Maintenance Procedures: Other Volkswagen Passat B5 рестайлинг

Engine characteristics

*In exceptional circumstances min. 95 RON unleaded, however with reduced performance.

*In exceptional circumstances min. 91 RON unleaded, however with reduced performance.

*May not be driven with RME fuel (bio Diesel)!

*When operating with diesel fuel with elevated sulfur content, the diesel particle filter service life is reduced.

Technical Data - AEB

Technical Data - AHA

Technical Data - ATQ

Technical Data - AUG & AWM

Technical Data - ATW

Technical Data - BDP & BHW

VW engine oil standards

Refer to Fluid Capacity Chart for appropriate Model and Year.

Filter change interval

Refer to Maintenance Service Circular for appropriate Model and Year.

Toothed belt change interval

Refer to Maintenance Service Circular for appropriate Model and Year.

Oil change service

Refer to Maintenance Service Circular for appropriate Model and Year.

Sticker

Apply sticker "First service" (at the delivery inspection) --> "First service" sticker .

Apply sticker "Next service" --> Sticker "Next service" .

Apply "data sticker" in customers service schedule --> Sticker "Data sticker" .

"First service" sticker

1. Attach during delivery inspection

1. Attach sticker on drivers side door beam (B-pillar).

Scheme 36

The sticker can be found as an instruction contained in the very front of the owner information packet.

1. Destroy the instruction after attaching the sticker!

Scheme 37

1. Mark Oil change service or Inspection service (whichever is the case next) with a cross and enter date / mileage or kilometer reading.
2. Attach sticker on drivers side door beam (B-pillar).

Scheme 38

1. Attach the upper of the two data stickers - arrow - in customers service plan.

Vehicles --> 09.00

Note. Connection for self-diagnosis is located on the right next to the parking brake lever beneath the cover.

1. Remove cover over Data Link Connector (DLC) on the right next to parking brake lever.
2. Connect diagnostic cable VAS 5051/6A connector to Data Link Connector (DLC) - arrow -.

Now follow information given on screen to start the desired functions.

Scheme 39

Vehicles 10.00 -->

Note. Connection for self-diagnosis is located in left footwell - arrow -.

1. Connect diagnostic cable VAS 5051/6A connector to Data Link Connector (DLC) - arrow -.
2. Turn on the tester.

Now follow information given on screen to start the desired functions.

Safety precautions

Lifting points for lifting platform and trolley jack

Front

Scheme 40

Position support plate on longitudinal floor plate reinforcement in dotted line area - arrow -.

Rear

Scheme 41

1. Position support plate at side member vertical stiffener in dotted line area - arrow 1 -.

The center of the support plate must align with marking - arrow 2 -.

Scheme 42

The vehicle identification number - arrow B - is found on the plenum chamber.

Meaning of Vehicle Identification Number (VIN)

Scheme 43

The vehicle data sticker - arrow - is located in rear of vehicle on the left in the spare wheel well. The vehicle data sticker can also be found in the service schedule for the customer.

Sticker contains the following vehicle data

Additional components for vehicles with time or distance dependent service

Engine oil level sensor Engine oil level sensor .

Brake pad wear indicator Brake pad wear indicator .

Lead-calcium-battery Lead-calcium-battery .

Engine oil level sensor

A sensor in the engine oil sump determines the oil level and oil temperature at intervals. A yellow warning lamp lights up in instrument cluster, if oil must be replenished.

Brake pad wear indicator

The brake pad wear indicator in the instrument cluster indicates whether the brake pads must be replaced (warning lamp). The wear measurement is made at the left front brake.

Lead-calcium-battery

Using a maintenance-free 12V battery.

Description: Black battery housing, magic eye, pasted over sealing plugs

Scheme 44

With this battery, the "magic eye" - arrow - has two functions

1. To indicate the amount of charge the battery has.
2. To indicate the electrolyte conditions of the battery acid.

Engine code and engine number

Engine code and engine identification -->

1. «10 ENGINE - ASSEMBLY»(ref-255332-S35124850702007053000000) for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): AEB, ATW
2. «00 TECHNICAL DATA»(ref-255335-S04607301802007053000000) for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): AUG, AWM
3. «00 GENERAL, TECHNICAL DATA»(ref-255334-S10333076382007053000000) for 2.0 LITER 4-CYL. 2V TDI PD ENGINE MECHANICAL, FUEL INJECTION GLOW PLUG, ENGINE CODE(S): BHW
4. «00 - GENERAL, TECHNICAL DATA»(ref-255333-S04291017552007053000000) for 2.8 LITER V6 5V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): AHA, ATQ
5. «00 - GENERAL, TECHNICAL DATA»(ref-255331-S34091013382007053000000) for 4.0 LITER 8-CYL. 4V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): BDP

Type plate

The type plate - arrow A - is in the engine compartment in the area of the right strut tower attached to the plenum chamber.

Vehicles for certain export countries have no type plate.

Airbag for driver and passenger, visually checking airbag units

Driver side airbag

Scheme 45

The airbag is indicated by the word "AIRBAG" embossed on the upholstered cover of the steering wheel.

1. Perform a visual inspection for any damages to the upholstered cover.

Front passenger side airbag

Scheme 46

The airbag is indicated by the word "AIRBAG" embossed on the right side of the instrument panel.

1. Perform a visual inspection for any damage to the surface of the instrument panel.

8-way seat with memory, perform initialization (activation)

Note. After disconnecting and reconnecting the vehicle battery, the memory system for the electric seat adjustment will not function. Therefore, the seats must be initialized again immediately, before a new vehicle is delivered. Thereafter, the vehicle battery should not be disconnected again.

Perform the following work procedure to initialize the memory system for the electric seat adjustment

1. Open drivers door.
2. Switch ignition on.
3. Adjust seat surface forward and upward until stop.
4. Adjust seatback forward until stop.

Automatic transmission, ATF level, checking

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1. «37 AUTOMATIC TRANSMISSION - CONTROLS, HOUSING»(ref-255345-S04734256242007053000000) for 5 SPD. AUTOMATIC TRANSMISSION 01V FRONT WHEEL DRIVE
2. «37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING»(ref-255347-S11050598652007053000000) for 5 SPD. AUTOMATIC TRANSMISSION 01VA FRONT AND ALL WHEEL DRIVE - EXTERNAL COMPONENTS, SERVICING
3. «37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING»(ref-255348-S38746189502007053000000) for 5 SPD. AUTOMATIC TRANSMISSION 01VA FRONT AND ALL WHEEL DRIVE - INTERNAL COMPONENTS, SERVICING

Battery, check battery terminals for secure seating

Special tools, testers and auxiliary items required

Scheme 47

1. Torque wrench V.A.G 1331

Note. Tight battery connections assure trouble-free battery function and long service life.

Perform the following work procedure

Scheme 48

1. Push battery cover toward left - arrows - and remove cover upward.

Scheme 49

1. Check whether battery terminal clamps - 3 - and - 4 - are seated securely on the battery terminals by moving the battery positive wire - 1 - and the battery Ground (GND) wire - 2 - back and forth by hand.

