Repair manual
Volkswagen Passat B5 рестайлинг Repair Manual
Step-by-step repair and maintenance instructions for the Volkswagen Passat B5 рестайлинг (2000–2005): removal, installation, adjustment, diagnostics and parameter checks with illustrations.
77sections
1920articles
ENManual language
- Technical data
- Engine data
- Notes on removing
- Notes on installing
- Part I
- Ribbed belt for air conditioning compressor, removing and installing
- Ribbed belt, removing and installing
- Sealing flanges and flywheel/drive plate, removing and installing
- Crankshaft seal, removing
- Crankshaft seal, installing
- Removing
- Installing
- Drive plate, removing and installing
- Crankshaft, removing and installing
- Crankshaft dimensions
- Piston and cylinder dimensions
- Cylinder head, removing and installing
- Toothed belt, removing
- Toothed belt, installing
- Toothed belt, tensioning
- Valve train, servicing
- Valve seats, refacing
- Maximum Permitted Refacing Dimension Is Calculated As Follows
- Oil seal for intake camshaft, replacing
- Oil seal for exhaust camshaft, replacing
- Hydraulic valve lifters, checking
- Camshafts, removing and installing
- Valve guides, checking
- Valve stem seals, replacing
- Engine oil
- Cooling system components, removing and installing
- Radiator, removing and installing
- Coolant pump, removing and installing
- Viscous fan clutch, removing and installing
- Fuel supply system components (vehicles with front-wheel drive), removing and installing
- Safety precautions when working on fuel supply system
- Rules for cleanliness
- Fuel Level Sensor G , removing and installing
- Fuel tank, removing and installing
- Crash fuel shut-off
- Checking delivery rate
- Fuel Pump (FP) check-valve, checking
- Fuel supply system components (All Wheel Drive (AWD) vehicles), removing and installing
- Fuel tank
- Filler tube
- Checking pressure retention valve
- Fuel tank, emptying
- A - Emptying A Fuel Tank More Than 3/4 Filled
- B - Emptying A Fuel Tank Less Than 3/4 Filled
- Fuel delivery unit, removing
- Fuel Level Sensor 2 G169 , removing and installing
- Fuel Level Sensor 3 G237 , removing and installing
- Suction jet pump, removing, installing, and checking
- Fuel pump, checking
- Electronic power control (EPC)
- Functions of EPC system
- Evaporative emissions (EVAP) system
- Checking Leak Detection Pump (LDP) V144 for internal leaks
- Conditions
- Charge air system with turbocharger
- Safety precautions
- Charge pressure system, checking
- Vacuum diaphragm for wastegate bypass regulator valve, checking
- Deceleration shut-off valve, checking
- Fuel injection system, servicing
- General notes on fuel injection
- Components, checking
- Fuel injectors, checking
- Fuel pressure regulator and residual pressure, checking
- Engine control module
- Adapting functions and components
- Engine Control Module (ECM), replacing
- Exhaust system components, removing and installing
- Individual components of mounting
- Secondary air system
- Function
- Combination valve, checking
- Ignition system, servicing
- General notes on ignition system
- Ignition coils with power output stage, removing and installing
- Technical data, spark plugs
- Technical data
- Engine data
- Engine, removing and installing
- Engine, removing
- Engine, installing
- Vehicles with air conditioning, additional information
- Ribbed belt, removing and installing
- Removing
- Installing
- Sealing flange for crankshaft on flywheel side, removing and installing
- Sealing flange, removing
- Sealing flange, installing
- Drive plate, removing and installing
- Crankshaft dimensions
- Piston and cylinder dimensions
- Cylinder head
- Cylinder head, removing and installing
- Valvetrain
- Valve seats, reworking
- Maximum permitted reworking dimension
- Camshaft seals, replacing
- Notes about sealing rings
- Hydraulic valve lifters, checking
- Camshafts, removing and installing
- Camshafts, removing
- Camshafts, installing
- Valve guides, checking
- Valve stem seals, replacing
- Engine oil
- Oil pan (lower part), removing and installing
- Chain tensioner for oil pump, checking and removing and installing oil pump
- Checking chain tensioner
- Installing oil pump
- Upper part of oil pan, removing and installing
- Oil pump/front sealing flange, drive chain and chain sprocket for oil pump, removing and installing
- Oil check valves, replacing
- Oil pressure, checking
- Cooling system components
- After-run coolant pump, checking
- Filling
- Work sequence
- Coolant pump, removing and installing
- Coolant thermostat, removing and installing
- Viscous fan coupling, removing and installing
- Fuel supply system components (vehicles with Front Wheel Drive (FWD))
- Safety precautions when working on fuel supply system
- Rules for cleanliness
- Fuel tank, emptying
- A - Emptying A Fuel Tank More Than 3/4 Filled
- B - Emptying A Fuel Tank Less Than 3/4 Filled
- Fuel pump, removing and installing
- Fuel pump, removing
- Fuel level sensor, removing and installing
- Fuel tank, removing and installing
- Crash fuel shut-off
- Fuel pump, checking
- Delivery rate, checking
- Fuel Pump (FP) check valve, checking
- Fuel supply system components (vehicles with All Wheel Drive (AWD))
- Fuel tank
- Filler tube
- Checking pressure retention valve
- Fuel delivery unit, removing and installing
- Fuel delivery unit, removing
- Fuel Level Sensor G, removing and installing
- Fuel Level Sensor 2 G169, removing and installing
- Fuel Supply Sensor 3 G237, removing and installing
- Suction jet pump, removing and installing, checking
- Accelerator mechanism (vehicles with engine code AHA)
- Accelerator pedal cable, adjusting
- Electronic Engine Power Control (EPC) (vehicles with engine code ATQ)
- Functions of EPC system
- Evaporative Emissions (EVAP) system (vehicles with engine codes AHA, ATQ)
- Leak Detection Pump (LDP) V144, checking for internal leaks
- Conditions
- Fuel injection system, servicing
- Safety precautions
- Crankcase ventilation
- Components, checking
- Engine control module
- Engine Control Module (ECM), replacing
- Adapting functions and components
- Exhaust system components, removing and installing
- Secondary Air Injection (AIR) system (vehicles with engine code ATQ)
- Connecting pipe and combi-valves, removing and installing
- Secondary Air Injection (AIR) pump relay J299
- Combi-valve, checking
- Combi-valve, removing and installing
- Ignition system
- Technical data, spark plugs
- Technical data
- Engine data
- Engine, removing and installing
- Engine, removing
- Engine securing to Engine and Transmission Holder VAS 6095
- Engine, installing
- Ribbed belt, removing and installing
- Drive plate, removing and installing
- Cylinder heads
- Cylinder bank 1
- Cylinder bank 2
- Cylinder head cover, removing and installing (cylinder banks 1 and 2)
- Cylinder head (cylinder banks 1 and 2), removing and installing
- Removing
- Installing
- Chain drive system components, removing and installing
- Marking roller chains
- Valve timing, adjusting
- Valve gear (cylinder banks 1 and 2), servicing
- Valve seats, refacing
- Reworking exhaust valve seat
- Camshafts, removing and installing
- Valve guides, checking
- Valve stem seals, replacing
- Oil pans, removing and installing
- Removing lower oil pan
- Removing upper oil pan
- Installing upper oil pan
- Installing lower oil pan
- Oil pump, removing and installing
- Cooling system components, removing and installing
- Coolant hose connection diagram
- Filling
- Radiator, removing and installing
- Coolant Pump, removing and installing
- Fuel supply system components, removing and installing
- Safety precautions when working on fuel supply system
- Rules for cleanliness
- Suction jet pump, removing, installing, and checking
- Fuel delivery unit in fuel tank, removing and installing
- Fuel Level Sensor, removing and installing
- Auxiliary Tank Fuel Level Sensor, removing and installing
- Fuel tank, removing and installing
- Crash fuel shut-off
- Fuel Pump (FP) in fuel tank, checking
- Checking delivery rate
- Fuel Pump (FP) check-valve, checking
- Function
- Checking Leak Detection Pump (LDP) V144 for internal leaks
- Conditions
- Functions of EPC system
- Fuel injection system, servicing
- General notes on fuel injection
- Safety precautions
- Components, checking
- Fuel Injectors, checking
- Fuel pressure regulator and residual pressure, checking
- Engine control module
- Engine Control Module (ECM), replacing
- Adapting functions and components
- Exhaust system components, removing and installing
- Secondary air injection (AIR) system
- Ignition system, servicing
- General notes on ignition system
- Technical data, spark plugs
- Ignition coils with power output stage, removing and installing
