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Passat B2
General information
Introduction to instructions
Preface to the repair manual
Vehicle Passport Data
Car models
Lifting and towing a car
Layout of the Volkswagen Passat
General requirements for car repair
Tightening torques for threaded connections
Technical characteristics of wheels and tires
Body specifications
User manual
Starting the engine
Engine lubrication system
Engine cooling system
Power supply system
Ignition system
Automatic transmission
Front wheel drive
Steering system
Front and rear suspension
Brake system
Battery charge indicator light
Programmable speed controller
Sunroof
Heating and ventilation
Windshield and side window defogging
Interior heating
Ventilation
Air conditioner
Controls and instrumentation
Fuels and lubricants of domestic production and their foreign analogues
Power unit
Engines 4-cylinder FZ
Design and technical characteristics. General information
Cylinder head specifications
Technical characteristics of the cylinder block
Technical characteristics of the crank mechanism
Technical characteristics of the valve timing mechanism
Technical characteristics of the lubrication system
Technical characteristics of the cooling system
Technical characteristics of the power supply system
Technical characteristics of the ignition system
Tightening torques of main threaded connections, kgf.m
Checking and adjusting clearances in the valve drive mechanism
Fuel pump
Carburetor Pierburg 1B1. Carburetor adjustment
The design and operating principle of the ignition system
The principle of operation of the ignition system
Setting the ignition timing
Ignition system troubleshooting diagram, voltage testing
Removal and installation the camshaft drive belt
Adjusting the tension of the timing belt
Removal and installation the cylinder head
Disassembly and assembly of the cylinder head
Removal and installation the engine
Disassembly and assembly of the engine
Preparatory stages of engine assembly
Engine assembly
Removal and installation of the oil pump of the lubrication system
Checking the oil pressure in the lubrication system
Replacing the coolant in the cooling system
Removal and installation the water pump
Engines 4-cylinder
Design and technical characteristics. General information
Cylinder head specifications
Technical characteristics of the cylinder block
Technical characteristics of the crank mechanism
Technical characteristics of the valve timing mechanism
Technical characteristics of the lubrication system
Technical characteristics of the cooling system
Technical characteristics of the power supply system
Technical characteristics of carburetors
Technical characteristics of the ignition system
Tightening torques of main threaded connections, kgf.m
Checking and adjusting clearances in the valve drive mechanism
Fuel pump of the power supply system
Operating principle of the Keihin 26-30 DC carburetor
Adjusting the Keihin 26-30 DC carburetor
Operating principle of the Pierburg 1B3 carburetor
Checking and adjusting the Pierburg 1B3 carburetor
Operating principle of the Pierburg 2B5 carburetor
Checking and adjusting the Pierburg 2B5 carburetor
Operating principle of the Pierburg 2E2 carburetor
Checking and adjusting the Pierburg 2E2 carburetor
The structure and principle of operation of the electronic ignition system
Checking and adjusting the ignition system
Removal and installation the ignition distributor sensor
Setting the ignition timing
Removal and installation the camshaft drive belt
Removal the cylinder head
Installing the cylinder head
Disassembly and repair of the cylinder head
Cylinder head assembly
Removal and installation the engine
Disassembling the engine
Engine assembly
Removal and installation the oil pump
Disassembly, inspection of technical condition and assembly of the oil pump
Replacing the coolant
Removal and installation the water pump
Disassembling and assembling the water pump
Adjusting the alternator drive belt tension
Engines 5-cylinder
Design and technical characteristics. General information
Technical characteristics of the cylinder block
Technical characteristics of the crank mechanism
Technical characteristics of the valve timing mechanism
Technical characteristics of the lubrication system
Technical characteristics of the cooling system
Technical characteristics of the power supply system
Technical characteristics of the fuel injection system «K-Jetronic» of the engine model JS
Technical characteristics of the ignition system
Tightening torques of main threaded connections, kgf.m
Checking and adjusting clearances in the valve drive mechanism
Construction of hydraulic tappets
Operating principle of hydraulic tappets
Checking the technical condition of hydraulic tappets
Fuel pump for WN engine
Carburetor Pierburg 2B5
Features of the device and the operating principle of the K-Jetronic system
Checking and adjusting the K-Jetronic system
Possible malfunctions of the K-Jetronic fuel injection system, their causes and methods of elimination
The structure and principle of operation of the electronic ignition system
Checking and adjusting the ignition system
Removal and installation the ignition distributor sensor
Removal and installation the camshaft drive belt
Cylinder head
Installing the cylinder head
Disassembly and repair of the cylinder head
Cylinder head assembly
Removal and installation the engine
Disassembling the engine
Engine assembly
Removal and installation the oil pump
Replacing the coolant
Removal and installation the water pump
Transmission
Clutch
Clutch design and specifications
Tightening torques of the main threaded connections of the clutch, kgf.m
Removal and installation the clutch
Mechanical clutch drive
Removal and installation the clutch release bearing with hydraulic drive
Removal and installation the hydraulic clutch slave cylinder
Removal and installation the master cylinder of the hydraulic clutch drive
Bleeding the clutch hydraulic drive
Adjusting the free travel of the hydraulic clutch pedal
Four-speed gearbox
Design and specifications of a four-speed gearbox
Tightening torques of main threaded connections, kgf.m
Removal and installation the gearbox
Disassembly and assembly of the gearbox
Disassembly and assembly of the primary shaft of the gearbox
Disassembly and assembly of the secondary shaft of the gearbox
Gearbox assembly
Disassembling and assembling the differential
Adjusting the distance between the end of the drive gear and the differential axle
Gear shift control mechanism
Five-speed gearbox
Design and technical characteristics
Tightening torques of main threaded connections, kgf.m
Removal and installation the gearbox
Disassembly and assembly of the gearbox
Disassembly and assembly of the primary shaft
Disassembly and assembly of the secondary shaft
Gearbox assembly
Adjusting the distance between the end face of the main gear pinion and the differential axle
Gear shift control mechanism
Hydromechanical gearbox
Design and technical characteristics
Gearbox specifications
Tightening torques of main threaded connections, kgf.m
Removal and installation of automatic transmission
Torque converter
Checking the torque converter
Gearbox control mechanism
Front wheel drive
Design and technical characteristics
Tightening torques of main threaded connections, kgf.m
Removal and installation front wheel drive shafts
Removal and installation the inner joint of the front wheel drive shaft
Removal and installation the outer joint of the wheel drive shaft
Chassis
Front suspension
Front suspension specifications
Front Wheel Specifications
Tightening torques of main threaded connections, kgf.m
Removal and installation of shock absorbers and springs
Removal and installation the anti-roll bar
Adjusting the front wheel alignment angles
Checking and adjusting the front wheel alignment
Checking and adjusting the front wheel alignment
Checking the longitudinal tilt angle of the pivot axis
Disassembly and assembly of front wheel hubs
Rear suspension
Rear suspension specifications
Technical characteristics of the rear wheels
Tightening torques of main threaded connections, kgf.m
Removal and installation the shock absorber with suspension spring
Removal and installation the rear suspension
Replacing the silent blocks of the rear suspension beam
Removal and installation rear wheel hubs
Replacing hub bearings
Adjusting the clearance in the rear wheel hub bearings
Steering
Design and technical characteristics
Tightening torques of main threaded connections, kgf.m
Removal and installation of the steering gear of the mechanical steering
Adjusting the clearance between the stop and the rack of the mechanical steering
Removal and installation the mechanical steering shaft
Removal and installation of the power steering gear
Replacing the seal and sealing gaskets of the valve body
Disassembly and assembly of the steering mechanism
Checking the tightness of the power steering system
Checking the power steering pump discharge pressure
Checking the pressure in the power steering system
Adjusting the tension of the power steering pump drive belt
Filling the power steering system
Brake system
Design and technical characteristics
Technical characteristics of the front wheel brake mechanisms
Technical characteristics of the rear wheel brake mechanisms
Technical characteristics of the brake drive
Tightening torques of main threaded connections, kgf.m
ATE brand front wheel brakes. Brake pad replacement
Replacement of front brake pads with VWII brake mechanisms
Removal and installation of the front brake mechanism of the VWII brand
Removal and installation the rear brake disc
Replacing rear brake pads
Removal and installation the brake master cylinder
Checking and adjusting the brake drive pressure regulator
Bleeding the brake hydraulic system
Bleeding the brake hydraulic system using a special installation
Bleeding the brake hydraulic system without special installation
Adjusting the parking brake
Body
Body elements
Upper body panels
Body floor parts
Checkpoint diagram of the body of Volkswagen «Passat» and «Santana» cars
Checkpoint diagram of the body of Volkswagen Passat and Santana cars with a sedan body
Checkpoint diagram of the Volkswagen Passat and Santana station wagon body
Checkpoint diagram of the Volkswagen Passat and Santana hatchback cars
Electrical equipment
Equipment and devices
Design and technical characteristics
Technical characteristics of the rechargeable battery
Generator specifications
Starter specifications
Technical characteristics of fuses
Technical characteristics of headlights
Removal and installation the generator
Disassembly and assembly of the generator
Adjusting the alternator drive belt tension
Removal and installation the starter
Disassembling and assembling the starter
Removal and installation the windshield wiper motor
Removal and installation the instrument cluster
Headlight adjustment
Removal and installation the heater
Electrical circuits
Legend of the electrical equipment diagram of Volkswagen «Passat» and «Santana» cars
1. Electrical diagram of the Passat L, S, L5, GL and GLS cars of the 1981 model year
2. Electrical diagram of the Passat C, CL, GL, GL5 and Santana LXy GX and GX5 1982 model year
3. Electrical diagram of Passat C, CL, GL and Santana LX, GX 1984 model year cars
4. Electrical diagram of the Passat CL5 and GL5 and Santana LX5 and GX5 1984 model year
7. Features of the electrical equipment diagram of cars with the DS engine of the 1983 model year
8. Features of the electrical equipment diagram of cars with JS engine
9. Features of the electrical equipment diagram of the Formula E cars of the 1981 and 1982 model years
10. Features of the electrical equipment diagram of cars of the model «Formule E» of the 1983 model year
11. Features of the electrical equipment diagram of cars of the model «Formule E» with chassis number 32 B 087 125
12. Features of the electrical equipment diagram of Santana cars of the «Formule E» model since 1983 model year
13. Features of the electrical equipment diagram of cars with automatic transmission manufactured before August 1982
14. Features of the electrical equipment diagram of cars with automatic transmission produced since August 1982
15. Features of the electrical equipment of vehicles with an automatic engine stop and start device
Passat B3
General information
User manual
About the environmental friendliness of the Volkswagen Passat
Car security systems
General view of controls
Car keys
Central lock
Back door
Car alarm system
Infrared remote control
Front seat adjustment
Rear seats of a car
Car luggage compartment
Pedals and handbrake
Manual transmission
Automatic transmission
Height adjustable steering column
Car ignition switch
Starting the car engine
Instrument panel
Control lights
Dashboard switches
Direction indicator and low/high beam switch lever
Constant speed control device
Windscreen wipers/washers (right steering column switch)
Heating and ventilation (manual heater)
Automatically controlled heater (Thermotronic)
Car air conditioning
Driving Tips
Running in a new car — the first 1500 km
Economical operation of the car (recommendations)
Technical conditions and condition of the car
Instructions for vehicles with a catalytic converter in the exhaust system
Braking a car
Maintenance instructions
Refueling a car
Fuel used — petrol engines
Fuel used — diesel engines
Automatic transmission oil
Power steering system
Opening the hood
Engine compartment
Motor oil
Cooling system
Radiator fan
Brake fluid
Car battery
Spark plugs
V-shaped drive belts
Car windshield washers
Windscreen wiper blades
Heater air intake filter
Car wheels and tires
Operating a vehicle in other countries
Spare tire of a car
Fuses for electrical circuits
Lifting a car
Starting the engine from an external battery
Towing a car
Car wash
Paint and varnish care
Protection of the underbody and body cavities with anti-corrosion agents
Protection of the engine compartment with anti-corrosion agents
Caring for cushion upholstery
Essential tools for car maintenance
VW PASSAT Service Chart
Technical data
Engine characteristics
Speed characteristics
Fuel consumption
Wheel sizes
Tire pressure
Weight of vehicle and trailer
Dimensions and filling volumes
Vehicle details
Power unit
Engine repair
Basic information about engines
Key engine characteristics
Removal and installation the engine
V-belt/toothed belt drive
Loosening/tightening the timing belt
Removal and installation the timing belt
Camshaft / valve drive 4-cylinder
Removal and installation the camshaft 4-cylinder
Cylinder head
Removal and installation the cylinder head
6-cylinder camshaft chain drive
Removal and installation the cylinder head 6-cylinder
Checking hydraulic tappets
Removal and installation valves
Replacing valve stem seals
Checking the valve guides
Finishing of the seat/valve seat chamfer
Lapping valve seats
Tensioning/replacing the V-belt
Tensioning/replacing the poly V-belt
Jump starting from another car
Towing a car
Visual inspection for oil leaks
Checking the V-belt / poly V-belt
Checking the condition and tension of the toothed belt
Compression check
Engine fault diagnostics
Ignition system
General information about the ignition system
Ignition system TSZ-H
Ignition system VEZ
Digifant Ignition System
Precautions when working with electronic ignition systems
Checking the ignition coil
Checking high voltage wires
Checking the distributor rotor
Distributor of ignition systems TSZ and Digifant
Removal and installation the ignition distributor
Checking the TSZ-H system switch
Checking the Hall sensor
Adjusting the ignition timing and checking the knock sensor
Checking/adjusting ignition timing
Ignition timing angle values
Spark plugs
Checking the distributor cap
Checking electrical connections
Removal and installation spark plugs
Ignition system fault diagnostics
Lubrication system
General information about the lubrication system
Oil circulation
Oil pan / oil pump
Dynamic oil pressure control
Checking hydraulic switches/oil pressure
Removal and installation the oil pan / replacing the gasket
Removal and installation / checking the oil pump
Engine oil change
Diagnosing oil circulation problems
Cooling system
Coolant circulation
Coolant pump/thermostat
Replacing the coolant
Removal and installation / checking the thermostat
Removal and installation the coolant pump
Checking the thermal switch of the electric fan
Removal and installation the radiator
Checking the cooling system
Checking the additional fan activation
Checking the Low Coolant Level Indicator
Checking the additional coolant pump
Visual inspection of tightness
Checking the coolant level
Antifreeze check
Antifreeze specifications
Diagnostics of cooling system faults
Supply system
General information about the power supply system
Carburetor adjustment
Fuel supply problems with a carburetor
Be careful when working with fuel supply systems
The device of the carburetor 2E3
Removal and installation the carburetor
Checking/adjusting idle speed and CO content
Adjusting the gas thrust
Checking the automatic device for enriching the combustible mixture at start-up
Removal and installation of automatic device for enriching the combustible mixture at start-up
Checking and adjusting the crankshaft speed of a cold engine at idle speed
Checking the thermo-pneumostatic valve
Checking the fuel shut-off valve
Checking and adjusting the performance of the accelerator pump
Checking the vacuum limiter (Pulldown)
Checking the time-delay thermal valve
Checking the intake manifold heating system
Removal and installation the air intake guide casing
Checking the intake air heating
Removal and installation the fuel pump
Removal and installation the fuel level sensor
Replacing the air filter
Replacing the fuel filter
Carburetor fault diagnostics
Petrol injection system
General information about the injection system
Exhaust gas toxicity control
Safety precautions when working with injection systems
Mono-Jetronic injection system
Querying the memory device for fault codes
Checking idle speed and CO content
Checking the injector valves / idle switch
Checking the throttle potentiometer
Checking the oxygen sensor
Checking the temperature sensor
Checking the intake manifold heating system
Electrical test of the Mono-Jetronic injection system
Injection system Digifant / Simos
Checking/adjusting idle speed and CO content Digifant
Checking the regulation of the oxygen sensor Digifant
Checking the Idle Speed Increase Valve Digifant
Checking the forced idle and enrichment switch with the throttle fully open
Removal and installation / checking of Digifant/Simos valve injectors
Simos injection system since 10/94
Electrical test of the Digifant injection system
K-Jetronic injection system
KE-Motronic injection system
Checking/adjusting idle speed and CO content K-Jetronic
Checking the stabilization of the engine speed at idle speed K-Jetronic
Checking the K-Jetronic Idle Switch
Checking the temperature sensor K-Jetronic, KE-Motronic
Checking and adjusting the position of the K-Jetronic, KE-Motronic flow meter flap
Checking the control lever and the distribution piston K-Jetronic, KE-Motronic
Removal and installation the fuel starter valve / K-Jetronic thermostat
Motronic injection system
Prescribed CO content values
Removal and installation / inspection of K-Jetronic valve injectors
Checking/removing and installing the fuel pump
Checking the fuel pump relay
Adjusting the gas thrust
Checking the intake air heating
Replacing the air filter
Diagnostics of faults of injection systems K-Jetromic / Digifant
Diesel engine
How a diesel engine works
Turbocharger
Adjusting the timing belt tension
Toothed belt drive
Removal and installation the timing belt / adjusting the engine control
Checking the preheating system/glow plugs
Removal and installation glow plugs
Diesel engine injection system
Checking/replacing the fuel shut-off solenoid valve
Adjusting the gas thrust
Adjusting the cold start thrust
Checking and adjusting idle speed/maximum speed
Checking the start of the high pressure fuel pump
Removal and installation injectors
Fuel supply in a diesel engine
Fuel filter — preheating system
Replacing the air filter of a diesel engine
Removal water/replacing fuel filter
Diagnostics of faults of the injection system of diesel engines
Exhaust system
Exhaust gas system
Removal and installation of the exhaust system
Replacing the pressure springs
Removal and installation the subsequent muffler
Removal and installation the oxygen sensor
Cars with a catalytic converter
Handling of vehicle catalytic converters
Visual inspection of the exhaust system
Transmission
Clutch
Clutch device
Clutch drive
Removal and installation / checking of the clutch
Bleeding air from the clutch drive
Replacing the clutch cable
Diagnosing Clutch Faults
Car gearbox
Removal and installation the gearbox
All wheel drive
Checking the gearbox oil level
Visual inspection of gearbox tightness
Gear shifter
Adjusting the gear shifter
Removal and installation the gear shift lever
Removal and installation gear shift cables
Automatic transmission
Checking the oil level / changing the oil in the automatic transmission
Adjusting the throttle of the automatic transmission
Chassis
Suspension
Front axle design
Front suspension device
Removal and installation the front shock absorber strut
Shock absorber strut device
Removal and installation the shock absorber / disassembling the shock absorber strut
Removal and installation the propeller shaft
Cardan shaft device
Disassembly and assembly of the cardan shaft
Visual inspection of the front wheel suspension
General information about the rear axle
Rear shock absorber strut device
Removal and installation / disassembly of the rear shock absorber strut
Wheel with drum brake mechanism
Removal and installation the rear wheel hub bearing
Adjusting the wheel hub bearing clearance
Wheel with disc brake mechanism
Steering
General information about steering
Steering drive device
Precautions when working with an airbag
Removal and installation the airbag assembly
Removal and installation the steering wheel
Removal and installation the tie rod end
Checking the steering wheel free play
Power steering vane pump
Checking the tightness of the steering drive
Bleeding the steering gear
Elimination of vibrations of the steering wheel / front of the car
Steering maintenance
Definition of chassis parameters
Brake system
General information about the braking system
Front Brake Caliper VW II (vehicle models up to 9/93)
Removal and installation front disc brake pads VW II
Girling Front Brake Caliper
Removal and installation Girling front disc brake pads
Front brake caliper Ate/Teves (cars with engines of 150, 174 hp from 10/93)
Removal and installation front disc brake pads Ate/Teves
Girling Rear Brake Caliper
Removal and installation rear disc brake pads
Eliminating Disc Brake Squealing
Checking the thickness of brake discs
Removal and installation the brake disc / brake caliper
Brake drum device
Removal and installation the brake drum
Brake pads device
Removal and installation brake pads
Removal and installation the wheel brake cylinder
Brake fluid
Bleeding the brake system
Replacing the brake line / brake hose
Checking the brake booster
Checking the brake force regulator
Adjusting the handbrake
Description of the ABS system
Checking the brake fluid level
Checking the thickness of brake pads
Visual inspection of brake lines
Replacing brake fluid
Brake fault diagnostics
Wheels and tires
Wheel and tire sizes
Wheel and tire designations
Wheel replacement
Running in and storing tires
Wheel balancing
Anti-skid chains
Emergency wheel
Tire maintenance
Diagnosis of tire faults
Body
Exterior
General information about the body
Removal and installation the front bumper
Removal and installation the rear bumper
Removal and installation the front wing
Removal and installation the front trim
Removal and installation the trunk lid trim
Removal and installation the rear door trim
Removal and installation the outside mirror / replacing the mirror glass
Removal and installation the protective cover
Removal and installation wheel arch trim / door protective trim
Removal and installation the lower side member trim
Removal and installation the lock beam with the front trim
Cleaning the water drainage hoses of the sliding roof panel
Removal and installation the roof lining
Removal and installation the roof rail
Interior
Removal and installation the hood cable drive
Removal and installation the trunk lid lock
Removal and installation the rear door lock/cylinder housing
Removal and installation the lock cylinder
Central locking system
Removal and installation the actuator of the front door lock
Removal and installation the rear door gas-filled shock absorber
Removal and installation / adjustment of the door
Removal and installation the front door window glass
Removal and installation the outer window glass guide
Removal and installation the front door window regulator
Removal and installation the door lock
Removal and installation the door handle
Removal and installation the inner door seal
Removal and installation / adjustment of the rear door
Removal and installation the rear door window regulator
Removal and installation rear door window glass
Replacing the outer window glass guide
Adjusting the trunk lid
Rear door adjustment
Removal and installation door trim
Rear door trim
Removal and installation the center console
Visual inspection of seat belts
Heating system
General information about the heating system
Removal and installation the suction pipe
Checking, removing and installing the heater fan
Removal and installation of the heating system control unit
Removal and installation / adjustment of heating system rods
Removal and installation the blower
Compressor V-belt tension
Removal and installation the dust and pollen filter
Diagnostics of heating system faults
Electrical equipment
Power devices
Electrical equipment system
Measuring instruments
Measurement technique
Installation of additional components of the electrical equipment system
Removal and installation the battery
Charging the battery
Spontaneous battery discharge
Battery maintenance
Electronic anti-theft system
Replacing fuses
Fuses/Relay Locations
Car Generator
Removal and installation the generator
Replacement / check of generator brushes / voltage regulator
Generator fault diagnostics
Removal and installation the starter
Starter fault diagnostics
Lighting system
Main headlight and turn signal light
Replacing bulbs in cars up to 9/93
Removal and installation headlight/turn signal light
Removal and installation the reflector
Removal and installation the headlight leveling actuator motor
Removal and installation fog lights
Headlight adjustment
Rear light arrangement
Replacing bulbs in cars since 10/93
Replacing interior lighting bulbs
Replacing the rear light bulbs
Replacing the license plate light bulb
Equipment and devices
Removal and installation the instrument panel
Removal and installation the tachometer shaft cover
Removal and installation the printed circuit board
Location of instrument panel terminals
Checking the voltage stabilizer
Replacing LEDs
Removal and installation the steering column switch
Removal and installation the steering wheel shaft lock housing
Removal and installation steering column trim
Removal and installation the ignition lock cylinder/steering wheel shaft
Removal and installation radio
Entering the radio code
Removal and installation the antenna
Removal and installation the roof antenna
Wiper system
Replacing the rubber band of the windshield wiper blade
Removal and installation / adjustment of windshield washer nozzles
Front wiper drive
Rear wiper drive
Windscreen washer system
Headlight washer system
Checking/replacing the windshield washer pump
Removal and installation the windshield wiper motor
Checking/Adjusting the Wiper Blade Angle
Diagnosing Windscreen Wiper Blade Rubber Band Faults
Electrical circuits
Getting to know the electrical circuit
Battery, ignition switch and starter
Generator, starter, intake manifold preheater
Mono-Motronic system control unit
Instrument panel, universal indicator switch
Instrument cluster diagram
Interior, luggage compartment and glove box lights
Headlights, parking lights, direction indicators
Direction indicators, brake lights, parking lights
Heated rear window, horn
Glass cleaning and washing system
Control unit of the direct injection system of a diesel engine
Heated and adjustable exterior mirrors
Thermal fuse for window lifter, window lifter switch
Heated driver and passenger seats next to the driver
Central locking system
Passat B4
General information
User manual
Control lamps on the instrument cluster
Controls and instrumentation
On-board computer
Opening the hood
Ignition or instrument and starter switch
Starting a gasoline engine
Starting a diesel engine
Starting the engine using an auxiliary battery
Gear shifting
Lighting and signaling
Replacing lamps
Glass cleaners and washers
Ventilation and heating of the passenger compartment
Doors and windows
Rear view mirrors
Adjusting the position of the steering wheel
Seat belts
Front and rear seats
Spare wheel
Lifting and towing a vehicle
Maintenance
View of the engine compartment
Checking the engine oil level
Engine oil change
Checking the coolant level
Air filter
Checking the fluid level in the power steering reservoir
Checking the fluid level in the brake hydraulic reservoir
Checking the electrolyte level in the battery
Tire pressure
General requirements for car repair
Technical data
Car models
Mass of cars
Overall dimensions of cars
Petrol 8-valve engines
Petrol 16-valve engines
Diesel engines
Performance indicators of cars
Filling tanks and used fuels and lubricants
Vehicle Passport Data
Tightening torques for main threaded connections
8-valve engine
Engine repair
Removal and installation of the power unit
Disassembling the engine
Engine assembly
Cylinder block. Features of the device
Checking the technical condition and repairing the cylinder block
Crank mechanism design
Connecting rod and piston group
Crankshaft and flywheel
Valve timing mechanism
Cylinder head
Removal and installation the cylinder head
Features of engine repair for cars «Passat GT 1.8 G60 Syncro»
Cooling and lubrication system
Features of the cooling system
Replacing the coolant
Removal, disassembly and assembly of the water pump
Checking the cooling system
Features of the lubrication system
Removal, disassembly, inspection of technical condition and assembly of the oil pump
Maintenance of the lubrication system
Supply system
EZ Engine Power System
Checking and adjusting the carburetor
Ignition system
Features of the ignition system of the EZ engine
Removal and installation the ignition distributor sensor
Setting the ignition timing using a stroboscope
Ignition system for «RP» engines manufactured before 1993.
Fuel injection «Mono-Jetronic»
Central fuel injection system «MONO-JETRONIC»
Checking and adjusting the fuel injection system «MONO-JETRONIC»
Fuel pump
System self-diagnosis
Checking the electrical circuits of the system
Checking the engine idle speed
Checking and adjusting the throttle valve opening
Checking the idle speed control valve
Checking the ignition retard control valve
Checking the fuel pressure regulator
Checking the throttle position sensor
Checking the coolant temperature sensor
Checking the incoming air temperature sensor
Checking the injector
Checking the injector ballast resistor
Checking the oxygen sensor in the exhaust gases
Checking the intake manifold heater
Checking the throttle damper
Control system «Mono-Motronic»
Integrated engine management system «MONO-MOTRONIC»
Checking and adjusting the fuel injection control subsystem
Checking the forced idle system
Fuel pump
Self-diagnosis
Ignition Timing Control Subsystem
Checking the KSUD «Motronic 2.9» of the «AEK» engine of the «Passat 1.6» car
Control system «Digifant»
Integrated engine management system «DIGIFANT»
Fuel injection control subsystem
Checking and adjusting engine idle speed
Checking the Idle Speed Control Solenoid Valve
Checking the supply voltage of the idle and full load switches on vehicles with a «PB» engine
Checking and adjusting the idle switch on the RV engine
Checking and adjusting the full load switch on the RV engine
Checking the forced-run and mixture enrichment system with the throttle valve fully open on the RV engine
Checking the fuel pressure regulator and residual fuel pressure
Fuel pump
Checking the air flow meter
Checking the coolant temperature sensor
Checking the incoming air temperature sensor
Checking the injectors
Checking the starting injector on the «2E» engine
Checking the intake manifold heater
Checking the oxygen sensor in the exhaust gases
Checking the electrical circuits of the KSUD «DIGIFANT»
Ignition Timing Control Subsystem
Adjustment of the fuel injection control subsystem of the Passat GT 1.8 G60 Syncro vehicles
Spiral supercharger «G60» of cars «Passat GT 1.8 G60 Syncro»
Control system «Simos»
Integrated engine management system «SIMOS»
Checking and adjusting idle speed
Checking and adjusting the throttle valve opening
Checking the fuel pressure in the system
Checking the idle switch
Checking the supply voltage of the mass air flow meter
Checking the coolant temperature sensor
Checking the intake air temperature sensor
Checking the idle speed control valve
Checking injection nozzles
Checking the oxygen sensor in the exhaust gases
Checking the camshaft position sensor
Checking the supply voltage of the crankshaft speed sensor
Checking the vehicle speed sensor
Checking the supply voltage and ground connection of the controller
Ignition Timing Control Subsystem
Spark plugs
Checking the operation of the ignition advance angle (IAA) control subsystem
16-valve engine
Engine repair
Features of the design of 16-valve gasoline engines
Crank mechanism
Features of the gas distribution mechanism
Features of the cylinder head design
Removal and installation the cylinder head
Disassembly and repair of the cylinder head
Removal and installation the camshaft drive belt
Main technical data of the «AAA» engine
Features of repair of the cylinder head of the engine «AAA»
Cooling and lubrication system
Cooling system. General information
Removal and installation the water pump
Disassembling and assembling the water pump
Lubrication system
Removal and installation the oil pump
Disassembly, inspection of technical condition and assembly of the oil pump
Checking the oil pressure in the lubrication system
Fuel injection «K-Jetronic»
Fuel injection system «K-Jetronic»
Design of some injection system devices
Work in different modes
Location of the K-Jetronic fuel injection system and ignition system components
Adjusting engine idle speed
Adjusting the throttle opening
Adjusting the throttle cable
Checking the performance of the fuel pump
Checking the air flow meter
Adjusting the position of the air flow meter pressure disc
Pressure check
Checking the fuel pressure in the system
Adjusting the fuel pressure in the system
Checking the control pressure on a cold engine
Checking the control pressure on a warm engine
Checking residual fuel pressure
Checking the fuel pressure in the system when the engine is stopped
Checking and adjusting the throttle position sensor
Checking the tightness of the injectors and the uniformity of fuel injection
Checking the starting injector
Checking the thermal time relay
Checking the control pressure regulator
Checking the idle speed control valve
Checking the coolant temperature sensor
Checking the mixture enrichment during acceleration with a cold engine
Checking for fuel cut-off during engine braking
Removal and installation the metering unit with air flow meter
Removal and installation injectors
Ignition system of the engine «KR»
Removal and installation the ignition distributor
Setting the initial ignition timing angle
Checking the automatic ignition advance
Checking and adjusting the fuel injection system «KE-Jetronic» of the engine «PL»
Possible malfunctions of the KE-Jetronic fuel injection system of the PL engine
Control system «KE-Motronic»
Integrated engine management system «KE-Motronic»
Fuel injection control subsystem
Checking and adjusting the fuel injection control subsystem
Checking the idle speed
Adjusting the CO content in exhaust gases
Checking and adjusting the idle switch
Checking and adjusting the full load switch
Adjusting the air flow meter potentiometer
Adjusting the position of the air flow meter pressure disc
Checking the idle speed control valve
Checking the supply voltage of the heating element of the oxygen sensor in the exhaust gases
Checking the mixture enrichment
Checking for fuel cut-off at forced idle
Checking the electromagnetic shut-off valve of the adsorber
Checking the fuel pressure in the system
Self-diagnosis system
Checking and adjusting the subsystem
Fuel system of the engine «9A»
Wiring diagram of the KE-Motronic control system for the 9A engine
Adjustment of the fuel injection control subsystem KSUD «Motronic» of the engine «AAA»
Possible malfunctions of the fuel injection control subsystem KSUD «Motronic» of the engine «AAA»
Control system «Digifant»
Integrated engine management system «Digifant 3.0/3.2»
Checking and adjusting the main units of the subsystem
Checking and adjusting the idle switch
Ignition Timing Control Subsystem
Checking the operation of the ignition timing control subsystem
Diesel engine
Engine repair
Diesel engines. General information
Removal and installation the engine
Disassembling the engine
Engine assembly
Cylinder block
Features of the connecting rod and piston group
Checking the technical condition of the connecting rod and piston group
Features of the crankshaft and flywheel
Features of the gas distribution mechanism
Features of the cylinder head design
Removal and installation the cylinder head
Disassembly, assembly, technical condition check and repair of the cylinder head
Removal and installation the camshaft drive belt
Cooling and lubrication system
Features of the cooling system
Removal and installation the water pump
Features of the lubrication system
Removal and installation the oil pump
Disassembly, inspection of technical condition and assembly of the oil pump
Maintenance of the lubrication system
Exhaust gas system
Power and control system
Features of the power supply system of engines «1Y», «RA», «SB», «AAZ»
Power supply system with mechanical drive of engines «1Y», «RA», «SB», «AAZ»
Removal and installation of fuel injection pump
Adjusting the fuel injection advance angle
Diesel Idle Speed Adjustment
Adjusting the fast idle speed of the diesel engine «AAZ»
Adjusting the maximum engine speed without load
Adjusting the residual fuel supply
Removal and installation injectors
Disassembly and inspection of the technical condition of injectors
Checking the operation of the injector needle valve
Checking and adjusting the injection start pressure of the injectors
Draining sediment from the fuel filter
Removal air from the fuel system
Diesel pre-heating system
Malfunctions of the diesel fuel system
Turbocharging system
Turbocharging system — general information
Removal and installation a turbocharger
Checking the boost pressure
Features of the turbocharging system
Operating principle of a variable geometry turbocharger
Removal and installation a turbocharger on an AFN engine
Checking the exhaust gas recirculation solenoid valve
Checking the boost pressure
Digital control system
Digital engine control system «1Z» and «AFN»
The structure and operating principle of a digital diesel control system
Checking and adjusting the central control system
Removal and installation injectors
Checking the injection start pressure of the injectors
Checking the tightness of the injectors
Checking the air flow meter and intake air temperature sensor
Checking the fuel temperature sensor
Checking the injection advance regulator slider potentiometer
Checking the speed controller
Checking the electrical circuits of the central control system
Checking the voltage in the pre-heating system
Checking the spark plugs
Transmission
Clutch
Clutch — features of the device
Removal and installation the clutch
Mechanical clutch drive
Checking the clutch operation
Removal and installation the clutch servo spring
Removal and installation the clutch master cylinder
Removal and installation the clutch slave cylinder
Bleeding the clutch hydraulic drive
Manual gearbox
Features of the mechanical gearbox
Removal and installation the gearbox
Disassembling the gearbox
Primary shaft of the gearbox
Assembling the primary shaft
Determining the thickness of the adjusting ring of the primary shaft bearings
Secondary shaft of the gearbox
Secondary shaft assembly
Selecting an adjusting ring for adjusting the preload of secondary shaft bearings
Replacing the bearings of the reverse intermediate gear axle
Differential
Selecting the differential bearing adjusting ring
Gearbox assembly
Removal and installation shift and gear selection cables
Adjusting the gear shift drive
Hydromechanical gearbox
Features of the hydromechanical gearbox type 096
Features of the hydromechanical gearbox type 01
Removal and installation of automatic transmission type 096
Checking the gearbox oil level
Gearbox oil change
Checking the oil level in the differential housing
Checking the oil level and replacing the oil in the gearbox housing of type 096 CNK, 096 CRR, 096 CSK, 096 CNP and type 01M
Checking the oil level in the differential housing
Replacing the mesh filter
Checking the gearbox control drive
Checking the instrument switch and starter key extraction lock
Disassembly and assembly of the gearbox control drive
Adjustment of the transmission control cable of type 096 CNK, 096 CRR, 096 CSK, 096 CNP and type 01M
Differential
Electrical diagram of the hydromechanical gearbox control system
Adjusting the electromagnetic locking device of the selector lever
Removal, installation and adjusting the selector lever lock cable
Replacing differential output shaft seals
Adjusting the bearings of the main gear drive shaft-pinion
Adjusting the bearings of the main drive pinion
Adjusting the differential turning resistance moment
Front wheel drive
Features of the front wheel drive device
Removal and installation front wheel drive shafts
Replacing the protective covers of the outer joints of the front wheel drive shafts
Replacing the protective covers of the inner joints of the front wheel drive shafts
Disassembly and assembly of constant velocity roller joints
Syncro transmission of Passat GT 1.8 G60 Syncro cars
Chassis
Car suspension
Features of the front suspension device
Removal and installation of telescopic struts and springs of the front suspension
Removal and installation front suspension arms
Replacing the silent blocks of the front suspension arms
Adjusting the front wheel alignment angles
Front wheel hubs
Features of the rear suspension device
Removal and installation the shock absorber with the rear suspension spring
Replacing the rear suspension air shock absorbers
Removal and installation the control unit of the compressor of the body position regulator
Replacing the silent blocks of the rear suspension beam
Removal and installation rear wheel hubs
Adjusting the clearance in the rear wheel hub bearings
Wheels and tires
Rear suspension of cars «Passat GT 1.8 G60 Syncro»
Steering
Features of the steering device
Removal and installation the steering shaft
Removal and installation the steering gear
Mechanical steering
Power steering system
Brake system
Features of the brake system
Brake drive
Anti-lock braking system
The principle of operation of the braking system
Operation of the braking system
Checking the electrical circuits of the brake system
Precautions for vehicles with ABS
Removal and installation of the electronic control unit with the hydraulic unit
Removal and installation front wheel speed sensors
Bleeding the brake hydraulic system
Front wheel brakes
Replacing the front brake pads on cars manufactured since July 1995 with an AVE engine
Removal and installation the front wheel brake mechanism
Disassembly and assembly of the front wheel brake mechanism
Removal and installation the front brake disc
Rear wheel drum brakes
Rear wheel disc brakes
Brake drive
Parking brake system
Body
Body elements
Features of the body structure
Paint care
Lubrication of moving parts of doors and hood
Removal and installation of the body
Reference dimensions of body openings for Volkswagen Passat sedans produced in 1988-93.