If the battery clamp on positive terminal is not seated securely

Note. Before disconnecting battery, obtain radio anti-theft code. When the battery is re-attached, remember to check the vehicle accessories (radio, clock, electric window regulators, etc.) according to the repair manual and/or the operators manual.

1. First disconnect battery clamp - 4 - at battery negative (-) pole.
2. Tighten battery clamp - 3 - on battery positive terminal to 5 Nm.
3. Re-connect battery clamp - 4 - on battery negative terminal and tighten to 5 Nm.

If the battery clamp on negative terminal is not seated securely

1. Tighten ground connection - 4 - on battery to 5 Nm.

Battery, check

1. Check battery as described in the following --> «27 - BATTERY, STARTER, GENERATOR, CRUISE CONTROL»(ref-255357-S00731330752007053000000)

Checking tires, tire condition, wear pattern, inflation pressure and tread depth

Checking condition of tires --> Tire condition, checking .

Checking tread wear --> Checking tire wear pattern .

Depth of tire tread (including spare wheel): Checking --> Depth of tire tread: Checking and noting .

General notes --> General notes .

Tire pressure: Checking, correcting inflation pressures if necessary --> Tire pressure: Checking, correcting inflation pressures if necessary .

Special tools, testers and auxiliary items required

Scheme 50

1. Tire filling unit VAS 5216

Tire condition, checking

Tests during delivery inspection

1. Check tires (tread and side walls) for damage and remove foreign material for example nails and glass splinters if necessary.

Tests during inspection service

1. Check tires (tread and side walls) for damage and remove foreign material for example nails and glass splinters if necessary.
2. Check tires for scuffing, one sided wear, porous side walls, cuts and fractures.

Checking tire wear pattern

The tread wear on the front tires will help determine whether toe or camber need to be checked.

1. Feathered edges of the treads may indicate faulty toe adjustment.
2. One-sided tread wear is mainly attributed to incorrect camber.

When wear of this nature is noticed determine cause by performing alignment checks (repair measure).

Scheme 51

1. Check tire tread depth

Minimum 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 depth is approaching the legal minimum permissible depth, the customer must be informed.

General notes

Note. "Check tire inflation pressure" applies also to the spare wheel in case the vehicle is equipped with a regular spare tire or mini-spare tire. Tire inflation pressure table applies to normal tires, for all tire sizes installed at factory. Observe that the inflation pressure specifications refer to the air pressure of cold tires. Do not reduce increased pressures on warm tires. Tires pressures for the relevant model are on a sticker attached to the inside of fuel tank flap. Adapt tire pressure corresponding to load. The spare wheel receives the highest tire pressure designated for the vehicle. Utility vehicles are predominantly driven with the tire pressure specified for full load. The specified tire inflation pressures include a trailer up to a speed of 80 mph (130 km/h).

Winter tires

Note. Important information on the recommended winter tires can be found in ElsaWin ; Technical Information; Wheels/tires guidebook. For winter tires, tire inflation pressure must be increased approx. 0.2 bar.

Meaning of speed indexes in the table

1. Q - up to 100 mph (160 km/h)
2. T: up to 118 mph (190 km/h)
3. H: up to 130 mph (210 km/h)
4. W: up to 167 mph (270 km/h)

1. Y: up to 186 mph (300 km/h)

Tire pressure: Checking, correcting inflation pressures if necessary

Tire pressure values (for all tire sizes installed by the factory)

Tire pressure value table for summer tires or all-season tires

1. Sedan with gasoline engine, refer to «Sedan With Gasoline Engine»(ref-255362-S16322795892007110100000) .
2. Sedan with diesel engine, refer to «Sedan With Diesel Engine»(ref-255362-S13609611482007110100000) .
3. Sedan with gasoline engine and All Wheel Drive (AWD), refer to «Sedan With Gasoline Engine And All-Wheel Drive»(ref-255362-S08851627652007110100000) .
4. Sedan with diesel engine and all-wheel drive, refer to «Sedan With Diesel Engine And All-Wheel Drive»(ref-255362-S35510542302007110100000) .
5. Wagon with gasoline engine, refer to «Wagon With Gasoline Engine»(ref-255362-S18294595682007110100000) .
6. Wagon with diesel engine, refer to «Wagon With Diesel Engine»(ref-255362-S38177199142007110100000) .
7. Wagon with gasoline engine and all-wheel drive, refer to «Wagon With Gasoline Engine And All-Wheel Drive»(ref-255362-S28560395232007110100000) .
8. Wagon with diesel engine and all-wheel drive, refer to «Wagon With Diesel Engine And All-Wheel Drive»(ref-255362-S18700605702007110100000) .

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

Spare wheel with standard tire

The spare wheel receives the highest tire pressure designated for the vehicle.

Brake system, visual check for leaks and damage

Check the following components for leaks and damage

1. Brake master cylinder
2. Brake booster (on anti-lock braking system: Hydraulic unit)
3. Brake pressure regulator and
4. Brake calipers

1. Check that brake hoses are not twisted.
2. Turn steering to left stop and to right stop. During this operation no brake hose must touch any vehicle components.
3. Check brake hoses are not porous or brittle.
4. Check brake hoses and pipes for chafing.

1. Check brake connections and methods of securing for correct seating, leaks and corrosion.

Front and rear brake pads, checking thickness

Special tools, testers and auxiliary items required

Scheme 52

1. Pliers VAS 3314

Scheme 53

1. Torque wrench V.A.G 1332
2. Electric flashlight and mirror

Perform the following work procedure

Remove full wheel cover

The removal hook for removing the wheel cover is located in the vehicles tool kit.

Wheel bolts

The adapter to loosen/tighten the anti-theft wheel bolts is located with the vehicle tool kit.

Scheme 54

1. If necessary, remove wheel bolt caps using pliers 3314 or remove wheel trim.
2. Mark position of wheel in relation to brake disc.
3. Unbolt wheel securing bolts and remove wheel.

Scheme 55

1. Measure inner and outer pad thickness.

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). Inform customer!

Note. When replacing brake pads, it is absolutely necessary to check brake discs for wear! Checking and if necessary replacing brake discs is a repair measure.

1. Check brake disc for wear --> «46 - BRAKES - MECHANICAL COMPONENTS»(ref-255350-S22067375672007053000000)
2. Install wheel to marked position.
3. Tighten wheel securing bolts, using diagonal sequence to following tightening torque

Tightening torque: 120 Nm

1. Place adapter with vehicle tool kit after completing work.
2. Reinstall wheel bolt covers if necessary.

Full wheel cover, installing

Scheme 56

1. Install wheel cover by guiding the tire inflating valve through the designated recess - arrow -.

Rear disc brake pads

1. If necessary, remove wheel covers.
2. Illuminate area behind hole in wheel using an electric flashlight.

Scheme 57

1. Determine thickness of outer pad by checking visually.
2. Illuminate inner pad using an electric flashlight and mirror.
3. Determine thickness of inner pad by checking visually.

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). Inform customer!

Note. When replacing brake pads, it is absolutely necessary to check brake discs for wear! Checking and if necessary replacing brake discs is a repair measure.

