY,BLV,CCTA,CBFA] Removal and Installation .
-- Disconnect the connector -2- from the driver front airbag crash sensor -G283- -3-.
-- Remove bolts -1- (4.5 Nm).

Fig. 64: Identifying Bolts, Connector And Driver Front Airbag Crash Sensor
Installation
FRONT PASSENGER FRONT AIRBAG CRASH SENSOR
NOTE: The passenger front airbag crash sensor -G284- is located on the right side of
the lock carrier.
-- Disconnect the battery. Refer to [For engine(s) BPY,BLV,CCTA,CBFA] Removal and Installation .
Removing
-- Disconnect the connector -2- from the front passenger front airbag crash sensor -G284- -3-.
-- Remove bolts -1- (4.5 Nm).

Fig. 65: Identifying Bolts, Connector And Front Passenger Front Airbag Crash Sensor
Installation
DRIVER THORAX AIRBAG CRASH SENSOR
The driver side airbag crash sensor -G179- may be installed in several different locations:
 On the outside of the front door subframe

 On the inside of the front door subframe
Crash Sensor Installed on Outside of Subframe
Removing
Sedan and Wagon
-- Remove driver side front door trim. Refer to DRIVER SIDE FRONT DOOR TRIM
Passat CC
-- Remove driver side front door trim. Refer to FRONT DOOR TRIM
All vehicles
-- Remove front door subframe. Refer to [[Editorial:Pick one xref]]Removal and Installation Remote Control
Keys, Adapting to Immobilizer Remote Control Keys, Adapting
-- Drill out pop rivet -1-.
-- Press connector lock and remove connector -4- from Driver's Side Airbag Crash Sensor -G179- -3-.
Fig. 66: Identifying Drivers Side Airbag Crash Sensor G179 And Connector
Installing
-- Connect connector -4- to Front Passenger Side Airbag Crash Sensor -G179- -3-.
-- Blind rivet the driver thorax airbag crash sensor -G179- to the subframe using the blind rivet -2- and the pop
rivet pliers -VAS 5072-.
-- Use pop rivet -1- to secure the driver thorax airbag crash sensor -G179- to subframe as described.
Crash Sensor Installed on Inside of Subframe

Removing
Sedan and Wagon
-- Remove driver side front door trim. Refer to DRIVER SIDE FRONT DOOR TRIM
Passat CC
-- Remove driver side front door trim. Refer to FRONT DOOR TRIM
All vehicles
-- Press connector lock and remove connector -2- from driver thorax airbag crash sensor -G179- -1- -arrow-.

Fig. 68: Identifying Connector, Driver Thorax Airbag Crash Sensor And Pop Rivets
Installing
-- Blind rivet the driver thorax airbag crash sensor -G179- to the subframe using the blind rivet -4- and the pop
rivet pliers -VAS 5072-.
-- Use pop rivet -3- to secure the driver thorax airbag crash sensor -G179- to subframe as described.
-- Connect connector -2- to Front Passenger Side Airbag Crash Sensor -G179- -1-.
FRONT PASSENGER THORAX AIRBAG CRASH SENSOR

The front passenger thorax airbag crash sensor -G180- may be installed in several different locations:
 On the outside of the front door subframe

 On the inside of the front door subframe
Crash Sensor Installed on Outside of Subframe
Removing
Sedan and Wagon
-- Remove passenger side front door trim. Refer to PASSENGER SIDE FRONT DOOR TRIM
Passat CC
-- Remove passenger side front door trim. Refer to FRONT DOOR TRIM
All vehicles
-- Remove front door subframe. Refer to [[Editorial:Pick one xref]]Removal and Installation Remote Control
Keys, Adapting to Immobilizer Remote Control Keys, Adapting
-- Press connector lock and remove connector -4- from front passenger thorax airbag crash sensor -G180- -3-.
Fig. 70: Identifying Front Passengers Side Airbag Crash Sensor G180 And Connector
Installing
-- Connect the connector -4- to the passenger side thorax airbag crash sensor -G180- -3-.
-- Blind rivet the passenger thorax airbag crash sensor -G180- to the subframe using the blind rivet -2- and the
pop rivet pliers -VAS 5072-.
-- Use pop rivet -1- to secure the passenger thorax airbag crash sensor -G180- to subframe as described.
Crash Sensor Installed on Inside of Subframe

Removing
Sedan and Wagon
-- Remove passenger side front door trim. Refer to PASSENGER SIDE FRONT DOOR TRIM
Passat CC
-- Remove passenger side front door trim. Refer to FRONT DOOR TRIM
All vehicles
-- Press connector lock and remove connector -2- from passenger thorax airbag crash sensor -G180- -1- -arrow-.

Installing
-- Blind rivet the passenger thorax airbag crash sensor -G180- to the subframe using the blind rivet -4- and the
pop rivet pliers -VAS 5072-.
-- Use pop rivet -3- to secure the passenger thorax airbag crash sensor -G180- to subframe as described.
-- Connect the connector -2- to the passenger side thorax airbag crash sensor -G180- -1-.
LEFT REAR THORAX AIRBAG CRASH SENSOR

NOTE: The left rear thorax airbag crash sensor -G256- is installed on the driver side in
front of the rear wheel housing.
Removing
Sedan/Passat CC
Wagon
All vehicles

-- Remove the wheel housing trim around the left rear thorax airbag crash sensor -G256- out of the retainers.
Refer to WHEEL HOUSING TRIM
-- Press connector lock -1- and disconnect connector -2- from left rear thorax airbag crash sensor -G256- -3-.
NOTE: Alternatively, the left rear thorax airbag crash sensor -G256- may be secured by
a single screw.
Fig. 74: Identifying Connector Lock, Rear Side Airbag Crash Sensor (On Drivers Side) G256 And
Connector
Installation

RIGHT REAR THORAX AIRBAG CRASH SENSOR
NOTE: The right rear thorax airbag crash sensor -G257- is installed on the passenger
side in front of the rear wheel housing.
Removal and installation of the right rear thorax airbag crash sensor -G257- is similar to removal and
installation of the left rear thorax airbag crash sensor -G256- and the procedure can be derived from this:
 Left Rear Thorax Airbag Crash Sensor, Removing and Installing -G256-. Refer to LEFT REAR
THORAX AIRBAG CRASH SENSOR
SPECIAL TOOLS
 Special hook -3370-
Fig. 75: Identifying Front End Hook VAS 3370

 Engine/transmission holder -VAS 6095-

Fig. 76: Identifying Engine And Transmission Holder VAS 6095

 Seat repair stand -VAS 6136-
Fig. 77: Identifying Fixture For Seat Repair VAS 6136

 Torque wrench -V.A.G 1783-


Fig. 79: Identifying Diagnostic Operation System VAS5051A

Accessories & Equipment Rear Doors
Rear Doors
58 REAR DOORS
REAR DOOR, SEDAN
REAR DOOR ASSEMBLY OVERVIEW
Fig. 1: Rear Door, Assembly Overview

1. Door
 Removing and Installing, refer to DOOR
 Removing and Installing, refer to DOOR HANDLE

 Without lock cylinder.
4. Door lock
5. Subframe
 Removing, refer to SUBFRAME
6. Socket head bolt

 Different tightening specifications


8. Bolt
 This screw must be removed to remove door at hinge.
9. Door hinge
10. Door hinge

11. Door hinge

12. Bolt

The lower part of the hinge may be attached either with a bolt -7- or a nut -8-.
Lubricate new hinges. Refer to the appropriate "Maintenance" information for

the procedure.

1. Door
2. Socket head bolt
3. Socket head bolt


 The lower part of the hinge may be attached to the upper part either with a bolt -7- or a nut -8-.
5. Socket head bolt

 Installed from the inside of the vehicle
 Remove the lower B-pillar trim. Refer to Removal and Installation

Always replace bolts after removing them.

6. Socket head bolt

7. Bolt
 Remove the bolt or the nut -8- in order to be able to remove the door from the hinge.
8. Nut

 Remove the nut or the bolt -7- in order to be able to remove the door from the hinge.
9. Door hinge
 The upper part of the hinge may be attached to the lower part either with a bolt -7- or a nut -8-.
10. Door hinge


Tightening specification: 28 Nm

14. Door hinge


DOOR, ADJUSTING

NOTE: Vehicle must stand on its wheels in order to be able to perform the rear door
adjustment.
The rear door is properly adjusted when there is an overall even gap dimension
or adjusting work.
For correct gap dimension adjustment, screws -5, 6, 9 and 12- at B-pillar must be loosened. The B-pillar lower
trim must be removed in order to access the bolt -5-. Use socket3410. Refer to Removal and Installation .
Other measures, such as aligning the door upward, are not effective. Excess pressure thereafter will again cause
the door to sag.
Door adjusting wrench 3320 with bit insert 3320/3 must be used for this.
-- Adjust the striker pin.
NOTE: The following describes adjusting the right rear door only. Adjusting the left
rear door is identical.
When closing, the rear door must latch completely without having to press it
 If the rear door does not align to the rear side panel.
-- Loosen the striker pin -1- by loosening the bolts -2- at the C-pillar.

-- Adjust the rear door with the striker pin -1- so the rear door aligns with the rear side panel when it is closed
(wind noise).
REAR DOOR, WAGON
REAR DOOR ASSEMBLY OVERVIEW

Fig. 5: Rear Door, Assembly Overview

1. Door
 Door, adjusting, refer to DOOR, ADJUSTING

 Door handle with KESSY, removing

4. Door lock
5. Subframe
 Removing, refer to SUBFRAME
6. Socket head bolt

 different tightening specifications


 Lower section
8. Door hinge
 Upper part is placed on the lower part of the hinge
9. Door hinge
 The nut -11- attaches the hinge lower section to the upper section.
10. Door hinge

 The nut -11- attaches the hinge upper section to the lower section.
11. Nut
The lower hinge may be attached either with bolt -8- or a nut -9-.
Lubricate new hinges. Refer to appropriate "Maintenance" information for the

procedure. .

1. Door
Removing and Installing, refer to DOOR
2. Socket head bolt
3. Socket head bolt

 Only this bolt must be removed in order to remove the door from the hinge if the bolt -8- or nut -9-
is not there.

NOTE: 3 different versions of the lower hinge are being used.
Either a mounted hinge or a hinge attached by a bolt -8- or by a nut -

9-.
5. Socket head bolt

 Installed from the inside of the vehicle
 Remove the lower B-pillar trim. Refer to Removal and Installation

6. Socket head bolt
7. Door hinge
 Upper section
NOTE: 3 different versions of the lower hinge are being used.
Either a mounted hinge or a hinge attached by a bolt -8- or by a nut -

9-.
8. Bolt
 Remove the bolt or the nut -9- in order to be able to remove the door from the hinge.
9. Nut
 Remove the nut or the bolt -8- in order to be able to remove the door from the hinge.
10. Door hinge

 Lower section

12. Nut
14. Door hinge

 Upper section
 With threaded pin for nut.

DOOR, ADJUSTING

NOTE: Vehicle must stand on its wheels in order to be able to perform the rear door
adjustment.
The rear door is properly adjusted when there is an overall even gap dimension
or adjusting work.
For correct gap dimension adjustment, screws -5, 6, 9 and 12- at B-pillar must be loosened. The B-pillar lower
trim must be removed in order to access the bolt -5-. Use socket3410. Refer to Removal and Installation .
Other measures, such as aligning the door upward, are not effective. Excess pressure thereafter will again cause
the door to sag.
Door adjusting wrench 3320 with bit insert 3320/3 must be used for this.
-- Adjust the striker pin.
NOTE: The following describes adjusting the right rear door only. Adjusting the left
rear door is identical.
When closing, the rear door must latch completely without having to press it
 If the rear door does not align to the rear side panel.
-- Loosen the striker pin -1- by loosening the bolts -2- at the C-pillar.

-- Adjust the rear door with the striker pin -1- so the rear door aligns with the rear side panel when it is closed
(wind noise).
DOOR COMPONENTS
Fig. 9: Subframe, Assembly Overview

1. Subframe
2. Door lock
3. Bolt
 Quantity: 11
4. Sealing plugs
5. Window Regulator Motor
SUBFRAME
NOTE: Removing and installing the right subframe is described here. Removing and
installing the left subframe is identical.
The removal and installation of the subframe is different on the sedan and
wagon.
The window regulator, door lock and speaker are secured to the subframe.
The door lock can only be removed with the subframe.
The subframe can be removed only if the door window is detached at the clamping screws on the window
regulator.
If it is not possible to drive down the door window by the electrical window regulator, first the exact cause of
malfunction must be determined.
Check the DTC memory for the Comfort System. Refer to Vehicle diagnosis testing and information system
VAS 5051.
If electrical malfunction is present, repair this malfunction first.
If there is an electrical malfunction due to window regulator motor, it can be unscrewed from subframe and
door window can be slid by hand into the necessary work position.
Removing

-- Remove the door trim panel. Refer to Removal and Installation .
-- Remove door handle, refer to DOOR HANDLE.
For wagon only
-- Remove the door window and guide rail GUIDE RAIL BRACKET .
For sedan only

3-.
-- Screw in a 8 mm bolt (approximately. 80 mm long) into spreader plug -3- and pull spreader plug -3- out of
window regulator mount -2-.
All vehicles
-- Disengage retainer of protective sleeve -6- on B-pillar -arrow a- and pull off protective sleeve.
-- Open lock of harness connector -8- of B-pillar by swiveling downward -arrow b- and disconnect harness
connector.
Fig. 11: Mounting Bracket And Bolts

-- Remove the screws -4- for the door lock -5-.
-- Remove bolt -3- for mounting bracket -2-.
-- Slide mounting bracket in -direction of arrow- to disengage hook of mounting bracket from door.
-- Remove the screws -6- , -9- and -arrows-.

Fig. 12: Removing Subframe

-- Guide wire -3- into the door.
-- Pull off lower area of subframe from door -arrow a-. Lower section of window regulator must be guided out
of door along with it.
-- Pull subframe downward at an angle toward hinge pillar -arrow b- out of door. First, upper section of window
regulator must be guided out of door, then the door lock.
Installing
Fig. 13: Installing Subframe

-- Insert subframe -1- upward -arrow a- at an angle into door.
-- Guide door lock -2- and wiring harness -3- in door to the corresponding component locations.
-- Place subframe on to door.

Fig. 14: Mounting Bracket And Bolts

-- Align subframe -1- in door cutout with the centering pins -7 and 8-.
-- Install all bolts. Tighten screw -9- first and then screw -6-.
-- Tighten the remaining bolts -arrows- in any desired sequence.
-- Tightening specification of bolts -6, 9 and arrows- : 8 Nm.
-- Secure the door window.

-- Tightening specifications for screw -4- : 20 Nm.
INTERNAL DOOR SEALS
The inner door seals are equipped at the factory with sealant, applied to the door flange and then rolled on.
With partially removed seals, press the edges of the seal together before
installing.
INSULATION ASSEMBLY OVERVIEW

Fig. 15: Insulation, Assembly Overview

1. Door
2. Insulation
 Self-adhesive
 Installing:
-- Cut to fit as necessary and align between the door edges.
-- Heat using a hot air gunV.A.G 1416 and press onto the outer door panel.
3. Adhesive strips
 Quantity: 2
 20 mm x 40 mm commercially available cloth reinforced adhesive tape
DOOR HANDLE AND DOOR LOCK ASSEMBLY OVERVIEW
Fig. 16: Door Handle And Door Lock, Assembly Overview

1. Door lock

2. Angle bracket
 Inserted on and engaged on door lock.
 Also adopts function of the previously known cover.
3. Cable
 Allows the interior door mechanism to unlock the lock
4. Bolt
5. Mounting bracket
 Mounting bracket is bolted from outside and inserted on angled mounting bracket.

7. Cover
 For lock cylinder housing.
 Removing and Installing, refer to COVER

 Without lock cylinder.
9. Backing
10. Cable
 To lock release mechanism of exterior door handle.
11. Relay level

 For mounting lock cylinder housing.
12. Bolt
REAR DOOR, SEDAN
DOOR
Lubricate new hinges. Refer to "Maintenance" for the procedure.
Removing

-- Release bellows -4- by pressing on locking mechanism -arrow a- and remove bellows from B-pillar.
station.
-- Remove screw -7- from upper hinge.
-- Remove the bolt -2- (or nut -3-) from the lower hinge.
-- Lift door -1- upward -arrow c- out of hinges.

Installing
NOTE: The tightening specification for the bolt -2- (or nut -3-) are different for the lower
hinge.
-- Tightening specification for the bolts -2 and 7- : 28 Nm.
-- Tightening specification for the nut -3- : 14 Nm.
-- Make sure the rear door gap dimensions are correct.
REAR DOOR, WAGON
DOOR
3 different hinges are being used. The lower hinge may be attached with bolt -4-
or a nut -3-. Or the hinge is simply mounted and is secured by the door bolt -2-.
Lubricate new hinges. Refer to "Maintenance" for the procedure.
Removing

-- Release bellows -5- by pressing on locking mechanism -arrow a- and remove bellows from B-pillar.
station.
-- Screw hex nut -8- downward from hinge pin.
NOTE: Note the following regarding the different hinges being used:
 Either remove the lower bolt -2- using the door adjusting wrench3320 and box spanner 3320/3,
 or remove the bolt -4- ,

 or nut -3- from the hinge.
-- Lift door -1- upward -arrow c- out of hinges.
Installing
NOTE: Note the different procedures and tightening specifications for the lower hinge:


-- Tighten the nut -8- on the upper hinge.
-- Tightening specifications for the nut -8- 14 Nm
NOTE: Note the different procedures and tightening specifications for the lower hinge:
-- Tighten the bolt -2- on the lower hinge.
-- Tightening specification for the bolt: -2- 20 Nm + 1 /4 turn (90°).
 Bolt -2- must always be replaced.
-- Or tighten the bolt -4- or nut -3-.
-- Bolt -4- tightening specification: 28 Nm
-- Tightening specifications for the nut -3- 14 Nm
-- Make sure the rear door gap dimensions are correct.
DOOR COMPONENTS
LOCK CYLINDER HOUSING COVER CAP
Removing
NOTE: When removing cover cap of lock cylinder housing, emergency key must not be
turned and do not use prying motions with emergency key.
-- Remove emergency key from remote control key.
-- Press emergency key -3- lightly -arrow a- into hole on underside of cover cap for lock cylinder housing.
Fig. 20: Removing Lock Cylinder Housing Cover Cap

-- Pull off cover cap for lock cylinder -1- , together with emergency key, lightly at underside from door -arrow
b-.
-- Slide cover cap upward -arrow c- from lock cylinder housing.
Installing
-- Place cover cap for lock cylinder housing -2- lightly at an angle from above -arrow a- on to lock cylinder
housing.
Fig. 21: Removing Lock Cylinder Housing Cover Cap

-- Press cover cap of lock cylinder housing -2- on to door -arrow b- until cover cap engages with lock cylinder
housing.
LOCK CYLINDER HOUSING
NOTE: Removing and installing the lock cylinder housing is described. Removing and
installing the left lock cylinder is identical.
Removing
 Cover cap for lock cylinder housing has been removed, refer to LOCK CYLINDER HOUSING
COVER CAP .
-- Pry out cover cap -4- in front of bolt -3-.

Fig. 22: Installing Lock Cylinder Housing

-- Pull out door handle -1- in -direction of arrow- until it stops and unscrew bolt -3- far enough until lock
cylinder housing -2- can be pulled out.
-- Remove lock cylinder housing -2- at right angle to door from door handle mounting bracket.
Installing
In pulled-out position -arrow- , door handle must stand off from door.
Fig. 23: Installing Lock Cylinder Housing

-- Insert lock cylinder housing -3- at right angle into mounting bracket.
-- Screw bolt -3- into mounting bracket.
Door handle -1- swings automatically on to door.
NOTE: During installation, lock cylinder housing must be pressed onto the outer door
panel.
DOOR HANDLE

Removing
-- Remove lock cylinder housing, refer to LOCK CYLINDER HOUSING.
Fig. 24: Removing Door Handle

-- Swivel door handle around in -direction of arrow b-.
-- Remove door handle at right angle -arrow c- to door from mounting bracket -1-.
Installing
-- Insert door handle -1- at right angle to door -arrow a- into mounting bracket -2-.
Fig. 25: Installing Door Handle

-- Install the lock cylinder housing.
DOOR HANDLE WITH KESSY

Removing
-- Remove lock cylinder housing.
Fig. 26: Removing Door Handle

-- Swing door handle down in -direction of arrow b- , the KESSY connector is carried along in the mounting
bracket.
-- If door handle is at a right angle to the door, KESSY connector is in a "park position".
Fig. 27: Identifying Door Handle Assembly

-- Pull door handle -1- at a right angle -arrow- out of mounting bracket -1- , the KESSY connector -2- loosens at
the same time.
Installing
-- Insert door handle -1- in mounting bracket at a right angle -arrow- and in KESSY connector -2- locking tab.
Fig. 28: Identifying Mounting Bracket and Locking Tab

-- Swing door handle -1- into door -arrow b-.

Fig. 29: Installing Door Handle

-- Install the lock cylinder housing.
Function Test, Performing
-- Remove remote control key from ignition lock and from vehicle.
-- Lock vehicle via button on door handle.

-- Erase the DTC memory. Refer to Vehicle diagnosis, testing and information system VAS 5051.
 On Board Diagnostic (OBD)

 46 - comfort system central control module
 004 DTC memory contents
DOOR LOCK
NOTE: Removing and installing the door lock is described. Removing and installing the
left door lock is identical.
Removing
Fig. 30: Door Lock And Angled Mounting Bracket

-- Remove the subframe. Refer to SUBFRAME.
-- Rotate subframe -5- around and disconnect harness connector -2- from door lock -1-.
-- Drive out clips -3- using a mandrel.
-- Using a screwdriver, pry off door lock -1- with angled mounting bracket -6- and mounting bracket -7- from
subframe.
Fig. 31: Removing Angel Bracket

-- Remove bearing bracket. Refer to BRACKET.
-- Remove the bracket. Refer to ANGLED BRACKET.
-- Lift retainer -5- out of mount -arrow b-.
-- Swivel cable -4- 90° -arrow c- and remove the cable nipple -3- from eyelet -2-.
Fig. 32: Removing Nipple From Eyelet

-- Rotate lock -1- around.
-- Remove retainer -2- from mount.
-- Swivel cable -3- in -direction of arrow b- and remove cable nipple -4- from eyelet -5-.
Installing
 Then a function test must be performed with door open, since the door cannot be opened if release is not
correctly adjustment or clipped in.
BRACKET
Removing
Fig. 33: Sliding Mounting Bracket Until Mounting Points In Guide Of Angled Mounting Bracket Are
Visible
-- Press down locking mechanism on mounting bracket -5- -arrow a-.

-- Slide mounting bracket -1- in -direction of arrow b- until mounting points -6- in guide of angled mounting
bracket -2- are visible.
-- Remove mounting bracket from angled mounting bracket.
-- Remove cable -1- out of guide in mounting bracket -2-.
Fig. 34: Bearing Bracket Remove/Install Components

-- Swivel cable -1- in -direction of arrow- and remove cable nipple -3- from eyelet.
Installing
-- Secure the cable nipple -3- of cable in eyelet and swivel cable -1- in opposite -direction of arrow- on to
mounting bracket.
Fig. 35: Bearing Bracket Remove/Install Components

-- Secure cable -1- in guide in mounting bracket -2-.

Fig. 36: Sliding Mounting Bracket Until Mounting Points In Guide Of Angled Mounting Bracket Are
Visible
-- Guide mounting points -6- of mounting bracket -1- into guides of angled mounting bracket -5-.
-- Slide the bracket into the retainer until the it engages -arrow a-.
ANGLED BRACKET
Removing
Fig. 37: Angled Mounting Bracket Remove/Install Components

-- Disengage catches -arrows a-.
-- Pull off angled mounting bracket -1- from door lock -2- -arrow c-.
Installing
Fig. 38: Angled Mounting Bracket Remove/Install Components

-- Slide angled mounting bracket into mount of lock -arrow b-.
-- Engage angled mounting bracket -1- and door lock -2- with each other -arrows a-.
INNER DOOR SEAL
NOTE: The following describes removal and installation of the left inner door seal only.
The procedure for the right inner door seal is derived accordingly from this.
Removing
Fig. 39: Inner Door Seal

-- Pull off inner door seal -1- from body flange.
Installing
Fig. 40: Inner Door Seal

-- Align inner door seal with vulcanized point -arrow- at the height of the lower hinge.
-- Start installation of inner door seal in upper radius of door cutout.
OUTER DOOR SEAL
NOTE: The following describes removing and installing the right outer door seal only.
Removing and installing the left outer door seal is identical.
Remove protective film just prior to assembly. The processing temperature is

approximately 68° F (20 °C).
Removing
Fig. 41: Outer Door Seal

-- Pull off outer door seal from door.
Installing
Fig. 42: Outer Door Seal

-- Remove any adhesive residue with the adhesive strip removerVAS 6349 radial disc.
-- Thoroughly clean the adhesive surface with adhesive remover D 002 000 10 right before installing the outer
door seal.
-- Align outer door seal with vulcanized point -arrow- at the height of the lower hinge.
-- Remove the protective film and apply the seal to the door. Do not stretch the outer door seal excessively so
-- Start installation of outer door seal in upper radius of door cutout.
Fig. 43: Pressing Entire Adhesive Surface On Seal Firmly Onto Door All Around Using Application
Roller 3356
-- Press the entire adhesive surface of the seal -3- firmly onto the door all around -1- using the roller 3356.
-- This way, the seal is pressed to the side -arrow a- so that the roller 3356 comes into direct contact with the
seal contact surface.
The force -arrow b- from the roller can only reach the adhesive surface -2- if the procedure described above is
used.
-- If the seal has become too long, cut it back to the correct length and press the area with the joint on well.
-- If small areas of the seal -3- loosen again, press them back on with the roller 3356.
NOTE: To ensure that the outer door seal does not loosen or slide again, do not close
the door for 2 hours.
SPECIAL TOOLS
 Application roller for door insulation foil 3356

 Hot air gunV.A.G 1416
 Adhesive removerVAS 6349
Fig. 44: Identifying Special Tools -- Door Components

 Socket T10054
Fig. 45: Identifying Socket T10054

 Door adjusting wrench 3320

 Joint for 33203320/1
 Torque WrenchV.A.G 1331
 Socket 3410
Fig. 46: Identifying Special Tools -- Front Door

Suspension Rear Suspension
Suspension
Rear Suspension
42 REAR SUSPENSION
GENERAL INFORMATION
CONVERTING TO NIVOMAT, FWD
The following points should be observed when converting the rear axle to Nivomat:
 The conversion may only be done on vehicles with basic suspension. Other vehicles may not be
converted to Nivomat
 The shock absorbers (Nivomat) and corresponding coil springs should be replaced on both sides of the
vehicle.
 After replacing shock absorbers and coil springs, a vehicle alignment must be done - the camber value for
the rear axle must be set to 1°45'.
CONVERTING TO NIVOMAT, AWD
The following points should be observed when converting the rear axle to Nivomat:
 The conversion may only be done on vehicles with basic suspension. Other vehicles may not be
converted to Nivomat
 The shock absorbers (Nivomat) and corresponding coil springs should be replaced on both sides of the
vehicle.
 After replacing shock absorbers and coil springs, a vehicle alignment must be done - the camber value for
the rear axle must be set to 1°45'.
CONVERTING TO HEAVY DUTY SUSPENSION, FWD
CAUTION: If the vehicle has a heavy duty suspension, the speed should limited to
210 km/h at the most with the engine control module. Damage to the drive
axles can occur at speeds above 210 km/h. Perform guided function "Limit
maximum speed" with Vehicle Diagnostic Tester.
CONVERTING TO HEAVY DUTY SUSPENSION, AWD
CAUTION: If the vehicle has a heavy duty suspension, the speed should limited to
210 km/h at the most with the engine control module. Damage to the drive
axles can occur at speeds above 210 km/h. Perform guided function "Limit
maximum speed" with Vehicle Diagnostic Tester.
PREPARATION WORK, INSTALLING A STEEL SUBFRAME, AWD

NOTE: Only steel subframes are available as a replacement part.
When replacing an aluminum subframe, a steel subframe must be installed.
Before starting, look the identification and transmission code letters for the rear
axle transmission and compare it in the list. Refer to "Code Letters" table
below.
The preparation work on the subframe must be perform only on the rear axle
transmissions listed below.
NOTE: The identification -arrow- on the bottom of the final drive tells which final drive
is installed.

Example on a 02D Final Drive
-arrow A- final drive part number


-arrow B- final drive code letters
-arrow C- final drive build date
Example:
HEZ 12 01 04
I I I I
I I I I
Code letters Day Month Year of manufacture -2004-
Code Letters
NOTE: The preparation work on the subframes must performed only the rear final
drives with the code letters listed here.
Rear Final Drive Code Letters

FWQ
FWR
02D
HEY
HEZ
HHJ
HHK
0AV
HVY
HVZ
Preparation Work
 Angle grinder, commercially available
-- Disconnect the bracket -2- at the separating point -1- with the angle grinder.
Fig. 3: Identifying Bracket And Separating Point

CAUTION:  The separating point -1- is located on the end of the upper elbow. It
may be in the welding area.
 Do not damage the front transverse pipe.
-- Remove any burrs on the cutting edge and spray with zinc spray -D 007 500 A2- to prevent corrosion.
TIE RODS FOR TRAILING ARMS, ALLOCATION
NOTE: The current production is now using the reinforced trailing arms. The old
trailing arms are no longer available as a replacement part.
Trailing Arm Characteristics
Fig. 4: Identifying Standard Trailing Arm -1-, Reinforced Trailing Arm -2- And Distinguishing Features
1. Standard trailing arm

2. Reinforced trailing arm
The reinforced trailing arm has the following distinguishing features:
A - Additional reinforcement
B - Additional opening
C - Lengthened rib
 Interchanging the trailing arms is permitted

 Note the different tie rod versions when replacing the trailing arm. Refer to Tie Rod Characteristics.
 Allocation of the trailing arms to the tie rods, refer to Note allocation of tie rods for trailing arms.
Tie Rod Characteristics
Fig. 5: Identifying Reinforced Tie Rod -1- And Standard Tie Rod (Open) -2-
1. Reinforced tie rod closed in direction of travel

2. Standard tie rod open downward
 The reinforced tie rod is different on the right and left sides.
 The standard tie rod is the same on the left and right sides.
 Arrow points in direction of travel.
 Interchanging the tie rods is permitted.
 Pay attention to the different trailing arm versions when replacing the tie rod. Refer to Trailing Arm
Characteristics.
 Allocation of the trailing arms to the tie rods. Refer to Note allocation of tie rods for trailing arms.
Note allocation of tie rods for trailing arms

Fig. 6: Identifying Reinforced Trailing Arm -1- And Reinforced Tie Rod -2-
NOTE: It is absolutely necessary to follow the allocation of the tie rods to the trailing
arms. A different allocation is not permitted.
It is absolutely necessary that a reinforced tie rod -2- is installed when replacing a reinforced trailing arm -1-. If
this is not the case, then the tie rod must be replaced.
Make sure a reinforced trailing arm -1- is installed in the vehicle when a reinforced tie rod -2- is being installed.
If a standard trailing arm -1- is being replaced, then it is permissible to install either tie rod version -2- and -3-.
Fig. 7: Identifying Standard Trailing Arm -1-, Reinforced Tie Rod -2- And Standard Tie Rod
If a standard trailing arm -1- is installed in the vehicle, then both versions of the tie rod can be installed.
FRONT WHEEL DRIVE (FWD)
REAR SUSPENSION OVERVIEW
NOTE: Welding and straightening work on supporting or wheel carrying components

of suspension is not permitted.
Always replace self-locking nuts.
Always replace corroded bolts/nuts.
Bonded rubber bushings can only be turned to a limited extent. Therefore, only
tighten bolts on components with bonded rubber bushings when wheel bearing
housing is lifted (curb weight position). Refer to REAR AXLE, LIFTING TO CURB
WEIGHT POSITION.
Always replace bonded rubber bushings on both sides of vehicle.
Fig. 8: Identifying Subframe Assembly Overview And Transverse Links And Tie Rods Assembly
Overview
1. I - Refer to SUBFRAME ASSEMBLY OVERVIEW.

2. II - Refer to TRANSVERSE LINKS AND TIE RODS ASSEMBLY OVERVIEW.
Fig. 9: Identifying Wheel Bearing Housing / Trailing Arm Assembly, DCC Shock Absorber / Coil Spring
Assembly And Stabilizer Bar Assembly
1. III - Refer to WHEEL BEARING HOUSING AND TRAILING ARM ASSEMBLY OVERVIEW.
2. IV - Shock absorber and coil spring, refer to SHOCK ABSORBER AND COIL SPRING ASSEMBLY
OVERVIEW.
3. IV - Adaptive chassis DCC shock absorber, refer to REAR SHOCK ABSORBER ASSEMBLY
OVERVIEW, FWD .
4. V - Refer to STABILIZER BAR ASSEMBLY OVERVIEW.
REAR AXLE, LIFTING TO CURB WEIGHT POSITION

 Engine/transmission jack -V.A.G 1383 A-

 Tensioning strap -T10038-
 Wheel hub support -T10149-
By raising axle on one side using -V.A.G 1383 A- and -T10149-, this position can be simulated on the hoist.
Before lifting the axle on one side, the vehicle must be secured on both sides to the lift arms of the lift using -
T10038-.
Fig. 10: Identifying Vehicle Secured To The Lift Arms Of The Lift Using Tensioning Strap T10038
WARNING: If a vehicle is not secured, there is danger that the vehicle could slip off
the lift!
-- Install -T10149- with wheel bolt.
Threading in must only occur after dimension -a- , measured before installation, between wheel hub center and
lower edge of wheel housing was attained!

Basic suspension with adaptive chassis DCC and 18" 373 +/- 10 mm
wheels (G41)
Blue Motion (G37/G38) 375 +/- 10 mm
WHEEL ALIGNMENT SPECIFIED VALUES
-- Using -V.A.G 1383 A-, lift wheel bearing housing until dimension -a- is reached.
WARNING:
 Do not lift or lower vehicle with -V.A.G 1383 A- below vehicle.

 Do not leave -V.A.G 1383 A- below vehicle any longer than
necessary.
-- Move -V.A.G 1383 A- away from under vehicle.
-- Remove -T10149-.
The -arrow- points in driving direction.

Fig. 12: Identifying Subframe Assembly

1. Subframe
2. Rear Bonded Rubber Bushing
 Replacing, refer to SUBFRAME BONDED RUBBER BUSHING.
3. Front Bonded Rubber Bushing

 Replacing, refer to SUBFRAME BONDED RUBBER BUSHING.
TRANSVERSE LINKS AND TIE RODS ASSEMBLY OVERVIEW

Fig. 13: Identifying Subframe, Transverse Link, Tie Rod - Front Wheel Drive (FWD), Assembly
Overview
1. Eccentric Bolt
 For camber setting.
 After loosening, perform vehicle alignment. Refer to WHEEL ALIGNMENT .
2. Nut
 M12 x 1.5
 95 Nm
 Self-locking

 Always tighten threaded connections in curb weight position. Refer to REAR AXLE, LIFTING
TO CURB WEIGHT POSITION.
3. Eccentric Washer
 Inner bore with tab.
4. Eccentric Bolt
 For toe setting.
5. Eccentric Washer
6. Nut
 M12 x 1.5
 95 Nm
 Self-locking
7. Subframe
 Removing and installing, refer to SUBFRAME.
 Servicing, refer to SUBFRAME BONDED RUBBER BUSHING.
8. Bracket for Rear Muffler

9. Bolt
 M12 x 1.5 x 110
 90 Nm + 90° turn
10. Lower Transverse Link

 Removing and installing, refer to LOWER TRANSVERSE LINK.
11. Nut
 M12 x 1.5 x 75
 90 Nm + 90° turn
 Self-locking
12. Bolt
13. Threaded Rivet

 M6
14. Expanding Rivet

15. Stone Protection Plate

16. Bolt
 M6 x 12
 8 Nm
17. Nut
 Self-locking
18. Washer
19. Bolt
 M14 x 1.5 x 115
 130 Nm + 90° turn
20. Washer
21. Upper Transverse Link
 Removing and installing, refer to UPPER TRANSVERSE LINK.
22. Washer
23. Nut
 Self-locking
25. Washer
26. Bolt
 M14 x 1.5 x 115
 130 Nm + 90° turn
27. Tie Rod
 There are different versions. Refer to Tie Rod Characteristics.
 Closed in direction of travel (the right and left tie rods are different).
 Opened downward (the right and left tie rods are the same).
 It is possible to interchange.
 Pay attention to the allocation of the trailing arms when replacing them. Refer to Note allocation of
tie rods for trailing arms.

 Removing and installing, refer to TIE ROD.
28. Bolt
 M12 x 1.5 x 95
 90 Nm + 90° turn
29. Bolt
 M12 x 1.5 x 90
30. Nut
 90 Nm + 90° turn
 Self-locking
LEFT REAR LEVEL CONTROL SYSTEM SENSOR ASSEMBLY OVERVIEW, THROUGH MY 2007
NOTE: Assembly overview for adaptive chassis DCC, refer to LEFT REAR LEVEL
CONTROL SYSTEM SENSOR ASSEMBLY OVERVIEW, FWD .
Vehicle level sensor is available as replacement part only complete with

coupling rod and upper and lower retaining plates.

Fig. 14: Identifying Vehicle Level Sensor In Vehicles With Automatic Headlight Vertical Aim Control
1. Subframe
3. Bolt
 M5 x 20
 5 Nm
4. Left Rear Level Control System Sensor -G76-


THROUGH MY 2007.
 After replacing, perform basic setting of the headlamps using the Vehicle Diagnostic Tester.
LEFT REAR LEVEL CONTROL SYSTEM SENSOR ASSEMBLY OVERVIEW, FROM MY 2008
CONTROL SYSTEM SENSOR ASSEMBLY OVERVIEW, FWD .

Replacing with subframe installed. Refer to LEFT REAR LEVEL CONTROL

SYSTEM SENSOR, FROM MY 08.
Fig. 15: Identifying Left Rear Level Control System Sensor Assembly
1. Subframe
3. Bolt
 M5 x 20
 5 Nm


FROM MY 08.
 After replacing, perform basic setting of the headlamps using Vehicle Diagnostic Tester in "Guided
Fault Finding" function.
WHEEL BEARING HOUSING AND TRAILING ARM ASSEMBLY OVERVIEW
Fig. 16: Identifying Assembly Overview: Wheel Bearing Housing And Trailing Arm - Front Wheel Drive
(FWD)
1. Cover
2. Mounting Bracket
3. Coupling Rod
 Connects stabilizer to trailing arm/wheel bearing housing.

4. Bolt
 Follow the tightening sequence.
 M12 x 1.5 x 40
 90 Nm + 90° turn
5. Trailing Arm
 Various versions, refer to Trailing Arm Characteristics.
 Removing and installing, refer to TRAILING ARM WITH MOUNTING BRACKET.
 Servicing, refer to TRAILING ARM BONDED RUBBER BUSHING.
 Note the tie rod allocation when replacing them. Refer to Note allocation of tie rods for trailing
arms.
6. Bolt
 M6 x 16
 8 Nm
7. Right Rear ABS Wheel Speed Sensor -G44- / Left Rear ABS Wheel Speed Sensor -G46-
 Before inserting sensor, clean inner surface of mounting hole and coat with Polycarbamide grease -
G 000 650-.
9. Bonded Rubber Bushing

 Replacing, refer to WHEEL BEARING HOUSING BONDED RUBBER BUSHING.
 Either the washer or the wheel bearing front seal is installed. Refer to Fig. 17.
10. Washer
 The washer chamfer must face outward.
 Either the washer or the wheel bearing front seal is installed. Refer to Fig. 17.
11. Nut
 45 Nm
12. Brake Disc

13. Bolt
 4 Nm
14. Dust Cap

 Removing and installing, refer to WHEEL BEARING AND WHEEL HUB.
NOTE: An appropriate seal can only be achieved with a new dust cap.
15. Bolt
Loosen and tighten using bit XZN 18 -T10162-.

 M16 x 1.5 x 70
 200 Nm + 90° turn

Wheel bearing and wheel hub are installed together.
This wheel bearing/hub unit is maintenance and adjustment free. Adjusting or servicing is not
possible!
17. Bolt
 M6 x 10
 12 Nm
18. Cover Plate

19. Bolt
 M12 x 1.5 x 80
 90 Nm + 90° turn

 Replacing, refer to TRAILING ARM BONDED RUBBER BUSHING.
21. Bolt
 M10 x 35
 50 Nm + 90° turn

Fig. 17: Identifying Wheel Bearing Front Seal -1-

CAUTION: When installing the wheel bearing front seal -1- , make sure the hole -
arrow- is installed at the center of the speed sensor -2-.
SHOCK ABSORBER AND COIL SPRING ASSEMBLY OVERVIEW
NOTE: Assembly overview, adaptive chassis DCC, refer to REAR SHOCK ABSORBER
ASSEMBLY OVERVIEW, FWD .
Fig. 18: Identifying Assembly Overview: Shock Absorber And Coil Spring - Front Wheel Drive (FWD)
1. Lower Spring Support

 Spring end rotated up to stop.
2. Assembly Aid
 Must not be used after removal.
3. Coil Spring
 Note different suspension versions. Refer to VEHICLE DATA LABEL .
 Removing and installing, refer to COIL SPRING.
 Always following instructions for converting to Nivomat. Refer to CONVERTING TO

NIVOMAT, FWD.
 Always following instructions for converting to heavy duty suspension. Refer to CONVERTING
TO HEAVY DUTY SUSPENSION, FWD.
4. Upper Spring Support
5. Bolt
 M14 x 1.5 x 85
 180 Nm
6. Bolt
 M10 x 35
 50 Nm + 90° turn
7. Shock Absorbers
 Removing and installing, refer to SHOCK ABSORBER.
 There are different suspension versions. Refer to VEHICLE DATA LABEL .

NIVOMAT, FWD.
TO HEAVY DUTY SUSPENSION, FWD.
8. Washer

STABILIZER BAR ASSEMBLY OVERVIEW

Fig. 19: Identifying Assembly Overview: Stabilizer Bar - Front Wheel Drive (FWD)
1. Stabilizer Bar
 Be aware of the various suspension versions. Refer to VEHICLE DATA LABEL .
2. Rubber Bushing
 Replace mounts always on both sides of vehicle.
3. Clamp
4. Bolt
 M8 x 30
 Tighten uniformly.

6. Nut
 45 Nm
 Self-locking
 Counterhold at socket head of bolt when tightening. See item: 7.
7. Bolt
8. Coupling Rod
 Connects stabilizer to trailing link/wheel bearing housing.
9. Subframe
ALL WHEEL DRIVE (AWD)
REAR SUSPENSION OVERVIEW

Bonded rubber bushings can only be turned to a limited extent. Therefore, only
tighten bolts on components with bonded rubber bushings when wheel bearing
housing is lifted (curb weight position). Refer to REAR AXLE, LIFTING TO CURB
WEIGHT POSITION
Always replace bonded rubber bushings on both sides of vehicle.

Fig. 20: Identifying Rear Axle, Overviews (1 Of 2)

1. I - Refer to SUBFRAME AND FINAL DRIVE ASSEMBLY OVERVIEW.

2. II - Refer to TRANSVERSE LINK AND TIE ROD ASSEMBLY OVERVIEW.
Fig. 21: Identifying Rear Axle, Overviews (2 Of 2)

1. III - Refer to WHEEL BEARING HOUSING AND TRAILING ARM ASSEMBLY OVERVIEW.
2. IV - Shock absorber and coil spring, refer to SHOCK ABSORBER AND COIL SPRING ASSEMBLY
OVERVIEW.
3. IV - Adaptive chassis DCC, refer to REAR SHOCK ABSORBER ASSEMBLY OVERVIEW, AWD .
4. V - Refer to STABILIZER BAR ASSEMBLY OVERVIEW.
REAR AXLE, LIFTING TO CURB WEIGHT POSITION


By raising axle on one side using -V.A.G 1383 A- and -T10149-, this position can be simulated on the hoist.
Before lifting the axle on one side, the vehicle must be secured on both sides to the lift arms of the lift using -
T10038-.
WARNING: If a vehicle is not secured, there is danger that the vehicle could slip off
the lift.
-- Install -T10149- with wheel bolt.

Threading in must only occur after dimension -a- , measured before installation, between wheel hub center and
lower edge of wheel housing was attained!

Basic suspension with adaptive chassis DCC and 18" 373 +/- 10 mm
wheels (G41)
R36 (G36) 358 +/- 10 mm
R36 with adaptive chassis DCC (G46) 358 +/- 10 mm
WHEEL ALIGNMENT SPECIFIED VALUES
-- Using -V.A.G 1383 A-, lift wheel bearing housing until dimension -a- has been reached.
WARNING:  Do not lift or lower vehicle with -V.A.G 1383 A- below vehicle.
 Do not leave -V.A.G 1383 A- below vehicle any longer than

necessary.
-- Move -V.A.G 1383 A- away from under vehicle.
-- Remove -T10149-.
SUBFRAME AND FINAL DRIVE ASSEMBLY OVERVIEW

Fig. 24: Identifying Assembly Overview: Subframe, Final Drive - All Wheel Drive (AWD)
1. Subframe
 Different versions: Aluminum and steel.
NOTE: Only steel subframes are available as a replacement part.
When replacing an aluminum subframe, a steel subframe must be

installed.
Before installing a steel subframe, some preparation work must be

performed on certain rear axle transmissions. Refer to
PREPARATION WORK, INSTALLING A STEEL SUBFRAME, AWD.
2. Nut
 50 Nm + 90° turn
3. Spacer Sleeve
 Between subframe front bonded rubber bushings and body.
4. Rear Bonded Rubber Bushing

 Replacing, aluminum subframes, refer to ALUMINUM SUBFRAME BONDED RUBBER
BUSHING.
 Replacing, steel subframes, refer to STEEL SUBFRAME BONDED RUBBER BUSHING.
5. Front Bonded Rubber Bushing

 Replacing, aluminum subframes, refer to ALUMINUM SUBFRAME BONDED RUBBER
BUSHING.
 Replacing, steel subframes, refer to STEEL SUBFRAME BONDED RUBBER BUSHING.
6. Crossmember
 Omitted with the steel subframe
7. Bolt
 M10 x 115
8. Final Drive
9. Bolt
 60 Nm + 90° turn
10. Washer
 Installed between final drive and subframe.
11. Washer
 Washer must be placed with holes on tabs of bonded rubber bushing.
12. Bolt
 60 Nm + 90° turn
13. Bracket
TRANSVERSE LINK AND TIE ROD ASSEMBLY OVERVIEW

Fig. 25: Identifying Assembly Overview: Transverse Link And Tie Rod - All Wheel Drive (AWD),
1. Eccentric Bolt
 Do not turn more than 90° right or left (that is smallest to largest possible adjustment).
2. Nut
 M12 x 1.5
 95 Nm
 Self-locking


3. Eccentric Washer
4. Eccentric Bolt
 Do not turn more than 90° right or left (that is smallest to largest possible adjustment).
5. Eccentric Washer
6. Nut
 M12 x 1.5
 80 Nm
 Self-locking
NOTE: Adjust torque wrench -V.A.G 1332- to 80 Nm when tightening nut.
This tightening specification does only apply in conjunction with

insert tool 18 -T10179-
7. Subframe
8. Bolt
 M12 x 1.5 x 125
 90 Nm + 90° turn
 Always replace if removed

 Removing and Installing, refer to LOWER TRANSVERSE LINK.
10. Nut
 90 Nm + 90° turn
 Self-locking
11. Bolt
 M12 x 1.5 x 75
12. Threaded Rivet

 M6
13. Expanding Rivet
14. Stone Protection Plate
15. Bolt
 M6 x 12
 8 Nm
16. Nut
 Self-locking
17. Washer
18. Bolt
 M14 x 1.5 x 95
 130 Nm + 90° turn
19. Washer
20. Upper Transverse Link
 Removing and installing, refer to UPPER TRANSVERSE LINK.
21. Washer
22. Nut
 Self-locking

24. Washer
25. Bolt
 M14 x 1.5 x 95
 130 Nm + 90° turn
26. Tie Rod
 Various versions. Refer to Tie Rod Characteristics
 Closed in direction of travel (the right and left tie rods are different).
 Opened downward (the right and left tie rods are the same).
 It is possible to interchange.
 Pay attention to the allocation of the trailing arms when replacing them. Refer to Note allocation of
tie rods for trailing arms.
 Removing and installing, refer to TIE ROD.
27. Bolt
28. Bolt
 M12 x 1.5 x 100
29. Nut
 90 Nm + 90° turn
 Self-locking
LEFT REAR LEVEL CONTROL SYSTEM SENSOR ASSEMBLY OVERVIEW, THROUGH MY 07
CONTROL SYSTEM SENSOR ASSEMBLY OVERVIEW, AWD .

Replacing with subframe installed, refer to LEFT REAR LEVEL CONTROL

Fig. 26: Identifying Assembly Overview: Left Rear Level Control System Sensor G76
1. Subframe
3. Bolt
 M5 x 20
 5 Nm


THROUGH MY 07.
LEFT REAR LEVEL CONTROL SYSTEM SENSOR ASSEMBLY OVERVIEW, FROM MY 08
CONTROL SYSTEM SENSOR ASSEMBLY OVERVIEW, AWD .

Replacing with subframe installed. Refer to LEFT REAR LEVEL CONTROL

Fig. 27: Identifying Assembly Overview: Left Rear Level Control System Sensor
1. Subframe
3. Bolt
 M5 x 20
 5 Nm


FROM MY 08.
WHEEL BEARING HOUSING AND TRAILING ARM ASSEMBLY OVERVIEW
Fig. 28: Identifying Assembly Overview: Wheel Bearing Housing, Trailing Arm - All Wheel Drive (AWD)
1. Cover
2. Mounting Bracket
3. Coupling Rod
4. Bolt
 90 Nm + 90° turn
 Observe tightening sequence, refer to Fig. 195.
5. Trailing Arm
 Different versions. Refer to Trailing Arm Characteristics.
 Removing and installing, refer to TRAILING ARM WITH MOUNTING BRACKET.
 Servicing, refer to TRAILING ARM BONDED RUBBER BUSHING.
 Note the tie rod allocation when replacing them. Refer to Note allocation of tie rods for trailing
arms.
6. Drive Axle
 Assembly overview, Refer to DRIVE AXLE ASSEMBLY OVERVIEW
 Removing and installing, refer to DRIVE AXLE.
7. Bolt
 M14 x 1.5 x 45
 70 Nm + 90° turn

9. Right Rear ABS Wheel Speed Sensor -G44- / Left Rear ABS Wheel Speed Sensor -G46-
 Before inserting sensor, clean inner surface of mounting hole and coat with Polycarbamide grease -
G 000 650-.
10. Bolt
 M6 x 16
 8 Nm

 Replacing, refer to WHEEL BEARING HOUSING BONDED RUBBER BUSHING.
12. Nut
 M12 x 25
 45 Nm
 Self-locking
13. Brake Disc

14. Bolt
15. Bolt
 Hex head bolt = 200 Nm + 180° turn
 Loosening and tightening the hex bolt, refer to DRIVE AXLE HEX BOLT CONNECTION,

bolt.
WITH RIBS, LOOSENING AND TIGHTENING .
Always replace if removed.

The wheel bearing and wheel hub are installed together in a housing.
This wheel bearing/hub unit is maintenance and adjustment free. Adjusting or servicing is not
possible!
17. Bolt
 M6 x 12
 12 Nm
18. Cover Plate

19. Bolt
 M12 x 1.5 x 80
 90 Nm + 90° turn

 Replacing, refer to TRAILING ARM BONDED RUBBER BUSHING.
21. Bolt
 M10 x 35
 50 Nm + 90° turn
Fig. 29: Identifying Differences Between a Twelve-Point Bolt with Ribs and a Twelve-Point Bolt without
Ribs
I - Twelve-point bolt with ribs -arrow A-.
II - Twelve-point bolt without ribs -arrow B-.
SHOCK ABSORBER AND COIL SPRING ASSEMBLY OVERVIEW
NOTE: Assembly overview, adaptive chassis DCC, refer to REAR SHOCK ABSORBER
ASSEMBLY OVERVIEW, AWD .
Fig. 30: Identifying Assembly Overview: Shock Absorber And Coil Spring - All Wheel Drive (AWD)

2. Assembly Aid
 Must not be used after removal.
3. Coil Spring
 Removing and installing, refer to COIL SPRING.
 Always follow instructions for converting to Nivomat. Refer to CONVERTING TO NIVOMAT,

AWD.
 Always follow instructions for converting to heavy duty suspension. Refer to CONVERTING TO
HEAVY DUTY SUSPENSION, AWD.
5. Bolt
 M14 x 1.5 x 70
 180 Nm
6. Bolt
 M10 x 35
 50 Nm + 90° turn
7. Shock Absorbers

NIVOMAT, AWD.
TO HEAVY DUTY SUSPENSION, AWD.
8. Washer

STABILIZER BAR ASSEMBLY OVERVIEW

Fig. 31: Identifying Assembly Overview: Stabilizer Bar - All Wheel Drive (AWD)
1. Stabilizer Bar
2. Rubber Bushing
 Replace mounts always on both sides of vehicle.
3. Clamp
4. Bolt
 M8 x 30

6. Nut
 M10 x 55
 45 Nm
 Self-locking
7. Bolt
8. Coupling Rod
9. Subframe
DRIVE AXLE ASSEMBLY OVERVIEW

Fig. 32: Identifying Assembly Overview: Drive Axle

1. Outer CV Joint
 Removing, refer to Fig. 225.
2. Bolt
 M16 x 1.5 x 80
 Loosening and tightening drive axle hex bolt, refer to DRIVE AXLE HEX BOLT
CONNECTION, LOOSENING AND TIGHTENING.

ribs. Distinguishing characteristic, refer to Fig. 33.
bolt.
3. Drive Axle
4. Clamp
 Tensioning, refer to Fig. 231.
5. Protective Boot
 Material: (polyelastomer).
6. Clamp
7. Dished Washer
8. Spacer
9. Securing ring
10. CV Boot

11. Clamp
12. Backing Plate

13. Bolt
sequence.
 M8 x 48
 40 Nm
14. Securing Ring

 Remove and install using snap ring pliers -VW 161 A-.
15. Gasket
16. Inner CV Joint

 Replace only as complete unit
 Pressing off, refer to Fig. 227.
 Pressing on, refer to Fig. 229.
17. Dished Washer

 With inner splines.

Ribs
I - Twelve-point bolt with ribs -arrow A-.
II - Twelve-point bolt without ribs -arrow B-.
DRIVE AXLE HEX BOLT CONNECTION, LOOSENING AND TIGHTENING
 Angle wrench -V.A.G 1756-
NOTE: The wheel bearing must not be under a load while the drive axle threaded
If the bearings are loaded by the vehicle's own weight the wheel bearing will be
damaged. This reduces the service life of the wheel bearings. Therefore,
observe the following:
Procedure for loosening hex bolt.
Vehicles without a drive axle must not be moved, otherwise the wheel bearing will be damaged. If vehicle must
be moved, observe the following:
-- Install an outer joint in place of the drive axle.

-- Tighten outer joint to 120 Nm.
Loosening
-- With vehicle still standing on its wheels, loosen hex bolt a maximum of 90°, otherwise wheel bearing will be
damaged.
-- Remove hex bolt -arrow-.
Fig. 34: Identifying Wheel Hex Bolt

Tightening
-- Replace hex bolt.
-- Tighten hex bolt to 180 Nm.
-- Turn bolt an additional 180°.