Reference dimensions of the body openings of Volkswagen Passat station wagons produced in 1988-93.
Removal and installation the radiator grille
Removal and installation the front bumper
Repair of front and rear bumpers
Welding the bumper
Removal and installation of optical elements of headlights and front direction indicators
Removal and installation front fenders
Removal and installation front doors
Removal and installation front and rear door trim
Removal and installation of window lifters
Removal and installation front door locks
Removal and installation rear doors
Removal and installation of windshield and rear glass
Repair of rear window heating element
Removal and installation a glued interior rearview mirror
Removal and installation the trunk lid
Removal and installation the tailgate of station wagons
Removal and installation the rear bumper
Removal and installation the instrument panel
Removal and installation the heater electric fan
Removal and installation the heater radiator
Electrical equipment
Power devices
Electrical equipment. Features of the device
Rechargeable battery
Generator
Removal and installation the generator
Adjusting the alternator drive belt tension
Disassembly and assembly of the generator
Starter
Removal and installation the starter
Disassembling and assembling the starter
Checking the starter
Lighting and appliances
Lighting fixtures
Light and sound signaling devices
Headlight adjustment
Removal and installation headlights
Removal and installation fog lights
On-board computer
Removal and installation the instrument cluster
Ignition or instrument and starter switch
Outdoor Light Switch
Headlight, direction indicator and parking light switch
Windshield wiper and washer switch
Windscreen wiper and washer
Rear window cleaner and washer for station wagons
Removal and installation the windshield wiper
Removal and installation the rear window wiper
Headlight washer
Rear window heating element
Digital display watch
Electric windows
Electric fan of the cabin heater
Central door locking system
Electrically adjustable exterior mirrors
On-board electrical circuit
Mounting block
Electrical circuits
Electrical diagram of the Passat car with the RV engine
Conventional symbols on electrical equipment diagrams
Symbols used in electrical diagrams
Wiring diagrams for cars with the «EZ» engine
Electrical diagrams of cars with the «RP» engine and the «Mono-Jetromc» injection system
Electrical equipment diagrams for cars with the «2E» engine with the «Digifant» KSUD
Electrical diagrams of cars with the engine «KR»
Electrical equipment diagrams for cars with engine «9A» with KSUD «KE-Motronic»
Wiring diagrams for cars with ABS brakes
Electrical diagrams of cars with turbocharged diesel engines
Wiring diagram of the KSUD «Digifant 3.0/3.2» for vehicles with an «AVR» engine
Wiring diagram of the Simos control system for vehicles with the AGG engine
Airbag Wiring Diagram
Passat B5
General information
User manual
Controls, instruments and equipment
Vehicle keys
Doors, central locking
Trunk lid (rear door of the station wagon)
Remote control of locks
Electric window control
Rear view mirrors
Seat belts
Inflatable airbag system
Seat headrests
Front seats
Front seats (manual adjustment)
Front seats (electrically adjustable)
Memory for driver's seat
Memorizing seat and exterior mirror adjustments for forward movement
Calling up seat and exterior mirror adjustments for forward driving
Rear bench seat (Sedan)
Rear bench seat (Station wagon)
Cover for long luggage
Seat armrests
Luggage compartment
Luggage compartment shelf (station wagon)
Parking brake
Manual transmission
Automatic transmission
Automatic transmission selector positions
Sequential automatic transmission
Sequential automatic transmission selector positions
Adjustable steering column
Ignition switch
Starting the engine
Engine stop
Control devices
Control lamps
Automatic control system with multifunctional indicator
Violations of primary importance (red pictograms)
Minor violations (yellow pictograms)
Navigation system
Switches and switches
Steering column switch for direction indicators and headlights
Cruise control
Windscreen wipers and washers
Heating and ventilation
Heating and ventilation air supply nozzles
Air conditioning system
Air conditioning air supply nozzles
Climate control system «Climatronic»
Air supply nozzles for the «Climatronic» unit
Lift and slide roof hatch panel
Interior lighting
Box for things
Power sockets in the luggage compartment
How to drive economically
Braking a car
Anti-lock braking system
Traction control system (reduced engine torque, ASR)
Traction control system with wheel braking (EDS)
Electronic Stability Program (ESP)
Power steering system
Fuel (petrol engines)
Fuel (diesel engines)
Work in the engine compartment
Opening the engine compartment hood
Basics of safe vehicle operation
Vehicle performance characteristics
Weekly checks
Starting the engine from an external source (another car)
If the engine does not start and the starter does not work
If the engine does not start even though the starter works normally
Towing a car
Wheel replacement
Checking the tightness of connections
Weekly inspection locations
Engine oil level
Coolant level
Checking the windshield wipers
Windscreen washer fluid level
Brake fluid level
Checking the electrical system
Checking the battery
Tires and checking tire pressure
Types of tread wear
Maintenance
General information about maintenance
Technical characteristics of the car
Frequency of car maintenance
Vehicle identification data
Types of motor oils
Oil and oil filter change
Checking the exhaust system
Engine cooling system
Cooling system fan
Spark plugs
Replacing spark plugs
Draining water from the fuel filter (diesel engines)
Replacing the fuel filter (diesel engines)
Checking the tightness of the hoses and fluid leakage
Replacing the air filter element
Checking the condition of the poly V-belt
V-belts
Measuring wear of timing belts on diesel engines
Gearbox/Main gear
Checking the drive shaft protective boot
Visual inspection of gearbox tightness
Checking the oil level in a manual transmission
Checking the oil in the main gear of automatic transmissions
Checking/replacing the oil level in the automatic transmission
Checking the front suspension and steering
Checking the dust covers of the front suspension joints
Checking the shock absorber
Radiator check
Checking electrical circuits
Brake fluid
Checking the brake fluid level
Replacing brake fluid
Checking the front brake pads
Checking the rear brake pads
Checking brake hoses
Checking the Power Steering Fluid Level
Replacing the dust filter
Battery maintenance
Lubrication of door hinges
Windscreen Washer Maintenance
Windscreen wiper blades
Checking the initial position of the windshield wiper arm
Checking the angle of the windshield wiper arm
Replacing the battery in the remote control key
Resetting the Service Indicator
Power unit
Engine repair
Engine specifications
Engine design
Lower engine compartment splash guard
Removal and installation a timing belt for petrol engines
Removal and installation of cylinder head of 1.6-I and 1.8-I engines
Checking hydraulic valve lifters
Cylinder head repair
Gas distribution mechanism drive
Removal and installation the cylinder head of the 2.3-I-VR5 engine
Removal and installation a toothed belt of a diesel engine
Removal and installation the cylinder head of a diesel engine
Removal and installation the timing belt of the 2.8-I-V6 engine
Removal and installation the cylinder head of the 2.8-I-V6 engine
Checking the compression in the engine cylinders
Checking the engine with a vacuum gauge
Removal and installation a poly V-belt
General recommendations for motor oils
Engine oil circuit
Checking oil pressure and oil pressure sensor
Removal and installation the oil pan
Starting the engine after major repairs
Main faults when starting the engine
Main faults of the lubrication system
Cooling system
Engine cooling system device
Topping up the coolant
Coolant mixture composition
Replacing the coolant
Removal and installation the thermostat
Removal and installation the radiator
Water pump (1.8-I and 1.6-I ADP engines)
Cooling system hoses
Cooling system malfunctions
Fuel system (petrol)
Fuel system device
Fuel pump/fuel level sensor
Fuel filter on models with petrol engines
Adjusting the accelerator cable (petrol engine)
Additional adjustment (automatic transmission)
Fuel system (diesel)
Technical data of diesel engine control systems
Diesel fuel system device
Checking the diesel engine preheating system
Checking glow plugs
Removal and installation glow plugs
Fuel heating system
Removal and installation fuel injectors
Main faults of the engine management system
Engine management
Technical data of engine management systems
Operation of the engine management system
Checking the fuel injection system
Sensors and actuators of the engine management system
Ignition system
Direct ignition system (except 1.6-I ADP engines)
Ignition system with ignition distributor (engine 1.6-I ADP)
Removal and installation the ignition distributor
Fuel line and fuel injectors
Checking fuel injectors (4-cylinder petrol engine)
Checking the voltage supply to the fuel injectors
Checking the spray pattern and tightness of the fuel injector
Main faults of the engine management system
Exhaust system
Exhaust system device
Exhaust system catalytic converter
Operation of vehicles with a catalytic converter
Turbocharger for diesel engines
Replacing the muffler
Oxygen sensor
Transmission
Clutch
Clutch device
Hydraulic clutch drive device
Clutch disc — removal, inspection and installation
Bleeding the hydraulic clutch drive
Main clutch faults
Car gearbox
General information about manual transmission
Removal the gearbox
Gearbox installation
Gearbox repair
Special automatic transmission
Adjustment of the gear shift mechanism of a special automatic transmission
Fully automatic transmission
Adjusting the shift cable of a fully automatic transmission
Transmission of all-wheel drive vehicles
Drive shafts
Removal and installation the drive shaft
Lubricant for drive shaft joints
Replacing the inner constant velocity joint
Replacing the outer constant velocity joint
Disassembling the outer constant velocity joint
Drive shaft faults
Chassis
Car suspension
Front suspension device
Front suspension shock absorber
Front shock absorber strut repair
Rear suspension device
Unscrewing the upper mount of the rear shock absorber
Removal and installation the shock absorber and rear suspension spring
Removal and installation rear wheel bearings/hubs
Shock absorber strut of rear suspension of all-wheel drive vehicles
Repair of the rear suspension shock absorber
Checking the rear shock absorber
Shock absorber disposal
Wheels and tires
General information about wheels and tires
Instructions for using tires
Checking the tire valve
Wheel rotation
Wheels and tires
Spare wheel
Wheel replacement
Wheel mount security bolts
Anti-skid chains
Lifting a car
Steering
Steering device
Removal and installation the airbag
Removal and installation the steering wheel
Transverse steering rod
Installing a Power Steering Pump
Front wheel alignment angles
Basic faults of suspension and steering
Brake system
Technical characteristics of the brake system
The structure and operation of the braking system
ABS/EBV/EDS/ASR/ESP systems
Checking the brake booster
Replacing the front brake pads
Replacing the front brake pads on a Lucas caliper
Replacing rear brake pads
Checking the brake disc
Removal and installation the brake disc
Bleeding the hydraulic brake system
Brake lines and hoses
Replacing the brake hose
Brake light switch
Handbrake lever
Adjusting the handbrake
Handbrake cable for front wheel drive vehicles
Handbrake cable for all-wheel drive vehicles
Main brake faults
Body
Exterior (external elements)
General information about body repair
Car body care
Caring for upholstery and carpets
Repair of minor body damage
Repair of severe body damage
Front crossbar
Installing the front cross panel in the service position
Removal the front bumper
Removal the hood lock lever
Adjusting the side guide bracket of the bumper
Rear bumper
Front wing
Front wheel well trim
Air intake grille
Removal and installation the hood
Adjusting the hood position
Radiator grille
Hood release cable
Disconnecting the hood release cable
Hood lock
Outside rear view mirror/mirror glass
Outside mirror housing
Roof fencing/curb strip
Side body trim
Replacing rubber bands of windshield wipers
Windshield washer nozzles
Windscreen wiper arms
Interior (internal elements)
Interior door trim
Differences when removing the trim of the right front door
Door mechanism control unit
Door seal
Side trim of the luggage compartment of the Sedan models
Side trim of the luggage compartment of the station wagon models
Rear luggage compartment trim on Sedan models
Trunk lid trim
Trunk door trim
Luggage compartment floor covering on Estate models
Interior rear view mirror
Central console
Front ashtray
Rear ashtray
Decorative cover for the lever (automatic transmission)
Decorative trims under the radio
Driver's side lower instrument panel trim
Glove box
Interior decorative trim for outside rear view mirror
Ceiling handle
Sun visors
Door sill trims
Windshield and rear glass
Front seats
Removal the headrest
Side airbags
Back seat
Left backrest of the rear seat
Carpeting
Interior finishing elements
Doors and covers
Trunk lid
Trunk lock
Trunk lid lock cylinder
Rear door lock on station wagon models
Rear door lock cylinder
Rear Door Lock Cylinder Bracket
Front door
Front door lock cylinder
External door opening handle
Door lock
Manual lowering of the door glass
Door glass
Door bracket
Ventilation and heating
Heating and ventilation system device
Ventilation nozzles
Heater control panel
Central damper lever
Heater control unit
Heater resistor block
Heater and air conditioner control unit
Air conditioning compressor
Heater fan
Electrical equipment
Power devices
Battery Care Rules
Checking the battery
Charging the battery
Removal and installation the battery
Charging system
Generator device
Replacing the generator brushes and voltage regulator
Engine starting system
Removal and installation the starter
Starter solenoid relay
Main generator faults
Main faults of the starter
Lighting and appliances
Incandescent lamps
Electrical equipment of a car
Electrical circuits
Open Circuit Detection
Fuse box location
Replacing exterior lighting bulbs
Replacing interior light bulbs
External lighting devices
Headlight corrector actuator motor
Headlight adjustment
Gas discharge lamps for low beam headlights
Instrument cluster
Multi-function steering column switches
Removal the switches
Removal and installation the radio
High frequency loudspeakers
Low frequency speakers
External radio antenna
Checking the rear window defroster
Windshield wiper motor
Rear window wiper motor
Windscreen washer pump
Central locking system
Electrical circuits
Explanations of electrical diagrams
Location of relays and fuses
Symbols on electrical diagrams
Conventional symbols of elements in electrical circuits
Battery, ignition switch and overload relay for X-contact
Diagnostic connector, generator and instrument cluster lamps
Instrument cluster, clock, trip meter and lighting buzzer
Brake system and exterior lighting control lamps
Instrument cluster, indicator, air temperature sensor
Handbrake light and windshield washer fluid level sensor
Turn signal switch, light signaling (left side)
Light and lamp switch (right side)
Brake light switch, brake lights and rear turn signals
Radio socket, cigarette lighter and instrument lighting
Instrument illumination intensity regulator
Glove box switch and light
Fog lights, switch and rear side light
Two-tone horn and signal relay
Air recirculation control switch and motors
Rear Window Switch and Defroster
Windscreen and rear window wipers, wiper relay
Windscreen wiper switch and windscreen washer pump
Battery, starter and generator
Engine management system Motronic, alarm
Throttle, knock sensors, air temperature (Motronic engine)
Motronic engine, crankshaft speed and knock sensors
Motronic Engine, Air Flow Meter, Fuel Pump Relay
Oxygen sensor, camshaft actuator valve (Motronic)
Oil pressure, speed, fuel system sensors
Oil pressure, temperature, buzzer warning lights
Battery, starter, generator and glow plugs
Forced downshift, accelerator sensor
Air flow meter, engine shut-off valve
Accelerator and clutch pedal position sensors
Coolant glow plugs and relays, oil pressure sensor
Oil pressure sensor, fuel system, relay
Instrument cluster
Passat B6
General information
User manual
Identification data
Replacing the battery in the remote control
Remote control of locks
Unlocking a single door
Doors, central locking
Central locking key
Trunk lid
Security alarm system
Electric window control
Operation of window lifts with ignition on
Lift and slide roof hatch panel
Solar Powered Fan Drive
Opening the engine compartment hood
Instrument panel and controls
Control and signal lamps
Switches and switches
Steering column switch for direction indicators and headlights
Windscreen wipers and washers
Interior lighting
Rear view mirrors
Cup holders
Cigarette lighter
Boxes for things
Fuel tank filler flap
Trunk
Luggage rack
Roof rack
Spare wheel
On-board tool and jack
Front seats
Seat adjustment
Front seats (electrically adjustable)
Headrests
Armrests
Rear seats
Loading the long luggage cover
Heating and ventilation
Heating, ventilation and air conditioning (HVAC) systems
Climate control
Starting the engine
Manual transmission
Four and five-speed automatic transmissions
Electronically controlled parking brake
Anti-skid system
Parking warning light
Maintenance
Motor oil
Checking the engine oil level
Fuel for the car
Diesel fuel
Checking the coolant level
Filling the windshield washer reservoir with liquid
Adjusting the position of the windshield washer nozzles
Replacing windshield wipers
Replacing brake fluid
Rechargeable battery
Car wheels and tires
Wheel replacement
Using an auxiliary battery when starting the engine
Towing a car
Filter replacement intervals
Timing Belt Replacement Intervals
Service intervals for petrol and diesel engines
Car specification
Technical terms, their abbreviations and explanations
Petrol engine 1.6L
Engine repair
General recommendations for engine maintenance and repair
Removal and installation the upper engine casing
Checking the camshaft drive toothed belt
Removal the engine
Engine installation
Disassembly and assembly of the engine
Removal and installation a poly V-belt
Removal and installation the timing cover
Replacing the crankshaft oil seal on the belt pulley side
Method of tightening the belt drive sprocket mounting bolt
Disassembly and assembly of pistons and connecting rods
Cylinder head
Checking the valve timing
Adjusting the valve timing
Removal and installation the camshaft housing
Removal and installation the cylinder head
Compression check
Valve mechanism repair
Checking the valve guides
Replacing valve stem seals
Cooling and lubrication system
Removal and installation the oil pan
Removal and installation the oil pump
Removal and installation of cooling system components
Draining and filling the coolant
Removal and installation the radiator
Removal and installation the water pump
Fuel injection system
Fuel injection system repair
Checking the tightness of the vacuum receiver in the intake manifold
Removal and installation the air filter
Removal and installation injectors
Checking the intake air preheating
Petrol engine 2.0L
Engine repair
Compression check
Removal and installation the engine
Installing a timing belt
Valve drive
Removal and installation camshafts
Replacing the valve stem seals (with the cylinder head installed)
Replacing the exhaust camshaft seal
Removal and installation the phase shifter
Removal and installation valve 1 of the valve timing regulator
Removal and installation a poly V-belt
Replacing the crankshaft oil seal on the belt pulley side
Removal and installation the sealing flange on the belt pulley side
Removal and installation the crankshaft flange on the flywheel side
Removal and installation the flywheel
Removal and installation the slave disk
Crankshaft
Pistons and connecting rods
Checking pistons, piston rings and cylinder diameter
Removal and installation the cylinder head cover
Removal the cylinder head
Installing the cylinder head
Characteristics of 2.0 liter petrol engines
Lubrication system
Checking oil pressure and oil pressure sensor
Removal and installation the oil filter holder
Emptying the oil filter housing
Removal and installation the oil pan — BLX, BLY, BLR engines
Removal the oil pump with balance shaft drive
Installation and adjustment of the oil pump with balance shaft drive
Cooling system
Checking the cooling system for leaks
Draining the coolant
Filling with coolant
Removal and installation the water pump
Removal and installation the coolant supply pipe
Cooling system with characteristic control (engines BLX, BLY, BLR)
Removal and installation the engine cooling system thermostat according to the algorithm
Removal and installation the radiator fan and radiator fan 2 V177
Removal and installation the radiator
Fuel and exhaust systems
Removal fuel from the fuel tank when the fuel tank is more than 3/4 full
Pumping fuel from a fuel tank less than 3/4 full
Checking the functionality and power supply
Checking fuel pressure
Checking the residual pressure
Performance Check
Electronic engine power control (electronic accelerator drive)
Removal and installation the accelerator pedal assembly
Operating principle of the absorber
Checking the fuel tank bleed
General instructions for the injection system
Removal and installation the intake manifold
Removal and installation injectors
Checking the intake manifold switch
Removal and installation the exhaust manifold
Removal and installation the inlet pipe with the catalytic converter
Exhaust gas recirculation device (engines BLR, BLX, BVX, BVY)
General instructions for the ignition system
Removal and installation of ignition coils with output stages
Diesel engine 2.0L
Engine repair
Removal the engine
Removal and installation a poly V-belt
Replacing the crankshaft oil seal on the belt pulley side
Removal and installation the sealing flange on the belt pulley side
Replacing the crankshaft seal on the flywheel side
Removal and installation the engine speed sensor
Removal and pressing in the flywheel needle bearing
Piston and connecting rod
Cylinder head
Removal and installation the cylinder head cover
Removal, installation and tensioning the timing belt
Removal and installation the cylinder head
Valve mechanism
Removal and installation exhaust valve roller levers
Removal and installation the roller levers of the intake valves
Checking the valve guides
Replacing valve stem seals
Removal and installation camshafts
Removal and installation the camshaft oil seal
Characteristics of the 1.6-liter petrol engine
Characteristics of 2.0 liter diesel engines
Cooling and lubrication system
Motor oil
Removal and installation the oil pump (for chain-driven balance shaft module)
Removal and installation the oil pan
Checking oil pressure and oil pressure sensor
Checking the cooling system for leaks
Checking the pressure reducing valve in the expansion tank cap
Checking the oil radiator for leaks
Draining and filling the coolant
Removal and installation of fans with brackets
Removal and installation the water pump
Removal and installation the thermostat
Fuel and exhaust systems
Checking the fuel supply pressure
Removal and installation of a tandem pump
Checking the fuel pump
Removal and installation the fuel supply module
Removal and installation the fuel level sensor
Removal the fuel tank
Installation of hose connections with nipple connectors of the supercharging system
Safety precautions when repairing the direct fuel injection system
Removal and installation the cable connection of pump-injectors and glow plugs
Removal and installation of the pump-injector
Replacing the O-rings of the pump-injector
Free installation of the exhaust system
Exhaust gas recirculation system
Checking glow plugs
Removal, installation, inspection of ceramic glow plugs
Transmission
Clutch
Differences in clutches
Bleeding air from the clutch assembly
Removal and installation the support bracket
Removal and installation the servo spring
Removal and installation the clutch pedal
Removal and installation the clutch master cylinder
Hydraulic clutch system
Removal and installation the clutch slave cylinder
Installing the gear shift drive
Removal and installation a Sachs clutch
Removal and installation of clutch manufactured by LuK
Checking the clutch drive
Gear shift drive repair
Removal and installation a cuff with a switch button and noise insulation
Removal and installation control cables — parts and components
Removal and installation the gear shift drive
Adjusting the gearshift drive
Troubleshooting, causes and solutions
Letter designations, correspondence of units and filling volumes
Mechanical gearbox
Gearbox marking
Checking and filling transmission oil
Removal the gearbox
Gearbox installation
Adjusting the gear shift drive
Automatic gearbox
Gearbox Description
Gearbox marking
Planetary gear and final drive
Checking the ATF fluid level and topping up
Draining and filling ATF
Electrical/electronic components and their installation location
Removal the gearbox control lever with selector
Removal and installation the gear selector cable
Checking the selector lever cable
Adjusting the selector lever cable
Removal and installation the handle
Checking the gear shift mechanism
Gearbox removal, Passat 2006 with «external» water ATF cooling radiator
Gearbox installation, Passat 2006 with «external» ATF cooling radiator
Drive shafts
Removal the shaft seal ring with flange
Installing a shaft seal ring with a flange
Removal and installation the drive shaft
Removal the outer CV joint
Checking the outer CV joint
Checking the inner CV joint
Checking the functionality of the CV joint
Drive shaft with tipoid joint AAR3300i for 6-speed automatic transmission 09M (all-wheel drive)
Chassis
Wheels and tires
General information on wheels and tires
Technical conditions for the conversion of wheels and tires
Tyre speed ratings
Composite disks
Tire wear and mileage
High-speed tire wear
Tire maintenance
Evenly worn tires
Measuring the tread depth
One-sided tire wear
Diagonal uneven wear
Tire rolling noise
Wheel balancing
Radial and lateral runout of wheels and tires
Minimization of mounted wheels
Lateral vehicle pull
Eliminating lateral drift
Tire damage
Radial tire construction
Loss of air pressure in tires
Tyre damage due to errors during tyre fitting (fitting damage)
Tyre sidewall markings
Wheel rotation
General provisions for wheel alignment (WAA) of the Passat
Front axle wheel alignment correction
Rear Axle Camber Adjustment
Rear Axle Wheel Alignment
Front Axle Wheel Alignment
Passat Wheel Information Since 2006 Model Year
Checking the condition, wear pattern, pressure, and tread depth of the tires
Car suspension
Checking the front suspension joint
Removal and installation the front subframe
Removal and installation the front suspension joint
Removal and installation the front suspension stabilizer
Removal and installation the wheel bearing module
Removal and installation the front shock absorber strut
Rear wheel suspension repair (front wheel drive)
Rear subframe repair
Replacing the vehicle body level sensor
Removal and installation the rear upper wishbone
Removal and installation the rear lower wishbone
Removal and installation the rear transverse tie rod
Removal and installation the rear trailing arm with support bracket
Repair of the rear trailing arm
Removal and installation the rear coil spring
Front suspension tightening torques
Rear Suspension Tightening Torques (Front Wheel Drive)
Steering
General information about the steering mechanism
Checking the steering wheel play
Checking the steering wheel effort
Bleeding the power steering system
Checking the tie rod ends and seals
Testing constant velocity joints
Checking the tightness of the power steering
Checking the power steering fluid level
Removal and installation the steering wheel
Removal and installation the steering column
Maintenance and transportation of the steering column
Checking the steering column for damage
Removal and installation the support bracket
Removal and installation the damper
Removal and installation the steering gear
Removal and installation the boot
Removal the steering rod
Installing the steering rod
Tightening torques for steering components
Possible malfunctions, their causes and troubleshooting methods (power steering)
Brake system
General information about the braking system
Electronic brake system components
Brake system components
Technical characteristics of brakes
Pressure leak test
Checking the brake fluid level
Replacing brake fluid
Visual inspection of the brake system for leaks and damage
Checking the thickness of the front and rear brake pads
Removal and installation brake pads
Removal and installation the electromechanical parking brake control unit
Removal and installation the parking brake drive
Disconnecting the brake pedal from the brake booster
Connecting the brake pedal to the brake booster
Removal and installation the piston for the FN 3 brake caliper
Removal and installation the brake caliper piston
Removal and installation the brake light switch F
Removal and installation the master brake cylinder
Removal and installation the brake booster
Repair of brake pipes
General information about the anti-lock braking system
Removal and installation the speed sensor on the front axle
Removal and installation the speed sensor on the rear axle
Removal and installation the speed sensor on the rear axle (all-wheel drive)
Removal and installation the low pressure sensor in the brake booster
Possible malfunctions, their causes and methods of elimination
Body
Exterior (external elements)
Design Features
Removal and installation the front bumper trim
Removal and installation the rear bumper trim
Removal and installation the front mudguard
Removal and installation the rear mudguard
Removal and installation mirror glass
Removal and installation the side mirror housing
Removal and installation the overlay
Removal and installation the side turn signal
Removal and installation the rear view mirror
Removal and installation the radiator grille
Removal and installation the emblem
Removal and installation the license plate holder
Removal and installation roof rails
Removal the corner holder
Installing the corner holder
Installing a new corner holder
Removal and installation the waterproof cover
Adjusting the hood
Adjusting the hood lock
Adjusting the trunk lid
Adjusting the lock bracket
Door adjustment
Removal the windshield
Electrical equipment
Power devices
General information about electrical equipment
Searching for the location of a short circuit
Rechargeable battery
Generator and its drive belt
Removal and installation of a three-phase generator (1.6L engine with injection)
Removal and installation a poly V-belt pulley without a freewheel mechanism
Removal and installation a poly V-belt pulley with a freewheel mechanism, manufacturer Bosch
Removal and installation a voltage regulator, manufacturer Bosch
Removal and installation the starter (1.6 l FSI engine, automatic transmission)
Removal and installation the starter (1.6L engine with injection, manual transmission)
Removal and installation the starter (2.0L TDI engine, DSG gearbox)
Lighting and appliances
Removal and installation headlights
Headlight position adjustment
Replacing the low beam lamp
Replacing the high beam lamp
Replacing the parking light bulb
Removal and installation the headlight corrector servo drive (manufacturer Hella)
Removal and installation the headlight corrector servo drive (manufacturer Valeo)
Checking headlight adjustment
Checking headlight adjustment using a calibration screen without a 15° adjustment line
Adjustment of main headlights with gas discharge lamps
Adjusting the main headlights with halogen lamps
Main turning lights with gas discharge lamps
Replacing a gas discharge lamp
Removal and installation front turn signal lights
Removal and installation lighting in the side mirror to facilitate boarding
Removal and installation the rear light in the side of the body
Removal and installation license plate light (sedan)
Removal and installation license plate light, station wagon (Variant)
Removal and installation the hood contact switch
Removal and installation the light switch
Removal and installation the headlight corrector regulator and the button and instrument panel illumination regulator
Removal and installation the front passenger airbag deactivation indicator lamp
Removal and installation glove box lighting
Removal and installation the SAFE function indicator lamp of the central lock
Replacing the front interior light
Removal and installation center console switches
Removal and installation the main fuse box
Removal and installation the junction box in the left side of the engine compartment
Removal and installation the relay block on the left side of the front panel
General instructions for repairing car electrical systems
Repair of CAN bus wires
Wire break with repairs in two places
Repair of contacts in connector housings
Mechanical locking of the connector housing
Round contacts
Flat contacts with asymmetrical locking tabs
Electrical circuits
Wiring diagram of the Climatronic air conditioning system (part 1)
Wiring diagram of the Climatronic air conditioning system (part 2)
Wiring diagram of the Climatronic air conditioning system (part 3)
Wiring diagram of the Climatronic air conditioning system (part 4)
Wiring diagram of the Climatronic air conditioning system (part 5)
Wiring diagram of the Climatronic air conditioning system (part 6)
Climate control system wiring diagram (part 1)
Climate control system wiring diagram (part 2)
Climate control system wiring diagram (part 3)
Climate control system wiring diagram (part 4)
Golf 1
General information
Specifications
Decoding the VIN number of a car
Engine specifications
Technical characteristics of the lubrication system
Technical characteristics of the cooling system
Technical characteristics of the high pressure fuel pump
Transmission specifications
Chassis and electrical equipment specifications
Weight characteristics of cars
Overall dimensions of the car
Filling volumes (in liters)
Maintenance
Layout of components in the engine compartment
Checking the engine oil level
Checking the coolant level
Checking the brake fluid level
Checking the level of working fluid in the automatic transmission
Checking the fluid level in the washer reservoir
Checking tire pressure
Checking the car lighting
Checking the direction indicators and hazard warning lights
Checking brake lights
Checking the windshield wiper and washer
Checking the brakes
Regular maintenance and its planning
Safe workplace
Checking the engine oil level
Additional oil filling
Engine oil consumption
Motor oil quality and its specification
The right choice of oil viscosity. Seasonal and all-season oils
Engine oil change
Replacing the oil filter
Checking the tightness of a manual gearbox
Checking the level of working fluid in an automatic transmission
Main gear of automatic transmission
Lubrication of rods, hinges and locks
Clutch, brake and throttle rods
Troubleshooting issues
Power unit
Engine repair
Description of the design of a diesel engine
Individual engine components
Running in a new engine
Uncontrolled increase in RPM
Measuring compression in cylinders
Cranking the engine crankshaft
Finding Top Dead Center
Thermal valve clearance
Valve adjustment
Timing Belt Adjustment
Checking the condition and tension of the toothed belt
Timing Belt Tension
Replacing the timing belt
Removal and installation the cylinder head
Choosing the Right Cylinder Head Gasket
Removal the camshaft
Removal the cup tappets
Removal valves
Evaluation of valve and head suitability
Replacing valve stem seals (oil seals)
Additional valve grinding
Checking engine tightness (oil leak)
Engine damage
Engine dismantling
Disconnecting the engine from the gearbox
Engine installation
Exhaust and turbocharger
Description of the turbocharger design
Removal and installation a turbocharger
Possible faults in the turbocharger
Description of the design of the exhaust system
Checking the condition of the exhaust system suspension
Exhaust system update
Removal the exhaust system
Removal the front exhaust pipe
Removal the exhaust pipe
Cooling system
Description of the engine cooling system
Checking the coolant level
Topping up the coolant
Antifreeze agent
Checking the tightness of the cooling system
Radiator — design description
Replacement of coolant hoses
Radiator cleaning
Draining the coolant
Filling the cooling system
Removal the radiator
Removal the expansion tank
Cooling system plug
Checking the safety and vacuum valve
Thermostat — design description
Removal the thermostat
Checking the Thermostat
Water pump — removal and installation
V-belt — inspection
Radiator Fan — Design Description
Radiator Fan Malfunctions
Removal the fan motor
Electrolysis in the cooling system
Checking the radiator and fan housing
Checking the thermal switch
Malfunctions in the cooling system
Fuel system
All about diesel fuel
Winter diesel fuel
Normal fuel consumption
How the car itself affects fuel consumption
Fuel efficient driving
Draining fuel from the tank
Removal the fuel tank
Replacing the fuel tank
Fuel quantity sensor
Fuel tank ventilation
Gravity valve
Fuel filter
Bleeding the fuel system
Fuel injection system
Fuel supply diagram
High pressure fuel pump
Fuel pump operation
Fuel injectors
Removal and installation fuel injectors
Disassembling fuel injectors
Fuel inflow switch to injectors
Adjusting the start of delivery of the high-pressure fuel pump
Gas traction — removal and installation
Adjusting the gas traction (for manual transmission)
Adjusting the accelerator pedal drive (for automatic transmission)
Cold start accelerator cable
Idle speed check
Air filter — cleaning and replacement
Malfunctions in the diesel injection system
Transmission
Clutch and drive shafts
How does a clutch work?