- Fuel supply system components, removing and installing
- Safety precautions when working on fuel supply system
- Rules of cleanliness
- Crash fuel shut-off
- Fuel Pump (FP) in fuel tank, removing and installing
- Checking Fuel Pump (FP) Check Valve
- EVAP canister system, checking for proper seal
- Evaporative Emission (EVAP) canister purge regulator valve, checking
- Leak Detection Pump (LDP), checking
- EVAP system, checking using KLI 9210 tester
- Function of EPC system
- Throttle Position (TP) sensor, checking
- General Notes on Fuel Injection
- Safety precautions
- Technical data
- Oxygen sensor heater for oxygen sensors before Three Way Catalytic Converter (TWC), checking
- Oxygen sensor heater for oxygen sensors behind Three Way Catalytic Converter (TWC), checking
- Mass Air Flow (MAF) sensor, checking
- Voltage Supply For Mass Air Flow (MAF) Sensor, Checking
- Checking Signal And Ground Wires Of Mass Air Flow (MAF) Sensor
- Throttle valve control module, checking
- Engine Coolant Temperature (ECT) sensor, checking
- Intake Air Temperature (IAT) sensor, checking
- Engine Speed (RPM) sensor, checking
- Map controlled engine cooling thermostat, checking
- Engine Coolant Temperature (ECT) Sensor (on Radiator), checking
- Electro-Hydraulic Engine Mount Solenoid Valve, checking
- Fuel injectors, checking
- Checking Injection Quantity And Proper Seal Of Fuel Injectors
- Intake system for leaks (false air), checking
- Oxygen sensors and oxygen sensor regulation before catalytic converter, checking
- Checking Oxygen Sensor Wires
- Oxygen sensors and oxygen sensor regulation behind catalytic converter, checking
- Function
- Engine Control Module (ECM), replacing
- Speed signal, checking
- Terminal resistance for CAN-Bus, checking
- Exhaust system components, removing and installing
- Catalytic converter module, checking
- Secondary Air Injection (AIR) system
- Secondary Air Injection (AIR) system, checking for proper seal
- Secondary Air Injection (AIR) valve, checking
- Secondary Air Injection (AIR) pump motor, checking
- Combination valves, checking
- General notes on ignition system
- Ignition coils with power output stage, removing and installing
- Ignition coils with power output stages, checking
- Checking Activation
- Camshaft Position (CMP) sensor, checking
- Knock sensors, checking
- Multi-Function Transmission Range (TR) Switch, replacing
- Installing
- Multi-Function Transmission Range (TR) Switch, checking
- Checking Wires To Transmission Control Module (TCM)
- Sensor for transmission RPM, checking
- Sender for transmission output RPM, Checking
- Check Sensor Resistance
- Solenoid valves in valve body, checking
- Checking Resistance Of Solenoid Valves
- Pressure regulator valves in valve body, checking
- Checking Resistance Of Pressure Regulator Valves
- Transmission Control Module (TCM), replacing
- Read readiness code
- Readiness code, generating
- Work Sequence
- Fuel and air mixture and additional emission regulations
- Fuel and air ratios
- Ignition system
- Additional exhaust regulation
- Speed and idle control
- Control module and output signals
- Network, electrical
- Network, communication
- Calculating overall ratio "i"
- General repair instructions
- Gaskets, seals
- Locking devices
- Bolts and nuts
- Bearings
- Shims
- Synchronizer rings
- Gears
- Selector gears
- Clutch mechanism
- Clutch mechanisms, differentiating
- Removing
- Installing
- Master cylinder, removing and installing
- Clutch Master Cylinder Operating Rod, installing
- Clutch Pedal Switch F36 , installing (clutch pedal switch is secured in mounting bracket with a retaining clip)
- Clutch Pedal Switch F36 , checking/adjusting (clutch pedal switch is secured in mounting bracket with a retaining clip)
- Clutch Pedal Switch F36 , removing and installing, adjusting (clutch pedal switch is secured directly in mounting bracket)
- New Clutch Pedal Switch F36 , removing and installing
- Clutch system, bleeding
- Connecting Brake Filler/Bleeder Unit VAS 5234
- Clutch Pedal Starter Interlock Switch F194 , removing and installing
- Shift lever and shift lever mount, servicing
- Selector rod, connecting rod and push rod, servicing
- Selector mechanism, adjusting
- Function
- Transmission oil, checking
- Pressing roller bearing for input shaft into gear carrier
- Determining new Shim S 4
- A - Determining shim when replacing gear carrier
- B - Determining shim when replacing 1st gear needle bearing
- C - Determining shim
- Driving in seal for input shaft
- Speedometer Vehicle Speed Sensor (VSS) G22 , replacing
- Speedometer drive gear, replacing
- Differential, removing and installing
- General notes
- Recommended sequence for adjusting gear set
- Ring gear, adjusting
- Determine total shim thickness S total (S 1 plus S 2 )
- Torsional backlash, adjusting
- Calculating mean backlash
- Determining shim thickness S 2
- Determining shim thickness S 1
5 Spd. Automatic Transmission 01VA Front and All Wheel Drive - External Components, Servicing
99 subsections- Notes for 5-speed automatic transmission 01VA All Wheel Drive (AWD)
- Transmission Control Module (TCM) J217 with driving situation shifting (fuzzy logic)
- Gear change point variations for gradients
- Code letters and date of manufacture of rear final drive
- Planetary gear
- Front final drive
- Center differential
- Rear final drive
- General repair instructions
- Gaskets, sealing rings
- Locking elements
- Shims
- Removing
- Installing
- Tester, connecting
- Continued for all vehicles
- Two Types Of Hydraulic Control
- Selector lever mechanism, servicing
- Selector lever mechanism, checking
- Selector lever in position "P" and ignition switched on
- Selector lever in position "N" and ignition switched on
- Selector lever in position "D" , ignition and lights switched on
- Selector lever position indicator
- Checking
- Vehicles with V6- and W8-engine
- Adjusting
- There are different handles which are removed and installed differently.
- Handle with red-brown plastic part, removing and installing
- Handle with black plastic part, removing
- Handle with black plastic part, installing
- Selector mechanism, removing and installing
- Retaining spring for locking cable, removing and installing
- Locking cable, adjusting
- Transmission, removing and installing
- Transmission, removing and installing (vehicles with V6 gasoline engine)
- Automatic transmission, transporting
- Right transmission support, removing
- Left transmission support, removing
- ATF level, checking
- ATF, replacing
- Additional ATF check for vehicles with auxiliary ATF cooler
- Position of selector elements with hydraulic control E17
- Position of selector elements with hydraulic control E18/2
- Auxiliary ATF cooler, removing and installing
- ATF lines and ATF cooler, cleaning
- Valve body, removing and installing
- Inner oil line, removing and installing
- Transmission Input Speed (RPM) Sensor G182 , replacing
- Transmission with hydraulic control E17
- Transmission with hydraulic control E18/2
- Multi-Function Transmission Range (TR) Switch F125 , replacing
- Vehicles with TDI engine
- Gear oil in front final drive, checking
- Front final drive, servicing
- Right flanged shaft oil seal, replacing
- All vehicles
- Left flanged shaft oil seal, replacing
- Left flanged shaft, removing
- Oil seal, installing
- Left flanged shaft, installing
- Front final drive sealing ring/transmission housing, replacing
- O-ring at cover for front final drive, replacing
- Axle oil in transfer case, checking and topping off
- Additional information
- Axle oil, filling
- Transfer case, servicing
- Transfer case, removing and installing
- Rear flanged shaft oil seal, replacing
- Seal in front final drive intermediate flange, replacing
- Sealing ring in drive pinion, replacing
- Needle bearing for spur gear -2, replacing
- Vehicles without threaded hole in facing side of rear final drive
- Drive shaft with nominal dimension 60 mm at front and rear
- Drive shaft with nominal dimension 60 mm at front and 70 mm at rear
- Drive shaft with nominal dimension 60 mm at front and 65 mm at rear
- Vehicles with threaded hole in facing side of rear final drive
- Table of shims
- Sealing rings for flanged shafts, replacing (rear final drive installed)
- Sealing ring for flange/drive shaft, replacing (rear final drive installed)
- Radial play at flange/drive shaft, measuring
- Rear final drive, removing and installing
- Axle oil in rear final drive, checking
- Differential bevel gears, adjusting
- Pulling off flange
- Inserting O-ring
- Driving in seal for drive shaft flange
- Installing flange
- Locking Drive Pinion Hexagon Nut
- General notes
- Recommended sequence for adjusting gear set
- Performing measurement check - checking dimension "r"