DRIVE AXLE TWELVE-POINT BOLT WITH RIBS, LOOSENING AND TIGHTENING
 Socket XZN 24 -T10361-

Ribs
I - Twelve-point bolt with ribs -arrow A-
II - Twelve-point bolt without ribs -arrow B-
bearings.

following:

Loosening
-- With vehicle still resting on wheels, loosen 12-point bolt with -T10361- maximum 90°, otherwise, wheel

Tightening

DRIVE AXLE TWELVE-POINT BOLT WITHOUT RIBS, LOOSENING AND TIGHTENING

Ribs
bearings.
following:

Loosening
-- With vehicle still resting on wheels, loosen 12-point bolt with -T10361- maximum 90°, otherwise, wheel

Tightening

NOTE: Wheels must not yet touch thefground to tighten the drive axle, wheel bearing
SPECIFICATIONS

ABS Wheel Speed Sensor Bolt M6 x 16 8
Brake Disc to Wheel Hub Bolt - 4
Crossmember to Subframe Nut, AWD (1) - 50 + 90° turn
Coupling Rod to Stabilizer Bar Nut (1) - 45
Coupling Rod to Wheel Bearing Housing Nut (1) - 45
Cover Plate to Wheel Bearing Housing Bolt - 12
CV Joint Boot Clamp - 25
Drive Axle to Final Drive Bolt, AWD 1, 3 M8 x 48 40
Drive Axle to Wheel Hub Bolt, AWD (1)
- Hex Head Bolt - 200 + 180° turn
- Twelve-Point Bolt with Ribs - 70 + 90° turn
- Twelve-Point Bolt without Ribs - 200 + 180° turn
Final Drive to Subframe Bolt, AWD - 60 + 90° turn
Level Control System Sensor Bolt M5 x 20 5
Lower Transverse Link to Subframe Nut 1, 2 M12 x 1.5 95
Lower Transverse Link to Wheel Bearing Housing Nut 1, 2 - 90 + 90° turn
Shock Absorber to Body Bolt (1) - 50 + 90° turn
Shock Absorber to Shock Absorber Mounting Nut (1) - 25
Shock Absorber to Wheel Bearing Housing Bolt (1) - 180
Stabilizer Bar to Subframe Bolt (1) - 25 + 90° turn
Stone Protection Plate to Lower Transverse Link Bolt M6 x 12 8
Subframe to Body Bolt (1) - 90 + 90° turn
Tie Rod to Subframe Nut 1, 2 - 90 + 90° turn
Tie Rod to Wheel Bearing Housing Bolt 1, 2 - 130 + 90° turn
Trailing Arm to Mounting Bracket Bolt (1) M12 x 1.5 x 80 90 + 90° turn
Trailing Arm to Wheel Bearing Housing Bolt (1) - 90 + 90° turn
Trailing Arm Mounting Bracket to Body Bolt (1) M10 x 35 50 + 90° turn
Upper Transverse Link to Subframe Nut 1, 2
- FWD - 95
- AWD - 80
Upper Transverse Link to Wheel Bearing Housing Bolt 1, 2 - 130 + 90° turn
Wheel Hub to Wheel Bearing Housing Bolt (1)
- FWD M16 x 1.5 x 70 200 + 180° turn
- AWD M14 x 1.5 x 45 70 + 90° turn
(2) Always tighten threaded connections in curb weight position.
(3) Pre-tighten to 10 Nm in a diagonal sequence, then tighten to tightening specification in a diagonal

sequence.
OUTER CV JOINT, CHECKING
It is necessary to disassemble the joint whenever replacing the grease or if the ball surfaces show wear or
damage.
Removing
-- Mark position of ball hub to ball cage and to housing before disassembling, using electro-writer or
grindstone.
Fig. 39: Identifying Ball Hub And Ball Cage Swiveled

-- Remove balls in sequence.
-- Turn cage, until two rectangular windows -arrow- contact joint body.
Fig. 40: Identifying Two Rectangular Windows Aligned With The Joint Housing
-- Lift out cage with hub.
-- Swing segment of hub into rectangular window of cage.

Fig. 41: Identifying Tilting Hub Out Of Cage

-- Fold hub out from cage.
6 balls for each joint belong to a tolerance group. Check stub axle, hub, cage and balls for small depressions
(pitting build-up) and chafing. Excessive circumferential backlash in joint makes itself noticed via tip-in shock,
in such cases joint should be replaced. Flattening and running marks of balls are no reason to replace joint.
Installing
-- Press in half of the total grease amount (40 grams) into joint body.
-- Insert cage with hub into joint body.
-- Press in opposing balls in sequence, during this, previous position of ball hub to ball cage and to joint body
must be established again.
-- Install new circlip into the hub.
-- Distribute remaining grease in cover.
-- CV joint, checking for function

INNER CV JOINT, CHECKING
Removing
The joint must be disassembled to replace dirty grease or for checking the balls and ball tracks for wear and
damage.
Fig. 42: Identifying Direction To Press Out Ball Joint Housing

-- Press out ball joint housing in direction of arrow.
-- Press balls out of cage.
NOTE: Ball hub and joint piece are paired. Do not interchange.
-- Flip out ball hub from ball cage via running path of ball -arrows-.
Fig. 43: Identifying Tilt Direction To Flip Ball Hub Out Of Ball Cage Over Ball Track
-- Check joint piece, ball hub, ball cage and balls for small broken off depressions (pitting build-up) and
chafing.
Excessive circumferential backlash in joint makes itself noticed via tip-in shock. Joint must be replaced in such
cases. Flattening and running marks of balls are no reason to replace joint.
Installing
-- Insert ball hub into ball cage via two chamfers. The installation position is at random. Press balls into cage.
Fig. 44: Inserting Ball Hub Over Both Chamfers Into Ball Cage
Ball hub has 2 different distances between ball tracks, a larger and a smaller.
-- Insert hub with cage and balls upright into joint piece, a smaller space -b- must face toward open side of joint
piece when doing this.
Fig. 45: Identifying Wide Space On Joint Housing Aligned With The Narrow Space On The Hub
-- Also note chamfer on inner diameter of ball hub, it must be visible after swiveling in.
-- Swing in ball hub; to do so, swing out hub far enough out of cage -arrows- (as depicted in illustration).
Fig. 46: Identifying Ball Hub Installed With Hub Able To Be Swivelled Out Of The Cage
-- Swing in hub with balls by pressing forcefully onto cage -arrow-.

Fig. 47: Identifying Cage Pressed Firmly Until Hub Is In Position

-- CV joint, checking for function
FRONT WHEEL DRIVE (FWD)
SUBFRAME

 Engine/transmission jack -V.A.G 1383 A- with universal transmission support -V.A.G 1359/2-
 Locating pins -T10096-
Removing
-- Remove wheels.
-- Remove coil springs. Refer to COIL SPRING.
-- Disconnect electrical connections between subframe and body.
-- Remove bolt -arrow-.
Fig. 48: Identifying Shock Absorber Bolt

-- Disconnect brake lines, items -1- and -2-.
Fig. 49: Identifying Brake Lines

-- Disconnect electrical parking brake connections at brake caliper.
-- Remove retainer -1- , pressing out inner pins of rivets -arrows A-.
Fig. 50: Identifying Retainer And Inner Pins Of Rivets

-- Remove line -1- at mounting bracket -arrow A-.
Fig. 51: Identifying Mounting Bracket, Line And Bolts

-- Mark installation position of mounting bracket -2- on body.

-- Remove bolt -B arrows-.
-- Disconnect Left Rear Level Control System Sensor -G76- connector.
-- Now secure vehicle on both sides to lifting arms on hoist with -T10038-.
WARNING: If vehicle is not secured, it could slide off of hoist.
-- Place -V.A.G 1383 A- with -V.A.G 1359/2- below subframe and secure with strap.
Fig. 53: Identifying Engine/Transmission Jack V.A.G 1383 A With Universal Transmission Support
V.A.G 1359/2 Below Subframe
-- Remove bolt -1- or -2- on both sides.
Fig. 54: Identifying Bolts -1- And -2-

NOTE: For the sake of a better illustration, only the left side of the vehicle is shown.
To locate subframe, -T10096- must be screwed in one after the other on both sides of the vehicle at positions -1-
and -2-.
-- Location position of subframe with -T10096-.
Fig. 55: Identifying Tool -T10096- On Subframe

NOTE: -T10096- may only be tightened to a maximum of 20 Nm, since otherwise the
-- Replace subframe bolts one after the other on both sides using -T10096- and tighten them to 20 Nm.
Position of subframe is now secured.
-- Carefully lower subframe with components.
NOTE: When lowering, ensure the brake lines and electrical lines have sufficient
clearance.
Installing
Install in reverse order of removal. Observe the following when doing so:
-- When installing the wires for the electrical parking brake, make sure the dimension -a- between the connector
-1- and the retainer -2- is exact.
Fig. 56: Identifying Dimension -a-, Connector And Retainer

Dimension -a- = 150 mm
-- Bleed brake system. Refer to General Information .

Subframe to
body
90 Nm + 90° turn
 Use
new
bolts.
Shock
absorber to
wheel 180 Nm
bearing
housing.
Mounting
bracket to
body
50 Nm + 45° turn
 Use
new
bolts.

 Hydraulic press -VAS 6178- with pressure head -T10205/13-
 Pneumatic/hydraulic foot pump -VAS 6179-
 Assembly tool -T10356-
-- Disconnect electrical connections between rear suspension and body.
-- Remove the stabilizer bar. Refer to STABILIZER BAR.
-- Now secure vehicle on both sides to lifting arms on hoist with T10038.

-- Remove hex head screw -1- or -2- on both sides.
Fig. 59: Identifying Bolts -1- And -2-

and -2-.
Fig. 60: Identifying Tool -T10096- On Subframe

-- Lower subframe approximately 10 cm using -V.A.G 1383 A-.
Pulling Out Front Bonded Rubber Bushing
-- Install special tools as depicted in the illustration.

Fig. 61: Identifying Front Bushing Install/Remove Tools

1 - Nut -T10263/5-
2 - Thrust piece -T10356/1-
3 - Subframe
4 - Tube -T10356/2-
5 - VAS 6178 with pressure head -T10205/13-
6 - Nut -T10263/5-
7 - Spindle -T10263/4-
-- Pretension special tools.
-- Pull out bonded rubber bushing by operating pump.

NOTE: The bearing outer race is sheared off when the bonded rubber bushing is
removed. There is a loud crack when this happens.
After removing the bonded rubber bushing, it must be removed from the Tube -
T10356/2- by tapping lightly with a hammer.
Pulling In Front Bonded Rubber Bushing
-- Insert special tools with bonded rubber bushing into subframe as illustrated.
Fig. 62: Identifying Front Bushing Install/Remove Tools

1 - Nut -T10263/5-
2 - Guide Piece -T10356/3- with side A toward subframe
3 - Subframe
4 - Bonded rubber mount

5 - Thrust Piece -T10356/4- with side A toward bonded rubber bushing
6 - Tube -T10356/2-
8 - Nut -T10263/5-
9 - Spindle -T10263/4-
-- Pretension special tool with bonded rubber bushing.
-- Carefully insert bonded rubber bushing by operating pump until collar lies on subframe >>without a gap<<.
Pulling Out Rear Bonded Rubber Bushing
Fig. 63: Identifying Rear Bushing Install/Remove Tools

1 - Nut -T10263/5-
3 - Subframe
4 - Tube -T10356/6-
6 - Nut -T10263/5-
7 - Spindle -T10263/4-
After removing the bonded rubber bushing, it must be removed from the Tube -
T10356/2- by tapping lightly with a hammer.
Pulling In Rear Bonded Rubber Bushing
Fig. 64: Identifying Rear Bushing Install/Remove Tools

1 - Nut -T10263/5-
2 - Guide Piece -T10356/3- with side B toward subframe
3 - Subframe
5 - Thrust Piece -T10356/4- with side B toward bonded rubber bushing
7 - Nut -T10263/5-
8 - Spindle -T10263/4-

Further installation is in the reverse sequence to removal. Observe the following when doing so:

Subframe to
body
90 Nm + 90° turn
 Use
new
bolts
LEFT REAR LEVEL CONTROL SYSTEM SENSOR, THROUGH MY 2007
Removing
Fig. 65: Identifying Vehicle Level Sensor Components


-- Remove sensor.
Installing
Sensor lever must face toward outside in direction of travel.
-- After replacing, perform basic setting for headlamps.

Left rear
level
control
system
sensor -
5 Nm
G76- to
lower
transverse
link and
subframe
LEFT REAR LEVEL CONTROL SYSTEM SENSOR, FROM MY 08
NOTE: Left rear level control system sensor for adaptive chassis DCC, removing and
installing, refer to LEFT REAR LEVEL CONTROL SYSTEM SENSOR, FWD .
Removing

Fig. 66: Identifying Harness Connector And Bolts

-- Remove the bolts -2- from the lower transverse link.
-- Remove bolts -arrows- from the subframe.
-- Remove left rear level control system sensor.
Installing
The left rear level control system sensor lever must point toward the outside of the vehicle.
-- After replacing, perform a headlamp basic setting using Vehicle Diagnostic Tester in "Guided Fault Finding"
function.

Left rear
level
control
system
sensor lever 5 Nm
-G76- to
lower
transverse
link and
subframe
UPPER TRANSVERSE LINK
Removing
-- Remove coil spring. Refer to COIL SPRING.
-- Unhook speed sensor wiring -arrow A- from the upper transverse link.
Fig. 67: Identifying Speed Sensor Wiring At Upper Transverse Link

-- Remove bolt -1-.
-- Mark, e.g. using a felt-tip marker, position of eccentric bolt -arrow- to subframe.
Fig. 68: Locating Eccentric Bolt On Subframe

-- Remove upper transverse link.
Installing
-- Insert the upper transverse link into the vehicle and tighten the bolts by hand.
NOTE: Only bolt on upper transverse link if dimension "a" is reached! Refer to Fig. 11
-- Bolt upper transverse link to subframe and tighten new nut.

Fig. 69: Locating Eccentric Bolt On Subframe

-- Note applied marking of eccentric bolt -arrow- to subframe.
-- Tighten the bolt -1- on the upper transverse link.
Fig. 70: Identifying Speed Sensor Wiring At Upper Transverse Link

NOTE: Make sure that washer is installed between bolt and wheel bearing housing.
-- Hook speed sensor wiring -arrow A- in at the upper transverse link.

-- Install coil spring. Refer to COIL SPRING.
MOUNTING WHEELS .
-- Perform vehicle alignment. Refer to WHEEL ALIGNMENT .

Upper
transverse link
to wheel
bearing
housing
 Use a
new bolt 130 Nm + 90° turn
and nut.
 Tighten
bolts in
curb
weight
position.
Upper
transverse link
to subframe
95 Nm
 Use new
nut
 Adjust torque wrench -V.A.G 1332- to 80 Nm when tightening nut.
 Tighten
 Only applies in conjunction with Insert Tool SW 18 -T10179-.
bolts in
curb
weight
position.
LOWER TRANSVERSE LINK
Removing
-- Measure dimension from wheel center to lower edge of wheel housing.

-- Remove bolt -arrow- for lower transverse link -1-.
Fig. 71: Locating Bolt For Lower Transverse Link

Vehicles with Dynamic Headlamp Range Control

Fig. 72: Identifying Lower Transverse Link Bolts

-- Mark, e.g. using a felt-tip marker, position of eccentric bolt -arrow B- to subframe.
-- Disengage rear exhaust system and lower.
-- Remove lower transverse link.
Installing
-- Insert lower transverse link into vehicle and tighten the bolts by hand.
NOTE: Only bolt on transverse link if dimension "a" is reached! Refer to Fig. 11.
-- Connect the upper transverse link to the subframe and tighten the new nut -arrow- to the tightening
specification only.

-- Note applied marking of eccentric bolt -arrow B- to subframe.
-- Suspend rear exhaust system.

-- Install the bolts -1- to the lower transverse link.
-- Tighten bolt -arrow- for lower transverse link -1-.

-- Install coil spring. Refer to "Installing" under: COIL SPRING.
MOUNTING WHEELS .

Lower transverse link to wheel bearing housing
Use a new bolt and nut. 90 Nm + 90° turn

 Tighten bolts in curb weight position.
Lower transverse link to subframe 95 Nm
 Use new nut.

Left rear level control system sensor -G76- to lower 5 Nm

transverse link
TIE ROD

Removing
-- Remove coil spring. Refer to "Removing" under: COIL SPRING.
-- Remove the nut -1- and pull coupling rod -2- out of stabilizer.
Fig. 75: Identifying Tie Rod, Bolt, Connecting Link, Nut And Stabilizer Bar
-- Remove bolt -arrow- for tie rod -3-.
-- Remove bolts -arrows- for stabilizer clamp.

Fig. 76: Identifying Stabilizer Bar Clip Bolts

-- Remove the nut -arrow- and remove bolt toward rear.
Fig. 77: Identifying Tie Rod Bolt

-- Remove tie rod -1-.
Installing
CAUTION: Pay attention to the different trailing arm versions when replacing the tie
rod. Refer to Trailing Arm Characteristics.
Note the allocation of the tie rods for the trailing arms. Refer to Note
allocation of tie rods for trailing arms.
-- Insert tie rod into vehicle and tighten the bolts by hand.
NOTE: The bolted connections of the tie rod must only be fastened when the
dimension "a" is achieved. Refer to Fig. 11.
-- Fasten the tie rod -1- to the subframe and tighten the new nut -arrow-.
Fig. 78: Identifying Tie Rod Bolt

-- Tighten bolts -arrows- for stabilizer clamp.


-- Tighten bolt -arrow- for tie rod -3-.
NOTE: Make sure that washer is installed between nut and wheel bearing housing.
-- Insert coupling rod -2- into stabilizer and tighten nut -1-.

MOUNTING WHEELS .

Tie rod to
wheel bearing
housing
 Use a
new bolt
and nut. 130 Nm + 90° turn
 Tighten
bolts in
curb
weight
position.
Tie rod to
subframe
 Use a
new bolt
 Tighten
bolts in
curb
weight
position.
Stabilizer bar
to subframe
 Use new
bolts.
25 Nm + 45° turn
 Tighten
bolts in
curb
weight
position.
Stabilizer bar 45 Nm
to connecting
link
 Use new
nut.
Removing
-- Remove wheel bearing/wheel hub unit. Refer to WHEEL BEARING AND WHEEL HUB.
-- Remove cover plate.
-- Remove ABS wheel speed sensor from wheel bearing housing.

-- Remove bolt for tie rod -1- , upper transverse link -2- and lower transverse link -3- from wheel bearing
housing -4-.
Fig. 82: Identifying Tie Rod Bolt, Upper Transverse Link, Lower Transverse Link And Wheel Bearing
Housing
-- Remove connecting link -arrow- from the wheel bearing housing.
-- Hold wheel bearing housing and remove bolts -arrows-.
Fig. 83: Identifying Wheel Bearing Housing Bolt And Connecting Link
-- Pull coupling rod -1- out of trailing arm.

Installing
Threaded connection of trailing arm/wheel bearing housing must only be tightened when all other components
(spring and strut always) of the respective wheel suspension have been already assembled. To tighten,
suspension must be unloaded. Only now do the trailing arm and wheel bearing housing move into the position
required -arrows-.
Fig. 84: Identifying Longitudinal Control Arm And Wheel Bearing Housing Moved To Required Position
NOTE: Always perform the following work in the sequence given!
-- Install bolt for tie rod -1- , upper transverse link -2- and lower transverse link -3- , but do not tighten.
Housing
-- Hand-tighten coupling rod -arrow- to wheel bearing housing -4-.
-- Install bolts -arrows- and insert connecting link -1- into trailing arm.
-- Tighten bolt -arrow- for shock absorber.


NOTE: Bolting at wheel bearing housing may occur only when dimension "a" has been
obtained. Refer to Fig. 11.
-- Tighten bolt for tie rod -1- , upper transverse link -2- and lower transverse link -3-.
Housing
-- Tighten the coupling rod nut -arrow-.
-- Tighten bolts -arrows-.
Vehicles with Wheel Bearing Front Seal
Fig. 90: Identifying Wheel Bearing Front Seal And Center Of The Speed Sensor
CAUTION: When installing the wheel bearing front seal -1- , make sure the hole -
arrow- is installed at the center of the speed sensor -2-.
-- Install cover plate.
-- Install wheel bearing/wheel hub unit.
-- Install ABS wheel speed sensor in wheel bearing housing.
-- Install brake disc.
-- Install brake carrier with brake caliper. Refer to Removal and Installation .
MOUNTING WHEELS .

Wheel bearing
housing to
upper
transverse link
 Use a
and nut.
 Tighten
bolts in
curb
weight
position.
Wheel bearing
housing to
lower
transverse link
 Use a
and nut.
 Tighten
bolts in
curb
weight
position.
Wheel bearing
housing to tie
rod
 Use a
new bolt
 Tighten
bolts in
curb
weight
position.
Trailing arm
to wheel
bearing
 Use new
bolts.
Connecting
link to wheel
bearing
housing 45 Nm
 Use new
nut.
Cover plate to
wheel bearing 12 Nm
housing
ABS speed
sensor to
8 Nm
wheel bearing
housing
Shock
absorber to
wheel bearing
housing.
180 Nm
 Use a
new
bolt.
Brake disc to
wheel bearing 4 Nm
housing
WHEEL BEARING HOUSING BONDED RUBBER BUSHING

 Assembly tool -3346-

 Fitting sleeve -3378-
 Tappet -3390-
Removing
-- Remove wheel bearing/wheel hub unit. Refer to WHEEL BEARING AND WHEEL HUB.

Pressing Out Bonded Rubber Bushing
-- Attach tools as depicted in illustration.

Fig. 92: Identifying Tool Assembly To Press Out Bonded Rubber Bushing
1. Nut -3346/3-
2. -3390-
3. -3350-
4. Nut, commercially available
5. Spindle -3346/2-
-- Remove bonded rubber bushing by turning spindle.
Installing
Pulling In Bonded Rubber Bushing

Fig. 93: Identifying Bonded Rubber Bushing

1. Nut -3346/3-
2. -3346-
3. Bonded rubber bushing
4. -3378-
6. Spindle -3346/2-
-- Install bonded rubber bushing by turning support arm bearing installation tool.
NOTE: Do not use lubricant.
Insert bearing with care so it is not canted.
obtained. Refer to Fig. 11


MOUNTING WHEELS .

Wheel bearing
housing to
lower
transverse link
 Use a
and nut.
 Tighten
bolts in
curb
weight
position.
Cover plate to
wheel bearing
12 Nm
housing
Brake disc to
wheel bearing 4 Nm
housing
WHEEL BEARING AND WHEEL HUB
 Grease cap puller -VW 637/2-

 Seal installer -3241-
 Ring spanner insert AF 21 -T10162-
Removing
-- Remove wheel.
Loosen dust cap from seat by tapping lightly on claw of -VW 637/2-.
Fig. 95: Identifying Hammer And Grease Cap Puller VW 637/2

-- Press off dust cap.

Fig. 96: Identifying Grease Cap Puller VW 637/2 To Pull Off Dust Cap
-- Remove brake carrier with brake caliper and hang on body with tie wire. Refer to Removal and
Installation .
NOTE: Suspend brake caliper from body.
-- Remove the brake rotor bolt and the brake rotor.
-- Remove multi-point socket head bolt using -T10162-.
-- Pull wheel hubs/wheel bearing unit off stub axle.
Installing
-- Carefully slide wheel hub/wheel bearing unit onto stub axle.
NOTE: Make sure that wheel hubs/wheel bearing unit do not cant.
-- Tighten using a new multi-point socket head bolt.
NOTE: First tighten bolt to specified tightening specification using torque wrench.
Use solid wrench for additional torque angle.
-- Drive in dust cap using installation sleeve -3241/4-.
Fig. 97: Identifying Dust Cap Installation Sleeve 3241/4

NOTE: Always replace dust caps.
Damaged dust caps allow moisture to enter. Therefore, always use the tool
shown.
Rest of installation is the reverse of removal.
MOUNTING WHEELS .

Wheel hub
with wheel
bearing to
wheel
bearing
200 Nm + 180° turn
housing
 Use a
new
bolt.
Brake disc
to wheel
4 Nm
bearing
housing
TRAILING ARM WITH MOUNTING BRACKET

Removing
Fig. 98: Identifying Retainer, Connecting Links, Trailing Arm And Fasteners
-- Remove the coupling rod -2- from trailing arm.
-- Remove bolts -arrows B-.
-- Unclip electrical wire from mounting bracket.
-- Mark installation position of mounting bracket on body.

Fig. 99: Identifying Trailing Arm With Mounting Bracket And Bolts
-- Remove longitudinal control arm -1- with mounting bracket.
NOTE: If longitudinal control arm is being replaced, mounting bracket must be

removed from longitudinal control arm.
-- To do so, clamp longitudinal control arm into vise so that mounting bracket -1- makes contact at vise -arrow-.
Fig. 100: Identifying Longitudinal Control Arm Clamped Into Vise And Bolt
-- Remove bolt -2-.
Installation position of mounting bracket to trailing link must then be adjusted.
Determining Installation Position of Mounting Bracket Relative to Trailing Arm
Measure dimension -a- from center of bolt to outer edge of mounting bracket.
Fig. 101: Identifying Measurement From Center Of Bolt To Outer Edge Of Mounting Bracket
Dimension -a- : 57,5 +/- 1 mm.
1. Mounting bracket
2. Trailing link
-- When dimension -a- has been adjusted, tighten bolt.
Installing
CAUTION: Note the different tie rod versions when replacing the trailing arm. Refer to
Tie Rod Characteristics.
required -arrows-.
Fig. 102: Identifying Longitudinal Control Arm And Wheel Bearing Housing Moved To Required
Position
Always perform the following work in the sequence given!
-- Attach longitudinal control arm and mounting bracket with bolts -arrows- to wheel bearing housing, but do
not tighten.
-- Insert coupling rod -1- in trailing link, do not tighten nut yet.
-- Raise wheel suspension using -V.A.G 1383 A- and -T10149- until mounting bracket makes contact on body.
-- Tighten bolts -arrows- on old impression.
-- Let down wheel suspension again using -V.A.G 1383 A- and remove -T10149- from wheel hub.
-- Tighten bolts -arrows B- for longitudinal control arm to tightening specification, observe required position of
components while doing so. Refer to Fig. 102.
-- Tighten the coupling rod nut -2- to the wheel bearing housing.
-- Install retainer -1- , pressing in inner pins of rivets -arrows A-.

MOUNTING WHEELS .

Trailing
arm to
wheel
bearing 90 Nm + 45° turn
housing
 Use
new
bolts.
Trailing
arm to
mounting
bracket
90 Nm + 90° turn
 Use a
new
bolt.
Mounting
bracket to
body
50 Nm + 45° turn
 Use
new
bolts.
Coupling
rod to
trailing arm
45 Nm
 Use
new
nut.
TRAILING ARM BONDED RUBBER BUSHING
 Thrust plate -VW 401-

 Installation device -3372-
-- Remove trailing arm. Refer to TRAILING ARM WITH MOUNTING BRACKET.
-- Clamp longitudinal control arm into vise so that mounting bracket -1- makes contact at vise -arrow-.
-- Remove bolt -2-.
-- Install tools as shown in the illustration.

Fig. 108: Identifying Assembly To Press Out Bonded Rubber Bushing

1. Tube -T10230/3-
2. Thrust piece -T10230/10-
3. -3372-
4. -VW 401-
5. -VW 402-
-- Press out the bonded rubber mount.
-- Place trailing arm on a level surface.

Fig. 109: Identifying Trailing Arm Placed On A Level In Order To Measure And Mark Dimensions
-- Place trailing arm on level surface so that dimension -A- = 113 mm.
-- Mark a vertical line onto bushing of trailing link -arrows-.
Position bonded rubber bushing on longitudinal control arm so that marked line is between protrusions -1-.
Fig. 110: Identifying Bonded Rubber Bushing Positioned On Trailing Arm So That Marked Line Is
Positioned Between Protrusions
NOTE: Always make sure that bonded rubber bushings are in correct installation
position to bushing of trailing link.
Fig. 111: Identifying Assembly To Press In Bonded Rubber Bushing

1. Tube -T10230/5-
2. Thrust plate -T10230/12-, chamfer must point to bonded rubber bushing
4. -3372-
5. -VW 402-
-- Press in bonded rubber bushing flush.
-- Install mounting bracket on trailing arm. Refer to "Determining Installation Position of Mounting Bracket
Relative to Trailing Arm" under: TRAILING ARM WITH MOUNTING BRACKET.
COIL SPRING
 Spring compressor kit -V.A.G 1752-

 Spring holder -V.A.G 1752/3A-
-- Insert spring compressor -3-.
Fig. 112: Identifying Spring Compressor Inserted Using V.A.G 1752/4

WARNING: Make sure that coil spring is seated correctly in -V.A.G 1752/3A- -2-
(danger of accident).
-- Use a wrench or a reversible ratchet to tighten spring compressor.

-- Compress coil spring far enough until it can be removed.
-- Remove spring.
1. -V.A.G 1752/3A-
2. -V.A.G 1752/9-
3. Spring compressor -V.A.G 1752/1-
Observe installation position.
The spring start -arrow- must touch bottom of spring seat.
Fig. 113: Identifying Spring Start Touching Bottom Of Spring Seat

-- Install spring together with spring seat.
-- Spring seat has a pin on bottom.
-- This pin is inserted into hole of lower transverse link -arrow-.

Fig. 114: Identifying Pin Inserted Into Hole Of Lower Transverse Link
-- Then insert spring seat at top into upper spring end.
-- Relieve tension on spring, place upper spring seat onto tab of chassis when doing this.
-- Remove spring tensioner.
MOUNTING WHEELS .
SHOCK ABSORBER
NOTE: Adaptive chassis DCC shock absorber, removing and installing, refer to REAR
SHOCK ABSORBER, FWD .
Removing
-- Remove the wheel housing liner. Refer to Removal and Installation .

Fig. 115: Locating Upper Shock Absorber Bolts


-- Remove shock absorber.
Installing

The bolted connections of the shock absorber to the wheel bearing housing must only be fastened when the
dimension "a" is achieved. Refer to Fig. 11.
-- Insert shock absorber and tighten bolts -arrows-.

-- Tighten the bolt -arrow-.

-- Install wheel housing liner. Refer to Removal and Installation .
MOUNTING WHEELS .

Shock
absorber to
body
50 Nm + 45° turn
 Use
new
bolts.
Shock
absorber to
wheel
bearing
housing. 180 Nm
 Use a
new
bolt.
STABILIZER BAR
Removing
NOTE: The following work steps are described for the left side of the vehicle. These
work steps also apply simultaneously for right side of vehicle.
NOTE: Do not loosen bolt -arrow- for tie rod -3-.

-- Remove the stabilizer bar.
Installing
-- Insert stabilizer into vehicle.
-- Tighten the bolts -arrows- for stabilizer clamp uniformly.

-- Install the coupling rod -2- in the stabilizer bar and tighten the nut -1-.

Stabilizer bar
to subframe
 Use new
bolts.
25 Nm + 45° turn
 Tighten
bolts in
curb
weight
position.
Stabilizer bar
to connecting
link
45 Nm
 Use new
nut
ALL WHEEL DRIVE (AWD)
SUBFRAME

 Tensioning straps -T10038-
 Locating fixtures -T10096-
Removing
NOTE: Be aware that if there is additional work where the drive axle hex head screw
must be loosened, this must also occur with the vehicle resting on the wheels.
Loosening drive axle hex head bolt. Refer to DRIVE AXLE HEX BOLT
CONNECTION, LOOSENING AND TIGHTENING.
-- Remove wheels.
-- Remove exhaust system rear muffler. Refer to CENTER AND REAR MUFFLER, SEPARATING .
-- Disconnect electrical connections between subframe and body.



-- Disconnect electrical parking brake connections at brake caliper.
Fig. 125: Identifying Retainer And Inner Pins Of Rivets

-- Remove line -1- at mounting bracket -arrow A-.
Fig. 126: Identifying Mounting Bracket, Line And Bolts

-- Mark installation position of mounting bracket -2- on body.
-- Remove bolt -B arrows-.
-- Disconnect Left Rear Level Control System Sensor -G76- connector.

-- Check whether there is a marking (colored point) -arrows- on joint washer or final drive flange. If there is no
mark, mark position of joint washer and final drive flange to each other -arrows-.
Fig. 127: Identifying Alignment Markings On Driveshaft At Flange Of Haldex Clutch

-- Disconnect Right Rear ABS Wheel Speed Sensor -G44- and Left Rear ABS Wheel Speed Sensor -G46-
connectors.
-- Remove rear driveshaft tube from rear final drive with joint washer and vibration damper -arrows-.
Fig. 128: Identifying Rear Driveshaft Tube At Rear Final Drive With Joint Washer And Vibration
Damper
-- Remove the center bracket bolts -arrows- two turns.
Fig. 129: Locating Center Bracket Screws

-- Support driveshaft at tunnel support with a piece of wood.
Fig. 130: Identifying Driveshaft Supported At Tunnel Support With A Piece Of Wood
-- Move rear driveshaft tube as far as possible in direction of transmission.
-- Disconnect connector to Haldex clutch above final drive.

and -2-.
Fig. 133: Locating Hex Bolts

Fig. 134: Identifying Subframe Position Secured With 2 Locating Pins T10096
-- Carefully lower subframe with components.
NOTE: Make sure there is enough clearance for brake lines, electrical lines and
driveshaft centering pin when lowering.
Installing

Remove driveshaft at rear final drive.


Subframe to
body
90 Nm + 90° turn
 Use
new
bolts.
Shock
absorber to
wheel 180 Nm
bearing
housing.
Mounting
bracket to
body
50 Nm + 45° turn
 Use
new
bolts.
ALUMINUM SUBFRAME BONDED RUBBER BUSHING

Front or Rear Bonded Rubber Bushings, Removing
-- Disconnect electrical connections between rear axle and body.

-- Remove tie rods. Refer to TIE ROD.



and -2-.
-- Lower subframe 10 cm using -V.A.G 1383 A-.
-- Mark installation position of bonded rubber bushing to subframe, e.g. with a felt-tip pen.

Fig. 141: Identifying Bonded Rubber Bushing And Special Tools

1 - Nut -T10263/5-
2 - Washer, commercially available
3 - Subframe
4 - Tube -T10263/1-
7 - Nut -T10263/5-
8 - Spindle -T10263/4-

Front or Rear Bonded Rubber Bushings, Installing
Front and rear bonded rubber bushings have slightly different installation heights. When installing, observe
allocation.
Bonded rubber bushing must be installed in the correct direction, note marking on subframe.
Fig. 142: Identifying Bonded Rubber Bushing And Special Tools

WARNING: Thrust piece -T10263/3- must be positioned so that locking tabs on

bonded rubber bushing align with opening on -T10263/3-.
1 - Nut -T10263/5-
3 - T10263/3
4 - Subframe
9 - Nut -T10263/5-
10 - Spindle -T10263/4-

Subframe to
body
90 Nm + 90° turn
 Use new
bolts.
Tie rod to
subframe
 Use a
new bolt
 Tighten
bolts in
curb
weight
position.
STEEL SUBFRAME BONDED RUBBER BUSHING


Front bonded rubber bushing, removing, refer to Front Bonded Rubber Bushing, Removing.
Pull in front bonded rubber bushing, refer to Pull In Front Bonded Rubber Bushing.
Pulling out rear bonded rubber bushing, refer to Pulling out rear bonded rubber bushing.
Pulling in rear bonded rubber mounting, refer to Pulling In Rear Bonded Rubber Bushing.
Front Bonded Rubber Bushing, Removing
-- Disconnect electrical connections between rear axle and body.
-- Remove tie rods. Refer to TIE ROD.


NOTE: Do not disconnect the brake line.


and -2-.

Fig. 148: Identifying Bushing Install/Remove Tools

1 - Nut -T10263/5-
2 - Washer, from -T10263-
3 - Tube -T10263/6-
5 - Nut -T10263/5-
6 - Spindle -T10263/4-
-- After removing the rubber bonded bushing, it must then be removed from the tube -T10356/6-
Fig. 149: Identifying Bushing Install/Remove Tool T10356/6

-- Mount the -T10356/6- on the provided surfaces in a vice.
-- Pry a screwdriver between the -T10356/6- and the rubber bonded bushing -arrow- and, if necessary, remove
the bushing by tapping lightly with a hammer on the drift.
Pull In Front Bonded Rubber Bushing
Distinguishing characteristic, rubber bonded bushing

Fig. 150: Identifying Front And Rear Bonded Rubber Bushings

I - Bonded rubber bushing, front
II - Rear bonded rubber bushing, rear
The front rubber bonded bushing had two notches -arrows- on top and have slightly different installation
heights.
-- Install the rubber bonded bushing -1- into the subframe, so that the tab and the plate -arrows- face
perpendicular to direction of travel.
Fig. 151: Identifying Rubber Bonded Bushing And Tool T10263/3

-- Mount the -T10263/3- -2- so that the flat side faces perpendicular to direction of travel.

1 - Nut -T10263/5-
6 - Nut -T10263/5-
7 - Spindle -T10263/4-
-- Install the tie rods. Refer to TIE ROD.
-- Install stabilizer bar. Refer to STABILIZER BAR.
-- Connect the electrical connections between the subframe and the body.
-- Install the rear muffler. Refer to EXHAUST SYSTEM, INSTALLING .
-- Install coil springs COIL SPRING.
-- Mount the rear wheels.
Pulling out rear bonded rubber bushing

NOTE: Do not disconnect the brake line.


and -2-.

1 - Nut -T10263/5-
2 - Washer, from -T10263-

5 - Nut -T10263/5-
6 - Spindle -T10263/4-
-- After removing the rubber bonded bushing, it must then be removed from the tube -T10356/6-
Fig. 159: Identifying Rubber Bonded Bushing Install/Remove Tool

-- Mount the -T10356/6- on the provided surfaces in a vice.

the bushing by tapping lightly with a hammer on the drift.
Pulling In Rear Bonded Rubber Bushing
Distinguishing characteristic, rubber bonded bushing
Fig. 160: Identifying Rubber Bonded Bushing Install/Remove Tool

I - Bonded rubber bushing, front
II - Rear bonded rubber bushing, rear
The front rubber bonded bushing had two notches -arrows- on top and have slightly different installation
heights.
-- Install the rubber bonded bushing -1- into the subframe, so that the tab and the plate -arrows- face
perpendicular to direction of travel.
Fig. 161: Identifying Rubber Bonded Bushing And Tool T10263/3

-- Mount the -T10263/3- -2- so that the flat side faces perpendicular to direction of travel.

1 - Nut -T10263/5-
6 - Nut -T10263/5-
7 - Spindle -T10263/4-
-- Install the rear muffler. Refer to EXHAUST SYSTEM, INSTALLING .
-- Install coil springs. Refer to COIL SPRING.
-- Mount the rear wheels.

Subframe to
body
90 Nm + 90° turn
 Use
new
bolts
LEFT REAR LEVEL CONTROL SYSTEM SENSOR, THROUGH MY 07
Removing
Fig. 163: Identifying Vehicle Level Sensor Components


-- Remove sensor.
Installing
Sensor left must face toward outside of vehicle.
-- After replacing, perform basic setting for headlamps.
LEFT REAR LEVEL CONTROL SYSTEM SENSOR, FROM MY 08
NOTE: Left rear level control system sensor -G76-, adaptive chassis DCC, removing
and installing, refer to LEFT REAR LEVEL CONTROL SYSTEM SENSOR, AWD .
Removing
Fig. 164: Identifying Harness Connector And Bolts

-- Remove bolts -arrows- from the subframe.

-- Remove left rear level control system sensor.
Installing
The left rear level control system sensor lever must point toward the outside of the vehicle.
-- After replacing, perform a headlamp basic setting using Vehicle Diagnostic Tester in Guided Fault Finding
function.

Left rear
level
control
system
sensor to 5 Nm
lower
transverse
link and
subframe
UPPER TRANSVERSE LINK
Removing
-- Unhook speed sensor wiring -arrow A- from the upper transverse link.
Fig. 165: Identifying Wheel Speed Sensor Wire And Bolt

-- Remove bolt -1-.
-- Mark, e.g. using a felt-tip marker, position of eccentric bolt -arrow- to subframe.
Fig. 166: Identifying Transverse Link And Eccentric Bolt

-- Remove upper transverse link -1-.

Installing
-- Insert the upper transverse link into the vehicle and tighten the bolts by hand.
NOTE: Only bolt on transverse link if dimension "a" is reached. Refer to Fig. 23.
-- Fasten upper transverse link -1- to the subframe and tighten the new nut -arrow-.
Fig. 167: Identifying Transverse Link And Eccentric Bolt

-- Tighten the bolt -1- on the upper transverse link.

Fig. 168: Identifying Wheel Speed Sensor Wire And Bolt

NOTE: Make sure that washer is installed between bolt and wheel bearing housing.
-- Hook speed sensor wiring -arrow A- in at the upper transverse link.
-- Install coil spring. Refer to "Installing" under COIL SPRING.
MOUNTING WHEELS .

Upper transverse link to wheel bearing housing

Upper transverse link to subframe 95 Nm
 Use new nut.  Adjust torque wrench -V.A.G 1332- to 80

 Tighten bolts in curb weight position. Nm when tightening nut.
 Only applies in conjunction with Insert
Tool SW 18 -T10179-.
LOWER TRANSVERSE LINK

Removing
-- Measure dimension from center of wheel to lower edge of wheel housing. Refer to REAR AXLE, LIFTING



-- Mark, e.g. using a felt-tip marker, position of eccentric bolt -arrow B- to subframe.
-- Disengage rear exhaust system and lower.
-- Remove lower transverse link.
Installing
-- Insert lower transverse link into vehicle and tighten the bolts by hand.
NOTE: Only bolt on transverse link if dimension "a" is reached. Refer to Fig. 23.
-- Connect the upper transverse link to the subframe and tighten the new nut -arrow- to the tightening
specification only.

-- Suspend rear exhaust system.
-- Install the bolts -1- to the lower transverse link.


MOUNTING WHEELS .

Lower transverse link to wheel bearing housing

Lower transverse link to subframe 95 Nm
 Use new nut.

Left rear level control system sensor -G76- to lower transverse 5 Nm

link
TIE ROD

Removing
-- Remove bolt -arrow- for tie rod -3-.


-- Remove the nut -arrow- and remove bolt toward rear.
Fig. 175: Identifying Tie Rod And Nut

-- Remove tie rod -1-.
Installing
CAUTION: Pay attention to the different trailing arm versions when replacing the tie
rod. Refer to Trailing Arm Characteristics.
-- Insert tie rod into vehicle and tighten the bolts by hand.
NOTE: The bolted connections of the tie rod must only be fastened when the
dimension "a" is achieved! Refer to Fig. 23.
-- Fasten the tie rod -1- to the subframe and tighten the new nut -arrow-.
Fig. 176: Identifying Tie Rod And Nut

-- Tighten bolts -arrows- for stabilizer clamp.


-- Tighten bolt -arrow- for tie rod -3-.
NOTE: Make sure that washer is installed between nut and wheel bearing housing.
-- Insert coupling rod -2- into stabilizer and tighten nut -1-.

MOUNTING WHEELS .

Tie rod to
wheel bearing
housing
 Use a
new bolt
 Tighten
bolts in
curb
weight
position.
Tie rod to
subframe
90 Nm + 90° turn
 Use a
new bolt
and nut.
Stabilizer bar
to subframe
 Use new
bolts.
25 Nm + 45° turn
 Tighten
bolts in
curb
weight
position.
Stabilizer bar
to connecting
link
45 Nm
 Use new
nut.

Removing
TIGHTENING.
-- Remove brake carrier and brake caliper and tie to body with wire. Refer to Removal and Installation .

-- Remove bolts -arrows- and cover plate -1-.

Fig. 180: Identifying Cover Plate And Screws

-- Remove bolt for tie rod -1- , upper transverse link -2- and lower transverse link -3- from wheel bearing
housing -4-.
Fig. 181: Identifying Tie Rod Bolt, Upper Transverse Link, Lower Transverse Link, Wheel Bearing
Housing And Connecting Link
-- Remove connecting link -arrow- from the wheel bearing housing.
-- Pull coupling rod -1- out of trailing arm.

-- Hold wheel bearing housing and remove bolts -arrows-.
-- Remove wheel bearing housing.
Installing
Position
Threaded connection of trailing link/wheel bearing housing must only be tightened when all other components
suspension must be unloaded. Only now do the trailing link and wheel bearing housing move into the position
required -arrows-.
Always perform the following work in the sequence given.
-- Place trailing arm on wheel bearing housing with screws -arrows- but do not tighten yet.
-- Tighten bolts -arrows- for longitudinal control arm to tightening specification, observe required position of
-- Connect the coupling rod -1- to the wheel bearing housing and stabilizer bar.
Connections to wheel bearing housing may only be carried out of dimension between wheel hub center and
lower edge of wheel housing, measured before assembly, is achieved. Refer to Fig. 23.
MOUNTING WHEELS .
-- Tighten the drive axle bolt to wheel hub:
TIGHTENING.

weight.
Ribs

MOUNTING WHEELS .

Wheel bearing
housing to
upper
transverse link
 Use a
and nut.
 Tighten
bolts in
curb
weight
position.
Wheel bearing
housing to
lower
transverse link
 Use a
and nut.
 Tighten
bolts in
curb
weight
position.
Wheel bearing
housing to tie
rod
 Use a
new bolt
 Tighten
bolts in
curb
weight
position.
Trailing arm
to wheel
bearing
housing
90 Nm + 90° turn
 Use new
bolts.
Connecting
link to wheel
bearing
housing 45 Nm
 Use new
nut.
Cover plate to
wheel bearing 10 Nm
housing
ABS speed
sensor to
9 Nm
wheel bearing
housing
Shock
absorber to
180 Nm
wheel bearing
housing.
Brake disc to
wheel bearing 4 Nm
housing
Drive axle to
wheel hub
"hex head
bolt"
200 Nm + 180° turn
 Use a
new
bolt.
Drive axle to
wheel hub
"twelve-point
bolt with ribs"
70 Nm + 90° turn
 Use a
new
bolt.
Drive axle to
wheel hub
"twelve-point
bolt without
ribs"
 Use a 200 Nm + 180° turn

new
bolt.
WHEEL BEARING HOUSING BONDED RUBBER BUSHING

 Tappet -3390-
Removing
NOTE: Suspend brake caliper from body.
-- Remove the brake rotor bolt and the brake rotor.


Fig. 187: Identifying Tool Assembly To Press-Out Bonded Rubber Bushing

1. Nut -3346/3-
2. -3390-
3. -3350-

5. Spindle -3346/2-
-- Remove bonded rubber bushing by turning spindle.
Installing
Pulling In Bonded Rubber Bushing
Fig. 188: Identifying Tool Assembly To Pull-In Bonded Rubber Bushing

1. Nut -3346/3-
2. -3346-
3. Bonded rubber bushing
4. -3378-
6. Spindle -3346/2-
-- Install bonded rubber bushing by turning support arm bearing installation tool.
NOTE: Do not use lubricant.
Insert bearing with care so it is not canted.

obtained. Refer to Fig. 23.

MOUNTING WHEELS .
Wheel bearing
housing to
lower
transverse link 90 Nm + 90° turn
 Use a
new bolt
and nut.
 Tighten
bolts in
curb
weight
position.
Cover plate to
wheel bearing 10 Nm
housing
Brake disc to
wheel bearing 4 Nm
housing
WHEEL BEARING AND WHEEL HUB

Removing
-- Remove the drive axle. Refer to DRIVE AXLE.
NOTE: Do not allow brake caliper to hang from brake line.
-- Remove the brake disc bolt and the brake disc.

Fig. 190: Identifying Wheel Hub/Wheel Bearing Screws

-- Remove wheel hub/wheel bearing unit from wheel bearing housing.
Installing
-- Install a new hex head bolt and tighten. Refer to DRIVE AXLE HEX BOLT CONNECTION,

Wheel hub
with wheel
bearing to
wheel
bearing
70 Nm + 90° turn
housing
 Use a
new
bolt.
Brake disc
to wheel
4 Nm
bearing
housing
TRAILING ARM WITH MOUNTING BRACKET

Removing
-- Remove the coupling rod -2- from trailing link.
-- Remove bolts -arrows B-.
-- Unclip electrical wire from mounting bracket.
-- Mark installation position of mounting bracket on body.
-- Remove the screws -arrows-.

-- Remove longitudinal control arm -1- with mounting bracket.
If longitudinal control arm is being replaced, mounting bracket must be removed from longitudinal control arm.
-- To do so, clamp longitudinal control arm into vise so that mounting bracket -1- makes contact at vise -arrow-.
-- Remove bolt -2-.

Installation position of mounting bracket to trailing link must then be adjusted.
Determining Installation Position of Mounting Bracket Relative to Trailing Arm
Measure dimension -a- from center of bolt to outer edge of mounting bracket.
Fig. 194: Identifying Measurement From Center Of Bolt To Outer Edge Of Mounting Bracket
Dimension -a- : 57,5 +/- 1 mm.
1. Mounting bracket
2. Trailing link
-- When dimension -a- has been adjusted, tighten bolt.
Installing
CAUTION: Note the different tie rod versions when replacing the trailing arm. Refer to
Tie Rod Characteristics.
required -arrows-.
Position
Always perform the following work in the sequence given.
-- Attach longitudinal control arm and mounting bracket with bolts -arrows- to wheel bearing housing, but do
not tighten.
-- Raise wheel suspension using -V.A.G 1383 A- and -T10149- until mounting bracket makes contact on body.
-- Tighten bolts -arrows- on old impression.
-- Install coil spring. Refer to "Installing" under COIL SPRING
-- Tighten bolts -arrows B- for longitudinal control arm to tightening specification, observe required position of
-- Tighten the coupling rod nut -2- to the wheel bearing housing.
-- Install retainer -1- , pressing in inner pins of rivets -arrows A-.

MOUNTING WHEELS .

Trailing
arm to
wheel
bearing 90 Nm + 90° turn
housing
 Use
new
bolts.
Trailing
arm to
mounting
bracket
90 Nm + 90° turn
 Use a
new
bolt.
Mounting
bracket to
body
50 Nm + 45° turn
 Use
new
bolts.
Coupling
rod to
trailing arm
45 Nm
 Use
new
nut.
TRAILING ARM BONDED RUBBER BUSHING

-- Remove trailing arm. Refer to TRAILING ARM WITH MOUNTING BRACKET.
-- Clamp longitudinal control arm into vise so that mounting bracket -1- makes contact at vise -arrow-.
-- Remove bolt -2-.

Fig. 201: Identifying Assembly To Press Out Bonded Rubber Bushing

1. Tube -T10230/3-
2. Thrust piece -T10230/10-
3. -3372-
4. -VW 401-
5. -VW 402-
-- Press out the bonded rubber mount.
-- Place trailing arm on a level surface.

Fig. 202: Identifying Trailing Arm Placed On A Level In Order To Measure And Mark Dimensions
-- Place trailing arm on level surface so that dimension -A- = 113 mm.
-- Mark a vertical line onto bushing of trailing arm -arrows-.
Position bonded rubber bushing on longitudinal control arm so that marked line is between protrusions -1-.
Fig. 203: Identifying Bonded Rubber Bushing Positioned On Trailing Arm So That Marked Line Is
Positioned Between Protrusions
NOTE: Always make sure that bonded rubber bushings are in correct installation
position to bushing of trailing arm.
Fig. 204: Identifying Assembly To Press In Bonded Rubber Bushing

1. Tube -T10230/5-
2. Thrust plate -T10230/12-, chamfer must point to bonded rubber bushing
4. -3372-
5. -VW 402-
-- Press in bonded rubber bushing flush.
-- Install mounting bracket on trailing arm. Refer to "Determining Installation Position of Mounting Bracket
Relative to Trailing Arm" under: TRAILING ARM WITH MOUNTING BRACKET.
COIL SPRING

Removing
-- Insert spring compressor -3-.
Fig. 205: Identifying Spring Compressor Inserted Using V.A.G 1752/4

WARNING: Make sure that coil spring is seated correctly in -V.A.G 1752/3A- -2-
(danger of accident).
-- Use a wrench or a reversible ratchet to tighten spring compressor.
-- Compress coil spring far enough until it can be removed.
-- Remove spring.
1. -V.A.G 1752/3A-
2. -V.A.G 1752/9-
3. Spring compressor -V.A.G 1752/1-
Installing
Observe installation position.
The spring start -arrow- must touch bottom of spring seat.
Fig. 206: Identifying Spring Start Touching Bottom Of Spring Seat

-- Install spring together with spring seat.
-- Spring seat has a pin on bottom.
-- This pin is inserted into hole of lower transverse link -arrow-.

Fig. 207: Identifying Pin Inserted Into Hole Of Lower Transverse Link
-- Then insert spring seat at top into upper spring end.
-- Relieve tension on spring, place upper spring seat onto tab of chassis when doing this.
-- Remove spring tensioner.
MOUNTING WHEELS .
SHOCK ABSORBER
NOTE: Adaptive chassis DCC shock absorber, removing and installing, refer to REAR
SHOCK ABSORBER, AWD .
Removing



Installing

NOTE: The bolted connections of the shock absorber to the wheel bearing housing
must only be fastened when the dimension "a" is achieved. Refer to Fig. 23.
-- Insert shock absorber and tighten bolts -arrows-.


MOUNTING WHEELS .

Shock
absorber to
body
50 Nm + 45° turn
 Use
new
bolts.
Shock
absorber to
wheel 180 Nm
bearing
housing.
STABILIZER BAR

Removing
NOTE: The following work steps are described for the left side of the vehicle. These
work steps also apply simultaneously for right side of vehicle.
NOTE: Do not loosen bolt -arrow- for tie rod -3-.

If the upper bolts on the stabilizer bar clamp on the right side of the vehicle cannot be removed, then the
following work steps must be performed.
Only for the Right Vehicle Side (Depending on Equipment)
-- Remove the right rear wheel.
-- Install -T10149- with a wheel bolt to the wheel hub.

-- Lift the wheel hub with the -T10149- and -V.A.G 1383 A- far enough until it is possible to access the bolts on
the right stabilizer bar clamp.
Procedure for Both Vehicles Sides
-- Remove the stabilizer bar.
Installing
-- Insert stabilizer into vehicle.
-- Tighten the bolts -arrows- for stabilizer clamp uniformly.


Only for the Right Vehicle Side (Depending on Equipment)
-- Remove the -T10038-.
-- Install wheel and tighten. Refer to TIGHTENING SPECIFICATION FOR MOUNTING WHEELS .
Procedure for Both Vehicles Sides
-- Install the coupling rod -2- in the stabilizer bar and tighten the nut -1-.

Stabilizer bar
to subframe
 Use new
bolts.
25 Nm + 90° turn
 Tighten
bolts in
curb
weight
position.
Stabilizer bar
to connecting
link
45 Nm
 Use new
nut.
DRIVE AXLE

overflexing.
Removing
TIGHTENING.
bearings.
following:

-- Remove wheel.
-- Remove bolts for tie rod -1- and lower transverse link -3- from wheel bearing housing -4-.
Fig. 218: Identifying Tie Rod Bolt, Upper Transverse Link, Lower Transverse Link, Wheel Bearing
Housing And Connecting Link

-- Loosen input shaft at transmission flange.
-- Swing wheel bearing housing upward and remove drive axle from inner splines.
-- Remove drive axle.
Installing
TIGHTENING.

weight.
Ribs

NOTE: Connections to wheel bearing housing may only be carried out of dimension
between wheel hub center and lower edge of wheel housing, measured before
assembly, is achieved. Refer top Fig. 23.