Checking the clutch
Free play of the clutch pedal
Driving with a broken clutch cable
Replacing the clutch rod
Clutch installation and removal
Clutch unit faults and troubleshooting methods
Drive axle shafts — general description
Checking the axle shaft covers
Troubleshooting axle shafts
Removal the drive axle shaft
Disassembling the drive shaft
Car gearbox
General description of a manual gearbox
Adjusting the gear shift unit
Adjusting the shift shaft
Removal and installation the gearbox
Replacement of the release clutch (release bearing)
Noise in the gearbox
Automatic transmission — general information
Checking the automatic transmission shift modes
Automatic transmission faults
Removal the automatic transmission
Main gear — general information
Chassis
Suspension and wheels
Description of the design of the front suspension and steering
Description of the rear suspension design
Chassis shock absorbers and shock absorbers
Checking the wheel bearing play
Checking the shock absorber
Shock absorber malfunctions
Installing the shock absorber strut on the supports
Disassembling the front wheel suspension
Dismantling the stabilizer
Replacing the triangular suspension arm
Replacing the ball joint
Removal the chassis shock absorber strut
Replacing the shock absorber and spring
Wheel angle adjustment
Signs of improper wheel installation
Measuring angles when installing wheels
Replacing the rear shock absorber
Replacing the rear shock absorber and coil spring
Replacing the rear axle
Replacing the rear axle strut
Removal wheel bearings
Adjusting the wheel bearing play
Replacing the wheel axle
Steering
Checking the steering gear protective cover
Checking the dust caps and play of the tie rod joints
Checking the ball joint dust caps
Checking the play of ball joints
Checking the steering play
Replacing the steering rod joints
Replacing the tie rod and steering gear cuff
Replacing wheel bearings
Steering wheel replacement
Brake system
General description of the braking system
Brake fluid — general description
Checking the brake fluid level
Checking the brakes
Checking the tightness and serviceability of the brake system
Cam disc brakes with floating caliper
Measuring the thickness of disc brake pads
Checking the condition of the brake discs
Replacing disc brake pads
Disc brake mechanism with floating caliper from ATE (replacement of linings)
Disc brake mechanism with floating caliper from Girling (replacement of linings)
Cam disc brake mechanism (replacement of linings)
Providing mobility to the caliper and piston of the disc brake
Removal the brake caliper
Replacing the piston seal
Removal the brake disc
Drum brakes — general description
Checking the thickness of drum brake linings
Checking the brake pedal travel
Additional adjustment of drum brakes
Removal the brake drum
Checking the condition of brake drums
Removal brake pads in cars manufactured before August 1978
Removal brake pads in cars produced after August 1978
Replacing brake pads
Handbrake — design description
Checking the free travel of the handbrake lever
Replacing the handbrake rod
Adjusting the handbrake
Hydrovacuum booster — design description
Checking the brake booster
Brake force regulator — design description
Checking the brake force regulator
Working with the hydraulic brake system
Removal the brake pipe
Replacing the brake hose
Removal the wheel brake cylinder
Removal the master brake cylinder
Removal the brake booster
Bleeding the brake system
Replacing brake fluid
Brake system malfunctions
Wheels and tires
What tires to install
Construction and designation of tires
Rims and their combinations with tires
What wheel mounting bolts to use
Checking the air pressure in the tires
Wide tires and rims
Tire condition monitoring
Changing a wheel
Repair of tires with metal cord
Wheel imbalance
Buying new tires
Winter tires
Body
Heating and ventilation
Description of the heating and ventilation system
Checking heating and ventilation
Removal the heating system tap
Removal the heater radiator
Removal the heating system drives
Troubleshooting a Fan
Removal the heating system fan
Removal the fan switch
Removal the air distribution nozzles
Troubleshooting the heating system
Exterior (external elements)
Removable body parts
Removal and installation the engine hood
Adjusting the hood lock
Broken hood rod
Removal the radiator grille
Removal the trunk lid
Removal the rear cover lock
Removal the front bumper
Replacing plastic lining
Wings and wheel arch inserts
Removal wheel arch trims and extensions
Removal the front spoiler of the Golf model
Outside mirror
Decorative strips and overlays
Body preservation work
Interior (internal elements)
Removal the seats
Seat back retainer repair
Removal the seat headrest
Removal trim (interior panels)
Removal boxes and lids (manufactured before July 1980)
Removal boxes and lids (produced after August 1980)
Doors and windows
Removal and installation the door
Removal the door trim (panel)
Removal the door lock
Removal the door handle
Removal the lock cylinder
Removal the side glass
Removal the window regulator
Removal and installation the windshield
Electrical equipment
Equipment and devices
Electrical engineering and electronics — general description
Electrical Wires — General Information
Fuses with regular and flat plugs
Checking control instruments and bulbs
Removal the instrument panel
Replacing the lamps that illuminate the devices
Disassembling the instrument panel
Voltage stabilizer — check and replacement
Fuel level sensor — check
Coolant temperature gauge
Shift indicator
Speedometer (speed indicator)
Removal the flexible shaft of the speedometer drive
Clock and direction indicator control
Brake, high beam and battery warning lights
Oil pressure warning light
Pre-incandescent warning light
Key switch — removal and installation
Steering column switch — removal and installation
Starter and glow switch
Driving with a faulty starter and glow switch
Checking the switch
Relays and control devices
Heated rear window
Checking the windshield wiper and washer
Removal the wiper arm, blade and rubber part
Windscreen wiper motor — check and replace
Windscreen wiper malfunctions and how to fix them
Rear window cleaner
Removal the rear window wiper motor
Filling with water for washing glass
Rear Window Wiper Malfunctions
Windscreen washers — removal, adjustment and inspection
Radio receiver — removal and installation
Mounting the radio antenna
Installing speakers
Lighting system
Lighting check and spare bulbs
Replacing headlight bulbs
Replacing the parking light bulb
Replacing the bulb in the fog light in the radiator grille
Replacing the bulb in the fog light under the bumper
Removal and installation headlights
Fog lamp in the radiator grille
Checking the installation of headlights
Replacing the bulbs in the front turn signal
Replacing the bulbs in the rear lights
Reverse light switch
Rear number plate light
Interior lamp
Door contact switch
Replacing interior lighting bulbs
Installation of fog lights
Checking the hazard warning lights and direction indicators
Checking brake lights
Checking the sound and light signal
Power devices
How does a battery work?
Battery technical data
Maintenance-free batteries
Checking the acid level in the battery
Removal the battery
Battery care
Checking the battery charge status
Charging the battery
Starting with a dead battery
Alternator — General Information
Voltage regulator
Checking the generator contact brushes
Checking the V-belt tension
Checking the condition of the V-belt
Removal and installation the V-belt
Torn V-belt
Removal the alternator
Driving with a faulty alternator
Battery charge monitoring device
Battery and generator faults
Description of the starter design
Removal the starter in a car with a manual transmission
Removal the starter in a car with an automatic transmission
Replacing the starter contact brushes
Starter malfunctions and how to fix them
Pre-heating system
Glow plugs — selection and replacement
Detecting defects in glow plugs
Troubleshooting the Pre-Glow System
Complications that arise when starting the engine
Pre-glow indicator light does not light
Electrical circuits
Structure of electrical circuits
Rear window wiper and windscreen washer (after August 1977)
Front and rear fog lamp (before July 1982)
Diesel model «Golf-L» (produced after August 1977)
Diesel and turbodiesel Golf/Jetta models (after August 1982)
Brake system indicator light (after August 1978)
Wiring diagram for trailer hitch
Golf 1
General information
Characteristics
Sequence of release of Volkswagen Golf, Jetta, Scirocco models
Vehicle identification data
Dimensions and weight of the car
Data for maintenance purposes
Engine adjustment data
Engine data 1.1/1.3 l
Engine data 1.5/1.6/1.8 l
Engine electrical equipment data
Cooling system data
Fuel system data
Clutch and manual transmission data
Automatic transmission data
Steering data
Suspension data
Brake system data
Electrical equipment data
User manual
Checking a car parked on the ground
Checking a car raised by a lift
The engine stalled or won't start
Checking engine systems
Safety measures during work
Changing a wheel, jacking up the car and installing supports
Basic tools and equipment
Basic repair operations
Charging the battery
Jump starting the engine from another car's battery
How to Crank an Engine
Engine lift
Maintenance
Maintenance Schedule
Car maintenance work
Tools and equipment
Engine oil and filter
Air filter
Fuel filters
Cooling system
Brake fluid
Checking the battery
Drive belt
Clutch adjustment
Oil in manual and automatic transmission
Brake system
Wheels and tires
Exhaust system
Lighting and fixtures
Windscreen wipers and washers
Lubrication works
Power unit
Engine adjustment
General information about engine tuning
Tools and equipment
Spark plugs
Compression check
Thermal valve clearances
Distributor and ignition timing
Carburetor adjustment
Fuel injection system (injector engine)
Engine 1.1/1.3
General information about 1.1/1.3 l engines
Tools and equipment
Timing Belt (Camshaft Drive Belt)
Camshaft oil seal
Cylinder head
Crankshaft seals
Oil pump
Removal and installation the engine
Engine repair
Exhaust system (exhaust system)
Engine 1.5/1.6/1.8
General information about engines 1.5/1.6/1.8 l
Tools and equipment
Valve clearances
Toothed belt
Camshaft
Cylinder head
Crankshaft seals
Auxiliary shaft seal
Oil pump
Removal and installation the engine
Engine repair
Possible engine malfunctions
Engine electrical equipment
General information about the engine electrical equipment
Tools and equipment
Checking the charging circuit
Removal and installation the generator
Generator repair
Ignition distributor
Ignition coil
Checking the starter
Removal and installation the starter
Starter repair
Replacing sensors
Possible malfunctions of the engine electrical equipment
Cooling system
General information about the cooling system
Tools and equipment
Replacing the coolant
Removal and installation the radiator
Radiator fan and thermal switch
Checking and replacing the thermostat
Hoses and clamps
Cooling pump
Coolant temperature sensor
Interior heater
Possible malfunctions of the cooling system
Fuel system
General information about the fuel system
Tools and equipment
Fuel pump
Air filter
Carburetor drive
Removal and installation the carburetor
Solex PICT/PIC carburetors
Carburetors Pierburg/Zenith 1B3
Zenith 2B2/2B5 Carburetors
Carburetor Pierburg 2E2
Fuel injection system
Removal and installation the fuel tank
Possible malfunctions of the fuel system
Transmission
Clutch and manual gearbox
General information about the clutch and manual transmission
Tools and equipment
Clutch cable
Clutch — 1.1/1.3L engines
Clutch — 1.5/1.6/1.8L engines
Gear shift drive — 1.1/1.3 l engines
Gear shift drive — 1.5/1.6/1.8 l engines
Gearbox 084 — engines 1.1 /1.3 l
Gearbox 020 — engines 1.5/1.6/1.8 l
Gearbox repair type 084 — engines 1.1/1.3 l
Differential 084 — 1.1/1.3L engines
Gearbox repair type 020 — engines 1.5/1.6/1.8 l
Secondary shaft and differential — engines 1.5/1.6/1.8
Possible faults of the clutch and manual transmission
Automatic gearbox
General information about automatic transmission
Tools and equipment
Transmission testing in a braked state
Selector lever cable
Starter interlock switch
Removal and installation of transmission
Torque converter seal
Possible malfunctions of automatic transmission
Chassis
Steering
General information about steering
Tools and equipment
Front wheel alignment adjustment
Steering rods and joints
Steering gear
Steering shaft
Steering column
Possible steering malfunctions
Front suspension
General information about the front suspension
Tools and equipment
Replacing wheel bearings
Telescopic strut shock absorbers
Replacing ball joints
Front suspension arms and bushings
Anti-roll bar
Drive shafts
Rear suspension
General information about the rear suspension
Wheel bearings
Replacing shock absorbers
Replacing the hub journal
Rear axle and anti-roll bar
Brake system
General information about the braking system
Tools and equipment
Hydraulic brake system
Bleeding the brake system (removing air)
Front brake calipers (Teves)
Front brake calipers (Girling)
Front Brake Calipers (VW Mk II)
Replacing rear drum brake pads
Rear brake cylinders
Master brake cylinder
Brake servo booster
Brake pressure regulator
Handbrake
Possible malfunctions of the brake system
Electrical equipment
Lighting and appliances
General information about electrical equipment
Tools and equipment
Replacing lamps
Replacing the lights
Fuses, relays and turn signal switch
Instrument cluster
Ignition Switch/Steering Column Lock
Switches and cigarette lighter
Windscreen wipers and washers
Sound signal
Gear shift/fuel consumption indicator
Possible electrical equipment faults
Electrical circuits
How to use diagrams
Symbols and designations of electrical circuits
Codes (designations) of elements of electrical connection diagrams
A Devices
In Sensors and sound signal
C Battery
E Light bulbs
F Fuses
G Generator
H Light signaling
K Relay
M Electric Motors
P Instruments and indicators
R Resistors
S Switches
T Transformers
X Connectors
Y Electromagnets
Body
Body and equipment
General information about the body and equipment
Tools and equipment
Front wing
Bumpers
Doors and door trim
Door handles and locks
Hood lock and its drive (cable)
Radiator grille
Telescopic tailgate stop
Front seat
Speedometer cable
Dashboard
Optional equipment
General information about additional equipment
Removal and installation tool
Installing a radio and speakers
Installing the antenna
Radio interference suppression
Child seat
Additional lighting devices
Towbar and towbar electrical equipment
Golf 2
General information
Characteristics
Towing a car trailer (s)
Trailer Operating Instructions
Engine — General Information
Exhaust gas control system
Transmission — General Information
Technical data: steering, suspension, brakes, body/chassis
Technical data of the car
Vehicle weight
Vehicle designation
Car care
Volkswagen Golf and Jetta Manual System: Preliminary Information
Car operation: the first 1500 km of mileage and subsequent
Safety rules for operating a car
Driving: economically and with minimal air pollution
Instructions for driving a car with a trailer
Car Care: Fuel Tank
Car care: fuel supply
Car care and protection from pollution
Exterior care of the car
Car interior maintenance
Protecting your car from corrosion
Engine hood maintenance
Engine bay maintenance
Motor oil: specification and viscosity
Consumption and replacement of engine oil
Engine Oil Filter Maintenance
Fuel System Maintenance (Diesel Engines Only)
Transmission oils
Caring for your air purifier
Air Filter Maintenance
Power steering
Maintenance of the cooling system
V-profile belt
Caring for brake fluid in a car
Battery care
Windshield Cleaning Solution Tank
Replacing windshield wiper blades
Tire (wheel) care
New Tires: Lifespan, Wear and Replacement
Technical characteristics of the tire
Tires used in winter
Driving a car in difficult operating conditions
Driving in winter
Additional accessories, modifications and replacement of components and assemblies
Maintenance
General principles of repair
Set of tools for minor repairs
Occupational safety during maintenance
Maintenance frequency
Electrical system faults
Vehicle maintenance
Jack and tools for self-service
Spare wheel
Wheel replacement
Fuses
Replacing lamps
Headlight beam adjustment
Installation and replacement of radio
Emergency start
Emergency towing of vehicles by a technical assistance vehicle
Lifting a car
Power unit
Engine repair
Engine technical data
Motor housing
Crankcase air bleed system
Oil sump
Flywheel — removal, repair and installation
Engine assembly
Starting the engine after repair and adjustment
Engine fault tables
Engine 1.05/1.30
Removal the engine from the car
Disconnecting the gearbox
Engine equipment
Timing belt and timing gears
Camshaft
Crankshaft seals
Removal the engine head
Removal the engine head
Grinding of engine head valves
Engine head installation
Installing the head on the engine
Valve clearances
Pistons and connecting rods. Extraction
Piston inspection and repair
Installation of pistons and connecting rods
Crankshaft: extraction, inspection, repair, installation
Installing the engine in a car
Engine 1.60/1.80
Removal the engine from the car
Fuel Injected Engine — Extraction
Engine equipment
Camshaft
Engine head
Valve clearances — adjustment
Removal pistons and connecting rods
Installing the engine in a car
Timing belt and timing gears
Cooling and lubrication system
Technical data of the cooling and lubrication system
Cooling system device
Operation of the cooling system
Periodic maintenance of the lubrication and cooling system
Draining the coolant
Rinsing the system
Filling the lubrication and cooling system
Antifreeze — General Information and Replacement
Radiator — removal and installation
Radiator fan
Radiator Fan Thermal Switch
Thermostat — 1.1 and 1.3L engines
Thermostat — 1.6 and 1.8 L engines
Water pump — 1.1 and 1.3L engines
Water pump — 1.6 and 1.8L engines
Water temperature sensor, thermal switches
Lubrication system device
Checking the engine oil level
Engine oil change
Oil pump — 1.1 and 1.3L engines
Oil pump — 1.6 and 1.8L engines
Power and exhaust system
Carburetor engines
Tools and equipment for repair
General description of gasoline fuel systems
Air Filter Insert — Replacement
Air filter assembly
Intake air temperature controller
Fuel pump — carburetor engines
Fuel pump — gasoline injection engines
Fuel sump
Fuel tank
Fuel level sensor
Fuel tank check valve
Gas cable
Gas cable — automatic transmission
Gas pedal
Starter Cable — 1.1L Engine
Carburetor — removal and installation
Carburetor — 31 PIC-7
Engine speed control — PIC carburetor with manual choke
Engine speed control — PICT carburetor with automatic choke
Carburetor Zenith 1B3
Carburetor Zenith 2B5
Carburetor 2E2
Adjusting the gap of the diaphragm of the carburetor 2E2
Carburetor 2EZ
Preheating of underwater manifold
Collectors — intake and exhaust
Table of malfunctions of the carburetor fuel system
Petrol injection systems
General description of the injection system
Air flow meter
Fuel supply
Fuel distributor
Cold engine start valve
Engine preheating valve
Additional air valve
Fuel Injection System — Service Intervals
Replacing the air filter insert
Engine Idle Speed — Adjustment
Adjustment of exhaust gas composition
Cold start valve and temporary thermal switch
Additional air valve
Engine preheating valve
Enrichment system during cold engine revving
Fuel injectors
Flow meter plate and control piston
Fuel distributor
Air flow meter
Pressure regulator
Fuel feed pump
Fuel pump located outside the fuel tank
Fuel filter
Pressure accumulator
Suction manifold
Exhaust manifold (exhaust)
Fuel injection system fault table
Exhaust system maintenance
Transmission
Clutch
Technical data
Clutch device
Clutch — adjustment
Clutch cable — replacement
Clutch pedal — disassembly and assembly
Clutch — Gearbox 084
Clutch — 084 control
Clutch Release Mechanism — 084
Clutch 020 — disassembly and assembly
Clutch 020 — control
Clutch Release Mechanism 020
Clutch Fault Table
Car gearbox
Technical data
General characteristics of a manual gearbox
Frequency of inspection of the gearbox
Removal the gearbox 084
Disassembly and repair of gearbox 084
Clutch housing — repair
Gearbox housing — repair
Input shaft of box 084
Output shaft of box 084
Synchronizers — box 084
Differential mechanism — box 084
Installation of gearbox 084
Gear selection mechanism for gearbox 084
Removal the gearbox 020, 4 and 5 speed
Disassembly and repair of gearbox 020, 4-speed
Gearbox assembly 020, 4-speed
Disassembly and repair of gearbox 020, 5-speed
Input and output shafts 020, 5-speed
Synchronizers for 020 gearbox, 4- and 5-speed
Gearbox installation 020, 5-speed
Gear selection mechanism for gearbox 020
General characteristics of automatic transmission
Automatic transmission service
Removal the automatic transmission
Overload test
Automatic transmission gear selector cable
Carburetor cable and gas pedal cable
Gearbox fault table
Drive shafts
Technical data
Drive axles: device
Drive axle shaft — replacement
Drive joints
Disassembling the outer hinge
Assembling the outer hinge
Installing the outer joint on the axle shaft
Inner hinge
Disassembling the inner joint
Mounting the inner hinge
Inner Hinge — GTI Models
Drive flange seal
Chassis
Brake system
Technical data
The structure of the braking system
Frequency of maintenance of the brake system
Brake pedal
Servo
Brake cylinder
Rigid and flexible brake lines
Brake force corrector
Front wheel brake calipers
Front brake disc
Rear wheel brake calipers
Rear brake disc
Rear drum brakes
Bleeding the brake system
Handbrake lever
Brake system fault table
Steering
Technical data
Control system device
Maintenance and care
Steering wheel
Steering column
Steering wheel lock
Steering gear housing
Steering rods and ball joints
Steering gear (without power assistance)
Steering gear assembly
Power assisted control system
Front wheel installation, adjustment
Table of faults
Suspension
Technical data
Front and rear suspension design
Maintenance and care
Front suspension spring column
Disassembling the front suspension spring column
Front stabilizer
Wheel balancing
Tire maintenance
Fault Table — Wheels and Tires
Body
Body and equipment
Front buffer
Radiator protection
Front part
Front end assembly
Rear buffer
Replacing the buffer pad
Disassembling the front wing
Disassembly and assembly of the wheel carrier
Pipes that drain water from the roof
Roof cornice
Side decorative cornice
External door handle
Central door locking
Door lock
External rear view mirror
Door trim
Front door
Disassembling the interior door handle
Manual glass lifting mechanism
Door glass
Replacement of side body windows
Removal and installation the front seat
Trunk lid
Heating
Windshield wiper
Rear window wiper
Glass sprinkler
Dividing board
Electrical equipment
Lighting and appliances
Technical data
Electrical system device
Battery
Checking the battery under load
Maintenance free batteries
Removal and installation the battery
Charging the battery
AC generator
Removal and installation the generator
Replacing the V-belt
Replacing generator brushes
Disassembling the generator
Control of generator elements
Starter
Disassembling the starter
Checking the starter elements
Ignition system
The structure and operating principle of the classic ignition system
Ignition system TSZ-H
Ignition system VEZ
Precautions when repairing electronic ignition systems
Removal the ignition distributor
Checking the breaker contacts
Replacing breaker contacts
Setting the ignition timing
Checking the capacitor
Checking the cap
Checking the Halotron
Checking the TSZ-H control system
Spark plugs
Type of spark plug
Lighting equipment
Replacing headlight bulbs
Replacing the parking light bulb
Headlight replacement
Installation of lighting (light)
Replacing the front turn signal bulb
Removal the rear complex (connected) lamp cap
Replacing the registration plate (number) lighting lamp
Relays in Golf and Jetta cars
List of electrical equipment
Summary of mass points
Expanded electrical diagrams
Electrical circuits
Overload cut-off valve and suction manifold heater (models up to 07.87)
Starter, generator, battery and ignition system (models 1.1, 1.3 and 1.6 up to 07.87)
Oil pressure sensor (models 1.1, 1.3 and 1.6 before 07.87)
Glove compartment and trunk lighting, radio and cigarette lighter bulbs (models 1.1, 1.3)
Light and indicator lighting switch (models 1.1, 1.3 and 1.6 up to 7.87)
Main and rear lighting and flash signal switch (models 1.1, 1.3 and 1.6 before 07.87)
Fog lights and heated rear window (models 1.1, 1.3 and 1.6 up to 07.87)
Indicators and warning lights (models 1.1, 1.3 and 1.6 up to 07.87)
Brake lights, blowers, reversing lights and radiator fan (models 1.1, 1.3 and 1.6 up to 7.87)
Two-tone signal, handbrake tightening signal and brake fluid level control signal (models 1.1, 1.3 and 1.6 before 07.87)
Windscreen wiper motor and sprayer (models 1.1, 1.3 and 1.6 golf up to 12.85 and Jetta up to 07.87)
Rear window wiper (models 1.1, 1.3 and 1.6 up to 12.85)
Suction manifold and automatic suction heater (models 1.3 up to 07.86)
Starter, generator, battery and ignition system (1.8 models with carburetor)
Overload cut-off valve and intake manifold heater (1.8 models with carburetor)
Table of gauges, stash light, gear shift diagram, fuel gauge and oil pressure gauge (models up to 07.85)
Table of indicators and multi-function sensor (models 1.8 up to 07.85)
Central locking, interior lighting, boot lighting, radio and cigarette lighter (models 1.8 up to 07.85)
Light switch, distribution board and registration plate lighting (models up to 07.87)
Rear lighting and light, headlamp flasher switch (1.8 models up to 07.85)
Rear fog light and heated rear window (1.8 models up to 07.85)
Indicators and control lamps (models 1.8 up to 07.85)
Brake lights, blower, reversing lights and radiator fan (1.8 models up to 7.85)
Two-tone signal, handbrake tightening signal and brake fluid level indicator light (models 1.8 to 7.85)
Sprinkler and wipers (models 1.8 to 7.85)
Control of outside mirror, sprinkler and rear window wiper (model 1.8 up to 12.85)
Electric window lift (1.8 models with carburetor up to 7.87 g.)
Starter, alternator, battery and ignition system (1.8 models with fuel injection up to 7.84 g.)
Fuel supply system, gear shift and fuel consumption indicator (1.8 models with fuel injection)
Starter, alternator, battery, ignition system and system that increases engine speed during heating (1.8 models with fuel injection from 8.84 to 7.87 g.)
Fuel system, gear shift system, fuel gauge and coolant level (1.8 models)
Main light sprinkler on all models
Radiator Fan (250W) Models 1.6 and 1.8
Elements installed in the automatic transmission (1.6 models)
Headlight setting control on all models
Multifunctional pointer (models 1.8)
Starter, alternator, battery and ignition system (models 1.1 from 8.85)
Heater for intake manifold, automatic intake and idle speed increase system during engine warm-up (models 1.1 from 8.85)
Starter, alternator, battery and ignition system (1.3 models from 8.85)
Suction manifold heater, automatic suction (models 1.3 from 8.85)
Starter, generator, battery (models 1.8 16V)
Ignition system (models 1.8 16V)
Coolant level indicator light (1.8 16V models)
Idle speed control and overload cut-off valve system (1.8 16V models)
Fuel supply system (models 1.8 16V)
Starter, generator, battery and ignition system (1.6 models from 8.85 to 7.87)
Radiator fan (models 1.6 and 1.8 from 3.86 to 7.87)
Windscreen wipers in all Golf models from 1.86 to 7.87.
Front and rear window wipers and sprinklers in all Golf models
Starter, generator, battery and ignition system (1.6 models from 8.87)
Heater for the supply manifold and automatic suction (models 1.6 from 8.87)
Table of indicators, optical and acoustic low oil pressure indicator and rev counter (models from 8.87)
Interior and trunk lighting, radio (models from 8.87)
Light and license plate light switch (models from 08.87)
Main light, tail light, headlamp flasher switch, brake light switch and reversing light switch (models from 08.87)
Indicators and control lamps in all models from 8.87.
Automatic window opening motors (models 1.6 from 08.87)
Handbrake, brake fluid level indicator light, low coolant level indicator and more on all models since '87.
Rear window wipers and radiator fan (1.1, 1.3 and 1.8 fuel injected models from 08.87)
Automatic transmission (1.6 models from 01.89)
Generator, battery, starter and ignition system (models 1.6 and 1.8 with carburetor since 01.89)
Radiator fan and fresh air supply (models 1.6 and 1.8 with carburetor from 01.89)
Automatic intake and heater of the supply manifold (models 1.6 and 1.8 with carburetor from 01.89)
Ignition system and overload cut-off valve (models 1.6 and 1.8 with carburetor since 01.89)
Distribution panel and oil pressure sensor (models 1.6 and 1.8 with carburetor from 01.89)
Distribution panel: rev counter, fuel and temperature gauge (models 1.6 and 1.8 with carburetor since 01.89)
Handbrake tightening signal and brake fluid level indicator light (models 1.6 and 1.8 with carburetor since 01.89)
Lighting for the cache, cigarette lighter, radio and lighting for the cassette container (models 1.6 and 1.8 with carburetor from 01.89)
Lighting for the car interior, trunk and registration plate (models 1.6 and 1.8 with carburetor since 01.89)
Main lighting, side lighting and headlight signal switch (models 1.6 and 1.8 with carburetor from 01.89)
Direction indicators, control lamps and side light switch (models 1.6 and 1.8 with carburetor from 01.89)
Direction indicators and rear light (models 1.6 and 1.8 with carburetor from 01.89)
Light switch and brake light switch (models 1.6 and 1.8 with carburetor from 01.89)
Reversing light, heated rear window, two-tone signals (models 1.6 and 1.8 with carburetor since 01.89)
Rear fog light and heated front window sprinklers (models 1.6 and 1.8 with carburetor from 01.89)
Windscreen wipers and sprinklers (models 1.6 and 1.8 with carburetor since 01.89)
Electrically adjustable exterior mirrors in all models from 01.89.