- Ring gear, adjusting
- " S total " , determining (S 1 + S 2 )
- Initial shim " S 1 " , determining thickness
- Torsional backlash, adjusting
- Mean backlash, calculating
- Shim S 2 , determining thickness
- Shim S 1 , determining thickness
- Glossary
5 Spd. Automatic Transmission 01VA Front and All Wheel Drive - Internal Components, Servicing
38 subsections- Overlap of technology
- General Repair Notes
- Rules of cleanliness for working on automatic transmissions
- Frequent damages
- ATF leakage between engine and transmission
- ATF pump and ATF supply housing, removing and installing
- ATF supply housing with stator shaft, removing and installing
- Stator shaft, removing and installing
- ATF pump shaft seal, replacing
- Transmission installed, servicing
- Valve body, removing and installing
- Inner oil line, removing and installing
- Transmission Vehicle Speed Sensor (VSS) G38 / Transmission Output Speed (RPM) Sensor G195, removing and installing
- Transmission Input Speed (RPM) Sensor G182, removing and installing - transmission with hydraulic control "E17"
- Transmission Input Speed (RPM) Sensor G182, removing and installing - transmission with hydraulic control "E18/2"
- Evaluating wear by evaluating ATF color and impurities
- Clutch "F"
- Clutch "D/G" with freewheel
- Checking rotating and locking direction of freewheel
- Checking coated and outer plate for wear
- Planetary drive "III"
- Clutch "B"
- Clutch "A"
- Check cylinder "A" inner circumference for scoring from lining discs
- Check cylinder "A" outer circumference for scoring from lining discs
- Checking Contact Surface For Rectangular Rings In Cylinder "A" For Wear
- Clutch "E"
- Checking rectangular rings for wear
- Clutch "C"
- ATF pump
- Checking brass sleeve of ATF pump housing for wear
- Checking components of ATF pump for grooves and signs of wear
- Check yoke in ATF pump wheel
- Front final drive and transfer case, servicing
- Transfer case with Torsen differential, removing and installing
- Driveshaft output flange shaft seal, replacing
- Shaft seal in drive pinion, replacing
- Needle bearing for spur gear 2, replacing
5 Spd. Automatic Transmission 01VA Front and All Wheel Drive - Internal Components, Servicing: Overhaul
17 subsections- Transmission, attaching to assembly stand
- Planetary gear, disassembling and assembling
- Disassembling
- Assembling
- Tower "I", disassembling and assembling
- Tower "I", disassembling
- Clutch "F", disassembling and assembling
- Clutch "D/G" with freewheel, disassembling and assembling
- Tower "I", assembling
- Tower "II", disassembling and assembling
- Tower "II", disassembling
- Clutch "B", disassembling and assembling
- Clutch "A", disassembling and assembling
- Clutch "E", disassembling and assembling
- Clutch "C", disassembling and assembling
- ATF pump, disassembling and assembling
- ATF pump with assembled transmission, removing and installing
- Transmission, identifying
- Notes on 5-speed automatic transmission 01V
- General repair instructions
- Throttle position (TP) sensors -G69- and -G79- and accelerator pedal position sender -G185
- Selector lever mechanism, servicing
- Selector lever mechanism, checking
- Selector lever cable, checking and adjusting
- Selector lever mechanism, removing and installing
- Removing
- Installing
- Selector lever handle, servicing
- Selector lever handle with red-brown plastic, removing and installing
- Removing and installing securing spring for locking cable
- Shift lock solenoid -N110-, removing and installing
- Selector lever cable, removing and installing
- Locking cable, removing and installing
- Locking cable, adjusting
- Transmission, removing and installing (vehicles with 4-cylinder engine)
- Transporting The Automatic Transmission
- Transmission, removing and installing (vehicles with V6 engine)
- Automatic transmission, transporting
- ATF level, checking
- ATF, replacing
- Position of selector elements with hydraulic control Type E17
- Position of selector elements with hydraulic control Type E18/2
- ATF lines and ATF cooler, cleaning
- Oil pan, removing and installing
- Valve body, removing and installing
- Internal oil line, removing and installing
- Transmission vehicle speed sensor (VSS) -G38- and Sender for transmission output RPM -G195-, replacing
- Sensor for transmission RPM -G182-, replacing
- Transmission with hydraulic control -E17
- Transmissions with hydraulic control E18/2
- Transmissions with hydraulic control -E17
- Selector shaft seal, replacing
- Multi-function Transmission Range (TR) switch -F125-, replacing
- Speedometer vehicle speed sensor -G22- and Vehicle speed sensor -G68-, replacing
- Gear oil in front final drive, checking
- Removing flange shaft (left side)
- Grooved Ball Bearing, removing and installing
- Installing oil seal
- O-ring on cover for front final drive, replacing
- Gasket for front final drive, replacing
- Definitions
- Calculation of transmission ratios "i"
- General Repair Notes
- Seals, sealing rings
- Circlips
- Nuts, bolts
- Mount
- Shims
- Synchronizer rings
- Gears
- Sliding Gears
- Clutch control
- Clutch master and slave cylinders, function check
- Differentiation of clutch mechanism
- Removing
- Installing
- Master cylinder, removing and installing
- Operating Rod Retainer, installing
- New Clutch Pedal Switch F36, installing (clutch pedal switch is secured in mounting bracket using securing clip)
- Clutch Pedal Switch F36 checking/adjusting
- Clutch Pedal Switch F36, removing and installing, adjusting (clutch pedal switch is secured directly in mounting bracket)
- Clutch system, bleeding
- Clutch release mechanism, servicing
- Slave cylinder, removing and installing
- Installed position of manual transmission
- Shift lever, shift lever bushing, pivot rod and shift rod, servicing
- Shift mechanism, adjusting
- Function
- Shift knob with shift lever boot as of 11/00, removing and installing
- Removing transmission
- Transporting the transmission
- Installing transmission
- Gear oil, checking
- Marking of transmission cover and housing
- Gear lock for 5th and reverse gear, checking and replacing
- Screw in securing bolt
- Circlips Selection for synchronizer hub for 3rd and 4th gear
- Circlips Selection for synchronizer hub for 5th gear
- Modified synchronization 3rd and 4th gear as of transmission manufacture date 23 06 3
- Input shaft adjusting
- Pulling off securing bushing for small tapered roller bearing outer race
- Inserting spring into gear
- Checking synchronizer for wear
- Pulling off outer race of small tapered roller bearing
- Pulling out double tapered roller bearing outer race
- Pressing in double tapered roller bearing outer race
- Pressing off tapered roller bearing inner race
- Press off synchronizer hub for 5th and reverse gear
- Pressing off 4th gear
- Pressing off double tapered roller bearing inner race
- Determining circlip
- Installed position of circlips
- Pressing on 4th gear
- Checking synchronizer ring for 5th and reverse gears for wear
- Press on synchronizer hub for 5th and reverse gear
- Differentiation of thrust plates
- Differentiation of rubber washers
- Speedometer Vehicle Speed Sensor (VSS), replacing
- Drive gear for speedometer, replacing
- Removing and installing securing ring
- Drive pinion and ring gear, adjusting
- Preload for tapered roller bearing for drive pinion, checking
- Determine dimension "e"
- Perform check measurement
- Ring gear, adjusting
- Measuring backlash
- Checking measurement
- Calculation of transmission ratios "i"
- General Repair Notes
- Seals, sealing rings
- Circlips
- Nuts, bolts
- Bearings
- Shims
- Synchronizer rings
- Gear wheels
- Selector gears
- Clutch control
- Clutch master cylinder and clutch slave cylinder, checking function
- Difference of clutch mechanisms
- Removing
- Installing
- Master cylinder, removing and installing
- Clutch Master Cylinder Operating Rod, installing
- Clutch Pedal Switch F36 , removing and installing (clutch pedal switch is secured to mounting bracket by a retaining clip)
- Clutch Pedal Switch F36 , checking/adjusting
- Clutch Pedal Switch F36 , removing and installing (clutch pedal switch is secured directly to mounting bracket)
- Clutch system, bleeding
- Clutch release mechanism, servicing
- Slave cylinder, removing and installing
- Shift lever, shift lever bearing, pivot rod and shift rod, servicing
- Shift mechanism, adjusting
- Function
- Shift knob with shift lever boot as of 11 00, removing and installing
- Transmission, removing
- Transmission, transporting
- Transmission, installing
- Cover with Torsen differential, removing and installing
- Gear oil, checking
- Gear lock for 5th gear and reverse gear, checking and replacing
- Synchronization of 3rd and 4th gears modified as of transmission manufacture date 23 06 3