Drive axle to
wheel hub
"hex head
bolt"
200 Nm + 180° turn
 Use a
new
bolt.
Drive axle to
wheel hub
"twelve-point
bolt with
ribs" 70 Nm + 90° turn
 Use a
new
bolt.
Drive axle to
wheel hub
"twelve-point
bolt without
ribs" 200 Nm + 180° turn
 Use a
new
bolt.
Drive axle to
rear final
drive flange
shaft
 Use 40 Nm
new
bolts.  Pre-tighten to 10 Nm in diagonal sequence.
 Use
new
backing
plates.
SHOCK ABSORBER, FWD
NOTE: Adaptive chassis DCC shock absorber, FWD, servicing, refer to SHOCK
ABSORBER, FWD .
Fig. 221: Exploded View Of Shock Absorber

1. Shock Absorbers

2. Protective Cap
3. Protective Tube
4. Support Ring
5. Buffer Stop
 For shock absorber with supporting ring. See item 4.
6. Shock Absorber Mounting

7. Nut
 M10 x 1.0
 25 Nm
 Loosening and tightening, refer to Fig. 222
8. Cover
 For shock absorber without supporting ring. See item 4.
10. Buffer stop

Disassembling and Assembling

 Shock absorber set -T10001-
Fig. 222: Identifying Removal Of Hex Nut From Shock Absorber

1. Ratchet (commercially available)

2. Socket wrench 21 mm -T10001/9-
3. Ratchet -T10001/11-
4. Socket wrench 21 mm -T10001/1-

Shock
absorber
mounting to
shock
absorber 25 Nm
 Use
new
nut.
SHOCK ABSORBER, AWD
NOTE: Adaptive chassis DCC shock absorber, AWD, servicing, refer to SHOCK
ABSORBER, AWD .
Fig. 223: Exploded View Of Shock Absorber

1. Shock Absorbers
2. Protective Cap
3. Protective Tube
4. Support Ring
5. Buffer Stop

7. Nut
 M10 x 1.0
 25 Nm
 Loosening and tightening, refer to Fig. 224
8. Cover
10. Buffer Stop


Loosening and Tightening Bolted Connection for Shock Absorber Mount

Fig. 224: Identifying Removal Of Hex Nut From Shock Absorber

1 - Ratchet (commercially available)
2 - Socket wrench 21 mm -T10001/9-
3 - Ratchet -T10001/11-
4 - Socket wrench 21 mm -T10001/1-

Shock
absorber
mounting to
shock 25 Nm
absorber
 Use
new
nut.
DRIVE AXLE

 Punch -VW 408 A-
 Punch -VW 411-
 Sleeve -VW 416 B-
 Thrust pad -VW 447 H-
 Circlip pliers -VW 161 A-
 CV joint boot clamp tool -V.A.G 1682-
Disassembling
Outer CV Joint, Pressing Off

Fig. 225: Identifying Outer CV Joint, Pressing Off

-- Fold back boot.
-- Drive CV joint from drive axle using a drift -A-.
Drift must be placed precisely on star of CV joint.
Driving Joint On
Installed Location: Spring Washer and Thrust Washer On Outer Joint

Fig. 226: Identifying Dished Washer And Thrust Washer On Outer Joint
1. Dished washer
2. Thrust washer
-- Drive onto shaft with plastic hammer until securing ring engages.
Removing the Inner CV Joint

Fig. 227: Identifying Inner Constant Velocity Joint

-- Press off CV from joint using drift.
-- Remove both clamps and slide joint boot toward outer joint.
Assembling
Installed Location of Spring Washer on Inner Joint

Fig. 228: Identifying Spring Washer On Inner Joint

1. Dished washer
Fig. 229: Identifying Tool Assembly To Press On Inner Constant Velocity Joint
NOTE: Chamfer on inner diameter of ball hub (splines) must face the contact shoulder
on the drive axle.
Tightening Hose Clamp On Outer Joint
Fig. 230: Identifying Tool Assembly To Attach CV Joint Boot Clamp Tool V.A.G 1682
-- Attach -V.A.G 1682- as shown in illustration. Be sure that edges of clamping pliers are seated in corners -
(compared to rubber). This clamp can only be tensioned using -V.A.G 1682-.
Use torque wrench -C- with adjustment range 5 to 50 Nm (e.g. -V.A.G 1331-).
Fig. 231: Identifying Tool Assembly To Tighten Clamp For CV Joint Boot (Inner, Small Dia.)
SPECIAL TOOLS

 Tensioning straps -T10038-
Fig. 232: Identifying Angle Wrench V.A.G 1756

Fig. 233: Identifying Socket XZN 24 T10361



Fig. 235: Identifying Wheel Hub Support T10149


Fig. 236: Identifying Spring Compressor Kit V.A.G 1752

Fig. 237: Identifying Spring Compressor Kit V.A.G 1752/3-7


Fig. 238: Identifying Shock Absorber Set T10001

Fig. 239: Identifying Special Tools -- Wheel Bearing Housing Bonded Rubber Bushing, Replacing

 Tappet -3390-
Fig. 240: Identifying Special Tools -- Wheel Bearing And Wheel Hub Unit, Removing And Installing
 Grease cap puller -VW 637/2-

 Seal installer -3241-
 Ring spanner insert -AF 21T10162-
Fig. 241: Identifying Special Tools -- Subframe, Servicing


Fig. 242: Identifying Special Tools - Axle Shaft Assembly


 Punch -VW 408 A-
 Punch -VW 411-
 Sleeve -VW 416 B-
 Thrust pad -VW 447 H-
Fig. 243: Identifying Special Tools - Axle Shaft Assembly

 Circlip pliers -VW 161 A-

 CV joint boot clamp tool -V.A.G 1682-
Accessories & Equipment Seat Frames
Seat Frames
72 SEAT FRAMES
PNEUMATIC LUMBAR ADJUSTMENT ASSEMBLY OVERVIEW, LEATHER SPORT SEAT R36
NOTE: Removing and installing apply only to leather power seats.
Removal and installation of the lumbar pneumatic adjuster is described for left
front seat backrest frame.
Removal and installation of the lumbar pneumatic adjustment on the right front
seat frame is performed in the same way.
Fig. 1: Identifying Pneumatic Lumbar Adjustment Assembly Overview, Leather Sport Seat R36
1. Pump
 Removing, refer to PNEUMATIC LUMBAR ADJUSTMENT PUMP, R36 LEATHER SPORT
SEAT
2. Hose
 Supply line (yellow) for the pneumatic valve blocks
3. Distributor piece
 Supply branch for the second pneumatic circuit
4. Center lumbar hose

 Supply line (red) for the center lumbar support
 Outbound form the left valve block

5. Pneumatic side piece hose
 Pneumatic side piece supply line (blue)
 Outbound form the left valve block
6. Lumbar support and side piece pneumatic valve block

 Controls the pressure increase and decrease of the pneumatic side piece and center lumbar support
 Removing, refer to PNEUMATIC LUMBAR ADJUSTMENT VALVE BLOCKS, R36

LEATHER SPORT SEAT
7. Lumbar pneumatic valve block
 Controls the pressure increase and decrease for the upper and lower lumbar support
 Removing, refer to PNEUMATIC LUMBAR ADJUSTMENT VALVE BLOCKS, R36

LEATHER SPORT SEAT
8. Upper lumbar support hose
 Upper lumbar support supply line (brown)
 Outbound from the right valve block
9. Lower lumbar support hose

 Lower lumbar support supply line (green)
 Outbound from the right valve block
10. Pneumatic side piece

 Left and right
 Cannot be replaced separately
 If the side cushion is defective, then the complete backrest cushion must be replaced
11. Lower lumbar support

 If the lower cushion is defective, then the complete backrest cushion must be replaced
12. Center lumbar support

 If the center cushion is defective, then the complete backrest cushion must be replaced
13. Upper lumbar support

 If the upper cushion is defective, then the complete backrest cushion must be replaced
FRONT SEATS
FRONT SEAT
Removal and installation applies to manual and electric seats.
Removing
CUT-OUT UNITS SAFETY PRECAUTIONS .
-- Position seat as far back as possible using fore/aft adjustment.
-- Move seat approx. 4 cm forward. This is necessary in order to be able to remove the belt buckle during the
following steps.
-- Remove the cap -5- from coupling station.

-- Depending on vehicle equipment, disconnect seat wiring harnesses from the coupling station.
-- Connect airbag adapter VAS 6229 to wiring harness for side airbag -6-.
If the airbag adapter VAS 6229 does not fit, use airbag adapter VAS 6281.
-- Remove wiring harness from its mount in vehicle floor.

Fig. 2: Identifying Front Seat Components

Installation
-- Lift seat through the front doors and into the vehicle.
-- Insert seat into corresponding holes in vehicle floor via centering pins on tunnel side.
-- Tip seat back until backrest rests again rear bench seat cushion.
-- Remove airbag adapter VAS 6229/ airbag adapter VAS 6281.

-- Engage the remaining wiring harnesses in connector station, according to vehicle equipment.
-- Secure wiring harness in mount on floor and insert cover cap -5- into coupling station.
-- Tip seat forward. Centering pins on tunnel side must then be located in corresponding holes in vehicle floor.
-- Tighten screw -1- (40 Nm).

Fig. 3: Identifying Front Seat Components

COVER CAP
Removing and installing on the left side of the vehicle is described here. Removing and installing on the right
side is identical.
The removal and installation instructions are written on the electrically adjustable seat. Removing and replacing
the cap and seat for the remaining seats is done in the same manner.
Removing
-- Mount the fixture for seat repair VAS 6136 on the engine and transmission holder VAS 6095.
-- Secure the seat to the fixture for seat repair VAS 6136.
-- Compress clamping pin -1- inward and remove expanding clip -2-.
-- Remove electric seat cover cap -3- from mounts in seat frame.
Fig. 4: Identifying Cover Cap Components

POWER SEAT FRONT SIDE TRIM
side is identical.
Removing
-- Remove electric seat front side trim -4- from mounts in seat frame.
Fig. 5: Identifying Power Seat Front Side Trim Components

Installation
POWER SEAT TRIM
side is identical.
Removing
Fig. 6: Identifying Clamping Pin, Expanding Pin And Bolt

-- Loosen trim -2- from seat frame and disconnect wiring harnesses on inner side of trim from switches.
-- Remove screw -3- (3.5 Nm) and remove trim -4- from seat frame.
Fig. 7: Identifying Power Seat Trim Components

Installation
POWER SEAT TRIM BRACKET
side is identical.
Removing
NOTE: For the sake of illustration, cover and upholstery are partially not depicted in
illustration.
-- Remove front bracket -3- from seat frame.
-- Remove rear bracket -6- from seat frame.

Fig. 8: Identifying Power Seat Trim Bracket Components

Installation
PARTIAL POWER SEAT TRIM
side is identical.
Removing
-- Pull handle -2- upward.
-- Press securing clip metal tab -1- inward using a small screwdriver and remove handle -2- from adjustment
lever -3-.
NOTE: For the sake of illustration, securing clip is depicted as removed in the
illustration.
-- Remove the securing clip -1- from the adjusting lever -3-.
-- Loosen trim -7- from seat frame and disconnect wiring harnesses on inner side of trim from switches.
Fig. 9: Identifying Partial Power Seat Trim Components

Installation
HEIGHT-ADJUSTABLE SEAT TRIM
side is identical.
Removing
lever -3-.
illustration.
-- Using assembly tool 3399, reach behind a locking mechanism for the backrest adjusting wheel -4-.
-- Pry assembly tool 3399 outward -arrow A- and remove backrest adjusting wheel from seat.
-- Remove trim -8- from seat frame.

Fig. 10: Identifying Height-Adjustable Seat Trim Components

Installation
PASSENGER SEAT TRIM, WITH PASS-THROUGH
Removing

Fig. 11: Identifying Securing Clip Metal Tab Pressed Inward With A Small Screwdriver To Removed
Handle From Adjustment Lever
lever -3-.
illustration.
-- Remove the release lever -4- and remove the clip -5-.
NOTE: Because it is not possible to remove the release lever and the clip without
destroying them, the parts should be replaced before installation.
-- Loosen the sill-side trim -6- and the cover cap -7- from the seat.
Fig. 12: Identifying Passengers Seat Trim, With Pass-Through Components (1 Of 2)

-- Loosen the tunnel-side cover caps -3- and -4- from the seat.
Fig. 13: Identifying Passengers Seat Trim, With Pass-Through Components (2 Of 2)

Installation
PARTIAL POWER/HEIGHT-ADJUSTABLE SEAT TRIM BRACKET AND OPERATING LEVER
side is identical.
Removing
-- Remove seat trim:
 Partially electric: PARTIAL POWER SEAT TRIM

 Height-adjustable: HEIGHT-ADJUSTABLE SEAT TRIM
-- Remove the front seat right trim. Refer to PASSENGER SEAT TRIM, WITH PASS-THROUGH.
-- Remove screws -1- and -2- (3.5 Nm) and remove bracket -3-.
-- Remove the two bolts -5- (3.5 Nm) and remove operating lever -4-.
Fig. 14: Identifying Partial Power/Height-Adjustable Seat Trim Bracket And Operating Lever
Components
Installation
SEAT TRIM, WITHOUT HEIGHT ADJUSTMENT
side is identical.
Removing
-- Using assembly tool 3399, reach behind a locking mechanism for the backrest adjusting wheel -1-.
-- Pry assembly tool 3399 outward -arrow A- and remove backrest adjusting wheel from seat.
-- Remove trim -5- from seat frame.

Fig. 15: Identifying Seat Trim, Without Height Adjustment Components

Installation
SEAT TRIM BRACKET, WITHOUT HEIGHT ADJUSTMENT
side is identical.
Removing
ADJUSTMENT
-- Remove screws -1- and -2- (3.5 Nm) and remove bracket -3-.
Fig. 16: Identifying Seat Trim Bracket, Without Height Adjustment Components
LEFT FRONT SEAT BACKREST
side is identical.
Removing
Electric Seat
Fixed Seat
ADJUSTMENT
-- Remove the front seat trim. Refer to PASSENGER SEAT TRIM, WITH PASS-THROUGH.
NOTE: The illustration shows a manual/partially electric seat. Removal and installation
of electric seat is the same.
-- Depending on vehicle equipment, loosen backrest wiring harnesses from seat frame.
-- Connect Airbag Adapter VAS 6229 to wiring harness for side airbag.
-- Remove two screws -1- and -2- on left and right.
-- Using a screwdriver, bend backrest in area of threaded connections outward slightly and loosen backrest from
seat frame.
Fig. 17: Identifying Front Seat Backrest Components

Installation
Tightening specification for screws -1- and -2- is:
 Manual or partially electric seat: 34.5 Nm.

 Power seat: 27 Nm.
Fig. 18: Identifying Front Seat Backrest Components

POWER SEAT CONTROL MODULE
Removing
-- Remove driver side front seat. Refer to FRONT SEAT
-- Pull side tabs outward -arrows- and remove control module -1- from mounts.
-- Disconnect all wiring harnesses from control module.
Fig. 19: Identifying Power Seat Control Module Components

Installation
SEAT SWITCH UNIT, POWER/PARTIAL POWER SEAT
NOTE: This description is for removing the selector unit; removing the selector unit
from the partially electrical seat is done in the same manner.
Removing
Electric Seat
-- On outer side of trim, pry switch actuators -1- and -2- out of mounts using trim removal wedge 3409.
-- On inner side of trim, remove two screws -3- and screw -4-.
-- Remove seat adjustment switch unit -5- from trim.
-- Remove two screws -6- and remove lumbar support adjustment switch -7- from trim.
-- Press two locking elements together -arrows- and remove switch strip -8- from trim.
Fig. 20: Identifying Seat Switch Unit, Power/Partial Power Seat Components
Installation
POWER FORWARD/BACK ADJUSTMENT UNIT
This removal and installation procedure describes the seat forward/back adjustment for the front left seat frame.
The procedure is the same for the right front seat frame.
Removing
-- Remove cover and cushion from front seat backrests. Refer to FRONT SEAT CUSHION COVER AND
UPHOLSTERY
-- Remove screws -1- and -2- on right side.
-- Remove screw -3- in rear area.
NOTE: Screw -3- in installation position points from inside toward outside.
-- Remove screw -4- in front area.
-- Remove seat pan -5- from longitudinal adjuster -6-.

Fig. 21: Identifying Electric Seat Longitudinal Adjuster Components

Installation
POWER SEAT PAN
This removal and installation procedure describes the lower seat frame for the front left seat frame, which is the
same for the right front seat frame.
Removing
UPHOLSTERY
-- Remove screws -1- and -2- on right side.
-- Remove screw -3- in rear area.
-- Remove seat pan -5- from longitudinal adjuster -6-.

Fig. 22: Identifying Electric Seat Longitudinal Adjuster Components

Installation
If the lower seat frame currently in the vehicle is being replaced, then the new one must be the "Sportline"
equipment variant. Clips -1- and -2- must be removed if this lower seat frame is installed in a vehicle with a
different equipment variant.
To avoid contamination, seat tracks -3- and -4- must be covered with a cloth when removing brackets -1- and -
2-.
Fig. 23: Identifying Power Seat Pan Seat Tracks And Brackets
POWER SEAT ANGLE ADJUSTMENT UNIT
This removal and installation procedure describes the tilt adjustment for the left front seat frame, which is the
same process as for the right front seat frame.
Removing

UPHOLSTERY
-- Disconnect wiring harness -1- from inclination adjuster -2-.
-- Remove inclination adjustment -2- from seat frame.

Fig. 24: Identifying Power Seat Inclination Adjuster Components

Installation
POWER SEAT HEIGHT ADJUSTMENT UNIT
This removal and installation procedure describes the height adjustment for the left front seat frame, which is
the same process as for the right front seat frame.
Removing
-- Remove electric seat trim bracket POWER SEAT TRIM BRACKET
UPHOLSTERY
-- Remove screw -1- in rear area of seat base.
-- Disconnect wiring harness -2- from height adjuster -3-.
-- Remove height adjuster -3- from mounts in seat base.

Fig. 25: Identifying Power Seat Height Adjuster Components

Installation
POWER LUMBAR SUPPORT
NOTE: This removal and installation procedure describes the lumbar support for the
left front backrest frame, which is the same process as for the right front
backrest frame.
Removing
-- Secure backrest on fixture for seat repair VAS 6136.
-- Remove cover and upholstery from front seat backrest. Refer to FRONT BACKREST COVER AND
UPHOLSTERY, EXCEPT TRENDLINE
-- Remove front side airbag. Refer to FRONT SIDE AIRBAG
-- Disconnect wiring harness from drive motors -1- and -2-.
-- Drill out rivet -3- in lower area on rear side.
-- Drill out two rivets -4- on left side.
-- Drill out two rivets -5- on right side.
-- Disengage lumbar support from mounts in backrest frame -arrows-.
-- Remove components of lumbar support from backrest frame.

Fig. 26: Identifying Power Seat Lumbar Support Components

Installation
Use pop rivet pliers to install the rivets VAS 5072 -3- , -4- and -5-.
Fig. 27: Identifying Power Seat Lumbar Support Components

POWER SEAT BACKREST ADJUSTMENT MOTOR
If backrest adjustment motor is faulty, backrest frame must be replaced.
HEADREST
side is identical.
Removing
-- Press button -1- inward as far as stop and remove head rest from backrest.
Fig. 28: Identifying Head Rests Components

Installation
SEAT VENTILATION SWITCH, PASSAT CC
side is identical.
Removing
-- Actuate the seat ventilation switch -E655- -1- latches on the inside of the trim -arrows- , and remove the
switch from the trim and disconnect the connector.
Fig. 29: Identifying Seat Ventilation Switch, Passat CC

Installation
FRONT SEAT BLOWER FAN V268, PASSAT CC
side is identical.
On vehicles registered in the USA, always follow "additional safety precautions for working on seat occupied
recognition" when working on the passenger front seat blower fan -V268-. Refer to PASSENGER
OCCUPANT DETECTION SYSTEM SAFETY PRECAUTIONS .
Removing and installing the passenger front seat blower fan -V268- applies only to vehicles in the USA that are
registered according to the following description.
Removing
Electric Seat
ADJUSTMENT
HEIGHT ADJUSTMENT
All Seats
-- Remove the front seat cushion. Refer to FRONT SEAT CUSHION COVER AND UPHOLSTERY
NOTE: It is not necessary to remove the upholstery.
-- Cut the glued-on fleece -1- around the front seat blower fan -V268- -2- and remove it from the cushion -3-.
-- Remove the front seat blower fan -V268- from the cushion.
Fig. 30: Identifying Glued-On Fleece, Front Seat Blower Fan & Cushion
Installation
-- Install the front seat blower fan -V268- -2- into the proper opening in the cushion -1-.
-- Remove the protective strip from fleece -1- and affix the fleece to cushion -3- without any folds in it.
FRONT SEAT BLOWER FAN V269, PASSAT CC
side is identical.
Removing
Electric Seat
Fixed Seat
-- Remove fixed seat trim. Refer to SEAT TRIM, WITHOUT HEIGHT ADJUSTMENT
All Seats

Remove the cover and upholstery from the front seat backrest:
 All vehicles except the Trendline: FRONT BACKREST COVER AND UPHOLSTERY, EXCEPT
TRENDLINE
 Trendline: FRONT BACKREST COVER AND UPHOLSTERY, TRENDLINE
-- Cut the glued-on fleece -3- around the front seat blower fan -V269- -2- and remove it from the cushion -1-.
-- Remove the front seat backrest blower fan -V269- from the cushion.
Installation
-- Install the front seat backrest blower fan -V269- -2- into the opening in the cushion -1-.
-- Remove the protective strip from fleece -3- and affix the fleece to cushion -1- without any folds in it.
FRONT SPORT SEATS, R36
SPORT SEAT R36

NOTE: Removing and installing the power seat applies to both the leather and cloth
seat.
Removal and installation are described for the left side of the vehicle.
Removal and installation for the right side are performed in the same manner.
Removing
Fig. 34: Identifying Sport Seat R36 Assembly

-- Position the sport seat as far forward as possible using forward/backward adjustment.
-- Position the sport seat as far back as possible using the forward/backward adjustment.
For the following removal steps, move the sport seat into the following positions:
 Move the sport seat approximately 4 cm forward. This is necessary in order to be able to remove the belt
latch on the sport seat.
 Raise the sport seat into the highest position in order to be able to remove the height adjustment motor.
 Adjust the sport seat into the horizontal position in order to be able to remove the inclination adjustment
motor.
-- Remove the cap -6- from coupling station.

-- Disconnect the sport seat wiring harnesses from the coupling station.
-- Connect airbag adapter VAS 6229 to wiring harness for side airbag -5-.
If the airbag adapter VAS 6229 does not fit, use airbag adapter VAS 6281.
-- Remove the wiring harness from its mount on the vehicle floor panel.
-- Remove the sport seat from the vehicle through the front door.
Installation
Fig. 35: Identifying Sport Seat R36 Assembly

-- Lift the sport seat through the front doors and into the vehicle.
-- Install the sport seat above the centering pins into the openings in the vehicle floor panel.
-- Tip the sport seat back until the backrest touches rear bench seat cushion.
-- Remove airbag adapter VAS 6229/ airbag adapter VAS 6281.
-- Engage wiring harness for side airbag -5- in coupling station.

-- Secure the wiring harness in its mount on the vehicle floor panel and lock the cap -6- to the coupling station.
-- Tip the sport seat forward.
NOTE: Make sure the centering pins are inside the openings in the vehicle floor panel.
-- Tighten the bolts -1- and -4- to 40 Nm.
-- Position the sport seat as far forward as possible using forward/backward adjustment.
-- Tighten the bolts -2- and -3- to 40 Nm.
SPORT SEAT TRIM, R36
seat.
Removing
-- Remove the R36 sport seat. Refer to SPORT SEAT R36
-- Attach the sport seat to the fixture for seat repair VAS 6136.
Fig. 36: Identifying Expanding Clip & Clamping Pin

Fig. 37: Identifying Trim Panel, Bolts & Electrical Wiring Harnesses
-- Remove the trim panel -3- from the lower seat frame. From the inside of the trim panel, detach the electrical
wiring harnesses -5- from their individual position switches.
-- Remove the trim -3- from seat frame.
-- Remove the trim -1- from the seat frame.

Installation
SPORT SEAT BACKREST, R36
seat.
Removing
-- Remove the R36 sport seat trim. Refer to SPORT SEAT TRIM, R36
Fig. 38: Identifying Screws & Backrest Heater

-- Disconnect the side airbag wiring harness and remove the backrest heater -3- from the seat frame.
-- Connect the airbag adapter VAS 6229 to side airbag wiring harness.
-- Remove two screws -1- and -2- on left and right.
-- Using a screwdriver, slight bend the backrest frame outward in the area of the threaded connections.
-- Remove the backrest frame from the seat frame.

Fig. 39: Identifying Screws & Backrest Heater

-- Tighten bolts -1- and -2- to 27 Nm.
SPORT SEAT SWITCH UNIT, R36
seat.
Removing
Fig. 40: Identifying Switch Actuators, Pneumatic Side Piece Switch, Lumbar Support Adjustment
Switch, Screws, Seat Adjustment Switch Unit & Switch Strip
-- On outer side of trim, pry switch actuators -1- and -2- out of the mounts using the trim removal wedge 3409.
-- On inner side of trim, remove two screws -7- and screw -5-.
-- Remove seat adjustment switch unit -6- from trim.
-- Remove two screws -8- and remove lumbar support adjustment switch -4- from trim.
-- Compress the two latches on the inside of the trim -arrows A - and remove the pneumatic side piece switch -
NOTE: Removing the side piece pneumatic switch -3- applied only to the leather power
seat.
-- Compress the two latches on the inside of the trim -arrows B - and remove the switch strip -9- from the trim.
Installation
SEAT FORWARD AND BACKWARD ADJUSTMENT, SPORT SEAT R36
seat.
The seat forward/backward adjustment drive is part of the seat adjustment unit
and cannot be replaced by itself.
The following describes removing and installing the seat forward/back

adjustment on the left front seat frame.
Removal and installation of the right seat longitudinal adjuster is performed in

the same way.
Removing
-- Remove the R36 sport seat backrest. Refer to SPORT SEAT BACKREST, R36
-- Remove cover and upholstery from front R36 sport seat backrests. Refer to COVER AND CUSHION, R36
FRONT SPORT SEAT CUSHION
Fig. 41: Identifying Seat Adjustment Unit Screws

-- Remove the screws -1- , -2- and -3- on the right side.
NOTE: The screws -3- and -4- illustrate the installation position from the inside toward
the outside.
-- Remove the screw -4- from the inside.

Fig. 42: Identifying Seat Pan, Inclination Adjustment, Seat Forward/Backward Adjustment Frame &
Height Adjustment
-- Remove the seat pan -1- in -direction of arrow- from the seat forward/backward adjustment frame -3-.
NOTE: The drive for the inclination adjustment -2- and the drive for the height
adjustment -4- can be replaced individually.
Installation

-- Tighten the screws -1- , -2- , -4- and -5- to 27 Nm.
-- Tighten the screws -3- to 15 Nm.
SPORT SEAT PAN, R36
seat.
The following describes removing and installing the lower seat frame on a left
front seat.
Removal and installation of the right seat pan is performed in the same way.
Removing
-- Remove cover and upholstery from front R36 sport seat backrests. Refer to COVER AND CUSHION, R36
FRONT SPORT SEAT CUSHION

-- Remove the screws -1- , -2- and -3- on the right side.
NOTE: The screws -3- and -4- illustrate the installation position from the inside toward
the outside.
-- Remove the screw -4- from the inside.
-- Remove the seat pan from the seat forward/backward adjustment frame.
Installation

-- Tighten the screws -1- , -2- , -4- and -5- to 27 Nm.
-- Tighten the screws -3- to 15 Nm.
SEAT INCLINATION ADJUSTMENT, SPORT SEAT R36

seat.
Removal and installation of seat inclination adjuster is described for left

backrest frame.
Removal and installation of the right seat inclination adjuster is performed in

the same way.
Removing
Fig. 46: Identifying Inclination Adjustment Drive, Bolts, Electrical Connector & Seat Inclination
Adjustment Motor
-- Disconnect the electrical connector -3- from the seat inclination adjustment motor -4-.
-- Remove the bolt -2- (15 Nm).
-- Remove the four bolts -1- (8 Nm)
-- Remove the inclination adjustment drive -4- from the front seat frame.
Installation
SPORT SEAT HEIGHT ADJUSTMENT, R36
seat.
Removal and installation of seat height adjuster is described for left backrest
frame.
Removal and installation of the right seat height adjuster is performed in the
same way.
Removing
Fig. 47: Identifying Eight Adjustment Drive Guide Pins, Bolts, Screws, Front Seat Frame, Height
Adjustment Drive & Connector
-- Remove the bolts in the back of the front seat frame -2- (27 Nm).
-- Disconnect the connector -5- from the height adjustment drive -4-.
-- Remove the height adjustment drive guide pins -3- from the seat frame mounts.
-- Remove the height adjustment drive -4- from the seat frame.
Installation
Fig. 48: Identifying Backrest Frame, Height Adjustment Drive & Serrated Washer
NOTE: Make sure to install the serrated washer -3- between the backrest frame -1- and
the height adjustment drive -2-.
PNEUMATIC LUMBAR ADJUSTMENT PUMP, R36 LEATHER SPORT SEAT
Removing
NOTE: Removing applies only to the power leather sport seat.
Removing the lumbar support pneumatic pump is described for the left front
seat frame.
Removing the lumbar support pneumatic pump for the right front seat frame is
identical.
Fig. 49: Identifying Backrest Cover, Supply Lines, Lumbar Support Adjustment Pump, Supply Line &
-- Remove the backrest cover -arrows- and fold the left and right cover as well as the protective foil to the side.
-- Loosen the back part of the supply line -1- and fold it up.
-- Disconnect the supply lines -2- to both valve blocks for the lumbar support pneumatic.
-- Remove the lumbar support adjustment pump -3- from the retainer in the backrest frame.
-- Disconnect the lumbar support pump connector -5-.
-- Remove the lumbar support pneumatic pump -3- and supply line -4- from the backrest frame.
Installing
PNEUMATIC LUMBAR ADJUSTMENT VALVE BLOCKS, R36 LEATHER SPORT SEAT
Removing
NOTE: Removing applies only to the power leather sport seat.
Removing the lumbar support pneumatic valve blocks is described for the left
front seat frame.
Removing the lumbar support pneumatic valve blocks for the right front seat
frame is identical.
Fig. 50: Identifying Supply Lines, Valve Blocks & Electrical Connectors
-- Remove the backrest cover and fold the left and right cover as well as the protective foil to the side. Refer to
COVER AND CUSHION, BACKREST, R36 SPORT SEAT .
-- Disconnect the supply lines -9- to both valve blocks -7- and -8-.
-- Remove the lumbar support pneumatic valve blocks -7- and -8- from their Velcro connector and turn them
toward the inside -arrows-.
-- Disconnect the electrical connectors -2- and -5-. Remove both valve blocks from the backrest frame.
Installing
INCLINATION ADJUSTMENT DRIVE, R36 SPORT SEAT
NOTE: If the drive is faulty, then the backrest frame must be replaced.
HEADREST GUIDES, R36 SPORT SEAT
seat.
To remove headrest guides, backrest cover must be partially removed.
The backrest cover and cushion are not shown in the illustration.
Removal and installation of the headrest guide is described for left backrest
frame.
Removal and installation of the headrest guide for the right front seat frame is
identical.
Removing

Fig. 51: Identifying Headrest Guide And Backrest Frame Guides

-- Remove cover from backrest until underside of headrest guides are accessible. Refer to COVER AND
CUSHION, BACKREST, R36 SPORT SEAT
-- Reach into the backrest frame and push the lock -arrow A- from the front and from the side -arrow B- to the
side.
-- Remove the headrest guide -1- from the backrest frame.
-- Reach into the backrest frame and operate the lock -arrow C- from the front.
Installation
REAR SEATS
SEAT BENCH, SEDAN/PASSAT CC
Removing
-- In vehicles with heated rear seats, switch ignition off.
Vehicles with integrated child seat
-- Swing integrated child seat -1- upward.
Fig. 52: Identifying Integrated Child Seat And Foot Compartment

-- Pull the foot compartment -2- out of mounts in bench seat.
-- For vehicles with one integrated child seat, remove two bolts -1- (8 Nm).
-- For vehicles with two integrated child seats, remove two bolts -2- and -3- (8 Nm) respectively.
Fig. 53: Identifying Integrated Child Seat Bolts

All vehicles
NOTE: To provide a better overview, rear seat backrest is not depicted in the
illustration.
Removing and installing the seat bench is identical on the sedan and the Passat
CC. The sedan seat bench is shown in the illustrations.
-- Pull the front of the bench seat -1- up and out of the two mounts -2- -arrows A-.
-- Push the bench seat toward rear -arrow B-.
-- Pull the back of the bench seat up and out of side guide plates -3-.
-- On vehicles with heated rear seats, disconnect seat heating wiring harness.
-- Remove the bench seat from vehicle.
Fig. 54: Identifying Sedan Seat Bench Components

Installation
NOTE: Before installation, check both mounts -2- fro damage and replace if necessary.
Fig. 55: Identifying Sedan Seat Bench Components

SEAT BENCH, WAGON
Removing
NOTE: To provide a better overview, rear seat backrest is not depicted in the
illustration.
-- Fold the left bench seat -1- forward.
-- Fold the right bench seat -2- forward.
-- Remove the two bolts -3- (8 Nm) and then remove the left bench seat -1- from the vehicle.
-- Remove the two bolts -4- (8 Nm) and then remove the right bench seat -2- from the vehicle.
Fig. 56: Identifying Wagon Seat Bench Components

LEFT REAR BACKREST
Removing
-- Remove clamp -2- from center backrest bearing -3-.
-- Lift out left backrest -4- from center backrest bearing and remove backrest from pin -5-.
-- Remove left backrest from vehicle.

Fig. 57: Identifying Left Rear Backrest Components

Installation
RIGHT REAR BACKREST
Removing
Wagon
All vehicles
-- Remove the bolt -1- (40 Nm) and remove the belt latch -2- from the floor panel.
-- Lift out right backrest -6- from center backrest bearing and pull backrest off pin -7-.
-- Remove right backrest from vehicle.

Fig. 58: Identifying Right Rear Backrest Components

Installation
FIXED REAR BACKREST, PASSAT CC)
Removing
-- Remove the luggage compartment carpet.

NOTE: This is necessary when removing the fixed rear seat backrest.
There is a hidden loop on the left and right sides of the rear seat backrest which
make it possible to unlock and then fold the backrest.
-- Using the assembly tool T10118, reach between the backrest and the body and pull the right loop -1- out of
the retainer -arrow-.
-- Pull the left loop out of the retainer.
-- Pull the loops -1- and -2- toward the inside and fold the backrest forward.
Fig. 59: Identifying Assembly Tool T10118 To Reach Between Backrest And Body And Pull Right Loop
Out Of Retainer
-- Move the backrest into it vertical position.
-- Pull the left side of the backrest off the hinge -4- -arrow A-.
-- Pull the right side of the backrest off the hinge -5- -arrow B- and remove it from the vehicle.
Installation
SIDE UPHOLSTERY WITH SIDE AIRBAG
Removal and installation is described for the right side of the vehicle. Removing and installing on the left side is
identical.
Removing
Sedan/Passat CC
Wagon
All vehicles
-- Pull side upholstery -2- upward out of mounts -3- and -4-.

-- Disconnect wiring harness from side airbag.

Fig. 61: Identifying Side Upholstery With Side Airbag Components

Installation
SIDE UPHOLSTERY WITHOUT SIDE AIRBAG
Removal and installation is described for the right side of the vehicle. Removing and installing on the left side is
identical.
Removing
Sedan/Passat CC
Wagon
All vehicles
-- Pull side upholstery -2- upward out of mounts -3- and -4-.
Fig. 62: Identifying Side Upholstery With Side Airbag Components

Installation
CENTER ARMREST
Removing
Equipment: Highline, Sport and Comfort
-- Unclip the cushion insert -1-.

Fig. 63: Identifying Cushion Insert

-- Fold the armrest down and open the pass-through flap.
Equipment: Trendline
-- Remove two nuts -1- (8 Nm) and remove center armrest -2- from mounts in backrest.
Equipment: Highline, Sport and Comfort
-- Remove two screws -3- (8 Nm) and remove center arm rest -4- from mounts in backrest.
Fig. 64: Identifying Center Armrest Components

Installation
CENTER ARMREST CUP HOLDER
Removing
-- Fold center armrest forward and open cup holder.
-- Press locking clamp inward on both sides with a screwdriver -arrow A- and remove cup holder -1- from
center armrest -2- -arrow B-.
Fig. 65: Identifying Center Armrest Cupholder Components

Installation
SPECIAL TOOLS
 Engine/transmission holder VAS 6095


 Seat repair stand VAS 6136


Fig. 68: Identifying Torque Wrench 40-200 Nm VAG 1332


 Airbag adapter VAS 6229

Fig. 70: Identifying Airbag Adapter VAS 6229

 Assembly tool 3399
Fig. 71: Identifying Assembly Tool 3399



 Pop rivet pliers VAS 5072
Fig. 73: Identifying Pop Rivet Pliers VAS 5072

 Airbag adapter VAS 6281

Fig. 74: Identifying Airbag Adapter VAS 6281


Accessories & Equipment Seat Upholstery, Covers
Seat Upholstery, Covers
74 SEAT UPHOLSTERY, COVERS

FRONT SEAT COVERS AND UPHOLSTERY
FRONT SEAT CUSHION COVER AND UPHOLSTERY
This removal and installation procedure describes the left front seat cushion. The procedure is the same for the
right front seat cushion.
WARNING: If the upholstery, front seat cushion on front passenger side is replaced,
the front passenger seat occupant sensor -G128- must always be
replaced, too! Refer to FRONT PASSENGER SEAT OCCUPANT SENSOR .
Removing
Electric Seat
ADJUSTMENT
HEIGHT ADJUSTMENT
All Seats
-- Disengage profile -1- on both sides in rear area of seat frame.
-- Disengage profile -2- on both sides from mount -3- on bottom side of seat frame.
-- Disengage profile -4-.

Fig. 1: Identifying Cover And Upholstery, Front Seat Cushion (1 Of 2)

-- Disengage profile -1- from seat frame on both sides.
-- Disengage profile -2- from seat frame on front side.

Fig. 2: Identifying Cover And Upholstery, Front Seat Cushion (2 Of 2)

-- Roll up cover on sides -arrows-.

Fig. 3: Identifying Rolling Up Cover On Sides

-- Cut through all upholstery hooks -arrows- with a diagonal cutter.
-- Remove cover -1- and upholstery -2- from seat frame -3-.
Fig. 4: Identifying Cover, Upholstery And Seat Frame

Installation
NOTE: When securing cover -1- to upholstery -2- , use upholstery clip pliers V.A.G
1634.
Fig. 5: Identifying Cover, Upholstery And Seat Frame

FRONT BACKREST COVER AND UPHOLSTERY, EXCEPT TRENDLINE
This removal and installation procedure describes the left seat. The procedure is the same for the right seat.
Removing
Electric seat
ADJUSTMENT
All Seats
NOTE: The following illustrations describe how to remove the sport seat's cover and
cushion. Use the same procedure for the other equipment variants, except for
the Trendline.
-- Loosen side profiles -1- and -2- from molding -3-.
-- Remove side retaining straps -4- from backrest frame.
-- Release profile -5- from molding -3-.

Fig. 6: Identifying Front Backrest Cover And Upholstery, Except Trendline Remove/Install Components
(1 Of 3)
-- Loosen side profiles -1- from molding -2-.
-- Fold back side of cover upward and loosen molding seal -3- from mounts in backrests.
-- Loosen both profiles -4- from mounts in backrest.
-- Remove backrest cover -5- from the backrest frame.

(2 Of 3)
-- Remove cover -1- and upholstery -2- from backrest frame -3-.
-- Remove cover and upholstery over both head rest guides -4-.
(3 Of 3)
Installation
1634.
(3 Of 3)
FRONT BACKREST COVER AND UPHOLSTERY, TRENDLINE
This removal and installation procedure describes the left seat. The procedure is the same for the right seat.
Removing

Height-adjustable seat
Seat without height adjustment
ADJUSTMENT
All seats
-- Detach wiring harness from seat frame.
-- Release profile -1- from molding -2-.

Fig. 10: Identifying Front Backrest Profile And Molding

-- Fold the cover upward and loosen the clamping profile -1- from the mounts in the backrest frame.
Fig. 11: Identifying Backrest Frame Cover

-- Fold the cover farther up and cut through the three upholstery clips -arrows- on the front side.
Fig. 12: Identifying Upholstery Clips

-- Fold the cover farther up and cut through more upholstery clips.
-- On the rear side of the backrest, disengage profiles -1- and -2- from the wires in the backrest frame.
Fig. 13: Identifying Rear Side Profiles And Wires In Backrest Frame
-- Remove backrest cover -1-.

Fig. 14: Identifying Backrest Cover

-- Remove the remaining upholstery clips and remove the seatback cover. It is not necessary to remove the
headrest guides.
-- Disconnect the cushion from the seatback frame. It is not necessary to remove the headrest guides to do this.
Installation
NOTE: Use upholstery clip pliers V.A.G 1634 when attaching cover to upholstery.
REAR SEAT HEATING ELEMENTS
The backrest and seat cushion heating elements are sown into the cover.
If one of the heat elements is faulty, the corresponding cover should be replaced.
 Cover and upholstery, front seat cushion, removing and installing, refer to FRONT SEAT CUSHION
COVER AND UPHOLSTERY
 Front Backrest Cover and Upholstery, Except Trendline, Removing and Installing, refer to FRONT
BACKREST COVER AND UPHOLSTERY, EXCEPT TRENDLINE
 Front Backrest Cover and Upholstery, Trendline, Removing and Installing, refer to FRONT
BACKREST COVER AND UPHOLSTERY, TRENDLINE
COVERS AND CUSHIONS, R36 SPORT SEAT

NOTE: Removing and installing apply to leather power seats.
Removing and installing the power cloth sport seat is identical to the
description for the leather sport seat with a few slight differences.
WARNING: If the upholstery, front seat cushion cover on the front passenger side is
replaced, the front passenger seat occupant sensor -G128- must always
be replaced as well! Refer to FRONT PASSENGER SEAT OCCUPANT
SENSOR .
Removing
Fig. 15: Identifying Removal Of Profiles At Back Of Seat Frame

-- Remove the profiles at the back of the seat frame -1- , -2- and -3- in -direction of arrow-.
Fig. 16: Identifying Disengagement And Removal Of Profiles Using Tool 3399
-- Remove the profile on the front side -2- using the assembly tool 3399 -3- from the lower seat frame.
Fig. 17: Identifying Seat Heating Connector And Seat Cover

-- Disconnect the seat heating connector -1- from underneath.
-- Fold the seat cover forward and on the sides -arrows-.

Fig. 18: Identifying Removal Of Seat Cover

-- Remove the cover -1- and cushion -3- from the seat frame -2-.
Installation
1634.
Fig. 19: Identifying Installation Of Seat Cover

COVER AND CUSHION, BACKREST, R36 SPORT SEAT
NOTE: Removing and installing apply to leather power seats.
Removing and installing the power cloth sport seat is identical to the
description for the leather sport seat with a few slight differences.
Removing

Fig. 20: Identifying Removal Of Profiles At Bottom Of Backrest Frame

-- Remove the profiles at the bottom of the backrest frame -1- , -2- and -3- in -direction of arrow- from the
piping -4-.
Fig. 21: Identifying Removal Of Profiles

-- Remove the side profiles in -direction of arrow A - from the piping.
-- Remove the two profiles -1- on the left and right side from the retaining track -2- from the backrest frame.
-- Fold the back side of the backrest cover -3- in -direction of arrow B - upward.
Fig. 22: Identifying Removal Of Headrest Guides

-- Fold the backrest cover -1- down.
-- Remove the headrest guides -2- ; refer to HEADREST GUIDES, R36 SPORT SEAT
NOTE: The backrest cover is attached to the front side of the backrest cushion with
Velcro on the following locations -1- , -2- and -3-.
Be careful not to tear the Velcro when loosening it.

Fig. 23: Identifying Removal Of Backrest Cover

-- Disconnect the seat heater connector.
-- Carefully loosen the Velcro -4- on the backrest cover in -direction of arrow B - from the Velcro stop on the
backrest cushion -5-.
-- Remove the backrest cover in -direction of arrow A - from the backrest cushion downward.
NOTE: If the Velcro strips -1- , -2- and -3- loosen from the backrest cushion, then the
cushion must be replaced!
Fig. 24: Identifying Removal Of Valve Blocks

-- Remove the valve blocks -1- and -2- PNEUMATIC LUMBAR ADJUSTMENT VALVE BLOCKS, R36
LEATHER SPORT SEAT .
Fig. 25: Identifying Couplings For Pneumatic Side Piece

-- Disconnect the couplings -3- and -4- for the pneumatic side piece.
Fig. 26: Identifying Removal And Installation Of Backrest Cushion

-- Remove the backrest cushion -2- from the backrest frame -1-.
Installation
NOTE: Make sure the Velcro strips -1- , -2- and -3- are secure on the backrest cushion.
If the Velcro strips have come loose during the removal, then the backrest
cushion must be replaced!
Fig. 27: Identifying Velcro Strips On Backrest Cushion

SEAT HEATING ELEMENT, R36 SPORT SEAT
NOTE: The seat heating elements in the backrest and the seat cushion are sewn into
the cover.
If one of the heat elements is faulty, the corresponding cover should be

replaced.
 Cover and Cushion, R36 Front Sport Seat Cushion, Removing and Installing, refer to COVER AND
CUSHION, R36 FRONT SPORT SEAT CUSHION
 Cover and Cushion, Backrest, R36 Sport Seat, Removing and Installing, refer to COVER AND
CUSHION, BACKREST, R36 SPORT SEAT
REAR SEATS, COVERS AND UPHOLSTERY
SEAT BENCH COVER AND UPHOLSTERY, SEDAN

NOTE: The following description illustrates the "Sportline" variant. The work
procedures are the same for the other variants.
Removing
-- Remove the bench seat, sedan, refer to SEAT BENCH, SEDAN/PASSAT CC
-- Cut through all upholstery clips -arrows- all around bottom side of bench seat with suitable pliers.
-- Loosen cover -1- at outer sides from upholstery -2- and roll up the sides.
Fig. 28: Identifying Seat Bench Cover And Upholstery, Sedan Remove/Install Components (1 Of 2)
-- Remove the cover -1- from the padding -2-.
Installation
1634.

SEAT BENCH COVER AND UPHOLSTERY, WAGON
NOTE: The work steps are described for the right bench seat. The work steps for the
left bench seat are identical.
Removing
-- Remove bench seat, wagon, refer to SEAT BENCH, WAGON
-- Using a screw driver, pry clamping profiles -1- , -2- and -3- of cover -5- all around out of mounts in seat pan -
4-.
Fig. 31: Identifying Clamping Profiles Of Cover Pried All Around Out Of Mounts In Seat Pan Using A
Screw Driver
-- Fold back cover -1-.
-- Cut through the five upholstery clips -arrows- in rear area using a diagonal cutter.
Fig. 32: Identifying Back Cover And Upholstery Clips

-- Cut through all upholstery clips -arrows- and loosen cover -1- from upholstery -2- using a diagonal cutter.
-- Loosen upholstery from seat pan.

Fig. 33: Locating Upholstery Clips

Installation
NOTE: Use upholstery clip pliers V.A.G 1634 when attaching cover to upholstery.
SEAT BENCH COVER AND CUSHION, PASSAT CC
Removing
-- Remove the storage compartment, seat bench, Passat CC. Refer to STORAGE COMPARTMENT AND
SEAT BENCH, PASSAT CC
Fig. 34: Identifying Upholstery Clips And Cover

-- Cut through all the upholstery clips -2- using a diagonal cutter.
-- Loosen the clamping profile all the way around -arrows- from the mount and fold up the cover -1-.
-- Remove the cover -1- from the padding -2-.

Installation
1634.

Fig. 37: Identifying Seat Bench Cover And Upholstery, Sedan Remove/Install Components
SEAT BENCH COVER AND UPHOLSTERY WITH INTEGRATED CHILD SEAT
NOTE: The work described is for the right child seat in the sedan bench seat. The work
for the left child seat in the sedan bench seat and the right and left child seats
in the wagon is the same, except for minor changes.
Removing
-- Remove the bench seat:

 Sedan: SEAT BENCH, SEDAN/PASSAT CC

 Wagon: SEAT BENCH, WAGON
-- Swing integrated child seat -1- upward.
-- Release the two retaining hooks -A arrows- and remove foot compartment -2- from mounts in the bench seat.
NOTE: Before installing the foot compartment -2- , evenly pull cover fabric -3- taut -
arrow B- until it is free of wrinkles.
Fig. 38: Identifying Integrated Child Seat, Foot Compartment And Fabric
-- Swing integrated child seat -1- downward.
-- Remove upholstery clips -2-.
-- Fold integrated child seat -1- back up.
-- Open zip fastener -3- all around.
Fig. 39: Identifying Integrated Child Seat, Upholstery Clips And Zip Fastener
-- Remove the four pop rivets -arrows- and remove the child seat -1- from the seat frame.
Fig. 40: Identifying Child Seat And Pop Rivets

-- Remove all of the upholstery clips -4- all around.
-- Loosen the molding seal -2- from the mounts in the trim -1-.
-- Loosen the two molding seals -3- from the mounts in the child seat adjusting unit.
Fig. 41: Identifying Cover, Molding Seals And Upholstery Clips

-- Fold the cover -2- up at the outer edges.
-- Remove the two upholstery clips each on both sides -4-.
-- Remove the cover -2- with the upholstery -3- from the child seat adjusting unit -1-.
NOTE: The cover -2- is permanently bonded to the upholstery -3-. They cannot be
separated without destroying the fabric and must be replaced as a single unit.
Fig. 42: Identifying Cover And Upholstery

Installation
NOTE: When securing the cover on the child seat adjusting unit, use the upholstery
clip pliers V.A.G 1634.
When securing the integrated child seat the seat pan or seat frame, use the pop
rivet pliers V.A.G 1753A.
CHILD SEAT ADJUSTING UNIT, PUSH BUTTON WITH TRIM
Removing
-- Remove the bench seat:
 Sedan: SEAT BENCH, SEDAN/PASSAT CC

 Wagon: SEAT BENCH, WAGON
-- Remove the cover and upholstery from the integrated child seat. Refer to SEAT BENCH COVER AND
UPHOLSTERY WITH INTEGRATED CHILD SEAT.
-- Slide the transfer element -2- forward -arrow- and disengage it from the press button -1-.
-- Remove the two securing pop rivets -6-.
-- Press the two retaining hooks -4- and -5- and loosen trim -7- with press button -1- from child seat adjusting
unit -3-.
-- Unclip press button from trim.

Fig. 43: Identifying Child Seat Adjusting Unit, Push Button With Trim Remove/Install Components
Installation
RIGHT REAR BACKREST, COVER AND UPHOLSTERY
Removing
-- Remove center armrest. Refer to CENTER ARMREST
Wagon
All vehicles
-- Press buttons in head rest guides and remove both head rests from backrest.
NOTE: The cover and upholstery are only partially shown in the illustration.
-- Press catches on both sides of cover -1- inward with a screwdriver -arrow A- and remove cover upward from
backrest.
Sedan and Wagon
-- Press catches on both sides of cover -2- inward with a screwdriver -arrow B- and remove cover upward from
backrest.
Fig. 44: Identifying Removal Of Covers

-- On back side, pry frame -1- out of mounts in backrest using release lever T10039.
-- Remove collar -2- on right side.
-- Pry clamping profiles -3- and -4- out of mounts in backrest using screwdriver.
-- Pry rest of clamping profile all around out of mounts in backrest, as described.
Fig. 45: Identifying Backrest Mount Frame, Collar And Clamping Profiles
-- Roll cover up at sides and press upholstery and cover over head rest guides.
-- Using a small screwdriver, press apart side ribs of mounts -1- and pull out grip channels -2-.
-- Release cover -3- and upholstery -4- from backrest frame -5-.
Fig. 46: Identifying Backrest Frame, Upholstery And Cover

Installation
LEFT REAR BACKREST, COVER AND UPHOLSTERY
Removing
-- Remove rear left backrest. Refer to LEFT REAR BACKREST
-- Press button in head rest guide and remove head rest from backrest.
-- Press catches on both sides of cover -1- inward with a screwdriver -arrow A- and remove cover upward from
backrest.
Fig. 47: Identifying Right Side Collar And Cover

-- Pry clamping profile -1- out of mounts in backrest using a screwdriver.
Fig. 48: Identifying Clamping Profile To Pry Out Of Mounts In Backrest Using A Screwdriver
-- Roll cover up at sides and press upholstery and cover over head rest guides.
-- Using a small screwdriver, press apart side ribs of mounts -1- and pull out grip channels -2-.
-- Release cover -3- and upholstery -4- from backrest frame -5-.
Fig. 49: Identifying Backrest Frame, Upholstery And Cover

Installation
FIXED REAR BACKREST COVER AND CUSHION, PASSAT CC
Removing
-- Remove the luggage compartment carpet.
-- Remove the fixed rear seat backrest, Passat CC. Refer to FIXED REAR BACKREST, PASSAT CC)
-- Press button in head rest guide and remove head rest from backrest.
-- Pull headrest guide -4- upward out of headrest tube -2-.
-- Remove the clip -2- from backrest frame.
Fig. 50: Identifying Removal Of Clamping Profiles And Clip

-- On back side, pry frame -1- out of mounts in backrest using release lever T10039.
-- Using a screwdriver, pry the clamping profile all the way around the pass-through opening off the mount.
-- Carefully remove the clamping profile -3- from the clips -arrows-.
Fig. 51: Identifying Frame, Release Lever T10039, Collar And Clamping Profile
-- Roll up the cover on the sides and pull the cushion over the head restraint guides -1- and -2-.
-- Using a small screwdriver, press apart side ribs of mounts -arrows- and pull out grip channels.
Fig. 52: Identifying Cushion, Head Restraint Guides And Side Ribs Of Mounts
-- Remove the remaining attachments and remove the cover from the backrest.
-- Fold the upholstery -1- up until the headrest tubes -2- welded into the backrest shell -3- with the headrest
guides -4- are visible.
Fig. 53: Identifying Upholstery, Headrest Tubes / Guides And Backrest Shell
-- Press the retaining tab -arrow A- down until the headrest guide -4- is no longer locked.
-- Remove upholstery from backrest frame.
Installation
Installation is reverse of removal.
SPECIAL TOOLS
 Upholstery clip pliers V.A.G 1634

Fig. 54: Identifying Upholstery Clip Pliers V.A.G 1634

 Assembly tool 3399
Fig. 55: Identifying Assembly Tool 3399

 Engine/transmission holder VAS 6095


 Seat repair stand VAS 6136

Edition 03092011
Suspension Self-Leveling Suspension
Suspension
Self-Leveling Suspension
43 SELF-LEVELING SUSPENSION
GENERAL INFORMATION
DAMPENING ADJUSTMENT BUTTON
The dampening adjustment button -E387- is located on the right side next to the gearshift lever in the center
console.
Fig. 1: Dampening Adjustment Button

The system can be adjusted to three different setting using the dampening adjustment button:
 Normal
 Sport
 Comfort
The sequence is -Normal- > -Sport- > -Comfort- > -Normal- > •••
When actively selecting -Sport- and -Comfort- a yellow LED light will light up in the dampening adjustment
button.
When -normal- is selected, the dampening adjustment button does not light up.
ADAPTIVE CHASSIS DCC, BASIC SETTING
-- Connect the Vehicle Diagnostic Tester and select "Guided Fault Finding".
Chassis
Wheel damping electronics
Functions
Basic setting
Follow the instructions on the screen to perform the basic setting.
ADAPTIVE CHASSIS DCC COMPONENTS AND INSTALLATION LOCATIONS
CAUTION: The body acceleration sensors may not be interchanged with each other.
Fig. 2: Adaptive Chassis DCC Components And Installation Locations

1. Dampening Adjustment Button -E387-

 Component location: In front of the selector lever in the center console.
 Explanations, refer to DAMPENING ADJUSTMENT BUTTON.
2. Shock Absorber with Right Rear Dampening Adjustment Valve -N339-

 Removing and installing, FWD, refer to REAR SHOCK ABSORBER, FWD.
 Removing and installing, AWD, refer to REAR SHOCK ABSORBER, AWD.
3. Electronic Damping Control Module -J250-

 Component location: Behind the right side luggage compartment trim.
 If the electronic damping control module was replaced, then a basic setting to the adaptive chassis
DCC must be performed. Refer to ADAPTIVE CHASSIS DCC, BASIC SETTING.
4. Rear Body Acceleration Sensor -G343-
 Component location: on the rear left shock absorber mount.
 Removing and installing, FWD, refer to REAR BODY ACCELERATION SENSOR, FWD.
 Removing and installing, AWD, refer to REAR BODY ACCELERATION SENSOR, AWD.
5. Shock Absorber with Left Rear Dampening Adjustment Valve -N338-

 Removing and installing, FWD, refer to REAR SHOCK ABSORBER, FWD
 Removing and installing, AWD, refer to REAR SHOCK ABSORBER, AWD

 Removing and installing, FWD, refer to LEFT REAR LEVEL CONTROL SYSTEM SENSOR,
FWD
 Removing and installing, AWD, refer to LEFT REAR LEVEL CONTROL SYSTEM SENSOR,
AWD
 If the left rear level control system sensor was removed and then installed, then a basic setting to
the adaptive chassis must be performed. Refer to ADAPTIVE CHASSIS DCC, BASIC
SETTING.
Headlamps basic setting using Vehicle Diagnostic Tester in "Guided Fault Finding" function.
7. Left Front Body Acceleration Sensor -G341-

 Removing and installing, refer to LEFT FRONT BODY ACCELERATION SENSOR.
8. Shock Absorber with Left Front Dampening Adjustment Valve -N336-

 Suspension strut, removal and installation, refer to FRONT SUSPENSION STRUT.
 Suspension strut, servicing, refer to FRONT SUSPENSION STRUT ASSEMBLY OVERVIEW.
 Removing and installing, refer to FRONT LEVEL CONTROL SYSTEM SENSORS.
 If the level control system sensor was removed and installed, then a basic setting to the adaptive
chassis DCC must be performed. Refer to ADAPTIVE CHASSIS DCC, BASIC SETTING.
Headlamps basic setting using Vehicle Diagnostic Tester in "Guided Fault Finding" function.
10. Shock Absorber with Right Front Dampening Adjustment Valve -N337-
 Suspension strut, removal and installation, refer to FRONT SUSPENSION STRUT.
 Suspension strut, servicing, refer to FRONT SUSPENSION STRUT ASSEMBLY OVERVIEW.
11. Right Front Body Acceleration Sensor -G342-

 Removing and installing, refer to RIGHT FRONT BODY ACCELERATION SENSOR.
FRONT SUSPENSION STRUT ASSEMBLY OVERVIEW

Fig. 3: Front Suspension Strut Assembly Overview

1. Shock Absorber with Left Front Dampening Adjustment Valve -N336-

 Individually replaceable
 For the correct allocation .
2. Buffer Stop
3. Protective Sleeve
4. Coil Spring
 Removing and installing, refer to FRONT SUSPENSION STRUT.
Spring allocation via PR No.
These numbers can be found on vehicle data plate.
 Surface of spring coil may not be damaged.