Golf 2
General information
Introduction to guide
Description of design features of Golf 2 cars
Vehicle identification data
General instructions for maintenance and repair
Technical data for maintenance and repair
Tightening torques for threaded connections
Lifting a car with a jack
User manual
Controls and instruments
Opening the hood
Location of units and parts in the engine compartment
Ignition switch lock
Starting a car engine
Multifunctional display
Gear shifting
Steering wheel tilt adjustment
Lighting and signaling
Windscreen and rear window wipers and washers (Golf)
Ventilation and heating
Ventilation and heating with air conditioning system
Gear and fuel consumption indicator
Doors and windows
Adjusting the front seats
Wheel replacement
Checking the level of working fluids
Replacing the air filter element
Checking tire pressure
Petrol engines 1.3 l
Engine repair
Removal and installation the engine
Disassembling the engine
Engine assembly
Cylinder head — general information
Removal the cylinder head without removing the engine
Disassembling the cylinder head
Cylinder head repair
Cylinder head assembly
Cylinder head installation
Checking hydraulic valve clearance compensators
Replacing the camshaft seal
Removal pistons and connecting rods from the cylinder block
Measuring cylinder diameters
Checking piston rings, ring grooves and connecting rods
Assembly of the connecting rod and piston group
Installing pistons and connecting rods into cylinders
Cylinder Block — Check
Removal the crankshaft
Checking the crankshaft
Installing the crankshaft
Removal the crankshaft seals
Installing crankshaft seals
Flywheel replacement
Valve timing mechanism — design description
Replacing the timing belt
Checking and setting valve timing
Replacing the camshaft without removing the engine
Lubrication system
Engine lubrication system — design description
Oil pan replacement
Replacing the oil pump
Adjusting the oil pump
Replacing the oil filter
Checking oil pressure
Possible malfunctions of the lubrication system and how to eliminate them
Cooling system
Engine cooling system — design description
Replacing the coolant
Radiator check
Radiator Banners
Checking the radiator fan
Checking the thermal switch
Replacing the coolant pump
Adjusting the V-belt tension
Replacing the thermostat
Repair of interior heater
Possible malfunctions of the cooling system
Carburetors
Replacing the Solex 1B3 carburetor
Disassembling the Solex 1B3 carburetor
Adjusting the Solex 1B3 carburetor
Disassembling the Weber TLA carburetor
Weber TLA Carburetor Adjustment
Carburetor Pierburg 2E3 — design description
Adjusting the Pierburg 2E3 carburetor
Carburetor calibration data
Possible malfunctions of the fuel system of carburetor engines
Supply system
Fuel injection systems — general information
Description of the Digijet injection system
Adjusting the idle speed parameters of the Digijet injection system
Possible malfunctions of injection systems
Fuel pump and filters
Fuel level sensor
Fuel tank — removal and installation
Inertia and ventilation valves
Replacing the exhaust manifold
Replacing exhaust system components
Ignition system
Safety of work with the ignition system
Contact ignition system
Transistor ignition system TSZ-H
Checking the ignition coil
Checking the distributor rotor, wires, spark plug tips
Removal and installation the ignition distributor
Replacement of the contact group of the breaker (contact ignition system)
Checking the angle of the closed state of contacts (contact ignition system)
Adjustment of the UZSK (contact ignition system)
Checking the capacitor (contact ignition system)
Checking the Hall sensor (electronic ignition systems)
Checking the switch (electronic ignition systems)
Adjustment of the ignition advance angle (moment)
Spark plugs
Maintenance work on the ignition system
Petrol engines 1.6/1.8 l
Engine repair
Camshaft Drive — Design Description
Removal and installation the camshaft
Adjusting valve clearances
Removal and installation the cylinder head (8V)
Removal and installation the cylinder head cover (16V)
Removal camshafts (16V)
Removal the cylinder head (16V)
Supply system
Fuel injection system KE-Jetronic from Bosch
Mono-Jetronic fuel injection system
Digifant fuel injection system
Replacing the exhaust manifold
Ignition system
General description of the ignition system
Electronic ignition system VEZ
Removal and installation of the VEZ ignition distributor
Checking the VEZ ignition system
Checking the ignition timing angle Digifant
Adjusting the ignition timing (moment) angle Digifant
Spark plugs
Diesel engines
Engine repair
Description of diesel and turbodiesel engines
Removal and installation the engine
Disassembling the engine
Engine assembly
Cylinder head
Removal the cylinder head from the engine installed on the vehicle
Disassembling the cylinder head
Checking valve springs
Checking the valve guides
Checking valve seats
Checking the valves
Checking the cylinder head
Checking the camshaft (engine with hydraulic tappets)
Checking hydraulic valve lifters
Cylinder head assembly
Installing the cylinder head
Pistons and connecting rods — design description
Removal connecting rod and piston group parts from the cylinder block
Checking the connecting rod and piston group parts
Assembly of the connecting rod and piston group
Installation of connecting rod and piston group
Measuring the axial clearance of the crankshaft
Removal the crankshaft
Replacing crankshaft seals
Checking the crankshaft
Installing the crankshaft
Cylinder Block — Check
Flywheel — replacement
Replacing the intermediate shaft
Automatic transmission drive
Valve timing mechanism — design description
Toothed Belt Banners
Replacing the camshaft
Replacing the camshaft seal
Adjusting valve clearances
Maintenance of diesel and petrol engines
Lubrication system
Description of the design of the engine lubrication system
Oil pan replacement
Replacing the oil pump
Oil pump repair
Replacing the oil filter
Oil cooler replacement
Checking oil pressure
Cooling system
Description of the design of the engine cooling system
Replacing the coolant
Checking and replacing the radiator
Checking the coolant level
Replacing the liquid pump
Liquid pump repair
Adjusting the V-belt tension
Replacing the thermostat
Power and exhaust system
General description of the fuel system of diesel engines
Fuel filter maintenance
High pressure fuel pump (HPFP) banners
Checking and adjusting the compression torque (Bosch pump)
Checking and adjusting the compression torque (CAV pump)
Adjusting the accelerator thrust
Adjusting the starting device
Adjusting the idle speed
Adjusting the maximum speed
Replacing the injector
Replacing the turbocharger
Installing a turbocharger
Checking the turbocharger
Replacing the intake and exhaust manifolds
Starter plugs
Replacing the exhaust manifold
Transmission
Clutch
Clutch (petrol engine models)
Clutch replacement (petrol)
Replacing the clutch cable (petrol)
Replacing the clutch release bearing (petrol)
Clutch (diesel models)
Clutch replacement (diesel)
Replacing the clutch cable (diesel)
4-speed gearbox 084
Technical data for gearboxes
Gearbox replacement
Disassembling the gearbox
Gearbox housing repair
Disassembling the primary shaft
Disassembling the secondary shaft
Checking the wear of gearbox parts
Secondary shaft assembly
Assembling the primary shaft
Installing the secondary shaft
Installing the primary shaft
Assembling the rod locking device
Repair of the main gear and differential
Assembly of the main gear and differential
Gear selection mechanism repair
5-speed gearbox 085
Gearbox replacement
Disassembling the gearbox
Removal the primary shaft
Disassembling the secondary shaft
Gearbox assembly
Disassembling the differential mechanism
Installing the gear selection mechanism
4-speed gearbox 020/4R
General description of the four-speed gearbox 020 (4R)
Gearbox replacement
Disassembling the gearbox
Assembling the primary shaft
Secondary shaft installation
Installation of the main gear
Adjustment after gearbox assembly
Adjusting the primary shaft
Secondary shaft adjustment
Installing the main gear
Replacement and adjustment of the gear selection mechanism
5-speed gearbox 020/4T
Five-speed gearbox (model 020/4T or 9A)
Disassembling the gearbox
Installing the primary and secondary shaft
Gearbox housing assembly
Gearbox adjustment
Installing the gear selection mechanism
Checking the oil level
Automatic gearbox
Checking the transmission oil level
Transmission oil change
Adjusting the vacuum chamber
Gearbox replacement
Drive shafts
Replacing drive shafts
Replacing the inner constant velocity joint (CV joint)
Replacing the outer constant velocity joint (CV joint)
Replacing the anti-vibration weight
All-wheel drive vehicles
Chassis
Steering
General description of steering
Replacing the steering gear
Adjusting the play in the steering mechanism
Twin-shaft steering column banners
Replacing a Steering Column with a Solid Shaft
Replacing the intermediate shaft
Replacing the steering rod on a removed steering gear
Replacing the steering rod on the steering gear installed on the vehicle
Adjusting the front wheel alignment angles
Replacing the power steering gear
Steering rod banners (with hydraulic booster)
Replacing the fluid in the power steering
Adjusting the play in the steering mechanism (with power steering)
Adjusting the V-belt tension
Car suspension
Front suspension — design description
Replacing front suspension components
Disassembling the front suspension
Front suspension repair
Assembling the front suspension
Replacement of front suspension components and parts
Rear suspension — design description
Replacing the rear axle beam
Replacing the shock absorber and rear suspension spring
Replacing rear wheel hub bearings
Checking the rear wheel alignment angles
Wheels and tires
Brake system
General description of the braking system
Replacing the front brake pads
Repair of front brake calipers
Front brake disc repair
Checking and replacing rear brake pads
Master Brake Cylinder — Design Description
Replacing the master brake cylinder (MBC)
Vacuum brake booster — design description
Pressure regulator — removal and installation
Bleeding the brake system, replacing the brake fluid
Parking brake — design description
Checking the free play of the parking brake
Replacing the parking brake cable
Adjusting the parking brake
Anti-lock braking system (ABS)
Possible malfunctions of the brake system
Body
Body elements
General description of the car body
Radiator grille — removal and installation
Upper cross member of the radiator frame
Installation and adjustment of the hood lock
Front bumper — removal and installation
Rear bumper — removal and installation
Front wing — removal and installation
Electrically adjustable rear view mirror
Rear view mirror without electric drive
Interior door trim — removal and installation
Front seat — removal and installation
Doors, locks and windows
Door handle — removal and installation
Door Lock Cylinder — Removal and Installation
Door Lock Cylinder — Replacement and Repair
Internal door opening handle
Replacement of glass of a window of a door
Glass lifting mechanism without electric drive
Electric window lift mechanism
Replacement of windshield and side windows
Electrical equipment
Equipment and devices
General description of on-board electrical equipment
Headlight adjustment
Banners of lamps in headlights
Windscreen wiper — design description
Replacing fuses
Using Electrical Schematics
Structure of the electrical circuit
Power devices
Generator replacement
Bosch Generator Repair
Motorola Generator Repair
Possible generator faults
Rechargeable battery
Possible faults of the battery
Description and testing of the starter
Starter replacement
Starter repair
Golf 3
Petrol engine
Engine repair
Engine with a working volume of 1.4 liters
Engine with a working volume of 1.8 liters
Engine with a working volume of 2.0 liters
Technical parameters of the gasoline engine
Tightening torques for engine threaded connections
Removal and installation the engine
Separation of engine and gearbox
Alignment of the engine and gearbox
Disassembly and assembly of the engine
Cylinder head and valves
Removal the cylinder head
Disassembling the cylinder head
Cylinder head valve springs
Cylinder head valve seats
Cylinder head valves
Cylinder head
Camshaft
Cylinder head assembly
Cylinder head installation
Hydraulic tappets
Replacing the camshaft sealing ring
Pistons and connecting rods
Cylinder block
Crankshaft and main bearings
Crankshaft sealing rings
Drive mechanism
Removal the toothed belt
Installation of a toothed belt
Checking and adjusting the installation marks
Intermediate shaft
Compression pressure control
Lubrication system
Engine lubrication system
Dismantling and installation of the crankcase
Oil pump
Oil filter
Oil pressure control
Oil radiator
Cooling system
Engine cooling system
Cooling means
Radiator and fan
Water pump
Thermostat
Coolant circulation pump
Ignition system
Ignition system. General information
Safety precautions
Ignition distributor. General information
Maintenance of the ignition distributor
Removal and installation the ignition distributor
Ignition distributor repair
Setting the ignition timing
Spark plugs
Diesel engine
Engine repair
Suction motor with a working volume of 1.9 liters
Turbodiesel with a displacement of 1.9 liters
Diesel Engine. General Information
The principle of diesel
Cylinder block
Crankshaft
Pistons
Cylinders
Cylinder head gasket
Cylinder head and camshaft
Toothed belt
Hydraulic tappets
Lubrication system
Engine crankcase ventilation
Checking the engine for oil loss
Running in a new engine
Engine life
Measuring compression pressure
Engine fault diagnostics
Timing Belt Fault Diagnosis
Cylinder Head Gasket Fault Diagnosis
Work on the cylinder head
Bearing damage
Removal and installation the engine
Turbocharged diesel engine
Boost pressure regulator
Removal the turbocharger
Troubleshooting
Diesel injection system
Diesel engine injection system. General information
High pressure fuel pump
Cold start accelerator
Fuel injection system of suction diesel engine
Fuel injection system on a turbodiesel engine
Nozzles
Adjusting the injection timing (start of delivery) of the high-pressure fuel pump
Gas traction
Cold start accelerator rod
Idle speed check
Checking exhaust gases for soot content
What is the air filter for?
Diagnostics of diesel injection system faults
Digifant fuel injection system for 2.0 liter engine
Pre-glow system
Diesel Engine Pre-Glow System. General Information
Two different pre-heating systems
Operation of the pre-heating system
Glow plugs
Troubleshooting the Pre-Glow System
Glow Plug Troubleshooting Sequence
Checking the tape fuse (all engines)
Checking the voltage supply (all motors)
Checking glow plugs (all engines)
Checking the pre-glow relay
Checking the glow plug relay (55 kW turbodiesel)
Checking the automatic glow time control device (55 kW turbodiesel)
Checking the pre-glow system temperature sensor (all engines)
Pre-glow indicator lamp does not light
Transmission
Clutch
Clutch technical parameters
Clutch. General information
Clutch mechanism
Replacing the clutch cable
Clutch removal
Clutch overhaul
Clutch installation
Clutch release mechanism
Clutch faults
Gearbox and drive shafts
Technical parameters of the gearbox
Tightening torques for gearbox threaded connections
Gearbox. General information
Dismantling and installation of the M5 box
M5 gearbox disassembly
Checking gearbox parts
Gearbox assembly
Gearbox and differential adjustment
Dismantling and installation of box 02A
Disassembling the gearbox 02A
Automatic four-speed gearbox. General information
Removal an automatic transmission
Checking the oil and working fluid levels in the automatic transmission and final drive
Front drive shafts
Dismantling and installation of the drive shaft
Repair of the drive shaft
Dismantling and installation of the shock absorber
Restoration of rubber cuffs
Chassis
Steering
Technical parameters of the steering system
Tightening torques for steering threaded connections
Power steering gear
Removal the steering gear
Installing the steering gear
Restoration of transverse steering rods
Filling the hydraulic system
Bleeding air from the hydraulic system
Checking the hydraulic system for leaks
Adjusting the steering wheel free play
Adjusting the tension of the V-belt of the hydraulic power steering pump
Installation and removal of hydraulic parts of the power steering mechanism
Height adjustable steering column
Dismantling and installation of the hydraulic power steering pump
Installing the front wheels
Wheel alignment
Wheel alignment
Longitudinal inclination of wheels
Negative rolling radius of wheels
Differential angle of movement of wheels
Brake pressure regulator
Wheels and suspension
Technical parameters of the suspension
Tightening torques for threaded connections of suspension
Wheels and tires. General information
Front Wheel Suspension. General Information
Dismantling and installation of shock absorber struts
Disassembling the shock absorber strut
Repair of shock absorber strut
Assembling the shock absorber strut
Dismantling and installation of individual suspension parts
Rear suspension. General information
Removal and installation the rear axle
Dismantling and installation of shock absorber struts
Rear wheel bearings
Geometric design of the rear wheels
Brake system
Technical parameters of brakes
Tightening torques for brake threaded connections
Brake system. General information
Brake adjustment
Replacing the front disc brake pads
Repair of the brake seat of the front disc brake
Modification of front brake discs
Checking and replacing brake pads on the rear wheel drum brake mechanism
Brake support plates for rear wheel drum brakes
Wheel brake cylinder
Modification of rear wheel brake drums
Master brake cylinder
Removal and installation of the master brake cylinder
Brake Drive Booster
Bleeding the brakes
Removal and installation rear disc brake pads
Repair of the brake saddle of the rear disc brake
Modification of brake discs of rear wheel brakes
Handbrake
Dismantling and installation of handbrake cables
Dismantling and installation of the handbrake lever
Anti-lock device
Removal anti-lock braking system components
Electrical equipment
Lighting and appliances
Technical parameters of electrical equipment
Electrical equipment. General information
Rechargeable battery
Checking the battery
AC generator
Precautions when working with the charger
Checking the built-in generator
Dismantling and installation of an alternator
Repair of car generator «Bosch»
Repair of the car generator «Valeo»
Starter
Removal and installation the starter
Disassembling and assembling the starter
Dismantling and installation of incandescent lamps
Removal and installation of headlights
Dismantling and installation of a servomotor for adjusting the lighting range
Headlight adjustment
Fog lights
Screen cleaner
Front turn signal light
Rear light
Electrical circuits
Generator, starter, ignition switch
Cooling fan, fresh air fan
Injection control device, suction channel preheating system
Injection control unit, lambda probe, ignition system
Instruments, oil pressure switch, long-range thermometer temperature sensor
Instruments, signal lighting, fuel supply, long-range thermometer
Removable instrument cluster, multi-function indicator, tachometer sensor
Interior lighting, rear ashtray lighting, number plate lights
Handbrake and brake fluid warning device, trunk lighting
Adjusting the lighting range
Headlights, parking lights, low beam and signal lights
Flashing lights and circular signal flashers, parking light switches
Light switches and rear fog lights
Reversing light, heated rear window and dual tone horn
Windscreen wiper and washer
Windscreen wiper and washer, rear brake lights
Starter, battery, generator and ignition system
Power supply system with integrated Digifant system
Ignition system, injection system «Digifant»
Control unit for the Digifant system, lambda probe and injection nozzles
Coolant shortage detection device and oil pressure monitoring
Tachometer sensor, oil pressure switch if VR6 engine is present
Generator, starter, ignition switch if there is a VR6 engine
Monotronic control unit, lambda probe and ignition system with VR6 engine
Motronic control unit, engine speed sensor, throttle potentiometer
Monotronic control unit, injection valve, air quantity sensor with VR6 engine
Motronic control unit, current relay, coolant pump for VR6 engine
Golf 4
General information
User manual
Controls, instruments and equipment
Control devices
Control lamps
On-board computer with multifunctional indicator
Functional control
Violations of primary importance (red pictograms)
Minor violations (yellow pictograms)
Navigation system
Car keys
Car doors
Back door
Central locking
How to unlock only one of the front door locks
Central locking button
Security alarm system
Remote control of locks
Unlocking and locking the car
Electric windows
Operation of window lifts with ignition on
Operation of window lifts when ignition is off.
Lift and slide roof hatch panel
Switches and switches
Electronic stabilization system ESP
Anti-slip regulation ASR
Steering column switch for direction indicators and headlights
Interior lighting
Windscreen wipers and washers
Windscreen wiper blades
Replacing windshield wipers
Rear view mirrors
Rear window heating
Sun visors
Front seats
Driver's seat
Memory for driver's seat
Front passenger seat
Electrically adjustable seat
Seat and exterior mirror adjustments for forward movement
Adjusting the outside mirror when reversing
Remote control key for locks
Calling up seat and mirror adjustments for forward movement
Calling for setting the right mirror when reversing
Instructions for using the E-lock switch
Initialization of the memory system
Seat headrests
Armrests
Heated seats
Adjustable steering column
Mounting lugs
Luggage compartment shelf
Rear bench seat
Cup holders
Ashtrays
Heating and ventilation
Heating and ventilation air supply nozzles
How to clear ice from windshield and side windows
How to prevent fogging of the windshield and side windows
How to quickly increase the temperature in the cabin
How to maintain a pleasant warmth in the car interior
Ventilation (supply of fresh air to the cabin)
Air conditioning controls
Air conditioning system air supply nozzles
How to set the normal air cooling mode
How to set the maximum air cooling mode
Interior ventilation
Economical operation of the air conditioning system
Malfunctions of the air conditioning system
Climate control system «Climatronic»
Using the «Climatronic» installation
Using «Climatronic» in automatic mode (AUTO)
Deviation from the standard automatic mode of the «Climatronic» installation
Air supply nozzles for the «Climatronic» unit
Economical operation of the «Climatronic» unit
Failures in the operation of the «Climatronic» unit
Manual transmission
Automatic transmission
Automatic transmission selector positions
Recommendations for choosing automatic transmission positions
Parking brake
Ignition switch
Cruise control
Turning on cruise control
Setting (entering into memory) the desired speed of movement
Changing the set speed of movement
Temporary cruise control disabling
Turning off cruise control permanently
Inflatable airbags
Action of inflatable pillows
Disabling the front passenger airbag
Side airbags
Operation of the side airbag system
Refueling
Fuel for gasoline engines
Fuel for diesel engines
Braking a car
Anti-lock braking system
Traction Control System (EDS)
Traction control with torque reduction (ASR)
Power steering
Engine compartment hood
Towing eyes
Driving a car
Weekly checks
Starting from an external source (another car)
If the engine does not start and the starter does not work
If the engine does not start even though the starter works normally
Wheel replacement
Towing a car
Checking the tightness of connections
Weekly inspection locations
Checking the engine oil level
Checking the coolant level
Checking the windshield wipers
Checking the windshield washer fluid level
Checking the brake fluid level
Checking the electrical system
Checking the battery
Tires and checking tire pressure
Vehicle identification data
Maintenance
Vehicle maintenance
Technical characteristics of the car
Maintenance frequency
Maintenance schedule
Viscosity and specifications of motor oil
Qualities of motor oils
Mixing motor oil
Oil and oil filter change
Replacing the oil filter on diesel engines
Checking the exhaust system
Engine cooling system
Checking the coolant level and density
Loss of coolant
Topping up the coolant
Replacing the air filter element
Checking the condition of the poly V-belt
Spark plugs
Replacing spark plugs
Some practical tips on choosing and maintaining spark plugs
Replacing the fuel filter (diesel engines)
Checking the tightness of the hoses and fluid leakage
V-belts
Measuring wear of timing belts on diesel engines
Gearbox/Main gear
Checking the drive shaft protective boot
Visual inspection of gearbox tightness
Checking the oil level in a manual transmission
Checking the oil level in the main gear of the automatic transmission
Checking/replacing the oil level in the automatic transmission
Checking the front suspension and steering
Checking the dust covers of the front suspension joints
Checking the shock absorber
Radiator check
Checking the electrical wiring
Checking the Power Steering Fluid Level
Brake fluid
Checking the brake fluid level
Replacing brake fluid
Checking the front brake pads
Checking the rear disc brake pads
Checking the rear brake shoes of drum brakes
Checking brake hoses
Checking the condition of seat belts
Airbags
Door hinges
Replacing the dust filter
Rechargeable battery
Checking the electrolyte level
Operation of the battery in winter conditions
Battery charge
Disconnecting the battery from the on-board network
Removal and installation the battery
Purchasing a battery
Windscreen washers
Windscreen wiper blades
Checking the initial position of the windshield wiper arm
Replacing the battery in the remote control key
Resetting the Service Indicator
Power unit
Petrol engines
Petrol engines
Technical characteristics of engines
Removal and installation the lower mudguard of the engine compartment
Removal the 1.6-/1.8-I engine
Installing the 1.6-/1.8-I engine
Removal the timing belt of 1.6-/1.8-I engines
Setting the piston of the first cylinder to TDC of engines 1.6-/1.8-I
Inspection of the toothed belt of engines 1.6-/1.8-I
Installing the timing belt for 1.6-/1.8-I engines
Cylinder head of the 1.6-I engine
Removal the cylinder head of 1.6-/1.8-I engines
Preparing the 1.6-/1.8-I engine head for installation
Installation of engine head 1.6-/1.8-I for installation
Checking hydraulic valve lifters of 1.6-/1.8-I engines
Disassembling the cylinder head of engines 1.6-/1.8-I
Cleaning and checking the cylinder head of 1.6-/1.8-I engines
Assembly of cylinder head for 1.6-/1.8-I engines
Toothed belt for 1.4-I engine
Removal the cylinder head of the 1.4-I engine
Installing the cylinder head of the 1.4-I engine
Engine timing drive 2.3-I-VR5
Removal and installation the cylinder head of the 2.3-I-VR5 engine
Checking the compression in the engine cylinders
Removal the poly V-belt of 1.6-/1.8-I engines
Installation of poly V-belt for 1.6-/1.8-I engines
Removal the poly V-belt of 1.4-I engines
Installation of poly V-belt for 1.4-I engines
Removal the poly V-belt of 2.3-I engines
Installation of poly V-belt for 2.3-I engines
Recommendations for motor oils
Engine oil circuit
Checking oil pressure and oil pressure sensor
Removal and installation the oil pan
Starting the engine after major repairs
Engine fault diagnostics
Main faults of the lubrication system
Diesel engines
Diesel engines — general information
Technical characteristics of diesel engines
Removal and installation of the power unit
Toothed belt for TDI and SDI diesel engines
Removal the timing belt
Setting the piston of the first cylinder to TDC
Installing and tensioning the timing belt
Checking the Timing Belt Tensioner Roller
Removal and installation the cylinder head
Removal and installation the intake manifold of a diesel SDI engine
Checking the compression in the engine cylinders
Removal and installation a poly V-belt
Checking oil pressure and oil pressure sensor
Removal and installation the oil pan
Diagnostics of diesel engine faults
Main faults of the lubrication system
Cooling system
Elements of the cooling system
Topping up the coolant
Coolant mixture composition
Replacing the coolant
Draining the coolant
Filling the cooling system
Removal the thermostat
Checking the functionality of the thermostat
Installing a thermostat
Removal the radiator and fan
Installing the radiator and fan
Removal and installation a water pump on a 4-cylinder gasoline engine
Removal and installation a water pump on a 5-cylinder gasoline engine
Removal and installation a water pump on a diesel engine
Cooling system hoses
Cooling system malfunctions
Fuel system (petrol)
Fuel tank of cars with gasoline engines
Removal and installation the fuel pump/fuel level sensor
Removal and installation the fuel filter (petrol engines)
Adjusting the accelerator cable
Removal and installation the air filter housing
Remote fuel pump testing
Checking the fuel pump voltage supply
Checking the performance of the fuel pump
Checking the fuel pump relay
Control system (petrol)
Engine management system
Technical data of the engine management system
Operation of the engine management system
Checking the fuel injection system
Sensors and actuators of the engine management system
Ignition system
Ignition coil device
Spark plugs
Removal and installation of fuel lines and injectors
Main faults of the engine management system
Fuel system (diesel)
Cars with diesel engines
Direct fuel injection
Technical data of diesel fuel system
Checking the diesel engine preheating system
Checking glow plugs
Removal and installation glow plugs
Fuel heating system
Fuel injectors
Removal and installation fuel injectors
High pressure fuel pump injection timing
Main faults of the engine management system
Exhaust system
Exhaust system device
The device and use of the catalyst
Removal and installation of the exhaust system
Exhaust system alignment
Replacement of middle/rear muffler
Removal and installation of one muffler
Removal and installation the lambda sensor
Transmission
Clutch
Removal the clutch disc
Checking the clutch disc
Installing the clutch disc
Removal the clutch disc on cars with 1.4 and 1.6-I engines
Checking the clutch disc on cars with 1.4 and 1.6-I engines
Installing the clutch disc on cars with 1.4 and 1.6-I engines
Bleeding the hydraulic clutch drive
Bleeding air using a pressure bleeding kit
Main clutch faults
Car gearbox
Gearbox Description
Removal and installation of gearbox (engines 1.8/1.9/2.3-I)
Removal and installation of gearbox (engines 1.4/1.6-I)
Removal and installation of automatic transmission
Gear shift mechanism
Removal and installation the gear shift lever housing
Adjusting the gear shift cables (1.4-/1.6-I engines)
Adjusting the gear shift cables (engines 1.8-/1.9-/2.3-I)
Checking the adjustment of the gear shift cables
Evaluation of the performance of an automatic transmission
Adjusting the gear shift lever cable tension
Checking the gear shift cable adjustment
Drive shafts
Removal and installation the drive shaft
Replacing the drive shaft protective covers
Mounting position of disc springs
Filling the joints with grease
Drive shaft faults
Chassis
Car suspension
Front suspension device
Removal the front suspension shock absorber
Installing the front suspension shock absorber
Removal and assembling the shock absorber and spring of the front suspension
Rear suspension device
Removal and installation the shock absorber and rear suspension spring
Checking the rear shock absorber
Shock absorber disposal
Steering
Steering Description
Removal and installation the airbag
Removal and installation the steering wheel
Removal and installation the steering rod end
Basic faults of suspension and steering
Wheels and tires
General information about wheels and tires
Operating Instructions for Directional Tread Tyres
Tire wear indicators
Checking the valve
Wheel rotation
Wheels and tires
Spare wheel
Wheel replacement
Wheel mount security bolts
Anti-skid chains
Lifting a car
Brake system
Description of the car braking system
Technical specifications
Brake system diagram
Removal the front brake pads on the FS-III caliper
Installing front brake pads on FS-III caliper
Removal brake pads on FN-3 caliper
Installing brake pads on the FN-3 caliper
Removal rear brake pads on disc brakes
Installing rear brake pads on disc brakes
Checking the brake disc
Removal and installation the brake disc
Adjusting the handbrake
Removal rear brake shoes on drum brakes
Installing rear brake shoes on drum brakes
Removal and installation the rear wheel cylinder
Bleeding the hydraulic brake system
Bleeding brakes — basic method (two people)
Bleeding brakes — using a one-way valve kit
Bleeding brakes — using a pressure bleeding kit
Bleeding brakes — all methods
Brake lines and hoses
Checking the brake booster
Removal, installation and adjusting the brake light switch
Removal and installation handbrake cables
Main brake faults
Body
Exterior (external elements)
General information about body repair
Car body care
Repair of minor body damage
Repair of severe body damage
Front body panel
Removal and installation the front bumper
Removal and installation the rear bumper
Removal and installation the front wing
Removal and installation the front wing niche trim
Removal and installation the rear wing niche trim
Removal and installation the hood
Adjusting the hood position
Removal and installation the hood lock
Removal and installation the hood lock release handle
Removal and installation the radiator grille
Removal and installation the side body trim
Cleaning the gutter
Removal and installation the outside rearview mirror/mirror glass
Removal the exterior mirror housing
Interior (internal elements)
Caring for upholstery and carpets
Removal and installation the interior rearview mirror
Removal and installation a rearview mirror with a rain sensor
Automatic dimming interior rearview mirror
Removal and installation the front section of the center console
Removal and installation the rear section of the center console
Removal and installation the rear ashtray/cup holder
Removal and installation the front cup holder
Removal and installation upper trim in driver's footwell
Removal and installation the glove box
Removal and installation the side trim of the footwell
Removal and installation threshold pads
Removal and installation the lower trim of the central pillar
Removal and installation the right side trim of the luggage compartment
Removal and installation the luggage compartment floor covering
Removal and installation the rear luggage compartment trim
Removal and installation the front seat
Side airbags
Removal the rear bench seat cushion
Removal and installation the rear seat back
Ventilation and heating
Elements of the heating and ventilation system
Removal and installation air supply nozzles
Installing the central damper lever
Removal and installation the heater fan and additional resistor
Removal and installation heating and ventilation system control cables
A damper that regulates the temperature of the air supplied to the passenger compartment
Removal and installation the heater control unit
Car interior ventilation
Air recirculation valve actuator motor
Air conditioning system
Air Conditioning Compressor Brackets
Car doors and sunroof
Removal and installation the rear door pillar
Adjusting the position of the trunk lid/tailgate
Removal and installation the rear door lock
Removal and installation the door
Removal and installation interior door trim
Removal and installation the internal door lock button
Removal and installation door glass
Removal and installation the door bracket
Removal and installation the outer door opening handle
Removal and installation the lock cylinder housing
Removal and installation the door lock
Central locking system
Removal and installation the upper trim of the rear door
Removal and installation the rear door lower trim
Hatch drive
Removal and installation the glass sliding sunroof cover
Removal and installation the hatch cover seal
Removal and installation sunroof fairings
Removal and installation the sun blind
Removal, adjusting and installing the sunroof opening drive mechanism
Checking the parallelism of the hatch movement
Washers and glass cleaners
Replacing rubber bands of windshield wipers
Adjusting the windshield washer nozzles
Removal and installation windshield washer nozzles
Removal and installation rear window washer nozzles
Removal and installation windshield wiper arms
Removal and installation the windshield wiper motor
Removal and installation tanks and washer pump
Removal and installation the rear window wiper motor
Electrical equipment
Power devices
Battery Care Rules
Checking the battery
Charging the battery
Removal the battery
Installing the battery
Notes regarding batteries with vent plugs
Battery charging system
Description of the generator
Removal and installation the generator
Replacing the generator brushes and voltage regulator
Main generator faults
Description of the starter
Engine starting system
Removal and installation the starter
Checking, removing and installing the starter traction relay
Main faults of the starter
Lighting and appliances
General information about electrical equipment
Incandescent lamps
Electrical circuits
Open Circuit Detection
Detecting a broken chain
Detecting the source of a short circuit
Detecting poor grounding
Location and purpose of fuses
Replacing exterior lighting bulbs
Removal and installation additional brake light
Replacing interior light bulbs
Removal and installation headlights
Removal and installation the rear light
Headlight adjustment
Removal and installation the headlight corrector actuator motor
Removal and installation the instrument cluster
Removal and installation steering column switches
Removal and installation switches
Removal and installation the radio
Removal and installation high-frequency speakers
Removal and installation low frequency speakers
Recommendations for installing the phone
External antenna
Checking the rear window defroster
Electrical circuits
Explanations of electrical diagrams
Electrical Wiring Diagram (VW Golf from September 1997)
Location of relays and fuses
Symbols on electrical diagrams
Conventional symbols of elements in electrical circuits
Schematic 1. Battery, ignition switch and overload relay for X-contact
Scheme 2. Instrument cluster and driving safety
Scheme 3. Instrument cluster, tachometer, tachograph
Scheme 4. Instrument cluster, control of the tightened handbrake lever...
Scheme 5. Turn signal switch, dimming and light signal switch...
Scheme 6. Hazard warning light switch with turn signal relay, front and right lamps
Scheme 7. Brake light switch, brake light, fog light...
Scheme 8. Rear right side light, brake light, right reversing light...
Scheme 9. Diagnostics, radio receiver, cigarette lighter
Scheme 10. Light switch
Scheme 11. Two-tone horn, glove compartment light, license plate light
Scheme 12. Headlight corrector, headlight corrector actuator motor
Scheme 13. Heater fan and recirculated air switch, heater fan...
Scheme 14. Rear window defroster, rear window wiper motor...
Scheme 15. Windscreen wiper switch, windscreen wiper motor
Scheme 16. Front ceiling light, left rear reading light, left door signal light
Scheme 17. Reading lamp right rear, signal lamp right door
Scheme 18. Starter, generator
Scheme 19. Control unit for fuel injection system 4AV, ignition system...
Scheme 20. Control unit for fuel injection system 4AV, throttle control unit...
Scheme 21. Control unit for fuel injection system 4AV, intake manifold pressure sensor...
Scheme 22. Control unit for fuel injection system 4AV, Lambda sensor...
Scheme 23. Oil pressure sensor, fuel pump, fuel level sensor...
Scheme 24. Instrument cluster, optical and acoustic oil pressure check...
Scheme 25. Instrument cluster, coolant temperature gauge, fuel gauge...
Scheme 26. Generator, starter (diesel engines)
Scheme 27. Control unit of direct diesel injection system, KICK-DOWN, idle switch...
Scheme 28. Control unit of direct diesel injection system, coolant temperature sensor...
Scheme 29. Control unit for direct diesel injection system
Scheme 30. Control unit of the direct injection system of diesel, switching valve of the suction pipeline
Scheme 31. Control unit of the direct diesel injection system, speed control switch (GRA)...
Scheme 32. Control unit of the direct injection system of diesel, glow plugs
Scheme 33. Fuel level sensor, low coolant level sensor
Scheme 34. Instrument cluster, optical and acoustic oil pressure check, speed sensor...
Scheme 35. Instrument cluster, coolant temperature gauge, fuel gauge
Scheme 36. Heated windshield wiper nozzles
Scheme 37. Left reverse lamps, left rear side light, brake light, fog light
Scheme 38. Electrical socket for operation of the vehicle with a trailer, fog light switch
Scheme 39. Rear right side light, brake light, left reversing light...
Scheme 40. Left fog light, left headlight, left parking light...
Scheme 41. Right fog lamp, fog lamp relay, right headlight...