- Input shaft adjusting
- Pulling out locking bushing for outer race for tapered roller bearing
- Inserting spring into sliding gear
- Checking synchronizer ring for wear
- Pulling out outer race for double tapered roller bearing
- Pressing in outer race for double tapered roller bearing
- Pressing off inner race for double tapered roller bearing
- Determining circlip
- Pressing out outer race for tapered roller bearing
- Pressing off inner race for tapered roller bearing
- Pressing on tapered roller bearing inner race
- Pressing off 4th-gear gear wheel
- Pressing on 3rd-gear wheel
- Pressing on 4th gear wheel
- Pressing on synchronizer hub for 5th gear and reverse gear
- Flanged shaft seals, replacing (when transmission is installed)
- Flange shaft/driveshaft seal, replacing
- Vehicle Speed Sensor (VSS) G54, replacing
- Speedometer sensor wheel, replacing
- Removing and installing securing ring
- Pinion shaft and ring gear, adjusting
- Pinion shaft, adjusting
- Available shims for "S4"
- Perform check measurement
- Ring gear, adjusting
- Measuring backlash
- Checking measurement
- Driveshaft, servicing
- Driveshaft, removing and installing
- Measure radial play at flange/driveshaft and mark
- Driveshaft, adjusting
- Flange shaft oil seal, replacing
- Seal, removing
- Sealing ring, installing
- Rear final drive, removing and installing
- Rear final drive, removing
- Final drive, installing
- Gear oil in rear final drive, checking
- Differential, removing and installing
- Installing ring gear
- Installing small differential bevel gears
- Pull off driveshaft flange from pinion shaft
- Inserting O-ring
- Driving in oil seal for driveshaft flange
- Installing flange
- Securing pinion shaft nut
- Gear set, adjusting and marking
- Adjusting gear set, sequence
- Adjusting backlash
- Available shims for "S1"
- Calculating overall ratios "i"
- General repair instructions
- Gaskets, seals
- Locking elements
- Bolts and nuts
- Bearings
- Shims
- Synchronizer rings
- Gears, synchronizer hubs
- Selector gears
- Clutch mechanism
- Differentiation of clutch mechanisms
- Removing
- Installing
- Master cylinder, removing and installing
- Clutch Pedal Switch F36 , installing (clutch pedal switch is secured in mounting bracket with a retaining clip)
- Clutch Pedal Switch F36 , checking/adjusting (clutch pedal switch is secured in mounting bracket with a retaining clip)
- Clutch Pedal Switch F36 , removing and installing, adjusting (clutch pedal switch is secured directly in the mounting bracket)
- Clutch system, bleeding
- Shift lever and mount for shift lever, servicing
- Selector rod, connecting rod and push rod, servicing
- Selector mechanism, adjusting
- Function
- Transporting transmission
- Transmission oil, checking
- Driving in seal
- Pressing roller bearing for input shaft into gear carrier
- Determining shim after replacing gear carrier
- Determining shim after replacing hollow shaft
- Driving in seal for input shaft
- Oil pump, removing and installing
- Oil pressure lines, removing and installing
- Left and right flange shaft seal, replacing
- Speedometer Vehicle Speed Sensor (VSS) G22, replacing
- Speedometer drive gear, replacing
- Differential, removing and installing
- Pulling off large inner race/tapered bearing
- Installing differential planetary gears
- Differential planetary gears, adjusting
- Driving out large taper roller bearing outer race from cover
- Recommended sequence for adjusting gear set
- Pinion, adjusting
- Ring gear, adjusting
- Total shim thickness " S total " (S 1 plus S 2 ), determining
- Torsional backlash, adjusting
- Calculating mean backlash
- Determining shim thickness S 2
- Determining shim thickness S 1
- Only redetermine shim S 2
- Radial play at flange/driveshaft, measuring and marking
- Driveshaft, markings, installing
- Rear final drive, removing and installing
- Rear final drive gear oil, checking
- Pressing on small tapered bearing inner race
- Install ring gear
- Pulling off flange
- Inserting O-ring
- Driving in seal for driveshaft flange
- Installing flange
- Secure nut for pinion
- " S total " Determining (S 1 + S 2 )
- Determining initial shim thickness S 1
- Separating slave cylinder from line/hose assembly
- Transmission, disassembling and assembling
- Assembly sequence
- Assembling
- Prying input shaft seal out of assembled transmission
- Installing seal and selector shaft with assembly sleeve
- Differential (transmission with oil pump), disassembling and assembling
- 5 Spd. Automatic Transmission 01V on Board Diagnostic (OBD)
- 5 Spd. Automatic Transmission 01V Front Wheel Drive 6
- 5 Spd. Automatic Transmission 01VA Front and All Wheel Drive - External Components, Servicing 9
- 5 Spd. Automatic Transmission 01VA Front and All Wheel Drive - Internal Components, Servicing 4
- Molded foam parts
- Reinforcements, W8
- Laser welds
- Bonded joints
- Repair methods for replacing body components
- Galvanized body parts
- Wagon, vehicles 10.00
- Longmember for upper wheelhousing, replacing
- Removing
- Separating areas
- Wheel housing stiffening plate, replacing 10.00
- Roof, replacing (sedan)
- Roof, replacing (wagon)
- Rear roof crossmember, replacing (sedan)
- Rear roof crossmember, replacing (wagon)
- Includes: Wheel housing reinforcement
- B-pillar, replacing
- Foam filling
- Inner B-pillar
- Side member reinforcement, replacing ( 09.00)
- Side member reinforcement, replacing (10.00 )
- Inner side member, replacing
- Welding
- Floor panel, replacing (partial section)
- Partial section
- Rear cross panel, replacing (sedan)
- Rear cross panel, replacing (wagon)
- Corner reinforcement, replacing (wagon with 4-motion)
- Rear lock carrier, replacing (sedan)
- Rear lock carrier, replacing (wagon)
- Tail light mount, replacing (sedan 09.00)
- Tail light mount, replacing (sedan 10.00 )
- Tail light mount, replacing (wagon)
- Rear longitudinal member, replacing (4-motion)
- Side panel, replacing (sedan)
- Side panel, replacing (wagon)
- Separating areas 10.00
- Outer wheelhousing liner, replacing (partial section)
- Spare wheel well, replacing (4-motion)
- Spare wheel well, replacing -partial section
- Reinforcement for wheelhousing, replacement
- Front wheelhousing, replacement
- Replacement part
- Front longmember, replacement
- Replacement parts
- Front piece of longmember, replacement (sub-part)
- Front roof crossmember, replacement
- A-pillar, replacement
- Outer sill panel, replacement
- Rear longmember, replacement
- Spare wheelwell, replacement
- Removing
- Installing
- Lock carrier and front bumper reinforcement, service position 09.00
- Performing service position
- Tools
- Hood, adjusting
- Basic setting of hood
- Gas-filled strut, removing
- Releasing gas from gas-filled strut
- Bowden cable, disconnecting
- Hood lock, adjusting
- Insulation, removing and installing
- Trunk lid, adjusting 09.00
- Trunk lid, adjusting 10.00
- Actuator, removing
- Front door, removing and installing
- Front door, adjusting
- Adjusting door at striker plate
- Door handle, removing and installing
- Door lock, removing and installing
- Vehicles with electrical window regulators
- Bosch window regulators
- Siemens window regulators
- Inner release handle, removing
- Door seals
- Inner door seal, removing and installing
- Securing knob for locking rod, removing and installing
- Adaptation of keys with radio-frequency remote control
- Rear door, removing and installing
- Rear door, adjusting
- Adjusting door striker
- All vehicles
- Door window, installing to window regulator
- Glass panel for sunroof, removing
- Glass panel for sunroof, installing
- "0" position
- Panel seal, adjusting
- Panel seal, replacing
- Wind deflector, removing
- Sun protection, removing
- Drive motor for sunroof, removing
- Drive motor for sunroof, adjusting ("0" position)
- Parallel movement, checking
- Parallel movement, adjusting
- Slotted guide rail, removing
- Function
- Automatic rotary switch for sunroof, removing
- Release lever, removing
- Guide piece, adjusting
- Protective molding, removing and installing
- Bumper strip, removing and installing
- Materials
- Windshield, removing
- Windshield, installing
- Undamaged side window, removing
- Damaged side window, removing
- Side window, installing
- Undamaged rear window, removing (Wagon)
- Undamaged rear window, removing
- Damaged rear window, removing
- Installing rear window
- Preparing undamaged window for glazing
- Preparing new side window for glazing
- Preparing window flange for glazing
- Minimum curing time
- Paint damage, repairing
- Cleaning when soiled by adhesive sealing material
- Front door window, removing
- Door window, adjusting
- Rear door window, removing
- Door window to window regulator, installing