1. Check brake disc for wear --> «46 - BRAKES - MECHANICAL COMPONENTS»(ref-255350-S22067375672007053000000)
2. If necessary, install wheel trim.

Electric windows, perform initialization (activation)

Note. After disconnecting and connecting the vehicle battery the automatic opening and closing features for the electric windows do not function. Therefore, the electric window regulators must be initialized from now on before the new vehicle is delivered. Thereafter, the vehicle battery should not be disconnected again.

Perform the following work procedure to initialize the electric window regulators

1. Close all doors and windows completely.
2. Lock the vehicle doors from the outside, either at the driver or passenger front door..
3. Unlock vehicle.
4. Lock vehicle anew from outside using drivers or front passengers door. Hold key a minimum of 1 second in locking position when doing this.

Ribbed belts, replacing (4 cyl. gasoline engines)

Special tools, testers and auxiliary items required

Scheme 58

1. Drift 3204

1. Torque wrench V.A.G 1331
2. Drift 5 mm

Perform the following work procedure

Removing

1. Set the lock carrier to service position: --> «50 BODY, FRONT»(ref-255352-S40424905372007053000000)
2. Mark rotational direction of ribbed belt if to be reused.

Scheme 59

1. Move tensioner in - direction of arrow - to release tension on ribbed belt.
2. Lock tensioning device using drift 3204.
3. Remove ribbed belt.
4. Remove fan from viscous fan pulley.

Scheme 60

1. Lock belt pulley to viscous fan pulley using drift ( 5 mm) - 1 -.
2. Remove bolt for viscous fan pulley (with 8 mm socket-head wrench - 2 - ) and remove viscous fan pulley together with belt pulley.
3. Mark installation position of 2-part belt pulley for coolant pump.

Scheme 61

1. Lock belt pulley of power steering pump with drift.
2. Unbolt 2-part belt pulley for coolant and remove ribbed belt.

Installing

1. Attach 2-part belt pulley to coolant pump and install new belt between coolant pump and power steering pump.
2. Tighten belt pulley evenly until belt has moved to outside of its running surface. If necessary turn power steering pulley or coolant pump pulley.
3. Lock power steering pump with drift.
4. Tighten belt pulley with 25 Nm to coolant pump.

Note. It is not necessary to adjust the ribbed belt tension via shims or similar.

1. Slide viscous fan in and install ribbed belt at viscous fan.
2. Tighten belt pulley with 30 Nm to viscous fan pulley.
3. Tighten viscous fan pulley to 45 Nm.
4. Install ribbed belt.

1. Tension ribbed belt, remove drift 3204 to do so.

Note. When installing ribbed belt be sure it fits properly in pulleys.

1. Start engine and check belt performance.

Scheme 62

1. Crank engine at vibration damper/belt pulley.
2. Check ribbed belt - 1 - for

1. Sub-surface cracks (cracks, core ruptures, cross sectional breaks)
2. Layer separation (top layer, cord strands)
3. Base break-up
4. Fraying of cord strands

1. Flank wear (material wear, frayed flanks, flank brittleness -glassy flanks-, surface cracks)
2. Traces of oil and grease

Note. Replace the belt if any damage is found. This will avoid possible break-downs or operating problems. The replacement of a ribbed belt is a repair measure.

Fuel filter, replacing (diesel engine)

Note. When installing, make sure water drain bolt of fuel filter does not make contact with oil filter bracket. The bolt could be loosened and get leaky. Install fuel filter so that water drain bolt is accessible.

4-cyl. TDI engines

Remove engine cover --> Upper engine cover, removing and installing .

Removing

Scheme 63

1. Remove pressure line from charge air cooler, loosen clamps - A - and bolt - B - to do so.

Scheme 64

1. Remove fuel line from hose connections - 1 - and - 2 -.

Note. Make sure that no diesel fuel gets onto the coolant hoses. If necessary, clean hoses immediately! Observe waste disposal regulations!

1. To apply a counter torque when loosening the filter from the filter head, attach a 17 mm open-end wrench at the water drain bolt - 3 -.
2. Loosen clamp - 4 - at bracket and remove filter from bracket.
3. Remove filter from upper part of fuel filter.

Install a new filter

1. Lightly lubricate new sealing and new rubber seal with diesel fuel.
2. Fill new filter with diesel fuel. This way the engine can be started faster.
3. Hand-tighten filter at upper part.

1. Insert fuel filter into bracket and tighten using a clamp screw - 4 -.

Note. Direction of flow is marked with arrows. Do not interchange connections!

1. Install the fuel lines to the hose connections - 1 - and - 2 - and secure hoses with hose clamps.

1. Install pressure line and secure using clamps - A - and bolt - B -.
2. Start the engine and perform a visual inspection of the fuel system for leaks.
3. Depress accelerator pedal several times to bleed fuel system.

Perform the following work procedure

1. Loosen ventilation screw - 3 -.
2. Connect hose at connection of water drain bolt - 5 - , loosen bolt and drain approx. 0.1L of fluid.

Note. Make sure that no diesel fuel gets onto the coolant hoses. If necessary, clean hoses immediately! Observe waste disposal regulations!

1. Tighten water drain bolt - 5 - and disconnect hose.
2. Close ventilation screw - 3 -.
3. Start the engine and perform a visual inspection of the fuel system for leaks.
4. Depress accelerator pedal several times to bleed fuel system.

Cooling system, freeze protection and coolant level, checking

Note. All engines are filled with freeze and corrosion protection additives G 12 Plus according to TL VW 774 F (purple color). Be sure to use only G 12 Plus. Purple G 12 Plus is compatible with the red G 12 coolant additive!

Note. G 12 Plus is suitable as a filled-for-life filling for cast iron and all-aluminum engines and gives optimum protection against freezing, corrosion damage, scaling and over-heating. G 12 Plus increases the boiling point to 275 ° F (135 ° C) and ensures for a better heat dissipation. The coolant portion of the mixture must amount to at least 40% (freeze protection to -13 ° F [-25 ° C]) and should not exceed 60% (freeze protection to -40 ° F [-40 ° C]). Otherwise the freeze protection will be reduced and the cooling efficiency will be worsened.

Checking freeze protection and adding coolant additive if necessary

Special tools, testers and auxiliary items required

Scheme 65

1. Refractometer T10007

Note. Read the bright/dark boundary to obtain an accurate reading for the following tests. Place a drop of water on the glass to improve the readability of the bright/dark boundary. The bright/dark boundary can be clearly recognized on the "WATERLINE".

1. Check the concentration of the coolant additive using refractometer T10007 (operating instructions).

Scheme 66

The scale - 1 - of the refractometer is designed for coolant additives G 12 according to TL VW 774 D, G 11 according to TL VW 774 C and G 12 Plus according to TL VW 774 F.

The scale - 2 - is designed for coolant additive G 13.