Scheme 42. Light switch, fog light switch, lighting switch
Scheme 43. Fog lamp, right rear parking light, brake light, reversing lamp
Scheme 44. Radio, CD changer, front speakers
Scheme 45. Radio receiver, front speakers, rear speakers
Scheme 46. Radio receiver, antenna
Golf 5
General information
User manual
Introduction to the Volkswagen Golf 5 manual
Car control panel
Keys on the multifunction steering wheel
Instrument panel
Display in the instrument panel
On-board computer (MFA)
Warning and information messages on the display
Main menu on the instrument cluster display
Signal and control lights
Car keys
Central lock
Locking the rear side doors when transporting children
Remote control of locks
The alarm system activates the alarm mode when there is an attempt to break into the car
Heater control
Air Conditioning Control
Climate control management
Ignition switch
Manual transmission
Automatic transmission
Manual gear shifting «tiptronic»
Turning on cruise control
Technical data of cars
Maintenance
Starting the engine using an auxiliary battery
Towing a car
Jacking up a car
Maintenance — General Information
Maintenance — Work Plan
Maintenance — works
Engine oil level — check
Engine Oil and Oil Filter — Replacement
Coolant — Checking the Level
Fuel filter — replacement (diesel)
Air filter — replacing the filter element
V-belt — check
Exhaust system — visual inspection
Toothed Belt — Check
Spark plugs — replacement
Gearbox. Main gear
Automatic Transmission — Checking Transmission Oil Level
Automatic transmission DSG — oil and oil filter change
Haldex Differential — Oil Change
Front suspension and steering
Brakes. Tires. Wheels
Brake lining thickness — check
Brake lines — check
Brake fluid — replacement
Measuring the tread depth of a tire
Tire pressure — checking
Tires and wheels — designations
Wheel balancing
Anti-skid chains
Removal and installation wheels
Tire pressure monitoring
Some recommendations for tire care
Tire Repair Kit — Check and Replace
Tire Pressure Monitoring System Indicator — Setting
Seat belts and airbags
Cabin filter — replacement
Electrical system of the car
Battery capacity — check
Windscreen wiper blades — checking the home position
Troubleshooting
Identifying and troubleshooting engine faults
Identifying and troubleshooting engine cooling system faults
Possible malfunctions of the heating system, their causes and methods of elimination
Identifying and troubleshooting gasoline injection system faults
Identifying and troubleshooting brake system faults
List of starter faults and their elimination
Identifying and troubleshooting generator faults
Identifying and troubleshooting battery problems
Identifying and troubleshooting windshield wiper problems
Power unit
Engine repair
Engine specifications
Vehicle and engine identification
Upper Engine Cover — Removal and Installation
Timing drive (1.4 liter petrol engine, 75 hp)
TDC of piston of cylinder No. 1 (petrol engine 1.4 liters, 75 hp, VSA)
Cylinder head (petrol engine 1.4 liters, 75 hp, VSA)
Cylinder head (1.4/1.6 litre FSI petrol engines, BKG/BLN/BAG/BLF/BLP)
Timing drive (1.6 liter petrol engine, 102 hp)
TDC of piston of cylinder No. 1 (petrol engines 1.6 liters, 102 hp, BGU/BSE/BSF)
Cylinder head (1.6L petrol engines, 102hp, BGU/BSE/BSF)
Timing drive (petrol engine FSI 2.0 liter, 150 hp)
Cylinder head (petrol engines 2.0 liter, 150 hp, AWX/BLR/BLX/BLY)
Timing drive (diesel engines 1.9/2.0 liters, 55-77 kW)
TDC of piston of cylinder No. 1 (diesel engines 1.9/2.0 liters, 75/90/100/105 hp, AVQ/BRU/BJB/BKC/BLS/BDK)
Timing Belt — Installation (Diesel Engines 1.9/2.0L, 75/90/100/105 HP, AVQ/BRU/BJB/BKC/BLS/BDK)
Cylinder head cover and cylinder head — removal and installation
Timing drive (2.0 liter diesel engines, 100/103 kW)
TDC of the piston of cylinder No. 1 and the installation of the toothed belt
Tightening torques for threaded connections of engine suspension components
V-belt — removal and installation
Engine — Start
Engine lubrication system
Oil pump and oil pan (1.4/1.6 litre FSI petrol engines)
Cooling and ventilation system
Engine cooling system
Coolant — Replacement
Thermostat — removal and installation
Thermostat — check
Water pump — removal and installation
Radiator — removal and installation
Radiator Blower Fan — Removal and Installation
Heater and air conditioner
Outside Air Temperature Sensor — Removal and Installation
Central deflector — removal and installation
Side deflectors — removal and installation
Interior air deflectors — removal and installation
Heater/Air Conditioner Control Unit — Removal and Installation
Temperature control flap traction cable removal and installation
Air distribution flap actuator motor — removal and installation
Electric motor and additional resistance of the cabin air blower — removal and installation
Heating element — removal and installation
Fuel system
Fuel Injection System Specifications (Petrol)
General description of the fuel system and precautions (petrol)
Fuel injection system — general check (petrol)
Lower intake manifold — removal and installation (1.6 liter BGU/BSE/BSF, gasoline)
How a diesel engine works
Glow Plugs — Removal and Installation (Diesel)
Preheating device-check (diesel)
General provisions on the fuel system
Fuel Pump and Fuel Gauge Sensor — Removal and Installation
Fuel gauge sensor — removal and installation
Fuel filter — removal and installation
Air filter — removal, installation and disassembly
General information about the exhaust system
Exhaust system — removal and installation
Main and additional mufflers — replacement
Ignition system
General description and safety precautions
Spark plugs and coils (petrol)
Glow Plugs — Replacement (Diesel)
Ignition system — diagnostics
Measuring signals from sensors and other components of the ignition system with an oscilloscope
Transmission
Clutch
General description of the clutch
Clutch pedal — removal and installation
Clutch Master Cylinder — Replacement
Mechanical gearbox
General information about mechanical transmission
Gear Selector Cables — Adjustment
Gear shift mechanism — removal and installation
Gearbox — removal and installation
Automatic gearbox
General information about automatic transmission
Removal and installation the automatic transmission control mechanism
Checking the automatic transmission control mechanism
Removal the selector cable of the automatic transmission control mechanism
Installing the gear shift cable
Adjusting the gear shift cable
Gearbox oil pan and oil intake — removal and installation
Multi-function switch — removal, installation and adjustment
Valve and sensor housing — removal and installation
Chassis
Brake system
Brake system specifications
General information about the braking system
Front Disc Brake Pads — Removal and Installation
Front Brake Caliper — Removal and Installation
Rear disc brakes
Rear Brake Pads — Removal and Installation
Rear Wheel Brake Caliper — Removal and Installation
Brake disc — check
Brake disc — removal and installation
Parking brake cable — removal and installation
Parking brake — adjustment
Brake system — bleeding
Brake booster vacuum — check
Brake hoses — removal and installation
Brake Light Switch — Removal and Installation
Car suspension
General information about the suspension
Front suspension of the car
Front shock absorber strut — removal and installation
Front shock absorber strut — disassembly
Drive shaft — removal and installation
Drive shaft — disassembly
Drive shaft — CV joint seal replacement
Hub bolt — removal and installation
Rear suspension of the car
Rear Suspension Coil Spring — Removal and Installation
Rear shock absorber — removal and installation
Rear shock absorber — disassembly and assembly
Steering
Steering — General Information
Airbags — Safety Precautions
Steering Wheel Airbag Unit — Removal and Installation
Steering wheel — removal and installation
Tie Rod End — Removal and Installation
Steering gear cuff — removal and installation
Body
Interior (internal elements)
Salon — General Provisions
Rear view mirror — removal and installation
Sun visor — removal and installation
Handle above the door — removal and installation
Gear Shift Boot — Removal and Installation
Center console — removal and installation (Golf)
Center console — removal and installation (Touran)
Footwell Side Trim — Removal and Installation (Touran)
Radio receiver and heater switch block trim — removal and installation
Steering column trim — removal and installation
Instrument panel — removal and installation
Lower instrument panel trim, driver's side (Touran)
Lower instrument panel trim driver's side (Golf)
Upper instrument panel trim driver side (Golf)
Cover under the side of the heater switches (Golf)
Glove box — removal and installation
Door sill trim — removal and installation
Front pillar trim — removal and installation (Golf)
Center pillar trim — removal and installation (Golf)
Upper rear pillar trim — removal and installation (Golf)
Trim above rear wheel arch inside cabin (Golf)
Side trim for the rear of the car (Golf)
Luggage compartment shelf — removal and installation (Golf)
Side trim of the trunk — removal and installation
Rear cross member trim — removal and installation
Decorative ceiling crossbar trim — removal and installation
Door sill trim — removal and installation
Front pillar trim — removal and installation (Touran)
Central pillar trim — removal and installation (Touran)
Rear pillar trim — removal and installation
Rear side trim — removal and installation
Rear D-pillar trim — removal and installation (Touran)
Trunk floor — removal and installation (Touran)
Rear Panel Trim — Removal and Installation (Touran)
Front seat — removal and installation
Rear Seat — Removal and Installation (Golf)
Rear Seat Side Armrests — Removal and Installation (Golf)
Rear seats — removal and installation (Touran)
Belt guide bracket (Golf)
Exterior (external elements)
Body — General Description and Precautions
Engine Mudguard — Removal and Installation
Fairing grille — removal and installation
Upper front cross member — installation in service position
Front bumper — removal and installation
Rear bumper — removal and installation
Radiator grille — removal and installation
Front fenders — removal and installation
Mudguard — removal and installation
Moldings — removal and installation
Hood — removal and installation
Hood — fit
Hood lock — removal, installation and adjustment
Hood Lock Drive Cable — Removal and Installation
Gas-filled strut — removal and installation
Mirror glass — removal and installation
Rear view mirror housing — removal and installation
Side rear view mirror — removal and installation
Doors and covers
Rear Tailgate — Removal, Installation and Fitting
Tailgate Lock — Removal and Installation
Trunk Lock Lid — Removal and Installation (Jetta)
Rear Tailgate Trim — Removal and Installation
Door — removal and installation (Golf)
Door — Fit (Golf)
Front Door — Device (Golf)
Front Door Outer Part — Removal and Installation
Side rear door — removal and installation of the outer part of the door
Door lock and outer door handle mounting bracket — removal and installation
Side door reinforcements — removal and installation
Door glass — removal and installation
Window lifter motor — removal and installation
Window lifters — removal and installation
External door handle — removal and installation
Lock cylinder — removal and installation
Door — removal and installation (Touran)
Door lock — removal and installation (Touran)
Window lifter — removal and installation (Touran)
Electric window motor — removal and installation (Touran)
Door trim — removal and installation
Window lifter handle — removal and installation
Electrical equipment
Power devices
Battery — Removal and Installation
Battery — Check
Generator — Voltage Check
Generator — removal and installation
Starter — removal and installation
Washers and wipers
Windscreen wiper — removal and installation
Windscreen washer jets — removal and installation
Rear Window Washer Nozzle — Removal and Installation
Headlight washer jet — removal and installation
Washer reservoir — removal and installation (Golf)
Washer reservoir — removal and installation (Touran)
Windshield Wiper Blade Holders — Removal and Installation
Windscreen wiper motor (Golf)
Windscreen wiper motor (Touran)
Rear Tailgate Windscreen Wiper Arms — Removal and Installation
Rear Window Wiper Motor — Removal and Installation
Rain sensor — removal and installation (Golf)
Lighting and appliances
Disconnecting plug connections
Sound signal — removal and installation
Power elements in the remote control
Parking Assist Sensors — Removal and Installation
Fuses — replacement
Lighting fixtures — general provisions
Headlight Bulbs — Replacement (Golf)
Headlight bulbs — replacement (Touran)
Headlight — removal and installation
Executive electric motor of the tilt controller of the optical axis of the headlights (Golf)
Fog lights — removal and installation
Rear headlight — removal and installation (Golf)
Rear headlight — removal and installation (Touran)
Side turn signal repeater — removal and installation
Door Light — Removal and Installation
License Plate Light — Removal and Installation
Additional brake light — removal and installation
Interior Lights — Bulb Replacement (Golf)
Interior Lights — Bulb Replacement (Touran)
Instrument cluster — removal and installation
Steering column switches — removal and installation
Light switch — removal and installation
Interior Switches — Removal and Installation (Golf)
Interior Switches — Removal and Installation (Touran)
Radio receiver — removal and installation
CD changer on the center console — removal and installation
Speakers — Removal and Installation (Golf)
Speakers — Removal and Installation (Touran)
Antenna signal booster — removal and installation
Roof Antenna — Removal and Installation
Electrical circuits
Reading electrical diagrams
Conventional designations of the most important units and parts
Instructions for reading electrical diagrams
Scheme 1. Battery, terminals 30 and 15 of the power relay...
Scheme 2. Switching relay of the on-board electrical system, fuses
Scheme 3. Left headlight, left and right fog light...
Scheme 4. Right headlight, light regulator, switch illumination...
Scheme 5. Right side light, left side light, left fog light bulb...
Scheme 6. Light switch, fog light switch...
Scheme 7. Additional brake light bulb, license plate light...
Scheme 8. Relay for steering column adjustment system, windshield wiper switch...
Scheme 9. Tempomat switch, terminal X unloader relay, steering column angle relay...
Scheme 10. Ignition switch, steering column tilt relay, turn signal switch...
Scheme 11. Bonnet contact switch, rain and light sensor, relay 2 of dual washer pump...
Scheme 12. Windscreen wiper motor, washer pump, rear window heater...
Scheme 13. Low tone horn, dual tone horn relay, fuel door motor...
Scheme 14. Front interior light, left rear reading light...
Scheme 15. Cigarette lighter, 12 V socket, rear cigarette lighter, driver's vanity mirror lighting...
Scheme 16. Hazard warning light switch, hazard warning light...
Scheme 17. Heater switches, additional resistance of the interior blower...
Scheme 18. Instrument cluster, anti-theft system reading coil, parking brake light sensor...
Scheme 19. Instrument panel, engine oil pressure sensor, outside air temperature sensor...
Scheme 20. Instrument panel, switching relay of the on-board electrical system, signal lamps...
Scheme 21. Instrument cluster, diagnostic connector, signal lamps
Scheme 22. Switching relay of the on-board electrical system, diagnostic connector
Polo 3
General information
User manual
Information about Polo Classic, Polo Variant and Caddy cars
Location of switches, instruments and control levers
Removal and adjusting headrests
Seat adjustment
Rear seats
Parking brake system actuator lever
Manual transmission
Steering wheel height adjustment
Ignition switch
Instrument panel
Signal lights
Device switches
Heating and ventilation system
Air Conditioning Regulators
Opening and closing the hood
Underhood space
Checking the levels of the main working fluids
Wheel rotation
Spare wheel
Main and additional fuses
Replacing incandescent lamps
Starting the engine from an auxiliary battery
Identification plates
Maintenance
Engine specifications
Scheduled maintenance
Replacing the air filter element
Replacing spark plugs
Checking the oil level in the manual transmission
Checking the thickness of brake linings
Power unit
Petrol engines 1.4 and 1.6
Technical characteristics of engines AEX, APQ, AKV, ANX 1.4 l and AEE, ALM 1.6 l
Removal and installation the ribbed belt
Checking the self-adjusting tension roller
Installing the timing belt
Cylinder block, camshaft and flywheel
Connecting rod and piston group
Cylinder head
Compression check
Gas distribution mechanism
Valve seat machining
Removal and installation the camshaft
Checking hydraulic compensators
Checking the valve guide bushing
Lubrication system
Checking oil pressure and oil pressure sensor
Cooling system
Power supply system
Adjusting the accelerator cable
Checking the fuel pump
Gasoline vapor recovery system with carbon filter
Exhaust gas system
Fuel injection and ignition control system
Self-diagnosis of the injection system
Connecting the VAG 1551 fault code reader
Checking and clearing fault memory
Reading the measured value block and basic settings
Checking the fuel pressure regulator and holding pressure
Checking the engine operating modes
Checking the intake manifold pressure sensor
Checking the coolant temperature sensor
Checking the inlet air temperature sensor
Checking the oxygen sensor (lambda probe)
Checking the oxygen sensor heater
Checking the injector
Checking and adjusting the ignition timing angle
Checking the Hall sensor
Checking the ignition coil
Checking the knock sensor
Error codes
Petrol engines 1.4 (V16)
Technical characteristics of engines APE, AUA 1.4 16V
Disassembling the engine
Removal and installation the ribbed belt
Checking the valve timing
Removal and installation the timing belt
Cylinder block, sealing flange and flywheel
Connecting rod and piston group
Cylinder head
Removal and installation the camshaft housing
Compression check
Gas distribution mechanism
Valve seat machining
Checking the valve guide bushing
Lubrication system
Checking oil pressure and pressure sensor
Cooling system
Checking the fuel pump
Electronic Engine Control (EPC)
Checking the accelerator pedal position sensor
Gasoline vapor recovery system
Exhaust gas system
Exhaust gas recirculation system
Fuel injection and ignition control system
Self-diagnosis of the injection system
Connecting the tester
Checking and clearing fault memory
Reading a block of measured values
Checking the intake manifold pressure sensor
Checking the inlet air temperature sensor
Checking the coolant temperature sensor
Checking the crankshaft speed sensor
Checking the fuel pressure regulator and holding pressure
Checking the Hall Sensor
Checking the ignition coil
Error codes
Petrol engines 1.6 and 1.8
Technical characteristics of engines 1F, AFT 1.6 l and ADZ 1.8 l
Disassembling the engine
Removal and installation the timing belt
Crankshaft
Connecting rod and piston group
Cylinder head
Compression check
Gas distribution mechanism
Valve seat machining
Checking hydraulic compensators
Checking the valve guide bushing
Lubrication system
Checking oil pressure and pressure sensor
Cooling system
Adjusting the accelerator cable
Checking the fuel pump
Gasoline vapor recovery system with carbon filter
Exhaust gas system
Mono-Motronic fuel injection and ignition control system
Self-diagnosis of the injection system
Connecting the VAG 1551 fault code reader
Querying fault memory
Clearing fault memory
Reading the measured value block and basic settings
Checking the oxygen sensor and lambda control
Checking the Oxygen Sensor Heater
Checking the engine operating modes
Checking the coolant temperature sensor
Checking the injector
Checking the inlet air temperature sensor
Installing the ignition distributor
Checking and adjusting the ignition timing angle
Checking the Hall sensor
Checking the ignition coil
Error codes
Diesel engines 1.7 and 1.9
Diesel engines AKW, ANV 1.7 SDI, AEY 1.9 SDI, AFN, AHU and ALE 1.9 TDI, 1Y 1.9 D
Disassembling the engine
Timing belt drive with single pulley injection pump
Timing belt drive with double pulley injection pump
Sealing flange and flywheel / drive disc / pressure disc
Crankshaft
Connecting rod and piston group
Checking the piston protrusion at TDC
Cylinder head
Compression check
Gas distribution mechanism
Valve seat machining
Checking the valve guide bushing
Checking hydraulic compensators
Swirl chamber replacement (1Y engines only)
Lubrication system
Checking oil pressure and pressure sensor
Cooling system
Power supply system
Fuel filter
Accelerator pedal
Checking the accelerator pedal position sensor (engines AEY, AFN, AHB, AHU, AKW, ALE)
Adjusting the accelerator pedal position sensor (engines AEY, AFN, AHB, AHU, AKW, ALE)
Turbocharging a diesel engine
Intercooler (intermediate cooling of the supercharged air)
Exhaust gas recirculation system
Checking the components of the exhaust gas recirculation system
Checking the mechanical EGR valve
Diesel fuel injection control system
Self-diagnosis of the injection system
Connecting the VAG 1551 fault code reader
Querying fault memory
Clearing fault memory
Reading a block of measured values
Removal and installation of fuel injection pump
Checking the valve timing
Checking the injectors
Checking the crankshaft speed sensor
Checking the coolant temperature sensor
Checking the temperature sensor in the intake manifold (on AFN, AHU, ALE engines)
Checking the inlet air temperature sensor (on AEY, ANV, AKW engines)
Checking the fuel temperature sensor
Checking the injector needle displacement sensor
Error codes
Diesel engines 1.9 D and TD
Technical characteristics of AGP, AQM, AYQ 1.9 D and AGR, ALH 1.9 TD engines
Disassembling the engine
Ribbed belt
Sealing flange and flywheel
Connecting rod and piston group
Checking the piston protrusion at TDC
Cylinder head
Intake manifold
Removal and installation the timing belt
Compression check
Gas distribution mechanism
Valve seat machining
Checking the valve guide bushing
Checking hydraulic compensators
Lubrication system
Checking oil pressure and pressure sensor
Cooling system
Fuel filter
Accelerator pedal
Checking the accelerator pedal position sensor
Adjusting the accelerator pedal position sensor
Turbocharging a diesel engine
Intercooler (intermediate cooling of the supercharged air)
Diesel fuel injection control system
Self-diagnosis of the injection system
Connecting the VAG 1551 fault code reader
Querying fault memory
Clearing fault memory
Reading a block of measured values
Removal and installation of fuel injection pump
Checking the injectors
Checking the crankshaft speed sensor
Checking the coolant temperature sensor
Checking the fuel temperature sensor
Checking the injector needle displacement sensor
Checking the air flow meter
Checking the intake manifold switching valve
Error codes
Transmission
Mechanical gearbox 085
Manual transmission identification
Technical characteristics of manual transmission
Clutch drive
Clutch cable without automatic adjuster
Clutch cable with automatic regulator
Clutch release mechanism
Gear shift mechanism
Checking the oil level in the manual transmission
Disassembly and assembly of the gearbox
Differential
Mechanical gearbox 020/02K
Manual transmission identification
Technical characteristics of manual transmission
Checking the oil level in the manual transmission
Chassis
Front suspension
Subframe, anti-roll bar and lower arm
Removal, installation and inspection of the ball joint
Removal and installation the lower arm
Removal and installation the subframe
Steering knuckle
Shock absorber strut
Constant velocity joint axle shafts
Tripod type axle shafts
Checking the inner CV joint
Checking the outer CV joint
Wheel alignment angles
Front wheel camber adjustment
Front wheel alignment adjustment
Rear suspension
Rear suspension of Classic, Estate cars
Wheel bearing for Classic, Estate cars
Shock absorber strut for Classic, Estate cars
Rear suspension of Caddy cars
Wheel bearing of Caddy cars
Removal and installation of springs of Caddy cars
Steering
Steering column, steering wheel and driver's airbag
Removal and installation the steering column pipe with the steering column
Steering column height adjustment tube
Driver's airbag
Steering gear
Checking the length of the left steering rod
Power steering pump
Brake system
Technical data of brake mechanisms up to 09.99
Technical data of brake mechanisms from 10.99
Front brakes with brake calipers «VW I» and «VW II»
Removal and installation of brake pads and brake caliper up to 01.96
Removal and installation of brake pads and brake caliper since 01.96
Front brakes with Girling/Lucas brake calipers
Removal and installation brake pads and brake caliper «Girling/Lucas»
Brake calipers «VW I» and «VW II» front brake mechanisms
Removal and installation the brake caliper piston
Front brake calipers «Girling/Lucas»
Removal and installation the brake caliper piston «Girling/Lucas»
Rear drum brakes
Rear disc brakes
Brake master cylinder and brake booster
Brake force regulator
Anti-lock braking system ABS
Self-diagnosis of the brake system
Error codes
Body
Exterior
Bumper reinforcement with fasteners
Front wing
Hood and opening cable
Fuel tank cap
Front and rear door
Central lock
Removal and installation the central lock pump
Front and rear bumper
Radiator grille
Drainage cover
Front and rear wheel fender liner
Outside rear view mirror
Car body dimensions
Interior
The location of some elements inside the cabin
Driver's storage compartment
Removal and installation interior door trim
Removal and installation the instrument panel (up to 09.99)
Removal and installation the instrument panel (since 10.99)
Electrical equipment
Equipment and instruments (until 2000)
Removal and installation the starter (petrol 1.4 l)
Removal and installation the starter (petrol 1.6 and 1.8 l)
Car Generator
Removal and installation the instrument panel
Location of bulbs in the instrument panel
Resetting the service display
Windscreen wipers and washers
Removal and installation windshield wiper elements
Adjusting windshield and headlight washers
Headlight adjustment
Rear light
Removal and installation multi-function switches
Interior switches on the instrument panel
Equipment and instruments (after 2000)
Removal and installation the instrument panel
Rear view of the instrument panel
Preparing for self-diagnosis of the instrument panel
Instrument cluster fault codes
Removal and installation the immobilizer control unit
Removal and installation the light switch
Removal and installation switches on the instrument panel
Heating and air conditioning system
Removal and installation dust and pollen filters
Removal and installation deflectors
Removal and installation heater controls
Disassembly and assembly of the heater
Location of air conditioning system elements
Air conditioning compressor bracket (ARE engine)
Air conditioning compressor electromagnetic clutch (Sanden)
The structure of the evaporator and condenser
Electrical circuits
How to read and use electrical diagrams
Battery, ignition switch (since 11.1995)
Fresh air fan (since 11.1995)
Fuel level, coolant level and temperature gauge (since 11.1995)
Signal and indicator lights, trip meter (since 11.1995)
Tachometer, parking brake control switch (since 11.1995)
Door light switch, interior light (since 11.1995)
Self-diagnostic wiring distributor, cigarette lighter (since 11.1995)
Headlight range adjustment, sound signal (since 11.1995)
Headlights, parking light (since 11.1995)
Manual switch for low beam headlights and light signal (since 11.1995)
Hazard warning light system (since 11.1995)
Rear direction indicator, brake light (since 11.1995)
Headlight switch (since 11.1995)
Number plate light, reversing lights (since 11.1995)
Windscreen wipers and washers, heated rear window (since 11.1995)
Rear window washer and wiper (since 11.1995)
Battery, ignition switch (since 08.1997)
Fresh air fan (since 08.1997)
Fuel level, oil level and temperature gauge (since 08.1997)
Signal and indicator lights, trip meter (since 08.1997)
Tachometer, parking brake system sensor (since 08.1997)
Door light switch, interior light (since 08.1997)
Diagnostic connector, cigarette lighter (since 08.1997)
Double horn, heated rear window (since 08.1997)
Windscreen wipers and washers (since 08.1997)
Rear window wiper and washer (since 08.1997)
Manual switch for low beam headlights and light signal (since 08.1997)
Hazard warning lights (since 08.1997)
Headlights, parking lights, front direction indicators (since 08.1997)
Rear direction indicator, brake light (since 08.1997)
Headlight switch (since 08.1997)
License plate light (since 08.1997)
Headlight beam angle adjustment (since 08.1997)
Wiring diagrams (petrol)
Generator, starter, fuel pump, fuel level sensor (since 10.1995)
Simos system control unit, ignition system (since 10.1995)
Simos system control unit, oxygen sensor (since 10.1995)
Simos system control unit, air flow meter (since 10.1995)
Oil temperature sensor, oil pressure sensor (since 10.1995)
Instrument cluster, oil pressure control (since 10.1995)
Generator, starter, intake manifold preheater (since 10.1995)
Mono-Motronic system control unit, ignition system (since 10.1995)
Mono-Motronic system control unit, throttle potentiometer (since 10.1995)
Mono-Motronic system control unit, oxygen sensor (since 10.1995)
Instrument cluster, fuel gauge (since 10.1995)
Generator, starter, intake manifold preheater (since 08.1997)
Mono-Motronic system control unit, ignition system (since 08.1997)
Mono-Motronic system control unit, throttle potentiometer (since 08/1997)
Mono-Motronic system control unit, oxygen sensor (since 08.1997)
Instrument cluster, fuel gauge (since 08.1997)
Instrument cluster, oil pressure control (since 08.1997)
Generator, starter, fuel pump, fuel gauge sensor (since 08.1997)
Simos system control unit, ignition system (since 08.1997)
Simos system control unit, oxygen sensor (since 08.1997)
Simos system control unit, air flow meter (since 08.1997)
Oil temperature sensor, oil pressure switch (since 08.1997)
Instrument cluster, trip meter (since 08.1997)
Generator, starter (since 12.1997)
Mono-Motronic system control unit, ignition system (since 12.1997)
Coolant temperature sensor (since 12.1997)
Injectors, throttle position regulator (since 12.1997)
Electromagnetic valve of the EGR tank, speed sensor (since 12.1997)
Instrument cluster, fuel gauge (since 12.1997)
Ignition switch, wire distributor for terminal 30 (since 10.1999)
Motronic system control unit, Hall sensor, ignition coil (since 10.1999)
Throttle position regulator (since 10.1999)
Knock sensor, injectors (since 10.1999)
Brake light switch, speed sensor (since 10.1999)
Thermal switch of the cooling system fan (since 10.1999)
Coolant temperature gauge, speedometer (since 10.1999)
Tachometer, generator indicator light (since 10.1999)
Battery, starter, ignition switch (since 10.1999)
Generator, relay-regulator, wire distributor for terminal 30 (since 10.1999)
Simos system control unit, Hall sensor (since 10.1999)
Throttle control unit (since 10.1999)
Pneumatic switch / power steering (since 10.1999)
Knock sensor I, air flow meter (since 10.1999)
Simos system control unit, injector 1st cylinder (since 10.1999)
Catalytic converter oxygen sensor, oxygen sensor heater (since 10.1999)
Clutch pedal sensor, brake pedal sensor, speed sensor (since 10.1999)
Fuel level sensor, fuel pump (since 10.1999)
Speedometer, oil pressure indicator light (since 10.1999)
Oil pressure buzzer, generator light (since 10.1999)
Starter, generator, relay-regulator, ignition switch (since 10.1999)
Ignition coil, spark plug wire tip (since 10.1999)
Idle switch, coolant sensor (since 10.1999)
Motronic control unit, clutch pedal sensor (since 10.1999)
Motronic control unit, knock sensor I, injectors (since 10.1999)
Oxygen sensor, air flow meter (since 10.1999)
Electromagnetic valve of the fuel pump control system, fuel pump relay (since 10.1999)
Fuel level indicator sensor, fuel pump (since 10.1999)
Coolant temperature gauge, speedometer (since 10.1999)
Oil pressure warning sound signal lamp (since 10.1999)
Battery, starter, generator, voltage regulator (since 05.2000)
4LV injection system control unit, voltage supply (since 05.2000)
Direct injection system control unit (since 05.2000)
Inlet air temperature sensor, Hall sensor (since 05.2000)
Engine speed sensor, knock sensor (since 05.2000)
Injectors, electronic engine blocking control unit (since 05.2000)
Oxygen sensor before and after catalytic converter (since 05.2000)
Brake light switch, clutch pedal sensor (since 05.2000)
Fuel level sensor, fuel pump, speed sensor (since 05.2000)
Speedometer, oil pressure indicator light (since 05.2000)
Control unit with indicator block in the instrument panel (since 05.2000)
Wiring diagrams (diesel)
Battery, generator (since 01.1998)
Control unit for direct injection system of diesel fuel (since 01.1998)
Dispenser, injector needle movement sensor (since 01.1998)
Relay for providing voltage to terminal 30, glow plugs (since 01.1998)
Glow plugs, fuel shut-off valve, injection start valve (since 01.1998)
Multi-function indicator sensor, speed sensor (since 01.1998)
Instrument cluster, coolant level indicator (since 01.1998)
Instrument cluster, oil pressure control (since 01.1998)
Battery, generator (since 12.1997)
Control unit for direct injection system of diesel fuel (since 12.1997)
Dispenser, injector needle movement sensor (since 12.1997)
Relay for providing voltage to terminal 30, glow plugs (since 12.1997)
Glow plugs, fuel shut-off valve, injection start valve (since 12.1997)
Multi-function indicator sensor, speed sensor (since 12.1997)
Instrument cluster, coolant level indicator (since 12.1997)
Speedometer, multi-function indicator switch (since 12.1997)
Battery, starter, generator, voltage regulator (since 10.1999)
Control unit for direct injection system of diesel fuel (since 10.1999)
Engine crankshaft speed sensor (since 10.1999)
Exhaust gas recirculation valve (since 10.1999)
Glow plug relay, glow plugs (since 10.1999)
Coolant temperature sensor, injection start valve (since 10.1999)
Fuel cut-off control unit (since 10.1999)
Thermal switch for cooling system fan (since 10.1999)
Control unit with indicator block in the instrument panel (since 10.1999)
Warning sound alarm system for oil pressure monitoring (from 10.1999 year of manufacture)
Starter, battery, generator, voltage regulator (since 10.1999)
Glow plugs, terminal 30 voltage supply relay (since 10.1999)
Intake manifold pressure sensor (since 10.1999)
Boost pressure limiting solenoid valve (since 10.1999)
Glow plug relay for coolant (since 10.1999)
Coolant temperature sensor (since 10.1999)
Brake light switch, clutch pedal sensor (since 10.1999)
Oil pressure sensor, fuel level indicator sensor (since 10.1999)
Coolant temperature gauge (since 10.1999)
Tachometer, oil pressure indicator light (since 10.1999)
Battery, starter, generator, voltage regulator (since 05.2000)
Control unit for direct injection system of diesel fuel (since 05.2000)
Fuel temperature sensor, throttle position sensor (since 05.2000)
Terminal 30 voltage supply relay, clutch pedal sensor (since 05.2000)
Brake light switch, intake manifold temperature sensor (since 05.2000)
Glow plug relay, glow plugs (since 05.2000)
Coolant temperature sensor, speed sensor (since 05.2000)
Coolant temperature gauge, speedometer (since 05.2000)
Relay-regulator, fuse housing, battery (since 05.2000)
Electronic engine immobilizer control unit (since 05.2000)
Dosing unit, fuel temperature sensor, valve travel sensor (since 05.2000)
Engine crankshaft speed sensor (since 05.2000)
Kick-down switch, idle switch (since 05.2000)
Fuel cut-off valve, glow plug relay (since 05.2000)
Thermal switch fan, cooling system fan (since 05.2000)
Polo 4
General information
User manual
Vehicle and engine identification
Engine specifications
Car wash
Paint care
Anti-corrosion protection of the underbody/hidden internal cavities
Pillow Upholstery Care/Cushion Cleaning
Repairing damage from stone impacts
The tool
Jump starting the engine from another car's battery
Towing a car
Lifting a car
Vehicle controls
Car dashboard
Instrument cluster warning lights
Switches in the car interior
Emergency alarm system
Steering column multifunction switch
Cruise control system
Rear window defroster
Interior lighting
Windscreen wipers and washers
Seat heaters
Power windows with electric drive
Rear view mirrors
Upper hatch (roof panel)
Engine compartment hood
Heating, ventilation and air conditioning in the cabin
Climatronic air conditioning controls
Adjusting the front seats
Airbags
Steering column adjustment
Car keys
Central lock
Unlocking and locking doors
Manual transmission
Automatic transmission
Starting the engine
Engine stop
Maintenance
Maintenance at irregular intervals (Longlife-Service)
Maintenance at scheduled intervals
Maintenance with engine oil change
Maintenance card
Additional work within the framework of maintenance
Maintenance work
Engine and exhaust system
Engine/engine compartment: visual inspection of connections for tightness
Checking/filling engine oil
Engine oil change/oil filter change
Draining engine oil
Replacing the oil filter
Filling with engine oil
Checking/filling coolant level
Checking/increasing antifreeze concentration
Removal water from the fuel filter
Replacing the fuel filter
Engine Air Filter: Replacing the Filter Element
Checking the poly V-belt
Visual inspection of the exhaust system
Checking the condition of the timing belt
Replacing spark plugs
Repair of spark plug threads in cylinder head
Standard spark plugs for POLO/IBIZA car engines
Gearbox/Main gear
Visual inspection of the gearbox for leaks
Manual Transmission/Final Drive: Checking Oil Level
Automatic Transmission: Checking ATF Level
Front axle/steering
Checking tie rod ends and ball joints
Checking the corrugated covers of the cardan shafts
Checking the oil level in the power steering reservoir
Brakes/tires/wheels
Checking the brake fluid level
Checking the thickness of brake linings
Visual inspection of brake lines
Replacing brake fluid
Checking the tire tread pattern
Checking tire inflation pressure
Checking the tire valve
Replacing the container with sealant for repairing damaged tires
Body/interior equipment
Visual inspection of seat belts
Visual inspection of the airbag assembly
Replacing the replaceable element of the fine air filter
Sliding roof panel: cleaning/lubricating the guide rails
Lubrication of door travel limiter and mounting pins
Electrical equipment system
Checking electricity consumers
Checking the battery
Checking the rubber bands of the windshield wipers/adjusting the installation angle of the arm
Checking the initial position of the windshield wipers
Resetting the service interval indicator to its original position
Power unit
Engine repair
Petrol engine with a working volume of 1.2 liters
Engine timing mechanism
Cylinder head of the AZQ petrol engine with a displacement of 1.2 litres and a power of 47 kW (64 hp)
Cylinder head — AWY petrol engine with a displacement of 1.2 liters and a power of 40 kW (55 hp)
1.4 litre petrol engine with 55/74 kW (75/100 hp)
Toothed belt drive of the 1.4 l AUA/BBY/AUB/BBZ petrol engine with 55/74 kW (75/100 hp)
Setting the engine crankshaft to the TDC ignition position for cylinder 1
Installation instructions for the timing belt of the AUA/BBY/AUB/BBZ 1.4 l 55/74 kW petrol engine
Cylinder head of the AUA/BBY/AUB/BBZ petrol engine with a displacement of 1.4 l and a power of 55/74 kW (75/100 hp)
1.4L AXU petrol engine with direct fuel injection
Diesel engine with a working volume of 1.4 liters
Diesel engine with a working volume of 1.9 liters
Toothed belt drive of the 1.9 l ASY diesel engine with 47 kW (64 hp)
Removal and installation the timing belt (SDI engine)
Cylinder head (SDI engine)
Toothed belt drive (PD-TDI engine)
Removal and installation the timing belt (PD-TDI engine)
Cylinder head cover/cylinder head (PD-TDI engine)
Removal and installation the poly V-belt of the AWY/AZQ petrol engine with a working volume of 1.2 l
Petrol engine AUA/AUB/BBY/BBZ/AXU with a working volume of 1.4 l
1.4L Diesel Engine: Removal and Installation
1.9L Diesel Engine: Removal and Installation
Starting the engine
Engine fault diagnostics
Oil pressure control values
Cooling and lubrication system
Lubrication system
Checking oil pressure and oil pressure sensor
Oil pump/oil pan
Coolant circulation
Antifreeze
Replacing the coolant
Removal and installation the thermostat
Checking the thermostat of a diesel engine
Removal and installation the coolant pump (petrol engines)
Removal and installation the coolant pump (diesel engines)
Removal and installation the radiator
Diagnostics of cooling system faults
Control system
Gasoline injection and ignition system
Safety precautions when working with the injection system of a gasoline engine
Operation of the gasoline engine management system
Sensors and actuators of injection systems
Checking/adjusting idle speed/ignition timing/CO content
General inspection of the injection system
Intake manifold/fuel manifold/valve injectors
Technical characteristics of injection systems for gasoline engines
Diagnostics of malfunctions of injection systems of gasoline engines
Ignition system
Ignition coils/spark plugs
Injection system (diesel)
Methods of mixture formation in diesel engines
Preheating system
Removal and installation glow plugs
High pressure fuel pump/nozzle/unit-nozzle
Checking the preheating system
Diagnostics of faults in diesel engine injection systems
Saving fuel while driving
Supply system
Power supply system. General information
Safety and cleanliness rules when working with the fuel supply system
Safety rules when working with the power supply system
Fuel tank/fuel pump/fuel filter
Removal and installation the fuel pump/fuel level sensor
Removal and installation the fuel level sensor
Removal and installation a fuel filter for a gasoline engine
Fuel filter for diesel engine with a working volume of 1.4 l
Fuel filter for diesel engine with a working volume of 1.9 l
Removal and installation/disassembly of the air filter
Exhaust system
Exhaust gas system
Preventing Damage to the Catalytic Converter
Operation of the catalytic converter
Turbocharger for PD-TDI engine with a displacement of 1.4/1.9 l
Exhaust system design (1.2L petrol engine)
Exhaust system design (1.4L petrol engine)
Exhaust system design (1.4L diesel engine)
Exhaust system design (1.9L diesel engine)
Removal and installation of the exhaust system
Replacing the pre/post muffler
Checking the exhaust system for leaks
Chassis
Front suspension
General information
Front wheel suspension
Removal and installation the shock absorber strut
Shock absorber/ shock absorber/ coil spring
Disassembling the shock absorber/shock absorber/removing and installing the coil spring
Checking/removing and installing the ball joint
Removal and installation the propeller shaft
Cardan shaft/cardan shaft bellows/constant velocity joints
Disassembling the cardan shaft
Rear suspension
Rear wheel suspension
Removal and installation the rear coil spring
Removal and installation the rear shock absorber
Disassembly and assembly of the shock absorber
Checking the shock absorber
Rear wheel hub
Removal the rear wheel hub
Steering
Steering system/ inflatable airbag
Safety precautions when working with an airbag
Removal and installation of the airbag unit of POLO vehicles
Removal and installation the steering wheel
Removal and installation the steering rod end
Steering gear/steering rods/corrugated boots/wiring diagram
Wheels and tires
Wheels and tires. General information
Tire inflation pressure
Tyre and wheel designations/date of manufacture
Wheel balancing
Changing wheels/maintaining direction of rotation
Removal and installation a wheel
Anti-skid chains
Tire care
Incorrect tire wear
Brake system
Brake system. General information
Technical characteristics of the brake system
Front disc brake mechanism FS-II
Front disc brake mechanism FS-III
Removal and installation front brake pads on POLO vehicles
Removal and installation of front brake pads of IBIZA cars
Rear drum brake mechanism
Removal and installation rear drum brake shoes
Rear disc brake mechanism
Removal and installation rear disc brake pads
Checking the thickness of brake discs
Removal and installation the brake disc/brake caliper together with the pad guide
Adjusting the handbrake
Removal and installation the wheel brake cylinder
Bleeding the brake system
Removal and installation the brake hose
Checking the brake booster
Handbrake lever/wiring diagram
Removal and installation the handbrake cable
Removal and installation the brake light switch
Rear wheel bearing/hub
Brake fault diagnostics
Body
Interior
Important instructions for performing work operations and safety precautions
Removal and installation spacer/spring clamps
Removal and installation the interior rearview mirror
Removal and installation the handle on the ceiling
Removal and installation the sun visor
Removal and installation of the central console of POLO cars
Removal and installation of the central console of IBIZA cars
Removal and installation the radio console/heating control unit trim
Removal and installation of the instrument panel of POLO cars
Removal and installation the handbrake lever trim
Removal and installation the side covers of the instrument panel
Removal and installation of storage shelves of POLO cars
Removal and installation the upper casing in the footwell of IBIZA vehicles
Removal and installation the glove compartment cover of IBIZA cars
Removal and installation of the glove compartment of POLO cars
Removal and installation the A-pillar trim on POLO vehicles
Removal and installation the trim of the B pillar of POLO cars
Removal and installation the upper trim of the pillar C in a POLO vehicle
Removal and installation of rear side trim of POLO vehicles
Removal and installation the lower trim of the pillar C of POLO vehicles
Removal and installation the threshold trim
Removal and installation the trunk lid support
Removal and installation the side trim of the luggage compartment
Removal and installation the rear end trim
Removal and installation of interior trims of IBIZA cars
Removal and installation the front seat
Removal and installation the rear seat
Removal and installation the front seat belt
Safety instructions for handling electrical seat belt tensioners
Removal and installation the front seat belt guide bracket
Removal and installation the front seat belt eyelet
Removal and installation the front seat belt height adjustment mechanism
Removal and installation the front seat belt buckle
Removal and installation the rear seat belt of POLO cars
Removal and installation the rear seat belt of IBIZA cars
Exterior
Exterior of the body
Safety precautions when performing bodywork
Windshield damage from stone impacts
Removal and installation the lower engine compartment casing
Removal and installation the fairing grille
Transferring the lock beam to the position for maintenance work
Removal and installation of the front bumper/bumper cover of POLO cars
Removal and installation the front bumper/bumper cover IBIZA
Removal and installation the rear bumper/bumper cover POLO
Removal and installation the rear bumper/bumper cover IBIZA
Removal and installation the front wing
Removal and installation wheel arch trim
Removal and installation the radiator grille
Removal and installation/adjustment of the engine compartment hood
Removal and installation/adjustment of the engine compartment hood lock
Removal and installation the engine compartment hood lock cable
POLO rear door
Removal and installation/adjustment of the rear door
Removal and installation the rear door lock POLO
Removal and installation the rear door trim POLO
Removal and installation the rear door trim IBIZA
Removal and installation the POLO door
Door adjustment
Door handle and door lock
Removal and installation the door handle
Removal and installation the lock cylinder
Removal and installation the POLO door lock
Removal and installation the front door mechanism holder together with the POLO window lifter
Removal and installation the rear door mechanism holder together with the POLO window lifter
Removal and installation the electric motor of the window lifter POLO
Removal and installation door trim
Removal and installation door trim IBIZA
Removal and installation the window lift handle
Removal and installation the POLO exterior rearview mirror housing
Removal and installation the outside rearview mirror (electric)/mirror glass POLO
Removal and installation the outside rearview mirror (manual)/mirror glass POLO
Removal and installation the outside rearview mirror IBIZA
Removal and installation the side protective trim
Electrical equipment
Equipment and devices
Electrical equipment system. General information
Installation of additional components of the electrical equipment system
Troubleshooting electrical equipment
Checking the serviceability of an electrical switch
Checking the relay
Checking the rear window heating
Disconnecting electrical plug connectors
Checking the brake light
Removal and installation the POLO on-board electrical system control unit
Removal and installation the horn
Removal and installation batteries in a key with a remote radio control
Removal and installation batteries/bulbs in a key with backlight
Replacing fuses
Removal and installation the POLO fuse holder
Removal and installation the battery/battery holder
Cleaning the battery terminals
Checking the battery
Spontaneous discharge of the battery
Charging the battery
Storage of the battery
Diagnosis of battery faults
Removal and installation the generator/checking the generator charging voltage
Removal and installation the voltage regulator/replacing the voltage regulator brushes
Generator fault diagnostics
Removal and installation the starter
Checking the starter traction relay
Starter fault diagnostics
Removal and installation the instrument panel
Removal and installation steering column switches
Removal and installation light switches
POLO: headlight beam angle adjuster
Radio/heating control unit switches on console
Driver's door window switches
Switch in the passenger door next to the driver/in the rear door
Driver's door mirror electric switch
Removal and installation of POLO radio
Removal and installation speakers
Removal and installation the antenna on the roof of the POLO
Wiper system
Replacing the rubber band of the windshield wiper blade
Removal and installation the windshield washer nozzle
Removal and installation the rear window washer nozzle
Removal and installation the washer pump
Removal and installation the washer reservoir
Removal and installation the windshield wiper arm
Removal and installation the windshield wiper motor
Removal and installation the rear window wiper arm/motor
Diagnosing Wiper Blade Rubber Band Faults
Lighting system
Table of lamps
Replacing POLO headlight bulbs
Replacing headlight bulbs IBIZA
Removal and installation headlights
Removal and installation the side turn signal light
Removal and installation fog lights POLO
Removal and installation fog lights IBIZA
Removal and installation additional brake light
Replacing the license plate light bulb
Removal and installation the rear light POLO
Removal and installation the rear light (Limousine models only)
Removal and installation the rear light IBIZA
Replacement of incandescent lamps for interior lighting POLO
Replacement of incandescent lamps for interior lighting IBIZA
Electrical circuits
Getting to know the electrical circuit
Construction of electrical circuits
Conventional symbols in electrical circuits
Battery, ignition and starter switch...