- Installing window regulator motor
- Mirror housing, removing
- Mirror housing with turn signal, removing and installing
- Side protective moldings, removing and installing
- Automatic dimming interior mirror
- Materials
- Installing
- Mirror base for interior mirror with rain sensor, bonding
- Preparing windshield
- Preparing detached and new mirror base
- Bonding mirror base
- Cleaning and removing excess adhesive
- Removing
- Front ashtray, removing
- Selector lever cover, removing and installing
- Cover for outside rearview mirror, removing
- Screen separator wall, retrofitting
- Safety precautions for seatbelt tensioners
- Disposing (deploying) of belt tensioner units
- Rear seatbelt with belt tensioner, removing and installing (Passat Wagon)
- Rear seatbelt with belt tensioner, removing and installing (Passat Sedan)
- Automatic belt retractor, removing
- Check points
- Check belt webbing
- Check automatic retraction (stop function)
- Checking guide stops and seatbelt lock tongue
- Check anchoring components and anchoring points
- Safety precautions when working on airbags
- Additional safety precautions for vehicles with side curtain airbag
- Airbag units, disposal (deploying)
- Accident where airbag deployed
- Accident where airbag did not deploy
- Vehicles with four-spoke steering wheel
- Vehicles with three-spoke steering wheel (except Passat W8)
- Return spring with slip ring -F138-, removing and installing
- Airbag control module -J234-, removing and installing
- Drivers side/passengers side side curtain airbag (Recaro seat), removing and installing
- Drivers side/passengers side side curtain airbag (Sedan), removing and installing
- Drivers side/passengers side side curtain airbag (Wagon), removing and installing
- Deformation elements (sidemount) (Sedan without sunroof), removing and installing
- Deformation elements (C-pillar) (Sedan), removing and installing
- Retrofitting
- Deformation elements (side curtain airbag) (vehicles without sunroof), removing and installing
- Deformation elements (side mount) (Wagon without sunroof), removing and installing
- Door trim
- Pillar and side trim
- Vehicles with side curtain airbag
- Drivers side
- Passengers side
- Luggage compartment trim, removing and installing (wagon)
- Roof trim panels
- Front seats, removing and installing
- 8-way seat trim, removing
- 8-way seat control module, removing
- 8-way seat operating unit, removing
- Recaro seat, removing and installing
- Spring cover, removing and installing
- Side seat trim panels, removing and installing
- Backrest, removing and installing
- Vehicles without center three-point seatbelt
- Vehicles with center three-point seatbelt
- Vehicles with part leather trim
- Vehicles with full leather or leather/Alcantara trim
- Only for vehicles with heated rear seats
- Vehicles up to CW 31/98
- Vehicles as of CW 32/98
- Rear lower anchor bracket for LATCH "Lower Anchors and Tethers for CHildren", installing
- Seat heating element, removing
- Heating elements for Recaro seat, removing and installing
- General notes on anti-lock braking system (ABS)
- Notes for repair work on Anti-lock Braking System (ABS)
- ABS Bosch 5.3 up to model year 1999 - Vehicles up to VIN 3B X 600 000
- ABS Control Module, removing and installing separately
- Control module and hydraulic unit, removing and installing
- ABS Bosch 5.3 from model year 2000 - Vehicles from VIN 3B Y 000 001
- ABS Hydraulic Unit N55 with Hydraulic pump for traction control V156 , removing and installing
- ABS Control Module J104 and ABS Hydraulic Unit N55 , removing and installing
- Brake Pressure Sensor 1 G201 , removing and installing
- ABS system components on front axle, removing and installing
- Speed sensor on front axle, removing and installing
- Rotor on front axle, checking, removing and installing
- ABS system components on rear axle, removing and installing (vehicles with front wheel drive)
- ABS wheel speed sensor on rear axle, removing and installing (vehicles with front wheel drive)
- Rotor on rear axle, checking
- Speed sensor on rear axle, removing and installing (vehicles with all wheel drive)
- Rotor on rear axle, checking, removing and installing
- Components of ESP system, removing and installing
- Installing
- ABS Control Module J104 (Bosch 5.3) vehicles without ESP, removing and installing
- ABS Control Module J104 (Bosch 5.7) vehicles without ESP, removing and installing
- Rotation Rate Sensor G202 , removing and installing
- Removing
- Transverse Acceleration Sensor G200 , removing and installing
- Transverse Acceleration Sensor G200 and Rotation Rate Sensor G202 , removing and installing
- Steering angle sensor G85 , removing and installing
- Brake pads for C54 brake caliper, removing and installing
- FN3 brake caliper, servicing
- Brake pads for FN3 brake caliper, removing and installing
- HP-2 brake caliper, servicing
- 2FN brake caliper, servicing
- Brake pads for 2FN brake caliper, removing and installing
- Brake pads, removing and installing
- Parking brake, adjusting
- Brake pedal, removing and installing
- Joining brake pedal to brake booster
- Brake Light Switch F and Brake Pedal Switch F47 , removing, installing and adjusting, up to model year 2002
- Function of brake light switch, checking
- Brake light switch F and Brake Pedal Switch F47 , adjusting, as of model year 2003
- Installing and adjusting brake light switch
- C54 brake caliper, servicing
- Piston for C54 brake caliper, removing and installing
- HP2 brake caliper, servicing
- Piston for HP2 brake caliper, removing and installing
- Piston for 2FN brake caliper, removing and installing
- Piston for FN3 brake caliper, removing and installing
- Rear brake caliper, servicing
- Piston for rear brake caliper, removing and installing
- Braking system, bleeding
- Bleeding brake system with brake filler and bleeder unit VAS 5234
- Bleeding (normal)
- Subsequent bleeding
- Bleeding brake system without brake filler and bleeder unit
- Brake system vacuum pump V192
- Brake system vacuum pump V192 , removing and installing
- Brake system vacuum pump V192 , checking
- Brake master cylinder, removing and installing (Vehicles up to model year 1999)
- Brake master cylinder, removing and installing (Vehicles as of model year 2000)
- Brake booster, removing and installing (Vehicles up to model year 1999)
- Brake booster, removing and installing (vehicles as of model year 2000)
- Brake master cylinder with brake booster
- Brake master cylinder with brake booster, removing and installing, (as of model year 2002)
- VAG1551 Scan Tool (ST)
- On Board Diagnostic (OBD), technical data
- Test requirements
- Scan Tool (ST), connecting
- VAG1551 Scan Tool (ST), connecting and selecting functions
- Check DTC Memory (function 02)
- Diagnostic Trouble Code (DTC) table
- Test sequence and test tables with measured values
- Output Diagnostic Test Mode (DTM) (function 03)
- ABS/EDL/ASR Bosch 5.3, electrical testing
- Notes for test table
- ABS/EDL/ASR with ESP Bosch 5.7 On Board Diagnostic (OBD)
- Radio - "Premium III", removing and installing
- Radio - "Premium IV", removing and installing
- Radio - "Premium III", multi-pin connector assignments
- Radio - "Premium IV", multi-pin connector assignments
- Anti-theft security code - "Premium III", inputting
- Anti-theft security code - "Premium IV", inputting
- Radio, removing and installing
- Radio - "Premium V", multi-pin connector assignments
- Radio - "Premium V - Monsoon", multi-pin connector assignments
- Anti-theft security code, inputting
- Radio - "Premium VI", multi-pin connector assignments
- Radio - "Premium VI - Monsoon", multi-pin connector assignments
- Amplifier, removing and installing
- Wagon, removing
- Treble Speaker -R20- / -R22- in front doors, removing
- Treble Speaker -R14- / -R16- in rear doors, removing
- Bass Speaker -R15- / -R17- / -R21- / -R23- in doors, removing
- Diversity antenna system (W8 only)
- Antenna Selection Control Module -J515- (W8 only), removing and installing
- Antenna Selection Control Module Electrical And Antenna Connections, Layout
- Diversity antenna amplifiers (W8 Sedan), removing and installing
- Amplifiers under rear parcel shelf, removing
- Installing
- Amplifiers behind left and right rear D-pillar side trim, removing
- Diversity antenna amplifiers (W8 Wagon), removing and installing
- Antenna cables and connectors, replacing
- Reception interference, suppression measures
- CD Changer through 09.00, removing and installing
- CD Changer from 10.00, removing and installing
- CD Player, removing and installing
- Operating unit in steering wheel, removing and installing
- Multi-function steering wheel control module, removing and installing