Note. The coolant additive G 13 is currently used only in vehicles of type "L 80". Freeze protection must be guaranteed to approx.-13 ° F (-25 ° C) (approx.-31 ° F (-35 ° C) in countries with an arctic climate). If climate conditions make greater freeze protection necessary, the amount of G 12 can be increased up to 60% (Freeze protection to approx. -40 ° F (-40 ° C). Adding more coolant reduces the freeze protection and reduces the cooling efficiency.

1. If freeze protection is insufficient, drain off required quantity shown in freeze protection table and add coolant additive G12 Plus which corresponds to TL VW 774 F.

Note. Observe waste disposal regulations!

Freeze protection table

1. Check coolant additive concentration after test drive again.

Checking coolant level and adding coolant if necessary

1. Check the coolant level in the coolant reservoir with the engine cold.

Scheme 67

1. Delivery inspection: Coolant level at max. marking.
2. Inspection service: Coolant level between min. and max. marking.

1. If coolant is too low, add required amount according to mixture ratio.

Note. Determine cause of fluid loss which cannot be attributed to normal use and rectify (repair measure).

Mixture ratio

Note. Coolant additive G 12 Plus prevents freezing and corrosion damage, scaling and also raises boiling point of coolant. 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%.

Scheme 68

Note. Depending on equipment, a strainer - 1 - is installed in lower section of filter housing in area of air intake channel.

This screen has the function of catching snow and ice in winter months, thus preventing blockage of the air filter element.

When filter element is removed and strainer - 1 - gets visible, proceed as follows

1. Unscrew mounting bolt - 2 -.
2. Remove strainer - 1 - upward from guide.
3. Tap on screen and blow out with compressed air.
4. Install screen, press downward and secure using mounting bolt.

Air cleaner: Cleaning housing and replacing filter element

Scheme 69

1. If present, remove cover - 1 - upward.

Note. On some vehicles, cover - 1 - is secured with bolts.

1. Remove intake air hose - 2 -.

Scheme 70

1. Remove screws - arrows - and remove heat shield.

Note. The heat shield is not installed on all vehicles.

Scheme 71

1. Open fasteners - 1 -.
2. Remove hose clamp - 2 - and remove air intake hose.

Note. On some vehicles, the air intake tube does not need to be removed.

1. Lift upper filter housing and remove upward or lay aside.

Scheme 72

1. Remove old filter element - 1 -.
2. Check whether a snow screen is present «Air filter housing with snow strainer»(ref-255362-S11913452182007121400000) .

Note. Observe waste disposal regulations!

1. Clean filter housing and install new air filter element.

1. Insert upper section of filter housing and secure using fasteners - 1 -.
2. If necessary, connect air intake hose and secure using hose clamp - 2 -.

1. If necessary, install heat shield, and fasten with screws - arrows -.

1. Install air intake hose - 2 -.
2. If necessary, install cover - 1 - and clip into guides or bolt on.

Engine oil level, check

Note the following

After stopping engine, wait at least 3 minutes to allow oil to flow back into oil pan.

1. Pull out oil dipstick and wipe with clean rag. Replace dipstick and push down to stop.

Note. Observe waste disposal regulations!

1. Pull out dipstick again and read oil level.

Scheme 73

If the dipstick appears as illustrated

If oil level is above area - A - , the catalytic converter can be damaged.

1. When oil level is below marking - C - , top off with oil to marking - A -. Oil specification --> «Service tables»(ref-255362-S11456457172007053000000) .

Applying data sticker in service schedule, --> Sticker .

Oil filter, replacing

Replacing oil filter, 4-cyl. Gasoline and TDI diesel engines, 6-cyl. gasoline engine 4-Cyl. Gasoline And Diesel Engines As Well As 6-Cyl. Gasoline Engine .

Replacing oil filter, 8-cyl. Gasoline engine 8-Cylinder Gasoline Engine .

Note. Avoid engine oil drips on components in engine compartment. Oil new O-rings before installation. Observe waste disposal regulations!

4-Cyl. Gasoline And Diesel Engines As Well As 6-Cyl. Gasoline Engine

Perform the following work procedure

Scheme 74

1. Cover subframe hole - 1 - using a cloth. This measure prevents used oil from dripping into the carrier.

Note. Observe waste disposal regulations!

Scheme 75

1. Loosen oil filter - arrow - with oil filter wrench or oil filter strap wrench and remove oil filter.
2. Thoroughly wipe oil filter flange using a cloth. This prevents used oil from dripping onto the subframe.

Note. Observe waste disposal regulations!

1. Clean engine sealing surface.
2. Lightly coat oil filter seal with oil. The oil filter can adhere better when tightening, which allows for best possible sealing.
3. Screw on new filter and hand-tighten.

8-Cylinder Gasoline Engine

Special tools, testers and auxiliary items required

1. Torque wrench (5 - 50 Nm) V.A.G 1331

Removing

Note. Observe waste disposal regulations! Oil new O-rings before installation. Avoid engine oil drips on components in engine compartment.

Scheme 76

1. Unscrew oil drain plug - 1 - of screw cap and drain oil.
2. Loosen screw cap - 3 - on hex head - 2 - or on circumference and remove.
3. Clean sealing surfaces at cap and at oil filter housing.

Scheme 77

Installing

1. Install oil filter - 5
2. Install cap - 3 - with new O-ring - 4 - and tighten to 25 Nm.
3. Install new sealing ring - 2 - for oil drain plug - 1 - and tighten to 10 Nm.

Installation is reverse of removal.

Filling engine oil

Oil specifications --> Service tables .

Engine oil capacities --> Fluid Capacity Chart for appropriate Model and Year.

General notes

Note. Observe waste disposal regulations!

1. After topping off with oil wait at least 3 minutes then check oil level.
2. Pull out oil dipstick and wipe with clean rag. Replace dipstick and push down to stop.
3. Pull out dipstick again and read oil level.

If the dipstick appears as illustrated

If oil level is above area - A - , the catalytic converter can be damaged.

1. At an oil level below marking - C - , fill up with oil up to marking - A -.

Engine and components in engine compartment (from above and below), visual check for leaks and damage

Perform visual check as follows

1. Check engine and components in engine compartment for leaks and damage.
2. Check hoses, pipes and connections of

1. Fuel system
2. Cooling and heating system
3. and brake system

for leaks, abrasions, porosity and brittleness.

Note. Ensure that all malfunctions detected are repaired within repair measures. If fluid losses are greater than can be reasonably expected, determine cause and repair (repair measure)

Upper engine cover, removing and installing

4-cyl. TDI engines --> 4-Cylinder TDI Engines .

1.8 L engines, (without intermediate shaft) --> 1.8L- Engine (Without Intermediate Shaft) .

1.8 L 5-valve engines --> 1.8 L 5-Valve Engines .

V6 gasoline engines --> V6- Gasoline Engines .

W8- engines --> W8 Engines .

Scheme 78

1. Remove screws - arrows - and remove engine cover upward.

Scheme 79

1. Remove screws - arrows - and remove engine cover upward.

Scheme 80

1. Loosen clamps - 1 - and remove engine cover upward.

Scheme 81

1. Remove cover - 1 - upward.

4-Cylinder TDI Engines

Removing

1. Pull out oil dipstick from guide tube.
2. Pry out covers - arrows - using a screwdriver.

Scheme 82

1. Remove hex nuts located underneath and remove engine cover.
2. Remove noise insulation lying beneath.

Installing

1. Install the engine cover, fasten with hex nuts, and clip in the caps - arrows -.
2. Reinsert oil dipstick into guide tube.