Rear window defroster switch, X-terminal load relief relay, cigarette lighter
Windscreen wiper and washer relay, windscreen wiper switch...
Contact switches for the rear door, rear seat back, engine compartment hood...
Fresh air fan switch, heating element switch...
Electrical system control unit, fuse holder
Fuse Holder, 12 Volt Socket
Data bus diagnostic interface, diagnostic connector, horn relay...
Control unit with a block of indicating instruments in the instrument panel...
Handbrake indicator switch, brake fluid level contact...
Touareg 1
General information
Vehicle device
Dimensions of the car
Vehicle identification
Car engine number
Technical data of the Touareg car
Additional equipment installed on vehicles
Set of keys
Remote control of locks
Central lock
Central locking keys
Children's castle
Security alarm
Back door
Opening and closing windows
Controls and instruments
Controls on the multifunction steering wheel
Control devices
Black and white display in the instrument cluster
Colour display in the instrument cluster
Warning and information messages on the display
Signal and control lamps
Electric sunroof control
Outdoor Lighting Control
Emergency alarm system
Steering column switch for headlights and turn signals
Windscreen wiper control
Mirror control
Fuel tank filler flap
Opening the engine compartment hood
Making it easier to get into the car
Heated front seats
Front central armrest with storage compartment for small items
Central armrest with two drawers for small items
Rear center armrest
Rear center console
Ashtrays and cigarette lighter
Standard fire extinguisher
Luggage compartment
Dividing grid
Roof rack
CD Receiver Control Panel
Air Conditioning Control
Climate control 2C-Climatronic
Seats and safety
Tips for drivers and passengers
Adjusting headrests
Adjusting the front seats
Electrically adjustable steering wheel position
Folding and returning the rear seat backrest
Seat belt warning light
Putting on the seat belt
Removal seat belts
Pretensioners and their action
Inflatable airbags
Front airbags
Side airbags
Window airbags
Disabling and connecting airbags
Maintenance and management
Starting the engine
Emergency removal of the ignition key
Starting a gasoline engine
Starting a diesel engine
Stopping a gasoline engine
Keyless access
Automatic transmission
Manual gear shifting — «Tiptronic» (selector)
Using kickdown
Manual transmission
Using air suspension
Adjusting the suspension stiffness
Parking brake
Car parking
Cruise Control (CHA)
Design features of an off-road vehicle
Differential lock
Intelligent systems
Power steering
Catalytic converter
Additional equipment of the vehicle with a towing hitch
Work in the engine compartment
Car batteries
Wheels and tires
On-board tool, spare wheel, tire repair kit, jack
Wheel replacement
Fuses
Engine Starting Assistance
Towing a car
Jacking up a car
Power unit
Engine checks
Engine specifications
Inspection for leaks and damage
Checking the condition of the poly V-belt
Removal and installation a poly V-belt (4.2L petrol engine)
Removal and installation a poly V-belt (3.2L petrol engine)
Checking the belt drive pulleys for misalignment (4.2L petrol engine)
Removal and installation the lower noise insulation screen of the engine compartment
Removal and installation the upper engine casing
Compression test (3.2L petrol engine)
Compression test (5.0L diesel engine)
Petrol engine 3.2L
Technical characteristics of the 3.2L petrol engine
Removal the power unit
Removal and installation left and right engine mount cushions
Removal and installation the slave disk
Removal and installation the seal on the flywheel side
Replacing the crankshaft oil seal on the vibration damper side
Replacing the crankshaft sealing flange on the vibration damper side
Removal and installation the crankshaft
Removal and installation the side cover
Removal and installation the cylinder head cover
Removal and installation the cylinder head
Checking the valve timing
Adjusting the valve timing
Removal camshafts
Installing camshafts
Checking the axial displacement of the camshafts
Marking of camshafts
Replacing valve stem seals
Checking the valve guides
Valve seat machining
Valve sizes
Checking pistons, piston rings and cylinder diameter
Tightening torques for 3.2L petrol engine mounting
Petrol engine 4.2L
Technical characteristics of the 4.2L gasoline engine
Checking the valve guides
Replacing the crankshaft oil seal on the vibration damper side
Removal and installation the drive disc
Removal and installation the flange on the drive disk side
Removal, installation and tensioning of the timing belt
Checking the axial clearance of the camshafts
Replacing camshaft seals
Replacing Hall sensor seals
Removal and installation of camshafts and valve timing adjusters
Diesel engine 5.0L
5.0L Diesel Engine Specifications
5.0L Diesel Engine Fastening Tightening Torques
Removal the engine
Removal and installation of engine mounts and cushions
Crushing and installing the slave disk
Removal and installation the crankshaft support ramp
Front flange seal and vibration damper
Replacing the crankshaft oil seal on the vibration damper side
Replacing the crankshaft oil seal on the engine timing side
Replacing the generator drive shaft seal
Installing the timing cover
Removal and installation the camshaft drive gear
Checking the valve timing
Adjusting the valve timing
Removal and installation cylinder heads
Removal and installation cylinder head covers and gaskets
Cylinder head repair
Valve seat machining
Checking the valve guides
Replacing valve stem seals
Checking the supercharging system for leaks
Installation of hose connections with nipple connectors
Checking the turbocharger
Cooling system
Removal and installation of cooling system components (petrol engine)
Draining and filling coolant (petrol engine)
Removal and installation the radiator (petrol engine)
Removal and installation the water pump (petrol engine)
Pressure testing of the cooling system (petrol engine)
Cooling system (diesel engines)
Draining and filling coolant (diesel engine)
Removal and installation the fan mount (diesel engine)
Crush and install radiator (diesel engine)
Removal and installation of cooling system fittings (diesel engine)
Removal and installation the water pump (diesel engine)
Lubrication system
Removal and installation of lubrication system elements (petrol engine)
Removal and installation oil injector (petrol engine)
Removal and installation the oil drain check valve (petrol engine)
Disassembly and assembly of the oil pump (petrol engine)
Removal and installation the oil pan (petrol engine)
Checking the oil pressure sensor (petrol engine)
Checking oil pressure (petrol engine)
Checking the engine oil level (diesel engine)
Oil lines in the oil pan (diesel engine)
Application of sealant (diesel engine)
Unscrewing and screwing the oil filter cover (diesel engine)
Checking oil pressure and oil pressure sensor (diesel engine)
Checking the oil pressure at the front of the engine (diesel engine)
Injection system
General instructions for the injection system (petrol engine)
Checking injectors (petrol engine)
Checking the amount of fuel injected (petrol engine)
Checking the fuel pressure regulator and residual pressure (petrol engine)
Removal and installation of the engine control unit (petrol engine)
Removal and installation of the engine control unit with anti-theft protection (petrol engine)
Checking and adjusting the position of the pump-injector pistons (diesel engine)
Removal and installation the intake manifold (diesel engine)
Removal and installation of the pump-injector (diesel engine)
Replacing the O-rings of the pump-injector (diesel engine)
Exhaust system
Exhaust gas system
Exhaust system alignment
Removal and installation of the exhaust manifold and inlet pipe with primary catalytic converters
Secondary air supply system
Checking the combination valve
Fuel supply system
Fuel system components (petrol engine)
Fuel line and fuel tank connection plan (petrol engine)
Safety precautions when working on the fuel system (petrol engine)
Replacing the fuel filter (petrol engine)
Fuel leakage from tank (petrol engine)
Removal and installation of fuel supply module, fuel level sensor and ejector pumps (petrol engine)
Checking the power supply of the pumps (petrol engine)
Electronic engine power control (electronic accelerator drive)
Activated carbon absorber
Transmission
Automatic gearbox 09D
Checking the level and topping up ATF oil
Checking ATF level
Checking the torque converter
Pumping fluid out of the torque converter
Installing a torque converter
Gear shift drive repair
Removal and installation the selector handle
Checking and adjusting the selector rod
Removal and installation the selector rod
Removal and installation the overlay
Removal and installation the frame
Removal and installation the N380 selector lock solenoid
Removal and installation the N110 selector lock solenoid
Removal and installation the selector switch (lever locked in position «P») F319
Removal and installation the gear shift drive
Removal and installation of gearbox, cars with diesel engine R5
Removal and installation of gearbox, cars with petrol engines V6 and V8
Removal and installation of ATF lines and radiator
Removal and installation the automatic transmission control unit J217
Replacing the secondary shaft seal ring
Removal and installation the oil pan
Removal and installation a mesh oil filter
Removal and installation the pressure sensor for hydraulic system 1 in automatic transmission G193 and hydraulic system 2 in automatic transmission G194
Removal and installation the valve box
Removal, installation and adjustment of the multi-function switch F125
Mechanical gearbox 08D
Transfer case marking
Letter designations, filling volumes of units (transfer case)
Letter designations, gear ratios, filling volumes (main forward gear)
Letter designations, gear ratios, filling capacities (main reverse gear)
Front main gear marking
Marking of the rear main gear
General instructions about the gearbox
Electronic components and their installation locations on the transfer case
Removal and installation the control unit of the transfer case E473
Removal and installation the transfer case control unit J646
Removal the transfer case
Installing a transfer case
Laying the ventilation tube on the transfer case
Replacing the rubber-metal support of the gearbox bracket
Checking the oil level in the transfer case
Removal and installation sealing rings of the PTO/cardan shaft flange and the transfer case electric motor
Replacing the PTO/Front Propeller Shaft Flange Seal (Transfer Case Installed)
Replacing the PTO/Rear Propeller Shaft Flange Seal (Transfer Case Installed)
Removal the V253 Transfer Case Electric Motor
Installing the V253 Transfer Case Electric Motor
Checking the oil level in the main gear of the front axle
Cardan shaft
Cardan shaft and front final drive
Removal and installation the front propeller shaft
Removal and installation the rear propeller shaft
Checking the oil level in the rear main gear
Removal the front final drive
Installing the front final drive
Installing the Front Main Gear Ventilation Tube
Replacing the sealing ring of the left shaft with flange
Replacing the shaft boot with flange
Replacing the rubber-metal support of the front main gear
Replacing the left flange shaft seal ring for vehicles without differential lock
Replacing the left flange shaft seal ring for vehicles with differential lock
Removal and installation the drive shaft
Disassembling the drive shaft
Drive shaft assembly
Chassis
Wheels and tires
General information on wheels and tires
Technical conditions for the conversion of wheels and tires
Tyre speed ratings
Marking on disks
Composite disks
Tire wear and mileage
High-speed tire wear
Tire maintenance
Evenly worn tires
Measuring the tread depth
One-sided wear
Diagonal uneven wear
Tire rolling noise
Wheel balancing
Radial and lateral runout of wheels and tires
Checking the radial and lateral runout of a rim with a tire using a dial indicator for tires VAC 1435
Minimizing wheel runout
Lateral vehicle pull
Eliminating lateral drift
Tire damage
Loss of air pressure in tires
Tyre damage due to errors during tyre fitting (fitting damage)
Tyre sidewall markings
Wheel rotation
Tires used on Touareg since 2003 model year
Tire Pressure Monitoring System Repair
Crush and install the tire pressure monitoring system control unit J502
Repair of clearance control system
Components of the clearance control system and their installation locations
Removal and installation a compressor without a solenoid valve block
Air Duct Repair
Front suspension
Subframe, stabilizer, lower control arm
Removal and installation the subframe
Switchable stabilizer
Removal the disconnectable stabilizer
Checking the level and topping up the hydraulic oil system of the disconnectable stabilizers
Bleeding the disconnectable stabilizer
Front wheel suspension
Removal and installation the shock absorber strut
Removal and installation of the G78/G289 body level sensor on vehicles with shock absorber struts
Wheel support
Removal the coil spring
Installing a coil spring
Rear suspension
Removal and installation the rear body level sensor G76/G77
Rear wheel suspension
Removal and installation the shock absorber strut
Wheel support
Removal the wheel hub with bearing
Steering gear
Removal and installation the steering column
Removal and installation the sealing cuff
Removal and installation the power steering drive
Removal and installation the steering rod
Vane pump, 5-cyl. diesel engine
Removal and installation vane pump, 5-cyl. diesel engine
Removal and installation vane pump, 6-cyl. diesel engine
Removal and installation vane pump, 6-cyl. petrol engine
Bleeding the steering system and checking for leaks
Checking the steering system for leaks
Brake system
Example of a vehicle data plate
Front brakes
Rear brakes
Checking the brake system
Bleeding the brake system
Pumping (main)
Additional pumping
Removal and installation the brake booster diaphragm stroke potentiometer G420
Removal and installation the brake vacuum pump V192
Removal and installation the brake booster pressure sensor G294
Removal and installation the master brake cylinder
Removal and installation the brake booster
Repair of brake pipes
Front brake repair, brake caliper Brembo 17 (1LC)
Repair of rear wheel brakes, brake caliper FN 44
Adjusting the parking brake
Adjusting brake pads on two wheels
Checking the free travel of the pedal parking brake lever
Removal and installation the foot brake lever
Removal and installation rear brake cables
Disconnecting the brake pedal from the brake booster
Connecting the brake pedal to the brake booster
Removal, installation and adjusting the brake light switch
Anti-lock braking system (ABS)
Electrical and electronic components of the braking system
Body
Outdoor elements
Removal and installation the hood
Removal the gas strut
Releasing gas from the gas strut
Removal and installation of insulation
Removal and installation the hood lock
Adjusting the hood lock
Disconnecting the flexible cable
Removal and installation the tailgate
Adjusting the tailgate with hinge
Adjusting the lock loop
Removal and installation the tailgate hinge
Removal and installation the gas strut plug
Removal and installation door locking and unlocking elements
Removal and installation the tailgate lock
Removal and installation the door closer hinge
Removal and installation the electric motor for opening the luggage compartment door
Removal and installation of the rear spoiler
Removal and installation fuel tank hatch locking and unlocking elements
Door adjustment
Removal and installation the lock cylinder housing
Removal and installation the door handle
Removal and installation the door lock
Rear door adjustment
Removal and installation the rear door lock cylinder housing
Lift and slide sunroof with glass panel
Removal the glass panel of the lift-and-slide sunroof
Installing a glass panel for a lift and slide sunroof
Adjusting the glass panel of the lift-and-slide sunroof
Checking the parallel movement of the glass panel
Fitting the hatch panel seal
Removal the sun shield
Removal and installation the front bumper trim
Removal and installation the rear bumper trim
Electrical equipment
Battery
General information about electrical equipment
Types of batteries
Checking the battery
Adding distilled water to the battery
Checking the density of the electrolyte
Checking the battery open circuit voltage
Disconnecting and connecting the battery, cars with one battery
Disconnecting and connecting the battery, cars with two batteries
Removal and installation the battery located under the driver's seat
Removal and installation the battery disconnect relay
Generator and starter
Removal and installation the starter (6-cyl. engine with injection 3.2 and 3.6 l)
Removal and installation the starter (8-cyl. engine with injection 4.2 l)
Removal and installation the starter (10-cyl. TDI engine 4.9 l)
Three phase generator
Removal and installation of a three-phase generator, 6-cyl. engine with injection
Removal and installation of a three-phase generator, 8-cyl. engine with injection
Removal and installation the voltage regulator
Instruments and wipers
Removal and installation the instrument cluster
Location of instrument cluster connector contacts
Front windshield wiper
Removal the driver's side windshield wiper arm
Removal the windshield wiper arm from the passenger side
Removal the water drainage box casing
Removal the windshield wiper linkage with rods and the windshield wiper motor V
Installing the wiper linkage with rods and the wiper motor V
Installing the casing of the water drainage box
Setting the initial position of the wiper blades
Removal and installation the windshield wiper «aero»
Removal and installation headlights
Headlight position adjustment
Removal and installation the headlight corrector servo drive
Main headlights with gas discharge lamps
Electrical diagram of the Climatronic air conditioning system
Tiguan 1
General information
Characteristics
Vehicle identification data
Overall dimensions and characteristics
Identification information
Dimensions of gaps between body parts
Vehicle overview
Exterior of the car
Driver's door overview
Driver's side view
Upper part of the center console
Lower part of the center console
Front passenger side view
Signal and control lamps
Overview of control devices
Compass setup and calibration
Maintenance indicator
Power unit
Petrol engine 1.4 BWK
Car engine number
Specifications of the 1.4 litre/110 kW petrol engine (BWK)
Removal the engine
Engine installation
Disassembling the engine
Engine assembly
Removal and installation of lubrication system elements
Removal and installation of cooling system components
Draining and filling the coolant
Removal and installation the radiator and radiator fan V7
Removal and installation the cooling system pump
Relieving pressure in the high pressure area of the fuel system
Fuel tank device
Removal and installation of the fuel tank
Removal and installation of power supply system components
Turbocharger device
Removal and installation a turbocharger
Removal and installation the turbocharger vacuum block
Compressor device
Removal and installation the compressor
Turbocharging system
Removal and installation the intercooler
Fuel injection system
Checking the operation of the intake manifold flap
Removal and installation the throttle valve control unit and the throttle valve control unit
High pressure fuel pump
Removal and installation the high pressure pump
Removal and installation engine control unit J623
Theft-protected engine control unit
Catalyst and exhaust system attachments
Silencer with add-on elements
Removal and installation the exhaust pipe
Ignition system repair
Petrol engine 1.4 CAVA
Car engine number
Characteristics of the 1.4 litre/110 kW petrol engine (CAVA)
Removal the engine
Engine installation
Disassembling the engine
Engine assembly
Removal and installation of lubrication system parts
Removal and installation of cooling system components
Draining and filling the coolant
Fuel tank device
Removal and installation the fuel tank
Removal and installation of fuel system components
Turbocharger device
Removal and installation a turbocharger
Compressor device
Removal and installation the compressor (all-wheel drive vehicles)
Turbocharging system
Fuel injection system
Removal and installation of exhaust system components
Removal and installation the exhaust pipe (all-wheel drive vehicles)
Removal and installation the exhaust pipe
Ignition system repair
Removal and installation of ignition coils with output stages
Engine 2.0 (petrol)
Car engine number
Characteristics of the petrol engine 2.0 liter / 125/147 kW
Removal the engine
Engine installation
Cylinder Block — Belt Drive Side
Cylinder block from the gearbox side
Timing chain drive
Camshaft drive chain
Removal and installation the camshaft drive chain
Balance shaft drive chain
Removal and installation the balance shaft drive chain
Cylinder head
Removal and installation a vacuum pump
Repair of the lubrication system
Oil filter, oil cooler and oil pressure sensor
Removal and installation a Chasselas cooler
Cooling system hose connection plan
Draining and filling the coolant
Coolant pump and thermostat
Removal and installation the thermostat
Removal and installation coolant temperature sensor G62
Coolant pipes
Coolant run-off pump V51
Radiator, fan rack and radiator fan
Safety rules for working with the power supply system
Pressure relief in high pressure areas (CAWA, CAWB, CCTA, CCTB)
Fuel tank device
Removal and installation the fuel tank
Fuel system repair
Turbocharger device
Removal and installation a turbocharger
Turbocharging system
Fuel injection system
Air filter device
Intake manifold device
Fuel ramp device (Rail)
Removal and installation the intake manifold with fuel rail
Removal the fuel (Rail) ramp from the intake manifold
Removal and installation injectors
High pressure pump with fuel pressure regulating valve N276
Exhaust gas system
Removal and installation of catalytic converters with a receiving pipe
Ignition system repair
Engine 2.0 (diesel)
Car engine number
Specifications of the 2.0 liter diesel engine / 100/103/120/125 kW
Removal and installation the engine casing
Removal the engine
Engine installation
Poly V-belt drive
Removal and installation the additional units bracket
Toothed belt transmission
Cylinder block device
Removal and installation covers and flywheel
Cylinder head
Removal and installation the Hall sensor G40
Carved versions of the rear toothed belt guard
Valve cover device
Cylinder head cover, removal and installation
Removal, installation and tensioning the timing belt
Motor oil
Oil pump, oil pan, balance shaft block
Removal and installation the oil level and temperature sensor G266
Removal and installation the oil pump
Removal the balance shaft assembly
Oil filter bracket, oil pressure sensor, oil cooler and oil pressure line
Removal and installation the oil filter bracket with oil cooler
Removal and installation the pressure oil line to the turbocharger
Rules for working with the cooling system
Cooling system parts and units installed on the body
Cooling system parts and components installed on the engine
Cooling system hose connection diagram
Draining and filling the coolant
Procedure for incorrect fuel system filling
Fuel tank device
Removal and installation the fuel tank
Removal and installation the fuel level sensor
Fuel filter device
Removal and installation the upper part of the fuel filter
Removal and installation the fuel filter
Removal and installation additional fuel pump V393
Accelerator drive parts and components
Turbocharger with add-on elements
Removal and installation a turbocharger
Charge air cooling system
Vacuum hose connection diagram
Diesel engine fuel injection system
Fuel system device
Removal and installation of injectors (piezo injectors)
Checking the fuel pressure regulator N276
Removal and installation of high pressure fuel pump (HPFP)
Intake manifold with attachments
Removal and installation the intake manifold
Air filter device
Front part of the exhaust system with diesel particulate filter
Removal and installation the particulate filter
Removal and installation a diesel particulate filter (front-wheel drive vehicles)
Silencer device
Exhaust gas recirculation systems
Removal and installation a pin glow plug
Transmission
6-speed manual gearbox 0A6
Location of markings on the manual transmission
Marking, gear ratios, filling capacities
Location of markings on the transfer case
Clutch pedal assembly
Removal and installation the support bracket
Removal and installation the clutch pedal servo spring
Removal and installation the clutch master cylinder
Clutch hydraulic drive parts and components
Repair of the clutch release mechanism
Clutch repair
Gear shift mechanism repair
Repair of the gear shift lever and gear shift housing
Removal and installation drive cables
Removal the gearbox (front-wheel drive vehicles)
Gearbox installation (front-wheel drive vehicles)
Checking the oil level in a manual transmission
Removal the transfer case (vehicles with a turbocharged diesel engine)
Installation of transfer case (cars with diesel engine with turbine)
Checking the oil level in the transfer case
6-speed automatic gearbox 09M
Marking on the gearbox
Letter designation, compatibility of units
Electrical and electronic units and parts and their installation locations
Removal the F125 multifunction switch
Overview of the switching drive
Checking the cable traction
Emergency release of the selector
Checking the gear shift drive
Gearbox Removal — 2.0L 147kW TSFI Engine Vehicles
ATF radiator
Removal and installation the ATF radiator
Draining and filling ATF
Electrohydraulic unit of the gearbox
Removal and installation the wiring harness for the solenoid valves and sensors
Drive shafts
Cardan shaft device
Removal and installation the propeller shaft
Removal and installation the rear final drive
Silent blocks
Places of installation of electrical/electronic units and components
All-wheel drive control unit J492
Removal and installation the Haldex coupling
Assembly and disassembly of the Haldex coupling (generation IV)
Checking the oil level in the rear final drive or adding oil
Adding oil to the Haldex coupling
Chassis
Front suspension
Subframe, stabilizer, triangular lever
Removal and installation the subframe with steering gear
Checking the condition of the ball joint
Removal and installation the ball joint
Removal and installation the triangular lever and its support bracket
Wheel hub bearing unit parts and components
The structure of the shock absorber strut
Removal and installation the shock absorber strut
Loosening and tightening the twelve-point hub bolt
Removal and installation a drive shaft with an internal ball joint
Removal and installation of the drive shaft with an internal joint of the tripod type AAR3300I (mounted on the gearbox axle shaft)
Removal and installation of the drive shaft with an internal joint of the tripod type AAR3300I (inserted into the gearbox)
Applicable drive shafts
Heat shields for drive shafts
Drive shaft with ball CV joint VL107
Tripod Joint Drive Shaft AAR3300I
Drive shaft with tripod joint type AAR3300I for cars with automatic transmission 09M
Rear suspension (2x4)
Subframe device
Removal and installation of the subframe assembly with the units installed on it
Parts and assemblies of transverse levers and transverse rods
Details and assemblies of the rear left ground clearance sensor G76
Removal and installation the upper wishbone
Removal and installation the lower wishbone
Removal and installation the transverse tie rod
Parts and units of the hub bearing housing and trailing arm
Removal and installation the wheel bearing housing
Shock absorber and coil spring
Removal and installation a coil spring
Removal and installation the shock absorber
Shock absorber repair
Anti-roll bar
Rear suspension (4x4)
Parts and units of the subframe, main gear
Removal and installation of the subframe assembly with the units installed on it
Parts and assemblies of transverse levers and transverse rods
Removal and installation the upper wishbone
Removal and installation the lower wishbone
Parts and units of the hub bearing housing and trailing arm
Shock absorber and coil spring
Shock absorber repair
Anti-roll bar
Drive shaft device
Removal and installation the drive shaft
Air suspension
Adaptive undercarriage control system DCC components and their installation locations
Damping adjustment key E387
Parts and assemblies of the front left/right ride height sensor G78/G289
Parts and assemblies of the rear left ground clearance sensor G76 (front-wheel drive)
Parts and assemblies of the rear left ground clearance sensor G76 (4x4)
Front Suspension Cable Routing Left
Front suspension cable routing right
Rear Suspension Cable Routing
Components and assemblies of the shock absorber strut of the adaptive chassis control system DCC
Components and assemblies of the shock absorber of the adaptive chassis control system DCC (front-wheel drive vehicle)
Removal and installation the shock absorber of the adaptive chassis control system DCC (front-wheel drive)
Repair of shock absorber of adaptive chassis control system DCC (front-wheel drive)
Adaptive Chassis Control System DCC (4x4) shock absorber parts and assemblies
Removal and installation the shock absorber of the adaptive chassis control system DCC (4x4)
Wheels and rims
Wheel bolt tightening torque
Tire Pressure Monitoring Indicator
Tire pressure monitoring system
Tire pressure sensor device
Removal and installation the tire pressure sensor
Brake system
General information about the brake system
Electrical/electronic components and their installation locations
General instructions regarding the anti-lock braking system
Hydraulic unit parts and components
Connecting brake pipes from the master cylinder to the hydraulic unit
Removal the control unit and hydraulic block
Removal and installation front axle ABS system components
Removal and installation of rear axle ABS system components (front wheel drive)
Removal and installation of rear axle ABS system components (4x4)
Removal and installation of ESP system components
Front brake repair, brake caliper FN 3
Removal and installation front brake pads FN 3
Removal and installation the front brake caliper FN 3
CII41 Rear Brake Repair
Removal and installation rear brake pads CII41
Removal and installation the rear brake caliper CII41
Electromechanical parking brake
Removal and installation the parking brake electric motor
Brake pedal
Repair of brake caliper FN 3
Repair of rear brake calipers
Brake booster/master cylinder parts and assemblies
Brake booster vacuum pump
Removal and installation the vacuum sensor G608
Removal and installation the brake light switch F
Removal and installation the master brake cylinder
Removal and installation the brake booster
Steering gear
Steering column
Removal and installation the steering wheel
Removal and installation the steering column
Steering gear with electromechanical power steering
Removal and installation the steering gear
Differences between 2nd and 3rd generation steering mechanisms
Removal and installation the corrugated cover
Removal and installation the steering rod
Body
External equipment
Front support panel
Installation in service position
Removal and installation the front support panel assembly
Removal and installation wings
Soundproofing casing
Device, removal and installation of the hood
Disconnecting the bonnet cable
Adjusting the hood
Hood release lever
Luggage compartment door
Removal and installation tailgate hinges
Tailgate locking mechanism
Removal and installation the tailgate lock
Removal and installation the handle cover with the opening key
Adjusting the tailgate
Adjusting the lock bracket
Adjusting the stops
Gas struts
Filler cap and actuator
Front door device
Door hinges
Removal and installation door hinges
Upper door hinge bolt
Door adjustment
Door support panel with hanging equipment
Removal and installation of the supporting panel with attachments
Door opening limiter
Door handle and lock
Removal and installation the roof of the lock cylinder
Removal and installation of the stuttering larva
Removal and installation the cover (without the cylinder)
Removal and installation the outer door handle
Removal and installation the door stutter
Removal and installation the outer handle housing
Removal and installation the door lock bracket
Soundproofing of the door
Central lock
Removal and installation the power element of the folding ignition key with remote control
Back door
Rear door hinges
Lubricating new door hinges
Installing hinges after replacing the B-pillar
Rear door adjustment
Load-bearing panel with attachments
Removal and installation the supporting panel with attachments
Rear door handle and lock
Removal and installation the lock cover
Removal and installation the rear door handle
Removal and installation the rear door lock
Removal and installation the handle housing
Removal and installation the rear door bracket
Panoramic sunroof control
Initializing the sunshade motor
Removal and installation the front glass section of the sunroof
Removal and installation the rear glass section of the sunroof
Height adjustment of the front and rear sections of the hatch
Replacing hatch seals
Removal and installation the sunroof fairing
Removal and installation the sun blind
Removal and installation the lifting mechanism and drive cable of the front section of the hatch
Hatch frame device
Hatch maintenance
Opening and closing the hatch without power supply
Cleaning drain hoses
Front bumper trim
Removal and installation the front bumper trim
Front bumper trim add-on parts
Internal fastening parts of the front bumper trim
Front bumper parts and components
Front bumper trim in off-road version
Removal and installation the front bumper trim
Front bumper trim add-on parts
Front bumper parts and components
Rear bumper trim
Removal and installation the rear bumper trim
Rear bumper trim add-on parts
Internal fastening parts of the rear bumper trim
Rear bumper beam
Hitching device
Glued glass
Front door glass
Removal and installation the window lift motor
Removal and installation the glass guide
Rear door windows
Removal and installation rear door glass
Removal and installation the rear door window lift motor
Mudguard parts and components
Exterior rear view mirrors
Removal and installation the radiator grille
Roof rails
Moldings and trims
Removal and installation of wheel arch liners
Attached car parts in the special Volkswagen Individual package
Nameplates
Internal equipment
Interior rear view mirror
Overlays, covers and decorative shields
Removal and installation the center console without armrest
Removal and installation the center console with armrest
Removal and installation center console brackets
Replacing the rear cup holder
Removal and installation the central decorative trim of the front panel
Removal and installation the glove box
Removal and installation the steering column switch block trim
Removal and installation the heater and air conditioning control panel trim
Removal and installation the left trim panel on the driver's side
Removal and installation the lower trim of the front panel
Removal and installation the overhead console
Removal and installation sun visors
Removal and installation rear door sill trims
Removal and installation rear wheel arch trim
Removal and installation front seat belts
Removal and installation the seat belt height adjustment mechanism
Removal and installation the front seat belt buckle
Removal and installation rear side seat belts
Removal and installation the 3-point central seat belt
Safety rules when working with airbags
Removal and installation the airbag control unit
Removal and installation the driver's airbag