- Multi-function steering wheel from 12.01, performing OBD program functions using VAS 5051/5052
- Telematic Control Head -E264-, removing and installing
- Telematic Control Module -J499- - Passat Wagon, removing and installing
- Telematic Control Module -J499- - Passat Sedan, removing and installing
- Telematic Control Module -J499-, coding
- Telematic Control Module -J499-, reconfiguring
- Continued For All
- GPS/Telematics antenna
- Removing
- GPS/Telematics antenna - Passat Sedan, removing and installing
- Transport Mode, deactivating
- Performing repairs, notes
- 4.0L 8-CYL 4V Engine Mechanical, Fuel Injection Ignition, Engine Code(s): Bdp 6
- 2.8L V6 5V Engine Mechanical, Fuel Injection Ignition, Engine Codes: Aha, Atq 7
- 1.8L - Engine Mechanical, Fuel Injection Ignition, Engine Code(s): Aug, Awm 6
- 2.8L V6 5V Generic Scan Tool, Engine Code(s): Aha,atq 4
- 4.0L 8-CYL 4V Generic Scan Tool, Engine Code(s) Bdp 5
- Battery A
- Valve-regulated lead acid battery (AGM battery)
- Gel battery
- Dangers when handling vehicle batteries
- Battery terminal connection
- Battery, checking
- Sequence for checking a battery
- Battery with "magic eye", checking
- Battery acid level, checking
- Filling with distilled water
- Electrolyte specific gravity, checking
- Static voltage of battery, checking
- Battery tester with printer VAS 5097 A
- Charge battery
- Battery charging unit VAS 5095 A
- Charging battery using battery charging unit VAS 5095 A
- Charging severely discharged battery using battery charging unit VAS 5095 A
- Assistance mode using battery charging unit VAS 5095 A
- Battery charging unit VAS 5900
- Charging battery using battery charging unit VAS 5900
- Service charging using battery charging unit VAS 5900
- Charging severely discharged batteries using battery charging unit VAS 5900
- Assistance mode using battery charging unit VAS 5900
- Charge retention using battery charging unit VAS 5900
- Severely discharged batteries
- Battery A, disconnecting and connecting
- Work steps after connecting battery
- Battery A, removing and installing
- Starter B
- Starter, checking
- Starter, removing and installing (vehicles with 4- and 6-cylinder engines)
- Starter, removing and installing (vehicles with 8-cylinder engine)
- Generator C
- Characteristics of compact generators
- Securing B+ wire to generator
- V-belt, checking
- Generator, checking
- Generator, removing and installing (8-cylinder gasoline engine)
- Carbon brushes for generator C, checking (vehicles 05.99)
- Voltage regulator C1 for generator C, removing and installing (vehicles 05.99)
- Ribbed belt pulley at generator C, removing and installing
- Ribbed belt pulley with free wheel, installing
- Cruise control (vehicles with diesel engine)
- Cruise control (vehicles with 4- and 6-cylinder gasoline engine)
- 4-cylinder engine
- 6-cylinder engine
- Actuator, removing
- Vacuum pump, removing and installing
- Cruise Control System (CCS), removing and installing (vehicles with Electronic Power Control (EPC))
- Instrument cluster
- Instrument cluster, replacing
- Instrument cluster, removing and installing
- Bulbs in instrument cluster, replacing
- Connector assignment of connectors on instrument cluster (vehicles 05.99 04.01)
- 20-pin connector T20, red
- Connector assignment of connectors on instrument cluster (vehicles 05.01)
- 32-pin connector T32a, blue
- 32-pin connector T32b, green
- Indicator lamp symbols in instrument cluster (vehicles 11.03)
- Windshield wiper system
- Front windshield wiper system, removing and installing
- Windshield wiper system, removing
- Wiper arms, removing
- Plenum chamber cover, removing
- Cowl, removing
- Wiper frame with linkage and Windshield Wiper Motor V, removing
- Installing Windshield Wiper Motor V into wiper frame
- Wiper frame with linkage and Windshield Wiper Motor V, installing
- Wiper arms, removing and installing
- Windshield wiper rest position, adjusting
- Wiper blade, removing and installing
- Aero wipers, removing and installing
- Wiper blade, removing and installing (aero wiper)
- Rain sensor G213, removing and installing
- Pre-treatment of windshield
- Windshield washer system
- System with two separate tanks for window washer system and headlamp cleaning system
- System with one tank for window washer system and headlamp washer system (not for vehicles with turbocharged engine)
- Tank for window washer system and headlamp cleaning system, removing and installing (vehicles 10.00 -->)
- Windshield and Rear Window Washer Pump V59, removing and installing
- Spray nozzles for windshield washer system, removing and installing
- Spray nozzles for windshield washer system, adjusting
- Rear window wiper system
- Rear window wiper, removing and installing
- Wiper arm, removing
- Rear Window Wiper Motor V12, removing and installing
- Wiper arm, installing
- Rest position of rear windshield wiper, adjusting
- Wiper blade, replacing
- Rear window washer system
- Spray nozzle, adjusting
- Headlamp cleaning system
- Headlamp Washer Pump V11, removing and installing
- Lift cylinder for spray nozzles, removing and installing (vehicles --> 09.00)
- Lift cylinder for spray nozzles, removing and installing (vehicles 10.00 -->)
- Lift cylinder cap, replacing (vehicles 10.00)
- Spray nozzles for headlamp cleaning system, adjusting
- Headlamp washer system, ventilating
- Washer hose repairs
- Repair methods for corrugated pipes
- Main headlamps
- Headlamp, removing and installing (vehicles 09.00)
- Headlamp, removing and installing (vehicles 10.00)
- Fog lamp, removing and installing (vehicles 10.00)
- Side headlamp locating pin, servicing (vehicles 09.00)
- Headlamp retainers, servicing (vehicles 10.00)
- Upper outer retainer, servicing
- Upper inner retainer, servicing
- Lower outer retainer, servicing
- Lower inner retainer, servicing
- Bulbs for headlamp, replacing (vehicles 09.00)
- Bulb for parking light, replacing
- Left Low Beam Headlamp M29 and Right Low Beam Headlamp M31, replacing
- Left High Beam Headlamp M30 and Right High Beam Headlamp M32, or two-filament bulb for high beam and fog lamp, replacing
- Bulbs for headlamp, replacing (vehicles 10.00)
- Left High Beam Headlamp M30 and Right High Beam Headlamp M32, replacing
- Left Front Turn Signal Lamp M5 and Right Front Turn Signal Lamp M7, replacing
- Bulb for fog lamp, replacing
- Main headlamp, adjusting
- Fog lamps, adjusting
- Notes on hazardous high voltage / currents
- Notes on pressure, temperature and glare
- Disposal regulations for gas discharge lamps
- Left High Intensity Gas Discharge (HID) Lamp L13 or Right High Intensity Gas Discharge (HID) Lamp L14, replacing
- Left High Intensity Gas Discharge (HID) Lamp L13 or Right High Intensity Gas Discharge (HID) Lamp L14 for low beam, replacing
- Vehicles 10.00 -->
- Left High-intensity Gas Discharge Lamp Control Module J343 or Right High-intensity Gas Discharge Lamp Control Module J344, removing and installing (vehicles 09.00)
- Left High-intensity Gas Discharge Lamp Control Module J343 or Right High-intensity Gas Discharge Lamp Control Module J344 (vehicles 10.00)
- Headlamp Range Control Module, removing and installing
- Left Front Level Control System Sensor G78, removing and installing (vehicles 10.00)
- Left Rear Level Control System Sensor G76, removing and installing (vehicles 10.00)
- Headlamps with gas discharge lamps, adjusting
- Front turn signal lamps
- Front turn signal lamp, removing and installing (vehicles 09.00)
- Left Side Turn Signal Lamp M18 and Right Side Turn Signal Lamp M19 (vehicles 10.03)
- Drivers Exterior Mirror Turn Signal Lamp L131 and Front Passengers Exterior Mirror Turn Signal Lamp L132 (vehicles 11.03)
- Taillamp, removing and installing (vehicles 09.00)
- Taillamp, removing and installing (sedan 10.00)
- Taillamp, removing and installing (wagon 10.00)
- Bulb carrier for taillamp, removing and installing (vehicles 09.00)
- Bulb carrier for taillamp, removing and installing (vehicles 10.00)
- Bulb carrier for taillamp, removing and installing (wagon 10.00)
- License Plate Light X, removing and installing (vehicles 09.00)
- License Plate Light X, removing and installing (vehicles 10.00)
- High-mount Brake Light M25, (sedan 09.00)
- Bulb carrier, removing and installing
- High-mount Brake Light M25, removing and installing
- High-mount Brake Light M25, (sedan 10.00)
- Steering column switch, removing and installing
- Lock cylinder, removing and installing
- Ignition/Starter Switch D, removing and installing
- Immobilizer
- Anti-Theft Immobilizer Control Module J362, replacing
- Anti-theft Immobilizer Control Module J362, removing and installing
- Induction Coil of Anti-theft Immobilizer D2, removing and installing
- Transponder
- Glove Compartment Light W6, removing and installing