5. Axial Groove Ball Bearing
6. Suspension Strut Bearing
 Note installed position. Refer to Fig. 24.
7. Nut
 M14 x 1.5
 60 Nm
 Self-locking
8. Suspension Strut Dome

9. Bracket
 For the left front body acceleration sensor.
 Removing and installing, refer to FRONT BODY ACCELERATION SENSOR BRACKET.
 An "L" is stamped on the retainer.
NOTE: Be sure to use the correct retainer.
10. Left Front Body Acceleration Sensor -G341-

 Removing and installing, refer to LEFT FRONT BODY ACCELERATION SENSOR.
 Note the installation position of the retainer. Refer to Fig. 4.
11. Bolt
 5 Nm
12. Bolt
 M8 x 26
 15 Nm + 90° turn
13. Bracket
 For the right front body acceleration sensor.
 Removing and installing, refer to FRONT BODY ACCELERATION SENSOR BRACKET.
 An "R" is stamped on the retainer.
14. Right Front Body Acceleration Sensor -G342-

 Removing and installing, refer to RIGHT FRONT BODY ACCELERATION SENSOR.

15. Nut
 5 Nm
Fig. 4: Identifying Tab On Retainer Fitting Into Recess In Left Front Body Acceleration Sensor
The tab on the retainer -1- must fit into the recess in the left front body acceleration sensor -arrow-.
NOTE: Be sure to use the correct retainer. An "LA" is stamped on the retainer
Fig. 5: Installation Position Right Front Body Acceleration Sensor -G342- On Retainer
The tab on the retainer -1- must fit into the recess in the right front body acceleration sensor -arrow-.
NOTE: Be sure to use the correct retainer. An "R" is stamped on the retainer.
REAR SHOCK ABSORBER ASSEMBLY OVERVIEW, FWD
Fig. 6: Rear Shock Absorber Assembly Overview, FWD



2. Coil Spring
 Note different suspension versions. Refer to VEHICLE DATA LABEL .
 Removing and installing, refer to COIL SPRING .

4. Bracket
 For the rear body acceleration sensor.
5. Rear Body Acceleration Sensor -G343-

 Removing and installing, refer to REAR BODY ACCELERATION SENSOR, FWD.
6. Bolt
 5 Nm
7. Bolt
 M14 x 1.5 x 85
 180 Nm
8. Bolt
 M10 x 35
 50 Nm + 90° turn
9. Shock Absorber with Left and Right Rear Dampening Adjustment Valve -N338/N339-
 Removing and installing, refer to REAR SHOCK ABSORBER, FWD.
 There are different suspension versions. Refer to VEHICLE DATA LABEL .
10. Washer
 Removing and installing, refer to LOWER TRANSVERSE LINK .

 Removing and installing, refer to WHEEL BEARING HOUSING .
Installation Position Rear Body Acceleration Sensor -G343- on the Retainer

Fig. 7: Installation Position Rear Body Acceleration Sensor -G343- On Retainer

The tab on the retainer -1- must fit into the recess in the rear body acceleration sensor -arrow-.
REAR SHOCK ABSORBER ASSEMBLY OVERVIEW, AWD

Fig. 8: Rear Shock Absorber Assembly Overview, AWD


2. Coil Spring
 Removing and installing, refer to COIL SPRING .

4. Bracket
 For the rear body acceleration sensor.
 Removing and installing, refer to REAR BODY ACCELERATION SENSOR, AWD.

6. Bolt
 5 Nm
7. Bolt
 M14 x 1.5 x 70
 180 Nm
8. Bolt
 M10 x 35
 50 Nm + 90° turn
9. Shock Absorbers
 Removing and installing, refer to REAR SHOCK ABSORBER, AWD.
10. Washer
 Removing and installing, refer to LOWER TRANSVERSE LINK .

 Removing and installing, refer to WHEEL BEARING HOUSING .
Installation Position Rear Body Acceleration Sensor -G343- on the Retainer

FRONT LEVEL CONTROL SYSTEM SENSOR ASSEMBLY OVERVIEW
NOTE: A replacement front left and right level control system sensor -G78/G289-
comes complete with the coupling rod and the upper and lower retaining plate.
Fig. 10: Front Level Control System Sensor Assembly Overview

1. Subframe
2. Bolt
 M6 x 16
 9 Nm
 Removing and installing, refer to FRONT LEVEL CONTROL SYSTEM SENSORS.
 If the sensor was removed and installed, then a basic setting to the adaptive chassis DCC must be
performed. Refer to ADAPTIVE CHASSIS DCC, BASIC SETTING.
 After replacing, perform basic setting of the headlamps using the Vehicle Diagnostic Tester in
"Guided Fault Finding" function.
4. Control Arm
5. Nut
 9 Nm
 Self-locking
LEFT REAR LEVEL CONTROL SYSTEM SENSOR ASSEMBLY OVERVIEW, FWD
NOTE: Vehicle level sensor is available as replacement part only complete with

SYSTEM SENSOR, FWD.
Fig. 11: Left Rear Level Control System Sensor Assembly Overview, FWD
1. Subframe
2. Bolt
 M5 x 20
 5 Nm

 Removing and installing, refer to LEFT REAR LEVEL CONTROL SYSTEM SENSOR, FWD.

LEFT REAR LEVEL CONTROL SYSTEM SENSOR ASSEMBLY OVERVIEW, AWD
NOTE: Vehicle level sensor is available as replacement part only complete with

SYSTEM SENSOR, AWD.
Fig. 12: Left Rear Level Control System Sensor Assembly Overview, AWD
1. Subframe
2. Bolt
 M5 x 20
 5 Nm

 Complete with components
 Lever -arrow- must point toward vehicle exterior
 Removing and Installing, refer to LEFT REAR LEVEL CONTROL SYSTEM SENSOR, AWD
 If the sensor was removed and then installed, then a basic setting to the adaptive chassis must be
LEFT FRONT AXLE WIRE ROUTING
NOTE: Always check the wire routing.
Always make sure that all the wires are attached in order and are not twisted in
their retainer.
Fig. 13: Left Front Axle Wire Routing

1. Wire for Left Front Dampening Adjustment Valve -N336-

 The wire must be mounted in the retainer on the shock absorber -arrow-.
2. Left Front ABS Wheel Speed Sensor -G47- Wire

3. Wire for Brake Pad Wear Indicator
RIGHT FRONT AXLE WIRE ROUTING
their retainer.
Fig. 14: Right Front Axle Wire Routing

1. Right Front Dampening Adjustment Valve -N337- Wire

2. Right Front ABS Wheel Speed Sensor -G45- Wire
REAR AXLE WIRE ROUTING

their retainer.
Fig. 15: Rear Axle Wire Routing

1. Left and Right Rear Dampening Adjustment Valve -N338/N339- Wire

2. Right and Left Rear ABS Wheel Speed Sensor -G44/G46- Wire
SPECIFICATIONS


Front Body Acceleration Sensor to Retainer
- 5
Bolt/Nut
Front Level Control System Sensor to Subframe
M6 x 16 9
Bolt
Front Level Control System Sensor to Control
- 9
Arm Nut (1)
Rear Body Acceleration Sensor to Retainer Bolt - 5
Rear Level Control System Sensor Bolt - 5
Shock Absorber to Body Bolt (1) M10 x 35 50 + 90° turn
Shock Absorber to Mount Nut (1) M10 x 1.0 25
Shock Absorber to Wheel Bearing Housing Bolt
(1) - 180
Strut to Body Bolt (1) M8 x 26 15 + 90° turn

Strut to Suspension Strut Bearing Nut (1) M14 x 1.5 60
Suspension Strut to Wheel Bearing Housing (1) - 70 + 90° turn
FRONT SUSPENSION STRUT
 Spreader3424
 Torque wrenchV.A.G 1332
 Engine/transmission jackV.A.G 1383 A
 Wheel hub supportT10149
 Pilot driftVW 222 A
Removing
-- Loosen drive axle bolt to wheel hub. Refer to DRIVE AXLE TWELVE-POINT BOLT WITH RIBS,
LOOSENING AND TIGHTENING .
-- Remove the level control system sensor from the control arm.
-- Remove the nut -arrow- of the connecting link from suspension strut.
Fig. 16: Locating Suspension Strut Coupling Hex Nut


-- Remove the drive axle outer joint from the wheel hub.
-- Secure drive axle to body using wire.

NOTE: The drive axle must not hang down, otherwise the inner joint will be damaged
by over flexing.
-- Bolt ball joint to control arm again.
-- Fasten V.A.G 1383 A using T10149 to wheel hub with a wheel bolt.
-- Disconnect the connector and remove the wire from the suspension strut

-- Disconnect threaded connection of wheel bearing housing/suspension strut -arrow-.

-- Press brake disc in direction of suspension strut by hand.
NOTE: Otherwise strut tube may be canted in hole of wheel bearing housing.
-- Pull off wheel bearing housing downward from strut tube and lower using V.A.G 1383 A as far until strut
tube hangs freely.
-- Tightly tie wheel bearing housing to console/subframe using binding wire.
-- Remove V.A.G 1383 A from below wheel bearing housing.
-- Remove plenum chamber cover. Refer to Removal and Installation .
-- Remove the hex bolts for the upper strut mount and remove suspension strut.
Fig. 22: Hex Bolts For Upper Strut Mount

Installing
-- Secure V.A.G 1383 A with T10149 to wheel hub using a wheel bolt.
-- Attach suspension strut to wheel bearing housing and secure suspension strut using socket head bolt and new
nut.
NOTE: Socket head bolt tip must point in direction of travel.
-- Remove 3424.
One of two markings -arrows- on spring plate must point in direction of travel.
Fig. 24: Identifying Suspension Strut Markings

Left Suspension Strut
Fig. 25: Left Front Dampening Adjustment Valve

The suspension strut must be installed so that the left front dampening adjustment valve -N336- faces opposite
the drive direction.
Right Suspension Strut
Fig. 26: Right Front Dampening Adjustment Valve

The suspension strut must be installed so that the right front dampening adjustment valve -N337- faces opposite
the drive direction.
Continuation for Both Sides
-- Check the installation position of the front left and right body acceleration sensor -G341/G342- retainer.
Fig. 27: Checking Installation Position Of Front Left And Right Body Acceleration Sensor Retainer
NOTE: Use an 11 mm drill -1- and the VW 222 A to check the installation position.
The holes in the retainer must align with the holes in the shock absorber dome.
-- Remove wire on wheel bearing housing.
-- Carefully lift the wheel bearing housing with the transmission jack enough so that the suspension strut/strut
tower bolts can be installed.
Fig. 28: Suspension Strut/Strut Tower Bolts

If necessary, use ladder, e.g. step ladder VAS 5085 to install bolts.
-- Tighten the hex bolts for the upper strut mount.
-- Remove T10149.
-- Tighten threaded connection of wheel bearing housing/suspension strut -arrow-.


-- Insert drive axle into wheel hub.
-- Insert wheel bearing housing with ball joint into control arm.
-- Connect the level control system sensor to the control arm.
-- Connect the connector to the left and right front dampening adjustment valve -N336/N337- .
-- Tighten drive axle bolt onto the wheel hub. Refer to DRIVE AXLE TWELVE-POINT BOLT WITH
RIBS, LOOSENING AND TIGHTENING .
NOTE: Vehicle must not be standing on its wheels when doing this, otherwise wheel
-- Install plenum chamber cover. Refer to Removal and Installation .
-- Install wiper arms. Refer to WIPER ARMS .
MOUNTING WHEELS .

Suspension strut
to wheel bearing
housing
70 Nm + 90° turn
 Use new
nut.
Suspension strut
to body
(suspension strut
tower) 15 Nm + 90° turn
 Use new
bolts.
Ball joint to steel
control arm
60 Nm
 Use new
nuts.
Ball joint to sheet
steel or aluminum
control arm
100 Nm
 Use new
nuts.
Connecting link to
suspension strut
 Use new
nut. 65 Nm
 Counterhold
at joint pin
inner multi-
point fitting.
Drive axle to
wheel hub
70 Nm + 90° turn
 Use a new
bolt.
Level control
system sensor to 9 Nm
the control arm
REAR SHOCK ABSORBER, FWD
Removing
For the Left Shock Absorber Only
-- Remove the left rear level control system sensor -G76- from the lower transverse link.
-- Remove coil spring. Refer to COIL SPRING .
-- Disconnect the connector and remove the wire from the shock absorber.
Fig. 31: Shock Absorber Connector

-- Remove the shock absorber bolts.
Fig. 32: Shock Absorber Bolts

-- Remove the rear body acceleration sensor -G343- from the shock absorber mount.

Fig. 33: Shock Absorber Bolt

Installing
must only be fastened when the dimension "a" is achieved! Refer to Fig. 34
Fig. 34: Identifying Dimension Between Wheel Hub Center And Lower Edge Of
Wheel Housing
Note the shock absorber installation position.
Fig. 35: Right Rear Dampening Adjustment Valve

NOTE: The left and right rear dampening adjustment valve -N338/N339- must point
toward the outside of the rear wheel.
-- Mount the rear body acceleration sensor on the shock absorber mount.
Fig. 36: Mounting Retainer On Shock Absorber Mount From Rear So Retainer Tabs Fit Into
Depressions On Shock Absorber Mount
-- Mount the retainer on the shock absorber mount from the rear, so that the retainer tabs -1- fit into the
depressions on the shock absorber mount.
-- Turn the retainer forward so that it contact the shock absorber mount.
The tab -arrow- is used for adjusting the rear body acceleration sensor retainer.
-- Install the shock absorber and tighten the bolts.


-- Connect the connector to the left and right rear dampening adjustment valve -N338/N339- .
-- Install coil spring. Refer to COIL SPRING .
-- Connect the left rear level control system sensor -G76- to lower transverse link.
MOUNTING WHEELS .

Shock
absorber to
body
50 Nm + 45° turn
 Use
new
bolts.
Shock
absorber to
wheel
bearing
housing.
180 Nm
 Use a
new
bolt.
Left rear
level
control
system
5 Nm
sensor to
lower
transverse
link
REAR SHOCK ABSORBER, AWD
Removing
-- Remove the left rear level control system sensor -G76- from the lower transverse link.
-- Remove coil spring. Refer to COIL SPRING .
-- Disconnect the connector and remove the wire from the shock absorber.
Fig. 38: Shock Absorber Connector

-- Remove the shock absorber bolts.
Fig. 39: Shock Absorber Bolts

-- Remove the rear body acceleration sensor -G343- from the shock absorber mount.


Installing
must only be fastened when the dimension "a" is achieved! Refer to Fig. 34
Fig. 41: Identifying Dimension Between Wheel Hub Center And Lower Edge Of
Wheel Housing
Note the shock absorber installation position.
Fig. 42: Right Rear Dampening Adjustment Valve

The left and right rear dampening adjustment valve -N338/N339- must point toward the outside of the rear
wheel.

-- Mount the rear body acceleration sensor on the shock absorber mount
Fig. 43: Mounting Retainer On Shock Absorber Mount From Rear So Retainer Tabs Fit Into
Depressions On Shock Absorber Mount
-- Mount the retainer on the shock absorber mount from the rear, so that the retainer tabs -1- fit into the
depressions on the shock absorber mount.
-- Turn the retainer forward so that it contact the shock absorber mount.
The tab -arrow- is used for adjusting the rear body acceleration sensor retainer.
-- Install the shock absorber and tighten the bolts.


-- Connect the connector to the left and right rear dampening adjustment valve.
-- Install coil spring. Refer to COIL SPRING .
-- Connect the left rear level control system sensor to lower transverse link.
MOUNTING WHEELS .

Shock
absorber to
body
50 Nm + 45° turn
 Use
new
bolts.
Shock
absorber to
wheel
bearing
housing.
180 Nm
 Use a
new
bolt.
Left rear
level
control
system
5 Nm
sensor to
lower
transverse
link
LEFT FRONT BODY ACCELERATION SENSOR
Removing
-- Remove the left plenum chamber cover. Refer to Removal and Installation .

Fig. 45: Bolts And Front Body Acceleration Sensor

-- Remove the bolts and the front body acceleration sensor -G341-.
Installing
CAUTION: The front body acceleration sensors must never be interchanged with the
rear body acceleration sensors.
-- Be sure to pay attention to the installation position of the left front body acceleration sensor retainer.

Left front
body
acceleration 5 Nm
sensor to
the retainer
RIGHT FRONT BODY ACCELERATION SENSOR
Removing
-- Remove the left plenum chamber cover. Refer to Removal and Installation .

Fig. 47: Nuts And Right Front Body Acceleration Sensor

-- Remove the nuts and remove the right front body acceleration sensor -G342-.
Installing
CAUTION: The front body acceleration sensors must never be interchanged with the
rear body acceleration sensors.
-- Be sure to pay attention to the installation position of the right front body acceleration sensor retainer.

Right front
body
acceleration 5 Nm
sensor to
the retainer
FRONT BODY ACCELERATION SENSOR BRACKET

 DriftVW 222 A
 Spiral bore diameter: 11 mm
Removing
-- Remove the left front body acceleration sensor -G341-. Refer to LEFT FRONT BODY ACCELERATION
SENSOR.
-- Remove the right front body acceleration sensor -G342-. Refer to RIGHT FRONT BODY
ACCELERATION SENSOR.
-- Remove the retainer screws and remove the retainer from the shock absorber dome.
Fig. 49: Shock Absorber Dome Retainer Screws And Retainer

Installing
CAUTION: The body acceleration sensors must not be interchanged.
-- Clean the shock absorber dome.
Front Left Body Acceleration Sensor -G341-
-- Attach the front left body acceleration sensor to the retainer.
-- Be sure to pay attention to the installation position of the left front body acceleration sensor retainer.
Right Front Body Acceleration Sensor -G342-
-- Attach the front right body acceleration sensor to the retainer.
-- Be sure to pay attention to the installation position of the right front body acceleration sensor retainer.
-- Remove the adhesive on the sealing surfaces of the retainer and apply two-sided adhesive tape.
-- Using an 11 mm drill, secure the retainer and the VW 222 A
Fig. 52: Checking Installation Position Of Front Left And Right Body Acceleration Sensor Retainer
NOTE: The holes in the retainer must align with the holes in the shock absorber dome.
-- Install the bolts on after the other by hand and then tighten to the tightening specification.
-- Connect the connector to the body acceleration sensor.

Suspension
strut to
body
(suspension
strut tower)

new
bolts.
FRONT LEVEL CONTROL SYSTEM SENSORS
Removing
NOTE: In order to be able to remove the left front level control system sensor -G78- the
steering wheel must be turned all the way to the right; this assures that there is
enough clearance between the control arm and the stabilizer bar.
In order to be able to remove the right front level control system sensor -G289-
the steering wheel must be turned all the way to the right; this assures that
there is enough clearance between the control arm and the stabilizer bar.
Fig. 53: Level Control System Sensor Bolt And Nut

-- Remove the bolt and the nut.

-- Remove level control system sensor.
Installing
-- Perform a basic setting on the adaptive chassis DCC. Refer to ADAPTIVE CHASSIS DCC, BASIC
SETTING.
-- Perform a basic setting on the headlamps using Vehicle Diagnostic Tester in "Guided Fault Finding" function.

Bolt to
9 Nm
subframe
Nut
 Use 9 Nm
new
nut.
LEFT REAR LEVEL CONTROL SYSTEM SENSOR, FWD
Removing

Fig. 54: Left Rear Level Control System Sensor Bolts

-- Remove the bolts.
-- Remove left rear level control system sensor -G76-.
Installing
The level control system sensor lever must point toward vehicle exterior.
SETTING.

Bolt to
subframe/lower 5 Nm
transverse link
LEFT REAR LEVEL CONTROL SYSTEM SENSOR, AWD

Removing
Fig. 55: Left Rear Level Control System Sensor Bolts

-- Remove the bolts.
-- Remove left rear level control system sensor -G76-.
Installing
The level control system sensor lever must point toward vehicle exterior.
SETTING.

Bolt to
subframe/lower 5 Nm
transverse link
Removing
NOTE: Component location: Behind the right side luggage compartment trim.
-- Switch off all electrical consumers.
-- Remove the ignition key.
-- Remove the right luggage compartment side trim. Refer to Removal and Installation .
-- Remove the electronic damping control module -J250- -1- from the compartment.
Fig. 56: Electronic Damping Control Module

-- Release and disconnect the connector -2-.
Installing
SETTING.
REAR BODY ACCELERATION SENSOR, FWD

Removing
-- Remove the left rear wheel housing liner. Refer to Removal and Installation .
Fig. 57: Rear Body Acceleration Sensor Bolts

-- Remove the bolts and remove the rear body acceleration sensor -G343-.
Installing
CAUTION: The rear body acceleration sensor must never be interchanged with the
front body acceleration sensors.
-- Note the rear body acceleration sensor installation position on the retainer.

Rear body
acceleration
5 Nm
sensor to
the retainer
REAR BODY ACCELERATION SENSOR, AWD
Removing
-- Remove the left rear wheel housing liner. Refer to Removal and Installation .

Fig. 59: Rear Body Acceleration Sensor Bolts

-- Remove the screws and remove the rear body acceleration sensor -G343-.
Installing
CAUTION: The rear body acceleration sensor must never be interchanged with the
front body acceleration sensors.
-- Note the rear body acceleration sensor installation position on the retainer.

Rear body
acceleration
5 Nm
sensor to
the retainer
SHOCK ABSORBER, FWD

Fig. 61: View Of Shock Absorber, FWD Assembly

 Removing and installing, refer to REAR SHOCK ABSORBER, FWD.
2. Protective Cap
3. Protective Tube
4. Buffer Stop

 M10 x 1.0
 25 Nm
 Loosening and tightening, refer to Fig. 62.
7. Cover

Fig. 62: Removing Hex Nut From Shock Absorber

1. Ratchet (commercially available)

2. Socket wrench 21 mm T10001/9
3. RatchetT10001/11
4. Socket wrench 21 mmT10001/1

Shock
absorber
mounting to
shock
absorber 25 Nm
 Use
new
nut.
SHOCK ABSORBER, AWD

Fig. 63: View Of Shock Absorber, FWD Assembly

 Removing and installing, refer to REAR SHOCK ABSORBER, AWD.
2. Protective Cap
3. Protective Tube
4. Buffer Stop

 M10 x 1.0
 25 Nm
 Loosening and tightening, refer to Fig. 64.
7. Cover

 Shock absorber setT10001
Fig. 64: Removing Hex Nut From Shock Absorber

1 - Ratchet (commercially available)
2 - Socket wrench 21 mm T10001/9

3 - Ratchet T10001/11
4 - Socket wrench 21 mm T10001/1

Shock
absorber
mounting to
shock
absorber 25 Nm
 Use
new
nut.
SPECIAL TOOLS
Fig. 65: Torque Wrench V.A.G 1410



 DriftVW 222 A
Fig. 67: Drift VW 222 A

 Shock absorber setT10001

Fig. 68: Shock Absorber Set T10001

Fig. 69: Identifying Special Tools -- Suspension Strut, Golf Plus, Removing And Installing
 Spreader3424
 Engine/transmission jackV.A.G 1383 A
 Wheel hub supportT10149
Suspension Steering
Suspension
Steering
48 STEERING
GENERAL INFORMATION
The maximum possible care, cleanliness and proper tools are essential to ensure satisfactory and successful
steering gear repairs. Understandably, general safety guidelines apply when performing repairs.
A series of applicable general notes for individual repair procedures - otherwise listed several times at many
points in the repair information - has been collected here. They apply for this repair information.
A description of design and function of the electromechanical steering can be found in Self Study Program No.
317, Electromechanical Power Steering Design and Function.
A description of the design and function of the steering "APA" can be found in Self Study Program No. 399,
Electromechanical steering with axis parallel drive.
Steering Gear
 Thoroughly clean connecting points and their surrounding areas before loosening.
 When installing steering gear, make sure centering sleeves are correctly seated between console and
steering gear.
 Place removed parts on a clean surface and cover to prevent contamination. Use foils and paper. Only use
lint-free cloths!
 Only install clean components: Only unpack replacement parts immediately prior to installation.
 Use exclusively lubricants and sealants marked with part numbers.
 Carefully cover or seal open components, if repairs are not carried out immediately.
Gaskets and Seals
 Always replace seals and gaskets.

 After removing seals, inspect contact surface on housings and shafts for burrs and damage and repair if
necessary.
 Remove all residual sealant of fluid seals from sealing surfaces, no sealant residue must enter the steering
gear housing when doing this.
Bolts and Nuts

Suspension Steering
Fig. 1: Identifying Nut And Bolt

 Loosen and tighten the bolts and nuts of covers and housings in a diagonal sequence.
 Do not cant but loosen and tighten especially sensitive parts in diagonal manner in stages, e.g. servo
motor with control module.
 Torque specifications for unoiled bolts and nuts are given.
Electrical Components
Surely everyone has been shocked at one time or another when coming into contact with a metal object. The
reason for this is the build-up of static electricity in the human body. This charging can lead to malfunctions by
touching electrical components in the steering gear and the steering column.
-- Touch a grounded object - for example a water pipe, heating pipe, metal carrier or a vehicle hoist - before
working on electrical components. Do not make direct contact on connector terminals.
Guided Fault Finding, OBD and Test Instruments

Suspension Steering
Fig. 2: Identifying VAS 5051

 Before performing repairs on the electromechanical steering gear, determine the cause of the damage as
closely as possible using the Vehicle Diagnostic Tester in the " Guided Fault Finding" , "Vehicle Self-
Diagnosis" and "Measurement" modes.
TIE ROD ENDS ALLOCATION
I - Right tie rod end is identified with -A-.

Suspension Steering
Fig. 3: Tie Rod Ends Allocation

II - Left tie rod end is identified with -B-.
STEERING GEAR, SERVICING
Currently, there is no service work to be performed on steering gear.
STEERING COLUMN, HANDLING AND TRANSPORTING
WARNING:  The correct handling of the steering column must always be

observed.
 Incorrect handling of steering column may cause damage to steering
column and therefore lead to a safety risk.
Correct Handling and Transport of Steering Column

Suspension Steering
Fig. 4: Correct Handling And Transporting Of Steering Column

 Transport steering column with two hands

 Hold steering column at upper steering rod tube and in area of upper universal joint
 Clamping lever -1- must always point upward during transportation so drive axle does not come into
contact with steering column lock -2-.
Incorrect Handling of Steering Column

Suspension Steering
Fig. 5: Incorrect Handling Of Steering Column

Transporting at the following components leads to pre-damage to steering column:
1. Clamping lever
2. Weight compensation springs
3. Deformation element
Incorrect Handling of Steering Column with Safety Risk

Suspension Steering
Fig. 6: Incorrect Handling Of Steering Column With Safety Risks

The following handling practices lead to damage of steering column lock -1- :
 Transporting steering column with one hand on drive axle.

 Bending joints beyond 90° and coming to a stop on steering column lock.
 Placing drive axle on steering column lock.
 Placing steering column on steering column lock.
STEERING COLUMN ASSEMBLY OVERVIEW


Suspension Steering
Fig. 7: Steering Column Assembly Overview

1. Bolt
 M8 x 30; M8 x 85
 20 Nm
2. Lateral Control Arm for Steering Column

3. Mounting Bracket
 Removing and installing, refer to MOUNTING BRACKET.
4. Bolt
 M8 x 30
Suspension Steering

5. Steering Column
 Removing and installing, refer to STEERING COLUMN.
6. Handle Plate
7. Brake Pedal Crash Brace
8. Bolt
 M6 x 10
 3 Nm
9. Clutch Pedal Crash Brace

10. Bolt
 M8 x 35
 20 Nm + 90° turn
11. Electronic Steering Column Lock Control Module -J764-

 Removing and installing, refer to ELECTRONIC STEERING COLUMN LOCK CONTROL
MODULE.
12. Shear Head Bolt
13. Strut
 Removing and installing, refer to STRUT.
14. Bolt
 M8 x 94
 20 Nm
15. Bolt
 M8 x 48
 20 Nm
STEERING GEAR ASSEMBLY OVERVIEW, THROUGH MY 2008
NOTE: The generation 2 steering gear is no longer available as a replacement part.
Install a generation 3 steering gear if replacing a steering gear.
In addition to this, the electrical wiring set from the E-box to the steering gear
must be changed. It will be included with the new steering gear.
The electrical wiring set is delivered complete together with the wiring for the
service interval display.
If the vehicle does not have a service interval display, then the 3-pin connector,
not being used, must be sealed off with a flat terminal housing with contact seal
Suspension Steering
1J0 973 803.
Fig. 8: Electro-Mechanical Steering Gear, Assembly Overview

1. Universal Joint
2. Bolt
 M6 x 35
 30 Nm
3. Electrical Wiring
4. Power Steering Gear
Suspension Steering
 With Power Steering Control Module -J500-.

 With Electromechanical Power Steering Motor -V187-.
 With Steering Torque Sensor -G269-.
 Can be checked in Guided Fault Finding using the Vehicle Diagnostic Tester
 Removing and Installing, refer to STEERING GEAR, THROUGH MY 2008.
NOTE: The generation 2 steering gear is no longer available as a replacement

part.
NOTE: Correct any faults stored in the DTC memory before replacing the steering
gear.

6. Nut
 M12 x 1.5
 Self-locking.
7. Subframe
8. Bolt
 M10 x 70
 50 Nm + 90° turn
 Always replace the clamp for the steering gear.
9. Shield
10. Bolt
 6 Nm
 Self-tapping
STEERING GEAR ASSEMBLY OVERVIEW, FROM MY 2009

Suspension Steering
Fig. 9: Steering Gear Assembly Overview, From My 2009

1. Universal Joint
2. Bolt
 M8 x 35
 30 Nm

 With Power Steering Control Module -J500-.
 With Electromechanical Power Steering Motor -V187-.

Suspension Steering
 Removing and installing, refer to STEERING GEAR, FROM MY 2009.
NOTE: Correct any faults stored in the DTC memory before replacing the
steering gear.

5. Nut
 M12 x 1.5
 Self-locking.
6. Subframe
7. Bolt
 M10 x 70
 50 Nm + 90° turn
8. Shield
9. Bolt
 6 Nm
 Self-tapping.
10. Electrical Wiring
SPECIFICATIONS

Frequency Damper to Body - 20
Handle Plate to Steering Column Bolt M6 x 10 3
Mounting Bracket to Lateral Control Arm Bolt - 20
Shield to Steering Gear Bolt - 6
Steering Column to Mounting Bracket Bolt (1) - 20
Steering Column to Steering Gear Bolt (1) M8 x 35 30
Steering Gear to Subframe Bolt (1) M10 x 70 50 + 90° turn
Steering Wheel to Steering Column Bolt (1) - 30 + 90° turn
Strut to Mounting Bracket Bolt M8 x 94 20
Tie Rod to Steering Gear - 100
Tie Rod End to Tie Rod Nut - 70
Suspension Steering
Tie Rod End to Wheel Bearing Housing Nut 1, 2 - 100

(2) Tighten to 100 Nm, then loosen by 180° and tighten to 100 Nm again.
STEERING ANGLE SENSOR BASIC SETTING, CHECKING
Steering angle sensor -G85- basic setting must be checked after the following assembly work:
 If the steering angle sensor was removed or replaced.

 After removing or replacing steering column.
 After removing or replacing steering gear.
 If the steering wheel was offset.
STEERING COLUMN, CHECKING FOR DAMAGE
Visual Check
-- Check whether parts of steering column indicate damage.
Functional Check
-- Check whether steering column can be turned without catching or difficulty of movement.
-- Check that the steering column can be adjusted with respect to height and reach.
CHECKING PLAY, SECURITY AND JOINT BOOTS OF TIE ROD ENDS
-- With vehicle raised (wheels hanging free), check play by moving tie rods and wheels. Play: Zero play.
-- Check attachments.
-- Check boots are not damaged and are seated correctly.
STEERING WHEEL
Removing
Suspension Steering
-- Remove driver side airbag unit. Refer to Removal and Installation .
-- Disconnect harness connectors -1- and -2- for spiral spring.
Fig. 10: Removing And Installing Steering Wheel

-- Turn steering wheel into center position (wheels in straight ahead position).
-- Remove bolt -3- and pull steering wheel off steering column.
Installing
Suspension Steering
-- Center markings for steering wheel and steering column -arrows- must align.
Fig. 11: Removing And Installing Steering Wheel

-- Guide connector terminal for steering angle sensor -G85- into provided opening in steering wheel base.
-- Connect connector -1- to connector terminal -2- of steering angle sensor.
-- Secure steering wheel with bolt -3-.
Suspension Steering

Steering wheel to steering column 30 Nm + 90° turn
 Always replace bolt.
STEERING COLUMN

Removing
The steering column is delivered only as a complete replacement part. Servicing is not possible.
WARNING: Before working on the electrical system, or removing the steering wheel
and steering column, the following conditions must be met:
 The technician must electrostatic discharge. This is done by

touching a grounded metal part, for example, water lines, heater
pipe, metal carriers or a workshop hoist. Refer to GENERAL REPAIR
INFORMATION.
If this not done, the electronic steering column lock control module -J764-
could fail later!
-- Set the wheels to the straight ahead position.
-- Pull lever downward beneath steering column.
-- Swing steering column downward as far as possible and pull out.
-- Push lever under steering column upward again.
-- Remove airbag from steering wheel. Refer to Removal and Installation .
-- Remove steering wheel. Refer to STEERING WHEEL.
-- Remove steering column switch trim. Refer to Removal and Installation .
-- Remove the cover in the driver side footwell. Refer to Removal and Installation .
-- Remove the trim panel in the driver side footwell. Refer to Removal and Installation .
-- Remove footwell vent outlets beneath steering column. Refer to [For engine(s) BPY,BLV,CCTA,CBFA]
Suspension Steering
-- Remove steering column switch. Refer to [For engine(s) BPY,BLV,CCTA,CBFA] Removal and
Installation .
-- Disconnect all harness connectors and ground (GND) wire from steering column.

-- Remove the bolt -1- and pull off universal joint -2- from steering gear.
Suspension Steering

-- Remove cable channel -1- beneath steering column. To do so, slightly lift tabs -arrows- on both sides and pull
cable channel out of guide on steering column.
Fig. 14: Locating Cable Channel Below Steering Column And Plastic Screws
Vehicles Equipped with Crash Braces

Suspension Steering
Fig. 15: Crash Brace Bolts

-- Remove the screw -1- and remove the clutch pedal crash brace -2-.
Fig. 16: Clutch Pedal Crash Brace, Screws & Brake Pedal Crash Brace
-- Remove the screw -3- and remove the brake pedal crash brace -4-.
-- Lower steering column slightly and carefully pull out upward.

Suspension Steering
CAUTION: Pay particular attention to the correct handling and transport of the
steering column. Refer to STEERING COLUMN, HANDLING AND
TRANSPORTING.
Installing
-- Engage steering column into assembly aid on mounting bracket.
-- Align steering column to mounting bracket and install.
Fig. 17: Mounting Bracket Pins And Steering Column Holes Positioned Toward Each Other
When doing this, pins -arrows A- of mounting bracket and holes -arrows B- of steering column must be
positioned toward each other and inserted into one another.
NOTE: Only in this way is the correct installation position of steering column to
mounting bracket guaranteed.
-- Tighten the bolts -2- on the steering column.

Suspension Steering
Vehicles Equipped with Crash Braces
-- Tighten the bolts -1- on the steering column.

Suspension Steering
Fig. 19: Crash Brace Bolts

-- Install the clutch pedal crash brace -2- and tighten the bolt -1-.
Fig. 20: Clutch Pedal Crash Brace, Screws & Brake Pedal Crash Brace
-- Install the brake pedal crash brace -4- and tighten the bolt -3-.
-- Install cable channel -1- beneath steering column.

Suspension Steering
Tabs -arrows- must engage into guide on both sides.
-- Connect universal joint -2- onto steering gear pinion and tighten the bolt -1-.
Suspension Steering

-- Install foot well trim -1- and secure with nuts -arrows-.

-- Connect all harness connectors and ground (GND) wires to steering column.
-- Install footwell vent outlets beneath steering column. Refer to [For engine(s) BPY,BLV,CCTA,CBFA]
Suspension Steering
-- Install the trim panel in the driver side footwell. Refer to Removal and Installation
-- Install the cover in the driver side footwell. Refer to Removal and Installation .
-- Install steering column switch. Refer to [For engine(s) BPY,BLV,CCTA,CBFA] Removal and
Installation .
-- Install steering column switch trim. Refer to Removal and Installation .
-- Installing steering wheel. Refer to STEERING WHEEL.
-- Install airbag in steering wheel. Refer to Removal and Installation .

Universal joint to steering gear 20 Nm + 90° turn
 Use a new bolt.

Steering column to mounting bracket 20 Nm
 Use a new bolt.
MOUNTING BRACKET
Removing
-- Remove the steering column. Refer to STEERING COLUMN.
-- Remove the instrument cluster. Refer to [For engine(s) BPY,BLV,CCTA,CBFA] Removal and
Installation .
-- Remove bolts -arrows- under the console.

Suspension Steering
Fig. 24: Installing Bolts Under Console

-- Slide connector -1- in -direction of arrow- and remove it from mount in mounting bracket.
Fig. 25: Identifying Connector, Mounting Bracket, Bolts And Bracket Body Bolts
-- Remove the bolt -arrow A-.
-- Remove bolts -arrows B- from console on body.
NOTE: The bolts -arrows B- are installed through the crossmember.

Suspension Steering
-- Remove the bolts -1- and -2- and remove mounting bracket from body.
Fig. 26: Identifying Mounting Bracket Bolts

Installing
-- Install mounting bracket and install bolts -1- and -2-.
Fig. 27: Identifying Mounting Bracket Bolts

-- Install bolts -arrows B-.

Suspension Steering
Fig. 28: Identifying Connector, Mounting Bracket, Bolts And Bracket Body Bolts
NOTE: The bolts -arrows B- are installed through the crossmember.
-- Install bolt -arrow A-.
-- Insert connector -1- into mount in mounting bracket and slide it in opposite -direction of arrow- until it stops.
-- Install bolts -arrows- under console.
Fig. 29: Installing Bolts Under Console

Suspension Steering
-- Install the steering column. Refer to Installing.
-- Install the instrument cluster. Refer to [For engine(s) BPY,BLV,CCTA,CBFA] Removal and Installation .
-- Perform basic setting on the steering angle sensor -G85- using the Vehicle Diagnostic Tester.

Mounting bracket to body 20 Nm
Strut to mounting bracket 20 Nm
Steering column to mounting bracket 20 Nm
STRUT
Removing
-- Remove plenum chamber bulkhead. Refer to Description and Operation .
-- Remove bolt -arrow- in plenum chamber.
Fig. 30: Plenum Chamber Bolt


Suspension Steering
Fig. 31: Identifying Strut And Bolts

-- Remove bolt -2- and remove strut -3-.
Installing
-- Secure strut to body, tighten bolt -arrow- to do this.
Fig. 32: Plenum Chamber Bolt

Suspension Steering
-- Install the bolt -2- and tighten.
Fig. 33: Identifying Strut And Bolts

-- Tighten the bolts -1- for strut -3- to 10 Nm.
-- Install the steering column. Refer to STEERING COLUMN => Installing.
-- Install plenum chamber bulkhead. Refer to Description and Operation .
-- Perform steering angle sensor -G85- basic setting with Vehicle Diagnostic Tester.

Strut to mounting bracket 20 Nm
Frequency damper to body 20 Nm
ELECTRONIC STEERING COLUMN LOCK CONTROL MODULE
 Socket insert T10424
Removing

Suspension Steering
CAUTION: Correct handling and transport of steering column, refer to STEERING

COLUMN, HANDLING AND TRANSPORTING.
-- Carefully tension the steering column -1- in the vice using protective pads.
Fig. 34: Tension The Steering Column & Universal Joint

-- Carefully move the universal joint -2- downward.
-- Loosen the lower shear bolt -arrow- using the T10424.
Fig. 35: Loosening Lower Shear Bolt Using T10424

Suspension Steering
-- Remove any chips with a brush.
CAUTION: The chips must not get into the steering column.
-- Turn the steering column 180° tension it in the vice.
Fig. 36: Electronic Steering Column Lock Control Module -J764 & Universal Joint
-- Carefully move the universal joint -2- downward.
NOTE: It is necessary to turn the steering column 180° so that any chips that may fall
down from above when loosening the shear bolt cannot get into the steering
column.
-- Loosen the lower shear bolt -arrow- using the T10424.
-- Remove any chips with a brush.
-- Remove the electronic steering column lock control module -J764- -1-.
Installing
-- Install the electronic steering column lock control module -1- with new shear bolts -arrows-.
Suspension Steering
Fig. 37: Electronic Steering Column Lock Control Module

-- Tighten the shear bolts -arrows- evenly until the bolt heads shear off.
-- Install the steering column. Refer to Installing.
-- If the steering column with an electronic steering column lock control module was replaced, then the
electronic steering column lock control module must be adapted using the Vehicle Diagnostic Tester.
Guided Functions
Select vehicle system or function
25 anti-theft immobilizer
Adapt electronic steering column lock
Follow the instructions on the screen to perform the adaptation.
STEERING GEAR, THROUGH MY 2008

Suspension Steering
Removing
NOTE: The generation 2 steering gear is no longer available as a replacement part.
Install a generation 3 steering gear if replacing a steering gear.
In addition to this, the electrical wiring set from the E-box to the steering gear
must be changed. It will be included with the new steering gear.
The electrical wiring set is delivered complete together with the wiring for the
service interval display.
If the vehicle does not have a service interval display, then the 3-pin connector,
not being used, must be sealed off with a flat terminal housing with contact seal
1J0 973 803.
NOTE: Correct any faults stored in the DTC memory before replacing the steering gear.
-- Connect the Vehicle Diagnostic Tester and start "Guided Fault Finding".
Follow the instructions on the screen.
-- Turn the steering wheel to the straight-ahead position and remove the ignition key so that the steering wheel
lock engages.
Suspension Steering


CAUTION: To protect thread, screw nut on pin a few turns.

Suspension Steering

Suspension Steering



Suspension Steering


Suspension Steering

-- Now unscrew bolts -3-, -6-, -11- and -14- for steering gear and stabilizer.
Suspension Steering

-- Secure subframe and brackets. Refer to SUBFRAME, SECURING .
-- Place V.A.G 1383 A under subframe.

Suspension Steering

-- Remove bolts -4- and -5- and lower subframe with brackets slightly. Observe electrical wires when doing
this.
Suspension Steering

-- Remove heat shield -1- above exhaust system.

Suspension Steering
Fig. 48: Heat Shield And Bolts Above Steering Gear

-- Remove bolts -arrows-.

-- Unclip all other cable mounting points on steering gear.
-- Disconnect all electrical connections from steering gear.

Suspension Steering
-- Carefully lower subframe using V.A.G 1383 A.
-- Lift down steering gear from subframe.
-- Set down steering gear as depicted in the illustration.
Fig. 50: Steering Gear And Control Module

This prevents damage to the control module -1-.
Installing
Steering gear threaded sleeves must sit in bracket holes.
steering gear.
After placing steering gear onto universal joint, make sure that seal on steering
gear makes contact on assembly plate without kinks and opening to footwell is
correctly sealed. Ingress of water and/or noises may be the result.
Before fastening the bolts for subframe, position steering gear on subframe and fasten bolts for steering gear
and stabilizer.

Suspension Steering
-- Bolt universal joint to steering gear.
-- Connect battery. Refer to [For engine(s) BPY,BLV,CCTA,CBFA] Removal and Installation .
It is necessary to adapt the electromechanical steering with Vehicle Diagnostic Tester if a new steering gear was
installed.
-- Adapt the electromechanical power steering with Vehicle Diagnostic Tester.
Chassis (Repair Groups: 01; 40 to 49)
Electromechanical power steering
01 - OBD-capable system
Functions
Adapting electromechanical steering
NOTE: If the vehicle has "Park Assist" , then the Power Steering Control Module -J500-
must be coded after a new steering gear has been installed using the Vehicle
Diagnostic Tester.
After installation, position of steering wheel must be checked with a road test.
If steering wheel is at an angle or a new steering gear was installed, vehicle must be aligned.

Stabilizer bar to subframe 20 Nm + 90° turn
 Use new bolts.

Stabilizer bar to connecting link
 Use new nut. 65 Nm

 Counterhold at joint pin inner multi-point fitting.
Suspension Steering
Ball joint to steel control arm 60 Nm
 Use new nuts.

Ball joint to sheet steel or aluminum control arm 100 Nm
 Use new nuts.

Shield to subframe
6 Nm
 M6 bolt is self-tapping.
Steering gear to subframe
 Use new bolts. 50 Nm + 90° turn

 Always replace the clamp.
Universal joint to steering gear

30 Nm
 Use a new bolt.
Shield to steering gear
6 Nm
Tie rod end to wheel bearing housing Tighten to 100 Nm, then loosen by 180° and
tighten to 100 Nm again
 Use new nut.
Exhaust system bracket to the subframe, refer to FASTENER TIGHTENING SPECIFICATIONS .

M12 x 1.5 x 90 70 Nm + 90° turn
 Use new bolts.

M12 x 1.5 x 100 70 Nm + 90° turn
 Use new bolts.

M12 x 1.5 x 110 70 Nm + 90° turn
 Use new bolts.
Differences, refer to Tightening Specifications, Pendulum Support to the
Transmission .
Suspension Steering

M10 x 35 strength class 8.8: 40 Nm + 90° turn
Use a new bolt.

Use a new bolt.

Use a new bolt.

 Use a new bolt.
M12 x 1.5 x 85 60 Nm + 90° turn
 Use a new bolt.
STEERING GEAR, FROM MY 2009

Removing
NOTE: Correct any faults stored in the DTC memory before replacing the steering gear.
-- Connect the Vehicle Diagnostic Tester and start "Guided Fault Finding".
-- Remove foot well trim -1-, unscrew nuts -arrows- to do so.

Suspension Steering
Fig. 51: Foot Well Trim & Nuts



Suspension Steering

Suspension Steering

Fig. 55: Transmission Pendulum Support Bolts

-- Remove exhaust system bracket from the subframe -arrows-.

Suspension Steering
Fig. 56: Heat Shield Bolts

With FWD


Suspension Steering
-- Remove the bolts -5- and -6- on the steering gear.
Fig. 58: Steering Gear Bolts

-- Remove the stabilizer bar bolts -7- and -8-.

Suspension Steering
Fig. 59: Stabilizer Bar Bolts

-- Subframe, locating, refer to SUBFRAME, SECURING .
-- Disconnect the connector for the service interval extension to the oil pan.
-- Place V.A.G 1383 A under subframe.

Suspension Steering

-- Remove the bolts -9- and -10- and slightly lower the subframe. Pay attention the electrical wiring while doing
this.
Suspension Steering
Fig. 61: Subframe Bolts

-- Remove heat shield -1- above exhaust system.

Suspension Steering
Fig. 62: Heat Shield And Bolts Above Steering Gear

-- Remove bolts -arrows-.

-- Unclip all other cable mounting points on steering gear.
-- Disconnect the connectors -1- and -2- from the steering gear.
Suspension Steering
Fig. 64: Steering Gear Connectors

-- Carefully lower subframe using V.A.G 1383 A.
-- Now, lift the stabilizer bar -1- toward the front, over the subframe -2- and down, while turning the stabilizer
bar slightly.
Fig. 65: Identifying Lift Stabilizer Toward Front, Over Console And Down From Subframe
-- Lift down steering gear from subframe.

Suspension Steering
-- Set down steering gear as depicted in the illustration.
Fig. 66: Steering Gear Control Module

This prevents damage to the control module -1-.
Installing
-- Make sure the white pressure membrane -arrow- is clean and not damaged.
Suspension Steering
Fig. 67: White Pressure Membrane

-- If necessary, carefully clean the pressure membrane.
NOTE: If the pressure membrane is damaged, then the steering gear must be replaced.
-- Connect the connectors -1- and -2- so that they audibly click into place.
Fig. 68: Steering Gear Connectors

The threaded sleeve must seat in subframe hole.
steering gear.
After placing steering gear onto universal joint, make sure that seal on steering
gear makes contact on assembly plate without kinks and opening to footwell is
correctly sealed. Ingress of water and/or noises may be the result.
Before fastening the bolts for subframe, position steering gear on subframe and fasten bolts for steering gear
and stabilizer.
-- Bolt universal joint to steering gear.

Suspension Steering
-- Connect battery. Refer to [For engine(s) BPY,BLV,CCTA,CBFA] Removal and Installation .
It is necessary to adapt the electromechanical steering with Vehicle Diagnostic Tester if a new steering gear was
installed.
-- Adapt the electromechanical power steering with Vehicle Diagnostic Tester.
Chassis (Repair Groups: 01; 40 to 49)
01 - OBD-capable system
Functions
Adapting electromechanical steering
NOTE: If the vehicle is equipped with park assist 2, then the Power Steering Control
Module -J500- must be coded again using Vehicle Diagnostic Tester.
After installation, position of steering wheel must be checked with a road test.
If steering wheel is at an angle or a new steering gear was installed, vehicle must be aligned.

Mounting bracket to body 70 Nm + 90° turn
 Use new bolts.

Stabilizer bar to subframe 20 Nm + 90° turn
 Use new bolts.

Stabilizer bar to connecting link
 Use new nut. 65 Nm

 Counterhold at joint pin inner multi-point fitting.
Suspension Steering
Ball joint to steel control arm 60 Nm
 Use new nuts.

Ball joint to sheet steel or aluminum control arm 100 Nm
 Use new nuts.

Shield to subframe
6 Nm
Steering gear to subframe
50 Nm + 90° turn
 Use new bolts.
Universal joint to steering gear
30 Nm
 Use a new bolt.
Shield to steering gear
6 Nm
tighten to 100 Nm again.
 Use new nut.
Exhaust system bracket to the subframe, refer to FASTENER TIGHTENING SPECIFICATIONS .

M12 x 1.5 x 90 70 Nm + 90° turn
 Use new bolts.

M12 x 1.5 x 100 70 Nm + 90° turn
 Use new bolts.

M12 x 1.5 x 110 70 Nm + 90° turn
 Use new bolts.

M10 x 35 50 Nm + 90° turn
 Use a new bolt.

M10 x 75 50 Nm + 90° turn
Suspension Steering
Use a new bolt.

M12 x 1.5 x 85 60 Nm + 90° turn
 Use a new bolt.
STEERING GEAR BONDED RUBBER BUSHING, FROM MY 2009
Removing
NOTE: The bonded rubber bushings must always be replaced in pairs on each side.
The following describes removing and installing one bonded rubber bushing.
Removing and installing the second bonded rubber bushing is identical.
Always pay attention to the allocation of the bonded rubber bushings for the
power steering gear. Refer to Allocation of the Bonded Rubber Bushings for the
Power Steering Gear.
-- Remove the power steering gear. Refer to STEERING GEAR, FROM MY 2009.
-- Mount the tools as illustrated.

Suspension Steering
Fig. 69: Mounting Tube T10390/1 & Nut T10390/3

1. Nut T10390/3
2. Tube T10390/1
-- Remove the bonded rubber bushing.
Allocation of the Bonded Rubber Bushings for the Power Steering Gear
Suspension Steering
Fig. 70: Allocation Of Bonded Rubber Bushings For Power Steering Gear
1. Short bonded rubber bushing for left front

2. Short bonded rubber bushing for right front
3. Long bonded rubber bushing for right rear
4. Long bonded rubber bushing for left rear with centering
Installing
-- Always pay attention to the allocation of the bonded rubber bushings for the power steering gear. Refer to
Allocation of the Bonded Rubber Bushings for the Power Steering Gear.
-- Coat the outer bonded rubber bushing with soapy water.
-- Position the bonded rubber bushing so that the flat surface is parallel to the inside -arrows-.
Suspension Steering
Fig. 71: Positioning Bonded Rubber Bushing So Flat Surface Is Parallel To Inside
NOTE: Always install the bonded rubber bushing from above in the direction of the
drive steering shaft.
-- Mount the tools as illustrated.

Suspension Steering
Fig. 72: Mounting Tools T10390/3, Bonded Rubber Mount & Tube T10390/2
1. T10390/3
3. Tube T10390/2
-- Install the bonded rubber bushing all the way in until the rubber lip folds over the edge -arrow-.
NOTE: The bonded rubber bushing will move slightly backward after loosening the
T10390.
-- Mount the plate -1- on the bonded rubber bushing so that the edges and the flat surface interlock.
Suspension Steering
Fig. 73: Securing Plate With Cable Tie

-- Secure the plate -1- with the cable tie -2-.
NOTE: Tighten the cable tie secure so that the plate cannot move when the power
steering gear is being installed.
-- Install the power steering gear. Refer to STEERING GEAR, FROM MY 2009.
-- Remove the cable tie from the steering gear.
BOOT, THROUGH MY 2008

 Insert tool 24 V.A.G 1332/11
 Locking pliers VAS 6199
Removing
NOTE: If bellows is faulty, moisture and dirt penetrates into steering gear. There must
be a noticeable grease film present on steering rack in area of splines. If grease
film is not present, steering gear must be replaced. Steering gear must also be
replaced if there is corrosion or steering gear is damaged or worn out.
-- Turn steering wheel into straight ahead position.