Radio, Radio/Navigation system, activating anti-theft coding

Radios and radio/navigation systems are delivered with a security code. Fixed code means that every unit with anti-theft coding has been programmed with its own code. This code is not active from the factory.

Refer to --> 91 RADIO, TELEPHONE, NAVIGATION, TRIP COMPUTER

Scheme 83

The tire repair kit is located in the spare wheel well - arrow

Scheme 84

In addition to the compressor, the tire repair kit contains a tire inflation cylinder with sealant.

Note. The tire sealant in the bottle has a limited shelf-life. Therefore, on the bottle, the expiration date - arrow - is displayed.

In this example, the expiration date 05/2003 has passed, and the bottle must then be replaced.

1. Check the expiration date and enter in maintenance tables.
2. Replace tire sealant, if expiration date has been reached.

Note. Residual tire sealant or full bottles, which have expired, must be disposed of. Old tire sealant or remainder of it must not be mixed with other fluids and must be disposed of.

Observe waste disposal regulations!

Climatronic, setting temperature to 72 F (22 C)

Note. A comfortable vehicle climate can be achieved the fastest with a temperature setting of 72 ° F (22 ° C). Therefore, this setting should only be adjusted when it is personally preferred.

1. Switch ignition on

Scheme 85

1. Check to see if 72 ° F (22 ° C) is set - 3 - in the display.

If necessary, perform the temperature setting as follows

1. Press button - 1 - for automatic operation. The display - 2 - will indicate "AUTO".
2. Adjust temperature to 72 ° F (22 ° C) by pressing button - 4 - for "cooler" or button - 5 - for "warmer".

Instrument panel cluster, adapting language

Note. The language variations for driver information can only be adapted for midline and highline instrument panel clusters.

1. Connect the diagnostic unit, --> «Diagnostic testing unit, connecting»(ref-255362-S17681944162007053000000) .
2. To perform the work procedure, use the Vehicle Diagnosis, Testing and Information System VAS 5051 A in the "Guided Fault Finding" function.

Windshield wash/wipe system and headlight wash system, checking function

Check freeze protection content of windshield cleanser concentrate G 052 164 --> Checking windshield wash/wipe system freeze protection concentration, add fluid if necessary .

Windshield wipe-/wash system: Checking spray nozzle adjustment --> Windshield washer system, checking nozzle setting, adjusting nozzles if necessary .

Headlight wash system: Checking spray nozzle adjustment --> Headlight wash system, checking nozzle setting, adjusting nozzles if necessary .

Note. If during the function test it is determined that the wiper blades are juddering or making noises, check the pitch angle of the wiper blades --> Windshield wiper blades, rest position, checking if windshield wiper blades are juddering , pitch angle, checking .

Windshield washer system, checking nozzle setting, adjusting nozzles if necessary

Note. In the event contamination in spray nozzle produces an uneven spray pattern, remove spray nozzle --> 92 - WINDSHIELD WIPER AND WASHER SYSTEM , and rinse it with water in the opposite direction of spray. Subsequently blowing through in the opposite direction of the spray flow with compressed air is permitted.

Spray nozzles for windshield washer system without presetting --> Spray Nozzles For Windshield Washer System Without Presetting .

Pre-adjusted spray jets for front windshield washer system --> Preset Spray Nozzles For Windshield Washer System .

Rear window washer system spray nozzle --> Spray Nozzle For Rear Window Washer System .

Spray Nozzles For Windshield Washer System Without Presetting

The spray nozzles are preset and cannot be adjusted afterwards since there is no vertical adjuster.

Scheme 86

In case both spray areas are not at the same height

1. Remove spray nozzle with lower spray area and install spray nozzle with vertical adjuster (repair measure).

Scheme 87

Preset Spray Nozzles For Windshield Washer System

The washer nozzles are preset. Small height adjustments can be made.

1. If both spray fields are not at same height, adjust spray direction upward or downward as follows

Scheme 88

1. Rotate eccentric on spray nozzle in - direction of arrow - using a screwdriver in order to adjust the spray jet upward.
2. To adjust spray jet downward, rotate eccentric on spray nozzle against - direction of arrow -.

Scheme 89

or

1. Adjust spray jet on adjuster - 1 - by hand upward or downward.

Spray Nozzle For Rear Window Washer System

Special tools, testers and auxiliary items required

Scheme 90

1. Windshield washer aiming tool T10127

Scheme 91

1. Check nozzle adjustment.

The spray jet must encounter wiper area at center.

1. If necessary, adjust spray nozzle using windshield washer aiming tool T10127.

Headlight wash system, checking nozzle setting, adjusting nozzles if necessary

Note. In the event contamination in spray nozzle produces an uneven spray pattern, remove spray nozzle --> 92 - WINDSHIELD WIPER AND WASHER SYSTEM , and rinse it with water in the opposite direction of spray. Subsequently blowing through in the opposite direction of the spray flow with compressed air is permitted.

Special tools, testers and auxiliary items required

Scheme 92

1. Adjustment device T10167

Headlight wash system: Checking nozzle setting and adjusting, vehicles --> 09.00

Perform the following work procedure

Scheme 93

Spray jet adjustment for left headlight (right headlight is identical but reversed)

1. Check nozzle adjustment.
2. If necessary, adjust spray jets as follows

Note. Mark the four mentioned points on windshield using a water soluble marker.

Scheme 94

1. Pull out spray nozzle - arrow - up to stop and align to the respective spray points using headlight washer adjusting tool T10167.

Headlight wash system: Checking nozzle setting and adjusting, vehicles 10.00 -->

Perform the following work procedure

Scheme 95

Spray jet adjustment for left headlight (right headlight is identical but reversed)

1. Check nozzle adjustment.

Note. Mark the four mentioned points on windshield using a water soluble marker.

1. If necessary, adjust spray jets as follows

Scheme 96

1. Pull out spray nozzle - arrow - up to stop and align to the respective spray points using headlight washer adjusting tool T10167.

Telematics Transport Mode, deactivating

For deactivating procedures see --> 91 RADIO, TELEPHONE, NAVIGATION, TRIP COMPUTER

Windshield wiper blades, checking rest position, adjusting if necessary

Special tools, testers and auxiliary items required

1. Torque wrench V.A.G 1331

1. Check the park position.

Scheme 97

Driver side

The space - A - between the wiper rubber and bottom edge of windshield must be 20 mm.

1. If necessary, adjust the park position by relocating the wiper arm.

Torque wiper arm: 20 Nm

Scheme 98

Passenger side

The space - A - between the wiper rubber and bottom edge of windshield must be 20 mm.

1. If necessary, adjust the park position by relocating the wiper arm.

Torque wiper arm: 20 Nm

Rear window (wagon)

1. Check the park position.

Scheme 99

The distance - a - between wiper blade and lower edge of windshield must be 25 mm (measured from lower edge of glass).