- Interior lamp, removing and installing
- Bulb, replacing (interior lamp)
- Bulb, replacing (reading lamp for driver or front passenger)
- Luggage Compartment Light W3, removing and installing
- Right Rear Reading Light W12 and Left Rear Reading Light W11
- Removing and installing
- Bulb, replacing
- Right Rear Reading Light W12 with Interior Monitoring Sensor G273 and Left Rear Reading Light W11 with Interior Monitoring Transmitter G274
- Front Passengers Airbag Disabled Indicator Lamp K145, removing and installing
- Headlamp Adjuster E102 and E20 with Headlamp Adjuster Control Illumination L54, removing and installing
- Light Switch E1 and Fog Lamp Switch E23 with Headlamp Switch Illumination L9, removing and installing
- Drivers Window Regulator Switch, removing and installing (vehicles --> 04.97)
- Drivers Window Regulator Switch, removing and installing (vehicles 05.97 -->)
- Window Regulator Switch (in RF door) E107 and in rear doors, removing and installing (vehicles 05.97 -->)
- Luggage Compartment Light Switch F5 with Rear Lid Unlock Switch E165, removing and installing (wagon)
- Fuel Tank Lid Unlock Button E319, removing and installing (vehicles 09.00)
- Fuel Tank Lid Unlock Button E319 and Rear Lid Remote Unlock Switch E188 with Remote Unlock Switch Illumination L104, removing and installing (vehicles 10.00)
- Switch in center of instrument cluster, removing and installing
- Emergency Flasher Switch, removing and installing
- Door contact switch, removing and installing
- Sunroof Regulator E139, removing and installing
- Rear Lid Handle Unlock Switch E234, removing and installing (vehicles 10.00)
- Rear lid lock carrier, removing
- Rear Lid Central Locking System Motor V53 in rear lid lock carrier, removing and installing
- Anti-theft protection system with interior monitoring
- Comfort System Central Control Module J393
- Checking
- Interior Monitoring Sensor G273, right and Interior Monitoring Transmitter G274, left, removing and installing
- Interior Monitoring Deactivation Switch E267 with Interior Monitoring Deactivation Switch Illumination L118, removing and installing
- Alarm Horn H12, removing and installing
- Alarm Horn H8, removing and installing
- Fuse holder and relay carrier, removing and installing
- Fuse holder, removing and installing
- Relay panel and 13-pin relay carrier, removing and installing
- Protective housing for control modules in plenum chamber, removing and installing
- Secondary relay carrier with secondary fuse holder, removing and installing
- General notes on repairs to vehicle electrical system
- Airbag and seat belt tensioner wires, repairing
- Repairing CAN-Bus wires
- Antenna wires, replacing
- Wires with a cross-section up to 0.35 mm 2, repairing
- Contacts in contact housing, repairing
- Secondary lock
- Primary lock
- Round connector systems
- Flat connector systems
- Special connector systems
- Engine Performance Diagnostic Routine Outline - General Information
- Engine Performance Safety Precautions
- Parasitic Load Explanation & Test Procedures - General Information 2
- Waveforms - Injector Pattern Tutorial - General Information 2
- Electrostatic Discharge Warning - General Information
- State Emission Standards - Diesel
- Exhaust System Components, Removing and Installing
- Individual Components of Suspension
- Function Test
- Secondary Air Injection (Air) System(vehicles with Engine Code Atw, Aug, Awm)
- Function
- Secondary Air Injection (Air) System Components, Removing and Installing
- Secondary Air Injection (Air) Pump Relay -J299-* (-1-) with Fuse -2- in Protective Housing (Engine Compartment, Left)
- Checking Proper Seal
- Secondary Air Injection (Air) Valve, Checking
- Recommended Special Tools and Equipment
- Test Requirements
- Test Sequence
- List of available functions
- Basic Setting (function 04)
- Prerequisites
- End Output (function 06)
- Climatronic Control Module J255 , coding (function 07)
- CODING TABLE
- Read Measuring Value Block (function 08)
- Table of selectable display group numbers
- Safety measures
- Commercial designation
- Color
- Temperature/pressure relationship
- Refrigerant oil
- Airborne properties
- Affects on plastic
- Affects on metal
- Water solubility
- Flammability
- Refrigerant containers
- Leak detection
- R-134a refrigerant oil
- Heating and A/C components in passenger compartment, servicing
- Side air outlets (later production), removing
- Fresh Air Blower Series Resistor With Fuse N24 , replacing
- Fresh Air Blower V2 , removing and installing
- Fresh/Recirculating Air Door Motor V154 , removing and installing
- Installing
- Heating and A/C cables, installing
- Temperature and central flap cables, removing and installing
- Removing
- Heating and A/C components in engine compartment, servicing
- Ventilation system, checking
- Clutch plate, removing
- Clutch pulley, removing and installing
- Clutch coil, installing
- Clutch plate gap, checking
- Tools
- Climate control options
- A/C Control Head E87 , functions
- Climatronic components in passenger compartment, servicing
- Footwell Outlet Temperature Sensor G192, removing and installing
- Air outlet for glove compartment, removing and installing
- Center Outlet Temperature Sensor G191, removing and installing
- Sunlight Photo Sensor G107 , removing and installing
- A/C Control Head E87 with Climatronic Control Module J255 , removing and installing
- Air flap motors (for climate control regulation), removing and installing
- Air Flow Flap Motor V71 , removing and installing
- Temperature Regulator Flap Motor V68 , removing and installing
- Central Air Flap Motor V70 , removing and installing
- Footwell/Defroster Flap Motor V85 , removing and installing
- Climatronic components in engine compartment, servicing
- A/C system hoses and lines
- A/C Pressure Switch F129
- A/C refrigerant system through 09.00, servicing
- A/C refrigerant system from 10.00, servicing
- High pressure service valve, removing
- Low pressure service valve, removing
- A/C Pressure Switch F129 , electrical checking
- A/C Pressure Switch F129 , functional checks
- A/C Pressure Switch F129 through 09.00, removing and installing
- A/C Pressure Switch F129 from 10.00 or High Pressure Sensor G65, removing and installing
- Restrictor, removing and installing
- Pressure relief valve - Zexel compressor, checking
- Pressure relief valve - Denso compressor, checking
- Heater core, removing and installing
- Evaporator, removing and installing
- A/C refrigerant system, replacing components
- A/C refrigerant system pressures and temperatures, checking
- Measuring pressure and temperature in a "switched-on" refrigerant system
- Measuring pressure and temperature in a closed container or "switched-off" refrigerant system
- A/C refrigerant system, discharging
- A/C refrigerant system, evacuating and recharging
- Requirements
- Compressor noisy
- A/C compressor noisy immediately after switching A/C ON and/or when driving around corners or braking (refrigerant shock) - system overcharged
- With an otherwise properly operating A/C system, water sprays out of instrument panel vents
- A/C refrigerant system pressures, checking
- A/C refrigerant system cooling performance, checking
- Checking
- Specified result
- Vehicles through 09.00
- Vehicles from 10.00
- PAG oil, distribution
- Engine characteristics
- VW engine oil standards
- Filter change interval
- Toothed belt change interval
- Oil change service
- Sticker
- "First service" sticker
- Vehicles --> 09.00
- Vehicles 10.00 -->
- Safety precautions
- Lifting points for lifting platform and trolley jack
- Additional components for vehicles with time or distance dependent service
- Engine oil level sensor
- Brake pad wear indicator
- Lead-calcium-battery
- Engine code and engine number
- Type plate
- Airbag for driver and passenger, visually checking airbag units
- 8-way seat with memory, perform initialization (activation)
- Automatic transmission, ATF level, checking
- Battery, check battery terminals for secure seating
- Battery, check
- Checking tires, tire condition, wear pattern, inflation pressure and tread depth
- Tire condition, checking
- Checking tire wear pattern
- General notes
- Tire pressure: Checking, correcting inflation pressures if necessary
- Sedan With Gasoline Engine
- Sedan With Diesel Engine
- Sedan With Gasoline Engine And All-Wheel Drive
- Sedan With Diesel Engine And All-Wheel Drive
- Wagon With Gasoline Engine
- Wagon With Diesel Engine
- Wagon With Gasoline Engine And All-Wheel Drive
- Wagon With Diesel Engine And All-Wheel Drive
- Brake system, visual check for leaks and damage
- Front and rear brake pads, checking thickness
- Rear disc brake pads
- Electric windows, perform initialization (activation)