Suspension Steering
-- Clean outside of steering gear in area of bellows.
NOTE: While doing this, no dirt must enter the steering gear through the faulty bellows.
-- Mark position of nut -arrow 3- on tie rod.
Fig. 74: Adjusting Toe At Front Axle

-- Loosen nut -arrow 3- , counter-holding at tie rod end -arrow 2-.
-- Loosen spring clamp -arrow 1- using V.A.G 1275 from bellows and slide onto tie rod.
-- Remove clamp and pull off bellows from steering gear housing.
-- Now twist tie rod out of tie rod end.
-- Pull off bellows with spring clamp from tie rod.
NOTE: If corrosion, damage, wear-out or first signs of soiling on steering rack can be
seen, complete steering gear must be replaced.
If no grease film is visible on steering rack, steering gear must also be replaced
completely.
Installing
Suspension Steering
CAUTION: Do not lubricate the steering rack.
-- Guide new clamp and bellows onto tie rod.
-- Install the tie rod up to the marking made during removal.
-- Tighten lock nut -3- to tightening specification, counterhold on tie rod end -arrow 2- while doing this.

-- Slightly grease the sealing surface of the bellow to the tie rod with grease G 052 168 A1 (from the repair kit,
from Fuchs Renolit JP1619).
-- Slide bellows -2- onto tie rod -1- as depicted in the illustration.
Suspension Steering
Fig. 76: Identifying Boot And Tie Rod

-- Secure spring clamp on bellows using V.A.G 1275.
-- Slightly grease the sealing surface of the bellow to the steering gear housing with grease G 052 168 A1 (from
the repair kit, from Fuchs Renolit JP1619).
-- Push the boot all the way onto the steering gear housing.
-- Tighten new clamp using VAS 6199 to the extent depicted in the illustration.
Fig. 77: New Clamp Tightened

Suspension Steering
After the installation the vehicle must be measured.
-- Perform vehicle alignment WHEEL ALIGNMENT .
-- The boots have been exchanged, then perform a basic setting for the steering angle sensor -G85- using
Vehicle Diagnostic Tester in Guided Fault Finding.
-- Then perform basic setting of steering system via Vehicle Diagnostic Tester in Guided Fault Finding.

Tie rod end to tie rod 70 Nm
BOOT, FROM MY 2009

Removing
NOTE: If the bellow is faulty, moisture and dirt will penetrate into steering gear. There
must be a noticeable grease film present on steering rack in area of splines. If
grease film is not present, steering gear must be replaced.
Replace the steering gear:
If there is corrosion.
If it is damaged.
If it is worn out.
If there is dirt on the steering rack.

Suspension Steering
-- Loosen the wheel bolts.
-- Mark the location of the nut on the tie rod.
-- Remove the tie rod end. Refer to TIE ROD BALL JOINT, FROM MY 2009.
NOTE: While doing this, no dirt must enter the steering gear through the faulty bellows.
-- Open the clamps.
-- Remove the boot from the steering gear and the tie rod.
completely.
Installing
-- Slide the boot -2- onto the tie rod -1- as illustrated.
Suspension Steering

-- Tighten the new clamp with VAS 6199 as illustrated.

Suspension Steering
-- Install the tie rod end up to the marking made earlier during the removal. Refer to TIE ROD BALL JOINT,
FROM MY 2009.
-- Install the front wheel and tighten the bolts. Refer to TIGHTENING SPECIFICATION FOR
MOUNTING WHEELS .
-- If both tie rods were replaced, then it is necessary to adapt the basic setting for the steering end stops using
Vehicle Diagnostic Tester.
-- Perform a basic setting to the steering using Vehicle Diagnostic Tester.
Component Tightening specification

TIE ROD, THROUGH MY 2008

 38 mm open end wrench insert V.A.G 1923
Removing
Loosen nut -arrow 3-, counterhold on tie rod end -arrow 2- while doing this.
Suspension Steering

-- Remove front wheel.
-- Press off track rod ball joint from wheel bearing housing using 3287 A and now unscrew nut.
Fig. 81: Pressing Off Tie Rod End From Wheel Bearing Housing With Ball Joint Puller 3287A
Suspension Steering
-- Loosen spring clamp using V.A.G 1275 from bellows and slide onto tie rod. See Fig. 74.
-- Remove clamp and pull off bellows from steering gear housing.
-- Remove the tie rod from steering gear using V.A.G 1923.
Fig. 82: Identifying Tie Rod At Steering Gear And 38 Mm Open End Wrench Insert V.A.G 1923
completely.
Installing
-- Twist tie rod far enough into tie rod end until dimension -a- is obtained.
Suspension Steering
Fig. 83: Identifying Tie Rod Dimension

Dimension -a- = 376 +/- 1 mm
-- Rotate tie rod in steering rack and tighten.
-- Slide bellows -2- onto tie rod -1- , pay attention to correct position when doing this.
Suspension Steering

-- Slide bellows onto steering gear housing until it stops.
-- Tighten new clamp using VAS 6199 to the extent depicted in the illustration.

Suspension Steering
After the installation the vehicle must be measured.
-- Perform vehicle alignment WHEEL ALIGNMENT .
-- If both tie rods have been exchanged, then perform a basic setting for the steering angle sensor -G85- using
Vehicle Diagnostic Tester in Guided Fault Finding.
-- Then perform basic setting of steering system via Vehicle Diagnostic Tester in Guided Fault Finding.

Tie rod to steering rack 100 Nm
 Use new nut.
TIE ROD, FROM MY 2009

Removing
Suspension Steering
Fig. 86: Loosening Nut Of Track Rod Ball Joint

-- Open the clamps and push back boot.
-- Remove tie rod.
Fig. 87: Loosening/Tightening Tie Rod

Suspension Steering
1. V.A.G 1923
2. V.A.G 1332
completely.
Installing
-- Make sure the correct tie rod end is installed on each side.

Suspension Steering
I - Right tie rod end identified with an "A"
II - Left tie rod end identified with a "B"
-- Twist tie rod far enough into tie rod end until dimension -a- is obtained.
Fig. 89: Identifying Tie Rod Dimension

Dimension -a- = 367 +/- 1 mm
-- Tighten the tie rod.

Suspension Steering
Fig. 90: Loosening/Tightening Tie Rod

1. V.A.G 1923
2. V.A.G 1332
-- Slide bellows -2- onto tie rod -1-, pay attention to correct position when doing this.

Suspension Steering
-- Tighten the new clamp with VAS 6199 as illustrated.

MOUNTING WHEELS .
-- If both tie rods were replaced, then it is necessary to "adapt the basic setting for the steering end stops" using
Vehicle Diagnostic Tester.

Tie rod to steering rack 100 Nm
 Use new nut.
Suspension Steering
TIE ROD BALL JOINT, FROM MY 2009
 Ball joint puller T10187

Removing
-- Loosen nut -1-.
Fig. 93: Loosening Tie Rod End Nut

-- Mark the position of the tie rod end on the tie rod.
-- Loosen the tie rod end nut -2- but do not remove it.
-- Remove the tie rod from the wheel bearing housing and remove the nut.
Suspension Steering
1. T10187
-- Remove the tie rod end from the tie rod.
Installing
-- Make sure the correct tie rod end is installed on each side.

I - Right tie rod end identified with an "A"
II - Left tie rod end identified with a "B"
-- Turn the tie rod end to marking made earlier on the tie rod and secure it with a locking nut.
-- Install the tie rod end into the wheel bearing housing.
Suspension Steering
-- Install the tie rod end with a new nut.
-- Install the front wheel and tighten the bolts. Refer to TIGHTENING SPECIFICATION FOR
MOUNTING WHEELS .

 Use new nut.
STEERING GEAR ASSEMBLY OVERVIEW
NOTE: Currently, there is no service work to be performed on steering gear.

Suspension Steering
Fig. 95: Steering Gear Assembly Overview

1. Right Tie Rod End

 Identified with "A". Refer to Fig. 88.
 Removing and installing, refer to TIE ROD BALL JOINT, FROM MY 2009.
 Checking, refer to CHECKING PLAY, SECURITY AND JOINT BOOTS OF TIE ROD
ENDS.
 Installed position TIE ROD ENDS ALLOCATION.
2. Nut
 70 Nm
3. Clamp
Suspension Steering
4. Boot
 Must not be twisted after toe is adjusted.
 Removing and installing, refer to BOOT, FROM MY 2009.
5. Clamp
 Replace
6. Tie Rod
 100 Nm
 Removing and installing, refer to TIE ROD, FROM MY 2009.
7. Long Bonded Rubber Bushing

 Left, rear with centering
 Replacing, refer to STEERING GEAR BONDED RUBBER BUSHING, FROM MY 2009.

 Removing and installing, refer to STEERING GEAR, FROM MY 2009.
9. Long Bonded Rubber Bushing

 Right rear.
10. Short Bonded Rubber Bushing

 Left and right front.
11. Backing Plate

12. Left Tie Rod End
 Identified with "B". Refer to Fig. 88.
 Removing and installing, refer to TIE ROD BALL JOINT, FROM MY 2009.
 Checking, refer to CHECKING PLAY, SECURITY AND JOINT BOOTS OF TIE ROD
ENDS.
 Installed position, refer to TIE ROD ENDS ALLOCATION.
SPECIAL TOOLS

 Socket insert T10424
Suspension Steering
Fig. 96: Socket Insert T10424

Fig. 97: Assembly Tool T10390

 Ball joint puller T10187

Suspension Steering
Fig. 98: Ball Joint Puller T10187

Suspension Steering
Fig. 99: Identifying Special Tools -- Steering Gear, Removing And Installing

Suspension Steering
Fig. 100: Identifying Special Tools -- Tie Rod, Removing And Installing

Accessories & Equipment Sunroof
Sunroof
60 SUNROOF
SLIDING/TILTING SUNROOF WITH GLASS PANEL - MERITOR
FUNCTION
All moving functions of sunroof with glass panel can be performed with ignition switched on.
After the ignition is switched off, these functions are available until the driver or passenger door is opened.
The opening of glass panel for sliding -2- and tilt position -3- is pre-selected using the rotary switch.
On the rotary knob, there are markings for preset sliding and tilt positions of the glass panel.
Opening the sunroof in the so-called comfort position -1- prevents most driving noise which may occur when
open completely -2-.
Switch for automatic preset
Fig. 1: Sunroof Controls

The sunroof with glass panel has pinch protection. The glass panel runs in the opposite direction if it runs into
an obstruction during the closing or opening procedure from the tilt or sliding position.
There is also an emergency close feature. If there are problems closing, sunroof with glass panel can be forced
closed by pressing the preselector, which must be located in the "sunroof closed" -4- position.
For the emergency close function, the closing force limit is deactivated.
The drive motor for sunroof with glass panel is protected against overheating via a running time limit. The
locking mechanism activates after an uninterrupted operation of approximately two minutes.
If there is a malfunction in the electrical system, the sunroof and glass panel motor can be moved using a
commercially available 4 mm hex wrench.
SLIDING/TILTING SUNROOF WITH GLASS PANEL ASSEMBLY OVERVIEW
Fig. 2: Sunroof With Glass Panel - Assembly Overview

1. Sunroof glass panel (one-piece safety glass)

 Sunroof Glass Panel, Adjusting, refer to SUNROOF GLASS PANEL, ADJUSTING HEIGHT
2. Panel seal
 Adjusting panel seal, refer to PANEL SEAL, ADJUSTING
 Seal joint at center in rear area.
 Panel Seal, Replacing, refer to PANEL SEAL
3. Sun shade
 Sun Shade, Removing and Installing, refer to SUN SHADE
4. Bolt
 Screws are micro encapsulated and must always be replaced after removing.
 Quantity: 4
5. Spring glider
 Bolted on to sun shade.
 Quantity: 4
 Can be replaced separately
6. Bellows
 For covering slotted guide rail.
7. Water channel
8. Guide locking hook
 Removed together with slotted guide rail.
9. End piece, upper part

 Clipped to lower part of end piece.
10. End piece, lower part

 Can be replaced separately
 Use butyl adhesive sealing cord AKL 450 005 05 for sealing.
11. Assembly unit

 Removing and installing installation unit, refer to ASSEMBLY UNIT
 If necessary use special grease G 000 450 02 exclusively to grease guide channels, otherwise the
functions cannot be guaranteed.
12. Bolt
 Screws are micro-encapsulated and must always be replaced after removing.
 Quantity: 3
13. Emergency operation hex key

 The hex wrench in the previously known shape is not longer supplied in the vehicle. Use a
commercially available size 4 hex wrench.

14. Electrical drive motor
 Removing, refer to SUNROOF GLASS PANEL DRIVE
 Drive Motor, Neutral Position, Adjusting, refer to SUNROOF GLASS PANEL DRIVE,
ADJUSTING (ZERO POSITION)
15. Spring
 Quantity: 2
 To open wind deflector.
 Clipped in on wind deflector and cannot be replaced individually.
 Removing, refer to WIND DEFLECTOR
16. Wind Deflector

 Adjusting, on vehicles from 08.2005 >, refer to WIND DEFLECTOR, ADJUSTING,

VEHICLES FROM 08.05
17. Bearing for wind deflector
 Quantity: 2
 Clipped in on wind deflector and cannot be replaced individually.
 Removing
18. Front guide

 Can be slid individually out of guide rail.
19. Rear guide, lower part

 Removed together with slotted guide rail.
20. TORX bolt

 TORX T25
21. Slotted guide rail

 Removing and Installing, refer to SLOTTED GUIDE RAIL, REMOVING AND INSTALLING.
22. Spacer
 Removing and Installing, refer to Fig. 49.
SUNROOF GLASS PANEL, ADJUSTING HEIGHT
NOTE: The glass panel height adjustment is to be performed after the glass panel has
been closed out of sliding position.
Zero position of glass panel for sunroof OK.
-- Remove bellows. Refer to BELLOWS

Fig. 3: Glass Panel For Sunroof And Mounting Bolts

-- Loosen mounting bolts -1- for glass panel of sunroof -2-.
-- Drive sunroof glass panel into position "open".
-- Drive sunroof glass panel into position "closed".
-- Perform height adjustment for glass panel for sunroof at front and rear on both sides as follows:
Front panel adjustment:

Fig. 4: Identifying Panel Adjustment At Front

-a- = 0 to 1 mm lower than roof
-arrow- = driving direction
-- Tighten front bolts to 5 Nm.
Rear panel adjustment:
Fig. 5: Identifying Panel Adjustment At Rear

-b- = 0 to 1 mm higher than roof
-- First tighten center, then rear bolts to 5 Nm.
NOTE: To achieve the best possible exterior optical characteristics, make sure that the
adjustment on left and right sides is performed as evenly (symmetrically) as
possible.
Glass panel must not be higher than roof at any point at front or lower than roof
at any point at rear.
-- Install bellows. Refer to BELLOWS
PANEL SEAL, ADJUSTING

-- Using a strip of cardboard about 0.3 mm thick, for example, a business card, check if pretension between
panel seal -2- and body is even all around. Cardboard should slide between panel seal and roof frame with firm
resistance.
Fig. 6: Adjusting Panel Seal

-- Sunroof Glass Panel, Removing, refer to SUNROOF GLASS PANEL.
-- If pretension is insufficient, the panel seal -2- can be pressed open with a trim removal wedge 3409 -1-.
-- If the pretension is excessive, press the panel seal -1- closed around circumference using application roller
3356.
Fig. 7: If Panel Seal Pre-Tension Is Too High, Use Application Roller 3356 (As Shown)
WIND DEFLECTOR, ADJUSTING, VEHICLES FROM 08.05
On vehicles from 08.2005, the wind deflector can be adjusted.
-- Insert hook for front end 3370 between roof edge and wind deflector bearing -2-.
Fig. 8: Inserting Special Tool Special Hook 3370 Between Roof Edge And Wind Deflector Bearing
-- Pull wind deflector bearing -2- out of side locking mechanism of left and right guide rails using the special
hook 3370 in -direction of arrow a-.
-- Slide wind deflector -1- parallel into guide rails -arrow b- until dimension -c- is adjusted between 0.3 mm and
1.3 mm.
-- Press wind deflector bearing -2- into guide rails.
NOTE: Wind deflector bearing must engage in guide rails audibly.

SUNROOF GLASS PANEL DRIVE, ADJUSTING (ZERO POSITION)
Adjustment of zero position may be necessary if the drive motor was removed while not in zero position or the
glass panel of sunroof was closed or opened via emergency operation.
The drive motor is removed but the electrical wires are connected.
-- Move control knob to "roof opened" position.
-- Move automatic control knob to "roof closed" position.
-- Move automatic rotary switch to "roof tilted" position.
-- Move automatic control knob to "roof closed" position.
-- Install drive motor in this position (zero position) with sunroof glass panel closed.
 Drive motor for glass panel of sunroof is in zero position when a white dot can be seen in the opening -
arrow- of drive motor.
Fig. 9: Identifying Drive Motor For Glass Panel Of Sunroof In Zero Position
PARALLEL MOVEMENT, CHECKING
Marking -arrow- on upper part of rear guide -1- must be located on both sides between markings dimension -a-
at slotted guide rail -2-.
Fig. 10: Identifying Marking On Upper Part Of Rear Guide Between Markings Dimension At Slotted
Guide Rail
Link guide -2- must be engaged in guide rail (cannot be moved by hand).
PARALLEL MOVEMENT, ADJUSTING
NOTE: The parallel movement adjustment can only be performed with removed drive
motor and glass panel (in zero position).
-- Remove drive motor for sunroof. Refer to SUNROOF GLASS PANEL DRIVE.
Guide Rail
-- Slide upper part of guide -1- at left and right centered between the markings.
-- Install drive motor (zero position) in this position.
 Then check the zero position.
INSTALLATION UNIT ASSEMBLY OVERVIEW

Fig. 12: Assembly Unit, Removing And Installing

1. Assembly unit
2. Bolt
 Quantity: 12
3. Connector
4. Connections for water drain hoses
5. Drive motor for sunroof
OPERATING WITHOUT ELECTRICITY
NOTE: If there is a malfunction in the electrical system, the sunroof and glass panel
motor can be moved using a hex wrench. Hex wrench is located in headliner, at
right next to opening for rear interior/reading light.
-- Disengage retaining hooks -2- using trim removal wedge 3409.
Fig. 13: Disengaging Retaining Hooks Using Trim Removal Wedge 3409
-- Fold down cover -1- -arrow a-.
-- Pull cover downward -arrow b- out of retainer.
-- Guide hex wrench -1- through opening into bolt -2- of drive motor -3-.
Fig. 14: Hex Wrench Guided Through Opening Into Bolt Of Drive Motor
-- Push wrench -1- upward to release the drive motor.
The screw -2- can be pushed in a few millimeters -a-. The sunroof glass panel can be moved only in this
position.
WATER DRAIN HOSES, CLEANING
NOTE: For cleaning, it is recommended that you create your own assisting tool that
resembles a speedometer inner cable in size and flexibility and is approximately
8 feet (2300 mm) in length or an equivalent tool.
Front Water Drain Hoses

Fig. 15: Front Water Drain Hoses

The front water drain hoses run through the A-pillars and end at the bulkhead crossmember. Cleaning is
performed at opening for sunroof.
Rear Water Drain Hoses, Sedan

Fig. 16: Rear Water Drain Hoses - Sedan

The rear water drain hoses run through the C-pillars and end in the rear wheel housings. Cleaning is performed
in the wheel housing, but the wheel housing liner must be removed.
Rear Water Drain Hoses, Wagon

Fig. 17: Rear Water Drain Hoses - Wagon

SUNROOF WITH SOLAR PANEL - WEBASTO
FUNCTION
All sunroof functions are available when the ignition is switched on.
After the ignition is switched off, these functions are available until the driver or passenger door is opened.
The opening of the solar panel of the sunroof can be pre-selected using rotary knob. The panel trim is
permanently attached to the solar panel and cannot be moved separately.
Fig. 18: Sunroof Controls

The sunroof is equipped with a closing force limiter in area of window. When an obstruction is met during the
closing sequence, the roof opens again by itself.
If there are problems closing, sunroof can be forced closed by pressing the preselector, which must be located in
the "sunroof closed" position. There is also an emergency closing function.
During emergency closing, pinch protection has increased pinch force.
The sunroof drive motor is protected against overheating by a running time limiter. The locking mechanism
activates after an uninterrupted operation of approximately two minutes. Operation can only be resumed after a
cool-down period.
If there is a malfunction in the electrical system, the sunroof motor can be moved using a hex wrench.
The integrated photoelectric cells -1- in the solar panel of the sunroof generate voltage in sunlight. This voltage
is transferred to the vehicle blower via the terminals -2-. This functions only when the ignition is switched off
and the solar panel is tilted or closed.
Fig. 19: Integrated Photoelectric Cells And Terminals

SUNROOF WITH SOLAR PANEL ASSEMBLY OVERVIEW

Fig. 20: Sunroof With Solar Panel - Assembly Overview

1. Sunroof solar panel (one-piece safety glass)

 Sunroof Solar Panel, Adjusting, refer to SUNROOF SOLAR PANEL, ADJUSTING HEIGHT
2. Panel seal
 Panel Seal, Replacing, refer to PANEL SEAL
3. Panel trim
 Panel Trim, Removing and Installing, refer to SOLAR PANEL TRIM
4. Slider
 For panel trim.
 1 screw per slider

6. Water channel
 Component of assembly unit, cannot be replaced individually.
7. Guide with cable

 Always replace as a pair.
8. Slotted guide rail

 Component of assembly unit, cannot be replaced individually.
9. Bolt
10. End piece
 Use butyl adhesive sealing cord AKL 450 005 05 for sealing.
11. Assembly unit

 Assembly Unit, Removing, refer to ASSEMBLY UNIT
 U-frame (with guide channels) - The guide channels can be lubricated if necessary, but only use
special grease G 000 450 02. Otherwise, proper function cannot be guaranteed.
12. Bolt
13. Solar panel electrical contact

 On installation unit.
 Both terminals with electrical wire and connector.
 Removing, refer to SOLAR PANEL ELECTRICAL CONTACT ON INSTALLATION UNIT
14. Electrical drive motor

 Removing, refer to SUNROOF DRIVE MOTOR
 Drive Motor, Neutral Position, Adjusting, refer to SUNROOF DRIVE MOTOR, ADJUSTING
NEUTRAL POSITION
15. Bolt
 Screws are micro-encapsulated and must always be replaced after removing.
 Quantity: 3
16. Spring
 To open wind deflector.
17. Bolt
18. Wind Deflector

19. Bolt
20. Solar panel electrical contact

 Removing, refer to SOLAR PANEL ELECTRICAL CONTACT ON PANEL
SUNROOF SOLAR PANEL, ADJUSTING HEIGHT
-- Open the sunroof about 10 cm.
-- Pull the trim -2- in the center -arrow- out of the mount -1-.
Fig. 21: Pulling Middle Of Trim Downward Out Of Retainer

-- Push the trim back.
-- Move the solar panel to the neutral position.
To prevent wind noise, adjust the front and rear height of the solar panel as shown in the illustration.
Fig. 22: Panel Adjustment At Front

Front panel adjustment:
-a- = 0 to 1 mm lower than roof
Rear panel adjustment:
Fig. 23: Panel Adjustment At Rear

-b- = 0 to 1 mm higher than roof
-- Tighten the solar panel bolts to 5 Nm.
SOLAR PANEL, CHECKING PARALLEL MOVEMENT

-- Move the solar panel to the neutral position.
The centering pin must align with the marking -arrow- on left and right guide rails.
Fig. 25: Guide Pin Aligned With Marking On Left And Right Guide Rails
If this is not the case, adjust the parallel movement. Refer to SOLAR PANEL, ADJUSTING PARALLEL
MOVEMENT.
SOLAR PANEL, ADJUSTING PARALLEL MOVEMENT
NOTE: The parallel movement adjustment can only be performed with removed drive
motor and solar panel (in zero position).
-- Remove the sunroof motor. Refer to SUNROOF DRIVE MOTOR.
-- Slide slotted guide rails by hand and only from the front.
-- Install the drive motor and solar panel.
SUNROOF DRIVE MOTOR, ADJUSTING NEUTRAL POSITION
The drive motor is removed but the electrical wires are connected.
-- Move automatic rotary knob to "roof closed" position.
-- The drive motor automatically runs to the neutral position and switches off.
-- The window is protected by a cover. Pry out the cover -1-.

Fig. 27: Adjusting Drive Motor For Sliding/Tilting Sunroof

-- Colored marking -2- and the protruding lug -3- must align in the sight window.
-- Install the drive motor in this position (neutral position) with the sunroof closed.
OPERATING WITHOUT ELECTRICITY
NOTE: If there is a malfunction in the electrical system, the sunroof and solar panel
motor can be moved using a hex wrench.
The hex wrench in the previously known shape is not longer supplied in the
vehicle. Use a commercially available size 4 hex wrench.
-- Disengage retaining hooks -2- using trim removal wedge 3409.

Fig. 28: Disengaging Retaining Hooks Using Trim Removal Wedge 3409
-- Fold down cover -1- -arrow a-.
-- Pull cover downward -arrow b- out of retainer.
-- Guide hex wrench -1- through opening into bolt -2- of drive motor -3-.
Fig. 29: Hex Wrench Guided Through Opening Into Bolt Of Drive Motor
-- Push wrench -1- upward to release the drive motor.

The screw -2- can be pushed in a few millimeters -a-. The sunroof solar panel can be moved only in this
position.
WATER DRAIN HOSES, CLEANING
NOTE: For cleaning, it is recommended that you create your own assisting tool that
resembles a speedometer inner cable in size and flexibility and is approximately
8 feet (2300 mm) in length or an equivalent tool.
Front Water Drain Hoses
Fig. 30: Front Water Drain Hoses

The front water drain hoses run through the A-pillars and end at the bulkhead crossmember. Cleaning is
performed at opening for sunroof.
Rear Water Drain Hoses Sedan
Fig. 31: Rear Water Drain Hoses - Sedan

Rear Water Drain Hoses, Wagon

Fig. 32: Rear Water Drain Hoses - Wagon

SLIDING/TILTING SUNROOF WITH GLASS PANEL - MERITOR
BELLOWS
Removing
Fig. 33: Bellows Remove/Install Components

-- Slide sun shade toward rear.
-- Tilt open sunroof glass panel.
-- Carefully unclip bellows -1- from lower section of slotted guide rail -3- using a trim removal wedge 3409.
-- Pull bellows -1- off mounting pins -4-.
-- Disengage bellows -1- at top - rear -2-.

Installing
Fig. 34: Bellows Remove/Install Components

-- Slide sun shade toward rear.
-- Tilt open sunroof glass panel.
-- Engage bellows -1- first at top - rear -2-.
-- Clip bellows -1- with mounting pins -4- into slotted guide rail.
rail.
SUNROOF GLASS PANEL
-- Remove bellows. Refer to BELLOWS
-- Remove mounting bolts -1- on left and right sides.

-- Remove glass panel for sunroof -2- upward.
WARNING: Slotted guide rail must not be driven into "opened" position with sunroof
glass panel removed because the rain channel is no longer pressed down
by the glass panel and may be wedged in roof.
Installing
 The panel must be installed in the neutral position (panel closed).
Neutral position:
Guide Rail
If this is not the case, adjust the parallel movement. Refer to PARALLEL MOVEMENT, ADJUSTING.
-- Insert glass panel for sunroof -2- from above and screw in mounting bolts -1-.

-- Tighten mounting bolts -1- lightly.
-- Adjust glass panel for sunroof (height adjustment). Refer to SUNROOF GLASS PANEL, ADJUSTING
HEIGHT.
NOTE: Tighten bolts after panel height adjustment (5 Nm).
Install bellows after panel height adjustment.
PANEL SEAL
-- Pull off seal -1- from glass panel for sunroof -2-.
Fig. 38: Identifying Glass Panel Seal

-- Pull new seal -1- at rear panel edge in center, beginning from bottom to top, onto glass panel for sunroof -2-.
Fig. 39: Identifying Glass Panel Seal

NOTE: Coat the edge of the panel with soapy water to make it easier to install the seal.
If the seal is not correctly installed, the seal surface is wavy.
Panel seal must be shortened corresponding to the panel circumference.
-- Install glass panel for sunroof.
-- Adjust panel seal. Refer to PANEL SEAL, ADJUSTING.
WIND DEFLECTOR
Removing
-- Open sunroof glass panel completely.
-- Press wind deflector with height stop out of front roof opening and tilt wind deflector open vertically.
-- Insert hook for front end 3370 between roof edge and wind deflector bearing -arrow-.
Fig. 40: Pulling Wind Deflector Bearing Out Of Side Locking Mechanism, Using Special Tool Hook 3370
-- Pull wind deflector bearing out of side locking mechanism of left and right guide rails using hook for front
end 3370 in -direction of arrow-.
-- Remove wind deflector upward from guide rail.
Installing
-- Insert wind deflector into guide rail and slide wind deflector with height stop under front roof opening at left
and right sides.
-- Using light pressure, press wind deflector bearing into guide rails.
NOTE: Wind deflector bearing must engage in guide rails audibly.
SUN SHADE
Removing
-- Slide sun shade slightly toward rear.

Fig. 41: Forward Screw And Stop

-- Remove the front screw -arrow- on the left and right side. Slide the spring glider forward over the stop -1-.
-- Slide sun shade forward and lift sun shade slightly over the roof cutout and out.
Fig. 42: Identifying Sliding Headliner Rear Bolts & Headliner

-- Remove the rear screws -arrow- on the left and right side. Slide the spring glider to the rear and remove the
sun visor -1-.
Installing
SUNROOF GLASS PANEL DRIVE
Removing
-- Remove the lamps and controls. Refer to [For engine(s) BPY,BLV,CCTA,CBFA] ROOF TRIM LAMPS
AND SWITCHES .
Changing motor - detection of preselector switch:
NOTE: In order to interrupt the release signal and thereby to activate switch detection,
the conditions described below must be met.
If this is not the case, it may lead to the drive motor incorrectly detecting the
preset switch and the selected position is not reached. If this happens, it must
be realized that glass panel will remain stationary at a closed switch position
approximately. 10 cm short of the actual closing position.
WARNING: Only remove and install drive motor for sunroof glass panel when roof is
closed (zero position).
Requirements for removing and installing the drive: the engine and the
ignition must be off, remove the key and open the door.
-- Switch off engine and ignition, remove key and open door.
 This state must be maintained up to installation of the drive motor.
-- Remove bolts -arrows- and pull off drive motor for sunroof.
Fig. 43: Removing Bolts And Pulling Off Drive Motor For Sunroof
Installing
 The bolts for the sunroof drive motor are micro-encapsulated and must always be replaced 3.5 Nm.
-- After installation has been performed, key can be reinserted into lock cylinder of ignition/starter switch.
SUNROOF GLASS PANEL ROTARY SWITCH
-- Remove the automatic rotary switch for the sunroof glass panel. Refer to [For engine(s)
BPY,BLV,CCTA,CBFA] ROOF TRIM LAMPS AND SWITCHES .
Fig. 44: Switch For Automatic Preset

ASSEMBLY UNIT
Removing
NOTE: Always follow the Safety Precautions when working on the airbag. Refer to
Only Passat Wagon with a screen separator

Fig. 45: Curtain Airbag Remove/Install Components

-- Remove screw -3- for side curtain airbag -5-.
-- Lower side curtain airbag -5- until you can reach the screws -2-.
-- Remove screws -2- for grab handle assembly frame -4- and remove assembly frame.
-- Slide screen separator wall bracket -8- in -direction of arrow- down from side curtain airbag gas generator -6-
.
All vehicles
NOTE: When removing assembly unit, make sure it does not come in contact with side
curtain airbag.

-- Disconnect water drain hoses -4- from installation unit -1-.
-- Disconnect harness connector -3- from drive motor of glass panel for sunroof -5-.
-- Remove bolts -2- and remove installation unit -1- from vehicle with a second mechanic.
Installing
All vehicles
NOTE: When installing assembly unit, make sure it does not come in contact with side
curtain airbag.

-- With a second mechanic, insert installation unit -1- into roof cutout.
-- During installation, align installation unit -1- via two cylindrical pins (reversed drill bit) 12 mm at right front -
arrow- and 10 mm left rear -arrow- in roof.
Installation unit must not make contact with roof frame.
-- Insert bolts -2-.
-- Check wires and harness connectors for electrical consumers at roof for correct routing and reproduce if
necessary.
-- Install the unit -1- for the sunroof drive -5- beginning on the left and right sides and working toward the rear.
Tightening specification for the bolts -2- : 8 Nm.
-- Install water drain hoses -4-.
-- Connect harness connector -3- for drive motor of glass panel for sunroof -5-.


-- Tighten screws -7- for screen separator wall bracket -8- , tightening specification: 20 Nm.
-- Tighten the screws -2- for grab handle assembly frame -4- , tightening specification: 5 Nm.
-- Tighten screw -3- for side curtain airbag -5- : tightening specification: 5 Nm.
SLOTTED GUIDE RAIL, REMOVING AND INSTALLING
Removing

Fig. 49: Unclip Spacer At Front Of Slotted Guide Rail And Retaining Hooks At Rear Of Guide Using A
Screwdriver
-- Using a screwdriver, unclip spacer -2- at front of slotted guide rail -1- and retaining hooks -arrows- at rear of
guide.
-- Pull spacer -2- in -direction of arrow- out of slotted guide rail -1- and guide retaining hook.
-- Fold up slotted guide rail -1- in -direction of arrow-.
Fig. 50: Folding Up Slotted Guide Rail

-- Slide front guide -2- toward front and pull out slotted guide rail -1- in -direction of arrow- from front guide -
2-.
Fig. 51: Front Guide Slid Toward Front And Pulled Out Slotted Guide Rail From Front Guide
Installing
LINK
NOTE: Always replace guides with cable as a pair.
Removing
-- Removing installation unit, refer to ASSEMBLY UNIT.
-- Remove drive motor for sunroof, refer to SUNROOF GLASS PANEL DRIVE.
-- Remove slotted guide rail.
-- Using a screwdriver, carefully disengage rain channel -1- in -direction of arrow- on both sides at bearing on
guide retaining tabs -2- and remove rain channel.
Fig. 52: Carefully Disengaging Rain Channel On Both Sides At Bearing On Guide Retaining Tabs Using
A Screwdriver And Removing Rain Channel
-- Disengage clip mechanism -arrows- of upper end piece -1- from lower end piece -2- using a screw driver and
pull upper end piece off.
Fig. 53: Disengaging Clip Mechanism Of Upper End Piece From Lower End Piece Using A Screw Driver
And Pulling Upper End Piece Off
-- Slide lower part of rear guide -1- in -direction of arrow- in guide rail -3- until the lock mechanism of guide
catch -2- is released.
Fig. 54: Pulling Lower Part Of Rear Guide And Guiding Catch Together In Out Of Guide Rail
-- Pull lower part of rear guide -1- and guide catch -2- together in -direction of arrow- out of guide rail -3-.
Installing
SUNROOF WITH SOLAR PANEL - WEBASTO
SUNROOF SOLAR PANEL
Removing

-- Tilt open the sunroof.
-- Remove bolts (TORX socket T25; 5 Nm).
Fig. 56: Removing Solar Panel

-- Remove solar panel upward.

Installing
 The panel must be installed in the neutral position (panel closed).
Neutral position:
If this is not the case, adjust the parallel movement. Refer to SOLAR PANEL, ADJUSTING PARALLEL
MOVEMENT.
-- Insert the sunroof panel from above and install the guide rail/panel mounting bolts.
Fig. 58: Inserting Sunroof Panel From Above And Bolts

-- Slightly tighten bolts (TORX T25).
NOTE: Tighten the mounting bolts to 5 Nm after adjusting the panel height.
PANEL SEAL
-- Sunroof Solar Panel, Removing, refer to SUNROOF DRIVE MOTOR.
Fig. 59: Identifying Seal And Glass Panel

-- Remove the seal -1- from the solar panel.
-- Press the center of the new seal into the solar panel -2-.
NOTE: Coat the edge of the panel with soapy water to make it easier to install the seal.
WIND DEFLECTOR
Removing
-- Open the sunroof completely.
-- Press the wind deflector -2- on both sides toward the center of the vehicle -arrow- and out of the mount -3-.
Fig. 60: Pressing The Wind Deflector On Both Sides Toward The Center Of The Vehicle And Out Of The
Mount
-- Remove wind deflector with height stop -1- under roof toward rear.
SOLAR PANEL TRIM
Removing
-- Remove the sunroof. Refer to SUNROOF SOLAR PANEL.

Fig. 61: Identifying Bolts, Guide For Water Channel, Angle Bracket, Roof Trim & Slider
-- Remove guide -3- for water channel and angle bracket -4-.
-- Push back roof trim slightly -1- and remove slider -5- from guide.
-- Pry out roof trim -1- upward.
SUNROOF DRIVE MOTOR
Removing
-- Remove the lamps and controls. Refer to [For engine(s) BPY,BLV,CCTA,CBFA] SUNROOF SWITCH -
E8- .
Changing motor - detection of preselector switch:
NOTE: In order to interrupt the release signal and thereby to activate switch detection,
the conditions described below must be met.
If this is not the case, it may lead to the drive motor incorrectly detecting the
preset switch and the selected position is not reached. If this happens, it must
be realized that solar panel will remain stationary at a closed switch position
approximately 10 cm short of the actual closing position.
WARNING: Only remove and install drive motor for sunroof solar panel when roof is
-- Switch off engine and ignition, remove key and open door.
 This state must be maintained up to installation of the drive motor.
NOTE: Only remove and install drive motor for sunroof when roof is closed (zero
position, refer to SUNROOF DRIVE MOTOR, ADJUSTING NEUTRAL POSITION).
-- Remove the bolts -arrows- and remove drive motor for sunroof.
Fig. 62: Removing Bolts And Pulling Off Drive Motor For Sunroof
-- Unclip and disconnect the connector.
The drive motor bolts are micro-encapsulated and must always be replaced, tightening specification: 3.5 Nm.
AUTOMATIC ROTARY SWITCH FOR SLIDING/TILTING SUNROOF

Removing
-- Remove the automatic rotary switch for the sunroof glass panel. Refer to [For engine(s)
BPY,BLV,CCTA,CBFA] SUNROOF SWITCH -E8- .
Fig. 63: Switch For Automatic Preset

SOLAR PANEL ELECTRICAL CONTACT ON PANEL
Removing
-- Sunroof Solar Panel, Removing, refer to SUNROOF SOLAR PANEL.
-- Place solar panel on suitable surface, top face down to prevent damage.
-- Remove the bolt -2- and the contact -1- from the guide in -direction of arrow-.
Fig. 64: Removing Solar Contact In Solar Panel

-- Tightening specification for screw -2- : 2 Nm.
SOLAR PANEL ELECTRICAL CONTACT ON INSTALLATION UNIT
Removing
-- Open the sunroof completely.
-- Remove the headliner -2-. Refer to Removal and Installation .

Fig. 65: Removing Solar Contact In Assembly Unit

-- Disconnect the connector on the contact.
-- Pull the contact -1- out of guide from under the assembly unit.
-- Tighten the screw -arrow- to 1 Nm.
ASSEMBLY UNIT
Removing
NOTE: Always follow the Safety Precautions when working on the airbag. Refer to


-- Remove screw -3- for side curtain airbag -5-.
-- Lower side curtain airbag -5- until you can reach the screws -2-.
-- Remove screws -2- for grab handle assembly frame -4- and remove assembly frame.
-- Slide screen separator wall bracket -8- in -direction of arrow- down from side curtain airbag gas generator -6-
.
All vehicles
NOTE: When removing assembly unit, make sure it does not come in contact with side
curtain airbag.
Fig. 67: Identifying Water Drain Hoses, Installation Unit & Bolts
-- Removing automatic rotary switch for sunroof. Refer to AUTOMATIC ROTARY SWITCH FOR
SLIDING/TILTING SUNROOF.
-- Pull off water drain hoses from assembly unit -1- -arrows-.
-- Remove bolts -2- and remove assembly unit from the vehicle with the help of a second mechanic.
Installing
All vehicles
NOTE: When installing assembly unit, make sure it does not come in contact with side
curtain airbag.
Fig. 68: Identifying Water Drain Hoses, Installation Unit & Bolts
-- With a second technician helping, insert the assembly unit -1- into the roof opening.
-- Align installation unit in roof frame with cylindrical pins (reversed drill) 12 mm at front right and 10 mm at
rear left. The assembly unit must not rest on the roof frame.
-- Check the routing of the electrical consumer wires and connectors on the roof and correct if necessary.
-- Secure installation unit -1- of sunroof drive motor -3- beginning at left and right toward rear, screws -2-
(quantity: 12) tightening specification: 8 Nm.
-- Install water drain hoses -arrows-.
-- Connect harness connector for drive motor -3-.


-- Tighten screws -7- for screen separator wall bracket -8- , tightening specification: 20 Nm.
-- Tighten the screws -2- for grab handle assembly frame -4- , tightening specification: 5 Nm.
-- Tighten screw -3- for side curtain airbag -5- : tightening specification: 5 Nm.
SPECIAL TOOLS
 Roller 3356
 Special hook 3370
Fig. 70: Identifying Special Tools -- Sliding/Tilting Sunroof With Glass Panel
2009 SYSTEM WIRING DIAGRAMS Volkswagen - Passat
USING MITCHELL1'S WIRING DIAGRAMS

For information on using these wiring diagrams, see USING MITCHELL1'S SYSTEM WIRING
DIAGRAMS article.
AIR CONDITIONING
Fig. 1: Automatic A/C Circuit (1 of 3)



Fig. 4: Manual A/C Circuit (1 of 2)

Fig. 5: Manual A/C Circuit (2 of 2)
ANTI-LOCK BRAKES
Fig. 6: Anti-lock Brakes Circuit (1 of 2)

Fig. 7: Anti-lock Brakes Circuit (2 of 2)
ANTI-THEFT
Fig. 8: Anti-theft Circuit, Sedan (1 of 3)



Fig. 11: Anti-theft Circuit, Wagon (1 of 3)


BODY CONTROL MODULES

Fig. 14: Comfort System Central Control Module Circuit

Fig. 15: Steering Column Electronic Systems Control Module Circuit

Fig. 16: Vehicle Electrical System Control Module Circuit (1 of 2)

Fig. 17: Vehicle Electrical System Control Module Circuit (2 of 2)
COMPUTER DATA LINES

Fig. 18: Computer Data Lines Circuit (1 of 2)

Fig. 19: Computer Data Lines Circuit (2 of 2)
COOLING FAN
Fig. 20: Cooling Fan Circuit
CRUISE CONTROL
Fig. 21: Cruise Control Circuit

DEFOGGERS
Fig. 22: Defoggers Circuit
ELECTRONIC POWER STEERING

Fig. 23: Electronic Power Steering Circuit
ENGINE PERFORMANCE
2.0L
Fig. 24: 2.0L, Engine Performance Circuit, BPY (1 of 5)





Fig. 29: 2.0L, Engine Performance Circuit, CAWB (1 of 6)






Fig. 35: 2.0L, Engine Performance Circuit, CCTA (1 of 6)





3.6L
Fig. 41: 3.6L, Engine Performance Circuit (1 of 6)






EXTERIOR LIGHTS
Fig. 47: Backup Lamps Circuit

Fig. 48: Exterior Lamps Circuit (1 of 2)

Fig. 49: Exterior Lamps Circuit (2 of 2)
GROUND DISTRIBUTION
Fig. 50: Ground Distribution Circuit (1 of 6)





HEADLIGHTS
Fig. 56: Headlights Circuit, W/ High Intensity Gas Discharge Headlights (1 of 2)

Fig. 57: Headlights Circuit, W/ High Intensity Gas Discharge Headlights (2 of 2)

Fig. 58: Headlights Circuit, W/O High Intensity Gas Discharge Headlights
HORN
Fig. 59: Horn Circuit
INSTRUMENT CLUSTER
Fig. 60: Electronic Compass Circuit

Fig. 61: Instrument Cluster Circuit (1 of 2)

Fig. 62: Instrument Cluster Circuit (2 of 2)
INTERIOR LIGHTS
Fig. 63: Courtesy Lamps Circuit (1 of 2)

Fig. 64: Courtesy Lamps Circuit (2 of 2)

Fig. 65: Instrument Illumination Circuit (1 of 2)

Fig. 66: Instrument Illumination Circuit (2 of 2)
MEMORY SYSTEMS
Fig. 67: Memory Systems Circuit (1 of 2)

Fig. 68: Memory Systems Circuit (2 of 2)
NAVIGATION
Fig. 69: Navigation Circuit, W/ Amplifier (1 of 2)

Fig. 70: Navigation Circuit, W/ Amplifier (2 of 2)

Fig. 71: Navigation Circuit, W/O Amplifier (1 of 2)

Fig. 72: Navigation Circuit, W/O Amplifier (2 of 2)

Fig. 73: Parking Assistant Circuit, Sedan

Fig. 74: Parking Assistant Circuit, Wagon

Fig. 75: Rear Camera Circuit
POWER DISTRIBUTION
2.0L
Fig. 76: 2.0L, Power Distribution Circuit (1 of 4)



3.6L





POWER DOOR LOCKS

Fig. 85: Power Door Locks Circuit, Sedan (1 of 3)



Fig. 88: Power Door Locks Circuit, Wagon (1 of 3)


POWER MIRRORS
Fig. 91: Automatic Day/Night Mirror Circuit

Fig. 92: Power Mirrors Circuit
POWER SEATS
Fig. 93: Driver Power Seat Circuit

Fig. 94: Front Heated Seats Circuit, W/ Comfort & Leather Seats (1 of 2)
Fig. 95: Front Heated Seats Circuit, W/ Comfort & Leather Seats (2 of 2)
Fig. 96: Front Heated Seats Circuit, W/ Sport Seats (1 of 2)

Fig. 97: Front Heated Seats Circuit, W/ Sport Seats (2 of 2)

Fig. 98: Front Heated Seats Circuit, W/ Standard Seats

Fig. 99: Passenger Power Seat Circuit

Fig. 100: Rear Heated Seats Circuit, W/ Comfort & Leather Seats (1 of 2)
Fig. 101: Rear Heated Seats Circuit, W/ Comfort & Leather Seats (2 of 2)
Fig. 102: Rear Heated Seats Circuit, W/ Sport Seats (1 of 2)

Fig. 103: Rear Heated Seats Circuit, W/ Sport Seats (2 of 2)

Fig. 104: Rear Heated Seats Circuit, W/ Standard Seats
POWER TOP/SUNROOF
Fig. 105: Power Top/Sunroof Circuit
POWER WINDOWS
Fig. 106: Power Windows Circuit
RADIO
Fig. 107: Multimedia Interface Circuit

Fig. 108: Radio/Navigation Circuit, W/ Amplifier (1 of 2)

Fig. 109: Radio/Navigation Circuit, W/ Amplifier (2 of 2)

Fig. 110: Radio/Navigation Circuit, W/O Amplifier (1 of 2)

Fig. 111: Radio/Navigation Circuit, W/O Amplifier (2 of 2)

Fig. 112: Rear Seat Entertainment Circuit
SHIFT INTERLOCK
Fig. 113: Shift Interlock Circuit
STARTING/CHARGING
2.0L
Fig. 114: 2.0L, Charging Circuit

Fig. 115: 2.0L, Starting Circuit
3.6L
Fig. 116: 3.6L, Charging Circuit

Fig. 117: 3.6L, Starting Circuit
SUPPLEMENTAL RESTRAINTS
Fig. 118: Supplemental Restraints Circuit, W/ Rear Side Air Bag (1 of 3)



Fig. 121: Supplemental Restraints Circuit, W/O Rear Side Air Bag (1 of 2)
Fig. 122: Supplemental Restraints Circuit, W/O Rear Side Air Bag (2 of 2)
TRANSMISSION
Fig. 123: A/T Circuit

Fig. 124: AWD Circuit

Fig. 125: Steering Wheel Control Switch Circuit
TRUNK, TAILGATE, FUEL DOOR

Fig. 126: Trunk & Fuel Door Release Circuit, Sedan

Fig. 127: Trunk & Fuel Door Release Circuit, Wagon
WARNING SYSTEMS
Fig. 128: Warning Systems Circuit
WIPER/WASHER
Fig. 129: Wiper/Washer Circuit

TRANSMISSION Torque Converter 09G
TRANSMISSION
Torque Converter 09G
32 TORQUE CONVERTER
GENERAL INFORMATION
TORQUE CONVERTER
-- Always secure the converter.
Unsecured converters could slide out if the transmission is tipped.
Always handle with care.
TORQUE CONVERTER IDENTIFICATION
There are different torque converters. Use the code letters to designate them.
TORQUE CONVERTER, DRAINING
 Oil Extracting Device -V.A.G 1358 A-

 Oil Extracting Sensor -V.A.G 1358 A/1-
-- Extract the transmission fluid from the torque converter using the oil extracting device -V.A.G 1358 A- and
the oil extracting sensor -V.A.G 1358 A/1-.
TORQUE CONVERTER SEAL

 Extractor Lever -VW 681-
Removing
-- Pry the seal out using the extractor lever -VW 681-.
Fig. 1: Identifying Torque Converter Oil Seal And Special Tool VW 681
Installing
-- Install the seal until it is flush using the thrust piece -T10175-.
Fig. 2: Identifying Use Of Thrust Piece T10175 To Drive-In Seal Flush

TORQUE CONVERTER, INSTALLING
-- Press the torque converter hub through the seal as far as the first stop.
-- Lightly press the torque converter toward the transmission and rotate it until the slots on the torque converter
hub -arrow- engage in the drive lugs on the pump gear and the torque converter slides noticeably inward.
Fig. 3: Identifying Area To Inspect Torque Converter Hub For Irregular Grooves
The converter is installed correctly if it is easy to turn is by hand and if it fits evenly in the transmission.
CAUTION: If the engine and transmission are connected with force when the
converter is installed incorrectly, damage to the transmission and
converter results.
SPECIAL TOOLS
 Oil Extracting Sensor -V.A.G 1358 A/1-

 Oil Extracting Device -V.A.G 1358 A-
Fig. 4: Identifying Oil Extractor V.A.G 1358 A


 Extractor Lever -VW 681-

Fig. 6: Identifying Extractor Lever VW 681

Suspension Wheels, Tires, Wheel Alignment - General Information
Suspension
Wheels, Tires, Wheel Alignment - General Information
44 WHEELS, TIRES, WHEEL ALIGNMENT

GENERAL INFORMATION
WHEELS AND TIRES
This guide provides you with important information in the event of tire damage or concerns.
This information contains general information on tires and wheels.
Wheels are high-tech products which have been optimally matched to the operating conditions of modern
vehicles.
As for all technically highly developed products, careful handling, care and maintenance are required for tires as
well. Only then is the safety, performance and driving comfort guaranteed for the entire service life of the tire.
The tires are subject to a process of constant further development. As a result of modern construction
techniques, finishing processes and constant quality checks, high-quality tires are produced. All tires
recommended by VW have been tested by technical development and matched to the respective vehicle type in
cooperation with the tire manufacturers.
When replacing tires, mounting recommended tire brands is always recommended.
Vehicle safety always has the highest priority, with regard to the various operating conditions, such as;
 Different speed ranges.