Removal and installation the front passenger airbag
Checking the need for laying an additional ground wire in the car
Front passenger and driver seats
Removal and installation the rear side airbag
Removal and installation the driver/passenger side upper airbag
Removal and installation the seat occupancy sensor
Procedure after an accident with deployment of pretensioners and/or airbags
Seat Occupancy Recognition System (USA)
Seat occupancy detection system repair kit
Removal the seat occupied system components
Impact sensors
Removal and installation the front panel
Removal and installation of the supporting frame
Installing the front panel in the correct position
Front panel adjustment
Removal and installation the front door trim
Removal and installation the rear door trim
Pillar facings
Luggage compartment door trims
Luggage compartment trims
Ceiling lining
Removal and installation the front seat
Removal and installation front seat components
Front seat with manual height adjustment
Driver's seat with electrical adjustments
Rear seats
Front seat cushions and upholstery
Rear seat upholstery and cushions
Electrical equipment
Power devices
Disconnecting and connecting the battery
Removal and installation the battery
Starter (cars with 1.4 l TSI engines and MQ500 manual transmission)
Starter (cars with 2.0 l TDI engines and MQ500 manual transmission)
Starter (cars with 2.0 l TDI engines and AQ450 automatic transmission)
Generator (1.4L TSI engine)
Removal and installation the generator (1.4 l TSI engine)
Generator (2.0 l TDI engine)
Removal and installation the generator (2.0L TDI engine)
Generator (2.0L TSI engine)
Removal and installation the generator (2.0L TSI engine)
Appliances and lighting
Instrument cluster
Symbols of control lamps in the instrument cluster
Front windshield wiper
Removal and installation the front windshield wiper
Removal the windshield wiper motor from the windshield wiper linkage
Adjusting the extreme position of the windshield wipers
Removal and installation frameless windshield wiper blades
Removal and installation the rain and light sensor G397
Windscreen washer
Removal and installation the windshield washer reservoir and headlight washer
Removal and installation the windshield and rear window washer pump
Removal and installation the windshield washer fluid level sensor
Removal and installation windshield washer nozzles
Rear window wiper
Removal and installation the rear wiper
Rear window washer
Headlight cleaning system
Main headlight with halogen lamps
Removal and installation the main headlight with halogen lamps
Adjusting the installation position of the headlight
Replacing the low beam headlight bulb
Replacing the high beam headlight bulb
Replacing the parking light bulb
Replacing the front turn signal bulb
Main turning lights with gas discharge lamps
Headlights with gas discharge lamps and adaptive lighting
Removal and installation headlights with gas discharge lamps and adaptive lighting
Replacing a gas discharge lamp
Replacing the adaptive lighting lamp
Replacing the front turn signal bulb
Replacing the parking light bulb
Removal and installation the headlight switching device with a gas discharge lamp
Removal and installation of the AFS power module
Control unit for adaptive lighting and headlight range control
Vehicle ground clearance sensor
Fog lights
Turn signal lamp in the side mirror for easy entry and illumination
Rear light (SBBR) in the side of the body
Rear lights (SBBR) in the tailgate
Additional brake lights
License plate light
Reversing lights in the bumper cover
Side marker lights
Steering column switch
Ignition and starter switch and lock cylinder
Rear Parking Assist (PDC)
Front Parking Assist (PDC)
Parking Assist (PLA)
Rear view camera
Lamps and switches internal
Lighting and switches in the front doors
Lighting and switches in the rear doors
Lighting and switches in the trunk
Lighting and switches in the ceiling trim
Lighting and switches in the center console
Sound signal
Immobilizer
Anti-theft alarm (DWA)
Fuse and relay boxes
Switching blocks
Control units
Cigarette lighter U1
Communication systems
Audio system RCD 300
Audio system RCD 500
Radio navigation system RNS 300
Radio navigation system RNS 510
Audio amplifier
CD changer
Digital Satellite Radio Tuner, Car for USA and Canada
Apple iPOD player socket
Multimedia system control unit
Acoustic systems
Telephony systems
Antenna systems
Multifunctional steering wheel
Heating and air conditioning
Heater device
Removal and installation of heater elements
Removal and installation the heat exchanger
Checking the heating element of the additional air heater
Checking the exhaust ventilation
Removal and installation of inlet ventilation grilles
Removal and installation the heater
Heater parts and components
Heater and air conditioning system Climatic
Functions of the control keys for the heater and air conditioning system Climatic
Removal and installation of the rotary control unit of the heater and air conditioning system Climatic
Electrical connectors of the rotary control unit of the heater and air conditioning system Climatic
Checking the drain hose for water condensate of the heating and air conditioning module
Removal and installation the air recirculation flap actuator motor
Removal and installation the actuator motor of the temperature control flap
Removal and installation the footwell air duct temperature sensor
Removal and installation the central deflector temperature sensor
Outside temperature sensor
Air conditioning system with automatic control Climatronic
Location of parts and units of the Climatronic air conditioning system in the car interior
Electrical connectors of the Climatronic control unit
Removal and installation the control panel and display of the Climatronic climate control system
Removal and installation the supply fan control unit
Climatronic evaporator housing
Removal and installation the left footwell air duct temperature sensor
Removal and installation the right footwell air duct temperature sensor
Removal and installation the evaporator temperature sensor
Description of the air pollution sensor operation
Removal and installation of the air pollution sensor (cars from calendar week 22/08)
Removal the temperature sensor of the left and right deflectors
Removal the G107 and G134 light sensors
Removal and installation of the actuator motor of the supply ventilation flaps
Removal and installation the control mechanism of the supply ventilation flaps
Removal and installation the actuator motor of the right temperature control flap
Removal and installation the central flap actuator motor
Fluids for air conditioning systems
Safety precautions when working with the Thermo Top V additional heater
Repair of additional heater Thermo Top V
Manufacturer's plates on the Thermo Top V heater
Removal and installation of the heater exhaust system
Removal and installation the heater radio signal receiving device
Crush and install additional heater Thermo Top V
Removal and installation of additional heater attachments Thermo Top V
Disassembly and assembly of the additional heater Thermo Top V
Connection diagram of an additional heater to the cooling circuit
Removal and installation the auxiliary heater control unit
Removal and installation a glow plug with a flame sensor
Removal and installation the temperature sensor and overheating sensor
Power supply system of the heater Thermo Thor V
Removal and installation of the dosing pump of the Thermo Top V heater
Thermo Top V additional heater control
Description of heater operation when controlled via radio channel
Electrical circuits
Control units in the luggage compartment
Control units in the engine compartment
Control units in the cabin
Electrical connector blocks
Location of fuses
Relay location
List of ground connection points in the engine compartment
List of ground connection points in the passenger compartment
List of ground connection points in the luggage compartment
Battery, relay 2 power supply terminal 15, relay power supply terminal 50, fuses
Fuses, ABS control unit, electromechanical parking brake control unit
Contact X unloading relay, fuses
Ignition Key Removal Lock Electromagnet
Steering wheel angle sensor, horn switch
Multi-function display call key, Multi-function display memory switch
Left fog lamp, left headlight, left headlight corrector actuator
Headlight corrector regulator, two-tone horn relay
Right fog lamp, right headlight, right headlight corrector actuator motor
Light Switch Backlight Lamps, Light Switch
Rear direction indicators, left and right brake lights, reversing lights
Number plate lighting, turn signal repeater lamps in outside mirrors
Washer nozzle heating resistors, brake light switch
Windscreen wiper motor, rain and light sensor, ASR and ESP deactivation button
Footwell lighting, glove compartment light
Rear interior light, front interior light, reading lights
Limit switches for vanity mirror lighting, cigarette lighters, 12V socket
Rear window heating element, rear window heating relay
Diagnostic connector, diagnostic data bus interface
Data bus diagnostic interface, bonnet open indicator lamp, instrument cluster
Brake pad wear indicator, instrument cluster, immobilizer control unit
Fuel gauge, temperature and coolant level monitoring system
Steering Column Control Module, SB16 Fuse, Starter/Ignition Switch
Cruise control switch, horn switch
Multifunction keys on the steering wheel on the left
Multifunction keys on the steering wheel on the right
Diagnostic connector, diagnostic interface of data buses, instrument clusters
Sharan 1
General information
Introduction to guide
Minivan VW Sharan — annotation
Vehicle identification
General recommendations for car repair
Conditions of work and tools used
Correct lifting of the car
Lubricants and sealants
Rules for handling threaded connections, bolts, nuts
Appendix 1. Technical data and characteristics
Appendix 2. Basic data for adjustments and control
Appendix 3. Tightening torques for threaded connections
Maintenance
Repair and maintenance work
Checking the engine oil level and replacing it
Checking the brake fluid level
Checking the operation of brake lights
Checking the operation of the lighting system
Checking tire pressure
Checking the air filter
Checking the coolant level
Checking the Power Steering Fluid Level
Regular maintenance operations
Maintenance every 12 months or every 15,000 km
Maintenance every 12 months
Maintenance every 24 months or every 30,000 km
Maintenance every 60,000 / 120,000 km
Petrol engines
Engine repair 2.8 l (AAA)
VR6 Engine — Design Description
Removal and installation the engine
Removal and installation the gearbox from the engine
Additional operations on a car with air conditioning
Engine mount
General recommendations for engine disassembly and assembly
Removal the cylinder head
Disassembling the cylinder head
Cylinder head repair
Cylinder head assembly
Installing the cylinder head
Hydraulic tappet — removal and installation
Removal pistons and connecting rods
Measuring the inner diameter of a cylinder
Checking pistons and connecting rods
Assembly of pistons and connecting rods
Installing pistons and connecting rods
Cylinder Block — Check
Removal the crankshaft
Checking the crankshaft
Installing the crankshaft
Crankshaft seals
Flywheel — removal and installation
Timing drive mechanism — design description
Removal the timing drive components
Installing the timing drive
Intermediate shaft — removal and installation
Checking the compression in the engine cylinders
Additional air supply system
Removal and installation the exhaust manifold
Removal and installation of the exhaust system
Engine repair 2.0 l (ADY)
Removal and installation the engine
General disassembly of the engine
Engine assembly
Cylinder head and valves — general information
Removal the cylinder head
Disassembling the cylinder head
Cylinder head repair
Cylinder head assembly
Installing the cylinder head
Hydraulic pusher
Replacing the camshaft seal
Removal pistons and connecting rods
Measuring the inner diameter of a cylinder
Checking pistons and connecting rods
Measuring connecting rod clearance
Assembly of pistons and connecting rods
Installing pistons and connecting rods
Cylinder Block — Design Description
Removal the crankshaft
Checking the crankshaft parts
Installing the crankshaft
Crankshaft seals — removal and installation
Removal and installation the flywheel (car with manual transmission)
Torque converter drive pulley (for vehicles with automatic transmission)
Timing drive mechanism — design description
Removal the toothed drive belt
Installing a toothed drive belt
Ignition setup
Adjusting the tension of the drive belt of engine units
Intermediate shaft — removal and installation
Lubrication system
Engine lubrication system — design description
Removal and installation the oil pan
Removal and installation the oil pump
Oil pump repair
Oil filter — removal and installation
Checking oil pressure
Oil radiator — removal and installation
Engine oil change
Cooling system
Engine cooling system — design description
Replacing the coolant
Antifreeze — General Information and Precautions
Radiator Cap and Radiator Check
Removal and installation the radiator
Checking the cooling system fan
Checking the temperature sensor of a remote thermometer
Removal and installation the water pump
Removal and installation the water pump of the VR6 engine
Water pump repair
Thermostat 2.0 liter engine
VR6 Engine Thermostat
Poly V-belt
Coolant circulation pump
Fuel injection system
Fuel injection system of the VR6 engine
Precautions when carrying out repair work on the injection system
Operating principle of the ECM under various conditions
Electronic control unit — general information
Throttle body
Fuel pressure regulator
Fuel injection system faults
Removal and installation of fuel injectors
Checking the mass air flow sensor
Throttle drive cable
Electric Fuel Pump — General Information
Checking the performance of the fuel pump
Removal and installation the fuel pump
Fuel filter — removal and installation
Fuel level sensor in the tank
Description and operation of the Simos injection system (2.0 l engine)
Simos system idle mode (2.0L engine)
Ignition system
General description and operation of the ignition system
Ignition distributor. Ignition coil
Ignition output stage
Engine Crankshaft Speed Sensor
Knock sensor. Knock adjustment
Precautions when performing repair work on the ignition system
Carrying out repair and maintenance work on the ignition system
General check of the ignition system
Checking the ignition coil
Checking the Hall and Knock Sensor
Ignition distributor for 2.0 liter engine
Servicing the ignition distributor
Removal and installation the ignition distributor
Ignition distributor repair
Adjusting the ignition timing of a 2.0-liter engine
Spark plugs — removal, installation and adjustment
Diesel engines
Engine repair
Diesel engine — general information
Removal and installation the engine
Disassembling the engine
Engine assembly
Cylinder Head — Removal with Engine Installed
Disassembling the cylinder head
Cylinder head repair
Cylinder head assembly
Installing the cylinder head
Hydraulic tappets — removal and installation
Poly V-belt and toothed drive belts
Removal the timing belt
Installing the toothed drive belt and adjusting the timing drive
Connecting rod and piston group — design description
Removal and disassembly of the connecting rod and piston group
Checking pistons and connecting rods
Assembly of pistons and connecting rods
Installing pistons and connecting rods
Removal the intermediate shaft
Installing the intermediate shaft
Flywheel — removal and installation
Camshaft and oil seal
Removal the camshaft
Camshaft oil seal
Installing the camshaft and oil seal into the cylinder head
Determination of axial clearance of the crankshaft
Crankshaft seals — removal and installation
Checking the crankshaft parts
Measuring cylinder bores
Checking the mating surface of the cylinder block
Lubrication system
Diesel Engine Lubrication System — General Information
Removal and installation the oil pan
Removal and installation the oil pump
Oil pump repair
Oil filter — removal and installation
Checking oil pressure and replacing it
Oil radiator — removal and installation
Cooling system
Diesel Engine Cooling System — General Information
Filling the cooling system with coolant
Radiator Cap and Radiator Check
Removal and installation the radiator
Checking the cooling system fan
Removal and installation the water pump
Coolant pump repair
Poly V-belt — removal and installation
Thermostat — Removal, Installation and Checking
Supply system
Diesel engine fuel system and turbocharger
Precautions when repairing the injection system
Diesel fuel — general information
Fuel filter — removal and installation
High Pressure Fuel Pump — General Information
Removal and installation the high pressure fuel pump
Injectors — removal and installation
Removal and installation a turbocharger
Glow Plugs — Checking
Charge Air Radiator — Removal and Installation
Transmission
Clutch
Clutch — design description
Removal the clutch
Checking the technical condition and checking the clutch
Clutch installation
Clutch release drive — design description
Removal and installation the clutch slave cylinder
Removal and installation the clutch master cylinder
Bleeding the Clutch Hydraulic Drive
Possible clutch malfunctions
Manual gearbox and shafts
5-speed manual transmission
Removal the gearbox
Gearbox installation
Gear shift mechanism
Replacing gear shift cables
Checking the functionality of the gear shift mechanism
Checking the gearbox oil level
Wheel Drive Shafts — Design Description
Removal and installation the drive shaft (manual transmission)
Removal and installation the drive shaft (automatic transmission)
Drive shaft repair
Chassis
Steering
Removal and installation the steering gear
Replacing the tie rods
Replacing the tie rod end
Replacing the entire tie rod
Filling and bleeding the hydraulic system
Checking the hydraulic system for leaks
Adjusting the tension of the V-belt of the power steering pump
Removal and installation the power steering pump
Power Steering Hoses and Pipes
Car suspension
Front suspension — general information
Removal and installation the front suspension
Front suspension repair
Coil spring and shock absorber
Replacing wheel bearings
Removal and installation transverse arms
Anti-roll bar
Adjusting the front wheel alignment angles
Rear suspension — design description
Removal and installation the rear suspension
Trailing arm / suspension springs
Removal and installation shock absorbers
Rear wheel bearings
Brake system
Brake system — general information
Adjusting the service brake system
Adjusting the parking brake
Checking the thickness of the front brake pads
Removal and installation front brake pads
Disassembly and assembly of the front wheel brake mechanism
Removal and installation the front brake caliper
Checking the thickness of the rear brake pads
Replacing rear brake pads
Disassembly and assembly of the rear wheel brake mechanism
Brake disc treatment
Master Brake Cylinder — General Information
Removal and installation the master brake cylinder
Repair of the main brake cylinder
Checking the brake booster
Bleeding the brake hydraulic system
Parking brake — general information
Removal and installation the parking brake cable
Removal and installation the parking brake lever
ABS (Anti-lock Braking System)
Removal and installation a vacuum booster on a car with ABS
Electrical equipment
Equipment and devices
General information about on-board electrical equipment
Windscreen wipers — design description
Replacing the windshield wiper arm
Replacing the rubber band of the wiper blade and the wiper blade itself
Replacing the windshield wiper gear motor
Headlights — General Information
Replacing headlight bulbs
Removal and installation headlights
Disassembling and assembling the headlight
Headlight adjustment
Rear lights — removal and installation
Replacing front turn signal bulbs
Power devices
Battery — General Information
Checking the battery status
Generator — General Information
Precautions when working with the electrical supply system
Checking the generator
Removal and installation the generator
Generator repair
Starter — general information and malfunctions
Checking the starter
Removal and installation the starter
Disassembling and assembling the starter
Electrical circuits
Conventional symbols for electrical circuits
Wiring diagrams for Volkswagen Sharan, basic configuration
Wiring diagrams for Volkswagen Sharan with 2.8L VR6 engine
Electrical diagrams for Volkswagen Sharan with turbodiesel
Transporter T3
General information
Maintenance
Checking brake hoses and lines
Lubrication of movable joints
Lubrication and maintenance of diesel vehicles
Lubricants
Smoke Testing
Gearbox and final drive oil change
Installing a car on trestles
Maintenance plan (diesel, production up to 8.85)
Maintenance plan (diesel, production since 9.85)
Maintenance plan (petrol, release up to 8.85)
Maintenance plan (petrol, release from 9.85)
Petrol engines
Engine repair
General description of gasoline engines
Main technical data of the gasoline engine
Engine Identification Number
Removal and installation the engine
Disassembly and assembly of the engine
Removal and installation the cylinder head
Basic valve clearance adjustment
Removal and installation the pushrod protective tube
Cylinder head with valves
Removal, installation and inspection of valves
Lapping of valve seats
Valve processing
Checking the valve guides
Valve seat machining
Checking the tightness of valve seats
Checking the compression in the cylinders
Cylinders, pistons and piston rings — design description
Removal and installation of cylinders, pistons and piston rings
Checking the pistons
Checking cylinder bores
Removal and installation the flywheel, replacing the crankshaft seal
Checking and adjusting the axial play of the crankshaft
Disassembly and assembly of the engine crankcase
Removal and installation the camshaft
Removal and installation the crankshaft
Removal and installation connecting rods
Removal and installation the crankshaft oil seal
Removal and installation the belt pulley
Engine fault diagnostics
Removal and installation the engine beam
Lubrication system
Purpose of motor oil
Engine oil change
Replacing the oil filter
Oil pump, oil filter and pressure reducing valve
Removal and installation the oil pressure reducing valve
Checking, removing and installing a hydraulically operated oil switch
Automatic oil pressure control
Checking the oil switch, checking the oil pressure
Removal and installation the oil pump
Diagnostics of engine lubrication system faults
Cooling system
Description of the design of the engine cooling system
Engine cooling circuit
Coolant — General Information
Draining and filling the coolant
Removal and installation the radiator
Removal and installation the thermostat
Checking the Thermostat
Removal and installation the coolant temperature gauge sensor
Removal, installation and checking the temperature switch of the electric fan
Removal and installation the water pump
Water hose connection diagram
Diagnostics of engine cooling system faults
Power and exhaust system
Carburetor / fuel injection device
Maintenance of the carburetor device
Carburetor adjustment
Fuel supply problems
Air filter and vacuum connections of the carburetor 34 PICT
Air filter and vacuum connections of the 2E3 carburetor
Adjusting the intake air heating
Checking the Thermostat
Removal and installation the fuel pump
Removal and installation the fuel filter
Cable throttle drive — design description
Removal and installation the gas cable
Cable-operated gas drive on cars with automatic transmission
Fuel tank — design description
Removal and installation the fuel tank
Carburetor fault diagnostics
Exhaust system of the 1.9L engine
Exhaust system of the 2.1L engine with catalytic converter
Removal and installation the muffler
Vehicles with a catalytic converter — general information
Operation of vehicles with a catalytic converter
Carburetor 34 PICT
Carburetor 34 PICT — design description
Removal and installation the carburetor 34 PICT
Carburetor adjustment 34 PICT
Removal and installation the float needle valve
Checking the air circulation shut-off valve
Adjusting the carburetor cable 34 PICT
Checking the throttle and air valve shafts
Checking and adjusting idle speed and CO content
Automatic engine start system
Removal and installation the heating coil
Adjusting the automatic engine starting system
Checking the automatic engine start system
Checking and adjusting the injection quantity of the accelerator pump
Checking and adjusting the air damper gap size
Checking and adjusting the idle speed of a cold engine
Checking and adjusting the shut-off damper and the slow-down valve
Removal and installation the intake pipe with the carburetor
Checking and replacing the intake manifold heater
Basic data of the 34 PICT carburetor
Carburetors 2E3 and 2E4
Carburetor 2E3 — design description
Checking the throttle control valve
Removal and installation of the 2E4 carburetor
Checking and adjusting idle speed and CO content
Automatic engine start system
Partial Load Channel Heating Test
Checking and adjusting the idle speed of a cold engine
Checking and adjusting the air damper gap size
Checking and adjusting the injection quantity of the accelerator pump
Pulldown device check
Checking the idle air cut-off valve
Inlet pipe of carburetor 2E3 and 2E4
Basic data of carburetor 2E3 and 2E4
Checking the thermostat housing and vacuum membrane
Fuel injection system
Fuel injection device for gasoline engines
Digijet and Digifant injection systems
Adjusting the idle speed and CO content (Digijet)
Adjusting the idle speed and CO content (Digifant)
Checking the operation of the catalyst
Replacing the air filter insert
Removal and installation the fuel filter
Ignition system
Ignition system — general information
Safety precautions when working with the ignition system
Operation of the transistor ignition system TSZ-H
Digifant Ignition and Fuel Injection System
Checking the ignition coil
Checking high-voltage wires and spark plug tips
Removal and installation the ignition distributor
Removal and installation the ignition distributor drive shaft
Checking and adjusting the ignition timing
Connecting the switching unit of the idle speed stabilization system
Checking the TSZ-H ignition system switching unit
Checking the Hall sensor
Diesel engines
Engine repair
Main technical data of the engine
The principle of operation of a diesel engine
Operating principle of a gas turbine supercharger
Removal and installation the engine
Additional vibration damper
Sealed toothed belt guard
Removal and installation the timing belt
Toothed belt transmission — design description
Checking and adjusting the timing belt tension
Cylinder head — design description
Removal and installation the cylinder head, replacing the gasket
Valve drive — design description
Dismantling and installation of the camshaft
Dismantling and installation of valves
Valve seat finishing
Checking the valve guides
Replacing piston rod seals
Adjusting valve clearance
Checking the compression in the cylinders
Emergency engine start
Diesel Engine Fault Table
Gas turbine supercharger — design description
Rules for maintaining cleanliness when working with a gas turbine supercharger
Removal and installation of a gas turbine supercharger
Lubrication system
Description of the design of the engine lubrication system
Oil and oil filter change
Engine oil consumption
Checking engine oil pressure
Removal and installation of oil bath
Removal and installation the oil pump
Dynamic oil pressure control
Oil circulation system fault table
Cooling system
Description of the design of the engine cooling system
Cooling system hose connection diagram
Antifreeze — General Information
Replacing the coolant
Radiator — design description
Removal and installation a radiator
Removal and installation the regulator valve
Checking the regulator valve
Removal and installation of the cooling pump
Removal and installation the temperature gauge sensor
Installing and dismantling the fan thermostat and checking it
Removal and installation the V-belt of the cooling pump, tensioning the belt
Cooling system circulation pump
Engine cooling system 1.7 liters
Cooling system fault table
Power and exhaust system
General description of the fuel system
Fuel injection system repair
Removal water from the fuel filter, replacing the filter
Installing a fuel filter preheating system
Features with all-wheel drive Syncro
Checking and adjusting the maximum number of revolutions
Dismantling and installation of gas traction
Adjusting the gas thrust
Cold start thrust adjustment
Checking and adjusting the idle speed
Cleaning and replacing the air filter insert
Checking the preheating system
Checking glow plugs
Removal and installation of injectors
Table of faults at idle speed
Checking and adjusting the fuel pump start
Table of faults with excessive fuel consumption
Checking and adjusting the valve timing
Table of faults with reduced engine power
Fuel tank — design description
Removal and installation the fuel tank
Removal and installation the fuel tank sensor
Dismantling and installation of the exhaust system
Fault Table: Excessively Black Exhaust Gases
Transmission
Clutch
The principle of operation of the clutch
Description of the clutch design
Clutch removal and installation
Hydraulic clutch control
Clutch Fault Table
Car gearbox
General description of the gearbox
Dismantling and installation of transmission
All-wheel drive system
Gear shifting — design description
Installing the gear shift mechanism
Chassis
Front suspension
Description of the design of the front suspension and steering
Removal and installation the spring (steering knuckle) and guide rod
Front wheel suspension — design description
Removal and installation the shock absorber
Checking the shock absorber
Removal and installation the upper guide rod / checking the bearings
Front wheel support
Removal and installation the brake disc and wheel bearings
Checking and adjusting bearing clearance
Car suspension measurement
Checking and adjusting the front wheel alignment
Checking and adjusting the front wheel alignment
Checking and setting the longitudinal inclination of the kingpin
Adjustable toe-in, camber and kingpin caster
Adjustable front wheel toe-in values for 4WD vehicles
Car wheels and tires
Rear suspension
Rear Axle — General Description
Rear suspension — design description
Removal and installation the shock absorber
Removal and installation the spring
Removal and installation the brake drum
Dismantling and installation of the cardan shaft
Disassembling the cardan shaft, replacing the protective casing and joint
Checking and adjusting rear wheel alignment
Checking and adjusting the rear wheel alignment
Steering
Description of the steering design
Removal and installation the steering wheel
Hydraulic booster — design description
Checking the servo control for leaks
Checking the servo oil level
Checking the steering
Removal and installation the transverse steering rod
Steering gear and tie rod
Brake system
General description of the braking system
Checking the thickness of the brake pads of a disc brake
Removal and installation brake pads
Rear wheel brake — design description
Checking the thickness of the brake disc
Rear drum brake, brake lining control
Disabling the rear wheel brake
Removal and installation brake pads
Adjusting the rear wheel brake
Replacing brake pads
Brake lines and hoses
Dismantling and overhauling the wheel brake cylinder
Replacing the brake hose
Brake fluid reservoir
Bleeding the brake system
Handbrake — design description
Adjusting the handbrake
Dismantling and installation of handbrake rods
Anti-lock braking system (ABS)
Brake system fault table
Body
Body and interior elements
Removal and installation the front bumper
Removal and installation the rear bumper
Removal and installation the driver's seat
Camping Equipment — Safety Precautions
Checking the indicator lights of camping equipment
Testing the water pump of camping equipment
Dismantling and installation of a water tap
Dismantling and installation of the central locking servomotor
Description of the design of the cabin heating system
Adjustment of fresh air and heating ducts
Doors, locks and windows
Dismantling and installation of door trim
Replacing the glass of the external mirror
Dismantling and installation of the front door
Dismantling and installation of a door window
Removal and installation of window regulator
Removal and installation of corner glass
Removal and installation the lock cylinder
Front door adjustment
Removal and installation sliding door trim
Dismantling and installation of a sliding door
Sliding door adjustment
Adjustment of the sliding door of buses with increased cabin height
Removal and installation of a remote control lock
Dismantling and installation of the central lock
Replacement of worn parts of the articulated device
Side windshield replacement
Electrical equipment
Lighting system
Headlight bulb replacement
Replacing the parking light bulb
Headlight adjustment
Removal and installation of interior lighting lamp
Removal and installation the front turn signal
Removal and installation the license plate light
Removal and installation the rear light
Removal and installation headlights
List of used lamps
Equipment and devices
Control devices — design description
Removal and installation the control panel
Removal and installation the speedometer shaft
Switches on the steering column
Removal and installation switches on the steering column
Dismantling and installation of the antenna
Windscreen and headlight washer
Adjusting the windshield washer nozzles
Replacing the rubber wiper blades
Removal and installation the wiper blade holder
Windscreen wiper blade fault chart
Removal and installation the windshield wiper
Windscreen wiper malfunction table
Power devices (diesel)
Electrical system of diesel vehicles
Removal and installation the battery
Checking the battery
Charging the battery
The battery is self-discharging
List of fuses
Removal and installation of relays
Battery malfunction table
Dismantling and installation of the generator
Tensioning and replacing the V-belt
Checking the W terminal of the generator
Replacing the voltage regulator
Generator Fault Table
Removal and installation the starter
Starter fault table
Power devices (petrol)
Fuse box table
Removal and installation the relay
Removal and installation the generator
Replacing the voltage regulator
Removal and installation the starter
Generator fault diagnostics
Starter fault diagnostics
Wiring diagrams (diesel)
Working with schematic diagrams
Current flow diagrams (diesel and turbodiesel, 1990 model)
Preheating system (VAG 1466), cooling pump (turbo diesel)
Battery, starter, alternator, ignition switch
Control panel, optical and acoustic oil level control
Control panel, water temperature and water shortage indicator (VAG 1466), sensor
Cigarette lighter, radio, interior lighting
Light switches, number plate light, parking light, instrument lighting
Headlight, taillight, light and signal switch
Direction indicator with flashing light and signal light
Brake light, tail light, horn
Fog light, rear fog light, heated rear window
Fans for supply air, radiator (450 or 500 W) and warm air
Windscreen wiper and washer (VAG 1466)
Rear window wiper and washer (VAG 1466), handbrake and brake fluid control
Wiring diagrams (petrol)
Electrical diagrams of cars with gasoline engines
Starter, battery, alternator, ignition switch
Ignition system
Intake manifold heating, automatic engine start
Instrumentation kit, visual and acoustic oil pressure monitoring
Instrumentation, coolant temperature gauge, sensors...
Cigarette lighter, radio, interior lighting
Light switch, license plate lights...