1. If necessary, adjust the park position by relocating the wiper arm.

Torque wiper arm: 15 Nm

Scheme 100

Note. Check the angle setting only if the wiper blades pulsate or make noise.

Special tools, testers and auxiliary items required

1. Wiper blade adjuster 3358 B

Perform the following work procedure

1. Park windshield wiper arms.
2. Remove windshield wiper.

Scheme 101

1. Set windshield wiper arm - 2 - in the wiper blade adjuster 3358 B and secure with the locking screw - 3 -.
2. Check the angle setting.

If necessary, adjust angle setting to specified value as follows

1. Place open-end spanner (24 mm) - 1 - onto adjustment device and set windshield wiper arm - 2 - to specified value - arrows -.
2. Release wiper arm - 2 - from adjustment fixture and again tighten lock screw - 3 -.
3. Compare adjusted value with specified value. If necessary repeat procedure until specified value is reached.
4. Remove adjustment fixture and reinstall wiper blade.

1. Check wiper blade for pulsation-free operation.

Transportation wiper blades, removing

Service

For all Models arriving at your dealership with transportation wiper blades

Transportation wiper blades are shorter than original equipment wiper blades and colored blue or yellow.

Original equipment blades are temporarily installed during Perfect Delivery Inspection to check wiper blade park position.

To ensure customer satisfaction, leave transportation wiper blades on vehicle until time of retail vehicle delivery.

Removing

Transportation blades can easily be removed as follows

Scheme 102

1. Grasp blade as shown and rotate in direction of - arrow - (toward windshield)

Scheme 103

1. Rotate blade in opposite direction - arrow - then, carefully slide blade off wiper arm.

Note. Wiper arm/blade alignment has been preset at factory, then checked and adjusted (if necessary) during PDI. DO NOT twist or bend wiper arm. If wiper arm/blade alignment is incorrect, chattering and/or streaking will occur. If arm has been bent: --> 92 - WINDSHIELD WIPER AND WASHER SYSTEM

1. Install original equipment wiper blades (located in trunk) at time of retail vehicle delivery.

Scheme 104

1. Wiper blade with air deflector - arrow - must be installed on drivers side with deflector on bottom of wiper blade.

Scheme 105

1. Passengers side wiper blade may be curved, install with curved ends of blade pointing up.

Headlights, adjusting (vehicles --> 09.00)

Headlights, adjusting (vehicles 10.00 --> ) --> HEADLIGHTS, ADJUSTING (VEHICLES 10.00 --> )

Adjusting headlights with gas-discharge lamps --> Headlight with gas discharge lamps

Note. When adjusting low beam, high- beam headlights are also adjusted at the same time.

Scheme 106

Headlight (left)

Both adjustment screws on right-hand headlight are similar.

1. Guide a Phillips-head screwdriver or socket head wrench through holes in lock carrier.
2. Turn the adjusting screws for lateral adjustment - 1 - and for height adjustment - 2 - until the specified setting is achieved.

Note. Also check whether both headlights work evenly when operating the headlight range adjuster. The adjustment of fog lights is performed automatically when adjusting headlights.

Other additional lights

Accessory auxiliary light systems must be checked and adjusted according to the guidelines valid for them.

Headlights, adjusting (vehicles 10.00 --> )

Note. When adjusting low beam, high- beam headlights are also adjusted at the same time.

Scheme 107

Headlight (left)

Both adjustment screws on right-hand headlight are similar.

1. Guide a Phillips-head screwdriver or socket head wrench through holes in lock carrier.
2. Turn the adjusting screws for lateral adjustment - 1 - and for height adjustment - 2 - until the specified setting is achieved.

Note. Also check whether both headlights work evenly when operating the headlight range adjuster.

Right fog light

Scheme 108

1. Unclip cover - arrow - in lower part of bumper from center of vehicle in order to adjust the fog lights.

Scheme 109

1. Turn adjustment screw - 1 - toward right to lower beam range. Lateral adjustment is not possible.

The left fog lamp adjustment is in the same location, but reversed.

Other additional lights

Accessory auxiliary light systems must be checked and adjusted according to the guidelines valid for them.

Headlight with gas discharge lamps

Note. Vehicles with gas discharge lamps are equipped with an automatic headlight range control. For these vehicles the "Basic Setting" sequence must be performed to adjust the headlights.

The following test- and adjustment instructions are applicable to all countries. But national legislation and regulations of the respective country is to be adhered to.

The following are prerequisites when adjusting headlights with gas discharge system

1. Tire pressure OK.
2. Lenses must not be damaged or dirty.
3. Reflectors and bulbs OK.
4. Parking brake must be released and no gears selected.

1. The steering wheel must be in straight-ahead position.
2. The vehicle must not be moved during basic setting (do not "open/close" doors, lean on vehicle or exit/enter vehicle).
3. Nobody may be in the vehicle and the vehicle must not be loaded.
4. 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.

1. Vehicle and headlight adjuster must be on a level surface. User manual for headlight adjuster.
2. Vehicle and headlight adjuster must be aligned.
3. Inclination must be set.

In the trim above the headlight, inclination measurements are stamped in "%". The headlights must be adjusted according to these measurements. Percentage information is based on a projection distance of 10 meters. For example: inclination of 1.2 % converts to approx. 12 cm.

Scheme 110

Headlight (left)

Both adjustment screws on right-hand headlight are similar.

1. Turn lateral adjustment screw - 2 - and vertical adjustment screw - 3 - respectively until the correct settings are achieved.

High-beam headlight (left)

Adjusting screw on right headlight is allocated symmetrically.

Note. The high-beam headlight can only be adjusted vertically. Lateral adjustment is pre-adjusted and must not be changed.

1. Turn the adjustment screw for height adjustment - 1 - until the correct setting is achieved.

Right fog light

1. Unclip cover - arrow - in lower part of bumper from center of vehicle in order to adjust the fog lights.

1. Turn adjustment screw - 1 - toward right to lower beam range. Lateral adjustment is not possible.

The left fog lamp adjustment is in the same location, but reversed.

Other additional headlights

Accessory auxiliary light systems must be checked and adjusted according to the guidelines valid for them.

Basic setting

Since the automatic Headlamp Range Control does not have a manual adjustment, the basic setting procedure must be performed to adjust the headlights.

The adjusting mechanism in the headlight housing will be damaged if the automatic Headlamp Range Control Basic Settings are not performed.

After the headlights are adjusted, the DTC memory must be checked. For that reason, this procedure must be strictly adhered to.

1. Press button.
2. Turn off ignition and disconnect diagnostic connection.

Perform basic setting

1. Connect the Vehicle Diagnosis, Testing and Information System VAS 5051 A --> «Diagnostic testing unit, connecting»(ref-255362-S17681944162007053000000) .
2. Switch ignition on.

Scheme 111

Indicated on display

Select mode of operation

1. On the display, press the button for "Vehicle On-Board Diagnostics" - arrow -.

Note. If the indications shown in the work procedure are not indicated on the display: User manual for VAS5051 tester

Scheme 112

Indicated on display

1. Press "55 - headlight range adjuster" - arrow - on the display.

Scheme 113

Indicated on display

Control module identification and the coding will be displayed - arrow -.