 Winter and summer use.
 Wet and dry roads.
An optimal compromise must be found to ensure driver safety.
Every tire faces many different types of stress over distance and time. Therefore, it is important that the basic
requirements for optimal use of tires are fulfilled.
The correct adjustment of the axle geometry while performing a vehicle alignment is an important requirement
for an optimal service life of the tire. Therefore, the adjustment of the axle geometry must lie within the
specified tolerance range.
Information for vehicle alignment, refer to WHEEL ALIGNMENT .
NOTE: There are many causes for tire damage and complaints. Therefore, it is very
important to recognize whether the complaint arises from the tires or from other
components.
The running characteristics of the tire change in the course of normal wear. Rolling noises and vibrations can
result from this. These are not damage in the sense of tire defects, but rather symptoms resulting from use.
These can be corrected, at least partially, by specific measures. In certain cases, rolling noise cannot be
completely eliminated.
Special Models
Special models are only partially included in the approval certificate tables. The retrofitting possibility for these
vehicles depends on the motorization of the respective base model.
LEGAL AND TECHNICAL REQUIREMENTS FOR RETROFITTING WHEEL AND TIRE COMBINATIONS
LEGAL REQUIREMENTS, RETROFITTING WHEEL AND TIRE COMBINATIONS
The manufacturer is granted general type approval for the whole vehicle including all parts and for specific
retrofitting (general type approval according to 20 StVZO (Motor Vehicle Construction and Use Regulations or
EU type approval).
Retrofitting to wheels and tires can only be made under certain circumstances. The following points must be
taken into consideration:
 If the wheel and tire sizes along with the load index and speed symbol are contained in the general type
approval or EU type approval, then this tire/wheel combination can be mounted on the vehicle. Refer to
CERTIFICATE OF CONFORMITY.
NOTE: It is not necessary to install the wheel/tire combination specified in the

registration certification Part I (vehicle registration). All combinations in the
general type approval or EU type approval can be mounted on the vehicle. Refer
to CERTIFICATE OF CONFORMITY.
 There is no general type approval according to 22 StVZO for the retrofittings recommended by
VOLKSWAGEN, AG (see approval certificate).
 If the wheels and/or tires are not contained in the general type approval or EU type approval, then vehicle
cannot be retrofitted according to the StVZO specifications.
NOTE: These statements refer to legal requirements in the European Union. No claims
are made as to their completeness. Other legal requirements apply outside the
European Union.
The tables of the approval certificate show the wheel and tire combinations for VW vehicles released by
VOLKSWAGEN AG and recommended by the Test Laboratory for Vehicle Technology at the T U V NORD
STRASSENVERKEHR GMBH (German Technical Inspectorate) and the conditions to be taken into account.
The use of original disc wheels on a vehicle to which they have not been assigned is not permissible.
The possible retrofittings shown here are combinations which meet VOLKSWAGEN AG's requirements for
handling and road safety. They are the results of practical tests and for this reason, VOLKSWAGEN AG
recommends them.
NOTE: Observe the information regarding new vehicle certification documents since
October 1, 2005. Refer to NEW VEHICLE REGISTRATION DOCUMENTS SINCE
OCTOBER 1, 2005.
TECHNICAL REQUIREMENTS, RETROFITTING WHEEL AND TIRE COMBINATIONS
 The wheel and tire combinations or retrofittings listed in the individual vehicle tables refer exclusively to
Volkswagen original disc wheels.
 Release of wheel/tire combinations or retrofittings with disc wheels from the accessories trade is not
possible with the enclosed approval certificate.
 Tubeless radial tires may only be used with stepped rims with a bead retaining contour, e.g. a round
hump.
 Run-flat tires (reinforced sidewall) may only be used on disc wheels with extended hump and vehicles
with a tire pressure monitoring system. Refer to INSTALLING/CONDITIONS FOR USING RUN-
FLAT TIRES.
 The correct tire inflation pressure values must be observed when the specified wheel and tire
combinations are used. The tire inflation pressure values for summer tires are shown on the sticker on the
inside of the fuel tank flap or in the individual vehicle tables.
 Sufficient clearance between the wheels and tires and the wheel housing, suspension and brake
components is ensured if the instructions and conditions specified in the approval certificate are observed
under all operating conditions.
 If not otherwise specified, snow chains may be mounted only on the drive wheels. Only the front wheels
on all wheel drive vehicles and also the back wheels on the Touareg are equipped with snow chains.
ADDITIONAL WHEEL HOUSING ENLARGEMENT, FLAPS
On some vehicles with certain wheel/tire combinations, wheel housing enlargements (FLAPS) must be attached
on the fenders or bumper for technical reasons -arrows-.
Fig. 1: Identifying Additional Wheel Housing Enlargement, Flaps

Please check whether FLAPS must be installed.
The necessary wheel/tire combination information can be found in the overview table for the respective vehicle.
80 SERIES TIRES
Tires of the "80" series (e.g. 145/80 R 13 74S) will replace the "82" series (e.g. 145/82 R 13 74S). All tires of
the "82" series may be replaced by tires of the "80" series without any entry in the registration documents.
For this, the tires of the "80" series require to have the same section width, tire design (diagonal or radial ply
tires), and the same or a higher load-carrying capacity characteristic number.
The "80" and "82" series tires may only be used if they are entered in the vehicle registration documents.
DOCUMENTS AND DESIGNATIONS
NEW VEHICLE REGISTRATION DOCUMENTS SINCE OCTOBER 1, 2005
The implementation of EU guideline 1999/37/EG "Vehicle Registration Documents" in national legislation and
legal data protection requirements have made the introduction of new, fraud resistant registration documents
necessary.
Since 01.10.2005, the new documents are issued by the authorities in the case of new registrations, change of
owner, entry of technical changes and all other changes.
The new registration documents consist of:

 The registration certificate part II that supersedes the vehicle title.
Registration Certificate Part I (Vehicle Registration)
 Contains all technical vehicle data that must be present to register a vehicle in Europe but only a standard
approved wheel/tire combination is specified.
 Has the EU-wide alphanumeric codes allocated to the technical data so that the German registration
document can be converted without problems in the foreign countries of the EU into the registration
document required there.
 Contains a field to document the temporary or final decommissioning of the vehicle and is no longer
drawn in the case of a temporary or final decommissioning.
Registration Certificate Part II (Vehicle Title)
 Contains information that the bearer of the registration certificate is not declared the owner.
 Only contains the current and, if available, last vehicle owner, the actual number of previous owners is
indicated numerically.
 Only contains a small portion of the technical vehicle data.
 Does not document temporary vehicle decommissioning. In the future, the vehicle and body type listed
under digit 1 in the old vehicle documentation will no longer exist. It is replaced in the new documents
with EU standardized vehicle classes with body type.
The introduction of the new registration documents results in hardly any changes for the driver.
As with the old vehicle registration the registration certificate part I (vehicle registration) should be kept in the
vehicle and presented to responsible persons upon request.
It is not necessary to install the wheel/tire combination specified in the registration certification Part I (vehicle
registration). All combinations approved according to the vehicle general type approval or EU type approval
maybe be used.
The permissibility of a wheel/tire combination that deviates from the vehicle general type approval or EU type
approval must be verified with an entry in the registration certificate part I (vehicle registration), an installation
certificate due to a parts certificate or a general type approval for the wheel/tire combination.
CERTIFICATE OF CONFORMITY
The vehicle manufacturer must request an EU type approval for all passenger vehicles (vehicle class M1).
A certificate of conformity is produced based on this type approval.
This document confirms that the vehicle conforms to the EU operating license and is registered in every EU
country without the need for individual approval.
The issuing applies to all vehicles that were produced in accordance with the EU operating license.
These vehicles have an EU type plate (black sticker) in the driver door area or in the engine compartment on
older vehicles.
The certificate of conformity has the same importance as the operating license, so the original should not be
kept in the vehicle.
The certificate of conformity contains the EU type approval number and detailed technical information about
the vehicle such as the emissions category and all permitted wheel/tire combinations. Refer to EU TYPE
APPROVAL NUMBER, SALES TYPE AND SALES OR TRADE NAME.
EU TYPE APPROVAL NUMBER, SALES TYPE AND SALES OR TRADE NAME
Since 01/01/1998, all passenger vehicles licensed for road use within the European Union must possess type
approval according to EU guidelines. Vehicles licensed for road use with single-vehicle approval according to
21 StVZO in Germany are excepted.
Therefore, the same guidelines apply to all automobile manufacturers. Consequently, international trade within
the EU has been simplified.
The certificate of conformity contains the EU type approval number and detailed technical information about
the vehicle such as the emissions category and all permitted wheel/tire combinations. Refer to CERTIFICATE
OF CONFORMITY.
EU Type Approval Number

(Type Approval) Sales Type Sales/Trade Designation
5Z 5Z Fox 2006 >
6R 6R Polo 2010 >
1K 5K Golf 2009 >
1K 517 Golf Convertible from MY 12
16 162 Jetta 2011 >
1KM AJ5 Golf wagon 2010 >
1KP 521 Golf Plus 2009 >
1T 1T Touran from 2003; Cross Touran from 2008
16 5C1 Beetle from MY 12
13 137 Scirocco from MY 2009
1F 1F Eos 2006 >
3C 362 Passat Sedan from MY 11
3C 365 Passat wagon 2011 >
3CC 357 Passat CC from MY 09, CC from MY 10
3D 3D Phaeton 2003 >
5N 5N Tiguan from 2008
7N 7N Sharan from MY 11
7P 7P Touareg 2010 >
TIRE WEAR AND PERFORMANCE
WEAR AND PERFORMANCE
Numerous demands are made on a tire. Refer to TIRE REQUIREMENTS
Each of these demands is made on every tire to a certain degree.
Depending on the use of the tire and the vehicle type, certain demands may be more heavily weighted while
others are accordingly less significant.
One expects greater adhesion, even on wet or flooded surfaces from H, V and Z tires for "high-powered
vehicles". Consequently, the service life for tires of this type is not as high as for S or T tires, for example.
TIRE REQUIREMENTS
Fig. 2: Tire Performance Pie Chart

A - Wet braking behavior
B - Comfort
C - Steering precision
D - Driving stability
E - Tire weight
F - Service life expectancy

G - Rolling resistance
H - Hydroplaning
The pie chart represents the tire's performance. It shows how the extent of the demands A through H could be
distributed in tire construction and rubber compound.
The improvement of one characteristic leads to the worsening of another one.
Example:
The improvement of wet braking behavior -A- leads to losses in comfort -B- , rolling resistance -G- and service
life expectancy -F-.
The service life expectancy of car tires depends not only on the rubber compound and the tire construction. The
operating conditions, circumstances specific to the vehicle and the driving style all have a strong influence on
the tire's service life.
With modern vehicles and appropriate engines, especially gentle and economical but also extremely sporty
driving is possible. Service life of 5000 to 40000 km and even more is possible.
NOTE: Driving style is the decisive influencing factor on the life of the tires.
HIGH SPEED TIRES, WEAR CHARACTERISTICS
These tires are designed for the highest speeds. Good traction on wet roads is emphasized when developing
these tires. Tread compounds do not have the abrasion resistance of tires for lower speeds, such as T and H
tires.
Therefore the service life expectancy of high-speed tires is substantially lower under comparable operating
conditions.
TIRE SERVICE LIFE, INFLUENCES
The following factors influence the service life of a tire in varying degrees.
Driving Style
 Speed, refer to I. Constant driving without deceleration and acceleration

 Braking, refer to II. Braking (driving style)
 Acceleration, refer to III. Accelerating (driving style)
 Driving around curves, refer to IV. Driving around curves (driving style)
More information on driving style factors, refer to DRIVING STYLE.
Service
 Tire pressure, refer to Air Pressure of Tire
More information on maintenance factors, refer to TIRES, MAINTAINING
Area
 Paving
 Exterior temperature/climate
Vehicle
 Weight
 Dynamic toe and camber values
Tire Operating Conditions
 Speed range
 Wet or dry
Tire Construction
Winter/summer
DRIVING STYLE
I. Constant driving without deceleration and acceleration
Example:
Speed (km/h) Slip Abrasion

100 1 1
180 3 9
II. Braking (driving style)
The highest abrasion is achieved when braking.
Example: Braking at a speed of 50 km/h.
Deceleration (m/s2 ) g
Braking Distance (meters) = acceleration of fall: Slip Abrasion
9.81 m/s
Coasting vehicle 0 0
100 0.1 x g 4 1
50 0.2 x g 8 4
12.5 0.4 x g(1) 32 2000 - 3000

(1) A deceleration with 0.4 x g corresponds to strong braking.
1. g = acceleration of fall: 9.81 m/s2 .
III. Accelerating (driving style)
The slip that occurs during a gentle acceleration from a stop is approximately the same as the slip that occurs at
a steady speed of approximately 100 km/h.
Example:
Slip Abrasion
Gentle
1-2 1
acceleration
Normal
7-8 5
acceleration
Acceleration
with driving 20 and more 100 - 200
wheels
IV. Driving around curves (driving style)
A >>sporty<< driving style and driving at higher speeds also cause greater wear when driving around curves.
In practice, this means doubling the speed in a curve leads to an increased abrasion by a factor of 16. This is the
>>"extra charge"<< for driving faster.
Example: Driving around a curve with a radius of 150 m.
Lateral
Acceleration
Speed (km/h) (m/s2 ) g = Abrasion
gravitational
acceleration:
9.81 m/s
50 1 = 0.13 x g 1
2.5 = 0.33 x
80 6,5
g
100 4 = 0.53 x g 16
1. g = gravitational acceleration: 9.81 m/s2 .
TIRES, MAINTAINING
Air Pressure of Tire
The weight of the vehicle flattens the tire's contact patch. When the tire rolls, this results in deformation all
around the circumference of the tread and the entire belt assembly. With low pressure, there is a greater
deformation which results in more intense warming and greater rolling resistance. This all results in a greater
wear and a greater safety risk.
Example: Specified series production tire pressure depending on load on cold tires.
Air
Air Pressure (Bar) Pressure Service Life (%)
(%)
2.3 100 100
1.9 80 85
1.4 60 60
1.0 40 25
Excessive air pressure leads to greater wear at the center of the tire and reduced rolling comfort. It is
recommended always to maintain the air pressure indicated by the manufacturer.
NOTE: The diagrams presented cannot be applied in general.
They only illustrate the wear characteristics on the front and rear axles as well
as wear characteristics of front and all-wheel drive vehicles.
Depending on operating conditions and chassis, the service life that can be
attained may deviate substantially.
Diagram 1
Fig. 3: Tire Wear/Service Life (Front Wheel Drive And V Tires)

Tread depth over service life for vehicles with front wheel drive and V tires.
P - Tread depth
S - Distance driven
1 - Front axle
2 - Rear axle
Diagram 2
Fig. 4: Tire Wear/Service Life (All Wheel Drive And V Tires)

Tread depth over service life for vehicles with all wheel drive and V tires.
P - Tread depth
S - Distance driven
1 - Front axle
2 - Rear axle
As can be seen in diagrams 1 and 2, for a given distance, more tread wears off tires with a complete tread than
off tires which are quite worn. After the first 5000 km, no conclusion can be made about the total service life
because the wear curve is not linear.
On front-wheel drive vehicles, the front wheels must transmit the major portion of the lateral and braking forces
as well as the steering and traction forces. Due to these demands, the front tires on front wheel vehicles wear
more quickly than rear tires. Even usage of all tires is achieved by regularly exchanging front and rear tires.
Refer to ROTATING.
TIRE, UNIFORMLY WORN
The demands on the tires increase constantly.
The causes are the following factors:
 Higher vehicle weight.

 High speeds.
 Increased vehicle safety.
A high load on tires naturally causes high wear.
The driving style has a profound influence on the tire wear. Therefore, for complaints about wear when the
treads are uniformly worn, the tires will not be replaced under warranty.
The actual service life of a tire can only be determined when the tread depth is 2 mm. Diagram, refer to
Diagram 1
TREAD DEPTH, MEASURING
NOTE: When measuring tread depth, take measurements in the main grooves.
Do not take measurements at the tread wear indicator.
Tread depth of a tire must be measured in the main grooves at the points showing the most wear. The positions
of the tread wear indicators are marked along the tire shoulder. Refer to SIDE WALL LETTERING
Fig. 5: Locating Tread Wear Indicator

In place of "TWI" , there may also be a "delta" or "VW emblem".
The TWI protrusions are 1.6 mm tall. This is the minimum tread depth legally prescribed in Germany.
Different values may apply in other countries.
Tread Wear Indicators (TWI) must not be included in the measurement. The deepest point of the groove must
Fig. 6: Identifying Tread Wear Indicators

A - Tread Wear Indicators in main grooves.
B - Main grooves with Tread Wear Indicators -arrows-.
TIRE WEAR, ONE SIDED
In many causes, this is caused by driving style, but sometimes it is also caused by incorrect axle adjustment.
Increased One-Sided Wear

Fig. 7: Identifying One-Sided Tire Wear Condition

One-sided wear, in conjunction with scrub marks on tread ribs and finer grooves, always appears when tires roll
at an extreme slip angle and consequently "scrub" on the road surface.
Driving quickly around curves leads to increased wear, especially on the outside edge.
A rounded tire shoulder in conjunction with especially high wear on the outer tread bars indicates fast driving
around curves. This wear pattern is influenced by the driving style.
The suspension is adjusted to certain toe and camber values to optimize handling. When tires roll under
conditions other than those specified, increased and one-sided wear must be expected.
Strong one-sided wear can be caused especially by incorrect toe and camber values. This increases the danger of
diagonal wear spots.
Toe-Out or Negative Toe-In

Fig. 8: Identifying Toe-Out Condition

The distance between the fronts of the tires -A- is greater than the distance between the backs of the tires -B- (-
C- = direction of travel).
Toe-In or Positive Toe-In
Fig. 9: Identifying Toe-In Condition

The distance between the fronts of the tires -A- is less than the distance between the backs of the tires -B- (-C- =
direction of travel).
To avoid one-sided tire wear, ensure that the wheel alignment remains within the tolerances specified by the
vehicle manufacturer. The most common deviation of wheel alignment is caused by external influences, for
example hard contact with the curb when parking.
A measurement of the axle geometry can determine whether the wheel alignment is within the specified
tolerances or whether a correction of the wheel alignment is necessary.
Changes to the Suspension
If a "lowering-kit" and/or light alloy wheels from accessories which have not been recommended by VW are
used, wheel alignments which deviate from the alignment specified in design may occur during travel.
Even if the adjustment of the axle geometry measured on a standing vehicle is correct, changes in the body
height and positions of the wheels during travel can lead to changes to the paths of travel of the wheel
suspension.
For this reason, uneven wear is pre-programmed.
Improper Use of Air Suspension Height Adjustment
The use of off road levels is only recommended when driving off road. The permanent use of off road levels on
normal roads can lead to increased tire wear because the changed height changes the wheel alignment relative to
the road level.
NOTE: To prevent one-sided tire wear, correct axle geometry adjustment should be
ensured on the one hand, and intended use of the vehicle on the other hand.
Good vehicle and tire maintenance helps to prevent tire wear. The following points should especially be
observed.
 The specified minimum tire pressures must be maintained.

 Different wear on front and rear axle cannot be avoided depending on driving style. This can be
counteracted by regular tire rotation. This lends itself, for example, to the rotational change from summer
to winter tires and back. This change has the positive side effect of all tires wearing evenly so a complete
set of new tires can be installed. This prevents use of different tire tread depths on both axles, which can
have negative effects on driving behavior.
 The formation of heel and toe wear is a normal wear pattern, particularly with a very smooth driving
style. This can lead to increased rolling sounds which are generally improved with increased tread depth.
If heel and toe wear is light or is still forming, exchanging tires on both sides is generally sufficient. With
strong heel and toe wear, tires should be rotated so that their direction of travel is reversed. Refer to
HEEL AND TOE WEAR
 On some tire profiles, the effect of premature wear can be detected visually. If winter tire ribs or profile
recesses have been worn off, only compact profile blocks without tread pattern, which gives the
impression of a worn tire. In this case, the remaining profile depth in each tread groove must be
measured. If it is greater than the legally required minimum tread depth (Germany 1.6 mm; it is
recommended to use winter tries with a remaining profile of 4 mm only in summer use [regulation in
Austria]), the tires can be reused without restrictions.
TIRE WEAR, OUTER SHOULDER
Improper Use of Air Suspension Height Adjustment
The use of off road levels is only recommended when driving off road. The permanent use of off road levels on
normal roads can lead to increased tire wear because the changed height changes the wheel alignment relative to
the road level.
NOTE: To prevent one-sided tire wear, correct axle geometry adjustment should be
ensured on the one hand, and intended use of the vehicle on the other hand.
Good vehicle and tire maintenance helps to prevent tire wear. The following points should especially be
observed.
 The specified minimum tire pressures must be maintained.

 Different wear on front and rear axle cannot be avoided depending on driving style. This can be
counteracted by regular tire rotation. This lends itself, for example, to the rotational change from summer
to winter tires and back. This change has the positive side effect of all tires wearing evenly so a complete
set of new tires can be installed. This prevents use of different tire tread depths on both axles, which can
have negative effects on driving behavior.
 The formation of heel and toe wear is a normal wear pattern, particularly with a very smooth driving
style. This can lead to increased rolling sounds which are generally improved with increased tread depth.
If heel and toe wear is light or is still forming, exchanging tires on both sides is generally sufficient. With
strong heel and toe wear, tires should be rotated so that their direction of travel is reversed. Refer to
HEEL AND TOE WEAR
 On some tire profiles, the effect of premature wear can be detected visually. If winter tire ribs or profile
recesses have been worn off, only compact profile blocks without tread pattern, which gives the
impression of a worn tire. In this case, the remaining profile depth in each tread groove must be
measured. If it is greater than the legally required minimum tread depth (Germany 1.6 mm; it is
recommended to use winter tries with a remaining profile of 4 mm only in summer use [regulation in
Austria]), the tires can be reused without restrictions.
TIRE WEAR, CENTER
This wear pattern is found on drive wheels on high-powered vehicles that often drive long stretches at high
speed.
At high speeds, the centrifugal force increases the tire diameter at the center of the tread more than at the
shoulders of the tire. The drive forces from the center area of the tread are transferred to the road surface. This is
reflected in the wear pattern.
These effects can appear especially extreme on wide tires.
NOTE: Reducing the tire pressure is not an effective remedy for this wear pattern.
WARNING: For safety reasons, tire pressure must never be lowered below specified
pressure under any circumstances.
A largely even wear pattern can be achieved if tires are changed in a timely manner from the tractive to the non-
tractive axle.
Increased Tread Wear
Fig. 10: Identifying Center Tire Wear Condition

Typical wear pattern of tires on the tractive axle of high-powered vehicles.
The increased wear at the tread center is caused by stresses related to the centrifugal force of the tire and the
transmission of traction forces.
DIAGONAL WASHOUTS
Diagonal Wear Spots on Tires

Fig. 11: Identifying Diagonal Tire Wear Spots Condition

Diagonal wear spots run at an angle of approximately 45° with respect to the plane of circumference.
They usually occur once, but may also occur several times along the tire circumference.
Wear spots appear almost exclusively on the non-tractive tires, especially the rear left tire. There are vehicle
models where wear spots appear rounded, which are not a problem. The effect is increased by high toe values.
Toe values at the lower tolerance limit of the specified value improve the wear pattern.
The tire component integration is often found in the area with the most pronounced diagonal wear spots.
Wheels with toe-in roll with a slip angle even when the vehicle is traveling straight ahead. This leads to
diagonal tension in the contact zone between tires/road surface.
Driving with reduced tire pressure will improve the wear pattern. To prevent such wear patterns, the toe values
of both rear wheels should be the same and the specified tire pressure should be maintained.
If wear spots are detected, mount the wheels on the tractive axle if the wear spots are still in the initial stage.
Deeper wear spots are irreparable.
Faulty Adjustment
When a customer complains of "diagonal wear spots" , the toe adjustment must be checked. If it is OK, the
cause for the diagonal wear spots is most likely in the tires.
Tires with diagonal wear spots which developed due to faulty adjustment of the axle geometry are excluded
from the warranty.
TIRES, ROLLING NOISES
ROLLING NOISES
Rolling noise perceived by the human ear is caused by vibrations transmitted from the noise source to the ear
via the air.
Here we are interested in noises created by certain characteristics of the tires as well as the effects of rolling
(noise source).
The cause for the noise generation depends primarily on the combination of road surface and tire.
The surface structure and material of the road surface also have a strong influence on the rolling noise. For
example, the noise level on a wet road is substantially higher than on a dry road.
The design of the tread has a great influence on the noise generation. Tires with cross grooves at an angle of 90°
are louder than tires with grooves running diagonally.
Small tread blocks are unstable. Due to strong deformation, the air is excited by the rolling tires. Air vibrations
occur, which will generate noises.
Wider tires are louder. They require more tread grooves for water displacement. Air is displaced by these tread
grooves while rolling, which also cause air vibrations.
Other effects which also have an influence on noise generation:
 "Tire vibration" is the main cause of rolling noise. The noise is generated by the excitation of the air
column in the grooves.
 "Air pumping" is the compression and expansion of air as the contact patch comes in contact with the
road surface and the tread blocks are deformed.
Aid to Reasoning of Rolling Noise
Noise generation is created chiefly by tires and the road surface.
Influencing factors of road surface are roughness, structure and material.
Influencing factors for tires fall under different tire and rim widths. A wider tire generates more noise due to its
wider contact patch than a narrower tire does, because more air is displaced and a greater "mass" is caused to
vibrate.
A wider rim also causes the tire to have a wider contact patch. The effects on noise generation are basically the
same as those of a wider tire. In addition, the noise suppression characteristics of the tire can, under certain
circumstances, be negatively affected by the wider rim.
The tire rolling noise is significantly noticeable in the rear of vehicles with front engines, because wind and
engine noise are less audible in the back.
HEEL AND TOE WEAR
Heel-and-toe wear is step-like wear of individual tread blocks, due to which an increased rolling noise can
develop. The heel-and-toe wear is caused by the uneven distortion of the tread blocks in the contact patch. Heel-
and-toe wear appears in more extreme forms on non-tractive wheels than on tractive wheels.
New tires have a stronger tendency to heel-and-toe wear, because the high tread blocks have greater elasticity.
As tread depth decreases, the rigidity of the tread blocks increases and the tendency to heel-and-toe wear
decreases.
Fig. 12: Identifying Heel-And-Toe Wear Condition

A - Tread blocks of a new tire; viewed in direction of travel -arrow 1- , tread blocks have the same height in
front and rear.
B - Heel-and-toe wear; viewed in direction of travel -arrow 1- , the tread blocks are higher in front than in rear -
arrow 2-.
C - Viewed in direction of travel -arrow 1- , tread blocks exhibit significant wear in forward area of "heel-and-
toe wear" -arrow 3-.
Extreme heel-and-toe wear may lead to customer complaints about noise.
Increased heel-and-toe wear occurs with:
 Toe values too great.

 Incorrect air pressure.
 Deep, open treads.
 Tires which are not mounted on the tractive axle.
 Extreme driving style around curves.
Non-Directional Tires
When heel-and-toe wear occurs, the direction of travel of the tire must be reversed. If increased heel-and-toe
wear and rolling noise develop, the tires should be rotated diagonally. This leads to a reduction of heel-and-toe
wear.
On vehicles with front wheel drive, this effect is increased by increased wear on front axle.
The rolling noise is somewhat louder immediately after rotating the wheels, but the normal noise level will be
reached after traveling approximately 500 to 1000 km.
Directional Tires
In the event of increased heel-and-toe wear of the tires on the rear axle - most common with front-wheel drive -
rotate the wheels from back to front. In the event of increased heel-and-toe wear on the outer edges on one axle,
reverse both tires on their rims. Then the left wheel must be mounted on the right side and the right wheel on
the left side.
WEAR SPOTS
Wear spots are caused by a hard stop with locked wheels whereby the rubber compound is abraded from the
contact patch.
When the tires slide across the road surface, frictional heat is generated which reduces the abrasion resistance
on the tread compound.
Even the most abrasion-resistant tread compound cannot prevent wear spots which can occur during extreme
braking.
Even ABS cannot completely prevent brief locking and the resulting slightly flat spots.
The degree of abrasion is primarily dependent on the vehicle speed, road surface and tire load. For clarification
see the following examples.
If a vehicle with locked front wheels is decelerated until it comes to a stop, the abrasion of rubber on the post
card sized contact patch is approximately:
 From 57 km/h = 23.8 m braking distance, up to 2.0 mm.

Wear Spots in Tread
Fig. 13: Identifying Tire Wear Spot Condition

Tires with this type of damage cannot be used and must be replaced.
WHEEL AND TIRE VIBRATION
CAUSES FOR VIBRATION
There are many causes for vibration. Vibration can also be caused by tire wear, among other things. Tire wear
caused by driving does not always develop evenly over the entire tread. Due to this, a slight imbalance develops
which disturbs the smoothness of the formerly accurately balanced wheel.
This slight imbalance cannot yet be felt in the steering wheel, but it is present. It increases the tire wear and
consequently reduces the service life of the tire.
Recommendation
Over the entire service life of a tire, in order to guarantee:
 Optimal safety
 Optimal smoothness
 Uniform wear
It is recommended that wheels/tires be balanced at least two times within the tire's service life.
BALANCING
Before beginning balancing, the following requirements must be fulfilled:
 Tire inflation pressure must be OK.

 The tire tread must not be worn down on one side and should be at least 4 mm deep.
 The tires must not have any damage such as cuts, holes, foreign bodies, etc.
 The suspension, steering, tie rods and damper must be in proper working order.
 A road test has been performed.
ROAD TEST, PERFORMING BEFORE BALANCING
If a vehicle comes to the workshop with the complaint "vibration" , a road test must be performed before
balancing the wheels.
 That way, information about the type of vibration can be obtained.

 Observe at which speed range(s) the disturbance takes place.
-- Raise the vehicle on the platform immediately after the road test.
-- Mark the installation position on the tire.
Component
Location of Identification with:
Tire
Left front
LF
tire
Right front
RF
tire
Left rear
LR
tire
Right rear
RR
tire
-- Remove wheels from vehicle.
-- Balance the wheels.
STATIONARY BALANCING MACHINE
Tension Wheel on Balancing Machine
NOTE: Please keep in mind that cleanliness is very important when balancing as well,
just as for any other repairs you perform. Only then can a proper result be
obtained!
Dirt and rust in the area of the contact surfaces and centering of the wheel distort the result.
-- Clean contact surfaces, centering seat and wheel disc before tensioning wheel on balancing machine!
-- Tension wheel with tire on balancing machine.
NOTE: To mount wheel on wheel balancer, use the wheel balancing machine centering
system VAS 5271.
Fig. 14: Centering System For Wheel Balancing Machines VAS 5271
This way a 100% centering of the wheel and gentle mounting is possible!
It is not possible to center it 100% on balancing machine with conical

tensioners.
With a deviation of 0.1 mm outside the center, there is an imbalance of 10 grams

on the wheel/tire.
Wheel/Tire Balancing Procedure
-- Let the wheel and tire rotate on the wheel balancer.
-- Check the run of the characteristic lines on the sidewall of the tire in the area of the rim flange.
-- Check the tire wear pattern while the wheel and tire are rotating.
NOTE: In the event of one-sided wear, flat spots from braking or severe wear spots,
smooth running cannot be achieved by balancing. In this case, the tire must be
replaced.
-- Check the run-out of the wheel and tire. If the wheel with tire runs untrue although there are no flat spots, a
radial or lateral run-out may be the cause.
-- Check wheel with tire for radial and lateral run-out. Refer to WHEEL AND TIRE RADIAL AND
LATERAL RUN-OUT, CHECKING WITH TIRE DIAL GAUGE
-- If the radial and lateral run-out are within the specified tolerance, balance the wheel and tire.
NOTE: Do not use more than 60 grams of weight per wheel.
If more weight is necessary, a smoother running can achieved by matched

mounting of the tire. Refer to MATCHED MOUNTING.
The display in the balancing machine should show 0 grams when completed.
Vibration control tire balancer VAS 6230 can be inserted as an alternative to

matching. Refer to VIBRATION CONTROL TIRE BALANCER VAS 6230.
-- Bolt the wheel to the vehicle.
-- First, tighten the lowest wheel bolt by hand to approximately 30 Nm.
-- Now tighten the remaining wheel bolts diagonally also to about 30 Nm. This process centers the wheel on the
wheel hub.
-- Put the vehicle on its wheels.
-- Now use a torque wrench to tighten the wheel bolts diagonally to the specified tightening specification.
Road Test, Performing
-- Perform a road test after balancing wheel/tire.
If a vibration is still detected during the road test, the cause may be due to tolerance in the wheel centering.
The component tolerances of wheels and wheel hubs can be additive in unfavorable cases. Vibration can result
from this. This can be eliminated using a finish balancer. Refer to FINISH BALANCER
VIBRATION CONTROL TIRE BALANCER VAS 6230
Expanded functions can be performed using vibration control tire balancer VAS 6230 in addition to the
previously known balancers.
Fig. 15: Vibration Control Tire Balancer (VAS 6230)

A special characteristic of this system is testing the radial force of wheel/tire during rolling.
For this purpose, a roller presses a force of approximately 635 kg against the wheel. This simulates the tire
contact force against the street surface while driving.
Tire contact forces fluctuate due to radial and lateral run-out and differing rigidity in the tires.
The VAS 6230 detects and stores the position of the maximum measured radial force in the tires. After that, the
position of smallest dimension between rim flange and disc wheel center is measured.
FINISH BALANCER
NOTE: Working with a finish balancer requires instruction from the manufacturer of the
balancer.
For the balancing, the wheels of the tractive axle are set upon the turntable
sensors, i.e. front wheels for Front Wheel Drive (FWD) and all 4 wheels for All
Wheel Drive (AWD).
If it is determined when balancing on the vehicle the remaining imbalance is more than 20 grams, the wheel
should be rotated on the wheel hub.
-- Mark the point at which the imbalance is indicated.
-- Afterwards, unbolt the wheel and rotate its position on the wheel hub so that the marking points downward.
NOTE: The wheel hub must not turn during this procedure.
-- First, tighten the lowest wheel bolt by hand to approximately 30 Nm.
-- Now tighten the remaining wheel bolts diagonally also to about 30 Nm. This process centers the wheel
properly on the wheel hub.
-- - Check again whether the imbalance is less than 20 grams using the finish balancer.
NOTE: The imbalance should not be smaller than 20 grams under any circumstances
before changing balance weight.
-- Remove the wheel bolts again if necessary.
-- Rotate the wheel relative to the wheel hub once more by one or two wheel bolt holes.
-- Tighten the wheels using the method described above.
NOTE: The imbalance should only be reduced by changing balance weight if the
imbalance is less than 20 grams.
-- Balance the wheels until the imbalance is below 5 grams.
-- Tighten the wheel bolts to the specified tightening specification if you have not already done so.
WARNING: Always tighten the wheel bolts to the specified tightening specification
with a torque wrench.
WHEELS AND TIRES, RADIAL LATERAL RUN-OUT
Radial and lateral run-out occur when the wheel and tire are not running precisely true.
For technical reasons, 100% true running is not possible.
Therefore the manufacturers of these components allow a precisely specified tolerance.
Mounting the tire in a unfavorable position on the wheel can be the cause for exceeding the maximum allowed
tolerance for wheel with tire.
The table shows the maximum permissible tolerance values for the wheel with mounted tire.
Tolerances for Radial and Lateral Run-Out of Disc Wheel with Tire
Radial Lateral
Run- Run-
Wheel with Tire
Out Out
(mm) (mm)
1.1 (1.3
in
Passenger vehicle 0.9 vicinity
of
lettering)
WHEEL AND TIRE RADIAL AND LATERAL RUN-OUT, CHECKING WITH TIRE DIAL GAUGE
Checking Lateral Run-Out
-- Load the tire dial gauge approximately 2 mm.
-- Set up tire dial gauge on the side wall of the tire.

Fig. 16: Checking Lateral Run-Out

-- Slowly rotate the wheel.
-- Note the smallest and the largest dial readings.
NOTE: If the difference is greater than 1.3 mm, the lateral run-out is too great.
In this case, lateral run-out can be reduced by matched mounting of the tire. Refer to MATCHED
MOUNTING.
Peak values on the tire dial gauge due to small irregularities in the rubber may be disregarded.
Checking Radial Run-Out
-- Set up tire dial gauge on the tire tread.

Fig. 17: Checking Radial Run-Out

-- Slowly rotate the wheel.
NOTE: If the difference is greater than 1 mm, the radial run-out is too great.
In this case, radial run-out can be reduced by matched mounting of the tire. Refer to MATCHED
MOUNTING.
DISC WHEEL, CHECKING RADIAL AND LATERAL RUN-OUT
-- Mount the disc wheel on the wheel balancer.
-- Use the wheel balancing machine centering system VAS 5271.
-- Slowly turn the disc wheel.

Fig. 18: Identifying Areas To Check Wheel For Radial Run-Out & Lateral Run-Out
S - Lateral run-out
H - Radial run-out
-- Compare determined value with specifications in the table.
NOTE: Peak values on the tire dial gauge due to small irregularities may be
disregarded.
Specifications for Radial and Lateral Run-Out on Disc Wheel
Radial Lateral
Run- Run-
Disk Wheel
Out Out
(mm) (mm)
Passenger vehicle Steel wheel 0.5 0.5
Light alloy wheel 0.5 0.8
NOTE: If the measured value exceeds the specified value, no acceptable smooth
running can be attained.
MATCHED MOUNTING
General Information
If radial or lateral run-out from wheel or tire meet each other, the untrue running of the wheel and tire is
increased.
For technical reasons, 100% true running is not possible. Refer to WHEELS AND TIRES, RADIAL
LATERAL RUN-OUT
Drive the tires until they are warm before matching them to the tires already on the vehicle. This eliminates flat
spots from standing which may exist. Refer to FLAT SPOTS IN TIRES FROM STANDING
Work Procedure for Match-Mounting
-- Let the air out of the tire.
-- Press the tire beads off the rim flanges.
-- Coat the tire beads all around with tire mounting paste.
-- Rotate the tire 180° relative to the disc wheel.
-- Inflate the tire to approximately 4 bar.
-- Tension wheel with tire on balancing machine.
-- Check the run-out or the radial and lateral run-out, as necessary.
NOTE: If the radial and lateral run-out value is not exceeded, the wheel can be
balanced to 0 grams. Specifications, refer to Tolerances for Radial and Lateral
Run-Out of Disc Wheel with Tire
If the radial and lateral run-out lies outside the specified values, the tire must be
turned again.
-- Let the air out of the tire and press the tire beads off the rim flanges.
-- Rotate the tire 90° (one quarter turn) relative to the disc wheel.
-- Inflate the tire to 4 bar and check for true running.
NOTE: If the radial and lateral run-out value is not exceeded, the wheel can be
balanced to 0 grams.
If the radial and lateral run-out is still outside the specified values, the wheel
must be turned again.
-- Press the tire beads off the rim flanges.
-- Rotate the tire 180° (one half turn) relative to the disc wheel.
If the values for radial or lateral run-out are still outside the specified values, check the wheel for radial and
lateral run-out. Refer to DISC WHEEL, CHECKING RADIAL AND LATERAL RUN-OUT
If the measured values for radial and lateral run-out of the wheel disc are within the specified values, then the
tire has excessive radial or lateral run-out. In this case, the tire must be replaced.
NOTE: Assembly paste from mounting tires is located between tires and rim flanges.
Avoid strong braking or acceleration maneuvers during the first 100 to 200 km.
Otherwise, the tires can rotate on the rims and the work done would then be
undone!
FLAT SPOTS IN TIRES FROM STANDING
What is a flat spot from standing?
Terms like flat portion, flattening, are also used as a term for flat spots from standing.
Flat spots from standing cause vibration, like an incorrectly balanced wheel. It is important to recognize a flat
spot in the tread from standing as such!
Flat spots from standing cannot be corrected by balancing, and can occur again at any time under various
circumstances. Flat spots from standing can be corrected without complicated special tools. Providing that the
flat spot was not caused by wheel lock during hard braking. Refer to WEAR SPOTS
NOTE: Wear spots due to wheel lock are irreparable! Tires with such damage must be
replaced.
Causes of Flat Spots from Standing
 The vehicle stands for several weeks in a location without being moved.
 Tire pressure is too low.
 The vehicle was placed in a paint system drying cabinet after painting.
 The vehicle was parked with warm tires in a cold garage or similar for a long time. In this case, a flat spot
can develop overnight.
Flat Spots, Correcting
 Flat spots cannot be removed from tires with workshop equipment.

 Such flat spots can be "driven out" only by driving the car until the tires are warm.
 We do not recommend the following method during cold or winter weather.
Requirements/Conditions
-- Check and correct the tire pressure as necessary.

-- Drive the vehicle on the highway, if possible.
-- If the traffic and road conditions permit, drive at a speed of 120 km/h to 150 km/h for a distance of 20 to 30
km.
WARNING:  Do not endanger yourself or other persons during this road test.
 Observe valid traffic laws and speed limits during the road test!
-- Raise the vehicle immediately after the drive.
-- Remove wheels from vehicle.
-- Balance the wheels on the stationary balancing machine. Refer to STATIONARY BALANCING
MACHINE
VEHICLE PULLS TO ONE SIDE
GENERAL INFORMATION
Perform a road test to determine if a vehicle pulls to one side and if so, when and to which side. If the vehicle
pulls to one side. Refer to CORRECTIVE ACTION WHEN VEHICLE PULLS TO ONE SIDE
If the vehicle alignment is measured, submit the measurement printout and the complaint report with the tire.
Manufacturer's tolerances can lead to taper in the tire construction. This results in a side force when the tire
rolls, which acts directly on the suspension and can therefore lead to vehicle self-steering behavior. Targeted
rotation of the wheels can balance out this self-steering behavior.
TAPER
Taper is caused by slightly offsetting the tread and/or the belt by a few tenths of a millimeter from the geometric
center of the tire. Taper cannot be recognized visually nor can it be measured with workshop equipment.
Components of a Tire
Fig. 19: Components Of A Tire (1 Of 2)

1 - Bead
2 - Shoulder
3 - Tread
4 - Steel belt
A - Geometric center of tire
B - Actual position of belt. It can be offset to inside or outside.
Shown out of proportion to provide a better illustration.

Fig. 20: Components Of A Tire (2 Of 2)

1 - Belt/tread offset
F1 - Unequal forces on contact patch
F2 - Unequal forces on contact patch
Fk - Force of taper
The offset produces differences in rigidity of the inner and outer shoulders of the tire, which lead to differing
forces on the contact patch. Due to this, the belt and tread will not be pressed against the road surface with the
same force (F1, F2). A taper forms. The resulting force (force of taper Fk) can become so large depending on
speed, that the vehicle pulls to one side.
If the force (Fk) on one wheel of the axle is, for example, 50 Newton and on the other wheel also 50 Newton,
and both forces are exerted in the same direction, the forces are additive. Reversing a tire on the rim can
compensate for the pulling because the forces then act against each other.
Because the direction in which the force of taper is exerted is not visible at the tire, only road tests and targeted
rotation of wheels and tires can establish which tires cause the pulling.
The tire consists of numerous components and materials which are vulcanized to a single part at the end of a
complicated manufacturing procedure. This leads to differing construction tolerances which can make
themselves noticeable through more or less strong lateral forces (lateral forces of taper). These forces can also
develop in new tires.
One-sided Pulling on Front Axle

Pulling to one side can be caused by the suspension. However, experience shows that in 90% of all complaints,
the tires cause pulling to one side.
One-sided Pulling During Normal Driving Style
On a straight, level road surface, the vehicle wants to pull to one side at a constant speed or with moderate
acceleration. A force can be felt at the steering wheel.
One-sided Pulling During Strong Accelerating
Pulling to one side during fast acceleration is, in part, due to the design of vehicles with front wheel drive.
Various frictional conditions of left and right wheels, for example, possible irregularities in the road surface (pot
holes) and consequently varying adhesion to ground have a substantial influence on the handling characteristics.
This does not constitute a complaint in the sense of warranty coverage.
CORRECTIVE ACTION WHEN VEHICLE PULLS TO ONE SIDE
Test Conditions Before and During the Road Test
-- Check all suspension components on front and rear suspension for damage.
-- Check tire pressure and correct if necessary.
-- Check the tires for external damage. Holes, cuts, bulges in the side wall, flat spots from braking and/or
damage to the tread.
-- Ask the customer if a tire had been damaged by a nail or similar object and perhaps repaired by a tire dealer.
You may have to replace such tires.
-- Check tires for even wear and tread depth.
-- Are all tires of the same type, manufacture and tread pattern?
-- If the tires are non-directional, ensure that all DOT classifications on the tire face outwards. It may be that the
vehicle's wheels and tires were already changed around at an earlier date.
-- Are the tire brands factory recommended as initial equipment?
-- For the road test, use a level, straight driving surface that does not slope off to one side and does not have
ruts.
-- Perform the road test with the customer under the conditions specified above. The customer should
demonstrate the problem.
NOTE: There should not be any side wind when road test takes place.
If the complaint is justified, it is recommend to rotate the wheels and tires as described in the following
Information.
Before beginning, observe the following notes, otherwise all effort will be for nothing!
NOTE: Mark tires/wheels before the first rotation, e.g. LF, RF, LR, RR.
After rotating wheels or reversing the tire on its rim, observe very carefully how
the vehicle behaves during the road test. Note what was replaced and how.
The intensity or any possible change to the one-sided pulling should be

assessed.
To do this, it is absolutely essential that the road tests are always performed by
the same person on the same road. It is best to drive the "test course" in both
directions.
Replacing a tire with a new tire does not guarantee that pulling to one side will
be eliminated. Therefore, it is recommended to perform a targeted exchange of
the wheels as described below.
If there are large differences in the tread depth of the tires on the front and rear
axles, the tires with the deeper tread should always be mounted on the front
axle.
TARGETED ROTATING OF WHEELS FOR NON-DIRECTIONAL TIRES
?
Perform a road test to determine if a vehicle pulls to one side and if so, when and to which side?
?
If the vehicle pulls to one side, swap the front wheels.
?
Vehicle travels straight - END
Vehicle pulls opposite Vehicle pulls to the same side
? ?
Reverse one tire on its rim on the front axle (reverse the direction of
Rotate wheels from front to back
travel)
? ?
Road Test, Performing Road Test, Performing
Vehicle travels straight - END Vehicle travels straight - END
Vehicle does not travel straight Vehicle does not travel straight.
? ?
Vehicle pulls
Swap front wheels and swap back wheels No change
opposite
? ? ?
Reverse one tire
Check
on its rim on the
alignment of
front axle
Road Test, Performing front and rear
(reverse the
axles, adjust if
direction of
necessary.
travel)
If adjustment is
correct, inform
Product
Support.
Vehicle does not travel straight.
?
Swap the front wheels
? ?
Road Test,
Performing
Vehicle does not Vehicle travels
travel straight straight END
Vehicle does
? not travel
straight
Install new tires on Install new tires
front axle on front axle
? ?
Road Test, Road Test,
Performing Performing
Vehicle travels Vehicle travels
straight - END straight - END
? ?
Vehicle does not travel straight, inform Product Support.
WHEELS, TARGETED ROTATING FOR DIRECTIONAL TIRES
?
Perform a road test to determine if a vehicle pulls to one side and if so, when and to which side.
?
If the vehicle pulls to one side, swap wheel with tire front and back.
?
?
First, replace one tire on the front suspension.

?
?
Replace second tire on the front suspension.
?
?
Measure vehicle at front and back.
?
Vehicle does not travel straight, inform Product Support.
TIRE DAMAGE
GENERAL INFORMATION
Because tire damage can have serious consequences, the technician and the driver should regularly check the
tires, as it is the best form of early problem recognition.
Pre-damaged tires cannot withstand driving situations like high vehicle speed, long driving distance, sporty
driving style and similar situations.
Damage can occur from various causes, such as the following:
 Driving with low tire pressure

 Mistakes during tire mounting
 Damage during run-in
 Aging
 Incorrect storage
WARNING: As soon as a safety risk cannot be ruled out, the tire must be replaced.
RADIAL TIRES, CONSTRUCTION
Cross-Section of a Radial Tire

Fig. 21: Cross-Section Of A Radial Tire

1. Tread Block
2. Tread Groove
3. Tread
4. Nylon Ply
5. Belt Layers
 Consists mostly of steel.
6. Bead Bundle
 Consists of steel wires vulcanized into rubber.
7. Bead Filler
8. Wheel Flange Protection
 Protects the rim and tire from abrasion due to, for example, contact with the curb.
 Tires with flange protection are designated by the abbreviation MFS.
The nylon ply -4- , belt layers -5- , bead bundle -6- and bead filler -7- form the carcass. The carcass is the "load-
bearing structure" of the tire.
IMPACT DAMAGE
A swelling in the flank of the tire indicates that the substructure of the carcass has been damaged.
Typical causes for such damage include, for example, driving over curbs at a sharp angle.
Fig. 22: Example Of Curb Impact

Pinching the carcass of a tire this way can damage the carcass.
The substructure of the tire is stretched so far that individual fibers in the carcass may break.
The extent of the damage depends on the speed of impact, the angle of impact, the air pressure, the axle load
and the type of obstacle.
Evidence of Pinching on the Sidewall of a Tire -arrows-

Fig. 23: Evidence Of Pinching On Sidewall Of Tire

NOTE: Driving over curbs must be avoided!
When it cannot be avoided, curbs should be driven over very slowly at the
bluntest possible angle.
Interior View of a Tire with a Punctured Carcass.
Fig. 24: Interior View Of A Tire With A Punctured Carcass

Due to a severe impact, the carcass was pinched on the rim flange and is ruptured in the contact patch.
Inside Tire Damage Due to Impact Damage (Double Rupture)
Fig. 25: Inside Tire Damage Due To Impact Damage (Double Rupture)
Double rupture -arrows- caused by pinching when driving over a curb. Often not detectable from outside.
CUTS
Cut Caused by a Sharp-Edged Obstacle -arrow-.

Fig. 26: Tire Damage Caused By A Sharp-Edged Object

DAMAGE FROM FOREIGN BODIES
Driving over hard, pointed objects like nails, screws and the like can pierce the tire.
This always leads to tire damage.
Damage from Imbedded Foreign Bodies
Fig. 27: Tire Damage From Imbedded Object

Frequently, the foreign object -marking- is so securely embedded in the tire that it will not free itself even at
higher speeds. Due to this, it can act as a plug and seal the tire relatively well. The result is gradual loss of
pressure which the driver does not notice immediately but which can lead to sudden and complete tire failure.
NOTE: No repair should be attempted on steel belted tires of which the structure has
been punctured by a foreign body.
AIR LOSS
If the customer complains of loss of air from a tire, the tire must absolutely be checked for embedded foreign
bodies.
NOTE: No repair should be attempted on steel belted tires of which the structure has
been punctured by a foreign body.
Corrosion can develop on the steel wires. This will always lead to the separation of the rubber from the steel
belt.
Generally, it cannot be determined when the foreign body was embedded. Therefore, the tire structure may
already have been damaged due to driving with insufficient tire pressure.
Damaged belt wires will lead to separation of the rubber from the steel belt sooner or later. As a result, the tire
can fail completely after a certain running time, long after the tire damage has occurred.
Tire damage caused by foreign objects is not covered by warranty.
TIRE PRESSURE
Air pressure must be checked regularly. It is recommended to check the tire pressure every 14 days. The correct
tire pressure is especially important during long trips or if a load must be carried. A sporty driving style also
requires correct or even slightly increased air pressure.
Slow Loss of Air Pressure
The slow loss of tire pressure is an especially tricky process because even experienced drivers often do not
notice it.
The insufficient air pressure and the related increase in force required to flex the tire (inner friction) cause the
tire material to heat up so much that the various components and rubber compounds can separate.
The final stage is usually the complete destruction of the tire. Refer to DAMAGE FROM LOW TIRE
PRESSURE
The cause for the slow pressure loss cannot always be determined because the tire is severely damaged and
components of the tire are missing.
DAMAGE FROM LOW TIRE PRESSURE
The most common causes of failure are small external damage, a defective valve or a leaky rim due to corrosion
or damage.
Separation of Carcass and Rubber

Fig. 28: Identifying Separation Of Tire Carcass And Rubber

Strong heating due to driving with substantially insufficient pressure led to overheating and subsequent
separation of carcass from rubber material -arrows-. Refer to TIRE TEMPERATURE, RISING WHEN
TIRES PRESSURE IS TOO LOW
The tire shown here was sporadically driven with tire pressure insufficient for the load. Typical indications for
this are the circumferential abrasions in the area of the bead caused by the rim flange and the discoloration.
Small, furrowed folds are visible along the inner sidewall.
When the tire rolls, strong shear forces develop between the steel belt layers, especially at the ends of the belts.
Tires with Wide Furrows Along the Circumference in the Area of the Bead
Fig. 29: Identifying Wide Furrows Along Circumference Of Tire Bead

Wide furrows along the circumference in the area of the bead -arrows- indicate that the tire was driven with
insufficient air pressure.
Driving a vehicle with insufficient tire pressure or ignoring or not recognizing tire damage can have serious
consequences.
The tire can no longer withstand the forces developing during travel.
The function of the tire is limited by the defects mentioned above. The rubber compounds separate from one
another, resulting in partial separation of tire components up to complete destruction.
Tires with Torn-out Tread

Fig. 30: Tire With Torn-Out Tread

Such damage usually develops over a longer period of time. If an already damaged tire is exposed to high stress,
the centrifugal force at higher speeds can tear components off the tire.
Illustration shows a tire with torn-out tread due to driving with insufficient tire pressure.
TIRE TEMPERATURE, RISING WHEN TIRES PRESSURE IS TOO LOW
The diagram shows the temperature behavior of a tire at speed of 180 km/h.
Fig. 31: Tire Temperature Behavior Graph

A - Normal range: When maintaining the specified tire pressure, the temperature remains stable.
B - Danger zone: When the air pressure is 0.3 bar below specification, the temperature rises to above 120°C
(248°F) at higher speeds.
C - Critical temperature limit: The tire defect is triggered.
T - Temperature in °C.
t - Driving time in minutes.
DAMAGE DUE TO MOUNTING ERROR, DAMAGE FROM FITTING THE TIRE
Bead Bundle Broken During Tire Inflation
Modern radial car tires are mounted only on safety rims. These have a hump -1- running along the shoulders.
Fig. 32: Identifying Wheel Components (Cross-Sectional View)

1. Hump (double hump H 2, extended double hump EH2)

2. Rim flange
3. Inner bead seat (e.g. oblique seat)
4. Rim
5. Wheel disc
6. Bed
7. Outer bead seat (e.g. oblique seat)
The hump prevents the tire from being pressed out of the bead seat during travel with insufficient tire pressure.
When the tire is inflated, the tire bead may not slip completely over the outer rim hump.
In this case, there is the danger that the bead bundle will be overstretched if the tire pressure is too high and the
steel wires rupture partially or completely. Torn bead bundles are often not detectable from outside.
Special Information for Run-flat Tires

Rims with an extended double hump (extended hump EH2) are required for run-flat tires. Refer to DISC
WHEEL STRUCTURE. The extended double hump prevents the low tires from slipping from the rim when
flat.
NOTE: To prevent damage when assembling, follow the instructions for mounting run-
flat tires. Refer to RUN-FLAT TIRES SAFETY PRECAUTIONS .
WARNING:  Tires with damaged bead bundles are not seated safely and securely
on the rim. Such tires are a safety risk!
 In addition, there is the danger that a partially broken bead bundle
tears during continued operation and the tire suddenly tears open. If
the bead bundle breaks during inflation, the carcass will also be
destroyed.
Tires with Broken Bead Bundle and Destroyed Carcass
Fig. 33: Tire With Broken Bead Bundle & Destroyed Carcass
Illustration shows a tire with broken bead bundle and destroyed carcass caused by an excessive pulling force
during fitting.
Bead Damage by Faulty or Incorrect Wheel Mounting Using Tire Changers
The following mistakes when fitting tires can lead to severe tire damage.
 When rolling in the upper bead on the tire changer, the opposing tire bead does not lie completely in its
bed.
 When the fitting head was incorrectly adjusted.
 When the edge of the fitting roller rolls onto the bead.
 When the guide rollers are worn or have sharp edges.
Tire with Bead Split Open
Fig. 34: Tire With Bead Split Open

In these cases, the bead, which is under great tension, can be cut into in the direction of rotation, split open
and/or be crushed down to the bead bundle.
Frequently, mounting and run out marks from the guide rollers are identified in the damaged area.
NOTE: Both tire beads as well as the bead seats must always be coated with fitting
paste.
If mounting damage is undetected, there is the danger that the tire will fail later when driving.
THEREFORE!
 Never fit a tire without fitting paste.

 Do not inflate the bead seating pressure above 3 bar.
 Do not inflate the tire filling pressure above 4 bar.
 After the tire has been fitted, reduce the air pressure to the specified value.
TIRES WITH EMERGENCY RUNNING CHARACTERISTICS
GENERAL INFORMATION
Run-flat tires have a reinforced sidewall in comparison to standard tires. This reduces the tendency for the
sidewall to roll when there is a loss of pressure and prevents the sides of the tire from being pinched. This
allows the vehicle to be driven while still maintaining close to normal driving behavior. It also eliminates the
need to install the spare tire in dangerous situations such as on the highway or in poor weather conditions.
When there is a flat tire, the vehicle can still be driven to the nearest workshop (within approximately 50 km) as
long as the vehicle speed (maximum 80 km/h) and driving style are adapted accordingly, see the Owner's
Manual.
If there is a flat tire, the driver is ultimately responsible for checking the affected tire and deciding if it is
possible to continue driving.
-I- Tires with Normal Pressure
Fig. 35: Identifying Run Flat and Standard Tire Air Pressures
1 - Run-flat tires (reinforced sidewall -red-)
2 - Standard tires
-II- Tires without Air Pressure
If the standard tire -2- loses pressure, the rim pushes the side wall together. When the tire is the flat, the sidewall
becomes extremely hot from the rolling motion and or is pinched. This destroys the tire.
In run-flat tires -1- , the reinforced sidewall (-red-) supports the tire. Because of a special rubber compound and
the reduced flexing of the reinforced sidewall, the tires does not become as hot and the vehicle can still be
steered.
NOTE: Read and follow the special requirements for using run-flat tires. Refer to
INSTALLING/CONDITIONS FOR USING RUN-FLAT TIRES
STRUCTURE AND IDENTIFICATION
Identification
Run-flat tires are identified with the following abbreviations: DSST, Euforia, RFT, ROF, RSC, SSR or ZP.
These abbreviations are located on the tire flank behind tire designation of the respective tire manufacturer.
Fig. 36: Identifying Run Flat Tires Abbreviation Mark

Structure
Fig. 37: Identifying Tire Structure

1 - Bead with bead bundle.
2 - Sidewall
3 - Sidewall reinforcement.
4 - Rim with extended hump (EH2) on both sides - required when using run-flat tires.
INSTALLING/CONDITIONS FOR USING RUN-FLAT TIRES
CAUTION: Using run-flat tires on Volkswagen vehicles is permitted only if the run-flat
tire is supplied with the vehicle either as standard equipment or as an
option.
Because pressure loss in a run-flat tire is not always visible, these tires should only be used on vehicles
equipped with a tire pressure monitoring system. This system warns the driver when the tire pressure falls
below a certain value.
The following are permitted:
Direct measuring systems, refer to TIRE PRESSURE MONITORING SYSTEM, DIRECT SYSTEM .
Indirect measuring systems, refer to TIRE PRESSURE MONITORING SYSTEM, INDIRECT SYSTEM .
Only mount run-flat tires on disc wheels with an extended double hump (extended hump - EH2). Refer to DISC
WHEEL STRUCTURE
Read and follow the special mounting instructions. Refer to RUN-FLAT TIRES SAFETY PRECAUTIONS .
Do not install both run-flat tires and standard tires, even if the two tires on each axle will be the same.
A standard tire can only be installed in exception cases for a short time or a limited driving distance. The
specific characteristics designed for driving with a flat tire will not be available. The driver must be informed of
this.
NOTE: Always note the recommended tire make. Refer to RECOMMENDED SUMMER
TIRES and RECOMMENDED WINTER TIRES
REPAIRING
WARNING:  Run-flat tires must be replaced after they have gone flat.
 Read and follow the special mounting instructions. Refer to RUN-
FLAT TIRES SAFETY PRECAUTIONS .
General Information
-- The wheel must be inspected before mounting, as with conventional wheel and tire systems.
-- Check the wheel for damage after a flat tire (true running, axial run-out, other damage) to prevent more
serious damage in the future, for example if driving through a pothole. Refer to DISC WHEEL, CHECKING
RADIAL AND LATERAL RUN-OUT
-- Always replace a damaged wheel.
ROLLING RESISTANCE TIRES
Tire deformation when rolling causes the vehicle to lose energy that makes the rolling resistance noticeable.
Deformation is significantly lowered on rolling resistance tires due to new construction and low-wear surface
mixtures.
Tires installed on the Volkswagen Blue Motion and Blue Motion Technology are rolling resistant and conform
to all safety and customer relevant properties.
The recommended tire manufactures are summarized in the following information. Refer to
RECOMMENDED SUMMER TIRES
DISC WHEELS
DISC WHEEL STRUCTURE

Fig. 38: Identifying Disc Wheel Structure

1. 1 - Rim Flange
 Stop for the side tire bead
2. 2 - Hump (H2) on Both Bead Seats

 Prevents the tire from slipping off the bead seat when driving around tight curves.
 An extended hump (EH2) is required when using run-flat tires. Refer to DISC WHEELS,
IDENTIFICATION.
3. 3 - Bed
 Makes it easier to mount the tire.
4. A - Rim Width
 Distance between the tire contact surfaces on both rim flanges.