- Ribbed belts, replacing (4 cyl. gasoline engines)
- Removing
- Installing
- Fuel filter, replacing (diesel engine)
- 4-cyl. TDI engines
- Cooling system, freeze protection and coolant level, checking
- Checking freeze protection and adding coolant additive if necessary
- Checking coolant level and adding coolant if necessary
- Engine oil level, check
- Oil filter, replacing
- 4-Cyl. Gasoline And Diesel Engines As Well As 6-Cyl. Gasoline Engine
- 8-Cylinder Gasoline Engine
- Filling engine oil
- Engine and components in engine compartment (from above and below), visual check for leaks and damage
- Upper engine cover, removing and installing
- 4-Cylinder TDI Engines
- Radio, Radio/Navigation system, activating anti-theft coding
- Climatronic, setting temperature to 72 F (22 C)
- Instrument panel cluster, adapting language
- Windshield wash/wipe system and headlight wash system, checking function
- Windshield washer system, checking nozzle setting, adjusting nozzles if necessary
- Spray Nozzles For Windshield Washer System Without Presetting
- Preset Spray Nozzles For Windshield Washer System
- Spray Nozzle For Rear Window Washer System
- Headlight wash system, checking nozzle setting, adjusting nozzles if necessary
- Telematics Transport Mode, deactivating
- Windshield wiper blades, checking rest position, adjusting if necessary
- Transportation wiper blades, removing
- Headlights, adjusting (vehicles --> 09.00)
- Headlights, adjusting (vehicles 10.00 --> )
- Headlight with gas discharge lamps
- Tie rod ends, check play, security and joint boots
- Front axle control arm, checking
- Digital clock
- Analog clock
- Underbody protection, perform visual check for damage
- Plenum chamber, cleaning
- Camshaft drive toothed belt, replacing (4-cyl. TDI engines)
- Camshaft drive toothed belt and toothed belt tensioner, replacing (V6 gasoline engine)
- Camshaft drive toothed belt, replacing (1.8L 4 cyl. 5-valve gasoline engines)
- Condition of toothed belt, checking
- Spark plugs, replacing
- Spark plugs, V6-cyl. 5-valve engines, replacing
- Spark plugs, 1.8L 5-valve engines, replacing
- Spark plugs, 1.8L 5-valve engines (without intermediate shaft), replacing
- Spark plugs, W8- engines, replacing
- Equipment
- Selectable functions when using VAG1551/1552 or VAS5051
- Selectable functions (modes) under address word 33, CARB / OBD II
- Malfunction Indicator Lamp (MIL), significance
- Engine code ATW
- Engine codes AUG, AWM
- Electronic Power Control (EPC) warning lamp (for power accelerator activation) in the instrument cluster, significance
- Connect VAS5051
- Select operating mode
- Select vehicle system
- Procedure
- Example printout on VAG1551 printer
- Explanation
- DTCs P0010 to P0688, VAG 16394 to 17072
- DTCs P1102 to P1913, VAG 17510 to 18321
- Vehicles with engine code AWM from 05. 01
- Procedure - all engine codes
- Activating Evaporative Emission (EVAP) canister purge regulator valve -N80
- Activating Secondary Air Injection (AIR) solenoid valve -N112
- Activating secondary Air Injection (AIR) pump relay -J299
- Activating Wastegate bypass regulator valve -N75
- Activating Leak Detection Pump (LDP) -V144
- Activating Recirculating valve for turbocharger -N249
- Activate Brake system vacuum pump -V192
- Activate Fuel injectors -N30- to -N33
- Function
- Readiness code, reading (vehicles with engine code AWM up to 04.01 and engine codes ATW, AUG)
- Explanation of 8 -digit readiness code
- Readiness code, generating (vehicles with engine code AWM up to 04.01 and engine codes ATW, AUG)
- Readiness code, reading (vehicles with engine code AWM from 05.01)
- Readiness code, generating (vehicles with engine code AWM from 05.01)
- Safety precautions
- Read Measuring Value Block (function 08)
- Explanation of 8 digit numeric block
- Evaluation display group 1, display field 1 - engine speed (idle speed)
- Evaluation display group 4, display field 2 - control module voltage supply
- Evaluation display group 4, display field 3 - Engine coolant temperature
- Evaluation display group 4, display field 4 - intake air temperature
- Evaluation display group 14, display field 3 - number of ignition misfires
- Evaluation display group 15, display fields 1 to 3 and display group 16, display field 1 -ignition misfires cyl. 1 to cyl. 4
- Evaluation display groups 22/23, display fields 3 and 4 - ignition angle retardation
- Meaning of 3 digit number block in display fields 1 and 2
- Evaluation display group 32, display fields 1 and 2 - oxygen sensor adaptation values
- Oxygen sensor voltage U in mV
- Evaluation display group 33, display field 1 - oxygen sensor control before catalytic converter
- Evaluation display group 33, display field 2 - sensor voltage of oxygen sensor before catalytic converter
- Engine code ATW, note for display fields 3 and 4
- Evaluation display group 36, display field 1 - sensor voltage of oxygen sensor behind catalytic converter
- Engine code ATW, note for display field 3
- Explanation of 5 -digit indication
- Explanation of digits in 4-digit indication, display field 2, switch for brakes, clutch and cruise control.
- Explanation of digits in the 4-digit indication, display field 4, operating switch for cruise control
- Explanation of digits in 8-digit indication, display field 2, switch for brakes, clutch and cruise control.
- Explanation of digits in the 8-digit indication, display field 4, operating switch for cruise control
- Check list for evaluating the suspension of accident vehicles
- Wheels, tires
- Evaluation of accident vehicles
- Left Front Level Control System Sensor G78 on front axle
- Left Rear Level Control System Sensor G76 on rear axle, vehicles with front wheel drive
- Left Rear Level Control System Sensor G76 on rear axle, vehicles with all wheel drive
- Front suspension, servicing
- Wheel bearing housing as of model year 2002, modified
- Control arm as of model year 2002, modified
- Connecting link for stabilizer, modified
- Threads in longitudinal member, servicing
- Separating connections between upper control arms and wheel bearing housing
- Removing
- Wheel bearing housing, removing and installing
- Installing
- Front wheel bearing, pressing out and in with wheel bearing housing installed
- Pressing in wheel bearing
- Lower control arm, checking
- Lower control arm, removing and installing
- Guide link, removing and installing
- Bushings for front and rear upper control arms, replacing
- Rear axle in unloaded position
- Measure -a- from lower edge of wheelhouse to center of wheel
- Measurement -a- measured
- Rear axle, removing and installing
- Shock absorber for vehicles with steel wheel bearing housings, removing and installing
- Shock absorber for vehicles with aluminum wheel bearing housings, removing and installing
- Bonded rubber mounting for transmission support, pressing out and in
- Steel wheel bearing housing and control arm, servicing (vehicles with all wheel drive)
- Rear wheel bearing, pressing out and in with wheel bearing housing installed
- Pulling bearing inner race off hub
- Pressing out first bonded rubber mounting
- Installing bonded rubber mounting into wheel bearing housing
- Wheel bearing housing (aluminum) and control arm, vehicles with all wheel drive, servicing
- Pressing out first bonded rubber bushing
- Installing bonded rubber bushing into wheel bearing housing
- Drive axle, removing and installing
- Drive axle with constant velocity joint, servicing
- Pressing Off Inner Constant Velocity Joint
- Pressing On Inner Constant Velocity Joint
- Wheel mounting
- General
- Vehicles with Electronic Stabilization Program (ESP)
- Requirements
- Explanation of PR. No. 1BA, 1BC, 1BE, 1BB, 1BF and 1BP
- Rim run-out compensation
- Toe constant "S"
- Suspension 1BA, 1BC, 1BE, 1BF
- Vehicles with heavy duty suspension 1BB/1BP, 1BF
- Raising vehicles with Suspension 1BA, 1BC, 1BE, 1BF
- Raising vehicles with heavy duty suspension 1BB/1BP, 1BF
- Vehicles pulling to one side
- Vehicles involved in an accident
- Checking center position on steering rack
- Front axle camber, centering
- Rear axle camber (vehicles with front-wheel drive), checking
- Rear axle toe (vehicles with front-wheel drive), centering
- Toe on front axle, adjusting
- Wheel centering seat, protecting against corrosion
- Steering column, checking for damage
- Tie rod, removing and installing
- Steering gear, vehicles with 4 or 6-cylinder engines, removing and installing
- Steering gear, vehicles with 8-cylinder engine, removing and installing
- Steering system, bleeding
- Steering system, checking for leaks
- Power steering gear, adjusting
- Power steering pump delivery pressure, 6-cylinder injection engine, checking
- Power steering pump for 8-cylinder injection engine, removing and installing