Scheme 114

Indicated on display

1. Press "04 - Begin basic setting" - arrow - on the display.

Scheme 115

Indicated on display

1. Press 001 on the display number block - arrow - (001 selects "display group number 001" ).
2. Confirm entry with Q button on display number block.

After "wait" , the following display appears

Scheme 116

Indicated on display

1. Adjust headlights now (vehicles --> 09.00 --> «HEADLIGHTS, ADJUSTING (VEHICLES --> 09.00)»(ref-255362-S32969224032007053000000) , vehicles 10.00 --> --> «HEADLIGHTS, ADJUSTING (VEHICLES 10.00 --> )»(ref-255362-S21232383312007053000000) , vehicles with gas discharge lamps --> «Headlights with gas discharge lamps, adjusting»(ref-255362-S00671970692007053000000) )
2. After adjusting the headlights, press the - arrow - button on the display.

Indicated on display

1. Press 002 on the display number block - arrow - (002 selects "display group number 002" ).
2. Confirm entry with Q button on display number block.

Scheme 117

Indicated on display

The control position of the headlights is now "learned" by the control module.

1. Press the - arrow - button on the screen display.

Indicated on display

1. Press the - arrow - button on the screen display.

Scheme 118

Indicated on display

1. Press "02 - Check DTC memory" - arrow - on the display.

Scheme 119

Indicated on display

Any system malfunctions that are stored will be displayed.

If malfunctions are stored then a repair measure is required. Pass malfunction protocol on for repair.

1. Press the - arrow - button on the screen display.

Scheme 120

Indicated on display

1. Press the Go to - arrow - button on the display.

Scheme 121

Indicated on display

1. Press the Exit - arrow - button on the display.
2. Press the Exit button in the exit menu.
3. Turn off ignition and disconnect diagnostic connection.

Tie rod ends, check play, security and joint boots

Perform the following work procedure

1. With vehicle raised (wheels hanging free), check play by moving tie rods and wheels. Play: zero play
2. Check mountings.

Scheme 122

1. Check joint boots - 1 - of control arms and joint boots - 2 - of tie rods for damage and proper seating.

Scheme 123

The filter is located in the plenum chamber, right side, below the cover - arrow -.

Perform the following work procedure

Removing

1. Remove bolt - 1 - and remove cover - arrow -.

Scheme 124

1. Remove retainer - 1 - upward.
2. Press filter element upward and remove toward front.

Note. Observe waste disposal regulations!

Installing

Note. When installing the new filter element, make sure the message "TOP-OBEN" on the element points upward.

Scheme 125

1. Insert new filter element - 1 - into frame - 2 -.
2. Slide in filter element beneath retainer - 3 - until stop.

1. Press retainer - 1 - in spring clip - 2 -.

Note. Both retainers secure the filter element in the frame.

1. Secure the cover - arrow - using the bolt - 1 -.

Filter is located on right side in plenum chamber under cover.

Perform the following work procedure

Removing

Scheme 126

1. Remove rubber seal - 1 - on plenum chamber cover toward front.
2. Carefully remove plenum chamber cover - 2 - upward.

Scheme 127

1. Remove retainer - 1 - upward.
2. Press filter element upward and remove toward front.

Note. Observe waste disposal regulations!

Installing

Scheme 128

1. Insert new filter element - 1 - into frame - 2 -.

Note. When installing the new filter element observe installation position.

1. Insert retainer - 3 - and push downward until stop.

1. Install plenum chamber cover - 2 -.
2. Install rubber seal - 1 - on plenum chamber cover.

Front axle control arm, checking

Work procedure

> 40 FRONT SUSPENSION

Scheme 129

For some models the front suspension struts have transportation protection devices installed. These models can be identified by a tag attached at the mirror - arrow -.

Note. Locking pieces should prevent vehicle from bouncing when being driven on to an automobile transport or railroad car and thereby become damaged.

Perform the following work procedure

Note. It is not necessary to remove the wheels.

1. Relieve load on coil spring by raising vehicle on lifting platform.
2. Remove transport locks (locking pieces) from suspension struts.

Digital clock

Please perform adjustment as follows

Hour setting

Scheme 130

1. Turn the adjusting button - 1 - (to the lower right of the tachometer) counterclockwise.

With every brief turn of the adjusting button, the setting changes by one hour. When turning and holding the adjusting button, the setting continually adjusts.

Minute setting

1. Turn the adjusting button - 1 - clockwise.

With every brief turn of the adjusting button, the setting changes by one minute. When turning and holding the adjusting button, the setting continually adjusts.

The clock can be set accurately to the second using the adjustment button - 1 - as follows

1. Turn the adjusting button to the right until the clock is one minute less than the time that is to be set.
2. Briefly turn the adjusting button to the right as soon as the second indicator of the reference clock reaches the full minute mark.

Analog clock

Please perform adjustment as follows

Note. There is an adjusting button in the instrument cluster at the lower right next to the tachometer. By pulling on this button, the time is set.

To move the indicator in minute mode

1. Briefly pull adjusting button.

To move the indicator slowly at first, and then faster

1. Pull and hold adjusting button.

Underbody protection, perform visual check for damage

During visual check, observe floor pan, wheel housings and sills!

Note. Malfunctions found must be repaired (repair measure). This inhibits corrosion and rusting through.

Plenum chamber, cleaning

Special tools, testers and auxiliary items required

1. Wet and dry vacuum cleaner VAS 5128

Note. On vehicles 1997 --> 2000 (V --> Y), the plenum chamber must be cleaned as part of an inspection service.

1. Thoroughly clean plenum chamber using a wet and dry vacuum cleaner.

Scheme 131

1. Always make sure the water drain - arrow - below the brake booster is free of debris.

Camshaft drive toothed belt, replacing (4-cyl. TDI engines)

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.

> 13 ENGINE - CRANKSHAFT, CYLINDER BLOCK for 2.0 LITER 4-CYL. 2V TDI PD ENGINE MECHANICAL, FUEL INJECTION GLOW PLUG, ENGINE CODE(S): BHW.

Camshaft drive toothed belt and toothed belt tensioner, replacing (V6 gasoline engine)

1. > «15 - ENGINE - CYLINDER HEAD, VALVETRAIN»(ref-255333-S38144838522007053000000) for 2.8 LITER V6 5V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): AHA,ATQ.

Camshaft drive toothed belt, replacing (1.8L 4 cyl. 5-valve gasoline engines)

1. > «15 ENGINE - CYLINDER HEAD, VALVETRAIN»(ref-255332-S28866690222007053000000) for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): AEB, ATW.

Condition of toothed belt, checking

1. Open fasteners of upper toothed belt cover and remove cover.
2. Check condition of toothed belt for

1. Cracks, cross-sectional breaks
2. Separation (cover layer, belt cords)
3. Wear-through on cover layer
4. Fraying of cord strands

1. Surface cracks (plastic shroud)
2. Traces of oil and grease

Note. It is essential to replace toothed belt if malfunctions are found. This will avoid possible break-downs or operating problems. Replacing the belt is a repair procedure.