Switch for low beam and high beam signaling
Direction indicators and hazard warning lights
Brake lights, reversing lights, horn
Fog lights, rear fog lights, heated rear window
Fresh air fan, radiator fan, warm air fan
Radiator fan (200/300/450 W)
Windscreen wiper and washer
Headlight washer, wiper and rear window washer
Starter, battery, alternator, ignition switch (2.1L engine)
Ignition system (2.1L engine)
Intake manifold heating, automatic engine start (2.1 l engine)
Ignition system, Digifant control unit, electric crankcase ventilation heating
Digifant control unit, lambda probe, digital fuel injection system
Idle speed stabilization circuit
Permanent all-wheel drive, lock, flasher relay, indicator lamp
Transporter T4
General information
User manual
Bulkhead modifications
Dimensions of the car
Replacing rubber wiper blades
Windscreen Washer Jets — Removal, Installation and Adjustment
Headlight Wash System
Windscreen wiper drive device
Windscreen wiper motor — removal and installation
Windshield Washer Water Pump — Checking and Replacing
Diagnosis of wiper malfunctions
Car wash
Care of varnish coating
Care of plastic parts
Glass cleaning
Caring for rubber seals
Caring for aluminum rims
Seat belts
Bottom protection and preservation of axle shafts
Caring for upholstered furniture
Starting the engine from another source
Towing a car
Installing the machine on stands
Vehicle identification
Maintenance
Service oil change
Maintenance schedule
Machine maintenance work
Engine and exhaust system
Engine oil change
Draining engine oil
Filling engine oil
Checking for oil leaks by visual inspection
Checking the engine oil level
Checking the coolant level
Checking the tightness of the cooling system by external inspection
Frost resistance test
Adding VW concentrate to the cooling system
Replacing spark plugs
Checking electrical connections
Replacing the air filter element
Draining water from the fuel filter
Replacing the fuel filter
Checking the V-belt
Tensioning and replacing the timing belt
Checking the exhaust system by visual inspection
Brakes, tires, wheel rims
Checking the brake fluid level
Checking the thickness of brake linings
Checking brake pipes by visual inspection
Replacing brake fluid
Checking the air pressure in the tires
Checking the tread profile
Checking tire valves
Steering and front axle
Dust caps for tie rods and axle joints
Checking the steering play
Checking the power steering oil level
Body and interior equipment
Gearbox and wheel drive
Checking the transmission for leaks using external inspection
Checking the rubber seals of the drive axle shafts
Checking the oil level in an automatic transmission
Checking the electrical system
Checking the battery
Power unit
Engine repair
Engine design
General engine data
Removal and installation the engine
Removal the radiator
Removal and installation the engine mudguard
Toothed belt — design description
Timing Belt Adjustment (4-Cylinder Petrol)
Timing Belt Adjustment (4-Cylinder Diesel)
Timing Belt Adjustment (5-Cylinder Petrol)
Timing Belt Adjustment (Diesel 5-Cylinder)
Removal and installation the timing belt (petrol 4-cylinder)
Removal and installation the timing belt (diesel 4-cylinder)
Removal and installation the timing belt (petrol 5-cylinder)
Removal and installation the timing belt (5-cylinder diesel)
Cylinder head — design description
Removal and installation the cylinder head (petrol 4-cylinder)
Removal and installation the cylinder head (diesel 4-cylinder)
Removal and installation the cylinder head (petrol 5-cylinder)
Removal and installation the cylinder head (diesel 5-cylinder)
Removal and installation the camshaft
Hydraulic disc tappets
Replacing the valve stem seals
Removal and installation valves
Checking the valve guides
Finishing the valve seat in the cylinder head
Lapping of valve seats
Checking the compression in the cylinders
V-belt for alternator or alternator and water pump
Power steering pump V-belt
Removal, installation and tensioning the V-belt
Engine fault diagnostics
Ignition system
Ignition system — general information
Operation of the ignition system
Safety precautions when handling an electronic ignition system
Ignition distributor — design description
Removal and installation the ignition distributor
Checking the high voltage transformer
Checking the Hall sensor
Checking and adjusting the ignition timing
Spark plugs — general information
Installing spark plugs
Selecting spark plugs for gasoline engines
Ignition system fault diagnostics
Lubrication system
Engine lubrication system — design description
Operating conditions of motor oil
Dilution of oil in a gasoline engine
Viscosity of motor oil
All-season and easy-flowing oil
Oil application area and viscosity grades
Motor oil specification
Engine oil consumption
Circulation of engine oil
Dynamic oil pressure control
Checking sensors and oil pressure
Diagnostics of lubrication system faults
Cooling system
Checking the pressure in the engine cooling system
Coolant circulation
Radiator and antifreeze — design description
Removal and installation the radiator
Replacing the coolant
Coolant Thermostat — Removal, Checking and Installation
Water pump — removal and installation
Electric Fan Temperature Sensor — Check
Coolant circulation temperature sensor
Diagnostics of cooling system faults
Fuel system (petrol)
Engine fuel system — general information
Rules for maintaining cleanliness when working with the power supply system
Connecting the remote control
Checking for voltage at the fuel pump
Checking the amount of fuel supplied
Checking the fuel pump check valve
Checking the fuel pump relay
Removal and installation the fuel pump and pump sensor
Activated carbon system
Throttle cable
Cold start acceleration cable
Fuel system (diesel)
How a diesel engine works
Fuel filter heating system
Checking and adjusting idle speed and maximum speed
Sealing of fuel injection pump connecting fittings
Injectors — removal, inspection and installation
Checking the start of injection pump supply
Operation of vehicles equipped with a catalytic converter
Turbocharging system — design description
Diagnostics of diesel fuel injection system faults
Injection system (petrol)
Petrol injection system — general information
Checking idle speed and CO content
Idle speed stabilization
Throttle body Shock Absorber
Injection valves — removal and installation
Checking injection valves
Idling switch
Temperature sensor resistance value
Checking the intake air heating
Technical data of the Digifant system
Diagnostics of faults of the fuel injection system Digifant
Exhaust system
Exhaust gas removal system — design description
Removal and installation of the exhaust system
Replacing spring plates
Exhaust muffler and exhaust pipe — removal and installation
Lambda probe — removal and installation
Transmission
Clutch
Clutch — design description
General clutch data
Removal, installation and checking the clutch
Bleeding air from the clutch drive
Replacing the clutch cable
Diagnosing Clutch Faults
Car gearbox
Removal and installation the gearbox
Engine-gearbox mount
Fully automatic transmission
Gearbox shifting system
Adjusting the shift drive and checking operation
Chassis
Car suspension
Front suspension — design description
General information about the front suspension
Upper steering knuckle support
Shock absorber — removal and installation
Removal and installation front drive axle shafts
Disassembly and assembly of front drive axle shafts
Rear suspension — design description
General information about the rear suspension
Removal and installation the rear shock absorber
Checking the rear shock absorber
Rear shock absorber coil spring
Steering
Steering — design description
General information about steering
Steering wheel — removal and installation
Ball joint and tie rod — removal and installation
Checking the tightness of the control system
Bleeding air from the control system
Eliminate vibration of the steering wheel and the front of the car
Basic parameters for adjusting the chassis
Toe-in, kingpin lateral tilt, kingpin longitudinal tilt back
Brake system
General information about the brake system
Technical data of the brake system
Front disc brake pads (14-inch wheels)
Front disc brake pads (15-inch wheels)
Eliminating squeaks from disc brakes
Checking the thickness of brake discs
Brake disc and brake mechanism — removal and installation
Brake drum — removal and installation
Brake pads — removal and installation
Basic rear wheel brake adjustment
Adjusting the handbrake
Brake fluid
Bleeding the brake system
Replacing brake fluid
Wheel brake cylinder — removal and installation
Brake line and brake hose
Brake force regulator
Brake light switch
Anti-lock braking system (ABS)
Brake fault diagnostics
Wheels and tires
General information about wheels and tires
Rim designation
Tyre designation
Wheel replacement
Rules for tire care
Snow chains (anti-slip chains)
Spare wheel — removal and installation
Incorrect tire wear
Diagnosis of wheel faults
Body
Exterior
General information about the car body
Bumpers — removal and installation
Front End Beam — Removal and Installation
Hood cover — removal and installation
Hood cover — removal and installation
Radiator grille — removal and installation
License plate light protective strip
Outside mirror — removal and installation
Replacing exterior mirrors
Interior
Interior mirror — removal and installation
Front seat — removal and installation
Middle row of seats in the passenger compartment — removal and installation
Rear seat bench — removal and installation
Glove box — removal and installation
Doors and windows
Rear door — removal and installation
Adjusting the tailgate
Removal and installation the gas shock absorber of the trunk door
Front door device
Removal, installation and adjustment of the front door
Front door interior trim
Door glass — removal and installation
Window lifter — removal and installation
Door handle and lock — removal and installation
Door seal — removal and installation
Sliding door device
Removal and installation a sliding door
Removal and installation the sliding door guide rail
Rear double door — removal and installation
Heating system
Heating system device
Intake manifolds — removal and installation
Heater motor — removal and installation
Air deflectors — removal and installation
Heating regulator — removal and installation
Heater control cables — removal and installation
Additional heat exchanger — removal and installation
Additional heating system on the Caravelle model
Diagnostics of heating system faults
Electrical equipment
Equipment and devices
Electrical Equipment System — General Information
Voltage measurement
Measuring current
Measuring resistance
Installation of additional electrical accessories
Troubleshooting electrical equipment
Checking the incandescent lamp
Checking Electric Motors
Checking switches
Checking lamp switches and electric motors
Checking sensors
Relay — description and testing
Windscreen wiper motor — description and testing
Direction indicator system — description and testing
Stop light — check
Sound signal — description and verification
Rear Window Heated — Description and Testing
Replacing fuses
Control lamps — removal and installation
Testing LEDs
Voltage stabilizer — removal, testing and installation
Control devices — removal and installation
Speedometer shaft — removal and installation
Instrument cluster — design description
Instrument visor (dashboard) on the instrument panel
Steering Wheel Combination Switch — Design Description
Removal and installation the steering wheel combination switch
Connections on the combination steering wheel switch and steering lock
Digital clock backlight lamp
Radio receiver — removal and installation
Entering radio code for radio receivers
Lighting and signaling
Lighting and signaling system — general information
Table of lamps
Replacing lamps
Direction indicator housing — removal and installation
Headlight adjustment
Servo motor for adjusting the light range
Fog light — removal and installation
Tail light — removal and installation
Power devices
Battery — General Information
Removal and installation the battery
Checking the battery
Charging the battery
Storage of the battery
Self-charging of the battery
Diagnosis of battery faults
Generator — design description
Checking the generator voltage
Removal and installation the generator
Replacing the generator's graphite brushes and checking the voltage regulator
Generator fault diagnostics
Starter — General Information
Removal and installation the starter
Starter Magnetic Relay — Removal, Checking and Installation
Starter fault diagnostics
Electrical circuits
General information about electrical circuits
Letter designation of the most important devices
Decoding the colors of the conductors
Set of fuses and their ratings
Identification of electrical circuits depending on the engine
Instructions for using the electrical circuit
Designation of elements in electrical circuits
Generator, battery, starter, ignition switch
Ignition system, injection system control unit Digifant
Digifant fuel injection control unit, self-diagnostic unit
Digifant Fuel Injection System Control Unit
Instrument cluster: control instruments
Instrument cluster: speedometer, turn signal and brake lights
Instrument cluster: tachometer, brake system sensor
Fan (150W, 250W) and additional cooling system pump
Connecting the radio, cigarette lighter and underhood lamp
Interior lighting
Headlights Wiring Diagram
Headlight adjustment system
Turn signal, hazard warning, parking light switches
Direction indicators, rear lights
Light switch, number plate light
Fog lights, reversing lights
Fans for cooling systems (150, 250W), heating and ventilation
Rear window heating and sound signal
Windshield wiper and washer
Rear window wiper and washer
Diesel: preheating system, fuel shut-off valve
Diesel: instrument panel, control lamps
Diesel: instrument cluster, tachometer, indicator lights
Diesel: radio, cigarette lighter and underhood lamp
Diesel: fog lights, reversing lights
Diesel: heating fan, additional cooling pump
Diesel: cooling system fans (2x350W)
Diesel (ABL): exhaust gas aftertreatment system
Diesel (ABL): glow plugs, additional cooling pump
Diesel (ABB): preheating system, fuel cut-off
Diesel (ABB): additional cooling pump
Central door locking system
Rear door lock motors
Connection of additional battery since November 1990
Beetle
General information
Maintenance
Car body wash
Care of the paintwork
Care for chrome parts, glass and rubber
Seat upholstery care
Basic and additional set of tools
Motor oil — general description
Transmission oil — general description
Engine oil change
Changing the oil in the gearbox and main gear housing
Front suspension lubrication
Lubrication of door hinges
Lubrication of door locks and latches
Cleaning the paper air filter element
Cleaning the gutters
Vehicle maintenance work
Power unit
Engine repair
General description of engines
Lifting a car
Removal and installation the engine
Disassembly and assembly of the engine
Removal and installation cylinder heads
Removal, checking and installation valves
Valve grinding
Lapping valves
Checking valve seats for leaks
Checking the valve guides
Valve seat machining
Adjusting valve clearances
Checking the compression in the cylinders
Removal and installation of cylinders, pistons and piston rings
Checking the pistons
Checking piston rings
Checking the inner diameter of the cylinders
Removal and installation the rear engine cover
Replacing V-belt pulleys
Removal and installation the flywheel
Replacing the crankshaft seal
Checking and adjusting the axial play of the crankshaft
Intake manifold and preheating ducts
Main engine attachments
Disassembly, inspection and assembly of the crank mechanism
Removal, checking and installation the camshaft
Removal, disassembly, assembly and installation of the crankshaft
Removal, checking and installation connecting rods
Engine malfunctions and how to fix them
Cooling and lubrication system
General description of the engine lubrication system
Main elements of the lubrication system
Removal and installation the safety valve
Removal, installation and checking the oil pressure sensor
Removal, checking and installation the oil pump
Removal and installation the oil filler neck
Removal and installation an oil radiator
Engine lubrication system malfunctions
Engine cooling system — design description
Removal and installation the fan shroud
Removal, installation, adjustment and testing of the thermostat
Supply system
Maintenance of the power supply system
Carburetor — design description
Carburetor adjustment
Fuel supply problems
Removal and installation the carburetor
Checking the fuel-air mixture shut-off valve
Adjusting the accelerator drive
Disassembling the carburetor
Removal, checking and installation the float needle valve
Checking and adjusting idle speed
Checking and adjusting the CO content in exhaust gases
Adjusting the throttle closing damper
Throttle adjustment
Checking and adjusting the air damper clearance
Checking the thermal switch
Checking and adjusting the fuel supply by the accelerator pump
Automatic Start — General Description
Removal, installation, adjustment and testing of the heating coil
Replacing the accelerator cable
Removal and installation the fuel pump
Removal, cleaning and installing the fuel pump mesh filter
Replacing the air filter
Removal and installation the fuel tank
Removal and installation the fuel level sensor
Technical data of the carburetor
Carburetor malfunctions and how to fix them
Exhaust system
Exhaust system — design description
Replacing the exhaust system
Removal and installation the valve levers of the heating and ventilation system
Replacing the exhaust pipe
Removal and installation the heat exchanger
Transmission
Clutch
Description of the clutch design
The principle of operation of the clutch
Removal, checking and installation the clutch
Removal and installation the clutch cable
Checking and adjusting the deflection of the clutch cable guide
Adjusting the clutch pedal free travel
Clutch malfunctions and how to fix them
Car gearbox
Description of the gearbox design
Removal and installation of gearbox (rear axle with diagonal balancer)
Replacing the front rubber-metal support
Removal and installation of gearbox (with independent wheel suspension)
Replacement of axle shaft protective covers
Replacing seals in axle bearing caps
Removal and installation the gear shift lever
Removal and installation the sliding rod
Adjusting the gear shift mechanism
Chassis
Front suspension
Front suspension on shock absorber struts
Shock absorber strut — design description
Removal and installation shock absorber struts
Removal, installation and inspection of shock absorbers and coil springs
Front suspension on torsion bars
Removal and installation steering knuckles
Replacing shock absorbers
Removal and installation of brake drums, discs and hub bearings
Front wheel brakes
Checking and adjusting the play of wheel hub bearings
Rear suspension
Rear suspension (independent) — design description
Replacing rear brake drums
Replacing the rear wheel hub bearing seals
Replacing torsion bars (rear axle with independent suspension)
Adjusting the elastic levers
Removal and installation of balancers
Rear suspension parts
Removal and installation shock absorbers
Replacing wheel hub bearing seals
Rear brake components (suspension with diagonal balance beam)
Removal and installation of axle shafts, joints and their protective covers
Steering
Description of the steering design
Removal and installation the steering wheel
Removal and installation the steering column switch
Steering elements
Removal, checking and installation the steering shock absorber
Removal and installation transverse steering rods
Checking and adjusting the roller steering mechanism
Adjustment and inspection of the rack and pinion steering mechanism
Roller steering gear malfunctions
Brake system
General description of the braking system
Checking the thickness of the friction linings of disc brakes
Removal and installation friction linings of disc brakes
Checking the thickness of the friction linings of drum brakes
Adjusting drum brakes
Removal and installation front brake pads
Front torsion bar suspension brake parts
Front suspension brake parts on shock absorber struts
Rear wheel brake — design description
Removal and installation rear brake pads
Removal, disassembly, assembly and installation of wheel brake cylinders
Replacement of brake lines and hoses
Brake fluid reservoir
Bleeding the brake system
Removal and installation the parking brake lever
Replacing the parking brake cable
Adjusting the parking brake
Brake system malfunctions
Wheels and tires
General description of wheels and tires
Wheel balancing
Tire wear
Uneven tire wear
Wheel replacement
Geometrical parameters of wheel installation
Checking and adjusting the front wheel alignment (torsion bar suspension)
Front wheel alignment adjustment
Rear wheel alignment (rear axle with independent suspension)
Front wheel alignment (shock absorber suspension)
Front wheel alignment (shock absorber suspension)
Setting values of wheel alignment and camber angles
Abnormal tire wear
Body
Exterior
Removal and installation front fenders
Removal and installation rear fenders
Removal and installation the trunk lid
Removal and installation the trunk lid lock
Removal and installation the hood
Removal and installation the hood lock
Checking the gutters of the sliding roof (convertible)
Replacing the sliding roof seal (convertible)
Removal and installation doors
Adjusting the door locking plates
Removal and installation door trim
Removal and installation of window lifters
Removal and installation of door handles and lock cylinders
Replacement of windshield and side windows
Electrical equipment
Equipment and devices
General description of on-board electrical equipment
Maintenance of electrical equipment
Removal and installation of headlights and their lamps
Replacing parking light bulbs
Replacing the bulbs in the rear lights
Removal and installation interior lighting lamps
Front direction indicators and number plate light
Adjusting the angle of the headlight beam
Replacing fuses
Instrument panel — removal and installation
Removal and installation a watch (Kafer 1303)
Removal and installation the speedometer (Kafer 1303)
Removal and installation the speedometer (Kafer 1200)
Removal and installation the speedometer cable
Checking and replacing brake light switches
Removal and installation the windshield washer switch
Replacing the steering wheel lock and ignition lock
Removal and installation windshield wiper arms (Kafer 1200)
Replacing windshield wipers
Removal and installation the windshield wiper motor (Kafer 1200)
Removal and installation windshield wiper arms (Kafer 1303)
Removal and installation the windshield wiper motor (Kafer 1303)
Possible malfunctions of windshield wipers
Power devices
Removal and installation the battery
Checking the battery
Possible battery faults
Generator — design description
Removal and installation the generator
Removal, installation and tensioning the generator drive V-belt
Possible generator faults
Ignition system — general information
Maintenance of the ignition system
Checking the ignition coil
Checking the capacitor
Distributor parts
Removal and installation the ignition distributor
Removal and installation the ignition distributor drive
Replacing breaker contacts
Checking and adjusting the angle of the closed state of contacts
Adjusting the gap between the breaker contacts and the angle of their closed state
Adjusting the ignition timing using instruments
Adjusting the ignition timing using a test lamp
Ignition Timing Adjustment Data
Spark plugs
Maintenance and inspection of spark plugs
Electrical circuits
Using Electrical Schematics
Conventional symbols of electrical circuit elements
Electrical diagram of Kafer 1200/1200L vehicles produced since August 1975.
Electrical diagram of the Kafer 1303 car, produced since August 1974.
Electrical diagram of the Kafer 1200 car, produced since August 1974.
Additional electrical diagram of Kafer 1300/1303 cars produced since August 1974.
Fog lights and rear fog lights
Changes in the electrical circuit (generator and voltage regulator)
Caddy 3
General information
User manual
Governing bodies
Instrument cluster
Instrument cluster indicator lights
Multifunctional instrument cluster indicators
Multifunction Display (MFD) Control
Indication of total, daily mileage or mileage remaining before maintenance
Odometers
Ambient temperature indicator
Warning and information texts in MFD
Warning light indicators
Main menu of the multifunctional display
Vehicle keys
Central lock switch
Remote control battery health indicator
Anti-theft alarm
Child-proof sliding door protection device
Car exterior lighting
Car interior lighting
Windscreen wiper control
Exterior rear view mirrors
Heated seats
Warning triangle and dressing box
Interior heating and cooling control
Steering wheel adjustment
ESP stabilization system and ASR traction control system
Ignition and instrument switch with anti-theft device
Description and location of fuses (before 2005)
Technical characteristics of cars
Daily care
Location of relays and fuses (since 2005)
Incandescent lamps used in cars
General information about maintenance
Frequency of maintenance work
Car inspection service
Lifting a car on a lifting platform and jack
Visual inspection of the battery
Checking the electrolyte level in the battery
Checking battery voltage without load
Checking the wear status of tires
Checking the brake fluid level
Visual inspection of the brake system for leaks and damage
Checking the thickness of the brake pads of disc brakes
Visual inspection of constant velocity joint (CV) boots
Checking the tie rod ends
Checking the oil level in the power steering reservoir
Visual inspection of axle joints
Visual inspection of parts in the engine compartment and on the bottom
Checking the engine oil level
Checking the condition of antifreeze and coolant level
Poly V-belt — checking condition
Checking the positioning of electric windows
Checking the antifreeze content in the washer fluid concentrate
Adjusting the windshield washer jets
Adjusting headlight washer sprayers
Performing a test drive
Maintenance
Disconnecting and connecting terminals from the battery
Removal and installation the battery
Removal the center cap of the wheel
Replacing brake fluid
Changing engine oil and oil filter
Removal and installation the engine compartment protective tray
Removal and installation the upper engine casing
Replacing the fuel filter in a diesel engine
Replacing the air filter element
Checking the camshaft timing belt (4-cyl. petrol engines)
Checking the timing belt (SDI and TDI diesel engines)
Replacing the timing belt of 1.4L petrol engines BCA and BUD
Replacing the timing belt of petrol engines 1.6 l BGU, VSE and BCF
Replacing the timing belt in TDI and SDI diesel engines
Removal and installation the timing belt (with the engine support installed remotely)
Replacing spark plugs
Oil and filter change in 6-speed dual clutch transmission 02E
Checking headlight adjustment
Petrol engines 1.4 l
Engine repair
Technical characteristics of petrol engines 1.4 l BCA, BUD and 1.6 BGU, BSE, BSF
Removal and installation of 1.4L engine (BCA and BUD)
Engine disassembly and assembly (BCA and BUD)
Removal and installation a poly V-belt
Cylinder block for 1.4 l petrol engines (BCA and BUD)
Removal and installation the front and rear crankshaft covers
Removal and installation the rear cylinder block cover
Pressing the flange with the toothed rim onto the crankshaft
Disassembly and assembly of pistons and connecting rods
Checking the thermal clearance in the joints of piston rings
Checking the clearance between the piston ring and the groove in the axial direction
Checking pistons and cylinders
Removal and installation the cylinder head
Disassembly and assembly of the cylinder head
Checking the deformation of the cylinder head mating plane
Notes on the specifics of performing work on disassembling and assembling the cylinder head
Valve mechanism repair
Fixing both camshaft toothed pulleys
Processing of the cylinder head seating surface
Camshaft — Checking Endplay
Valve seat machining
Cooling and lubrication system
Elements of the lubrication system
Removal and installation of lubrication system parts
Removal and installation the oil filler neck
Removal and installation the oil pan
Removal and installation the oil pump
Cooling system connection diagram
Hydraulic parts and components of the cooling system
Parts and units of thermostat, radiator and expansion tank
Parts and units of the cooling system fan unit
Precautions when working with the cooling system
Cooling system elements installed on the body
Cooling system components associated with the thermostat
System components associated with the coolant pump
Removal and installation the fan, radiator (V7) and radiator fan 2 (V177)
Removal and installation the radiator
Removal and installation the coolant pump
Power and exhaust system
General information on removing and installing power supply system components
Parts and components of the power supply system
Crash Fuel Cut-off System
Checking the performance of the fuel pump
Fuel manifold parts with injectors
Air filter housing for engines with BCA designation
Air filter housing for engines with the designation BUD
Air Filter Housing for BCA Engines — Removal and Installation
Air filter housing for BUD engines — removal and installation
Cleaning the throttle control unit (J338)
Removal and installation of fuel injectors
Checking the intake air preheating
Checking the amount of fuel injected
Checking the tightness and quantity of injected fuel (since 2006)
Fuel pressure regulator and residual pressure
Removal and installation of the engine control unit with theft protection
Exhaust system parts and components (BCA engines)
Exhaust system parts and components (BUD engines)
Petrol engines 1.6 l
Engine repair
1.6L Petrol Engines (BGU, BSE and BSF) — Design Description
Removal a gasoline engine
Installing a gasoline engine
Disassembly and assembly of a gasoline engine
Removal the upper part of the timing belt cover
Removal and installation a poly V-belt
Cylinder Block Covers and Flywheel
Removal and installation the rear cylinder block cover
Installing the front cylinder block cover
Removal and installation the timing rotor
Marking of upper main bearing shells of the crankshaft
Parts and units of cylinder-piston and connecting rod-piston groups
Mounting position of bearing shells
Checking cylinders, pistons and piston rings
Cylinder head parts and components
Checking the cylinder head for warpage
Removal and installation of the cylinder head
Removal, installation and tensioning the timing belt
Checking the semi-automatic timing belt tensioner roller
Valve mechanism parts and components
Processing of the cylinder head mating plane
Valve sizes
Valve seat machining
Checking the valve guides
Removal and installation the camshaft
Cooling and lubrication system
Lubrication system — design description
Oil filter with heat exchanger — design description
Oil pan removed and installed
Removal and installation the oil pump
Cooling system parts and components installed on the engine
Cooling system hose connection diagram
Draining and filling the coolant
Removal and installation the coolant pump
Installing a thermostat in the cylinder block
Power and exhaust system
Air and fuel injection system
Parts and units of the air supply system of engines BGU, BSE, BSF
Fuel manifold parts with injectors for 1.4 and 1.6 l engines
Parts and units of the air supply and filtration system
Removal and installation the lower intake manifold (BGU)
Removal and installation the lower part of the intake manifold (BSE, BSF)
Removal and installation injectors
Switching in the control system to check the parameters of the injection system
Parts and units of the inlet pipe with a catalytic converter
Parts and units of additional and main mufflers
Exhaust Gas Recirculation (BGU) System
Secondary air supply system (BGU, BSE)
Diesel engines
Engine repair
Technical characteristics of diesel engines 1.9 l and 2.0 l
Timing drive components and parts
Auxiliary unit drive
Cylinder block and related units
Removal and installation a poly V-belt
Removal and installation the sealing flange and flywheel
Cylinder block for diesel engines 1.9 and 2.0 l BDJ, BST, BJB, BSU, BLS
Removal and installation the crankshaft speed sensor (G28)
Crankshaft and main bearings
Crank mechanism parts
Connecting rod and piston group
Checking thermal glare of piston rings
Checking the height clearance between the groove and the ring
Checking the cylinder diameter
Mounting position and matching of pistons to cylinders
Measuring the piston protrusion from the cylinder block at TDC
Cylinder head gasket markings
Cylinder head for diesel engines 1.9 and 2.0 l BDJ, BST, BJB, BSU, BLS
List of parts and assemblies of the cylinder head
Checking the cylinder head for warpage
Installing the valve cover
Removal and installation the cylinder head
Camshaft, valves and pump-injector drive
List of valve mechanism components and parts
Checking the axial run of the camshaft
Valve sizes
Removal and installation the camshaft
Cooling and lubrication system
List of units and parts of the lubrication system
List of oil filter and heat exchanger parts
Turbocharger bearing lubrication pressure oil line
General information about the engine cooling system
Cooling system parts and units installed on the body
Cooling system parts and components installed on the engine
Cooling system hose connection diagram
Cooling system of diesel engines 1.9 l BJB
Cooling system of diesel engine 2.0 l BDJ
Engine cooling system 2.0 l BDJ with independent heater
Cooling system of diesel engine 2.0 l BST
Cooling system for 2.0L BST diesel engines with independent heater
Cooling system of diesel engines 1.9 l BLS, BSU
Cooling system for 1.9L BJB diesel engines with independent heater
Power and exhaust system
Fuel supply system
Fuel filter parts and components
Removal and installation the fuel supply module
Removal and installation the fuel level sensor
Removal and installation a twin pump
Fuel and vacuum pump
Quick release hose connections
1.9L BJB Engine Turbocharged Air Intake System
Components and parts of the intake tract of a 1.9 l diesel engine BJB
1.9L BJB Engine Intercooler Parts and Components
1.9L BLS and BSU Turbocharged Air Intake System
Specification of units and parts of the intake tract of the 1.9L BJB engine
Removal and installation a turbocharger
Non-turbocharged air supply system
Fuel injection system — description
Specification of unit injectors for diesel engines
Vacuum hose connection diagram
Removal and installation the accelerator pedal
Parts and units of the exhaust system with a catalyst for BJB, BSU engines
Parts and components of the exhaust system with a diesel particulate filter BLS
Associated parts of the diesel particulate filter
Adjustment of the position of the exhaust system elements
Exhaust gas recirculation system parts and components
Vacuum hose connection diagram (BJB, BSU and BLS)
Muffler with fasteners — design description
Exhaust Gas Recirculation System Parts
Transmission
Mechanical gearbox 0AH
Identification data of manual transmission
Types and design of manual transmission
Description of the clutch design
Repair of the clutch release mechanism
Gear shift mechanism — design description
Gearbox — removal
Gearbox — installation
Checking the oil level in the manual transmission
Parts and units of manual transmission type 0AH
Removal and installation the gearbox housing cover and 5th gear wheels
Removal and installation of the manual transmission housing
Removal and installation of the primary shaft, secondary shaft, differential
Disassembling the gearbox
Gearbox assembly
Internal gear shift mechanism of manual transmission
Disassembly and assembly of the internal gear shift mechanism
Dismantling and assembly of the primary shaft
Disassembly and assembly of the hub with a sliding sleeve of the synchronizer of 3rd and 4th gears
Checking the synchronizer locking ring for wear
Determining the thickness of the thrust ring
Disassembly and assembly of the hub with a sliding sleeve of the 5th gear synchronizer
Removal and installation the secondary shaft
Disassembly and assembly of the secondary shaft
Setting position of 3rd and 4th gears
Checking the inner ring of the 1st and 2nd gear synchronizer for wear
Checking the 1st and 2nd gear synchronizer locking ring for wear
Installation position of the outer, inner and locking rings of 2nd gear
Disassembly and assembly of the hub with a sliding sleeve of the synchronizer of 1st and 2nd gears
Differential — design description
Dismantling and assembling the differential
Mechanical gearbox 0A4
Description of the design of the mechanical transmission 0A4
Gear shift mechanism
Checking the operation of the gear shift mechanism
Removal and installation the gear shift mechanism
Adjusting the gear shift mechanism
Disassembly and assembly of the gear shift mechanism
Disassembly and assembly of the secondary shaft
Position of the inner, intermediate and blocking ring of the 1st gear synchronizer
Disassembly and assembly of the clutch with the synchronizer hub of 1st and 2nd gears
Pressing on the clutch and hub of the synchronizer of 1st and 2nd gears
Disassembly and assembly of the clutch with the synchronizer hub of the 3rd and 4th gears
Drive shafts
General description of drive shafts
Removal the drive shaft
Installing the drive shaft
Parts and units of the drive shaft with CV joint VL100
Parts and units of the drive shaft with CV joint VL107
Disassembling the drive shaft
Drive shaft assembly
Chassis
Car suspension
Front Wheel Suspension — Design Description
Removal and installation the subframe
Setting the suspension to the position corresponding to the unladen weight
Checking the condition of ball joints
Removal and installation the ball joint
Tightening torques for fasteners of front suspension parts and assemblies
Steering knuckle assembly with hub
Removal and installation the shock absorber strut
Rear suspension repair
Tightening torques for threaded connections in the rear suspension
Steering
Removal and installation the steering wheel
Removal and installation a multifunctional steering wheel
Steering column — design description
Steering column — removal and installation
Removal and installation the steering rod
Hydraulic Power Steering — Design Description
Power steering — removal and installation
Bleeding the steering system
Steering gear repair
Rotary pump for hydraulic power steering
Steering gear with electromechanical power steering
Repair of the steering mechanism with electromechanical power steering
Removal and installation the steering rod (electromechanical power steering)
Tightening torques for threaded fasteners of steering components
Brake system
Technical characteristics of the brake system
List of parts and components of the front brake FS III
Removal and installation brake pads (FS III)
Removal and installation the brake caliper (FS III)
Brake Caliper Repair (FS III)
Removal and installation the brake caliper piston (FS III)
List of parts and components of the front brake FN 3
Removal and installation brake pads (FN 3)
Removal and installation the brake caliper (FN 3)
Brake caliper repair (FN 3)
List of parts and assemblies of the rear brake
Removal and installation rear brake pads
Removal and installation the rear brake caliper
Adjusting the parking brake
Repair of rear brake calipers
Brake booster, brake master cylinder
Parts and units of the brake booster vacuum pump (diesel)
Brake light switch (F) from 2007
Removal and installation the master brake cylinder
Removal and installation the brake booster
Exchange Rate Stability System ESP
List of ABS Mark 70 (ABS/ASR) System Elements
List of ABS Mark 60 (ABS/EDS/ASR/ESP) system components
Indication of faults using indicator lamps
List of parts and components of the master brake cylinder
Installation of ABS system components
Body and wiring diagrams
Interior and exterior
Removal and installation the front part of the center console (van)
Removal and installation the front part of the center console (station wagon)
Removal and installation the center console (van)
Removal and installation the center console (station wagon)
Removal storage compartments and sections
Removal and installation trim in the footwell
Removal and installation the central decorative trim of the front panel
Removal and installation the front panel side trims
Removal and installation the steering column switch block trim
Compartments, trims and linings of interior elements
Fastening front and rear seats
Control dimensions of the body
Dimensions of gaps between body parts
Electrical circuits
Rules for using electrical circuits
List of electrical equipment elements shown in the diagrams
Motronic injection system for 1.4 l 55 kW BCA petrol engine
Simos injection system for 1.6 l, 75 kW engines, BGU, BSE, BSF since May 2005
Diesel injection system 1.9L BSU and BLS
Injection system for diesel engines 2.0 l 51 kW, BDJ, BST
Continuously adjustable radiator fan 350 W (200 W and 150 W) from 05.2005
Continuously adjustable radiator fan 500 W (300 W and 200 W) from 05.2005
Radiator fan cooling system, 1-speed since 05.2005
Anti-lock braking system (ABS) with ASR from 05.2005
Anti-lock braking system ABS with EDS, ASR and ESP since 05.2005
Electromechanical power steering since 05.2005
Basic electrical equipment diagrams from 05.2005
Sockets (12 V) from 05.2005

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