 Dimensions in inches.
5. B - Rim Diameter
 Distance between the rim contact surfaces on the opposite tire shoulders.
 Dimensions in inches.
6. C - Offset
 Distance between the vertical wheel center and the inner wheel contact surface.
 Dimensions in mm.
7. D - Pitch Circle Diameter

 Circle diameter where the wheel bolt holes are located.
8. E - Center Hole
 Enables centering.
DISC WHEELS, IDENTIFICATION
Several indications can be found on the disc wheels. The indications required for the clear identification of the
disc wheel, can be seen in the following example:
Replacement Parts Number: 6E0 601 027 A

6 J x 15 6 - Rim width in inches J - Shape of
Size of disc wheel:
rim flange 15 - Rim diameter in inches
Offset in mm: 43
Indication for hump on bead seat: EH2 Extended Hump (1))
(1) ) Raised round hump on both bead seats. These ensure that when using a tire with emergency mode
properties in airless condition, the tire does not slip from the bead seat. Wheels with EH2 are only
necessary if tires with emergency mode properties are mounted. Refer to TIRES WITH
EMERGENCY RUNNING CHARACTERISTICS.
DISC WHEELS RIMS, PITCH CIRCLE DIAMETER
Pitch Circle Diameter Models

Polo
100 mm
2010 >
Fox
2006 >
Golf
Phaeton Golf Plus
112 mm
2003 > 2004 > 2005
>
Cross
Sharan
Eos Golf
from
2007 > from
MY 11
2007
Golf
Jetta Touran
2009
2011 > 2003 >
>
Cross Golf
Tiguan
Touran wagon
from
from 2010
2008
2008 >
Passat
Scirocco CC
CC
from from
from
MY MY
MY
2009 10
2009
Passat Beetle
Passat
Sedan from
wagon
from MY
2011 >
MY 11 12
Touareg
130 mm
2010 >
MULTIPART COMPOSITE WHEELS
Composite wheels consist of various parts.
The primary components are rims and wheel discs. These components are fastened to each other with special
screws and a special procedure. This ensures the wheel's function, proper seal, safety and true running. These
important requirements cannot be guaranteed under shop conditions and using shop tools.
WARNING: Composite wheels must not be disassembled or repaired!
LIGHT ALLOY WHEELS, REPLACEMENT DECORATION ELEMENTS
These disc wheels are equipped with replaceable decoration elements. Note the following when installing.
-- Clean the thread in the disc wheel before screwing in the new bolts.
Fig. 39: Identifying Decoration Elements & Bolts

-- Use new bolts only!
1. Decoration element
2. Hex socket bolts
Tightening specification for self-locking hex socket bolts: 5 Nm
LIGHT ALLOY WHEELS, REPLACEMENT DECORATION ELEMENTS (ZARAGOZA)
 Cartridge Gun V.A.G 1628

 Hot Air Blower V.A.G 1416
Materials
 1K window adhesive DH 009 100 A2

 Silicone remover LSE 020 100 A3
Decorative Trim, Removing
NOTE: It is not possible remove the decorative trim without damaging it.
Fig. 40: Using Special Tool To Warm Trim

-- Loosen the lock washers -2- from the inside of the light alloy wheel.
-- Warm the decorative trim -1- from the outside using the V.A.G 1416.
CAUTION: Do not overheat tires and light alloy wheels.
-- Loosen the decorative trim -1- from the inside of the light alloy wheel using the 3409.
-- Grab under one corner from the outside and pull the decorative trim -1- off the light alloy wheel.
NOTE: The adhesive points for the PUR label are cut into the light alloy wheel.
The remaining material serves as the adhesive base for the new decorative trim.
The new decorative trim can be installed immediately.
Decorative Trim, Installing
These light alloy wheels are equipped with replaceable decoration elements. Note the following when installing.
 Make sure the adhesion area on the light alloy wheels and decorative trim are free of dust and grease.
 Clean the adhesion area with silicone remover LSE 020 100 A3.
Fig. 41: Identifying Adhesive And Adhesive Surfaces

-- Apply 1K window adhesive DH 009 100 A2 on the adhesive surfaces -arrows- using the V.A.G 1628.
 Adhesive point: length = approximately 25 mm and diameter = approximately 10 mm
Fig. 42: Identifying Decorative Trim, And Lock Washers

-- Press the decorative trim -2- into the light alloy wheels -1- using firm pressure.
-- Secure the decorative trim -2- to the inside of the light alloy wheel with lock washers -3-.
Minimum curing time: 3 hours at room temperature of minimum 15 °C (59 °F).
WARNING: The light alloy wheel must be balanced again. Refer to STATIONARY
BALANCING MACHINE.
LIGHT ALLOY WHEELS, CARE AND MAINTENANCE
To maintain the decorative appearance of light alloy wheels for a long time, regular care is necessary.
In particular, road salt and dust from brake abrasion must be thoroughly washed off every 2 weeks. Otherwise,
the paint of the light alloy wheel will be attacked.
Cleaning Agent
The following are appropriate cleaning agents:
 Water or water and soft soap.

 Water and vinegar essence.
 Light alloy wheel cleaning agents without acids or harsh solvents.
Do not exceed the soaking time of the cleaning agent.
The shorter the specified soaking time is, the stronger and more aggressive the cleaning solution is.
Paint Damage
Fix paint damage as soon as possible. Refer to LIGHT ALLOY WHEELS, PREPARING.
Removing Adhesive Residue from Glued Balance Weights on Light Alloy Rims
 Harsh solvents and acids attack the paint on light alloy wheels and the surface of the wheel becomes
matte and milky. These agents therefore must not be used.
 To remove adhesive residue on light alloy wheels, use light alloy cleansers or benzene-based cleanser. Do
not exceed the soaking time of the cleaning agent.
 After cleaning or removing adhesive residue on the tires, they must be rinsed again with water.
LIGHT ALLOY WHEELS, PREPARING
WARNING:  Do not repair damaged rims by heating, welding or adding or

removing material.
 Do not repair damaged or deformed rims or rims with cracked or
deformed bolt holes.
 Only prepare wheels with tested and specified original paint
materials.
 No warranty claims can be made against the manufacturer after

preparing rims.
Do not repair rims that have cracks forming on the edges. Replace them immediately.
Cutting work, application of heat and welding applications of any kind are not permitted.
Reshaping material is not permitted.
The true running and axial run-out deviations before preparation must not exceed the manufacturing tolerance
of 0.8 mm.
Only cast light alloy wheels may be primed. These wheels have the material identification AIsi xx on the inside.
Forged wheels may only be painted.
Preparation is limited to the painted surfaces.
Wheels that have been worn smooth that only have a clear coat may not be repaired.
Only surface damage on the visible side of the wheel may be repaired.
Damage must not be more than 1 mm deep.
Up to 50 mm of the rim flange may be removed and filled.
RUBBER VALVE
Fig. 43: Rubber Valve Stem Components

1. Valve body
2. Valve core
3. Valve cap
Valve Body
The rubber valve for tubeless tires is designed to seal air-tight in the hole in the rim. The elastic material of the
rubber body presses itself tightly into the hole in the rim.
When valves with threaded metal feet are used, a rubber seal is used to seal the rim. The area around the edge of
the valve hole is a sealing area. Therefore, they must be free of rust, dirt and damage.
Valve Core
The valve core has the most important job in the valve. It creates a seal and enables the regulation of the air
pressure. The small plate seal on the valve core can only do its job when it is free of impurities, dirt and
moisture. The compressed air system must be free of water and oil!
Valve Cap
A valve cap must always be screwed onto the valves. It prevents dirt from getting into the valve. Dirt which
may be in the valve would reach the seal of the valve plate when the tire is inflated and cause a leak.
The valve must be replaced every time a new tire is fitted.
If the vehicle is driven without caps on the valves, there is the danger that dirt may get into the valve. This leads
to gradual loss of air and therefore lead to the destruction of the tire:
 Separation of carcass and rubber, refer to Separation of Carcass and Rubber.

 Wide circumferential furrows in the area of the bead, refer to Tires with Wide Furrows Along the
Circumference in the Area of the Bead.
 Disintegrated tread or torn-out tread, refer to Tires with Torn-out Tread.
WARNING: An air-tight seal is ensured only if the valve cap is secured tightly.
WHEELS, MOUNTING
ROTATING
Vehicles with front-wheel drive experience more tread wear on the front wheels due to the increased stress on
them.
In order for all 4 wheels on the vehicle to have the same service life, it is recommended to rotate the front and
rear wheels.
Be sure not to mix up tires, which have the direction of rotation marked on them.
Diagonal rotation is possible only with non-directional tires. This wheel rotation is especially advantageous for
heel-and-toe wear. Refer to HEEL AND TOE WEAR.
If heel-and-toe wear has already progressed very far and the tread is more than 50% worn, only slight
improvement can be achieved and rotation is no longer recommended. The elasticity of the tread blocks
declines and the heel-and-toe wear does not progress.
CHANGING AND MOUNTING
WARNING: The secure seating of the wheel bolts and the wheels is only ensured if
the instructions and checks below are followed.
-- Make sure the contact surfaces -arrows- on the brake disc are free from corrosion and dirt.
Fig. 44: Checking Disc Brakes For Corrosion And Dirt

-- Make sure the contact surfaces -arrow- on the brake disc center seat are free of corrosion and dirt.
Fig. 45: Checking Disc Brake Center Seat For Corrosion And Dirt
-- Make sure the contact surface -arrow- on the wheel inner side (rim) as well as the central seat in the rim is
free of corrosion and dirt.
Fig. 46: Checking Inner Wheel Rim And Central Seat Rim For Corrosion And Dirt
-- The spherical caps * in the wheel bolt openings and the wheel bolt threads must likewise be free of corrosion,
dirt, oil or grease.
* The spherical cap is the curved surface of a section of a sphere.
-- Check whether the wheel bolts can be easily screwed in by hand. The threads of the wheel bolts must not
touch the holes in the brake disc -arrow-.
Fig. 47: Checking Wheel Threading And Inner Rim For Dirt And Corrosion
If the thread of the wheel bolt touches the hole -arrow- , turn the brake disc relative to the wheel accordingly.
NOTE: If necessary, clean any dirt and corrosion, oil or grease off the surfaces and
thread in the wheel hub and/or wheel bolts.
WARNING: Heavily corroded, difficult to turn or damaged wheel bolts must be

replaced.
Wheel Mounting
-- Apply corrosion protection to the wheel centering seat. Refer to WHEEL CENTERING SEAT,
PROTECTING AGAINST CORROSION .
Fig. 48: Identifying Incorrect Tightening Method

1. When mounting a wheel, tighten all wheel bolts uniformly by hand.

2. Tighten the wheel bolts diagonally to 30 Nm.
3. Place the vehicle on the floor and tighten all of the wheel bolts in a diagonal sequence to the specification
with a torque wrench. Refer to Specifications . .
WARNING: Never use an impact wrench to install the wheel bolts!
EMERGENCY WHEELS, USING
Inform your customer as necessary of the notes listed in the following and also, if necessary, refer to the vehicle
owner's manual.
The notes listed in the following also apply to spare wheels, e.g. 7 J x 16 with 205/55 R 16 tires, which are
marked with the lettering "MAX 80 km/h" or "MAX 50 mph" on a yellow sticker.
NOTE: Depending on vehicle equipment, e.g. Passats with light alloy wheels and 225
tires, have such a spare wheel with a sticker as described above in place of an
emergency wheel.
Emergency wheel/spare wheel is designed only for sporadic and brief use.
Therefore it is to be replaced with the normal wheel again as soon as possible.
After mounting the emergency wheel/spare wheel, tire inflation pressure must
be checked as soon as possible. The correct tire inflation pressure can be
found in the following tire inflation pressure table on the respective vehicle or
the respective Service Information: Maintenance.
Always pay attention to speed information on the wheel ("MAX 80 km/h" or

"MAX 50 mph").
Wide Open Throttle (WOT) acceleration, strong braking and rapid driving
around curves should be prevented.
Never drive with more than one emergency wheel/spare wheel.
It is not permissible to use snow chains on the emergency wheel for technical
reasons.
If vehicle must be driven with snow chains, therefore the emergency wheel
must be installed on the rear axle for a breakdown on the front axle. The rear
wheel freed up must then be mounted in place of the faulty front wheel.
SPARE TIRES AND EMERGENCY WHEELS
Observe notes for the use of emergency wheels EMERGENCY WHEELS, USING.
Refer to appropriate service information for replacement part number.
Disk
Tires
Wheel
Model Dimension Dimension Manufacturer Tread
3 1 /2 J x S300 CST
Polo, Hankook Continental Komho
T125/70 R 16 96M 17 121
type 6R 16 ET 25, Maxxis
5 M9599N
Beetle,
3 J x 16
type 5C1 T125/90 R 16 98M Continental CST 17
ET 15
(16)
Golf, 3 1 /2 J x Conv. Spare

type 5K T125/70 R 18 99M Goodyear Continental
18 ET 25,5 CST 17
(1K)
3 1 /2 J x S300 CST
Hankook Continental Komho
16 ET 25,5 T125/70 R 16 96M Maxxis
17 121
(1) M9599N
Golf
Plus, 3 1 /2 J x Conv. Spare
Type T125/70 R 18 99M Goodyear Continental
18 ET 25,5 CST 17
521
(1KP)
3 1 /2 J x S300 CST
Hankook Continental Komho
16 ET 25,5 T125/70 R 16 96M Maxxis
17 121
(1) M9599N
Golf 3 1 /2 J x Conv. Spare
Wagon, T125/70 R 18 99M Goodyear Continental
CST 17
type AJ5 18 ET 25,5
Jetta, 3 1 /2 J x
T125/70 R 18 99M Continental CST 17
type 162 18 ET 25,5
Tiguan 4 J x 18
Type 5N ET 27,5
Scirocco, 3 1 / J x
2 Conv. Spare
Type T125/70 R 18 99M Goodyear Continental
18 ET 25,5 CST 17
137 (13)
3 1 /2 J x CST 17
Continental Hankook Kumho
16 ET 25,5 T125/70 R 16 96M Maxxis
S300 121
(2) M9500N
Touran 3 1 /2 J x Conv. Spare
T125/70 R 18 99M Goodyear Continental
1T 18 ET 25,5 CST 17
Eos, type 3 1 /2 J x
1F 18 ET 25,5
3 1 /2 J x CST 17
16 ET 25,5 T125/70 R 16 96M Continental Hankook Maxxis S300
(2) M9500N
Touareg, 6 1 /2 J x 195/75 R 18 106P collapsible spare
Vredestein Spacemaster
type 7P 18 ET 28 tire
(1) not for 4 MOTION and trailer equipment
(2) not for trailer equipment

RECOMMENDED SUMMER TIRES
Notes About Recommended Summer Tires
 Tires are one of the most important construction elements of a vehicle and significantly influence driving
safety. Therefore, the numerous requirements detailed in the DIN standards and the W.d.K. (Trade
association of the German rubber industry) and tire manufacturers' guidelines must be fulfilled. In
addition, extensive tests are performed by Volkswagen before the tires are approved for original
equipment on our vehicles.
 The following tire manufacturers meet the listed requirements. We recommend using tired made by these
manufacturers when installing new tires.
 The following is a list of all tire manufacturers whose tires are installed on VW vehicles at the time of
manufacture.
 The listed tire manufacturers and tire profiles are the most current at the time of this publication. Just like
any other product, tires are constantly being developed further. It is possible that changes in tire
manufacturers and tire profiles were made after this list was published. If a tire profile is no longer
available, we recommend using the subsequent profile of the tire manufacturer.
 Pay attention to the important information regarding run-flat tires. Refer to TIRES WITH
 Pay attention to the important information regarding tires with self-sealing characteristics "ContiSeal".
Refer to RUN-FLAT TIRES, CONTISEALRUN-FLAT TIRES, CONTISEAL .
PASSAT SEDAN, FROM MY 2006
Please observe the Notes About Recommended Summer Tires
Tire Tread
Manufacturer Comments
Size Designation
205/55
R 16 Goodyear Excellence
91H
Rolling resistance tires,
Energy
Michelin refer to ROLLING
Saver
RESISTANCE TIRES.
SP Sport
Dunlop Fast
Response
Michelin Primacy
SP Sport 01
Dunlop
A
Goodyear NCT -6
Bridgestone ER 300
Premium
Continental
Contact2
205/55 Michelin Primacy
94 V
Energy
Michelin
Saver
Goodyear Excellence
Sport
Continental
Contact 2
Bridgestone ER 300
Run-flat tires, refer to
215/55 TIRES WITH
ER 300
R 16 Bridgestone EMERGENCY
RFT
97V RUNNING
CHARACTERISTICS.
215/55
R 16 Michelin Primacy
97W
SP Sport 01
Dunlop
A
SP Fast
Dunlop
Response
Bridgestone ER 300
Premium
Continental
Contact
Premium
Continental
Contact 2
Pirelli P7
Goodyear Excellence
Run-flat tires
235/45
Sport "ContiSeal" , refer to
R 17 Continental
Contact 3 RUN-FLAT TIRES,
94W
CONTISEAL .
235/45
P Zero
R 17 Pirelli
Rosso
97W
Sport
Continental
Contact 2
Dunlop SP Sport 1
Bridgestone RE 050A
Run-flat tires
235/40
R 18 Continental
95W
CONTISEAL .
235/40
P Zero
R 18 Pirelli
Rosso
95Y
Sport
Continental
Contact 2
Michelin Pilot Sport 2
Dunlop SP Sport 1
PASSAT SEDAN, BLUE MOTION, FROM MY 2008
Tire Tread
Size Designation
205/55
91H Rolling resistance tires,
Energy refer to ROLLING
Michelin
Saver RESISTANCE
SP Sport TIRES.
Dunlop Fast
Response
Michelin Primacy
SP Sport 01
Dunlop
A
Goodyear NCT -6
Bridgestone ER 300
Premium
Continental
Contact2
205/55
94 V
Energy
Michelin
Saver
Goodyear Excellence
Sport
Continental
Contact 2
Bridgestone ER 300
215/55 TIRES WITH
ER 300
RFT
97V RUNNING
CHARACTERISTICS
215/55
97W
Dunlop SP Sport 01
A
SP Sport
Dunlop Fast
Response
Bridgestone ER 300
Premium
Continental
Contact
Premium
Continental
Contact 2
Pirelli P7
Goodyear Excellence
Run-flat tires
235/45
R 17 Continental
94W
CONTISEAL .
235/45
P Zero
R 17 Pirelli
Rosso
97W
Sport
Continental
Contact 2
Dunlop SP Sport 1
Bridgestone RE 050A
Run-flat tires
235/40
R 18 Continental
95W
CONTISEAL .
235/40
P Zero
R 18 Pirelli
Rosso
95Y
Sport
Continental
Contact 2
Dunlop SP Sport 1
PASSAT WAGON, FROM MY 2006
Tire Tread
Size Designation
205/55
91H
Michelin Energy refer to ROLLING
Saver RESISTANCE TIRES

SP Sport
Dunlop Fast
Response
Michelin Primacy
SP Sport 01
Dunlop
A
Goodyear NCT -6
Bridgestone ER 300
Premium
Continental
Contact2
205/55
94 V
Energy
Michelin
Saver
Goodyear Excellence
Sport
Continental
Contact 2
Bridgestone ER 300
215/55 TIRES WITH
ER 300
RFT
97V RUNNING
CHARACTERISTICS.
215/55
97W
SP Sport 01
Dunlop
A
SP Fast
Dunlop
Response
Bridgestone ER 300
Premium
Continental
Contact
Premium
Continental
Contact 2
Pirelli P7
Goodyear Excellence
Run-flat tires
235/45
R 17 Continental
94W
CONTISEAL .
R 17 P Zero
Pirelli
97W Rosso
Sport
Continental
Contact 2
Dunlop SP Sport 1
Bridgestone RE 050A
Run-flat tires
235/40
R 18 Continental
95W
CONTISEAL .
235/40
P Zero
R 18 Pirelli
Rosso
95Y
Sport
Continental
Contact 2
Dunlop SP Sport 1
PASSAT WAGON, BLUE MOTION, FROM MY 2008
Tire Tread
Size Designation
205/55
91H
Energy
Michelin refer to ROLLING
Saver
RESISTANCE TIRES
SP Sport
Dunlop Fast
Response
Michelin Primacy
SP Sport 01
Dunlop
A
Goodyear NCT -6
Bridgestone ER 300
Premium
Continental
Contact2
205/55
94 V
Energy
Michelin
Saver
Goodyear Excellence
Sport
Continental
Contact 2
Bridgestone ER 300
215/55 TIRES WITH
ER 300
RFT
97V RUNNING
CHARACTERISTICS.
215/55
97W
SP Sport 01
Dunlop
A
SP Fast
Dunlop
Response
Bridgestone ER 300
Premium
Continental
Contact
Premium
Continental
Contact 2
Pirelli P7
Goodyear Excellence
Run-flat tires
235/45
R 17 Continental
94W
CONTISEAL .
235/45
P Zero
R 17 Pirelli
Rosso
97W
Sport
Continental
Contact 2
Dunlop SP Sport 1
Bridgestone RE 050A
Run-flat tires
235/40
R 18 Continental
95W
CONTISEAL .
235/40
P Zero
R 18 Pirelli
Rosso
95Y
Sport
Continental
Contact 2
Dunlop SP Sport 1
PASSAT R36, FROM MY 2008
Tire Tread
Size Designation
Run-flat tires
235/45 "ContiSeal" ,
Sport
R 17 Continental refer to RUN-
Contact 3
94W FLAT TIRES,
CONTISEAL .
235/45
P Zero
R 17 Pirelli
Rosso
97W
Sport
Continental
Contact 2
Dunlop SP Sport 1
Bridgestone RE 050A
Run-flat tires
235/40 "ContiSeal" ,
Sport
R 18 Continental refer to RUN-
Contact 3
95W FLAT TIRES,
CONTISEAL .
235/40
P Zero
R 18 Pirelli
Rosso
95Y
Sport
Continental
Contact 2
Dunlop SP Sport 1
235/35
R 19 Pirelli P Zero
91Y
Sport
Continental
Contact 2
Run-flat tires
"ContiSeal" ,
Sport
Continental refer to RUN-
Contact 3
FLAT TIRES,
CONTISEAL .
TOUAREG HYBRID, FROM MY 11

Tire Size Manufacturer Tread Designation

255/55 R 18,109V Michelin Latitude Tour HP
255/55 R 18 109W XL Goodyear Eagle F1
Bridgestone Dueler HP Sport
Michelin Latitude Sport
265/50 R 19,110V XL Michelin Latitude Sport
265/50 R 19 110W XL Pirelli Scorpio Verde
Bridgestone Dueler HP Sport
XL means "Extra Load". Refer to WINTER TIRES, EXTRA LOAD, SPEED RATING V.
RECOMMENDED ALL SEASON TIRES
Notes about recommended all season tires
equipment on our vehicles.
manufacture.
Please observe the Notes about recommended all season tires
Tire
Manufacturer Tread Designation Comments
Size
205/55
R 16 Goodyear Vector 2
94 V
215/55
R 16 Goodyear Eagle LS For USA
97H
Continental Pro Contact
Michelin MXM 4
215/55 TIRES WITH
R 16 Bridgestone ER 300 RFT EMERGENCY
97V RUNNING
CHARACTERISTICS.
235/45
R 17 Michelin MXM 4 For USA
97H
Goodyear Eagle LS2
235/40
R 18 Pirelli P 6 4Season For USA
95H
Tire
Size
205/55
94 V
Tire
Size
205/55
94 V
215/55
R 16 Goodyear Eagle LS For USA
97H
Michelin MXM 4
215/55 TIRES WITH
R 16 EMERGENCY
97V Bridgestone ER 300 RFT RUNNING
CHARACTERISTICS.
235/45
R 17 Michelin MXM 4 For USA
97H
Goodyear Eagle LS2
235/40
R 18 Pirelli P 6 4Season For USA
95H
Tire
Size
205/55
94 V
Tire
Size
235/45
R 17 Michelin MXM 4
97H
For USA
Goodyear Eagle LS2
235/40
R 18 Pirelli P 6 4Season
95H
RECOMMENDED WINTER TIRES
Notes about recommended winter tires
manufacture.
Please observe the Notes about recommended winter tires
Tire
Size
195/65  Only for Japan:
R 15 Michelin X-Ice 1.6 FSI and 2.0L
91Q FSI engines
205/55
R 16 Dunlop Winter Sport 3D
91H
Pirelli Winter 210
Goodyear Eagle UG GW3
205/55
94H
Pirelli Winter 210
Nokian WR G2
TIRES WITH
Dunlop Winter Sport M3 DSST EMERGENCY
RUNNING
CHARACTERISTICS
205/50
93H
Run-flat tires
"ContiSeal" , refer to
Continental TS810
RUN-FLAT TIRES,
CONTISEAL .

R 16 2.0L FSI and
Michelin X-Ice
97Q 2.0L FSI turbo
XL engines
 Only for Japan:
235/45 2.0L FSI turbo
R 17 Michelin X-Ice engines and V6
94Q 3.2L FSI
4Motion
235/45
R 17 Dunlop Winter Sport M3
94H
Tire
Size
205/55
91H
Pirelli Winter 210
205/55
94H
Pirelli Winter 210
Nokian WR G2
Run-flat tires. Refer to
TIRES WITH
RUNNING
CHARACTERISTICS
205/50
93H
Run-flat tires
Continental TS810
RUN-FLAT TIRES,
CONTISEAL .

Tire
Size
R 15 Michelin X-Ice 1.6 FSI and 2.0L
91Q FSI engines
205/55
91H
Pirelli Winter 210
205/55
94H
Pirelli Winter 210
Nokian WR G2
TIRES WITH
RUNNING
CHARACTERISTICS.
205/50
93H
Run-flat tires
Continental TS810
RUN-FLAT TIRES,
CONTISEAL .
215/55
R 16  Only for Japan:
Michelin X-Ice 2.0L FSI and 2.0L
97Q
XL FSI turbo engines.
 Only for Japan:

235/45 2.0L FSI turbo
R 17 Michelin X-Ice engines and V6
94Q 3.2L FSI
4Motion.
235/45
94H

Tire
Size
205/55
91H
Pirelli Winter 210
205/55
94H
Pirelli Winter 210
Nokian WR G2
TIRES WITH
RUNNING
CHARACTERISTICS
205/50
93H
Run-flat tires
Continental TS810
RUN-FLAT TIRES,
CONTISEAL .
Tire
Size
205/50
93H
Run-flat tires
"ContiSeal" ,
Continental TS810 refer to RUN-
FLAT TIRES,
CONTISEAL .
235/45
94H
SIDE WALL LETTERING
Example: Continental ContiPremiumContact 2
Fig. 49: Identifying Side Wall Lettering

1. Size Designation
 For example 205/55 R 16, refer to Tire Dimension Explanation
2. Position of Tread Wear Indicators (TWI)

3. Manufacturer (Trade Name)
4. Construction
 Radial - radially-oriented fibers in carcass.
 Tubeless - Identifier for tubeless tires.
5. Load Index/Speed Rating

 For example 91, refer to Load Index (LI)
 For example H, refer to Speed Rating/Maximum Speed
6. Specified Direction of Travel of Tire/Assembly Tool

7. Maximum Permissible Load
 Specifications for North America only.
8. Maximum Permissible Tire Pressure

 Specifications for North America only.
9. Number of Ply Layers in the Center of the Tread and in the Sidewalls, and Information About the
Material.
10. ER Number = Approval Number
 The tires fulfill all European guidelines.
11. Manufacturing Code/Date of Manufacture

 Identification number for manufacturer's factory, tire size and tire model.
 Tire age/date of manufacture, refer to TIRES, AGING.
12. DOT - Department of Transportation

 Tire meets the guidelines of the American traffic authorities.
13. Identification for Brazil

14. Identification for China
15. Country of Manufacture
 For example: Made in Germany.
16. Safety Notes for Use or Fitting of Tires

17. Tread Wear Index - Resistance to Abrasion
 Based on a US standard test.
18. Traction Rating - Evaluation of Wet Braking Ability AA, A, B or C

 According to US test.
19. Temperature Resistance Index A, B or C

 According to US test.
20. Identifying Run-flat Tires

 For example, Self Supporting Runflat.
 Identifying run-flat tires, refer to STRUCTURE AND IDENTIFICATION.
21. Tread Designation

 For example, ContiPremiumContact.
TIRE LETTERING EXPLANATION

Tire Dimension Explanation
Tires Speed 1 2 3 4 5 6 7
up to
Summer
240 195 65 R 15 91 V -
Tires
km/h
up to
Winter
160 195 65 R 15 91 Q M+S
Tires
km/h
up to
Winter
190 195 65 R 15 91 T M+S
Tires
km/h
High over
Speed 240 225 50 ZR 16 91 - -
tires km/h
1. Tire width
2. Aspect ratio in %
3. Tire construction code "R" (means radial)
4. Rim diameter designation
5. Load index (LI)
6. Speed code
7. Winter tire/designation for all-season tire
Speed Rating/Maximum Speed
Speed
High Speed in km/h
Code
L 120
M 130
N 140
P 150
Q 160
R 170
S 180
T 190
U 200
H 210
V 240
ZR over 240
W 270
Y 300
Load Index (LI)
The load capacity index can be found on the sidewall of the tire. It provides information about the maximum
load that the tire can bear.
The load capacity index is located in the size designation, e.g. 195/65 R 15 91T, of the tire. It is indicated on the
tire as a code according to ETRTO. The following table shows the load capacity index used at VW with the
corresponding load capacity of the tires.
Load Index Maximum Load of Tire in kg

75 387
78 425
79 437
80 450
81 462
82 475
83 487
84 500
85 515
86 530
87 545
88 560
89 580
90 600
91 615
92 630
93 650
94 670
95 690
96 710
97 730
98 750
99 775
100 800
101 825
102 850
103 875
104 900
110 1060
112 1120
TIRES, SPEED RATINGS

The speed rating (e.g.: "T") behind the tire size specification (e.g.: 185/65 R 14 86T) indicates the maximum
permissible speed (vmax ) for the tire.
When selecting the tires for a vehicle, ensure that their maximal permissible speed lies above the maximum
speed attainable by the vehicle ("design-related").
Vehicles with National Type Approval
For all vehicles with national type approval, the maximum speed is calculated using the following formula:
Formula for Vehicles with vmax up to 150 km/h
vmax = 1.03 x v + 3.5 km/h
NOTE: For the letter "v" , enter the specified maximum speed in the vehicle registration
Part I or II in the field "T" or in the vehicle title under number 6. This conversion
is necessary, because due to technical reasons, all vehicles reach different
maxim speeds within a legally permissible range.
Example: Indicated maximum speed v = 145 km/h.
vmax = 1.03 x 145 km/h + 3.5 km/h = 152.85 km/h.
In this example, a "Q" tire or a tire with a higher-order speed rating must be used.
Formula for Vehicles with vmax from 151 km/h
vmax = 1.01 x v + 6.5 km/h
vmax = 1.01 x 163 km/h + 6.5 km/h = 171.13 km/h.
In this example, an "S" tire or a tire with a higher-order speed rating must be used.
Vehicles with EU Type Approval
For all vehicles with EU-registration, the maximum speed is calculated using the following formula:
vmax = 1.05 x v
vmax = 1.05 x 172 km/h = 180.60 km/h.
In this example, a "T" tire or a tire with a higher-order speed rating must be used.
Using tires with a higher-order speed rating is permitted. The same applies for tires with higher-order load-
carrying capacity characteristic number (load index).
CRACKING
Cracking is the term for shallow cracks in the sidewall of the tire.
They run starting from the bulge in the direction of the tire shoulder. See Illustration for the mentioned
components. Refer to Components of a Tire
The cause is the increase in material at the joints of the tire components.
Cracking has no effect on:
 Safety.
 Service life.
 Vehicle handling.
 Other characteristics of the tire.
Cracks can be of varying visibility. Removing the tire from the rim or an examination is not necessary.
How did the cracks form?
Modern steel belted tires are constructed with single-ply sidewalls to save weight.
The sidewall components consist of long strips before they are joined together to form a tire. They must overlap
at the joints. Small irregularities/ripples form in the area of the overlapping components. The overlaps are easier
to see from the outside due to the single-ply construction.
TIRES, STORING
Storage Room
Tire storage must be:
 Dark
 Dry
 Cool
 Ventilated
WARNING: Stored tires must not come in contact with fuel, oil, grease or chemicals
under any circumstances. Otherwise, the material in the tire will be
damaged by chemical reactions which are not always visible.
This may lead to life-threatening situations when the car is driven.
However, tire damage occurs only when the reaction time of the chemicals is long. If a few drops of fuel land
on a tire during a fill-up, this is harmless.
Tire Storage
Complete Wheels
Tires mounted on wheels can be stored flat, stacked on upon another. When doing this, always ensure that
wheels are clean and dry. The air pressure should be raised to a maximum of 3 bar.
Tires without Wheels
Tires without wheels are best stored standing vertically. If tires lie stacked upon another for longer periods of
time, they will be strongly pressed together. This makes mounting more difficult because the tires do not lie on
the bead seat. If the tires are stored standing vertically, it is recommended to turn them every 14 days to avoid
severe flattening.
TIRES, AGING
 Even tires that look in good shape, new or hardly use and have sufficient tread depth and that are older
than 6 years, can age caused by moisture and winter conditions.
 Tire test show that through continual development, new rubber mixtures, modern raw materials and
optimizing the tire profile and profile geometry, better tires are being produced.
 The highly engineered vehicles manufactured by Volkswagen, plus constant growing customer
expectations, demand economical tires that offer the highest degree of safety, driving dynamic and
comfort.
 Tires age as a result of physical and chemical processes whereby the function can be impaired. Tires
which are stored for longer periods of time become harder and brittle faster than tires which are
constantly in use on a vehicle.
 Older tires may develop hairline cracks from aging.
 When tires are in constant use, the kneading activates softeners in the rubber, preventing hardening and
the development of cracks.
 Therefore, one should note not just the tread depth but also the age of spare tires, stored tires and tires
which are not permanently in use.
 Tire age can be determined from the DOT code which contains, among other things, the tire's production
date.
Example of a DOT number through 12/31/1999
DOT ...... 5 0 9 <

stands for 199_
Production year last digit
Calendar week
In this example, the production date is the 50th week of 1999.
Example of a DOT number from 01/01/2000
DOT ...... 0 1 0 0
Production year last two digits
Calendar week
In this example, the production date is the 01st week of 2000.
Recommendation
 Using summer and winter tires that are more than 6 years old is not recommended. The aging process
reduces the original characteristics. The gripping capabilities of winter tires are especially reduced.
 When new tires are fitted, the spare tire may also be used if it is in flawless condition and is not more than
6 years old. The age of the tire has a great influence on the high-speed capability of the tire. The
combination of a spare tire which is several years old with new tires is possible, but it can influence the
car's handling.
 Tires are constantly being further developed, this can lead, for example, to slight changes in the rubber
compound, even if the tires are of the same make, size and tread.
 All VW vehicles are factory-fitted with four identical tires and wheels.
Vehicles with FWD
 For driving safety reasons, tires of the same make and with the same tread should be mounted on one
Vehicles with AWD
 Vehicles with AWD always must be equipped with four wheels that have tires of the same size,
construction, tread pattern and make.
Tires, Replacing
Tires must be changed when:
 The legal minimum tread depth of 1.6 mm is reached.

 There is visible damage from mechanical damage.
TIRE SIZES, AWD VEHICLES
Note the following regarding AWD vehicles:
 Only tires having the same size and are manufactured by the same manufacturer and have the same
profile may be used on the front and rear.
 Different rolling circumferences will lead to tension on the drivetrain and increased tire wear with
possible damage to the drivetrain.
 This also applies to front and rear tires that are worn differently. In this case, install tires with a larger
tread depth.
WINTER TIRES
Using Winter Tires
From May 1, 2006, the road traffic regulations were changed to include the following: "Vehicle equipment must
be adapted to the weather conditions. This includes suitable tires and freeze protection in the windshield washer
system."
Inform the customer that since May 1st, 2006, he or she is obligated to adapt vehicle equipment, especially tires,
to winter weather conditions.
For the winter operation, it is recommended to mount winter tires in the sizes shown in the parts certificate
table.
Always Applicable
All tire sizes listed in the vehicle papers can also be driven as winter tires!
The handling characteristics may be affected due to the use of winter tires the resulting changes in wheel and
tire dimensions. For this reason, driving speed must be adapted to the changed handling characteristics and road
conditions.
To attain best handling characteristics winter tires must be mounted on all wheels.
If while mounting the winter tires, the vehicle is equipped with rims that are not factory-fitted, the following
must be observed:
 Wheels and wheel bolts are coordinated to each other!

 When retrofitting to different wheels, the corresponding wheel nuts with the correct length and cup shape
1 must be used. The secure seating of the wheels and the function of the brake system depend on it!
 Winter tires with tread depth of less than 4 to 5 mm are only for limited use during winter operation.
 In some countries, at least 4 mm tread depth are required for winter tires.
 It is recommended to not use winter tires longer than six years. The aging process reduces the particular
"winter characteristics" of these tires independently from the mileage.
Vehicles with Tire Pressure Monitoring System
On vehicles with tire pressure monitoring system, the tire pressure must be resaved or adapted after each change
from summer to winter tires or vice versa.
1. Spherical cap is the curved surface of a section of a sphere. The spherical cap can be seen in the wheel
bolt and in the wheel (rim) in the wheel bolt hole.
WINTER TIRES WITH SPEED RATING V
The tire industry delivers winter tires with V-rating also. These tires can be applied up to the maximum
permissible speed vmax = 240 km/h only under certain conditions.
Vehicles with V-Tires
Vehicles that require V-tires according to vehicle registration, can be driven with V winter tires without
limitations up to vmax = 240 km/h.
Vehicles with W-, Y- or ZR-Tires
Vehicles that require W, Y, or ZR tires according to vehicle registration, cannot be driven with V winter tires up
to vmax = 240 km/h under certain conditions.
Why?
V summer tires and V winter tires without special designation (The same conditions apply for these tires as
for V winter tires without special designation) guarantee 100% of the load capacity indicated by their Load
Index ("LI") (91) only up to a speed of 210 km/h.
Speeds above 210 km/h are only possible if the maximum load capacity of the tire is not exceeded. The load
capacity of the tire decreases as the speed increases.
The maximum permissible axle load and the attainable maximum speed of certain VW vehicles are so high that
the load capacity of V tires is not sufficient for speeds above 240 km/h.
Example: Tires 205/55 R 16 91 V
The Load Index (LI) 91 for this tire indicates a load capacity of 615 kg per tire up to 210 km/h.
At 240 km/h, the load capacity of this tire is reduced to only 560 kg. For this reason, the axle load can only be
maximum 1,120 kg.
The Passat Wagon V6 4 MOTION has an additional axle load of 1,150 kg and an attainable maximum speed of
232 km/h. This vehicle can be driven with V winter tires up to a speed of 230 km/h.
NOTE: This applies to all V winter tires that do not have a special designation.
WINTER TIRES, EXTRA LOAD, SPEED RATING V
V winter tires with XL designation have a higher load capacity than the V winter tires without this designation.
Higher speeds can be attained with XL V-winter tires, but the maximum speed of the V tires of 240 km/h is not
permissible for every VW passenger car.
The same conditions apply for these tires as for V winter tires without special designation
Tire Pressure in Extra Load V Tires
The following table shows the speed which the concerned VW passenger cars can attain with V-winter tires,
depending on their axle load. Refer to WINTER TIRES, MAXIMUM SPEEDS FOR V AND EXTRA
LOAD.
WINTER TIRES, MAXIMUM SPEEDS FOR V AND EXTRA LOAD
Driving Winter vmax with V Winter Tires

Vehicle Description Maximum Axle Load
Mode Tires
Phaeton
235/60
2003 >
Sedan FWD 1,420 kg R 240 km/h
3.2L/177
16,100V
kW V6
Short
235/55
and long
R 17 235 km/h
wheel
99V
base
235/50
R
18,101V 240 km/h
extra
load
245/45
R 19
102V
extra 230 km/h
load
255/40
R
19,100V 240 km/h
extra
load
Phaeton
2003 > 235/55
3.0L/165 Sedan 4MOTION 1,490 kg R 17 220 km/h
kW V6 99V
TDI
235/50
Short
R
and long
18,101V 240 km/h
wheel
extra
base
load
245/45
R 19
102V 230 km/h
extra
load
255/40
R
19,100V 230 km/h
extra
load
Phaeton
235/55
2003 >
Sedan 4MOTION 1,430 kg R 17 235 km/h
4.2L/246
99V
kW V8
235/50
Short R
wheel 18,101V 240 km/h
base extra
load
245/45
R 19
102V 230 km/h
extra
load
255/40
R 240 km/h
19,100V
extra
load
Phaeton
235/55
2003 >
Sedan 4MOTION 1,450 kg R 17 230 km/h
4.2L/246
99V
kW V8
235/50
Long R
wheel 18,101V 240 km/h
base extra
load
245/45
R 19
102V 230 km/h
extra
load
255/40
R
19,100V 240 km/h
extra
load
Phaeton
2003 >
235/50
5.0L/230
R
kW V10
Sedan 4MOTION 1,640 kg 18,101V 210 km/h
TDI
extra
short
load
wheel
base
Phaeton
2003 >
235/50
5.0L/230
R
kW V10
TDI
extra
long
load
wheel
base
235/50
Phaeton
R
2003 >
6.0L/309
extra
kW W12
load
245/45
R 19
102V 230 km/h
extra
load
255/40
Short
R
and long
19,100V 220 km/h
wheel
extra
base
load
Permission Stipulations in Germany
Only when using winter tires is it permitted that the highest speed attainable by the vehicle lies above the
highest speed of winter tires specified by the speed rating.
In this case, a warning sign must be applied with the following content:
Attention, Winter Tires!

Maximum permissible speed...km/h
NOTE: This warning sign must be in the driver's field of view!
TIRES, REINFORCED, EXTRA LOAD
Some time ago, the designation "Reinforced" was replaced with the designation "Extra Load" by some tire
manufacturers. In countries outside Europe, this designation has been conventional for some time. There are no
technical differences.
Some tire manufacturers also use the "XL" designation for Extra Load tires.
Tires with the designations "Reinforced" or "Extra Load (XL)" are the same.
SNOW CHAINS
Snow chains may be mounted only on the drive wheels.
Only the front wheels on all wheel drive vehicles and also the back wheels on the Touareg are equipped with
snow chains.
Snow chains are not possible with all wheel/tire combinations. Corresponding notes can be found in the vehicle
parts certificate table.
If no special snow chain type is specified, a snow chain with small chain links can be used. Only chains which
do not stand up more than 15 mm, including chain lock, may be applied on tire tread and inner sides.
With some models and certain wheel/tire combinations, only snow chains with small chain links can be used.
Corresponding notes can be found in the vehicle parts certificate table.
NOTE: The legally permitted maximum speed when driving with snow chains is 50
km/h.
Remove the snow chains before driving on snow-free roads. It does not make sense to leave them on because
the handling characteristics become worse. During this, the tires are stressed unnecessarily and the chain wear is
particularly high.
Suspension Wheels, Tires, Wheel Alignment - Specifications
Suspension
Wheels, Tires, Wheel Alignment - Specifications
44 WHEELS, TIRES, WHEEL ALIGNMENT

SPECIFICATIONS
General Information
Volkswagen vehicles are designed according to high safety standards. To keep it that way, it is recommended to
use only genuine Volkswagen replacement parts. These can be recognized by the VW Audi logo and by the part
number. These parts are known to be reliable, safe and suitable.
Despite constant appraisal of the market, we cannot assess other products on these points, even where in
isolated cases they have been passed by official inspectors or have been granted official approval. Therefore, we
cannot assume any liability if these products are installed.
WARNING: Products from Volkswagen Original Replacement Parts and Votex

Original Accessories may differ in regards to assembly requirements,
tightening specifications, etc.
Always follow the respective assembly and operating instructions.
The wheel and tire combinations or retrofittings listed in the vehicle tables refer exclusively to Volkswagen
original disc wheels. Release of wheel/tire combinations or retrofittings with disc wheels from the accessories
trade is not possible with the enclosed approval certificate.
WARNING: When assembling disc wheels by Votex Original Accessories, assembly

requirements and tightening specifications may deviate from those for
disc wheels by Volkswagen Original Replacement Parts.
Therefore always pay attention to tightening specifications for wheel bolts

as well as respective assembly and operating instructions.
PASSAT SEDAN, TYPE 3C, MY 2006
Supplement to parts certificate 8106807121
Type Approval Number: e1*2001/116*0307*00 to e1*2001/116*0307*09
Overview
Model/Engine Disk Offset (ET) Snow

Performance Tires Tire Size Wheel in mm Chains Comments

1.6L 75 kW;
1.6L 85 kW Standard 205/55 R 6 1/2
42 Yes
Gasoline Tires 16 91H Jx16
engines;
General information about:
1.9L 77 kW
TDI; 2.0L 88 Winter tires, refer to
215/55 R 6 1/2 
kW TDI; 2.0L Modification 42 No WINTER TIRES
16 93H Jx16
90 kW TDI
 Snow chains, refer to
Diesel engines
SNOW CHAINS
205/55 R Volkswagen recommended
7 J X 16 45 No
16 91H tire brands:
 Summer tires, refer to
PASSAT SEDAN,
FROM MY 2006
215/55 R  All-season tires, refer to
7 J X 16 45 No PASSAT SEDAN,
16 93H
FROM MY 2006
 Winter tires, refer to
PASSAT SEDAN,
FROM MY 2006
235/45 R 7 1/2
47 No
17 94V Jx17
 * Tires 235/40 R 18
95Y on rims 8 J x 18 ET
44 are permitted only if
the conditions listed are
fulfilled!
CAUTION:
It is possible to mount
235/40 R 8 J x 18 wheels only
8 J X 18 44 No under the following
18 95Y*
conditions:
 Either a sport
suspension with
approximately
15 mm lowering
and spring
travel limiter or
spring travel
limiters with
Votex part
number
000.071.501/A
must be
installed on
front and rear
axle. In both
cases, the
camber on the
front axle must
be set to -1°45'.
205/55 R 6 1/2
Winter Tires 42 Yes  In addition,
16 91H/V Jx16
wheel housing
enlargements
(FLAPS) must
be installed,
except in
Germany - there,
the
discontinuation
of wheel
housing
enlargements
(FLAPS) is
possible with T
U V certificate
no. 2174/05.
Refer to
ADDITIONAL
WHEEL
HOUSING
ENLARGEMENT,
205/50 R FLAPS .
6 J X 17 45 Yes
17 93H/V
 A 235/40 R 18 95 W
tire on a 8 J x 18 ET 44
rim can be used in place
of a 235/40 R 18 95Y
rim. Refer to "approval
95W tires Passat" from
the Federal Motor
Vehicle Office.
2.0L 110 kW
Standard 205/55 R 6 1/2
Gasoline 42 Yes
Tires 16 91V Jx16
engine
215/55 R 6 1/2
Modification 42 No
16 93V Jx16
205/55 R
7 J X 16 45 No
16 91V
215/55 R
7 J X 16 45 No
16 93V
235/45 R 7 1/2
47 No
17 94V Jx17
235/40 R
18 95Y*
Tires
235/40 R
18 95Y on 8 J X 18 44 No
rims 8 J x
18 ET 44
are
permitted
205/55 R 6 1/2
Winter Tires 42 Yes
16 91H/V Jx16
205/50 R
6 J X 17 45 Yes
17 93H/V
2.0 L 100 kW
TDI 2.0 L 103 If load index LI 94 is entered
kW TDI 2.0 L (205/55 R16 94V) in the
Standard 205/55 R 6 1/2
120 kW TDI 42 Yes vehicle documentation on
Tires 16 94V Jx16
2.0 L 125 kW vehicles equipped with the
TDI Diesel 100/103/120/125 kW TDI
engines engine, then winters tires with
215/55 R 6 1/2 load index LI 91 (205/55 R 16
Modification 42 No
16 93V Jx16 91H) may be used. The
205/55 R "Safety and confirmation
7 J X 16 45 No
16 94V certificate must be submitted
215/55 R to the administrative authority
7 J X 16 45 No (licensing agency)" together
16 93V
235/45 R 7 1/2 with test report no. 1423/07.
47 No
17 94V Jx17
235/40 R
18 95Y*
Tires
235/40 R
18 95Y on 8 J X 18 44 No
rims 8 J x
18 ET 44
are
permitted
205/55 R 6 1/2
Winter Tires 42 Yes
16 91H/V Jx16
205/50 R
6 J X 17 45 Yes
17 93H/V
Standard 205/55 R 6 1/2
2.0L 147 kW 42 Yes
Tires 16 91W Jx16
engine
215/55 R 6 1/2
Modification 42 No
16 93W Jx16
215/55 R
7 J X 16 45 No
16 93W
235/45 R 7 1/2
47 No
17 94W Jx17
235/40 R
18
95Y*Tires
235/40 R
18 95Y on 8 J X 18 44 No
rims 8 J x
18 ET 44
are
permitted
205/55 R 6 1/2
Winter Tires 42 Yes
16 91H/V Jx16
205/50 R
6 J X 17 45 Yes
17 93H/V
3.2L 184 kW
Standard 235/45 R 7 1/2
Gasoline 47 No
Tires 17 94W Jx17
engine
235/40 R
Modification 8 J X 18 44 No
18 95Y*
205/50 R
Winter Tires 6 J X 17 45 Yes
17 93H/V
Tire pressures can be found on the inside of the fuel tank flap .
PASSAT SEDAN, TYPE 3C, MY 2007 THROUGH MY 2008
CAUTION: Please follow the specifications for wheel/tire combinations from type
approval number: e1*2001/116*0307*13, Type approval number:
e1*2001/116*0307*13 through e1*2001/116*0307*14.
Type Approval Number: e1*2001/116*0307*10 through e1*2001/116*0307*12
Overview

Tires Tire Size Comments
Performance Wheel in mm Chains
1.6L 85 kW
Standard 205/55 R 6 1/2
Gasoline 42 Yes
Tires 16 91H Jx16
engines;
1.9L 77 kW 215/55 R Winter tires, refer to
6 1/2 
TDI; Diesel Modification 16 42 No WINTER TIRES
Jx16
engines 93H/V
SNOW CHAINS
205/55 R
Volkswagen recommended
16 7 J X 16 45 No
tire brands:
91H/V
PASSAT SEDAN,
FROM MY 2006
16 7 J X 16 45 No PASSAT SEDAN,
93H/V FROM MY 2006
PASSAT SEDAN,
FROM MY 2006
235/45 R
7 1/2
17 47 No
Jx17
94H/V
 * Tires 235/40 R 18
fulfilled!
CAUTION:
8 J x 18 wheels only
under the following
8 J X 18 44 No conditions:
 Either a sport
suspension with
235/40 R approximately
18 95Y* 15 mm lowering
Tires and spring
235/40 R travel limiter or
spring travel
18 95Y limiters with
on rims 8 Votex part
J x 18 number
ET 44
are must be
permitted installed on
front and rear
axle. In both
cases, the
camber on the
front axle must
be set to -1°45'.
 In addition,
wheel housing
enlargements
(FLAPS) must
be installed,
except in
Germany - there,
the
discontinuation
of wheel
housing
enlargements
205/55 R (FLAPS) is
6 1/2 possible with T
Winter Tires 16 42 Yes
Jx16 U V certificate
91H/V no. 2174/05.
Refer to
ADDITIONAL
WHEEL
HOUSING
ENLARGEMENT,
FLAPS .
 A 235/40 R 18 95 W
205/50 R rim can be used in place
17 6 J X 17 45 Yes of a 235/40 R 18 95Y
93H/V tire on a 8 J x 18 ET 44
the Federal Motor
Vehicle Office.
2.0L 110 kW Standard 205/55 R 6 1/2
42 Yes
Gasoline engine Tires 16 91V Jx16
215/55 R 6 1/2
Modification 42 No
16 93V Jx16
205/55 R
7 J X 16 45 No
16 91V
215/55 R
7 J X 16 45 No
16 93V
47 No
235/45 R 7 1/2
17 94V Jx17
235/40 R
18 95Y*
Tires
235/40 R
18 95Y
8 J X 18 44 No
on rims 8
J x 18
ET 44
are
permitted
205/55 R
6 1/2
Jx16
91H/V
205/50 R
17 6 J X 17 45 Yes
93H/V
2.0L 100 kW
TDI Diesel
engine with Standard 205/55 R 6 1/2
42 Yes
automatic/direct Tires 16 94H Jx16
shift If load index LI 94 is entered
transmission (205/55 R16 94V) in the
2.0L 103 kW vehicle documentation on
215/55 R
TDI Diesel 6 1/2 vehicles equipped with the
Modification 16 42 No
engine Jx16 100/103 kW TDI engine, then
93H/V
4MOTION winters tires with load index
2.0L 103 kW LI 91 (205/55 R 16 91H) may
TDI Diesel be used. The "Safety and
engine with confirmation certificate must
205/55 R
automatic/direct be submitted to the
16 7 J X 16 45 No
shift administrative authority
94H/V
transmission (licensing agency)" together
and front wheel with test report no. 1423/07.
drive
215/55 R
16 7 J X 16 45 No
93H/V
235/45 R
7 1/2
17 47 No
Jx17
94H/V
235/40 R
8 J X 18 44 No
18 95Y*
205/55 R
6 1/2
Jx16
91H/V
205/50 R
17 6 J X 17 45 Yes
93H/V
2.0L 100 kW
TDI Diesel
Standard 205/55 R 6 1/2
engine with 42 Yes
Tires 16 94V Jx16 If load index LI 94 is entered
manual
transmission (205/55 R16 94V) in the
2.0L 103 kW vehicle documentation on
TDI Diesel vehicles equipped with the
engine with 100/103/120/125 kW TDI
215/55 R 6 1/2 engine, then winters tires with
manual Modification 42 No
16 93V Jx16 load index LI 91 (205/55 R 16
transmission
and front wheel 91H) may be used. The
drive "Safety and confirmation
certificate must be submitted
2.0L 120 kW
to the administrative authority
TDI 2.0L 125 205/55 R
7 J X 16 45 No (licensing agency)" together
kW TDI Diesel 16 94V
with test report no. 1423/07.
engines
215/55 R
7 J X 16 45 No
16 93V
235/45 R 7 1/2
47 No
17 94V Jx17
235/40 R
8 J X 18 44 No
18 95Y*
205/55 R
6 1/2
Jx16
91H/V
205/50 R
17 6 J X 17 45 Yes
93H/V
2.0L 147 kW Standard 205/55 R 6 1/2
42 Yes
Gasoline engine Tires 16 91W Jx16
215/55 R 6 1/2
Modification 42 No
16 93W Jx16
215/55 R
7 J X 16 45 No
16 93W
235/45 R 7 1/2
47 No
17 94W Jx17
235/40 R
8 J X 18 44 No
18 95Y*
205/55 R
6 1/2
Jx16
91H/V
205/50 R
17
6 J X 17 45 Yes
93H/V
3.2L 184 kW Standard 235/45 R 7 1/2
47 No
235/40 R
18 95Y*
205/50 R
Winter Tires 17 6 J X 17 45 Yes
93H/V
Type approval number: e1*2001/116*0307*13 through e1*2001/116*0307*14
Overview