Scheme 132

While checking the condition, take notice of the following defects

Spark plugs, replacing

Technical data, engine specifications --> Engine characteristics .

Spark plugs, 1.8L 5-valve engines, replacing --> Spark plugs, 1.8L 5-valve engines, replacing .

Replacing spark plugs, 1.8L 5-valve engines (without intermediate shaft) --> Spark plugs, 1.8L 5-valve engines (without intermediate shaft), replacing .

Spark plugs, V6- engines, replacing --> Spark plugs, V6-cyl. 5-valve engines, replacing .

Spark plugs, W8 engines, replacing --> Spark plugs, W8- engines, replacing .

Special tools, testers and auxiliary items required

Scheme 133

1. Spark plug wrench 3122 B

Scheme 134

1. Puller T10094

Scheme 135

1. Puller T10166

Scheme 136

1. Removal/installation tool T10029

1. Torque wrench V.A.G 1331

Scheme 137

1. Removal/installation tool T10118

Scheme 138

1. Puller T40039

Spark plugs, V6-cyl. 5-valve engines, replacing

Technical data, engine specifications, --> Engine characteristics .

Removing

Removing and installing top engine cover --> Upper engine cover, removing and installing .

Scheme 139

1. If a cover for the cylinder heads is present, loosen clamp screws - arrows - and remove cover upward.

Scheme 140

1. If a tool - arrow - for pulling off the spark plug connectors is attached to one of the plug connectors, remove tool from spark plug connector.

Scheme 141

1. Pull off spark plug connectors using spark plug connector tool - arrows -. If there is no spark plug connector tool, pull spark plug connectors off using spark plug connector tool T10029.

Scheme 142

1. Remove spark plugs using spark plug wrench 3122 B.

Installing

Note. Spark plug identification and tightening torque --> 28 - IGNITION/GLOW PLUG SYSTEM for 2.8 LITER V6 5V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): AHA, ATQ Observe waste disposal regulations!

1. Screw in new spark plugs using spark plug removal tool 3122 B and tighten to correct tightening torque.
2. Connect spark plug connectors.
3. Check ignition cables and connectors for proper connections.
4. Install engine covers.

Spark plugs, 1.8L 5-valve engines, replacing

Technical data, engine specifications, --> Engine characteristics .

Removing

Removing and installing top engine cover --> Upper engine cover, removing and installing .

Scheme 143

1. Remove ignition coils with spark plug connectors - 2 - and carefully remove upward. Disconnect spark plug connectors - 2 (center and bottom) - using spark plug connector tool T10029.
2. Remove spark plugs using spark plug wrench 3122 B.

Note. Spark plug identification and tightening torque --> 28 IGNITION/GLOW PLUG SYSTEM for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): AEB, ATW 28 IGNITION SYSTEM for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): AUG, AWM 28 IGNITION/GLOW PLUG SYSTEM for 2.0 LITER 4-CYL. 2V TDI PD ENGINE MECHANICAL, FUEL INJECTION GLOW PLUG, ENGINE CODE(S): BHW 28 - IGNITION/GLOW PLUG SYSTEM for 2.8 LITER V6 5V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): AHA, ATQ 28 - IGNITION/GLOW PLUG SYSTEM for 4.0 LITER 8-CYL. 4V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): BDP Observe waste disposal regulations!

Installing

1. Screw in new spark plugs using spark plug removal tool 3122 B and tighten to correct tightening torque.
2. Connect ignition coils - 2 - with spark plug connector and tighten. Connect spark plug connectors - 2 - using spark plug connector tool T10029.
3. Check ignition cables and connectors for proper connections.
4. Install engine cover.

Spark plugs, 1.8L 5-valve engines (without intermediate shaft), replacing

Engines (without intermediate shaft), TECHNICAL DATA - ATW , TECHNICAL DATA - AUG & AWM , TECHNICAL DATA - AUG & AWM .

Scheme 144

Technical data, engine specifications, --> Engine characteristics .

Removing

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

Removing and installing top engine cover --> Upper engine cover, removing and installing .

Spark plugs are located under ignition coils with power output stages - 2 -.

Scheme 145

Note. Note installation position of ignition coils with power output stages!

1. Remove both bolts - 1 -.

Scheme 146

Scheme 147

1. Pull all ignition coils approx. 30 mm out of cylinder head in - direction of arrow - using ignition coil puller T40039.
2. Push connector in direction of ignition coils with power output stages, press catch down by hand and disconnect connectors - arrows -.

Scheme 148

1. Remove spark plugs using spark plug wrench 3122 B.

Note. Spark plug identification and tightening torque --> 28 IGNITION/GLOW PLUG SYSTEM for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): AEB, ATW 28 IGNITION SYSTEM for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): AUG, AWM 28 IGNITION/GLOW PLUG SYSTEM for 2.0 LITER 4-CYL. 2V TDI PD ENGINE MECHANICAL, FUEL INJECTION GLOW PLUG, ENGINE CODE(S): BHW 28 - IGNITION/GLOW PLUG SYSTEM for 2.8 LITER V6 5V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): AHA, ATQ 28 - IGNITION/GLOW PLUG SYSTEM for 4.0 LITER 8-CYL. 4V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): BDP Observe waste disposal regulations!

Installing

Scheme 149

1. Screw in new spark plugs using spark plug removal tool 3122 B and tighten to correct tightening torque.

Scheme 150

1. Guide ignition coils with power output stages into cylinder head.
2. Align ignition coils with power output stages into designated recesses of cylinder head cover.
3. Connect all connectors to ignition coils - arrows -.

1. Press ignition coils with power output stages onto spark plugs by hand until stop. They must engage audibly.
2. Secure wiring using bolts - 1 -.
3. Install engine cover.

Spark plugs, W8- engines, replacing

Technical data, engine specifications, --> Engine characteristics .

Removing

Removing and installing top engine cover --> Upper engine cover, removing and installing .

1. Remove both side parts of intake manifold as follows

Scheme 151

1. Remove bolts - arrows - and carefully remove side part of intake manifold.
2. Remove rubber/metal seal.

Scheme 152

1. Disconnect connector from ignition coils 1 to 8 - arrows -.

Scheme 153

1. In order to be able to release the connector, use the Puller T10166.

Scheme 154

1. Remove spark plugs using spark plug wrench 3122 B.

Note. Spark plug identification and tightening torque --> 28 - IGNITION/GLOW PLUG SYSTEM for 4.0 LITER 8-CYL. 4V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): BDP Observe waste disposal regulations!

Installing

1. Screw in new spark plugs using spark plug removal tool 3122 B and tighten to correct tightening torque.
2. Insert ignition coil with power output stage into respective spark plug shaft so that the connector connections make no contact with the cylinder head cover.
3. Push ignition coil with power output stage onto spark plug by hand.
4. They must engage audibly.

1. Install rubber/metal seal.

1. Carefully install side part of intake manifold and tighten bolts - arrows - to 8 Nm.
2. Install engine cover.