1.6L 75 kW;
1.6L 85 kW
Standard 205/55 R 6 1/2
1.4L 90 kW 42 Yes
Tires 16 91H Jx16
Gasoline
engines;
1.9L 77 kW 215/55 R Winter tires, refer to
6 1/2 
TDI; Diesel Modification 16 42 No WINTER TIRES
Jx16
engines 93H/V
SNOW CHAINS
205/55 R
16 7 J X 16 45 No
tire brands:
91H/V
PASSAT SEDAN,
FROM MY 2006
16 7 J X 16 45 No PASSAT SEDAN,
93H/V FROM MY 2006
PASSAT SEDAN,
FROM MY 2006
235/45 R 47 No
17 7 1/2
94H/V Jx17
 * Tires 235/40 R 18
fulfilled!
235/40 R CAUTION:
8 J X 18 44 No
18 95Y * It is possible to mount
under the following
conditions:
 Either a sport
suspension with
approximately
15 mm lowering
and spring
travel limiter or
spring travel
limiters with
Votex part
number
000.071.501/A
must be
installed on
front and rear
205/55 R axle. In both
6 1/2
Winter Tires 16 42 Yes cases, the
Jx16 camber on the
91H/V
front axle must
be set to -1°45'.
 In addition,
wheel housing
enlargements
(FLAPS) must
be installed,
except in
Germany - there,
the
discontinuation
of wheel
housing
enlargements
(FLAPS) is
possible with T
U V certificate
no. 2174/05.
Refer to
ADDITIONAL
WHEEL
HOUSING
ENLARGEMENT,
FLAPS .
 A 235/40 R 18 95 W
205/50 R tire on a 8 J x 18 ET 44
17 6 J X 17 45 Yes rim can be used in place
93H/V of a 235/40 R 18 95Y
the Federal Motor
Vehicle Office.
1.8L 118 kW
Standard 205/55 R 6 1/2
2.0L 110 kW 42 Yes
Tires 16 91V Jx16
Gasoline engine
215/55 R 6 1/2
Modification 42 No
16 93V Jx16
205/55 R
7 J X 16 45 No
16 91V
215/55 R
7 J X 16 45 No
16 93V
235/45 R 7 1/2
47 No
17 94V Jx17
235/40 R
8 J X 18 44 No
18 95Y *
205/55 R
6 1/2
Jx16
91H/V
205/50 R
17 6 J X 17 45 Yes
93H/V
2.0L 100 kW
TDI Diesel
engine with Standard 205/55 R 6 1/2
42 Yes
automatic/direct Tires 16 91H Jx16
shift
transmission
2.0L 103 kW
215/55 R
TDI Diesel 6 1/2
Modification 16 42 No
engine Jx16
93H/V
4MOTION
2.0L 103 kW
TDI Diesel
engine with
205/55 R
shift 16
transmission 91H/V
7 J X 16 45 No
and front wheel
drive
215/55 R
16 7 J X 16 45 No
93H/V
235/45 R
7 1/2
17 47 No
Jx17
94H/V
235/40 R
8 J X 18 44 No
18 95Y *
205/55 R
6 1/2
Jx16
91H/V
205/50 R
17 6 J X 17 45 Yes
93H/V
2.0L 100 kW
TDI Diesel
Standard 205/55 R 6 1/2
engine with 42 Yes
Tires 16 91V Jx16
manual
transmission
2.0L 103 kW
TDI Diesel
engine with
215/55 R 6 1/2
manual Modification 42 No
16 93V Jx16
transmission
and front wheel
drive
2.0L 120 kW
TDI 2.0L 125 205/55 R
7 J X 16 45 No
kW TDI Diesel 16 91V
engines
215/55 R
7 J X 16 45 No
16 93V
235/45 R 7 1/2
47 No
17 94V Jx17
235/40 R
8 J X 18 44 No
18 95Y *
205/55 R
6 1/2
Jx16
91H/V
205/50 R 6 J X 17 45 Yes
17
93H/V
2.0L 147 kW Standard 205/55 R 6 1/2
42 Yes
215/55 R 6 1/2
Modification 42 No
16 93W Jx16
215/55 R
7 J X 16 45 No
16 93W
235/45 R 7 1/2
47 No
17 94W Jx17
235/40 R
18 95Y *
Tires
235/40 R
18 95Y
8 J X 18 44 No
on rims 8
J x 18
ET 44
are
permitted
205/55 R
6 1/2
Jx16
91H/V
205/50 R
17 6 J X 17 45 Yes
93H/V
3.2L 184 kW Standard 235/45 R 7 1/2
47 No
235/40 R
18 95Y *
205/50 R
93H/V
PASSAT SEDAN, TYPE 3C, MY 2009
approval number: e1*2001/116*0307*19. Type approval number:
e1*2001/116*0307*19.
Overview
Type Approval Number: e1*2001/116*0307*15 through e1*2001/116*0307*18.
Model/Engine Tire Disk Offset (ET) Snow

Tires Comments
Performance Size Wheel in mm Chains
1.6L 75 kW;
1.6L 85 kW 205/55
Standard 6 1/2
1.4L 90 kW R 16 42 Yes
Tires Jx16
Gasoline 91H
engines;
1.9L 77 kW General information about:
TDI; 2.0L 81
kW TDI; 2.0L 215/55 Winter tires, refer to
6 1/2 
100 kW TDI Modification R 16 42 No WINTER TIRES
Jx16
2.0L 103 kW 93H/V
TDI Diesel  Snow chains, refer to
engines SNOW CHAINS
205/55
R 16 7 J X 16 45 No
tire brands:
91H/V
PASSAT SEDAN,
FROM MY 2006
215/55  All-season tires, refer to
R 16 7 J X 16 45 No PASSAT SEDAN,
93H/V FROM MY 2006
PASSAT SEDAN,
FROM MY 2006
235/45
7 1/2
R 17 47 No
Jx17
94H/V
 * Tires 235/40 R 18
fulfilled!
235/40
CAUTION:
R 18 8 J X 18 44 No
95Y * 8 J x 18 wheels only
under the following
conditions:
 Either a sport
suspension with
approximately
15 mm lowering
and spring
travel limiter or
spring travel
limiters with
Votex part
number
000.071.501/A
must be
205/55 installed on
6 1/2 front and rear
Winter Tires R 16 42 Yes
Jx16 axle. In both
91H/V cases, the
camber on the
front axle must
be set to -1°45'.
 In addition,
wheel housing
enlargements
(FLAPS) must
be installed,
except in
Germany - there,
the
discontinuation
of wheel
housing
enlargements
(FLAPS) is
possible with T
U V certificate
no. 2174/05.
Refer to
ADDITIONAL
205/50 WHEEL
R 17 6 J X 17 45 Yes HOUSING
93H/V ENLARGEMENT,
FLAPS .
 A 235/40 R 18 95 W
of a 235/40 R 18 95Y
the Federal Motor
Vehicle Office.
2.0L 105 kW 205/55
Standard 6 1/2
TDI Diesel R 16 42 Yes
Tires Jx16
engine 91H
205/55
Modification R 16 7 J X 16 45 No
91H/V
205/50
R 17 6 J X 17 45 Yes
93H/V
235/45
7 1/2
R 17 47 No
Jx17
94H/V
235/40
R 18 8 J X 18 44 No
95Y*
205/55
6 1/2
Jx16
91H/V
205/50
R 17 6 J X 17 45 Yes
93H/V
205/55
1.4L 110 kW Standard 6 1/2
R 16 42 Yes
EcoFuel Tires Jx16
91V
205/55
91V
205/50
R 17 6 J X 17 45 Yes
93V
235/45
7 1/2
R 17 47 No
Jx17
94V
205/55
6 1/2
Jx16
91H/V
205/50
R 17 6 J X 17 45 Yes
93H/V
1.8L 118 kW
205/55
2.0L 110 kW Standard 6 1/2
R 16 42 Yes
Gasoline Tires Jx16
91V
engine
2.0L 120 kW
215/55
TDI 2.0L 125 6 1/2
Modification R 16 42 No
kW TDI Jx16
93V
Diesel engines
205/55
R 16
7 J X 16 45 No
91V
215/55
R 16 7 J X 16 45 No
93V
235/45
7 1/2
R 17 47 No
Jx17
94V
235/40
R 18 8 J X 18 44 No
95Y*
205/55
6 1/2
Jx16
91H/V
205/50
R 17 6 J X 17 45 Yes
93H/V
2.0L 147 kW 205/55
Standard 6 1/2
Gasoline R 16 42 Yes
Tires Jx16
engine 91V
215/55
6 1/2
Jx16
93W
205/55
R 16 7 J X 16 45 No
91V
215/55
R 16 7 J X 16 45 No
93W
235/45
7 1/2
R 17 47 No
Jx17
94W
235/40
R 18 8 J X 18 44 No
95Y*
205/55
6 1/2
Jx16
91H/V
205/50
R 17 6 J X 17 45 Yes
93H/V
3.2L 184 kW 235/45
Standard 7 1/2
Gasoline R 17 47 No
Tires Jx17
engine 94W
235/40
R 18
95Y*
205/50
Winter Tires R 17 6 J X 17 45 Yes
93H/V
Overview
Type approval number: e1*2001/116*0307*19

1.6L 75 kW;
1.4L 90 kW Standard 205/55 R 6 1/2
42 Yes
Gasoline Tires 16 91H Jx16
engines;
2.0L 81 kW
TDI; 2.0L 100 Winter tires, refer to
215/55 R 6 1/2 
kW TDI 2.0L Modification 42 No WINTER TIRES
16 93H/V Jx16
103 kW TDI
Diesel engines
SNOW CHAINS
205/55 R Volkswagen recommended
7 J X 16 45 No
16 91H/V tire brands:
PASSAT SEDAN,
FROM MY 2006
7 J X 16 45 No PASSAT SEDAN,
16 93H/V
FROM MY 2006
PASSAT SEDAN,
FROM MY 2006
235/45 R 7 1/2
47 No
17 94H/V Jx17
 * Tires 235/40 R 18
fulfilled! It is possible
wheels only under the

following conditions:
CAUTION:
235/40 R under the following
8 J X 18 44 No
18 95Y* conditions:
 Either a sport
suspension with
approximately
15 mm lowering
and spring
travel limiter or
spring travel
limiters with
Votex part
number
000.071.501/A
must be
installed on
front and rear
axle. In both
cases, the
205/55 R 6 1/2 camber on the
Winter Tires 42 Yes front axle must
16 91H/V Jx16 be set to -1°45'.
 In addition,
wheel housing
enlargements
(FLAPS) must
be installed,
except in
Germany - there,
the
discontinuation
of wheel
housing
enlargements
(FLAPS) is
possible with T
U V certificate
no. 2174/05.
205/50 R Refer to
6 J X 17 45 Yes ADDITIONAL
17 93H/V
WHEEL
HOUSING
ENLARGEMENT,
FLAPS .
 A 235/40 R 18 95 W
of a 235/40 R 18 95Y
the Federal Motor
Vehicle Office.
2.0L 105 kW
Standard 205/55 R 6 1/2
TDI Diesel 42 Yes
Tires 16 91H Jx16
engine
205/55 R
16 91H/V
205/50 R
6 J X 17 45 Yes
17 93H/V
235/45 R 7 1/2
47 No
17 94H/V Jx17
235/40 R
18 95Y*
Tires
235/40 R
18 95Y 8 J X 18 44 No
on rims 8
J x 18 ET
44 are
permitted.
205/55 R 6 1/2
Winter Tires 42 Yes
16 91H/V Jx16
205/50 R
6 J X 17 45 Yes
17 93H/V
1.4L 110 kW Standard 205/55 R 6 1/2
42 Yes
EcoFuel Tires 16 91H Jx16
205/55 R
16 91H
205/50 R
6 J X 17 45 Yes
17 93H
235/45 R 7 1/2
47 No
17 94H/V Jx17
205/55 R 6 1/2
Winter Tires 42 Yes
16 91H/V Jx16
205/50 R
6 J X 17 45 Yes
17 93H/V
1.8L 118 kW Standard 205/55 R 6 1/2

2.0L 110 kW Tires 42 Yes
16 91V Jx16
engine
2.0L 125 kW
215/55 R 6 1/2
TDI; Diesel Modification 42 No
16 93V Jx16
engines
205/55 R
7 J X 16 45 No
16 91V
215/55 R
7 J X 16 45 No
16 93V
235/45 R 7 1/2
47 No
17 94V Jx17
235/40 R
8 J X 18 44 No
18 95Y *
205/55 R 6 1/2
Winter Tires 42 Yes
16 91H/V Jx16
205/50 R
6 J X 17 45 Yes
17 93H/V
2.0L 147 kW
Standard 205/55 R 6 1/2
Gasoline 42 Yes
Tires 16 91V Jx16
engine
215/55 R 61/2
Modification 42 No
16 93W Jx16
205/55 R
7 J X 16 45 No
16 91V
215/55 R
7 J X 16 45 No
16 93W
235/45 R 7 1/2
47 No
17 94W Jx17
235/40 R
8 J X 18 44 No
18 95Y *
205/55 R 6 1/2
Winter Tires 42 Yes
16 91H/V Jx16
205/50 R
6 J X 17 45 Yes
17 93H/V
3.2L 184 kW
Standard 235/45 R 7 1/2
Gasoline 47 No
Tires 17 94W Jx17
engine
235/40 R
18 95Y *
205/50 R
Winter Tires 6 J X 17 45 Yes
17 93H/V
PASSAT SEDAN, TYPE 3C, MY 2010 THROUGH MY 2011

Overview
Model/Engine Disk Offset (ET) in Snow

Performance Wheel mm Chains
1.6L 75 kW;
1.4L 90 kW Standard 205/55 R
6 1/2 Jx16 42 Yes
Gasoline Tires 16 91H
engines;
General information
about:
2.0L 81 kW
TDI; 2.0L 100 215/55 R Winter tires, refer

kW TDI 2.0L Modification 16 6 1/2 Jx16 42 No to WINTER

103 kW TDI 93H/V TIRES
Diesel engines  Snow chains,
refer to SNOW
CHAINS
205/55 R Volkswagen
16 7 J X 16 45 No recommended tire
91H/V brands:
 Summer tires,
refer to PASSAT
SEDAN, FROM
MY 2006
215/55 R  All-season tires,
16 7 J X 16 45 No refer to PASSAT
93H/V SEDAN, FROM
MY 2006
 Winter tires, refer
to PASSAT
SEDAN, FROM
MY 2006
235/45 R
17 7 1/2 Jx17 47 No
94H/V
* 235/40 R 18 95W tires
on 8 J x 18 ET 44 rims
are only permitted if the
conditions are met.
CAUTION:
under the following
conditions:
 Either a sport
suspension with
approximately
15 mm lowering
and spring
travel limiter or
spring travel
limiters with
Votex part
number
000.071.501/A
must be
installed on
front and rear
axle. In both
cases, the
235/40 R camber on the
front axle must
18 95W 8 J X 18 44 No be set to -1°45'.
*
 In addition,
wheel housing
enlargements
(FLAPS) must
be installed,
except in
Germany - there,
the
discontinuation
of wheel
housing
enlargements
(FLAPS) is
possible with T
U V certificate
no. 2174/05.
Refer to
ADDITIONAL
WHEEL
HOUSING
ENLARGEMENT,
FLAPS .
205/55 R
Winter Tires 16 6 1/2 Jx16 42 Yes
91H/V
205/50 R
17 6 J X 17 45 Yes
93H/V
2.0L 105 kW
Standard 205/55 R
TDI Diesel 6 1/2 Jx16 42 Yes
Tires 16 91H
engine
205/55 R
Modification 16 7 J X 16 45 No
91H/V
205/50 R
17 6 J X 17 45 Yes
93H/V
235/45 R
17 7 1/2 Jx17 47 No
94H/V
* 235/40 R 18 95W tires
conditions are met.
CAUTION:
under the following
conditions:
 Either a sport
suspension with
approximately
15 mm lowering
and spring
travel limiter or
235/40 R spring travel
18 95W 8 J X 18 44 No limiters with
* Votex part
number
000.071.501/A
must be
installed on
front and rear
axle. In both
cases, the
camber on the
front axle must
be set to -1°45'.
 In addition,
wheel housing
enlargements
(FLAPS) must
be installed,
except in
Germany - there,
the
discontinuation
of wheel
housing
enlargements
(FLAPS) is
possible with T
U V certificate
no. 2174/05.
Refer to
ADDITIONAL
WHEEL
HOUSING
ENLARGEMENT,
FLAPS .
205/55 R
91H/V
205/50 R
17 6 J X 17 45 Yes
93H/V
6 1/2 Jx16 42 Yes
EcoFuel Tires 16 91H
205/55 R
Modification 7 J X 16. 45 No
16 91H
205/50 R
6 J X 17 45 Yes
17 93H
235/45 R
17 7 1/2 Jx17 47 No
94H/V
205/55 R
91H/V
205/50 R
17 6 J X 17 45 Yes
93H/V
1.8L 118 kW
6 1/2 Jx16 42 Yes
Gasoline Tires 16 91V
engine
2.0L 125 kW
215/55 R
TDI; Diesel Modification 6 1/2 Jx16 42 No
16 93V
engines
205/55 R
7 J X 16 45 No
16 91V
215/55 R
7 J X 16 45 No
16 93V
235/45 R
17 94V 7 1/2 Jx17 47 No

* 235/40 R 18 95W tires
conditions are met.
CAUTION:
under the following
conditions:
 Either a sport
suspension with
approximately
15 mm lowering
and spring
travel limiter or
spring travel
limiters with
Votex part
number
000.071.501/A
must be
235/40 R installed on
front and rear
18 95W 8 J X 18 44 No axle. In both
* cases, the
camber on the
front axle must
be set to -1°45'.
 In addition,
wheel housing
enlargements
(FLAPS) must
be installed,
except in
Germany - there,
the
discontinuation
of wheel
housing
enlargements
(FLAPS) is
possible with T
U V certificate
no. 2174/05.
Refer to
ADDITIONAL
WHEEL
HOUSING
ENLARGEMENT,
FLAPS .
205/55 R
91H/V
205/50 R
17 6 J X 17 45 Yes
93H/V
2.0L 147 kW
Standard 205/55 R
Gasoline 6 1/2 Jx16 42 Yes
Tires 16 91V
engine
215/55 R
Modification 6 1/2 Jx16 42 No
16 93W
205/55 R
7 J X 16 45 No
16 91V
215/55 R
7 J X 16 45 No
16 93W
235/45 R
7 1/2 Jx17 47 No
17 94W
* 235/40 R 18 95W tires
conditions are met.
CAUTION:
under the following
conditions:
 Either a sport
suspension with
235/40 R approximately
18 95W 8 J X 18 44 No 15 mm lowering
* and spring
travel limiter or
spring travel
limiters with
Votex part
number
000.071.501/A
must be
installed on
front and rear
axle. In both
cases, the
camber on the
front axle must
be set to -1°45'.
 In addition,
wheel housing
enlargements
(FLAPS) must
be installed,
except in
Germany - there,
the
discontinuation
of wheel
housing
enlargements
(FLAPS) is
possible with T
U V certificate
no. 2174/05.
Refer to
ADDITIONAL
WHEEL
HOUSING
ENLARGEMENT,
FLAPS .
205/55 R
91H/V
205/50 R
17 6 J X 17 45 Yes
93H/V
3.2L 184 kW
Standard 235/45 R
Gasoline 7 1/2 Jx17 47 No
Tires 17 94W
engine
* 235/40 R 18 95W tires
conditions are met.
CAUTION:
under the following
conditions:
 Either a sport
suspension with
approximately
15 mm lowering
and spring
travel limiter or
spring travel
limiters with
Votex part
number
000.071.501/A
must be
installed on
front and rear
axle. In both
cases, the
camber on the
front axle must
be set to -1°45'.
235/40 R
18 95W  In addition,
* 235/40 wheel housing
enlargements
R 18 (FLAPS) must
95W be installed,
Modification tires on 8 8 J X 18 44 No except in
J x 18 Germany - there,
ET 44 the
rims are discontinuation
only of wheel
housing
permitted enlargements
(FLAPS) is
possible with T
U V certificate
no. 2174/05.
Refer to
ADDITIONAL
WHEEL
HOUSING
ENLARGEMENT,
FLAPS .
205/50 R
93H/V
WHEEL ASSIGNMENT, PASSAT SEDAN, TYPE 3C, MY 2006 THROUGH MY 2011
Explanatory notes of indications on disc wheels, refer to DISC WHEELS, IDENTIFICATION .
Wheel bolt tightening specifications, refer to TIGHTENING SPECIFICATION FOR MOUNTING

WHEELS .
Pitch
circle 112 mm
diameter:
Number
of wheel
bolt 5
holes:
6 1/2 J X 16
CAUTION: Pay attention to wheels/tires assignments for respective engine versions

which are listed in the overview chart. Refer to Overview.
3C0 601 027 H - Wheel/tire combination. Refer to 6 1/2 J X 16 in the chart under PASSAT SEDAN, TYPE
3C, MY 2006.
Fig. 1: 1J0 601 027 - Wheel

Dimension: 6 1 /2 J x 16
Offset in
42
mm:
Wheel load
650
in kg:
3C0 601,027 AA - Wheel/tire combination. Refer to 6 1/2 J X 16 in the chart under PASSAT SEDAN, TYPE
3C, MY 2006.
Fig. 2: 1J0 601 027 - Wheel

Offset in
42
mm:
Wheel load
650
in kg:
Winter Tire
3C0 601 025 F - Wheel/tire combination. Refer to 6 1/2 J X 16 in the chart under PASSAT SEDAN, TYPE
3C, MY 2006.
Fig. 3: 3C0 601 025 F/M - Wheel

Offset in
42
mm:
Wheel load
650
in kg:
7 J X 16

3C0 601 025, 3C0 601 025 AD - Wheel/tire combination. Refer to 7 J X 16 in the chart under PASSAT
SEDAN, TYPE 3C, MY 2006.
Fig. 4: 3C0 601 025 - Wheel

Dimension: 7 J x 16
Offset in
45
mm:
Wheel load
650
in kg:
3C0 601,025 A - Wheel/tire combination. Refer to 7 J X 16 in the chart under PASSAT SEDAN, TYPE 3C,
MY 2006.
Fig. 5: 3C0 601 025 A - Wheel

Dimension: 7 J x 16
Offset in
45
mm:
Wheel load
650
in kg:
3C0 601 025 AE - Wheel/tire combination. Refer to 7 J X 16 in the chart under PASSAT SEDAN, TYPE 3C,
MY 2006.
Fig. 6: 3C0 601 025 AE - Wheel

Dimension: 7 J x 16
Offset in
45
mm:
Wheel load
650
in kg:
3C0 601 025 AF - Wheel/tire combination. Refer to 7 J X 16 in the chart under PASSAT SEDAN, TYPE 3C,
MY 2006.
Fig. 7: 3C0 601 025 AF - Wheel

Dimension: 7 J x 16
Offset in
45
mm:
Wheel load
650
in kg:
3C0 601,025 B - Wheel/tire combination. Refer to 7 J X 16 in the chart under PASSAT SEDAN, TYPE 3C,
MY 2006.
Fig. 8: 3C0 601,025 B - Wheel

Dimension: 7 J x 16
Offset in
45
mm:
Wheel load
650
in kg:
3C0 601 025 C - Wheel/tire combination. Refer to 7 J X 16 in the chart under PASSAT SEDAN, TYPE 3C,
MY 2006.
Fig. 9: 3C0 601 025 C - Wheel

Dimension: 7 J x 16 EH2, refer to DISC WHEELS, IDENTIFICATION .

Offset in
45
mm:
Wheel load
650
in kg:
6 J X 17

Winter Tire
3C0 601 025 M - Wheel/tire combination. Refer to 6 J X 17 in the chart under PASSAT SEDAN, TYPE 3C,
MY 2006.
Fig. 10: 3C0 601 025 F/M - Wheel

Dimension: 6 J x 17
Offset in
45
mm:
Wheel load
650
in kg:
7 1/2 J X 17

3C0 601 025 AQ - Wheel/tire combination. Refer to 7 1/2 J X 17 in the chart under PASSAT SEDAN, TYPE
3C, MY 2006.
Fig. 11: 1K0 601 025 AE & 3C0 601 025 S - Wheel
Offset in
47
mm:
Wheel load
650
in kg:
3C0 601 025 BB - Wheel/tire combination. Refer to 7 1/2 J X 17 in the chart under PASSAT SEDAN, TYPE
3C, MY 2006.
Fig. 12: 3C0 601 025 BB - Wheel/tire Combination

Offset in
47
mm:
Wheel load
650
in kg:
3C0 601 025 D - Wheel/tire combination. Refer to 7 1/2 J X 17 in the chart under PASSAT SEDAN, TYPE
3C, MY 2006.
Fig. 13: 1K0 601 025 AD & 3C0 601 025 D - Wheel
Offset in
47
mm:
Wheel load
650
in kg:
3C0 601 025 E - Wheel/tire combination. Refer to 7 1/2 J X 17 in the chart under PASSAT SEDAN, TYPE
3C, MY 2006.
Fig. 14: 3C0 601 025 E - Wheel

Offset in
47
mm:
Wheel load
650
in kg:
3C0 601 025 G - Wheel/tire combination. Refer to 7 1/2 J X 17 in the chart under PASSAT SEDAN, TYPE
3C, MY 2006.
Fig. 15: 3C0 601 025 G - Wheel

Offset in
47
mm:
Wheel load
650
in kg:
3C0 601,025 J - Wheel/tire combination. Refer to 7 1/2 J X 17 in the chart under PASSAT SEDAN, TYPE 3C,
MY 2006.
Fig. 16: 3C0 601 025 J - Wheel

Offset in
47
mm:
Wheel load
650
in kg:
3C0 601 025 K - Wheel/tire combination. Refer to 7 1/2 J X 17 in the chart under PASSAT SEDAN, TYPE
3C, MY 2006.
Fig. 17: 3C0 601 025 K - Wheel

Offset in
47
mm:
Wheel load
650
in kg:
3C0 601 025 R - Wheel/tire combination. Refer to 7 1/2 J X 17 in the chart under PASSAT SEDAN, TYPE
3C, MY 2006.
Fig. 18: 1K0 601 025 AF/AJ & 3C0 601 025 R - Wheel
Offset in
47
mm:
Wheel load
650
in kg:
3C0 601 025 S - Wheel/tire combination. Refer to 7 1/2 J X 17 in the chart under PASSAT SEDAN, TYPE
3C, MY 2006.
Fig. 19: 1K0 601 025 AE & 3C0 601 025 S - Wheel
Offset in
47
mm:
Wheel load
650
in kg:
3C0 601 025 AJ - Wheel/tire combination. Refer to 7 1/2 J X 17 in the chart under PASSAT SEDAN, TYPE
3C, MY 2006.
Fig. 20: 3C0 601 025 AJ - Wheel/Tire Combination

Offset in
47
mm:
Wheel load
650
in kg:
8 J X 18

CAUTION: It is possible to mount 8 J x 18 wheels only under the following conditions:
 Either a sport suspension with approximately 15 mm lowering and

spring travel limiter or spring travel limiters with Votex part number
000.071.501/A must be installed on front and rear axle. In both cases,
the camber on the front axle must be set to -1°45'.
 In addition, wheel housing enlargements (FLAPS) must be installed,
except in Germany - there, the discontinuation of wheel housing
enlargements (FLAPS) is possible with T U V certificate no. 2174/05.
Refer to ADDITIONAL WHEEL HOUSING ENLARGEMENT, FLAPS .
3C0 601 025 AA - Wheel/tire combination. Refer to 8 J X 18 in the chart under PASSAT SEDAN, TYPE 3C,
MY 2006.
Fig. 21: 3C0 601 025 AA - Wheel

Dimension: 8 J x 18
Offset in
44
mm:
Wheel load
650
in kg:
3C0 601 025 AB, 3C0 601 025 AP - Wheel/tire combination. Refer to 8 J X 18 in the chart under PASSAT
Fig. 22: 3C0 601 025 AB - Wheel

Dimension: 8 J x 18
Offset in
44
mm:
Wheel load
650
in kg:
3C0 601 025 AC- Wheel/tire combination. Refer to 8 J X 18 in the chart under PASSAT SEDAN, TYPE 3C,
MY 2006.
Fig. 23: 3C0 601 025 AC- Wheel

Dimension: 8 J x 18
Offset in
44
mm:
Wheel load
650
in kg:
3C0 601 025 T, 3C0 601 025 AN - Tire/wheel combination. Refer to 8 J X 18 in the chart under PASSAT
Fig. 24: 3C0 601 025 T - Wheel

Dimension: 8 J x 18
Offset in
44
mm:
Wheel load
650
in kg:
3C0 601 025 AG - Wheel/tire combination. Refer to 8 J X 18 in the chart under PASSAT SEDAN, TYPE 3C,
MY 2006.
Fig. 25: 3C0 601 025 AG - Wheel/Tire Combination

Dimension: 8 J x 18
Offset in
44
mm:
Wheel load
650
in kg:
3C0 601 025 BA - Wheel/tire combination. Refer to 8 J X 18 in the chart under PASSAT SEDAN, TYPE 3C,
MY 2006.
Fig. 26: 3C0 601 025 AA - Wheel

Dimension: 8 J x 18
Offset in
44
mm:
Wheel load
650
in kg:
General Information



PASSAT SEDAN BLUEMOTION, TYPE 3C, MY 2008 THROUGH MY 2009
Overview

1.9L 77 kW Winter tires, refer to
Standard 205/55 R 6 1/2 
TDI; Diesel 42 Yes WINTER TIRES
Tires 16 91H Jx16
engine
SNOW CHAINS
205/55 R
tire brands:
91H/V

PASSAT SEDAN,
Winter Tires 42 Yes BLUE MOTION,
FROM MY 2008
16 6 1/2
91H/V Jx16 BLUE MOTION,

FROM MY 2008
PASSAT SEDAN,
BLUE MOTION,
FROM MY 2008
2.0L 81 kW
Standard 205/55 R 6 1/2
TDI Diesel 42 Yes
Tires 16 91H Jx16
engine
205/55 R
91H/V
205/50 R
17 6 J X 17 45 Yes
93H/V
235/45 R
7 1/2
17 47 No
Jx17
94H/V
 * Tires 235/40 R 18
fulfilled!
CAUTION:
235/40 R under the following
18 95Y * conditions:
Tires
235/40 R  Either a sport
18 95Y suspension with
8 J X 18 44 No approximately
on rims 8 15 mm lowering
J x 18 and spring
ET 44 travel limiter or
are spring travel
permitted limiters with
Votex part
number
000.071.501/A
must be
installed on
front and rear
axle. In both
cases, the
camber on the
front axle must
be set to -1°45'.
 In addition,
wheel housing
enlargements
205/55 R (FLAPS) must
6 1/2 be installed,
Jx16 except in
91H/V
Germany - there,
the
discontinuation
of wheel
housing
enlargements
(FLAPS) is
possible with T
U V certificate
no. 2174/05.
Refer to
ADDITIONAL
WHEEL
HOUSING
ENLARGEMENT,
205/50 R FLAPS .
17 6 J X 17 45 Yes
93H/V  A 235/40 R 18 95 W
of a 235/40 R 18 95Y
the Federal Motor
Vehicle Office.
PASSAT SEDAN BLUEMOTION, TYPE 3C, MY 10 THROUGH MY 11
Overview
Model/Engine Tire Disk Offset (ET) in Snow

Tires Comments
Performance Size Wheel mm Chains
General information

to WINTER
1.4L 90 kW 205/55
Standard TIRES
Gasoline R 16 6 1/2 Jx16 42 Yes
Tires  Snow chains,
engine 91H
refer to SNOW
CHAINS
1.6L77 kW
TDI; 2.0L 81 205/55 Volkswagen
kW TDI; 2.0L Modification R 16 7 J X 16 45 No recommended tire
103 kW TDI 91H/V brands:
Diesel engine
 Summer tires,
refer to PASSAT
SEDAN, BLUE
MOTION,
FROM MY 2008
 All-season tires,
205/50 refer to PASSAT
R 17 6 J X 17 45 Yes SEDAN, BLUE
93H/V MOTION,
FROM MY 2008
to PASSAT
SEDAN, BLUE
MOTION,
FROM MY 2008
235/45
7 1/2 J X
R 17 47 No
17
94H/V
 * Tires 235/40 R
18 95Y on rims 8
J x 18 ET 44 are
permitted only if
the conditions
listed are
fulfilled!
235/40
R 18 8 J X 18 44 No
95W* CAUTION:
under the following
conditions:
 Either a sport
suspension with
15 mm lowering
and spring
travel limiter or
spring travel
limiters with
Votex part
number
000.071.501/A
205/55 must be
Winter Tires R 16 6 1/2 Jx16 42 Yes installed on
91H/V front and rear
axle. In both
cases, the
camber on the
front axle must
be set to -1°45'.
 In addition,
wheel housing
enlargements
(FLAPS) must
be installed,
except in
Germany - there,
the
discontinuation
of wheel
housing
205/50 enlargements
R 17 6 J X 17 45 Yes (FLAPS) is
93H/V possible with T
U V certificate
no. 2174/05.
Refer to
ADDITIONAL
WHEEL
HOUSING
ENLARGEMENT,
FLAPS .
PASSAT SEDAN BLUEMOTION WHEEL ALLOCATION, TYPE 3C, MY 2008 THROUGH MY 2011
Explanatory notes of indications on disc wheels, refer to DISC WHEELS, IDENTIFICATION .
Wheel bolt tightening specifications, refer to TIGHTENING SPECIFICATION FOR MOUNTING

WHEELS .
Pitch
circle 112 mm
diameter:
Number
of wheel
5
bolt
holes:
6 1/2 J X 16

which are listed in the overview chart. Refer to PASSAT SEDAN
BLUEMOTION, TYPE 3C, MY 2008 THROUGH MY 2009.
3C0 601 027 H - Wheel/tire combination. Refer to 6 1/2 J x 16 in the chart under PASSAT SEDAN
Fig. 27: 1J0 601 027 - Wheel

Offset in
42
mm:
Wheel load
650
in kg:
3C0 601,027 AA - Wheel/tire combination. Refer to 6 1/2 J x 16 in the chart under PASSAT SEDAN
Fig. 28: 1J0 601 027 - Wheel

Offset in
42
mm:
Wheel load
650
in kg:
Winter Tire
3C0 601 025 F - Wheel/tire combination. Refer to 6 1/2 J x 16 in the chart under PASSAT SEDAN
Fig. 29: 3C0 601 025 F/M - Wheel

Offset in
42
mm:
Wheel load
650
in kg:
7 J X 16

BLUEMOTION, TYPE 3C, MY 2008 THROUGH MY 2009 => Overview.
3C0 601 025, 3C0 601 025 AD - Wheel/tire combination. Refer to 7 J X 16 in the chart under PASSAT
SEDAN BLUEMOTION, TYPE 3C, MY 2008 THROUGH MY 2009.
Fig. 30: 3C0 601 025 - Wheel

Dimension: 7 J x 16
Offset in
45
mm:
Wheel load
650
in kg:
3C0 601,025 A - Wheel/tire combination. Refer to 7 J X 16 in the chart under PASSAT SEDAN
Fig. 31: 3C0 601 025 A - Wheel

Dimension: 7 J x 16
Offset in
45
mm:
Wheel load
650
in kg:
3C0 601,025 B - Wheel/tire combination. Refer to 7 J X 16 in the chart under PASSAT SEDAN
Fig. 32: 3C0 601 025 B - Wheel

Dimension: 7 J x 16
Offset in
45
mm:
Wheel load
650
in kg:
3C0 601 025 C - Wheel/tire combination. Refer to 7 J X 16 in the chart under PASSAT SEDAN
Fig. 33: 3C0 601 025 C - Wheel

Dimension: 7 J x 16 EH2, refer to DISC WHEELS, IDENTIFICATION .

Offset in
45
mm:
Wheel load
650
in kg:
6 J X 17

Winter Tire
3C0 601 025 M - Wheel/tire combination. Refer to 6 J X 17 in the chart under PASSAT SEDAN
Fig. 34: 3C0 601 025 F/M - Wheel

Dimension: 6 J x 17
Offset in
45
mm:
Wheel load
650
in kg:
7 1/2 J X 17

3C0 601 025 AQ - Wheel/tire combination. Refer to 7 1/2 J X 17 in the chart under PASSAT SEDAN
Fig. 35: 1K0 601 025 AE & 3C0 601 025 S - Wheel
Offset in
47
mm:
Wheel load
650
in kg:
3C0 601 025 BB - Wheel/tire combination. Refer to 7 1/2 J X 17 in the chart under PASSAT SEDAN
Fig. 36: 3C0 601 025 BB - Wheel/tire Combination

Offset in
47
mm:
Wheel load
650
in kg:
3C0 601 025 D - Wheel/tire combination. Refer to 7 1/2 J X 17 in the chart under PASSAT SEDAN
Fig. 37: 1K0 601 025 AD & 3C0 601 025 D - Wheel
Offset in
47
mm:
Wheel load
650
in kg:
3C0 601 025 E - Wheel/tire combination. Refer to 7 1/2 J X 17 in the chart under PASSAT SEDAN
Fig. 38: 3C0 601 025 E - Wheel

Offset in
47
mm:
Wheel load
650
in kg:
3C0 601 025 G - Wheel/tire combination. Refer to 7 1/2 J X 17 in the chart under PASSAT SEDAN
Fig. 39: 3C0 601 025 G - Wheel

Offset in
47
mm:
Wheel load
650
in kg:
3C0 601,025 J - Wheel/tire combination. Refer to 7 1/2 J X 17 in the chart under PASSAT SEDAN
Fig. 40: 3C0 601 025 J - Wheel

Offset in
47
mm:
Wheel load
650
in kg:
3C0 601 025 K - Wheel/tire combination. Refer to 7 1/2 J X 17 in the chart under PASSAT SEDAN
Fig. 41: 3C0 601 025 K - Wheel

Offset in
47
mm:
Wheel load
650
in kg:
3C0 601 025 R - Wheel/tire combination. Refer to 7 1/2 J X 17 in the chart under PASSAT SEDAN
Fig. 42: 1K0 601 025 AF/AJ & 3C0 601 025 R - Wheel
Offset in
47
mm:
Wheel load
650
in kg:
3C0 601 025 S - Wheel/tire combination. Refer to 7 1/2 J X 17 in the chart under PASSAT SEDAN
Fig. 43: 1K0 601 025 AE & 3C0 601 025 S - Wheel
Offset in
47
mm:
Wheel load
650
in kg:
3C0 601 025 AJ - Wheel/tire combination. Refer to 7 1/2 J X 17 in the chart under PASSAT SEDAN
Fig. 44: 3C0 601 025 AJ - Wheel/Tire Combination

Offset in
47
mm:
Wheel load
650
in kg:
8 J X 18

CAUTION: It is possible to mount 8 J x 18 wheels only under the following conditions:
 Either a sport suspension with approximately 15 mm lowering and

spring travel limiter or spring travel limiters with Votex part number
000.071.501/A must be installed on front and rear axle. In both cases,
the camber on the front axle must be set to -1°45'.
 In addition, wheel housing enlargements (FLAPS) must be installed,
except in Germany - there, the discontinuation of wheel housing
enlargements (FLAPS) is possible with T U V certificate no. 2174/05.
Refer to ADDITIONAL WHEEL HOUSING ENLARGEMENT, FLAPS .
3C0 601 025 AA - Wheel/tire combination. Refer to 8 J X 18 in the chart under PASSAT SEDAN
Fig. 45: 3C0 601 025 AA - Wheel

Dimension: 8 J x 18
Offset in
44
mm:
Wheel load
650
in kg:
3C0 601 025 AB, 3C0 601 025 AP - Wheel/tire combination. Refer to 8 J X 18 in the chart under PASSAT
Fig. 46: 3C0 601 025 AB - Wheel

Dimension: 8 J x 18
Offset in
44
mm:
Wheel load
650
in kg:
3C0 601 025 AC- Wheel/tire combination. Refer to 8 J X 18 in the chart under PASSAT SEDAN
Fig. 47: 3C0 601 025 AC- Wheel

Dimension: 8 J x 18
Offset in
44
mm:
Wheel load
650
in kg:
3C0 601 025 T, 3C0 601 025 AN - Tire/wheel combination. Refer to 8 J X 18 in the chart under PASSAT
Fig. 48: 3C0 601 025 T - Wheel

Dimension: 8 J x 18
Offset in
44
mm:
Wheel load
650
in kg:
3C0 601 025 AG - Wheel/tire combination. Refer to 8 J X 18 in the chart under PASSAT SEDAN
Fig. 49: 3C0 601 025 AG - Wheel/Tire Combination

Dimension: 8 J x 18
Offset in
44
mm:
Wheel load
650
in kg:
3C0 601 025 BA - Wheel/tire combination. Refer to 8 J X 18 in the chart under PASSAT SEDAN
Fig. 50: 3C0 601 025 AA - Wheel

Dimension: 8 J x 18
Offset in
44
mm:
Wheel load
650
in kg:
General Information



PASSAT WAGON, TYPE 3C, MY 2006
Type Approval Number: e1*2001/116*0307*00 to e1*2001/116*0307*09
Overview
Offset
Model/Engine Snow
Tires Size Disk Wheel (ET) in Comments
Performance Chains
mm
1.6L 75 kW;
205/55
1.6L 85 kW Standard
R 16 6 1/2 J X 16 42 Yes
Gasoline Tires
91H
engines;
1.9L 77 kW
TDI; 2.0L 88 215/55  Winter tires, refer to
kW TDI; 2.0L Modification R 16 6 1/2 J X 16 42 No WINTER TIRES
90 kW TDI 93H
Diesel engines  Snow chains, refer to
SNOW CHAINS
205/55
R 16 7 J X 16 45 No
tire brands:
91H
PASSAT WAGON,
FROM MY 2006
 All-season tires, refer to
215/55
PASSAT WAGON,
R 16 7 J X 16 45 No
FROM MY 2006
93H
PASSAT WAGON,
FROM MY 2006
235/45
R 17 7 1/2 J X 17 47 No
94V
 * Tires 235/40 R 18
fulfilled!
CAUTION:
235/40 8 J x 18 wheels only
R 18 8 J X 18 44 No under the following
95Y* conditions:
 Either a sport
suspension with
approximately
15 mm lowering
and spring
travel limiter or
spring travel
limiters with
Votex part
number
000.071.501/A
must be
installed on
front and rear
axle. In both
cases, the
205/55 camber on the
Winter Tires R 16 6 1/2 J X 16 42 Yes front axle must
91H/V be set to -1°45'.
 In addition,
wheel housing
enlargements
(FLAPS) must
be installed,
except in
Germany - there,
the
discontinuation
of wheel
housing
enlargements
(FLAPS) is
possible with T
U V certificate
no. 2174/05.
Refer to
ADDITIONAL
WHEEL
205/50 HOUSING
R 17 6 J X 17 45 Yes ENLARGEMENT,
93H/V FLAPS .
 A 235/40 R 18 95 W
of a 235/40 R 18 95Y
the Federal Motor
Vehicle Office.
2.0L 110 kW 205/55
Standard
Gasoline R 16 6 1/2 J X 16 42 Yes
Tires
engine 91V
215/55
Modification R 16 6 1/2 J X 16 42 No
93V
205/55
7 J x 16, refer
R 16 45 No
to 7 J X 16
91V
215/55
R 16 7 J X 16 45 No
93V
235/45
R 17 7 1/2 J X 17 47 No
94V
235/40
R 18 8 J X 18 44 No
95Y*
205/55
Winter Tires R 16 6 1/2 J X 16 42 Yes
91H/V
205/50
R 17
6 J X 17 45 Yes
93H/V
2.0 L 100 kW
TDI 2.0 L 103
kW TDI 2.0 L 205/55
Standard
120 kW TDI R 16 6 1/2 J X 16 42 Yes If load index LI 94 is entered
Tires
2.0 L 125 kW 94V (205/55 R16 94V) in the
TDI Diesel vehicle documentation on
engines vehicles equipped with the
215/55 100/103/120/125 kW TDI
Modification R 16 6 1/2 J X 16 42 No engine, then winters tires with
93V load index LI 91 (205/55 R 16
205/55 91H) may be used. The
R 16 7 J X 16 45 No "Safety and confirmation
94V certificate must be submitted
215/55 to the administrative authority
R 16 7 J X 16 45 No (licensing agency)" together
93V with test report no. 1423/07.
235/45
R 17 7 1/2 J X 17 47 No
94V
235/40
R 18 8 J X 18 44 No
95Y*
205/55
91H/V
205/50
R 17 6 J X 17 45 Yes
93H/V
2.0L 147 kW 205/55
Standard
Gasoline R 16 6 1/2 J X 16 42 Yes
Tires
engine 91W
215/55
Modification R 16 6 1/2 J X 16 42 No
93W
215/55
R 16 7 J X 16 45 No
93W
235/45
R 17 7 1/2 J X 17 47 No
94W
235/40
R 18 8 J X 18 44 No
95Y*
205/55
91H/V
205/50
R 17 6 J X 17 45 Yes
93H/V
3.2L 184 kW 235/45
Standard
Gasoline R 17 7 1/2 J X 17 47 No
Tires
engine 94W
235/40
95Y*
205/50
93H/V
PASSAT WAGON, TYPE 3C, MY 2007 THROUGH MY 2008
approval number: e1*2001/116*0307*13. Refer to Type approval number:
e1*2001/116*0307*13 through e1*2001/116*0307*14.
Overview

Tires Comments
1.6L 75 kW;
205/55
1.6L 85 kW Standard 6 1/2 J X
R 16 42 Yes
Gasoline Tires 16
91H
engines;
1.9L 77 kW 215/55 Winter tires, refer to
6 1/2 J X 
TDI; Diesel Modification R 16 42 No WINTER TIRES
16
engines 93H/V
SNOW CHAINS
2.0L 110 kW 205/55

Gasoline R 16 7 J X 16 45 No
tire brands:
91H/V
4MOTION
PASSAT SEDAN,
2.0L 110 kW FROM MY 2006
Gasoline 215/55  All-season tires, refer to
engine with R 16 7 J X 16 45 No PASSAT SEDAN,
automatic 93H/V FROM MY 2006
transmission  Winter tires, refer to
PASSAT SEDAN,
FROM MY 2006
235/45
7 1/2 J X
R 17 47 No
17
94H/V
 * Tires 235/40 R 18
fulfilled!
CAUTION:
235/40 8 J x 18 wheels only
R 18 8 J X 18 44 No under the following
95Y* conditions:
 Either a sport
suspension with
approximately
15 mm lowering
and spring
travel limiter or
spring travel
limiters with
Votex part
number
000.071.501/A
must be
installed on
front and rear
axle. In both
205/55 cases, the
6 1/2 J X
Winter Tires R 16 42 Yes camber on the
16
91H/V front axle must
be set to -1°45'.
 In addition,
wheel housing
enlargements
(FLAPS) must
be installed,
except in
Germany - there,
the
discontinuation
of wheel
housing
enlargements
(FLAPS) is
possible with T
U V certificate
no. 2174/05.
Refer to
205/50 ADDITIONAL
R 17 6 J X 17 45 Yes WHEEL
93H/V HOUSING
ENLARGEMENT,
FLAPS .
 A 235/40 R 18 95 W
of a 235/40 R 18 95Y
the Federal Motor
Vehicle Office.
2.0L 110 kW
Gasoline 205/55
Standard 6 1/2 J X
engine with R 16 42 Yes
Tires 16
manual 91V
transmission
215/55
6 1/2 J X
16
93V
205/55
R 16 7 J X 16 45 No
91V
215/55
R 16 7 J X 16 45 No
93V
235/45
7 1/2 J X
R 17 47 No
17
94V
235/40
R 18 8 J X 18 44 No
95Y*
205/55
6 1/2 J X
16
91H/V
205/50
R 17 6 J X 17 45 Yes
93H/V
2.0L 100 kW 205/55
Standard 6 1/2 J X
TDI Diesel R 16 42 Yes
Tires 16
engine 94H
2.0L 103 kW 215/55 If load index LI 94 is entered
6 1/2 J X (205/55 R16 94V) in the
TDI Diesel Modification R 16 42 No
16 vehicle documentation on
engine 93H/V
205/55 vehicles equipped with the
R 16 7 J X 16 45 No 100/103 kW TDI engine, then
94H/V winters tires with load index
LI 91 (205/55 R 16 91H) may
215/55 be used. The "Safety and
R 16 7 J X 16 45 No confirmation certificate must
93H/V be submitted to the
235/45 administrative authority
7 1/2 J X
R 17 47 No (licensing agency)" together
17
94H/V with test report no. 1423/07.
235/40
R 18 8 J X 18 44 No
95Y*
205/55
6 1/2 J X
16
91H/V
205/50
R 17 6 J X 17 45 Yes
93H/V
2.0L 120 kW If load index LI 94 is entered
205/55
TDI 2.0L 125 Standard 6 1/2 J X (205/55 R16 94V) in the
R 16 42 Yes
kW TDI Tires 16 vehicle documentation on
94V
Diesel engines vehicles equipped with the
215/55 120/125 kW TDI engine, then
6 1/2 J X
Modification R 16 42 No winters tires with load index
16
93V LI 91 (205/55 R 16 91H) may
205/55 be used. The "Safety and
R 16 7 J X 16 45 No confirmation certificate must
94V be submitted to the
215/55 administrative authority
R 16 7 J X 16 45 No (licensing agency)" together
93V with test report no. 1423/07.
235/45 7 1/2 J X 47 No
R 17 17
94V
235/40
R 18 8 J X 18 44 No
95Y*
205/55
6 1/2 J X
16
91H/V
205/50
R 17 6 J X 17 45 Yes
93H/V
2.0L 147 kW 205/55
Standard 6 1/2 J X
Tires 16
engine 91W
215/55
6 1/2 J X
16
93W
215/55
R 16 7 J X 16. 45 No
93W
235/45
7 1/2 J X
R 17 47 No
17
94W
235/40
R 18 8 J X 18 44 No
95Y*
205/55
6 1/2 J X
16
91H/V
205/50
R 17 6 J X 17 45 Yes
93H/V
3.2L 184 kW 235/45
Standard 7 1/2 J X
Gasoline R 17 47 No
Tires 17
engine 94W
235/40
95Y*
205/50
93H/V
Type approval number: e1*2001/116*0307*13 through e1*2001/116*0307*14

Overview

Tires Comments
1.6L 75 kW;
1.6L 85 kW 205/55
Standard 6 1/2 J X
1.4L 90 kW R 16 42 Yes
Tires 16
Gasoline 91H
engines;
1.9L 77 kW
TDI; 2.0L 100 215/55 Winter tires, refer to
6 1/2 J X 
kW TDI; 2.0L Modification R 16 42 No WINTER TIRES
16
103 kW TDI; 93H/V
Diesel engines  Snow chains SNOW
CHAINS
2.0L 110 kW
205/55
Gasoline 7 J x 16 7 J Volkswagen recommended
R 16 45 No
engine X 16 tire brands:
91H/V
4MOTION
PASSAT SEDAN,
2.0L 110 kW FROM MY 2006
Gasoline 215/55  All-season tires, refer to
7 J x 16 7 J
engine with R 16 45 No PASSAT SEDAN,
X 16
automatic 93H/V FROM MY 2006
transmission  Winter tires, refer to
PASSAT SEDAN,
FROM MY 2006
235/45
7 1/2 J X
R 17 47 No
17
94H/V
 * Tires 235/40 R 18
fulfilled!
235/40
R 18 8 J X 18 44 No
95Y* CAUTION:
under the following
conditions:
 Either the
series-
production
suspension for
18" wheels (Pr.
no. front axle
G07; rear axle
1JK) - see
service
booklet/data
205/55 sheet - or spring
6 1/2 J X
Winter Tires R 16 42 Yes travel limiters
16
91H/V with Votex part
number
000.071.501/A
must be
installed on the
front and rear
axle. In both
cases, the
camber on the
front axle must
be set to -1°45'.
 In addition,
wheel housing
enlargements
(FLAPS) must
be installed,
except in
Germany - there,
the
discontinuation
of wheel
housing
enlargements
(FLAPS) is
205/50 possible with T
6 J x 17 6 J U V certificate
R 17 45 Yes
X 17 no. 1342/06.
93H/V Refer to
ADDITIONAL
WHEEL
HOUSING
ENLARGEMENT,
FLAPS
 A 235/40 R 18 95 W
of a 235/40 R 18 95Y

the Federal Motor
Vehicle Office.
2.0L 110 kW
Gasoline 205/55
Standard 6 1/2 J X
engine with R 16 42 Yes
Tires 16
manual 91V
transmission
1.8L 118 kW 215/55
6 1/2 J X
Gasoline Modification R 16 42 No
16
engine 93V
2.0L 120 kW
205/55
TDI 2.0L 125
R 16 7 J X 16 45 No
kW TDI
91V
Diesel engines
215/55
R 16 7 J X 16 45 No
93V
235/45
7 1/2 J X
R 17 47 No
17
94V
235/40
R 18 8 J X 18 44 No
95Y*
205/55
6 1/2 J X
16
91H/V
205/50
R 17 6 J X 17 45 Yes
93H/V
2.0L 147 kW 205/55
Standard 6 1/2 J X
Tires 16
engine 91W
215/55
6 1/2 J X
16
93W
215/55
R 16 7 J X 16 45 No
93W
235/45
7 1/2 J X
R 17

2009 2013 VW Passat

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2009 2013 VW Passat

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2009-2013 VOLKSWAGEN PASSAT

SERVICE AND REPAIR MANUAL

2.0 Liter - Cooling System - Engine Code(s): CBFA & CCTA

Risk of scalding due to hot steam and hot coolant.

DRAINING AND FILLING

Special tools and workshop equipment required

 Adapter -V.A.G 1274/8-

Risk of scalding due to hot steam and hot coolant.

-- Open the coolant expansion tank cap.

-- Remove the noise insulation. Refer to Description and Operation .

Passat, CC, GTI and Eos

Fig. 1: Identifying Charge Air Hose And Clamps

NOTE: Collect leaking coolant in a clean container for disposal or reuse.

Fig. 2: Identifying ECT Electrical Connector

Fig. 3: Identifying Coolant Hose After-Run Coolant Pump V51

Fig. 4: Identifying After-Run Coolant Pump V51 Bracket Bolt -2-

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Remove the after-run coolant pump bracket bolt -2-.

NOTE: The after-run coolant pump stays in the installed position.

-- Remove the coolant hose -1-.

Fig. 5: Identifying Coolant Hoses

Fig. 6: Identifying Coolant Hose After-Run Coolant Pump V51

If for climatic reasons a greater frost protection is required, the amount of

The refractometer -T10007- is recommended for determining freeze protection

Recommended Mixture Ratios

Frost Protection to Anti-Freeze G 12 Plus-Plus (1) Distilled Water (1)

-- Connect the lower coolant hose -1- to the radiator.

Fig. 7: Identifying ECT Electrical Connector

-- Install the charge air hose.

-- Connect the coolant hose to the after-run coolant pump -arrow-.

Fig. 8: Identifying Coolant Hose After-Run Coolant Pump V51

-- Install the noise insulation. Refer to Description and Operation .

Filling with the Cooling System Charge Unit -VAS 6096-

-- Install the adapter -V.A.G 1274/8- onto the expansion tank.

Filling without the Cooling System Charge Unit -VAS 6096-

Fig. 9: Identifying Expansion Tank

-- Install the expansion tank cap.

Risk of scalding due to hot steam and hot coolant.

DESCRIPTION AND OPERATION

COOLANT HOSE CONNECTION DIAGRAM

Vehicles with a Manual Transmission

 With the cap.

10. from the Auxiliary Heater

11. Heater Core

Vehicles with a Automatic Transmission

 With the cap.

10. from the Auxiliary Heater

11. Heater Core

COOLANT PUMP AND THERMOSTAT OVERVIEW

Fig. 12: Identifying Assembly Overview: Coolant Pump And Thermostat

 Make sure it is tight.

7. Engine Coolant Temperature Sensor -G62-

 On a new coolant pump, remove the protective cap.

11. Centering Pin

12. Toothed Belt

 Removing and installing, refer to COOLANT PUMP TOOTHED BELT.

13. Toothed Belt Guard

 Has left hand threads.

16. Drive Gear for the Toothed Belt

17. Shaft Seal

18. Balance Shaft

20. Centering Pin

22. Connecting Piece